Name: ______________________ Badge Number: _____________ Date: March 8, 2011

1. What is the required thickness, given the design conditions below for an existing piping system with a zero corrosion allowance (internally lined)? A) 0.168 inches B) 0.147 inches C) 0.135 inches D) 0.186 inches

Given: Design Pressure & Temperature = 600 psig @ 500F, 10 NPS A-106-B Seamless pipe Show your work in the space provided and include all math steps as shown in class:

2. What is the required thickness, given the same design conditions in question # 1 above utilizing a given Corrosion Allowance of .062 inches (1/16)? A) 0.197 inches B) 0.230 inches C) 0.209 inches D) 0.248 inches

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3. What is the required thickness (as defined by API 570), given the same design conditions in the question # 1 above and owner/user Engineering structural minimum thickness requirement of .150 inches for NPS 10 piping systems of all Classes? A) 0.147 inches B) 0.150 inches C) 0.168 inches D) None of these

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Name: ______________________ Badge Number: _____________ Date: March 8, 2011

4. For calculating minimum required thickness for straight pipe under internal pressure, what values are used in the formulas for pressure design thickness & minimum required thickness? A) T = pressure design thickness and t = minimum required thickness B) t = pressure design thickness and T = minimum required thickness C) t m = pressure design thickness and t = minimum required thickness D) t = pressure design thickness and t m = minimum required thickness

5. What is the minimum required thickness of a blank made from ASTM A516 Gr. 60 Plate Material with a with a ring joint design and gasket pitch diameter of 12 inches in a piping system with a design pressure of 400 psi @ 300F? A) .632 inches. B) .756 inches. C) .692 inches D) .734 inches.

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6. Using the same given design and values as question # 5 above, include a given Corrosion allowance of .125 inches (1/8). What is the required minimum thickness now? A) .757 in. B) .881 in. C) .817 in. D) .859 in.

7. For calculating minimum thickness of a blank, value dg = all of the following except: A) Inside diameter of gasket for raised or flat face flanges B) Inside diameter of gasket for ring joints C) Gasket pitch diameter for ring joints D) Gasket pitch diameter for fully retained gasketed flanges

8. What is the minimum metal temperature exempt from impact testing for API 5L, Grade X-60 seamless pipe having a .750 nominal thickness & having been normalized during manufacture? A) 53F B) 15F C) -20F D) 30F

Name: ______________________ Badge Number: _____________ Date: March 8, 2011

INSTRUCTIONS: THIS PROBLEM COVERS QUESTIONS 9 14 ON THIS PAGE Inspection records contain the following information for thickness measurement location (TML) in an elbow located just outside of a cooling tower flanged connection. Thickness 0.375 @ Baseline UT performed in 2000, 0.350 after 5 years in 2005, and 0.300 after 10 years in 2010. Other Information: The .300 inch thickness is the lowest reading in the piping circuit and showed an increase in loss since the last inspection, due to increased flow velocity, according to the Plant Corrosion Specialist. The required thickness is .200 in. and the piping Circuit was designated as Class 3 for Cooling Water and the 24 NPS line is insulated and adjacent to the cooling tower! 9. On the basis of information above, long-term corrosion rate for the location is: A) 1 mils per year B) 7.5 mils per year C) 10 mils per year D) 15 mils per year.

10. On the basis of information above, short-term corrosion rate for the location is: A) 1 mils per year B) 5 mils per year C) 10 mils per year D) 15 mils per year.

11. On the basis of information above, remaining life of the piping system is: A) 1 years B) 5 years C) 10 years D) 25 years

12. On the basis of information above, half-remaining life of the piping system is: A) 9 months B) 2.5 years C) 5 years D) 12.5 years

13. On the basis of info above, maximum inspection interval of the piping system is: A) 9 months B) 2.5 years C) 5 years D) 10 years

14. The insulation on this 24 NPS line approximately 100 meters long and is damaged in some locations. The Inspector has called for the API 570 recommended % of insulation removal for this condition & total area of insulation = 190 sq. meters. How much insulation will be removed? A) 19 sq. meters B) 1.9 sq. meters C) 47.5 sq. meters D) 4.75 sq. meters

Name: ______________________ Badge Number: _____________ Date: March 8, 2011

15. A piping system designed at 500 psi & 600F is to be hydrostatically tested using the liquid content which is flammable. The pipe material is A-53B Seamless Sch 80 NPS 6. What is the hydrostatic test pressure if the test is conducted at 100F or below? A) 750 psig B) 794 psig C) 812 psig D) 867 psig

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16. The minimum hold time for a Hydrostatic leak test per ASME B31.3 code is: A) 5 minutes B) 10 minutes C) 15 minutes D) 30 minutes

17. Determine the Corrosion Rate, correct Inspection Interval (from choices given) & MAWP of corroded pipe given the detailed information below and be sure to follow API 570 rules! Design pressure/temp = 500 psig/500F for A106 Gr B Seamless NPS 10 STD wall Pipe, Measured Thickness in 2001 = .360, in 2006 = .330, in 2011 = .300, Corr. Rate = unknown A) Corrosion rate is 6 MPY, the inspection interval = 5 years, and the MAWP = 857 psi B) Corrosion rate is 5 MPY, the inspection interval = 10 years, and the MAWP = 864 psi C) Corrosion rate is 6 MPY, the inspection interval = 5 years, and the MAWP = 844 psi D) Corrosion rate is 6 MPY, the inspection interval = 5 years, and the MAWP = 867 psi

Name: ______________________ Badge Number: _____________ Date: March 8, 2011

18. You are evaluating Charpy impact test results for piping material with a 0.236 in. thickness, and where the largest attainable Charpy V-notch specimen has a width along the notch of 0.157. At what temperature must Charpy testing be conducted? A) Design minimum temperature B) Not higher than design minimum temperature C) 15F below MDMT D) 30F below MDMT

Answer questions 19 through 21 below (PQR Review)

Given: NPS 12 schedule 120 (1.00 in. thick), A-106-C, P No-1, Group 2 (C-Mn-Si Composition) Note: All test results were signed & accepted by Egyptian Mech. Testing Group (Babu B. Babu) Tensile Test specimen # 1 (full size 25mm) Results = 66,500 Failure location = Base metal Tensile Test specimen # 2 (full size 25mm) Results = 69,900 Failure location = Weld metal Guided Bend (side bend) specimen # 1 results = Pass 3 mm slag in the weld area Guided Bend (side bend) specimen # 2 results = Pass 2 mm crack in the weld area Guided Bend (side bend) specimen # 3 results = Pass 3.5 mm incomplete fusion in weld area 19. The two tensile test values provided above were reviewed and found to be: A) Specimen # 1 & 2 are rejectable, both below the required tensile value in ASME IX B) Specimen # 1 is rejectable and # 2 is acceptable as per ASME IX C) Specimen # 1 is acceptable and # 2 is rejectable as per ASME IX D) Specimen # 1 & 2 are acceptable because Babu signed the report

20. The guided bend test results provided above were reviewed and: A) Specimen # 1 & 2 are acceptable, and specimen # 3 is rejectable as per ASME IX B) Specimen # 1 is rejectable, # 2 is acceptable, and # 3 is rejectable as per ASME IX C) Specimen # 1 is acceptable and # 2 is rejectable, and # 3 is acceptable as per ASME IX D) Specimen # 1 is rejectable, and # 2 is acceptable, and # 3 is acceptable as per ASME IX

21. Are the number of tensile test & guided bend test specimens adequate as per ASME IX? A) Yes, Per Table QW-451, the side bends may be substituted for face & root bends B) Yes, because only two specimens are required for each test, given the information above C) Both A & B are correct. The number of specimens is acceptable even if the results are not D) No, because the requirements & notes of Table QW-451 have not been met

Name: ______________________ Badge Number: _____________ Date: March 8, 2011

22. Essential variables are those in which a change, as described in the specific variables, is considered to affect the mechanical properties of the weldment, and shall require requalification of the WPS. Nonessential variables are those in which a change, as described in the specific variables, may be made in the WPS without requalification. All WPS & PQR points must never be left blank (even when a non-essential variable). Supplementary essential variables are: A) Required for metals only when other code Sections specify notch-toughness tests B) In addition to the essential variables for each welding process when impact tests are required C) The same as essential variables, depending upon the welding process utilized D) Both A & B are correct 23. Regarding hole-type Image quality Indicator (IQI) placement & location, IQIs must be placed on the source side of the film. However, where inaccessibility prevents hand placement of IQI(s) on source side, IQI(s) shall be placed on film side in contact with the part being examined. What additional requirements exist regarding this placement of the IQI on the film side? A) Lead letter F shall be placed adjacent to or on IQI(s) B) Lead letter F shall not mask any essential hole where hole type IQIs are used C) Both A & B are correct D) None of the above is correct 24. The code user must have a Quality Program that details how NDE personnel are qualified and
certified. Qualifications must be in accordance with SNT-TC-1A or CP-189. What is meant by the term code user as it relates to a Quality Program for NDE training as per ASME V Code?

A) Manufacturer, fabricator, or Installer performing NDE B) Employer of the NDE personnel C) Any organization conducting NDE to the requirements of ASME V D) None of those listed above 25. What is the essential hole & hole type designation (assume a source side IQI was used) for 4 inch NPS Sch 40 pipe weld in the as welded condition. Apply code rules and use the Table! A) Essential hole is a 2T, with a hole type designation of 10 B) Essential hole is a 2T, with a hole type designation of 12 C) Essential hole is a 2T, with a hole type designation of 15 D) None of the above are acceptable

Name: ______________________ Badge Number: _____________ Date: March 8, 2011

Fig. 328.5.2B Typical Details for Double-Welded Slip-On Flg Attachment Welds 26. What are the minimum required fillet weld sizes (front & back welds) for a double welded slip on flange per Fig.328.5.2B using Detail (1), given a 3 NPS Sch 40 pipe & class 150 rated slip-on welding flange? A) 5.6 mm for the front weld (ID) & 8.6 mm for the back weld (OD) B) 6.0 mm for the front weld (ID) & 7.8 mm for the back weld (OD) C) 6.0 mm for the front weld (ID) & 6.0 mm for the back weld (OD) D) 5.6 mm for the front weld (ID) & 7.8 mm for the back weld (OD)

Show your work in the space provided and include all math steps:

27. What is the minimum required fillet weld size for a socket weld on a NPS 1 Sch 160 Seamless A-106 Gr B pipe, design @ 750 psi & 400F? (Fig.328.5.2C of ASME B31.3) A) .024 inches B) .130 inches
Solve for t Show

C) .187 inches

D) .125 inches

your work in the space provided and include all math: