26-2-2018 Closed and open book exam

1- Included Fluid Services

Except as provided in 1.2.2, API 570 applies to piping systems for process
fluids, hydrocarbons, and similar
flammable or toxic fluid services, such as the following:
a) raw, intermediate, and finished petroleum and chemical products;
2- abandoned-in-place
Piping system, circuit or contiguous sections thereof meeting all of the
following: has been decommissioned with no
intention for future use; has been completely de-inventoried/purged of
hydrocarbon/chemicals; and; is physically
disconnected (e.g. air-gapped) from all energy sources and/or other
piping/equipment.

3- deadlegs
Components of a piping system that normally have little or no significant
flow. Some examples include blanked
(blinded) branches, lines with normally closed block valves, lines with one
end blanked, pressurized dummy support
legs, stagnant control valve bypass piping, spare pump piping, level bridles,
pressure relieving device inlet and outlet
header piping, pump trim bypass lines, high-point vents, sample points,
drains, bleeders, and instrument connections.
Deadlegs also include piping that is no longer in use but still connected to
the process.

4- defect
An imperfection of a type or magnitude exceeding the acceptance criteria.

5- material verification program

A documented quality assurance procedure used to assess metallic alloy
materials (including weldments and
attachments where specified) to verify conformance with the selected or
specified alloy material designated by the
owner/user.
NOTE This program may include a description of methods for alloy material
testing, physical component marking, and program
recordkeeping (see API 578).

6- minimum alert thickness (flag thickness)

A thickness greater than the minimum required thickness that provides for
early warning from which the future service
life of the piping is managed through further inspection and remaining life
assessment.

7- postweld heat treatment

PWHT
A work process which consists of heating an entire weldment or section of
fabricated piping to an elevated
temperature after completion of welding in order to relieve the detrimental
effects of welding heat, such as reducing
residual stresses, reducing hardness, and/or slightly modifying properties
(See ASME B31.3, paragraph 331).

8- quality assurance
All planned, systematic, and preventative actions required to determine if
materials, equipment, or services will meet
specified requirements so that the piping will perform satisfactorily in-
service. Quality assurance plans will specify the
necessary quality control activities and examinations.
NOTE The contents of a quality assurance inspection management system
for piping systems are outlined in 4.3.1.

3.1.86
9- quality control
Those physical activities that are conducted to check conformance with
specifications in accordance with the quality
assurance plan (e.g. NDE techniques, hold point inspections, material
verifications, checking certification documents,
etc.).

9- testing
Procedures used to determine pressure tightness, material hardness,
strength, and notch toughness.
EXAMPLE Example: Pressure testing, whether performed hydrostatically,
pneumatically, or a combination of hydrostatic/
pneumatic or mechanical testing.
NOTE Testing does not refer to NDE using techniques such as PT, MT,
etc.

10- Fewer CMLs can be selected for piping systems with any of the
following three characteristics: long, straight-run piping systems.
11- The type of surface preparation required depends on the
individual circumstances and NDE technique, but surface preparations
such as wire brushing, blasting, chipping,
grinding, or a combination of these preparations may be required.

12- When designating an injection point circuit for the purposes of

inspection, the recommended upstream limit of the
injection point circuit is a minimum of 12 in. (300 mm) or three pipe
diameters upstream of the injection point,
whichever is greater. The recommended downstream limit of the injection
point circuit is the second change in flow
direction past the injection point, or 25 ft (7.6 m) beyond the first change in
flow direction, whichever is less.

13- The owner/user is cautioned to avoid exceeding 90 % of the

specified minimum yield strength (SMYS) for the material at
test temperature and especially for equipment used in elevated
temperature service.

14- If the liquid is flammable, its flash point shall be at least 120 °F
(49 °C) or greater

15- 5.12 Material Verification and Traceability

The owner/user shall assess the need for and extent of application of a
material verification program consistent with
API 578 addressing inadvertent material substitution in existing alloy piping
systems. A material verification program
consistent with API 578 may include procedures for prioritization and risk
ranking of piping circuits. That assessment
may lead to retroactive PMI examination, as described in API 578, to
confirm that the installed materials are
consistent with the intended service. Components identified during this
verification that do not meet acceptance
criteria of the PMI examination program (such as in API 578) would be
targeted for replacement. The owner/user and
authorized piping inspector, in consultation with a corrosion specialist, shall
establish a schedule for replacement of
those components. The authorized inspector shall use periodic NDE, as
necessary, on the identified components until
the replacement.
In lines in older process units operating above 500 °F (260 °C) and subject
to sulfidation corrosion, carbon steel
piping containing less than 0.1 wt % silicon can corrode at significantly
higher rates than higher silicon carbon steels
(modern “silicon-killed” process). For piping systems / circuits that have
been identified in sulfidation corrosion service
that may contain older low silicon carbon steels, consideration should be
given to conducting inspection of each
piping segment in order to identify the worst case corrosion rate / limiting
component.

16- 6.3.4.3 Class 2

Services not included in other classes are in Class 2. This classification
includes the majority of unit process piping
and selected off-site piping. Typical examples of these services include but
are not necessarily limited to those
containing the following:
a) on-site hydrocarbons that will slowly vaporize during release such as
those operating below the boiling point but
above the flash point,
b) on-site hydrogen, fuel gas, and natural gas,
c) on-site strong acids and caustics.
 17- PRDs shall be tested and repaired by a repair organization
experienced in pressure relieving device maintenance.
PRDs should be inspected, tested, and maintained in accordance with API
576.

18- Pressure-relieving devices shall be tested and inspected at

intervals that are frequent enough to verify that the valves
perform reliably in the particular service conditions. Other pressure-
relieving devices (e.g. rupture disks and vacuumbreaker
valves) shall be inspected at intervals based on service conditions. The
inspection interval for all pressurerelieving
devices is determined by the inspector, engineer, or other qualified
individual per the owner/user's quality
assurance system

19- 6.7.3.2 PRD Testing and Inspection Intervals

Unless documented experience and/or an RBI assessment indicates that a
longer interval is acceptable, test and
inspection intervals for pressure-relieving devices in typical process
services should not exceed:
a) 5 years for typical process services, and
b) 10 years for clean (non-fouling) and noncorrosive services.

The principles of ASME B31.3 or the code to which the piping system was
built shall be followed to the extent
practical for in-service repairs.

All proposed methods of design, execution, materials, welding procedures,

examination, and testing shall be
approved by the inspector or by the piping engineer, as appropriate.
Owner/user approval of on-stream welding is
required.

20- If the repair area is localized (for example, pitting or pinholes)

and the SMYS of the pipe is not more than 40,000 psi
(275,800 kPa),

21- patches may be any shape but shall have rounded corners [1
in. (25 mm) minimum radius].
See ASME PCC-2 Part 2 for more information on various welded repairs to
piping systems.

22- Definition of HAZ

23- All repair and alteration welding shall be done in accordance
with the principles of ASME B31.3 or the code to which
the piping system was built.
Any welding conducted on piping components in operation shall be done in
accordance with API 2201

24- PWHT  to relieve residual stresses

25- Buried piping  very important

26-

27- Leak Testing Intervals

An alternative or supplement to inspection is leak testing with liquid at a
pressure at least 10 % greater than maximum
operating pressure at intervals one-half the length

the line repressurized to original test pressure and isolated from the
pressure source. If, during the
remainder of the test period, the pressure decreases more than 5 %, the
piping should be visually inspected
externally and/or inspected internally to find the leak and assess the extent
of corrosion. Sonic measurements may be
helpful in locating leaks during leak testing.

ASME V  MT about 4 questions open book

ASME IX  WPS & PQR open book

API 571  Sulfidation & Galvanic Corrosion

The noble material in Galvanic corrosion is the Cathode

ASME B31.3  Reinforcement & undercut in table 331.1

ASME B31.3  Modulus of elasticity

About 15 questions on Remaining life time & corrosion rate

1. Temporary piping repairs may remain for an indefinite period of time if they are
approved and documented by the:

A) Authorized Piping Inspector

B) Manager of Maintenance

C) Operations Manager

D) Piping Engineer

Answer: D … API 570, Para. 8.1.4.1, last sentence in Paragraph, API 570 Pg 52!

5. TML readings on a piping system indicate that a corrosion rate has increased.
The Inspector’s most appropriate response is to:

A) Recalculate the inspection interval of the system

B) Recalculate the piping circuit average corrosion rate

C) Schedule the next inspection within six months (very soon)

D) Report this change in condition to the Maintenance Supervisor

Answer: A … API 570, Para. 7.1.1, Last Para.  LT & ST corrosion rates should be
compared to see which results in shortest RL as part of the data assessment!

08. To which of the following fluid services does API 570 specifically apply?
A) Category D fluid services as defined in ASME B31.3

B) Raw, intermediate, and finished petroleum products

C) Hydrocarbons and utility streams

D) Steam and steam condensate

Answer: B … API 570, Para. 1.2.1 & 1.2.1.a

10. An imperfection exceeding the acceptable criteria is known as a/an:

A) Flaw B) Defect

C) Discontinuity D) Indication

Answer: B … API 570, Para. 3.1.17  Definition of Defect

‫صيغه السؤال مختلفه لكن االجابه واحده‬

11. During radiographic examination of a weld, a wire-type IQI shall be placed:

A) Adjacent to the weld so that the length of the wire is perpendicular to the weld

B) Adjacent to the weld so that the length of the wire is parallel to the weld

C) On the weld so that the length of the wire is perpendicular to the weld

D) On the weld so that the length of the wire is parallel to the weld

Answer: C … API 577, Para. 9.8.2.a, ASME V, Art 2, T-277.1.d  Know Hole type!

‫صيغه السؤال مختلفه لكن االجابه واحده‬

15. Measurements from inspection of Class 3 pipe reveal actual metal thickness
of 0.350 inches. Calculated minimum thickness is 0.250 inches. If the corrosion
rate is 0.0025 inches/year, the NEXT thickness measurement inspection is due in:

A) 3 years B) 5 years C) 10 years D) None of these

Answer: C … API 570, Para. 6.3.3 & Table 2 (Should state NO RBI … old question)
Solution: Use the Lesser of ½ RL or Table 2 Value for UT Class 3 (which is 10
yrs) .350 - .250 = .100 mils RL ÷ 0.0025 loss/yr = 40 yrs RL = ½ RL = 20 years 
Use 10

19. After each inspection or significant change in operating conditions, the:

A) Corrosion Engineer must be notified

B) Inspection intervals must be adjusted

C) Authorized piping inspector must be notified

D) Inspection intervals must be reviewed and adjusted as needed

21. Vertical supports constructed of pipe components should be checked to
determine if they are filled with water, because water inside a support may cause:

A) Internal corrosion of the support B) Internal corrosion of the process pipe

C) External corrosion of the support D) Additional stress to be placed on a support

Answer: A … API 570, Para. 5.5.4 (2nd Paragraph)  External Inspection Question

26. Which inspection method is most appropriate for detecting chloride stress
corrosion cracking in austenitic stainless-steel piping systems?

A) Longitudinal wave ultrasonics

B) Dry magnetic particle method

C) Liquid Penetrant

D) Radiography

Answer: C … API 571, Para. 4.5.1.7.b

28. On what basis are image quality indicators selected?

A) The strength of the radiation source

B) The film type used by the radiographer

C) The alloy content of the material being radiographed

D) The thickness of base material plus weld reinforcement

Answer: D … ASME V, Art T-276 (a) & (b) … IQI reinforcement rule (Table T-276)

30. Evaluation of the record of the previous inspection reveals that thickness
readings and the resulting calculation were inaccurate. The corrosion rate to be
used for the next inspection period shall:

A) Be the short-term corrosion rate from the record

B) Be changed to agree with the actual corrosion rate found

C) Not be changed to actual rate found until rate is confirmed at the next inspection

D) Be the average of the short-term and long-term corrosion rates from the record
Answer: B … API 570 Section 7.1.3, 2nd Para

1. A piping system has a design pressure/temp of 500 psig at 900°F. What is the
minimum acceptable flange class if the flange material is ASTM A-182 Gr. F22?
A) Class 300 B) Class 400

C) Class 600 D) Class 900

Ans: B … 2009 ASME B16.5 Table 1A Mat’l Grp 1.10 on pg 4 Table 2-1.9 (pg 118)
Use psi tables (not bar)  Class 300 = Only good for 450  Class 400 = OK to 600

12. An inspection reveals that a repaired NPS 4 seamless pipe, A-53 Gr. B, has a
thickness of 0.180 inches. If the service is 1000 psig at 500°F, what is the actual
remaining corrosion allowance considering only internal pressure?
A) 0.043 inches B) 0.064 inches C) 0.070 inches D) 0.116 inches

Answer: B … Barlow calc, ASME B31.3 Table A-1 (S=19 ksi), Table A-1B (E = 1.0),
PD = 1,000 x 4.500 = 4,500 ÷ 38,000 (2SE=2x19000x1)=.118 … .180 - .118 = 0.062 in.

13. For piping systems where service conditions have been changed, if data for
the same or similar service is not available, a corrosion rate is estimated from the
experience of the owner/operator or from:
A) Published data on piping systems in comparable service

B) The highest known corrosion rate in the unit

C) A default corrosion rate of 10 mils per year

D) Worst case industry data

Answer: A … API 570, Para. 7.1.2.b …

14. An NPS 12 carbon steel standard pipe in Class 2 service, designed to operate
at 450 psig and 500°F (260°C) with an allowable stress of 20 ksi, has a thickness
at inspection of 0.280 inches (7.1 mm). What is the maximum interval for the next
thickness measurement inspection (assume no RBI, E=1.0, Corr. rate = 25 MPY)?

A) 2.7 years B) 5 years

C) 5.5 years D) 10 years

Ans: A … 570 Par. 6.3.3  UT Thickness meas interval = Lesser of 10 yrs or ½ RL

t required = PD ÷ 2SE: 450 x 12.75 ÷ 2 (20,000) (1) = 5,738 ÷ 40,000 = 0.143 inches

RL = 0.280 in. (t actual) – 0.143 inches = 0.137 inches ÷ 0.025 (25 MPY) = 5.48 yrs

Use lesser of ½ RL (½ RL = 2.74 yrs) or Table 2 value 10 years (Class 2) = 2.7 yrs

3. An NPS 8 pipe operating at a maximum of 675 psi and 650°F (ASTM A106 Gr. B)
will use what stress value to determine the pipe’s minimum thickness?

A) 16.5 ksi (16,500 psi) B) 17 ksi (17,000 psi)

C) 17.3 ksi (17,300 psi) D) 20 ksi (20,000 psi)

Answer: C … 2010 ASME B31.3 A-1 Tables (Pg 153)  Use col. 650°F = 17.3 ksi!

7. The maximum depth of undercut for a girth weld in normal fluid service having
a thickness of 0.50 inches (13 mm) is:
A) No visible undercut B) 1/64 inch (0.4 mm)

C) 1/32 inch (1 mm) D) 1/16 inch (1.5 mm)

Answer: C … 2010 ASME B31.3 Table 341.3.2 (Normal Fluid Service = H = ≤ 1mm)

9. In evaluating a thinned area of piping, the allowable stress shall not be greater
than:
A) ½ of the SMYS B) 2/3 of the SMYS

C) 90% of the SMYS D) 75% of the ultimate tensile strength

Ans: C … 570, Para. 5.8 Caution Note … Know the 90% SMYS rule!

10. Which of these MAWP values is correct for a piping system designed at 380
psig at 700°F, having A53 Gr. B seamless pipe, latest UT = 0.28 inches, observed
corrosion rate = 0.005 inches per year, and the next inspection is in 4 years?

API left out diameter on this test question … Assume an 18 NPS piping system

A) 337 psig B) 380 psig

C) 396 psig D) 446 psig

Answer: D … 570, Table 4 MAWP Calc = MAWP = 2SEt ÷ D … Note D = not given!
S = 16.7 KSI (B31.3 A-1 Tables), E = 1.0 Seamless Pipe (A-1B Tables), D = 18.0
Step # 1: Solve t … .280 in. minus twice ECL (ECL = .020) = .280 - .040 = .240 in.
Step # 2 … Math … 2 x 16,700 x .240 ÷ 18 = 33,400 x .240 ÷ 18 = 8,016 ÷ 18 = 445.33

14. The density of step wedge comparison film and densitometer calibrations
shall be verified by using calibrated step wedge film traceable to:

A) An ASME V Standard certified film B) An ASME calibrated step wedge

C) An ASNT certified procedure D) National standard (step tablet)

Answer: D … ASME V, Art. 2, T-262.1.a  Densitometer/Step Wedge Comp. Film

23. In general, the corrosion resistance of iron and nickel alloys in sulfidation
atmospheres is dependent upon the content of:

A) Molybdenum B) Chromium C) Nickel D) Niobium or titanium

Answer: B … API 571, Par. 4.4.2.3.e  McConomy Curves  Chromium content

34. Which of these is a predominant factor in mechanical fatigue cracking?

A) Operating equip past remaining life B) Low-stress stamping

C) Impact toughness D) Surface notches

Answer: D … API 571, Par. 4.2.16.3.a.1 … Also know good design prevents MF

36. What is maximum permissible height of weld reinforcement for a girth weld in
Normal Fluid service for piping having a wall thickness of 3/8 inch (10 mm)?
A) 1/16 in (1.5 mm) B) 1/8 in (3 mm)

C) 5/32 in (4 mm) D) 3/16 in (5 mm)

40. A welding discontinuity is:

A) Condition of being imperfect/departure of quality characteristic from its intended cond

B) An imperfection or unintentional nonconformance that is detectable by NDE

C) A lack of cohesion; an interruption in the normal physical structure

D) The response or evidence from the application of NDE

Answer: C … API 577, Table 8, Page 56, Definition A-2 … Very hard to find …
Make notes in definitions to look here  Be smart!!!!

Qs 48 – 52 refer to WPS/PQR EM-2-1 on following 4 pages

48. Do tensile test results shown on PQR EM2-1 meet the requirements for WPS?

A) Yes

B) No, specimen 1 does not meet requirements

C) No, specimens 1 & 3 do not meet requirements

D) No, because multiple specimens cannot be used

Answer: B … ASME IX, Table QW-451.1 & QW-150 (151/152/153) & QW-422 Tables

Note: Specimens are ½ size (reduced t from 1.25 in), need 4 not 2 per Table 451.1

Note: Tensile = 55,000 per QW-422 Tables … specimen breaking in the weld metal
is OK at 55,000 … specimen breaking in base metal = Ok at 55,000 x 95% (5% rule)
and 55,000 x 0.95 = 52,250, so specimen # 3 is OK breaking at 53,000 … Specimen
# 1 that broke in the weld metal at 53,350 must be rejected for being under 55,000.

49. Bend test results shown on PQR EM2-1 are:

A) Acceptable

B) Unacceptable, wrong type of bend specimen was used

C) Unacceptable, because multiple specimens are required

D) Unacceptable, because of an insufficient number of bend specimens

Answer: B … ASME IX, Table QW-451.1 & QW-160  Four SIDE bends required

API 570 EXAM D, Part 1 (50 OPEN BOOK Q & A)

50. Does the WPS show the maximum base metal thickness range that could be
qualified by the PQR EM2-1?

A) Yes
B) No, it should be 3/16 inch to 1.25 inches

C) No, it should be 3/16 inch to 2.50 inches

D) No, it should be 3/16 inch to 8.00 inches

Answer: C … ASME IX, Table QW-451.1  Big T column for WPS qualified range

END OF API HOT DOG (OPEN BOOK 50 Q&A)

2 Bonus Qs  KNOW GTAW RULES ALSO

(Know 10 SMAW Essential Variables QW-253)

51. Does the PQR properly qualify the WPS regarding PWHT requirements?

A) Yes

B) Yes, but only because the thickness range covers the entire WPS range

C) No, because the PQR does not show evidence that PWHT was performed

D) No, because the PQR does not cover the lower transformation temperature range

Answer: C … ASME IX, Table QW-253 Table (SMAW) & QW-407.1  PWHT rules

52. Does the PQR properly qualify the WPS regarding Preheat requirements?

A) Yes, the preheat on the PQR covers all ASME IX rules for WPS application

B) Yes, but only because the interpass temperature range is required for P-No 1

C) No, because PQR preheat temps were performed outside of essential variable limits

D) Neither no or yes because there is still an outstanding issue to be resolved in writing

Answer: A … ASME IX, Table QW-253 Table (SMAW) & QW-406.1  Preheat rules

See WPS & PQR-EM2-1 Next 4 pages (Qs 48 –

52)
3. Welders who qualify with one filler metal are qualified to weld with any filler
metal having the same:

A) F–number B) P–number

C) A–number D) A–number & P–number

Answer: A … API 577, Para. 7.3, 2nd Para.  ASME IX, Table QW-432 (F-Nos)

33. Measurements from inspection of Class 3 pipe reveal actual metal thickness
of 0.350 inches. Calculated minimum thickness is 0.250 inches. If the corrosion
rate is 0.0025 inches/year, the NEXT thickness measurement inspection is due in:

A) 3 years B) 5 years C) 10 years D) None of these

Answer: C … API 570, Para. 6.3.3 & Table 2 (Should state NO RBI … old question)
Solution: Use the Lesser of ½ RL or Table 2 Value for UT Class 3 (which is 10
yrs) .350 - .250 = .100 mils RL ÷ 0.0025 loss/yr = 40 yrs RL = ½ RL = 20 years 
Use 10

34. Which 2 positions qualify a welder for all positions when welding 8-inch pipe?

A) 2G and 5G B) 1G and 3G

C) 1G and 2G D) 2G and 3G

Ans: A … ASME IX, QW-303 sends you to TABLE QW-469.1 (MUST KNOW TABLE)
YOU MUST KNOW … “6G” RULE & “2G+5G” RULE & “24 NPS RULE PIPE/PLATE
… SO BE SURE TO HIGHLIGHT ALL CRITICAL TABLES IN ASME IX

46. ASNT recommended Practice SNT-TC-1A is a:

A) Manual covering nondestructive examination (NDE) safety procedures

B) Procedure for the visual examination of piping systems

C) Document covering NDE personnel qualifications

D) Document covering NDE procedures

Answer: C … API 570, Sect 2 Reference/Para. 4.3.5.2 & ASME V … MUST KNOW

56. Soil-to-air interface inspections should be included in:

A) Deadleg inspections
B) Injection point inspections

C) External piping inspections

D) Corrosion under insulation inspections

Answer: C … API 570, Para 5.5.5 & Sect 6, Table 2 & API 574, Para. 7.4.5  2 rules

59. In-service ultrasonic testing measurements at TML points indicate thinning in

the heat-affected zone of an elbow-to-weld neck flange on an NPS 30 vapor line.
What is the best method to determine the extent of the deterioration during the
next scheduled downtime?

A) Internal inspection

B) UT A-scan of the elbow

C) Spot radiograph of the welds

D) Full radiography of the elbow

Answer: A … API 570, Para. 5.5.1 … 2nd sentence

61. How many welds does API 577 require to be inspected?

A) None B) All welds

C) Representative number D) 50% of welds

Answer: C … API 577, Section 1 Scope, 2nd Para … Selected by Inspection, etc

62. Acceptance of a welded repair or alteration shall include NDE in accordance

with the applicable code and:

A) B31.3 specifications

B) Owner/user specifications

C) ASME/ANSI V specifications

D) Guidelines of owner/user’s insurance carrier

Answer: B … API 570, Section 8.2.6, 1st Sentence

64. Which of the following is NOT considered an effective means of cleaning the
surface of piping to be inspected for cracks?
A) Steamout & chemical cleaning

B) High-pressure water blasting

C) Wire brushing

D) Sandblasting

Answer: A … API 572, Section 8.2 … Last Paragraph & Section 9.3.14, 9 th Para.

95. After completion of alterations or major repairs, a pressure test is:

A) Normally required
B) Not normally required
C) Required if deemed necessary by Examiner
D) Mandatory per API 570
Answer: A (API 570, 8.2.6 First Paragraph) … Normally required after alterations

‫بس جاه بصيغة تانية‬

97. Any welding conducted on piping components in operation must be done in accordance
with this document, and Inspector shall use as a minimum “Suggested Hot Tap Checklist”
contained in this document for hot tapping performed on piping components. Which of the
following documents referenced in API 570 addresses hot tapping?
A) API 2201 B) API 574 C) ASME B31.3 D) ASME PCC-2

Answer: A (API 570, 8.2)

100. General types of inspection & surveillance recognized for piping systems per API 570
include all of these EXCEPT:
A) Internal visual and external visual inspections

B) On-stream and thickness measurement and supplemental inspections

C) CUI inspection and vibrating piping inspection and Injection point inspection

D) Infrared Thermography for Hot spots, RT for fouling/plugging, Soil/Air interface inspections

Answer: D (API 570, 5.5)  These are not general types of inspection as per API 570