API-653 Examination Preparation Course

Practice Examination - Open Book

1. Roof plates corroded to an average thickness of less than _____ inch in any ______ square
inch area shall be repaired of replaced.
a) 0.9 inch in any 100 square inch area
b) 0.09 inch in any 10 square inch area
c) 0.09 inch in any 144 square inch area (1 square foot)
d) 0.09 inch in any 100 square inch area

2. An in-service aboveground storage tank contains a fluid with a specific gravity of less
than one. The thickness of the plate in the first course is 7/8”. What is the minimum
thickness of the annular plate ring, seismic loading is not a consideration, and the stress
in the first course is 27,850 pound per square inch?

a) 0.22 inch
b) 0.31 inch
c) 0.20 inch
d) 0.23 inch

3. According to industry experience and laboratory tests, what membrane stress is required
to cause failure due to brittle fracture?
a) 6ksi
b) 7ksi
c) 10ksi
d) 12ksi

4. What is the maximum shell plate thickness permitted for a tank fabricated of ASTM A
285 Grade C material?
a) This plate material is limited to 1.000 inches
b) This plate material is limited to 1.250 inches
c) This plate material is limited to 1.500 inches
d) This plate material is limited to 1.750 inches

5. During the inspection of a 140ft diameter aboveground storage tank an area of general
corrosion is encountered. The corroded area is 28 inches wide by 25 inches high. The
length “L” begins 3 feet up from the bottom horizontal joint of the third course and
minimum acceptable thickness in this area is .365”. The stored product has a specific
gravity of .76, the designed liquid level of the tank is 56 feet, and it is constructed of
eight 8-feet courses of A-516 Grade 60 material. What is the permitted operating liquid
level of this tank?
SEt min
H=
2.6 DG
a) 37.15 feet
b) 33.77 feet
c) 56 feet
d) 53 feet

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Practice Examination - Open Book

6. What is the required average longitudinal impact value of three specimens taken from a
1.5 inch thick A 516-70 as rolled test coupon?
a) 35 foot-pounds
b) 25 foot-pounds
c) 20 foot-pounds
d) 30 foot-pounds

7. The thickness of the first shell course of an aboveground storage tank is 1&5/8th inches.
The hydrostatic test stress in the first shell course is 33,000 psi. What is the minimum
permissible thickness of the annular bottom plates?
a) Minimum permitted thickness is 5/8th inch
b) Minimum permitted thickness is 9/16th inch
c) Minimum permitted thickness is 3/4 inch
d) Minimum permitted thickness is 11/16th inch

8. Using the formula in B-3.2, determine the maximum permissible deflection (out of plane
distortion) for a tank with the following data reported.

Diameter 130 feet

Height 48 feet
Material Carbon Steel (Young's modulus = 29,000,000 psi)
Yield strength 30,000psi
Arc length between measurements 31.4 feet

a) S = .116 feet
b) S = 1.16 feet
c) S = 11 feet
d) S = 1.16 inches

9. During the inspection of an AST, an area of general corrosion is found in the second
course beginning 3.5 feet above the bottom of horizontal joint. The tank is 155 feet in
diameter, fabricated of 8ft. A-285 Grade C shell courses, and stores a product with a
specific gravity of .87. The minimum thickness recorded in this corroded area is .293”.
What is the permitted operating liquid level of this tank?
SEt min
H=
2.6 DG
a) 31.2 feet
b) 23.2 feet
c) 19.7 feet
d) 31.5 feet

10. The fabricator of an AST obtains the approval of the purchaser to use the alternative shell
design permitted in Appendix A in the design of a 60 foot diameter tank using 3/8th inch
A 516 Grade 60 plate. What allowable stress would be used in the design calculations?
a) 21,300
b) 24,000
c) 21,000
d) 32,000
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11. Exposure to high solution strength caustic can result in general corrosion of carbon steel
above:

a) 175ºF (79ºC) and very high corrosion rates above 200ºF (93ºC)
b) 250ºF (79ºC) and very high corrosion rates above 300ºF (93ºC)
c) 350ºF (79ºC) and very high corrosion rates above 400ºF (93ºC)
d) 475ºF (79ºC) and very high corrosion rates above 500ºF (93ºC

12. The owner/operator requires a connection to be made in an in-service tank. The shell
material is of unknown toughness and the thickness is 1.25”. The minimum design metal
temperature is 45°F. What is the maximum diameter hot tap connection that may be
installed in this tank?
a) NPS 18
b) NPS 14
c) NPS 8
d) NPS 4

13. The acceptance standards for radiographic examinations shall be in accordance with
which of the following?
a) Paragraph UW-51(b) in Section VIII of the ASME Code
b) Paragraph PW-51(b) in Section I of the ASME Code
c) Paragraph 341.3.2 in B31.3 Process Piping of the ASME Code
d) Paragraph RB-3233 in the National Board Inspection Code (NBIC)

14. The owner/operator requires an NPS 3 ½ nozzle to be installed in an in-service tank. The
tank is 110 feet in diameter, 60 feet maximum fill height, shell thickness at the point of
hot tap is .75”, and the material is of unknown toughness with a minimum design metal
temperature of 38°F. This nozzle is to be installed adjacent to an existing nozzle. What is
the minimum spacing between these nozzles?
a) Minimum distance is 22.25”
b) Minimum distance is 9.08”
c) Minimum distance is 19.08”
d) Minimum distance is 2.24”

15. What is the maximum depth of a local depression in a tank bottom if the radius of an
inscribed circle is equal to 7.5 feet?
a) BB = .2775 inches
B

b) BB = 2.775 inches
B

c) BB = 27.75 inches
B

d) BB = .02775 inches
B

16. For installation of a new tank bottom in a tank with shell plates of unknown toughness, as
defined in Section 3 of API-653, new welds in the bottom or annular ring shall be spaced
at least the greater of _____ inches or ____t from existing vertical weld joints in the
bottom shell course. (t is the thickness of the bottom shell course)
a) three, five
b) six, five
c) five, three
d) five, six
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17. The manufacturer has the approval of the purchaser to use a material listed in API-650
but not included in the applicable table of ASME Section IX. What Group number would
this material be included in if the minimum tensile strength is specified at 73,000 psi?
a) This material would be included in Group number 2
b) This material would be included in Group number 1
c) This material would be included in Group number 3
d) This material can not be used in AST construction

18. The purchaser of an AST, that is designed to be gas tight, required the roof to be tested
pneumatically. What maximum pressure would be applied to a tank with ¼” thick roof
plates?
a) The maximum pneumatic pressure permitted is .053 psi
b) The maximum pneumatic pressure permitted is .071 psi
c) The maximum pneumatic pressure permitted is .083 psi
d) The maximum pneumatic pressure permitted is .091 psi

19. What is the maximum acceptable undercut for vertical butt joints of reconstructed tanks?
a) 3/32nd inch
b) 3/64th inch
c) 1/32nd inch
d) 1/64th inch

20. What is the maximum out-of-plumbness of the top of the shell, relative to the bottom of
the shell, of a reconstructed tank with a total height of 62.25 feet?
a) 7.47”
b) .6225”
c) 6.25”
d) 5”

21. The minimum thickness of a tank was established at 0.573 inch. The shell was fabricated
from 1.0 inch plate and included a 0.125 inch corrosion allowance. The tank has been in
service for eight years and current ultrasonic thickness measurements reveal an average
thickness of 0.834 inch. Based on this information determine when the next ultrasonic
thickness measurements will be required.
a) Fifteen years
b) Ten years
c) Six years
d) Three years

22. An aboveground reconstructed tank is 126.5 feet in diameter. What is the maximum or
minimum radius permitted measured at the second shell course up from the bottom?
Maximum Minimum
a) 759.75” 758.25
b) 761.25” 756.75”
c) 1520.25” 1515.75”
d) 128.75” 124.25”

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23. For a reconstructed tank, what is the maximum weld reinforcement thickness permitted
on each side of the plate for a plate which is 7/8” thick?

Vertical joints Horizontal joints

a) 3/32” 1/8”
b) 1/8” 3/16”
c) 3/16” 1/4
d) 1/4 5/16”

24. What is the minimum thickness permitted at the next inspection for a tank bottom
designed with a means to provide detection and containment of a bottom leak?

a) 0.01 inch
b) 0.10 inch
c) 0.50 inch
d) 0.05 inch

25. During welding inspections, verification of the base and filler metal chemistries may be
required. This may be accomplished by any or a combination of the following actions
except:

a) Reviewing the certified material test reports

b) Reviewing the markings or stamps on the components
c) Positive material identification
d) Mechanical testing

26. A 24-inch manhole is to be installed in a roof plate and it is anticipated that work may be
carried on through the manhole while the tank is in use. What is the diameter of the
opening to be cut in the roof plate and what is the outside diameter of the reinforcing
plate?

a) The diameter of the opening is 24.625” and the OD of the reinforcing plate is 42”
b) The diameter of the opening is 24.625” and the OD of the reinforcing plate is 46”
c) The diameter of the opening is 24.750” and the OD of the reinforcing plate is 42”
d) The diameter of the opening is 24.750” and the OD of the reinforcing plate is 46”

27. The purchaser has ordered a 36-inch manhole to be installed in the first course of an
AST. The thickness of the shell plate and the reinforcing plate is 1.375 inches. What is
the maximum hole diameter that must be cut in the tank to accommodate this manhole?

a) 36 & 1/4 inch

b) 36 & 1/2 inch
c) 36 & 3/4 inch
d) 36 & 5/8 inch

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Practice Examination - Open Book

28. For foundations of reconstructed tanks, specified to be sloped from a horizontal plane, the
actual elevation shall not deviate from the calculated differences by more than which of
the following where concrete ringwalls are provided?
a) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference measured
from the average elevation
b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference
c) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference measured
from the average elevation
d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference

29. A 110 ft diameter tank shall have a top angle not less than ____ inches.
a) 2 X 2 X 3/8
b) 2 X 3 X 3/8
c) 3 X 3 X 3/8
d) 3 X 2 X 3/8

30. In radiography, how shall wire image quality indicators be placed?

a) Wire image quality indicators shall be placed parallel to the length of the weld
b) Wire image quality indicators shall be placed perpendicular to the length of the weld
c) Two wires shall be placed to the right of the area of interest and the other two to the
left and the fifth wire shall be placed in the center of the area of interest perpendicular
to the length of the weld
d) Two wires shall be placed to the right of the area of interest and the other two to the
left and the fifth wire shall be placed in the center of the area of interest parallel to the
length of the weld

31. In Magnetic Particle examination, using the wet particle technique, what is the maximum
temperature of the wet particle suspension and the surface of the part permitted according
to ASME Section V?
a) As prescribed by the purchaser of the AST
b) As prescribed by the AST manufacturer
c) As prescribed by the particle manufacturer
d) 135°F

32. What is the maximum permitted transmitted density limit between the body of the image
quality indicator and the area of interest for single film viewing for radiographs using an
X-Ray source?
a) 1.8 ± .05
b) 4.0 ± .05
c) 1.4 ± .05
d) 8.0 ±. 05

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33. A welder qualifies by radiography on a 3/8” coupon. A 3/16” slag inclusion is shown on
the radiograph. Is the welder qualified? Why or why not?
a) Yes, the maximum slag inclusion allowed for this thickness is 1/4”
b) No, the maximum slag inclusion allowed for this thickness is 1/8”
c) Yes, slag inclusions are not a rejectable discontinuity when qualify by RT
d) No, the maximum slag inclusion allowed for this thickness is 3/16”

34. Atmospheric corrosion is a form of corrosion that occurs from moisture associated with
atmospheric conditions. Marine environments and moist polluted industrial environments
with airborne contaminants:

a) Are not as severe and result in very little corrosion

b) Are most severe and result in higher corrosion rates
c) Are not a concern as long as the systems are insulated
d) Have the same rate of corrosion as dry rural environments

35. An in-service AST has a diameter of 148 feet. The tank was fabricated of 8ft. A-516
Grade 65 steel plates and consists of six courses. The product stored in the tank has a
specific gravity of .76. The original thickness of the bottom course was 11/16” and a joint
efficiency of .85 was used in the original calculations. The tank has been in service for 10
years and current thickness measurements show the bottom course has deteriorated to a
minimum thickness of .556”. What will be the maximum fill height in five years?
t SE
H5years = min
2.6DG
a) H = 32.39 feet
b) H = 36.78 feet
c) H = 38.79 feet
d) H = 39.79 feet

36. An aboveground storage tank is designed to store a product with a specific gravity of .85.
The tank will be 33.528 meters in diameter and 18.288 meters in height with a designed
liquid level of 17.2212 meters. The shell courses are fabricated from A-36 eight-foot
plates and the purchaser requires a 3.175mm corrosion allowance. What is the minimum
required design thickness of the first course shell plate?

a) 17.943mm
b) 18.212mm
c) 18.874mm
d) 14.768mm

37. An NPS 12 nozzle is to be installed in an existing 96 feet diameter AST. The shell course
thickness is .625” and the reinforcement plate thickness is .75”. What minimum size of
nozzle-to-reinforcing plate fillet weld is required to comply with API-650?

a) .3125
b) .4375
c) .5625
d) .6250

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38. Based on the following information, what is the minimum remaining thickness of tank
bottom plates at the end of a ten-year in-service period of operation?
RTbc = .1630
RTip = .1873
StPr = .002
UPr = .003
Or = 10
a) MRT = .113
b) MRT = .137
c) MRT = .0113
d) MRT = .0137

39. In the Shielded Metal Arc Welding (SMAW) process, electrode covering performs all but
which of the following?

a) Provides scavengers, deoxidizers, and fluxing agents to cleanse the weld

b) Provides a slag blanket
c) Provides a means of adding alloying elements
d) Provides elements to reduce hardness

40. Prior to welding the new vertical joints, the existing horizontal joints shall be cut for a
minimum distance of ____ inches beyond the new vertical joints.
a) Six
b) Eight
c) Twelve
d) Sixteen

41. What is the minimum projection of trimmed bottom plates beyond the outside edge of the
weld attaching the bottom to the shell of a new AST having no low type reinforcing
pads?
a) Minimum projection is 0.02 inch
b) Minimum projection is 0.20 inch
c) Minimum projection is 2.00 inch
d) Minimum projection is 20.0 inch

42. In liquid penetrant examination, ASME Section V states that either a color contrast or a
fluorescent penetrant shall be used in PT techniques.
a) True
b) False

43. A sand pad beneath a tank bottom is found to be contaminated with gravel and crushed
stones. What type of problem could this contamination cause?
a) Pitting corrosion at points of contact
b) Punctures of the tank bottom at points of contact
c) Air spaces which provide even corrosion
d) Cracking at the point of contact

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44. An aboveground storage tank contains a fluid with a specific gravity of greater than one.
The thickness of the plate in the first course is 7/8”. What is the minimum thickness of
the annular plate ring, seismic loading is not a consideration, and the hydrostatic test
stress in the first shell course is 27,850 pound per square inch?

a) 1 / 4 inch
b) 3 / 8 inch
c) 9 / 32 inch
d) 11 / 32 inch

45. One advantage of thick-film lining is _________.

a) It can provide a good surface to attach internal corrosion monitoring devices
b) It can provide sufficient strength to bridge over large perforations in the tank bottom
c) It can provide sufficient strength to bridge over small perforation in the tank bottom
d) It can provide sufficient strength to prevent leakage should the tank bottom
completely corrode away

46. How often should all sources of impressed current be checked?

a) At intervals not exceeding two years
b) At intervals not exceeding one year
c) At intervals not exceeding two months
d) At intervals not exceeding two weeks

47. Floating roof support legs and attachments shall be designed to support the roof and a
uniform live load of at least _____ per square foot.
a) 100 pounds
b) 75 pounds
c) 50 pounds
d) 25 pounds

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Questions 48 through 50 apply to the attached Welding Procedure Specification (WPS)

and Procedure Qualification Record (PQR)

48. Regarding the joint shown, the Welding Procedure Specification:

a) Includes all required information

b) Should specify uphill or downhill progression
c) Must show the weld layers
d) Should address the joint angle

49. Regarding the mechanical tests shown, the Procedure Qualification Record qualifications:

a) Have not been met because one of the guided bend tests failed
b) Have not been met because on tensile test failed
c) Have all be met
d) Have not been met because face and root bends were not performed

50. Regarding the thickness range shown on the Welding Procedure Specification, a correct
statement is that the:

a) Upper limit could be eight inches

b) Lower limit could be 1/16 inch
c) Lower limit could be 1/8 inch
d) Range is accurate as shown

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Practice Examination - Open Book
Welding Procedure Specification (WPS)
Front
Company Name BAY Tech By: Chip Beaph
Welding Procedure Specification No. S21 Date 10/03/03 Supporting PQR No(s) S21
Revision No. 0 Date ---
Welding Process(es) SMAW Type(s) Manual
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402) Details
Joint Design Single V Groove
37 1/2º ± 5º typical
Backing: (yes) (no.)
Backing Material (Type): Weld
(Refer to both backing and retainers)

Metal Nonfusing Metal Root spacing: 1/16”

Root face: 1/8” Max
Nonmetallic Other

Sketches, Production Drawings, Weld Symbols or Written

Description should show the general arrangement of the
parts to be welded. Root spacing and weld groove details
may be specified where applicable

(At the option of the manufacturer, sketches may be attached)

The joint designs above are typical for groove welds, check
the production drawing for weld joint design and root

*Base Metals (QW-403)

P-No. 1 Group No. 1 To P-No 1 Group No 1
OR
Specification type and grade
To Specification type and grade
OR
Chem. Analysis and Mech. Prop.
To Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove: .1875 to ,8640 Fillet: All
Pipe Dia. Range: Groove: All Fillet: All
Other:

* Filler Metals (QW-404) Root Balance

Spec. No. (SFA) 5.1
AWS No. (Class) E7018
Root Balance
F. No. F-4 F-4
A-No. A-1 A-1
Size of Filler Metals 1/8 & 5/32
Weld Metal
Thickness Range:
Groove .1875 to .8640
Fillet to 3/4 throat
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert
Other
*Each base metal - filler metal combination should be recorded individually.

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Welding Procedure Specification (WPS) (Back)

Positions (QW-405 Postweld Heat Treatment (QW-407)
Position(s) of Groove All Temperature Range None
Welding Progression: Up XX Down XX Time Range None
Position of Fillet All
Preheat (QW-406) Gas (QW-408)
Percent Composition
Preheat Temp. Min. 50 Deg. F Gas(es) (Mixture) Flow Rate
Interpass Temp. Max. 550 Deg. F
Preheat Maintenance None Shielding N/A
(Continuous or special heating where applicable should be recorded) Trailing N/A

Backing N/A
Electrical Characteristics (QW-409)
Current AC or DC DC Polarity Reverse
Amps (Range) 90-220 Volts (Range)
(Amps and volts range should be recorded for each Electrode size, position, and thickness, etc
This information may be listed in a tabular form

Tungsten Electrode Size and Type

(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW
(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range

Technique (QW-410)
String or Weave Bead String and Weave
Orifice or Gas Cup Size N/A
Initial and Interpass Cleaning (Brushing, Grinding, etc.) Brushing or grinding 1" Both sides of weld joint

Method of Back Gouging Grinding

Oscillation N/A
Contact Tube to Work Distance N/A
Multiple or Single Pass (per side) Multiple
Multiple or Single Electrode Single
Travel Speed (Range) Various
Peening None
Other:

Travel Other
Weld Process Filler Metal Current Volt Speed (e.g. Remarks Comments, hot
wire addition, technique, Torch
Layers Range Range Angle, Etc.
All SMAW E-7018 1/8" DCRP 90-160 -- -- --
All SMAW E-7018 5/32" DCRP 130-220 -- -- --

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Procedure Qualification Report (PQR)

(QW-200.2 of Section IX, ASME B & PV Code)

Company Name BAY Tech

Procedure Qualification Record Number S21 Date 10/03/03
WPS Number S21
Welding Process(es) SMAW Type(s) Manual
(Manual, Automatic, Semi-Auto)
Joints (QW-402)

Coupon thickness: .4320”

Root face: 3/32”
Root spacing: 1/16”
(for combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or process used)
Base Metals (QW-403) Postweld Heat Treatment (QW-407)
Material Specification SA-516 Temperature None
Type or Grade Grade 70 Time
P-No. 1 to P-No. 1 Other
Thickness of Test Coupon .4320
Diameter of Test Coupon Plate Gas (QW-408)
Other Percent Composition
Gas(es) Mixture Flow Rate
Filler Metals (QW-404) Shielding N/A
SFA Specification 5.1 Trailing N/A
AWS Classification E-7018 Backing N/A
Filler Metal F-No. F-4 Electrical Characteristics (QW-409)
Weld metal analysis A-No. A-1 Current
Size of Filler Metal 1/8” Polarity
Other Amps Volts
Deposited Weld Metal .4320” Tungsten Electrode Size
Position (QW-405) Other
Position of Groove Flat Technique (QW-410)
Weld Progression (uphill, downhill) Flat Travel Speed
Other String or Weave Bead
Preheat (QW-406) Oscillation
Preheat Temp. 50 Deg. F Multiple or Single Pass (per side)
Interpass Temp. 550 Deg. F Single or Multiple Electrodes
Other Other

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QW-483 (Back) Procedure Qualification Report (PQR)

Tensile Test (QW-150)
Ultimate Ultimate Type of
Specimen Total Load Unit Stress failure &
No. Width Thickness Area lb psi location
1 0.996 0.350 0.349 23250 66,620 Base Metal

2 1.002 0.350 0.351 24600 70,085 Base Metal

Guided Bend Tests (QW-160)

Type and Figure No. Results
Side Bend, QW-462.2 No Defects
Side Bend, QW-462.2 No Defects
Side Bend, QW-462.2 1/8” defect in heat affected zone
Side Bend, QW-462.2 No Defect

Toughness Tests (QW-170)

Specimen Notch Notch Test Impact Lateral Exp Drop Weight
No. Location Type Temp Values % Shear Mills Break No Break

Fillet Weld Tests (QW-180)

Results -Satisfactory: Ye No Penetration into Parent Metal: Yes No

s
Macro - Results

Other Tests
Type of Test
Deposit Analysis
Other

Welder’s Name Slim Pickins Clock No. 99 Stamp No. SP

Tests conducted by: BAY Tech Laboratory Test No. S21 1 & 2
We certify that the statements in this record are correct and that the test welds were prepared,
welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer BAY Tech

Date: 10/03/03 Signature: Chip Beaph

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