Section 5 - Inspection Examination And Testing Practices Flashcards
Our in-service pressure vessel’s in the Petrochemical industry must:
A. Have been Hydro tested prior to service.
B. Be built to ASME section VIII
C. Be post weld heat treated if the thickness is over 1-1/2”.
D. Have an inspection plan.
D. Have an inspection plan.
All in-service pressure relief devices in the petrochemical industry must:
A. Have an inspection plan.
B. Be built to a ASME section VI
C. Be set at a pressure not higher than 100% MAWP.
D. Have a balance Bellows
D. Have a balance Bellows
The inspection plan for a pressure vessel should be developed by:
Either the inspector or the engineer.
The inspection plan for a pressure relief device should be developed by:
Either the inspector or the engineer.
When developing a vessels inspection plan, who should help, we needed, to identify specific damage mechanisms and their locations?
Corrosion specialist.
A significant factor in developing an inspection plan is to determine the:
A. Anticipated cost.
B. Anticipated schedule.
C. Availability of NDE examiners.
D. Potential damage mechanisms.
D. Potential damage mechanisms.
What is the MOST important factor when selecting the NDE to use in a future inspection?
A. Ability of the method to find the anticipated damage mechanism
B. Ability of NDE method
C. Cost of NDE method
D. Ease of use of the NDE method
A. Ability of the method to find the anticipated damage mechanism
Which of the following is not a factor in determining the interval for examinations in a vessels inspection plan?
A. Cost of equipment outage
B. IOW exceedances
C. Maximan code intervals
D. Probability that the NDE will find expected damage
E. Rate of damage occurring
A. Cost of equipment outage
Which of the following is an NOT required to be included in a vessels inspection plan?
A. Name of individual that will perform the inspection
B. Next inspection date
C. Surface cleaning requirements
D. Type of and NDE that will be used
A. Name of individual that will perform the inspection
Which of the following is not required in a vessels inspection plan?
A. Lightning requirements
Capital B. Location where NDE will be performed
C. Planned pressure test
D. Planned repairs
A. Lightning requirements
What “Optional Items” should really be part of a vessel’s Inspection plan ?
A. confine entry requirements
B. Special access requirements
C. Special lighting requirements
D. Types of damage expected in the vessel
D. Types of damage expected in the vessel
In the RBI process, what are the two primary factors used to determine risk?
A. Consequence of failure and service class
B. Reliability and the On-stream percentage
C. Probability and consequence of failure
D. Inspection Effectiveness and Corrosion Mechanism
C. Probability and consequence of failure
Who is responsible to decide an RBI assessment will be used to determine inspection intervals for a pressure vessel?
A. Corrosion Specialist
B. Inspector
C. Owner/User
D. Pressure Equipment Engineer
C. Owner/User
RBI assessments should be done in accordance with ?
A. API 579
B. API 580
C. API 583
D. API 584
B. API 580
Which of the following is NOT a significant factor in an RBI assessment of a pressure vessel?
A. Vessel construction code
B. Process fluid
C. Potential degradation mechanisms
D. Effectiveness of past inspections
A. Vessel construction code
During a risk assessment, which of the following is NOT a significant factor in the Probability of failure?
A. Amount of process fluid
B. Expected damage mechanisms
C. Quality of the inspection program
D. Quality of the maintenance program
A. Amount of process fluid
During an RBI assessment of a pressure vessel, what are the two biggest factors of consequence of failure?
A. Amount of product and expected corrosion rate .
B. Amount of product and type of product
C. Expected corrosion rate and type of product
D. Quality of inspection program and Quality of maintenance program
B. Amount of product and type of product
During a RBI assessment, which of the following is NOT a significant factor in the consequence of failure?
A. Environmental damage
B. Equipment damage
C. Equipment downtime
D. Health impacts
E. Public image
E. Public image
All RBI assessments must be .
A. Thoroughly documented
B. Repeated every 5 years
C. Approved only by the authorized inspection
D. Conducted per guidelines in API 579
A. Thoroughly documented
An RBI assessment is used to determine the interval for the internal inspection.
When does the RBI assessment NOT have to be repeated?
A. After each internal inspection
B . After any significant process change
C. After any significant change in inspection personnel
D. After any significant hardware change
E. At least once every 10 years
C. After any significant change in inspection personnel
All NDE equipment used in petrochemical facilities must .
A. Have a safety rating appreciate for the gaseous environment at the exam site .
B. Be calibrated daily
C. Be used by a technician that is qualified to ASNT SNT- TC-1A
D. Have an ASME section V approval seal
A. Have a safety rating appreciate for the gaseous environment at the exam site .
Which of the following is NOT a requirement prior to performing an internal vessel inspection?
A. Review previous vessel history
B. Obtain permission from the appropriate operation personnel
C. Check that all equipment used during the inspection is safe to use
D. Be certified as an ASNT SNT-TC-1A Level 2 in VT
D. Be certified as an ASNT SNT-TC-1A Level 2 in VT
Prior to performing an inspection the inspector should ?
A. Calibrate their pit gauge
B. Familiarize themselves with prior history
C. Review API 571 for expected damage mechanisms.
D. Retake an eye test
B. Familiarize themselves with prior history
Prior to performing an inspection, which of the following is NOT a requirement for the inspector?
A. Familiarize themselves with the current inspection plan
B. Familiarize themselves with past inspection plans
C. Familiarize themselves with prior inspection history
D. Familiarize themselves with prior repairs
B. Familiarize themselves with past inspection plans
Which of the following damage mechanisms creates either general or localized corrosion?
A. Graphitization
B. HTHA
C. Naphthenic
D. Temperature embrittlement
C. Naphthenic
Which of the following damage mechanisms does NOT create either general or localized corrosion?
A. Fatigue
B. Galvanic
C. MIC
D. Sulfidation
A. Fatigue
Which of the following damage mechanisms does NOT create surface connected cracks ?
A. Chloride stress corrosion cracking
B. Hydrogen included cracking
C. Polythionic stress corrosion cracking
D. Thermal fatigue
B. Hydrogen included cracking
Which damage mechanism creates sub-surface cracking ?
A. Carbon dioxide corrosion
B. Caustic stress corrosion cracking
C. Mechanical fatigue
D. Wet hydrogen sulfide cracking
D. Wet hydrogen sulfide cracking
Which damage mechanism creates micro-fissuring which leads to macro-cracking ?
A. Creep
B. Graphitization
C. Hydrogen blistering
D. Naphthenic acid
A. Creep
The inspector should be ?
A. Familiar with process conditions.
B. Familiar with construction details
C. Familiar with potential damage mechanisms
D. With all the above
D. With all the above
Vessels in cyclic service should be inspected for ?
A. Creep
B. Excessive strain
C . Fatigue
D. Stress corrosion cracking
C . Fatigue
Where is a great place to check for damage on vessels that are subject to fatigue damage?
A. Nozzle-to- flange welds
B. Circumferential welds
C. Places of stress intensification
D. Shell-to-head welds
C. Places of stress intensification
Which of the following vessels is most likely to be affected by thermal fatigue?
A. Coke drum
B. Distillation column
C. Knockout drum
D. Overhead accumulator
A. Coke drum
Deviations from an inspection plan should be approved by the
Engineer or inspector
Who is responsible for performing the internal inspection on a pressure vessel?
Authorize Inspector
An NDE examiner can ?
A. Always assist in the internal inspection
B. Perform the internal inspection
C. Assist In the internal inspection when approved by the engineer.
D. Assist In The internal inspection when approved by the inspector
D. Assist In The internal inspection when approved by the inspector
When may inspections from ports be substituted for the internal inspection?
A. Always
B. Never
C. Only if the inspector approves
D. Only if the vessel is too small to enter
E. Only if the vessel is too small to enter or all internal surfaces of vessel can be clearly seen from the port
E. Only if the vessel is too small to enter or all internal surfaces of vessel can be clearly seen from the port
Prior to the internal inspection?
A. All removable internals must be removed
B. All process deposits must be removed
C. All removed internals and all process deposits must be removed.
D. Some removable internals may not need to be removed, but all process deposits must be removed
E. Some process deposits may not need to be removed, but all removable internals must be removed
F. Some removable internals and some process deposits may not need to be removed
F. Some removable internals and some process deposits may not need to be removed
Who is responsible to determine wether process deposits should be removed prior to the internal inspection?
Authorized inspector and corrosion specialist
Which of the following describes the needed surface preparation before performing an internal inspection?
The amount to clean and the degree of cleanliness is based on expected type of degradation mechanisms
Which of the following is true about the need to remove process deposits prior to internal inspections?
A. All deposits must always be removed
B. Amount to remove is based on the vessel classification
C. Amount to remove is based on the consequence of failure
D. Amount to remove is based on whether deposits actually protect the shell or cause corrosion.
D. Amount to remove is based on whether deposits actually protect the shell or cause corrosion.
Internal inspection is conducted on a refractory -line vessel. How much refractory should be removed to check the condition of the vessels internal surface ?
Removal of refractory is not required unless there is a reason to suspect that corrosion is according under the refractory
Who is responsible to perform a vessel o -stream inspection?
Authorized inspector or an examiner
All on-stream work performed by an examiner must be approved by the ?
Authorized inspector
On-stream inspection?
A. Should be performed while the vessel is pressurized
B. Should be performed while the vessel is depressurized
C. Can be performed while the vessel is pressurized or depressurized
C. Can be performed while the vessel is pressurized or depressurized
Who is responsible to perform the external inspection on a pressure vessel?
Authorized inspector or qualified others
Personnel performing the external inspection must ?
A. Be qualified by appropriate training
B. Have a valid API 510 certificate
C. Have a valid ASNT certificate
D. Have either an API 510 or ASNT certification.
A. Be qualified by appropriate training
During the external inspection extra attention should be given to ?
Attachment welds
Weep-holes in repads should ?
A. Remain open on in - service vessels.
B. Be used to test the repad welds during each vessel outage
C. Be threaded and plugged after fabrication is complete.
D. Be used to pump leak sealant compounds in the cavity between the shell and the repad
A. Remain open on in - service vessels.
The inspector interval for buried vessel is based on the ?
Known corrosion rate and the effectiveness of CP.
A portion of the soil around a buried vessel may be excavated to allow thickness measures of vessel to be taken. When excavating care must be given so that ?
Any cathodic protection or any external coating is not damage.
Thickness measurements are taken to verify the ?
Thickness of the vessel components
The inspector should be consulted with a corrosion specialist when ?
A. CUI is discovered during the external inspection.
B. The grounding connection is found corroded
C. The short - term corrosion rate changes significantly
D. Determining an external inspection interval
C. The short - term corrosion rate changes significantly
Who must assure that personnel performing thickness readings are trained and qualified?
Owner/ user
CUI is an Inspection concern for insulated carbon steel vessels that operate between?
10 to 350 F
CUI is an inspection concern for insulated austenitic stainless steel vessels that operate between?
140 to 350F
CUI is an inspection concern for insulated duplex stainless vessels that operate between?
280 to 350 F
CUI is an inspection concern for insulated vessels that operate at 500F and ?
Are in entermittent service
Which of the following insulated vessels is most likely to experience CUI ?
A. CS vessel that operates at 600F . But is in an intermittent service
B. CS vessel that operates continuously at 375F
C. CS vessel that operates continuously at -20F
D. CS vessel operating at cyclic temperatures ranging from 400-600F
A. CS vessel that operates at 600F . But is in an intermittent service
CUI damage on carbon steel and low alloy materials usually appear as ?
Localized corrosion
CUI of austenitic and duplex stainless steel vessels?
Normally appears as stress corrosion cracking
CUI damage?
Can be very unpredictable
Which of the following is NOT a most susceptible area for CUI damage on an insulated vessel?
A. Below stiffening rings
B. Bottom heads
C. Ladder clips
D. Nozzles
A. Below stiffening rings
External inspection is planned for an insulated vessel. How much insulation should be removed to check the condition of the external surface?
Insulation removal is not required unless there is a reason to suspect that corrosion occurring under the insulation
Which type of insulation is MOST likely to absorb and hold water ?
Calcium silicate
A CML is a spot for ?
Checking for various damage types , (wall loss, cracking, or HTHA).
When thickness reading are due, what is the minimum number of thickness reading that should be taken ?
A represented number of reading on heads, shell, and nozzles.
Thickness readings are taken on a vessel. Which CMLs must always be included in this exam ?
CMLs with the highest corrosion rate and the CMLs with the lowest remaining life .
A minimum number of CMLs on a vessel is acceptable when the ?
Corrosion rate is low and localized corrosion is not expected
UT thickness readings will be taken on a vessel. Which of the following best describes the process for taking readings at a specific examination point ?
Take multiple reading and record the lowest reading or average of the set
CMLs should always be ?
Permanently marked on a drawing and /or on the vessel.
Who should be consulted about placement and number of CML’s for vessels with suspected localized corrosion?
A. Corrosion specialist
Which of the following conditions would justify fewer CML’s on a vessel?
A. Corrosion rate is less than 0.010 ipy
B. Localize corrosion is expected
C. Uniform corrosion is expected
D. Vessel contains propane
C. Uniform corrosion is expected
The number of CML’s can be eliminated or reduced if ?
A. The consequence of vessel failure is low
B. The probability of vessel failure is low
C. Both the consequence and probability of vessel failure is low
D. Either the consequence or the probability of vessel failure is low
D. Either the consequence or the probability of vessel failure is low
Who should be consulted, if CML’s on a vessel are eliminated?
Corrosion specialist
Who should be consulted if CML’s on a vessel are substantially reduced?
Corrosion specialist
The NDE method called Alternating current Flux Leakage is useful in finding ?
Porosity in welds
The NDE method Advanced Ultrasonic Backscatter Technique is useful for detecting?
HTHA
Examiners performing UT flaw detection on welds on an in-service vessel should be qualified to ?
API QUITE/QUSE or equivalent
Which of the following forms of degradation is most easily missed when performing a visual examination?
A. Uniform corrosion
B. Localized thinned areas
C. Random putting
D. Isolated pitting
A. Uniform corrosion
What is the preferred examination technique for determining the vessel wall thickness of a 60” I.D. Vessel that has localized thinning ?
UT scanning
What is a good examination technique for determining the nozzle wall thickness of an insulated 6” NPS nozzle that has localized thinning?
Profile RT!
Thickness readings are taken using UT. At what temperature should special procedures be used in order to ensure accurate readings ?
Above 150°F
Which of the following is NOT a factor that contributes to poor accuracy when performing UT thickness gauging?
A. Improper calibration
B. Laminations In the metal
C. Low levels of lighting
D. Surface roughness
C. Low levels of lighting
A pressure test is normally conducted after all ?
Alterations and major repairs.
A pressure test shall be conducted after ?
Repairs,when the inspector believes one is necessary.
A Nozzle has been added to the vessel. Instead of pressure testing the entire vessel, just the nozzle will be pressure tested ( temporary cap welded on the inside of the vessel) This substitution of a component pressure test instead of testing the entire vessel requires the approval of ?
Just the engineer
An alteration has been made on a vessel that was built to ASME Section VIII, 1990 edition. A hydrotest will be conducted. What is the recommended test pressure?
150% of the MAWP corrected for temperature
A major repair has been completed on a vessel that was built to ASME SECT. VIII,1990 edition. In 2007 the vessel was rerated to the 2007 edition of sect. VIII. A hydrotest will be conducted. What is the recommended test pressure?
130% of MAWP corrected for temperature
A hydrotest is conducted on an exchanger shell to check for roll leaks. What is the recommended test pressure?
At a pressure specified by the owner/user
When a tightness test is performed on a vessel, the test pressure is
Specified by the owner/user
A hydrotest is being conducted on an in-service vessel after a major repair . The vessel MAWP is 100 psig and the test pressure is 150 pisg. The close visual examination should be conducted at what pressure?
Less than or qual 100 pisg
A hydrotest is being conducted on a vessel. The relief device is not removed or blinded. What other option can be used to keep the relief device from popping?
Place the test clamps on the relief device
A hydrotest is planned for a large low-chrome vessel. Be sure that .
The supporting structure is adequate for the weight of the water
What is a concern when hydro testing sensitized austenitic stainless steel ?
Polytechnic stress corrosion cracking
A hydrotest is conducted on an austenitic SS vessel. What is the maximum allowed content of chloride in the hydrotest ?
50 ppm
Which of the following is NOT a good reason for substituting a pneumatic test for a hydrotest?
A. Less expensive
B. Support structure cannot hold the weight of the water
C. Traces of water will put the product “ off spec”
D. Vessel is refractory lined
A. Less expensive
Which of the following is true when pneumatic testing is performed after a major repair on a vessel that has a shell that is 0.375” thick ?
A. An engineer should develop a specific procedure
B. The test pressure should be 130% of MAWP and corrected for temperature
C . The metal temperature should be anything above MDMT
D. The owner/user should approve
A. An engineer should develop a specific procedure
Brittle fractures usually have accrued ?
During the first hydrotest or overload
Which of the following materials is most prone to temperature embrittlement?
A. Carbo steel
C. High nickel alloys
C. Low chromes
D. Stainless steel
C. Low chromes
A hydrotest is performed on a vessel with austenitic ss cladding . What is the maximum allowed water temperature?
120°F
NDE is being substituted for a pressure test after a major repair on an In-service vessel. Who must approve this substitution?
Both the inspector and engineer
Per API 510, during repairs and alterations, the inspector shall verify that the new materials being used are correct. What is the minimum amount of verification that the inspector shall perform?
A sampling of all metallurgy’s
During repairs and alterations, who determines the percentage of new materials to check for conformance to specifications?
Inspector or engineer
Who should perform PMI?
Examiner or inspector
What document provides addition guidance about material verification?
API 578
An existing vessel component fails. Analysis of the failure determines that an incorrect material was inadvertently substituted during fabrication. Who should determine whether other components should be checked for correct metallurgy?
Inspector
During an in-service inspection, a crack - like flaw was discovered in a weld . This imperfection must be ?
Evaluated by an engineer or corrosion specialist.
During an in-service inspection, preferential corrosion was discovered in a weld. This imperfection shall be evaluated by ?
An inspector
Flange leaks in certain fluids an cause?
Bolts to crack or corrode
A leaking flange was repaired by a leak sealing company that pumped sealant in the gasket area . Later the flange leaks again. what should be done ?
Examine bolts with UT prior repumping
Flange bolts are unacceptable if the lack of engagement exceeds?
1 thread.
