1

API 653 Exam 2016/2017 1)

What Source side hole IQI designation would be required, using Gamma-ray radiography, for
examination of a weld repair in AST that is 1” thick?? Answer:

30.

Ref: API 650, 8.1.3.4 /ASME V, T-276

T= 1 + 3/32= 1.09375 in.

2)

During an internal inspection of a tank, pitting that measures 0.30 inches deep with dimension along
vertical line is 1.5 in. length 8 in. was found in the shell (0.625 Thickness). The required thickness of
the shell in this area is 0.5 inches. Comment on the acceptability of the corroded condition. Answer:

Rejected because of the depth

Ref: API 653, 4.3.2.2

t min.=t required = 0.5 in. , t initial = 0.625 in. , so C.A = 0. 625 – 0.5 =0.125 in. t initial = 0.625 in. t
depth pitting =0.3 , so Thickness at bottom of pit = 0.625 – 0.3=0.325 in. Thickness at bottom of pit
(excluding C.A.)= 0.325 in. -0.125 =0.2 in. The pits are acceptable if: Thickness at bottom of pit
(excluding C.A.) ≥ ½ tmin.; and Dr. Samir Saad

Email: [email protected]

Mobile: +966 546770956 / 540787077

2 Sum of dimensions in 8” length ≤ 2 , Thickness at bottom of pit (excluding C.A.)= 0.2 in. and ½
tmin.=1/2 x 0.5= 0.25 in. ,So Thickness at bottom of pit (excluding C.A.) < ½ tmin. ------------ not ok
Sum dimension along vertical line is 1.5 in. length 8 in.----------------------ok

3)

{How far past the outer perimeter of the foundation must the drip ring extend?} / The drip ring shall
extend at least ______________beyond the outer periphery of the foundation ringwall and then turn
down (up to 90°) at its outer diameter}. Answer:

4)

Ref: API 650, 5.4.5 (3)

When qualifying either a procedure or a scanning operator, Plate for procedure of tank bottom less
than 0.5 in., the operator must be able to detect_________. Answer:

5)
3 in. (75 mm).

more than 90 % to 100 %

Ref: API 653, G.5.2.2

What is the maximum fill-rate for the “top” course of a tank with a ½” thick bottom shell course?
Answer:

12 in./hr.

Dr. Samir Saad

Ref: 650, 7.3.6.5 & Table

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6)

hot tap connection size 18 NPS will be installed on the shell in an in-service tank, what is the
minimum shell thickness if the material is of recognized Toughness? Answer:

7)

1/2 inch.

Ref: API 653, 9.14.1.1 (a) / Table 9.1

What is the required fillet weld size for the tombstone reinforcement pad when a new bottom is
installed under the existing tombstone reinforced nozzle for a ¾” shell thickness? Answer:

1/4 inch.

Dr. Samir Saad

Ref: API 653,Figure 9.10 / API 650 par 5.1.5.7

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8)

What will be Allowable hydrostatic test stress for ASTM A-516, Grade 70 in first course (lower
course) shell in tank? Answer:
9)

33,000 psi.

Ref: API 653, 4.3.3.1 / Table 4.1

What is the minimum acceptable shell plate thickness for a tank shell made of A 285 grade C material,
70 feet in diameter and 50 feet high? Specific gravity of contents is 0.8. Original joint efficiency was
100 %.? Stress not given Answer:

0.304 in.

Ref: API 653, 4.3.3.1

10) A tanks bottom course has corroded in a general uniform manner (including the welds). The tank’s
diameter is 137 feet and its height is 40 feet. The liquid stored in the tank is hydrocarbon with a
specific gravity of 0.82 and it is not corrosive. The tank was constructed from ASTM A-285, Grade C
carbon steel with allowable product stress of 23,600 psi . Determine the minimum thickness of the
bottom course for full height operation. Round to the nearest hundredth. Answer:

0.483 in.

Dr. Samir Saad

Ref: API 653, 4.3.3.1

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11) What is the minimum acceptable thickness of the bottom course of an existing AST that is 135 feet
in diameter, maximum fill height is 56.5 feet? The product stored in the tank has a specific gravity of
0.87 and all shell butt- welds were 100% radiographically examined. The yield strength of the material
is 30,000 and the tensile strength is 60,000. Answer:

0.7 in.

Ref: API 653, 4.3.3.1 D = 135 feet , H= 56.5 feet , E= 1 , G=0.87 2

S: Maximum allowable stress, lbf/in (from Table 4.1 for materials listed in the current and previous
editions of API 12C and API 650) If not found in table , it can be calculated as the following:

For first Two courses (from the bottom)= smaller of 0.80 Y or 0.429T For other courses= smaller of
0.88Y or 0.472T Where: Y : Minimum Yield Strength =30,000 PSI T: Tensile strength =60,000 PSI
So : S: smaller of S= 0.8Y=24,000 PSI OR S= 0.429T= 25,740 PSI S= 24000 psi tmin = 2.6(H-1)
DG/SE = 2.6(55.5)135x0.87/ (24000) = 0.7061”

12) The minimum width of the stairways is___________ Answer: 28

in (710 mm).

Ref: API 650, 5.8.10 /Table 5.18 (2)]

13) Give product specific gravity less than 1 of unknown material and give thickness of first shell
course is 0.5 in and its Stress 23,600 psi, the required bottom plate minimum Thickness is _____
Answer:

0.17.

Dr. Samir Saad

Ref: API 653,4.4.6.2 /Table 4.5

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14) What is the weld joint efficiency factor for Corroded area if far 10 in. from joint for a tank built in
1954 as per API 12C with a single butt welded joint with a ‘back-up bar’? Answer:

0.85.

Ref: API 653, Table 4.2

15) What is the weld joint efficiency factor for Corroded area if far 10 in. from joint for a tank built for
API-12C 14th Edition with a single butt welded joint with a ‘back-up bar’? Answer:

0.85.

Dr. Samir Saad

Ref: API 653, Table 4.2

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16) Tanks fabricated from steels of unknown material specifications, 1/2 in. and operating at a shell
metal temperature 20 °F , these tanks___________. Answer: safe for use. Ref: API 653, 5.3.8/Figure
5-2 `

17) During Alterations and reconstruction full not at lowest one day temperature per API 650 Fig. 4-2,
these tanks to be ___________. Answer: Hydrotested to demonstrate fitness for continued service.
Ref: API 653, 5.3.1/ Figure 5.1
Dr. Samir Saad

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18) hot tap connection size 18 NPZ will be installed on the shell in an in-service tank, what is the
minimum shell thickness if the material is of recognized Toughness? Answer: 1/2 in. Ref: API 653,
9.14.1.1 (a) / Table 9.1

19) A new bottom will be installed through an existing tombstone reinforcing plate Shell plate
thickness of 1/2ʺ and required the distance from the splice weld to existing shell penetration is
________. Answer: 3 in. (H) Ref: API 653, Figure 9.12

Dr. Samir Saad

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20) A new bottom will be installed through an existing tombstone reinforcing plate, Shell plate
thickness of 1/2ʺ and required the distance from the splice weld to new bottom is__________ Answer:
3 in. (J) Ref: API 653, Figure 9.12

21) What is the allowable edge settlement of a 120 feet diameter tank that has an area of settlement
that starts to slope 4 feet from the shell and the bottom lap weld is approximately parallel to the shell?
Answer:

Ref: API 653, B.3.4.1 /Fig. B11

4.6 inches.

Dr. Samir Saad

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10

22) The lowest one day mean temperatures for Los Angles is _______ Answer:

35 °F.

Ref: API 650, Figure 4.2

23) The lowest one day mean temperatures for California is _______ Answer:
30 °F.

Dr. Samir Saad

Ref: API 650, Figure 4.2

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11

24) What is the Sulfuric acid corrosion rate if the Sulfuric acid 85% and Temperature 125 ºF? Answer:

50mpy

Ref: API 571, 5.1.1.11.3 (b)/ Figure 5-21

25) The fabricator may stress relieve at a temperature of 1000°F when it is impractical to stress relieve
at a minimum temperature of 1100°F providing _____. Answer:

The holding time is increased to 4 hours per inch of thickness. Ref: API 653, 5.7.4.5

Dr. Samir Saad

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12

26) What is product “Class” of heavy sticky crude oil ? Answer: Class H.

Ref: API 653, Table H.1

27) What is the minimum number of radiographs required when a 12” x 24” rectangular plate section
was replaced? Answer: 6

films

Dr. Samir Saad

Ref: API 653, 12.2.1.6.2

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13
28) Thickness readings taken on a tank shell after 5 years of service show a minimum thickness of
0.750 inches. The data sheet shows the original thickness as 0.725 inches. What is the maximum
interval between visual external inspection if tmin is 0.630 inches? Answer: 4.5

years.

Ref: API 653, 6.3.2.1

What is Corrosion Rate (N)? N = Metal Loss / time = ( t initial– t present) / time N= (0.750 – 0.725) /
5 = 0.005 N = 0.005 in./year = 5 mils/year

What is Remining Corrosion rate RCA? RCA = t actual – t required RCA= 0.725- 0.630 = 0.095 N =
0.095 in.= 95 mils

What is the maximum interval between visual external inspection ? I = at least every 5 years or
RCA/4N years whichever is less. I = 5 years or (95/4X5)= 4.75 years whichever is less. I = 4.75 years

29) A 125 feet diameter and 40 feet high storage tank has questionable thickness annular plates. The
first shell course thickness is 0.61 in. The thickness of the corrosion allowance for the tank is 0.125 in.
The product specific gravity is less than 1. What is the stress of the first course? Answer: 18700 psi.
Ref: API 653, Table 4.5, formula Note (b) Stresses are calculated from [2.34D (H – 1)]/t. Stress= 2.34
x125x39 / 0.61 = 18700 psi. 30) An existing tank, 48 feet high with a diameter of 430 feet, is
undergoing major repairs. What is the maximum out-of-plumbness allowed? Answer: 5 in. Ref: API
653, 10.5.2.1 (H=48 x 12= 576 in. ---- maximum out-of-plumbness= 576/100 = 5 in.) 31) New tank
has Shell seams lining up with roof seam matches up - that has to mean plumbness shall ___________
Answer: not exceed 1/200 of the total tank height. Ref: API 650, 7.5.2

Dr. Samir Saad

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14

32) If there is a conflict of technical requirements between API 650 or its predecessor API 12C and
API 653 on activities that must be carried out on an in-service tank, what actions would you take?
Answer:

the API 653 standards govern

Ref: API 653, 1.1.2

33) Prior to welding the new vertical joints, the existing horizontal welds shall be cut for a minimum
distance of __________beyond the new vertical joints. Answer: 12 inches. Ref: API 653, 9.2.2.2 34)
All requirements of _______, shall be considered before changing the service of a tank to operation at
temperatures above 200 F. A) API 650, Annex M Answer:

API 650, Annex M

Ref: API 653, 4.2.4.3

35) Critical length (L): L= 𝟑.𝟕 √𝑫𝒕𝟐 , but not more than ______. Answer:

40 in.

Ref: API 653, 4.3.2.1 (b)

36) Critical length (L): L= 𝟑.𝟕 √𝑫𝒕𝟐 , ( L ) is ______. Answer:

Maximum vertical length.

Ref: API 653, 4.3.2.1 (b)

37) Procedure is qualified on plate 0.5 thick which of the following thicknesses is not qualified?
Answer:

1/8 in.

Ref: ASME IX, Table QW-451.1

38) If piping near the tank enters the ground, the soil should be excavated _____inches for inspection.
Answer:

6-12.

Ref: API 575, 8.2.10

39) In order to comply with API 650, the finished surface of a weld reinforcement on plate ½ ʺ thick
horizontal butt joint may have a reasonably uniform crown not to exceed_____________ for
radiographic examination. Answer:

1/16 in.

Dr. Samir Saad

Ref: API 650, 8.1.3.4

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15

40) If a repair/modification weld is made on a tank shell plate that is thicker than 1ʺ, the base metal I
thin 3ʺ inches of the welding shall be heated to a temperature of approximately _______degrees.
Answer:

140 F

Ref: API 653, 10.4.2.3

41) How many root bend and face bend are required to qualify Welder a 3/8ʺ plate groove weld?
Answer:

2 (I root, 1 face).

Ref: ASME IX, Table QW-452.1(a)

42) The maximum acceptable undercutting on horizontal butt weld of a reconstructed is _________
inch Answer: 1/32

Ref: API 653, 8.5.2(b)

43) According the WPS AND PQR given AWS E-7018 and the inspector found the welder start
welding by E-7010 what action taken by the inspector: Answer: Cutting

the weld and used E-7018 the weld. Ref: ASME IX, Table QW- 253 / QW-404.4

44) What is the primary reason(s) for using floating roof? Answer: To

minimize vapor space.

Ref: API 575, 4.2.3

45) Tank is constructed as per API 650, 40 feet Nominal tank diameter, Nominal tank diameter, 8 feet
Hight of shell course and 0.125 in., the designed corrosion allowance and minimum thickness t2 is
among following reading (0.345ʺ, 0.4ʺ, 0.3ʺ, .025ʺ, 0.45ʺ) if the location of the critical length is 1 feet
from the second course of the shell what is the value of H in the formula for calculating tmin? Answer:

31 feet

(H=40-8-1=31 feet)

Ref: 653 ,4.3.3.2 /API 650, 5.6.3.2

46) All peripheral seals and their attachment to the floating roof shall be designed to accommodate
________of local deviation between the floating roof and the shell. Answer:

±100 mm (±4 in.)

Ref: API 650, H.4.4.3

47) What’s the most effective method of inspection before decide the method of repairing of lining?
Answer: visual

Dr. Samir Saad

inspection

Email: [email protected]

Ref: API 652, 10.2

Mobile: +966 546770956 / 540787077

16

48) The best way to determine the extent of lining before repair is by ______. Answer: Visual

inspection.

Ref: API 652, 10.2

49) Cracks in the shell-to-bottom weld are allowed under which condition? Answer: None.

(They are never allowed)

Ref: API 653,4.3.6

50) Work necessary to maintain or restore a tank to a condition _____ Answer:

suitable for safe operation.

Ref: API 653, 3.26

51) When service of a tank is changed from heavy stored naphta to diesel service Vents shall be _____
Answer:

inspected for proper operation.

Ref: API 653, 4.2.4.5.1

52) Cracks in the shell-to-bottom weld _____ Answer:

Shall be removed.

Ref: API 653,4.3.6

53) API supports the use of a release prevention system (RPS) to_________. Answer:

maintain the integrity of tank bottoms & thus protect the environment. Ref: API 653,4.4.3

54) A formal visual external inspection by an Authorized Inspector shall be made Answer:

At least every 5 years or RCA/4N years.

Ref: API 653,6.3.2.1

55) The RBI assessment shall be reviewed and approved by a team at intervals not to
exceed____________________ Answer:

10 years or more often if warranted by process, equipment, or Ref: API 653, 6.4.2.2.
consequence changes 56) The RBI assessment shall be performed by __________ Answer:

Personal knowledge in RBI methodology and Tank Design. Ref: API 653 ,6.4.2.2.2

Dr. Samir Saad

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Mobile: +966 546770956 / 540787077

17

57) Corrosion rates from low inspection effectiveness such as spot UT shall ____ Answer: not be used
in the RBI process. Ref: API 653 ,6.4.2.2.2 58) The results of any experiences with _______shall be
documented on repair/alteration history. Answer: Coating and linings Ref: API 653, 6.8.4 59) The
minimum repair plate dimension is ____________. Answer: 4 in. Ref: API 653, 6.8.4 60) Welded-on
patch plate shall not be placed over area of the tank bottom that have________. Answer:

Global dishing

Ref: API 653, 9.10.1.1(c)

61) Welded-on patch plats are not permitted in the critical zone on a tank bottom with an operating
temperature__________ for carbon steel. Answer: Exceeding 200 F Ref: API 653, 9.10.1.2.3
9.10.1.2.3 Welded-on patch plates are not permitted in the critical zone on a tank bottom with an
operating temperature exceeding 200 F for carbon steel or 100 F for stainless steel.

62) Welder identification is not required for _______ Answer: Roof plate welds and flange-to-nozzle
neck welds

Ref: API 653, 9.4

63) Low-hydrogen electrodes shall be used for welding temporary and new permanent attachments to
shells of API 650 Group IV, IVA, V, or VI materials. The welding procedure selected shall not
cause_______ Answer: underbead cracking Ref: API 653, 9.4 64) Measurements to verify these
tolerances shall be taken_____________ Answer: before the hydrostatic test of the reconstructed tank
Ref: API 653, 10.5.1.2 65) {What is method NDT enable continues monitoring for Crack is _____}/
{Method most used to detected cracks is__________} Answer: PT/MT 66) A full hydrostatic test can
be waived on a tank _______. Answer: if the owner or operator has authorized the exemption in
writing. Ref: API 653, 12.3.2.2 (b) Dr. Samir Saad

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18

67) Radiographs of repaired work and records of radiographs of repaired work shall be marked
with__________. Answer: the letter “R” Ref: API 653, 12.2.3.2 68) How many settlement points are
required for an external settlement of AST If the nominal diameter is 75 feet? Answer: 8
Measurements {N= D/10 = 75/10 =7.5 (but not less than 8). } Ref: API 653, 12.5.2/ Annex B, Fig.B-1
69) Minimum required number of settlement measurement points shall Answer: not be less than 8 Ref:
API 653, 12.5.2/ Annex B, Fig.B-1 70) The maximum spacing of measurement points around the
perimeter of a tank for an hydrostatic test is? Answer: 32 feet Ref: API 653, 12.5.2/ Annex B, Fig.B-1
71) Internal measurement for tank bottom settlement taken across the diameter of the tank must be
taken at what maximum spacing of readings across the ID? Answer: 10 feet Ref: API 653, 12.5.2/
Annex B, Fig.B-1 72) Where does the new nameplate need to be attached to a reconstructed tank?
Answer: Adjacent to the existing nameplate Ref: API 653, 13.1.1.2 73) How much time do you need
to keep the radiographs of a reconstructed tank? Answer:

at least one year.

Ref: API 653, 13.2.3 (d)

74) Measurement of tank settlement should be performed by ______________. personnel experienced

in the types of measurement procedures being performed. Ref: API 653, B.2.1 Answer:

75) Out-of-plane settlement that does not meet these limitations should be further examined by
___________________. Answer:

a more rigorous engineering assessment to determine the need for repairs. Ref: API 653, B.3.2

76) Before roof tank inspection, the deck plate shall be ______. Answer:

Ref: API 653, C.1.4.1

UT testing.

Dr. Samir Saad

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Mobile: +966 546770956 / 540787077

19

Note:- For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen
hammer to test the deck plate near the edge of the roof for thinning 77) Presence of crushed rock under
the steel bottom usually results in ______. Answer:

Ref: API 653, C.1.1.4

severe underside corrosion.

78) Swing line inspection for the purpose of ______. Answer:

Ref: API 653, C.2.11.6

check the freedom movement of the line.

79) The bottom-scanning examiners (operators and or UT examiner) should be requalified when
___________. Answer: API
Ref: API 653, F

650, Section 8.5.1.

80) As per API 653, examiner for Visual inspection qualification shall be as per ________. Answer:
the

authorized inspection agency has reason agency has reason to question the ability of the examiner.
Ref: API 653, G.4.9 81) Ambient Conditions: Any differences in the following factors between the
control tank and the candidate tank must be assessed in determining whether the candidate tank is in
similar service as the control tank: Answer:

Ref: API 653, H.2.1.9

low one day mean temperature

82) The floating-roof tank is designed to______________. Answer: breathing

losses.

Ref: API 575, 4.2.3

83) The presence of clay, wood, gravel, or crushed stone as contaminants in a sand pad may cause
_____________at each point of contact. Answer: pitting

corrosion.

Ref: API 575, 5.2.1

84) Internal corrosion of these tanks in the vapor space caused by________. Answer: hydrogen

sulfide vapor, water vapor, oxygen.

Ref: API 575, 5.2.2

85) Flame arrestors should be ______________________. Answer: opened

Dr. Samir Saad

at appropriate intervals.

Email: [email protected]

Ref: API 575, 8.2.10

Mobile: +966 546770956 / 540787077

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86) Which is the maximum allowable slope of a frangible roof of a tank 15 m or greater? Answer:
2:12.

Ref: API 650, 5.10.2.6 (a)(1)

87) Personnel who perform and evaluate radiographic examination shall be qualified according
to_________. Answer:

ASNT SNT-TC-1A.

Ref: API 650, 8.1.3.2

88) NED shall with the applicable required in accordance with a that is certified with the applicable
requirement of_________. Answer:

section V of the ASME code.

Ref: ASME V, T-150

89) When an array of components in a circle is radiographed, at least ________ shall show on each
component image Answer:

one IQI.

Ref: ASME V, T-277.2(b)(8)

90) performing a ________of the bottom and welds prior to performing the vacuum-box test Answer:
visual

examination

Ref: API 650, 8.6.2(a)

91) Vacuum box testing requires how many psig of Partial vacuum test minimum? Answer: 3psig

Ref: API 650, 8.6.3

92) When do you use thin film linings? Answer:

When the tank is new or has light corrosion

Ref: API 652, 6.1

93) The anchor pattern required for linings is typically____________. Answer:

1.5 mils to 4.0 mils (38 microns to 102 microns)

Ref: API 652, 7.5

94) Holiday testing of thick-film linings shall be carried out with __________in accordance with
NACE RP0188. Answer:
a high-voltage detector

Ref: API 652, 9.3.4

95) Holiday testing for thin-film should be done with_____ Answer: low-voltage (67.5V) wet sponge
applicator

Dr. Samir Saad

Email: [email protected]

Ref: API 652, 9.3.4

Mobile: +966 546770956 / 540787077

21

96) Holiday testing for “Thick” film coatings should be done with_____ Answer: High-voltage. Ref:
API 652, 9.3.4 97) the mere physical presence of bacterial deposits [e.g. sulfate reducing bacteria
(SRB) and acid producing bacteria (APB)] can promote_________. Answer: aggressive pitting
corrosion Bacteria by the concentration cell mechanism. Note: In some cases, severe corrosion has
been attributed to Microbiologically Influenced Corrosion (MIC). Ref: API 652, 4.5 98) What’s the
most likely effect on the failure of the lining of tank bottom? Answer: wrong coating specification.
Ref: API 652, 5.2 99) What is the minimum density, in the area of interest, for gamma ray source
radiography? Answer: 2 Ref: ASME V, T-282 100) The portion of the base metal whose mechanical
properties or microstructure have been altered by the heat of welding or thermal cutting IS ________.
Answer: heat affected zone (HAZ) Ref: API 577, 3.1.30 101) What is the suitable gauge used for
measurement of weld preparation Angel? Answer: Bridge cam gauge Ref: API 577, 9.3.2.4(b) 102)
Cathodic Protection surveys shall be performed ___________. Answer:

Annual.

Ref: API 651, 11.3.1.2

103) prior to commissioning a cathodic protection system is to _______. Answer:

measure the structure-to-soil potential.

Ref: API 651, 11.3.1.1

104) All sources of impressed current should be checked at intervals _______. Answer:

not exceeding two months.

Ref: API 651, 11.3.2.2

105) Records related to the effectiveness of cathodic protection should be retained for a period of
____________unless a shorter period is specifically allowed by regulation. Answer:

five years.
Dr. Samir Saad

Ref: API 651, 11.4.7

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22

106) Each MFL operator, who only use the bottom scanning equipment, shall receive a minimum of
___________hours of training. Answer:

40.

Ref: API 653, G.4.4

107) The unit’s meter reading of magnetizing shall___________________, relative to the actual
current value as shown by the test meter. Answer: not deviate by more than ±10 % of full scale. Ref:
ASME V, T-761.1 (c) 108) {Reinforcement pad welds should be pneumatically tested at _____} /
{which Leak test pressure for reinforced plate is_______.} Answer: 15 psig. Ref: API 650, 7.3.4 109)
Welders who qualify on the required tests for plate groove welds Are _________. Answer: also
qualified on most fillet welds. Ref: ASME IX, QW-303.1 / Table 452.6 110) To minimize burn
through, the first weld pass to equipment or piping less than 1/4 in. (6.35 mm) thick should be made
with 3/32 in. (4.76 mm) or_________. Answer: smaller diameter welding electrode to limit heat input.
Ref: API 577, 11.2.4.1 111) An interruption of the typical structure of a material, such as a lack of
homogeneity in its mechanical metallurgical physical characteristics is _______. Answer:
discontinuity. Ref: API 577, 3.1.22 112) What is the thickness of an IQI designation 17? Answer:
0.035 in. (0.89 mm). Ref: ASME V, Table T-233.1 113) {Which of the following has most
atmospheric corrosion?}/ {which of the following was the most corrosive?} Answer: marine area
(environment). Ref: API 575, 5.2.1/ API 571, 4.3.2.3 (a) 114) {If there is any doubt about the
condition of the grounding connection, so your action is __________} / {During visual inspection the
tank ground connection is observed to have electrical damage so your action is_____________}.
Answer: its resistance can be checked. Ref: API 575, 8.2.5 115) Inorganic zinc (zinc silicates) is often
applied to internal tank surface however_______. Answer:

it is not considered a thin film coting according to API 653. Ref: API 652, 6.2.1

Dr. Samir Saad

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Mobile: +966 546770956 / 540787077

23

116) The best method to measure the depth of isolated pitted area____________. Answer: pit gauging.
Ref: API 575, 8.4.4 117) Caustic embrittlement is a form of stress corrosion cracking characterized by
that _____________occur in piping and equipment exposed to caustic, primarily adjacent to non-
PWHT’d welds. Answer: surface-initiated Cracks Ref: API 571, 4.5.3.1 118) Carbon steel and 300
Series SS have serious corrosion problems in high strength caustic solutions above
about_________________. Answer: 150°F (66°C). Ref: API 571, 4.3.10.6 C 119) Connected pipe
outside tank and go underneath ground, the soil around pipe shall be removed and
_____________________at the point where they enter the earth or attach to a grounding rod and at the
tank. Answer: the pipe visually examined for corrosion. Ref: API 575, 8.2.5 120) Bolting flange shall
conform to____________. Answer: ASTM A 193 B7.

Ref: API 653, 4.7 (a)

121) {Inspectors should be alert to accumulation of dry pyrophoric material (self-igniting when
exposed to ambient conditions) during internal inspection. These accumulations may occur on
______________.} /{During internal inspection accumulation of self-ignition sources can be found
on_________.} Answer: the tank bottom, in the seal rim space areas, or on the top of rafters. Ref: API
575, 8.4.2 122) Usually, close visual inspection is sufficient when checking for cracklike flaws but for
increased detection capability, ___________. Answer: liquid penetrant or magnetic particle
examination should be used. Ref: API 575, 8.2.8.6. 123) The standard method of determining the
effectiveness of cathodic protection on a tank bottom is___________________. Answer: the tank-to
soil potential measurement. Ref: API 651, 8.3.1

Dr. Samir Saad

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Mobile: +966 546770956 / 540787077

24

124) For the purpose surface preparation prior to lining application, the preparation procedure is as
following______________. Answer: remove all hydrocarbon residues such as oil by solvent cleaning
and high or ultra-high pressure water or steam cleaning and followed by a fresh water rinse and then
sand blasting. Ref: API 652, 7.2.1 125) Abrasive blasting should not be performed if the temperature
of the steel surface is _____________. Answer: less than 5 °F (3 °C) above the dew point temperature
(10 °F). Ref: API 652, 8.3 126) The external visual inspection shall be every five years, when this
inspection can be made before this period, if the interval is __________. Answer: calculated to be less
than the one-fourth Remaining life (1/4 corrosion rate life). Ref: API 653, 6.3.2 127) Prior to
conducting internal or external inspection, the inspector should thoroughly__________. Answer:
review any available inspection records to become familiar with previous problems and
recommendations noted. Ref: API 575, 8.1. 128) Upon completion of welding of the new tank bottom,
the welds shall be inspected by which one of the following methods? Answer: Vacuum or tracer gas.
Ref: API 653, 7.3.3(a)&(b) 129) Newly welded bottom joints shall be tested using vacuum box and
solution film or by mean of___________________. Answer: tracer gas and detector examination. Ref:
API 653, 7.3.3(a)&(b) 130) Ultrasonic examination of shell plate for laminations shall be made in the
immediate area affected when_______________. Answer: adding a reinforcing plate to an existing
unreinforced shell penetration and adding a hot tap connection. Ref: API 653, 12.1.2.1 (a)&(b) 131)
Which of the following is considered to be an alteration? Answer: installation

of shell penetration of NPS 14 in.

Dr. Samir Saad

Email: [email protected]
Ref: API 653, 3.20 (a)

Mobile: +966 546770956 / 540787077

25

Alteration: - installing a shell penetration larger than NPS 12 beneath the design liquid level 132)
When ultrasonic thickness measurements are used to take in-service thickness measurements, what is
the maximum interval for re-inspection on a tank shell corroding at a rate of 0.5 mils per year and has
a remaining corrosion allowance of 17 mils? Answer: 15 years. Ref: API 653, 6.3.3.2 (b) When the
corrosion rate is known, the maximum interval shall be Smaller of RCA/2N = 17 /(2x0.5) = 17 years
or 15 years. 133) There is one pit vertically on the north side of the tank, in the first course has
minimum thickness is 3/8 in and the depth of the pit 0.18 in. Comment on the acceptability of the
corroded condition? Answer: The pitting is acceptable without repairs. Ref: API 653, 4.3.2.2 134) If
the drains are blocked, an accumulation of liquid can cause ____________. Answer: floating roofs to
sink or to be severely damaged. Ref: API 575, 8.2.9 135) On a fixed roof, planks long enough to span
at least----------------- rafters should laid to use as walkways for inspection? Answer:

Two (2).

Ref: API 575, 8.2.9

136) When new bottoms are installed through slots, each sketch plate should be welded in place or
securely wedged to the upper part of the shell plate before cutting the next slot and if bottom of shell is
seriously corroded, at least__________ beyond the projection of the new bottom. Answer:

3 in. (76 mm) sand bed.

Ref: API 575, 8.2.9

137) The critical zone of the tank bottom is within the __________________. Answer: Annular or
bottom plates within 3 inches of the inside edge of the shell. Ref: API 653, 3.10 138) Disadvantages of
impressed current systems are _________. Answer: more frequent monitoring. Dr. Samir Saad

Email: [email protected]

Ref: API 651, 6.3.3

Mobile: +966 546770956 / 540787077

26

139) If a tank has had a suitability for service evaluation per API 653 and a tank shell thickness is no
greater than 0.5 in., the risk of failure due to brittle fracture is___________. Answer: Minimal. Ref:
API 653, 5.2.5 140) No known tank failures attributed to brittle fracture have occurred at shell metal
temperatures of _____. Answer: 60°F and above. Ref: API 653, 5.2.6 141) If it is decided to change
the service to a more severe service, it is necessary to______________. Answer: Consider the need for
hydrostatic testing. Ref: API 653, 5.2.3 142) Corroded Roof plates shall be repaired or replaced
when_____________. Answer: an average thickness of less than 0.09 in. in any 100 in.2 area or roof
plates with any holes through. Ref: API 653, 4.2.1.2 143) The magnetizing yokes with an ammeter
used for magnetic particle examinations shall be calibrated _______________. Answer: at least once a
year, or whenever the equipment has been subjected to major electric repair, periodic overhaul, or
damage. Ref: ASME V, T-761.1 (a) 144) what type of damage would occur to concrete foundations
when exposed to high temperatures for an extended period of time? Answer: Calcining. Ref: API 653,
4.5.1.2 (a) 145) the internal inspection is required solely for the purpose of determining the condition
and integrity of the _____________. Answer: tank bottom. Ref: API 653, 6.4.1.2 146) If the internal
inspection is required solely for the purpose of determining the condition and integrity of the tank
bottom, the internal inspection may be ____________. Answer: accomplished with the tank in-service
utilizing various ultrasonic robotic thickness measurement. Ref: API 653, 6.4.1.2

Dr. Samir Saad

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147) When a lapped patch shell repair is used, the repair plate material shall be __________. Answer:
the smaller of 1/2 in. or the thickness of the shell plate adjacent to the repairs, but not less than 3/16 in.
Ref: API 653, 9.3.1.3 148) {Welder or welding operator's identification marks shall be located
adjacent to completed welds at intervals not exceeding______________.} / {What distance the welder
symbol shall be stamped?} / {Space between welder stencils is_______} Answer: {3

feet} / {EVERY 3 feet} / {not exceeding 3ft}. Ref: API 653, 11.2.2 / API 650,9.4

149) Lapped patch shell repair plates may be circular, oblong, square, or rectangular. All corners,
except at the shell-to-bottom joint, shall be _____: Answer: rounded to a minimum radius of 2 in. Ref:
API 653, 9.3.1.4

150) The maximum (allowed by API 653) vertical and horizontal dimensions of any lapped patch shell
repair plate, and also the minimum dimension is_______. Answer: 48 inches (vertical) and 72 inches
(horizontal) maximum, and minimum repair plate dimension is 4 in. Ref: API 653, 9.3.1.7 151) No
welding or weld overlays are permitted within the critical zone except for the welding of __________
in the bottom plates. Answer: widely scattered pits. Ref: API 653, 9.10.1.2.1 9.10.1.2.1 No welding or
weld overlays are permitted within the critical zone except for the welding of: widely scattered pits,
pinholes, cracks in the bottom plates, the shell-to-bottom weld, welded-on patch plates, or where the
bottom plate welded to the shell is being replaced.

152) Minimum dimension for a welded-on patch plate repair overlapping a bottom seam or an existing
patch is________________. Answer: 12 inches. Ref: API 653, 9.10.1.1 (a) 153) Welding on hot taps
shall be done with what type of electrodes? Answer: Low hydrogen electrodes only. Ref: API 653,
9.14.1.3

Dr. Samir Saad

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28
154) Annex G may be used to provide additional guidance in qualifying personnel and procedures
when magnetic flux leakage (MFL) tools are used to examine tank bottom, _________. Answer:
owner/operators should determine specific requirements to meet their tank bottom integrity needs.
Ref: API 653, 12.1.1.4 155) The critical of factors in brittle fracture can occur ________. Answer: the
stress concentration effect of a flaw. Ref: API 571, 4.2.7.3(a)(2) 156) If the floating swing from angle
exceeds 65 degrees, _________. Answer: recommended installation of a limiting bracket. Ref: API
653, C.2.11.6 (i) 157) {Caustic stress corrosion cracking Failures have occurred in improperly heat-
traced piping or equipment as well as_________.} /{Caustic stress corrosion cracking occurs in
equipment as well as___________.} Answer: heating coils and other heat transfer equipment. Ref:
API 571, 4.5.3.4 (b) 158) which metal is resistance to (MIC) Microbiologically Induced Corrosion?
Answer: nickel base alloys. Ref: API 571, 4.3.10.6 (c) 159) at what temperature would cooling water
corrosion become more aggressive? Answer: 150°F . Ref: API 571, 4.3.4.3 (c) Note :- above 140°F
(60°C), a scaling potential exists with fresh water above about 115°F (46°C) may cause serious scaling
with Brackish and salt water 160) MIC corrosion is usually observed as___________. Answer:
localized pitting under deposits or tubercles that shield the organisms. Ref: API 571, 4.3.8.5 (a) 161) If
a tank was built today using an API or UL standard for tanks, it would be referred to as: Answer:
Current applicable standard. Ref: API 653, 3.11 162) Cathode protection these measurements are
commonly made with ________in contact with the soil at several placed around the perimeter of the
tank. Answer: reference electrode placed. Ref: API 651, 8.3.1

Dr. Samir Saad

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29

163) When checking for pits, bulges, and depressions during an internal inspection of the shell and
bottom of a tank using flashlight, the flash light beam gives best results when held: Answer: Parallel
and closed to the surface to be inspected. Ref: API 575, 8.2.8.5 8.2.8.5 Visual examination should be
aided by use of hand-held lighting of sufficient candlepower (at least 100 lumens) under low ambient
lighting conditions, holding the flashlight against the shell so the light beam shines parallel to the shell
surface.

164) Fitness-for-service or other appropriate evaluation methodology based on established principles

and practices to exempt a repair from hydrostatic test, this evaluation shall be performed by
_______________. Answer: an engineer experienced in storage tank design and the evaluation
methodologies used. Ref: API 653, 12.3.2.7 165) unsupervised RT examiner shall qualify to
_________. Answer: ASNT SNT-TC-1A level II or Level III.

Ref: API 653, 8.1.3.2

8.1.3.2 Personnel who perform and evaluate radiographic examinations according to this section shall
be qualified and certified by the Manufacturer as meeting the requirements of certification as generally
outlined in Level II or Level III of ASNT SNT-TC-1A. all Level-I personnel shall be under the direct
supervision of Level-II or Level-III personnel.

166) For settled areas where measured settlement B exceeds 75 % of Bew (Maximum allowable
settlement) should be examined ______________. Answer: visually and suspect areas should be
examined with either magnetic particle examination or liquid penetrant examination. Ref: API 653,
B.3.4.2 167) Riveted tank in service, the Rivet Inspection is performed by _______________. Answer:

ultrasonic examination plus hammer test.

Ref: API 575, 8.2.8.7.

168) Which of the following shall be used to evaluate different conditions or new information such as
wind-induced buckling loading to take it into account? Answer: the original standard of construction;
and engineering judgment shall be used. Ref: API 653, 4.3.3.5 169) Which of these is an repair
organization to do repair? Answer: an owner/operator of aboveground storage tanks who repairs or
alters his/her own equipment in accordance with this standard. Ref: API 653, 3.27

Dr. Samir Saad

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30

170) Roof plates corroded to an average thickness of less than 0.09 in. in any 100 in.2 area or roof
plates with any holes through the roof plate shall be________. Answer: repaired or replaced. Ref: API
653, 4.2.1.2 171) Tank with service temperature 24 °F to be reconstructed. What should you do during
welding ( 0-32 °F) or thickness thicker than 1” ? Answer:

Preheat worm to hand (140°F).

Ref: API 653, 10.4.2.3

172) Reconstruction maximum hydro test unknown material, an allowable stress value of
___________________________________shall be used. Answer:

the lesser of 3/4 yield strength or 3/7 tensile strength. Ref: API 653, 8.4.3

173) Due to strength requirements, the minimum thickness of annular plate ring is usually_____.
Answer:

greater than 0.10 in.

Ref: API 653, 4.4.6.2 /Table 4.5

174) Annular plate 0.3 in changed to 0.2 in thickness, the new annular plate is______. Answer:

accepted because it is more than 0.10 in.

Ref: API 653, 4.4.6.2 /Table 4.5

175) Which of the following is not considered shell distortion? Uniform settlement of a tank, rigid
settlement, loss of thickness, undersize weld……etc. Ref: API 653, 4.3.5.1 4.3.5.1 Shell distortions
include out-of-roundness, buckled areas, flat spots, and peaking and Answer:
banding at welded joints.

176) Minimum diagnostic length of a radiograph is _________ Answer:

6 inches

Ref: API 653, 12.2.1.7

177) Columns, ladders, and other rigid vertical appurtenances that penetrate the deck shall be provided
with a seal that will permit a local deviation of_____ Answer:

±5 in. (±125 mm). Ref: API 650, H.4.5. Note: Appurtenances shall be plumb within a tolerance of ±75
mm (±3 in.).

178) What would happen if Inoperative drains with installed plugs (or with closed valves) on the
floating roofs? Answer:

The pontoon roof could sink.

Dr. Samir Saad

Email: [email protected]

Ref: API 575, 5.5. Mobile: +966 546770956 / 540787077

31

Inoperative drains with installed plugs (or with closed valves) can cause enough rain water to
accumulate on the roof to sink a pontoon-type floating roof. Note:

179) In determining if adequate cathodic protection is being achieved, which of the following would
be correct? A negative (cathodic) potential of at least 850 mV with the cathodic protection current
applied. Ref: API 651, 8.2.2.1. Answer:

180) The maximum dimension of the lapped patch repair plate Length (L) and Width from edge of
seem weld shall not exceed________________. Answer:

48 in. length and 72 in. width.

Ref: API 653, 9.3.1.7.

181) A Frangible roof where the continuous fillet weld between the roof plates and the top angle does
not exceed ________________. Answer:

3/16 in.

Ref: API 650, 5.10.2.6.

182) New construction for Carbon steel AST as per API 650, the limits design temperature to be no
more than__________. Answer:
93°C (200°F).

Ref: API 650, 1.1.1

183) The RBI assessment shall be reviewed and approved by a team at intervals not to
exceed____________________. 10 years or more often if warranted by process, equipment, or
consequence changes. Ref: API 653, 6.4.2.2.1. Answer:

184) Process by which corrosion rates and inspection intervals are established for a candidate tank
using corrosion rates and service history from a control tank for the purpose of establishing the next
inspection date is called a(n): Answer:

Similar service assessment.

Ref: API 653, 3.28.

185) What is the cause for rejection of the “B” image on a film due to excessive backscatter? Answer:

A Light (White) image of the “B”.

Ref: API ASME V, T-284

186) New welding on the shell-to-bottom joint shall be inspected for its entire length by
______________. Answer:

a right-angle vacuum box and a solution film, or by applying light diesel oil.

Dr. Samir Saad

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32

Ref: API 653, 12.1.6 187) Qualification test plates for floor scan, with flaws, should be a minimum
of____. Answer:

70 sq. ft.

Ref: API 653, G.5.1.1

188) Welders shall be qualified in accordance with_________ . Answer:

ASME Section IX.

Ref: API 650, 9.3.2

189) Personnel who perform and evaluate radiographic examination shall be qualified according to
ASNT SNT-TC-1A _____________. Answer:
at least Level I.

Ref: API 650, 8.1.3.2

190) All tanks shall be given a visual external inspection by an authorized inspector shall be done at
least____________. Answer:

Every 5 years or 1/4 of remaining life years whichever is less. Ref: API 653, 6.3.2.1

191) {Hardness testing of weld and HAZ is often required to ensure welding process and
PWHT___________.}/ {Hardness test after PWHT to confirm it is______.} Answer: {acceptable

soft result} / {soft weld}

Ref: API 577, 9.10

192) A welder’s performance qualification will expire if he/she has not welded with a specific process
for more than Six months should be________. Answer: Prequalified

Ref: ASMI IX, QW-322.1 /API 577 ,8.2

193) A full hydrostatic test can be waived on a tank _______. Answer:

if the owner or operator has authorized the exemption in writing. Ref: API 653, 12.3.2.2 (b)

194) Who is responsible for decide hydrostatic test? Answer:

owner engineer.

Ref: API 653, 12.3.2.2 (a)

195) Tank with service temperature 24 °F to be reconstructed, during reconstruction welding the
thickness over 1.5 in., based on the thickness of the thicker part, what is the required preheat
temperature? Answer:

200°F.

Dr. Samir Saad

Ref: API 653, 10.4.2.3 / 10.4.4.3 Email: [email protected]

Mobile: +966 546770956 / 540787077

33

196) What is the minimum preheating temperature when using the preheat alternative method for a
weld repair on a Tank that originally had PWHT? Preheat of 300°F (150°C) or higher, with interpass
temps not exceeding 600°F (315°C). Ref: API 653, 11.3.1 (d) Answer:

197) When removing / Dismantling an existing tank bottom, all arc-gouged areas of the tank shell-to-
bottom weld shall be__________, and defective areas repaired and reexamined. Answer:

magnetic particle examined.

Ref: API 653, 9.10.2.3

198) The magnetizing power of yokes, each weight shall be weighed with a scale from a reputable
manufacturer and stenciled with______________________. Answer:

the applicable nominal weight prior to first use.

Ref: ASME V, T-762(d)

199) The magnetizing power of yokes shall be verified______________. Answer:

prior to use each day the yoke is used and whenever the yoke has been damaged or repaired. Ref:
ASME V, T-762(a)

200) Tank plates being welded which do not have proper identification (unknown material) shall be
subjected to _________. chemical analysis and mechanical tests as required in ASTM A6 and ASTM
A370 including Charpy V-notch. Ref: API 653, 7.3.1.2 Answer:

201) Vacuum Box Testing examiner/opertor qualification according to_______. Answer:

API Std 650, Section 8.6.4.

Ref: API 653, Annex F/ API 650, 8.6.4

202) During routine inspection, the tank ground connection is observed Cable found hazard of electric
shock, so your action is_____________. Answer: its resistance can be checked. Ref: API 575, 8.2.5

203) If it is decided to change the service to a more severe service, it is necessary

to_______________. Answer:

Consider the need for hydrostatic testing.

Dr. Samir Saad

Email: [email protected]

Ref: API 653 5.2.3

Mobile: +966 546770956 / 540787077

34

204) In order to qualify for a hydrotest exemption after a major repair or a major alteration, the
Owner/Operator may utilize which of the following evaluation methodologies? Fitness for service
based on established principles and practice to exempt repairs. Ref: API 653, 12.3.2.7 Answer:

205) Thick-film Reinforced Linings are frequently used as__________________. Answer:

an alternative to replacing the steel bottom (floors).

Ref: API 652, 6.4

206) New full penetration welds attaching existing shell plate to existing shell plate shall be examined
by radiographic methods in addition, for plate thicknesses greater than 1 in., the back-gouged surface
of the root pass and final pass (shall be examined for its complete length by ______________.
Answer:

magnetic particle or liquid penetrant methods.

Ref: API 653, 12.1.5.1

207) if you want to use A-283 instead of A-36 on patch plate, What must to do? Answer:

Obtain the prior written approval of the Purchaser.

Ref: API 650, 4.1.5

208) Before work begins, all repair work on critical zone must be authorized by__________. Answer:

An Authorized inspector or an engineer experienced in storage tank design. Ref: API 653, 9.1.3

Dr. Samir Saad

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35

Questions 209 through 214 refer to the WPS/PQR documents on the following pages 209) How many
essential variables mentioned on the WPS No. SAMW-001? Answer:

8.

Ref: ASME IX, QW-253

210) joint design on the WPS No. SAMW-001 is _____________. Answer:

missing angle bevel and groove angle.

Ref: ASME IX, QW-200.1(B) /QW-253

211) Does the WPS show the maximum base metal thickness range that could be qualified by the PQR
- 001? Answer:

No, it should be 3/16 inch to 1 inches.

Ref: ASME IX, QW-451.1

C)

212) Does the WPS show the Weld Metal Deposited Thickness range that could be qualified by the
PQR - 001? No, it should be it should be 1/4 in maximum For E6010 and 3/4 in maximum for E7108.
OR No, it should be it should be 1 in maximum. Ref: ASME IX, QW-451.1 Answer:

Dr. Samir Saad

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36

213) Do tensile test results shown on PQR - 001 meet the requirements for WPS? Answer:

No, specimen 2 does not meet requirements. Ref: ASME IX, Table QW-451.1 & QW-150
(151/152/153) & QW-422 Tables

1. In order to pass the tension test, the specimen shall have a tensile strength (70,00 psi) that is not less
than the minimum specified tensile strength of the weld metal. So specimen No. (1) mentioned on
PQR breaking in the weld metal is OK at 76,200 2. if the specimen breaks in the base metal outside of
the weld or weld interface, the test shall be accepted as meeting the requirements provided the strength
is not more so specimen # 2 is rejected breaking at 65,500.than 5% below the minimum specified
tensile strength of the base metal. = 0.95 x specified tensile strength =70,000 x 0.95 = 66,500,

214) Bend test results shown on PQR - 001 are_________. Answer:

Unacceptable, because of defect greater than 1/8 in. (3 mm). Ref: ASME IX, Table QW-451.1 & QW-
150 (151/152/153)

Dr. Samir Saad

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FORM QW-482 FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-
200,1, Section iX, ASME Boiler and Pressure Vessel Code) Organization Name Welding Procedure
Specification No. Revision No. 0

WELDING COMPANY, INC SMAW - 001 Date

Welding Process(es): JOINTS(QW-402) Joint design Backing: Yes Backing Material (Type)

12/31/16

By Supporting PQR No(s)

SMAW

Type:

JOHN SMITH PQR - 001

MANUAL DETAILS

Singe V No

X Weld Metal Refer to both backing amd retainers

Metal

Nonfusing Metal

Nonmetallic

Other

BASE METALS (QW-403) P-No. 1 OR

Group No.

Specification and type/grade or UNS number to Specification and type/grade or UNS number OR
Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. Thickness Range: Base Metal:
Groove Maximum Pass Thickness