Vol_1_API_570

6 Days Course on
API 570: certification preparatory course

for
AUTHORISED PIPING INSPECTOR
COURSE NOTES
VOLUME – 1
CONDUCTED BY
Asian Academy Of Professional Training

Pune, INDIA
Instructor
Narendra Sadashiv Thatte
PUNE INDIA
18 - 23 SEPTEMBER 2023
API 570 - PIPING INSPECTOR COURSE
PROGRAM SCHEDULE
DAY-1
• Pre-course Test
• Introduction to API 570 certification
• ASME B 31.3 Scope and applicability
• Service/Fluid Classification
• Joint Quality Factors
• Allowable stresses
• Design for Internal Pressure
• Design of permanent blanks
• Impact testing for Low temperature service
• Acceptance of Impact test results
• Welding requirements-Preheat Temperatures
• Post Weld Heat Treatment
• Hardness Testing after PWHT
• Inspection and testing
• Non Destructive Examination Requirements
• Acceptance Criteria
• Leak testing-Hydrostatic
• Leak testing-Pneumatic
• Precautions during Pneumatic test
• Thermal Expansion of Piping-Table C1
• ASME B16.5, Pipe Flanges and Flanged Fittings Scope
• Pressure Temperature Ratings, Dimensions of Flanges
• System pressure Test
DAY-2.
• Scope of API 570
• Definitions Owner/user inspection organization
• API authorized piping inspector qualification and certification
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• Inspection and testing practices.
• Risk-based inspection
• Preparation for inspection
• Inspection for specific types of corrosion and cracking
• Introduction to Damage mechanisms API 571
• Types of inspection and surveillance
• Thickness measurement locations
• Thickness measurement methods
• Inspection of welds in-service
• Inspection of flanged joints.
DAY-3.
• Frequency and extent of inspection
• Piping service classes
• Inspection intervals
• Extent of visual external and cui inspections
• Inspection data evaluation, analysis, and recording
• Corrosion rate determination
• Case Studies
• Maximum allowable working pressure determination
• Case studies
• Overview of API 574 Inspection of piping, tubing, valves, and fittings
• Repairs, alterations, and rerating of piping systems
• Inspection of buried piping
• Types and methods of inspection
• Frequency and extent of inspection
• Repairs to buried systems
DAY-4.
• ASME boiler and pressure vessel code, Sec. IX
• Review of a WPS and PQR
• Essential and Nonessential Variables
• Determine that the number and type of mechanical tests are correct tests
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• Determine whether the results are acceptable
• ASME Section V, nondestructive examination
• Article 1, general requirements
• Article 2, radiographic examination
• Article 6, liquid penetrant examination
• Article 7, magnetic particle examination (yoke and prod techniques only)
• Article 9, visual examination
• Article 10, leak testing and Mandatory Appendix I Bubble Test –Direct
Pressure Technique
• Article 23, Ultrasonic Standards, Section SE–797 only
• API RP 571, Damage mechanisms in the Refining Industry
3.3 Amine Stress Corrosion Cracking
3.8 Atmospheric Corrosion
3.9 Boiler Water and Stream Condensate Corrosion
3.14 Caustic Corrosion
3.15 Caustic Stress Corrosion Cracking
3.17 Chloride Stress Corrosion Cracking
3.22 Corrosion Under Insulation
3.27 Erosion/Erosion – Corrosion
3.31 Galvanic Corrosion
3.37 Hydrochloric Acid Corrosion
3.43 Mechanical Fatigue (Including Vibration-induced Fatigue)
3.45 Microbiologically Influenced Corrosion
3.57 Soil Corrosion
3.58 Sour Water Corrosion (Acidic)
3.61 Sulfidation
DAY-5.
• ASME PCC – 2: Repair of Pressure Equipment and Piping
1. Article 201: Butt-Welded Insert Plates in Pressure Components
2. Article 206: Full Encirclement Steel Reinforcing Sleeves for Piping
3. Article 209: Alternatives to Post-weld Heat Treatment
4. Article 210: In-Service Welding on to Carbon Steel Pressure Components or
Pipelines
5. Article 211: Weld Build-up, Weld Overlay, and Clad Restoration
6. Article 212: Fillet Welded Patches
7. Article 304: Flaw Excavation and Weld Repair
8. Article 305: Flange Repair and Conversion
9. Article 306: Mechanical Clamp Repair
10. Article 501: Pressure and Tightness of Piping and Equipment
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11. Article 502: Nondestructive Examination in Lieu of Pressure Testing for
Repairs and Alternations
DAY-6.
• Overview of API RP 577, Welding Inspection and Metallurgy

• API RP 576, Inspection of Pressure-Relieving Devices
6.1 Reasons for Inspection and Testing
6.2 Shop Inspection/Overhaul
6.3 Inspection, Testing, Maintenance, and Setting of Direct-acting Spring-
loaded Valves on Equipment
8 Pressure-relief Valve Visual On-stream Inspection
8.1 General
8.2 Post-relief Event
10 Records and Reports
10.1 General
10.2 The Need to Keep Records
10.3 Responsibilities
• Overview of API Recommended Practice 578 – Material Verification program for

New and Existing Alloy piping Systems
Final Examination
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BODY OF KNOWLEDGE
API 570 AUTHORIZED PIPING INSPECTOR
CERTIFICATION EXAM
2023 (Replaces 2022)
API Authorized Piping Inspectors must have a broad knowledge base relating to maintenance, inspection, alteration, and
repair of in-service metallic piping systems. The API Authorized Piping Inspector Certification Exam is designed to
determine if applicants have such knowledge.
Questions may be taken from anywhere within each document in this BOK, unless specifically excluded herein.
If specific sections of a document are listed as excluded– all other sections within that document are included.
In some cases, specific paragraphs, or sections, such as the example shown below, are included as an aid to the candidate.
This is not intended to exclude other paragraphs.
For example: In the “Corrosion Rate and Inspection Intervals” section of this BOK (Section A, Sub-section 1), it
states:
The Inspector must be able to calculate:
a) Corrosion Rates (API 570, 7.1.2).
This means that the corrosion rate calculation will be found in 7.1.2 It does not mean that other paragraphs in that
section are excluded.
The exam consists of two parts. The closed-book part tests the candidate on knowledge and tasks requiring everyday working
knowledge of API Standard 570 and the applicable reference documents. The open-book portion of the exam requires the use
of more detailed information that the inspector is expected to be able to find in the documents but would not normally be
committed to memory. During the exam, applicants will be expected to choose the best answer from the options provided.
REFERENCE PUBLICATIONS:
A. API Publications:
API 570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems
API Recommended Practice 571, Damage mechanisms Affecting Fixed equipment in the Refining Industry
API Recommended Practice 574, Inspection Practices for Piping System Components
API Recommended Practice 576, Inspection of Pressure-Relieving Devices
API Recommended Practice 577, Welding Inspection and Metallurgy
API Recommended Practice 578, Guidelines for a Material Verification Program (MVP) for New and Existing Assets
B. ASME Publications:
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code:
Section V, Nondestructive Examination
Section IX, Qualification Standard for Welding, Brazing and Fusion Procedures; Welders; Brazers; and
Welding, Brazing and Fusing Operators
B16.5, Pipe Flanges and Flanged Fittings

B31.3, Process Piping
PCC-2, Repair of Pressure Equipment and Piping (Newly Added)
7/2022
Note: Refer to the Publications Effectivity Sheet on the ICP Website (www.api.org/ICP) for a list of specific editions,
addenda, and supplements of the reference publications that are effective for your exam date.
I. CALCULATIONS FOR EVALUATING THICKNESS MEASUREMENTS, INSPECTION INTERVALS,

AND PIPING INTEGRITY
A. Code calculation questions will be oriented toward existing in-service piping, not new piping. API Authorized Piping
Inspectors should be able to check and perform calculations relative to in-service deterioration, repairs, rerates, or
alterations, such as those included in the following eight categories.
Note: Candidates are expected to understand the US customary units (inches, feet, PSI, etc.) and the SI units (metric
system) and to use both system formulas.
1. CORROSION RATES AND INSPECTION INTERVALS
The Inspector should be able to understand inspection data and determine the thickness measurement and visual external
inspection intervals.
The Inspector must be able to calculate:
a) Corrosion Rates (API 570, 7.1.2)

b) Remaining Life (API 570, 7.2)
c) Inspection Interval (API 570, 6.3.3 & Table 1)
The formulas for performing the above calculations and rules for setting the inspection intervals may be "closed-book”
during the exam.
2. WELD JOINT QUALITY FACTORS AND CASTING QUALITY FACTORS
The inspector should be able to determine the weld joint quality factor “Ej” of a longitudinal pipe weld joint. The inspector
should be able to determine:
a) Casting Quality factor, Ec from ASME B31.3, 302.3.3(b) and Table A-1A
b) Weld Joint Quality factors from ASME B31.3, 302.3.4 and Table A-1B;
c) Increased Joint Quality Factors by performing supplemental NDE from ASME B31.3, Table 302.3.4;
Determining weld joint quality factor may be part of an internal pressure problem since the joint factor Ej is used in the
formulas for determining required thickness or internal design pressure.
3. INTERNAL PRESSURE / MINIMUM THICKNESS OF PIPE
The inspector should be able to determine:
a) The minimum required thickness or pressure design thickness of a straight pipe section for internal pressure only
(ASME B31.3, 304.1.1 and 304.1.2);
b) The minimum required thickness of a permanent blank for a given design pressure (ASME B31.3, 304.5.3);
c) The "MAWP" of corroded pipe, compensating for expected corrosion loss at the next inspection (API 570, 7.5)
The inspector should also be able to compensate for the corrosion allowance. (Add or subtract based on requirements
from the exam problem).
4. PRESSURE TESTING
The inspector should be able to:
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a) Demonstrate knowledge concerning hydrostatic leak testing (ASME B31.3, 345.4)
b) Demonstrate knowledge concerning pneumatic leak testing (ASME B31.3, 345.5)
c) Calculate a hydrostatic or pneumatic leak test pressure (ASME B31.3, 345.4 and 345.5)
5. IMPACT TESTING
The inspector should be able to:
a) Determine the minimum metal temperature of a material, which is exempt from impact testing (ASME B31.3,
323.2.2, Figure 323.2.2A and Table A-1).
b) Determine the minimum required Charpy V-notch impact values of a given material. (ASME B31.3, 323.3 and
Table 323.3.5)
6. PREHEATING AND HEAT TREATMENT REQUIREMENTS
The inspector should be able to determine which weld sizes require preheating and/or heat treatment. The inspector also
should be able to determine what is the required or recommended preheat temperature (ASME B31.3, 330 and Table
330.1.1).
7. THERMAL EXPANSION
The inspector should be able to determine the total thermal expansion of a material between temperatures (ASME B31.3,
Appendix C, Table C-1).
8. MINIMUM WALL THICKNESS & WORKING PRESSURES FOR FLANGES
The inspector should be able to determine the minimum wall thickness and working pressure requirements for flanges.
The inspector should also be able to:
a) Determine the working pressure and minimum/maximum system hydrostatic test pressure for a flange of specified
material and temperature (ASME B16.5, Section 2 and Table 1.1-1 and Tables 2-1.1 through 2-3.19 and Tables 2-
1.1C through 2-3.19C).
b) Determine the minimum dimensions of a given flange (ASME B16.5, Tables 7 through 22 and Tables 7C through
22C).
c) Determine maximum working pressure of a flange when given the design temperature, flange material and flange
class.
d) Determine maximum temperature of a flange when given the design pressure, flange material and flange class.
e) Determine most cost-effective flange when given the design pressure, design temperature, and flange material.
9. MINIMUM REQUIRED THICKNESS OF A PERMANENT BLANK (ASME B31.3, 304.5.3)
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B. The following are the ASME B31.3 code engineering requirements that are excluded from the examination and
that the API Authorized Piping Inspectors will NOT be expected to know for the purposes of certification testing.
1. 302- Design criteria – (All except for 302.3.3 Casting Quality Factor, Ec, and 302.3.4, Weld Joint Quality Factor, Ej)
2. 304.1.3- Straight Pipe Under External Pressure
3. 304.2- Curved and Mitered Segments of Pipe
4. 304.3- Branch Connections
5. 304.4- Closures
6. 304.5- Pressure Design of Flanges and Blanks (All except 304.5.3, Blanks)
7. 304.6- Reducers
8. 304.7- Pressure Design of Other Components
9. 315- Tubing Joints
10. 316- Caulked Joints
11. 317- Soldered and Brazed Joints
12. 318- Special Joints
13. 319.4- Flexibility Analysis
14. 319.5- Reactions
15. 319.6- Calculation of Movements
16. 319.7- Means of Increasing Flexibility
17. 322.3- Instrument Piping
18. Chap.VII- Nonmetallic Piping and Piping Lined With Nonmetals
19. Chap.VIII- Piping for Category M Fluid Service
20. Chap.IX- High Pressure Piping
21. App.B- Stress Tables and Allowable Pressure Tables for Nonmetals
22. App.D- Flexibility and Stress Intensification Factors
23. App.E- Reference Standards
24. App.G- Safeguarding
25. App.H- Sample Calculations for Branch Reinforcement
26. App.J- Nomenclature
27. App.K- Allowable Stresses for High Pressure Piping
28. App R - Use of Alternative Ultrasonic Acceptance Criteria
29. App.X- Metallic Bellows Expansion Joints
30. App.Z- Preparation of Technical Inquiries
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II. WELDING PROCEDURE AND QUALIFICATION EVALUATION
A. ASME BPVC SECTION IX
The inspector should have the knowledge and skills required to review a Procedure Qualification Record, Welding Procedure
Specification and Welder Performance Qualification to determine the following:
1. Determine if procedure and qualification records are in compliance with applicable ASME Boiler and Pressure Vessel
Code and any additional requirements of API 570. The weld procedure review will include:
• Weld Procedure Specification (WPS)
• Procedure Qualification Record (PQR)
• Welder Performance Qualification (WPQ)
2. Determine if all required essential and non-essential variables have been properly addressed. (Supplemental essential
variables will not be a part of the WPS/PQR)
3. Determine that the number and type of mechanical tests that are listed on PQR are the proper tests, and whether the
results are acceptable.
4. Determine that the welder is qualified to make a production weld according to the WPS
WELD PROCEDURE REVIEW MAY INCLUDE SMAW, GTAW, GMAW, OR SAW, WITH THE FOLLOWING
LIMITATIONS:
1. No more than one process will be included on a single WPS, PQR or WPQ and the WPS to be reviewed will be
supported by a single PQR.
2. Filler metals will be limited to one-per-process for SMAW, GTAW, GMAW, or SAW
3. The PQR will be the supporting PQR for the WPS.
4. The WPQ test coupon is to be welded in accordance with a qualified WPS.
5. Base metals will be limited to P-No. 1, P-No. 3, P-No. 4, P-No. 5, and P-No. 8.
6. Dissimilar base metal joints, and dissimilar thicknesses of base metals will be excluded.
7. Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and dissimilar metal welds
with buttering of ferritic member will be excluded.
8. For P-No. 1, P-No. 3, P-No. 4, and P-No. 5, for the purpose of the exam the lower transition temperature will be 1330°F
and the upper transformation temperature will be 1600°F.
B. ASME B31.3
The inspector should be familiar with and understand the general rules for welding in ASME B31.3, Chapter V such as:
1. Typical joints and definitions

2. Weld sizes
3. Restrictions on joints
4. Maximum allowable reinforcement
5. Inspection requirements
6. Preheating and Heat Treatment
C. API 570
The inspector should be familiar with and understand any rules for welding in API 570. Any rules for welding given in API-
570 shall take precedence over those covering the same areas in ASME, B31.3.
Note: "Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are
excluded. This includes items such as the revision level of the WPS, company name, WPS number and date, and name of
testing lab. However, the API Authorized Piping Inspector should know that the PQR and WPQ must be signed and dated.
D. The inspector shall be familiar with all the requirements of and information in API RP 577.
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III. NONDESTRUCTIVE EXAMINATION
A. ASME Section V, Nondestructive Examination
Note: The exam will cover only the main body of each referenced Article, except as noted.
1. Article 1, General Requirements:

The inspector should be familiar with and understand;
a) The Scope of Section V

b) Rules for use of Section V as a referenced Code
c) Responsibilities of the Owner / User, and of subcontractors
d) Calibration
e) Definitions of "inspection" and examination"
f) Record keeping requirements
2. Article 2, Radiographic Examination:

a) The Scope of Article 2 and general requirements,

b) The rules for radiography as typically applied on butt welded seams such as, but not limited to:
• Required marking
• Type, selection, number, and placement of IQI’s,
• Allowable density and density ranges
• Control of backscatter radiation
c) Records
3. Article 6, Liquid Penetrant Examination (Including mandatory appendices II and III):

The inspector should be familiar with and understand the general rules for applying and using the liquid penetrant
method, including but not limited to the following:
a) The Scope of Article 6,

b) General requirements such as but not limited to:
• Procedures
• Contaminants
• Techniques
• Examination
• Interpretation
• Documentation and record keeping
4. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

The inspector should be familiar with and understand the general rules for applying and using the magnetic particle
method including, but not limited to the following:
a) The Scope of Article 7,

• Procedures
• Techniques (Yoke and Prod only)
• Calibration
• Examination
• Interpretation
c) Documentation and record keeping
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5. Article 9, Visual Examination:
The inspector should be familiar with and understand the general rules for applying and using the visual examination
method including, but not limited to the following:
a) The scope of Article 9,

• Procedures
• Physical requirements
• Procedure/technique
• Evaluation
6. Article 10, Leak Testing (Including Mandatory Appendix I Bubble Test –Direct Pressure Technique):
The inspector should be familiar with and understand the general rules for applying and using the leak testing method
including, but not limited to the following:
a) The scope of Article 10,

• Procedures
• Equipment
• Calibration
• Test
• Evaluation
7. Article 23, Ultrasonic Standards, Section SE–797 only – Standard practice for measuring thickness by manual ultrasonic
pulse-echo contact method:
a) The Scope of Article 23, SE-797,

b) The general rules for applying and using the Ultrasonic method
c) The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.
B. ASME B31.3 and API 570: General nondestructive exam requirements:
ASME B31.3: The inspector should be familiar with and understand the general rules for NDE (Chapter VI).
API 570: The inspector should be familiar with and understand the general rules for NDE in API 570.
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IV. PRACTICAL KNOWLEDGE - GENERAL
The following topics may be covered:
1. Organization and Certification Requirements.

2. Types and Definitions of Maintenance Inspections.
3. Welding on Piping
4. Corrosion and Minimum Thickness Evaluation.
5. Estimated Remaining Life.
6. Inspection Interval Determination and Issues Affecting Intervals.
7. Maintenance Inspection Safety Practices.
8. Inspection Records and Reports.
9. Repairs/Alterations/Reratings to Piping.
10. Rerating Piping.
11. Pressure Testing After Repairs, Alterations, or Rerating
12. Pressure Temperature Ratings
13. Markings
14. Materials
15. Dimensions
16. Test
17. Limiting Dimensions of Gaskets
18. Methods for Establishing Pressure-Temperature Ratings
19. Methods of performing positive material identification and related record keeping.
More information relative to each of the categories is contained in section "V. PRACTICAL KNOWLEDGE - SPECIFIC"
where each reference publication applicable for study for the exam has been listed with relevant topics that may be covered
on the exam.
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V. PRACTICAL KNOWLEDGE - SPECIFIC
• API 570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems – Entire document is subject to
testing
• API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
ATTN: Exam questions will be based on the following portions of the document only:
Section 2 Definitions
Par. 3.3 Amine Stress Corrosion Cracking
3.57 Soil Corrosion
3.61 Sulfidation
• API RP 574, Inspection of Piping, Tubing, Valves, and Fittings – Entire document is subject to testing
• API RP 576, Inspection of Pressure-Relieving Devices

ATTN: Exam questions will be based on the following portions of the document only:
Sections 5
Sections 6.1-6.3
Section 8
Sections 10.1-10.3
• API RP 577, Welding Inspection and Metallurgy – Entire document is subject to testing
• API RP 578, Material Verification program for New and Existing Alloy piping Systems- Entire document is subject
to testing
• ASME B16.5, Pipe Flanges and Flanged Fittings

o Scope
o Pressure Temperature Ratings
o Markings
o Materials
o Dimensions
o Test
o Limiting Dimensions of Gaskets
o Methods for Establishing Pressure-Temperature Ratings
• ASME PCC-2, Repair of Pressure Equipment and Piping

ATTN: The examination will cover each referenced Article and its Appendices.
Article 201: Butt-Welded Insert Plates in Pressure Components
Article 206: Full Encirclement Steel Reinforcing Sleeves for Piping
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Article 209: Alternatives to Postweld Heat Treatment
Article 210: In-Service Welding on to Carbon Steel Pressure Components or Pipelines
Article 211: Weld Buildup, Weld Overlay, and Clad Restoration
Article 212: Fillet Welded Patches
Article 304: Flaw Excavation and Weld Repair
Article 305: Flange Repair and Conversion
Article 306: Mechanical Clamp Repair
Article 501: Pressure and Tightness of Piping and Equipment
Article 502: Nondestructive Examination in Lieu of Pressure Testing for Repairs and
Alternations
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API 570 Exam Publications Effectivity Sheet
FOR: 2023
Listed below are the effective editions of the publications required for this exam for the date(s) shown above.
Please be advised that API and ASME documents and publications are copyrighted materials.
Reproducing these documents without API permission is illegal.
API Standard 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-Service Piping
Systems, 4th Edition, February 2016 with Addendum 1 (May 2017), Addendum 2 (March 2018) and Errata 1
(April 2018)
API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry,
3rd Edition, March 2020
ATTENTION: Only the following sections / mechanisms from RP 571 are included on the exam:
Section 2 Terms and Definitions
Par. 3.3 Amine Stress Corrosion Cracking
3.57 Soil Corrosion
3.61 Sulfidation
API Recommended Practice 574, Inspection Practices for Piping System Components, 4th edition, November
2016.
API Recommended Practice 576, Inspection of Pressure-Relieving Devices, 4th Edition, April 2017.
Sections 5, 6.1-6.3, 8 and 10.1-10.3
API Recommended Practice 577, Welding Inspection and Metallurgy, 3rd Edition, October 2020
API Recommended Practice 578, Material Verification Program for New and Existing Alloy Piping Systems, 3rd
Edition, February 2018.
American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2021 Edition
I. Section V, Nondestructive Examination, Articles 1, 2, 6, 7, 9, 10, and 23 (Section SE-797 only).
II. Section IX, Qualification Standard for Welding, Brazing and Fusion Procedures; Welders; Brazers; and
Welding, Brazing and Fusing Operators, (Welding only)
American Society of Mechanical Engineers (ASME)

B16.5, Pipe Flanges and Flanged Fittings, 2020 Edition (Issued January 2021)
B31.3, Process Piping, 2020 Edition (Issued June 2021)
570_EffSheet 2023 7/2022

Newly Added Document and Sections beginning in February 2023
PCC-2, Repair of Pressure Equipment and Piping, 2018

ATTENTION: Only the following sections from PCC-2 are included on the exam:
Article 201: Butt-Welded Insert Plates in Pressure Components
Article 206: Full Encirclement Steel Reinforcing Sleeves for Piping
Article 209: Alternatives to Postweld Heat Treatment
Article 210: In-Service Welding on to Carbon Steel Pressure Components or Pipelines
Article 211: Weld Buildup, Weld Overlay, and Clad Restoration
Article 212: Fillet Welded Patches
Article 304: Flaw Excavation and Weld Repair
Article 305: Flange Repair and Conversion
Article 306: Mechanical Clamp Repair
Article 501: Pressure and Tightness of Piping and Equipment
Article 502: Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alternations
_________________________________________________________________________
Please ensure you obtain authorized documents from one of API’s redistributors:
Techstreet: www.techstreet.com; Phone: 1-800-699-9277
IHS Documents: www.global.ihs.com; Phone: 1-800-854-7179
570_EffSheet 2023_
ATTENTION
Announcing some changes to API 510, 570 and 653

examination administrations
Beginning with the December 5, 2012 exam administration API will make two minor changes to
the API 510, 570 and 653 examination processes. API believes that these changes will help to
maintain the value of our credentials by improving the exam experience for all candidates and
keeping exam content current, relevant and free of errors.
1. The number of questions by which test takers will be graded or scored.

The API 510, 570 and 653 tests in the past have always contained 150 questions on
which candidates were scored. These exams will now contain 125 scored questions,
plus 25 questions that will not be scored (otherwise known as "pre-test" items).
All exam grading will still be based on the number of correct responses. The minimum
number of correct responses required to achieve a passing score will be established
based on the 125 scored items only. API will continue to utilize the statistical method of
equating in order to maintain the same level of difficulty of the exams. The equating
process will take into account that 25 of the test questions are now “pre-test” questions
and establish an accordingly reduced passing grade for all exams.
The pre-test questions will appear on all tests for all candidates; so each test taker
receives the same, fair experience. Test takers will not know which test questions are
scored and which are not.
2. Exam day will be shortened.

The total time allotted to candidates to complete an examination will be reduced from 8
hours to 7 hours. In analyzing the details of tests taken previously, it has become clear
that the overwhelming majority of test takers complete their examinations in 6-7 hours.
API has therefore decided to officially shorten the length of the exams and is completely
confident that candidate performance will not be hindered in any way. The open book
section of the exam will remain 4 hours long. The closed book part will now be only 3
hours. This change will also allow candidates and proctors to have a slightly longer
lunch break.
FAQ
What stays the same?
The most important thing that will stay the same is that the exams will still yield accurate, fair
results for all candidates. The test will still have 150 total questions to be answered. Using pre-
test items on an exam in no way impacts scoring or test taker performance, since test takers are
unable to identify which questions are scored and which are not. Test takers shouldn't notice
any difference at all. The minimum passing score will be calculated based on the 125 scored
items. Each scored item will continue to be worth 1 point each.
7_2012‐Effective beginning 12_2012

What is a pre-test question?
Pre-test questions are usually newly-written or recently revised questions. These questions
need to be vetted by the candidates before being approved.
What is the purpose of using pre-test questions?
Using pre-test items is a standard practice in the certification industry. It helps determine
whether the new questions are valid, reliable and fair to be used for scoring on future exams.
Candidates will continue to be able to challenge every item on the test. When reviewing the
challenges we receive on pre-test questions, we will easily find out whether those questions are
misleading, unfair, or not written well. We will then be able to improve these questions before
they appear on any exams again.
In the long run, pre-testing will allow us to improve the overall quality of the exam questions and
reduce the number of challenges received after each exam administration.
Does the use of pre-test question impact how scoring works?
Absolutely not. Exams will be scored in terms of number of correct responses. The passing
score will be based on a minimum number based on 125 items. The use of pre-test items does
not impact the overall exam difficulty or question difficulty in any way.
How will the passing score be comparable to the score required on the 150 item test?
API makes every effort to select questions that are equal in difficulty for every new examination
we develop. However, sometimes there are slight variations in difficulty levels from one exam to
the next. API will continue to use the “equating” method to establish comparable scores on the
examinations. The equating process essentially adjusts the passing point of each examination
to compensate for differences in the difficulty level of the two exams. Thus, the passing point
always represents the minimum knowledge required and the absolute knowledge standard is
held constant. The test results of candidates only reflect whether they have this minimum
amount of knowledge or not. The equating process will take into account that there are only 125
test questions to score and establish an accordingly reduced passing grade for all exams.
Are exams marked on a curve?
No. Marking on a “curve” means comparing the scores of one candidate to all the other
candidates who took the examination and assigning grades or passing status according to a
fixed percentage. The implication is that whether an individual passes the examination or not
might depend on the ability level (or preparation) of all the other candidates who took the
examination. This would not be fair for a credentialing examination.
7_2012‐Effective beginning 12_2012

Step-by-step certification process
Please complete the following steps in order to get certified:
1. Check the minimum qualification requirements for your chosen certification program to
determine your eligibility for certification.
2. Review API's testing and certification policies, exam calendar and deadlines.
3. Determine the most convenient examination window for your chosen program.
4. Activate your account or register a new one at our application portal:
https://inspector.api.org
5. Be prepared to upload necessary information – such as copies of your diplomas, proof of
payment (copy of your check or wire payment). You will also need to provide business e-
mail addresses for supervisors who will confirm your experience and employment (two
contacts per company).
6. Follow the instructions on the portal to submit your application.
7. If paying my check or wire, make sure you mail the payment to API by the deadline
indicated. In order to identify your payment, please include your name and ICP order
number, or a copy of the invoice.
8. Download the Body of Knowledge for your chosen program.
9. Obtain necessary technical documents and publications. Document titles and relevant
edition numbers can be found on the Publications Effectivity Sheet published for each
program (http://www.api.org/certification-programs/individual-certification-program-
icp/specific-info). Instructions for ordering publications are on the effectivity sheets.
10. Prepare for the examination. Training programs are optional and are not provided by
API.
11. Once you receive the exam authorization letter from API, you must log on to the
Prometric website ( www.prometric.com/apiexams) and register yourself at a location
and exam date of your choice. NOTE: It is mandatory that you schedule your exam date
and location. API staff will not be able to schedule you.
12. Once you register, Prometric’s website will issue you an exam confirmation notice which
you could print and bring to the exam.
13. Take the examination on the scheduled date and time.
14. Examination scores and results are sent to each applicant via e-mail approximately 8
weeks after the examination. API will issue a certification number and forward an actual
certificate and wallet card to each successful candidate who has provided all necessary
paperwork and has passed the examination.
StepbyStep 10/2013
Welcome to the computer-based exam tutorial for the API 510, 570 and 653 exams.
* These items will be identified by a line that states “This may have more than one correct answer, please select all
answers that apply.”
1 2 3 4 5 6 7 8
Items 1-4, the arrows are used to pan within a zoomed image.
Items 5 & 6, Use the +/- magnifying glass to zoom in or out.
Item 7, Use the refresh (circular arrows) button to return the image back to its original zoom.
Item 8, Use the four-way arrow button to return the image back to its original zoom.
The exhibit window can be moved and adjusted (minimized, maximized, resized) much like you would any other window
on a computer screen.
* On the image on the next page, the bookmark icon is circled in red.
* To remove the PDF dropdown menu from view, click on the library button a second time.
Drag and Drop:
Applicants will be presented with a list of options and must select all that answer the question by placing them in the provided
answer box.
The applicant may remove a selection from the box by clicking and holding the option and dragging it out of the box.
Applicants will answer the question correctly only if they place all correct options in the provided box. If any option placed in the box
is incorrect, the question is wrong. No partial credit is given.
Ordered Response:
Applicants will be asked to identify the correct order of a process. Several options will be listed under the question and applicants
must arrange them, by clicking and dragging, in the correct step order in the boxes provided below the question. All options will be
used in the answer and no options will be used twice.
To answer the question correctly, an applicant must place all options in the right order. If any option is out of order, then the
question is incorrect. No partial credit is given.
Extended Matching
Applicants will be presented with two columns and be asked to match options on the left with options on the right. To
match the options, click on option box on the left or the right and then click on the corresponding answer in the
opposite column. When a match is made a black line will appear between the matches.
If you wish to un-match two boxes, place the curser over the line, which will turn red, and a scissor symbol will appear.
Click the symbol to remove the line.
Extended matching questions will be correct if the options in the left and right columns are correctly matched. No partial
credit will be given.
* For each exam section, closed book and open book, if “Finish Section” is clicked before time is up, warnings will be
displayed to ensure that the candidate confirms that they wish to leave the section. Two warnings pop-ups will be
issued, and candidates must answer “Yes, I would like to finish this section” and “finish section.”
Question Screen:
GUIDELINES FOR ACHEVING SUCCESS IN API 570 EXAMINATION
INTRODUCTION
API Individual Certification Programs are designed to promote self-regulation,
health and safety, improved inspection capabilities, and improved management
control and environmental performance. Certified inspectors are recognized as
working professionals who are fully knowledgeable of industry inspection codes,
and who are performing their jobs in accordance with those requirements.
API's Individual Certification Programs (ICP) are based on industry-developed

standards that are recognized and used with confidence worldwide. These
standards have also provided a uniform platform that serves as a model for
many state and government regulations. These API programs emphasize
professional credibility and process integrity and provide an essential
springboard for inspectors to make even more valuable contributions to the
safety and quality of industry operations.
This course provides the participants the guidelines and methodology of

carrying out inspection of “in-service” equipments. It also provides techniques
for the assessment of the wear and tear of the equipments as well as to measure
de-gradation and damages caused to the process equipments due to the process
conditions. It also helps the participant to successfully sit for the API-570 exam.
The majority of the classroom study will focus on the Body of Knowledge. The
goal, is to obtain a perfect score. Therefore please take your daily classroom
activity and assigned homework seriously. The material contained in this manual
is to be thoroughly studied and practiced prior to attending the course. The math
examples and practice problems are based on the types of questions given on the
API-570 exam. Through the use of these examples, you will be exposed to many
of the formulas used during the course.
57 | 2 2 9
The Examination
In order to take API 570 examination, you must possess one of the following
combinations of education and experience
Refer to site
• http://www.api.org/products-and-services/individual-
certification-programs/certifications
• The API 570 exam day is 8.5 hours long, and includes a short tutorial
session, 3 hours for the closed-book portion, a 1-hour lunch break, and 4
hours for the open-book section.
• There are 150 questions on the API 570 exam, of which only 125 are
scored. The remaining 25 are pretest questions.
• A few of the multiple-choice questions will require you to perform a
calculation. You will need to perform the calculation and then pick the
correct answer.
• Each question is multiple choice questions with given 4 possible choices.
Only one is the correct choice.
• Papers and books are not allowed in Prometric computer testing centers.
PDF documents of pertinent codes and standards will be available on
58 | 2 2 9
your computer during the open book portion of the exam, and will be
presented in English.
The test is divided into two sections, a closed-book section and an open-book
section. The closed-book examination includes such questions which the
inspector is normally expected to know without referring the Codes, i.e., the
questions are “awareness level” questions. Whenever you find a very definitive
or quantitative statement in body of the Code, a closed book question may be
expected on it. Thus, the basic requirements of a code, specific “DO” and
“DON’T” statements, important quantified statements, important definitions and
well-known inspection principles will constitute such questions.
Where the student is required to refer to the diagrams or formulas or tables or

graphs and curves from the Codes, it will always be an “open-book” question.
Here the participant is expected not to remember the information but should
know where to find it in the body of the Code. No reference material of any kind
will be permitted during the closed book portion.
WEIGHTAGE OF MARKS
You have only a limited amount of time to study, so you need to invest your time
where you can get the MAXIMUM return! Approximately 50% of the test
questions are directly from API 570. So, that's your priority! For every hour spent
studying the other publications, spend 2 hours studying API 570.
There will be about 75 test questions directly from API 570. This document is
about 40 pages, that averages almost 2 questions per page. The remaining 65
questions will come from the 600+ pages contained in the other documents.
That's only 1 question for every 10 pages.
59 | 2 2 9
Following distribution scheme will help the participant to decide how much time
he should spend for each document during preparation.
Note: The weightage indicated is approximate and for guidance only.
A . API Publications:
API 570, Piping Inspection Code…………………………………45- 47%
API RP 571, Damage Mechanisms……………………………… 3-4%
API RP 574, Recommended practice. Inspection of Piping….… 3-4%
API RP 578, Material verification Program………………..…….. 3-4%
API RP 577, Welding Inspection and Metallurgy………………. 3- 4%
API RP 576, Inspection of Pressure-Relieving Devices, ………. 3-4%
B. ASME Publications:
Section V, Nondestructive Examination……………………………3-4 %
ASME B 31.3 Process piping code……………….………………….20-22%
ASME B 16.5 Flanges and flanged fittings………………………….2-3%
Section IX, Welding and Brazing Qualifications….………………..5-6%
ASME PCC 2 ………………………………………………………….. 3-4%
60 | 2 2 9
API 570- PIPING INSPECTOR PREPARATORY COURSE
(VOLUME- I)
Part- 2
Case studies illustrating use of code rules for
API 570- PIPING INSPECTORS
61 | 2 2 9
API 570 - PIPING INSPECTOR COURSE
CODE CALCULATIONS
(Thickness Determination)
Exercise-1.
Determine the Pressure design thickness and minimum required thickness for a piping with the
following design conditions:
Design Pressure = 500 psig (3447 KPa(g))
Design Temperature = 650 degrees F (344 Deg C)
Pipes to be used = A 53 gr. B Electric Resistance Welded (ERW)
Pipe size = NPS 6
Corrosion Allowance = 0.125 inch (3 mm)
62 | 2 2 9
CODE CALCULATIONS
Exercise-1. (SOLUTION)
/
1. Pressure Design thickness, t = PD 2 (SEW + PY)
Here, P = 500 psig (3447 KPa(g))

D= 6. 625 (168.28 mm) (Ref. table in API 574 )
S= 17,300 psi (118 MPa) Table A-1 (ASME B 31.3)
E= 0.85 Table A-1B (ASME B 31.3)
Y= 0.4 Table 304.1.1 (ASME B 31.3)
W= 1.0 Table 302.3.5 (ASME B 31.3)
Now, t = 500 x 6.625 / 2 [(17,300 x0.85x1) + (500 x 0.4)]
= 0.111 inch
Thus, Pressure Design thickness = 0.111 inch
t = 3447 x 168.28 / 2 [(118*1000 x0.85x1) + (3447 x 0.4)]
= 2.88 mm
Now Min. Required thickness tm =t + c.

Min. Required thickness = 0.111 inch + 0.125 inch (2.88 mm + 3 mm)
Min. Required thickness = 0.236 inch (5.88 mm)
63 | 2 2 9
CODE CALCULATIONS
Exercise-2.
Determine the Pressure design thickness and minimum required thickness for a piping with the
following design conditions:
Design Temperature = 700 degrees F (371 Deg C)
Pipes to be used = A 106 gr. C (Seamless)
Pipe size = NPS 12
Corrosion Allowance = 0.1 inch (2.54 mm)
64 | 2 2 9
CODE CALCULATIONS
/
1. Pressure Design thickness, t = PD 2 (SEW + PY)
Here, P = 800 psig (5516 KPa(g))

D= 12.75 (323.8 mm) (Ref. table in API 574 )
S= 18,300 psi (127 MPa) Table A-1 (ASME B 31.3)
E= 1.0 Table A-1B (ASME B 31.3)
Y= 0.4 Table 304.1.1 (ASME B 31.3)
W= 1 Table 302.3.5 (ASME B 31.3)
Now, t = 800 x 12.75 / 2 (18300 x 1 x 1 + 800 x 0.4)
= 0.273 inch
Thus, Pressure Design thickness = 0.273 inch
t = 5516 x 323.8 / 2 [(127x1000 x 1 x 1) + (5516 x 0.4)]
= 0.273 inch (6.91 mm)
Now Min. Required thickness tm =t + c.

Min. Required thickness = 0.273 inch + 0.1 inch (6.91 mm + 2.54 mm)
Min. Required thickness = 0.373 inch (9.54 mm)
65 | 2 2 9
CODE CALCULATIONS
(Thickness of Permanent Blank)
Exercise-3.
Find Minimum required Thickness of a seamless Permanent Blank to be inserted at a

flanged joint for the following piping:
Design Temperature = 600 OF (315 Deg C)
Blank Material A 516 Gr 60
Corrosion Allowance= 0.0625 inch (1.6 mm)
Gasket Internal Diameter = 8.0” (203 mm)
66 | 2 2 9
CODE CALCULATIONS
Min required thk for permanent blank
3P
Tm = dg +C
16SEW
P = 250 psig (1724 KPa(g))

C = 0.625 inch (1.6 mm)
S = 16400 psig (113 MPa)
E = 1.0
W = 1.0
dg = 8 inch (203 mm)
Key-in the values in above formula
Minimum required thickness = 0.427 inch +0.0625 inch (10.85 + 1.6)
Minimum required thickness = 0.490 inch (12.45 mm)
67 | 2 2 9
CODE CALCULATIONS
(Impact testing requirements)
Exercise-4.
Q.1 A Piping system is to be constructed using 12.7mm (0.50 inch) thick pipes. Pipe
specification is A 106 Grade A (de-oxidised). Design minimum temperature is 0
deg.C (32OF). Will you require impact testing as per ASME B 31.3?
Q. 2 If the Design minimum temperature in Q. 1 above is changed to - 40OC (-40OF).

Will impact testing be required?
Q. 3 If the Design minimum temperature in Q. 1 above is changed to -29OC (-

20OF). Will impact testing be required?
Q.4 If all conditions in Q. 1 above are same except that we now use 30 mm (1.18
inches) thick pipe . Will you specify impact test?
Q.5 Impact testing was conducted on A 106 Grade A pipes. Using 3 specimen.
Test impact values reported were:
Specimen 1 : 16 ft lb (21.7 J)
Specimen 2 : 15 ft 1b (20.3 J)
Specimen 3 : 11 ft 1b (14.9 J)
Is impact test acceptable?
68 | 2 2 9
CODE CALCULATIONS
(Impact testing requirements)
1) In this example Curve B will apply. Referring to Fig 323.2.2A , the point is
clearly above the curve, hence Impact Testing is not required.
2) Now the point lies clearly below the curve. Impact testing is required.
3) Now the point lies very close to the curve. Decision whether point is
above or below is difficult. Go to table 323.2.2A. We see that point is very close on
the curve. Impact testing is NOT required.
4) Now the Point is clearly below curve.

Impact test required.
5) Required Average for 3 specimen = 13 ft 1b (18 J)
Actual average obtained =16 + 15 + 11 = 14 ft 1b 21.7+20.3+14.9 = 18.96 J

3 3
Average obtained ,14 ft-lb > 13 ft lb (18.96 J > 18 J) ……. OK
Only one specimen has gone below the 13 ft-lb (18 J)

Its value must be more than 10 ft-lb (14 J). And its actual value=11ft-lb (14.9J).
11 > 10 ft-lb (14.9 > 14 J) -----------------OK
Both criteria of Average & minimum are satisfied – Test is accepted.
69 | 2 2 9
CODE CALCULATIONS
(Pressure testing requirements)
Exercise-5.
Following information is taken from data sheet for a Piping system.

Design Pr = 150 psig. (1034 KPa(g))
Stress value of the pipes at design temperature = 18000 psi (124 MPa)
Stress value at test temperature = 19800 psi (137 Mpa)
Calculate the following

Q.1 Hydrostatic Test Pressure
Q.2 Pneumatic Test Pressure
Q.3 Max. Relief value set Pressure for Pneumatic Test
Q.4 First stage pressure for Pneumatic Test
Q.5 Inspection pressure at which leak check shall be performed for Pneumatic Test
CODE CALCULATIONS
70 | 2 2 9
(Pressure testing requirements)
Exercise-5.(SOLUTION)
1) Hydrostatic Test Pr = 1.5 X Design pressure X Stress ratio

= 1.5 X 150 X 19800/18000 (1.5 X 1034 X 137/124)
= 1.5 x 150 x 1.1 (1.5 X 1034 X 1.1)
= 247.5 psig (1706 KPa(g))
2) Pneumatic Test Pr = 1.1 x Design pressure

= 1.1 x 150 (1.1 X 1034)
= 165 psig (1137 KPa(g))
3) Max. Relief Value set Pr. = 1.1 X Pneumatic Test Pr

= (165 + 0.1 X165) Or 165+50
= (1137 + 0.1x1137) Or 1137 + 345
whichever is low
= 181.5 psig (1250.7 KPa(g))
4) First stage pressure for Pneumatic is smaller of 50% of test pr. or 25 psi
= Smaller of 165/2 (1137/2) or 25 psig (170 KPa(g))
= 25 psi. (170 KPa(g)
5) Pneumatic Inspection Pressure = Design pressure = 150 psig ( 1034 KPa(g))
71 | 2 2 9
CODE CALCULATIONS
(Pre-heating temperatures)
Exercise-6.
Determine if pre-heating is required in following cases and if required, provide

minimum pre-heat temperature
Q.1 All pipes A 106 Gr B pipes ,NPS 10, Sch 80, % of Carbon = 0.28
Q. 2. A 106 Gr C pipes, NPS 12, Sch 80 pipe welded to NPS 12 Sch 160 pipe, % of
Carbon = 0.34
Q.3 All pipes A 335 Grade 12 , NPS 10 Sch 40 Strength is 60 KSI
Q.4 A 335 Grade P12 pipes NPS 10, Sch 80 pipes welded to A 335 Grade P5
pipes NPS 10, Sch 80 strength is 60 KSI
72 | 2 2 9
CODE CALCULATIONS
(Pre-heating temperatures)
Exercise-6.( SOLUTION)
1) Solution to Q.1
• For A106 Gr. B pipes P no. is 1
• Tensile strength is 60000 psi (414 MPa), % of carbon = 0.28
• Thickness for NPS 10 sch 80 is 0.594 inch (15.09 mm)
• From table 330.1.1 Preheat temp. = 50 OF (10 OC)
2) Solution to Q.2
• For A106 Gr. C pipes P no. is 1

• Tensile strength is 70000 psi (483 MPa) and % of Carbon = 0.34
• Thickness of NPS 12 sch 80 is 0.688 inch (17.48 mm). And Preheat temp = 50
OF (10 OC)
• Thickness of NPS 12 sch 160 is 1.312 in (33.32 mm). And Preheat temp. =
200 OF (93 OC)
• Preheat at Higher preheat temperature = 200 OF (93 OC)
3) For A 335 Gr.12 pipes, the P no. is 4.

From table 330.1.1 Preheat temp. = 250 OF. (121 OC)
4) For A 335 Gr.12 pipes P no. is 4. and For A 335 Gr.P5, the P no. is 5B
Thickness : 0.594 inches (15.09 mm)
For P no.4, Preheat temp= 250 OF (121 OC)
For P no.5B, Preheat temp= 300 OF (149 OC)
Use higher Preheat temp. = 300 OF (149 OC)
73 | 2 2 9
CODE CALCULATIONS
(PWHT Requirements)
Exercise-7.
Find out whether PWHT is required in following cases and if required, provide
minimum PWHT temperature and time. There is no Service related PWHT
requirement.
Q.1 All pipes A 106 Gr B, NPS 10, Sch 80, multilayer welding is carried out
Q.2 All pipes A 335 Grade 12, NPS 10 Sch 80,
(preheat of 250OF (121 OC) is applied and multilayer welding is carried out, %
of Carbon = 0.15)
Q.3 All pipes A 335 Grade P5, NPS 10 Sch 80
(preheat of 300OF (149 OC) is applied and multilayer welding is carried out, %
of Carbon = 0.15)
74 | 2 2 9
CODE CALCULATIONS
(PWHT Requirements)
Exercise-7.(SOLUTION)
1) Solution to Q.1
• For A106 Gr. B pipes P no. is 1

• Tensile strength is 60000 psi (414 MPa)
• Thickness for NPS 10 sch 80 is 0.594 inch (15.09 mm)
• From table 331.1.3 PWHT Not required
2) Solution to Q.2
• For A 335 Gr.12 pipes. the P no. is 4.

• Thickness for NPS 10 sch 80 is 0.594 inch. (15.09 mm)
• preheat of 250OF (121 OC) is applied and multilayer welding is carried out,
% of Carbon = 0.15
• From table 331.1.1 PWHT is NOT required
3) Solution to Q.3
• For A 335 Gr.P5 pipes. the P no. is 5B.

• Thickness for NPS 10 sch 80 is 0.594 inch. (15.09 mm)
• preheat of 300OF (149 OC) is applied and multilayer welding is carried
out, % of Carbon = 0.15
• From table 331.1.3 PWHT is required
• PWHT temp. = 1250 - 1400OF (675 – 760 OC) (Table 331.1.1)
• Holding time = 35 minutes minimum
75 | 2 2 9
CODE CALCULATIONS
(Thermal Expansion of Pipes)
Exercise-8.
1. Estimate the total length after heating if a 200 feet (61 meters) long, A 106 Gr.B pipe was
heated from 70OF (20 OC) to 800 OF (427 OC)
2. Estimate the contraction in A312 TP 304 pipe 200 feet (61 meters) if it was cooled from
atmospheric temperature 70OF (20 OC) to a low temperature -325OF (198 OC)
3. What will be the total length after heating if a 280 feet (85 meters) long pipe was heated
from 70OF to 900OF. Out of 280 feet (85 meters) length, 150 feet (45 meters) was Carbon
Steel and 130 feet (40 meters) was Austenitic Stainless steel (18Cr-8Ni)
76 | 2 2 9
CODE CALCULATIONS
(Thermal Expansion of Pipes)
Exercise-8.( SOLUTION)
1) Go to Table C-1 of ASME B 31.3

Thermal expansion for 100 feet = 6.8 inch (5.7 mm/meter)
For 200 feet the expansion = 13.6 inch (347.7 mm)
Total length after heating = 200 feet + 13.6 inch = 201 feet and 1.6 inch (61.348 meter)
Total length after heating =201 feet and 1.6 inch (61.348 meter)

Thermal contraction (negative expansion) for 100 feet = 3.6 inch (3.0 mm/meter)
For 200 feet (61 meters) the contraction = 7.2 inch (183 mm)

For Carbon steel, Thermal expansion for 100 feet = 7.9 inch (200 mm)
For 150 feet Carbon steel pipe the expansion = 11.85 inch (300 mm)
For Stainless Steel, Thermal expansion for 100 feet = 10.2 inch (259 mm)
For Stainless Steel, Thermal expansion for 130 feet = 1.3 X 10.2 = 13.26 inch (337 mm)
Total expansion after heating = 25.11 inch (637 mm)
Total length after heating = 280 feet + 25.11 = 282 feet and 1.11 inch (85.637 meters)
Total length after heating =282 feet and 1.11 inch (85.637 meters)
77 | 2 2 9
CODE CALCULATIONS
(Numerical Examples in API 570 Code)
Exercise-9.
(A) Following information is available from Pipe data sheet & inspection
records for a class1 Piping in service. The service in unchanged from 2002
& will continue.
Initial thickness = 1.2 inch (30 mm) in 1992 May

First shutdown inspection thickness = 1.1 inch (27.9 mm) in 1997 May
Second shutdown inspection thickness = 1.05 inch (26.7 mm) in 2002 May
Current inspection thickness = 0.9 inch (22.9 mm) in 2007 May
Required thickness = 0.60 inch (15.3 mm)
Calculate following :
1. Long term corrosion rate
2. Short term corrosion rate
3. What corrosion rate is to be considered of for Remaining life calculation?
4. Calculate Remaining Life.
5. What are next maximum Thickness measurement & External inspection
intervals?
(B) A fillet patch is to be installed on a Pipe with ID = 16 inch & minimum required
thickness for the patch to be welded is ½”. What should be minimum toe to toe
distance from a similarly welded existing patch?
78 | 2 2 9
(C) Estimate the maximum permitted Thickness measurement & External inspection
intervals for following 5 Piping systems . No RBI is performed.
1. Class 1 piping , Remaining life = 14 years

4. Injection points in Class 1 piping , Remaining life = 8 years
5. Injection points in Class 3 piping , Remaining life = 22 years
(D) A Class 1 Piping was inspected for thickness measurement. Actual thickness
was found to be 0.86 inch (21.9 mm). Next thickness inspection interval is 5
years. Corrosion rate = 10 mpy (0.25 mm/yr). What value of thickness should
be used in MAWP calculation?
79 | 2 2 9
CODE CALCULATIONS
(Numerical Examples in API 570 Code)
Exercise-9 (SOLUTION).
(Solution for A)
t initial = 1.2 inch (May 1992)
t previous = 1.05 inch (May 2002)
t actual = 0.9 inch (May 2007)
t required = 0.60 inch
1) Corrosion rate (L.T.) = t initial – t actual
No. of years between t initial & t actual
= 1.2 –0.9 (30 - 22.9)

15 15
= 0.020”/year = 20 mpy (0.47 mm/yr)
2) Corrosion rate (S.T.) = t previous – t actual

No. of years betn t previous & t actual
= 1.05 –0.9 26.7-22.9
5 5
= 0.030”/year = 30 mpy (0.76 mm/yr)
3) S.T. rate reflects current process used S.T. Corrosion rate [30 mpy (0.76
mm/yr)] for remaining life calculation.
4) Remaining life = (t actual – t required)/ Corrosion rate

= 0.9-0.60 (22.9 - 15.3)
0.030 0.76
= 10 years
80 | 2 2 9
(5) Next Thickness inspection = Lower of (1/2 x 10) or 5 years
= 5 years
External inspection = 5 years
( Solution B) Spacing (d) = 4 √RT . Here, R= 8 inch

= 4 √8 x ½
d = 4√ 4 = 8 inches.
(Solution C ) 1. For Class 1 piping:
Max. Thickness measurement Interval = Lower of ½ (R.L) or 5 years
= Lower of ½ x 14 or 5 years
= 5 years.
External = years.
Similarly for other Piping calculation can be done
2. Class 2 piping : Thk. measurement = 8 years, External = 5 years
3. Class 3 piping : Thk. measurement = 10 years, External = 10 years
4. Injection points in Class 1 piping = Lower of ½ (R.L) or 3 years

Thk. measurement Interval = 3 years
External by class (class1) = 5 years.
5. Injection points in Class 3 piping = Lower of ½ (R.L) or 3 years
Thk. measurement Interval = 3 years
External by class (class 3) = 10 years.
(Solution D) Thickness (t) = tactual – 2 (C.R x Interval)
= 0.86 – 2 (0.010 x 5) [21.9 - 2(0.25 x 5)]
= 0.86 –0.1 = 0.76 inch (21.9 – 2.5 = 19.4 mm)
81 | 2 2 9
API 570- INSERVICE PIPING INSPECTOR
PREPARATORY COURSE
CASE STUDIES ON ASME PCC-2
Repair of Pressure Equipment

and Piping
ASME PCC-2–2011
82 | 2 2 9
Case Studies on ASME PCC-2
CASE STUDY 1-(Question)
A certain pressure vessel had undergone severe non-uniform corrosion of its wall
thickness in several of its parts. After extensive thickness gauging and after
applying concepts of inspection as per API 510 followed by FFS analysis of
critically bad areas, it has been found that two areas which are far apart from
each other cannot continue to provide service and remediation measures are
called for. The vessel has an internal diameter of 2000 mm and internal as well
as external access is available for welding and radiography. The two areas,
labeled A and B are 300 mm x 500 mm and 1200 mm x 850 mm in size
approximately. Required thickness is 15 mm while nominal thickness used for
vessel construction was 20 mm. Corrosion allowance originally provided was 4
mm. The areas A and B have localized corrosion and level I FFS assessment
had found these to be unfit for service. Many thickness readings in area A show
that thickness is as low as 7 mm. There is no evidence of any cracking. MOC is
carbon steel [SA 516 grade 60]. Vessel does not operate in creep range. Tensile
tests carried out report that tensile strength is 65000 psi.
a) If Butt welded insert plates or external weld overlay are possible repair
methods which remedial measures or methods of repairing are possible
and which do you recommend?
b) If external weld overlay is to be used for area A, then what should be the
area of overlaid welding and to what thickness the overlay be built up?
c) If external weld overlay on area A is to be carried out while vessel is in

operation, is welding procedure qualification required?
d) How the overlay design can be qualified by a ‘prequalified design’? If burst

test method is to be used, what is the test pressure? Since this test may
‘destroy’ or damage the vessel, how this qualification is to be carried out?
e) In what direction and in what manner welding should proceed?

83 | 2 2 9
CASE STUDY 1-(Answer)
a). Butt welded insert plates, external weld overlay are possible repair methods
that can be used. Both of these can theoretically be used for area A as well as
area B. Of these, external weld overlay will a better choice for area A because of
smaller area over which welding has to be deposited. Butt welded insert plate will
be more convenient for area B.
b) Overlay should extend by a minimum distance B beyond the boundaries of

corroded area where
B= where R is outer radius of vessel, and tnom is nominal

thickness. Here R is 1020 mm and nominal thickness is 20 mm. So B works out
to 107.12 mm. This means the overlay should extend about 110 mm beyond
actual boundaries of corroded area. In other words the overlay area will be 520
mm x 720 mm approx.
Thickness of overlay should not exceed nominal thickness which is 20 mm here.
Actual overlay thickness may be kept at about 8mm + corrosion allowance that
needs to be provided, considering the fact that at least 7 mm thickness is
available and required thickness is 15 mm. Conservatively, 12 mm thick uniform
overlay should be workable. Provide corner radius for overlay area as 12mm
c) Procedure qualification is mandatory. Requirements of Section IX have to be

followed, and further, requirements of Article 2.10 of ASME PCC-2 shall also be
followed. These requirements include many more essential variables to be
included in WPS and qualification to be done on a mock-up. Requirements for
tests are also more stringent; nick-break, metallographic, and hardness tests
being specified, apart from face- bend and side-bend tests.
84 | 2 2 9
d) Weld overlay design has to be qualified by a ‘pre-qualified design’, ‘engineered
design’, or, a ‘burst test’. Here prequalified design is ruled out because size of
overlay exceeds 200 mm. So either engineered design qualification or a burst
test qualification has to be performed.
Minimum burst test pressure is given by S act

Where D is OD in inches, t is minimum specified thickness [excluding mfg.
tolerance] of base material, in inches, i.e. required thickness, and S act is actual
reported tensile strength of base material in psi.
The burst pressure is then = 955 psi min.

The burst test is to be performed on a mock-up.
e) First passes should be along the mapped periphery of proposed overlay,

maintaining a weld edge taper of 300. Welding may then proceed inward in a
spiral fashion. Heat treatment as per applicable API 510 edition shall be used.
85 | 2 2 9
If area B is question no. 1 has size 1200 x 850 to be repaired by an insert plate,
what shall be thickness and size of this insert plate? What should be the groove
design from point of view of minimizing heat input? What spacing is required
between adjacent butt welds and the peripheral welds of the insert plate.
86 | 2 2 9
Size of insert plate should extend about 50 mm beyond corroded area, taking
care to see that weld is always in sound base metal. Minimum size requirement
given in standard is not applicable here as the corroded area is larger than this
size. Provide minimum 75mm rounded corners.
Insert plate thickness should be minimum 20 mm. i.e., minimum equal to nominal
thickness of base metal.
Since both side access is available for welding and RT, preferable a double V
groove with a small included angle should be used. If this type of edge
preparation is not possible, then a single V groove with a small included angle of
50 or 60 degrees should be used using root pass with TIG to ensure full
penetration weld.
The spacing between adjacent butt welds shall be at least 250 mm. If less make
the size of insert plate larger so as to extend up to adjacent butt weld and make
the insert plate in ‘doghouse’ shape or extend the insert plate further away by
250mm
The spacing between adjacent butt welds 160 mm, provided both butt welds are
ground smooth, 100% RT or UT examined and 100% MT or PT examined after
completion of welding in areas where the spacing between the adjacent butt
welds is less than 250mm .
As an alternative, the root pass and the weld, after half of the groove is filled,
may be either 100% MT or PT examined in place of the 100% RT or UT
examination requirement.
87 | 2 2 9
A portion of NPS 4 sch 40, A 106 Gr B process pipe is thinned out due to
selective erosion over a length of 300mm and is likely to puncture prior to next
scheduled shutdown. It is proposed to use a welded box for the repair. Original
code of construction is ASME B 31.3 . Construction drawings specified spot
radiography. No cracks were detected in affected area. There is no service
related PWHT. Prepare a repair proposal for welded box repair as per guidelines
of ASME PCC-2.
88 | 2 2 9
A) Material selection for welded box:
1. Similar to original material (considering weldability, galvanic corrosion

aspects etc). A 106 Gr B for straight pipe and A 234 WPB for end caps.
2. Welded Box pipes may be NPS 8.
B) Design of welded box:
1. As per original design Sch 40 thickness was OK. Hence Sch 40 thickness
for welded box will be OK.
2. Use spot radiography (E=0.9) as per original code of construction.
3. As pipe is not leaking vents and drains are not required.
C) Fabrication of welded box:
1. As the length of affected area is 300mm, take length of box as approx.

400mm so that the circumferential welded joint connecting the box with
the pipe will be on sound metal thickness of pipe.
2. The box longitudinal welds ( split seams) and split seams in end caps shall
be staggered ( say 3 and 9 o’clock for long. Seams and vertical split seam
for the caps)
3. Weld joints in box shall be full penetration. Use of TIG + SMAW may be
considered.
4. Qualified Welders and Procedures as per ASME IX shall be used
5. No PWHT is required for service as well as code considerations ( thk< 20
mm)
6. On-stream installation may be done by following guidelines of Article 2.10
89 | 2 2 9
D) Examination
1. While specifying Examination, one should consider requirement of original

code of construction and also substituting NDE for pressure test of the
box.
2. Considering the excessive thinning (likely to puncture prior to next
scheduled shutdown) there is possibility of collapsing due to pressure,
also the fact that there are no vents and drains provided to box, the
pressure test is risky and impractical.
3. As per original code of construction, spot radiography calls for 2 spots of
150 mm on long seams and 1 spot on circ seams (assuming one welder
has was used) but as the pressure test is not proposed carry out 100% RT
or UT.
4. Carry out 100% PT or MT ( MT preferred) for joints between box and line
pipe
5. Carry out 100% visual as per ASME B 31.3
90 | 2 2 9
CASE STUDY 4 -(Question)
Certain vessel shell needs to be repaired by fillet welded patch plates. Metal loss
area is about 10” dia circular shape and may grow by 1” width along the
perimeter radially outwards. Present thickness loss = 0.3”. Allowable stress for
MOC is 15,000 psi. Vessel diameter at mid-wall is 40 in. Design pressure is 300
psi. Design temp=500 deg F, E=1. Present uncorroded shell thickness 0.9”, FCA
= 0.05 “. There are no loads other than loads due to process pressure. Give
essential details like size and thickness of patch plate, perimeter fillet weld size,
clear spacing from nearby fillet welds and NDT if any, for this repair. Credit can
be taken for remaining shell thickness.
91 | 2 2 9
CASE STUDY 4 -(Answer)
Induced circumferential load PD/2 = 300x40/2 = 6 000 lb/in.

Allowable load on perimeter fillet weld is FA = wmin E Sa where wmin is min. leg
dimension, E is weld joint efficiency, Sa is allowable stress of base metal. FA has
to be more than 6000 lb/in., so let us take a value of 6100 lb/in.
So, 6100 = Wmin x 0.55 x 15000. So Wmin works out to 0.74 in.
So, min. weld leg length should be 0.74”. Patch plate thickness can be 0.75”.
If Credit can be taken for remaining shell thickness, then only the lost thickness
needs to be compensated = 0.3 +0.05 = 0.35
Patch plate thickness =0 .35 / 0.55 = 0.64”
Choose Patch plate thickness ( higher of 0.64 and o.75) =0.75”.
Patch plate size = Expected defect size plus overlap of 1” but also accommodate
3” rounding.
Expected defect size = 12”
Min Patch plate size = 14” dia round shape, single piece as the size is small.
spacing from nearby fillet welds = 2√Rt = 2√20X0.9 = 8.48”
NDT this repair: UT at weld location prior to welding to determine sound metal
and PT or MT of repair welds after welding and PWHT if any.
92 | 2 2 9
A pipe line of cold formed and fabricated from SA 516 grade 60 steel has
severely corroded in some areas and leaks have also developed. Pipe OD is 300
mm. Required thickness was 7 mm, original corrosion allowance provided was 2
mm, and nominal thickness was 10 mm. Weld joint efficiency considered during
manufacturing was 1.0. There are 3 such locations. Cyclic service is not a
consideration here. Operating pressure = 200 psi.
Full encirclement sleeves are to be used for repairs.
[a] What type of sleeve should be used?
[b] What should be thickness and width of sleeve? Assume that UT may not be
possible.
[c] Should backing strip be used or not in longitudinal weld joint?
[d] What should be size of fillet weld for circumferential joints?
[e] What Pressure shall be maintained if repair was done on-stream?
93 | 2 2 9
[a] Type B sleeve should be used since leaks have already developed and
strength also has to be provided to the base metal.
[b] Since UT may not be possible, a joint efficiency factor of 0.8 has to be used.
Original construction had this factor of 1 and nominal thickness of 10 mm. So the
sleeve thickness should be 10/0.8 = 12.5 mm. minimum. The sleeve width should
be equal to width of corroded area + 100 mm [ 50 mm or either side]. A tight
fitting sleeve as far as possible, with a gap of maximum 2 mm between pipe OD
and sleeve ID should be used.
[c]Backing strip with a relief groove should be used for longitudinal joint to ensure
full penetration without danger of a burn through. An appropriate filler material
must however be introduced in the filler groove. A bulge in the sleeve to
accommodate existing circumferential weld reinforcement shall be prepared for
the two areas mentioned in question.
[d] Since sleeve thickness is less than 1.4 times the pipe nominal thickness, a
fillet weld size of sleeve thickness + 2 mm [gap] should be used.
[e] pressure shall be between 100-160 psi if repair is done on-stream
94 | 2 2 9
A) A 1600 mm ID, clad cylindrical shell ( SA 516 Gr.70 base metal 40mm+3mm
SS 304 corrosion resistant clad) had undergone localized loss of thickness from
process side. The affected area showed complete loss of cladding and also loss
of base metal thickness up to 8mm. Vessel was in Hydrocarbon service. Original
code of construction is ASME VIII Div.1 . Construction drawings specified Full
radiography. Vessel is not subjected to low temperature service hence impact
test is not required. There is no service related PWHT and PWHT is to be
avoided after repairs if possible. Prepare a repair proposal for as per guidelines
of ASME PCC-2. Will this repair be termed as temporary or permanent?
B) What additional requirement will be needed if loss of base metal thickness of

12mm
C) What additional requirement will be needed if base metal was SA 387 Gr 11

(1.25 Cr-0.5 Mo)
95 | 2 2 9
Design considerations in repair:
1..As per Article 2.11 of ASME PCC-2, The remaining base metal thickness
shall be adequate to accommodate weld buildup. In this case it is 32-
8=24mm which is more than adequate for the build up.
1. When the strength of the original base metal is to be restored by weld

buildup, the weld metal tensile strength should equal or exceed that of
the base metal. Therefore use of E 7018 Electrodes will be used for base
metal restoration.
2. An intermediate overlay using SS 309 electrodes followed by SS 308
electrodes should be used.
3. The total depth of overlay 3 mm or greater in thickness. Hence deposit
SS308 thickness of 4 mm keeping 1 mm final dress up grinding. The
number of weld layers shall not be less than the of weld layers deposited
for weld overlay procedure qualification tests as per ASME IX.
Steps in weld deposit
1. As the vessel was in Hydrocarbon service, first carry out the out-gassing
base metal. For this, the temperature of the repair area shall be raised to a
temperature of 500°F ± 50°F (260°C ± 30°C) for a minimum period of two
hours to assist out-gassing diffusion of any hydrogen picked up during
exposure of base metal to hydrocarbon service.
2. Grind the area of metal build up to make it free of rust, scale, and other
contaminants, and to have a smooth contour.
3. Carry out PT or MT of the area to ensure no defects remain
4. The weld build up area shall be preheated and maintained at a minimum
temperature of 300°F (150°C) during welding. The 300°F (150°C)
96 | 2 2 9
temperature should be checked to assure that 4 in. (100 mm) of the
material or four times the build thickness, i.e 4 X 8 = 32 mm (whichever is
greater) on each side of the edge is maintained at the minimum
temperature during welding
5. Welding procedures and welders shall be qualified in accordance with
ASME Sec. IX
6. Deposit base metal build-up up to one pass lower than base metal build-
up thickness
7. PWHT of this build-up is not required as per API 510 Chapter 8.
8. Carry out PT or MT of deposited metal to ensure no defects remain.
9. Prior to corrosion resistant weld metal deposit, existing cladding of
adjoining area shall be stripped back a minimum of 6 mm(1⁄4 in.) from the
edge of the affected area.
10. Deposit one layer of weld metal build-up using SS 309 electrodes.
11. Deposit first layer of the weld metal build-up using SS 308 electrodes and
perform liquid penetrant examination if multiple-layer weld overlay was
done
12. Build up deposit with SS308 up to thickness of 4 mm keeping 1 mm final
dress up grinding.
13. After cooling to ambient temperatures, and dress up grinding and blend
grinding the deposit shall be inspected by the PT method.
14. Carry out PMI of original cladding in neighboring area and weld deposit
area as additional check, if required.
15. Pressure testing is generally not needed for weld buildup and restoration
type repairs.
As per ASME PCC-2, This repair will be treated as temporary and on-stream
monitoring by UT is recommended. If cause if this damage mechanism is
prevented totally then it can be called permanent repair.
If loss of base metal thickness of 12mm, as per clause 5.1.2 Art 2.11 of ASME
PCC-2, base metal build up shall be examined by volumetric examination
methods such as radiographic or ultrasonic testing prior to step 10 above..
97 | 2 2 9
If base metal was SA 387 Gr 11 ( 1.25 Cr-0.5 Mo) it will be classified as P no.4
material. Preheating as substitute to PWHT can not be used. If Controlled-
deposition Welding Method for base metal build up was done as per API 510,
PWHT can be avoided.
Intermediate PWHT
After performing weld repairs to low alloy steel base metal, but before
application of weld overlay, a dehydrogenation heat treatment or an intermediate
PWHT should be considered, (Especially if the base metal is 21⁄4Cr or higher
alloy, or heavy wall,(greater than 38 mm or 11⁄2 in. thick) to expel hydrogen pick-
up during welding.
Delayed cracking:
As per API 510, The base metal in the area of repair should also be examined for
cracking by the ultrasonic examination irrespective of thickness This inspection
is most appropriately accomplished following a delay of at least 24 hours after
completed repairs for alloys that could be affected by delayed cracking.
98 | 2 2 9
Thermal gouging (Carbon arc) was done to remove following flaws in 32 mm

thick SA 516 Gr. 70 pressure component. Suggest various follow up actions
according to ASME PCC-2 guidelines.
1. 10 mm deep 120 mm long crack flaw

2. Corroded area 16 mm deep. Area size 300X250mm
3. Pitted area max. pit depth 10 mm deep and pitted area size 230
mmX180 mm
4. Crack of depth 28 mm and length 300 mm.
99 | 2 2 9
1. Excavated 10 mm deep 120 mm long crack flaw:

As per ASME PCC-2, If the excavation is performed using a thermal removal
process (carbon arc or plasma arc gouging), an additional 1.5 mm (1⁄16 in.) of
material shall be removed by a mechanical removal process such as grinding,
prior to the final inspection and before welding begins.
This may result in thickness loss up to approx. 12 mm. Then provide 3:1 taper as
in (b) in fig.1 below
Verify defect removal by inspecting the cavity by visual examination (VT) and
(PT) or MT as appropriate.
100 | 2 2 9
Measure the remaining wall thickness by UT .If remaining thickness is greater
than the minimum required thickness as determined by a fitness-for-service
evaluation for groove; ( for FFS evaluation take the depth of groove as 12mm)
the excavation cavity need not be filled with weld deposit. Otherwise build up the
thickness. Volumetric examination (RT or UT) shall be considered where there is
a possibility of flaws introduced during repair welding, such as shrinkage cracks
from deep weld repairs in thick sections.
Pressure test is not required after the repair.
2.. Corroded area 16 mm deep. Area size 300X250mm:

The steps will be essentially similar to those in case of crack above. For FFS
evaluation use methodology of locally thinned area.
Pressure test is not required after the repair.
3.. Pitted area max. pit depth 10 mm deep and pitted area size 230 mmX180
mm
o Prior to gouging, Pitted area FFS evaluation using methodology for pitted
area can be adopted. If fitness-for-service evaluation shows the area
acceptable, no further action is needed.
o If fitness-for-service evaluation shows the area unacceptable, all pits shall

be removed by gouging, with subsequent grinding, provide 1:3 taper on all
edges and FFFS evaluation using methodology of locally thinned area. If
fitness-for-service evaluation shows the area acceptable, no further action
is needed.
o If fitness-for-service evaluation shows the area unacceptable build up the

thickness as ASME PCC-2.
o Pressure test is not required after the repair.
101 | 2 2 9
4.. Crack of depth 28 mm and length 300 mm.
This defect is not likely to be acceptable under any FFS evaluation. It is

convenient to prepare through thickness edge preparation, carry out PT or MT of
the weld groove edge preparation and complete the full penetration weld. Carry
out RT as per Code of Construction.
Pressure test will be required after the repair.
102 | 2 2 9
API 570- INSERVICE PIPING INSPECTOR
PREPARATORY COURSE
ASME PCC 2
ASSIGNMENTS
(VOLUME- I)
Part- 3
WPS/PQR Review Case studies

Review of WPS/PQR (Road Map)
Start at Front side of PQR.
No Do the P, F & A Nos. match with

mtl. Spec No & filler AWS No.
Go to back side of PQR.Are the (QW 140)

No results for tensile, and bend tests
stated.
Yes
No For tensile test are qty of
specimen, area and unit (QW – 451.1)
stress calculation right
Yes
No
Is location of failure stated
R
Yes
No Is unit stress >
(QW – 153)
SMTS of base metal
Start E Yes Was break in
Yes
weld metal
No
Is the WPS supported by No Is unit stress >
PQR. Does WPS show No
95% of SMTS (QW – 153)
reference No. of the J of base metal
supporting PQR
Yes
Yes No Is bend test Qty, type
Yes stated and correct
(QW – 451.1)
Has PQR been revised
Yes
No E No
No Is the result stated & OK (QW – 163)
Is PQR signed and dated Yes
Yes No Are results for toughness
test (if any) OK (QW – 172)
Accept for C Yes
detailed Place WPS & PQR side by side
review
Go to tables as follows
T SMAW - QW 253
SAW – QW 254
No Check WPS/PQR for QW 402 to
QW 410 for the following
WPS: EV, NEV, PQR: EV,
Are the documents OK?
If the welder is to be qualified on the

No
basis of PQR. Is his Identifying code.
Position of welding recorded on PQR.?
Yes
Accept
Mistakes in WPS/PQR Documentation.
PQR REVIEW:
A. PQR/2007/011 (Front side):
1. Check P,F and A Nos…….P No. 1 is OK, F No. should be 4 instead of 2, A No.
OK
B. PQR (Back Side)
1. No. of Tensile Test Specimen=2 …OK. But result of first tensile

specimen(W.M.fracture)is not accepted. Second specimen is OK
2. Bend tests specimen Nos. = 4…OK, Test results also OK, but specimen tested
are wrong. They must be 4 side bends for Test coupon thickness=o.75 inch.
WPS REVIEW:
C. WPS/ 2007/24(Front side)
Check P.No , F No, A No. Change F No. to agree with PQR ( change F no. to 4)
Base metal thickness range shall be= 3/16 inch to 1 ½ inch.
Weld metal thickness range shall be = 0 to 1 ½ inch.
D. WPS (Back side)
Min. Preheat shall be 120 deg.F

PWHT shall be Nil….since PQR is without PWHT.
(VOLUME- I)
Part- 4
Points To Recall of
API 570- PIPING INSPECTORS
125 | 2 2 9
Points To Recall - 1
1. API 570 Code is applicable for inspection, repairs, alteration

and re-rating of in-service , metallic piping.
2. ASME B 31.3 piping is used for construction of new piping

installation.
3. Revised edition and addenda of API and ASME Codes may be

used from beginning with date of issue. But they become
mandatory from 6 months after issue date.
4. Table A-1B of B 31.3 Code gives weld joint quality factor for
manufactured pipes. The factor can be increased for Electric
Fusion welded pipes by conducting additional radiography
(spot or full) as per Table 302.3.4.
5. Minimum required thickness (tm) for a pipe of outside

diameter (D), made from material having safe stress (S) and
subjected to internal pressure (P) is given by:
PD
tm = +C
2( SEW + PY )
where E = weld joint factor

Y = material co-efficient (Table 304.1.1)
C = corrosion and other allowances
W=Weld Joint Strength Reduction Factor
(Table 302.3.5)
6. Maximum allowable internal pressure for a pipe for given

metal thickness is worked out by substituting net thickness in
Barlow formula and calculating the required internal Pressure
(P).
(Nett thickness = Available Thickness – Corrosion Allowance)
7. Thickness of a permanent blank for the pipe is given by:
126 | 2 2 9
3P
tm = dg +C
16SEW
Where, dg = the inside diameter of gasket
8. Hydrostatic Test pr = 1.5  Design pr x stress ratio
Stress ratio is ratio of material stress at test temp to the

stress at design temp. Stress ratio is always greater than or
equal to 1.
9. Pneumatic test pr = 1.1 x Design pr
During pneumatic test a pressure relief valve (with set pr ≤

1.1 x Test pr.) shall be installed. Pressurization should be in
steps. Initially, pressure shall be slowly increased to 25 psi or
50% of test pressure (whichever is lower). Check for leakage,
if any, and correct them.
Thereafter, the pressure shall be increased in steps up to the

full pressure. Inspection shall be carried out at Design
Pressure.
10. Hydrostatic test is preferred over Pneumatic test. The butt

joints where Hydro or Pneumatic test can not be performed,
100% RT or UT may be done on butt welds, and PT or MT
may be done on other welds (branch welds, fillet welds, etc.)
as alternative to Leak testing.
11. If temperature – thickness combination falls on or above

the material curve (Fig. 323.22), impact testing is NOT
required. (If below the curve – impact testing is required)
12. For impact testing 3 specimen are required. If the average of

3 specimen > = Required Average and Value of only one
specimen is less than average but more than minimum for
one specimen — Accept
127 | 2 2 9
13. If average of 3 specimen > = Minimum for one specimen and
a. Value of one specimen is less than average and also

less than minimum for one specimen — Retest
b. Value of two specimen is less than average — Retest
After retest, all specimen must have value > =

Average Value
14. Table 330.1.1 gives required pre-heat temperatures.
15. In dissimilar pipe joints higher temperature of the two is to be

used for pre-heating.
16. PWHT Table (331.1.1) gives temperature range, and minimum

holding time. Table 331.1.3 provides exemptions to mandatory
PWHT.
128 | 2 2 9
1. Thermal expansion and contraction for different temperatures
is given in Table C-1. To determine total expansion net effect
shall be considered.
2. Working pressure for flanges and flanged fittings can be read

from pressure-temperature ratings of flange. The hydrostatic
test pressure is taken as 1.5 times the pressure rating at
100º F, rounded to the next 25 psi.
3. “Repair” on piping system means work necessary to restore a

piping system to the design conditions.
4. “Alteration” means any change in piping components that

affects the design conditions.
5. API 570 shall not be used for new construction. It shall not
violate jurisdiction requirements.
6. Authorized inspection agency means any of the following:
a. Inspection organization of jurisdiction

b. Inspection organization authorized by
jurisdiction
c. Inspection organization of owner user
d. Inspection organization contracted by owner
user
e. Inspection organization of insurance
company that undertakes insurance of
piping system
7. Repair Organization means any of the following:
a. Owner user who repairs or alters his own piping

b. A contractor authorized by owner user and
who carries out work as per API 570
c. Organization authorized/accepted or not prohibited by
jurisdiction and who carries out work in accordance with
API 570
129 | 2 2 9
8. Ultimate responsibility for executing the work as per API 570
rests with owner/user.
9. Soil-to-Air interface is subjected to combined action

from atmosphere as well as soil, and is taken up to
6” above and 12” below the soil.
10. Deadlegs means piping components where there is no

significant flow (almost stagnant fluid).
11. Piping Circuit is part of piping system which is subjected to

similar corrosivity.
12. Piping system is the piping subjected to same design

conditions.
13. Examiner is NDT person who assists the API 570 inspector but
does not decide acceptance / rejection of NDT results.
14. Risk Based Inspection (RBI) means: Assessment of likelihood

of failure and consequences of failure and evolving inspection
scheme keeping in view both.
15. Injection points may cause accelerated or localized corrosion.

During scheduled inspections, extensive inspection should be
applied beginning 12 inches upstream.
16. Deadlegs: Stagnant liquids in deadlegs can cause more

corrosion than the active piping in the process.
130 | 2 2 9
1. CUI is more likely on insulated pipings exposed to

water/mist/moisture and in the range of 10º to 350ºF.
2. Erosion is caused due to impacts of solid particles in

liquids/gases or liquid particles in gases. It is more serious if
corrosion is also present.
3. Fatigue failure is caused due to cyclic stress or stress reversals

(vibrations, thermal changes).
4. Creep failure is dependent on time, temperature and stress.
5. The two important inspections carried out periodically on piping

are:
a. Thickness measurement inspection, and
b. External visual inspection
6. Thickness measurements are usually carried out by:

a. Ultrasonic thickness measurements for pipes
larger than NPS 1
b. Profile radiography for pipes NPS 1 and smaller
7. External visual shall include checking for leaks, misalignments,

vibrations pipe support conditions, external corrosion, condition
of insulation/coating/painting.
8. CMLS shall be selected representing suspect areas and shall

include elbows, tees, injection points and S/A interface.
9. In API 570, pipes are classified as follows:
Class 1: Services with highest potential of resulting

in emergency if the leak occurs.
i.e The flammable fluids which readily
vaporise on leakage.
Class 2: Those pipes which are not included in

Classes 1 and 3
131 | 2 2 9
Class 3: Services that do not significantly vaporize
and not located in high activity area.
10. Inspection Intervals:

a. Thickness measurements: Lower of half the
remaining life or
i. 5 years for Class 1
ii. 10 years for Classes 2 and 3
iii. 3 years for injection points
b. External visual:
i. 5 years for Classes 1 and 2
ii. 10 years for Class 3
iii. Injection points and S/A interface —
by class
11. CUI inspection shall be done by NDE or insulation removal on the

following areas:
Class Areas with Damaged Suspect Areas Within

Insulation Susceptible Temperature
1 75 % 50 %
2 50 % 33 %
3 25 % 10 %
12. Pipes systems having remaining life more than 10 years and are
adequately protected, need not be included for inspection of
suspect area as above.
13. Inspection of SBP:
a. SBP in Process Piping

— As per other process piping
b. SBP in Secondary Piping

1. For Class 1: Same as other Class 1
2. For Classes 2 and 3: Inspection is optional,
however deadlegs shall be inspected.
132 | 2 2 9
1. a. Remaining life = t actual – t required

corrosion rate
b. L. T. Corrosion rate = t initial – t actual_____________

years between t initial & t actual
c. S. T. Corrosion rate = t previous – t actual_________

years between t previous and t actual
2. If corrosion rate is not available for new service, it shall be

determined within 3 months of service and shall be confirmed by
subsequent measurements.
3. MAWP of piping system is worked out on basis of:
2 SEt
MAWP = .
D
t = t actual – 2 x corrosion loss up to next insp.
For unknown material, assume lowest grade and lowest joint

efficiency permitted by the Construction Code.
4. Authorization for repair may be given by Inspector, however

authorization for alteration shall be given only after consultation
with and approval by piping engineer. After completion, all repairs
and alteration work shall be checked and approved by Inspector.
5. A temporary repair may be made by fillet welding a plate patch if

SMYS of pipe does not exceed 40,000 psi.
6. Insert patches may be used for repairs if:
a. Full penetration groove welds are provided

b. For class 1 and 2 piping the welds are 100% radiographed or
UT checked and
c. Patches have rounded corners 1” min. radius
133 | 2 2 9
7. Any welding done on-stream shall be done in accordance with hot
tapping checklist as per API 2201.
8. Pre-heating (and maintaining) to minimum 300°F can be

substituted as alternative to PWHT for P-1 and some P-3 steels
(except Mn-Mo steels). The weld shall be covered with insulation
to slow cooling rate.
9. For other steels, PWHT has to be performed as per construction

code.
10. Pressure tests are normally required after alterations and major
repairs. However, NDE maybe utilized if Pressure Test is not
practical, if accepted by piping Engineer.
11. The above grade survey of buried piping shall be conducted at an

interval of approximately 6 months.
12. For piping buried in lengths greater that 100 feet and not
cathodically protected (CP), the soil resistivity shall be checked at
5 year interval.
13. For poorly coated pipes or pipes with improper cathodic

protection, close-interval potential survey shall be made every 3
to 5 years.
14. Thickness measurement of buried pipes without CP shall be done

at interval of 5, 10, and 15 years if soil resistivity is less than
2000, 2000 to 10,000 and more than 10,000 ohm-cm
respectively. Thickness measurement is performed by “intelligent
pigging” or by excavation and UT check.
15. Leak testing at minimum pressure = 1.1 x M.O.P. shall be done at

half the above intervals for non-C.P. pipes and same intervals for
C.P. pipes. Pressure shall not drop more than 5% in 4 hours
period (Pressure-Decay Test).
134 | 2 2 9
16. Repairs using clamps for buried pipes, the location and date of
clamp shall be shown on the marker (flag) and also on the
inspection report. Clamp shall be replaced by permanent repair
at first available opportunity.
17. All fatigue failure take place due to initiation of surface crack
and propagation of crack due to stress fluctuation. There are
3-types of fatigue failures.
If surface cracks are due to stress concentration, weld
undercuts, notches etc and stress fluctuation due to
mechanical reasons (unbalanced shafts, alternate tension-
compression etc.) then it is Mechanical Fatigue. If stress
fluctuation is due to temperature swing, it is Thermal Fatigue.
If stress fluctuation is due to vibrations, water hammer etc., it
is Vibration Fatigue.
18. Corrosion Erosion is due to combined action of corrosion and

erosion. It can be reduced by controlling corrosion (by coating
or using corrosion resistant materials) and by controlling
erosion (by controlling flow velocity, providing harder
surface).
19. Caustic embrittlement occurs due to combined action of high

caustic strength and higher temperature. It can be controlled
by carrying out PWHT and upgrading materials by Nickel
alloys.
20. Sulphidation occurs due to sulpher or H2S content in the fluid

handled. It can be reduced by using Chromium containing
steels as construction materials.
21. High temperature Hydrogen Attack (HTHA) is due to

migration of Hydrogen atoms in the carbon steels which
combines with carbon in carbons steel at high temperature to
form Methane gas (CH4) which collects at grain boundaries
causing internal cracks. It can be reduced by selecting the
construction materials according to Nelsen Curves. (The
material should be above the point of temperature and
Hydrogen pressure).
135 | 2 2 9
1. PQR gives data used in PQR test and test results, and cannot be
revised.
2. WPS gives parameters to be used in production job, and must be

within ranges qualified by the PQR test.
3. Essential variables (EV), if changed require new procedure

qualification. Non essential variables (NEV) may be changed in
WPS without new PQR.
4. Supplementary essential variables (SEV) are considered as (EV)

only if there is impact strength requirement. Otherwise, they are
“non-essential” variables.
5. Tensile test for procedure qualification is passed if failure is in:
c. Weld metal at strength >= Base metal SMTS, or

d. Base metal at strength >= 95% of base metal SMTS
6. Bend test crack shall not exceed 1/8” in any direction.
7. Radiography / UT can be used for performance qualification only

and the acceptance criteria shall be as per ASME IX.
8. P-numbers represent parent metal groupings of similar

composition and properties, i.e., similar strength and ductility.
F-numbers give similar usability aspects of filler material.
A-numbers give similar chemical composition of weld metal in
“As welded” condition.
9. For performance, 1G is flat, 2G is horizontal, 3G is vertical and

4G is overhead position. Pipe 5G qualifies 1G, 3G and 4G, but
pipe 6G qualifies all positions.
136 | 2 2 9
10. For acceptance criteria of production welds refer to Table
341.2.3 of B31.3 for:
• Weld reinforcement
• For radiographic results
• General acceptance of welds
11. Reasons for inspection are to ensure safety, reliability and to

meet regulatory requirements.
12. On-stream inspections can reduce down-time by
• Extending plant run as inspection is done when plant is still

“on”.
• If replacement of piping is required, fabrication of
replacement piping can be done in advance.
• Reducing work-load and peak-manpower requirement during
shutdown
13. UT thickness measurement at high temperature requires

correction of about 1% for each 100°F.
14. Radiography has advantages like:
• Pipe insulation need not be removed for pipe wall thickness

measurement.
• Small diameter piping, nipples, threaded connections can be
inspected
• Permanent record is available
15. Flanged fittings and valves are made thicker than pipes. The
thickness is given by:
t = 1.5 X Cylindrical thk + 0.1” for 150 lb to 2500 lb rating

S = 7,000 psi for new condition
16. For 4,500 lb rating a factor of 1.35 is used instead of 1.5 in

above formula.
17. For retirement thickness of valves and flanged fittings the value
of “S” is selected from stress tables of ASME B31.3.
137 | 2 2 9
18. Flanged joints and fittings are hydrostatically tested. Minimum
Test pressure shall be 1.5 times the 100°F rating rounded to
next higher 25 psi. This is also the maximum System-test
pressure.
19. To locate the correct pressure temperature ratings for any

flange, first refer to Table 1A of B16.5, which gives which table
to refer for which material.
138 | 2 2 9
1. GENERAL:
a. ASME Sec. V is NDT procedure/methods code and is

applicable only if it is referenced by the relevant
construction code. The extent of NDT and acceptance
standards is given in relevant construction code.
b. NDT equipment and their calibration shall be as per

ASME Sec. V.
c. Examiner is NDT person in employment of fabricator or

repair organization. Inspector means Authorized
Inspector who finally accepts/rejects NDT results.
2. FOR RT:
a. Satisfactory radiograph shall meet requirements of density

and IQI image (2T hole for hole type and designated wire for
wire type).
b. Backscatter:
Light image of B on dark background - Unacceptable
c. Density Limitations:
Min 1.8 for X Ray / 2.0 for G-Ray

Max 4.0 for X / G Ray
Density Variation = -15 % to + 30%
d. Double wall viewing (DWDI) - Up to 3.5” outside diameter
e. Penetrameter Selection: Table T-276. Thickness includes

weld reinforcement. But not backing.
f. Penetrameter shall be normally placed on source side. If

not possible, it may be placed on film side with lead letter
“F”.
139 | 2 2 9
3. FOR PT:
a. Control of Contaminants: Sulphur (for Nickel alloys)
shall not exceed 1% of residue. Chlorine + Fluorine
(for S.S. and Titanium) shall not exceed 1% of
residue.
b. Temp. shall be between 10oC to 52oC, for standard
procedures.
c. Penetrants are colour (visible) type and fluorescent
type. Each of these have:
▪ water washable
▪ post emulsifying
▪ solvent removable
Thus, total 6 categories of penetrant are available.
d. Emulsifier is applied after applying penetrant and
required dwell time is completed. Lipopholic
emulsifier is applied without pre-rinsing. Hydropholic
emulsifier is applied after pre-rinsing.
e. For dwell time for penetrant and developer refer
Table T-672.
f. After applying developer, interpretation shall be done
within 10 to 60 minutes.
g. All penetrant materials should be from same
manufacturer.
4. FOR MT:
a. Prod Technique:
- Use direct (rectified) current for magnetization
- Prod spacing 3” to 8”
- Useful for surface and sub-surface defects.
140 | 2 2 9
b. Yoke Technique:
- Use D.C. or A.C. or permanent magnet
- Suitable for surface defects only.
c. Calibration:
Equipment Ammeter to be calibrated once a
year comparing with standard Ammeter, take 3
readings. Deviation shall not exceed ±10% of
full scale.
d. Lifting Power of Yokes

- AC shall have lifting power of at least 4.5 kg
(10 lb.)
- DC shall have lifting power of at least 18.1 kg
(40 lb.)
e. Minimum two examinations on each area, the second

is perpendicular to first
5. FOR VT:
a. There shall be a written procedure for VT indicating

the essential and non-essential variables.
b. The procedure used to be re-qualified if the essential
variable is changed.
c. The acceptance of procedure is the criteria to detect
a defect of width not more than 1/32” (0.8 mm)
made on similar surface.
d. The examiner shall be annually tested for Jaeger J-
1.
e. For direct Visual testing, the eye of examiner shall
be at an angle of min.30 deg. to the surface, and
within 24 inches from surface
6. FOR LEAK TESTING (BUBBLE TEST):
a. The testing medium maybe air or any other inert gas.

b. The test temperature shall be between 4ºC to 52º C.
c. The pressure gauge range shall be twice the test
pressure preferably, however, the gauge range shall not
be lower than 1.5 times and higher than 4 times the
141 | 2 2 9
test pressure. Pressure gauges shall be calibrated at
least annually
d. Prior to inspection, the test pressure shall be held min.
15 minutes.
e. The presence and growth of bubble at leak location
would constitute a defect.
f. After repair the leak test shall be repeated.
7. SE-797 UT MEASUREMENT:
a. Pulse-echo method can be adopted up to 200°F
b. Apparatus: 3 types
- CRT read out
- CRT + direct read out
- Direct thickness read out
c. Search Units: 3 types

- Straight beam contact type
- Delay line type (delay block to minimize dead zone)
- Dual element type. There are two crystals set at
a small range. Low roof angle used for higher
range and higher angle for low range.
d. High thickness measurement:
Use of multiple echoes is made. (i.e., for thickness

between 50 mm and 60mm, use 10mm calibration block
then 5th back echo will be 50 mm and 6th will be 60mm.
Set the 5th echo to zero and 6th at the screen range. The
screen is calibrated to 50-60mm.
e. While taking measurement for high temperature

condition a positive error of 1% per 55°C (100°F)
results. Hence temperature correction is necessary.
g. CRT read out is recommended on corroded

and rough surface.
142 | 2 2 9
API RP 578
1. API RP 578 can be used for new and existing piping system.
Carbon steel components are not covered in RP 578.
2. One inspection lot means items taken from one heat only.
3. Mill test report is not substitute to PMI test.
4. PMI testing of at least one electrode should be carried out from

each lot or package.
5. PMI Test Methods:

a. X-ray Fluorescent: It cannot detect elements lighter than
sulpher. Carbon cannot be detected. The equipment uses
gamma rays to analyze material.
b. Optical Emission Spectrometer: Uses electric arc to
analyze light spectrum. May be used to detect carbon.
c. Chemical analysis by removing small sample.
6. When PMI testing is conducted on new or existing piping, records

of results shall be kept as long as the piping exists in original
location.
143 | 2 2 9
(VOLUME- I)
Part- 5
QUESTION BANK FOR
API 570 PREPARATORY COURSE
144 | 2 2 9
Questions from API 570 Piping Inspection Code- 2018 Edition
Closed Book Questions
QUESTIONS FROM CHAPTER-1
1. API 570 covers inspection, rating, repair, and alteration procedures for which of the
following that have been placed in service
a. Metallic piping systems
b. Fiberglass reinforced plastic (FRP)
c. Associated pressure relieving devices
d. All of above
Ans: d. API 570 Para 1.1.1
2. The extruded, generally homogenous nonmetallics, such as high and low-density

polyethylene are:
a. Excluded from API 570
b. Included in API 570
c. Optional to include in API 570
d. Depends on the owner/user
Ans: a. API 570 Para 1.2
3. The intent of API 570 code is to specify -------------- that is needed to determine the
integrity of piping.
a. The in-service inspection program
b. Condition-monitoring program for in service piping.
c. Both the inspection and condition-monitoring program for in service piping.
d. The condition-monitoring program for both New and in service piping
Ans: c. API 570 Para 1.1.2
4. Which of the following is true?

a. API 570 shall not be used as a substitute for the original construction
requirements
b. It shall not be used in conflict with any prevailing regulatory requirements
c. If the requirements of API 570 code are more stringent than the regulatory
requirements, then the requirements of API 570 code shall govern
d. All of above are true
145 | 2 2 9
5. Fluid services that are optional to include in API 570 scope are:
a. Hazardous fluid services below threshold limits, as defined by jurisdictional
regulations;
b. Category D fluid services, as defined in ASME B31.3
c. Both a and b
d. None of a or b
6. According to API 570, the Piping systems that are exempted from the applicable
process piping construction code are ----------- in scope of API 570 code
a. Included
b. Excluded
c. Optional
d. API 570 is silent on this aspect
Ans: c. API 570 Para 1.2.2 c
7. API 570 inspection code recognizes Fitness-For-Service concepts (API 579) for
evaluating in-service damage of :
a. Pressure containing parts as well as non-pressure parts
b. Pressure containing parts
c. Non-pressure parts
d. Use of API 579 is not recognized by API 570
Ans: b. API 570 Para 1.3
146 | 2 2 9
1. Which of the following document is referenced in API 570 for: Material Verification
Program for New and Existing Piping Systems
a. API Recommended Practice 578,

b. API Recommended Practice 580,
c. API Recommended Practice 581,
d. API Publication 2201,
Ans: a. API 570 Section 2
2. Which of the following document is referenced in API 570 for: Fitness-for-service

c. API Publication 2201
d. API Standard 579-1/ASME FFS-1
Ans: d. API 570 Section 2
3. Which of the following document is referenced in API 570 for: Risk-based Inspection

c. API Publication 2201
d. API Recommended Practice 574,
Ans: b. API 570 Section 2
4. Which of the following document is referenced in API 570 for: Safe Hot Tapping
Practices in the Petroleum and Petrochemical Industries

b. API Publication 2201,
c. API Recommended Practice 571,
d. API Recommended Practice 580,
Ans: b. API 570 Section 2
147 | 2 2 9
1. For purposes of API 570 code,
a. Carbon steels are not considered as alloys,

b. Carbon steels are considered as alloy of Iron and carbon,
c. Depends on opinion of owner/user,
d. Depends on opinion of Authorized inspector
Ans: a. API 570 Para 3.1.2
2. Designated areas on piping systems where periodic examinations are conducted are
called.
a. Corrosion measuring locations

b. Corrosion monitoring locations
c. Condition monitoring locations
d. Examination locations
3. Which of the inspection agencies listed below is not an Authorised Inspection

Agency as defined in API 570.
a. Jurisdictional inspection organisation

b. Owner-user inspection organisation
c. ASTM inspection organisation
d. Independent inspection organisation
4. A person acceptable to the owner/user who is knowledgeable and experienced in the

specific process chemistries, corrosion degradation mechanisms, materials selection,
corrosion mitigation methods, corrosion monitoring techniques, and their impact on
piping systems is referred in API 570 as:
a. Corrosion specialist
b. Corrosion Expert
c. Corrosion Engineer
d. Piping Engineer
148 | 2 2 9
5. A defect is an imperfection of a type or magnitude exceeding the __________ criteria.
a. Non-specific
b. Imprecise
c. General
d. Acceptable
6. Which of the following piping can be called as “in service Piping systems”.
a. Piping systems that are still under construction .

b. Piping systems that are in transport to the site prior to being placed in service
c. Piping systems that have been retired
d. Piping systems that are not currently in operation due to turnaround, or other
maintenance activity
7. Corrosion barrier is The corrosion allowance in -----------typically composed of an

inner surface and an interior layer which is specified as necessary to provide the best
overall resistance to chemical attack
a. Metallic equipment
b. FRP equipment
c. Any non-metallic equipment
d. None of these
Ans: b. API 570 Para 3.1.13
8. An examiner is a person who __________ the inspector
a. Supplants
b. Assists
c. Supervises
d. Directs
Ans. b. API 570 Para 3.1.26
149 | 2 2 9
9. Welding repairs that involve removal and replacement of large sections of piping
systems are called :
a. Major alteration
b. Major repairs
c. Routine repairs
d. Routine alterations
10. What is an imperfection?
a. It is a flaw or discontinuity noted during inspection that may be subject to

acceptance.
b. It is a defect noted during inspection that is unacceptable.
c. It is a weld flaw noted during an inspection that may be subject to repair
d. It is a blemish that is only cosmetic and acceptable under all conditions.
11. Which of the following is “off-site piping”
a. Piping systems associated with a hydrocracker,

b. Piping systems associated with an ethylene cracker
c. Both a and b .
d. Tank farm piping
12. Small-bore piping means
a. Piping that is less than NPS 2.

b. Piping that is less than or equal to NPS 2.
c. Piping that is less than or equal to NPS 3.
d. Piping that is less than NPS 3.
150 | 2 2 9
13. Hold point is a point in the repair or alteration process beyond which work may not
proceed until the __________ has been performed and documented
a. PWHT required
b. Required inspection
c. RT required
d. Ultrasonic testing
14. Which of the following is NOT process piping

a. Piping located on pipe rack,
b. Piping located in tank farm,
c. Utility piping.
d. Tank farm piping and utility piping.
15. Calculations to establish pressures and temperatures appropriate for a piping system,
including design pressure/temperature, MAWP, structural minimums, required
thicknesses, etc. are called
a. Re-rating
b. Derating
c. Rating
d. Changed rating
16. __________ is a response or evidence resulting from the application of a non-

destructive evaluation technique
a. Indication
b. Imperfection
c. Breach
d. Division
151 | 2 2 9
17. In API 570 code the Acronym PMI means
a. Primary material inspection

b. positive material identification
c. preliminary material identification
d. positive material inspection
18. In API 570 code the Acronym CUI stands for:
a. Control unit inspector

b. Corrosion under insulation
c. Corrected unobtrusive inserts
d. Corroded underground installation
19. In API 570 code the Acronym MOC means
a. management of corrosion
b. measurement of corrosion
c. management of change
d. measurement of condition
Ans: c. API 570 Para 3.2
20. In API 570 code the Acronym SMYS means
a. Specified maximum yield strength

b. Specified measured yield strength
c. Sample monitored yield strength
d. Specified minimum yield strength
Ans: d. API 570 Para 3.2
21. In API 570 code the Acronym MDR means
a. Management data reports

b. Materials data reports
c. Material damage reports
d. Manufacturer’s data reports
152 | 2 2 9
22. In API 570 code the Acronym MTR means
a. Material test report

b. Manufacturer’s Test reports
c. Measurement thickness reports
d. Manufacturer’s test record
Ans: a. API 570 Para 3.2
153 | 2 2 9
1. Who shall be responsible to the owner-user for determining that the requirements of
API 570 for inspection, examination, and testing are met.
a. Inspector
b. Repair Organisation
c. Operating Personnel
d. Piping Engineer
2. Who is responsible for implementing an effective MOC process that will review and
control changes to the process and to the hardware.
a. Authorized Piping Inspector

b. The owner/user
c. Piping Engineer
d. Repair Organization
Ans: b. API 570 Para 4.3.1.2
3. Who bears overall responsibility for the control of piping system inspection programs,
inspection frequencies and maintenance of piping?
a. Authorised Piping Inspector

b. Jurisdiction
c. Contractor
d. Owner-user
Ans: d. API 570 Para 4.3.1.2
4. As per API 570, an authorized piping inspector shall have certain qualifications.
Which of the following is not acceptable qualification to become API 570 inspector.
a. High school education plus 3 years of experience in the design, construction,

repair, operation, or inspection of piping systems
b. Two year certificate in engineering or technology plus 2 years of experience in
the design, construction, repair, operation, or inspection of piping systems.
c. Four years of experience inspecting in-service piping systems
d. Degree in engineering plus one year experience in the design, construction, repair,
operation, or inspection of piping systems.
154 | 2 2 9
Ans: c. API 570 Annex A
5. “Actively engaged as an authorized piping inspector” shall be defined as

a minimum of -------------spent performing inspection activities or
supervision of inspection activities, or engineering support of inspection
activities, as described in the API 570, over the most recent three year
certification period.
a. 10 % of time
b. 20 % of time
c. 25 % of time
d. 50 % of time
Ans: b. API 570 Annex A
6. Once every other recertification period, inspectors actively engaged as an authorized

piping inspector shall demonstrate knowledge of revisions to API 570 that were instituted
during the previous----------.
a. Six years
b. Three years
c. Five years
d. Ten years
Ans: a. API 570 Annex A
155 | 2 2 9
1. The inspection plan shall be developed by:
a. The inspector
b. The inspector and/or engineer
c. The engineer
d. None of above
Ans: b API 570 Para 5.1.1.1
2. A corrosion specialist should be consulted when developing the inspection plan for
piping systems:
a. That operate at elevated temperatures[above 750 °F (400 °C)]

b. That operate below the ductile-to-brittle transition temperature
c. Both a and b
d. For each and every piping system
Ans: c API 570 Para 5.1.1.1
3. As per API 570, RBI can be used to determine
a. Inspection intervals
b. The type and extent of future inspection/examinations.
c. Both a and b
d. None of above
Ans: c. API 570 Para 5.2
4. In RBI assessment includes systematic evaluation of probability of piping failure and

the associated consequence of failure. In assessing the probability of piping failure
includes ientifying and evaluating:
a. Potential damage mechanisms,

b. Current equipment condition
c. The effectiveness of the past inspections
d. All of above
Ans: d API 570 Para 5.2
156 | 2 2 9
5. In RBI assessment includes systematic evaluation of probability of piping failure and
the associated consequence of failure. Consequence assessment shall consider In
assessing
a. The potential incidents that may occur as a result of fluid release,

b. The size of a potential release,
c. The type of a potential release (explosion, fire, or toxic exposure)
d. All of above
Ans: d API 570 Para 5.2.2
6. When RBI assessments are used to set equipment inspection intervals, the assessment
shall be updated after
a. Each time process or hardware changes are made

b. Each time the Inspection person is changed
c. Both a and b
d. Each time any RBI team member is changed
Ans: a API 570 Para 5.2.4
7. Safety precautions shall be included when preparing piping systems for inspection and
maintenance activities. One such organization issuing safety Regulations is “OSHA”,
which means
a. Operational Safety and Health Administration (OSHA)

b. Occupational Safety and Health Administration (OSHA)
c. Operational Safety and Health Agency (OSHA)
d. Occupational Safety and Hazard Agency (OSHA)
Ans: b API 570 Para 5.3.1
8. Prior to entering large piping, the piping system shall be isolated from all sources of
liquids, gases, vapors. The piping system should be-------------- (Choose correct
Sequence from following)
a. Drained, gas tested, cleaned, purged, ventilated before it is entered

b. Drained, gas tested, purged, cleaned, ventilated before it is entered
c. Ventilated, gas tested purged, drained, cleaned before it is entered
157 | 2 2 9
d. Drained, purged, cleaned, ventilated, gas tested before it is entered.
9. Before performing any of the required inspections on piping system, inspectors should
review:
a. The piping system’s prior inspection results, prior repairs, current inspection plan
b. The piping system’s Design calculations and drawings
c. The piping system’s drawings and current inspection plan
d. The piping system’s Stress analysis, flexibility calculations and inspection plan
10. Example of Subsurface cracking is:
a. Fatigue cracking
b. Caustic stress corrosion cracking
c. Hydrogen induced cracking
d. Chloride stress corrosion cracking
Ans: c API 570 Para 5.4.1.1 Table 1
11. Which of the following can result in General and local metal loss
a. Graphitization
b. Temper embrittlement
c. Sulfidation
d. a and b
Ans: c API 570 Para 5.4.1.1 Table 1
12. As per API 570, When possible and practical, internal visual inspections may be
scheduled for systems such as large-diameter piping systems. Such inspections should
be conducted with-----------
a. Methods and procedures similar to those outlined in API 510

b. Methods and procedures similar to those outlined in API 5 74
c. Methods and procedures similar to those outlined in API 510 and 574
d. Methods and procedures similar to those outlined in API 579
Ans: c API 570 Para 5.5.1
158 | 2 2 9
13. According to API 570, all on-stream inspections should be conducted by
a. Either an inspector or examiner.

b. Both inspector and examiner
c. Inspector
d. Examiner
14. All on-stream inspection work performed by an examiner shall be :
a. Approved by the inspector

b. Need not be approved by the inspector
c. Authorized and approved by the inspector
d. Depends on the opinion of inspector
14. According to API 570, thickness measurements on piping systems are normally taken
while the piping is:
a. On-stream
b. Not in operation
c. Under maintenance
d. Empty and cleaned
15. What inspector should do when the short-term corrosion rate changes significantly
from the previous identified rate to determine the cause
a. Consult with a corrosion specialist

b. Consult with Piping Engineer
c. Consult with Design Engineer
d. Ignore the short-term corrosion rate and use long term corrosion rate
159 | 2 2 9
16. An inspection performed to determine the condition of the piping insulation system,
painting, and coating systems, and associated hardware; and to check for signs of
misalignment, vibration, and leakage is called-------------
a. Vibrating piping inspection

b. External Visual Inspection
c. Supplemental inspection
d. CUI Inspection
17. According to API 570, some welds in a piping system that has been subjected to
radiography according to ASME B31.3:
a. Will meet random radiograph requirements and will perform satisfactorily in-
service without a hydrotest
b. Will not meet random radiograph requirements, and will not perform
satisfactorily in-service even though hydrotested.
c. Will meet random radiograph requirements, and will not perform satisfactorily in-
service after a hydrotest
d. Will not meet random radiograph requirements, but will still perform
satisfactorily in-service after being hydrotested.
18. The periodic external inspection should normally be conducted by the inspector, but
may be conducted by----------------when acceptable to the inspector
a. Qualified maintenance personnel

b. Qualified operating personnel
c. Qualified operating or maintenance personnel
d. Inspector himself must conduct this inspection
19. For Carbon Steel piping Inspection for CUI shall be considered for externally-
insulated piping with possibility of moisture ingress and susceptible temperature
range, which is-------------
a. Between 10 °F (–12 °C) and 350 °F (175 °C).
b. Between 25 °F (–4 °C) and 250 °F (120 °C).
c. Between 32 °F (0 °C) and 212 °F (100 °C).
d. Between 10 °F (–12 °C) and 250 °F (120 °C).
160 | 2 2 9
20. The recommended upstream limit of the injection point circuit
is………………………...
a. Up to length of three pipe diameters upstream

b. 12 in. (300 mm) upstream
c. 12 in. (300 mm) or three pipe diameters whichever is smaller
d. 12 in. (300 mm) or three pipe diameters whichever is greater
21. The recommended downstream limit of the injection point circuit is……………….
a. Second change in flow direction, or 25 ft beyond the first change whichever is

more.
b. Second change in flow direction, or 25 ft beyond the first change whichever is
less
c. Second change in flow direction, or ten pipe diameters whichever is greater
d. Second change in flow direction, or ten pipe diameters whichever is less
22. During periodic scheduled inspections, more extensive inspection should be applied
to an area beginning ---------------------- upstream and continuing for at least --------
-----downstream of the injection point.
a. 12 in.(300 mm) upstream and at least ten pipe diameters downstream

b. Three pipe diameters upstream and at least ten pipe diameters downstream
c. 12 in.(300 mm) upstream and at least 25 ft downstream
d. 12 in.(300 mm) upstream and at least ten pipe diameters downstream
23. The preferred methods of inspecting injection points to establish the minimum
thickness at each TML are--------------
a. Radiography and Magnetic particle testing

b. PT or MT
c. Eddy current and UT
d. Radiography and/or UT
161 | 2 2 9
24. For thickness measurements on pipe diameters of NPS 1 and smaller, preferred
technique is:.
a. Radiographic profile techniques

b. Magnrtic particle –Fluorescent particles
c. Fluorescent Liquid penetrant
d. Ultrasonic thickness measurements
25. Pressure tests are ------------ conducted as part of a routine inspection
a. Always
b. Not normally
c. Never
d. Usually
Ans: b API 570 Para 5.8
26. When a pressure test is required on in-service piping it -------------any heat treatment.
a. Shall be conducted after

b. Shall be conducted prior to
c. May be conducted after or before
d. Depends on opinion of inspector
Ans: a API 570 Para 5.8
27. When a pressure test is required on in-service piping, API 570 has cautioned
the owner/user is to avoid --------------for the material at test temperature
a. Exceeding the SMYS

b. Exceeding 90 % of the SMYS
c. Exceeding the SMTS
d. Exceeding 90 % of the SMTS
28. To minimize the risk of brittle fracture during a pressure test, the metal temperature
162 | 2 2 9
should be maintained at least --------- above the MDMT for piping that is more than
2 in. (5 cm) thick, and ------- above the MDMT for piping that have a thickness of 2
in. (5 cm) or less.
a. 30 °F and 10 °F respectively
b. 10 °F and 30 °F respectively
c. 17 °F and 6 °F respectively
d. 6 °F and 17 °F respectively
29. According to API 570, when a pressure test is not performed after a major repair or
alteration acceptable alternative is:.
a. Carry out Appropriate PWHT

b. Carry out Appropriate RBI studies
c. Carry out Appropriate Fitness for service assessments
d. Carry out Appropriate NDE
30. Substituting NDE procedures for a pressure test after an alteration is allowed only
after --------------- the substitution.
a. The engineer has approved

b. The inspector has approved
c. The engineer and inspector have approved
d. The engineer or inspector has approved
31. PMI testing can be accomplished by the ---------------with the use of suitable
methods as described in API 578.
a. Inspector
b. Examiner
c. Inspector and the examiner
d. Inspector or the examiner
32. Normally, thickness measurements -------------- on valves during scheduled
163 | 2 2 9
inspections.
a. Are routinely taken

b. Are not routinely taken
c. Are usually taken
d. Are never taken
33. Fasteners should be fully engaged. Any fastener failing to do so is considered

acceptably engaged if--------------.
a. The lack of complete engagement is not more than two thread

b. The lack of complete engagement is not more than three thread
c. The lack of complete engagement is not more than half thread
d. The lack of complete engagement is not more than one thread
34. The audit team should typically be from ------------------ experienced in refining
and/or petrochemical process plant inspection
a. Another owner/user plant site or from a third party

b. Within the same plant site or from a third party
c. Another owner/user plant site
d. From a third party
164 | 2 2 9
1. An RBI assessment may be used to ----------------the inspection intervals

described in API 570..
a. Increase
b. Decrease
c. Increase or decrease
d. None of these
2. Who establishes inspection interval for thickness measurements, external visual

inspections and for internal and supplemental inspections?
a. Piping engineer
b. Owner-user or the inspector
c. Chemical Engineer
d. Piping engineer and the jurisdiction
3. The classification in API 570 is used to establish frequency and extent of

inspection.The piping classification scheme in API 570 is based on----------
a. The consequence of a failure

b. The likelihood and consequence of a failure
c. The likelihood of a failure
d. The likelihood and consequence of a failure
Ans: a API 570 Para 6.3.4.1
4. Of the four classification of piping systems, which includes the majority of unit
processes and selected off-site piping?
a. Class 3
b. Class 4
c. Class 1
d. Class 2
Ans: d API 570 Para 6.3.4.3
165 | 2 2 9
5. Class 3 piping is described as being in services:
a. With the highest potential of resulting in an immediate emergency if a

leak occurs.
b. That are flammable but do not significantly vaporize when they leak
and are not located in high-activity areas
c. That are not flammable and pose no significant risk to populated areas
d. That are not in classes 1 and 2.
Ans: b API 570 Para 6.3.4.4
6. The appropriate inspection shall provide the information necessary to determine that
Piping is safe to operate until--------------.
a. The Remaining life.

b. Next 10 years
c. The next scheduled inspection
d. Next 10 years or the Remaining life whichever is shorter.
Ans: c API 570 Para 6.1
7. Thickness measurement inspection should be scheduled based on the calculation of not

more than
a. One half the remaining life determined from corrosion rates or the
maximum interval of 5 years whichever is shorter.
b. One half the remaining life determined from corrosion rates or the
maximum interval allowed by API 570 in Table 2, whichever is
shorter
c. One fourth the remaining life determined from corrosion rates or the
maximum interval of 10 years whichever is shorter.
d. One quarter the remaining life determined from corrosion rates or the
maximum interval allowed by API 570 in Table 2, whichever is
shorter.
8. Table 2 of API 570 contains recommended maximum inspection intervals for Classes
1, 2 and 3 of piping services. Maximum intervals for Class 4 piping are ------------------
166 | 2 2 9
a. Optional.
b. Same as class 3
c. Same as class 1
d. Same as class 2
Ans: a API 570-Table 2
9. Piping systems that are known to have a remaining life of over __________ years or
that are protected against external corrosion need not have insulation removed for the
periodic external inspection.
a. 10
b. 15
c. 5
d. 20
10. If Piping Service is Changed then-------------shall be established for the new service.
a. The allowable service conditions

b. The inspection interval
c. The remaining life and the inspection interval
d. The allowable service conditions and the inspection interval
11. As per API 570, Services with the ------------------------ are in Class 1.
a. Highest potential of resulting in an immediate emergency if a leak were

to occur
b. Highest Inspection Interval as per Table 2 of API 670
c. Lowest potential of resulting in an immediate emergency if a leak were
to occur
d. Lowest remaining life
12. Identify correct statements from following
167 | 2 2 9
a. Fluids that can rapidly vaporize during release, are class 1.
b. On-site hydrocarbon fluids that will slowly vaporize during release
are class 2
c. Hydrocarbon Fluids that do not significantly vaporize during release
are class 3
d. All of above
13. Identify correct statements from following
a. Services that are essentially nonflammable but may be toxic are in Class
4,
b. Services that are essentially flammable and nontoxic are in Class 4,
c. Services that are essentially nonflammable and nontoxic are in Class 4,
d. Services that are essentially flammable and toxic are in Class 4,
14. Pressure-relieving Devices PRDs should be inspected, tested, and maintained in

accordance with …………..
a. API 579
b. API 578
c. API 577
d. API 576
15. As per API 570 , test and inspection intervals for pressure-relieving devices in typical
process services should not exceed:
a. 5 years for typical process services,

b. 10 years for clean (nonfouling) and noncorrosive services.
c. Both a and b
d. 10 years for all services
168 | 2 2 9
1. If LT and ST corrosion rates are showing different values, The authorized inspector,
in consultation with a corrosion specialist, shall select the corrosion rate that-------------
a. Is higher of LT and ST corrosion rates

b. best reflects the current process.
c. Is lower of LT and ST corrosion rates
d. Is average of LT and ST corrosion rates
2. You have a new piping system 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?
a. 1 month
b. 3 months
c. 6 months
d. 12 months
3. When the MAWP is recalculated, the wall thickness used in these computations
shall be the actual thickness determined by inspection ------------------
a. Minus the estimated corrosion loss before the date of the next
inspection
b. Plus the estimated corrosion loss before the date of the next inspection
c. Minus twice the estimated corrosion loss before the date of the next
inspection
d. Plus twice the estimated corrosion loss before the date of the next
inspection
4. Inspection deferral is appropriate when the piping circuit’s current interval is still
considered to be correct given the available data but an extension of the inspection date
based on --------------
169 | 2 2 9
a. A documented stress analysis process is acceptable to the inspector
b. A documented risk analysis process is acceptable to the inspector
c. A documented flexibility analysis process is acceptable to the inspector
d. A documented both sress and flexibility analysis process is acceptable to
the inspector
5. If a piping system is made up of unknown materials and computations must be made to

determine the minimum thickness of the pipe, what can the inspector or the piping
engineer do establish the minimum thickness?
a. The lowest grade material and joint efficiency in the applicable code
may be assumed for calculations.
b. Samples must be taken from the piping and testing for maximum
tensile stress and yield strength will determine the allowable stress to
be used.
c. The piping made of the unknown material must be removed from
service and current piping of known material must be installed.
d. The piping of unknown material may be subjected to a hydrostatic
stress tests while having strain gages on it to determine its yield
strength and thus allowable stress.
6. As per API 570, Piping system and pressure-relieving device records shall contain
four types of information pertinent to mechanical integrity. Which of the following
is NOT part of these records.
a. Fabrication, Construction and Design Information to the Extent

Available
b. Inspection History—inspection reports
c. Repair, Alteration, and Re-rating Information
d. RBI documentation
7. The __________ shall maintain appropriate permanent and progressive records of each
piping system covered by API 570.
170 | 2 2 9
b) Inspector
c) Piping system owners and users
d) Jurisdiction
e) Examiner
171 | 2 2 9
1. When making repairs and alterations to piping systems, the principles of ---------------
-------- shall be followed:
a. ASME B31.3
b. Code to which the piping system was built
c. Or b.
d. ASME B&PV Code
2. Repair and alteration work must be done by a repair organisation as defined in API
570 and must be authorised by the __________ prior to its commencement:
a. Jurisdiction
b. Inspector
c. Owner-user
d. Examiner
3. Authorization for ------------------ to a piping system may not be given without

prior consultation with, and approval by, the piping engineer
a. Alteration work
b. Repair work
c. Any repair as well as alteration work
d. Replacement of any piping component
4. What type of repairs and procedures may the inspector give prior general
authorisation to continue (provided the inspector is satisfied with the competency
of the repair organisaton)?
a. Major repairs and minor procedures

b. Limited or routine repairs and procedures
172 | 2 2 9
c. Alterations and re-ratings
d. Minor re-ratings and alterations
5. Who approves all proposed methods of design, execution, materials, welding

procedures, examination and testing of in-service piping?
a. The jurisdiction or the piping engineer as appropriate

b. The analyst and the operator as appropriate
c. The examiner and the piping programmer as appropriate
d. The inspector or the piping engineer as appropriate
6. Who must give approval for any on-stream welding?
a. Owner-user
b. Jurisdiction
c. Examiner
d. Analyst
6. Temporary repairs should be removed and replaced with a suitable permanent

repair at the next available maintenance opportunity. Temporary repairs may
remain in place for a longer period of time only if approved and documented by
the----------.
a. Examiner
b. piping engineer
c. Inspector
d. Corrosion engineer
173 | 2 2 9
7. What type of defect, should not be repaired by a full encirclement welded split
sleeve?
a. A longitudinal check
b. A circumferential crack
c. Pits that are one half through wall
d. General corrosion in the longitudinal direction.
8. If a repair area is localised (for example, pitting or pin-holes) and the specified
minimum yield strength (SMYS) of the pipe is not more than __________ psi, a
temporary repair may be made by fillet welding a properly designed plate patch over
the pitted area:
a. 30,000 psi
b. 55,000 psi
c. 40,000 psi
d. 36,000 psi
9. Insert patches (flush patches) may be used to make permanent repairs. One of the
condition for making these is that :
a. Class 1 piping systems, the welds shall be 100 % radiographed or

ultrasonically tested
b. Class 2 piping systems, the welds shall be 100 % radiographed or
c. Class 3 piping systems, the welds shall be 100 % radiographed or
d. Class 1 and Class 2 piping systems, the welds shall be 100 % radiographed or
174 | 2 2 9
10. Insert patches may be used to repair damaged or corroded areas of pipe if several
requirements are met. One of these is that an insert patch shall have rounded
corners with __________ minimum radii.
a. 0.375"
b. 0.50"
c. 0.75"
d. 1"
11. An inspector finds a pin-hole leak in a weld during an on-stream inspection of a

piping system. A permissible temporary repair is :-
a. The use of sealant of reputed brand to seal off the leak

b. The installation of a proper bolted leak clamp
c. Driving a wooden plug into the hole
d. Screwing a self tapping screw into the hole
12. Any welding conducted on piping components in operation must be done in

accordance with
a. API Publication 2201
b. API Standard 577
c. API Standard 579
d. ASME B31.3
13. For carrying out repairs by welding qualified welding procedures and welders have
to be used. Who ------------------shall maintain records of welding procedures and
welder performance qualifications.
a. Repair organization
b. Inspector
c. Owner-user
d. Examiner
175 | 2 2 9
14. The records of welding procedures and welder performance qualifications shall be
available to the inspector:
a. At the end of the job

b. After the start of welding
c. Following the start of welding
d. Before the start of welding
15. Preheating to not less than __________ °F may be considered as an alternative to

post weld heat treatment for alterations or repairs of piping (materials P No.1)
initially post weld heat treated as a code requirement.
a. 150
b. 200
c. 300
d. 350
16. Piping butt joints made during repairs shall be:
a. Double fillet welds

b. Single fillet welds
c. Full-penetration groove welds with backing strip
d. Full-penetration groove welds
17. Fillet welded patches (weld-on patches) shall be designed by
a. An engineer
b. The inspector
c. The piping engineer
d. The repair organisation
176 | 2 2 9
18. As per API 570, pressure tests normally required----------
a. After alterations and any repair

b. After alterations and major repairs
c. After major and minor repairs
d. After each inspection
19. When a pressure test is not necessary or practical, NDE shall be utilized in lieu of a
pressure test after consultation with --------------------
a. The inspector
b. Piping engineer.
c. The inspector and the piping engineer.
d. Corrosion specialist.
20. As per API 570, Rerating of piping systems can be done under certain conditions
which of the following is/are such condition/s for performing Rerating
a. Calculations are performed by the piping engineer or the inspector.

b. All reratings shall be established in accordance with the requirements
of the applicable code.
c. Current inspection records verify that the appropriate corrosion
allowance is provided.
d. All the above
21. As per API 570, Rerating of piping systems can be done under certain conditions
which of the following is/are such condition/s for performing Rerating
a. Rerated piping systems shall be leak tested unless a previous leak test was
done at greater than or equal to the test pressure for the new condition.
b. Full radiography of all butt welds must be performed.
c. PMI testing of piping systems shall be done
d. A and C above
177 | 2 2 9
1. For Inspection Of Buried Piping Above-Grade Visual Surveillance by observing leaks

change in the surface contour of the ground, discoloration of the soil, pool formation
etc. shall be done at approximately----------
a. 3-month intervals
b. 6-month intervals
c. Once a year
d. Once every 3 years
2. Corrosion cells can form on Buried pipes (both bare and coated pipe) where bare steel
contacts the soil. How can these cells be detected ?
a. Run an acoustic emission test on the piping

b. Visually survey the route of buried piping
c. Carry out a close-interval potential survey
d. Run an internal survey of the piping using a video camera
3. A pipe coating holiday survey is used to locate coating defects on coated pipes. More
often, it is used on buried pipe to--------------
a. Measure differences in electrical potential in corroded areas

b. Evaluate coating serviceability for buried piping that has been in-
service for along time.
c. Determine the leakage of service fluid in piping.
d. Evaluate the cathodic protection system
4. If an "smart” or “intelligent pigging" system is used to inspect buried piping, what

type of bends are usually required in the piping system ?
a. Five diameter bends

b. Short radius elbows
c. Ten diameter bends
d. Three diameter bends
178 | 2 2 9
5. Measurements of soil resistivity should be performed using ---------------- in

accordance with ASTM G57.
a. Holiday detector
b. Intelligent pigging.
c. Boroscopes .
d. Wenner Four-Pin Method
6. For piping buried in lengths greater than 100 feet (30 m) and not cathodically
protected, evaluations of soil corrosivity should be performed at ---------
a. 3-year intervals half of remaining life whichever is shorter

b. 5-year intervals
c. 5-year or half of remaining life whichever is shorter
d. 3-year intervals
7. How often should poorly coated pipes with inconsistent cathodic protection potentials
have a pipe-to-soil potential survey made ?
a. Yearly
b. Every 2 years
c. Every 3 years
d. Every 5 years
8. In Intelligent pigging inspection method (involving the insertion and travel of a

device through the piping) can be performed-------------
a. While piping is in-service

b. While piping has been removed from service
c. Either while piping is in-service or after it has been removed from
service
179 | 2 2 9
d. Only on small bore piping
9. The external condition of buried piping that is ------------------should be determined

by either pigging, which can measure wall thickness, or by excavating according to
the frequency given in Table 5
a. Cathodically protected
b. Not painted and not cathodically protected
c. Painted and cathodically protected
d. Not cathodically protected
Ans: d API 570 Para 9.2.
10. An alternative or supplement to inspection of buried piping is leak testing with liquid
at a pressure at least __________ % greater than the maximum operating pressure
a. 5
b. 25
c. 10
d. 50
11. In a certain leak test for a buried piping system, specified Leak test pressure was 200
psi and piping was pressurized to this pressure. Four hours after the initial
pressurization of the piping system, the pressure dropped to 285 psi . As per API
570, What should be done ?
a. Pressure decrease is more than 5 %, Reject the test

b. Nothing is required. The loss of pressure is negligible accept the test.
c. The system should be re-pressurised to the original leak test
pressure, isolated from the pressure source, then pressure reduction
shall be observed.
d. Pipe should be drained and made empty. Stat a new the pressure test
again.
180 | 2 2 9
12. If buried piping leaks are repaired by putting clamps and reburied What shall be done
as per API 570:
a. No further action is required unless the piping leaks again

b. The location and date of installation of the clamp shall be logged in the
inspection record for future corrective action at the first opportunity
c. The clamped line shall be pigged by intelligent pigging.
d. The clamped line shall be put back in service but the service pressure
shall be reduced to 80% of original pressure
181 | 2 2 9
Practice questions API-570 course
API 570 PRACTICE QUESTIONS

(OPEN BOOK)
1) A 18" O.D. pipe has a corroded area on it. What is the maximum size of a fillet
patch that may be used to repair the corroded area?
a. 3.5”
b. 9”
c. 6”
d. 6.5”
2) A 10’ long carbon steel pipe is welded to a 10'long 18-8 stainless pipe and is
heated uniformly to 475 degrees F from 70 degrees F. Determine its total
length after heating
a. 20.067’
b. 20.156’
c. 20.234’
d. 20.095’
3) A seamless NPS 10 pipe, ASTM A106 Grade B material operates at 750 psi
and 700 degrees F maximum. Considering only pressure design thickness,
what minimum thickness is required?
a. 0.244”
b. 0.200”
c. 0.282”
d. 0.173”
4) A seamless NPS 6, ASTM A106 Grade A pipe operates at 300 degrees F and
765 psi. The allowable stress is 16,000 psi. Using the Barlow equation,
determine the retirement thickness for these conditions
a. 0.446”
b. 0.332”
c. 0.231”
d. 0.158”
5) A seamless NPS 10 pipe, ASTM A106 Grade B material, operates at 750 psi
and 700 degrees F (maximum). The thickness of the pipe as determined by the
last inspection is 0.30". The pipe has been in service for 10 years. The original
182 | 2 2 9
thickness (measured when installed) was 0.365". Two years previous to the
0.30" measurement the thickness of the pipe was measured to be 0.31".
Determine the greatest corrosion rate i.e. short or long term
a. 0.0050 inches per year

b. 0.0065 inches per year
c. 0.0100 inches per year
d. 0.0130 inches per year
183 | 2 2 9
ANSWER KEY – OPEN BOOK
1. b API 570, APP

2. a B31.3, Table C-1
3. a B31.3, 304.1.1
4. d B31.3 304.1.1
5. b API 570, 7.1 and 7.2
184 | 2 2 9
Practice Questions API-570 course
ASME B 31.3 PROCESS PIPING
Closed Book
Q1) Piping code to be adopted for process piping within a large fertilizer
factory will be:
(a) ASME B 31.1

(b) ASME B 31.3
(c) ASME B 31.4
(d) None of Above
Q2) Most of the fluids normally covered by B 31.3 code falls under
Category
a. Category M
b. Category K
c. Category D
d. Normal
Q3) The term 'Y' in pipe thickness formula in B 31.3 represents numerical
factor of value.
a.Which is more than 1 and depends on type of pipe materials and

design temperature?
b. Less than 1 and does not depend on materials & temp.
c. Less than 1, but depends on materials & temp.
d. More than 1, but does not depend on materials and design
temp.
Q4) Impact test is to be conducted with how many specimen for applying
acceptance criteria of ASME B 31.3
(a) 3 (b) All 5 (c) 2 (d) 4
Q5) ASME B31.3 applies to piping for all fluids except for which of the
below?
a. Tubes of fired heaters, plumbing lines.

b. Raw, intermediate and finished chemicals
c. Petroleum products, fluidized solids and refrigerants
d. Gas, steam, air, and water
185 | 2 2 9
Q6) As per ASME 31.3, the increased quality factors by conducting
additional NDT is permitted for:
a. ERW pipes
b. Seamless pipes
c. Electric fusion welded pipes
d. All types of pipes
Q7) The thickness formula t = PD/2 (SE+PY) What is the term E?
a. Weld Strength factor

b. Wind factor
c. Weld Quality factor
d. Weight factor of pipe
Q8) The Term ‘S’ used in formula for calculating thickness of permanent
blinds as per 31.3 code, represents:
a. Safe stress Value of pipe materials

b. Safe stress value of blind materials
c. Lower of (a) and (b)
d. Higher a. and b.
Q9) ASME B 31.3 code is meant for new piping installations in:
a. Steam piping in Power stations

b. Piping in Refinery and process plants
c. Cross-country piping
d. Gas transmission piping
Q10) Identify incorrect statement/s:
a. In impact test exemption curves, curve D

represents better toughness material than
curve B
b. Curve C represents more brittle material than
Curve B
c. Fully de-oxidized steels are tougher than non-
deoxidized materials
d. Both a and c
186 | 2 2 9
Q11) The requirements of the latest edition of ASME Code Section B 31.3 and
any subsequent Addenda become effective:
a. As soon as the latest edition is issued

b. Immediately from date of issue and all piping
installed per earlier editions must be upgraded to
latest edition/addenda
c. After 6 months from date of issue
d. After 1 year from date of issue
Q12) Fluid service that is non-flammable, non-toxic, and not damaging to

human tissue and its gauge pressure does not exceed 150 psi and the design
temperature is form –20 degrees through 366°F is known as a category
________ fluid.
a. D
b. C
c. M
d. N
Q13) A fluid service in which the potential for personnel exposure is judged to
be significant and in which a single exposure to a very small quantity of a
toxic fluid, caused by leakage, can produce serious irreversible harm to
persons on breathing or bodily contact, even when prompt restorative
measures are taken is known as a category _________ fluid.
a. D
b. M
c. H
d. N
Q14) What type weld is considered to furnish no strength and is

only used to prevent leakage of threaded joints?
a. Tack weld
b. Seal weld
c. Fillet weld
d. Butt weld
Q15) In the equation tm = t + c, pick the correct definition of the value "t".
187 | 2 2 9
a. Minimum required thickness, including mechanical,
corrosion, & erosion allowances
b. Pressure design thickness, as calculated for internal
pressure.
c. Nominal wall thickness (As per purchase
specification)
d. Minimum design temperature of the pipe
Q16) The theoretical throat of a fillet weld is = _____ x the leg.
a. 0.707
b. 0.770
c. 1.414
d. 0.500
Q17) The pre-heat zone shall extend at least -----inch beyond the edge of the
weld.
a. 2inch b. 4 inch c. Half inch d. 1 inch
Q18) In ASME B 31.3, the term ‘Unlisted materials’ means:
a) Materials not listed by purchaser in the Data

Sheets
b) Materials of Unknown specifications.
c) Materials not listed in the code but meeting
other published specification
d) Materials prohibited by code.
Q19) Impact testing is not required If Design Minimum temperature-Thickness

combination is-----------the material Curve
a) Above
b) Below
c) On or above
d) On or below
Q20) Choose correct statement:
a) Curve A material is least brittle

b) Curve A material is most brittle
c) Curve D material is most brittle
188 | 2 2 9
d) Curve B material is most brittle
Q21) As per ASME B 31.3,the code used for Qualification of Welding Procedure
and welders is:
a) ASME Sec. IX
b) API 1104
c) Any one of a or b above may be used.
d) Both a and b above must be used
Q22) Pre-heating, whenever specified is:
a) Applicable to strength welds and not for tack welds

b) Strength welds and seal welds only
c) Strength welds, tack welds and seal welds
d) Strength welds only
Q23) Performing impact test requires testing of a set of:
a. Three specimen
b. At least two specimen
c. Minimum three specimen
d. Maximum three specimen
Q24) Code ASME B 31.3 stipulates recommended and required pre-heat

temperatures for welding of pipes. When do you follow recommendations as
mandatory requirement?
a. Pipe thk 1"

b. Pipe thk ¾"
c. Ambient temp is less than 0oC
d. None of above
Q25) If Two pipes different pre-heat requirements say t1 and t2 are to be welded,
the preheat for their joining shall be
a. Higher of to1 and to2

b. Lower of to1 and to2
c. Average of to1 and to2
d. None of above
189 | 2 2 9
Q26) To have a safe Pressure Test of Piping which type of test will you
recommend?
a) Hydrostatic
b) Pneumatic
c) Either a or b both are equally safe.
d) Code does not accept a or b
Q27) VT, MT, PT, UT and RT shall be performed as specified in the:
a. ASME BPV Code, Section V

b. ASME BPV Code, Section IX
c. ASME BPV Code, Section VIII
d. ASME BPV Code, Section I
Q28) What is the only category fluid service that may be subject to an initial
service leak test?
a) Category M
b) Category D
c) Category N
d) Category K
Q29) What will be Hydrotest pressure for a piping system with design pr = 100
psig, and safe stress at design condition is 18,000 psi while safe stress at test
condition (ambient) is 19,800 psi?
a. 150 psig
b. 130 psig
c. 165 psig
d. None of above
Q30) A piping is to be pneumatically tested at test pr = 80 psig. What will the

pressure at which a preliminary leak check shall be performed?
a. 40 psig
b. 20 psig
c. 25 psig
d. 80 psig
Q31) For pressure testing of piping systems, which of the following

statement(s) are correct?
190 | 2 2 9
a. Pneumatic test must be done using air only and no other
gas..
b. For hydro testing water alone can be used and no other
liquid.
c. Pneumatic test shall be conducted only if hydrostatic test is
impracticable.
d. a and c above
Q32) According to ASME B 31.3 ,In case of fabricated piping Pressure test is
conducted
a. After fabrication but before examination

b. After Examinations are completed.
c. Before PWHT
d. Anytime is okay
Q33) What is the minimum time that a leak test must be maintained as per B
31.3?
a. 60 minutes
b. 45 minutes
c. 30 minutes
d. 10 minutes
Q34) According to ASME B31.3 how much minimum experience in the

design, fabrication, or inspection of industrial pressure piping
must a Owner’s inspector have .
a. 10 years
b. 8 years
c. 6 years
d. 4 years
Q35) After PWHT, the hardness of weld and Heat affected Zone will generally -
------------
a. Increase
b. May increase or reduce.
c. Remain unaffected.
d. Reduce.
191 | 2 2 9
Practice Questions API-570 course
Closed Book- Answer Key
Q. NO. ANSWER
1 B
2 D
3 C
4 A
5 A
6 C
7 C
8 B
9 B
10 B
11 C
12 A
13 B
14 B
15 B
16 D
17 a
18 a
19 b
20 d
21 b
22 c
23 b
24 d
25 a
26 a
27 a
28 b
29 d
30 b
31 c
32 b
33 d
34 a
35 d
192 | 2 2 9
Open Book
Q1) What is the longitudinal weld joint factor, Ej, for API 5L ERW (Electric
Resistance Welded) pipe?
a. 1.00
b. 0.95
c. 0.85
d. 0.60
Q2) “S” is defined as the stress value for material from Table A-1 of ASME
B31.3. Pick the value of “S” when the material is ASTM A335 Grade P5 and
the temperature is 950 degrees F.
a. 11,400 psi
b. 10,600 psi
c. 8,000 psi
d. 20,00 psi
Q3) Select appropriate Y factor for Austenitic Stainless Steel pipes for Design
temperature of 630 deg. C.
a. 0.4 b. 0.6 c. 0.5 d. 0.7
Q4) A Water piping with Design Pressure=180 psig and Design temperature= -
10 deg. F, will be classified as Fluid Service
a. D. b. M c. High Pressure d. Normal
Q5) If Design temperature in above question is changed to -30 deg.F what will
be the fluid service.
Q6) Water piping with Design Pressure=130 psig and Design temperature= -10
deg. F, will be classified as Fluid Service

193 | 2 2 9
Q7) NPS 12, Sch 80 and Sch 160 pipes (M.O.C = A 106 gr B) are to be used at (–10º C.)
Determine whether,
a. Both pipes require impact testing

b. Only Sch 160 will require impact test but Sch
80 would be exempt.
c. Both would be exempt
d. Sch 80 would require but Sch 160 will be
exempt.
Q8) 6” NB Sch 40 pipe is selected for following conditions.

Design Pr = 360 psi
Design Temp. = 300 degrees F
M.O.C. = A 53 gr B (ERW)
Corrosion Allowance = 2.0 mm
Assume standard mill tolerance
Your assessment is:
a. Pipe design meets code requirement

b. Pipe design does not meet code requirement
c. Depends on opinion of Piping Inspector
d. Depends on opinion of Piping Design Engineer
Q9) A flat plate (without joints) is used as permanent blank for flanged point
with gasket I.D = 200 mm Design pr. = 200 psi and safe stress value for plate
is 18,000 psi, for given temperature of 250oC. What shall be the minimum
blank thickness from given options? Corrosion allowance is Nil code of
construction B 31.3.
a. 8 mm
b. 10 mm
c. 12 mm
d. 14 mm
Q10) Maximum Brinell hardness observed (after PWHT) on

following three Joints was as follows:
Joint 1: P No. 4, thk = 16 mm, Hardness = 240 HB

Your assessment is:
194 | 2 2 9
a) All joints are okay as per ASME B 31.3
b) Joint 2, and 3 are okay, joint 1 not okay
c) Only joint 1 is okay. Joint 2, and 3 are not
d) None of the above are correct answers.
Q11) An ASTM A53 Grade B pipe with a maximum wall thickness of 0.75” is
being considered for use in a cold service. What minimum temperature can it
be used and not have an impact test?
a. +20 degrees F
b. +15 degrees F
c. +10 degrees F
d. 0 degrees F
Q12) PWHT is required for all SMTS of piping over ½ inch for which of the
following materials?
a. P Nos. 1 and 2
b. P Nos. 1 and 3
c. P Nos. 2 and 3
d. P Nos. 4 and 5
Q13) A piping system has design pressure=200psig. The piping material has
allowable stress at design temperature=16000psi. It has allowable stress at test
temperature=17600 psi . Its minimum Hydro test pressure will be
a 300 psi b. 330 psi c.260 psi d. 220 psi.
Q14) A austenitic (18Cr-8Ni) stainless steel piping system operates between

temperatures of – 50 oF and 350 oF .The temperature of installation was 100 oF.
The approximate values of minimum expansion and contraction range for
sliding support installed at 150 ft from the anchored end will respectively be:
a. 2.4 inch and 4.3 inch

b. 4.3 inch and 2.4 inch
c. 1.9 inch and 4.8 inch
d. None of the above
Q15) A radiograph taken on Girth weld of 12 mm thick piping in Normal fluid

service shows a slag inclusion of length= 8 mm . Is the individual slag length
acceptable as per ASME B 31.3?
a) Accept
b) Reject
c) Accept only if it is Stainless steel pipe
d) Reject only if it is Stainless steel pipe
195 | 2 2 9
Q16) A radiograph taken on Girth weld of 12 mm thick piping in Severe Cyclic
condition shows a slag inclusion of length= 8 mm . Is the slag length
acceptable as per ASME B 31.3?
a. Accept
b. Reject
c. Accept only if it is Stainless steel pipe
d. Reject only if it is Stainless steel pipe
Q17) PWHT is required for all SMTS of piping over ¾ inch for
which of the following materials?
a. P Nos. 1 and 2
b. P Nos. 1 and 3
c. P Nos. 2 and 3
d. P Nos. 4 and 5
Q18) Piping system has design pressure=150 psig. Its Pneumatic test pressure
will be
a 200 psi b. 230 psi c.165 psi d. 225 psi.
Q19) What will be the inspection pressure in above question
a 150 psi b. 200 psi c.165 psi d. 225psi
Q20) ASME B 16.5 permits pipe flanges made from plates for which of the
following type?
a. Slip on type
b. Weld neck type
c. Blind flanges
d. None of above
Q21) Suitable Class for pipe flanges (A105) for Design pr = 400 psi, design
temp = 400oF will be:
a) Class 600
b) Class 300
c) Class 400
d) None of the above
Q22) What will be the System Hydrostatic Test pressure for above flange.
196 | 2 2 9
a. 300psig
b. 1000psig
c. 1100psig
d. 1125 psig
Q23) A carbon steel ASTM A 106 Grade B material is being impact tested.
What is the minimum average energy requirement for this material
(average for 3 specimens-fully deoxidized steel)?
a. 7 ft-lbs
b. 10 ft-lbs
c. 13 ft-lbs
d. 15 ft-lbs
Q24) Where the design temperature of the system is the same as the
hydrostatic test temperature, the hydrostatic test pressure shall not be
less than: (Yield stress during hydro test is not governing factor.)
a. 1.15 times design pressure

b. 1.1 times the design pressure
c. 1.25 times the operating pressure
d. 1.5 times the design pressure
Q25) A NPS 10 pipe made from ASTM A53 Grade B carbon steel is to be
checked for thickness (t). The pipe operates at 975 degrees F. Determine the
coefficient Y.
a. 0.4
b. 0.5
c. 0.6
d. 0.7
Q26) You have a fluid that does not operate at high pressure. The fluid is not
toxic. The fluid is not flammable. Exposure to the fluid will not cause damage
to human tissue. The design gage pressure is 120 psi and the operating
temperature is 1000F. What category fluid service would you design?
a. Normal fluid service

b. Category D fluid service
c. Category M fluid service
d. High pressure fluid service
Q27) If a pneumatic Pressure test test is used, the test pressure shall be
__________% of design pressure.
197 | 2 2 9
a. 50
b. 150
c. 125
d. 110
Q28) A 106 gr B pipe after installation, required pneumatic leak test.

Design pressure is = 300 psi. What is first stage pressure for
preliminary check and final inspection pressure for leak check?
a. 150 psi and 330 psi

b. 25 psi and 300 psi
c. 150 psi and 450 psi
d. 25 psi and 450 psi
198 | 2 2 9
ASME B31.3 PROCESS PIPING COURSE
Open Book Answer Key.
Q. NO. ANSWER
1 c
2 c
3 d
4 d
5 d
6 a
7 b
8 a
9 b
10 d
11 b
12 d
13 b
14 b
15 a
16 b
17 b
18 c
19 a
20 c
21 b
22 d
23 c
24 d
25 b
26 b
27 d
28 b
199 | 2 2 9
API-578 recommended practice
CLOSED BOOK
Q1) API 578 provides guidelines for a quality assurance system to verify:
a all metals.
b. all alloy materials.
c. non-ferrous materials.
d. For Carbon steels
Q2) An inspection lot includes:
a. all materials from same supplier.

b. all materials from same manufacturer.
c. all materials of the same material type but different heat numbers
d. all materials of the same material type and from the same heat
numbers
Q3) Who has the responsibility to verify that the material verification program
is properly implemented?
a. Authorized inspector
b. Owner/User
c. Repair organization
d. Engineering organization
Q4) The material verification program specified by API 578 covers:

a. only new pressure-containing components
b. only old pipe, and fittings.
c. only old and new pipe, fittings, and welds.
d. .none of these
Q5) During alloy welding:
a. one electrode from each box should be sampled.

b. two electrodes from each box should be sampled.
c. one electrode from each lot should be sampled.
d. two electrodes from each lot should be sampled.
Q6) Who has the responsibility to determine the extent of PMI testing required
on existing piping systems?
a. Authorized inspector
200 | 2 2 9
b. Owner/User
c. Repair organization
d. Engineering organization
Q7) PMI tools that use X-Ray fluorescence can not detect:
a. carbon content.
b. chrome content.
c. iron content.
d. molybdenum content.
Q8) All personnel performing PMI tests should be:
a. qualified by ASNT exam.

b. qualified by the owner/user.
c. knowledgeable about the operation of the PMI test equipment.
d. knowledgeable about the operation of the plant where the PMI is
conducted.
201 | 2 2 9
Api-578 recommended practice
CLOSED BOOK ANSWER KEY
1 b
2 d
3 b
4 c
5 a
6 b
7 a
8 c
202 | 2 2 9
ASME B 16.5
PRACTICE QUESTIONS – OPEN BOOK
1. The allowable pressure (in psig) on a 1000F, Class 150 8”

flange made from A-182 Grade F2 material is:
a. 170
b. 290
c. 300
d. 400
2. If a Class 1500 flange is to be made from A-182 F347

stainless steel and will be used at 280 psig with a carbon
content of 0.09%, at what maximum temperature can this
flange be used?
a. 10000F
b. 13000F
c. 11800F
d. 20000F
3. What is the maximum system hydrostatic test pressure

required for a Class 300 flange that is made from Group
1.10 material?
a. 1125 psig
b. 450 psig
c. 1000 psig
4. What is the maximum system hydrostatic test pressure

required for a Class 600 flange in a flanged joint made
from Group 3.5 material?
a. 2250 psi
b. 1500 psi
c. 1000 psi
203 | 2 2 9
ASME B 16.5
ANSWER KEY- OPEN BOOK
1. b
2. a
3. a
4. a
204 | 2 2 9
API 570 CERTIFICATION PREPARATORY COURSE
Practice Questions. ( Closed Book )
ASME Sec. V
1. Liquid penetrant inspection can find which type of discontinuity?
a. Internal cracking of welds.

b. Cracks open to the surface.
c. Subsurface porosity.
d. Laminations on the surfaces of plate.
Ans. b. Ref. ASME V . T-620
2. Certification of contaminants shall be obtained for all PT materials used on
a. Carbon steels
b. Ferritic stainless steels
c. Austenitic stainless steels
Ans. b. Ref. ASME V . T-640
3. The scope of the ASME Boiler and Pressure Vessel, Code, Section V includes:
A. NDE acceptance criteria

B. NDE metod and procedures to perform NDE
C. Extent of NDE ( i.e. what welds to examine )
D. All of above
Ans. B. Ref. ASME V . T-110
205 | 2 2 9
4. For Ammeter calibration for Magnetising equipment , The allowable tolarence
is:
a. + 5%
a. + 10 %
b. + 15 %
d. + 20
Ans. b.. Ref. ASME V . T-761
5. The basic features section V focuses on for any NDT technique is
a. Qualification of personnel
b. Calibration of NDE equipments
c. Correct procedure for NDE
d. All of the above
Ans. d. Ref. ASME V . T-110
6. In the radiography, penetrameter is put on the job to :
a. Evaluate the image quality of the radiograph.

b. Measure the strength of the penetrating radiation.
c. Check the density of the radiograph.
d. All of above.
Ans. a . Ref. ASME V . T-640
7. Describe how a liquid penetrant examination should be performed in order to

detect discontinuities, which are open to the surface :-
206 | 2 2 9
(a) clean the part, apply the developer, apply the penetrant, remove excess
penetrant, inspect the part, clean the part;
(b) clean the part, apply the penetrant, remove excess penetrant, apply the
developer, inspect the part, clean the part;
(c) clean the part, apply the developer, apply the penetrant, inspect the part,
remove excess penetrant, clean the part;
(d) clean the part, apply the developer, apply the penetrant, inspect the part,
clean the part.
Ans : (b) Ref. : ASME Sec. V-T620
What it the minimum permitted density of radiographic film using an Iridium

source ?
(a) 2.0; (b) 1.8; (c) 1.3; (d) 4.0
Ans. a. Ref. ASME V . T-282
8. When reviewing a radiograph, a light image of the letter B can be seen on the
film
(a) This is cause for rejection;

(b) This is not cause for rejection;
(c) This is the same as a light letter B
(d) An unusual safety hazard existed during the exposure.
Ans. a.. Ref. ASME V . T-284
9. The accuracy of a piece of magnetizing equipment that is equipped with an

ammeter shall be verified :
a. Each year
207 | 2 2 9
b. Each two years
c, When possible
d. Every 6 months
Ans. a.. Ref. ASME V . T-761
10. How shall Non-destrutive Examination Personnel be qualified?

a. To SNT-TC 1A
b. To CP-189
c. To referencing code requirements
d. Both a and b above
Ans. d.. Ref. ASME V . T-284
11. For MT examination by Prod technique the spacing between prods shall be
between
a. 4 inch to 12 inch
b. 4 inch to 10 inch
c. 3 inch to 10 inch
d. 3 inch to 8 inch
Ans. d.. Ref. ASME V . T-752.3
13. What is the difference between an inspection and an examination per Section V of
the ASME Code?
a. Inspection performed AI
b. Examination performed by manufacturer's personnel
c. There is no difference between the two
d. Both a and b, above
Ans. d... Ref. ASME V . T-170
208 | 2 2 9
14. In pulse –echo contact method, When does a considerable Vee - error will result
while measuring thickness?
a. Thickness measurement on thin sections using Dual Crystal probe

b. . Thickness measurement on thick sections using Dual Crystal probe
c. . Thickness measurement on thin sections using sinlgle Crystal probe
d. . Thickness measurement on thin sections using single Crystal probe
Ans. a.. Ref. ASME V . Art. 23.8.3.1
15. In pulse –echo contact method which disply of UT results is recommended when
reflecting surface is rough.
a. CRT display
b. Direct Digital display
c. Any of a or b are OK
d. UT is prohibited when reflecting surface is rough
Ans. a.. Ref. ASME V . Art. 23. 8.8
209 | 2 2 9
ASME Sec. IX
1. Essential variable on a welding procedure specification are :-
(a) those in which a change, as described in the specific variables, is considered to

affect the mechanical properties of the weldment;
(b) those in which a change, as described in the specific variables, is considered not to
affect the mechanical properties of the weldment;
(c) both (a) and (b) above are essential variables
(d) They are applicable only if Impact testing of weld is specified.
ANS : (a) REF : Section IX, QW 251.2
2. The Heat Affected Zone is :-
(a) that portion of the base metal which has not been melted;
(b) whose mechanical properties or micro structures have been altered by the heat of
welding;
(c) is least likely to contain discontinuities;
(d) both (a) and (b) above.
ANS : (d) REF : Section IX, QW-492
3. A welder may deviate from the parameters specified in WPS if they are nonessential
variables :-
210 | 2 2 9
(a) Provided the change is documented on revised WPS;
(b) Provided the supporting PQR is also revised;
(c) No;
(d) Nonessential variables only apply to PQRs
Ans. a REF : Section IX, QW-200.1
4 A welder is a qualified welder but gives consistently defective weld. What will be
your action as a Quality Control Manager?
(a) Cut his salary to compensate your cost.

(b) Remove him from your company
(c) Discontinue him from the job and retrain and re-qualify him as per
code requirements.
(d) Do not worry as anyway he is only going to repair his work.
Ans c. REF : Section IX, QW-322
5. Tensile test was carried out for qualifying a welding procedure (PQR). The specified
minimum tensile strength of the base metal is 70,000 psi. If the test specimen
breaks in parent metal (outside weld and fusion zone) and the tensile strength
calculated is 68,000 psi.
a. the test is acceptable

b. the test is rejected
c. the test is void and fresh test plate should be welded.
d. none of the above
Ans a. REF : Section IX, QW-151.1
6. A weld procedure is qualified in 1G position. This procedure can be used for welding
in _______ positions
a. 1G
211 | 2 2 9
b. 2G
c. 4G
d. all of the above
Ans d. REF : Section IX, QW- 203
7. Guided bend test are used to determine the
a. ultimate tensile strength of the weld joint

b. degree of soundness of fillet welds
c. notch toughness of weldment
d. degree of soundness and ductility of groove weld joints
Ans d. REF : Section IX, QW- 141
8. When radiographic testing is used in place of bend tests in welder’s performance

qualification on groove welds on plate, the minimum length of spot to be exposed
is :
(a) 6”
(b) 12”
(c) 15”
(d) Radiography cannot be used for welder qualification
Ans a. REF : Section IX, QW- 302.2
9. When a tensile specimen breaks in the base metal outside of the weld
or fusion line, the strength recorded may be at most ____ below the
specified tensile and be accepted.
A. 3.5%
B. 0.5%
C. 5%
212 | 2 2 9
D. All of the above
Ans C. REF : Section IX, QW- 153
10. The basic purpose of testing a welder is to establish the welder’s

a. Knowledge of welding requirements
b. Ability to deposit sound weld metal
c.. Mechanical ability to operate equipment
d.. General attitude toward welding inspectors
Ans b. REF : Section IX, QW- 100.2
11. What is the number of transverse guided bend tests required for
Performance Qualification in a 6G position?
a. 2 b. 3 c. 4 d. 6
Ans c. REF : Section IX, QW- 302.3
12. The procedure qualification test is used to determine:
a. The skill of the welder

b. That the proposed production weldment is capable of having the required properties
c..The corrosion-resistance of the proposed weldment
d.. None of the above
13. What period of inactivity from a given welding process requires the
welder to re-qualify in that process?
e. 3 months
f. 6 months
g. 9 months
d. 12 months
213 | 2 2 9
14. Groove weld test may be used for qualification of welders. Which
of the following shall be used for evaluation?
h. Only bend tests
i. Only radiography
j. Both radiography and bend tests
k. Either bend tests or radiography
Ans d. REF : Section IX, QW- 300.1
15. Under which of the following conditions can a welder be qualified

during production work?
a. A 6” length of the first production groove weld may be

qualified by radiography
b..A bend test coupon may be cut from the first 12” length
of weld
c. .A macro examination may be taken from the first 3” of
weld length
Ans a. REF : Section IX, QW- 300.1
214 | 2 2 9
Practice Questions. ( Open Book )
ASME Sec. V
1. The recommended minimum development time allowed for a material made of high
temperature alloy is
a. 5 min
b. 10 min
c. 7 min
d. 60 min
Ans: b. Reference ASME Sec. V Art.6, T676.1
2. What is the geometric unsharpness allowed as per code for a thickness of 2.0” (50.8
mm) as per code?
a. 0.020” ( 0.508mm)
b. 0.030” (.00.762mm)
c. 0.010 (0.254mm)
Ans: b. Reference ASME Sec. V Art.2, table 274.2
3. For steel plates and welds to be checked by LPI, what shall be the penetration time
for Penetrant
a) 10 min for weld, 5 min for plate
b) 5 min for both
c) 10 min for both
d) 5 min for weld, 10 min for plate
Ans: d. Reference ASME Sec. V Art.6, Table T-672
215 | 2 2 9
4. A 1” thickness butt weld has 0.125” acceptable reinforcement was radiographed.
The applicable plate type penetrameter on (Film side) and essential hole shall be
a. ASME 30 - 2T
b. ASME 25 - 2T
c. ASME 20 - 2T
d. ASME 30 - 4T
Ans: b. Reference ASME Sec. V Art2, table 276
5. What weight shall be used to check adequacy of lifting power of a permanent magnet
yoke. ?
(a) 10 pounds (b) 20;pounds c) 30 pounds (d) 40 pounds.
Ans: d. Reference ASME Sec. V Art.7, T-762
6. When should a densitometer be calibrated as a minimum?
a. Annually
b. Every 90 days
c. Whenever it is turned on
d. As required by the Examiner
Ans: b. Reference ASME Sec. V Art.2, T-262
8. In puse –echo UT technique, calibration was done at 100 deg. F. Thickness

measurement at 700 deg. F showed trading of 50 mm. After temperature correction
what is correct thickness?
a. 48 mm
b. 47mm
c. 53mm
d. 52mm
216 | 2 2 9
Ans: b. Reference : ASME Sec. V Art.23, 9.5
9. What wire No. shall make image on the film If type of penetrameter is wire type which
was put source side. Nominal single wall thickness is 0.875 inch and permissible
reinforcement is 0.125 inch. (wire decimeter in inch)
1. 0.025 (No. 10)

2. 0.016 (No. 8)
3. 0.020 (No. 9)
4. None of the above
Ans: 3. Reference : ASME Sec. V Art.2, Table T-276
10. After applying the developer the examiner checked four welds by PT after
following period, weld A - 7 minutes, weld B - 15 minutes, weld C - 25 minutes
and welds D - 70 minutes. Which of the welds were checked with incorrect
interpretation time?
a. A and B
b. B and C
c. C and D
d. A and D
Ans: b. Reference : ASME Sec. V Art.6, T-676
217 | 2 2 9
Practice Questions. ( Open Book )
ASME Sec. IX
1. A welder is decided to be qualified on his initial production weld on 1/4” thick

longitudinal seam of carbon steel shell. The first 6” length of the weld was
radiographed. The radiograph reveals slag length of 5 mm. Your decision in this case
will be
a. welder is not qualified .

b. welder is qualified since he meets acceptance criteria of ASME sec. VIII
Div.1
c. Data not adequate. In addition to radiography, bend tests are required.
d. Data not adequate. In addition to radiography, tension tests are required.
Ans: a. Reference : ASME Sec. IX, QW 191.2.1
2. 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. Quality new PQR with E 7015 electrodes.
b. Revise only WPS showing the change from E 7018 to E
7015 and submit WPS as a new revision.
c. Revise only the PQR document showing the change and
resubmit for approval.
d. Revise both WPS and PQR showing the change and
resubmit for approval
218 | 2 2 9
Ans: b.. Reference : ASME Sec. IX, and Table QW-253.
3. What positions are necessary to qualify a welder for all position pipe
welding?
a. 3G and 4G
b. 2G and 5G
c. 3G and 1G
d. 4G and 5G
Ans: b. Reference : ASME Sec. IX, QW Table 461.9
4. The maximum preheat temperature decrease allowed without re-

qualification of a GMAW groove weld procedure is:
a. 500F
b. 1000F
c. 1250F
d. 1500F
Ans: b. Reference : ASME Sec. IX, table QW 355
5. The P numbers are assigned on the basis of
a. Hardness
b. Composition, weldability & mechanical properties
c. Ductility only
Ans: b. Reference : ASME Sec. IX, QW-420
6. A groove weld was made with 1 ¼” thickness plate with SMAW process for PQR
Qualification and the test were found acceptable. This PQR can be used up to a
maximum weld thickness of:
219 | 2 2 9
a. 1 ¼”
b. 2.5”
c. 8”
Ans: b. Reference : ASME Sec. IX, QW 451
7. A welder qualifies in the 3G position on a plate coupon, he is then qualified to weld in

the position(s) on NPS 6 pipe :-
6. F, V;
7. F only;
8. F, V, O;
9. ALL
Ans: b. Reference : ASME Sec. IX, QW 461.9

8. A welder who gave procedure test in 3G position is also qualified for performance in
(a) 3G and 1G
(b) 1G only
(c) None. Procedure does not qualify performance. Must requalify
( d ) All positions
Ans: a. Reference : ASME Sec. IX, QW 203
9. A welding procedure qualified on ¼ inch thick plate can be used to weld groove welds
in materials from to :-
(a) 3/16 to 3/4; (b) 1/16 to 3/4;

(c) 3/8 to 3/4; (d) 1/16 to 1/2.
Ans: d. Reference : ASME Sec. IX, QW 451.1
220 | 2 2 9
10. E7018 electrodes are classified as F number :-
a 1;
b 2;
c 4;
d 5.
Ans: c. Reference : ASME Sec. IX, QW 432
221 | 2 2 9
QUESTIONS ON API RECOMMENDED PRACTICES
API RP 571 Damage Mechanisms :
Q.1 Temper embrittlement typically takes place with which of the following materials:
a. Austenitic Stainless steels

b. Carbon Steels
c. Low alloy steels containing Chromium
d. Duplex Stainless Steels
Ans: c Reference : API RP 571 4.2.3
Q.2 Brittle fracture typically takes place with which of the following materials:
a. Austenitic Stainless steels

b. Carbon Steels
c. Low alloy steels
d. Both b and c
Q.3 which of the following is true for Thermal fatigue :
a. It is caused due to Stress concentration and thermal cycling

b. It is caused at welds where materials with differing thermal exansion coefficint
are welded
c. They are Dagger shaped, oxide filled and initiate form the surface.
d. All of above.
Ans: d Reference : API RP 571 4.2.9
Q.4 Erosion/Corrosion can be controlled by :

222 | 2 2 9
a. Increasing the pipe diameter to decrease velocity
b. Increasing surface hardness by using harder alloys or hard facing
c. Using corrosion resistant alloys
d. All of the above.
Q.5 “Clam shell” type cracking failure is typically found in:
a. Mechanical fatigue.
b. Creep failure.
c. Stress corrosion cracks.
d. Hydrogen induced cracks.
Ans: a Reference : API RP 571 4.2.16
Q.6 which of the following is true for Atmospheric corrosion
a. It increases in marine environment.

b. It causes environmental cracks in Carbon steels
c. It reduces in dry rural environment.
d. Only a and c
Q.7. Cooling water corrosion increases with:
a. Increases with high flow velocity or turbulence.

b. Increases with stagnant or low velocity flow.
c. Increases with high dissolved oxygen
d. Only b and c
223 | 2 2 9
Q.8. The dissolved gases which cause Boiler water condensate corrosion are:
a. Oxygen and Hydrogen

b. Hydrogen and Carbon di oxide
c. Chlorine and Hydrogen
d. Oxygen and Carbon Dioxide
Q. 9 What construction material will you suggest where you are expecting serious
Sulphidation problem.
a. Upgrade to higher nickel alloys

b. Upgrade to higher chromium alloys
c. Upgrading to higher copper based alloys
d. All of the above.
Ans: b Reference : API RP 571 4.4.2
Q.10 Characteristic of Chloride SCC in Austenitic S.S. is: Cracks which are:
a. Transgranular, branching and aggravated at elevated temperature

b. Intergranular and unidirectional (straight)
c. Independent of chloride content
Ans: a Reference : API RP 571 4.2.3
Q.11 Identify the correct statement (s)
a. SSC is aggravated due to wet H2S

b. Hydrogen blistering may occur on I.D, O.D, or any where within wall thickness of
the pressure vessel.
224 | 2 2 9
c. High hardness & High strength steels are more likely to undergo damage due to
wet H2S compared to low strength/ low hardness steels
d. All of the above are correct statements
Q.12 High temperature hydrogen attack is typically due to
a. Methane gas formation.

b. Wet H2S
c. Creep rupture
d. Presence of Nickel in alloy steels.
Ans: a Reference : API RP 571 5.1.3.1
225 | 2 2 9
QUESTIONS ON API RECOMMENDED PRACTICES
API RP 577- Welding and Metallurgy :
1. If Coated electrodes and fluxes become wet, What should be done.

a. Dry the Coated electrodes and carry out oven baking to ensure they are
completely dry before re-using
b. Dry the Fluxes and carry out oven baking to ensure they are completely dry
before re-using
c. Both a and b.
d. discard them
Ans: d Reference : API RP 577
2. A radiograph shows slag inclusion linear indication of length 19 mm. Acceptable

length is 12 mm. This indication can be classified as:
a Recordable indication
b Reportable indication
c both a and b
d None of above
Ans: c. Reference : API RP 577
3. For carbon steel welding, Heat affected Zone typically means:
a. Zone adjacent to the weld which is not melted

b. Has its properties or microstructure altered
c. Was heated to more than 700 deg.F
d. All of above
226 | 2 2 9
4. A sub –surface terrace and step-like crack with basic orientation parallel to the
base metal surface caused by tensile stresses normal to thickness direction is
called
a. Lamination
b. Step-wise cracking
c. Lamellar tearing
d. Stress corrosion crack
Ans: c Reference : API RP 577
5. The “Slag inclusion” is typically not found in welding performed by
a. SMAW
b. c and d below
c GTAW
d GMAW
Ans: b Reference : API RP 577
6. Most applicable method for Performance qualification of welders as per

ASME Sec. IX for GMAW-S process is:
a. Radiography only
b. Bend tests only
c. Either radiography or bend tests
d. Both Radiography and bend tests
7. For direct visual examination, accessibility of eye shall be:
a. within 6” – 24” with angle less than 30° with the surface
b. within 6”- 24”with angle not less than 30° with surface
c. within 24” with angle less than 30°
d. beyond 24”with angle not less than 30°
227 | 2 2 9
8. A perfectly clear radiography film indicates film density of
a. 4 b. 1. c Zero d. 2
Ans: c Reference : API RP 577

9. B-scan In UT examination didplays::
a. cross-sectional elevation view of object scanned.

b. Plan view of object scanned
c. Pulse –Echo view
d. None of above
Ans: a Reference : API RP 577
10. Steels with CE greater than 0.55% typically require:
a. Preheating only
b. Pre-heating & PWHT
c. No preheating or PWHT
d. PWHT only
11. Simplest Weldability tests are those that evaluate
a. Strength and Ductility of the weld

b. Strength and hardnedd of the weld
c. Strength and toughness of the weld
d. Toughness and Ductility of the weld
228 | 2 2 9
12. A method to assure that PWHT on the welds was performed satisfactorily is
to perform which of the following after PWHT
a. Hardness testing of weld & HAZ

b. Radiography of weld &HAZ
c. Calibrate Thermocouples
d. UT of weld & HAZ
13. Among the following Welding processes, identify the one that has highest
metal deposition rate
a. all of below.
b. GTAW followed by SMAW
c. GMAW
d. SAW
14. A welding process which allows welding to be done without adding filler
metal is
a. SMAw
b. GTAW
c. GMAW
d. FCAW
15. As hardness of Heat affected zone increases -------

a. Susceptibility of Hydrogen assisted Cracking increases.
b. Susceptibility of Hydrogen assisted Cracking decreases
c. Tensile Strength of the weld decreases
d. All of above

229 | 2 2 9

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6 Days Course on

API 570: certification preparatory course

Asian Academy Of Professional Training

• Overview of API RP 577, Welding Inspection and Metallurgy

• Overview of API Recommended Practice 578 – Material Verification program for

2023 (Replaces 2022)

B16.5, Pipe Flanges and Flanged Fittings

I. CALCULATIONS FOR EVALUATING THICKNESS MEASUREMENTS, INSPECTION INTERVALS,

1. CORROSION RATES AND INSPECTION INTERVALS

The Inspector must be able to calculate:

a) Corrosion Rates (API 570, 7.1.2)

2. WELD JOINT QUALITY FACTORS AND CASTING QUALITY FACTORS

3. INTERNAL PRESSURE / MINIMUM THICKNESS OF PIPE

The inspector should be able to determine:

The inspector should be able to:

The inspector should be able to:

6. PREHEATING AND HEAT TREATMENT REQUIREMENTS

8. MINIMUM WALL THICKNESS & WORKING PRESSURES FOR FLANGES

The inspector should also be able to:

9. MINIMUM REQUIRED THICKNESS OF A PERMANENT BLANK (ASME B31.3, 304.5.3)

A. ASME BPVC SECTION IX

1. Typical joints and definitions

A. ASME Section V, Nondestructive Examination

1. Article 1, General Requirements:

a) The Scope of Section V

2. Article 2, Radiographic Examination:

a) The Scope of Article 2 and general requirements,

3. Article 6, Liquid Penetrant Examination (Including mandatory appendices II and III):

a) The Scope of Article 6,

4. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

a) The Scope of Article 7,

a) The scope of Article 9,

a) The scope of Article 10,

a) The Scope of Article 23, SE-797,

B. ASME B31.3 and API 570: General nondestructive exam requirements:

The following topics may be covered:

1. Organization and Certification Requirements.

• API RP 576, Inspection of Pressure-Relieving Devices

• ASME B16.5, Pipe Flanges and Flanged Fittings

• ASME PCC-2, Repair of Pressure Equipment and Piping

American Society of Mechanical Engineers (ASME)

570_EffSheet 2023 7/2022

PCC-2, Repair of Pressure Equipment and Piping, 2018

Announcing some changes to API 510, 570 and 653

1. The number of questions by which test takers will be graded or scored.

2. Exam day will be shortened.

What stays the same?

7_2012‐Effective beginning 12_2012

What is the purpose of using pre-test questions?

Does the use of pre-test question impact how scoring works?

7_2012‐Effective beginning 12_2012

API's Individual Certification Programs (ICP) are based on industry-developed

This course provides the participants the guidelines and methodology of

Where the student is required to refer to the diagrams or formulas or tables or

Case studies illustrating use of code rules for

API 570- PIPING INSPECTORS

Design Pressure = 500 psig (3447 KPa(g))

Design Temperature = 650 degrees F (344 Deg C)

Pipes to be used = A 53 gr. B Electric Resistance Welded (ERW)

Pipe size = NPS 6

Corrosion Allowance = 0.125 inch (3 mm)

Here, P = 500 psig (3447 KPa(g))

Now, t = 500 x 6.625 / 2 [(17,300 x0.85x1) + (500 x 0.4)]

t = 3447 x 168.28 / 2 [(118*1000 x0.85x1) + (3447 x 0.4)]