9) api 510 day 1

G T Technical & Management Institute Pvt.Ltd.,ISO 9001 Certified Institution

API 510 DAY 1

API 510 -2006 BENCH MARK QUIZ

Note: Encircle the letter of only one alternative which you think is most appropriate.

1. Which of the following types of discontinuities is not normally detected by radiography?a. Cracksb. Incomplete penetration c. Laminationsd. Slag

2. API 510 __________ be used as a substitute for the original construction of pressure vessels before it is placed in-service.a. Shall notb. Shouldc. Mayd. Shall

3. Compared to ASTM A 515 Gr. 60 plates, ASTM A 516 Gr. 60 plates have:a. Better Tensile Strengthb. Better toughnessc. Better high temp propertiesd. None of above

4. Who establishes inspection interval for thickness measurements and external visual inspections.a. Vessel engineer;b. Owner-user or the inspectorc. Corrosion Engineerd. NDE engineer

5. ASME Sec. VIII Div. 1 is based on factor of safety equal toa. 4b. 3c. 3.5d. 2.5

6. Identify incorrect statement from following, if any.a. A welder performing procedure test is also qualified in that position.b. Supplementary essential variables become essential variables when impact test is specified.c. For procedure qualification, the test can be performed in any position as the position is not essential variable for procedure qualification.d. None of above is incorrect statement

7. In plate specification A 516 Gr 70, the letter A indicates:a. That material is ASME material. (A for ASME)b. That material is Ferrous materialc. That material is Non-Ferrous materiald. None of the above

8. The symbol which indicates ASME code stamping for vessels manufactured to ASME Section VIII Div. 1 is a. U1b. U2 c. U d. None of these

9. What will be the applicable mandatory Edition and addenda for ASME Sec. VIII, Div. 1 to be used if contract for manufacturing a new vessel was signed on 14 December 20011? a. 2010 edition and 2011 addendab. 2009 edition and 2010 addendac. 2010 edition d. None of the above

10. Term E used in shell thickness formula in ASME Sec. VIII Div.1, represents weld joint efficiency, whose value is equal to 1, if: a. Longitudinal and circumferential welds are radiographed for their entire length b. Longitudinal welds are radiographed for their entire length and circumferential welds are spot radiographed.c. Both welds are spot radiographedd. a and b above

11. A restoration work by weld-overlay was carried out on corroded wall of vessel and it can now be used as per the design conditions of the vessel. This activity will be termed as:a. Renewal of vesselb. Repair of vesselc. Alteration to vesseld. Re-rating of vessel

12. In certain MP. Check of pr. Vessel, The size of "indication" for a certain discontinuity was seen as 4 mm but after the MP. Check and using magnifying glass it was seen having actual size as 2.5mm only. If stipulated acceptance criteria for that type of discontinuity was 3 mm, your decision is: a. The size of indication is higher than 3mm. Reject. b. The size of discontinuity is lower than 3 mm, Accept. c. Depends on opinion of Examiner. d. Depends on the procedure adopted for MPI, i.e dry or wet particles.

13. ASME Code requires averaging of impact test values of how many specimen for the relevant acceptance criteria. a. 2b. 3 c. 4 d. None of these

14. A stainless steel weld has a crack open to the surface. Which NDT method will reveal it effectively?a. Liquid Penetrantb. Magnetic particlec. Radiographyd. All of above.

15. PQR document normally may be revised and re submitted for acceptance.a. True b. Falsec. Depends on company policyd. Depends on Third party inspectors discretion.

16. Hot tapping is best described by statement:a. It is technique of preheating the vessel wall to specified temperature and tapping with 1lb. rounded hammer to detect wall thinning b. It is technique of providing a tapping connection while the system is in operation c. It is technique of fixing a on/off tap on drain nozzle of pressure vessel d. It is act of pre heating the component before using the tap and die for threading so that less effort is required for threading operation.

17. Which of the following represent grouping of weld-metals in ASME IX?a. P Nos b. F Nos c. S Nos d. A Nos

18. A inspector should be stricter while carrying out inspection on:a. Longitudinal Joint b. Circumferential Jointsc. Both are equally critical as per ASME Sec. VIII, Div.1d. Depends on QA plan

19. PT examination is used to detect the surface cracks in welds as well as in base metal plates. For proper detection, a. We should allow higher penetrant time on weldb. We should allow higher penetrant time on platesc. Penetrant time on weld as well as plates is samed. Depends on type of penetrant used.

20. As per ASME Sec. VIII Div. 1, Weld joint category means:a. Type of weld, i.e., Single V type, Double V type, U type etc.b. Type of weld, i.e., Full penetration, partial penetration etc.c. Location of weld, i.e., longitudinal, circumferential, nozzle attachment welds etc. d. Type of weld joint, i.e., Butt-weld joint, fillet weld joint, lap joint, etc .

BENCH MARK QUIZANSWER KEY

Q. NO.ANSWERREFERENCE

1CSec V Table A 110

2AAPI 510 , 1.1.1

3B( SEC IX 422)

4B( 6.4.1 Last two line & 6.5.2.1)

5CGK

6D( Sec IX WQ 461.9, QW 251.2, Page no 19-45)

7BGK

8C( UG 116)

9D( Forward, 2 nd page, First column)

10D( Sec VIII UW 11 & UW 12)

11B( API 510 , 3.53)

12A(Sec VIII Apx 6.3 & 6.4)

13B( UG 84 c)

14A( T 620)

15B( Qw 200.2.C )

16B( API 2201)

17D( Sec IX, QW 422)

18A( GK- Due to Hoof Stress )

19B( Sec V, Table T 672)

20C( UW 3 , First 2 lines)

DAILY POINTS TO RECALL (DAY 1)

1. ASME codes edition is issued once in 3 years and addenda, once a year both on 1 July. Edition and addenda become effective on 1st January of next year (i.e., 6 months after issue).

2. ASME Sec VIII Div.1 is Unfired Pressure Vessel and is applicable to pressures exceeding 15 psig, and diameters above 6.0. Pump and turbine casings are excluded from scope.

____PRSE 0.6P3. Thickness of cylindrical shell t = + C

4. Longitudinal weld is more critical because it is subjected to double the stress than Circ. Weld.

5. Weld joint categories A, B, C, D are based on joint locations in the vessel and stress levels encountered weld Types (type 1, 2, 3 etc.) describe the weld it self.

6. Depths of 2:1 Ellip and hemisph. heads are D/4 and D/2 respectively. (D= Head diameter.)

7. Weld Joint categories: Category A: - All longitudinal welds in shell and nozzles. - All welds in heads, Hemisph-head to shell weld

Category B: - All circumferential welds in shell and nozzles, - Head to shell joint (other than Hemisph.)

Category C and D are flange welds and nozzle attachment welds respectively.

8. Weld Types: Type 1: Full penetration welds ( Typically Double welded) Type 2: Welds with Backing strip. Type 3: Single welded partial penetration welds. Type 4, 5, 6 are various Lap welds (rarely used)

9. For full penetration welds (type 1),Joint efficiency, E = 100% ( Full RT) E = 85% ( SPOT RT ) E= 70%, ( NIL RT ).

10.Radiography marking on name plates (typically for Type-1 welds)

RT-1: (E=1) All butt welds full length radiography. RT-2: (E=1.0) All Cat. A Butt welds Full length Cat B- spot RT-3: (E=0.85)Spot radiography of both Cat A and B welds RT-4:(E=0.7) Partial / No radiography

11. For seamless heads, E=1, If head to shell weld is fully radiographed ( if Cat. A), and at least spot radio graphed (if Cat. B)

12. For Welded Heads for E=1, all welds within the head require full length radiography (since they are all Cat A welds) and head to shell weld is fully radiographed (if Cat A), or at least spot radiographed (if Cat. B)

13. Compared to Cylindrical shell, thickness of 2:1 Ellipsoidal head is approx. same as shell, Hemisph. head approx. half and Torisph head is 77% higher.

14. MAWP is calculated for: Working condition (Hot & Corroded). Vessel MAWP is always taken at the top of the Vessel and is lowest of all part MAWPs adjusted for static pressure.


1. Hydro-Test is Standard Pressure test on Completed Vessels. Hyd. Test Pr. = 1.3 x MAWP x stress ratio Min. Insp. Pressure (hydro) = test pr. / 1.3 Min. Test temp. = MDMT + 30F (recommended) Max. Inspection temp. = 120 deg. F

2. Pneumatic test is performed if Hydro is not possible due to design or process reasons. Prior to the test, NDT as per UW-50 is mandatory. Pneumatic Test pr = 1.1 x MAWP x Stress ratio, Pressure should be increased in steps (Total 6).

1st step 50% of Test pressure 2nd to 6 step 10% of Test Pr. Insp. Pr. (pneumatic) = Test pr. /1.1

3. Pressure Gauge range should be about twice the Test Pressure, However, in any case it shall not be lower than 1.5 times and not higher than 4 times the Test Pressure.

4. Vessel MAWP represents the Maximum Safe Pressure holding capacity of the vessel. Vessel MAWP is measured at top-most point. And is lowest of vessel part MAWPs adjusted for static pressure of liquid.

5. For vertical vessels, Hydrostatic pressure due to liquid with specific gravity = 1 1 ft of height = 0.433 psig. 6. Total pressure at any point of Vertical vessel is given by: Total Pr. = Vessel MAWP + h x 0.433. (h = height from top in ft.)

7. If part MAWP and elevations are known, Vessel MAWP can be calculated by the deducting hydrostatic pressure from part MAWP.

8. External Pressure analysis is required when vessels are operating under vacuum or they jacketed type.

9. Ext. pressure is worked out on basis of Geometric factor A (which depends on L/Do and Do/t ratios) and factor B ( depends on A, )

Allowable Ext. Pressure, Pa = For values of A falling to left of material line in the material chart,

Pa = 10. Name plate shows The Code stamping, MAWP, design temp., MDMT, and Extent of Radiography.

11. For the impact test requirement, use UCS 66 curve. If MDMT-thickness combination falls on or above the curve, impact testing is exempted. Additional Exemptions are given as per UG-20(f) and UCS 68 (c).

12. ASME materials (SA) shall be used for code stamped vessel fabrication instead of ASTM (A) materials.


1. Reinforcement pad is not required, if the size of finished opening is Not exceeding 2 3/8 for all thicknesses of vessel Not exceeding 3 1/2, if vessel thickness is < 3/8

2. Reinforcement pad with OD = 2d and thk = vessel thk is always safe (d= dia of finished opening)

3. Reinforcement Limit along vessel wall = 2d

4. Reinf. Limit normal to vessel wall = smaller of: 2.5 t or 2.5 tn

5. In reinforcement pad calculations, credit can be taken for area available in shell and nozzle.

6. Fillet weld Throat dimension = 0.707 x leg of weld

7. Adequacy of weld sizes shall be checked as required by UW-16. The nozzles construction shall be one of the Code acceptable types.

8. The maximum permitted ovality tolerance (D max D min) shall not exceed 1% of nominal diameter of vessel. If there is opening, then the tolerance can be increased by 2% x d (d = diameter of opening) if measurement is taken within a distance of d from axis of opening.

9. The mis-match tolerances and the maximum allowable weld reinforcement is more strict on longitudinal welds compared to circumferential welds (UW-35).

10. Principle of reinforcement: Area removed = Area compensated. Compensation area shall be within reinforcement limits.

11. For use as pressure parts, the plates shall be fully identified. Maximum permitted under tolerance on plates is 0.01 (0.3 mm) or 6% of ordered thickness, whichever is less.

12. All Welding (including welding of pr. parts to load carrying non-pr. parts) shall be done using Qualified procedures and welders

13. Mandatory Full Radiography is required for all welding with thickness exceeding Table UCS-57, and also for lethal service vessels and Unfired boilers with Design Pr. More than 50 psig.

14. PWHT is Code Requirement if thickness exceeds those given in tables UCS-56 (given in notes under the tables). These tables also give min. PWHT temperature and min. holding time (soaking period) based on P-nos. and thickness respectively.

15. For Furnace PWHT, Loading Temperature shall not exceed 800 deg. F, Max. heating rate 400 deg F/hr/inch of thickness, Max. cooling rate 500 deg. F /hr/inch of thickness. Still air cooling permitted below 800 deg. F. During Soaking period, the temperature difference between hottest and coldest part shall not exceed 150 deg. F.

16. Min. Overlap for PWHT in multiple heats = 5 ft.


1. API 510 is applicable to vessels that have been placed in service, and it cannot be adopted for new constructions. 2. Following are excluded from scope of API 510:a. All mobile vesselsb. All exclusions of ASME Sec VIII, Div. 1c. Vessels not exceeding 5 cubic feet and 250 psi design pressure or 1.5 cubic feet and 600 psi design pressure

3. Alteration: It is change in component that has design implications affecting pressure and/or temperature rating. 4. Repair: It is restoring vessel suitable for operations at the present design conditions. Repairs do not change Pr-Temp rating of vessel.

5. Authorized inspection agency. Any one of following:a. Jurisdiction organizationb. Insurance company which under writes insurance of pressure vessels c. Inspection organization of owner-user d. Inspection organization under contract with owner user

6. Repair Organization: Any one of following:a. Holder of ASME certificate & appropriate code symbol stampb. Owner-user c. Contractor under contract with owner-user d. Organization authorized by jurisdiction

7. On-stream inspection means NDT inspection done on Vessel without entering inside vessel. This inspection is basically to know process side deterioration.

8. Re-rating: A change in either MAWP or temperature rating or change in both.

9. Owner-User bears Ultimate responsibility for all activities (inspection, Engineering, repairs etc.) under API 510.

10. Authorised Inspector is responsible to Owner-User to:a. Determine that all work (inspection, repairs ,alteration) is carried out as per requirements of API-510b. By getting involved in the actual activities performedc. Evaluate & accept/reject results of NDT and other tests. 11. Repair Organization is responsible to Owner-User for the use of proper materials, Quality Control, Workmanship during the repair work performed by them.

12. Prior to any inspection, safety rules (OSHA or other) shall be reviewed and followed. NDT equipment shall be as per Safety rules and Protective clothing shall be used where required.

13. Modes of failure:

a. Chemical corrosion due to contaminants in fluid handled. b. Fatigue: Due to stress reversals (vibration, changes of temperature or pressure)c. Creep: At elevated temp (in areas of stress concentration)d. Freeze Damage: Failure due to freezing and expansion of water/aqueous solutions. e. Brittle failure: Due to loss of impact strength at lower temperaturef. Tamper Embrittlement: Loss of ductility in Cr-Steels due to improper PWHT or service at high temperature (>700F)


1. For new service, or for changed service, if corrosion rate is not known, The corrosion rate may be calculated based on corrosion data for similar service, or based on published data. If both are not available, on-stream determination after 1,000 hours shall be made to establish the corrosion rate. MAWP = SEt/(R+0.6t)

Where t = t actual 2 x Cn Cn = metal loss up to next inspection

2. For corrosion area of considerable size; thickness averaging along most critical element shall not exceed following length (l) measured longitudinally:

a. Vessel I.D. < 60... l = D/2 or 20 use smaller valueb. Vessel I.D. > 60... l = D/3 or 40 use smaller value

3. The widely scattered pits, can be ignored if:

a. Remaining thickness below the pit is greater than half the required thickness.b. Total pit area does not exceed 7 square inches within 8 inch diameter circle.c. Total sum along any line in circle does not exceed 2 inches.

4. As alternative, evaluation of thinning of pressure retaining walls may be performed by employing methods outlined in ASME Sec. VIII Div. 2, in consultation with the Pr. Vessel Engineer.

5. For surface remote from weld, (weld E < 1), shell thickness can be recalculated with E = 1. Shell area is considered remote from weld if it lies on either side weld beyond 1 or 2 times the thickness (whichever is greater).

6. For dished Heads, the Crown portion lies within a circle concentric to dish but with circle dia. = 0.8 x shell dia.

7.For Ellipsoidal or Torispherical heads, crown portion thickness can be recalculated considering the Crown as part of sphere of radius equal to D, (for standard Torispherical) or K1 D (for Ellipsoidal). Where, D is shell diameter

8. For ellipsoidal head K1 depends on D/2h ratio (h=head depth) For 2:1 Ellipsoidal Head, K1 = 0.9

9. Fitness for Service evaluations are performed as per API RP 579.

10. RBI methodology is based on assessment of Likelihood of failure (LOF) and Consequence of Failure (COF) and is conducted and documented as per API RP 580.

11. RBI assessment may be used as an alternative to establish the Frequency of Internal and External Inspections.

12. If 10 year limit Is increased based on RBI, the RBI assessment shall be reviewed and approved by both Pressure Vessel Engineer and Inspector at intervals not exceeding 10 years or more often if LOF or COF changes.


1. Frequency of inspection:

a. External visual: 5 years or same as internal (or on-steam) inspection, use smaller duration.b. Internal/on-stream: Smaller of half remaining life or 10 years, if remaining life is < 4 years full remaining life up to maximum of 2 years.c. For non-continuous service external same as (a) above but internal will be after 10 years of actual exposed life for non corrosive, where as for corrosive it will be smaller of half remaining life or 10 years. 2. For Insulated vessels, CUI is likely to occur If there is possibility of moisture ingress and operate between 25 to 250 degrees F.

3. On-Stream inspection may be substituted for internal inspection if:

a. There is no access to enter.b. If Corrosion rate is less than 5 mpy and R. L. is more than 10 years there are no questionable conditions found during external inspection. Also, the vessel is not subject to Environmental damage or Strip/plate lined.

4. Remaining life = Remaining C.A. / Corrosion rate

Corrosion rate =

5. Pressure test:

Min. Test temp. = MDMT + 30F (thickness > 2) = MDMT + 10F (thickness 2) Perform Pneumatic test, if hydro is impractical.

6. If service conditions are changed, the allowable service conditions (Max. pressure, max. and min. temperature) and inspection intervals shall be determined for new condition.

7. If both ownership and location are changed vessel shall be cleaned internally and externally and allowable conditions of service and next period of inspection shall be established.8. Inspection records shall have 4 type of information:

a. Design and Construction (permanent) records b. Running (progressive) inspection records c. Repair and alteration (modification) recordsd. Fitness for service records

9. For vessels whose material is not known, MAWP can be calculated assuming stress value for A 283 Gr. C material and Joint Efficiency equal to 0.7.

10. Pressure relieving devices: Inspection interval not to exceed 5 years normally but for clean non-corrosive service may be 10 years.

11. Authorization for repairs/alteration of vessels constructed as per:

ASME Sec. VIII, Div. 1: Repairs API inspector Alterations API inspector and P.V. engineer ASME Sec. VIII, Div.2: Repairs & Alterations API inspector and P.V. engineer

12. If PWHT is impracticable, materials under P No. 1 (group 1, 2, 3) and P No. 3 (group 1, 2) shall be repair welded as follows (if impact testing is not required).

a. Preheat to 300 degrees F for a distance 4 or 4t on either side of groove (t = weld metal thickness)b. Welding process shall be SMAW, GMAW, or GTAWc. Control interpass temperature not to exceed 600 degrees F

13. If impact testing is required and PWHT is impracticable, the materials under P No. 1, 3, 4 shall be welded as follows:

a. Adopt SMAW/GMAW/GTAW process with temper bead of half bead techniqueb. Requalify the procedures as per table 7-1c. Use low Hydrogen Electrodes. Carry out Hydrogen bake out treatment if required (Electrodes designation > H4)

14. For all other materials other than 12 and 13 above, PWHT shall be carried out after repair if it was carried out originally as per code of construction.


1. Local PWHT may be substituted for 360-degree banding if:a. Original PWHT was not due to service requirementb. Effects of Local strains/distortions are consideredc. Pre-heat & maintainance of 300 deg. F during weldingd. PWHT temp is maintained beyond the weld upto twice base metal thicknesse. Heat is applied to any nozzles /attachments within PWHT area.

2. For repairs of following :

a. Cracks: By preparing V or U-shaped groove and depositing weld metal Cracks at area of stress concentrations (i.e., nozzle welds) shall not be repaired without consulting the pressure vessel engineer.

b. Localized corroded area: By weld deposit. Low strength electrodes may be used if thickness of deposit is increased by ratio of B.M. strength to W.M. strength and Depth of deposit does not exceed half of thickness Increased thickness is blended with 3:1 taper

3. For repair welds, the weld preparation before welding, and the completed weld shall be checked by PT or MT. Additionally, the butt-welds shall be radiographed by the rules of original Code of construction (depending on joint efficiency).

4. The carbon and alloy steel materials used in making repairs and alterations shall not have carbon content over 0.35%.

5. Pressure test is required after repair/alterations, if authorised inspector thinks it necessary. Pressure test is normally required after alteration.

6. Insert patches must be with full penetration welds. Fillet patches shall be approved by P.V. Engineer. Normally, a fillet patch equivalent to reinforced opening is okay.7. Normally, temporary repairs are replaced by permanent repairs at next available maintenance opportunity. But temporary repairs can remain for longer period if approved by P.V. engineer.

8. Non-penetrating nozzles (including pipe caps) are accepted method of long term repairs for other than cracks.

9. Full encircle lap band is considered as long term repair for other than cracks.

10. Full encircle lap band is considered as long term repair for other than cracks.

11. Re-rating calculations shall be done by pressure vessel engineer, and the inspector shall oversee the new stamping or New name plate showing rerating (new MAWP, temp.) is attached to vessel.

12. Procedure qualifications give suitability of weld for required mechanical properties (i.e., strength, ductility), while performance qualifications show ability of the welder to make sound weld.

13. Tension test gives tensil value, while bend test shows ductility and soundness. Radiography also indicates soundness.Thus, Procedure Qualification : by Tension test + Bend test Performance Qualification: by Bend test or Radiography

14. Tensile test for procedure qualification is passed if failure is in:

a. Weld metal at strength>= Base metal SMTS orb. Base metal at strength>= 95% of base metal SMTS.

15. Bend test crack shall not exceed 1/8 in any direction. Radiography criteria are stricter than radiography for job.

16. P-numbers represent parent metal classification of similar composition and properties, i.e., similar strength and ductility.

F-numbers give similar usability aspects of filler material.A-numbers give similar chem. comp. In As welded condition.

17. Essential variables (EV), if changed require new procedure qualification. Non-essential variables (NEV) may be changed without new procedure qualification.

18. Supplementary essential variables (SEV) are considered as (EV) only if there is impact strength requirement. Otherwise they are non-essential variables.

19. EV and SEV are included in PQR document. EV, SEV and NEV are included in WPS document.

20. PQR gives data used in PQR test and test results, and cannot be revised.

21. WPS gives parameters to be used in production job, and must be within ranges qualified by the PQR test.

22. WPS may be revised within the EVs qualified. The NEVs can always be revised without affecting validity of PQR.

23. For performance, 1G is flat, 2G is horizontal, 3G is vertical and 4G is overhead position. Pipe 5G qualifies 1G, 3G and 4G, but pipe 6G qualifies all positions.

24. Welder who welds test coupon for procedure qualification test in certain position also qualifies for performance in that position if procedure Qualification was OK

25. Performance Qualification of welder is affected if he has not welded with that process for last 6 months.

26. Inspector can revoke performance qualification if welder is repeatedly unable to produce satisfactory welds meeting the requirements.


1. GENERAL: a. ASME Sec. V is NDT procedure/methods code and is applicable only if it is referenced by the relevant construction code. The extent of NDT and acceptance standards is given in relevant construction code.

b. NDT equipment and their calibration shall be as per ASME Sec. V.

c. Examiner is NDT person in employment of fabricator or repair organization. Inspector means Authorized Inspector who finally accepts/rejects NDT results.

2. FOR RT:

a. Satisfactory radiograph shall meet requirements of density and IQI image (2T hole for hole type and designated wire for wire type). b. Backscatter: Light image of B on dark background - Unacceptable

c. Density Limitations: Min 1.8 for X Ray / 2.0 for G-Ray Max 4.0 for X / G Ray Density Variation = -15 % to + 30%

d. Double wall viewing (DWDI) - Up to 3.5 outside diameter

e. Penetrameter Selection: Table T-276. Thickness includes weld reinforcement. But not backing.

f. Penetrameter shall be normally placed on source side. If not possible, it may be placed on film side with lead letter F.

FOR PT:a. Control of Contaminants: Sulphur (for Nickel alloys) shall not exceed 1% of residue. Chlorine + Fluorine (for S.S. and Titanium) shall not exceed 1% of residue.b. Temp. shall be between 10oC to 52oC, for standard procedures.c. Penetrants are colour (visible) type and fluorescent type. Each of these have: water washable post emulsifying solvent removableThus, total 6 categories of penetrant are available.d. Emulsifier is applied after applying penetrant and required dwell time is completed. Lipopholic emulsifier is applied without pre-rinsing. Hydropholic emulsifier is applied after pre-rinsing.e. For dwell time for penetrant and developer refer Table T-672.f. After applying developer, interpretation shall be done within 10 to 60 minutes.g. All penetrant materials should be from same manufacturer

4.FOR MT:a. Prod Technique: Use direct (rectified) current for magnetization Prod spacing 3 to 8 Useful for surface and sub-surface defects.

b. Yoke Technique: Use D.C. or A.C. or permanent magnet Suitable for surface defects only.

c. Calibration:Equipment Ammeter to be calibrated once a year comparing with standard Ammeter, take 3 readings. Deviation shall not exceed 10% of full scale.

d. Lifting Power of Yokes AC shall have lifting power of at least 4.5 kg (10 lb.) DC shall have lifting power of at least 18.1 kg (40 lb.)e. Minimum two examinations on each area, the second is perpendicular to first

5. SE-797 UT MEASUREMENT:

a. Pulse-echo method can be adopted up to 200F

b. Apparatus: 3 types CRT read out CRT + direct read out Direct thickness read out

c. Search Units: 3 types Straight beam contact type Delay line type (delay block to minimize dead zone) Dual element type. There are two crystals set at a small range. Low roof angle used for higher range and higher angle for low range.

d. High thickness measurement:Use of multiple echoes is made. (i.e., for thickness between 50 mm and 60mm, use 10mm calibration block then 5thback echo will be 50 mm and 6th will be 60mm. Set the 5thecho to zero and 6th at the screen range. The screen iscalibrated to 50-60mm.

e. While taking measurement for high temperature condition a positive error of 1% per 55C (100F) results. Hence temperature correction is necessary.

f. CRT read out is recommended on corroded and rough surface.


1. Vessel inspections are for the safety, continuity, reliability.2. Graphitization in Carbon Steels takes place due to prolonged exposure in 825 to 1400 deg. F range resulting in decomposition of Steel into Ferrite Crystals and Graphite Nodules. In-situ metallography is used to detect the Graphitization3. External inspection of Pressure Vessels and Exchangers should start with ladders, platforms, stairways connected to or bearing on vessel.4. External surfaces of vessels shall be examined for not only for corrosion but also for leaks, cracks, buckles, etc.5. If any settling is seen on vessel, nozzles and adjacent shell area shall be inspected for distortion and cracking.6. Hammer test shall be followed by suitable NDT. 7. Grounding connection resistance shall not exceed 25 ohms but 5 ohms is normally preferred.8. In presence of acidic corrodents (PH < 7) hydrogen blistering is expected above and below (close to) liquid level.9. Auxiliary equipments (Pressure gauges, sight glass, safety valves etc. may be visually inspected while in service. Undue vibrations shall be arrested by providing additional supports or qualified engineer should determine if these could lead to fatigue failure. 10. First step for internal inspection is review of previous records. 11. For heavy wall vessels at high pressure, major concern is crack damage particularly at the welds (Weld & HAZ).12. Laminations run slant while cracks run normal to surface. 13. Spark testing is effective method for breaks/leaks in paint, glass, plastic and rubber lining.14. UT is the primary means of obtaining thickness measurements. Other methods like profile radiography, Step-wedge comparison radiographs, Corrosion buttons, test holes and depth drilling are some other methods.15. Tamper embrittlement of chromium steel occurs due to loss of ductility due to prolonged exposure to high temperature above 650oF. It can be controlled by limiting "J" factor for base metals and "X" factor for weld metals.16. All fatigue failure take place due to initiation of surface crack and propagation of crack due to stress fluctuation. There are 3-types of fatigue failures. If surface cracks are due to stress concentration, weld undercuts, notches etc and stress fluctuation due to mechanical reasons (vibrations, water hammer etc.) then it is Mechanical Fatigue. If stress fluctuation is due to temperature swing, it is Thermal Fatigue. If initial surface cracks are due to corrosion, pitting etc., it is Corrosion Fatigue.17. Corrosion Erosion is due to combined action of corrosion and erosion. It can be reduced by controlling corrosion (by coating or using corrosion resistant materials) and by controlling erosion (by controlling flow velocity, providing harder surface).18. Caustic embrittlement occurs due to combined action of high caustic strength and higher temperature. It can be controlled by carrying out PWHT and upgrading materials by Nickel alloys.19. Sulphidation occurs due to sulpher or H2S content in the fluid handled. It can be reduced by using Chromium containing steels as construction materials.20. Hydrogen blistering takes place due to migration of Hydrogen items in the steel vessel walls. Hydrogen induced cracking (HIC) takes place if several Hydrogen blisters join together in the material.21. Stress assisted HIC (SAHIC) takes place due to propogation of HIC cracks under effect of applied stress. Crack propagates perpendicular to stress direction.22. High temperature Hydrogen Attack (HTHA) is due to migration of Hydrogen atoms in the carbon steels which combines with carbon in carbons steel at high temperature to form Methane gas (CH4) which collects at grain boundaries causing internal cracks. It can be reduced by selecting the construction materials according to Nelsen Curves. (The material should be above the point of temperature and Hydrogen pressure).


1.API 576 provides practical guidelines to meet API 510 requirements for pressure relieving devices (PRDs). It does not cover training requirements.

2. Inspection of PRDs is essential for:

a. Protection of equipments and safety of personnelb. To determine condition of device itself and its operational characteristics

3. Inspection frequency:

a. Inspection and shop maintenance Normal frequency is 5 years (max.) but may be up to 10 years for clean, non-corrosive, non-fouling mediumb. Visual on-line survey 5 years max.

4. Safety valve is pop-opening valve, used on gases and vapors. Relief valve is proportional opening valve used on liquids. Safety relief valves can function both ways. Backpressure correction is done on balanced safety relief valves. 5. After the valve is removed from service, first action is to check its relieving pressure (pop pressure) in the as received condition. Subsequently, carry out detailed visual examination, dismantling, cleaning, and lapping of valve seat. Set the pop at desired pressure and confirm the same at least once. Carry out leak test.

6. Leak test is carried out (at 90% of relieving pressure) by monitoring air bubbles appearing per minute under head of and comparing with acceptance chart.

IMPORTANT INFORMATION

API 510 EXAM

It is an 8 hour exam, Morning 4 hours- open book Questions. Here you can refer code books and answer. It may contain 50- 55 questions.

Afternoon 4 hours session is a closed Book exam. Here no reference material is allowed. Total No 0f questions may be 95 to 100, making the Total Q no 150. To pass, you have to answer minimum 105 questions correctly.

The books you can refer are the code books API Publication API 510 Pressure VVessael inspection code API P 571 Damage mechanisms affecting the equipment in thee refinery industries API RP 572 Inspection of Pressure Vessels API RP 576 Inspection of pressure Relieving devices API RP 577 welding inspection and Technology

ASME PublicationSec V NDT ExaminationSec VIII- Division i- rules for constructing Pressure VesselsSec IX- welding & brazing qualifications

Items to study in Recommended Practice 571, ATTENTION: Only the following mechanisms to be included:Par. 4.2.3 Temper Embrittlement4.2.7 Brittle Fracture4.2.9 Thermal Fatigue4.2.14 Erosion/Erosion-Corrosion4.2.16 Mechanical Failure4.3.2 Atmospheric Corrosion4.3.3 Corrosion Under Insulation (CUI)4.3.4 Cooling Water Corrosion4.3.5 Boiler Water Condensate Corrosion4.4.2 Sulfidation4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)4.5.2 Corrosion Fatigue4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC)5.1.3.1 High Temperature Hydrogen Attack (HTHA)

API 510 - Authorized Pressure vessel Inspector

1. Pressure vessel inspectors are to be certified as stated in this (Api 510) inspection code.

2. When the ASME Code cannot be followed because of its new construction orientation (new or revised material specifications, inspection requirements, certain heat treatments and pressure tests, and stamping and inspection requirements), the engineer or inspector shall conform to this inspection code rather than to the ASME Code.

3. Authorized pressure vessel inspector: An employee of an authorized inspection agency who is qualified and certified to perform inspections under this inspection code.

4. The owner-users inspection program shall provide the controls that are necessary when contract inspectors are used.

5. Examiner: A person who assists the API authorized pressure vessel inspector by performing specific NDE on pressure vessels but does not evaluate the results of those examinations in accordance with API 510, unless specifically trained and authorized to do so by the owner or user

6. The examiners employer shall maintain certification records of the examiners employed, including dates and results of personnel qualifications and shall make them available to the API authorized pressure vessel inspector.

7. Authorized pressure vessel inspectors shall have education and experience in accordance with Appendix B of this inspection code.

8. OWNER-USER ORGANIZATION RESPONSIBILITIES: Reports to the authorized pressure vessel inspector any process changes that could affect pressure vessel integrity.

9. When inspections, repairs, or alterations are being conducted on pressure vessels, an API authorized pressure vessel inspector shall be responsible to the owner-user for determining that the requirements of API 510 on inspection, examination, and testing are met, and shall be directly involved in the inspection activities.

10. The API authorized pressure vessel inspector may be assisted in performing visual inspections by other properly trained and qualified individuals, who may or may not be certified vessel inspectors11. Personnel performing nondestructive examination shall meet the qualifications identified in 3.18 but need not be API authorized pressure vessel inspectors. However, all examination results must be evaluated and accepted by the API authorized pressure vessel inspector.

12. The thickness measurement procedure shall be approved by the authorized pressure vessel inspector. 13. The authorized pressure vessel inspector should be familiar with the operating conditions of the vessel and with the causes and characteristics of potential defects and deterioration.

14. INSPECTION OF PARTS - list - Authorized pressure vessel inspectors must supplement this list with any additional items necessary for the particular vessel or vessels involved.

15. The inspection, as deemed necessary by the authorized pressure vessel inspector, may include many of a number of nondestructive techniques, including visual inspection. Internal inspection is preferred because process side degradation (corrosion, erosion, and environmental cracking) can be nonuniform throughout the vessel and, therefore, difficult to locate by external NDE.

16. A RBI assessment may be used to establish the appropriate inspection intervals for internal and on-stream inspections, including a potential increase in the 10-year inspection limit described in 6.4, as well as the external interval described in 6.3. When used to increase the 10-year limit, the RBI assessment shall be reviewed and approved by a pressure vessel engineer and authorized pressure vessel inspector at intervals not to exceed 10 years, or more often if warranted by process, equipment, or consequence changes.

17. At the discretion of the authorized pressure vessel inspector, on-stream inspection may be substituted for internal inspection. 18. If an on-stream inspection is conducted, the authorized pressure vessel inspector shall be given sufficient access to all parts of the vessel (heads, shell, and nozzles) so that the inspector is satisfied that an accurate assessment of the vessel condition can be made.

19. Long-term and short-term corrosion rates should be compared as part of the data assessment. The authorized inspector, in consultation with a corrosion specialist, shall select the corrosion rate that best reflects the current process.

20. The determination of corrosion rate may include thickness data collected at more than two different times. Suitable use of short-term versus long-term corrosion rates shall be determined by the authorized pressure vessel inspector.

21. When there is a discrepancy between short-term and long-term corrosion rates, a pressure vessel engineer experienced in corrosion may need to be consulted about the use of these rates, at the discretion of the inspector, for calculating the remaining life and next inspection date.

22. When the authorized pressure vessel inspector believes that a pressure test is necessary or when, after certain repairs or alterations, the inspector believes that one is necessary (see 7.2.9), the test shall be conducted at a pressure in accordance with the construction code used for determining the maximum allowable working pressure.

23. Before any repairs or alterations are performed, all proposed methods of execution, all materials, and all welding procedures that are to be used must be approved by the authorized pressure vessel inspector and, if necessary, by a pressure vessel engineer experienced in pressure vessel design, fabrication, or inspection.

24. All repair and alteration work must be authorized by the authorized pressure vessel inspector before the work is started by a repair organization

25. The authorized pressure vessel inspector will designate the fabrication approvals that are required.

26. The authorized pressure vessel inspector may give prior general authorization for limited or routine repairs as long as the inspector is sure that the repairs are the kind that will not require pressure tests.

27. The authorized pressure vessel inspector shall approve all specified repair and alteration work after an inspection of the work has proven the work to be satisfactory and any required pressure test has been witnessed.

28. No crack shall be repaired without authorization from the authorized pressure vessel inspector.

29. The repair organization shall maintain records of its qualified welding procedures and its welding performance qualifications. These records shall be available to the inspector prior to the start of welding.

30. After the weld is completed, it shall be examined again by either of the above methods to determine that no defects exist using acceptance standards acceptable to the Inspector or code of construction most applicable to the work planned.

31. In situations where it is not practical to perform radiography the accessible surfaces of each non-radiographed repair weld shall be fully examined using the most appropriate nondestructive examination method to determine that no defects exist, and the maximum allowable working pressure and/or allowable temperature shall be reevaluated to the satisfaction of the authorized pressure vessel inspector and jurisdiction at the location of installation.

32. The repair procedure(s) to restore removed, corroded, or missing clad or overlay areas shall be reviewed and endorsed prior to implementation by the pressure vessel engineer and authorized by the inspector.

33. Repairs shall be monitored by an inspector to assure compliance to repair requirements.

34. Temporary repairs using fillet-welded patches shall be approved by the authorized pressure vessel inspector and a pressure vessel engineer competent in pressure vessel design; and the temporary repairs should be removed and replaced with suitable permanent repairs at the next available maintenance opportunity.

35. Temporary repairs may remain in place for a longer period of time only if evaluated, approved, and documented by the pressure vessel engineer and the authorized API pressure vessel inspector.

36. Fillet-welded patches may be applied to the internal or external surfaces of shells, heads, and headers as long as, in the judgment of the authorized pressure vessel inspector.

37. A full encirclement lap band repair may be considered a long term repair if the design is approved, and documented by the pressure vessel engineer and the authorized API pressure vessel inspector.

38. Where use of these nondestructive examination techniques is not possible or practical, alternative nondestructive examination methods may be used provided they are approved by the pressure vessel engineer and the authorized pressure vessel inspector.

39. After repairs are completed, a pressure test shall be applied if the authorized pressure vessel inspector believes that one is necessary.

40. Substituting nondestructive examination procedures for a pressure test after an alteration may be done only after a pressure vessel engineer experienced in pressure vessel design and the authorized pressure vessel inspector have been consulted.

41. For cases where UT is substituted for radiographic inspection, the owner/user shall specify industry-qualified UT shear wave examiners for closure welds that have not been pressure tested and for weld repairs identified by the pressure vessel engineer or authorized inspector.

42. The pressure vessel inspection and rerating is acceptable to the authorized pressure vessel inspector.

43. The pressure vessel rerating will be considered complete when the authorized pressure vessel inspector oversees the attachment of an additional nameplate or additional stamping that carries the following information:Rerated byMaximum Allowable Working Pressure psi at FDateCopyright American Petroleum Institute

44. An API 510 authorized pressure vessel inspector certificate may be issued when an applicant provides documented evidence of passing the National Board of Boiler and Pressure Vessel Inspectors examination and meets all requirements for education and experience of API 510.

45. An API certificate for an authorized pressure vessel inspector is valid for three years from its date of issuance.

46. An API 510 authorized pressure vessel inspector certification s valid in all jurisdictions and any other location that accepts or otherwise does not prohibit the use of API 510.

47. Recertification by written examination will be required for authorized pressure vessel inspectors who have not been actively engaged as authorized pressure vessel inspectors within the most recent 3-year certification period.

48. Once every other recertification period, (every six years) inspectors actively engaged as an authorized pressure vessel inspector shall demonstrate knowledge of revisions to API 510 that were instituted during the previous six years.

API 510 QB

1. Post weld heat treatment of vessel welds generally results in:a. Reduction in hardnessb. Increase of tensile strengthc. Increase of both strength and ductilityd. None of the above

2. A pressure vessel fabricated in 1960 was in service. It has been decided to remove the top head and extend the height and replace the dish head with a new one. The proposal is:a. The proposal can be accepted for review by authorised inspectorb. No modification is allowed on this vesselc. A pressure vessel engineer should be consulted for approvald. None of the above

3. Vessels that are known to have a remaining life of over __________ years or that are protected against external corrosion need not have insulation removed for the periodic external inspection.a. 10b. 15c. 5d. 20

4. After an inspection interval is completed and if calculations indicate that an inaccurate rate of corrosion has been assumed initially, how do you determine the corrosion rate for the next inspection period?a. Check the original calculations to find out what the error is in the original assumption.b. Unless the corrosion rate is changed by Jurisdiction, the initial rates shall be used.c. The corrosion rate shall be adjusted to agree with the actual rate found.d. Call in a corrosion specialist

5. If a vessel is made up of unknown materials and computations must be made to determine the MAWP what can the inspector or the vessel engineer do to establish the MAWP?a. The lowest grade material and highest joint efficiency in the applicable code may be assumed for calculations.b. Assume MOC as SA 283 Gr. C and joint efficiency = 0.7c. The vessel made of the unknown material must be removed from service and vessel of known material must be installed.d. The vessel of unknown material shall be subjected to hydrostatic tests while having strain gages on it to determine its yield strength and thus allowable stress.

6. RBI assessment can be used to alter the inspection strategy provided:a. The degradation methods are identified and evaluatedb. The RBI is fully documented.c. A third party conducts the RBId. Both A and B above

7. The minimum hydro test temperature for in-service vessel of 2 thickness is:a. MDMT+10F b. MDMT+30F c. MDMT+ 0C d. MDMT+ 0C

8. What type of repairs and procedures may the inspector give prior general authorization to continue (provided the inspector is satisfied with the competency of the repair organization)?a. Major repairs and minor proceduresb. Limited or routine repairsc. Major alterations and re-ratingsd. Minor re-ratings and alterations

9. A vessel in service has different zones of corrosion. The next inspection frequency will be decided by:a. Zone with highest rate of corrosionb. Zone with lowest remaining lifec. Average rate of corrosion shall be taken into considerationd. Average remaining life of the vessel shall be considerede. None

10. Inspection records contain the following information for a TML on a dished head. (Thk. in inches) On the basis of this information, the long-term corrosion rate for the location is:

ThicknessYear

0.5000

0.4255

0.40010

a. 1 mils per yearb. 5 mils per yearc. 10 mils per year d. 100 mils per year

11. A certain C. S. vessel which required impact testing was required to have PWHT initially according to code requirement. After 10 years when repaired by welding PWHT is to be carried out. Performing PWHT is found to be impracticable. Which of the following is relevant (as per API-510)?a. PWHT may be exempted, if proper NDE is carried out.b. Carry out temper-bead welding as alternative to PWHT.c. Carry out both hydro-testing and pneumatic testing in lieu of the PWHT.d. Carry out preheating to minimum 200F

12. Materials used for making repair by welding in carbon steel vessels shall have the following limitations?a. They shall meet the requirements stipulated in NACE Standard.b. The carbon content shall not be over 0.35%c. Welding repair shall be done by using only the GTAW processd. All of the above

13. For non-continuous corrosive service with remaining life 25 years, external inspection shall be performed not later than:a. 10 years b. 12.5 years c. 5 years d. None of above

14. An 2: 1 ellipsoidal head has an internal diameter of 76 inches and depth of 21 inches (including a straight face dimension of 2 inches). What should its spherical (crown) radius be?a. 76.9 inchesb. 15.6 inchesc. 68.4 inchesd. All of the above

15. For carrying out temper bead welding technique in lieu of PWHT, apart from other requirements, which of the following is acceptable?a. The root and final pass of weld shall be radiographed. b. Weld metal shall be deposited for second pass while the first pass below the second pass is still not cooled down and its cooling rate is retarded due to the heat of second pass.c. After depositing each layers of the weld, the weld shall be PT checked.d. Both b and c

16. Calculate the remaining life and external insp. interval of a vessel given the following data:

Actual thickness = 0.955 inch Minimum thickness required = 0.759 inch Thickness at previous inspection 5 years prior to present inspection = 1.025 inch

a. 20 years, 10 yearsb. 14 years, 5yearsc. 28 years, 10 yearsd. None of the above

17. As per API 510, the organization who carry out PRV repair, testing has to be:a. Needs to be a certified company to perform all repair work in accordance to ASME.b. Needs to have have documented quality control procedurec. Needs to have qualified personnel to carry out the job within scope of repaird. Only b and c above

18. A vessel which was inspected six years ago and had shell thickness = 0.870. As on today the thickness as reported by filed inspection is 0.786. What was the corrosion rate over last six years?a. 10 mpyb. 12 mpyc. 14 mpyd. none of above

19. If the vessel in above question has minimum permissible thickness = 0.618 for the present design conditions. What will be estimated remaining life of the vessel if corrosion rate remains same?a. 10 years b. 12 years c. 14 yearsd. None of above

20. For a vessel, remaining life is estimated as 22 years from now, next planned internal and external inspection shall not be later than:a. 11 Years, 5 Yearsb. 10 Years, 5 Yearsc. 5 Years, 5 Years d. None of the above

21. Which of the following are commonly preferred to know the process side degradation of pressure vessels?a. On stream inspection.b. Internal inspectionc. External inspection as alternative to internal inspectiond. Any of above is OK

22. While deciding the governing thickness for crown portion for corroded 2:1 ellipsoidal head, API 510 stipulates that & crown thickness shall be calculated:a. According to relevant ellipsoidal dished head formula b. According to code formula for spherical heads with head radius equal to 0.9 D, where D is shell dia meter.c. Thickness of crown shall be same as knuckle thickness. d. None of the above

23. Part MAWP for lower dished head in vertical vessel will generally be:a. Lower than top head b. Lower than shellc. Higher than both shell and top headd. Same as both top head and shell

24. Vessel MAWP is 200 psi. What will be the total pressure at a point 20 feet from top, if vessel is completely filled with liquid (specific gravity = 1).a. 220.00 psi b. 208.66 psic. 204.33 psi d. 191.34 psi

25. The size of a properly deposited equal fillet weld is shown as 10 mm. The throat dimension for this weld will be approximately:a. 10 mm b. 8 mm c. 7 mm d. 9 mm

26. The notch test is better described as:a. Plastic formation and fractureb. Brittle failurec. Energy observed at the notchd. toughness

27. The material not requiring PWHT by code requirement has been heat-treated. The PWHT carried out on this material is most likely due to:a. Due to process requirementb. Because of the materialc. As per authorized inspector requirementd. Because of welding process.

28. For a vertical column, Int. dia. = 48'' and height (T-T) = 80ft, The vessel MAWP is 60 psi. Minimum vessel part MAWP for bottom dished head (2:1 Ellip type) shall be:a. 94.6 psi b. 82.8 psi c. 95.5 psi d. None of above29. The size of a properly deposited equal fillet weld is shown as 10 mm. The throat dimension for this weld will be approximately:a. 10 mm b. 8 mm c. 7 mm d. 9 mm

30. The hydrostatic pressure caused by 10 ft. of liquid column (sp. gr. = 1) will be:a. 10 psi b. 43.3 psi c. 4.33 psi d. None of the above

31. A new pressure vessel should be inspected to which of the following codes?a. API 510 , b. ASME Sec. 1, c. ASME Sec. VIII Div. 1, d. None of these

32. Code rules for testing vessels in service are detailed in:a. API 510 b. API 570 c. ASME Section VIII Div.1 d. None of above

33. Which of the following statements is true? a. All defects are not discontinuities. b. All discontinuities are defects. c. Discontinuities are rejectable defects. d. Defects are rejectable discontinuities.

34. If there is a conflict between ASME VIII & API 510 Code, for vessels in-service:a. ASME will precedentb. API will precedent c. ASNT will precedentd. Owner user will decide

35. The API authorized pressure vessel inspector may give prior authorization for repairs that do not involve:a. Pressure tests b. Radiography c. Pneumatic testing of padsd. Final visual inspections

36. Widely scattered pits may be ignored as long as the following conditions are satisfied:i.Thickness at bottom of pits is greater than one half the vessels required wall thickness ii.The total area of the pits does not exceed 7 square inches (45 square centimeters) within any 8-inch (20-centimeter) diameter circle.iii.The sum of their dimensions along any straight line within the circle does not exceed 2 inches (5 centimeters).iv. ?What is the missing item in iv above?a. The thickness at bottom of pit must be measured by pit gauge. b. The 8diameter is to be measured from the center of the deepest pit. c. There are no missing items; there are only 3 items to be consideredd. The total area of the pits cannot exceed 3.5 square inches in a 4-inch diameter circle.

37. Before any repair to a pressure vessel in accordance with its code of construction, what if any additional requirements (over and above those in API 510) may need to be considered?a. Jurisdictional requirements that might override the API 510 Code. b. Is repair being done by repair organisation? c. The quality of the repair materials. d. The need for qualified welding procedures.

38. A new vessel has been installed, what must be done in order to accept the vessel for operation?a. A first internal inspectionb. A first internal inspection, however if a manufacturers data report (U1) assuring that the vessel is satisfactory for its intended service is available the first internal inspection may be waived. c. Base line thickness readings must be taken per OSHA 1920 (j). d. Base line thickness reading must be taken per OSHA 1910 (j). 39. Temper embrittlement is best described as:a. Cracking due to operating at high temperatures above 700Fb. Loss of ductility and notch toughness due to exposure above 700Fc. Flaking of the metal surfaces, causing dip pits d. Cracking due to low temperature service

40. Which of the following are essential elements of a Quality control system of a repair organization?a. Statement of authority and responsibilityb. Welding procedures used for repair/alterationsc. The Control of procedures and Qualifications of NDE personnel d. All of the above

41. A repair work on a pressure vessel is to be carried out. Who is responsible to have WPS/PQR made for the repair work?a. Owner user b. Repair organizationc. Authorized inspector d. Third party who does the inspection work

42. Before entering into a vessel for inspection the vessel shall be evaluated for safety in accordance to:a. OSHA b. API c. ASME/API d. ANSI

43. The __________ shall be responsible to the owner-user for determining that the requirements of API 510 for inspection, and testing are met.a. Vessel engineerb. Authorised inspectorc. Repair organisationd. Operating personnel

44. A pressure vessel of 60 ID has three pits within a circle of 7 diameter. The nominal thickness of the shell is 0.75 and the CA is 0.15. The details and dimensions of the pits are listed below. Your assessment is:Pit 1:0.5 dia depth 0.28Pit 2: 0.8 dia depth 0.22Pit 3: 0.4 x 0.5, depth 0.23a. The pit area is more than the acceptableb. The pit length is more than the acceptablec. The pit depth is more than the acceptabled. The pits are acceptable as they are meeting the requirement

45. Insulation inspection on an insulated vessel with no damage to insulation shall be done by:a. Removing at least 10% of insulation to check the conditionb. Removing insulation on at least 25% areac. Removing the entire insulation d. Not required to remove insulation

46. Vessel MAWP of existing vessel will be affected: a. If higher corrosion allowance is provided from existing vessel thicknessb. If design pressure is reduced (other factors remaining same)c. If design temperature is changedd. (a) and (c)

47. The Code formula for a torispherical head thickness as per ASME Section VIII Div. 1 actually gives the thickness required:a. At crown portionb. At knuckle portionc. Mean of (a) and (b)d. Lower of (a) and (b)

48. Original construction code of a pressure vessel is ASME Sec. VIII, Div.1. The vessel has corrosion problems and is being evaluated according to ASME Sec. VIII Div. 2. Who should approve the evaluation based on Sec. VIII, Div. 2?a. Pressure vessel engineer/organization who is experienced in designb. An authorized inspector c. A pressure vessel engineer/organization who is experienced in design and authorized pressure vessel inspectord. Only the owner-user49. The factors of LOF and COF are considered for which methodological evaluation?a. FFS b. RBI c. API 510 d. ASME Sec. VIII Div. 1 and API 510

50. Where can fatigue cracking typically be first detected?a. At points of low-stress intensification such as reinforced nozzlesb. At points of high-stress intensification such as branch connectionsc. At points where cyclic stresses are very lowd. At points where there are only the primary stresses

51. For a new vessel the corrosion rate will be established based on:a. Run the vessel for 6 weeks and establish the corrosion rateb. Run the vessel for 12 weeks and establish the corrosion ratec. Run the vessel for 18 weeks and establish the corrosion rated. A corrosion engineer should be consulted for establishing corrosion rate52. A pressure vessel internal inspection frequency can be increased more than 10 years provided RBI evaluation is carried out. It should be approved by?a. Owner user/Jurisdictionb. Pressure vessel engineer c. Authorized inspector d. Pressure vessel engineer & authorized inspector

53. Identify incorrect statement.a. ASME Sec. VIII, Div. 1 may be adopted for unfired steam boilersb. ASME Sec. VIII, Div. 1 may be adopted for vessels containing lethal fluidsc. ASME Sec. VIII, Div. 1 may be used for design of mobile vesseld. ASME Sec. VIII, Div. 1 may be used for design of pump casings

54. Typical mode of failure in ferrous metals at low temperatures is:a. Ductile failureb. Creep failurec. Fatigue failured. Brittle failure

55. Which of the following is typical phenomenon in low-alloy chromium steels?a. Creep failureb. Temper embrittlementc. Caustic embrittlement d. Stress corrosion cracking

56. The term away from weld for recalculating the required thickness (Vessels with E

9) api 510 day 1

Documents

asme material

procedure test

asme section

size of discontinuity

vessel engineerb

new vessel

asme code stamping

circumferential welds