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510 IRS Pune Open Book Questions Final
510 IRS Pune Open Book Questions Final
1.
A PQR was qualified in 5G position using a new welder. But production welding is to be done by the same
welder in 2G position. Which of the following are applicable as a minimum.
A.
B.
C.
D.
2.
A procedure is required with preheat temp = 250F. Two WPS were made based on this PQR. All other
parameters being same WPS (A) showed preheat temp = 280F and WPS (B) showed preheat temp = 145F,
will you,
A.
B.
C.
D.
3.
In a certain PQR for SMAW, the electrodes used for all passes were of AWS classification (E 7018).
Corresponding WPS also showed filler materials as E 7018. Now the manufacturer proposes to change the
filler material in WPS to E 7015. Will you ask manufacturer to:
A.
B.
C.
D.
4.
A PQR in GTAW process was qualified with PWHT with A 516 grade 70 materials, inch thick. The
thickness for production welds is 1.0 inch, but without PWHT. Manufacturer claims that same PQR will be O.K.
What is your assessment?
A.
B.
C.
D.
5.
It
It
It
It
For 515 gr 60 material, following results were obtained for two tensile test specimen in PQR qualification.
Your assessment is
A.
B.
C.
D.
6.
PQR
PQR
PQR
PQR
A procedure is qualified with Base metal thickness = 20mm. Two WPS were made based on this PQR. Other
parameters being same, WPS (A) showed Base metal thickness = 38 mm and WPS (B) showed B. M. thickness is
6mm. What will you do?
A.
B.
C.
D.
7.
Calculate estimated inspection period for external and internal inspection for a vessel whose remaining
life is estimated as 12 years.
A.
B.
C.
D.
8.
A 2.0 inch thick vessel data-sheet shows MDMT= 50 deg. F. The minimum pressure-test temperature for Hydro
test to be carried out after alteration shall be:
A.
70 deg F
Page 1 of 6
B.
C.
D.
9.
For vessel 1.0 inch thick, MDMT specified was +20F and material of Construction used was SA 515 Gr 60, A insert
type patch repair is proposed to be carried out. Based on code requirements, will you specify impact testing of repair
plate. After repairs, vessel will be hydro-tested but not stress relieved. Vessel does nor undergoes temperature /
pressure fluctuations or cyclic loading during service.
A.
B.
C.
D.
10.
80 deg. F
60 deg. F
None of above.
Specify impact
Impact testing
Specify impact
Specify impact
testing.
need not be specified
testing if API 510 inspector feels it is necessary.
testing if Pressure vessel engineer feels it is necessary.
Following is full scale pitting pattern as observed on inside surface of a pressure vessel during the recent planned
inspection vessel thickness required = 7/8 including C.A = 1/8
(See diagram on last page)
Your assessment is:
A.
B.
C.
D.
11.
D.
5 to 32 mm
0 to 16 mm
Any thickness
0 to 32 mm
2.0mm
2.4mm
1.2mm
None of above
The period between External inspections for vessels (remaining life > 4 years) shall not exceed which of following
A.
B.
C.
D.
15.
Which of the following is / are to be undertaken in case the Service conditions of vessel are changed
A.
B.
C.
14.
is
is
is
is
For a vessel which is planned for internal inspection after 8 years what should be the minimum remaining corrosion
allowance in the vessel if corrosion rate is 150 microns per year.
A.
B.
C.
D.
13.
pattern
pattern
pattern
pattern
A procedure qualification test was carried out for a groove weld on a plate with weld metal thickness of 16mm
thickness by SMAW process. The test was found satisfactory. This procedure can be used with SMAW for weld
thickness of:
A.
B.
C.
D.
12.
Pitting
Pitting
Pitting
Pitting
Smaller of : One half of the remaining life of the vessel and 10 years
5 years
The lesser of a and b
The higher of a. and b.
Following combination of Base metal and welding electrode was qualified by a certain PQR. Impact testing is not
required. Base Metal = SA 285 GrC Plates, 3/4" thickness, Welding electrode = AWS E 6015. This PQR will qualify
which of the following combinations.
16
A.
B.
C.
D.
None of above
In liquid Penetrant Testing, a procedure is qualified to a temperature of 15 0C. Pick up a correct statement.
Page 2 of 6
A.
B.
C.
D.
17. Calculate the remaining life of a vessel given the following data: Actual thickness = 0.955 inch. Minimum thickness
required = 0.787 inch Thickness at pervious inspection 5 years prior to present inspection = 1.015 inch
A.
20 years
B.
14 years
C.
28 years
D.
18. The minimum thickness available for a seamless tori spherical head for following data are as given in options. Select
suitable head thickness for a new construction of vessel with design pressure 200 psig, Safe stress 17500 psig and
internal diameter is 96 inches and has no corrosion allowance provided.
A.
B.
C.
D.
1 inch thick
1.25 inch thick
0.75 inch thick
1.125 inch thick
19. For given configuration, correct minimum weld dimension (x) required as per ASME sec. VIII Div. 1 shall be:
A.10 mm
B.12mm
C.14mm
D.none of above
20. A pressure vessel constructed according to ASME Sec VIII Div 1 with shell thickness 7/8 (Material of Construction SA
387 gr 11 cl.1) is to be repaired by using insert plates. The requirement of radiography to be incorporated in repair
procedure shall be:.
A.
B.
C.
D.
Full radiography
Spot radiography
May be a, or b depending on joint efficiency
Data is not adequate
21. A vessel with seamless 2:1 Ellipsoidal head 60 inch ID, 400 psi design pressure, (corrosion allowance = 0) and (S =
20000 psig) was inspected. Available thickness of only 5/8 was observed on the crown portion. The Knuckle thickness
was found to be adequate. Your assessment is:
A.
B.
C.
D.
22. Choose correct hydrostatic test pressure from given options for a vessel with following data.
Design Pressure
Design temp
Material of construction (M.O.C)
Allow stress (Ambient)
Allow stress (675F)
A.
B.
C.
D.
=
=
=
=
=
200 psi
675 F
SA 537 Cl. 1
18000 psi
15000 psi
350 psig
260 psig
312 psig
none of above
23. The temperature measured at a weld layer for a magnetic material is around 45 0C. But the weld is in vertical position.
It is decided to carryout a surface NDT method. Choose a suitable NDT method.
A.
B.
C.
D.
Page 3 of 6
24
If anchor bolt corrosion is anticipated for vertical vessels what testing methods are recommended?
A.
B.
C.
D.
25. A weld procedure is qualified on pipe OD=2, in 1G position. This procedure can be used for welding
A.
B.
C.
D.
6 OD pipe in 1G only
2 OD pipe in 1G only
Any pipe in any position
Pipes smaller than 2 OD in 1G only
26. A procedure qualification test was carried out for a groove weld on a plate of 16mm thickness by SMAW process. The
test was found satisfactory. This procedure can be used with SMAW a thickness of:
A.
B.
C.
D.
5mm to 32 mm
5mm to16 mm
Any thickness
8 mm to 16mm
27. In one of the External inspections, observed resistance of electrical grounding connections for Pressure vessels
was 42 ohms. your advise is:
A.
B.
C.
D.
Accept.
Resistance must be reduced to 25 Ohms maximum.
Resistance must be increased to 25 Ohms minimum,
Depends on opinion of electrical engineer.
28. A pressure vessel (M.O.C. 516 Gr. 70) has external jacket spread over 72 inches length of the shell. (Jacket pressure
200 psig, Jacket temperature 3500 F) the vessel OD 36 inches. Shell thickness is 0 .5 inch and with no C.A. Decide
which of the following are applicable in the present case.
A.
B.
C.
D.
29. For a certain nozzle to shell joint (No corrosion allowance is required) following data is presented. Shell thickness
provided is 0.42 inch, Nozzle I.D. is 3.2 in., Pad size is 6.4 in. O. D., Thickness of pad is 0.42. Your assessment is:
A.
B.
C.
D.
30. SA 516 Gr. 70 (normalized) Plates of 1 inch thick were impact tested at -35 F. Now the MDMT is changed to 50 F. If
the vessel was not given PWHT earlier now receives PWHT,
A.
B.
C.
D.
31. A weld with a nominal thickness of 1.75 inch is to be radiographed using a film side penetrameter. The penetrameter
designation should be
A.
B.
C.
D.
25-4T hole
30-2Thole
35-2T hole
40-2T hole
32. A welder qualifying by making a groove weld on pipe with an O.D. of in the 5G position is qualified to
weld groove welds in :
A.
B.
C.
D.
Page 4 of 6
33. For procedure qualifications with the GTAW process _______ is Non-essential variable.
A.
B.
C.
D.
Change of P No
Change of F No.
Change of S No
Groove Design
34. An ellipsoidal head has an internal diameter of 80 inches and depth of 22 inches (including a straight face dimension of 2
inches). What should its spherical (crown) radius be?
A.
B.
C.
D.
35.
76.9 inches
72.0 inches
68.4 inches
All of the above
For non-continuous corrosive service with remaining life 25 years, external inspection shall be performed not later
than:
A.
B.
C.
D.
10 years
12.5 years
5 years
None of above
36. The crown portion for tori spherical head ( ID=40 inches) may be considered as the portion lying entirely within a circle
whose center will be same as head center and diameter will be
A.
B.
C.
D.
36
40
32
200
37. For 2:1 Ellipsoidal head (ID=75 inches), The crown portion would lie within similar circle of diameter
A.
B.
C.
D.
60
30
54
48
A.
B.
C.
D.
40. One PQR was qualified for Austenitic Stainless steel plates in GTAW process. This PQR will support a WPS made with
Austenitic Stainless steel plates but process changed to SMAW
A.
B.
C.
D.
The maximum permitted reinforcement on circumferential welds with plate thickness up to 1 inch will be:
A. 1/8
Page 5 of 6
B. 1/16
C. 3/16
D.
43 For a vertical with column int. dia. = 48'' and height ( tan-tan) =98 ft, The Hydrostatic heead for bottom dished head
(2: 1 Ellip type) will be
A.
B.
C.
D.
40.6 psi
42.4 psi
43.3 psi
None of above
44. A pressure vessel has been in service for 12 years and has a history of corrosion over its service life. The original
thickness was 1.9375 inches; the current thickness is 1.405 inches. What is the corrosion rate for this vessel?
A.
B.
C.
D.
0.044
0.089
0.266
0.532
inch
inch
inch
inch
per
per
per
per
year
year
year
year
Water
Water
Water
NONE
46. Vessel 60 ID, a nozzle opening of finished opening = 8 inches was present in thinned out patch on inside surface and
lying close to a reinforced nozzle with R.F. pad OD=8. what length will be taken for corrosion averaging is taken for
corrosion analysis
A.
B.
C.
D.
8 inches
16 inches
20inches
30 inches
47. What will be total thinning (metal loss) up to next inspection due after 10more years if Corrosion rate is 6 mills per year
(mpy).
A.
B.
C.
D.
0.05 inch
0.06 inch
0.006 inch
0.6 inch
48. Radiographic density obtained for a radiograph at the IQI (2T hole) was 3.6. The variation of density over the examination
area on film was 3.2 to 4.5. The film shall be
A.
B.
C.
D.
Rejected, the value for Density at the IQI is beyond the acceptable range.
Rejected, the lower limit of range is beyond specified lower limit
Rejected, the upper limit of range is above specified upper limit
Acceptable.
49. A PQR was qualified by GTAW process using Austenitic Stainless Steel plates (ss304) this PQR will quality
A.
B.
C.
D.
50. Which of the following documents referenced in API 510 addresses the Hot Tapping requirements.
A.
B.
C.
D.
API 2201
API Recommended practice 572
API Publication 576
None of above.
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