BOON INDIA

API 510 CALCULATIONS - 2023

1. A vessel is inspected after a four year of service and the thinnest part of
the shell is found to be 1.360 in (34.5 mm). If the original thickness was
1.438in. (35.5 mm) and the minimum required thickness is 1.232in (31.3
mm) what thickness of material is available for the remaining corrosion
allowance:

a. 0.064in.
b. 0.078in.
c. 0.128in.
d. 0.206in.

2. After being in service for 5 year a 14ft. seamless vertical vessel has a
measured thickness of 0.82in. (20.8 mm) over the entire length of the
cylindrical shell. The measure inside diameter is 38.13 in. (968.5 mm).
the material of construction was originally 0.875in.(22.2mm) thick with
an allowable stress of 17500 psi (120.6 MPa) was fully radiographed and
was design for a pressure of 600psi(4.13MPa), including static head.
Assuming a corrosion rate of 0.018 in/yr.(0.4572 mm/yr) and a required
thickness of 0.545in.(13.8 mm), what is the interval for the next internal
inspection?

a. 7.6 years.
b. 5 years.
c. 9.1 years.
d. 10 years.

3. What is the remaining life of a vessel corroding at a rate of 0.017in (0.432

mm) a year? When the last inspection measurement was 0.638in (16.205
mm) and the minimum required thickness is 0.513 in (13.030mm).

a. 3.67 year.
b. 7.35 year.
c. 10 years.
d. 14.7 year.

4. A vessel has an actual thickness of 0.500 in (12.70mm) an original

thickness of 0.606in (15.37mm) and a minimum required thickness of
0.425in (10.80mm). The vessel is corroding at 0.015 in/year (0.380
mm/year). What is the remaining life of the vessel?

a. 2.5 years.
b. 5 years.
c. 6 years.
d. 12 years.
5. A vessel has a measured head thickness of 0.875 in (2202mm) and a
required thickness of 0.563 in (14.3 mm). If the corrosion rate is 0.019
in/yr (0.4826 mm/yr) what is the interval for the next internal inspection
of the vessel.

a. 4.1 years.
b. 8.2 years.
c. 10.0 years.
d. 16.4 years.

6. Three pressure gauges are installed for convenience in the hydrostatic

testing of a vertical pressure vessel which is 125 feet in overall length.
The first gauge is installed 45 feet from the top and read 169.5 psig. The
second gauge is 100 feet from the top end read 193.3 PSI (1.334 MPA )
What is the pressure of the gauge installed at the vessel top? (Static
head for 1feet of water = 0.433 PSI ).

a. 140 psig (0.96 MPa).

b. 150 psig (1.03 MPa).
c. 189 psig (1.03 MPa).
d. 204 psig (1.40 MPa)

7. DELETED.

8. A CS pressure vessel was built in 2003 (ASME VIII D1 2001 Edition and
add 2002 and 2003) and was repaired and given a re-hydro test in 2010.
The Design pressure is 130 psi and MAWP is 150 psi , Allowable Stress
at design temp 750°F is 14800 psi and Allowable stress at testing temp is
17500 psi, what is the hydro test pressure to be given to the vessel?
(MDMT is 20°F and the required thickness is 1 inch)

a. 230.57 psi.
b. 199.83 psi.
c. 142.9 psi.
d. 164.9 psi.

9. A pressure vessel having joint efficiency as 0.85 was found to be having

corrosion near the longitudinal weld joint. The thickness of pressure
vessel is 3 inches. The corrosion was found at a distance of 5 inches on
one side and 6 inches on the other side from the toe of the weld. How
you will approach for analysing the situation as per API 510?

a. Calculate the thickness required with E = 1 and proceed.

b. Calculate the required thickness with E = 0.85 and proceed.
c. Calculate the required thickness with E = 0.70 and proceed.
d. Calculate the required thickness with E = 0.65 and proceed.
10. When a pressure vessel remaining life is 1.5 years, the internal or on-
stream inspection Interval may be a maximum of:

a. Full remaining life (1.5 years in this case).

b. A maximum of 3 years in this case.
c. A maximum of 2 years in this case.
d. Only ½ of the vessel’s remaining life (0.75 years in this case).

11. For a pressure vessel in non-continuous service (operates only 6

months in every year & placed under a nitrogen purge each time after
being idled), what are the maximum possible internal & external
inspection intervals (assume NO RBI & calculated remaining life = 30
yrs)?

a. Internal inspection interval = 10 calendar yrs & external inspection interval

= 5 calendar yrs.
b. Internal inspection interval = 15 calendar yrs & external inspection interval
= 10 calendar yrs.
c. Internal inspection interval = 20 calendar yrs & external inspection interval
= 5 calendar yrs.
d. Internal inspection interval = 30 calendar yrs & external inspection interval
= 10 calendar yrs.

12. If vessel entry is physically possible, on-stream inspection may possibly

be substituted for internal inspection if approved by Inspector &
corrosive character of contents has been established by (how many)
years of same or similar service:

a. At least 1 year.
b. At least 2 years.
c. At least 3 years.
d. At least 5 years.

13. After 10 years of being in service, a vessel is inspected and the thinnest
shell section is found to be 1.250 inch (31.75 mm). If the original
thickness was 1.275 and the required thickness is 1.125 inch (28.57 mm),
what thickness of material is available for corrosion allowance?

a. 0.125”.
b. 0.15”.
c. 0.0025”.
d. 0.75”.
14. A vessel has a single corrosion-rate of 0.020” per year (0.508 mm/yr).
The required thickness for the shell and heads is 0.750 inch (19.05 mm).
The actual thickness of the head is 0.875 inch and shell is 0.900 inch.
What is the remaining life of the vessel?

a. 7.5 years.
b. 6.25 years.
c. 5.0 years.
d. 6.75 years.

15. A vessel with a required thickness of 0.375” that operates at 60°F at 300
psig was placed in service in July 1, 1996. Thickness readings taken
prior to placing this vessel in service indicated a thickness of
0.725”.Thickness data taken January 25, 2006 indicated a thickness of
0.464”. What should the external inspection interval be?

a. 3.3 years.
b. 1.6 years.
c. 5 years.
d. 10 years.

16. A vessel that has a remaining life calculated from the thickness data
taken March 2010. The remaining life of the vessel is 7 years. What is
“next External inspection date”?

a. 3.5 years.
b. 1.75 years.
c. 5 years.
d. 7 years.

17. A recent inspection discovered isolated pitting in the vessel wall.

Minimum required wall thickness is 1.250”. Current thickness of the
vessel is 1.625”. What is the minimum allowed remaining thickness
allowed at the deepest pit?

a. 0.375”.
b. 1.0”.
c. 0.625”.
d. 0.8125”.

18. A vessel CML readings of a pressure vessel are as follows.

 October 1 2010 – 0.430”, 0.420”, 0.435”.

 August 30 2014 _ 0.395”, 0.400”, 0.385”
 February 28 2018 _0.335”, 0.340”, 0. 330”.
What is the long term and short term corrosion rate of the CML?
a. 0.0157” and 0.012” / year.
b. 0.012” and 0.012” / year.
 c. 0.012” and 0.0157” / year.
d. 0.0157” and 0.0140” / year.

19. A vessel Torispherical head is found to severely corroding during

thickness measurement inspection. The vessel outside diameter is 70
inches and the corroded area is located 24 inch from the head centre.
Which head formula should be used for calculating the minimum
required thickness of the head and what should be the L value to be
used in the formula?

a. Torispherical formula and L = 35”.

b. Torispherical formula and L = 70”.
c. hemispherical formula and L = 70”.
d. hemipherical formula and L = 56”.

20. What is the minimum distance required between two fillet welded
patches if inside radius of the vessel is 40 inches and original thickness
of the vessel is 1.0 inch and actual thickness is 0.75”. The fillet weld
patch thickness is 0.85”.

a. 23.32”.
b. 21.90”.
c. 25.29”.
d. 40.0”.

21. What should be the minimum thickness of repair weld if repair depth
0.500 inch, Base metal thickness is 0.75”, Base metal tensile strength is
70,000 psi and filler metal tensile strength is 60,000 psi?

a. 0.428”.
b. 0.58”.
c. 0.875”.
d. 0.64”

22. Calculate estimated inspection period for external and internal

inspection for a vessel whose remaining life is estimated as 12 years.

a. Internal = 6 years, external = 10 years

b. Internal = 6 years, external = 5 years
c. Internal = 5 years, external = 10 years
d. None of the above.

23. What will be total thinning (metal loss) up to next inspection due which
is after 10 more years if Corrosion rate is 6 mills per year (mpy).

a. 0.05 inch
b. 0.06 inch
c. 0.006 inch
d. 0.6 inch.
24. Calculate the remaining life and external insp. interval of a vessel given
the following data:
 Actual thickness = 0.955 inch
 Minimum thickness required = 0.755 inch
 Thickness at previous inspection 5 years prior to present
inspection = 1.025 inch

a. 20 years, 10 years
b. 14 years, 5years
c. 28 years, 10 years
d. None of the above.

25. A pressure vessel of 60” has three pits within a circle of 8” diameter. The
nominal thickness of the shell is 0.75” and the CA is 0.125”. The details
and dimensions of the pits are listed below.
Your assessment is:
 0.475” x 0.385” depth 0.21”
 1” diameter depth 0.35”
 0.375” x 0.385” depth 0.23”

a. The pit area is more than the acceptable

b. The pit length is more than the acceptable
c. The pit depth is more than the acceptable
d. The pits are acceptable as they are meeting the requirement.

26. A pressure vessel was placed into service in 1989 and was constructed
with a thickness of 0.750”. In 2001 the wall thickness was measured at
0.630”. Based on this information and a minimum thickness of 0.550”,
when is the next internal inspection due to this pressure vessel?

a. 4 years
b. 2 years
c. 8 years
d. 10 years.

27. A pressure vessel is currently 0.370” thickness 10 years from now the
vessel is scheduled to be inspected again. The stress is 17,100 psi and
the vessel is stamped RT-2 with Type 2 longitudinal weld seams. The last
thickness measurements (5 years ago) reflected that the vessel was
0.407” thick. If the vessel is 72” ID and the corrosion rate is expected to
continue, what MAWP should be allowed on the vessel per API 510 Para
6.4? P = SET/ (R+0.6T)

a. 94.5 psi
b. 150 psi
c. 180 psi
d. 200 psi.
28. A vessel is ultrasonically checked on the shell in 1990 and is 0.637”
thick. This same spot is checked again in 1996 and is 0.607” thick. It is
on-stream inspected again in 1999 and is 0.509” thick. What is the
remaining life of this vessel if the minimum required thickness is 0.411”
thick?

a. 1.5 years
b. 2.7 years
c. 3.0 years
d. 6.4 years.

29. A pressure vessel installed in January 1993 had an initial thickness of

0.32 inch. In Jan 2004, a thickness of 0.20 inch was recorded just prior to
a change of service on the pressure vessel system .The thickness
measurement in Jan 2009 was 0.18 inch. The retirement thickness of
0.15 inch will be met in:

a. January 2012
b. June 2016
c. January 2015
d. January 2039.

30. A new replacement vessels maximum allowable working pressure is 150

psi.at 300°F.the allowable stress is the same at this temperature as the
hydrostatic test temperature. The operating pressure is 140psig
( 0.96MPa).the minimum design metal temperature is 20°F (-6.6C ).the
appropriate post fabrication hydrostatic test pressure is:

a. 128 psig.
b. 195 psig.
c. 210 psig.
d. 225 psig.