Bay.t-510 Open Prac Exam #3 2s2b10
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API-510 Examination Preparation Course Practice Exam #3 – Open Book 1. What is the minimum permitted overlap when it is necessary to PWHT a vessel in more than one heat due to length? a) b) c) d)
One foot Two and a half feet Five feet Ten feet
2. When performing Charpy V-notch impact tests in accordance with ASME Section VIII, Div.1, which of the following is correct? a) b) c) d)
The test shall consist of four specimens The test shall consist of three specimens The test shall consist of two specimens The test shall consist of one specimen
3. What film side hole IQI designation would be required, using Gamma-ray radiography, for examination of a weld repair in a vessel that is 0.875” thick? a) b) c) d)
10 20 30 35
4. A process vessel has the following characteristics: ID = 60”, Efficiency = 1.0, allowable stress = 17500psi, and design pressure (including static head) = 500psig. If the vessel is uniformly corroded, what is the minimum required thickness of the shell under design conditions? a) b) c) d)
0.857 inch 0.872 inch 1.714 inches 1.744 inches
5. During a turnaround, two 2-inch nozzles were added to a vessel. The vessel was originally fabricated of 0.699 inch thick SA-387 Gr. 22 (P-5A material) plate. The vessel was also PWHT for ASME Code compliance. Which of the following statements apply to the heat treatment of this work? a) b) c) d)
The material prevents substituting preheat for PWHT Temper-bead installation may be used instead of PWHT Vessel alterations prevent applying preheat as a PWHT alternative Preheat to not less than 300°F is an alternative to PWHT
BAY Technical Associates, Inc.
1
API-510 Examination Preparation Course Practice Exam #3 – Open Book 6
An unstayed flat head is to be replaced. Vessel records provide the following information: Arrangement is per Figure UG-34(b-1) of ASME Section VIII, Division 1 where: d = 28 inches P = 500psig (including static head) S = 13800psi E = 1.0 What is the minimum required thickness of the head after forming without a corrosion allowance? a) b) c) d)
1.099 inches 1.685 inches 2.197 inches 2.384 inches
7. Which of the following is an essential variable of an SMAW WPS? a) b) c) d)
Upward or downward progression Change in groove design Decrease of over 100°F in preheat Addition or deletion of backing
8. A 48” inside diameter vessel has a nominal thickness of ¾” and the minimum required thickness is 0.68”. Inspection revealed, three pits in the vessel shell: Pit #1 1.5”X1/4”X1/4” deep Pit #2 1” diameter X 0.36” deep Pit #3 ½” X ¾” X 1/8” deep The pits are all located in a six-inch diameter circle with the sum of their dimensions along a straight line is 1.9375”. Which of the following statements is true? a) b) c) d)
The pits are acceptable because small, widely scattered pits may be ignored The pits are acceptable, based on their area, length, and depth The pits are not acceptable in any circumstance The pits are not acceptable, based on their length
9. What is the maximum permitted offset for a repaired ¾” Category B weld t? a) b) c) d)
1/16” 1/8” 3/16” 1/4”
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API-510 Examination Preparation Course Practice Exam #3 – Open Book 10. According to ASME Section VIII, Division 1, how long must radiographs taken during fabrication and assembly of a pressure vessel be retained? a) b) c) d)
For five years For the lifetime of the vessel For a time not specified in the construction Until the data report is signed by the Authorized Inspector
11. Of the following, which is not a requirement when the minimum specified tensile strength of the filler metal, used for weld repairs, is lower than that of the base metal? a) The thickness of the repair shall be increased by the ratio of the base metal tensile strength to filler metal tensile strength b) The repair shall be made with fewer than two es c) The repair shall have rounded corners d) The repair thickness shall be no more than 50% of the required base metal thickness excluding corrosion allowance 12. A weld overlay is done for a repair on a vessel fabricated of P-5 material. The next day, the base metal, in the repair area, should be examined for cracking by which type of examination? a) b) c) d)
Ultrasonic Radiography Liquid penetrant Magnetic Particle
13. What is the minimum design metal temperature that a vessel can be designed for if it is fabricated from 1.125” thick non-normalized SA-516Gr.60 material without impact testing? a) b) c) d)
-26°F 2°F 37°F 75°F
14. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head. What is the t category of the head to shell weld? a) b) c) d)
A B C D
BAY Technical Associates, Inc.
3
API-510 Examination Preparation Course Practice Exam #3 – Open Book 15. What is the minimum postweld heat treatment (PWHT) holding time for 3” SA-516 Gr. 70 material? a) b) c) d)
2 hours 2 hours 15 minutes 2 hours 30 minutes 3 hours
16. A seamless standard torispherical head with an inside crown radius of 64 inches (1.63M) has a current thickness of 0.563” (8mm). The original MAWP was 125psi (0.86MPa). The vessel has been in service for ten years. The operating parameters will be lowered to 100psi and the vessel will be de-rated. The original head plate thickness was 0.6875” (17.5mm), allowable stress (S) = 15,500psi, t efficiency of 0.85, and had a corrosion allowance of 0.125” (3.2mm). What is the minimum required thickness of the head for the new condition? a) b) c) d)
0.430 inch (10.9mm) API-510 Paragraph 7.2.1 0.305 inch (6.2mm) 0.555 inch (14.1mm) 0.399 inch (9.3mm)
17. In a sour crude refinery, a carbon steel tray is removed from a fractionation tower section that operates at 450°F. The tray is thin throughout, and it’s Type 410 stainless steel tray valves appear relatively uncorroded. Which of the following is most likely responsible for the damage? a) b) c) d)
High temperature sulfidic corrosion Naphthenic acid corrosion Polythionic acid corrosion Hydrochloric acid corrosion
18. What is the maximum acceptable out of roundness for a 50” ID vessel shell, unless a detailed analysis is performed? a) 1/8” b) 1/4” c) 3/8” d) 1/2” 19. Magnetic Particle Examination (MT) is most effective when the: a) current flow is 45º to the major axis of discontinuities b) magnetic flux is parallel to the major axis of discontinuities c) magnetic flux is 90º to the major axis of discontinuities d) current flow is normal to the major axis of discontinuities
BAY Technical Associates, Inc.
4
API-510 Examination Preparation Course Practice Exam #3 – Open Book 20. A nozzle has an opening diameter of 10 inches, and a nominal thickness of 0.375 inch. The vessel shell has a required thickness of 0.75 inch and a nominal thickness of 0.850 inch. Both the nozzle and the vessel materials are the same and there is no corrosion allowance on this nozzle. What is the required area of reinforcement? a) b) c) d)
3.75 square inches 7.50 square inches 8.50 square inches 11.25 square inches
21. What is the maximum allowable continuous length of slag (elongated indication) permitted in a radiograph of a repair weld in 1.25” thick plate for a vessel stamped RT-1? a) b) c) d)
0.312” 0.333” 0.417” 0.750”
22. The density of step wedge comparison films and densitometer calibration shall be verified by comparison with a calibrated step wedge film traceable to which of the following? a) b) c) d)
Film certified according to ASME Section V An ASTM certified wedge An ASNT certified procedure A national standard
23. A sphere has an ID of 80 feet, the material of construction is A-516 Gr. 70 (allowable stress = 20000psi), the weld t efficiency is 85%. The minimum thickness of plate material is 2.5 inches without a corrosion allowance. What is the MAWP excluding head pressure? a) b) c) d)
1049psi 105psi 176psi 2099psi
24. Which of the following information is not required to be documented for a radiograph? a) b) c) d)
Minimum source-to-object distance Geometric unsharpness Material type Single or double wall exposure
BAY Technical Associates, Inc.
5
API-510 Examination Preparation Course Practice Exam #3 – Open Book 25. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head using a single welded butt t with a backing strip that will be left in place. What is the t type of the head to shell weld? a) b) c) d)
1 2 3 4
26. A pressure vessel shell, fabricated of SA-515 Gr. 70 plate, has a thickness of 1.125”. PWHT was performed though it was not otherwise required by Code. The ratio of design stress to allowable stress is 1.0. What is the lowest minimum design metal temperature that would not require impact testing? a) b) c) d)
7°F 37°F 45°F 75°F
27. A vessel with an ID of 54” has a corroded area of considerable size in which circumferential stresses govern. The smallest measured thickness may be averaged over a length of not more than: a) b) c) d)
18 inches 20 inches 27 inches 40 inches
28. How far away from the weld must the corroded area be in order to allow a t efficiency of 100% in recalculating the required thickness of a vessel with a t efficiency of 85%? a) b) c) d)
The greater of one half inch or two times the minimum thickness The greater of one inch or two times the minimum thickness The greater of one inch or three times the minimum thickness The greater of two inches or three times the minimum thickness
29. A pressure relief valve has a set pressure of 400psi. The valve is tested for accuracy of set pressure before it is installed. What is the maximum acceptable test pressure? a) b) c) d)
400psi 402psi 412psi 420psi
BAY Technical Associates, Inc.
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API-510 Examination Preparation Course Practice Exam #3 – Open Book A vertical vessel is to be re-rated for liquid full water service to a new MAWP. After allowing for corrosion, calculations provided the following values without compensating for head pressure. Vessel part Top Top head Upper shell cylinder section Middle shell cylinder section Lower shell cylinder section Bottom head
Distance from vessel top 0 feet 4 feet 19 feet 34 feet 49 feet 53 feet
MAWP 725psig 736psig 731psig 745psig 743psig
30. What is the MAWP that can be applied to this vessel? a) b) c) d)
712psi 716psi 720psi 724psi
31. The SMAW process is used to perform controlled deposition welded repairs to a vessel that originally received PWHT. At what temperature must the weld area be maintained? a) b) c) d)
350°F ± 50°F for a minimum of 1 hour after completion 350°F ± 50°F for a minimum of 2 hours after completion 500°F ± 50°F for a minimum of 1 hour after completion 500°F ± 50°F for a minimum of 2 hours after completion
32. A pressure vessel, in service for five years, has an annual corrosion rate of less than 0.004 inches. In order to permit an on-stream inspection in lieu of an internal inspection, all of the following requirements must be met except that: a) b) c) d)
The vessel must not be strip lined or plate lined No questionable condition is disclosed by periodic external inspections The vessel will not be operated in excess of 500psi or 500°F The operating temperature of the vessel must not exceed the lower temperature limits for the creep rupture range of the vessel material
33. What is the maximum upper range for a dial gage used during a hydrostatic test? a) b) c) d)
1.25 times the test pressure 1.5 times the test pressure 2 times the test pressure 4 times the test pressure
BAY Technical Associates, Inc.
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API-510 Examination Preparation Course Practice Exam #3 – Open Book 34. A pressure vessel is to be re-rated, the vessel nameplate is stamped RT-4 and the t efficiency is 1.0. Considering the 1.336 (measured thickness) 2:1 ellipsoidal head, what is the maximum design pressure of the head? The data report provides the following information: the head is seamless and has an inside diameter of 60.0625”, the allowable stress of the head material is 17500psi, and the head is attached to the vessel by a Category B, Type 1 t. a) b) c) d)
542psi 620psi 659psi 775psi
35. How often should the black light intensity be check for the fluorescent particle technique of Magnetic Particle examination? a) Every 8 hours and whenever the workstation is changed b) Every 4 hours and whenever the workstation is changed c) Whenever the light’s power source is interrupted and at the completion of the examination d) Whenever the light’s power source is interrupted and at the end of each days’ examinations 36. The ASME Code recommends that weld not be performed when the base metal temperature is lower than: a) b) c) d)
0°F 10°F 32°F 60°F
37. Which of the following is an API-510 requirement for controlled deposition welding? a) b) c) d)
The metallurgical review shall be performed by an engineer prior to its use The weld area must be preheated to at least 425°F The vessel for repair must be constructed of P-5 or P-7 material The vessel was originally post weld heat treated due to the characteristics of the fluids contained in it.
38. For material thicknesses less than 2”, what is the maximum geometric unsharpness permitted when required by the referencing code? a) b) c) d)
0.01 inch 0.02 inch 0.03 inch 0.04 inch
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API-510 Examination Preparation Course Practice Exam #3 – Open Book 39. What is the maximum inter temperature when using the preheat alternative method for a weld repair on a vessel that originally had PWHT? a) b) c) d)
300°F (150°C) 400°F (205°C) 500°F (260°C) 600°F (315°C)
40. What is the maximum density, in the area of interest, for gamma ray source radiography? a) b) c) d)
1.3 1.8 2.0 4.0
Questions 41 through 43 – refer to the attached welding procedure and procedure qualification record. 41. Regarding the t shown, the Welding Procedure Specification: a) b) c) d)
Includes all required information Should specify uphill or downhill progression Must show the weld layers Should address the t angle
42. Regarding the mechanical tests shown, the Procedure Qualification Record qualifications: a) b) c) d)
Have not been met because one of the guided bend tests failed Have not been met because on tensile test failed Have all be met Have not been met because face and root bends were not performed
43. Regarding the thickness range shown on the Welding Procedure Specification, a correct statement is that the: a) b) c) d)
Upper limit could be eight inches Lower limit could be 1/16 inch Lower limit could be 1/8 inch Range is accurate as shown
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API-510 Examination Preparation Course Practice Exam #3 – Open Book Welding Procedure Specification (WPS) Front Company Name BAY Tech By: Chip Beaph Welding Procedure Specification No. S21 Date 10/03/03 ing PQR No(s) Revision No. 0 Date --Welding Process(es) SMAW Type(s) Manual
S21
(Automatic, Manual, Machine, or Semi-Auto)
Details
ts (QW-402) t Design Single V Groove Backing: (yes) (no.) Backing Material (Type): Weld
37 1/2º ± 5º typical
(Refer to both backing and retainers)
Metal Nonmetallic
Root spacing: 1/16” Root face: 1/8” Max
Nonfusing Metal Other
Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be welded. Root spacing and weld groove details may be specified where applicable (At the option of the manufacturer, sketches may be attached) The t designs above are typical for groove welds, check the production drawing for weld t design and root
*Base Metals (QW-403) P-No. 1 Group No. 1 OR Specification type and grade To Specification type and grade OR Chem. Analysis and Mech. Prop. To Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove: Pipe Dia. Range: Groove: Other: * Filler Metals (QW-404) Spec. No. (SFA) 5.1 AWS No. (Class) E7018 Root Balance F. No. A-No. Size of Filler Metals 1/8 & 5/32
To P-No
1
.1875 to ,8640 All
Group No
1
Fillet: Fillet:
All All
Root
F-4 A-1
Balance
F-4 A-1
Weld Metal Thickness Range: Groove .1875 to .8640 Fillet to 3/4 throat Electrode-Flux (Class) Flux Trade Name Consumable Insert Other *Each base metal - filler metal combination should be recorded individually.
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API-510 Examination Preparation Course Practice Exam #3 – Open Book Welding Procedure Specification (WPS) (Back) Positions (QW-405 Postweld Heat Treatment (QW-407) Position(s) of Groove All Temperature Range None Welding Progression: Up XX Down XX Time Range None Position of Fillet All Preheat (QW-406) Gas (QW-408) Percent Composition Gas(es) (Mixture) Flow Rate Preheat Temp. Min. 50 Deg. F Inter Temp. Max. 550 Deg. F N/A Preheat Maintenance None Shielding (Continuous or special heating where applicable should be recorded) N/A Trailing N/A Backing Electrical Characteristics (QW-409) Current AC or DC DC Polarity Reverse Amps (Range) 90-220 Volts (Range) (Amps and volts range should be recorded for each Electrode size, position, and thickness, etc This information may be listed in a tabular form Tungsten Electrode Size and Type (Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW (Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range Technique (QW-410) String or Weave Bead Orifice or Gas Cup Size Initial and Inter Cleaning (Brushing, Grinding, etc.) Method of Back Gouging Oscillation Tube to Work Distance Multiple or Single (per side) Multiple or Single Electrode Travel Speed (Range) Peening Other:
Weld Layers
Process
All All
SMAW SMAW
Grinding N/A N/A Multiple Single Various None
Filler Metal E-7018 E-7018
BAY Technical Associates, Inc.
Steing and Weave N/A Brushing or grinding 1" Both sides of weld t
1/8" 5/32"
Current DCRP DCRP
90-160 130-220
Volt Range
Travel Speed Range
---
---
Other (e.g. Remarks Comments, hot wire addition, technique, Torch Angle, Etc.
---
11
API-510 Examination Preparation Course Practice Exam #3 – Open Book
Procedure Qualification Report (PQR) (QW-200.2 of Section IX, ASME B & PV Code) Company Name BAY Tech Procedure Qualification Record Number WPS Number S21 Welding Process(es) SMAW
S21 Type(s)
Date
10/03/03
Manual (Manual, Automatic, Semi-Auto)
ts (QW-402)
Coupon thickness: .4320” Root face: 3/32” Root spacing: 1/16”
(for combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or process used)
Base Metals (QW-403) Material Specification Type or Grade P-No. 1 Thickness of Test Coupon Diameter of Test Coupon Other
SA-516 Grade 70 to P-No. 1 .4320 Plate
Filler Metals (QW-404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. F-4 Weld metal analysis A-No. A-1 Size of Filler Metal 1/8” Other Deposited Weld Metal .4320” Position (QW-405) Position of Groove Flat Weld Progression (uphill, downhill) Other Preheat (QW-406) Preheat Temp. 50 Deg. F Inter Temp. 550 Deg. F Other
BAY Technical Associates, Inc.
Flat
Postweld Heat Treatment (QW-407) Temperature None Time Other Gas (QW-408) Percent Composition Gas(es) Mixture Flow Rate Shielding N/A Trailing N/A Backing N/A Electrical Characteristics (QW-409) Current Polarity Amps Volts Tungsten Electrode Size Other Technique (QW-410) Travel Speed String or Weave Bead Oscillation Multiple or Single (per side) Single or Multiple Electrodes Other
12
API-510 Examination Preparation Course Practice Exam #3 – Open Book
Specimen No. 1
Width 0.996
2
1.002
QW-483 (Back) Procedure Qualification Report (PQR) Tensile Test (QW-150) Ultimate Ultimate Total Load Unit Stress Thickness Area lb psi 0.350 0.349 23250 66,620 0.350
0.351
24600
Type of failure & location Base Metal
70,085
Base Metal
Guided Bend Tests (QW-160) Type and Figure No. Side Bend, QW-462.2 Side Bend, QW-462.2 Side Bend, QW-462.2 Side Bend, QW-462.2
Specimen No.
Notch Location
Notch Type
Results No Defects No Defects 1/8” defect in heat affected zone No Defect Toughness Tests (QW-170) Test Impact Lateral Exp Temp Values % Shear Mills
Drop Weight Break No Break
Fillet Weld Tests (QW-180) Results -Satisfactory: Macro - Results
Yes
No
Penetration into Parent Metal:
Yes
No
Other Tests Type of Test Deposit Analysis Other Welder’s Name Slim Pickins Clock No. 99 Stamp No. SP Tests conducted by: BAY Tech Laboratory Test No. S21 1 & 2 We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer Date:
10/03/03
BAY Technical Associates, Inc.
BAY Tech
Signature:
Chip Beaph
13
API-510 Examination Preparation Course Practice Exam #3 – Open Book
BAY Technical Associates, Inc.
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One foot Two and a half feet Five feet Ten feet
2. When performing Charpy V-notch impact tests in accordance with ASME Section VIII, Div.1, which of the following is correct? a) b) c) d)
The test shall consist of four specimens The test shall consist of three specimens The test shall consist of two specimens The test shall consist of one specimen
3. What film side hole IQI designation would be required, using Gamma-ray radiography, for examination of a weld repair in a vessel that is 0.875” thick? a) b) c) d)
10 20 30 35
4. A process vessel has the following characteristics: ID = 60”, Efficiency = 1.0, allowable stress = 17500psi, and design pressure (including static head) = 500psig. If the vessel is uniformly corroded, what is the minimum required thickness of the shell under design conditions? a) b) c) d)
0.857 inch 0.872 inch 1.714 inches 1.744 inches
5. During a turnaround, two 2-inch nozzles were added to a vessel. The vessel was originally fabricated of 0.699 inch thick SA-387 Gr. 22 (P-5A material) plate. The vessel was also PWHT for ASME Code compliance. Which of the following statements apply to the heat treatment of this work? a) b) c) d)
The material prevents substituting preheat for PWHT Temper-bead installation may be used instead of PWHT Vessel alterations prevent applying preheat as a PWHT alternative Preheat to not less than 300°F is an alternative to PWHT
BAY Technical Associates, Inc.
1
API-510 Examination Preparation Course Practice Exam #3 – Open Book 6
An unstayed flat head is to be replaced. Vessel records provide the following information: Arrangement is per Figure UG-34(b-1) of ASME Section VIII, Division 1 where: d = 28 inches P = 500psig (including static head) S = 13800psi E = 1.0 What is the minimum required thickness of the head after forming without a corrosion allowance? a) b) c) d)
1.099 inches 1.685 inches 2.197 inches 2.384 inches
7. Which of the following is an essential variable of an SMAW WPS? a) b) c) d)
Upward or downward progression Change in groove design Decrease of over 100°F in preheat Addition or deletion of backing
8. A 48” inside diameter vessel has a nominal thickness of ¾” and the minimum required thickness is 0.68”. Inspection revealed, three pits in the vessel shell: Pit #1 1.5”X1/4”X1/4” deep Pit #2 1” diameter X 0.36” deep Pit #3 ½” X ¾” X 1/8” deep The pits are all located in a six-inch diameter circle with the sum of their dimensions along a straight line is 1.9375”. Which of the following statements is true? a) b) c) d)
The pits are acceptable because small, widely scattered pits may be ignored The pits are acceptable, based on their area, length, and depth The pits are not acceptable in any circumstance The pits are not acceptable, based on their length
9. What is the maximum permitted offset for a repaired ¾” Category B weld t? a) b) c) d)
1/16” 1/8” 3/16” 1/4”
BAY Technical Associates, Inc.
2
API-510 Examination Preparation Course Practice Exam #3 – Open Book 10. According to ASME Section VIII, Division 1, how long must radiographs taken during fabrication and assembly of a pressure vessel be retained? a) b) c) d)
For five years For the lifetime of the vessel For a time not specified in the construction Until the data report is signed by the Authorized Inspector
11. Of the following, which is not a requirement when the minimum specified tensile strength of the filler metal, used for weld repairs, is lower than that of the base metal? a) The thickness of the repair shall be increased by the ratio of the base metal tensile strength to filler metal tensile strength b) The repair shall be made with fewer than two es c) The repair shall have rounded corners d) The repair thickness shall be no more than 50% of the required base metal thickness excluding corrosion allowance 12. A weld overlay is done for a repair on a vessel fabricated of P-5 material. The next day, the base metal, in the repair area, should be examined for cracking by which type of examination? a) b) c) d)
Ultrasonic Radiography Liquid penetrant Magnetic Particle
13. What is the minimum design metal temperature that a vessel can be designed for if it is fabricated from 1.125” thick non-normalized SA-516Gr.60 material without impact testing? a) b) c) d)
-26°F 2°F 37°F 75°F
14. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head. What is the t category of the head to shell weld? a) b) c) d)
A B C D
BAY Technical Associates, Inc.
3
API-510 Examination Preparation Course Practice Exam #3 – Open Book 15. What is the minimum postweld heat treatment (PWHT) holding time for 3” SA-516 Gr. 70 material? a) b) c) d)
2 hours 2 hours 15 minutes 2 hours 30 minutes 3 hours
16. A seamless standard torispherical head with an inside crown radius of 64 inches (1.63M) has a current thickness of 0.563” (8mm). The original MAWP was 125psi (0.86MPa). The vessel has been in service for ten years. The operating parameters will be lowered to 100psi and the vessel will be de-rated. The original head plate thickness was 0.6875” (17.5mm), allowable stress (S) = 15,500psi, t efficiency of 0.85, and had a corrosion allowance of 0.125” (3.2mm). What is the minimum required thickness of the head for the new condition? a) b) c) d)
0.430 inch (10.9mm) API-510 Paragraph 7.2.1 0.305 inch (6.2mm) 0.555 inch (14.1mm) 0.399 inch (9.3mm)
17. In a sour crude refinery, a carbon steel tray is removed from a fractionation tower section that operates at 450°F. The tray is thin throughout, and it’s Type 410 stainless steel tray valves appear relatively uncorroded. Which of the following is most likely responsible for the damage? a) b) c) d)
High temperature sulfidic corrosion Naphthenic acid corrosion Polythionic acid corrosion Hydrochloric acid corrosion
18. What is the maximum acceptable out of roundness for a 50” ID vessel shell, unless a detailed analysis is performed? a) 1/8” b) 1/4” c) 3/8” d) 1/2” 19. Magnetic Particle Examination (MT) is most effective when the: a) current flow is 45º to the major axis of discontinuities b) magnetic flux is parallel to the major axis of discontinuities c) magnetic flux is 90º to the major axis of discontinuities d) current flow is normal to the major axis of discontinuities
BAY Technical Associates, Inc.
4
API-510 Examination Preparation Course Practice Exam #3 – Open Book 20. A nozzle has an opening diameter of 10 inches, and a nominal thickness of 0.375 inch. The vessel shell has a required thickness of 0.75 inch and a nominal thickness of 0.850 inch. Both the nozzle and the vessel materials are the same and there is no corrosion allowance on this nozzle. What is the required area of reinforcement? a) b) c) d)
3.75 square inches 7.50 square inches 8.50 square inches 11.25 square inches
21. What is the maximum allowable continuous length of slag (elongated indication) permitted in a radiograph of a repair weld in 1.25” thick plate for a vessel stamped RT-1? a) b) c) d)
0.312” 0.333” 0.417” 0.750”
22. The density of step wedge comparison films and densitometer calibration shall be verified by comparison with a calibrated step wedge film traceable to which of the following? a) b) c) d)
Film certified according to ASME Section V An ASTM certified wedge An ASNT certified procedure A national standard
23. A sphere has an ID of 80 feet, the material of construction is A-516 Gr. 70 (allowable stress = 20000psi), the weld t efficiency is 85%. The minimum thickness of plate material is 2.5 inches without a corrosion allowance. What is the MAWP excluding head pressure? a) b) c) d)
1049psi 105psi 176psi 2099psi
24. Which of the following information is not required to be documented for a radiograph? a) b) c) d)
Minimum source-to-object distance Geometric unsharpness Material type Single or double wall exposure
BAY Technical Associates, Inc.
5
API-510 Examination Preparation Course Practice Exam #3 – Open Book 25. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head using a single welded butt t with a backing strip that will be left in place. What is the t type of the head to shell weld? a) b) c) d)
1 2 3 4
26. A pressure vessel shell, fabricated of SA-515 Gr. 70 plate, has a thickness of 1.125”. PWHT was performed though it was not otherwise required by Code. The ratio of design stress to allowable stress is 1.0. What is the lowest minimum design metal temperature that would not require impact testing? a) b) c) d)
7°F 37°F 45°F 75°F
27. A vessel with an ID of 54” has a corroded area of considerable size in which circumferential stresses govern. The smallest measured thickness may be averaged over a length of not more than: a) b) c) d)
18 inches 20 inches 27 inches 40 inches
28. How far away from the weld must the corroded area be in order to allow a t efficiency of 100% in recalculating the required thickness of a vessel with a t efficiency of 85%? a) b) c) d)
The greater of one half inch or two times the minimum thickness The greater of one inch or two times the minimum thickness The greater of one inch or three times the minimum thickness The greater of two inches or three times the minimum thickness
29. A pressure relief valve has a set pressure of 400psi. The valve is tested for accuracy of set pressure before it is installed. What is the maximum acceptable test pressure? a) b) c) d)
400psi 402psi 412psi 420psi
BAY Technical Associates, Inc.
6
API-510 Examination Preparation Course Practice Exam #3 – Open Book A vertical vessel is to be re-rated for liquid full water service to a new MAWP. After allowing for corrosion, calculations provided the following values without compensating for head pressure. Vessel part Top Top head Upper shell cylinder section Middle shell cylinder section Lower shell cylinder section Bottom head
Distance from vessel top 0 feet 4 feet 19 feet 34 feet 49 feet 53 feet
MAWP 725psig 736psig 731psig 745psig 743psig
30. What is the MAWP that can be applied to this vessel? a) b) c) d)
712psi 716psi 720psi 724psi
31. The SMAW process is used to perform controlled deposition welded repairs to a vessel that originally received PWHT. At what temperature must the weld area be maintained? a) b) c) d)
350°F ± 50°F for a minimum of 1 hour after completion 350°F ± 50°F for a minimum of 2 hours after completion 500°F ± 50°F for a minimum of 1 hour after completion 500°F ± 50°F for a minimum of 2 hours after completion
32. A pressure vessel, in service for five years, has an annual corrosion rate of less than 0.004 inches. In order to permit an on-stream inspection in lieu of an internal inspection, all of the following requirements must be met except that: a) b) c) d)
The vessel must not be strip lined or plate lined No questionable condition is disclosed by periodic external inspections The vessel will not be operated in excess of 500psi or 500°F The operating temperature of the vessel must not exceed the lower temperature limits for the creep rupture range of the vessel material
33. What is the maximum upper range for a dial gage used during a hydrostatic test? a) b) c) d)
1.25 times the test pressure 1.5 times the test pressure 2 times the test pressure 4 times the test pressure
BAY Technical Associates, Inc.
7
API-510 Examination Preparation Course Practice Exam #3 – Open Book 34. A pressure vessel is to be re-rated, the vessel nameplate is stamped RT-4 and the t efficiency is 1.0. Considering the 1.336 (measured thickness) 2:1 ellipsoidal head, what is the maximum design pressure of the head? The data report provides the following information: the head is seamless and has an inside diameter of 60.0625”, the allowable stress of the head material is 17500psi, and the head is attached to the vessel by a Category B, Type 1 t. a) b) c) d)
542psi 620psi 659psi 775psi
35. How often should the black light intensity be check for the fluorescent particle technique of Magnetic Particle examination? a) Every 8 hours and whenever the workstation is changed b) Every 4 hours and whenever the workstation is changed c) Whenever the light’s power source is interrupted and at the completion of the examination d) Whenever the light’s power source is interrupted and at the end of each days’ examinations 36. The ASME Code recommends that weld not be performed when the base metal temperature is lower than: a) b) c) d)
0°F 10°F 32°F 60°F
37. Which of the following is an API-510 requirement for controlled deposition welding? a) b) c) d)
The metallurgical review shall be performed by an engineer prior to its use The weld area must be preheated to at least 425°F The vessel for repair must be constructed of P-5 or P-7 material The vessel was originally post weld heat treated due to the characteristics of the fluids contained in it.
38. For material thicknesses less than 2”, what is the maximum geometric unsharpness permitted when required by the referencing code? a) b) c) d)
0.01 inch 0.02 inch 0.03 inch 0.04 inch
BAY Technical Associates, Inc.
8
API-510 Examination Preparation Course Practice Exam #3 – Open Book 39. What is the maximum inter temperature when using the preheat alternative method for a weld repair on a vessel that originally had PWHT? a) b) c) d)
300°F (150°C) 400°F (205°C) 500°F (260°C) 600°F (315°C)
40. What is the maximum density, in the area of interest, for gamma ray source radiography? a) b) c) d)
1.3 1.8 2.0 4.0
Questions 41 through 43 – refer to the attached welding procedure and procedure qualification record. 41. Regarding the t shown, the Welding Procedure Specification: a) b) c) d)
Includes all required information Should specify uphill or downhill progression Must show the weld layers Should address the t angle
42. Regarding the mechanical tests shown, the Procedure Qualification Record qualifications: a) b) c) d)
Have not been met because one of the guided bend tests failed Have not been met because on tensile test failed Have all be met Have not been met because face and root bends were not performed
43. Regarding the thickness range shown on the Welding Procedure Specification, a correct statement is that the: a) b) c) d)
Upper limit could be eight inches Lower limit could be 1/16 inch Lower limit could be 1/8 inch Range is accurate as shown
BAY Technical Associates, Inc.
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API-510 Examination Preparation Course Practice Exam #3 – Open Book Welding Procedure Specification (WPS) Front Company Name BAY Tech By: Chip Beaph Welding Procedure Specification No. S21 Date 10/03/03 ing PQR No(s) Revision No. 0 Date --Welding Process(es) SMAW Type(s) Manual
S21
(Automatic, Manual, Machine, or Semi-Auto)
Details
ts (QW-402) t Design Single V Groove Backing: (yes) (no.) Backing Material (Type): Weld
37 1/2º ± 5º typical
(Refer to both backing and retainers)
Metal Nonmetallic
Root spacing: 1/16” Root face: 1/8” Max
Nonfusing Metal Other
Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be welded. Root spacing and weld groove details may be specified where applicable (At the option of the manufacturer, sketches may be attached) The t designs above are typical for groove welds, check the production drawing for weld t design and root
*Base Metals (QW-403) P-No. 1 Group No. 1 OR Specification type and grade To Specification type and grade OR Chem. Analysis and Mech. Prop. To Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove: Pipe Dia. Range: Groove: Other: * Filler Metals (QW-404) Spec. No. (SFA) 5.1 AWS No. (Class) E7018 Root Balance F. No. A-No. Size of Filler Metals 1/8 & 5/32
To P-No
1
.1875 to ,8640 All
Group No
1
Fillet: Fillet:
All All
Root
F-4 A-1
Balance
F-4 A-1
Weld Metal Thickness Range: Groove .1875 to .8640 Fillet to 3/4 throat Electrode-Flux (Class) Flux Trade Name Consumable Insert Other *Each base metal - filler metal combination should be recorded individually.
BAY Technical Associates, Inc.
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API-510 Examination Preparation Course Practice Exam #3 – Open Book Welding Procedure Specification (WPS) (Back) Positions (QW-405 Postweld Heat Treatment (QW-407) Position(s) of Groove All Temperature Range None Welding Progression: Up XX Down XX Time Range None Position of Fillet All Preheat (QW-406) Gas (QW-408) Percent Composition Gas(es) (Mixture) Flow Rate Preheat Temp. Min. 50 Deg. F Inter Temp. Max. 550 Deg. F N/A Preheat Maintenance None Shielding (Continuous or special heating where applicable should be recorded) N/A Trailing N/A Backing Electrical Characteristics (QW-409) Current AC or DC DC Polarity Reverse Amps (Range) 90-220 Volts (Range) (Amps and volts range should be recorded for each Electrode size, position, and thickness, etc This information may be listed in a tabular form Tungsten Electrode Size and Type (Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW (Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range Technique (QW-410) String or Weave Bead Orifice or Gas Cup Size Initial and Inter Cleaning (Brushing, Grinding, etc.) Method of Back Gouging Oscillation Tube to Work Distance Multiple or Single (per side) Multiple or Single Electrode Travel Speed (Range) Peening Other:
Weld Layers
Process
All All
SMAW SMAW
Grinding N/A N/A Multiple Single Various None
Filler Metal E-7018 E-7018
BAY Technical Associates, Inc.
Steing and Weave N/A Brushing or grinding 1" Both sides of weld t
1/8" 5/32"
Current DCRP DCRP
90-160 130-220
Volt Range
Travel Speed Range
---
---
Other (e.g. Remarks Comments, hot wire addition, technique, Torch Angle, Etc.
---
11
API-510 Examination Preparation Course Practice Exam #3 – Open Book
Procedure Qualification Report (PQR) (QW-200.2 of Section IX, ASME B & PV Code) Company Name BAY Tech Procedure Qualification Record Number WPS Number S21 Welding Process(es) SMAW
S21 Type(s)
Date
10/03/03
Manual (Manual, Automatic, Semi-Auto)
ts (QW-402)
Coupon thickness: .4320” Root face: 3/32” Root spacing: 1/16”
(for combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or process used)
Base Metals (QW-403) Material Specification Type or Grade P-No. 1 Thickness of Test Coupon Diameter of Test Coupon Other
SA-516 Grade 70 to P-No. 1 .4320 Plate
Filler Metals (QW-404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. F-4 Weld metal analysis A-No. A-1 Size of Filler Metal 1/8” Other Deposited Weld Metal .4320” Position (QW-405) Position of Groove Flat Weld Progression (uphill, downhill) Other Preheat (QW-406) Preheat Temp. 50 Deg. F Inter Temp. 550 Deg. F Other
BAY Technical Associates, Inc.
Flat
Postweld Heat Treatment (QW-407) Temperature None Time Other Gas (QW-408) Percent Composition Gas(es) Mixture Flow Rate Shielding N/A Trailing N/A Backing N/A Electrical Characteristics (QW-409) Current Polarity Amps Volts Tungsten Electrode Size Other Technique (QW-410) Travel Speed String or Weave Bead Oscillation Multiple or Single (per side) Single or Multiple Electrodes Other
12
API-510 Examination Preparation Course Practice Exam #3 – Open Book
Specimen No. 1
Width 0.996
2
1.002
QW-483 (Back) Procedure Qualification Report (PQR) Tensile Test (QW-150) Ultimate Ultimate Total Load Unit Stress Thickness Area lb psi 0.350 0.349 23250 66,620 0.350
0.351
24600
Type of failure & location Base Metal
70,085
Base Metal
Guided Bend Tests (QW-160) Type and Figure No. Side Bend, QW-462.2 Side Bend, QW-462.2 Side Bend, QW-462.2 Side Bend, QW-462.2
Specimen No.
Notch Location
Notch Type
Results No Defects No Defects 1/8” defect in heat affected zone No Defect Toughness Tests (QW-170) Test Impact Lateral Exp Temp Values % Shear Mills
Drop Weight Break No Break
Fillet Weld Tests (QW-180) Results -Satisfactory: Macro - Results
Yes
No
Penetration into Parent Metal:
Yes
No
Other Tests Type of Test Deposit Analysis Other Welder’s Name Slim Pickins Clock No. 99 Stamp No. SP Tests conducted by: BAY Tech Laboratory Test No. S21 1 & 2 We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer Date:
10/03/03
BAY Technical Associates, Inc.
BAY Tech
Signature:
Chip Beaph
13
API-510 Examination Preparation Course Practice Exam #3 – Open Book
BAY Technical Associates, Inc.
14
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