Api 510 Practice Exam B (150 Questions) : Design Temp Test Temp

NAME/BADGE #: __________________________________________________ Date:
____________
API 510 PRACTICE EXAM B (150 QUESTIONS)
1. During inspection of a vertical pressure vessel with an inside diameter of 90 in.
(2.25 meters), a generally corroded area (360 around the vessel ID and 40 inches
in height) was found in a shell course indicating liquid line corrosion. Remaining wall
thickness can be determined by:
A) Only by performing UT thickness on the area of the deepest pit & measuring
remaining wall
B) Averaging remaining wall thickness at equally spaced readings over a length L
= to 20 in.
C) Averaging remaining wall thickness at equally spaced readings over a length L
= to 30 in. D) Averaging remaining wall thickness at equally spaced readings over a
length L = to 40 in.
Answer: C (API 510, Para. 7.4.2.1) L = the lesser of 40 in. or 1/3 Vessel
Diameter (30 in.)
2. A horizontal vessel having a U Stamp & constructed in 1991 must now undergo a
hydrostatic test after an alteration. What is required test pressure at the top
of the vessel?
Given: Original (1991) Vessel U stamp reads MAWP: 1000 psi @ 500F
The S design temp = 15 ksi and S test temp = 16.3 ksi
A) 1630 psi B) 1500 psi C) 1413 psi D) 1300
psi
Answer: A (API 510, Para. 5.8.2.1) See Solution below using the API 510
formula!
Test Pressure in psi (MPa) = 1.5 MAWP (Stest temp/Sdesign temp), before
1999 addendum rule
Solution: 1.5 x 1000 x (16,300 15,000) = 1500 x (1.0866) = 1629.9 psi or
1630 psi
3. Given: A pressure vessel has been in service since January 1, 2001 and has a
history of active corrosion over its service life. Original thickness = .700 inches
(Actual & U-Stamp) & current thickness on Jan. 1, 2011 is .500 inches. Previous
thickness on January 1, 2006 was 0.600 inches. The minimum thickness for this
vessel as listed on the Data Sheet = 0.200 inches and the Vessel Corrosion
Allowance as per the U stamp = .500 inches. Determine corrosion rate,
remaining corrosion allowance and remaining life (RL) for this pressure
vessel?
A) Corrosion Rate = .020 inches per year, RCA = .030 inches and RL = 15 years
B) Corrosion Rate = .050 inches per year, RCA = .500 inches and RL = 10 years
C) Corrosion Rate = .020 inches per year, RCA = .300 inches and RL = 15 years
D) None of these are correct
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NAME/BADGE #: __________________________________________________ Date:
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Step # 1 Determine metal loss and both the LT & ST Corrosion Rates!
Step # 2 Compare two Corrosion rates & choose the one that best reflects current
conditions!
Step # 3 Determine the RL of the vessel in years given a Minimum t of 0.200
inches
Answer: C (API 510, Para. 7.1 Formulas for LT & ST Corrosion Rates)
.700 .500 = .200 in. loss 10 yrs = 20 MPY
.600 .500 = .100 loss 5 yrs = 20 MPY

Remaining Corrosion Allowance = .500 (given) minus .200 (given) = .300
inches
Solution: .500 inches (current) .200 inches (t min) = .300 in .020* = 15
= 15 years
(*Both LT & ST corrosion rate are .020 inches per year = 20 MPY you
must use 20 MPY)
USE THIS INFORMATION TO SOLVE QUESTIONS 4, 5, & 6 ON THIS PAGE
Original vessel thickness was found to be 0.750 inches thick (Baseline UT on January
1, 1996)
Latest vessel thickness taken during an internal vessel inspection on Jan. 1, 2011
was 0.600 in.
Vessel U-stamp reads MAWP 150 psi @ 350F, RT 1, Corrosion Allowance = 0.250
inches!
Pressure vessel Minimum thickness required on the data sheet & the U-stamp = .
500 inches!
Date of last external inspection was January 1, 2009 when a CUI survey was also
performed! The bottom head in the CS vessel in hydrocarbon service has SS weld
overlay and both VT & UT have found no metal loss over 15 years. Low readings are
located in a vapor space at the shell and top head. Corrosion rates have remained
steady for the vessels 15 year service life.
A) Corrosion rate < 5 MPY and .010 inches remain in the CA and remaining life is 2
years
B) Corrosion rate < 5 MPY and .200 inches remain in the CA and remaining life is 20
years
C) Corrosion rate > 5 MPY and .100 inches remain in the CA and remaining life is 10
years
4. Determine corrosion rate, remaining CA & remaining vessel life given
the above!
Answer: C (API 510, Para. 7.1, See steps below)
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NAME/BADGE #: __________________________________________________ Date:
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Step # 1 Determine loss & Corr. Rate .750 .600 = .150 in. 15 years = .
010 or 10.0 mpy
Step # 2 Determine remaining CA .600 in. minus .500 in. = .100 inches CA
remaining
Step # 3 Determine RL =0.100 in. .010 = 10.0 Use 10 years RL
5. Given the above information (Assume No RBI), determine the date & the
next type of Inspection (Internal or can an On-Stream inspection be done)
using API 510 rules?
A) Internal inspection absolutely must be performed and will be due on January 1,
2021
B) On-Stream inspection MAY be performed (in lieu of internal) and will be due on
July 1, 2025
C) Either an internal or an On-Stream inspection will be due on January 1, 2021
D) None of these is correct
Answer: D (API 510, Para. 6.5.1.1 & 6.5.2.1) RL Rule Internal due Jan.
1, 2016)
6.5.1.1 Unless justified by a RBI assessment, the period between internal or
on-stream inspections shall not exceed the remaining life of a vessel or 10
yrs, whichever is less.
6.5.2.1 At the discretion of the inspector, an on-stream inspection may be
substituted for the internal inspection in the following situations:
b. When vessel entry for internal inspection is physically possible & all the following
conditions are met:
Item # 1 Vessel general corrosion rate is known to be less than 5MPY
Corrosion rate = 10MPY
Item #2 Vessel remaining life is greater than 10 years It is not It is
exactly 10 years
6. Given the above (assume no RBI), when is the next External inspection
due & why?
A) Jan 1, 2016 External inspections never exceed a lesser of 5 yrs or the
Internal/OSI interval
B) Jan 1, 2016 Because external inspections may NEVER exceed 5 years without
RBI
C) Jan 1, 2014 Because external inspections may NEVER exceed 5 years without
RBI
D) Jan 1, 2021 At the same time as the On-Stream inspection as allowed by API
510
Answer: C (API 510, Para. 6.4.1) Last external insp was Jan. 1, 2009 Due
Jan 1, 2014
6.4.1 Unless justified by RBI assessment, each aboveground vessel shall be given a
visual external insp at an interval that does not exceed the lesser of five years
or the required internal/on-stream inspection.
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NAME/BADGE #: __________________________________________________ Date:
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7. On April 1, 2011, the remaining life of a vessel was been determined to
be exactly 3 years. What is the latest possible date allowed by the code to
perform a next Internal or OSI inspection and to also perform the next
external inspection?
A) Next Internal or OSI AND external inspection interval = 1.5 years, due on October
1, 2012
B) Next Internal or OSI AND external inspection interval = 2 years, due on April 1,
2013
C) Next Internal or OSI AND external inspection interval = 3 years, due on April 1,
2014
D) None of these is correct. External inspection will be required before an
internal/OSI.
Answer: B (API 510, Para. 6.5.1.1 & 6.4.1)
Solution: RL = 3 years Apply RL less than 4 years rule in 6.5.1.1 Maximum = 2
years
External inspection will be 5 years or the internal/OSI interval whichever is
less
Solution: We must inspect no later than 2 yrs for both Internal/OSI &
External Inspection
6.5.1.1 When remaining life is less than 4 years, inspection interval may be full
remaining life up to a maximum of two years The RL rule does not
apply here!!!
6.4.1 Unless justified by an RBI assessment, each aboveground vessel shall be
given a visual external inspection at an interval that does not exceed the lesser of
five years or the required internal/on-stream inspection. It is preferred to
perform this inspection while the vessel is in operation. Per most
inspection plans, do externals just before shutdowns!
8. A new vessel is brought in to replace an old vessel being retired from a

hydrocarbon service after 35 years. Service will be changed (new type of
chemical to be injected into process as a trial with no similar service data
published). Service was never handled before by the owner/user. New
vessels probable corrosion rate is best determined by:
A) Take baseline & 1,000 hour service UT thickness measurements & follow-up UT
thereafter
B) Corrosion rates may be estimated owner/users experience (old records) or
similar service
C) Corrosion rates may be estimated from any published data regarding sour crudes
Answer: A (API 510, Para. 7.1.2) Read question well No alternatives
except UT
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NAME/BADGE #: __________________________________________________ Date:
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9. Regarding the question above, if it is later determined that an
inaccurate corrosion rate was assumed, what must be done regarding the
corrosion rate for RL calculations?
A) Make subsequent determinations at appropriate intervals until an accurate rate is
established
B) Consult the corrosion specialist to determine which rate to apply, ST or LT
Corrosion rate
C) Corrosion rate in the remaining life calcs shall be changed to the actual corrosion
rate
D) Nothing because the corrosion rate will be likely to keep changing again and
again
Answer: C (API 510, Para. 7.1.2) Read the last paragraph (sentence) in
the section
10. What is MDMT & Charpy Impact test temp required for a 5 mm or -
sized test specimen? (Assume SA-516 Gr. 70 plate (2.25 in.) quenched and
tempered & now is requiring Impact Test)
A) 0F & -20F B) 30F & 10F C) 67F & 47F D) None of these
Ans: A (Fig UCS-66 (4) Pg 181 Curve D Table UCS-66 Pg 184 Table UG-84.2 Pg
69
Step 1 Determine what curve on Page 181 B or D quenched & tempered = D
Pg 184 Use MDMT Column for D & row for 2.25 in. (use F values) = 0F Now go to
Pg 69 Table & a 5 mm specimen is a - sized so there is 20F reduction from 0F
or -20F Answer = A
11. Using Fig. UW-16.1 (a), determine value for tc Assume t = 38 mm & tn
= 22 mm!
A) 6 mm B) 13 mm
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NAME/BADGE #: __________________________________________________ Date:
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C) 19 mm D) 22 mm
Answer: A (ASME Section VIII, Div. 1, UW-16.b Symbols & See the Legend & See
Figure)
Solve for tmin = 19 mm or 22 mm (lesser = 19mm) 0.7 x t min or 19 mm
= 13.3 mm
Solve for tc = lesser of tmin or 13.3 mm or 6 mm = 6 mm
12. Regarding a 2:1 ellipsoidal head, which is code acceptable

approximation value for the knuckle radius and the spherical radius?
A) An acceptable approximation is a knuckle radius of 0.356D and a spherical radius

of 0.665D
B) An acceptable approximation is a knuckle radius of 0.90D and a spherical radius
of 0.885D
C) An acceptable approximation is a knuckle radius of 0.885D and a spherical radius
of 0.17D
D) An acceptable approximation is a knuckle radius of 0.17D and a spherical radius
of 0.90D
Answer: D (UG-32 d Read the last sentence underneath the formula 1)
13. Which statement is false regarding joint efficiencies for calculations

that involve circumferential stress in seamless vessel sections or for
thickness of seamless heads?
A) E = 1.0 when the spot radiography requirements of UW-11(a)(5)(c) is met

B) E = 1.0 when the spot radiography requirements of UW-11(a)(5)(b) is met
C) E = 0.85 when the spot radiography requirements of UW-11(a) (5) (b) are not
met
D) E = 0.85 if Cat. A or B welds to seamless vessel sections or heads are Type No. 3,
4, 5 or 6
Answer: A UW-12 (d) & (e) & Table UW-12
14. Given a vessel with .500 in. seamless ellipsoidal heads and a 24 inch
OD seamless piping shell (.375 in. wall), attached by RT Type 1 Category A
Butt Joints (Lethal Service), Corrosion Allowance = .125 inches, Design
Pressure is 600 psi at 300 F, and the material stress values are given as
S = 20 ksi for head and S = 19.7 ksi for shell
Determine E & required minimum t for 2:1 ellipsoidal heads show your
calculations!
A) E = 1, and required head t = 0.328 in.

B) E = 1, and required head t = 0.350 in.
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NAME/BADGE #: __________________________________________________ Date:
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C) E = 0.85 & required head t = 0.368 in.
D) E = 1, and required head t = 0.390 in.
Answer: B (UG-32 formula for ellipsoidal heads) See also App L

examples for practice
Formula to use to determine minimum ellipsoidal head

thickness
Step 1: Determine PD = 600 psi x 23.250 in.* *24 in OD = outside
Diameter.
Head thickness .500 in. CA .125 in. = .375 in. So, 24 minus (2)(.375 in) =
23.250 in. = D
Step 2: Determine SE S = 20 ksi, E = 1 because we see UW-3 illustration
(always check)
= Category A. Next we use Table UW-12, Type 1, where E = 1.00, so use 1 as the
value for E
Step 3: PD = 600 x 23.250 = 13,950, SE = 2 (20,000) (1) - 0.2 (600) = 40,000
120 = 39,880
Final solution is 13,950 39,880 = 0.3497 or .350 inches (always use 3
decimals)
For a vessel calculation, the following is given for questions 15 & 16 (see
the next page):
Heads: 2:1 ellipsoidal heads (.875 in. nominal).

Shell: 30 in. OD (.750 inches) with Longitudinally Welded Type 1 Category
A joint (No RT).
The shell and heads are attached by a Type 1 Category A Butt Joint (again,
No RT)
Corrosion allowance = .125 inches! Design Pressure/Temp = 400 psi at
200F
Head Material = S = 20 ksi. Shell Material = S = 20.4 ksi.
15. Determine value E & required minimum ellipsoidal head thickness.

Show your calcs!
A) E = .70, required head t = 0.286 inches B) E = .70, required head t = 0.347

inches
C) E = .85, required head t = 0.336 inches D) E = .70, required head t = 0.408
inches
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NAME/BADGE #: __________________________________________________ Date:
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Answer: D (UG-32d & formula 1) No RT =.70 per Table UW-12 See
L.1.5.1.c example
Formula to use to determine minimum 2:1 ellipsoidal head

thickness
Step 1 PD = 400 x 28.5* = 11,400. Note: D = 30.0 - 2 x (.875 -.125) or 30 -
1.5 = 28.5
Step 2 SE = 2 (20,000) (.70) minus 0.2 (400) = (28,000 80) = 27,920
Step 3 Final math solution = 11,400 27,920 = .4083 = .408 inches
16. Use same given information as question # 15 on the previous page.

Determine value E & required minimum shell thickness assuming
circumferential stress as the basis for the calculation & show your work!
A) E = .70, and required t = 0.286 inches B) E = .85, and required t =

0.336 inches
C) E = .70, and required t = 0.347 inches D) E = .70, and required t =
0.409 inches
Answer: D (UG-27c & formula 1) See also Appendix L-1.5.3.a example for
practice
Formula to determine minimum shell t with circumferential

stress**
Step 1 PR = 400 x 14.375* = 5,750 *15.0 minus (.750 -.125) = 14.375 = R
Step 2 SE = 20,400 (.70 from UW-12d Table) minus 0.6 (400) 5,750 (14,280
240) = .409544 = .409 inches again!
Note: Given S values were manipulated so answers would be .409 for both
questions above
17. What is the normal PWHT holding temperature and minimum holding
time for a weld made to SA-516 Gr. 70 that is 2.00 inches (50 mm) thick?
A) Normal Holding Temp = 1100F and minimum holding time = 2 hours total
B) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 4
minutes
C) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 15
minutes
D) Normal Holding Temp = 1100F and minimum holding time = 2 hours & 45
minutes
Answer: A Table UCS-56 for P-No 1 Materials
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See question 18 below for static head calcs!

18. A vessel 80 feet high is filled with HO under pressure. At the lowest
part of vessel, 80 feet from top, it reads 455 psi at a calibrated gauge.
What will be pressure values be at 54 feet from the top, at 32 feet from
the top, at 4 feet from the top, and lastly, at the very top?
A) 54 ft from top = 434 psi, 32 ft from top = 424 psi, 4 ft from top = 412 psi & at
the top = 410 psi
B) 54 ft from top = 444 psi, 32 ft from top = 434 psi, 4 ft from top = 422 psi & at
the top = 420 psi
C) 54 ft from top = 466 psi, 32 ft from top = 476 psi, 4 ft from top = 488 psi & at
the top = 490 psi
D) 54 ft from top = 474 psi, 32 ft from top = 484 psi, 4 ft from top = 492 psi & at
the top = 490 psi
Ans: B UW-3d, Note 2 Static head per 1 foot of HO = 0.433 psi least
pressure @ top
19. Welded longitudinal joints within a sump are considered what joint
category?
A) Category A B) Category B C) Category C
D) Category D
Answer: A Figure UW-3 & UW-3d, Note 2
20. Regarding Carbon and Low alloy steel Long Weld Neck flanges, no
impact testing is required when used at Minimum Design Metal
Temperatures not colder than:
A) -40F (-40C) B) 20F (29C) C) 32F (0C) D) None of these
Answer: B UCS-66 (c) (4) same applies for B16.5 flanges Top left
column, pg 183
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21. How many tensile & guided bend tests are needed for a PQR coupon
using material grade A516 Grade 70 that is 3/4 inch (20 mm) thick?
A) Two tensile tests & four guided bend tests (2 face + 2 root bends are required)
B) Two tensile tests & four guided bend tests (4 face bends are required)
C) Two tensile tests & four guided bend tests (4 side bends are required)
Answer: C Table Qw-451 See the Row for 19 mm 38 mm thickness
22. Are guided bend test results acceptable for A516 Grade 70 at a 3/4 in.
(20 mm) thick PQR Coupon (4 side bends taken), if Specimen # 1 = 3.0 mm
slag, Specimen # 2 = 3.0 mm porosity, and Specimen # 3 = 2.9 mm slag,
and specimen # 4 had 3.0 mm of porosity?
A) T1 & T2 = Acceptable, T3 & T4 are unacceptable & 4 Guided bend tests =

Acceptable
B) T1 & T2 = Acceptable, T3 & T4 are unacceptable & 4 Guided bend tests =
Unacceptable
C) T1 & T2 & T4 = Acceptable, T3 = unacceptable & 4 Guided bend tests =
Acceptable
D) T1 & T2 & T3 & T4 = Acceptable & 4 side bend tests = Acceptable
Answer: D Table QW-451 See the Row for 7mm thickness
Assume all f & fr values = 1
23. Using illustration above and Figure UG-37.1, what is the total area
required (A value) for a reinforced nozzle, given a shell opening of 13.00
in. (value d) with a shell required thickness of 1 inch (value tr) & what is
the Dp value (repad OD) to be used in any calcs?
A) A = 1.1 inches & Dp = 17.75 inches B) A = 1.3 inches & Dp = 18.75 inches
C) A = 1.5 inches & Dp = 19.38 inches D) None of these is correct
Answer: D Fig. UG-37.1 & Legend = A = dtr (shortcut formula) = 13.00 x
1.00 = 13.00 in.
Dp = 12.750 + 3 + 3 = 18.750 inches = OD of Nozzle + 2 (repad value of 3
inches shown)
Solution: Answer = D because A = 13.0 inches and value Dp = 18.75 in.
(repad O.D.)
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NAME/BADGE #: __________________________________________________ Date:
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24. Determine the correct wire number, wire set & wire diameter for a film
side radiograph taken on a .875 inch thick nozzle to flange circumferential
weld?
A) 8 wire, Set B, Wire Diameter 0.016 B) 9 wire, Set B, Wire Diameter 0.020
C) 10 wire, Set B, Wire Diameter 0.025 D) 11 wire, Set B, Wire Diameter 0.030
Answer = B: Wire-Type Essential Wire # 9 = Set B = Wire Diameter =
0.020in (0.51mm)
Step 1 Use thickness given in exam question = .875 in.
Step 2 Add weld reinforcement (Tables UW-3 & UW-35) = 3/16 or .188 in.
Step 3 Add .875 + .188 = 1.063 in for a Cat. B Butt welded Nozzle to Flg girth weld
UW-3 Solution: Use Over 1.00 thru 1.50 row (T-276) Film Side Column
9 wire T-233.2
25. If a radiograph (gamma radiography) has a density equal to 2.4 in the
area of interest adjacent to a single wire-type IQI, what is the acceptable
density range along the weld?
A) 2.0 to 3.1 B) 2.1 to 3.0 C) 2.2 to 3.1 D) 2.0 4.0 for
gamma RT
Answer: A (ASME V, Art. 2, T-282.2) Apply the Density variation rule of
-15% to +30%
2.4 x 85% or .85 (-15% rule) = 2.04 = 2.0 2.4 x 130% or 1.3 (+30% rule)
= 3.12 = 3.1
26. What is the minimum penetrant dwell time when performing a PT
examination on vessel weld (Plate material = A516 Grade 70) at a
temperature of 45F?
A) 5 minutes B) 10 minutes C) 20 minutes D)

None of these
Answer: C (ASME V, Art. 6, T-672 & Note 1) Apply the 2 x dwell time rule
for low temps! This tricky question is on nearly every API exam Plate
Plate Plate remember, one inch on either side of the weld is on the
plate select plate (10 mins) always and double the time when a test is
performed below temp limits of T-672, Note 1 20 mins!!!
27. Inspector measured undercut on a girth weld (No PWHT

required) and it was found to be 1/32 in. (1mm) in depth. Shell
material is .360 inches thick (9mm). Inspector shall:
A) Accept the weld because undercut is within ASME Section VIII, Div. I code
allowed tolerance
B) Reject the weld because undercut will affect RTFI interpretation & request
surface grinding
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NAME/BADGE #: __________________________________________________ Date:
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C) Accept the weld, as 1mm undercut is allowed on non-PWHTd welds per
ASME VIII, Div 1.
D) Reject the weld because it exceeds the ASME Section VIII, Div. I code
allowed tolerance
Answer: D (ASME VIII, Div 1, UW-35.b.2) 1mm or 10%, whichever

is less 0.9 mm allowed)
28. If radiographic exam is used for qualification of a welder or

welding operator, the minimum length of coupon to be examined is
any of the following items EXCEPT:
A) The entire weld circumference for pipe coupons (Typically Size 2 NPS &
Size 8 NPS used)
B) The entire circumference for their first three production joints (ASME
B31.3 Case)
C) 3 feet (0.91 meters) for welding operators (ASME IX Rule)
D) 6 inches (152.4 mm) minimum in any case (ASME IX Rule)
Answer: B Ref: API 577, Section 8.2 Welder Qualification WPQ
QUESTION # 29
Given: CALCULATE MAWP @ SHELL
FOR A PROPOSED 10-YEAR RUN
Original vessel thickness was found to be 0.975 inches thick (Baseline UT on January
1, 1986)
Latest vessel thickness taken during an internal vessel inspection on Jan. 1, 2011
was 0.860 in.
Vessel U-stamp reads Design:150 psi @ 350F, RT 1, Corrosion Allowance = 0.250
inches!
Pressure vessel Minimum thickness required on the data sheet & the U-stamp = .
725 inches!
Date of last external inspection was January 1, 2009 when a CUI survey was also
performed! The lower half of the vessel in hydrocarbon service has a SS strip lining
and both VT & UT have found no metal loss over 25 years. Low readings are located
in the vapor space at the shell and top head. Corrosion rates have remained
steady for the vessels 25 year service life.
Additional Given Information: Shell S Value = 16 ksi, Lethal Service &
Full Radiography
Internal Radius = 82 in. Established Corrosion Rate = 4.6 mils or .0046
inches per year
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A) t = .860 and MAWP = 167 psi that is greater than 150 psi design, so a 10 year
run is OK
B) t = .814 and MAWP = 158 psi that is greater than 150 psi design, so a 10 year
run is OK
C) t = .768 and MAWP = 149 psi that is less than 150 psi design, so a 10 year run is
NOT OK
D) None of these is correct, but the MAWP is greater than 150 psi design & a 10
year run is OK
Answer: C (ASME VIII, UG-27.c.1 Formula 1 & API 510 Section 7.3.3
Formula for MAWP)
First step Solve for t using API 510 Code rules &
formula
7.3.3 In corrosive service, the wall thickness used in these computations
shall be the actual thickness as determined by inspection (see 5.6.2) minus
twice the estimated corrosion loss before the date of the next inspection, as
defined by:
t = tactual 2 (Crate x Iinternal) API 510, Para. 7.3.3 = .860 2 (.0046 x 10) =
.768
Correct is 16,000 (1) (.768) = 12,288 (82 + .461) or 82.461 = 149 psi <
150, so not OK
30. In lieu of insulation removal for a vessel, what alternative is

given in API 510?
A) Inspector may use similar service results from another similar vessel at
owner/users location
B) Shell thickness measurements taken internally (during int. insp.) at typical
CUI problem areas
C) Use of special removable & replaceable type insulation is a preferred
method of 510 code
D) None of these is correct per API 510
Answer = B Ref: API 510, Par. 5.5.6.3 CUI Inspection!
31. What is the minimum shell temperature to be maintained during

a hydrostatic test after a major repair if a pressure vessel shell is
1.75 inches thick?
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o o
A) 30 F (17 C) above the material MDMT
B) 30o F (17oC) above ambient metal temp
C) 10o F (6oC) above the material MDMT
D) 10o F (6oC) above ambient metal temp
Answer: C (API 510 Section/Para. 5.8.6.2 Be aware of 2 in & less

rule = +10o F only)
Note: There is a conflict between ASME VIII, Div 1 Section UG-98
(30o F above MDMT for all)
32. For a pressure vessel in non-continuous service (operates only 4

months in every year & placed under a nitrogen purge each time
after being idled), what are the maximum possible internal &
external inspection intervals (assume NO RBI)?
A) Internal inspection interval = 10 calendar yrs & external inspection

interval = 10 calendar yrs
B) Internal inspection interval = 15 calendar yrs & external inspection
C) Internal inspection interval = 20 calendar yrs & external inspection
D) Internal inspection interval = 30 calendar yrs & external inspection
Ans: C (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.2) Reason:
In this case, 30 calendar years of operation is equal to 10 actual
operation years! External interval ALWAYS = 5 years
33. Regarding Fitness for Service Analysis of Corroded areas in

heads (assume an ellipsoidal head is corroded in the knuckle
region), the thickness required can be determined by using the
ASME Section VIII, Div. 1 Construction Code formula for:
A) Ellipsoidal head thickness only
B) Torispherical head thickness
C) Hemispherical head thickness and you must also use the API 510 Table
Answer: B (API 510, Par. 7.4.6.1) FFS Analysis of Corroded Regions

Corroded Areas in Heads
The formula for Hemispherical head thickness would be used for
corrosion in radiused region
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34. When installing a fillet-welded patch adjacent to an existing
fillet-welded patch, the distance between the toes of the fillet weld
shall not be less than:
A) 4 x the square root of (vessel inside radius x actual vessel wall thickness
under the patch)
B) 2 x the square root of (vessel inside radius x actual vessel wall thickness
under the patch)
C) 2 x the square root of (vessel inside radius x nominal vessel wall thickness
under the patch)
D) 4 x the square root of (vessel inside radius x nominal vessel wall thickness
under the patch)
Answer: A (API 510, Para. 8.1.5.1.2.3) Temporary Repair Rules

Lap Patch Spacing Rules
35. Assuming no RBI and the Internal Inspection Interval has been
set at 4 years, what is the maximum external inspection interval
allowed per API 510 rules?
A) Five (5) years is the maximum inspection interval allowed
B) Four (4) years is the maximum inspection interval allowed
C) Two (2) years is the maximum inspection interval allowed
D) None of these is correct per API 510 rules
Answer: B (API 510, External Inspection Rules, Para. 6.4.1) 5 years

or the Internal/OSI interval, use the lesser)
36. Assuming no RBI assessment, the period between internal or on-

stream inspections:
A) Shall not exceed 10 years or one half the remaining life of the vessel,
whichever is greater
B) Shall not exceed 10 years or one half the remaining life of the vessel,
whichever is lesser
C) Shall not exceed 10 years or the remaining life of the vessel, whichever is
the greater
D) Shall not exceed 10 years or the remaining life of the vessel, whichever is
the lesser
Answer: B (API 510, Internal & On-stream Inspection Rules, Para.
6.5.1.1)
37. Regarding evaluation of corroded regions and joint efficiency
adjustments for areas near corroded welds, when the vessel surface
Page | 15
NAME/BADGE #: __________________________________________________ Date:
____________
AWAY FROM A WELD is corroded & joint efficiency is less than 1.0,
an independent calc using an appropriate weld joint factor (typically
= 1.0) can be made. For this calculation, the surface at a weld
includes (what distance)?
A) 1 inch on either side of a weld (measured from toe) regardless of
thickness
B) 2 inches on either side of a weld (measured from toe) regardless of
thickness
C) 1 inch (OR 2 x t required) on either side of a weld (measured from toe),
use greater value
D) 2 inches (OR 2 x t required) on either side of a weld (measured from toe),
use greater value
Ans: C (API 510, Par. 7.4.5) FFS Analysis of Corroded Regions Joint
Efficiency Adjustments
38. For a pressure vessel constructed in 1950 having no nameplate
and minimal design and construction documentation, which of the
following is a correct action to be taken for calcs?
A) Use allowable stress values of the 1999 Addenda (based on current design
factors)
B) Use allowable stress values from Code Case 2290 (based on current
design factors)
C) Use allowable stress values of the current ASME Code (based on design
factor of 3.5)
D) None of these is the correct action to take
Ans: D (510, Par. 7.7) Evaluation of existing Equip (Minimal
documentation) Must know!
39. Assuming no RBI, a maximum internal inspection interval using
the MAWP method is:
A) Determined by MAWP calcs B) 10 yrs
C) 15 yrs D) 20 yrs
Ans: B (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.3)
Alternative MAWP calc method
40. When a pressure vessel remaining life is 1.5 years, the internal
or on-stream inspection Interval may be a maximum of:
A) Only of the vessels remaining life (0.75 years in this case)
B) Full remaining life (1.5 years in this case)
C) A maximum of 3 years in this case
D) A maximum of 2 years in this case
Page | 16
NAME/BADGE #: __________________________________________________ Date:
____________
Answer: B (API 510, Internal & On-stream Inspection Rules, Para.
6.5.1.1)
41. When PWHT is performed for environmental-assisted cracking
resistance, LOCAL PWHT MAY be substituted for 360-degree banding
on local repairs on all materials, provided that:
A) Local PWHT may NEVER be substituted for 360 banding to prevent
environmental cracking B) Local PWHT temp is maintained for a distance not
less than 2 x base metal t (from weld toe)
C) A preheat of 300F (150C) or higher, as specified in the WPS, is
maintained during welding
D) A metallurgical review shall be conducted to assess whether the
procedure is acceptable
Answer: D (API 510, Para. 8.1.6.4.1) Welding & Hot Tapping

PWHT Rules for Weld Repairs
42. If vessel entry is physically possible, on-stream inspection may
possibly be substituted for internal inspection if approved by
Inspector & the vessel is not subject to:
A) Chloride Stress Corrosion cracking or Creep stress rupture damage from
the service
B) Stress Corrosion cracking or high temperature oxidation damage from the
service
C) Damage Mechanisms requiring the Inspector to consult the Corrosion
Specialist
D) Environmental cracking or hydrogen damage from the fluid being handled
Ans: D (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.6) Phys. Poss.
Environmental Cracking & Hydrogen Damage Rules API 571, 4.5.1,
4.5.2, 4.5.3, 5.1.2.3, & 5.1.3.1 5 DMs!
43. Assuming no RBI, If vessel entry is physically possible & all of

the seven conditions allowing an on-stream inspection to be done in
lieu of an internal inspection were not met, what must the Inspector
do regarding scheduling of the next inspection to be performed?
A) Next inspection shall be internal B) Next inspection may be internal
C) Next inspection shall be On-Stream D) Next inspection may be On-
Stream
Answer: A (510, Int. & OSI (Insp.), Par. 6.5.2.2) Physically Possible
7 Rules to allow OSI!
Page | 17
NAME/BADGE #: __________________________________________________ Date:
____________
44. If a RBI assessment is not performed, what is the greatest
possible time period allowed by API 510 between testing of pressure
relieving devices?
A) 5 years (for all services)
B) 10 years (for non corrosive services)
C) At intervals often enough to verify reliability
D) None of these is correct because the quality assurance manual must be
followed
Ans: B (510, 6.6.2.2 PZV Rules for Insp Intervals = Five yrs &
10 yrs 2 Rules to KNOW)
45. When calculating corrosion rates using API 510 formulas, which
of the following statements is FALSE regarding the value for t
initial?
A) t initial = the initial thickness at the same CML as t actual (for any given
CML in inches or mm)
B) t initial = the initial thickness at a different CML from the one determining
the lowest t actual
C) t initial may a first thickness measurement taken (new vessel) at a given
CML (inches or mm)
D) t initial may be the thickness at the start of a new corrosion rate
environment at a given CML
Answer: B (API 510, Para. 7.1.1.1) Corrosion Rate Determination

Rules
46. LT & ST Corrosion Rates should be compared (data assessment).

When a significant difference exists between the two rates, WHO
selects which rate is to be used and WHY?
A) Inspector alone selects a rate that best reflects current conditions

B) Corrosion Specialist alone selects a rate that best reflects current
conditions
C) Inspector (consults Engineer) & selects a rate that best reflects current
conditions
D) Inspector (consults corrosion specialist) & selects a rate that best reflects
current conditions
Answer: D (API 510, Para. 7.1.1.2) Corrosion Rate Determination

Rules
47. For a pressure vessel with .425 inch nominal hemispherical heads
(head segment welds are RT Type 1 butt joints) and 24 inch OD seamless
pipe shell (.500 in. nom. wall) attached by RT Type 1 Category A Butt Joints
Page | 18
NAME/BADGE #: __________________________________________________ Date:
____________
(Lethal Service), Corrosion Allowance = .125 inches, Design Pressure is
600 psi at 300F. S = 20 ksi for heads & 19.7 ksi for shell
Determine value E & required minimum hemispherical head t and show

your calcs!
A) E = 1, and required head t = 0.166 in. B) E = 1, and required head t = 0.176

in.
C) E = .85 & required head t = 0.186 in. D) E = 1, and required head t = 0.196
in.
Answer: B (UG-32. f, formula 3) See also Appendix L-1.5.1(d) example

for practice
Formula to use to determine minimum hemispherical head

thickness
Step 1: Determine PL or PR = 600 psi x 11.7 in.* *24 in OD = 12 in outside
spherical radius.
Note: Appendix L uses PR (typo error) L is the same as R, they want the
inside radius!
Head thickness .425 in. minus CA .125 in. = .300 in. So, 12 minus .300 in =
11.7 in. = L
Step 2: Determine SE S = 20 ksi, E = 1 because we see UW-3 illustration
(always check) = Category A. Next we use Table UW-12, Type 1, where E = 1.00, so
use 1 as the value for E
Step 3: PL or PR = 600 x 11.7 = 7020, SE = 2 (20,000) (1) - 0.2 (600) = 40,000
120 = 39,880 Final solution is 7020 39,880 = 0.17603 = 0.176 inches (or 176
mils, always use 3 decimals)
48. After rolling a plate into a cylinder designed for internal pressure it is measured for
out of roundness and it is acceptable if the out-of-roundness is no more than:
A) 1% B) 2%
C) 3% D) None of these are correct
Answer = A Ref: UG-80 (a) (1)
49. What is the maximum length of a rounded indication when spot radiography has been
specified for a given pressure vessel as per ASME Section VIII, Division 1?
A) Per the approved RT procedure

C) 12 mm
Page | 19
NAME/BADGE #: __________________________________________________ Date:
____________
B) 6 mm
Ans: D (ASME VIII, Div I, UW-52.c.3 Rounded indications are not a factor No limit
Spot Radiography Rules UW-52

(c) Standards for Spot Radiographic Examination. Spot examination by radiography shall be
made in accordance with the technique prescribed in UW-51(a). The minimum length of spot
radiograph shall be 6 in. Spot radiographs may be retained or be discarded by the Manufacturer
after acceptance of the vessel by the Inspector. Acceptability of welds examined by spot
radiography shall be judged by the following standards:
(3) Rounded indications are not a factor in the acceptability of welds not required to be fully
radiographed.
50. Welder ABC has welded a performance test coupon inch thick in the 6G position.
Welder DEF has welded performance test coupons inch thick in 2G & 5G combination.
Which statement below is true regarding the number and type of test specimens required
for each of these welders to pass their qualification tests?
A) Welder ABC must pass 2 side bend tests & Welder DEF must pass 4 side bend tests
B) Welder ABC must pass 4 side bend tests & Welder DEF must pass 8 side bend tests
C) Welder ABC must pass 6 side bend tests & Welder DEF must pass 12 side bend tests
Ans: D (ASME IX Table QW-452.1.a & 3 Notes) API 577, Section 8 Table QW-452.1a)
See Note 1 ABC must pass 4 side bend tests & Welder DEF must pass 6 side bend tests
END OF API 510 OPEN BOOK EXAM B

TAKE A BREAK & BEGIN CLOSED BOOK
EXAM QUESTIONS (100) 3 HOURS
CLOSED BOOK EXAM (100 Questions in 3 hours)
51. Who is responsible to the owner/user to assure that the NDE,

inspection, and pressure testing activities meet API 510
requirements?
A) Authorized Pressure Vessel Inspector

B) Authorized Inspection Agency
C) Examiner and his employer
Answer = A Ref: API 510, Para. 4.2.4 Inspector responsibilities
Page | 20
NAME/BADGE #: __________________________________________________ Date:
____________
52. Which of these should be considered an alteration to a pressure
vessel per API 510?
A) Any comparable or duplicate replacement due to severe corrosion or other

reasons
B) Addition of any reinforced nozzle greater than the size of existing
reinforced nozzles
C) Addition of small bore nozzles or welded couplings that do not require
reinforcement
D) Adding a reinforced nozzle (12 NPS or greater) equal to a size of existing
reinforced nozzles
Answer = B Reference: API 510, Section 3.2 (Definition of an

Alteration)
53. Per API 510, a non-standard vessel is one that was:

A) Not fabricated to recognized construction codes & meeting no known
recognized standards
B) Not constructed & approved as jurisdictional special based on jurisdiction
acceptance rules
C) Fabricated to a recognized construction code but has lost its nameplate or
stamping
D) Not constructed in accordance with an applicable construction code
Answer = C Reference: API 510, Para. 1.1.1.d Non-Standard

vessel missing a nameplate
54. Designated areas on pressure vessels where periodic exams are

conducted are called:
A) Thickness measurement points B) Examination points
C) Inspection points D) None of these are correct
Answer = D Ref: API 510, Section 3.9 (Definition of Condition

Monitoring Locations or CMLs)
55. All NDE results must be evaluated and accepted by the:
A) Certified welding inspectors and NDE technicians doing the examinations

B) NDE technicians doing the work in assistance to the inspector
C) Examiners doing the work in assistance to the inspector
Answer = D Ref: API 510, Para. 4.2.4 Inspector responsibilities
Page | 21
NAME/BADGE #: __________________________________________________ Date:
____________
56. Per API 510, all on-stream inspections should be conducted by:
A) An Inspector only
B) Either an inspector or examiner
C) An inspector approved Examiner
D) An owner/user approved and trained examiner
Answer = B Ref: API 510, Para. 5.5.3.1 On-Stream Inspection
57. Pressure tests are normally required:
A) After an alteration
B) After temporary repairs
C) After most routine repairs
D) At the discretion of the Inspector
Answer: A (API 510, Para. 5.8.1.1)
58. For a SMAW welding electrode marked E-7018, the meaning of

the number 1 and the meaning of the number 8 respectively in 7018
is:
A) 1 = certified as moisture free (low hydrogen) and 8 = coating operating

characteristics
B) 1 = certified as moisture free (low hydrogen) and 8 = coating chemical
composition
C) 1 = position of welding recommended and 8 = coating operating
characteristics
D) 1 = position of welding recommended and 8 = coating chemical
composition
Answer: C (API 577, Appendix A & Figure A-7)
59. The principal reason for inspecting a pressure relief device is to:
A) Determine if it is functioning properly (so it can provide protection to

equipment/personnel)
B) Prevent fouling and plugging from occurring that could render a valve
inoperable
C) Assure equipment (pressure vessel) safety by preventing over
pressurization
D) Assure personnel and equipment safety in a process plant
Answer: A (API 510, Par. 6.6 & 6.6.2.1 & API 576 Ch. 6, Para. 6.1.1)
API website Sample Q
Page | 22
NAME/BADGE #: __________________________________________________ Date:
____________
60. To be considered valid by an Inspector, PQRs must be certified
by:
A) Mechanical tests per ASME IX
B) Approved Test Lab Signature & date
C) A corresponding and supporting WPS
D) The owner user inspection organization
Answer: B (API 510 Body of Knowledge Part 2 (Notes) 2013 exams
Must know
61. Which of the following is considered a physical property of a

metal?
A) Ductility B) Hardness
C) Density D) Toughness
Answer: C (API 577, 10.3, 2nd Para) Physical properties can be

measured without force
Melting temp, thermal/electrical conductivity, coefficient of
thermal expansion & density
Inspectors should know 4 mechanical properties
(strength/ductility/toughness/hardness)
62. A relief valve has been shipped lying down on its side. This is a
problem because:
A) Flange faces may be damaged during shipment

B) Springs may slip out and be lost during shipment
C) Relief valves are often heavy and are sometimes difficult to upright
D) Springs inside may shift and distort and as a result not exert the same
force on stems & seats
Answer: D (API 576, 5.8.2.2, 1st Para) Ship/store UPRIGHT

Affects spring seating force
63. After removing an exchanger bundle, CS tubes showing a blue

color are likely indicating:
A) Alkaline residues and likely resulting in cracking in the discolored tubes

B) Acidic corrosion and likely resulting in cracking in the discolored tubes
C) Ferri-ferrocyanide and likely resulting in blistering in discolored tubes
Answer: D (API 572, Appendix A.9.2 last Para) Presence of Ferri-

ferrocyanide is indicated
Page | 23
NAME/BADGE #: __________________________________________________ Date:
____________
but the Inspector should look for blisters on the shell ID, not on the
discolored tubes
64. Susceptibility of an alloy to Sulfidation is determined by its

ability to:
A) Form protective layers of magnetite on internal surfaces

B) Form protective sulfide scales on internal surfaces
C) Prevent carburization of internal surface layers
Answer: B (API 571, Sect. 4.4.2.3.b) Sulfidation is DM # 1 on API

571 list Critical Factors
65. The rerating of a vessel requires that:
A) Calcs are from a vessel manufacturer or owner-user engineer experienced

in pressure vessels
B) Inspection records verify vessel has been in the proposed service
previously & CA is adequate
C) Vessel shall be pressure tested using applicable testing formulas from a
code used in rerating
D) Rerating (all calcs) meet latest edition of ASME code or any applicable
construction code
Answer: A Ref: API 510, Section 8.2.1.a/b/c 4 rules SHALL BE

MET for rerating
66. What does this welding symbol designate?
A) Weld all around (in field) B) Weld Spot weld (in field)
C) Plug weld (in field) D) Weld all around
Answer: D Ref: Appendices & Fig A-4 Std Weld Symbols Field
weld has black flag
67. The most sensitive method of locating cracking in a vessel made

of ferrous material is:
A) Fluorescent PT Method
B) Radiographic Testing Method
C) Fluorescent Magnetic Particle Method
D) Close visual Inspection with good lighting
Page | 24
NAME/BADGE #: __________________________________________________ Date:
____________
Answer: C Ref: API 572 Sect 9.4.4.2 & 9.3.14 & Figure 17 WFMPT
is most sensitive for CS
68. Inspectors may be assisted in performing inspections by other

properly trained and qualified individuals who are not inspectors.
These are called:
A) Certified welding inspectors and NDE technicians

B) Operating Personnel and NDE technicians
C) Examiners and Operating personnel
D) Examiners only are allowed
Answer = C Ref: API 510, Para. 4.2.4 & 4.2.6 Inspector

responsibilities
69. API 510 recognizes risk-based-inspection concepts for:
A) Evaluating in-service damage using API 510 rules only

B) Evaluating in-service damage using API 579 rules
C) Evaluating in-service damage using API 580 rules
Answer = D Reference: 510, Para. 1.3 API 580 is used to

determine inspection intervals!
70. What documents cover NDT requirements for examiner

qualification and certification?
A) CP-189 Standard & Practice SNT-TC-1A

B) ASNT Practice SNT-TC-1A & ASME Section V Code rules
C) CP-189 Standard & ASME Section V Code rules
D) API 510 rules & CP-189 Standard & Practice SNT-TC-1A & ASME Section V
Code rules
Answer = A Reference: 510, Section 2
71. Any welding technique used to obtain controlled grain

refinement and tempering of the underlying heat affected zone
(HAZ) in the base metal is called:
A) Controlled-deposition welding
B) Temper-bead welding
C) Half-bead welding
D) None of these
Page | 25
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = A Ref: API 510, Section 3.11 (Definition of Controlled-
Deposition Welding)
72. A point in the repair or alteration process beyond which work

may not proceed until the required inspection or NDE has been
performed and documented is called a(n):
A) Hold Point B) Witness Point

C) Inspection Point D) Examination Point
Answer = A Ref: API 510, Section 3.24 (Definition of Hold Point)
73. A strategy defining how and when a pressure vessel or pressure-

relieving device will be repaired, inspected, and/or maintained is
called a(n):
A) Repair Plan
B) Quality Plan
C) Inspection Plan
D) QA Inspection/Repair Mgmt System
Answer = C Ref: API 510, Section 3.32 (Definition of Inspection

Plan)
74. A repair organization may be any one of the following EXCEPT:
A) Holder of a valid ASME Certificate of Authorization (U-stamp)

B) Holder of a valid ASME Certificate of Authorization (R-stamp)
C) Owner/User of pressure vessels who repairs his own equipment
D) An individual or organization that is authorized by the legal jurisdiction
Ans = B Ref: API 510, Sect 3.54 (Definition of Repair Org)

National Board issues R-Stamp
75. Temper Embrittlement affects which low alloys and occurs in

what temperature range?
A) TE affects 1.25Cr-0.5Mo alloy steels in the 650F 1100F (345C 595C)

temp range
B) TE affects 2.25Cr-1.0Mo alloy steels in the 650F 1100F (345C 595C)
temp range
C) TE affects 1.25Cr-0.5Mo alloy steels in the 750F 1100F (400C 595C)
temp range
D) TE affects 2.25Cr-1.0Mo alloy steels in the 750F 1100F (400C 595C)
temp range
Page | 26
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = B Ref: API 510, Sect 3.59 (Definition of Temper
Embrittlement)
76. For P1, P3, P4, and P5 materials (for purpose of API 510
examination) the lower transition temperature and upper
transformation temperature regarding PWHT will be (respectively):
A) 1200F & 1500F

B) 1250F & 1500F
C) 1300F & 1600F
D) 1330F & 1600F
Answer = D Ref: API 510, Sect 2 (References) See the API 510
BODY OF KNOWLEDGE
77. Which of these is an inspection organization as recognized by

the API 510 code?
A) Inspection organization of a jurisdiction from outside of a jurisdiction where a

pressure vessel is used
B) Inspection organization of an insurance company that did not insure a given
pressure vessel
C) Owner or User who maintains an inspection organization for his own equipment
D) Independent outside contractor hired by an owner or user that is recognized by a
jurisdiction
Answer = C Reference: API 510, Para. 3.6.d Must be

recognized by a jurisdiction
78. Repair organization is responsible to owner/user and shall

provide all of these EXCEPT:
A) Materials
B) Equipment
C) Workmanship
D) Quality Assurance
Answer = D Ref: API 510, Par. 4.2.3 Repair Organization

provides Quality Control, not QA
79. Regarding CUI Inspection of externally-insulated vessels, the

susceptible temperature range for Austenitic Stainless Steel refers
to which of these operational temperature ranges?
A) 10F (12C) to 350F (175C)

B) 10F (12C) to 400F (205C)
C) 50F (10C) to 350F (175C)
D) 140F (60C) to 400F (205C)
Page | 27
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = D Ref: API 510, Par. 5.5.6.1.a/b CUI Inspection!
A) Eight (8) years is the maximum inspection interval since it cannot exceed
the Internal interval
B) Five (5) years is the maximum inspection interval allowed by API 510
given these conditions
C) Four (4) years is the maximum inspection interval allowed by API 510
given these conditions
Answer: B (API 510, External Inspection Rules, Para. 6.4.1)
81. RBI can be used to determine:
A) Inspection intervals only

B) Inspection intervals and the type of future inspections required only
C) Inspection intervals and the type and extent of future inspections only
D) Inspection intervals and the type and extent of future inspections and
examinations
Answer = D Ref: API 510, Para. 5.2 Risk-based Inspection
82. Per API 510, shell insert (flush) patches must meet all of these
requirements EXCEPT:
A) RT (applicable code) or UT (Inspector approved procedure/industry-

qualified SW examiner)
B) Any insert plate corners extend to an existing longitudinal or horizontal
weld
C) All insert plate corners are rounded with a - inch minimum radius
D) Full-penetration groove welds are required
Answer: C (API 510, Para. 8.1.5.2.2) The 1-inch radius rule must be
met Must know
83. The internal inspection shall be performed by:

A) An inspector in accordance with the inspection plan
B) An inspector in accordance with the owner/user quality manual
C) An examiner acceptable to the inspector in accordance with quality
manual
D) An inspector in accordance with the detailed procedures of the Authorized
Insp agency
Page | 28
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = A Ref: API 510, Para. 5.5.2.1 Internal Inspection
84. The API 510 recommended shell temp during a hydrostatic test
(A vessel = 2.5 in. thick)?
A) 30 o F above MDMT
B) 30 o F above ambient
C) 10 o F above MDMT
D) 10 o F above ambient
Answer: A (API 510 Sect/Para. 5.8.6.2 Be also aware of 2 in & less

rule = +10o F or +30o F)
85. Corrosion specialist shall be consulted when developing the

inspection plan for vessels that operate at elevated temperatures
above:
A) 650F (345C)
B) 700F (371C)
C) 750F (400C)
D) 800F (427C)
Answer = C Ref: API 510, Para. 5.1.1.1 Development of an

Inspection Plan
86. Direct visual examination is conducted when access is sufficient

to place the eye:
A) Within 6 in24 in (150600 mm) of exam surface & at an angle not less
than 20 to surface
B) Within 6 in12 in (150300 mm) of exam surface & at an angle not less
than 20 to surface
C) Within 12in-24 in (300-600 mm) of exam surface & at an angle not less
than 20 to surface
Answer: D Ref: API 577, Sect. 9.3.2.3 Answer = 6 24 inches

& 30 to surface
87. P-Number assignments are based on all of the following

comparable base metal characteristics except:
A) Weldability B) Composition
C) Welding Process types D) Mechanical properties
Answer: C Ref: API 577, Section 7.2 Materials P-Numbers
Page | 29
NAME/BADGE #: __________________________________________________ Date:
____________
88. Before performing any inspection, inspectors shall familiarize
themselves with prior history of the vessel and should review:
A) Prior inspection results & repairs, current inspection plan & similar service
inspection results
B) Prior repairs & prior inspection plans & similar service inspection results
only
C) Prior inspection & repair results & similar service inspection results only
D) Prior inspection and repair results only
Answer = A Ref: API 510, Para. 5.3 Preparation for Inspection

(Records Review)
89. When RBI assessments are used to set inspection intervals,

assessments shall be updated:
A) After each vessel inspection as defined in API 580

B) After a vessel undergoes any process change as per API 580
C) Only when the vessel inspection interval will be changed as per API 580
D) Only one time as documented and shall remain on file for the life of the
vessel per API 580
Answer = A Ref: API 510, Para. 5.2.4 Frequency of RBI

Assessments
90. Safety precautions are important in pressure vessel inspection

and maintenance activities and regulations govern many aspects of
vessel entry and must be followed. In addition, the:
A) Safety requirements of OSHA regarding confined space rules apply to API

510 inspections
B) Owner/users safety procedures must be reviewed and followed in all
cases
C) Vessel Inspection Plan must detail any confined space entry requirements
Answer = B Ref: API 510, Para. 5.3 Preparation for Inspection
91. A pressure vessel should be maintained according to:

A) The latest API 510 code requirements
B) The code under which it was designed and constructed
C) The latest API 510 code requirements and owner-user specifications
D) None of these
Answer: B (API 572, Section 4 Last Paragraph)
Page | 30
NAME/BADGE #: __________________________________________________ Date:
____________
92. Preheat temps used in making welding repairs shall be in
accordance with the applicable code and qualified welding
procedure, and the inspector should assure that:
A) Both welders and supervisors know the required preheat values
B) Welders know the minimum preheat temperature requirements
C) The minimum preheat temperature is measured and maintained
D) None of these are correct per API 510
Answer: C (API 510, Para. 8.1.6.3)
93. Vessel internals need not be removed completely as long as

reasonable assurance exists that damage at vessel areas covered by
the internals is:
A) Occurring to an extent that is not greater than that found in more
accessible vessel areas
B) Occurring to an extent that is not lesser than that found in more
accessible vessel areas
C) Occurring to an extent that is considered negligible or insignificant by the
Inspector
Answer = A Ref: API 510, Para. 5.5.2.2 Internal Inspection of

Vessel Internals
94. After repairs are completed, a pressure test shall be applied in

all of these cases EXCEPT:
A) If Inspector believes one is necessary
B) If an Engineer believes one is necessary
C) In event that a vessel section or component has been given a new nozzle
D) In event of a crack repair at a very deep excavation in an area of high
stress concentration
Answer: B (API 510, Para. 5.8.1.1 & 5.8.1.2)
95. If internal linings are in good condition and there is no reason to

suspect that damage is occurring behind them, what does API 510
state?
A) Extent and examination percentage beneath linings must be as stated in
the Inspection Plan
B) It is left to the discretion of the Authorized Pressure Vessel inspector &
Corrosion Specialist
C) Only spot exams need to be done so that there is reasonable assurance
no damage exists
D) It not necessary to remove linings during the internal inspection
Page | 31
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = D Ref: API 510, Para. 5.5.2.3 Internal Inspection of
Deposits and Linings
96. If the lining appears damaged, bulged or cracked, it may be

advisable to do all of the following EXCEPT:
A) Perform external NDE techniques to explore for vessel damage beneath

internal linings
B) Completely remove damaged, bulged & cracked linings for inspection of
vessel beneath
C) Remove small portions of linings & investigate vessel surfaces (Consult
Corrosion Specialist)
D) Remove small portions of linings & investigate lining condition (Consult
Corrosion Specialist)
Answer = B Ref: API 510, Para. 5.5.2.3 Internal Inspection of

Deposits and Linings
97. Rerating of a pressure vessel can involve all of these EXCEPT:
A) Changing its design temperature B) Changing its minimum metal

design temp
C) Changing its MAWP D) Changing its service
Answer: D (API 510, Para. 8.2.1)
98. Which of the following statements are NOT TRUE regarding On-
Stream Inspections?
A) An external inspection may be a part of an on-stream inspection

B) Inspections may include several NDE techniques to check for various
types of damage
C) Techniques are chosen for ability to identify internal damage mechanisms
from the exterior
D) Techniques are chosen for capabilities to perform at on-stream conditions
(e.g. metal temps)
Answer = A Ref: API 510, Para. 5.5.3.2 On-Stream Inspection

External Thickness Insp
99. During the external inspection, particular attention should be

given to:
A) Leakage, hot spots and evidence of vibration

B) The outside surface of the vessel and the insulation and coating systems
Page | 32
NAME/BADGE #: __________________________________________________ Date:
____________
C) Welded attachments such as reinforcement plates & clips checking for
cracks or defects
D) Associated structure, allowance for expansion, and general vessel
alignment on its supports
Answer = C Ref: API 510, Para. 5.5.4.1.2 External Inspection
100. If vessel stamp shows a 1997 construction date & a vessel has
not been rerated, then what is the minimum test pressure is to be
applied to satisfy API 510 code requirements?
A) Test Pressure in psi = 1.3 MAWP (S test temp / S design temp)

B) Test Pressure in psi = 1.4 MAWP (S test temp / S design temp)
C) Test Pressure in psi = 1.5 MAWP (S test temp / S design temp)
D) The test pressure is left to the discretion of the Inspector
101. After repairs are completed, a pressure test is to be applied.

Vessel stamp construction date = 1997 and the vessel was rerated
in 2009. Given: Vessel MAWP = 1,000 psi (2009) and the Stest
temp/Sdesign temp ratio = 1.1. What test pressure is to be applied
to meet code?
A) Test Pressure = 1.5 1000 x 1.1 = 1650 psi B) Test Pressure = 1.3
1000 x 1.1 = 1430 psi
C) Test Pressure = 1.4 1000 x 1.1 = 1540 psi D) None of these are
correct
Answer: B (API 510, Para. 5.8.2.1)
102. During repairs or alterations of pressure vessels, the inspector

shall verify that all new materials (including carbon steel) are
consistent with the specifications. At the discretion of owner/user or
inspector, assessment can be done by all of the following methods
EXCEPT:
A) 100% verification checks
B) Sampling a percentage of materials in critical situations
C) Positive Material Identification (PMI) Practices & Procedures
D) Optical fluorescence analyzers or x-ray spectrographic analyzers
Answer: D (API 510, Para. 5.9.1)
103. With no RBI, External vessel Inspection is required how often

and preferred when?
Page | 33
NAME/BADGE #: __________________________________________________ Date:
____________
A) Every five years, with the vessel in operation or out of operation, it
doesnt matter
B) Lesser of 5 yrs or required internal/on-stream inspection interval, vessel in
operation
C) Lesser of 5 yrs or required internal/on-stream inspection interval, vessel
not in operation
D) Lesser of 5 yrs or required internal/on-stream inspection interval, as the
Inspector requests
Answer: B (API 510, Definition of inspection, Para. 6.4.1)
104. For pressure vessels in non-continuous service, inspection

intervals can be based on the number of years of actual service that
the vessel operated, not calendar years, provided that all of the
following precautions are taken EXCEPT:
A) After being idled, a vessel is isolated from all process fluids
B) After being idled, a vessel is placed under a nitrogen purge
C) After being idled, a vessel is filled with non-corrosive hydrocarbons
D) After being idled, a vessel is completely drained and then opened to dry
out
Answer: D (API 510, Para. 6.5.1.2)
105. The inspector shall approve all specified repair and alteration
work at designated hold points and after completion of the work in
accordance with the:
A) Repair plan B) Inspection Plan
C) QA Plan D) QC Plan
Answer: A (API 510, Para. 8.1.2.2)
106. If the corrosion rate of a vessel is determined to be less than a

given amount per year, is it possible to perform an on-stream
inspection in lieu of internal inspection, yes or no, and what is the
value of the corrosion rate (CR) & the remaining life that cannot be
exceeded?
A) Yes and Corrosion rates must always be below 0.002 per year and
remaining life > 5 years
B) Yes and Corrosion rates must always be below 0.005 per year and
C) Yes and Corrosion rates must always be below 0.008 per year and
Page | 34
NAME/BADGE #: __________________________________________________ Date:
____________
D) No, it is not possible to exempt any vessel from its internal inspection with
any of the above
107. When reviewing RT film, a darkened perfectly straight line can

be seen in the very center of the root pass (lightest area). The
length of the line is about 75mm long. It is most likely:
A) Crack B) Incomplete fusion
C) Internal root undercut D) Incomplete penetration
Answer: D (API 577 Illustration for IP, Note 2)
108. Progressive records must be regularly updated and include

new information pertinent to all of the following items except:
A) Personnel Safety history with the equipment

B) Maintenance history of the equipment
C) Operational history of the equipment
D) Inspection history of the equipment
Answer: A (API 510, Para. 7.8.1)
109. Documentation of temporary repairs includes all of the

following EXCEPT:
A) Due date for installing a permanent repair

B) Plans to make a temporary repair permanent
C) Location of temporary repairs and specific repair details
D) Details of analyses performed and future inspection requirements
Answer: B (API 510, Para. 8.1.5.1.1)
110. Who must be consulted before repair of a crack at a

discontinuity where stress concentrations may be serious?
A) Both Engineer & Inspector B) R Stamp Holder or Vessel

Manufacturer
C) Inspector only D) Engineer only
Answer: D (API 510, Para. 8.1.5.2.1)
111. Typical permanent repair techniques include all of the following

EXCEPT:
A) Replacing an entire section or component containing defects
Page | 35
NAME/BADGE #: __________________________________________________ Date:
____________
B) Excavating a defect and contour blend-grinding per API 579
C) Lap Band repairs and Weld overlays of corroded areas
D) Excavating a defect and repair welding the excavation
Answer: C (API 510, Para. 8.1.5.2.1)
112. API authorized inspectors may give prior authorization for

routine repairs not involving:
A) Pressure tests B) Radiography

C) Pneumatic testing D) Final visual inspections
Answer: A (API 510 Section/Para. 8.1.1 Make sure you know the
routine repair rule)
113. The repair organization shall maintain records of its qualified

welding procedures and its welding performance qualifications.
What is the responsibility of the repair organization to the Inspector
regarding these records?
A) Records shall be available to the inspector at the start of welding

B) Records shall be available to the inspector prior to the start of welding
C) Records shall be available to the inspector anytime after the start of
welding
D) Records shall be available to the inspector within 1 week after the start of
welding
Answer: B (API 510, Para. 8.1.6.2.2)
114. Regarding PWHT, Local PWHT may be substituted for 360-

degree banding on local repairs on all materials, provided that the
following precaution is taken regarding preheating:
A) Preheat of 150F or higher, as specified in welding procedure, is
B) Preheat of 200F or higher, as specified in welding procedure, is
C) Preheat of 250F or higher, as specified in welding procedure, is
Answer: D (API 510, Para. 8.1.6.4.1) Preheat of 300F or higher
115. The most common forms of CUI are localized corrosion of

carbon steel and:
A) Localized pitting type corrosion of stainless steels
Page | 36
NAME/BADGE #: __________________________________________________ Date:
____________
B) General pitting type corrosion of stainless steels
C) Chloride SCC of austenitic stainless steels
D) None of the above attack stainless steels
Answer: C (API 572, Section 8.2.1)
116. If a RBI assessment is not performed, what is the greatest

possible time period allowed by API 510 between testing of pressure
relieving devices?
A) At intervals frequent enough to verify valves reliable performance
B) 5 years (for normal process services) and 10 years (for non-corrosive
services)
C) 10 years (for normal process services) and 10 years (for non-corrosive
services)
D) At every shutdown or T &I or as deemed necessary by the authorized
inspector
Answer: B (API 510, 6.6.2.2 Five years (typical process services /
10 yrs non-corrosive)
117. If the requirements of API 510 are met who determines if a

temporary fillet weld patch may be used in a repair?
A) An engineer and API authorized inspector

B) The API authorized inspector
C) A repair concern that holds a valid NBIC R stamp
D) The engineer
Answer: A (API 510 Section/Para. 8.1.5.1.2.1)
118. If white salts are found at cracks in a vessel, what is the likely
damage mechanism?
A) It is an indication that the vessel may suffer from hydrogen blistering

B) It is an indication that the vessel may suffer from caustic embrittlement
C) It is an indication that the vessel may suffer from chloride stress corrosion
cracking
D) It is an indication that the vessel may suffer from amine stress corrosion
cracking
Answer: B (API 572 Section/Para. 10.3.13 Third paragraph)
119. The rules for impact testing of carbon steel in Section VIII, Div.
1, Carbon steel vessel materials require what kind(s) of impact
tests?
A) Brinnell & Rockwell
Page | 37
NAME/BADGE #: __________________________________________________ Date:
____________
B) Izod & Charpy V-notch
C) Charpy V-notch
D) Brinnell
Answer: C (ASME IX, QW-170)
120. The purpose of the PQR is to establish the:
A) Properties of a weldment
B) Suitability of the weldment
C) Record for weldment construction
D) None of these are correct per API 577
Answer: A Ref: API 577, Sect. 6.1 Procedures General
121. ASME Section IX requires WHO to develop welding

procedures?
A) Each owner/user Engineering Organization

B) Each owner/user of the equipment
C) Each manufacturer & contractor
D) Each Inspection Organization
Answer: C Ref: API 577, Sect. 6.2 Procedures WPS Section
122. A completed WPS for a given welding process (assume it is

SMAW) shall address:
A) All essential variables

B) All essential and nonessential variables
C) All essential variables (Including supplemental essential variables if notch
toughness is reqd)
D) All essential & nonessential variables (supp. essential variables only if
notch toughness reqd)
Answer: D Ref: API 577, Sect. 6.2 Procedures WPS Section
123. The PQR shall record all of the following items except:
A) Manufacturers certification of accuracy in the qualification of a WPS

B) The nonessential variables used to weld a test coupon
C) The essential variables used to weld a test coupon
D) Coupon test results
Answer: B Ref: API 577, Sect. 6.3 Procedures PQR Section
124. F-number groupings are based essentially on their usability

characteristics, which fundamentally determine:
Page | 38
NAME/BADGE #: __________________________________________________ Date:
____________
A) The chemical composition of the electrode only
B) The chemical composition of the electrode and the weldability
C) The ability of welders to make satisfactory welds using similar composition
filler metals
D) The ability of welders to make satisfactory welds using a given process
and given filler metal
Answer: D Ref: API 577, Section 7.3 Materials F-Numbers
125. The A-number grouping in ASME Section IX, Table QW-442 is

based on the:
A) Chemical composition of the deposited weld metal and the base metal
B) Chemical composition of the deposited weld metal
C) Tensile strength of filler metal and base metal
D) Chemical composition of the base metal
Answer: B Ref: API 577, Section 7.5 Materials A-Numbers
126. Welder performance qualification expires if a welding process

is not used during a:
A) 3-month period
B) Six-month period
C) Nine-month period
D) Twelve-month period
Answer: B Ref: API 577, Section 8.2 Welder Qualification WPQ
127. Undercut (Per API 577, Table 6) can be corrected by (Practical

Solution Column):
A) Proper heat input & proper welding technique

B) Reduce travel speed and control arc length
C) Proper heat input & proper joint design
D) Reduce travel speed
Answer: D Ref: API 577, Section 9.1 NDE Discontinuities (Table

6)
128. Magnetic particle examination is effective in:

A) Locating surface discontinuities of ferromagnetic materials
B) Locating surface or near surface discontinuities of ferromagnetic materials
C) Locating surface or near surface discontinuities of ferromagnetic and
paramagnetic materials
Page | 39
NAME/BADGE #: __________________________________________________ Date:
____________
Answer: B Ref: API 577, Sect. 9.4.1 NDE MT General
129. For added sensitivity, which of the following PT techniques may

be used to detect fine linear type indications?
A) Fluorescent penetrant (Used in exams in darkened areas with filtered
black light)
B) Color Contrast Solvent Removable Visible Dye Penetrant (Technique)
C) Color Contrast Post emulsifiable Visible Dye Penetrant (Technique)
D) Color Contrast Water washable Visible Dye Penetrant (Technique)
Answer: A Ref: API 577, Sect. 9.6.1 NDE Liquid PT Techniques
130. Factors that can contribute to reduced accuracy of ultrasonic

measurements include all of the following EXCEPT:
A) Small flaw detector screens
B) Subsurface material flaws, such as laminations
C) Doubling of the thickness response on thicker materials
D) Temperature effects at temperatures above 150F (65C)
Ans = C Ref: API 510, Par. 5.7.2.4 Thickness Meas. Methods

(On thinner materials)
131. Regarding CUI Inspection of externally-insulated vessels, the

susceptible temperature range for Carbon & Low Alloy steels refers
to which of these operational temperature ranges?
A) 10F (12C) to 350F (175C) B) 10F (12C) to 400F (205C)
C) 50F (10C) to 350F (175C) D) 50F (10C) to 400F (205C)
Answer = A Ref: API 510, Par. 5.5.6.1.a/b CUI Inspection!
A) Five (5) years = maximum inspection interval allowed by API 510 rules
B) Four (4) years = maximum inspection interval allowed by API 510 rules
C) Two (2) years = maximum inspection interval allowed by API 510 rules
Answer: B (API 510, External Inspection Rules, Para. 6.4.1)
133. When a pressure vessel remaining life is less than 4 years, the
internal or on-stream inspection Interval may be:
A) Full remaining life (but less than 4 years)
Page | 40
NAME/BADGE #: __________________________________________________ Date:
____________
B) Full remaining life up to a maximum of 3 years
C) Full remaining life up to a maximum of 2 years
D) Only of the vessels remaining life in all cases where remaining life is
less than 4 years
Answer: C (API 510, Internal & On-stream Inspection Rules, Para.

6.5.1.1)
134. Assuming no RBI, On-stream inspections may be substituted

for internal inspections if all of the following are true EXCEPT:
A) Inspector must approve the substitution

B) Size or configuration makes internal inspection or vessel entry physically
impossible
C) General Corrosion rate is less than 5 MPY & vessel remaining life is greater
than 10 years
D) No questionable conditions were in evidence during performance of
External Inspections
Ans: B (510, Int. & On-stream Insp., Para. 6.5.2.1.b.1) PHYSICALLY

POSSIBLE = 7 RULES!
135. Who shall maintain certification records of examiners

employed, including dates and results of personnel qualifications
(that shall be made available to the inspector)?
A) Owner/user B) Examiners employer

C) Authorized Inspection Agency D) Authorized Pressure Vessel
Inspector
Ans = C Ref: 510, Par. 4.2.5.3 Inspectors employer By

definition = Auth. Insp Agency
136. Spring failures are almost always caused by:
A) Mechanical failure due to excessive movement and vibration

B) Corrosion that includes surface corrosion and stress corrosion cracking
C) Stress related failure due to improper sizing and using substandard parts
Ans: B (510, Para. 6.6.6 & API 576, Para 5.3.2 & Fig 30) PZV
Spring Failure Cause = Corrosion
137. Most cases of Brittle Fracture occur only at:
Page | 41
NAME/BADGE #: __________________________________________________ Date:
____________
A) Temperatures above Charpy Impact transition temperatures
B) Charpy Impact temperatures have no relationship to Brittle Fracture
occurrences
C) Temperatures below ambient and only in thick sections
D) Temperatures below Charpy Impact transition temperatures
Answer = D See Paragraph 4.2.7.3.e below Critical Factors
138. Equipment that suffers from Temper Embrittlement (TE) may be

susceptible to what other damage mechanism during start-up and
shut down?
A) Brittle Fracture B) Thermal Shock

C) Creep D) None of these
Answer = A API 571 Para 4.2.3.1 Last Sentence (Must Know)

Description of Damage
139. Which Equipment items below have experienced major

problems with Thermal Fatigue?
A) Coke Drums
B) Deaerators
C) Thermal or Catalytic Reactors
D) None of these
Answer = A 572 Section 9 statements regarding cracking and also

571, Para. 4.2.9.4.b & Figure 4-21 & 4-22 Appearance & Affected
Equipment API 572 highlighted item
140. Erosion-Corrosion occurs when corrosion contributes to erosion

by creating additional metal loss due to:
A) CO2 and/or oxygen gases

B) Removal of protective films and/or scales
C) Impact from solids, liquids, vapor or any combination of these
Answer: B API 571, Para. 4.2.14.1.b Erosion/Erosion-Corrosion

Question
141. Which item below best describes thermal fatigue cracking?
A) Surface initiated, narrow and along the grain boundaries, and oxide filled
craze cracks
Page | 42
NAME/BADGE #: __________________________________________________ Date:
____________
B) Surface initiated, generally wide and transgranular, oxide filled and
dagger shaped
C) Surface or subsurface initiated, wide, oxide filled and spider-web
appearance
Answer = B See Para. 4.2.9.5.a/b & Figures (Appearance)
142. Regarding examiner responsibilities, which of the following is

not a true statement?
A) He must be proven competent by owner/users & must hold certs in all

NDE procedures used
B) He does not need 510 certification and does not need to be an employee
of the owner/user
C) He shall perform the NDE in accordance with job requirements
D) He needs to be trained & competent in the NDE procedures being used
Answer = A Ref: API 510, Para. 4.2.5.1/2 Examiner

responsibilities May not must
143. The inspection plan should be developed by the:
A) Authorized Inspection agency

B) Inspector or Engineer
C) Owner/User
D) Engineer only
Answer = B Ref: API 510, Para. 5.1.1.1 Development of an

Inspection Plan
144. After an RBI assessment has been conducted, the results can
then be used to establish the:
A) Most appropriate inspection and NDE methods, tools, and techniques

B) Extent of NDE and the interval for internal, external, and on-stream
inspections
C) Need for pressure testing after damage has occurred or after
repairs/alterations are done
D) Vessel inspection plan
Answer = D Ref: API 510, Para. 5.2.3 Documentation (related to

RBI)
145. Pressure vessels are susceptible to various types of damage

mechanisms. The various types of damage mechanisms include all
of the following EXCEPT:
Page | 43
NAME/BADGE #: __________________________________________________ Date:
____________
A) Isolated and local metal loss and Blistering
B) Surface connected cracking and subsurface cracking
C) Metallurgical changes and material property changes
D) Dimensional changes and Microfissuring/microvoid formation
Answer = A Ref: API 510, Para. 5.4.1 Types of Damage General

and local metal loss
146. Which of the following steels are most susceptible to Temper

Embrittlement?
A) Carbon steels
B) C 0.5 Moly
C) 1.25Cr 0.5 Mo
D) 2.25Cr 1 Mo
Answer = D API 510 (Definition 3.59, Para 5.8.6.1 last sentence) &
571 Para 4.2.3.2.a
147. The most important factor in determining components

resistance to fatigue cracking is:
A) Geometry of the component

B) Stress levels & number of cycles
C) Material properties (strength, hardness, microstructure)
D) Design of the component is the most important of all factors
Answer: D API 571, Para. 4.2.16.3.a Mechanical Fatigue Question

GOOD DESIGN
148. HTHA damage is caused by which of these gases and is best

detected (determined) by:
A) Methane UT velocity ratio & backscatter

B) Hydrogen and sulfur WFMT
C) Hydrogen MT or PT
Answer = A See Paragraph 5.1.3.1.7.b Inspection & Monitoring
149. Severe internal grooving with deep pitting was found at the
bottom of a 4-inch CS elbow in a steam condensate system. This
damage was most likely caused by:
A) Erosion/Corrosion B) Chloride Corrosion

C) Ammonium Bisulfide Corrosion D) CO Corrosion
Page | 44
NAME/BADGE #: __________________________________________________ Date:
____________
Answer = D See Paragraph 4.3.6.5.b Appearance or Morphology
of Damage
150. Sulfidation damage is accelerated by the presence of:

A) Hydrogen
B) Sulfur
C) Salts
D) Corrosive Water
Answer = A See Paragraph 4.4.2.1 (Description of Damage)
Page | 45

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NAME/BADGE #: __________________________________________________ Date:

.700 .500 = .200 in. loss 10 yrs = 20 MPY

.600 .500 = .100 loss 5 yrs = 20 MPY

8. A new vessel is brought in to replace an old vessel being retired from a

12. Regarding a 2:1 ellipsoidal head, which is code acceptable

A) An acceptable approximation is a knuckle radius of 0.356D and a spherical radius

Answer: D (UG-32 d Read the last sentence underneath the formula 1)

13. Which statement is false regarding joint efficiencies for calculations

A) E = 1.0 when the spot radiography requirements of UW-11(a)(5)(c) is met

Answer: A UW-12 (d) & (e) & Table UW-12

A) E = 1, and required head t = 0.328 in.

Answer: B (UG-32 formula for ellipsoidal heads) See also App L

Formula to use to determine minimum ellipsoidal head

Heads: 2:1 ellipsoidal heads (.875 in. nominal).

15. Determine value E & required minimum ellipsoidal head thickness.

A) E = .70, required head t = 0.286 inches B) E = .70, required head t = 0.347

Formula to use to determine minimum 2:1 ellipsoidal head

16. Use same given information as question # 15 on the previous page.

A) E = .70, and required t = 0.286 inches B) E = .85, and required t =

Formula to determine minimum shell t with circumferential

See question 18 below for static head calcs!

A) T1 & T2 = Acceptable, T3 & T4 are unacceptable & 4 Guided bend tests =

Assume all f & fr values = 1

A) 5 minutes B) 10 minutes C) 20 minutes D)

27. Inspector measured undercut on a girth weld (No PWHT

Answer: D (ASME VIII, Div 1, UW-35.b.2) 1mm or 10%, whichever

28. If radiographic exam is used for qualification of a welder or

Answer: B Ref: API 577, Section 8.2 Welder Qualification WPQ

30. In lieu of insulation removal for a vessel, what alternative is

Answer = B Ref: API 510, Par. 5.5.6.3 CUI Inspection!

31. What is the minimum shell temperature to be maintained during

Answer: C (API 510 Section/Para. 5.8.6.2 Be aware of 2 in & less

32. For a pressure vessel in non-continuous service (operates only 4

A) Internal inspection interval = 10 calendar yrs & external inspection

33. Regarding Fitness for Service Analysis of Corroded areas in

D) None of these are correct

Answer: B (API 510, Par. 7.4.6.1) FFS Analysis of Corroded Regions

Answer: A (API 510, Para. 8.1.5.1.2.3) Temporary Repair Rules

Answer: B (API 510, External Inspection Rules, Para. 6.4.1) 5 years

36. Assuming no RBI assessment, the period between internal or on-

Answer: D (API 510, Para. 8.1.6.4.1) Welding & Hot Tapping

43. Assuming no RBI, If vessel entry is physically possible & all of

Answer: B (API 510, Para. 7.1.1.1) Corrosion Rate Determination

46. LT & ST Corrosion Rates should be compared (data assessment).

A) Inspector alone selects a rate that best reflects current conditions

Answer: D (API 510, Para. 7.1.1.2) Corrosion Rate Determination

Determine value E & required minimum hemispherical head t and show

A) E = 1, and required head t = 0.166 in. B) E = 1, and required head t = 0.176

Answer: B (UG-32. f, formula 3) See also Appendix L-1.5.1(d) example

Formula to use to determine minimum hemispherical head

Answer = A Ref: UG-80 (a) (1)

A) Per the approved RT procedure

Spot Radiography Rules UW-52

END OF API 510 OPEN BOOK EXAM B

51. Who is responsible to the owner/user to assure that the NDE,

A) Authorized Pressure Vessel Inspector

Answer = A Ref: API 510, Para. 4.2.4 Inspector responsibilities

A) Any comparable or duplicate replacement due to severe corrosion or other

Answer = B Reference: API 510, Section 3.2 (Definition of an

53. Per API 510, a non-standard vessel is one that was:

Answer = C Reference: API 510, Para. 1.1.1.d Non-Standard

54. Designated areas on pressure vessels where periodic exams are

A) Thickness measurement points B) Examination points