API 510 Repair and Alteration Standards 5 — Questions and Answers
Question 1: Which ASME code section provides the rules used by the National Board 'R' stamp repair organization when repairing a pressure vessel?
- ASME Section VIII, Division 1 or 2 (original construction code) (Correct answer)
- ASME Section I (Power Boilers)
- ASME B31.3 (Process Piping)
- ASME Section V (NDE methods only)
Correct answer: ASME Section VIII, Division 1 or 2 (original construction code)
Repairs must conform to the rules of the original construction code (typically ASME Section VIII Div. 1 or 2), as referenced by the NBIC.
Question 2: Weld procedure qualification for pressure vessel repair requires the welding procedure specification (WPS) to be supported by:
- Procedure Qualification Records (PQRs) demonstrating mechanical test results (Correct answer)
- Only welder performance qualifications
- The foreman's written approval and visual inspection results
- Material certifications alone
Correct answer: Procedure Qualification Records (PQRs) demonstrating mechanical test results
A WPS must be supported by PQRs that document mechanical test results proving the procedure produces welds meeting code requirements.
Question 3: What is the key engineering difference between a 'repair' and an 'alteration' of a pressure vessel under API 510?
- A repair restores original design conditions; an alteration changes the vessel from its original design intent (Correct answer)
- A repair requires stamping; an alteration does not
- An alteration is always a minor change; a repair is always major
- There is no difference — both terms are interchangeable in API 510
Correct answer: A repair restores original design conditions; an alteration changes the vessel from its original design intent
A repair returns the vessel to a safe operating condition within its original design parameters, while an alteration changes the design basis, rating, or configuration.
Question 4: A vessel owner wants to install an additional nozzle on an existing pressure vessel. This activity is classified as a(n):
- Alteration, requiring engineering design, documentation, and jurisdiction notification (Correct answer)
- Routine repair requiring only an R-stamp organization
- Minor maintenance requiring no documentation
- Non-code activity because the vessel already exists
Correct answer: Alteration, requiring engineering design, documentation, and jurisdiction notification
Adding a nozzle changes the vessel from its original construction and is classified as an alteration under API 510 and the NBIC.
Question 5: When establishing a weld repair procedure for a P-No. 4 (Cr-Mo) steel vessel, a critical requirement is:
- Preheat and PWHT per the applicable code to prevent reheat cracking and restore toughness (Correct answer)
- Welding at the lowest possible heat input to avoid distortion
- Using only gas tungsten arc welding (GTAW) for all passes
- Keeping the interpass temperature below ambient to accelerate cooling
Correct answer: Preheat and PWHT per the applicable code to prevent reheat cracking and restore toughness
P-No. 4 Cr-Mo steels require carefully controlled preheat, interpass temperature, and PWHT to prevent HAZ cracking and restore creep properties.
Question 6: According to API 510 and the NBIC, after completing an alteration on a pressure vessel, the alteration organization must notify:
- The jurisdiction (state or local authority) and the authorized inspection agency (Correct answer)
- Only the vessel owner/user with no external notification
- ASME headquarters for re-stamping
- Only OSHA if the vessel is in a regulated process
Correct answer: The jurisdiction (state or local authority) and the authorized inspection agency
The alteration organization must notify the jurisdiction and the authorized inspection agency so the required inspections and documentation can be completed.
Question 7: A half-pipe heating jacket on a pressure vessel is severely corroded and must be replaced. The replacement jacket must be designed and constructed to:
- The applicable ASME pressure vessel code for external pressure or the jacket pressure rating (Correct answer)
- No pressure code because jackets are not pressure-containing
- Any available pipe schedule that physically fits
- ASME B31.1 piping code requirements only
Correct answer: The applicable ASME pressure vessel code for external pressure or the jacket pressure rating
Half-pipe jackets are pressure-containing and must be designed and constructed to the applicable pressure vessel code for the jacket operating conditions.
API 510 Repair and Alteration Standards 5
Which ASME code section provides the rules used by the National Board 'R' stamp repair organization when repairing a pressure vessel?