Questions & Answers

Formulas to be memorise :a) Min thickness / design pressure of shells (cylinders)

= UG 27 IR , APP1
OR = Thickness of the shells under internal pressure - circumferential stress
( longitudinal joints ) when the thickness does not exceed one half of the inside
radius, or P does not exceed 0.385 SE
T = PR / SE - 0.6P
or
P = SEt / R + 0.6t
b) Min thickness / design pressure of shells (cylinders)
= UG 27 IR , APP1
OR Thickness of the shells under internal pressure - longitudinal stress
( circumferential joints ) when the thickness does not exceed one half of the inside
radius, or P does not exceed 1.25 SE
T = PR / 2SE +0 .4P
or
P = SEt / R - 0.4t
c) Min thickness / design pressure of formed heads = UG 32 (d)(e)(f)
=
Thickness of the shells under internal pressure - spherical shells - when the
thickness of the shell of a wholly spherical vessel ( sphere )/ 2:1 elliptical does not
exceed 0.356R, or P does not exceed 0.665 SE
hemispherical ( sphere )/ 2:1 elliptical T = PD or PL / 2SE -0 .2P
= 2SEt / D or L + 0.2t

or

Thickness of torispherical head t = 0.885PL / SE 0.1 P + C

d) Minimum Thickness of flat unstayed circular heads From UG 34
square root of CP/SE

t= d

e) MAWP of cyliderical shell circumferential with uniform external corrosion

Ro 0.4 t

P=Set /

f) The weld joint efficiencies- UW 11, UW 12 table UW12

RT 1
full 1.0 or 0.90
RT 2
- full on cat A spot on cat B (UW -11(a)(5)(b) - 1.0 or 0.9
RT 3
- spot 1 50 foot weld - 1 for each welder 85 or 80
RT 4
- combination of above
No RT
- 0.70 or 0.65
Seamless - 0.85 if UW 11(a)(5)(b) is not met
1.0 if UW 11(a)(5)(b) is met
g) The value of factor C of flat circular heads = C = 0.33 x m , m = Tr / Ts
h) Hydrostatic testing pressure = 1.3 x MAWP x stress ratio
i) MAWP
+flange
j) Pneumatic test pressure

= hydrostatic head x 0.433 & depth of head = ID

= 1.1 x MAWP x stress ratio

k) Metal temperature during PT = 30 deg F above MDMT for more than 2

= 10 deg F above MDMT for 2 or less and max 120
deg F
l) Evaluation of locally thinned areas ID less than or equal to 60
is less
ID greater than 60
whichever is less

= of vessel diameter or 20 whichever

= 1/3 of vessel diameter or 40

m) Corroded areas of ( 2 : 1 ) ellipsoidal head , crown radius = 0.9 D

n) ellipsodical head spherical (crown) radius Spherical radius K1D i.e D/2h = K1 and
for many ellipsodical heads d/2h = 2.0, Then from table 7-1 2.0 of d/2h equals 0.9
of K1
o) For torisph head, for crown portion, use hemisphere formula using R = D
p) Corroded areas of ( 2 : 1 ) ellipsoidal head, Crown portion lies in circle of diameter
equal to 0.8D
q) Torispherical head Crown radius h = D = 60 & knuckle radius = 6% of crown radius
r) Internal inspection = RL or 10 yrs whichever is less
External inspection = does not exceed lesser of 5 yrs or the required internal
inspection
s) area of a circle = pie r square , Tensile strength = load / area or UTS x width x thk
t) external pressure on cylinders = UG 2B and external pressure parts

thickness of shells and tubes under external pressure L / Do & Do / t and

maximum allowable external working pressure Pa = 4B / 3 ( Do / t )
u) for coil technique ( longitudinal magnetization technique ) a. if L/D ratios less than 4 but not less than 2 = ampere turns = 45000 / (L/D)
b. if L/D ratios equal to or greater than 4 = ampere turns = 35000 / (L/D)+2
v) prod technique
a. Current shall be minimum 100 amp / inch to maximum 125 amp / inch for
sections thick or greater.
b. For less than thick, the current shall be 90 amp / inch to 110 amp/inch
prod spacing.
w) circular magnetization technique
a. Current shall be 300 amp / inch to 800 amp / inch of outer diameter
x) pit may not exceed the parts t min
y) Nozzle weld sizes UW 16 & fig UW 16
Tc
= not less than the smaller of or 0.7 t min
Tmin
=smaller of or thickness of parts
Min. throat required = t1,t2= smaller of 6mm or 0.7 t min
Min. inner corner radius (r1) = smaller of t or 19mm
Leg = 1.414 x throat & throat = 0.707 x leg
z) The permissible ovality of vessel
= Cross section passes through within 1 ID of the
opening measured from the centre of the opening = 1% of nominal dia + 2 % of ID
of opening
aa)Reinforcement
ab)

= d ( t tr ) or 2 ( t + tn ) ( t tr ) use larger

Widely scattered pits may be ignored the remaining thickness below the pit is
greater than one-half the required thickness. (1/2 t required)

ac)The total area of the pits does not exceed 7 square inches (45 sq.
within any 8 inch (20 centimeter) diameter circle.

centimeters)

ad)

The sum of their dimensions along any straight line within the circle does not
exceed 2 inches

ae)Hydrostatic head

= UG 99

= 0.433 psi x each (1) foot of height

af) Head depth (dish)

hemispherical heads

= UG 32

= x D for elliptical heads, x D for

*******************************************************************************************
****
1) An existing 30 tall pressure vessel is stamped RT-2 and is constructed of seamless
2:1 elliptical head s, shell material and head material is SA-515-60. All joints are type 2.
Inside diameter of the vessel is 66. The vessel has corroded in the shell and heads
approximately 1/8 and the original thickness of the both the heads and the shell was
5/8 according to the manufacturer data report. Stress is 14,760 psi. MAWP is 300 psig
@ 670 deg F. the minimum thickness of the shell, considering hydrostatic head is
__________?
a) 0.788

b) 0.701

c) 0.650

d) 0.500

MAWP 300 psig @ 670 deg F + HH = 312.99, ts = 0.500 th = 0.500, id = 66, ir = 33,
SV = 14,760
650 = 15,000
50=600
15000
E = RT2 = 0.90
700=14,400 1=12 x 20 = 15,000 240 = 14,760
T = PR / SE - .6P = 312.99 x 33 / 14,760 x 0.9 - .6 x 312.99
= 10,328.67 / 13284
187.794
= 10,328.67 / 13,096.20 =0.788 required
Answer A
2) The required thickness of the bottom head on the above ( Question no 1 )vessel will
be
a) 0.788

b) 0.701

c) 0.650

d) 0.500

t = PD / 2SE - .2P = t
= 312.99 x 66 / 2 x 14,760 x 1.0 2 x 312.99
= 20657.34 / 29520 62.598
= 20657.34 / 29457.402
=
0.701
Answer B
3) During the internal inspection of a vertical vessel a minimum thickness reading of
1.270 was found on a shell course. The data report reflects an original thickness of
1.50, and allowable stress at 600 degrees F (315 deg C) of 14,500 psi, full radiography,
and a MAWP of 650 psi. The MAWP was based on a retirement diameter of 49.02 inches
after the corrosion allowance was expended. Inspection records indicate a L.T. corrosion
rate of 0.025 inches a year. If the corrosion rate does not change what is the maximum
time before the next on stream or internal inspection?
a) 5.6 years
b) 10 years
c) 90 days
d) 2.815 years
Ans = D ( API 510 7.1.1)
Corrosion rate
= 0.025 per year P=650, S = 14,500 psi, E=1.0 full RT, R=49.02 / 2
= 24.51
Calculate min shell t ( from UG 27 ) = PR / SE 0.6 P
= 650 x 24.51 / (14,500 x1.0 ) (0.6 x650) = 15931.5/14110= 1.1290928
Present thickness = 1.2700000
retirement thickness = 1.1290928
Remaining C.A
= 0.1409072
Remaining life
= C.A / C.R = 0.1409072 / 0.025000 = 5.63 years

Next inspection shall not exceed one half of the estimated remaining corrosion rate life
of the vessel or 10 years, whichever is less
Therefore : 5.63 / 2 = 2.815 years
4) A fifteen year old vessel made of SA-203. Gr.B was measured as having a thickness of
0.645. The inside diameter is 42 and the MAWP is 450 psi at 650 deg F. the vessel did
comply with UW-11(a) (5) (b). Material stress is 17500 psi. The previous reading on the
material had a thickness of 0.68 during the first 10 year interval. Data report indicated
that the material had a nominal thickness of 0.75. (Take E=1).
The corrosion rate is (in)
a) 0.007
b) 0.07
c) 0.035
d) 0.0035
Ans

- CR = 0.68 0.645 = 0.035 /5 = 0.007 = Ans = A

5) For Q4, The required minimum thickness is (in)

a) 0.548
b) 0.645
c) 0.610
d) 0.788
Ans A
Tk = 0.645 after 15 yrs, D=42, MAWP=450, S = 17,500 psi, tk after 10 yrs = 0.68,
E=1.0 , nominal tk=0.75 R=42 / 2 = 21
Calculate min shell t ( from UG 27 ) = PR / SE 0.6 P
T = 450 x 21 / (17500x1) (0.6x450) = 0.548 = ans = A
6) For Q4, The remaining corrosion allowance is (in)
a) 0.097
b) 0.00350
c) 0.035
d) 0.0097
Ans

- CA = 0.645 - 0.548 = 0.097 = ans =A

7) For Q4, The remaining service life in years is

a) 5
b) 2.5
c) 13.8
d) 6.9
RL = 0.097 / 0.007 = 13.85 yrs = ans = C
8) Vessel 60 ID, a nozzle opening of finished opening = 8 inches was present in thinned
out patch on inside surface and lying close to a reinforcing nozzle with RF pad OD = 8.
What length will be taken for corrosion averaging is taken for corrosion analysis
a) 8 inches
Ans

b) 16 inches

c) 20 inches d) 30 inches

-B

9) The minimum nominal thickness of new cylindrical shell with design pr = 555 psi, inside
diameter = 58, S = 20000 psi and E = 0.85 with corrosion allowance of 1/8 ( C.A for
expected life of 20 years ) will be
a) 1.0 inch
b) 0.75 inch
c) 1.125 inch
d) 1.25 inch

T = PR / SE 0.6 P
= 555 x 29.125 ( R = 29.125 ( half of diameter ) / 20000 x 0.85 0.6 x 555 = 16164 /
16667
=0.967 + 0.125 = 1.09 = Ans = C
10)
After 10 years of service, extensive corrosion was observed on the shell over a
patch lying entirely beyond 6 inches from weld for the vessel in Q133 above. Thinning
as measured on this area was 3/16, while on weld area; the corrosion was within
expected limits. As on today, is the vessel is:
a)
b)
c)
d)

Safe for design conditions

unsafe for design conditions
safe only if welds are fully radiographed and ok
safe only if welds are UT checked and ok

Thickness away from weld ( required thk ) t = PR / SE 0.6P

T = 555 x 30 / 20000-333 = 0.8465
Available shell thickness = 1.125 0.1875 ( 3/16 = 0.1875)
=0.9375 > 0.8465 ( safe ) = ans = A

take E=1

11)
A 12 year old vessel made of SA-516-70 material has a current thickness of
0.955. The inside diameter is 58 and MAWP of the vessel is 500 psi at 650 deg F. what
is the minimum thickness required to operate the vessel in lethal service at the working
pressure? The material stress at 650 deg F is 17,500 psi
a) 0.825
Ans

b) 0.955

c) 0.843

d) 0.765

12)
What is the required thickness of a 60 inch ID cylindrical shell if: it has an
allowable stress at design of 17500 psi. The vessel category A and D type 1 joints are
fully radiographed. All category B joints are type 1 also and have been spot
radiographed per UW-11(a) (5) (b). The vessel MAWP must be 350 psi at 450 deg F. the
shell will see 11 psi of static head at its bottom.
a) 0.6072
b) 0.7388
c) 0.7159
d) 0.6266
ans=D ( UG-27 and API 510 body of knowledge)
t=? from UG-27 =t = PR / SE-0.6 P P=350+11 = 361 psi S=17500 psi E=1.0 per
UW 12(a) R=60/2=30
t=361 x 30 / (17500x1.0)-(0.6x361) = 0.6266
13)
What is the minimum hydrostatic pressure for a pressure vessel given the
following
Shell material is SA-240T304
S=10200 psi@900 deg F
S=18800 psi @ 100
deg F
T=1/2
CA=0
design temp=900 deg F
MDMT = 50 deg F
Category A type 1 joint RT 1
diameter = 38OD
not for lethal service
a) 271.2
Ans

b) 499.8

c) 406.8

d) 749.7

14)
You are designing a vessel to contain water, with multiple course vertical vessel
using rolled and welded plates without RT on all joints. The design parameters are
Service = water tank
Head and shell material = SA-516-70
MAWP = 250 psi
Temp = 400 deg F ID = 24
type 1 welds
stress = 17,500 pi
Shell height=24 feet
2:1 seamless ellipsoidal heads
What is the minimum material thickness you can use for the bottom shell course?
a) 0.2587

b) 0.2479

c) 0.2126

d) 0.1988

Ans

15)

What is the minimum material thickness you can use for the upper head?

a) 0.2020
Ans
16)

c) 0.3141

d) 0.2288

What is the minimum material thickness you can use for the lower head?

a) 0.2020
Ans

b) 0.2104

b) 0.2104

c) 0.3141

d) 0.2288

17)
A vessel has undergone welded repairs and will require a hydrostatic test. This
vessel is horizontal and has an ID of 6 feet. The vessel operates at 150 psi and the data
report reflects an E of 0.85 for the vessel based on RT-3. The limiting thickness of the
vessel is its shell coarse. The vessel is made of SA-515-gr 70 material with an allowable
stress at temperature of 15500 psi. Its allowable stress at test temperature 17500 psi.
What is the required thickness of this vessel and what shall the pressure be as read
from a gage on the bottom of the vessel during the test. The upper most part of the
vessel is 6 feet above the centreline of the vessels horizontal shell. The static head of
water is 0.433 psi per vertical foot.
a) T = 0.3621 and gage pressure will be 169.3 psi
b) T = 0.875 and gage pressure will be 260.624 psi
c) T = 0.4234 and gage pressure will be 224.057 psi
d) T = 0.4234 and gage pressure will be 254.032 psi
ans=C (UG-99 and API 510 body of knowledge)
t=?
P=150+3.897=153.897 psi
S=15500 psi design
S=17500 psi test
E=0.85
R=36
HH=0.3897 psi
Hydro pressure 1.3 x 17500 /15500 x 150 = 220.16 psi at the top gauge. Bottom gauge
reads 220.16 +3.897 =224.057 psi during test. Thickness required from UG
27=t=PR/SE-0.6P
=153.897 x 36 / (15500 x 0.85)-(0.6x153.897)=5540.292 / 13082.6618=0.4234
Answers=t min 0.4234 pressure at bottom during test is 224.057 psi
18)
A pressure vessel was manufactured and ready for hydro test. The operating
pressure is 90 psi. The MAWP is 100 psi. the hydro test pressure for this vessel is
a) 130 psi

b) 117 psi

c) 150 psi

d) 135 psi

Ans = a ( UG 99)
1.3 x MAWP x stress ratio = 1.3 x 90 x 100/90 = 130 psi
19)
choose correct hydrostatic test pressure from given options for a vessel with
following data:
design pr = 200 psi, design temp = 675 deg F, MOC = SA 537 cl 1, allow stress
( ambient) = 18000psi
allow stress (675 deg F)=15000 psi
a) 350 psig b) 260 psig c) 312 psig

d) none

Ans = c ( UG 99)
1.3 x MAWP x stress ratio = 1.3 x 200 x 18000/ 15000 = 312 psi
20)
A hydrostatic test is conducted on a vessel that is 60 tall. A pressure gauge is
located 35 up from the bottom of the vessel. If the stress ration is 1.0 and the MAWP of

the vessel is 100 psi, what approximate pressure should the gauge read to meet ASME
VIII requirements?
a) 141 psig

b) 145 psig

c) 130 psig d) 186 psig

Ans - stress ratio = 1.0 Hydro pressure at top = 1.3 x MAWP x stress ratio
=1.3x100x1.0=130 psig
Hydrostatic head at 35 elevation = 60 35 = 25 25 x 0.433 = 10.825 psig
Pressure at gauge level during test = 130 + 10.825 psig = 140.825 psig = Ans = A
21)
A hydrostatic test is being performed on a vertical vessel with an elevation of 48
feet. The MAWP of the vessel in its normal operating position is 225 psi. All RVs has
been removed and the vessel is blinded off from all other components. The gauge will
be installed at an elevation of 22.5 feet. What shall this gauge pressure be during the
hydrostatic test at the 22.5 elevation? The material design stress allowed is 16,800 psi
and the stress allowed at test temperature of 70 degree F (21 deg C) is 17,500 psi. H.H
is 433 psi per vertical foot.
a) 362.6 psi
b) 351.0 psi
c) 339.9 psi
d) 315.7 psi
Ans - D - UG 99
MAWP
- 225 psi
stress at test
- 17,500 psi stress by design
- 16,800
psi
Gauge pressure during test at the 22.5elevation=?
Least ratio of stresses
= 17,500 / 16,800 = 1.0416666
Hydrostatic test pressure at the top
= 1.3 x 1.04166 x 225 = 304.6870 pressure at
top
Calculating H.H present at the 22.5 elevation
= 48.0 22.5
= 25.5
25.5 x 0.433psi
= 11.0415 psi
Pressure at gauge level during test = 304.6870 + 11.0415
= 315.7285 psi
22)
Choose correct hydrostatic pressure from given option for a vessel with the
following data:
Design pressure
= 360 psi
Design temp
= 675 deg F
MOC
= SA 537 cl.1
Allow stress (ambient)
= 18600 psi
Allow stress (675 deg F)
=16900 psi
a) 540 psig
b) 515 psig
c) 450 psig
d) None of above
Ans

- Hydrostatic test pressure = 1.3 x design pr x stress ratio ( ambient/deg F)

= 1.3 x 360 x 18600 / 16900 = 515 psig = ans = B

23)
The pressure vessel has design pressure = 300 psi. Its safe stress values at
ambient and design temperatures are 17100 psi and 16300 psi respectively. The
hydrostatic test pressure and inspection pressure for above will be:
a) 450 psi and 346 psi
b) 409 psi and 315 psi
c) 415 psi and 300 psi
d) None of the above
Ans

- Hydrostatic test pressure = 1.3 x design pr x stress ratio ( ambient/deg F)

= 1.3 x 300 x 17100 / 16300 = 409.141 psi
Inspection pressure = hydrostatic pressure / 1.3 = 409 / 1.3 = 314.65 psi = Ans
= B ( check C? )

24)
A pressure vessel has design pressure = 300 psi. Its safe stress values at
ambient and design temperatures are 19800 psi and 18000 psi respectively. The
minimum hydrostatic test pressure and inspection pressure respectively for above will
be :
a) 450 psi, 390 psi
b) 390 psi, 330 psi
c) 429 psi, 330 psi
d) None of the above
Ans - C = UG 99 (b) and (g)
Hydrostatic test pressure = 1.3 x design pr x stress ratio ( ambient/deg F)
= 1.3 x 300 x 19800 / 18000 = 429 psi
Inspection pressure = hydrostatic pressure / 1.3 = 429 / 1.3 = 330 psi = Ans =
C
25)
What is the gauge reading when performing a hydrostatic test on a vessel
having an MAWP of 75 psi at 800 F. The material stress at 800 F is 12,800 psi and the
material stress at hydro test temp is 17,500 psi. The gauge is located at the bottom of
50 ft vessel positioned vertically during hydro testing
a) 1538 psi
Ans

b) 1560 psi

c) 1025 psi

d) 1047 psi

26)
A vessel is to undergo a hydrostatic test after a repair. The vessels stress
allowable at the test temperature is 15000 psi and its stress allowable at its operating
temperature is 13800 psi. The vessels MAWP at its design temperature is 125 psi. What
will be the required test pressure at the top of the vessel?
a) 203.8 psi
b) 169.6 psi c)176.6 psi
d) 143.7 psi
Ans - C ( UG-99)
Stress at test = 15000 psidesign stress = 13800 psi MAWP = 125 psi
Test pressure = 1.3 x 15000/13800 x 125
= 176.63 psi
27)
What is the minimum hydrostatic pressure for a pressure vessel given the
following
Shell material is SA-240T304
S=10200 psi@900 deg F
S=18800 psi @ 100
deg F
T=1/2
CA=0
design temp=900 deg F
MDMT = 50 deg F
Category A type 1 joint RT 1
diameter = 38OD
not for lethal service
b) 271.2
Ans

b) 499.8

c) 406.8

d) 749.7

- ref UG 99 B

28)
A vessel is undergoing a hydrostatic test after repair. The vessel is marked with
an MAWP of 100 psig at 750 degree F ( 399 deg C). the materials allowable stress at
operating temperature is 15,000 psi and its allowable stress at test temperature is
17,500 psi. the visual inspection shall take place at
a) 100 psi
b) No less than the MAWP of the vessel
c) 116.66 psi
d) 106.66 psi
Ans - C ( UG -99(b))
1.3 x MAWP x least ratio of stresses
Ratio of stress
= 17,500 / 15,000 = 1.16666
1.3 x 1.166 x 100
= 151.58
Inspection not less test press / 1.3 per UG 99 = 151.58 / 1.3

= 116.6 psi

29)
A vessel is to be pneumatically tested to a pressure of 172.7 psi and this
pressure has been adjusted for a stress ratio of 1.1666. the pressure which the vessel
should be inspected at will be;
a) 104.6 psi
b) 125.6 psi
c) 157.0 psi
d) 97.1 psi
Ans - c
1.1 x 157 = 172.7
UG 100 (d) - visual inspection at no loss than test pressure / 1.1 pressure = 172.7 / 1.1
= 157 psi
30)

a)
b)
c)
d)

Choose correct pneumatic test pressure for a vessel with the following data:
Design pressure
= 160 psi
Design temp
= 675 deg F
Allow stress (ambient)
= 20000 psi
Allow stress (675 deg F)
=19200 psi
176.0 psig
215.6 psig
183.3 psig
None of above

Ans

- 1.1 x 160 x 20000/ 19200

=C

ASME VIII, UG 100 (b)

31)
A 250 psi vessel (design pressure) is to be pneumatic tested in accordance with
the original ASME Sec VIII div 1 rules. The material is SA-516-70 and has a design stress
of 12000 psi and a stress of 17500 psi at ambient test temperature.
What is the pneumatic test pressure required?
a) 455 psi

b) 401 psi

c) 375 psi

Ans - B ( ASME VIII, UG 100 (B))

Pneumatic test pressure = 1.1 x 250 x 17500 / 12000
32)

= 401.041 psi

What is the minimum temperature at which a fabricated vessel can be tested?

a) 10 degrees above operation temp

b) 10 degrees above MDMT
c) 30 degrees above MDMT
d)
Ans

d) 313 psi

30 degrees above zero

- C ( ASME VIII, UG 100 (C))

33)
What is the first test pressure reading of the vessel gauge when pneumatically
tested?
a) 401 psi
Ans
34)

c) 187 psi

d) 201 psi

- D ( ASME VIII, UG 100 (D))

What is the pressure reading when inspection is performed?

a) 401 psi
Ans

b) 227 psi

b) 412 psi

c) 364 psi

- C ( ASME VIII, UG 100 (D))

d) 318 psi

35)
A 250 psi vessel 100ft tall is to be pneumatic tested in accordance with the
original ASME Sec VIII div 1 rules. The material is SA-516-70 and has a design stress of
12000 psi and a stress of 17500 psi at ambient test temperature.
What is the pneumatic test pressure required?
b) 455 psi
Ans
36)

b) 546 psi

c) 375 psi

- ( ASME VIII, UG 100 (B)) check

What is the minimum temperature at which a fabricated vessel can be tested?

a) 10 degrees above operation temp

b) 10 degrees above MDMT
c) 30 degrees above MDMT
d)
Ans

d) 313 psi

30 degrees above zero

check thickness

37)
What is the first test pressure reading of the vessel gauge when pneumatically
tested?
a) 313 psi
Ans

b) 227 psi

c) 187 psi

d) 273 psi

check

38)
What is the pressure reading on the gauge after the THIRD step in testing the
vessel?
a) 344 psi
Ans

b) 412 psi

c) 225 psi

d) 318 psi

check

39)
A pressure vessel is scheduled for pneumatic testing using the methodology of
ASME code, Section VIII Div 1.with the MAWP = 635 psig at 375 deg F. The vessel is
constructed of SA-516-65 material and is neither enabled for lined. The test metal
temperature will be a minimum of 50 Deg F, per the owner specifications. How many
pressurization steps are needed to achieve the minimum required test pressure, and at
what minimum pressure will the visual examination be performed?
a) 6 steps : 635 psig
b) 6 steps : 793.75 psig
c) 9 steps : 635 psig
d) 9 steps : 793.75 psig
Ans

-A

40)
A 250 psi ( design pressure) vessel is to be pneumatic tested in acc with original
ASME section VIII div 1 rules. The material is SA-516-70 and has a design stress of
12000 psi and stress of 17500 psi at ambient test pressure. What is the pneumatic test
pressure required?
a) 455 psi
b) 401 psi
c) 375 psi
d) 313 psi
Ans - B
( SEC VIII UG 100 B )
Pneumatic test pressure = 1.1 x 250 x 17500 / 12000 = 401.041 psi = B
41)
Following four new seamless (2:1) ellipsoidal heads are available for use under
following design conditions. Choose the correct one.
Design pr = 332 psi, Head I.D = 60 and S = 20000 psi with no C.A
a) Design thk = 0.7382. provided thk after forming = 0.75

b) Design thk = 0.9788. provided thk after forming = 1.0

c) Design thk = 0.4985. provided thk after forming = 0.5
d) Design thk = 0.7377. provided thk after forming = 0.75
Thickness of new ellipsoidal head (2:1) is given by ASME formula, t = PD / 2SE 0.2 P
= 332 x 60 / 2 x 20000 x 1 0.2 x 332 = 19920 / 39933.6 = 0.4985
Provided thk of 0.5 is OK. Correct ans C
42)
a)
b)
c)
d)

Head in Q15 ( ellip head B) value of crown whose radius can be taken as:
72
60
48
54

Ans
43)
a)
b)
c)
d)

- For ( 2 : 1 ) ellip head, for API analysis crown radius = 0.9 D = 54 Ans = D

For head B, the crown portion would lie within similar circle of diameter
60
30
54
48

Ans

- Crown portion lies in circle of diameter equal to 0.8D = 0.8 x 60 = 48 Ans = D

44)
A vessel with 60 inches ID is to be provided std. torispherical heads. The heads
shall be formed with crown radius and min. knuckle radius as follows ( head thickness =
1.2 inch):
a) 60 inch, 4 inch
b) 60 inch, 3.6 inch
c) 25 inch, 3 inch
d) None of the above
Ans - Crown radius h = D = 60 & knuckle radius = 6% of crown radius = 3.6 inch =
Ans B ( UG32-j)
45)
An ellipsoidal head has experienced corrosion at a radius 31 inches above the
centre of the head. The head is attached to a shell that is 8 in diameter using a type 2
weld that has been fully radiographed. This corroded area may be considered within the
spherical portion because the greatest distance allowed for this calculation from the
heads centre is:
a) 76.8 inches
b) 38.4 inches
c) 80.0 inches
d)
40.0
inches
Ans - b ( API 510 7.4.6.1(b))
80% of the shells diameter 0.80 x 96 = 76.8 Radius = 76.8 / 2 = 38.4 since 31 is with
in the 38.4 radius it may consider within the spherical portion
46)
An ellipsodical head has an internal diameter of 76 inches and depth of 21 inches
( including a straight face dimension of 2 inch ) . what should its spherical (crown)
radius be?
a) 76.9 inches

b) 15.6 inches

c) 68.4 inches

d) all the above

Ans - c
( API 510 7.4.6.3 )
Spherical radius K1D i.e D/2h = K1 and for many ellipsodical heads d/2h = 2.0
Then from table 7-1 2.0 of d/2h equals 0.9 of K1
= 0.9 x 76 = 68.4 inches

47)
The crown portion for torisph. Head (ID 40 inch) may be considered as the
portion lying entirely within a circle whose centre will be same as head centre and
diameter will be
a) 36
Ans

b) 40

c) 32

d) 200

- API 510 7.4.6.1(b)

48)
For 2:1 ellip head ( ID = 75 inches ), the crown portion would lie within similar
circle of diameter
a) 60
Ans

b) 30

c) 54

d) 48

- API 510 7.4.6.1(b)

49)
A vessel with seamless 2:1 elliptical head 60 inch ID, 400 psi design pressure, CA
= 0, S = 20000 psig was inspected. Available thickness of only 5/8 was observed on
the crown portion. The knucle thickness was found to be adequate. Your assessment is
a) Head thickness in crown portion is still ok for operation
b) thickness is adequate
c) depends on opinion of third party inspector
d) API 510 inspector
Ans

- A check

50)
A 2 to 1 ellipsoidal head has experienced corrosion in the central portion of the
head and will require calculations for continued service. Using the following information,
what is to be used as the diameter of the spherical segment when evaluating the
corrosion? The vessels shell diameter is 96 inches.
a) 96 inches
b) 76.8 inches
c) 80 inches
d) 38.4 inches
Ans

- b ( API 510 7.4.6.1(b) = 80 % of the shells diameter 0.80 x 96 = 76.8

51)
Following four new seamless standard torispherical heads are available for use
under following design conditions. Design pr = 235 psi, Head I.D = 72 and S = 20000
psi with no C.A. Required minimum thickness of crown portion for analysis as per API
510 for head A shall be
a) 0.3695
b) 0.4075
c) 0.4235
d) 0.4825
For torisph head, for crown portion, use hemisphere formula using R = D
T = PR / 2SE 0.2P
use R=D=72, S = 20000 PSI, E = 1, P = 235
= 235 x 72 / 2 SE 0.2 P = 16920 / 39933.6 = 0.4235 = Ans = C
52)
Following four new seamless (2:1) ellipsoidal heads are available for use under
following design conditions. Choose the correct one. Design pr = 332 psi, Head I.D =
60 and S = 20000 psi with no C.A. Required minimum thickness of crown portion for
analysis as per API 510 for head B shall be
a) 0.4490
b) 0.4262
c) 0.3652
d) 0.4863
Again use hemispherical head formula for crown part: t = PR / 2SE -0.2P
For hemispherical head, use R = 0.9 D, S = 20000 psi, E = 1, P =332
= 332 x 0.9 x 60 / 2 SE 0.2P = 332 x 54 / 39933.6 = 0.4489 = Ans = A

53)
A cylindrical shell has a seamless hemispherical head on one end and a seamless
ellipsoidal head on the other end. The elliptical head is attached by a type 2 weld
meeting the spot radiography requirements of UW-11(a) (5) (b). The shell has a single
longitudinal joint. All category A butt welds are type 1 with full radiography applied. The
vessel will require an MAWP of 50 psi. The material of the shell and head is SA-515gr.60. The allowable stress at the operating temperature is 15000 psi. The heads inside
diameter is 10-0. What is the required thickness of the 2 to 1 ellipsoidal head?
a) 0.250
b) 0.235
c) 0.200
d) 0.1003
Ans = C (UG-32-d)
P=50 S=15000
E=1.0 D=10 x 12 = 120 t=?
T= PD / 2SE 0.2 P = 50 x 120 / (2x15000x1.0)-(0.2x50) = 0.200
54)
A vessel was designed to the 2001 edition of the ASME section VIII div 1 code.
The ID of the head is 48 inches. The design pressure is 500 psig and the design
temperature is 300 F. the vessel seams have been radiographically inspected per UW51. The vessel material is SA-516-70. The corrosion allowance is 0.125 inch. The
minimum required thickness of the 2:1 elliptical head per the code of construction is
a) 0.940 inch
b) 0.730 inch
c) 0.610 inch
d) 0.820 inch
Ans - B ( ASME Sec VIII UG 32 (d) check
T=PD / 2SE 0.2P
= 0.125 +(500)(48)/((2)(1)-(0.2)(500))=0.727
55)
A hemispherical head formed from solid plate is 48.0 inches in inside diameter
this head is attached to a seamless shell and has not had radiography on the category
A type 1 weld that attaches the head to the shell. The vessel is horizontal and operates
at 500 psi water pressure with an allowable stress on the heads material of 15000 psi.
The heads thickness required is?
a) 0.5741
b) 0.577
c) 1.1432
d) 0.2356
ans = B ( UG-32)
P= 500 + hydrostatic head
H.H=4feet x 0.433=1.732 psi
P=501.732 psi
S=15000
L=48/2=24 t=?
E=0.70 for category A weld no RT
From UG 32 t=PL / 2E 0.2 P = 501.732 x 24 / (2x15000x0.70)(0.2x501.732)=0.576
56)
A pressure vessel has been in service for 12 years and has shown a history of
corrosion over its service life. The original thickness was 1.9375 thick and the present
thickness is 1.405. What is the corrosion rate for this vessel?
a) 0.266250 in / yr b) 0.532500 in/yr
Ans d

c) 0.088750 in/yr

d)0.044375 in/yr

i.e. CR = (1.9375-1.405)/12 = 0.044375

57)
During an internal inspection a vessels shell was measured and found to have a
remaining wall thickness of 0.486 inches. It was last inspected 4 years ago. The
retirement thickness of the vessel shell is 0.475 inches and its previous thickness was
0.500 inches. Based on this data, per API 510 what is the present corrosion allowance of
the vessel?
a) 0.025
b) 0.110
c) 0.011
d) 0.014
Ans - C ( API 510 body of knowledge )
C.A = present previous = 0.486 0.475 = 0.011
58)
Calculate the remaining life and the external inspection interval of a vessel the
following data: actual thickness = 0.955 inch, minimum thickness required = 0.755
inch, thickness at previous inspection 5 year prior to present inspection = 1.025 inch

a) 20yrs & 10yrs

b) 14yrs & 5yrs

c) 28yrs & 10 yrs

d)none

Ans - d
CR = (1.025 0.955)/5 = 0.014
RL = (0.955 0.755)/ CR = 14.28 yrs
External inspection = lesser of 5 yrs or RL = 5yrs
59)
A vessel was inspected six years ago and had shell thickness =0.870. as on
today the thickness as reported by filed inspection is 0.786. What was the corrosion
rate over last six years
a) 10mpy

b) 12 mpy

c) 14mpy

d) none

Ans - c
CR = (0.870 0.786) / 6 = 0.014 i.e. 14 mpy
60)
If the vessel in above question has minimum permissible thickness = 0.618 for
the present design conditions. What will be estimated remaining life of the vessel if the
corrosion rate remains same?
a) 10yrs

b) 12 yrs

c) 14yrs

d) none

Ans - b
RL = (0.786 0.618)/0.014 = 12 yrs
61)

For a vessel in Q18 & Q19 find interval for next thickness inspection

a) 10
Ans

b) 6
-b

c) 8

d) 5

i.e. RL

62)
For a vessel which is planned for internal inspection after 8 years what should be
the minimum remaining corrosion allowance in the vessel if corrosion rate is 150
microns / year
a) 2.0 mm
Ans

b) 2.4 mm

c) 1.2 mm

d) none

- RL = x / 150 microns = 8 yrs i.e. x = 150 microns x 8 yrs = 1.2 mm

Corrosion rate = RL x 2
i.e. 1.2 x 2 = 2.4 mm
Ans = b

63)
Calculate the remaining life of a vessel given the following data: actual thickness
= 0.955 inch, minimum thickness required = 0.787 inch, thickness at previous
inspection 5 year prior to present inspection = 1.015 inch
a) 20yrs
Ans

b) 14yrs

c) 28yrs

d)none

- CR = 1.015 0.955 / 5 yrs = 0.012 per year

RL = 0.955 0.787 / 0.012 = 14 yrs
Ans = b

64)
A pressure vessel has been in service for 12 years and has a history of corrosion
over its service life. The original thickness was 1.9375 inches. The current thickness is
1.405 inches. What is the corrosion rate of this vessel?
a) 0.044 in/ yr
Ans

b) 0.089 in/yr

c) 0.266 in/yr

d) 0.532 in /yr

- CR = 1.9375 1.405 / 12 =0.044 in / year = a

65)
A 15 year old vessel was measure to have a general average thickness of 0.645.
A previous inspection reading taken 10 years ago was 0,895 and the original data

report of the vessel indicated that the thickness was 1.00. To determine the remaining
life of the vessel which corrosion rate would you as the inspector use?
a) 0.0210
Ans

b) 0.0180

c) 0.0236

d) 0,0250

- CR = 1.00 0.645 /15 yrs = 0.0236 = C

66)
An existing pressure vessel has been inspected on a given year and found to be
0.750 thick in the shell and heads. The next inspection is performed 3 years later, and
the thickness of the shell and heads is shown to be 0.560 (uniform). Calculations show
that the vessel required thickness is 0.450. From this information determine the
following information, per API 510
a) Total metal loss b) corrosion rate
Ans
a)
b)
c)
d)
e)

c)CA d) remaining life e) inspection interval

Total metal loss - 0.750 0.560

= 0.190
Corrosion rate - 0.190 / 3
= 0.0633 / year
CA
- 0.560 0.450 = 0.110
Remaining life - 0.110 / 0.0633
= 0.86
Inspection interval
- check for correct ans

check for correct ans

67)
A fifteen year old vessel made of SA-203,Gr B was measured as having a
thickness of 0.645.The inside diameter is 42 and the MAWP is 450 psi at 650 Deg F.
The backing ring was left in place and the vessel did comply with UW-11(a) (5) (b).
Material stress is 17,500 psi. The previous reading on the material had a thickness of
0.68 during the first 10 year interval. Data report indicated that the material had a
nominal thickness of 0.75. The corrosion rate is
a) 0.007
Ans
68)

69)
a) 5
Ans

c) 0.035

d) 0.0035

CR = T initial T actual / years i.e. 0.68 0.645 / 5 = 0.007 per year = Ans =a
As per above Q36, The required minimum thickness is

a) 0.548
Ans

b) 0.07

b) 0.645

c) 0.610

d) 0.788

- check material SA 203 Gr B not correct

As per above Q36, The remaining service life in years is
b) 2.5

c) 13.8

d) 6.9

- first do Q37

70)
During the internal inspection of a vertical vessel a minimum thickness reading of
1.270 was found on a shell course. The data report reflects an original thickness of
1.50, and allowable stress at 600 degrees of 14,500 psi, full radiography, and a MAWP
of 650 psi. The MAWP was based on a retirement diameter of 49.02 inches after the
corrosion allowance was expended. This yields a retirement thickness of 1.129 inches.
Inspection records indicate a corrosion rate of 0.025 inches a year. If the corrosion rate
does not change what is the maximum time before the next on stream or internal
inspection?
a) 5 years
b) 5.6 years
c) 10 years
d) 2.8 years

Ans - d
1.270 1.129 / 0.025 = 5.64 yrs remaining life
Next inspection no more than remaining life or 10 years use the lesser
5.64/2 = 2.82 years
71)
A pressure vessel has been measured to have a minimum wall thickness of 0.235
inch after 5 years of service. The vessels original wall thickness was 0.250. Its
minimum allowable wall thickness is 0.195 inch. How long until the next required
inspection as per API 510?
a) 13.3 years
b) 10 years
c) 5 years
d) 6 and 2/3 years
Ans - d
API 510 ( 7.1.1 )
Wall loss = T initial t actual = 0.250-0.235=0.015
Corrosion rate = 0.015 / 5 yrs = 0.003/year = 3 mils / year
Rem C.A = t actual t required = 0.235-0.195 = 0.040 or 40 mils
Remaining life
= C.A / C.R = 0.040 / 0.003
= 13.33 years
Next inspection = one half estimated C.R. life or ten years whichever less
13.333 / 2 = 6.66
= 6 2/3 years
72)
A vessel was placed in service on 1/15/60 with an original wall thickness of
0.875. It lost wall at an average rate of 0.005 per year until 1/15/75. Service
conditions have changed and this inspection, 1/15/96 the vessel has a present wall
thickness of 0.630. The previous thickness 5 year ago was 0.789. If the present rate
of corrosion continues and the retirement thickness is 0.525, what will be the
retirement year of the vessel?
a) First quarter of 1997
b) Second quarter of 1999
c) Second quarter of 2001
d) last quarter of 1999
ans -b
Metal loss calculation : previous actual = metal loss
0.789-0.630 = 0.159
Short term corrosion rate = 0.159 / 5 yrs = 0.0318
Previous actual = remaining C.A = 0.630 0.525 = 0.105
Remaining life = remaining C.A / short term corrosion rate = 0.105 / 0.0318 = 3.3
years R.L
Present date + 3.3 yrs = second quarter 1999
73)
What is the remaining life of a vessel corroding at a rate of 0.017 inch per year
when the last inspection measured 0.638 inch and the minimum required thickness is
0.513 inch.
a) 4 years
b) 10 years
c) 6.3 years
d) 7.3 years
Ans - d
T actual t required = 0.638 0.513 = 0.125
Remaining corrosion allowance = 0.125
Remaining life = t actual t required / corrosion rate = 0.125 / 0.017 =7.35 yrs
74)
For a vessel find estimated remaining life and next planned external inspection if
actual thickness measured during inspection is 0.45 and minimum required thickness
is 0.37. Estimated corrosion rate is 10 mpy.
a) 10 years, 5 years
b) 8 years, 5 years

c) 8 years, 4 years
d) 10 years, 10 years
Actual tk = 0.45 min tk reqd= 0.37 CR = 10 mpy
RL = 0.45-0.37 / 10= 0.08 / 10 mpy
= 8 yrs
Internal inspection = RL or 10 yrs whichever is less
= 4 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 4 yrs
Ans = 8 yrs of RL and 4 yrs of next planned internal inspection = C
75)
In above question, if estimated corrosion rate is 20 mpy. The next planned
inspection and external inspection shall not be later than
a) 8 years, 4 years
b) 4 years, 4 years
c) 2 years, 2 years
d) 8 years, 5 years
Ans = C
RL = 0.45-0.37 / 10= 0.08 / 20 mpy
= 4 yrs
Internal inspection = RL or 10 yrs whichever is less
= 2 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 2 yrs
Ans = 2 yrs of internal and 2 yrs of next planned external inspection = C
76)
For a vessel remaining life is estimated as 24 years from now, next planned
internal and external inspection shall not be later than
a) 12 years, 5 years
b) 10 years, 10 years
c) 10 years, 5 years
d) None of the above
Ans = C
RL = 24 yrs
Internal inspection = RL or 10 yrs whichever is less
= 10 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal
inspection=5 yrs
Ans = 10 yrs of internal and 5 yrs of next planned external inspection = C
77)
For a vessel remaining life is estimated as 3 years from now, next planned
internal and external inspection may be planned ________ years from now
a) 1.5 years, 3 years
b) 2 years, 2 years
c) 1.5 years, 1.5 years
d) 2 and 3 above
Ans = D
RL = 3 yrs
Internal inspection = RL or 10 yrs whichever is less
= 1.5 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 1.5 yrs
Ans = D
78)
For a vessel remaining life is estimated as 2 years from now, next planned
internal and external inspection shall not be later than
a) 1 years,1 years
b) 2 years, 2 years
c) 1 years, 2 years
d) any of the above
Ans =A
Internal inspection = RL or 10 yrs whichever is less

= 1 yr

External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 1 yr
Ans = 1 yr of internal and 1 yr of next planned external inspection = A
79)
for a non-continuous corrosive service with remaining life 25 years, external
inspection shall be performed not later than
a) 10 years
b) 12,5 years
c) 5 years
d) None of above
Ans = C
Internal inspection = RL or 10 yrs whichever is less
= 10 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 5 yr
Ans = 10 yrs of internal and 5 yrs of next planned external inspection = C
80)
A vessel which was inspected six years ago and had shell thickness = 0.870. As
on today the thickness as reported by filed inspection is 0.786. What was the corrosion
rate over last six years?
a) 10 mpy
b) 12 mpy
c) 14 mpy
d) None of the above
Ans = C
Shell tk = 0.870@ 6 yrs ago
now tk =0.786
CR = 0.870 0.786 / 6
= 0.084 / 6 = 84 mpy / 6

= 14 mpy

= Ans = c

81)
If the vessel in above question has minimum permissible thickness = 0.618 for
the present design condition. What will be estimated remaining life of the vessel if
corrosion rate remains same?
a) 10 yrs
b) 12 yrs
c) 14 yrs
d) None of the above
Ans = B
Permissible tk
= Ans = B

= 0.618 now tk = 0.786

RL = 0.786-0.618 / 14

= 12 yrs

82)
Calculate the remaining life and external inspection of a vessel given the
following date: actual thickness 0,955 inch, minimum thickness required 0.759 inch,
thickness at previous inspection 5 years prior to present inspection 1.025 inch.
a) 20 years, 10 years
b) 14 years, 5 years
c) 28 years, 10 years
d) None of the above
Ans - B
CR= 1.025 0.955 / 5 = 0.014
RL = 0.955 0.759 / 0.014 = 14 yrs
Internal inspection = RL or 10 yrs whichever is less
= 7 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 5 yr
Ans = 14 yrs of RL and 5 yrs of next planned external inspection = B
83)
For a vessel remaining life is estimated as 22 years from now, next planned
internal and external inspection shall not be later than
a) 11 years, 5 years

b) 10 years, 5 years
c) 5 years, 5 years
d) None of the above
Ans =
B
RL = 22 yrs
Internal inspection = RL or 10 yrs whichever is less
= 10 yrs
External inspection = does not exceed lesser of 5 yrs or the required internal inspection
= 5 yr
Ans = 10 yrs of internal and 5 yrs of next planned external inspection = B
84)
An existing vessel is inspected on a given year and found to be 0.500 thick in
the shell and heads. The next inspection is performed 3 years later, and the thickness
of the shell and heads is shown to be 0.310 (uniform). The vessel minimum thickness
is calculated to be 0.200". from this information, the remaining life (RL) and internal
inspection interval (I.I)on this vessel is approximately
a) 5 years RL, 10 years I.I
b) 7 years RL, 15 years I.I
c) 1.73 years RL, 1.73 years I.I
d) 10 years RL, 10 years I.I
Ans - permissible tk 0.500 next inspection 3 years later and present tk = 0.310,
min tk reqd = 0.200
CR = 0.500 0.310 / 3 = 0.0633
RL = 0.310-0.200 / 0.0633
= 1.73 years
Internal inspection = RL or 10 yrs whichever is less
or whenever the remaining
life is less than 4 years, the inspection interval may be the full remaining life upto
maximum of 2 years. Hence 1.73 yrs I.I
Ans = 1.73 yrs of RL and 1.73 yrs of next planned internal inspection = C
85)
A vessel shell course was replaced on September 1 st of 1982. The initial thickness
was 0.378 on sep 1st of 1982. The second reading for thickness was on sep 1 st of 1987
and was 0.364. the last thickness measured was 0.345 in sep 1 st of 1992. Based on
the most aggressive corrosion what is the value in mils per year to be used in
calculating the remaining life of the vessel?
a) 3.8 mils / yr
b) 5.15 mils/yr
c) 4.77 mils/yr
d) 3.3
mils/yr
Ans - A ( API 510 7.1.1.1)
Time in years long term = sep 1st 1982 to sep 1st 1992 = 10 years
Corrosion rate (L.T) = t initial t actual / time = 0.378 0.345 /10 = 0.0033 3.3
mils/yr
Time in years short term = sep 1st 1987 to sep 1st 1992 = 5 years
Corrosion rate (S.T) = t previous t actual / time = 0.364 0.345 /5 = 0.0038 3.8
mils/yr
Ans the most aggressive corrosion is short term 3.8 mils /yr
86)
A vessel was built to the 1980 edition of section VIII Div 1 and put into service
that year. Shell material is SA516-70 with an internal diameter of 120 inches. All welded
seams were radiographed. The design pressure is 140 psig and design temperature is
650 deg F. origin nal shell thickness is 5/8 in with 1/8 in corrosion allowance. An
inspection in dec 1999 showed a wall thickness was 0.610 in. in dec 2002, the
inspected wall thickness was 0.585 in. what is the long term corrosion rate?
a) 0.0018 in/yr
b) 0.018 in / yr
c) 0.015 in / yr
d) 0.0015 in / yr
Ans - A ( API 510 6.4)
LTCR = ( 0.625 0.585)/22 = 0.0018 in /yr
87)
A vessel put into service in december 1980. The vessel had the original shell
thickness of 0.625 inches. An inspection in December 1990 measured a wall thickness

of 0.610 inches. In December 2002, the inspected wall thickness was 0.585 in. what is
the long term corrosion rate?
a) 0.0015 in /yr
b) 0.018 in / yr
c) 0.0018 in / yr
d) 0.015 in /yr
Ans - C ( API 510 6.4)
LTCR = (0.625-0.585)/22 = 0.0018 in / yr
88)
A vessel is ultrasonically inspected when it is new and cold in June 1987 and
found to be 0.800 thick in the shell. The next inspection is done in June 1995 and the
vessel found to be 0.650 thick. If the minimum thickness by calculation is 0.510,
when (approximately) should the next internal or on stream inspection be scheduled
per API 510?
a) Feb 1999
b) Nov 2010
c) Jun 2005
d) Oct 2002
Ans - A
June 1987
- 0.800
June 1995
- 0.650 ( after 8 years )
Min tk
- 0.510
CR
- 0.800 0.650 = 0.150/8= 0.01875
RL
- 0.650 0.510 / 0.01875 = 7.46 years
Internal inspection = RL or 10 yrs whichever is less i.e. 7.46 / 2 = 3.73 yrs = 44.76
yrs = feb 1999
89)
During an internal inspection the following minimum thickness readings were
taken on a vertical vessel. Top head present = 0.235, shell coarse present = 0.225,
bottom head present = 0.195.this vessel has been in service for 6.5 years and all
components had an original thickness of 0.250 inch. The engineer calculated a
minimum thickness of the top head to be 0.145 and the bottom head minimum
thickness to be 0.155 and the shells minimum thickness to be 0.205. Based on the
readings what is the corrosion rate for the shell element?
a) 0.025/year
b) 0.0023/year
c) 0.020/year
d)
0.00384 / year
Ans - D (API 510 7.1.1.1)
0.250 0.225 / 6.5 = 0.0038461
90)
be
a)
b)
c)
d)

For a vessel which is planned for internal inspection after 8 years. What should
the minimum remaining allowance in the vessel if corrosion rate is 150 mpy
2.0 mm
2.4 mm
1.2 mm
None of the above

Ans

- D check

91)
A round weld tensile specimen is tested and found to fail in the base metal at a
load of 14.876 lb. the specimen was measured before the test to have a diameter of
0.503 inches. The ultimate tensile strength of this specimen is: ( hint : the area of circle
is equal to 3.141 (pi) times its radius squared)
a) 74.878 psi
b) 18.829 psi
c) 235.185 psi
d) 74.380
psi
Ans - A (IX art I QW-153)
load = 14876 lbs diameter=0.503 radius=0.503/2 = 0.2515 area of a circle = pie r
square
= 3.141 x (0.2515)2=3.141x0.2515x0.2515=0.19867
Finally compute the tensile strength = load / area = 14876 / 0.19867 = 74877.938 psi

92)
A 3-1/2 inch thick plate weld procedure test coupon must be tensile tested. This
will require the cutting of the test coupon into smaller pieces. The tensile testing
machine is capable of pulling up to 1 thick specimens. How many pieces will be
required to for a complete test per section IX?
a) 6
b) 8
c) 2
d) 12
Ans - B ( IX art I QW-151.1(c))
thickness of coupon=3.5 3.5 /4 = 0.875 ( 4 pieces for each tensile specimen)
2 tensile tests are always required therefore; 2 x 4 = 8 pieces
93)
You have received the following tension test results for a welding procedure.
What is the ultimate unit stress for these two specimens?
Specimen
width thickness
area ultimate total load lb
ultimate unit stress
1
0.750 0.410
0.308
22600
?
2
0.748 0.409
0.306
25800
?
a) 72380 & 83314 b) 72377 & 83296 c) 73377 & 84314 d) 74377 & 83314
Ans - C (Sec ix QW-152)
Specimen 1 = 22600/0.308 = 73376 psi specimen 2 = 25800 / 0.306 = 84313 psi
94)
The ultimate load on a 0.510 diameter tensile specimen is 15 ksi. The ultimate
tensile strength on this specimen is approximately :
a) 73,529 psi
Ans

b) 90,200 psi

c) 85,100 psid) 18,359 psi

95)
Two plate tensile test specimens have been tested and found to be acceptable.
The characteristics of each specimen are as follows :
specimen 1 : width =0.752, tk =0.875,UTS=78,524 psi
specimen 2 : width =0.702, tk =0.852,UTS=77,654 psi
What is the ultimate load for each specimen that was reported on the lab report?
a) 51,668 & 46,445
Ans

-a

b) 67,453 & 56,443c) 78,524 & 77,654 d)none

UTS x width x thk

96)
A pressure vessel has been designed for external pressure using SA-516-60
material. The total length of support is 8 ft. The MAWP ( external) stamped on the
vessel is 250 psig@500 deg F. The OD is 48 can this vessel be safety operated with a
minimum shell thickness of 0.250? (yield strength = 28ksi)
a) Yes. Vessel is acceptable
b) No. vessel is not acceptable
c) Not enough information given to form an answer
d) Material cannot be used for external pressure without full RT.
Ans - SA 516-60 yield = 32,000
( see ASME Sec II part D page 10 for YS of SA
516 Gr 60 )
L=8 or 96 P=250
Do=48
t=0.250 Do/t=48/0.250=192
Do/t=192
L/Do=2
=96/48=2
A=0.00025 b=3400
Pa= 4 x 3400 / 3 (192)
= 13,600 / 576
=23.611
No. this vessel cannot be operated at 250 psig.
Answer = B
97)
A pressure vessel has been designed using SA516-60 material (32,000 yields).
Total length of support is 8 ft. The stamped MAWP (external) is 150 psig@500 deg F. The
OD is 48. Can this vessel be safely operated if the thickness has corroded down to
0.250

a)
b)
c)
d)

Yes. This vessel is safe down to 0.250

No. this vessel is not safe for 150 psig
Not enough information provided to solve the problem
Yes. This vessel could actually be operated at 250 psig

Ans - copied from Q52. Check for correct answer

SA 516-60 yield strength = 32,000 ( see ASME Sec II part D page 10 for YS of SA
516 Gr 60 )
L=8 or 96 P=150
Do=48
t=0.250 Do/t=48/0.250=192
Do/t=192
L/Do=2
=96/48=2
A=0.00025 b=3400
Pa= 4 x 3400 / 3 (192)
= 13,600 / 576
=23.611
No.this vessel cannot be operated at 250 psig.
Answer = B
98)
A small exchanger has experienced internal corrosion of its tubes. The tubes are
required to withstand an external pressure of 350 psi. The tubes have and OD of 2.0
inch and are 60 inches in length with a wall thickness of 0.025 inch. What would be the
approximate factor a value for this combination of length diameter and thickness of
tube?
a) 0.0056
b) 0.00055 c) 0.057
d) 0.10
Ans - B (UG-28)
Calculate Do / t and L/Do Do/t = 2.0 / 0.025 = 80
Factor A = 0.00055

L/Do = 60/2.0 = 3.0

99)
A pressure vessel (MOC 516 gr 70) has external jacket spread over 72 inches
length of the shell. ( jacket pressure = 180 psi, jacket temperature = 350 deg F) the
vessel OD = 36 inches, shell thickness=0.5 inch, CA=nil. Decide which of the following
are applicable in the present case
a) Shell thickness is ok
b) Shell thickness is not ok
c) Data are not adequate
d) Acceptance of shell thickness depends on opinion of vessel engineer
Ans - L / Do = 72 / 36 = 2.0 and Do / t = 36 / 0.5 = 72
From fig G of ASME II part D , A=0.002
From fig CS-2, B=11500
Allowable ext pressure = 4B / 3 (Do/t) = 4 x 11500 / 3 x 72 = 212.9 psi > 180 psi =ok=
Ans =A
100)
A 30 ID 0.280 thick circular man way has been welded to an existing pressure
vessel with a full penetration weld into the shell. The shell is made of SA-516-70
material is 0.625 thick and is 72ID. The manhole is SA-106-Cand extends past the
vessel wall. 3 on the outside of the vessel. The man way is flushed to the ID of the
vessel. MAWP is 250 psig@600 deg F. The man way does not pass through a welded
joint and has a x leg fillet weld around the nozzle on the top of the full
penetration weld. Radiography is RT-1. The required (calculated) thickness of the shell is
0.518 and the required (calculated) thickness of the nozzle 0.216. From this
information, this nozzle is
a)
b)
c)
d)

Is adequately reinforced without a repad

Does not need to be calculated for additional reinforcement
Will need reinforcing pad to be acceptable
Not enough information to form an answer

Ans - A = 30 x 0.518 x 1 +0 = 15.54

A1=30( 1x0.625-1*0.518)-0=3.21
A1=2(0.625+0.280)(1x0.625-1x0.518+0)=1.81 x 0.107 =0.1936
A2=5(0.280-0.216)1x0.625=0.20

A2=5(0.280-0.216)1x0.280=0.0896
A3=0
A41=0.5 square x 1 = 0.25
A43=0
3.21+0.0896+.25=3.549 opening need pad
101)
Two nozzles are to be added to an existing pressure vessel. One nozzle is 3.5 in
OD and the other is 2 in OD. How close may these nozzles be placed in the vessel wall
without their areas of reinforcement overlapping?
a) 2.5 inches
b) 3 inches
c) 5.5 inches
d) 2 inches
Ans - C ( UG 42 a ) page 49
Minimum distance without overlapping areas of reinforcement per UG 42 not less than
two times their average diameter
3.5 nozzle 1 + 2.0 nozzle 2 = 5.5 /2
= 2.75 average diameter
2 x 2.75
= 5.5 answer
102)
For a certain nozzle to shell joint ( no CA reqd) following data presented.
Shell thickness provided -=0.42 inch, nozzle ID = 3.2 inch, pad size = 6.4 in OD, thk of
pad = 0.42
a)
b)
c)
d)

Nozzle is adequately reinforced

Reinforcement is inadequate
Data is inadequate - nozzle thickness must be given
Data is inadequate - design shell thickness must be given

Ans

- A

103)
6 nozzle, vessel thickness = 0.500, required t = 0.416. Nozzle thickness = 0.3,
diameter D = 5.71. Calculate the reinforcement area?
Ans

104)
A steel bar is 15 long x 3 in diameter. What are the proper ampere/turns to be
applied when using the coil technique?
a) 4375
Ans

b) 5000

c) 35000

d) 2000

- for coil technique ( longitudinal magnetization technique )

- if L/D ratios less than 4 but not less than 2 = ampere turns = 45000 /

(L/D)
- if L/D ratios equal to or greater than 4 = ampere turns = 35000 / (L/D)
+2
-

35000 / ( 15/3 ) +2

= 5000 ampere turns = Ans = B

105)
On 1 thick piece that will be MT tested by prods, the spacing between the prods
will be 5. The correct amperage range for this spacing would be
a) 1000 2000 amps
amps
Ans

b) 150-300 amps

c)100-125 amps

d)

500-625

- prod technique
- Current shall be minimum 100 amp / inch to maximum 125 amp / inch
for sections thick or greater. For less than thick, the current
shall be 90 amp / inch to 110 amp/inch prod spacing.
- 100 to 125 amp /inch x 5 = 500 to 625 amps = ans = d

106)
A round steel bar is 14 long x 7diameter. What is the proper amperage to be
applied when using the circular direct contact technique?
a) 4900-6300
Ans

107)

a)
b)
c)
d)

b) 2100-5600

c) 5 turns

d) 1500-1600

- circular magnetization technique

- Current shall be 300 amp / inch to 800 amp / inch of outer diameter
- OD = 7 i.e. 300 x 7 to 800 x 7 = 2100 to 5600 = ans = B
If 6000 amp-turns are required to magnetize a part, how many amps are required for a 5-turn coil?

1000
6000
1200
100

Ans

-C

108)
A vertical vessel has been determined to need de-rating to a lower MAWP. The
new MAWP is based on the engineers calculation for pressure allowed on the top shell
section listed below. The vessel has an elevation of 55 feet to its very top. The following
pressure is calculated to the bottom of the element listed. Top shell section, elevation
40.3 feet, P=458.3 psi. What is the MAWP of this vessel based on this calculation?
a) 439.6 psi
b) 440.8 psi
c) 451.9 psi
d) 457.6 psi
Ans - C ( UG 99 & body of knowledge)
Total elevation
= 55 feet , elevation of interest = 40.3 feet ( bottom of top shell
coarse)
55.0-40.3 = 14.7 feet of H.H
14.7 x 0.433 psi = 6.365 psi,
MAWP of vessel shell coarse at its bottom H.H present= 458.3 psi 6.365 psi =
451.935 psi
Do not exceed 451.9 at the top or pressure will exceed 458.3 at the 40.3 elevation
109)
A vessel is constructed of rolled and welded SA-516 gr 70 steel plate. It is 96
inches in diameter with a communicating chamber, which extends 18 inches below this
horizontal vessel. This vessel is in water service and operates at working pressure of
150 psi. What will be the gauge pressure at working pressure as read on a gauge
mounted on the bottom of the vessels communicating chamber?
a) 150 psi
b) 154.11 psi
c) 153.46 psi
d) 199.36 psi
Ans - B
( UG 99 API 510 body of knowledge )
H.H= 8 + 1.5
= 9.5 x 0.433
= 4.1135 psi
Pressure at the bottom = Working pressure 150 + hydrostatic head 4.1135
154.1135 psi

110)
A column was hydro tested having total height of 45 feet. The top pressure
gauge is reading 45 psig. The bottom pressure gauge will read approximately
a) 22.5 psig b) 67.5 psig c) 45 psig
Ans =

d) none of the above

= 1.5 top pr = bottom pr = 67.5 psig

111)
Following four new seamless standard torispherical heads are available for use
under following design conditions. Choose the correct one.
Design pr = 235 psi, Head I.D = 72 and S = 20000 psi with no C.A
a) Design thk = 0.9882. provided thk after forming = 1.0
b) Design thk = 0.4886. provided thk after forming = 0.5
c) Design thk = 0.6184. provided thk after forming = 0.625
d) Design thk = 0.7496. provided thk after forming = 0.75
Ans - D
Thickness of new torispherical head is given by ASME formula, t = 0.885PL / SE 0.1
P
L= crown radius therefore L = diameter of head, E = 1 ( seamless )
= 0.885 x 235 x 72 / 20000 0.1 x 235 = 14974.2 / 19976.5 = 0.7496 mm
Provided thk of 0.75 is OK.
Correct ans d
112)
Head in Q62 ( torisph head A) is to be analysed according to API 510, after
placing the vessel in service for 10 years. For the purpose of API 510 analysis, value of
crown whose radius can be taken as:
a) 72
b) 60
c) 48
d) 54
Ans - Torisph head D = 72 For API 510 analysis crown radius = diameter = 72 =
Ans = A
113)
The crown portion for head A may be considered as the portion lying entirely
within a circle whose centre will be same as head centre and diameter will be
a) 68.5
b) 36.4
c) 57.6
d) 54.0
Ans
C

- Crown portion lies in circle of diameter equal to 0.8D = 0.8 x 72 = 57.6 Ans =

114)
The standard seamless , ASME F &D head (torispherical) is used for the following
conditions:
Material of construction = SA515 gr 60
Design pressure
=250 psig
Design temp
=580 deg F
Inside crown radius
=72 inches
Minimum available thk
=1.14 inches
Category B welds are spot radiographed. Corrosion allowance = 0.125 inches
Allowable stress at design temp = 16400 psig
Your assessment is
a) The head does not meet code requirements
b) The head meets the code requirements
c) Suitability would depend on decision of pressure vessel inspector
d) Data are not adequate
Ans Ref ASME VIII, UG 32 (e), t = 0.885 PL / SE 0.1P +C
E=1 (as head is seamless and category B welds are spot radiographed)
= ( 0.885 x 250 x 72.125 / 16400 x 1 0.1 x 250 ) + 0.125 = (15957.6 / 16375)+0.125
=0.974+ 0.125 = 1.0995
Available thickness = 1.14 = ok = Ans = B

115)
A circular flat head at the top of a vessel is measured at 1.25 inches thickness
during inspection. The flat head has a diameter of 14 inches. The vessels data is as
follows: MAWP is 500 psi C = 0.33 S=17,500 psi E=1.0. What is required thickness of
this part?
a) 1.35940 inch
b) 1.24563 inch
c) 0.958633 inch
d) 1.75200 inch
Ans - A ( sec VIII UG 34 )
P = 500 psi s=17500
E=1.0
C=0.33
d=14
From UG 34 t= d square root of CP/SE
T= 14 square root of 0.33 x 500 / 17500x1.0 = 14 square root of
165/17,500=1.3594056
116)
A flat unstayed circular head with a diameter of 14 is operating at 350 psi@500
deg F. The stress value is 17,500 psi with an efficiency of 1.0 and a C factor of 0.33. Can
this head be operated with the corroded thickness of 1, 25?
a)
b)
c)
d)

Yes. Can continue to operate

No. cannot be operated
C factor is incorrect for design
Circular heads cannot be use at 1.25

Ans -A
P = 300 psi s=17500
E=1.0
C=0.33
d=14
From UG 34 t= d square root of CP/SE
T= 14 square root of 0.33 x 300 / 17500x1.0 = 14 square root of 99/17,500=1.0529
117)
A flat circular head of 24 ID is attached by inside and outside fillet weld as
shown in UG 34 sketch f. the head is made from SA 516 gr 70 material and the MAWP
is 200 psig@500g. assuming the fillet weld comply with the code and a C factor of 0.20.
what is the minimum thickness required for this head?
Ans P = 200 psi s=17500
E=1.0
C=0.20
d=24
From UG 34 t= d square root of CP/SE
T= 24 square root of 0.20 x 200 / 17500x1.0 = 14 square root of 40/17,500=1.14
118)
A circular flat head is to be attached to a cylindrical shell as depicted in fig.UG34(f). The value of the thickness required for the shell has been computed to be 0.358
and the actual thickness is 0.500. The value of factor C in this calculation will be?
a) 0.46089
b) 0.20
c) 0.23628
d) 0.33
Ans - C
Fig UG 34 ( f)
C = 0.33 x m , m = Tr / Ts = 0.358 / 0.500 = 0.716
C = 0.33 x 0.716 = 0.23628
119)
A vessel has pitting in a small area; the area will fit in an 8 inch diameter circle
with its centre at the deepest pit. The shell course has a minimum thickness of 0.740.
the pits within the circle are more than 2 inches apart in any straight line with the
following depths;
#1.385#2.301#3.235#4.287, this area cannot be ignored because;
a) The pits are too much in number
b) The pits are too close together
c) The square inches of the pits exceed 7 square inches

d) One of the pits is two deep to allow averaging

Ans Pit depth of deepest pit = 0.385
0.740 / 2 = 0.370 < 0.385

Shell coarse minimum t = 0.740

120)
A cluster of scattered of pits was observed on exterior of vessel shell. The
description of pits is as follows: nominal vessel thickness = 5/8, CA = 1/8, total area
of pits = 5.8 sq.inch,
Pit of largest depth : 0.5 inch dia, 0.20 deep
All pits could be enclosed in a circle of 8 inch dia and maximum cumulative length is
1.75 inch within circle.
a) Pits may be ignored as per API510
b) Pits are unsafe as the total area of the pits is beyond limits
c) The cluster is unsafe as depth of deepest pit is beyond limits
d) The cluster is unsafe, they are exceeding cumulative length criteria
Ans

-A
Area within 8 diameter circle = 5.8 sq.in (ok)
Length along straight line in circle = 1.75 (ok)
Depth 5/8 = 1/8 0.25(ok)
Ans = A

121)
If in above Q69, depth of deepest pit was 0.15, cumulative length was 2.3 inch
( other data remaining same ) your analysis will be:
a) The cluster is still safe
b) Cluster is unsafe as depth is still beyond limit
c) Unsafe as cumulative length is beyond limit
d) 2 and 3
Ans

- Length 2.3 inch > 2 inch----------(not ok) = Ans = C

122)
If total area of cluster is 8 sq.in other data remain same as Q136, what is your
evaluation?
a) Cluster is unsafe due to increased cluster area
b) Cluster is unsafe due to pit depth still being unsafe
c) Cluster is unsafe due to 1 and 2
d) Cluster is safe
Ans

- Area 8 sq.in > 7 sq.inch-----------(not ok)=Ans = A

123)
A vessel shell has scattered corrosive pits caused by hydrochloric acid. The
greatest pit depth found excluding corrosion allowance in 0.333 inch deep in the shell.
Which has minimum required thickness of 0.521 inch? The sum of pits areas within an
8 inch diameter circle does not exceed 7 sq.inches. this pit must be repaired because
the limit of the pit depth in this situation is:
a) 0.1302
b) 0.2605
c) 0.3000
d) 0.3250
Ans - b ( API 510 7.4.3 (a))
shells t min = 0.521 pit depth = 0.333 the rule says that the pit may not exceed
the parts t min = 0.521 / = 0.2605 the pit must be repaired
124)
While inspecting a torispherical head it was discovered to have some severe
corrosion and must be evaluated for continued service. This corrosion occurs at a radius
33.256 from the exact centre of the head. The shell diameter of the vessel the head is
attached to is 7-0. To evaluate this head for continued service what is the greatest
distance from the centre that the corrosion can be and still be allowed to use the
formula for spherical shells given in section VIII Div.1 of the ASME code?
a) 67.2
b) 48.0
c) 33.6

d) 84.0
Ans - C
API510 5.7 (h) - diameter = 80% of shells diameter
= 0.80 x 84 ( 7 x 12 ) = 67.2
Greatest distance must be with a radius = 67.2 / 2 = 33.6 radius
125)
The minimum throat dimension for a fillet weld as shown fig UW-16(c) for a 1
thick nozzle joined to a 2 thick head is
a) 0.530
b) 0.750
c) 0.250
d) 1.00
Ans - C
Tc = not less than the smaller of or 0.7 t min
T min = = 0.7 x 750 = 0.525
Lesser of 0.250 or 0.525 = 0.250
126)
A cylindrical shell has been discovered to have uniform external corrosion. The
shells original thickness was 7/8 inch; it is presently 0.745 inch in thickness. The
original OD of the shell was 30 inches. The vessel operates at 650 deg F with a stress
allowable on the material of 15000 psi. 100 % RT was performed on the vessel. All joints
are types 1. What is the vessels present MAWP?
a) 760 psi
b) 772.13 psi
c) 766.88 psi
d) 382.10 psi
Ans - C ( UG-27 & UG-116)
from appendix 1 P=Set / Ro 0.4 t
wall loss= 0.875 0.745 = 0.130 outside
dia = 30.0
Ro=30.0/2 = 15.0-0.130 =14.87
corroded outside radius = 14.87
Calculate pressure allowed
t=0.745
S=1500 psi Ro=14.87 E=1.0
P=?
P=15000 x 1.0 x 0.745 / 14.87 (0.4 x 0.745) = 766.88 psi
127)
While inspecting a vessel you discovered the cylindrical shell has corroded
externally to a present thickness of 0.498 in thickness at its thinnest point. The
vessels corroded outside diameter is 95.82 and its material has an allowable stress of
13,800 psi at 750 deg F. the vessel shell is seamless and it has met the spot
radiography requirements listed in UW-12(d). What will be the MAWP of the vessel?
a) 71.87 psi
b) 143.5 psi
c) 144.0 psi
d) 83.45 psi
Ans - C
Appendix 3, section VIII P = S E t / Ro 0.4 t
T = 0.498 E=1.0 Ro = 95.82 / 2 = 47.91 S = 13,800 psi
P = 13,800 x 1.0 x 0.498 / 47.91 ( 0.4 x 498) = 6872.4 / 47.7108 = 144.04
128)

For a certain pressure vessel with spot radiography, and all welds type 1, OR ( Name
plate of a certain pressure vessel has name plate stamping as RT 3 for the
radiography, all Weds are type 1 welds. )
Vessel diameter
= 72 inch ID
MOC
=SA 515 gr 70
Design temp
= 600 deg F
Allowable stress at design temp = 20000 psi
If shell thk = 5/8 and CA = 1/8, the MAWP for the shell will be
a) 234 psi
b) 168 psi

c) 256 psi
d) None of the above
Ans - A
Ref UG 27 c (1) =MAWP = Set / R +0.6t ( E=0.85 from table UW-12)
And t=5/8-1/8 = after deducting corrosion allowance
MAWP=20000 x 0.85 x 0.5 / 36.125 + 0.6 x 0.5 Note R in corroded condition = 36.125
=233.36 psi = Ans = A
129)
A vessel was built to the 1980 edition of section VIII division 1 and put into
service in 1980. Shell material is SA516-70 with an internal diameter of 120 inches. All
welded seams were fully radiographed. The design pressure is 140 psig and design
temperature is 650 deg F. original shell thickness is 5/8 in with 1/8 in corrosion
allowance. In December 2002, the inspected wall thickness was 0.585 in. what is the
maximum allowable working pressure to which the vessel can be re-rated per figure 7.1
of API 510?
a) 193 psig
b) 165 psig
c) 207 psig
d) 171 psig
Ans - A ( ASME Section VIII UG 27 (c) (1)
from UG 27 P=SEt / R + 0.6 t i.e P= (20000)(1)(0.585)/(60+(0.6)(0.585)) = 193 psig
Assuming no corrosion allowance and a lower design temperature
130)
A shell course is being replaced with the new course being 60 inches in inside
diameter and 7/8 inches thick. The vessel coarse material is SA-515 gr 60 plate at a
design temperature of 750 deg F the stress allowed is 13000 psi. the vessel joints are
all type 2 and the vessel is stamped RT-3. What is the MAWP of this shell coarse?
a) 298.11 psi
b) 316.74 psi
c) 150.35 psi
d) 335.38 psi
Ans - A (UG-27 & UG-116)
from UG 27 P=SEt / R + 0.6 t
S=13000
E=0.80
t=0.875
R=60/2=30
P=13000 x 0.80 x0.875 / 30 + (0.6x0.875) = 9100 / 30.525 = 298.11 psi
131)
A sphere constructed of SA-516-70 has an ID of 80 feet. The joint efficiency of the
welded joints is 0.85. the operating temperature will not exceed 200 deg F. if the
minimum wall thickness is 2.5 inches. What is the maximum allowable working pressure
of the sphere if it was designed to the 1998 edition of the ASME BPV code section VIII
division 1, 2000 addenda?
a) 155 psig
b) 208 psig
c) 88 psig
d) 177 psig
Ans - A (ASME Section VIII UG 27 (d)
P = 2Set / R + 0.2 t i.e P= 2(17500)(0.85)(2.5)/(480+0.2(2.5))=155 psig
132)
The inside surfaces of a vessels shell have corroded down to a minimum
thickness of 0.369. The original thickness was 0.500. The vessels new and cold inside
diameter was 96 inches. What will be the internal dimension used to calculate the
vessels MAWP?
a) 96.262
b) 48.0
c) 96.0
d) 48.131
Ans - D
96/2 = 48 radius = 48 + ( 0.500 0.369) = 48.131
133)
A pressure vessel of overall height 80 has its part MAWP at various parts as
detailed in the sketch. What is the vessel MAWP ( hydrostatic head 1 = 0.433 psi)?
a) 419 psi
b) 420 psi
c) 430 psi

d) 426 psi
Ans

-A
For location at 4 feet from top = 426 0.433 x 4 = 424.265 psi
For location at 32 feet from top = 440 0.433 x 32 = 426.144 psi
For location at 54 feet from top = 442.5 0.433 x 54 = 419.118 psi
For location at 80 feet from top = 454.64 0.433 x 80 = 420 psi
MAWP is the lowest of above = 419.118 psi

134)
Vessel MAWP is 200 psi . what will be the total pressure at a point 20 feet from
top , if vessel is completely filled with liquid ( specific gravity = 1)
a) 220.00 psi
b) 208.66 psi
c) 204.33 psi
d) 191.34 psi
Ans

- for location 20 feet from top = 200 -0.433x20 = 208.66 psi = Ans = B

135)
A standard ellipsoidal head with a 1-1/2 flange is attached to the bottom of the
vertical vessel. The heads inside diameter is 56 inches. The vessel has a total elevation
of 100 feet. The elevation at this head to shell joint is 5 feet. What amount of
hydrostatic head must be considered for use in this heads required thickness
calculation?
a) 41.135 psi
b) 41.909 psi
c) 41 psi
d) 41.69 psi
Ans - D (41.135 + 0.559(hydro hd. In head depth))=41.69
depth of head = ID +flange
56/4 +1-1/2=14+1-1/2=15-1/2
hydrostatic pressure on head=95 feet + 1.2916
feet
=96.2916 x 0.433 = 41.69 psi
136)
For the given configuration total area to be compensated will be _________.data
with usual notation. D=100mm, t=12mm, tn=6mm, tr=10.5mm, trn=5mm
a) 920 mm sq
b) 870 mm sq
c) 1020 mm sq
d) 1050
mm sq
Ans- D ( ASME Sec VIII UG 37, fig UG 37.1 see A )
137)
Two nozzles are to be added to an existing pressure vessels shell which has a
thickness of (0.250). One nozzles finished opening is 2.5 in ID and the other is 2 in
OD. How close may these nozzless centres be placed in the vessel wall without
requiring reinforcement calculations?
a) 2.5 inches
b) 3 inches
c) 4.5 inches
d) 2 inches
Ans - C ( UG-42(a))
Minimum spacing for the centres of nozzles must be not less than the sum of their
diameters apart.
2.5 + 2.0 = 4.5 therefore nozzles must be 4.5 a part center to center
138)
An additional 4 inch nozzle was added to a pressure vessel and is similar to the
one in fig UW-16.1(i). The minimum thickness of the nozzle is 0.377 inch and the shell
minimum thickness is 0.750 inch. What is the decimal value of the minimum throat
required for each of two equal leg size fillet welds on this attachment?
a) 0.235
b) 0.267
c) 0.250
d) 0.750
Ans - C (UW-16)
UW-16 / fig UW-16.1(i). t min = 0.377

T1 + t2 >=1-1/4 t min = t1 + t2 >= 1.25 x 0.377 = 0.47125 ( total throat required)

T1 or t2 = 0.47125 / 2 = 0.2356 ( split between two equal sized fillet welds)
By the rule : t1 or t2 not less than the smaller of in or 0.707 x t min
0.707 x 0.377 = 0.2665 = 0.267
Ans : 0.250 no individual throat can fall below this value per this rule
The t1 + t2 >= rule is still satisfied ( not less than 0.47125) since 0.250 +0.250 =
0.500
139)
A pressure vessel with nominal diameter 1200 mm was inspected for ovality of
shell. An opening of 200 mm ID exists. The permissible ovality at the vessel cross
section which is 150 mm from centre of the opening is :
a) 12 mm
b) 16 mm
c) 14 mm
d) 18 mm
Ans - Ans =B = UG 80 (a)2 page 62
Cross section passes through within 1 ID of the opening measured from the centre of
the opening = 1% of nominal dia + 2 % of ID of opening = 12 mm + 4 mm = 16 mm
140)
A vessel shell is 65 I.D and is made from material with a stress value of 16200
psi. The vessel has category A type 1 butt welds and is stamped RT-2. If the thickness
has corroded down to 0.285 thick. What MAWP can be allowed on this vessel?
a) 400 psig
b) 190 psig
c) 250 psig
d) 139 psig
Ans

141)
During an alteration, a 16 circular man way is attached to an unstayed vessel
head by a method similar to that shown in fig UW 16.1(c) of Sec VIII. The head is SA516-60 (S=15,000 psi), 48 ID and 1-1/8 plate thickness. Working pressure is 500 psi.
The circular man way is SA-335-P12 (s=15,000 psi). wall thickness and does not
extends to the inside surface of the head. Calculate the size of reinforcement window.
Ans

142)
Using the above Q, if the required thickness tr of the head to resist the 500 psi
pressure is 7/8, what is the area A required for compensation?
a) 13 sq.in
Ans
143)

c) 15 sq.in

d) 16 sq.in

Using the above Q, the area of excess thickness in the head A1 is

a) 4 sq.in
Ans

b) 14 sq.in

b) 3.8 sq.in

c) 4.5 sq.in

d) 5.0 sq.in

144)
A 10 ID pressure vessel 2 thick made of SA-516-70 material, minimum
thickness is 1.390 was designed for 400 deg F. A 24 ID SA-516-70 nozzle thick is
to be installed during a shutdown. It will be installed in accordance with fig UW-16.1(a1). The attaching fillet welds will have legs. A reinforcing pad 6 diameter by 1
thickness will be added. What is the size of the window?
Ans

145)
What is the MAWP for a pressure vessel where shell measurement thickness is
3/8 thick, SA-516-70(normalised). Corrosion allowance is 1/16, ID is 42, and the
proposed MDMT is -20 deg F@MAWP? Category A joint is type 2 weld. Material stress
is 17,500 psi
Ans
146)
Ans

Are impact test and PWHT is required for the above conditions?
-

147)
A vessel shell is 66 ID and is made from material with a stress value of 16,200
psi. The vessel has category A type 1 butt welds and is stamped RT-2. If the thickness
has corroded down to 0.285thick, what MAWP can be allowed on this vessel?
a) 400 psig
Ans

b) 190 psig

c) 250 psig

d) 139 psig

148)
A standard seamless torispherical head has a skirt OD of 56and a corroded
thickness of 1.27. The material stress value is 16,100 psi and the head is attached to
the bottom of a vertical vessel that is 20 tall full of water. If the vessel is stamped RT-2,
what approximate MAWP would be allowed on this vessel?
a) 600 psig b) 402 psig c) 704 psig
Ans

d) 302 psig

149)
A forged cylindrical vessel having an outside diameter of 16 was measured to
have an actual shell thickness 0f 0.312. Both ends of the circular forged flat head are
inch. Using fig UG 34(b-1) what is the maximum allowable pressure for both the
heads? S=17,500 psi
a) 104 psi
Ans

b) 118 psi

c) 123 psi

d) 135 psi

150)
For a vertical with column internal dia =48 and height (T-T )=80ft, the vessel
MAWP is 60psi. the vessel part MAWP for bottom dished head (2:1 ellip type ) will be
a) 94.6 psi b) 82.8 psi c) 95.5 psi
Ans

-C

d)none of above

id = 48 = 48/12 = 4 ft & r = 2 ft
h = 82 ft.' head = 82 x 0.433 = 35.506 psi (BOK) & MAWP = 60 + 35.506 =

95.506 psi

151)
For a vertical with column internal dia =48 and height (T-T )=98 ft,
thehydrostatic head for bottom dished head (2:1 ellip type ) will be
b) 40.6 psi b) 42.4 psi c) 43.3 psi
Ans

-C

d)none of above

id = 48 = 48/12 = 4 ft & r = 2 ft
h = 100 ft.' head = 100 x 0.433 = 43.3 psi (BOK)

152)
A horizontal vessel is provided with 2:1 elliptical heads on both ends. The tan
tan shell length = 120 in. vessel dia = 40 in. What will be overall length of the vessel?
a) 150 inches
b) 140 inches

c) 160 inches
d) None of above
Ans

153)
A vessel is ultrasonically inspected when it is new and cold in June 1987 and
found to be 0.800 thick in the shell. The next inspection is done in June 1995 and the
vessel found to be 0.650 thick. If the minimum thickness by calculation is 0.510,
when (approximately) should the next internal or on stream inspection be scheduled
per API 510?
a) Feb 1999
b) Nov 2010
c) Jun 2005
d) Oct 2002
Ans

154)
A flat unstayed circular head with a diameter of 14 is operating at 350 psi @
500 deg F. the stress value is 17500 psi with an efficiency of 1.0 and a C factor od 0.33.
Can this head be operated with a corroded thickness of 1.25?
a) Yes. Can continue to operate
b) No cannot be operated
c) C factor is incorrect for design
d) Circular heads cannot be use at 1.25
Ans

155)
Shell dia = 50 the pitch for the above reading is 4 x 4. The required thickness
for the shell is 2 (circumferential stress governed). What is the minimum thickness to be
considered after averaging for calculation of MAWP?
a) 1.322
b) 1.392
c) 1.316
d) 1.426
Ans

156)
A 12 dia pipe, wall is to be installed as a nozzle on the shell. With corrosion
allowance of 1/16. What is the minimum thickness t allowed to be used for
calculating the MAWP of the pipe?
a) 0.500
Ans

b) 0.375

c) 0.437

d) 0.475

157)
The minimum thicknesses available for a seamless torispherical head for the
following data are given in options. Select suitable head thickness for a new
construction of vessel. P = 200 psi, S = 17,500 psi, ID = 96 inches no CA
a) 1 inch thk
thk
Ans

b) 1.25 inch thk

c) 0.75 inch thk

d)

1.125

inch

-A

158)
For a given configuration, correct minimum weld dimension (x) required as per
ASME Sec VIII div 1 shall be
a) 10mm
b) 12 mm
c) 14mm
d) none
Ans

- B ( ASME SEC VIII UW 16 fig (P))

159)
A pressure vessel (MOC 516 Gr 70) has external jacket spread over 72 inches
length of the shell ( jacket pressure =200 psi, jacket temp =350 deg F) the vessel OD =
36 inches, shell thickness = 0.5 inch, CA = nil . Decide which of the following are
applicable in the present case.
a) Shell thickness is ok
b) Shell thickness is not ok
c) Data not adequate
engineer
Ans

d) acceptance of shell thickness depends vessel

-A

160)
A 15 OD vessel 3/8 thick is attached to a forged circular flat head as shown in
fig UG 34(b-1) of Sec VIII. What is the minimum thickness required using the forged
material with a stress value of 11,500 psi for the 150 psi vessel?
a) 0.635
Ans

b) 0.529

c) 0.565

d) 0.420

161)
Nozzle reinforcement :Total area required to be compensated Ar = d x tr mm 2
Reinforcement limit (X) parallel to vessel wall X = 2d mm
Reinforcement limit(Y) normal to vessel wall Y = 2.5t or 2.5tn use smaller value
Extra area available in shell As = d(t-tr) mm2
Extra area available in Nozzle An= Y ( tn-trn)x2 mm2
Total area (Av) available inherant to the vessel Av= (As + An) mm2
Area ( Ap) to be provided by pad Ap = Ar Av mm2
If pad OD = 320 mm, pad thickness (tp) tp =
( pad OD pad ID )

Ap