Open Book API 510 Practice Exam B

Do not mark on your exam, use the answer sheets provided

Questions 1 to 35 are OPEN BOOK and simulate the first half of exam.

1. A vertical vessel has been determined to need de-rating to a lower MAWP. The new MAWP is based
on the engineer's calculations for pressure allowed on the top shell section listed below. The vessel
has an elevation of 55 feet to its very top. The following part MAWP is calculated to the bottom of
the element listed.

Bottom of top shell section, elevation 40.3 feet, P = 458.3 psi

What is the MAWP of this vessel at the top based on this calculation?

1. 439.6 psi
2. 440.8psi
3. 451.9 psi
4. 457.6 psi

2. A shell course is being replaced in an existing vessel made of SA-515 GR. 55 rolled plate. The shell
course will have a thickness of 1.25 inches and inside radius of 40 inches. The Data Report on the
vessel indicates the original design called for a joint E of 1.0, a MAWP of 675 psig at 450 oF(232 oC)
and that the MDMT required is 5 oF (-15 oC). A Preheat to 200 oF (93 oC) was used all during the
welding. Postweld heat treatment was performed also. The ratio of design stress to allowable stress is
.90. What reduction in MDMT can be taken for the ratio of design stress of .90?

1. 20 o F (-7 oC)
2. 10 o F (-12oC)
3. 15 o F (-9 oC)
4. 30 o F (-1oC)

3. A hydrostatic test is being performed on a vertical vessel with an elevation of 48 feet. The MAWP of
the vessel in its normal operating position is 225 psi. All RVs have been removed and the vessel is
blinded off from all other components. The gage will be installed at an elevation of 22.5 feet. What
will gage pressure be during the hydrostatic test at the 22.5’ elevation? The materials design stress
allowed is 16,800 psi and the stress allowed at test temperature of 70 oF (21 oC) is 17,500 psi. H.H. is
.433 psi per vertical foot.

1. 362.6 psi
2. 351.0 psi
3. 339.9 psi
4. 315.7psi

4. The internal inspection of a vertical vessel a minimum thickness reading of 1.270" was found on a
shell course. The Data Report reflects an original thickness of 1.50", and allowable stress at 600 oF
(315 oC) of 14,500 psi, full radiography, and a MAWP of 650 psi. The MAWP was based on a
retirement diameter of 49.02 inches after the corrosion allowance was expended. Inspection records
indicate a L.T. Corrosion rate of 0.025 inches a year. If the corrosion rate does not change what is the
maximum time before the next on-stream or internal inspection?

1. 5.63 years
2. 10 years
3. 90 days
4. 2.81 years

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 Open Book API 510 Practice Exam B
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5. A repair to a vessel is planned. The vessel is built of SA-516 grade 70 normalized materials. The vessel
operates at an MDMT of 38 oF. This vessel is in ordinary service and has thickness of 1.125 inch. It will not receive
postweld heat treatment. The coincident Ratio of stress is 0.90.? This vessel cannot be exempted for impact testing
per paragraph UG-20 (f) because;

1. SA-516 is not a P No. 1 material.

2. 38 oF is too low a temperature.
3. It exceeds the thickness limit for a curve A material.
4. It exceeds the thickness limit for a curve D material.

6. A fillet weld patch is to be welded on a vessel; there is an existing patch in the immediate area, how
close to the existing patch may the new one be located given the following data?

The vessel’s inside radius is 36 inches and the actual vessel thickness of the underlying wall is .310 inch.

1. 13.36 ”
2. 44.64 ”
3. 4.64’
4. 4.44’

7. Two nozzles are to be added to an existing pressure vessel’s shell which has a thickness of 1/4”
(0.250”). One nozzle’s finished opening is 2.5 in I.D. and the other is 2 in I.D., how close may these
nozzle’s centers be placed in the vessel wall without requiring reinforcement calculations?

1. 2.5 inches
2. 3 inches
3. 4.5 inches
4. 2 inches

8. A pressure vessel has been measured to have a minimum wall thickness of .235 inch after 5 years of
service. The vessel’s original wall thickness was .250. Its minimum allowable wall thickness is .195
inch. How long until the next required inspection per API 510?

1. 13.3 years
2. 10 years
3. 5 years
4. 6 and 2/3 years

9. A vessel is undergoing a hydrostatic test after repair. The vessel is marked with an MAWP of 100
psig at 750 oF (399 oC). The materials allowable stress at operating temperature is 15,000 psi and its
allowable stress at test temperature is 17,500 psi. The visual inspection shall take place at;

1. 100 psi.
2. No less than the MAWP of the vessel.
3. 116.66 psi.
4. 106.66 psi

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 Open Book API 510 Practice Exam B
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10. During an internal inspection a vessel’s shell was measured and found to have a remaining wall
thickness of .486 inches. It was last inspected 4 years ago. The retirement thickness of the vessel
shell is .475 inches and its previous thickness was .500 inches. Based on this data, per API 510 what
is the remaining corrosion allowance of the vessel?

1. 0.025"
2. 0.110"
3. 0.011"
4. 0.014"

11. A vessel is constructed of rolled and welded SA-516 gr. 70 steel plate. It is 96 inches in diameter with
a communicating chamber, which extends 18 inches below this horizontal vessel. This vessel is in
water service and operates at working pressure of 150 psi. What will be the gage pressure at working
pressure as read on a gage mounted on the bottom of the vessel’s communicating chamber?

1. 150 psi
2. 154.11 psi
3. 153.46 psi
4. 199.36 psi

12. An Ellipsoidal head was found to have minimum thickness of .523 inch. This head is attached by a
type 2 weld to a seamless shell. The category B welds meet the requirements of UW-11(a) (5) (b) and
UW52. It is a seamless head and the E =1.0 The heads material has an allowable stress at operating
temperature of 14,800 psi. The head has an O.D. of 36 " and an inside crown radius of 36". What is
the welded joint's efficiency from Table UW-12 that attaches the head to the shell (not the
head’s E)?

1. 1.0
2. .85
3. .80
4. .90

Answer the following questions about the attached WPS and PQR (pages 5 to 8) from Excellent Welding.
Consider both the WPS and its supporting PQR when answering the questions.

13. (WPS) In the Joints QW-402 there is a mistake because;

1. Only metal is checked for backing type.

2. A root gap of 1/32” is too small.
3. There should be a drawing of the weld joint.
4. There are no mistakes.

14. (WPS) In base metals QW-403 the Group No is not important because;

1. The group numbers match.

2. P-No. 1 is only produced as group 2 material.
3. Impact tests have not been performed on the PQR.
4. Impact tests have been performed on the WPS.

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 Open Book API 510 Practice Exam B
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15. (WPS) As regards Filler Metals QW-404 the SFA No. is;

1. Correct for an E-6010 electrode.

2. Required per QW-253.
3. SFA is not on the WPS or PQR forms.
4. Not required per QW-253.

16. (WPS) The correct F No. for E 6010 is;

1. 2
2. 3
3. 4
4. 6.

17. In corrosive service, the wall thickness used in these computations shall be the actual thickness as
determined by inspection (see 5.6.2) minus ____________________before the date of the next
inspection.

Fill in the blank;

1. the estimated corrosion loss

2. twice the estimated corrosion loss
3. three times the estimated corrosion loss
4. four times the estimated corrosion loss

18. A weld repair using the preheat and controlled deposition welding methods described in the API 510
is to be performed on a groove type repair in a vessel wall, and will require a welding procedure
qualified using notch toughness tests. What would be the maximum base metal thickness allowed to
be welded using this procedure if the procedure test groove coupon was 2 5 in. (64 mm) in thickness?

1. Unlimited thickness.
2. Less than 2 in. (50mm) 3. Not more than 1-1/2 in. (38mm) 4. Not more than 1 in. (25mm).
3. Not More than 1-1/2” (38mm)
4. Not More than 1” (25mm)

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19. Per Section VIII Div. 1 a P number 1 material is required to be post weld heat treated when it exceeds
what thickness at the joint?

1. 1”
2. 1-1/8” and has not had the required pre-heat applied.
3. 1-1/4” and has not had the required pre-heat applied.
4. 2”

20. According to Section IX of the ASME Code, which of the following is not required to be present on
the supporting PQR?

1. Weld coupon thickness.

2. Post-weld heat treatment applied or the lack of.
3. Joint design.
4. Welding process used to make the PQR weld coupon.

21. Per Section IX a 3/8” PQR coupon will support the following range of thicknesses in production.

1. 1/16 to 3/4 inches.

2. 3/8 to 3/4 inches.
3. 3/8 to 1 inches.
4. 3/16 to 1 inches.

22. In order to substitute 4 side bends for the required face and root bend tests the PQR coupon must be at
least what thickness?

1. 1”
2. 3/4”
3. 3/8”
4. 1/2”

23. What is the required holding time at normal PWHT temperature for P num. 1 Material, 3 inches thick?

1. 2-1/4 hours.
2. 2 hours.
3. 2-1/2 hours.
4. P number 1 material is not required to receive PWHT per Section VIII Div. 1.

24. Per Section IX, the following number of tensile specimens is required on the PQR.

1. 6
2. 4
3. 8
4. 2

25. According to Section IX which of the following describes all the possible combinations for bends
tests.

1. Four face bends.

2. Four root bends.
3. Four side bends.
4. Two face and two roots or four side bends.

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 Open Book API 510 Practice Exam B
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26. While attempting to PWHT a vessel's shell it is discovered that the equipment on hand cannot reach
the minimum temperature for the P No. 1 Group 3 material that the vessel is constructed of. It is 2”
thick at the location of heat treatment. If the vessel can be post weld heat treated at a lower
temperature, what is that lowest temperature?

1. 900 o F (482 oC)

2. 1000 o F (538 oC)
3. 950 o F (510 oC)
4. Lower temperatures are not allowed on P No.1 Group 3 materials.

27. Which of the following is the maximum out of roundness allowance for a cylinder per ASME VIII?

1. 1%
2. plus or minus 1%
3. 1.2%
4. 2”

28. If a 3 inch thick welded plate specimen must be impact tested what will be approximate required
absorbed energy requirement if it has a 55 ksi minimum yield strength?

1. 30 psi
2. 30 ft/lb
3. 27 psi
4. 27 ft/lb

29. What would be considered acceptable proof of having performed Charpy Impact tests on the part of
the manufacturer of steel plates per Section VIII Div. 1?

1. Shipment of the broken specimens with the plate.

2. Shipment of the broken specimens with the plate and certificates of compliance.
3. Shipment of reports or certificates of compliance from the manufacturer.
4. No proof is required beyond the invoice of the manufacturer listing impacts as having been done.

30. The set pressure for a relief valve set at 200 psi may not exceed;

1. 206 psi.
2. 200 psi.
3. 203 psi
4. 199 psi.

31. The maximum reinforcement on a circumferential butt welded joint made in a plate shell of 2 inches in
thickness is;

1. 1/32 inch.
2. 1/4 inch
3. 1/16 inch.
4. 1/8 inch.

32. Deleted Obsolete No Longer on Exam

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 Open Book API 510 Practice Exam B
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33. A vessel owner is repairing a vessel by replacing a duplicate seamless ellipsoidal head, which is butt
welded to the shell. The name plate is marked RT-2, W and HT below the Code symbol. The owner
is allowed to use what type or types of butt welded joints to replace this head?

1. Any type permitted in Section VIII Div. 1

2. Type 1
3. Type 2
4. Type 1 or 2

34. A vessel shell course was replaced on September 1st of 1982.

• The initial thickness was .378” on September 1st of 1982.

• The second reading for thickness was on September 1st of 1987 and was .364”. The last thickness
measured was .345” in September 1st of 1992.

• Based on the most aggressive corrosion what is the value in mils per year to be used in calculating
the remaining life of the vessel?

1. 3.8 mils/yr
2. 5.15 mils/yr
3. 4.77 mils/yr
4. 3.3 mils/yr

35. A shell plate made of SA-285 grade C is to be used in a repair of a vessel. What is the lowest
temperature that this plate may operate at without impact testing if it is 1.5 inches thick, will not
receive post weld heat treatment and has a 695oF (368 oC) maximum temperature and has coincident
Ratio is 1.0?

1. 51 o F (10.5 oC)
2. 14 o F (-10 oC)
3. 88 o F (31 oC)
4. 24 o F (-4.4 oC)

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 Open Book API 510 Practice Exam B
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ANSWER LOCATION OF ANSWER

(Example) B API 510 4.1.2
1. 3 UG-99 API 510 Body of Knowledge
2. 2 UCS-66 & FIG UCS 66.1
3 4 UG-99
4. 4 API 510 7.1.1
5. 4 UCS-66 & FIG UCS-66
6. 1 UG-28 (c)
7. 3 UG-42 (a)
8. 4 API 510 7.1.1
9. 3 UG-99 (b)
10. 3 API 510 Body of Knowledge
11. 2 UG-99 API 510 Body of Knowledge
12. 3 UW-12 (b)
13. 4 IX QW-253
14. 3 Supplementary Essentials not required IX QW-200.2 (b) no impacts
15. 4 IX QW-253
16. 2 IX QW-432.1
17. 2 API 510 7.3.3
18. 1 API 510 Table 8-1
19. 3 VIII UCS-56
20. 3 Joint design is a non-essential variable IX ART 2 QW-200.2
21. 1 IX QW-451.1
22. 3 IX QW-451.1 Note 5
23. 1 VIII UCS-56
24. 4 Tension test column IX QW-451.1
25. 4 IX QW-451
26. 2 See Foot Notes in UCS-56.1 Table VIII UCS-56.1 Table
27. 1 VIII UG-80
28. 2 VIII UG-84 FIG. UG-84.1
29. 3 VIII UG-84 (e)(2)
30. 1 UG-126 (d)
31. 2 VIII UW-35
32. Deleted Not On Exam deleted
33. 4 VIII TABLE UW-12
34. 1 API 510 7.1.1.1
35. 3 VIII UG-20(f) / UCS-66-68

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 Open Book API 510 Practice Exam B
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1. Determine Vessel MAWP based on lowest Part MAWP 451.9

Total elevation of vessel = 55 feet

Elevation of interest = 40.3 feet (bottom of top shell course)

55.0 - 40.3 = 14.7 feet of H.H.

14.7’ x .433 = 6.365 Psi

MAWP of vessel shell course at its bottom 458.300

Hydrostatic Head present - 6.365
451.935 (rounding down) 451.9 PSI'

Do not exceed 451.9 at the top or pressure will exceed 458.3 at the 40.3’ elevation

3. MAWP = 225 Psi

Stress at Test = 17,500 Psi
Stress by Design = 16,800
Gage Psi during test at the 22.5’ elevation =?

Hydrostatic test pressure at the top = 1.3 x 17,500/16,800 x 225 = 1.3 x 1.0416 x 225 = 304.687 at the top

Calculating the H.H. present at the 22.5’ elevation 48’ - 22.5 = 25.5’ of H.H.
25.5 x .433 = 11.0415 Psi 304.6
48'

Pressure at gage level during test = 304.687 + 11.0415 = 315.7285 (rounded to 315.7)

22.5'
315.7 Psi

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 Open Book API 510 Practice Exam B
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4. Corrosion Rate = 0.025” per year

Calculate the shell t min;

t =?
P = 650
S = 14,500 Psi
E = 1.0 Full RT
R = 49.02/2 = 24.51”

Corrosion Allowance 0.1409072

Remaining Life = = 5.63 Years
Corrosion Rate 0.025”
Next inspection shall not exceed one half the estimated remaining life of the vessel or 10 years, whichever
is less.

Therefore: 5.63/2 = 2.815 years (rounded to 2.8)

5. Fig. UCS-66 Exemption Curves

6.
d = 4 36x.310 = 13.36”

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7. Minimum spacing for the centers of nozzles must be not less than the sum of their diameters apart.

2.5 + 2.0 = 4.5”

Nozzles must be 4.5” a part center to center.

9. 1.3 x 17,500/15,000 x 100= 151.58

Inspection not less than test pressure/1.3 = 151.58/1.3 = 116.6 Psi

10. .486-.475 = .011”

11.
MW-1
96" = 8'

18" = 1.5'

H.H. = 8’ + 1.5 = 9.5’ x .433 = 4.1135 Psi Pressure at the bottom = 150 + 4.1135 = 154.1135

12. The welded joint is a Type 2 and has been spot radiographed. From Table UW-12 the joint E = .80

This question is about the weld joint E, it is not about the E used to calculate the seamless head!!!

32. Deleted No longer on exam

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 Open Book API 510 Practice Exam B
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34. A vessel shell course was replaced on September 1st of 1982.

• The initial thickness was .378” on September 1st of 1982.

• The second reading for thickness was on September 1st of 1987 and was .364”.
• The last thickness measured was .345” in September 1st of 1992.

• Based on the most aggressive corrosion what is the value in mils per year to be used in calculating
the remaining life of the vessel?

Time in years Long Term = September 1st 1982 to September 1st 1992 = 10 years

t(inital)- t(actual)
Corrosion rate (L.T.)=
time(years ) between t(intial) and t(actual)

Corrosion rate (L.T.)= 0.0033 = 3.3mils / yr.

Time in years Short Term = September 1st 1987 to September 1st 1992 = 5 years

t (previous) - t(actual)
Corrosion rate (S.T.) = --------------------------------------------
time (years ) between t(previous) and t(actual)

S.T. =.364 - .345/5.0 years = 0.019/5.0 = .0038” per year C.R.

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