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According to ASME PCC-2 guidelines for bending pipes, the term “hot bending” refers to the bending of ferritic steels at a temperature above the——-

a. Lower critical temperature

b. Upper critical temperature

C. Preheating temperature

D. Stress relieving temperature

“Type B Full Encirclement Steel Reinforcing Sleeves for Piping” is considered a generally appropriate solution for—–

a. Local Wall Thinning

b. Laminations

C. Blisters

D. All of the above

Pipework welded repairs
Which of these is only allowed as a temporary repair on process pipework?

a) Flush ‘insert’ patches

b) Grinding out a through-wall defect and rewelding

c) Full encirclement welded split sleeve

d) Weld overlay

A corroded area on the non-post weld heat-treated cylindrical shell was completely removed by making a 150mm diameter opening, which is to be repaired by using circular Butt-welded Insert Plates. What will be the Minimum diameter of the Insert Plate?

a. Lesser of 12t or 380 mm (where t is the thickness of the parent material)

b. Greater of 12t or 380 mm (where t is the thickness of the parent material)

C. 150mm diameter

d. 300 mm diameter

Scope of Post Construction Codes (PCCs)
When doing site weld repairs to pressure envelope components using PCCs, one criterion of the construction code which is commonly overridden is:

a) PWHT requirements

b) Welding consumable P-No

c) Welder qualifications

d) WPS essential variables

A full encirclement sleeve where ends are welded circumferentially to the carrier pipe is called:

a. Type 1 sleeve

b. Type A sleeve

C. Type 2 sleeve

d. Type B sleeve

A full encirclement sleeve where ends are not welded circumferentially to the carrier pipe is called

a. Type 1 sleeve

b. Type A sleeve

C. Type 2 sleeve

D. Type B sleeve

Type A sleeves shall be fabricated or manufactured from steel meeting the material specifications of the construction code, and should have a minimum thickness equal to

a. Two-thirds the thickness of the carrier pipe

b. Full thickness of the carrier pipe

c. The half thickness of the carrier pipe

d. The three-fourth thickness of the carrier pipe

Full encirclement Types A and B sleeves shall be at least:

a. 100 mm (4 in.) long and extend beyond the defect by at least 50 mm (2 in.)

b. 100 mm (4 in.) long and extend beyond the defect by at least 25 mm (1 in.)

C. 150 mm (6 in.) long and extend beyond the defect by at least 75 mm (3 in.)

d. 150 mm (6 in.) long and extend beyond the defect by at least 50 mm (2 in.)

10.

Fillet-welded patches
According to API codes, which of these items are allowed to have fillet-welded ‘lap’ patches added as a permanent repair for wall-thinning corrosion?

a) Pipework

b) Unfired pressure vessels

c) Atmospheric oil storage tanks

d) None of the above

11.

In the context of ASME PCC-2, the total depth of overlay or back cladding shall be ——— thickness, unless otherwise specified.

a. 3 mm (18 in.) or lower

b. 3 mm (18 in.) or greater

C. 1.5 mm (V16 in.) or greater

D. 1.5 mm (116 in.) or lower

12.

The freeze plug isolation method was planned for repair on NPS 3 piping. According to ASME PCC-2, which of the following is appropriate?

A. Use Carbon Dioxide Freeze Plugs with the jacket length not less than three pipe diameters

B. Use Liquid nitrogen Freeze Plugs with the jacket length not less than four pipe diameters

C. Use Liquid nitrogen Freeze Plugs with the jacket length not more than four pipe diameters

D. Use Carbon Dioxide Freeze Plugs with a jacket length of not more than three pipe diameters

13.

The freeze plug isolation method was planned for repair on NPS 6 piping. According to ASME PCC-2, which of the following is appropriate?

a. Use Carbon Dioxide Freeze Plugs with a jacket length of not more than four pipe diameters

b. Use Carbon Dioxide Freeze Plugs with the jacket length not less than four pipe diameters

C. Use Liquid nitrogen Freeze Plugs with a jacket length of not more than three pipe diameters

d. Use Liquid nitrogen Freeze Plugs with the jacket length equal to three pipe diameters

14.

Fillet welded patch restrictions
Which of these features is prohibited on fillet-welded patches to API 570?

a) A patch on the material of 20,000psi tensile strength

b) 3in a long patch on a 12in line

c) A patch on the material of 35,000psi tensile strength

d) 8in a long patch on a 12in line

15.

According to ASME PCC-2 guidelines, for “repair by weld” on base metal, if weld thickness is ————-then it should be examined by volumetric examination methods such as radiographic or ultrasonic testing.

a. Over 19 mm (34 in.) thick

b. Over 25 mm (1 in.) thick

c. Over 9.5 mm (3/8 in.) thick

d. Over 12.7 mm (12 in.) thick

16.

Mechanical Clamp Repair can be used on-stream for:

a. General Wall Thinning

b. Local Wall Thinning

c. Pitting

d. B and C

17.

Unless an engineering evaluation is Performed for Shell and Tube Heat exchangers, tube plugging with Friction fit tapered plugs can be done only if

a. shell-side operating pressure is 1.5 MPa (200 psi)or less

b. shell-side operating temperature 205°C (400°F)or less

c. tube-to-tube sheet joints are expanded and not welded

d. All the above conditions must be met

18.

When an in-service leak test is performed on equipment or piping, the test medium normally will be?

a. Water

b. Air

c. Process Fluid

d. Nitrogen

19.

For pressure testing on vessels and piping, the Pressure gage/recorder ranges shall be greater than —-times and less than — times the required test pressure

a. 1.5, 3

b. 1.5,4

c. 1.5, 2.5

d. 2,4

20.

In order to reduce the risk of brittle fracture during the pressure test, the temperature of the metal during the test of pressure vessels should be maintained at a minimum of ——– the minimum design metal temperature (MDMT)

a. 17°C below

b. 17°F above

c. 30°F above

d. 30°C above

21.

The excavated boat samples’ have which following advantages

a. The cavity left by the removal of the sample is very conducive to repairing welding

b. The tapered nature of the cavity allows complete access for most welding processes

c. Sloping curvature of the cavity allows complete access for most welding processes

d. All of the above

22.

For the safe distance calculation for the pneumatic test, if the scaled consequence factor is 5m/kg 1/3 (12.5ft/lb 13), what effect do you expect on human beings if the vessel is burst during the test

a. Eardrum rupture

b. Lung damage and Eardrum rupture

c. Fatal

d. Safe. No effects

23.

According to ASME PCC-2 guidelines for conducting a pneumatic tightness test, the test pressure should be no less than

a. The higher of 105 kPa (15 psi) or 25% of the system design pressure

b. 105 kPa (15 psi)

c. 25% of the system design pressure

d. The lesser of 105 kPa (15 psi) or 25% of the system design pressure

24.

According to ASME PCC-2 guidelines, Fillet Welded Patches ———–used for lethal service applications

a. Should not

b. Shall not

c. Maybe

d. There is no such guideline in ASME PCC-2

25.

Weld overlay repair on flange faces
When can weld overlay be used to build up a heavily corroded area on a flange face?

a) Never; it is not allowed by construction code or PCC

b) If the flange is not yet corroded to minimum code thickness

c) If Carbon Equivalent is less than 0.3%

d) In all cases, as long as the materials are compatible

26.

“Butt-welded Insert Plates in Pressure Components” is considered generally appropriate repair method for which of the following defects

a. General Wall Thinning

b. Local Wall Thinning

c. Circumferential and Longitudinal Cracks

d. All of the above

27.

A sub-contractor proposed “Welded Leak Box Repair” as a repair method for the following defects. For which of the following it is NOT permitted repair method as per ASME PCC-2

a. Local Wall Thinning

b. General wall thinning

c. Pitting

d. All of above

28.

“Full encirclement Steel Reinforcing Sleeves for Piping” is proposed for repairing leaking defects. Which of the following type will be considered a generally appropriate solution

a. Type A

b. Type B

c. Either Type A or B

d. None of above

29.

For ‘doghouse” type insert plate having its edge abutting with existing longitudinal weld, what length of the existing weld shall be cut on each side of the insert plate and re-welded

a. 150 mm maximum

b. Minimum 6 times thickness of insert plate

c. 150 mm minimum

d. Lower of b and c

30.

For the ‘doghouse” type insert plate having its edge abutting with existing longitudinal weld, a certain length of the existing weld shall be cut on each side of the insert plate and re-welded. What NDT should be performed on this weld?

a. Full RT

b. Full UT

C. MT or PT on both sides of a weld

d. Any one of a,b,c

31.

A post-weld heat-treated vessel 40mm thick was repaired using square insert plates of 40 mm thickness. Butt welds around the periphery of this insert plates shall be spaced no closer to existing welds than——

a. 150mm

b. 80 mm

c. 6 times the thickness of the insert plate ( 240mm)

d. 8 times the thickness of the insert plate ( 320mm)

32.

The outer diameter of the cylindrical shell is 640 mm and the nominal wall thickness of the shell is 20mm and is to be repaired by “External Weld Overlay to Repair Internal Thinning”. Unless otherwise justified by fitness for a service assessment, External Weld Overlay shall extend on-base Metal beyond the affected base metal for a minimum distance, B, equal to:

a. 40mm(twice nominal wall thickness)

b. 60mm

c. 80mm

d. None of above

33.

A cylindrical shell 30mm thick was repaired by depositing 20mm “ External Weld Overlay to Repair Internal Thinning”. The corners of the weld overlay shall be rounded to ——radius

a. Maximum 20mm

b. Minimum 20mm

c. Minimum 30mm

d. Maximum 30mm

34.

A cylindrical shell 32mm thick is to be repaired by depositing “External Weld Overlay to Repair Internal Thinning”. According to ASME PCC-2 guidelines, what is the maximum thickness which can be deposited for such repair?

a. 75% of wall thickness 24mm

b. 150% of wall thickness, 48mm

c. 50% of wall thickness, 16mm

d. None of the above

35.

To qualify a repair design made with “External Weld Overlay to Repair Internal Thinning” a burst test was successfully made on 12 inches OD cylindrical mock-up. This test qualifies repair components of ———-Outside diameter.

a. 12 inches to unlimited

b. Any OD up to 12 inch

c. 6-inch to 24-inch

d. Any OD up to 24 inch

36.

Full encirclement sleeve used for leaking repairs, which of the following welds are NOT allowed for making longitudinal weld joint of the sleeve.

a. Overlapping side strip welds

b. Butt joint with backing strip

c. Butt joint without backing strip

d. All of the above are not allowed I

37.

It is proposed to carry out a repair on the carrier pipe using a Type B sleeve. The wall thickness required for the maximum allowable design pressure for carrier pipe is 12 mm. The sleeve should have a wall thickness equal to or greater than ————

a. 8mm. (two-thirds of carrier pipe thickness required for MAWP)

b. 6mm. ( Half of carrier pipe thickness required for MAWP)

c. 12 mm (full thickness of the carrier pipe required for MAWP)

d. 9mm (Three-fourth thickness of the carrier pipe required for MAWP)

38.

While designing fillet patches with plug welds the design can be based on:

a. Considering the combined strength of the patch plate, the underlying shell, and plug welds

b. Considering the strength of the patch plate alone

c. Considering the strength of the underlying shell and plug welds

d. Considering the strength of the patch plate and plug welds

39.

In the “Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug weld holes should have a diameter not less than ———and not more than———–,( The component thickness is 24 mm and fillet patch thickness is 16 mm)

a. 16mm, 24mm

b. 25mm, 50 mm

c. 22mm, 38 mm

d. 12mm, 24 mm

40.

Alternatives to the Traditional Welding Preheat method, the Welds in steels having a Carbon equivalent > 0.5 % are prone to delayed cracking. A waiting period of ———- should be allowed to detect delayed cracking before the final NDT

a. 12 hours or more is performed

b. 24 hours or more

c. Not more than 12 hours

d. Not more than 24 hours

41.

Carbon equivalent (CE) may be used as a means for determining the necessity for preheat. According to ASME PCC-2 guidelines, Preheat is optional if

a. CE is <= 0.3%

b. CE is <= 0.4%

c. CE is <= 0.45%

d. CE is <= 0.5%

42.

When the Cracking parameter (cm) is used as a means for determining the necessity for preheating and the level required. According to ASME PCC-2 guidelines, Preheat is optional if :

a. Pcm is <= 0.3%

b. Pcm is <= 0.25%

c. Pcm is <= 0.15%

d. Pcm is <= 0.2%

43.

In the context of ASME PCC-2, the term ————-refers specifically to the application of carbon steel or low alloy weld metal, applied for the purpose of restoring base metal thickness.

a. Weld Overlay

b. Weld build-up

c. Clad Restoration

d. Back Cladding

44.

According to ASME PCC-2 guidelines, the total linear expansion of 20 meters long vessel (MOC: SA 516 Gr.70) at a typical PWHT temperature of 650°C (1,200°F) may be estimated as:

a. 240mm

b. 60 mm

c. 120 mm

d. 160 mm

45.

There are two sources of water, A and B, with a chloride content of 70 ppm and 40 ppm respectively. As per ASME PCC-2, which water can be used for Hydro testing of austenitic steel vessels or piping systems,

a. Both A and B are OK

b. Only A is OK

c. Only B is OK

d. Both are not OK

46.

The calculated stored energy of a Pressure vessel under Pneumatic testing is 135,500, 000 J (100,000,000 ft-lb), According to ASME PCC-2, considering this stored energy, the minimum safe distance between all personnel and the equipment being pneumatically tested should be calculated, and adhered to, if:

a. Test pressure is Greater than 100 psi

b. Test pressure is Greater than 125 psi

c. Test pressure is Greater than 150 psi

d. It is not a mandatory requirement considering the given stored energy

47.

A pneumatic tightness test is to be performed on a piping system with a Design pressure of 200 psi. According to ASME PCC-2 guidelines, the maximum test pressure should be not more than ——-

a. 70 psi

b. 100 psi

C. 200 psi

d. 220 psi

48.

In the Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug welds shall be spaced such that their pitch (center-to-center spacing) should not be less than——– mm ( the bottom diameter of the hole in which the weld is made =20 mm)

a. 50

b. 60

C. 70

D. 80

49.

Inspection and repair methods for shell and tube heat exchangers as given in ASME PCC-2 are not applicable to heat exchangers constructed in accordance with

a. TEMA standards

b. ASME BPVC Section VIII, Division 1

C. ASME BPVC Section VIII, Division 2

d. ASME BPVC Section VIII, Division 3

50.

“External Weld Overlay Repair Method for Internal Thinning” is generally not an appropriate repair method for which of the following defects

a. Pitting

b. General Wall Thinning

C. Local Wall Thinning

d. Gouges

51.

For Flange repair, According to ASME PCC-2 guidelines, Under-thickness of a raised face due to refinishing shall be acceptable, provided the minimum finished height of the raised face is

a. 0.8 mm (0.031 in.)

b. 0.16 mm (0.062 in.)

C. 0.24 mm (0.093 in.)

d. No under the thickness of raised face is accepted

52.

In the Fillet Welded Patches repair method, in addition, to completely encompassing the damaged area the size (length and width) of the patch plate shall also be large enough to encompass any additional area anticipated to experience similar damage during the life of the repair and The patch plate should overlap sound base metal by distance at least ———-

a. 25 mm (1 in.)

b. 50 mm (2 in.)

c. Equal to the nominal wall thickness of the component

d. Twice the nominal wall thickness of the component

53.

In the insert plate repair method, rectangular and square insert plates of 20 mm thickness shall have corners rounded to a minimum radius equal to:

a. 3 times insert plate thickness i.e 60mm

b. 6 times insert plate thickness i.e120mm

c. 75 mm

d. 150 mm

54.

For Pre-qualified Design, for repair made with “External Weld Overlay to Repair Internal Thinning”, the maximum dimension (L, length along axis) compensated by a circular, oval, or rectangular overlay should not exceed:

a. One-half the nominal outside diameter of the component

b. 200 mm (8 in.)

C. Lesser of one-half the nominal outside diameter of the component or 200 mm (8 in.)

d. Higher of one-half the nominal outside diameter of the component or 200 mm (8 in.)

55.

In the “Fillet Welded Patches with Reinforcing Plug Welds” repair method, the Plug welds may be designed to take up to———– of the patch plate load.

a. 50%

b. 25%

C. 100%

d. 30%

Question 1 of 55

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In this Practice Test, we are covering all the topics with questions and answers given in the list below:

Article 201: Butt-Welded Insert Plates
Article 202: External Weld Buildup for Internal Thinning
Article 209: Alternatives to PWHT
Article 210: In-Service Welding on CS Components
Article 211: Weld Buildup, Weld Overlay & Clad Repairs
Article 304: Flaw Excavation & Weld Repair

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