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) One foot
b) Two and a half feet
c) Five feet
d) 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) The test shall consist of four specimens

b) The test shall consist of three specimens
c) The test shall consist of two specimens
d) 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) 10
b) 20
c) 30
d) 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) 0.857 inch
b) 0.872 inch
c) 1.714 inches
d) 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) The material prevents substituting preheat for PWHT

b) Temper-bead installation may be used instead of PWHT
c) Vessel alterations prevent applying preheat as a PWHT alternative
d) Preheat to not less than 300°F is an alternative to PWHT

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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) 1.099 inches
b) 1.685 inches
c) 2.197 inches
d) 2.384 inches

7. Which of the following is an essential variable of an SMAW WPS?

a) Upward or downward progression

b) Change in groove design
c) Decrease of over 100°F in preheat
d) 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) The pits are acceptable because small, widely scattered pits may be ignored
b) The pits are acceptable, based on their area, length, and depth
c) The pits are not acceptable in any circumstance
d) The pits are not acceptable, based on their length

9. What is the maximum permitted offset for a repaired ¾” Category B weld joint?

a) 1/16”
b) 1/8”
c) 3/16”
d) 1/4”

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10. According to ASME Section VIII, Division 1, how long must radiographs taken
during fabrication and assembly of a pressure vessel be retained?

a) For five years

b) For the lifetime of the vessel
c) For a time not specified in the construction
d) 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 passes
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) Ultrasonic
b) Radiography
c) Liquid penetrant
d) 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) -26°F
b) 2°F
c) 37°F
d) 75°F

14. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head.
What is the joint category of the head to shell weld?

a) A
b) B
c) C
d) D

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15. What is the minimum postweld heat treatment (PWHT) holding time for 3” SA-516
Gr. 70 material?

a) 2 hours
b) 2 hours 15 minutes
c) 2 hours 30 minutes
d) 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, joint 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) 0.430 inch (10.9mm) API-510 Paragraph 7.2.1

b) 0.305 inch (6.2mm)
c) 0.555 inch (14.1mm)
d) 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) High temperature sulfidic corrosion

b) Naphthenic acid corrosion
c) Polythionic acid corrosion
d) 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

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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) 3.75 square inches

b) 7.50 square inches
c) 8.50 square inches
d) 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) 0.312”
b) 0.333”
c) 0.417”
d) 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) Film certified according to ASME Section V

b) An ASTM certified wedge
c) An ASNT certified procedure
d) 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 joint 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) 1049psi
b) 105psi
c) 176psi
d) 2099psi

24. Which of the following information is not required to be documented for a

radiograph?

a) Minimum source-to-object distance

b) Geometric unsharpness
c) Material type
d) Single or double wall exposure

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25. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head
using a single welded butt joint with a backing strip that will be left in place. What is
the joint type of the head to shell weld?

a) 1
b) 2
c) 3
d) 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) 7°F
b) 37°F
c) 45°F
d) 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) 18 inches
b) 20 inches
c) 27 inches
d) 40 inches

28. How far away from the weld must the corroded area be in order to allow a joint
efficiency of 100% in recalculating the required thickness of a vessel with a joint
efficiency of 85%?

a) The greater of one half inch or two times the minimum thickness
b) The greater of one inch or two times the minimum thickness
c) The greater of one inch or three times the minimum thickness
d) 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) 400psi
b) 402psi
c) 412psi
d) 420psi

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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 Distance from vessel top MAWP

Top 0 feet -
Top head 4 feet 725psig
Upper shell cylinder section 19 feet 736psig
Middle shell cylinder section 34 feet 731psig
Lower shell cylinder section 49 feet 745psig
Bottom head 53 feet 743psig

30. What is the MAWP that can be applied to this vessel?

a) 712psi
b) 716psi
c) 720psi
d) 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) 350°F ± 50°F for a minimum of 1 hour after completion

b) 350°F ± 50°F for a minimum of 2 hours after completion
c) 500°F ± 50°F for a minimum of 1 hour after completion
d) 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) The vessel must not be strip lined or plate lined

b) No questionable condition is disclosed by periodic external inspections
c) The vessel will not be operated in excess of 500psi or 500°F
d) 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) 1.25 times the test pressure

b) 1.5 times the test pressure
c) 2 times the test pressure
d) 4 times the test pressure

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34. A pressure vessel is to be re-rated, the vessel nameplate is stamped RT-4 and the joint
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 joint.

a) 542psi
b) 620psi
c) 659psi
d) 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) 0°F
b) 10°F
c) 32°F
d) 60°F

37. Which of the following is an API-510 requirement for controlled deposition welding?

a) The metallurgical review shall be performed by an engineer prior to its use

b) The weld area must be preheated to at least 425°F
c) The vessel for repair must be constructed of P-5 or P-7 material
d) 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) 0.01 inch
b) 0.02 inch
c) 0.03 inch
d) 0.04 inch

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39. What is the maximum interpass temperature when using the preheat alternative
method for a weld repair on a vessel that originally had PWHT?

a) 300°F (150°C)
b) 400°F (205°C)
c) 500°F (260°C)
d) 600°F (315°C)

40. What is the maximum density, in the area of interest, for gamma ray source
radiography?

a) 1.3
b) 1.8
c) 2.0
d) 4.0

Questions 41 through 43 – refer to the attached welding procedure and procedure

qualification record.

41. Regarding the joint shown, the Welding Procedure Specification:

a) Includes all required information

b) Should specify uphill or downhill progression
c) Must show the weld layers
d) Should address the joint angle

42. Regarding the mechanical tests shown, the Procedure Qualification Record
qualifications:

a) Have not been met because one of the guided bend tests failed
b) Have not been met because on tensile test failed
c) Have all be met
d) 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) Upper limit could be eight inches

b) Lower limit could be 1/16 inch
c) Lower limit could be 1/8 inch
d) Range is accurate as shown

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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 Supporting PQR No(s) S21
Revision No. 0 Date ---
Welding Process(es) SMAW Type(s) Manual
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402) Details
Joint Design Single V Groove 37 1/2º ± 5º typical
Backing: (yes) (no.)
Backing Material (Type): Weld
(Refer to both backing and retainers)

Metal Nonfusing Metal Root spacing: 1/16”

Root face: 1/8” Max
Nonmetallic 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 joint designs above are typical for groove welds, check
the production drawing for weld joint design and root

*Base Metals (QW-403)

P-No. 1 Group No. 1 To 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: .1875 to ,8640 Fillet: All
Pipe Dia. Range: Groove: All Fillet: All
Other:

* Filler Metals (QW-404) Root Balance

Spec. No. (SFA) 5.1
AWS No. (Class) E7018
Root Balance
F. No. F-4 F-4
A-No. A-1 A-1
Size of Filler Metals 1/8 & 5/32
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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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
Preheat Temp. Min. 50 Deg. F Gas(es) (Mixture) Flow Rate
Interpass Temp. Max. 550 Deg. F
Preheat Maintenance None Shielding N/A
(Continuous or special heating where applicable should be recorded) Trailing N/A
Backing N/A
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 Steing and Weave
Orifice or Gas Cup Size N/A
Initial and Interpass Cleaning (Brushing, Grinding, etc.) Brushing or grinding 1" Both sides of weld joint

Method of Back Gouging Grinding

Oscillation N/A
Contact Tube to Work Distance N/A
Multiple or Single Pass (per side) Multiple
Multiple or Single Electrode Single
Travel Speed (Range) Various
Peening None
Other:

Travel Other
Weld Process Filler Metal Current Volt Speed (e.g. Remarks Comments, hot
wire addition, technique, Torch
Layers Range Range Angle, Etc.
All SMAW E-7018 1/8" DCRP 90-160 -- -- --
All SMAW E-7018 5/32" DCRP 130-220 -- -- --

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Procedure Qualification Report (PQR)

(QW-200.2 of Section IX, ASME B & PV Code)

Company Name BAY Tech

Procedure Qualification Record Number S21 Date 10/03/03
WPS Number S21
Welding Process(es) SMAW Type(s) Manual
(Manual, Automatic, Semi-Auto)
Joints (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) Postweld Heat Treatment (QW-407)
Material Specification SA-516 Temperature None
Type or Grade Grade 70 Time
P-No. 1 to P-No. 1 Other
Thickness of Test Coupon .4320
Diameter of Test Coupon Plate Gas (QW-408)
Other Percent Composition
Gas(es) Mixture Flow Rate
Filler Metals (QW-404) Shielding N/A
SFA Specification 5.1 Trailing N/A
AWS Classification E-7018 Backing N/A
Filler Metal F-No. F-4 Electrical Characteristics (QW-409)
Weld metal analysis A-No. A-1 Current
Size of Filler Metal 1/8” Polarity
Other Amps Volts
Deposited Weld Metal .4320” Tungsten Electrode Size
Position (QW-405) Other
Position of Groove Flat Technique (QW-410)
Weld Progression (uphill, downhill) Flat Travel Speed
Other String or Weave Bead
Preheat (QW-406) Oscillation
Preheat Temp. 50 Deg. F Multiple or Single Pass (per side)
Interpass Temp. 550 Deg. F Single or Multiple Electrodes
Other Other

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QW-483 (Back) Procedure Qualification Report (PQR)

Tensile Test (QW-150)
Ultimate Ultimate Type of
Specimen Total Load Unit Stress failure &
No. Width Thickness Area lb psi location
1 0.996 0.350 0.349 23250 66,620 Base Metal

2 1.002 0.350 0.351 24600 70,085 Base Metal

Guided Bend Tests (QW-160)

Type and Figure No. Results
Side Bend, QW-462.2 No Defects
Side Bend, QW-462.2 No Defects
Side Bend, QW-462.2 1/8” defect in heat affected zone
Side Bend, QW-462.2 No Defect

Toughness Tests (QW-170)

Specimen Notch Notch Test Impact Lateral Exp Drop Weight
No. Location Type Temp Values % Shear Mills Break No Break

Fillet Weld Tests (QW-180)

Results -Satisfactory: Yes No Penetration into Parent Metal: Yes No

Macro - Results

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 BAY Tech

Date: 10/03/03 Signature: Chip Beaph

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