ASME PCC-2 ( Edition-2011)

Select only one option which you think is most appropriate

1. “External Weld Overlay Repair Method for Internal Thinning” is generally not appropriate
repair method for which of the following defects

a. Pitting

b. General Wall Thinning

c. Local Wall Thinning

d. Gouges

Ans: b. REF: Part 1 Table 1 ASME PCC-2

2. “Type B Full Encirclement Steel Reinforcing Sleeves for Piping” is considered generally
appropriate solution for----------

a. Local Wall Thinning

b. Laminations

c. Blisters

d. All of above

Ans: d. REF: Part 1 Table 1 ASME PCC-2

3. In insert plate repair method, rectangular and square insert plates of 20 mm thickness
shall have corners rounded to a minimum radius equal to:

a. 3 times insert plate thickness i.e 60mm

b. 6 times insert plate thickness i.e120mm

c. 75 mm

d. 150 mm

Ans: c. REF: Clause 3.4 , Art 2.1 ASME PCC-2

4. A corroded area on non-post weld heat-treated cylindrical shell was completely removed
by making a 150mm diameter opening, which is to be repaired by using circular Butt-welded
Insert Plates. What will be Minimum diameter of Insert Plate?

a. Lesser of 12t or 380 mm (where t is the thickness of the parent material).

b. Greater of 12t or 380 mm (where t is the thickness of the parent material)

c. 150mm diameter

d. 300 mm diameter

Ans: a. REF: Clause 3.6.1 , Art 2.1 ASME PCC-2

5. For Pre-qualified Design, for repair made with “External Weld Overlay to Repair Internal
Thinning” , the maximum dimension (L, length along axis) compensated by a circular, oval,
or rectangular overlay should not does not exceed:

a. One-half the nominal outside diameter of the component

b. 200 mm (8 in.)

c. Lesser of one-half the nominal outside diameter of the component or 200 mm (8 in.)

d. Higher of one-half the nominal outside diameter of the component or 200 mm (8 in.)

Ans: b. REF: Clause 3.1.3.1 f, Art 2.2, ASME PCC-2

6. Full encirclement sleeve where ends are welded circumferentially to the carrier pipe is
called:

a. Type 1 sleeve

b. Type A sleeve

c. Type 2 sleeve

d. Type B sleeve

Ans: d. REF: Clause 1.1.2 , Art 2.6 ASME PCC-2

7. Full encirclement sleeve where ends are not welded circumferentially to the carrier pipe is
called

a. Type 1 sleeve

b. Type A sleeve

c. Type 2 sleeve
 d. Type B sleeve

Ans: b. REF: Clause 1.1.2 , Art 2.6 ASME PCC-2

8. Type A sleeves shall be fabricated or manufactured from steel meeting the material
specifications of the construction code, and should have a minimum thickness equal to

a. Two-thirds the thickness of the carrier pipe.

b. Full thickness of the carrier pipe.

c. Half thickness of the carrier pipe.

d. Three-fourth thickness of the carrier pipe.

Ans: a. REF: Clause 3.1, Art 2.6, ASME PCC-2

9. Full encirclement Types A and B sleeves shall be at least:

a. 100 mm (4 in.) long and extend beyond the defect by at least 50 mm (2 in.).

b. 100 mm (4 in.) long and extend beyond the defect by at least 25 mm (1 in.).

c. 150 mm (6 in.) long and extend beyond the defect by at least 75 mm (3 in.).

d. 150 mm (6 in.) long and extend beyond the defect by at least 50 mm (2 in.).

Ans: a. REF: Clause 3.4, Art 2.6, ASME PCC-2

10. In “Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug welds
may be designed to take up to----------- of the patch plate load.

a. 50%

b. 25%

c. 100%

d. 30%

Ans: d. REF: Clause 3.5, Art 2.7, ASME PCC-2

11. In context of ASME PCC-2, the total depth of overlay or back cladding shall be ------------
thickness, unless otherwise specified.

a. 3 mm (1⁄8 in.) or lower

b. 3 mm (1⁄8 in.) or greater

 c. 1.5 mm (1⁄16 in.) or greater

d. 1.5 mm (1⁄16 in.) or lower

Ans: b. REF: Clause 3.3, Art 2.11, ASME PCC-2

12. Freeze plug isolation method was planned for repair on NPS 3 piping. According to
ASME PCC-2, which of the following is appropriate.

a. Use Carbon Dioxide Freeze Plugs with the jacket length not less than three pipe
diameters

b. Use Liquid nitrogen Freeze Plugs with the jacket length not less than four pipe
diameters

c. Use Liquid nitrogen Freeze Plugs with the jacket length not more than four pipe
diameters

d. Use Carbon Dioxide Freeze Plugs with the jacket length not more than three pipe
diameters

Ans: d. REF: Clause 3.7, Art 3.2, ASME PCC-2

13. Freeze plug isolation method was planned for repair on NPS 6 piping. According to
ASME PCC-2, which of the following is appropriate.

a. Use Carbon Dioxide Freeze Plugs with the jacket length not more than four pipe
diameters

b. Use Carbon Dioxide Freeze Plugs with the jacket length not less than four pipe
diameters

c. Use Liquid nitrogen Freeze Plugs with the jacket length not more than three pipe
diameters

d. Use Liquid nitrogen Freeze Plugs with the jacket length equal to three pipe diameters

Ans: c. REF: Clause 3.6, Art 3.2, ASME PCC-2

14. In Fillet Welded Patches repair method, in addition to completely encompassing the
damaged area the size (length and width) of the patch plate shall also be large enough to
encompass any additional area anticipated to experience similar damage during the life of
the repair and The patch plate should overlap sound base metal by distance at least ----------

a. 25 mm (1 in.).

b. 50 mm (2 in.).
 c. Equal to nominal wall thickness of component

d. Twice the nominal wall thickness of component

Ans: a. REF: Clause 3.1d, Art 2.12, ASME PCC-2

15. According to ASME PCC-2 guidelines, for “repair by weld” on base metal, if weld
thickness is -------------then it should be examined by volumetric examination methods such
as radiographic or ultrasonic testing.

a. Over 19 mm (3⁄4 in.) thick

b. Over 25 mm (1 in.) thick

c. Over 9.5 mm (3⁄8 in.) thick

d. Over 12.7 mm (1⁄2 in.) thick

Ans: c. REF: Clause 5.1.2, Art 2.11, ASME PCC-2

16. Mechanical Clamp Repair can be used on-stream for:

a. General Wall Thinning

b. Local Wall Thinning

c. Pitting

d. B and C

Ans: d. REF: Part 1 Table 1 ASME PCC-2

17. Unless an engineering evaluation is performed for shell and tube Heat exchangers, tube
plugging with Friction fit tapered plugs can be done only if

a. shell-side operating pressure is 1.5 MPa (200 psi)or less

b. shell-side operating temperature 205°C (400°F)or less

c. tube-to-tube sheet joints are expanded and not welded

d. All above conditions must be met

Ans: d. REF: Clause 4.2b, Art 3.12, ASME PCC-2

18. When in-service leak test is performed on equipment or piping, the test medium normally
will be
 a. Water

b. Air

c. Process fluid

d. Nitrogen

Ans: c. REF: Clause 3.1, Art 5.1, ASME PCC-2

19. For pressure testing on vessels and piping, the Pressure gage/recorder ranges shall be
greater than ----times and less than --- times the required test pressure

a. 1.5, 3

b. 1.5, 4

c. 1.5, 2.5

d. 2,4

Ans: b. REF: Checklist item 7, Mandatory App I. Art 5.1, ASME PCC-2

20. In order to reduce the risk of brittle fracture during the pressure test, the temperature of
the metal during the test of pressure vessels should be maintained at a minimum of --------
the minimum design metal temperature (MDMT)

a. 17°C below

b. 17°F above

c. 30°F above

d. 30°C above

Ans: c. REF: Clause 6.1b, Art 5.1, ASME PCC-2

21. The excavated „boat samples‟ have which of following advantage

a. The cavity left by the removal of the sample is very conducive to repair welding.

b. The tapered nature of the cavity allow complete access for most welding processes

c. Sloping curvature of the cavity allow complete access for most welding processes.

d. All of above

Ans: d. REF: Clause I-7g, Art 3.4 Mandatory App I, ASME PCC-2
22. For the safe distance calculation for pneumatic test, if the scaled consequence factor is
5m/kg1/3 (12.5ft/lb1⁄3), what effect you expect on human beings if vessel is burst during test

a. Eardrum rupture

b. Lung damage and Eardrum rupture

c. Fatal

d. Safe. No effects

Ans: b. REF: Table III-1, Mandatory App III. Art 5.1, ASME PCC-2

23. According to ASME PCC-2 guidelines for conducting a pneumatic tightness test, the test
pressure should be no less than

a. The higher of 105 kPa (15 psi) or 25% of the system design pressure.

b. 105 kPa (15 psi)

c. 25% of the system design pressure.

d. The lesser of 105 kPa (15 psi) or 25% of the system design pressure.

Ans: d. REF: Clause 6.2.1.5b, Art 5.1, ASME PCC-2

24. According to ASME PCC-2 guidelines, Fillet Welded Patches-----------used for lethal
service applications

a. Should not

b. Shall not

c. May be

d. There is no such guideline in ASME PCC-2

Ans: b. REF: Clause 2c, Art 2.12, ASME PCC-2

25. According to ASME PCC-2 guidelines for bending of pipes the term “hot bending” refers
to bending of ferritic steels at a temperature above the------------

a. Lower critical temperature

b. Upper critical temperature
c. Preheating temperature
d. Stress relieving temperature
 Ans: a. REF: Clause 4.3.1, Art 3.7, ASME PCC-2

26. “Butt-welded Insert Plates in Pressure Components” is considered generally appropriate

repair method for which of the following defects

a. General Wall Thinning

b. Local Wall Thinning

c. Circumferential and Longitudinal Cracks

d. All of above

Ans: d. REF: Part 1 Table 1 ASME PCC-2

27. A sub-contractor proposed “Welded Leak Box Repair” as repair method for following
defects. For which of the following it is NOT permitted repair method as per ASME PCC-2

a. Local Wall Thinning

b. General wall thinning

c. pitting

d. All of above

Ans: b. REF: Part 1 Table 1 ASME PCC-2

28. “Full encirclement Steel Reinforcing Sleeves for Piping” is proposed for repairing leaking
defect. Which of the following type will be considered generally appropriate solution

a. Type A

b. Type B

c. Either Type A or B

d. None of above

Ans: b. REF: Clause 1.1.2, Art 2.6 ASME PCC-2

29. For „doghouse” type insert plate having its edge abutting with existing longitudinal weld,
what length of existing weld shall be cut on each side of insert plate and re-welded

a. 150 mm maximum

b. Minimum 6 times thickness of insert plate

 c. 150 mm minimum

d. Lower of b and c

Ans: c. REF: Note 4 Fig-3 , Art 2.1 ASME PCC-2

30. For „doghouse” type insert plate having its edge abutting with existing longitudinal weld,
certain length of existing weld shall be cut on each side of insert plate and re-welded. What
NDT should be performed on this weld?

a. Full RT

b. Full UT

c. MT or PT both sides of weld

d. Any one of a,b,c

Ans: d. REF: Note 4 Fig-3 , Art 2.1 ASME PCC-2

31. A post weld heat-treated vessel 40mm thick was repaired using square insert plates of
40 mm thickness. Butt welds around the periphery of this insert plates shall be spaced no
closer to existing welds than------.

a. 150mm

b. 80 mm

c. 6 times thickness of insert plate ( 240mm)

d. 8 times thickness of insert plate ( 320mm)

Ans: b. REF: clause 4.3.3, Art 2.1 ASME PCC-2

32. The outer diameter of cylindrical shell is 640 mm and nominal wall thickness of the shell
is 20mm is to be repaired by “External Weld Overlay to Repair Internal Thinning”. Unless
otherwise justified by a fitness for service assessment, External Weld Overlay shall extend
on base Metal beyond the affected base metal for a minimum distance, B, equal to:

a. 40mm(twice nominal wall thickness)

b. 60mm

c. 80mm

d. None of above

Ans: b not c. REF: clause 3.1.2.2, Art 2.2, ASME PCC-2

33. A cylindrical shell 30mm thick was repaired by depositing 20mm “ External Weld Overlay
to Repair Internal Thinning”. The corners of the weld overlay shall be rounded to ------radius

a. Maximum 20mm.

b. Minimum 20mm.

c. Minimum 30mm .

d. Maximum 30mm.

Ans: b. REF: clause 3.1.2.5, Art 2.2, ASME PCC-2

34. A cylindrical shell 32mm thick is to be repaired by depositing “External Weld Overlay to
Repair Internal Thinning”. According to ASME PCC-2 guidelines, what is the maximum
thickness which can be deposited for such repair.

a. 75% of wall thickness 24mm

b. 150% of wall thickness, 48mm

c. 50% of wall thickness, 16mm

d. None of above

Ans: d. REF: clause 3.1.2.8, Art 2.2, ASME PCC-2

35. To qualify a repair design made with “External Weld Overlay to Repair Internal Thinning”
a burst test was successfully made on 12 inch OD cylindrical mock up. This test qualifies
repair components of -----------------Outside diameter.

a. 12 inch to unlimited

b. Any OD up to 12 inch

c. 6 inch to 24 inch

d. Any OD up to 24 inch

Ans: c. REF: clause 3.2.1.1i, Art 2.2, ASME PCC-2

36. Full encirclement sleeve used for leaking repairs, which of the following welds are NOT
allowed for making longitudinal weld joint of the sleeve.

a. Overlapping side strip welds

b. Butt joint with backing strip

 c. Butt joint without backing strip

d. All of above are not allowed l

Ans: a. REF: Fig.2, Art 2.6, ASME PCC-2

37. It is proposed to carry out repair on carrier pipe using Tybe B sleeve. The wall thickness
required for the maximum allowable design pressure for carrier pipe is 12 mm. The sleeve
should have a wall thickness equal to or greater than --------------

a. 8mm.( two thirds of carrier pipe thickness required for MAWP)

b. 6mm.( Half of carrier pipe thickness required for MAWP )

c. 12 mm (full thickness of the carrier pipe required for MAWP).

d. 9mm (Three-fourth thickness of the carrier pipe required for MAWP).

Ans: c REF: Clause 3.2, Art 2.6, ASME PCC-2

38. While designing fillet patches with plug welds the design can be based on:

a. Considering the combined strength of the patch plate, the underlying shell
and plug welds.
b. Considering the strength of the patch plate alone

c. Considering the strength of the underlying shell and plug welds

d. Considering the strength of the patch plate and plug welds

Ans: a REF: Clause 3.1 g , Art 2.7, ASME PCC-2

39. In “Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug weld
holes should have a diameter not less---------and not more than-----------,( The component
thickness is 24 mm and fillet patch thickness is 16 mm)

a. 16mm, 24mm

b. 25mm, 50 mm

c. 22mm, 38 mm

d. 12mm, 24 mm

Ans: c REF: Clause 3.5b, Art 2.7, ASME PCC-2

40. Alternatives to Traditional Welding Preheat method, the Welds in steels having a Carbon
equivalent > 0.5 % are prone to delayed cracking. A waiting period of ---------- should be
allowed to detect delayed cracking before final NDT

a. 12 hours or more is performed.

b. 24 hours or more

c. Not more than 12 hours

d. Not more than 24 hours

Ans: b REF: Clause 3.4 , Art 2.8, ASME PCC-2

41 Carbon equivalent (CE) may be used as a means for determining the necessity for
preheat. According to ASME PCC-2 guidelines, Preheat is optional if
a. CE is <= 0.3%
b. CE is <= 0.4%
c. CE is <= 0.45%
d. CE is <= 0.5%

Ans: c REF: Clause 3.4, Art 2.8, ASME PCC-2

42 When Cracking parameter (Pcm) is be used as a means for determining the necessity for
preheat and the level required. According to ASME PCC-2 guidelines, Preheat is optional if :
a. Pcm is <= 0.3%
b. Pcm is <= 0.25%
c. Pcm is <= 0.15%
d. Pcm is <= 0.2%

Ans: c REF: Clause 3.5, Art 2.8, ASME PCC-2

43. In context of ASME PCC-2, the term-------------refers specifically to the application of

carbon steel or low alloy weld metal, applied for the purpose of restoring base metal
thickness.

a. Weld Overlay

b. Weld build up

c. Clad Restoration
 d. Back Cladding

Ans: b REF: Clause 1.5.2, Art 2.11, ASME PCC-2

44. According to ASME PCC-2 guidelines, the total linear expansion of 20 meters long
vessel (MOC : SA 516 Gr.70) at typical PWHT temperature of 650°C (1,200°F) may be
estimated as:

a. 240mm.

b. 60 mm.

c. 120 mm.

d. 160 mm.

Ans: d REF: Clause 3.2 , Art 2.14, ASME PCC-2

45. There are two sources of water, A and B, with chloride content of 70 ppm and 40 ppm
respectively. As per ASME PCC-2, which water can be used for Hydro testing of austenitic
steel vessels or piping systems,

a. Both A and B are OK

b. Only A is OK

c. Only B is OK

d. Both are not OK

Ans: c REF: Clause 6.1.t.7, Art 5.1, ASME PCC-2

46. The calculated stored energy of Pressure vessel under Pneumatic testing is 135,500,
000 J (100,000,000 ft-lb), According to ASME PCC-2, considering this stored energy, the
minimum safe distance between all personnel and the equipment being pneumatically tested
should be calculated and adhered to, if:

a. Test pressure is Greater than 100 psi

b. Test pressure is Greater than 125 psi

 c. Test pressure is Greater than 150 psi

d. It is not mandatory requirement considering given stored energy

Ans: d REF: Clause 6.2 e, Art 5.1, ASME PCC-2

47. Pneumatic tightness test is to be performed on a piping system with Design pressure of
200 psi. According to ASME PCC-2 guidelines, the maximum test pressure should be not
more than -------

a. 70 psi

b. 100 psi

c. 200 psi

d. 220 psi

Ans: a REF: Clause 6.3.c, Art 5.1, ASME PCC-2

48. In Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug welds
shall be spaced such that their pitch (centre-to-centre spacing) should not be less than--------
mm ( the bottom diameter of the hole in which the weld is made =20 mm)

a. 50

b. 60

c. 70

d. 80

Ans: b REF: Clause 3.5b, Art 2.7, ASME PCC-2

49. Inspection and repair methods for shell and tube heat exchangers as given in ASME
PCC-2 are not applicable to heat exchangers constructed in accordance with

a. TEMA standards.
b. ASME BPVC Section VIII, Division 1.
 c. ASME BPVC Section VIII, Division 2.
d. ASME BPVC Section VIII, Division 3.
Ans: d REF: Clause 2.2 a, Art 3.12, ASME PCC-2

50. For Flange repair, According to ASME PCC-2 guidelines, Under-thickness of a raised
face due to refinishing shall be acceptable, provided the minimum finished height of the
raised face is

a. 0.8 mm (0.031 in.).

b. 0.16 mm (0.062 in.).
c. 0.24 mm (0.093 in.).
d. No under thickness of raised face is accepted.

Ans: a REF: Clause 3.1, Art 3.3, ASME PCC-2