Day - 2 api

API 510 – DAY 2 BOOK

API 510 IMPORTANT TIPS

UG UG 4 – UG 15 Pressure Part Material Testing UG 10 – code for the material not fully identified UG 16 – UG 20 Pressure Part Design UG-20 Design Temperature UG-22 Loading UG-25 Corrosion UG-27 Thickness of Shells Under Internal Pressure UG-28 Thickness of Shells and Tubes (External Pressure) UG-32 Formulas and Rules for Using Formed Heads UG-34 Un stayed Flat Heads and Covers (Circular) UG-36 Openings in Vessels- 3/8 ‘ and 2 3/8 ‘ formula UG-37 Reinforcement of Openings UG-40 Limits of Reinforcement UG-41 Requirements for Strength of Reinforcement UG-42 Reinforcement of Multiple Openings UG-77 Material Identification UG 78 – Repair of effects in the Material UG -80 Permissible out of roundness UG 81 – tolerance for formed Heads UG 84 Impact force, Ave impact strength, Temperature reduction below MDMT Charpy Impact Test Requirements UG-93 Inspection of Materials UG-98 Maximum Allowable Working Pressure UG-99 Hydrostatic Test Pressure and Procedure UG-100 Pneumatic Test Pressure and Procedure UG-102 Test Gages UG-116 Name Plate Markings UG-119 Name Plates UG-120 Data Reports

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UW UW-3 Weld Categories UW-11 RT and UT Examinations UW-12 Maximum Allowable Joint Efficiencies Table UW-16 Weld Size Determination Minimum Requirements for Attachment Welds at Openings UW 33 Misalignment tolerance , UW 35 Re- inforcement UW-40 Procedures for Postweld Heat Treatment UW 50 NDT UW-51 RT Examination of Welded Joints UW-52 Spot Examination of Welded Joints UW 53 UT

UCS UCS-56 Requirements for Post weld Heat Treatment UCS-66 Materials- MDMT , Exemption from impact testing UCS-67 Impact Testing of Welding Procedures UCS-68 Design Exercises UG 20 –UCS 66 – 67

Tips Film width – Minimum 5 times the thickness of the thinner plate Film length minimum 6 inch Film length should be = 3 times the length of opening RT not required for Cat b & Cat C , if it is below NPS 10 or 1 1/8 inch thick or both Pressure Tolerance of the Pressure relieving device is 3 % 1. Minimum Thickness For Cylindrical Shell. t=

PxR SE – 0.6P

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P= R= S= E= T=

Mawp Inner Radius Stress of the Mass Efficiency Thickness of the shell – Minimum

2. Minimum Thickness of Ellipsoid Head T = PD / (2SE-0.2P ) , Where P = MAWP, D = internal dia , in all these formulae check which is dia or which is radius, inner or outer and whether corrosion allowance has to be included , if so how much 3. Minimum thickness for torispherical Head T = 0.885 P L / ( SE- 0.1P ) , where L is inside spherical or Crown radius 4. Minimum thickness for Hemispherical Head = T = PL /( 2SE- 0.2P ) 5. ALLOPWABLE External Pressure Pa = 4B/ 3 ( D0/t) , or Pa = 2AE / ( 3 D0 /t), where Constant A & B values will be given, and E is the modulus of elasticity. 6. Hydrostatic test pressure = 1.3 x MAWP x Stress Ratio 7. Hydrostatic Inspection pressure = Test pressure/ 1.3 8. Pneumatic test pressure = 1.1 x MAWP x Stress Ratio 9. Pneumatic inspection pressure = Test Pressure /1.1, and increase in terms of six steps from 50 % by 10 %. 10. For MDMT use UCS 66 table., for High toughness ie for lower brittlity, use curve D of UCS 66 11. To find out joint efficiency use UW 12 12. For PWHT use UCS 56, PWHT is a must for P no 3 group no3 for all thickness, 13. Write what’s is P no, A no, S no ,F no .and Which table we have to locate 14. Reinforcement = Dia x Thickness 15. Efficiency of seamless joint is 1, Efficiency of EWR weld is also 1

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16. Crown Dia Flat Dish end = o.8 x dia of shell Ellipsoid dish= 0.9 x Dia of shell Torispherical Head = 1 X dia of the D Shell Knuckle radius = 6 % crown radius + Thickness of the Head 17. Thickness of the Head Hemispherical= 0.5 x t Ellipse = 1 x t Torrispherical= 1.77 t 18. Crown radius is different from crown portion. For crown portion use Flat Disc formulae ie 0.8 x dia, and for crown portion thickness use Hemispherical thickness head formulae. 19. Charpy Impact – Full size specimen 10 mm x 10 mm, Sub size specimen is 10m x 6.7 mm 20. Minimum 3 specimen should be taken. Find the average. If any one is having the value less than the 2/3 of the average, do the retest of 3 more specimen 21. For the Materials having specified minimum tensile strength of 95 Ksi, use minimum lateral expansion opposite to the notch 22. For reduction in MDMT based on thickness (table) & impact test temperature differential etc refer UG 84 tables 23. When heat treatment is not performed by the manufacturer, fabricator or people under his control has to do and place letter T followed by G 24. For plates MTR ie Material Test Report is a must 25. VT is done at inspection pressure ie test pressure/1.3 for hydrostatic and for test pressure /1.1 f Pneumatic test 26. For Hydrostatic test Small liquid relief valve set to 1.33 times the test pressure is recommended. It may get warmed up during the test when the personnel is absent 27. Marking on the pressure Vassal : 28. U – Pressure vessal, UM- Mimniature Pressure vessal, UV for PRV, and UD for rupture Disc Full pressure vessel U1 or U1A Pressure Vessel Part U2 or U2A

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W – arc weld or gas weld P – Pressure weld B =-braze RES – resistance weld L – Lethal service UB – unfired Steam Boiler DF—directly fired UB SEC VIII Div 1, DF is SEC VIII Div 2 1- means single chamber A – means shop fabricated 29. Partial data reports should have the PART mentioned in the sketch. This does not apply to Hand hole cover and man hole cover 30. Certificate of authorization for U,UV,UD is valid for 3 years. For UM it is valid for one year but reviews for second and third year are done by Authorized inspection agency 31. Name plate thickness shall not be less than .5 mm . Characters Height should not be less than 4mm and on a minimum raised level of 0.1 mm 32. The manufacturers certificate of compliance shall be maintained by the manufacturer for 5 years 33. The spring in the PRV shall not deviate by + or – 5% than the marking on the valve.. The set Pressure tolerance hall not exceed 2 Psi up to 70 Psi and 3 % above 70 Psi. Pressure tolerance of PRV device is 3 % 34. RV size should be atleast NPS 1//2 35. The set pressure of PRV shall not exceed 110 % MAWP or 3 psi 36. Rupture disc is a non re closing PRV 37. Acceptance Standards of defects as per Sec VIII Appendix RT APX 4 UT APX 12 MT APX 6 PT APX 8 Radio Procedure Std Sec V RT ART 2 UT ART 5, ART 23 UT Standards MT ART 7 PT ART 6 API 510 – DAY 2

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RT Ace Rounded Indication For t > 2 inch Relevant Indication is . 1/16 inch Maximum size of rounded indication is ¼ t or 5/32 inch which ever is small For thickness . 2 inch, the maximum size is 3/8 inch Sum of dia of aligned rounded indication should be less than t in thee length of 12t RT Linear Indication For Thk up to 19 mm ¼ inch For Thk 19 mm to 57 mm, it is 1/3 t For Thk over 57 mm , it is 19 mm MT / PT ACE Relevant . 1/16 inch dia Linear is l > 3w IT is acceptable , if it is free from a) relevant linear indication b) relevant rounded indication greater than 3/16 inch c) Four or more rounded indication gap of less than 1/16 inch

UT : Imperfection having response greater than 20 % has to be investigated Cracks, LP and LF are not allowed Other imperfection For Thk up to 19 mm ¼ inch For Thk 19 mm to 57 mm, it is 1/3 t For Thk over 57 mm , it is 19 mm Manufacturer should make and retain thee UT report until the Manufacturers data report is signed by the inspector

38.

Tolerance

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Tolerance for the formed Heads.: The inners surface of Torri spherical, Hemispherical or ellipsoidal head shall be between 5/8 % D and 1 1/4 % D , where D is ID Pipe Wall thikness 12.5% General mill tolerance = .01 “ or 6 % thickness which ever is smaller Ovality Tolerance , 1 % nominal dia + 2 % ID of the opening if the cross section passes through the 1 ID of the opening Allignment taper : If difference in thickness is ¼ t or 1/8 inch which ever iis less ie within the allowable tolerance use 3;1 taper Reinforcement Pad not required when the size finished opening does not exceed a) 3 ½ inch for thickness equal to less than 3/8 inch b) 2 3/8 inch for thickness greater than 3/8 inch For Calculating the average length for the corrosion over the large area For the Pipes ID Less than 60 inch , Choose D /2 or 20 inch which ever is less For ID more than 60 inch choose D/3 or 40 inch which ever is less

39. When thickness of CS weld or P no 1 exceeds 16 mm , then PWHT is required 40. seamless weld joints efficiency is 1. for full radiography E=1 for spot radiography also when 11a- 5b conditions are met E = 0.85, when spot radiography conditions for UW 11a -5b are not met

41. Welding Mark interval is max 3 feet 42. Minimum soak band ie pre heat width = widest weld width + 1t or 2 inch which ever is less on each side of the weld \ 43. When two material of different PWHT requirements are faced, Use higher PWHT temperature API 510 – DAY 2

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44. P1 Gr 1, No Special Restriction NO PHT 45. P3, Gr 3, PWHT is Mandatory 46. If thickness is . 4 inch, and MDMT is less than 120 deg F then impact testing is needed 47. Impact test exemption is : Upper Limit 120 Deg F, Lower limit is -55 deg f for curve and -20 deg F for curve B 48. PWHT is for UCS 56 or UHT 56 49. Filler metal containing more than .06 % of Vanadium shall not be used for the weldments Subjected to PWHT 50. Max weld reinforcement shall not exceed 10 % plate thickness or 1/8 inch which ever is less 51. MTR is to be prepared by the original manufacturer only. Supplier can generate only the certificate of compliance 52. Hydrostatic test has to be conducted at least 30 deg F above MDMT 53. In spot radiography rounded indication is not concerned 54. Leak tightness of the PPRV is checked at the water head 0.5 inch at 90 % set pressure 55. For Short circuit transfer ( GMAW) RT is not required 56. HOT TAPPING To minimize burn through, the first weld pass to equipment or piping less than 1/4 in. (6.4 mm) thick should be made with a 3/32 in. (2.4 mm) or smaller diameter welding electrode to limit heat input. Subsequent passes should be made with a 1/8 in. (3.2 mm) diameter electrode, or smaller if the metal thickness does not exceed 1/2 in. (12.7 mm). Minimum base thickness requirements shall be stated in the written documentation for the job. A minimum base metal thickness of 3/16 in. (4.8 mm) is recommended for most applications of welding and hot tapping.

The actual minimum thickness is a function of the thickness required for strength, plus a safety factor, usually 3/32 in. (2.4 mm), to prevent burn through. 57. For Pre heat WPS temp can go down maximum by 100 Deg F than the PQR 58. But For interpass tem this can increase maximum by 100 deg F than PQR API 510 – DAY 2

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59. For P1,P2 ,P3,P5 materials Lower transformation temp is 1333 Deg F and upper transformation tem is 1600 Deg F

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CASE STUDY 2 THICKNESS CALCULATIONS DATA: Design pr

= 48kg/cm2

= 683 psig

Design temp

= 300ºC

= 572ºF

Inside dia

= 1200 mm

= 47.25 in

M.O.C.

= 515 gr 70

Corr./Erro. Allow

= 2.5 mm (0.1 in)

Allowable Stress

= 19400 psi

Length (T-T)

= 315 in (8000mm)

Radiography

= Full / Spot

Calculate required thickness, Design thickness and Nominal thickness for shell and heads considering both cases of radiography.

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SOLUTION:

AA) Shell Thickness t= =

PR SE – 0.6P 683 x 602.5 = 21.7……………….for E=1 19400 – 0.6 x 683

Required thickness = 21.7+2.5 = 24.2 mm. Nominal thickness= 26.0 mm. By similar calculations for E=0.85 t =

683 x 602.5 + 2.5 = 25.5+2.5=28.0mm (E=0.85), Say, 28.0 mm. 19400 x 0.85 – 0.6x683

BB) Dished Head : 1) Hemspherical (E=1)

t=

PxR 683 x 602.5 mm 2SE=– 0.2P = 10.64 2 x 19400 x 1 –0.2x683

Adding C.A, Required thk. = 13.14, Nomonal thk= 14.0 mm With E = 0.85, t = 12.75mm . Adding C.A , Thk = 15.25. Say, 16.0 mm. 2) 2:1 Ellip. Head With E =1.0,

t =

PD 2SE – 0.2P

=

683 x 1205 2 x 19400 – 0.2 x 683

= 21.28. Adding C.A of 2.5 mm, thk = 23.78 , Say, 24 mm.

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By similar calculations for E=0.85, t=

683 x 1205 == 25.5 mm 2 x 19400 x 0.85 –0.2x683

(E=0.85)

Adding C.A. = 28.0 mm. Say, 28 mm plate 3) Torispherical head 0.885 x P x L SE – 0.1 P

t=

+C

=

0.885 x 683 x 1205 19400 – 0.1 x 683

t=

0.885 x 683 x 1205 19400 x 0.85 – 0.1 x 683

L= Dia = 1205 mm. = 37.5 +2.5 = 40.0 mm Choose thk=40 mm = 44.35 + 2.5 = 46.8 mm

Say, 47.0 mm. thk

COMPARISON OF THICKNESS Item

Shell E=1.0

Shell E=0.85

Torisph. Torisph. E=1.0 E=0.85

2:1 Ellip E=1.0

2:1Ellip E=0.85

Hemisph. E=1.0 E=0.85

1)

Calculated Thickness

21.7

25.5

37.5

44.35

21.28

25.5

10.64

12.75

2)

Thk + C.A

25.0

28.0

40.0

48.0

24.0

28.0

14.0

16.0

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CASE STUDY 3 MAWP ANALYSIS DATA: Following data is presented for a tall process column Vessel ID (actual) = 8’-0”. (96”) Vessel height (Tan – Tan) = 60’ Types of Dished head = 2:1 Ellip. Corrosion Allowance = Nil Vessel MAWP (Stamped) = 180 psi Safe stress for material = 20,000 psi Vessel thk = 0.55” (14.0 mm ) Vessel was fully radiographed. Due to erosion, three patches were observed at locations A,B,C located at 5’, 54’ and 57’ from top-tan line. The thicknesses measured at locations A,B,C were 0.45” (11.4mm), 0.47”(12.0mm), 0.50”(12.7mm). Calculate: 1. 2. 3. 4. 5.

Vessel part MAWPs at A,B and C Hydrostatic Pressure at A,B and C Total Pressure at A, B, C Identify Unsafe patch (es), if any Considering limiting patch (es) what is safe vessel MAWP?

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SOLUTION: 1

Vessel part MAWP = S E t R+0.6t MAWP at A = 20000 x 0.45 = 186.4 psi 48 +0.6x0.45 MAWP at B = 2 20000 x 0.47 = 194.7 psi 48 + 0.6x0.47 MAWP at C = 20000 x 0.5 48 + 0.6x0.5

2

= 207.0 psi

Hydrostatic pressure at any point = h x 0.433 psi (h = height from top in ft.) Head depth = D/4 = 8/4 = 2’ At A, At B, At C,

3

h = 5’ + 2’ = 7’, h = 54’ + 2’ = 56’ h = 57’ + 2’ = 59’

Hyd. Pr. = 7’x0.433=3.03psi Hyd. Pr. = 56’ x 0.433 = 24.25 psi Hyd. Pr. = 59’ x 0.433 = 25.55 psi

Total pressure at any point = Vessel MAWP + Hyd. Pressure At A, At B, At C,

180 + 3.03 = 183.03 psi 180 + 24.25 = 204.25 psi 180 + 25.55 = 205.55 psi

4

Since Total pressure at B is > part MAWP at B, it is unsafe.

5

For safety, total pressure at B < part MAWP at B Take total pressure at B = MAWP = 194.7 psi Deducting hydraulic pressure at B = 24.25 psi Safe MAWP for vessel = 170.45 Say, 170 psi

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CASE STUDY 4 IMPACT TESTING DATA: Verify whether impact testing shall be specified for plates required for following 4 vessels. All vessels are to be Hydrotested after completion and no shock loading is expected during operation.

Vessel A: MOC = SA516 Gr 70 ( Normalised ) MDMT = ( -5°F), Thk = 2.0”

Vessel B: MOC = SA515 Gr 60 MDMT = ( -15°F), Thk = 1”

Vessel C: MOC = SA285 Gr C MDMT = ( +40°F), Thk = 0.75”

Vessel D: MOC = SA516 Gr 60 MDMT = ( -30°F), Thk = 1” To be stress relieved by PWHT

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SOLUTION: Vessel A:

- Refer fig UCS – 66 - The material is represented by curve D MDMT – Thk combination falls almost on curve but not certain. - Go to Table UCS-66, - Exemption temp >=(-4°F) - Impact testing is required

Vessel B: - From UCS – 66, for curve B, Impact testing is required - Ref UG – 20 (f), material is PNo. 1 Group 1, Thk - 20°F - Impact testing is exempted

Vessel C: - From UCS-66, for curve A, Impact tecting is required - Ref UG – 20 ( f ) since thk > 0.5” - Impact testing is required

Vessel D: - From UCS – 66, for curve C Impact testing is required ( transition temp from table= -3 deg.F) - Since MDMT < - 20° F, Impact testing is not exempt per UG – 20 (f) - But since PWHT is carried out as service requirement ( and not code requirement, Since thk < 1.25”.), - UCS-68 (c) is applicable. Exemption temp = -3 – 30 = - 33°F - Impact testing not required

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CASE STUDY 5 PRESSURE TESTING DATA: Vessel Design Pressure = 180 psig, Vessel MAWP = 200 psig Vessel Design temp = 500˚F, Safe stress at Design temp = 16000 psig Vessel MDMT = 40˚ F, Safe stress (from -20˚ F to 200˚ F) =17600 psig Answer the following: 1

What is the recommended minimum test temp. for hydrostatic test ?

2

What is mandatory minimum test temp for Pneumatic test

3

What is Hydrostatic Test pressure?

4

What is minimum inspection pressure for Hydrostatic Testing?

5

What is Pneumatic test pressure ?

6

What is inspection pressure for pneumatic test?

7

What is the first stage of pressurisation for pneumatic test?

8

What is incremental pressure for second stage of pressurization for pneumatic test ?

9

What will be total pressure at the end of 3rd stage?

10 Following 5 pressure gauge ranges are available. Which of the two you will choose for Hydrostatic test? 0–400psi, 0–600 psi, 0–750 psi, 0–1000psi, 0–1200psi 11 For Pneumatic testing which of the two gauges from the given five you find suitable? 12 If ambient temp. is 125˚F, the hydrostatic test inspection shall be carried out at : a. 125˚F b. Lower than 120˚F c. Above 120˚F d. 100˚F SOLUTION: API 510 – DAY 2

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1 The recommended minimum test temp. for hydrostatic test Test temp > MDMT + 30˚F , i.e 70˚F 2 Mandatory minimum test temp for Pneumatic test Test temp > MDMT + 30˚F , i.e 70˚F 3

Hydrostatic Test pressure Test pressure = 1.3 x MAWP x Stress ratio = 1.3 x 200 x 17600 = 286 psig 16000

4 Minimum inspection pressure for Hydrostatic Testing Insp. Pressure = Test pressure = 286 = 220 psig 1.3 1.3 5

Pneumatic test pressure Test pressure = 1.1 x MAWP x stress ratio = 1.1 x 200 x 176 = 242 psig 160

6 Inspection pressure for pneumatic test Inspection Pressure = Test pressure = 242 = 220 psig 1.1 1.1 7 First stage of pressurisation for pneumatic test First stage = 50 % of test pressure = 121 psig 8 Incremental pressure for second stage of pressurization for pneumatic test 10% of test pressure = 24.2 psig 9 Total pressure at the end of 3rd stage 121 + (2 x 24.2) = 169.4 psig

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10 The two gauges for Hydrostatic test Lower limit of range 0 – 1.5x286 = 0 – 429 psi Upper limit of range 0 – 4 x 286 = 0 – 1144 psi Preffered range = 0 – 2x286 = 0 – 572 psi Choose 0 – 600psi and 0 – 750psi 11 For Pneumatic testing the two gauges from the given five Lower limit = 0 – 1.5 x 242 = 0 – 363 psi Upper limit = 0 – 4 x 242 = 0 – 968 psi Preferred range = 0 – 2 x 242 = 0 – 484 psi Choose 0-400 psi and 0-600 psi 12 Ans. (b)

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NOZZLE WELDS Fig. A – This configuration is represented by code Fig. (g) in ASME code. 1. The radius at top 2 mm R shall be 3.2 mm min. 2. The 70° angle shall be 60° max. 3. Nozzle to shell fillet weld : Min. throat required = tc = smaller of 6mm or 0.7 t min = 6mm or 0.7 (smaller of 19, 22, 26) = 6mm or 0.7x 19 i.e. 6 mm Change throat size to 6 mm 4. Min. inner corner radius (r1) = smaller of ¼ t or 19mm (r1) = smaller of ¼ x 28 or 19 mm Change (r1 ) = 7 mm min. Fig. B – This configuration is represented by code Fig (l) in ASME code 1. Shell to nozzle outer fillet throat t1 >= smaller of 6 mm or 0.7 tmin >= 6mm or 0.7 (smaller of 19, 20, 40) Min. size of fillet weld = 6

.= 8.57 say… 9 mm 0.7 Change 6mm to 9mm (size of weld).

2. Shell to nozzle weld (t2) shall be 6 mm – ok 3. t1 + t2 >= 1 ¼ ( t min ) >= 1 ¼ ( smaller of 19,20,40) >= 23.75 t1 = 9 x 0.7 = 6.3 therefore t2 >= 23.75 – 6.3 t2 >= 17.45 say 18 mm. 4. Inside corner fillet weld throat ( tc ) >= smaller of 6mm or 0.7 tmin Min. tc = 6mm Fillet weld size =

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6 = 8.5 0.7

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CASE STUDY 7 NOZZLE REINFORCEMENT ANALYSIS DATA: A new vessel has the following data: Shell thickness provided (t)= 20mm , corr. Allow=Nil. Design shell thickness for seamless shell (tr)= 18.5mm Nozzle thickness provided (tn)=12mm Nozzle thickness for seamless pipe (trn)= 6.5mm Finished nozzle opening (d)=160mm, Nozzle type=set on

Answer the following: 1) What is the total area required to be compensated (Ar) 2) What is reinforcement limit(X) parallel to vessel wall 3) What is reinforcement limit(Y) normal to vessel wall 4) What is extra area available in shell ( As) 5) What is extra area available in Nozzle 6) What is total area (Av) available inherant to the vessel (Av) 7) Is the additional reinforcement pad required for the nozzle? 8) What shall be the area ( Ap) to be provided by pad 9) What is the Max. pad O.D. possible? 10) If pad OD = 320 mm, what shall be pad thickness (tp)

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SOLUTION: 1) Total area required to be compensated (Ar) Ar = d x tr = 160 x 18.5 = 2960 mm2 2) Reinforcement limit (X) parallel to vessel wall X = 2d

X = 2x160 . X = 320 mm

3) Reinforcement limit(Y) normal to vessel wall Y = 2.5t or 2.5tn use smaller value = 2.5 x 20 or 2.5x12 , Y=30.0mm 4) Extra area available in shell ( As) As = d(t-tr) = 160 ( 20 – 18.5) = 240 mm2 5) Extra area available in Nozzle An= Y ( tn-trn)x2 = 30 x (12 - 6.5)x2 = 330 mm2 6) Total area (Av) available inherant to the vessel (Av) Av= (As + An) = 240 + 330 = 570 mm2 7) Is the additional reinforcement pad required for the nozzle? Since Av < Ar , R.F. pad is required 8) Area ( Ap) to be provided by pad Ap = Ar – Av = 2960 – 570 = 2390 mm2 9) Max. pad O.D. possible Max. pad O.D. = X = 320 mm 10) If pad OD = 320 mm, pad thickness (tp) tp =

Ap = 2390 . (pad OD – pad ID) ( 320 – 184 )

160 +12+12= 184 So tp = 16.4 mm ………… say 18 mm

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ASME VIII AND API 510 SAMPLE CALCULATIONS 1. A horizontal deaerator has been in-service for approximately 10 years. An onstream inspection shows that the vessel shell thickness is .275” (uniform) and that the heads have both pitted reducing the thickness at the crown radius to 0.300. The MDR for this vessel reflects that the shell is made from SA 414 GR E plate with Type #2 longitudinal joints in all three courses with an I.D of 66”. The heads are made from SA 285 GR C material, and are full hemispherical, with weld seams (Type 1) with an I.D. of 66” The nameplate stamping shows that the original MAWP is 280 psig @ 550ºF and complies with the rules for spot radiography (RT-3) with no static head considered can this vessel be allowed to continue to operate at this pressure and temperature? If it should be reduced. What is the MAWP that can safely be applied to this vessel? (Shell S = 16,200. Head S= 13,800) a. No – allowable pressure should be reduced to approximately 212 psig b. No – allowable pressure should be reduced to approximately 107 psig c. Yes – vessel is acceptable for operation at 280 psig d. Yes – vessel is acceptable for operation at 280 psig, if impact tests are conducted. 2. A tubular heat exchanger is constructed with a flat, unstayed, seamless circular head, welded to the shell with inside and outside fillet welds as shown in Fig.UG-34, Sketch (F) (C=0.20). The measured thickness of the head is 1”, and is corroding approximately 1/32” (uniform) every year. The thickness of the shell has not corroded, and an on-stream inspection shows the shell to be 0.375” thick. There are Type #1 joints in the shell, with full RT, and a vessel I.D of 30”. The fillet welds are in good condition, and are measured at .375” on both the inside and outside welds. The diameter of the head is 30”, and the vessel is stamped for an MAWP of 90 psig @ 500ºF. The head is constructed of SA-516 GR 70 material, and the shell is constructed of SA 285 GR C material. Assuming that the corrosion rate of 1/32” per year will continue, how may more years may this vessel be allowed to operate within the principles of the ASME Code? (head S = 17,500) a. 1.96 years b. 3.42 years c. 9.62 years d. 1.21 years API 510 – DAY 2

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3. A new pressure vessel has been received from a manufacturer with the following information made available to the inspector about the shell: MAWP 500 psig @ 780ºF MDMT 10ºF 200 psig Spot RT 60” ID Hydro pressure 750 psig @ 70ºF Material: SA 387 GR 21. CL 1 Thickness. 0.350” (P# 5 material Stress = 14000) Type 1 Category A welds Vertical height: 140 feet No impact tests performed No heat treatment performed Material not normalized From the above given information. How many individual Code violations can you as the inspector find as reason for not accepting this replacement part? a. No violations – This part meets all Code requirements b. 3 Code violations c. 5 Code violations d. 10 Code violations 4. A fractionating tower is 14’ ID x 21’ long, bend line to bend line, and is fitted with fractionating trays. The tower is designed for an external design pressure of 15 psig @ 700ºF. The tower is constructed of SA-285 GR C carbon steel, yield strength 30,000psi, and the design length is 39” between the fractionating trays, which are adding support to the vessel. Does this construction comply with ASME VIII requirements (assuming a designed thickness of ½”)? a. Yes, meets Code requirements b. No – does not meet code – pressure should be increased to 30 psig c. No – does not meet code – pressure should be decreased to 10 psig d. No – does not meet code – thickness should be increased to 3.6”

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5. An ASME – stamped pressure vessel has been altered and now requires a hydrostatic pressure test to be applied. The vessel is 175’ tall and has a pressure gauge at the top of the vessel and another gauge 25’ up from the bottom of the vessel for the inspector to look at. The MAWP is 125 psig. The ratio of design to material test stress = 1. What pressure should be shown on the gauge at the 25’ level to meet API 510 requirements? a. Approximately 275 psig b. Approximately 185 psig c. Approximately 125 psig d. Approximately 228 psig 6. An existing carbon steel pressure is stamped for lethal vapor service, and has an elliptical 2:1 head. The head is measured at 60.25” I.D in the corroded condition. The head, when new was 1.375” thick and 60” I.D. The stress value is 13,800, the MAWP is 300 psig, and the head is attached to the shell with a Type 1 Category B weld. Assuming a corrosion rate of 1/8” per year. Answer the following questions: y y y

What are the radiography requirements for the head-to-shell joint? Does the head in its corroded condition, meet ASME Code requirements? If the answer to B is yes, how many more years can the vessel operate within the parameters of ASME Code requirements? a. b. c. d.

Full. Yes. 4.75 years Spot. Yes. 8.95 years Partial. No. 10.65 years None of the above

7. A torispherical head is connected to a seamless vessel with a single welded butt joint with backing. The seam has been welded by a single welder, and is spot radiographed per UW11(a)(5)(b) y

What is the type of Joint. Joint category and joint efficiency factor? a. b. c. d.

Type 1. Cat D. E = 85 Type 2. Cat B. E = 10 Type 3. Cat A. E = 10 Type 4. Cat B. E = 85

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8. A 60”I.D pressure vessel will require a fillet welded with a (temporary) patch plate. The patch and the shell are both SA 515-60 material (S=15,000). The patch is .375” thick and the vessel is .622” thick with no corrosion allowance. The vessel has Type 1 Category A welds, and is stamped for RT-2, 200 psig @ 500˚F, and an MDMT of -15˚F. From the information given will this repair require the use of a welding procedure that has been impact testing? a. yes impact tests are required on the welding procedure b. no. impact tests are not required on the welding procedure c. yes, impact tests are required on both the base metal and welding procedure d. no, impact tests are only required on the base metal 9. A nozzle is installed in a vessel shell, as illustrated in Fig. UW-16.1(i), using two equal size fillet welds. The minimum shell thickness is 3/4 inch and the nozzle wall is 7/16 inch minimum thickness. Using equal leg fillet welds, what is the leg dimension of the welds rounded up to the next larger 1/16 inch? a. 7/16” b. 3/16” c. 9/16” d. 11/16 10. A vertical vessel is to be rerated to a new maximum Allowable Working Pressure based on calculations of the vessel parts. The top of the vessel is located at an elevation of 75 feet. The following calculation values (P) have been determined by the Engineer (elevations are given to the bottom of the items being considered, (static head of water equals 0.433 psi per vertical foot): 1) 2) 3) 4) 5)

top head. Elevation 72.5 feet, P-351.3 psi top shell section, elevation 65 feet, P-352.6 psi manway connection. Elevation 50 feet, P = 360 psi Reducer section. Elevation 30 feet, P = 372.5 psi bottom head. elevation 6 feet. P = 425 psi

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What is the maximum value of MAWP which can be applied to this vessel? a. 450 psig b. 360 psig c. 395 psig d. 348 psig 11. During the inspection of a horizontal pressure vessel. A torispherical head is measured and found to have the following dimensions. Thickness equals 1.25 inches. Inside diameter of skirt = 48 inches. The distance from the bottom of the head to the top of the vessel is 5 ft 6 in. The weight of the water equals 0.433 psi/ft. Form the vessel data report S = 15000 psi. and ‘RT-2’ has been met. At what Maximum Allowable Working Pressure can this head be used with no corrosion allowance? a. 490 psig b. 390 psig c. 416 psig d. 426 psig 12. A lap patch is to be installed on a pressure vessel built to ASME code. Section VIII, Div. 1 as part of a repair of the vessel. The patch is made of SA-515 Gr. 70 material (P-no. 1). 1-1/8 inch thickness without normalization. The owner’s engineer has determined the ratio of the allowable stress to the actual stress to be 1.0. The vessel nameplate lists the MDMT as 50ºF with “HT” for the heat treatment, therefore, the patch will be voluntarily heat treated. Will the patch plate require impact testing? a. Yes b. No c. No. if welding procedure is impact tested d. None of the above

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13. A pressure vessel cylindrical shell is measured and found to be 1.36 inches thickness at its thinnest point. The inside radius was measured at 28.625 inches. Plane records provide the following information: 1) The vessel has been in service for 4 years 2) the original vessel thickness was 1.4375 inches minimum 3) the allowable stress of the vessel material is 17500 psi at design temperature 4) the weld seam efficiency is 1 5) the maximum allowable working pressure is 745psi with a static head of water equal to 5psi ƒ ƒ

Based on the above, how much material thickness is available as remaining corrosion allowance? What is the remaining life of the vessel? a. b. c. d.

111”/10.61 years 250”/3.6 years 101”/5.31 years 202”/4.1 years

14. A vessel’s cylindrical shell has corroded down to 25”in thickness. The cylinder is 40º od with an unsupported length of 10’ Design temperature is 300ºF and the material yield strength is 30,000psi. What is the allowable external pressure allowed on this vessel? a. 38psi(approximately) b. 45psi(approximately) c. 12psi(approximately) d. 23psi(approximately)

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15. During the inspection of an existing pressure vessel you find it necessary to determine the weld seam efficiency of several joints on a vessel. The vessel nameplate shows RT-4. The joints type and degree of RT we read from ASME data reports for the vessel. What are the joint efficiencies for the following? Type Efficiency 1. Type1 2. Type2 3. Type3 a. 1.85 2.60 3.90 b. 1.90 2.90 3.100 c. 1.100 2.1 00 3.100 d. 1.85 2.80 3.80

Category

RT

joint

Cat A Cat B Cat C

spot Full RT Full RT

__________ __________ __________

16. A vessel cylindrical shell is measured today and found to be 1.0625” at the thinnest point. The inside radius is 24” Plant records provide the following: 1) 2) 3) 4) 5) 6)

Vessel has been in service 64 years. Original t was 1.1875” min. SV=15000 at design Efficiency = 85 MAWP = 500psi with a static head of water equal to 6psi Previous(last) inspection was completed 8 years ago and the wall thickness was 1.087

• Based on the above information, how much material t is available as remaining corrosion allowance? • What is the remaining life of the vessel? a. b. c. d.

.065”/40.6 years .0868”/29.93 years .001”/32 years .862”/15.6 years

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17. A flat unstayed circular head with a diameter of 14” is operating at 350psi at 500ºF. The SV = 17500 with an efficiency of 1.0 the C factor = .33. Can this head continue in service its present state or would a repair be necessary, if the present thickness is 1.25”? a. No, head must be replaced b. No, head must be repaired c. Yes, head can continue in service d. No, head thickness must be 2.5” to be acceptable

18. A vessel owner is to repair a pressure vessel by replacing one of the vessels seamless ellipsoidal heads with a duplicate head, but welded to the shell. The original vessel name plate is stamped “W” “Rt-2” and ”HT” • What type or types welded joints may be used in the repair? • What Radiographic Testing of the joint is required? a. b. c. d.

Type 1/full RT Type 2/spot RT Type 3/full RT Type 1or 2/spot RT

19. A vertical pressure vessel in water service with type 1 Category “A” Long seam welds is 10’ seam/seam is made from ½” thick SA516 GR70 material (S = 17.500) is stamped for an MAWP of 100 psig @ 650ºF, and is also stamped as “RT-3” (satisfies spot radiography rules) with an I D of 60”. What is the actual minimum thickness of this vessel including hydrostatic head a. .211” b. .250” c. .350” d. .360”

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20. The heads on the vessel in #19 are 2.1 elliptical heads are seamless and are made from the same material, same diameter, same thickness and are welded to the vessel with Category “B” Type 1 circumferential welds. What is the minimum thickness of the bottom head if the extra radiograph required by UW-11(a)(5)(b) is taken on head-to-shell weld? (Remember static head) a. .250” b. .200” c. .179” d. .105” 21. Assuming the same parameters for the above pressure vessel in #19 but the heads are seamless hemispherical heads with a 30” spherical radius attached with a category “A” Type 1 full penetration weld, what is the minimum thickness of the bottomhead? a. .250 b. .220” c. .179 d. .105” 22. An 8 feet I.D horizontal pressure vessel with Type 1 weld joints is constructed totally of SA285 GR C (S = 12,100) plate with two courses (one circumferential seam joining two cylinders.) The original thickness is .375” uncorroded (new and cold) and the vessel is stamped for full radiography (RT-1). The MAWP is 50 psig @750ºF. The heads are torispherical, 6% knuckle, 96.75” O.D skirt. And were .375” thick also when new. A onstream, inspections shows the vessel has corroded evenly over the head and shell with a uniform ¼” external corrosion. What MAWP can this vessel be operated at, assuming no static head? a. 25 psig b. 31 psig c. 17 psig d. 50 psig

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23. What is the required thickness of a seamless flat, unstayed circular head with a diameter (or short span) of 24” an internal design pressure of 250 psig @ 650ºF with material of SA105 (S=17.500)? Attachment is as shown in Fig UG-34(A), and the inside corner radius is not less than three the required head thickness a. 1.1” b. 1.9” c. 2.3” d. 1.66” 24. Given the parameters of the above flat head in #23, assume the head is not circular but elliptical with the same short span and a long span of 36”. What is the required thickness of this head? (NOTE: This question is not supposed to be in the test but a similar question has been asked previously) a. 1.9” b. 1.5” c. 2.1” d. 1.66” 25. A 60” I.D 1” thick pressure vessel constructed of SA442 GR60 material is stamped RT-3 and is also stamped for an MAWP of 70 psig @ 650ºF. A nozzle is located in the shell and doesn’t pass through a welded joint. Details of the attachment are as follows. Nozzle material – SA106 GR B Nozzle I.D – 16” Nozzle thickness – 375” Nozzle attached to shell by penetration weld into shell and a cover fillet weld on the outside of the shell only. Fillet weld leg lengths are ½”х ½”. Attachment detail is as shown in Fig UW 16 1 sketch (C). Does this construction need a repad? Assuming Fr, F and E=1.0 and tR = .890” and tRS = .290” a. No b. Yes c. Not enough information given d. None of the above

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26. What are parallel and perpendicular (or normal) limits of reinforcement for the nozzle in #25 above? a. Parallel – 16” Normal – 2.5” b. Parallel – 9.375” Normal – .9375” c. Parallel – 9.375” Normal – 2.5” d. Parallel – 16” Normal – .9375” 27. A pressure vessel has a new 18” ID manway installed in the shell, with a configuration similar to Fig UW = 16(a-1). The shell thickness is .350”, the manway is .280” thick and the repad is .375”thick. The cover weld attaching the pad to the shell is .300”in size and the cover weld attaching the pad nozzle is .300” in size. The nozzle is SA 516-70 rolled and welded plate (17.500 stress) fully RT’d and the vessel is also SA 516-70 (fully RT’d. the vessel is 50” ID and is constructed for 200 psig @ 500ºF. The od of the repad is 24” and the ID of the hole in the pad is 19”. The repad is also SA 516-70 material. Is this manway property reinforced? (All Fr. E and F = 1.0, tR = .287” and tRs = .103”) a. b. c. d.

Yes No Not enough information given None of the above

28. A vertical one course pressure vessel in vapor service is 12” tall is made of .300” nominal wall seamless pipe, SA 106 Gr B (S = 15,000). Design pressure is 250 psig 500ºF. The outside radius of the shell is 18”. The vessel is stamped RT=3 (spot RT) attached to the shell are two seamless torispherical heads made from SA516 Gr 70 plate (S = 17,500). The inside crown radius of the heads is also 18”. The heads are also .300” thick. What is the MAWP of this vessel based on the shell and heads? a. 250 psig b. 279 psig c. 220 psig d. 249 psig API 510 – DAY 2

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29. A 20’ tall pressure vessel is stamped for 1000 psig MAWP @ 900ºF. The hydrostatic test is to be applied at 70ºF. Materials are SA516 GR70 and SA240 type 302 S.S. plate. What is the minimum hydrostatic test pressure that should be applied at the vessel to satisfy ASME Code requirements? (stress value for SA240 Type 304 is 14,700 at 900º and 18,800 at 70º) a. 4038 psig b. 1500 psig c. 2000 psig d. 1659 66 30. what is the maximum allowable external pressure allowed on the following pressure vessel: OD = 24” Material = SA106 GR C (yield strength = 40,000psi) Nominal thickness = .500” Total length between lines of support = 48” Design temperature = 500ºF a. 327 psig b. 390 psig c. 456 psig d. 512 psig 31. A stationary vessel is made from SA516 GR70 plate that has been normalized. The MDMT is 30ºF @ 470psig. The actual material thickness is 3.0” thick and the vessel id is 48” and the joint efficiency is 1.0 Does this material require impact testing? a. Yes b. No c. Not enough information d. None of the above 32. Assume the same vessel as in #31 above except that the plate has not been normalized. Does this material require impact tests? If so. What FT LBS of energy would be required for this plate? a. No impacts required b. Yes impacts required, 25ft.lbs for 3 specimens(avg.) c. Yes impacts required, 17ft.lbs for 3 specimens(avg.) d. Yes impacts required, 35ft.lbs for 1 specimens(minimum) API 510 – DAY 2

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33. A pressure vessel has been inspected and found to be thinned over a 20” long area parallel with the long seam. Thickness readings in this area are .275”, .279” .280” and .295”. Original thickness is .375”. The vessel is now 11 years old. MAWP is 80 psig @ 100ºF. 24” ID and material stress is 16,800. Joint efficiency is .85 1. What is the minimum shell thickness? 2. What is the longest dimension that can be corrosion averaged per API 510? 3. What is the internal or onstream inspection interval for the vessel based on the above? a. b. c. d.

1) 1) 1) 1)

.067” .100” .500” .050”

2) 2) 2) 2)

12” 6” 2.44” 2.14”

3) 3) 3) 3)

10 years 10 years 10 years 10 years

34. An existing pressure vessel material thickness is measured at .500” on an inspection. 4 years later this same thickness is measured at .250” at the same location. Required thickness (by calculation) shows that the vessel must be .125” thick to withstand the given pressure per API 510, and from this information, what is the: a. Metal loss = b. Corrosion rate = c. Corrosion allowance = d. Remaining life = e. Inspection interval = 35. A pressure vessel made of SA 285 GR B (12,100 = stress) material has been in service 10 years it has a measured shell thickness of ½” at the thinnest section. If this vessel is to be operated with a stamping that indicates an internal MAWP of 300 psig@ 700 Deg F.RT-2, Type 1 joints, and an ID of 80”. What will the minimum thickness of the shell be to support this pressure? a. Approximately 1.200” b. Approximately 1.00” c. Approximately 750” d. Approximately 890”

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36. What is the minimum thickness required for a pressure vessel that is stamped with a 600 psig @ 500º MAWP is 70” OD complies with the rules for spot radiography has Type 2 joints is made from SA 515 GR 60 (S=15,000) material and is 25’ high in water service? a. 1.950” b. 1.074” c. 1.560” d. 1.746” 37. A pressure vessel head is thinned at the knuckle radius to 25C” thick. The head is attached to the vessel with a Type 1 joint that is fully radiographed and operated at 600ºF. The head is a 2:1 elliptical head with an ID of 45” and is made from SA 285 GR C (S= 12 000) material. What MAWP can be operated on this head with no static head considered? a. 175 psi b. 153 psi c. 190 psi d. 142 psi 38. A pressure vessel shell is 80” ID. 375” thick and the heads are torispherical (6% knuckle radius) and are also 80” ID and .375” thick. Both shell and heads are made from SA 36 plate (14.500 stress), and the stress complies with spot radiography. The heads are spliced (welded) and comply with spot radiography. Assuming all joints are Type 1. What is the MAWP allowed on this vessel based on the heads assuming a 500” temperature and vapor pressure only? a. 70 psi b. 85 psi c. 64 psi d. 110 psi 39. If a vessel is built from SA 106 GR B (S = 15 000) seamless pipe is 375” nominal wall thickness and has one circumferential weld joint and is 24” ID, what is the MAWP allowed if the temperature is 500ºF and the vessel is stamped “RT-2”? a. 403 psi b. 425 psi c. 387 psi d. 415 psi API 510 – DAY 2

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40. An 8” nozzle on a vessel is replaced with an identical nozzle with an attachment similar to UW 16.1 Sketch C. If the nozzle thickness is .500” and the vessel shell thickness is 1”. What is the minimum size of throat and leg dimensions for the attachment fillet welds? a. .170” throat/.250” leg b. .750” throat/1.00” leg c. .250” throat/.353” leg d. .250” throat/.250” leg 41. A vessel nozzle has corroded around the attachments fillet welds, reducing them to a 125 throat thickness. With a nozzle wall thickness of .350” and a shell thickness of .500” and assuming a joint configuration in compliance with UW 16.1 Sketch (i) will this condition meet ASME Code? a. Yes b. No c. Fillet welds not required for this nozzle d. Not enough information given 42. An 8” nozzle in a pressure vessel if to be replaced with a 10” ID SA 106 B nozzle that is .280” thick. The vessel is 75” thick and is stamped for an MAWP of 350 psig @ 600ºF. The vessel ID is 60” and the vessel complies with the rules for spot RT (Type #1 joints). The installation is similar to UW–16 1 Sketch (c) with a 750” throat fillet weld. Does this nozzle require a reinforcing pad? The S.V for the shell is 15,000 psi. The required thickness of the shell is 490” and the required thickness of the nozzle is 160” (All E.F. FR= 1.0) a. Yes b. No c. Not enough information given d. No reinforcement calculations required per UG-36 (c)(3)(a)

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43. A 50’ high Amine Tower has been altered and requires a hydrostatic test. The MAWP is 350 psig @ 750ºF. The vessel material are SA 516 GR 70, SA 285 GR A, and SA 53 GR B (seamless) pipe. If the test is to be conducted to ASME VIII requirements. What is the minimum hydrostatic pressure required on the bottom head if the test will be conducted at 70ºF? a. 455 psi b. 546 psi c. 518 psi d. 670 psi 44. A vessel is to pneumatically tested @ 70ºF per the Code. The MAWP is 200 psig @ 700 Deg F. The materials are SA 240 Type 304 stainless steel and SA 515 GR 65. What is the minimum pneumatic pressure required on this vessel? The S.V. for SA 240 Type 304 @ 700º F is 16,800 psi, and 18,000 psi @ 70ºF. a. 231 psi b. 220 psi c. 300 psi d. 425 psi 45. A circular flat head is seamless and is 20” diameter and is attached similar to Figure UG 34, (b-1). If the MAWP of the vessel is 300 psig @ 500 Deg F and the material is SA 105 (S = 17,500), what is the minimum required thickness of this head? a. .894” b. .970” c. .900” d. 1.07” 46. A circular flat head is 30” in diameter and is attached to the shell with a weld similar to Fig. UG 34.(h). The head is splice-welded (seamed) with a Type 1 joint and has been spot radiographed. The heat is made from SA 515 GR 60 (S = 15,000) What is the minimum thickness required on this head. Assuming a temperature of 650ºF and an MAWP of 375 psig? a. 1.677” b. 2.09” c. 2.955” d. 3.650”

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47. A vessel is constructed for external pressure and is supported at 7’ intervals. The OD is 48” the thickness is .500” and the temperature is 600ºF. What is the approximate maximum external pressure allowed on this vessel? The material yield strength is 28 000psi a. 111 psi b. 160 psi c. 181 psi d. 195 psi 48. A vessel is made from SA 662 GR A material SA 182 GR 21 normalized and tempered material and SA 516 GR 70 material. All materials are .375” nominal thickness and the vessel is made for a design temperature of -30ºF. Which materials, if any will require impact testing? a. All materials b. Only the SA 662 and SA 182 materials c. Only the SA 182 and SA 516-07 d. Only the SA 516-70 49. A 30” ID vessel is fully radiographed, has Type 1 joints, is .500” thick and is stamped for an MAWP of 100 psig @ 300 Deg F; with a corrosion allowance of 1/16”, and a minimum temperature of -40ºF. If the material is SA 516 GR 70 (not normalized), does this vessel require impact testing? (A reduction stress ratio of 1.0 will be used, per UCS 66 1). a. Yes, requires impact testing b. No. does not require impact testing c. Exempted from impacts per UG-20(f) d. Not enough information provided 50. A vessel is checked during an internal inspection and is found to be .753 inches thick. 5 years later the vessel is shown to be .500” thick. With a minimum thickness required of 350”. a. Metal Loss = b. Corrosion rate = c. Corrosion allowance = d. Remaining service life = e. Inspection interval per API 510 =

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51. An 80” ID vessel is fully radiographed, is 1” thick and is made from SA 516 GR 70 (S = 17,500) material with Type #1 joints with an MAWP of 150 psig @ 600ºF. If this vessel corrodes at an even rate of 1/8” per year, how many years may the vessel operate within the principals of the ASME Code? a. 5 24 years b. 2.62 years c. 10 48 years d. 3 15 years 52. A pressure vessel is 175’ tall and is stamped with an MAWP of 150 psig. What is the minimum hydrostatic test pressure that should be shown on a pressure gauge that is placed 25’ up from the bottom of the vessel, assuming the ratio of design stress to test stress is 1.0, and all other rules of ASME have been met? a. 225 psi b. 235 psi c. 250 psi d. 260 psi

53. An elliptical head (2:1 ratio) is attached to an existing pressure vessel. The heat has internally corroded around the skirt and is measured at 1/8” uniform corrosion. The original inside diameter of the head was 60”, and the MAWP of the vessel is 150 psig @ 650ºF allowable stress value is 17.500. With a stamping of RT-2 applied to the vessel using a Type 2 weld what is the minimum thickness required for this head? a. .208” b. 258” c. 312” d. 335” 54. A seamless ellipsoidal head is attached to pressure vessel using a single “Vee” grove weld with a backing strip. If spot radiography per RT-2 is conducted on this vessel, determine the following and the applicable ASME Code paragraph? a. Head Efficiency _________________ Para. _____________________ b. Joint Category __________________ Para. _____________________ c. Joint Type ______________________ Para. _____________________ API 510 – DAY 2

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55. A pressure vessel has the following measurements (averaged) at the below locations on one year. The same readings are taken 5 years later at the same locations. With a minimum thickness of .125” at all location determining the remaining life of each component:

st

1 year 5th year Remaining Life

Top Head .350 .300

Bottom Head .300 .270

Shell # 1 .285 .270

Shell # 2 Nozzle # 1 .275 .265 .200 .150

Nozzle # 2 .250 .230

________

________

________

________ ________

________

56. A vessel is stamped for 400 psig design pressure and is currently measured to be .788” thick. The shell material stress value is 16,800, and the joint efficiency is .85. The i.d. of the vessel is 47.5”. If the corrosion rate is known to be .072” per year, and the next inspection is scheduled for 6 years from the current inspection, per API 510 this vessel: a. May continue to be operated for 6 years at the current design pressure b. Should be reduced in pressure or inspection interval c. Should be allowed to operate at 550 psi d. Should be immediately removed from service

57. A 60 KSI tensile strength weld metal is used to repair a 75 KSI tensile strength base metal. Total base metal thickness is .390” and the depth of the repair is .195” What is the required total thickness of this weld deposit, per API 510? a. .195” b. .390’ c. .520” d. .243”

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ASME VIII AND API 510 SAMPLE CALCULATIONS ANSWERS

1. Shell: P = ? t = .275 E = .80 R = 33 S = 16,200 P = (16,200 x .80 x .275) / (33 + .6 x .275) P = 3565 / 33.165 P = 107 462 psig (No H H) Heads: P = ? t = .300 L = 33 E = .85 S = 13,800 P = (2 x 13,800 x .85 x .300) / (33 + .2 x .300) P = 7038 / 33.06 P = 212.88 psig (No H.H.) ANSWER: B

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2. t = ? d = 30 P = 90 S = 17,500 E = 1.0 C = .20 t = 30 (0.20 x 90 / 17,500)1/2 t = .962 1 – .962 = .38CA / 03125CR = 1.21 years ANSWER : D

3. 1. 2. 3. 4. 5.

Pressure not to Code for thickness Impacts required Hydro pressure insufficient Heat treatment required Full Radiography required

ANSWER: C

4. L = 39 A = 0.001 Dρ = 169” t = .5 L/Dρ = .230 Dρ/t = 338 Yield = 30,000 PA = (4 x 8000) / (3 x 338) PA = 32,000 / 1014 PA = 31. 55 psig ANSWER: A

API 510 – DAY 2

yes. Meets Code

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5. 175’ tall with a gauge at 25’ = 150 ft of head pressure acting on gauge MAWP = 125 DS/MS = 1.0 1.3 X MAWP X (1.0) + (H.H.) = 1.3 X 125 + (.433 X 150) = 162.5 + 64.95 = 227.45 PSIG ANSWER ANSWER: D

6. A FULL, Per UW – 11(a)(1) B.

T = 1.25” P = 300 (No H.H) S = 13,800 E = 1.0 D = 60.25

From UG-32

t = PD / (2SE-0.2P)

t = (300 x 60.25) / (2 x 13,800 x 1 – 0.2 x 300) t = (18,075) / (27,600-60) t = 18,075 / 27,540 = 0.656 REQUIRED ANSWER B – YES 0.656 REQU < 1.25 ACTUAL CA = RL , R.L= (1.25- 0.656)/).125 = 0.54/0.125= 4.75 CR ANSWER: A

7. Type 2. Category B weld with a joint efficiency of or 1.0 per UW- 11(A)(5)(b) ANSWER: B

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8. S = 15,000 E = 1.0 R = 30 t = .622” P = 200 t = (200 x 30) / (15,000 x 1– 0.6 x 200) t = 6,000 / 14,880 t = 0.403 From Fig UCS – 66 – Curve B @ 0.622 = 5ºF From Fig UCS – 66 1 – (0.403 x 1.0) / (0.622 – 0) = 0.64 Allowable reduction = 35ºF Allowable = +5 -35ºF = -30ºF, which is lower than -15ºF ANSWER: B No, impact tests not required.

9.

UW – 16.1 Sketch (I): tmn =0.4375” 7 tmn = 0.306” 1.1/4t =0 .546

From UW -16.1 Sketch (I) Welds must be: (a) t1+t2 = 1.1/4 tmn (b) t1 or t2 not less than smaller of ¼” or 7 tmn Step 1 0.546/2 =0. 273 +0. 273 = 1 1/4 tmn “a” is satisfied Step 2 0.273 is greater than 0.250” - “b” is satisfied Step 3. Convert Throat to Leg – 0.273 x 1. 414 = 0.386” Rounding up to next larger 1/16” = 7/16” ANSWER: A = 7/16”

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10.

a) 351.3 – (2.5 x0.433) =350.218 b) 352.6- ( 10 x0.433) =

348.27

c) 360 – 10.825 = 349.175 d). Reduce elev 30’ @ 372.5 -( 75 – 30 ) 0.433 =372.5 – 17.32 = 355.18 e). Bottom head elev 6’ @ 425 psi = 75’-6’ = 69’ x .433 = 29.877 425 – 29.877 = 395.123 Question. What is the max. value of MAWP which can be applied to this vessel? ANSWER: D

API 510 – DAY 2

348,27 psig

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11. Torispherical head-given: t = 1.25 Skirt i d = 48 L = skirt OD = 50.5 S = 15,000 E = 1.0 (UW – 11 (A)(5)(b) has been met) H.H = 5.5 x .433 = 2.381 psig From UG-32 P = SEt / (885L – 0.1t) P = (15,000 x 1 x 1.25) / (.885 x 50.5 + .1 x 1.25) P = 18,750 / (44.69 + .125) P = 418.3 psig – 2.3 psig (H.H.) = 416 pig ANSWER:C

12.

SA 515 Gr 70 not normalized 11/8” thick Allowable stress ratio = 1, MDMT -10°F a) UG-20 (f) – Not exempt b) UCS 66 (Figure) General notes – curve A material c) UCS 66 (Figure) – Requires impacts @ 75° for 1.25” material d) UCS 66 (b) Figure – Allows reduction of 0 for 1.0 ratio e) UCS 68 (c) - 30° reduction allowed for voluntary PWHT, 75°F – 30°F = 45°F -40°F Vessel requires impact testing ANSWER : A

50.

A .753 – .500 = .253” B .253” / 5 = .050” per year C .500” – .350” = .150” D .150” / .050” = 3 E 2 years per API 510

51.

From UG-27 tr = ? P = 150 S = 17,500 E = 1.0 R = 40 t = 150x40 / (17,500x1 – .6x150 ) t = 6000 / 17410= 0.344 1.0” – .344” = 0.656 .656 / .125 = 5.24 years

ANSWER : A

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52.

From UG - 99 1.3 X MAWP X (St / SD) + H.H H.H = 150 X.433 = 64.95 or 65 1.3 X 150 X 1 + 65 = 260 psi

ANSWER : D 53.

From UG-32 P = 150 S = 17.500 E = 1.0 D = 60 + (1/4”) = 60.25 t = (150x60.25 / (2x17.500x1-.2x150)) t = 9037.5 / (35000 – 30) t = .285”

ANSWER : B

54.

A. E = 1.0, UW-11(a)(5)(b) and UW-12(d) B. Category B UW-3 C. Type 2,UW-12 Table

55.

Top Head (.300 -.125) / .01 = 17.5 years Bottom Head (.270 -.125) / .006 = 24.16 years Shell#1 (.270 -.125) / .003 = 48.33 years Shell#2 (.200 -.125) / .015 = 5 years Nozzle #1 (.150 -.125) / .023 = 1 years Nozzle #2 (.230 -.125) / .004 = 26.85 years

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56.

From API 510 – C/R = .072” per year x 6 = .432 metal loss .788 - .432 = .356 From UG-27 P = (16.800x.85x.356) / (23.75 – 0.6x.356) = 5083.68 / 23.963 P = 212.14 – Pressure or Inspection Interval must be reduced ANSWER: B

57.

From API 510 – 75/60 = 1.25,

1.25 X (.195) =0 .243”

ANSWER : D

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ASME SEC VIII QB 1. What will be the size of nozzle to shell weld for nozzle weld configuration? Conforming to Fig.-‘j’ of UW-16. (Nom. Shell thickness = 28 mm., Nom. Nozzle thickness = 16mm., weld size t2= 12mm) a. 8 mm b. 10 mm c. 12 mm d. 14 mm 2. A radiograph for a long seam in new pressure vessel (UW 51) of

25mm thick plate shows 3mm crack, and 6 mm long isolated slag. Your decision for acceptance of the radiograph will be: uw 51 second column 1 & 2 a. b. c. d.

Repair crack, repair slag Repair slag, accept crack Repair crack, accept slag Accept crack, accept slag

3. For vessel 2.5 inch thick, MDMT specified was 60ºF and material of construction used was SA 515 gr 60, without impact testing. The vessel failed later due to brittle failure. Maintainance Department says SA 516 GR 60 should have been used. What is your assessment? a. SA 515 GR 60 failed but 516 gr 60 would not have failed b. 516gr 60 would not have made any difference c. Impact strength was not apparent reason for failure d. b and c above 4. Choose correct hydrostatic test pressure from given options for a vessel with following data: Design pressure Design temperature M.O.C Allow stress (Ambient) Allow stress (675ºF) a. b. c. d.

= = = = =

200 psi 675º F SA 537 Cl.1 18,000 psi 15,000 psi

350 psig 260 psig 312 psig None of above

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5. In liquid penetrant examination the maximum permitted rounded indication size for circumferential welds with plate thickness up to 1 inch will be: a. 1/8” b. 1/16 c. 3/16” d. ¼” 6. A pressure vessel constructed according to ASME Sec. VIII, Div. 1 with shell thickness 7/8’’ (Material of Construction P No. 4, group no. 1) is to be repaired by using insert plates. The requirement of radiography to be incorporated in repair procedure shall be: a. Full radiography b. Spot radiography c. May be a, or b depending on joint efficiency d. Data is not adequate 7. An in-service vessel with seamless 2:1 Ellipsoidal head 60 inch ID, 400 psi design pressure, (corrosion allowance = 0) and (S = 20000 psig) was inspected. Available thickness of only 5/8” was observed on the crown portion. The knuckle thickness was found to be adequate. Your assessment is: a. Head thickness in crown portion is still ok for operation. b. Thickness is inadequate. c. Depends on the opinion of third party inspector d. Depends on the opinion of API 510 inspector 8. For a certain nozzle to shell joint (No corrosion allowance is required.) following data is presented. Shell thickness provided Nozzle I.D. Pad size Thickness of pad

= = = =

0.42 inch. 3.2 in. 6.4 in. O. D. 0.42.

Your assessment is: a. Nozzle is adequately reinforced. b. Reinforcement is inadequate. c. Data is inadequate: nozzle thickness must be given. d. Data is inadequate: design shell thickness must be given. 9. For a vertical process column with column ID. = 48'' and height (tan-tan) =98 ft., the hydrostatic head for bottom dished head (2:1 Ellip. Type, ie Depth 2 feet) will be: a. 40.6 psi b. 42.4 psi c. 43.3 psi d. None of above

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10. Following four new seamless std. torispherical heads are available for use for following design conditions. Choose the correct one. Design pr = 235 psi, Head I.D = 72’’, S = 20000 psi with no C.A. a. Design thk = 0.9882”. Provided thk after forming = 1.0” b. Design thk = 0.4886”. Provided thk after forming = 0.5” c. Design thk = 0.6184”. Provided thk after forming = 0.625” d. Design thk = 0.7496”. Provided thk after forming = 0.75” 11. Following four new seamless (2:1) ellipsoidal heads are available for the following design conditions. Choose the correct one. Design pr = 332 psi, Head I . D = 60’’ S = 20000 psi with no C A a. Design thk = 0.7382”. Provided thk after forming = 0.75” b. Design thk = 0.9788”. Provided thk after forming = 1.0” c. Design thk = 0.4985”. Provided thk after forming = 0.5” d. Design thk = 0.7377”. Provided thk after forming = 0.75” 12. Head in Q1 (torisph Head-A) is to be analysed according to API 510, after placing the vessel in service for 10 years. For the purpose of API 510 analysis, value of crown whose radius can be taken as: a. 72’’ b. 60’’ c. 48’’ d. 54’’ 13. For head in Q.2 (Ellip. Head - B) value of crown radius for API 510 analysis can be taken as: a. 72’’ b. 60’’ c. 48’’ d. 54’’ 14. The crown portion for head A may be considered as the portion lying entirely within a circle whose centre will be same as head centre and diameter will be a. 68.5’’ b. 36.4’’ c. 57.6’’ d. 54.0’’ 15. For head B, the crown portion would lie within similar circle of diameter: a. 60’’ b. 30’’ c. 54’’ d. 48’’

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16. Required minimum thickness of crown portion for analysis as per API 510 for head A shall be: a. 0.3695’’ b. 0.4075’’ c. 0.4235” d. 0.4825’’ 17. Required minimum thickness for crown portion for head B as per API 510 shall be: a. 0.4490” b. 0.4262’’ c. 0.3652’’ d. 0.4863’’ 18. The minimum nominal thickness of new cylindrical shell with design pr=555 psi inside diameter = 58’’, S= 20000 psi and E = 0.85 with corrosion allowance of 1/8’’ will be: a. 1.0 inch b. 1.50 inch c. 1.125 inch d. 1.25 inch 19. After 10 years of service, extensive corrosion was observed on the shell (shell Nominal thickness as per above question) over a patch lying entirely beyond 6 inches from weld for the vessel above. Thickness measured in this area was only 0.96’’, while on weld area, the corrosion was within expected limits. If Corr. Allowance required for remaining life is 1/16” (0.06”), the vessel is: a. Safe for design conditions b. Unsafe for design conditions c. Safe only if welds are fully radio graphed and ok d. Safe only if welds are UT checked and OK 20. You are planning for the Hydro-test of a vessel with test pressure 40Kg/cm2g. The calibrated test gauges available are: 0-50 Kg/cm2g, 0-100 Kg/cm2g, 1-150 Kg/cm2g and 0-200 Kg/cm2g. Which two gauges are acceptable for this test? a. 0-50 Kg/cm2g and 0-100 Kg/cm2g b. 0-100 Kg/cm2g and 0-200 Kg/cm2g c. 0-50 Kg/cm2g and 0-200 Kg/cm2g d. 0-100 Kg/cm2g and 0-150 Kg/cm2g 21. PWHT is required for vessels, constructed with material classified as P No. 3, Group 3 for a thickness exceeding: a. 1inch b. 5/8 inch c. 0 inch d. 1.5 inch

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22. Min. PWHT temperature and soaking period of weld with P4 and P5A, materials both with thickness = 3.0”, would be as follows: a. Temp= 1100°F, Time = 2hr., 15 min. b. Temp= 1100°F, Time = 3hr. c. Temp= 1250°F, Time = 3hr. d. Temp= 1250°F, Time = 2hr., 15 min. 23. For the given configuration, total reinforcement area to be compensated will be________. Data with usual notation: d = 100 mm, t = 12 mm, tn = 6 mm. , tr = 10.5 mm, trn = 5 mm a. 920 mm sq. b. 870 mm sq. c. 1020 mm sq. d. 1050 mm sq. 24. The length of a charpy specimen is: a. 2.165” (55.0mm) b. 2.10” (54.0 mm) c. 2.15” (54.6 mm) d. 2.00” (50.8mm) 25. General mill under tolerance for the plate is: a. 0.01” or 6% (whichever is greater) b. 0.1” or 6% (whichever is smaller) c. Under tolerance for the plates is always zero d. 0.01” or 6% (whichever is smaller) 26. A pressure vessel is scheduled for pneumatic testing using the methodology of ASME Code, Section VIII, Division 1, with the maximum allowable working pressure = 635 psig at 375° F. The vessel is neither enameled nor lined. How many pressurization steps are needed to achieve the minimum required test pressure, and at what pressure will the visual examination be performed? a. 6 steps; 635 psig b. 6 steps; 793.75 psig c. 9 steps; 635 psig d. 9 steps; 793.75 psig 27. A nozzle is installed in a vessel shell, as illustrated in Fig. UW- 16.1(i), using two equal size fillet welds. The minimum shell thickness is 3/4 inch and the nozzle wall is 7/16 inch minimum thickness. Using equal leg fillet welds, what is the leg dimension of the welds rounded up to the next larger 1/16 inch? a. 7/16” b. 3/16” c. 9/16” d. 11/16

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28. A vessel with 60 inches ID is to be provided Std. torispherical heads. The heads shall be formed with crown radius and min. knuckle radius as follows (head thickness = 1.2 inch): a. 60 inch, 4 inch b. 60 inch, 3.6 inch c. 25 inch, 3 inch d. None of above 29. A pressure vessel with nominal diameter 1200 mm was inspected for ovality of shell. A opening of 200 mm I.D. exists. The permissible ovality at the vessel cross section which is 150 mm from center of the opening is: a. 12 mm b. 16 mm c. 14 mm d. 18 mm 30. A pressure vessel has design pressure = 300 psi. Its safe stress values at ambient and designed temperatures are 19,800 psi and 18000 psi respectively. The minimum hydrostatic test pressure and inspection pressure respectively for above will be: a. 450 psi, 390 psi b. 390 psi, 330 psi c. 429 psi,330 psi d. None of the above 31. A vessel is to be pneumatically pressure tested. What are some of the essential requirements for this test? a. While pressuring, increase the pressure stepwise. b. While pressuring, reach the test pressure without stopping, so that pressure does not fall during pressurisation stage. c. Ensure that test pressure is retained till completion of inspection of all welds using soap sud. d. All of above. 32. For a Pressure vessel with MDMT = 2 deg. C, is to be tested. The test shall be conducted at a temperature: a. 32°C to 48°C b. 32°C to 120°C c. 19°C max d. 19°C to 48°C

hydrostatically

33. General “mill under tolerance” according to ASME Sec., VIII Div. 1 for the plates is a. 0.01” or 6% (whichever is smaller) b. 0.1” or 6% (whichever is smaller) c. 0.1mm or 6% (whichever is larger) d. None of the above is a correct statement

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34. Following two combinations of nozzle pipe diameter and shell thickness are to be checked for reinforcement requirements Case 1: Vessel wall thk = 1/2 " and nozzle size 4” N.D. (4-1/2” OD) Case 2: Vessel wall thk = ¾" Nozzle size 2” N.D. (2-3/8” OD) According to ASME Sec. VIII Div 1, separate reinforcement pad calculations must be performed: a. b. c. d.

For both cases For none Calculations required for 1 but not for 2 Calculations required for 2 and not for 1

35. Check whether Impact testing is required or not for following two plates. Plates are to be used for Storage vessels which will be Hydrotested. Vessels neither do nor undergo temperature / pressure fluctuations or cyclic loading during service. Plate-1: M.O.C. Sa 515 Gr.70, thk=0.5”, MDMT= +10°F Plate-2: M.O.C. Sa 516 Gr.70, thk=1.0” MDMT= - 5°F a. Both require impact testing. b. Both do not require impact testing c. only Plate -1 requires impact testing

d. Only Plate-2 requires impact testing 36. For vessel 0.75 inch thick, MDMT specified was (-45ºF) and material of construction used was SA 516 Gr 60. a. Specify impact testing of material b. Impact testing of material need not be specified c. Specify impact testing of vessel after PWHT d. Specify impact testing of vessel after fabrication, prior to PWHT. 37. For the given configuration, reinforcement area available in shell will be: Data: t = 16 mm tr = 15 mm tn = 8 mm d =112 mm a. 1680 mm sq b. 112 mm sq c. 224 mm sq d. None of above

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38. For given configuration, correct minimum weld dimension (x) required as per ASME Sec. VIII, Div. 1 shall be: a. 10 mm b. 12mm c. 14mm d. none of above 39. The minimum PWHT temperature and minimum holding time for 1.5 inch thick welded joints P no. 5A plates shall be. a. 13000 F, 1.5 hrs. b. 12500 F, 1.5 hrs c. 11000 F, 1.5 hours d. None of above 40. A standard seamless (E=1) torispherical head (1 inch nom. thk) is to be used for construction of new pressure vessel with 72 inch ID, and design pressure = 300 psig. Material of construction has allowable stress of 20,000 psig. Which of the following statements is most appropriate? (Corrosion allowance is nil.) a. Conforms ASME Sec. VIII Div. 1 b. Does not conform ASME Sec. VIII, Div. 1 c. Depends on opinion of Vessel engineer d. Torispherical head is not permitted for use by code 41. A seamless (E=1) 2:1 Ellipsoidal head 60 inch ID, 400 psi design pressure, (corrosion allowance = 0) and (S = 20000 psig) when new, was provided thickness of 5/8”. Your assessment is: a. Head was designed correctly as per ASME Sec. VIII, Div. 1 b. Head was not designed correctly. Thickness is inadequate. c. Depends on the opinion of third party inspector d. None of the above 42. What is the alignment tolerance of a Category “A” weld joint, where the thinner of the two plates is 1-1/2” thick? a. 1/16 t b. 1/8” c. 3/16” d. 1/8 t 43. What is the maximum reinforcement permitted for a 1 inch thick circumferential weld? a. 3/32” b. ¼” c. 3/16” d. 1/8”

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44. A seamless shell (1 course) with two seamless elliptical heads are combined to form a vessel. Spot radiography was performed on the attaching type 1 welds. What joint efficiency / quality factor must be used for the head and shell calculations? (Assume circumferential stress governs.) (Hint UW 12 D governs) a. 0.90 b. 0.85 c. 1.00 d. 0.70 45. A rounded indication ¼” diameter was found during spot radiography of a 1/2” thick vessel weld. Your interpretation would be that: a. The indication is not acceptable to ASME VIII, UW – 51. b. The indication is not acceptable to spot radiography ASME VIII, UW – 52. c. The rounded indications are not a factor in the acceptability of welds not required to be fully radiographed. d. The rounded indications are not a factor for fully radiographed welds. 46. What is the length of a discontinuity permitted in a weld joining 0.575” thick plates when found by the radiographic method (RT – 1) a. 1/3t b. ¼” c. ¾” d. 1/3” Questions 47 – 50 are from this set of conditions. A 250 psi (Design Pressure) vessel is to be pneumatic tested in accordance with the original ASME Section VIII, Div. 1 rules. The material is SA-516 – 70 and has a design stress of 12,000 psi and stress of 17,500 psi at ambient test temperature. 47. What is the pneumatic test pressure required? a. 455 psi b. 401 psi c. 375 psi d. 313 psi 48. What is the minimum temperature (°F) at which a fabricated vessel can be tested? a. 10 degrees above operating temperature b. 10 degrees above MDMT c. 30 degrees above MDMT d. 30 degrees above zero

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49. What is the first stage pressure reading of the vessel gauge when pneumatically tested? a. 401 psi b. 227 psi c. 187 psi d. 201 psi 50. What is the pressure reading when inspection is preformed? a. 401 psi b. 412 psi c. 364 psi d. 318 psi 51. ASME Section VIII, Division 1 magnetic particle nondestructive examination personnel shall be qualified in accordance with: a. Section VIII, Division 1 (Appendix) 6 standards b. Section IX c. SNT-TC-1A d. ASME Code, Section V 52. A standard conditions:

seamless, Head (Torispherical) is used for the following

Material of Construction Design Pressure Design temp Inside Crown Radius Minimum available thk.

= = = = =

SA 515 gr 60 250 psig 580ºF 72 inches 1.14 inches

Category B welds are spot radiographed. Corrosion allowance = 0.125 inches Allowable stress at design temp. = 16400 psig Your assessment is: a. The head does not meet code requirements. b. The head meets the code requirements. c. Suitability would depend on decision of Pressure Vessel inspector. d. Data are not adequate. 53. A pressure vessel is to be constructed with MDMT = +20°F, M.O.C = SA 515 gr 60 . Impact testing not performed. Required shell thickness = ¾ , dished head thk. = 1-⅛ " ( torisph. head). Determine if this material is suitable for: a. Both shell as well as dished head b. Suitable for head but not for shell c. Suitable for shell only but not for head d. Not suitable for either

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54. For a certain pressure vessel with spot radiography, and all Welds type 1, Vessel diameter = 72 inch I.D. M.O. C = SA 515 gr 70 Design temp. = 600°F Allowable stress at design temp. = 20,000 psi If shell thk. = 5/8" and C. A = 1/8", the MAWP for the shell will be: a. 234 psi b. 168 psi c. 256 psi d. None of the above 55. A pressure vessel (M.O.C. 516 gr. 70) has external jacket spread over 72 inches length of the shell. (Jacket pressure = 180 psi, Jacket temperature = 350°F) the vessel OD = 36 inches. Shell thickness= 0.5 inch, C.A. = Nil. Decide which of the following are applicable in the present case. a. Shell thickness is OK. b. Shell thickness is NOT OK. c. Data are not adequate. d. Acceptance of shell thickness depends on opinion of vessel engineer. 56. Choose correct hydrostatic test pressure from given options for a vessel with the following data: Design Pr Design temp = M.O.C = Allow stress (Ambient) Allow stress (675°F) = a. 540 psig b. 515 psig c. 450 psig d. None of above

= 360 psi 675ºF SA 537 Cl. 1 = 18600 psi 16900 psi

57. Impact test requirement for the two plates is to be assessed for MDMT = 0ºF, to be used for Vessel which will be hydrotested and used for steady operation. Plate A. Plate B.

Plates 537 class 1, 2.0 inch thick Plates 515 gr 60, 0.75 inch thick

Your assessment is: a. Plate (A) and plate (B) both require impact test. b. Only (A) requires, (B) is exempt. c. Only (B) requires, (A) is exempt. d. Both do not require impact testing.

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58. For vessel shell, thk= 4.0 inch, max. weld mismatch shall be as follows: a. Long seam = ¼”, circ seam = ½” b. Long seam = ¼”, circ seam = 7/32” c. Long seam = 7/32”, circ seam = ¼” d. Long seam = 5/8”, circ seam = ½” 59. Toughness (opposite of brittleness) will be best for which materials: a. Materials represented by curve A b. Materials represented by curve B c. Materials represented by curve C d. Materials represented by curve D 60. In a pressure vessel one of the 2:1 ellipsoidal dished head is removed and a new seamless dished head of same type is installed with a single ‘V’ joint with backing strip and full radiography. What is the joint category, type and efficiency of the joint now? a. Category-B, Type-1 & E-0.9 b. Category-B, Type-2 & E-0.9 c. Category-A, Type-2 & E-1.0 d. Category-B, Type-2 & E-1.0 61. A pressure vessel of overall height 80’ has its part MAWP at various parts as detailed in the sketch. What is the vessel MAWP (hydrostatic head 1’ = 0.433 psi)? a. 419 psi b. 420 psi c. 430 psi d. 426 psi

4'

426 psi 32'

54'

80'

440 psi

442.5 psi

454.64 psi

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62. A vessel is to under go a hydrostatic test after a repair. The vessel’s stress allowable at the test temperature is 15,000 psi and its stress allowable at its operating temperature is 13,800 psi. The vessel’s MAWP at its operational temperature is 125 psi. What will be the required test pressure at the top of the vessel? a. b. c. d.

203.8 psi 169.6 psi 176.6 psi 143.7 psi

63. A cylindrical shell contains a welded long joint that is made using a backing strip that remains in place. All of the radiography requirements of UW 12 (a) have been met. For purposes of calculating circumferential stress on the cylinder, what will be the value of the joint E used in the calculation? a. b. c. d.

1.0 .85 .80 .90

64. A small exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand an external pressure of 350 psi. The tubes have and O. D. of 2.0 inch and are 6 inches in length with a wall thickness of .025 inch. What would be the approximate Factor A value for this combination of length diameter and thickness of tube is? a. b. c. d.

.0056 .00055 .057 10

65. An additional 4 inch nozzle was added to a pressure vessel and is similar to the one in Fig UW-16 1(i) The minimum thickness of the nozzle is .377 inch and the shell minimum thickness is .750 inch. What is the decimal value of the minimum throat required for two equal leg size fillet welds on this attachment? a. .235” b. .263” c. .250” d. .750”

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66. A cylindrical shell has a seamless hemispherical head on one end and a seamless ellipsoidal head on the other end. The elliptical head is attached by a type 2 weld meeting the spot radiography requirements of UW-11(a)(5)(b). The shell has a single longitudinal joint. All category A butt welds are type 1 with full radiography applied. The vessel will require an MAWP of 500 psi. The material of the shell and head is SA515-Gr.60. The allowable stress at the operating temperature is 15,000 psi. The heads inside diameter is 10’-0”. What is the required thickness of the 2 to 1 ellipsoidal head? a. b. c. d.

.250 .235 .209 .1003

67. Which types of butt-welded joints are allowed to be used to construct vessels in lethal service? a. A and D only b. A,B,C and D are permitted c. 1 and 2 dependent upon Category. d. But welds are not permitted in lethal service.

68. After rolling a plate into a cylinder designed for internal pressure it is measured for out of roundness; a. b. c. d.

It is acceptable if it is no more than 1% out of roundness. It is acceptable if it is no more than 10% out of roundness It is acceptable if it is no more than ½% out of roundness It is acceptable if it is no more than 2% out of roundness

69. What is the lowest metal temperature permitted to pneumatically test a vessel per Section VIII Div. 1? a. 30 ºF b. 30 ºF above MDMT. c. 30 ºF below MDMT. d. There is no such requirement, it is only a recommendation.

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70. What is the required thickness of a 60 inch I.D. cylindrical shell if; It has and allowable stress at design of 17,500 psi The vessel’s Category A and D Type 1 joints are fully radiographed. All Category B joints are Type 1 also and have been spot radiographed per UW-11(a) (5) (b) The vessel MAWP must be 350 PSI at 450ºF. The shell will see 11 psi of static head at its bottom. a. b. c. d.

.6072” .7388” .7159” .6266”

71. A hemispherical head formed form solid plate is 48.0 inches in inside diameter this head is attached to a seamless shell and has not had radiography on the Category A type 1 weld that attaches the head to the shell. The vessel is horizontal and operates at 500 PSI water pressure with an allowable stress on the head’s material of 15,000 PSI. The head’s thickness required is? a. b. c. d.

.5741” .5761” 1.14832” .2356”

72. A cylindrical shell has been discovered to have uniform external corrosion. The shells original thickness was 7/8 inch; it is presently .745 inch in thickness. The original O.D of the shell was 30 inches. The vessel operates at 650ºF with a stress allowable on the material of 15,000 psi 100 % RT was performed on the vessel. All joints are types 1 what is the vessel’s present MAWP? a. b. c. d.

760 psi 772.13 psi 766.88 psi 382.10 psi

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73. A shell course is being replaced with the new course being 60 inches in inside diameter and 7/8 inches thick. The vessel course material is SA515 gr 60 plate at a design temperature of 750ºF the stress allowed is 13,000 psi The vessel joints are all type 2 and the vessel is stamped RT3. what is the MAWP of this shell course? a. b. c. d.

298.11 psi 316.74 psi 150.35 psi 335.38 psi

74. A torispherical head which can be calculated using UG-32 of Section VIII Div. It has an outside skirt diameter of 84 inches and an inside knuckle radius of 6 % O.D this means that the inside crown radius must be; a. b. c. d.

42 inches 5.04 inches 84 inches 2.52 inches

75. A vessel has undergone welded repairs and will require a hydrostatic test. This vessel is horizontal and has an I D. of 60 feet. The vessel operates at 150 psi and the Data Report reflects an E of .85 for the vessel based on RT-3. The limiting thickness of the vessel is its shell course. The vessel is made of SA-5 15 Gr 70 material with an allowable stress at temperatre of 15,500 psi its allowable stress at test temperature is 17,500 psi. What is the required thickness of this vessel and what shall the pressure be as read from a gage on the bottom of the vessel during the test. The upper most part of the vessel is 6 feet above the centerline of the vessel. The static head of water is .433 psi per vertical foot. a. T = 3621 and gage pressure will be 169.3 psi b. T = .875 and gage pressure will be 260.624 psi c. T = .4599 and gage pressure will be 224.057 psi

76. A standard ellipsoidal head with a 1 1/2” flange is attached to the bottom of a vertical vessel. The heads inside diameter is 56 inches. And it’s depth is 16 inches The vessel has a total elevation of 100 feet from the ground The elevation at this head to shell joint is 5 feet. What amount of hydrostatic head must he considered for use in this head’s required thickness calculation? a. 41.135 psi b. 41.909 psi c. 41 psi

d. 41.69 psi

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ASME SEC VIII QB Q. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

ANSWER C C A C C A A A C D C A D C D C A C A

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

D C C D A D A C B B C A D A C B A B

API 510 – DAY 2

REFERENCE ASME VIII, UW – 16 (j) Notes ASME VIII, UW - 51 ASME VIII, Fig. UCS - 66 ASME VIII, UG - 99 ASME VIII, Appendix 8, 8.4 API 510 and ASME VIII, Table UCS - 57 API 510, 57 (e) and ASME VIII, UG-32 (f) Pad OD = 2d and pad thickness – shell thk is always ok h = 100 ft.; head = 100 x 0.433 = 43.3 psi (BOK) Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII Use 510 5.7 e also along with ASME SEC VIII USE API 510 5.7 g LAST 3 Lines along with ASME Shell and Head calculation ASME VIII, UG – 102 ASME VIII, Table UCS – 56 for PNo. 3, Note 2. ASME VIII, UCS – 56 (c) ASME VIII, UG – 37, Fig. UG – 37.1, See A ASME VIII, Fig. UG - 84 ASME VIII, UG – 16 (c) ASME VIII, UG - 100 ASME VIII, UW – 16, typ. pad to shell. (1/2 tmin) ASME VIII, UG – 32 (j) ASME VIII, UG – 80 (a) 2 ASME VIII, UG – 99 (b) and (g) ASME VIII, UG – 100 (d) ASME VIII, UG – 99 (h) ASME VIII, UG – 16 (c) ASME VIII, UG – 36 (c), 3 (a) ASME VIII, UCS – 66 and UG – 20 (f) ASME VIII, Fig. UCS - 66 ASME VIII, Fig. UG – 37.1

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38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

B B A A B C C C B B C D C A B C A A B D A D B A C D B B C C A B D B C A C C D

API 510 – DAY 2

ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII, ASME VIII,

UW – 16, Fig (p) UCS – 56, Table for P5 UG – 32 (e) UG – 32 (d) UW – 33 (a) UW - 35 UW – 3 and UW – 12 (d) UW – 52 c (3) UW – 51 b (2) a UG – 100 (b) UG – 100 (c) UG – 100 (d) UG – 100 (d) App. 6

UG-99 UW-12 UG-28 UW-16 UG-32 VIII UW-2(a)(1)(a)&(b) VIII UG-80 (a)(1) VIII UG-100© UG-27 and API 510 Body of Knowledge UG-32 UG-27 UG-116-UG UG 27 UG-116 UG 32(e) UG-99 and API 510 Body of Knowledge 41.135 + .559 (hydro hd. in head depth)=41.69

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SOLUTION : 1) t1 + t2 = 1.25 x 16= 20, But t1 = 12, so t2=8 So Size = 8 x 1.4 = 12 10.

Thickness of new torispherical head is given by ASME formula, t = 0.885 PL SE – 0.1 P

L = Crown radius .˙. L = Diameter of head E = 1 (seamless)

= 0.7496 mm Provided thk of 0.75” is ok. Correct answer:

d

11. Thickness of new Ellipsoidal head (2:1) is given by ASME Formula: t=

PxD 2SE-0.2P

= 332 x 60 2 x 20000 x 1 – 0.2 x 332 = 19920 39933.6 = 0.4985” Provided thk = 0.5” (OK) Correct Answer: c

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12.

For Torisph. Head, D = 72” For API 510 analysis Crown Radius = Diameter = 72” Correct answer: a

13.

For 2:1 Ellip head, for API 510 analysis Crown radius = 0.9 D = 54” Correct answer: d

14.

Crown portion lies in circle of diameter equal to 0.8D = 0.8 x 72 = 57.6” Correct answer: c

15.

Crown Portion lies in circle of dia. equal to 0.8D = 0.8 x 60 = 48” Correct answer: d

16.

For torisph head, for crown portion, use hemisphere formula using R = D t =

PxR 2SE – 0.2P

t=

235 x 72 2SE - 0.2P

=

use

R = D = 72” S = 20000 PSI

E=1 P = 235

16920 39933.6

= 0.4235” Correct answer: c

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17.

Again, use hemispherical head formula for Crown part: for Hemispherical head, t= PxR 2SE – 02P use R = 0.9 D S = 20000 psi = 332 x 0.9 x 60 E=1 2SE – 0.2P P = 332 = 332 x 54 39933.6 = 0.4489 Correct answer: a

18.

Required thickness t =

P X R SE – 0.6P

=

555 x 29.125 20,000 x 0.85 – 0.6 x 555

=

16164 16667

=

0.967” + 0.125 =

(R = 29.125” ,Half dia.)

1.09

Correct answer: c 19.

Thickness away from weld (required thk) t= t=

PxR SE – 0.6P

take: E=1

555 x 29.125 20,000 – 333

= 0.83” Available shell thickness Excluding required C.A.= 0.96”-0.06” = 0.9” 0.9” > 0.83” . . . (Safe) Correct answer: a

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SOLUTION

27) UW – 16.1 Sketch (I): tmn = .4375” 7 tmn = .306” 1.1/4t = .546

From UW -16.1 Sketch (I) Welds must be: (a) t1+t2 = 1.1/4 tmn (b) t1 or t2 not less than smaller of ¼” or 7 tmn Step 1. 546/2 = 273 + 273 = 1 1/4 tmn “a” is satisfied Step 2 .273 is greater than .250” - “b” is satisfied Step 3. Convert Throat to Leg – 273 x 1 414 = .386” Rounding up to next larger 1/16” = 7/16” ANSWER: A = 7/16”

40)Torrispherical t= .885 x 300 x 72 / {( 20000 x10 – (0.1 x30)}= 0.9572 in . It is less than 1in. So it is OK 41) Ellipsoid t = {400 x 60} / {(2 x20000 x 1) - )0.2 x400)} = 0.6012 in which is less than 5/8 inch . So ok

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Q.52 Ref.: ASME VIII, UG – 32 (e), T= E=

0.885 PL +C SE − 0.1P

1, (As head is seamless and Category B welds are spot radiographed.)

=

0.885 x 250 x 72.125 + 0.125 16,400 x 1 − 0.1 x 250

=

15957.6 + 0.125 16,375

=

0.974” + 0.125

=

1.0995” Available thickness = 1.14” ——— OK

CORRECT ANSWER:

b

Q.53 Refer Fig. UCS – 66 from ASME VIII Div.1 Material is represented by curve B MDMT – Thickness point for ¾” thickness is above the curve MDMT - Thickness point 1-1/8” is below the curve Material OK for ¾” thickness — Shell Material NOT OK for 1-1/8” thickness — Head CORRECT ANSWER: c

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Q.54 Ref.: UG – 27 c (1) MAWP =

SEt R + 0.6t

E = 0.85 from Table UW – 12

And t = 5/8” – 1/8” = ½” after deducting corrosion allowance MAWP =

20,000 x0.85 x0.5 36.125 + 0.6 x0.5

Note: R in corroded condition = 36.125”

= 233.36 . . . . say 234 psi CORRECT ANSWER: a Q.55 L/Do

= 72 / 36 = 2.0

and

Do / t = 36 / 0.5 = 72

From Fig. G of ASME II – Part D, A = 0.0011 From Fig. CS-2, B = 11500 4 x 11500 4B Allowable Ext. Pr.= = = 212.9 psi > 180 psi . . . OK 3( Do / t ) 3 x 72 CORRECT ANSWER: a Q.56 Refer UG – 99 of ASME VIII Hydrostatic test pressure = = =

1.3 x design pressure x stress ratio 18600 1.3 x 360 x 16900 515.0 psi

CORRECT ANSWER: b

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Q.57 Plates 537 clause 1 is curve D and 515 gr60 is curve B. From Fig. UCS – 66, plate A, the point is above curve. So impact testing not required for plate A. For plate B, point is below the curve. Now go to UG – 20 (f). Material is P No. 1 and < 1”, and temperature > 20°F. So impact testing for B is also not required. CORRECT ANSWER: d Q.58 Refer UW – 33 Table from ASME VIII For 4” thk for long seam — 1/16” x 4 = ¼” or 3/8”, use lower value. So for long seam, mismatch = ¼” For circ seam 1/8” x 4” or ¾”, use lower value. So for circ seam, mismatch = 1/2” CORRECT ANSWER: a Q.59 Refer Fig. UCS – 66 of ASME VIII Curve D is representing the materials which are not becoming brittle when other materials (curve A, B, C) become brittle. CORRECT ANSWER: d Q.60 Refer Table UW – 12 of ASME VIII — This joint is type 2. — This joint is category B (Ref. UW – 3 of ASME VIII). Since the joint is between 2:1 ellip. head and the shell. — Refer (Table UW – 12 of ASME VIII), the head is seamless and joint is full radiographed. Hence, E=0.9. CORRECT ANSWER: b API 510 – DAY 2

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Q.61 Vessel MAWP = Vessel Part MAWP — Static Head Vessel MAWP will be worked out considering Part MAWPs. For location at 4 feet from top = 426 – 0.433 x 4 = 424.268 psi For location at 32 feet from top = 440 – 32 x 0.433 = 426.144 psi For location at 54 feet from top = 442.5 – 54 x 0.433 = 419.118 psi For location at 80 feet from top = 454.64 – 80 x 0.433 = 420.0 psi Vessel MAWP is lowest of all part MAWPs adjusted for hydrostatic head. Therefore, lowest value 419.118 psi is vessel MAWP. CORRECT ANSWER: a 62)

1.3 x 125 x 15/13.8= 176.6

65)

t = 1.25 x 0.377/2= 0.235 . but it should not be less than 0.250 or 0.7 x 0.377 is o.263 in which is the answer

70)

Pressure 350 + 11 = 361 psi, So t ={ 361 x30} /{ (17500)- (0.6 x 361 )} = 0.6266 in

71)

Use Hemi Spherical formula E from table UW 12 is 0.7 So t= {500 x 4} /{(2 x 15000 x 0.7) – (0.2 x 50)}= 1.14832

72)

MAWP = {SEt / R +.6 P }= {(15000 x 1 x 0.745)} /{ 14.255 +( 0.6 x 0.745)}.= 760 Here E is found from table UW 12 and R is used as nw corroded condition and t is also taken as of now reduced thk due to corrosion

73)

MAWP = SEt /( R + 0.6 t) ={ 13000 x 0.8 x .875} / { 30 + (0.6 x 0.875)} = 298.116 psig

76)

{ (100 -5) + (16/120)} x{ 0.433} = 41.69

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OPEN BOOK API SEC VIII 1. A vertical vessel has been determined to need de-rating to a lower MAWP. The new MAWP is based on the engineer’s calculations for pressure allowed on the top shell section listed below. The vessel has an elevation of 55 feet to its very top. The following pressure is calculated to the bottom of the element listed. Top shell section, elevation 40.3 feet, p= 458.3 Psi a. 439.6 psi b. 440 8psi c. 451.9 psi d. 457.6 psi 2. A shell course is being replaced in an existing vessel made of SA-515 GR. 55 rolled plate. The shell course will have a thickness of 1.25 inches and inside radius of 40 inches. The Data Report on the vessel indicates the original design called for a joint E of 10, a MAWP OF 675 psig at 450 degrees F and that the MDMT required is 5 degrees F. preheat to 200 degrees was used prior to welding Postweld heat treatment was performed also. The ratio of design stress to allowable stress is. 90. What reduction in MDMT can be taken for the ratio of design stress of 90? a. 20º F b. 10º F c. 15º F d. 30º F 3. A hydrostatic test is being performed on a vertical vessel with an elevation of 48 feet. The MAWP of the vessel in its normal operating position is 255 psi. ALL RVs have been removed and the vessel is blinded off from all other components. The gage will be installed at an elevation of 22.5 feet. What shall this gage pressure be during the hydrostatic test at the 22.5’ elevation? The materials design stress allowed is 16,800 psi and the stress allowed at test temperature of 70 degrees F is 17,500 psi. H.H. is 433 psi per vertical foot. a. 362.6 psi b. 351.0 psi c. 339.9 psi d. 315.7 psi

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4. A repair to vessel is planned. The vessel is built of SA-516 grade 70 normalized material. The vessel operates at an MDMT of 38ºF. This vessel is in ordinary service and has thickness of 1.125 inch. It will not receive postweld heat treatment. The coincident Ratio of stress is 0.90.? This vessel cannot be exempted for impact testing per paragraph UG-20 (f) because; a. SA-516 is not a P No. 1 material; b. 38 ºF is too low a temperature. c. It exceeds the thickness limit for a curve A material. d. It exceeds the thickness limit for a curve D material. 5. An exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand an external pressure of 350 psi. The tubes have and O.D of 1.98 inch and are 88 inches in length with a wall thickness of .025 inch. The value of L/DO is? a. 44.44 b. .0225 c. 79.2 d. 4.44 6. Two nozzles are to be added to an existing pressure vessel. One nozzle is 3.5 in O D. and the other is 2 in O. D., how close may these nozzles be placed in the vessel wall without their areas of reinforcement overlapping? a. 2.5 inches b. 3 inches c. 5.5 inches d. 2 inches 7. A vessel is undergoing a hydrostatic test after repair. The vessel is marked with an MAWP of 100 psig at 750 ºF. The materials allowable stress at operating temperature is 15,000 psi and its allowable stress at test temperature is 17,500 psi. the visual inspection shall take place at; a. 100 psi b. No less than the MAWP of the vessel. c. 116.66 psi d. 106.66 psi

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8. A vessel is constructed of rolled and welded SA-516 gr. 70 steel plate. It is 96 inches in diameter with a communicating chamber, which extends 18 inches below this horizontal vessel. This vessel is in water service and operates at working pressure of 150 psi. What will be the gage pressure at working pressure as read on a gage mounted on the bottom of the vessel’s communicating chamber? a. 150 psi b. 154 11 psi c. 153.46 psi d. 199.36 psi 9. A torispherical head was found to have minimum thickness of .523 inch. This head is attached by a type 2 weld to a seamless shell. The category B welds meet the requirements of UW-11 (a)(5)(b) and UW- 52 The heads material has an allowable stress at operating temperature of 14,800 psi. The head has an O.D. of 36” and an inside crown radius of 36”. What is the welded joint’s efficiency that attaches the head to the shell? a. 10 b. .85 c. .80 d. .90 Answer the following questions about the attached WPS and PQR (pages 5 to 8) from Excellent Welding Consider both the WPS and its supporting PQR when answering the questions. 10. Per Section VIII Div. I a P number I material is required to be post weld heat treated when it exceeds what thickness at the joint? a. 1” b. 1-1/8” and has not had the required pre-heat applied. c. 1-1/4” and has not had the required pre-heat applied. d. 2” 11. What is the required holding time at normal PWHT temperature for P number I material with a thickness of 3”? a. 2-1/4 hours. b. 2 hours c. 2-1/2 hours d. P number I material is not required to receive PWHT per Section VIII.

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12. While attempting to PWHT a vessel’s shell it is discovered that the equipment on hand cannot reach the minimum temperature for the P No. 1 Group 3 material that the vessel is constructed of It is 2 inches thick at the location of heat treatment. If the vessel can be post weld heat treated at a lower temperature, what is that lowest temperature? a. 900 ºF b. 1000 ºF c. 950 ºF d. Lower temperatures are not allowed on P No 1 Group 3 materials. 13. Which of the following is the maximum out-of roundness allowance for a cylinder per ASME VIII? a. 1% b. plus or minus 1% c. 1.2% d. 2” 14. If a 3 inch thick welded plate specimen must be impact tested what will be approximate required absorbed energy requirement if it has a 55 ksi minimum yield strength? a. 30 psi b. 30 ft/lbs c. 27 psi d. 27 ft/lbs 15. What would be considered acceptable proof of having performed Charpy Impact tests on the part of the manufacturer of steel plates per Section VIII Div. I? a. Shipment of the broken specimens with the plate. b. Shipment of the broken specimens with the plate and certificates of compliance. c. Shipment of reports or certificates of compliance from the manufacturer. d. No proof is required beyond the invoice of the manufacturer listing impacts as having been done. 16. The set pressure for a relief valve set at 200 psi may not exceed; a. 206 psi. b. 200 psi. c. 203 psi. d. 199 psi.

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17. The maximum reinforcement on a circumferential but welded joint made in a plate shell of 2 inches in thickness is; a. 1/32 inch. b. ¼ inch c. 1/16 inch. d. 1/8 inch. 18. A vessel owner is repairing a vessel by replacing a duplicate seamless ellipsoidal head, which is butt welded to the shell. The name plate is marked RT-2, W and HT below the Code symbol. The owner is allowed to use what type or types of butt welded joints to replace this head? a. Any type permitted in Section VIII Div. I b. Type 1 c. Type 2 d. Type 1 or 2 19. A Circular flat head at the top of a vessel is measured at 1.25 inches thickness during inspection. The flat head has a diameter of 14 inches. The vessel’s data is as follows; MAWP is 500 psi C=0.33 S=17,500 psi E=1.0 what is required thickness of this part? a. 1.35940 inch b. 1.24563 inch c. .958633 inch d. 1.75200 inch 20. A shell plate made of SA-285 grade C is to be used in a repair of a vessel. What is the lowest temperature that this plate may operate at without impact testing if it is 1.5 inches thick, will not receive post weld heat treatment and has a 695º F maximum temperature and has coincident Ratio is 1.0?. a. 51º F b. 14º F c. 88º F d. 14º F 21. A welding procedure is being qualified for use with a vessel that will require impact testing; the coupon will be 4 inches thick. How many Charpy specimens will be required total? a. 9 b. 6 c. 3 d. 12 API 510 – DAY 2

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22. A vessel is marked RT-3 this indicates that all welded joint efficiencies will be taken from Column B of table UW-12. The vessel contains only Type 1 welded joints so all welds will have an E of ? a. .90 b. .85 c. .70 d. .65 23. A vessel is to be pneumatically tested to a pressure of 172.7 psi and this pressure has been adjusted for a stress ratio of 1.1666. The pressure which the vessel should be inspected at will be; a. 104.6 psi b. 125.6 psi c. 157.0 psi d. 97.1 psi. 24. Two nozzles of 1.0” thickness are to be attached to vessel using fillet welds, if the shell is 2.0” thick the value of t min for this configurations will be; a. .707” b. 1.0” c. .750” d. .530”. 25. A circular flat held is to be attached to a cylindrical shell as depicted in Fig UG-34 (f) The value of the thickness required for the shell has been computed to be .358” and the actual thickness is .500”. The value of Factor C in this calculation will be? a. .46089 b. .20 c. .23628 d. .33 26. While inspecting a vessel you discovered the cylindrical shell has corroded externally to a present thickness of 498” in thickness at its thinnest point. The vessel’s corroded outside diameter is 95.82” and its material has an allowable stress of 13,800 psi at 750º F The vessel shell is seamless and it has met the spot radiography requirements listed in UW-12(d). What will be the MAWP of the vessel? a. 71.87 psi b. 143.5 psi c. 144.0 psi d. 83.45 psi API 510 – DAY 2

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27. According to Section VIII the minimum NPS for a liquid relief valve is: a. NPS 1” b. NPS ¾” c. NPS 7/8’ d. NPS1/2” 28. What temperature shall be used when calculating a pressure vessel’s MAWP? a. Nominal. b. Maximum that it can obtain by design, c. Average through wall temperature. d. The average temperature experienced over the entire vessel’s design. 29. Which of the following explains the closest that two isolated unreinforced openings can be to each other without reinforcement calculations being required? a. 4 times their diameters b. 3-1/2 times their diameters. c. The sum of their diameters. d. There is no such requirement 30. The required diameter of tell-tale holes for re-pads is? a. Maximum NPS ¼” b. Minimum NPS ¼” c. Minimum NPS ½” d. Maximum NPS ½” 31. The minimum throat dimension for a fillet weld as shown in Fig UW-16 (c) for a 1” thick nozzle joined to a 2” thick head is. a. .530” b. .750” c. .250” d. 1.00” 32. The inside surfaces of a vessel’s shell have corroded down to a minimum thickness of .369”. The original thickness was .500”. The vessel’s and old inside diameter was 96 inches. What will be the internal dimension used to calculate the vessel’s MAWP? a. 96.262” b. 48.0” c. 96.0” d. 48.131”

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OPEN BOOK SEC VIII ANSWERS Q.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

ANSWER C B D D A C C B C C A B A B C A B D A C A B C C C C D B C A C D

API 510 – DAY 2

LOCATION OF ANSWER UG-99 API 510 Body of Knowledge UCS-66 & FIG UCS 66.1 UG-99 UCS-66 & FIG UCS-66 UG-28 ( c ) UG-42(a) UG-99 (b) UG-99 API 510 Body of Knowledge UW-12 (b) VIII UCS-56 VIII UCS-56 VIII UCS-56.1 Table VIII UG-80 VIII UG-84 FIG.UG- 84.1 VIII UG- 84(e)(2) UG-126(d) VIII UW-35 VIII TABLE UW-12 VIII UG-34 VIII UG-20(f)/UCS-66-68 VIII UG-84 (3sets × 3 specimens = 9) UG-116 AND TABLE UW-12 VIII UG-100 (d) UW-16 NOMENCLATURE UG-34 FIG. UG 34 (f) C = .33 X M VIII APPENIX I R o Calculations VIII UG-128 VIII UG-20 (a) VIII UG-36 (c ) (3) (c ) VIII UW-15 (d) VIII UW-16 NOMENCLATURE UG-27 AND TEXT BOOK

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ASME SEC VIII QB 1. Minimum Design thickness for a vessel shell is 10 mm. Following four plates were received with actual thickness equal to: 10.2 mm, 9.7mm, 10.3mm, and 9.6 mm. As per ASME Sec. VIII Div.1, how many plates will you release for vessel fabrication? a. 1 b. 2 c. 3 d. All 4 2. As per ASME Sec. VIII Div. 1, if permanent deformation is observed due to over pressure during hydrotesting: a. The inspector should ask for re-test using proper test pressure and new pressure gauges. b. Follow-up the hydro-testing by a pneumatic test at proper pressure, taking suitable precautions as given in code c. The inspector may ask for providing additional stiffening rings around vessel and carry out re-hydro test at proper test pressure. d. The inspector may reject the vessel. 3. A Shell with nom. I.D. = 2200 mm is rolled and the inspector observed following readings, D max = 2215mm, D min = 2195 mm. Should the shell be: a. Accepted b. Rejected c. Accept after NDT d. Depends on opinion of inspector. 4. A horizontal vessel is provided with 2:1 elliptical heads on both ends. The tan – tan shell length = 120 in. vessel dia = 40 in. What will be overall length of the vessel? a. 150 inches b. 140 inches c. 160 inches d. None of above

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5. According to API 510, authorized inspection agency is: a. Jurisdiction organization b. Insurance company which under writes insurance of pressure vessels c. Inspection organization of owner-user d. Any of above 6. A pressure vessel has design pressure = 300 psi. Its safe stress values at ambient and designed temperatures are 17100 psi and 16300 psi respectively. The hydrostatic test pressure and inspection pressure for above will be: a. 450 psi and 346 psi b. 409 psi and 315 psi c. 415 psi and 300 psi d. None of the above 7. The rules for impact testing of carbon steel in Section VIII vessel materials require what kind(s) of impact test? a. Brinell & Rockwell b. Izod & Charpy V-notch c. Charpy V-notch only is acceptable. d. Brinell only is acceptable. 8. Prior to witnessing a pneumatic test of a pressure vessel, the inspector should: a. Ensure that welds around nozzles were inspected by PT or MT prior to commencement of test. b. Ensure that test pressure is maintained throughout the leak testing inspection. c. Ensure that all butt welds were UT checked prior to commencement of test. d. Both a and b 9. A vessel made with full penetration double welds shows name plate marking of ‘RT2’. The joint efficiency for this vessel will be: a. 0.85 b. 1.0 c. 0.7 d. None of these

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10. Who is responsible for transferring the plate marking to the balance plate for a vessel repair work? a. Authorized inspector who is overseeing the repair activities b. Repair organization who does the repair work c. The plate marking and cutting persons involved in the repair process d. The pressure vessel Engineer who approved the repair work 11. If vessel longitudinal and circumferential welds are type 1 and spot radiographed only, then stamping on name plate will be: a. RT1 b. RT2 c. RT3 d. RT4 12. In the above question, if welds were fully radiographed for their entire length, the purpose is to conform to ________ stamping to be put on name plate: a. RT1 b. RT2 c. RT3 d. RT4 13. As per ASME Sec. VIII, Div. 1, in pressure testing, if stress ratio = 1, the test pressure as compared to design pressure shall be: a. 1.5 times for hydrotest b. 1.3 times for pneumatic test c. Same for both hydro and pneumatic d. None of the above 14. As per ASME Sec. VIII, Div. 1, if permanent deformation is observed due to over pressure during hydrotesting: a. The inspector should ask for re-test using proper test pressure. b. Follow-up the hydro-testing by a pneumatic test at proper pressure, taking suitable precautions as given in code for pneumatic test. c. The inspector may ask for providing additional stiffening rings around vessel and carry out re-hydro test at proper test pressure. d. The inspector may reject the vessel. 15. Identify incorrect statements. The pressure vessel materials tend to be less brittle: a. As material thickness increases b. As service temperature increases above transition temperature c. a and b d. None of above is a correct statement. API 510 – DAY 2

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16. If the part to be PWHT’ed is longer than the furnace, multiple shot PWHT is proposed. What is the minimum over lap as per code to ensure proper PWHT? a. 2 feet b. 5 feet c. 2 meter d. 5 meter 17. In PWHT of pressure vessels that are built in carbon and low-alloy steels: a. Minimum PWHT temperature increases with increase of vessel thickness. b. PWHT Soaking period increases with increasing vessel thickness. c. Thickness has to be accounted for working out heating and cooling rates. d. Only (b) and (c) above 18. Three corrosion patches were seen on the shell for a tall vertical vessel to decide their effect on vessel MAWP: a. Work out part MAWP at thinnest patch and that will represent vessel MAWP b. Vessel MAWP does not get affected by thinning of the vessel c. Work out part MAWP for lowest head, and that will represent vessel MAWP d. Lowest value, as worked out by the worst combination of part MAWP and corresponding hydrostatic head at that location 19. When dial-type indicating and recording pressure gauges are used to monitor leak testing, the maximum gauge range shall not exceed which multiple of the expected test pressure? a. 1½ times b. 2½ times c. 3 times d. 4 times 20. A vessel is to be pneumatically pressure tested to 250 psi. This test pressure will be reached in how many stages of pressurization? a. 5 stages b. 2 stages c. 6 stages d. 7 stages

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21. 21. In above question what will be the incremental values of pressurization at first and second stage if pneumatic test pressure is 250 psi? a. 125 psi, 25 psi b. 50 psi, 50 psi c. 100 psi, 50 psi d. None of above 22. Pneumatic test is proposed for a vessel instead of standard hydro test. Most probable reason for this could be: a. The vessel internal is lined with refractory b. No water is available c. The skirt of the vessel is too week to take care of the static water head and pressure. d. Any one or both of a and c above 23. In post weld heat treatment inspection what important things you will verify: a. Loading temperature and heating rate b. Holding temperature and holding time c. Cooling rate and un-loading (from furnace) temperature d. All of the above are important things to be verified 24. Vessel containing lethal substance with shell thickness of 20mm requires: a. Spot radiography (RT-3) b. Full length radiography (RT-1) c. No radiography (RT-4) d. Penetrant is sufficient if radiography testing is not available 25. In a 30 mm thick cylindrical shell, the longitudinal as well as circumferential joints are double welded butt welds with full penetration. Which of the following is true as regards the longitudinal and circumferential joints? a. They are of same category but different types. b. They are of same type but different categories. c. Both the category as well as type are same. d. Both the category as well as type are different.

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26. Vessel MAWP of existing vertical vessel will be affected for which of the following? a. If Vessel Part MAWP changes for any vessel part. b. If design pressure is reduced (other factors remaining same) c. Vessel height is changed by adding/deleting a shell course d. A and C 27. A Shell with Inside dia = 2200 mm, and Corr. allow.= 5 mm is to be designed as per ASME Sec. VIII , Div.1. What will the value of “R” in design formula for shell thickness? a. 1100 mm b. 1105 mm c. 1095 mm d. 1110 mm 28. In thickness formula for internal pressure for shell, term ‘E’ refers to: a. Modules of Elasticity of material b. Thermal Expansion c. Joint efficiency of the weld d. None of above 29. Identify category A joints from following: a. Longitudinal joints b. Circumferential joints, shell to shell c. Shell to hemispherical head joint d. a and c above 30. If all other conditions are remains same the design thickness of which dished end (Torispherical, Hemispherical, and Ellipsoidal) will be maximum? a. Torispherical b. Hemispherical c. Ellipsoidal d. All will be same 31. Any thickness-offset within the allowable tolerance shell be provided a minimum taper transition of: a. 3 to 1 min b. 4 to 1 min c. 3 to 2 min d. 1 to 2 min

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32. ASME Sec VIII Div. 1 specifies different acceptance level for weld reinforcement, which of the following statements are true in your opinion? a. Permitted reinforcement for long. seems is higher than circ. seems b. Permitted reinforcement for long. seems is lower than circ. Seems c. Permitted reinforcement for long. seems is same as circ. seems d. Permitted reinforcement does not depend on location of seems. 33. Vessel MAWP for vertical vessel is measured at: a. Top most point of vessel b. Bottom most point of vessel c. At the mid point between top & bottom d. None of above 34. A Pressure Vessel is designed for 0.85 joint efficiency with full penetration welds. RT requirement will be: a. Nil b. Spot c. 100 % d. T-joints radiography 35. A vessel with 50 inches OD and 1¼ in. thickness is to be provided Std. torisph. heads. The heads shall be formed with crown radius and min. knuckle radius as follows: a. 25 inch, 4 inch b. 50 inch, 3 inch c. 50 inch, 3¾ inch d. 25 inch, 2 inch 36. Two head to shell joints, one joining a seamless Hemisph, head to shell was radiographed for full length and the other joint joining seamless std. torisph. head to shell was spot radiographed, The weld joint efficiency for each of these heads respectively will be: a. 1, 0.85 b. 1, 1 c. 0.85, 1 d. 0.85, 0.85 37. ASME Sec. VIII Div. 1 recommends use of U.T. in place of R.T. (for a fully radiographed vessel) for: a. All butt welds in vessel b. All butt and fillet welds in vessel c. For closing seams only d. The code does not permit use of U.T. at all API 510 – DAY 2

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a. b. c. d.

Greater than vessel part MAWPs Lower than Vessel part MAWPs May be (a) or (b) depending on Vessel height Is always same as vessel design pressure

39. For a vessel constructed with Type 1 welds: a. RT3 means E = 1 b. RT2 means E = 0.85 c. RT1 and RT2 may mean E = 1 d. RT4 means spot radiography 40. Choose correct Pneumatic test pressure for following vessel Design Pressure = 160 psi Design temp. = 675 ºF Allow stress (Ambient) = 20,000 psi Allow stress (675ºF) = 19,200 psi a. 176.0 psig b. 215.6 psig c. 183.3 psig d. None of above 41. Choose correct statement. Allowable external pressure for a vessel: a. Will depend on Joint efficiency (E) and extent of radiography b. Depends on vessel temperature c. Is affected by internal corrosion allowance d. Both b and c 42. The rules for impact testing of carbon steel in Section VIII vessel materials require what kind(s) of impact test. a. Brinell & Rockwell b. Izod & Charpy V-notch c. Charpy V-notch only is acceptable d. Brinell only is acceptable 43. Prior to witnessing a pneumatic test of a pressure vessel, the inspector should: a. Ensure that welds around nozzles were inspected by PT or MT prior to commencement of test b. Ensure that test pressure is maintained throughout the leak testing inspection c. Ensure that all butt welds were UT checked prior to commencement of test d. Both a and b API 510 – DAY 2

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44. Hydrostatic pressure test of vessels may be replaced by pneumatic test: a. At the option of vessel manufacturer b. At the option of vessel inspector c. Permitted only if water is not available in the region and Client approves d. Permitted only if design or operating conditions do not permit use of water as test medium. 45. What will be the minimum inspection pressure if pneumatic testing was carried out at 220 psig, as per code? a. 220 psi b. 250 psi c. 200 psi d. 260 psi 46. For external pressure calculations, the value of “E” is worked out on the basis of: a. E = 1 for full radiography b. E = 0.85 for spot radiography c. E = 0.7 for no radiography d. E is modulus of elasticity and does not depend on radiography 47. In external pressure calculations for cylindrical shell, the Factor – A, depends on: a. O.D. and thickness of shell b. Design temperature c. Safe stress value ‘S’ of material d. All of the above 48. ASME Sec. VIII, Div. 1 permits which of the following nozzle constructions? a. “Set-in” type b. “Set-on” type c. Both (a) and (b) d. None of (a) or (b) 49. Ovality tolerance of a vessel shell with internal pressure is: a. 1% for shell I.D. b. 1% for shell O.D. c. 1% of Inside radius of shell d. 1% of Outside radius of shell

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50. Reinforcement area required for an opening of diameter of 8” inside diameter and minimum required shell wall thickness 1.0” will be: a. 9.0 sq. inches b. 8.0 sq. inches c. 1 inch thickness d. 10 sq. inches 51. A vessel is constructed by using SA516 Gr. 70 normalised plates of thickness 1.125”. Minimum MDMT without any impact testing for this vessel will be: a. -26°F b. -30°F c. -22°F d. -16°F 52. Evaluation of radiographs for “Porosity” shall be carried out for Pressure vessels subjected to a. Full radiography b. Spot radiography c. For both a and b d. For none of a or b 53. The radiographs and radiography reports of a vessel shall be maintained till: a. 5 years b. Till the MDR is signed c. 3 years d. 10 years 54. Pneumatic test should be carried out on a vessel at 300 psig. The design temperature and the test temperature are same. What is the test pressure and in how many steps the pressure should be applied. a. 350 psig, 6 steps b. 330 psig, 6 steps c. 350 psig, 2 steps d. 330 psig, 2 steps

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55. A vessel is to undergo a hydrostatic test after an alteration; the test pressure will be 785 psi. Using standard commercially available gauges what is the minimum and maximum gage pressure range acceptable for this test? a. 0-1000 to 0-3000 psi b. 0-1500 to 0-3000 psi c. 0-1000 to 0-2500 psi d. 0-850 to 0-1500 psi 56. Which is the most severe stress caused by internal pressure in a cylindrical shell? a. Circumferential stress acting along the longitudinal axis. b. Longitudinal stress acting along the longitudinal axis c. Circumferential stress acting along the circumferential axis. d. Longitudinal stress acting along the circumferential axis. 57. Of the types of stresses placed on a thin walled cylinder the most severe is; a. Circumferential b. Longitudinal c. Compressive d. Radial 58. The rules for impact testing of carbon steel in Section VIII vessel materials require what kind(S) of impact test. a. Brinell & Rockwell b. Izod & charpy V-notch c. Charpy V-notch only is acceptable d. Brinell only is acceptable. 59. You have measured undercut on a girth weld during the repair to a vessel, it was found to be 1/32 inch in depth. The base metal is 2 inches thick, and you should? a. Reject the weld b. Accept the weld. c. Consult the API 510 code for accept/reject criteria before making a decision d. Consult with the chief inspector or Engineer 60. The two types of impact tests required by section VIII Div.1 are; a. Izod and drop weight b. Brinell and Rockwell c. Charpy and Drop Weigth d. Weld metal and Base metal API 510 – DAY 2

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61. In Section VIII Div.1 acceptance of a radiograph is based on; a. The speed of the film used. b. The geometric unsharpness of the image c. The absence of backscatter. d. The ability to see the essential hole or wire, if a wire type IQI is used 62. A spot radiograph of a butt weld in a 1 inch thick of a vessel market RT3 was found to have a rounded indication, the dimension of such an indication according to section VIII div 1 is; a. 1/32 of an inch b. 1/3 of an inch c. 2/3 of an inch d. None, rounded indications are not a consideration with spot radiography 63. Section VIII Div 1, is very specific about the number of spot radiographs required when applying it for quality control, the basic premise is to; a. Insure that all welds are made perfectly b. Make sure someone is held responsible for any poor welding c. apply the radiographs immediately after welding in order to take connective steps if needed. d. fire as many welders as possible 64. A P No.1 material that is plate has been rolled into a cylinder and butt welded. The cylinder is exactly 1-1/4” thick, and it is used in the repair of a pressure boundary on a U stamped vessel, the following is a true statement. a. It must receive full radiography b. It may be not spot radiographed c. It may not be fully radiography d. It may receive spot, full or no radiography depending on the original UI form 65. Charpy impact tests are intended to prove that a material is; a. Tough at the desired MDMT of the vessel to be constructed using that material b. Some what prone to brittle fracture. c. acceptable for use in high temperature service d. not required to be heat treated

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66. The testing apparatus used and the techniques for performing charpy impact tests are found in; a. Section VIII Div. 1 paragraph UG-84 b. SA-270 c. SA-370 d. Section IX paragraph 401.32 67. Prior to witnessing a pneumatic test of pressure vessel, which has been repaired by welding the inspector should; a. Determine if the vessel has had all relief devices removed b. Observe that the digital pressure gage to be used for the test is of the proper range c. Check that the personnel conducting the test have been properly trained to perform hazardous tests. d. Make sure that the analog pressure gage is of the proper range for the test pressure 68. The number of charpy impact specimens required for a 1-3/4” Thick weld procedure test plate is; a. 2 sets of 3. b. 3 sets of 2. c. 3sets of 3. d. Dependent on the type of material to be used in the construction of the vessel.

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ASME SEC VIII QB ANSWERS Q. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

ANS. C D A B D B C A B B C A D D A B D D D C A D D B B D B C D A A B A B C B C B

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REFERENCE ASME VIII, UG – 16 (c) ASME VIII, UG - 99 ASME VIII, UG-80 a (1) ASME VIII, UG-32 (d) API 510, 3.4 ASME VIII, UG-99 (b) and (d) ASME VIII, UG-84 ASME VIII UG-100 UG – 116 e-2 and Table UW - 12 UG – 77 and API 510 ASME VIII, UG – 116 ASME VIII, UG - 116 UG – 99 and UG - 100 UG – 99 (d) ASME VIII, Fig. UCS – 66 ASME VIII, UW – 40 a2 UCS – 56, d1, 5 ASME VIII, UG – 98 (a) ASME VIII, UG - 102 ASME VIII, UG - 100 ASME VIII, UG – 100 Application of UG – 100 (a) UCS – 56, d1, 2, 5 ASME UW-11(a) ASME VIII, UW – 3 (a) ASME VIII, UG – 98 (a) ASME VIII, UG – 27 (a), UG -16 (e) ASME VIII, UG – 27 (a) ASME VIII, UW – 3 (a) (1) ASME VIII, UG – 32, d, e, f ASME VIII, Fig. UW - 9 ASME VIII, UW - 35 ASME VIII, UG – 98 (a) ASME VIII, Table UW - 12 ASME VIII, UW – 32 (j) ASME VIII, UW – 12 (d) ASME VIII, UW – 11 (a) - 7 ASME VIII, 98 (a)

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39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

C C D C A D C D A C A B A A B B B A A C B D D D C D A C D C

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ASME VIII, UG – 116 (e) ASME VIII, UG – 100 (b) ASME VIII, UW – II (c) ASME VIII, UG - 84 ASME VIII, UG - 100 ASME VIII, UG – 100 (a) ASME VIII, UG – 100 (d) ASME VIII, UG – 28, Step 7 ASME VIII, UG – 28, Steps 2 and 3 ASME VIII, UW – 16, Fig. UW 16.1 ASME VIII, UG – 80 (a) ASME VIII, UG - 37 ASME VIII, Fig. UCS - 66 ASME VIII, UW-52. ASME VIII, UW – 51 c (1) ASME VIII, UG – 100 (d) UG-102 UG-27&API 510 VIII UG-27 VIII UG-84 VIII UW-35 VIII UG-84 VIII UW-51(a)(3) VIII UW-52 ( c ) (3) VIII UW-52 header note VIII UW-11(a)(3)&UCS-57 (table notes) VIII UG-84 definition of Charpy (notch toughness)! VIII UG-84 refers SA-370 for details VIII UG-100&102&UW-50 VIII UG-84 (h)

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CLOSED BOOK ASME SEC VIII 1. Which of the following best describes a part of the definition of maximum allowable working pressure for a vessel? a. The vessel’s design pressure. b. The vessel’s design pressure plus the hydrostatic head. c. The maximum gage pressure permitted at the bottom of the vessel. d. The maximum gage pressure permitted at the top of the vessel, in its operating position. 2. The symbol PHT on a vessel’s name plate indicates; a. A combination pneumatic and hydrostatic test. b. The vessel has been post-weld heat treated. c. The vessel is good for high temperatures. d. The vessel was partially heat treated 3. If an duplicate ASME Code name plate is to be attached to pressure vessel it must be placed only on; a. The skirt b. One of the heads (does not matter which). c. On the shell. d. Any permanent attachment to the vessel. 4. A welded carbon steel joint has a MDMT which is lower than 120 ºF above what thickness must impact tested material be used. a. 6 inches. b. 4 inches. c. 2 inches. d. 3 inches. 5. A safety valve must be tested using; a. Water. b. Steam. c. Air. d. Product fluids only.

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6. If inspecting a vessel using non-destructive inspections, where can guidance be found to accept or reject a condition in a weld that has been discovered during the inspection? a. Section V of the ASME Code. b. Section VIII of the ASME or Code of construction. c. API 510 Inspection Code. d. NBIC. 7. Which of the following markings cannot be found on an ASME Code Vessel’s nameplate? a. The manufacturer’s serial no. b. The manufacturer’s name. c. The year built. d. The names of all welders who worked on the vessel. 8. List three places where category B welds are located in an ASME Code Section VIII Div 1 vessel. a. Longitudinal joint in shells, in nozzles and communicating chambers. b. Circumferential joints in transitions in diameter, connecting heads to communicating chambers and hemispherical heads to shells. c. Circumferential joints in transitions in diameter, connecting heads to communicating chambers and ellipsoidal heads to shells. d. Circumferential joints in transitions in diameter connecting heads to communicating chambers and the joints used to make a sphere from two hemispheres. 9. Describe a Type 3 weld in accordance with ASME Section VIII Div.1. a. A weld made form one side only with a backing ring, which remains in place. b. A weld made from both sides, and which is restricted in diameter and thickness limits. c. A weld made from both sides. d. A weld made from one side only, which does not have a backing ring. 10. What type material is always required to have a mill test report in accordance with Section VIII Div 1 of the ASME Code? a. ASTM pipe. b. ASTM forged pressure parts. c. Gray cast iron parts used for pressure. d. Plate.

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11. A spot radiograph in accordance with UW-53 has revealed rounded indications that exceed those allowed in Appendix 4 of Section VIII Div.1. What must be done? a. Two tracer radiographs must be performed and if they pass the area that failed in the first shot repaired and retested. b. Nothing. c. The entire joint must be radiographed fully. d. Ultrasonic inspection must be performed on the welded joint. 12. The term ‘Full Radiography” in Section VIII Div. 1 means that a vessel must have; a. 100% of its welds radiographed b. All of the welds required by code to be fully radiographed examined c. 100% of the all of the welds which exceed NPS 10 and or 1-1/8” radiographed d. Radiography applied to all types of weld including fillet welds. 13. Indications observed by the dye penetrant NDE method are often larger than the actual imperfection in the material. What is the accept reject criteria based on? a. The dimensions of the imperfection revealed by the inspection. b. The dimensions of the developed test. c. The dimensions of the developed test, following a written procedure. d. The dimension size allowed by the prevailing code. 14. The hydrostatic head must be considered when rating a liquid filled vessel’s a. Bottom shell course’s material of construction. b. Top formed head’s geometry. c. Reinforcement pad material selection d. Each component MAWP. 15. A vessel is undergoing a hydrostatic test per the rules of the ASME, the pressure it shall be visually inspected at is; a. The test pressure divided by 1.3 b. No less than the test pressure divided by 1.3 c. No less than the test pressure divided by 1.1. d. No less than 4/5 the test pressure.

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16. If heads are formed so that the pressure is on the concave side they are considered by the ASME to be a. Minus heads. b. Seamless. c. Plus heads d. Spun heads. 17. A forget flat head attached to a vessel by butt welding must follow all the rules for a. Circumferential welds given in Part UW of Section VIII b. Longitudinal welds given in Part UW of Section VIII c. Circumferential welds given in Part UCS of Section VIII d. Longitudinal welds given in part UCS of Section VIII

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Closed Book SEC VIII ANSWER Q.No.

ANSWER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

D D D B B B D C D D B B C D B C A

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LOCATION OF ANSWER UG-98 & API 510 3.9 UG-116 VIII UG-119 (f) VIII UCS-66(a)(1)(d) VIII UG-125 VIII APPENDIX 4,6 AND 8 UG-116 UW-3(b) UW-12 TABLE UG-93(a)(1) UW-52 (c ) (3) UW-11(a) VIII APPENDIX 8.4(d) VIII UG-99 VIII UG-99 VIII UG-32 NOMEMCLATURE VIII UG-34

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These question cover both the open and closed book portion of the exam; in general any table lookup questions would be in the open book part of the examination. Only the correct choice and the paragraph where the answer is found are given, so you will be required to read the paragraphs to confirm the answers 1. Which of the following describes the service restrictions on welded joint types in lethal substance service? a. All joints of Category A shall be Type No (1) of Table UW-12 b. All joints of Category A and B shall be Type No. (1) of Table UW-12. c. All joints of Category B and C shall be of Type No (2) of Table UW-12 d. All joints may be of any type permitted in Section VIII Div. 1. 2. When a vessel is to be used with a lethal substance it shall be; a. Completely ultrasonically tested if made of any high alloy. b. Pre-heated if constructed of carbon or low alloy steel. c. Receive Postweld heat treatment. d. Made only from an approved list of base materials in Section VIII Div 1. 3. The term Category used in Section VIII Div I refers to? a. The type of substance that is to be contained by a vessel. b. The location of a welded joint in a vessel. c. The type of weld used to make the welded joint. d. The welding process used o make the welded joint. 4. Which of the following describe? “A welded joint used to make flange connections” a. Category A b. Type C c. Type B d. Category C 5. A category “A” butt-welded joint can be which of the following? a. Circumferential weld connecting one shell course to another shell course. b. A Circumferential weld connection a hemispherical head to a shell c. A flange connection to a head. d. A nozzle connection to a shell or head.

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6. Materials used in the construction of welded pressure vessels shall be of weldable quality. This requires that a material be proven by; a. Successful qualification of a Welding Procedure in accordance with Section IX of the ASME Code. b. Acceptance by Section II Part D of the ASME Code. c. Chemical tests and mechanical testing. d. Listing in the stress tables in Section VIII Div. 1 7. Welding materials used for production shall comply with the requirements of Section VIII Div 1. those of Section IX, and the applicable qualifed welding procedure specification: when the welding materials comply with one of the specifications in Section II, Part C: the marking or tagging of the material, containers, or packages as required by the applicable Section II specification may be accepted for identification in place of; a. The actual testing of the weld filler metal b. The welding procedure requirements. c. The certificate of compliance or certified test report. d. Markings may not be substituted for a manufacturer’s documentation. 8. The minimum thickness for shells and heads of vessels built to Section VIII Div I is: a. 3/32” b. 5/32” c. 1/8” d. 1/16” 9. The mill under tolerance for a plate of ½” thickness in Section VIII Div. I is: a. 6% of the thickness. b. .010” c. .001” d. 3% of the thickness. 10. The loadings to be considered in designing a vessel shall include those from: a. Internal pressure only. b. Internal and external pressure only. c. Internal and external pressure, weight of the vessel and contents. d. Internal and external pressure, weight of the vessel and contents and superimposed loads from attachments.

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11. Section VIII Div. I states that when specifying a corrosion allowance; a. A corrosion allowance may be given to all vessels. b. A corrosion allowance can be considered in MAWP calculations. c. The owner/user shall designate any corrosion allowance for a vessel subject to corrosion or thinning and it should be adequate for the expected life of the vessel. d. No requirement for a corrosion allowance exists in Section VIII Div. I; it is solely up to the owner/user to require one. 12. According to Section VIII Div I telltale holes may be used; a. To determine if welding penetration is adequate. b. To determine if a repad is leaking. c. To determine if a fillet weld has adequate throat dimensions. d. To determine if thickness of a vessel part has been reduced to a dangerous degree. 13. Corrosion resistant or abrasion resistant linings, whether or not attached to the wall of a vessel shall; a. Not be considered as contributing to the strength of the wall. b. Be considered as contributing to the strength of the wall c. Always contribute to the strength of the vessel wall. d. Not be considered as contributing to the strength except as listed in Part UCI. 14. The thickness of shells under internal pressure shall be not less than that computed by the following formulas. In addition, provision shall be made for; a. Any of the other loading listed in UG-22, when such loadings are expected. b. Corrosion. c. Atmospheric pressure d. External loadings. 15. When calculating the external pressure allowed on a vessel you shall enter the Factor A. Chart when the value of L/Do is greater than 50 at: a. The value divided by two. b. The value of 50 c. The value of Do/t d. You cannot use the chart you must use the formulas of Appendix 5.

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16. When cutting plate or other stock for fabrication of a Section VIII Div I vessel the; a. The cutting shall only be performed by mechanical means, sawing etc.. b. The edges shall be rounded if exposed to corrosion. c. Exposed inside edges shall be chamfered or rounded. d. The cutting shall be performed by thermal processes only. 17. For traceability of parts used in a Section VIII Div. I vessel the vessel Manufacturer shall maintain traceability of the material to the original identification markings by which of the following methods; a. Identification by a coded marking traceable to the original required marking. b. Marking the part numbers on the fabrication drawings. c. Welding maps to be turned over the owner/user of the vessel. d. No markings are required. 18. If the material used in the fabrication of a vessel has defects they: a. May not be repaired and the entire part shall be rejected. b. May be repaired only by the steel mill who manufactured the part material. c. Defects in material may be repaired provided acceptance by the Inspector is first obtained for the method and extent of repairs. d. Defects in material may be repaired. Defective material that cannot be satisfactorily repaired may be rejected at the inspector’s discretion. 19. All plates for shell sections and for heads shall be formed to the required shape by any process that will not unduly impah the physical properties of the material. If plates are to be rolled to form a cylinder; a. They must be heated to the materials transition temperature prior to rolling. b. They must be volumetrically examined by a suitable NDE process prior to rolling. c. The adjoining edges of circumferential joints of cylindrical vessels shall first be shaped to the proper curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed. d. The adjoining edges of longitudinal joints of cylindrical vessels shall first be shaped to the proper curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed.

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20. For a cylindrical shell that was designed for internal pressure the tolerance for out-of-roundness must be maintained and is based on the difference of the maximum and minimum inside diameters. This tolerance is: a. It shall not exceed 1% b. It shall not exceed 0.10% c. It shall not exceed 10% d. It shall not exceed 15% 21. The inner surface of a torispherical, toriconical, hemispherical, or ellipsoidal head shall not deviate outside of the specified shape by more than; a. 1-1/2 % of D b. 1-3/4 % od D c. 2 % of D d. 1-1/4 % of D 22. When plate specification heat treatments are not performed by the material manufacturer, they shall be performed by, or be under the control of, the fabricator who shall then place the letter (s); a. “T” following the letter G” in the Mill plate makings b. “HT” following the letter G” in the Mill plate markings c. “T” following the letter GP” in the Mill plate markings d. “HT” following the letter MG” in the Mill plate markings. 23. For plates, the vessel Manufacturer shall obtain; a. Detailed list of all heat numbers. b. A complete set of all mill test coupons. c. The material test report or certificate of compliance. d. The steel mills run logs that apply to the heat number stamped on the plate at the mill.

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24. All materials to be used in constructing a pressure vessel shall be examined before fabrication for the purpose of detecting, as far as possible, imperfections which would affect the safety of the vessel. This would include; a. Particular attention to rounded edges and other parts of pipe which would disclose the existence of serious laminations, shearing cracks, and other imperfections. b. Particular attention to corners of lap plates. c. Particular attention to the inside corners of reinforcement plates. d. Particular attention to cut edges and other parts of rolled plate which would disclose the existence of serious laminations, shearing cracks, and other imperfections. 25. The _____________ Shall examine the pressure retaining parts to make certain they conform to the prescribed shape and meet the thickness requirements after forming. The ________ Shall verify the dimensions. a. Manufacturer, Inspector b. Inspector, Manufacturer. c. Vendor surveyor, manufacturer. d. Manufacturer, Vendor surveyor. 26. The maximum allowable working pressure for a vessel is the maximum pressure permissible at the top of the vessel in its normal operating position at the designated coincident temperature specified for that pressure. It is the least of the values found for maximum allowable working pressure for any of the essential parts of the vessel by the principles given in (b) below, and adjusted for any difference in _________? a. The height of the vessel b. The weight of the vessel c. Any static head that may exist d. Any static head exerted on the part with the highest MAWP 27. Which of the following describes a Standard Hydrostatic Test? a. Test to be conducted at the calculated MAWP of the vessel. b. Test to be conducted at the calculated MAWP of the vessel multiplied by 1.5. c. Test to be conducted at the calculated MAWP of the vessel multiplied by 1.1 d. Test to be conducted at the calculated MAWP of the vessel multiplied by 1.3

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28. The visual inspection of joints and connections for leaks at the Standard Hydrostatic Test Pressure calculated by dividing the ratio of stresses may be waived provided: a. No gas leak test will be applied. b. Substitution of the gas leak test is by agreement reached between Manufacturer and Owner. c. The vessel will not contain a “lethal” substance d. The vessel will not contain a “flammable” substance. 29. A small liquid relief valve set to ____ times the test pressure is recommended for the hydrostatic pressure test system, in case a vessel, while under test, is likely to be warmed up materially with personnel absent. a. 1-1/3 b. 1-1/2 c. 1-1/4 d. 1-3/4 30. Prior to performing a Pneumatic Test per Section VIII Div. I, the manufacturer must perform non destructive tests The requirements for these lests are given in _________ a. UG-40 b. UW-50 c. UG-50 d. UW-35 31. The pressure in the vessel shall be gradually increased to not more than on-half of the test pressure. Thereafter, the test pressure shall be increased in steps of approximately ___ of the test pressure until the required test pressure has been reached. a. Approximately one-tenth b. One-quarter c. One-fifteenth d. Exactly One-length.

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32. Subject to the provisions of UG-99(a)(1) and (a)(2), a pneumatic test prescribed in this paragraph may be used lieu of the standard hydrostatic test prescribed in UG-99 for vessels: a. Are readily dried and are to be used in services where traces of the testing medium can be tolerated. b. That are so designed and/or supported that they cannot safely be filled with water. c. That are so designed and/or supported that they can be safely filled with water. d. Only for vessels with an enamel lining 33. An indicating gage shall be connected directly to the vessel. If the indicating gage is not readily visible to the operator controlling the pressure applied _____________ a. A second operator must be used to shout out pressure steps b. A pressure chart recorder must be used. c. An additional indicating gage shall be provided where it will be visible to the operator throughout the duration of the test. d. The hydrostatic test equipment must be moved to provide the operator with operator with a clear line of sight to the gage. 34. Dial indicating pressure gages used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1 ½ nor more than 4 times that pressure ____________ having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. a. Scientific laboratory gages b. Chart recording gages c. Mason-Hanson dial feeder gage d. Digital reading pressure gages 35. The name plate on an ASME Section VIII Div.1 vessel has the single letter P stamped on it, this means? a. It was constructed using pressure welding b. It was proof tested in lieu of hydrostatic testing c. It will be a permanent vessel and will not be on a trailer or otherwise transported d. There is no such example given in the ASME Code Section VIII Div.I

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36. The letters PHT shall be applied under the Code Symbol when; a. the vessel has received Postweld Heat Treatment as provided in UW10 b. Only part of the complete vessel has been Postweld Heat Treated as provided in UW-10 c. the vessel has received only partial heat treatment, to its longitudinal seams d. The vessel has received only partial heat treatment, to its circumferential seams. 37. An additional nameplate in accordance with (a) through (d) may be installed on the skirt, supports, jacket, or other permanent attachment to a vessel. All data on the additional plate, including the Code Symbol, shall be as required for the mandatory nameplate. The marking need not be witnessed by the Inspector. The additional nameplate shall be marked: a. “REPRODUCTION” b. “COPY” c. “DUPLICATE” d. Only one nameplate is permitted. 38. A data Report shall be filled out on _____________ by the Manufacturer and shall be signed by the manufacturer and inspector for each pressure vessel marked with the Code U Symbol. a. Form U-1 or Form U-1A b. Form U-2 or Form U-2A c. Form R-1 or Form R-1A d. Form UG-1 or UG-1A 39. Data reports for those parts of a pressure vessel which are furnished by a parts Manufacturer to the user of an existing Code vessel as replacement or repair parts shall be executed on Form U-2 or U-2A by the parts Manufacturer and his Inspector in accordance with the requirements of this Division. A copy of the _________ shall be forwarded to the owner of the vessel. a. U-1 Form b. Material Test Report and the Form U-2 or U-2A c. Certificate of Conformance and the Form U-2 or U-2A d. Form U-2 or U-2A

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40. Safety, safety relief, and relief valves shall be of the ___________ a. bellows expansion type b. direct spring loaded type c. Indirect spring loaded type d. dead weight type 41. The set pressure tolerances, plus or minus, of pressure relief valves shall not exceed _ psi for pressures up to and including 70 psi and __for pressures above 70 psi a. 2, 3% b. 5, 5% c. 1, 3% d. 3, 2% 42. A_________ is a pressure relief valve actuated by inlet static pressure and characterized by rapid opening or pop action. A_________ is a pressure relief valve actuated by inlet static pressure which opens in proportion to the increase in pressure over the opening pressure. A_________ is a pressure relief valve characterized by rapid opening or pop action or by opening in proportion to the increase in pressure over the opening pressure, depending on application. A________ a pressure relief valve in which the major relieving device is combined with and is controlled by a self-actuated auxiliary pressure relief valve. a. safety relief valve-safety valve –relilef valve-pilot operated pressure relief valve. b. safety valve-relief valve-safety relief valve-pilot operated pressure relief valve c. pilot operated pressure relief valve-safety relief valve-safety valve-relief valve d. relief valve-safety valve-pilot operated pressure relief valve-safety relief valve 43. A___________ is a pressure relief device which is designed to reclose and prevent the further flow of fluid after normal conditions have been restored. a. balanced bellow control valve. b. vacuum vent valve. c. pressure relief valve d. Anderson-Greenwood reducing pressure regulator.

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44. A rupture disk device __________ be used as the sole pressure relieving device on a vessel. a. May not b. May under certain circumstances c. May d. Can if approved by the owner. 45. In accordance with Section VIII Div.1 a liquid relief valve can be no smaller that____ in pipe size (NPS) a. 3/4 inch b. 1 inch c. 5/8 inch d. 1/2 inch 46. Carbon or low alloy steel having a carbon content of more than __ by heat analysis shall not be used in welded construction or be shaped by oxygen cutting (except as provided elsewhere in this Division) a. 0.035% b. 0.35% c. 3.5% d. 0.0035% 47. When radiographic examination is required for butt welded joints by UCS-57. Joints of Categories__and (see UW-3) shall be of Type No.1or No.2 of Table UW-12. a. B and C b. A and D c. A and B d. C and D 48. Shells of pressure vessels may be made from seamless pipe or tubing listed in Tabel 1A of Section II Part D provided the material of the pipe is manufactured by the __________ process. a. Open-hearth, basic oxygen or electric furnace b. Open hearth, reducing oxygen c. Closed-hearth, basic oxygen or electric furnace process d. Basic oxygen or electric furnace process

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49. Ellipsoidal, torispherical, hemispherical and conical heads having pressure on the convex side are also referred to as__________ a. Plus heads b. Minus heads c. Reverse concave heads. d. Inverse convex heads. 50. Before applying the detailed requirements and exemptions in these paragraphs, _______ shall be performed. a. Satisfactory weld procedure qualifications of the procedures to be used b. Satisfactory heat treatment tests of the procedures to be used c. Chemical and mechanical tests of a production coupon d. A survey of current ASTM requirements 51. The operation of post weld heat treatment shall be carried out by one of the procedures given in UW-40 in accordance with the following requirements___________ a. The temperature of furnace shall not exceed 800ºF at the time the part is placed in it. b. The temperature of the furnace shall not exceed 400ºF at the time the part is placed in it. c. The temperature of the furnace shall not exceed 600ºF at the time the part is placed in it. d. The temperature of the furnace shall not exceed 300ºF at the time the part is placed in it. 52. During the heat treatment holding period there shall not be a greater difference than____between the highest and lowest temperature throughout the portion of the vessel being heat treated. a. 100ºF b. 250ºF c. 150ºF d. 50ºF 53. As concerns Impact Testing exemptions for a material that is 2 inches thick and assigned to Curve C in the tables of Section VIII Div.1 the coldest Minimum Design Temperature allowed is _______ without impact testing, disregarding any other exemption? a. 26ºF b. 99ºF c. - 4ºF d. 63ºF

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54. Section VIII Div.1 paragraph UCS-67(a) states that welds made with filler metal shall be impact tested in accordance with UG-84 when any of the following apply: a. When both base metals require impact testing b. When either of the base metals requires impact testing c. When the vessel will be in lethal service d. When the vessel will be a non-stationary vessel. 55. Welded joints shall comply with UW-2(b) when the minimum design metal temperature is colder than _____, unless the coincident ration defined in Fig. UCS-66.1 is less than 0.35. a. -20ºF b. 55ºF c. -55ºF d. 20ºF 56. Carbon and low alloy steel plates shall _____ formed cold by blows. a. Not be b. Be c. May be d. Not be unless post weld heat treated after forming. 57. The rules in part UHT are applicable to pressure vessels and vessel parts that are constructed of ferritic steels suitable for welding, whose tensile properties have been enhanced by___________? a. forming while heated to the lower transformation temperature b. Heat treatment c. Mechanical blows followed by heat treatment d. forming at the upper transformation temperature and heat treating. 58. Part UHT states that impact test procedures, and size, location and orientation of the specimens shall be the same as required by_____ except that for plates the specimens shall be oriented transverse to the final direction of rolling and for circular forgings the specimens shall be oriented tangential to the circumference a. UCS-66 b. UCS-68 c. UG-42 d. UG-84

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59. A cylindrical shell if to be rolled and welded and is made of SA-517 Grade A plate. The nominal thickness of the shell course is 1.0”. which of the following is the heat treatment temperature range? a. 1025-1085ºF b. 1000-1100ºF c. 950-1100ºF d. 1025-1125ºF 60. Which of the following UHT materials can be exempled from production impact tests of the weld metal in accordance with UG-84? a. SA-353 b. SA-517 c. SA-724 d. SA-933 61. The requirements of UW-35(a) and UW-51(b) shall be met except that for _____material the maximum weld reinforcement shall not exceed 10% of the plate thickness or 1/8 in (3.2 mm), whichever is less. a. SA-724 b. SA-553 c. SA-517 d. SA-645 62. Radiographic indications with a maximum length of three times the width or less on the radiograph are defined as_______ indications. These indications may be circular, elliptical, conical, or irregular in shape and may have tails. When evaluating the size of an indication, the tail shall be included. The indication may be from any imperfection in the weld, such as porosity, slag, or tungsten. a. Elongated b. Transverse c. Rounded d. Ellipsoidal 63. The maximum size of a random rounded indication on a radiograph in US customary units for a thickness of 1/2’ is____ a. 0.125” b. 0.0125” c. 0.158” d. 0.100”

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64. A liner indication when using magnetic particle testing is described as one_____________ a. Having a width greater than two times the length. b. Having a length greater than four times the width. c. Having a length greater than three times the width. d. Having a width greater than three times the length. 65. After repairs to a defect found by the use of magnetic particle testing have been made, the repaired area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or corners and reexamined by the magnetic particle method any by all other methods examination that were originally required for the affected area, except that, __________________________ re radiography may be omitted. a. When the depth of repair is more than the radiographic sensitivity required b. When the depth of repair is less than the magnetic sensitivity required c. When the depth of repair is less than the radiographic sensitivity required d. When the depth of repair is more than the magnetic sensitivity required 66. An indication of an imperfection found using the dye penetrant technique may be larger than the imperfection that causes it; however, the size of the indication is the basis for acceptance evaluation. Only indications with major dimensions greater than _____ in shall be considered relevant. a. 1/16 b. 1/8 c. 1/32 d. 1/4. 67. These penetrant acceptance standards shall apply unless other more restrictive standards are specified for specific materials or applications within this Division. All surfaces to be examined shall be free; a. relevant rounded indications greater than 1/16 in b. relevant rounded indications greater than 1/8 in c. relevant rounded indications greater than 1/4 in d. relevant rounded indications greater than 3/16 in

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68. Section VIII Div.1 states that when performing ultrasonic examination of weld that imperfections which produce a response greater than _____of the reference level shall be investigated to the extent that the operator can determine the shape, identity, and location of all such imperfections. a. 1/3 of t b. 10% c. 20% d. 1/4 of t 69. Openings in vessels not subject to rapid fluctuations in pressure do not require reinforcement other than that inherent in the construction under the following conditions; a. The vessel will not contain a lethal substance b. The vessel will not have a rated MAWP greater than 15 psig. c. Section VIII Div.1 listed size thickness combinations are not exceeded. d. The vessel will not be constructed to Part UHT so Section VIII Div.1. 70. Section VIII Div.1 states that no two isolated _________openings, shall have their centers closer to each other than the sum of their diameters; a. Unreinforced b. reinforced c. beveled d. fillet welded 71. All pressure vessels for use with ___________ and those subject to internal corrosion or having parts subject to erosion or mechanical abrasion, except as permitted otherwise in this paragraph, shall be provided with suitable manhole, handhole, or other inspection openings for examination and cleaning a. Sulfuric acid b. water c. Hydrogen chloride d. Compressed air

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72. As regards the Section VIII Div.1 formula for the calculation of unstayed flat heads when determining the variable C a valve of m must first be found, this done by finding the ratio of thickness of the ________to ________ a. Shell to the head b. Thickness required of a seamless shell to the actual thickness of the shell c. Thickness required of a seamless shell to the nominal thickness of the shell. d. any long seam joint efficiency in the shell and that of a seamless shell. 73. Section VIII Div.1 states that for formed head that E=lowest efficiency of any joint in the head; for hemispherical heads this includes head-toshell joint, for welded vessels, use the efficiency specified in UW-12, what category of weld joints do all hemispherical heads contain? a. A and C b. B only c. A and B d. A 74. The required wall thickness for tubes and pipe under external pressure shall be determined in accordance with the rules in ______ a. UG-28 b. UW-28 c. UCS-28 d. UG-32 75. Section VIII Div 1 allows that in some cases it is desirable to pressure test vessels when partly filled with liquids. For such vessels a combined hydrostatic and pneumatic test may be used as an alternative to the pneumatic test of this paragraph, provided the liquid level is set so that the maximum stress including the stress produced by pneumatic pressure at any point in the vessel (usually near the bottom) or in the support attachments, does not exceed 13 times the allowable stress valve of the material multiplied by the _______________________ a. Ratio of material’s stress at test and design temperatures b. Applicable joint efficiency c. Material stress allowed at design temperature d. Material stress allowed at test temperature.

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API 510 Practice Exam Section VIII Div 1 ANSWER Q.NO.

ANS

LOCATION OF ANSWER

1 2 3 4 5 6 7 8

A C B D B A C D

9

B

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

D C D D A B C A C D A D A C D A C D C A B A B C D A

1-1UW-2 2-3 UW-2 3-2 UW-3 UW-3 UW-3 UW-5 UG-9 UG-16 16 (6% dose not come into play until the plate approaches 3/16”) UG-22 UG-25 UG-25 UG-26 UG-27 UG-28 UG-76 UG-77 UG-78 UG-79 UG-80 UG-81 UG-85 UG-93 UG-93 UG-96 UG-98 UG-99 UG-99 UG-99 foot note UG-99 Banner UG-100 UG-100 UG-100 UG-102 UG-116

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36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

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B C A D A A B C C D B C A B A A C A B C A B D B A C C A C C A D C C A D C D A B

UG-116 UG-119 UG-120 UG-120 UG-126 UG-126 UG-126 foot note 45 UG-126 foot note 14 UG-127 UG-128 UCS-5 UCS-19 UCS-27 UCS-33 UCS-56 UCS-56 UCS-56 Table UCS-66 UCS-67 UCS-68 UCS-79 UHT-1 UHT-6 UHT-56 UHT-82(d) UHT-84 Appendix 4 Appendix 4 Table 4 Appendix 6 Appendix 6 Appendix 8 Appendix 8 Appendix 12 UG-36 UG-36 UG-46 UG-34 UW-3 UG-31 UG-100 Foot note 36

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ASME SECTION VIII.DIV.1 PRACTICE QUESTIONS 1.

An item which can not be found on a mill test report for material, is : a. SA Specification number b. Heat number c. Allowable stress value d. Chemical composition

2.

What is the minimum thickness of plate that can be used in the shell or head of a pressure vessel? a. 1/4” b. 3/16” c. 1/16” d. There is no minimum thickness

3.

Surface defects in materials may be repaired when: a. Approved by the inspector b. Accepted by the engineering department c. Approved by the pressure vessel engineer d. Less than 2” in depth

4.

Design and fabrication of power boilers is in accordance with which of the following: a. ASME Section 1 b. ASME Section VIII c. Engineering guides and general specifications d. API-Pressure Vessels

5.

Which of the following types of heads will normally require the greatest wall thickness? a. 2:1 elliptical head b. Dished torispherical c. Hemispherical head d. Flat head

6.

Design and fabrication of pressure vessels shall be in accordance with which of the following a. ASME Section 1 b. ASME Section VIII c. Engineering Guides and general specifications d. API – pressure vessels section IV

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7.

A nozzle was originally PWHT when the vessel was constructed because of lethal service application. The material was SA-516 Gr 70 with a thickness of 1/8 in A full thickness repair is made The minimum holding time is ____hours a. 1/2 hour b. 1/4 hour c. 1 hour d. 4 hours

8.

The maximum deviation from the true circular form of a vessel shall not exceed: a. 2% b. 1% c. 10% of the nominal inside diameter d. 5%

9.

The maximum acceptable severity level for a imperfections in a steel casting of 1 ½ in thickness is: a. 1 b. 3 c. 2 d. 0

10.

A casting which was previously PWHT is being repaired, PWHT of the repaired casting is required when: a. Specified by the customer b. Required by either the casting specification or Section VIII. Division 1 c. The thickness exceeds 1 inch d. Required by the casting specification

11.

Which of the following liquid penetrant indications would be unacceptable? a. Relevant linear indications b. Relevant rounded indications greater than 3/16” c. Four or more relevant rounded indications in a line separated by 1/16” or less d. All of the above

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category

A

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12.

According to the ASME code section VIII. The metal temperature during pneumatic test shall be at least ____ above the minimum design metal temperature to minimize the risk of brittle fracture. a. 20ºF b. 30ºF c. 40ºF d. 50ºF

13.

The maximum postweld heat treatment cooling rate required for a 1 ½ inch SA-516 Gr 70 material flush patch installed as part of a repair to a pressure vessel is: a. 333ºF/hr b. 500ºF/hr c. 267ºF/hr d. 400ºF/hr

14.

Ultrasonic examination may be substituted for radiography when: a. Radiographic equipment is not available b. Final closure seam of a vessel does not permit interpretable radiographs c. Required by the designer d. Final closure seam exceeds 2-in thickness

15.

If a vessel is so large that it must be PWHT in more than one heat what is the minimum overlap in the furnace? a. 5’ b. 10’ c. 15’ d. 50’

16.

What documentation is required for a plate of SA-516 Gr. 70 material to be used in a repair procedure? a. A certified material test report b. A certificate of conformity c. A material test report d. A certified of compliance

17.

A vessel nameplate is stamped RT 4 this indicates that: a. Only part of the complete vessel has satisfied the radiographic requirements of UW-11(a) b. The complete vessel satisfies the requirements of UW-11(a)(5) and the spot radiography requirements of UW-11 (a)(5)(b) have been applied c. All butt welds have been 100% radiographed d. All butt welds have been spot radiographed perUW-52

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18.

What is the maximum allowable working pressure of a vessel? a. The vessel’s design pressure b. The vessel’s design pressure plus the static head c. The maximum gauge pressure permitted at the bottom of the vessel which includes hydrostatic head d. The maximum gauge pressure permitted at the top of the vessel

19.

The symbol “HT” on a pressure vessel nameplate indicates a. Vessel was hammer tested b. Whole vessel was post weld heat treated c. Vessel is good for high temperature d. Vessel was hydrotested If an additional ASME code nameplate (in addition to the original nameplate) is installed on the skirt jacket or other permanent attachment to the vessel how should the nameplate be marked? a. SAMPLE b. DUPLICATE c. ADDITIONAL d. EXTRA

20.

21.

A welded carbon steel joint has an MDMT that is colder than 120ºF,at what governing thickness must impact tested materials always be used? a. >4 in b. < 2 in c. 6 in d. 3 in

22.

The manufacturer’s data report for a shop fabricated single chamber pressure vessel is: a. U-1 b. U-3 c. U-1A d. U-2

23.

An isolated rounded indication is found in a 3/4 inch thick weld. The maximum acceptable size is: a. 0.250 in b. 0.156 in c. 0.031 in d. 0.568 in

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24.

What is the minimum size for a liquid pressure relief valve? a. NPS ¾ b. NPS ¼ c. NPS ½ d. NPS 1 ½

25.

If a user signs a contract to build a pressure vessel on May 1 1997, what edition and addenda of the code would be mandatory? a. 1995 Edition. Addenda 1996 b. 1995 Edition. Addenda 1995 c. 1995 Edition. No Addenda d. The date of the edition when the vessel is complete

26.

Which of the following is not considered a piping component and therefore not exempt from the scope of the Code? a. Pipe b. Fittings c. Valves d. Product storage vessel Which of the following pressure vessel categories are exempt from inspection by an Authorized inspector during construction? a. Those having a volume of 5 cu ft and design pressure of 250 PSI b. Those having a volume of 3 cu ft and design pressure of 400 PSI c. Those having a volume of 1.2 cu ft and design pressure of 900 PSI d. Those having a volume of 1.5 cu ft and design pressure of 605 PSI

27.

28.

Pressure vessels with a volume of 1 ½ cu ft and 600 PSI design pressure can be exempted from Authorized Inspection provided they are not required by the rules to be_____ a. Provided with quick actuating closures b. Used for water service only c. Used for steam service less than 400ºF d. Used for noncorrosive service

29.

Who establishes the design requirements for a new pressure vessel? a. Manufacturer b. Design firm c. The user or his designated agent d. ASME

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30.

Which of the following are classified as service restrictions under section VIII Division 1? a. Lethal b. Vessels operating below certain temperatures c. Unfired steam boilers exceeding 50 PSI d. All of the above

31.

Vessels containing lethal substances are required to be postweld heat treated in what thicknesses? a. All b. Above 5/8 in c. Above 1 ¼ in d. Above 1 in

32.

Butt welds in vessels that contain lethal substances are required to be ____ radiographed a. Spot b. Fully c. Partially d. None of the above

33.

Pressure vessels subject to direct firing do not permit what type weld joints for category A and B joints? a. 3 b. 4 c. 1 d. None of the above Longitudinal welded joints within the main shell or nozzles are category_____ a. C b. D c. A d. B

34.

35.

The temperature used when calculating the required thickness of a shell or head is know as the ____ design temperature a. Marginal b. Minimum c. Maximum d. Optimal

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36.

The acronym MDMT stands for____ a. Major Design Method Theory b. Minimum Design Metal Temperature c. Minimum Design Metal Temperature d. Minimum Design Material Temperature.

37.

Which carbon low-alloy material listed below can be exempted from impact testing per UG-84? a. P-No 8, ½ in b. P-No 1, Group 3 Curve E, 1 in c. P-No 1, Group 1 or 2, Curve C, not exceeding 2 in d. P-No 1, Group 1 or 2, Curve D, not exceeding 1 in

38.

P-No 1Group 1 or 2 material listed on Curve A is exempted from impact testing if it does not exceed____ a. 1 in b. 2 in c. ½ in d. 9/16 in

39.

Loading to be considered in designing a pressure vessel are: a. Internal and external pressure b. Wind c. Snow d. All of the above

40.

If a steel casting has a weld seam with a joint efficiency of 0.70 and is examined in accordance with the minimum requirements of the material specification what would be the appropriate “E” value to use when calculating the required thickness of the casting? a. 0.70 b. 1.00 c. 0.80 d. 1.00

41.

You are calculating the required thickness of a cylindrical shell under internal pressure. The inside radius including corrosion allowance is 24 in. The corrosion allowance is 0.125 in what inside radius would you use? a. 24 in b. 24.125 in c. 48.50 in d. 26 in

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42.

A full size Charpy impact test specimen has a dimension of _____ a. 10 mm ×11 mm b. 0 .394 in ×0.394 in c. 0.394 in ×0.393 in d. 0 .262 in × 0.394

43.

What is done when full size impact test specimens cannot be obtained? a. Estimate the ft-Ibf that could be obtained b. Refer to standard tables c. Subsize specimens are to be used d. Use a drop weight test as an alternative

44.

You are to impact test a material, which is 1 in thick, and has a minimum specified yield strength of 55 ksi. What is the required average for the 3 specimens? a. 20 ft-Ibf b. 15 ft-Ibf c. 30 ft-Ibf d. 50 ft-Ibf

45.

When full radiography is required of the Category A and D butt welds, the category B and C butt welds shall as a minimum meet the requirements for_____ a. Full radiography in accordance with UW-51 b. Spot radiography in accordance with UW-52 c. Partial radiography in accordance with UW-53 d. Spot radiography in accordance with UW-51

46.

Ultrasonic examination in accordance with UW-53 may be substituted for radiography for what condition? a. It is never permitted b. When radiographic equipment is not available c. For the final closure seam if the construction does not permit interpretable radiographs d. For longitudinal welded seams when they are in excess of 1 ¼ in

47.

Joint efficiencies for welded joints shall be in accordance with____ a. Subsection C b. UW-11(a)(5)(b) c. Paragraph UW-12(d) d. Table UW-12

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48.

When a value of E is taken from column (a) of Table UW-12 what are the values for Type 1 and Type 2 welded joints? a. 1.00 & 0.90 b. 1.00 & 0.85 c. 0.85 & 0.70 d. 0.85 & 0.65

49.

What would be the value of E for a butt-welded longitudinal joint welded from both sides? a. 1.00 b. 0.85 c. 0.45 d. 0.60

50.

Material for pressure parts shall comply with the requirements for materials given in ___ a. UG-4 thru UG-15 b. UG-93 c. UW-15 d. UG-15 thru UG-27

51.

Material for non-pressure parts. Which are welded to the vessel ____ prior to being used in the vessel. a. Must be tested using PT or MT b. Must be proven of weldable quality c. Must be ultrasonic thickness tested d. Must be pressure tested

52.

For material which is not identifiable in accordance with UG-10,UG11,Ug-15,or UG-93 proof of weldable quality can be demonstrated by: a. Using weld material which meets the requirements of an SFA specification b. Preparing a butt joint test coupon from each piece of non-identified material and making guided bend tests c. Satisfactory qualification of the welding procedure d. Both 2 and 3 above.

53.

When adjacent abutting sections differ in thickness by more than the lesser of one-fourth the thickness of the thinner section of 1/8 in what must be done? a. Provide a tapered transition of at least 3:1 b. Make six inch radiograph c. Nothing d. Provide a tapered transition of at least 4:1

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54.

Longitudinal welded joints of adjacent courses shall separated by at least ____to avoid the radiographic requirement a. Five times the minimum thickness of the plate b. Five times the thickness of the thinner plate c. Six inches d. Four times the thickness of the thicker plate

55.

Full radiography is required for which of the following butt welds: a. In shells and heads of vessels containing lethal substances b. In shells and heads of unfired steam boilers having design pressures less than 50 PSI c. In all vessels where the least nominal thickness exceeds 1 in d. None of the above

56.

Category B and C butt welds in nozzles and communicating chambers never require radiographic examination provided they neither exceed: a. NPS 10 b. 1 1/8 in c. NPS 6 d. NPS 10 nor 1 1/8 in

57.

What formula would be used to determine the internal design pressure for a circular unstayed flat cover? a. UG-34, (1) b. UG-34, (3) c. UG-32(e) d. UG-34, (7)

58.

The maximum inside diameter of a welded opening in a vessel head of ½ in thickness. Which does not require a reinforcement calculation. Is____ a. 3 ½ in b. 6 in c. 3tr d. 2 3/8 in.

59.

No two isolated unreinforced openings shall have their centers closer to each other than: a. Five times their radii b. The sum of their diameters c. 3d d. 12 in

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60.

When calculating the required thickness of a seamless nozzle for a reinforcement problem and the nozzle is made from ERW pipe what efficiency would be used? a. 0.65 b. 0.90 c. 1.00 d. 0.85

61.

The allowable stresses of the nozzle and shell are 17500 and 13800 respectively what would be the maximum strength reduction factor? a. 1.00 b. 1.268 c. 0.788 d. 0.60

62.

What happens to the formula for A in Figure UG-37.1 when fr1 = 10 inch a. Nothing b. Everything after the plus (+) sign is equal to 0 c. (1-fr1) = 1 d. F becomes 0.5

63.

When calculating the limits of reinforcement normal to the surface and there is no reinforcing element installed the value of ____is used for te” a. 1.0 b. 0.5 c. 0 d. 32

64.

The governing limit of reinforcement parallel to the vessel surface is the larger of: a. R or Dn + t b. D or Rn + tn + t c. R or Rn + tn + t d. 1 or 3 above

65.

What is the set pressure tolerance for a pressure relief device set at 350 PSI? a. +/- 2 PSI b. +/- 30 PSI c. +/- 10.5 PSI d. +/- 15%

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66.

A pressure vessel, which is 50 in inside diameter, has a flat spot. What is the maximum permitted out of roundness at this location? a. 2.00 in b. 1.00 in c. 0.750 in d. 0.500 in

67.

The formula that is to be used calculating thickness and pressure for cylindrical shells subject to circumferential stress is found in Appendix_____ a. 1-1, formula 2 b. 1-1, formula 1 c. 1-4, formula 3 d. 1-8, formula 1

68.

When calculating the required thickness for external pressure of a shell factor B must be determined Considering the Do / t ratio what are the three parameters required to determine the factor? a. Material, stress temperature b. Factor A, modulus of elasticity. Material c. Factor A, material, and the design temperature d. Thickness, factor A, design temperature

69.

A nozzle similar to Figure UW-16. 1, sketch (e) has a shell thickness of 9/16 in and a nozzle thickness of 3/4 in what is the value of tmin? a. 9/16 in b. ½ in c. 1 1/2 in d. 1 in

70.

Two shells are to be butt welded together to form a circumferential joint. Each shell is 1” thick. What is the maximum permitted offset? a. 3/16 in b. 1/4 t c. 1/8 in d. 3/4 in

71.

Pressure vessels with a volume of 1 ½ cu ft and 600 PSI design pressure can be exempted from Authorized inspection provided they are not to be _____ a. Provided with quick actuating closures b. Used for water service only c. Used for steam service less than 400ºF d. Used for noncorrosive service

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72.

If a head is formed with a flattened spot what is the C factor that must be used? a. 0.33m b. 0.25 c. 1.2 d. 0.17

73.

When performing thickness calculations for shells and tubes under external pressure what value must first be determined? a. L/Do ratio b. D/D ratio c. Do/t ratio d. t/Do ratio

74.

Reinforcing plates and saddles of nozzles attached to the outside of a vessel shall be provided with a least one telltale hole ____in size a. Maximum NPS ¼ tap b. Maximum NPS 2 c. Maximum NPs ½ tap d. 2 in

75.

A pressure vessel is to be hydrostatically tested in accordance with the ASME Code. The MAWP is 654 PSI Sd = 8600 PSI and St = 17500 PSI what is the minimum required test pressure? a. 981 b. 818 c. 1996 d. 1308

76.

The temperature of the furnace shall not exceed ____ºF at the time the vessel or part is placed in it a. 600 b. 500 c. 800 d. 300

77.

Ultrasonic examination of welds shall be performed using methods described in ____ of ASME Code Section V a. Article 1 b. Article 4 c. Article 5 d. Article 23

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78.

Ellipsoidal heads of what ratio are calculated using the formula in UG32? a. 3:1 b. 2:1.2 c. 4:1 d. 2:1

79.

It is recommended that no welding be performed when the metal is lower than ___ºF a. 32 b. 60 c. 0 d. 5 SECTION VIII, SUBSECTION A QUESTIONS

80.

If a user signs a contract to build a pressure vessel on January 1, 1997, what edition of the Code would be applicable as a minimum? a. 1995 Edition. Addenda 1996 b. 1995 Edition. Addenda 1995 c. 1995 Edition. No Addenda d. The data of the edition when the vessel is completed

81.

Which of the following is not considered a piping component and therefore not exempt from the scope of the Code? a. Pipe b. Fittings c. Valves d. Product storage vessel

82.

Which of the following pressure vessel categories are exempt from inspection by an Authorized Inspector during construction? a. Those having a volume of 5 cu ft and design pressure of 250 PSI b. Those having a volume of 3 cu ft and design pressure of 400 PSI c. Those having a volume of 1.2 cu ft and design pressure of 900 PSI d. Those having a volume of 1.5 cu ft and design pressure of 605 PSI

83.

Pressure vessels with a volume of 1 ½ cu ft and 600 PSI design pressure can be exempted from Authorized Inspection provided they are not required by the rules to be ______ a. Provided with quick actuating closures b. Used for water service only c. Used for steam service less than 400ºF d. Used for noncorrosive service

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84.

Who establishes the design requirements for a new pressure vessel? a. Manufacturer b. Design firm c. The user or his designated agent d. ASME

85.

What is the date of the acceptable edition of SNT-TC-1A to be used for new construction? a. 1992 b. 1984 c. 1996 d. 1975

86.

Material subject to stress due to pressure shall conform to _____ a. ASTM, latest edition b. Section VIII Division 1, Subsection B c. Section VIII Division 1, Subsection C d. Section II

87.

Which of the following parts are not considered to be subject to stress due to pressure? a. Reinforcing pads b. Legs of the vessel c. Shells d. Stiffening rings

88.

The term plate is considered to also include: a. Strip and sheet b. Lugs c. Skirts d. Baffles

89.

Welding materials only have to comply with the requirements for ____to be used in the manufacture of a pressure vessel a. Carbon content b. Proper chemistry c. Correct length d. Marking or tagging

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90.

The code paragraph that allows using of a material that is not fully identified with a specification permitted by the Code is_____ a. UG-77 b. UG-10 c. Appendix 3 d. Ug-11

91.

When no specific exceptions apply the minimum thickness of the heat transfer plates of plate type heat exchangers is _____ a. ¼ in b. No minimum c. 1/16 in d. 3/8 in

92.

Plate material may be used at full design pressure when the mill undertolerance does not exceed _____ a. 12 ½% b. 18% c. The value established by the owner d. The smaller of 0.01 in or 6% of the ordered thickness

93.

Pipe is ordered by its nominal thickness, where would this manufacturing undertolerance limits be found? a. In the owners purchasing specification b. In section VIII, Division 1 c. In section II, Part D d. In the pipe and tube specification listed in subsection C

94.

The dimensional symbols used in the design formulas throughout the code represent dimensions in the ___condition a. Corroded b. As built c. As designed d. Normally desirable

95.

The temperature used when calculating the required thickness of a shell or head is known as the _____design temperature a. Marginal b. Minimum c. Maximum d. Optimal

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96.

The acronym MDMT stands for_____ a. Major Design Method Theory b. Minimum Design Metal Temperature c. Maximum Design Metal Temperature d. Minimum Design Material Temperature

97.

Which carbon low-alloy material listed below can be exempted from impact testing per UG-84? a. P-No 8. ½ in b. P-No 1, Group 3 Curve E 1 in c. P-No 1, Group 1 or 2, Curve C, not exceeding 2 in d. P-No 1, Group 1 or 2 ,Curve D, not exceeding 1 in.

98.

P-No 1, Group 1 or 2 material listed on Curve A is exempted from impact testing if it does not exceed______ a. 1 in b. 2 in c. ½ in d. 9/16 in

99.

Loadings to be considered in designing a pressure vessel are: a. Internal and external pressure b. Wind c. Snow d. All of the above

100. If a steel casting has a weld seam with a joint efficiency of 0.70 and is examined in accordance with the minimum requirements of the material specification what would be the appropriate “E” value to use when calculating the required thickness of the casting? a. 0.70 b. 1.00 c. 0.80 d. 1.00 101. You are calculating the required thickness of a cylindrical shell under internal pressure. The inside radius including corrosion allowance is 24 in. The corrosion allowance is 0.125 in what inside radius would you use? a. 24 in b. 24.125 in c. 48.50 in d. 26 in

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102. What is the weld joint efficiency to be used on an NPS 12 nozzle of PNo. 1 material butt welded to a ¾ in. shell which has a backing strip left in place and is spot radiographed? a. 0.85 b. 0.60 c. 1.00 d. 0.80 103. When performing thickness calculations for shells and tubes under external pressure what value must first be determined? a. L / Do ratio b. D / D ratio c. Do / t ratio d. t / Do ratio 104. You are calculating the required thickness for external pressure of a shell having a Do / t ratio of 66. the actual L / Do ratio is 75. At what value would you enter figure G on the L / Do ordinate? a. 50 b. 75 c. 0.50 d. 0.20 105. When calculating the required thickness for external pressure of a shell factor B must be determined Considering the Do / t ratio what are the three parameters required to determine the factor? a. Material stress temperature b. Factor A modulus of elasticity, material c. Factor A material and the design temperature d. Thickness factor A design temperature 106. The minimum required thickness of a formed head with pressure on the concave side is the thinnest point after_____ a. Cutting the plate b. Forming c. Heat d. Welding 107. Ellipsoidal heads of what ratio are calculated using the formula in UG32? a. 3:1 b. 2:1.2 c. 4:1 d. 2:1 API 510 – DAY 2

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108. The semiellipsoidal form is defined as: a. The minor axis equals one-half the inside head diameter b. Half a sphere c. Half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the outside head diameter d. Half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the inside head diameter. 109. The UG-32 formula for determining minimum thickness of a torispherical head considers what specific knuckle radius? a. 10% of outside crown radius b. 6% of the inside crown radius c. 2.88 in d. 6% of the inside head diameter 110. If a head is formed with a flattened spot what is the C factor that must be used? a. 0.33m b. 0.25 c. 1.2 d. 0.17 111. An unstayed flat head similar to Figure UG-34(f) is made up of two pieces welded together using a type 2 butt joint. Which is only visually examined what joint efficiency would be applicable? a. 0.65 b. 0.80 c. 0.90 d. 1.00 112. A seamless unstayed flat head similar to Figure UG-34 (b)(1) is welded to a shell using a butt weld. what efficiency would be used to calculate required thickness if there was no radiography performed on the circumferential weld? a. 1.00 b. 0.55 c. 0.85 d. 0.90

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113. What formula would be used to determine the internal design pressure for a circular unstayed flat cover? a. UG-34, (1) b. UG-34, (3) c. UG-32, (e) d. UG-34, (7) 114. The maximum inside diameter of a welded opening in a vessel head of ½ in thickness, which does not require a reinforcement calculation, is_____ a. 3 ½ in b. 6 in c. 3tr d. 2 3/8 in. 115. No two isolated unreinforced openings shall closer to each other than: a. Five times their radii b. The sum of their diameters c. 3d d. 12 in.

have their centers

116. When calculating the required thickness of a seamless nozzle for a reinforcement problem and the nozzle is made from ERW pipe what efficiency would be used? a. 0.65 b. 0.90 c. 1.00 d. 0.85 117. The allowable stresses of the nozzle and shell are 17500 and 13800 respectively what would be the maximum strength reduction factor? a. 1.00 b. 1.268 c. 0.788 d. 0.60 118. What happens to the formula for A in Figure UG-37 1 when fr1 = 1 0? a. Nothing b. Everything after the plus (+) sign is equal to 0 c. (1 – fr1) = 1 d. F becomes 0 5

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and there is no reinforcing element installed the value of _____is used for te a. 1.0 b. 0.5 c. 0 d. 32 120. The governing limit of reinforcement parallel to the vessel surface is the larger of a. R or Dn + t b. D or Rn + tn + t c. R or Rn + tn + t d. 1 or 3 above 121. With the exception of studding outlet flanges ____ within the limits of reinforcement shall not be considered to have reinforcing value. a. Bolted flange material b. Split reinforcing elements c. Bolting d. Stiffener 122. Exposed inside edges shall be ____or _____ a. Machined, chamfered b. Chamfered, rounded c. Avoided, rounded d. Tapered, rounded 123. Material traceability can be maintained by several methods. One of those is; a. Transfer of the original identification markings b. Tell the QC Inspector c. A coded marking d. Marking the ASTM material specification on the material 124. Where service conditions prohibit the use of die-stamping for material identification which of the following is a substitute? a. Magic marker b. Vibro etching c. Color coding d. All of the above

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125. When plates are rolled to form a longitudinal joint for a cylindrical shell they are first____ to avoid flat spots along the finished joint a. Crimped b. Beveled c. Radiographed d. Visually inspected 126. When a shell section is welded into a vessel operating under internal pressure the difference between the maximum and minimum inside diameters at any cross section shall not exceed _____of the nominal diameter at the cross section being considered a. 2% b. Square root of Rt c. 5/8% d. 1% 127. When pressure parts extend over pressure retaining welds the welds shall be ____for the portion of the weld to be covered. a. Left as is b. Ground flush c. Notched d. Radiographed 128. Non pressure parts extending over pressure retaining welds shall be ____or____to clear those welds a. Ground flush,notched or coped b. Machined beveled c. Radiographed, MT d. MT,PT 129. Each set of impact test specimens shall consist of ___specimens a. One b. Two sets of three c. Four d. Three 130. A full size charpy impact test specimen has a dimension of ____ a. 10 mm × 11 mm b. 0 394 in × 0 394 in c. 0.394 in × 0.393 in d. 0.262 in × 0.394 in

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131. What is done when full size impact test specimens cannot be obtained? a. Estimate the ft-Ibf that could be obtained b. Refer to standard tables c. Subsize specimens are to be used d. Use a drop weight test as an alternative 132. You are to impact test a material which is 1 in thick and has a minimum specified yield strength of 55 ksi what is the ft-Ibf requirement? a. 20 ft-Ibf b. 15 ft-Ibf c. 30 ft-Ibf d. 50 ft-Ibf 133. The acceptance criteria for materials having a specified minimum tensile strength of 95,000 PSI or greater is based on the ____ a. The ratio of stresses to the ft-Ibf value b. Maximum lateral expansion opposite the notch c. Minimum lateral expansion opposite the notch d. Charpy V Notch values taken. 134. A subsize impact test specimen must be used which is 0.118 in thick. What temperature reduction would be taken? a. 30ºF b. 40ºF c. 80ºF d. 15ºF 135. The material being impact tested has a minimum specified yield strength of 35 ksi. A ____ temperature difference permitted. a. 25ºF b. 15ºF c. 0ºF d. 10ºF 136. When the plate material manufacturer does not performed the heat treatments required by the material specification a letter _____ is marked next to the material specification designation on the plate. a. T b. G c. NPT d. N

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137. Duties of the inspector include which of the following a. Verifying that welding procedures and welders have been qualified b. Verifying that heat treatments have been properly performed c. Verifying that required nondestructive examinations have been performed d. All of the above 138. ____ materials are the only product from that must have a material test report provided a. Plate b. Pipe c. Casting d. Forging 139. A 1 in shell in to be welded to a tube sheet 3 in thick using a corner joint per Figure UW-13.2. what must be done to the weld preparation in the flat plate prior to welding? a. Visually examine the entire surface b. UT 10% of the circumference c. Examined by either MT or PT d. Examined by random radiography 140. Before welding a nozzle into a shell the inspector must: a. Make certain the nozzle fits the vessel curvature b. Verify the identification markings c. Examine the material for imperfections d. All of the above 141. The maximum allowable working pressure for a complete vessel is: a. Maximum internal or external pressure including static head b. Maximum internal or external pressure excluding static head c. Maximum pressure at the top of the vessel excluding and static head d. Average maximum pressure between the top and bottom of the vessel 142. The maximum allowable working pressure for a vessel part is: a. Maximum internal or external pressure including static head b. Maximum internal or external pressure excluding static head c. Maximum pressure at the bottom of the part d. Average maximum pressure between the top and bottom of the vessel

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143. The formula for hydrostatic testing is: a. P = 1.5 × MAWP b. P = 1.25 × MAWP × St / Sd c. P = 1.5 × MAWP × St / Sd d. P = 3 × Design Pressure 144. A special hydrostatic pressure test is permissible which utilizes the ____ thickness including corrosion allowance and the allowable stress at ____ temperature multiplied by 1 ½ a. Nominal, test b. Minimum, design c. Postulated,100ºF d. Assumed test 145. When a hydrostatic test exceeds the test pressure either accidentally or intentionally what must be done? a. The vessel is rejected b. Have an engineer perform a stress analysis c. Stop the test and repeat d. Must be inspected by the inspector for visible distortion 146. When hydrostatic testing a pressure vessel which has more than one chamber each chamber ____ a. Shall be tested using the differential in any adjacent chamber b. Shall be tested without pressure in any adjacent chamber c. Shall be tested with the full test pressure in all other chambers d. Shall be tested using a combined hydrostatic pneumatic test 147. Single wall pressure vessels designed for vacuum service only shall be hydrostatic pressure tested at not less than______ a. 1 ½ times the difference between normal atmospheric pressure and the minimum design internal absolute pressure b. 30” of water gage c. Two times the difference between normal atmospheric pressure and the minimum design internal absolute pressure d. 15 PSI 148. The required visual inspection after application of the hydrostatic test pressure is conducted at not less than____ a. Four-fifths the test pressure b. The MAWP to be stamped on the vessel c. Two-thirds the test pressure d. Ten percent above operating pressure

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149. What type liquids may be used for hydrostatic testing? a. Water b. Any nonhazardous liquid if below its boiling point c. Combustible liquids having a flash point less than 110ºF d. All of the above 150. The recommended test temperature above the MDMT for hydrostatic testing in accordance with the ASME Code is____ a. 10ºF b. 30ºF c. 20ºF d. 50ºF 151. The hydrostatic test pressure shall be applied to a filled pressure vessel when____ a. The vessel and its contents are at about the same temperature b. The inspector believes it should be applied c. Required by the test procedure d. All personnel are at a safe distance from the test site 152. What is the maximum metal temperature that need not be exceeded during a hydrostatic pressure test? a. 70ºF b. 30ºF above the MDMT c. 120ºF d. 10ºF above the Design temperature 153. A small liquid relief valve installed on the vessel set to ____ times the hydrostatic test pressure is a recommended precaution to prevent overpressure and damage a. 3 b. 2 c. 1 1/2 d. 1 1/3 tones 154. Except for lethal service a vessel ____ be painted, coated or internally lined prior to the hydrostatic pressure test a. May b. May not c. Should d. Must

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155. The formula for determining the pneumatic test pressure is: a. P = 1.25 × Minimum Operating Pressure b. P = 1.5 × MAWP × St /Sd c. P = 1.25 × MAWP × St / Sd d. P = 3 × Minimum Operating Pressure 156. The metal temperature during ASME pneumatic test shall be maintained at least ____ above the MDMT a. 10ºF b. 20ºF c. 60ºF d. 30ºF 157. The two steps in pressurizing a vessel for the pneumatic test are: a. Increase to one-half test pressure then in steps of one-tenth test pressure until test pressure is reached b. Rapidly raise to one-third test pressure then raise slowly to test pressure c. Increase to one-third test pressure then in steps of one-twentieth test pressure d. Raise to one-half test pressure then to full test pressure in equal steps 158. The required visual inspection after application of the pneumatic test pressure is conducted at a pressure equal to ____of test pressure a. Two-thirds b. Four-fifths c. One-half d. One-tenth 159. Except for lethal service a vessel ____be painted coated or internally lined prior to the pneumatic pressure test a. May b. May not c. Should d. Must 160. Indicating test gages shall be connected____ a. Directly to the vessel b. Within 30 feet of the bottom of the vessel c. In sets of three to the vessel d. Always with a recording gage to the vessel

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161. When the operator controlling a pressure test cannot see the pressure gage___ a. A telephone system shall be installed between the test gage observer and test controller b. A second gage shall be installed that can be observed by the test pressure controller c. They estimate when the test pressure is reached d. Visual communication between pressure gage observer and pressure test controller must be established 162. An indicating pressure gage which has a range ____ should be used for pressure tests a. About double the test pressure b. About 1 ½ times the test pressure c. About three times the test pressure d. About 1 1/3 times the test pressure 163. In no case shall indicating pressure gages have a range of neither less than ___nor more than ___ times the test pressure. a. 2, 4 b. 3, 4 c. 1 ½, 4 d. 3, 5 164. A digital pressure gage having ___ may be used for pressure tests a. Any range b. A range specified by the inspector c. A very narrow range d. A range of only 0.5 to 6 times the test pressure 165. Pressure test gages shall be calibrated against____ a. A calibrated master gage b. A standard deadweight tester c. A deadweight test gage d. Either 1 or 2 above 166. When magnetic particle examinations are prescribed they shall be done in accordance with appendix___ a. 12 b. 6 c. 8 d. 7

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167. When liquid penetrant examinations are prescribed they shall be done in accordance with Appendix___ a. 12 b. 6 c. 8 d. 7 168. The units of measurement that are mandatory for Manufacturer’s Data Reports and markings on pressure vessels is: a. U S Customary and metric b. U S Customary c. English d. Metric 169. Which of the following can be found on the required marking for a pressure vessel? a. The name of the manufacturer preceded by the words “made by” b. The MAWP____ PSI at___ ºF c. The month and year built d. The minimum design product temperature 170. A vessel is constructed by are or gas welding, what symbol would appear under the Code symbol stamp to denote this type of construction? a. A b. L c. P d. W 171. A vessel is constructed for special service as an unfired steam boiler what symbol would appear under the Code symbol stamp to denote this service condition? a. UB b. DF c. W d. HT

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172. A vessel has been radiographed in accordance with UW-11 where the complete vessel satisfies the requirements of UW-11(a)(5) and the spot radiography requirements of UW-11 (a)(5)(b) have been applied, what marking would appear under the Code symbol stamp? a. None b. RT 2 c. RT 3 d. SR 173. A vessel has been radiographed in accordance with UW-11 where the complete vessel satisfies the spot radiography requirements of Uw11(b) what marking would appear under the Code symbol stamp? a. None b. SR 3 c. RT 3 d. RT4 174. A vessel has been radiographed in accordance with UW-11 where only part of the vessel has satisfied the radiographic requirements of UW-11(a) and none of the markings RT 1 RT 2 or RT 3 apply, what marking would appear under the Code symbol stamp? a. None b. SR 3 c. RT 3 d. RT 4 175. A vessel has been radiographed in accordance with UW-11 where the complete vessel has had all butt welds radiographically examined for their full length, what marking would appear under the Code symbol stamp? a. None b. SR 2 c. RT 1 d. RT 2 176. A vessel has been designed with only visual examination required of the butt welded joints. What marking would appear under the Code symbol stamp for this condition? a. RT 4 b. None c. RT 3 d. Nr

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177. The marking HT is used for vessels that have been___ a. Fully heat treated b. Partially heat treated c. Hydrostatically tested d. Hydrogen tested 178. The marking PHT is used for vessels that have been___ a. Partially hydrogen tested b. Partially head tested c. Partially heat treated d. Pneumatically tested 179. A pressure vessel is a single chamber and has been completely shop fabricated what Manufacturer’s Data Report from would be used? a. U-1 b. P-4 c. P-1 d. U-1A 180. What Manufacturer’s Data Report form would be used for a pressure vessel part? a. P-3 b. U-1 c. U-2 d. P-4A 181. All pressure vessels other than unfired steam boilers shall be protected by a pressure relieving device that shall prevent the pressure from rising more than the greater of___% or ____PSI above the MAWP a. 10,3 b. 15,5 c. 25,10 d. 40,3 182. What is the minimum size of liquid relief value permitted by section VIII, Division 1? a. NPS 10 b. NPS 24 c. NPS 1 d. NPS 1/2

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183. When a single pressure relief device is used on a pressure vessel it shall be set to operate at a pressure not exceeding ____ a. The MAWP b. The operating pressure c. The design pressure d. The mean design pressure SECTION VIII,SUBSECTION B QUESTIONS 184. Which of the following are classified as service restrictions under section VIII, Division 1? a. Lethal b. Vessels operating below certain temperatures c. Unfired steam boilers exceeding 50 PSI d. All of the above 185. Vessels containing lethal substances are required to be postweld heat treated in what thickness? a. All b. Above 5/8 in c. Above 1 1/4 in d. Above 1 in 186. Butt welds in vessels that contain lethal substances are required to be ___ radiographed a. Spot b. Fully c. Partially d. None of the above 187. Pressure vessels subject to direct firing do not permit what type weld joints for Category A and B joints? a. 3 b. 4 c. 1 d. None of the above 188. Longitudinal welded joints within the main shell or nozzles are category____ a. C b. D c. A d. B API 510 – DAY 2

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189. Circumferential welded joints within the main shell or transitions in diameter are Category____ a. A b. B c. C d. None of the above 190. Circumferential welded joints connecting hemispherical heads to main shells to nozzles are Category___ a. B b. A c. C d. D 191. Welded joints connecting flanges, tubesheets or flat heads to main shell or formed heads are Category___ a. B b. A c. C d. D 192. Welded joints connecting communicating chambers or nozzles to main shells or heads are Category___ a. A b. B c. C d. D 193. When a Circumferential welded joint connecting a transition in diameter exceeds 30º it is not considered a ____ a. Butt weld b. Groove weld c. Fillet weld d. Full penetration weld 194. Material for pressure parts shall comply with the requirements for materials given in____ a. UG-4 thru Ug-15 b. Ug-93 c. Uw-15 d. Ug-15 thru UG-27

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195. Material for nonpressure parts which are welded to the vessel ___prior to being used in the vessel a. Must be tested using PT or MT b. Must be proven of weldable quality c. Must be ultrasonic thickness tested d. Must be pressure tested 196. For material which is not identifiable in accordance with UG-10 UG-11 UG-15 or UG-93 proof of weldable quality can be demonstrated by: a. Using weld material which meets the requirements of an SFA specification b. Preparing a butt joint coupon from each piece of nonidentified material and making guided bend tests c. Satisfactory qualification of the welding procedure d. Both 2 and 3 above 197. When adjacent abutting sections differ in thickness by more than the lesser of one-fourth the thickness of the thinner section of 1/8 what must be done a. Provide a tapered transition of at least 3:1 b. Make a six inch radiograph c. Nothing d. Provide a tapered transition of at least 4:1 198. Longitudinal welded joints of adjacent courses shall be separated by at least____ to avoid the radiographic requirement a. Five times the minimum thickness of the plate b. Five times the thickness of the thinner plate c. Six inches d. Four times the thickness of the thicker plate 199. Full radiography is required for which of the following butt welds? a. In shells and heads of vessels containing lethal substances b. In shells and heads of unfired steam boilers having design pressure less than 50 PSI c. In all vessels where the least nominal thickness exceeds 1 in d. None of the above

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200. Category B and C butt welds in nozzles and communicating chambers never require radiographic examination provided they neither exceed: a. NPS 10 b. 1 1/8 IN c. NPS 6 d. NPS 10 nor 1 1/8 in 201. When full radiography is required of the Category A and D butt welds the Category B and C butt welds shall as a minimum meet the requirements for____ a. Full radiography in accordance with UW-51 b. Spot radiography in accordance with UW-52 c. Partial radiography in accordance with UW-53 d. Spot radiography in accordance with UW-51 202. Ultrasonic examination accordance with UW-53 may be substituted for radiography for what condition? a. It is never permitted b. When radiographic equipment is not available c. For the final closure seam if the construction does not permit interpretable radiographs d. For longitudinal welded seams when they are in excess of 1 ¼ in 203. Joint efficiencies for welded joints shall be in accordance with___ a. Subsection C b. UW-11(a)(5)(b) c. Paragraph UW-12(d) d. Table UW-12. 204. When a value of E is taken from column (a) of Table UW-12 what are the values for Type 1 and Type 2 welded joints? a. 1.00 & 0.90 b. 1.00 & 0.85 c. 0.85 & 0.70 d. 0.85 & 0.65 205.

What would be the value of E for a butt welded longitudinal joint welded from both sides? a. 1.00 b. 0.85 c. 0.45 d. 0.60

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206. A seamless vessel section is welded into a vessel with the requirements of UW-11 (a)(5)(b) spot radiography requirements met What value of E would be used in the calculation for the shell?. a. 0.85 b. 0.65 c. 0.90 d. 1.00 207. A seamless head is welded to a vessel shell using a Type 4 joint. What value of E would be used in the calculation for the head? a. 0.55 b. 0.45 c. 0.85 d. 1.00 208. An ERW pipe is being used as the shell of a vessel. What E value would be used in the calculation of the shell if the requirements of UW-11(a)(5)(b) were met? a. 1.00 b. 0.85 c. 0.45 d. 0.60 209. A single unreinforced opening meeting the requirements of UG36(c)(3) is located in a Category B weld joint what radiographic requirements must be met? a. A radiograph must be taken that is two times the diameter of the hole in length b. A six inch radiograph must be taken which is centered over where the hole will be placed c. A twenty inch radiograph must be taken which is centered over the hole area d. A radiograph must be taken that is three times the diameter of the hole in length 210. Strength calculations are required for which of the following nozzle configurations? a. Figure UW-13.2, sketch h b. Figure UW-16.1, sketch a-1 c. Figure UW-16.1, sketch b d. Figure UW-13.1, sketch d

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211. Reinforcing plates and saddles of nozzles attached to the outside of a vessel shall be provided with at least one telltale hole _________ in size a. Maximum NPS ¼ tap b. M Maximum NPS 2 c. Maximum NPS ½ tap d. 2 in 212. The largest throat size required for a tc fillet weld when only pressure loading is being considered is: a. 3/4 in b. 1/3 the thickness of the nozzle c. 3/16 in d. 1/4 in. 213. A nozzle similar to Figure UW-16.1, sketch (e) has a shell thickness of 9/16 in and a nozzle thickness of 3/4 in.. what is the value of tmin? a. 9/16 in b. ½ in c. 1 ½ in d. 1 in 214. When calculating the allowable load on fillet welds a joint efficiency of ________% is used a. 60 b. 55 c. 1.0 d. 85 215.

Welding procedures used in welding pressure parts and in joining load-carrying nonpressure parts shall be qualified in accordance with: a. AWS B1 b. ASME Section IX c. ASME Section VIII d. Company engineering specifications

216.

When welding nonpressure-bearing attachments. Which have no load-carrying function. Is made by any automatic welding process procedure qualification testing is: a. Required when thickness exceeds ½ b. Required for pressure parts only c. Not required d. Not required unless requested by the inspector

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217. Each welder and welding operator shall be assigned a/an ____ by the manufacturer/repair film a. Clock number b. Welding helmet c. Blue uniform d. Identifying number. Letter or symbol 218. It is recommended that no welding be performed when the metal is lower than _______ F a. 32 b. 60 c. 0 d. 5 219. Tack welds used to secure alignment shall be; a. Removed completely b. Ground on the starting and stopping ends c. Examined with the PT method d. Either 1 or 2 220. Surfaces to be welded shall be cleaned within what distance from the weld joint? a. 1” b. Two times the plate thickness c. There is no mandatory distance d. As required by the inspector 221. Two shells are to be butt welded together to form a circumferential joint Each shell s thick. What is the maximum permitted offset? a. 3/16 in b. 1/4 t c. 1/8 in. d. 3/4 in. 222. What is the maximum permitted weld reinforcement for a butt in a pressure vesse: seil that is 1 ½ thick? a. 1/2 in b. 3/32 in c. 1/8 in d. 1/4 in.

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223. When welds are identified by stamping, each welder or welding operator shall stamp their identification at what intervals for steel fabrications? a. 6 ft b. 2 ft c. 10 ft d. 3 ft 224. Peening shall not be used on which of the following welds if the vessel is not subsequently post weld heat treated? a. Initial (root layer) b. Intermediate layers c. Final face layer d. 1 and 3 225. When is the minimum overlap that must be provided when a vessel is heat treated in more than one heat in a furnace? a. 10 ft b. 5 ft c. No minimum specified d. 15 ft 226. Postweld heat treatment when required shall be done ____ a. Either before or after the hydrostatic test b. Prior to minor repairs c. Before hydrostatic test d. After hydrostatic test. 227. An example of nominal thickness for the purpose of determining heat treatment time is: a. The depth of a repair weld b. The thickness of the attachment when a nonpressure part is welded to a pressure part c. The thickness of the tubesheet in shell to tubesheet connections d. The thicker of the two adjacent welded butt welded parts 228. Surface weld metal buildup is required to be examined over the full surface of the deposit by which of the following? a. Radiographic b. Ultrasonic c. Magnetic particle d. Acid etching

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229. The Inspector shall assure that which of the following has been accomplished? a. Welding procedures used have been qualified b. Welders used have been qualified c. Postweld neat treatments have been correctly performed d. All of the above 230. When pneumatic testing is used instead of hydrostatic testing which of the following welds must be examined with MT or PT? a. All welds around openings b. Welds around openings over 12 in. OD c. Attachment welds with throat thickness exceeding 3/8 in d. None of the above 231. When full radiography is required the radiographic personnel shall be qualifed to which standard? a. Manufacturer’s b. ISO 926 c. SNT-TC-1A d. AWS-1104 232. A longitudinal butt weld is being fully examined. The weld is ¾ in. thick which includes a 1/16 in reinforcement What is the longest elongated inclusion permitted? a. 3/16 in. b. 1/4 in. c. 3/4 in. d. 1/2 t. 233. For spot radiography, one spot shall be examined on each vessel for each ________ of length. a. 50 ft. b. 25 ft. c. 60 ft. d. 10% 234. The minimum length of a spot radiograph shall be _______ a. 24 in b. No minimum specified c. 12 in d. 6 in

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235. When a spot radiograph does not meet Code requirements _____ a. The entire increment will be acceptable if the weld is repaired at the failed spot b. Two additional spots shall be examined c. One additional spot shall be examined d. The entire increment must be rewelded and a new spot examined. 236. Ultrasonic examination when required is performed in accordance with____ a. Section V. Article 5 b. Appendix 8 c. Appendix 12 d. Appendix 7 SECTION VIII, SUBSECTION C QUESTIONS 237. For welded construction the carbon content for carbon and low alloy steels shall not exceed ____% a. 0.035 b. 0.35 c. 3.5 d. 10 238. SA-36 and SA-283 Grades A,B,C, and D steel plates may be used as pressure parts for which of the following applications? a. Unfired steam boilers not exceeding 50 PSI b. Vessels containing lethal substances c. Vessels processing gasoline d. None of the above 239. The term nominal thickness for determination of postweld heat treatment holding time is defined as: a. Thickness of the weld including corrosion allowance b. Thickness of the base metal c. Thickness of the weld excluding corrosion allowance d. Thickness of the base metal plus one-half the corrosion allowance 240. When pressure parts of two different P-Number groups are joined by welding the postweld heat treatment shall be that specified in: a. UCS-66 or UHT-56 b. UCS-56 or UHA-32 c. UHT-56 or UHA-32 d. UNF-56 or UCS-56 API 510 – DAY 2

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241. The temperature of the furnace shall not exceed ___ºF at the time the vessel or part is placed in it a. 600 b. 500 c. 800 d. 300 242. Above 800ºF the heating rate shall not be more than ____ a. 500ºF/hour divided by the maximum metal thickness b. 400ºF/hour divided by the maximum metal thickness c. 900ºF/hour divided by the maximum metal thickness d. 200ºF/hour divided by the maximum metal thickness 243. During the postweld heat treatment holding period there shall be no greater difference than ___ºF between the highest and lowest temperature throughout the portion of the vessel being heat treated a. 150 b. 200 c. 300 d. 250 244. During the heating and cooling periods, the furnace atmosphere shall be controlled as to avoid ____ a. Excessive corrosion b. Excessive bending c. Excessive stress d. Excessive oxidation 245. Above 800ºF cooling shall be done in ___ a. A furnace b. A furnace or cooling chamber c. A cooling chamber d. Still air 246. Above 800ºF the cooling rate shall not be more than___ a. 500ºF/hour divided by the maximum metal thickness b. 400ºF/hour divided by the maximum metal thickness c. 900ºF/hour divided by the maximum metal thickness d. 200ºF/hour divided by the maximum metal thickness

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247. What is the normal holding temperature for a P-No.1 Group 3? a. 1100ºF b. 1200ºF c. 900ºF d. 600ºF 248. What is the minimum holding time for a P-No.1 Group 2 welded joint 2 in thick? a. 4 hours b. 2 hours 15 minutes c. 2 hours d. 3 hours 249. What is the minimum holding time for a P-No 1 Group 3 welded joint 1/8 in thick? a. 1 hour b. 12.5 minutes c. 15 minutes d. None of the above 250. What is the minimum holding time for a P-No 3 Group 2 welded joint 6 in thick? a. 3 hours b. 3 hours 30 minutes c. 2 hours d. 5 hours 251. A welded joint in a P-No 1 Group 1 material is 1 3/16 in thick. No special service requirements apply what would the minimum holding time be? a. 1 hour 11.25 minutes b. No PWHT required c. 2 hours d. None of the above 252. The special service conditions of UW-2 apply to a P-No 1 Group 3 material. Which of the following can be exempted from PWHT if a minimum 200ºF preheat is applied? a. Groove welds not over ½ in that attach nozzles with an inside diameter of 2 in b. Fillet welds with a throat thickness of ¾ in that attach nonpressure parts to pressure parts c. Any weld less than 1 ½ in d. Any weld not over 1 ¼ in. API 510 – DAY 2

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that does not require a repostweld heat treatment for a P-No.1 Group 2 material is___ a. 2 in b. 1 ¼ in c. 1 ½ in d. 5/8 in 254. After completing all welding, the repair area shall be maintained at a temperature of ____for a minimum period of ____hours. a. 300-400ºF 5 hours b. 400-500ºF 5 hours c. 450-550ºF 4 hours d. 400-500ºF 4 hours 255. The alternative postweld heat treatment temperature of 950ºF is to be used for a P-No.1 Group 2 weld joint of 4 in thick. What would the minimum holding time be? a. 10 hours 45 minutes b. 10 hours c. 4 hours d. 2 hours 30 minutes 256. For P-No 1 Group 1 material full radiography is required when the thickness exceeds ____in a. 0 b. 1 ½ c. 1 ¼ d. 5/8 257. Unless otherwise exempted impact testing is required for a combination of thickness and ___ a. Minimum design metal temperature b. Maximum design temperature c. Specification and grade of material d. Allowable stress 258. Components which are to be evaluated to establish impact test exemptions are: a. Shells b. Heads c. Attachments which are essential to the structural integrity of the vessel when welded to pressure retaining components d. All of the above API 510 – DAY 2

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259. The governing thickness tg for a corner fillet or lap welded joint is defined as: a. The throat thickness of the attaching weld b. The thinner of the two parts joined c. The nominal thickness of the thickest welded joint d. The thickness of the thicker member divided by 4 260. When the governing thickness for a welded joint exceeds ___in and is colder than ___ºF impact tested material shall be used. a. 4,-50 b. 4, 120 c. 6, 120 d. 2 -50 261. The governing thickness of a flat nonwelded tubesheet of 16 in thickness is: a. 4 in b. 16 in c. Dependent on the attaching shell thickness d. 6 in 262. If the governing thickness of a nonwelded part exceeds 6 in., below what MDMT must the material be impact tested? a. 100ºF b. 60ºF c. 120ºF d. None of the above 263. What is the basic minimum design metal temperature for a SA-216 Grade WCB casting which is produced to a fine grain practice and water quenched and tempered with the largest nominal thickness 1 ½ in? a. 88ºF b. 14ºF c. 43ºF d. 51ºF 264. When the coincident ratio as defined in Figure UCS-66 .1 is 0.70 what is the further reduction in the MDMT of the material? a. 20ºF b. 30ºF c. 40ºF d. 110ºF API 510 – DAY 2

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265. No impact testing is required for B 16.5 steel flanges used at design metal temperature no colder than ____ºF a. 120ºF b. -20ºF c. -50ºF d. 20ºF 266. No impact testing is required for UCS materials less than ___ in thick. a. 1.000 b. 0.099 c. 0.098 d. 0.250 267. If postweld heat treating is performed on a weld joint joining P-No. 1 materials when not otherwise required by section VIII an additional ___ºF in impact testing exemption temperature may be given to the minimum permissible temperature from Figure UCS-66 a. 30 b. 35 c. 50 d. 70 SECTION VIII, APPENDICES QUESTIONS 268. The formula that is to be used calculating thickness and pressure for cylindrical shells subject to circumferential stress is found in Appendix _____ a. 1-1, formula 2 b. 1-4, formula 3 c. 1-1, formula 1 d. 1-8, formula 1 269. When evaluating rounded indications thickness “t” is the thickness of the weld___ a. Including the reinforcement on the pressure side only b. Including any allowable reinforcement c. Excluding a maximum of 1/32 in. allowable reinforcement on each side d. Excluding any allowable reinforcement

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270. A butt weld is ½ in thick with the maximum weld reinforcement on each side. The maximum acceptable size of a random rounded indication is __in. a. 0.168 b. 0.125 c. 0.250 d. 0.063 271. For magnetic particle examinations only indications that are greater than ___in shall be considered relevant. a. 1/8 b. 1/32 c. 1/16 d. 1 272. A steel casting 2 in thick is being radiographically examined what is the maximum severity level for a category B imperfection? a. 5 b. 0 c. 1 d. 2 273. A steel casting is being examined by the magnetic particle method. What degree must a Type II shrinkage exceed to be unacceptable? a. 2 b. 3 c. 0 d. 5 274. Whenever an imperfection is repaired the excavation areas shall be examined by which method(s) to ensure removal or reduction to an acceptable size? a. RT b. UT c. MT d. Either A or C 275. Which of the following are acceptance standards for liquid penetrant examination? a. Relevant linear indications b. Relevant rounded indications greater than 3/16 in c. Four or more relevant rounded indications in a line separated by 1/16 in or less d. All of the above API 510 – DAY 2

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276. Liquid penetrant examiners are certified by the manufacturer with a ___ a. NDE examiners certification b. Certificate of Competency c. SNT-TC-1A certification d. None of the above 277. Ultrasonic examination of welds shall be performed using methods described in ____of ASME Code Section V a. Article 1 b. Article 4 c. Article 5 d. Article 23 278. Personnel performing examinations of welds shall be qualified in accordance with___ a. SNT-TC-1A 1992 Edition b. SNT-TC-1A 1984 Edition c. AWS 193 d. Manufacturer’s standard 279. For UT other than cracks. Lack of fusion and incomplete penetration. Other imperfections are unacceptable if the indications exceed the reference level and have lengths which exceed. a. ¼ in for t up to ¾ in b. 1/3 t fort from ¾ in to 2 ¼ in c. ¾ in for t over 2 ¼ in d. All of the above 280. The manufacturer shall maintain a record of all UT reflections from uncorrected areas that exceed ___%of the reference level a. 60 b. 50 c. 100 d. 20 281. The manufacturer’s Data Report from used for a single chamber, completely shop fabricated vessel is: a. U-3 b. U-1 c. U-1A d. U-4

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282. The Manufacturer’s Data Report from used for a part of a vessel is: a. U-2 b. U-1A c. U-3 d. U-4

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ASME SECTION VIII.DIV.1 PRACTICE ANSWARE

API 510 – DAY 2

Q.NO.

ANS

Q.NO.

ANS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

C C A A D B B B C B D B B B A C A D B B A C A C B D A D C D A B A C C B D C D A

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

B B C A B C D A A A B D A B A D A D B C A B C C C D B C A A A B C A C C C D C

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SUBSECTION A ANSWER Q.NO. 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 API 510 – DAY 2

ANS B D A A C A C B A D B B D D A C B D C D A B D C A C B D D B B A C A D B C A B

Foreword U-1 (e) U-1 (J) U-1 (J) U-(2) Table U-3 UG-4 (a) B UG-4 (b) UG-5. Note 2 UG-9 UG-10 UG-16 (b)(1) UG-16 (C) UG-16 (d) UG-16 (e) UG-20 (a) Figure UCS-66.2 UG-20 (f) (1) (b) UG-20 (f) (1) (a) UG-22 UG-24 (a) UG-27 (c) & UG-16 (e) Table UW-12 UG-28 UG-28 (C)(1) Step 2 UG-28 (C)(1) Step 4 UG-32 (a) UG-32 (d) UG-32 (d) UG-32 (e) UG-32 (o) UG-34 UG-34 (c)(2) & UW-12 UG-34(c)(2) UG-36 (c)(3)(a) UG-36 (c)(3)(c) UG-37 (a) UG-37 (a) Figure UG-37.1 Page 192

119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160

API 510 – DAY 2

C C A B A D A D B A D B C A C B D B D A C A C A C A D B A C B B A C D A C D A B A A

UG-37 (a) Figure UG-37 1 & ug-40 (b)(1) & (2 UG-40(e) UG-76(c) UG-77(a) UG-77(b) UG-79(b) UG-80(a) UG-82(a) UG-82(b) UG-84(c)(1) UG-84(c)(2) UG-84(c)(3) Figure UG-84.1b UG-84(c)(4)(b) Table UG-84.2 Table UG-84.4 UG-85 UG-90(c)(1) UG-93(a)(1) UG-93(d) UG-96 UG-98(a) UG-98(b) UG-99(b) UG-99(c) UG-99(d) UG-99(e) UG-99(f) UG-99 (g) UG-99 (h) UG-99 (h) UG-99 (h) UG-99 (h) UG-99 (h) UG-99 (k) UG-100 (b) UG-100 (c) UG-100 (d) UG-100 (d) UG-100 (e) UG-102 (a)

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161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183

B A C A D B C B B D A B C D C B A C D C A D A

UG-102 (a) UG-102 (b) UG-102 (b) UG-102 (b) UG- 102 (c) UG-103 UG-103 UG-115 (b) UG-116(a)(3) UG-116 (b)(1) UG-116 (c) UG-116 (e)(2) UG-116 (e)(3) UG-116 (e)(4) UG-116 (e)(1) UG-116(e) UG-116(f)(1) UG-116(f)(2) UG-120 & Appendix W UG-120 (c) UG-125 (c) UG-128 UG-134 (a)

SUBSECTION B ANSWARE Q.NO. 184 185 186 187 188 189 190 191 192 193 194 195 196 197

API 510 – DAY 2

ANS D A B A C B B C D A A B D A

UW-2 UW-2 (a) UW-2 (a) UW-2 (d)(2) UW-3 (a)(1) UW-3 (a)(2) UW-3 (a)(1) UW-3 (a)(3) UW-3 (a)(4) UW-3 (b) UW-5 (a) UW-5 (b) UW-5(b)(3) UW-9(c)

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API 510 – DAY 2

198 199 200 201 202 203 204

B A D B C D A

205

B

206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236

D C A D B A D A B B C D C D C A C D D B C A C D A C B A D B C

UW-9 (d) UW-11(a)(1) UW-11 (a)(2) & (4) UW-11 (a)(5)(b) UW-11(a)(7) UW-12 Table UW-12 Column(a) Table UW-12 Column(b) type 1 UW-12(d) UW-12 (d) UW-12 (e) UW- 14 (b) UW-15 (b) UW-15 (d) UW-16(b) UW-16 (b) UW-18 (d) UW-28 (b) UW-28 (c)(2) UW-29(c) UW-30 UW-31 (c) UW-32 (a) Table UW-33 Table UW-35 UW-35 UW-39(a) UW-40 (a)(2) UW-40(e) UW-40 (f)(6) UW-42 (b)(2) UW-47, 48, 49 UW-50 UW-51(a)(2) UW-51 (b)(2) UW-52 (b)(1) UW-52 (c) UW-52 (d) (2) UW-53

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SUBSECTION C ANSWARE Q.NO. 237 238 239 240 241 242 243 244 245 246

ANS B C A B C B A D B A

247

A

248

C

249

C

250

A

251

B

252

A

253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269

C D A C A D B B A C D B B C A C D

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UCS-5(b) UCS-6(b) UCS-56(a) UCS-56(c) UCS-56(d)(1) UCS-56(d)(2) UCS-56 (d)(3) UCS-56 (d)(4) UCS-56 (d)(5) UCS-56 (d) (5) Table UCS-56, P-No. 1 material Table UCS-56. P-No. 1 material Table UCS-56. P-No. 1 material Table UCS-56. P-No. 3 material Table UCS-56. P-No. 1 material Table UCS-56. P-No. 1 material UCS-56(f)(2) UCS-56 (f)(4)(c) Table UCS-56.1 Table UCS-57 UCS-66 (a) UCS66 (a) UCS-66 (a)(1)(b) UCS-66(a) UCS-66 (a)(3) UCS-66 (a) (5) Figure UCS-66 & Table UCS-66 Figure UCS-66.1 UCS-66(c) UCS-66 (d) UCS-68(c) Appendix 1-1, Formula 1 Appendix 4-2(c)

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270 271 272 273 274 275 276 277 278 279 280 281 282

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B C D A C D B C A D B C A

Appendix 4, Table 4-1 Appendix 6-3 Appendix 7-3 (a)(1) Appendix 7-3 (a)(3) Appendix 7-4 (a) Appendix 8-4 Appendix 8-2 Appendix 12-1 (b) Appendix 12-2 Appendix 12-3 (b) Appendix 12-4 Appendix W, Form U-1A Appendix W, Form U-2

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