API 510 PRE-COURSE STUDY GUIDE COPYRIGHT 2015 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT. Table of Contents

Transcription

1

2 Table of Contents Topic Page Course Location Effectivity Sheet Pre-Course Prep Checklist General Information API Documents API 510 Quiz API RP 571 Quiz API RP 572 Quiz API RP 576 Quiz API RP 577 Quiz ASME Code Section V ASME Code Section VIII, Division ASME Code Section IX...29 Answer Keys. 32 PLEASE NOTE: This information is based on the Edition, Addenda, and Supplement(s) of the API, ASME AND AWS Codes and Standards as required for the specific API examination that this text has been prepared for. CodeWest makes no claims as to the accuracy of this information. Use for any other purpose than intended is forbidden and holders of this document are subject to all of the Terms and Conditions of attendance at CodeWest courses as stated on the CodeWest Registration Form. This includes criminal prosecution, civil prosecution, possible prison sentences, and other possible legal actions that may be brought by CodeWest, the State of Texas, The United States of America, or other countries and jurisdictions. Registered trademark no Copyright 2015 All rights reserved. No part of this book covered by the copyright hereon may be reproduced or used in any form or by any means-graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems without the written permission of CodeWest. Violators will be prosecuted to the full extent possible under U. S. Federal copyright laws. Copyright violations are investigated by the FBI, prosecuted by the United States Attorney, and punishable by fines and incarceration in Federal Prison. Contact CodeWest for further information or permission to copy this document. DO NOT COPY WITHOUT WRITTEN PERMISSION FROM CODEWEST I PR0715LL 1

3 CodeWest Course and Hotel Location: The API 510 course will be presented in the Hilton hotel at: Hilton Westchase 9999 Westheimer Houston, Texas For reservations call hotel direct: PH: Internet site: MAKE RESERVATIONS AT LEAST 30 DAYS IN ADVANCE DON T FORGET TO ASK FOR THE CODEWEST DISCOUNT AT THE HILTON COURSE SCHEDULE: 10 Day Class: August 25 September 3, Day Class: August 27 September 3, 2015 Class will be held from 8 am. to 5 p.m. every day including Saturday and Sunday. The API exam window is scheduled for September Introduction The API 510 Examination format is based on a total of 150 multiple choice questions. The closed book portion of the examination consists of about questions. Maximum three hour duration is allowed on the closed book portion of the examination. Because no documents are permitted during the closed book portion of the examination the information contained in these documents must be committed to memory. It is important to read and understand the documents thoroughly. The open book portion of the examination consists of about 40 to 60 questions. All of the documents (both API and ASME) can be used to answer the open book questions. This portion of the examination covers most of the math questions and all of the specific questions on the WPS/PQR documents. This portion of the examination is for a maximum duration of four hours. The written questions that have been used in this study guide have been taken directly from the text of the API publications and the ASME Code Sections. To obtain the most benefit from this study guide as a preparation to attending the CodeWest course it is recommended that all assignments in this study guide be accomplished prior to the course: Read the portions of the codes and standards referenced then complete the questions using the code books without reference to the answer key. Check your answers using the paragraphs listed in the answer key. Restudy those areas where weaknesses exist. Below are the editions and addenda of the codes used when the exam was made up and checked by the exam construction committee and the ones specified by API for use during the exam. If you call us up to ask about using other editions or addenda we will tell you that it is best to have these editions and addenda. If you do not have these you will lower your chances of passing the exam. To purchase the required publications (API 510 Exam Pack) contact: Techstreet at PH: or Order your Codes & Standards NOW if you do not have them. Check your Codes & Standards NOW to be certain you have the correct Editions and Addenda. DO NOT WAIT DO IT NOW! I PR0715LL 2

4 **Reproduced with permission from API** I PR0715LL 3

5 Precourse Preparation: Students come from many backgrounds. We have inspectors who have picked up their knowledge and experience over the years in the same class with recently graduated engineers who are just entering the inspection field. All have strengths and weaknesses. Nondestructive examination is normally a strength for inspectors and a weakness for engineers. Engineers are usually more familiar with the calculations than inspectors. ASME Section IX welding requirements can be a weakness for both. In order to smooth over some of the rough spots we are recommending the following activities as "homework" before you come to class. API 510 Body of Knowledge: It is your responsibility to get a copy of the "API 510 Body of Knowledge". Why your responsibility? Because API has no schedule for publishing changes or updates to the Bodies of Knowledge and because of this we can not be certain of providing you with an up-to-date version in this guide. The "Body of Knowledge" is free and you may obtain one by calling API at or downloading one at The "Body of Knowledge" for each certification specifically identifies the areas in the codes and standards referenced that you should be familiar with. In some cases specific paragraphs are identified in or at the end of "knowledge statements" in the documents. Read all the areas of the codes noted in the Body of Knowledge at least once. The Bodies of Knowledge usually have a section on what NOT to study. Read this too so you do not waste time studying information that you will not be tested on. The questions for the exam are written by volunteers like you and, like all volunteer projects, are probably done the night before they are due. Read the documents as though you are looking for some nice facts to make multiple choice questions out of and highlight them. Memorize that information. Use the information in different contexts so you develop a complete understanding. ASME Section IX - Welding: If Section IX is a weak area you need to be familiar with the basic welding processes that may be covered on the exam. They are (in ASME terminology): SMAW: Shielded Metal Arc Welding (commonly called "stick welding") SAW: Submerged Arc Welding (commonly called "sub arc") GTAW: Gas Tungsten Arc Welding (commonly called TIG ) GMAW: Gas Metal Arc Welding (commonly called MIG ) To become familiar with the processes you should actually witness welding and have the process explained by an experienced welding engineer, inspector or welding technician. You will be expected to review Procedure Qualification Records (PQR's) and Welding Procedure Specifications (WPS's). Section IX requires tensile and bend tests to be performed to qualify WPS's. These results are documented on the PQR. Go to a welding testing lab and get a good look at the coupons cut from test weldments and the testing process. You should also witness the welding and of a weldment using these processes. Get copies of a simple SMAW PQR & WPS and take a look at the information contained in them. Compare that to the essential and nonessential variables required to be addressed by Section IX. We do have one caution: Don't pay much attention to what you are told about ASME Section IX requirements as we have found that they are universally misunderstood and proper compliance is rare. ASME Section V - NDE - Nondestructive Examination: If NDE is a weak area you will need to witness these basic methods: RT - Radiography - ASME Section V, Article 2 UT - Ultrasonics - ASME Section V, SE-797 from Article 23 (Thickness measurement only) PT - Penetrant Examination - ASME Section V, Article 6 (All methods) MT - Magnetic Particle Examination - ASME Section V, Article 7 (Yoke & Prod Methods only) Go out in the field and witness these methods being applied and witness the interpretation of the final results of the examinations. Read the required contents for the NDE procedures in ASME Section V and compare a procedure to the required information. Witness the actual application of the procedures to see if they are being carried out correctly. Witness the interpretation of radiographs and be familiar with the required markings, location markers, Image Quality Indicators (IQI's or what we did call penetrameters or "pennies"), and image quality factors such as density and IQI image. I PR0715LL 4

6 API CHECKLIST: Make travel arrangements: Airline reservations Hotel reservation (Hilton Westchase reservations should be made 30 days in advance.) Rental car Buy or check nonprogrammable calculator and extra batteries if needed Get study supplies highlighters, page tabs, scratch paper, pencils, etc. Double check codes and standards to be certain you have the correct editions and addenda Important contact information: Supplier for API & ASME Publications: Techstreet PH: or Hotel and Houston Course location / Westchase Hilton: Call for reservations or go to: Call the hotel and ask for our discounted room rates. Hilton Westchase reservations should be made 30 days in advance. CodeWest: PH: Fax: WEBSITE: API ICP: PH: Fax: WEBSITE: GENERAL INFORMATION: Classroom assignments: We will post signs in the meeting room area at the east end of the hotel with a map to the classrooms and which room each class will be presented in. Please be sure to go to your assigned classroom. Class starts at 8AM the first day of class. Dress code: Casual what you d wear to any casual business meeting is OK. You might want to bring a light jacket as we can never make everyone happy at the same time as far as room temperature goes. Electronic Devices in classroom: Cell phones must be turned off during class. Laptops, notebooks, etc, are discouraged. If you insist, please note that we do not provide extra space or electrical cords and we will not take class time to cover basic computer skills such as navigating a PDF file. Meals and Breaks: CodeWest provides beverages throughout the daytime sessions. We also provide a morning break around 9AM that varies but typically includes baked goods sometimes fruit, breakfast tacos or Kolaches (bread with sausage and cheese or a similar filling baked inside). You are on your own for all meals other than the morning break. Several restaurants and a large Kroger grocery store with a Deli are a very short distance from the classroom location. The hotel has a restaurant and bar and often offers specials for CodeWest students. Local transportation: CodeWest does not provide any type of transportation. The Hilton is on the shuttle route from both Hobby and George Bush airports. You can get by without a car during class. The courses are presented in the Westchase Hilton Hotel: There are several restaurants just across the street as well as a large grocery store with a pharmacy and some school supplies such as highlighters and page tabs. CodeWest Security Policy: During recent courses some individuals were caught going through the classrooms in the evening and picking up some of the class notes and code books that belonged to our students. Others were confronted trying to enter the classrooms under false pretenses during breaks during the day. In order to help us protect against this activity we are asking that you wear your CodeWest name badge whenever you are in the classroom area. The name badges will be in the classrooms as you enter the first day of class. The staff and security personnel will have a complete list of students and which classroom they are scheduled to be in. You may be asked to produce identification if you do not have your name badge on. Please cooperate. We regret any inconvenience this may cause but we believe this is a small price to pay to protect your property and the investment you are making by attending the CodeWest course. I PR0715LL 5

7 API DOCUMENTS During the CodeWest course the five API documents will be reviewed. The following quizzes cover these documents. You must be able to answer all the quiz questions without reference to any of the documents to be considered to have an adequate knowledge of their content. API 510 QUIZ 1. How would one calculate long term corrosion rate? 2. Name three types of pressure vessels and containers that are excluded from the requirements of API How is the MAWP determined for the continued use of a pressure vessel? 4. What is the minimum content of an Inspection Plan? 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 the four types of information that the owner/user records must maintain for each pressure vessel? 13. Which of the following are considered to be repair organizations? a. holder of an ASME "S" Certificate. b. owner or user who repairs his own equipment. c. a contractor whose qualifications are acceptable to the owner-user. d. 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? 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 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? I PR0715LL 6

8 21. When may in service inspection be substituted for internal inspection. 22. How far apart should the toes of fillet welds be placed for two fillet welded patches? 23. Define uniform corrosion? 24. Name and describe the five methods by which the minimum actual thickness and maximum corrosion rate may be 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 five features that must be covered in the owner-user quality assurance manual for assessing 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? 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. What repairs and alterations to pressure vessels are covered by API 510? 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? If so are these repairs permanent? 39. What are the minimum hydrostatic test temperatures recommended by API 510? Pneumatic? 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 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? I PR0715LL 7

9 44. In addition to the fifteen 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. 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 for vessels not subject to impact testing? 49. When is a pressure test considered mandatory? Can this requirement be waived? 50. What must be done for a pressure vessel that has no nameplate and minimum or no design documentation in order to place this vessel in the Owner s 510 program? 51. When local PWHT is substituted for full what four conditions must be adhered to? 52. Define a repair organization per API 510? 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 of 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 may be used to calculate the minimum required thickness? 58. When the filler metal for a repair has a strength lower than that of the base metal, what is the minimum number of weld passes required? 59. Who must review and approve the repair procedures used on stainless steel weld overlay and cladding? 60. For the controlled deposition welding method using SMAW, the weld area shall be maintained at what temperature and for what time after completion of the repair? Why? 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 major repair or alteration what is required as a substitute, explain? 63. What minimum preheat temperature may be considered an alternative to PWHT for repairs or alterations to P-1 materials of a vessel not required to meet notch toughness requirements? 64. What is the minimum number of thickness measurements that should be taken on each vessel to satisfy the internal or on-stream requirements? 65. When may widely scattered pitting be ignored? I PR0715LL 8

10 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. In what instance do the requirements of API 510 not apply? 69. Materials for repairs or alterations shall conform to what requirements? 70. What are the important steps in a RBI assessment? 71. What are examples of degradation mechanisms? 72. What are other factors that should be considered in a RBI assessment? 73. Can the 10 year inspection limit be increased or decreased as a result of the RBI assessment? 74. What are the responsibilities of the inspector and pressure vessel engineer regarding RBI? 75. What are the requirements for preheat or controlled deposition welding methods as alternatives to PWHT? 76. What mandatory NDE must be performed prior to and after weld repairs? 77. Can a vessel constructed in accordance with the ASME Code Section VIII prior to 1968 be rerated using the latest Edition/Addenda of the Code? I PR0715LL 9

11 API RP 571 QUIZ 1. What are typical affected units for when temper embrittlement is an issue? 2. What inspections and monitoring is done for temper embrittlement? 3. Brittle fracture primarily affects what units and equipment? 4. What are some methods applied for prevention of brittle fracture? 5. What is the definition of thermal fatigue? 6. What is the appearance or morphology for thermal fatigue? 7. What is the description of erosion/erosion-corrosion? 8. What are some units susceptible erosion/erosion-corrosion? 9. What are the critical factors of Mechanical Fatigue? 10. What is the signature mark of a mechanical fatigue failure? 11. Where is atmospheric corrosion most severe? 12. What are prevention methods for atmospheric corrosion? 13. What are some critical factors causing corrosion under insulation (CUI)? 14. What are the inspection/monitoring methods to detect CUI? 15. What are the critical factors of cooling water corrosion? 16. How can damage from cooling water corrosion be prevented? 17. What are affected materials for boiler water condensate corrosion? 18. What is the appearance of damage for boiler water condensate corrosion? 19. How can sulfidation be detected? 20. Above what temperature does sulfidation begin? 21. What is the appearance for chloride stress corrosion cracking? 22. How is chloride stress corrosion cracking inspected? 23. What are the critical factors for corrosion fatigue? 24. What is the appearance of corrosion fatigue? 25. What are the affected units for caustic stress corrosion cracking? 26. How can caustic stress corrosion cracking be prevented? 27. What are the descriptions of the four types of damage caused by wet H2S? 28. How can wet H 2 S damage be prevented? I PR0715LL 10

12 29. Hydrochloric acid (aqueous HCl) causes both and : 30. Damage in refineries from hydrochloric acid is most often associated with dew point corrosion in which vapors containing water and hydrogen chloride condense from the: 31. Hydrochloric acid corrosion affects what refinery materials? 32. Steel will corrode due to acidic sour water containing H2S between what ph values. 33. What material is the least resistant to sour water corrosion? 34. At a given pressure, the H2S concentration in the sour water as temperature increases. 35. is a common term applied to the cracking of steels under the combined action of tensil stress and corrosion in aqueous alkanolamine systems used to remove/absorb H 2 S and/or CO2 and their mixtures from various gas and liquid hydrocarbon streams. 36. Amine cracking is a form of stress corrosion cracking. 37. What type materials are affected by amine stress corrosion cracking? I PR0715LL 11

13 RP 572 QUIZ 1. What is the most common material used in the construction of pressure vessels? 2. Inspection of vessel parts while the unit is in service is called? 3. When should new vessels be inspected? 4. How would you check heavily corroded sections of metallic linings? 5. Name three types of heat exchangers? Shell & tube, air-cooled and. 6. What are two methods of providing corrosion resistant surfaces in pressure vessels? 7. List the safety precautions that must be taken prior to entering a pressure vessel? 8. What are the basic reasons for inspection a pressure vessel? 9. can be used as an alternative method to establish inspection intervals. 10. How are metallic linings installed? 11. What is the purpose of a guy wire(s)? 12. The frequency with which a pressure vessel should be inspected depends on what factors? 13. The condition of most parts can be determined by. 14. Name three opportunities when inspections are possible? 15. What should the Inspector do before starting the inspection of a pressure vessel, particularly one in severe service? 16. Is it necessary to remove all surface deposits for an inspection? Give reasons. 17. Is it necessary to remove internals completely during an inspection? Why? 18. Most pressure vessels are built in accordance with ASME Code Section VIII, Division. 19. What are two common materials used for tubes in heat exchangers? 20. What are the basic reasons for inspection? 21. List six of the tools used in the inspection of a pressure vessel? 22. When inspecting a pressure vessel externally what should the inspection start with? 23. Briefly describe the items to be checked when externally inspecting the following equipment: a. foundations and supports b. nozzles c. steel supports 24. Upon what will the number of thickness readings taken depend? 25. Name the principal strip-lining methods used in refinery vessels? 26. is one of the best methods of protecting steel structures from corrosion? I PR0715LL 12

14 27. What two methods of inspection are used when all the tubes in a bundle are checked for defects? 28. What would be inspected by hammer testing? 29. Briefly describe how you would make a detailed internal inspection of a pressure vessel? 30. What are the three most important factors to consider when checking metallic linings? 31. What types of nonmetallic linings are commonly used? 32. What should be accomplished during the preliminary visual inspection? 33. Name three methods of measuring metal thickness? 34. When should hammer testing be used and when is it not recommended? 35. What inspection techniques are used to inspect nonmetallic linings? 36. To whom should general inspection reports be sent? 37. Describe briefly precautions to observe prior to hydrostatic test of a pressure vessel? 38. What test method would be used for testing a vacuum vessel for leaks? 39. What testing is customarily done to a heat exchanger before dismantling? 40. What testing is customarily done to a heat exchanger after reassembly? 41. When should a pressure test be applied after a repair? 42. How would you calculate minimum wall thickness for the shell of a vessel? 43. Copies of completed reports recommending repairs should be distributed to whom? 44. When would de-rating of a vessel be considered? 45. What data should each type of record contain? 46. What data should the general reports contain? 47. Cracks are more likely to occur where there are sharp changes in shape or size or near. 48. What is the first step in inspecting a tube bundle? 49. How are thin spots in tubes determined? 50. How are scattered pits best repaired? 51. Some jurisdictions require the repair firm to possess what authorization to perform the repair? 52. Name three likely locations of corrosion on tubes in a tube bundle? 53. What would be checked during the visual inspection of an extended plate exchanger? 54. What must be done to the finned tubes of an air-cooled exchanger before starting the inspection? 55. Where is erosion-corrosion of tubes most prevalent in an air-cooled exchanger? I PR0715LL 13

15 56. Define a pressure vessel. 57. List four methods of construction used on pressure vessels. 58. What two NDE methods are most commonly used to measure thickness? 59. Where would you find ferri-ferrocyanide? I PR0715LL 14

16 RP 576 QUIZ 1. Briefly describe the applications and limitations for the following safety relief devices: a. safety valve b. relief valve c. conventional 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 is the principal reason for inspecting relieving devices? 5. What is the primary consideration in evaluating the inspection frequency to be established for relieving devices? 6. There are four bases for establishing the inspection frequency. What is each and briefly describe? 7. What inspections and testing should be done on new relieving device installations? 8. If a valve fails to open within the set pressure tolerance, what should be done? 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 identification data should be carried on a relieving device tag? 13. When repairing a relieving device in place what precautions should be observed? 14. What operating information should be contained in the operating history of a relieving device? 15. Flat metal rupture disks are usually limited to what percentage of the disks predetermined bursting pressure? 16. What medium is generally used to test relieving devices on the shop test block? 17. Briefly describe the shop test block used for testing with air? Make a sketch. 18. What things should be done prior to the removal of the relief devices to the shop? 19. List at least six of the nine points that should be visually checked during the dismantling 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 points are to be checked? 22. What basic information should the Specification Record contain? I PR0715LL 15

17 23. What data should the Historical Record contain? 24. List six causes of improper performance in relieving devices? 25. What is the meaning of CDTP? 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 two things are tested for in the test block? 29. List the applications and limitations for each type of non-reclosable relieving device. I PR0715LL 16

18 1. What is arc length? 2. What is a recordable indication? RP 577 QUIZ 3. What are the quality assurance tasks during welding? 4. What are the appearance and finish tasks upon completion of welding? 5. Who should non-conformances be reported to? 6. What best describes the SMAW process? 7. What are the advantages and limitations of the SMAW welding process? 8. What are the three filler metal transfer modes in the GMAW welding process? 9. What are at least six types of essential variables that must be shown on the WPS? 10. What must the manufacturer do on the PQR? 11. What are the three steps used when reviewing a WPS/PQR? 12. F-No s are grouped according to? Why are F-No s used? 13. The A-number applies to which type of filler metals? 14. Where can ASME guidelines be found for the storage and handling of filler metals? 15. Direct visual examination is conducted when access is sufficient to place the eye within? 16. Burn-thru and tungsten inclusions are detected by? 17. If a residual field is left in partially completed weld, what would happen? 18. What are four of the requirements that apply to the PT method? 19. Exposed radiographic film allows what percentage of light to pass through it? 20. What are the two common radioactive sources used for RT? 21. When using the double wall technique for RT how many exposures are required when both walls are superimposed? 22. What are four prerequisites for certifying an interpreter of radiographs? 23. The temperature of the ultrasonic calibration standard shall be within what temperature range of the part to be examined? 24. What is the purpose of the DAC? 25. What are three types of automated ultrasonic testing? 26. Welding processes are akin to what? 27. What is a common leak testing method that is used during hydrostatic testing? I PR0715LL 17

19 28. What items of inspection results are to be reported in an inspection report? 29. What effect do trace elements of carbon, sulfur and phosphorus have in a cast structure? 30. What are other terms for the rapid heating or cooling of a wrought material within certain temperature ranges? 31. What is the HAZ? 32. What makes aluminum difficult to weld? 33. What are metals with a high coefficient of thermal expansion susceptible to? 34. Stress in relation to a tensile test is defined as? 35. Ductility is usually expressed as a percentage of the elongation within a gage length. 36. Name three common hardness testing methods? 37. What is the relevance of 55 HRC? 38. What is an example of an in-service degradation that is hardness related? 39. What are six reasons for performing pre-heating? 40. What is the name applied to a notched bar impact test? 41. What is the size of a standard notch impact specimen? 42. What is the primary reason for PWHT? 43. Brinell hardness limits for steels in refining services are? 44. How is hardenability determined? 45. What are the two types of material test reports? 46. What are factors related to weldability? 47. What is the primary factor affecting weldability of metals and alloys? 48. What do steels having a CE between require when welding? 49. The simplest weldability tests are those that evaluate what? 50. The Lehigh Test evaluates what types of cracks? 51. What is the percentage range of nickel in austenitic stainless steels? 52. How can the loss of corrosion resistance due to chromium depletion be prevented? 53. Is it an advantage or disadvantage to apply preheating to nickel alloys when welding? 54. What type electrodes produce adverse effects when performing hot tap and in-service welds? 55. What is the required liquid flow rate in piping when in-service welding is performed? I PR0715LL 18

20 56. To minimize burn-through the first weld pass should be made with what diameter electrode? 57. What are some inspection tasks typically associated with hot tapping or welding on in-service equipment? 58. What is the limiting factor for base metal thickness when welding with the GMAW-S process? 59. What is the transfer mode for GMAW-S? 60. What are the five basic types of weld joints? 61. What do the first two XX s stand for on the SMAW electrode identification system? 62. Explain the identification system for GMAW/GTAW and FCAW electrodes? I PR0715LL 19

21 ASME CODE SECTION V The following articles fall within the scope of the examination and should be studied. All Mandatory and Non Mandatory Appendices and Subsection B are excluded except as noted in the API 510 Body of Knowledge. Article 1, General Requirements Article 2, Radiographic Examination. Article 23, SE-797 Standard Practice for Measuring by Manual Ultrasonic Pulse-Echo Contact Method Article 6 Liquid Penetrant Examination Article 7 Magnetic Particle Examination, only the prod and yoke methods apply. 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 an 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 QUIZ 1. Which NDE methods are required to have written procedures? 2. To what standard are NDE personnel to be qualified and certified for the RT method? 3. Describe how a check of backscattered radiation is performed? 4. What permanent identification must appear on the radiograph? How is this done? 5. How is density monitored? 6. What is the formula for thickness when measured by the pulse-echo ultrasonic method? 7. What are the thickness and hole sizes for a number 30 IQI? 8. What are the two radiographic exposure techniques permitted by the Code? 9. What are the two types of IQI s used per Article 2 of Section V? 10. What are requirements for calibrating densitometers? 11. What are requirements for calibrating step wedge comparison films? 12. Is geometric unsharpness an essential variable when radiographing welds in pressure vessels? 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? 16. A circumferential seam is to be radiographed as a single exposure, what are the minimum number of IQI s to be used? I PR0715LL 20

22 17. Shims are acceptable on a radiograph when the image? 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 Division 1? 21. For which two NDE methods are there 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 PT written procedure shall contain what information? 25. What is the maximum temperature covered in SE-797? 26. For UT per SE-797, what type unit is recommended where reflecting surfaces are rough? 27. What is the UT rule of thumb regarding apparent readings obtained from steel walls having elevated temperatures? 28. Is it necessary to measure thickness from both sides of a material when using UT? 29. Up to what maximum temperature can materials be measured for thickness using UT? 30. Which calibration Case applies where a high degree of accuracy is required for thick sections? 31. Where is a wire type IQI placed when radiographing a weld? A hole type? 32. When using penetrant materials on nickel base alloys, austenitic stainless steels and titanium what certifications must be obtained? 33. How many items are to be considered for inclusion in the UT (SE-797) procedure? 34. How many items are to be included in the UT (SE-797) report? 35. When are shims required to be placed under hole type IQI s? 36. Liquid penetrant examinations detect discontinuities that are: a. open to the surface b. near surface c. both a and b d. none of the above 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. Should thicknesses of calibration blocks be in round numbers or miscellaneous values? 40. What is the term penetrant materials meant to cover? I PR0715LL 21

23 41. The acceptance tolerance for the unit s ammeter (MT) is 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 method what is the preferred method to use? 46. The magnetic particle examination method can detect: a. near surface discontinuities b. surface discontinuities c. both a and b above 47. Final interpretation of a PT examination shall be made within what time range after developer application? 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. When using dual search UT (SE-797) units if a wide range of thicknesses is to be measured which calibration Case is the most suitable? 56. What are the definitions of lipophilic and hydrophilic emulsifications? I PR0715LL 22

24 ASME CODE SECTION VIII, DIV-1 The examination concentrates mainly on the math. 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 types of math problems which may be on the exam. 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-37 Reinforcement Required for Openings in Shells and Formed Heads. 5. UW-11 Radiographic and Ultrasonic Examination. 6. UW-12 Joint Efficiencies. 7. Appendix 1, 1-1 Thickness of Cylindrical and Spherical Shells. 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. The following are some typical math problems which cover the formulas that you will study. 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. No corrosion allowance is specified. 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 20,000 psi. What is the maximum pressure permitted for this thinned area? a. 737 psi b. 559 psi c psi d. 445 psi I PR0715LL 23

25 QUESTION: 2 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 = 16,400 psi. What is the maximum permitted pressure on the head for the conditions given? a. 980 psi b. 755 psi c. 325 psi d. 579 psi QUESTION: 3 A pressure vessel shell with the following characteristics is to have a plate replaced using SA material. Actual thickness = 1.125" Inside radius = 30" E = 1.00 MAWP = F. PWHT = Applied to original vessel but not mandatory MDMT = -20 F. S = 20,000 psi Ratio of design stress to allowable tensile stress = 1.00 After all exemptions are taken what is the adjusted MDMT of the plate? a. 45 degrees b. 45 degrees c. 75 degrees d. 30 degrees QUESTION: 4 The inner wall of a jacketed vessel is inch, the cylinder is 45 inch outside diameter, the unsupported length is 120 inches, and is made of SA-516 Gr. 70 material. Material chart CS-2 applies. What is the maximum pressure permitted on the inner wall of the jacket with a temperature rating of 300 F if Factor B is 11,600? a. 175 psi b. 208 psi c. 218 psi d psi QUESTION: 5 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? a. 65 psi b. 188 psi c. 228 psi d. 300 psi I PR0715LL 24

26 QUESTION: 6 A welding procedure requires impact testing for a thickness range of 3/16-8. The specimen is 1-1/2 having a 65 ksi yield strength. What is the minimum acceptable impact test values for the three specimens? a b c d QUESTION: 7 A seamless hemispherical head has the following characteristics: Thickness 0.875" L 48" S 20,000 psi E 1.00 MAWP 350 psig What is the maximum pressure permitted? a. 703 psi b. 412 psi c. 659 psi d. 750 psi ASME SECTION VIII QUIZ QUESTIONS 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 UG-55 through UG UG-102 through UG UW-1 through UW UCS-1 through UCS Appendices 1-1, 3, 4, 6, 8, 12. I PR0715LL 25

27 ASME SECTION VIII DIVISION 1 QUIZ 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 hemispherical head on a vessel must be replaced, what formula would apply. 10. What are the two methods of calculating the MAWP for a convex head with the pressure on the convex side? 11. A 2:1 ellipsoidal head on an in-service vessel has excess corrosion in the spherical portion of the crown. What Section VIII formula applies to its replacement? 12. What product forms are required to have a material test report or certificate of compliance? 13. Must welding materials be provided with a Certified Test Report or a Certificate of Compliance? 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? 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? I PR0715LL 26

28 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 ellipsoidal 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 required 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. Where do you find the extent of radiography on a vessel when the nameplate indicates RT 4? 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. Must all pressure vessels for external pressure service have stiffener rings installed? 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? 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. What is the maximum stress that bolting may be subjected to during hydro? 41. What markings must be applied to the stamping for vessels that have been RT or UT examined? 42. What is the minimum size of letters that can be stamped directly on a vessel? I PR0715LL 27