Api 570 book pdf free download

They are all actual measured readings:. Think of this as the last inspection that was actually done. The timescale in Fig. Look at table in your copy of API see Fig. The other terms and words used should be self- explanatory. Figure 3. Note, how- ever, the new acronym in this section.

We will see it appearing regularly in the ASME codes:. Section 8. Re-rating of piping systems is perfectly allowable under the requirements of API , as long as code compliance is maintained. In the USA, the API authorized inspector is responsible for re-rating the pipework, once happy with the results of thickness checks, change of process conditions, etc.

This means above the ground level, i. Holiday survey in section 9. A high voltage 20 kV or more is applied across the coating and any pinholes or cuts show up as a stream of sparks.

Hence it is also sometimes called a spark test. These changes are usually small. You can track down the answers from the code section given in the question. API section 3. Section 6. Section 7. Table of API is based on which concept? At the same time the MAWP of the entire system is being increased owing to changed process conditions.

Is this situation classed as? It is a code that is strongly linked to API and, in some areas, contains some of the same information that appears in API API is divided into twelve sections sections 1 to 12 and one single-page appendix.

The body of the text i. The API examination body of knowledge requires candidates to have knowledge of effectively all of the twelve sections. In layout, API is a heavily unbalanced code; i. The only way to approach API is from a section-by- section viewpoint, to build a general understanding of its content.

The best way of doing this is by reading important sections of the document and then attempting questions on the content. In section 4. The different types of valves in section 4. You need to be able to recognize them, not draw them. There are no drawing questions in the API exam.

API section 4. API table 3: ferritic pipe tolerances What is the normal acceptable thickness under-tolerance on wall thickness for A plain carbon steel pipe up to NPS 48? The use of corrosion circuits to help manage the inspec- tions, calculations and record keeping relating to piping inspection.

Note how twelve of them are repeats from a similar list in API Then look at these important topics in API section Thickness measurements: section Concentrate on the explanations of the limitations of UT measurement techniques.

Radiographic inspection: section This gives a brief summary of the types of RT techniques that can be useful in piping inspection. Pressure tests: section This explains the reason for pressure testing and some of its limitations. API section API section 6. API is divided into seven sections sections 1 to 7. This means that, unlike for some of the codes, all of the sections of API are covered in the syllabus.

Historically, ASME and API codes for pressure equipment and many other things as well have made little reference to material traceability. There is an ASTM standard on material traceability but it does not have particularly wide use. Note, however, that it adopts a different approach from EN Note the following points:. Physically these materials look very similar unlike stainless steel which looks different so mix-ups are perhaps more likely.

The main ones are:. In this technique, gamma rays excite the material, causing it to emit X-rays. These are analysed, indicating the elements present in the material. Emission spectrometry. Here, an electric arc stimulates the atoms in the material. The emitted spectrum shows which atoms are present. API section 1. Here they are in Fig. Remember that these are all DMs that are found in the 1. Brittle fracture 2. Thermal fatigue 3. Erosion—corrosion 4. Mechanical fatigue 5. Vibration-induced fatigue 6.

Atmospheric corrosion 7. Corrosion under insulation CUI 8. Boiler condensate corrosion 9. Flue-gas dewpoint corrosion Microbiological-induced corrosion MIC Soil corrosion SCC Caustic embrittlement The list contains a mixture of high- and low-temperature DMs, some of which affect plain carbon steels more than alloy or stainless steels and vice versa.

There are also various subdivisions and a bit of repetition thrown in for good measure. None of this is worth worrying about, as the order in which they appear is not important. In order to make the DMs easier to remember you can think of them as being separated into three groups. Figure 6. One important feature of API is that it describes each DM in some detail, with the text for each one subdivided into six subsections. These six subsections are important as they form the subject matter from which the API examination questions are taken.

As there are no calculations in API , and only a few graphs, etc. The questions could come from any of the six subsections shown in Fig. Note how these DMs tend to be environment-related. Remember to identify the six separate subsections in the text for each DM.

Again, remember to identify the six separate subsections in the text for each DM, trying to anticipate the type of examination questions that could result from the content. This module will also introduce you to the API RP Welding inspection and metallurgy in your code document package.

This document has only recently been added to the API examination syllabus. As a Recommended Practice RP document, it contains technical descriptions and instruction, rather than truly prescriptive requirements. Shielded metal arc welding SMAW. Gas tungsten arc welding GTAW. Gas metal arc welding GMAW. There is a wide choice of electrodes, metal and fluxes, allowing application to different welding conditions.

The gas shield is evolved from the flux, preventing oxidation of the molten metal pool Fig. An electric arc is then struck between a coated electrode and the workpiece. SMAW is a manual process as the electrode voltage and travel speed is controlled by the welder. It has a constant current characteristic.

Figure 7. The electrode is therefore consumed, being fed from a motorized reel down the centre of the welding torch Fig. GMAW is known as a semi-automatic process as the welding electrode voltage is controlled by the machine. Filler metal is provided from a separate rod fed automatically into the molten pool Fig. GTAW is another manual process as the welding electrode voltage and travel speed are controlled by the welder.

Submerged arc welding SAW In SAW, instead of using shielding gas, the arc and weld zone are completely submerged under a blanket of granulated flux Fig. A continuous wire electrode is fed into the weld.

It is usually automatic, with the welding head being mounted on a traversing machine. Long continuous welds are possible with this technique. The advantage of the technique is that it can be used for outdoor welding, as the gas shield is less susceptible to draughts.

We can break these down into the following three main areas:. Filler wires, rods, flux-coated electrodes. Flux granular fluxes. Figures 7. API section 5. API sections 5. API is for in-service inspection of process piping and therefore most welding carried out will be repair welds, rather than welds carried out on new systems.

Much of API is also concerned with the repair of corroded areas and on-stream systems hot tapping where process fluid is still being carried through the piping. API section 8. In practice, this will only be for areas that do not directly conflict with API requirements. The welding requirements are laid down in B We will also look later at the inspection requirements including accep- tance criteria that are laid down in B In essence, many areas of welding and inspection are common to both codes with only a few areas that differ between codes.

This means that, in practice, most repair welding on pipework is done in accordance with the requirements of ASME B Read through this carefully. The clause numbers match those in the code. Note that there are two sections to look at: section 8 and appendix C. Note that he will only authorize alteration work after gaining approval from the piping engineer. As a general principle, the inspector may give prior authorization for fairly straightforward, limited or routine repairs to compe- tent repair organizations, providing he is happy that they are competent.

The inspector or piping engineer if more appropriate must approve all aspects of the repair. The inspector can approve repairs at designated hold points. The piping engineer must be consulted before in-service cracks are repaired. The coupling or patch is properly designed. The material matches the base material. Repairs should be replaced at next available maintenance opportunity unless an extension is approved and documented by the piping engineer.

Note, however, the three requirements for this:. Full penetration groove welds have to be used. The inserts must have rounded corners with a minimum 1 in 25 mm radius.

The reason for the difference between cold repair welding and hot tapping is that welds on systems in operation can be very dangerous due to the process fluid still being present. There is also the risk of burning through the pipe and igniting the process fluid, with catastrophic results if it is a flammable gas or liquid. Preheat can also be used on other steels at the discretion of a piping engineer after consideration of environmental cracking risk mainly meaning stress corrosion cracking and toughness impact strength.

In this technique heating bands are wrapped around the workpiece. Local PWHT may be substituted for banding if:. A procedure is developed by the piping engineer. All relevant factors such as material thickness and properties, NDE, weld joint, welding stresses and distor- tions, etc. The required PWHT temperature is maintained at least two material thicknesses 2t from the weld and monitored by a minimum of two thermocouples. Controlled heating is applied to a branch or attachments within the PWHT area.

The PWHT is for code compliance and not environmental cracking resistance. Butt joints have to be full penetration groove welds. API appendix C: repairs One of the most important points here is the welding processes that are allowed to be used for repairs. These processes were explained previously.

Small repair patches should not exceed 12 pipe diameter in any direction. Avoid weaving weld beads when using low-hydrogen electrodes. All welds shall be done in accordance with a WPS.

Cracked tack welds shall be removed. Bridge tacks will be removed. Welding must be protected from the weather. Check the following areas in your code:. Figures One point worth noting is that if a reinforcing pad or saddle is used then a vent hole must be provided at the side not the crotch to:. Note: repairs here relate to initial fabrication repairs and not in-service repairs. In fact preheat also retards the cooling rate of the material, and so helps its mechanical properties.

Some key points are as follows: B The WPS will include the heat treatment requirements. The hardness limit applies to weld metal and HAZ close to the weld. This includes the weldment and an area extending 1 in 25 mm beyond the ends.

It goes on to say section Consumable insert suitability. Step 1: qualify the WPS. A preliminary WPS this is an unsigned and unauthorized document is prepared specifying the ranges of essential variables, supplementary variables if required and non- essential variables required for the welding process to be used. The required numbers of test coupons are welded and the ranges of essential variables used recorded on the PQR. Figure 9. The WPS see Fig.

This is because it is the skill of the welder and his ability to follow a procedure that is being tested. The code section splits the variables into three groups:. Essential variables. Non-essential variables. Supplementary variables These are listed on the WPS for each welding process.

Note how this is a very long section of the code, consisting mainly of tables covering the different welding processes. There are subtle differences between the approach to each process, but the guiding principles as to what is an essential, non-essential and supplementary variable are much the same. Remember that the actual format of the procedure sheets is not mandatory, as long as the necessary information is included.

The review will be subject to the following limitations to make it simpler for you :. Remember that this annex B is not contained in your code document package; instead, you have to look at the formats in API appendix B, where they are shown they are exactly the same.

The open-book questions on these documents in the API exam, however, only contain one of those welding processes. This means that there will be areas on the WPS and PQR documents that will be left unaddressed, depending on what process is used.

In the exam questions, you will need to understand the variables to enable you to determine if they have been correctly addressed in the WPS and PQR for any given process. What it does do, however, is cross- reference a lot of other clauses particularly in article IV , which is where the more detailed technical requirements are contained.

From the API exam viewpoint, most of the questions that can be asked about article I are:. Read the following summaries through carefully but treat article I more as a lead-in to the other articles, rather than an end in itself.

There should be nothing new to you here. They are:. The WPS must address the essential and non-essential variables for each welding process used in production. The WPS must address the supplementary essential variables if notch toughness testing is required by other code sections. Tension tests are used to determine the strength of groove weld joints. Guided-bend tests are used to determine the degree of soundness and ductility of groove-weld joints.

Tests are used to determine the notch toughness of the weldment. In common with article I, it cross-references other clauses particularly in article IV.

From the API examination viewpoint there is much more information in here that can form the basis of open-book questions, i. Where can the complete list of variables be found? Which of the following statements is true? Note how variables are subdivided into procedure and performance aspects. QW joints. QW base metals. QW position. QW preheat. QW postweld heat treatment. QW gas. QW electrical characteristics. This grouping of materials allows a reduction in the number of PQRs required.

Ferrous P- number metals are assigned a group number if notch toughness is a consideration. There is no mandatory require- ment that S-numbers have to be used, but they often are. Note these two key points:. QW F-numbers F-number grouping of electrodes and welding rods is based essentially on their usability characteristics.

Note the two governing principles of API examination questions in this subject:. You need only consider essential and non-essential variables you can ignore supplementary variables. Note the following points to remember as you go through the checklist steps of Fig. This table shows the relevant essential and non-essential variables for the welding process.

Check that all the relevant essential variables are addressed on the PQR and highlight any that are not. Check that all the relevant essential variables are addressed on the WPS and highlight any that are not. Check that all the relevant non-essential variables are addressed on the WPS and highlight any that are not. STEP 5: number of tensile and bend tests. Check that the correct type and number of tensile and bend tests have been carried out and recorded on the PQR.

Figures 9. Typical questions are given, followed by their answer and explanation. Step 1: variables table Q1. Therefore the brief of variables used will be those in table QW Look at table QW and check the brief of variables for base metals QW Note that QW Therefore the base material thickness must be addressed on the PQR.

When we read QW The correct answer must therefore be c. Therefore the weld metal thickness must be addressed in the PQR. The correct answer must therefore be d. WPS Check of consumable type. The correct answer must therefore be a.

WPS Preheat check. The correct answer must therefore be b. PQR Check of tensile test results. On reading this section you will notice that it directs you to the tension test acceptance criteria in QW For API exam purposes the bend tests will be transverse tests. Note these important sections covering bend tests:. QW gives acceptance criteria for bend tests.

QW contains PQR thickness limits and test specimen requirements. Check of test specimen requirements. QW contains the PQR thickness limits and test specimen requirements. The correct answer is therefore c. Essential variable QW If it is optionally shown on the PQR it needs to be checked to make sure it is correct. In this case the position shown refers to the test position of the plate, rather than the pipe.

This means it is a non- essential variable and is not required in the PQR but can be included by choice remember. High C. Negative D. Positive Answer: A. MAWP B. Yield C. Creep range D. Critical Answer: B. More B. Less C.

Usually D. Not Answer: A. Question No : 11 Many thermal fatigue cracks are filled with: A. Answer: C. Question No : 13 Heat treatment can have a significant effect on the toughness and hence fatigue resistance of a metal.

Fine, Course B. Austenetic, martensitic C. Course, Fine D. Martensitic, austenetic Answer: A. Sulfide stress cracking B. Hydrogen stress cracking C. Caustic stress cracking D. What classification does the majority of unit process piping fall into?

CLASS 3 b. CLASS 2 c. CLASS 1 d. API b. API c. API RP d. ASME B Others b. The employer c. The use of AWS prequalified, D1. The use of API qualified procedures. A weld is changed from multipass per side to single pass per side. How does this effect the PWHT limitation? The PWHT is not a consideration d. Besides ultrasonic instruments, what other method can be used to determine thickness measurement a. AET b. Welding b. Compression c. Epoxy resin d. Bell and spigot. Buried piping inspected periodically by excavation shall be inspected in lengths of a.

Any length as long as it is inspected full circumference d. In a piping circuit, which of the following does not routinely have thickness measurement taken?

Valves b. Straight Run Pipe c. Fitting d. What is the maximum measurement for open defects in the weld or heat affect zone for a guided bend specimen? No open defects are allowed. What is a thermocouple pyrometer? A device used to check the heat treatment temperature, usually connected by capacitor discharge welding b.

A device taped to the pipe that will record temperature variations c. A flammable material that, when ignited, will create enough heat to stress relieve piping d. A vibration device that generates heat through friction producing a stress relived weldment.

What is the acceptable method to temporarily repair a longitudinal crack in an existing piping system? Installing a full encirclement welded split sleeve b. Welding over the crack c. Welding a box over the cracked area d. Using a full encirclement welded split sleeve, with the approval of the piping engineer. Erosion of the piping system usually occurs at a. Elbows b. Along straight run pipe c.

Upstream of pump discharges d. Any low-velocity and low-turbulence areas. An operator notices a pipe off its support, what should be done? Ignore the situation b.

Report the situation to engineering or inspection personnel c. Keep a record or the situation for future reference d. Contact maintenance personnel for immediate repair. When heat treating welded joints between dissimilar ferritic metals, the temperature range shall be for which metal? The one with the higher temperature range b. The one with the lower temperature range c.

The average of both materials d. Either one may be used. Two threads past their nuts b. Completely through their nuts c. Only half way through their nuts d. At least. The piping engineer or the inspector b.

The plant manager. An out-side engineering firm d. A third party inspection organization. There is no limit to temperature. Where the number should be placed on a radiograph? Under the film. On the material being radiographed. Under the material being radiographed. On the film source pack.

Radiographic profile techniques are preferred over ultrasonic thickness measuring instruments for pipe diameters of : a. NPS 1 and over b. NPS 2 and over c. NPS 1 and under d. NPS 2 and under. Class 3 b. Class 2 c. Class 1 d. Welder b. PQR c. NACE d. What is the most common problems in FRP pipes can be a.

Poor construction practice b. UV degradation c. Use of wrong corrosion barrier d. An API certification b. An API certification d. Not less than 10 years experience dealing with piping. Inspector b. Piping engineer c. Repair organization d. The purchasing department. To determine if back scatter radiation is exposing the film b. To show the distance from the source of radiation to the weld c. To function as a location marker for the radiograph d.

To designate whether the penetrameter is on the film side or the back side. Show complete joint penetration and complete fusion of weld metal and base metal. Of the following examples, which one may cause a leak in a threaded joint?

Back — welded the fitting b. Lack of thread lubricant c. Under — pressuring the part d. Changing the direction of flow in the piping system. Source b. Film c. Weld d. What is the maximum thickness measurement inspection interval for an injection point? By class. Piping engineer b. Inspector c. Applicable standard, API d. Repair procedure. Using the same welding process within the limits of the essential variables b.

Any other qualified weld procedure c. Using a different welding process of a qualified weld procedure d. Required piping thickness b. Maximum piping thickness c. Actual piping thickness d. Average piping thickness. What document may be used as a guide when examiners are being qualified their employer?

API Pressure , mechanical and structural considerations b. Previous experience of the owner c. Corrosiveness of the product only d. Availability of the piping materials.

What is the prescribed alignment for the inside surfaces of circumferential welds to be groove welded a. Within the dimensional limits in the WPS d. Why should a leaking threaded joint not be tightened while the system is in service? The craftsman should not be near the threaded connection b. Rust or corrosion might be holding the pressure c. The joint might be unscrewed d.

A crack in a thread root might fail. Prior to the start of welding b. Any time during welding c. After completion of welding d. When the repair organization releases the information. A transverse crack was discovered in the root pass of a completed weld on the outside of a Category D Fluid Service piping system during a PT test.

Which of the following statement is most accurate? The weld is acceptable b. The PT test should be repeated c. The welder should be requalified d. The PT test will not show this type of discontinuity from the outside. Choose the wrong option: The Nipples size is usually a. Above than 8 inch c. It is a form of SBP. Allow any inert gas into the system b. Use water in the system c. Over-pressure the system d. Under-pressure the system. API,Section 1 d. An area defined by a circle having a diameter not greater than 2 inches for a line diameter not exceeding 10 inches, in which thickness readings may be averaged is; a.

TML b. WFMT c. Test point d. Averaging point. Internal discontinuities of a weld b. Surface discontinuities of a weld c. Both internal and surface discontinuities of a weld d.

Subsurface discontinuities of a weld. ASME B When an entire piping assembly is to be treated, but it will not fit into the furnace , what action should be taken? Heat treat as much as possible and hardness test the untreated area c.

Radiograph the untreated area d. MT the untreated area. What is the maximum allowable deviation for the ammeter on each piece of magnetizing equipment? The joint is leaking b.

The joint has straight threads only c. The joint has tapered threads only d. All exposed threads are covered. Radiograph shall be considered unacceptable. Radiograph should not be rejected c. All piping systems repair and alteration welding shall be done in accordance with: a. ASME B- 3. A piping system started with a wall thickness of. Over a five year period the wall thickness is now. Given the above information, what is the short term corrosion rate of the above piping system?

When testing cast iron pipe, which of the following methods should not be used? Radiographic test b. Leak test c. Ultrasonic testing d.

Hammer test. Lower levels of soil resistively are: a. Less corrosive than higher resistivity soils. More corrosive than higher resistivity soils c. Has no effect on corrosion. More desirable because of increased electrolyte. When may welding not be performed? If the weld area is frosted or wet b. If the weld area above F c. If the weld area is in an inert atmosphere d.

If the weld area is not in direct sunlight. Code allowable stress b. Assumption stress c. Nil-weight ductility stress d. CTOD stress. Removed b. Ground flush, with grinding direction parallel to the weld c. Ground flush, with grinding direction perpendicular to the weld d. Removed if irregularities mask discontinuities. In lieu of the required heat treatment after welding, what may be used as an alternative? Quenching c. Air Hardening d. Strain Harmonics.

A piping system has a corrosion rate of. What is the remaining life? The inspection shall approve all repair and alteration work at designated times, referred to as a. Hold points b. Work stop points c. Inspection delay points d. Who is authorized to make a tack weld?

A qualified welder b. A helper c. A fitter d. The welding foreman. Corrosion Under Insulation b. Cold Under-ground In-service piping c. Corrosion Under Inside flow d.

Carpet Under Infra-structure. Butter fly valves are used a. High pressure services b. Corrosive service below Deg C c. To prevent the back flow d. Low pressure service for coarse flow control. A calibration of each piece of magnetizing equipment c. At least three separate examinations d. Peening of the weld is prohibited on what part of the weld?

Root and final pass b. Intermediate passes c. Along the toe of the weld d. Creep b. Swing check b. Slide c. Plug d. Cracks caused by vibration, thermal cycling, thermal expansion problems and environmental cracking are considered a. HAZ cracks. Who has the responsibility for qualifying welding procedures? Each employer b. Each subcontractor c. Each welder d. Each contractor. New construction b. New tank construction c.

In-service piping d. In-service vessels. Hammer testing of piping is a common practice; however, which of the following should never be hammered? Cast iron piping b. Caustic piping c. All welded piping d. Both a and b. Aboveground piping is subject to atmospheric corrosion.

What is buried piping subject to? Erosion b. Anodic reaction c. Soil electrolytes d. Soil corrosion. When can welding procedures qualified by other than the employer be used? When there is specific approval of the inspector b.

When the job contract gives authorization c. When the procedure is used only one time d. When the production weld is radiographed. Butt welded b. Brazed c.

Threaded d. Welding repairs of cracks that occurred in-service should not be attempted without prior consultation with the a. Inspector only c. Plant manager d. Welding foreman. Air b. Water c. Inert gas d. Without the benefit of an impact test, what is the minimum operating temperature for A Grade B material used in a Category D Fluid Service? Gate b. Globe d. Ball check. Inspector or piping engineer b. New construction contracts. Where Radiation level is more b. Where the hot tap is being done c.

Critical zone around the leak site d. Zone where pipe temp is more than Deg F. A-c Bridge b. Six pin method c. Holiday pipe survey d. Wenner 4-pin method. S where sulfur content is More than 0. Table QW IX 39 b QW IX 40 b QW V 51 d Apx. A-2, API 52 c Pg. V d. V b. V c Pg. Introduction API a Pg.

IX, B What is the height of the raised face on regularly furnished class Raised Face Flanges? What is the actual remaining corrosion allowance? Which of the following are nonessential variables for SMAW?

Change of electrode b. Change in the groove design c. Change in the PWHT d. Change in the welding process. Quenching b. Normalizing c. Annealing d. Solution heat treatment. Will detect all the defects in a pipe weld b. Can be performed by anyone with little or no training c. Cannot supply a permanent visual record d. Is not an ignition source in the presence of hydrocarbons. Inspector specifically approves b. Piping engineer approves c.

Other employer is subcontractor for the current employer. No open defects allowed. What is the hole type IQI designation if the penetrameter is placed on the source side? In a piping system, The accelerated corrosion occurs a. Because of high velocity of flow b. Because of locations where there is no flow c. Injection points circuits d. All e. What is the minimum thickness of a class NPS 4 blind flange? Wall thickness divided by 3 d. System service; classification ; identification numbers c.

All ASME requirements d. Original heat and batch numbers of the system. The F number of SFA — 5. All of the above. As a part of general maintenance, any repair organization may make repairs to piping system as long as : a. The inspector is satisfied with the competency of the repair organization b. The piping engineer is on site c.

The repair organization has a contract d. Their hourly rate is acceptable. Welder joints in 2. Pearlite structure b. Annealing c. Temper embrittlement d.