Understanding api icp653 reading 9 worksheet 6

Readings on APIICP650 Reading 9 - Q&A Practices My Pre-exam Self Study Notes 11th March 2016

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Petroleum Tanks

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Petroleum Tanks

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Petroleum Tanks

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API 653 Exam Administration -- Publications Effectivity Sheet FOR: November 2015, March 2016 and July 2016 Listed below are the effective editions of the publications required for this exam for the date(s) shown above.

API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Second Edition, April 2011

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ATTENTION: Only the following sections / mechanisms from RP 571 are included on the exam: 1. Section 3, Definitions 2. Par. 4.2.7 Brittle Fracture 3. 4.2.16 Mechanical Fatigue 4. 4.3.2 Atmospheric Corrosion 5. 4.3.3 Corrosion Under insulation (CUI) 6. 4.3.8 Microbiologically Induced Corrosion (MIC) 7. 4.3.9 Soil Corrosion 8. 4.3.10 Caustic Corrosion 9. 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 10. 4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement) 11. 5.1.1.10 Sour Water Corrosion (Acidic) 12. 5.1.1.11 Sulfuric Acid Corrosion

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     

API Recommended Practice 575, Inspection of Atmospheric and LowPressure Storage Tanks, Third Edition, April 2014 API Recommended Practice 577 – Welding Inspection and Metallurgy, Second Edition, December 2013 API Standard 650, Welded Tanks for Oil Storage, Twelfth Edition, March 2013 with Addendum 1 (September 2014), Errata 1 (July 2013), and Errata 2 (December 2014).

API Recommended Practice 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, Fourth Edition, September 2014.

API Recommended Practice 652, Lining of Aboveground Petroleum Storage Tank Bottoms, Fourth Edition, September 2014 API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction, Fifth Edition, November 2014.

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American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2013 Edition i. ASME Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and 23 (section SE-797 only) ii. Section IX, Welding and Brazing Qualifications (Welding Only)

See end of this study note for API Official BOK

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http://independent.academia.edu/CharlieChong1 http://www.yumpu.com/zh/browse/user/charliechong http://issuu.com/charlieccchong

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http://greekhouseoffonts.com/

The Magical Book of Tank Inspection ICP

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闭门练功

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Fion Zhang at Xitang 11th March 2016

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SME- Subject Matter Expert

我们的大学,其实应该聘请这些能干的退休 教授. 或许在职的砖头怕被排斥. http://cn.bing.com/videos/search?q=Walter+Lewin&FORM=HDRSC3 https://www.youtube.com/channel/UCiEHVhv0SBMpP75JbzJShqw

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Practice-01 API 653 PREPARATORY COURSE Final Exam — Open Book

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Q 1. Exclusive of corrosion allowance, what is the minimum nominal thickness for all new construction bottom plates? a. ½ inch b. ¼ inch c. 3/16 inch d. 5/8 inch ANS: b Q 2. For new or repaired shell horizontal joints, how many radiographs shall be taken for each 50 feet of horizontal joint, not including those required at intersection of vertical and horizontal joints? a. 1 b. 2 c. 3 d. 4 ANS: a 1st 10” and subsequent 200” without regards to the welders/operator

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Q 3. The recommended minimum development time (penetrant testing ) allowed for a material made of high temperature alloy is: a. 5 min b. 10 min c. 7 min (?) d. 60 min ANS: b T-672 Penetration (Dwell) Time Penetration (dwell) time is critical. The minimum penetration time shall be as required in Table T-672 or as qualified by demonstration for specific applications.

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Q 4. Select suitable Hole type (source side) penetrameter for following weld joint a) No 20 b) No 25 (?) c) No 30 d) None of the above ANS: total thickness 1 3/16� used c

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Q 5. If type of penetrameter is Q.4 is changed to wire type what shall be the wire designation (wire diameter in inch) a. 0.025 (NO. 10) b. 0.016 (NO. 8) c. 0.032 (NO. 11) d. none of the above (?)

ANS: a Set B/ wire #10 Q 6. For steel plates and weld to be checked LP, 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

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Q 7. After applying the developer the examiner checked four welds for surface defects after following period, weld A- after 5 minute, weld B after 10 minute, weld C was checked after 30 minutes and weld D after 65 minutes which of the weld were checked wrongly a. weld A and B b. weld C and D c. weld D only d. weld A and D (?)

ANS: not less than 10 min nor more than 60 min, answer C

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Q 8. Following combination of base metal and welding electrode was qualified by a certain PQR… impact testing is not required.

Base Metal =SA 285 Gr C Plates, ¾” thk Welding electrode = AWS E 6015 This PQR will qualify which of the following combination of base metal- welding electrodes. a. 1” thk SA 515 Gr 60 plates, E 6013 electrodes b. 1 ¾ “ thk SA 285 GrC plates, E 6013 electrodes c. 1 ¼ thk plates SA 516 Gr 70, E 7018 electrodes (?) d. None of the above ANS SA-283 C K02401 55 (380) P1 SA-516 60 K02100 60/70 (415)(485) P1 E6013 F2 SFA-5.1 EXX13 E7018 F4 SFA-5.1 EXX18 Over 3⁄8 (10), but less than 3⁄4 (19) qualified min 3⁄16 (5) / max 2T Answer: a Charlie Chong/ Fion Zhang

Q 9. For MT examination by prod techniques 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 Q 10. For a tank with 130 ft diameter thickness of top course worked out was td=5mm tt=4mm. What will be minimum nominal thickness provided for this course according to API 650 for a new tank? a. 3/16” (5mm) b. 1/4” (6mm) c. 5/16” (8mm) d. None of the above ANS: c td is the design shell thickness, in mm; tt is the hydrostatic test shell thickness, in mm; Charlie Chong/ Fion Zhang

Q 11. For a tank with diameter 100ft was found to have thickness reduction in a localized area. Minimum thickness observed (t2) was 1 inch. What will be the minimum vertical length of for the area? a. 40 inches b. 37 inches c. 45 inches d. None of the above ANS L =3.7√(Dt2) = 37, used b Q 12. On a tank roof plate two corroded areas was observed at locations A and B for Location A, average thickness = 0.085 inches, area = 105 in2 Location B, average thickness = 0.095 inches, Area = 105 in2 your decision will be: a. Both A and B are within limits b. Location A is OK, location B is art of limits c. Both A and B are out of limits d. Location B in OK, location A is out of limits ANS: d. min 0.09 in 100in2

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Q 13. Hot tap connection is to be made on tank with following description shell plate thickness = ¾ inch. Design temperature =30⁰F the plates were not tested for impact testing, (Consr. Code API 650-1974). What will be the maximum size of tapping connection? a. 8 inches NPS b. 6 inches NPS c. 10 inches NPS d. 4 inches NPS ANS: d, for plate with unknown toughness. If toughness is known and acceptable ≤18 NPS allowed.

Q 14. A replacement plate to be used on a shell thickness of 5/8 inch, on the second course of the tank. Thickness of first course and third course is also 5/8 inch. Following 3 plates are available which one is most suitable to be used as replacement plate. a. Plate thickness = ¾” b. Plate thickness = 5/8” c. Plate thickness = 1/2” d. Plate thickness = 1” ANS: b Charlie Chong/ Fion Zhang

Q 15. A tank is having remaining corrosion allowance of 2.5mm and corrosion rate of the shell is 0.1mm per year. What will be inspection interval for next ultrasonic thickness inspection from outside of the tank? a. 15 Years b. 12.5 Years (?) c. 10 Years d. 5 Years ANS: interval = 2.5/0.1 = 25 years, used 5 yr.. max. answer= d Q 16. Typical corroded areas on a shell plate are exhibited below in figure 1 with measured thickness in inches indicated on the sketch. The un-corroded thickness of the shell palte is 0.750 inches and C.A is 0.125” The total length of a arrow line drawn is 8 inches. The length of the line in each of the corroded areas A, B and C are 1.5”, 0.8” and 0.5 inches respectively.

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Comment on the acceptability of the corroded condition. a. The pitting can be ignored as a case of widely scattered pitting as both pitting depth and dimensions are within limits b. Not acceptable as size are not OK, total length of the pit dimensions is more than permitted c. The pitting can be ignored as a case of widely scattered pitting since depth are OK d. The pitting cannot be ignored as a case of widely scattered pitting since depth are not OK ANS Line of corroded area = 2.8in exceed 2” max. td = 0.625” / ½ td = 0.3125”, Pitmax is ok Not acceptable. Answer b

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Q 17. Two plates sample A and B were tested for longitudinal impact testing. Following were results observed. They belonged to Group No.1 as per API 650: Results of impact test for sample A were 18ft lb, 8ft lb, 16ft lb. sample B were 12ft lb, 14ft lb, 20 ft. lb Your assessment will be: a. sample A and B both OK b. sample A and B both to be re-tested c. sample B is OK, A shall be re-tested (?) d. sample a is OK, B shall be re-tested ANS: G1, longitudinal 15 ft-lbf / transverse 13 ft-lbf A with sample less than 2/3, B with 2 specimen less than specified. Both not OK, answer: b

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Q 18. For replacement to an existing 0.25” thick shell plate of an AST, another plate of 0.25” thickness to ASTM A36 is used. What should be the minimum clear distance between the outer edges of the adjacent butt welds of vertical and horizontal joints, respectively? a. 10” & 6” b. 6” & 3” c. 8” & 4” d. 12” & 6” ANS: b

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Q 19. Repair of a 5/8” thick shell, using lapped (lap welded) patch plate of 1/8” thick was carried out, without informing the Owner. Such a repair is not acceptable as per API standard 653, because: a. Owner had not specified use of patch plate repairs b. Lap patch plate of less than 3/16” is not permitted c. Lap patch plate repair on shell thickness more than above ½” is not permitted d. All of above ANS: d Q 20. As per API Standard 650, the offset between vertical seams of adjacent shells shall be a minimum distance of: a. 5 t, where ‘t’ is the plate thickness of thicker shell course at the offset b. 4t, where ‘t’ is the plate thickness of thicker shell course at the offset c. 3 t, where ‘t’ is the plate thickness of thicker shell course at the offset d. 2 t, where ‘t’ is the plate thickness of thicker shell course at the offset ANS: a

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Q 21. When butt welded annular bottom plates are used, in an AST built to API Standard 650, their width from inside of the shell shall be at least: a. 900 mm b. 300 mm c. 600 mm (24�) d. None of the above ANS: c 5.5.2 Annular bottom plates shall have a radial width that provides at least 600 mm (24 in.)

Q 22. Misalignment in a completed 20 mm thick vertical seam of an AST built to API Standard 650 shall be more than: a. 2 mm b. 1.5 mm c. 0.8 mm d. 3 mm ANS: a Misalignment in completed vertical joints for plates greater than 16 mm (5/8 in.) thick shall not exceed 10 % of the plate thickness or 3 mm (1/8 in.), whichever is less;

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Q 23. Out of roundness measured as deviation from radius measured 1 foot above the bottom corner weld of a 250 ft diameter AST built to API Standard 650, shall not exceed: a. 1” (25 mm) (?) b. ½ “ (12.7 mm) c. ¾” (19 mm) d. 1-1/4” (32 mm) ANS: d Q 24. Local deviations from theoretical shape of an aboveground storage tank (AST), built to API Standard 650, specifically “Peaking” at vertical joints or “Banding” at horizontal weld joints as measured over an appropriate sweep board of 36” shall not exceed: a. 19 mm (3/4”) b. 13 mm (1/2”) c. 16 mm (5/8”) d. 1/8 mm (3”) ANS: b Charlie Chong/ Fion Zhang

Q25. An AST has remaining corrosion allowance of 3.2 mm. The known rate of corrosion of shell is 200 microns per year. As per API Standard 653, when should the external visual inspection by an Authorized Inspector shall be carried out at an interval not exceeding: a. 5 years b. 8 years c. 4 years (?) d. 15 years ANS: interval = 3.2/0.2 = 16 years. Used 5 year max. Answer: a

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API 653 PREPARATORY COURSE Final Exam – Open Book Answer Key

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Practice-02 API 653 PREPARATORY COURSE Final Exam — Closed Book

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Q1. The complete or partial removal and replacement of more than 12 inches of a vertical weld joining shell plates is considered a : (a) minor alteration; (b) minor repair; (c) major alteration; (d) major repair.

ANS: d Q2. A single film technique was used to make a radiograph using a Cobalt-60 source. The minimum permitted density in the area of interest is: a. 4.0 b. 1.8 c. 2.0 d. 1.3 ANS: c

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Q3. At what level is the atmosphere considered oxygen-deficient? a. Less than 19.5% b. Less than 21.9% c. Less than 24.9% d. Less than 16.0% ANS: a Q4. __________ is a change from previous operating conditions involving different properties of the stored product such as specific gravity or corrosivity and / or different service conditions of temperature and / or pressure: (a) Re-rating; (b) Change in service; (c) Repair; (d) Reconstruction ANS: b

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Q5. Describe how a liquid penetrant examination should be performed in order to detect discontinuities which are open to the surface. a. Clean the part, apply the developer, apply the penetrant, remove excess penetrant, inspect the part, clean the part b. Clean the part, apply 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 Q6. A radiographic technique in which radiation passed through two walls and both the walls are viewed on the same radiograph (double wall, double image – ellipse) the limitation for the outside diameter is: a. 3-1/2” b. 2” c. 4” d. Any diameter possible ANS: a

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Q7. Information needed when determining the rate of corrosion: a. Original thickness or last inspection thickness b. Current thickness c. Length of time in service d. All the above ANS: d Q8. The maximum acceptable undercutting for base metal in repaired or altered horizontal welds is :(a) 1/64"; (b) 1/32"; (c) 1/16"; (d) 1/8" ANS: b

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Q9. The definition of a confined space is: a. large enough to enter b. restricted means of entry c. not designed for continuous occupancy d. all of the above are required ANS: d Q10. An individual stationed outside one or more permit spaces who monitors the authorized entrants and orders the authorized entrants to evacuate the permit space under unsafe conditions.

This individual is referred as: a. Supervisor b. A qualified person c. An attendant d. None of above ANS: b

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Q11. A corroded area of a tank bottom plate is repaired by welding overlay.

There is no change in the rating and no change is made on the nameplate.

Which of the following is the correct term to describe this process? a. Reconstruction b. Repair c. Alteration d. None of the above ANS: b Q12. The maximum interval between internal inspections shall not exceed ____ years: (a) 10; (b) 20; (c) 5; (d) 15.

ANS: b

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Q13. Hot taps are not permitted under which of the following conditions? a. On plates requiring PWHT. b. On ultrasonically sound plate c. On tanks with dia. more than 80 feet. d. None of above.

ANS: a Q14. For a tank of 160ft dia. Is to be checked for shell settlement.

Minimum number of equally spaced settlement points to be checked will be: a. 16 b. 20 c. 24 d. 12 ANS: a

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Q15. For a tank made by reconstruction, under what circumstances may a new shell-to-bottom weld be exempt from hydrostatic testing? a. When the root pass has been visually inspected and the final weld is fully examined, visually and radiographically. b. Reconstructed tank is never exempted from hydrostatic testing. c. When the root pass has been visually inspected and the final weld is fully examined, visually and by vacuum box. d. When the welding method has been reviewed and approved by an engineer experienced in tank design in accordance with API Standard 650.

ANS: c

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Q16. In atmospheric conditions, bottom coatings may be applied if the steel temperature is: a. 2째F above the dew point b. 5째F below the dew point. c. 10째F above the dew point. d. at the dew point.

ANS: b Q17. Procedure qualification for welding of tanks is done in accordance With a. AWS D1.1 b. API 1104 c. ASME Section IX d. All of the above ANS: c

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API 652: 8.3 Temperature and Humidity Control The temperature of the steel surface should conform to the lining manufacturer’s recommended application and curing ranges. As a general rule, the surface temperature must be at least 5°F (3°C) above the dew point temperature in the tank and the relative humidity should be below 80 % at the steel surface. If the surface temperatures and/or humidity level expected to deviate from the recommended range, climate control equipment should be employed to ensure the proper conditions are maintained. It should be noted that durations of surface preparation, lining application, and cure may be continuous over a 24-hour period. If so, the required environmental conditions must be maintained around the clock. Owner operations may interfere with continuous use of environmental control equipment. These operational considerations should be reviewed prior to the execution of the tank lining project. NACE 6A192/SSPC-TR 3 provides guidance on the use of dehumidification and heating equipment for environmental controls during tank lining work. Climate control equipment is also used to advantage by protecting workers from heat stress during hot summer months. Improved productivity, due to better working conditions, is a secondary benefit.

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Q18. Widely scattered pits may be ignored under the following conditions a. Where the service fluid is corrosive or hard to hold. b. If sum of bit length along 8� vertical line does not exceed 2� c. When no pit has depth which results in the minimum thickness being less than one-half the minimum acceptable thickness of the shell plate exclusive of corrosion allowance d. b and c ANS: d Q19. For verification of radiographic sensitivity and image quality, which of the following are used: a. Cassettes b. Penetrameters c. Cameras d. Collimators ANS: b

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Q20. Internal corrosion in the vapour space above liquid level occurs due to: a. Hydrogen Sulphide vapour b. Water vapour c. Oxygen d. Any combination of the above three ANS: d Q21. API 650: Appendix M provides requirements for Tanks designed to operate at the following range of temperatures : a. exceeding 260 deg C b. above 90 deg C c. below 90 deg C d. “B” or “C” ANS: b

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Q22. For a reconstructed tank as per API 653 Verticality (out-ofplumbness) of top of the shell shall not exceed, a. 1/300 of total tank height b. 1/250 of total tank height c. 1/400 of total tank height d. None of the above ANS: d Q23. Tank bottom linings are called “thick film lining� when the lining thickness is: a. more than 1 mm thk b. equal or more than 20 mils c. more than 20 mils d. more than 2 mm thk ANS: c

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Q24. Hot tap can be performed on: a. vapour space in the shell a. on the roof b. in the shell below liquid level c. anywhere on the tank ANS: b Q25. A radiograph was having density near the penetrameter equal to 3.0. Hence the acceptable density range of the radiograph is: a. 1.7 to 4 b. 2.55 to 3.9 c. 2.0 to 4.0 d. None of the above ANS: min = 3x 0.85, max 3x1.3 = 2.55~3.9. answer b

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T-282.2 Density Variation (a) General. If the density of the radiograph anywhere through the area of interest varies by more than minus 15% or plus 30% from the density through the body of the hole IQI or adjacent to the designated wire of a wire IQI, within the minimum/maximum allowable density ranges specified in T-282.1, then an additional IQI shall be used for each exceptional area or areas and the radiograph retaken. When calculating the allowable variation in density, the calculation may be rounded to the nearest 0.1 within the range specified in T- 82.1. (b) With Shims. When shims are used with hole-type IQIs, the plus 30% density restriction of (a) above may be exceeded, and the minimum density requirements of T-282.1 do not apply for the IQI, provided the required IQI sensitivity of T-283.1 is met.

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Q26. The examiner for conducting magnetic particle testing on the tank welds shall be: a. Qualified as per ASNT Level II or III b. Able to read Jagger-2 c. Qualified as per ASME Sec. V d. None of the above ANS: b Q27. In atmospheric conditions, bottom coatings may be applied if the steel temperature is: a. 2째F above the dew point. b. 5째F below the dew point c. 10째F above the dew point d. at the dew point ANS: b

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API 652: 8.3 Temperature and Humidity Control The temperature of the steel surface should conform to the lining manufacturer’s recommended application and curing ranges. As a general rule, the surface temperature must be at least 5°F (3°C) above the dew point temperature in the tank and the relative humidity should be below 80 % at the steel surface. If the surface temperatures and/or humidity level expected to deviate from the recommended range, climate control equipment should be employed to ensure the proper conditions are maintained. It should be noted that durations of surface preparation, lining application, and cure may be continuous over a 24-hour period. If so, the required environmental conditions must be maintained around the clock. Owner operations may interfere with continuous use of environmental control equipment. These operational considerations should be reviewed prior to the execution of the tank lining project. NACE 6A192/SSPC-TR 3 provides guidance on the use of dehumidification and heating equipment for environmental controls during tank lining work. Climate control equipment is also used to advantage by protecting workers from heat stress during hot summer months. Improved productivity, due to better working conditions, is a secondary benefit.

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Q28. How many equally spaced measurements are required for the thickness averaging technique? (a) 2; (b) 5; (c) 4; (d) 3.

ANS: b Q29. How many specimens and impact tests must be performed from a single test coupon or test location? (a) 1; (b) 2; (c) 3; (d) 4.

ANS: c Q30. Hydrostatic tests shall be held for ____ hours:(a) 2; (b) 8; (c) 24; (d) 72.

ANS: c

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Q31. In a radiographic film of a weld, how is back scatter checked? (a) by use of a penetrameter; (b) by film density; (c) using lead letter “B�; (d) all of the above.

ANS: c Q32. In general, if shell thickness does not exceed ____ inch, it does not require further assessment for brittle fracture:(a) 0.25; (b) 0.75; (c) 1.00; (d) 0.50 ANS: d

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Q33. Potential for brittle fracture exists for tanks constructed according to: (a) API 650 – 7th edition (b) API 650 – latest edition (c) API 650 – 4th edition (d) none of the above ANS: d API653: 5.3.2 Step 1—The tanks meet the requirements of API 650 (Seventh Edition or later) or API 650, Appendix G (Fifth and Sixth Editions) to minimize the risk of failure due to brittle fracture. Alternatively, tanks may also be shown to meet the toughness requirements of API 650 (Seventh Edition or later) by impact testing coupon samples from a representative number of shell plates.

Q34. Three types of external inspections are :(a) scheduled, routine and liquid penetrant; (b) scheduled, routine and UT thickness; (c) scheduled out of service, routine and UT thickness; (d) unscheduled, routine and liquid penetrant.

ANS: b

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Q35. Welders qualifications shall expire as they do not weld :(a) within a given process for a 6 month period; (b) using a given procedure for a 6 month period; (c) on a tank for 6 months; (d) for a 3 month period.

ANS: a Q36. What are penetrameters used for :(a) A penetrameter is used for radiographic technique in that it serves as an image quality indicator (b) It indicates the magnetic properties of the materials (c) To check penetrant quality in PT inspection (d) To check weld penetration during welding ANS: a

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Q37. Unless otherwise agreed to by the purchaser, what is the minimum nominal width of a shell plate? (a) 36 inches; (b) 48 inches; (c) 72 inches; (d) 96 inches.

ANS: b 5.6.1.2 Unless otherwise agreed to by the Purchaser, the shell plates shall have a minimum nominal width of 1800 mm (72 in.). Plates that are to be buttwelded shall be properly squared.

Q38. Vertical welds must be fully radiographed if the shell thickness exceeds inches :(a) 3/4; (b) 1; (c) 1 1/4; (d) 1 1/2.

ANS: d Q39. Welding filler metals are grouped into groupings based on their AWS classification:(a) P-numbers; (b) F-numbers; (c) Z-numbers; (d) ASTM spec.

ANS: b

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Q40. When reviewing a radiograph, a light image of the letter B can be seen on the film with dark background. (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 Q41. Which of the following penetrant system is generally considered least sensitive? a. Water-washable – visible dye. b. Solvent removable – visible dye. c. Water-washable – fluorescent dye. d. Post-emulsification – visible dye.

ANS: a

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Q42. The nondestructive examination method to be used for a particular inspection should be determined by the: a. Availability of certified NDE examiners. b. Length of time since the last inspection. c. Age of the component to be inspected. d. Type, location, and orientation of the expected flaws.

ANS: d Q43. Most suitable UT equipment for use on rough surface is: a. CRT type b. Direct readout type c. Either a or b, anything is okay d. a and b, both are not suitable ANS: a

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API 653 PREPARATORY COURSE Final Exam – Closed Book Answer Key

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Practice-03 API 653 PREPARATORY COURSE Final Exam

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The following is a collection of questions remembered by various students who took the API 653 Exam in the past.

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Q 1. What is the minimum thickness for a tank floor plate with no means for leak detection or secondary containment if an RBI program is not in place? a. .005” b. .050” c. .075” d. .100” Q 2. Which one of the following types of external floating roofs does not require a check valve in the roof drain? a. Annular pontoon (single deck) b. Double deck c. Pan-type d. Plastic sandwich-panel-sphere type floating roof

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Q 3. Surface preparation is a critical part of the lining operation, generally abrasive blast to a white metal finish of __________ is desired. a. NACE No. 1/SSPC-SP5 b. NACE No. 2/SSPC-SP10 c. NACE No. 3/SSPC-SP15 d. NACE No. 4/SSPC-SP20 Q4. When a full hydrostatic test is required, it shall be held for _____ hours. a. 8 b. 12 c. 16 d. 24

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Q 5. If any provision of API 653 presents a direct or implied conflict with any statutory regulation and the statutory regulation is more stringent . a. the government regulations govern b. the API 653 standards govern c. the owner/operator requirements govern d. the inspector will decide which regulations govern Q 6. The maximum permissible limit for exposure to organic lead in a normal 8 hour work day is . a. 2 micrograms per cubic foot b. 1 PPM in air c. 0.075 pounds per cubic feet per day d. .05 grams per cubic centimeter

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Q 7. Radiographic film density shall be checked by a densitometer calibrated on a stepwedge film traceable to . a. API 650 b. ASNT-SNT-TC-1A c. ASME Section IX d. a national standard Q 8. A 200’ diameter tank, 40’ tall, storing a product with a specific gravity of .85. A corroded area was noted with UT on the bottom course with a minimum thickness of .51” at1’ above the weld. No thinning was noted within 10” of any weld. What is the L length ofthe corroded area? a. not enough information to answer b. 10.10” c. 37.37” d. 40”

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Q 9. A gummy carbonaceous substance, fouling service, is stored in a tank.

Where would problems most likely occur? a. The floating suction b. The operation of check valves c. Around nozzles d. On the floor Q 10. Routine visual in-service inspections of aboveground storage tanks from the ground may be done by ? a. authorized inspectors only b. owner/user personnel other than authorized inspectors c. jurisdictional inspectors only d. insurance inspectors only

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Q 11. An existing tank, 48 feet high with a diameter of 127 feet, is undergoing major repairs. What is the maximum out-of-plumbness allowed? a. 1.27” b. 4.8” c. 5.0” d. 5.76” Q 12. Which of the following is not considered shell distortion? a. Uniform settlement of a tank b. Out-of-roundness of a tank c. Flat spots d. Peaking and banding at weld joints

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Q 13. A welder that qualifies on a plate groove weld can weld . a. groove weld only b. groove and fillet welds c. fillet welds only d. “J” welds only Q 14. An 8” NPS hot tap is to be added to a tank. What is the minimum wall thickness of the nozzle neck? a. Schedule 40 b. Schedule 60 c. Standard weight d. Extra-strong

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Q 15. A welder may be qualified by RT in any welding process except for which of the following? a. GMAW (short-circuiting mode) b. GMAW (spray-arc mode) c. GTAW d. SMAW Q 16. Which of the following repairs are allowed within the critical zone of a tank bottom? a. Welded-on patch plates over existing patches. b. Welding of widely scattered pits, pinholes and cracks in the bottom plate. c. Welded-on structural steel angles to the tank shell and the annular plate. d. One pass perimeter welds on welded-on patch plates.

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Q 17. What is the maximum spacing for MT prods? a. 2” b. 4” c. 8” d. 10” Q 18. A formal visual external inspection by an Authorized Inspector shall be made at least every ______ years or RCA/4N years, whichever is less. a. 2 b. 3 c. 4 d. 5

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Q 19. During the inspection of an AST it is discovered that the ground wire connection has come loose. How should the ground system be inspected? a. Ignore it b. Test the current using a volt ohm meter c. PT or MT d. Visually checked Q 20. The presence of rock under the steel bottom of an AST would have what effect? a. Porosity in the bottom b. Promote corrosion c. Create longer tank bottom life d. Have no effect on the tank bottom

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Q 21. During a welder qualification test on 3/8� plate in the horizontal position, how many transverse bends are required? a. 6 side bends b. 2 nick breaks c. 1 face and 1 root bends d. 4 tinsel specimens Q 22. If a contractor is to relocate or reconstruct an aboveground storage tank, the limits of responsibilities are defined by ? a. API 653 b. the contractor c. the authorized inspector d. the owner/operator

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Q 23. A new tank is to be hydrostatically tested. The tank is constructed from ASTM A 36M steel. What allowable stress must be used to determine the maximum hydrostatic test head for the tank. a. 29,400 psi b. 23,200 psi c. 24,900 psi d. 27,000 psi Q 24. Where should the numbers be placed on a radiograph? a. Under the film. b. On the material being radiographed. c. Under the material being radiographed. d. On the film source pack.

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Q 25. A new tank is placed in service. In seven years, which of the following inspections should have been made? a. routine inspection b. routine and external inspections c. routine, external, visual and internal inspections d. routine visual, formal visual (external) and UT inspections

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Q 26. How many roof rafters must a plank cross over for inspection of the roof of a tank? a. 1 b. 2 c. 3 d. 4 Q 27. The maximum acceptable undercutting on horizontal butt welds of a reconstructed tank is _____ inch. a. 1/64 b. 1/32 c. 1/16 d. 1/8

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Q 28. The minimum number of settlement points around a tank periphery is . a. 12 b. 10 c. 8 d. 6 Q 29. A weld shall be acceptable by visual inspection if the inspection shows which of the following? a. The weld has no cracks, no undercutting, and less than 20% coldlap. b. The weld has no cracks, undercutting is acceptable, and any surface porosity does not exceed one cluster in any 2” of length and the diameter of each cluster does not exceed 1/16”. c. The weld has no crater cracks or other surface cracks, undercutting is acceptable, and any surface porosity does not exceed one cluster in any 3” of length and the diameter of each cluster does not exceed 1/8”. d. The weld has no crater cracks, other surface cracks or arc strikes in or adjacent to the welded joint, undercutting is acceptable, and any surface porosity does not exceed one cluster in any 4” of length and the diameter of each cluster does not exceed 3/32”.

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API650: 8.5.2 A weld shall be acceptable by visual examination if the inspection shows the following. a) There are no crater cracks, other surface cracks or arc strikes in or adjacent to the welded joints. b) Maximum permissible undercut is 0.4 mm (1/64 in.) in depth for vertical butt joints, vertically oriented permanent attachments, attachment welds for nozzles, manholes, flush-type openings, and the inside shell-to-bottom welds. For horizontal butt joints, horizontally oriented permanent attachments, and annular-ring butt joints, the maximum permissible undercut is 0.8 mm (1/32 in.) in depth. c) The frequency of surface porosity in the weld does not exceed one cluster (one or more pores) in any 100 mm (4 in.) of length, and the diameter of each cluster does not exceed 2.5 mm (3/32 in.). d) The reinforcement of the welds on all butt joints on each side of the plate shall not exceed the following thicknesses:

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Q 30. Penetrameters are normally placed on the _____ of the part being examined. a. source side b. film side c. weld side d. obverse side Q 31. External, UT measurements of a new tank shell shall be made not later than _____ years after commissioning. a. 5 b. 4 c. 3 d. 2

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Q 32. A liquid having a closed cup flash point equal to or greater than 100â °F is considered. a. flammable material b. combustible liquid c. gasoline d. diesel Q 33. Thin film linings are usually used for application to . a. the bottoms of new storage tanks. b. pitted bottoms of older storage tanks. c. corroded bottoms of previous service tanks. d. rough and pitted surfaces.

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https://www.wisconsin.edu/ehs/osh/flam-liq/

Q 34. With a horizontal sweep board 36� long, peaking shall not exceed _____ inch. a. 0.250 b. 0.375 c. 0.500 d. 0.625 Q 35. If a welder tests in a 6G position, he qualifies to weld . a. all positions b. uphill only c. downhill only d. vertical only

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Q 36. An anode is . a. an electrode of an electrochemical cell at which no corrosion occurs b. an electrode of an electrochemical cell at which corrosion occurs c. a chemical substance containing ions that migrate d. a metallic connection that provides electrical continuity Q 37. Widely scattered pits may be ignored, provided . a. no pit depth results in the remaining shell thickness being less than 1/2t min acceptable tank shell thickness, exclusive of corrosion allowance. b. the average pit depth is greater than 1/2t min, exclusive of the corrosion allowance c. no pit depth is greater than 1/2t min, including the corrosion allowance d. no pit depth is less than 1/2t min, including the corrosion allowance

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Q 38. The critical zone of the tank bottom is within the . a. Annular plate ring, within 6” of the shell or within 6” of the inside edge of the annular ring. b. Annular plate ring, within 10” of the shell or within 10” of the inside edge of the annular ring. c. Annular plate ring, within 12” of the shell, or within 12” of the inside edge of the annular plate ring. d. Annular or bottom plates within 3 inches of the inside edge of the shell.

Q 39. The space between the outer periphery of the roof and the tank shell of an external floating roof tank shall be sealed by a flexible device that provides . a. a minimum 1/2” gap over no more than 24” b. an area of no more than 15 square inches opening calculated by measuring the length and width of the gaps. c. a reasonably close fit to the shell surfaces d. a minimum of 3 openings 24” long with gaps no more than 1/4”

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Q 40. What is the minimum thickness for a tank floor plate with a > 0.05” or thicker reinforced internal lining? a. .005” b. .050” c. .075” d. .100” Q 41. A full hydrostatic test is always required on . a. a tank that has an annular plate installed with the longest dimension less than 12” b. a tank that has a door sheet installed c. a tank that has a nozzle 12” NPS installed d. a reconstructed tank

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Q 42. What is the maximum temperature that dry MT can be used? a. 600⁰ F b. 135⁰ F c. 400⁰ F d. Within the temperature range limitations set by the manufacturer Q 43. If a repair/modification weld is made on a tank shell plate that is thicker than 1”, the base metal within 3 inches of the welding shall be heated to a temperature of approximately degrees. a. 120o F b. 140⁰ F c. 160⁰ F d. 200⁰ F (1½“) 10.4.2.3 No welding of any kind shall be performed when the surfaces of the parts to be welded are wet from rain, snow, or ice; when rain or snow is falling on such surfaces; or during periods of high winds unless the welder and the work are properly shielded. No welding of any kind shall be performed when the temperature of the base metal is less than 0 °F. When the temperature of the base metal is between 0 °F and 32 °F or the thickness is in excess of 1 in.,the base metal within 3 in. of the place where welding is to be started shall be heated to a temperature warm to the hand (approximately 140 °F) before welding. (See 10.4.4.3 for preheat requirements for shell plates over 1 1/2-in. thick.)

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Q 44. What is the main factor in determining the efficiency of a rivet joint in a tank? a. The allowable stress of the rivets b. The number of rivet rows and type of joint c. The allowable stress of the plate d. Whether the joints have butt straps or not Q 45. It is not necessary for the inspector to check which of the following? a. All test results on the PQR b. All essentials and non-essentials on WPS c. All essentials and non-essentials on WPS and PQR d. All non-essentials on PQR

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Q 46. A new tank built in January, 1984, was removed from service and internally inspected in January, 1994. The bottom course of the tank showed the most general corrosion (no isolated corrosion was found). The original thickness of the bottom course of the tank was 1”. The measured thickness of the bottom course at the inspection was 0.93”. Determine the yearly corrosion rate. a. .0035” b. .0070” c. .0140” d. .0700” Q 47. When the corrosion rates of a tank are not known and the bottom plate thickness can not otherwise be determined, inspection(s) should be performed within the next _____ years of tank operation to establish corrosion rates. a. 5 b. 10 c. 15 d. 20 6.4.2.1.1 The interval from initial service date until the first internal inspection shall not exceed 10 years unless a tank has one or more of the leak prevention, detection, corrosion mitigation, or containment safeguards listedin Table 6.1. The initial internal inspection date shall be based on incremental credits for the additional safeguards in Table 6.1 which are cumulative.

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Q 48. The maximum spacing of settlement points is _____ feet around the circumference of the tank. a. 40 b. 35 c. 32 d. 25 Q 49. A 100 foot diameter tank must have at least _____ inch thick shell plates. a. 1/8 b. 3/16 c. 1/4 d. 1/2

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Q 50. The maximum acceptable undercutting on vertical butt welds of a reconstructed tank is _____ inch. a. 1/64 b. 1/32 c. 1/16 d 1/8

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Dinner Time

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Q51. The letter “B” is placed on radiographic film holder for what reason? a. To determine if back scatter radiation is exposing the film. b. To show the distance from the source of radiation to the weld. c. To function as a location marker for the radiograph. d. To designate whether the penetrameter is on the film side or the back side.

Q52. A tanks bottom course has corroded in a general uniform manner (including the welds). The tank’s diameter is 137’ and its height is 40’ (5-eight foot courses). The liquid stored in the tank is hydrocarbon with a specific gravity of 0.82 and it is not corrosive. The tank was constructed from ASTM A-283, Grade C (A 283M, Grade C) carbon steel. Determine the minimum thickness of the bottom course for full height operation. Round to the nearest hundredth. (This tank was built to API 650, Eighth edition). a. 0.805” b. 0.691” c. 0.200” d. 0.483” Ans: tmin = 2.6(H-1)DG/SE = 2.6(39)137x0.82/(23600)= 0.483, answer: d

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Q53. When preparing to enter a storage tank for inspection, the most important thing to do is . a. obtain a written entry permit b. to have all equipment needed for inspection ready and available c. to be wearing protective clothing d. to check all platforms and ladders for serviceability Q54. A tank course made from 3/4” plate is welded with low hydrogen electrodes. The welder undercuts a horizontal butt weld to a depth of 0.02” and he reinforces the weld with a 0.20” reinforcement. a. The weld is acceptable b. The weld is unacceptable because of the excess undercut c. The weld is unacceptable because of the excess reinforcement d. The weld is unacceptable because of the excess reinforcement and excess Undercut Ans: under cut <1/32” OK, Reinf. >3/16 Not OK, answer: c

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Q55. What is the inspection frequency for flame arrestors? a. 2 years b. 5 years c. 10 years d. Annually Q56. How many tensile tests are required to qualify a 1/4â&#x20AC;? plate groove weld? a. 2 b. 3 c. 4 d. 6

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Q57. The minimum bottom plate thickness for a tank with an applied reinforced lining greater than 0.05â&#x20AC;? thick, applied in accordance with API RP 652, is inch. a. 0.10 b. 0.05 c 0.125 d. 0.0625 Q58. The oxygen content for non-permit required confined space must be __________. a. 0 - 10% b. 10% - 15% c. 19.5% - 23.5% d. 25.2% - 32.7%

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Q59. The acceptance criteria for a radiograph of a tank repair weld is found in . a. Section V of the ASME Code b. Section IX of the ASME Code c. Section VIII of the ASME Code d. ASNT SNT-TC-1A Q60. All leaks in pontoons or compartments of double deck floating roofs shall be repaired by . a. caulking the leaking joints and/or using soft patch material b. rewelding the leaking joints and/or the use of patch plates c. cutting out the leaking area and flush patching d. weld overlay any cracks and/or use soft patch material

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Q61. For what diameter tank is the variable point method for calculating shell thickness mandatory? a. Tanks with a diameter of 200 feet and greater b. Tanks with a diameter greater than 300 feet c. Tanks with a diameter greater than 200 feet d. Tanks with a diameter of 300 feet and greater Q62. What is the minimum lifting power of an AC electromagnetic yoke used in magnetic particle inspection? a. 40 pounds lifting power at the maximum pole spacing b. 10 pounds lifting power at the maximum pole spacing c. 10 amps lifting power at the maximum pole spacing d. 30 pounds lifting power at the minimum pole spacing

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Q63. What is the allowable edge settlement of a 100’ diameter tank that has an area of settlement that starts to slope 36” from the shell and the bottom lap weld is approximately parallel to the shell? a. 13.32” b. 3.75” c 18.5” d. 2.22” Q64. A tank was constructed from welded ASTM A-516, Grade 60 (A 516M, Grade 415) steel. The third course must be evaluated for continued service.

What is the allowable stress that must be used in the calculations? a. 21,300 psi b. 25,560 psi c. 28,200 psi d. 28,320 psi

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Q65. A 125’ diameter X 40’ high storage tank has questionable thickness annular plates. The first shell course thickness is .61”. The thickness of the corrosion allowance for the tank is 0.125”. The product specific gravity is less than 1. What is the minimum thickness for the annular plate? a. 0.17” b. 0.20” c. 0.325” d. 0.295” Q66. The principal advantage of thin-film linings are . a. better protection of older storage tank bottoms and ease of application b. less susceptible to mechanical damage and easier to repair c. lower cost and not as sensitive to pitting d. lower cost and ease of application compared to thick-film coating systems

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Q67. In no case shall the internal inspection interval of an aboveground storage tank exceed _____ years, if an RBI program is not in place. a. 5 b. 10 c. 20 d. 25 The initial inspection interval shall not exceed 20 years for tanks without a Release Prevention Barrier, or 30 years for tanks with a Release Prevention Barrier.

6.4.2.1.2 As an alternative to establishing the initial interval in accordance with Section 6.4.2.1 and Table 6.1, the initial internal inspection date and reassessment can be established using Risk Based Inspection (RBI) assessment per 6.4.2.2.2. These assessments may establish an initial inspection interval exceeding 10 years but shall not exceed 20 years for tanks without a Release Prevention Barrier, or 30 years for tanks with a Release Prevention Barrier except as follows.

Q68. Welders are qualified to what standard or code? a. Section VIII of the ASME Code b. Section V of the ASME Code c. Section I of the ASME Code d. Section IX of the ASME Code

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Q69. What is the maximum acceptable undercut of a nozzle to shell weld? a. 1/64” b. 1/32” c. 1/16” d. 1/8” Q70. The nameplate for a reconstructed tank shall be attached to the tank shell adjacent to. a. the existing nameplate b. a manway in bottom tank course c. the stairway or ladder to the tank roof d. the door sheet

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Q71. When a welder has not welded with a process during a period of _____, his qualifications for that process shall expire. a. 3 months or more b. 6 months or more c. 9 months or more d. 12 months or more Q72. What allowable stress is used in evaluating a riveted joint when using joint efficiencies given in Table 4-3 of API 653? a. 16,000 psi b. 18,000 psi c. 19,000 psi d. 21,000 psi

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Q73. Radiographs of repaired work and records of radiographs of repaired work shall be marked with . a. a grease pencil b. the mark of the welder who made the repair c. the letter â&#x20AC;&#x153;Râ&#x20AC;? d. the initial of the inspector Q74. The transmitted film density through the radiographic image of the body of the appropriate hole penetrameter and the area of interest shall be _____ minimum for radiographs made with a gamma ray source. a. 1.8 b. 2.0 c. 2.2 d. 2.6

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Q75. A tank has a corroded area on its second course. It is elliptical in shape with the major axis parallel to the horizontal weld seam. The major axis dimension is 35” and the vertical minor axis is 21”. The tank diameter is 127’ and its height is 40’ (5-eight foot courses). The minimum thickness measured in the corroded area is 0.52. The general thickness of the second course (away from the corroded area) is 0.75”. What is the maximum critical length that can be used in determining the averaging out of the hoop stresses around the corroded area. Round to the nearest 0.1”. a. 40” b. 36.1” c. 30.1” d. 28.1” L = 3.7√(Dt2) = 30.1”

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Q76. What is the P number for the tank as listed above? a. 1.5 b. 1 c. 6 d. 24

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Q77. What is the maximum fill rate for the tank as listed above? a. 3 feet per second b. 6 feet per second c. 3 feet per minute d. 6 feet per minute Q78. What is the SFA number for E 7018 electrodes? a. 5 b 5.1 c. 5.29 d. 5.42

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API 650: 7.3.6.5 The minimum fill and discharge rate, if any, shall be specified by the Purchaser on the Data Sheet, Line 23. When settlement measurements are specified by the Purchaser, the maximum filling rates shall be as follows, unless otherwise restricted by the requirements in 5.8.5.

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Q79. What is the filler number (F) for E-7018 electrodes? a. 1 b. 2 c. 3 d. 4 Q80. What is the minimum acceptable shell plate thickness for the first course of T 3-27, if the specific gravity of the stored product is 1.3?

NOTE: current inspection (2003) based on product alone, and full height operation. a. .316” b. .500” c. .262” d. Not enough information given t min = 2.6(39)47x1.3/(20000) = 0.309” or 3/16 whichever greater, used 0.309. t min = 2.6(39)47x1.3/(23600) = 0.262” inservice tank

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Q81. What is the hydrostatic test height of T 3-27 if the joint efficiency is .85 and the specific gravity of the product is 1.3? a. 57.24' b. 40' c. 28.27' d. Not enough information given tmin = 2.6(Ht-1)x47/ (26000x0.85), Ht = 44.71’, used 40’ Q82. What is the minimum acceptable shell plate thickness for the top course of T 3-27 if each course is 120" tall? a. .1" b. .062" c. .269" d. Not enough information given t min = 2.6(9)47x 1.3/26000 = 0.05” used 0.1”, answer = a

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Q83. What is the joint efficiency for T 3-27? a. 1 b. .85 c. .70 d. .35 Q84. What is the corrosion allowance for T 3-27? a. .185" b. .125" c. .0625" d. Not enough information given (?)

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Q85. If T 3-27 was new, what would be the minimum first course thickness, based on product alone? a. .269" b. .310" c. .500" d. Not enough information given t min = 2.6(39)47x1.3/(20000) = 0.309â&#x20AC;? or 3/16 whichever greater, used 0.309 Q86. How many settlement points are required for an external settlement of T 3-27? a. 4 b. 6 c. 8 d. 10

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Q87. A depression in the floor is discovered near the east manway of T 3-27.

The diameter of the depression is 96", the deepest point in the depression is 4". The area _________. a. is rejectable. b. is acceptable. c. must be monitored. d. can be filled in with epoxy and accepted.

BB” = 0.37R’ = 1.48” Q88. During the internal inspection of T 3-27, a patch plate welded to the floor, with a tombstone shaped pad, extending to the inside of the shell was discovered. The plate had been seal welded to the floor and shell, with a minimum dimension of 12 inches. The inspector should _____________. a. have the patch removed. b. inspect the patch. c. recommend removal of the patch and floor plates in the repaired area, replacing withnew floor plates. d. this repair is in the critical zone and not allowed.

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Q89. During the same internal inspection of T 3-27, a square lap-welded patch was found over an existing nozzle. The inspector should __________. a. have the patch removed. b. inspect the patch. c. cut out the entire shell plate. d. radiograph the patch for weld quality.

Q90. T 3-27 has a hole, less than 1" in diameter, in the roof. Rain water does not contaminate the stored product. Is a repair required by API 653? a. A repair may be made by using duct tape. b. Only if the owner requires the repair. c. No d. Yes

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Q91. What is the position designation for welding pipe in the horizontal fixed position? a. 2G b. 3G c. 5G d. 6G Q92. During a fluorescent MT test, the black light intensity shall be measured at least once every . a. hour b. 2 hours c. 4 hours d. 8 hours

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Q3. Terminology for weld metal in excess of the specified weld size. a. Weld reinforcement b. Good weld technique c. Weld toe d. Weld throat Q94. If T 3-27 had a new nozzle installed in the third course, north side, could the shell-to-nozzle weld be made using the oxyfuel welding process, if impact testing is not required? a. Yes b. No c. The oxyfuel process is not allowed by ASME Section IX d. Nozzle welds must be made using SMAW only

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Q95. A diesel oil test is required for ______________. a. all new nozzle welds b. all new floor welds c. all new shell welds d. all new shell-to-bottom welds Q96. The minimum PSIG for a vacuum box test is __________. a. 1 PSIG b. 2 PSIG c. 3 PSIG d. 4 PSIG

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Q97. A pipe welder is qualified to API 1104 only. What welds can he make on the tank if he is qualified in the 6G position? a. Nozzle Welds b. Shell Welds c. Floor and roof fillet welds d. None Q98. A procedure is qualified on plate .500" thick. Which of the following thicknesses is not qualified? a. 1" b. 1/2" c. 1/4" d. 1/8"

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Q99. A procedure is qualified on plate .500" thick. Four nick break specimens were substituted for the four side bends. a. The procedure is qualified. b. ASME does not allow nick breaks. c. Two tension specimens were required. d. Nick breaks are used only on pipe.

Q100. A welder is qualified in the 3F and 4F positions. Which of the following groove welds can he make? a. 1G b. 2G c. 6G d. None

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Practice-04 API 653 PREPARATORY COURSE Final Exam — Open Book

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Q 1. The liquid penetrant examination method is an effective means for detecting _______. a. internal discontinuities of a weld b. surface discontinuities of a weld c. both internal and surface discontinuities of a weld d. subsurface discontinuities of a weld Q 2. A WPS is a written qualified welding procedure prepared to ________. a. provide direction for making production welds to Code requirements b. provide direction for the welder to make temporary welds c. provide direction for the inspector for inspection of the welds d. provide direction for the welder to use as a general guideline

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Q 3. Welding in the 3G position qualifies a welder in what positions? a. Flat and horizontal b. Horizontal and vertical c. Flat and vertical d. Vertical and overhead Q 4. Which of the following is an essential variable for the WPS? a. A change in groove design b. A change in backing c. A change in post weld heat treatment d. A change in electrode angle

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Q 5. A welder may be qualified by RT if ___________. a. the welder uses SMAW b. the welder uses GMAW Short Circuiting mode c. the welder uses GMAW Short Circuiting mode root pass with SMAW fill and reinforcement d. the welder obtains approval from the inspector Q 6. A peripheral seal, on an internal floating roof, shall be designed to accommodate ______ of local deviation between the floating roof and the shell. a. the manufacturer’s standard b. ±4 inches c. ±1/8inch d. inspector’s experience API650: H.4.4.3 All peripheral seals and their attachment to the floating roof shall be designed to accommodate ±100 mm (±4 in.) of local deviation between the floating roof and the shell.

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API650: H.4.4.3 All peripheral seals and their attachment to the floating roof shall be designed to accommodate Âą100 mm (Âą4 in.) of local deviation between the floating roof and the shell.

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Q 7. What is the maximum allowable prod spacing using an AC prod (yoke?) technique? a. t/2 b. 8 inches c. 10 inches d. No spacing required Q 8. Welders that weld tank shell vertical joints shall be qualified in accordance with______. a. API 1104 b. ASME Section V c. ASME Section IX d. AWS D1.1

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T-752 Prod Technique T-752.3 Prod Spacing. Prod spacing shall not exceed 8 in. (200 mm).

Shorter spacing may be used to accommodate the geometric limitations of the area being examined or to increase the sensitivity, but prod spacings of less than 3 in. (75 mm) are usually not practical due to banding of the particles around the prods. The prod tips shall be kept clean and dressed. If the open circuit voltage of the magnetizing current source is greater than 25 V, lead, steel, or aluminum (rather than copper) tipped prods are recommended to avoid copper deposits on the part being examined.

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Q 9. Geometric unsharpness of the radiograph of a component under 2” thick shall not exceed __________. a. 0.020 b. 0.030 c. 0.040 d. 0.050 Q 10. For measuring the thickness of materials using the contact pulse-echo method, temperatures are not to exceed________. a. 200°F b. 93°C c. both 1 and 2 d. 50°F SE797: 1. Scope 1.1 This practice provides guidelines for measuring the thickness of materials using the contact pulse-echo method at temperatures not to exceed 200°F (93°C).

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Q 11. Each piece of magnetizing equipment shall be calibrated ___________. a. at the beginning of each shift b. at least once a year or whenever the equipment has been subject to major electrical repair c. whenever the technician feels like it d. at least once every 90 days Q 12. During calibration of an ammeter the unit shall not deviate by more than ____ of full scale. a. 10% b. 20% c. 30% d. 40%

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T-761 Frequency of Calibration T-761.1 Magnetizing Equipment (a) Frequency. Magnetizing equipment with an ammeter shall be calibrated at least once a year, or whenever the equipment has been subjected to major electric repair, periodic overhaul, or damage. If equipment has not been in use for a year or more, calibration shall be done prior to first use. (b) Procedure. The accuracy of the unit’s meter shall be verified annually by equipment traceable to a national standard. Comparative readings shall be taken for at least three different current output levels encompassing the usable range. (c) Tolerance. The unit’s meter reading shall not deviate by more than ±10% of full scale, relative to the actual current value as shown by the test meter.

T-761.2 Light Meters. Light meters shall be calibrated at least once a year or whenever a meter has been repaired. If meters have not been in use for one year or more, calibration shall be done before being used.

T-762 Lifting Power of Yokes (a) Prior to use, the magnetizing power of electromagnetic yokes shall have been checked within the past year. The magnetizing power of permanent magnetic yokes shall be checked daily prior to use. The magnetizing power of all yokes shall be checked whenever the yoke has been damaged or repaired. (b) Each alternating current electromagnetic yoke shall have a lifting power of at least 10 lb (4.5 kg) at the maximum pole spacing that will be used. (c) Each direct current or permanent magnetic yoke shall have a lifting power of at least 40 lb (18 kg) at the maximum pole spacing that will be used.

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Q 13. An inspector is evaluating a radiograph, a bright white image of a “B” appears on a darker background of the radiograph, __________. a. the radiograph shall be considered unacceptable b. the radiograph should not be rejected c. the “B” is for identification of the welder d. the “B” is for identification of the weld Q 14. Ultrasonic examination of hot tap connections or reinforcement is required by API 653 when _______. a. in lieu of radiographic testing b. searching for weld flaws c. searching for laminations d. requested by the welder

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Q 15. During an internal inspection of a tank, pitting that measures 0.30 inches deep was found in the shell (0.625 Thickness). The required thickness of the shell in this area is 0.5 inches. Based on the above information should a repair be made? a. Yes b. No c. The inspector option d. Repair contractorâ&#x20AC;&#x2122;s option API653: 4.3.2 Actual Thickness Determination 4.3.2.1 e) The criteria for continued operation is as follows: i) the value t1 shall be greater than or equal to tmin (see 4.3.3 or 4.3.4), subject to verification of all other loadings listed in 4.3.3.5; ii) the value t2 shall be greater than or equal to 60 % of tmin; and iii) any corrosion allowance required for service until the time of the next inspection shall be added to tmin and 60 % of tmin.

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The following applies to questions 16 through 25 below: An inspection is performed on an AST 24’ tall, 22’ fill height, 94’ diameter, water storage service, earth foundation. There is one area of general internal corrosion on the south side of the shell 20” wide and 20” in vertical length.

There is evidence of bottom settlement.

Q 16. Calculate the minimum thickness of the first course based on product alone. a. 1.175” b. 0.228” c. 0.551” d. 0.217” tmin = 2.6(21)94/23600 = 0.2174, however, tmin shall not be less than 0.1 in. for any tank course; used 0.2174” OK answer: d Q 17. Calculate the minimum thickness for the third course, if each course is 4’ in height. a. .122” b. .100” c. .275” d. .132” tmin = 2.6(13)94/26000 = 0.0094”, used 0.1” answer: b Charlie Chong/ Fion Zhang

Q 18. Calculate the “L” length for an area of general corrosion found 10’ from the bottom on the south side of the shell, T2= .125”. a. 40” b. 12.68” c. 680” d. 11.75” L =3.7√(Dt2) = 12.68, answer: b Q 19. There are three pits aligned vertically on the north side of the tank, in the first course. The diameter of the pits are 1 .250”, 1 “, and .500” in length along a vertical line 8” long.

Note: Assume pit depth of slightly less than one-half of the minimum acceptable tank shell thickness, exclusive of the corrosion allowance. a. Because the pits are aligned vertically no repair is required (?) b. Scattered pits may be ignored c. If the pit is round, it may be ignored d. A repair is required answer: d 4.3.2.2 Widely scattered pits may be ignored provided that: a) no pit depth results in the remaining shell thickness being less than one-half the minimum acceptable tank shell thickness exclusive of the corrosion allowance; and b) the sum of their dimensions along any vertical line does not exceed 2 in. in an 8-in. length (see Figure 4.2).

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Q 20. Three circumferentially scattered pits are located on the west side of the tank 18” from the bottom. The pits measure .500”, .477” and .732” in diameter. Note: Assume pit depth of one-half of the minimum acceptable tank shell thickness, exclusive of the corrosion allowance. a. Because the pits are scattered circumferentially no repair is required b. All pits may be ignored c. If the pit is round, it may be ignored d. A repair is required Answer: b, <2” cumulative pit length in 8” length, thus acceptable Q 21. A bulge is found on the tank floor, the diameter of the bulge is 30”.

What is the maximum permissible height for the bulge? a. 11.1” b. .460” c. .962” d. 1.11” BB = 0.37R = 11.1”, answer: a B.3.3 Internal Bottom Settlements or Bulges Measure the bulge or depression. The permissible bulge or depression is given by the following equation (see Note). BB = 0.37R Where: BB is maximum height of bulge or depth of local depression, in inches; R is radius of inscribed circle in bulged area or local depression, in feet.

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Q 22. An area of edge settlement in the tank bottom 6’ from the shell has sloped down and settled. The settlement measures 2” at the deepest point.

(The bottom lap welds are approximately parallel to the shell). a. A more rigorous stress analysis must be performed b. The area should be repaired c. Sloped edge settlement is usually no problem d. The area should be documented and checked during the next inspection Answer: d Q 23. What is the hydrostatic test height of this tank based on a minimum thickness found in question 16, as the controlling thickness? a. 24’ b. 34.2’ c. 18.6’ d. Not enough information given (Ht -1)= tmin StE/(2.6D), given tmin =0.217” Ht = 24.085, tested to full height 24’. Answer = a

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Q 24. A depression is noted on a section of the bottom near the middle of the east quadrant. The depression measures 5/8” deep, with a diameter of 36 inches. Should a repair be recommended? a. Yes b. No c. Not enough information given d. The tank holds water, no problem BB = 0.37R = 0.55 < 5/8” thus OK, answer: b BB is maximum height of bulge or depth of local depression, in inches; R is radius of inscribed circle in bulged area or local depression, in feet.

Q 25. If the maximum liquid level in the tank were to be lowered by 5’, what is the minimum thickness of the first course? a. 1.73” b. .166” c. .200” d. No change from original design thickness tmin = 2.6(16)94/23600 = 0.1656”, answer = b

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The following applies to questions 26 through 27 below: Or = 10 years RTbC = .200 RTip = .190 StPr = .002 UPr = .010 Q 26. Using data from above, calculate MRT. (metal loss from the bottom side corrosion). a. .250 b. .070 c. .002 d. .080 MRT = (Minimum of RTbc or RTip) – Or (StPr + UPr) = 0.07!

Answer = 10x0.002 = 0.02” answer: c Q 27. Using data from above, calculate MRT. (metal loss from internal corrosion). a. .250 b. .070 c. .002 d. .080 Internal corrosion 10x 0.01=0.1”

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Q 28. The weld ripples of reinforcement of butt-welded joints shall be before _________ radiography. a. removed b. ground flush, with grinding direction parallel to the weld c. ground flush, with grinding direction perpendicular to the weld d. removed if irregularities mask discontinuities answer: d Q 29. What is the hydrostatic test height of an in-service welded AST built to API 650, 8th Edition, 82’ diameter, 40’ tall with a minimum first course thickness of 0.197”. The material of construction is A-516, Grade 70 (A 516M Grade 485). a. 40’ b. 36’-2” c. 32’-8” d. 31’-6” Ht = SEtmin/2.6D +1 = 33000 x 0.197/(2.6x82) +1 = 31.49’, answer: d

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Q 30. For a single-wall material thickness, over 0.375” through 0.50”, what is the hole-type designation for a source side penetrameter? a. 15 b. 17 c. 20 d. 25 answer:b Q 31. The temperature range to conduct a standard technique liquid penetrant examination is ______. a. 500 ⁰F to 1350 ⁰F b. 500 ⁰F to 1250 ⁰F c. 700 ⁰F to 1150 ⁰F d. 500 ⁰F to 800 ⁰F T-652 Techniques for Standard Temperatures As a standard technique, the temperature of the penetrant and the surface of the part to be processed shall not be below 40°F (5°C) nor above 125°F (52°C) throughout the examination period. Local heating or cooling is permitted provided the part temperature remains in the range of 40°F to 125°F (5°C to 52°C) during the examination. Where it is not practical to comply with these temperature limitations, other temperatures and times may be used, provided the procedures are qualified as specified in T-653.

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Q 32. During an MT examination, __________ shall be performed on each area. a. 100% coverage at the required sensitivity b. a calibration of each piece of magnetizing equipment c. at least three separate examinations d. prod spacing of at least 10â&#x20AC;? ans: a Q 33. An AC yoke shall have a lifting power of at least ____________. a. 5lbs. b. 8 lbs. c. 10 lbs. d. 40 lbs.

Ans: c

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Q 34. A DC yoke shall have a lifting power of at least _________. a. 5lbs. b. 8 lbs. c. 10 lbs. d. 40 lbs.

Ans:d Q 35. A new tank will hold a product with the specific gravity of 1.05; The corrosion allowance is .10; The thickness of the first course is 1 .25 inches; Hydrostatic test stress 25,000 PSI. What is the thickness required for the annular plate? (Note: Include corrosion allowance). a. 5/16” b. 11/16” c. 3/8” (6/16) d. 7/16” Ans: 0.236 + .1 = 0.336” used 3/8” (0.375”) answer= c

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Q 36. A leak is noted 1 1/2” away from the shell-to-bottom weld in the floor of an existing welded tank. The hole in the floor is 4” in diameter. What type of repair, in compliance with API 653, 3rd Edition, should be made? a. Use RBI. Because the product might not contaminate the soil or waterways, no repair is required. b. Weld build-up the area. c. Install a ‘tombstone’ shaped, welded-on patch plate, intersecting the shellto-bottom joint at approximately 90°. d. Install a non-welded patch plate and fiberglass/epoxy to coat the area.

Ans:c Q 37. When using the SMAW process, a welder has changed from an F#4 electrode to an F#3 electrode. Does the procedure need to be requalified? a. Yes b. No c. Only if low hydrogen electrodes are used d. API 650 allows this change QW-404.4 A change from one F-Number in table QW-432 to any other Fumber or to any other filler metal not listed in table QW-432.

Ans: b Charlie Chong/ Fion Zhang

Q 38. During a welder qualification test, for plate coupons, all surfaces (except areas designated “discard”) shall _______. a. show complete joint penetration with complete fusion of weld metal and base metal b. show no more than 1/3t inadequate penetration c. show no more than 1/3t nonfusion d. be allowed one 5/32” crater crack ans: a Q 39. What is the hydrostatic test thickness for a new tank whose diameter is 150’, and has a fill height of 40’? The shell material is A 36M. a. 0.655 b. 0.611 c. 0.563 d. 0.500 tmin = 2.6(39)150/(24900) = 0.611 answer: b

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New Tank

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Old Chinese Tank

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Old Japanese Tank

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Old German Tank

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Q 40. In order to comply with API 650, the finished surface of a weld reinforcement on plate 1/2” thick, horizontal butt joints, may have a reasonably uniform crown not to exceed ____________ for radiographic examination. a. 1/4” b. 3/16” c. 1/8” d. 1/16” ans: d Q 41. If piping near the tank enters the ground, the soil should be excavated ______ inches for inspection. a. 1—3 b. 3—6 c. 6—12 d. Piping is not addressed by any of the documents listed in the API 653 Body of Knowledge.

Ans: c

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Q 42. Floating roofs on new tanks shall be sufficiently buoyant to remain floating after ______. a. Fifteen inches of rainfall in a 24-hour period b. Ten inches of rainfall in a 24-hour period c. Thirty inches of snow in a 24-hour period d. Thirty inches of sand in a 24-hour period Q 43. A sudden rapid fracture under stress, where the material exhibits little or no evidence of ductility or plastic deformation, is called _________? a. brittle fracture b. cavitation c. atmospheric corrosion d. caustic corrosion C.3.4 Pontoon Design C.3.4.1 Floating roofs shall have sufficient buoyancy to remain afloat on liquid with a specific gravity of the lower of the minimum design specific gravity or 0.7 and with primary drains inoperative for the following conditions. a)250 mm (10 in.) of rainfall in a 24-hour period over the full horizontal tank area with the roofs intact. This condition does not apply to double-deck roofs provided with emergency drains designed to keep water to a lesser volume that the roofs will safely support. Such emergency drains shall not allow the product to flow onto the roof.

NOTE The rainfall rate for sizing the roof drains in C.3.8 may result in a larger accumulated rainfall.

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Pontoon

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Q 44. Each floor scanning operator, who only use the bottom scanning equipment, shall receive a minimum of ________ hours of training. a. 8 b. 12 c. 20 d. 40 G.4.4 The authorized inspection agency is responsible for training each scanning operator they employ. Each scanning operator should receive a minimum of 40 hours of training. This training should include: ans: d Q 45. Variables in the procedure that can be changed without having to requalify the procedure and/or the scanning operators are ________. a. essential variables b. non-essential variables c. qualification tests d. TBEQ Ans: b

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Questions 46 through 50 apply to the WPS)PQR Procedure which begins on page 12.

Q46. What is the root face limitation as listed on the attached WPS and PQR? a. 3/32” b. 1/8” c. No limit d. Not designated Non essential variable Q47. If the supporting PQR is used, are the P-no’s correct on the attached WPS? a. Yes b. No c. Could be if properly preheated d. Not enough information P8 is for stainless steel, PQR tested P1 to P1

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Q48. Is the thickness range on the WPS supported by the PQR? a. Yes b. No c. Requalification is required by API 570 d. Requalification is required by ASME V Range qualified = 0.187~2T Q49. Is the attached PQR properly qualified? a. No, because RT is not allowed during PQR qualification b. No, because there are not enough tensile tests c. No, because peening is allowed by B31.3 d. Yes

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Q50. What should have been the correct number and type of guided bends on the PQR? a. 6 side bends b. 2 face and 2 root bends c. 1 side, 1 face and 1 root bend d. 2 face, 2 root and 4 side bends

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Reference

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Reference

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Practice-05 API 653 PREPARATORY COURSE Final Exam — Closed Book

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Please close all materials.

The remainder of the exam is “Closed Book.”

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Q51. Who has the ultimate responsibility for complying with the provisions of API Standard 653? a. API b. Owner/operator c. Inspector d. Contractor/builder ANS: b Q52. If cracks are suspected in nozzles or nozzle welds they should be checked by ______. a. ultrasonic digital thickness gauge b. MT or PT examination c. eddy current testing d. infra-red thermography ANS: b

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Q53. Localized corrosion due to the concentration of caustic or alkaline salts is ______? a. erosion b. brittle fracture c. caustic corrosion d. phase failure ANS: c Q 54. Per API 653, tanks shall have a formal visual inspection once every _____ years or RCA/4N years, whichever is less. a. three b. four c. five d. seven ANS: c

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Q 55. Monthly visual inspections of the external condition of in-service tanks may be performed by ___________. a. API 653 inspectors b. owner/operator personnel c. NDE technicians d. plant managers ANS: b Q 56. The critical zone for repairs to tank bottoms is that portion of the bottom or annular plate within _______ inches of the inside edge of the shell. a. 3 b. 6 c. 12 d. 24 ANS: a

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Q 57. On a fixed-type roof, planks long enough to span at least _____ roof rafters should be laid and used as walkways. a. none allowed b. 1 c. 2 d. 3 ANS: c Q 58. Cathodic protection surveys are recommended to ensure the effectiveness of cathodic protection. How often should this survey be done? a. Every 10 years b. Every time the tank is empty c. Annually d. Semi-annually ANS: c

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Q 59. The deflection of an arc from its normal path because of magnetic forces is _____. a. arc blow b. arc length c. arc strike d. arc angle ANS: a Q 60. During the reconstruction of a tank shell, welding operators, welders and welding procedures must be qualified in accordance with _______. a. API 650 b. ASME Section V c. ASME Section IX d. API 1104 ANS: c

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Q 61. Upon completion, the roof of a tank designed to be gas tight shall be tested by which one of the following methods? a. Magnetic particle testing of all welds b. Application of internal air pressure not exceeding the weight of the roof plates and applying a solution suitable for the detection of leaks c. Penetrant testing the weld joints d. Visual inspection of the weld joints ANS: b Q 62. In regard to API 653, roof plates corroded to an average thickness of _______ inch in any 100 square inch area shall be repaired or replaced. a. less than 0.09 b. 0.09 c. greater than 0.09 d. no API 653 requirement, ownerâ&#x20AC;&#x2122;s requirement ANS: a 4.2.1.2 Roof plates corroded to an average thickness of less than 0.09 in. in any 100 in.2 area or roof plates with any holes through the roof plate shall be repaired or replaced.

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Q 63. A fusion weld made without filler metal is _______. a. brazing b. SMAW weld c. autogenous weld d. SAW weld ANS: c Q 64. Each welder making welds on a tank shall be certified by _________. a. erection/fabrication manufacturer b. purchaser c. Nuclear Regulatory Commission d. certified inspector ANS: a

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Q 65. A discontinuity with a length that is substantially greater than its width is called a ______. a. round discontinuity b. linear discontinuity c. non-linear discontinuity d. rejectable defect ANS: a Q 66. A form of corrosion that occurs from moisture associated with atmospheric conditions is called ______ a. brittle fracture b. caustic corrosion c. stress cracking d. atmospheric corrosion ANS: d

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Q 67. Which of the following tanks are used to reduce filling and breathing loss by eliminating vapor space? a. Cone roof tank b. Umbrella-roof tank c. Vapor-dome roof tank d. Floating roof tank ANS: d Q 68. Per API 650, external floating roof deck plates having support leg or other rigid penetrations closer than_____ inches to lap weld seams must be full fillet welded not less than 2 inches on 10 inch centers. a. 6 b. 12 c. 14 d. 18 ANS:

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Q 69. Foundation pads that have washed out or settled under the bottoms of atmospheric storage tanks can be repaired by _________. a. pumping in water b. pumping in argon c. pumping in sand, dirt or thin concrete d. pumping in gas ANS: c Q 70. When corrosion rates are not known and similar service experience is not available, the actual bottom thickness shall be determined by inspections within the next _____ year(s) of tank operation to establish corrosion rates. a. five b. ten c. three d. one ANS: b

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Q 71. The mechanical working of metals using impact blows is referred to as ______. a. inclusion b. corrosion c. fatigue d. peening ANS: d Q 72. Calcining can occur when concrete has been exposed to ______. a. chemical attack b. sulfate - type alkalis c. chlorides d. high temperature ANS: d

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Q 73. A contributing factor for determining internal inspection intervals shall be time, not to exceed _____ years for any reason, if an RBI program is not in place. a. 10 b. 5 c. 20 d. 15 ANS: c Q 74. Upon completion of welding of the new tank bottom, the welds shall be inspected by which one of the following methods? a. Radiographs b. Vacuum c. Penetrant testing d. Hammer testing ANS: b

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Q 75. The junction of the weld face and the base metal is the __________. a. heat affect zone b. weld toe c. stress riser d. dilution zone ANS: b Q 76. Tank plates being welded which do not have proper identification shall be subjected to _______. a. chemical analysis b. UT thickness measurements c. PT testing d. RTtesting ANS: a

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Q 77. An assembly whose component parts are joined by welding is a _________. a. spool piece b. weldment c. fillet weld d. groove weld ANS: b Q 78. ______ identifies a procedure for installing a nozzle in the shell of a tank that is in service. a. Repair b. Alteration c. Hot tap d. Reconstruction ANS: c

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Q 79. Annular bottom plates shall have a radial width that provides at least ________ inches between the inside of the shell and any lap-welded joint in the remainder of the bottom. a. 10 b. 30 c. 24 d. 18 ANS: c Q 80. For known materials, all shell plates and bottom plates welded to the shell shall meet, as a minimum, the chemistry and mechanical properties of material specified for the application with regard to thickness and design metal temperature, per ________. a. ASM Requirements b. ASME Requirements c. API 650 Requirements d. ASTMA 7 Requirements ANS: c

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Q 81. What action should be taken after a flat spot is discovered in the second ring of a 200â&#x20AC;&#x2122; diameter AST? a. The shell distortion shall be evaluated b. The area shall be cut out and replaced c. Since no product is leaking out of the area, it may be ignored d. The inspector has the option to repair or ignore ANS: a Q 82. Routine in-service visual inspections of the external condition of the tank shall not exceed _______. a. one month b. six months c. one year d. five years ANS: a

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Q 83. A separation at the joint root between the work pieces is referred to as a ________. a. gap b. root face c. root edge d. root opening ANS: d Q 84. Minimum thickness for tank bottom plate, when there is no means of leak detection and containment, is ________ inch. a. .10 b. .075 c. .15 d. .05 ANS: a

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Q 85. When used, the ultrasonic thickness measurements shall be made at intervals not to exceed ________. a. one month b. one year c. five years, (unknown corrosion rate) d. ten years, (unknown corrosion rate) ANS: c Q 86. Cavity-type discontinuities formed by gas entrapment during solidification of the weld are ________. a. cracks b. tungsten inclusion c. slag d. porosity ANS: d

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Q 87. The most likely point of occurrence of cracks in riveted tanks is around _________. a. internal piping b. flanged connections c. roof seals d. rivet holes ANS: d Q 88. Qualified inspectors shall have education and experience equal to at least one of the following: a. a degree in engineering plus 1 year of experience in inspection of tanks, pressure vessels or piping b. two years of experience in work related field c. two year certificate in technology from technical college d. high school education ANS: a

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Q 89. The maximum acceptable undercutting of the base metal for vertical butt joints is _______ inch. a. 3/32 b. 1/8 c. 1/64 d. 3/64 ANS: c Q 90. When used, ultrasonic thickness measurements shall be made at ____ year intervals after commissioning new tanks. a. 5 b. 7 c. 10 d. 15 ANS: 5

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Q 91. On a reconstructed tank, all new shell joints shall be __________. a. full fillet welded with complete fusion b. butt-welded with complete penetration and complete fusion c. lap-welded with complete penetration and complete fusion d. single grove with backing strip ANS: b Q 92. A non-metallic product resulting from the mutual dissolution of flux and non-metallic impurities in some welding processes is __________. a. porosity b. tungsten inclusion c. slag d. cracking ANS: c

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Q 93. A double-welded butt weld is ___________. a. a joint between two abutting parts lying in approximately the same plane b. a joint between two abutting parts lying in approximately the same plane that is welded from both sides c. a joint between two overlapping members in which the overlapping edges of both members are welded with fillet welds d. a fillet weld whose size is equal to the thickness of the thinner joined member ANS: b Q 94. All requirements of API 650, _____ shall be considered before changing the service of a tank to operation at temperatures above 200째F. a. Appendix M b. Appendix J c. Appendix C d. Appendix K ANS: a

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Q 95. Openings in tank shells larger than required to accommodate a _______ inch flanged or threaded nozzle shall be reinforced. a. one b. two c. three d. four ANS: b Q 96. The API 653 standard employs the principles of _________. a. API 650 b. ASME Article 4 c. AWS D1.1 d. API 1104 ANS: a

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Q 97. Qualification test plates for floor scan, with flaws, should be a minimum of ___________ sq. ft. a. 20 b. 70 c. 90 d. 150 ANS: b G.5 Qualification Testing G.5.1 Qualification Test Plates G.5.1.1 The qualification test will be performed on a sample tank bottom with designed flaws. The sample tank bottom should be a minimum of 70 ft2 to provide space for the designed flaws. The plate material used to fabricate sample plates may be either new steel or used steel. It should be noted that the results obtained during qualification tests might not be indicative of the results of examinations performed on other plates of differing quality or permeability. When used steel is utilized for qualification purposes, the qualification test acceptance standards recommended in G.5.2 may not be appropriate. The owner/operator should establish its own acceptance standards in such cases.

Q 98. A fracture-type discontinuity characterized by a sharp tip and high ratio of length to width to opening displacement is referred to as _______. a. crack b. slag c. porosity d. spatter ANS: a

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Q 99. The acceptability of welds examined by radiography shall be judged by the standards in ______. a. ASME Section V, Division 7 b. ASME Section IX, Paragraph QW191 c. ASME Section VIII, Division 1, Paragraph UW-51 (b) d. API1104 ANS: c Q 100. Per API 653, what is the maximum allowable banding, using a vertical 36” sweep board? a. 1” b. 1/2” c. 3/8” d. 3/32” ANS: a API653: 10.5.5 Banding With a vertical sweep board 36-in. long, banding shall not exceed 1 in.

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Q 101. The arrangement of direct current arc welding leads in which the electrode is the negative pole and the work piece is the positive pole of the welding arc is _____? a. DCEN b. DCEP c. AC d. AC/DC ANS: a Q 102. Any work on a tank that changes its physical dimensions or configuration is considered a/an ____________. a. reconstruction b. rebuilding c. reworking d. alteration ANS: d

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Q 103. When bottom annular plates are required by paragraph 3.5.1 of API 650, the radial joints shall be radiographed. For single welded joints using a backup bar, one spot radiograph shall be taken on _____ percent of the radial joints. a. 10 b. 30 c. 50 d. 100 ANS: a Q 104. What is the maximum allowable misalignment on a 3/4” vertical butt joint? a. 10% b. 1/16” c. 10% or maximum of 1/8” d. 12% or maximum of 3/32” ANS: c

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API 650: 8.1.2.9 When bottom annular plates are required by 5.5.1, or by M.4.1, the radial joints shall be radiographed as follows: (a) For double-welded butt joints, one spot radiograph shall be taken on 10 % of the radial joints; (b) For single-welded butt joints with permanent or removable back-up bar, one spot radiograph shall be taken on 50 % of the radial joints.

Extra care must be exercised in the interpretation of radiographs of single-welded joints that have a permanent back-up bar. In some cases, additional exposures taken at an angle may determine whether questionable indications are acceptable. The minimum radiographic length of each radial joint shall be 150 mm (6 in.). Locations of radiographs shall preferably be at the outer edge of the joint where the shell plate and annular plate join.

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API 650: 7.2.3 Shells 7.2.3.1 Plates to be joined by butt welding shall be matched accurately and retained in position during the welding operation.

Misalignment in completed vertical joints for plates greater than 16 mm (5/8 in.) thick shall not exceed 10 % of the plate thickness or 3 mm (1/8 in.), whichever is less; misalignment for plates less than or equal to 16 mm (5/8 in.) thick shall not exceed 1.5 mm (1/16 in.).

7.2.3.2 In completed horizontal butt joints, the upper plate shall not project beyond the face of the lower plate at any point by more than 20 % of the thickness of the upper plate, with a maximum projection of 3 mm (1/8 in.); however, for upper plates less than 8 mm (5/16 in.) thick, the maximum projection shall be limited to 1.5 mm (1/16 in.).

7.2.3.3 The upper plate at a horizontal butt joint shall have a 4:1 taper when its thickness is more than 3 mm (1/8 in.) greater than the lower plate.

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Q 105. Atmospheric storage tanks are those tanks that have been designed to operate in their gas and vapor spaces at internal pressures which approximate pressure. a. 16 lbs. to 25 lbs. b. 12 lbs. to 15lbs. c. more than 25 lbs. d. atmospheric ANS: d Q 106. The arrangement of direct current welding leads in which the electrode is the positive pole and the work piece is the negative pole of the welding arc is _________? a. DCEN b. DCEP c. AC d. AC/DC ANS: b Charlie Chong/ Fion Zhang

Q 107. The portion of the groove face within the joint root is called __________. a. land b. root face c. stringer bead d. root pass ANS: b Q 108. Welder identification on roof welds and flange-to-nozzle neck welds shall ________. a. be hand or machine stamped b. be stamped every 3 feet c. be stamped on the top side of each nozzle an in every 3 feet of roof weld d. not require identification ANS: d

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Q 109. Annular bottom plates must extend a minimum of _______ inches outside the tank shell. a. 1½ b. 2 c. 3 d. 4 ANS: b API650: 5.4.2 Bottom plates of sufficient size shall be ordered so that, when trimmed, at least a 50 mm (2 in.) width will project outside the shell or meet requirements given in 5.1.5.7 d whichever is greater.

API653: 4.4.5.7 The thickness of the projection of the bottom plate beyond the shell as measured at the toe of the outside bottom-to-shell fillet weld shall not be less than 0.1 in. The projection of the bottom plate beyond the outside toe of the shell-to-bottom weld shell shall be at least 3/8 in.

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Q 110. For penetrations using insert plates, how shall the completed butt welds between the insert plate and shell plate be inspected? a. 100% RT b. Spot RT c. MT d. Visual ANS: a 12.2.1.8 For penetrations installed using insert plates as described in 9.8.6, the completed butt welds between the insert plate and the shell plate shall be fully radiographed.

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Q 111. NDE examiners that meet the requirements of ASME Section V, Article 1, are qualified with ASNI/ASNT CP-189 or _________. a. AWS QC-1 b. API c. ASNT SNT-TC1A d. ABS ANS: c Q 112. The maximum operating temperature for tanks constructed to API 650 (not including appendices) is ______. a. 500째F b. 500째C c. 200째F d. 200째C ANS: c

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Q 113. New _______ for floating roof support legs and for fixed roof support columns shall be installed when replacing a tank floor. a. mud rings b. leg guides c. bearing plates d. support leg pins ANS: c Q 114. Where does the new nameplate need to be attached to a reconstructed tank? a. Adjacent to the existing nameplate b. Does not need one c. On the roof d. Over the suction piping ANS: a

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Q 115. The corrosion rate for an AST is 5 mils per year. Based on API 653 requirements when should the next external UT inspection be scheduled?

Note: Remaining Corrosion Allowance is .17 inches. a. 17years b. 15 years c. 20 years d. 10 years ANS: 0.17/0.005 = 34 years used 15 years. Ans b Q 116. The design thickness of a reconstructed tank is based on _________. a. original shell thickness b. measurements taken within 180 days prior to relocation c. measurements taken when the tank was removed from service d. new product loads ANS: b

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Q 117. The maximum design liquid level for product shall be determined by calculating the maximum design liquid level for each shell course based on _________. a. amount of product needed b. the specific gravity of the product c. material coating d. number of penetrations in the first shell course ANS: b Q 118. SW is the acronym for what type of welding? a. Submerged Welding b. Shielded Metal Arc Welding c. Slick Welding d. Stud Welding ANS: d

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Q 119. You are adding a 6 inch blending nozzle to the bottom course, the shell is 5/8” thick. What size insert plate is required when used with a reinforcement plate? a. 12” diameter b. 18” diameter c. Three times the diameter of the penetration d. The diameter of the reinforcement plate, plus 12” ANS: d Q 120. Who is responsible for compliance with the API 650 standards? a. Manufacturer b. Purchaser c. State Inspector d. API 653 Inspector ANS: a

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Q 121. ____________ settlement occurs when the tank shell settles sharply around the periphery, resulting in deformation of the bottom plate. a. Uniform b. Edge c. Out-of-Plane d. Rigid Body Tilting ANS: b Q 122. A full hydrostatic test can be waived on a tank _________. a. after replacement of door sheet that intersects the shell-to-bottom weld b. when a 36-inch nozzle has been installed c. after partial or complete jacking of a tank shell d. if the owner or operator has authorized the exemption in writing ANS: d

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Q 123. Which type of tank settlement will rotate the tank in a tilted plane? a. Uniform settlement b. Rigid body c. Out-of-Plane settlement d. Differential settlement ANS: b Q 124. Due to the fast-freezing nature of this process, there is potential for lack of sidewall fusion when welding thick-wall equipment or a nozzle attachment. a. GMAW - Pulsed b. GMAW - Spray c. GMAW - G d. GMAW - S ANS: d

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Q 125. The minimum thickness of new roof plates shall be _____ inch, plus any corrosion allowances, as specified in the repair specifications. a. 1/2 b. 7/8 c. 3/16 d. 3/8 ANS: c Q 126. Express 50 mils as ______ inch(es). a. .500 b. .050 c. .005 d. .0005 ANS: b

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Q 127. For replacement of tank bottom floor, what is a suitable non-corrosive material for use between the old and new floor? a. Dirt b. Sand or concrete c. Fiberglass insulation d. Air ANS: b Q 128. According to API 653, the basis for repairs and alterations shall be an ________. a. API Standard 650 equivalence b. API Standard 2207 equivalence c. ASME Section V equivalence d. AWS D 1 .1 equivalence ANS: a

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Q 129. All new shell joints shall be _______ joints, with complete penetration. a. butt welded b. lap welded c. riveted d. chemically bonded ANS: a Q 130. During the repair of an AST, one new vertical shell weld was installed.

How many radiographs are required on the vertical? (The shell is 1.25â&#x20AC;? thick). a. One radiograph shall be taken in every vertical joint b. 100% of the vertical joint c. Two radiographs shall be taken in the vertical joint d. No radiographs required ANS: b

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Q 131. Settlement can result from _______. a. frequent freezing and thawing of the ground b. nearby equipment operating with extreme vibration c. too much product being stored in the tank d. high wind ANS: a Q 132. Storage tanks shall be ____ and gas-freed prior to commencement of dismantling. a. filled b. drained c. cleaned d. vented ANS: c

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Q 133. All bottom plates shall have a minimum nominal thickness of _________ inch, exclusive of any corrosion allowance specified by the purchaser for the bottom plates. a. 3/8 b. .250 c. .516 d. .325 ANS: b API650: 5.4 Bottom Plates 5.4.1 All bottom plates shall have a corroded thickness of not less than 6 mm (0.236 in.) [49.8 kg/m2 (9.6 lbf/ft2) (see 4.2.1.2)]. Unless otherwise agreed to by the Purchaser, all rectangular and sketch plates (bottom plates on which the shell rests that have one end rectangular) shall have a nominal width of not less than 1800 mm (72 in.).

Q 134. ____________ means the work necessary to reassemble a tank that has been dismantled and relocated to a new site. a. Reconstruction b. Rebuilding c. Reworking d. Alteration ANS: a Charlie Chong/ Fion Zhang

Q 135. Repairs shall not be attempted on a tank that is filled with _____ or on a tank that has contained until the tank has been emptied, cleaned and gas freed in a safe manner. a. nitrogen b. oil c. water d. grain ANS: b Q 136. According to API 653, a full hydrostatic test, held for 24 hours, shall be performed on: a. a new tank b. an in-service tank c. a reconstructed tank d. an out-of-service tank ANS: c

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Q 137. Misalignment in completed vertical joints over 5/8” shall not exceed what percentage of the plate thickness? a. 25% with a maximum of 1/16” b. 2% with a maximum of 3/64” c. 5% with a maximum of 3/8” d. 10% with a maximum of 1/8” ANS: d Q 138. New or altered reinforcing plates of shell penetrations shall be given a(n) __________ test, in accordance with API Standard 650. a. diesel b. air c. stress d. gas ANS: b

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Q 139. Ultrasonic acceptance standards, in accordance with API 653, shall be __________. a. ASME Section VIII b. ASME Section V c. ASME Section Xl d. Agreed upon by the purchaser and the manufacturer ANS: d API650: 8.3.2.5 Acceptance standards shall be agreed upon by the Purchaser and the Manufacturer.

Q 140. Column-based clip-guides shall be welded to the tank bottom to prevent ________. a. internal erosion b. structural uplifting c. lateral movement of column bases d. lateral expansion and contraction ANS: c

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Q 141. Any specific design considerations, other than normal product loading, shall be specified by _______. a. owner/operator b. contractor c. engineer d. welding foreman ANS: a Q 142. A(n) ________ is an electrode of an electrochemical cell at which oxidation (corrosion) occurs. a. bathode b. anode c. cathode d. electrolyte ANS: b

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Q 143. A(n) ________ is an electrode of an electrochemical cell at which a reduction reaction occurs. a. bathode b. anode c. cathode d. electrolyte ANS: c Q 144. A __________ is a discontinuity in a coating film that exposes the metal surface to the environment. a. vacation b. surface interruption c. stress riser d. holiday ANS: d

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Bee Gees- Holiday

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Bee Gees- Holiday

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Q 145. ____________ occurs when two metals with different compositions (thus different electrolytic potentials) are connected in an electrolyte (usually soil). a. Scattered metal growth b. Scattered metal blistering c. Galvanic corrosion d. Erosion ANS: c Q 146. A Galvanic system is a _________. a. system that uses a metal less active than the structure to stop corrosion b. system that uses a metal more active than the structure to stop corrosion c. system that uses a chemical to stop corrosion d. system that uses a coating to stop corrosion ANS: b

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Q 147. All tanks shall be given a formal visual external inspection by an inspector qualified in accordance with API 653, Paragraph 4.10 at least every _____ years. a. 10 b. 7 c. 6 d. 5 ANS: 5 Q 148. Welding consumables shall conform to the classification that is applicable to the intended use. a. ASNT b. AWS c. ASME d. API ANS: b

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Q 149. The rules given in API 653 are _________ for tank inspection, repairs, alterations and reconstruction. a. minimum requirements b. maximum requirements c. guideline requirements d. suggested requirements ANS: a Q 150. ____________ means any work on a tank involving cutting, burning, welding or heating operations that changes the physical dimensions and/or configuration of a tank. a. Repair b. Reconstruction c. Reworking d. Alteration ANS: d

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Charlie Chong/ Fion Zhang

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Good Luck!

Charlie Chong/ Fion Zhang

Good Luck!

Charlie Chong/ Fion Zhang