API 653 Tank Inspection Code_04.pdf

26.

How many roof rafters must a plank cross over for inspection of the roof of a tank? a. b. c. d.

1 2 3 4

Section: 27.

The maximum acceptable undercutting on horizontal butt welds of a reconstructed tank is _____ inch. a. b. c. d.

1/64 1/32 1/16 1/8

Section: 28.

Reference Publication:

The minimum number of settlement points around a tank periphery is a. b. c. d.

.

12 10 8 6

Section: 29.



A weld shall be acceptable by visual inspection if the inspection shows which of the following? a. b. c. d.

The weld has no cracks, no undercutting, and less than 20% coldlap. 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”. 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”. 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”.

Section:


API 653 Exam Prep Homework #2 Questions Page 3

30.

Penetrameters (IQIs)are normally placed on the _____ of the part being examined. a. b. c. d.

source side film side weld side obverse side

Section: 31.


External, UT measurements of a new tank shell shall be made not later than _____ years after commissioning. a. b. c. d.

5 4 3 2

Section: 32.

“Penetrameter” is another common term for a. b. c. d.


Thin film linings are usually used for application to a. b. c. d.

.

the bottoms of new storage tanks. pitted bottoms of older storage tanks. corroded bottoms of previous service tanks. rough and pitted surfaces.

Section: 34.

.

flammable material IQI outside diameter film holder

Section: 33.



With a horizontal sweep board 36” long, peaking shall not exceed _____ inch. a. b. c. d.

0.250 0.375 0.500 0.625

Section:



35.

If a welder tests in a 6G position, he qualifies to weld a. b. c. d.

all positions uphill only downhill only vertical only

Section: 36.

An anode is a. b. c. d.

b. c. d.



The critical zone of the tank bottom is within the a. b. c. d.

.

no pit depth results in the remaining shell thickness being less than 1/2t min acceptable tank shell thickness, exclusive of corrosion allowance. the average pit depth is greater than 1/2t min, exclusive of the corrosion allowance no pit depth is greater than 1/2t min, including the corrosion allowance no pit depth is less than 1/2t min, including the corrosion allowance

Section:

.

Annular plate ring, within 6” of the shell or within 6” of the inside edge of the annular ring. Annular plate ring, within 10” of the shell or within 10” of the inside edge of the annular ring. Annular plate ring, within 12” of the shell, or within 12” of the inside edge of the annular plate ring. Annular or bottom plates within 3 inches of the inside edge of the shell.

Section: 39.

.

Widely scattered pits may be ignored, provided a.

38.


an electrode of an electrochemical cell at which no corrosion occurs an electrode of an electrochemical cell at which corrosion occurs a chemical substance containing ions that migrate a metallic connection that provides electrical continuity

Section: 37.

.


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. b. c. d.

a minimum 1/2” gap over no more than 24” an area of no more than 15 square inches opening calculated by measuring the length and width of the gaps. a reasonably close fit to the shell surfaces a minimum of 3 openings 24” long with gaps no more than 1/4”

Section:

Reference Publication: API 653 Exam Prep Homework #2 Questions Page 5

40.

What is the minimum thickness for a tank floor plate with a > 0.05” or thicker reinforced internal lining? a. b. c. d.

.005” .050” .075” .100”

Section: 41.

A full hydrostatic test is always required on a. b. c. d.

o 600 F o 135 F o 400 F Within the temperature range limitations set by the manufacturer

Section:


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. b. c. d.

120o F o 140 F o 160 F o 200 F

Section: 44.


What is the maximum temperature that dry MT can be used? a. b. c. d.

43.

.

a tank that has an annular plate installed with the longest dimension less than 12” a tank that has a door sheet installed a tank that has a nozzle 12” NPS installed a reconstructed tank

Section: 42.



What is the main factor in determining the efficiency of a rivet joint in a tank? a. b. c. d.

The allowable stress of the rivets The number of rivet rows and type of joint The allowable stress of the plate Whether the joints have butt straps or not

Section:



45.

It is not necessary for the inspector to check which of the following? a. b. c. d.

All test results on the PQR All essentials and non-essentials on WPS All essentials and non-essentials on WPS and PQR All non-essentials on PQR

Section: 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. b. c. d.

.0035” .0070” .0140” .0700”

Section: 47.

5 10 15 20

Section:


The maximum spacing of settlement points is _____ feet around the circumference of the tank. a. b. c. d.

40 35 32 25

Section: 49.


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. b. c. d.

48.



A 100 foot diameter tank must have at least _____ inch thick shell plates. a. b. c. d.

1/8 3/16 1/4 1/2

Section:



c. d

1/16 1/8

Section:



Study Sheets Based on API 653 Exam Information The following is a collection of questions remembered by various students who took the API 653 Exam in the past. This study sheet is designed to help a student prepare for the API 653 Exam. Read each question carefully and select the best answer by circling your choice. After selection of your answer, write in the section number and publication in which your answer was found. Look up each question in the reference publications listed below; remember, this exercise is to help you to learn to use the reference material. Generally, the assignment is broken into several sections. Each section should take approximately one hour to complete. Answers will be discussed at the beginning of class the following morning. The answers will be found in the following reference publications: API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, First Edition, December, 2003 ATTENTION: Only the following mechanisms are included in the exam: Par. 4.2.7 – Brittle Fracture Par. 4.2.16 – Mechanical Fatigue Par. 4.3.2 – Atmospheric Corrosion Par. 4.3.3 – Corrosion Under Insulation (CUI) Par. 4.3.8 – Microbiologically Induced Corrosion (MIC) Par. 4.3.9 – Soil Corrosion Par. 4.3.10 – Custic Corrosion Par. 4.5.1 – Chloride Stress Corrosion Cracking (Cl-SCC) Par. 4.5.3 – Caustic Stress Corrosion Cracking (Caustic Embrittlement) Par. 5.1.1.11 – Sulfuric Acid Corrosion API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks, First Edition, November, 1995 API RP 577, Welding Inspection and Metallurgy, First Edition, October, 2004 API 650, Welded Steel Tanks for Oil Storage, Tenth Edition, November, 1998, including Addendum 1 (March, 2000), Addendum 2 (November, 2001), and Addendum 3 (September, 2003). API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, Second Edition, December, 1997 API RP 652, Lining of Above Ground Petroleum Storage Tank Bottoms, Second Edition, December, 1997 API 653 Exam Prep Homework #3 Questions Page 1

API 653, Tank Inspection, Repair, Alteration and Reconstruction, Third Edition, December, 2001, including Addendum 1 (September, 2003). ASME Boiler & Pressure Vessel Code, 2004 Edition Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and 23 (Section SE-797 only) Section IX, Welding and Brazing Qualifications, Section QW only


51.

The letter “B” is placed on radiographic film holder for what reason? a. b. c. d.

To determine if back scatter radiation is exposing the film. To show the distance from the source of radiation to the weld. To function as a location marker for the radiograph. To designate whether the penetrameter (IQI) is on the film side or the back side.

Section: 52.

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. b. c. d.

0.805” 0.691” 0.200” 0.483”

Section: 53.


When preparing to enter a storage tank for inspection, the most important thing to do is . a. b. c. d.

obtain a written entry permit to have all equipment needed for inspection ready and available to be wearing protective clothing to check all platforms and ladders for serviceability

Section: 54.



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. b. c. d.

The weld is acceptable The weld is unacceptable because of the excess undercut The weld is unacceptable because of the excess reinforcement The weld is unacceptable because of the excess reinforcement and excess undercut

Section:



55.

What is the inspection frequency for flame arrestors? a. b. c. d.

2 years 5 years 10 years Annually

Section: 56.

How many tensile tests are required to qualify a 1/4” plate groove weld? a. b. c. d.

2 3 4 6

Section: 57.

0.10 0.05 0.125 0.0625

Section:


The oxygen content for non-permit required confined space must be __________. a. b. c. d.

0 - 10% 10% - 15% 19.5% - 23.5% 25.2% - 32.7%

Section: 59.


The minimum bottom plate thickness for a tank with an applied reinforced lining greater than 0.05” thick, applied in accordance with API RP 652, is inch. a. b. c d.

58.



The acceptance criteria for a radiograph of a tank repair weld is found in a. b. c. d.

Section V of the ASME Code Section IX of the ASME Code Section VIII of the ASME Code ASNT SNT-TC-1A

Section:



.

60.

All leaks in pontoons or compartments of double deck floating roofs shall be repaired by . a. b. c. d.

caulking the leaking joints and/or using soft patch material rewelding the leaking joints and/or the use of patch plates cutting out the leaking area and flush patching weld overlay any cracks and/or use soft patch material

Section: 61.


For what diameter tank is the variable point method for calculating shell thickness mandatory? a. b. c. d.

Tanks with a diameter of 200 feet and greater Tanks with a diameter greater than 300 feet Tanks with a diameter greater than 200 feet Tanks with a diameter of 300 feet and greater

Section: 62.


What is the minimum lifting power of an AC electromagnetic yoke used in magnetic particle inspection? a. b. c. d.

40 pounds lifting power at the maximum pole spacing 10 pounds lifting power at the maximum pole spacing 10 amps lifting power at the maximum pole spacing 30 pounds lifting power at the minimum pole spacing

Section: 63.


What is the allowable edge settlement of a 100’ diameter tank that has an area of settlement that starts to slope 36” from the shelland the bottom lap weld is approximately parallel to the shell? a. b. c d.

13.32” 3.75” 18.5” 2.22”

Section: 64.


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. b. c. d.

21,300 25,560 28,200 28,320

Section:

psi psi psi psi Reference Publication: API 653 Exam Prep Homework #3 Questions Page 5

65.

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. b. c. d.

0.17” 0.20” 0.325” 0.295”

Section: 66.

The principal advantage of thin-film linings are a. b. c. d.

5 10 20 25

Section:


Welders are qualified to what standard or code? a. b. c. d.

Section VIII of the ASME Code Section V of the ASME Code Section I of the ASME Code Section IX of the ASME Code

Section: 69.


In no case shall the internal inspection interval of an aboveground storage tank exceed _____ years, if an RBI program is not in place. a. b. c. d.

68.

.

better protection of older storage tank bottoms and ease of application less susceptible to mechanical damage and easier to repair lower cost and not as sensitive to pitting lower cost and ease of application compared to thick-film coating systems

Section: 67.



What is the maximum acceptable undercut of a nozzle to shell weld? a. b. c. d.

1/64” 1/32” 1/16” 1/8”

Section:



70.

The nameplate for a reconstructed tank shall be attached to the tank shell adjacent to . a. b. c. d.

the existing nameplate a manway in bottom tank course the stairway or ladder to the tank roof the door sheet

Section: 71.


When a welder has not welded with a process during a period of _____, his qualifications for that process shall expire. a. b. c. d.

3 months or more 6 months or more 9 months or more 12 months or more

Section: 72.

What allowable stress is used in evaluating a riveted joint when using joint efficiencies given in Table 4-3 of API 653? a. b. c. d.

16,000 18,000 19,000 21,000

Section: 73.

psi psi psi psi Reference Publication:

Radiographs of repaired work and records of radiographs of repaired work shall be marked with . a. b. c. d.

a grease pencil the mark of the welder who made the repair the letter “R” the initial of the inspector

Section: 74.



The transmitted film density through the radiographic image of the body of the appropriate hole penetrameter (IQI) and the area of interest shall be _____ minimum for radiographs made with a gamma ray source. a. b. c. d.

1.8 2.0 2.2 2.6

Section:



75.

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. b. c. d.

40” 36.1” 30.1” 28.1”

Section:



Study Sheets Based on API 653 Exam Information The following is a collection of questions remembered by various students who took the API 653 Exam in the past. This study sheet is designed to help a student prepare for the API 653 Exam. Read each question carefully and select the best answer by circling your choice. After selection of your answer, write in the section number and publication in which your answer was found. Look up each question in the reference publications listed below; remember, this exercise is to help you to learn to use the reference material. Generally, the assignment is broken into several sections. Each section should take approximately one hour to complete. Answers will be discussed at the beginning of class the following morning. The answers will be found in the following reference publications: API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, First Edition, December, 2003 ATTENTION: Only the following mechanisms are included in the exam: Par. 4.2.7 – Brittle Fracture Par. 4.2.16 – Mechanical Fatigue Par. 4.3.2 – Atmospheric Corrosion Par. 4.3.3 – Corrosion Under Insulation (CUI) Par. 4.3.8 – Microbiologically Induced Corrosion (MIC) Par. 4.3.9 – Soil Corrosion Par. 4.3.10 – Custic Corrosion Par. 4.5.1 – Chloride Stress Corrosion Cracking (Cl-SCC) Par. 4.5.3 – Caustic Stress Corrosion Cracking (Caustic Embrittlement) Par. 5.1.1.11 – Sulfuric Acid Corrosion API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks, First Edition, November, 1995 API RP 577, Welding Inspection and Metallurgy, First Edition, October, 2004 API 650, Welded Steel Tanks for Oil Storage, Tenth Edition, November, 1998, including Addendum 1 (March, 2000), Addendum 2 (November, 2001), and Addendum 3 (September, 2003). API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, Second Edition, December, 1997 API RP 652, Lining of Above Ground Petroleum Storage Tank Bottoms, Second Edition, December, 1997


API 653, Tank Inspection, Repair, Alteration and Reconstruction, Third Edition, December, 2001, including Addendum 1 (September, 2003). ASME Boiler & Pressure Vessel Code, 2004 Edition Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and 23 (Section SE-797 only) Section IX, Welding and Brazing Qualifications, Section QW only



76. What is the P number for the tank as listed above? a. b. c. d.

1.5 1 6 24

Section: 77.

If studs were installed on this tank, what polarity would have been used for the “stud gun”? a. b. c. d.

DECN DECP AC No polarity

Section: 78.

5 5.1 5.29 5.42

Section:


What is the filler number for E-7018 electrodes? a. b. c. d.

1 2 3 4

Section: 80.


What is the SFA number for E 7018 electrodes? a. b c. d.

79.



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. b. c. d.

.316” .500” .262” Not enough information given

Section:



81.

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. b. c. d.

57.24' 40' 28.27' Not enough information given

Section: 82.


What is the minimum acceptable shell plate thickness for the top course of T 3-27 if each course is 120" tall? a. b. c. d.

.1" .062" .269" Not enough information given

Section: 83.


What is the joint efficiency for T 3-27? a. b. c. d.

1 .85 .70 .35

Section: 84.

What is the corrosion allowance for T 3-27? a. b. c. d.


Section: 85.



If T 3-27 was new, what would be the minimum first course thickness, based on product alone? a. b. c. d.


Section:



86.

How many settlement points are required for an external settlement of T 3-27? a. b. c. d.

4 6 8 10

Section: 87.


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. b. c. d.

is rejectable. is acceptable. must be monitored. can be filled in with epoxy and accepted.

Section: 88.


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. b. c. d.

have the patch removed. inspect the patch. recommend removal of the patch and floor plates in the repaired area, replacing with new floor plates. this repair is in the critical zone and not allowed.

Section: 89.


During the same internal inspection of T 3-27, a square lap-welded patch was found over an existing nozzle. The inspector should __________. a. b. c. d.

have the patch removed. inspect the patch. cut out the entire shell plate. radiograph the patch for weld quality.

Section:



90.

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. b. c. d.

A repair may be made by using duct tape. Only if the owner requires the repair. No Yes

Section: 91.

What is the position designation for welding pipe in the horizontal fixed position? a. b. c. d.

2G 3G 5G 6G

Section: 92.

hour 2 hours 4 hours 8 hours

Section:


Terminology for weld metal in excess of the specified weld size. a. b. c. d.

Weld reinforcement Good weld technique Weld toe Weld throat

Section: 94.


During a fluorescent MT test, the black light intensity shall be measured at least once every . a. b. c. d.

93.



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. b. c. d.

Yes No The oxyfuel process is not allowed by ASME Section IX Nozzle welds must be made using SMAW only

Section:



95.

A diesel oil test is required for ______________. a. b. c. d.

all new nozzle welds all new floor welds all new shell welds all new shell-to-bottom welds

Section: 96.


The minimum PSIG for a vacuum box test is __________. a. b. c. d.

1 2 3 4

PSIG PSIG PSIG PSIG

Section: 97.

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. b. c. d.

Nozzle Welds Shell Welds Floor and roof fillet welds None

Section: 98.


A procedure is qualified on plate .500" thick. Which of the following thicknesses is not qualified? a. b. c. d.

1" 1/2" 1/4" 1/8"

Section: 99.



A procedure is qualified on plate .500" thick. Four nick break specimens were substituted for the four side bends. a. b. c. d.

The procedure is qualified. ASME does not allow nick breaks. Two tension specimens were required. Nick breaks are used only on pipe.

Section:



100.

A welder is qualified in the 3F and 4F positions. Which of the following groove welds can he make? a. b. c. d.

1G 2G 6G None

Section:



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Lap Patches Considerations: Does the owner prohibit the use of a lap patch? (Para. 9.3.1) Will the repair prevent gas freeing the tank to perform hot work, at a later date? (Para. 9.3.4.5) Will crevice corrosion or a corrosion cell between the shell plate and repair plate likely occur? (Para. 9.3.4.4) An affirmative answer to any of the above is cause to stop planning on a lap patch. Since the inception of API 653, Tank Inspection, Repair, Alteration, And Reconstruction, the fillet weld lap patch has been prohibited, until the Second Edition, 1995, First Addenda, 1996. The owner/user may now use paragraph 9.3, “Shell Repairs Using Lap Welded Patch Plates” under certain conditions and size limitations. The first 11 paragraphs apply to lap patches generally. 1.

The lap patch is considered a permanent repair and subject to ongoing inspection and maintenance. (Para. 9.3.1)

2.

All the repair material must conform to the requirements of API 653, which will reference API 650, Welded Steel Tanks for Oil Storage.

3.

A lap patch may not be used on any shell course thickness that exceeds 1/2 inch or to replace doorsheets or shell plates. (Para 9.3.1.2)

4.

Patch plates may be from 3/16 to 1/2 inches thick, depending to the thickness of the shell plate to be repaired. (Para. 9.3.1.3)

5.

The repair plate may be circular, oblong, square, or rectangular with rounded corners, except at the shell to bottom joint. The radius of the corners shall be 2 in. minimum. (Para. 9.3.1.4)

6.

The butt welded seams that are covered, by the patch, must be ground flush and must over lap a minimum of 6 inches, use Figure 9-1 as a guide. (Para. 9.3.1.5)

Figure 9-1 is on the next page.

Notes on Patch Plates, 2003 Page 1

Figure 9-1 - Acceptable Details for Replacement of Shell Plate Material


7.

Refer to Figure 9-2 for details on welding the lap patch to the shell to bottom joint. Note: An internally installed patch must be located such that the toe-to-toe weld clearances are a minimum of 6 inches to the shell to bottom weld. (Para. 9.3.1.6)

T

T Tank Shell

W

3/16 Repair Plate

W

3/16

Trim repair plate to clear Shell-to-bottom weld

8.

The maximum size of a patch plate is 48 inches by 72 inches, the minimum size is 4 inches. The patch shall be formed to the shell radius. (Para. 9.3.1.7)

9.

Shell openings and reinforcements shall not be positioned within a lapped patch shell repair. (Para. 9.3.1.8)

10.

An ultrasonic inspection for laminations and other plate defects shall be performed on the shell plate in the areas to be welded. (Para. 9.3.1.9)

11.

Repair plates shall not be lapped on lap welded shell seams, riveted shell seams, other lapped patch repair plates, distorted areas, or unrepaired cracks or defects. (Para. 9.3.1.10)


The next 5 paragraphs apply to the use of lap patches to close holes in the shell. 12.

A lap patch may be used for the closure of holes, where openings have been removed or the removal of severely corroded/eroded areas, but there are special requirements. (Para. 9.3.2)

13.

The weld shall be continuous on the inside and outside of the patch plate, the removed opening must be at least 2 inches in diameter, a minimum corner radius of 2 inches is required for plate removal. (Para. 9.3.2.1)

14.

Nozzles and reinforcement pads must be removed entirely before the repair plate is installed. (Para. 9.3.2.2)

15.

Repair plates, for opening repairs, shall be of a design that conforms to API 653, using a joint efficiency not exceeding 0.70. All fillet welds shall be full (equal leg) fillet welds. The overlap of the repair plate shall not exceed 8 times the shell thickness, minimum overlap is 1 inch. The minimum repair plate dimension shall be 4 in. (Para. 9.3.2.3)

16.

The repair plate shall not exceed the nominal thickness of the shell plate adjacent to the repair. (Para. 9.3.2.4)

The next 4 paragraphs apply to the use of lap patches to repair areas of thinned shells due to deterioration. 17.

Lap patches may be used to reinforce areas of deteriorated shell plates and to reinforce shell plates that are below retirement thickness. (Para. 9.3.3)

18.

The repair plate thickness shall be based on API 653, using a joint efficiency not exceeding 0.35, the perimeter weld shall be full fillet (equal leg) weld. (Para. 9.3.3.1)

19.

The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker repair plate than the existing shell plate is allowed. (Para. 9.3.3.2)

20.

The remaining strength of the deteriorated areas under the repair plate shall not be considered as effective in carrying the calculated service or hydrotest loads. (Para. 9.3.3.3)

The next 4 paragraphs apply to the use of lap patches to repair leaks or potential leaks in the shell. 21.

Lap patches may be used to repair leaks or minimize the potential leaks form pitting. (Para. 9.3.4)

22.

To install a lap patch over a leak, the existing shell thickness, excluding holes and pits, must meet the minimum acceptable shell thickness (t min.). (Para. 9.3.4.1)

23.

The repair plate must be designed to withstand the hydrostatic pressure load between the repair plate and the shell assuming a hole exists in the shell using a joint efficiency of 0.35. (Para. 9.3.4.2)

24.

The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker repair plate than the existing shell plate is allowed. A full (equal leg) fillet perimeter weld is required. (Para. 9.3.4.3) Notes on Patch Plates, 2003 Page 4

The last 3 paragraphs apply to safety warnings and inspection requirements of lap patches. 25.

Do not use a lap patch if corrosion between the shell plate and repair plate is likely to occur. (Para. 9.3.4.4)

26.

Do not use a lap patch if the repair plate will prevent gas freeing the tank to perform future hot work, remember a penetration is not allowed in the patch. (Para. 9.3.4.5)

27.

Future inspection must be performed on the patch plates. (Para. 9.3.4.6)



Name:

API 653/650 Math Review Quiz Answer each question, show all work, circle your final answer. 1.

Add: 1' 4 1/2" + 3' 5 11/32" + 10' 6 5/8" =

2.

Subtract:

3.

Solve:38" = ____ feet

4.

Express 7/16" as a decimal fraction _____

5.

Solve for A: A = 11 X 24 - (45 + 6)3

6.

What is the Square Root of 1849?

7.

What is the radius of a circle whose diameter is 182'?

287' - 3' 4 15/16" =

API 653 Math Review Quiz 01/05

Page 1

8.

What is the area of the circle in Question 7 ?

9.

10" = ____ mm

10.

1/4” = ____ mm

11.

200’ = ____ m

12.

Solve for Z: 296 = 10(Z+6)

13.

Solve for t t=

2.6 X 50 (41-1) X .85 + .125 20,000


Page 2

14.

Solve for t t=

2.6 X 80 (30-1) 26,300

15.

An inspection is performed on an existing AST 67' tall, 190' in diameter with a fill height of 60'. What is the minimum thickness of the first course, based on product alone, if the specific gravity of the product is .8?

16.

What is the minimum thickness of the fourth course of the tank in question 15, if each course is 5' high?


Page 3

17.

In performing a settlement survey on a tank 100’ in diameter, what spacing should be used for survey reference?

18.

What is the design first course thickness of a new tank that is 60' tall, fill height of 58', diameter of 90', the material is A 516M Grade 485, the corrosion allowance is .125" and the specific gravity of the stored product is 1?


Page 4

19.

What is the hydrostatic test first course thickness of the new tank in question 18?

20.

What is the annular plate thickness of the new tank in question 18, if an annular plate is required?


Page 5

21.

What is the minimum thickness of the first course of an existing tank if the nameplate reads as follows: Height: 40' Diameter: 60' Year Completed: 1990 All Courses: A516-70 Specific Gravity: 1.3


Page 6

Name:

API 653/650 Math Review Quiz (Answer Key) Answer each question, show all work, circle your final answer. 1.

Add: 1' 4 1/2" + 3' 5 11/32" + 10' 6 5/8" = 15' 4 15/32" Solution:

2.

3.

4.

Subtract:

287' - 3' 4 15/16" = 283' 7 1/16"

Solution:

287' = 286' 11 16/16" - 3' 4 15/16" 283' 7 1/16"

Solve:

38" = _3' 2" or 3.167 ___ feet

Solution:

(1' = 12")

38 ÷ 12 = 3' 2" or 3.16'

Express 7/16" as a decimal fraction ___.438"__ Solution:

5.

1' 4 1/2" = 1' 4 16/32 3' 5 11/32" = 3' 5 11/32 10' 6 5/8" = 10' 6 20/32 14' 15 47/32" = 15' 4 15/32"

7/16 = 7 ÷ 16 = .438"

Solve for A: A = 11 X 24 - (45 + 6)3 Solution:

A = 11 X 24 - (45 + 6)3 A = 11 X 24 - (51)3 A = 11 X 24 - 153 A = 264 - 153 A = 111

6.

What is the Square Root of 1849? ____ Solution: 1849 = 43

7.

What is the radius of a circle whose diameter is 182'? Solution:

(Radius = Diameter ÷ 2) R = 182 ÷ 2 = 91'

API 653 Math Review Quiz 01/05 Key

Page 1

8.

What is the area of the circle in Question 7 ? Solution:

9.

(Area of a circle = r2 ) A = (3.1416) (912 ) A = (3.1416) (8281) A = 26,015.589 Sq. Ft.

10" = __254__ mm Solution:

(1" = 25.4 mm) 10 X 25.4 = 254 mm

10.

1/4” = __6__ mm Solution:

(1" = 25.4 mm) .25 X 25.4 = 6.35 mm (API rounded to 6 mm)

11.

200’ = __60__ m Solution:

(1’ = .3 m) 200 X .3 = 60 m

12.

Solve for Z: Solution:

296 = 10(Z+6) 296 = 10(Z+6) 10 10 29.6 = Z+6 29.6 - 6 = Z + 6 - 6 23.6 = Z

13.

Solve for t t=

2.6 X 50 (41-1) X .85 + .125 20,000

t=

2.6 X 50 (40) X .85 20,000

t=

4420 20,000

t=

.221 + .125

t=

.346

+ .125

+ .125


Page 2

14.

15.

Solve for t t=

2.6 X 80 (30-1) 26,300

t=

2.6 X 80 (29) 26,300

t=

6032 26,300

t=

.229

An inspection is performed on an existing AST 67' tall, 190' in diameter with a fill height of 60'. What is the minimum thickness of the first course, based on product alone, if the specific gravity of the product is .8? Solution: Use the formula, Minimum Thickness Calculation for Welded Tank Shell, from API 653, page 4-3, paragraph 4.3.3.1. tmin= 2.6 (H-1)DG SE tmin= 2.6 (60-1) (190) (.8) 23,595 (1)

Values substituted

tmin= 2.6(59)(190).8 23,595 tmin= 23,316.8 23,595 tmin= .988" 16.

What is the minimum thickness of the fourth course of the tank in question 15, if each course is 5' high? Solution: Use the formula, Minimum Thickness Calculation for Welded Tank Shell, from API 653, page 4-3, paragraph 4.3.3.1. tmin= 2.6 (H-1)DG SE tmin= 2.6 (45-1) (190) (.8) 25,960 (1)

Values substituted

tmin= 2.6(44)(190).8 25,960 tmin= 17,388.8 25,960 tmin= .670" API 653 Math Review Quiz 01/05 Key

Page 3

17.

In performing a settlement survey on a tank 100’ in diameter, what spacing should be used for survey reference? Solution:

N = D ÷ 10 N = 100 ÷ 10 N = 10

N = minimum required number of settlement measurement points

C=D C = (3.1416) (100) C = 314.16

Perimeter of the tank

314.16 ÷ 10 = 31.416 feet apart API 653 requires no more than 32 feet between measurement points, an additional point is not required. 18.

What is the design first course thickness of a new tank that is 60' tall, fill height of 58', diameter of 90', the material is A 516M Grade 485, the corrosion allowance is .125" and the specific gravity of the stored product is 1.? Solution: Use the formula, 1-Foot Method from API 650, page 3-7, paragraph 3.6.3. td =

2.6 D (H-1) X G Sd

+ CA

td =

2.6 X 90 (58-1) X 1 25,300

+ .125

td =

2.6 X 90 (57) X 1 25,300

+ .125

td =

13,338 25,300

td =

.527

td =

.652"

+ .125

+ .125


Page 4

19.

What is the hydrostatic test first course thickness of the new tank in question 18? Solution: Use the formula, 1-Foot Method from API 650, page 3-7, paragraph 3.6.3.

20.

tt =

2.6 D (H-1) St

tt =

2.6 X 90 (58-1) 28,500

tt =

2.6 X 90 (57) 28,500

tt =

13,338 28,500

tt =

.468"

What is the annular plate thickness of the new tank in question 18, if an annular plate is required? Solution: Use the formula, in Table 3-1 and paragraph 3.5.3 from API 650, page 3-6. Hydrostatic Test Stress =

2.6 D (H-1) t

Hydrostatic Test Stress =

2.6 X 90 (58-1) .652


2.6 X 90 (57) .652


13,338 .652


20,457

1/4" required + CA (.125) = .375"


Page 5

21.

What is the minimum thickness of the first course of an existing tank if the nameplate reads as follows: Height: 40' Diameter: 60' Year Completed: 1990 All Courses: A516-70 Specific Gravity: 1.3 Solution: Use the formula, Minimum Thickness Calculation for Welded Tank Shell, from API 653, page 4-3, paragraph 4.3.3.1. tmin= 2.6 (H-1)DG SE tmin= 2.6 (40-1) (60) (1.3) 30,000 (1)

Values substituted

tmin= 2.6(39)(60) (1.3) 30,000 tmin= 7,909.3 30,000 tmin= .264"


Page 6

API 653/650 Math Review Quiz (Useful Circle Formulas) Area of a Circle = pi (3.1416) X radius2 or A = r2 Circumference = pi (3.1416) X Diameter or C = D Radius = Diameter ÷ 2 or

R=D 2

Circumference

Diameter

Radius


Page 7

API 653/650 Math Review Quiz (API Metrics) 1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 11/16 3/4” 13/16 7/8” 15/16 1”

= = = = = = = = = = = = =

6 mm 8 mm 10 mm 11 mm 12.5 mm 14 mm 16 mm 18 mm 20 mm 21 mm 22 mm 24 mm 25 mm

The above information taken from API 650, page 3-19.


Page 8

NAME:

DATE: A S NS ON STTIIO ES UE QU M 22000066 Q AM XA EX PII 665533 E AP ((S Seelleecctt TThhee B weerr)) Annssw Beesstt A

TThhee ffiirrsstt ppaarrtt ooff tthhee eexxaam Booookk,,"" m iiss ""O Oppeenn B ffeeeell ffrreeee ttoo uussee aannyy ooff tthhee ffoolllloow wiinngg:: The following is a collection of questions remembered by various students who took the API 653 Exam in the past. This study sheet is designed to help a student prepare for the API 653 Exam. Read each question carefully and select the best answer by circling your choice. After selection of your answer, write in the section number and publication in which your answer was found. Look up each question in the reference publications listed below; remember, this exercise is to help you to learn to use the reference material. Generally, the assignment is broken into several sections. Each section should take approximately one hour to complete. Answers will be discussed at the beginning of class the following morning. The answers will be found in the following reference publications: API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, First Edition, December, 2003 ATTENTION: Only the following mechanisms are included in the exam: Par. 4.2.7 – Brittle Fracture Par. 4.2.16 – Mechanical Fatigue Par. 4.3.2 – Atmospheric Corrosion Par. 4.3.3 – Corrosion Under Insulation (CUI) Par. 4.3.8 – Microbiologically Induced Corrosion (MIC) Par. 4.3.9 – Soil Corrosion Par. 4.3.10 – Custic Corrosion Par. 4.5.1 – Chloride Stress Corrosion Cracking (Cl-SCC) Par. 4.5.3 – Caustic Stress Corrosion Cracking (Caustic Embrittlement) Par. 5.1.1.11 – Sulfuric Acid Corrosion API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks, First Edition, November, 1995

API 653 Practice Exam, Spring, 2006

Page 1

API RP 577, Welding Inspection and Metallurgy, First Edition, October, 2004 API 650, Welded Steel Tanks for Oil Storage, Tenth Edition, November, 1998, including Addendum 1 (March, 2000), Addendum 2 (November, 2001), and Addendum 3 (September, 2003). API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, Second Edition, December, 1997 API RP 652, Lining of Above Ground Petroleum Storage Tank Bottoms, Second Edition, December, 1997 API 653, Tank Inspection, Repair, Alteration and Reconstruction, Third Edition, December, 2001, including Addendum 1 (September, 2003). ASME Boiler & Pressure Vessel Code, 2004 Edition Section V, Nondestructive Examination, Articles 1, 2, 6, 7 and 23 (Section SE-797 only) Section IX, Welding and Brazing Qualifications, Section QW only

B Beeggiinn tthhee ooppeenn bbooookk ppoorrttiioonn ooff tthhiiss eexxaam m oonn tthhee nneexxtt ppaaggee..


Page 2

A S NS ON STTIIO ES UE QU M 22000055 Q AM XA EX PII 665533 E AP O Booookk Oppeenn B 1.

The liquid penetrant examination method is an effective means for detecting 1. 2. 3. 4.

2.

3.

Flat and horizontal Horizontal and vertical Flat and vertical Vertical and overhead

A change in groove design A change in backing A change in post weld heat treatment A change in electrode angle

A welder may be qualified by RT if 1. 2. 3. 4.

6.

provide direction for making production welds to Code requirements provide direction for the welder to make temporary welds provide direction for the inspector for inspection of the welds provide direction for the welder to use as a general guideline

Which of the following is an essential variable for the WPS? 1. 2. 3. 4.

5.

.

Welding in the 3G position qualifies a welder in what positions? 1. 2. 3. 4.

4.

internal discontinuities of a weld surface discontinuities of a weld both internal and surface discontinuities of a weld subsurface discontinuities of a weld

A WPS is a written qualified welding procedure prepared to 1. 2. 3. 4.

.

.

the welder uses SMAW the welder uses GMAW Short Circuiting mode the welder uses GMAW Short Circuiting mode root pass with SMAW fill and reinforcement the welder obtains approval from the inspector

A peripheral seal, on an internal floating roof, shall be designed to accommodate of local deviation between the floating roof and the shell. 1. 2. 3. 4.

the manufacturer's standard + 4 inches + 1/8 inch inspector's experience


Page 3

7.

What is the maximum allowable prod spacing using an AC prod technique? 1. 2. 3. 4.

8.

Welders shall be qualified in accordance with 1. 2. 3. 4.

9.

3. 4.

200oF 93 oF both 1 and 1 50 oF .

at the beginning of each shift at least once a year or whenever the equipment has been subject to major electrical repair whenever the technician feels like it at least once every 90 days

During calibration of an ammeter the unit shall not deviate by more than scale. 1. 2. 3. 4.

13.

0.020 0.030 0.040 0.050

Each piece of magnetizing equipment shall be calibrated 1. 2.

12.

API 1104 ASME Section V ASME Section IX AWS D1.1

For measuring the thickness of materials using the contact pulse-echo method, temperatures are not to exceed . 1. 2. 3. 4.

11.

.

Geometric unsharpness of the radiograph of a component under 2" thick shall not exceed . 1. 2. 3. 4.

10.

t/2 8 inches 10 inches No spacing required

of full

10% 20% 30% 40%

An inspector is evaluating a radiograph, a bright white image of a "B" appears on a darker background of the radiograph, . 1. 2. 3. 4.

the radiograph shall be considered unacceptable the radiograph should not be rejected the "B" is for identification of the welder the "B" is for identification of the weld


Page 4

14.

Ultrasonic examination of hot tap connections or reinforcement is required by API 653 when . 1. 2. 3. 4.

15.

in lieu of radiographic testing searching for weld flaws searching for laminations requested by the welder

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? 1. 2. 3. 4.

Yes No The inspector option Repair contractor's option


Page 5

TThhee ffoolllloow w:: wiinngg aapppplliieess ttoo qquueessttiioonnss 1166 tthhrroouugghh 2255 bbeelloow 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. 16.

Calculate the minimum thickness of the first course based on product alone. 1. 2. 3. 4.

17.

Calculate the minimum thickness for the third course, if each course is 4' in height. 1. 2. 3. 4.

18.

Because the pits are aligned vertically no repair is required Scattered pits may be ignored If the pit is round, it may be ignored A repair is required

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. 1. 2. 3. 4.

21.

40" 12.68" 6.80" 11.75"

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. N Noottee:: Assume pit depth of slightly less than one-half of the minimum acceptable tank shell thickness, exclusive of the corrosion allowance. 1. 2. 3. 4.

20.

.122" .100" .275" .132"

Calculate the "L" length for an area of general corrosion found 10' from the bottom on the south side of the shell, T2 =.125". 1. 2. 3. 4.

19.

1.175" 0.228" 0.551" 0.217"

Because the pits are scattered circumferentially no repair is required All pits may be ignored If the pit is round, it may be ignored A repair is required

A bulge is found on the tank floor, the diameter of the bulge is 30". What is the maximum permissible height for the bulge? 1. 2. 3. 4.

11.1" .460" .962" 1.11"


Page 6

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). 1. 2. 3. 4.

23.

What is the hydrostatic test height of this tank based on a minimum thickness found in question 16, as the controlling thickness? 1. 2. 3. 4.

24.

24’ 34.2’ 18.6’ Not enough information given

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? 1. 2. 3. 4.

25.

A more rigorous stress analysis must be performed The area should be repaired Sloped edge settlement is usually no problem The area should be documented and checked during the next inspection

Yes No Not enough information given The tank holds water, no problem

If the maximum liquid level in the tank were to be lowered by 5', what is the minimum thickness of the first course? 1. 2. 3. 4.

1.73" .166" .200" No change from original design thickness


Page 7

TThhee ffoolllloow w:: wiinngg aapppplliieess ttoo qquueessttiioonnss 2266 tthhrroouugghh 2277 bbeelloow Or RTbc RTip StPr UPr

= = = = =

26.

Using data from above, calculate MRT. (metal loss from the bottom side corrosion). 1. 2. 3. 4.

27.

removed ground flush, with grinding direction parallel to the weld ground flush, with grinding direction perpendicular to the weld removed if irregularities mask discontinuities

40’ 36’ - 2” 32’ - 8” 31’ - 6”

For a single-wall material thickness, over 0.375" through 0.50", what is the hole-type designation for a source side penetrameter? 1. 2. 3. 4.

31.

before

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). 1. 2. 3. 4.

30.

.250 .070 .002 .080

The weld ripples of reinforcement of butt-welded joints shall be radiography. 1. 2. 3. 4.

29.

.250 .070 .002 .080

Using data from above, calculate MRT. (metal loss from internal corrosion). 1. 2. 3. 4.

28.

10 years .200 .190 .002 .010

15 17 20 25

The temperature range to conduct a standard technique liquid penetrant examination is . 1. 2. 3. 4.

50oF to 135oF 50oF to 125oF 70oF to 115oF 50oF to 80oF API 653 Practice Exam, Spring, 2006

Page 8

32.

During an MT examination, 1. 2. 3. 4.

33.

.

5 lbs. 8 lbs. 10 lbs. 40 lbs.

5/16" 11/16" 3/8" 7/16"

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? 1. 2. 3. 4.

37.

5 lbs. 8 lbs. 10 lbs. 40 lbs.

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). 1. 2. 3. 4.

36.

.

A DC yoke shall have a lifting power of at least 1. 2. 3. 4.

35.

100% coverage at the required sensitivity a calibration of each piece of magnetizing equipment at least three separate examinations prod spacing of at least 10"

An AC yoke shall have a lifting power of at least 1. 2. 3. 4.

34.

shall be performed on each area.

Use RBI. Because the product might not contaminate the soil or waterways, no repair is required. Weld build-up the area. Install a ‘tombstone’ shaped, welded-on patch plate, intersecting the shell-to-bottom joint at approximately 90o. Install a non-welded patch plate and fiberglass/epoxy to coat the area.

When using the SMAW process, a welder has changed from an F number 4 electrode to an F number 3 electrode. Does the procedure need to be requalified? 1. 2. 3. 4.

Yes No Only if low hydrogen electrodes are used API 650 allows this change


Page 9

38.

During a welder qualification test, for plate coupons, all surfaces (except areas designated "discard") shall . 1. 2. 3. 4.

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. 1. 2. 3. 4.

40.

inches for

1–3 3–6 6 – 12 Piping is not addressed by any of the documents listed in the API 653 Body of Knowledge.

Floating roofs on new tanks shall be sufficiently buoyant to remain floating after 1. 2. 3. 4.

43.

1/4" 3/16" 1/8" 1/16"

If piping near the tank enters the ground, the soil should be excavated inspection. 1. 2. 3. 4.

42.

0.655 0.611 0.563 0.500

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. 1. 2. 3. 4.

41.

show complete joint penetration with complete fusion of weld metal and base metal show no more than 1/3t inadequate penetration show no more than 1/3t nonfusion be allowed one 5/32" crater crack

.

Fifteen inches of rainfall in a 24-hour period Ten inches of rainfall in a 24-hour period Thirty inches of snow in a 24-hour period Thirty inches of sand in a 24-hour period

A sudden rapid fracture under stress, where the material exhibits little or no evidence of ductility or plastic deformation, is called .? 1. 2. 3. 4.

brittle fracture cavitation atmospheric corrosion caustic corrosion


Page 10

44.

Each floor scanning operator, who only use the bottom scanning equipment, shall receive a minimum of hours of training. 1. 2. 3. 4.

45.

8 12 20 40

Variables in the procedure that can be changed without having to re-qualify the procedure and/or the scanning operators are . 1. 2. 3. 4.

essential variables non-essential variables qualification tests TBEQ

Q whhiicchh Prroocceedduurree w RP QR PQ S//P PS WP Quueessttiioonnss 4466 tthhrroouugghh 5500 aappppllyy ttoo tthhee W bbeeggiinnss oonn ppaaggee 1122.. 46.

What is the root face limitation as listed on the attached WPS and PQR? 1. 2. 3. 4.

47.

If the supporting PQR is used, are the P-no’s correct on the attached WPS? 1. 2. 3. 4.

48.

Yes No Requalification is required by API 570 Requalification is required by ASME V

Is the attached PQR properly qualified? 1. 2. 3. 4.

50.

Yes No Could be if properly preheated Not enough information

Is the thickness range on the WPS supported by the PQR? 1. 2. 3. 4.

49.

3/32” 1/8” No limit Not designated

No, because RT is not allowed during PQR qualification No, because there are not enough tensile tests No, because peening is allowed by B31.3 Yes

What should have been the correct number and type of guided bends on the PQR? 1. 2. 3. 4.

6 side bends 2 face and 2 root bends 1 side, 1 face and 1 root bend 2 face, 2 root and 4 side bends


Page 11

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name: DLV WELDING, INC. By: I.A. WELDER Welding Procedure Specification No. S M A W - P 1 Date: 1 1 / 2 2 / 0 1 Supporting PQR No.(s) SMAW-P1-A Revision No. Date: Welding Process(es): SMAW Type(s): MANUAL Automatic, Manual, Machine, or Semi-Auto

JOINTS (QW-402) Joint Design SINGLE VEE, ALL FILLETS Backing (Yes) (No) X Backing Material (Type) N/A

Details

(Refer to both backing and retainers) Metal Nonmetalic

Nonfusing Metal Other

Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified.

3/32” – 1/8”

(At the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g., for notch toughness procedures, for multiple process procedures, etc.)

*BASE METALS (QW-403) P-No. 1 Group No. 1 to P-No. 8 OR Specification type and grade to Specification type and grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal: Groove .125 – 1” U Pipe Dia. Range: Groove UNLIMITED Other: N No pass greater than 1/2”

E

Group No.

1

Fillet Fillet

*FILLER METALS (QW-404) SMAW Spec. No. (SFA) 5.1 AWS No. (Class) E-6010 F-No. 2 A-No. 1 Size of Filler Metals 3/32” – 1/8” Weld Metal Thickness Range: Groove .250” max. Fillet ALL Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other SUPPLEMENTAL FILLER SHALL NOT BE USED

ALL ALL SMAW 5.1 E-7018 2 1 3/32” – 1/8” .750” max ALL N/A N/A N/A

*Each base metal-filler metal combination should be recorded individually


Page 12

2 2 E1 S 1 8

A

QW-482 (Back) WPS No. SMAW-P1

POSITIONS (QW-405)

Rev.

POSTWELD HEAT TREATMENT (QW-407)

Position(s) of Groove FLAT Welding Progression: Up N / A Position(s) of Fillet

Temperature Range Time Range

Down N / A

NONE

GAS (QW-408) PREHEAT (QW-406)

Percent Composition Gas(es) (Mixture) Flow Rate 5 0o F

Preheat Temp. - Min. Interpass Temp. - Max. Preheat Maintenance

Shielding Trailing Backing

(Continuous or special heating where applicable should be recorded)

N/A N/A N/A

______ ______ ______

______ ______ ______

ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC Amps (Range)

DC 70-160

Polarity

DCRP

Volts (Range)

19-30

(Amps and volts range should be recorded for each position, and thickness, etc. This information may be listed in a tabular form similar to that shown below. Tungsten Electrode Size and Type

N/A

Mode of Metal Transfer for GMAW

N/A

(Pure Tungsten, 2% Thorated, etc.) (Spray arc, short-circuiting arc, etc.) Electrode Wire feed speed range

TECHNIQUE (QW-410) String or Weave Bead STRING OR WEAVE Orifice or Gas Cup Size N/A Initial and Interpass Cleaning (Brushing, Grinding, etc.) HAND AND POWER TOOLS MAY BE USED Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Other

N/A N/A N/A E-6010 SINGLE SINGLE NONE

Filler Metal Weld Layer(s) 1

Process

Class

SMAW

E-6010

3/32 1/8”

E-7018

3/32 1/8”

BALANCE SMAW

E-7018 MULTIPLE

Dia.

Current Type Polar DCEP

DCEP

Amp Range 70-130

70-160

Volt Range

Travel Speed Range

24-30 1 1/2 51PM 19-28 2-81PM


Page 13

Other (e.g., Remarks, Comments, Hot Wire Addition, Technique, Torch Angle, Etc.)

QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon Company Name DLV WELDING, INC. Procedure Qualification Record No. SMAW P1-A WPS No. SMAW – P1 Welding Process(es) SMAW Types (Manual, Automatic, Semi-Auto.) MANUAL

Date 1 1 / 2 2 / 0 1

JOINTS (QW-402)

3/32” – 1/8”

Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness will be required for each filler metal or process used.)

BASE METALS (QW-403)

POST WELD HEAT TREATMENT (QW-407)

Material Spec. A-106 A-283 Type or Grade C P. No. 1 to P-No. 1 Thickness of Test Coupon .500 Diameter of Test Coupon N/A Other

Temperature Time Other

NONE N/A

GAS(QW-408)

FILLER METALS (QW-404) SFA Specification 5.1 AWS Classification E-6010 Filler Metal F-No. 2 Weld Meal Analysis A-No. 1 Size of Filler Metal 1/8” Other Weld Metal Thickness

.250 max

7018 5. 1 E-7018 2 1 3/32”

.500 max

Shielding Trailing Backing

Gas(es) N/A N/A N/A

Percent Composition (Mixture) Flow Rate _______ ________ _______ ________ _______ ________

ELECTRICAL CHARACTERISTICS (QW-409) Current DC Polarity DCEP Amps. 7 0 - 1 6 0 Volts Tungsten Electrode Size N/A Other

19 - 30

POSITION (QW-405)

TECHNIQUE (QW-410)

Position of Groove 3G Weld Progression (Uphill, Downhill) Other

Travel Speed 1 1/2 – 8 IPM String or Weave Bead BOTH Oscillation N/A Multipass or Single Pass (per side) BOTH Single or Multiple Electrodes S I N G L E Other

PREHEAT (QW-406) Preheat Temp. Interpass Temp. Other

UPHILL

5 0oF


Page 14

QW-483 (Back) PQR No.

SMAW-P1-A

Tensile Test (QW-150) Specimen No.

Width

1

1.5

Thickness

.5

Area

.75

Ultimate Total Load lb.

97,900

Ultimate Unit Stress psi

Type of Failure & Location

77,484

BASE

Guided-Bend Tests (QW-160) Type and Figure No.

1 2 3 4

SIDE BEND SIDE BEND FACE BEND ROOT BEND

GOOD GOOD GOOD GOOD

POROSITY 1/16” DIA.

Toughness Tests (QW-170) Specimen No.

Notch Location

Notch Type

Test Temp.

Impact Values

Lateral Exp. % Shear Mils

Drop Weight Break No Break

Fillet-Weld Test (QW-180) Result- Satisfactory: Macro - Results

Yes

No

Penetration into Parent Metal: Yes

No

Other Tests Type of Test RT - GOOD Deposit Analysis Other ...................................................................................................................................................... Welder’s Name TOM SMITH Clock No. Tests conducted by: O,K. TEST LAB

BR549 Stamp No. Laboratory Test No.

JP 11-22-01-637

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer Date

11-22-04

By

DLV WELDING, INC. (SIGNED)

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of test required by the Code.)


Page 15

Please close all materials. The remainder of the exam is “Closed Book.”


Page 16

TThhee sseeccoonndd ppaarrtt ooff tthhee eexxaam Booookk,,"" m iiss ""C Clloosseedd B 51.

Who has the ultimate responsibility for complying with the provisions of API Standard 653? 1. 2. 3. 4.

52.

If cracks are suspected in nozzles or nozzle welds they should be checked by . 1. 2. 3. 4.

53.

?

errosion brittle fracture caustic corrosion phase failure

Per API 653, tanks shall have a formal visual inspection once every or RCA/4N years, whichever is less. 1. 2. 3. 4.

55.

ultrasonic digital thickness gauge MT or PT examination eddy current testing infra-red thermography

Localized corrosion due to the concentration of caustic or alkaline salts is 1. 2. 3. 4.

54.

API Owner/operator Inspector Contractor/builder

three four five seven

Monthly visual inspections of the external condition of in-service tanks may be performed by . 1. 2. 3. 4.

API 653 inspectors owner/operator personnel NDE technicians plant managers


Page 17

years

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. 1. 2. 3. 4.

57.

On a fixed-type roof, planks long enough to span at least laid and used as walkways. 1. 2. 3. 4.

58.

.

arc blow arc length arc strike arc angle

API 650 ASME Section V ASME Section IX API 1104

Upon completion, the roof of a tank designed to be gas tight shall be tested by which one of the following methods? 1. 2. 3. 4.

62.

Every 10 years Every time the tank is empty Annually Semi-annually

During the reconstruction of a tank, welding operators, welders and welding procedures must be qualified in accordance with . 1. 2. 3. 4.

61.

none allowed 1 2 3

The deflection of an arc from its normal path because of magnetic forces is 1. 2. 3. 4.

60.

roof rafters should be

Cathodic protection surveys are recommended to ensure the effectiveness of cathodic protection. How often should this survey be done? 1. 2. 3. 4.

59.

3 6 12 24

Magnetic particle testing of all welds Application of internal air pressure not exceeding the weight of the roof plates and applying a solution suitable for the detection of leaks Penetrant testing the weld joints Visual inspection of the weld joints

In regard to API 653, roof plates corroded to an average thickness of any 100 square inch area shall be repaired or replaced. 1. 2. 3. 4.

less than 0.09 0.09 greater than 0.09 no API 653 requirement, owner's requirement


Page 18

inch in

63.

A fusion weld made without filler metal is 1. 2. 3. 4.

64.

round discontinuity linear discontinuity non-linear discontinuity rejectable defect

brittle fracture caustic corrosion stress cracking atmospheric corrosion

Cone roof tank Umbrella-roof tank Vapor-dome roof tank Floating roof tank

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. 1. 2. 3. 4.

69.

.

Which of the following tanks are used to reduce filling and breathing loss by eliminating vapor space? 1. 2. 3. 4.

68.

erection/fabrication manufacturer purchaser Nuclear Regulatory Commission certified inspector

A form of corrosion that occurs from moisture associated with atmospheric conditions is called . 1. 2. 3. 4.

67.

.

A discontinuity with a length that is substantially greater than its width is called a 1. 2. 3. 4.

66.

brazing SMAW weld autogenous weld SAW weld

Each welder making welds on a tank shall be certified by 1. 2. 3. 4.

65.

.

6 12 14 18

Foundation pads that have washed out or settled under the bottoms of atmospheric storage tanks can be repaired by . 1. 2. 3. 4.

pumping in water pumping in argon pumping in sand, dirt or thin concrete pumping in gas


Page 19

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. 1. 2. 3. 4.

71.

The mechanical working of metals using impact blows is referred to as 1. 2. 3. 4.

72.

10 5 20 15

Radiographs Vacuum Penetrant testing Hammer testing

The junction of the weld face and the base metal is the 1. 2. 3. 4.

76.

chemical attack sulfate - type alkalis chlorides high temperature

Upon completion of welding of the new tank bottom, the welds shall be inspected by which one of the following methods? 1. 2. 3. 4.

75.

.

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. 1. 2. 3. 4.

74.

.

inclusion corrosion fatigue peening

Calcining can occur when concrete has been exposed to 1. 2. 3. 4.

73.

five ten three one

?

heat affect zone weld toe stress riser dilution zone

Tank plates being welded which do not have proper identification shall be subjected to . 1. 2. 3. 4.

chemical analysis UT thickness measurements PT testing RT testing


Page 20

77.

An assembly whose component parts are joined by welding is a 1. 2. 3. 4.

78.

ASM Requirements ASME Requirements API 650 Requirements ASTMA 7 Requirements

What action should be taken after a flat spot is discovered in the second ring of a 200' diameter AST? 1. 2. 3. 4.

82.

10 30 24 18

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 . 1. 2. 3. 4.

81.

Repair Alteration Hot tap Reconstruction

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. 1. 2. 3. 4.

80.

spool piece weldment fillet weld groove weld

identifies a procedure for installing a nozzle in the shell of a tank that is in service. 1. 2. 3. 4.

79.

.

The shell distortion shall be evaluated The area shall be cut out and replaced Since no product is leaking out of the area, it may be ignored The inspector has the option to repair or ignore

Routine in-service visual inspections of the external condition of the tank shall not exceed . 1. 2. 3. 4.

one month six months one year five years


Page 21

API 653 Tank Inspection Code_04.pdf

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