IRC ‘ASME IX AND V TEST copYRIGHT 2900. IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED 00 NOT cOFY OR DISTRIB! QW-482 (Back) ws Rev Mo [POSITIONS (QW-405) [POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove: __ALL temperatuie Range Hetng Progression: Up__X down x | Time Range. aa Positions(s) of Filet Scorer erereereceeeeear PREHEAT (QW-406) GAS ((QW-408) Preheat Temp Min: __ 100° MINIM Percent Composition | interpass Temp Max ___650° MAXIMUM Gasies) (Mature Flow Rate Preheat Maint Shielding: _YES 00% AR___10-15 CEH ‘Trang: NONE. ERR Nig POR INT ‘Backing: YES TSARI25CO2 __2.CFH ELECTRIGAL CHARACTERISTICS (QW-408) Current AG or DC _DC Polarity_REVERSE ‘Amps Range _ 100-120 Volts (Range) _24-27 ange ardels ange SOU be read foreach tered se Penge shea eT rforaton say belie 3 ‘Sr trm sma at hown betow ) Tungsten Electrode Size and Type ‘Pare Targaan Be Thad Ge SPRAY OR SHORT ARC. Boray are. show creung are cre) Mode of metal Transfer for GMAW Electrode Wire feed speed range ‘TECHNIQUE (QW-410) String or Weave Bead STRING Orifice or Gas Cup Size 412" peer esnd interness Cleaning (Brushing, Ganding, ete) BRUSHING AND GRINDING Mathod of Back Gouging ‘AIR AR Oscillation REVERSE Contact Tube to Work Distance ia ‘Multiple or Single Pass (per side |_____MULTIPLE. Multiple or Single Electrodes SINGLE {SIEM - 30 1PM. NONE Travel Speed (Range) Peening Other ae i | ie 7 Type | wera Da Polar ame | j_tevera | Process Case ange lL aL Gina | ERSOS BF) TAB -ST_ | CRP ea) Tea FM L SPRAY i c i t 7 £ t i T i r L i C i cOPYRIOGHT 2i- IRG?SCHINDLER & ASSOCIATES - ALL FIGH HTS RESERVED -00 NOT COPY OR DIgpuucacacooansacomsosanageasonoeeann ASME IX AND V TEST IRC COPYRIGHT 2000-IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘API 510 COURSE ASME V AND IX TEST ANSWER SHEET COPYRIOGHT 1 RC7SCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIBUTScage aR ASME IX AND V TEST IRC COPYRIGHT 2000: IRCISCHINOLER 2 ASSOCIATES _ALL RIGHTS RESERVED. 00 YOT COPY OR DISTRIBUTE ‘QW-483 (Back) PQR No: GMAW-SP-1 Tensile Test (QW-150) eee Type of 1 Specimen | Total Loaa Faiuro & No. Width | Thickness | Area) bb. ra HA [soa DIA) tg7__| 4.200 DF-HAZ acer NA “500 DIA. “186 | 12.000 DE-HAZ : t i = C L I i i Guided Bend Tests (AW-160) ype and Figure No. Result FACE Wis" GRACK OK ROOT ‘CORNER CRACK OK FACE NO INDICATION OK ROOT 1ia° CRACK OK Toughness Tests (QW-170) innpact Values specimen | Notch | Specimen | Test scien | Not | reise. | Temp. | Fetbs. | %Shear | mils | Drop Weight Break (VN) | i | T 1 1 t Comments: Fillet Weld Test (QW-180) Satisfactory: Yes: No: Penetration into Parent Metal: Yes: No: Result Macro ~- Results’ z Other Tests Type of Test: Deposit Analysis: Other: Welders Name: _JOE BLOW JR. Glock No. ‘Stamp No.: Tests conducted by: _ XYZ COMPANY. Laboratory Test No: _1234 We cortty thatthe 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: _ XYZ COMPANY. Date: By: _JOE BLOW SR. COPTRIGGRT UT IRGTSGHINDLER & ASSOCIATES -ALL RIGHTS RESERVED -DO NOT COPY OF DISTRIBUTEoe ASME IX AND V TEST IRC COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT GOPY OR OISTRIBUTE ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiler & Pressure Vessel Code) Company Name: __ XYZ COMPANY. By:__ JOE BLOW SR Welding Procedure Spec. No.: _GMAW-SP-1 Date: Revision No: _0 Date; _2-2-92 Welding Process(s):_GMAW-SPRAY ARC _ Typet JOINTS (QW-402) : eras Joint Design:_SEE PRODUCTION DRAWINGS. Backing: (Yes) _X wo) _X. Backing Mateflal: (Typey WELD METAS, if USED ‘Refer fo both backing & retainers) XMotal | Nonfusing Metal ) should be 16" c @ should be 1/16" - 500° should be 3/16" = 2° 29 The preheat temperature shawn on the WPS. is acceptable should be increased to 20°F should be decreased to 50°F ‘should be increased to 180°F COPYRIOGHT 2)-1RC7SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRISUTE31 32 33 36 ASME IX AND V TEST COPYRIGHT 2000- IRC/SCHINOLE! ‘Tha tension iests shown on the PC! 22 acceptable 2= shown ‘are dimensionally unacceptable to the Code ‘The bend tests shown on the POR: are acceptable 2s shown should be all side bends are unacceptable because the root bend has a corner crack none of the above goce ‘The ultimate stress shown on the POR: a. is unacceptable for T-2 1B, is unacceptable for T-1 @ is too high for both specimens @ should be at least 75,000 PSI for both specimens ‘The joint design specified on the WPS is: acceptable as shown, ifthe drawings show the required details should show only a single vee groove weld should not address backing should be drawn on the WPS as a sketch nord ‘The POR is unacceptable because: the position of welding does not match the product welded the gas backing mixture does not match the WPS: the joint design is not shown as a sketch on the POR: the travel speed is too fast ‘The A# shown on the WPS and POR: is acceptable as shown ig unacceptable because ait should have been used a 5) is unacceptable because it does net correlate to chrome filer metal d ts unacceptable because A-t filler metal requires PWHT per ASME IX COPYRISGHT U- RC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBU IRC RASSOCIATES -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE.ASME IX AND V TEST IRC IRCISCHINDLER & ASSOCIATES -ALL RIGHTS RESERVED .DO NOT COPY OR DISTRIBUTE “GW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PGR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Coupon Company Name: _XYZ COMPANY Procedure Qualification Record No.: _ GMAW-SP-1 Date: 2-29-82 |AW-SP-1 (GMAW (SPRAY ARC) ‘ute ‘SEMEAUTO. JOINTS [aw-402) Groove Deigna! Test Cosson ( oreoronation qusfcasons the daosiag wos meal edness sa be cored ft ach er mete proves use} [BASE METALS (GW-403) POSTWELD HEAT TREATMENT (QW-407) | Material Spec.:__SA 387 CL.4 ‘Temperatu: Type or Grade: GR 22 Time: NONE, P-No. 5A ‘to P-No: 5A Other ‘Thickness of Test Coupon:, 500 Diameter of Test Coupon: __N/A aoe Other: COMPOSITION - 27/4% CHROME, 1% MOLY PASS THICKNESS 1/5” GAS [QW-A08) Percent Composition FILLER METALS (QW-404) Gas(es) (Mixture) Flow Rate SFA Specification: _5.8 | AWS Classification: ER 90SB2 Shielding: _YES 400% ARGON 20-30 Cf Filler Metal F No:: 6 Trailing: _ NONE Weld metal Analysis No 1 Backing: YES 00% ARGON 10-48 CPHL Size of Filler metal: _1/8 ELECTRICAL CHARACTERISTICS (QW-408) j Other: 2 114% CHROME Current:___DC | FILLER METAL Polarity: REVERSE Weld Metal Thickness: _.500 Amps.:___128 Vents: 24 Tungsten Electrode Size: NIA FOsTION(aw4s)SS—~—~SN othe: eee te Position of Groove: 6G Weld Progression (Uphill, Downhill): UPHILL TECHNIQUE (W470) Other: |_| Travel Speed: _12 1PM String or Weave Bead: STRING. Oscillation REVERSE, ae Preheat Temp. 250° Multipass or Single Pass (per side):__MULTIPASS Interpass temp.; 650° MAX Single or Multiple Electrodes:__ SINGLE - Other: SOLID WIRE ONLY, NO SUPPLEMENTAL — | Other: POWDER, FILLER, OR FLUX USED PREHEAT (QW-406) COPYRIGHT TI IROTECHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTEead APIS%0 FINAL EXAMINATION 1 - OPEN-BOOK ec COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIATES = ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE apisio FINAL EXAMINATION #1 OPEN BOOK DATE, NAME. Suet eee Questions 4-10 analy to WPS 11 ang Susoorting POR #15, attached on back. Ht The P #'s shown on the WPS are: F A. qualified by the POR B should be changed to P3 to P3 only should not show P #4 D- should show P1 to Pt only 2. The AWS Classification shawn on the WPS: a, A. should be changed to & 71T1-4 B is acceptable as shown Cig a 90,000 tensile electrode 1. is acceptable ff the "T” was changed to “S" 3 The base metal thickness range shown on the WPS: A, Is correct as shown B. should be 1/16" = 1/2" CC should be 3/16" = 1/2" ©. should be 3/16" 1" 4 The pestweld heat treatment condition shown on the PAR: ‘A. is not acceptable to the Code Bis acceptable to the Code © should be changad to show PWHT was done 1D should show the required pre-heat 5 ‘The ges mixture shown on the WPS is unaccepteble because! ao A. the CO2 was not property qualified 5 the Argon was not properly qualified C. the flow cate is beyond the range allowed 0 bon S&C above 4 6 The tensile test results shown on the POR are: -eptable as shown 8 ‘otable - the tensile strength on 7-1 is too low © unacceptable - the load on T-2 is too low D. unacceptable - the area calculations are incorract on ‘The bend test results shown on the PQR are: acceptable as shown Unacceptable - side bend #1 has unacceptable porosity unacceptatle - not snough specimens were tested both B & C above vam» |S ASSOCIATES - ALL FIGHTS RESERVED -0O NOT COPY OR OISTRIGUTE COPYRIGHT 20¢0 = 1RCISCHINO10 2 COPYRIGHT 2000 - IRCISCHINOLER & ASSOCIAT APIS10 FINAL EXAMINATION 1 - OPEN BOOK IRC “ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE The POR should be A, notarized B legalized © rormaiized D certified The pass restriction of QW 403.9 is: acceptably addressed on the WPS only acceptably addressed on the POR only acceptably addressed on both the WPS and PAR unacceptably addressed on both the WPS and the POR o0n> ‘The A# range shown on the WPS is: unacceptable - should show A-t only ‘unacceptable - should show A-2 only ‘unacceptable - should show A-3 acceptable as shown comp A pressure vessel has been designed using SA516 - 60 material (32,000 yield). Totallength of ‘support is 8 feet. The stamped MAWP (external )is 180 psig @ S00°F. Theod is 48°. Can this vessel be safely operated If the thickness has correded down to 250"? A yes. this vessal is safe down to 250" 5 no. this vessel is not safe for 150 psig CC. not enough infarmation provided to solve the problem Dyes. this vessel could actually be operated at 250 psig ‘An existing vessel is inspected on a given year end found to be 500” thick in the shell and heads. The next inspection is performed 3 years later, anc the thickness of the shell and heads is shown to 2 310° (uniform) The vessel minimum thickness is calculated to be 200°. From this information. the Remaining Life (RL) and internal inspection Interval (1) on this vessel is approximately 13 A. Syears RL. 10 years LI B 7 years RL. 15 years | © 173 years RL 173 years I DB tO years RL. 10 years L MOMT of -38°F. (not ‘niuch wail require 'cact testing? ‘An ammonia processing vessel is stamped for an MAWP cf 50 asig with ‘examoted per UG-201) Various materials have cracked and/or coi welded recairs Which of the following materials, if any. will require © A. SA 537 Class 1, 3/4” thick BSA 387 Grade 21 normalized and tempered, 4/8" thick © SA 516-70 normalizec thick’ none of ne above will require impact tests A full size (or standard) Charpy impact specimen is: A ue xe B 10mmx 10mm © temx 10cm D 3eex tem ERVED 00 NOT 79 OR OISTAIBUT: NGHTS Fi COPYRIGHT 2000 IRCISCHINDLER & ASSOCIATES - A17 18 20 API 510 FINAL EXAMINATION 1 - OPEN 300K IRC COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIGUTE. ‘Avvassel shell is 66° .O and is made from material with a stress value of 13.200 psi. The vessel has Category A Type 1 buttwelds and is stamped “RT-2". Ifthe thickness has corroded down to 285° thick, what MAWP can oe allowed on this vesset? A. 400 esi B. 190 psig © 250 psig D139 psig ‘Awire 10! with a diameter of 020° would be found in an ASTM SET A a c D cour ‘A fat unstayed circular head with a diameter of 14” is operating at 360 PSI @ S00*F. The stress value Is 17,500 PSI with an efficiency of 1.0 and aC Factor of 33. Can this head be operated with @ corroded thickness of 1.25"? A. yes, can continue to operate B. na, cannot be operated . °C" Factor is incorrect for design D. circular heads cannot be use at 1 25° ‘Avvessel has @ nozzle installed as shown In Figure UW-16 Sketch (using two equal size fille welds The shell thickness is 3/4” and the nozzle wall thickness is 7/16". Using equalleg fillet welds, wnat eg dimension is required on these welds, rounded up to the next 116°? A gne B 76" coune 0 3a" In visual examination. the procedure is qualified by using @ test methed thet allows resolution of a fine fine that is __" or less in wath. A132 Be C18 Dove Gna 1" thick piece that will be MT tested by procs. the soacing Setwsan the prods wil ‘ct amp range fer this spacing would be: 4900 - 2000 ames 150 - 300 amps 106 -125 ames 500 - 825 amps A © D An ASME vessel is to be repai stamped °RT-3". and the total length of the buttw Complete the work on both patches How many radiographs will be 10 API S10? nas to the shell The vessel is ‘One waider wil be used to Wired. f the work is core sw Aus is willbe by adding wo cour OPY OR OISTRISY COPYRIGHT 2000 ~IRCISCHINDLER 8 ASSOCIATES ~ALL RIGHTS RESERVED 00 W'23 24. 25 28 2 28 wz 2 ‘API510 FINAL EXAMINATION 4 - OPEN BOOK IRC COPYa:GH? 2000 IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY C2 DISTRIBUTE ‘An exampie of 2 ‘siandard pressure par on a pressure vessel would be: A. apiece of 1 nick piss &. a welded elliptical head. C. a pipe fitting (Forged) 3 22 length of SA-106 B pipe 9 A radiograph is produced to “full RT requirements Thrae elongated slag inclusions are seen the radiograoh that are measured individually at 1/2" long, 3/4" ong. and 3/8" erg. Tne weic 1s 3 1/2" thick The interpretation of this radiograoh i See eee : B. unacceptaole C. slag inclusions are not a factor in RT D. none 6f the above ‘A standard seamless torispharical head has a skirt od, of 56" and a correded micxress of 1.27" The material stress value is 16,100 psi, and the head is atached to the bottom cia vertical ves: that {5 20' tall ful of water. Ifthe vessel is stamped "RT-2", what approximate MAV/P would be allowed on this vessel? Sea A. 600 psig 8 402 psige-~ C704 psig D302 psig Aweld repair is made on P-4 material, 3 1/2" o.d. pipe, 3/8” thick, carbon con minimum preheat of 200°F is maintained. Is PWHT mandatory on this repair? A no Byes ©. depends upon servic: D depends upon joint efficiency 10%. anda A2" thick carbon steel pressure vessel is to be postweld heat treated, The re: (ebove 300°F up to 1100*F) on this vessel shall nat exce: A. 400°F ne B g00*Fmr 200°Fihr ‘A vessel is ultrasonically inspected when itis new and cold in June 1987 anc thick in the shell. The next inspection is done in June 1995 and the vessel is teu": 50° thick. If the minimum thickness by calculation is $10", when (approxime: I or on-streem inspection be scheduled, per API 5107 wary 1989°~ 8 November 2010 ©. June 2005 © October 2002 An example of a “double wall exposure, double wall view" would b: A, ellicical exposure (ellips®) 5 suermposed exposure C_ single wall exposure (sour D both A&B above in middle of cylinder) CosvaiGHt 2000 - IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OF 2ISTRI23 30 1 32 33 API510 FINAL EXAMINATION 1 - OPEN BOOK IR COPYRIGHT 2000 ~IRCISCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE A welding cperator is qualified by making a radicgraph of her first production wele an 2 spot (R7- 3) vessel that is 1/2" thick. The weld shows several rounded incications that are 1/4” diameter tnat are interpreted as gross porosity. This welder would be: A. accepted to weld in production 5. accepted 10 wela in progucuon, put on: © not accepted to weld in production —~ ©. automatically requalified by welding two more test coupons 1 a 26 posicn ‘Acozzle is 1" thick and is attached to a pressure vessel 1 1/2" thick using a joint configuration waters Sig Wane # Geateh tak Tea af theags ar he sor curation (tc) wou" be ar 8 saute & sa Bt Reinforcing plates and saddles attached to the outside of a vessel with filet welds shall be provided with at least one tell-tale hole with a maximum tap size of NPS Auge 812 C13 Dt ‘A hydrostatic test is conducted on a vessel that is 60' tall, A pressure gauge is located 35° up from the bottom of the vessel. If the stress ratio Is 1.0 and the MAWP of the vessel is 100 Fsi, what zoproximate‘fressure should the gauge read to mest ASME Vil requirements? A. 141 psigh B 143 psig ©. 130: D188 psig ‘Awelder hes been qualified in the 6G position on 3/4” thick material, How many bend tests wit bee required? A, 4 side bends-~ & 2 side bends © 2 root bends no bend tests - tension tesis only All of the following statements conceming a “UM’ vessel are true xceat A. “UM" vessels are exempt from inspection by API 310 © “UM" vessels Mig. Data Raports are not signed by an Al ~ © "UM" vessels are exempt ay ASME Vill from the scope of the Code 1D “UM vessei manufacturer's must maintain an inspection agreement wits an AIA Atensicn tast specimen is made from welded plate, SA-299. The diameter of the turned: simen ig 300° and the load is 15 KSI. Does this specimen mast ASME IX requirements? A no B yes © tension specimens are nat required by ASME 1X D. the diamater of tne specimen does not mest Cace & ASSOCIATES - ALL RIGHTS RESERVEO -00 NOT COPY OR OISTRIGUTE COPYRIGHT 2000 ~ IRCISCHINOLFAPI 510 FINAL EXAMINATION 1 - OPEN BOOK IRC COPYRIGHT 2000 -IRCISCHINDLER & ASSOCIATES ~ ALL RIGHTS RESERVED -00 NOT COPY OR OISTRIGUTE, ‘QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boller & Pressure Vessel Code) Company Name: XYZ COMPANY, By JOE BLOW Welding Procedure Spec. No _11 Date: .57-82Supporting PR No. (s):_46 Revision No.:_0 Date: FCAW-SPRAY ARC TRANSFERType(s): _SEMI-AUTOMATIC Welding Procass(s) -SEMI-AUTOMATIC _ (Automatic, Manual, Machine, or Semi-Auto JOINTS (QW-402) = Details Joint Design:__ DOUBLE VEE GROOVE, ONLY Backing: (Yes) x. (No} Backing Material: (Type): WELD METAL ONLY (Refer to both backing & retainers) xXMetal + Nonfusing Metal + Nonmetalic + Other ‘Sketches, Production Drawings, Weld Symbols or Written Description ROOT OPENING - 1/16" - 1/8" ‘Should show tne general arrangement of the parts to be'welded. Where GROOVE ANGLE - 60° - 70° 2pplcable. the root spacing and the details of weld greove may be ecified Gettne option ofthe Migr, Sketches may be attached to Mustrate ont Gesign. weld layers. and the bead sequence, e.g. for notch toughness procedures. for multiole process orocedures, etc.) TBASE METALS (QW-403) Z P-No.___3 Group No. 1 to P-No. Pd. 3.1 Group No. 1 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: _1/16" Pipe Dia. Range: Groove: ALL Other:_NO PASS GREATER THAN 1/2" THICK Fillet: ALL ALL TFILLER METALS (QW-404) Spec. No. (SFA): SFA 5.29 ee AWS No. (Class): __E81T4 (1.2.3.4) TS Filler Metal F-Nos 6 ne Chem. Comp. -A No TOR2 ee Size of Filler Metais: ALL a Weld Metal Thickness range Groov: Te MAX —————— Fillet ALL oO Electrode-Flux (Class): Flux Trade Name: Consumable Insart: oe Other, _NOSUPP. FILLERS OR PeReeeeeere eee eeeeee POWDERS TO BE USED = Zach base metabfiler metal combination should be recorded individually {VEB 00 NOT COPY OF DISTRIBU COPYRIGHT 7000 = IRCISCHINOLER § ASSOGIATES “ALL RIGHTS1 Scalia etme ir tn Aa ET EN BOOK IRC =DO NOT coPY OR DISTRIBUTE API 510 FINAL EXAMINATION 1 COPYRIGHT 2000 - IRC'SCHINOLER & ASSOCIATES ~ALL RIGHTS ‘Qw-482 (Back) WPS No: Rev Nos [ POSTTIONS (aw-405) | POSTWELD HEAT TREATMENT (W607) 1 Position(s) of Groo ALL Temperswure range 1130 = 1200¢ Welding Progression: Up __X Down | Time Range 1 HR PER INCH, 15 MINT MINIMUM Positions(s) of Fillet__ALL | | GAS (ance) Parcent Composition 1p Min.:200° MINIMUM Interpass Temp Max:__650° MAXIMUM Gas(es) (Mixture) Flow Rate Preheat Maint: NONE. Shielding ARGONICO2 _75%-25% __ _10-20 CEH ina Traling? ; Backing: _O2 700% 5.10 CF Ta We MGs Ee TE ET ELECTRICAL CHARACTERISTICS (QW-408) 7 =, ‘Currant AC or DC —_DC. Polarity_REVERSE ee ‘Amps Range __ 100-150" Volts (Range) _18-25, {Amps and vls Tage should Be recorded for eat elecade SB. positon, and ikness, ete. This information may be std in {ular form sia to rat show below.) ‘Tungsten Electrode Size and Type, ‘Pars Tongaien, Be Thersied. we] Mode of metal Transfer for GMAW SPRAY ARC TRANSFER ONLY ‘(Soray ae anor rearing we ee) oo Electrode Wire feed spaed range FECHNIQUE (QW-410) String or Weave Bead _BOTH. Orifice or Gas Cup Size iz _ Initial and Intergass Cleaning (Brushing ie. ) BRUSH AND GRIND BY USING MANUAL METHODS af Method of Back Gouging ___ CARBON ARC Oscillation _NONE _ Contact Tubs to Work Distance 1/4" = 1/2" Multiple or Single Pass (per side)_MULTIPASS a or Multiple of Single Siectrodes: SINGLE. a es Peerage Reece Teen cee Sree eae ALLOWED otner | RE ar ae 7 1 i veg. seman reve, | Sonmane met f wate Spee d years) | Prats | cess Renae q ALL ALE DCREV_ 100-150 a 1 | amo Pare r T L 1 i T EB 190 NOT COPY OR DISTRIBU GASSOCIATES - ALL RIGHTS RESERVE! COPYRIGHT 2000 ~IRCISCHIND.API 510 FINAL EXAMINATION 1 - OPEN 800K IRC COPYAIGHT 2000 = IRC/SCHINOLER & ASSOCIATES - ALL RIGHTS RESERVED .50 NOT COPY OR DISTRIBUTE ‘OW-183 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (POR) (See QW-200.2, Section IX, ASME Boiler and Pressure vessel Code) Record Actual Conditions Used to Weld Test Cougon Company Name:___XYZ COMPANY n Record No.: 44 Date: 8-31-82 Welding Process(s): FCAW (TUBULAR) — Types (Manual, Automatic, Semi-Auto. ): __ SEMILAUTOMATIC SPRAY TRANSFER, JOINTS (Gw-202) Groove Design of Test Coupan (For combination quaifcations, the deposed wold metal thickness shall be recordad foreach Mer metal of process used.) BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407) Material Spec: __SA 302. ‘Temperature: _NONE USED Type or Grade: __ GRADE 5. Time: 2.No: __3 to PN 3 Other: Thickness of test Coupon:__/2 THICK E Diameter of Test Coupon: ___N/A= PLATE Other. NO PASS GREATER THAN 1/8" THICK GAS (QW-408) FILLER METALS (GW-404) Percent Composition SFA Specification: _SEA- 6.29 Gas(es) (Mixture) Flow Rate AWS Classification: _E7iT1-4 Shielding: _CO2 100% 42.18 CEH Filler Metal F No. € Trailing: __NONE. Weld metal Analysis No. A2(80,000 TENSILE). Backing: NONE Size of Filler metal: _1/8"___ ELECTRICAL CHARACTERISTICS (QW~403) Other: NO SUPPLEMENTAL FILLERS OR Current: _ DIRECT POWDERS USED. Polarity: REVERSE rece Weld Metal Thickness: __ 1/2" THICK Amps.:____130 Volts: 28 Tungsten Electrode Sizer __ Other: : POSITION (QW -405) Position of Groove:__ FLAT Weld Progression (Uphill, Downhill: NIA TECHNIQUE (aW-10) Other: Travel Speed: __15 12M String or Weave Sead: _ WEAVE Oseillation: NONE Multipass or Single Pass (per side):_MULTIPASS Interpass temp! Single or Mu Other: Other: PREHEAT (W205) Preheat Temp.:___400°F le Electrodes:_SINGLE ___ ‘caPYRIGHT 20¢0 ~IRG:SCHINO! RIGHTS RESERV: ‘API 510 FINAL EXAMINATION 1 - OPEN BOOK IRC (COPYRIGHT 2000 - IRCISCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - 09 NOT COPY OR DISTRIBUTE QW-483 (Back) PQR No: __14 Tensile Test (QW-150) | | [ _Uitinaie’ | Gisate | Type of Specimen Total toad | unit stress | Falture & No. | Width _| Thickness |__Area_ | tb. |__Lecation we | ae se [OG | SRBASE | | METAL [eae | besASe METAL i 1 1 T i 1 I I i [os I i Guided Bend Tests (QW-180) 7 Type and Figure No. Result = | [SEBEND HT ow-622 POROSITY - Ge" DIA) - ACCEPTABLE | [SIDE BEND #2 - QW. 462.2 ‘CORNER POROSITY - 1/8” DIAM. - ACCEPTABLE Toughness Tests (QW-170) Impact Values = Specimen | Notch | Specimen | Test No. | Location ize _|Temp.| Ft.Lbs. | %Shear| mits | drop Weight Break (YIN) = { Comments: Fillet Weld Test (QW-120) Result — Satisfactory: Yes: No: Penetration into Parant Metal: Yes:_No:_~_ Macro — Results: Other Tests Type of Test: Deposit Analysis: Other: Welders Name: JOE BLOW JR. GlockNo: A Stamp No __4 Tests conducted by: __ BILLS TEST LAB. Laboratory Test No.:_123. We cartify 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 Cade Manufacturer: ___XYZ COMPANY. 8/31/92 a By! _JOE BLOW SR. COPYRIGHT 2000 ~ IRCISCHINOLER 2 ASSOCIATES - ALL RIGHTS RESERVED -00 NOT COPY OR CISTRIBUTEASME IX AND V TEST IRC SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE AP! 510/570 COURSE ASME SECTION IX AND V TEST (ALL OPEN BOOK) NAME DATE, 1. AWS s primary purpose is to: a qualify the POR qualify the WP sc, provide direction to the welder during production welding document all non-essential variables 2. APQR's primary purpose is to: sa,’ qualify the WPS qualify the WPQ cc. _ provide direction to the welder when making the test welds d— botha&c, above 3 AWPQ's primary purpose is to: a. _ chow ine ranges quid by 2 wolderopeator b show the actual variables used to qualify a welder/operator A Reet per eet & a all of the above 4 ‘The nan-desvucve examination tht wil be covered bythe AP 510/570 sxrinaton a # > F elton $e 5 What ypes of ane maybe detected by PT? ay sutece only B Mea ony c surface cracks. only Fee erty abeutace é—sanduest acceptance cite is specifedin Paragraph __ of ASME Seton ik 2 awass 2 Santee 2 Bates § Gkagh 7 Wanting the SMAW process a decrease of more han YOO" in the peseat temperature qualified is an variable Essential Non-Essential Supplementary Essential Not a variable COPYRIGHT 2/- IRCZSCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE10 " 12 13 14, 15 ASME IX AND V TEST IRe COPYRIGHT 2000- IRC/SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE SFA 5.28 's considered to be an Fi, per ASME IX. A penetrameter is used for? Judging RT flim density by Judging RT fim sensitivity ¢ Judging RT film exposure qd Judging UT acceptability ( ‘What is the minimum frequency range of ultrasonic instruments to be used for ASME Code examination? a 25 MHz b 18 Khz cc 8-10 MHz d. none of the above What is the difference between X and Gamma Rays? Xi a longer ray than Gamma ‘Gamma is a harder ray than X ‘Tne origination of the ray (source vs machine) Xis only used in alloy analysis MT using AG yokes is: acceptable to find all discontinuities acceptable to find surface discontinuities, only acceptable to find sub-surface discontinuities acceptable to find cracks, only What device or devices may be used to measure RT film density? 2 Calibrated density strip b Calibrated densitometer c Calibrated penetrameter @— Botha&b. above ‘Tension tests may be used to. a Qualify a welder b Qualify a walding operator c Prove the ductility of a proposed welding procedure: Qualify a welding procedure Essental variables must be addressed on a wes b PAR c¢ wpa d— Allof the above COPYRIOGHT 2)- IRC?SCHINDLER & ASSOCIATES - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTEASME IX PRACTICE QUESTIONS COPYRIGHT 2000 ~IRCIT. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBU ASME SECTION IX PRACTICE QUESTIONS TIONS ARE CLOSED 200K + The purpose of tne WPS and PGR is to determine that. A. the welder is qualified B the base metals are strong enough C the weldment has the desired properties D the skill of the welder 2. The WPS lists: A nonessential variables B essential variebles ranges for 1 & 2 above D alllof the above 3. The POR must lst A essential variables B qualification test & examination results supplementary essential variables (when notch toughness is required) D allof the above 7 4 Whats tha earliest Edition of Section IX recognized by the current edition? A 1958, B 1992 c 1987 D 1962 5 New Welding Procedure Specifications must meet the Edition and Addenda of Section IX A 1962 8 current c 1986 D 1995 6 Each shall conduct the tests required by Section IX to qualify the WPS's used during the construction. alteration. or repair A Welder or welding operator B Manufacturer or contractor Inspector © Allof the above 7 The records of procedure, welder and welding operator qualitication must pe available to the A Manufacturer B Welder Authorized Inspector D Foreman coPYRIGHT 000 -IRCTT. SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -DONOT COPY OF DISTRISUTE 2ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 ~IRG/T. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 8 Awelder qualifying witn a groove weid in 2 plate and pipe over 24°O D in atleast the positions ig in the 4G positicr.¢ ified to weld groove weics A Vertical _B Flat & horizontal C Fiat & overhead 2 Horizontal 9 Awelder qualifying with plate filet welds in the 3F and 4F positions is qualified to weld groove welds in plate in the positions, A Flat only 8 Flat and horizontal © Flat and vertical None of the above 40 A welder qualifying by making a groove weld on pipe with an O.D of 3/4” in the 5G position is qualified to weld groove welds in: 7 ae A 1/2" Q.D Pipe in the overhead position & 6" OD Pipa in the vertical position C 3/4" OD pipe in the horizontal position-+ D None of the above 11. In general, qualification on groove welds also qualifies a welder to make: A Stud welds B Overhand welds © Fillet welds D Allof the above 12. Charpy V-notch tests are med to determine a weldment's A Tensile strength B Ductiity © Notch toughness D Allof above 13. Awelder making @ groove weld using the SAW process on P1 materials may be qualified using radiography A Tue B False 44 When a tensile specimen breaks in the base metal outside of the weld or fusion fine the strength recorded may 02 at most ___ below the specified tensile and be accented A 35% B 5% © 5% D Allof the above COPYRIGHT 2000 ~ IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 3ASME IX PRACTICE QUESTIONS: COPYRIGHT 2000 ~ IRCIT. SCHINDLER AND CODEWEST - ALL. RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE, 18 Guided-bend specimens shall have no open defects in the weld or heat effected zone exceeding rneacured in anv direction on the convex surface of the specimen after bending c 1" B None of the above 16 When using radiographs to qualify welders. the acceptance standards used are found in A ASME Section V B ASME Section Ix © ASME Section Vill D The referencing code 17 AWPS must describe: A Essential variables q B Nonessential variables © Supplementary essential variables when required for notch toughness D Allof the above 18 APQR must describe A Nonessential variables 8B Essential variables C Results of Welder Qualification tests D Project description & NDE methods 19 The must certify the PR as accurate A Inspector B Manufacturer or contractor C Welder © Allof the above 20. For the SMAW process is an essential variable for the WPS. A Groove design & Post Weld Heat Treatment Root spacing © Method of cleaning 21. For the SAW process is an essential variable for the WPS A Supplemental powdered filer metal (if used) 8 Filer metal diameter © Preheat maintenance D Addition or deletion of peering 22 Tne basic purpose of testing a welder is to establish the welders A Knowledge of welding requirements 8 Ability to deposit sound weld metat C mechanical ability to operate equipment D General attitude toward welding inspectors, 23 The record of a welder's performance testis called @ COPYRIGHT 2000 ~ IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 4ASME IX PRACTICE QUESTIONS. COPYRIGHT 2000 - IRCFT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE A POR B war cWPS 24. fa welder qualified with the SMAW process on Jan_1, 1904 and last welded with SMAW on March 15, 1994, would he still be qualified on October 7, 19847 vn ogee A Yes B No : 25. Awelderqualiyng with a groove weld welded ftom bath sides is quali i we A Without backing 8 With allbase metals uc © With backing only > seco 1 « L z D With P1 backing onty + dame eh be Can cr ba weeel poe 26. Immediate retests of welders qualifications coupons A. Must use the same method i he 3. May use any method © Are not alowed D. ReauireInepector approval Hee ae eetnt 27 Welder performance qualification records must describe all the variables specified A Essential & nonessential B Nonessentiat © Essential © Brazing 28 Awelder depositing 1/2" of weld metal with the SMAW process is qualified to epesit up to of weld metal. ag B Max to be welded 29. "P" numbers are used to designate groups of A Electrodes 8B Flux © Base metals D Joints 30 A welder qualifying by welding P-No 21 to P-No 21 is qualified to wale A Pal Pet to Pet Pott 5 P8-PB © P-21-P-25 to P-21 = P-25 © P2t to P21 only 31 Welding electrodes are grouped in Section IX by COPYRIGHT 2000 = IRG/T. SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE 5ASME IX PRACTICE QUESTIONS COPYRIGHT 2000-IRCIT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘A. AWS class. B ASME specification C SFA 1D "F* number 32. Ferrous weld metal chemical composition may be designated using AP" number B Welder 1D C -"AY number D page number 33. For welder qualification with the SMAW process. is an essential variable A Base metal thickness 8 Peening C. P-number D Electrode diameter 34. Each welder must be assigned a(n) A P number B Unique identifier GC Hood & gloves © Inspector 35 May a welder, qualified in the 2G position on 1/4 inch thick plate, weld a 1 inch outside diameter pipe. 1/4 inch thick in the horizontal position without requalification? A Yes wd B No , CNet enough information provided D. Yes, provided pipe is carbon stee!. Pit 36 Whatis the basic difference between gas metal arc welding and gas tungsten arc welding processas? A. How they are produced B The,SFA specification of the filer metal C The Fé of the filler metal 9 GTAWis run with gas: gas is optional with GMAW 37 Awelder has been tested in the 6-G position. using an E-7018 F-4 electrode. on 6” sch 160 (718 nom) SA 1088 pipe Is this welder qualified to weld a 2" 300# ANSI schedule 60 bore fienge toa 2” schedule 80 SA 106 B nozzle neck? Yas No Not enough information provided Yes provided a backing strip is provided in the 2° weld pour 28 May a welder who is quaified using a double-groove weld, make a single V-groove weld without backing? COPYRIGHT 2000 IRCIT, SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 638 40 at a2 43 a4 45 ASME IX PRACTICE QUESTIONS - COPYRIGHT 2000 -IRCIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE A Yes B No Not ercugh infomation provided D. Yes. because backing is not an essential variable for a welder May a GTAW welder be qualiied by radiograpty, in lieu of bend tests? The test coupon walle -22 material and the production welds will be P-22 also A Yes 3 No © Not encugh information provided 5 Yes provided the P-22 is welded with F-22 filers Who is responsible for qualification of welding procedures. welders and welding operators? A. The Inspector 8. TheAt © The Shop Foreman 1D. The Manufacturer of Contractor Awelding electrode has the marking £-6010. The “1" marking indicates: A. Flat position only B_ Horizontal position only © Allpositions D. Only good for heat treated welds May a FCAW welder qualified using UT. be used to weld in production? A Yes, welder can be used B_ No welder cannot be used CC Yes. # welder is using GMAW (Short Arc) D. Yes. ifweider is qualified with backing ‘A welder may deviate from the parameters specified in 2 WPS if they are @ nonessential variable (True oF False) A Tue B False ‘A repair organization has a WPS which states itis qualified for P-8 to P-8 material welded with dither £308 E308L. £309. E316. electrodes (SMAW process) The PR, supporting this WPS, cuates the weld test coupons were SA-240 Type 304L material, welded with £308 electrodes Is the WPS properly qualified for the base material listed? A Yes 8 No Not enough information given D Yes if properly heat treated What positions are necessary to qualify a welder for all position pipe welding? A 3G and 4G B 2Gand 8G COPYRIGHT 2000 ~IRC/T SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBU= ASME IX PRACTICE QUESTIONS. COPYRIGHT 2000 ~ IRG/T. SCHINDLER AND CODEWEST ~ ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE C 3Gand 1G D 4G and 5G 46 What ASME Code Section has welding electrode storage requirements? A. ASME IX B ASME Vili © ASME B31 1 D ASME I Part C 47 What are the numberof transverse guided bend tests required for Performance Qualifeation in @ 6G postion? vomr 148, May a GMAW, shor circuit transfer, welding procedure be qualified using real-time ultrasonics? A Yes . B No © Not enough information given D_ Yes, provided bend tests are done 49 Three are welding processes are: A BMAW, SMAW, EFGAW B FCAW, SAW, ESW © SMAW, GTAW, PAW D PTAW. SLAW, PEAW 50 You are reviewing a WP (QW-484) for a welder testing in the 6-G position: on SA-53 grade B pipe (TS-60,000 psi) The test results indicate the folowing: #1 Tensile developed 51,000 psi, broke in the weld 22 Tensile developed 56,500 psi, broke in base metal #1 Transverse root bend satisfactory #2 Transverse face bend satisfactory Will these test qualify the welder? Yes No Not enough information given Tension test is acceptable but #1 is unacceptable poe 51. Is awelding procedure qualified under the 1965 ASME Code Section IX still applicable? A Yes B No. must be requalified CIs only applicable for 1985 pressure vessels COPYRIGHT 2000 ~ IRCIT, SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUT=ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 -IRCIT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRISUTE 'D_ Cannot be used for new construction - repairs only 52. A nonessential variable must oe aocumented on: A The wea B The POR C The WPS D Allof the above 53. What are the various positions in which a welder may quality for plate groove welds? 1G 3G 4G All ofthe above ooo 54 Awelderwas qualified with a P-t test coupon using SMAW E7018 electrodes. May the welder Onis bt material using E8028 electrodes with backing in production? (Assume the P-4 procedure Using £8028 electrodes has been qualified ) A Yes 8 No C Not enough information provided 1D None of the above sj5. What are the primary classifications of guided-bend tests permited by the Code?” A. Side and Transverse B Face and Root © Transverse and Longitudinal D Side and Face 56 Awelder quaified by welding in the 5G position is qualified for what position on plate? Which oft following is a covered electrode? A &8010 B E7018 c E9028 D allof the above 58 Apolicabie essential variables must be documented on which of the following? A The WPS: B ThePOR C The wPa 1D Allof the above COPYRIGHT 2000 -IRG/T SCHINDLER & CODEWEST - ALL. RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 9ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 - IRCIT. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 159. In performance quaitfication of pipe welds to ASME Section IX, which positions require more than two guided bend specimens for qualification? A. 5G and 6 5 2G and 4F © 4G and 5G 4 None of the above 60 Name two defects that would cause visual rejection of @ welder's test ipe or plate? A. Porosity, underfill 8 Lack of penetrationifusion © Slag, overlap D. Anyof the above 1 Avariable that, when changed will cause a change in the mechanical properties of the weldment is calied a: A Essential variable B. Non-essential variable © Supplementary essential variable D Allof the above 62. The test that determines the ultimate strength of groove-weld joints is a! ‘A Notch Toughness Test B Tension Test C Fillet Weld Test D Guided-Bend Test 63. The procedure qualification tast is used to determine: ‘A. The skill of the welder © That the proposed production weldment is capable of having the required properties ©The corrosion -resistance of the proposed weldment 1D None of the above ‘aa Achange ina supplementary essential variable requires requalfeation when notch toughness iS @ consideration True or False (circle one) 65 When using Mecto-examination of fila weld test, the weld and the HAZ must not revel cracks when magnified at. A 8x B 2x © 10x No magnification is required - visual examination is requirec only 66 A non-essential variable may be changed without re-qualifcation because, ‘A. Nobody cares about non-essential variables 8 The welder is allowed to change variables at his discretion . Nemcessential variables do nat affect the mechanical or notch-toughness propertias 'D. Non-essential variables cannot be changed without re-qualification GoPYRiGHT 2000 ICT SCHINDLER & CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 10ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 ~IRCIT, SCHINDLER AND CODEWEST - ALL FIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 67, The data recorded on a POR (nor-etitorial) may be changed provided: ‘A. The Al approves 2 The test data on a POR is a record of what occurTed and should never be changed. srged on a POR Srly editors © The API 510 Inspector approves D. The date of the WPS is changed 68 A WPS must only address essential and, if applicable, supplementary essential variables True or False (circle one) 68 Tension tests may be used in lau of bend tests to qualify welders or welding operators True or False (circle one) 70 A groove weld bend test reveals a linear indication on the face of the bend surface that measures eacily 1/8" long. No other indications are seen. Does this coupon pass or fal? A Pass Fall 71. Unless notch-toughness is a consideration, ¢ qualification in any position qualifies a welding procedure for all positions, Tre or False (circle one) i 72 The purpose of a WPS and POR is to determine #f a welder has the ski necessary to make sound production welds True or False (circle one) 73 Welders can be qualified by radiograph when using P 6X materials? True of False (circle one) 74. itis permissible to sub-contract welding of coupons as wal as ether work to prepare coupons True OF False (circle one) Variable QW 402 4 for SMAW procedure qualification is a variable A Essential 8 Non-essential Supplemental essential D_ None of the above 76. Variable QW 404 24 for SAW procedure qualification is an variable A. Essential 8 Non-essential C. Supplemental essential None of the above 77 Each manufacturer must certify the POR (by signature) indicating that the information given is CosYRIGHT 2000 -IRCIT SCHINDLER & CODEWEST -ALL FIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE n78 73 80 a 82 83 a4 85 8% 87 ASME IX PRACTICE QUESTIONS COPYRIGHT 2000 - IRC/T. SCHINDLER AND CODEWEST ~ALL RIGHTS RESERVED - DO MOT COPY OR DISTRIBUTE true and correct Tre Or False (circle one) Welder variable QW- 405 1 (for welders qualifying with the SMAW process) is & vanadie A. Essential 8 Non-essential C Supplemental essential 1D Noné of the above The purpose of a WPS and POR js to determine if a proposed weldment to be used in construction is capable of providing the required properties for the intended sppication True or False (circle one) A qualification in a 4G position qualifies a welder for all groove weld positions. Tre or False (circle one) AWPS must address all applicable non-essential variables True or False (circle one} Groove weld coupons shall be tested by macro-examination when qualivrg a welding procedure True or False (circle one) ‘A.welsing procedure must be qualified with impact tests only when requiree by tne appficable ‘construction code, such as ASME Vili Div 1 True or False (circle one) ‘Awelder qualified to weld in the 26 position on pipe would have to be cueied in which of he 50°F 8 100°F © 125°F D 150°F E None of the above ‘welder is qualified to weld all thicknesses of material when’ ‘The test is any thickness above 3/8 inch ‘The test thickness was ¥4 inch ‘The test thickness was 3/4 inch or over ‘The test pipe wall thickness wes 5/8 inch and nominal pipe size was over V4 inches None of the above moaw> What is the maximum defect permitted on the convex surface of a welder cuaification bend test see ynrgrit 2000 IRGYT. SCHINDLER & CODEWEST -ALL RIGHTS RESERVED -O0 NOT COPY OR DISTRIBUTE 1288 9 90 an 2 93 ASME 1X PRACTICE QUESTIONS COPYRIGHT 2000 ~1RC/T. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE afer bending except for comer cracks and corrosion resistant weld overlay? A tis inch 8 1/Binch D ‘What period of inactivity from a given welding process requires the welder to process? A. 3months BS months CS months O12 months E As stated by the Al Notch-toughness requirements are mandatory A. For heat treated metals B. For quenched and tempered metals C Forhardened and tempered metals D For annealed and tempered metals When specified as required by the referencing Code section ‘Awelder qualified for SMAW using an £7018 electrode is also qualified to weit with £7015 E5011 6010 E7024 All of the above moom> Macro examination of an etched filet weld section for performance qualification is acceptable i the ‘examination shows > Complete fusion and freedom from cracks. excepting linear indications not axceeding 1/32 inch ai the root 8 Cancavity or convexity no greater than 1/16 inch © Not more than 1/8 inch difference in Jeg lengths © Allofthe above E Scth Band C above Each manufacturer or contractor is responsible for the welding or brazing dore ay his organization ‘Whenever these words are used in Section IX. they shall include: A, Designer or architect 3 Designer or installer C Architect or installer 1D Installer or assembler E Assembler or designer For P-11 materials, weld grooves for thicknesses. shall be prepared by thermal COPYRIGHT 2000 ~IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED . DO NOT COPY OR DISTRISUTE 13ASME IX PRACTICE QUESTIONS ‘COPYRIGHT 2000 IRCIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIGUTE processes when such processes are to be employed during fabrication A. Less than 5/8 inch c D 7-174 inches E None of the above 94 Awelder using SMAW must be requalified if there is a change in which of the following conditions? A AHS B 6NPS 102 NPS ©. uphill to downhill in the groove D both B &C. above 95 Achange in @ non-essential variable requires re-certification of the POR. True or False (circle one) 96 Reduced-section tensile test specimens conforming to QW-462 1 (b) may be used on al thicknesses of pipe having an outside diameter greater than: ‘| A. 2inches B 2-1/2 inches C 3inches D 3-172 inches E inches 97 Groove weld tests may be used for qualification of welders Which of the following shail be used for evaluation? A. Only bend tests B. Only radiography ©. Both radiography and bend tests D Either bend tests or radiography E None of the above 98 Under which of the following conditions can a welder be qualified during production work? ‘A A 6! length of the first production groove weld may be qualified by radiography 8 Abend test coupon may be cut from the first 12" length of weld Amacro examination may be taken from the first 3" of weld length None of the above ANSWER KEY FOR PRACTICE WELDING QUESTIONS: 9eeeB0000 o COPYRIGHT 2000 -IRCIT SCHINDLER & CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 14ry ASME IX PRACTICE QUESTIONS: | SOPH 000 -MEM_ SANDLER AND CODEWEST ALL UGHTS RESERVED. DOWNoTCOFY OR EISTRIBUTE 4 2 B 0> 00> > O0009>0000F00>0N0000000>0R09>a0NOMND>AD 56 87. 58 59 61 62 63 64 65 moosaarm>room 67 68 z alse COPYRIGHT 2000 -IRC/T. SCHINDLER & CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 18ASME IX PRACTICE QUESTIONS: COPYRIGHT 2000 IRGIT. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 69 70 7 72 73 74 1 B 7 78 73 False Pass True False False False B A True A True False True False True >oopo>oomm@aoao & COPYRIGHT 2000 -IRGMT, SCHINDLER & CODEWEST -ALL RIGHTS RESERVED - 00 NOT Ci 16 JOPY OR DISTRIGUT:REVIEW OF ASME IX -T. SCHINDLER “COPYRIGHT 2800 -IRCIT SCHINDLER AND GODEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR OXSTRIBUTE API AUTHORIZED PRESSURE VESSEL INSPECTOR PREPARATION COURSE FOR CERTIFICATION EXAMINATION 2000 INNOVATIVE RESEARCH CONSULTANTS ‘SCHINDLER & ASSOCIATES AND CODEWEST AUTHORED BY: T. SCHINDLER ‘coPvmiGHT 2000 sR! SCHNDLER ANO CODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR OSTRIBUTEREVIEW OF ASME IX - T. SCHINDLER. Ccopynicst 2000 IRGIT. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: INTRODUCTION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE CERTIFICATION TEST WITH TYPES AND FORMS OF INFORMATION IN WHIGH THEY MUST BE KNOWLEDGEABLE REFERENGES:BODY OF KNOWLEDGE, AP! AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION. ASME SECTION IX WELDING QUALIFICATION CODE. INTRODUCTION Section IX relates to the qualification of: = Welders: ‘+ Welding Operators © Brazers ‘+ Brazing Operators © Welding/Brazing Procedures who are employed in welding or brazing in accordance with the: + ASME Boller and Pressure Vessel Code and - + ASME Piping Codes PURPOSE ‘The Welding Procedure Specification (WPS) and the Procedure Qualification Record (PQR) are used to determine that the weldment proposed for construction is capable of having the required properties “The procedure qualification testis to establish the properties of the weldmentVorazement, NOT the skill of the welder/orazer ORGANIZATION Section IX is divided into two parts: + Welding, Identified as QW + Brazing. identified as 08 “These two parts are further divided into four Actes: + General Requirements + Procedure Quelification + Performance Qualification CcoprmichT 2000 «IRC! SCHINDLER AKD CODEWEST -ALL RIGHTS RESERVED - D0 NOT GOPY OR OISTRIBUTE 2REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 7000 - INCI. SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE + Data PROCEDURE QUALIFICATION Each process is listed separately with the applicable essential and non-essential variables + Change in an ESSENTIAL variable requires requaiification + Change ina NON-ESSENTIAL variable requires a revision to WPSIBPS + Change ina SUPPLEMENTARY ESSENTIAL variable requires requalification ADDITIONAL RULES In addition to covering various joining processes, rules also exist for special processes: + Corrosion Resistance Weld Metal Overlay + Hard-Facing Weld Metal Overlay . PERFORMANCE QUALIFICATION Each process is listed separately with the applicable essential variables + Welderwelding Operator can be qualified by: + Mechanical Tests + Radiography of the Test Plate/pipe + Radiography of Initial Production Weld + BrazeriBrazing Operators CANNOT be qualified by radiography ARTICLE! WELDING GENERAL REQUIREMENTS QW-1003 WPS. PQR, and Records of Performance Qualification can be used for construction built according to either the , + ASME Boiler and Pressure Vessel Code — orthe = + B31 Code for Pressure Piping Providing it meets the requirements of either the + 1962, or later, editions of Section 1X 2 pre-1962 Edition of Section IX meeting ALL requirements of 1962 oF later. ecitions: ‘A. Qualification/requalification of WPS MUST conform with the current Edition and Addenda of Section IX Scope Rules in this section apply to Qw-101 + preparation of WPS “+ qualification of welding procedures, welders, and welding operator for ALL. manualimachine welding processes permitted in other sections COPYRIGHT 2000 iG! T SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED - D0 NOT COPY OR OISTRIBUTE 3REVIEW OF ASME IX -T. SCHINDLER ‘COPYRIGHT 2000~IRGT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE Responsibility Manufacturer/contractor is responsible for welding QWw-103 + MUST conduct tests to qualify Welding Procedure and Welders/Welders Operators, ‘Test results MUST be kept by manufacturer/contractor + MUST be certified by Manufacturer/contractor Types and Purpose of Tests and Examinations Qw-140 Mechanical Tests aw-141 Tension Tests Determine the ultimate strength of groove-weld joints await 2 heey Guided-Bend Tests Determine the degree of soundness and ductility of groove-weld Qw-14t2 joints. Fillet-Weld Tests Determine the size, contour, and degree of soundness of filet welds Qw-1413 Notch-Toughness Determine the notch toughness of the weldment Tests Qw-14t 4 ‘Stud-Weld Tests Determine the acceptability of stud welds Qw-141 5_ Tension Test To determine the ultimate strength of a jeint, expose sample to stress Qw-150 levels exceeding stated limitations Tension Test Sample shall be ruptured under tensile load Procedure ow-182 + Calculation: Tensile Strength = Meximum Load Minimum Cross- Sectional Area ~- Measurements MUST be taken before load is applied Acceptance Criteria Tension Tests Qw-153 Tensile Strength Minimum tensile strength requirements: QW-153 1 + Stated base metal limitation. of + Stated base metal limitation of WEAKEST specimen when two different strength levels are present, or COPYRIGHT 2000-1RG!T SCHINOLER AND CODEWEST - ALL RIGHTS RESERVED -O NOT COPY OR DISTRIBUTE 4REVIEW OF ASME IX -T. SCHINDLER. COPYRIGHT 2000 REIT SCHNDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE + Stated weld metal imitation when the applicable Section requires use of weld metal with @ lower room temperature strength than the base metal + Strength is NOT MORE than 5% below the stated base metal limitation JF the Spesinien breaks outside the Fusion Zone and weld in the base material Guided Bend Tests Using a test jig, bend the sample into a "U" shape Qw-160 ‘Types of Guided Bend Tests aWw-t61 Transverse Side Bend Weld is transverse to the longitudinal axis of the specimen aw-16tt Side surface of the weld becomes the convex surface of the specimen Transverse Face Welds tansverse tothe longitudinal axis ofthe specimen awiet 2 Face surface of the weld becomes the convex surface of the specimen ‘Transverse Root Weld is transverse to the longitudinal axis of the specimen awe foot surface ofthe weld becomes the convex surface ofthe specimen Longitudinal Face Bend Weld is parallel to the longitudinal axis of the specimen Qw-16t6 Face surface of the weld becomes the convex surface of the specimen Longitudinal Root Weld is parallel to the longitudinal axis of the specimen Bend Qw-1617 Root surface of the weld becomes the convex surface of the specimen ‘Acceptance Criteria. Weld and heat affected zone MUST BE ENTIRELY within the bent QWw-163 area of the specimen "Specimen MUST NOT have eny defects greater than 1/8 inch «Measurements ten ampere on ourded surface + Comer cracks disedunted unless evidence of internal defects are present Corrosion Resistant Weld Overlay Cladding requirements: + No defects greater than 1/16 inch (cladding) + Nodefects greater than 1/8 inch (bond fine) =, 4. =e Notch Toughness When required by the Code. one of the following fests MUST be conducted aw:r70 + Charpy V-notch + Drop Weight impact COPYRIGHT 2990 ARC/T. SCHINDLER AND CODEWEST ALL FIGHTS RESERVED “D0 NOT COPY OR DISTRIGUTE 5REVIEW OF ASME IX -T. SCHINDLER Ccoprnich 00 ~IRC/T SCHINDLER AND GODEWEST-ALL RIGHTS RESERVED "00 NOT COPY OR DISTRIBUTE Other Tests and Examinations aw-t30 Visual examination of welder/operator qualification test is required. > Radiographic May be substituted for mechanical testing for weldershwelding operators Examination ———— a 7 Qw-191 MUST meet requirements of Article 2, Section V MUST mest acceptance criteria of QW-191 2 Cannot be used on GMAW short- arc process Stud Weld Tests Procedure Qualification QWw.192, : . Required Tests ‘Ten required for each procedure : Qw-192 1 Five alternately MUST be hammered over untt a 1 +14 of length is flat, » + Bent to na less than @ 15% angle AND returned to original position Remaining five alternately MUST be torque tested “ + Tensile testing also acceptable Bend and Hammering All five studs MUST NOT have visible fractures or separations: aw-192.2 Torque Test or Torque: Tensile Test QWw-1923 + Stud MUST meet required torque before falling Tensile: = Stud MUST withstand at least 35,000 psi before falling Macro-Exemination All five sections, the weld, and the HAZ MUST NOT reveal cracks when Qw-192 4 ‘magnified at 10X Slud Weld Tests Performance Qualification Qw.193 Required Tests Five required for each operator Qwe-193 1 Allfive studs MUST be hammerad or bent as required by procedure qualification Criteria for acceptance is identical to procedure qualifications COPYRIGHT 2000 IRC) T SCHINDLER ANO CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIOUTE 6REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 IRCIT SCHRNDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE General QW.200 Welding Procedure: Specification (WPS) Qw.200 1 Procedure Qualification Qw-200 2 ARTICLE It WELDING PROCEDURE QUALIFICATIONS: ‘Whitten directions for the welder/welding operator making production welds describing all variables involved © ESSENTIAL VARIABLE Welding specification change affecting mechanical properties of the ‘weldment Requires specification requaiification + SUPPLEMENTARY ESSENTIAL VARIABLE Weld specteation change afecng roth toughness properties of the Requires specification requalification + NON-ESSENTIAL VARIABLE Welding specication venange NOT affecting he mechanical or notch Requaification NOT required providing WPS is amended Essential variable for one process may be non-essential for another or may not be required at all for a third process Non-essential variables can be changed without requaiification + Change MUST be documented by variable on either a new, or amended original, WPS: Tests to determine that the weld can provide the required (POR) properties for the intended application All variables of the WPS MUST be followed Base metal of the specimen can be‘in any form + Procedure qualification transferable between plate and pipe welding PQR components: = Allessential and supplementary essential variables used during test coupon welding MUST be recorded” + Anynon-essential or other variables can be recorded at 2 later date + Any vatiables recorded MUST be the actual variable --"> = ‘+ Variables not monitored MUST NOT be recorded + Ifmore than one pracess/filler metal is employed, RECORD the approximate deposit weld thickness of each COPYRIGHT 2098 IRC! SCHINDLER ANO CODEWEST - ALL RIGHTS RESERVED - D9 NOT COPY OR DISTRIBUTE 7COPYRIGHT 200 Multiple WPS's with One POR/Multiple PR's with one wes Qw-200 4 Qw-201 but all ‘Table Gw 282 - aw 265 - General QW-300 Qw-300.1 aw-300.2 Intent Qw-3011 esis, Qualification of Tests QW-301 2 REVIEW OF ASME IX - T. SCHINDLER IRert SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIGUTE ‘Changes! + NOT allowed except as an editorial or addenda + REQUIRES recertification Several WPS's may be prepared from data on one POR ‘One WPS may cover numerous essential variable changes providing a POR existe for all essential and supplementary essential variables Combination welding procedures (more than one process) are allowed; however [ALL variables and ranges for each process shall be applied and identified Note restriction on GMAW -SC are. : Manufacturers/Contrectors. responsibilty to conduct tests, document results, and ‘maintain records NOT permissible to sub-contract welding of coupons, bother work in preparing coupons and testing can be subcontracted \Vetiable Tables per process ARTICLE It WELDING PERFORMANCE QUALIFICATIONS , ‘Welder qualfication is lmited by the essential variabies given for each process Welderfwelding operator can be qualified by +. Radiography of test eounon + Radiography of intial production welding + Bend tests taken from test coupon Visual examination of al tests is required Manufacturericontractor MUST conduct tests to qualify weldersiwelding operators in accordance with a quslified WPS + This is to ensure thet weldersivelding operators can develop the minimum requirements specified for an acceptable weldment Determine the ability of the weldersiwelding operators to make sound welds Performance qualifi ‘WPS jon tests MUST be welded in accordance with qualifies Welder/Welding operator who prepares the WPS qualification test coupon is also qualified within the performance qualification range of the performance variables: COPYRIGHT 2000 Re) SCHINDLER ANO CODEWEST- ALL RIGHTS RESERVED -0O NOT COPY OR DISTRIBUTE 8REVIEW OF ASME IX -T. SCHINDLER COPYRIGHT 2000 ~IRGI. SCHINDLER AND CODEWEST ALL RIGHTS RESERVED - D0 NOT COPY OR OISTRIBUTE Identification of Mustbe assigned an individual identifying WeldersWeldng =” numb, Operators =o aWw.301 3 7 symbol ALL work must be identified in this manner Record of Tests. WP@ record MUST include: QWw-301 4 7 Essential variables 7 Type of test Test results Qualified range of welderiwelding operator Use form QW.-484 oF equivalent Welders Welders MUST pass the mechanical est prescribed in QW-302.1 w-304 + Exception: special requirements Welder making groove-welds using - sMAW + SAW + GTAW ; + PAW + GMAW (except short- 2° SA‘S37 CLASS 2 (MIN w t A tb ta 180009841448 116,000 wm Acceptable Ref QW- 183 (a) tb 1490 0997 1485 114.000 76720 PM Acceptable | Ref QW- 153 1a) 2a 1197 0.960 4137 91,200 80.000 WM Acceptable Ref QW- 153.12) 2 = 1.280 0981 1228 98.000 79,934 WM. Unacceptable Ref QW- 153.1(@) NOTE: Full set unacceptable because of 2b Reference QW-151 1(c) SPECIAL NOTE. The math is incorrect on ta The area is 1 476 which makes the PS! 78.590 which is unacceptable Reference QW-153 1 COPYRIGHT 2000 IRC! T SCHINOLER AND CODEWEST- ALL RIGHTS RESERVED -00 NOT COPY OR OISTHVBUTE 14REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 ~IRCIT. SCHINDLER AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE Qw-150 ‘TENSILE TEST “TURNED SPECIMENS” “0.505” IS Ay) EXAMPLE: Base Metal Tensile Strength = 75,000 NOTE: EACH PROCESS OR PROCEDURE SHALL. BE INCLUDED IN THE TENSION, BEND OR IMPACT TEST SPECIMEN. REF. QW-200.4(a) w t A LOAD Psi Loc. Results 1 ost1D 0.208 15570 75,950 BM 2 0s01D =—0.497 14,520 73,750 wi NOTE: Turned Specimens(QW-151.3) “REF. QW-462.1(d) Ref. QW-153.1(a) D = 0.6000 0.010 In. 2 COPYRIGHT 2000-~iRC)T SCHINDLER AND CODEWEST- ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE: 15REVIEW OF ASME IX - T. SCHINDLER “COPYRIGHT2000 IRGTT SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE WELDING DOCUMENTATION AND WELDING REQUIREMENTS Introduction ‘This session will deal with the welding documentation and welding requirements for fabrication to the ASME Boller and Pressure Vessel Code, Section Vill, Division 1. The reader should come away with an tnderstancing of what will be needed regarding welding documents and what parameters these: Gocuments must contain in order to prove qualification in accordance with ASME Section IX and Section vil tn al sections of the ASME Code the responsibly for construction and documentation is placed with he al fecturer or contractor This is true with welding documentation also. The ASME Code requires that rattan provedure be avaliable prior to construction and that the procedure contain directions for the anger and the supervisor to insure that a weld meeting the mechanical property requirements of the ASME Code are met inva welding procedure three distinct types of variables must be adcressed_ The first is en essential (rable, which is a variable that if changed wil cause a change in the mechanical properties of the waigment. Anytime an essential variable is changed outside of the range specified on the welding vrmceure spectieaton, the procedure must be requelfid by performing mechanical testing on & Weldment made with the new parameters “The second type of variable thet must be addressed on every welding procedure specification is called 2 ae onlial variable Changes in these variables can be made without requaliication of the welding procedure; however, the welding procedure must be revised to reflect these changes “The thir type of variable to be addressed on @ welding procedure specification is called a supplementary cecchtisl Conable These supplementary essential variables must be addressed on a welding procedure Specification only when impact propertios are required of the weldment. When impact propettics =r seScired then the supplementary essential variables become essential variables and the welding must be Sane within the specified range of these variables Any changes outside of the range specified on welding procedure specification must be requalified by mechanical ang impact testing “The purpose of this handout is not to instruct the API 510 Candidate in every welding process recognized trite ASME Boler and Pressure Vessel Code, What is attempted isa recap of those variables thet Ti Oa ae amen wring and qualifying a welding procedure for the shielded metal arc welding (SMAW) process Il. Preparing or Reviewing a Welding Procedure Specification (WPS) ie Coney to start wring or reviewing a welding procedure specication ts 10 refer to Acie 2 in ASME Ree reset his instance we wil refer specticall to paragraph QW-253 which oa table that specifes the essential, supplementary essential, and nonessential variables for the SMAW process “his table refers us to eight categories that must be addressed on a veking procedure specication The fret eatagorys welding ont, W402 From QW.253. there are no essential or supplementary essential variebles for joints However, there ore Fae noneccential variables and as previously stated all the variables specified for a particular process toe ee eaced on the welding procedure specification Taking the fist nonessential variable, the Xin Trenelume ncicates that we must refer to OW-402 1 QW-402 1 states that a change in the type of qrosve e.g nonessential variable This means that a change from a V groove to @ U groove, fs 6 chenge Sve a dati variable As previously stated, the welding procedure specification must be revised 1 Teor change, When wring or reviewing a welding procedure specification. there is @ chance Wet rec ah one joint dasign will be used in a weldment Therefore, the welding procedure specification cen Tioraly spect that types of joint design to be used willbe shown on drawing and not resin he Gocument to ary unique joint design COPYRIGHT 2000-IRCIT SCHINDLER AND CODEWEST- AL RIGHTS RESERVED -00 NOT GOPY OR DISTRIGUTE 16REVIEW OF ASME IX-T. SCHINDLER CoprrcitT 2000 - RCI. SCHMDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIGUTE ‘The next variable in the joints category, Is the deletion of backing. This is specified in QW-402 4. Again, a in the joint design, # restrictions are not needed on our production facilties, the WPS can simply Specify thatthe joint can be made with or without backing If the WPS states that the weld is to be made with backing, that is what must happen in production until the welding procedure is revised ‘The next variables in QW-253, are @ change in the root spacing and the addition or deletion of retainers. Because these are nonessential variables, a welding procedure specification should have as wide tolerances as possible for these categories Because the addition or deletion of retainers is @ nonessential variable for the shielded metal arc welding process, it must aiso be addressed If you are not {going to use retainers. you should state this on your welding procedure specification ‘The second category for variabies is base metal These variables are addressed in paragraph QW-403 In this category there are no nonessential variables, and all the variables that are jisted are either essential variables or supplementary essential variables ‘As stated earlier. supplementary essential variables apply only if impact properties are required of the weldment Supplementary essential variables have restrictions on the base material that can only be qualified with a single procedure qualification record. It also puts restrictions on the base metal thickness range that is qualified when qualifying a procedure quaification ‘The list of essential variables starts with the base material and weld metal thickness limitations when trying to qualify for thicknesses greater than 8 inches. The reader is advised that when impact properties are required the supplementary essential variables are additional to the essential variables “The next essential variable addresses whenever there is @ change in the base material thickness qualified Essentially it stipulates that the welding procedure depending on the thickness of the coupon Used in the procedure qualification is qualified fora range of base metal thicknesses, if base metal thickness gges beyond the range of qualification another test piate must be welded and tested to ascertain that the welding procedure develops the required mechanical properties in the new thickness range One essential variable that is often overlooked on welding procedure specifications is that a single pass of weld material that is more than 1 inch thick has @ range of qualification different from that when using weld passes of less then % inch thick This % inch limitation must be addressed somewhere on the welding procedure specification if you are not going to allow welding greater than % inch thickness in one pass, you must state this on your welding procedure specification. ‘The last two essential variables listed for the shielded metal arc welding process have to do with base. material P-numbers Qualifying for P1 material, does not quaiify for any other P-number material. If its desired to weld on other P-numbers, qualification tasts must be performed on materials listed in the P- numbers for which qualifications are sought QW 424 allows some alternatives to be used when qualifying on P-5, P-4. or P-3 materials ‘The third category of variables listed is for filer metals _In this categbry all three variable types are applicable The first two have to do with the chemistry and the types of electrodes used in the welding process The F number is 2 grouping of electrodes that have similar characteristics in the way that they produce mechanical properties and they have similar deposition characteristics The other property thal is, Gealt with as an essential variable is the A-number. This is @ chemical limitation in that electrodes that falt within a particular A-number category have similar chemical properties Changes in either of these variables wil require requaiification of the procedure ‘The diameter of the electrode is listed as a nonessential variable The welding procedure should list 2s many diameters of electrodes to be used 2s possible to preclude problems in production If the writer of the welding procedure lists just one diameter of electrode. before a different diameter of electrode may b= used in production, the weld procedure must be revised to include these new diameters, Two supplementary essential variables are listed under filer metals One refers to QW.404 7 and deals with large diameter electrodes. It states that if impact properties are required and the use of an electrode COPYRIGHT 2060 IRC! SCHNDLER AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 7REVIEW OF ASME IX -T. SCHINDLER. COPYRIGHT 2000 -IRCFT SCHINDLER ANO CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE diameter of greater than a quarter of an inch is necessary, the specific electrode diameter must be {qualified for impact values ‘The other supplementary essential variable fisted in QW404 12 is the AWS classification All filler metal specifications (SFA) presently recognized as standard filler metal by the ASME Code ae listed in ASME Section ll part G.This supplementary essential requires that a change in the electrode SFA number requires requalification of the welding procedure # impact values are required ‘QW 404 30 deals with deposited weld matal thickness (or DWM) This variable is sometimes overlooked, tut must be addressed. especially i restrictions are placed on the DWM, or if partial penetration welds are used “The next category for variables for the shielded metal arc welding process is position. There are three Yerlables listed and, withaut going into detail, the reader should know that when impact values are not required, the position of the weiding is a nonessential variable, meaning that a welding procedure can be {Qualified by running a test plate or pipe in any position and the procedure is then qualified to be used in all positions When impact values are required for the qualification of the welding procedure, position Beeomes an essential variable when changed from any position to the vertical uphill progression. Further, if you change from 2 stringer bead in the vertical uphill progression to @ weave bead, this would also require requalifcation for impact properties. ‘fifth category of variables for the shielded metal arc welding process is preheat. There is one essential Variable, one supplementary essential variable, and one nonessential variable listed in this table The weeentisl variable is that f a procedure is qualified at a given preheat value, the preheat may not be ‘Gecreased more than 100 degrees from that qualified without requalification of the procedure. The onessential variable for preheat has to do with the maintenance of the preheat temperature when post = dield heat treatment is required. The maintenance that is addressed in Section IX is the continuance of the preheat temperature after the completion of welding. The preheat temperature is going to be maintained after completion of welding for 2 period of time or iit willbe allowed to cool in air and not Tronitored after the completion of welding. The supplemental essential variable mentioned in this category Cf variables deals with interpass temperature and not with preheat temperature ‘When a welding procedure requires impact testing, the interpass temperature must be monitored and mnustbe maintained below a maximum value. The supplemental essential variable for interpass: temperature states that ifthe interpass temperature is increased by more than 100 degrees over that qualified, the procedure must be requalified “The next category of variables is postweld heat treatment. The first variable listed is a change in postweld heat treatment and this is classified as an essential variable itis not always necessary to postweld heat treat P-1 material The construction or repair code will dictate when this is necessary However, the Code does specify that a change in the postweld heat treatment is ‘on essential variable and therefore must be addressed on the welding procedure The PWHT treatment ca iabies must be watched closely, as upper/lower critical temperatures on each material may differ. and this may have a bearing on what can be done in production To state that postweld heat treatment is not applicable is not correct_If there is to be no postweld heat treatment then the welding procedure specification should state "No Postweld Heat Treatment” or “None” of somehow indicate that no postweld heat treatment will be performed “The next variable listed for postweld heat treatment deals with a change in the time and temperature range for the postweld heat treatment Whenever the time at temperature or the temperature range itself is changed, (outside of the renge initially writen and qualified) the procedure must be requalfied whenever impact properties are required ‘The last variable has to do with the thickness of the base metal qualified The variable is stated in QW- 407 4 and requires that whenever the upper transformation temperature for the alloy is exceeded. the fraxirum thickness that is quatified with that post-weld heat treatment is 1 1 times the thickness of the COPYRIGHT 2000 RCI SCHINDLER AND CODEWEST- ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 18REVIEW OF ASME IX - T. SCHINDLER COPYRIGHT 2000 ~!RCIT SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE test coupon. This is a restriction over the normal 2 X base metal thickness that can be qualified # the upper transformation temperature has not been exceeded, ‘The next variable category in QW-253 is electrical characteristics Both variables listed in this category deel with current and votage The first variable listed is @ change in the current or an Increase in the heat input and this classified as a nonessential variable, which can have an effect on impact values. ‘When qualifying a welding procedure with impact values the amount of heat input due to the welding process must be controlled This variabie stated in QW-409 1 requires that when the type of currant or the polarity of the current are changed, if the heat input is increased, or if the volume of weld metal deposited per unit length of weld is increased, the procedure must be requalified for impact values 2 ‘The other variable isted in electrical characteristics is a change in the type of current or a change in the current and voltage range. This is a nonessential variable. Referring to QW-409.8, if the type of current or polarity is changed or the range of amperage is outside the range inially listed on the welding procedure specification, then the welding procedure must be revised to indicate this new range of weiding Parameters. Voltage for shielded metal arc welding is not a variable, and therefore its not necessary to fiat the voltage range on a SMAW weld procedure specification. Usually the electrode manufacturer's recommendation for amperage is adequate and many manufacturers use this range on their welding procedure specification ‘The last category of variables for the shielded metal arc welding process is titled “technique”. Such things as string or weave bead, the method of cleaning, whether manual or automatic welding. pening, and the method of back gouging a joint must be addressed on the welding procedure specification Since these ‘re nonessential variables, a change may be made without requalification of the procedure. However, the Code is very specific in requiring that they must be addressed on the welding procedure specification. ill Preparation/Review of a Procedure Qualification Record (PQR) ‘The next document that the ASME Code requires for welding is the procedure qualification record (POR). ‘The purpose of this document is to record the essential variables used during the welding of a test coupon. and to record the values of the mechanical properties obtained when testing the welded coupon foend fests, tensile tests, notch toughness tests, oF filet weld tests, as applicable) The ASME recommended form (QW-483), has spaces to list all essential , nonessential, and supplementary essential variables for the various recognized welding processes ‘The only information reauired to be on the POR is the listing of the values for the essential and supplementary essential variables used while welding the test plate and the mechenical values obtained when doing the testing on the test coupons. Ifthe manufacturer or contractor voluntary wishes to list the fonessental variables on this form, the values that are to be listed are those that were actually used or Obtained during the welding of the test coupon For example, the same range of amperage that is Specified on the welding procedure should not be listed on the procedure qualification record, unless that entire range was used during the welding of the test coupon ‘When qualifying welding procedures, two of the primary areas are the base material thickness qualified and the deposited weld metal thickness qualified. The ASME Code allows a range of thickness ‘Qualification when welding a specific thickness of base material for the procedure qualification As en ‘example, when the test coupon is made from a 74" thick plate, the welding procedure is qualified to be Used on a range of base metal thicknesses from 3/16 inch to 1 inch. When qualifying welding procedures the manufacturer or contractor should ensure that the thickness of the test coupon will qualify the weiding procedure over the range of base metal thicknesses that will be needed in production ‘When using a combination of welding processes or a combination of filer materials, each filler or process ‘will have a range of qualification. The thickness deposited by the different processes or the thicknesses ‘COPYRIGHT 2000 RC) T. SCHINDLER AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE, 19REVIEW OF ASME IX T. SCHINDLER Ccopvmigir 2000 -Incrt, SCHINDLER AND GODEWEST- AL RIGHTS RESERVED - D0 NOT COPY OR DISTRIBUTE deposited by different filer metals must be measured when welding the test coupon for procedure qualification These thicknesses then must be documented on the procedure quaification record. These Values will determine the welding procedure range of qualification. As an example, if a manufacturer were to use gas metal arc welding to run the first 1/4" of weld in a 7 inch thick plate, and then use shielded metal are welding to finish the weld, each process would be qualified to deposit % inch of metal and the procedure would be qualified to weld on base metal up to 1 inch thick. Neither of the welding processes is, ‘Qualified to weld a 1 inch thick deposit in a 1 inch thick plate, but together they can be used to weld a 1 inch thick plate ‘The physical testing criteria should be closely reviewed The number, type and results of the tests should be compared with the applicable acceptance criteria in Articie 1 and the requirements of Article 4 for the test involved All PQR’s must be certified (by signature) by the Manufacturer or Contractor 1V Preparation/Review of a Welders Performance Qualification (WPQ) The last document to be discussed will be the welder performance qualification record The purpose of this document isto lst the actual values used by the welder when welding a test coupon and also to list the thickness ranges for which the welder is qualified Using the table in paragraph QW-353 of Section IX, the essential variables for welder qualifications, are variables that affect welder’s ability or skill and whenever any one of these variables is changed the welder must be requalified The first essential variable in this table has to do with joints and states that if a welder is qualified to weld with backing and that backing is deleted, the welder must requalify to perform an open butt joint. Variables regarding base metal that affect welder qualifications are pipe diameter and a change in the P number material Paragraph GW-423 allows @ range of P-number qualifications by welding on one P-number for welder Gualification, only. As can be seen, it requires a very drastic change in base material before a welder has to requalify due to this essential variable ‘Three variables are listed for filer metal. The first variable regards nickel electrodes (F41. F42, F43, ete} and states that a qualification with any nickel electrode qualifies for all nickel electrodes The second Nariable deals with all other electrodes and fimits the range of qualifications for the various F-numbers ‘The most commonly used range is when a welder quaifies with an F4 electrode He is then qualified to weld with F3. F2, and Ft electrodes with backing, only Any electrodes used above an F4 only qualify for the F number, and F1, F2. and F3 do not qualify.up for F4 deposits. See QW-433 Table “The last essential variable for filer metals is the thickness of the weld deposit and this chart refers to the variable QW-404 3 which limits the welder to the range of thickness qualifications as shown in QW-452 ‘The last category of variables for welder qualification is position ‘The manufacturer or contractor should ‘watch this variable closely As an example. if a welder takes a qualifying test in the horizontal position he js also qualified to weld in the flat position There are several other combinations that can be oblained the proper position for qualification is selected Table QW 461 9 is, often overlooked and misunderstood, sn this context ‘The last variable mentioned in QW-353 is @ change from vertical up to vertical down welding, and refers to paragraphs QW-405 3 ‘As previously stated. whenever any one of these variables is changed outside the range of qualification. the welder must requalify for the new range_ Its the responsibilty of the manufacturer or contractor to insure that welders are qualified for the production welds made This has been a brief review of the three welding documents that are required by the ASME Boiler and Pressure Vessel Code The reader is advised to thoroughly research the requirements of Section IX before undertaking the process of writing or reviewing a welding procedure The reader is further advised that many of the construction codes (Section |, IV. Vill, ll, B3ta) can further restrict welding requirements ‘Many companies are in compliance with the requirements of Section 1X, but net using a welding procedure that is in compliance to the Construction Code Sections of ASME, or other repairlatteration codes. Ccopricitt 2000 IRC! T.SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 20REVIEW OF ASME IX - T, SCHINDLER (COPYRIGHT 2000 IRCIT SCHINDLER AND CODEWEST -ALL RIGHTS RESERVED -DONOT COPY OR DISTRISLTE COPYRIGHT 2000 4RCIT. SCHINDLER AND CODEWEST. ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE aoF ee i ENT NOL ann API AUTHORIZED INSPECTOR PREPARATION COURSE FOR CERTIFICATION EXAMINATION 2000 INNOVATIVE RESEARCH CONSULTANTS. . SCHINDLER & ASSOCIATES: AND CODEWEST AUTHORED BY: 7. SCHINDLER COPYRIGHT 2000 -IRC/T. SCRNDLER, JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1REVIEW OF ASME SECTION V NDE REQUIREMENTS? ¥, Sci comrntnt a0 mal soanbiee aw OEY AND CODES -ALLNDNTE RECEIVED eh Soe on ISTRBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW GENERAL REQUIREMENTS FOR NDE OBJECTIVE: _ FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT GENERAL REQUIREMENTS FOR NDE. REFERENCE: ASME SECTION V, ARTICLE 1 7-410 SCOPE A) General requirements for NDE when referenced by other Codes. B) General NDE terims are defined in the Mandatory Appendix and SE-1316 7-420 GENERAL ‘A) Subsection A describes methods of NDE to be used B) Subsection B lists NDE Standards - Standards are Mandatory when referenced by Subsection A C) Reference to a paragraph in Subsection A or referencing Code includes all applicable rules in the paragraph ) Standards in Subsection B are mandatory only to the extent specified when referenced 7-430 EQUIPMENT ‘The manufacturer, installer, of fabricator is responsible for equipment compliance 7-440 REQUIREMENTS. |A) NDE Personnel shal! be qualified per the referencing Code section ; nat aw 22! re ey B) When Article 1 is referenced personnel shall be qualified per: eee ~ ASNT SNT-TC-1A oF - an alternate system accepted by the referencing Code section C) When no personnel qualification standard is referenced qualification may be by demonstration in 7 routine operations of competency in accordance with Manufacturer's procedures: by 1) Limited certification of NDE personnel who perform only one operation of an NDE method or perform within e limited scope may be based on less hours than specified in SNT-TC-1A euch conditions shall be described in the Written Practice and noted on any certfication: 7-150 PROCEDURE {k) Special conditions such as part geometry or materials may requite special procedures usec = If requited they shall: oe “he equivalent or superior to the methods and techniques described in Section V z = produce interpretable examination results Pree ~ be capable of detecting discontinuities oye be submitted 0 the inspector for approval , 8B) The manufacturer, fabricator or installer is responsible for establishing: = examination procedures 7 a - personnel cerlfication procedures COPYRIGHT 2000 -IRC/T SCHINDLER. JW COLEY AND CODEWEST ALL. RIGHTS RESERVED -DO NOT COPY OR O:STRIBUTE 2 cn me BEEREVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000-—IR67T SCHINDLER.JW COLEY AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTREUTE 6) All NDZ performed shali o& done in accoraance with a written procedure = demonstrated to the satisfaction of the Inspector, L in compliance with the applicable Article of Section V - Made available to the Inspector on request - available to the NDE personnel perfuming the examinations. T-460 CALIBRATION |A) The manufacture, installed or fabricator shall assure that all required calibrations are performed 8) The manufacturer, installed or fabricator shall specify what calibrations are needed when using special procedures; if required T-170 EXAMINATIONS AND INSPECTIONS ‘A) The Inspactor is responsible for: - verifying that all examinations meet all requirements of Section V and referencing Code “witness any examinations to the extent stated in the referencing Code © Hus Jn tev y - Inspector means the Authorized Inspector as defined in the referencing Code 8) Inspection: : L ~ Refers to the functions of the Authorized Inspector“ “ME og ~ Examination = Refers to the functions of the NDE personnel iya- 9 “= 3 Shen = There are some minor conflicts in these definitions in the ASTM documents 7-180 EVALUATION Acceptance standars are as stated in the referencing Code 7-190 RECORDSIDOCUMENTATION - Records shall be in compliance with = The referencing Code and + Section V ~The manufacturer, installed or fabricator shall be responsible for all records and documentation CCOPyRIGHT2000~IRG/T SCHINDLER. JW GOLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT COPY OR DISTRIBUTE 3REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000~ RET SCHINDLER. JW COLEY AND CODEWEST ALL RIGNTS RESERVED - DO NOT COPY OR OSTRISUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW OF RADIOGRAPHIC EXAMINATION METHOD OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH THE REQUIREMENTS FOR RADIOGRAPHY. REFERENCE: ASME SECTION V, ARTICLE 2- RADIOGRAPHIC EXAMINATION T-210-SCOPE When this Article is specified by the referencing Code Section, he radiographic method described in this Article shal be used together with Article 1, General Requirements. Definitions Definitions of terms used in Article 2 are found in Mandatory Appendix V, Standerd Definition of Terms and SE-1316. Some important definitions are: “Defect ~ a flaw (imperfection or unintentional discontinuity) of such size. shape, orientation, location, or properties as to be rejectable -Discontinuity a lack of continuity or cohesion; an interruption in the normal physical structure of ‘material or a product. Evaluation of indications — The process of deciding the severity of the condition after the indication ‘has been interpreted Evaluation leads to the decision as to whether the part must be rejected salvaged, or may be accepted for use -Flaw — an imperfection or unintentional discontinuity which is detectable by NDE imperfection — a condition of being imperfect; a departure of a quality characteristic from its intended condition. indication — the response or evidence from the application of a NDE. limited certification — Limited certification within a given method or technique is defined 2s ‘accreditation of an individual's qualification to perform a limited scope of work -Method — A method is the utilization of a physical principle in nondestructive examination (NDE). “Procedure — In NDE a procedure is an orderly sequence of rules that describes how @ specific technique will be applied “Source side — that surface of an ares of interest being radiographed for evaluation nearest the ‘source of radiation “Technique — A technique is a specific way of utilizing a particular NDE method Each technique is identified by et least one important variable from another technique within the method ( Example RT -- method — X-Ray/Gamma Ray Techniques) COPYRIGHT 2000 - REIT SCHINDLER. JW COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT GOPY OR DISTRIBUTE 4REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER (COPYRIGHT 2090 —IRG/T. SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR OISTRIBUTE 1-220 GENERAL REQUIREMENTS: 1-221 Procedure Requi ments 7-221 1 Compliance Without a Writen Radiographic Procedure. When Article 2 is required by the ‘eferencing Code Section, the density and penetremeter image requirements of this Aticls on production or technique radiographs shall bé consideréd a satisfactory demonstration of compliance 7-221 2 Requirements and Compliance for @ Written Radiographic Procedure Minimum Contents of a Written Procedure: -malerial & thickness range: isotope used gr maximum X-ray voltage minitnum source-to-fim distance smaximum source size Parc! 1 arson Demonstration of the density and penetrameter image requirements of the written procedure on production or technique radiographs shall be considered satisfactory evidence of compliance with that procedure 7-222 Surface Preparation ye hid precsaze $2204 Mater — 3PM ‘Surfaces shall satisfy the requirements of the applicable materials specification. Additional ccrsiipang ray be required (ginang, ete), necescary by ary sufable process toa degiae {fat sutacs rreguarics cannat manor be confused wih surface dlconinutes| 1-222.2 Welds \Weld ripples or weld surface irregularities on both the inside and outside shall be removed by any suitable process to such a dagree that the resulting radiographic image due to any irregularities cannot mask or be confused with the image of any discontinuity 7-222 3 Surface Finish ‘The finished surface of all butt-welded joints may be flush with the base material or may be reasonably uniform crowns, with reinforcement not to exceed that specified in the referenced Code Section ( API 650 and/or API 652 in the case of Tanks) 7-223 Backscatter Radiation 9 +" Alead symbol “B" with minimum dimensions of 1/2" in height and 1/16" in thickness, shall be attached to the back of each film holder during each exposure to determine if beckscatter radiation is exposing the film 1-224 System of identification Permanent identification system shall be established to trace radiograph to the contract. component. weld or weld seam, or part numbers, as appropriate In addition: - Manufacture''s symbol or name and the date of the radiograph shall be plainly and permanently included on the radiograph =| D system doas not require that the information appear as radiographic image See ne « the information shall not obscure the area of interest 1-225 Mo ing Density Limitations of Radiographs Either a densitometer or step wedge comparison film shall be used for judging fim density COPYRIGHT 2800 —IRCIT. SCHINDLER. W COLEY AND GODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 5REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER Ccopynici 2000 -IRG/T SCHINDLER, W. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OF DISTRIBUTE 7-230 EQUIPMENT AND MATERIALS. 7-234 Film Radiographs shall be made using industrial radiographic film ‘7-232 Intensifying Screens May be used except when restricted by the referencing Code Section 7-233 image Quality Indicator (IQ!) Design - Penetrameters shall be either hole type or wire type = Manufactured and identified in accordance with: ‘SE-1025 (for hole type) ‘SE-747 (for wire type) - ASME standard penetrameters shall consist of those in: ‘Table T-233 1 for hole type (See table in Section V) ‘Table 233.2 for wire type (See table in Section V) * 7-234 Facilities for Viewing Radiographs - Viewing Facilites shall provide subdued background of an intensity that will not cause troublesome reflections, shadows, or glow on the radiograph. Equipment used for viewing shall provide a variable light source: sufficient for essential ‘penetrameter hole or designated wire to be visible for the specified density range - Viewing conditions shail be such that light from around the outer edge of the radiograph or ‘Coming through low-density portions of the radiograph does not interfere with interpretation 7-260 CALIBRATION 7-281 Source Size . ce 7-261 1 Verification of Source Size ~foliow manufacturer's or supplier's publications, technical manuals, or written statements documenting the actual or maximum source size or focal spots 7-261 2 Determination of Source Size ~ X-ray 320 kV or less, use pinhole method = For IR-192., determine by ASTM E 1114-85 ‘T- 262 Step Wedge Film & Densitometer - density of step wedge comparison films and densitometer calibration shall be verified by comparison with a calibrated step wedge film traceabie to a national standard - densitometers shall be calibrated in accordance with Paragraph 6 of SE-1078 COPYRIGHT2000 = IREIT SCHINDLER JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY Of DISTRIBUTE 6REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER see CoPyRoHT2009-REMY SOHNDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED-DONOTCOPYOR DISTRIBUTE =. ‘7-270 EXAMINATION 22%: T-271 Radiographic Téchnique ~ 7-271.1 Single-Wall Technique -Use whenever practical -Radiation passes throtigh only one wall of the weld (mater Adequate number of exposures shall be made to demonst 1-271.2 Double-Wall Technique -Use when a single-wall technique is not practical > -Radiation passes through two walls of the weld (material) ‘Adequate number of exposures shall be made to demonstrate required coverage |) Single-Wall Viewing vie Double-Wall Technique F welds in components viewed for acceptance on the radiograph. rage (s required for circumferential welds, a minimum of 3 exposures. 8 is eachother shall be made" "* Face nt ») Double-Wall Viewing via Double-Wall Technique for materiale and for welds in components 3.5-inches or less in nominal OD. the radiation passes through two walls/weld in both walls is viewed for acceptance 2 only a source side penetrameter shall be used «If the geometric unsharpness requirement cannot be met use single-wail viewing _, 3 1-272 Selection of Radiation Energy 7-272. X-Ratiation - Must show proper 1GI image He -272.2 Gamma Radiation WES From a radicactive isotope for thickness as follows: 8 Recommended Minimum Thickness. Material tridium Cobalt Steel O75" 1s Copper or High Nickel oss" ww ‘Aluminum, 25" Note: Overall radiographic sensitivity is primarily influenced by factors such as: im selection ~intensifying screen selection “geometric unsharpness -film density -maximum thickness for use of radioactive isotopes is primerily dictated by exposure time upper limits are not shown -minimum recommended thickness limitation may be reduced when the radiographic technique demonstrates the required radiographic sensitivity 1-272 Special Conditions -When no! practical to perform radiography with the limitations previously noted “the procedure shall be proven satisfactory by actual demonstration of penetrameter -on the minimum thickness of the material radiographed 17-278 Direction of Radiation : centered on the area of interest whenever practical, ‘COPYRIGHT 2000 - IRC. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOTCOPY OR DISTRIBUTEREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copyniGi stnd= MEN SOmnosER JW EOLEY AND CODEWEST Alt RIGHTS RESERVED DO NOT COPY OR DSTIEUTE ‘J-274 Geometric Unsharpness -'") ~-) ~ Geometric unsharpness ofthe radiograph shall be determined in accordance with Ug = FD where: Ug = geometric unsharpness. F” = Source size, the maximum projected dimension ofthe radiating source (or effective focal spot) in the plane perpendicular to the distance D from the weld or object being radiographed, inches D = distance ftom source of radiation to weld or object being radiographed, inches = distance ftom source side of weld &r object being radiographed, inches iu 1-276 Location Markers (See Fig 7-275) + tha film See vo appear as radiographic images on the fim 1 Shal'be placéd on the part not on the exposure holder / cassette —— «Rak tocations are to be pemenently marked on surface of part being raiographed e «Gr on 2 map in'a manner permiting the area of interest to be accurately traceable a ~ Poeduons thal be availabe for the required retention period ofthe raciograph =) ~ EXidonce provided onthe rediograph that the required coverage has been obtained yy, 7-275.1 Single-Wall Viewing A) Source Side Markers: 7 ‘Location markers shall be piaced on the source side when radiogrephing the following: sflat components or iongitudinal joints in cylindrical or conical components “curved or spherical components whose concave side is tower the source ‘and the "source-to-materia” distance is less than the inside radius ofthe component -curved or spherical components whose convex side is toward the source B) Film Side Markers: Location markers shall be placed on the film side when: “radiographing either curved or spherical components/concave side toward the source and the “source-to-material" distance is greater than the inside redius ‘As an alternative to source side placement, location markers may be placed on the film side when the radiograph shows coverage beyond the location markers to the extent demonstrated in Fig T- 275 (2) and is documented in the radiographic report ) Either Side Markers: Location markers may be placed on either the source side or fm side when: Fadiagraphing either curved or spherical componentsiconcave side is toward the source and the ‘"gouree-to-material” distance equals the inside radius of the component 7-278.2 Double-Wall Viewing: - For double wall viewing, at least one location marker shall be placed on the source side surface adjacent to the weld for each radiograph 1-275 3 Mapping the Placement of Location Markers: When inaccessibility or other limitations prevent the placement of markers as stipulated in "Single Wall Viewing” and "Double-Wail Viewing”, a dimensioned map of the actual marker placement shall accompany the radiographs to show that full coverage has been obtained COPYRIGHT 2000 INGFT SCHINDLER JW COLEY AN CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR O1STRIBUTE 8REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER (COPYRIGHT 2060~IRCIT. SCHINDLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-276 101 Selection * er 7-278 1 Q's shail Be of similar alloy gfotips as shown in SE-1025 or an alloy of lower radiation absorption than the material being rediographed . T-276.2 The designated hole penetrameter when essential hole or designated wire diameter shall be ‘ ‘as specified in ASME Code, Saction V, Articie 2, Table 275 (See table in Section V) ~a smaller hole in a thicker penetrameter oF alarger hole in a thinner penetrameter ‘may be substituted for eny section thickness listed in Table 276 provided equivalent penetrameter sensitivity is maintained and all other requirements for radiography are met, Approximate e-quivalence between hole and wire penetrameters is shown in ASME Code, Section V, B-220 of Aricle2 Nonmandstory Appencix B. and may be uscd ts det ‘valence between hole < penetrameters 8... i ; i A) Welds With Reinforcements ‘Thickness of penstrameter based = nominal single wall thickness + the estimated weld reinforcement lap ond. ) = Backing rings or strips are not considered as part ofthe thickness, 4 eo. Actual measurement of the weld reinforcement is not required. Ke! r B) Welds Without Reinforcement ‘Thickness of penetrameter based on: ‘ ~ nominal single wall thickness - Backing rings or strips are not considered as part ofthe thickness T-277 Use of IQ! (Penetrameters) to Monitor Radiographic Examination ‘7-277.4 PLACEMENT OF PENETRAMETERS A) Source Side Penetrameters - Place on the source side except for the condition described under T-277. 1(b). - Place on a separate biock when size of configuration prevents placing on the part or weld: = Blocks shall be made of the same or radiographically similar materials = No restriction on the separate block thickness provided the panetrameter / area-of-inferest density tolerance requirements of Paragraph T-282.2 are met 8) Film Side Penetrameters Where inaccessibilty prevents hand placing the penetrameter(s) on the source side, the penetrameter(s) shall be placed: on the film side in contact with the part separate block or “shim” placed as close to part as possible ~ block shall be larger than the penetrameter/3 sides of penetrameter must be visible on film lead letter “F* placed next to or on the penetrameter =F" may not mask the essential hole in the penetrameter ©) Penetrameter Location for Welds — Hole Penetrameters -Place penetrameter(s) adjacent to or on the weld. = 1D numbers, lead letter "F", shall not be in the area of interest except as in (1) and (2) 1) configuration makes it impractical to place the penetrameters as outlined above 2) when weld metal is not radiographically similar to the base material ( See SE-142) (COPYRIGHT 2000 -IRCVT. SCHINDLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 8 ee EC posronselREVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CCopreiGHT 2000 IRG/T SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE D) Penetrameter Location for Welds ~ Wire Penetrameters on the wala $0 mat ine engin of wifes 1s pempendicuiar is the length af the weld ID numbers. lead letter “F", shall not be in the area of interest except as in (1) and (2) 1) configuration makes it impractical to place the penetrameters as outlined above 2) when weld metal is not radiographically similar to the base material ( See SE-142) E) Penetrameter Location for Materials other than Welds -The penetrameter(s) with the penetrameter ID number(s), and, lead letter "F”, may be placed in the area of interest -277.2 Number Of Penetrameters - For components where one or more fm holders are used, at least one penetrameter image ‘shall appear on each radiograph except as outlined in "Special Cases” ‘A) Multiple Penetrameters = One shall be representative of the lightest area of interest and the other the darkest area of interest; intervening densities on the radiograph shall be considered as having acceptable density B) Special Cases 41) Cylindrical vessels where source is placed on axis of the object and one or more film holders used for single exposure of a complete circumference Three penetrameters shall be spaced approximately 120 degrees apart. ‘Where sections of longitudinal welds agjoin circumferential welds and are radiographed simultaneously with circumferential weld, an additional penetrameter shall be placed on each longitudinal weld at the end of each section most remote from the junction with the circumferential weld being radiographed 2) Cylindrical vessels where source is placed on the axis ofthe object and four or more film holders are used for single exposure of a section ofthe circumference: - Atleast three penetrameters shall be used One stall be in the approximate center ofthe section exposed and one at each end = ifthe section exceeds 240 degrees, the ruie for cyindrical vessels eppiies and additional fim locations may be required to obtain necessary penetremeter spacing otherwise atleast one penetrameter shall appear on each film 3) Spherical vessels where source is located at the center of the vessel and one or more film holders used for single exposure of a complete circumference: - Three penetrameters shall be spaced approximately 120 degrees apart = One additional penetcameter shall be placed on each other weld 4) Segments of spherical vessels where source is located at the center of the vessel and four or more film holders are used for single exposure of a section of the circumference: - At leas! three penetrameters shall be used = One penetrameter shall be in the approximate center and one at each end = When the portion exceeds 240 degrees, the rule for spherical vessels applies and additional film locations may be required to obtain necessary penetramet otherwise at least one penetrameter shall appear on each fim r spacing: 5) When an array of objects in a circle is radiographed, at least one penetrameter shall show on each object image COPYRIGHT 2000 -IRC"T SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT GOPY OK OISTRIBUTE 10REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER : CoPYRIGHT 200 = C/T. SCHINDLER. COLEY AND CODEWEST-ALL FIGHTS RESERVED -D NOT COPY OR DISTRIBUTE 6) In order to maintain the continuity of records involving subsequent exposures. all radiographs ‘xhbling penelrameters which qualfy the techniques permtied above must be retained ices esuetay 7-277.3 Shims Under Hole Penetramoters ; : ; ~ material radiographically similar to the weld metal penetrameter if needed " © - the radiographic density throughout the area of interest shall be no more than minus 15% from (lighter than) the radiographic derisity through the penetra : - the Shim dimensions shall exceed the penetrartieter dimensions such that the outine of at least three sides of the penetrameter image shall be visible in the radiograph hall be placed between the part and the Soles 2 7-280 EVALUATION 7-281 Quality of Radiographs ‘Al radiographs must be free froin mechanical, cherticl, or other blemishes to the extent that they do not mask and are not confused with the imagé of any discontinuity in the area of interest of the object Being radiographed Such blemishes include, but are.net limited to: - Sogait a et “processing defects such as streaks, watermarks, or chemical stains Eeratches, finger marks, crimps, dtness, static marks, smudges, oF tears € “false Indications due to defective screens 17-282 Radiographic Density 71-282. 1 Density Limitations. The transmitted film density through the radiographic image of the body of the appropriate hole penetrameter or adjacent to the designated wire of a wire penetrameter and the area of interest shall be: 2 AL& minimum for single fim viewing for radiographs made with an X-ray source 72'0 minimum for radiographs made with a gamma ray source [For composite viewing of multiple fim exposures, each film of the composite set shall have a minimum density of 1.3 - The maximum density shall be 40 for either single or composite viewing {A tolerance of 0.05 in density is allowed for variations between densitometer readings -282.2 Density Variation |A) If the density of the radiograph anywhere through the area of interest varies by more than minus "15% of plus 30% from the densiy through the body of the hole penetrameter of adjacent to the designated wire of the wire panetiameter, within the minimum / maximum allowable density ranges specified in T-262.1: ‘afGedtional penetrameter shall be used for each exceptional area and the radiograph reteken “ihn calculating the alowable variation in density, the calculation may be rounded to the nearest (01 within the range specified in T-282 4 'B) when shims are used the plus 30% density restriction of (a) above may be exceeded: ~ provided the required penetrameter sensitivity is displayed and the density limitations of | T- 282.1 are not exceeded ” “COPYRIGHT 2000 ~ IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE onREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDL Ccorruc 20007 REVT. SCHINDLER, JW. GOLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT Gr ‘OR DISTRIBUTE. F-28310! Sensitivity Radiography shatt be performed with 2 technique of sufficient sensitivity to display -the hole penetremeter image and the specified hole “of the designated wire of a wire penetrameter = the radiographs shall play the ID numbers and letters Tine lets noe penelrameter mage and specTied hole, or designated wiro, do not show on any fim in multiple fim technique, but do show in composite fm viewing, interpretation shall be permited only by composite fim viewing i 1-284 Excessive Backscatter (Show ge Date bilfe. = Hfalight image of the "B" appears on a derker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable ~ A dark image of the "B" on a lighter background ie not cause for rejection. 7-285 Geometric Unsharpness Limitations Shall not exceed: Material ug B “Thickness in inches Maximum in inches Under 2" 0.020" — 2a» 2 through 3” : 0.030" Over 3" through 4” 0.040 Groaterthan 4” ss 0.070 NOTE: Material thickness is the thickness on which the penetrameter is based 7-286 EVALUATION BY MANUFACTURER This paragraph was added in the 1998 Addends to clearly refiect that frm review consists of two separate and distinct elements — 1.) A Technique Review — 2) Evaluation and Interpretations ofthe indications present on the film ‘The review form documenting the acceptability of the technique must be completed prior to the evaluation on the film Both sheets must be completed and accepted prior to submittal to the Inspector 7-290 DOCUMENTATION 7-291 Radiographic Technique Details. Details of the radiographic examination technique used shall be documented. As @ minimum the information shail inciude. identification. eg job or heat number “data specified in T-275 3 when applicable (dimensioned or ID marker map) = number of exposures or radiographs ~ isotope or maximum X-ray voltage used + effective focal spot size or physical source size “material type and thickness, weld thickness, weld reinforcement thickness minimum object-to-fim distances film designation and manufacturer COPYRIGHT 2000 INIT SCHINDLER. JW. COLEY AND CODEWEST- ALL FIGHTS RESERVED -D0 NOT COPY OF DISTRIBUTE 12REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000- ROT. SCHINDLER, J W.COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE : - nufnber of films per cassette fs ~ single- or double-wail éxposuré i single: or double viewing. 7-282 Radiographic Review Form # ‘Manufacturer shall prepare a radiographic review form. This form must contain at least: a) Alisting of each film location. b) The information in T-291 or by reference. ¢) Evaluation and disposition of each weld or material d) Name of the Mfg's representative that accepted the film. ge e) Date - Be atiched ele spel daa jeeh on te Ty ec eaters alec Sk Peipy at 1 # baat. Chad ty Lorre or doe bon, Lp at 4 Sree COPYRIGHT 2000 IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -D0 NOT COPY OF DISTRIBUTE. 3REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER oPrnicus i900 Rar SCHINDLER. JW EOLEY AND COOEWEST ALLRIGHTS RESERVED -DO NOT COPY OR DISTRISUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR ULTRASONIC EXAMINATION OBJECTIVE: _FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR ULTRASONIC EXAMINATION, REFERENCE: ASME SECTION V, ARTICLE 5 J-810-SCOPE “This Article describes or references requirements which are to be used in selecting and developing ultrasonic examination procedures when examination to any part of this Article is a requirement of a referencing Code Section ‘The referencing Code Section shall be consulted for specific requirements for the following: = Personnel Qualification / Certification Requirements, = Procedure Requireinents/techniques = Examination System Characteristics = Retention and Control of Calipration Blocks ~ Acceptance Standards to Be Used for Evaluation - Extent and Retention of Records = Report Requirements ~ Extent of Examination and/or Volume to be Scanned 7-820 GENERAL REQUIREMENTS 7-521 BASIC REQUIREMENTS AND TERMS USED - Use with requirements of Article 1 = Definitions of terms used are in: =a) Mandatery Appendix Il which will send you to: b) SE-1316 (now @ general section on definitions as of the 1994 addenda) - The SA. SB & SE documents referenced are in Article 23. ‘Some commen definitions are given below: ‘A-scan ~ a method of data presentation utilizing a horizontal base line that indicates distance, or time, and a vertical deflection from the base fine which indicates amplitude back reflection — indication of the echo from the far boundary of the material under test ‘contact inspection — the method in which the search unit makes direct contact with the material, with a minimum couplant fn couplant --a substance used between the search unit and test surface to permit or improve transmission of ultrasonic energy. crystal — a piezoelectric element in a probe or search unit duel search unit {twin probes) -— 2 prabe or search unit containing two elements. one a transmitter the other a receiver (T-R. S-E) echo — indication of reflected energy initia! pulse --- the response of the ultrasonic system display to the transmitter pulse (sometimes called the “main bang” ) interface —- the boundary between two materials 2 oss of back reflection — an absence or significant reduction in the amplitude of the indication from tne back surface of the part under examination multiple back reflections —- successive refiections from the back surface of the material under examination normal incidence (straight beam)—- @ condition in which the axis of the ultrasonic beam is perpendicular to the entry surface of the part under examination COPYRIGHT 2000 IRCIT SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGNTS RESERVED .00 NOT GOPY OR GISTRISUTE 14REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER 2 ‘coprruGit 2000= RGM. SCHINDLER, JM. COLEY AND CODEWEST-ALL RIGHTS RESERVED -DO NOT COPY Of DISTIUBUTE pulse echo method — an inspection method in which the presence and the position of a reflector are indicated by the echo amplitude and time. reference block — a block used to establish a measurdifieht Scale, and a means of producing 4 * ' reflection of known characteristics. i PEEeEEEEet ~ >seanning — the relative movement of the search unit ovér.a test piece. iz searéh unit — a device incorporating one or more transducers. straight beam — a vibrating puise wave train traveling normal tothe test surface. BMG wee ee fransducer — an electro-acoustical device for converting electrical energy into acoustical energy and vice verse Ultrasonic — pertaining to mechanical vibrations having frequency greater than approximately 20,000 He faueratrange 6s t-1 YM) 4 PERSONNEL REQUIREMENTS (FROM API-650, SECTION 6, PARA 6.3.3) Personnel performing the UT examination chall be qualified as required by the referencing Code Section. ( API 853 and API 650 in our case ) Examiner performing UT shall be: - qualified and certified by the manufacturer, Rat peer ~as Level il or Level iil sai 7 : cperASNT SNT-TC-1A = shold ne stat fig b bay (AsMg Vil - Laval 's may be used if: a) given written acceptiteject criteria prepared by a Level Il or Ill b) must be under the direct supervision of a Level It or Itt . au 7-522 WRITTEN PROCEDURE REQUIREMENTS ae) UT examination shall be performed in accordance with a written procedure, Each procedure shall contain at least the following: i “weld types and configuration to be exatnined including thickness dimensions, materials, and product form (casting, plate, etc.) = surface or surfaces from which the examination shall be performed - surface condition = couplant “technique (straight beam, angled beam, contact and/or immersion; angles and modes of wave propagation in the material; : - search unit type, frequency, and transducer size(s) - special search units, wedges, shoes, or saddles ultrasonic instrument type(s) - description of calibration blocks and technique - directions and extent of scanning ~ data to be recorded and method of recording (manual or automatic) = automatic alarm and recording equipment, or both - rotating, revolving, or scanning mechanisms = post examination cleaning ‘COPYRIGHT 2000 ~IRGI. SCHNDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 15REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copmmichr2000- RTT SCHMNDLER,JW COLEY AND CODEWEST -ALL RIGHTS RESERVED - DONOT COPY OR DISTRIBUTE 7-523 GENERAL EXAMINATION REQUIREMENTS (FOR OTHER THAN THICKNESS MEASUREMENTS) 7-523 1 Examination Coverage = Scan the entire examination volume by moving the search unit over the examination surface Each pass shall overlap a minimum of 10% of the transducer dimension perpendiculer to the direction of scan 7-523.2 Rate of transducer movement = not to exceed 6" / sec unless calibrated at a higher speed 7-523 3 Record of Sensitivity Level - recording of indications shall be made with respect to the reference level 7-530 EQUIPMENT & SUPPLIES 7531 FREQUENCY « shall use pulse echo instruments generating frequencies of at ieast 1 MHz to 5 MHz “other frequencies may be used if equal or better sensitivity can be demonstrated and documented 7-832 SCREEN HEIGHT LINEARITY Instrument shall provide: «linear vertical presentation within + 5% of the full screen height for 20% to 80% of the calibrated ‘screen height [base line to maximum calibrated screen point(s)] 7-533 AMPLITUDE CONTROL LINEARITY Instrument shall utilize an amplitude contrat accurate over its useful range to plus or minus 20% of the nominal amplitude ratio «Shall allow measurements of indications beyond the linear range of the vertical display on the screen Appendix Il provides procedure for evaluating amplitude control linearity «shall be checked the lesseraf. = before each period of extand@ use or every three months 7-534 EQUIPMENT CALIBRATION «= checks shail include function of the entire examination system - ~ calibrate using a calbration standard «at the beginning of each exam = when examination personnel are changed any time 2 maifunction is suspected “re lest all areas tested since last calibration if mattunction is 7-536 SEARCH UNITS. 2) may contain single or dual transducer elements b) contoured contact wedges may be used fused calibration must be done using the wedges to be used during examination coPvRIGhT 2000~iRGIT SCHINOLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 16REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CoPvRIGHT 2000 RGM SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DONOT COPY OR DISTRIBUTE. T-540 APPLICATIONS Temes us | Several sparifc requirements are given here as related to product form. The specifications referenced are intended for inspection of new materials to be delivered and used in fabrication of new equipment. In seme cases the intended use of the equioment is relevant An examole is SB-509 which is a requirement for inspection of piate for nuclear applications. The inspector should be aware of this as ew materials may be required for repairs and alterations but for the most part we are dealing with T- 54d 2g a general method of taking ultrasonic thickness measurements on equipment that is inservice “not new material to be used in new construction 7-544 THICKNESS MEASUREMENT Applicable Documents: Y= J = SE-114 and SE-797) ~ ‘2) A brief outline of SE-797 is below. Know the location and general scope of both -SE-797 Standard Practice for Thickness Measurement by Manual Contact Ultrasonic Method Significant areas of docurnent 1. Scope Le GBs = for contact puise-echo method + 3 sat temperature <200°F 13.3 ¢ / = in any material in which ultrasonic waves will propagate at constant velocity and “in which back reflections can be obtained and resolved 4. Significance and Use for use at less then 200°F “measurements made from one side only “Used to determine wall thinning from erosion and corrosion 5 Apparatus Flaw detectors.with CRT readout “Flaw detectors with GRT and direct thickness readout = Direct thickness readout — >/< 6 Procedure - Calibration and Adjusiment of Apparatus ~ Contains descriptions of calibration methods for the following: = Case | — Direct Contact, Single-Element Search Unit “Case it - Delay Line Singla-Element Search Unit ~ Case Ill - Dual Search Unit -———_ Ly ~ Case IV - Thick Sections te 7 Technical Hazards op ete cet “surface conditions - roughness Timaterial properties - velocity and attenuation -8 ad . “Scanning speed - for equipment and operator capabilities Sean “part geometry - parallel surfaces, curved surfaces wt “temperature - high temperature correction an = instruments - base linearity check back reflection wavetrain: ~ reduction of error in direct readout instruments «Calibration blocks with equal attenuation characteristics “use instrument with automatic gain control - ORT display recommended for rough, pitted and corroded surfaces caution on use of direct readout equipment in certain conditions - calibration on actual material to be checked at a point of known thickness; @ Procedure Requirements = See T-522 also @ Report - See T-590 also COPYRIGHT 1000 =IRGIT SCHINDLER. JW COLEY AND GODEWEST ALL RIGHTS RESERVED -00 NOT COPY OR DISTRISUTS 17REVIEW OF ASME SECTION V NDE REQUIREMENTS - 7. SCHINDLER copynicht 20 RET SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DONOTCOPYOROISTRIEUTE > ‘7-880 EVALUATION 7-581 EXAMINATION USING DAC (DISTANCE AMPLITUDE CORRECTION CURVE) any reflector causing an indication over 20% of DAC must be investigated to the extent that t'can be evaluated in terms of the acceptance standard 7-590 REPORTS AND RECORDS - 2 report shall be made = report shall include: ~ welds or area examined (may be a sketch) -focation of each measurement taken operator for exam or each portion of exam (See T-593), 7-592 CALIBRATION RECORDS caliorations in accordance with T-530 shall be included “system calibration requirements in accordance with T-534 shall be included calibration block identity shall be included 7-593 EXAMINATION RECORDS Identity and recor folowing information for each uitrasonic examination: . = procedure “Uhrasont examination system (equipment) “examination personnel identity and level “Calibration sheet entity . “identification and location of weld or volume scanned “Rurface from which exeminaton is conducted TTnap oF record of nications detected or areas clear Tete ond ime examination were performed ——— gy ~~ couplant io ~ basic calibration block identification io Pome Et “urace eorsition : - : “irequency z "special equipment Pett mold 7-594 EVALUATION RECORD Records of any evaluations of indications shall be maintained and documented coPrmicHT 2000 REM? SCHNDLER. JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR OSTRIGUTE 18REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 2000 |RETT SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR LIQUID PENETRANT EXAMINATION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR LIQUID PENETRANT EXAMINATION. REFERENCE: ASME SECTION V, ARTICLE 6 7-600 INTRODUCTION ‘ - PT is effective method for detecting discontinuities open to the surface of nonporous metals - Typical detectable discontinuities: Roo = cracks: Bestel Ee 7 8BAME oR tore ot mes, “ -laps , ren “cold shuts slaminations ciamingtione Principles “ penetrant applied to surface and allowed to enter discontinuity “excess penetrant removed = partis dried = developer applied a : “developer acts as blotter to absorb penetrant and as contrasting background + peroscore = ere! Becher! alin f pas spe T5101 Liquid penetrant examination techniques describe in Article 6 shall be used when specified by the referencing Code Section Listed SE Standards (ASTM) Provide details which may be considered in specific procedures - SE-165, Standard Practice for Liquid Penetrant Inspection Method * SE-1209. Standard Test method for Fluorescent Penetrant Examination Using Water Washable Process - SE-1219, Standard Test method for Fluorescent Penetrant Examination Using Solvent Removable Process _ SE-1220. Standard Test Method for Visible Penetrant Examination Using the Solvent Removable Process - Use PT method as described in Article 6 togather with Article 1, General Requirements Definition of terms = Found in Mandatory Appendix | of this Article which will send you to SE-1316 COPYRIGHT 2000 -IRGPT SCHINDLER. JW. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT GOPY OR O:STRIGUTE 19REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000- CIT. SCHINDLER, JW. GOLEY AND GODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 7-620 GENERAL 7-621 Procedure T-621 1 Initial Procedure Procedure Minimum Information: - the materials, shapes, sizes, to be examined and extent of examination - type of each penetrant, penetrant remover, emulsifier, and developer - details for pre-examination cleaning and drying including the cleaning materials used & minimum drying time processing details for applying penetrant, dwell time, and the temperature of the surface to be ‘examined and the penetrant during the exam if outside 60F to 125F range (NOTE: should be 50°F - committee error) ate - = processing details for removing excess penetrant from the surface, and for drying surface before applying developer - processing details for applying developer and length of developer time before interpretation - processing details for post-examination cleaning “Ss 1-621 2 Procedure Revision Revision 6 procedure may be required when: = change or substitution is made in the type or family group of penetrant materials, or in processing techniques - 2 change or substitution is made in the type of precleaning materials or processes, ~ any change in part processing that can ciose surface openings of discontinuities of leave interfering deposits, such as use of grit blast cleaning or acid treatments 7-630 EQUIPMENT 7-831 Penetrant Materials - Include all penetrants, solvents, cleaning agents, developers, etc. used in the process +. 7-640 REQUIREMENTS - 7-641 Control of Contaminants || ~required for penetrant materials when used on | cnicket based alloys, austenitic stainless steels, titanium eh toy. ss0""7-642 SURFACE PREPARATION °°" 7 @ Awa, ‘A) When as welded, 2s cast, or as rolled congilion is not satisfactory preparation by grinding, ‘matehing or other methods may be required 8) Prior to examination the area to be examined and all adjacent areas within 2t least 1 inch shall be {ee of matter that can interfere with the examination ) Cleaning agents may be used to remove matter that wil interfere with the examination 1) Cleaning agents must meet the requirements of T641 i applicable 7-643 DRYING AFTER PREPARATION - after cleaning drying may be accomplished by evaporation or forced hot or cold air minimum time must be established to assure cleaning agents dry prior to applying penetrant COPYRIGHT 2900 - REIT SCHINDLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 20REVIEW OF ASME SECTION V'NDE REQUIREMENTS -T. SCHINDLER ‘COPYRIGHT 2000~ IRCIT SCHINDLER, JW. COLEY AND CODENEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE, ‘7-60 PROCEDUREITECHNIQUES: 7-851 Techniques: Six liquid penetrant techniques: = color contrast (visible) penetrant water washable = post-emulsifying -solvent removable - fluorescent penetrant: water washable = post-emulsifying - solvent removable 1-852 TECHNIQUES FOR STANDARD TEMPERATURES ard ermperature range: 80°F 0 1289F —— "Sot - local heating and cooling is permitted au 7-853 TECHNIQUES FOR NON STANDARD TEMPERATURES =<“ 853 1 General -below 50° F or above 125° F {procedure qualified for standard ranges must be requaiified for non standard ranges comparator is usad for nonstandard qualification -853 2 Liquid Penetrant Comparator - specific requirements for making comparators are given ‘1653.3 Comparator Application - specific requirements for qualifying procedures for nonstandard temperatures are given 7-864 TECHNIQUE RESTRICTIONS fluorescent penetrant shall not follow a color cantrast examination { intermixing of penetrant materials from different families or manufacturers not permitted “retest with water weshable penetrants may cause loss of marginal indications 7-670 EXAMINATION 7-671 PENETRANT APPLICATION ~ by any sultable means Be bbe em ee wa l Oy “dipping, Spraying. or Brushing < ( “Compressee-er ype spray requires aibe fered to Keep out contaminants <9" 7-672 PENETRATION TIME = Critical = minimum time as shown in Table T: = as qualified by demonstration 72 oF aS COPYRIGHT 2000 = NFT-SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY Of DISTRIBUTE 24REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER ‘GOPYRIGHT2000~ GIT. SCHINOLER, JW. COLEY AND CODEWEST ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE 1-673 EXCESS PENETRANT REMOVAL 7-673.1 Water Washable Penetrants ~ remove with water spray = pressure 50 PSI or less = temperature 110F or less 43.3 ¢ 7-673 2 Post-Emulsifying Penetrants - apply emulsifier by spray or dipping cee ~ emulsification time shall be qualified by actual tests <~ . = remove by water spray using same process as for washable penetrants 1-673.2 Solvent Removabie Penetrants = ramove by wiping with cloth or absorbent paper = traces removed by cloth or absorbent paper moistened with solvent = FLUSHING SURFACE WITH SOLVENT IS PROHIBITED \ SPROHIBITED < __s) 1-674 DRYING AFTER EXCESS PENETRANT REMOVAL ‘A) Water washable or post-emulsifying technique: = Blot with clean materials or by circulating air Air o not raise surface temperature above 125F B) Solvent Removable Technique: = Dry by normal evaporation, blotting, wiping, or forced air 1-675 DEVELOPING - apply as soon as possible efter penetrant removed = time interval to not exceed time per procedure i = insufficient coating thickness may not-deawout penetrant —_ = excess coating thickness may mask indications ===) “use only wet developer with color contrast pehetrants ae “wet or dry may be used with fluorescent penetrants -875. 1 Dry Developer Application = powder dusted evenly over entire surface to be examined, = apply to dry surface only ~ apply by soft brush, hand powder bulb, powder gun. or other means 7-875 2 Wet Developer Application ‘Must agitate suspension type prior to application. Ensure adequate dispersion of suspended particles ‘A) Aqueous Developer Appiication = apply to either wet or dry surface = apply by dipping, brushing, spraying, or other means = thin coating needed over entire surface = dry time may be reduced using warm air so long as surface does not exceed 125F = blotting not permitted B) Nonaqueous Developer Application = apply only to dry surface ~ apaly by spraying can apply by brushing where safely or access preclude spraying = dry by normal evaporation 7-675 3 Developing Time for Final Interpretation = begins immediately after application of dry developer «= begins as soon as wet developer coating Is dry COPYRIGHT 2000 ~IRC/T SCHINDLER. J. COLEY AND CODEWEST -ALL RIGHTS RESERVED 00 NOT COPY OR DISTRIBUTE 22REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINOLER COPYRIGHT 2000 = IRETT SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR O'STRIBUTE 7-676 INTERPRETATION ‘T-676.1 Final Interpret Thelin Ita Borrnutos after developing time Jeed-out does not alter examination results surface (letge area) can nov he cone within orescribed time 7-676 2 Characterizing Indication(s) if penetrant diffuses excessivaly into developer and discontinuities difficult to evaluate, close ‘observation af formation of indications should be done. -678.3 Color Contrast Penetrants - Developer forms uniform white coatir * Bleed-out indicate discontinuities - usually deep red color ~ Light pink color indicates excessive cleaning = Inadequate cleaning may leave excess background ~ Adsgunte iluminalin is fequred to insure adequate senstivty =. head f- val T-676 4 Fluorescent Penetrants Essentially same as Color Contrast process above except examination is by using Ultraviolet Light (black light) Perform examination as follows: ~ In darkened area Examiner in darkened ares 1 minute prior to performing examination i 1 Glasses of lenses wom by examiner shall not be photosensitive ——"\w/~ «Blacklight shall be warmed up minimum of 5 minutes before use or measurement of the intensity of the UV light emitted - Measure biack-light with black light meter * Minimum of 1000 Wisq. cm on surface of part required = Measure intensity at least once every 8 hours ke ‘7-680 EVALUATION T6804 |A) Al indications shall be evaluated in terms of acceptance standards B) Discontinuties at surface will be indicated by blee-out of penetrant "Surface irregularities may produce false indications C) Broad areas of fluorescence or pigmentation can mask Indications ~ Such areas must be cleaned and reexamined ¥-890 DOCUMENTATION Shall be in accordance with referencing Code Section |v COPYRIGHT 2000 -IRCIT SCHNDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED D0 NOT COPY OR DISTRIGUTE 23REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2000 IRGIT SCHINDLER, JW. COLEY AND CODENEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-741 SURFACE PREPARATION & ENHANCEMENT A) Results ususlly satisfactory when surfa concition ~ Grinding or machining may be necessary where surface iregularities could mask indications .. discontinuities B) Prior to examination: examine surface and all adjacent areas within 1 inch shall be dry, free of dirt ‘grease, Int, scale, welding fiux, weld spatter, paint, ol, and other extraneous matter that could Interfere with the examination ©) Typical cleaning agents: detergents, organic solvents, descaling operations, and paint removers. degreasing, sand or grit blasting, or ultrasonic cleaning methods also may used __-- D) IF coatings left on part, it must be demonstrated that indications can be detected through the 1) maximum coating thickness = When temporary coatings are used to enhance particle contrast it must be demionstrated that ol indications can be detected through the enhancement coating 9. asccast of assforged 7-750 PROCEDURE / TECHNIQUE MT examination procedures shall be based on following information: =the materials, shapes, or sizes to be examined, and the extent of examination 1 + magnetization techniques used equipment 1o be used for magnetization + surface preparation ( finishing and cleaning) “type of ferromagnetic particles to be used: manufacturer, color, wet or dry, ete * ~ magnetization currents ( type and amperage) sdemagnetization cen care stew Arce 2 we! 7-751 METHOD OF EXAMINATION Examination shall be done by the continuous method. “the magnetizing current remaining on while the examination medium is being applied and while the excess of the examination medium is being removed 7-752 TECHNIQUES AND MATERIALS - Ferromagnetic particles shall be either wet or dry = May be either fivorescent or nonfluorescent = One of more of five magnetization techniques shall be used = prod technique -———~ pee ae “longitudinal magnetization technique ries - circular magnetization technique = yoke technique —~ ‘multidirectional magnetization technique COPYRIGHT 2000 IR¢rT SCHINDLER. JW COLEY AND CODEWEST ALL RIGHTS RESERVED -D9 NOTCGPY OR DISTRIBUTE 25REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000-IRCTT. SCHNOLER. JW COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-753 MAGNETIZING FIELD ADEQUACY AND DIRECTION 1-753.1.1 Pie Shaped Gauges - Place gage on part surface - Clearly dafined line across copper face of indicator indicates suitable flux or field strength = When clearly defined line not present, the magnetizing technique shall be changed or adjusted - Best used with dry particles 7-753.1.2 Other Methods Used to Verify Field Adequacy * = Astificil Flaw Shims - Hall Effect Tangentialfield Probe rv zee Mee ee M, sort 1-753 3 Magnetic Field Direction -Adequacy and Direction of the field can be verified using indicators or shims only with longitudinal, circular, or mult-directional techniques. 1-754 RECTIFIED CURRENT A) when direct current is required rectified current may be used, Rectified current shall be either 3- phase or single-phase B) amperage required with 3-phase, full rectified current / verified by measuring average current C) Amperage required with single phase current / veriied by measuring the average current during the ‘conducting half cycle only. ‘1-755 DEMAGNETIZATION Do any time after completion of examination if residual magnetism in the part could interfere with subsequent processing. 7-760 CALIBRATION OF EQUIPMENT 1-761 Frequency of Calibration (for equipment with ammeters) A) Frequency: ~ Calibrate each piece of equipment at least once per year «Calibrate prior to frst use after major electrical repair, periodic overhaul, or damage B) Procedure: accuracy of meter verified annually by equipment traceable to a national standard Take readings at 3 cifferent current out put levels encompassing the usable range ©) Tolerance: Uni’s meter, reading shall not deviete more than #10% full scale. relative to the actual current value shown by the test meter T-762 LIFTING POWER OF YOKES A) - Check magnetizing force once per year - whenever a yoke hes been damaged = Ifnot used for one year, check before first use £8) - Alternating current yoxe shall have a iting power of atleast 10 LB at the maximum pole spacing to be used — ) - Direct current yoke or permanent magnet yoke shall have a liting power of at least 40 LB at the maximum pole spacing to be used — D) - Test weights to be weighed with a scale from a reputable manufacturer and ste the applicable nominal weight prior to its first use - Verify weight only if damagad in a manner that could have caused potential weight loss ‘led with COPYRIGHT 2000 -IRCrT SCHINDLER, J\W. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE. 26REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER Ccopynichr 000 ROMY SCHINDLER, JW ESLEY AND CODEWEST- AL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 1-770 EXAMINATION 7-771 DIRECTION OF EXAMINATION = Perform 2 separate examinations on each area “punng 2nd examination, lines of magnetic ux shall be approximately perpendicular to those used during tst examination -Adifferent technique may be used for 2nd examination 7-772 EXAMINATION COVERAGE = Conduct with sufficient overlap to assure 100% coverage at required sensitivity (SEE 1-763) 1-73 PROD TECHNIQUE T-T734 Magnetizing Procedure = Magnetize by portable prod type electrical contacts pressed against area to be examined Avold areitg via remote switch that is operated oniy after prods have been properly posiioned -773.2 Magnetizing Current - Direct or rectified magnetizing current shall be used = Current shall be 100 (min) ampfin. to 125 (max) ampiin. of prod spacing for sections > 3/4” = Current shall be 90 amp/in to 110 amplin. of prod spacing for sections < 3/4” 1-773.3 Prod Spacing - Space shall not exceed 8 in "shorter space to accommodate geometric limitations orto increase sensitivity “Prod spacing less than 3 in. usually not practical, Particles band around prods Keep prod tps clean and dressed : “if open circut voltage is greater than 25 volts, lead, steel, or aluminum (rather than copper) tipped prods ere recommended to avoid copper deposits on parts being examined. = Magnetic field adequacy shall be verified using a using 2 “Pie Gage" (See T-753 & Fig T-775.2) 1-776 YOKE TECHNIQUE 1-776.4 Application i ‘Shall only be applied to detect discontinuities that are open to the surface of the part T-776.2 Magnotizing Procedure ~ Alternating or direct current electromagnetic yokes, or permanent magnet yokes, shall be used 1-778 1 Non-Flucrescent Examinations must have 0 fe (500 ix) light intensity eee 1-778 2 - Fluorescent Particles, = - Examination performed using ultraviolet or “black light” as folows: ~in a derkened area + examiner shall be in darkened area for 5 minutes prior to exam “examiners glasses or lenses shall not be photosensitive ~biack light” warmed up for min of 5 minutes or intensity measured “black light” intensity shall be 2 minimum of 1000 jx W/cm? on the part surface + intensity measured every 8 hours or when work station changed COPYRIGHT 2000 ~IRCIT SCHINDLER, JW. COLEY AND CODEWEST . ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 27REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2600 ~IRGTT. SCHINDLER, JW.COLEY AND CODEWEST ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 7-780 EVALUATION ‘A) - Evaluate all indications in terms of acceptance standards of the referencing Code Section 8) - Discontinuities on or near surface indicated by retention of the examination medium ~ False indications may exist because of localized surface irregularities due to machining ‘marks of other surface conditions ) - Particle accumulations in broad areas might mask indications and are prohibited ~ Such areas must be cleaned and reexamined 1-790 REPORTS, 7-791 Mutidirectional Magrietization Technique Sketch Technique skatch shall be prepared for each different geometry examined {Sketch to show the part geometry, cable arrangement and connections, magnetizing current for each circuit, and the areas of examinatic quate field strengths are obtained - Parts with repetitive geometry but different sizes can be examined using one sketch, provided the ‘magnetic field strength is adequate when demonstrated using the magnetic particle field strength indicator. (SEE 1-7772) Sp leer * inp fae ead : Rad T3794 (longs trdinel Meynels gad YD SY Ange chen . 35.088 (lp )a a. ion Techn vague J Save pT S483 é Yn <4 Ampitun . US ev ee Bh COPYRIGHT 2000 -IRCIT. SCHINDLER, JN, COLEY AND CODEWEST- ALL RIGHTS RESERVED -DONOT COPY OR DISTRISUTE 28REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000 IRCIT. SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ALL QUESTIONS ARE CLOSED BOOK ASME SECTION V PRACTICE QUESTIONS NOTE: Some questions in this section are true/false or essay type questions, instead of multiple choice Historically, it has been shown that test questions on ASME V involves a good deal of theory that cannot adequately be explored through multiple choice questions (although multiple choice questions oniy will be on the test) - 1. Afilmside penetrameter can be used for: A. inaccessible welds ( unable to hand place a source penetrameter) B allwelds all Castings at any time D_ analternative to a source-side wire penetrameter 2. Adark image of the “B" on @ lighter background is ‘A. Acceptable B. Rejeciable © Sometimes rejectable D_ None of the above 3. One of the procedural requirements for conducting PT is to address the processing details for A. Postiexamination cleaning B. Pre-examination cleaning Apply the penetrant D All of the above 4. Non-equeous developer may be applied to a wet surface. True or False (circle one) 5. The accuracy of a piece of magnetizing equioment that is equipped with an ammeter shail be verified A. Each year B Each two years When possibie D Every 6 months 6. When using fluorescent particles, the examiner shall be in a darkened area for at least minutes prior to performing the examination 7 10 9 1 vow 7 Awire penetrameter shall be placed adjacent to the weld, with the wires parallel to the weld True of False (circle one) ‘COPYRIGHT 2000 IREVT SCHINDLER, JW. COLEY ANO CODEWEST ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE 23REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CcoPyRIGHT2000 = RCT SCHNDLER, JW. COLEY ANO CODEWEST-ALL RIGHTS RESERVED - 00 NOT COPY OR DISTRIBUTE. 8. A field indicator is composed of, low carbon stee! pie sections, fumace brazed together. A2 B6 c 10 DB 9 The type and amperage of magnetizing current must be identified on the written MT procedure True of False (circle one) c 10. Certification of contaminants shail be obtained for ail PT materials used on A. carbon steels B. Ferntic stainless steets . Austenitic stainless steels D_ None of the above 11 Black light intensity shall be measured with when conducting fluorescent PT. A. Dark room meter B Phot-meter Black light meter D_ None of the above 12. Astee! bar is 15" long x 3" in diameter What is the proper ampere/tums to be applied when using the coil technique? 45,000 = ampere tums A 4375 uo 8 5,000 ¢ 35,000 D 2,000 13. The location markers required by ASME V are required to appear as radiographic images. True or False (circie one) 44. DC yokes may be used for detecting subsurface discontinulties, per ASME V? True or False (circle one) 15. When coatings are applied to ennance contrast, the procedure must be demonstrated that indications can be detected through the coating True or False (circle one) 16 How many total liquid penetrant techniques are listed in ASME V? goer COPYRIGHT 2000 IRCIT SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGHTS RESERVED -09 HOT COPY OR OISTRIGUTE 30REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000 -IRG/T. SSHINDLER, JW. COLEY AND CODEWEST - ALL AIGHTS RESERVED -DONOT COPY OR DISTRIBUTE 17. Prior to examination, each adjacent surface shall be cleaned within at least * of the area to be examined ° 18. Weter washable penetrant shall be removed with a water spray not exceeding 60 psi and 100°F. True or False (circle one) 19. Emulsification time shall not exceed minutes, unless other times have been qualified by actual test. AS 8 10 c 45 B 20 20. Densitometers shall be calibrated by verification with a calibrated. A. Densitometer B. Step Wedge Comparison Strip C Light Meter D_ Transmission moniter : 21. If 6000 amp-turns are required to magnetize a part, how many amps are required for a §-turn coi? A 1000 B 6000 c 1200 D 100 22 Around steel bar is 14" long x7" diameter What is the proper amperage to be applied when using @ circular direct contact technique? (300 ~ 900 ampsfinch of diameter required) A. 4900 - 8300 B 2100-5600 © Sturns D_ 1500-1600 23 When a PT test cannot be conducted between 50° - 125°F, what must be done. per ASME V? A The procedure must be quaified B The surface must be re-cleaned © The test cannot be conducted D None of the aoove 24 The sulfur content of @ penetrant is measured to be less than 00259 This material is acceptable for use on A. Nickel-base alloys B Carbon steel C Ferftic steel D_ All of the above COPYRIGHT 2000 = IRCIT SCHINDLER, JW COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR ISTRIBUTE 34REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER . COPYRIGHT 2000 IREIT SCHINDLER, 4. COLEY AND CODEWEST ALL RIGHTS RESERVED -DO NOTCOPY OR DISTRIBUTE 25. All indications are to be evaluated in accordance with, A. ASME Will 5B ASME V ©. The referencing Code section D. The written procedure 26. The scope of the ASME Boiler and Pressure Vessel Code, Section V includes: A. NDE acceptance criteria B_ How to perform NDE to achieve a desired result C. Where to do NDE (le., what welds to examine) D. Who can be the Al 27. UT equipment is calibrated? A. Before heat-treatment B. After completing the examination ©. Prior fo visual examination D. Prior to PT examination 28. What finished surface is required of butt welds for PT examination? ‘A. Smooth surface prepared by grinding B Cosmetically clean acid etched surface CG Anear white bast surface D None of the above 29. Apenetrameter is used on a DWE/DWV. The penetrameter selection is based on. A. The single wall thickness and weld reinforcement B Both wall thicknesses ©The single wall thickness for Sch 80 pipe D_ None of the above 30. Assuitable means for applying penetrant. A Dipping B Brushing C Spraying D Any orallof the above 31. What materais require the use of tested and certified liquid penetrants as tothe contaminants in the penetrant? A. Nickel alloys B. Austenitic stainless steel alloys © Fertiticimartensitic stainless ste! D Both A & 8, above 32. How shall indications be evaluated, ie , scceptance standards for RT A ToASMEV B To ASME Vill ©. ToB313 D. To the referencing Code section 33 Thicknass readings may be displayed on? coPraiGHT 2600 = RCI SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 32REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER coPyRioiT 2000—IRCIT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE A SRT B PRT c. CRT D. Strip chart recorder 34 How many copies of a procedure must be available to the Manufacturers Nondestructive Examination Personnel? 1 2 3 4 pom> 36. How shall Nondestructive Exemination Personnel be qualified? A To SNT-TC-1A B ToCP.189 ©. To referencing code requirements D TOACCP mules 36 Which NDE methods are considered “stirface” methods? A PT B RT Cc MT BD BothA& C above 37. What designation is used to indicate the penetrameter is on the film side? an"e an“€" oO an“FS" com> 38 What is 2 shim used for? A. UT field adequacy BRT field direction ©. MT field sirength and direction DMT field current applications 39. Why must the surface be closely observed during the application of the PT developer? A To ensure proper coating application B To ensure excess penetrant removal © To allow proper characterization of discontinuities D. To see the “groovy” lines form 40 One of the five magnetization techniques is? A. Round B Circular © Shearwave D. Halleffect Tangential-fietd 41. A true UT indication is one which exceeds A 20% of DAC ‘coPyRIGHT 2000 (Cr SCHINDLER. JW COLEY AND CODEWEST ALL RIGHTS RESERVED -00 NOT COPY ORDISTRIEUTE 33,REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 200 =IRGIT. SCHINDLER, JW. GOLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIGUTE B 20% of CAD © 20% of DEC D. 10% of DAC 42. Name one typical discontinuity detectable by the magnetic particle method. A. Lack of penetration B. Interpass lack of fusion Slag inclusions D. Toe cracks 43. For a DWE/SWV RT Technique, a minimum of _, exposures shall be made oop 44, When are location markers placad on the film-side in SWV for curved surfaces? A. Concave side is toward the source B. Source-to-material distance greater than IR © Acobat source is used D Both A&B, above 45. Whats the difference between an inspection and an examination per Section V/ of the ASME Code ‘A. Inspection performed by Al 8 Examination performed by manufacturer's personnel ©. There is no difference between the two D Both &B, above 46. Geometric unsharpness is determined by: A UG=FuD © UG =fdd D UG=fid 47. UT Thickness velocities are usually obtained from: ‘A. Tim's Handy Velocity Book B Similar materials C. Similar product forms D Both B&C, above 48 Name one typical discontinuity detectable by the liquid penetrant method A IP onan NPS2 girth weld B_ IF atthe root of an NPS 2 girth weld CHAZ surface cracks on a NPS 2 girth weld 1D. Slag inclusions on a NPS 8 longitudinal weld 49. What is to be done to excess penetrant remaining on the surface after the specified penetration time has elapsed? A. It must be removed COPYRIGHT 2000 - RCT SCHINDLER. JW. COLEY AND GODEWEST -ALL RIGHTS RESERVED -BO NOT COPY OF DISTRIBUTE 34REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER CoPvRiGHT 2000 “IRGIT. SCHINDLER. JW. COLEY AND CODEWEST - ALL RIGHTS RESEAVED -DO NOT COPY OR DISTRIBUTE SUBJECT: API AUTHORIZED INSPECTOR CERTIFICATION EXAMINATION LESSON: REVIEW REQUIREMENTS FOR MAGNETIC PARTICLE EXAMINATION OBJECTIVE: FAMILIARIZE CANDIDATES FOR THE API-510 CERTIFICATION WITH RELEVANT REQUIREMENTS FOR MAGNETIC PARTICLE EXAMINATION. REFERENCE: © ASME:SECTION V, ARTICLE T-710 SCOPE . = When specified by referencing Code Section, the MT techniques of this Article shall be used This Article generally in conformance with ASTM SE-709, Standard Recommended Practice for Magnetic Particle Examination - SE-709 provides additional details to be considered in the procedures used ~ Aricle 7 shall be used together with Article 1, General Requirements = Definition of terms used found in Mandatory Appendix Ii which will send you to SE-1316 1-720 GENERAL, ‘The magnetic particle method is appliad to detect cracks and other discontinuities on or near the surfaces of ferromagrietic materials, ty greatest for surface discontinuities ity decreases rapidly with increasing depth of discontinuity = Discontinuities detected typically are: ~ cracks ~laps = seams = cold shuts = laminations Principle: + Magnetizing an area to be examined ~ Applying ferromagnetic particles to the surface Patticlessfogt) patterns on surface! discontinuities cause distortions in normal magnetic field - Patterns 276 usually characteristic of type of discontinuity detected < Maximum sensitivity isto linear discontinuities oriented perpendicular to the lines of flux-— / "Examine each area twice for optimum effectiveness in detecting all types of discontinuities —> «Lines of flux during one examination to be perpendicular to lines of flux during the other 7-730 EQUIPMENT 4 ~ Suitable and appropriate means used to produce the necessary magnetic flux = Use techniques listed in T-751 and described in 7-770 7-731 EXAMINATION MEDIUM Ferromagnetic particles shall meet the following requirements: - Dry Particles: ~ adequate contrast with surface - specific requirements given in SE-70S =not used over 600° F - Wet Particles: = adequate contrast with surface - specific requirements given in SE-709 ~not used over 135° F ‘COPYRIGHT 5000~IRC/T. SCHINDLER. JW COLEY AND CODEWEST ALLRIGHTS RESERVED -DO NOT COPY OR DISTRISUTE 24REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. COPYRIGHT 2000 -IROT. SCHINDLER, JW. COLEY AND CODEWEST -ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE B. Itcan remain on the part ©. Itmust be developed D. Itmust be femoved with water only 50. What must be done to ensure 100% coverage on any NDE method? 51. When surface irregularities may mask indications of unacceptable discontinuities, what is required? 52. List the type of discontinuities magnetic particle examination is effective in detecting 53. What are the six penetrant techniques to be used? 54. What are the approved methods of indicating UT thickness measurements? 55. How isthe “quali of a adiograph evalustes? 56. Where are RT locaton makers placed, on hepato on the radiograph? 57. Penetrameters may be of what Wo ype? 58, How many hoes are in a hole ype 10? 58. Whatidentty must aso be included inthe UT calraion records? 60. The peretvameters normaly placed on which ste of apart? 61. AAT hole on 220 penstrameter has a diameter of 62st 4ypes of blemishes ot permite on fn 53. When sa writen rediogretie procedure required by ASME V7 54. When should the developer be sped? 65. What type of discontinuity is the magnetic particle method most sensitive to? 66. What is the examination medium when using MT? What is the probing medium when using MT? COPYRIGHT 2000 IRC/T SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 35REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER ‘COPYRIGHT 2000~IRETT. SCHINDLER, |W. COLEY ANO COOEWEST-ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 67. When must ultrasonic equipment be calibrated? 68. How many penetrameters should appear on each radiograph, except for panoramic techniques? 69. Ave intensifying screens permitted for radiography per ASME V? 70. What two radiographic techniques are noted as available for examinations? 71. How can compliance with a written radiographic procedure be demonstrated? 72. List the type of discontinuity liquid penetrant examination is effective in detecting. 73. What must be done when a penetrant is to be applied on parts beyond 50 - 125°F? 74. The lifting power of yokes must be checked when? 75. How should wekled buttjoints be prepared for radiography? 76. Steel greater than * thick should be radiographed with a cobalt source a Tue b False 77 Inmagnetic particle examination of a welded joint using yokes, is alternating current or direct current allowed? 78. What method of Ultrasonic examination of the welds is permitted by the Code? 79. Name three different methods of conducting “Visual Examinations” (VT) 80. From what type of material should shims be fabricated when they are to be used to radiograph welds in pressure retaining itemis? is a device used to determine the image quality of Bt A radiograph a Astep wedge comparison film b Adensitometer c Apenetrameter di Allofthe above COPYRIGHT 2000 ~IRC/T, SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIGUTE 36REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER: [COPYRIGHT 2000 -IRCIT. SCHINDLER, J:W. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DONGT COPY OR DISTRIBUTE @ None of the above? 82. In accordance with Section V, wiretype penetrameters: a Cen always be used. b. Can be used unless restricted by the referencing Code. cc Can never be used. Can be used only with Type 1 film: 83. @ What is meant by “nondestructive examination” of a welded joint? Name four methods of nondestructive examination 84. Ina radiographic film of a weld, how are the following characteristics measured or judged? a. Film sensitivity or quality b Film density 85. What is radiography? 86. Whatis the minimum and maximum allowable density through the image of the penetrameter for radiographs made with: 3 A2000kV tube? . cobalt 60 (C080)? 87. Asingle fim technique was used to make a radiograph using 2 Gobalt-80 source, The minimum permitted density in the area of interest is a4o b 18 c 20 d 13 None of the above BB Under ASME Code Sedtion V, what upper and lower density limits are acceptable for viewing if the density through the body of the penetrameter is 2.77 Assume single fim viewing 89. As a radiographer is removing cassettes (film holders) from a weld seam that has just been rediographed, you notice that there is nothing attached to the back of the cassettes Would these radiographs be acceptable? Expiain your answer. COPYRIGHT 2000 -IRCIT SCHINDLER, JW COLEY AND GODEWEST - ALL RIGHTS RESERVED -D0 NOT COPY OR DISTRIBUTE 37REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER COPYRIGHT 2000 -IRGTT. SCHINDLER, JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE ‘90 What is the minimum number of penetrameters required for the following: 18. Acomplete gith seam containing 20 rediographs shot witha single exposure? b. Twelve radiographs on a longitudinal seam shot from the outside with a single exposure? 91. A radiograph is made using an X-ray source, and two films in each film holder. Ifthe film is to be viewed separately the minimum permitted density would be: a 40 7 b 18 20 13 e None of the above? (92. Aweld with @ nominal thickness of 1.8 inch Is o be radographed using a fim side penetrameter ‘The penetrameter designation should be: (NOTE: This is an open book question) a ’ é 35 d_ Both a and b are acceptable? 93. (a}What are hole-type penetrameters and what are they used for? (b) What are wire penetrameters and what are they used for? 94 In radiographing a butt welded joint of 1” thicknass, on what side of the weld is the penetrameter normally placed? 985. What type of flaws may be detected by: Liquid Penetrant testing? Magnetic Particle testing? Radiographic exemination? Ultrasonic examination? 96. What is 2 densitometer used to determine? 97 @._ What is the purpose of shims when performing radiography? b Where are they placed? What kind of material may they be made from? 98. Describe how the following surfaces should be prepared for Ultrasonic examination: 2. Contact surfaces. b Weld surfaces, Base material COPYRIGHT 2090 -IRC/T SCHINDLER. JW. COLEY AND CODEWEST - AL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE 38REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER COPYRIGHT 2t00 = 1ROTT SCHINDLER, 14 COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 99. Why are lead intensifying screens used in the X-ray examination process? 400. Name two radiation sources permitted for radiographic examination in ASME Boller and Pressure Vessel Code 401. When reviewing a radiograph, a dark image of the letter 8 can be seen on the film. Does this indicate an unacceptable radiograph? 102. Describe how liquid penetrant examination should be performed in order to detect discontinuities which are open to the surface, per Article 6 of ASME Code section V 403. a If penetrameters are not placed on the source side, what rules apply? bb For materials being radiographed other than welds, where are the penetranteters placed? 104. Ifthe density through the penetrameter is 2.50, what would the maximum _ allowable density and minimum allowable density be through the weld represented by this penny? 405. Ona set of cassettes containing film for a seam just radiographed you notice the lead location markers (ie, 1-2, 2-3, etc) are taped to the cassettes Would these radiographs be ‘cceptable? Explain your answer ASME V PRACTICE QUESTIONS ANSWER KEY alse o> mo>> COPYRIGHT 7000 = RCIT. SCHINDLER, J W.COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 39REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER copyrucirr2000 rT. SCHINDLER, .W.COLEY AND CODEWEST -AL RIGHTS RESERVED -D0 NOT COPY OR DISTRISUTE. 7. False an) 9 Tne wo OC un G 2 8B 130 The 14 False 16 Tne FOF ODOTF BOO> OOF OTTOFODBOOPDODY IED 43 50 _All examinations must overlap to ensure 100% coverage of the part 51 Grinding. machining, or other methods 52. Surface and slight subsurface indications 53 Color contrast or water washable a) water washable b) post-emulsifying ) solvent removable 54 CRT. Digital, or meter 55 _Abilty to see the prescribed hole or wire on the designated penetrameter and compliance with density requirements COPYRIGHT 2000 ROT. SCHNDLER. JW COLEY AND CODEWEST- ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘40© REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. CcopyicttT 2000 CMT. SCHINDLER, JW. GOLEY AND CODEWEST - ALL RIGHTS RESERVED - DO HOT COPY OR DISTRIBUTE 56 87. 58 59, 60 81 62. 63 65. 67 68 69 70 n 72 73 74 75. 76 77 78 79 80 ‘On the part Hole or wie types 3 Calibration biock identity Source side 80" a Fogging bb Processing defects Scratches, finger marks, etc False indications due to defective screens ‘When required by the referencing Code section ‘As soon as possible after penetrant removal Surface discontinuties aligned perpendicular to the magnetic field Ferro magnetic particles, magnetic fields, 2) Beginning and end of each examination b) When personnel are changed ©) Anytime matfunction is suspected ‘Atleast one on each radiograph Yes. except when restricted by the referencing Code Single wall and double wall By compliance with density and penetrameter image on the production or technique radiographs Surface discontinuities only ‘The procedure must be qualified using a quench-cracked aluminum block ‘At last once each year or ifthe yoke has bean damaged, ‘The weld ripples or surface irregularities on both the inside {if accessible) and outside shall be removed by any suitable process to such a degree that the resulting radiographic image due to any irregularities cannot mask or be confused with the image of any discontinuity. 15" thick Alternative current is used Pulse-Echo Shear Wave Ultrasonics a Direct indirect or (remote visual examination) c Translucent A shim shall be fabricated of radiographically similar material to the object to be inspected “COPYRIGHT 2600 =IRC/T. SCHINDLER. JW. COLEY AND CODEWEST- ALL RIGHTS RESERVED - DO NOT GOFY OR DISTRIBUTE atREVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER ‘COPYRIGHT 2060 -IRCIT SCHINDLER, JW. COLEY AND CODEWEST - ALL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE ar 82. 83 85 86 ar 88 89 90 a1 92 93 c A a An examination of a welded joint that will disclose surface and sub-surface discontinuities without physical harm to the welded joint Such exar tic conducted by radiography, ultrasonics, quid penetrant or magnetic particle testing b Radiographic Examination Uttrasonie Examination Magnatic Particle Examination Liquid Penetrant Examination. a Penetrameter b _Densitometers or step-wedge comparison films, ‘A radiograph is a shadow picture produced by the passage of X-rays or gamma-rays through an object onto a fim. When the rays pass through the object, part ofthe radiation penetrates the material and partis absorbed. The amount of radiation absorbed and the amount which penetrates are a function of the thickness of the material. Where a void or discontinuity exists, there is essentially less material to absorb the radiation. Therefore, more radiation will pass through this section and a dark spot corresponding to the projected position of the void will appear on the film y @ 18-40 (for any X-ray source) b —-2.0- 4.0 (for any gamma source) E ~The correct answer is ~15% from the transmitted density through the body of the penetrameter “15% = 2.295 430% = 3.510 No, as @ check on backscattered radiation, a lead symbol “B" with minimum dimensions of 4/2" height and 1/16" thickness shall be attached to the back of each film holder. if a ight image of the “B” appears on a darker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable A dark image on a lighter background is not cause for rejection a Requires at least 3 penetrameters spaced 120° apart b. Requires at least 12 penetrameters, one on each film 8 A (a) A penetrameter is a smal strip of material. fabricated of radiographically similar material to the object being inspected, and having a thickness of approximately 2% of the object being radiographed. The penetrameter has three holes in it The sizes of these holes are 17, 2T ‘and 4T where “T” is the thickness of the penetrameter The 27 is designated as the essentia! hole, 1 the hole whose image must appear on the radiograph Penetrameter thickness and essential hole size requirements are listed in tables in Section V of the ASME Code “The penetrameter is identified with a number made of lead which is attached to the penetrameter This number indicates the thickness of the penetrameter in thousandths of an inch COPYRIGHT 2000 -IRCIT SCHINDLER, JW. COLEY AND CODEWEST - AL RIGHTS RESERVED -DO NOT COPY OR DISTRIBUTE 42: Sarre REVIEW OF ASME SECTION V NDE REQUIREMENTS -T. SCHINDLER coPrwoitr 2000 - ROM. SCHINDLER, JW. COLEY AND COCEWEST -ALL RIGHTS RESERVED - DO NOT COPY OR DISTRIBUTE ‘A penatrameter is used for evaluating radiographic technique in that It serves as an image {quality indicator, proper technique should display the penetrameter image and the specified hole, (©) Wire type penetrameters use thin wires to ascertain sensitivity instead of holes The ability to see the wire required by the Code indicates a quality radiograph 94 The panetrameter should be placed the source side of the material being radiographed. However, where inaccessibility prevents this, the penetrameter may _be placed on the film side of the material being radiographed provided a lead letter “F” at least as high as the identification number is placed adjacent to the penetrameter, 95 Surface discontinuities Surface and slight sub-surface discontinuities. ‘Surface and sub-surface discontinuities, Surface and sub-surface discontinuities noose 96. Adensitometer ( or step wedge comparison fim) shall be used for judging film density requirements Film density is a measure of overall readability 87 a_ Shims may be used when necessary to produce a radiograph in which the radiographic density throughout the area of interest is no more than minus 15% from (lighter than) the radiographic density through the penetrameter b.. Thay are placed under the penetrameter c. _Aradiogrephically similar material to that being examined 98 a, _The finished contact surface shail be free from weld splatter and any roughness that would interfere with free movement of this search unit or impair the transmission of ultrasonic vibrations bb _The weld surfaces shall be finished so they cannot mask or be confused with reflections from defects, and should merge smoothly into the surfaces of the adjacent base materials ¢ The volume of base material through which the sound will travel in angle bearn ‘examination shall be completely scanned with a straight beam search unit to detect reflectors which might affect interpretation of angle beam results 99 Lead foil intensifying screens used in the X-ray examination may be placed directly in front of the fim. The screen provides an intensifying action and, in addition, the back one acts as @ filter by preferentially absorbing backscattered radiation from the specimen thus improving image quality. 100. The two common radiographic sources in industria! use today are X-ray machines end attificially-produced radioactive isotopes éf certain metalic elements 101 No 402 The partis frst thoroughly cleaned of ol, dirt, etc., then a liquid penetrant is applied to the surface to be examined and allowed to enter the discontinuities. All excess penetrant is then removed. the partis cried, and a developer is applied The developer functions both 2s a blotter to absorb penetrant that has been trapped in discontinuities and as @ contrasting background to enhance the visibly of penetrant indications. The dyes in penetrants are either color contrast (visible under white light) of fluorescent (visible under ultraviciet light) 403. a _ The penetrameter should be placed on the source side of the material being radiographed However, where inaccessibility prevents this, the penetrameter may bbe placed on the fim side of the material being radiographed provided a lead ietier “Fat least as high as the identification number is placed adjacent to the penetrameter ‘COPYRIGHT 2008 = IRC. SCHINDLER. JW. COLEY ANO CODEWEST - ALL RIGHTS RESERVED - 00 NOT COPY 9 DISTRIBUTE 43REVIEW OF ASME SECTION V NDE REQUIREMENTS - T. SCHINDLER. ‘COPYRIGHT 2000 ET SEMNDLER, JW.COLEY AND CODEWEST-ALL RIGHTS RESERVED -00 NOT COPY OR DISTRIBUTE For material other than weld a source side penetrameter shall be placed in the area of interest 104 Minus 15% to plus 30% allowed, 26+ 30%=25+ 75=3.25 25-15% =2.5-4= 2.125 405 No. Location markers that are to appear on the radiographic film should be placed on the part being examined and not on the cassettes COPYRIGHT 2000 =IRCIT SCHINDLER. JW. GOLEY AND CODENEST -ALL RIGHTS RESERVED -O0 NOT COPY OR DISTRIBUTE adOpen Book API 510 Practice Exam A 6 You have received the following tension test results for a welding procedure, what is the ultimate wait tess for these two specimens? Specimen Width Thickness Area Ultimate Total Ultimate Unit ‘Loud tb Stress. ! 750 Alo 308 72,600 2 2 748 409 306 25,800 2 L 2 3 4 7. A pressure vessel has been measured to have a minimum wall thickness of 235 inch after 5 years of service. The vessel's original wall thickness was 250. Tts minimum allowable wall thickness is. 195 inch, How long until the next tequired inspection per API 510 10 years S yeuts 66 years 6-1/2 years Answer the following questions 10s 3 to 6) from Captain Bob's Welding Consider both the WPS and its supporting POR when auswering the questions. 8. (WPS) In the JOINTS (QW-402) section, the following statement is true; 1. ‘There must be a sketch of the joint configuration to be used in production, 2. Any groove design is allowed in production, 3. The box is propeuly addressed and contains no mistakes 4. Flux dam retaining is permitted 9 (WPS) In the BASE METAL (QW-403) thete is a mistake because the; Pipe diameter is not addressed Group number is not addressed and its « supplemental essential variable Fillet welds are addiessed as ALL. ‘Thete is no mistake; none ofthe above is tue, 1 83 are for information only, number 2 is not needed for this procedure because no impact tests are required of the weldment 10. (WPS) In the TECHNIQUE (QW-410) should have addiessed the following: 1 Travel speed 2. Method of back gouging 3. Nothing itis pesfect. 4 The length of groove 2 Fast Track Techni 281-482-2252 — www. apiexams.ory, 04/04 RevaOpen Book API 510 Practice Exam A ‘QW.482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION {WPS} (Soe QW-200.1, Section IX, ASME Boller and Pressure Vessel Code} (eae ce atria BE pring os EES ‘Woiding Procesrey)_ SHAY. eee Typets Hanae aa 5 tare eter to production macehoen ileal ar Teethogs Bee YSHAecetats saat aonene fete bob becibg nd vices) and fit up specifications {DMort — A Nontusing Marat ‘Retainer 1f needed in alloved copper or { EDnowrantic lower ‘ceranie te required ‘Sivcim,Prouslon Drawings, a Syeol of Wilten Onion ‘ould few the genes araemant othe par 0B ade har {Ae eeoton of oe tp atte may tated ante on to. wa inven wd Bead vegan, efor mle taghnne oo ASE METALS [OW 4O31 Pet Group No 19 PL croup Skontntn pe and se 10 Seteion ype dyads on | setbun amir sein, Pos eer faith ror HEN 9/8" 0 HOE 13/4" pt ABE He ron Sr ie cece eer oe “ILLEn WETALS (ant0d) AWS Ne (clemi 229028 — —- oo Sono Fetal ms Fast track Feenmiea trammg 5 281-482-2252 - wwapiesams.ore 04/04 Reva4 Open Book API 510 Practice Exam A ‘0-402 (Baek) wesno. 202s Posrriows \awa08) TOSTWELD HEAT TREATIAENT (Gwag7 Pasion of Grooe 22 | tempore ange Bo Bestvetd MP Wiuting ropenion: Up-QULZ———Oown—————— | Tine Rae, Ponto Econ Preece eee PRcWeAT aN06) eam Conoriion Feean Teo | ot ues) inure) ow ite Prete ainyaney —30-miga | sang | ee {Coniovow ore novi wie sppianewtoubeveoaesl | asim [ELECTRICAL GHAMACTERIETICS (08) ‘snot Wan 75_=_ 250 Vo anon) 28 = 38 ‘Pep and vols ang halberd or ech aoe te Peston, and thistnee ae Th lores may be ined 8 ‘Serta nat io ble) “Toren eos lesa Ty ‘TechnauE (onto! Sg or Wane Gong SEED (eset mtmee OE coe Ine roa Geog runing Gane ve SESBG and Brush es weeded Matiod Bek Gong (cornet Tite @ Werk Bnet Mio or Sine Pa fw BE EHEC EEE E EEE EGE EEE EERE EEE EE Maio Sng Eaade ce Tent gee ang) — Seer ——— ‘Omer HO Single pose to exéeed 1/7 inch Treat | mune Horwee aves | tees | con | oe | ear | range | ce | tine | Tony Ange Set Fast Track Technical Training 281-482-2252 — www.apiexams.orp 40d RevaOpen Book API 510 Practice Exam A ‘OWi-#t3 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD {ran} {See OW.200.2, Section IX, ASME Boller und Pressure Vessel Code) Record Actuel Gondltlans Used to Weld Test Coupon. Coase nana SaPtein bob's folding ‘oe Pent) BERR “yee Maca Automat, Set tae) SSE Taner Tazo teow Onin of Tt Cons or gonbinngaeon, ne seogne arate be med et mt aE META ae POETWELD HEAT THEATER CAO Toe one To eam Comgcien Gate _ tara) Flo a FiLLen wevaLs once) ei er ee {015 Cmitenon EZR Wed ie isk Postion ono ‘els regan (Ui. Gomni) Fast Track Technical Training 5 281-182-2252 ~ www.nplexamis.ore aod Revd6 Open Book API 510 Practice Exam A ct te Tent ow oH 0) oe ae aot ethane ate fa a a ee oo = ie aie ed Tn O60 Sia tear — are ee noe “Toughness Torta (0W-170) " ‘pes Flv Tas (130) ena — Sastacon: Yow _—— Penevston no Pcent Mn Yes no eas Other Taste Devos Analy Eocene cee EEE CECE ‘Wo ery tnt fw stteens ata seer ae eonnC En Hn eR rl war Captain Bob-s Trailers and You anateauter aE) cle Technical Training, 281-482-2252 - wwrw.upiexams.ore 4/04 RevsOpen Book API 510 Practice Exam A 16. When performing standavd dye penetrant examinations, the greatest temperal to be examined is re permitted fox the part 17. Regarding conosion evaluation, for the purposes of determining whether a weld joint efficiency or the surface remote from the weld governs in calculations the following must be (rue for this to be a consideration; 1. The joins efficiency must be 1.0 2. The joins efficiency must be less than 1.0 3. ‘The joints efficiency must he exactly $0 4. The jin’ efficiency nas no bea ing on conosion evaluations 18. The following describes the location of corrosion as measured in a vessel shell with tie following dimensions and minimums: © 700 inch thickness mini © Longitudinal joint B = 85 '* The thickness of the shell in the welded joint is 705 inch '* The thickness 3 inches remote Irom the welded joint is.698 inch 1m for shell from original calculations Using the :ules for corrosion evaluation in API 510, the following conclusion evaluation of the vessel for its continued service with out repair; bbe made about the 1. The thickness at the weld governs calculations. 2. The thickness remote from the weld governs calculations 3. Nosuch mule exits in APL S10 4. Separate calculations will be requized to determine which thickness governs 19. A210 1 ellipsoidal head has experienced uniform courasion on its inner surface To determine the governing thickness and evaluate the head for continued service or the need for separ or derating we would; 1, Calculate the required thickness of the knuckle region using the fourm given in UG-32 of Section VII Div. 1 2. Calculate the thickness required of the spherical postion ofthe head using the forrmuta from UG 27 of Section VII Div. | for a spherical shell 3. Calculate the equivalent shell based on the heads inside diameter 4. Calculate both { and 2 above to determine the need for vepair or derating 8 Fast Track Technical Training 281-482-2252 — wwwaaplexams.org, 4/04 RevOpen Book API 510 Practice Exam A 25. What isthe required thickness ofa 60 inch LD. cylindrical shell: thas and allowable stress a design of 17,500 pi ‘The vessel's Category A and D Type I joints are fully radiographed. All Category B joints are Type # also and have been spot radiograpted per UW-1 I(a) (5) (b) ‘The vessel MAWP must be 350 PSI at 450°F The shell will see 11 psi of static head at is bottom. 6072" 7388" 1159" 6266" 26 A hemispherical head formed from solid plate is 48.0 inches in inside diameter this head ig attached to ‘seamless shell and has not had radiography on the Category A Type | weld that attaches the head to the shell The vessel is horizontal and opetates at 500 PSI water pressure with an allowable stress on the head's material of 15,000 PSI The heads thickness requived is? svar 2. 5761" 3.14432" 4. 2356" 27. A314" weld procedure test coupon must be tensile tested. This will require the cutting of the test ‘coupon into smaller pieces. ‘The tensile testing machine is capable of pulling up to 1" thick specimens How many pieces witl be required to for a complete test per Section 1X? 2 28 A round weld tensile specimen is tested und found to fail inthe base metal specimen was measured before the test to hav this specimen is: load of 14,876 Ib. The 4 diameter of 503 inches, the ultimate tensile suength of 1. 74,863 pounds per square inch 2. 18,829 pounds per square incl 3. 235,185 pounds per squate inch 4. 74,380 pounds per square inch ist Track Technienl Training 281-482-2252 ~ wwwanpiesams.org 4/04 RevdOpen Book API 510 Practice Exam A ANSWER ‘LOCATION OF ANSWER (Example) B —APISIO 4.1.2 T3 UG.59 [24 UW-12 3.2 a WG-28 a3 UW-I6 3.3 UG-32 63 7 TXARTO 7. TAPISIO 64 8.3 TX ART QW-255, a 7 a TX ARTI QW.253 z TX ART H QW-253, 3 Vit Ow2 M@A 2.1 Seo ‘Vill WG-80 (@)(t) 13.4 ‘APISIO 43 14.3 QW.160 15.2 i Vill UG-100 (6) 16.3 if SECTION VARTS 1 172. EE APISIO_ 5.7 18.4 : ‘APISIO_ 5.7 19.4 API SIO 5.7 20.2 API SO_5.7— ise APISIO 5.7, 22.2 APISIO_5.7 23.2 ‘APISIO 5.7 2a 3 = ‘APISIO_5.7 35.4 WG-37 and APIS10 Body of Knowledge 26.2 UG-32 [27.2 TART I OW-IS1.1 28.1 DCARTI QW-153 29.3 G59 and API 510 Body of Knowledge 30.4 APISIO_ 6.4 313 APISIO5.4 32.3 WG-27 UG-116-0G 3.1 = UG 27 UG-116 Md “41,135 + 559 (hyuio hd. in heal depihy= 41,69, 35.3 UG 2@) Fast Track Technical Training B 281-482-2252 ~ www.aplexams.org 04104 RevdClosed Book API 510 Practice Exam A 54. What is the maxirmum inspection interval for a vessel with a remaining safe operating life of less than four years? 1. The ft semaining safe operating life up to a maximum of 4 years, 2. The full vemaining safe operating life up to a maximum of 2 years, 3. The fall remaining safe operating life up to a maximum of 1 4. ‘The fall remaining life ofthe vessel 55. What does the tesm construction code mean, as it regards repairs toa pressure vessel? 1. ‘The eunrent ASME Code edition, 2. TheNBIC 3. The Code the vessel was constiucted to including non-standard and jurisdictional special vessels. 4. The API510 Code. 56. What Code is used to evaluate a vessel after it has been placed in service? 1, ASME Section VIIL 2. ASME Section V 3. APISIO 4, RPST72 57. When a vessel is to be entered for inspection which of the following precautions should be observed? 1. The atea should be roped off and no one else iso be working in the ares, 2. Inspect the vessel for proper electrical grounding if a thunderstorm is inthe area 3. All hot work permits in the immediate area must be revoked until the inspection is complete 4. OSHA rules should be reviewed and followed where applicable, : ‘58 Liquid penettant inspection can find which type of discontinuity? J, Internal cracking of welds 2. Cracks open to the surface 3. Subsurface porosity 4. subsurface plate lamin: ns ‘59 For proper internal or external visual inspection surfaces mus! be: Wire brushed Walnut shell blasted. Hydto blasted The type of susface preparation depends on individual circumstances and could be any of the above. 60. Who normally performs welde certification tet, that is, which organization is responsible for performance and acceptance? 1. Inspection department 2 Company employing the welder 3. OSHA 4. The company safety department Fast Track Technical Training 281-482-2252 ~ www.apiexams.org 04/04 Rev. 4Closed Book API 510 Practice Exam A. 61, What isthe definition of a construction code? 1. Any standard used to vepait vessel 2. Any technique of construction 3° Any standard used to build a vessel 4. The Code or standard to which a vessel was o1 nally built, 62. Of the following tools which should th :pector have on hand for vessel inspections? Pencil and sote pad, flash light and scraper Social security card Clean fire retardant clothing Electrical conductivity testing equipment to test liners, 63. The pupose of a Welding Pioceduie Specification and its Procedie Qualification Record is: ‘To make sure every one involved in the repait process has a listing of nonessential variables ‘Make sure the welder follows the essential vaviables To prove the weld will provide the required properties Keep testing labs in business 64, Many of the problems that develop in operating vessels may be uaced to; 1 Cold winters 2. Qn-Streain inspections 3. Blectrical shorts 4. Faulty materials and workmanship 65. ‘The maximum content of iron in a nonferrous metal is 1. 35% 2 50% 3. 15% 4. 45% 66. Which of the following types of over pressure protection is not found on a pressure vessel? 1. Safety Reliet 2. Pilot Operated 3. Ruplwe Disk 4. Pressute/Vacuum Vent 67. If steel of a vessel has exceeded its yield point upon the removal of pressue and heat it will, 1. return to its original shape 2. contain a permanent deformation 3. split or ruptue 4. beoblong 6 Fast Track Technical Training 281-482-2252 ~ wwis.apiexams.or 0404 Rev. 4Closed Book API 510 Practice Exam A 68 Of the types of stresses placed on a thin walled cylinder the most severe is; 1 Circunferentiat 2. Longitudinal 3 Compressive 4° Radial 69. The report for qualifying a welder is: wes: POR weg WOR 70 Which of the following inspection techniques requites direct vi 1 examination ofthe test specimen? 1 Radiography testing 2. Ultasonic testing 3 Magnetic particle 4 Bddy cursent 71. A welding procedure is a detailed plan developed by whom to ensure sound welds. | API-S10 Inspector 2 Welder 3. Quality Control Manager 4, Fabricator 72. The primary cause of deterioration in pressure vessels is: 1. Corrosion 2. Operating conditions 3. Improper installation 4 Water damage 73, High pressure may develop in a vessel as a result of Rapid venting of a vessels pressure source Lowering heat below normal operating conditions ‘Thermal contraction of trapped fluids F Blocking off against a pressure source 74. Which ofthe following techniques is considesed the primary means to determine the minimum thickness ofa vessel’s components? ‘A hoat sample remove from a thin area Measuring from a corroded area Any suitable destructive method of examination ‘Ulasonie thickness measurements Fast Track Teel 281-482-2252 ~ www.apiexams.ore, 04/04 Rey.Closed Book API 510 Practice Exam A 75. The rules for impact testing of carbon steel in Section VILL vessel materials require what kind(s) of impact test. Brinelt & Rockwell Tod & Charpy V-notch Charpy V-notch only is acceptable Brinell only is acceptable 76 You have measured undercut on a girth weld during the repair to a vessel, it was found to be 1/32 inch jn depth, The base metal is 2 inches thick, and you should? 1. Reject the weld 2. Accept the weld 3. Consult the API S10 Code for accepteject crt 4. Consult with the Chief Inspector or Engineer before making a decision, 77. What is the minimum length of weld metal to be radiographed for a Weldei’s Pesformance Quatification using an NPS 6 inch pipe coupon made of P No 5 materials utilizing the SMAW process? 1 Six inches of weld metal 2. The entire citcumnference of the 3. Stops and starts only 4. None, not allowed by Section IX ‘coupon 78. ‘The API authorized pressure vessel inspector may give prior authorization for repairs that do not involve; 1. Prossure tests 2 Radiography 3. Pheumatic testing 4. Final visual inspections 79. The two types of impact tests required by Section VII Div. 1 are: 1. Jzod and Drop Weight 2 Brinell nd Rockwell 3 Charpy and Drop Weight 4, Weld metal and Base metal 80. Tn Section VII Div. 1 acceptance of a radiograph is based on; 1. the speed ofthe film used. 2. the geomettic unsharpness of the image 3° the absence of backscatter 4. the ability to see the essential hole or te, if a wine type 1Q1 is used. 281.482.2252 ~ www.apiexams.ore, 04/04 Rev. 4Closed Book API 510 Practice Exam A 81. A spot radiograph of a butt weld in 1 inch thick shell of a vessel marked RT-3 was found to have a rounded indication, the dimension of such an indication according to Section VII Div. 1 is; 1/32 of an inch. 1 of an inch, 2B of an inch 4, None, rounded indications are not a consideration with spot radiography. 82. Section VINI Div. 1, is very specific about the number of spot radiographs required when applying it for quality control, the basic premise is to; insure that all welds are made peafectly. ‘make sure someone is held responsible for any poor welding, apply the radiographs immediately after welding in order ta take convective steps if needed. five as many welders as possible, 83. A P No. | material that i plate has beet rolled inte a cylinder and butt welded. The cylinder is exactly 1-1/4" thick, and itis used in the repair of a pressure boundary on a U stamped vessel, the following is a teu statement 1. Teanust receive full radiography 2. Itmay be not spot radiographed 3. Itmay not be fully radiography. 4. Wmay receive spot, full, or nora sgraphy depending on oviginal the original UI form 84. Charpy impact tests are intended to prove that a material is; tough at the desired MDMT of the vessel to be constructed using that material. ‘some What prone to britle fracture acceptable for use in high temperature service, nol required to be heat treated, 85. According to Section IX, all welders must be re-ested for a process; 1. if they haye not been tested before. 2. they have not used a process in the past 9 months or longer: 3. _ifthey have not used a process forthe past [2 months or longer and have not been welding with other processes, 4. ifthe welder's ability to make sounds welds with process is in doubt. 86 ‘The testing apparatus used, and the techniques for pesforming Charpy impact tests are found ins 1. Section VII Div. 1 Paragraph UG-84 7 2 SA-270 3. $A-370 4. Section IX paragraph 401 32 87. An above the ground vessel is required to receive an exteinal inspection; 1 Bvery 4 yemrs 2. At the half corrosion-rate lif. 3. Byery 10 years 4. Every five years or atthe same interval as the intesnal inspection whichever is less. Fast Track Technical Trai 281-482-2252 ~ wws.ap ng 9 s.0re 4/04 Rev. 4Closed Book API 510 Practice Exam A 93. Before any repair to a pressure vessel in accordance with its code of construction, what if any additional requirements for inspection may need to be considered? 1. Junisdictionat requirements that might override the API 510 Code 2. Who is doing the repait? 3. The quality of the repair materials, 4, The need for qualified welding procedures. 94. Some jurisdictions require that welded repairs toa pressure vessel he documented by the completion and filing of A detailed report of the focation and extent of repairs A qualifications record of all repair personnel ‘A permit issued by the jurisdiction ‘The National Board of Boiler and Pressure Vessel Inspectors Form “R-1" 95. While inspecting an operating vessel you observe thal cacks are present in the connecting welds for a ‘znuge glass, you also notice vibrations are occurting in the assembly. Before you recommend corrective actions you should; J. Re-evahuate the materials sed in the fabrication ofthe gauge glass 2. Write a report ofthe location with a recommendation for the type of repairs needed. 3. Research the inspection records for previous failures ofthis type- 4, Check with a pessune vessel engineer (0 see ifthe cracks are caused by fatigue failure. 96. Which of the following describes a type/s of rupture disks? 1. Multiple layer of graphite impregnated Keviar fibers 2. Various metals - usually fat except ste! 3. Impervious graphite un-bul ped 4. Various metals, usually pre-bulged or impervious graphite, usually lat 97 The two types of graphitization are; |. Localized and random graphitization 2. Femitic and martensite graphitization. 3. Austenitic and martensitic grapbitization 4. Circular or globular graphitization 98. The main weason(s) for inspecting heat exchanger bundles after removal and prior to eleaning is/are; ‘Location of scale on tubes can reveal non-operational problems. Deposits on the tubes ean reveal acid contamination problems Color ofthe tube ends can reveu! de-zincification Color of deposits and scale can reveal coriasion problems Fast Track Technical Training n 281-482-2252 - plexams.org 04/04 Rev. 4Closed Book API 510 Practice Exam A 99. Hydrogen chloride becomes a problem when; 1. Exposed to air, it will thermally react and result in a fire 2. Exposed to water, it forms hydrochloric acid. 3. Exposed to water, it becomes unstable and can form an explosive compound 4. Exposed to water and air it produces formic acid 100. Which one of the following types of coating failures may not easily detected? Rust Blisters. 4. Film dispersions. IDL. Are nondestructive procedures allowed in Liew of hydrostatic testing, if so what must be done? |. Engineer experienced in pressure vessel design and the API inspector must be consulted 2. The API inspector and NBIC inspector must be consulted 3. The API inspector must be éonsulted. 4. Anexperienced engineer must be consulted. 1O2_ A new vessel has been installed, what must be done in order accept the vessel for operation? 1. A fits internal inspection. 2. A first internal inspection, however if a manufactures’ data report (Ul) assuring that the vessel is satisfactory for ils intended service is available the first internal may be waived 3. Buse line thickness readings must be taken per OSHA 1920 (j) 4 Base line thickness reading must be taken per OSHA 1910G). 103. A vessel is in a service that subjecs i to acidic fluids, what is a major concern for this type of service? 1. Graphitic induced conesion 2. Caustic blistering 3. Caustic embrittlement and cracking 4 Accelerated corrasion, Hydrogen blistering, and Hydrogen induced crac 108. Ordinarity non-metallic coatings and li igs can be most effectively inspected by what technique? 1. Law holiday tester 2. Radiography 3. Hammer testing 4. Using.a high voltage low current brush type electrode device (Spark Teste!) 105. A reliet valve has been shipped lying down on its side; this isa problem becnuse; 1 Relief valves are often heavy and are sometimes difficult to upright 2. Flange faces may be damaged during shipment 3. Springs inthe valve may shift and distost and as a result not exert the same force on stems and seals 4 Springs may stip out and be lost during shipment 2 Fast Track Technical Training 281-482-2252 - www.npiexams.org 04/04 Rev. 4Closed Book API 510 Practice Exam A. 106, A major concern(s) when inspecting « nozzle flange face is fare; 1. Brand name of the flange. 2. Biand name of the gaskets used in the Flange. 3, Surface cowtosion in the bot circle 4 Distortion of the flange and the condition of the gasket seating surfaces. 107. If there are leaks in a vessel's insulation system or protective coatings, corrosion can occut. At below what temperature is this corrosion most likely to be a problem? 250 °F 212 0F 350F 275 °F 108 Which of the following is subject to de-alloying when exposed to steam containing sulfur compounds? 1. Cuppro brass. 2. Naval brass 3. Admiralty brass, 4. Monel 109 Titanium alloys are subject to loss of ductility in certain environments, what is this condition called” 1, High temperature embrittlement. 2 Low temperature embrittlement 3. Hialloy effect 4. Hydriding 110. Which of the following normally determines the frequency of shop inspection/overhaul of a relief device? 1. Normal Basis 2 Manufacturer’ s Basis. 3. Other Basis 4 Inspector's basis and analysis, TLL Which of the following describes a crack in metal? J. Chicks run paraltel to the surface 2. Cracks run at right angles tothe surface 3. Cuacks are usually wide at one end and narrow at the other 4. Cracks run at obtuse angles to the surface. 112. Which of the following describes a lamination in metal plate? t ns usually represent large cavities. 2Laminations are fish mouth type openings and are only found on the edges of plate 3. Laminations run ata slant to the plate surface 4, Laminations run at an obtuse angle (o the plate surface Fast Track Technical Training B 281-482-2252 - wwwe.aplexams.ore 404 Rev. 4Closed Book API 510 Practice Exam A. 113. Above what temperature must hydrogen atack be considered a concesn in an operating carbon steel vessel? above 650°F below 650 OF below 450 °F above 450 OF 114, After removing an exchanger bundle you find a Prussian blue coating on the tubes, what da you suspect causes this coating? 5. Amino acid 2. Cyanide 3. Reitiferrocyanide 4. Phospharie acid 115. One major area of concern when inspecting guy wites for a vessel is crevice comosion, where does this occu? 1. On the free end of the tum buckle 2. Inthe threaded areas 3. On the guy wires 4 Where the wires comtact the ground 116. You are inspecting a failure in a vessel wall, what conditions would you look for if it was believed. thatthe fracture was brittle? 1. There is almost a no lack of ductility 2. The fractured surfaces has a smooth surface 3. The surface of the crack would have jagged edges 4. There is an almost complete lack of ductility and the failure site will have a faceted surface 17. What is the idest time to inspect pressure relief valves? 1. When the unit isin operation 2. When the unit is out of operation 3. For relief valves when the boiler is undergoing Jurisdictional Inspections. 4. When the inspection least intesfetes with the process and maintenance manpower is readily available 118. Temper embrittlement is best described as; 1, Cracking due to operating at high temperstures above 100 degrees F 2. Loss of ductility and notch toughness due to exposure above 700 degrees F 3. Flaking of the metal surfaces, causing dip pits 4. Ciacking due to low temperature service 119. Carbon dioxide considered corrosive when? When combined with glyco! When combined with water. ‘When combined with etylene. When combined with water arid high temperatures: 4 Fast Track Technical Training 281-482-2252 ~ ww yanlesams.ore 04/04 Rev. 4Closed Book API 510 Practice Exam A 120 Tf white salts are Found ot eracks in a vessel; itis an indication thatthe vessel contains an alkaline based chernical itis an indication thatthe vessel contains an acidic based chemical itis an indication thatthe vessel contains a low pH chemical itis an indication thatthe vessel had been operated above normal temperatures 121 The first consideration that must be given when the half bead temper bead technique of repair is proposed should he; |. Consultation with the jurisdiction, 2. Time required to do the repair, and personnel safety 3. Suitabtity fora given fluid service and any corrosion 4. Close monitoring of the welding operation stance required 122 A poor choice of material for ammonia service would be: L Stainless steels 2. Copper based alloys 3. Carbon steels 4. Carbon Molybdenum sieels 123. When manufacturing lubricating oils and aromatics the following chemical is used; 1. phenol 2. ammonia 3. hydrogen eyanide 4 glycol 124 Aluminum chloride can affect stainless steel in which ofthe following ways? 1. Severe pitting consion only 2. Inlergranular eracking only 3. Suess conosion cracking only 4, Stress comosion cracking and/or intergranular cracking ean occur 125. The Jow temperature corrosion of gray east irons is called; 1. graphitic corrosion 2. temper embrittlement 3. brittle fracture 4, incipient melting Fast Track Technical Training 15 281-482-2252 — wwieapiexams.org 04/04 Revs 4Closed Book API 510 Practice Exam A 126. A bulged metal rupeure disk with the pressure on the concave side has life expectancy of; 1. 5 years 2 2yeais 3. Lyear 4. Indefinite length 127. Most active of sulfur compounds found in vefinery service i 1. Mercaptans 2. Organic sulfur compounds 3, Hydrogen sutfide 4. Polymorphic sulfides when combined with polymer products 128. Which of the following are the materials could be expected to produce reliable magnetic particle ‘examination results? Monels Cupro-Nickels Austenitic Stainless Steels, Common Carbon Steels 129. Which of the fotlowing is an example of a microstructure change in metal? 1. Graphitization 2. Inteistitial conosion 3. Dembrittlement 4. Embossing 130. A common conosive compound found in enude oll is; 1. Nitwogen compounds 2. Phenolic acid 3. Napthinic acid, 4. Carbonic acid 131, Dezincification ocewrs by attacking metals which contains ‘Copper - zine alloys containing less than 95% of copper used in wate: service Copper- zinc alloys containing less than 85% of copper use in water service Copper - zine alloys containing les than 85% of cqpper used in caustic service Copper'- zinc alloys containing less than 95% of copper use in acidic service 132. Which of the following describes a physical change in metal? 1. Inte: granular contosion 2 Sensitization, 3. Banite solution 4. Amphorie layering 16 Fost Track Technical Training 281-482-2252 ~ www.aplesams.o1e 04/04 Rev. &133, Closed Book API 510 Practice Exam A ‘When looking for suiface cracks in a vessel made of ferrous material which of the following is the ‘most capable of detection? 135 136. 137 1, Fluorescent Penetiant Method. 2. Radiography 3. Fluorescent Magnetic Particle Method 4. Close visual Inspection with good lighting. ‘The majority of vessel foundations are constiucted using; 1. Hiigh grode (load bearing) concrete compounds 2. Structural ste! fireproofed with concrete 3. Concrete reinforced with polymers 4 Stiuctoral steel overlaid with refractory Which ofthe following is considered a construstion code? ASMEB 31.23 ASME B 33.2 ASME Section V ‘ASME Section VIII Div. 1 ‘Vanadium Oxide corrosion is not known to cea below: 1 1,050°R 2 1,100°F 3. 950° 4. 800 °F ‘Under which of the following condition(s) should you require to the removal of safety velief device(sy? 138 1. Ifa pressure test is being conducted in which the test pressure will exceed the get pressure of the safety relief valve with the lowest setting ‘The safety relief device was opening on a regulat, unexplainable basis Seepage had been discovered and operators have been consulted Surface corosion on the body ofthe deviee ‘The terating of vessel invalves the: Calculations fiom only a manufacturer experienced in pressure vessels Use of Non-Code requirements as established in accordance with the alternative 1ules of B31 3, Review Inspection records verify the pressure vesset has been in the proposed service previously. CCaleutations from either the manufacturer or an owner-user engineer experienced in pressure vessels Fast Track Technical Training 0 281-482-2252 — woe apiexams.org 04/04 Rev. 4