API 653 Tank Inspection Code - 04 PDF

26.
How many roof rafters must a plank cross over for inspection of the roof of a tank?
a.
b.
c.
d.
1
2
3
4
Section:
27.
The maximum acceptable undercutting on horizontal butt welds of a reconstructed

tank is _____ inch.
a.
b.
c.
d.
1/64
1/32
1/16
1/8
Section:
28.
Reference Publication:
The minimum number of settlement points around a tank periphery is

a.
b.
c.
d.
12
10
8
6
Section:
29.
A weld shall be acceptable by visual inspection if the inspection shows which of the
following?
a.
b.
c.
d.
The weld has no cracks, no undercutting, and less than 20% coldlap.
The weld has no cracks, undercutting is acceptable, and any surface porosity
does not exceed one cluster in any 2 of length and the diameter of each cluster
does not exceed 1/16.
The weld has no crater cracks or other surface cracks, undercutting is
acceptable, and any surface porosity does not exceed one cluster in any 3 of
length and the diameter of each cluster does not exceed 1/8.
The weld has no crater cracks, other surface cracks or arc strikes in
or adjacent to the welded joint, undercutting is acceptable, and any surface porosity
does not exceed one cluster in any 4 of length and the diameter of each cluster
does not exceed 3/32.
Section:
API 653 Exam Prep Homework #2 Questions Page 3
30.
Penetrameters (IQIs)are normally placed on the _____ of the part being examined.
a.
b.
c.
d.
source side
film side
weld side
obverse side
Section:
31.
External, UT measurements of a new tank shell shall be made not later than _____
years after commissioning.
a.
b.
c.
d.
5
4
3
2
Section:
32.
Penetrameter is another common term for

a.
b.
c.
d.
Thin film linings are usually used for application to

a.
b.
c.
d.
the bottoms of new storage tanks.

pitted bottoms of older storage tanks.
corroded bottoms of previous service tanks.
rough and pitted surfaces.
Section:
34.
flammable material
IQI
outside diameter
film holder
Section:
33.
With a horizontal sweep board 36 long, peaking shall not exceed _____ inch.
a.
b.
c.
d.
0.250
0.375
0.500
0.625
Section:
35.
If a welder tests in a 6G position, he qualifies to weld

a.
b.
c.
d.
all positions
uphill only
downhill only
vertical only
Section:
36.
An anode is
a.
b.
c.
d.
b.
c.
d.
The critical zone of the tank bottom is within the

a.
b.
c.
d.
no pit depth results in the remaining shell thickness being less

than 1/2t min acceptable tank shell thickness, exclusive of corrosion
allowance.
the average pit depth is greater than 1/2t min, exclusive of the corrosion
allowance
no pit depth is greater than 1/2t min, including the corrosion allowance
no pit depth is less than 1/2t min, including the corrosion allowance
Section:
Annular plate ring, within 6 of the shell or within 6 of the inside edge of the
annular ring.
Annular plate ring, within 10 of the shell or within 10 of the inside edge of the
annular ring.
Annular plate ring, within 12 of the shell, or within 12 of the inside
edge of the annular plate ring.
Annular or bottom plates within 3 inches of the inside edge of the shell.
Section:
39.
Widely scattered pits may be ignored, provided

a.
38.
an electrode of an electrochemical cell at which no corrosion occurs

an electrode of an electrochemical cell at which corrosion occurs
a chemical substance containing ions that migrate
a metallic connection that provides electrical continuity
Section:
37.
The space between the outer periphery of the roof and the tank shell of an external
floating roof tank shall be sealed by a flexible device that provides
.
a.
b.
c.
d.
a minimum 1/2 gap over no more than 24

an area of no more than 15 square inches opening calculated by measuring the
length and width of the gaps.
a reasonably close fit to the shell surfaces
a minimum of 3 openings 24 long with gaps no more than 1/4
Section:
40.
What is the minimum thickness for a tank floor plate with a > 0.05 or thicker reinforced
internal lining?
a.
b.
c.
d.
.005
.050
.075
.100
Section:
41.
A full hydrostatic test is always required on

a.
b.
c.
d.
o
600 F
o
135 F
o
400 F
Within the temperature range limitations set by the manufacturer
Section:
If a repair/modification weld is made on a tank shell plate that is thicker than 1, the
base metal within 3 inches of the welding shall be heated to a temperature of
approximately
degrees.
a.
b.
c.
d.
120o F
o
140 F
o
160 F
o
200 F
Section:
44.
What is the maximum temperature that dry MT can be used?

a.
b.
c.
d.
43.
a tank that has an annular plate installed with the longest dimension less than
12
a tank that has a door sheet installed
a tank that has a nozzle 12 NPS installed
a reconstructed tank
Section:
42.
What is the main factor in determining the efficiency of a rivet joint in a tank?
a.
b.
c.
d.
The allowable stress of the rivets

The number of rivet rows and type of joint
The allowable stress of the plate
Whether the joints have butt straps or not
Section:
45.
It is not necessary for the inspector to check which of the following?

a.
b.
c.
d.
All test results on the PQR

All essentials and non-essentials on WPS
All essentials and non-essentials on WPS and PQR
All non-essentials on PQR
Section:
46.
A new tank built in January, 1984, was removed from service and internally inspected
in January, 1994. The bottom course of the tank showed the most general corrosion (no
isolated corrosion was found). The original thickness of the bottom course of the tank was
1. The measured thickness of the bottom course at the inspection was 0.93. Determine
the yearly corrosion rate.
a.
b.
c.
d.
.0035
.0070
.0140
.0700
Section:
47.
5
10
15
20
Section:
The maximum spacing of settlement points is _____ feet around the circumference of
the tank.
a.
b.
c.
d.
40
35
32
25
Section:
49.
When the corrosion rates of a tank are not known and the bottom plate thickness can
not otherwise be determined, inspection(s) should be performed within the next _____
years of tank operation to establish corrosion rates.
a.
b.
c.
d.
48.
A 100 foot diameter tank must have at least _____ inch thick shell plates.
a.
b.
c.
d.
1/8
3/16
1/4
1/2
Section:
c.
d
1/16
1/8
Section:
Study Sheets
Based on API 653 Exam Information
The following is a collection of questions remembered by various students who took the API 653
Exam in the past.
This study sheet is designed to help a student prepare for the API 653 Exam. Read each
question carefully and select the best answer by circling your choice. After selection of your
answer, write in the section number and publication in which your answer was found. Look up each
question in the reference publications listed below; remember, this exercise is to help you to learn
to use the reference material. Generally, the assignment is broken into several sections. Each
section should take approximately one hour to complete. Answers will be discussed at the
beginning of class the following morning.
The answers will be found in the following reference publications:
API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, First
Edition, December, 2003
ATTENTION: Only the following mechanisms are included in the exam:
Par. 4.2.7 Brittle Fracture
Par. 4.2.16 Mechanical Fatigue
Par. 4.3.2 Atmospheric Corrosion
Par. 4.3.3 Corrosion Under Insulation (CUI)
Par. 4.3.8 Microbiologically Induced Corrosion (MIC)
Par. 4.3.9 Soil Corrosion
Par. 4.3.10 Custic Corrosion
Par. 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC)
Par. 4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)
Par. 5.1.1.11 Sulfuric Acid Corrosion
API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks, First Edition,
November, 1995
API RP 577, Welding Inspection and Metallurgy, First Edition, October, 2004
API 650, Welded Steel Tanks for Oil Storage, Tenth Edition, November, 1998, including
Addendum 1 (March, 2000), Addendum 2 (November, 2001), and Addendum 3
(September, 2003).
API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, Second
API RP 652, Lining of Above Ground Petroleum Storage Tank Bottoms, Second
API 653, Tank Inspection, Repair, Alteration and Reconstruction, Third Edition,
December, 2001, including Addendum 1 (September, 2003).
ASME Boiler & Pressure Vessel Code, 2004 Edition
Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and
23 (Section SE-797 only)
Section IX, Welding and Brazing Qualifications, Section QW only
51.
The letter B is placed on radiographic film holder for what reason?

a.
b.
c.
d.
To determine if back scatter radiation is exposing the film.

To show the distance from the source of radiation to the weld.
To function as a location marker for the radiograph.
To designate whether the penetrameter (IQI) is on the film side or the back side.
Section:
52.
A tanks bottom course has corroded in a general uniform manner (including the
welds). The tanks diameter is 137 and its height is 40 (5-eight foot courses). The liquid
stored in the tank is hydrocarbon with a specific gravity of 0.82 and it is not corrosive. The
tank was constructed from ASTM A-283, Grade C (A 283M, Grade C) carbon steel.
Determine the minimum thickness of the bottom course for full height operation. Round to
the nearest hundredth. (This tank was built to API 650, Eighth edition).
a.
b.
c.
d.
0.805
0.691
0.200
0.483
Section:
53.
When preparing to enter a storage tank for inspection, the most important thing to do
is
.
a.
b.
c.
d.
obtain a written entry permit

to have all equipment needed for inspection ready and available
to be wearing protective clothing
to check all platforms and ladders for serviceability
Section:
54.
A tank course made from 3/4 plate is welded with low hydrogen electrodes. The
welder undercuts a horizontal butt weld to a depth of 0.02 and he reinforces the weld with a
0.20 reinforcement.
a.
b.
c.
d.
The weld is acceptable

The weld is unacceptable because of the excess undercut
The weld is unacceptable because of the excess reinforcement
The weld is unacceptable because of the excess reinforcement and excess
undercut
Section:
55.
What is the inspection frequency for flame arrestors?

a.
b.
c.
d.
2 years
5 years
10 years
Annually
Section:
56.
How many tensile tests are required to qualify a 1/4 plate groove weld?
a.
b.
c.
d.
2
3
4
6
Section:
57.
0.10
0.05
0.125
0.0625
Section:
The oxygen content for non-permit required confined space must be __________.
a.
b.
c.
d.
0 - 10%
10% - 15%
19.5% - 23.5%
25.2% - 32.7%
Section:
59.
The minimum bottom plate thickness for a tank with an applied reinforced lining
greater than 0.05 thick, applied in accordance with API RP 652, is
inch.
a.
b.
c
d.
58.
The acceptance criteria for a radiograph of a tank repair weld is found in

a.
b.
c.
d.
Section V of the ASME Code

Section IX of the ASME Code
Section VIII of the ASME Code
ASNT SNT-TC-1A
Section:
60.
All leaks in pontoons or compartments of double deck floating roofs shall be repaired
by
.
a.
b.
c.
d.
caulking the leaking joints and/or using soft patch material

rewelding the leaking joints and/or the use of patch plates
cutting out the leaking area and flush patching
weld overlay any cracks and/or use soft patch material
Section:
61.
For what diameter tank is the variable point method for calculating shell thickness
mandatory?
a.
b.
c.
d.
Tanks with a diameter of 200 feet and greater

Tanks with a diameter greater than 300 feet
Tanks with a diameter greater than 200 feet
Tanks with a diameter of 300 feet and greater
Section:
62.
What is the minimum lifting power of an AC electromagnetic yoke used in magnetic

particle inspection?
a.
b.
c.
d.
40 pounds lifting power at the maximum pole spacing

10 pounds lifting power at the maximum pole spacing
10 amps lifting power at the maximum pole spacing
30 pounds lifting power at the minimum pole spacing
Section:
63.
What is the allowable edge settlement of a 100 diameter tank that has an area of
settlement that starts to slope 36 from the shelland the bottom lap weld is approximately
parallel to the shell?
a.
b.
c
d.
13.32
3.75
18.5
2.22
Section:
64.
A tank was constructed from welded ASTM A-516, Grade 60 (A 516M, Grade 415) steel.
The third course must be evaluated for continued service. What is the allowable stress that
must be used in the calculations?
a.
b.
c.
d.
21,300
25,560
28,200
28,320
Section:
psi
psi
psi
psi
65.
A 125 diameter X 40 high storage tank has questionable thickness annular plates.
The first shell course thickness is .61. The thickness of the corrosion allowance for the tank is
0.125. The product specific gravity is less than 1. What is the minimum thickness for the
annular plate?
a.
b.
c.
d.
0.17
0.20
0.325
0.295
Section:
66.
The principal advantage of thin-film linings are

a.
b.
c.
d.
5
10
20
25
Section:
Welders are qualified to what standard or code?

a.
b.
c.
d.
Section VIII of the ASME Code

Section V of the ASME Code
Section I of the ASME Code
Section IX of the ASME Code
Section:
69.
In no case shall the internal inspection interval of an aboveground storage tank

exceed _____ years, if an RBI program is not in place.
a.
b.
c.
d.
68.
better protection of older storage tank bottoms and ease of application

less susceptible to mechanical damage and easier to repair
lower cost and not as sensitive to pitting
lower cost and ease of application compared to thick-film coating
systems
Section:
67.
What is the maximum acceptable undercut of a nozzle to shell weld?

a.
b.
c.
d.
1/64
1/32
1/16
1/8
Section:
70.
The nameplate for a reconstructed tank shall be attached to the tank shell adjacent to
.
a.
b.
c.
d.
the existing nameplate

a manway in bottom tank course
the stairway or ladder to the tank roof
the door sheet
Section:
71.
When a welder has not welded with a process during a period of _____, his
qualifications for that process shall expire.
a.
b.
c.
d.
3 months or more
6 months or more
9 months or more
12 months or more
Section:
72.
What allowable stress is used in evaluating a riveted joint when using joint efficiencies
given in Table 4-3 of API 653?
a.
b.
c.
d.
16,000
18,000
19,000
21,000
Section:
73.
psi
psi
psi
psi
Radiographs of repaired work and records of radiographs of repaired work shall be

marked with
.
a.
b.
c.
d.
a grease pencil
the mark of the welder who made the repair
the letter R
the initial of the inspector
Section:
74.
The transmitted film density through the radiographic image of the body of the
appropriate hole penetrameter (IQI) and the area of interest shall be _____ minimum for
radiographs made with a gamma ray source.
a.
b.
c.
d.
1.8
2.0
2.2
2.6
Section:
75.
A tank has a corroded area on its second course. It is elliptical in shape with the major
axis parallel to the horizontal weld seam. The major axis dimension is 35 and the vertical
minor axis is 21. The tank diameter is 127 and its height is 40 (5-eight foot courses). The
minimum thickness measured in the corroded area is 0.52. The general thickness of the
second course (away from the corroded area) is 0.75. What is the maximum critical length
that can be used in determining the averaging out of the hoop stresses around the corroded
area. Round to the nearest 0.1.
a.
b.
c.
d.
40
36.1
30.1
28.1
Section:
Study Sheets
Based on API 653 Exam Information
Exam in the past.
November, 1995
(September, 2003).
76. What is the P number for the tank as listed above?

a.
b.
c.
d.
1.5
1
6
24
Section:
77.
If studs were installed on this tank, what polarity would have been used for the stud gun?
a.
b.
c.
d.
DECN
DECP
AC
No polarity
Section:
78.
5
5.1
5.29
5.42
Section:
What is the filler number for E-7018 electrodes?

a.
b.
c.
d.
1
2
3
4
Section:
80.
What is the SFA number for E 7018 electrodes?

a.
b
c.
d.
79.
What is the minimum acceptable shell plate thickness for the first course of T 3-27, if the
specific gravity of the stored product is 1.3? NOTE: current inspection (2003) based on
product alone, and full height operation.
a.
b.
c.
d.
.316
.500
.262
Not enough information given
Section:
81.
What is the hydrostatic test height of T 3-27 if the joint efficiency is .85 and the specific
gravity of the product is 1.3?
a.
b.
c.
d.
57.24'
40'
28.27'
Section:
82.
What is the minimum acceptable shell plate thickness for the top course of T 3-27 if each
course is 120" tall?
a.
b.
c.
d.
.1"
.062"
.269"
Section:
83.
What is the joint efficiency for T 3-27?

a.
b.
c.
d.
1
.85
.70
.35
Section:
84.
What is the corrosion allowance for T 3-27?

a.
b.
c.
d.
.185"
.125"
.0625"
Section:
85.
If T 3-27 was new, what would be the minimum first course thickness, based on product
alone?
a.
b.
c.
d.
.269"
.310"
.500"
Section:
86.
How many settlement points are required for an external settlement of T 3-27?
a.
b.
c.
d.
4
6
8
10
Section:
87.
A depression in the floor is discovered near the east manway of T 3-27. The diameter of
the depression is 96", the deepest point in the depression is 4". The area _________.
a.
b.
c.
d.
is rejectable.
is acceptable.
must be monitored.
can be filled in with epoxy and accepted.
Section:
88.
During the internal inspection of T 3-27, a patch plate welded to the floor, with a tombstone
shaped pad, extending to the inside of the shell was discovered. The plate had been
seal welded to the floor and shell, with a minimum dimension of 12 inches. The inspector
should _____________.
a.
b.
c.
d.
have the patch removed.

inspect the patch.
recommend removal of the patch and floor plates in the repaired area, replacing with
new floor plates.
this repair is in the critical zone and not allowed.
Section:
89.
During the same internal inspection of T 3-27, a square lap-welded patch was found over
an existing nozzle. The inspector should __________.
a.
b.
c.
d.
have the patch removed.

inspect the patch.
cut out the entire shell plate.
radiograph the patch for weld quality.
Section:
90.
T 3-27 has a hole, less than 1" in diameter, in the roof. Rain water does not contaminate the
stored product. Is a repair required by API 653?
a.
b.
c.
d.
A repair may be made by using duct tape.

Only if the owner requires the repair.
No
Yes
Section:
91.
What is the position designation for welding pipe in the horizontal fixed position?
a.
b.
c.
d.
2G
3G
5G
6G
Section:
92.
hour
2 hours
4 hours
8 hours
Section:
Terminology for weld metal in excess of the specified weld size.

a.
b.
c.
d.
Weld reinforcement
Good weld technique
Weld toe
Weld throat
Section:
94.
During a fluorescent MT test, the black light intensity shall be measured at least
once every
.
a.
b.
c.
d.
93.
If T 3-27 had a new nozzle installed in the third course, north side, could the shell-to-nozzle
weld be made using the oxyfuel welding process, if impact testing is not required?
a.
b.
c.
d.
Yes
No
The oxyfuel process is not allowed by ASME Section IX
Nozzle welds must be made using SMAW only
Section:
95.
A diesel oil test is required for ______________.

a.
b.
c.
d.
all new nozzle welds

all new floor welds
all new shell welds
all new shell-to-bottom welds
Section:
96.
The minimum PSIG for a vacuum box test is __________.

a.
b.
c.
d.
1
2
3
4
PSIG
PSIG
PSIG
PSIG
Section:
97.
A pipe welder is qualified to API 1104 only. What welds can he make on the tank if he
is qualified in the 6G position?
a.
b.
c.
d.
Nozzle Welds
Shell Welds
Floor and roof fillet welds
None
Section:
98.
A procedure is qualified on plate .500" thick. Which of the following thicknesses is not
qualified?
a.
b.
c.
d.
1"
1/2"
1/4"
1/8"
Section:
99.
A procedure is qualified on plate .500" thick. Four nick break specimens were substituted
for the four side bends.
a.
b.
c.
d.
The procedure is qualified.

ASME does not allow nick breaks.
Two tension specimens were required.
Nick breaks are used only on pipe.
Section:
100.
A welder is qualified in the 3F and 4F positions. Which of the following groove welds can
he make?
a.
b.
c.
d.
1G
2G
6G
None
Section:
This page intentionally left blank
Lap Patches
Considerations:
Does the owner prohibit the use of a lap patch? (Para. 9.3.1)
Will the repair prevent gas freeing the tank to perform hot work, at a later date?
(Para. 9.3.4.5)
Will crevice corrosion or a corrosion cell between the shell plate and repair plate
likely occur? (Para. 9.3.4.4)
An affirmative answer to any of the above is cause to stop planning on a lap patch. Since
the inception of API 653, Tank Inspection, Repair, Alteration, And Reconstruction, the fillet
weld lap patch has been prohibited, until the Second Edition, 1995, First Addenda, 1996.
The owner/user may now use paragraph 9.3, Shell Repairs Using Lap Welded Patch
Plates under certain conditions and size limitations.
The first 11 paragraphs apply to lap patches generally.
1.
The lap patch is considered a permanent repair and subject to ongoing inspection
and maintenance. (Para. 9.3.1)
2.
All the repair material must conform to the requirements of API 653, which will
reference API 650, Welded Steel Tanks for Oil Storage.
3.
A lap patch may not be used on any shell course thickness that exceeds 1/2 inch or
to replace doorsheets or shell plates. (Para 9.3.1.2)
4.
Patch plates may be from 3/16 to 1/2 inches thick, depending to the thickness of the
shell plate to be repaired. (Para. 9.3.1.3)
5.
The repair plate may be circular, oblong, square, or rectangular with rounded
corners, except at the shell to bottom joint. The radius of the corners shall be 2 in.
minimum. (Para. 9.3.1.4)
6.
The butt welded seams that are covered, by the patch, must be ground flush and
must over lap a minimum of 6 inches, use Figure 9-1 as a guide. (Para. 9.3.1.5)
Figure 9-1 is on the next page.
Notes on Patch Plates, 2003 Page 1
Figure 9-1 - Acceptable Details for Replacement of

Shell Plate Material
7.
Refer to Figure 9-2 for details on welding the lap patch to the shell to bottom joint.
Note: An internally installed patch must be located such that the toe-to-toe weld
clearances are a minimum of 6 inches to the shell to bottom weld. (Para. 9.3.1.6)
T
Tank Shell
3/16
Repair Plate
3/16
Trim repair
plate to clear
Shell-to-bottom
weld
8.
The maximum size of a patch plate is 48 inches by 72 inches, the minimum size is 4
inches. The patch shall be formed to the shell radius. (Para. 9.3.1.7)
9.
Shell openings and reinforcements shall not be positioned within a lapped patch
shell repair. (Para. 9.3.1.8)
10.
An ultrasonic inspection for laminations and other plate defects shall be performed
on the shell plate in the areas to be welded. (Para. 9.3.1.9)
11.
Repair plates shall not be lapped on lap welded shell seams, riveted shell seams,
other lapped patch repair plates, distorted areas, or unrepaired cracks or defects.
(Para. 9.3.1.10)
The next 5 paragraphs apply to the use of lap patches to close holes in the shell.
12.
A lap patch may be used for the closure of holes, where openings have been
removed or the removal of severely corroded/eroded areas, but there are special
requirements. (Para. 9.3.2)
13.
The weld shall be continuous on the inside and outside of the patch plate, the
removed opening must be at least 2 inches in diameter, a minimum corner radius of
2 inches is required for plate removal. (Para. 9.3.2.1)
14.
Nozzles and reinforcement pads must be removed entirely before the repair plate is
installed. (Para. 9.3.2.2)
15.
Repair plates, for opening repairs, shall be of a design that conforms to API 653,
using a joint efficiency not exceeding 0.70. All fillet welds shall be full (equal leg)
fillet welds. The overlap of the repair plate shall not exceed 8 times the shell
thickness, minimum overlap is 1 inch. The minimum repair plate dimension shall be
4 in. (Para. 9.3.2.3)
16.
The repair plate shall not exceed the nominal thickness of the shell plate adjacent to
the repair. (Para. 9.3.2.4)
The next 4 paragraphs apply to the use of lap patches to repair areas of thinned
shells due to deterioration.
17.
Lap patches may be used to reinforce areas of deteriorated shell plates and to
reinforce shell plates that are below retirement thickness. (Para. 9.3.3)
18.
The repair plate thickness shall be based on API 653, using a joint efficiency not
exceeding 0.35, the perimeter weld shall be full fillet (equal leg) weld. (Para. 9.3.3.1)
19.
The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker
repair plate than the existing shell plate is allowed. (Para. 9.3.3.2)
20.
The remaining strength of the deteriorated areas under the repair plate shall not be
considered as effective in carrying the calculated service or hydrotest loads.
(Para. 9.3.3.3)
The next 4 paragraphs apply to the use of lap patches to repair leaks or potential
leaks in the shell.
21.
Lap patches may be used to repair leaks or minimize the potential leaks form pitting.
(Para. 9.3.4)
22.
To install a lap patch over a leak, the existing shell thickness, excluding holes and
pits, must meet the minimum acceptable shell thickness (t min.). (Para. 9.3.4.1)
23.
The repair plate must be designed to withstand the hydrostatic pressure load
between the repair plate and the shell assuming a hole exists in the shell using a joint
efficiency of 0.35. (Para. 9.3.4.2)
24.
The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker
repair plate than the existing shell plate is allowed. A full (equal leg) fillet perimeter
weld is required. (Para. 9.3.4.3)
The last 3 paragraphs apply to safety warnings and inspection requirements of lap
patches.
25.
Do not use a lap patch if corrosion between the shell plate and repair plate is likely
to occur. (Para. 9.3.4.4)
26.
Do not use a lap patch if the repair plate will prevent gas freeing the tank to perform
future hot work, remember a penetration is not allowed in the patch. (Para. 9.3.4.5)
27.
Future inspection must be performed on the patch plates. (Para. 9.3.4.6)
Name:
API 653/650 Math Review Quiz

Answer each question, show all work, circle your final answer.
1.
Add: 1' 4 1/2" + 3' 5 11/32" + 10' 6 5/8" =
2.
Subtract:
3.
Solve:38" = ____ feet
4.
Express 7/16" as a decimal fraction _____
5.
Solve for A: A = 11 X 24 - (45 + 6)3
6.
What is the Square Root of 1849?
7.
What is the radius of a circle whose diameter is 182'?
287' - 3' 4 15/16" =
API 653 Math Review Quiz 01/05
Page 1
8.
What is the area of the circle in Question 7 ?
9.
10" = ____ mm
10.
1/4 = ____ mm
11.
200 = ____ m
12.
Solve for Z:
296 = 10(Z+6)
13.
Solve for t
t=
2.6 X 50 (41-1) X .85 + .125

20,000
Page 2
14.
Solve for t
t=
2.6 X 80 (30-1)
26,300
15.
An inspection is performed on an existing AST 67' tall, 190' in diameter with a fill height of
60'. What is the minimum thickness of the first course, based on product
alone, if the specific gravity of the product is .8?
16.
What is the minimum thickness of the fourth course of the tank in question
15, if each course is 5' high?
Page 3
17.
In performing a settlement survey on a tank 100 in diameter, what spacing

should be used for survey reference?
18.
What is the design first course thickness of a new tank that is 60' tall, fill height of 58',
diameter of 90', the material is A 516M Grade 485, the corrosion allowance is .125" and the
specific gravity of the stored product is 1?
Page 4
19.
What is the hydrostatic test first course thickness of the new tank in question 18?
20.
What is the annular plate thickness of the new tank in question 18, if an annular plate is
required?
Page 5
21.
What is the minimum thickness of the first course of an existing tank if the nameplate reads
as follows:
Height: 40'
Diameter: 60'
Year Completed: 1990
All Courses: A516-70
Specific Gravity: 1.3
Page 6
Name:

(Answer Key)
Answer each question, show all work, circle your final answer.
1.
Add: 1' 4 1/2" + 3' 5 11/32" + 10' 6 5/8" = 15' 4 15/32"

Solution:
2.
3.
4.
Subtract:
287' - 3' 4 15/16" = 283' 7 1/16"
Solution:
287' = 286' 11 16/16"

- 3' 4 15/16"
283' 7 1/16"
Solve:
38" = _3' 2" or 3.167 ___ feet
Solution:
(1' = 12")
38 12 = 3' 2" or 3.16'
Express 7/16" as a decimal fraction ___.438"__

Solution:
5.
1' 4 1/2" =
1' 4 16/32
3' 5 11/32" = 3' 5 11/32
10' 6 5/8" = 10' 6 20/32
14' 15 47/32" = 15' 4 15/32"
7/16 = 7 16 = .438"
Solve for A: A = 11 X 24 - (45 + 6)3

Solution:
A = 11 X 24 - (45 + 6)3
A = 11 X 24 - (51)3
A = 11 X 24 - 153
A = 264 - 153
A = 111
6.
What is the Square Root of 1849?

____
Solution:
1849 = 43
7.
What is the radius of a circle whose diameter is 182'?

Solution:
(Radius = Diameter 2)
R = 182 2 = 91'
API 653 Math Review Quiz 01/05 Key
Page 1
8.
What is the area of the circle in Question 7 ?

Solution:
9.
(Area of a circle = r2 )
A = (3.1416) (912 )
A = (3.1416) (8281)
A = 26,015.589 Sq. Ft.
10" = __254__ mm
Solution:
(1" = 25.4 mm)

10 X 25.4 = 254 mm
10.
1/4 = __6__ mm
Solution:
(1" = 25.4 mm)

.25 X 25.4 = 6.35 mm (API rounded to 6 mm)
11.
200 = __60__ m
Solution:
(1 = .3 m)
200 X .3 = 60 m
12.
Solve for Z:
Solution:
296 = 10(Z+6)
296 = 10(Z+6)
10
10
29.6 = Z+6
29.6 - 6 = Z + 6 - 6
23.6 = Z
13.
Solve for t
t=
2.6 X 50 (41-1) X .85 + .125

20,000
t=
2.6 X 50 (40) X .85

20,000
t=
4420
20,000
t=
.221 + .125
t=
.346
+ .125
+ .125
Page 2
14.
15.
Solve for t
t=
2.6 X 80 (30-1)
26,300
t=
2.6 X 80 (29)
26,300
t=
6032
26,300
t=
.229
An inspection is performed on an existing AST 67' tall, 190' in diameter with a fill height of
60'. What is the minimum thickness of the first course, based on product
alone, if the specific gravity of the product is .8?
Solution: Use the formula, Minimum Thickness Calculation for
Welded Tank Shell, from API 653, page 4-3, paragraph 4.3.3.1.
tmin= 2.6 (H-1)DG
SE
tmin= 2.6 (60-1) (190) (.8)
23,595 (1)
Values substituted
tmin= 2.6(59)(190).8
23,595
tmin= 23,316.8
23,595
tmin= .988"
16.
What is the minimum thickness of the fourth course of the tank in question
15, if each course is 5' high?
tmin= 2.6 (H-1)DG
SE
tmin= 2.6 (45-1) (190) (.8)
25,960 (1)
Values substituted
tmin= 2.6(44)(190).8
25,960
tmin= 17,388.8
25,960
tmin= .670"
Page 3
17.
In performing a settlement survey on a tank 100 in diameter, what spacing

should be used for survey reference?
Solution:
N = D 10
N = 100 10
N = 10
N = minimum required number of

settlement measurement points
C=D
C = (3.1416) (100)
C = 314.16
Perimeter of the tank
314.16 10 = 31.416 feet apart

API 653 requires no more than 32 feet between measurement points, an
additional point is not required.
18.
What is the design first course thickness of a new tank that is 60' tall, fill height of 58',
diameter of 90', the material is A 516M Grade 485, the corrosion allowance is .125" and the
specific gravity of the stored product is 1.?
Solution: Use the formula, 1-Foot Method
from API 650, page 3-7, paragraph 3.6.3.
td =
2.6 D (H-1) X G
Sd
+ CA
td =
2.6 X 90 (58-1) X 1
25,300
+ .125
td =
2.6 X 90 (57) X 1
25,300
+ .125
td =
13,338
25,300
td =
.527
td =
.652"
+ .125
+ .125
Page 4
19.
What is the hydrostatic test first course thickness of the new tank in question 18?
Solution: Use the formula, 1-Foot Method
from API 650, page 3-7, paragraph 3.6.3.
20.
tt =
2.6 D (H-1)
St
tt =
2.6 X 90 (58-1)
28,500
tt =
2.6 X 90 (57)
28,500
tt =
13,338
28,500
tt =
.468"
What is the annular plate thickness of the new tank in question 18, if an annular plate is
required?
Solution: Use the formula, in Table 3-1 and paragraph 3.5.3
from API 650, page 3-6.
Hydrostatic Test Stress =
2.6 D (H-1)
t
2.6 X 90 (58-1)
.652
2.6 X 90 (57)
.652
13,338
.652
20,457
1/4" required + CA (.125) = .375"
Page 5
21.
What is the minimum thickness of the first course of an existing tank if the nameplate reads
as follows:
Height: 40'
Diameter: 60'
Year Completed: 1990
All Courses: A516-70
Specific Gravity: 1.3
tmin= 2.6 (H-1)DG
SE
tmin= 2.6 (40-1) (60) (1.3)
30,000 (1)
Values substituted
tmin= 2.6(39)(60) (1.3)

30,000
tmin= 7,909.3
30,000
tmin= .264"
Page 6

(Useful Circle Formulas)
Area of a Circle = pi (3.1416) X radius2 or
A = r2
Circumference = pi (3.1416) X Diameter or
C = D
Radius = Diameter 2 or
R=D
2
Circumference
Diameter
Radius
Page 7

(API Metrics)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
11/16
3/4
13/16
7/8
15/16
1
=
=
=
=
=
=
=
=
=
=
=
=
=
6 mm
8 mm
10 mm
11 mm
12.5 mm
14 mm
16 mm
18 mm
20 mm
21 mm
22 mm
24 mm
25 mm
The above information taken from API 650, page 3-19.
Page 8
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1.
The liquid penetrant examination method is an effective means for detecting

1.
2.
3.
4.
2.
3.
Flat and horizontal

Horizontal and vertical
Flat and vertical
Vertical and overhead
A change in groove design

A change in backing
A change in post weld heat treatment
A change in electrode angle
A welder may be qualified by RT if

1.
2.
3.
4.
6.
provide direction for making production welds to Code requirements

provide direction for the welder to make temporary welds
provide direction for the inspector for inspection of the welds
provide direction for the welder to use as a general guideline
Which of the following is an essential variable for the WPS?

1.
2.
3.
4.
5.
Welding in the 3G position qualifies a welder in what positions?

1.
2.
3.
4.
4.
internal discontinuities of a weld

surface discontinuities of a weld
both internal and surface discontinuities of a weld
subsurface discontinuities of a weld
A WPS is a written qualified welding procedure prepared to

1.
2.
3.
4.
the welder uses SMAW

the welder uses GMAW Short Circuiting mode
the welder uses GMAW Short Circuiting mode root pass with SMAW fill and
reinforcement
the welder obtains approval from the inspector
A peripheral seal, on an internal floating roof, shall be designed to accommodate

of local deviation between the floating roof and the shell.
1.
2.
3.
4.
the manufacturer's standard

+ 4 inches
+ 1/8 inch
inspector's experience
Page 3
7.
What is the maximum allowable prod spacing using an AC prod technique?

1.
2.
3.
4.
8.
Welders shall be qualified in accordance with

1.
2.
3.
4.
9.
3.
4.
200oF
93 oF
both 1 and 1
50 oF
.
at the beginning of each shift

at least once a year or whenever the equipment has been subject to major
electrical repair
whenever the technician feels like it
at least once every 90 days
During calibration of an ammeter the unit shall not deviate by more than
scale.
1.
2.
3.
4.
13.
0.020
0.030
0.040
0.050
Each piece of magnetizing equipment shall be calibrated

1.
2.
12.
API 1104
ASME Section V
ASME Section IX
AWS D1.1
For measuring the thickness of materials using the contact pulse-echo method, temperatures
are not to exceed
.
1.
2.
3.
4.
11.
Geometric unsharpness of the radiograph of a component under 2" thick shall not
exceed
.
1.
2.
3.
4.
10.
t/2
8 inches
10 inches
No spacing required
of full
10%
20%
30%
40%
An inspector is evaluating a radiograph, a bright white image of a "B" appears on a darker

background of the radiograph,
.
1.
2.
3.
4.
the radiograph shall be considered unacceptable

the radiograph should not be rejected
the "B" is for identification of the welder
the "B" is for identification of the weld
Page 4
14.
Ultrasonic examination of hot tap connections or reinforcement is required by API 653

when
.
1.
2.
3.
4.
15.
in lieu of radiographic testing

searching for weld flaws
searching for laminations
requested by the welder
During an internal inspection of a tank, pitting that measures 0.30 inches deep was
found in the shell (0.625 Thickness). The required thickness of the shell in this area is
0.5 inches. Based on the above information should a repair be made?
1.
2.
3.
4.
Yes
No
The inspector option
Repair contractor's option
Page 5
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An inspection is performed on an AST 24' tall, 22' fill height, 94' diameter, water storage service,
earth foundation. There is one area of general internal corrosion on the south side of the shell 20"
wide and 20" in vertical length. There is evidence of bottom settlement.
16.
Calculate the minimum thickness of the first course based on product alone.
1.
2.
3.
4.
17.
Calculate the minimum thickness for the third course, if each course is 4' in height.
1.
2.
3.
4.
18.
Because the pits are aligned vertically no repair is required

Scattered pits may be ignored
If the pit is round, it may be ignored
A repair is required
Three circumferentially scattered pits are located on the west side of the tank 18" from
the bottom. The pits measure .500", .477" and .732" in diameter. Note: Assume pit
depth of one-half of the minimum acceptable tank shell thickness, exclusive of the
corrosion allowance.
1.
2.
3.
4.
21.
40"
12.68"
6.80"
11.75"
There are three pits aligned vertically on the north side of the tank, in the first course.
The diameter of the pits are 1.250", 1", and .500" in length along a vertical line 8" long.
N
Noottee:: Assume pit depth of slightly less than one-half of the minimum acceptable tank
shell thickness, exclusive of the corrosion allowance.
1.
2.
3.
4.
20.
.122"
.100"
.275"
.132"
Calculate the "L" length for an area of general corrosion found 10' from the bottom on
the south side of the shell, T2 =.125".
1.
2.
3.
4.
19.
1.175"
0.228"
0.551"
0.217"
Because the pits are scattered circumferentially no repair is required

All pits may be ignored
If the pit is round, it may be ignored
A repair is required
A bulge is found on the tank floor, the diameter of the bulge is 30". What is the
maximum permissible height for the bulge?
1.
2.
3.
4.
11.1"
.460"
.962"
1.11"
Page 6
22.
An area of edge settlement in the tank bottom 6' from the shell has sloped down and
settled. The settlement measures 2" at the deepest point. (The bottom lap welds are
approximately parallel to the shell).
1.
2.
3.
4.
23.
What is the hydrostatic test height of this tank based on a minimum thickness found in
question 16, as the controlling thickness?
1.
2.
3.
4.
24.
24
34.2
18.6
A depression is noted on a section of the bottom near the middle of the east quadrant.
The depression measures 5/8" deep, with a diameter of 36 inches. Should a repair be
recommended?
1.
2.
3.
4.
25.
A more rigorous stress analysis must be performed

The area should be repaired
Sloped edge settlement is usually no problem
The area should be documented and checked during the next inspection
Yes
No
The tank holds water, no problem
If the maximum liquid level in the tank were to be lowered by 5', what is the minimum
thickness of the first course?
1.
2.
3.
4.
1.73"
.166"
.200"
No change from original design thickness
Page 7
TThhee ffoolllloow
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Or
RTbc
RTip
StPr
UPr
=
=
=
=
=
26.
Using data from above, calculate MRT. (metal loss from the bottom side corrosion).
1.
2.
3.
4.
27.
removed
ground flush, with grinding direction parallel to the weld
ground flush, with grinding direction perpendicular to the weld
removed if irregularities mask discontinuities
40
36 - 2
32 - 8
31 - 6
For a single-wall material thickness, over 0.375" through 0.50", what is the hole-type
designation for a source side penetrameter?
1.
2.
3.
4.
31.
before
What is the hydrostatic test height of an in-service welded AST built to API 650, 8th
Edition, 82 diameter, 40 tall with a minimum first course thickness of 0.197. The material of
construction is A-516, Grade 70 (A 516M Grade 485).
1.
2.
3.
4.
30.
.250
.070
.002
.080
The weld ripples of reinforcement of butt-welded joints shall be

radiography.
1.
2.
3.
4.
29.
.250
.070
.002
.080
Using data from above, calculate MRT. (metal loss from internal corrosion).
1.
2.
3.
4.
28.
10 years
.200
.190
.002
.010
15
17
20
25
The temperature range to conduct a standard technique liquid penetrant examination

is
.
1.
2.
3.
4.
50oF to 135oF
50oF to 125oF
70oF to 115oF
50oF to 80oF
Page 8
32.
During an MT examination,
1.
2.
3.
4.
33.
5 lbs.
8 lbs.
10 lbs.
40 lbs.
5/16"
11/16"
3/8"
7/16"
A leak is noted 1 1/2 away from the shell-to-bottom weld in the floor of an existing welded
tank. The hole in the floor is 4 in diameter. What type of repair, in compliance with API
653, 3rd Edition, should be made?
1.
2.
3.
4.
37.
5 lbs.
8 lbs.
10 lbs.
40 lbs.
A new tank will hold a product with the specific gravity of 1.05; The corrosion
allowance is .10; The thickness of the first course is 1.25 inches; Hydrostatic test
stress 25,000 PSI. What is the thickness required for the annular plate? (Note:
Include corrosion allowance).
1.
2.
3.
4.
36.
A DC yoke shall have a lifting power of at least

1.
2.
3.
4.
35.
100% coverage at the required sensitivity

a calibration of each piece of magnetizing equipment
at least three separate examinations
prod spacing of at least 10"
An AC yoke shall have a lifting power of at least

1.
2.
3.
4.
34.
shall be performed on each area.
Use RBI. Because the product might not contaminate the soil or waterways, no
repair is required.
Weld build-up the area.
Install a tombstone shaped, welded-on patch plate, intersecting the shell-to-bottom
joint at approximately 90o.
Install a non-welded patch plate and fiberglass/epoxy to coat the area.
When using the SMAW process, a welder has changed from an F number 4 electrode to
an F number 3 electrode. Does the procedure need to be requalified?
1.
2.
3.
4.
Yes
No
Only if low hydrogen electrodes are used
API 650 allows this change
Page 9
38.
During a welder qualification test, for plate coupons, all surfaces (except areas
designated "discard") shall
.
1.
2.
3.
4.
39.
What is the hydrostatic test thickness for a new tank whose diameter is 150, and has a fill
height of 40? The shell material is A 36M.
1.
2.
3.
4.
40.
inches for
13
36
6 12
Piping is not addressed by any of the documents listed in the API 653 Body of
Knowledge.
Floating roofs on new tanks shall be sufficiently buoyant to remain floating after
1.
2.
3.
4.
43.
1/4"
3/16"
1/8"
1/16"
If piping near the tank enters the ground, the soil should be excavated
inspection.
1.
2.
3.
4.
42.
0.655
0.611
0.563
0.500
In order to comply with API 650, the finished surface of a weld reinforcement on plate
1/2" thick, horizontal butt joints, may have a reasonably uniform crown not to exceed
, for radiographic examination.
1.
2.
3.
4.
41.
show complete joint penetration with complete fusion of weld metal and base
metal
show no more than 1/3t inadequate penetration
show no more than 1/3t nonfusion
be allowed one 5/32" crater crack
Fifteen inches of rainfall in a 24-hour period

Ten inches of rainfall in a 24-hour period
Thirty inches of snow in a 24-hour period
Thirty inches of sand in a 24-hour period
A sudden rapid fracture under stress, where the material exhibits little or no evidence of
ductility or plastic deformation, is called
.?
1.
2.
3.
4.
brittle fracture
cavitation
atmospheric corrosion
caustic corrosion
Page 10
44.
Each floor scanning operator, who only use the bottom scanning equipment, shall receive a
minimum of
hours of training.
1.
2.
3.
4.
45.
8
12
20
40
Variables in the procedure that can be changed without having to re-qualify the procedure
and/or the scanning operators are
.
1.
2.
3.
4.
essential variables
non-essential variables
qualification tests
TBEQ
Q
whhiicchh
Prroocceedduurree w
RP
QR
PQ
S//P
PS
WP
Quueessttiioonnss 4466 tthhrroouugghh 5500 aappppllyy ttoo tthhee W
bbeeggiinnss oonn ppaaggee 1122..
46.
What is the root face limitation as listed on the attached WPS and PQR?
1.
2.
3.
4.
47.
If the supporting PQR is used, are the P-nos correct on the attached WPS?
1.
2.
3.
4.
48.
Yes
No
Requalification is required by API 570
Requalification is required by ASME V
Is the attached PQR properly qualified?

1.
2.
3.
4.
50.
Yes
No
Could be if properly preheated
Not enough information
Is the thickness range on the WPS supported by the PQR?

1.
2.
3.
4.
49.
3/32
1/8
No limit
Not designated
No, because RT is not allowed during PQR qualification

No, because there are not enough tensile tests
No, because peening is allowed by B31.3
Yes
What should have been the correct number and type of guided bends on the PQR?
1.
2.
3.
4.
6 side bends
2 face and 2 root bends
1 side, 1 face and 1 root bend
2 face, 2 root and 4 side bends
Page 11
QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)

(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)
Company Name: DLV WELDING, INC.
By: I.A. WELDER
Welding Procedure Specification No. S M A W - P 1
Date: 1 1 / 2 2 / 0 1 Supporting PQR No.(s) SMAW-P1-A
Revision No.
Date:
Welding Process(es): SMAW
Type(s): MANUAL
Automatic, Manual, Machine, or Semi-Auto
JOINTS (QW-402)
Joint Design
SINGLE VEE, ALL FILLETS
Backing (Yes)
(No) X
Backing Material (Type)
N/A
Details
(Refer to both backing and retainers)

Metal
Nonmetalic
Nonfusing Metal
Other
Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be
welded. Where applicable, the root spacing and the details of
weld groove may be specified.
3/32 1/8
(At the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g., for
notch toughness procedures, for multiple process procedures,
etc.)
*BASE METALS (QW-403)

P-No. 1
Group No. 1
to P-No.
8
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 .125 1
U
Pipe Dia. Range:
Groove UNLIMITED
Other: N
No pass greater than 1/2
Group No.
Fillet
Fillet
*FILLER METALS (QW-404)

SMAW
Spec. No. (SFA)
5.1
AWS No. (Class)
E-6010
F-No.
2
A-No.
1
Size of Filler Metals
3/32 1/8
Weld Metal
Thickness Range:
Groove
.250 max.
Fillet
ALL
Electrode-Flux (Class)
N/A
Flux Trade Name
N/A
Consumable Insert
N/A
Other SUPPLEMENTAL FILLER SHALL NOT BE USED
ALL
ALL
SMAW
5.1
E-7018
2
1
3/32 1/8
.750 max
ALL
N/A
N/A
N/A
*Each base metal-filler metal combination should be recorded individually
Page 12
2
2
E1
S
1
8
QW-482 (Back)
WPS No. SMAW-P1
POSITIONS (QW-405)
Rev.
POSTWELD HEAT TREATMENT (QW-407)
Position(s) of Groove
FLAT
Welding Progression: Up N / A
Position(s) of Fillet
Temperature Range
Time Range
Down N / A
NONE
GAS (QW-408)
PREHEAT (QW-406)
Percent Composition
Gas(es)
(Mixture)
Flow Rate
5 0o F
Preheat Temp. - Min.

Interpass Temp. - Max.
Preheat Maintenance
Shielding
Trailing
Backing
(Continuous or special heating where applicable should be recorded)
N/A
N/A
N/A
______
______
______
______
______
______
ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC
Amps (Range)
DC
70-160
Polarity
DCRP
Volts (Range)
19-30
(Amps and volts range should be recorded for each

position, and thickness, etc. This information may
be listed in a tabular form similar to that shown below.
Tungsten Electrode Size and Type
N/A
Mode of Metal Transfer for GMAW
N/A
(Pure Tungsten, 2% Thorated, etc.)

(Spray arc, short-circuiting arc, etc.)
Electrode Wire feed speed range
TECHNIQUE (QW-410)
String or Weave Bead
STRING OR WEAVE
Orifice or Gas Cup Size
N/A
Initial and Interpass Cleaning (Brushing, Grinding, etc.) HAND AND POWER TOOLS MAY BE USED
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrodes
Travel Speed (Range)
Peening
Other
N/A
N/A
N/A
E-6010 SINGLE
SINGLE
NONE
Filler Metal
Weld
Layer(s)
1
Process
Class
SMAW
E-6010
3/32 1/8
E-7018
3/32 1/8
BALANCE SMAW
E-7018 MULTIPLE
Dia.
Current
Type
Polar
DCEP
DCEP
Amp
Range
70-130
70-160
Volt
Range
Travel
Speed
Range
24-30 1 1/2 51PM

19-28 2-81PM
Page 13
Other
(e.g., Remarks, Comments,
Hot Wire Addition, Technique,
Torch Angle, Etc.)
QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)

(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Conditions Used to Weld Test Coupon
Company Name
DLV WELDING, INC.
Procedure Qualification Record No.
SMAW P1-A
WPS No.
SMAW P1
Welding Process(es)
SMAW
Types (Manual, Automatic, Semi-Auto.)
MANUAL
Date 1 1 / 2 2 / 0 1
JOINTS (QW-402)
3/32 1/8
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness will be required for each filler metal or process used.)
BASE METALS (QW-403)
POST WELD HEAT TREATMENT (QW-407)
Material Spec.
A-106 A-283
Type or Grade
C
P. No.
1
to P-No.
1
Thickness of Test Coupon
.500
Diameter of Test Coupon
N/A
Other
Temperature
Time
Other
NONE
N/A
GAS(QW-408)
FILLER METALS (QW-404)

SFA Specification
5.1
AWS Classification
E-6010
Filler Metal F-No.
2
Weld Meal Analysis A-No.
1
Size of Filler Metal
1/8
Other
Weld Metal Thickness
.250 max
7018
5. 1
E-7018
2
1
3/32
.500 max
Shielding
Trailing
Backing
Gas(es)
N/A
N/A
N/A
Percent Composition
(Mixture)
Flow Rate
_______
________
_______
________
_______
________
ELECTRICAL CHARACTERISTICS (QW-409)

Current
DC
Polarity
DCEP
Amps.
7 0 - 1 6 0 Volts
Tungsten Electrode Size
N/A
Other
19 - 30
POSITION (QW-405)
TECHNIQUE (QW-410)
Position of Groove
3G
Weld Progression (Uphill, Downhill)
Other
Travel Speed
1 1/2 8 IPM
String or Weave Bead
BOTH
Oscillation
N/A
Multipass or Single Pass (per side)
BOTH
Single or Multiple Electrodes S I N G L E
Other
PREHEAT (QW-406)
Preheat Temp.
Interpass Temp.
Other
UPHILL
5 0oF
Page 14
QW-483 (Back)
PQR No.
SMAW-P1-A
Tensile Test (QW-150)

Specimen
No.
Width
1.5
Thickness
.5
Area
.75
Ultimate
Total Load
lb.
97,900
Ultimate
Unit Stress
psi
Type of
Failure &
Location
77,484
BASE
Guided-Bend Tests (QW-160)

Type and Figure No.
1
2
3
4
SIDE BEND
SIDE BEND
FACE BEND
ROOT BEND
GOOD
GOOD
GOOD GOOD
POROSITY 1/16 DIA.
Toughness Tests (QW-170)

Specimen
No.
Notch
Location
Notch
Type
Test
Temp.
Impact
Values
Lateral Exp.
% Shear
Mils
Drop Weight
Break
No Break
Fillet-Weld Test (QW-180)

Result- Satisfactory:
Macro - Results
Yes
No
Penetration into Parent Metal: Yes
No
Other Tests
Type of Test
RT - GOOD
Deposit Analysis
Other
......................................................................................................................................................
Welders Name TOM SMITH
Clock No.
Tests conducted by:
O,K. TEST LAB
BR549
Stamp No.
Laboratory Test No.
JP
11-22-01-637
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
11-22-04
By
DLV WELDING, INC.

(SIGNED)
(Detail of record of tests are illustrative only and may be modified to conform to the type and number of test required by the Code.)
Page 15
Please close all materials.

The remainder of the exam is
Closed Book.
Page 16
TThhee sseeccoonndd ppaarrtt ooff tthhee eexxaam

Booookk,,""
m iiss ""C
Clloosseedd B
51.
Who has the ultimate responsibility for complying with the provisions of API Standard
653?
1.
2.
3.
4.
52.
If cracks are suspected in nozzles or nozzle welds they should be checked by

.
1.
2.
3.
4.
53.
errosion
brittle fracture
caustic corrosion
phase failure
Per API 653, tanks shall have a formal visual inspection once every
or RCA/4N years, whichever is less.
1.
2.
3.
4.
55.
ultrasonic digital thickness gauge

MT or PT examination
eddy current testing
infra-red thermography
Localized corrosion due to the concentration of caustic or alkaline salts is

1.
2.
3.
4.
54.
API
Owner/operator
Inspector
Contractor/builder
three
four
five
seven
Monthly visual inspections of the external condition of in-service tanks may be

performed by
.
1.
2.
3.
4.
API 653 inspectors

owner/operator personnel
NDE technicians
plant managers
Page 17
years
56.
The critical zone for repairs to tank bottoms is that portion of the bottom or annular plate
within
inches of the inside edge of the shell.
1.
2.
3.
4.
57.
On a fixed-type roof, planks long enough to span at least

laid and used as walkways.
1.
2.
3.
4.
58.
arc blow
arc length
arc strike
arc angle
API 650
ASME Section V
ASME Section IX
API 1104
Upon completion, the roof of a tank designed to be gas tight shall be tested by which
one of the following methods?
1.
2.
3.
4.
62.
Every 10 years
Every time the tank is empty
Annually
Semi-annually
During the reconstruction of a tank, welding operators, welders and welding

procedures must be qualified in accordance with
.
1.
2.
3.
4.
61.
none allowed
1
2
3
The deflection of an arc from its normal path because of magnetic forces is
1.
2.
3.
4.
60.
roof rafters should be
Cathodic protection surveys are recommended to ensure the effectiveness of cathodic

protection. How often should this survey be done?
1.
2.
3.
4.
59.
3
6
12
24
Magnetic particle testing of all welds

Application of internal air pressure not exceeding the weight of the roof plates
and applying a solution suitable for the detection of leaks
Penetrant testing the weld joints
Visual inspection of the weld joints
In regard to API 653, roof plates corroded to an average thickness of

any 100 square inch area shall be repaired or replaced.
1.
2.
3.
4.
less than 0.09

0.09
greater than 0.09
no API 653 requirement, owner's requirement
Page 18
inch in
63.
A fusion weld made without filler metal is

1.
2.
3.
4.
64.
round discontinuity
linear discontinuity
non-linear discontinuity
rejectable defect
brittle fracture
caustic corrosion
stress cracking
atmospheric corrosion
Cone roof tank

Umbrella-roof tank
Vapor-dome roof tank
Floating roof tank
Per API 650, external floating roof deck plates having support leg or other rigid
penetrations closer than
inches to lap weld seams must be full fillet welded not
less than 2 inches on 10 inch centers.
1.
2.
3.
4.
69.
Which of the following tanks are used to reduce filling and breathing loss by eliminating
vapor space?
1.
2.
3.
4.
68.
erection/fabrication manufacturer
purchaser
Nuclear Regulatory Commission
certified inspector
A form of corrosion that occurs from moisture associated with atmospheric conditions is
called
.
1.
2.
3.
4.
67.
A discontinuity with a length that is substantially greater than its width is called a
1.
2.
3.
4.
66.
brazing
SMAW weld
autogenous weld
SAW weld
Each welder making welds on a tank shall be certified by

1.
2.
3.
4.
65.
6
12
14
18
Foundation pads that have washed out or settled under the bottoms of atmospheric
storage tanks can be repaired by
.
1.
2.
3.
4.
pumping in water
pumping in argon
pumping in sand, dirt or thin concrete
pumping in gas
Page 19
70.
When corrosion rates are not known and similar service experience is not available,
the actual bottom thickness shall be determined by inspections within the next
year(s) of tank operation to establish corrosion rates.
1.
2.
3.
4.
71.
The mechanical working of metals using impact blows is referred to as

1.
2.
3.
4.
72.
10
5
20
15
Radiographs
Vacuum
Penetrant testing
Hammer testing
The junction of the weld face and the base metal is the
1.
2.
3.
4.
76.
chemical attack
sulfate - type alkalis
chlorides
high temperature
Upon completion of welding of the new tank bottom, the welds shall be inspected by
which one of the following methods?
1.
2.
3.
4.
75.
A contributing factor for determining internal inspection intervals shall be time, not to
exceed
years for any reason, if an RBI program is not in place.
1.
2.
3.
4.
74.
inclusion
corrosion
fatigue
peening
Calcining can occur when concrete has been exposed to

1.
2.
3.
4.
73.
five
ten
three
one
heat affect zone

weld toe
stress riser
dilution zone
Tank plates being welded which do not have proper identification shall be subjected to
.
1.
2.
3.
4.
chemical analysis
UT thickness measurements
PT testing
RT testing
Page 20
77.
An assembly whose component parts are joined by welding is a

1.
2.
3.
4.
78.
ASM Requirements
ASME Requirements
API 650 Requirements
ASTMA 7 Requirements
What action should be taken after a flat spot is discovered in the second ring of a 200'
diameter AST?
1.
2.
3.
4.
82.
10
30
24
18
For known materials, all shell plates and bottom plates welded to the shell shall meet,
as a minimum, the chemistry and mechanical properties of material specified for the
application with regard to thickness and design metal temperature, per
.
1.
2.
3.
4.
81.
Repair
Alteration
Hot tap
Reconstruction
Annular bottom plates shall have a radial width that provides at least
inches
between the inside of the shell and any lap-welded joint in the remainder of the
bottom.
1.
2.
3.
4.
80.
spool piece
weldment
fillet weld
groove weld
identifies a procedure for installing a nozzle in the shell of a tank that is in

service.
1.
2.
3.
4.
79.
The shell distortion shall be evaluated

The area shall be cut out and replaced
Since no product is leaking out of the area, it may be ignored
The inspector has the option to repair or ignore
Routine in-service visual inspections of the external condition of the tank shall not
exceed
.
1.
2.
3.
4.
one month
six months
one year
five years
Page 21

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26.

The maximum acceptable undercutting on horizontal butt welds of a reconstructed

The minimum number of settlement points around a tank periphery is

API 653 Exam Prep Homework #2 Questions Page 3

Penetrameter is another common term for

Thin film linings are usually used for application to

the bottoms of new storage tanks.

API 653 Exam Prep Homework #2 Questions Page 4

If a welder tests in a 6G position, he qualifies to weld

The critical zone of the tank bottom is within the

no pit depth results in the remaining shell thickness being less

Widely scattered pits may be ignored, provided

an electrode of an electrochemical cell at which no corrosion occurs

a minimum 1/2 gap over no more than 24

A full hydrostatic test is always required on

What is the maximum temperature that dry MT can be used?

The allowable stress of the rivets

API 653 Exam Prep Homework #2 Questions Page 6

It is not necessary for the inspector to check which of the following?

All test results on the PQR

API 653 Exam Prep Homework #2 Questions Page 7

API 653 Exam Prep Homework #2 Questions Page 8

API 653 Exam Prep Homework #3 Questions Page 2

The letter B is placed on radiographic film holder for what reason?

To determine if back scatter radiation is exposing the film.

obtain a written entry permit

The weld is acceptable

API 653 Exam Prep Homework #3 Questions Page 3

What is the inspection frequency for flame arrestors?

The acceptance criteria for a radiograph of a tank repair weld is found in

Section V of the ASME Code

API 653 Exam Prep Homework #3 Questions Page 4

caulking the leaking joints and/or using soft patch material

Tanks with a diameter of 200 feet and greater

What is the minimum lifting power of an AC electromagnetic yoke used in magnetic

40 pounds lifting power at the maximum pole spacing

The principal advantage of thin-film linings are

Welders are qualified to what standard or code?

Section VIII of the ASME Code

In no case shall the internal inspection interval of an aboveground storage tank

better protection of older storage tank bottoms and ease of application

What is the maximum acceptable undercut of a nozzle to shell weld?

API 653 Exam Prep Homework #3 Questions Page 6

the existing nameplate

Radiographs of repaired work and records of radiographs of repaired work shall be

API 653 Exam Prep Homework #3 Questions Page 7

API 653 Exam Prep Homework #3 Questions Page 8

API 653 Exam Prep Homework #4 Questions Page 1

API 653 Exam Prep Homework #4 Questions Page 2

API 653 Exam Prep Homework #4 Questions Page 3

76. What is the P number for the tank as listed above?

What is the filler number for E-7018 electrodes?

What is the SFA number for E 7018 electrodes?

API 653 Exam Prep Homework #4 Questions Page 4

What is the joint efficiency for T 3-27?

What is the corrosion allowance for T 3-27?

API 653 Exam Prep Homework #4 Questions Page 5

have the patch removed.

have the patch removed.

API 653 Exam Prep Homework #4 Questions Page 6

A repair may be made by using duct tape.

Terminology for weld metal in excess of the specified weld size.

API 653 Exam Prep Homework #4 Questions Page 7

Express 7/16" as a decimal fraction _.438"