Api 510 MCQ
Api 510 MCQ
Api 510 MCQ
A) Not fabricated to a recognized construction code & 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 = A … Reference: API 510, Para. 1.1.1.b Non-Code vessel = self explanatory answer
Answer = B … Reference: API 510, Para. 1.1.1.d Non-Standard vessel = missing a nameplate
Answer = D … Reference: 510, Par. 1.1.2 Ans = C All 5 entities are required
4. Which API 510 Appendix lists qualification and certification requirements for Inspectors?
A) Appendix A B) Appendix B
C) Appendix C D) Appendix D
5. Which statement is true regarding conflicts between API 510 and jurisdictional regulations?
A) Even if 510 code rules are less stringent, 510 code rules will always apply
B) Both 510 and jurisdiction rules must always be met and conflicts resolved
C) If 510 code rules are more stringent, then the 510 code rules will always apply
D) Owner/User may elect to follow either of the rules as long as it is documented
Answer = C … Reference: 510, Par. 1.1.3. … Also, remember this *** Star Question … We can
never break any jurisdiction rules by following API 510 code … API 510 does not allow this!!!
API 510 Code Closed Book Exam Questions (Sections 1 & 2)
6. Which Appendix in API 510 lists the types of vessels that MAY be excluded from the code?
A) Appendix A B) Appendix B C) Appendix C D) Appendix D
7. Which of these are NOT to be excluded from specific requirements of API 510 code?
A) Classes of containers listed for exemption from the scope of ASME Section VIII, Div. 1 & 2
B) Those with internal/external operating pressures not exceeding 15 psi regardless of size
C) Cargo or volume tanks on trucks, ships, and barges covered by jurisdictional regulations
D) Those containing water with design pressure/temp above 300 psi & above 210°F (99°C)
Answer = D … Ref: 510, Para. 1.2.2 & App. A, item a.1, b.1, b.6, b.8 … OPEN OR CLOSED BOOK
Note: B might also be correct except that the 6 inch (15 cm) minimum rule applies to the size
8. Which of these are excluded from the specific requirements of the API 510 code?
A) Pressure vessels on movable structures not covered by other jurisdictional regulations
B) All classes of containers not exempted by the scope of ASME Sect. VIII, Div 1
C) Pressure vessels designed for an internal pressure less than 15 psig
D) Pressure vessels with designs exceeding NPS 6 (inside diameter)
9. Pressure Vessels excluded from the API 510 code rules may include all of the following that
are located on movable structures and covered by jurisdictional regulations EXCEPT for:
A) Cargo or volume tanks for trucks, ships, and barges
B) Pressure vessels installed for railways or those that use railcars
C) Air receivers associated with braking systems of mobile equipment
D) Pressure vessels installed in ocean-going ships, barges, and floating craft
10. Vessels containing water under pressure are excluded from 510 code rules if design
pressure & temperature does not exceed:
A) 250 psi and 212°F (100°C)
B) 300 psi and 210°F (99°C)
C) 350 psi and 212°F (100°C)
D) 400 psi and 210°F (99°C)
A) Maximum Volume of 5ft³ (0.141 m³) with a maximum design pressure of 250 psi (1723 KPa)
B) Maximum Volume of 3ft³ (0.08 m³) with a maximum design pressure of 350 psi (2410 KPa)
C) Maximum Volume of 2.5ft³ (.07 m³) with a maximum design pressure 1000 psi (6892 KPa)
D) Maximum Volume of 1.5ft³ (.042 m³) with a maximum design pressure 600 psi (4137 KPa)
Ans = C … Ref: 510, App. A, Subsect.* reads d … 510 Typo … C exceeds limits OPEN BOOK
Answer = B … Reference: 510, Para. 1.3 API 580 is used to determine inspection intervals!
14. What API Publication covers welding & hot tap procedures for in-service pressure vessels?
15. What documents cover NDE examiner qualification and certification respectively?
A) Addition of a size 8 NPS reinforced nozzle in a vessel having nozzles sized 2NPS, 3NPS & 6NPS
B) Addition of several new LWN-type nozzles size 2 NPS and 3 NPS not requiring reinforcement
C) Replacement of an existing size 18 NPS reinforced man way nozzle
D) None of the above should be considered an alteration
17. Which of these should be considered an alteration to a pressure vessel per API 510?
18. Which of these should be considered an alteration to a pressure vessel per API 510?
19. Which of these should be considered an alteration to a pressure vessel per API 510?
20. Which of these should NOT be considered an alteration to a pressure vessel per API 510?
A) Replacement of a corroded sump (20 NPS Schedule 40) with a new sump (20 NPS Sch. 80)
B) Addition of a reinforced nozzle less than or equal to the size of existing reinforced nozzles
C) Replacement of a corroded hemi head (E = 0.85, RT 2) with a new hemi head (E = 1.00, RT 1)
D) Addition of 2 new reinforced nozzles in a shell with no shell nozzles & 2 smaller head nozzles
A) Rerating B) Redesign
C) Repair D) Alteration
22. The code, code section, or other recognized and generally accepted engineering standard
or practice to which the pressure vessel was built or which is deemed by the owner/user or
the engineer to be most appropriate for the situation is called the:
Answer = D … Reference: API 510, Section 3.3 (Definition of applicable construction code)
23. The code or standard for which a vessel was originally built to is called the:
24. A shortened title for API 510 is … Or … API 510 is called the:
25. Which one of these is NOT considered an Authorized inspection agency per API 510?
A) Inspection organization of the jurisdiction outside of that in which the pressure vessel is used
B) An Insurance company’s inspection organization that is licensed & writes insurance for a PV
C) Inspection organization of an owner/user of pressure vessels who maintains an inspection
organization for his equipment only and not for vessels intended for sale or resale
D) Independent organization under contract and under the direction of an owner/user that is
recognized by the jurisdiction in which the pressure vessel is used.
Answer = A … Reference: API 510, Section 3.6 (Definition of Authorized Inspection Agency)
API 510 Code Closed Book Exam Questions (Section 3)
26 duplicated. Which of these is NOT considered Authorized inspection agency per API 510?
A) Inspection organization of the jurisdiction outside of that in which the pressure vessel is used
B) An Insurance company’s inspection organization that is licensed & writes insurance for a PV
C) Inspection organization of an owner/user of pressure vessels who maintains an inspection
organization for his equipment only and not for vessels intended for sale or resale
D) Independent organization under contract and under the direction of an owner/user that is
recognized by the jurisdiction in which the pressure vessel is used.
Answer = A … Reference: API 510, Section 3.6 (Definition of Authorized Inspection Agency)
27. Which one of these is NOT considered an Authorized inspection agency per API 510?
A) Inspection organization of the jurisdiction in which the pressure vessel is used
B) An Insurance company’s inspection organization that is licensed & writes insurance for a PV
C) Inspection organization of an owner/user of pressure vessels who maintains an inspection
organization for his equipment and also for the sale or resale of pressure vessels
D) Independent organization under contract and under the direction and controls of an
owner/user that is recognized by the jurisdiction in which the pressure vessel is used.
Answer = C … Reference: API 510, Section 3.6 (Definition of Authorized Inspection Agency)
28. An employee of an authorized inspection agency who is qualified and certified to perform
inspections under the API 510 is called a(n):
A) QA Inspector B) QC Inspector
C) Examiner D) None of these
Answer = D … Ref: API 510, Section 3.7 (Definition of Authorized Pressure Vessel Inspector)
29. Whenever the term inspector is used in API 510, it refers to a(n):
A) QA Inspector B) QC Inspector
C) Examiner D) None of these
Answer = D … Ref: API 510, Section 3.7 (Definition of Authorized Pressure Vessel Inspector)
EXAM TIP: When you see a “None of the Above” answer It’s most likely a correct answer
Correct answer was “too easy” … so they used “None of these” … EXPECT A FEW LIKE THIS!
30. A shortened title used in API 510 for Authorized Pressure Vessel Inspector is:
A) QA Inspector B) Inspector
C) Examiner D) Vessel Inspector
A) QA Inspector B) QC Inspector
C) Examiner D) AWS CWI Inspector
32. Designated areas on pressure vessels where periodic exams are conducted are called:
Answer = D … Ref: API 510, Section 3.9 (Definition of Condition Monitoring Locations or CMLs)
Correct answer was “too easy” … I used “None of these” hoping to trick you! Did it work?
33. CMLs are an abbreviation (for what term) and were previously referred to (as what term)
in past API 510 code editions?
Answer = B … Ref: API 510, Section 3.9 (Definition of Condition Monitoring Locations or CMLs)
34. Any welding technique used to obtain controlled grain refinement and tempering of the
underlying heat affected zone (HAZ) in the base metal is called:
35. In the half-bead welding technique, the term “half-bead” refers to the fact that:
A) The weld shall be deposited with stringer beads and is half the width of a normal weld bead
B) All welded layers must be ground down after being deposited (removal of half of all layers)
C) The thickness of the first weld layer deposited must be reduced by one-half by grinding
D) The thickness of the final weld layer deposited must be reduced by one-half by grinding
Answer = C … Ref: API 510, Section 3.11 (Definition of Controlled-Deposition Welding)
Note: Temper-bead technique refers to “tempering of the layer below the current bead being
deposited” … Know both are Controlled-Deposition Welding Methods used in lieu of PWHT
API 510 Code Closed Book Exam Questions (Section 3)
36. A methodology whereby flaws and conditions contained within an equipment item are
assessed in order to determine the integrity of the equipment for continued service is called:
37. 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
38. A response or evidence resulting from the application of a Nondestructive exam is called:
A) Defect B) Imperfection
C) Discontinuity D) Indication
39. An imperfection whose type or size exceeds the applicable acceptance criteria is called:
A) Discontinuity B) Flaw
C) Defect D) Indication
Answer = C … Ref: API 510, Section 3.15 (Definition of Defect) Beware of the Open Book
question on Table 8,9,10 of API 577 Pg 56 that asks for Definition of Discontinuity, flaw, etc)
40. A Flaw or other discontinuity noted during inspection that may or may not exceed the
applicable acceptance criteria is called:
A) Defect B) Imperfection
C) Indication D) None of these
A) Repair Plan
B) Inspection Plan
C) Quality Plan
D) QA Inspection/Repair Mgmt System
42. Work needed to restore a vessel to a condition suitable for safe operation at design
conditions is called a(n):
A) Alteration B) Rerating
C) Repair D) Derating
43. If any of the restorative work to a pressure vessel results in a change to the design
temperature, MDMT, or MAWP, the work shall be considered a(n):
A) Alteration B) Rerating
C) Repair D) Derating
44. A change, either an increase or a decrease, in either design temperature rating, MDMT or
MAWP rating of a vessel is called a(n):
A) Alteration B) Rerating
C) Modification D) Derating
45. When a vessel is nearing its minimum allowed thickness, a permissible way to provide for
additional corrosion allowance without using a repair organization is:
A) Perform an alteration on the vessel and change the original design conditions
B) Rerating the vessel above the original design conditions
C) Repairing the vessel to restore the original design conditions
D) Derating the vessel below original design conditions
Ans = B … Ref: API 510, Sect 3.54 (Definition of Repair Org) National Board issues R-Stamp
Ans = D … Ref: API 510, Sect 3.54 (Definition of Repair Org) acceptable to the Owner/User
Ans = C … Ref: API 510, Sect 3.54 (Definition of Repair Org) authorized by legal jurisdiction
53. Type of assessment & management process that is focused on inspection planning for loss
of containment of pressurized equipment in process facilities due to material deterioration is:
54. Regarding RBI, risks are managed primarily through Inspection in order to influence:
55. Reduction in toughness due to a metallurgical change can occur in some low alloy steels
as a result of long term exposure at 650ºF – 1100ºF (345ºC – 595ºC) temp range is called:
A) Creep
B) Brittle Fracture
C) Temper Embrittlement
D) High Temperature Hydrogen Attack (HTHA)
A) TE affects 1.25Cr-0.5Mo alloy steels in the 650ºF – 1100ºF (345ºC – 595ºC) temp range
B) TE affects 2.25Cr-1.0Mo alloy steels in the 650ºF – 1100ºF (345ºC – 595ºC) temp range
C) TE affects 1.25Cr-0.5Mo alloy steels in the 750ºF – 1100ºF (400ºC – 595ºC) temp range
D) TE affects 2.25Cr-1.0Mo alloy steels in the 750ºF – 1100ºF (400ºC – 595ºC) temp range
A) 1200°F & 1500°F B) 1250°F and 1500°F C) 1300°F and 1600°F D) 1330°F & 1600°F
Answer = D … Ref: API 510, Sect 2 (References) See the API 510 BODY OF KNOWLEDGE
59. Which of these does NOT qualify a person for an API 510 certification?
A) BS Eng. degree with 2 years total PV experience (1 year in PV Inspection per API 510)
B) AS Eng. degree with 2 years total PV experience (1 year in PV Inspection per API 510)
C) HS graduate with 2 years total PV experience (1 year in PV Inspection per API 510)
D) Any Person with 5 years total PV experience (1 year in PV Inspection per API 510)
Answer = C … Ref: API 510, Para. B.2.1.c Three years total PV experience is required
60. All of these describe experience that may qualify one to be an API 510 Inspector EXCEPT?
A) Both performance & supervision of Inspection activities per API 510
B) Experience in design of PVs & supervision of Inspection activities per API 510
C) Experience in operation of PVs & performance of Inspection activities per API 510
D) Experience in Construction & Repair of Pressure Vessels in accordance with API 510
Answer = D … Ref: API 510, Para. B.2.1.b/c/d 1 year must be in Insp Supervision/Performance
API 510 Code (16 Closed Book Topics) Topic # 1
61. Which of these is NOT an authorized inspection agency according to API 510?
A) Insurance company inspection organization that did not insure a given pressure vessel
B) Independent outside contractor hired by owner or user but not recognized by a jurisdiction
C) Owner or user who maintains an insp org for his equip only (not for vessels for sale or resale)
D) Inspection organization of a jurisdiction outside a jurisdiction where a pressure vessel is used
Answer = C … Ref: API 510, Para. 3.6.c His equipment only … not intended for sale or resale
Ans = A … Ref: API 510, Para. 3.54.a/b/c/d Must be “authorized” by the legal jurisdiction
64. Who is responsible to execute the inspection plan including the established schedule?
65. Who shall exercise overall control of activities relating to in-service inspection, repair,
alteration & rerating of pressure vessels and pressure relieving devices?
Answer = C … Ref: API 510, Para. 4.2.3 Repair Organization responsibilities MUST KNOW
68. Owner/user quality assurance insp/repair management system contains all these EXCEPT:
69. Who is responsible to owner/user for activities involving design, analysis, or evaluation of
pressure vessels and pressure-relieving devices covered by the API 510 code?
A) Authorized Inspection Agency B) Authorized Pressure Vessel Inspector
C) Corrosion Specialist D) None of these are correct
Answer = D … Ref: API 510, Para. 4.2.2 ENGINEER RESPONSIBILITIES Tricky answer = D!!!
70. Who is responsible to the owner/user to assure that the inspection, NDE, and pressure
testing activities meet API 510 requirements?
Answer = B … Ref: API 510, Par. 4.2.3 Repair Organization provides Quality Control, not QA
72. Inspectors may be assisted in performing inspections by OTHER PROPERLY TRAINED AND
QUALIFIED INDIVIDUALS called:
Answer = C … Ref: API 510, Para. 4.2.4 & 4.2.6 Inspector responsibilities
Answer = D … Ref: API 510, Par. 4.2.4 Inspector responsibilities Did you miss it again?
74. 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 needs to be trained and competent in the NDE procedures being used
D) He shall perform the NDE in accordance with job requirements
Answer = A … Ref: API 510, Para. 4.2.5.1/2 Examiner responsibilities MAY NOT MUST
75. Who shall maintain certification records of examiners employed, including dates and
results of personnel qualifications (that shall be made available to the inspector)?
Ans = C … Ref: 510, Par. 4.2.5.3 Inspector’s employer By definition = Auth. Insp Agency
Note: API 570 requires the Examiners’ Employer to maintain certification records
API 510 Code (16 Closed Book Topics) Topic # 2
76. Per API 510, a strategy defining how and when a pressure vessel or pressure-relieving
device will be inspected, repaired, and/or maintained is called a(n):
78. Who shall be consulted when needed to clarify potential damage mechanisms and
specific damage locations when developing an Inspection Plan?
79. Corrosion specialist shall be consulted when developing the inspection plan for vessels
that operate at elevated temperatures above:
80. Examinations must be scheduled at intervals that consider ALL THESE FACTORS EXCEPT:
Answer = D … Ref: API 510, Para. 5.1.1.2 Development of an Inspection Plan … Maximum
intervals are defined in the codes and standards, not in the inspection plan
API 510 Code (16 Closed Book Topics) Topic # 2
81. Inspection plans shall contain inspection tasks and schedule required to MONITOR
DAMAGE MECHANISMS & ASSURE EQUIPMENT’S MECHANICAL INTEGRITY. Inspection plans
should cover all of the following details EXCEPT:
A) Describe any required repairs and include the repair plan in detail
B) Describe necessary pressure tests, type of tests, test pressures, and duration
C) Define type(s) of inspection needed & identify next inspection date for each inspection type
D) Describe insp & NDE technique & extent & location of insp & NDE including cleaning needed
Answer = A … Ref: API 510, Para. 5.1.2 MINIMUM CONTENTS OF AN INSPECTION PLAN
82. What types of inspection plans are based on industry standards and practices and may be
used under API 510 rules:
A) Similar service inspection plans B) Generic inspection plans
C) Standard Industry Practices D) Risk-based inspection plans
Answer = B … Ref: API 510, Para. 5.1.2 Minimum Contents of an Inspection Plan
83. Inspection plans may or may not exist in a single document, but the contents of the plan
should be readily accessible from:
A) Inspection Records B) Inspection data systems
C) Authorized Inspection Agency files D) Progressive records
Answer = B … Ref: API 510, Para. 5.1.2 Minimum Contents of an Inspection Plan
84. Inspection plans may also contain “other additional details” to assist in understanding the
rationale for the plan and in executing the plan that may include:
Answer = C … Ref: API 510, Para. 5.1.3 Additional Contents of an Inspection Plan
88. When owner/user conducts an RBI assessment, it must include a systematic evaluation of:
89. In RBI, important steps in assessing the probability of a pressure vessel failure include:
A) Identifying and evaluating effectiveness of past equipment inspection methods & techniques
B) Assessing those existing damage mechanisms (DMs) that are most likely to affect equipment
C) Identifying/evaluating potential DMs/current equip conditions/past inspection effectiveness
D) Assessing all possible DMs likely to affect current equipment using existing insp techniques
90. In RBI, important steps in assessing the consequence of a pressure vessel failure include
identifying and evaluating all of these EXCEPT:
A) The nature of the process fluid(s) B) Potential injuries that could occur
C) Environmental/equipment damage D) Potential damage mechanisms
Answer = C … Ref: API 510, Para. 5.2.1 Probability Assessment (related to RBI)
A) Associated health effects, environmental and equipment damage and equipment downtime
B) Type and amount of process fluid contained in the equipment
C) Potential incidents that may occur as a result of fluid release
D) Size and the type of a potential release
Answer = B … Ref: API 510, Para. 5.2.2 Consequence Assessment (related to RBI)
93. After an RBI assessment is conducted, the results can be used to establish the:
94. After an RBI assessment is conducted, the results can be used to establish the VESSEL
INSPECTION PLAN and better define all of these items EXCEPT:
A) The most appropriate inspection and NDE methods, tools, and techniques
B) The extent of NDE (percentage of vessel to examine) and the applicable inspection interval
C) The need for pressure testing after damage has occurred or after repair/alterations are done
D) The prevention & mitigation steps to eliminate probability & consequences of a vessel failure
Answer = D … Ref: API 510, Para. 5.2.3 Documentation (related to RBI) Reduce probability
95. When RBI assessments are used to set vessel inspection intervals, assessments shall be:
A) Documented one time and shall remain on file for the life of the vessel
B) Updated only when the vessel inspection interval will be changed
C) Updated after any a vessel undergoes any process change
D) Updated after each vessel inspection
97. Personal protective equipment shall be worn when required for all these reasons EXCEPT:
A) Regulations (Jurisdictional & others) B) Owner/user requirements
C) Authorized Inspection Agency rules D) Repair organization requirements
Answer = C … Ref: API 510, Para. 5.3 Preparation for Inspection (Equipment)
98. Which of these statements are not true regarding precautions to be taken before
beginning any vessel inspection & maintenance activities (NDE, pressure test, repair, etc)?
A) Obtain permission to work in the area from operating personnel responsible for a vessel
B) When individuals are inside a vessel, all persons working around a vessel should be informed
C) Individuals working inside vessels should be informed when work is going on outside a vessel
D) Permission should be obtained from the owner/user Safety Department
Answer = D … Ref: API 510, Para. 5.3 Preparation for Inspection (Communication)
99. All of the following statements are true regarding precautions to be taken prior to
entering a vessel EXCEPT:
A) Vessel shall be isolated from all sources of liquids, gases, vapors, radiation and electricity
B) Vessel shall be drained, purged, cleaned, ventilated, and then gas tested before it is entered
C) Procedures to ensure continuous safe ventilation and precautions to ensure safe egress and
emergency evacuation of personnel from the vessel should be clear
D) Documentation of safety precautions is required prior to any vessel entry. Before entering a
vessel, individuals must obtain permission from the responsible operating personnel
Answer = B … Ref: API 510, Para. 5.3 Preparation for Insp (Vessel Entry) … Should not shall
100. Before performing any of the required API 510 inspections, inspectors shall familiarize
themselves with the vessel’s prior history and should review:
A) Prior inspection results/repairs, current inspection plan, and similar service inspection results
B) Prior inspection and repair results, prior inspection plans & similar service inspection results
C) Prior inspection and repair results, and prior inspection plans only
D) Prior inspection and repair results only
Answer = A … Ref: API 510, Para. 5.3 Preparation for Inspection (Records Review)
API 510 Code (16 Closed Book Topics) Topic # 2
101. Pressure vessels are susceptible to various types of damage mechanisms that include all
of these EXCEPT:
Answer = A … Ref: API 510, Par. 5.4.1 Types of Damage General and localized metal loss
102. The presence or potential of damage in a vessel is dependent upon its material of
construction, quality of construction, operating conditions and:
103. Detailed information in API 571 about common damage mechanisms (DMs) includes:
A) The most important DMs, such as CUI & general and localized metal loss
B) Critical factors, affected equipment, and appearance or morphology for each DM
C) Critical factors, appearance and typical inspection & monitoring techniques for each DM
D) Critical factors, appearance, prevention and mitigation, and affected equipment for each DM
Answer = C … Ref: API 510, Para. 5.4.3 General types of Inspection There are Routine
inspections, but the routine inspection is not considered one of 5 general types of inspection!
Answer = D … Ref: API 510, Para. 5.4.3 General rules for the 5 general types of Inspection
API 510 Code (16 Closed Book Topics) Topic # 2
106. The internal inspection shall be performed by:
A) An inspector in accordance with the detailed procedures of the Authorized Insp agency
B) An examiner acceptable to the inspector in accordance with quality manual
C) An inspector in accordance with the owner/user quality manual
D) An inspector in accordance with the inspection plan
108. For equipment not designed for entry by personnel, what must be done per API 510?
A) Only On-Stream inspections must always be done when a vessel is inaccessible
B) A combination of On-Stream and External inspections and UT thickness must be employed
C) A best effort internal insp may be done by removing pipe spools (view through the nozzle)
D) Inspection ports shall be opened for ID surface exams allowing remote visual insp techniques
109. When vessels are equipped with removable internals, internals may need removal to:
A) Assure no unusual condition or corrosion on inaccessible parts of removable internals exist
B) Allow inspection of pressure boundary surfaces to an extent deemed necessary by Inspector
C) Allow inspection of vessel internal components to an extent deemed necessary by Inspector
D) Assure that the removable internals are in serviceable condition and fit for continued service
Answer = B … Ref: API 510, Para. 5.5.2.2 Internal Inspection of Vessel Internals
110. 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
D) None of these is correct
Answer = A … Ref: API 510, Para. 5.5.2.2 Internal Inspection of Vessel Internals
API 510 Code (16 Closed Book Topics) Topic # 2
111. Who should determine when it is necessary to remove deposits or linings to perform
adequate internal inspections?
Answer = A … Reference: API 510, Para. 5.5.2.3 Internal Inspection of Deposits and Linings
112. 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?
Answer = B … Reference: API 510, Para. 5.5.2.3 Internal Inspection of Deposits and Linings
113. If the lining appears damaged, bulged or cracked, it may be advisable to take all of the
following actions (EXCEPT):
A) Completely remove damaged, bulged & cracked linings for inspection of vessel beneath
B) Remove small portions of linings & investigate lining condition (Consult Corrosion Specialist)
C) Remove small portions of linings & investigate vessel surfaces below (Consult Corr. Specialist)
D) Perform external NDE techniques to explore for vessel damage beneath these internal linings
Answer = A … Reference: API 510, Para. 5.5.2.3 Internal Inspection of Deposits and Linings
A) Authorized and approved by owner/user who may require additional qualification tests
B) Authorized and approved by the Authorized Inspection Agency
C) Authorized and approved by the Engineer
D) Authorized and approved by Inspector
Answer = D … Ref: API 510, Para. 5.5.3.1 On-Stream Inspection
API 510 Code (16 Closed Book Topics) Topic # 2
116. When on-stream inspections of a pressure boundary are specified, they shall be
designed to:
117. Which of the following statements are NOT TRUE regarding On-Stream Inspections?
Answer = A … Ref: API 510, Para. 5.5.3.2 On-Stream Inspection External Thickness Insp
120. When acceptable to the Inspector, who may conduct external inspections per API 510?
A) Associated structure, allowance for expansion, and general vessel alignment on its supports
B) Condition of the outside surface of the vessel and the insulation and coating systems
C) Leakage, hot spots and evidence of vibration
D) Thickness measurement checks
122. During the external inspection, particular attention should be given to:
A) Welded attachments such as reinforcement plates & clips checking for cracks or defects
B) Associated structure, allowance for expansion & general vessel alignment on supports
C) The outside surface of the vessel and the insulation and coating systems
D) Leakage, hot spots and evidence of vibration
123. During External inspection, vessels shall be examined for visual indications (evidence) of:
124. If any distortion of a vessel is suspected or observed, overall vessel dimensions shall be:
125. What API document provides more information on external pressure vessel inspection
and should be used when performing an API 510 external pressure vessel inspection?
A) Owner/User representative
B) Engineer
C) Repair or Maintenance Organization
D) Inspector
127. Buried vessels shall be inspected to determine external surface condition & inspection
intervals shall be based on corrosion rate info obtained from any of these (methods) EXCEPT:
A) During maintenance activity on any connecting piping that is attached to the buried vessel
B) From the interval examination of similarly buried corrosion test coupons of like material
C) From representative (random areas chosen by Inspection) portions of the actual vessel
D) From a vessel in similar circumstances (having similar buried conditions, i.e., soil conditions)
Ans = A … Ref: API 510, Par. 5.5.4.2 Ext Insp of Buried Vessel Must be similar type piping
128. Thickness measurement data taken from pressure vessels is used to:
A) Examiner
B) Inspector
C) Inspector or examiner
D) Anyone authorized by the Inspector
130. Which of these statements are true regarding Thickness measurements per API 510?
B) Measurements to be obtained are required while the pressure vessel is not on-stream
C) On-stream monitoring is not a good tool for monitoring corrosion
D) On-stream monitoring is a good tool to assess potential damage due to process changes
Answer = D … Ref: API 510, Par. 5.5.5.2 Thickness Inspection
A) No one, because the Inspector is responsible for determining the corrosion rate
B) Owner/User representative responsible for Operations
C) Pressure Vessel Engineer responsible for Operations
D) None of these is correct
Answer = D … Ref: API 510, Par. 5.5.5.3 Thickness Insp Answer = Corrosion Specialist
132. The inspector should consult with a corrosion specialist when the short term corrosion
rate changes significantly from the previous identified rate (for what reason)?
Answer = B … Ref: API 510, Par. 5.5.5.3 Thickness Insp UT scans in suspect areas
134. Which of the following statements is true regarding the training and qualification
requirements in API 510 for personnel taking thickness measurement readings (UTT exams)?
A) They only need to be trained & qualified by their employers before performing any exams
B) They need to be trained & qualified enough to demonstrate their proficiency to the Inspector
C) They only need to be trained & qualified as per the applicable procedure used during exams
D) None of these is correct per API 510
135. Who is responsible to assure that all individuals taking thickness readings are trained
and qualified in accordance with the applicable procedure to be used during examinations?
A) Owner/User B) Inspector
C) Authorized Inspection Agency D) Examiner’s employer
Answer = A … Ref: API 510, Par. 5.5.5.4 Thickness Insp Owner User … again!
A) Metal loss is always generally smooth and uniform, and may be difficult to detect visually, so
thickness measurements may be necessary to determine the extent of the corrosion
B) Metal loss may be irregular (pitted) or generally uniform and not difficult to detect visually,
so thickness measurements may be necessary to determine the extent of the corrosion
C) Pitted surfaces may actually be thinner than they appear during visual exams & when there is
uncertainty about the original surface location, thickness determinations may be necessary
D) If no uncertainty exists for an original surface location in pitted areas, take thickness readings
Ans = C … Ref: API 510, Par. 5.7.2.1 Thickness Meas. Meth! If uncertainty exists UTT
137. Which of these is not suitable to determine minimum remaining vessel part thickness?
Ans = B … Ref: 510, Par. 5.7.2.1.a/b/c Thickness Meas Meth Gauging from uncorroded …
138. Proper repair of insulation and insulation weather coating following ultrasonic readings
at CMLs is recommended to reduce the potential for:
139. What thickness measurement techniques are preferred where corrosion is localized or
the remaining thickness is approaching the required thickness.
140. Above what temperature must UT readings be corrected due to high temp effects?
A) 100°F (38°C) B) 150°F (65°C) C) 212°F (100°C) D) None of these are correct
Answer = B … Ref: API 510, Par. 5.7.2.3 Thickness Measurement Methods!
142. Factors that can contribute to reduced accuracy of ultrasonic measurements include all
of the following EXCEPT:
A) Doubling of the thickness response on thicker materials
B) Subsurface material flaws, such as laminations
C) Temperature effects at temperatures above 150ºF (65ºC)
D) Small flaw detector screens
Ans = A … Ref: API 510, Par. 5.7.2.4 Thickness Meas. Methods (On thinner materials)
143. Factors that can contribute to reduced accuracy of ultrasonic measurements include all
of the following EXCEPT:
A) Excessive surface roughness
B) Excessive “rocking” of the probe on curved surfaces
C) Doubling of the thickness response on thinner materials
D) Temperature effects at temperatures above 210ºF (99ºC)
Answer = D … Ref: API 510, Par. 5.7.2.4 Thickness Measurement Methods 150ºF (65ºC)
144. Due to the effects of doubling, where UT readings are doubled on very thin components,
what method(s) best determine thickness (nearing the minimum required) for NPS 1 nozzle?
A) Ultrasonic scanning techniques only using an A-scan display
B) Radiographic profile techniques only
C) Either UT scanning (A-scan) or RT profile techniques
D) Eddy Current Techniques
Answer = C … Ref: API 510, Par. 5.7.2.2 Thickness Measurement Methods!
145. What type of ultrasonic display is best used on a corroded surface (reflecting surfaces
are pitted) and where digital meter (D-Meter) results produced considerable uncertainty?
A) There is no other factor, and it’s all based on Operating temperature ranges only
B) The other factor is the type of insulation that is applied to the pressure vessel
C) The other factor is the continuity of the service (all intermittent services are susceptible)
D) The other factor is ambient temperature of the location of the pressure vessel
149. With carbon and low alloy steels, CUI usually causes:
150. With austenitic stainless steel materials, CUI usually is evident as:
152. Areas most susceptible to CUI on vessels include all of the following EXCEPT:
A) Insulation penetrations (Nozzles, ladder clips, pipe supports) that can allow moisture ingress
B) Areas showing evidence of damaged insulation or caulking (sealant) failure
C) Top and bottom heads and other areas that tend to trap and hold water or moisture
D) Insulation rings or stiffening rings having designs where water or moisture cannot collect
153. If CUI damage is found in an area that is considered among the most susceptible on a
vessel, the inspector should:
A) Inspect 100% of all susceptible areas on the vessel after removal of all insulation necessary
B) Consult the Corrosion Engineer prior to any significant removal of the vessel’s insulation
C) Inspect other susceptible areas on the vessel
D) None of these is correct
154. CUI inspection may require removal of some or all insulation. If external coverings are in
good condition and there is no reason to suspect damage behind them, what should be
done?
A) Only a small sampling should be removed to verify that no damage exists
B) It is not necessary to remove any insulation for the inspection of the vessel
C) The portion to be removed as given in the inspection plan must be removed
D) The portion to be removed as given in the inspection plan may or may not be removed
depending upon the Inspector’s judgment
155. Considerations for insulation removal may include all of these EXCEPT:
A) History of CUI for a vessel or comparable equipment (Incl. Condition/age of external coating)
B) Visual condition of external covering and insulation and evidence of fluid leakage or stains
C) Equipment that does not see full time operation (equipment in intermittent service)
D) Equipment that sees full time operation below the susceptible temperature range
Answer = A … Ref: API 510, Par. 5.6.1 & Def: 3.9 Condition Monitoring Locations (CMLs)
158. Condition monitoring locations (CMLs) are designated areas on pressure vessels where
periodic examinations are conducted (for what primary purpose):
A) Monitor the presence of damage
B) Monitor the presence and rate of damage
C) Monitor the remaining vessel wall thickness
D) Monitor the vessel’s coating system condition
159. Which of the following factors (or combination of factors) shall be considered regarding
the type of CMLs selected and the placement of the CMLs on a given pressure vessel?
A) Potential for both localized and general corrosion
B) Potential for general corrosion & service-specific damage modes of deterioration & failure
C) Potential for localized corrosion & service-specific damage modes of deterioration & failure
D) None of these is correct
160. Examples of CMLs may include all of the following locations EXCEPT:
162. Exam results at CMLs determine the limiting component of a vessel (by what means)?
A) Results help to identify Corrosion rates, remaining life and set the next inspection intervals
B) Results help to identify damage mechanisms that may shorten the life of the pressure vessel
C) Results help to identify improvements and revisions needed to the Vessel’s inspection plans
D) None of these is correct
Answer = A … Ref: API 510, Par. 5.6.2.1 CMLs
163. All of the following types of pressure vessels will normally have more CMLs and will also
be monitored more frequently EXCEPT for:
164. What data shall be used from CMLs (examination points) to calculate corrosion rates?
A) The thinnest reading is taken and used for a given examination point always (this is t min)
B) An average of several measurement readings taken within an area of an examination point
C) Lesser of thinnest reading OR average of several readings taken within an examination point
D) Thinnest reading OR average of several readings taken within area of an examination point
Answer = D … Ref: API 510, Par. 5.6.2.4 CMLs
165. CMLs and examination points should be permanently recorded (marked on inspection
drawings and equipment) in order to achieve which of the following results?
A) To allow repetitive measurements at CMLs to effectively determine vessel remaining life
B) To allow repetitive measurements at CMLs improving accuracy of calculated damage rates
C) To allow repetitive measurements at CMLs allowing the identification of damage
D) None of these is correct
Answer = B … Ref: API 510, Par. 5.6.2.5 CMLs
168. For pressure vessels susceptible to localized corrosion, who should be consulted about
the appropriate placement and number of CMLs.
Answer = D … Ref: API 510, Par. 5.6.3.1 CMLs The Corrosion Specialist Tricky
169. CMLs may be eliminated or the number significantly reduced when all of the following
conditions exist EXCEPT:
A) Corrosion specialist was consulted and concurs with the reduction or elimination of CMLs
B) Probability of failure is low due to the service (such as a clean noncorrosive hydrocarbon)
C) Consequence of failure is high
D) None of these is correct
Answer = C … Ref: API 510, Par. 5.6.3.2 CMLs The consequence of failure = LOW
170. In circumstances where CMLs will be substantially reduced or eliminated, WHO should
be consulted?
A) Owner/user B) Inspector C) Engineer D) None of these
Answer = D … Ref: API 510, Par. 5.6.3.2 CMLs The Corrosion Specialist Tricky
A) Any types of repairs are completed B) All permanent repairs are completed
C) After an alteration is completed D) After major repairs are completed
177. After repairs are completed, a pressure test SHALL be applied IF:
178. When a code hydrostatic pressure test is required, the minimum test pressure should be
in accordance with the rules of (which code):
179. If vessel stamp shows a 1997 construction date, and the vessel has not been rerated,
then what is the minimum test pressure to be applied to satisfy API 510 code requirements?
180. After repairs are completed, a pressure test is to be applied. Vessel stamp construction
date = 1997 and the vessel was rerated in 2011. Given: Vessel MAWP = 1,000 psi (2011) and
the Stest temp/Sdesign temp ratio = 1.1. What test pressure is to be applied to meet code?
182. What is the minimum test pressure for vessels that have been rerated using the design
allowable stress published in the 1999 addendum or later of ASME Section VIII, Division I, as
per Code Case 2290 or Code Case 2278?
A) 130% of MAWP & corrected for temperature B) Always only at 130% of MAWP
B) 150% of MAWP & corrected for temperature D) Always only at 150% of MAWP
Answer: A … (API 510, Para. 5.8.2.1) Pressure Testing Requirements
183. If vessel stamp shows a 2007 construction date, and the vessel has not been rerated,
then what is the minimum test pressure to be applied to satisfy API 510 code requirements?
A) The test pressure is left to the discretion of the Inspector
B) Test Pressure in psi = 1.3 MAWP × (S test temp / S design temp)
C) Test Pressure in psi = 1.4 MAWP × (S test temp / S design temp)
D) Test Pressure in psi = 1.5 MAWP × (S test temp / S design temp)
Answer: B … (API 510, Para. 5.8.2.1) Pressure Testing Requirements
184. After major repairs in 2011 are completed, a pressure test is to be applied. Vessel stamp
construction date = 1990 and vessel was never rerated. Given: Vessel MAWP = 100 psi and
the Stest temp/Sdesign temp ratio = 1.1. What test pressure is to be applied to meet code?
A) The test pressure is left to the discretion of the Inspector
B) Test Pressure in psi = 1.5 × 100 x 1.1 = 165 psi
C) Test Pressure in psi = 1.3 × 100 x 1.1 = 143 psi
D) Test Pressure in psi = 1.4 × 100 x 1.1 = 154 psi
Answer: B … (API 510, Para. 5.8.2.1) Pressure Testing Requirements
185. When a non-code related pressure test is performed after repairs, the test pressure may
be conducted at a pressure to be determined by:
195. What is the API 510 recommended minimum shell temperature to be maintained during
a hydrostatic test assuming that a pressure vessel is exactly 2 inches thick?
A) 30o F (17oC) 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 or +30o F)
Note: There is a conflict between ASME VIII, Div 1 Section UG-98 (30o F above MDMT for all)
A) 30oF (17oC) above the material MDMT B) 30oF (17oC) above ambient metal temp
C) 10oF (6oC) above the material MDMT D) 10oF (6oC) above ambient metal temp
Answer: A … (API 510, Para. 5.8.6.2 … Brittle Fracture – Be aware of 2 in & less rule = +10o F)
Note: There is a conflict between ASME VIII, Div 1 Section UG-98 (30o F above MDMT for all)
197. What is API 510 recommended maximum metal temperature to be maintained during a
hydrostatic test (assuming no other Brittle Fracture information indicates that a higher metal
temperature is needed)?
A) 30oF (17oC) above the material’s MDMT B) 30oF (17oC) above ambient metal temp
C) 120oF (50oC) is the maximum temperature D) There is no maximum limit in API 510
Answer: C … (API 510 Section/Para. 5.8.6.2 … Know the 120 o F or 50oC rule!)
198. When a pressure test is not desired after a major repair or alteration, what must be done
per API 510 rules to exempt the vessel from a pressure test?
A) Tests are always required after major repairs or an alteration
B) Tests may be waived ONLY if approved in writing by both owner/user and Engineer
C) Tests may be waived ONLY if approved by both the Engineer and the Authorized Inspector
D) Tests may be waived ONLY if proper NDE is done that is approved by an Engineer & Inspector
Answer: D … (API 510 Section/Para. 5.8.7.1 … Know the NDE in lieu of pressure test rules!)
199. Substituting NDE procedures for a pressure test after an alteration (taking a pressure test
exemption) may be allowed by API 510 rules only after WHO approves the exemption?
A) Owner user and Engineer (in writing) B) Engineer only (in writing)
C) Engineer and Inspector D) None of these is correct
Answer: C … (API 510 Section/Para. 5.8.7.1 … Know the NDE in lieu of pressure test rules!)
200. Related to NDE in lieu of pressure testing, for cases where UT is substituted for
radiographic inspection, the owner/user shall specify what type of examiners?
A) Only a certified UT Shear wave examiner
B) Only an industry-qualified UT shear wave examiner
C) Any certified or qualified UT Shear Wave examiners
D) UT may not be substituted for RT when RT is required by the code
Answer: B … (API 510 Section/Para. 5.8.7.2 … Know the NDE in lieu of pressure test rules!)
202. During repairs or alterations of pressure vessels, who shall verify that all new materials
(including carbon steel) are consistent with the specifications?
203. Who shall determine the amount of material verification testing to be performed to
verify that all new materials (including carbon steel) are consistent with the specifications?
A) Owner/User only
B) Owner/User or Engineer
C) Engineer or Inspector
D) Owner/User or Inspector
207. Per API 510, inspection for weld quality is normally accomplished as a part of the
requirements associated with all of the following EXCEPT:
A) New construction of vessels (inspection is to assure that welds meet code of construction
requirements just before they are placed into service)
B) Reratings of Pressure vessels (weld inspection must be done & also meet API 510 rules)
C) Repairs of welds on pressure vessels (weld inspection must be done & meet API 510 rules)
D) Alterations of Pressure vessels (weld inspection must be done & also meet API 510 rules)
Ans: B (API 510, Par. 5.10.1) … Insp of In-service welds Weld insp not done with reratings
208. During in-service inspections of welds, the welds and weld heat-affected zones are often
inspected for:
A) Corrosion related damage only
B) Service-induced cracking mechanisms only
C) Corrosion related damage and/or service-induced cracking mechanisms
D) Corrosion damage, service-induced cracking mechanisms, and metallurgical changes
Answer: C (API 510, Para. 5.10.1) … Inspection of In-service welds & joints Topic # 6
209. When preferential weld corrosion or cracking is noted by Inspection during inspection of
in-service welds, what should be done relative to inspection of other welds in the vessel?
A) Nothing additional, just report corrosion & cracking & have any necessary repairs performed
B) Ensure that additional welds of the pressure vessel are also examined & repaired as needed
C) Ensure that 100% of welds of the pressure vessel are also examined & repaired as needed
D) None of these is correct per API 510
Answer: B (API 510, Para. 5.10.1) … Inspection of In-service welds and joints Topic # 6
210. Per API 510, which API document provides guidance on Weld Inspection?
A) API 577 B) API 578
C) API 579 D) API 580
Ans: A (510, 5.10.1) … Insp of In-service welds/joints Topic # 6 Para. 8.1.6/& 577, 11.2
211. If crack-like flaws are detected (using UT or RT techniques) while the pressure vessel is in
operation, which of the following statements is NOT true per API 510?
Answer: D (API 510, Para. 5.10.2 & 5.10.3) … Inspection of In-service welds & joints Topic 6
Answer: B (API 510, Para. 5.10.2 & 5.10.3) … Inspection of In-service welds & joints Topic 6
Answer: C (API 510, Para. 5.10.3) … Inspection of In-service welds and joints Topic 6
214. Flanged joints and fasteners in caustic service should be examined for:
215. Accessible flange faces should be examined for distortion and to determine the:
A) Condition of fasteners
B) Condition of existing gaskets
C) Condition of flange facing coatings
D) Condition of gasket-seating surfaces
217. Flange fasteners should be examined for thread engagement and are considered to be
acceptably engaged per API 510 rules if engagement is:
A) Minus one, with lack of full engagement not more than one thread
B) Zero, because the end of the fastener must be flush with the end of the nut
C) Plus one, with at least one visible thread past the end of the nut
D) None of these is correct
218. The markings on a representative sample of newly installed fasteners and gaskets should
be examined to determine:
219. Fastener markings should be identified by the applicable ASME and ASTM standards.
Questionable fasteners should be:
A) Renewed if the Inspector cannot find material certification records
B) Renewed always without exception needing no verification testing
C) Verified (to be the correct specification) or deemed traceable to reports
D) Verified (to be the correct specification) or renewed
Answer: D (API 510, Para. 5.11.4) … Inspection of Flanged Joints Topic 2
220. Additional guidance on the inspection of flanged joints can be found in:
A) ASME B16.5 B) ASME B16.20
C) ASME PCC-1 D) ASME PCC-2
Answer: C (API 510, Para. 5.11.5) … Inspection of Flanged Joints Topic 2
API 510 Code (16 Closed Book Topics) Topics # 10 & 2 (again)
221. To ensure vessel integrity, all pressure vessels and pressure-relieving devices shall be
inspected at the intervals and frequencies provided in API 510 (what section)?
222. The appropriate inspection (External, Internal, etc) must provide information necessary
to determine that all of the essential sections or components of the equipment are:
A) Acceptable at the time of the inspection & in serviceable condition with adequate thickness
B) Acceptable at the time of the inspection & may be serviceable for the inspection interval
C) Acceptable at the time of the inspection & in serviceable condition only
D) Safe to operate until the next scheduled inspection.
Answer: D (API 510, Para. 6.1.2) … Inspection Interval General Rules Topic 10
223. When an internal inspection is being planned, what common risk associated with
operational shutdown and start-up that SHOULD always be evaluated?
A) Possibility of increased corrosion from vessel surface exposure to solidified process deposits
B) Possibility of increased oxidation due to exposure of vessel surfaces to air and moisture
C) Possibility of increased corrosion due to exposure of vessel surfaces to air and moisture
D) Possibility of conditions that may lead to an event causing Brittle Fracture
Answer: C (API 510, Para. 6.1.2) … Inspection Interval General Rules Topic 10
224. Per API 510, which of these statements is true regarding Vessel Installation Inspection?
Answer: D (API 510, Para. 6.2.1) … Vessel Installation Inspection Rules Topics 10 & 2
API 510 Code (16 Closed Book Topics) Topics # 10 & 2 (again)
226. The minimum Installation Inspection should include all of the following EXCEPT:
A) Verify nameplate information is copied (or photographed) & placed into Equipment records
B) Verify equipment is installed correctly, supports are adequate & secured, exterior equipment
(ladders, etc) are secured, insulation is properly installed & connections are properly assembled
C) Verify interior surfaces (including all nozzles and low points) of the vessel are clean and dry
D) Verify pressure-relieving devices are correct per design with correct set pressure as installed
Ans: A (510, Par. 6.2.1) Vessel Install Insp Topic 10 & 2 Verify info against Mfg Data Sht
227. The minimum Installation Inspection should include all of the following EXCEPT:
A) Verify equipment is installed correctly on foundations & all supports are adequate & secured
B) Verify exterior equipment (ladders, etc) are secured & insulation system is properly installed
C) Verify piping connections in the associated piping system are properly assembled
D Verify interior surfaces are clean & dry and pressure-relieving devices are correct per design
Ans: C (510, Par. 6.2.1) Vessel Install Insp Topic 10 & 2 Only connections to the vessel
228. Installation Inspections provide an opportunity for all of the following actions EXCEPT:
A) Collect desired base line information on the pressure vessel to be used in future inspections
B) Collect the initial thickness readings on the pressure vessel at any randomly selected TMLs
C) Designate areas of the vessel’s components for Condition Monitoring Locations (CMLs)
D) Collect desired base line information & obtain initial thickness readings at designated CMLs
Answer: B (API 510, Para. 6.2.1) … Vessel Installation Inspection Rules Topics 10 & 2
229. Internal field inspection of new vessels (upon installation) is not required provided (IF):
A) Inspector believes one is not necessary B) Engineer believes one is not necessary
C) Owner/user believes one is not necessary D) None of these is correct
Ans: D (510, Par. 6.2.1) … Vessel Install Insp Topic 10 & 2 Appropriate documentation,
e.g. manufacturer’s data reports, assures that a vessel complies with the specified designs.
230. Internal field inspection of new vessels (upon installation) is not required provided (IF):
A) A Manufacturer’s Data Report assures that a vessel complies with the specified designs
B) The both the Inspector AND Engineer believe that one is not necessary
C) The Inspector ONLY believes one is not necessary
D) The Engineer ONLY believes one is not necessary
Ans: A (API 510, Para. 6.2.1) … Vessel Install Insp Topic 10 & 2 # 228 & 229 = same Q
API 510 Code (16 Closed Book Topics) Topics # 10 & 2 (again)
231. If the service conditions of a vessel are changed, the inspection intervals shall be:
A) The same as the previous service until they can be established for the new service conditions
B) The same as the previous service until the Inspector determines it necessary to change them
C) Established for new service conditions in a manner deemed necessary by the Inspector
D) Established for new service conditions (new process contents, pressure, or temperature)
Answer: D (API 510, Para. 6.2.2.1) … Vessel Service Change Inspection Rules Topics 10 & 2
232. Which of these statements is FALSE regarding the requirement for establishing new
inspection intervals whenever a vessel service change occurs?
A) If process content (water to oil) changes, then a new inspection interval shall be established
B) If maximum operating pressure changes, then a new inspection interval shall be established
C) If minimum operating pressure changes, then a new inspection interval shall be established
D) If maximum (or min.) operating temps change, then a new insp interval shall be established
Answer: C (API 510, Para. 6.2.2.1) … Vessel Service Change Inspection Rules Topics 10 & 2
233. If both ownership & location of a vessel are changed, what are the API 510 inspection
rules (regarding inspections and inspection intervals) before the vessel is reused?
A) Vessel should be internally & externally inspected & new insp. intervals shall be established
B) Vessel shall be internally & externally inspected & new insp. intervals shall be established
C) Vessel may be exempt from Insp. by Data Reports & new Insp. intervals shall be established
D) None of these is correct because new inspection intervals “should” be established
Answer: B (API 510, Para. 6.2.2.2) … Vessel Service Change Inspection Rules Topics 10 & 2
234. If both the ownership and the location of a vessel are changed, what shall be established
for the new service?
A) Allowable service conditions (Design parameters) and inspection intervals
B) Only the allowable service conditions (Design parameters) need to be established
C) Allowable service conditions (Design parameters), corrosion allowance & inspection intervals
D) Only the inspection intervals need to be established per API 510
Answer: A (API 510, Para. 6.2.2.2) … Vessel Service Change Inspection Rules Topics 10 & 2
235. If Only ownership (not the location) of a vessel is changed (assume Company A bought
the refinery from Company B), what is required before Company B assumes operation?
A) Vessel should be internally & externally inspected & new insp. intervals shall be established
B) Vessel shall be internally & externally inspected & new insp. intervals shall be established
C) Vessel may be exempt from Insp. by Data Reports & new Insp. intervals shall be established
D) Vessel is exempt from any inspections & existing intervals (from Company B) may be used
Answer: D (API 510, Para. 6.2.2.2) … Vessel Service Change Inspection Rules Topics 10 & 2
237. RBI assessments may allow previously established inspection intervals to be exceeded.
Which of the following statements are FALSE regarding these inspections and interval limits?
A) Internal inspection maximum limits of 10 years or ½ Remaining Life (the lesser) may be exceeded
B) On-Stream inspection maximum limits of 10 years or ½ Remaining Life (the lesser) may be exceeded
C) External insp maximum limits of 5 years or Internal/On-stream interval (the lesser) may be exceeded
D) External insp maximum limits of 5 years or ½ Remaining Life (the lesser) may be exceeded
Answer: D (API 510, Para. 6.3.1) … Risk-Based Inspection Rules Topic 10
238. When a RBI interval for the internal or on-stream inspection exceeds the 10-year limit,
the RBI assessment shall be reviewed and approved by:
A) Engineer and Corrosion Specialist B) Engineer and Inspector
C) Owner/User and Engineer D) Engineer Only
Answer: B (API 510, Para. 6.3.2) … Risk-Based Inspection Rules Topic 10
239. If an RBI interval for the internal or on-stream inspection exceeds the 10-year limit, then
the RBI assessment shall be reviewed and approved (how often)?
A) At intervals NEVER exceeding 10 years (More often if warranted due to RBI considerations)
B) At the end of the designated extended inspection interval (11 yrs, 12 yrs, 13 yrs, etc)
C) At intervals not to exceed 20 years in any case
D) None of these is correct
Answer: A (API 510, Para. 6.3.2) … Risk-Based Inspection Rules Topic 10
240. When a RBI assessment is used to extend the internal or on-stream inspection
interval, the assessment should include which of the following?
A) Fitness-for-service evaluation of the vessel along with a review of Maintenance Records
B) Fitness-for-service evaluation of the vessel and a review of the inspection history
C) Fitness-for-service evaluation of the vessel, and a review of the inspection history and the
potential fouling of the vessel pressure-relieving device(s)
D) Review of the inspection history and potential fouling of vessel’s pressure-relieving device(s)
What is the maximum Ext insp interval (No RBI) allowed by the API 510 Code? Answer = Always 5 years
100 yr. RL what is max Ext Insp. Interval 100 ÷ 2 = 50 Use lesser of 50 or 5 5 yrs (rule applies)
12+ yr. RL what is max Ext Insp. Interval 12 ÷ 2 = 6 Use lesser of 6 or 5 5 yrs (ext rule applies)
10 yr. RL what is max Ext Insp. Interval 10 ÷ 2 = 5 Use lesser of 5 or 5 5 yrs (ext = I or OSI)
9 yr. RL what is max Ext Insp. Interval 9 ÷ 2 = 4.5 Use lesser of 4.5 or 5 4.5 yrs (I or OSI)
8 yr. RL what is max Ext Insp. Interval 8 ÷ 2 = 4 Use lesser of 4 or 5 4 yrs (I or OSI)
7 yr. RL what is max Ext Insp. Interval 7 ÷ 2 = 3.5 Use lesser of 3.5 or 5 3.5 yrs (I or OSI)
6 yr. RL what is max Ext Insp. Interval 6 ÷ 2 = 3 Use lesser of 3 or 5 3 years (I or OSI)
5 yr. RL what is max Ext Insp. Interval 5 ÷ 2 = 2.5 Use less of 2.5 or 5 2.5 years (I or OSI)
4 yr. RL what is max Ext Insp. Interval 4 ÷ 2 = 2 Use lesser of 2 or 5 2 years (I or OSI)
The 4 year Rule … Use maximum of 2 years or full RL … now applies to Internal & OSI intervals
3 yr. RL what is max Ext Insp. Interval 3 Use 2 max rule Use lesser of 2 or 5 2 years
2 yr. RL what is max Ext Insp. Interval 2 Use 2 max rule Use lesser of 2 or 5 2 years
1.5 yr. RL what is max Ext Insp. Interval 1.5 Use 1.5 Use lesser of 1.5 or 5 1.5 yrs
~~~~~~~~~~~~~~END OF EXERCISE~~~~~~~~~~~~~~
247. 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)
B) Full remaining life up to a maximum of 3 years
C) Full remaining life up to a maximum of 2 years
D) Only ½ of the vessel’s 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)
248. When a pressure vessel remaining life is 3.5 years, the internal or on-stream inspection
Interval may be a maximum of:
A) Full remaining life (3.5 yrs in this case) B) A maximum of 3 years in this case
C) A maximum of 2 years in this case D) Only ½ vessel remaining life (1.75 yrs this case)
Answer: C (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1)
249. When a pressure vessel remaining life is 1.5 years, the internal or on-stream inspection
Interval may be a maximum of:
A) Full remaining life (1.5 years in this case)
B) A maximum of 3 years in this case
C) A maximum of 2 years in this case
D) Only ½ of the vessel’s remaining life (0.75 years in this case)
Answer: A (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1)
250. Who is responsible for establishing & how is an External Inspection interval established?
A) By Inspector in accordance with the owner/user’s inspection plan
B) By Engineer in accordance with the owner/user’s quality plan
C) By Inspector or engineer in accordance with the owner/user’s inspection plan
D) By Inspector or engineer in accordance with the owner/user’s quality assurance system
Answer: D (API 510, Internal & On-stream Inspection Rules, Para. 6.5.1.1)
Ans: C (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.2) Reason: In this case, 20 calendar
years of operation is equal to 10 actual operation years! External interval ALWAYS = 5 years
253. 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 & calculated remaining life = 30 yrs)?
A) Internal inspection interval = 10 calendar yrs & external inspection interval = 5 calendar yrs
B) Internal inspection interval = 15 calendar yrs & external inspection interval = 10 calendar yrs
C) Internal inspection interval = 20 calendar yrs & external inspection interval = 10 calendar yrs
D) Internal inspection interval = 30 calendar yrs & external inspection interval = 5 calendar yrs
Ans: D (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
254. Alternative method of establishing required inspection intervals is to calculate projected
MAWP of vessel components. Inspection intervals are within the maximum permitted as long
as the projected MAWP of the limiting component is:
A) Not less than the lower of a nameplate or rerated MAWP + applicable static head pressure
B) Less than or = to the lower of nameplate or rerated MAWP + applicable static head pressure
C) Not less than the lower of nameplate or rerated MAWP – applicable static head pressure
D) Less than or = to the lower of nameplate or rerated MAWP – applicable static head pressure
Ans: A (API 510, Int. & On-stream Insp Rules, Par. 6.5.1.3) Alternative MAWP calc method
255. 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
API 510 Code (16 Closed Book Topics) Topic # 10
256. Who decides whether on-stream inspection may be substituted for internal inspection?
A) Owner/User B) Engineer
C) Inspector D) None of these alone can decide
Ans: C (API 510, Int. & On-stream Insp, Para. 6.5.2.1) Know Inspector responsibilities
257. On-stream inspections may be substituted for internal inspections whenever Inspector
approves the substitution and:
A) Whenever size or configuration makes internal inspection vessel entry physically impossible
B) Whenever the general corrosion rate is less than 5 MPY (.005 inches or 0.125 mm per year)
C) Whenever the vessel remaining life is greater than 10 years
D) Whenever no questionable condition is found during the External Inspection
Ans: A (510, Int. & On-stream Insp., Para. 6.5.2.1.b.1) PHYSICALLY POSSIBLE 5 MPY RULE!
258. If vessel entry is physically possible, on-stream inspection may possibly be substituted
for internal inspection if approved by Inspector & the vessel remaining life is known to be:
Ans: B (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.2) PHYSICALLY POSSIBLE > 10 YEAR RL RULE!
259. If vessel entry is physically possible, on-stream inspection may possibly be substituted
for internal inspection if approved by Inspector & corrosive character of contents has been
established by (how many) years of same or similar service:
Ans: D (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.3) PHYSICALLY POSSIBLE 5 YR Similar Service!
260. If vessel entry is physically possible, on-stream inspection may possibly be substituted
for internal inspection if approved by Inspector and external inspection resulted in:
A) No questionable conditions found
B) No corrosion or coating loss found
C) No CUI conditions or pitting found
D) None of these are correct
Ans: A (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.4) Phys. Poss. No questionable conditions!
… API 571 Creep Tables … Edition # 2 comes into effect Sept. 2012
Note: For 60 ksi and less ultimate tensile strength CS materials, the correct answer = A
263. 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) Stress Corrosion cracking or high temperature oxidation damage from the service
B) Chloride Stress Corrosion cracking or Creep stress rupture damage from the service
C) Environmental cracking or hydrogen damage from the fluid being handled
D) Damage Mechanisms requiring the Inspector to consult the Corrosion Specialist
Ans: C (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!
264. If vessel entry is physically possible, on-stream inspection may possibly be substituted
for internal inspection if approved by Inspector and the vessel does not have:
A) Internal coating (thin-film liner) B) Integrally bonded liner (SS or alloy weld overlays)
C) Internal coating (thick-film liner) D) Non-integrally bonded liner (strip lining or plate lining)
Ans: D (510, Int. & OSI (Insp.), Par. 6.5.2.1.b.7) Phys. Poss. No strip lining or plate lining!
265. 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!
272. The API 510 code states that Pressure-relieving devices shall be tested and repaired by:
A) An owner/user organization experienced in valve maintenance
B) A Repair organization experienced in valve maintenance
C) Any owner / user organization approved Contractor
D) Any approved Contractor holding an “R” Stamp
Answer = B … Reference: API 510, Para. 6.6 Rules regarding insp & testing of PZVs
273. What document covers inspection, testing & maintenance of pressure-relieving devices?
A) ASME VIII, Division 1, Section UG B) API 572
C) API 576 D) API 577
Answer = C … Reference: API 510, Para. 6.6 See API 576 Section 5 & 6 for many exam Qs
Must Know API 576 … Ch. 5 (Causes of Improper Performance) & Ch. 6 (Inspection & Testing)
E-Library API 510 folder for Exam questions! API 576 has 2 handouts!
*** In the margin & underlined areas are those where exam Q’s will be!
274. Spring failures are almost always caused by:
A) Corrosion that includes surface corrosion and stress corrosion cracking
B) Stress related failure due to improper sizing/using substandard parts
C) Mechanical failure due to excessive movement and vibration
D) Excessive chattering and wire drawing
Ans: A (510, 6.6.6 & 576, Para 5.1.1 & 5.3.2 & Fig 30) … PZV Spring Failure Cause = Corrosion
275. (Example API 576 Q) … The principal reason for inspecting a pressure relief device is to:
Ans: A (API 510, Par. 6.6 API 576 Ch. 6, Para. 6.1.1 in entirety) API website Sample Q
Answer = C … Reference: API 510, Para. 6.6.1.1 Repair Org QC System & QC Manual
277. Minimum items to be in a repair organization’s Quality Control Manual DO NOT include:
A) Title page, Revision log, Contents page, Statement of authority & responsibility
B) Organization Chart, Scope of work, Drawings and specification controls
C) Requirements for material and part control
D) Repair and Test Plan
Ans = D … Reference: API 510, Para. 6.6.1.1.i Repair & Inspection Program in QC Manual
278. Minimum items to be in a repair organization’s Quality Control Manual DO NOT include:
Ans = B … Ref: Par. 6.6.1.1.i Reqmts Calibrating Measurement & Test Gauges in QC Manual
279. Minimum items to be in a repair organization’s Quality Control Manual DO NOT include:
A) Requirements for updating and controlling copies of the quality control manual
B) Sample forms (QC forms to be used during work and to control the work)
C) Training and qualifications required for Inspection personnel
D) Requirements for handling of non-conformances
Ans = D … Ref: API 510 Par. 6.6.1.1.i Training & Quals for Repair Personnel in QC Manual
280. Each repair organization shall also have a fully documented training program that:
A) Shall ensure that repair personnel are qualified for all work tasks
B) Shall ensure that repair personnel are certified to perform inspections
C) Shall ensure that repair personnel are qualified within the scope of the repairs
B) Shall ensure that repair personnel are well-trained and qualified for every given repair task
Ans = C … Ref: API 510 Par. 6.6.1.1.i Training program requirements Repair Organizations
282. The inspection interval for all pressure-relieving devices is determined by (Who) in
accordance with what system requirements?
284. When a pressure-relieving device is found to be heavily fouled or stuck, which of the
following statements are FALSE regarding API 510 requirements?
A) Inspection & testing intervals shall be reduced unless a review shows that the device will
perform reliably at the current interval
B) Inspection & testing intervals shall be reduced as deemed necessary by the Inspector
C) Any review should try to determine the cause of the fouling (as applicable)
D) Any review should try to determine the reasons for improper operation
Answer: B (API 510, 6.6.2.3) … PZVs … Rules for Review … Intervals = Stuck or Fouled Rule
285. When a pressure-relieving device is found to be heavily fouled or stuck, which of the
following statements are TRUE regarding requirements for inspection and testing intervals?
A) They may be reduced if a review cannot show they will perform reliably at current intervals
B) They may be reduced as deemed necessary by the Inspector performing the review
C) They shall be reduced unless a review shows they will perform reliably at current intervals
D) They shall be reduced as deemed necessary by the Inspector performing the review
Answer: C (API 510, 6.6.2.3) … PZVs … Rules for Review … Intervals = Stuck or Fouled Rule
287. The determination of the corrosion rate may include thickness data collected at:
A) Only at one time
B) Only at two different times
C) More than two different times
D) None of these is correct
Answer: C (API 510, Para. 7.1.1.1) Corrosion Rate Determination Rules
288. Suitable use of short-term versus long-term corrosion rates shall be determined by the:
A) Engineer
B) Inspector
C) Corrosion Specialist
D) Owner/User
A) The most recent reading and one taken earlier in the life of the vessel (at same CML)
B) Any two thickness readings taken on the vessel (at a known thickness location)
C) Any two or more thickness readings taken on the vessel (at the same location or CML)
D) The two most recent thickness readings taken on the vessel (at the same location or CML)
A) The most recent reading and one taken earlier in the life of the vessel (at same CML)
B) Any two thickness readings taken on the vessel (at a known thickness location)
C) Any two or more thickness readings taken on the vessel (at the same location or CML)
D) The two most recent thickness readings taken on the vessel (at the same location or CML)
292. Long-term (LT) corrosion rates shall be calculated from which of these formulas?
A) Corr. rate (LT) = t previous – t actual ÷ time between t previous & t actual (in years)
B) Corr. rate (LT) = t initial – t actual ÷ time between t initial and t actual (in years)
C) Corr. rate (LT) = t actual – t initial ÷ time between t initial and t actual (in years)
D) Corr. rate (LT) = t actual – t previous ÷ time between t previous & t actual (in years)
294. 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 may a first thickness measurement taken (new vessel) at a given CML (inches or mm)
C) t initial may be the thickness at the start of a new corrosion rate environment at a given CML
D) t initial = the initial thickness at a different CML from the one determining the lowest t actual
295. When calculating corrosion rates using API 510 formulas, which of the following
statements is TRUE regarding the value for t actual?
A) t actual = Actual thickness of a CML (inches or mm) measured during most recent inspection
B) t actual = Actual first thickness measurement taken at a given CML (in inches or mm)
C) t actual = Actual thickness at the start of a new corrosion rate environment at a given CML
D) t actual = Actual thickness at a different CML from the one determining the lowest reading
297. 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 (consults corrosion specialist) & selects a rate that best reflects current conditions
B) Inspector (consults Engineer) & selects a rate that best reflects current conditions
C) Corrosion Specialist alone selects a rate that best reflects current conditions
D) Inspector alone selects a rate that best reflects current conditions
Answer: A (API 510, Para. 7.1.1.2) Corrosion Rate Determination Rules
298. For a new vessel, which one of the following methods CANNOT be used to determine the
vessel’s probable corrosion rate?
A) Data collected by the owner/user on vessels operating in the same or similar service.
B) On-stream determination (thickness measurements) after 1 month of service
C) Estimated from published data on vessels in same or similar service.
D) Estimated from the owner/user’s experience.
Answer: B (API 510, Para. 7.1.2) Corrosion Rate Determination Rules 1,000 Hour Rule
299. For an existing vessel where service conditions are being changed, which one of the
following methods CANNOT be used to determine the vessel’s probable corrosion rate?
A) Data collected by the owner/user on other vessels operating in the same plant
B) On-stream determination (thickness measurements) after 1,000 hours service
C) Estimated from published data on vessels in same or similar service.
D) Estimated from the owner/user’s experience.
Ans: A (510, Para. 7.1.2) Corrosion Rate Determination Rules Same/Similar Service Rule
300. Once an initial corrosion rate has been determined using the rules of API 510 for a new
vessel (or change of service for an existing vessel), which of these statements are true?
A) Remaining life & the inspection interval cannot both be estimated from this corrosion rate
B) Only inspection intervals can be estimated from this corrosion rate
C) Remaining life & the inspection interval can be estimated from this corrosion rate
D) Remaining life & the inspection interval can be established ONLY after 1,000 hours service
305. Remaining life of a vessel (in years) shall be calculated from which of these formulas?
307. When calculating Remaining Life using the API 510 formula, which of these statements is
TRUE regarding the value for t actual?
A) t actual = Actual first thickness measurement taken at a given CML (in inches or mm)
B) t actual = Actual thickness at the start of a new corrosion rate environment at a given CML
C) t actual = Actual thickness of a CML (inch/mm) measured during the most recent inspection
D) t actual = Actual thickness at a different CML from the one determining the lowest readings
Answer: C (API 510, Para. 7.2.1) Remaining Life Determination Rules
308. When calculating Remaining Life using the API 510 formula, which of these statements is
FALSE regarding the value for t required?
A) Required thickness (inch/mm) at the same CML or component as the t actual measurement
B) Computed by pressure design formula and excludes corrosion allowance & Mfg. tolerances
C) Computed by structural design formula and excludes corrosion allowance & Mfg tolerances
D) Computed by either pressure or structural design formulas and includes corrosion allowance
Answer: D (API 510, Para. 7.2.1) Remaining Life Determination Rules
309. Statistical analysis may be used in the corrosion rate and remaining life calculations for
pressure vessel sections, and may be applied for the assessment of (which of these):
A) Substituting an internal inspection for OSI or for determining the internal inspection interval
B) Substituting an internal inspection for OSI & determining an On-stream inspection interval
C) Determining the internal inspection interval only
D) Substituting an internal inspection for OSI only
Answer: A (API 510, Para. 7.2.2) Remaining Life Determination Rules
310. When statistical analysis is used for Corrosion Rate and Remaining Life Calcs, it may not
be applicable to vessels with:
A) Random Localized corrosion
B) Random Generalized corrosion
C) Random but significant localized corrosion
D) Random but significant generalized corrosion
Answer: C (API 510, Para. 7.2.2) Remaining Life Determination Rules
API 510 Code (16 Closed Book Topics) MAWP Calcs = Also Open Book
311. When applying Maximum Allowable Working Pressure (MAWP) Calcs to determine the
continued use of a pressure vessel in the corroded condition, MAWP shall be based upon:
A) Calcs as per original ASME Code edition that the vessel was built to
B) Calcs as per latest applicable ASME Code edition that the vessel was built to
C) Calcs as per latest applicable ASME Code edition or construction code a vessel was built to
D) Calcs as per original ASME Code edition or construction code that the vessel was built to
Answer: C … (API 510, Para. 7.3.1) MAWP Determination Rules
312. When applying Maximum Allowable Working Pressure (MAWP) Calcs to determine the
continued use of a pressure vessel in the corroded condition, MAWP calculation results shall:
A) Be equal to or less than original MAWP unless a rerating is to be performed as per API 510
B) Not be greater than original MAWP unless a rerating is to be performed as per API 510
C) Be greater than original MAWP unless a rerating is to be performed as per API 510
D) None of these are correct
Answer: B (API 510, Para. 7.3.1) MAWP Determination Rules
313. When applying MAWP Calcs to determine the continued use of a pressure vessel in the
corroded service condition, MAWP calculation values to be used for thickness SHALL be how
much (before the next inspection date):
A) t = Actual inspection thickness minus twice the estimated corrosion loss
B) t = Actual inspection thickness minus the estimated corrosion loss + corrosion allowance
C) t = Actual inspection thickness minus twice estimated corrosion loss + corrosion allowance
D) t = Actual inspection thickness minus twice estimated corrosion loss – corrosion allowance
Answer: A (API 510, Para. 7.3.3) MAWP Determination Rules
314. When applying MAWP Calcs to determine the continued use of a pressure vessel in the
corroded service condition, MAWP code calculation values used to determine value t SHALL
be done per which of these formulas in accordance with API 510 rules?
A) MAWP Code Calc Value t = t actual – (Corr. rate x Insp Interval in years) + any CA
B) MAWP Code Calc Value t = t actual – 2 (Corr. rate x Insp Interval in years) – any CA
C) MAWP Code Calc Value t = t actual – 2 (Corr. rate x Insp Interval in years) + any CA
D) MAWP Code Calc Value t = t actual – 2 (Corr. rate x Insp Interval in years)
Answer: D (API 510, Para. 7.3.3) MAWP Determination Rules
315. Regarding MAWP Calcs and t actual determinations, if actual thickness determined by
inspection is greater than a thickness reported in Material Test or Manufacturer Data Report,
it must be confirmed by multiple thickness measurements using a procedure approved by:
A) Inspector B) Engineer
C) Engineer & Inspector D) None of these
API 510 Code (16 Closed Book Topics) FFS Analysis Corroded Regions = also OB
316. The purpose for a fitness for service analysis of a corroded region in a pressure vessel is
to consider API 510 rules for evaluating corrosion and pitting at any inspection in order to:
A) Determine and adjust the actual thickness & maximum corrosion rate for any part of a vessel
B) Determine the minimum thickness and remaining corrosion allowance for the vessel
C) Determine the remaining thickness of a vessel and adjust it accordingly
D) Determine the remaining life of a vessel and adjust it accordingly
Answer: A (API 510, Para. 7.4.1) FFS Analysis of Corroded Regions
317. When evaluating a locally thinned area, wall thicknesses may be averaged over a length
not exceeding (Assume vessel ID is greater than 60 inches or 150cm):
A) The lesser of ½ vessel diameter or 20 in. (50 cm)
B) The lesser of 1/3 vessel diameter or 40 in. (100 cm)
C) The lesser of ½ vessel diameter or 40 in. (100 cm)
D) The lesser of 1/3 vessel diameter or 20 in. (50 cm)
Answer: B (API 510, Para. 7.4.2.1) FFS Analysis of Corroded Regions
318. When evaluating a locally thinned area, wall thicknesses may be averaged over a length
not exceeding (Assume vessel ID is less than or equal to 60 inches or 150cm):
A) The lesser of ½ vessel diameter or 40 in. (100 cm)
B) The lesser of 1/3 vessel diameter or 40 in. (100 cm)
C) The lesser of ½ vessel diameter or 20 in. (50 cm)
D) The lesser of 1/3 vessel diameter or 20 in. (50 cm)
Answer: C (API 510, Para. 7.4.2.1) FFS Analysis of Corroded Regions
319. When evaluating a locally thinned area and averaging corrosion over a length defined by
API 510 rules (based on vessel ID), how must these “averaging” thickness readings be spaced?
A) Readings shall be taken anywhere & shall be as many as deemed necessary by the inspector
B) Readings shall be taken along a straight line using at least 5 measurements (as a minimum)
C) Readings shall be taken along a straight line and there is no minimum number required
D) Readings shall be taken along a straight line & equally spaced (as selected by Inspector)
Answer: D (API 510, Para. 7.4.2.2) FFS Analysis of Corroded Regions
320. When evaluating a locally thinned area and averaging corrosion over a length defined by
API 510 rules (based on vessel ID) and longitudinal stresses govern, thickness readings are:
A) Taken in any orientation deemed necessary by Inspector (longitudinal, circumferential)
B) Taken along a circumferential length (in an arc)
C) Taken along a longitudinal length
D) None of these are correct
Answer: B (API 510, Para. 7.4.2.3) FFS Analysis of Corroded Regions
API 510 Code (16 Closed Book Topics) FFS Analysis Corroded Regions = also OB
321. When evaluating a locally thinned area and averaging corrosion over a length defined by
API 510 rules (based on vessel ID) and circumferential stresses govern, thickness readings are:
A) Taken in any orientation deemed necessary by Inspector (longitudinal, circumferential)
B) Taken along a circumferential length (in an arc)
C) Taken along a longitudinal length
D) None of these are correct
322. When evaluating a locally thinned area and averaging corrosion over a length defined by
API 510 rules (based on vessel ID) and this is near a nozzle, the designated length SHALL not:
A) Extend within an area of a nozzle by at least 20 in (50cm) or 40 in (100cm) based on vessel ID
B) Extend within the limits of the reinforcement as defined in the construction code
C) Extend within the area covered by the reinforcement element
D) None of these are correct
Answer: B (API 510, Para. 7.4.2.4) FFS Analysis of Corroded Regions
323. When performing remaining life calcs, the lowest average of any length (in any number
of lines selected by the Inspector where equally spaced readings were taken) in the corroded
area is to be substituted for calculation value:
A) t actual B) t required
C) t initial D) None of these
324. During the evaluation of pitting in a corroded region of a vessel, widely scattered pits
may be ignored as long as all of the following are true EXCEPT:
A) Sum of pit dimensions (deeper than CA) along any straight 8-in (20-cm) line is ≤ 2 in (5 cm)
B) Total pitted area (deeper than CA) does not exceed 7 in² (45cm²) in 8-in (20-cm) diam. circle
C) Remaining thickness below a pit is greater than one-half the required thickness
D) Any pitting deemed by the Inspector to be ignored (deeper than the CA)
Ans: D (API 510, Par. 7.4.3) FFS Analysis of Corroded Regions … Widely Scattered Pits 3 Rules
325. During the evaluation of pitting in a corroded region of a vessel, widely scattered pits
may be ignored if which of the following are true:
A) Sum of pit dimensions (deeper than CA) along any straight 8-in (20-cm) line is ≤ 2 in (5 cm)
B) Sum of pit dimensions (deeper than CA) along any straight 8-in (20-cm) line is ≥ 2 in (5 cm)
C) Sum of pit dimensions (no deeper than CA) on any straight 8-in (20-cm) line is ≤ 2 in (5 cm)
D) Sum of pit dimensions (no deeper than CA) on any straight 8-in (20-cm) line is ≥ 2 in (5 cm)
Answer: A (API 510, Para. 7.4.3) FFS Analysis of Corroded Regions … Widely Scattered Pits
API 510 Code (16 Closed Book Topics) FFS Analysis Corroded Regions = also OB
326. During the evaluation of pitting in a corroded region of a vessel, widely scattered pits
may be ignored if which of the following are true:
A) Total pitted area (deeper than CA) ≤ 8 in² (45cm²) in any 7-in (20-cm) diameter circle
B) Total pitted area (deeper than CA) ≥ 8 in² (45cm²) in any 7-in (20-cm) diameter circle
C) Total pitted area (deeper than CA) ≤ 7 in² (45cm²) in any 8-in (20-cm) diameter circle
D) Total pitted area (deeper than CA) ≥ 7 in² (45cm²) in any 8-in (20-cm) diameter circle
Answer: C (API 510, Para. 7.4.3) FFS Analysis of Corroded Regions … Widely Scattered Pits
327. During the evaluation of pitting in a corroded region of a vessel, widely scattered pits
may be ignored if which of the following are true:
A) Remaining thickness below a pit is greater than ½ of t required
B) Remaining thickness below a pit is greater than or equal to ½ of t required
C) Remaining thickness below a pit is greater than ½ of t required (less the CA)
D) Remaining thickness below a pit is greater than or equal to ½ of t required (less the CA)
Answer: A (API 510, Para. 7.4.3) FFS Analysis of Corroded Regions … Widely Scattered Pits
328. Regarding Evaluation Methods for Thinning, when API 579 design by analysis methods
are used to evaluate blend ground areas (after defect removal), it is important to ensure that:
A) Blend ground areas are not located in the immediate area of an existing pressure vessel weld
B) There are no sharp corners in blend ground areas (to minimize stress concentration effects)
C) That remaining wall thickness below a blend ground area is greater than or = to ½ t required
D) That remaining wall thickness below a blend ground area is greater than ½ t required
Answer: B (API 510, Para. 7.4.4.1) FFS Analysis of Corroded Regions … Blend Ground Areas
329. Regarding Evaluation Methods for Thinning, when using ASME Sect. VIII, Div. 2, App 4
values for determination of stress using the 2/3 stress rule, who shall perform this analysis?
A) Manufacturer of the vessel B) Inspector and Engineer
C) Manufacturer of the vessel and Engineer D) Engineer only
Answer: D (API 510, Para. 7.4.4.2) FFS Analysis of Corroded Regions … Div 2 … 2/3 Stress Rule
330. Regarding evaluation of corroded regions and joint efficiency adjustments for areas near
corroded welds, when the vessel surface 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
Note: “A” would be correct if … 1 inch minimum on either side of weld (measured from toe)
API 510 Code (16 Closed Book Topics) FFS Analysis & Evaluations = also OB
331. Regarding Fitness for Service Analysis of Corroded areas in heads (assume an ellipsoidal
head is corroded in the knuckle region), the t required can be determined by using the
Construction Code formula for:
A) Torispherical head thickness B) Ellipsoidal head thickness
C) Hemispherical head thickness D) None of these
Answer: B (API 510, Par. 7.4.6.1) FFS Analysis of Corroded Regions … Corroded Areas in Heads
332. Regarding Fitness for Service Analysis of Corroded areas in heads (assume an ellipsoidal
head is corroded in the central portion of a head), the t required can be determined by using
the Construction Code formula for:
A) Ellipsoidal head thickness B) Torispherical head thickness
C) Toriconical head thickness D) Hemispherical head thickness
Answer: D (API 510, Par. 7.4.6.1) FFS Analysis of Corroded Regions … Corroded Areas in Heads
333. Fitness-for-service evaluations, such as those documented in API 579, may be used for
the evaluation of specific damage types that include all of the following EXCEPT:
A) To evaluate metal loss where the remaining wall is less than t required
B) To evaluate blisters and laminations and crack-like flaws
C) To evaluate weld misalignment and shell distortions
D) To evaluate the effects of fire damage
Ans: A (API 510, Par. 7.5.a/b/c/d/etc) FFS Evaluation API 579 RW less than the Corr Allow!
334. When Inspectors are working on code calculations (Required Thickness Determinations),
they must know which of the following statements is TRUE regarding rules for t required.
A) Required thickness shall be based on pressure considerations using the appropriate design
formula and code allowable stress values
B) Required thickness shall be based on pressure and structural considerations using
appropriate design formulas and code allowable stress values
C) Required thickness shall be based on pressure, mechanical, and structural considerations
using the appropriate design formulas and code allowable stress values
D) Required thickness shall be based on pressure, mechanical and structural considerations
using any design formulas and stress values
Ans: C (API 510, Par. 7.6) t required Determinations Must know!
335. For services with high potential consequences if failure were to occur, the engineer
should consider increasing WHAT VALUE to provide for unanticipated/unknown loadings,
undiscovered metal loss, or resistance to normal abuse?
A) t required B) t structural
C) t initial D) Corrosion Allowance
Ans: A (API 510, Par. 7.6) t required determinations Must know!
API 510 Code (16 Closed Bk Topic) Eval. of Equip (Min. Documentation) = & OB
336. For a vessel built in 1970 having no nameplate and minimal design documentation,
which of these steps may NOT be used to properly verify operating integrity?
A) Define design parameters, prepare drawings & perform insp. to determine vessel condition
B) Perform design calculations based upon the applicable construction codes & standards used
C) Attach nameplate showing MAWP & Temperature, minimum allowable temperature & date
D) Perform pressure test as soon as practical (per the current applicable code of construction)
Ans: D … (510, Par. 7.7) Evaluation of existing Equip (Minimal documentation) Must know!
337. For a pressure vessel constructed in 1970 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!
338. ASME Code Sect. VIII, Div I, Par UG-10(c) provides guidance on evaluation of unidentified
materials and requires what actions to properly identify materials used in pressure vessels?
A) Cutting a sample and doing a chemical composition analysis
B) Cutting a sample and doing a chemical composition analysis and performing mechanical tests
C) Performing Positive Material Identification testing and performing limited mechanical testing
D) None of these are correct
Ans: B … (510, Par. 7.7 & UG-10c) Eval existing Equip (Minimal documentation) Open Book!
339. Alternative to ASME Code Sect. VIII, Div I, Par UG-10(c) (requiring cut samples, chemical
composition analysis and mechanical tests), it is allowed to ASSUME an “S” value (allowable
stress value used for calculations) for an unknown P-No 1 material specification using:
A) Stress Values for SA-283 Gr. A B) Stress Values for SA-283 Gr. B
C) Stress Values for SA-283 Gr. C D) Stress Values for SA-285 Gr. C
Ans: C … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
340. For a pressure vessel constructed in 1970 having no nameplate and minimal design and
construction documentation, using unknown materials made of alloys or nonferrous material,
what may be used to determine material type (to determining allowable stress values)?
A) X-ray fluorescence (XRF) analysis B) Chemical composition testing
C) Optical fluorescence analysis D) None of these
Ans: A … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
API 510 Code (16 Closed Bk Topic) Eval. of Equip (Min. Documentation) = & OB
341. For vessels with minimal or no design or construction information and the extent of
radiography originally performed is not known, what must be done per API 510 to determine
Value E for calculations in order to assure vessel integrity?
A) Use 0.7 joint factor (butt welds) or perform radiography if a higher joint factor is required
B) Use 1.0 joint factor (butt welds) only after performing full radiography on all vessel welds
C) Use 0.85 joint factor (butt welds) only after performing spot radiography on all vessel welds
D) Use 0.70 joint factor (butt welds) only after performing spot radiography on all vessel welds
Ans: A … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
342. What may be required after performing radiography on welds in a vessel with minimal
or no design and construction documentation and the extent of radiography originally done
was not known (in order to determine value E for calcs)?
A) Nothing is required because RT results may be ignored & value E always assumed to be 0.70
B) Nothing is required because RT results may be ignored & value E always assumed to be 1.00
C) RT findings may result in the need for a fitness-for-service evaluation and significant repairs
D) RT findings may result in the need for a fitness-for-service evaluation
Ans: C … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
343. As part of the process for verifying vessel integrity when minimal/no design documents
exist for a vessel, a nameplate or stamp must be attached to the vessel showing:
A) MAWP and temperature, minimum allowable temp, test pressure, extent of RT, and date
B) MAWP and temperature, minimum allowable temperature, test pressure, and date
C) MAWP and temperature, minimum allowable temperature, and date
D) None of these is correct per API 510 rules
Ans: C … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
344. As part of the process for verifying vessel integrity when minimal/no design documents
exist for a vessel, a pressure test must be performed as soon as practical as required by:
A) The latest edition of the applicable construction code & standards used for the vessel
B) The applicable code of construction used for the design calculations
C) Any code deemed acceptable by both the Engineer and Inspector
D) None of these is correct
Ans: B … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
345. As part of the process for verifying vessel integrity for a vessel when minimal/no design
documents exist for a vessel, Do not use allowable stress values of the current ASME Code
(based on design factor of 3.5) for vessels designed to an edition or addendum of the ASME
Code earlier than the (Assume No earlier Code Case was used):
A) 1996 Addenda B) 1997 Addenda C) 1998 Addenda D) 1999 Addenda
Ans: D … (Par. 7.7.3) Evaluation of existing Equip (Minimal documentation) Must know!
Answer: B … (API 510, Para. 7.8.1) Topic 13 Inspection Records & Reports)
347. Who is required to maintain permanent and progressive records & reports per API 510?
348. For how long must permanent records be maintained per API 510?
A) Throughout the service life of each pressure vessel and pressure-relieving device
B) For at least 5 years after the equipment is taken out of service
C) For the time period stated in the Quality Assurance Manual
D) None of these are correct
Answer: A (API 510, Para. 7.8.1) Topic 13 Inspection Records & Reports)
349. Progressive records must be regularly updated and include new information pertinent to
all of the following items except:
Answer: A (API 510, Para. 7.8.1) Topic 13 Inspection Records & Reports)
350. According to API 510 rules, Pressure vessel and pressure-relieving device records SHALL
contain all of the following types of information pertinent to mechanical integrity EXCEPT:
A) Construction & design information & any applicable repair, alteration & rerating information
B) Inspection History records including reports & data for each type of inspection conducted
C) Fitness-for-service assessment documentation as described in detail in API 579
D) Maintenance History records including any process upsets or unusual events
Answer: D (API 510, Para. 7.8.2) Topic 13 Inspection Records & Reports) Para. 7.8.3 states
maintenance history records SHOULD (not shall) be available to the Inspector)
Answer: B … (Para. 8.1) Topic 14 Repairs & Alterations Repair Org … R-Stamp = Nat. Board
352. All repairs and alterations shall be performed by … (this is on every API 510 examination)
a repair organization … in accordance with the principles of any of the following EXCEPT:
A) Applicable ASME code B) Applicable construction code
C) Applicable repair code D) API 510 code
Answer: D … (Para. 8.1) Topic 14 Repairs & Alterations Repair Org … 510 = inspection code
353. Repairs to pressure-relieving devices should follow the guidelines given by:
Answer: C … (Para. 8.1) Topic 14 Repairs & Alterations Repair Org … PZV = API 576
354. ALL Repair & Alteration work must ALWAYS be authorized by (Whom) BEFORE work is
started by:
A) ENGINEER authorizes the work BEFORE the work is started by a REPAIR ORGANIZATION
B) INSPECTOR authorizes the work BEFORE the work is started by a REPAIR ORGANIZATION
C) OWNER/USER authorizes the work BEFORE the work is started by a REPAIR ORGANIZATION
D) None of these are correct
355. Authorization for alterations to pressure vessels that comply with ASME Section VIII,
Divisions 1 and 2, and for repairs to pressure vessels that comply with ASME Section VIII,
Division 2, may not be given until:
A) INSPECTOR ALWAYS authorizes the work and ENGINEER shall also authorize the work
B) OWNER/USER ALWAYS authorizes the work and ENGINEER shall also authorize the work
C) ENGINEER authorizes the work and OWNER/USER ALWAYS shall also authorize the work
D) ENGINEER ALWAYS authorizes the work for ALL repairs and alterations
357. The inspector may give prior general authorization for limited or routine repairs on a
specific vessel IF any of the following conditions exist EXCEPT:
A) Repairs include grinding on existing welds (spatter removal) prior to installing a new coating
B) Inspector is satisfied with the competency of the repair organization
C) Repairs are welding overlay of pitting on a PWHT’d vessel
D) Repairs are the kind that will not require a pressure test
358. API authorized inspectors may give prior authorization for routine repairs not involving:
Answer: A (API 510 Section/Para. 8.1.1 … Make sure you know the “routine repair” rule)
359. Before any REPAIR OR ALTERATION is performed, all proposed methods of design,
execution, materials, welding procedures, NDE & testing SHALL be approved by:
A) BOTH ENGINEER & INSPECTOR approve all of these items before any repair or alteration
B) INSPECTOR always approves all of these items before any repair or alteration
C) ENGINEER always approves all of these items before any repair or alteration
D) Owner/User approves all of these items before any repair or alteration
360. Before any ALTERATION is performed, all proposed methods of design, execution,
materials, welding procedures, NDE & testing SHALL be approved by WHOM:
A) INSPECTOR & ENGINEER both must approve all of these items before any alteration
B) INSPECTOR only approves all of these items before any alteration
C) ENGINEER only approves all of these items before any alteration
D) Owner/User approves all of these items before any alteration
361. Part of the APPROVAL process for repairs or alterations is that the inspector may
establish hold points to be implemented (when):
363. New vessel nozzles, connections, or replacement parts must meet design requirements
for the:
364. The design of replacement parts and new nozzles shall employ a stress value that is
(what) and who shall approve the addition of all new nozzles?
A) Same allowable stress criteria used for vessel design & Engineer approves all new nozzles
B) Allowable stress criteria used in latest edition of code & Engineer approves all new nozzles
C) Any allowable stress criteria the engineer wants to use & Engineer approves all new nozzles
D) None of these is correct
365. The material used in making repairs or alterations shall conform to the:
A) Design code
B) Inspection code
C) Construction code
D) Applicable construction code
Answer: D … (Para. 8.1.4) Topic 14 Repair & Alteration Material Rules on Repair/Alteration
Answer: D … (Para. 8.1.4) Topic 14 Repair & Alteration Material Rules on Repair/Alteration
367. Materials used for welded repairs and alterations shall be:
A) Of known weldable quality and compatible with the original material
B) Of the same tensile strength and stress values as the original material
C) The same or greater tensile strength/stress values as the original material
D) Considered weldable with differing chemical composition value as the original material
Answer: A … (Para. 8.1.4) Topic 14 Repair & Alteration Material Rules on Repair/Alteration
368. Carbon or alloy steel with carbon content over what percentage shall not be welded.
A) 0.25% B) 0.30%
C) 0.35% D) 0.40%
Answer: C … (Para. 8.1.4) Topic 14 Repair & Alteration Material Rules on Repair/Alteration
369. Repairs to defects found in pressure vessel components may be made by several
techniques often dependent upon all of the following conditions EXCEPT for:
Answer: B … (Para. 8.1.5) Topic 14 Repairs & Alterations Defect Repairs (Repair/Alteration)
370. How may repair techniques be classified depending upon their design and conformance
to the applicable construction code?
372. Regarding Temporary Repair Documentation, Inspection Plans SHALL include (what):
A) Taking thickness readings ASAP in the immediate area adjacent to the temporary repair
B) Performing NDE after repair ASAP in the immediate area adjacent to a temporary repair
C) Monitoring the integrity of the temporary repair until permanent repairs are completed
D) None of these are correct
Answer: C … (API 510, Para. 8.1.5.1.1) Temporary Repair Rules
373. Temporary repairs may remain in place for a longer period of time (exceeding the
planned date for the permanent repair) only if evaluated, documented and approved by:
A) Inspector and Engineer, and with Owner/User approval also
B) Inspector and Engineer
C) Inspector only
D) Engineer only
Answer: B … (API 510, Para. 8.1.5.1.1) Temporary Repair Rules
374. If evaluated, approved & documented by the engineer and inspector, temporary repairs
may remain in place (exceeding the planned date for permanent repair) for how long?
A) For a maximum period of 5 years to be documented in inspection plans
B) Permanently because they can be considered permanent by an evaluation
C) For a period not exceeding the maximum internal/On-stream inspection interval
D) For a “longer period of time” than the planned date for the permanent repair installation
Answer: D … (API 510, Para. 8.1.5.1.1) Temporary Repair Rules
375. Temporary repairs should be removed & replaced with suitable permanent repairs
(when):
377. Fillet-welded patches may not be placed over existing cracks unless:
A) Engineer determines cracks will not be expected to propagate from under a patch
B) Corrosion Specialist determines cracks will not be expected to propagate from under a patch
C) Inspector & Engineer determine cracks will not be expected to propagate from under a patch
D) Inspector & Corrosion Specialist determine cracks will not be expected to propagate from
under a patch
Answer: A … (API 510, Para. 8.1.5.1.2.1) Temporary Repair Rules … Fillet-welded Patches
Answer: B … (API 510, Para. 8.1.5.1.2.1) Temporary Repair Rules … Fillet-welded Patches
379. Fillet-welded patches require special design consideration especially related to:
Answer: D … (API 510, Para. 8.1.5.1.2.2) Temporary Repair Rules … Fillet-welded Patches
380. Fillet-welded patches may be applied to the internal or external surfaces of shells,
heads, and headers provided that, in the judgment of the engineer, which of the following is
true:
A) Patches provide a design safety equivalency to applicable code designed reinforced openings
B) Strain in patches results in fillet-weld stresses that exceed allowable stresses for such welds
C) Fillet-welded patches are designed to absorb a portion of the membrane strain of the parts
D) Allowable membrane stress is exceeded in the vessel parts or the patches
Answer: A … (API 510, Para. 8.1.5.1.2.2) Temporary Repair Rules … Design Considerations
387. A full encirclement lap band repair may be considered if all the following requirements
are met EXCEPT:
A) The repair is covering a crack in the vessel shell
B) The band is designed to contain the full vessel design pressure
C) The design is approved and documented by the engineer and inspector
D) All longitudinal seams in the repair band are full penetration butt welds of code quality
Answer: A … (API 510, Para. 8.1.5.1.3) Temporary Repair Rules … Lap Band Repair Rules
388. Which of the following statements are FALSE regarding use of Non-Penetrating Nozzles
(including pipe caps attached as nozzles) using the appropriate code methods of attachment?
A) Nozzle material shall be suitable for contact with contained fluid at design conditions
B) They may be used as permanent repairs (excluding cracks) with appropriate code design
C) They may be used as permanent repairs (including cracks) with the appropriate code design
D) Damage mechanism causing the repair is considered along with future inspection monitoring
Answer: C … (API 510, Para. 8.1.5.1.4) Temporary Repair Rules … Unusual Nozzle Repair Rules
389. Typical permanent repair techniques include all of the following EXCEPT:
A) Excavating a defect & contour blend-grinding as per API 579 requirements
B) Excavating a defect & repair welding the excavation & weld overlay of corroded areas
C) Replacing a section or the component containing the defect
D) Adding strip or plate lining to the exterior surface.
Answer: D … (API 510, Para. 8.1.5.2.1) Permanent Repair Rules … Technique Rules
390. Who must be consulted before repair of a crack at a discontinuity where stress
concentrations may be serious?
A) Both the Engineer & Inspector
B) R Stamp Holder or Vessel Manufacturer
C) Inspector
D) Engineer
Answer: D … (API 510, Para. 8.1.5.2.1) Permanent Repair Rules … Technique Rules
API 510 Code (16 Closed Book Topics) Topic # 14
391. Typical permanent repair techniques include all of the following EXCEPT:
A) Excavating a defect and contour blend-grinding per API 579
B) Excavating a defect and repair welding the excavation
C) Replacing an entire section or component containing defects
D) Lap Band and Weld overlays of corroded areas
Answer: D (API 510, Para. 8.1.5.2.1) Permanent Repair Rules
392. Insert (flush) patches may be used if all of the following requirements are met EXCEPT:
A) Has full-penetration groove welds & is RT examined and approved per applicable code only
B) Has full-penetration groove welds & is Shear Wave UT’d & approved per applicable code only
C) Patch corners not extending to existing long/horizontal welds have a 25mm minimum radius
D) Weld proximity to existing welds (weld spacing) was reviewed and approved by the engineer
Ans: B … (510, Para. 8.1.5.2.1) Permanent Repair Rules … Insert Plate Special UT Rules apply
393. Insert (flush) patch permanent repairs may use Ultrasonic shear wave exams substituted
for RT. Regarding the use of insert (flush) patches, which of these is a FALSE statement?
A) All NDE (including UT Shear Wave) procedures are to be approved by the Inspector
B) An industry-qualified UT Shear Wave Examiner is to be used on the flush-patch repair
C) Weld proximity to existing welds (weld spacing) was reviewed and approved by the Inspector
D) Patch corners not extending to existing long/horizontal welds have a 25 mm minimum radius
Ans: C … (510, Para. 8.1.5.2.1) Permanent Repair Rules … Insert Plate Special UT Rules apply
394. Regarding Filler Metal Strength for Overlays and Repairs to Existing Welds, the filler
metal used for weld repairs SHOULD have a minimum specified tensile strength that is:
A) Equal to or greater than a minimum specified tensile strength of a base metal
B) Greater than the minimum specified tensile strength of the base metal
C) Equal to the minimum specified tensile strength of a base metal
D) Any of these depending upon calcs to determine strength
Ans: A … (510, Par. 8.1.5.3.1) Permanent Repair Rules … Filler Metal Strength Rules for Repair
395. If a filler metal to be used will have a minimum specified tensile strength lower than the
minimum specified tensile strength of a base metal, All of these items must be true EXCEPT:
A) Filler and base metal chemistry shall be compatible regarding weldability & service damage
B) Repair thickness shall not be more than 50% of base metal required thickness, excluding CA
C) Repair weld thickness shall be increased by the ratio of the differing min. tensile strengths
D) Repair weld thickness shall be decreased by the ratio of the differing min. tensile strengths
Ans: D … (510, Par. 8.1.5.3.2) Permanent Repair Rules … Filler Metal Strength Rules for Repair
API 510 Code (16 Closed Book Topics) Topic # 14
396. If a filler metal used will have a minimum specified tensile strength lower than that of a
base metal repaired, both filler metal and base metal chemistry shall be compatible regarding
weldability and service damage, and all of these must be true EXCEPT:
A) Repair thickness shall not be more than 75% of base metal required thickness, excluding CA
B) Repair weld thickness shall be increased by a ratio of the differing minimum tensile strengths
C) Increased repair thickness shall have rounded corners and a 3:1 taper blend into base metal
D) Repairs shall be made with a minimum of two passes.
Ans: A … (510, Par. 8.1.5.3.2) Permanent Repairs … Filler Metal Strength Rules 50% Rule
397. If a filler metal used will have a minimum specified tensile strength lower than that of a
base metal repaired, both filler metal and base metal chemistry shall be compatible regarding
weldability and service damage, and all of these must be true EXCEPT:
A) Repair thickness shall not be more than 50% of base metal required thickness, excluding CA
B) Repair weld thickness shall be increased by a ratio of the differing minimum tensile strengths
C) Increased repair thickness shall have rounded corners and a 4:1 taper blend into base metal
D) Repairs shall be made with a minimum of two passes.
Ans: C … (510, Par. 8.1.5.3.2) Permanent Repairs … Filler Metal Strength Rule 3:1 taper rule
398. If a filler metal used will have a minimum specified tensile strength lower than that of a
base metal repaired, both filler metal and base metal chemistry shall be compatible regarding
weldability and service damage, and all of these must be true EXCEPT:
A) Repair thickness shall not be more than 50% of base metal required thickness, excluding CA
B) Repair weld thickness shall be increased by a ratio of the differing minimum tensile strengths
C) Increased repair thickness shall have rounded corners and a 3:1 taper blend into base metal
D) Repairs shall be made with a minimum of one pass
Ans: D … (510, Par. 8.1.5.3.2) Permanent Repair - Filler Metal Strength 2 pass minimum rule
399. Regarding repairs to SS Weld Overlay and Cladding, the repair procedure(s) to restore
removed, corroded, or missing clad or overlay areas shall be first reviewed and approved by:
A) Inspector, Engineer and Owner/User B) Inspector and Engineer
C) Inspector D) Engineer
Ans: B … (510, Par. 8.1.5.4.1) Permanent Repair – SS Weld Overlays & Cladding Rules
400. Important factors that may affect repair plans for SS Weld Overlays are all these EXCEPT:
A) Deterioration of base metal properties by Chloride SCC of Chromium-Molybdenum alloys
B) Minimum pressurization temperatures and a need for future periodic examinations
C) Stress level, base material P-number, and service environment
D) Possible previously dissolved hydrogen and type of lining
Ans: A … (510, Par. 8.1.5.4.2) Permanent Repair – SS Weld Overlays Temper Embrittlement
402. How shall SS Weld Overlay repairs be monitored and inspected and what NDE applies?
A) Repair shall be Inspector monitored. PT exam is after a repair cools down to ambient temps
B) Repair may be Examiner monitored & PT’d only after a repair cools down to ambient temps
C) Repair may be inspector or examiner monitored & PT’d only after it cools to ambient temps
D) None of these is correct per API 510
Ans: A … (Par. 8.1.5.4.3) Perm. Rep, SS Weld Overlay, Inspector monitors work & PT exams
403. Regarding repairs to vessels constructed with P-3, P-4, or P-5 base materials that have
been overlay welded with SS, which of these following statements about NDE exams is False?
A) In addition to PT exams on weld overlays, base metal in repair areas should be UT examined
B) UT shear-wave exams for cracking are to be done as per ASME Sect. V, Art. 4 requirements
C) UT shear-wave exams are best done after at least a 48 hour delay after repairs are done
D) UT shear-wave exams are best delayed when alloys can be affected by delayed cracking
Ans: C … (Par. 8.1.5.4.4) Perm. Rep, Low Alloy repairs, UT exams = 24 HR delayed cracking
404. Regarding on-stream welds & Hot Taps on existing ASME Code constructed vessels,
which of these statements is FALSE?
A) All repair and alteration welding shall be as per the applicable requirements of ASME Code
B) Information regarding Oil & Gas Industry welding guidelines may be found in API 582
C) When making On-stream welds or Hot Taps, inspectors can refer to API 2201
D) For guidance on welding procedure review refer to API 578
Ans: D … (510, Par. 8.1.6.1 & 2) Welding & Hot Tapping – API 577 for WPS review
405. Which of these statements is FALSE regarding Repair Organization roles during welding?
A) They shall use welders and welding procedures qualified in accordance with ASME IX code
B) They shall maintain records of qualified WPSs & welding performance qualifications (WPQs)
C) Welders must weld within the ranges for which they are qualified on their WPSs
D) These records shall be available to the inspector before the start of welding
Ans: C … (Par. 8.1.6.2) Welding & Hot Tapping & WPS & WPQ – WPQs not WPSs
413. Regarding PWHT, LOCAL PWHT MAY be substituted for 360-degree banding on local
repairs on all materials, provided that the local PWHT temp is maintained for a distance not
less than two times base metal thickness (from weld toe) using how many thermocouples?
A) Suitable # of TCs shall be used (at least 4)
B) Suitable # of TCs shall be used (at least 3)
C) Suitable # of TCs shall be used (at least 2)
D) Suitable # of TCs shall be used (at least 1)
Answer: C … (API 510, Para. 8.1.6.4.1) Welding & Hot Tapping PWHT Rules for Weld Repairs
414. Preheat & Controlled Deposition Welding may be used in lieu of PWHT where PWHT is:
A) Inadvisable or mechanically unnecessary
B) Not required by the applicable code
C) Not recommended by Inspector
D) Not recommended by Engineer
Answer: A … (API 510, Para. 8.1.6.4.2.1.1) Welding & Hot Tapping PWHT Alternative Rules
415. Prior to using any alternative method for PWHT such as Preheat & Controlled Deposition
Welding methods, which of the following statements are NOT true?
A) Metallurgical review by engineer considers any susceptibility to SCC & weld location stresses
B) Metallurgical review by engineer must assure an alternative is suitable for the application
C) Metallurgical review by engineer considers any susceptibility to HTHA, creep, and others
D) Metallurgical review by engineer considers reasons to avoid costs of equipment PWHT
Ans: D … (Par. 8.1.6.4.2.1.1) Welding & Hot TapPWHT Alternative Original reason PWHT
API 510 Code (16 Closed Book Topics) Topic # 14
416. Which of the following statements is FALSE regarding the Preheating Method (Notch
Toughness Testing Not Required), when it is to be performed in lieu of PWHT?
A) Materials shall be limited to P-No. 3, Group 1 and 2 (excl. Mn-Mo steels in Gr. 2)
B) All Welding shall be limited to the SMAW, GMAW, and GTAW processes
C) Materials shall be limited to P-No. 1, Group 1, 2, and 3
D) Materials shall be limited to P-No. 8, Group 1 and 2
Ans: D … (Par. 8.1.6.4.2.2.1) Welding & Hot Tap PWHT Alternative Preheating Method
417. Which of the following is correct regarding the Preheating Method temperature to be
maintained, when preheating is used as an alternative in lieu of PWHT?
A) Preheat of 250°F (121°C) or higher, as specified in WPS, is maintained during welding
B) Preheat of 300°F (150°C) or higher, as specified in WPS, is maintained during welding
C) Preheat of 350°F (177°C) or higher, as specified in WPS, is maintained during welding
D) Preheat of 400°F (204°C) or higher, as specified in WPS, is maintained during welding
Ans: B … (Par. 8.1.6.4.2.2.2) Welding & Hot Tap PWHT Alternative Preheating Method
418. Which of the following statements is FALSE regarding the Preheating Method, when it is
to be performed as an alternative in lieu of PWHT?
A) Weld area shall be preheated/maintained at minimum temp of 300°F (150°C) during welding
B) Each side of a weld for 4 in. or 4 x depth of repair weld (use greater) is kept at 300°F (150°C)
C) Notch toughness testing is required when using this preheat method in lieu of PWHT
D) Maximum interpass temperature shall not exceed 600°F (315°C)
Ans: C … (Par. 8.1.6.4.2.2.2) Welding & Hot Tap PWHT Alternative Preheating Method
419. Which of the following statements is FALSE regarding the Preheating Method distance
and temperature to be maintained, when preheating is used an alternative in lieu of PWHT?
A) Each side of weld for 4 inches or 4 x depth of repair weld (use greater) is kept at 300°F/150°C
B) Each side of weld for 4 inches (as a minimum) is kept at 350°F/177°C as a minimum temp
C) Each side of weld for 2 inches or 2 x depth of repair weld (use greater) is kept at 300°F/150°C
D) Each side of weld for 2 inches (as a minimum) is kept at 350°F (177°C) as a minimum temp
Ans: A … (Par. 8.1.6.4.2.2.2) Welding & Hot Tap PWHT Alternative Preheating Method
420. Which of the following is correct regarding the Preheating Method temperatures to be
maintained as specified in a WPS, when preheating is used as an alternative in lieu of PWHT?
A) Preheat of 300°F (150°C) or higher, with interpass temperatures not exceeding 500°F (260°C)
B) Preheat of 300°F (150°C) or higher, with interpass temperatures not exceeding 600°F (315°C)
C) Preheat of 350°F (177°C) or higher, with interpass temperatures not exceeding 650°F (343°C)
D) Preheat of 350°F (177°C) or higher, with interpass temperatures not exceeding 650°F (343°C)
Ans: B … (Par. 8.1.6.4.2.2.2) Welding & Hot Tap PWHT Alternative Preheating Method
API 510 Code (16 Closed Book Topics) Topic # 14
421. Which of the following statements is FALSE regarding the Controlled-deposition Welding
Method, when it is to be performed in lieu of PWHT?
A) Materials shall be limited to P-No. 1, P-No. 3, and P-No. 4 steels
B) Welding shall be limited to the SMAW, GMAW, and GTAW processes
C) A weld procedure specification shall be developed and qualified for each application
D) Notch toughness tests are not needed if impact tests are req’d by original construction code
Ans: D … (Par. 8.1.6.4.2.3) WeldingPWHT AlternativeControlled Deposition Are needed
422. Which of the following statements is FALSE regarding minimum content of Controlled
Deposition Welding WPSs, if controlled deposition welding is to be done in lieu of PWHT?
A) WPS shall be developed & qualified only for first application of controlled deposition welding
B) WPS shall define preheat temperature & interpass temperature & also post-heating temps
C) WPS Qualification thickness for test plates & repair grooves shall be as per API 510 Table 8-1
D) PQR Test material shall be the same material specification as original material under repair
Ans: A … (Par. 8.1.6.4.2.3) WeldingPWHT Alternative Controll-Deposit Each application
423. Which of the following statements is FALSE regarding minimum content of Controlled
Deposition Welding WPSs, if controlled deposition welding is to be done in lieu of PWHT?
A) WPS shall be developed & qualified for each application of controlled deposition welding
B) WPS shall define only minimum preheat temperatures & maximum interpass temperatures
C) If special hardness limits are needed for corrosion resistance, a PQR shall incl. hardness tests
D) PQR Test material shall be the same material specification as original material under repair
Ans: B … (Par. 8.1.6.4.2.3) WeldingPWHT Alternative Controll-Deposit Post Weld Bake
424. Which of the following statements is FALSE regarding additional content of Controlled
Deposition Welding WPSs, if controlled deposition welding is to be done in lieu of PWHT?
A) WPS shall include technique (temper-bead or half-bead) that was also be used in the PQR
B) WPS shall include minimum preheat temperature & maximum interpass temperature limits
C) WPS shall include minimum weld heat input value for each layer that must not be exceeded
D) WPS shall include all applicable supplementary essential variables of ASME IX Code QW-250
Ans: C … (Par. 8.1.6.4.2.3)WeldPWHT Alternative ControlDeposit Maximum Heat Input
425. Which of the following statements is FALSE regarding additional content of Controlled
Deposition Welding WPSs regarding Hydrogen Bake Out (Post Heating), if controlled
deposition welding is to be done in lieu of PWHT?
A) SMAW welds are post-heated after welding & before cooling below preheat minimum temps
B) SMAW weld post-heat temps are 500°F ± 50°F (260°C ± 30°C) for minimum period of 2 hours
C) SMAW weld post-heat assists out-gassing diffusion of weld metal hydrogen (from welding)
D) SMAW welds use electrodes of supplemental diffusible-hydrogen designators of H4 or lower
Ans: D … (Par. 8.1.6.4.2.3) Weld PWHT Alternative Controlled Deposition H8 or lower
API 510 Code (16 Closed Book Topics) Topic # 14
426. Which of the following electrodes may eliminate the need for Hydrogen Bake-out post-
weld treatments (SMAW process), if controlled deposition welding is done in lieu of PWHT?
A) E7018-H8 B) E7018-H6
C) E7018-H4 D) E7018-H1
Ans: C … (Par. 8.1.6.4.2.3) WeldingPWHT Alternative Controlled-Dep … H4 Designation
427. What must be done when using the temper bead technique (SMAW process) after the
finished repair has finally cooled down to ambient temperature, if controlled deposition
welding is done in lieu of PWHT?
A) The final temper bead reinforcement layer shall be removed & made flush with base metal
B) The final temper bead reinforcement layer shall be examined (hold point) by an examiner
C) The final temper bead reinforcement layer shall receive a hardness test by an examiner
D) None of these are API 510 requirements
Ans: A … (Par. 8.1.6.4.2.3) WeldingPWHT Alternative Controlled-Dep … Flush ground
428. Which API document provides guidance on NDE of weld joints and weldments?
429. Regarding the NDE of weld repairs and areas that have been excavated and rewelded,
which of the following statements is FALSE?
A) Prior to welding repairs, the area prepared for welding after excavation is examined using
either the MT or PT examination technique to determine that no defects exist or remain there
B) MT or PT exams are especially important after removing cracks and other harmful defects
C) After welding repair is done, it shall be examined again by NDE in repair specs to determine
that no defects exist using acceptance standards acceptable to Inspector or an applicable code
D) Repair welds required to be originally radiographed also require either MT or PT examination
Ans: D … (510, Par. 8.1.7.1/2/3) Welding NDE of Welds RT Accessible? No MT or PT
430. Regarding repairs, where use of NDE techniques specified by the construction code is not
possible or practical, what must be done and who must approve this?
A) Alternative NDE techniques may be used if approved by engineer & inspector & owner/user
B) Alternative NDE techniques may be used if approved by engineer and inspector
C) Alternative NDE techniques may be used if approved by engineer
D) Alternative NDE techniques may be used if approved by inspector
Ans: B … (Par. 8.1.7.3) Welding NDE of Welds Alternative NDE Engineer & Inspector
API 510 Code (16 Closed Book Topics) Topic # 14 & 15 (Rerating)
431. Acceptance criteria for welded repairs or alterations should be in accordance with:
A) The applicable sections of the ASME Code or another applicable vessel rating code
B) The applicable inspection plan for the vessel under repair approved by Inspector
C) The applicable repair plan agreed upon before the start of repair work
D) None of these (API 510 Code Rules apply)
Ans: A … (510 Par. 8.1.7.3) Welding NDE of Welds Acceptance Criteria ASME Code
432. Regarding Weld Inspection of repairs when it is determined that Vessels repaired or
altered may be subject to Brittle Fracture, which of the following statements are FALSE?
A) For vessels constructed of materials that may be subject to brittle fracture, appropriate
inspection should be considered after welded repairs or alterations
B) Flaws, notches, or other stress risers found could initiate a brittle fracture in pressure tests
C) MT and other effective surface NDE methods should be considered for susceptible vessels
D) Inspection techniques should be selected to detect critical flaws as determined by examiner
Ans: D … (510 Par. 8.1.7.3) Welding NDE Brittle Fracture Detect critical flaws 579 FFS
433. Rerating of a pressure vessel may involve all of the following except:
A) Changing its design temperature B) Changing its minimum metal design temp
C) Changing its service D) Changing its MAWP
Answer: C (API 510, Para. 8.2.1) Topic 15 Begins … Rerating of a Pressure Vessel … Rules!
434. Rerating a pressure vessel by changing its design temperature, minimum metal design
temperature, or its maximum allowable working pressure may be done only after all of the
following requirements have been met EXCEPT:
A) Rerating shall be performed in accordance with requirements of a vessel’s construction code
B) Previous insp. records verify a pressure vessel is satisfactory for proposed service conditions
C) Calcs performed by an experienced owner/user design engineer justify the vessel’s rerating
D) Calcs using appropriate formulas (latest edition of applicable construction code) by an
experienced owner/user design engineer justify the vessel’s rerating
Answer: B (API 510, Para. 8.2.1) Topic 15 Begins … Rerating Vessel … Current Insp records!
435. To justify rerating, Current Inspection Records must show all of the following EXCEPT:
A) Verify that the pressure vessel is satisfactory for the proposed service conditions
B) Verify that the corrosion allowance provided is appropriate for proposed service conditions
C) Verify that an increase in allowable working pressure or design temperature is justified and
based on thickness data obtained from a recent internal or on-stream inspection
C) Verify that an increase in allowable working pressure or design temperature is justified and
based on thickness data obtained from any recent external inspection
Answer: D (API 510, Para. 8.2.1) Topic 15 Begins … Rerating Vessel … Current Insp records!
API 510 Code (16 Closed Book Topics) Topic # 15 (Rerating) & 16 (Pressure tests after)
436. Rerating a pressure vessel by changing its design temperature, minimum metal design
temperature, or its maximum allowable working pressure may be done only after all of the
following requirements have been met EXCEPT:
437. To justify rerating, an increase in allowable working pressure or design temperature shall
be based on thickness data obtained from:
438. To justify rerating, which of these is NOT required relative to pressure testing?
A) Vessel shall be pressure tested using applicable testing formula (of code used for rerating)
B) Vessel has been tested to a pressure ≤ the test pressure required (of code used for rerating)
C) Vessel has been tested to a pressure ≥ the test pressure required (of code used for rerating)
D) Vessel has been tested to a pressure < the test pressure required (of code used for rerating)
Answer: B (API 510, Para. 8.2.1) Topic 15 Begins … Rerating Vessel … Previous pressure test
440. The pressure vessel rerating will be considered complete when the inspector witnesses:
A) Attachment of an additional nameplate or stamp showing the rerate code parameters used
B) Calculations for the rerating as per code and verifies them as being correct
C) Engineering Rerating Report and signs off on the Inspection line
D) None of these is correct
Answer: A (API 510, Para. 8.2.1) Topic 15 Begins … Rerating Vessel … Add Nameplate or stamp
10 Bonus Questions for API 510
441. The most common forms of CUI are localized corrosion of carbon steel and:
A) Chloride stress corrosion cracking of austenitic stainless steels
B) Polythionic acid corrosion of stainless steels
C) Stress corrosion of stainless steels
D) None of the above attack stainless steels
Answer: A (API 572, Section 8.2.1)
442. A pressure vessel should be maintained according to the requirements of the code:
A) According to the latest code requirements
B) According to the owner-user specifications
C) Under which it was designed and constructed
D) None of these
443. Inspector measured undercut on a girth weld during the repair to an ASME Section VIII,
Div. I Carbon Steel vessel (Stamped RT 1) and it was found to be 1/32 inch (1mm) in depth
maximum. Shell base metal is 2 inches thick and having PWHT. Inspector shall:
A) Reject the weld because no undercut is allowed on any vessel welds requiring PWHT
B) Reject the weld because undercut will affect RTFI interpretation & request surface grinding
C) Accept the weld because undercut is within ASME Section VIII, Div. I code allowed tolerance
D) Consult with the Vessel (Welding) Engineer
444. 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 likely which
type of discontinuity?
A) Incomplete penetration B) Incomplete fusion
C) Wormhole porosity D) Crack
445. If white salts are found at cracks in a vessel, what is the likely damage mechanism?
447. What is the minimum length of a spot radiograph as per ASME Section VIII, Division 1?
A) Per the minimum dimension given in the Inspection Plan or approved RT procedure
B) 6 inches
C) 12 inches
D) None of these
Answer: B (ASME VIII, Div I, UW-52.c 6 inches) Could be on Closed Book exam also)
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.
448. 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 B) 6 mm
C) 12 mm D) None of these are correct
Ans: D (ASME VIII, Div I, UW-52.c.3 Rounded indications are not a factor No limit exists
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.
449. Exam Question: To be considered valid by an Inspector, PQRs must be certified by:
A) Mechanical tests per ASME IX B) A corresponding and supporting WPS
C) Approved Test Lab Signature & date D) The owner user inspection organization
Ans: C … (API 510 Body of Knowledge Part 2 (Notes) 2010 Edition/2011 exams Must know
450. Designated areas on pressure vessels where periodic exams are conducted are called:
A) Inspection points B) Survey points C) TMLs D) CMLs
Ans: D (API 510 definitions for Condition Monitoring Locations)
API 576 (Chapter 5 & 6) Exam Questions (API 510, Section 6.6)
Questions 272 to 285 cover API 510, Section 6.6 The API 510 to 576 Pathway
Must Know API 576 … Ch. 5 (Causes of Improper Performance) & Ch. 6 (Inspection & Testing)
E-Library API 510 folder for Exam questions! API 576 has 2 handouts!
*** In the margin & underlined areas are those where exam Q’s will be!
451. (Same as # 274 … repeated for effect). Spring failures are almost always caused by:
A) Corrosion that includes surface corrosion and stress corrosion cracking
B) Stress related failure due to improper sizing/using substandard parts
C) Mechanical failure due to excessive movement and vibration
D) Excessive chattering and wire drawing
Ans: A (510, 6.6.6 & 576, Para 5.1.1 & 5.3.2 & Fig 30) … PZV Spring Failure Cause = Corrosion
452. Which of the following may be installed on the inlet or outlet of a pressure-relief valve
to provide added corrosion protection of the valve internals?
A) Orifice plates limiting or restricting flow to and from relief valves to reduce hammering
B) Isolation valves that utilize the “double block and bleed” designs to prevent corrosion
C) In-line screens & filters that trap debris and prevent deposition at internal surfaces
D) Rupture disk devices that protect the relief valve against system fluids
Answer: D (576, Para 5.1.3) … Rupture discs that protect PZVs against system fluid corrosion
453. Which of these is not a cause of damaged relief valve seats in refinery service?
A) Careless handling during maintenance (bumping, dropping, jarring, or scratching valve parts)
B) Undersized relief valves that close abruptly resulting in disc/nozzle seating surface damage
C) Corrosion and foreign particles (mill scale, weld spatter/slag, dirt, etc) entering valve inlets
D) Improper or lengthy piping to valve inlets or line obstructions that cause valve chattering
Ans: B (576, Para 5.2.2.g) … Severe oversizing causes abrupt closing/damage
454. A rapid cycle of opening and closing subjecting relief valve seating surfaces to severe
hammering that sometimes damages the seating surfaces beyond repair is called:
A) Hammer B) Vibration-induced fatigue
C) Chatter D) Wire drawing
Answer: C (API 576, Para 5.2.2.c) … Chatter
455. Leakage past relief valve seating surfaces causing seat damage by erosion is called:
A) Hammer B) Leak-by or wicking
C) Chatter D) Wire drawing
Answer: D (API 576, Para 5.2.2.e) … Wire drawing is erosion/leakage across seating surfaces!
API 576 (Chapter 5 & 6) Exam Questions (API 510, Section 6.6)
Questions 272 to 285 cover API 510, Section 6.6 The API 510 to 576 Pathway
456. Which of these statements are NOT true regarding the causes of failed springs in refinery
relief valves?
A) Springs often weaken and fail due to the use of improper materials in high-temp service
B) Surface corrosion and stress corrosion cracking are the most common type of failure
C) Hydrogen sulfide (H²S) frequently causes corrosion fatigue failure of springs
D) Failed springs are almost always caused by corrosion
Ans: D (576, Sect 5.3.1/2/3/4) … H²S causes spring stress corrosion cracking (NACE MR0175)
457. When selecting the appropriate spring material, which of these factors are NOT the most
important for materials to prevent Stress Corrosion Cracking (SCC) in refinery relief valves?
A) Material strength B) Hardness
C) Ductility D) Heat treatment
Answer: C (API 576, Sect 5.3.4) … Page 30 below Figure 30 and the broken spring
458. During relief valve testing using air or bottled nitrogen, what does the inspector carefully
listen for to determine that the “set pressure” has been reached?
A) A distinct pop only must always be the determining factor
B) An audible leak (hissing noise) followed by a distinct pop
C) An audible leak (hissing noise) is the determining factor
D) None of these are correct
Answer: B (API 576, Sect 5.4.3) … A is arguably correct … Understand the term blowdown
459. When testing relief valves, the relief valve term “blowdown” refers to the:
A) Difference between set pressure and test or “pop” pressure
B) Difference between set and reseating pressure
C) Test or “Pop” pressure
D) Reseating pressure
Answer: B (API 576, Sect 5.4.6) … See also valve adjusting rings to control the blowdown
460. A term used related to sticking of the disk in a relief valve when foreign particles in the
guiding surfaces tend to roll the metal up (tearing the metal) is called:
A) Galling B) Chattering
C) Hammering D) Wire drawing
Answer: A (API 576, Sect 5.5.2) … Galling is a huge problem causing malfunctions in guiding
Surfaces and the correct lubricant selection plays an important role in the proper operation
API 576 (Chapter 5 & 6) Exam Questions (API 510, Sect. 6.6 Pathway)
461. Rough handling of a relief valve can cause of the following problems except:
A) Lifting levers may be damaged
B) A change in the set pressure can result
C) Internal or external leakage can occur when the valve is in service
D) The valve may become frozen in service and fail to perform its function
Answer: D (API 576, Sect 5.8.1) … Corrosion causes the valve to become frozen and function
462. Rough handling can occur when:
A) During shipment only
B) During shipment or maintenance
C) During shipment or maintenance or installation
D) During shipment or maintenance or installation or operation
Answer: C (API 576, Sect 5.8.1) … Easy question … D is there to fool you
463. Pressure relief valves should be shipped (transported) in what manner?
A) On pallets (packaged and secured to prevent damage)
B) In an upright position (to assure correct spring function)
C) In crates (packaged like the delicate instruments that they are)
D) Individually wrapped to secure the valve and prevent damage/corrosion
Answer: B (API 576, Sect 5.8.1 & 5.8.4.2)
464. Which of these provides seat loading to keep the pressure-relief valve tightly closed?
A) Blowdown
B) Cold differential test pressure (CDTP)
C) Proper capacity design = trouble-free operation
D) Differential between operating and set pressures
Answer: D (API 576, Sect 5.8.1) … blowdown = difference between set and reseating pressure
465. (Same as # 275 … repeated) The principal reason for inspecting a pressure relief device is:
A) To determine if it is functioning properly (so it can provide protection to equip/personnel)
B) To prevent fouling and plugging from occurring that could render a valve inoperable
C) To assure equipment (pressure vessel) safety by preventing Overpressurization
D) To assure personnel safety
Ans: A (API 510, Par. 6.6 API 576 Ch. 6, Para. 6.1.1 in entirety) API website Sample Q
2. Welding Inspection includes much more than just the non-destructive examination of the
completed weld. Many other issues are important & they include all of these below except:
3. Welding inspection activities can be separated into three stages corresponding to the
welding work process and include all of the following except:
4. What is the most important stage of welding to assure that welding problems are avoided
and changes and corrections necessary are made?
A) In the planning and preparation stage before any welding on job begins
B) Just immediately before the planned start of welding on a new job
C) During the welding of initial production joints
D) Either during welding or immediately after
5. Prior to welding, a review of drawings, standards, codes, and specifications is done to:
A) Understand the requirements for the welding and identify any inconsistencies
B) Ensure that the welder understands the specification and is qualified
C) Ensure that the drawings meet the specifications
D) None of these are correct per API 577
A) Welding symbols, weld sizes, weld joint designs, & weld dimensions are clearly specified
B) Weld maps identify welding procedure specification (WPS) used for specific weld joints
C) Dimensions are detailed and any potential for distortion has been addressed
D) Welding consumables specified are the ones being used in the welding
7. Which of the following are NOT Quality Control items to assess prior to welding?
8. Which of the following are NOT Quality Control items to assess prior to welding?
9. Which of the following are NOT potential inspector actions to be taken regarding
Quality Control item assessment prior to welding?
Ans: A … Ref: Sect. 4.2.1.2 QC Items to Assess Prior to Welding – Potential Insp Action
10. Inspectors shall review requirements for the weldment with the personnel involved with
executing the work (prior to work) and this can include all of the following entities except:
Answer: D … Ref: Sect. 4.2.2 Welding Inspection – weldment requirements Insp Org!
Exercise 4 (API 577 Welding Inspection – 35 Q&A)
11. Inspectors shall review requirements for the weldments (prior to work) and this can
include all of the following QC items to assess except:
A) Competency of inspection organization to supervise work process
B) Competency of welding organization to perform welding activities per Codes/STDs/Specs
C) Roles/responsibilities of engineers/welding org & inspectors is defined/appropriate for work
D) Independence of inspection organization from production organization is clear/demonstrated
Answer: A … Ref: Sect. 4.2.2.1 Weldment Requirements QC Items to Assess!
12. Inspectors reviewing requirements for the weldments (prior to work) and finding that
Potential Inspector action is required regarding QC items should take action as follows:
A) Make a log entry on the matter and await welding results
B) Document the deficiencies thoroughly and await welding results
C) Highlight deficiencies and concerns with the organizations to appropriate personnel
D) Highlight deficiencies/concerns to the appropriate personnel and demand corrective actions
Answer: C … Ref: Sect. 4.2.2.2 Weldment Requirements Potential Inspector Action!
13. Inspectors shall review welding procedures (WPS) & qualification records (WPQs)
prior to work to assure that:
A) All procedures & qualification records are completed
B) All procedures & qualification records are completed and acceptable for work
C) All procedures & qualification records are completed and signed by the Engineer
D) None of the above are correct
Answer: B … Ref: Sect. 4.2.3 Procedures & Qualification Records!
14. Inspectors reviewing welding procedures & qualification records (prior to work) should
assess all of the following Quality Control items except:
A) Welder performance qualifications (WPQ) meet requirements for the PQR
B) Welder performance qualifications (WPQ) meet requirements for the WPS
C) WPS are properly qualified/meet applicable codes, STDs & specs for work
D) Procedure qualification records (PQR) are properly performed & support WPS
Ans: A … Ref: Sect. 4.2.3.1 Procedures & Qualification Records QC Items to Assess!
15. Inspectors reviewing welding procedures & qualification records (prior to work) and
finding that Potential Inspector action is required regarding QC items should take all of
the following actions EXCEPT:
A) Obtain acceptable WPS(s) and PQR(s) for the work
B) Qualify WPS(s) where required and witness qualification effort
C) Qualify or re-qualify welders as required & witness a percentage of welder qualifications
D) Qualify WPQs where required and any PQRs needed & witness a % of welder qualifications
17. Inspectors reviewing NDE Information (prior to work) should assess all of the following
Quality Control items except:
A) NDE examiners are properly certified for the NDE technique
B) Condition of the equipment is acceptable
C) NDE procedures are current and accurate
D) Calibration of NDE equipment is current
18. Inspectors reviewing NDE Information (prior to work) and finding that Potential
Inspector action is required regarding QC items should take which of these actions?
A) Identify & correct deficiencies in certifications & procedures & obtain calibrated equipment
B) Identify & correct deficiencies in certifications & procedures
C) Identify & correct deficiencies in certifications
D) None of these are correct
19. Inspectors shall check Welding equipment & Instruments prior to work to:
A) Confirm Welding equipment & Instruments operate properly and are in good condition
B) Confirm Welding equipment & Instruments operate properly and are calibrated
C) Confirm Welding equipment & Instruments operate properly
D) Confirm Welding equipment & Instruments are calibrated
20. Inspectors checking welding equipment & instruments prior to work should assess all
of the following Quality Control items except:
A) Welding machine calibration is current
B) Instruments (ammeters, voltmeters, contact pyrometers) have current calibrations
C) Welding cabinets for large quantity storage of hermetically sealed containers exists on job
D) Welding consumable storage ovens operate (automatic heat control, visible temp indication)
Answer: C … Ref: Sect. 4.2.5.1 Welding Equip & Instruments QC Items to Assess!
Exercise 4 (API 577 Welding Inspection – 35 Q&A)
21. Inspectors checking welding equipment & instruments (prior to work) and finding that
Potential Inspector action is required regarding QC items should ensure which of these
actions is taken?
A) Calibrate equipment and instruments and reject any defective equipment and instruments
B) Calibrate equipment and instruments and replace any defective equipment and instruments
C) Recalibrate equipment and instruments and replace any defective equipment and instruments
D) None of these are correct
Answer: C … Ref: Sec. 4.2.5.2 welding equip & instrument Potential inspector action
22. Inspectors shall check Heat Treatment & Pressure Testing procedures/associated
equipment prior to work to in order to:
A) Confirm Heat Treatment & Pressure testing procedures/associated equipment are acceptable
B) Confirm Heat Treatment & Pressure testing associated equipment is acceptable
C) Confirm Heat Treatment & Pressure testing procedures are acceptable
D) None of these are correct
Answer: A … Ref: Sect. 4.2.6 Heat Treatment & Pressure Testing
23. Inspectors checking Heat Treatment & Pressure Testing procedures/associated
equipment prior to work should assess all of the following Quality Control items except:
A) Heat treatment procedure is available & appropriate & equipment calibrations are current
B) Pressure testing equipment & gauges calibrated & meet appropriate test requirements
C) Pressure testing procedures are available and detail the testing requirements
D) Trained personnel to perform activities have been approved for the work
Answer: D … Ref: Sect. 4.2.6.1 Heat Treat & Press Testing QC Items to Assess!
24. Inspectors checking Heat Treatment & Pressure Testing procedures/associated
equipment (prior to work) and finding that Potential Inspector action is required
regarding QC items should ensure which of these actions is taken?
A) Obtain calibrated equipment & identify & correct deficiencies in equipment & procedures
B) Obtain calibrated equipment & identify & correct deficiencies in procedures
C) Obtain calibrated equipment & identify & correct deficiencies in equipment
D) None of these are correct
Answer: B … Ref: Sec. 4.2.6.2 Heat Treat & Press Testing Potential Inspector Action
25. Inspectors shall check all Materials (for welding) prior to work to in order to ensure all
of the following except:
A) Ensure all filler metals, base materials, and backing ring materials are properly identified
B) Ensure all filler metals, base materials, and backing ring materials are properly marked
C) Ensure material traceability is maintained as per mandatory API 578 requirements
D) Ensure PMI is performed (if required) to verify the material composition
29. Welding inspection during welding operations should include audit parameters to
verify welding is performed to procedures and such tasks may include all of these except:
A) Quality Assurance (QA & QC umbrella is established with the welding organization)
B) Unacceptable workmanship (Addressed and such work is quarantined when found)
C) Weldment examinations (include physical checks, visual exams, in-process NDE)
D) Welding parameters and techniques (are supported by WPS and WPQ)
Ans: B … Ref: Sect. 4.3 (all) TASKS DURING WELDING Audit Parameters /3 tasks
30. Final tasks upon completion of the weldment and work should include those that assure
final weld quality before placing the weldment in service & they include all of these except:
A) Document Audit (Perform final audit of Insp dossier to identify inaccuracies/incomplete info)
B) Appearance & finish (Verify post-weld acceptance, appearance & finishing of welded joints)
C) NDE review (Verify NDE is performed at selected locations & review examiner’s findings)
D) Identify non-conformances and defects and take immediate corrective actions
Answer: D … Ref: Sect. 4.4 (all) TASKS UPON COMPLETION OF WELDING …
Correct is Document Audit, Appearance & finish, NDE review, PWHT, Pressure Testing …
Non-conformances and defects should be addressed AT ANY TIME during welding inspection
Exercise 4 (API 577 Welding Inspection – 35 Q&A)
31. Final tasks upon completion of the weldment and work should include those that assure
final weld quality before placing the weldment in service & they include all of these except:
A) Document Audit (Perform final audit of Insp dossier to identify inaccuracies/incomplete info)
B) Appearance & finish (Verify post-weld acceptance, appearance & finishing of welded joints)
C) NDE review (Verify NDE is performed at selected locations & review examiner’s findings)
D) PWHT (Verify PWHT is performed to the procedure and produces acceptable results)
E) Pressure Testing (Verify Pressure Test is performed to the procedure)
F) All are incorrect … Time for smoke break because I never do it right
Answer: F … Ref: Sect. 4.4 (all) TASKS UPON COMPLETION OF WELDING …
32. If defects or non-conformances (Inspector has work issues) to specification are found by
the Inspector, this should be handled when and in what manner (Identify False statement):
A) Inspector takes actions on these issues at any time during the welding inspection
B) Inspector takes actions on these issues after his welding inspections by report issuance
C) Inspector takes steps to ensure correction of the issues before welding proceeds further
D) Inspector brings issues to attention of those responsible before welding proceeds further
Answer: B … Ref: Sect. 4.5 NON-CONFORMANCES AND DEFECTS
33. Which of these statements are false regarding NDE Examiner Certifications?
A) ASME V may require examiners be qualified in accordance with ASNT SNT-TC-1A
B) ASME V may require examiners be qualified in accordance with ANSI/ASNT CP-189
C) ASNT SNT-TC-1A & CP-189 are mandatory whenever ASME V code applies to welding
D) ASNT SNT-TC-1A & CP-189 are guidelines & STDs for certification of NDE insp personnel
Answer: C … Ref: Sect. 4.6 NDE Examiner Certifications
34. Which of these statements are false regarding Safety Precautions for Welding?
A) The arc is a source of both visible and infrared light, but not ultraviolet light.
B) Eye protection using proper filters and proper clothing to cover the skin should be used
C) Proper ventilation is necessary to remove air-borne particulates that include vaporized metal
D) In areas of inadequate ventilation (confined space), filtered breathing protection may be req’d
Answer: A … Ref: Sec. 4.7 Safety Precaution Ultraviolet light may cause severe burn
35. Which of these statements are false regarding Safety Precautions for Welding?
A) Welding can produce sparks and other airborne debris that can burn the eyes
B) Ventilation practices in confined spaces should be carefully reviewed before work begins
C) Appropriate precautions around welding include eye protection/proper clothing to cover skin
D) Use of gas-shielded processes in confined spaces can create a nitrogen-deficient environment
Answer: D … Ref: Sect. 4.7 Safety Precautions
Exercise 5 (API 577 Welding Processes – 15 Q&A)
Tip: There are welding process questions in some exams like this easy example from the
API website From the 10 sample exam questions from the API website
Be ready for similar Qs about GMAW (solid wire) … FCAW (hollow flux-filled core wire),
etc … Know the basics of each welding process
A) SMAW uses arc heat (coming from tip of consumable covered electrode) to melt base metal
B) SMAW shielding is provided from the decomposition of the electrode covering
C) SMAW is the most widely used of the various arc welding processes
D) SMAW uses an arc between a bare electrode and the weld pool.
Ans: D … Ref: Sect. 5.2 SMAW Process SMAW See SAMPLE Q (API WEBSITE)
A) SMAW uses either ac or dc, depending on welding power supply & electrode selected
B) SMAW power supply that is preferred is the CV or constant-voltage power supply
C) SMAW is performed without the application of pressure
D) SMAW is always a manual welding process
Answer: B … Ref: Sect. 5.2 Welding Processes SMAW
4. Depending on the type of SMAW electrode being used, the covering performs all of the
following functions EXCEPT:
A) Establishes the mechanical properties and characteristics of the electrode
B) Provides slag blanket to protect hot weld metal from air & enhances mechanical properties
C) Provides a means of adding alloying elements to change weld metal mechanical properties
D) Provides gas to shield arc/prevent excessive atmospheric contamination of molten filler metal
Ans: A … Sect. 5.2.1 SMAW Electrode Covering establishes electrical characteristics
5. Some commonly accepted advantages of the SMAW process include all of these except:
A) Equipment is relatively simple/inexpensive/portable & can be used in areas of limited access
B) SMAW process is less sensitive to wind and draft than other welding processes
C) SMAW process is suitable for most of the commonly used metals and alloys
D) SMAW process allows for excellent control of root pass penetration
Ans: D … Sect. 5.2.2 Welding Processes Advantages of SMAW … D is an advantage
of the GTAW Process … Watch out for questions like this on the real API 577 exam!
Exercise 5 (API 577 Welding Processes – 15 Q&A)
6. Limitations associated with the SMAW process include all of the following EXCEPT:
A) Slag must be removed before depositing a weld bead adjacent to a previously deposited bead
B) Slag must be removed before depositing a weld bead onto a previously deposited weld bead
C) Deposition rates are lower than for all other processes (GTAW, GMAW, FCAW, SAW)
D) Slag must be removed at stops and starts
Answer: C … Sec. 5.2.3 Welding Processes SMAW Limitations … such as GMAW is
correct … not accepted over GTAW Process … Watch out for questions like this on exam!
A) GTAW DCEN welding offers advantages of deeper penetration and faster welding speeds
B) GTAW uses an arc between a consumable tungsten electrode and the weld pool
C) GTAW is used with a shielding gas & without the application of pressure
D) GTAW can be used with or without the addition of filler metal
Answer: B … Ref: Sect. 5.3 Welding Processes GTAW Non-consumable tungsten
8. Some commonly accepted advantages of the GTAW process include all of these except:
9. Limitations associated with the GTAW process include all of the following EXCEPT:
A) The welding equipment is more complex, more costly, and less portable than that for SMAW
B) Deposition rates = lower than rates possible with consumable electrode arc welding processes
C) GTAW has a low tolerance for contaminants on filler or base metals
D) Difficult to shield the weld zone properly in drafty environments
Answer: A … Sec. 5.3.2 Processes Limitations of GTAW A = GMAW limitation
A) GMAW uses shielding from externally supplied gas and without the application of pressure
B) GMAW uses an arc between continuous filler metal electrode and the weld pool
C) GMAW uses CC power supply & either short circuiting/globular/spray method
D) GMAW may be operated in semiautomatic, machine, or automatic modes only
Answer: C … Ref: Sect. 5.4 Welding Processes GMAW C = CV power supply used
Exercise 5 (API 577 Welding Processes – 15 Q&A)
11. Which of these statements regarding GMAW-S (Short-circuiting transfer) is not true?
A) It creates fast freezing weld pool best suited for joining thin sections/out-of position/root pass
B) It covers lowest range of welding currents/electrode diameters associated GMAW processes
C) Due to fast-freezing nature of this process, the potential for lack of sidewall fusion exists
D) It results in a highly directed stream of discrete drops accelerated by arc forces
12. Some commonly accepted advantages of the GMAW process include all of these except:
13. Limitations associated with the GMAW process include all of the following EXCEPT:
A) GMAW has a low tolerance for contaminants on filler metals or base metals
B) The welding arc should be protected from air drafts that will disperse the shielding gas
C) When using the GMAW-S process, the weld is more susceptible to lack of adequate fusion
D) The welding equipment is more complex, more costly, and less portable than that for SMAW
14. Some commonly accepted advantages of the FCAW process include all of these except:
A) Shielding is produced at the weld surface (more tolerant of stronger air currents than GMAW)
B) Only consumable electrode process that can be used to weld most commercial metals/alloys
C) Slag that supports and shapes the weld bead and flux that provides metallurgical benefits
D) High deposition and productivity rates than other processes such as SMAW
15. Limitations associated with the FCAW process include all of the following EXCEPT:
A) The welding equipment is more complex, more costly, and less portable than that for SMAW
B) Self-shielding FCAW generates large volumes of welding fumes/requires exhaust equipment
C) Backing material is required for root pass welding & slag requires removal between passes
D) FCAW process is limited to shop applications and the flat and horizontal positions
Answer: A … Ref: Sect. 6.1 Procedures General A = Test data (given in the PQR)
2. As a minimum, welding procedures qualified to ASME Sect IX are required by all of the
following examples where Codes are employed except:
A) Construction codes used in fabrication of new equipment & piping (refinery, chemical plant)
B) Construction codes used in fabrication of new equipment & piping (water treatment plants)
C) API 510 inspection code (repair welding)
D) API 570 inspection code (repair welding)
Answer: D … Ref: Sect. 6.1 Procedures General D = WPS is this … Not the PQR!
9. Essential variables affect mechanical properties of the weld. If they are changed beyond
what the reference code paragraph allows for the process, the WPS:
10. When nonessential variables are changed on the WPS, what must be done?
12. The PQR shall record all of the following items except:
13. Which of these statements are false regarding Mechanical Tests associated with a PQR?
A) Mechanical tests are required to qualify a WPS to demonstrate the properties of the weldment
B) Guided bend tests determine the degree of soundness and ductility of a groove weld
C) Notch toughness tests determine both the strength and toughness of a groove weld
D) Tension tests determine the ultimate strength of a groove weld
Ans: D … Sect. 6.3 Procedures PQRs 1 WPS may be qualified by more than one PQR
15. Which of these statements is false regarding review of a WPS & PQR per API 577?
A) Inspectors shall review the WPS & PQR to verify they are acceptable for welding to be done
B) Initial step verifies WPS completion & Section IX/construction/repair code issues addressed
C) 2nd step verifies PQR completion & Section IX/construction/repair code issues addressed
D) 3rd step confirms WPS essential variable values properly support range specified in PQR
Answer: D … Ref: Sec. 6.4 Reviewing WPS & PQR … 3rd Step reversed … PQR WPS
Exercise 7 (API 577 Welding Materials – 10 Q&A)
1. Base metals are assigned P-numbers in ASME Section IX to:
2. For ferrous base metals having specified impact test requirements, what types of
numbers are assigned by ASME IX Code?
3. P-Number assignments are based on all of the following comparable base metal
characteristics except:
A) Composition B) Weldability
C) Mechanical properties D) Welding Process types
8. Steel & Steel alloy filler metals are grouped in ASME IX according to A-numbers to:
9. 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
10. Which of these statements are false regarding consumable storage and handling?
A) Covered electrodes exposed to moisture become unstable due to moisture pickup by coatings
B) Moisture is a hydrogen source & open consumables should be stored in warm holding ovens
C) Low-hydrogen electrodes should be stored together with other types of electrodes in ovens
D) Low-hydrogen & stainless steel electrodes are particularly susceptible to moisture pickup
A) 3-month period
B) Six-month period
C) Nine-month period
D) Twelve-month period
10. Prior to any welding, inspectors should review the welders’ WPQ to:
A) Verify they are qualified to perform welding given its position & process
B) Verify they are qualified to perform welding given its position, thickness and process
C) Verify they are qualified to perform welding given its position, diameter and thickness
D) Verify they are qualified to perform welding given its position/diam./thickness/process
2. Undercut (Per API 577, Table 6) can be corrected by (Practical Solution Column):
3. Incomplete penetration (Per API 577, Table 6) can be corrected by (Practical Sol. Col):
4. During welding inspection, the inspector may need to verify the conformance of the base
material and filler metal chemistries with the selected or specified alloyed materials. This
may include reviewing all of the following EXCEPT:
9. In the illustration above, what is the name of the gauge being used?
A) Bridge Cam Gauge (GAL) B) Fillet Weld Gauge
C) Weld Size Gauge D) None of these is correct
Answer: B … Ref: Sect. 9.3.2.3.C & Fig 17/18 NDE VT Weld exam Devices
10. In the illustration above, what is the actual throat measurement (throat size)?
A) 12.7 mm B) 12.7 mm x .707 = 9 mm
C) Cannot be determined by the above D) None of these is correct
Answer: B … Ref: Sect. 9.3.2.3.C & Fig 17/18 NDE VT Weld exam Devices
Exercise 9 (API 577 NDE – 50 Q&A)
11. 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
D) None of these are correct
Answer: B … Ref: Sect. 9.4.1 NDE MT General
12. Which of the following statements is false regarding proper MT practice?
A) Particles used during the exam can be either dry or wet
B) Best results are achieved when the lines of flux are perpendicular to the discontinuity
C) If exam is performed with black light, color of particles should contrast with exam surface
D) Two inspections are performed, one parallel to weld & one across (perpendicular to the weld)
Answer: C … Ref: Sec. 9.4.1 NDE MT General If performed in normal lighting
FIGURE 25 FIGURE 26
13. Figure 25 above (left) will detect which of these following discontinuities listed below?
A) Discontinuities transverse to the weld and located on the surface or slightly sub-surface only
B) Discontinuities parallel to the weld and located on the surface or slightly sub-surface only
C) Discontinuities transverse to the weld and located on the surface only
D) Discontinuities parallel to the weld and located on the surface only
Answer: A … Ref: Sec. 9.4.1 & Fig. 25 NDE MT General
14. Figure 26 above (right) will detect which of these following discontinuities listed below?
A) Discontinuities transverse to the weld and located on the surface or slightly sub-surface only
B) Discontinuities parallel to the weld and located on the surface or slightly sub-surface only
C) Discontinuities transverse to the weld and located on the surface only
D) Discontinuities parallel to the weld and located on the surface only
Answer: B … Ref: Sec. 9.4.1 & Fig. 25 NDE MT General
Exercise 9 (API 577 NDE – 50 Q&A)
FIGURE 21 FIGURE 22
15. Which of the statements below is FALSE regarding Figure 21 above (left)?
A) Ferromagnetic particles applied to magnetized surface are attracted to magnetic field breaks
B) Figure 21 shows the disruption to the magnetic field caused by a defect open to the surface
C) Ferromagnetic particles will be drawn to the break in the flux field shown in Figure 21
D) Pattern of particles attracted in Fig. 21 will be less sharp & less distinct than Fig. 22
Answer: D … Ref: Sec. 9.4.1 & Fig. 21 NDE MT General
16. Which of the statements below is FALSE regarding Figure 22 above (right)?
A) Ferromagnetic particles applied to magnetized surface are attracted to magnetic field breaks
B) Ferromagnetic particles will be drawn to the break in the flux field shown in Figure 22
C) Pattern of particles attracted in Fig. 22 will be more sharp and distinct than Fig. 21
D) Figure 22 shows disruption to a magnetic field caused by a sub-surface defect
Answer: C … Ref: Sec. 9.4.1 & Fig. 21 NDE MT General
17. Which of the following statements are false regarding ACFM technique?
A) It can work in a range of different materials and through coatings of varying thickness
B) This technique is ideal for inspecting complex geometries such as nozzles & ring-grooves
C) It is electromagnetic non-contacting and is able to detect and size surface breaking defects
D) It requires extensive surface preparation & can be used at elevated temps up to 600°F (315°C)
Answer: D … Ref: Sect. 9.5 NDE ACFM
A) 125°F (52°C)
B) 120°F (49°C)
C) 150°F (65°C)
D) None of these are correct, because the limit can be exceeded
Answer: A … Ref: Sect. 9.6 NDE PT
20. Which of these statements are NOT true regarding techniques used in PT exam?
A) No indication of depth is possible because PT = Surface Exam Method (not volumetric exam)
B) Observes and then compares the indication bleed out to the opening size visible at the surface
C) Observes indication opening size visible at the surface and then estimates approximate depth
D) Observes the indication bleed out at the surface and then estimates the approximate depth
Answer: D … Ref: Sect. 9.6 NDE PT Shallow tight indications = light bleed out
22. General penetrant TECHNIQUES approved for use include which of the following?
23. General penetrant SYSTEMS approved for use include which of the following?
25. Which of these statements are NOT true regarding Eddy Current inspection?
A) Its magnetic fields & material discontinuities alter induced fields/show them on unit’s display
B) As with MT, ET is most sensitive (finds the defect) if a current is parallel to the discontinuity
C) It can measure thickness of protective, nonconductive surface coatings & cladding thickness
D) It detects surface & subsurface discontinuities (tubing, pipe) & is limited in weld inspection
26. Which of these statements are NOT true regarding Radiographic Testing (RT) method?
A) It uses the change in absorption of radiation by solid metal and in areas of a discontinuity
B) It is a volumetric exam method capable of examining entire specimen, not just the surface
C) Radiation sent reacts with film & permanent image is captured & processed into latent image
D) Some methods are available that use electronics to create a digital image & are called filmless
Answer: C … Ref: Sect. 9.8.1 NDE RT General … Latent image is first captured
then it is processed into a permanent image
27. Which of these statements are NOT true regarding Radiographic Testing (RT) methods
and examiners?
A) RT indications display a different density in contrast to a normal background image of a weld
B) NDT examiner interprets/evaluates the film for differences in absorption/transmission results
C) Radiographers ensure film is exposed by primary radiation source (not backscatter radiation)
D) Film examiners (interpret/evaluate/report) should be certified ASNT Level I as a minimum
28. The exposure and processing of a radiograph is considered acceptable when it meets the
required quality features in terms of:
A) Density
B) Sensitivity
C) Sensitivity and density
D) Sensitivity, density and film quality
Answer: B … Ref: Sect. 9.8.2 NDE RT IQI … Penetrameter no longer being used
Answer: A … Ref: Sect. 9.8.2 NDE RT … The “essential” wire must always be visible
… Figure 29
32. Diameter of holes in hole-type IQIs are a multiple of the thickness of a sheet. Common
hole diameters are HOW MANY times the thickness of the IQI shown in Fig. 29?
A) 2% and 4% holes in sheet metal strip having an actual thickness of 15 mm
B) 1%, 2% & 4% holes in sheet metal strip having an actual thickness of 15 mm
C) 2% and 4% holes in sheet metal strip having an actual thickness of 15 mils (.015 inches)
D) 1%, 2% & 4% holes in sheet metal strip having an actual thickness of 15 mils (.015 inches)
Answer: D … Ref: Sect. 9.8.2 NDE RT IQIs Projected as dark or gray spots
Exercise 9 (API 577 NDE – 50 Q&A)
33. IQIs (penetrameters) are selected based on which of the following values:
34. Which of the following statements are NOT true regarding IQIs & their placement?
A) Wire-type IQIs are most often placed perpendicular to weld center line
B) Hole-type IQIs are placed next to weld always on a shim where T = the weld build-up
C) Hole that is required to be visible on an acceptable radiograph is called the essential hole
D) Hole-type IQIs are placed next to weld on a base metal or on a shim (with T = weld build-up)
35. Which of the following statements are NOT true regarding RT film?
A) Film must be long & wide enough to cover 25 mm on consecutive circumferential exposures
B) Film must be long & wide enough to cover 19 mm coverage on either side of the weld
C) Film should be stored in a cool, dry, clean area away from the exposure area
D) Radiographic film Class I or II or III film are acceptable for use
36. Which of the following statements is TRUE regarding RT film source selection?
A) X-ray machines must also be used in addition to sources with decaying radioisotopes
B) For weld inspection, radioactive isotopes of Iridium 192 or Cobalt 60 are typically used
C) Iridium 192 is normally used for RT on steel (thickness = 1.5 – 7.0 in. or 38 mm – 178 mm)
D) Cobalt 60 is normally used for RT on steel (thickness = 0.25 – 3.0 in. or 6.3 mm – 76.2 mm)
37. Which of the following statements is NOT TRUE regarding RT film processing?
Answer: A … Ref: Sect. 9.8.5 NDE RT Film Processing … Five to eight minutes
Exercise 9 (API 577 NDE – 50 Q&A)
38. Which of the following statements is TRUE regarding RT surface preparation?
A) Surface conditions (visual) that can mask a defect should be remedied after the exposure
B) Weld ripples shall be removed so that RT images are not confused with any discontinuities
C) Weld ripples should be removed so that RT images are not confused with any discontinuities
D) Weld ripples should be removed to an extent so RT images are not confused with any defects
39. Which of the following statements is False regarding RT film identification (ID) on all
radiographs?
A) ID information should be plainly & permanently produced
B) Location markers will also appear on the film identifying the area of coverage
C) ID information shall be traceable to contract/manufacturer/date/component/weld or part #s
D) ID information will not obscure any area of interest (to prevent to proper film identification)
&
Figure 31 Figure 32
40. Which of these statements is FALSE regarding the most effective RT Technique that
can be used?
A) Most effective technique = double-wall exposure (film contacts surface opposite source)
B) Most effective technique = single-wall exposure (film contacts surface opposite source)
C) Most effective technique = double-wall exposure (film contacts surface nearest source)
D) Most effective technique = single-wall exposure (film contacts surface nearest source)
Answer: B … Ref: Sect. 9.8.8 NDE RT Techniques Single wall exposure (Fig 31)
Exercise 9 (API 577 NDE – 50 Q&A)
41. Which of these statements is FALSE regarding RT Techniques to be used?
A) Radiography is not sensitive to the orientation of tight planar discontinuities
B) Technique should be chosen based on ability to produce images of suspected discontinuities
C) Nature, location, and orientation should always be a major factor in establishing a technique
D) Tight planar discontinuity at an angle to a radiation source may be difficult/impossible to see
Answer: B … Ref: Sect. 9.8.8.1 NDE RT Techniques Single wall exposure (Fig 31)
43. When the single wall viewing technique is used (radiation passes through two walls) and
only the weld (material) on the film sidewall is viewed for acceptance, what is the minimum
number of exposures that should be taken (assume RT for circumferential welds)?
A) Minimum of one exposure is possible using the panoramic technique
B) Minimum of two exposures is possible using the superimposed technique
C) Minimum of four exposures taken at 90° to each other should be made as a general rule
D) Minimum of three exposures taken at 120° to each other should be made as a general rule
Ans: B … Ref: Sect. 9.8.8.3 NDE Double wall techniques 3.5 inch NPS & Less Rule
WARNING
INCOMPLETE = EXERCISE 9 & 10 &
APPENDIXES
See HIGHLIGHTED API 577
BE SURE TO STUDY HIGHLIGHTED AREAS &
APPENDIXES IN THE BACK OF API 577
FOR CHAPTERS 10 & 11 & APPENDIXES
WATCH OUT FOR TABLE IN END OF
SECTION 9 HAVING DEFINITIONS
More 577 Questions will be added in 2013
SEE STUDY GUIDE PART II (WELDING)
STUDY PRACTICE EXAM Qs IN THERE
End API 577 Q&A
EXTRA Q’S
1. Which of the following is an example of a limited or routine repairs per API 510 code?