API - 510 COURSE NOTES VOLUME -I DAILY PRACTICE EXAMSAPI 510 Prep.C ourse Pune. Jan 20-30 , 2008 API 510 PREPARATORY COURSE BENCH MARK QUIZ Note: Tick only one alternative, which you think is appropriate. 1. Which of the following types of discontinuities is not normally detected by radiography? a. Cracks b. Incomplete penetration “ Laminations y d. Slag 2. API 510 be used as a substitute for the original construction of pressure vessels before it is placed in-seivice. va) — Shall not b) Should c) May : d) Shall 3. Compared to ASTM A 515 Gr. 60 plates, ASTM A 516 Gr. 60 plates have: Better Tensile Strength Better toughness Better high temp. properties None of above 4. Who establishes inspection interval for thickness measurements, and external visual inspections. a) Vessel engineer; vb) — Owner-user or the inspector ¢) Corrosion Engineer d) NDE engineer 5. ASME Sec. VIII Div.1 is based on factor of safety equal to a) 4 b) 3 xy 3.5 d) 2.5API S10 Prop Conse Pune . Jan 20-30 , 2005 6. a 10. Identi’y incorrect statement from following, if any. a. b. G va. A welder performing procedure test is also qualified in that position. Supplementary essential variables become essential variables when impact test is specified. For procedure qualification, the test_can be performed in any position as the position is not essential variable for procedure qualification. None of above is incorrect statement In plate specification A 516 Gr 76, the letter A indicates: anso That material is ASME material. (A for ASME) That material is Ferrous material That material is Non-Ferrous material None of the above The symbol which indicates ASME code stamping for vessels manufactured to ASME Section VIII Div. 1 is a) b) 4“) a) UL . u2 U None of these What. will be the applicable mandatory Edition and addenda for ASME Sec. VIII, Div. 1 to be used If contract for manufacturing a new vessel was signed on 14 December 2004? eee 2001 edition and 2002 addenda 2001 edition and 2003 addenda 2001 edition with 2004 addenda None of the above Term E used in shell thickness formula in ASME Sec. VIII Div.1, represents weld joint efficiency, whose value is equal to 1, if: Longitudinal and circumferential welds are radiographed for their entire length Longitudinal welds are radiographed for their entire length and circumferential welds are spot radiographed . Both welds are spot radiographed a and b aboveAPI 510 Prop.Course Pune . Jan 20-30 , 2005. 14 12. 13. 14, 15. A restoration work by weld-overlay was carried out on corroded wall of vessel and it can now be used as per the design conditions of the vessel. This activity will be termed as: a. Renewal of vessel b./ Repair of vessel c. Alteration to vessel d. — Re-rating of vessel In certain MP. Check of pr. Vessel, The size of "indication" for a certain discontinuity was seen as 4 mm but after the MP. Check and using magnifying glass it was seen having actual size as 2.5mm only. If stipulated acceptance criteria for that type of discontinuity was 3 mm, your decision is: a... The size of indication is higher than 3mm. Reject. b. The size of discontinuity is lower than 3 mm, Accept. c. Depends on opinion of Examiner. d. Depends on the procedure adopted for MPI. i.e dry or wet particles 7 ASME Code requires averaging of impact test values of how many specimen for the relevant acceptance criteria. (a). 2 v(b) 3 (c) 4 (d) None of these - A stainless steel weld has a crack open to the surface . Which NDT method will reveal it effectively? a. Liquid Penetrant b. Magnetic particle c. Radiography d. All of above PQR document normally may be revised and re submitted for acceptance. a. True wb. False c. Depends on company policy d. wz Depends on Third party inspector's discretion.API 510 Pre Course Pune . Jan 20-30 , 2005, 16. Ho tapping is best described by statement: a. It is technique of preheating the vessel wall to specified cemperature and tapping with 1b. rounded hammer to detect walll thinning A. It is technique of providing a tapping connection while the system is in operation c. Ibis technique of fixing a on/off tap on drain nozzle of pressure vessel d. It is act of pre heating the component before using the tap and die for threading so that less effort is required for threading operation. 17. Which of the following represent grouping of weld-metals in ASME IX? a. P~ Nos b./ F ~ Nos ce A- Nos 18. A inspector should be stricter while carrying out inspection on: af Longitudinal Joint Circumferential Joints Both are equally critical as per ASME Sec. VIII, Div.1 Depends on QA plan ans 19. FT examination is used to detect the surface cracks in welds as. well as in base metal plates. For proper detection, a. We should allow higher penetrant time on weld Jb. We should allow higher penetrant time on plates c. » Penetrant time on weld as well as plates is same d. Depends on type of penetrant used. 20. As per ASME Sec. VIII Div. 1, "Weld joint category” means: a. Type of weld, i.e., Single V type, Double V type, U type etc. b. Type of weld, i.e., Full penetration, partial penetration etc. fc. Location of weld, i.e., longitudinal, circumferential, nozzle attachment weld etc. d. oC Type of weld joint, i.e., Butt-weld joint, fillet weld joint, lap joint, etc. —.API 510 Prep.Course Pune . Jan 20-30 , 2005 API 510 PREPARATORY BENCH MARK QUIZ Answer Key | l. >lo}0 eens S ioAPL 510 Prop. hoe se Pune . Jan 20-30 , 2005, API 510 PREPARATORY COURSE Exam 1 (Closed Book) In a 30 mm thick cylindrical shell, the longitudinal as well as circumferential joints are double welded butt welds with full Penetration. Which of the following is true as regards the longitudinal and circumferential joints? They are of same category but different types. Ahey are of same type but different categories. Both the category as well as type are same. Both the category as well as type are different. aoge Vessel MAWP of existing vertical vessel will be affected for which of the following? If Vessel Part MAWP changes for any vessel part. If design pressure is reduced (other factors remaining same) Vessel height is changed by adding/deleting a shell course Aandc , . aoge A Shell with Inside dia = 2200 mm, and Corr. allow.= 5 mm is to be designed as per ASME Sec. VIII , Div.1. What will the value of “R” in design formula for shell thickness? 1100 mm 1105 mm - 1095 mm 1110 mm aoco In thickness formula for internal pressure for shell, term ‘E’ refers to: Modules of Elasticity of material Thermal Expansion Joint efficiency of the weld v None of above ance The hydrostatic pressure caused by 10 ft. of liquid column (sp. gr. = 1) will be: 2 10ipel b. 43.3 psi © 4,33 psiv d. None of the aboveAPI S10 Prep.Cour codes? a. APIS1O, b. ASME Sec. 1, C. ASME Sec. VIII Div. 1, . d. None of these Code rules for testing vessels in service are detailed in: a API 510 v b. API570 ¢. ASME Section VIN Div.1 d. None of above 8. Identity category A joints from following: 2. Longitudinal joints ¢ b. Circumferential joints, shell to shell ¢. Shell to hemispherical head joint 4. aandcabove,, ; If all other conditions are remains same the design thickness of which dished end (Torispherical, Hemispherical, Ellipsoidal) will be maximum? a. Torispherical v b. — Hemispherical c. — Ellipsoidal d. All will be same 10. Any thickness-offset within the allowable tolerance shell be Provided a minimum taper transition of: a 3 to 1 mine b. 4tot min © 3to2 min d. ito 2 min 11. ASME Sec VII Div. 1 specifies different acceptance level for weld reinforcement, which of the following statements are true in your ‘opinion? 2 Permitted reinforcement for long. seems is higher than circ. seems b. Permitted reinforcement for long. seems is lower than circ. Seems eeeAPI 510 Prep Couse Pune. Jan 20-30 , 2005. 6 A new pressure vessel should be inspected to which of the following codes® API 510, ASME Sec. 1, ASME Sec. VIII Div. 1, None of these apse 7. — Code rules for testing vessels in service are detailed in: API 510 APL 570 ASME Section VIIT Div.1 None of above ange 8. Identity category A joints from following: 2. Longitudinal joints b. Circumferential joints, shell to shell Shell to hemispherical head joint 4. aandc above If all other’ conditions are remains same the design thickness of which dished end (Torispherical, Hemispherical, Eliipsoidal) will be maximum? a. Torispherical b. — Hemispherical c. — Ellipsoidal d. All will be same 10. Any thickness-offset within the allowable tolerance shell be provided a minimum taper transition of: a. 3to1min b. 4toimin © 3to2 min d. 1 to2 min 14, ASME Sec VIII Div. 1 specifies different acceptance level for weld Feinforcement, which of the following statements are true in your opinion? a Permitted reinforcement for long. seems is higher than circ. seems b Permitted reinforcement for long. seems is lower than circ. Seems eeeAPIS10 Prop.Course 12, 13, 14. ae 15. 16. 17. Pune . Jan 20-30 , 2005, Permitted reinforcement for long. seems is same as circ. Seems d Permitted reinforcement does not depend on location of seems. Vessel MAWP for vertical vessel is measured at: Top most point of vesse” Bottom most point of vessel At the mid point between top & bottom None of above aoc Which oF the following statements is true? All defects are not discontinuities. All discontinuities are defects. Discontinuities are rejectable defects. Defects are rejectable discontinuities. ange A Pressure Vessel is designed for 0.85 joint efficiency with full Penetration welds. RT requirement will be: Nil : Spoty 100 % T-joints radiography aoco A vessel with 50 inches OD and 1% in. thickness is to be provided Std. torisph. heads. The heads shall be knuckle radius as follows: 25 inch, 4 inch ve 30 inch, 3 inch B 7s 30 inch, 3% inch/ “ 25 inch, 2 inch x aoge If there is @ conflict between ASME VIII & API 510 Code, for vessels in- service: a ASME will precedent b. API will precedent ¢. ASNT will precedent 4. Owner user will decide Two head to shell joints, one joining a seamless Hemisph, head to shell was radiographed for full length and the other joint joining seamless std. torisph. head to shell was spot radiographad, The weld Joint efficiency for each of these heads respectively will be:API 510 Prep Course Pune . Jan 20-30 . 2005, eee e0.65) ; b 1,4 + ie Ost d. 0.85, 0.85 18. ASME Sec. VIII Div. 1 recommends use of U.T. in place of R.T. (for a fully radiographed vessel) for: All butt welds in vessel All butt and fillet welds in vessel For closing seams only « ‘The code does not permit use of U.T. at all pogo 19. Vessel MAWP for tall vertical vessel will normally be: a. Greater than vessel part MAWPs b. Lower than Vessel part MAWPs « «, May be (a) or (b) depending on Vessel height 4. _ Is always same as vessel design pressure 20. For a vessel constructed withType 1 welds: RT3 means E = 1 RT2 means E = 0.85 RT1 and RT2 may mean E = 1 RT4 means spot radiography aocoAPI 510 Prep Course Pune . Jan 20-30 , 2005. API 510 PREPARATORY Exam 1 - Closed Book ANSWER KEY [O.NO.[ ANSWER | “ASME VIII, UW - 3 (a) "ASME VIII, UG = 98 (a) | [ASME VIII, UG - 27 (a), UG -16 (e) ASME VIII, UG = 27 (a) Body of Knowledge, 3 (a), Page 2 API 510, 3.2 API 510, 1.1 PASME VII, UW-3(a)@) [ASME VIII, UG ~ 32, d, e, F _ [ASME Vill, Fig. UW - 9 [ASME VIII, UW - 35 ASME VIII, UG - 98 (a) [General Knowledge _TASME VIII, Table UW = 12 _ ~ [ASME VIII, UW - 32 Gj) [API 510, 3.2 0, 3.2 iE vill, UW 42 (4) [ASME VIII, UW = 11 (a)-7 ~ [ASME VIII, 98 (a) ~ [ASME VII, UG - 116 (e)_APL SIC Prop Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY Exam 2 - Open Book A standard seamless , ASME F & D head (Torispherical) is used for the following conditions: Material of Construction = — SA515 gr 60 Design Pressure = 250 psig Design temp = S80°F Inside Crown Radius = = ~—72 inches Minimum available thk. = 1.14 inches Category B welds are spot radiographed. Corrosion allowance .125 inches Allowable stress at design temp. 6400 psig Your assessment is: a. The head does not meet code requirements. b. The head meets the code requirements. ¢. Suitability would depend on decision of Pressure Vessel inspector, 4 Data are not adequate. 2. A pressure vessel is to be constructed with MDMT = +20°F, M.0.C = SA 515 gr 60 . Impact testing not performed. Required shell thickness = % , dished head thk. = 1-¥% " (torisph. head). Determine if this material is suitable for: @. Both shell as well as dished head b. Suitable for head but not for shell c. Suitable for shell only but not for head d. Not suitable for either 3. For a certain pressure vessel with spot radiography, and all Welds type 1, Vessel diameter 72 inch I.D M.0. C SA 515 gr 70 Design temp. = 600°F Allowable stress at design temp. = 20,000 psi If shell thk. = 5/8" and C. A = 1/8", the MAWP for the shell will be: 234 psi 168 psi 256 psi ”) None of the above angeAPL 510 Prep Course Pune. Jan 20-30 . 2005. A pressure vessel (M.0.C. 516 gr. 70) has external Jacket spread over 72 inches length of the shell. (Jacket pressure — 180 psi, Jacket teimperature = 350°F) the vessel OD = 36 inches. Shel thickness= 0.5 inch, CA. = Nil. Decide which of the following are applicable in the present case. Shell thickness is ox, / Shell thickness is NOT OK. Data are not adequate. Acceptance of shell thickness depends on opinion of vessel engineer. aoce Choose correct hydrosta tic test pressure from given options for a vessel with the following data: _ Design Pr 360 psi w/e Design temp = 6750F Sk M.0.C erent \ ¢ Allow stress (Ambient) 18600 psi ns :/ Allow stress (675°F) 16900 psi ‘ S,/ $7 a. 540 psig . ‘ b. 515 psig ~ ©. 450 psig 4. None of above Plate A, Plates 537 class 1, 2.0 inch thick Plata B, Plates 515 ar 60, 0.75 inch thick Your assessment is: Plate (A) and plate (B) both require impact test, Only (A) requires, (8) is exempt. Only (B) requires, (A) is exempt. Both do not require impact testing. For vessel shell, thk= 4.0 inch, max. weld mismatch shall be as follows: @. Long seam = 1%", circ seam = v4" 5. Long seam = ¥4") circ seam = 7/32" 1 ¢ Long seam = 7/32”, circ seam = 4” d Long seam = 5/8", circ seam = 14" Toushness (opposite of brittleness) will be best for which materials:API 510 Prop Course 10. f&ooe Pune . Jan 20-30, 20015, Materials represented by curve A Materials represented by curve B Materials represented by curve C Materials represented by curve D In a pressure vessel one of the 2:1 ellipsoidal dished head is removed and a new seamless dished head of same type is installed with a single ‘V’ joint with backing strip and full radiography. What is the joint category, type and efficiency of the joint now? Category-B, Type-1 7 Category-B, Type-2 Category-A, Type-2 Category-B, Type-2 aece A oressure vessel of overall height 80’ has its part MAWP at. various parts as detailed in the sketch. What is the vessel MAWP (hydrostatic head 1’ = 0.433 psi)? a.¥ 419 psi b. 420 psi 7 ©. 430 psi d. 426 psiAPI 510 Prep.Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY COURSE Exam 2 — Open Book (SOLUTION) Q.1 Ref.: ASME VIII, UG - 32 (e), - _ 0.885 PL + OP 1, (As head is seamless and Category B welds are spot radiographed.) 0.885 x 250 x 72.125 = 2 4 0.125 16,400 x 1 = 0.1 x 250 = 159878 9.195 16375 = 0.974" + 0.125 = 1.0995" Available thickness = 1.14” ——— OK CORRECT ANSWER: b Q.2 Refer Fig. UCS - 66 from ASME VIII Div.1 Material is represented by curve B MDMT ~ Thickness point for 34” thickness is above the curve MDMT - Thickness point 1-1/8" is below the curve Material OK for 34" thickness — Shell Material NOT OK for 1-1/8" thickness — Head CORRECT ANSWER: cAPI510 Prep. Course Pune . Jan 20-30 , 2005. E = 0.85 from Table UW - 12 And t = 5/8” ~ 1/8" = ¥%" after deducting corrosion allowance Mawp = 20.000x0.85x0.5 36.125+0.6x0.5 Note: R in corroded condition 36.125” 233.36... . say 234 psi_/ CORRECT ANSWER: a Q4 1/0, =72/36=2.0 and D./t=36/0.5=72 From Fig. G of ASME II ~ Part D, A = 0.0011 From Fig. CS-2, B = 11500 4B 4x11500 Allowable Ext. Pr.= 43 _ —— = 212.9 psi > 180 psi... OK 3D,1) 3x72 CORRECT ANSWER: a, / Q.5 Refer UG - 99 of ASME VIII Hydrostatic test pressure = _1.3 x design pressure x stress ratio 18600 16900 = 13x 360x = 515.0 psi CORRECT ANSWER: b 26 Plates 537 clause 1 is curve D and 515 gr60 is curve 8. From Fig. UCS ~ 66, plate A, the point is above curve. So impact testing not required for plate A. For plate B, point is below the curve. Now go to UG - 20 (f). Material is P No. 1 and < 1", and temperature > -20°F, So impact testing for B is also not required, CORRECT ANSWER: dAPI S10 Prep.Course Pune . Jan 20-30 , 2005. Q7 as a9 Q.10 Refer UW - 33 Table from ASME VIII For 4” thk for long seam — 1/16" x 4 = %” or 3/8", use lower value. So for long seam, mismatch = ¥%4" For circ seam 1/8” x 4” or 34", use lower value. So for circ seam, mismatch = 1/2" CORRECT ANSWER: a Refer Fig. UCS ~ 66 of ASME VIII Curve D is representing the materials which are not becoming brittle when other materials (curve A, B, C) become brittle. CORRECT ANSWER: d Refer Table UW ~ 12 of ASME VIII — This joint is type 2. — This joint is category B (Ref. UW - 3 of ASME VIII). Since the joint is between 2:1 ellip. head and the shell. — Refer (Table UW - 12 of ASME VIII), the head is seamless and joint is full radiographed. Hence, £=0.9 CORRECT ANSWER: b Vessel MAWP = Vessel Part MAWP — Static Head Vessel MAWP will be worked out considering Part MAWPs. For location at 4 feet from top 426 - 0.433 x 4 = 424.268 psi For location at 32 feet from top = 440 - 32 x 0.433 = 426.144 psi/ For location at 54 feet from top = 442.5 - 54 x 0.433 = 419.118 psi’ For location at 80 feet from top 54.64 - 80 x 0.433 = 420.0 psi Vessel MAWP is lowest of all part MAWPs adjusted for hydrostatic head. Therefore, lowest value 419.118 psi is vessel MAWP. / CORRECT ANSWER: aAPI 510 Prep.Course Pune. Jan 20-30 , 2005, API 510 PREPARATORY Exam 2 - Open Book ANSWER KEY [Q.NO. | ANSWER __|API SLO Prep Course Pane Jan 20-30 , 2008 API 510 PREPARATORY Exam 3 (Closed Book) 1. Choose correct Pneumatic test pressure for following vessel Design Pressure = 160 psi we Design temp. = 675°F on Allow stress (Ambient) = 20000 psi i Allow stress (675°F) 19200 psi s oe Ry 176.0 psig \ a b. 215.6 psig _/ c. 183.3 psig d. None of above Part MAWP for lower dished head in vertical vessel will generally be: Lower than top head Lower than shell Higher than both shell and top head « Same as both top head and shell ans Choose correct statement. Allowable external pressure for a vessel: Will depend on Joint efficiency (E) and extent of radiography Depends on vessel temperature Is affected by internal corrosion allowance Both b and c ao The rules for impact testing of carbon steel in Section VIII vessel Materials require what kind(s) of impact test. Brinell & Rockwell Izod & Charpy V-notch Charpy V-notch only is acceptable Brinell only is acceptable agco Prior to witnessing a pneumatic test of a pressure vessel, the inspector should:APLS10 Prep Course Pune. Jan 20-30 . 2005, “Ensure that welds around nozzles were inspected by PT or MT prior to commencement of test ». Ensure that test pressure is maintained throughout the leak testing inspection ‘Ensure that all butt welds were UT checked prior to commencement of test ©. Both aandb 6. Vessel MAWP is 200 psi. What will be the total Pressure at a Point 20 feet from top, if vessel is completely filled with liquid (Specific gravity = 1). a... 220.00 psi b. 208.66 psi ¥ C. 204.33 psi d.. 191.34 psi pydrostatic pressure test of vessels may be replaced by Pneumatic test: a At the option of vessel manufacturer b At the option of vessel inspector c Permitted only if water is not available in the region and Client approves Permitted only if design or operating conditions do not permit use of water as test medium. d 8. What will be the minimum inspection pressure if pneumatic testing was carried out at 220 psig, as per code: 220 psi A 250 psi 200 psir/ 260 psi aoce For external pressure calculations, the value of “E" is worked out on the basis of: | = 1 for full radiography = 0.85 for spot radiography = = 0.7 for no radiography $ modulus of elasticity and does not depend on radiography 10. In external pressure calculations for cylindrical shell, the Factor ~ A, depends onAPL S10 Prep Course 11. ok} 14, ay Pune Jan 20:30, »905 a - 0.D: and thickness of shell 5 Design temperature ©. Safe stress value ‘Ss’ of material d All of the above ASME Sec. VIII, Div. 1 permits which of the following nozzle constructions? a. “Set-in” type b. "Set-on" type Both (a) and (b) ~” d. None of (a) or (b) Ovality tolerance of a vessel shel with internal pressure is: 1% for shell 1.0.7 b. 1% for shell 0.0. C. 1% of Inside radius of shell d. 1% of Outside radius of shell The notch test is better described as: 2. Plastic formation and fracture b. Brittle failure «Energy observed at the notch d. toughness a. 9.0 sq. inches b. 8.0 sq. inches © 1 inch thickness d. 10 sq. inchesAPL SLO Prop Course 16. TE 18. 19. 20. Pune Jan 20-30 . 2005 The material not requiring PWHT by code requirement has been heat-treated. The PWHT lo]0|>\olalolo ASME VIII, UW = 16, typ. pad to shell. (1/2 tmin) API 510, 1.2.2 (b)API 510 Prep.Cou Pune, Jan 20-30 , 2005, API 510 PREPARATORY COURSE Exam 5 - Closed Book 1. Repair Organization is, ___and carries out repairs as per API 510 a Holder of ASME certificate & appropriate code symbol stamp Owner-user © Contractor under contract with owner-user Any of above 2, Which of the following are essential elements of a Quality control system of a repair organization? Organisational Structure and documentation methods Statements about working procedures Statement of controls to ensure quality Allofthe above + poop 3, Which of the following is a typical deterioration that can take place on the external surfaces of insulated vessels? cul b. Caustic embrittlement c. Erosion d.— Alllof the above > 4. Corrosion and minimum thickness evaluation may be conducted by? Use of a external micrometer Ultrasonic testing Using LPI None of above aoce 5, In API-510, the term “RBI’ means: Repairing Before Inspection Report Based Inspection Repair Based Inspection Risk Based Inspection aogp 6. Which of the following defines the term “hold point’ in inspection practice?APL S510 Prop.Course 10, 1 Pune. Jan 20-30 , 2005, & For a vertical pressure vessel held in Position by guy-wires, the holding points on the vessels connected ws ‘guy-wires. b. _Asupport ug welded onto the vessel & A point beyond which work may not proceed until inspections have been performed and documented 4. Aholding clamp used for aligning the joints for welding Repair on pressure vessels will @. Restore the vessels to intended (original)design conditions ©. Not change the rating of vessel c. wand b above d. Restore the vessels to some other usable conditions Which of the following best describes creep cracking? Creep crackin, temperatures, Creep is high temperature Phenomenon and is dependent upon: time temperature and stress Hydrogen attack aggravates creep cracks bande t 9 IS caused due to loss of ductility at low The failure mechanisms common in Vessels subjected to vibrations is: @ Creep b. Fatigue —c. Erosion d. All of above 4 Shell with nom. 1.D. = 2200 mm is rolled and the inspector observed following readings, “D max =2215mm, D my = 2195 mm. Should the shell be: b. Accepted © Rejected ¢. Accept after NDT e Depends on opinion of inspector. Widely scattered Pits may be ignored if which of the conditions are satisfied a Thickness available at bottom of required vessel wall thickness ©. The total area of the pits does not excee 8 inch diameter circle © The sum of their dimensions along any straight line within the circle O{ diameter 8 inches does not exceed 2 inches d. All of the above pit is greater than one half the d 7 square inches within anyAPL 510 Prop.Course 12, 13. 14, 15, 16, 47, Pune Jan 20-30 , 2005 Which of the following are areas on pressure vessel which are susceptible to cul? a. All the area which is below insulation b. Insulated areas below steam vents c. Insulated areas exposed to cooling tower mist 4. “b’ and °c” above Corrosion under insulation (CUI) due to environmental factors. like humidity, moisture, will be more pronounced at temperature a. 25°F to 250°F b. More than 250°F c Lower than 25°F 4. CULis independent of temperature What can be done to extend the life of a 2" thk. vessel with a corroded Grea in the shell plate 6 inches from the weld, a joint efficiency of less than |. and @ corrosion thickness currently near the minimum required thickness? Recalculate t minimum for, current operating conditions using E <1. Recalculate t minimun for” current operating conditions using E = 1 Recalculate t minimum for design conditions using E = 4, Monitor the thickness during the run. aec8 A horizontal vessel is provided with 2:1 elliptical heads on both ends. The fan ~ tan shell length = 120 in, vessel dia = 40 in. What will be overall length of the vessel? 3. 150 inches ~S. 140 inches 2. 160 inches 4. None of above According to API 510, authorized inspection agency is: a. Jurisdiction organization > Insurance company which under writes insurance of pressure vessels. ©, Inspection organization of owner-user dd. Any of above: Shells of vessels adjacent to inlet impingement plates are susceptible to a. Stress-corrosion cracking b. ErosionAPL 510 Prep Course Pune . Jan 20-30 , 2005. c. Hydrogen embrittlement d, Tamper emrittlement 18. For all repairs and alterations under API 510, the ultimate responsibility rests with a. Owner user b. API Committee c. _ API-510 Inspector d. Jurisdiction authority 19. Which of the following changes on a vessel could be termed as an alteration? a. Addition of a reinforced nozzle of size equal to an existing nozzle b. Addition of a nozzle not requiring reinforcement c. Addition of a reinforced nozzle of greater size, at same location. d. Only "b’ and*c” 20 A pressure vessel has design pressure = 300 psi. Its safe stress values at ambient and designed temperatures are 17100 psi and 16300 psi respectively. The hydrostatic test pressure and inspection pressure for above will be: a. 450 psi and 346 psi b.- 409 psi and 315 psi c, _ 415 psi and 300 psi d, None of the aboveAPI 510 Prep. Course Pune. Jan 20-30 , 200, 510 PREPARATORY COURSE Exam 5 - Closed Book ANSWER KEY Knowledge of Any Inspector — ‘a2 of Any Inspector 5.7 (a) PIB10, 5:7 (6). API S10, 6.3, API 510, 6.3 PI 510, 5.7 = —— ASME VIII, UG ~ 32 (a ASME VIL, 3.4 _{Seneral Knowledge JAPI 510, 4.1 API 510, 3.1 ane LASME VIII,_UG ~ 99"(b) and _ ASME VIII, UG =< ) and (d) — L t. LL [mialall uAPL S10 Prop.Course Pune . Jan 20-30 , 2005. API 510 PREPARATORY COURSE Exam 6 (Open Book) 1. Following four new seamless std. torispherical heads are available for use for following design conditions. Choose the correct one. Design pr = 235 psi, Head I.D = 72”, S = 20000 psi with no CA Design thk = 0.9882”. Provided thk after forming 0" Design thl 0.4886”. Provided thk after forming 5" eoso Design thk = 0.6184”, Provided thk after forming = 0.625” Design thk = 0.7496". Provided thk after forming = 0.75” 2. Following four new seamless (2:1) ellipsoidal heads are available for the following design conditions. Choose the correct one. Design pr = 332 psi, Head I. D = 60” S = 20000 psi with no C A ; a. Design thk = 0.7382”, Provided thk after forming = 0.75” b. Design thk = 0.9788". Provided thk after forming = 1.0” Cc. Design thk = 0.4985". Provided thk after forming = 0.5” d. Design thk = 0.7377”. Provided thk after forming = 0.75” 3. Head in Q1 (torisph Head-A) is to be analysed according to API 510, after placing the vessel in service for 10 years. For the Purpose of API 510 analysis, value of crown whose radius can be taken as: a. 72" b. 60” c 48” d. 54” 4. For head in Q.2 (Ellip. Head - B) value of crown radius for API 510 analysis can be taken as: 72" 60” 48” 54” aogseAPI S10 Prep. Course Pune . Jan 20-30 , 2005. 5. The crown portion. for head A may be considered as the portion lying entirely within a circle whose centre will be same as head centre and diameter will be a 68.5" b. 36.4" c. 57.6" d. 54.0" 6. For head B, the crown portion would lie within similar circle of diameter: a. 60" ow c 54” d. 480 7 Required minimum thickness of crown portion for analysis as per API 510 for head A shall be: a. 0.3695” b. 0.4075” 7 c 0.4235"/ d. 0.4825” 8. Required minimum thickness for crown portion for head 8 as per APT 510 shall be: a. 0.4490". b. 0.4262" c. 0.3652" d. 0.4863" 9. The minimum nominal thickness of new cylindrical shell with design pr=555 psi inside diameter = 58”, S= 20000 psi and E = 0.85 with corrosion allowance of 1/8” will be: a 1.0 inch b. 1.50 inch 1.125 inch d. 1.25 inch 10. After 10 years of service, extensive corrosion was observed on the shell (shell Nominal thickness as per above question) over a Patch lying entirely beyond 6 inches from weld for the vessel above. Thickness measured in this area was only 0.96”, while on weld area, the corrosion was within expected limits. If Corr.API510 Prep.Course Pune . Jan 20-30, 2005 Allowance required for remaining life is 1/16” (0.06"), the vessel is aoce Safe for design conditions Unsafe for design conditions Safe only if welds are fully radio graphed and ok Safe only if welds are UT checked and OK 11. According to API 510, for vessels with 1.0. = 48” corrosion averaging along most critical element can be done over a length not exceeding: ance 12 inches 16 inches 20 inches ¥ 24 inches 12. If diameter of vessel above in Q. 11 is changed to 72”, the length for corrosion averaging will be: eal 36 inches 24 inches 40 inches 18 inches 13. A cluster of scattered of pits was observed on exterior of vessel shell. The description of pits is as follows: Nomial vessel thickness = 5/8” \: Corrosion allowance = 1/8 inch Total area of pits = 5.8 sq inch Pit of largest depth: 0.5 inch dia., 0.20” deep All pits could be enclosed in a circle of 8 inch dia. and maximum cumulative length is 1.75 inch within the circle. a. b. c d. 14. Pits may be ignored as per API 510 Pits are unsafe as the total area pf the pits is beyond limits The cluster is unsafe as depth of deepest pit is beyond limits The cluster is unsafe , they are exceeding cumulative length criteria If in Q.13 above, depth of deepest pit was 0.15”, cumulative length was 2.3 inch ( other data remaining same) your analysis will be:APL 510 Prep.Course Pune . Jan 20-30 , 2005 The cluster is still safe Cluster is unsafe as depth is still beyond limit , Unsafe as cumulative length is beyond limit bandc eoge 15. If total area of cluster is 8 sq inch other data remain same as Q.13, what is your evaluation? | Cluster is unsafe due to increased cluster area Cluster is unsafe due to pit depth still being unsafe Cluster is unsafe due to a and b Cluster is safe aosAPI 510 Prep.Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY COURSE Exam 6 - Open Book Solution 1. Thickness of new torispherical head is given by ASME formula, t = 0.885 PL L = Crown radius SE-0.1P .”. L = Diameter of head E = 1 (seamless) = 0,885 X 235 x 72 20000-0,1x235 = 14974.2 19976.5 =0.7496mm + Provided thk of 0.75" is ok. Correct answer: d 2. Thickness of new Ellipsoidal head (2:1) is given by ASME Formula: t= Pxpd 2SE-0.2P = 332x60 2 x 20000 x 1 - 0.2 x 332 = 19920 39933.6 = 0.4985" Provided thk = 0.5” (OK) Correct Answer: cAPI 510 Prep.Course Pune . Jan 20-30. 2005, For Torisph. Head, D = 72” For API 510 analysis Crown Radius = Diameter = 72” Correct answer: a For 2:1 Ellip head, for API 510 analysis Crown radius = 0.9 D = 54” Correct answer: d Crown portion ties 1 circle of diameter equal to 0.8D = 0.8 x 72 = 57.6" Correct answer: c Crown Portion lies in circle of dia. equal to 0.8D = 0.8 x 60 = 48” Correct answer: d For torisph head, for crown portion, use hemisphere formula using R = D i t= PxR use R = D = 72” 2SE - 0.2P 20000 PSI 1 t= 235x72 P= 235 2SE - 0.2P = 16920 39933.6 = 0.4235" Correct answer: cAPISL0 Piep.Course Pune, Jan 20-30 , 2005. 8. Again, use hemispherical head formula for Crown part: t= PxR for Hemispherical head, 2SE - 02P use R=0.9D 20000 psi = 332 x 0.9 x 60 2SE - 0.2P = 332 x 54 39933, = 0.4489 Correct answer: a 9. Required thickness t = S855 x 29.125 (R = 29.125” ,Half dia.) 20,000 x 0.85 ~ 0.6 x 555 = 16164 16667 = 0.967"4+0.125 = 1,09 Correct answer: c 10. Thickness away from weld (required thk) t= PxR SE - 0.6P take: E=1 t= 555 x 29.125 20,000 - 333 = 0.83" Available shell thickness Excluding required C.A.= 0.96"-0.06" = 0.9” 0. > 0.83"... (Safe) Correct answer: aAPIS Prep.Course Pune . Jan 20-30 , 2005. 11. 12. 13 14, 15 ID or 20” use smaller value (ID < 60”) 2 24" or 20 ---- 20" Correct answer: c ID or 40” use smaller value (ID > 60”) | 72 or 40” 3 24 or 40"... 24” Correct answer: b Area within 8” diameter circle = 5.8 sq. in. (OK) Length along straight line in circle = 1.75 (OK) Depth 5/8” - 1/8" 0.25” (OK) Correct answer: a Length 2.3 inch > 2” ---------- (NOT OK) Correct answer: c Area 8 sq. in > 7 sq. in -~ -- (NOT OK) Correct answer: aAPI 510 Prop Course Pune. Jan 20-30 , 2005, - API 510 PREPARATORY Ye Exam 7 (Closed Book) 1. For corrosion area of considerable size; thickness averaging along most critical element shall not exceed following length for 48” 10 vessel and 72” ID vessel, \’. 20" and 40" respectively b. 16” and 24” respectively €, 20” and 24” respectively d. None of the above 2. A carbon steel pressure vessel has to be repaired with the Substitute plate of carbon steel with: Carbon content <0,35% and compatible with original material Carbor i anon 3. Which of the following are areas on the Pressure vessel which are susceptible to CUI? a All the area which is below insulation 5, Insulated areas below steam vents “Insulated piping exposed to cooling tower mist db’ and “c" above 4. Corrosion under insulation (CUI) due to environmental factors like humidity, moisture, will be more Pronounced at temperature 25°F to 250°F More than 250°F Lower than 250F CUL is independent of temperature aocAPI 510 Prep.Course Pune . Jan 20-30 , 2005, S. 6. a For a vessel find estimated remaining life and next planned external inspection if actual thickness measured during inspection is 0.45” and minimum required thickness is 0.37". Estimated corrosion rate is 10 mpy. a. 10 years, 5 years b. 8 years, 5 years c. 8 years, 4 years d. 10 years, 10 years In above question, if estimated corrosion rate is 20 mpy. The next planned internal and external inspection shall not be later than: a. 8 years, 4 years e& +2 b 4,years, 4 years Usce c. 2 years, 2 years . (ce d 8 years, 5 years 7 For a vessel, remaining life is estimated as 24 years from now, next planned internal and external inspection shall not be later than: 2 - 12 Years, 5 years 10 Years, 10 years 10 Years, 5 years None of the above aoc For a vessel, remaining life is estimated as 3 years from now, next planned internal and external inspection may be planned years from now. - a. 1.5 Years, 3 years bd, 2 Years, 2 years yw Y cy 1.5 Years, 1.5 years - <7 di, bande A stainless Steel cladded vessel, working in hydrogen environment at elevated temperature, repair of the missing /corroded cladding is to be cartied out. What heat:treatment on base metal (prior to cladding repair) and what NDT should be done after clad repair is performed. a. Local post weld heat treatment and MT check...ic~ b. Local post weld heat treatment and RT check c. Base metal out gassing and PT check.API 510 Prep.Course Pune . Jan 20-30 , 2005. d. Base metal out gassing and MT check 10. Which of the following is / are to be undertaken in case the ownership and location of vessel are changed. a. The vessel shall be hydro tested only. b. The vessel shall be internally and externally inspected before it is re-used. The allowable conditions of service shall be established and the next period of inspection shall be established for the new service. d. Only “b” and “c” 11. After completion of repairs, a pressure test: a. Must always be conducted. _ b. Shall be applied if the authorized pressure vessel inspector believes that one is:necessary. c. Must never be conducted. d. Shall be conducted only if repair is done on pressure parts. . 12. After completion of alterations a pressure test is: a. Normally required b. Subject to approval of the-jurisdiction (where applicable) appropriate NDE shall be required where pressure test is not performed c. Generally not required .d, Only “a” and “b” above 13. Authorization for which of the following approval from pressure vessel engineer is not mandatory: a. Repairs for vessels that comply with Sec. VIII, Div. 1 b. Alterations for vessels that comply with Sec. VIII, Div. 1 Repairs for vessels that comply with Sec. VIII, Div. 2 Alternations for vessels that comply with sec VIII, Div 2 ac 14. For vessel with M.O.C. = 516 9°70, PWHT was carried out initially as required by construction*code, major welding repairs were carried out. PWHT, is inconvenient. What can be done to. avoid the PWHT. Impact testing is not required.APL S10 Prep Course se 15. 16 17. 18. Pune . Jan 20-30 , 2005. Welding shall be done using SMAW/GMAW/GTAW Weld shall be pre-heated to 300°F (min) and interpass temperature limited to 600°F : Pre-heating to be maintained up to 4” or four times thickness (whichever is higher) on either side of weld groove. All of the above shall be done. Who is responsible for re-rating calculations for re-rating of pressure vessels? API certified inspector The pressure vessel engineer The national board inspector Corrosion expert ees For avoiding PWHT after welding repair is done on Vessels with M.O.C. falling in P_ Nos. 1, 3, 4 (with impact testing), The welding repair shall be done with: i va. Procedure qualification as per ASME Sec. IX only b. Procedure qualification shall be done as per Sec. IX Y and API-510 cc. Any one of the above is okay d. Procedure shall be qualified as per API 1104 Procedure qualification in above question shall be done using: a a. Temper-bead technique b. Half-bead technique +c. Any one (a) or (b) d. None of the above shall be used. Which of the following type of patches are permitted by API 510 for repairs on pressure vessels? a. Insert patch with full penetration weld b. Insert patch with partial penetration weld c. A full encirclement lap band d. aand conlyAPI 510 Prep.Course Pune . Jan 20-30 , 2005 19. API 510 requires that NDE of repair welds shall include: a. Prior to welding, the area prepared for deposit be examined by MT or PT b. After weld is completed it shall be examined again by MT or PT © Any one of a or b . Both of a and b 20. If remaining life for a vessel is estimated as 2 years from now, next planned internal and external inspection shall not be later than: wa. 1 Year, 1 years © b. 2 Years, 2 years c. 1 Years, 2 years d. Any of the aboveAPI 510 Prep.Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY COURSE Exam 7 - Closed Book ANSWER KEY Q.NO. | ANSWER | REFERENCE 1 Cc API 510, (a) : [2 A API_510 8 3. | D API 510, 4 A API 510, 6. _ _ 5 | CAPT S10, 6.3and6.4 _ 6 Cc API 510, 6.3 and 6.4 _ __7 C__ | API510, 6.3 and 6.4 8 D API 510, 6.3 and 6.4 — 9 c API510, 7.2.6 | 10° D API 510, 6.4 last para (emma B API 510, 7.2.10 ou [127] API 510, 7.2.10 (13 | Afar 510, 7.1.1 - 14 |b API 510, 7.2.3.2 _ 15 B API 510, 7.3 _ _— is |B API 510, 7.2.3.2 and 7.2.1 17 |__C__ [API 510, 7.2.3.2 f (7) = is | oD API 510, 7.2.7 19 D API 510, 7.2.4 20 |Ace BM | API 510, 6.4API 510 Prep Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY COURSE. EXAM-8 (To Answer the questions Refer to Attached PQR / WPS) 1. Choose correct statement from the following: a. The PQR shows root spacing of 1/8” and same shall be followed in production welding. b. _ PQR shows beval angle 37°. It shall be followed in production welding without change. c PQR does not show backing ring, hence production weld also can not be with backing ring d./ None of above is correct statement. 2. What condition below describes the results of the guided bend test” The three bend tests aré acceptable and the fourth one is not acceptable . b. The test result overall is acceptable c. The test result is not acceptable due to the linear indication d. The bend test result is indeterminable, carry out re-test. 3. The minimum qualified preheat temperature for the WPS is: a. 200° F b, 100°F c 75°F = d. 5mm (3/16") 4. What welding process is qualified by this PQR? a. GTAW b.. SMAW c. GMAW d. SAW 5. What is the P number and the tensile strength of SA-106-C? a. PNo. Land 70 ksi b. No. Land 60 ksi cP No, 3and 70 ksi d. — PNo. 3and 60 ksi 6. In accordance with the PQR, the WPS is qualified for what welding Positions?API 510 Prep.Course Pune. Jan 20-30 2005 aogo Flat and horizontal Flat, vertical, overhead and horizontal Vertical and overhead All positions 7. What is the F No. of an E 6010 electrode? aooe Fno. F No. F No. F No. BNUS The welder who welded the test plate for PQR 101 is qualified to weld in what position? ies Flat and horizontal Flat and vertical Flat, vertical and horizontal aoge ‘The bend test specimen used are side bend. They are: Not accepted since 2 face bend and 2 root bend must be used Accepted since as alternative to (a) 4 side bend may be used Accepted since only 2 bend tests are required where as 4 bend tests are performed Not accepted since all 3 types of bend tests (face, root, side) are required. As far as thickness ranges for Base Metal (B.M.) and weld metal (W.M.) as shown on WPS are concerned, your decision about the cualified range is: B.M. is okay and W.M. is not okay. Both B.M. and W.M. are okay. Both B.M. and W.M. are not okay. W.M. is okay and B.M. is not okay. PWHT of PQR test coupon shows "No PWHT”. It means that the PWHT. a 8 9. a 2b c d 10. = « at 5) 12. WPS may be with PWHT WPS must be without PWHT WPS must be without PWHT WPS may be with or without PWHT as PWHT is non-essential variable In production welds, if groove design is changed to double V groove for the qualified base metal thickness, as per ASME Sec. IX will you:APL SLO Prep.Course Pune . Jan 20-30 , 2005, ge 14, 15. @éivo oD a. Accept the change — since it is non- essential variable b. Will not accept — since it is essential variable c. Accept only if okay by radiography d. Accept only if okay by both radiography and UT Based on the specimen areas provided in PQR, are the ultimate stress caiculations correct (as rounded up to psi) for specimen T; and T2: a Calculation is okay for Ty alone. b. Calculation is okay for T alone. c. Calculations for both are okay. 4 Calculations for both are not okay. Which condition below best describes the result of tensile tests. reported on the PQR? Test T1 & T2 are acceptable Test T1 & T2 are unacceptable Test T1 is acceptable & T2 is unacceptable Test T1 is unacceptable & T2 is acceptable % ~ p - If electrode E7010 shown on WPS is changed to E7018, what is your decision? a. Revise WPS to show the change and re-submit as new revision No revision of WPS is necessary as both belong to same F number. e ‘A new PQR will be required to support the change. . No revision of WPS required but show the change in same PQR and submit it as new revision =& nN 18 Welding Documentation Forms Chapter 2 r (82 SUGGESTED FORMAT FOR WELDING PROCEDURE SPRGINCATONG TS (See QW-2001, Section IX ASHE Dolorand Pres yee oe | Company Name_Ay EX AN. By: Ti a ‘Welding Procedure Specification NOWBS= 201 Date 1G —9 ‘pporting PQR Nosh — Revision No. Date Welding Processies!_ SMAW, Typets) PMANUAL. . "eat, Manoa Ned p Sea Aor JOENTS (Qw402) Details Joint Design RE ~V=10 Backing (est (ior_W : Bocking Material spel Beal Nunta ea rey" 5 Nonmetate Other ert Bice Pod Drawings el Syn or Ween Sy Desstoton should show the general arrangement ofthe parts te is welded. Where applieable, the root spacing and the det Ftd groove may b> specified, i ion ofthe Mfr. sketches may he attached to illustrate fninc dosign, weld layers and head gequence. ei, for catch Procedures for multiple process prosedures, see) ALS QW 403) 4 Group No, to Poof Group No, oF Smicfcation wpe and grade — — 'e Sheeifcation type and grade aan oo OF cnet an Mech Prop a Thea eta ane Mech, Beep = ‘Thickness Range: Bias Metal Grooes 5 Siz ot Fier Mealy = pa Seid sted As Sha e DRS Tickets Range * Groove O To 4" Fee > Bletende Pay Chased a Flas rate Nowe Consume Other Tht m - Nonmancatory Appendix B (Page tof 2) nm ASME Section £8 - Welding Qualifications Third Eitiion20 Welding Documentation Forms Chapter 2 Company Name Procedure Qualication Record No. WPS Fo, 2 5 ee Welding Process(es) eee Perth ei aa SQ JOINTS (QW403, i hey Groove Design of Test. | i |_Se‘sombinationquaitcatons, the weld metal ehickres soh ena each Biller iets! oF process weed.t I r BASE MET: Material Spx | type or Gr Tiekness of Fest Coapan Diameter af Fact Con pon | Oder TSQu POSTWELD HEAT TRE TNENT qitaon : Temperature Nil. Tig Se Oto Percont Composition ‘Mire! Flow Rate FILLER N SEA Specification — AWS Specification — Files Metal Fo EMU Metal antes Ne, 2p ate 7 Wer Metal "yaa we leas Sarre eee —Be=P-0— Other ETAT (QWOu Amps. ‘Tungsten Electrode Soe Other WH Progression phils Dowahiy Sting or Weav TECHNIQUE @\ Travel Speed tive of Grogse Oscillation sure 2 QW-483 Form - Nonmandatory Appendix B Paze Lof 2 meh We ASME Section IN. Welding Qualications «Third BiitionAPI S10 Prep.Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY WPS / PQR -Open Book ix Answer Key en a x. ‘| Answer Reference Table QW - 253. Options a, b are non-essential variables. Option C is not EV or SEV or even NEV W = 163 Table QW - 253. Item QW 406.1 See PQR format 4" line from top 7 Table QW - 422 | QW- 203 ____| Table QW - 432 __ Table QW - 461.9 Table QW - 451.1 and Note 3 : | Table QW - 451.1 _ | Table QW - 253. Item QW 409.1 Table QW - 253. QW 402.1 General knowledge. Stress = Load / Area DT Qw - 453 (2) and (4) _ Table QW - 432 9 O8|0|>|@|0]00|>|0|o|>||o/cAPI S10 Prop. Course Pune . Jan 20-30 , 2005, API 510 PREPARATORY Exam 9 (Closed Book) Cracks are likely to occur in or adjacent to welded seams in which of the following vessels? a. b. c d Vessels constructed of high strength steels (above 70,000 psi) Vessels made from coarse grain steels Vessels made of low chrome materials and operating at high temperature All of the above High pressure may develop in a vessel as a result of: eog® Rapid venting of a vessel's pressure source Excessive heat input above normal operating conditions Thermal Expansion of trapped fluids B&C The rules for impact testing of carbon steel in Section VIII vessel materials require what kind(s) of impact test? a b. c. 4 Brinell & Rockwell Izod & Charpy V-notch Charpy V-notch only is acceptable Brinell only is acceptable. The API authorized pressure vessel inspector may give prior authorization for repairs that do not involv aosg Pressure tests Radiography Pneumatic testing of pads Final visual inspections Prior to witnessing @ pneumatic test of a pressure vessel, the inspector should: a b. Ensure that welds around nozzles were inspected by PT or MT prior to commencement of test. Ensure that test pressure is maintained throughout the leak testing inspectionAPI S10 Prop.Course Pune . Jan 20-30 , 2005. 6. ¢. Ensure that all butt welds were UT checked prior to commencement of test. d. Both a and b Widely scattered pits may be ignored as long as the following conditions are satisfied i. Thickness at bottom of pits is greater than one half the vessel's required wall thickness il, The total area of the pits does not exceed 7 square inches (45 square centimeters) within any 8-inch (20-centimeter) diameter circle. “ii, The sum of their dimensions along any straight line within a. b. c. d. a ooo a 9. the circle does not exceed 2 inches (5 centimeters). ee What is the missing it m_in “iv” above? The thickness at bottom of pit must be measured by pit gauge. The 8"diameter is to be measured from the center of the deepest pit. There are no missing items; there are only 3 items to be considered The total area of the pits cannot exceed 3.5 square inches in a 4-inch diameter circle. Sefore any repair to a pressure vessel in accordance with its “ode of construction, what if any additional requirements (over ind above those in API 510) may need to be considered? ‘urisdictional requirements that might override the API 510 Code. 1s repair being done by repair organisation? The quality of the repair materials. The need for qualified welding procedures. Hydrogen chloride becomes a problem when: Exposed to air, it will thermally react and result in a fire, Exposed to water, it forms hydrochloric acid. Exposed to water, it becomes unstable and can form an explosive compound. Exposed to water and air it produces formic acid. # new vessel has been installed, what must be done in order to accept the vessel for operation? a. A first internal inspectionAPI510 Prep.Course Pune. Jan 20-30 , 2005. 10. qa 12. 13 14. b. c A first internal inspection, however if a manufacturer's data report (U1) assuring that the vessel is satisfactory for its intended service is available the first internal inspection may be waived. Base line thickness readings must be taken per OSHA 1920 (j). Base line thickness reading must be taken per OSHA 1910 (j). Ordinarily non-metallic coatings and linings can be most effectively inspected by what technique? Low voltage holiday tester Radiography Hammer testing Using a high voltage low current brush type electrode device. (Spark Tester) aooo Titanium alloys are subject to loss of ductility in certain environments, what is this condition called? High temperature embrittlement Low temperature embrittlement Hi-alloy effect Hydriding aeco Which of the following describes a crack in metal? Cracks run parallel to the surface. Cracks run at right angles to the surface. = Cracks are usually wide at one end and narrow at the other. Le Cracks always run slant to the surface. se Temper embrittlement is best described as: sa. Cracking due to operating at high temperatures above 700°F b.~ Loss of ductility and notch toughness due to exposure above 700°F c. Flaking of the metal surfaces, causing dip pits d. Cracking due to low temperature service Carbon dioxide considered corrosive when? a. — When combined with glycol by’ When combined with water _c. When combined with ethyleneAPLS10 Prep Course Pune . Jan 20-30 , 2005, 1s. 16 17. 18. 19. d When combined with water and high temperatures . Most active of sulfur compounds found in refinery service is: Mercaptans Organic sulfur compounds Hydrogen sulfides Polymorphic sulfides when combined with polymer products Which of the following is a major concern when operating vessels that utilize the slurries with solid suspensions? a 2. 4, Overheating Erosion Corrosion Cracks The inspection of a vessel to determine if a hydrogen blister is oresent is often best performed by: oe 2 Researching the inspection records Determine the vessels material to see if hydrogen attack is likely Swaying a flash light parallel to the vessel’s surface Recommending metallurgical tests for blisters in a laboratory When preparing to inspect a vessel which has had previous nspections what is the initial step in preparation for the nspection? a. a i. Assemble all the required tools to perform the inspection. Review previous inspection records. Advice maintenance of any anticipated repairs. Insure that all non-destructive examinations required have been scheduled Which of the following best describes a “Corrosion Button” as might be found in a pressure vessel? a. Buttons made of highly corrosion resistant material from which corrosion loss can be measured.API 510 Prep.Course Pune . Jan 20-30 , 2005. 20 b. Buttons which corrode at about the same rate as the vessel’s material and are used to estimate the vessel's corrosion losses. . No such thing exists; there is however a corrosion tab used in vessels. d. A form of corrosive product produced by certain chemicals in a vessel when is constructed of high chrome alloy material. In a PRV in which the major relieving device or main valve is combined with and controlled by a self activated auxiliary pressure relief valve is: Pilot operated valve Bellow type balancing valve Relief valve Safety valve eosmAPI 510 Prep. Course Pune. Jan 20-30 , 2008. DPN AurRWNnNHe 10. li. 12. 13. 14, 15. 16. 47. 18 19. 20. D A A A API 510 PREPARATORY Exam 9 — Closed Book ANSWER KEY API 572, 10.4.4 CHAPTER II, 206.021 - .023 VIII, UG-84 API 510, 7.1.1 Vili UG-100 API 510, 5.7(e) API 510, 1.1 CHAPTER II, 202.022 API 510, 6.1 API 572, 10.4.6 API 572, 8.3.7 API 572, 10.4.4 API 510, 5.2 CHAPTER II, 202.024 CHAPTER II, 202.23 CHAPTER II, 202.32 API 572, 10.3.13 API 572, 10.4 .3 API 572, 10.5 API 576, 2.2.1.5API 510 PREPARA, URRY COURSE Exam A - Closed Book 1. Use of Radiography is mace for a. Performance qualification only. b. Procedure qualification only c Botha and b 4. Use of Radiograpny is not permitted by ASME Sec. IX. 2. According to ASME Sec. |, Supplementary Essential Variables are to be recorded if Impact testing is specified. Otherwise, ‘They shall be considered as Non-essential. They shall be considered as Essential. depends on decision of welding engineer depends on decision of API inspector 3. ASME Sec. IX is used for welding Qualifications for: Procedures for welding Pressure vessels Welders for welding Pressure vessels Structural fabrication and b above 4. Guided bend test for groove weld represents: 4. Ductility of weld. b.. Strength of weld Soundness and ductility of weld d. None of above 5. All positions of groove welds are qualified by: a b. c 4. positions 1G and 5G Pipe positions 2G and 56 Pipe position 5G only None of the above 6. Procedure Qualification is done by: a. Tensile and 2 bend tests b. 1 tensile and ‘radiography c. bend test and tradiography d. 2 tensile and 4 bend tests 7. In WPS PQR documentation, the essential, supplementary essential and Non- essential variables (EV, SEV, NEV) shall be addressed in these documents. Which document shall address which of the variables? a b « All EV s and SEV s shall be addressed in POR and WPS AILEV s , SEV s and NEV s shall be recorded in both WPS and POR PAR shall address all EV s and SEV s while WPS shall record all EVs, SEVs and NEVs WPS shall address EV s and SEV s while POR must record all EVs , SEV s and NEV s10. 1" 12 13, 14 1. Tre WPS ar site Je ave ased to determine’ a Ifthe welder is able to deposit sound weld metal it the welder is able to operate welding equipment. tne welders. ability to produce welds that are radiographically acceptable Backing strip 5/16" thk 10. If type of penetrameter in above question is changed to wire type what shall be the wire designation (wire diaimeter in inch) @. 0.025 dia. (No. 10) b. 0.016 dia. (No. 8) ©. 0.032 dia. (No. 11) St None of the above 11. For steel plates and welds to be checked by LPI, what shall be the penetration time for Penetrant @. 10 min for weld, 5 min for plate b. 5 min for both ©. 10 min for both \¥ 5'min for weld, 10 min for plate12. After applying the developer the examiner checked four welds for surface defects after following period, weld A — After 5 minute, weld B after 10 minutes, weld C was checked after 30 minutes and welds D after 65 minutes which of the welds were checked wrongly a. Weld Aand 8 b. Weld ¢ and 0 ©. Weld D only |@\0|0|0)o|—/a|>|API 510 PREPARATORY COURSE Exam C - Closed Book 4. The gamma ray radiography has maximum density of A. 2.0HD 8. 4.0HD C. No upper limit is prescribed D. Depends on the viewer ‘A re-rating of a vessel is not completed till the new name plate fixing is overseen by Jurisdiction ‘Authorzed inspector Pressure vessel engineer Insurance surveyor com> 2 The filler metal used should have minimum specified tensile strength equal to or greater than the minimum specified tensile strength of the base metal. Ifa filler metal is used that has @ minimum specified tensile strength lower than the minimum specified tensile strength of the base metal. Lower strength electrodes are not permitted for repair welding Maximum 50% of thickness can be repaired using such electrodes Increase weld deposit thickness suitably to compensate the lower strength Bac CGowr 4, The greatest time between the testing of pressure relieving devices per API 510? A 5 years, B. Pressure relief valves shall be tested at intervals that are frequent enough to verify that the valves perform reliably. C10 years, D. Pressure relief devices must be tested at every shutdown. 5. Ifyou were looking for the last date that a pressure relief valve was set, where should this information always be? ‘A. Inthe product literature from the valve company. QB) The API 510 mandatory computer inspection records. ‘C. Relief valve's tag. D. In the records of the repair shop. 2 ‘Which of the following should a progressive record for a pressure vessel contain? The exact location on a plot plan The piping schedule for the vessel. complete weld map from the original construction plans. Construction and design information, operating and inspection history. pom>7. If performing an extemal inspection of a vessel what consideration need be given the external insulation? A. It shall always be removed to inspect underneath. B. If insulation is in good condition and the vessel operates within the high and low temperatures stated in API 510, removal of insulation is not necessary for inspection of the vessel C. Selectec: portions must be removed for inspections. D. You may not use any plug locations used for UT thickness reading to inspect the vessel @ What must be considered important in the inspection of a metallic lining? That there are no dissimilar welds That the linings made of pure alloy only. That vent holes exist in all liners. That there are no holes or cracks present in the lining. pom> What do construction codes mean, as it regards repairs to a pressure vessel? The current ASME Code edition The NBIC The Code the vessel was constructed to, including non-standard and jurisdictional special vessels. The AP! 510 Code. o Om> 10. Which of the following over pressure protection is not found on a pressure vessel? A. Safety Relief \B. Pilot Operated C. Rupture Disk DB. Pressure/Vacuum Vent 11. The report for qualifying a welder is’ A WPS B.PQR C. WPQ D.WQR 12. Charpy impact tests are intended to prove that a material is; tough at the desired MDMT of the vessel to be constructed using that material. some what prone to brittle fracture. acceptable for use in high temperature service. ot required to be heat treated. pone 13. Accorcing to Section IX, all welders must be re-tested for a process; A. if they have not been tested before. B. if they have not used the process in the past 1 months or longer and have not been welding with other processes. C. if they have not used the process for the past 3 months or longer 0. ifthe welder’s ability to make sounds welds with process is in doubt.14. Witch of the following describes a type/s of rupture disks? |. Multiple layer of graphite impregnated fibers B \ Various metals - usually flat except steel C. Impervious graphite, un-bulged D4 Various metals, usually pre-bulged or impervious graphite, usually fat. 45, Which of the following describes a lamination in metal plate? Laminations usually represent large cavities. Laminations are present only on the edges of plate. Laminations run at a slant or parallel to the plate surface Laminations run normal to the plate surface, gom> 46, You are inspecting a failure ina Carbon Steel vessel wall, what conditions would you look for if it was believed that the fracture was a brittle one? There is almost a no lack of ductility. The fractured surfaces has a smooth surface The material might be a thin gauge material, and working at elevated temperature ‘There is an almost complete lack of ductility and the material might have been working at Low temperature. pop> 47. A bulged metal rupture disk with the pressure on the concave side has Ife expectancy of ; A. Syea's. B. 2years. G ‘year. D Indefinite length til it ruptures 48. for same bursting pressure of the disc higher operating pressures are possible with ‘A rupture disk of the type in which, the pressure acts on: B. Concave side C. Covex side ( Reverse buckling) D. Flat type. E. Operating pressures for all above will be same. 49. When a crack is discovered in a vessel thatis in a highly stressed area, What action Should you recommend be considered as a first step in any effort to correct the flaw? ‘A. Using an insert patch. 5. Removing the crack by grinding and inspect using an NDE procedure before repair 1-C! Callin a pressure vessel engineer. “P. Design an overiay patch that has rounded corners. 20. When looking for surface cracks inside a vessel made of ferrous material which of the following is the most capable of detection? ‘A. Fluorescent Penetrant Method B. Visible Color contrast penetrant method. C. Radiography D. Close visual Inspection with good lighting.1A 2.8 3D 4c 5.C 6D 7.8 8.0 a.c 10.0 11.€ 12. 43.0 14.0 15.C 16.0 17.C 18. 19.C 20. A API 510 PREPARATORY COURSE Exam C - Closed Book ANSWER KEY Sec V 1262.1 AFI 510-7.3-¢ APIS10. 7.2.11 API510 6.6 AP! 576 6.2.2 AP 510 6.7 AP 510 63 API572 10.4.5 API 510 1.1 AP 576 4.8.1 1X Qw-300.3 Vill UG-84 definition of Charpy (notch toughness)! IX QW-322.1 API 576 4.9.124.9.5 API S72 10.44 CHAPTER I 205.01 APIS76 4.9.3 API 576 4.9.3 API510 7.1.3 Basic Knowledge of PTAPI 510 PREPARATORY COURSE Exam D — Open Book | I'he corrosion rate of a vessel is determined to be less than a given amount per £27 it's Possible to exempt the vessel from intemal inspections. What is the value of he corrosion rate that cannot be exceeded? 0.001’ per year 0.001" between inspections not to exceed 5 years between inspections. 0.005" per year’ °.005' between inspections not to exceed 3 years between inspections ogy N You have measured undercut on a girth weld during the repair to a vessel, it was found to be 1/32 inch in depth, The base metal is 2 inches thick. and you should? Reject the weld 2 Accept the weid. / 3 Consult the API 510 Code for accept/reject criteria before making a decision Consult with the Chief Inspector or Engineer. com> A spot radiograph of a butt weld in a 1 inch thick shell of a vessel marked RT-3 was found to have @ rounded indication, the dimension of such an indication according to Section Vili Div. 1 is; A. 1132 of an inch . B. 1/3 of an inch. C. 2/3 of an inch D. None, rounded indications are not a consideration with spot radiography, 4. A P'No 1 material that is plate has been rolled into a cylinder and butt welded, The Gylinder is exactly 1-4/4" thick, and itis used in the repair of a pressure boundary on a U stamped vessel, the following is a true statement A. It must receive full radiography. B. Itmay be not spot radiographed C. It may not be fully radiography ©. It'may receive either spot, full, no radiography depending on the original MDR form o The surface remote from a welded joint is determined as follows; 1 inch on either side of the weld or twice the minimum thickness which ever is greater. Linch on either side of the weld or twice the minimum thickness which ever is less. For vessels with inside diameters less than 60 inches 20 inches or % the vessel diameter 2 inches on either side of the weld. 9 om >