% of Material examiniation for high risk

piping system with likely material mixup

100%

a 4" thick 5 chrome vessel operates at 1200

psig and 900F. When is the vessel lest
likely to fail from Brittle Fracture?

During normal operation

According to ASME/ANSI B16.5 flanges

from plate materials can only be used for:

Blind flanges

According to B31.3, a welder's qualification

records from a previous employer can:

Be accepted if the inspector

approves

Advantage of GTAW (Gas

tungsten arc welding)

Best control of weld pooling

API 574 discusses other areas of possible moisture

ingress that may be causes by the actual inspection
of the piping systems. Where would these areas be?

Locations where insulation plugs were removed to

permit piping thickness measurements
API 574 7.4.4.2

ASME code for valves

B16.34

ASME Sec. VIII had few limitations

concerning Brittle Fracture prior to:

1987

ASME/ANSI B16.5 requires

flanges to be:

marked with the class rating.

Buried piping, without adequate cathodic protection

should be included in scheduled external inspections.
What area is to be inspected during these scheduled
external inspections?

The soil-to-air interface shall be included

in the external inspection schedule.
API 574 7.4.5

The calculations for maximum allowable working pressure

(MAWP) for known materials shall be as provided for in ASME
B31.3 or the code to which the piping was designed and fabricated
(applicable code). What information is not required to be available
and comply with the principles of the applicable code?

The name of the original manufacturer

API 570 paragraph 7.2

Can the inspector give prior general

authorization for limited or routine repair
activities?

Yes, provided the inspector is satisfied with

the competency of the repair organization.
API 570 8.1.2

Carbon steel materials are most likely

to be incorrectly substituted in:

a chrome steel piping system.

Carbon steel piping which operates above

what temperature intermittently should be
inspected for CUI?

350F
API 574 7.4.4.1(f)

Change of an identical item, owing to

corrosion + MAWP increased for the
whole system is called?

repair and re-rating

Code for Cathodic Protection

API 651

Code for FFS (Fitness for

Service)

API 579

Code for NDE procedures

guidelines

ASME Section 5

Code for PMI (positive material

identification)

API 578

Code for RBI (Risk Based

Inspection)

API 580

Code for Valve Inspection and

testing

API 598

Code for Weld procedure

qualification

ASME Section IX

Code for Welder qualification

ASME Section IX

Code for Welding on In-Service equipment

containing Flammables (hot tapping)

API 2201

Code to follow when performing an

internal inspection on pipe

API 510

A combination of corrosion and erosion results in

greater metal loss than would be expected by either
corrosion or erosion alone. What three areas should
be inspected for this type of deterioration?
The corrosion rate for newly installed piping systems
or for changes in service must be established. API 570
provides three methods of determination probable
corrosion rates for these conditions.

Downstream of control valves, downstream of

pump discharges, and downstream of orifices.
API 574 7.4.7 (a)(b)(c)

API 570 paragraph 7.1.2

Corrosion rates on existing piping systems shall be

calculated on either a short-term or a long-term
basis. How is the long-term corrosion rate
calculated?

Wall thicknesses from the most recent and

initial (or nominal) inspections shall be used.
API 570 paragraph 7.1.1

Corrosion rates on existing piping systems shall be

calculated on either a short-term or a long-term
basis. How is the short-term corrosion rate
calculated?

Readings from the two most recent

inspections shall be used.
API 570 paragraph 7.1.3

Corrosion under insulation (CUI) is a serious

problem. What should be done to determine
the possibility of this condition existing?

Inspect the integrity of the insulation system

for conditions that could lead to CUI.
API 574 7.4.4

Corrosion under insulation is very aggressive where operating

temperatures cause frequent condensation and re-evaporation of
moisture. For carbon steel piping systems, what operating
temperature range would be considered most susceptible?

Between 10F and 350F

API 574 7.4.4.1(e)

The corrosiveness of soils can be

determined by measuring the soils:

Resistivity

Describe the 3G welding test

position.

Vertical groove Weld

Design code for fabrication of

piping relief devices

ASME section VIII

Distance to dig when inspectng

for soil to air corrosion

6-12 inches

During a direct visual exam of a pipe weld,

the minimum light intensity should be:

100 footcandles

During a hydrotest, all joints

should be:

left uninsulated

During a pipe repair, preheat is substituted

for the required PWHT. What is the
minimum preheat temperature.

300

During pipe fabrication who has overall

responsibility for compliance with the
code?

The owner/user

During pipe repairs, which welding

discontinuity is always unacceptable?

Cracks and Inadequate fusion

During welding, non-esential

variables:

Must be recorded only on the WPS

and must be followed by the welder.

Effect of T on Soil corrosion

rate

Corrosion Increases with

Increase in T

Electrode for SMAW (Shielded metal arc

weld) for low hydrogen application

Basic

Excessive repairs to pump

bearings may be a result of:

thermal growth

Flange bolts are unacceptable if inside the nut within 1 thread of

the bolt threads do not extend:
the nut face
Flange leaks in certain fluids
can cause:

bolts to crack and corrode

Flux type for low hydrogen use with

SAW (Submerged arc welding)

Agglomerated

The following is a Ferritic SS

405 series Stainless Steel

The following is a martensitic

SS

410 series Stainless Steel

The following is an Austenitic

SS

316 series Stainless Steel

The following is not a Ferritic

Steel

300 series Stainless Steel

for welded pipe, the normal

thickness of under-tolerance is?

.010 or 10 mils

Generally socket-welded pipe is not

used for nominal pipe sizes above:

2 inches

Generally, raised face flanges should

have a surface finish of:

125-250 micro- inches

Graphitization of carbon steels begins to

occur when metal temperatures exceed:

800F

Guides, added to control vibration, must

be checked to insure they do not:

Restrict thermal expansion.

API 570 paragraph 7.5

Heat Tracing could cause cracking

in carbon steel piping which is in:

Caustic service

Hole size that must be visible in

RT when using Hole-type IQI

2T

If there is no conformation to ASME

IX filler metal must be approved by

Owner/User

Important requirement of
Material verification program

Documented Roles and

responsibilities

In a hot tapping system, the high

point area may corrode. Why is that?

Corrosion may take place at the high point area of

deadlegs in hot piping systems due to convective
currents set up in deadleg.
API 574 7.4.3

In order to determine the cause and provide

corrective action, welding repairs of cracks that
occurred in-service should not be attempted without
consultation with:

The piping engineer

API 570 8.1.3

In severe refinery services which

type of pipe is normally used?

seamless pipe

An inservice process pipe should be

classified as Class 1 when the % of H2S
exceeds:

3%

Lead letter used during RT to

check for backscatter

Lead letter used during RT to

indicate a film-side IQI

Length of time before an API

570 inspector must recertify

6 years

Limits of soil to air area distance

in air away from interface

6 inches

Liquid thermal relief valves should be set

at a pressure not higher than:

120 %

Loose or broken anchor bolts at pipe

supports are most easily detected by:

hammer testing

Low alloy steels can contain up

to how much chrome?

9%

Material most susceptible to

brittle fracture

Ferritics CS & Low Alloy SS

The material verification program

specified by API 578 covers:

only pressure containing

components.

Material with highest resistance

to sulfidation

18/8 SS

Materials subject to chloride

stress corrosion cracking

300 series Stainless Steel

Materials subject to temperembrittlement

Low Alloy Chromes

Materials where preheat can be

substituted for PWHT

P1 & P3

Maximum allowed SMYS (Specified

Minimum Yield Strength) for pipe if fillet
welded patch is installed

40,000 psi

Maximum allowed thickness on a WPS

based on the plate thickness (T) of a PQR
coupon

2T

Maximum External Inspection

interval for Class 1 & 2 Piping

5 years

Maximum external inspection

interval for Class 3 piping

10 years

Maximum flange size covered

by B16.5

NPS 24

Maximum inspection inerval for

clean/non fouling service PRD's

10 years

Maximum interval for a visual

examiner's eye check

1 year

Maximum stress allowed

during a pressure test

90% of SMYS (Specified

Minimum Yield Strength)

Maximum thickness Inspection

interval for Class 2 & 3 piping:

The lesser of 10 years or half

life of the pipe.

Maximum thickness Inspection

interval for injection point

Lesser 3 years or Half life

Maximum time before obtaining thickness

readings when corrosion rate on new pipe
is not kmown (no other data available)

3 months

Maximum time that a welder maintains

qualifications for a welding process
without using that process

6 months

Mill tolerance of seamless pipe

"-12.5%"

Minimum downstream limit of

injection point circuit

lesser of 1st directional change +25

feet or 2nd directional change

minimum duration of hydro test to

evaluation integrity of a burried pipe

8hr

Minimum length of buried pipe to expose

when excavating for inspection

6-8 feet

Minimum time an examiner should be in a

darkened area prior to using a black light
when performing MT & PT exam

5 min

Minimun light intensity when

performing VT, MT, or PT exam

100 foot-candles

Mixed grades of carbon steel piping in hot corrosive

oil service are susceptible to service specific and
localized corrosion above what temperature and oil
sulfur content?

450F or higher and sulfur content in the

oil greater than 0.5% by weight.
API 574 7.4.6.2(j)

Modes of GMAW (Gas metal

arc weld)

Globular, short circuit, and

spray transfer.

most brittle fractures appear as:

Cleavage

Most Brittle Fractures occur:

Below the impact transition

temperature

NDE personnel qualification

ASNT SNT-TC-1A

Nickel alloys are what % nickel?

30%

Per B31.3 how much of the fabrication

should be visually examined for a pipe in
severe cyclic service:

100 %

Per B31.3, how much RT is conducted on

circumferential welds of a pipe in normal
service?

10%

pH of hydro test water needed

to reduce likelihood of MIC

>10

a pipe has a thickness designation of

"40S". what does the "S" mean?

Stainless steel

Piping most involved in

material mixup

bypass piping, small diameter

(2NPS) piping, valves and bolts.

Piping stress analysis can identify the most highly

stresses components in a piping system and predict
thermal movement. Where can this information be
used to enhance the inspection effort?

PMI stands for

To concentrate inspections at locations prone

to fatigue and/or creep damage.
API 570 paragraph 7.5

Positive Material Identification

A pneumatic pressure test is to be conducted on a

Normal Service piping system. During pipe erection,
how many of the joint assemblies should be
examined?

100 %

A PQR test coupon with a shell thickness

of "T" can generally be used to qualify a
wall thickness on the WPS up to.

2T

PQR using a S number qualifies

...

both S-number and P-number

Materials

Prefered inspection method for

injection points

RT and/or UT

Preheat should never be

substituted for PWHT if:

the PWHT was used to prevent

environmental cracking.

Pressure applied inside a pipe creates

stress in the pipe wall. These stresses are
highest on which weld orientation?

longitudinal weld

A pressure test is always

required:

whenever the authorized inspector

believes one is necessary

A propane piping system

should be classified as?

Class 1

The removal of surface material by the

action of numerous individual impacts of
solid or liquid particles is a definition of:

Erosion
API 574 7.4.7

Resistance to Brittle Fracture is

called:

toughness

The RT procedure used for a pipe repair

must conform to the requirements of:

ASME Section 5

Seal welding pipe threads:

may be used to prevent leaks

Suggested interval - Close interval

Potential Survey of buried pipe w/ poor CP

5 years

Suggested interval for above-grade visual

surveillance of burried pipe

6 months

Suggested interval for evaluation of

Soil corrosivity of buried pipe w/o CP

5 years

Thickness measurements are

suggested at pipe fittings since:

directional changes generally create

increased turbulence and corrosion.

To evaluate the effects of fire damage, FFS

evaluation should be performed in
accordance with:

API 579, section 11

True or False
A Brittle Fracture grows very rapidly with
minimum deformation prior to failure.

True

True or False
The minimum required pipe wall thickness, or
retirement thickness, is based solely on pressure.

False
API 570 paragraph 7.3

Two main types of

Environmental cracking

Caustic stress corrosion cracking and

Caustic embrittlement

Two most common CS pipe

materials

A53 & A106

Two primary gamma ray

radiation sources

Iridium & Cobalt

Typical external corrosion rate

for dry rural environment

<1 mpy

A welder becomes unqualified

when he has not welded in:

6 months

Welding process where filler

rod is added by hand

GTAW (Gas tungsten arc

welding)

Welding process which can be

automated

SAW (Submerged arc welding)

Welding process with no

creation of slag

GMAW(Gas Metal Arc Welding) and

GTAW (Gas Tungsten Arc Welding)

What are the most common forms

of corrosion under insulation?

Localized corrosion of carbon steel and chloride

stress corrosion cracking of austenitic stainless steels.
API 574 7.4.4

What are the most common material

nonconformances with serious
consequences?

Low Alloy steel pipe replaced by

Carbon steel pipe

What are the restrictions to repairing

longitudinal cracks with the full
encirclement or box enclosure method?

The piping engineer must determine the crack will

not propagate from under the sleeve.
API 570 8.1.4.1

What considerations do fillet

welded patches require.

Weld joint efficiency & Crevice

corrosion

What do you call a groove in the

parent metal at the toe of a weld?

undercut

What does the "H" mean in

Austenitic SS, like 316 H?

High Carbon

What does the "L" mean in

Austenitic SS, like 304 L?

Low Carbon

What increases the likelihood

of brittle fracture?

large grain size & Thicker

materials

What indicates internal CO2

corrosion

Smooth grooving of pipe wall

what is the interval for thickness

measurements on a class 1 piping system?

lesser of 5 years or half life of

the pipe

What is the limit of soil to air area distance

in soil away from interface?

12 inches

What is the minimum holding time

for all pressure tests on piping?

10 mins

What material is subject to polytheonic

acid stress corrosion cracking?

Sensitized 300 SS

What operating temperature range would be

considered most susceptible to chloride stress
corrosion cracking in austenitic stainless steel
piping?

What should be done when unexpected

movement of a piping system is observed?

Between 120F and 400F

API 574 7.4.4.1 (h)
The inspector should discuss these observations with
the piping engineer and evaluate the need for
conducting a piping stress analysis.
API 570 paragraph 7.5

What test is used to determine

a materials toughness?

Charpy Impact Test

What type of records is the owner/user

required to maintain according to API 570?

Permanent and progressive records

API 570 paragraph 7.6.1

What type of weld for flush insert patches

can be used in corroded areas?

penetration groove weld

what welding process cannot be

qualified by radiography

GMAW (short circuit mode)

When a relief device or valve is removed

for repair, the inspector should:

inspect the inside of the inlet and outlet

piping where the valve was removed.

When calibrating a UT instrument, that

has a delay line with single element unit,
use:

At least 2 test blocks with thicknesses near

the max and min to be examined.

When can radiography not be

used to qualify a welder?

when using the GMAW process

with the short circuit mode

When fabricating pipe,

unknown materials:

Should never be used (except

for door stops)

When is it necessary to inspect for

corrosion beneath the surface before
resealing the joint?

If the buried piping system is over 10 years old, and

the caulking or seal at the interface has deteriorated.
API 574 7.4.5

When making repairs and alterations to

piping systems covered by API 570, what
standards must be followed?

ASME B31.3 or the Code to which the

piping system was built.
API 570 8.1.1

When performing a visual exam, the

minimum angle of eye to part

30

When performing preheat prior to welding or

PWHT, the preheat zone and/or PWHT must
extend how far beyond the edge of the weld?

1 inch

When performing soil-to air inspections

on uncoated lines, it is recommended to
excavate the soil:

6-12 inches.

when qualifying a weld procedure

the essential variables must:

be recorded on both the WPS &

PQR

When recalculating MAWP of piping

systems for continued use, what thickness
is used?

The actual thicknesses determined by inspection

minus twice the estimated corrosion loss before the
date of the next inspection.
API 570 paragraph 7.2

When shall temporary leak sealing devices

be removed and pipe repaired?

Next turnaround

When should temporary pipe

repairs be replaced?

Next opportunity

When the MAWP is recalculated for piping

systems of unknown materials, what
information is used?

The lowest grade material and joint

efficiency in the applicable code.
API 570 paragraph 7.2

When welding together piping components

of different thicknesses, the thicker part
should be trimmed with a:

30 degree taper.

Where should wall thickness on deadlegs

be monitored by the inspector?

This inspection should include both the stagnant

end and the connection to an active line
API 574 7.4.3

Which dimension stay the same regardless

of the wall scheduled thickness?

Outside Diameter

Which material is Least

affected by Brittle Fracture?

300 series Stainless Steel

Which material must use low chloride

hydro test water & must be died after
hydro test?

300 series Stainless Steel

Who approves Welding

procedures qualified by others

The Inspector

Who has the responsibility to determine

the extent of PMI (Positive Material
Identification) performed?

The owner/user

Who must approve all proposed methods

of design, execution, materials, welding
procedures, examination, and testing?

The inspector or the piping engineer

API 570 8.1.3

Who must authorize any repair or

alteration work, prior to commencement
of the work?

The inspector
API 570 8.1.2

Whose approval for on-stream

welding is required?

The owner/user
API 570 8.1.3

With regard to alteration work, who must

the inspector consult with prior to giving
authorization?

The piping engineering

API 570 8.1.2