j(u,\f

API 510 STUDY QUESTIONS

HOW TO USE THESE QUESTIONS

The following questions and answers on the API material are

for memorization. The API questions will be open book on the
first part of the exam and closed book during the second half.

Practice remembering the key words as opposed to learning the

entire answer.
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AP! 510 EIGHTH ED JUNE, 1997 ADDENDA ii 1 DEC. 1998, ii 2 DEC. 2000, # 3 Dec. 2001 and
Aug.2003

REVIEW QUESTIONS

Section I - General Application

I. The primary code for the inspection of pressure vessels after they enter service is?
( I .I)

• The AP! 510 Code

2. Relative to pressure vessels, when does API 510 apply?

CI . I)

• Only applicable to vessels after they have been placed in service.

3. WI1at does the API inspection code cover'?

(I.I)

• Maintenance inspection. repair. alteration, and re-rating procedures fm pressure vessels used by
petroleum and chemical process industries.

4. Wimt type of pressure vessel is exempt from periodic inspection requirements?

( 1.2.2)

• Pressure vessels on movable structures covered by other jurisdictional requirements.

• All classes listed for exemption from the illspection scope of the ASME Code Section VIII.
Division!.
• Pressure vessels that do not exceed specified volumes & pressures_

Section 3 - Definitions

5. What is an alteration?
(3.1)

• A physical change in any component or a re-rating which has design implications which affect
pressurc containing capability beyond the scope of existing data reports.

6, What thfee situations slmuld nOt be'considered alterations?

(3.1)

• Comparable or duplicate replacement

• Addition of reinforced nozzle less than or equal to existing reinforced nozzles
• Addition of nozzles not requiring reinforcement

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7. In what situation would the term "applicable requirements of ASME Code" be used?
(3.2)

• When the ASME Code cannot be followed because of its new construction orientation (new or
revised material specifications. inspection requirements, certain heat treatments and pressure tests,
and stamping and inspection requirements}. the engineer or inspector shall conform to this
inspection code rather than to the ASME Code. If an item is covered by requirements in the ASME
Code and this inspection code or if there is a conflict between the two codes, for vessels that have
been placed in service, the requirements of this inspection code shall take precedence over the
ASME Code. As an example of the intent of this inspection code, the phrase "applicable
requirements of the ASME Code" has been used in this inspection code instead of the phrase "in
accordance with the ASME Code."

S. What is an Authorized Inspector or Inspector?

(3 ..3)

• An employee of an Authorized Inspection Agency who is qualified and certified to perform,

inspection under this inspection code.

9. List 4 ex.amples of an Authorized Inspection Agency.

(3.4}

• Inspection organization of the jurisdiction in which the pressure vessel is used or,
• Inspection organization of insurance company which is licensed or registered to write and actually
writes pressure vessel insurance.
• An owner or user of pressure vessels who maintains an inspection organization for activities
relating only to his equipment and not for vessels intended for sale or resale.
• An independent organization or individual licensed or recognized by the jurisdiction in which the
pressure vessel is used and employed by or acting under the direction of the owner or user.

10 . Define "construction code".

(35)

• The code or standard to which a vessel was originally built, such as API/ASME, API, or State
Special/non-ASME.

11 . What does the term "inspection code" refer to in API 510?

( 3.<i)

• Shortened title for API 510 used in this publication.

12. Define Jurisdictions .

(3..3)

• A legally constituted government administration, which may adopt rules relating to pressure
vessels .

I 3 . Define Maximum Allowable Working Pressure (MAWP) as it relates to API 510 .

(3.9) and (Sect VIII UG-98)

• The maximum gage pressure permitted at the top of a pressure vessel in its operating position for a
, , designated temperature that is based on calculations using the minimum (or average pitted)
i thickness for all critical vessel elements, not including corrosion allowance or loading other than
pressu re.

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14 When determining Minimum Allowable Shell thickness. what must be considered when making
calculations?
(J . 10)

• Temperature. pressure, and all loading.

15. What type of inspection uses nondestructive examination procedures to establish the suitability of
pressure vessels for continued operation?
(3.11)

• On-stream Inspection

16 . What is the key element of an On-stream inspection?

(3 . I I}

• Because the vessel may be in operation while an on-stream inspections being carried out. the
vessel is not entered for internal inspection.

17. What is a Pressure Vessel'?

(3..12) and (Sect VIII U-1 (a))

• A container designed to withstand internal or external pressure, which can be imposed by an

external source, by the application of heat from a direct or indirect source, or by any combination
thereof. This definition includes unfired steam generators and other vapor generating vessels, which
use heat from the operation of a processing system or other indirect heat source. (Specific limits
and exemptions of equipment covered by this inspection code are given in Section I and Appendix
A.)

18. Who shall be a pressure vessel engineer?

(3. 13)

• Shall be one or more persons or organizations acceptable to the owner-user who are
knowledgeable and experienced in the engineering disciplines associated with evaluating
mechanical and material characteristics which affect the integrity and reliability of pressure
vessels. The pressure vessel engineer, by consulting with appropriate specialists, should be
regarded as a composite of all entities needed to properly assess the technical requirements.

19 . What is the definition of quality assurance as given in API 510?

(3."14)

• All planned, systematic, and preventative actions required to determine if materials, equipment, or
services will meet specified requirements so that equipment will perform satisfactorily in service .
The contents of a quality assurance inspection manual are outlined in 4.3.

20 What is a Repair?
(3. 15 )

• The work necessary to restore a vessel to a condition suitable for safe operations at the design
conditions. "lF" design temperature or pressure changes due to restoration, then re-rating
requirements shall also be satisfied.

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21. . List the four examples of a Repair Organization.

(3.16)

• The holder of a valid ASME Certificate of Authorization for the use or an appropriate ASME
Code symbol stamp

• An owner or user of pressure vessels who repairs his own equipment in accordance with the API
510 code.

• A contractor whose qualifications are acceptable to the owner or user of pressure vessels and
makes repairs in accordance with this inspection code.

• A repair concern that is authorized by the legal jurisdiction

22. What is re-rating?

(3 .17)

• A change in either the temperature ratings or the maximum allowable working pressure rating of a
vessel. or a change in both. The maximum allowable working t emperature and pressure of a
vessel may be increased or decreased because of a re-rating, and sometimes a re-rating requires a
combination of changes. De-rating below original design conditions is a permissible way to
provide for corrosion. When a re-rating is conducted in which the maximum allowable working
pressure or temperature is increased or the minimum temperature is decreased so that additional
mechanical tests are required, it shall be considered an alteration.

23. What is a permissible way to provide corrosion?

(,.3 17)

• De-rating below original design conditions.

14. What distinguishes an examiner from and inspector?

(3.1 8)

• A person who assists the API authorized pressure vessel inspector by performing specific NDE on
pressure vessels but does not evaluate the results of those examinations in accordance with API
510, unless specifically trained and authorized to do so by the owner or user. 'The examiner need
not be certified in accordance with API 510 or be an employee of the owner or user but shall be
trained a nd competent in the applicable procedures in which the examiner is involved.

25. Define Controlled-Deposition Welding

(3.1 9)

• Any welding technique used to obtain controlled grain refinement and tempering of the underlying
heat affected zone (HAZ) in the base metal. Various controlled-deposition techniques, such as
temper-bead (tempering of the layer below the current bead being. deposited) and half-bead
(requiring removal of one-half of the first layer), are included. Controlled-deposition welding
requires control of the entire welding procedure including the joint detail, preheating. and post
heating, welding technique, and welding parameters..

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Section 4 - Owner-User Inspection Organization

26. What are the education and experience requirements for becoming an inspector?
(4.2 go to Appendix B)

• Degree in engineering & I year experience in the design, construction. repair, operation. or
inspection of boilers or pressure vessels.
2-year certificate in engineering or technology from a technical college & 2 years of experience in
the design. construction. repair, operation, or inspection of boilers or pressure vessels.
• Equivalent of a high school education plus 3 years of experience. (and) .
• Five years experience in the inspection of boilers or pressure vessels.

17 . Who will be responsible to the owner-user when alterations. inspections, or repairs are performed?
(4 .4)

• The API authorized pressure vessel inspector.

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Section 5- Inspection Practices

28. Why are safety precautions important in pressure-vessel inspections?

(5J)

• Because of the limited access lo and the confined spaces of pressure vessels.

29. What guidelines must an inspector follow to enter a vessel that has been in service'?
(5 . 1)

• OSHA Regulations regarding Confined Space Entry.

30. Explain the safely precautions and procedures that should be taken when performing an internal
inspection.
(5 . 1)

• Isolate vessel from all sources of liquids. gas or vapors.

• Drain. purge. clean and ventilate.
• Gas test.
• Wear protective equipment as required.
• Warn all persons working around the vessel that inspection personnel are inside .
• Warn all inside the vessel of work that is done outside the vessel
• Check all tools and safety equipment needed before inspection .
31. When developing an inspection plan for vessels that operate at elevated temperatures (750 to I 000
°F) what things should be considered when assessing the remaining life of the vessel?
(5 ..2) .

• Creep deformation and stress rupture.

• Creep crack growth.
• Effect of hydrogen on creep.
• Interaction of creep and fatigue.
• Possible metallurgical effects, including a reduction in ductility.

32. Locations where metals of different thermal coefficients of expansion are welded together are
susceptible to what?
(5.2)
• Thermal Fatigue.

· 33. T h e actual or estimated levels of what four items must be considered in any evaluation of Creep?
(5 .2)

• Time
• Temperature
• Stress
• Material Creep Strength

34. At ambient temperatures, carbon. low alloy, and other ferritic steels may be susceptible 10 what?
(5 .2)

• Brittle Failure

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35. Define Temper Embrittlement

(52)

o A loss of ductility and notch toughness due to PWHT or high temperature service above 700
degrees F (370 degrees C)

36. What kind of steel is prone to Temper Embrittlement?

(5.2)

• Low alloy steels. especially 2 1/4-C1°l Mo

37. What three methods may be used to determine the probable rate of corrosion'?
(5 3)

• Calculate rate from data collected from same or similar service.

• Estimate rate from owner-user experience or from published data on comparable service,
• On-stream determination after I 000 hours of service using a suitable corrosion monitoring
device or NDE thickness measurements (UT), subsequent inspections shall he made until the
corrosion rate has been established.

38, How should the MAWP for the continued use of n pressure vessel be established?
(5 A)

• By using the Code to which the vessel was fabricated or by using the appropriate formulas and
requirements of the latest edition of the ASME. Code to establish the design temperature and
pressure,

39. In corrosive service, the wall thickness used in the MAWP calculations shall he the actual
thickness obtained by inspection minus ,
(5.4)
Twice the estimated corrosion loss before the date of the next inspection, except modified in section
6.4

40. What is the most important and the most universally accepted method of inspection?
(5 5)

• Careful visual examination

41, What determines the parts of a vessel that should be inspected?

(5.5)

The type of vessel and its operating conditions.

42.. For proper visual examination, what surface preparation is required?

(5.5)

• The type of surface preparation depends on individual circumstances, but surface preparation such
as wire brushing, blasting, chipping, grinding, or u combination of these may be required.

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43. If distortion is suspected during the inspection of a pressure vessel what is the proper course
of action?
(5 5)

• If any distortion of n vessel is suspected or observed the overall dimensions of the vessel shall be
checked to confirm whether or not the vessel is distorted and, if it is distorted, to determine the
extent and seriousness of the distortion. The parts of the vessel that should be inspected most
carefully depend on the type of vessel and its operating conditions

44. What type of examiners shall the when the owner/user requires inspection for detection of interior surface
breaking planar flaws?
(5.5)

• Industry-qualified UT Shear Wave examiners.

45. List the inspections, which include the features that are common to most vessels and that are most
important
(5.6)

• Examine the surfaces of shells and heads carefully for possible cracks, blisters, bulges, and other
signs of deterioration.
• Examine welded Joints and the adjacent heal-affected zones for service-induced cracks or other
defects.
• Examine the surfaces of all man ways. nozzles, and other openings for distortion, cracks, and other
defects,
46. Name two reasons why it is necessary for the API 510 inspector to examine flange faces.
(5 .6)

• To look for distortion

• To determine the condition of gasket-seating surfaces

47. Corrosion may cause what two forms of loss?

(5.7)

• Uniform loss - n general, relatively even wastage of a surface area

• Pitted appearance - an obvious, irregular surface wastage

48. Name three ways the minimum thickness of a pressure vessel can be determined
(5.7)

• Any suitable nondestructive examination

• Measurements taken through drilled lest holes
• Gauging from un-corroded surfaces in the vicinity of the corroded area.

49. For a corroded area of considerable size in which the circumferential stresses govern, the least
thickness along the most critical element of the urea may be averaged over a length not exceeding
what?
(5.7)

• For vessels with inside diameters less than or equal to 60 inches ( 150 centimeters), one half the
vessel diameter or 20 inches (50 centimeters, ). Whichever is less.
o For vessels with inside diameters greater than 60 inches, one third the vessel diameter or 40 inches
(100 centimeters), whichever is less.

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50. When can widely scattered pits be ignored?

(5.7)

• No pit depth is more than 1/2 the vessel wall thickness exclusive of corrosion allowance.
• Total area of pits does not exceed 7 sq. inches in any 8 inch diameter circle.
• Sum of pit dimensions along any straight line within the circle does not exceed 2 inches,

51. When should the design by analysis methods of Section VIII, Division 2, Appendix 4, of the
ASME Code Be used?
(5 7)
To determine if components with thinning walls, which are below the minimum required wall
thicknesses, are adequate for continued service.
• To evaluate blend ground areas where defects have been removed,

52. What do you use to determine if the thickness at the weld 01 remote from the weld governs the
allowable working pressure when the surface at t he weld has a Joint factor other than 1.0?
(5.7.g)

• For this calculation, the surface at u weld includes I inch {2.5 centimeters) on either side of the
weld, or twice the minimum thickness on either side of the weld, whichever is greater.

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53. Describe the governing thickness when measuring the corroded thickness of ellipsoidal and
torispherical heads.
(5.7.h)

• The thickness of the knuckle region with the head rating calculated by the appropriate head
formula,
The thickness of the central portion of the dished region, in which case the dished region may be
considered a spherical segment whose allowable pressure is calculated by the code formula for spherical
shells.

54. What is the spherical segment of both ellipsoidal and torispherical heads"?
(5.7.h)

• That area located entirely within a circle whose center coincides with the center of the head and
whose diameter is equal to 80% of the shell diameter,
55. On torispherical heads. what is used as the radius of the spherical segment?
(5 .7.h)

Radius of the dish.

56. The radius of the spherical segment of ellipsoidal heads shall be considered to be what?
(5.7,h)

The equivalent spherical radius K1D, where D is the shell diameter (equal t o the major axis) and
Ki is given in Table I.

57. When evaluating metal loss in excess of a vessel’s corrosion allowance what API document
should be consulted?
(5.8)

• AP! RP 579 Sections 4.5 and 6

Section 6 - Inspection and Testing of Pressure Vessels and Pressure-Relieving Devices

58. When is an internal field inspection of new vessels not required'?

(6 I)

When the manufactures' data report (U1) assuring that the vessels are satisfactory for their
intended service is available.

59. Name two factors to be considered when inspection intervals are being determined.
(6.1)

The risk associated with operational shutdown and start-up and the possibility of increased corrosion
due to exposure of vessel surfaces to air and moisture.

60 What are the essential elements of a risk based assessment inspection?

(6.2)

• The combination of likclihootl of fnilure nnd the consequences of fnilure.

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61. What other fnt:tors should be considered inn RBI program?

(62)

Approptiateness of the materials, vessel tlesign comlilions relative lo operating conditions,

nppropriateness of the design codes and standards utilized, effectiveness of corrosion monitming
prngrnms; and the quality of inspection/ quality assrn once and maintenance programs ..

62. What uction should he taken afler an effeclive RBI assessment has been finisl1ed?
(6.2)

• Choose the most appropriate inspection tools and methods based on the degradnlion expected,
Set the approptinte fieqt1ency for inlemai nnd cx.temal nnd OIHlre,1111 inspections_
Detem1ine if pressure testing will be required bused on damage or after repairs,
Decide on prevention and mitigatioll steps to reduce the likelihood of n vessel failure.

63 How oflen should each above ground vessel be given a visual external inspection'?
(6.3)

Each vessel aboveground slmll be given n visuul external inspection. p1efernbly while in operntion,
·ut leost every 5 yeurs or at the sume interval as the required internal or OJMUeom inspection,
whichever is less.

64. When making an external i11spectio111 what shall the inspection include?
(63)

• Condilion of the exterior insulation

Condition of the supports
• Allowance for expansion
• Generul alignment of the vessel on its supports

65.. Buried vessels shall be periodically monitored to delennine their external environmental
condition. What shall the inspection intervals he bused on?
(6,3)

• Cmrosion mte infonnation ohlaincd during maintenance on adjacent connecting piping of similar
material.
• Information from the intervaf examination of similarly buried corrosion test coupons of similar
material.
• 1nfonnation from representative pmtions of lhe actual vessel,
• Infonnntion from a vessel in similar circumslnnces.

66- What is the minimum interval for checking the insulating system or outer jackeling of vessels that
are known to have a renmining. life of over JO years or that are protected against external
corrosion?
(6.3)

• Every 5 yeurs and repaired as needed.

67. What h; the maximum period between internal or on-stream inspection·?

(64)

• The maximum period shall not exceed t.llle half the estimated remaining corrosion-rate life or 10
years. whichever is less. ·'

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68. ff the remaining safe opernting life of a vessel is less than 4 yems, what is inspection interval'?
(6.4)

• Ime1vnl nrny be the full remnining sare operating life tip to a maximum of 2 yems.

69. Under what conditions would a vessel with a corrosion rate less than 0.005 inch (0.125
millimeter) per ycnr and nn estimated remaining life greater than l0 years be exempt from an
internal inspection and inspected ex!ernnlly instead?
(6A)

When size, configuration, or lack of access makes vessel entry for internal inspection physically
impossible.
When lhe genernl corrosion rate of a vessel is known to be less limn 0,005 inch (0. 125 millimeter)
per year nnd the estimated ·rcmninlng life is greater than 10 years, and all of the following
conditions me met:

• The corrosive clmrncter of the contents. including, the effect of trace co1nponents1 has been
established by nl least 5 yenrs of the some or comparable service experience with the type of
contents being handled.
• No questionable condition is disclosed by the external inspection specified in 6.2.
• The operating tempcrnture of the steel vessel shell does not exceed the lower temperature limits
for the creep-111pture tnnge of the vessel moterinl.
The vessel is not considered to be subject to environmental cracking or hydrogen domoge from the
fluid being hundled. Alternntively1 a RBI assessment, us pennitted in can be performed to
detem1ine thut the risk associated environmental crocking or hydrogen damage is acceptably low
and that the effectiveness of external inspection techniques is adequate fm the domage mechanism.
This assessment should include a review of past conditions and likely future process condltions.

• The vessel is not ship-lined or plate-lined.

70. Write the fonnula to he used when determining the safe remaining life of a vessel.
(6A)

tactual -t required
Remuning. Life Yrs.------
Corrosion rate

• Where: tactual = the th\ckness, in inches millimeters), measured at the time of inspectlon for the.
limiting section used to determine the minimum allowable thickness. t minimum= the minimum
allowable thickness, in inches (millimeters), for the limiting section or zone.

71. There ore two kinds of coffosion rates to be considered when calculating the remaining life of a
vessel. What are these types?

• Short Term and Long Term rates.

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72, When conc..lucting a pressure test as part of o. perior.lic inspection, what shnll the shell temperature
be during the test'?
(6.5)

To minimize the risk of brittle fracture during the test. the metal temperalme should be maintained
at least 30 ° F(-1 °C) above the minimum design metal temperntnre for vessels that are more lhan
2 inches thick, or 10 ° F (-12 °C}above for vessels that have a thickness of 2 inches or less. The
test temperature need not exceed 120 °F{50 °C) unless the1e is info11rn11ion on the hrillle
characteristics of the vessel mntetial indicating that a lower test temperntme is acceptable or n
higher test tempernture is needed.

73. When should pneumatic testing be done and what are some of the considerntions to be taken into
accounrl
{6 5)

Pneumatic testing may be used when hydrostatic testing is impracticable because of temperature,
founclntion or process reasons, however, the potential personnel and prope1ty I isks should be
considered.

74, Should snfoty relief valves ever be removed from a vessel during pressure testing?
(65)

• Yes, If a pressure test is heing conducted in which the test pressure will exceed the set pressure of
the safety ,elief valve with the lowest setting.

75. When a pressure relief valve requires repair, who is allowed to make this repair?
(6.6)

• Testing and repairs shall be made by a repair organization experienced in valve mainten::mce. 111e
repair organization shall have a written quality control system with the minimum requirements as
listed in 4.5 of the API 51O code and mnintnin a training program to insure the qualifications of the
repair personnel,

76. How often shull a safety relief valve be tested'?

(6-6)

• The intervals between pressure relieving device testing or inspection should he determined by the
performal)ce of the devices in the particular sei-vice concerned. Test ot inspection i11tervals on
pressure-relieving devices in typical process services should not exceed 5 years, unless service
experience indicates that a longer interval is acceptable For clean (non-fouling), non-conosive
services, maximum intervals may be increased to JO years.

77. Pressure vessel owners and users are required lo maintain permanent and progressive records of
their pressure vessels. What things me included in these records?
(6.7)

• Construction and design infmmatfon

• Ope1ating and inspection history.
• Repair, alternlion, amJ re-rating infonnation.
• Fitness-for-service assessment documentation.

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Section 7- Repairs, Altcrntions, nnd Rc roting of Pressure Vessels

78. Who must npp1ove any repairs or 11!1eratio11s'?

17. I .I)

All repair and nltetnlion work must be nulhorized by the authorized pressure vessel inspector
before the work is started by a repair organization (see 3.13). Authorization for nltemtions to
p1essure vessels that comply with Section VIII, Divisions I and 2, of the ASME Code and for
repairs to pressme vessels that comply with Section VITI. Divisi □O 2, of the AS?vlE Code muy not
he given until a pressure vessel engineer experienced in pressure vessel design has been consulted
nboul the ulterntions and repairs ond has approved them. The authorized pressure vessel inspector
will designate the fabrication npp1uvnls that are required. The authorized pressure vessel inspeclor
mny give pri01 general authorization ror limited or routine repairs as long us the inspeclor is sure
that the repairs are the kind that will not require pressure lests.

79, Who shall approve nil specified repoir and al!erntion work?
(7. U)

• The API nulhorized p1essure vessel inspector. uner the wmk hns been proven to he satisfoctory
nnd :my rec1uired pressure test has been witnessed.

80, What must be removed from base material prior to welding?

(7.13)

Surface irregularities and conlmninntion.

81 . All repair nm.I alteration welding shall he in accordance with what code?
(72)

• ASME CCJde, except ns permiued in 7.2.11

&2. What must be done before Preheat or Controlled Deposition Welding is used in lieu of PWHT?
(7.2.3)

• Prior to using any alternative method a metallurgical review must be conducted to dete1rnine if Lhe
proposed altemntive is suitable for the application.

83. Nume the mnterinls allowed when using the alternative ptehealing method when notch toughness
testing is not required. · ·
(7.23.1)

• The materials shall be limited to P-Nos. P-No. I Group 1,2 nnd 3 and P-No. 3, Group I and 2
(excluding Mn-Mo steels in G1oup 2).

84. Name the materials ul!owetl fo1 use wilh !he Controlled-Deposition Welcling Method.
{723.2)

• The materials slrnll be limited to P-No. I. P-No_ 3 and P-No. 4.

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85. Can local post weld heat treatment (PWHT) be substituted for 360 degree banding?
(7.2,5)

• YES provided the following conditions are met:

• Application is reviewed and prncedure developed by engineer experienced in pressure vessel

design & PWHT requirements.
• ln evaluating the suitability of u procedure, all applicable factors (base metal thickness, material
properties, etc.) are considered_
Pteheat of JOO deg1ee or higher per WPS is maintained.
PWHT temperature is maintained for distance not less than 2 times base metal thickness meoslired
from weld. A minimum of 2 lhermocouples is used. Hent is applied to any nozzle or other
allachment in PWHT nrea.

86. What considerations must be given to the repair of stainless steel overlay and claddings'?
(7.2.6)

Consideration shall be given to factms which may augment the repair sequence such as stress
level. P nm11ber of base muletinl, service environment. possible previously dissolved hydrogen,
type of lining, detellorntion of base metal properties (by temper embrittlement of chromium
molybdenum alloys), minimum pressurization temperatures, and a need for future periodic
examination.

87. Per API 510, state the design 1equirements for.

Bult Joint:;, Replace111e111 Parts,
New Con11ectio11s, Fillet Weld Pmches,
Overlay Patches, Flush patches
(7.2.7)

• BUTT JOINTS· shall have complete penetration and fusion.

REPLACEMENT PARTS. shall be fobticated in accordance with tlie applicable requirements
of the appropriate code.
NEW CONNECTIONS . design, location, and method of attachment shall be in accordnnce with
the applicable requirements of the appropriate code,
• FILLET WELDED PATCHES - require spedul design cons iderntions 1 they are lcmporory
repairs_ Al:m it must be tn.1e that;

(a) 1e fillet-welded patches pr.ovide clesig1i safety equivalent to reinforced openings

designed according to the applicable section of the ASME Code.
{b) The tillet-welded patches are designed to absorb the membrane strain of the pm1s so thot
In nccordnucc with the rules of the applicahle section of the ASME Code, the following
result:

The allownble membrane stress is not exceeded in the vessel parts or the
pu1ches,
• The strnin in the patches does not result in fillet-weld stresses that exceed
allowuble stresses for sueh welds,

• OVERLAY PATCHES - shall have rounded corners,

FLUSH {insert) PATCHES shall hove rounded comers and be installed with full penetration butt
joints.

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88. Summarize lhe mle5 for the use of n foll encirclement lap hand on a pressure vessel.

(72.7)

• A full encirdement !up band repair muy he considered a long tenn 1epair if the design is upproved.
and documented by the pressure vessel engineer an<l the nutho1ized API pressure vessel inspector
and the following requirements are met:

The repnir is nol being made lo a crack in the vessel shell,

The band alone is designed to contain the full design pressure.
• All longitudinal semns in the repair band ore run penetration butt welds wilh the design joint
efficiency and inspection consistent with the npptopriate code.
• The circumferential fillet welds attaching the band to the vessel shell are designed to H-ansfer lhe
full longitudinal fond in the vessel shell. using a joint efficiency of O 45, without counting on the
integrity of the original shell mo.lei ial covered by the bim<l,
• Fatigue of the nltachment welds, such as fotigue resulting from differential expunsion of the band
telative to the vessel shell, should he considered if npplicuble.
The band material and weld metnl nre suituble for contact with the contained nuid at the design
conditions nnd an appropriate corrosion allowance is provided in the band,
• The degradation mechanism leading to the need for tepair shall be considered in determining the
need for any additional monitoring nnd future inspection of the repair. Non-penetrating nozzles
{including pipe caps altached as nozzles) may be used as long term repairs for other than crncks
when the design am.I method of attachment comply with the applicable requirements of the
npprop1fote code. The design and reinforcement of such nozzles shull consider the loss of the
origim1l shell material endosed by the nozzle. The nozzle material shall be suitable Fm canto.ct
with the contained fluid nt the design conditions und nn appropriate corrosion allowance shnlJ be
provided.

89.. Describe the material suitable for making repairs or nltewtions.

(7.28)

• Shall conform to the applicable section of the ASME Code, be of known weldable quality and be
compatihle with the original material. Carbon or nllow steel with a carbon content over 0.35
percent shnll not be welded.

90. When making u repoir or ulteration, what should the acceptance criteria include?
(7.2.9)

• NDE techniques that are in ucconJnnce with the applicable sections of the ASME Code or another
applicable vessel rating code.

91- Afler 1epairs or nltcrutions, is a pressure test required?

(7.2 10)

• Repairs pressure test only npplied if inspector believes one is necessary._

• Altcr-ntions pressure test nre normally required. Subject to the approval of the Jurisdiction
(where the jurisdiction's approval is require<l), appropriate nondestnictive exuminutions shall be
required where u pressure test is not performed Substituting nom.1estrnctive examination
procedures for u pressure test after an alteration may be done only after a pressure vessel engineer
experienced in pressure vessel design und the authorized pressure vessel inspector have heen
consulted,

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92. Write the API 510 Test pressure formula

7.210

Test Pressure= I 3 MA\VP X Stress nt Test Temp/St1ei::sm Design Temp

93. Lisl the minimum tensile strength requirements for filler metals used on vessels weld repairs nnd
the details of this method of repair.
(7 211)

• The filler metal used for weld repairs should have minimum specified tensile strength equal to or
greater than the minimum specified tensile streng_th of the base mefol. If a filler metal is used that
has a minimum specified tensile strength lower than the minimum specified tensile strength of the
hnse mctul, the compatibility of the filler metul chemistry with the base metal chemisuy shall be
considered regunJing weld ability and service degradation. In addition, the following shall be met:

• The repair thickness shall not he mme than 50 percent of the required hnse melnl thickness,
excluding corrosion ulfowance.

• The thickness of the repair weld shall he increased by n ratio of minimum specified tensile
slrength of the buse metal and minimum specified tensile of the filler metal used for the repair.

The increased tliickncss of the repair shall have rounded comc1s and shnll he blended into the base
inelul using il 3 to J taper.

• The repair shall be made with u minimum of two passes.

94. Lisi the requirements associated with re-rating a p1essure vessel.

(7.3)

• Cuk:ulations from either the manufacturer or an owncM1ser pressure vessel engineer (or his
designated representntive) experienced in pressure vessel design, fabrication, or inspection shull
justify re rating.
A re-rating slmll he established in acconJance with the requi1ements of the coostruclioo code to
which the pressure vessel was built or hy computations that are determined using the appropriate
fom1ulns in the latest edition of lhe ASME Code if ail of the essential details comply with the
applicable requirements of the code being used_ If the vessel was designed to an edition or
addendum of lh.e AS.ME Code earlier Umn the 1999 Addenda and wus nol designed to Code Case
2290 or 2278, it may be re-roted lo the ]ates[ edilion/uddendum of U1e ASME Code if permitted by
Figure 7-
• Current inspeclion records verify that !he pressure vessel is satisfactory for the proposed service
conditions and that the corrosion ullowance provided is appropriate. An increase in allowable
working pressure m·Jemperatme slw.lJ he hnsed on thickness dataoblained from a recent internal
or on-slream inspection.
The pressure vessel has at some time been pressuie tested in nccordnnce with the new service
conditions, or the vessel integrity is maintained hy special nondestructive evaluntion inspection
techniques in lieu of testing.
• The pressure vessel inspection ond re•rnting is nccept.ihle to the nulhorized pressure vessel
inspector.

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95 When is the re•rnling of a pressure vessel consi<lerec.l complete?

(13)

• When the API authorized p1essure vessel inspector oversees the nttachmenl of an additional
nameplale or additional stamping that carries the following infonnation:
Rernled by:. _
Maximum Allowable Wo1king Pressure psi
nt degrees F. Dute _

AP! RECOMMENDED PRACTICE

576 SECOND EDITION, DECEMBER
2000 REVIEW QUESTIONS

Section 1 - General
J. Wlmt is the genernl scope of APl RP576'?
(I)

• To describe inspection and repair practices for nutomntic pressure-relieving devices commonly
used in the oil and petrochemical indust1ics,

Section 2 - Rcrcrcnces

1" What document should be referenced to determine the nppropriote size for a p1essure relief
device?
(2)

• RP 520 Sizing, Selection, nnd Installation of Pressure-Relieving Devices in Refineries

Section 3 - Definitions

3. Desc1 ibe n pin-acluate<l device.

(3.13)

• A non-reclosing pressure relief device nctunted by static pressure nnd designed to function by
buckling or brcuking a pin, which holds a piston or plug in pli.ice.

4. W\ tlt is a huddling dHlmber?

(3.2 2)

e An annular pressure chamber located Uownstremn of the seat of u pressure relief valve fm· lhe
purpose of assisting the valve in lifting.

5. Describe "rated relieving cnpn city'1 •

(3.3 6)

• 111c relieving capacity used as lhe hasis for the application of u pressrne vessel relief device
<letetmincd using the upplicuhle code or regulation.

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Section 4 - Pressure-Relieving Devices

6. What is the function of pressme-relieving <levices?

£4 I)

• To protect refinery equipment and personnel hy automatically opening at predetennincd pressures.

7. Name common examples of pressure relieving devices.

{4)

• Direct spring loaded

Pilol PRY
• Rurture disks
Weight londed devices
P1essure/Vacuum vent v:ilves

8. Nnme the five types ofp1esst1re 1clief valves

(4.2. 4.3. 4.4, 4.6. 4.7)

• Safety vntve
• Relief valve
• Safety relief valve
• Bulnnced Safety ReliefV.nlve
• Pilot-opera.Led safety relief valve

9. Describe n sufety vulve.

(4.2J(Seclion Vil! UG-126 foot notes)

• Actuated by stntic pressure upstream of a valve.

• Spring fully exposed outside casing to protect from escaping steam,
• Normally not pressure tight on their downstream side.

JO. Safety valves should not be used in what situations?

(4.2.2)

• Corrosive [efinery services.

• Any hnck pressure service.
• Where discharge is• piped to remote localibns. ·
Where escape of lading fluid around blowing vulves is not desirnble
• In liquid service
• As pressure control or bypass valves-

I L Describe a relief valve.

(43J(Seclion Vlll UG-126 foot notes)

• Actuated by stalk pressure upshenm of a valve.

• Lifls in propmtion lo the increase in pressure.
• Usually 1eaches full lift at either 10% or 25% ove1pressure.

12_ Why tfo relief valves have dosed bonnets?

(43)

• To prevent the release of con osive, toxic, flammable or expensive fluids.

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13 Relief vulvcs should not be used in what situations?

(4.31)

In steam, ait. gas. or vapor se1vice

• In services piped to an enclosed header unless the effects of any constant or variable backpressure
have been accounted for.
• As pressure control orbypnss valves.

14. There are two types of safety reHef valves. What are these two types?
(4.5,4 6)

Con\'cntional & Bnlm1ccd

15. Describe a conventionul safety relief valve.

(4.5)
Opening p1·essu1e, closing pressure and relieving cnpocity nre affected by back pressure.
• Hns a closed bonnet
• The bonnet cavity is vented to the downstream side.

16. Where are conventional safety relief valves used?

(4.5 I)

• Refinery process industries that handle nammnble1 hot, or toxic materials.

17. May a conventional safety relief valve be used on boiler steam drums or super heaters?
(4.5 2)

• No

18. Describe a balanced safety relief valve.

(4.6)

• Balanced safety relief valves are direct spring loaded nnd incorporate n bellows or other means to
minimize the effects al backpressure

19. What nre the proper applicntions for these pressure balanced safety relief devices:
(4.61)

• Bulance sufety relief valves are nonnally used in applications with flammable, hot or toxic
materials. where high pressures are present at the discharge of the valve.

20. Whnt is n pilot-operated safety relief valve?

(4.7)(Section Vlll UG-126 foot notes)

A pressure-relief valve in which the major relieving device is combined with and is controlled by a
self-uctunled pressLue relief valve (called a pilot valve).

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21 What nre some applicutions of pilot-operated sufety relief valves?

(4.7.1)

Where a lnrge relief n,ea and/or a high pressure is required

• Where a low dirterential ex.ists between normal vesset p1essure nnd set pressure of valves
' I
• On large low-pressure storage tanks (See APl Std 620).
• Where ve1y sl101t blow <lown required.
• Where back pressure is very high nnd a balanced design is required.
• Where the process 1equires the sensing of pressure al one location and the relief of fluid at another.
• Where inlet and outlet frictional losses are high,
• Where in-situ, in-service. set p1esst1re verification is desired.

22. Name some: limihltions on the use of pilot-opernted sufe1y relief vnlves..
(4,7.2)

• Where fluids nre dirty.

• Thick or viscous tluid service.
• With vapors which polymerize in the valve.

23. Whal are lhe three basic categories of pressure ond/or vncuum vent volvcs?
(4,8)

• Weight-loaded pullet vent valve

• Pilot-operated vent vulve
• Spring and weight-loaded vent valve

24. What ore tlle applications and limitations of pressure and/or vacuum vent valves?
(4_8 I and .2

They rue designed to protect atmospheric and low pressure stornge tanks and are not generally
used in npplications requiring set pressures above 15 lbf/in 2

25, Desclibe the pmts of a Rupture Disk Device.

(4 9)

• The c?mbination of a rupture disk and mpture disk holder is known as a 1upture disk device.

26 Name the types of rupture disks.

(4.9)

• Conventional Rupture Disk.

• Scored Tension-Loaded Rupture Disk.
• Composite Rupture disk,
• Reverse-Acting Rupture Disk
• Gruphitc Rupture Disk.

27 What is one advanlnge of the grnphile tlisk over mclnl <lisks'?

(4 9 I 5)

High co11osion rc:-;istnnce

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28. Whal is usm:illy the service lifo of pre-bulgell metal mpture disks installed so thnt pressure nets
ngai11s1 lhe cuneave side?

One year - If not replnced periodically they cnn rnpture under normal p1essures without warning,

29_ Normully the operating pressure of a system protected by a pre-bulged rupture disk is from 65%
to 85% of the disk's predetennined bursting pressure. What determines this pressure range'l
(4.9.l)

• The exnc1 pe1centage depends on the disk's type.

30. Whnt precaution should be taken when a mptrne disk is used in combination with anothenelief
devh.:e and removctl for any rcnson am.I will he reuse(.n
(4.9J)

• They should he lmndled with care to avoid dnmuge which might cause premntme rnpture.

Section 5 - Causes of improper Performance

31 What is the hnsk cause of many the dirficullies encountered with pressure relief devices?
(5.1)

• Cormsion

32. What effect can the severe over sizing of a relief valve have'!
(52)

Damaged valve seats.

33- List the major causes of improper performance in pressure-relieving devices.

(5)

Corrosion
Damaged sealing surfaces
Failed springs
Improper seating ncljustments
Plugging and sticking
MisapplicaliOn of materials
Improper location, history, or identificalion
• Rough-handling
Improper differential between opernling and set pressures
Improper piping test procedures

34. To prevent le.ikage of the l.iding fluid, what must be nmintained in the flatness of sealing
surfaces o·n pressure relief valves?
(52)

An optical precision on the aider of 3 light beuds/hnnds_

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35. Whnt nre some reasons fordnmnged valve seats'?

t5 2)

Corrosion
Foreign particles getting into valve
Improper or JengU1y piping to the valve inlet or obstructions in the line_
Careless handling du1ing maintenance,
• Leakage past the senting surfaces of a valve after it has been fostalled.
Improper blow down ring settings.
• Severe over sizing.

36.. What almost always causes b1oken springs in pressure relief valves'?

• Corrosion (Note: two types - surface & st1ess)

37, Whut chemicnl frequently causes stress•cmrosion spring failure in petrochemical plants?
(5-3)

• Hyd1ogen sulfide (HlS)

38. What muy he done lo prevent spting failure due to cmrosion?

(5-3)

• Spring material which can resist the action of the cmrosive agent
• Spring isolnted by a bellows.
• Spring coated by a conting that can withstand the operating tempernture and environment.

39. Whal medium should be used to set the following pressure relief devices'?

• Safoty relief valve - air or other gos.

• Vapor service vnlvc - air or inert gas.
• Stenm service valves - stenm but air may be used if suitable corrections are upplied.
• Liquid service valves - water,

40. What is 1ecornmended for lubricating sliding ports nnd threods on valves to prevent fouling?
(55)

• Valve parts should be lubricated with a mnterial lhut is compatible wilh the service and
lemperature.

41, In genenil1 what should he considered in delennining the material to be used for pressure
relieving devices?
(5.6)

• Temperature
• Pressure
• Corrosion resistance 1-equirements
• Atmospheric conditions

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42. Why should 1elief valves be shipped in 011 upright posillon?

(5.8.1)

When relief valves nre lnid on their sides. the springs may not exert the same force all nround t11e
seating surface

43. What is one important aspect of the work done to PRDs in the maintenance shop1
(5.81)

• Rough hnndling should he avoided such ns the application of excessive hackpressure to bellows
type valves.

44, If RV inlets and outlets are not covered during shipment what provisions should be made?
(5.8 3)

• Provision should be ma<le for sm:h covering during all future sltipments

45, What risks are incurred when a hydrostatic test of disdwrge piping for a PRD is performed?
(5.10)

• The disk, spring and body area on the discharge side of valve can be fouled.
• The bellows of n bahmced relief valve can be damaged by e;{cessive back pressure.
• The dome area and/or the pilot assembly of a pilot-opernled pressure RV are fouled and damaged
by the hack flow of Lhe fluid.

Section 6- Inspection and Testing

46. Name two types of inspections

(6. I)

• Shop inspections/ overhauls ond visunl on-stream inspections..

47. When o relief valve is removed for inspection or overhauls what additionnl inspection should be
made'?
(62)
• Inlet and outlet piping should be inspected for internal d posils an,d records made of their
comlitions.

48. After a PRY hns been rcinstnlled whnt should be checked?

(6.2 I)

After reinstalling the related piping should he checked lo ensure that it is not imposing loads that
would cause problems with the ptessure relief vnlve's body such as distortion leading to in-service
leoknge.

49. A complete operating history of each pre:;sure relief valve should be nmintnined and should
include whnt?
(6.23)

• Infomrntion on upsets und theiI effects on the valve.

• The extent of any leakage that hus occurred in operation
• Any other evidence of malfunctioning,

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50. When o relief device is removed from a system that is in operalion 1 nnme a necessary step to
prevent an unexpected pressure release.
(624)

• The space between the relief valve anti the m.ljacent block valve should he vented to release oil
pressure.

51. What must be done to valves in hydrofluoric acid service as soon as they nre removed'?
(62 5

• They must be correctly neutrnlized immediately nfler removnL

52. Since inspection of RV piping cannot be done when removing the valve while the system is in
service what nlternutive inspection can he done to check for line any mnjor blockage or fouling·?
(6 2.6)

• Radiographic Inspection.

53. What can visual inspection of the piping nfter the 1emoval of a PRD indicate?
(62.6)

• The condition of the process piping whose in!erior is not visible.

54. Why should caution be used with the rigging to remove a large PRD for maintenance?
(6.2.7)

• Prevent auxiliary piping nnd pilot assemblies from being damaged.

55. Prim to performing thens received pop test on a PRD what should he inspected and checked?
(6.2.8)

• Check thal the seals are intact on the pressure set screw and the btow down ring screw cover.

56" When may the as received pop pressure test be waived by the owner/user?
(6.2 8)

• When the valve is extremely foufed and the test may damage the valve.

57. When unusu I corrosio 111 deposits, or conditions ore noted upon receipt of a PRD at the
shop what should he done?
(6.2.9)

• The inspector should pnrticipate in the shop inspection of the PRD

58. When is it not necessary to disassemble at PRD at the shop'!

(62 10)

• If tl1e valve has been tested at the opprop1inle API 510 inte1-val nnd the us received pop test shows
the vnlve to he opernting properly disassembly is not mandatory.

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59.. List at least four of the sleps in the inspection of a relief valve upon disassembly
(6.2.11)

• Measure euc.:h purt·s dimensions.

• Check components fm weur or corrosion.
• Seating surfaces should be checked for roughness 01·damage.
• Springs should be checked for cracking.

60. Duiing re-assembly of n pressure Ielief valve what should never he done?
(62.12)

• The nozzle and seating surfaces should never be oiled.

6L Aftet re-assembly of a relief device how should ony hlow down rings be set?
(6.2.13)

In accordance with lhe manufncture1's recommendations. \-

62. Why <lo some manufactures recommern.l at least three pop tests before releasing n relief device for
installation?
(62.14)

• It is believed that the first pop test helps to nlign all of U1e components and tlrnt the successive
tests verify the acltml sel pressure.

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63. Once the vuIve is sel lo pop at its CDTP (cold differential lest p1essu1e) it should he checked for_?
(6.2.15)

leakage n11U seul tightness by increasing the pressure on the test block to 90% of the CDTP,

64. When applying the hydrnulic test method lo ASlvlE Section VITT pressure relief valves while on
equipment, what precnutio11s should be tnken7
(6 2.17)

• The potential for failure of the rupture tlisk in disk/relief valve combinations.
Possible introduction of foreign material into the valve sent are from popping.
Possible release of p1ocess material to the atmosphere..

65 May 11 pilot upewtcd pressure relief valve he tested in place if no block vnlve exi. ts hene th it'?
(6.2.19)

• No, it may be inspected and repaired only while the vessel is out of service,

66. Whe,c is a weight landed pressme nnd/or a vacuum vent used?

(6.220)

• On pressme storage tanks.

67, What type or failure are pressure and/or vncuum vent valves prone to?
(6-2.20)

• Sticking,

68. 1s ii pe1missible to reinstall a nipture disk once it hns been unbolted and removed from its holder?
(6.221)

No, il may not be possible to get 11 tight seul and unreliable perfrmnancc is probable.

69. _ Whal are lhc objectives of a visual on stream inspection of relief devices?
(6.3)

• Make sure lhe correct device is installed, that the correct pressure can he cJetennined, that there are
not nny blinds or 1stalled, that the s nls are intact and thnt the valve is not leaking. Also
bellows if so equipped are connected and clear and vent piping is routed to a safe location. Any
upstrenm or downstream block valves are sealed or chained in the proper position. That disclmrge
piping is suppm1ed, valve body drains and vent stacks are open, any required lifting lever is
present and properly positioned. Any heat tracing or insulation required is in good condition nnd
operational and if a rnplure disk is installed it is properly oriented.

70. API 510 establishes lhe muximum interval between device inspections or tests or IO years. what else
should he considered when selling the frequency of inspection and testing?
(64)

• The perfm1mmce of the device in a particular service.

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71. How is the frequency of shop inspection or overhaul normally dete1mined'?

(64.1.1 l

By the operating experience in the valve's present service.. corrosion service would be more
frequent for example.

Section 7- Records and Reports

72. What is the piincipul objective in keeping records on pressure-relieving devices?

(7 I)

• To make available the information needed to ensure the perfo1mnnce of the devices meets the
requirements of their various installations.

73, Whal should the record for a pressure-reliving device include?

(7.2)

• Its specification data and a continuously accumulnting record of its tests and inspections results.

74, Which of lhe following per API 576 might be expected to initiate a work request on a PRD? The API
inspector or the Process Unit Operator?
(7.3)

• Process Unit Operator

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AP! RECOMMENDED PRACTICE 572

SECOND EDITION, FEBRUARY 2001
REVIEW QUEs·noNS

Section l • General

I. What are the muin points covered in API RP 572?

(I Il

• Descriplions of the various types of pressure vessels,

• Standards for constrnction.
• Rensons for inspection
• Causes of deterioration.
• Frequency & methods of inspection.
Methods of repair.
Prepamtion of records and reports.

Sections 3, 4, 5 and 6 contain duplicate Information to that found In the APT 510. You should still
read these sections however, nt lcnst once.

Section 7 • Reasons for Inspection

2. What are lhe basic reasons for inspection?

(7 I)

, I • To determine the physical condition of the vessel.

• Determine the type1 ,ate and causes of deterioration..

3_ List nl least four additional reasons for inspections.

(7.], 7.2)

• Safety maintained
• Periods of operation without shutdown extended - well planned maintennnce progrnm
• Rnte of d-e..t..e,-r-,i,o, ration often reduced
• Future repair nnd replacement requirements estimated
Section 8 - Couses of Deterioration

4- List the 4 genernl forms of deterioration.

(8.1)

• Electrochemical
Chemical
• Medmnicnl
• Comhinntion of all three

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5. List the 4 general classifications of things that cause dete1iorntion upon coming into contact with a
vessel surface.
(8. I)

Oiganic & inorganic compounds

• Conluminnted or fresh water
• Steam
• Atmosphere

6. Name 6 factors, which nccclewte the rnte of deterioration.

(8 I)

• Temperuture
• Stress
• Fnligue
• Impingement
• High velocity
• lnegularily of flow
7. Whot is the prime cause of deterioration in a p1essme vessel?
(8,2)

• Corrosion

&. What are the most common internal con-odents in refineries'}

(8.2)

• Sulfur
• Sult/Chlm"ide compounds

9- Define erosion.
(8,2 2)

• The removnl of surface material caused by numerous individual impacts of solid or liquid pnrticles
or cuvirution.

!0, Erosion is typically found where in a vessel?

(8.22)

e Downstream of control valves

• Downstream of orifices
• Downstream of pump discharges
• Al any point of flow {lireclion change, such as impingemenl baffles.

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11, Problems wilh environmental cracking huve heen experieneed of high hnrdness. areas of high
stress or both. Examples of this include

• Chloride stress conusion cracking of nustenitic stainless steels due to moisture tmder insulation.
Polythionic acid stress corrosion cracking (PSCC)
Caustic stress conosion also know as caustic embriltlement
Amine stress conosion crm.:king in non-stress relieved vessels.
• Cmbonate stress corrosion cracking in nlkuline systems.
• Wet hydrogen su!fide stress cracking, hyd1ogen im]uced erncking, nnd hydrogen blistering.

12. Con-osion heneoth refractory linings can cause what'?

(8 2.4)

• Bulging of lhe refractory

13. What does fntigue cracking In a vessel result from?

(8 25)

• Excessive cyclic stresses the are oflen below the yield slrenglh of the malerial such as;
• Pressure stresses
• Mechanical stresses
• Thermal stresses

14. Creep dnmuge muy be difficult to delect umil _

(8.2.6)

• Significant damage has occured

15- Whul factor increases susceptibility Lo high tempernture hydrogen nuack in a vessel's mnlerial'?
m2n . · ,
• Increosing cmhon content of the materials

l 6, In !he tlbsence of i·... I_'-· t , sulfide corrosion rates of ore relatively low at metal tempernlmes
below 11 '· 1 , ..
(8,2.3)

• Water
• 450 'F

17. When buried vessels are equipped with adequate c:llhodic protection when will excavation be
required for inspection?
(8.2.9)

• When evitlem.:e of coating.or wrapping dumage is revealed ·

18. What n1e the most important microorganisms thaldirectly influences the rnte of metallic
conosion?
(8.210)

• Sulfate reducing bactetin found in may soils

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19. What causes titnnium alloys to lose Uuctility?

(8 3.7)

• Absorption of hydrogen

20. Mnny of lhe problems that mny develop in pressure vessels are traceable to what?
(85)

Foully material or fabrication

21. Poor welding 1 improper heat treatment, fabrication with dimensions outside tolerances nilowed by
ASME Code, improper instnHotion of internal equipment. and assembly of flnnged or threaded
joints are examples of what r_roblem?
(85,1)

• Faulty fabrication

22. List several consequences of improper welding techniques.

(852)

• Incomplete penetration
• L1ck of fusion
• Cracking
• Undercutting
• Slag inclusion
• Porous welds
23. High residual stresses near welds affecting the physical properties and conosion resistance of the
metal is caused by what?
(8.5.3)

Improper heal trenlment

24, Dimensional intolerance can lend to what'!

(8.54)

• Stress concentrations nnd subsequenl failures.

25. What me the consequences of improper installation of internnl equipment?

(8.55)

• Inefficient operation
• Blockage of passages
• Displacement of internal equipment with pressuie surges

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26. Improper fitting or tightening of flanges or threoded joints mny lend to what?
(8.5 6)
leaks and possible failure

Section 9 - Frequenc}' and Tirne of Inspection

27. Whnl nre the impmtant factors when determining the frequency with which n pressure vessel
should be inspected'?

• The iate of deterioration

• The remaining cnnosion nllownncc

28. Whnl event con provide nnd oppo1tunity for an inspection?

(9.2)
• An unscheduled shuLdown

29. Whnt occasional check moy !acute the cause of functiomil deterioiation'!
(92)
• A check of a vessel·s operating record

30. Who! ore the most important isslleS when sChe<luling a unit for inspections'!
(9,:3)
• Safety and reliability

Section 10 Inspection t\'lcthods nnd Limitations

31. Before starting inspection of a pressure vessel, what are some basic things the inspector should
do?

• Detennine pressure und tempe1ature conditions um.ler which the vessel has operated since last
inspection
• Ascertain the clrnrncter of the vessel contents nnd the function the vessel serves in the process

32. Name at least 8 types of tools required by an inspector to inspect a pressure vesseL
( 10.2.2)

• Pmtnble lights
• Thin bluded knife
• Broad chisel or scrnper
• Mirrors
• Calipers
• Steel tape measme(50 feet)
• H1.1mmer
• Notebooks nnd pencils
33, \Vheie should the external inspectkm start?
{1032)

• External inspection should slurt with Judders stairways. platforms, or walkways connected to or
heming on the vessel. The condition or most ports can be determined by hu111me1ing

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43- ff settling of n vessel has occurred, what shoult.1 be checked for distmtion nnd crncks?
(103.8

• Nozzles,

tl4. What is the recommended resistance for grounding connections?

(1039)

• 5 ohms or less, not to exceed 25 ohms

45. Unchecked vibrntions on nuxilinry equipment such ns gnuge connectors can en.use what type of
failure?
(103 10)

• Fatigue fnilure

46. What type of inspection is usually sufficient for protective coatings and insulation?
(10 3.1I)

• Visual
47. At what operating. tempcratme does CUl become a concern on externally insulated vessels subject
to moisture ingre::;s7
(103.11)

• Between 25 to 250 ° F

48. What are the nommlly required measurements on external metal surfaces of a vessel?
(10 3.12)

• Under noimal conditionsf at least one measurement in each shell ring and one on each head. If no
history exists for a vessel, then get a rending in ench qmidrnnt of each shell ring,

49, Whal types of conosion me found on external surfaces of vessel?

(10.3.13)

• Atmospheric
• C ustic Embrittlement
• Hydrogen blistering
• Soil corrosion

50. Vessels containing acidic corrotlent.s nre subject to hydrogen bliste1 ing. Where is this normally
found in the vessel'?
(103.13)

• Those meas below the liqt1id level in vessels contnining acidic corrodcnts are mme likely thon
othe, areas to be suhjecl to hydrogen blistering. Blistern are normally on the inside, but can occur
on the outside smface t\S well,

51 Whal should a vessel be checked for if a caustic is stored in it'!

(103.13)

0 If u caustic matesial is stored or used in u vessel, the vessel should be checked lbr caustic
embrittlement.

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52. Evillence of white salts seeping through cracks will indicate whot type of materfal?
(I0 ..JJ.J)

• Caustic material

51 Unless readily visible, lenks are best found by what means?

(I0.J.I3)

• Pressure or Vacuum testing

54. Describe how you would determine the extent of bulging or bm:kling on a vessel in service,
(10,3.13)

By measuring the ch?nges in circmnferem:es or hy muking profiles of the vessel wall. Profiles me
mude by taking measurements from a line pamlleJ to the vessel wall. A surve yo1 s transit or a
1

180 degree oplicul plummet mny ulso he used.

55. The degree of surface preparation needed for internal inspection will vnry with several factors.
Foremost among these ore:
( 10.4.1)
• Type of deterioration expected
Location or uny lleteriorntion

56 Clacks in vessels are most likely to occur where'?

(IOAJ)

• ln places where there me sharp clmnges in shape or size or near welded scams, especially if a high
stress is applied.

57. What may preliminary inspections teveal?

(10.4 3)

• Unsafe condilions, such as those due to loose internals that may fall or due to bad{y corroded or
hroken internal ludden; or platforms.

58. A detaifed inspection should sturt nl one end of' the vessel and work towa£d the other end and
include what?
(10.4.4)

• A systematic procedure lo avoid overlooking obscure bul imporlant items.

59. Whal should all parts of a vessel be inspected for?

(10.4.4)

• Corrnsion
Erosion
• Hydrogen blistering
• Cracking
luminntions

60. Some times the depth of u pit cun he estimated by using what simple method'?
(10.44) ,

• EXtending the lead of a meclrnnit:al pencil

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61. . What types of me!hods are used for detennining the extenl of cracks?
(10 4 4)

• Dye penetmnt
• Magnetic-particle (wet or dry)
• Ultrnsonic shenr-wnve

62, Explain the difference in appearance between erosion and corrosion.

(10,4 4)

• Erosion is chnracterized hy n smooth, bright uppeunmce: marked by the absence of the erosion
product; nnd metal loss, is usually confined to a clenrly marked local area.

• Corroded ureas are not often smooth or bright

63. Shells and heads of vessels should be inspected for deformntion. Which is more likely to suffer
1o \I i defomrntion?
)BAA,'

• The sheU of a vessel

64. How do you check for (a) small distortions, (b) bulging or buckling (c) out-of-roundness or
bulging?

• Small distortions - by placing a strnight edge againsl a vessel.

• Bulging/buckling - measuring the changes in circumference or by profile (measuring ft0m a line
strung parallel to the vessel)..
• Out-of round/bulge by measuring the minimum and mnxhmnn internal deviation at the cross
4

sectional area and compnring the two.

65. Whut is the best method of locuting suspected deformations?

( I 0.4.4)

• Dilecl n flashlight beam parallel to the surface to check for shadows in depressions ond on the
non-light sides of internol bulges.

66. Whal is the most sensitive method of locating surface cracking?

(10.44)

• Fluorescent Magnetic Pmticle Method.

67- What is the difference between cracks and laminations?

(104.4)

• Laminations nm at a slant to the plate surface,

• Crncks nm ut right angles to the su1foce.

68, Name three importunt focto1s in the inspection of metallic linings.

fI 0.4.5)

• Thul there is no corrosion.

• Timi the linings are propedy installed.
a That no holes or crncks exist.

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69. Explain how the Corrosive Tab Metlmd is used to determine the metal loss on vessel linings.
I 1045)

Smull I hy 2 inch tabs of lining that fonn a right angle are welded onto the lining with one leg
e>-.tentled into the vessel. During inspections the thickness of lhe protrnding leg is measured, nnd,
since both sides of the leg are exposed to corrosive nction, the loss in thickness would be twice
that of the lining.

70 What is the principle method used to inspect nonmetallic linings like glass. plastic, rubber.
concrete, and cnrbon block 01 brkk-
(10 4,6)

For the most part oil of the above will be visually inspected for discontinuities or physicnl damage.

Spec-inc:
• For paint, gloss. plastic, & mbber lining the spnrk tcs.tcr method is used to locate holidays. For
concrete, blick, tile, or ref1actory lining the hnmmcr testing melhod is used to locate lack of
bond,

71. Nnme the factors to consider when selecting tools for thickness measu1emenls
(I 0.5)

• Accessibility from hoth sides.

• Desire for NDE methods.
• Accuracy desired.
Time available_
• Economy

72 What is the primary means ofobinining thickness measurements?

(105)

Ultrusonic instruments.

71 To analyze defects in welded seams that are not visible on the surface of the metal, whul two
methods nre used'!
( 106)

Rod iogruphy.
Shear-wave Ultrasonic.

74 How does the Hnm01cr Test function in supplementing visual examination of o vessel for the
inspecto1·?
(IO 8 )J

•
11
Thin 11- Locate thin sections in vessel walls. heads. and nttochments.
· •
11
Tightncss"- Check for tightness of rivets, bolts, brackets.
"Cracks 0111.l Lnck of Bond" Check for cracks in metallic linings nml lack of bond in concrete
linings.
o "Scale 11- Remove scale nccumulutions for spot inspections.

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1 is use of the Hammer Test not recommended?

1 vessels are under pressure,

iping upstream from a catalyst hecL

. is pressure testing'?

1g u vessel with liquid or gt.1s nnd building up ,m internal pressure to a desired level

ih is the preferred melhotl, pressure or vncuum testing, and why?

:ure testing. Leaks from an internal pressure source are m01e easily located.. With vacuum
1g you will know if there me leaks. but the location is not evident.

l should an inspector ex.amine before applying test pressure to the shell side of an exchanger?

hould inspect the tube walls to he sure there is sufficient wall thickness to withstand external
iUfC,

1 exchanger where the cooling water is the lower pressure stream and a hydrocmbon is lhe

er pressure stream, whal is a possible way to detect a leak?

1y be possible to assess the hydrocarbon content upstream and downstream of the suspect
anger.

1e the two most limits of corrosion 01 othe1·deterioration that must be known by inspection.

retiring thickness of lhe part considered.

rnte of detcriorntion,
'n vessels have excess thickness above that required.for pressure. When taking redit for this
:ss thick11ess what must nlways he considered'?·

omc cases the excess thickness of the shell or hend plates was used by the designer to
1pensate for nozzle openings.

Jre <letermining the limiling or retiring thicknesses of parts of any pressure vessel, what must
'OWn'?

•nd edition of llmt Code it is to lie rated under.

·., regulations regarding limits am! allowable ,epairs.

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Section 11 • Methods of Repnir

83. When is it n::qui1cd that n r-cpnir concern making welded repairs lo a vessel have a National Bomd
R stump?
III)

When the Jurisdiction dictates thal the these repairs me to made by only R slnmp holders

84. When is a pressure test of a vessel normally a requirement?

(11)

• After an ulterution

Section 12 - Records nnd Reports

85, A complete record file should contain what three types or informntion?
(12.1)

• Bnsic data - manufacturer's diawings, data reports and specifications, design information, Jesuits
of any material tests.
• Flcld notes - notes amJ mensurements recorded on sile including record of condition of all parts
inspected nml repairs required.
• CQntlnuous file - all information on U1e vessel's opetnting history, previous inspections, corrosion
rnte Lnbles, records of repairs und replacements.

86. When mnking reports recommending repairs, who should receive these reports?
( 12.2)

• All management groups. This would normally include engineefing, opemtion, and maintcnnnce
depaitments. Reports should include the location, extent, and reasons for recommended tepair.

Appendix A • Exchnngcrs

87. Why should bundles he checked when they ore first pulled from the shells1
(A.91)

• The color, type, amount, and locution of scales and deposits ofteit helf) to pinpoint conosion·
problems_

88. A distinctive Prussian blue on bundle tubes indicates the presence ofwlinl'?
(A.9 2)

• Ferriferrocyanide

89. Coils in open corn.lern;er bnxes and double-pipe exchanger shells should be inspected according to
what APT Reeornmemled Prnctice?
(A. 10)

•
RP574 \

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CHAPTER II
CONDITIONS CAUSING DETERIORATION OR FAILURES
SECOND EDITION, 1973
201 General

I. What are the modes or failure that can he found in 1efinery equipment?
(20L2)

• Fntigue Fullurcs - caused by stress reversals. (In machinery these crncks slart at the surface and
progress with each stress reversal.)
Distortion Fnilurc - occurs when equipment is sultjected lo temperatures above design
temperntme. (Al high temperatures lhe melal becomes wenke, nnd distortion occurs which may
resull in failure.)
• Brittle Fracture - cnrbon steels are susceptible to brillle fracture at ambient temperatures and
below. {A m11nhe1· of tank failures have hecn attrilmted to the brittle condition of steel nt low
tempera.lures, combined with high loads that have heen imposed by thermal stress set up rapid
lempernture changes.)
• Excessive l'\'Ictnl Loss - may result in failme if remaining walJ thickness gets below safety valve
seltings. TI1is is u rare occmrence.
• Wrong Mnterinl or Wrong Goskcls - muy lend to failui e.

202 Corrosion

2. Crnrosion problems in refining operntions c,m he divided into three major groups, Whut ure these
groups?
(202 I)

• Corrosion from components present in crude oil.

• Corrosion from chemical use'd in refine1y processes.
• Environmental corrosion.

3. Name the conosion compounds found in crude oil.

(20Z.01)

• Hydrogen Chloride and organic/inorganic chloride..

• Hydrogen sulfide, me1capta11s1 & organic sulfur compounds,
• Carhon dioxide.
• Dissolved oxygen and water.
•· Organic acids.
• Nitr<?gen· compounds.

4. Whut is hydrogen chloride? When does it become a cmrosion problem in process streams?
(202.022)

• A d1y hydrochloric acid (normully not connsive in process streams), It becomes corrosive when
water is availnhfe to form hydrochloric ucid.

5. Whal do all ct ude oils contain'?

I (202.022)

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6. Whal is the mofit active of the sulfur compounds in causing corrosion in refinery equipment?
(202.023)

• Hyd,ogen Sulfide

7. At whal temperature range does accelerated hydrogen sulfide conusion occur in refinery equipment?
(202..023)
'
• Between 450 anh 900 'F
8. What makes carbon dioxide conosive'l
(202.024)

• When ii is combined with wntcr it hecomes carbonic ncicl.

9, Where is co1rosion by carbon dioxide found to he most severe'? .

(202.024)

• In hydrogen plants.

10. Dissolved oxygen and water is a corrosion problem in what equipment?

(202.025)

• Stornge tanks.

11. When are organic acids very corrosive?

(202 026)

• At their boiling temperatures, The most severe form of corrosion occurs upon condensation.

l 2. What two forms of c01roclents are formed when nitrogen is cracked in a cracking or catalytic cracking
unit?
(202.027)]

• Ammonin & Cynuidc

13. What is phenol and what is ii used

for? (202.033)

• Cmbolic ndd - Used in refinery operations in the lnunufucture oflubticnting oils and aromnlics.

14 What is cnustic und what is it usetl for in refinery operntions?

(202.035)

• Sotlium Hydroxide - Used for the neutrnlizntion of ncid components ontl for grease mnnufncture.

15. When nmmonin is permiued to contact copper base alloys in pH rnn_ges of 8.0 and above, severe
corrosion in three form of genernl metul loss and sttess corrosion ctiiCking will occur. How may thiS attack
he iuentified'l
(202.037) '

o By the nppei\rnnce of a blue salt deposit on the metal's surfoce. .,,...

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16. Whal me the primary uses of ammonia in the refining industry?

(202,037)

• As a rehigenmt
• For neullnlizution of acidic components in overhead streums, from pipe stills, and cntnlytic
cincking units.

17 What muterials is ammonia harmful to?

(202037)

• Copper b,ase alloys.

18. WhnL is chlorine used for in refinery operntions anti when does it become very coTT"osive'!
(202,038)

• Used for treating. cooling water and for the manufacture of sodium hypochloritc for treating oils.
It becomes ve1y corrosive in contact with small amounts of moisture

19. Aluminum Chloride What is it used for? What does it form in the presence of water'? How does it
affect cnrhon steel and stainless steels?
(102.039)

• Used as a catalyst in lsomerization units, .It forms hydrochloric acid in the presence of water.
Hydrochloric acid causes severe pitting conosion in cm bon steel and intergmmdar and stress
conosion cracking in stainless

20, What is the tenn applied to atmospheric corrosion1

(202,041)

• Galvanic_

21. What is needed to prevent atmospheric corrosion?

(202,041)

• Eliminate water from the surface of the metal by means of a protective bilffier or coating.

22. At what temperalure does hidden corrosion take place under insulation and fireproofing if moisture
penetrates through cracks in the insulnlion'l
(202,042)

• In vessels nnd piping operating below approximately 250 °F.

23. When does oxygen become destructive'?

(202052)

• At high temperatures oxygen 1eucls with steel lo cause scaling {iron oxide).

24. Why may steam nt high temperatures cause scaling'?

(202 051)

• Because the s1eam may be decomposed to hydiagen und oxygen, and the free oxygen may cause
severe scaling.

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25. Vanadium oxide corrosion does nol tnke pince below what temperature?
(202.054)

1.I00"F

26. The extent conosive attack by hot sulfur compounds (sulfur dioxide. hydrogen sulfide) depends on
what three things'?
(202 055)

Concentration, tempernture. and oxidizing power of the environment.

27. Al whnl tempernture does all gray cnst iron begin to detcriorale. resulting in extreme brittleness, loss of
strength, scaling, und g1owth?
{202.056)

• 800 "F

28. Gmwth of cast iron results from what two thin,gs?

(202056)

• Grnphitizntion & infiltration of corrosive gases into the structure.

29. What is grnphitic corrosion?

(202063)

• Low tempernture corrosion of grny cast irons in which metallic iron is converted into corrosion
products 1 leaving the graphite intact.

30. In whnt material do you find grophitic corrosion nnd nt wlml temperatrne does it occut?
(202.063)

• In ens! iron nt tempernlures below the dew point of water.

3 L How cnn you recognize graphllic corrosion?

(202 063)

• By the soft porous structure that remains in the urcns where it ocsms.
32 What materials is mercury harmful to?
(202064)

• Mone! and copper based alloys (stress corrosion crm::king)

• Aluminum alloys.

33. Define Stress Corrosion Cracking.

(202064)

• The spontaneous failure of metals by c1ncking unde1· the combined nction of co1rosion nm.I tensile
stress,

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34. What is dczincificntion'J

(202.066)

• A type of con-osion tlml can occur in copper- zinc alloys {brasses) containing less than 85%
copper and used in water setvice.

35. What are three types of dezincificntion?

(202.066)

• Plug - occurs in localized nreas.

• Lnycr - covers lorge areas.
• lntcrcrystnlline - occurs along groiil houndmies.

36. What are Inhibited

bmsses·? (202 066)

• Brnsses which have been nlloyed with arsenic, antimony, or phosphorus to inhihit dezincification.

37. What is galvanic corrosion?

(202.067)

• An elecLrochemical type corrosion tlmt occurs when two different metals are electrically
connectedt either by direct contact or by an electrical conductor, nnd ore in cOntact with an
clectricol solution called an "electrolyte".

38, What is contact corrosion (crevice corrosion)'?

(202.068)

• A type of corrosion thol occurs at the point of contact or in a crevice between a metal nod
nonmetal or· between two pieces of metal in the presence of a corrodent.

39- What is biological corrosion?

(202.069)

• Corrosion influenced by primitive organisms.

40. What me lhe mos! important microorganisms that directly influence the rntc of metallic corrosion'?
(202,069)

• Sulfate reducing bacteria found in many soils.

203 Erosion

41- Erosion is frequently a problem in equipment utilizing the fluidized solids principle. What is this
principle?
(203 02)

• If a gas stream of sufficient velocity is passed through a nw.s.'i of finely divided solids. such as a
pow<ler, the moss or portlcles will behove very mw:h like u !rue liquid.

42. Wllut method ofdeterio1ulion does cavitation induce?

(203.022)

• Erosion. Cavitntions erosion is ussocinled wilh the fonnrition and collnpse of cavities in a liquid
nl the metal to liquid interface.
I
_I
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204 - Effects of High Tempernlurcs

43. Define creep

(204012)

• The flow or plastic deformation of metals held for long periods of lime ul stress lower than the
normal yield suength

44_ A stress - rupture is wlrnl type of failure·?

(204013)

• A hrittle type failure - stress rnpture relates the till1e to foilme with temperature and stress,

/ 45. When austenilic slainless steels nre henlet.1 or cooled in lhe tempe1ature nmge of 750 to 1,650 °F. what
does lhis muke the material susceptible to?
1204022)

• Intergrnnufor corrosion
11
46. When ferritic steels are heated above a certain lempernture (above I. I 00 F for- mild steel). how does
this affect the material?
(204.022)

• Leads to general lowering of 1e tensile strength.

47. What is incipient melting (burning)?

(204.022)

• When ffnitic steels are heated above approximately 2,600 °F, melting and oxidation will begin at
the grain boundnries. The steel is called "burned" and will be very weak and brittle upon cooling,

48. What is Grnphitizntion·/

(204.022)

• A sltuctural change in certain feJTitic steels that have operated for u long period of time between
825 nnd 1.400 °F_ Cnrbide is uristable in that temperature rnnge and may decompose inlo iron
(ferrite) and grnphite (carbon).

;9. What are the two gener31 types of Graphitization?

(204.022)

• Random Grnphitization - graphite distdbuled uniformly throughout the sleel.

• Localized Grnphitizution - graphite highly concentrated in local regions.

50. What is Scnsitlznlion'? Whal happens to sensitized steel when exposed to conodents?
(204.022)

• When Austenitic stainless sleefs nre exposed to temperatures of750 lo 1650 °F, precipitation of
complex chromium carbides at the grain boundaries takes pince. When the. sensitized steel is
exposed to corrodents, intergnmular corrosion takes pince.

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51. Whnt is dccarburizotion:l

(204034)

• The loss of cai hon from the surface of a ferrous alloy as a result of heuting in a medium that
reacts with cnrbon. This results in lower tensile strenglh. hardness . nnd fatigue strength, It can only
be found by metallurgicul examination.

52. At what temperature does hydrogen haven very destrnctive effect on steels?
(204 035)

• Above 450 'F

53, What c:mve shows the different steel/temperature limits for hydrogen service?
(204.035)

• Nelson Chnrt

205 Subnormal nnd Ambient Temperature Effccls

54. Define notch toughness (a property of metals).

(205.01)

• The amount energy necessary to cause fracture in the presence of a shnrp notch or stress
concentrator.

55. Brittle fracture can be recognized by several churacleristics. Whal are these chnracteristics'l.
(205.01)

o Cracks propagate at high speed.

• There may he a loud report or shmp rending sound.
• There is nlmost n complete luck of ductility.
• The frnctured smface has a brittle or faceted surface,

206 • Excessive Pressure

56, What is excessive pressure?

(206.01)

• 1l10 e in excess of the MAWP of the equipment under consideration.

57. Name four causes of excessive ptessure.

(206.02 l; 206.022; 206.023: 206.024; 206.025)

• a Added heot in excess of nomml operntions

• b. Blocking off against n pressure soun:e
• c. Thermal expansion of n trnpped liquid.
• d. Hydrnulic hammer or resonnnt vihration.

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TECHNICAL
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207 - Oycrlondlng

58. Wlmf ore some indlcutions of ove, loading of equipment"?

(207 02)

• Visible distortion
Chnnge of shape.
• Change of position,

Appendix 1

59. Slee! (ferrous ulloy) is nn nlloy of iron und cari10n. What is the cnrhon coment rnnge?
(App I.A)

• 0.01% to 1.7% (Max, cm hon content of welt! :1hle steels for Code pmpose is 0.35%)

60. Usually for refinc,y construction steels have less thnn whut percenl cm bon?
(App I A)

• Less than I %.

61. Steels for welding have a maximum of what percent carbon content?
(App I.A)

• 0.35%

62. There me two genernl types of steels. Whnt Ure these'?

(App IA)

• Fcrritic Steel - ordinary cmbon steel, low and intermediate alloy steels, and high alloy steels
(sirnight chromium),
• Austcnitic - chromium - nickel stainless steels..

63. Nonferrous metals and alloys contain what percenl iron?

(App I B)

• Less than 50%

64. What is lhe only commqn copper - nickel alloy and what is ii used for?
,. (App I BJ

• Moncl [I is used for relatively low tempernturc corrosion resistance.

65, Whal are !he major uses of commercially pure copper in refine1ies'!
(App I B)

• Elect1icol conductor.;, gaskets, nml corrosion resistance.

66. What me the major uses of aluminum nnd its alloys in rcfinefie.,;;·l
{App I B)

• Corrosion resisrnnce und fo1 st1uclures which lightweight is n necessity.

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CORROSIVE MATERIALS AND THEIR USES IN THE PETROCHEM INDUSTRY

Sulfuric Acid and Hydrogen Fluoride - used in alkylution's units ns ll cmnlyst Concentrations of
85% to 95% for sulfuric acid and above 65% for hydrogen fluoride.

• Phenol (Carbolic Add) - used for the mnnufoctme of lubricating oils and nromalk hydrocarbons.

• Phosphoric Acid - used for n co.talyst in polymerization units.

• Caustic (Sodium Hydroxide)- used for neutmlizntion of acidic components

• Mercury - used in inslruments,

• Ammonia - use<l t1s a rcf1igcrant and for tlic neutrnliznlion of acidic components.

• Chlorine - used to treut cooling tower water and for the munufocture of sodium hypochlorite used
to treating oils.

• Aluminum Chlorhlc - used us a catalyst for isomerizntion units.

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