API-510 Examination Preparation Course

Practice Exam #3 Open Book

1. What is the minimum permitted overlap when it is necessary to PWHT a vessel in
more than one heat due to length?
a)
b)
c)
d)

One foot
Two and a half feet
Five feet
Ten feet

2. When performing Charpy V-notch impact tests in accordance with ASME Section
VIII, Div.1, which of the following is correct?
a)
b)
c)
d)

The test shall consist of four specimens

The test shall consist of three specimens
The test shall consist of two specimens
The test shall consist of one specimen

3. What film side hole IQI designation would be required, using Gamma-ray
radiography, for examination of a weld repair in a vessel that is 0.875 thick?
a)
b)
c)
d)

10
20
30
35

4. A process vessel has the following characteristics: ID = 60, Efficiency = 1.0,

allowable stress = 17500psi, and design pressure (including static head) = 500psig. If
the vessel is uniformly corroded, what is the minimum required thickness of the shell
under design conditions?
a)
b)
c)
d)

0.857 inch
0.872 inch
1.714 inches
1.744 inches

5. During a turnaround, two 2-inch nozzles were added to a vessel. The vessel was
originally fabricated of 0.699 inch thick SA-387 Gr. 22 (P-5A material) plate. The
vessel was also PWHT for ASME Code compliance. Which of the following
statements apply to the heat treatment of this work?
a)
b)
c)
d)

The material prevents substituting preheat for PWHT

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

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
6

An unstayed flat head is to be replaced. Vessel records provide the following

information:
Arrangement is per Figure UG-34(b-1) of ASME Section VIII, Division 1 where:
d = 28 inches
P = 500psig (including static head)
S = 13800psi
E = 1.0
What is the minimum required thickness of the head after forming without a
corrosion allowance?
a)
b)
c)
d)

1.099 inches
1.685 inches
2.197 inches
2.384 inches

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

a)
b)
c)
d)

Upward or downward progression

Change in groove design
Decrease of over 100F in preheat
Addition or deletion of backing

8. A 48 inside diameter vessel has a nominal thickness of and the minimum

required thickness is 0.68. Inspection revealed, three pits in the vessel shell:
Pit #1
1.5X1/4X1/4 deep
Pit #2
1 diameter X 0.36 deep
Pit #3
X X 1/8 deep
The pits are all located in a six-inch diameter circle with the sum of their dimensions
along a straight line is 1.9375. Which of the following statements is true?
a)
b)
c)
d)

The pits are acceptable because small, widely scattered pits may be ignored
The pits are acceptable, based on their area, length, and depth
The pits are not acceptable in any circumstance
The pits are not acceptable, based on their length

9. What is the maximum permitted offset for a repaired Category B weld joint?
a)
b)
c)
d)

1/16
1/8
3/16
1/4

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
10. According to ASME Section VIII, Division 1, how long must radiographs taken
during fabrication and assembly of a pressure vessel be retained?
a)
b)
c)
d)

For five years

For the lifetime of the vessel
For a time not specified in the construction
Until the data report is signed by the Authorized Inspector

11. Of the following, which is not a requirement when the minimum specified tensile
strength of the filler metal, used for weld repairs, is lower than that of the base metal?
a) The thickness of the repair shall be increased by the ratio of the base metal
tensile strength to filler metal tensile strength
b) The repair shall be made with fewer than two 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)
b)
c)
d)

Ultrasonic
Radiography
Liquid penetrant
Magnetic Particle

13. What is the minimum design metal temperature that a vessel can be designed for if it
is fabricated from 1.125 thick non-normalized SA-516Gr.60 material without impact
testing?
a)
b)
c)
d)

-26F
2F
37F
75F

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)
b)
c)
d)

A
B
C
D

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
15. What is the minimum postweld heat treatment (PWHT) holding time for 3 SA-516
Gr. 70 material?
a)
b)
c)
d)

2 hours
2 hours 15 minutes
2 hours 30 minutes
3 hours

16. A seamless standard torispherical head with an inside crown radius of 64 inches
(1.63M) has a current thickness of 0.563 (8mm). The original MAWP was 125psi
(0.86MPa). The vessel has been in service for ten years. The operating parameters
will be lowered to 100psi and the vessel will be de-rated. The original head plate
thickness was 0.6875 (17.5mm), allowable stress (S) = 15,500psi, 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)
b)
c)
d)

0.430 inch (10.9mm) API-510 Paragraph 7.2.1

0.305 inch (6.2mm)
0.555 inch (14.1mm)
0.399 inch (9.3mm)

17. In a sour crude refinery, a carbon steel tray is removed from a fractionation tower
section that operates at 450F. The tray is thin throughout, and its Type 410 stainless
steel tray valves appear relatively uncorroded. Which of the following is most likely
responsible for the damage?
a)
b)
c)
d)

High temperature sulfidic corrosion

Naphthenic acid corrosion
Polythionic acid corrosion
Hydrochloric acid corrosion

18. What is the maximum acceptable out of roundness for a 50 ID vessel shell, unless a
detailed analysis is performed?
a) 1/8
b) 1/4
c) 3/8
d) 1/2
19. Magnetic Particle Examination (MT) is most effective when the:
a) current flow is 45 to the major axis of discontinuities
b) magnetic flux is parallel to the major axis of discontinuities
c) magnetic flux is 90 to the major axis of discontinuities
d) current flow is normal to the major axis of discontinuities

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
20. A nozzle has an opening diameter of 10 inches, and a nominal thickness of 0.375
inch. The vessel shell has a required thickness of 0.75 inch and a nominal thickness of
0.850 inch. Both the nozzle and the vessel materials are the same and there is no
corrosion allowance on this nozzle. What is the required area of reinforcement?
a)
b)
c)
d)

3.75 square inches

7.50 square inches
8.50 square inches
11.25 square inches

21. What is the maximum allowable continuous length of slag (elongated indication)
permitted in a radiograph of a repair weld in 1.25 thick plate for a vessel stamped
RT-1?
a)
b)
c)
d)

0.312
0.333
0.417
0.750

22. The density of step wedge comparison films and densitometer calibration shall be
verified by comparison with a calibrated step wedge film traceable to which of the
following?
a)
b)
c)
d)

Film certified according to ASME Section V

An ASTM certified wedge
An ASNT certified procedure
A national standard

23. A sphere has an ID of 80 feet, the material of construction is A-516 Gr. 70 (allowable
stress = 20000psi), the weld 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)
b)
c)
d)

1049psi
105psi
176psi
2099psi

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

radiograph?
a)
b)
c)
d)

Minimum source-to-object distance

Geometric unsharpness
Material type
Single or double wall exposure

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
25. The repair of a pressure vessel involves replacement of a seamless ellipsoidal head
using a single welded butt joint with a backing strip that will be left in place. What is
the joint type of the head to shell weld?
a)
b)
c)
d)

1
2
3
4

26. A pressure vessel shell, fabricated of SA-515 Gr. 70 plate, has a thickness of 1.125.
PWHT was performed though it was not otherwise required by Code. The ratio of
design stress to allowable stress is 1.0. What is the lowest minimum design metal
temperature that would not require impact testing?
a)
b)
c)
d)

7F
37F
45F
75F

27. A vessel with an ID of 54 has a corroded area of considerable size in which

circumferential stresses govern. The smallest measured thickness may be averaged
over a length of not more than:
a)
b)
c)
d)

18 inches
20 inches
27 inches
40 inches

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

The greater of one half inch or two times the minimum thickness
The greater of one inch or two times the minimum thickness
The greater of one inch or three times the minimum thickness
The greater of two inches or three times the minimum thickness

29. A pressure relief valve has a set pressure of 400psi. The valve is tested for accuracy
of set pressure before it is installed. What is the maximum acceptable test pressure?
a)
b)
c)
d)

400psi
402psi
412psi
420psi

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
A vertical vessel is to be re-rated for liquid full water service to a new MAWP. After
allowing for corrosion, calculations provided the following values without compensating
for head pressure.
Vessel part
Top
Top head
Upper shell cylinder section
Middle shell cylinder section
Lower shell cylinder section
Bottom head

Distance from vessel top

0 feet
4 feet
19 feet
34 feet
49 feet
53 feet

MAWP
725psig
736psig
731psig
745psig
743psig

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

a)
b)
c)
d)

712psi
716psi
720psi
724psi

31. The SMAW process is used to perform controlled deposition welded repairs to a
vessel that originally received PWHT. At what temperature must the weld area be
maintained?
a)
b)
c)
d)

350F 50F for a minimum of 1 hour after completion

350F 50F for a minimum of 2 hours after completion
500F 50F for a minimum of 1 hour after completion
500F 50F for a minimum of 2 hours after completion

32. A pressure vessel, in service for five years, has an annual corrosion rate of less than
0.004 inches. In order to permit an on-stream inspection in lieu of an internal
inspection, all of the following requirements must be met except that:
a)
b)
c)
d)

The vessel must not be strip lined or plate lined

No questionable condition is disclosed by periodic external inspections
The vessel will not be operated in excess of 500psi or 500F
The operating temperature of the vessel must not exceed the lower temperature
limits for the creep rupture range of the vessel material

33. What is the maximum upper range for a dial gage used during a hydrostatic test?
a)
b)
c)
d)

1.25 times the test pressure

1.5 times the test pressure
2 times the test pressure
4 times the test pressure

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
34. A pressure vessel is to be re-rated, the vessel nameplate is stamped RT-4 and the 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)
b)
c)
d)

542psi
620psi
659psi
775psi

35. How often should the black light intensity be check for the fluorescent particle
technique of Magnetic Particle examination?
a) Every 8 hours and whenever the workstation is changed
b) Every 4 hours and whenever the workstation is changed
c) Whenever the lights power source is interrupted and at the completion of the
examination
d) Whenever the lights power source is interrupted and at the end of each days
examinations
36. The ASME Code recommends that weld not be performed when the base metal
temperature is lower than:
a)
b)
c)
d)

0F
10F
32F
60F

37. Which of the following is an API-510 requirement for controlled deposition welding?
a)
b)
c)
d)

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

The weld area must be preheated to at least 425F
The vessel for repair must be constructed of P-5 or P-7 material
The vessel was originally post weld heat treated due to the characteristics of the
fluids contained in it.

38. For material thicknesses less than 2, what is the maximum geometric unsharpness
permitted when required by the referencing code?
a)
b)
c)
d)

0.01 inch
0.02 inch
0.03 inch
0.04 inch

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 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)
b)
c)
d)

300F (150C)
400F (205C)
500F (260C)
600F (315C)

40. What is the maximum density, in the area of interest, for gamma ray source
radiography?
a)
b)
c)
d)

1.3
1.8
2.0
4.0

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

qualification record.
41. Regarding the joint shown, the Welding Procedure Specification:
a)
b)
c)
d)

Includes all required information

Should specify uphill or downhill progression
Must show the weld layers
Should address the joint angle

42. Regarding the mechanical tests shown, the Procedure Qualification Record
qualifications:
a)
b)
c)
d)

Have not been met because one of the guided bend tests failed
Have not been met because on tensile test failed
Have all be met
Have not been met because face and root bends were not performed

43. Regarding the thickness range shown on the Welding Procedure Specification, a
correct statement is that the:
a)
b)
c)
d)

Upper limit could be eight inches

Lower limit could be 1/16 inch
Lower limit could be 1/8 inch
Range is accurate as shown

BAY Technical Associates, Inc.

API-510 Examination Preparation Course

Practice Exam #3 Open Book
Welding Procedure Specification (WPS)
Front
Company Name BAY Tech
By:
Chip Beaph
Welding Procedure Specification No. S21
Date 10/03/03 Supporting PQR No(s)
Revision No. 0
Date
--Welding Process(es) SMAW
Type(s)
Manual

S21

(Automatic, Manual, Machine, or Semi-Auto)

Details

Joints (QW-402)
Joint Design
Single V Groove
Backing: (yes)
(no.)
Backing Material (Type): Weld

37 1/2 5 typical

(Refer to both backing and retainers)

Metal
Nonmetallic

Root spacing: 1/16

Root face: 1/8 Max

Nonfusing Metal
Other

Sketches, Production Drawings, Weld Symbols or Written

Description should show the general arrangement of the
parts to be welded. Root spacing and weld groove details
may be specified where applicable
(At the option of the manufacturer, sketches may be attached)
The 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
OR
Specification type and grade
To Specification type and grade
OR
Chem. Analysis and Mech. Prop.
To Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal:
Groove:
Pipe Dia. Range:
Groove:
Other:
* Filler Metals (QW-404)
Spec. No. (SFA) 5.1
AWS No. (Class) E7018
Root
Balance
F. No.
A-No.
Size of Filler Metals 1/8 & 5/32

To P-No

.1875 to ,8640
All

Group No

Fillet:
Fillet:

All
All

Root

F-4
A-1

Balance

F-4
A-1

Weld
Metal
Thickness Range:
Groove .1875 to .8640
Fillet to 3/4 throat
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert
Other
*Each base metal - filler metal combination should be recorded individually.

BAY Technical Associates, Inc.

10

API-510 Examination Preparation Course

Practice Exam #3 Open Book
Welding Procedure Specification (WPS) (Back)
Positions (QW-405
Postweld Heat Treatment (QW-407)
Position(s) of Groove All
Temperature Range
None
Welding Progression: Up XX
Down XX
Time Range None
Position of Fillet All
Preheat (QW-406)
Gas (QW-408)
Percent Composition
Gas(es)
(Mixture)
Flow Rate
Preheat Temp. Min.
50 Deg. F
Interpass Temp. Max.
550 Deg. F
N/A
Preheat Maintenance
None
Shielding
(Continuous or special heating where applicable should be recorded)
N/A
Trailing
N/A
Backing
Electrical Characteristics (QW-409)
Current AC or DC
DC
Polarity
Reverse
Amps (Range) 90-220 Volts (Range)
(Amps and volts range should be recorded for each Electrode size, position, and thickness, etc
This information may be listed in a tabular form
Tungsten Electrode Size and Type
(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW

(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range

Technique (QW-410)
String or Weave Bead
Orifice or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrode
Travel Speed (Range)
Peening
Other:

Weld
Layers

Process

All
All

SMAW
SMAW

Grinding
N/A
N/A
Multiple
Single
Various
None

Filler Metal
E-7018
E-7018

BAY Technical Associates, Inc.

Steing and Weave

N/A
Brushing or grinding 1" Both sides of weld joint

1/8"
5/32"

Current
DCRP
DCRP

90-160
130-220

Volt
Range

Travel
Speed
Range

---

---

Other
(e.g. Remarks Comments, hot
wire addition, technique, Torch
Angle, Etc.

---

11

API-510 Examination Preparation Course

Practice Exam #3 Open Book

Procedure Qualification Report (PQR)

(QW-200.2 of Section IX, ASME B & PV Code)
Company Name
BAY Tech
Procedure Qualification Record Number
WPS Number
S21
Welding Process(es)
SMAW

S21
Type(s)

Date

10/03/03

Manual
(Manual, Automatic, Semi-Auto)

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)

Material Specification
Type or Grade
P-No.
1
Thickness of Test Coupon
Diameter of Test Coupon
Other

SA-516
Grade 70
to P-No.
1
.4320
Plate

Filler Metals (QW-404)

SFA Specification
5.1
AWS Classification
E-7018
Filler Metal F-No.
F-4
Weld metal analysis A-No.
A-1
Size of Filler Metal
1/8
Other
Deposited Weld Metal
.4320
Position (QW-405)
Position of Groove
Flat
Weld Progression (uphill, downhill)
Other
Preheat (QW-406)
Preheat Temp.
50 Deg. F
Interpass Temp.
550 Deg. F
Other

BAY Technical Associates, Inc.

Flat

Postweld Heat Treatment (QW-407)

Temperature
None
Time
Other
Gas (QW-408)
Percent Composition
Gas(es)
Mixture
Flow Rate
Shielding
N/A
Trailing
N/A
Backing
N/A
Electrical Characteristics (QW-409)
Current
Polarity
Amps
Volts
Tungsten Electrode Size
Other
Technique (QW-410)
Travel Speed
String or Weave Bead
Oscillation
Multiple or Single Pass (per side)
Single or Multiple Electrodes
Other

12

API-510 Examination Preparation Course

Practice Exam #3 Open Book

Specimen
No.
1

Width
0.996

1.002

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

Tensile Test (QW-150)
Ultimate
Ultimate
Total Load
Unit Stress
Thickness
Area
lb
psi
0.350
0.349
23250
66,620
0.350

0.351

24600

Type of
failure &
location
Base Metal

70,085

Base Metal

Guided Bend Tests (QW-160)

Type and Figure No.
Side Bend, QW-462.2
Side Bend, QW-462.2
Side Bend, QW-462.2
Side Bend, QW-462.2

Specimen
No.

Notch
Location

Notch
Type

Results
No Defects
No Defects
1/8 defect in heat affected zone
No Defect
Toughness Tests (QW-170)
Test
Impact
Lateral Exp
Temp
Values
% Shear
Mills

Drop Weight
Break
No Break

Fillet Weld Tests (QW-180)

Results -Satisfactory:
Macro - Results

Yes

No

Penetration into Parent Metal:

Yes

No

Other Tests
Type of Test
Deposit Analysis
Other
Welders Name
Slim Pickins
Clock No.
99
Stamp No.
SP
Tests conducted by:
BAY Tech
Laboratory Test No.
S21 1 & 2
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of Section IX of the ASME Code.
Manufacturer
Date:

10/03/03

BAY Technical Associates, Inc.

BAY Tech

Signature:

Chip Beaph

13

API-510 Examination Preparation Course

Practice Exam #3 Open Book

BAY Technical Associates, Inc.

14