Open Book API 510 Practice Exam A

Questions 1 to 35 are OPEN BOOK and simulate the first half of the actual exam.

1. A vessel is to under go a hydrostatic test after a repair. The vessel’s stress allowable at the test
temperature is 15,000 psi and its stress allowable at its operating temperature is 13,800 psi. The vessel’s
MAWP at its design temperature is 125 psi. What will be the required test pressure at the top of the vessel?

1. 203.8 psi
2. 169.6 psi
3. 176.6 psi
4. 143.7 psi

2. A cylindrical shell contains a welded long joint that is made using a backing strip that remains in place.
All of the radiography requirements of UW 12 (a) have been met. For purposes of calculating
circumferential stress on the cylinder, what will be the value of the joint E used in the calculation?

1. 1.0
2. .85
3. .80
4. .90

3. A small exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand
an external pressure of 350 psi. The tubes have and O. D. of 2.0 inch and are 60 inches in length with a
wall thickness of .025 inch. What would be the approximate Factor A value for this combination of length
diameter and thickness of tube is?

1. .0056
2. .00055
3. .057
4. .10

4. An additional 4 inch nozzle was added to a pressure vessel and is similar to the one in Fig UW-16.1(i).
The minimum thickness of the nozzle is .377 inch and the shell minimum thickness is .750 inch. What is
the decimal value of the minimum throat required for each of two equal leg size fillet welds on this
attachment?

1. .235”
2. .267”
3. .250”
4. .750”

5. A cylindrical shell has a seamless hemispherical head on one end and a seamless ellipsoidal head on the
other end. The elliptical head is attached by a type 2 weld meeting the spot radiography requirements of
UW-11(a)(5)(b). The shell has a single longitudinal joint. All category A butt welds are type 1 with full
radiography applied. The vessel will require an MAWP of 50 psi . The material of the shell and head is
SA-515-Gr. 60. The allowable stress at the operating temperature is 15,000 psi. The heads inside diameter
is 10'-0". What is the required thickness of the 2 to 1 ellipsoidal head?

1. .250
2. .235
3. .200
4. .1003

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6. You have received the following tension test results for a welding procedure, what is the ultimate unit
stress for these two specimens?

Specimen Width Thickness Area Ultimate Total Ultimate Unit

Load lb Stress
1 .750 .410 .308 22,600 ?
2 .748 .409 .306 25,800 ?

1. 1 = 72,380 2 = 83,314
2. 1 = 72,377 2 = 83,296
3. 1 = 73,377 2 = 84,314
4. 1 = 74,377 2 = 83,314

7. An engineer is evaluating a pressure vessel’s head for impact testing requirements based on an MDMT
to be marked on the vessel of 40oF. As part of the calculations required it has been determined that this
head will have a coincident ratio of 0.60, this will allow a further reduction of the MDMT exemption given
by figure UCS-66 of __oF.

1. 30
2. 50
3. 40
4. 35

Answer the following questions about the WPS and PQR (pages 3 to 6) from Captain Bob’s Welding.
Consider both the WPS and its supporting PQR when answering the questions.

8. (WPS) In the JOINTS (QW-402) section, the following statement is true;

1. There must be a sketch of the joint configuration to be used in production.

2. Any groove design is allowed in production.
3. The box is properly addressed and contains no mistakes.
4. Flux dam retaining is permitted.

9. (WPS) In the BASE METAL (QW-403) there is a mistake because the;

1. Pipe diameter is not addressed.

2. Group number is not addressed and it is a supplemental essential variable.
3. Fillet welds are addressed as ALL.
4. There is no mistake; none of the above is true, 1 &3 are for information only, number 2 is not
needed for this procedure because no impact tests are required of the weldment.

10. (WPS) In the TECHNIQUE (QW-410) should have addressed the following;

1. Travel speed.
2. Method of back gouging.
3. Nothing, it is perfect.
4. The length of groove.

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11. Which types of butt-welded joints are allowed to be used to construct vessels in lethal service?

1. A and D only.
2. A, B, C and D are permitted
3. 1 and 2 dependent upon Category.
4. Butt welds are not permitted in lethal service.

12. After rolling a plate into a cylinder designed for internal pressure it is measured for out of roundness;

1. It is acceptable if it is no more than 1% out of roundness.

2. It is acceptable if it is no more than 10% out of roundness.
3. It is acceptable if it is no more than ½ % out of roundness.
4. It is acceptable if it is no more than 2% out of roundness.

13. During the internal inspection of a vertical vessel a minimum thickness reading of 1.270" was found on
a shell course. The Data Report reflects an original thickness of 1.50", and allowable stress at 600 degrees
of 14,500 psi, full RT, and a MAWP of 650 psi. The MAWP was based on retirement diameter of 49.02
inches after the corrosion allowance was expended; this yields a retirement thickness of 1.129 inches.
Inspection records indicate a corrosion rate of 0.025 inches a year. If the corrosion rate does not change
what is the maximum time before the next on-stream or internal inspection?

1. 5 years
2. 5.6 years
3. 10 years
4. 2.8 years

14. The inspection of bend tests for a welding procedure revealed an opening in the concave side of the
specimen, its greatest dimension was 3/32 of an inch and does not show any sign of a welding flaw. This
opening is not cause for rejection because:

1. It is less than 1/8 inch.

2. The opening is not caused by a flaw and it is less than 1/8 inch.
3. The code does not address this issue.
4. The welder had faulty equipment provided at the testing lab.

15. What is the lowest metal temperature permitted to pneumatically test a vessel per Section VIII Div. 1?

1. 30 oF.
2. 30 oF above MDMT.
3. 30 oF below MDMT.
4. There is no such requirement, it is only a recommendation.

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16. When performing standard dye penetrant examinations, the greatest temperature permitted for the part
to be examined is:

1. 250 oF
2. 600 oF
3. 125 oF
4. It doesn’t matter.

17. Regarding corrosion evaluation, for the purposes of determining whether a weld joint efficiency or the
surface remote from the weld governs in calculations the following must be true for this to be a
consideration;

1. The joints efficiency must be 1.0.

2. The joints efficiency must be less than 1.0.
3. The joints efficiency must be exactly .90.
4. The joint efficiency has no bearing on corrosion evaluations.

18. The following describes the location of corrosion as measured in a vessel shell with the following
dimensions and minimums:

 .700 inch thickness minimum for shell from original calculations

 Longitudinal joint E = .85.
 The thickness of the shell in the welded joint is .701 inch.
 The thickness 3 inches remote from the welded joint is .698 inch.

Using the rules for corrosion evaluation in API 510, the following conclusion can be made about the
evaluation of the vessel for its continued service with out repair;

1. The thickness at the weld governs calculations.

2. The thickness remote from the weld governs calculations.
3. No such rule exits in API 510.
4. Separate calculations will be required to determine which thickness governs.

19. A 2 to 1 ellipsoidal head has experienced uniform corrosion on its inner surface. To determine the
governing thickness and evaluate the head for continued service or the need for repair or derating we
would;

1. Calculate the required thickness of the knuckle region using the formula given in UG-32 of
Section VIII Div. 1.
2. Calculate the thickness required of the spherical portion of the head using the formula from UG 27
of Section VIII Div. 1 for a spherical shell.
3. Calculate the equivalent shell based on the heads inside diameter.
4. Calculate both 1 and 2 above to determine the need for repair or derating.

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20. A 2 to 1 ellipsoidal head has experienced corrosion in the central portion of the head and will require
calculations for continued service. Using the following information, what is to be used as the diameter of
the spherical segment when evaluating the corrosion?

 The vessel’s shell diameter is 96 inches

1. 96 inches
2. 76.8 inches
3. 80 inches
4. 38.4 inches

21. For calculating the required thickness of a standard torispherical head which has a corroded area in its
central portion, the head must be evaluated using a spherical shell calculation. What shall be used as the
radius of the dished portion in the calculation?

1. One half the shell’s inside diameter.

2. 80 % of the shell’s inside diameter.
3. The shell’s diameter.
4. The measured central portion of the head taken from its center and based on 80 % of the shells
diameter.

22. An ellipsoidal head has experienced corrosion at a radius 31 inches above the center of the head. The
head is attached to a shell that is 8’ in diameter using a type 2 weld that has been fully radiographed. This
corroded area may be considered within the spherical portion because the greatest distance allowed for this
calculation from the heads center is;

1. 76.8 inches
2. 38.4 inches
3. 80.0 inches
4. 40.0 inches.

23. A vessel shell has scattered corrosive pits caused by hydrochloric acid. The greatest pit depth found
excluding corrosion allowance is 0.333 inch deep in the shell, which has minimum required thickness of
0.521 inch. The sum of pit’s areas within an 8 inch diameter circle does not exceed 7 sq. inches. This pit
must be repaired because the limit of the pit depth in this situation is;

1. .1302”
2. .2605”
3. .3000”
4. .3250”

24. While inspecting a vessel you notice that there is corrosion that is general, but varies over an area of
the affected shell course, the vessel has an inside diameter of 88 inches. You wish to average this corrosion
for purposes of evaluation. Circumferential stress governs in this vessel, in inches what is the greatest
length that can be used to average this corrosion?

1. 40 inches
2. 39 inches
3. 29.33 inches
4. 88 inches

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25. What is the required thickness of a 60 inch I.D. cylindrical shell if:

It has and allowable stress at design of 17,500 psi.

The vessel's Category A and D Type 1 joints are fully radiographed. All Category B joints are Type 1
also and have been spot radiographed per UW-11(a) (5) (b).

The vessel MAWP must be 350 PSI at 450°F. The shell will see 11 psi of static head at its bottom.

1. .6072”
2. .7388”
3. .7159”
4. .6266”

26. A hemispherical head formed from solid plate is 48.0 inches in inside diameter this head is attached to
a seamless shell and has not had radiography on the Category A Type 1 weld that attaches the head to the
shell. The vessel is horizontal and operates at 500 PSI water pressure with an allowable stress on the head's
material of 15,000 PSI. The head's thickness required is?

1. .5741”
2. .577”
3. 1.1432”
4. .2356”

27. A 3 ½” thick plate weld procedure test coupon must be tensile tested. This will require the cutting of
the test coupon into smaller pieces. The tensile testing machine is capable of pulling up to 1” thick
specimens. How many pieces will be required to for a complete test per Section IX ?

1. 6
2. 8
3. 2
4. 12

28. A round weld tensile specimen is tested and found to fail in the base metal at a load of 14,876 lb. The
specimen was measured before the test to have a diameter of .503 inches, the ultimate tensile strength of
this specimen is:

1. 74,878 pounds per square inch.

2. 18,829 pounds per square inch.
3. 235,185 pounds per square inch.
4. 74,380 pounds per square inch.

(Hint: The area of a circle is equal to 3.141 (Pi) times its radius squared)

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29. A vessel has undergone welded repairs and will require a hydrostatic test. This vessel is horizontal and
has an I.D. of 6 feet. The vessel operates at 150 psi and the Data Report reflects an E of .85 for the vessel
based on RT-3. The limiting thickness of the vessel is its shell course. The vessel is made of SA-5 15 Gr 70
material with an allowable stress at temperature of 15,500 psi. Its allowable stress at test temperature is
17,500 psi. What is the required thickness of this vessel and what shall the pressure be as read from a gage
on the bottom of the vessel during the test. The upper most part of the vessel is 6 feet above the centerline
of the vessel’s horizontal shell. The static head of water is .433 psi per vertical foot.

1. t = .3621 and gage pressure will be 169.3 psi

2. t = .875 and gage pressure will be 260.624 psi
3. t = .4234 and gage pressure will be 224.057 psi
4. t = .4234 and gage pressure will be 254.032 psi

30. During an internal inspection the following minimum thickness readings were taken on a vertical
vessel
Top Head Present = .235”
Shell Course Present = .225”
Bottom Head Present = .195"

This vessel has been in service for 6.5 years and all components had an original thickness of .250 inch. The
engineer calculated a minimum thickness of the top head to be .145" and the bottom head minimum
thickness to be .155" and the shell's minimum thickness to be .205". Based on the readings what is the
Corrosion Rate for the shell element?

1. .025” / year
2. .0023” / year
3. .020” / year
4. .00384’ /year

31. Pitting has been discovered to be localized in a small area of an ellipsoidal head. The depth of the pits
does not exceed half of the required wall thickness. A circle is drawn that takes in all the pits and its
diameter is 8 inches. The maximum area of all the pits in square inches to allow averaging is;

1. 8 square inches.
2. 6 square inches.
3. 7 square inches.
4. 5 square inches.

32. A cylindrical shell has been discovered to have uniform external corrosion. The shells original
thickness was 7/8 inch; it is presently .745 inch in thickness. The original O.D. of the shell was 30 inches.
The vessel operates at 650 0F with a stress allowable on the material of 15,000 psi. 100 % RT was
performed on the vessel. All joints are types 1. What is the vessel's present MAWP?

1. 760 psi
2. 772.13 psi
3. 766.88 psi
4. 382.10 psi

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33. A shell course is being replaced with the new course being 60 inches in inside diameter and 7/8 inches
thick. The vessel course material is SA-515 gr 60 plate at a design temperature of 750 0F the stress allowed
is 13,000 psi.. The vessel joints are all type 2 and the vessel is stamped RT-3. What is the MAWP of this
shell course?

1. 298.11 psi
2. 316.74 psi
3. 150.35 psi
4. 335.38 psi

34. A standard ellipsoidal head with a 1 ½” flange is attached to the bottom of a vertical vessel. The heads
inside diameter is 56 inches. The vessel has a total elevation of 100 feet. The elevation at this head to shell
joint is 5 feet. What amount of hydrostatic head must be considered for use in this head’s required thickness
calculation?

1. 41.135 psi
2. 41.909 psi
3. 41 psi
4. 41.69 psi

35. A torispherical head which can be calculated using UG-32 of Section VIII Div. 1 has an outside skirt
diameter of 84 inches and an inside knuckle radius of 6 % of its O. D. this means that the inside crown
radius must be;

1. 42 inches.
2. 5.04 inches.
3. 84 inches.
4. 2.52 inches

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ANSWER LOCATION OF ANSWER

(Example) API 510 4.1.2
1. 3 UG-99
2. 4 UW-12
3. 2 UG-28
4. 3 UW-16
5. 3 UG-32
6. 3 IX ART I QW-152
7. 3 Fig UCS-66.1
8. 3 IX ART II QW-253
9. 4 IX ART II QW-253
10. 2 IX ART II QW-253
11. 3 VIII UW-2 (a)(1)(a)&(b)
12. 1 VIII UG-80 (a)(1)
13. 4 API 510 4.3
14. 3 QW-163 Evaluate on the Convex Side only
15. 2 VIII UG-100 (c)
16. 3 SECTION V ART 6 T-652
17. 2 API 510 5.7
18. 4 API 510 5.7
19. 4 API 510 5.7
20. 2 API 510 5.7
21. 3 API 510 5.7
22. 2 API 510 5.7
23. 2 API 510 5.7
24. 3 API 510 5.7
25. 4 UG-27 and API 510 Body of Knowledge
26. 2 UG-32
27. 2 IX ART I QW-151.1(c)
28. 1 IX ART I QW-153
29. 3 UG-99 and API 510 Body of Knowledge
30. 4 API 510 6.4
31. 3 API 510 5.4
32. 3 UG-27 UG-116-UG
33. 1 UG 27 UG-116
34. 4 41.135 + .559 (hydro hd. in head depth)= 41.69
35. 3 UG 32 (e)

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Open Book API 510 Practice Exam A

1. Stress at Test = 15,000 Psi

Design Stress = 13,800 Psi
MAWP = 125 Psi

Test Pressure = 1.3 x x 125 = 176.63 Psi

3. UG 28

Calculate Do/t and L/Do

Do/t = 2.0/.025 = 80 L/Do = 60/2.0 = 3.0

Factor A = .00055

4. UW-16 / Fig UW-16.1(i). t min = .377”

t1 + t2 1-1/4 t min
t1 + t2 1.25 x .377 = 0.47125 (total throat required)

t1 or t2 = = 0.2356” (split between two equal sized fillet welds)

By the rule;

t1 or t2 not less than the smaller of ¼ in. or .707x t min

or .707 x .377 = 0.2665 = 0.267”

Answer: 0.250” No individual throat can fall below this value per this rule.

The t1 + t2 rule is still satisfied (not less than 0.47125) since 0.250 + 0.250 = 0.500”

5. UG-32(d) =

P = 50
t =?
S = 15,000 t = 0.200”
E = 1.0
D = 10’ x 12 = 120”

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6. Specimen 1:

Specimen 2:

1 = 73,377 2 = 84,314

13. Remaining Life

Next inspection no more than ½ remaining life or 10 years use the lesser.

20. 80% of the shell’s diameter 0.80 x 96 = 76.8”

22. 80% of the shells diameter 0.80 x 96 = 76.8” Radius = 76.8/2 = 38.4 since 31” is with in the 38.4”
radius it may consider within the spherical portion.

23. Shell’s t min = 0.521”

Pit depth = 0.333”

The rule says that the pit may not exceed ½ the part’s t min

0.521/2 = 0.2605” The pit must be repaired.

24. The ID of the shell = 88”

1/3 of 88” or 40” which ever is less 88/3 = 29.33” Use 29.33”

25. t =? From UG-27

P = 350 + 11 = 361 Psi
S = 17,500 Psi
E = 1.0 per UW 12(a) = 0.6266”
R = 60/2 = 30

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26.

P = 500 + Hydrostatic Head

H.H. = 4 feet x 0.433 = 1.732 Psi

P = 501.732 Psi
S = 15,000
L = 48/2 = 24
t=?
E = .70 for Category A weld no RT

From UG 32

= = 0.576161”

Rounding up for thickness = 0.577”

27. Thickness of coupon = 3.5” 3.5/4= 0.875” (4 pieces for each tensile specimen)

2 tensile tests are always required therefore;

2 x 4 = 8 pieces

28. Load = 14,876 lbs

Diameter = 0.503” Radius = 0.503/2 = 0.2515

Area of a circle = x r2

= 3.141 x (0.2515)2 = 3.141 x 0.2515 x 0.2515 = 0.19867”

Finally compute the tensile strength = Load/Area = 14,876 / 0.19867 = 74,877.938 Psi

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29.

t=?
P = 150 + 3.897 = 153.897 Psi
S = 15,500 psi design
S= 17,500 psi test
E= .85
R = 36”
Hydrostatic Head = .3897 Psi

Hydro Pressure 1.3 x 17,500/15,500 x 150 = 220.16 Psi at the top gauge

Bottom gauge reads 220.16 + 3.897 = 224.057 Psi during test.

Thickness required.

From UG 27: = = = 0.4234

Answers: t min 0.4234”

Pressure at bottom during test is 224.057 Psi

30.

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32. From: Appendix 1

Wall Loss = 0.875 - 0.745 = 0.130”

Outside Diameter = 30.0”

Ro = 30.0/2 = 15.0 - 0.130 = 14.87

Corroded outside radius is 14.87”

Calculate pressure allowed.

t = 0.745 = 766.88 Psi

S = 15,000 Psi
P =?
Ro= 14.87”
E= 1.0

33. From: UG 27

P =?
S = 13,000
E = .80
t = 0.875”
R = 60”/2 = 30”

34. Depth of head = ¼ ID + Flange

56/4 + 1-1/2” = 14 + 1-1/2 = 15-1/2”

Hydrostatic Pressure on Head

95 feet + 1.2916 feet = 96.2916 x .433 = 41.69 Psi

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