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____________
B) 1500 psi
C) 1413 psi
D) 1300
Answer: A (API 510, Para. 5.8.2.1) See Solution below using the API 510
formula!
Test Pressure in psi (MPa) = 1.5 MAWP (Stest temp/Sdesign temp), before
1999 addendum rule
Solution: 1.5 x 1000 x (16,300 15,000) = 1500 x (1.0866) = 1629.9 psi or
1630 psi
3. Given: A pressure vessel has been in service since January 1, 2001 and has a
history of active corrosion over its service life. Original thickness = .700 inches
(Actual & U-Stamp) & current thickness on Jan. 1, 2011 is .500 inches. Previous
thickness on January 1, 2006 was 0.600 inches. The minimum thickness for this
vessel as listed on the Data Sheet = 0.200 inches and the Vessel Corrosion
Allowance as per the U stamp = .500 inches. Determine corrosion rate,
remaining corrosion allowance and remaining life (RL) for this pressure
vessel?
A) Corrosion Rate = .020 inches per year, RCA = .030 inches and RL = 15 years
B) Corrosion Rate = .050 inches per year, RCA = .500 inches and RL = 10 years
C) Corrosion Rate = .020 inches per year, RCA = .300 inches and RL = 15 years
D) None of these are correct
Page | 1
Step # 1 Determine metal loss and both the LT & ST Corrosion Rates!
Step # 2 Compare two Corrosion rates & choose the one that best reflects current
conditions!
Step # 3 Determine the RL of the vessel in years given a Minimum t of 0.200
inches
Answer: C (API 510, Para. 7.1 Formulas for LT & ST Corrosion Rates)
.700 .500 = .200 in. loss 10 yrs = 20 MPY
.600 .500 = .100 loss 5 yrs = 20 MPY
Remaining Corrosion Allowance = .500 (given) minus .200 (given) = .300
inches
Solution: .500 inches (current) .200 inches (t min) = .300 in .020* = 15
= 15 years
(*Both LT & ST corrosion rate are .020 inches per year = 20 MPY you
must use 20 MPY)
USE THIS INFORMATION TO SOLVE QUESTIONS 4, 5, & 6 ON THIS PAGE
Original vessel thickness was found to be 0.750 inches thick (Baseline UT on January
1, 1996)
Latest vessel thickness taken during an internal vessel inspection on Jan. 1, 2011
was 0.600 in.
Vessel U-stamp reads MAWP 150 psi @ 350F, RT 1, Corrosion Allowance = 0.250
inches!
Pressure vessel Minimum thickness required on the data sheet & the U-stamp = .
500 inches!
Date of last external inspection was January 1, 2009 when a CUI survey was also
performed! The bottom head in the CS vessel in hydrocarbon service has SS weld
overlay and both VT & UT have found no metal loss over 15 years. Low readings are
located in a vapor space at the shell and top head. Corrosion rates have remained
steady for the vessels 15 year service life.
A) Corrosion rate < 5 MPY and .010 inches remain in the CA and remaining life is 2
years
B) Corrosion rate < 5 MPY and .200 inches remain in the CA and remaining life is 20
years
C) Corrosion rate > 5 MPY and .100 inches remain in the CA and remaining life is 10
years
D) None of these are correct
4. Determine corrosion rate, remaining CA & remaining vessel life given
the above!
Answer: C (API 510, Para. 7.1, See steps below)
Page | 2
Step # 1 Determine loss & Corr. Rate .750 .600 = .150 in. 15 years = .
010 or 10.0 mpy
Step # 2 Determine remaining CA .600 in. minus .500 in. = .100 inches CA
remaining
Step # 3 Determine RL =0.100 in. .010 = 10.0 Use 10 years RL
5. Given the above information (Assume No RBI), determine the date & the
next type of Inspection (Internal or can an On-Stream inspection be done)
using API 510 rules?
A) Internal inspection absolutely must be performed and will be due on January 1,
2021
B) On-Stream inspection MAY be performed (in lieu of internal) and will be due on
July 1, 2025
C) Either an internal or an On-Stream inspection will be due on January 1, 2021
D) None of these is correct
Answer: D (API 510, Para. 6.5.1.1 & 6.5.2.1) RL Rule Internal due Jan.
1, 2016)
6.5.1.1
Unless justified by a RBI assessment, the period between internal or
on-stream inspections shall not exceed the remaining life of a vessel or 10
yrs, whichever is less.
6.5.2.1
At the discretion of the inspector, an on-stream inspection may be
substituted for the internal inspection in the following situations:
b. When vessel entry for internal inspection is physically possible & all the following
conditions are met:
Item # 1 Vessel general corrosion rate is known to be less than 5MPY
Corrosion rate = 10MPY
Item #2 Vessel remaining life is greater than 10 years It is not It is
exactly 10 years
6. Given the above (assume no RBI), when is the next External inspection
due & why?
A) Jan 1, 2016 External inspections never exceed a lesser of 5 yrs or the
Internal/OSI interval
B) Jan 1, 2016 Because external inspections may NEVER exceed 5 years without
RBI
C) Jan 1, 2014 Because external inspections may NEVER exceed 5 years without
RBI
D) Jan 1, 2021 At the same time as the On-Stream inspection as allowed by API
510
Answer: C (API 510, Para. 6.4.1) Last external insp was Jan. 1, 2009 Due
Jan 1, 2014
6.4.1 Unless justified by RBI assessment, each aboveground vessel shall be given a
visual external insp at an interval that does not exceed the lesser of five years
or the required internal/on-stream inspection.
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Page | 4
D) None of these
Ans: A (Fig UCS-66 (4) Pg 181 Curve D Table UCS-66 Pg 184 Table UG-84.2 Pg
69
Step 1 Determine what curve on Page 181 B or D quenched & tempered = D
Pg 184 Use MDMT Column for D & row for 2.25 in. (use F values) = 0F Now go to
Pg 69 Table & a 5 mm specimen is a - sized so there is 20F reduction from 0F
or -20F Answer = A
11. Using Fig. UW-16.1 (a), determine value for tc Assume t = 38 mm & tn
= 22 mm!
A) 6 mm
Page | 5
B) 13 mm
Answer: A (ASME Section VIII, Div. 1, UW-16.b Symbols & See the Legend & See
Figure)
Page | 7
Answer: D (UG-27c & formula 1) See also Appendix L-1.5.3.a example for
practice
Formula to determine minimum shell t with circumferential
stress**
Step 1 PR = 400 x 14.375* = 5,750 *15.0 minus (.750 -.125) = 14.375 = R
Step 2 SE = 20,400 (.70 from UW-12d Table) minus 0.6 (400) 5,750 (14,280
240) = .409544 = .409 inches again!
Note: Given S values were manipulated so answers would be .409 for both
questions above
17. What is the normal PWHT holding temperature and minimum holding
time for a weld made to SA-516 Gr. 70 that is 2.00 inches (50 mm) thick?
A) Normal Holding Temp = 1100F and minimum holding time = 2 hours total
B) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 4
minutes
C) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 15
minutes
D) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 45
minutes
Answer: A Table UCS-56 for P-No 1 Materials
Page | 8
= 434 psi, 32 ft from top = 424 psi, 4 ft from top = 412 psi & at
= 444 psi, 32 ft from top = 434 psi, 4 ft from top = 422 psi & at
= 466 psi, 32 ft from top = 476 psi, 4 ft from top = 488 psi & at
= 474 psi, 32 ft from top = 484 psi, 4 ft from top = 492 psi & at
Ans: B UW-3d, Note 2 Static head per 1 foot of HO = 0.433 psi least
pressure @ top
19. Welded longitudinal joints within a sump are considered what joint
category?
A) Category A
D) Category D
B) Category B
C) Category C
D) None of these
Answer: B UCS-66 (c) (4) same applies for B16.5 flanges Top left
column, pg 183
Page | 9
21. How many tensile & guided bend tests are needed for a PQR coupon
using material grade A516 Grade 70 that is 3/4 inch (20 mm) thick?
A) Two tensile tests & four guided bend tests (2 face + 2 root bends are required)
B) Two tensile tests & four guided bend tests (4 face bends are required)
C) Two tensile tests & four guided bend tests (4 side bends are required)
D) None of these are correct
Answer: C Table Qw-451 See the Row for 19 mm 38 mm thickness
22. Are guided bend test results acceptable for A516 Grade 70 at a 3/4 in.
(20 mm) thick PQR Coupon (4 side bends taken), if Specimen # 1 = 3.0 mm
slag, Specimen # 2 = 3.0 mm porosity, and Specimen # 3 = 2.9 mm slag,
and specimen # 4 had 3.0 mm of porosity?
A) T1 & T2 = Acceptable, T3 & T4 are unacceptable & 4 Guided bend tests =
Acceptable
B) T1 & T2 = Acceptable, T3 & T4 are unacceptable & 4 Guided bend tests =
Unacceptable
C) T1 & T2 & T4 = Acceptable, T3 = unacceptable & 4 Guided bend tests =
Acceptable
D) T1 & T2 & T3 & T4 = Acceptable & 4 side bend tests = Acceptable
Answer: D Table QW-451 See the Row for 7mm thickness
Page | 10
24. Determine the correct wire number, wire set & wire diameter for a film
side radiograph taken on a .875 inch thick nozzle to flange circumferential
weld?
A) 8 wire, Set B, Wire Diameter 0.016 B) 9 wire, Set B, Wire Diameter 0.020
C) 10 wire, Set B, Wire Diameter 0.025 D) 11 wire, Set B, Wire Diameter 0.030
Answer = B: Wire-Type Essential Wire # 9 = Set B = Wire Diameter =
0.020in (0.51mm)
Step 1 Use thickness given in exam question = .875 in.
Step 2 Add weld reinforcement (Tables UW-3 & UW-35) = 3/16 or .188 in.
Step 3 Add .875 + .188 = 1.063 in for a Cat. B Butt welded Nozzle to Flg girth weld
UW-3 Solution: Use Over 1.00 thru 1.50 row (T-276) Film Side Column
9 wire T-233.2
25. If a radiograph (gamma radiography) has a density equal to 2.4 in the
area of interest adjacent to a single wire-type IQI, what is the acceptable
density range along the weld?
A) 2.0 to 3.1
gamma RT
B) 2.1 to 3.0
C) 2.2 to 3.1
B) 10 minutes
C) 20 minutes
D)
Answer: C (ASME V, Art. 6, T-672 & Note 1) Apply the 2 x dwell time rule
for low temps! This tricky question is on nearly every API exam Plate
Plate Plate remember, one inch on either side of the weld is on the
plate select plate (10 mins) always and double the time when a test is
performed below temp limits of T-672, Note 1 20 mins!!!
QUESTION # 29
Given: CALCULATE MAWP @ SHELL
FOR A PROPOSED 10-YEAR RUN
Original vessel thickness was found to be 0.975 inches thick (Baseline UT on January
1, 1986)
Latest vessel thickness taken during an internal vessel inspection on Jan. 1, 2011
was 0.860 in.
Vessel U-stamp reads Design:150 psi @ 350F, RT 1, Corrosion Allowance = 0.250
inches!
Pressure vessel Minimum thickness required on the data sheet & the U-stamp = .
725 inches!
Date of last external inspection was January 1, 2009 when a CUI survey was also
performed! The lower half of the vessel in hydrocarbon service has a SS strip lining
and both VT & UT have found no metal loss over 25 years. Low readings are located
in the vapor space at the shell and top head. Corrosion rates have remained
steady for the vessels 25 year service life.
Additional Given Information: Shell S Value = 16 ksi, Lethal Service &
Full Radiography
Internal Radius = 82 in. Established Corrosion Rate = 4.6 mils or .0046
inches per year
Page | 12
A) t = .860 and MAWP = 167 psi that is greater than 150 psi design, so a 10 year
run is OK
B) t = .814 and MAWP = 158 psi that is greater than 150 psi design, so a 10 year
run is OK
C) t = .768 and MAWP = 149 psi that is less than 150 psi design, so a 10 year run is
NOT OK
D) None of these is correct, but the MAWP is greater than 150 psi design & a 10
year run is OK
Answer: C (ASME VIII, UG-27.c.1 Formula 1 & API 510 Section 7.3.3
Formula for MAWP)
First step Solve for t using API 510 Code rules &
formula
.768
Correct is 16,000 (1) (.768) = 12,288 (82 + .461) or 82.461 = 149 psi <
150, so not OK
B) 10 yrs
D) 20 yrs
Ans: B (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.3)
Alternative MAWP calc method
40. When a pressure vessel remaining life is 1.5 years, the internal
or on-stream inspection Interval may be a maximum of:
A) Only of the vessels remaining life (0.75 years in this case)
B) Full remaining life (1.5 years in this case)
C) A maximum of 3 years in this case
D) A maximum of 2 years in this case
Page | 16
Answer: A (510, Int. & OSI (Insp.), Par. 6.5.2.2) Physically Possible
7 Rules to allow OSI!
Page | 17
Page | 18
48. After rolling a plate into a cylinder designed for internal pressure it is measured for
out of roundness and it is acceptable if the out-of-roundness is no more than:
A) 1%
C) 3%
B) 2%
D) None of these are correct
B) Examination points
C) Inspection points
Page | 22
B) Hardness
D) Toughness
Answer: D Ref: Appendices & Fig A-4 Std Weld Symbols Field
weld has black flag
67. The most sensitive method of locating cracking in a vessel made
of ferrous material is:
A) Fluorescent PT Method
B) Radiographic Testing Method
C) Fluorescent Magnetic Particle Method
D) Close visual Inspection with good lighting
Page | 24
Page | 25
B) Witness Point
D) Examination Point
Page | 26
B) Composition
D) Mechanical properties
Page | 32
B) Inspection Plan
D) QC Plan
B) Incomplete fusion
D) Incomplete penetration
B) Radiography
D) Final visual inspections
Answer: A (API 510 Section/Para. 8.1.1 Make sure you know the
routine repair rule)
113. The repair organization shall maintain records of its qualified
welding procedures and its welding performance qualifications.
What is the responsibility of the repair organization to the Inspector
regarding these records?
A) Records shall be available to the inspector at the start of welding
B) Records shall be available to the inspector prior to the start of welding
C) Records shall be available to the inspector anytime after the start of
welding
D) Records shall be available to the inspector within 1 week after the start of
welding
Answer: B (API 510, Para. 8.1.6.2.2)
114. Regarding PWHT, Local PWHT may be substituted for 360degree banding on local repairs on all materials, provided that the
following precaution is taken regarding preheating:
A) Preheat of 150F or higher, as specified in welding procedure, is
maintained during welding
B) Preheat of 200F or higher, as specified in welding procedure, is
maintained during welding
C) Preheat of 250F or higher, as specified in welding procedure, is
maintained during welding
D) None of these are correct
Answer: D (API 510, Para. 8.1.6.4.1) Preheat of 300F or higher
115. The most common forms of CUI are localized corrosion of
carbon steel and:
A) Localized pitting type corrosion of stainless steels
Page | 36
B) Examiners employer
D) Authorized Pressure Vessel
B) Thermal Shock
D) None of these
Page | 44
B) Chloride Corrosion
D) CO Corrosion
Page | 45