API-510 Final Exam (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
 API-510 Final Exam (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) 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”
 API-510 Final Exam (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) 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
 API-510 Final Exam (Open Book)

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
 API-510 Final Exam (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) 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
 API-510 Final Exam (Open Book)

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
 API-510 Final Exam (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 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
 API-510 Final Exam (Open Book)

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
 API-510 Final Exam (Open Book)

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
 API-510 Final Exam (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
Backing: (yes) (no.) 37 1/2º ± 5º typical
Backing Material (Type): Weld
(Refer to both backing and retainers)

Metal Nonfusing Metal

Nonmetallic Other Root spacing: 1/16”
Root face: 1/8” Max

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.
 API-510 Final Exam (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
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 -- -- --
 API-510 Final Exam (Open Book)

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
 API-510 Final Exam (Open Book)

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

 API-510 Final Exam (Open Book)

44. A vessel is to under go a hydrostatic test after a repair. The vessel’s stress allowable at the test tempera-
ture is 15,000 psi and its stress allowable at its operating temperature is 13,800 psi. The vessel’s MAWP at
its design temperature is 125 psi. What will be the required test pressure at the top of the vessel?

1. 203.8 psi
2. 169.6 psi
3. 176.6 psi
4. 143.7 psi

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

1. 1.0
2. .85
3. .80
4. .90

46. A small exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand
an external pressure of 350 psi. The tubes have and O. D. of 2.0 inch and are 60 inches in length with a
wall thickness of .025 inch. What would be the approximate Factor A value for this combination of length
diameter and thickness of tube is?

1. .0056
2. .00055
3. .057
4. .10

47. An additional 4 inch nozzle was added to a pressure vessel and is similar to the one in Fig UW-16.1(i).
The minimum thickness of the nozzle is .377 inch and the shell minimum thickness is .750 inch. What is
the decimal value of the minimum throat required for each of two equal leg size fillet welds on this at-
tachment?

1. .235”
2. .267”
3. .250”
4. .750”

48. A cylindrical shell has a seamless hemispherical head on one end and a seamless ellipsoidal head on
the other end. The elliptical head is attached by a type 2 weld meeting the spot radiography requirements of
UW-11(a)(5)(b). The shell has a single longitudinal joint. All category A butt welds are type 1 with full ra-
diography applied. The vessel will require an MAWP of 50 psi . The material of the shell and head is SA-
515-Gr. 60. The allowable stress at the operating temperature is 15,000 psi. The heads inside diameter is
10'-0". What is the required thickness of the 2 to 1 ellipsoidal head?

1. .250
2. .235
3. .200
4. .1003
 API-510 Final Exam (Open Book)

49. You have received the following tension test results for a welding procedure, what is the ultimate
unit stress for these two specimens?

Specimen Width Thickness Area Ultimate Total Ultimate Unit

Load lb Stress
1 .750 .410 .308 22,600 ?
2 .748 .409 .306 25,800 ?

1. 1 = 72,380 2 = 83,314
2. 1 = 72,377 2 = 83,296
3. 1 = 73,377 2 = 84,314
4. 1 = 74,377 2 = 83,314

50. An engineer is evaluating a pressure vessel’s head for impact testing requirements based on an MDMT
to be marked on the vessel of 40oF. As part of the calculations required it has been determined that this
head will have a coincident ratio of 0.60, this will allow a further reduction of the MDMT exemption given
by figure UCS-66 of __oF.

1. 30
2. 50
3. 40
4. 35

Answer the following questions about the WPS and PQR (pages 3 to 6) from Captain Bob’s Welding.
Consider both the WPS and its supporting PQR when answering the questions.

51. (WPS) In the JOINTS (QW-402) section, the following statement is true;

1. There must be a sketch of the joint configuration to be used in production.

2. Any groove design is allowed in production.
3. The box is properly addressed and contains no mistakes.
4. Flux dam retaining is permitted.

52. (WPS) In the BASE METAL (QW-403) there is a mistake because the;

1. Pipe diameter is not addressed.

2. Group number is not addressed and it is a supplemental essential variable.
3. Fillet welds are addressed as ALL.
4. There is no mistake; none of the above is true, 1 &3 are for information only, number 2 is not
needed for this procedure because no impact tests are required of the weldment.

53. (WPS) In the TECHNIQUE (QW-410) should have addressed the following;

1. Travel speed.
2. Method of back gouging.
3. Nothing, it is perfect.
4. The length of groove.
API-510 Final Exam (Open Book)
API-510 Final Exam (Open Book)
API-510 Final Exam (Open Book)
API-510 Final Exam (Open Book)
 API-510 Final Exam (Open Book)

54. Which types of butt-welded joints are allowed to be used to construct vessels in lethal service?

1. A and D only.
2. A, B, C and D are permitted
3. 1 and 2 dependent upon Category.
4. Butt welds are not permitted in lethal service.

55. After rolling a plate into a cylinder designed for internal pressure it is measured for out of roundness;

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

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

56. During the internal inspection of a vertical vessel a minimum thickness reading of 1.270" was found on
a shell course. The Data Report reflects an original thickness of 1.50", and allowable stress at 600 degrees
of 14,500 psi, full RT, and a MAWP of 650 psi. The MAWP was based on retirement diameter of 49.02
inches after the corrosion allowance was expended; this yields a retirement thickness of 1.129 inches.
Inspection records indicate a corrosion rate of 0.025 inches a year. If the corrosion rate does not change
what is the maximum time before the next on-stream or internal inspection?

1. 5 years
2. 5.6 years
3. 10 years
4. 2.8 years

57. The inspection of bend tests for a welding procedure revealed an opening in the concave side of the
specimen, its greatest dimension was 3/32 of an inch and does not show any sign of a welding flaw. This
opening is not cause for rejection because:

1. It is less than 1/8 inch.

2. The opening is not caused by a flaw and it is less than 1/8 inch.
3. The code does not address this issue.
4. The welder had faulty equipment provided at the testing lab.

58. What is the lowest metal temperature permitted to pneumatically test a vessel per Section VIII Div. 1?

1. 30 oF.
2. 30 oF above MDMT.
3. 30 oF below MDMT.
4. There is no such requirement, it is only a recommendation.
 API-510 Final Exam (Open Book)

59. When performing standard dye penetrant examinations, the greatest temperature permitted for the part
to be examined is:

1. 250 oF
2. 600 oF
3. 125 oF
4. It doesn’t matter.

60. Regarding corrosion evaluation, for the purposes of determining whether a weld joint efficiency or the
surface remote from the weld governs in calculations the following must be true for this to be a considera-
tion;

1. The joints efficiency must be 1.0.

2. The joints efficiency must be less than 1.0.
3. The joints efficiency must be exactly .90.
4. The joint efficiency has no bearing on corrosion evaluations.

61. The following describes the location of corrosion as measured in a vessel shell with the following
dimensions and minimums:

 .700 inch thickness minimum for shell from original calculations

 Longitudinal joint E = .85.
 The thickness of the shell in the welded joint is .701 inch.
 The thickness 3 inches remote from the welded joint is .698 inch.

Using the rules for corrosion evaluation in API 510, the following conclusion can be made about the
evaluation of the vessel for its continued service with out repair;

1. The thickness at the weld governs calculations.

2. The thickness remote from the weld governs calculations.
3. No such rule exits in API 510.
4. Separate calculations will be required to determine which thickness governs.

62. A 2 to 1 ellipsoidal head has experienced uniform corrosion on its inner surface. To determine the
governing thickness and evaluate the head for continued service or the need for repair or derating we
would;

1. Calculate the required thickness of the knuckle region using the formula given in UG-32 of
Section VIII Div. 1.
2. Calculate the thickness required of the spherical portion of the head using the formula from UG 27
of Section VIII Div. 1 for a spherical shell.
3. Calculate the equivalent shell based on the heads inside diameter.
4. Calculate both 1 and 2 above to determine the need for repair or derating.
 API-510 Final Exam (Open Book)

63. A 2 to 1 ellipsoidal head has experienced corrosion in the central portion of the head and will require
calculations for continued service. Using the following information, what is to be used as the diameter of
the spherical segment when evaluating the corrosion?

 The vessel’s shell diameter is 96 inches

1. 96 inches
2. 76.8 inches
3. 80 inches
4. 38.4 inches

64. For calculating the required thickness of a standard torispherical head which has a corroded area in its
central portion, the head must be evaluated using a spherical shell calculation. What shall be used as the
radius of the dished portion in the calculation?

1. One half the shell’s inside diameter.

2. 80 % of the shell’s inside diameter.
3. The shell’s diameter.
4. The measured central portion of the head taken from its center and based on 80 % of the shells
diameter.

65. An ellipsoidal head has experienced corrosion at a radius 31 inches above the center of the head. The
head is attached to a shell that is 8’ in diameter using a type 2 weld that has been fully radiographed. This
corroded area may be considered within the spherical portion because the greatest distance allowed for this
calculation from the heads center is;

1. 76.8 inches
2. 38.4 inches
3. 80.0 inches
4. 40.0 inches.

66. A vessel shell has scattered corrosive pits caused by hydrochloric acid. The greatest pit depth found
excluding corrosion allowance is 0.333 inch deep in the shell, which has minimum required thickness of
0.521 inch. The sum of pit’s areas within an 8 inch diameter circle does not exceed 7 sq. inches. This pit
must be repaired because the limit of the pit depth in this situation is;

1. .1302”
2. .2605”
3. .3000”
4. .3250”

67. While inspecting a vessel you notice that there is corrosion that is general, but varies over an area of
the affected shell course, the vessel has an inside diameter of 88 inches. You wish to average this corrosion
for purposes of evaluation. Circumferential stress governs in this vessel, in inches what is the greatest
length that can be used to average this corrosion?

1. 40 inches
2. 39 inches
3. 29.33 inches
4. 88 inches
 API-510 Final Exam (Open Book)

68. What is the required thickness of a 60 inch I.D. cylindrical shell if:

It has and allowable stress at design of 17,500 psi.

The vessel's Category A and D Type 1 joints are fully radiographed. All Category B joints are Type 1
also and have been spot radiographed per UW-11(a) (5) (b).

The vessel MAWP must be 350 PSI at 450F. The shell will see 11 psi of static head at its bottom.

1. .6072”
2. .7388”
3. .7159”
4. .6266”

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

1. .5741”
2. .577”
3. 1.1432”
4. .2356”

70. A 3 ½” thick plate weld procedure test coupon must be tensile tested. This will require the cutting of
the test coupon into smaller pieces. The tensile testing machine is capable of pulling up to 1” thick speci-
mens. How many pieces will be required to for a complete test per Section IX ?

1. 6
2. 8
3. 2
4. 12

71. A round weld tensile specimen is tested and found to fail in the base metal at a load of 14,876 lb. The
specimen was measured before the test to have a diameter of .503 inches, the ultimate tensile strength of
this specimen is:

1. 74,878 pounds per square inch.

2. 18,829 pounds per square inch.
3. 235,185 pounds per square inch.
4. 74,380 pounds per square inch.

(Hint: The area of a circle is equal to 3.141 (Pi) times its radius squared)
 API-510 Final Exam (Open Book)

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

1. t = .3621 and gage pressure will be 169.3 psi

2. t = .875 and gage pressure will be 260.624 psi
3. t = .4234 and gage pressure will be 224.057 psi
4. t = .4234 and gage pressure will be 254.032 psi

73. During an internal inspection the following minimum thickness readings were taken on a vertical
vessel
Top Head Present = .235”
Shell Course Present = .225”
Bottom Head Present = .195"

This vessel has been in service for 6.5 years and all components had an original thickness of .250 inch. The
engineer calculated a minimum thickness of the top head to be .145" and the bottom head minimum
thickness to be .155" and the shell's minimum thickness to be .205". Based on the readings what is the
Corrosion Rate for the shell element?

1. .025” / year
2. .0023” / year
3. .020” / year
4. .00384’ /year

74. Pitting has been discovered to be localized in a small area of an ellipsoidal head. The depth of the pits
does not exceed half of the required wall thickness. A circle is drawn that takes in all the pits and its diam-
eter is 8 inches. The maximum area of all the pits in square inches to allow averaging is;

1. 8 square inches.
2. 6 square inches.
3. 7 square inches.
4. 5 square inches.

75. A cylindrical shell has been discovered to have uniform external corrosion. The shells original thick-
ness was 7/8 inch; it is presently .745 inch in thickness. The original O.D. of the shell was 30 inches. The
vessel operates at 650 0F with a stress allowable on the material of 15,000 psi. 100 % RT was performed
on the vessel. All joints are types 1. What is the vessel's present MAWP?

1. 760 psi
2. 772.13 psi
3. 766.88 psi
4. 382.10 psi
 API-510 Final Exam (Open Book)

76. A shell course is being replaced with the new course being 60 inches in inside diameter and 7/8 inches
thick. The vessel course material is SA-515 gr 60 plate at a design temperature of 750 0F the stress allowed
is 13,000 psi.. The vessel joints are all type 2 and the vessel is stamped RT-3. What is the MAWP of this
shell course?

1. 298.11 psi
2. 316.74 psi
3. 150.35 psi
4. 335.38 psi

77. A standard ellipsoidal head with a 1 ½” flange is attached to the bottom of a vertical vessel. The heads
inside diameter is 56 inches. The vessel has a total elevation of 100 feet. The elevation at this head to shell
joint is 5 feet. What amount of hydrostatic head must be considered for use in this head’s required thickness
calculation?

1. 41.135 psi
2. 41.909 psi
3. 41 psi
4. 41.69 psi

78. A torispherical head which can be calculated using UG-32 of Section VIII Div. 1 has an outside skirt
diameter of 84 inches and an inside knuckle radius of 6 % of its O. D. this means that the inside crown ra-
dius must be;

1. 42 inches.
2. 5.04 inches.
3. 84 inches.
4. 2.52 inches
 API-510 Final Exam (Open Book)

79. A vertical vessel has been determined to need de-rating to a lower MAWP. The new MAWP is based
on the engineer's calculations for pressure allowed on the top shell section listed below. The vessel has an
elevation of 55 feet to its very top. The following part MAWP is calculated to the bottom of the element
listed.

Bottom of top shell section, elevation 40.3 feet, P = 458.3 psi

What is the MAWP of this vessel at the top based on this calculation?

1. 439.6 psi
2. 440.8psi
3. 451.9 psi
4. 457.6 psi

80. A shell course is being replaced in an existing vessel made of SA-515 GR. 55 rolled plate. The shell
course will have a thickness of 1.25 inches and inside radius of 40 inches. The Data Report on the vessel
indicates the original design called for a joint E of 1.0, a MAWP of 675 psig at 450 degrees F and that the
MDMT required is 5 degrees F. Preheat to 200 degrees was used prior to welding. Postweld heat
treatment was performed also. The ratio of design stress to allowable stress is .90. What reduction in
MDMT can be taken for the ratio of design stress of .90?

1. 20 o F
2. 10 o F
3. 15 o F
4. 30 o F

81. A hydrostatic test is being performed on a vertical vessel with an elevation of 48 feet. The MAWP of
the vessel in its normal operating position is 225 psi. All RVs have been removed and the vessel is blinded
off from all other components. The gage will be installed at an elevation of 22.5 feet. What shall this gage
pressure be during the hydrostatic test at the 22.5’ elevation? The materials design stress allowed is 16,800
psi and the stress allowed at test temperature of 70 degrees F is 17,500 psi. H.H. is .433 psi per vertical
foot.

1. 362.6 psi
2. 351.0 psi
3. 339.9 psi
4. 315.7psi

82. During the internal inspection of a vertical vessel a minimum thickness reading of 1.270" was found on
a shell course. The Data Report reflects an original thickness of 1.50", and allowable stress at 600 degrees
of 14,500 psi, full radiography, and a MAWP of 650 psi. The MAWP was based on a retirement diameter
of 49.02 inches after the corrosion allowance was expended. Inspection records indicate a corrosion rate of
0.025 inches a year. If the corrosion rate does not change what is the maximum time before the next on-
stream or internal inspection?

1. 5.6 years
2. 10 years
3. 90 days
4. 2.8 years

1
83. A repair to a vessel is planned. The vessel is built of SA-516 grade 70 normalized materials. The
vessel operates at an MDMT of 38 oF. This vessel is in ordinary service and has thickness of 1.125 inch. It
will not receive postweld heat treatment. The coincident Ratio of stress is 0.90.? This vessel cannot be
exempted for impact testing per paragraph UG-20 (f) because;

1. SA-516 is not a P No. 1 material.

2. 38 oF is too low a temperature.
3. It exceeds the thickness limit for a curve A material.
4. It exceeds the thickness limit for a curve D material.

84. An exchanger has experienced internal corrosion of its tubes. The tubes are required to withstand an
external pressure of 350 psi. The tubes have and O.D. of 1.98 inch and are 88 inches in length with a wall
thickness of .025 inch. The value of L/Do is?

1. 44.44
2. .0225
3. 79.2
4. 4.44

85.Two nozzles are to be added to an existing pressure vessel’s shell which has a thickness of 1/4”
(0.250”). One nozzle’s finished opening is 2.5 in I.D. and the other is 2 in I.D., how close may these
nozzle’s centers be placed in the vessel wall without requiring reinforcement calculations?

1. 2.5 inches
2. 3 inches
3. 4.5 inches
4. 2 inches

86. A pressure vessel has been measured to have a minimum wall thickness of .235 inch after 5 years of
service. The vessel’s original wall thickness was .250. Its minimum allowable wall thickness is .195 inch.
How long until the next required inspection per API 510?

1. 13.3 years
2. 10 years
3. 5 years
4. 6 and 2/3 years

87 A vessel is undergoing a hydrostatic test after repair. The vessel is marked with an MAWP of 100 psig
at 750 oF. The materials allowable stress at operating temperature is 15,000 psi and its allowable stress at
test temperature is 17,500 psi. The visual inspection shall take place at;

1. 100 psi.
2. No less than the MAWP of the vessel.
3. 116.66 psi.
4. 106.66 psi
88. During an internal inspection a vessel’s shell was measured and found to have a remaining wall
thickness of .486 inches. It was last inspected 4 years ago. The retirement thickness of the vessel shell is
.475 inches and its previous thickness was .500 inches. Based on this data, per API 510 what is the
remaining corrosion allowance of the vessel?

1. 0.025"
2. 0.110"
3. 0.011"
4. 0.014"

89. A vessel is constructed of rolled and welded SA-516 gr. 70 steel plate. It is 96 inches in diameter with
a communicating chamber, which extends 18 inches below this horizontal vessel. This vessel is in water
service and operates at working pressure of 150 psi. What will be the gage pressure at working pressure as
read on a gage mounted on the bottom of the vessel’s communicating chamber?

1. 150 psi
2. 154.11 psi
3. 153.46 psi
4. 199.36 psi

90. A torispherical head was found to have minimum thickness of .523 inch. This head is attached by a
type 2 weld to a seamless shell. The category B welds meet the requirements of UW-11(a)(5)(b) and UW-
52. The heads material has an allowable stress at operating temperature of 14,800 psi. The head has an
O.D. of 36 " and an inside crown radius of 36". What is the welded joint's efficiency that attaches the head
to the shell?

1. 1.0
2. .85
3. .80
4. .90

Answer the following questions about the attached WPS and PQR (pages 5 to 8) from Excellent Welding.
Consider both the WPS and its supporting PQR when answering the questions.

91.(WPS) In the Joints QW-402 there is a mistake because;

1. Only metal is checked for backing type.

2. A root gap of 1/32” is too small.
3. There should be a drawing of the weld joint.
4. There are no mistakes.

92.(WPS) In base metals QW-403 the Group No is not important because;

1. The group numbers match.

2. P-No. 1 is only produced as group 2 material.
3. Impact tests have not been performed on the PQR.
4. Impact tests have been performed on the WPS.

3
93. (WPS) As regards Filler Metals QW-404 the SFA No. is;

1. Correct for an E-6010 electrode.

2. Required per QW-253.
3. SFA is not on the WPS or PQR forms.
4. Not required per QW-253.

94. (WPS) The correct F No. for E 6010 is;

1. 2
2. 3
3. 4
4. 6.

95. In corrosive service the wall thickness used in the MAWP calculations must be the actual
thickness as determined by the inspection, but must not be thicker than original thickness on the
vessel's original material test report or Manufacturer's Data Report ________________________.

Fill in the blank;

1. Plus twice the estimated corrosion loss before the next inspection.
2. Minus twice the estimated corrosion loss before the next inspection.
3. Minus three times the estimated corrosion loss before the next inspection.
4. Plus four times the estimated corrosion loss before the next inspection

96. A weld repair using the preheat and deposition welding methods described in the API 510 is to be
performed on a groove type repair in a vessel wall, and will require a welding procedure qualified
using notch toughness tests. What would be the allowed depth of repair if the procedure test
groove was 2 inches in depth?

1. 2 inches or more.
2. Less than 2 inches.
3. Not more than 1-1/2 inches.
4. Unlimited thickness would be permissible.
API-510 Final Exam (Open Book)

5
7
 97. Per Section VIII Div. 1 a P number 1 material is required to be post weld heat treated when it
exceeds what thickness at the joint?

1. 1”
2. 1-1/8” and has not had the required pre-heat applied.
3. 1-1/4” and has not had the required pre-heat applied.
4. 2”

98. According to Section IX of the ASME Code, which of the following is not required to be present
on the supporting PQR?

1. Weld coupon thickness.

2. Post-weld heat treatment applied or the lack of.
3. Joint design.
4. Welding process used to make the PQR weld coupon.

99. Per Section IX a 3/8” PQR coupon will support the following range of thicknesses in production.

1. 1/16 to 3/4 inches.

2. 3/8 to 3/4 inches.
3. 3/8 to 1 inches.
4. 3/16 to 1 inches.

100 . In order to substitute 4 side bends for the required face and root bend tests the PQR coupon must be at
least what thickness?

1. 1”
2. 3/4”
3. 3/8”
4. 1/2”

100.What is the required holding time at normal PWHT temperature for P number 1 material with a
thickness of 3”?

1. 2-1/4 hours.
2. 2 hours.
3. 2-1/2 hours.
4. P number 1 material is not required to receive PWHT per Section VIII.

101. Per Section IX, the following number of tensile specimens is required on the PQR.

1. 6
2. 4
3. 8
4. 2

102.According to Section IX which of the following describes all the possible combinations for bends
tests.

1. Four face bends.

2. Four root bends.
3. Four side bends.
4. Two face and two roots or four side bends.

9
103.While attempting to PWHT a vessel's shell it is discovered that the equipment on hand cannot
reach the minimum temperature for the P No. 1 Group 3 material that the vessel is constructed of.
It is 2 inches thick at the location of heat treatment. If the vessel can be post weld heat treated at a
lower temperature, what is that lowest temperature?

1. 900 o F
2. 1000 o F
3. 950 o F
4. Lower temperatures are not allowed on P No.1 Group 3 materials.

104.Which of the following is the maximum out-of roundness allowance for a cylinder per ASME
VIII?

1. 1%
2. plus or minus 1%
3. 1.2%
4. 2”

105.If a 3 inch thick welded plate specimen must be impact tested what will be approximate required
absorbed energy requirement if it has a 55 ksi minimum yield strength?

1. 30 psi
2. 30 ft/lbs.
3. 27 psi
4. 27 ft/lbs.

106.What would be considered acceptable proof of having performed Charpy Impact tests on the part
of the manufacturer of steel plates per Section VIII Div. 1?

1. Shipment of the broken specimens with the plate.

2. Shipment of the broken specimens with the plate and certificates of compliance.
3. Shipment of reports or certificates of compliance from the manufacturer.
4. No proof is required beyond the invoice of the manufacturer listing impacts as having been done.

107.The set pressure for a relief valve set at 200 psi may not exceed;

1. 206 psi.
2. 200 psi.
3. 203 psi
4. 199 psi.

108.The maximum reinforcement on a circumferential butt welded joint made in a plate shell of 2
inches in thickness is;

1. 1/32 inch.
2. 1/4 inch
3. 1/16 inch.
4. 1/8 inch.
 109.The inner wall of a jacketed vessel has corroded down to 0.635 inch; the inner cylinder has a 45”
O. D. in this corroded state, its unsupported length is 120 inches. The vessel operates at an
external pressure of 175 psig and a temperature of 300 o F. The factor A has been calculated to be
.00085, using the CS-2 factor B chart what is the approximate value of Factor B?

1. 17,000
2. 14,500
3. 11,500
4. 9,500

110.A vessel owner is repairing a vessel by replacing a duplicate seamless ellipsoidal head, which is
butt welded to the shell. The name plate is marked RT-2, W and HT below the Code symbol. The
owner is allowed to use what type or types of butt welded joints to replace this head?

1. Any type permitted in Section VIII Div. 1

2. Type 1
3. Type 2
4. Type 1 or 2

111 . A vessel shell course was replaced on September 1st of 1982.

• The initial thickness was .378” on September 1st of 1982.

• The second reading for thickness was on September 1st of 1987 and was .364”.
• The last thickness measured was .345” in September 1st of 1992.

• Based on the most aggressive corrosion what is the value in mils per year to be used in
calculating the remaining life of the vessel?

1. 3.8 mils/yr
2. 5.15 mils/yr
3. 4.77 mils/yr
4. 3.3 mils/yr

112.. A shell plate made of SA-285 grade C is to be used in a repair of a vessel. What is the lowest
temperature that this plate may operate at without impact testing if it is 1.5 inches thick, will not receive
post weld heat treatment and has a 695oF maximum temperature and has coincident Ratio is 1.0?

1. 51 o F
2. 14 o F
3. 88 o F
4. 14 o F

11