API 510 Exam B (150 Q&A)

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

1. During inspection of a vertical pressure vessel with an inside diameter of 90 in. (2.25 meters), a generally corroded area (360° around the vessel ID and 40 inches in height) was found in a shell course indicating liquid line corrosion. Remaining wall thickness can be determined by: A) Only by performing UT thickness on the area of the deepest pit & measuring remaining wall B) Averaging remaining wall thickness at equally spaced readings over a length “L” = to 20 in. C) Averaging remaining wall thickness at equally spaced readings over a length “L” = to 30 in. D) Averaging remaining wall thickness at equally spaced readings over a length “L” = to 40 in. Answer: C (API 510, Para. 7.4.2.1)  L = the lesser of 40 in. or 1/3 Vessel Diameter (30 in.) 2. A horizontal vessel having a U Stamp & constructed in 1991 must now undergo a hydrostatic test after an alteration. What is required test pressure at the top of the vessel? Given: Original (1991) Vessel U stamp reads MAWP: 1000 psi @ 500°F … The S design temp = 15 ksi and S test temp = 16.3 ksi … A) 1630 psi psi

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

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

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 @ 350°F, 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 vessel’s 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)

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

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)  ½ 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 ½ 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. Page | 3

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

7. On April 1, 2011, the remaining life of a vessel was been determined to be exactly 3 years. What is the latest possible date allowed by the code to perform a next Internal or OSI inspection and to also perform the next external inspection? A) Next Internal or OSI AND external inspection interval = 1.5 years, due on October 1, 2012 B) Next Internal or OSI AND external inspection interval = 2 years, due on April 1, 2013 C) Next Internal or OSI AND external inspection interval = 3 years, due on April 1, 2014 D) None of these is correct. External inspection will be required before an internal/OSI. Answer: B (API 510, Para. 6.5.1.1 & 6.4.1) Solution: RL = 3 years  Apply RL less than 4 years rule in 6.5.1.1  Maximum = 2 years External inspection will be 5 years or the internal/OSI interval whichever is less Solution: We must inspect no later than 2 yrs for both Internal/OSI & External Inspection 6.5.1.1 When remaining life is less than 4 years, inspection interval may be full remaining life up to a maximum of two years  The ½ RL rule does not apply here!!! 6.4.1 Unless justified by an RBI assessment, each aboveground vessel shall be given a visual external inspection at an interval that does not exceed the lesser of five years or the required internal/on-stream inspection. It is preferred to perform this inspection while the vessel is in operation.  Per most inspection plans, do externals just before shutdowns! 8. A new vessel is brought in to replace an old vessel being retired from a hydrocarbon service after 35 years. Service will be changed (new type of chemical to be injected into process as a trial with no similar service data published). Service was never handled before by the owner/user. New vessel’s probable corrosion rate is best determined by: A) Take baseline & 1,000 hour service UT thickness measurements & follow-up UT thereafter B) Corrosion rates may be estimated owner/user’s experience (old records) or similar service C) Corrosion rates may be estimated from any published data regarding sour crudes D) None of these is correct Answer: A (API 510, Para. 7.1.2)  Read question well  No alternatives except UT

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

9. Regarding the question above, if it is later determined that an inaccurate corrosion rate was assumed, what must be done regarding the corrosion rate for RL calculations? A) Make subsequent determinations at appropriate intervals until an accurate rate is established B) Consult the corrosion specialist to determine which rate to apply, ST or LT Corrosion rate C) Corrosion rate in the remaining life calcs shall be changed to the actual corrosion rate D) Nothing because the corrosion rate will be likely to keep changing again and again Answer: C (API 510, Para. 7.1.2)  Read the last paragraph (sentence) in the section 10. What is MDMT & Charpy Impact test temp required for a 5 mm or ½ sized test specimen? (Assume SA-516 Gr. 70 plate (2.25 in.) quenched and tempered & now is requiring Impact Test) A) 0°F & -20°F

B) 30°F & 10°F

C) 67°F & 47°F

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) = 0°F  Now go to Pg 69 Table & a 5 mm specimen is a ½ - sized so there is “20°F” reduction from 0°F or -20°F  Answer = A

… 11. Using Fig. UW-16.1 (a), determine value for tc … Assume t = 38 mm & tn = 22 mm! A) 6 mm

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B) 13 mm

NAME/BADGE #: __________________________________________________ Date: ____________ C) 19 mm

API 510 PRACTICE EXAM B (150 QUESTIONS) D) 22 mm

Answer: A (ASME Section VIII, Div. 1, UW-16.b Symbols & See the Legend & See Figure)

Solve for tmin = 19 mm or 22 mm (lesser = 19mm) … 0.7 x t min or 19 mm = 13.3 mm Solve for tc = lesser of tmin or 13.3 mm or 6 mm = 6 mm 12. Regarding a 2:1 ellipsoidal head, which is code acceptable approximation value for the knuckle radius and the spherical radius? A) An acceptable approximation is a knuckle radius of 0.356D and a spherical radius of 0.665D B) An acceptable approximation is a knuckle radius of 0.90D and a spherical radius of 0.885D C) An acceptable approximation is a knuckle radius of 0.885D and a spherical radius of 0.17D D) An acceptable approximation is a knuckle radius of 0.17D and a spherical radius of 0.90D Answer: D (UG-32 d … Read the last sentence underneath the formula 1) 13. Which statement is false regarding joint efficiencies for calculations that involve circumferential stress in seamless vessel sections or for thickness of seamless heads? A) E = 1.0 when the spot radiography requirements of UW-11(a)(5)(c) is met B) E = 1.0 when the spot radiography requirements of UW-11(a)(5)(b) is met C) E = 0.85 when the spot radiography requirements of UW-11(a) (5) (b) are not met D) E = 0.85 if Cat. A or B welds to seamless vessel sections or heads are Type No. 3, 4, 5 or 6 Answer: A … UW-12 (d) & (e) & Table UW-12 14. Given a vessel with .500 in. seamless ellipsoidal heads and a 24 inch OD seamless piping shell (.375 in. wall), attached by RT Type 1 Category A Butt Joints (Lethal Service), Corrosion Allowance = .125 inches, Design Pressure is 600 psi at 300° F, and the material stress values are given as … S = 20 ksi for head and S = 19.7 ksi for shell Determine E & required minimum “t” for 2:1 ellipsoidal heads show your calculations! A) E = 1, and required head t = 0.328 in. B) E = 1, and required head t = 0.350 in. Page | 6

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

C) E = 0.85 & required head t = 0.368 in. D) E = 1, and required head t = 0.390 in.

Answer: B (UG-32 formula for ellipsoidal heads) … See also App L examples for practice

Formula to use to determine minimum ellipsoidal head thickness Step 1: Determine PD = 600 psi x 23.250 in.* …*24 in OD = outside Diameter. Head thickness .500 in. – CA .125 in. = .375 in. So, 24 minus (2)(.375 in) = 23.250 in. = D Step 2: Determine SE … S = 20 ksi, E = “1” because we see UW-3 illustration (always check) = Category A. Next we use Table UW-12, Type 1, where E = 1.00, so use 1 as the value for E Step 3: PD = 600 x 23.250 = 13,950, SE = 2 (20,000) (1) - 0.2 (600) = 40,000 – 120 = 39,880 Final solution is 13,950 ÷ 39,880 = 0.3497 or .350 inches (always use 3 decimals) For a vessel calculation, the following is given for questions 15 & 16 (see the next page): Heads: 2:1 ellipsoidal heads (.875 in. nominal). Shell: 30 in. OD (.750 inches) with Longitudinally Welded Type 1 Category A joint (No RT). The shell and heads are attached by a Type 1 Category A Butt Joint (again, No RT) Corrosion allowance = .125 inches! Design Pressure/Temp = 400 psi at 200°F Head Material = S = 20 ksi. Shell Material = S = 20.4 ksi. 15. Determine value E & required minimum ellipsoidal head thickness. Show your calcs! A) E = .70, required head t = 0.286 inches inches C) E = .85, required head t = 0.336 inches inches

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B) E = .70, required head t = 0.347 D) E = .70, required head t = 0.408

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

Answer: D (UG-32d & formula 1) … No RT =.70 per Table UW-12 … See L.1.5.1.c example

Formula to use to determine minimum 2:1 ellipsoidal head thickness Step 1 … PD = 400 x 28.5* = 11,400. Note: D = 30.0 - 2 x (.875 -.125) or 30 1.5 = 28.5 Step 2 … SE = 2 (20,000) (.70) minus 0.2 (400) = (28,000 – 80) = 27,920 Step 3 … Final math solution = 11,400 ÷ 27,920 = .4083 = .408 inches 16. Use same given information as question # 15 on the previous page. Determine value E & required minimum shell thickness assuming “circumferential stress” as the basis for the calculation & show your work! A) E = .70, and required t = 0.286 inches 0.336 inches C) E = .70, and required t = 0.347 inches 0.409 inches

B) E = .85, and required t = D) E = .70, and required t =

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 = 1100°F and minimum holding time = 2 hours total B) Normal Holding Temp = 1100°F and minimum holding time = 2 hours & 4 minutes C) Normal Holding Temp = 1100°F and minimum holding time = 2 hours & 15 minutes D) Normal Holding Temp = 1100°F and minimum holding time = 2 hours & 45 minutes Answer: A … Table UCS-56 for P-No 1 Materials

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

See question 18 below for static head calcs! 18. A vessel 80 feet high is filled with H²O under pressure. At the lowest part of vessel, 80 feet from top, it reads 455 psi at a calibrated gauge. What will be pressure values be at 54 feet from the top, at 32 feet from the top, at 4 feet from the top, and lastly, at the very top? A) 54 ft from top the top = 410 psi B) 54 ft from top the top = 420 psi C) 54 ft from top the top = 490 psi D) 54 ft from top the top = 490 psi

= 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 H²O = 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

Answer: A … Figure UW-3 & UW-3d, Note 2 20. Regarding Carbon and Low alloy steel Long Weld Neck flanges, no impact testing is required when used at Minimum Design Metal Temperatures not colder than: A) -40°F (-40°C)

B) −20°F (−29°C) C) 32°F (0°C)

D) None of these

Answer: B … UCS-66 (c) (4) … same applies for B16.5 flanges … Top left column, pg 183

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

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

Assume all f & fr values = 1 23. Using illustration above and Figure UG-37.1, what is the total area required (A value) for a reinforced nozzle, given a shell opening of 13.00 in. (value d) with a shell required thickness of 1 inch (value tr) & what is the Dp value (repad OD) to be used in any calcs? A) A = 1.1 inches & Dp = 17.75 inches C) A = 1.5 inches & Dp = 19.38 inches

B) A = 1.3 inches & Dp = 18.75 inches D) None of these is correct

Answer: D … Fig. UG-37.1 & Legend = A = dtr (shortcut formula) = 13.00 x 1.00 = 13.00 in. Dp = 12.750 + 3 + 3 = 18.750 inches = OD of Nozzle + 2 (repad value of 3 inches shown) Solution: Answer = D because … A = 13.0 inches and value Dp = 18.75 in. (repad O.D.)

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

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

D) 2.0 – 4.0 for

Answer: A (ASME V, Art. 2, T-282.2) Apply the Density variation rule of -15% to +30% 2.4 x 85% or .85 (-15% rule) = 2.04 = 2.0 … 2.4 x 130% or 1.3 (+30% rule) = 3.12 = 3.1 26. What is the minimum penetrant dwell time when performing a PT examination on vessel weld (Plate material = A516 Grade 70) at a temperature of 45°F? A) 5 minutes None of these

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!!!

27. Inspector measured undercut on a girth weld (No PWHT required) and it was found to be 1/32 in. (1mm) in depth. Shell material is .360 inches thick (9mm). Inspector shall: A) Accept the weld because undercut is within ASME Section VIII, Div. I code allowed tolerance B) Reject the weld because undercut will affect RTFI interpretation & request surface grinding Page | 11

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) C) Accept the weld, as 1mm undercut is allowed on non-PWHT’d welds per ASME VIII, Div 1. D) Reject the weld because it exceeds the ASME Section VIII, Div. I code allowed tolerance Answer: D (ASME VIII, Div 1, UW-35.b.2) … 1mm or 10%, whichever is less  0.9 mm allowed) 28. If radiographic exam is used for qualification of a welder or welding operator, the minimum length of coupon to be examined is any of the following items EXCEPT: A) The entire weld circumference for pipe coupons (Typically Size 2 NPS & Size 8 NPS used) B) The entire circumference for their first three production joints (ASME B31.3 Case) C) 3 feet (0.91 meters) for welding operators (ASME IX Rule) D) 6 inches (152.4 mm) minimum in any case (ASME IX Rule) Answer: B … Ref: API 577, Section 8.2  Welder Qualification  WPQ

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 @ 350°F, 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 vessel’s 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

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

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

7.3.3 In corrosive service, the wall thickness used in these computations shall be the actual thickness as determined by inspection (see 5.6.2) minus twice the estimated corrosion loss before the date of the next inspection, as defined by: t = tactual – 2 (Crate x Iinternal)

… API 510, Para. 7.3.3 = .860 – 2 (.0046 x 10) =

.768 Correct is … 16,000 (1) (.768) = 12,288 ÷ (82 + .461) or 82.461 = 149 psi < 150, so not OK

30. In lieu of insulation removal for a vessel, what alternative is given in API 510? A) Inspector may use similar service results from another similar vessel at owner/user’s location B) Shell thickness measurements taken internally (during int. insp.) at typical CUI problem areas C) Use of special “removable & replaceable” type insulation is a preferred method of 510 code D) None of these is correct per API 510 Answer = B … Ref: API 510, Par. 5.5.6.3  CUI Inspection! 31. What is the minimum shell temperature to be maintained during a hydrostatic test after a major repair if a pressure vessel shell is 1.75 inches thick? Page | 13

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) o o A) 30 F (17 C) above the material MDMT B) 30o F (17oC) above ambient metal temp C) 10o F (6oC) above the material MDMT D) 10o F (6oC) above ambient metal temp Answer: C … (API 510 Section/Para. 5.8.6.2 … Be aware of 2 in & less rule = +10o F only) Note: There is a conflict between ASME VIII, Div 1 Section UG-98 (30o F above MDMT for all) 32. For a pressure vessel in non-continuous service (operates only 4 months in every year & placed under a nitrogen purge each time after being idled), what are the maximum possible internal & external inspection intervals (assume NO RBI)? A) Internal inspection interval = 10 calendar yrs & external inspection interval = 10 calendar yrs B) Internal inspection interval = 15 calendar yrs & external inspection interval = 10 calendar yrs C) Internal inspection interval = 20 calendar yrs & external inspection interval = 5 calendar yrs D) Internal inspection interval = 30 calendar yrs & external inspection interval = 5 calendar yrs Ans: C (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.2)  Reason: In this case, 30 calendar years of operation is equal to 10 actual operation years! External interval ALWAYS = 5 years 33. Regarding Fitness for Service Analysis of Corroded areas in heads (assume an ellipsoidal head is corroded in the knuckle region), the thickness required can be determined by using the ASME Section VIII, Div. 1 Construction Code formula for: A) Ellipsoidal head thickness only B) Torispherical head thickness C) Hemispherical head thickness and you must also use the API 510 Table D) None of these are correct Answer: B (API 510, Par. 7.4.6.1) FFS Analysis of Corroded Regions … Corroded Areas in Heads The formula for Hemispherical head thickness would be used for corrosion in radiused region Page | 14

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 34. When installing a fillet-welded patch adjacent to an existing fillet-welded patch, the distance between the toes of the fillet weld shall not be less than: A) 4 x the square root of (vessel inside radius x actual vessel wall thickness under the patch) B) 2 x the square root of (vessel inside radius x actual vessel wall thickness under the patch) C) 2 x the square root of (vessel inside radius x nominal vessel wall thickness under the patch) D) 4 x the square root of (vessel inside radius x nominal vessel wall thickness under the patch) Answer: A … (API 510, Para. 8.1.5.1.2.3) Temporary Repair Rules … Lap Patch Spacing Rules 35. Assuming no RBI and the Internal Inspection Interval has been set at 4 years, what is the maximum external inspection interval allowed per API 510 rules? A) Five (5) years is the maximum inspection interval allowed B) Four (4) years is the maximum inspection interval allowed C) Two (2) years is the maximum inspection interval allowed D) None of these is correct per API 510 rules Answer: B (API 510, External Inspection Rules, Para. 6.4.1)  5 years or the Internal/OSI interval, use the lesser) 36. Assuming no RBI assessment, the period between internal or onstream inspections: A) Shall not exceed 10 years or one half the remaining life of the vessel, whichever is greater B) Shall not exceed 10 years or one half the remaining life of the vessel, whichever is lesser C) Shall not exceed 10 years or the remaining life of the vessel, whichever is the greater D) Shall not exceed 10 years or the remaining life of the vessel, whichever is the lesser Answer: B (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1) 37. Regarding evaluation of corroded regions and joint efficiency adjustments for areas near corroded welds, when the vessel surface Page | 15

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) AWAY FROM A WELD is corroded & joint efficiency is less than 1.0, an independent calc using an appropriate weld joint factor (typically = 1.0) can be made. For this calculation, the surface at a weld includes (what distance)? A) 1 inch on either side of a weld (measured from toe) regardless of thickness B) 2 inches on either side of a weld (measured from toe) regardless of thickness C) 1 inch (OR 2 x t required) on either side of a weld (measured from toe), use greater value D) 2 inches (OR 2 x t required) on either side of a weld (measured from toe), use greater value Ans: C (API 510, Par. 7.4.5) FFS Analysis of Corroded Regions … Joint Efficiency Adjustments 38. For a pressure vessel constructed in 1950 having no nameplate and minimal design and construction documentation, which of the following is a correct action to be taken for calcs? A) Use allowable stress values of the 1999 Addenda (based on current design factors) B) Use allowable stress values from Code Case 2290 (based on current design factors) C) Use allowable stress values of the current ASME Code (based on design factor of 3.5) D) None of these is the correct action to take Ans: D … (510, Par. 7.7) Evaluation of existing Equip (Minimal documentation)  Must know! 39. Assuming no RBI, a maximum internal inspection interval using the MAWP method is: A) Determined by MAWP calcs C) 15 yrs

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 ½ of the vessel’s 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

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer: B (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1) 41. When PWHT is performed for environmental-assisted cracking resistance, LOCAL PWHT MAY be substituted for 360-degree banding on local repairs on all materials, provided that: A) Local PWHT may NEVER be substituted for 360° banding to prevent environmental cracking B) Local PWHT temp is maintained for a distance not less than 2 x base metal t (from weld toe) C) A preheat of 300°F (150°C) or higher, as specified in the WPS, is maintained during welding D) A metallurgical review shall be conducted to assess whether the procedure is acceptable Answer: D … (API 510, Para. 8.1.6.4.1) Welding & Hot Tapping PWHT Rules for Weld Repairs 42. If vessel entry is physically possible, on-stream inspection may possibly be substituted for internal inspection if approved by Inspector & the vessel is not subject to: A) Chloride Stress Corrosion cracking or Creep stress rupture damage from the service B) Stress Corrosion cracking or high temperature oxidation damage from the service C) Damage Mechanisms requiring the Inspector to consult the Corrosion Specialist D) Environmental cracking or hydrogen damage from the fluid being handled Ans: D (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.6)  Phys. Poss. Environmental Cracking & Hydrogen Damage Rules … API 571, 4.5.1, 4.5.2, 4.5.3, 5.1.2.3, & 5.1.3.1  5 DMs! 43. Assuming no RBI, If vessel entry is physically possible & all of the seven conditions allowing an on-stream inspection to be done in lieu of an internal inspection were not met, what must the Inspector do regarding scheduling of the next inspection to be performed? A) Next inspection shall be internal C) Next inspection shall be On-Stream Stream

B) Next inspection may be internal D) Next inspection may be On-

Answer: A (510, Int. & OSI (Insp.), Par. 6.5.2.2)  Physically Possible  7 Rules to allow OSI!

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 44. If a RBI assessment is not performed, what is the greatest possible time period allowed by API 510 between testing of pressure relieving devices? A) 5 years (for all services) B) 10 years (for non corrosive services) C) At intervals often enough to verify reliability D) None of these is correct because the quality assurance manual must be followed Ans: B … (510, 6.6.2.2 … PZV Rules for Insp … Intervals = Five yrs & 10 yrs – 2 Rules to KNOW) 45. When calculating corrosion rates using API 510 formulas, which of the following statements is FALSE regarding the value for t initial? A) t initial = the initial thickness at the same CML as t actual (for any given CML in inches or mm) B) t initial = the initial thickness at a different CML from the one determining the lowest t actual C) t initial may a first thickness measurement taken (new vessel) at a given CML (inches or mm) D) t initial may be the thickness at the start of a new corrosion rate environment at a given CML Answer: B (API 510, Para. 7.1.1.1) Corrosion Rate Determination Rules 46. LT & ST Corrosion Rates should be compared (data assessment). When a significant difference exists between the two rates, WHO selects which rate is to be used and WHY? A) Inspector alone selects a rate that best reflects current conditions B) Corrosion Specialist alone selects a rate that best reflects current conditions C) Inspector (consults Engineer) & selects a rate that best reflects current conditions D) Inspector (consults corrosion specialist) & selects a rate that best reflects current conditions Answer: D (API 510, Para. 7.1.1.2) Corrosion Rate Determination Rules 47. For a pressure vessel with .425 inch nominal hemispherical heads (head segment welds are RT Type 1 butt joints) and 24 inch OD seamless pipe shell (.500 in. nom. wall) attached by RT Type 1 Category A Butt Joints

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS)

(Lethal Service), Corrosion Allowance = .125 inches, Design Pressure is 600 psi at 300°F. S = 20 ksi for heads & 19.7 ksi for shell Determine value E & required minimum hemispherical head “t” and show your calcs! A) E = 1, and required head t = 0.166 in. in. C) E = .85 & required head t = 0.186 in. in.

B) E = 1, and required head t = 0.176 D) E = 1, and required head t = 0.196

Answer: B (UG-32. f, formula 3) … See also Appendix L-1.5.1(d) example for practice

Formula to use to determine minimum hemispherical head thickness Step 1: Determine PL or PR = 600 psi x 11.7 in.* …*24 in OD = 12 in outside spherical radius. Note: Appendix L uses PR (typo error) … L is the same as R, they want the inside radius! Head thickness .425 in. minus CA .125 in. = .300 in. So, 12 minus .300 in = 11.7 in. = L Step 2: Determine SE … S = 20 ksi, E = “1” because we see UW-3 illustration (always check) = Category A. Next we use Table UW-12, Type 1, where E = 1.00, so use 1 as the value for E Step 3: PL or PR = 600 x 11.7 = 7020, SE = 2 (20,000) (1) - 0.2 (600) = 40,000 – 120 = 39,880 Final solution is 7020 ÷ 39,880 = 0.17603 = 0.176 inches (or 176 mils, always use 3 decimals)

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

Answer = A … Ref: UG-80 (a) (1) 49. What is the maximum length of a rounded indication when spot radiography has been specified for a given pressure vessel as per ASME Section VIII, Division 1? A) Per the approved RT procedure C) 12 mm Page | 19

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) 6 mm D) None of these are correct Ans: D (ASME VIII, Div I, UW-52.c.3  Rounded indications are not a factor  No limit Spot Radiography Rules  UW-52 (c) Standards for Spot Radiographic Examination. Spot examination by radiography shall be made in accordance with the technique prescribed in UW-51(a). The minimum length of spot radiograph shall be 6 in. Spot radiographs may be retained or be discarded by the Manufacturer after acceptance of the vessel by the Inspector. Acceptability of welds examined by spot radiography shall be judged by the following standards: (3) Rounded indications are not a factor in the acceptability of welds not required to be fully radiographed. 50. Welder ABC has welded a performance test coupon ¾ inch thick in the 6G position. Welder DEF has welded performance test coupons ¾ inch thick in 2G & 5G combination. Which statement below is true regarding the number and type of test specimens required for each of these welders to pass their qualification tests? A) Welder ABC must pass 2 side bend tests & Welder DEF must pass 4 side bend tests B) Welder ABC must pass 4 side bend tests & Welder DEF must pass 8 side bend tests C) Welder ABC must pass 6 side bend tests & Welder DEF must pass 12 side bend tests D) None of these are correct Ans: D (ASME IX Table QW-452.1.a & 3 Notes) API 577, Section 8 Table QW-452.1a) See Note 1 – ABC must pass 4 side bend tests & Welder DEF must pass 6 side bend tests

END OF API 510 OPEN BOOK EXAM B TAKE A BREAK & BEGIN CLOSED BOOK EXAM QUESTIONS (100)  3 HOURS CLOSED BOOK EXAM (100 Questions in 3 hours) 51. Who is responsible to the owner/user to assure that the NDE, inspection, and pressure testing activities meet API 510 requirements? A) Authorized Pressure Vessel Inspector B) Authorized Inspection Agency C) Examiner and his employer D) None of these are correct Answer = A … Ref: API 510, Para. 4.2.4  Inspector responsibilities Page | 20

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 52. Which of these should be considered an alteration to a pressure vessel per API 510? A) Any comparable or duplicate replacement due to severe corrosion or other reasons B) Addition of any reinforced nozzle greater than the size of existing reinforced nozzles C) Addition of small bore nozzles or welded couplings that do not require reinforcement D) Adding a reinforced nozzle (12 NPS or greater) equal to a size of existing reinforced nozzles Answer = B … Reference: API 510, Section 3.2 (Definition of an Alteration) 53. Per API 510, a “non-standard vessel” is one that was: A) Not fabricated to recognized construction codes & meeting no known recognized standards B) Not constructed & approved as jurisdictional special based on jurisdiction acceptance rules C) Fabricated to a recognized construction code but has lost its nameplate or stamping D) Not constructed in accordance with an applicable construction code Answer = C … Reference: API 510, Para. 1.1.1.d  Non-Standard vessel missing a nameplate 54. Designated areas on pressure vessels where periodic exams are conducted are called: A) Thickness measurement points

B) Examination points

C) Inspection points

D) None of these are correct

Answer = D … Ref: API 510, Section 3.9 (Definition of Condition Monitoring Locations or CMLs) 55. All NDE results must be evaluated and accepted by the: A) Certified welding inspectors and NDE technicians doing the examinations B) NDE technicians doing the work in assistance to the inspector C) Examiners doing the work in assistance to the inspector D) None of these is correct Answer = D … Ref: API 510, Para. 4.2.4  Inspector responsibilities Page | 21

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 56. Per API 510, all on-stream inspections should be conducted by: A) An Inspector only B) Either an inspector or examiner C) An inspector approved Examiner D) An owner/user approved and trained examiner Answer = B … Ref: API 510, Para. 5.5.3.1  On-Stream Inspection 57. Pressure tests are normally required: A) After an alteration B) After temporary repairs C) After most routine repairs D) At the discretion of the Inspector Answer: A (API 510, Para. 5.8.1.1) 58. For a SMAW welding electrode marked E-7018, the meaning of the number 1 and the meaning of the number 8 respectively in 7018 is: A) 1 = certified as moisture free (low hydrogen) and 8 = coating operating characteristics B) 1 = certified as moisture free (low hydrogen) and 8 = coating chemical composition C) 1 = position of welding recommended and 8 = coating operating characteristics D) 1 = position of welding recommended and 8 = coating chemical composition Answer: C (API 577, Appendix A & Figure A-7) 59. The principal reason for inspecting a pressure relief device is to: A) Determine if it is functioning properly (so it can provide protection to equipment/personnel) B) Prevent fouling and plugging from occurring that could render a valve inoperable C) Assure equipment (pressure vessel) safety by preventing over pressurization D) Assure personnel and equipment safety in a process plant Answer: A (API 510, Par. 6.6 & 6.6.2.1 & API 576  Ch. 6, Para. 6.1.1) API website Sample Q

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 60. To be considered valid by an Inspector, PQRs must be certified by: A) Mechanical tests per ASME IX B) Approved Test Lab Signature & date C) A corresponding and supporting WPS D) The owner user inspection organization Answer: B … (API 510 Body of Knowledge Part 2 (Notes) 2013 exams Must know 61. Which of the following is considered a physical property of a metal? A) Ductility C) Density

B) Hardness D) Toughness

Answer: C … (API 577, 10.3, 2nd Para)  Physical properties can be measured without force … Melting temp, thermal/electrical conductivity, coefficient of thermal expansion & density … Inspectors should know 4 mechanical properties (strength/ductility/toughness/hardness) 62. A relief valve has been shipped lying down on its side. This is a problem because: A) Flange faces may be damaged during shipment B) Springs may slip out and be lost during shipment C) Relief valves are often heavy and are sometimes difficult to upright D) Springs inside may shift and distort and as a result not exert the same force on stems & seats Answer: D … (API 576, 5.8.2.2, 1st Para)  Ship/store UPRIGHT  Affects spring seating force 63. After removing an exchanger bundle, CS tubes showing a blue color are likely indicating: A) Alkaline residues and likely resulting in cracking in the discolored tubes B) Acidic corrosion and likely resulting in cracking in the discolored tubes C) Ferri-ferrocyanide and likely resulting in blistering in discolored tubes D) None of these are correct Answer: D … (API 572, Appendix A.9.2 last Para)  Presence of Ferriferrocyanide is indicated Page | 23

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) but the Inspector should look for blisters on the shell ID, not on the discolored tubes 64. Susceptibility of an alloy to Sulfidation is determined by its ability to: A) Form protective layers of magnetite on internal surfaces B) Form protective sulfide scales on internal surfaces C) Prevent carburization of internal surface layers D) None of these are correct Answer: B … (API 571, Sect. 4.4.2.3.b)  Sulfidation is DM # 1 on API 571 list … Critical Factors 65. The rerating of a vessel requires that: A) Calcs are from a vessel manufacturer or owner-user engineer experienced in pressure vessels B) Inspection records verify vessel has been in the proposed service previously & CA is adequate C) Vessel shall be pressure tested using applicable testing formulas from a code used in rerating D) Rerating (all calcs) meet latest edition of ASME code or any applicable construction code Answer: A … Ref: API 510, Section 8.2.1.a/b/c  4 rules SHALL BE MET for rerating

66. What does this welding symbol designate? A) Weld all around (in field) C) Plug weld (in field)

B) Weld Spot weld (in field) D) Weld all around

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

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer: C … Ref: API 572 Sect 9.4.4.2 & 9.3.14 & Figure 17  WFMPT is most sensitive for CS 68. Inspectors may be assisted in performing inspections by other properly trained and qualified individuals who are not inspectors. These are called: A) Certified welding inspectors and NDE technicians B) Operating Personnel and NDE technicians C) Examiners and Operating personnel D) Examiners only are allowed Answer = C … Ref: API 510, Para. 4.2.4 & 4.2.6  Inspector responsibilities 69. API 510 recognizes risk-based-inspection concepts for: A) Evaluating in-service damage using API 510 rules only B) Evaluating in-service damage using API 579 rules C) Evaluating in-service damage using API 580 rules D) None of these are correct Answer = D … Reference: 510, Para. 1.3  API 580 is used to determine inspection intervals! 70. What documents cover NDT requirements for examiner qualification and certification? A) CP-189 Standard & Practice SNT-TC-1A B) ASNT Practice SNT-TC-1A & ASME Section V Code rules C) CP-189 Standard & ASME Section V Code rules D) API 510 rules & CP-189 Standard & Practice SNT-TC-1A & ASME Section V Code rules Answer = A … Reference: 510, Section 2 71. Any welding technique used to obtain controlled grain refinement and tempering of the underlying heat affected zone (HAZ) in the base metal is called: A) Controlled-deposition welding B) Temper-bead welding C) Half-bead welding D) None of these

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = A … Ref: API 510, Section 3.11 (Definition of ControlledDeposition Welding) 72. A point in the repair or alteration process beyond which work may not proceed until the required inspection or NDE has been performed and documented is called a(n): A) Hold Point C) Inspection Point

B) Witness Point D) Examination Point

Answer = A … Ref: API 510, Section 3.24 (Definition of Hold Point) 73. A strategy defining how and when a pressure vessel or pressurerelieving device will be repaired, inspected, and/or maintained is called a(n): A) Repair Plan B) Quality Plan C) Inspection Plan D) QA Inspection/Repair Mgmt System Answer = C … Ref: API 510, Section 3.32 (Definition of Inspection Plan) 74. A repair organization may be any one of the following EXCEPT: A) Holder of a valid ASME Certificate of Authorization (U-stamp) B) Holder of a valid ASME Certificate of Authorization (R-stamp) C) Owner/User of pressure vessels who repairs his own equipment D) An individual or organization that is authorized by the legal jurisdiction Ans = B … Ref: API 510, Sect 3.54 (Definition of Repair Org)  National Board issues R-Stamp 75. Temper Embrittlement affects which low alloys and occurs in what temperature range? A) TE affects 1.25Cr-0.5Mo alloy steels in the 650ºF – 1100ºF (345ºC – 595ºC) temp range B) TE affects 2.25Cr-1.0Mo alloy steels in the 650ºF – 1100ºF (345ºC – 595ºC) temp range C) TE affects 1.25Cr-0.5Mo alloy steels in the 750ºF – 1100ºF (400ºC – 595ºC) temp range D) TE affects 2.25Cr-1.0Mo alloy steels in the 750ºF – 1100ºF (400ºC – 595ºC) temp range

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = B … Ref: API 510, Sect 3.59 (Definition of Temper Embrittlement) 76. For P1, P3, P4, and P5 materials (for purpose of API 510 examination) the lower transition temperature and upper transformation temperature regarding PWHT will be (respectively): A) 1200°F & 1500°F B) 1250°F & 1500°F C) 1300°F & 1600°F D) 1330°F & 1600°F Answer = D … Ref: API 510, Sect 2 (References)  See the API 510 BODY OF KNOWLEDGE 77. Which of these is an inspection organization as recognized by the API 510 code? A) Inspection organization of a jurisdiction from outside of a jurisdiction where a pressure vessel is used B) Inspection organization of an insurance company that did not insure a given pressure vessel C) Owner or User who maintains an inspection organization for his own equipment D) Independent outside contractor hired by an owner or user that is recognized by a jurisdiction

Answer = C … Reference: API 510, Para. 3.6.d  Must be “recognized” by a jurisdiction 78. Repair organization is responsible to owner/user and shall provide all of these EXCEPT: A) Materials B) Equipment C) Workmanship D) Quality Assurance Answer = D … Ref: API 510, Par. 4.2.3  Repair Organization provides Quality Control, not QA 79. Regarding CUI Inspection of externally-insulated vessels, the susceptible temperature range for Austenitic Stainless Steel refers to which of these operational temperature ranges? A) 10°F (–12°C) to 350°F (175°C) B) 10°F (–12°C) to 400°F (205°C) C) 50ºF (10ºC) to 350ºF (175ºC) D) 140ºF (60ºC) to 400ºF (205ºC) Page | 27

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = D … Ref: API 510, Par. 5.5.6.1.a/b  CUI Inspection! 80. Assuming no RBI and the Internal Inspection Interval has been set at 8 years, what is the maximum external inspection interval allowed per API 510 rules? A) Eight (8) years is the maximum inspection interval since it cannot exceed the Internal interval B) Five (5) years is the maximum inspection interval allowed by API 510 given these conditions C) Four (4) years is the maximum inspection interval allowed by API 510 given these conditions D) None of these is correct per API 510 rules Answer: B (API 510, External Inspection Rules, Para. 6.4.1) 81. RBI can be used to determine: A) Inspection intervals only B) Inspection intervals and the type of future inspections required only C) Inspection intervals and the type and extent of future inspections only D) Inspection intervals and the type and extent of future inspections and examinations Answer = D … Ref: API 510, Para. 5.2  Risk-based Inspection 82. Per API 510, shell insert (flush) patches must meet all of these requirements EXCEPT: A) RT (applicable code) or UT (Inspector approved procedure/industryqualified SW examiner) B) Any insert plate corners extend to an existing longitudinal or horizontal weld C) All insert plate corners are rounded with a ½ - inch minimum radius D) Full-penetration groove welds are required Answer: C (API 510, Para. 8.1.5.2.2) The 1-inch radius rule must be met … Must know 83. The internal inspection shall be performed by: A) An inspector in accordance with the inspection plan B) An inspector in accordance with the owner/user quality manual C) An examiner acceptable to the inspector in accordance with quality manual D) An inspector in accordance with the detailed procedures of the Authorized Insp agency Page | 28

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = A … Ref: API 510, Para. 5.5.2.1  Internal Inspection 84. The API 510 recommended shell temp during a hydrostatic test (A vessel = 2.5 in. thick)? A) 30 o F above MDMT B) 30 o F above ambient C) 10 o F above MDMT D) 10 o F above ambient Answer: A (API 510 Sect/Para. 5.8.6.2 … Be also aware of 2 in & less rule = +10o F or +30o F) 85. Corrosion specialist shall be consulted when developing the inspection plan for vessels that operate at elevated temperatures above: A) 650°F (345°C) B) 700°F (371°C) C) 750°F (400°C) D) 800°F (427°C) Answer = C … Ref: API 510, Para. 5.1.1.1  Development of an Inspection Plan 86. Direct visual examination is conducted when access is sufficient to place the eye: A) Within 6 in–24 in (150–600 mm) of exam surface & at an angle not less than 20ᴼ to surface B) Within 6 in–12 in (150–300 mm) of exam surface & at an angle not less than 20ᴼ to surface C) Within 12in-24 in (300-600 mm) of exam surface & at an angle not less than 20ᴼ to surface D) None of these is correct Answer: D … Ref: API 577, Sect. 9.3.2.3  … Answer = 6 – 24 inches & 30ᴼ to surface 87. P-Number assignments are based on all of the following comparable base metal characteristics except: A) Weldability C) Welding Process types

B) Composition D) Mechanical properties

Answer: C … Ref: API 577, Section 7.2  Materials  P-Numbers Page | 29

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 88. Before performing any inspection, inspectors shall familiarize themselves with prior history of the vessel and should review: A) Prior inspection results & repairs, current inspection plan & similar service inspection results B) Prior repairs & prior inspection plans & similar service inspection results only C) Prior inspection & repair results & similar service inspection results only D) Prior inspection and repair results only Answer = A … Ref: API 510, Para. 5.3  Preparation for Inspection (Records Review) 89. When RBI assessments are used to set inspection intervals, assessments shall be updated: A) After each vessel inspection as defined in API 580 B) After a vessel undergoes any process change as per API 580 C) Only when the vessel inspection interval will be changed as per API 580 D) Only one time as documented and shall remain on file for the life of the vessel per API 580 Answer = A … Ref: API 510, Para. 5.2.4  Frequency of RBI Assessments 90. Safety precautions are important in pressure vessel inspection and maintenance activities and regulations govern many aspects of vessel entry and must be followed. In addition, the: A) Safety requirements of OSHA regarding confined space rules apply to API 510 inspections B) Owner/user’s safety procedures must be reviewed and followed in all cases C) Vessel Inspection Plan must detail any confined space entry requirements D) None of these are correct Answer = B … Ref: API 510, Para. 5.3  Preparation for Inspection 91. A pressure vessel should be maintained according to: A) The latest API 510 code requirements B) The code under which it was designed and constructed C) The latest API 510 code requirements and owner-user specifications D) None of these Answer: B (API 572, Section 4 … Last Paragraph) Page | 30

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) 92. Preheat temps used in making welding repairs shall be in accordance with the applicable code and qualified welding procedure, and the inspector should assure that: A) Both welders and supervisors know the required preheat values B) Welders know the minimum preheat temperature requirements C) The minimum preheat temperature is measured and maintained D) None of these are correct per API 510 Answer: C (API 510, Para. 8.1.6.3) 93. Vessel internals need not be removed completely as long as reasonable assurance exists that damage at vessel areas covered by the internals is: A) Occurring to an extent that is not greater than that found in more accessible vessel areas B) Occurring to an extent that is not lesser than that found in more accessible vessel areas C) Occurring to an extent that is considered negligible or insignificant by the Inspector D) None of these is correct Answer = A … Ref: API 510, Para. 5.5.2.2  Internal Inspection of Vessel Internals 94. After repairs are completed, a pressure test shall be applied in all of these cases EXCEPT: A) If Inspector believes one is necessary B) If an Engineer believes one is necessary C) In event that a vessel section or component has been given a new nozzle D) In event of a crack repair at a very deep excavation in an area of high stress concentration Answer: B (API 510, Para. 5.8.1.1 & 5.8.1.2) 95. If internal linings are in good condition and there is no reason to suspect that damage is occurring behind them, what does API 510 state? A) Extent and examination percentage beneath linings must be as stated in the Inspection Plan B) It is left to the discretion of the Authorized Pressure Vessel inspector & Corrosion Specialist C) Only spot exams need to be done so that there is reasonable assurance no damage exists D) It not necessary to remove linings during the internal inspection Page | 31

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = D … Ref: API 510, Para. 5.5.2.3  Internal Inspection of Deposits and Linings 96. If the lining appears damaged, bulged or cracked, it may be advisable to do all of the following EXCEPT: A) Perform external NDE techniques to explore for vessel damage beneath internal linings B) Completely remove damaged, bulged & cracked linings for inspection of vessel beneath C) Remove small portions of linings & investigate vessel surfaces (Consult Corrosion Specialist) D) Remove small portions of linings & investigate lining condition (Consult Corrosion Specialist) Answer = B … Ref: API 510, Para. 5.5.2.3  Internal Inspection of Deposits and Linings 97. Rerating of a pressure vessel can involve all of these EXCEPT: A) Changing its design temperature B) Changing its minimum metal design temp C) Changing its MAWP D) Changing its service Answer: D (API 510, Para. 8.2.1) 98. Which of the following statements are NOT TRUE regarding OnStream Inspections? A) An external inspection may be a part of an on-stream inspection B) Inspections may include several NDE techniques to check for various types of damage C) Techniques are chosen for ability to identify internal damage mechanisms from the exterior D) Techniques are chosen for capabilities to perform at on-stream conditions (e.g. metal temps) Answer = A … Ref: API 510, Para. 5.5.3.2  On-Stream Inspection  External Thickness Insp 99. During the external inspection, particular attention should be given to: A) Leakage, hot spots and evidence of vibration B) The outside surface of the vessel and the insulation and coating systems

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NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) C) Welded attachments such as reinforcement plates & clips checking for cracks or defects D) Associated structure, allowance for expansion, and general vessel alignment on its supports Answer = C … Ref: API 510, Para. 5.5.4.1.2  External Inspection 100. If vessel stamp shows a 1997 construction date & a vessel has not been rerated, then what is the minimum test pressure is to be applied to satisfy API 510 code requirements? A) Test Pressure in psi = 1.3 MAWP × (S test temp / S design temp) B) Test Pressure in psi = 1.4 MAWP × (S test temp / S design temp) C) Test Pressure in psi = 1.5 MAWP × (S test temp / S design temp) D) The test pressure is left to the discretion of the Inspector Answer: C (API 510, Para. 5.8.2.1)

101. After repairs are completed, a pressure test is to be applied. Vessel stamp construction date = 1997 and the vessel was rerated in 2009. Given: Vessel MAWP = 1,000 psi (2009) and the Stest temp/Sdesign temp ratio = 1.1. What test pressure is to be applied to meet code? A) Test Pressure = 1.5 × 1000 x 1.1 = 1650 psi 1000 x 1.1 = 1430 psi C) Test Pressure = 1.4 × 1000 x 1.1 = 1540 psi correct

B) Test Pressure = 1.3 × D) None of these are

Answer: B (API 510, Para. 5.8.2.1) 102. During repairs or alterations of pressure vessels, the inspector shall verify that all new materials (including carbon steel) are consistent with the specifications. At the discretion of owner/user or inspector, assessment can be done by all of the following methods EXCEPT: A) 100% verification checks B) Sampling a percentage of materials in critical situations C) Positive Material Identification (PMI) Practices & Procedures D) Optical fluorescence analyzers or x-ray spectrographic analyzers Answer: D (API 510, Para. 5.9.1) 103. With no RBI, External vessel Inspection is required how often and preferred when? Page | 33

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) A) Every five years, with the vessel in operation or out of operation, it doesn’t matter B) Lesser of 5 yrs or required internal/on-stream inspection interval, vessel in operation C) Lesser of 5 yrs or required internal/on-stream inspection interval, vessel not in operation D) Lesser of 5 yrs or required internal/on-stream inspection interval, as the Inspector requests Answer: B (API 510, Definition of inspection, Para. 6.4.1) 104. For pressure vessels in non-continuous service, inspection intervals can be based on the number of years of actual service that the vessel operated, not calendar years, provided that all of the following precautions are taken EXCEPT: A) After being idled, a vessel is isolated from all process fluids B) After being idled, a vessel is placed under a nitrogen purge C) After being idled, a vessel is filled with non-corrosive hydrocarbons D) After being idled, a vessel is completely drained and then opened to dry out Answer: D (API 510, Para. 6.5.1.2) 105. The inspector shall approve all specified repair and alteration work at designated hold points and after completion of the work in accordance with the: A) Repair plan C) QA Plan

B) Inspection Plan D) QC Plan

Answer: A (API 510, Para. 8.1.2.2) 106. If the corrosion rate of a vessel is determined to be less than a given amount per year, is it possible to perform an on-stream inspection in lieu of internal inspection, yes or no, and what is the value of the corrosion rate (CR) & the remaining life that cannot be exceeded? A) Yes and Corrosion rates must always be below 0.002” per year and remaining life > 5 years B) Yes and Corrosion rates must always be below 0.005” per year and remaining life > 10 years C) Yes and Corrosion rates must always be below 0.008” per year and remaining life > 10 years Page | 34

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) D) No, it is not possible to exempt any vessel from its internal inspection with any of the above Answer: C (API 510, Para. 6.5.2.1) 107. When reviewing RT film, a darkened perfectly straight line can be seen in the very center of the root pass (lightest area). The length of the line is about 75mm long. It is most likely: A) Crack C) Internal root undercut

B) Incomplete fusion D) Incomplete penetration

Answer: D (API 577 Illustration for IP, Note 2) 108. Progressive records must be regularly updated and include new information pertinent to all of the following items except: A) Personnel Safety history with the equipment B) Maintenance history of the equipment C) Operational history of the equipment D) Inspection history of the equipment Answer: A (API 510, Para. 7.8.1) 109. Documentation of temporary repairs includes all of the following EXCEPT: A) Due date for installing a permanent repair B) Plans to make a temporary repair permanent C) Location of temporary repairs and specific repair details D) Details of analyses performed and future inspection requirements Answer: B (API 510, Para. 8.1.5.1.1) 110. Who must be consulted before repair of a crack at a discontinuity where stress concentrations may be serious? A) Both Engineer & Inspector Manufacturer C) Inspector only

B) R Stamp Holder or Vessel D) Engineer only

Answer: D (API 510, Para. 8.1.5.2.1) 111. Typical permanent repair techniques include all of the following EXCEPT: A) Replacing an entire section or component containing defects Page | 35

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) Excavating a defect and contour blend-grinding per API 579 C) Lap Band repairs and Weld overlays of corroded areas D) Excavating a defect and repair welding the excavation Answer: C (API 510, Para. 8.1.5.2.1) 112. API authorized inspectors may give prior authorization for routine repairs not involving: A) Pressure tests C) Pneumatic testing

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 150ºF or higher, as specified in welding procedure, is maintained during welding B) Preheat of 200ºF or higher, as specified in welding procedure, is maintained during welding C) Preheat of 250ºF 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 300ºF 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

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) General pitting type corrosion of stainless steels C) Chloride SCC of austenitic stainless steels D) None of the above attack stainless steels Answer: C (API 572, Section 8.2.1) 116. If a RBI assessment is not performed, what is the greatest possible time period allowed by API 510 between testing of pressure relieving devices? A) At intervals frequent enough to verify valve’s reliable performance B) 5 years (for normal process services) and 10 years (for non-corrosive services) C) 10 years (for normal process services) and 10 years (for non-corrosive services) D) At every shutdown or T &I or as deemed necessary by the authorized inspector Answer: B (API 510, 6.6.2.2 … Five years (typical process services / 10 yrs non-corrosive) 117. If the requirements of API 510 are met who determines if a temporary fillet weld patch may be used in a repair? A) An engineer and API authorized inspector B) The API authorized inspector C) A repair concern that holds a valid NBIC R stamp D) The engineer Answer: A (API 510 Section/Para. 8.1.5.1.2.1) 118. If white salts are found at cracks in a vessel, what is the likely damage mechanism? A) It is an indication that the vessel may suffer from hydrogen blistering B) It is an indication that the vessel may suffer from caustic embrittlement C) It is an indication that the vessel may suffer from chloride stress corrosion cracking D) It is an indication that the vessel may suffer from amine stress corrosion cracking Answer: B (API 572 Section/Para. 10.3.13 Third paragraph) 119. The rules for impact testing of carbon steel in Section VIII, Div. 1, Carbon steel vessel materials require what kind(s) of impact tests? A) Brinnell & Rockwell Page | 37

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) Izod & Charpy V-notch C) Charpy V-notch D) Brinnell Answer: C (ASME IX, QW-170) 120. The purpose of the PQR is to establish the: A) Properties of a weldment B) Suitability of the weldment C) Record for weldment construction D) None of these are correct per API 577 Answer: A … Ref: API 577, Sect. 6.1  Procedures  General 121. ASME Section IX requires “WHO” to develop welding procedures? A) Each owner/user Engineering Organization B) Each owner/user of the equipment C) Each manufacturer & contractor D) Each Inspection Organization Answer: C … Ref: API 577, Sect. 6.2  Procedures  WPS Section 122. A completed WPS for a given welding process (assume it is SMAW) shall address: A) All essential variables B) All essential and nonessential variables C) All essential variables (Including supplemental essential variables if notch toughness is reqd) D) All essential & nonessential variables (supp. essential variables only if notch toughness reqd) Answer: D … Ref: API 577, Sect. 6.2  Procedures  WPS Section 123. The PQR shall record all of the following items except: A) Manufacturer’s certification of accuracy in the qualification of a WPS B) The nonessential variables used to weld a test coupon C) The essential variables used to weld a test coupon D) Coupon test results Answer: B … Ref: API 577, Sect. 6.3  Procedures  PQR Section 124. F-number groupings are based essentially on their usability characteristics, which fundamentally determine: Page | 38

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) A) The chemical composition of the electrode only B) The chemical composition of the electrode and the weldability C) The ability of welders to make satisfactory welds using similar composition filler metals D) The ability of welders to make satisfactory welds using a given process and given filler metal Answer: D … Ref: API 577, Section 7.3  Materials  F-Numbers 125. The A-number grouping in ASME Section IX, Table QW-442 is based on the: A) Chemical composition of the deposited weld metal and the base metal B) Chemical composition of the deposited weld metal C) Tensile strength of filler metal and base metal D) Chemical composition of the base metal Answer: B … Ref: API 577, Section 7.5  Materials  A-Numbers 126. Welder performance qualification expires if a welding process is not used during a: A) 3-month period B) Six-month period C) Nine-month period D) Twelve-month period Answer: B … Ref: API 577, Section 8.2  Welder Qualification  WPQ 127. Undercut (Per API 577, Table 6) can be corrected by (Practical Solution Column): A) Proper heat input & proper welding technique B) Reduce travel speed and control arc length C) Proper heat input & proper joint design D) Reduce travel speed Answer: D … Ref: API 577, Section 9.1  NDE  Discontinuities (Table 6) 128. Magnetic particle examination is effective in: A) Locating surface discontinuities of ferromagnetic materials B) Locating surface or near surface discontinuities of ferromagnetic materials C) Locating surface or near surface discontinuities of ferromagnetic and paramagnetic materials D) None of these are correct Page | 39

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer: B … Ref: API 577, Sect. 9.4.1  NDE  MT  General 129. For added sensitivity, which of the following PT techniques may be used to detect fine linear type indications? A) Fluorescent penetrant (Used in exams in darkened areas with filtered black light) B) Color Contrast Solvent Removable Visible Dye Penetrant (Technique) C) Color Contrast Post emulsifiable Visible Dye Penetrant (Technique) D) Color Contrast Water washable Visible Dye Penetrant (Technique) Answer: A … Ref: API 577, Sect. 9.6.1  NDE  Liquid PT Techniques 130. Factors that can contribute to reduced accuracy of ultrasonic measurements include all of the following EXCEPT: A) Small flaw detector screens B) Subsurface material flaws, such as laminations C) Doubling of the thickness response on thicker materials D) Temperature effects at temperatures above 150ºF (65ºC) Ans = C … Ref: API 510, Par. 5.7.2.4  Thickness Meas. Methods  (On thinner materials) 131. Regarding CUI Inspection of externally-insulated vessels, the susceptible temperature range for Carbon & Low Alloy steels refers to which of these operational temperature ranges? A) 10°F (–12°C) to 350°F (175°C) C) 50ºF (10ºC) to 350ºF (175ºC)

B) 10°F (–12°C) to 400°F (205°C) D) 50ºF (10ºC) to 400ºF (205ºC)

Answer = A … Ref: API 510, Par. 5.5.6.1.a/b  CUI Inspection! 132. Assuming no RBI and the Internal Inspection Interval has been set at 4 years, what is the maximum external inspection interval allowed per API 510 rules? A) Five (5) years = maximum inspection interval allowed by API 510 rules B) Four (4) years = maximum inspection interval allowed by API 510 rules C) Two (2) years = maximum inspection interval allowed by API 510 rules D) None of these is correct per API 510 rules Answer: B (API 510, External Inspection Rules, Para. 6.4.1) 133. When a pressure vessel remaining life is less than 4 years, the internal or on-stream inspection Interval may be: A) Full remaining life (but less than 4 years) Page | 40

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) Full remaining life up to a maximum of 3 years C) Full remaining life up to a maximum of 2 years D) Only ½ of the vessel’s remaining life in all cases where remaining life is less than 4 years Answer: C (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1) 134. Assuming no RBI, On-stream inspections may be substituted for internal inspections if all of the following are true EXCEPT: A) Inspector must approve the substitution B) Size or configuration makes internal inspection or vessel entry physically impossible C) General Corrosion rate is less than 5 MPY & vessel remaining life is greater than 10 years D) No questionable conditions were in evidence during performance of External Inspections Ans: B (510, Int. & On-stream Insp., Para. 6.5.2.1.b.1)  PHYSICALLY POSSIBLE = 7 RULES! 135. Who shall maintain certification records of examiners employed, including dates and results of personnel qualifications (that shall be made available to the inspector)? A) Owner/user C) Authorized Inspection Agency Inspector

B) Examiner’s employer D) Authorized Pressure Vessel

Ans = C … Ref: 510, Par. 4.2.5.3 Inspector’s employer  By definition = Auth. Insp Agency 136. Spring failures are almost always caused by: A) Mechanical failure due to excessive movement and vibration B) Corrosion that includes surface corrosion and stress corrosion cracking C) Stress related failure due to improper sizing and using substandard parts D) None of these is correct Ans: B (510, Para. 6.6.6 & API 576, Para 5.3.2 & Fig 30) … PZV Spring Failure Cause = Corrosion 137. Most cases of Brittle Fracture occur only at: Page | 41

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) A) Temperatures above Charpy Impact transition temperatures B) Charpy Impact temperatures have no relationship to Brittle Fracture occurrences C) Temperatures below ambient and only in thick sections D) Temperatures below Charpy Impact transition temperatures Answer = D … See Paragraph 4.2.7.3.e below  Critical Factors 138. Equipment that suffers from Temper Embrittlement (TE) may be susceptible to what other damage mechanism during start-up and shut down? A) Brittle Fracture C) Creep

B) Thermal Shock D) None of these

Answer = A … API 571 Para 4.2.3.1 Last Sentence (Must Know) … Description of Damage 139. Which Equipment items below have experienced major problems with Thermal Fatigue? A) Coke Drums B) Deaerators C) Thermal or Catalytic Reactors D) None of these Answer = A … 572 Section 9 statements regarding cracking and also 571, Para. 4.2.9.4.b & Figure 4-21 & 4-22 … Appearance & Affected Equipment  API 572 highlighted item 140. Erosion-Corrosion occurs when corrosion contributes to erosion by creating additional metal loss due to: A) CO2 and/or oxygen gases B) Removal of protective films and/or scales C) Impact from solids, liquids, vapor or any combination of these D) None of these are correct Answer: B … API 571, Para. 4.2.14.1.b – Erosion/Erosion-Corrosion Question 141. Which item below best describes thermal fatigue cracking? A) Surface initiated, narrow and along the grain boundaries, and oxide filled craze cracks Page | 42

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) B) Surface initiated, generally wide and transgranular, oxide filled and dagger shaped C) Surface or subsurface initiated, wide, oxide filled and spider-web appearance D) None of these are correct Answer = B … See Para. 4.2.9.5.a/b & Figures (Appearance) 142. Regarding examiner responsibilities, which of the following is not a true statement? A) He must be proven competent by owner/users & must hold certs in all NDE procedures used B) He does not need 510 certification and does not need to be an employee of the owner/user C) He shall perform the NDE in accordance with job requirements D) He needs to be trained & competent in the NDE procedures being used Answer = A … Ref: API 510, Para. 4.2.5.1/2  Examiner responsibilities  May not must 143. The inspection plan should be developed by the: A) Authorized Inspection agency B) Inspector or Engineer C) Owner/User D) Engineer only Answer = B … Ref: API 510, Para. 5.1.1.1  Development of an Inspection Plan 144. After an RBI assessment has been conducted, the results can then be used to establish the: A) Most appropriate inspection and NDE methods, tools, and techniques B) Extent of NDE and the interval for internal, external, and on-stream inspections C) Need for pressure testing after damage has occurred or after repairs/alterations are done D) Vessel inspection plan Answer = D … Ref: API 510, Para. 5.2.3  Documentation (related to RBI) 145. Pressure vessels are susceptible to various types of damage mechanisms. The various types of damage mechanisms include all of the following EXCEPT: Page | 43

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) A) Isolated and local metal loss and Blistering B) Surface connected cracking and subsurface cracking C) Metallurgical changes and material property changes D) Dimensional changes and Microfissuring/microvoid formation Answer = A … Ref: API 510, Para. 5.4.1  Types of Damage  General and local metal loss 146. Which of the following steels are most susceptible to Temper Embrittlement? A) Carbon steels B) C – 0.5 Moly C) 1.25Cr – 0.5 Mo D) 2.25Cr – 1 Mo Answer = D … API 510 (Definition 3.59, Para 5.8.6.1 last sentence) & 571 Para 4.2.3.2.a 147. The most important factor in determining components resistance to fatigue cracking is: A) Geometry of the component B) Stress levels & number of cycles C) Material properties (strength, hardness, microstructure) D) Design of the component is the most important of all factors Answer: D … API 571, Para. 4.2.16.3.a – Mechanical Fatigue Question  GOOD DESIGN 148. HTHA damage is caused by which of these gases and is best detected (determined) by: A) Methane … UT velocity ratio & backscatter B) Hydrogen and sulfur … WFMT C) Hydrogen … MT or PT D) None of these is correct Answer = A … See Paragraph 5.1.3.1.7.b  Inspection & Monitoring 149. Severe internal grooving with deep pitting was found at the bottom of a 4-inch CS elbow in a steam condensate system. This damage was most likely caused by: A) Erosion/Corrosion C) Ammonium Bisulfide Corrosion

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B) Chloride Corrosion D) CO² Corrosion

NAME/BADGE #: __________________________________________________ Date: ____________

API 510 PRACTICE EXAM B (150 QUESTIONS) Answer = D … See Paragraph 4.3.6.5.b  Appearance or Morphology of Damage 150. Sulfidation damage is accelerated by the presence of: A) Hydrogen B) Sulfur C) Salts D) Corrosive Water Answer = A … See Paragraph 4.4.2.1 (Description of Damage)

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