API 510 Pressure Vessel Inspector Preparatory Program

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API 510 OB 24112010 R0 mockup no. 3

1. Equipments used for reviewing radiographs for interpretation shall provide

a variable light source sufficient for

1. Identifying defects in components

2. The essential IQI hole or designated wire to be visible for the
specified density range
3. Identify artifacts
4. Density 2 & 4

2. What is the maximum geometric un-sharpness allowed for a 3” thickness

weld of A 106 grade B material?

1. 1.02 mm
2. 0.51 mm
3. 0.76 mm
4. 1.78 mm

3. For retest of the welder’s qualification the Radiographically examined to

pieces of total ……………..” of weld which shall include the entire weld circum
furnace

1. 3“
2. 6”
3. 12”
4. 10”

4. A106 grade B pipe was welded for a PQR test and the tensile strength is
found to be as given below
a) T1 UTS 58000 psi failure in base metal
b) T2 UTS 59000 psi failure in weld metal

Comment on acceptability of the test:

1. T1 OK , T2 not OK
2. T2 OK , T1 not OK
3. T1, T2 both OK
4. T1, T2 both not OK

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5. SA 516 grade 70 material 6 mm thickness was used for welder’s
qualification. The bend test results are given below:
a) Root bend 1 (RB1) no crack
b) Face bend 1 (FB1) crack 2.5 mm length

Comment on acceptability of the test:

1. Both test specimens OK

2. RB1 OK FB1 not ok
3. Both test specimens not OK
4. 2 side bends required

6. Which is not the essential variable for procedure qualification of A 106

grade B 4” Sch 40 pipes welded by SMAW?

1. Root spacing
2. F no.
3. A no.
4. Decrease in pre heat by 150 o F

7. Lifting power of AC yoke shall be minimum

1. 4.5 kg
2. 18.1 kg
3. 45 kg
4. 10 kg

8. The near vision requirement and light requirement for the visual inspection as
per ASME section V is:

1. Jaeger J1 and 100 Lux

2. Jaeger J2 and 1000 Lux
3. Jaeger J1 and 1000 Lux
4. Jaeger J2 and 100 Lux

9. Which joint, out of following, is excluded from joint efficiency design

calculation?

1. butt joints those are double welded

2. fillet weld joints
3. welds with backing strip which remain in place during service.
4. butt joints those are single V welded

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10. Which of the following situation allows on-stream inspection to substitute to
internal inspection?

1. the general corrosion rate of the vessel is known to be less than

0.125 mm per year and the vessel remaining life is greater than 10
years
2. The corrosive character of the contents, including the effect of
trace components, has been established by at least five years of
the same or similar services.
3. No questionable condition is discovered during the external
inspection
4. All of the above.

11. A dark image of the letter “B” is( lead letter B kept for back scatter
detection seen on the radiograph)

1. acceptable
2. rejectable
3. must be there on all films.
4. not applicable in RT

12 Light intensity requirement of florescent type of penetrant test is:

1. =1000 µw/cm2
2. =1000 lux
3 ≥ 1000 µw/cm2
4 ≥1000 lux

13 A vessel of P NO 3 Gr 1 material is having thickness of 12 mm of shell

and 14 mm that of dished head. What PWHT is required for the weld
joints?

1 holding temp. minimum 5950C, holding time 35 min minimum.

2 only localized PWHT is allowed.
3 PWHT is not mandatory.
4 needs more data

14. Under what conditions welding is to be avoided?

1 the temperature is less than 0 0F

2 in house welding protected from Atmospheric disturbance viz.
windy climate, snowfall
3 the temp above 200C
4 the temp above 150C

15 Which of the following is excluded from category A weld joints?

1. circumferential weld joints connecting hemispherical dished head

to main shell
2. circumferential weld joints connecting other than hemispherical
dished head to main shell
3. spiral joint within main shell

API 510 OB 24112010 R0 mockup no. 3 3

 4. weld joint of sphere.

16 A vessel is designed to 200 psi pressure is to be hydrostatically

tested in line with ASME Section VIII Div 1 requirements. ( 2001Edn)
The material exhibits stress levels of 12,000 and 17,500 psi at design
and ambient test pressures respectively. What hydrostatic test
pressure is to be applied to the equipment?

1. 260 psi
2. 220 psi
3. 379 psi
4. 320 psi

17 If the same vessel is to be pneumatically tested, at what pressure the

vessel has to be visually inspected?
1. 260 psi
2. 220 psi
3. 379 psi
4. 292psi

18. What size out of following reinforcement is maximum allowed in long

seam welds if material is having 12 mm thickness for a new pressure
vessel?

1. 1.0 mm
2. 2.0 mm
3. 2.4 mm
4. 3.1 mm

19. A vessel is designed to material SA 516 Gr 70 material normalized.

Thickness of shell joint is 40 mm. joint efficiency is 1.0. What extent of RT
is required to be done?

1. spot radiography
2. full radiography
3. no radiography
4. UT can be done in place of RT which is full UT

20 What is the area of nozzle opening needs to be compensated if:

d=150 mm, t=16 mm, tn= 6.35 mm, tr =14.5 mm, trn= 0.5 mm

1. 2175 sq mm
2. 3840 sq mm
3. 225 sq mm
4. 75 sq mm

21 If shell thickness of a vessel is 20 mm, what thickness is

approximately required for forming a dished head of which is of
ellipsoidal type?

1 53.4 mm
2 20 mm
3 10 mm
4 40 mm

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22 What is A Number?

1 grouping of electrodes which show

equivalency in welding characteristics.
2 Grouping of deposited weld metal analysis
3 Grouping of parent metal for welding
4 Grouping of position qualified.

23 Name the weld discontinuity which can occur at weld toe or at root
surface.

1 under fill
2 LOP
3 Excessive reinforcement
4 Overlap

24 Which mode of metal transfer of GMAW results in negligible spatter?

1 Spray transfer
2 pulsating
3 globular
4 short circuiting

25 Which of the following is not a cause of preheating?

1 reduce shrinkage stress in the weld and in the base

metal.
2 Reduce the cooling rate in order to prevent hardening and a
reduction in ductility of the weld and base metal HAZ
3 Maintain weld inter pass temperature
4 Produces increased tensile strength effect

26 During MT (Magnetic Particle Testing), if prod spacing during testing is 4

in. and job thickness is 25 mm, what shall be the current used to develop
sufficient field strength?

1 100 - 125 amperes

2 90 - 110 amperes
3 360 - 440 amperes
4 400 - 500 amperes

27 Magnetizing equipment with ammeter shall be calibrated at what intervals?

1 every three months

2 every six months
3 every year
4 only when the ammeter is break down

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28. In equipment of 12 mm thickness is operating at 5150C and its thickness
reading is to be checked from outside. If a thickness gauge meter has its
probe which is calibrated at 200C. The reading shown by the meter is
10.5 mm. What is actual thickness of the vessel?

1 9.555 mm
2 11.445 mm
3 10.5 mm
4 12.00 mm

29 What is P No. / Group no of SA 106 Gr C material?

1 P No 1 , Group No 1
2 P No 1, Group No 2
3 P No 2, Group No 1
4 P No 2, Group No 2

30 A CS test coupon is welded from a material having UTS= 510 MPa and
elongation = 25%. What shall be bend diameter for bend test to qualify
the PQR? (t= thickness of welded coupon)

1 10t
2 4t
3 8t
4 2t

31 If a test plate coupon is welded by a welder in 3G position for WPQ

test, what position(s), is/are qualified to the welder?

1 3G only
2 1G, 3G
3 1G, 3G, 1F, 3F
4 1G, 3G, 1F, 2F, 3F

32 What is F number of E 7018 electrode? (SFA No: 5.1)

1 1
2 2
3 3
4 4

33 During PQR witnessing an inspector observed UTS values as 405 and

450 Mpa with both failures in base metal and 4 bend test pieces were
with no discontinuity. The parent material UTS value is 410 MPa min.
What should be his disposition?

1 acceptable
2 not acceptable
3 fire to the lab technician, welding supervisor and welder.
4 get designer’s concurrence.

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34 You have a new vessel that has just been installed. It is completely new
and no information exists to establish a corrosion rate. Also, information is
no available on a similar system. You decide to put the system in service
and NDT it later to determine the corrosion rate. How long do you allow
the system to stay in service before you take your first thickness readings
?

1. 500hours
2. 3 months
3. 1000hours
4. 12 months

35 Risk based inspections include which of the following :-

1. Likelihood of failure assessment

2. Consequence analysis
3. Evaluation of inspection frequencies based on RBI
4. All of the above

36 Erosion can be defined as :-

1. Galvanic corrosion of a material where uniform losses occur

2. Removal of surface material by action of numerous impacts of
solid or liquid particles
3. Gradual loss of material by a corrosive medium acting uniformly
on the material surface
4. Pitting on the surface of a material to the extent that a rough
uniform loss occurs

37 vessel fabricated of or having components of 300 series stainless steel

should be tested with __________

1. water with a pH of 4
2. water with a pH of 6
3. water with a chloride content of less than 50 ppm chlorides
4. Sea water

38. A standard seamless (E=1) torispherical head (1 inch nom. thk) is to be used
for construction of new pressure vessel with 72 inch ID, and design
pressure = 300 psig. Material of construction has allowable stress of
20,000 psig. Which of the following statements is most appropriate?
(Corrosion allowance is nil.)

1. Conforms ASME Sec. VIII Div. 1

2. Does not conform ASME Sec. VIII, Div. 1
3. Depends on opinion of Vessel engineer
4. Torispherical head is not permitted for use by code

API 510 OB 24112010 R0 mockup no. 3 7

39 A seamless (E=1) 2:1 Ellipsoidal head 60 inch ID, 400 psi design pressure,
(corrosion allowance = 0) and (S = 20000 psig) when new, was provided
thickness of 5/8”. Your assessment is:

1. Head was designed correctly as per ASME Sec. VIII, Div. 1

2. Head was not designed correctly. Thickness is inadequate.
3. Depends on the opinion of third party inspector
4. None of the above

40 General mill under tolerance for the plate is:

1. 0.01” or 6% (whichever is greater)

2. 0.1” or 6% (whichever is smaller)
3. Under tolerance for the plates is always zero
4. 0.01” or 6% (whichever is smaller)

The data given below has to be used for the questions 41,42 and 43
A vessel was built in 1994 . The original thickness provided was 25mm.
The required thickness was 21 mm
The thickness recorded in the first shutdown in 2002 was 24.2 mm and the
thickness recorded in the second shutdown which was carried out in 2010
was found to be 23 mm.

41 What is the long term corrosion rate for this vessel?

1. 0.125 mm
2. 0.15 mm
3. 0.1 mm
4. 0.2 mm

42 On the basis of the data given above What is the remaining life of the vessel
if the short term corrosion rate is to be considered for calculations?

1. 6.16 years
2. 13.3 years
3. 26 years
4. 5 years

43 On the basis of the data given above and considering the short term
corrosion rate what will be the next inspection interval for the internal inspection?

1. 6.65 years
2. 13 years
3. 3.08 years
4. 2.5 years

44. When insert patch is given ( flush patch) what NDE is required to be done?

1. Eddy current testing

2. Radiography as per applicable construction code
3. Penetrant testing only
4. Visual testing only

API 510 OB 24112010 R0 mockup no. 3 8

45 The inside diameter of the vessel was 50 inches. The actual wall
thickness is 1.0 inch. What shall be the minimum distance between the
adjacent fillet weld patches used for the repairs?
1. 20 inches
2. 10 inches
3. 28.28 inches
4. 50 inches

46. The pressure vessel rerating is considered complete when

1 The inspector witnesses the attachment of an additional

nameplate or additional stamping that carries required
information
2 The hydro test is complete
3 When the RT is complete
4 When the painting is complete.

47 If the remaining life of the vessel is calculated as 3.85 years what shall be the
next inspection interval for internal or on- stream inspection?

1. 3 years
2. 2 years
3. 2.5 years
4. none of the above

48 Generally a major reason for spring failure of the Pressure Relieving Devise
is …….

1. Tensile load
2. improper handling
3. Corrosion
4. Creep

49 What is the tolerance for the pop up pressure for a pressure-relieving device
having a set pressure of 350 psi?

1. plus or minus 3 %
2. plus or minus 2 %
3. Plus or minus 2 psi
4. Plus or minus 3 psi

50 What type of damage is expected in older calcium silicate insulation for

300 series SS?

1. Fatigue crack
2. Creep crack
3. Graphitization
4. Chloride stress corrosion cracking

51 At what places fatigue cracks usually initiate?

1. Internal surface
2. On the surface at notches
3. Openings
4. None of the above

API 510 OB 24112010 R0 mockup no. 3 9

52 PT or phase analysis EC techniques are preferred methods to detect

1. Brittle failure
2. Thermal fatigue
3. Erosion / erosion corrosion
4. Environment –assisted cracking

53 Carbon Steel pipes in Caustic service are given Stress Relieving Heat
Treatment ( PWHT) These pipes need to be checked for …and the NDE
technique which can be used is ………..

1. Cracks ….PT
2. Cracks… LEAK TESTING
3. Cracks …WFMT
4. Cracks Visual testing

You are given the WPS and PQR documents as listed below:

WPS No: AE/WPS/01Rev.0

PQR No: AE/PQR/01

Important Note:
Questions 54, 55 and 56 are to be solved on the basis of the WPS and
PQR attached at the end of this paper.
(Note that the data relevant to the questions is only filled in these
documents)

54. What you will comment on the bend test carried out by the PQR?

1. The bend test is not acceptable as the number of bends are not correct
2. The Bend test is not acceptable as the type of bend tests is not adequate.
3. The bend test is acceptable.
4. Bend test is not acceptable as the crack observed is more than 1.6 mm (
1/16 inch)

55 What is your decision on the acceptability of the tensile specimen?

1. The tensile specimen no. 1 is acceptable and no. 2 rejected.

2. Tensile specimen 1 is not ok 2 is ok.
3. Both tensile Tests pass the requirements.
4. Both Tensile test specimen are rejected

API 510 OB 24112010 R0 mockup no. 3 10

56. Comment on the acceptability of the range of base metal thickness
qualified by this PQR mentioned on WPS.

1. The upper limit is ok but the lower limit is not correct, it should be 1/16 inch
(1.5 mm)
2. The lower limit is ok but the upper limit is not ok, it should be 12 mm
3. The upper and lower limits are not ok and they shall be 1.5 mm to 12 mm.
4. The thickness limit specified by the WPS is OK

API 510 OB 24112010 R0 mockup no. 3 11

 API 510 Pressure Vessel Inspector Preparatory Program

* Open Book - *

API 510 OB 24112010 R0 mockup no. 3

MASTER

Q A Ref. Clause Page

1 2 ASME Sec V T 234 9
2 3 ASME Sec V T 774 10
3 3 ASME Sec IX QW 321.3 55
4 1 ASME Sec IX QW153.1d & 4 & 74
QW 422
5 1 ASME Sec IX QW 163 6
6 1 ASME Sec IX QW 253 21
7 1 ASME Sec V T 762 126
8 3 ASME Sec V T 923 & T 952 154 &
155
9 2 ASME Sec VIII UW 12 table 111/11
D1 2
10 4 API 510 6.5.2.1 6-2
11 1 ASME Sec V T 284 15
12 3 ASME Sec V T576.4 (c) 117
13 3 ASME Sec VIII UCS 56 162
D1
14 1 ASME Sect VIII Uw30 135
D1
15 2 ASME Sect VIII UW3 106/10
D1 7
16 3 ASME SECT UG99(b)/5.8.2. 74/5-9
VIII D1 /API 510 1
17 4 ASME SECT Ug100(b) 75
VIII D1
18 3 ASME SECT UW35 TABLE 136
VIII D1
19 2 ASME Sec VIII UCS 57 169
D1 TABLE
20 1 ASME Sec VIII Fig UG 37.1 42
D1
21 2 ASME Sec VIII UG 27,UG32 19,29
D1
22 2 API 577 clause 7.5 19
23 4 API 577 Table 2 22
24 1 API 577 5.4.3 11
25 4 API 577 10.5 & 10.6) 61
26 4 ASME Sec V article 7 - 123/12
T752.2 4
27 3 ASME Sec V article 7 -T 126
761.1

API 510 OB 24112010 R0 mockup no. 3 12

 API 510 Pressure Vessel Inspector Preparatory Program

* Open Book - *

API 510 OB 24112010 R0 mockup no. 3

MASTER

28 1 ASME Sec V article 23 SE 418

797 - 8.5)
29 2 ASME sec IX QW 422 74
30 2 ASME sec IX QW 466.1 182
31 4 ASME sec IX QW 461.9 151
32 4 ASME sec IX QW 432 129
33 1 ASME sec IX QW 153.1d 4
34 3 API 510 7.1.2 d 7-1
35 4 API 510 3,57 3-3
36 2 API 572 9.4.4.3 38
37 3 API 510 5.8.4.2 5-10
38 1 ASME Sec VIII UG 32 e 29
D1
39 1 ASME Sec VIII UG 32 d 29
D1
40 4 ASME Sec VIII UG 16 c 14
D1
41 1 API 510 7.1.1.1 7-1
42 2 API 510 7.1.1.1and 7-1
7.2.1
43 1 API 510 7.2.1 and 7-1 and
6.5.1.1 6.2
44 2 API 510 8.1.5.2.2 8-3
45 1 API 510 8.1.5.1.2.3 8-2
46 1 API 510 8.2.2 8.8
47 2 API 510 6.5.1.1 6-2
48 3 API576 5.3.2 27
49 1 API576 6.2.15.2 43
50 4 API 571 4.3.3.6.c 4-72
51 2 API571 4.2.16.3 4-53
52 2 API 571 4.2.16.3 4-53
53 3 API 571 4.5.3.7.(a) 4-139
54 3 ASME IX QW 451.1 139
55 3 ASME IX QW1 Art 1
56 3 ASME IX QW 451.1 139

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