API 570 Mega Problem

1. Pipe Calculations – Determine the following thickness

a) tmin ___________
b) tneeded (includes corrosion allowance) ___________
c) tadjusted (adjust for mill tolerance) ___________
d) tnominal and Pipe Schedule ___________

2. Flange Calculations

a) Determine appropriate Flange Class ___________

3. Blind Calculations – Determine the following thicknesses

a) tmin ________________
b) tneeded ________________
c) tnominal (plate thickness to order) ___________

4. Hydrotesting Pressures

Determine minimum system hydrrotest pressure __________

Determine maximum hydrotest pressure based on flanges __________

5. Pneumatic Testing Pressures – Determine the following pressures

a) Test Pressure __________

b) First-Step Test Pressure __________

c) Inspection Pressure (the exam is conducted at this pressure) __________

d) Set Pressure for PRV used during test __________

6. Weld Discontinuities – Determine the maximum allowed size of discontinuities

a) Height of reinforcement _________

b) Length of incomplete penetration _________
c) Depth of incomplete penetration _________
d) Length of individual _________
e) Cumulative length of Slag inclusion _________
f) Length of lack of fusion _________

7. Preheat & PWHT

a) A preheat of ___________ oF is recommended

b) The preheat zone includes the weld and ____________ beyond each edge of the
weld

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 API 570 Mega Problem

c) If PWHT was specified, the PWHT temperature should be ___________ oF.

8. Flange Bolts

a) Number of bolts _________________

b) Length of bolts _________________
c) Diameter of bolts _________________
d) Describe the needed thread engagement:__________________

9. The minimum size of fillets on the ¾” socket-welded vent is ________.

10. The Welder

a) The welder making this pipe should be qualified for which positions? ______
b) Which single test position qualifies the welder for these positions? ______
c) If bend tests were used for qualification, how many were conducted? ______

11. During the welder`s qualification test, this welder had to be qualified:

a) With backing
b) Without backing
c) Either with or without backing

12. The flage face finish for these flanges is _______________

13. Weld Examination

a) How many of these welds should be examined visually? ______

b) How many of these welds should be examined by RT? ______
c) If a weld defect is found, howmany more welds should be examined? ______

14. Pressure Test

a) The test should be maintained for at least _____________ minutes.

b) If a hydrocarbon is used for the test, the flash point should be above __________
o
F.

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 API 570 Mega Problem

15. Per B31.3, during the pressure test, all joints shall be left

a) Un-insulated
b) Un-insulated and not painted
c) Un-insulated and not pained or primed

16. This work would be classified, per API 570, as a(n)________________

17. This work must be authorized by the:

a) Inspector
b) Engineer
c) Inspector or engineer
d) Inspector and engineer

18. This work must be approved by the

a) Inspector
b) Engineer
c) Inspector or engineer
d) Inspector and engineer

19. Who has overall responsibility for this project?________

20. Minimum Design Metal Temperature

a) Find the lowest allowed MDMT for the pipe without impact testing ______
b) If impact testing is required, How many bars are needed for each set? ______
c) If impact tested, the average energy for each set must exceed ______
d) If impact tested, the minimum energy for one bar must exceed ______

21. Line Classification

a) Per B31.3, this piping should be classified as ______

b) Per API 570, this piping should be classified as ______

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 API 570 Mega Problem

22. Thermal growth

a) The horizontal portion of this line will grow _________

b) The vertical portion of this line will grow _________

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 API 570 Mega Problem

1. Pipe Calculation – Determine the following thicknesses

a) Calc tmin

tmin = ___PD____
2[(SE +PY)]
= __________500x 8.625_________
2[(16500 x 1) + (500 x 0.4)]

= 0.129”

b) add Corrosion Allowance

i. tneeded = tmin + C
= 0.129 + 0.125

= 0.254

c) Adjusted for mil tolerance

tadj = ___tneeded___ =0.254 = 0.290”

0.875

d) Pipe Schedule (0.322)

Order Sch 40

2. Flange Calculations

a) A 105 – Material Group 1.1

b) Select Class 300 good for 700oF good for 535 psi

3. Blind calculation – Determine the following thicknesses

a) Calc tmin

tmin = dg ________3P______ Square root

16SE

= 8.625

= 0.673”

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 API 570 Mega Problem

b) Add corrosion allowance

tneeded = tmin + C
= 0.673 + 0.125 + 0.798”

c) Plate to order 13/16” = (0.8125”)

4. Hydrotest

a. Pt = 1.5 P _St_
S
= 1.5 x 500 x _20_ = 909 psi
16.5

b. Class 300 A105

Pt = 1.5P100oF 25 psi
= 1.5 x 740 = 1110 psi Round up to = 1125 psi

5. Pneumatic

a. Test Pressure
Pt = 1.1 P = 1.1 x 500 = 550 psi

b. 1st Step
Lesser of: ½ Pt or 25psi = 25 psi

c. Insp Pressure
Pinsp = P = 500 psi

d. PRV pressure
Lesser of : 1.1Pt = 55 x 1.5 = 605
Pt + 50 = 550 + 50 = 600 psi

6. Weld Discontinuities

a) Reinforcement 1/8”
b) Length of IP 1.5” in 6” of weld
c) Depth of IP 1/32” (Lesser of 1/32” or 0.2 x 0.322)
d) Max slag – ind 0.644 ( 2 Tw = 2 x 0.322)
e) Max slag – cum 1.288” in 6” of weld (4 Tw in 6”)
f) Lack of fusion 0”

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 API 570 Mega Problem

7. Preheat

a) Recommended preheat 50oF

b) Preheat zone – weld plus 1” either side

c) 1100 – 1200 oF

8. Flange Bolts

a) 12 bolts
b) 5.50”
c) 7/8”
d) Lack of engagement is not more than one thread

9. Fillet – Minimum fillet size on socket weld: 0.125”

10. The Welder

a) All
b) 6G
c) 4

11. Welders Qualification Test

b. without backing

12. Flange

b. 125 – 250 micro – inch

13. Weld Examination

a) 5%
b) 5%
c) 2

14. Pressure Test

a. 10 minutes
b. 120 oF

15. a. Unisulated

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 API 570 Mega Problem

16. Alteration

17. d. Inspector and Engineer

18. a. Inspector

19. Owner