263187400.doc 1. Name 3 types types of pressure pressure vessels and and containers containers that are are excluded excluded from A! "10. "10. a. b. c. d.
PV’s PV’s cove covere red d by by jur juris isdi dict ctio iona nall reg regul ulat atio ions ns All PV’s with with classes exempted exempted in Sec VIII PV’ PV’s not not exce exceed edin ing g 5 cu cu !t !t " #5$ #5$ PSI PSI % & cu. 't " ($$ PSI
2. #o$ is %A& %A& determined determined for the continued continued use of of a pressure pressure vessel' vessel' )y calculations based on the latest edition o! Sec VIII *iv. % or the original construction code it was built
3. &hat type type of exami examinati nation on is most importa important' nt' Visual
4. &hat is the the differen difference ce (et$een (et$een alter alteratio ation n and repair repair' ' Any duplicate or comparable replacement or addition o! any rein!orced no++le less than or e,ual to the si+e o! the existing no++le ". Alteration is a change in the physical char. Such as wor-ing pressure and temp rating.
". !s the addition of an unreinforced unreinforced no))le an alteration alteration or repair' repair' the addition o! an unrein!orced no++le is not considered an alteration
6. &hen is is field field inspecti inspection on of a ne$ ne$ vessel vessel not re*u re*uire ired' d' As long as the manu!acturer’s data report assuring that the vessels are satis!actorily !or their intended use.
7. A(ove +round +round vessels shall shall (e +iven a visual external external inspection inspection at $hat $hat interval' interval' ach vessel aboveground shall be given a visual external inspection pre!erably wile in operation at least every 5 years or at the same interval as the re,’d internal or on stream inspection whichever is less.
8. Name 3 types types of surface surface prep prepara aration tion that that may may (e needed. needed. Power wire brushing/ abrasive grit cleaning/ high pressure water blasting and power chipping.
,. &hat is the max test-inspecti test-inspection on interval interval permitted permitted for pressure pressure relievin+ relievin+ devices' devices' 0ust not exceed 5 years.
10. efine on stream stream inspection. inspection. It is used to establish suitability suitability o! a PV !or cont’d. operation using 1* " is not entered !or internal inspection.
11. 11. Name the 3 types of information that the o$ner-user o$ner-user records records must maintain for each pressure vessel. 2onstruction and *esign In!o/ 3perating and Inspection 4istory/ epair/ Alteration Alteration and rerating in!o./ !itness !or service assessment documents
12. efine efine reratin+. reratin+. 2hange in temp rating or 0A6P o! a vessel
13. #o$ many years experience experience must a hi+h school +raduate have to *ualify as an /$ner-ser !nspector under A!"10' 5 years
14. Name " modes of deterioration. 7raphiti+ation/ erosion/ corrosion/ S2 crac-ing/ sul!idic crac-ing " metal dusting
1". &hen ne$ vessels are placed into service or the service conditions are chan+ed $hat are the 3 methods for determinin+ the pro(a(le rate of corrosion' 2orrosion rate data collected !rom owneruser on vessels o! similar service/ corrosion rate data !rom owneruser’s experience !rom published data o! similar vessels/ on stream determination a!ter %$$$ hrs. o! service
16. &hat other examination methods may (e used to supplement the visual examinations' 08/ P8/ 98/ 8
17. o you al$ays have to remove insulation at the time of each external inspection' 1o/ but must be observed every 5 years.
18. &hen $ould remova(le internals to (e completely removed' 6hen as long as reasonable assurance exists that deteriorations in regions inaccessible by the internals is not occurring to an extent beyond that !ound in more accessible parts o! the vessel.
1,. &hen may in service inspection (e su(stituted for internal inspection' 6hen signs o! deterioration have been detected
20. &hat areas should (e examined on riveted vessels' ivet head/ butt strap/ plate " caul-ed edges
21. efine uniform corrosion. ven wastage o! the sur!ace area
22. Name and define 4 methods that actual thicness and max corrosion rate may (e adusted. a. b. c. d. e. !.
valuation o! locally thinned areas valuation o! Pitting API 5:; evaluations e,’d thic-ness determination valuation o! existing e,uipment with minimal documentation eports and records
23. or an area of considera(le si)e in $hich circumferential stress +overns the least thicness alon+ a critical element may (e avera+ed over a len+th not exceedin+' a. b.
'or vessels w I*’s less than or e,ual to ($ & the diameter or #$< 'or vessels w I*’s more than ($ %= the diameter or >$<
24. an lar+e vessels $ith 2 or more )ones of differin+ corrosion rates have each )one treated independently re+ardin+ inspection intervals' ?es/ !or a large vessel w # or more +ones o! di!!ering corrosion rates/ each +one may be treated independently regarding the interval o! inspections.
2". 5ist " features that must (e covered in the o$ner-user A manual for assessin+ pressure vessel inspection systems. a.
3rgani+ation o! Inspection personnel
b. c. d.
*ocumentation and maintenance o! inspection " ,uality assurance procedures *ocumentation " reports o! inspection " test results 2orrective action !or inspection and test results
26. &hat is the efficiency factor to (e used $hen determinin+ the %A& for a corroded area in the solid material area of a vessel' When the vessel surface away from a weld is corroded and the joint eciency is less than 1.0, an independent calculation using the appropriate weld joint factor (typically 1.0) can be made. or this calculation, the surface at a weld includes 1 in. (!." cm) on either side of the weld (measured from the toe) or twice the re#uired thic$ness on either side of the weld, whichever is greater.
27. #o$ are intervals (et$een pressure relievin+ device inspection-testin+ determined' %ressure&relieving devices shall be tested and inspected at intervals that are fre#uent enough to verify that the valves perform reliably in the particular service conditions. 'ther pressure&relieving devices, (e.g. rupture dis$s and vacuum&brea$er valves) shall be inspected at intervals based on service conditions. he inspection interval for all pressure&relieving devices is determined by either the inspector, engineer, or other #ualied individual per the 'wner*+sers #uality assurance system.
28. &hat is the max period (et$een internal and on stream inspections' It shall not exceed & the estimated remaining li!e o! the vessel based on corrosion rate or %$ years.
2,. &hen an internal inspection is to (e performed name at least " safety precautions prior to entry into a vessel. Isolate/ Purge/ *rain/ 2lean/ Ventilate
30. urfaces of shells and heads are carefully examined for $hat' Sur!aces o! shells " heads should be examined !or possible crac-s/ blisters/ bulges " other !orms o! deterioration
31. or (uried vessels $hat is the (asis for esta(lishin+ the external inspection fre*uency' a. b. c. d.
corrosion rate during maintenance activity on adjacent connecting pipe o! similar material !rom internal inspection o! similarly buried test coupons o! similar material !rom representative portions !rom a vessel o! same circumstance.
32. epairs and alterations to 9:s are covered (y A! "10 provided $hat method is employed' 6elding
33. &hen o$nership and location of vessel has chan+ed $hat must (e done' the vessel shall be internally " externally inspected prior to reuse/ the allowable conditions o! service " the next period o! inspection shall be established !or the new service.
34. !s a pressure test re*uired after each periodic exam' 1o/ unless the AI determines it necessary.
3". %ay fillet patches (e used for repairs' ?es/ when used only !or temporary repairs.
36. &hat are the minimum pressure test temperatures recommended (y A! "10' =$ deg/ ' above the 0*08 !or more than #< %$ degrees ' above 0*08 !or #< or less 0A@ temp should not exceed %#$ deg. '
37. &hen a pneumatic test is to (e performed $hat additional examinations re*uired (y A%; prior to the test (ein+ performed' Sur!ace 1* methods
38. &hen the pressure test exceeds the settin+s of safety relief valves $hat must (e done' Sa!ety relie! valves or appurtances should be removed or use test clamps to hold valve dis-s
3,. epair or+. that repair pressure relief valves are re*uired to have $hat ind of $ritten pro+ram' uality 2ontrol System
40. Name at least , topics that are part of a pressure relief valve repair or+. *uality control< manual. a. b. c. d. e. !. g. h.
8itle page evision Bog 2ontents Page Statement " esponsibility 3rg. 2hart Scope o! wor- *rawing " Spec controls epair and Inspection Program
41. !n addition to the 1" topics in the pressure relief repair or+. *uality pro+ram $hat additional re*uirement is needed' 8raining Program
42. &hat is the efficiency factor to (e used $hen determinin+ the %A& for a corroded area in a $eld' Bess than %.$
43. &hat authori)ations and approvals are re*uired prior to the commencement of repairs or alterations' -efore any repairs or alterations are performed, all proposed methods of design, eecution, materials, welding procedures, /, and testing must be approved by the inspector and, if an alteration, by an engineer. he inspector may establish hold points to be implemented during the wor$ eecution .
44. &hat A%; code section are $eldin+ procedures and *ualify $elders $ith' Sec I@
4". &hat is the $eldin+ techni*ue that is used as an alternative to = for >1 and >3 materials' 2ontrolled *eposition
46. &hen is a pressure test mandatory' A!ter an Alteration
47. &hat must (e done for 9:s $ithout nameplates ? minimum desi+n documentation' • • • • • •
Per!orm inspection to determine condition o! vessel. 0a-e necessary repairs *e!ine design parameters " prepare drawings " calculations See Sec.VIII *iv % C97D%$cE !or guidance on evaluating unidenti!ied materials Attach a nameplate o! stamping showing the 0A6P/ 8emp./ 0in. Allow. 8emp " *ate )ase calculations on applicable codes " standards " condition o! vessel a!ter repairs Per!orm a pressure test as soon as practical/ as re,uired by code o! construction used !or design calc.
48. &hen local = is su(stituted $hat are 4 conditions that must adhere to' 8he application is reviewed " procedure is developed by an ngineer 8he suitability o! the procedure is evaluated • A preheat o! =$$ deg. ' or higher is maintained during welding • P648 temp shall be maintained !or a distance o! not less than #@ the base metal • thic-ness measured !rom the weld It should be monitored by at least # thermocouples • •
4,. &hat is pittin+' An obvious or irregular sur!ace wastage
"0. &hen fillet $elded patches are used for repairs $hat desi+n considerations must (e made' elating to e!!iciency/ may be used !or temporary repairs/ use o! !illet welded patches may be subject to jurisdictional and must be approved by AI and ngineer competent in vessel design
"1. &hat are the re*uirements for reratin+ a 9' a. calculations !rom manu!acturer or an owner user engineer experienced shall justi!y rerating. b. A rerating shall be established in accordance with the re,uirements o! the construction code or latest edition o! Sec VIII i! not rated prior to %;;;
"2. &hat alternative method may (e used to determine accepta(ility vessel $alls $hen corrosion has reduced the thicness (elo$ the min. re*:d. thicness' mploying design by analysis methods o! Sec VIII div # app>
"3. !f a corroded area is found in the center section of an ellipsoidal or torispherical head@ $hat formula $ould (e used to calculate the re*:d = min.' 8he thic-ness o! the central portion o! the dished region may be considered a spherical segment whose allowable pressure is calculated by the code !ormula !or spherical shells.
"4. &hich is preferred internal or on stream inspection' 'n&stream inspection may be acceptable in lieu of internal inspection for vessels under the specic circumstances dened in 2.".!. 3n situations where on&stream inspection is acceptable, such inspection may be conducted either while the vessel is depressuri4ed or pressured.
"". &ho must revie$ and endorse repair procedures used on stainless steel $eld overlay and claddin+' epair procedures should be reviewed " endorsed by an engineer " authori+ed by an AI
"6. or the controlled deposition $eldin+ method usin+ the %A&@ the $eld area shall (e maintained $hat temp. and for $hat time after completion of $eld' or welds made by 567W, after completion of welding and without allowing the weldment to cool below the minimum preheat temperature, the temperature of the weldment shall be raised to a temperature of "008 9 "08 (!208: 9 ;08:) for a minimum period of two hours to assist out&gassing di (such as ?01@&=>).
"7. =he repair area on stainless steel $eld overlay ? clad vessels constructed of >3@>4 or >" (ase materials should have the (ase materials examined for $hat type of defects and (y $hich method' 8he base metal area should be examined !or crac-ing by 98 and is appropriately accomplished !ollowing a #> hr. delay a!ter completed repairs !or e,uipment in 4ydrogen service " other alloys that could be a!!ected by delayed crac-ing.
"8. &hen a pressure test is not performed follo$in+ a repair or alteration $hat is re*:d as a su(stitute' 1*
",. &hat min. preheat temp. may (e considered an alternative to = for repairs or alterations to >1 materials' 60. &hat is the min. num(er of thicness measurements that should (e taen on each vessel to satisfy the internal or on>stream re*uirements' 3ne ,uadrant on shells/ no++les/ heads or cone sections
61. &hen may $idely scattered pits (e i+nored' a. b. c.
the remaining thic-ness below the pit is more than & the re,’d thic-ness the total area o! the pits does not exceed : s,uare inches within an F< diameter circle the sum o! their dimensions along a straight line within the circle does not exceed #<
62. &ho must (e consulted prior to repairs of cracs at hi+h stress concentrations' Vessel ngineer
63. &hen there is a conflict (et$een codes $hich document +overns' API 5%$ 64. !n $hat instance do the re*uirements of A! "10 not apply' 6hen the vessel has not yet been in service
6". %aterials for repairs or alterations shall conform to $hat re*uirements' AS0 Sec VIII div. %
66. &hat are the important steps in B! assessment' Internal/ xternal and 3n stream Inspection a. Screen operating units within a plant to identi!y areas o! high ris-. b. stimate a ris- value associated with the operation o! each e,uipment item in a re!inery or chemical process plant based on a consistent methodology. c. Prioriti+e the e,uipment based on the measured ris-.
d. *esign an appropriate inspection program. e. Systematically manage the risk o! e,uipment !ailures.
67. &hat are samples of mechanical de+radation' a. b. c. d. e. f. g. h.
Aeneral B Cocal metal loss 5urface connected crac$ing 5ubsurface crac$ing 6icrossuring*6icrovoid formation 6etallurgical changes -listering imensional changes 6aterial property changes
68. &hat are the other factors considered in an B! assessment' 2onse,uence and li-elihood o! !ailure
6,. an the 10 year inspection limit (e increased or decreased as a result of an B! assessment' Ces 70. &hat are the responsi(ilities of the !nspector ? vessel en+ineer' he engineer is responsible to the owner*user for activities involving design, engineering review, analysis, or evaluation of pressure vessels and pressure&relieving devices covered by this inspection code. he inspector is responsible to the owner*user to assure that the inspection, /, and pressure testing activities meet 7%3 "10 re#uirements. he inspector shall be directly involved in the inspection activities, which in most cases will re#uire eld activities to ensure that procedures are followed, but may be assisted in performing inspections by other properly trained and #ualied individuals, who are not inspectors e.g. eaminers and operating personnel. =owever, all / results must be evaluated and accepted by the inspector.
71. &hat are the re*uirements for preheat or controlled deposition $eldin+ methods as alternative to =' he preheat temperature shall be chec$ed to assure that > in. (100 mm) of the material or four times the material thic$ness (whichever is greater) on each side of the weld joint will be maintained at the minimum temperature during welding. When the weld does not penetrate through the full thic$ness of the material, the minimum preheat temperature need only be maintained at a distance of > in. (100 mm) or four times the depth of the repair weld, whichever is greater on each side of the joint
72. &hat mandatory N; must (e performed prior to and after $eld repairs' %rior to welding, usually the area prepared for welding is eamined using either the 6 or % eamination techni#ue to determine that no defects eist. his eamination is especially important after removing crac$s and other defects . 7fter the weld is completed, it shall be eamined again by the appropriate / techni#ue specied in the repair specication to determine that no defects eist using acceptance standards acceptable to the 3nspector or the applicable construction code.
73. an a vessel constructed in accordance $ith ec 9!!! prior to 1,68 (e rerated usin+ the latest edition of the code'
Ces