510 Open Exam C, Rev8

Open Book API 510 Practice Exam C
Rev. 8 10/06 DTM Enterprises Technical Training Division Page 1 of 13

281-330-9542 www.DTM-Enterprises.org
Questions 1 to 35 are OPEN BOOK and simulate the first half of the actual exam.

1. A welder has welded a performance test coupon in the 6G position; his coupon will be required to pass;

1. 2 bend tests.
2. 4 bend tests.
3. 8 bend tests.
4. 6 bend tests.

2. For a hole type IQI that has the designation number 15 the essential 2 T hole diameter must be;

1. 0.060
2. 0.030
3. 0.015
4. 0.045

3. In the pulse echo contact method of measuring thickness the velocity of the material being measured is a function of the
materials physical properties and is usually assumed to be a constant for a ________________.

1. its entire thickness
2. given class of materials
3. all ferrous materials
4. all non-ferrous materials.

4. When an examination to the requirements of Section V is required by the Code of construction it is the;

1. Responsibility of the plant inspector to establish nondestructive examination procedures.
2. Responsibility of the plant quality department to establish nondestructive examination procedures.
3. Responsibility of the examiner to establish nondestructive examination procedures.
4. Responsibility of the installer, fabricator or manufacturer to establish nondestructive examination procedures.

5. A welding procedure is being qualified for use with a vessel that will require impact testing; the coupon will be 4 inches
thick. How many Charpy specimens will be required total?

1. 9
2. 6
3. 3
4. 12

6. A vessel was placed in service on 1/15/60 with an original wall thickness of .875". It lost wall at an average rate of .005"
per year until 1/15/75. Service conditions have changed and this inspection, 1/15/96 the vessel has a present wall
thickness of .630". The previous thickness 5 years ago was .789". If the present rate of corrosion continues and the
retirement thickness is .525", what will be the retirement year of the vessel?

1. First quarter of 1997.
2. Second quarter of 1999.
3. Second quarter of 2001.
4. Last quarter of 1999.

7. A vessel is marked RT-3 this indicates that all welded joint efficiencies will be taken from Column B of table UW-12.
The vessel contains only Type 1 welded joints so all welds will have an E of?

1. .90
2. .85
3. .70
4. .65


8. A vessel is to be pneumatically tested to a pressure of 172.7 psi and this pressure has been adjusted for a stress ratio of
1.1666. The pressure which the vessel should be inspected at will be;

1. 104.6 psi.
2. 125.6 psi.
3. 157.0 psi.
4. 97.1 psi.

9. Densitometers shall be calibrated at least every ____ days during use.

1. 30
2. 120
3. 90
4. 45

10. A vessel shells governing thickness has been determined to be 4.5, it is mandatory that it be subjected to Charpy
Impact testing if it operates at a temperature of less than ___
o
F.

1. 100
2. 212
3. 120
4. -55

11. Local PWHT per API 510 specifies that the area to be heat treated shall extend for a given distance from the weld. What
would be the distance required for the local PWHT of a 10 inch .500" thick nozzle in a 3 inch thick shell?

1. 12 inches in all directions.
3. 1 inch in all directions.

12. When averaging a vessels corrosion over an area in which circumferential stress governs, the corrosion must be
averaged using ;

1. An 8 diameter circle.
2. The diameter of the vessel.
3. The most critical element in the corroded area.
4. The longitudinal weld involved.

13. A vessel has pitting in a small area; the area will fit in an 8 inch diameter circle with its center at the deepest pit. The
shell course has a minimum thickness of .740". The pits within the circle are more than 2 inches apart in any straight
line with the following depths;

#1 .385 #2 .301" #3 .235" #4 .287", this area cannot be ignored because;

1. The pits are too many in number.
2. The pits are too close together.
3. The square inches of the pits exceed 7 square inches.
4. One of the pits is too deep to allow averaging.

14. Name two types of water heaters.

1. Gas Fired and Electric.
2. Floating Head, U-Tube, and Fixed Tube Sheet.
3. Fixed Tube Sheet and Floating Tube Sheet.
4. Fixed Tube Sheet and Process Water Reheater.

15. While inspecting a vessel you discovered the cylindrical shell has corroded externally to a present thickness of .498" in
thickness at its thinnest point. The vessel's corroded outside diameter is 95.82" and its material has an allowable stress of
13,800 psi at 750
o
F. The vessel shell is seamless and it has met the spot radiography requirements listed in UW-12(d).
What will be the MAWP of the vessel?

1. 71.87 psi
2. 143.5 psi
3. 144.0 psi
4. 83.45 psi

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

16. (WPS) QW-402 J oints The following is true;

1. There are no mistakes.
2. The retainers have not been addressed.
3. The retainers and the joint design have not been addressed.
4. The joint design has not been addressed.

17. (WPS) QW-403 Base Metals the following is true;

1. The specification of the material has not been addressed and that is a mistake.
2. There are no mistakes.
3. In this category the fillet weld specifications needs to be addressed.
4. In this category the pipe diameter needs to be addressed.

18. (WPS) QW-404 Filler Metals There is no need to address the Flux Trade name because it applies to the following
process and not this one;

1. SAW
2. SMAW
3. GTAW
4. PAW

19. (WPS) QW-406 Preheat There (is/is not) a mistake because;

1. Interpass temperature has not been addressed.
2. Every thing required has been addressed.
3. Preheat maintenance is required for P No. 3 materials.
4. Preheat maintenance is never required for P No. 3 materials.

20. (WPS) QW-409 Electrical; what process below requires the tungsten electrode size to be filled in?

1. SMAW
2. GTAW
3. SAW
4. This term is undefined in Section IX.

21. (WPS) QW-410 In this box for the GMAW process the following information can be left out;

1. Type of weld bead string or weave.
2. Orifice or gas cup size.
3. Contact tube to work distance.
4. Tungsten electrode diameter.


22. When an owner-user chooses to conduct a RBI assessment, it must include a systematic evaluation of both the likelihood
of failure and the associated consequence of failure. This likelihood of failure assessment should be repeated whenever
what happens?

1. Each time equipment or process changes are made.
2. After it has been in service for 5 additional years.
3. If operations reports any significant upset in the unit.
4. Each time equipment or process changes are made that could significantly affect degradation rates or cause
premature failure of the vessel.

23. Preheat and controlled deposition welding, as described in 7.2.3.1 and 7.2.3.2, may be used in lieu of postweld heat
treatment (PWHT) where PWHT is inadvisable or mechanically unnecessary. Which of the following describes the
circumstances where an alternative to PWHT is allowed?

1. Preheating when notch toughness testing is not allowed and when notch toughness testing is allowed.
2. Preheating when notch toughness testing is not required and when notch toughness testing is required.
3. When the pressure vessel engineer has approved the technique or the API 510 A.I. has approved this method.
4. Preheating method when notch toughness testing is not required and controlled deposition welding when notch
toughness tests are required.









24. According to Section VIII the minimum NPS for a liquid relief valve is;

1. NPS 1
2. NPS
3. NPS 7/8
4. NPS

25. What temperature shall be used when calculating a pressure vessels MAWP?

1. Nominal.
2. Maximum that it can obtain by design.
3. Average through wall temperature.
4. The average temperature experienced over the entire vessels design.

26. Which of the following explains the closest that two isolated un-reinforced openings can be to each other without
reinforcement calculations being required?

1. 4 times their diameters.
2. 3-1/2 times their diameters.
3. The sum of their diameters.
4. There is no such requirement.

27. The required diameter of tell-tale holes for re-pads is?

1. Maximum NPS .
2. Minimum NPS .
3. Minimum NPS .
4. Maximum NPS

28. While inspecting a torispherical head it was discovered to have some severe corrosion and must be evaluated for
continued service. This corrosion occurs at a radius 33.256" from the exact center of the head. The shell diameter of the
vessel the head is attached to is 7'-0". To evaluate this head for continued service what is the greatest distance from the
center that the corrosion can be and still be allowed to use the formula for spherical shells given in Section VIII Div. 1 of
the ASME Code?

1. 67.2"
2. 48.0"
3. 33.6"
4. 84.0

29. If the head in problem number 28 corrosion cannot be evaluated using the spherical formula for shells, what shall be
done to evaluate it for continued service?

1. Use finite element analysis.
2. Average the corrosion over the area in an 8-inch diameter circle.
3. Use the formula from UG-32 for torispherical heads.
4. Call in a pressure vessel engineer per the API 510 Code.

30. The minimum throat dimension for a fillet weld as shown in Fig. UW-16 (c) of Section VIII Div.1 for a 1" thick nozzle
joined to a 2" thick head is;

1. .530"
2. .750"
3. .250"
4. 1.00

31. A wire type IQI is to be used in lieu of a hole type for a single wall source side radiograph, the thickness of the material
to be radiographed is 2.250" thick. What is the diameter of the wire that must be used to evaluate the image quality of
the radiograph?

1. 6
2. 8
3. 10
4. 12

32. The geometric unsharpness limitation for a material to be radiographed which is under 2" thickness is;

1. 0.030"
2. 0.020"
3. 1.0"
4. 0.0020

33. The inside surfaces of a vessel's shell have corroded down to a minimum thickness of .369". The original thickness was
.500". The vessel's new and cold inside diameter was 96 inches. What will be the internal dimension used to calculate
the vessel's MAWP?

1. 96.262".
2. 48.0".
3. 96.0".
4. 48.131".

34. Thickness measurement instruments are divided into groups which are _________________.

1. Flaw detectors with CRT readout, Flaw detectors with CRT and direct readout, and Flaw detectors with direct
readout
2. Flaw detectors with direct and CRT readout
3. Flaw detectors with CRT or Flaw detectors with direct readout
4. All flaw detectors are direct read out, one has a meter the other has a CRT display

35. What is the remaining life of a vessel corroding at a rate of 0.017 inch per year when the last inspection measured 0.638
inch and the minimum required thickness is 0.513 inch.

1. 4 years.
2. 10 years.
3. 6.34 years.
4. 7.35 years.

ANSWERS
ANSWER LOCATION OF ANSWER

1. 2 IX QW- 463.2 (d) & (e)
2. 2 V ART 2 TABLE T-233.1
3. 2 SE-797.2 4.3
4. 4 V ARTICLE. 1 T-150(b)
5. 1 VIII UG-84 (3 sets x 3 specimens =9)
6. 2 API 510 6.4
7. 2 UG-116 AND TABLE UW-12
8. 3 VIII UG-100 (d)
9. 3 V Art 2 T-262.1
10. 3 UCS-66(a)(1)(d)
11. 4 API 510 7.2.5(d)
12. 3 API 510 5.7(a) Second a
13. 4 API 510 5.7(b) Second b
14. 2 API 572 A.2.7
15. 3 VIII APPENIX 1 R o Calculations
16. 2 IX QW-255
17. 2 IX QW-255
18. 1 IX QW-254
19. 2 IX QW-255
20. 2 IX QW-256 box QW-409.12
21. 4 IX QW-255
22. 4 API 510 6.2
23. 4 API 510 7.2.3
24. 4 VIII UG-128
25. 2 VIII UG-20 (a)
26. 3 VIII UG-36 (c) (3)(c)
27. 1 VIII UW-15 (d)
28. 3 API 510 5.7(e)
29. 3 API 510 5.7(e)
30. 3 VIII UW-16 NOMENCLATURE
31. 4 V ARTICLE 2 TABLE T-276
32. 2 V ARTICLE 2 T-274.2
33. 4 UG -27 AND TEXT BOOK
34. 1 SE-797.2 6.1
35. 4 API 510 6.4


6. Metal Loss Calculation

.789 t Previous
-.630 t Actual
.159 Metal Loss

Short term corrosion rate

.159/5 yrs =.0318

Remaining Corrosion Allowance

.630 t Previous
- .525 t required
.105 Remaining C.A.

Remaining Life

.105/ .0318 =3.3 years Remaining Life

Next Inspection

The period between internal or on-stream inspections shall not exceed one half the estimated remaining life of the vessel
based on corrosion rate or 10 years, whichever is less. In cases where the remaining safe operating life is estimated to be
less than 4 years, the inspection interval may be the full remaining safe operating life up to a maximum of 2 years.

So present date plus 3.3 years, next inspection Second Quarter 1999

8. 1.1 x 157 =172.7 Psi

Visual inspection at not less than;

Test pressure/1.1 =172.7/1.1 =157 Psi

11. Post Weld Heat Treatment based on 3 thick shell.

Per API 510 7.2.5(d)

2 x 3 =6 in all directions.

13. Pit depth of the deepest pit =.385
Shell course t
min
=.740

.740/2 =.370 <.385


15. From Appendix 1:
t Ro
SEt
P
4 . 0
=

t =0.498
E =1.0
Ro =95.82/2 =47.91
S =13,800
P =?

28. API 510 5.7(h)

Diameter =80% of Shells Diameter
0.80 x 84 =67.2
Greatest distance must be with a radius not more the 67.2/2 =33.6

30. t
c
=not less than the smaller of or .707

t
min
=
.707 x .750 =.530
Lesser of .250 or .530
Use .250

33. 96/2 =48 Radius 48 + (.500-.369) =48.131
Wall loss

35. t
actual
- t
required
=.638 - .513 =.125 Remaining Corrosion Allowance =.125

Remaining Life = t actual - t required =.125/.017 =7.35 years
Corrosion Rate
=
=
) 498 . 4 . 0 ( 91 . 47
498 . 0 . 1 800 , 13
x
x x
P =
) 498 . 4 . 0 ( 91 . 47
498 . 0 . 1 800 , 13
x
x x
psi 04 . 144
7108 . 47
4 . 6872
=

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Open Book API 510 Practice Exam C

Rev. 8 10/06 DTM Enterprises Technical Training Division Page 1 of 13

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