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API-510 PRESTUDY GUIDE

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API 510 PRESTUDY GUIDE

This guide has been prepared for use by itcSkills, and is intended to be used only by those attending the
API 510 Examination Preparation Course.

This course is written by itcSkills, Schindler & Associates and Codewest. This document
represents a substantial investment of time and expense. It is provided to attendees of the
course as the course text. It is protected under the copyright laws of the United States of
America and Canada and may not be copied without written permission from Schindler &
Associates and Codewest. Do not copy or distribute this document. COPYRIGHT 2004,
itcSkills, SCHINDLER & ASSOCIATES AND CODEWEST. ALL RIGHTS RESERVED.
 itcSkills
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TABLE OF CONTENTS

Page

Introduction and What to Expect on the Actual Examination 1

Course Outline and Required Code Books 5

API 510 Body of Knowledge 7

API 510 Practice Questions 9

IRE II Practice Questions 13

RP 572 Practice Questions 15

RP 576 Practice Questions 18

ASME V NDE Practice Questions 20

Practice Math Problems 23

ASME VIII Div. 1 Practice Questions 26

ASME IX Practice Questions 31

Answers Keys to Practice Questions and Math Problems 34

Past Exam Questions Remembered by Ex-Students 52

Miscellaneous Quiz Questions 61

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API 510 TRAINING COURSE

PREPARATORY COURSE WORK

Welcome to the pre-study guide for the 2004 API 510 Training class. We are very pleased that you have
entrusted your training to us for this important examination, and we take this responsibility very seriously.
Our mission together is quite simple, and one which we will remain focused on until the day of your
examination. Simply put, this mission is:

“ACHIEVE A PASSING GRADE ON THE API 510 EXAMINATION”

This is our only goal, and together, with diligence, patience, and hard work, I know that we will succeed in
making this mission a reality.

In this regard, this Preparatory Course is provided to help get you started and better prepared for the journey
ahead. it consists of the following items:

?? Course Outline
?? Schedule and location information
?? API 510 Body of Knowledge
?? ASME/API Quiz
?? ASME questions and 10 practice math questions that can be studied to prepare for the
up-coming test
?? Answer sheets for the Quizzes/Math Problems
?? Actual past examination questions

Remember! This is your examination and your training course. You will only get out of it what you are
willing to put into it. Therefore, if you do not complete this material, you will only be lowering your chances
of successfully completing our mission.

You must complete this Preparatory to increase your probability of passing the test! Please set
aside time every day until class starts to study the material in this book.

Please come to class as prepared as possible. it is very important to attend every class, complete all
homework assignments, and pay very strict attention to the classroom presentation. Again, your
participation is the key ingredient to passing the test.

Once again, we appreciate the opportunity to provide this training and we are willing to “go the extra mile” to
ensure your success in the examination.

Review the documents upon which the examination is based and become familiar with their layout. Be
honest and identify your strong a weak areas so you can develop a study plan. Use the pre-study Guide as
a tool to prepare for the course and then come prepared with questions.

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INFORMATION FOR CANDIDAT ES

API 510, PRESSURE VESSEL INSPECTOR CERTIFICATION EXAMINATION

FORMAT OF THE EXAMINATION

The API 510 inspector certification examinations consist of objective multiple-choice questions covering
knowledge essential to the professional practice of inspecting in-service pressure vessels and process
piping. Each exam is constructed according to detailed test specifications. Each question has four
alternative answers, only one of which is correct.

The examinations contain 150 questions and are divided into two parts. Part 1 is open-book, and consists
of 35-45 questions, which can be answered using API and ASME reference material. Candidates will have 4
hours to complete Part 1. Part 2 is closed-book, and consists of 105-115 questions which must be
answered without access to any reference material. Candidates will have 4 hours to complete Part 2. A
total of 8 hours is allowed to complete each exam.

ADMISSION PROCEDURE

If you application and fee is received before the deadline, and you meet the education and experience
requirements set by API, you will be allowed to sit for the exam. You should receive notification of the test
site from the jurisdiction prior to the exam date. Please be aware of any special instructions that may be
included in the jurisdiction notification.

Please report to the test site no later than 7:30 AM on the morning of the exam. Seating of candidates,
distribution of test materials, and testing instructions will begin at 8:00 AM. Remember to allow adequate
travel time to find the testing site on the morning of the exam.

On the morning of the exam, candidates should bring an appropriate form of picture identification bearing
their signature. Examples of acceptable forms of ID are a driver’s license, a passport, or an employee
identification card. Social security cards are not acceptable.

If you move or change your address, it is your responsibility to notify API and the jurisdiction of your new
mailing address at least 4 weeks before the exam date so that your score report can reach you in a timely
manner.

EXAMINATION PROCEDURES

?? The testing time for each part of the exam is 4 hours. Additional time has been allowed for instructions.
There is a one-hour lunch break scheduled after Part 1 of the exam, but if you complete Part 1 before
time is called, you may leave the testing room. However, you may not re-enter the room until Part 2 of
the exam is about to begin.

?? Candidates should bring some sharpened #2 pencils with erasers, a non-programmable calculator, and
a set of API and ASME reference materials. Highlighting, underlining, page tabs, or written notes in the
margins of the code books are acceptable. Note: API and ASME publications are copyrighted
material. Photocopies of these reference documents are not permitted in the examination
room.

?? No loose notes, papers, or other books of any sort may be brought into the examination room.

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?? No test materials, documents, notes or memoranda of any sort are to be taken from the examination
room.

?? No questions concerning the content of the examination may be asked during the testing period.
Candidates should listen carefully to instructions given by the proctor.

?? Candidates have the opportunity to comment on any question believed to be misleading or inaccurate at
the end of the examination. A form for this purpose will be provided to candidates upon request. Be
specific when commenting on a question as each comment will be individually reviewed by the
Examination Committee. Individual responses to question comments will not be provided.

?? Proctors are authorized to maintain secure and proper test administration procedures, including
relocation of candidates. Candidates may not communicate with each other during the examination.

SUGGESTIONS FOR TAKING THE EXAMINATION

?? Answer the questions in order, but don’t waste time on questions containing unfamiliar or difficult
material. You can come back to them later, time permitting.

?? Make educated guesses at correct answers rather than leaving the answer spaces blank. The score on
the test will be based on only the number of correct responses, with no penalty for wrong answers.

?? Record your answers carefully on the separate answer sheet. The numbering of the questions in the
test booklet should match the numbering of the responses on the answer sheet.

?? Should you change your mind on any answer, erase previously marked responses thoroughly. Multiple
responses to a question will be scored as incorrect. Avoid making any stray marks on the answer
sheet.

A criterion referenced passing score has been established by a panel of content experts using appropriate
standard setting procedures. The passing score for each administration of the API 510 and 570 inspector
certification examinations are based on a statistical equating process which adjusts for fluctuation in
difficulty levels across different examinations. Equating ensures that candidates are evaluated according to
the same competency standard from year to year.

After each examination administration, individual test questions subject to comments from candidates are
evaluated for their clarity and accuracy by the API Exam Construction Task Group prior to the grading
process. Questions determined to be ambiguous may be scored with multiple correct answers at no
penalty to the candidates.

Exams are scored using an automated system. Any grievance or requests for manual scoring must be
submitted in writing to API within 90 days after receipt of your score. Requests for manual scoring must
include a viable reason why your exam should be re-graded. There is a $50 fee for manual scoring of
exams. Requests should be submitted to:

American Petroleum Institute

Industry Services Dept.
Inspector Certification Programs
1220 L Street, NM
Washington, D.C. 20005-4070
202-962-4739 (Fax)

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AFTER THE EXAM

Approximately 8 weeks after the examination, candidates will receive score reports. These reports will
contain the date of the test administration, the title of the examination, the candidate’s name and address,
the candidate’s identification number, the candidate’s total score, and the candidate’s subscores on each of
the content areas covered in the test. Should you pass the exam, you will receive a wallet card and
certificate approximately 6 weeks after notification of your score. Please do not call API for test results;
these results will not be given over the telephone.

SPECIAL ACCOMMODATIONS

Candidates with special needs may request special testing arrangements by submitting, with their
application; (a) a letter describing the basis for the need, such as a physical disability or cognitive
impairment; (b) a detailed description of the type of accommodation, such as large print or extended time;
and (c) written verification of the need, such as a letter or report from a licensed health professional. The
request and its accompanying documentation should be sent to API with the application. There is no
additional charge for special accommodations.

NOTES ON ROUNDING IN MATHEMATIC EQUATIONS

API has not published a policy on rounding (either up or down) when calculations are performed as part of
the examination, although they have been asked to publish this policy. The calculation answers are
normally far enough apart so that rounding does not usually present a problem. However, we can only
instruct based on (historically) what has worked best (so far). This is the rounding policy that will be used
during this course (but may be modified on the exam by API):

1.) Thickness Calculations : Round to the third decimal place, and don’t round-up/down.

Example #1 - “.0075” - is “.007” - (same as on test)

Example #2 - “.0993” - is “.099” - (may be shown as “0.100” on test)
Example #3 - “.9998” - is “.999” - (may be shown as “1.00” on test)

2. Pressure Calculations: Round to whole single digit as psi:

Example #1 - “239.3 psi” - is “239 psi” (same as test)

Example #2 - “1007.9 psi” - is “1007 psi” - (may be shown as “1008 psi” on test)
Example #3 - “999.99 psi” - is “999 psi” - (may be shown as “1,000 psi” on test)

3. Square Root - Do not round any number under a square root. Simply hit the square root button
( ) on the calculator and utilize that full number.

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COURSE OUTLINE FOR API 510 TRAINING SEMINAR

Day 1 - 8:30 AM to 5:00 PM

A.M. Instructor Introduction

Introduction to Training Course and what will be covered
Detailed coverage of what to expect on examination
Introduction to ASME and API Organizations

Begin review of ASME Section IX

P.M. Continue review of ASME IX, homework assignment

Day 2 - 8:30 A.M. to 5:00 P.M.

A.M. Continue review of ASME Section IX, Welding Procedure Review

P.M. Continue review of ASME IX, homework assignment

Day 3 - 8:30 A.M. to 5:00 P.M.

A.M. Continue review of ASME IX

P.M. ASME V, homework assignment

Day 4 - 8:300 A.M. to 5:00 P.M.

A.M. ASME V and IX Examination

P.M. Introduction and walkthrough of ASME VIII, homework assignment

Day 5 - 8:30 A.M. to 5:00 P.M.

A.M. ASME VIII Calculations

P.M. ASME VIII Calculations, homework assignment

Day 6 - 8:30 A.M. to 5:00 P.M.

A.M. ASME VIII Calculations

P.M. ASME VIII Calculations, homework assignment

Day 7 - 8:30 A.M. to 5:00 P.M.

A.M. ASME VIII Test

P.M. API 510, homework assignment

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Day 8 - 8:30 A.M. to 5:00 P.M.

A.M. Continue API 510 and corrosion/remaining life calculations

P.M. API RP 576, RP 572, IRE Chapter II

Day 9 - 8:30 A.M. to 5:00 P.M.

A.M. Open Book Practice Exam

P.M. Closed Book Practice Exam

Timings are approximate and subject to change

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To: API 510 Certification Candidates

RE: Required Sections of ASME Documents for API 510 ICP Exam December 2004

You require the following Code Books for the course and examination. Make sure you have the
correct editions and bring them with you.

ASME 2001 Edition With 2002 & 2003 Addenda

Section II, Materials, Part D, External Pressure Graphs – We will give you these during the course

Section V, Nondestructive Examination

Article 1, General Requirements
Article 2, Radiographic Examination
Article 6, Liquid Penetrant Examination
Article 7, Magnetic Particle Examination
Article 23 SE-797 Only

Section VIII, Rules for Construction of Pressure Vessels, Division I

UG, General Requirements for All Methods of Construction and All Materials
UW, Requirements for Pressure Vessels Fabricated by Welding
UCS, Requirements for Pressure Vessels Constructed of Carbon and Low Alloy Steels
UHT, Requirements for Pressure Vessels Constructed of Ferritic Steels With Tensile Properties
Enhanced by Heat Treatment
Appendix 1, Supplementary Design Formulas
Appendix 2, Rules for Bolted Flange Connections with Ring Type Gaskets
Appendix 3, Definitions
Appendix 4, Rounded Indications Charts Acceptance Standard for Radiographically Determined
Rounded Indications in Welds
Appendix 6, Methods for Magnetic Particle Examination (MT)
Appendix 8, Methods for Liquid Penetrant Examination (PT)
Appendix 12, Ultrasonic Examination of Welds (UT)

Section IX, Welding and Brazing Qualifications, Part QW.

API 510 Eighth Edition June 1997 Plus Addendum 1, 2 3 and 4

API 572 Second Edition February 2001

API 576 Second Edition December 2000

Guide for Inspection of Refinery Equipment Chapter II – Not Generally Available Ask for the Inspector
Certification Program Copy. Any problems call us.

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PRACTICE QUESTIONS

TO PREPARE FOR CLASS

This section contains the following:

?? API 510 Practice Questions

?? IRE Chapter II Practice Questions

?? RP 572 Practice Questions

?? RP 576 Practice Questions

?? ASME V and NDE Practice Questions

?? ASME VIII Practice Math Questions (10)

?? ASME VIII Practice Questions

?? ASME IX Practice Questions

?? Answer Sheets for the above Math Problems and Code References for the Answers to the Practice
Questions.

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API DOCUMENTS

During the course the four API documents will be reviewed. The following practice questions cover these four
documents thoroughly. You must be able to answer all the practice questions without reference to any of
the documents to be considered to have an adequate knowledge of their content.

API 510 PRACTICE QUESTIONS

1. The scope of API 510 covers?

a. boilers
b. pressure vessels
c. power piping
d. all the above

2. Name three types of pressure vessels and cont ainers that are excluded from the requirements of
API 510.

3. How is the MAWP determined for the continued use of a pressure vessel?

4. What type of examination is the most important?

5. What is the difference between an alteration and a repair?

6. Is the addition of an unreinforced nozzle an alteration or a repair?

7. When is field inspection of a new vessel not required?

8. Above ground vessels shall be given a visual external inspection at what interval?

9. Name three types of surface preparation that may be needed?

10. What is the maximum test/inspection interval permitted for pressure-relieving devices?

11. Define on-stream inspection.

12. Name four kinds of records that the owner/user must maintain for each pressure vessel?

13. Which of the following are considered to be repair organizations?

a. holder of an ASME "S" stamp.

b. owner or user who repairs his own equipment.
c. a contractor whose qualifications are acceptable to the owner-user.
d. a, b, c above.
e. b, c above.

14. Define rerating.

15. How many years experience must a high school graduate have to qualify as an Owner-User
Inspector under API 510?

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16. Name five modes of deterioration.

17. When new vessels are placed into service or the service conditions are changed what are the three
methods for determining the probable rate of corrosion?

18. What other examination methods may be used to supplement the visual examinations?

19. Do you always have to remove insulation at the time of each external inspection?

20. When would removable internals need to be completely removed?

21. When may in service inspection be substituted for internal inspection.

22. What areas should be examined on riveted vessels?

23. Define uniform corrosion?

24. Name and describe four items that must be considered when the minimum actual thickness and
maximum corrosion rate are adjusted?

25. For a corroded area of considerable size in which circumferential stress governs the least thickness
along a critical element may be averaged over a length not exceeding?

26. Can large vessels with two or more zones of differing corrosion rates have each zone treated
independently regarding inspection intervals?

27. List 15 features that must be covered in the owner-user quality assurance manual for pressure
vessel inspection systems.

28. What is the efficiency factor to be used when determining the MAWP for a corroded area in the
solid material area of a vessel (away from a weld by greater than 1” or twice the material
thickness)?

29. How are the intervals between pressure-relieving device testing/inspection determined?

30. What is the maximum period between internal or on-stream inspections?

31. When an internal inspection is to be performed name at least five safety precautions that should be
taken before entering the vessel.

32. For buried vessels what is the basis for establishing the external inspection frequency?

33. Surfaces of shells and heads should be carefully examined for?

34. What three things must be done when the service conditions of a vessel are changed?

35. Repairs and alterations to pressure vessels are covered by API 510 provided what method is
employed?

36. When both ownership and location of a vessel are changed what must be done?

37. Is a pressure test required after each periodic inspection?

38. May fillet welded patches be used for repairs?

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39. What are the minimum and maximum pressure test temperatures recommended by API 510?

40. When a pneumatic pressure test is to be performed, what are the additional examinations required
by the ASME Code prior to the test being performed?

41. When the pressure test pressure will exceed the settings of any safety relief valves or
appurtenances what must be done?

42. Repair organizations that repair pressure relief valves are required to have what kind of a written
program?

43. Name at least 9 topics that are part of a pressure relief valve repair organizations quality control
manual?

44. In addition to the 16 topics covered in the pressure relief valve repair organizations quality program,
what additional requirement must be met?

45. What is the efficiency factor to be used when determining the MAWP for a corroded area in a weld?

46. What authorizations and approvals are required prior to the commencement of repairs or
alterations?

47. What ASME Code section are welding procedures and welders qualified in accordance with?

48. What is the welding technique that is used as an alternative to PWHT for P-1 and P-3 materials?

49. When is a pressure test considered mandatory?

50. Is it permissible to substitute local PWHT for 360 degree banding on local repairs?

51. When local PWHT is substituted what are the four conditions that must be adhered to?

52. Define LT and ST Corrosion Rates?

53. When fillet welded patches are used for repairs what design considerations must be made?

54. What are the requirements that must be met when a pressure vessel is rerated?

55. Sketch the basic nameplate or stamping that is used for a rerated vessel.

56. What alternative method may be used to determine acceptability vessel walls when corrosion has
reduced the thickness below the minimum required wall thickness?

57. If a corroded area is found in the center portion of an ellipsoidal or torispherical head, what formula
would be used to calculate the minimum required thickness?

58. Which is the preferred method to use internal inspection or on-stream inspection?

59. Who must review and endorse the repair procedures used on stainless steel weld overlay and
cladding?

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60. For the controlled-deposition welding technique using SMAW, the weld area shall be maintained at
what temperature and for what minimum time after completion of the repair? (assuming 7018 H4
electrodes are not used)

61. The repair area on stainless steel weld overlay and clad vessels constructed of P-3, P-4 or P-5 base
materials should have the base materials examined for what type defects and by which NDE
method?

62. When a pressure test is not performed following a repair or alteration what is required as a
substitute?

63. When is the controlled deposition welding method used (i.e., what additional testing is required?)

64. What is the minimum number of thickness measurements that must be taken on each vessel to
satisfy the internal or on-stream requirements?

65. When may widely scat tered pitting be ignored?

66. Who must be consulted prior to repairs of cracks at high stress concentrations?

67. When there is a conflict between requirements specified in the ASME Code and API 510, which
document governs?

68. Do the requirements of API 510 apply to new construction of pressure vessels?

69. Materials for repairs or alterations shall conform to what requirements?

70. What are the two main elements of an RBI Program?

71. The RBI assessments must be reviewed and approved by whom, when used to increase or
decrease inspection intervals?

72. Name some of the factors to be considered in an RBI Assessment.

73. When should rupture disks and vacuum-breakers be examined?

74. When is fitness-for-service used?

75. What is RP 579 and what does it cover?

76. By definition, what constitutes an “industry-qualified” UT Shearwave examiner”?

77. What do each of the specific sections of RP 579 cover (Sections 4 – 11)?

78. Who selects the most appropriate corrosion rates to be used?

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IRE CHAPTER II PRACTICE QUESTIONS

1. Corrosion problems in refining operations are divided into three major groups. Name them?

2. Name four corrosive materials that may be added to the refinery processes?

3. Define stress corrosion cracking.

4. Carburization, decarburization and metal dusting are considered to be what kinds of changes to
metals and their alloys?

5. Oxygen reacts with steel at high temperature to cause?

6. The physical wearing away of vessels, piping, and other equipment by moving streams of gases or
liquids is called?

7. The formation and collapse of cavities in a liquid at the metal-liquid interface is called?

8. What two conditions are used to evaluate materials at high temperatures where the plastic
properties dominate?

9. Coarse grained materials are not suitable for high temperature service?

10. List and describe briefly three of the most serious structural changes that occur to refinery metals
and alloys?

11. What two metals and their alloys are seldom a problem from attack by oxygen?

12. Name and briefly describe five kinds of corrosion phenomena?

13. Mercury will cause stress corrosion cracking in which two metals?

14. Metals having good notch toughness are best employed in high temperature service?

15. The metal temperature at which the type of failure changes from ductile to brittle is called?

16. What is the most common metallic material of construction used in refineries?

17. Atmospheric corrosion is also called ______________ corrosion.

18. Of all the metals and alloys used in the refinery which is the only one to exhibit low-temperature
brittleness?

19. Name three causes of excessive pressure?

20. Overpressuring of shells and heads can cause what damaging results?

21. Name four compounds in crude oil that cause corrosion?

22. What are some typical observations that give evidence of overloading? Give five examples.

23. Give five examples of mechanical damage?

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24. Name three situations leading to improper selection of material and equipment and explain each
briefly?

25. List the equipment section(s) most likely affected by the following corrosive compounds:

a) hydrogen sulfide
b) sulfur compounds
c) organic acids
d) dissolved oxygen
e) hydrogen chloride

26. Name two types of linings that are used to resist erosion?

27. Define Ph.

28. Describe three overload conditions and their causes?

29. Where are phenols used in the refining process?

30. Sodium hydroxide will cause general corrosion of carbon steel above what temperature?

31. Phosphoric acid is not corrosive under what conditions?

32. What are some examples of damage caused by earthquake?

33. Name two sources of mechanical damage?

34. Ammonia is used for what two purposes in a refinery?

35. Name three considerations that control the amount of galvanic corrosion?

36. Organisms causing biological corrosion are divided into two categories, what are they?

37. Cavitation corrosion occurs most frequently in what equipment?

38. Name the corrosive materials added to the process in the following process units?

a. alkylation unit.
b. olefin-extraction units.
c. acid-concentration facilities.

39. Creep is dependent on what?

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RP 572 PRACTICE QUESTIONS

1. What is the most common material used in the construction of pressure vessels?

2. Inspection of external parts while the unit is in service should be made when?

3. When should new vessels be inspected?

4. How would you check the thickness of metallic linings?

5. Name three shell types for heat exchangers?

6. What are three materials that provide corrosion resistant surfaces in pressure vessels?

7. List the safety precautions that must be taken prior to entering a pressure vessel?

8. Prior to 1956 what pressure vessel construction code was used by refineries?

9. What are common internal corrodents?

10. List three visual signs of the application of faulty fabrication?

11. List at least three problems that can occur from using faulty materials?

12. What are the purpose of guy wires?

13. The frequency with which a pressure vessel should be inspected depends on what factors?

14. When is a service history record established?

15. Name three opportunities when inspections are possible?

16. What should the Inspector do before starting the inspection of a pressure vessel, particularly one in
severe service?

17. Is it necessary to remove all surface deposits for an inspection? Give reasons.

18. Is it necessary to remove internals completely during an inspection? Why?

19. What is hydriding?

20. When is it allowable to use the average thickness of a corroded area?

21. What are two common materials used for tubesheets?

22. What are the basic reasons for inspection?

23. What is the primary cause of deterioration in pressure vessels?

24. List six of the tools used in the inspection of a pressure vessel?

25. When inspecting a pressure vessel externally what should the inspection start with?

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26. Briefly describe the items to be checked when externally inspecting the following equipment:

a. foundations and supports

b. nozzles
c. steel supports

27. Upon what will the number of thickness readings taken depend?

28. Name the principal strip-lining methods used in refinery vessels?

29. What must every pressure vessel manufacturer prepare in order to obtain the ASME Code
Certificate of Authorization?

30. In addition to checking for corrosion on an external inspection name three other items to check for?

31. What two methods of inspection are used when all the tubes in a bundle are to be checked
internally for through-wall defects or thinning?

32. Name two ways to check the profile of a pressure vessel?

33. What would be inspected by hammer testing?

34. Briefly describe how you would make a detailed internal inspection of a pressure vessel?

35. What are the three most important factors to consider when checking metallic linings?

36. What types of nonmetallic linings are commonly used?

37. On what two factors does the degree of internal surface preparation depend?

38. What should be accomplished during the preliminary visual inspection?

39. Name three methods of measuring metal thickness?

40. When should hammer testing be used and when is it not recommended?

41. What inspection techniques are used to inspect nonmetallic linings?

42. To whom should general inspection reports be sent?

43. Describe briefly the steps to perform a hydrostatic test of a pressure vessel?

44. What test method would be used for testing a vacuum vessel for leaks?

45. What metallurgical changes would you be inspecting for and what tests would be used to determine
each change?

46. What is the retiring thickness of a part?

47. Name three conditions that will result in excess thickness of a pressure vessel shell?

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48. When should a pressure test be applied to a repair?

49. What code would you use to determine the minimum thickness required for pressure vessel
accessories such as trays and supports?

50. Briefly describe the repair method to be used for cracks?

51. What are the three types of records that should be kept in the record file?

52. Copies of completed reports recommending repairs should be distributed to whom?

53. What should the repair reports contain?

54. When an exchanger is removed from service what test is recommended prior to dismantling?

55. What basic data should each type of file contain?

56. What data should the continuous files contain?

57. Sketch an exchanger with two fixed tube sheets. (BEM)

58. What is the first step in inspecting a tube bundle?

59. How are thin spots in tubes determined?

60. How are scattered pits best repaired?

61. Some jurisdictions require the repair firm to possess what authorization to perform the repair?

62. Name three likely locations of corrosion on tubes in a tube bundle?

63. What would be checked during the visual inspection of an extended plate exchanger?

64. What must be done to the finned tubes of an air-cooled exchanger before starting an inspection?

65. Where is erosion-corrosion of tubes most prevalent in an air-cooled exchanger?

66. Define a pressure vessel?

67. List four methods of construction used on pressure vessels.

68. Improper heat treatment can be caused by?

69. What two NDE methods are now primarily used to measure thickness?

70. How can the extent of surface cracking be determined?

71. The selection of thickness measuring tools depends on what five factors?

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RP576 PRACTICE QUESTIONS

1. Briefly describe the following relief devices:

a. safety valve
b. relief valve
c. safety relief valve
d. pilot operated safety relief valve
e. balanced safety relief valve
f. rupture disk

2. What should be checked during a visual on-stream inspection of a relieving device?

3. List three applications for a rupture disk?

4. What are three reasons for inspecting relieving devices?

5. What is a primary consideration used to establish the inspection frequency of relieving devices?

6. There are three basis for establishing the frequency of shop inspections/overhauls. What is each
and briefly describe?

7. What inspections and testing should be done on new relieving device installations?

8. An on-stream inspection of a relieving device should be done on what intervals?

9. What is the ideal time to perform inspections of relieving devices?

10. What should be done after extended shutdowns with relieving devices left on a unit?

11. Following reassembly of the relieving device what tests should be done?

12. What is the principle objective in keeping records of safety relieving devices?

13. What precautions should be observed when inspecting pressure relief devices?

14. What service information should be contained in the history of a relieving device?

15. Name three applications for safety valves?

16. What medium is normally used to test relieving devices in the shop test block?

17. Briefly describe the shop test block used for testing with air? Make a sketch.

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18. What should be done immediately after the removal of HF relief devices that will be sent to the
shop?

19. List the nine points that should be visually checked during the dismantle of a relieving device?

20. Prior to the start of dismantling what test should be performed and why?

21. During the relieving device test after reassembly what two items are to be checked?

22. What basic information should the Specification Record contain?

23. What data should the Historical Record contain?

24. List six causes of improper performance in relieving devices?

25. When are resilient valve seats used?

26. What should be done with connecting piping and block valves before disconnecting relief valves?

27. What should be done before relief lines are opened to the atmosphere?

28. What are two types of hydrocarbon that can cause plugging or sticking?

29. List two limitations for each of the following pressure relief devices:

a. safety valve
b. relief valve
c. safety relief valve
d. pilot operated safety relief valve
e. balanced safety relief valve
f. rupture disk

30. Rupture disks should not be re-used after dismantling of the rupture disk device, even if they are
sound and have not ruptured, why?

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ASME CODE SECTION V

The following articles fall within the scope of the examination and should be studied:

Article 2 Radiographic Examination, excluding Appendices I, II and III

Article 5 Ultrasonic Examination Methods for Materials and Fabrication, concentrate on general
requirements and the specific requirements for castings and welds.

Article 6 Liquid Penetrant Examination

Article 7 Magnetic Particle Examination, concentrate on the prod and yoke methods only.

In the day to day inspection activities nondestructive examinations are used and the API Inspector must
have both an understanding of the practical applications as well as the specific requirements.

It is not necessary for the API Inspector to have the in-depth knowledge of the SNT-TC-IA Level II Examiner
for the nondestructive methods but should know where in the ASME Code to find the requirements.

ASME SECTION V AND NDE PRACTICE QUESTIONS

1. Which NDE methods are required to have written procedures?

2. To what standard are NDE personnel to be qualified?

3. Describe how a check of backscattered radiation is performed?

4. What permanent identification must appear on the radiograph?

5. How is density monitored?

6. Name three items of information that must be included on a UT Written Procedure.

7. What are the IQI thickness and hole sizes for a number 30 IQI?
8. What are the two radiographic exposure techniques permitted by the Code?

9. An IQI is an abbreviation for _____________________ ?

10. What is the recommended minimum thickness that steel can be radiographed using Iridium 192?

11. Can the minimum thickness limitations for gamma radiation be further reduced?

12. Is geometric unsharpness an essential variable when radiographing welds in pressure vessels to
ASME VIII?

13. For single wall viewing source side markers shall be used on what components?

14. The IQI is normally placed on the

a. source side
b. film side

15. Where is the lead letter "F" placed when film side IQI’s are used?

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16. A circumferential seam is to radiographed as a single exposure, what are the minimum number of
IQI’s to be used?

17. Shims are used when a radiographing__________________?

18. When viewing single film radiographs made with an X-ray source what is the minimum and
maximum permitted density?

19. It is required to radiograph a steel plate with a weld. The plate thickness is 7/16 inch and the weld
reinforcement is 1/16 inch. What source side IQI is required and what is the essential hole

20. Are intensifying screens permitted by ASME Code Section VIII Div. 1?

21. For which NDE methods are there alternative personnel qualification requirements in Section VIII?

22. What is the permitted density variation anywhere through the area of interest?

23. What minimum RT detail information must be provided to the Inspector along with the radiographic
film?

24. The initial PT procedure shall contain what information?

25. What type of technique is required for all ultrasonic examination of forging and bars?

26. Couplant used in ultrasonic examination of nickel base alloys shall contain no more than _____ppm
of sulfur.

27. Ultrasonic thickness measurements shall be performed in accordance with ________.

28. What material must be used for the calibration block?

29. What type of indications must be recorded per Article 5?

30. What is the nominal frequency for ultrasonic search units?

31. Where is the IQI placed when radiographing a weld?

32. When using penetrant materials on nickel base alloys, austenitic stainless steels and titanium what
certifications must be obtained?

33. The UT examination report shall contain what data?

34. The scanning of welds shall be performed at a gain setting that is how many times the primary
reference level?

a. three times
b. two times
c. one-one half times

35. Where are wire IQI’s always placed?

36. Liquid penetrant examinations detect discontinuities that are:

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a. slightly subsurface
b. open to the surface
c. both a and b

37. What are the essential variables that when changed in a PT procedure may require a new procedure
to be prepared?

38. List the two types of penetrants and the three basic penetrant processes?

39. Name 3 items (information) that must be on Ultrasonic Examination Records?

40. What is the term penetrant materials meant to cover?

41. The acceptance tolerance for the MT units ammeter shall be that the reading shall not deviate by
more than _______% of full scale relative to the actual current value as shown by the test meter?

42. Describe briefly the basic steps in making a liquid penetrant examination?

43. What is considered to be the standard temperature range for liquid penetrant examination?

44. What is the retention time for radiographic film and reports for radiography performed on pressure
vessels?

45. To remove excess penetrant after the penetration time has elapsed for the solvent removable
penetrant is it permissible to flush the test piece gently with solvent then wipe it dry?

46. The magnetic particle examination method can detect:

a. near surface discontinuities

b. surface discontinuities
c. both a and b above
47. Final interpretation shall be made not less than ___________minutes after the developer is dry?

48. What are the two types of radiation sources used in radiography?

49. What are the acceptance standards for liquid penetrant examinations of welds in pressure vessels?

50. The written procedure for the magnetic particle examination shall contain what minimum
information?

51. List the five techniques for magnetic particle examination?

52. Each piece of magnetizing equipment with an ammeter shall be calibrated at what frequency?

53. What is the acceptance criteria for the lifting power of yokes when they are checked annually?

54. What are the acceptance standards for magnetic particle examinations of welds in pressure
vessels?

55. Any imperfection that causes an indication in excess of ______% DAC shall be investigated?

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56. What is the minimum light intensity for visible MT examination?

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ASME CODE SECTION VIII, DIVISION 1

The examination concentrates mainly on the math problems, which accounts for 20% of the total possible
grade. While it is important to study the entire Code the emphasis should be placed on a complete
understanding of the various formulas and their application in solving the five examination math problems.

A thorough study must be made of the following paragraphs:

1. UG-27 Thickness of Shells Under Internal Pressure.

2. UG-28 Thickness of Shells and Tubes Under External Pressure.
3. UG-32 Formed Heads and Sections, Pressure on the Concave Side.
4. UG-34 Unstayed Flat Heads and Covers (Formula 1 only).
5. UG-37 Reinforcement Required for Openings in Shells and Formed Heads.
6. UG-116 Required Marking.
7. UW-11 Radiographic and Ultrasonic Examination.
8. UW-12 Joint Efficiencies.
9. Appendix 1, 1-1 Thickness of Cylindrical and Spherical Shells.
10. Appendix 10

When solving math problems whether for the examination or for actual work situations a few simple rules are
necessary.

1. Make a diagram of the problem.

2. List the given values.
3. Derive any values not given.
4. Show formula to be used including source designation.
5. Enter all factors into formula and make calculation.
6. Check calculation for errors.
7. State conclusion.

The examination math problems are normally based on the concept that the vessel or vessel part has been
in service. This means that there are no original design questions to consider.

Under these circumstances there are certain basic points that must be understood when solving the math
problems. These are:

1. Efficiencies are determined by the extent of radiography, type of joint and the application of Table
UW-12, UW-11(a)(5)(b) and UW-12(d) as applicable.

2. When determining allowable pressure or thickness in corroded conditions for cylindrical shells or
pipe the inside radius is taken at the bottom of the corroded area exclusive of corrosion allowance.

3. When solving a problem to determine tmin for use in a remaining life problem the inside radius to use
is the original radius increased by the amount of corrosion allowance specified in the problem.

4. Radii may have to be adjusted depending on the existence of corrosion allowances. Unless
specifically stated otherwise in the problem corrosion allowance is assumed to be "0".

5. Static head is to be considered only when the problem gives relevant height or other data, otherwise
it is assumed to be "0".

The following are some typical math problems which cover each of the formulas that you will study.

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QUESTION: 1

During the inspection of a horizontal pressure vessel a corroded area was found on the inside surface, the
thickness at the point was measured to be .906 inches thick. Checking the ASME Data Report for the
vessel it was found that the shell plate was 1-1/4 inch purchased thickness, 48 inch inside diameter, of
SA-516 Gr. 70 material, the shell was rolled and welded using a type 1 longitudinal seam with full
radiographic examination. No corrosion allowance was specified. The MAWP is 600 psig at 300 F. All
openings in the vessel are fully reinforced, welded connections. S is 17500.

As the Inspector what position would you take with regard to this area of thinned shell? (Show your
calculations upon which you based your decision.)

QUESTION: 2

A vessel has fixed tube sheets with 40, 4 inch outside diameter by 0.120 inch minimum wall thickness
tubes of SA-192 material installed between tubesheets. The total unsupported length is 72 inches. The
vessel is stamped 500 psig at 400 F.
on the shell side. Do these tubes comply with Code requirements?

QUESTION: 3

A seamless 2:1 elliptical head on a horizontal pressure vessel is found by inspection to have a minimum
thickness of 7/8 inch. The nameplate shows a MAWP of 500 psi at 600 degrees. The vessel has not been
radiographed and the Data Report shows that UW-11(a)(5)(b) has not been applied. The inside length of the
major axis is 42 inches. The material is SA-516 Grade 60, S = 15,000. Must the MAWP be reduced?

QUESTION: 4

A seamless flat circular head, attached to a cylinder as shown in Fig. UG-34(b-1), has been subjected to
corrosion near the center of the head which has reduced the thickness below acceptable limits. The reduced
area is to be restored by weld buildup. The head is made of SA-105 material, S = 17500 with an inside
diameter d of 36 inches. The hydrostatic head acting on the flat head is 10 psig. From the nameplate, the
MAWP is 550 psi at 475 F and RT-3 is the extent of radiography. What is the minimum required thickness
of the head after the weld buildup has been completed?

QUESTION: 5

A vessel is to be altered to add a new nozzle to a cylindrical shell. The Engineer has provided the following
information:

P= 605 psig design pressure F = 1 unitless (Fig. 37)

t= 3.0 in. vessel thickness R = 36 in. inside vessel radius
E 1= 1 for vessel and nozzle c = 0 in. corrosion allowance
t n= 1.5 in. nozzle thickness S= 15,000 psi vessel
d= 12 in. nozzle inside diameter S n= 15,000 psi nozzle
h= 0 in. internal nozzle projection

Outward nozzle weld leg = 1 in.

See Fig. UW-16.1(e) for mounting.

Does this nozzle have adequate reinforcement to meet Code without additional reinforcement?

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QUESTION: 6

A hydrostatic test is to be performed on a pressure vessel using the same methodology as required by
Section VIII, Div. 1 Code where the MAWP is 725 psig at 700 F. The vessel is a single chamber vessel
constructed of SA-516 Gr. 70 or equal materials. Sd= 16600, St = 17500. Describe the hydrostatic test
along with the required test pressure. (Show your calculations.)

QUESTION: 7

Calculate the pneumatic test pressure and describe the pressure test for a vessel of SA-515 Gr 60, S =
15000, with a temperature of 450 F and an MAWP of 800 psig. The MDMT is 100 F.

QUESTION: 8

A welded nozzle is installed into a vessel shell using two fillet welds as shown in Figure UW-16.1(i). The
nozzle thickness tn = 0.75 in., the shell thickness t = 1.5 in., t1= 0.5 in., and t2 = 0.375 inch. Does the as
measured weld throat dimension meet Code requirements?

QUESTION: 9

A pressure vessel shell with the following characteristics is to have a plate replaced using SA-515-70
material.

Minimum thickness 1.125"

Inside radius 30"
E 1.00
MAWP 641 psig @ 300 F.
PWHT Applied to original vessel but not mandatory
MDMT -20 F.
S 17500
Ratio of design stress 1.00
to allowable tensile stress

Does the replacement plate require impact testing?

QUESTION: 10

A vertical pressure vessel is to be hydrostatically tested for an MAWP of 125 psi. Two pressure gages will
be used to monitor pressure. One is placed at the top of the vessel at the 175 ft. The other is placed at the
25 ft. level. Stress ratio is 1.0 for the materials. As the Inspector you are to read the test pressure gauge at
the 25 ft level. What pressure reading would you expect to observe?

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The following general knowledge areas of Section VIII, Division 1 must be studied as a basis for answering
the quiz questions. These areas are:

1. U-1 through U-3, Introduction.

2. UG-4 through UG-46.

3. UG-55 through UG-100.

4. UG-102 through UG-120.

5. UW-1 through UW -60.

6. UCS-1 through UCS-115.

7. Appendices 1-1, 3, 4, 6, 7, 8, 10, 12, L, and W.

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ASME SECTION VIII DIVISION 1 PRACTICE QUESTIONS

1. The ASME Code used for the construction of pressure vessels is:

a. Section I
b. Section IV
c. Section VIII, Division 1

2. When designing pressure vessels containing cast material what corrections are required to be made
to the allowable stress values?

3. Material subject to stress due to pressure shall conform to:

a. ASTM standards
b. API-ASME specifications
c. ASME Section II, with specified limitations

4. Can material that is not identified with one of the permitted specifications in Section VIII be
accepted as meeting the requirements of a permitted specification?

5. Define minimum design metal temperature?

6. The design formulas in Section VIII address what loadings?

7. When calculating the required thickness or internal design pressure of a cylindrical shell the formula
most commonly used considers:

a. circumferential stress
b. longitudinal stress
c. both a and b

8. What is the minimum thickness permitted for shells and heads?

9. A torispherical head on a vessel must be replaced, what formula would apply if the knuckle radius is
6% of the inside crown radius?

10. What are the two methods of calculating the MAWP for a convex head with the pressure on the
convex side?

11. An circular unstayed flat head is to be replaced on a pressure vessel. The head is similar to that
shown in Figure UG-34(h). What formula would you use and what "C" factor would apply?

12. What product forms are required to have a material test report or certificate of compliance?

13. Welding materials must be provided with a Certified Test Report or a Certificate of Compliance?

True or False

14. What Code paragraph addresses Quick Actuating Closures?

15. Are openings in pressure vessels limited to only those of circular shape? If not, If no, what are the
permitted shapes?

16. What classes of vessels are not considered to be within the scope of Section VIII Division 1?

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17. Certain openings that are not subject to rapid fluctuation do not require reinforcement other than that
inherent in the construction. What are the size limitations for these openings?

18. When calculating the required thickness of vessel and nozzle walls to determine the required
reinforcement what "E" factor is used?

19. On what theory is the reinforcement of openings based?

20. What are the limits of reinforcement measured parallel to and normal to the vessel wall?

21. Can credit be taken for reinforcement material having an allowable stress value higher than that of
the vessel wall?

22. UG-41(b) requires that strength calculations be made for certain welded nozzle configurations.
Which configurations are exempt from these strength calculations?

23. Nozzle necks other than those for access openings and openings for inspection require special
attention regarding their required thickness. Where are these requirements found and briefly explain
their application?

24. A replacement torispherical head of P-No. 1, Group No. 1 material is required for a low alloy steel
vessel. The head thickness before forming is 1 inch and the knuckle radius is 3 inches. The head is
to be formed at 8000F. Does this head require heat treating after forming?

25. When nozzles are welded into a pressure vessel what must be done to the exposed inside edges?

26. What are the requirements for identification of material at the completion of a newly constructed
pressure vessel?

27. What is the maximum out of roundness permitted for any shell cross section?

28. Under what conditions may the out of roundness tolerance exceed the 1% value?

29. What are the shape tolerances that apply to torispherical and ellipsoidal heads?

30. What is the difference between RT 1 and RT 2?

31. The material specifications specify either a material test report or a certificate of compliance. What
is the difference between the two?

32. When a pressure part is to be welded to a flat plate thicker than 1/2 inch to form a corner joint some
additional examinations must be made. Where are these requirements found?

33. Define Maximum Allowable Working Pressure for a completed vessel and a part of a vessel?

34. All pressure vessels for external pressure service must have stiffener rings installed?

True or False

35. When determining the minimum required hydrostatic test pressure what correction factor must be
taken into account?

36. Non pressure parts that are welded to a vessel shall meet what criteria?

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37. What is the minimum and maximum range permitted for dial indicating test gages?

38. When openings are to pass through welded joints what additional provisions apply?

39. Is there any upper limit on the hydrostatic test pressure that is applied to a vessel?

40. Sketch a typical form of stamping with the following data included:

X Y Z Company
MAWP 400 psi @ 350 0F
MDMT - 200F @ 400 psi
Serial No. 12345
Vessel completed 4-25-91
Welded main seams
Vessel completely spot radiographed

41. What are the markings that can be applied to the stamping for vessels that have been
radiographed?

42. A carbon steel vessel has a required thickness of 3/16 inch. The shell is seamless and the vessel is
stamped RT3. Must additional corrosion allowance be provided?

43. You are reviewing the stamping on a vessel and note that the extent of radiography is RT 3. The
vessel was constructed in the year 1994. What "E" factor would you use when calculating the shell
and head thicknesses if type 1 joints were used?

44. What special service conditions are applicable in Section VIII and where are they found?

45. What are the four weld joint categories?

46. What is the mandatory minimum test temperature that shall be used during a hydrostatic or a
pneumatic pressure test?

47. Category defines:

a. location of joint
b. type of joint

48. You are welding a seamless torispherical head to a seamless shell. To be able to allow the full
allowable stress value on the head what must be done to the weld joint?

49. Do butt welds in nozzles and communicating chambers that neither exceed NPS 10 nor 1-1/8 inch
wall thickness in a lethal vessel require any radiographic examination?

50. Sketch an example of a Type 1 and Type 2 weld joint?

51. A nozzle neck is to be replaced. What are the requirements for determining the correct weld sizes
for partial penetration welds?

52. You are reviewing the stamping on a pressure vessel and find two nameplates, one of which is for a
part. What would you expect to find when you are reviewing the Manufacturer's Data Report for the
vessel?

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53. What is the permitted alignment tolerance when joining a torispherical head to a seamless shell
with both having a section thickness of 9/16 inch?

54. A finished Category B joint with a nominal thickness of 1-1/16 inch has a maximum reinforcement of
9/32 inch. Does this meet Code requirements?

55. You are replacing the head on a vessel constructed in 1994. The Data Report shows the material to
be SA-516 Grade 60 not normalized. The nominal thickness is 1-1/2 inch. What would be the
MDMT for this material considering the required thickness times E* equals the nominal thickness
minus corrosion allowance?

56. You are replacing the bolting on a vessel with SA-193 Grade B5 bolts. The MDMT is - 210F. Is
impact testing required?

57. You must replace the reinforcing plate around a nozzle. What is the requirement regarding the size
of the telltale hole?

58. To utilize SWP’s, additional controls must be added to what document?

59. What alternatives to SNT-TC-1A are allowed for personnel qualifications for radiographers or UT
operators?

60. What are the minimum sizes permitted for elliptical or obround manways or circular manways?

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ASME CODE SECTION IX

A good general knowledge of Section IX is required to evaluate the acceptability of a Welding Procedure
Specification (WPS) its qualifying Procedure Qualification Record (PQR) and the Welders Performance
Qualification Record (WPQ). The actual examination is limited to the welding portion of the Code only and to
the processes shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), gas metal arc
welding (GMAW) and submerged arc welding (SAW). No more than one process will be included on a WPS,
PQR or WPQ.

A technical knowledge of welding such as that held by a welding engineer or technician is not necessary to
perform the evaluation of the WPS, PQR and WPQ or to answer any of the quiz questions or those on the
examination.

The evaluation consists of four separate phases which are:

1. Are all of the essential, supplemental essential variables when applicable and nonessential variables
as required by the process addressed on the Welding Procedure Specification and are there any
errors or incompatibilities?
2. Are all the essential and supplemental essential variables when applicable as required by the
process recorded on the Procedure Qualification Record and are there any other errors or
incompatibilities?
3. Are all the required essential variables addressed for the qualification of the welder and are actual
values and qualified ranges recorded and are they correct or do incompatibilities exist?

Some examples of suspect data is as follows:

1. Base material specification and P-No. that are not compatible.

2. Welding material classification and F-No. that are not compatible.
3. Root gap and use of retainers is required to be addressed but is missing.
4. Tensile test specimen sizes, areas, ultimate unit stresses do not meet requirements.
5. Incorrect type or size of bend specimens.
6. An actual value for a welders essential variable is or is not given but no range qualified is indicated.

A study of the following areas of Section IX is required:

1. Part QW

a) Article I - Welding General Requirements.

b) Article II - Welding Procedure Qualification:
1) Excluding QW 202.4(1).
2) Limited to P-Nos. 1, 3, 5, and 8 base materials.
3) Excluding special welding processes.
c) Article III - Welding Performance Qualification.
d) Article IV - Welding Data:
1) Excluding QW-462.5 through .11.
2) Excluding QW-470.

You will be given several sample WPS’s and PQR’s to review during the course. The following
comprehensive quiz on ASME Section IX will help you prepare for that portion of the presentation.

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ASME CODE SECTION IX PRACTICE QUESTIONS

1. If a performance qualification is made on a groove weld in a pipe over 24" in the 3G test position for
what position(s) is the welder qualified?

2. What is the purpose of the WPS and PQR combination?

3. The performance qualification of a welder/welding operator shall expire when no welding is performed
in the process for what period of time?

4. If a tension test specimen breaks in the base metal outside of the weld or fusion zone what are the
acceptance criteria?

5. When corrosion resistant weld overlay cladding is not a factor would a 1/16" open defect be
acceptable for a guided bend specimen?

6. What is the purpose of a WPS?

7. Pipe diameter is not an essential variable for a welder under the GMAW process?

8. Under what conditions can a PQR be revised?

9. Does procedure qualification on a 1-1/2" thick base metal qualify the procedure to be used to repair
groove welds and to make weld buildups on base metal thicknesses no exceeding 8"?

10. 1G and 6G are test positions or positions for which a welder is qualified?

11. Groove design and retainers are essential variables for the SMAW process?

12. Anyone can supervise the welders making procedure and performance test coupons?

13. Performance test coupons are required to be visually examined to confirm complete joint
penetration and fusion?

14. The base metals and filler metals used during qualification do not have to be one or more of those
listed in the WPS?
15. Can an existing PQR be used to support a newly written WPS?

16. Can organizations with two or more companies having different names exchange WPS's and
PQR's?

17. The WPS specifies a single V groove design. Can the PQR use a double V groove to qualify the
WPS?

18. For what processes and P-No.'s may welders be alternatively qualified by radiographic examination?

19. When and immediate retest is made following failure of the visual examination how many test
coupons are required for each position which failed?

20. If a welder/welding operator has left the employ of an organization and has not welded for a period of
five years what are the qualification renewal requirements?

21. If QW-404.15 is shown as a variable can a welder who has welded F-No. 4 filler metal without
backing also weld F-No's 3, 2 and 1 without backing?

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22. Multiple reduced section specimens can be used for tension tests on thicknesses not exceeding 1
inch?

23. If QW-406.1 is shown as a variable and the preheat temperature qualified was 3500F, would a
preheat of 4520F require requalification?

24. When are longitudinal bend specimens permitted to be used?

25. What is the minimum specified tensile strength of the following base metals:

a) SA-53 Type F
b) SA336 Type F3V

26. If a welder uses a P-No. 1 material for a qualification test coupon what base metals is he qualified to
weld?

27. Can a welder who has passed the required tests for groove welds make fillet in all thicknesses and
pipe diameters of any size?

28. What ASME Specification and F-No. is the filler metal E-6010?

29. What are the procedure qualification bend test requirements for a 3/8" test coupon?

30. Is the term N/A addressing and essential or nonessential variable?

31. How many tension test specimens are required to qualify a welder?

32. If a 2-7/16" OD test coupon is welded by a welder what is the minimum and maximum outside
diameters qualified?

33. If a filler metal is A-No. 1 what elements must be shown on the analysis?

34. What is the specimen width of a tension test reduced section - plate?

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ANSWER KEYS

The references listed below for the written questions are where the answers to the quizzes can be found.

API 510

1. 1.1
2. Appendix A
3. 5.4
4. 5.5
5. 3.1 and 3.15
6. 3.1
7. 6.1
8. 6.3
9. 5.5
10. 6.6
11. 3.11
12. 6.7
13. 3.15
14. 3.16
15. App. B
16. 5.2
17. 5.3
18. 5.5
19. 6.3
20. 5.5
21. 6.4
22. 5.6
23. 5.7
24. 5.7
25. 5.7
26. 6.4
27. 4.3
28. 5.7
29. 6.6
30. 6.4
31. 5.1
32. 6.3
33. 5.6
34. 6.4
35. 7.1
36. 6.4
37. 6.5
38. 7.2.7
39. 6.5
40. 6.5
41. 6.5
42. 6.6
43. 6.6
44. 6.6
45. 5.7
46. 7.1
47. 7.2
48. 7.2.3.1
49. 6.5

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50. 7.2.5
51. 7.2.5
52. 6.4
53. 7.2.7

54. 7.3
55. 7.3
56. 5.7
57. 5.7
58. 6.4
59. 7.2.6
60. 7.2.3.2
61. 7.2.6
62. 7.2.10
63. 7.2.3.2
64. 6.4
65. 5.7
66. 7.1
67. 3.2
68. 3.2
69. 7.2
70. 6.2
71. 6.2
72. 6.2
73. 6.6
74. 3.20
75. 5.8
76. 3.21
77. 5.8
78. 6.4

IRE CHAPTER II

1. 202.01
2. 202.031
3. 202.064
4. 204.032 thru 204.034
5. 202.052
6. 203.01
7. 203.022
8. 204.011, 204.012, 204.013
9. 204.014
10. 204.022(a) thru (g)
11. 202.052
12. 202.06
13. 202.036
14. 205.01
15. 205.01
16. 202.041
17. 202.04
18. 205.01
19. 206.021 thru 206.025
20. 206.03
21. 202.021

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22. 207.02
23. 209.02
24. 210.021 thru 210.023
25. 202.021
26. 203.02
27. 202.022, 202.024(a), 202.064
28. 207
29. 202.033

30. 202.035
31. 202.034
32. 208
33. 209.01
34. 202.037
35. 202.067
36. 202.069
37. 203.022
38. 202.03
39. 204.012

RP572

1. 4.3
2. 9.2
3. 9.3
4. 10.4.5
5. Figure A-11
6. 4.3
7. 10.2.1
8. Section 5
9. 8.2
10. 8.5
11. 8.5
12. 10.3.7
13. 9.1
14. 9.1
15. 9.2
16. 10.1
17. 10.1
18. 10.1
19. 8.3.7
20. 10.5
21. 4.3
22. 7.1
23. 8.2
24. 10.2.2
25. 10.3.2
26. 10.3.3, 10.3.6, 10.3.8
27. 10.5
28. Figure 4
29. Section 5
30. 10.3.13
31. A.9.1
32. 10.3.13
33. 10.8.1
34. 10.4

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35. 10.4.5
36. 10.4.6
37. 10.4.2
38. 10.4.3
39. 10.5
40. 10.8.1
41. 10.4.6
42. 12.2
43. 10.8.2
44. 10.8.2
45. 10.7
46. 10.9

47. 10.9
48. Section 11
49. 10.9
50. Section 11
51. 12.1
52. 12.2
53. 12.2
54. 10.8.3
55. 12.1
56. 12.1
57. Figure A-11
58. A.9.1
59. A.9.1
60. Section 11
61. Section 11
62. A.9.2
63. A.11
64. A.12
65. A.12
66. 3.7
67. 4.2
68. 8.5.3
69. 10.5
70. 10.4.4
71. 10.5

RP576

1. 4.2 – 4.9
2. 6.3
3. 4.9.2
4. 6.1
5. 6.4
6. 6.4.1.1 – 6.4.1.3
7. 6.5.2
8. 6.4.2
9. 6.5.1
10. 6.5.4
11. 6.2.14 – 6.2.21
12. 7.1
13. 6.2.1
14. 7.2

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15. 4.2.1
16. B.2
17. Figure B-1
18. 6.2.5
19. 6.2.9
20. 6.2.8
21. 6.2.14 – 6.2.15
22. 7.2
23. 7.2
24. 5.1 – 5.10
25. 4.3
26. 6.2.4
27. 6.2.4
28. 5.5
29. 4.2 – 4.9
30. 6.2.21

Section V

1. T-150
2. T-140
3. T-223
4. T-224
5. T-225
6. T-522/Table T-522
7. Table T-233.1
8. T-271
9. T-276 or T-233
10. T-272.2
11. T-272.2
12. T-285 & Section VIII, UW-51(a)(3)
13. T-275.1
14. T-277.1
15. T-277.1(b)
16. T-277.2(b)(1)
17. T-277.3
18. T-282.1
19. T-276.2(a) & Table T-276
20. T-232
21. Section VIII, Appendices 6 & 8
22. T-282.2
23. T-291, T-292 & Section VIII UW-51(a)(1)
24. T-621.1
25. T-571.2(A)(B)
26. T-533.2(A)
27. T-574
28. T-534
29. T-591.2
30. T-532
31. T-277.1(c)
32. T-641
33. T-593 & Section VIII Appendix 12-4
34. b, T-542.7.2.2
35. T-277.1
36. b, T-600
37. T-621.2

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38. T-651
39. T-592
40. T-631
41. T-761(c)
42. T-642, T-643, T-670
43. T-652
44. Section VIII UW-51(a)(1)
45. T-673.3
46. c, T-720
47. T-676.1
48. T-272
49. Section VIII Appendix 8-4
50. T-750
51. T-752
52. T-761(a)
53. T-762(b) & (c)
54. Section VIII Appendix 6-4
55. T-580
56. T-778.1

SOLUTIONS TO PRACTICE MATH PROBLEMS

Section VIII Math

QUESTION: 1

GIVEN:

Material SA-516-70 = 17,500 psi R = 24"

P = 600 psig
T = 300F
t = .906"
E = 1.00

ASSUMPTIONS:

No static head applies

Circumferential stress governs
Thinned area in solid plate not weld
No corrosion allowance
P does not exceed .385SE
t is less than 1/2R

FORMULA: UG-27(c)(1)

Original thickness = 1.250"

Corroded thickness = 0.906"
Amount of corrosion = 0.344"

P= SEt
R + .6t

P = 17,500 x 1.00 x .906

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24.344 + .6 x .906

P = 637 psi

CONCLUSION:

No action necessary since remaining thickness is adequate to sustain present MAWP. Area should be
monitored at future inservice inspections to determine corrosion rate per API 510 paragraph 3.3.

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QUESTION: 2

GIVEN:

Do = 4 Do/t = 4/.120 = 33.33

t = 0.120"
L = 72" L/Do = 72/4 = 18
Material Chart = CS -1
Temperature = 4000F

FORMULA: UG-28(c)(1)

A = 0.001

B = 9800

Pa = 4B
3(Do/t)

P a = 4 x 9800
3 x 33.33

P a = 392.039 psi

CONCLUSION:

Tubes do not comply with Code for external pressure.

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QUESTION: 3

GIVEN:

P = 500
t = .875"
S = 15,000
D = 42
E = 0.85

ASSUMPTIONS:

The minimum thickness is occurring in the knuckle region.

FORMULA: UG-32(d) because head is a 2:1 ratio

P = 2SEt
D + 0.2t

P = 2 x 15,000 x 0.85 x 0.875

42 + 0.2 x 0.875

P = 529.046 psi

CONCLUSION:

Head can continue to operate at present MAWP.

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QUESTION: 4

GIVEN:

S = 17,500
d = 36"
P = 550
E = 0.85
Hydrostatic head = 10 psi
C = 0.17

ASSUMPTIONS:

Head is seamless.

FORMULA: UG-34(c)(2)

t=d CP
SE

t = 36 .17 x560 / 17500 x.85

t = 2.88"

CONCLUSION:

The minimum required thickness at the weld buildup is 2.88".

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QUESTION: 5

GIVEN:

P = 605 psi S & S n = 15,000 psi

F = 1.0 Outward weld leg = 1"
E 1 = 1.0 E = 1.0
Rv = 36" t = 3.0"
d = 12" fr1 & fr2 = 1.0
t n = 1.5" h=0

FORMULA: UG-37

Limits of reinforcement:

Parallel:

d = 12"

Rn + t n + t = 6 + 1.5 + 3.0 = 10.5"

Normal:

2.5t = 2.5 x 3.0 = 7.5"

2.5t n + t e = 2.5 x 1.5 + 0 = 3.75"

Shell and Nozzle required thickness:

t r = PRv / SE - 0.6P

t r = 605 x 36/ 15000 x 1.0 - .6 x 605

t r = 1.488"

t rn = PRn / SE - 0.6P

t rn = 605 x 6/ 15000 x 1.0 - .6 x 605

t rn = 0.248"

A = d x tr = 12 x 1.488 = 17.856 in2

A 1 = d(t - tr ) = 12(3.0 - 1.488) = 18.144 in2

A 1 = 2(t + t n) (t - t r ) = 2(3.0 + 1.5) (3.0 - 1.488) = 13.608 in2

A 1 > A Therefore reinforcement adequate

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WELD SIZE CHECK: Figure UW -16.1(e)

t c = not less than the smaller of 1/4" or 0.7t min

t c required = smaller of 1/4"

or

0.7 x .75 = 0.525" use 1/4"

t c actual = .707 x 1.0 = 0.707" Greater than 1/4" OK

CONCLUSION:

Nozzle reinforcement and weld sizes meet Code requirements. Nozzle adequately reinforced.

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QUESTION: 6

GIVEN:

P = 725
Design temperature = 700F
Material Sd = 16,600 psi at design temperature
Material St = 17,500 psi at test temperature

FORMULA: UG-99

P t = 1.3 x MAWP x St/Sd

P t = 1.3 x 725 x 17.5/16.6

P t = 993.39 psi

CONCLUSION:

The required test pressure is 994 psi. The steps necessary to perform the hydrostatic test are as follows:

1. Support vessel if necessary.

2. Close all openings with appropriately sized covers and bolting.
3. Fill with water and vent all air.
4. Attach pressure gage having a minimum range of 0 to 1491 and a maximum range of 0 to 3976psi.
5. Recommended metal test temperature of at least 30F above MDMT stamped on vessel but not in
excess of 120F.
6. Assure all hoses and connections subject to test pressure are adequate for the pressure.
7. Raise pressure slowly to test pressure.
8. Hold test pressure for time specified in written procedure, there is no Code mandated holding time.
9. Perform close examination of all joints and connections at a pressure of at least 2/3 of test
pressure.
10. Release pressure and assure vents open to avoid collapse of vessel.

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QUESTION: 7

GIVEN:

P = 800 psi
Design Temperature = 450 F
MDMT = 100 F
Material Sd = 15,000 psi at design temperature
Material St = 15,000 psi at test temperature

FORMULA: UG-100

P t = 1.0 x MAWP x St/S d

P t = 1.0 x 800 x 15/15

P t = 880 psi

CONCLUSION:

The test pressure is 880 psi and the test temperature is 130 F per API 510, 4.4 and UG-100 (c).

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QUESTION: 8

GIVEN:

t = 1.5"
t n = 0.75"
t 1 = 0.500" throat dimension
t 2 = 0.375" throat dimension
Figure UW -16.1(i)

FORMULA: UW-16(d)

t 1 + t2 1-1/4 tmin

and

t 1 or t 2 not less than the smaller of 1/4 in. or 0.7t min

t min = the smaller of 3/4 in. or the thickness of the thinner of the parts joined.

REQUIRED:

t 1 + t2 minimum is 1.25 x .75 = 0.9375 in.

0.7 x .75 = 0.525 use 1/4 in. because it is smaller of 0.525 in. and 1/4 in.

ACTUAL:

t 1 + t2 = 0.500 + 0.375 = 0.875 in. This is less than required.

t 1 and t2 both exceed 1/4 in. OK

CONCLUSION:

Construction does not meet Code because t1 + t2 is less than 1-1/4 tmin.

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QUESTION: 9

GIVEN:

t min = 1.125"
R = 30 in.
P = 641 psi
S = 17,500 psi at design temperature
E = 1.00
S d/S a = 1.00
MDMT stamped on vessel nameplate = -20 F.
PWHT has been performed but not required by Code.
SA-515-70 material is a Curve A material per Fig. UCS -66 note (a).

ASSUMPTION:

Original plate was butt welded

FORMULA: UG-27(c)(1) to determine if tmin is nominal thickness

t = PR/SE - 0.6P

t = 641 x 30/17,500 x 1.00 - 0.6 x 641

t = 1.124" use tmin as t nominal (governing thickness at welded joint).

Using Table UCS -66 or Figure UCS -66 the MDMT of the material is 75F.

MDMT = +75
Reduction per UCS-68(c) +30 -
+45 F

CONCLUSION:

Since the MDMT for the plate is 45 F. and no further exemptions are available the plate must be impact
tested at - 20 F. In accordance with UG-84, acceptance criteria is as shown in Figure UG-84.1.

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QUESTION: 10

GIVEN:

MAWP = 125 psi

Vessel height = 175'
Pressure gage location = 25' level

FORMULA: UG-99

P t = 1.3 x MAWP x St/S d

P t = 1.3 x 125 x 1.00

P t = 162.5 psi

There is 150 feet from top of vessel to pressure gage.

150 x .433 = 64.95 psi of static head

Test gage reading at 25' level = 162.5 + 64.95 = 227.45 psi

CONCLUSION:

The inspector would observe a pressure of approximately 228 psi minimum.

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Section VIII Written

1. (c), 58. UW-28(d)

2. UG-24 59. UW-51, Appendix 12
3. (c), UG-4(a) 60. UG-46 (g) (1)
4. UG-10
5. UG-20(b)
6. UG-22 Pressure only
7. a, UG-27(c)(1)
8. UG-16(b)
9. UG-32(e)
10. UG-33(a)(1) & (2)
11. UG-34 Form ula (1), UG-34(c)(2), C=0.33
12. UG-93(a)(1)
13. UG-9
14. UG-35
15. UG-36(a)(1) & (2)
16. U-1(c)(1) thru (10)
17. UG-36(c)(3)(a)
18. UG-37(a)
19. Area replacement
20. UG-40
21. UG-41(a)
22. UW-15(b)
23. UG-45
24. UCS-79(d)
25. UG-76(c)
26. UG-77(a)
27. UG-80(a)(1)
28. UG-80(a)(2)
29. UG-81(a)
30. UG-116(e)(1) & (2)
31. Appendix 3
32. UG-93(d)(4)
33. UG-98(a) & (b)
34. UG-28
35. UG-99(b)
36. UW-5(b)
37. UG-102(b)
38. UG-36(d) & UW-14
39. UG-99(d)
40. Figure UG-118
41. UG-116(e)
42. UCS-25
43. UG-116(e)(3) & Table UW-12
44. UG-116(c) & UW-2
45. UW-3(a)
46. UW-99(h) & UG-100(c)
47. a, UW-3(a)
48. UW-11(a)(5)(b) & UW-52
49. UW-11(a)(2) & (4)
50. Type 1 has no backing strip while Type 2 does.
51. UW-16
52. UG-120
53. UW-33 & Table UW-33

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54. UW-35
55. Figure UCS -66 +120
56. Yes, Figure UCS-66 [note (e)]
57. UW-15(d)

Section IX

1. QW-461.9
2. QW-100.1
3. QW-322.1
4. QW-153(d)
5. QW-163
6. QW-200.1(a)
7. QW-355
8. QW-200.2(c)
9. QW-202.3(b)
10. QW-120
11. QW-253
12. QW-201 & 300.2
13. QW-190
14. QW-211
15. QW-200.2(f)
16. QW-201
17. QW-212
18. QW-304
19. QW-321.1
20. QW-322.2(a)
21. QW-433
22. QW-151.1(a)
23. QW-406.1
24. QW-161.5
25. QW/QB-422
26. QW-423
27. QW-303.1
28. QW-432
29. QW-451.1
30. QW-401
31. QW-452.1
32. QW-452.3
33. QW-422
34. QW-462.1(a)

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API 510 INSPECTORS EXAMINATION

DECEMBER 2, 1998

OPEN BOOK PORTION - 51 QUESTIONS (REMEMBERED BY PREVIOUS STUDENTS)

1. There are 3 pressure gages on a 200 ft tower that is being hydrostatically tested. One gage is
installed 110 ft from the top and reads 198 psi. A second gage is on the 120 ft level and reads 185
psi. What would the pressure gage at the top of the vessel read? UG-98

1) 160 psi
2) 150 psi
3) 135 psi
4) 180 psi

2. An SA-240 Type 410S test specimen was used on a PQR. Which of the following would be the
minimum permitted tensile strength of a tensile test coupon to pass the tensile test? QW-153

1) 54,000 psi
2) 57,000 psi
3) 60,000 psi
4) 66,500 psi

3. The corrosion rate for a vessel is 0.004 in. per year based on a 5 year inspection interval. Which of
the following cannot be used to exempt the vessel from internal inspection if it remains in the same
service? API 510, 7.2.6

1) No questionable condition found on external inspections

2) Vessel installed to prevent inadvertent contamination from corrosive process streams
3) The operating temperature does not exceed the lower temperature limits for the creep-
rupture range of the vessel material
4) The vessel is strip lined

4. An eight foot diameter vessel has a large area of general corrosion (32 in. in length and width) and
has thickness readings taken in the circumferential (lettered rows) and longitudinal (numbered rows)
directions as shown below. What would be the least thickness along the most critical element
considering circumferential stress applies. API 510, 5.7

1a-0.290" 2a-0.240" 3a-0.190" 4a-0.185" 5a-0.260"

1b-0.260" 2b-0.230" 3b-0.185" 4b-0.190" 5b-0.220"
1c-0.220” 2c-0.180" 3c-0.200" 4c-0.210" 5c-0.240"
1d-0.210" 2d-0.190" 3d-0.120" 4d-0.240" 5d-0.195"
1e-0.190" 2e-0.195" 3e-0.200" 4e-0.205" 5e-0.185"

1) 0.206"

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2) 0.191"
3) 0.179"
4) 0.195"

5. A vessel that is 1.1375 in. thick is to have a butt welded patch installed of SA-515 Gr. 70 material.
The nameplate on the vessel is stamped HT under the Code symbol stamp and a MDMT of 600F.
Below what temperature would impact testing be required? UCS-66

1) 400F
2) 450F
3) 600F
4) 750F

6. To prevent brittle failure below - 500F which of the following materials would be best suited? UCS-
66

1) Austenitic stainless steels

2) Ferrous alloys
3) Fine grain materials
4) Impact tested materials

7. External pressure problem. Factor B given, UG-28

8. Which of the following is an essential variable for the SMAW process?, QW-253

1) Uphill or downhill progression

2) Groove design
3) Decrease of over 1000F in preheat
4) Change of backing

9. Question on thickness range qualified for SMAW WPS/PQR, QW-451.1

10. Question on preheat temperature for SMAW WPS/PQR, QW-406.1

11. Question on PWHT temperature for SMAW WPS/PQR, QW-407.1

12. Question on range of fillet weld that could have been specified on WPS for SMAW WPS/PQR, QW-
202.2

13. Question on backing strip for SMAW WPS/PQR, QW-253

14. Reinforcement math problem asking to determine A2. All parameters given, UG-37

15. Reinforcement math problem asking to determine A. All parameters given, UG-37

16. Elliptical head math problem asking to find corrosion allowance, UG-32(d)

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17. Elliptical head math problem to determine P, UG-32(d)

18. Thickness of torispherical head math problem, UG-32(e)

19. Permitted tolerance for calibration of an ammeter on MT unit, T-761

20. Size of weight for lifting power calibration of an MT AC yoke, T-762

21. Size of weight for lifting power calibration of an MT DC yoke, T-762

22. Size of UT transducer for examining castings, T-541.4.1

23. Determine correct source side IQI size for a given metal thickness, Table T-276

24. What is the maximum range permitted for a pressure gage used for a leak test? UG-102

25. Remaining life/corrosion rate problem, API 510, 6.3

26. Remaining life/corrosion rate problem, API 510, 6.3

27. Which of the following standards is used for air cooled heat exchangers? RP572, 1.2

1) API 510
2) Std. 661
3) Std. 660
4) RP 576

28. Hydrostatic test math problem, UG-99

29. Hydrostatic test math problem, UG-99

30. Cylindrical shell math problem to determine P, UG-27

32. Cylindrical shell math problem to determine P, UG-27

33. Question on elongated indications for full radiography, UW -51(3)(b)(2)

34. Question on education and experience for an API 510 inspector, API 510, 4.2

35. Question on length over which the least thickness may be averaged, API 510, 5.7

36. Question on definition of quality assurance, API 510, 3.13

37. Question on repair organization, API 510, 3.15

38. What is the maximum permitted geometric unsharpness for a material 2" thickness, T-285

39. What is allowable offset for a 1/4" shell joined to a 3/4" shell? UW-33

40. What is the maximum permitted out of roundness for a cylindrical shell, UG-80

41. Question on information on a nameplate, UG-116

42. Flat head math problem to determine tmin, UG-34

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43. Question on impact test specimen energy acceptability, UG-84

DECEMBER 1998 API 510 INSPECTORS EXAMINATION

CLOSED BOOK PORTION - 99 QUESTIONS (REMEMBERED BY PREVIOUS STUDENTS)

1. For a new vessel or a vessel for which service conditions are being changed, what time period is
required prior to on-steam determinations being made to determine the new corrosion rate?
API 510, 5.3

1) 2 weeks
2) 3 weeks
3) 6 weeks
4) 6 months

2. What is the best method for finding sub-surface flaws?

1) UT
2) MT
3) RT
4) ET

3. Below what temperature is no welding permitted? UW-30

4. What happens if the spring breaks in a relief device? RP576, 4.3

5. Per API 510 how long is temperature held after completion of a temper bead repair? API 510, 7.2.4

6. Which of the following must be considered when making repairs to stainless steel weld overlay and
cladding for vessels in hydrogen service? API 510, 7.2.6

1) Outgassing
2)
3)
4)

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7. How often are eye examinations required for MT or PT examiners? Appendix 6 & 8

8. Which of the following best describes the SMAW welding process? QW-492

1) Manual process w/flux coated electrode

2) Automatic process w/electrode submerged in flux
3) Manual process w/shielding gas
4)

9. In what service is a pilot operated best suited? RP576, 2.2.1.5

1) Dirty
2) High viscosity
3) Low differential between operating and set pressures
4)

10. What is the best service for a safety valve? RP576, 2.2.1.2

11. For a large vessel with two or more zones of differing corrosion rates what is the best way to treat
the vessel regarding each zone? API 510, 6.3

1) Treat as one zone

2) Treat each zone separably
3) The highest corrosion rate dictates the next inspection interval
4)

12. Determine short term corrosion rate, several past readings given. API 510, 6.3

1) .005 mils
2) .05 mils
3) .5 mils
4) 5 mils

13. When is it not necessary to remove external insulation for inspection? API 510, 6.2

1) When internal thickness readings can be taken

2)
3)
4)

14. Question on 885 embrittlement, Chapter II, 204.022

15. Question on excluded vessels, API 510, 1.2.2

16. Question on Authorized Inspection Agency, API 510, 3.4

17 Question on preparatory work prior to inspection, API 510, 5.1

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18. Question on when to inspect, API 510, 6.3

19, Remaining life/corrosion rate math problem, API 510, 6.3

20. Remaining life/corrosion rate mat h problem, API 510, 6.3

21. Remaining life/corrosion rate math problem, API 510, 6.3

22. Question on use of filler metals having lower tensile strength than base material, API 510, 7.2.11

23. Question on definition of a relief valve, RP576, 2.2.1.3

24. Question on suitable service for a rupture disk, RP576, 2.2.3

25. Question on as received pop test for relief device, RP576, 6.2.1

26. What is considered to by on schedule for inspection of relief device, RP576, 5.2.3

27. What are contents of relief device tag, RP576, 5.2.2

28. What are the methods of constructing shell rings, RP572, 2.2

29. What are the reasons for inspection, RP572, 5.1

30. What are the most common internal corrodents, RP572, 6.2

31. What are the first things to inspect on a vessel during an external inspection, RP572, 8.3.2

32. How do you check anchor bolts, RP572, 8.3.4

33. What are the most important conditions to check when inspecting metallic linings, RP572, 8.4.5

35. Question on pH, Chapter II, 202.022

36. Most corrosion in refineries caused by? Chapter II, 202.01

1) Components present in crude oil

2) Chemicals used in refining process
3) Environmental corrosion
4) All the above

37. Question on galvanic corrosion between carbon steel and magnesium, Chapter II, 202.067

38. Step wedge comparison films shall be traceable to what standard, T-262

39. How many IQIs required for a panoramic shot, T-277.2(b)

40. What examination must be performed prior to a shear wave examination, T-542.7.2.1

41. What is the minimum overlap permitted for a transducer, T-523.1

42. What is the maximum permitted rate of search unit movement, T-523.2

43. What must be done when both ownership and location of a vessel change, API 510, 6.3

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44. A weep hole in a reinforcement plate is left open so that leaks can be seen and for what other
reason? UG-UW-15

1) To prevent pressure buildup in the cavity

2) So that thickness measurements can be taken through the weep hole
3)
4)

45. When performing a Charpy V-notch toughness test you are performing a/an, QW -171.1

1) Impact test
2) Brinnell hardness test
3) Thickness test
4) Bend test

46. Which of the following qualifies a welder to weld in all positions? QW -461.9

1) 1G
2) 3G
3) 2G & 5G
4) 6F

47. What type corrosion occurs at the point of contact between a metal and nonmetal? Chapter II,
202.068

1) Galvanic
2) Conductivity
3) Crevice
4) Biological

48. The rerating of a pressure vessel is complete when: API 510, 7.3

1) API Inspector oversees the attachment of a nameplate

2) All calculations are complete and approved
3) The pressure vessel engineer oversees the attachment of a nameplate
4)

49. During an internal inspection of a pressure vessel a blister is found in one of the heads between the
knuckle and the circumferential head to shell weld. What would be the most appropriate action?
API 510, 7.1

1) Replace the head

2) Consult with a pressure vessel engineer
3) Drill the blister to relieve the pressure
4) Pressure test the vessel

50. A pressure vessel contains the following nozzles, (2-NPS 6, 1-NPS 10 and 4-NPS 3). Which of the
following would be an alteration? API 510, 3.1

1) Addition of an NPS 6 nozzle

2) Addition of an NPS 12 nozzle

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3) Addition of an NPS 3/4 nozzle
4) Addition of three NPS 1 nozzles

51. A pressure vessel is in service and has no corrosion data available. Where should thickness
readings be taken? RP572, 8.3.12

1) At least one on each shell course, head and nozzle

2) One in each quadrant of each shell course and head
3) One in each quadrant on each shell course at one foot intervals
4) At one foot spacings on each shell course

API 510 INSPECTORS EXAMINATION

JUNE 2, 1999
OPEN BOOK PORTION – 55 QUESTIONS (REMEMBERED BY PREVIOUS STUDENTS)
CLOSED BOOK PORTION – 95 QUESTIONS (REMEMBERED BY PREVIOUS STUDENTS)

The open book portion was reported to be very straight forward with no difficult math involved. Most values
including E were given.

At least 40 – 50% of total questions were based on API 510.

Closed book questions were worded in suc h a manner that two possible answers seemed correct. A
complete understanding of what was being asked was essential to choose the correct answer.

The following questions or similar to those from the Final Examination of the May 1999 Schindler &
Associates course were included in this examination;

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2, 12, 14, 15, 16, 22, 23, 26, 29, 32, 33, 35, 36, 38, 39, 42, 43, 44, 45, 46, 47, 48, 49, 52, 53, 55, 56, 58,
62, 66, 69, 72, 73, 74, 78, 84, 87, 89, 90, 92, 98, 100, 103, 105, 111, 116, 118, 123, 127, 129, 131, 132,
136, 140.

The following questions or similar to those from the Post Study Course Guide of the May 1999 Schindler &
Associates course were included in this examination.

1, 3, 5, 7, 9, 10, 12, 13, 14, 16, 18, 19, 21, 22, 23, 24, 25, 27, 28, 30, 32, 33, 34, 35, 37, 38, 41, 43, 48, 51,
52, 54, 55, 56, 57, 60, 63, 64, 67, 68, 69, 71, 72, 73, 74, 75, 76, 79, 81, 84, 85, 86, 88, 89, 92, 93, 96, 98,
100, 101, 103, 104, 107, 108, 115, 122, 126, 127, 129, 130, 134, 135, 144, 145, 148, 149.

Some specific questions remembered are as follows. There may be duplication from the numbered
questions listed above.

1. Flat head problem (1) UG-34

2. Remaining life and corrosion rate problems (many) API 510, 6.3

3. Cylindrical shell problems (2) UG-27

4. Elliptical head problem (1) UG-32(d)

5. Required area problems (2) UG-37

6. WPS/PQR (SMAW) (3)

(a) Base metal thickness range QW-451.1
(b) Tensile & bend tests QW-451.1
(c) Root spacing QW-402.10

7. Static head involving 2 pressure gages (1) UG-98

8. An E7018 designated filler metal is what kind of filler metal (covered electrode) QW-492

9. Several open book questions on RT

(a) Geometric unsharpness V, Table T-285
(b) Sizing IQIs, V, Table T-278
(c) Density step wedge film strip V, T-262
(d) Light letter B V, T-284

10. What examination method to check for surface cracks for vessels in amine service (wet mag)
RP572, 8.4.4

11. Questions on the temper bead process (4-5) API 510 7.2.4
(a) Holding time and temperature
(b) preheat
(c) P-No. 3 thickness limit

12. Questions on pitting (2-3) API 510, 5.7

(a) Which pit depths are acceptable
(b) Acceptability of pits in a line
(c) Acceptability of pits in a 6 in. circle

13. Welding positions for welders (several on closed book portion) QW-461.9

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14. For a weld repair on a vessel what are the PWHT requirements? API 510, 7.2.4

15. For new construction of a vessel what are the PWHT requirements? VIII, UCS-56

16. Amount of slag inclusion permitted in a 3/4 in. thick weld that was fully RT’d. VIII, UW-51

17. What can an API 510 inspector not do?

18. External pressure calculation for a tube? VIII, UG-28

19. Hydrostatic test pressure calculation. VIII, UG-99

20. PH scale question. Chapter II, 202.021

21. Contact crevice corrosion question. Chapter II, 202.068

22. Which of the following welding documents needs to have a signature? IX, QW-200.2 & 484

23. What is creep? Chapter II, 202.012

24. What is 885 embrittlement? Chapter II, 204.022(g)

25. Brittle versus ductile question. Chapter II, 205.01

26. API 510, 6.4 pressure test temperature question. API 510, 6.4

27. Questions on pressure relief valves (3-4) RP 576, 2.2

28. Question on a rerated vessel. Are you going to take more TML readings.

29. PWHT overlap question. VIII, UW-40

30. Question on using radiography to qualify welder for GMAW process. IX, QW-304

API 510 Inspectors Examination

June 5, 2002

Open book = ? questions

Closed book = ? questions

It appears that this examination is almost identical to the one in December 2001.

Open book portion

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SMAW welding procedure with three questions:

1.Do the tensile tests meet the requirements of Section IX - No, because one specimen failed in weld and
strength was below MSTS of base metal. IX, QW-153(d)

2.Do the bend tests meet Section IX, No because they used face & root instead of side bends. IX, QW
451.1

3. Did the base metal range on the WPS meet the requirements of Section IX, Yes, because the PQR
was 1" and the range shown was 3/16" - 2" and the ½" weld pass was addressed on both WPS and
PQR. IX, QW-451.1

4. Averaging question API 510, 5.7(d)

5. Question involving UG-20(f)(1)(b).

6. Weld surface distance from center of weld per API 510, 5.7(g).

7. Math problem involving a torispherical head with corrosion in center. Must use Spherical shell formula
in UG-27 to solve. Gave inside diameter of head to use as L =54", MAWP = 250, S = 17500, C.A. to
maintain = 0.125 API 510, 5.7(h)

8. Question on when can you substitute on stream for internal. See API 510, 6.4(b).

9. Who besides inspector has to approve using preheat in lieu of PWHT. API 510, 7.2.3

10. How long do you hold the 500 degrees +/- 50 degree temperature after completing a controlled
deposition welding method? API 510, 7.2.3.2(f)(8)

11. What NDE after completing weld repair to stainless weld overlay? API 510, 7.2.6

12. How is welding material identified in lieu of having a MTR or CofC? VIII, UG-9

13. Flat head thickness calculation with sketch UG-34(b-1) given. VIII, UG-34

14. Elliptical head thickness problem. VIII, UG-32(d)

15. Reinforcement problem to find A=dt r with d and t r given. VIII, UG-37

16. How many impact specimens to a set? VIII, UG-84

17. What Category weld with data given? VIII, UW-3

18. What type weld joint with data given? VIII, Table UW-12

19. What is alignment tolerance for 3/4" weld in a Category A joint? VIII, UW-33

20. What is overlap when heating vessel in more than one heat? VIII, UW-40(a)(2)

21. What is retention time for radiographs for fabrication and assembly of a vessel? VIII, UW -51(a)(1)

22. What is maximum length of a slag inclusion when vessel stamped RT 1 and 2.25" thick? VIII, UW
51(b)(2)

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23. What is minimum holding temperature for PWHT of a P-1 material? VIII, UCS-56

24. What is minimum holding time for a 3" weld in SA-516 Grade 70 material? VIII, UCS-56

25. What is MDMT for SA-515 Grade 70 material given a 0.5 St/S d as ratio and the stat ement that PWHT
required for a 1.125" thickness. VIII, UCS -66

26. What is the basic MDMT for SA-516 Grade 60 normalized? VIII, Table UCS-66

27. Which of the following is an essential variable for the SMAW process? Answer was preheat. IX,
QW-406.1

28. Densitometers are calibrated against what standard? national standard V, T262.1

29. What source side hole type IQI is used to radiograph a 1.5" weld? #30 V, Table T-276

30. What is maximum permitted density for a radiograph made with gamma source? V, T-282.1

31. What is rejection criteria for backscatter? Light letter B V, T-284

32. What is geometric unsharpness maximum for a weld under 2" thick? V, T-285

33. Which of the following is not required to be recorded on a radiographic evaluation sheet? Geometric
unsharpness V, T-292

34. What is frequency of calibration for magnitizing equipment? Whenever subjected to major repair of
overhaul. V, T761

35. What is calibration tolerance for a unit meter on MT equipment? +/- 10% V, T-761

36. What is lifting power for a DC yoke when calibrating? 40 lbs. V, T-762

37. Question on holidays in lining. RP572, 8.4.6

38. Frequency of vision check for a PT/MT NDE Examiner. VIII, Appendices 6 & 8

39. External shell pressure problem with Factor B, Do, t given. VIII, UG-28

40. Define temper (885) embrittlement. Chap. II, 204.022(g)

41. Question on degrees Baume. Chap. II, 202.035

42. Question on progressive records requiring regular updating. API 510, 6.7

43. Preheat and controlled-deposition welding may be used in lieu of PWHT. What condition must be
satisfied prior to using this alternative method? API 510, 7.2.3

44. Determination of an MDMT Curve. VIII, Table UCS-66

45. DC Yolk spacing when calibrating yolk. V, T-762

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Closed Book

1. Remaining life API 510, 6.4

2. Remaining life API 510, 6.4

3. Remaining life API 510, 6.4

4. Remaining life API 510, 6.4

5. Remaining life API 510, 6.4

6. Remaining life API 510, 6.4

7. Corrosion rate API 510, 6.4

8. Corrosion rate API 510, 6.4

9. Corrosion rate API 510, 6.4

10. Corrosion rate API 510, 6.4

11. Hydrotest math problem VIII, UG-99

12. Static head math problem with two pressure gages. Vertical vessel 125 ft high is under a hydro.
Pressure gage 100 ft from top reads 193.5 psi. Pressure gage 45 ft from top reads 169.5 psi. What
pressure does gage at top of vessel read? VIII, UG-98

13. What Standard is referenced for qualification of RT personnel? SNT-TC-1A VIII, UW -51(a)(2)

14. Which of the following is not part of a PT procedure? Amount of developer applied V, T-621

15. What is the immediate retest criteria if a welder was qualifying on a production weld of 6"? 12" IX,
QW-321.3(b)

16. Question on expiration of welders qualification. IX, QW -422

17. Question on expiration of welders qualification, IX, QW -422

18. What two welding positions qualify a welder to weld all positions? IX, QW-461.9

19. Question on termination of Code where external piping attached to vessel. Weld end connection
VIII, U-1(e)(1)(a)

20. Which of following can be exempted from API 510? Vessel on truck API 510, Appendix A

21. What is maximum tolerance permitted for setting of a PRV set at 400 psi? VIII, UG-126(d)

22. Who has to assist inspector when a crack is found in the knuckle of a toriconical head? PV Engineer
API 510, 7.1.3

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23. Making a repair, which of following types of material require an MTR? Plate VIII, UG-93(a)(1)

24. Hydrotest problem with ratio of 1.0 and MAWP given. VIII, UG-99

25. Maximum range for pressure gage during hydrotest. 4 times test pressure VIII, UG-102

26. What does HT on nameplate mean? VIII, UG-116(f)(1)

27. What is lowest permissible temperature for welding? VIII, UW-30

28. What is carbon maximum in material for welding? 0.35% API 510, 7.2.8 & VIII, UCS-5

29. What is the maximum depth that can be welded in a 3" plate of P-No. 3 material and have PWHT
waived? 5/8", however this was taken out of API 510 with the #2 Addendum. See 7.2.3

30. What is frequency of eye examination for an PT NDE examiner. VIII, Appendix 8-2

31. Who is responsible for maintaining WPS’s, PQR’s and WPQ’s? Repair organization API 510, 7.2.2

32. Which of the following is not an alteration? API 510, 3.1

33. Which of the following is an alteration? API 510, 3.1

34. Question on corrosion rate determination using 6 weeks time? API 510, 5.3

35. Which of the following is not considered corrosion? Cavitation Chap. II, 203.022

36. At what temperature range is CUI most active? 25 - 250 degrees F API 510, 6.3

37. At what temperature is CUI most active? -4 to 120 degrees C API 510, 6.3

38. What is next inspection interval? API 510, 6.4

39. What is maximum inspection interval for PRV’s? 10 years API 510, 6.6

40. How is inspection interval for PRV determined? Operational experience API 510, 6.6

41. You have a vessel with only one TML and localized corrosion is found in bottom shell, head and
nozzles. What would you do? Assign more TML’s to bottom head, shell and nozzles API 510, 6.4

42 You have a vessel 2.5" thick, when hydrotesting what temperature increase above MDMT to avoid
brittle fracture failure? API 510, 6.5

43. What must a company who repairs PRV’s have? QC program API 510, 6.6

44. How long are inspection records kept? Service life of vessel API 510, 6.7

45. Question on who authorizes repairs and alterations API 510, 7.1 & 7.1.1

46. Who qualifies welding procedures and welders? Repair organization API 510, 7.2.1

47. Who has to review the application and prepare procedures for the local postweld heat treatment
method? PV Engineer API 510, 7.2.5

48. When repairs are made to stainless overlay or cladding for equipment in hydrogen service which

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factor does the PV engineer consider? Outgassing base metal API 510, 7.2.6

49. A rerating is being performed on a vessel which of the following could be done with only a
calculation? API 510, 7.3

50. When is a rerating considered complete? When PV AI oversees attachment of

nameplate? API 510, 7.3

51. What is minimum time spent performing inspections to be considered actively

engaged? API 510, Appendix B

52. Mercury causes stress corrosion cracking in what metals? Chap. II, 202.036

53. Nonferrous metals contain less than what % iron? Chap. II, Appendix IB

54. Contact corrosion is also called what? Crevice corrosion Chap. II, 202.608

55. Materials having low energy values are usually prone to what type failure? Brittle
fracture Chap. II, 205.01

56. Improper heat treatment can cause which of the following? Loss of tensile
strength if kept at temperature too long RP572, 6.7.3

57. The continued use of a pressure vessel shall be based on which of the following? Latest ASME Code
or the original construction code API 510, 5.4

58. Which of the following progressive records shall be maintained? All new and previous thickness
readings API 510, 6.7

59. What cleaning methods would apply for wet sulfide cracking? See RP572, 8.4.2, hot water, steaming
and abrasive grit blasting

60. You find cracks in a metallic lining what would you do? (a) Remove some lining to inspect base metal
surface, (b) Check base metal for damage, ( c) Do nothing, (d) Repair liner. RP572, 8.4.5

61. If the vessel is insulated effectively to preclude entrance of moisture what must be done to the outer
jacketing? Observed every 5 years and repaired if necessary API 510, 6.3

62. What does an external inspection start with? Ladders, platforms and walkways? RP572, 8.3.2

63. How are ladders, platforms and walkways inspected? Visually, supplemented by hammering and
scraping. RP572, 8.3.2

64. What is major cause of failure in springs of PRV’s? Corrosion RP576, 5.3

65. What type of PRV uses a control unit? Pilot-operated RP576, 4.7

66. A vessel is in hydrogen service and is carbon steel with a titanium stabilized austenitic stainless steel
overlay. What is a probable type failure and how would you inspect for it? Cracking, UT and PT Chap.
II, 204.035 & API 510, 7.2.6

67. How long must an MT examiner be in darkened room prior to performing examinations? V, T-778.2

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68. Which of the following is a cause of a bulge in a liner. RP572, 8.4.5

69. Question on MT calibration. V, T-761

70. Question on dark letter B in a film. V, T-284

71. Definition of erosion. Chap. II, 203.01

72. Question on what type of inspection cannot be used for determining thickness. API 510, 6.4

73. Widely scattered pitting question. API 510, 5.7(e)

74. Question on AI authorization prior to start of work and exception permitted. API 510, 7.1.1

75. Question on minimum preheat temperature to avoid PWHT. API 510, 7.2.3.1

76. When pressure test will exceed set pressure of safety relief valve, what can be done as an alternative to
removing valve? API 510, 6.5

77. Question on ferriferrocyanide. RP572, A.9.2

78. At what temperature does incipient melting take place? Chap. II, 204.022(b)

79. Question on weld joint type 2. VIII, Table UW-12

80. Is a preliminary hydrotest allowed prior to PWHT? VIII, UCS -56(f) & UW-40(e)

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