EXAM QUESTIONS

1. What API-RP standards/API codes apply to the following equipment:

o Air Cooled Exchanger- API 661

o Plate Heat exchanger- API 662

o Shell & Tube Heat Exchanger- API 660

o In-service Inspection of pressure vessels-API 510

o Pressure Relieving Devices.-API 576

2. What section of the ASME Code covers the welding of pressure

vessels? ASME SECTION VIII

3. What the acronyms "TEMA" stands for? TUBULAR EXCHANGERS

MANUFACTURER’S ASSOCIATIONS

4. What is the most important factor in determining the inspection

frequency of a pressure vessel? THE FREQUENCY OF INSPECTION
IS DETERMINED BY THE RATE IN WHICH A VESSEL IS
CORRODING

5. Name 5 tools an inspector should have to perform an inspection.

FLASH LIGHT, PIT GAGE, UT MACHINE, SCRAPER MEASURING
TAP, PENCL AND NOTEBOOK.
6. List 6 items that should be inspected on the external of a pressure
vessel. EXTERNAL INSULATION, SUPPORTS, ALLOWANCE FOR
EXPANSION, GENERAL ALIGHNMENT, SIGNS OF LEAKAGE,
SIGNS OF CORROSION, ETC….

7. List three types of metallic lining? CLADDING, STRIP LINING AND

WELD OVERLAYS

8. Why is it important to inspect exchanger bundles when they are first

pulled from a shell? BECAUSE THE COLOR OF DEPOSITS AND
SCALE CAN REVEAL CORROSION PROBLEMS

9. What is the greatest allowed time between the testing of pressure

relieving devices per API 510? 10 YEARS

10. Who is responsible for the re-rating calculations of a pressure vessel as

denoted by API 510? THE MANUFACTURER OR AN OWNER-USER
ENGINEER ( OR HIS DESIGNATED ENGINEER)

11. What should be looked for when performing visual inspections of

ladders, stairs, walk ways or platforms? LOOSE NUTS, DAMAGED
TREADS, BROKEN PARTS AND CORRODED MATERIALS

12. Name three important factors in inspection of metallic linings.

1) SERVICE CORROSIVE ATTACK, 2) THAT LINING ARE
PROPERLY INSTALLED, 3) AND THAT NO CRACKS OR
HOLES ARE PRESENT IN THE LINING.

13. List the 2 basic reasons for inspection of pressure vessels: The main
reason for inspection is to 1) determine the physical condition,
2) and rate , type and cause of deterioration.
14. List four types of records that should be included in the record file for a
vessel. Manufacturer’s data report, vessel identification
number, rv information, results of inspection and any repairs
or alterations performed

15. How can you ensure the tube bundle will fit properly in the shell? By
dimensional checks

16. Name three (3) kinds of exchangers that are used in Saudi Aramco?
TUBE AND SHELL WITH FLOATING HEAD, TUBE AND SHELL
WITH FIXED TUBESHEET, TUBE AND SHELL WITH U-TUBE,
KETTLE, FINNED TUBE (FIN-FAN-AIR COOLER)

17. How many supports should a horizontal heat exchanger have? and
what is the type of its supports? TWO, THEY ARE SADDLE TYPE
SUPPORT

18. How many hydrotests are required on a heat exchanger with floating
head? and in what sequence?
3 TESTS,
1) RING HYDROTEST, THE BUNDLE IS INSIDE THE SHELL AND
THE CHANNEL, SHELL AND FLOATING HEAD COVERS ARE
REMOVED AND A TEST RING IS INSTALLED BETWEEN THE
FLOATING TUBE SHEET AND THE SHELL FLANGE. THEN,
WATER IS INTRODUCED INTO THE SHELLSIDE AND THE
REQUIRED PRESSURE IS THEN TO BE APPLIED.

2) TUBE SIDE HYDROTEST, THE BUNDLE IS INSIDE THE

SHELL, THE CHANNEL AND THE FLOATING HEAD COVER
ARE IN PLACE, WATER IS INTRODUCED INTO THE
TUBESIDE OF THE EXCHANGER AND PRESSURE IS THEN
APPLIED.

3) SHELL SIDES HYDROTEST, COMPLETE WITH SHELL COVER.

19. Which non-destructive test method(s) are used to test the integrity of
stainless steel internal strip lining? VT/UT

20. What information should be stamped on plate that will be used to

fabricate pressure vessels? NAME OR BRAND OF MANUFACTURER,
HEAT AND SLAB NUMBER, MATERIAL SPECIFICATION
NUMBER AND GRADE, CLASS AND TYPE.

21. What is the minimum holding time for a hydrostatic test required by
TEMA? 30 MINUTES

22. What is meant by the term “ floating header” in relation to an air-

cooled heat exchanger? ONE OF THE TWO HEADERS OF AN AIR-
COOLED EXCHANGER IS CALLED THE FLOATING HEADER,
WHICH SHOULD BE FREE TO MOVE WITH THE THRMAL
EXPANSION OF THE TUBES.

23. What is a pressure vessel as defined in ASME Code? A CONTAINER

DESIGNED TO WITHSTAND INTERNAL AND EXTERNAL
PRESSURE.

24. What is the deference between alteration and rerating?

Alteration is a physical change to a component that affect the

pressure containing capability of a vessel while rerating refers
to any change, i,e, temperature, pressure, thickness, etc,
which would affect the maximum allowable working pressure.
25. List 5 process conditions that could change the corrosion rate?

1) TEMPERATURE
2) STRESS
3) VIBRATION
4) IMPINGEMENT
5) HIGH VELOCITY

26. Fill in the blank. Choose your answer from the list below. One word will
be used twice:

Cylinder nozzle reinforcement pad

Ductility slotted pressure

Corrosion SIS strength

- ASME section VIII, Division 1 applies to PRESSURE vessels.

- A NOZZLE provides an opening for a process stream to enter

- or to exist a vessel.

- An Inspector checks the thickness of the metal in a vessel to

determine the amount of metal loss caused by CORROSION .

- The shell of a column is the shape of a CYLINDER .

- The bolt holes in the saddle on one end of a horizontal vessel are
SLOTED to allow for thermal expansion.

- A vessel liner protects the vessel from the effects of CORROSION.

- A REINFORCEMENT replaces the strength that is lost when

metal is removed from a vessel to make an opening.

- The SIS specifies the hydrostatic test pressure for

a given vessel.
 - DUCTILITY Is the property of metal that enables it to retain its
shape when external force is applied to it.

- The property of metal that enables it to be bent, shaped or formed

without fracturing or returning to its original shape is called
DUCTILITY

27. Match the lettered parts in Figure 1 with their names. Write your
answer in the blank spaces.

__A___ 1. Stationary tube

__H___ 2. Floating head

__E___ 3. Transverse baffles

__G___ 4. Floating end tube sheet

__F___ 5. Split ring

__D___ 6. Tie rod with spacers

__B___ 7. Impingement plate

__I___ 8. Tube
Figure 1: Internal parts of a heat exchanger
 28. Figure 2 shows cross sections of two fin fan exchangers. Find the
name of the part in the list below and write the correct letter in each
blank.

__A___ 1. Side frame

__D___ 2. Plug

__G___ 3. Tube sheet

__J___ 4. Tube support

__B___ 5. Tube

__E___ 6. Gasket

__H___ 7. Flange

__K___ 8. Stiffener

__C___ 9. Header

__F___ 10. Cover plate

__I___ 11. Pass partition

__L___ 12. Plug sheet

Figure 2
 29. Fill in the blank. Choose your answer from the list below. Not all
answers are used and one answer is used twice.

convect conduct headers side frame

groove cross-member spacer pass partition

gasket flanges

1. The __SPACER_____ is the part of a tube support that keeps the tubes
separated.
2. Tension-wound embedded fins are attached in a __GROOVE________ in
the external wall of the tube.
3. The purpose of the fins on the tubes is to __CONDUCT_____ the heat
away from the tube.
4. The part of a header that separates the inlet from the outlet is the
____PASS PARTITION______.
5. The tube sheets of a finfan exchanger are parts of the
___HEADERS_______.
6. A ___GASKET_______ seals the joint between the cover plate and the
header on a removable-cover plate finfan exchanger.
7. The part of a finfan exchanger that makes the tube bundle rigid is
___SIDE FRAME_______.
8. The __CROSS MEMBER__ provides structural support for the tube
support.
9. The __HEADERS___ provide space for the stream to flow into the tubes.
10. The removable cover plate finfan exchanger has __FLANGES________ to
attach the cover plate.
 30. Write the letter of the correct answer in the blank on the left.

__C___ 1. In a (n) __________-draft finfan exchanger, the fan is located

below the tube bundle.

A. reduced C. forced
B. induced D. natural
__A___ 2. A __________ tube is used in a finfan exchanger.

A. finned C. basic
B. fanned D. pitch
__C___ 3. A __________ drive requires a pulley on the driver and on the fan
shaft.

A. clutch C. belt
B. gear D. driver
__B___ 4. The __________ of the finfan exchanger prevent(s) loss of air at
the ends of the fan blades.

A. headers C. plenum
B. fan ring D. driver
__D___ 5. The __________ adjustment determines the volume of air the fan
can move.

A. fin C. gear
B. ratchet D. pitch
__C___ 6. The __________ of the finfan exchanger provide(s) space for air
movement around all parts of the tubes.

A. headers C. plenum
B. fan ring D. Driver
__B___ 7. A (n) __________ finfan exchanger has a fan that pulls the cool air
through the tube bundle.

A. reduced-draft C. forced-draft
B. induced-draft D. natural-draft

__A___ 8. A __________ plenum is smaller at the fan shroud than it is at the

tube bundle.

A. transition C. reduction
B. panel D. Conduction

31. Fill in the blank. Choose your answers from the list below. Some
answers may be used more than once.

Safety Instruction Sheet pressure vessels

Minimum thickness corrosion thickness

Standard Data Report Manufacturer’s Data Report

1. ASME Section VIII, Division 1 applies to heat exchanger because they are
____PRESSURE VESSELS____________________________.
2. ASME requires a _MANUFACTURER__________that provides the original
construction specifications for an exchanger.
3. To calculate the corrosion allowance for the shell of an exchanger, you
subtract the __MINIMUM THICKNESS_____from the original thickness.
4. Saudi ARAMCO Engineers prepare a document called a
______SIS_________________ that provides the corrosion allowances for
various exchanger parts.
5. The __MANUFACTURER's Data Report_________ indicates the kind of
metal used to make an exchanger shell.
6. Heat exchangers are ____PRESSURE VESSELS___________________
and also heat transfer equipment.
7. The Operating Limits section of the __SIS____________________ applies
to an exchanger throughout its useful life.
8. The ___SIS_______________________________ gives the routine test
pressure for the shell test of an exchanger
32. Write the correct lettered name of the part illustrated in the below fin-
fan drawings.

A- CROSS MEMBER
B- INDUCED DRAFT FAN
C- STIFFENER
D- PLENUM
E- GEAR SHAFT
F- PLUG
G- BELT
H- TUBE SUPPORT
I- TUBESHEET
J- FAN RING
K- PASS PARTITION
L- PLUGSHEET
M- NOZZLE
N- HEADER BOX
O- DRIVE MOTOR
33. Write the letter of each tube and shell exchanger part shown in the
below drawing beside its name in the list below. The arrows in the
drawing indicate the direction of the flow for each stream.

H 1.tubeside inlet nozzle

D 2.shell

A 3.channel cover

B 4.tubeside outlet nozzle

G 5.saddles

C 6.shell side inlet nozzle

E 7.shell cover

I 8.channel

F 9.shellside inlet nozzle

 34. Fill in the blank. Choose your answer from the list below.

Welded threaded bolted

Pass partition flanges shell

1. The shell cover and the shell have FLANGES that join them
together.

2. The channel cover is BOLTED to the channel.

3. The SHELL is the external part of an exchanger that is

shaped like a cylinder.

4. The saddles are joined to the shell by a WELDED joint.

5. The internal part of the channel that directs the stream into the tubes
is a PASS PARTITION .
35. A covers the floating end of a tube bundle

a) Shell cover
b) Floating tubesheet
c) Floating head
d) Channel cover

36. Indicates the least tube-wall thickness.

a) 11 BWG
b) 12 BWG
c) 13 BWG
d) 14 BWG

37. Saudi Aramco uses tubes in heat exchangers for salt

water service.
a) 70-30 cupro-ni
b) Carbon steel
c) Low chrome steel
d) Stainless steel alloy
38. Each statement applies to one of the types of exchanger listed below.
Write the letter of the exchanger type in the blank next to the
statements that apply to it.
A. Fixed tube sheet
B. U-tube exchanger
C. Kettle

B 1. Allows minimum space between the shell and

the outer tubes to increase the flow around all the tubes.
A 2. Has stationary tube sheets at both ends of the
tube bundle.
A 3. The tube bundle cannot be removed from the
exchanger for inspection or cleaning.
C 4. Has a vapour space in the shell side above tube
bundle.
B 5. Has only one tube sheet.
A 6. Must be used in low temperature services
because the tube bundle cannot expand.
C 7. Has a weir in the shell to keep the tube bundle
covered with liquid during the operation
A 8. Less expensive to make than the other heat
exchangers.
B 9. Must be used in non-fouling services because
the tubes cannot be mechanically cleaned
C 10. Uses the high temperature of some process
streams to generate steam.
 39. Match the terms with their definitions. Write the letters in the blanks.

__D___ 1. The difference between the amount of pressure that starts to

open a pressure-relief device and the amount of pressure at
which the device is fully open.

__L___ 2. The difference between the pressure level that causes a safety
valve to open and the pressure level that allows the valve to
close.

__H___ 3. The condition when a safety valve opens and closes rapidly and
does not stay in either position.

__A___ 4. The part of a valve that blocks the flow of liquids or gases when
the valve is closed.

___F__ 5. A valve with a pilot device that causes the valve to open and
close. The pilot operates by means of pressure-sensing
mechanism.

__K___ 6. To open suddenly.

__I___ 7. The condition that exists when a valve closes so tight that no
liquid or gas can flow through.

__C___ 8. Pounds per square inch of pressure.

__M___ 9. A valve that allows excess pressure to escape from a liquid

system.

___B__ 10. A pressure-relief device that breaks open when the pressure in a
system reaches a certain level.

___E__ 11. A valve that allows excess pressure to escape from a gas
system.

___G__ 12. A combination valve that allows excess pressure to escape from
a gas system.
__J___ 13. The damage that occurs to the valve disk when steam under
heavy pressure rushes out of a valve that is not fully open.

A. Disk

B. Rupture Disk

C. psi

D. Accumulation

E. Safety Valve

F. Pilot-activated valve.

G. Safety-relief valve

H. Chattering

I. Positive seating

J. Steam cutting

K. (to) pop

L. Blowdown

M. Relief valve
 40. Match the letters of the valve parts in Figure 3 with the terms below.
Write your answers in the blanks.

__C___ 1. Bonnet

__B___ 2. Hand wheel

__F___ 3. Packing

__D___ 4. Bonnet nut

__A___ 5. Hand wheel nut

__E___ 6. Stem

__G___ 7. Wedge (Disc)

Figure 3
 41. Complete the sentences with the terms below. Write your answers in
the blanks. Some of the terms will not be used.

blocked discharge chemical

expand explosion

instruments MAWP

power PZV

check valves valve

PCV PVC

1. The abbreviation for a pressure-relief device in Saudi Aramco is

______PZV______________.
2. Pressure-relief devices help to control the ______MAWP__________
during the refinery operation.
3. Overpressure in a vessel can produce a dangerous
________EXPLOSION____________.
4. Overpressure can occur when the liquids or gases have no place to go.
This condition may be caused by a _____BLOCKED DISCHARGED____.
5. Heat from a fire or from the sun can cause the liquids and gases inside a
vessel or pipeline to _EXPAND________________.
6. The operation of equipment in the oil refinery process is usually controlled
by ___INSTRUMENT________.
7. A ___POWER______________ failure will cause the electrical and
electronic instruments and control devices to stop functioning.
8. Excess heat can be caused by a fire, by the sun, or by a
___CHEMICAL__________ reaction .
9. The operator in an oil refinery can make mistakes that cause
overpressure. One type of mistake the operator can make is to close the
wrong _____VALVE_______________.
 42. Choose the correct term to complete the statement. Write the letter in
the blank.

_B____ 1. Figure 4 shows a ___________________________.

A. relief valve
B. safety valve
C. safety-relief valve
D. pilot-operated relief valve
E. rupture disk

Figure 4
___E__ 2. Figure 5 shows a ___________________________.

A. relief valve
B. safety valve
C. safety-relief valve
D. pilot-operated relief valve
E. rupture disk

Figure 5

__D___ 3. Figure 6 shows a ___________________________.

A. relief valve
B. safety valve
C. safety-relief valve
D. pilot-operated relief valve
E. rupture disk
Figure 6
___A__ 4. Figure 7 shows a ___________________________.

A. relief valve
B. safety valve
C. safety-relief valve
D. pilot-operated relief valve
E. rupture disk
Figure 7
__C___ 5. Figure 8 shows a ___________________________.

A. relief valve
B. safety valve
C. safety-relief valve
D. pilot-operated relief valve
E. rupture disk

Figure 8
 43. Write the letter of the correct answer in each blank.

__B___ 6. A relief valve is used in the oil refinery process for

___________________________.

A. air
B. liquid
C. vapor
D. air and power
__C___ 7. A ___________________________ pops open when the steam
pressure reaches a certain level.

A. rupture disk
B. relief valve
C. safety valve
D. pressure device
__D___ 8. A ___________________________ uses a bellows.

A. rupture disk
B. relief valve
C. safety valve
D. safety-relief valve
__A___ 9. A ___________________________ valve actually has two
valves. One valve controls the other.

A. pilot-operated
B. safety-relief
C. safety
D. relief
__B___ 10. A ___________________________ cannot close after it opens.

A. relief valve
B. rupture disk
C. safety valve
D. safety-relief valve
 44. Complete the sentence with the terms below. Write your answers in
the blanks.

vapor space block valve

coolant pipeline

pressure PZV

1. In the oil refinery process, overpressure is controlled by a

______PZV_______________.
2. A vessel that contains heated liquids must have a PZV installed above the
______VAPOR SPACE_______________.
3. Two pressure vessels can be protected by one PZV if they are directly
connected by a _____PIPELINE________________.
4. Two pressure vessels need to have two separate PZVs if there is a
____BLOCK VALVE_________________ between them.
5. Compressor units must be protected with PZVs because they can build up
too much ____PRESSURE_________________.
6. Reflux acts as a ___COOLANT__________________ that controls the
heat in a fractionating column.
 45. Complete the sentences with the terms below. Write your answers in
the blanks. Not all items will be used.

block inspection level

symbol PZV tests

test date identification number set pressure

10 16 21

1. A single pressure-relief device that is installed on a pressure vessel must

prevent the pressure from rising ____10_________________ percent
above MAWP.
2. When several pressure-relief devices are installed on a pressure vessel,
they must prevent the pressure from rising ______21_______________
percent above MAWP.
3. The ASME Code requires that each pressure-relief device that is at least ½
inch in pipe size must be stamped with the proper National Board
______SYMBOL_______________.
4. The capacity of a pressure-relief device is determined by laboratory
________TESTS_____________.
5. Saudi Aramco requires that each pressure-relief device must have a
corrosion-resistant tag with the following information: IDENTIFICATION
NUMBER_, ___SET PRESSURE_____ and ___TEST DATES___.
6. The ASME Code requires that liquid pressure-relief devices must be
connected below the normal liquid ___LEVEL__________________.
7. The ASME Code requires that there must not be ant intervening
______BLOCK_____________ valves between pressure-relief devices
and the point of discharge.
8. The AES require that all PZVs must be accessible to permit maintenance
and ______INSPECTION_______________.
46. What must be considered important in the inspection of a metallic
lining for in-service pressure vessel?

a) That there are no dissimilar welds

b) That the linings made of pure alloy only
c) That vent holes exist in all liners
d) That there are no holes and cracks in the lining.

47. Most pressure vessels are subjected to internal or external pressure

that exceeds:

a) 5 psig
b) 15 psig
c) 25 psig
d) 50 psig

48. What is the primary purpose of installing a lining on the inside of a

vessel?

a) Resist corrosion
b) Improve heat transfer
c) Improve fluid flow
d) Minimize effort to clean vessel.

49. An optionally part of an exchanger that is used to protect the tubes at

the inlet nozzle is called:

a) Baffle
b) Demister pad
c) Impingement plate
d) Strip lining

50. What code is often used when constructing vessels that operate at
high temperature?

a) ASME B&PV Code Section VIII Division 1

b) ASME B&PV Code Section V111 Division 2
c) API/ASME Code vessel code
d) TEMA
51. What Codes are used when constructing a heat exchanger that is used
in the petrochemical industry?

a) API 660, ASME Section VIII and TEMA

b) API 661
c) API 663
d) API 660 and API 661

52. The vessel manufacturer stamps the vessel with the code symbol “U”.
What is the meaning of this code stamp?

a) All applicable requirements of the ASME code have been met

b) All the requirements of the U-section in the ASME code have been met
c) Vessel has been hydrotested
d) Vessel has good thickness.

53. A vessel should be maintained in accordance with the :

a) Construction code
b) Latest edition of ASME section VIII
c) Code that was last used to rate the vessel
d) Any of the above

54. The definition of pressure vessels is:

a) A vessel for containment of process fluid with or without internal

pressure
b) A container designed to operate below atmospheric pressure
c) A container no greater than 6” in cross section
d) A container designed to withstand internal and external
pressure

55. The owner of a pressure vessel requires a head of the vessel to be

replaced with the same head because of corrosion. This is to be
classed as:

a) Repair
b) Alteration
c) Bothe A and B
d) It does not matter.
56. What does the term construction code mean, as it regards repair to
pressure vessel?

a) The current ASME code edition

b) The NBIC
c) The code the vessel was constructed to including non-
standard and jurisdictional special vessel
d) The API 510 Code

57. What code is used to evaluate a vessel after it has been placed in
service?

a) ASME section VIII

b) ASME section V
c) API 510
d) RB 572

58. Due to corrosion problems, the owner of a pressure vessel had both
ellipsoidal head of the vessel replaced with a torispherical head. How
would you as the Inspector classify this work?

a) Repair
b) Alteration
c) Both A and B
d) I do not know

59. During an internal inspection, operating deposits are found in a specific

section of the vessel. The inspector must:

a) Have all deposits removed

b) Determine the cause of the deposits
c) Determine if corrosion is occurring under the deposits
d) Record the volume of the deposits
60. A partial buried vessel should be inspected for soil-to.air corrosion. To
perform this inspection, the soil should be excavated:

a) 1 to 2 inches
b) 3 to 6 inches
c) 6 to 12 inches
d) 12 to 36 inches

61. What is a common micro-organism in soils that can cause biological

corrosion?

a) Chloride-reducing bacteria
b) Sulfate-reducing bacteria
c) Oxygen-reducing bacteria
d) Carbonate bacteria

62. Before performing a vessel inspection, which of the following activities

does the inspector NOT need to do?

a) Review past inspection records

b) Check with operations to determine whether there were any
abnormal operating conditions
c) Review the equipment construction details
d) Review the vessels’ service condition
e) Read ASME Code.

63. What is one important item to check during external inspection of an

exchanger?

a) Surface temperature at the inlet and outlet

b) The floating end of the exchanger is free to slide on its’ supports
c) Determine the fluid flow rate through the shell side and tube side of
the exchanger
d) Measure the clearance between the shell and the ground

64. What is the most important concern when hydrotesting a large in-
service vessel?
a) Rope off an area equal to 1000 seq. ft. for every 1’ of vessel hight
b) Provide calibrated gauges
c) Use condensate water as the hydrotesting media
d) Assure vessel foundation and supports are adequate for the
hydrotest weight.
65. A shell-side pressure test is being performed on an exchanger with a
floating head bundle. The bundle is in the shell and the channel cover
is removed. The test will show overall bundle integrity and can be used
to specifically locate which of the following leaks?
a) Stationary tubesheet roll leaks
b) Floating head tubesheet roll leaks
c) Floating head gasket leaks
d) Leaking tubes

66. A tube-side pressure test is being performed on an exchanger with a

floating head bundle. The bundle is in the shell and the piping
connected to a bottom shell nozzle is removed. This test will show
overall bundle integrity and can be used to specifically locate which of
the following leaks?

a) Stationary tubesheet roll leaks

b) Floating head tubesheet roll leaks
c) Floating head gasket leaks
d) Leaking tubes
e) The exact locations of any leak cannot be determined with this
test.

67. During a bundle pressure test, a leaking tube is discovered. The

inspection results indicate that the other tubes are acceptable for a
future operation run. The leaking tube is normally :
a) Replaced in kind
b) Replaced with different material
c) Plugged
d) Removed
e) Rerolled

68. During a bundle pressure test, a tube roll-leak is discovered. The

inspection results indicate that the other tubes are acceptable for
operation. The leaking tube is normally:

a) Replaced in kind
b) Replaced with different material
c) Plugged
d) Removed
e) Rerolled
69. For proper internal or external visual inspection surfaces of pressure
vessels must be cleaned:

a) Wire brushed
b) Hydro-jetted
c) Hydro blasted
d) The type of surface preparation depends on individual
circumstances and could be any of the above.

70. What is the definition of a construction code?

a) Any standard used to repair vessel

b) Any technique of construction
c) Any standard used to repair a vessel
d) The code or standard to which a vessel was originally built.

71. Of the following tools, which should the inspector have on hand for
vessel inspections?

a) Pencil and note pad, flash light and scraper

b) Social security card
c) Clean fire retardant clothing
d) Electrical conductivity testing equipment

72. Many of the problems that develop in operating vessels maybe traced
to:

a) Cold winters
b) On-stream inspections
c) Electrical shots
d) Faulty materials and workmanship

73. The primary cause of deterioration of in pressure vessels is:

a) Corrosion
b) Operating conditions
c) Improper installation
d) Water damage
74. Which of the following techniques is considered the primary means to
determine the minimum thickness of a vessel’s components?

a) A plate sample is removed from the area

b) Measuring from a corroded area
c) Any destructive method of determination
d) Ultrasonic thickness measurements.

75. The main reason(s) for inspecting heat exchanger bundles after
removal and prior to cleaning is/are:

a) Location of scale on the tubes can reveal non-operational problems

b) Deposits on the tubes can reveal acid contamination problems
c) Color of the tube ends can reveal good condition
d) Color of deposits and scale can reveal corrosion problems

76. Which of the following is considered a construction code?

a) ASME B31.23
b) ASME B33.2
c) ASME Section V
d) ASME Section VIII Div, 1

77. When preparing to inspect a vessel which has had previous

inspections, what is the initial step in preparation for the inspection?

a) Assemble all the required tools to perform the inspection

b) Review previous inspection records
c) Advise maintenance of any anticipated repairs
d) Ensure that all non-destructive examinations required have been
scheduled

78. When performing a visual inspection which of the following tools are
not required to be available:

a) A flashlight
b) A pit depth gage
c) UT thickness measurement equipment
d) Refinery Process Flow Diagram
79. Insulated carbon steel vessels maybe subject to CUI if operating:

a) Above 700 F
b) Below 700F
c) In an intermittent service
d) All of the above

80. Which of the following is not re-rating a vessel:

a) Increasing the MAWP

b) Increasing the maximum design temperature
c) Increasing the RV setting above the marked MAWP
d) Adding a 4” nozzle to a vessel which has other 4” nozzle.

81. The primary purpose of metallic linings is:

a) Increase the thickness of the vessel wall to resist internal pressure

b) Protect the pressure vessel wall from corrosion and or erosion
c) Serve as internal insulation
d) Prevent contamination of the content

82. If an duplicate ASME Code name plate is to be attached to pressure

vessel it must be placed only on:

a) The skirt
b) One of the heads (does not matter which)
c) On the shell
d) Any permanent attachment to the vessel

83. The maximum inspection interval for a pressure vessel with a

remaining life of 16 years is:

a) 10 years
b) 5 years
c) 8 years
d) 16 years
84. What is one of the most important elements in providing reliability in a
vessel’s operation?

a) Proper welding procedure in accordance with ASME Code

b) Regular scheduled external inspection made during equipment
operation
c) Highly trained operators
d) Avoidance of operational upsets

85. Certain insulated vessels are subject to CUI, among these are vessels
who are:

a) Going from low temperature to high temperature conditions

b) Going from high temperature conditions to low temperature conditions
c) Undergoing metallurgical and chemical changes
d) Exposed to mist or overspray from cooling towers

86. Many of the problems that may develop in pressure vessels can be
traced to faulty materials or fabrication, what are some of the
problems?
a) Out of plump shells
b) Obtuse components
c) Cracking, leakage, blockage and excessive corrosion
d) Out of alignment source piping

87. One advantage of doing external inspection while a vessel is in service

is,

a) The vessel then do not require internal inspection

b) The plant can continue to operate until the vessel shows signs of
failing
c) The required work load can be reduced for the vessel during
out of service Inspections
d) Extra personnel can be eliminated during shutdown period

88. A drum and a column are .

a) Storage tanks
b) Globe valves
c) Fittings
d) Pressure vessels
89. Causes carbon steel to corrode very quickly.

a) Air
b) Fresh water
c) Salt water
d) Gate valves

90. Liquids and vapors enter pressure vessels at the .

a) Inlet nozzle
b) Outlet nozzle
c) Flares
d) Slop storage tank

91. The most common forms of CUI on vessels are of what descriptions?

a) Asbestos under scale attack and localized corrosion of carbon steel

b) Asbestos under scale attack and chloride stress corrosion cracking of
austenitic stainless steels
c) General corrosion of carbon steel and binate corrosion of stainless steel
d) Localized corrosion of carbon steel and chloride stress
corrosion cracking of austenitic stainless steels

92. Leaks in a vessel are best found using what test method?

a) Vacuum testing
b) Acoustic emission
c) Pressure testing
d) MT or PT

93. As regards to a heat exchanger that has two fixed tube sheets, the
major disadvantage it has is,

a) It is limited in its diameter

b) The bundle are hard extracts
c) The shell side cannot be exposed for cleaning
d) Its length is limited to 30 feet.
94. Which of the following describes an induced draft air cooled heat
exchanger?

a) The tubes are finned

b) The tubes are usually made of aluminum
c) The fan is located above the tubes
d) The fan is located below the tubes

95. When inspecting heat exchanger bundles, an overall heavy build up of

scale on steel tubes should raise a suspicion that it has experienced
what condition?

a) Loss of process control during operation

b) Very dirty cooling mediums ( usually cooling water
c) General corrosion of tubes
d) Has suffered from microbiological attack

96. Tubes maybe tested for thickness during visual inspection using
different techniques, one of the most common and faster is to :

a) Tap the tubes using a light ball peen hammer

b) Ultrasonic thickness testing of the tubes
c) Measure the thickness using outside calibers
d) Eddy current testing

97. Locations where impingement corrosion in an exchanger is most likely

to occur include:

a) The outside surfaces of the tubes at each end of the exchanger

b) The outside surfaces of the tubes opposite shell inlet
nozzles
c) The outside surfaces of tubes opposite shell outlet nozzles
d) The inside surfaces of tubes opposite the channel head

98. A very common problem with Air-Cooled exchangers is the presence of

corrosion at the inlets, this is best found by,

a) Inspection using NDT

b) Visual inspection through the header-box plug holes
c) Removal of tube bundle
d) Pressure testing
99. Which of the following markings cannot be found on an ASME Code
vessel’s name plate?

a) The manufacturer’s serial number

b) The manufacturer’s name
c) The year built
d) The name of all welders who worked on the vessel

100. Corrosion underneath insulation and fire proofing exist due to

cracks allowing moisture to penetrate the steel and hidden corrosion
takes place. This corrosion normally occurs when the system is
operated at approximately:

a) Above 250F
b) Below 250F
c) Below 25F
d) At 225F

101. A visual external inspection of above ground pressure vessels is

required:

a) At least every 5 years

b) One quarter corrosion life
c) At least every 5 years or same as the required internal
inspection, whichever is less
d) At least every 5 years or same as the required internal inspection,
whichever is greater

102. The primary difference between an alteration and repair is:

a) Material considerations
b) Welding considerations
c) Design considerations
d) Inspector opinion
103. The scope of API 510 does not include:

a) Unfired steam boilers

b) Fractionating column
c) Heat exchangers
d) Fired heaters
104. An exchanger that has a tube bundle is free to move, which
permits free expansion and contraction with temperature changes is a,

a) Floating tube sheet exchanger

b) Floating header exchanger
c) Floating body exchanger
d) Fixed U tube heat exchanger

105. Erosion problems would be more likely in which of the following

conditions:

a) Sampling lines
b) Impingement point across from a vessel nozzle inlet
c) The bottom of a fractionating column
d) The bottom of a kettle type reboiler

106. External piping is connected to a vessel. The scope of ASME VIII

stops at:

a) The second welded joint

b) The first flange connection
c) The first stop valve
d) The first pipe hanger

107. Out of the many methods of inspection is

considered the most universally accepted method of inspection.

a) Radiographic examination
b) Careful visual inspection
c) Ultrasonic thickness measurements
d) Hammer testing

108. If external or internal coverings, such as insulation, refractory

protective linings, and corrosion resistant linings are in good condition
and there is no reason to suspect that unsafe condition is behind
them,:

a) It is not necessary to remove them for inspection

b) It is necessary to remove them completely for inspection
c) It is necessary to remove them for partial inspection
d) It is required to remove them completely for inspection on some set
intervals.
109. The most common material used to construct pressure vessels
is:

a) Titanium
b) Austenitic stainless steel
c) Monel carbon steel
d) Carbon steel

110. Construction codes are periodically revised as the designs of

pressure vessels improve and as new construction materials become
available. A pressure vessel should be maintained according to the:

a) Requirements under which it was designed and constructed

b) Standards and specifications of the owner/user
c) Principles and specifications of the jurisdiction
d) Guidelines of NBIC

111. The basic reasons for inspection are:

a) To meet the prerequisites of the ASME Code

b) To fulfill the provision of the API 510
c) To satisfy the requirements of OSHA
d) To determine the physical condition of the vessel and to
determine the type, rate, and cause of deterioration

112. Erosion is the attrition of a surface by:

a) Loss of material caused by sulfur and chloride components

b) Attrition of material caused by acid or caustic attack
c) The impingement of solid particles or liquid drops
d) Wearing down of a material caused by oxidation

113. Many problems with pressure vessels are caused by faulty

fabrication. Which item on the following list is not related to faulty
fabrication:

a) Poor welding
b) Chloride stress corrosion cracking
c) Improper heat treatment
d) Dimensional intolerance
114. The external inspection of pressure vessel should start with:

a) Vessel foundation and anchor bolts

b) Ladders, stairways, platforms or walkways connected or
bearing on vessel
c) Nozzles and connecting piping
d) Protective coating and insulation