API 653 PRE-COURSE STUDY GUIDE

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API 653 Questions

1. API publications necessarily address problems of what type?

2. API Standard 653 covers in service steel tanks built to what standards?

3. What API Standard always governs for tanks that have been placed in service?

4. API Standard 653 employs the design principles of what standard?

5. When design and construction details are not given and are not available in the standard to which the
in service tank was originally constructed, then details that will provide a level of integrity equal to the
level provided by the current edition of which standard must be used?

6. Who has the ultimate responsibility for complying with the provisions of API 653?

7. The inspection agency of the jurisdiction in which the above ground storage tank is operated is called
what?

8. An employee of an authorized inspection agency certified as an Aboveground Storage Tank Inspector

per API 653 Appendix D, is known as what?

9. What is the total metal loss divided by the period of time over which the metal loss occurred?

10. What is the definition of a “repair” to a tank?

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11. What must be done when the results of a tank inspection show that a change has occurred from the
original physical condition of that tank?

12. What must be done when the cone roof tank roof plates corrode to an average thickness of less than
0.09 inchs in any 100 square inches area?

13. What section of API 653 must be considered when changing the service of a tank to operation at
temperatures above 2000 F ?

14. What form of corrosion does not normally represent a significant threat to the overall structural
integrity of a tank shell unless it is present in a severe and numerous form?

15. When can widely scattered pits inside the tank shell be ignored?

16. A tank of single-butt welded with back-up bar construction, built to an unknown standard in 1940 is
inspected. Corrosion is general and an evaluation of the tank’s minimum thickness is required. What
joint factor would you use in your evaluation?

17. What can foundation settlement cause to appear in the shell of an AST.

18. Unless a stress analysis is performed, what is the minimum bottom plate thickness in the critical zone
of the tank bottom?

19. An AST operating at 2500F is evaluated for continuing service. The inspector checks the tank records
and finds that the tank was originally built of ASTM A516 Grade 60. What allowable stress should the
inspector use in evaluating the minimum thicknesses of the tank's shell?

20. A six year old storage tank is inspected. The tank has a diameter of 125 feet and its maximum liquid
level height is 40 feet. The tank was constructed of ASTM A-283 Grade C steel. The product stored in
the tank has a specific gravity of 0.85. The weld joint factor is 1. What is t min for the lower shell
course plates?

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21. An aboveground storage tank that has a diameter of 121 feet and a height of 40 feet (five eight foot
courses). Its bottom shell course has a thickness of 0.55” and a corrosion allowance of 0.1 inches. The
tank is built from ASTM A283 Grade C carbon steel. It has a joint efficiency of 0.85. The tank is to be
hydrostatically tested. Determine the hydrostatic test height. Round answer up to the nearest one
hundredth of a foot.

22. What is the risk of brittle fracture failure in continued service after a tank has demonstrated the ability
to withstand the combined effects of maximum liquid level (highest stresses) and lowest operating
temperature without failing … great, minimal, or average?

23. Using the Figure 5-2 of API Standard 653, determine the lowest temperature that a tank constructed
from carbon steel of unknown toughness may be used if its maximum shell thickness is 0.75 inches.

24. The external condition of storage tanks shall be monitored by close visual inspection from the ground
on a routine basis. This inspection can be done by owner/operator personnel, and can be done by
other than an Authorized Inspector. The interval of such inspections shall not exceed how many
months.

25. External ultrasonic thickness measurements of the shell, when used and when the corrosion rate is
not known, are taken at intervals not to exceed how many years?

26. Who assures the quality and completeness of NDE results obtained during a formal internal
inspection of a in service above ground storage tank?

27. The initial internal inspection interval for an aboveground storage tank shall not exceed how many
years (excluding RBI analysis)?

28. Name the three types of records the owner/operator is required to keep for AST’s.

29. If existing plates are to be used to reconstruct a tank, the plates shall be checked for what conditions?

30. New weld joint details on a reconstructed tank shall meet the welding requirements of what standard?

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31. Shell penetrations on reconstructed tanks shall be designed, detailed, welded and examined to meet
the requirements of what standard?

32. All repair work on an AST must be authorized by whom before commencement of work?

33. The minimum dimension for a replacement shell plate is?

34. Are lap patch shell repairs permitted at all in API 653?

35. Lapped patch plates shall not have a thickness less than how many inches?

36. What is the maximum vertical and horizontal dimension of a lapped patch repair plate per API 653?

37. What NDE techniques must be applied prior to application of a lapped patch shell repair. The areas
to be welded shall be checked for plate defects and remaining thicknesses.

38. When a reinforcement plate is used with a penetration, the minimum diameter of the insert plate shall
be determined how?

39. What is the minimum dimension of a welded-on patch plate that overlaps a bottom seam on a tank
bottom?

40. What is the maximum thickness of a welded-on patch plate that is used to make a bottom repair
within the critical zone?

41. What are some examples of a suitable non-corrosive material cushion that shall be used between an
old and a new tank bottom?

42. What method of repair is acceptable for external floating roofs?

43. What is the minimum height of tank liquid above a tank shell hot tap location during the hot tapping
operation?

44. Tanks and their structural attachments shall be welded in accordance with the processes specified in
which standards?

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45. May welding be performed during the reconstruction of a tank if the temperature of the base metal is
less than 32 0 F?

46. On a reconstructed tank, according to API Standard 653, reinforcement of new welds on all butt joints
on each side of the plate shall not exceed the following, for plate thickness < 1/2 inch, the maximum
reinforcement thickness for “vertical” joints is what?

47. During reconstruction of a tank shell with plate thickness 5/8 inch or less, misalignment in completed
vertical joints shall not exceed what dimension?

48. A reconstructed tank with a height of 36 feet and a diameter of 100 feet is checked for out-of-
plumbness. What is the calculated the maximum acceptable out-of-plumbness?

49. For ASTs, welding procedure specifications (WPS) and welders and welding operators shall be
qualified in accordance with what ASME standard?

50. The welder or welding operator's identification mark shall be hand or machine-stamped to along the
completed welds on reconstructed tanks. What is the interval spacing in feet?

51. For ASTs, NDT examinations shall be performed in accordance with which API standards.

52. What are you looking for when you check the immediate area of an addition of a reinforcing plate to
an existing penetration?

53. For ASTs, what NDE techniques shall be used to check completed welds attaching nozzle neck to
shell, and reinforcing plate to shell and to nozzle neck?

54. An inspector is responsible for inspecting a new shell plate that is joined to another new shell plate.
What inspection method(s) is/are required by API 653?

55. Upon completion of welding on a tank bottom, the plates and the entire length of new welds for tank
bottom plates shall be examined by what NDE technique to check for any potential defects and leaks?

56. Repaired vertical joints in existing shell plates shall have how many additional radiograph(s) taken at
each joint?

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57. What is the minimum number of radiographs required, when a new or replacement circular insert plate
is butt welded to the shell?

58. If you see a “R” on a radiographs and and on radiograph records of a repaired welds, what does the
“R” signify?

59. When a reconstructed tank and any tank that has undergone major repairs or major alterationsit shall
have a full hydrostatic test. How long is that hydrostatic test held (hrs)?

60. What steps and documentation is required by API 653 in order to exempt a major repair or major
alteration of a tank from hydrostatic testing?

61. When tanks reconstructed in accordance with API 653, what attachment is required to be attached to
the tank?

62. When should a monitoring program to determine the effects of settlement on storage tanks be
initiated?

63. What steps should be taken if at any time the settlement of a tank is deemed to be excessive?

64. When taking tank settlement readings internally across the bottom of a tank (tank is out of service),
what is the maximum spacing of the points along the tank diameters?

65. What type of settlement (more than all the others) should be evaluated to ensure the structural
integrity of the shell and bottom of the tank?

66. An API 653 inspector must satisfy the API criteria for education and experience. How many years
experience is required if the inspector has a high school diploma?

67. After an inspector has been certified, the inspector must demonstrate knowledge of revisions to API
653 after how many years from the inspector's initial certification date?

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API 650 Questions

1. API 650 covers material, design, fabrication, erection, and testing requirements for aboveground
welded steel storage tanks. Internal pressure allowed for these tanks approximates atmospheric
pressure. However, the internal pressures must not exceed what criteria?

2. What is the maximum temperature permissible for a “standard tanks covered by API 650, unless
additional requirements of Appendix M of API 650 are followed?

3. Appendix A provides alternative simplified design requirements for tanks where the stressed
components, such as shell plates and reinforcing plates. They are limited to a maximum nominal
thickness of what (inches)?

4. Who is responsible for complying with all of the provisions of API 650 when a new tank is built?

5. Required sections of this Standard become mandatory if the Standard has been adopted by
________________.

6. The lowest temperature considered in the design shall be assumed to be how many degrees
Fahrenheit above the lowest one-day mean ambient temperature of the locality where the tank is to be
installed?

7. Material used to construct a tank shall conform to the specifications of API 650. May other material
may be used?

8. Shell plates for API 650 tanks are limited to what maximum thickness?

9. A tank is to be fabricated using ASTM A-283 Grade C "killed" Material. The maximum thickness of the
lower two course plates is 3/4 inch. The tank is to be constructed in Las Vegas, Nevada. What
Minimum Design Metal Temperature could be used without impact testing?

10. An impact specimen is removed from a 1.25” thick ASTM A-516 Grade 55 plate. Three impact tests
are taken from the specimen. What average longitudinal impact value must the tests meet?

11. An aboveground storage tank is to be built in Mobile, Alabama. No other information is available.
What design temperature would you use for this tank?

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12. An aboveground storage tank’s bottom plates are 1/4 inch thick. They are single-welded lap-jointed.
The lap need not exceed how much?

13. The bottom course of a tank is made from 1 inch thick ASTM A-283 Grade C plate. The second
course of the tank is made from 3/4 inch thick plate. What is the minimum distance that a vertical
seam of the top course must be offset from a vertical seam of the bottom course?

14. In a butt-welded bottom, three plate joints shall be at least how many inches inches from each other
and from the tank shell.

15. Who specifies the design metal temperature, the design specific gravity, the corrosion allowance (if
any), and the design wind velocity for a new AST?

16. A tank is built from ASTM A-537M 1 (C-Mn-Si) normalized, quenched and tempered, killed fine-grain,
reduced carbon and TMCP steel. The welding is done by an automatic process. The purchaser
requires hardness testing of the welds. The tank diameter is 19.1 m. How many (if any) hardness
test(s) will be required for one circumferential weld?

17. A new AST is built. How far should the bottom sketch plates project beyond the outside of the shell
weld attaching the bottom to the shell plate? (These are not annular plates.)

18. Annular bottom plates shall have a radial width that provides at least how many inches between the
inside of the shell and any lap-welded joint in the remainder of the bottom?

19. An AST is to be designed using API 650. The tank is to be 50 ft diameter and 16 feet high (two 8 ft.
courses) No corrosion allowance is required. The stored liquid in the tank is a non-corrosive oil with
a 0.90 specific gravity. The material is ASTM A-285-C. What is the required thickness of the bottom
shell course?

20. An AST that is 100 feet in diameter is required by API 650 to have a minimum nominal shell thickness
of what )inches), even if the calculated thickness is less?

21. What is the minimum nominal width of shell plates (unless specified otherwise by the purchaser)?

22. What allowable design stress should be used when designing a new AST if it is constructed of
ASTM A-516 Grade 70 plate?

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23. The 1-foot method for calculation of AST shell thickness shall not be used for tanks larger than how
many feet in diameter?

24. Openings in AST tank shells larger than required to accommodate what size flanged or threaded
nozzle shall be reinforced?

25. How far must a reinforced NPS 10 nozzle be placed from the centerline of a non-stress relieved 0.75”
thick vertical butt-weld seam in the bottom course of the tank? The nozzle is located 3 feet up from
the bottom weld. The reinforcing plate of the nozzle is 0.75 inch thick and it is welded with a 0.5 inch
fillet weld around its periphery, and the nozzle welds have not been stress relieved.

26. A new AST is built. The tank is to be used to store a product that causes stress corrosion cracking
(such as amine). The thickness of the bottom shell plate is one inch (first shell course). The heat is
applied to the welds, but only 1025 F temperature can be obtained. How long must this temperature
0

be held on the bottom plate welds to obtain the desired results?

27. An AST has a diameter of 125 feet. Its maximum operating height is 40 feet. A 30 inch manhole is
installed in the tank. The corrosion allowance required by the purchaser is 1/8 inch. What is the
thickness required for a cover plate on this manway?

28. Reinforcement for an AST nozzle is provided in two segments. How many ¼ inch diameter telltale
holes are required?

29. A stiffening ring is placed on a tank. The ring is to be used as a walkway. How far below the top
angle of the tank should the ring be preferably placed?

30. What is the minimum thickness of roof plates on a new API 650 tank?

31. What is deemed sufficient to prove the quality of the plate steel furnished for fabrication of an AST?

32. When fabricating a new AST, the edges of the welds shall merge with the surfaces of the plate with
what “tolerance specification”?

33. A new AST, 40 feet high by 120 feet diameter, is checked for out-of-plumbness (top of shell to the
bottom of the shell). The inspector checks API 650 and finds the permissible out-of-plumbness must
not exceed what value (inches)?

34. The bottom course of a new AST, 120 feet in diameter by 40 feet high, is checked 1 foot above the
bottom to shell weld for out-of-roundness (radius tolerance). What is the maximum acceptable out of
tolerance?

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35.After construction of a new AST, who controls where the radiographic films shall be maintained?

36. Where is the nameplate of a new AST attached?

37. What is the maximum tensile stress used for designing a small AST according to Appendix A of API
650?

38. What joint efficiency is used for designing a small AST according to Appendix A of API 650 and using
spot radiography?

39. What is the required nominal thickness of deck plates of external floating roofs, unless otherwise
specified by the purchaser?

40. What is the minimum nominal diameter of a roof manhole on an AST’s external floating roof?

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API 575 Questions

1. The exterior surface of the tank bottom is known as the ________________.

2. What is a device that protects atmospheric storage tanks by maintaining the pressure difference
between the tank vapor space and the outside atmosphere to just a few ounces per square inch?

3. What is the most common type of atmospheric storage tank?

4. What is the purpose of a geodesic dome on a tank?

5. Why are atmospheric storage tanks generally inspected?

6. What is the prime cause of deterioration of steel storage tanks?

7. During the inspection of a tank, a section of the bottom is removed. Several globs of clay are found in
the pad. What would you suspect?

8. A tank that is supported above grade on a ringwall has its bottom exposed to the elements. As an
inspector, what would you do to prevent possible bottom corrosion?

9. What usually causes Internal corrosion of an atmospheric storage tank in the vapor zone?

10. Where is one of the most likely points and one of the potentially most critical points for a crack to
occur in a large storage tank?

11. If a pan type (single deck) floating roof has a plugged water draw off, what could be the most likely
consequence?

12. What API document provides requirements for inspection frequency?

13 An AST was built and put in service 1990. The minimum thickness of the bottom course was 0.35 inch.
The bottom course was constructed using a 0.5 inch thick plates. The tank was not inspected again
until 2006. The thickness of the bottom course was measured and found to be 0.42 inch. Determine
the corrosion rate and the calculated remaining life of the tank.

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14. What type of inspection provides another means of establishing suitability for continued service?

15. How should AST foundations should be checked for settlement?

16. Why should inspectors exercise great care when inspecting the roof of an insulated tank?

17. Coatings (paint, etc) may affect UT readings. What should be done?

18. A storage tank is used to store a product that must be kept warm (150+ degrees F). The product has
a high concentration of caustic and stress corrosion cracking is suspected because of caustic
embrittlement. Where would you look for cracks?

19. A riveted or bolted tank should have a number of random selected rivets or bolts checked for
tightness. How is this done?

20. If a fixed cone roof of a tank is suspected of being extremely thin, what precaution should an inspector
take to facilitate his inspection (beside using safety belts with attachments)?

21.---DELETED

22. Why do dry pyrophoric materials present a problem?

23. When statistical methods are used for assessing the probable condition of a tank bottom, what
controls the number of UT measurements taken?

24. What size coupon is recommended for removal from a tank bottom to check for underside corrosion?

25. When penetrating oil is sprayed on the outside shell to bottom weld for a test, what is this test called?

26. What is a method for checking for weld leaks in the bottom and in the shell?

27. Why is two pass welding recommended for seal welding leaking rivets?

28. How long should the AST records be maintained?

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API 577 Questions

1. What are the weldment requirements tasks prior to welding?

2. What are the materials requirements tasks prior to welding?

3. What are the quality assurance tasks during welding?

4. What are the appearance and finish tasks upon completion of welding?

5. Name two of the NDE personnel qualifications specified in ASME Section V, Article 1?

6. What are the six referenced welding processes mentioned in API 577?

7. What are the advantages and limitations of the SMAW welding process?

8. What are the three filler metal transfer modes in the GMAW welding process?

9. What are at least six types of essential variables that must be shown on the WPS?

10. What are four tests that can be found on the PQR?

11. What are the three steps used when reviewing a WPS/PQR ?

12. Where are the AWS Classifications found in ASME Section IX?

13. The A-number applies to which type of filler metals?

14. Where can ASME guidelines be found for the storage and handling of filler metals?

15. Direct visual examination is conducted when access is sufficient to place the eye within?

16. Name the five mechanical aids to visual examination?

17. For added sensitivity using MT which technique is recommended?

18. What are four of the requirements that apply to the PT method?

19. What are the common hole diameters of hole type IQI’s related to?

20. What are the two common radioactive sources used for RT?

21. When using the double wall technique for RT how many exposures are required when both
walls are superimposed?

22. What are four of the items that an interpreter of radiographs must possess?

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23. What are the three types of displays used with UT?

24. What is the purpose of the DAC?

25. What are the three types of automated ultrasonic testing?

26. The tip diffraction method is effective for sizing what type flaws?

27. What is a common leak testing method that is used during hydrostatic testing?

28. What items of inspection results are to be reported in an inspection report?

29. What effect does trace elements of carbon, sulfur and phosphorus have in a cast structure?

30. What are other terms for the rapid heating or cooling of a wrought material within certain
temperature ranges?

31. What is an important factor in the selection of shielding gases?

32. Materials with high thermal conductivity require higher or lower heat inputs to weld?

33. What are metals with a high coefficient of thermal expansion susceptible to?

34. Stress in relation to a tensile test is defined as?

35. Ductility is usually expressed as a percentage of the elongation within a _____ gage length.

36. Name three common hardness testing methods?

37. What is the meaning of 55 HRC?

38. What is an example of an in-service degradation that is hardness related?

39. What are six reasons for performing pre-heating?

40. What is the name applied to a notched bar impact test?

41. Materials are often impact tested at various temperatures to determine what?

42. What is the primary reason for PWHT?

43. Why is hardening of the weld and base metal HAZ are important in carbon and low-alloy
steels?

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44. How is hardenability determined?

45. What are the two types of material test reports?

46. What are the factors related to weldability?

47. What is the primary factor affecting weldability of metals and alloys?

48. What do steels having a CE between 0.35 – 0.55 require?

49. The simplest weldability tests are those that evaluate what?

50. The Lehigh Test evaluates what types of cracks?

51. What is the most common measure of weldability and susceptibility to hot cracking in
austenitic stainless steels?

52. Is distortion greater or less for austenitic stainless steel than for carbon steel?

53. Is it an advantage or disadvantage to apply preheating to nickel alloys when welding?

54. Hot tap and in-service welding operations should be carried out with what type electrodes?

55. What is the required liquid flow rate in piping when in-service welding is performed?

56. To minimize burn-through the first weld pass should be made with what diameter electrode?

57. What are the inspection tasks typically associated with hot tapping or welding on in-service
equipment?

58. What is the limiting factor for base metal thickness when welding with the GMAW-S
process?

59. What is the transfer mode for GMAW-S?

60. What are the five types of weld joints?

61. What do the first two XX’s stand for on the SMAW electrode identification system?

62. An electrode/flux identification is F7A6-EM12K. What is the identification of the flux?

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API 571 Questions

1. Brittle fracture affects what units and equipment?

2. What are the prevention methods for brittle fracture?

3. Where is atmospheric corrosion most severe?

4. What are prevention methods for atmospheric corrosion?

5. Corrosion under insulation (CUI) affects what equipment?

6. What are the inspection/monitoring methods to detect CUI?

7. What are the critical factors for chloride stress corrosion cracking?

8. How is chloride stress corrosion cracking inspected?

9. Where is MIC most often found?

10. How is the effectiveness of treatment monitored for MIC?

11. What are the affected units for caustic stress corrosion cracking?

12. How can caustic stress corrosion cracking be prevented?

13. The severity of soil corrosion is determined by what factors?

14. What is the most common method of monitoring underground structures for soil corrosion?

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15. An inspector is checking a tank that contains water bottoms and a hydrocarbon product that has been
neutralized by using caustic. He suspects there may be caustic corrosion. Where would be a likely
place for this to occur?

16. An inspector is checking a tank that contains a hydrocarbon product that has been neutralized by
using caustic. The tank has heating coils that contain steam at 325 0 F. The inspector suspects
caustic carryover in the product. Where would the inspector expect to find caustic corrosion or
damage?

17. Sulfuric acid promotes general and localized corrosion of carbon steel and other alloys. Where is the
most affected zones for severe corrosion in carbon steel?

18. What happens to the corrosion rate of carbon steel in sulfuric acid solution if your flow velocity is 5
fps?

19. When water is mixed with sulfuric acid what happens?

20. What is one good way to prevent sulfuric acid corrosion?

21. Is carbon steel more or less resistant to sour water corrosion?

22. What complication does the presence of “air” with sour water corrosion cause?

23. Is the corrosion damage from sour water corrosion typically general thinning or deep localized pitting?

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ASME Section IX – Welding

A good general knowledge of Section IX is required to evaluate the acceptability of a Welding Procedure
Specification (WPS), Procedure Qualification Record (PQR) and the Welders Performance Qualification
Record (WPQ). The actual examination is limited to the welding portion of the Code and to the following two
welding processes:

Shielded Metal Arc Welding (SMAW)

Submerged Arc Welding (SAW)

Evaluating welding documents require a thorough understanding of the following:

1. Essential Variables
2. Non Essential Variables
3. Supplemental Essential Variables
4. Mechanical Tests (Tension and Bend)

The examination will be based on the information contained in following articles:

Article I General Requirements.

Article II WPS/PQR
Article III WPQ
Article IV Supporting Data

The API 653 Body of Knowledge expects you to be able to review a Procedure Qualification Record and
a Welding Procedure Specification for correctness. The evaluation will be limited as follows:

No more than one process per WPS/PQR.

The welding processes will be SMAW and SAW
Each WPS will be supported by a single PQR.
The PQR shall be the supporting PQR for the WPS.
There will only be one filler metal per process.
Notch Toughness is not required so no supplemental essential variables will be evaluated
The base metals are limited to P-No’s 1, 3, 4, 5, and 8.
Dissimilar base metal joints and dissimilar thickness of base metals are excluded.
Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and
dissimilar metal welds with buttering of the ferritic member are excluded.
For P-No. 1, 3, 4, and 5 materials the lower transformation temperature is 1333 F and the upper
0

transformation temperature is 1600 F.

0

You will be given several sample WPS’s and PQR’s to review during the CodeWest course. The following
comprehensive quiz on ASME Section IX will help you prepare for that portion of the presentation.

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ASME Sec. IX Questions

1. If a performance qualification is made on a groove weld in a pipe over 24" in the 5G test position for
what position(s) is the welder qualified?

2. What is the purpose of the WPS and PQR combination?

3. The performance qualification of a welder/welding operator shall expire when no welding is

performed in the process for what period of time?

4. If a tension test specimen breaks in the base metal outside of the weld or fusion zone what are the
acceptance criteria?

5. When corrosion resistant weld overlay cladding is not a factor would a 1/16" open defect be
acceptable for a guided bend specimen?

6. What is the purpose of a WPS?

7. Pipe diameter is or is not an essential variable for a welder under the GMAW process?

8. Under what conditions can a PQR be revised?

9. Does procedure qualification on a 1-1/2" thick base metal qualify the procedure to be used to repair
groove welds and to make weld buildups on base metal thicknesses not exceeding 8"?

10. 1G and 6G are test positions or positions for which a welder is qualified to weld?

11. Groove design and retainers are essential variables for the SMAW process?

12. Can anyone supervise the welders making procedure and performance test coupons?

13. When are performance test coupons required to be visually examined?

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14. Are Base Metal specifications essential variables for a WPS in the SMAW process?

15. Can an existing PQR be used to support a newly written WPS?

16. Can organizations with two or more companies having different names exchange WPS's and
PQR's?

17. The WPS specifies a single V groove design. Can the PQR use a double V groove to qualify the
WPS?

18. For what processes and P-No.'s may welders be alternatively qualified by radiographic examination?

19. When an immediate retest is made following failure of the visual examination how many test
coupons are required for each position which failed?

20. If a welder has left the employment of an organization and has not welded for a period of five years
what are the qualification renewal requirements if he is rehired by the same organization?

21. If QW-404.15 is shown as a variable can a welder who has welded F-No. 4 filler metal without
backing also weld F-No's 3, 2 and 1 without backing?

22. Multiple reduced section specimens can be used for tension tests on thicknesses not exceeding 1
inch?

23. If QW-406.1 is shown as a variable and the preheat temperature qualified was 350 F, would a
0

preheat of 452 F require requalification?

0

24. When are longitudinal bend specimens permitted to be used?

25. What is the minimum specified tensile strength of the following base metals:

a) SA-53 Type F
b) SA336 Type F3V

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26. If a welder uses a P-No. 1 material for a qualification test coupon what base metals is he qualified to
weld?

27. Can a welder who has passed the required tests for groove welds make fillet in all thicknesses and
pipe diameters of any size?

28. What ASME Specification and F-No. is the filler metal E-6010?

29. What are the procedure qualification bend test requirements for a 3/8" test coupon?

30. Is the term N/A addressing and essential or nonessential variable of a WPS?

31. How many tension test specimens are required to qualify a welder?

32. If a 2-7/16" OD test coupon is welded by a welder what is the minimum and maximum outside
diameters qualified?

33. If a filler metal is A-No. 1 what elements must be shown on the analysis?

34. What is the specimen width of a tension test reduced section - plate?

35. A tensile specimen has a width of 0.75”, a thickness of 0.372” and an ultimate unit stress of 70,525
psi. What was the tensile machine ultimate total load in lbs.?

36. What is the minimum thickness of test coupon that qualifies a welder to weld the maximum
thickness?

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ASME Code Section V

The following articles fall within the scope of the examination and should be studied. Subsection B and all
Appendices are excluded except as noted.

Article 1 General Requirements

Article 2 Radiographic Examination.

Article 6 Liquid Penetrant Examination, including Mandatory Appendices II & III.

Article 7 Magnetic Particle Examination, only the prod and yoke methods apply.

Article 23 SE-797 Standard Practice for Measuring by Manual Ultrasonic Pulse-Echo Contact Method

In the day to day inspection activities nondestructive examinations are used and the API Inspector must have
both an understanding of the practical applications as well as the specific requirements.

It is not necessary for the API Inspector to have the in depth knowledge of an SNT-TC1A Level II Examiner
for the nondestructive methods but should know where in the ASME Code to find the requirements.

ASME SECTION V Questions

1. Which NDE methods are required to have written procedures?

2. To what standard are NDE personnel to be qualified if article 1 is referenced?

3. Describe how a check of backscattered radiation is performed?

4. What permanent identification must appear on the radiograph?

5. How is density monitored?

6. What is the formula for thickness when measured by the pulse-echo ultrasonic method?

7. What are the thickness and hole sizes for a number 30 IQI?

8. What are the two radiographic exposure techniques permitted by the Code?

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9. What are the two types of IQI’s?

10. What are the requirements for calibrating the densitometer?

11. What are the requirements for calibrating step wedge comparison films?

12. How often do you “periodic verify” that a densitometer is accurately working?

13. For single wall viewing source side markers shall be used on what components?

14. The IQI is normally placed on the

a. source side, or
b. film side

15. Where is the lead letter "F" placed when film side IQI’s are used?

16. A circumferential seam is to be radiographed as a single exposure, what are the minimum number of
IQI’s to be used?

17. When shims are used under the IQI, how many sides of the shim are required to be seen?

18. When viewing single film radiographs made with an X-ray source what is the minimum and
maximum permitted density?

19. A circumferential weld is required to be radiographed. The wall thickness is 7/16 inch and the weld
reinforcement is 1/16 inch. What source side IQI is required and what is the essential hole

20. Are intensifying screens permitted when radiography is done in accordance with Article 2 of ASME
Section V?

21. What is the allowable IQI alternate for a #17 IQI with an essential 2T hole?

22. What is the permitted density variation anywhere through the area of interest?

23. What is meant if you see a light letter “B” on the film?

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24. The initial PT procedure shall contain what information?

25. For standard thickness measurements what is the maximum temperature covered in SE-797?

26. For UT, what type screen is recommended where reflecting surfaces are rough?

27. What is the UT rule of thumb regarding apparent readings obtained from steel walls having elevated
temperatures?

28. Is it necessary to measure thickness from both sides of a material when using UT?

29. Up to what maximum temperature can materials be measured for thickness using UT?

30. Which UT calibration Case applies where a high degree of accuracy required for thick sections?

31. Where is the IQI placed when radiographing a weld?

32. When using penetrant materials on nickel base alloys, austenitic stainless steels and titanium what
certifications must be obtained?

33. What items are to be considered for a detailed UT procedure?

34. What information should be included in the UT report?

35. When are shims required to be placed under IQI’s?

36. Liquid penetrant examinations detect discontinuities that are:

a. near surface discontinuities b. surface discontinuities c. both a and b

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37. What are the essential variables that when changed in a PT procedure may require a new procedure
to be prepared?

38. List the two types of penetrants and the three basic penetrant processes?

39. Should thicknesses of UT calibration blocks be in round numbers or miscellaneous values?

40. What is the term penetrant materials meant to cover?

41. With MT the acceptance tolerance for the unit’s ammeter shall be that the reading shall not deviate
by more than 15% of full scale relative to the actual current value as shown by the test meter?

42. What is the penetration dwell time for Stainless Steel @ 50 degree F?

43. What is considered to be the standard temperature range for liquid penetrant examination?

44. How often should light meters be calibrated?

45. To remove excess penetrant after the penetration time has elapsed for the solvent removable
penetrant , what is the preferred method to use?

46. The magnetic particle examination method can detect:

a. near surface discontinuities b. surface discontinuities c. both a and b

47. Final interpretation of a PT examination shall be made within what time range after developer
application?

48. What are the two types of post emulsification penetrants?

49. PT indications will be evaluated in accordance with _______________?

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50. The written procedure for the magnetic particle examination shall contain what minimum
information?

51. List the five techniques for magnetic particle examination?

52. Each piece of magnetizing equipment with an ammeter shall be calibrated at what frequency?

53. What is the acceptance criteria for the lifting power of yokes when they are checked annually?

54. When MT examination is being performed, how many examinations per area are required?

55. When using dual search units if a wide range of thicknesses is to be measured which calibration
case is the most suitable?

56. What are the definitions of lipophilic and hydrophilic emulsifications?

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API 651 Questions

1. . An electrode of an electrochemical cell at which oxidation (corrosion) occurs is called what?

2. What is the name for the deterioration of a material, usually a metal, because of a reaction with its
environment?

3. How deep is a deep anode ground bed typically installed below the earth’s surface (ft)?

4. What the are four components in each corrosion cell?

5. What can the differences between weld metal, heat affected zones, and parent metal cause?

6. What is generally used to reduce or eliminate corrosion on the internal surfaces of aboveground storage
tanks?

7. . What is the measurable property of the soil that provides valuable information about the corrosivity of the
material used under and around a tank bottom?

8. Does a soil with a high resistivity measurement indicate that it will be very corrosive or not very corrosive?

9. If a tank with water bottoms leaks into the tank's cushion, what may happen to the environment under the
tank?

10. How does the installation of an impervious membrane lining under a tank bottom affect the effectiveness
of a cathodic protection system?

11. Are galvanic type cathodic protections installed on small or large diameter tanks?

12. What are some materials used for the anodes in an impressed current type cathodic protection system?

13. A successfully operating cathodic protection system can usually be determined by measuring the
minimum cathodic polarization between the structure surface and a stable reference electrode contacting
the electrolyte. The formation or decay of this polarization can be used in this criterion. This
measurement should be a minimum of how many volts?

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API 652 QUESTIONS

1. What is a mil, in inches?

2. A thick-film lining is a lining with a dry film thickness of _____ mils or more

3. What type of corrosion can occur on a steel tank bottom that has a corrodent, dissolved oxygen and
mill scale with breaks present?

4. What type corrosion occurs when a floating roof's support legs contacts the striker plate frequently and
continually removes the protective film from the plate and the bottom of the legs?

5. What can the presence of rocks or lumps of clay in contact with the underside of a steel tank bottom
cause?

6. What type of lining would you select, using Tables in API 652, 6.2, for foul water service and crude oil
at an operating temperature of 150 F?
0

7. What type of lining is preferred where internal corrosion has occurred?

8. What is the major cause of lining failure?

9. What is the recommended maximum relative humidity, before abrasive blasting is performed?

10. Holiday testing of thin-film tank bottom linings should be performed with a low-voltage (-_____ volts)
wet sponge detector.

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ANSWER KEYS

API 653
1. Special notes section
2. 1.1.3
3. 1.1.2
4. 1.1.3
5. 1.1.5
6. 1.2
7. 3.3
8. 3.4
9. 3.9
10. 3.25
11. 4.1.1
12. 4.2.1.2
13. 4.3.10
14. 4.3.1.3
15. 4.3.2.2
16. Table 4.2
17. 4.3.5.3 & 4.3.5.2
18. 4.4.5.4
19. 4.3.10.1.1(a)
20. 4.3.3.1

2.6H D G 2.6 x 40 x 125 x 0.85 11,050

tmin = --------------- = -------------------------------- = ---------------- = 0.468”

SE 23,600 x 1 23,600

21. 4.3.3.2

St E tmin 26,000 x 0.85 x 0.55

Ht = -------------- + 1 = ------------------------------- + 1 = 38.64 + 1 = 39.64 ft

2.6D 2.6 x 121

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22. 5.2.2
23. Fig. 5.2
24. 6.3.1.2
25. 6.3.3.2
26. 6.4.1.2
27. 6.4.2.1
28. 6.8.1
29. 7.3.4
30. 8.2.1
31. 8.5.1
32. 9.1.3
33. 9.2.2.1
34. 9.3.1
35. 9.3.1.3
36. 9..3.1.7
37. 9.3.1.9
38. 9.8.6 (b)
39. 9.10.1.1(a)
40. 9.10.1.2(a)
41. 9.10.2.1.1
42. 9.12.1
43. 9.14.1.2
44. 10.4.2.2
45. 10.4.2.3
46. 10.4.2.6 & Table 10.1
47. 10.4.4.1
48. 10.5.2.1
49. 11.1.1
50. 11.2.2
51. 12.1.1.1
52. 12.1.2.1
53. 12.1.2.3
54. 12.1.5.2
55. 12.1.7.1
56. 12.2.1.1 (c)
57. 12.2.1.6
58. 12.2.3.2
59. 12.3.1(a) & 12.3.1(b)
60. 12.3.2.2
61. 13.1.1
62. B.1.1
63. B.1.2
64. B.2.1, Fig. B.2
65. B.2.2.4
66. D.2.1
67. D.5.3

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API 650
1. 1.1.1
2. 1.1.1
3. 1.1.7
4. 1.3
5. 3.15
6. 3.6
7. 4.1.2
8. 4.2.1.4
9. Fig 4-2, 3.4
10. 4.2.9.3
11. 4.2.9.5, 3.4 & Fig. 4-2
12. 5.1.3.5
13. 5.1.5.2(c)
14. 5.1.5.4
15. 5.2.2
16. 5.3.4
17. 5.4.2
18. 5.5.2
19. 5.5.3 & Tab. 5-1b

2.6 D (H – 1) 2.6 x 50 (16 – 1)

td = ------------------- + C.A. = ------------------------ + 0 = 0.0975 + 0 = 0.0975”
Sd 20,000

2.6 D (H – 1) 2.6 x 50 (16 -1)

tt = -------------------- = --------------------- = 0.0866” normally you use the greater of td or tt ,but 5.6.1.1
St 22,500 says absolute minimum thickness of shell course
applies, so use 0.25”

20. 5.6.1.1
21. 5.6.1.2
22. Tab. 5-2b
23. 5.6.3.1
24. 5.7.2.1
25. 5.7.3.1(a)
26. 5.7.4.5
27. 5.7.5.1, 5.7.5.2 & Tab. 5-3b
28. 5.7.2.10
29. 5.9.4
30. 5.10.2.2
31. 6.2.1
32. 7.2.1.4
33. 7.5.2
34. 7.5.4
35. 8.1.8.2
36. 10.1.2
37. A.3.1
38. A.3.4
39. C.3.3.2
40. C.3.1

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API 575
1. 3.6
2. 4.2.2
3. 4.2.3
4. 4.2.3
5. 5.1
6. 5.2
7. 5.2.1
8. 5.2.1
9. 5.2.2
10. 5.4
11. 5.5
12. 6.1
13. 6.2
CORROSION RATE 1990 TO 2006

tprevious tactual 0.5" 0.42" 0.08"

CR 0.005" / yr
years between tactual & tmin. 1990 2006 16

REMAINING LIFE

tactual tminimum 0.42" 0.35" 0.07"

RL 14 yrs
corrosion rate 0.005" / YR 0.005" / yr

14. 6.3
15. 7.2.3
16. 7.2.7
17. 7.2.8.1
18. 7.2.8.3
19. 7.2.8.6
20. 7.2.9
21. DELETED
22. 7.4.2
23. 7.4.4
24. 7.4.4
25. 8.2.2
26. 8.2.4
27. 9.2.2
28. 10.2

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API 577
1. 4.2.2
2. 4.2.7
3. 4.3.1
4. 4.4.1
5. 4.6
6. 5
7. 5.2.2 & 5.2.3
8. 5.4.1, 5.4.2, 5.4.3
9. 6.2.1
10. 6.3
11. 6.4
12. 7.4
13. 7.5
14. 7.7
15. 9.3.1
16. 9.3.2.2
17. 9.4.1
18. 9.6.1
19. 9.8.2
20. 9.8.4
21. 9.8.8.3
22. 9.8.9.5
23. 9.9
24. 9.9.1.1
25. 9.9.6
26. 9.9.7.2
27. 9.11
28. 9.12.1.3
29. 10.2.1
30. 10.2.2
31. 10.2.3
32. 10.3.2
33. 10.3.4
34. 10.4.1
35. 10.4.2
36. 10.4.3
37. 10.4.3
38. 10.4.3
39. 10.5
40. 10.4.4
41. 10.4.4
42. 10.6
43. 10.7
44. 10.7
45. 10.8
46. 10.9
47. 10.9.1
48. 10.9.1
49. 10.9.2
50. Table 12
51. 10.10.1
52. 10.10.1
53. 10.10.2
54. 11.2.1
55. 11.2.2
56. 11.2.3
57. 11.2.4

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58. 11.3
59. 11.3
60. Figure A-1
61. Figure A-6
62. Figure A-9

API 571
1. 4.2.7.4
2. 4.2.7.6
3. 4.3.2.1
4. 4.3.2.6
5. 4.3.3.4
6. 4.3.3.7
7. 4.5.1.3
8. 4.5.1.7
9. 4.3.8.4
10. 4.3.8.7
11. 4.5.3.2
12. 4.5.3.6
13. 4.3.9.3
14. 4.3.9.7
15. 4.3.10.5(d)
16. 4.3.10.5(e)
17. 5.1.1.11.1
18. 5.1.1.11.3(c)
19. 5.1.1.11.3(d)
20. 5.1.1.11.6(c)
21. 5.1.1.10.2 (a) & (b)
22. 5.1.1.10.3 (h)
23. 5.1.1.10.5(a)

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ASME Section IX
1. QW-461.9
2. QW-100.1
3. QW-322.1
4. QW-153.1(d)
5. QW-163
6. QW-100.1, QW-200.1(a)
7. QW-355
8. QW-200.2(c)
9. QW-202.3(b)
10. QW-120
11. QW-253
12. QW-201 & 300.2
13. QW-302.4 & QW-194
14. QW-253
15. QW-201
16. QW-201
17. QW-212
18. QW-304
19. QW-321.1
20. QW-322.2(a)
21. QW-433
22. QW-151.1(a)
23. QW-406.1
24. QW-161.5
25. QW/QB-422
26. QW-423.1
27. QW-303.1
28. QW-432
29. QW-451.1
30. QW-200.1
31. QW-302.1 & QW-452.1
32. QW-452.3
33. QW-442
34. QW-462.1(a)
35. QW-152
36. QW-452.1(b)

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ASME Section V
1. T-150
2. T-120 (e)
3. T-223
4. T-224
5. T-225
6. SE-797, 4.1
7. Table T-233.1
8. T-271
9. T-233.1
10. T-262.1
11. T-262.2
12. T-262.3
13. T-275.1
14. T-277.1
15. T-277.1(b)
16. T-277.2(b)(1)
17. T-277.3
18. T-282.1
19. T-276.2(a) & Table T-276
20. T-232
21. Table T-283
22. T-282.2
23. T-284
24. T-621.1 & Table T-621
25. SE-797, 1.1
26. SE-797, 8.8
27. SE-797, 8.5
28. SE-797, 5.1
29. SE-797, 8.5
30. SE-797, 7.4
31. T-277.1(c)
32. T-641
33. SE-797, Section 9
34. SE-797, Section 10
35. T-277.3
37. T-621.2 & Table T-621
38. T-651
39. SE-797, 4.4
40. T-630
41. T-761(c)
42. Table-672
43. T-652
44. T-660
45. T-673.3
46. T-720
47. T-676.1
48. T-673.2
49. T-680
50. T-721.1 & Table T-721

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51. T-751
52. T-761(a)
53. T-762(b) & (c)
54. T-772
55. SE-797, 7.3.3
56. T-673.2 (a) & (b)

API 651
1. 3.2
2. 3.12
3. 3.15
4. 4.1.1
5. 4.1.3
6. 5.1.3
7. 5.3.1.2
8. 5.3.1.2
9. 5.3.1.5
10. 5.4.3.3
11. 6.2.1
12. 6.3.5
13. 8.2.2.1

API 652
1. 3.2.5
2. 3.31
3. 4.4
4. 4.7
5. 5.4
6. 6.2, Tab. 1
7. 6.3.1
8. 7.1
9. 7.4
10. 9.3.4

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