15 3 2019

API 653 THE DAY BEFORE

YOUR EXAM
BASSAM ABDELAZEEM
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Bassam Ghreeb Abdelazeem

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[email protected]
+966538391734
 1

API 653 Exam 1

1) When a frangible joint is required, what should be evaluated with requirements
under API 650?
Answer: Bottom-to-shell joint corrosion Ref: API 653, 4.2.2.2
2) Periodic assessments of tank bottom integrity shall be performed (how often)?
Answer: Less than or equal to internal inspection interval Ref: API 653, 4.4.1
3) The annular ring is typically greater than inches IF Tank bottom/foundation
design with no means for detection and containment of a bottom leak.?
Answer: 0.100 inches Ref: API 653, Table 4.4

4) What is the out of roundness radius tolerance measured at 1 foot above the shell to
bottom for a reconstructed 70-foot diameter tank?
Answer: 420.75 " to 419.25 " Ref: API 653, Table 4.4
D= 70 Feet , R = 35 feet = 35 x 12 = 420 in. +/- ¾
R= 420.75 " to 419.25 "

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5) Reference to the figure below, Does cut the extend past or stop short of extend
beyond an existing bottom plate weld is meet the requirements of API 653 if the
shell thickness is 0.5 inches?

Answer: No,the cut shall extend past or stop short of extend beyond an existing
bottom plate weld by at least 3 ‘’ Ref: API 653, Figure 9.1, Note 3
C = 3 inches or 5t, use the greater value
C= 3 inches or 5 x 0.5’’ =2.5 so C = 3 in.

Bassam Ghreeb Abdelazeem

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Bassam Ghreeb Abdelazeem
+966538391734 [email protected]
www.eliteservices-int.com
 3

6) Distortion of anchor bolts is likely an indication of -

Answer: either serious foundation settlement or a tank overpressure uplift condition
Ref: API 653, 4.5.3
7) What plate thickness shall be used for patch repair on the shell?

Answer: not less than 3/16” (Must know ½ max. and 3/16-inch min. rules)

Ref: API 653,9.3.1.3

8) What fillet weld size to use on 1-1/8” tombstone type reinforcing plate to nozzle neck?

Answer: 7/16” Ref: API 653 ,Figure 9.8

9) What is allowed to be done to tombstone type reinforcing plate when adding new
bottom to tank?
Answer: a) Trim reinforcing plate to increase spacing between welds. / b) Move The existing
penetration by cutting the section of the shell containing the fitting and reinforcing plate,
and raising the entire assembly to the correct elevation / c) Remove the existing reinforcing
plate carefully install a new reinforcing plate. All of the above

Ref: API 653, 9.9.2.

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10) What is the maximum reinforcement allowed on a 1" thick vertical butt weld made on
A reconstructed tank?
Answer: 1/8 in. Ref: API 653, 10.4.2.6 /Table 10.1

11) Minimum number of additional spot radiographs required for 1 in. rectangular
shell plate replacement shell as per API-653 is
Answer: 6 films Ref: API 653, 12.2.1.6.2

12.2.1.6.2 For square and rectangular replacement plates, at least one radiograph shall be taken in a vertical joint,
and at least one in a horizontal joint, and one in each corner. When the square or rectangular replacement plate is
located in a shell plate with thickness exceeding 1 in., the vertical joints shall be fully radiographed.

11) New tank constructed from ASTM A 36 shell plate with wall thickness of 1.6
inches. What Minimum preheat Temperature is Required?
Answer: 200 °F (93°C ) Ref: API 650, TABLE 7.1b

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12) What is the maximum filling rate below the top shell course during a hydro test
for a repaired tank having a ½” thick bottom shell course?
Answer: 18”/hr. Ref: 650, 7.3.6.5 & Table

13) What is the maximum filling rate for the top shell course during a hydro test for a
repaired tank having a ½” thick bottom shell course?

Answer: 12”/hr. Ref: 650, 7.3.6.5 & Table

14) Using data from below, calculate MRT. (metal loss from the bottom side corrosion). Or
= 10 years, RTbc = .200, RTip = .190, StPr = .002 and UPr = .010
Answer: 0.080 in. Ref: 650, 4.4.5.1

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15) Using data from below, calculate MRT. (metal loss from internal corrosion). Or =
10 years, RTbc = .200, RTip = .190, StPr = .002 and UPr = .010
Answer: 0.070 in. Ref: 650, 4.4.5.1

16) What is the Sulfuric acid corrosion rate if the Sulfuric acid 85% and Temperature
125 ºF?
Test questions will be based on the following mechanisms only:
Section 3: Definitions
4.2.7 - Brittle Fracture
4.2.16 - Mechanical Fatigue
4.3.2 - Atmospheric Corrosion
4.3.3 - Corrosion Under Insulation (CUI)
4.3.8 - Microbiologically Induced Corrosion (MIC)
4.3.9 - Soil Corrosion
4.3.10 – Caustic Corrosion
4.5.1 - Chloride Stress Corrosion Cracking (Cl-SCC)
4.5.3 - Caustic Stress Corrosion Cracking (Caustic Embrittlement)
5.1.1.10- Sour Water Corrosion (Acidic)
5.1.11 - Sulfuric Acid Corrosion

Answer: 50mpy Ref: API 571, 5.1.1.11.3 (b)/ Figure 5-21

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 17) What action to be taken if you notice a flat spot of size 1 in. deep, 50 feet wide
and 30 feet length on a 200 feet diameter tank?
Answer: accept since it is within tolerance Ref: API 653, table 10.2

18) What will be Allowable hydrostatic test stress for ASTM A-516, Grade 65 in
bottom shell course in reconstruction tank?
Answer: 30,700 psi. Ref: API 653, Table 4.1

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19) What will be Allowable product test stress for ASTM A-285, Grade C for Bottom
Course in new tank?
Answer: 20,000 psi. Ref: API 650, Table 5.1b

20) A new tank is to be hydrostatically tested. The tank is constructed from ASTM
A36 steel. What allowable stress must be used to determine the maximum
hydrostatic test head for the tank?
Answer: 24,900 psi. Ref: API 650, Table 5.1b

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21) What is the hydrostatic test height of an in-service welded aboveground storage
tank built to API 650, 8th Edition, 82 feet diameter, 40 feet tall with a minimum first
course thickness of 0.197 in. The material of construction is A-516, Grade 65?
Answer: 32.14 feet. Ref: API 653, 4.3.3.2
Ht = [St E tmin./2.6 D ] +1
St = 33,700 (From Table 4-1)
Ht = [ (33,700) (1) (.197) / 2.6(82)] +1 = 32.1393 feet

22) During an inspection, you are required to calculate the retirement thickness for
the bottom course of a tank. The information available is as follows: -
Nominal tank diameter 150 ft , Total height of tank 30 ft
Maximum fill height 30 ft , Number of courses equally spaced 5
Specific gravity of contents 0.85 , Construction code API 650 basic standard 5th edition
Material of construction A283 C

Answer: 0.48 in. Ref: API 653, 4.3.3.1

St = 23,600 (From Table 4-1)
tmin.= 2.6(H-1)DG/SE = 2.6(29)150x0.85/(23600x0.85) = 0.479

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23) An inspection is performed on an aboveground storage tank 24 feet tall, 22 feet

fill height, 94 feet diameter, water storage service, earth foundation. There is
evidence of bottom settlement. Calculate the minimum thickness for the third
course, if each course is 4 feet in height?
Answer: 0.122 in. Ref: API 653, 4.3.3.1
 H
rd
3 course= 22-2x4 =14 feet & S= 26,000 (From Table 4-1)

24) An inspection is performed on an a aboveground storage tank 24 feet tall, 22 feet

fill height, 94 feet diameter, water storage service, earth foundation. There is one
area of general internal corrosion on the south side of the shell 20 inches wide and
20 inches in vertical length. There is evidence of bottom settlement.
If the maximum liquid level in the tank were to be lowered by 5 feet, what is the
minimum thickness of the first course?
Answer: 0.168 in. Ref: API 653, 4.3.3.1
 H = 22-5=17 feet & S= 26,000 (From Table 4-1)

25) What is the minimum size fillet weld required on each side of the shell plate
attaching to the annular plate? The shell plate is 1.25” thick.
Answer: 5/16 in. Ref: API 650, 5.1.5.7 (a)

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26) Reconstructed AST has product specific gravity less than 1 of unknown material and
thickness of first shell course is 0.5 in and its Stress 23,600 psi, the required annular
bottom plate minimum Thickness is
Answer: 0.17. Ref: API 653,4.4.6.2 /Table 4.5

27) If the first course of a new tank fabricated from the material Group I and the
design metal temperature is -7 °C (20 °F), determine the thickness of the material
that not require impact test?
Answer: 0.5 in. Ref: API 653, 4.2.10.1/ Figure 4.1b

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28) What is the maximum Internal Inspection interval for a ¼ in. bottom that has a a
fiberglass lining?
Answer: 15 years. Ref: API 653, 6.4.2.1.1/Table 6.1
10 years (initial) + 5 years (fiberglass lining)) = 15 years

29) What is the maximum Internal Inspection interval for a ¼ in. bottom that has a
release prevention barrier and a fiberglass lining?
Answer: 25 years. Ref: API 653, 6.4.2.1.1/Table 6.1
10 years (initial) + 5 years (fiberglass lining) + 10 years (release prevention barrier) = 25 years

30) What is the maximum Internal Inspection interval for a ¼ in. bottom that has a
release prevention barrier and Thin-film coating?
Answer: 22 years. Ref: API 653, 6.4.2.1.1/Table 6.1
10 years (initial) + 2 years (Thin-film coating) + 10 years (release prevention barrier) = 22 years

31) What NDE is required for stress relieved assemblies?

Answer: MT or PT after stress relief but before hydro testing Ref: API 653, 12.1.2.4
32) WPS for shell repairs shall .
Answer: Shall be qualified with existing or similar materials and shall include impact
testing. Ref: API 653, 12.3.2.3.1
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33) What is the allowable edge settlement of a 120 feet diameter tank that has an area
of settlement that starts to slope (radius of settled area) 4 feet from the shell and
the bottom lap weld is approximately parallel to the shell?
Answer: 4.6 inches Ref: API 653, B.3.4.1 /Fig. B11

34) A fitness-for-service evaluation shall be done by_______________.

Answer: an engineer experienced in storage tank design and the evaluation methodologies
used.

35) Tracer gas testing procedure must be approved by .

Answer: Owner/Operator (the Purchaser). Ref: API 650 ,8.6.11 (A)

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36) What is allowed to be done to tombstone type reinforcing plate when adding
new bottom to tank?
Answer: The existing reinforcing plate may be removed, modified and re-installed after
the new shell-to-bottom weld is complete Ref: API 653, 9.9.4 (e)
37) When removing an existing tank bottom, All arc-gouged areas of the tank shell-
to-bottom weld shall be , and defective areas repaired and re-
examined.
Answer: magnetic particle examined. Ref: API 653, 9.10.2.3
38) With regard to installation of primary and secondary seals, what must be done if
the roof rim thickness is less than 0.10 inch?
Answer: It shall be replaced. The new roof rim shall be 3/16 inch thickness minimum.
9.13.6.2 If the roof rim thickness is less than 0.10-in. thick, it shall be replaced. The new roof rim shall be 3/16-in. thickness,
minimum. Ref: API 653, 9.13.6.2
39) If a repair/modification weld is made on a tank shell plate that is thicker than 1ʺ,
the base metal within 3ʺ inches of the welding shall be heated to a temperature
of approximately degrees.
Answer: 140 F (Preheat worm to hand) Ref: API 653, 10.4.2.3
40) When welding horizontal and vertical joints constructed of material that is over
1.5” thick, based on the thickness of the thicker part, what is the required preheat
temperature?
Answer: 200°F Ref: API 653, 10.4.4.3
41) Roof Insulation Inspect for
Answer: wet insulation under the weather coat. Ref: API 653, C.1.4.6

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 42) For horizontal and vertical joints in tank shell courses constructed of material
over 1 1/2-in. thick (based on the thickness of the thicker plate at the joint), multi-
pass weld procedures are required, with no pass more than thick
permitted

Answer: 3/4-in. Ref: API 653, 10.4.4.3

43) Reconstruction tank, what is the maximum allowable peaking, using a

horizontal 36" sweep board?
Answer: 0.5 in. Ref: API 653, 10.5.4
44) Completed welds of stress-relieved assemblies shall be examined by
Answer: MT or PT shall be done after stress relief and before hydrostatic testing.
Ref: API 653, 12.1.2.4
45) The nominal thickness of 13mm (1/2”) does not apply to?
Answer: bottom plates not welded to the shell Ref: API 650, A.1
A.1 Scope
A.1 The nominal thickness limit of 13 mm (1/2 in.) does not apply to:
1) bottom plates not welded to the shell;
2) the bottom reinforcing plate of flush-type cleanouts and flush-type shell connections;
3) flanges and cover plates of flush-type cleanouts;
4) flush-type shell connection necks attached to shell and flanges and cover plates of flush-type shell
connections;
5) nozzle and manhole necks, their flanges and cover plates;
6) anchor bolt chair components and shell compression ring.

46) What is required for repair to vertical joints in a tank that has a MDMT of 15 F?
Answer: impact tests required Ref: API 650, 9.2.2.3
47) {What liner is best suited for crude storage at 200 F (94 C)?}
Answer: Epoxy/amine Ref: API 652,6.4
Epoxy/amine Water, light products, distillates, aromatics, crude, and gasoline  160–220 (71–104 C)
Vinyl Water, crude oil, aromatics, solvents, alcohols, gasohol, oil, and chemicals  180 – 220 F (82 –
104 C)

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48) Flame arrestors should be visually inspected at .
Answer: appropriate intervals Ref: API 575, 8.2.10
49) {Hardness testing of weld and HAZ is often required to ensure welding process
and PWHT .}/ {Hardness test after PWHT to confirm it is .}
Answer: {acceptable soft result} / {soft weld} Ref: API 577, 9.10

49) Regarding extent of MFL, the numbers of measurements taken for a statistical
sampling will depend on the size of the tank and the degree of soil-side corrosion
found, Typically_______________.
Answer: 0.2% to 10% of bottom should be scanned randomly using statistical sampling
Ref: API 575, 8.4.4

50) What current shall be applied to determine if adequate CP has been achieved?
Answer: 850 mV Ref: API 651, 8.2.2.1

51) In determining if adequate cathodic protection is being achieved, which of them

following would be correct?
Answer: Anegative (cathodic) potential of at least 850 mV with the cathodic
protection current applied. Ref: API 651, 8.2.2.1.
52) Holiday testing for thin-film should be done with -
Answer: low-voltage (67.5V) wet sponge applicator Ref: API 652, 9.3.4
53) Spacing for stiffening ring drain holes for un-insulated tank is .
Answer: at least 25 mm (1 in.) diameter (or slot width) on 2400 mm (8 ft) centers or less.
Ref: API 650, 5.9.3.3.
54) {Attachments that will be welded to the pressure boundary shall not have a zinc
or cadmium coating in the weld area within of the weld} / {Length of
area to be cleaned from galvanized attachments to be welded to
tanks .}
Answer: 12 mm (0.5 in.). Ref: API 650, 6.1.1.3.
55) How much time do you need to keep the radiographs of a reconstructed tank?
Answer: 1 year
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 Ref: API 653, 13.2.3.
56) Repair = 12 inches long, {Minimum diagnostic length of a radiograph is }/
{What length is required to be radiographed?}
Answer: 6 inches
Ref: API 653, 12.2.1.7
57) {Internal measurement for tank bottom settlement taken across the diameter of
the tank must be taken at what maximum spacing?}/ {Maximum radial spacing
for settlement measurement inside tank .}
Answer: 10 feet Ref: API 653, B.2.1/ Fig.B-2/ 12.5.2
58) What is the maximum size of rectangular opening at the roof of a fixed conical
roof tank?
Answer: 900 mm (3 ft) max. Ref: API 650, 5.8.6.1/Figure 5.17/Figure 5.18

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 59) What are NDE methods and to what extent shall they be used for the
examination of repairs to butt welds?
Answer: UT or RT over full length. Ref: API 653, 12.1.3.2
60) How many radiographs shall be taken in a square 12” x 24” butt welded insert
plate in a shell over 1" thick?
Answer: 100% RT. Ref: API 653, 12.2.1.6.2

61) To check swing lines, scribe the flexible joint across the two moving faces and
raise end of swing line to check the joint’s _.
Answer: freedom of movement. Ref: API 653, C.2.11.6 (b)
62) Name plate information, drawings, specification, results of test and analysis shall
be part of which type of records.
Answer: Repair/alteration history, operational records, construction records.
Ref: API 650, 6.8.2/ 6.8.3/ 6.8.4
63) Brittle fracture least likely for _.
Answer: a tank shell thickness is no greater than 0.5 in.
Ref: API 653, 5.3.5/ step 4
64) If corrosion is noted on tank roof and top of shell, which statement is true?
Answer: structural members may be twice the rate of thinning of the roof or shell.
Ref: API 575, 8.4.8
65) Corrosion rate of roof structure as compared to shell and roof.?
Answer: double.
Ref: API 575, 8.4.8
66) One of the conditions hydrotesting is not required IF stress in the repair area
shall not exceed .
Answer: 7000 psi. Ref: API 653, 12.3.2.3.3 (C)

67) {Which is the maximum allowable slope of a frangible roof of a tank 15 m or

greater?} / {In a frangible roof design the slope of the roof at the top angle
attachment shall not exceed .}
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Answer: 2:12. Ref: API 653, 5.10.2.6 (a)(1)

68) The anchor pattern required for linings is typically .

Answer: 1.5 mils to 4.0 mils (38 microns to 102 microns) Ref: API 652, 7.5

69) Prior to blasting surface FOR the area to be lined shall be essentially cleaned
from
Answer: Oil, tar, grease must be removed (all hydrocarbon residues) Ref: API 652, 7.2.1

70) As Per API 650, what action is to be taken if the Openings in tank shells larger
than required to accommodate a NPS 2 flanged nozzle?
Answer: Nozzle shall be reinforced Ref: API 650, 5.7.2.1.
{Note: - No reinforcement required for nozzles 2” and smaller}.

71) {The maximum spacing of measurement points around the circumference of a

tank for a hydrostatic test is?} / {Maximum circumferential spacing for settlement
measurement .}
Answer: 32 in. Ref: API 653, B.2.1/ Fig.B-1

72) The RBI assessment shall be reviewed and approved by a team at intervals not to
exceed .
Answer: 10 years or more often if warranted by process, equipment, or consequence
changes. Ref: API 653, 6.4.2.2.1.

73) Which standard refers for design of partial vacuum condition of tanks?
Answer: 650 Appendix V. Ref: API 653, 4.2.4.2
74) Seams of riveted tank can be checked by .
Answer: running a thin-bladed scraper or knife along the riveted seam.
Ref: API 575, 8.4.4
75) On a fixed roof, planks long enough to span at least----------------- rafters should
laid to use as walkways for inspection?
Answer: TWO (2). Ref: API 575, 8.2.9

76) Abrasive blasting climate condition requirement, steel temperature shall be

.

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Answer: atleast 5 °F (3 °C) above the dew point temperature and the relative humidity
should be below 80 % at the steel surface. Ref: API 652, 8.3
77) What is the primary purpose of post weld heat treatment (PWHT)?
Answer: To reduce (relieve) residual stresses. Ref: API 577, 10.6

78) {Minimum number of radiographs that shall be taken to a circular butt welded
insert plate in a shell 1/2" thick} / {Minimum number of radiographs that shall be
taken to for circular replacement ¾ in. shell plate is .}
Answer: One (6 in.) Ref: API 653, 12.2.1.6.1
{Note: - 100% RT for T > 1 inch}
79) If corrosion rates are known, external UT measurements of a new tank shell
shall be made .
Answer: the smaller of RCA/2N {1/2 Remaining life} years or 15 years.

Ref: API 653, 6.3.3.2 (b)

80) If corrosion rates are not known, external UT measurements of a new tank
shell be made not later than how many years?
Answer: 5 Ref: API 653, 6.3.3.2(a)
81) {When an internal inspection may be waived?} / {External tank bottom
inspection is permitted )
Answer: {access to bottom side of tank }/ {where construction, size, or other aspects
allow external access to the tank bottom to determine bottom thickness}.
Ref: API 653, 6.5
82) Tank is constructed as per API 650, 40 feet Nominal tank diameter, 8 feet Hight
of shell course and 0.125 in., the designed corrosion allowance and minimum
thickness t2 is among following reading (0.345ʺ, 0.4ʺ, 0.3ʺ, .025ʺ, 0.45ʺ) if the
location of the critical length is 1 feet from the second course of the shell what is
the value of H in the formula for calculating tmin?
Answer: 31 feet (H=40-8-1=31 feet) Ref: API 653 ,4.3.3.2 /API 650, 5.6.3.2

83) A PQR test uses SMAW process to weld on a 5/8-inch-thick plate. Maximum
thickness of production weld qualified is .
Answer: 1 1/4 inches. (2T = 2x 5/8= 1-1/4 inches) Ref: ASME IX , Table QW-451.1
84) Which of the following must be included in a PQR?
Answer: Certification signature and date Ref: API 577, 6.4.3
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85) The thickness of plate to be used for shell replacement shall be the maximum
thickness of the adjoining member except in which condition .
Answer: where the adjoining plate is a thickened insert plate. Ref: API 653, 9.2.1

86) Correct statement regarding hot tapping .

Answer: Hot taps are not permitted on the roof of a tank or within the gas/vapor
space of the tank. Ref: API 653, 9.14.1.4
9.14.1 General
9.14.1.2 The minimum height of tank liquid above the hot tap location shall be at least 3 ft during the hot tapping
operation.
9.14.1.3 Welding shall be done with low hydrogen electrodes.
9.14.1.4 Hot taps are not permitted on the roof of a tank or within the gas/vapor space of the tank.
9.14.1.5 Hot taps shall not be installed on laminated or severely pitted shell plate.

87) What is important while considering internal cleaning of tanks?

Answer: the amount/types of scale, sediment, solid product, or other foreign material
that is present on the surfaces to be inspected. Ref: 575, 8.1
{includes the assessment of amount/types of sludge inside the tank, facility to mobilize
cleaning equipment inside the tank, obstructions inside the tank…. Etc.}

88) Which alternative method can be used if internal inspection is required only to
assess the bottom plate?
Answer: Scanning of bottom using robotic equipment (ultrasonic robotic thickness
measurement). Ref: API 653, 6.4.1.2
89) {Minimum diagnostic length of a radiograph is .} / {What is the
minimum length of radiograph to be taken for a reconstructed tank?
Answer: 6 inches Ref: API 653, 12.2.1.7
90) Calibrations shall include the complete ultrasonic system and shall be
performed .
Answer: prior to use of the system in the thickness range under examination / prior to
and at the completion of an examination. Ref: API 577, 9.9.3.1
91) RT Densitometers shall be calibrated .
Answer: at least every 90 days. Ref: ASME V, T-262.1
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92) The density of step wedge comparison film and densitometer calibrations shall be
verified by using calibrated step wedge film traceable to .
Answer: National standard (step tablet). Ref: ASME V, T-262.1(a)

93) When a welder is qualified as per an approved WPS under what conditions a
requalification is required?

Answer: an essential variable change. Ref: ASME IX, QW-300.1/ QG-105.2

94) An existing above storage tank, 40 feet Nominal tank diameter, ¾ in. thick shell,
material not known (unknown toughness) requires hot tapping of 4 NPS, 6 NPS, NPS 8
and NPS10 nozzles. Which of the following statement is true?

Answer: only diameter of 4 in. NPS nozzle can be made. Ref: API 653, 9.14.1.1 (b)(1)

95) All fasteners and washers used for Internal Floating Roofs for installation of seal
joints, including fabric seal joints, shall be .

Answer: austenitic stainless steel. Ref: API 650, H.4.4.5

96) {Welder or welding operator's identification marks shall be located adjacent to

completed welds at intervals not exceeding .} / {What distance
the welder symbol shall be stamped?}

Answer: {3 feet} / {EVERY 3 feet}. Ref: API 653, 11.2.2

97) {Welder symbol is not required for which type of joints?} / {Which of the
following types of welds do not need welder identification?}
Answer: Roof plate welds and flange-to-nozzle-neck welds. Ref: API 653, 11.2.2

98) {Reinforcement pad welds should be pneumatically tested at which pressure?} /

{What is the maximum pressure of pneumatic test of reinforcement pads?}
Answer: 15 psi Ref: API 650, 7.3.4

99) {Who should carry out RBI assessment} / {The RBI assessment shall be
performed by }
Answer: Personal knowledge in RBI methodology and Tank Design
Ref: API 653 ,6.4.2.2.2
100) For Recertification purpose, as per API 653 "Actively engaged as inspector " is
defined as which of the following .
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Answer: Minimum of 20% of time spent on performing or supervision of inspection

activities as per API 653 OR Performance of or supervision of inspection activities
on 75 aboveground storage tanks. Ref: API 653, D .5.2 (a) and (b)

101) When checking for hydrogen blisters during an internal inspection of the shell
and bottom of a tank using flashlight, the flash light beam gives best results when
held .
Answer: Parallel and closed to the surface to be inspected. Ref: API 575, 8.2.8.

102) Which Type of corrosion most likely to occur around connections for internal
heating units or coils at the tank wall?
Answer: Caustic stress corrosion cracking. Ref: API 575, 8.2.8.4

103) While altered by adding new plate material to increase the height of the tank she
l. The modified shell height shall be in accordance with the requirements of the
current applicable standard and shall take into consideration .
Answer: all anticipated loadings (wind and seismic). Ref: API 653, 9.5

104) While replacing a shell plate on a horizontal joint what is the minimum length of
horizontal joint to be cut on either side of new vertical joint?
Answer: 12 in. beyond the new vertical joints. Ref: API 653, Figure 9.1 Note 2

105) API 650, Appendix M Shall be used to evaluated for suitability of shell tank
service if tanks of welded construction that operate at elevated
temperatures
Answer: above 200 °F. Ref: API 653, 4.3.10
106) What is Maximum interval for Routine in-service visual inspections of the
external condition of the tank shall?
Answer: one month. Ref: API 653, 6.3.1.2

107) When Tank grounding system components such as shunts or mechanical

connections of cables will be checked?
Answer: External Inspection. Ref: API 653, 6.3.2.3

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108) If there is any doubt about the condition of the grounding connection, its
resistance can be checked. The total resistance from tank to earth should

Answer: not exceed approximately 25 ohms. Ref: API 575, 8.2.5

109) Materials to be used at a design metal temperature below , the qualification of the
welding procedure for vertical joints shall include impact tests of the weld metal.
Answer: 50°F. Ref: API 650, 9.2.2.3

110) What is the number of locations where UT thickness measurement shall be taken in
tank?
Answer: as determined by owner/operator. Ref: API 653, 6.3.3.1

111) Special safety procedures must comply with any federal or safety regulations
pertaining to .
Answer: confined space entry. Ref: API 653, 1.4

112) to measure settlement in an area where there is a bottom lap weld in the settled area
that is essentially to the shell.
Answer: parallel (±20°). Ref: API 653, B.2.3.3
113) How many settlement points are required for an external settlement of AST If the
nominal diameter is 65 feet?
Answer: 8 {N= D/10 = 65/10 =6.5 (but not less than 8). }
Ref: API 653, 12.5.2/ Annex B, Fig.B-1
114) {Where does the new nameplate need to be attached to a reconstructed tank?} /
{Where the name plates shall be attached to re-constructed tank?}
Answer: Adjacent to the existing nameplate. Ref: API 653, 13.1.1.2

115) {How much time do you need to keep the radiographs of a reconstructed
tank?} / {How many years’ radiographs shall be retained?
Answer: at least one year. Ref: API 653, 13.2.3 (d)

116) {inspection reports along with inspector recommendations and documentation

of disposition shall be maintained by the owner/operator for .} /

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23

{Inspection reports along with inspector recommendations and documentation

for disposition shall be kept up to }
Answer: the life of the tank Ref: API 653, 6.9.1
117) {Per API 653, Welding procedure specifications (WPSs) and welders and
welding operators by which of the following requirements?} / {Welding procedures
shall be qualified as per which code?}
Answer: ASME Section IX and the additional requirements of API 650 and API 653.
Ref: API 653, 11.1.1
118) Major reasons for coating failure (lining failure) of tanks?
Answer: Inadequate surface preparation (Improper specification) Ref: API 652, 7.1
119) If it is decided to change the service to a more severe service, it is necessary
to .
Answer: Consider the need for hydrostatic testing. Ref: API 653, 5.2.3

120) No known tank failures attributed to brittle fracture have occurred at shell metal
temperatures of
Answer: 60 °F and above. Ref: API 653, 5.3.6 Step 5
121) According to industry experience and laboratory tests, what membrane stress is
required to caused failure due to brittle fracture?
Answer: 7 ksi. Ref: API 653, 5.3.7 Step 6
122) When reviewing a group of UT thickness measurements reports, which of the
following information must be required and documented on UT thickness
measurements reports?
Answer: Type of instrument / Standardization blocks, size and material type / Size,
frequency, and type of search unit/ Scanning method/ Maximum and minimum
thickness measurements. / Location of measurements/ Personnel data,
certification level. /Results. f: ASME V, ARTICLE 23, SE-797, 11

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123) Tanks fabricated from steels of unknown material specifications, 1/2 in. and
operating at a shell metal temperature 20 °F , these tanks
Answer: safe for use. Ref: API 653, Figure 5-2

124) How many essential variables for SMAW Welding Procedure Specifications
(WPS)?
Answer: 10. Ref: ASME IX, QW-253
125) How many Supplementary Essential Variables for SMAW Welding Procedure
Specifications (WPS)?
Answer: 10. Ref: ASME IX, QW-253
126) How many Nonessential Variables for SMAW Welding Procedure Specifications
(WPS)?
Answer: 17. Ref: ASME IX, QW-253
127) A SMAW welding procedure specification (WPS) is selected for a repair on cold
service AST. Impact testing of the weldment is required. Which of the following
is /are required on the WPS?
Answer: Allessential, nonessential, and supplementary variables if notch toughness is
required. Ref: ASME IX, QW-200.1 / API 577,6.2

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Questions 128 through 177 refer to the WPS/PQR documents on

the following pages
128) How many essential variables mentioned on the WPS No. SAMW-001?
Answer: 8. Ref: ASME IX, QW-253

129) joint design on the WPS No. SAMW-001 is _____________.

Answer: missing angle bevel and groove angle. Ref: ASME IX, QW-200.1(B) /QW-253

131) Does the WPS show the maximum base metal thickness range that could be
qualified by the PQR - 001?
Answer: No, it should be 3/16 inch to 1 inches. Ref: ASME IX, QW-451.1

C)

132) Do tensile test results shown on PQR - 001 meet the requirements for WPS?
Answer: No, specimen 2 does not meet requirements.
Ref: ASME IX, Table QW-451.1 & QW-150 (151/152/153) & QW-422 Tables
1. In order to pass the tension test, the specimen shall have a tensile strength (70,00 psi) that is
not less than the minimum specified tensile strength of the weld metal. So specimen No. (1)
mentioned on PQR breaking in the weld metal is OK at 76,200

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26
2. if the specimen breaks in the base metal outside of the weld or weld interface, the test shall be
accepted as meeting the requirements provided the strength is not more so specimen # 2 is
rejected breaking at 65,500.than 5% below the minimum specified tensile strength of the base
metal. = 0.95 x specified tensile strength =70,000 x 0.95 = 66,500,

133) Bend test results shown on PQR - 001 are .

Answer: Unacceptable, because of defect greater than 1/8 in. (3 mm).
Ref: ASME IX, Table QW-451.1 & QW-150 (151/152/153)
134) Does the PQR properly qualify the WPS regarding Preheat requirements?
Answer: Yes, the preheat on the PQR covers all ASME IX rules for WPS application.
Ref: ASME IX, ASME IX, Table QW-253 Table (SMAW) & QW 406.1
Preheat rules QW-406.1 shows that a decrease of preheat > 100 F (55 C) is
defined as an essential variable

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135) preheat given on PQR – 001 is

Answer: meet the requirement API 650 (minimum preheat 32 F.)
Ref: API 653, 7.2.1.3 /Table 7.1b

136) Does the WPS show the electrode that could be qualified by the PQR – 001?
Answer: No, it should be E7018 or use the alternate electrode E7016 or E7015 (weld is
rejected) Ref: ASME IX, table QW-253 &Table QW-432

137) Check whether the A number provided in the WPS was correct or not?
Answer: correct (because A-No. 1 shall qualify for A-No. 2 and vice versa)
Ref: ASME IX, table QW-253 & QW- 404.5
138) Check whether the P-No. material used in PQR and corresponding was correct or
not?
Answer: correct
Ref: ASME IX, table QW- 442

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 FORM QW-482 FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
(See QW-200,1, Section iX, ASME Boiler and Pressure Vessel Code)

Organization Name WELDING COMPANY, INC By JOHN SMITH

Welding Procedure Specification No. SMAW - 001 Date 12/31/16 Supporting PQR No(s) PQR - 001
Revision No. 0

Welding Process(es): SMAW Type: MANUAL

JOINTS(QW-402) DETAILS
Joint design Singe V
Backing: Yes X No X
Backing Material (Type) Weld Metal
Refer to both backing amd retainers

X Metal Nonfusing Metal

Nonmetallic Other

BASE METALS (QW-403)

P-No. 1 Group No. 1 to P-No. 1 Group No. 1
OR
Specification and type/grade or UNS number A36
to Specification and type/grade or UNS number A36
OR
Chem. Analysis and Mech. Prop.
to Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/4 to 1.5 Fillet All
Maximum Pass Thickness <= 1/2 in. (13mm) Yes X No
Other

FILLER METALS (QW-404) 1

Spec. No (SFA) 5.1
AWS No. (Class) E7010
F-No 4
A-No 2
Size of filler metals 33/32" , 1/8" , 5/32"
Filler Metal product form Mild Steel, Cellulosic
Supplemental Filler Metal --
Weld Metal
Deposited thickness:
Groove 5/8"
Fillet All
Electrode-Flux (Class) --
Flux Type --
Flux Trade Name --
Consumable Insert --
Other --
 FORM QW-482 (back)

POSITIONS (QW-405) POST WELD HEAT TREATMENT (QW-407)

Position(s) of groove All Temperature range None
Welding progression: Up X Down X Time Range --
Position(s) of fillet: All positions Other --
Other

GAS (QW-408)
PREHEAT (QW-406) Percent composition
Preheat temperature, Minimum 50 °F Gas(es) Mixture Flow rate
Interpass temperature, Maximum --
Preheat Maintenance Yes, preheat during 5minutes Shielding N/A N/A N/A
Other Trailing N/A N/A N/A
(Continuous or special heating, where applicable, should be recorded) Backing N/A N/A N/A
Other N/A N/A N/A

ELECTRICAL CHARACTERISTICS (QW-409)

Filler metal
Other (e.g., Remarks,
Weld Current Wire Feed Energy or Travel
Comments, Hot Wire
Passes Process Classifi- Type and Amps (Range) Speed Power Volts (Range) Speed Addition, Technique,
Diameter Polarity (Range) (Range) (Range)
cation Torch Angle, etc.)

1 SMAW E7018 3/32" - 1/8" DCEP 40-70, 80-120 N/A N/A 26-29 2 - 51 ipm --

3/32" , 1/8" , 70-110, 90-

2-n SMAW E7018 DCEP N/A N/A 19-27 2 - 81 ipm --
5/32" 160, 130-210

Amps and vots, or power or energy range, should be recorded for each electrode size, position, and thickness,etc.

Pulsing current N/A Heat Input Max N/A

Tungsten electrode Size and type N/A
(Pure tungsten, 2% thoriated, etc.)
Mode of Metal Transfer for GMAW N/A
(Spray Arc, Short Circuiting Arc, etc.)
Other --

TECHNIQUE (QW-410)
String or Weave Bead String or weave
Orifice, nozzle, or gas Cup Size N/A
Initial and Interpass Cleaning (Brushing, grinding, etc.) Hand or power tools may be used
--
Method of Back Gouging Angle grinder
Oscillation --
Contact Tube to Work Distance --
Nultiple or Single Pass (per side) E-6010 SINGLE E-7018 MULTIPLE
Multiple or Single Electrodes --
Electrode Spacing --
Peening NO PEENING
Other
 FORM QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR)
(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Variables Used to Weld Test Coupon

Organization Name WELDING COMPANY, INC

Procedure Qualification Record No. PQR - 001 Date 12/31/16
WPS No. SMAW - 001
Welding Process(es) SMAW
Types (Manual, Automatic, Semi-Automatic) Manual

JOINTS (QW-402)

Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal and process used.)

BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407)

Material Spec. A516 Temperature No PWHT
Type/Grade, or UNS Number 70 Time --
P-No. 1 Group No 1 to P-No. 1 Gr 1 Other --
Thickness of Test Coupon 1/2" --
Diameter of Test Coupon N/A --
Maximum Pass Thickness --
Other --
-- GAS (QW-408)
-- Percent Composition
-- Gases Mixture Flow rate
--
Shielding -- -- --
FILLER METALS (QW-404) Trailing -- -- --
SFA Specification A5.1 Backing -- -- --
AWS Classification E7018 Other -- -- --
Filler Metal F-No 4
Weld Metal Analysis A-No 1 ELECTRICAL CHARACTERISTICS (QW-409)
Size of Filler Metal 1/8" Current DCEP
Filler Metal Product Form Low Hydrogen Polarity DCEP
Supplemental Filler Metal -- Amps. 100 and 125amps Volts 27 and 25volts
Electrode Flux Classification -- Tungsten Electrode Size --
Flux Type -- Mode of Metal Transfer for GMAW (FCAW) --
Flux Trade Name -- Heat Input --
Weld Metal Thickness 1/2" Other --
Other

POSITION (QW-405) TECHNIQUE (QW-410)

Position of Groove 1F Travel Speed 6ipm and 7ipm
Weld Progression (Uphill, Downhill) -- String or Weave Bead Weave
Other -- Oscillation 3d
-- Multipass or Single Pass (Per Side) Both
Single or Multiple Electrodes Single
PREHEAT (QW-406) Other --
Preheat Temperature 50°F --
Interpass Temperature -- --
Other -- --
 FORM QW-483 (Back)
PQR No PQR - 001
Tensile Test (QW-150)

Ultimate Total Ultimate Unit Type of failure

Specimen No. Width Thickness Area Load Stress (psi) and location
1 0.765" 1/2" 0.3825" 29.146.5 76,200 weld
2 0.758 1/2" 0.379 24824.5 65,500 Base
-- -- -- -- -- -- --
-- -- -- -- -- -- --

Guided-Bend Tests (QW-160)

Type and Figure No. Result

Face Bend Good
Face Bend 4 mm porosity is accep
Root Bend Good
Root Bend Good

Thoughness Tests (QW-170)

Impact Values
Specimen No. Notch Location Specimen size Test temperature Drop Weight Break (Y/n)
ft-lb or J % Shear Mils (in) or mm

-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
Comments

Fillet Weld Test (QW-180)

Result - Satisfactory: Yes -- No -- Penetration into parent metal: Yes -- No --

Macro-Results --

Other Tests

Type of Test Radiographic Test - Good

Deposit Analysis --
Other --

Welder´s Name JOHN SMITH Clock No WC-035 Stamp No. JS23

Test Conducted by NDT COMPANY Laboratory Test No LAB-252-TT-01

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 Boiler and Pressure Vessel Code.

Organization Cutech Arabia LLC, INC

Date 12/31/16 Certified By

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code.)
1
(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code.)