2) Full encirclement sleeve used for leaking repairs, which of the following welds are NOT allowed for

making longitudinal weld joint of the sleeve?

a. Overlapping side strip welds.
b. Butt joint with backing strip.
c. Butt joint without backing strip.
d. All of above are not allowed.
Article 201
Butt-Welded Insert Plates in Pressure Components

1) In insert plate repair method, rectangular and square insert plates of 20 mm thickness shall have
corners rounded to a minimum radius equal to:
a. 3 times insert plate thickness Le 60mm.
b. 6 times insert plate thickness i.e120mm.
c. 75 mm.
d. 150 mm.

201-3.4 Rectangular and Square Insert Plates

Rectangular and square insert plates shall have corners rounded to a radius, except when the entire
shell plate is replaced. Rectangular and square insert plates 13 mm (1∕2 in.) thick and up to and
including 25 mm (1 in.) thick should have a 75 mm (3 in.) or a larger corner radius. Insert
plates less than 13 mm (1∕2 in.) thick may have smaller corner radii. Insert plates over 25 mm (1 in.)
thick should have a 150 mm (6 in.) or a larger corner radius.

2.) A corroded area on non-post weld heat-treated cylindrical shell was completely removed by making a
150mm diameter opening, which is to be repaired by using circular Butt-welded Insert Plates. What will
Be Minimum diameter of Insert Plate?
a. Lesser of 12t or 380 mm (where t is the thickness of the parent material).
b. Greater of 12t or 380 mm (where t is the thickness of the parent material).
c. 150mm diameter.
d. 300 mm diameter.
201-3.6.1 Minimum Size of Insert Plates.
The minimum diameter, or length and width dimensions of non-post weld heat-treated, butt-welded
carbon and low alloy steel insert plates shall be the lesser of 12t or 380 mm (15 in.) (Where t is the
thickness of the parent material)
3) "Butt-welded Insert Plates in Pressure Components" is considered generally appropriate repair
Method for which of the following defects:
a. General Wall Thinning.
b. Local Wall Thinning.
c. Circumferential and Longitudinal Cracks.
d. All of above
4) For „doghouse" type insert plate having its edge abutting with existing longitudinal weld, what
length of existing weld shall be cut on each side of insert plate and re welded:
a. 150 mm maximum.
b. Minimum 6 times thickness of insert plate.
c. 150 mm minimum.
d. Lower of b and c.
5) For doghouse" type insert plate having its edge abutting with existing longitudinal weld, certain
Length of existing weld shall be cut on each side of insert plate and re welded. What NDT should be
Performed on this weld?
a. Full RT.
b. Full UT.
c. MT or PT both sides of weld.
d. Any one of a, b, c.
Figure 201-3.8-2
NOTES:
(1) Existing butt weld in vessel shell or head. (Figure 201-3.8-2 shows
butt weld in a cylindrical shell.)
(2) Length of cut in shell butt weld, 150 mm (6 in.) minimum on each side of intersecting insert plate
butt weld.
(3) Insert plate butt weld.
(4) Cut existing shell butt weld to 150 mm (6 in.) minimum on each side of intersecting insert plate butt
weld and bevel edges (or arc gouge edges) to the desired edge bevels. Reweld after completion of insert
plate butt weld. Full RT or UT, or MT or PT both sides of
new weld

6) A non-post weld heat-treated vessel 25 mm thick was repaired using square insert plates of 25 mm
thickness. Butt welds around the periphery of this insert plates shall be spaced no closer to existing
welds than
a. 250mm. t=25mm t>13mm the greatest of 250mm/8tw= 250 or 8*25=200 250/200 greater is 250
b. 80 mm.
c. 6 times thickness of insert plate (150 mm).
d. 8 times thickness of insert plate (200 mm.)
201-4.3.1 Minimum Spacing Between Nonpostweld Heat-Treated Butt Welds.
Nonpostweld heat-treated butt welds around the periphery of insert plates shall be spaced no closer to
existing nonpostweld heattreatedbutt welds or reinforcing plate attachment welds than
(a) for tw ≤ 13 mm (1∕2 in.), 150 mm (6 in.)
(b) for tw > 13 mm (1∕2 in.), the greater of 250 mm (10
in.) and 8tw
where
tw = thickness of the thicker of the two adjacent butt welds, mm (in.)
201-4.3.3 Spacing Betwen Stress-Relieved Butt Welds.
The spacing between the adjacent butt welds shall be not less than 2tw if the first butt weld has been
stress-relieved before making the second butt weld.
201-6.3 Leak Test
A separate leak test (visual, bubble-forming solutions, sniffer, etc.) may be desirable to check for leaks
before pressurizing the component to the maximum test pressure. Such a leak test should be performed
at a safe pressure that is substantially less than the maximum test pressure by pressurizing the
component to a desired pressure and reducing the pressure to the leak test pressure before performing
the leak test.
Article 202
1) Which of the following testing methods are not used to check the integrity of the system?
a. Hydrostatic testing.
b. Pneumatic testing.
c. Tightness testing.
d. All are used to check the integrity

2) A cylindrical shell 30mm thick was repaired by depositing 20mm " External Weld build up to Repair
Internal Thinning". The corners of the weld overlay shall be rounded to radius:
a. Maximum 20mm.
b. Minimum 20mm.
c. Minimum 30mm.
d. Maximum 30mm

3) A cylindrical shell 32mm thick is to be repaired by depositing "External Weld build up to

Repair Internal Thinning". According to ASME PCC-2 guidelines, what is the maximum
thickness which can be deposited for such repair?
a. 75% of wall thickness 24mm..
b. 150% of wall thickness, 48mm.
c. 50% of wall thickness, 16mm.
d. 100% of wall thickness, 32mm.
4) The outer diameter of cylindrical shell is 640 mm and nominal wall thickness of the shell is 20mm is
to be repaired by "External Weld Overlay to Repair Internal Thinning". Unless otherwise justified by a
fitness for service assessment, External Weld Overlay shall extend on base Metal beyond the affected
base metal for a minimum distance, B, equal to:
a. 40mm (twice nominal wall thickness).
b. 60mm. B=3/4√Rt= ¾*√320*20= 60mm
c. 80mm.
d. None of above.

5) Calculate the Burst pressure to qualify a repair design on pressure components for a actual reported
tensile strength of base metal 70000psi whose outside diameter of the pressure component is 60” for a
thickness of 1.75 .manufacturing allowance=0.3” burst pressure shall not be less than

a.3000psi

b.3383psi t=1.75-0.3= 1.45” P=2 t Sact/D =2*1.45”*70000/50=3383.33 psi

c.3500psi

d.4000psi

6) In context of ASME PCC-2, the term -refers specifically to the application of carbon steel or low
Alloy weld metal, applied for the purpose of restoring base metal thickness.
1 Mark(s) ✩
a. Weld Overlay.
b. Weld build up.
c. Clad Restoration.
d. Back Cladding.

207-4 FABRICATION

Q12) Paint, scale, rust, liquids, and other foreign material shall be removed from the weld zone and an
area not less than 40 mm (11∕2 in.) on either side of the weldment
Article 210
In-Service Welding Onto Carbon Steel Pressure Components or Pipelines
There are two primary concerns when performing inservice welding. The first concern is “burn-
through,” also
referred to as “blowout.”A burn-through occurs when the unmelted base material under the weld pool
loses the ability to contain the contents of the pressure components or pipeline allowing the contents to
be expelled.Such precautions include controlling the heat input or penetration of the welding process
and using smaller diameter electrodes [e.g., 2.4 mm (0.094 in.)] when the wall thickness is less than
6.4 mm (0.250 in.).
The second concern is hydrogen cracking. Hydrogen cracking occurs when tensile stresses are acting
on the weld, hydrogen is present in the weld and, when the weld solidifies, the resultant weld
microstructure is crack susceptible
1) When hydrogen cracking is a concern in service welding should be examined after:
a. 24 hours after welding.
b. 24 to 72 hours after welding.
c. 24 to 48 hours after welding.
d. 12 to 24 hours after welding.

2) How many side bends are required for in service welding procedure qualification of fillet welds of
12mm thick?
a. 4
b. 2.
c. 0.
d. 1.

210-4.1.1.2 Cooling Potential.

The rate at which a weld cools, or cooling potential, is an essential variable [e.g., cooling time from
800°C to 500°C (1,472°F to 932°F) (sec) or cooling rate at 556°C (1,000°F) (°/sec)]. An increase in the
cooling potential of the inservice pressure component or pipeline greater than the cooling potential
used during the qualification of the welding procedure requires requalification. The cooling potential
may be determined by direct measurement, calculation, computer models, or a combination of
these methods.
NOTE: In the procedure qualification, wall thickness is not an essential variable but is directly related
to the cooling potential of the pressure components or pipeline, which is an essential variable.
 Article 211
Weld Buildup, Weld Overlay, and Clad Restoration

1) In context of ASME PCC-2, the total depth of overlay or back cladding shall be - thickness, unless
Otherwise specified.
1 Mark(s) ✩
a. 3 mm (in) or lower.
b. 3 mm (1 in.) or greater.
c. 1.5 mm (1 in.) or greater.
d. 1.5 mm (1/16 in.) or lower

211-4.4 Back Cladding

211-4.4.1 Weld Groove Preparation.
(Typical weld joint details for back cladding are shown in Figure
211-4.4.1-1.)
Prior to back cladding butt joints, the weld groove in thebacking material shall be filled approximately
flush with, but not more than 1.5 mm (1∕16 in.) below the weld overlay fusion line or the clad bond line
adjacent to the weld groove prior to back cladding
2), According to ASME PCC-2 guidelines, for "repair by weld" on base metal, if weld thickness is -then
it should be examined by volumetric examination methods
such as radiographic or ultrasonic testing.
a. Over 19 mm (2/4 in.) thick.
b. Over 25 mm (1 in.) thick.
c. Over 9.5 mm (2/8 in.) thick.
d. Over 12.7 mm (1/2 in.) thick.

211-5.1.2 Nondestructive Examination After Welding.

Consideration should be given to the need for nondestructive examination of surfaces repaired by
welding. Surface examination methods such as magnetic particle, liquid penetrant, ultrasonic, or surface
eddy current may be utilized in accordance with the applicable construction code or post-construction
code. Welds on base metal over 9.5 mm (3∕8 in.) thick should be examined by volumetric examination
methods such as radiographic or ultrasonic testing. The acceptance criteria shall be in accordance with
the applicable construction code or post-construction code
 Article 212
Fillet Welded Patches

(e) This repair method is generally suitable for service temperatures above the nil-ductility
temperature of the materials of construction up to a maximum design temperature of 345°C (650°F).

1) In Fillet Welded Patches repair method, in addition to completely encompassing the damaged area
the size (length and width) of the patch plate shall also be large enough to encompass any additional
area anticipated to experience similar damage during the life of the repair and the patch plate should
overlap sound base metal by distance atleast
a. 25 mm (1 in.).
b. 50 mm (2 in.).
c. Equal to nominal wall thickness of component.
d. Twice the nominal wall thickness of component.

212-3.1 General

(d) The size (length and width) of the patch plate is governed by the requirement that all attachment
welds be located on sound base metal completely encompassing the damaged area(s) (see Figure 212-1-
1). The repair plate shall also be large enough to encompass any additional area(s) anticipated to
experience similar or related damage during the life of the repair. The patch plate should overlap sound
base metal by at least 25 mm (1 in.).

212-4 FABRICATION

(e) Field repair activities should conform to the following sequence:

 Article 216
Welded Hot Taps in Pressure Equipment or Pipelines

216-3.6 Hot Tap Location

(a) Hot taps may be performed in any position, or at any angle around the pressure equipment, as long
as there issufficient room to perform the tap and install the fitting, valve, and drilling machine.
(b) Hot taps should not be located on welded joints. Where installation on an existing weld seam cannot
be avoided, examination in accordance with para. 216- 5.1.3 shall be completed before the hot tap
installation.
(c) Hot taps should be located
(1) away from the weld seam (weld toe to weld toe) by the lesser of the following lengths:
(-a) 150 mm (6 in.)
(-b) 8 times the wall thickness, t, of the header or pressure equipment
(2) at least 5 Rt from flanges, small bore connections, and riveted joints, where R is the inside radius
of the pressure equipment at the location of the hot tap, and t is the measured wall thickness

1. The diameter of small bore pipe is 250 mm and the thickness is 30mm what shall be the minimum hot
tap distance away from the flange connection.
A.300 mm
B.400 mm
C.433 mm
D.500 mm

2 .
a.5.0mm
b.4.8mm
c.5.5mm
d.6mm

216-3.11 Wall Thickness to Prevent Burn-Through

During Welding
(a) Consideration shall be given to heat input, wall thickness, depth of weld penetration, and operating
conditions when determining burn-through risk. The probability of burn-through increases when
welding components are less than 6.4-mm (1∕4-in.) thick. To minimize the risk of burn-thorough for
such welding components, the first pass should be made with 2.4 mm (3∕32 in.) or smaller diameter
electrodes.
(b) The minimum pressure equipment wall thickness for hot taps should be (1) 4.8 mm (3∕16 in.) for
set-on-type fittings used for hot tap connections
3.9 Hot Tap Valve
(a) The hot tap valve should be full port API 600, or equivalent valve with a pressure rating not less than
that of the run pipe and the branch pipe
(d) The inside diameter of the hot tap valve shall provide sufficient clearance for the outside diameter
of the cutter. There should be at least 3 mm (1∕8 in.) clearance

Article 304
Flaw Excavation and Weld Repair

Drag & drop

304-6.2 Test Method

If a leak test is performed, it may be hydrostatic, pneumatic, sensitive leak, or in-service as required
by the applicable construction code or post-construction code.

304-I-7 BOAT SAMPLE CUTTING

1) The excavated "boat samples" have which of following advantages?

a. The cavity left by the removal of the sample is very conducive to repair welding.
b. The tapered nature of the cavity allow complete access for most welding processes.
c. Sloping
Curvature of the cavity allow complete access for most welding processes.
d. All of above.

g) Once the boat sample has been removed, the cutter can be detached from its mounted position and
the anchor bolts can be removed from the plate surface. The cavity left by the removal of the
excavated boat sample is very conducive to repair welding.

The tapered nature of the cavity ends and the sloping curvature of the cavity walls allow complete
and easy access for most welding processes
 Article 305
Flange Repair and Conversion

305-3.3.2 Finish
(a) Tongue and groove and small male and female flanges: not to exceed 3.2 μm (125 μin.) roughness.
(b) Ring joint: not to exceed 1.6 μm (63 μin.) roughness.
(c) Other: Either a serrated concentric or serrated spiral finish having a resulting surface finish from 3.2
μm to 6.4 μm (125 μin. to 250 μin.)

305-5.2 Nondestructive Examination

In cases where weld metal buildup is used in the repair, the area to be repaired shall be examined prior
to performing the weld buildup using an appropriate NDE method to determine the integrity of the
base metal. Consideration shall be given to examining each weld pass for surface defects by either
magnetic particle examination (MT) or liquid penetrant examination (PT),

Article 312
Inspection and Repair of Shell and Tube Heat Exchangers

1) Unless an engineering evaluation is performed for shell and tube Heat exchangers, tube plugging
with Friction fit tapered plugs can be done only if:
a. shell-side operating pressure is 1.5 MPa (200 psi)or less.
b. shell-side operating temperature 205°C (400°F)or less.
c. tube-to-tube sheet joints are expanded and not welded.
d. All above conditions must be met
312-4.2 Tubeside Repair by Plugging
(b) Friction fit tapered plugs (Figure 312-4.2-1) shall only be used in services that meet all of the
followingconditions, unless an engineering evaluation is performed indicating the acceptability of these
plugs in other
services:
(1) shell-side operating pressure 1.5 MPa (200 psi) or less
(2) shell-side operating temperature 205°C (400°F) or less
(3) tube-to-tubesheet joints are expanded and not welded

312-5.1 Examination of Tubes and Tube Bundle

(a) Eddy Current Examination (ET) is generally selected for inspection of nonferromagnetic tubes
312-3.2 General
(2) For heat exchangers deemed critical to the operation and/or process safey of the facility, the
following should also be considered:
(-a) total replacement of the tube bundle when tubes inspected indicate a wall loss of 40% or more of
the initial, nominal thickness

Article 501
Pressure and Tightness Testing of Piping and Equipment

501-3.2 Reasons for Pressure and Tightness ð18Þ

Testing
(a) The primary purpose of performing a pressure test is to verify the integrity of a pressure system. This
is especially true when welded repairs or alterations have been performed on the pressure boundary.
Pressure and tightness testing are not substitutes for proof testing a design.
(b) Pressure or tightness tests can be used to check for pressure system leakage, especially in flanged
joints. Tightness tests may be performed in conjunction with the pressure test
2) When a pressure testing may not be required?
a. After alteration.
b. After major repair.
c. After re rating using a higher allowable stress.
d. After relating using a lower allowable stress.

501-3.4 Pressure Test — General

(a) A pressure test of equipment or a piping system should be considered if an alteration or repair has
been performed, the equipment has been rerated, or it needs to be recertified to determine integrity.
(b) A pressure test may not be required for rerating equipment using a higher allowable stress since
the original pressure test could be higher than the test pressure required for rerating.
3.)Use of a test device for localized pressure testing may be considered when any of the following
conditions exist except:
a. Other welds in the system under consideration have already been tested or are exempt from testing.
b. Brittle fracture is not a consideration.
c. There is a need to minimize the amount of test fluid and/or avoid contamination of process items in
the system, such as catalyst, linings, refractory, or other process equipment.
d. A repair versus an alteration has been performed.

501-3.4.3 Localized Pressure Testing Considerations

(a) Use of a test device for localized pressure testing may be considered when any of the following
conditions exist:
(1) Other welds in the system under consideration have already been tested or are exempt from testing.
(2) Brittle fracture may be a consideration.
(3) There is a need to minimize the number of flanged joints to disassemble for the purpose of installing
isolation blind flanges.
(4) There is a need to minimize the amount of test fluid and/or avoid contamination of process items in
the system, such as catalyst, linings, refractory, or other process equipment.
4) The preferred testing medium for pneumatic testing is:
a. Nitrogen.
b. Compressed air.
c. inert gas.
d. Any of the above.

501-6.2 Pneumatic Pressure Test of Pressure

Vessels or Piping
(a) When a hydrostatic pressure test cannot be performed per para. 501-6.1 (see para. 501-3.4.1), a
pneumatic pressure test may be performed.
(b) Nitrogen should be the test medium since it cannot support combustion. Alternatively, clean, dry,
oil-free air meeting the requirements
5) Which of the following are reasons for pressure testing?
a. Checks for leakage of mechanical and welded joints.
b. May avoid an in-service failure and associated safety issues
c. Screens out gross design, material, fabrication deficiencies and provides mechanical stress relief.
d. All of the above.

6) According to ASME PCC-2 guidelines for conducting a pneumatic tightness test, the test pressure
should be no less than:
a. The higher of 105 kPa (15 psi) or 25% of the system design pressure.
b. 105 kPa (15 psi).
c. 25% of the system design pressure.
d. The lesser of 105 kPa (15 psi) or 25% of the system design pressure.
501-6.3.1 Pneumatic Tightness Test Procedures. The items specified in (a) through (f) should be
considered when developing pneumatic tightness test procedures for vessels or piping systems
(b) To minimize the stored energy of a system, the maximum test pressure should be not more than 35%
of the design pressure of the vessel or piping system. The test pressure should be no less than the
lesser of 105 kPa (15 psi) or 25% of the system design pressure
7) Pneumatic tightness test is to be performed on a piping system with Design pressure of 200 psi.
According to ASME PCC-2 guidelines, the maximum test pressure should be not more than
a. 70 psi. 35% of 200 psi =70psi
b. 100 psi.
c. 200 psi.
d. 220 psl

501-6.3.1 Pneumatic Tightness Test Procedures.

The items specified in (a) through (f) should be considered when developing pneumatic tightness test
procedures
for vessels or piping systems

(b) To minimize the stored energy of a system, the maximum test pressure should be not more than
35% of the design pressure of the vessel or piping system
8.Pressure testing alternative is which of the following

a. Tightness test

b. vaccum test

c. UT

D.MT

501-3.4 Pressure Test — General

(a) A pressure test of equipment or a piping system should be considered if an alteration or repair has
been performed, the equipment has been rerated, or it needs to be recertified to determine integrity.
(b) A pressure test may not be required for rerating equipment using a higher allowable stress since the
original pressure test could be higher than the test pressure required for rerating.
(c) Pressure testing [or alternatively, tightness testing

9.NDE in lie of pressure testing is performed to to detect which of the following

a.Leak test

b. vaccum test

c.Crack

d.Sensitivty test
501-6.1 Hydrostatic Pressure Test of Pressure
Vessels or Piping Systems
h) An evaluation for the need of overpressure relief devices shall be performed. The set pressure of a
pressure relief device should be no more than the lesser of:
(1) the test pressure plus 345 kPa (50 psi), or
(2) 110% of the test pressure

501-6 TESTING
501-6.1 Hydrostatic Pressure Test of Pressure
Vessels or Piping Systems (h point)

Q11. Pressure testing should be completed prior to painting weld joints, unless the weld joints were
previously tested.When deciding whether or not welds may be painted prior to
pressure testing, the following should be given consideration
multiple answer

ans
(1) the paint system(s) being used and its ability to mask a potential leak
(2) the probability that the process fluid(s) will act as a solvent on the paint system if a pinhole is
present, thus increasing the potential for a leak to occur

Article 502
Nondestructive Examination in Lieu of Pressure Testing for
Repairs and Alterations

1. NDE in lie of pressure testing is performed by which of the volumetric NDE

(a) Radiography
(b) Ultrasonic shear wave
(c) Automated ultrasonic, such as time-of-flight diffraction
(TOFD) and phased array ultrasonic

d. All of the above

Alternative NDE Methods: Volumetric
(a) Radiography
(b) Ultrasonic shear wave
(c) Automated ultrasonics, such as time-of-flightdiffraction
(TOFD) and phased array ultrasonics

2) Which of the following are reasons for pressure testing?

a. Checks for leakage of mechanical and welded joints.
b. May avoid an in-service failure and associated safety issues
c. Screens out gross design, material, fabrication deficiencies and provides mechanical stress relief.
d. All of the above

502-1.5 Pressure Test

502-1.5.1 Reasons for Pressure Testing in New Construction
(a) Checks for leakage of mechanical and welded joints
(b) May avoid an in-service failure and associated safety issues
(c) Screens out gross design, material, fabrication deficiencies
(d) Reduces the stress-multiplying capability of sharp notches, metallurgical defects, discontinuities
(flaw tip blunting)
(e) Provides mechanical stress relief