NBBI Pressure Equipment Inspector (PEI)

What is Risk-Based Inspection (RBI)?

• AA systematic process that uses risk analysis to prioritize and plan inspections based on…
• BAn inspection methodology based on random selection of equipment
• CAn inspection that only considers the age of equipment
• DA method that eliminates the need for periodic inspections

In Risk-Based Inspection, risk is defined as the combination of which two factors?

• AProbability of failure and consequence of failure
• BCost and schedule
• CAge and pressure
• DTemperature and thickness

What standard provides the methodology for fitness-for-service assessments of pressure equipment?

• AAPI 579-1/ASME FFS-1
• BASME Section I
• CASME Section V
• DNFPA 70

What are the three assessment levels in API 579-1/ASME FFS-1?

• ABasic, intermediate, and expert levels based on inspector experience
• BLevel 1 (screening), Level 2 (standard engineering evaluation), and Level 3 (advanced ana…
• CLevels based on pressure rating: low, medium, and high
• DAssessment levels based on vessel size: small, medium, and large

What is creep damage, and at what approximate temperature does it become a concern for carbon steel?

• AMechanical wear — occurs at all temperatures
• BTime-dependent plastic deformation under stress at elevated temperature — becomes signifi…
• CChemical corrosion — occurs below 200 degrees F
• DFatigue cracking — occurs only at cryogenic temperatures

What are the three stages of creep?

• AInitiation, propagation, and failure
• BHeating, soaking, and cooling
• CElastic, plastic, and fracture
• DPrimary (decreasing rate), secondary (steady-state rate), and tertiary (accelerating rate…

What is fatigue damage in pressure equipment?

• AGradual material softening at high temperatures
• BGradual buildup of scale deposits
• CCorrosion caused by fatigue in the operator
• DProgressive and localized structural damage that occurs when a material is subjected to c…

What is hydrogen damage in pressure vessel steels, and what are the primary mechanisms?

• ADamage from hydrogen fuel combustion
• BMechanical wear from hydrogen gas flow
• CCorrosion from acidic hydrogen peroxide
• DDegradation of steel caused by hydrogen at elevated temperatures or under cathodic chargi…

What is stress corrosion cracking (SCC), and what three conditions must be present simultaneously?

• ACracking from mechanical overload only — no specific conditions required
• BCracking from the simultaneous presence of a susceptible material, a specific corrosive e…
• CCracking caused only by high temperature
• DCracking that occurs in all materials under any conditions

What is erosion, and how does it differ from corrosion?

• AThere is no difference
• BErosion only occurs in piping
• CErosion is slower than corrosion
• DErosion is mechanical removal of material by impingement of solid particles, liquid dropl…

What is Phased Array Ultrasonic Testing (PAUT)?

• AAn advanced UT technique using an array of transducer elements that can be electronically…
• BA method using multiple X-ray sources simultaneously
• CA visual examination technique using phased lighting
• DA magnetic particle testing enhancement

What is Time-of-Flight Diffraction (TOFD)?

• AA method for measuring the flight time of aircraft
• BAn advanced ultrasonic technique that uses the diffraction of ultrasonic waves from crack…
• CA radiographic technique for thin materials
• DA visual examination enhancement

What is Acoustic Emission Testing (AE)?

• ATesting the noise level in the boiler room
• BTesting the acoustic properties of insulation
• CA method for testing safety valve set pressure
• DA passive NDE technique that detects stress waves emitted by materials under load, indica…

What is the purpose of corrosion rate calculation in pressure equipment inspection?

• ATo predict remaining equipment life, establish inspection intervals, and determine when w…
• BTo determine the cost of replacement materials
• CTo calculate the rate of chemical reactions in the process fluid
• DTo determine insurance premiums

How is the minimum required thickness (t_min) calculated for a cylindrical shell under internal pressure?

• At_min = P x R (pressure times radius)
• Bt_min equals the original construction thickness
• Ct_min = MAWP / 2
• Dt_min = PR / (SE - 0.6P), where P is design pressure, R is inside radius, S is allowable…

How is the Maximum Allowable Working Pressure (MAWP) recalculated based on actual remaining wall thickness?

• AMAWP = original MAWP regardless of current thickness
• BMAWP is always the nameplate pressure
• CMAWP can be recalculated by rearranging the code thickness formula to solve for pressure…
• DMAWP cannot be recalculated

What is a damage mechanism?

• AThe mechanical operation of equipment
• BThe method by which equipment is decommissioned
• CA type of insurance claim
• DA specific process by which deterioration or failure of pressure equipment occurs, such a…

What is High-Temperature Hydrogen Attack (HTHA)?

• ACorrosion of equipment by hydrogen peroxide
• BErosion caused by high-velocity hydrogen flow
• CA damage mechanism where hydrogen at high temperatures and pressures reacts with carbon i…
• DDiscoloration of steel at high temperatures

What are Nelson curves, and what do they predict?

• ACurves showing the relationship between pressure and flow rate
• BCurves predicting earthquake risk
• CCurves showing the relationship between cost and equipment age
• DGraphical representations that plot safe operating limits for steel alloys in hydrogen se…

What metallurgical property does the Charpy V-notch impact test measure?

• ATensile strength
• BYield strength
• CHardness
• DToughness — the material's resistance to fracture under impact loading at a specific temp…

What is the ductile-to-brittle transition temperature (DBTT)?

• AThe temperature at which metal melts
• BThe temperature range below which a material's fracture behavior changes from ductile (en…
• CThe temperature at which welding must begin
• DThe maximum operating temperature

What is sensitization in austenitic stainless steels?

• AIncreased sensitivity to scratching
• BPrecipitation of chromium carbides at grain boundaries when heated to 800-1500 degrees F,…
• CIncreased sensitivity to pressure
• DEnhanced sensitivity to light

What is temper embrittlement?

• AEmbrittlement from exposure to cold temperatures
• BEmbrittlement from excessive tempering heat treatment
• CA loss of toughness in alloy steels caused by segregation of impurity elements (P, Sn, As…
• DEmbrittlement caused by hydrogen

What is the purpose of hardness testing in pressure equipment inspection?

• ATo determine the material's color
• BTo assess the material's strength, verify heat treatment condition, check for changes due…
• CTo measure the material's weight
• DTo determine the material's melting point

What is the difference between general (uniform) corrosion and localized corrosion?

• AGeneral corrosion affects the entire surface relatively uniformly; localized corrosion (p…
• BThere is no difference
• CGeneral corrosion is faster than localized corrosion
• DLocalized corrosion is only caused by chemicals

What is a Remaining Strength Factor (RSF) in fitness-for-service assessment?

• AA dimensionless factor that compares the remaining strength of a damaged component to its…
• BA financial ratio comparing repair cost to replacement cost
• CThe ratio of remaining wall thickness to original thickness
• DThe safety factor used in original design

What NDE technique is most commonly used for measuring remaining wall thickness of in-service pressure equipment?

• ARadiographic testing
• BMagnetic particle testing
• CConventional ultrasonic thickness measurement (UT)
• DVisual examination

What is the purpose of a corrosion monitoring coupon?

• AA small metal specimen installed in the process stream to measure the actual corrosion ra…
• BA discount coupon for purchasing corrosion inhibitors
• CA decorative metal piece attached to the vessel
• DA tag identifying the material grade

What is a Heat Recovery Steam Generator (HRSG), and what unique inspection challenges does it present?

• AA boiler that uses exhaust heat from gas turbines to generate steam — presents challenges…
• BA simple domestic water heater — no special challenges
• CA device that converts steam to hot water — same inspection as any heat exchanger
• DA solar-powered steam generator — challenges are weather-related only

What is flow-accelerated corrosion (FAC)?

• ACorrosion caused by stagnant flow
• BCorrosion that only occurs in stainless steel
• CCorrosion accelerated by adding chemicals to the flow
• DAccelerated dissolution of the protective oxide layer on carbon and low-alloy steel in si…

What is the purpose of metallographic replication (replica) in field inspection?

• ATo create artistic copies of equipment nameplates
• BTo examine the microstructure of in-service equipment in the field without cutting a samp…
• CTo measure wall thickness
• DTo perform hydrostatic testing

What is the primary concern with equipment that has experienced fire damage?

• AThe mechanical properties of the material may have been permanently altered — including l…
• BThe paint will need to be replaced
• CThe insulation may have been damaged
• DThe nameplate may be discolored

What is the difference between a crack and a crack-like flaw in FFS assessment?

• AA crack has sharp tips with essentially zero radius; a crack-like flaw includes any plana…
• BThere is no difference
• CA crack-like flaw is less serious than a crack
• DA crack-like flaw is visible; a crack is not

What information is needed to perform a Level 1 FFS assessment of local metal loss per API 579-1?

• AOnly the location of the metal loss
• BRemaining thickness profile (grid of thickness readings), length and width of the corrode…
• COnly a visual photograph
• DOnly the age of the equipment

What is the critical crack size concept in fracture mechanics-based FFS assessment?

• AThe flaw size at which the applied stress intensity factor equals the material's fracture…
• BThe size at which a crack becomes visible to the naked eye
• CThe minimum size that can be detected by NDE
• DThe size at which a crack reaches 50% of the wall thickness

What damage mechanism is of primary concern in high-energy piping systems (main steam and hot reheat)?

• ACreep damage at seam welds and girth welds, particularly at high-stress locations
• BGeneral external corrosion
• CErosion from external weather exposure
• DPitting from rainwater

What is the Larson-Miller Parameter (LMP)?

• AA parameter for calculating pipe diameter
• BA time-temperature parameter used to correlate creep and stress-rupture data, enabling pr…
• CA formula for calculating corrosion rates
• DA measurement of safety valve capacity

What is the primary difference between carbon steel and low-alloy steel in terms of high-temperature service?

• AThey have identical high-temperature properties
• BLow-alloy steels are less expensive
• CCarbon steel is always stronger at high temperatures
• DLow-alloy steels (Cr-Mo) have better high-temperature strength, creep resistance, and oxi…

What is a pressure relief device (PRD) and why is regular inspection essential?

• AA device designed to prevent overpressure by opening at a set pressure to relieve excess…
• BA gauge that reads pressure — inspection ensures accuracy
• CA valve that controls process flow — inspection ensures proper flow rate
• DA drain valve — inspection ensures proper drainage

What is the purpose of a Failure Analysis?

• ATo assign blame for the failure
• BTo systematically determine the root cause of failure by examining the fracture surface,…
• CTo calculate the financial loss from the failure
• DTo determine if the failure was covered by warranty

What do beach marks (clamshell marks) on a fracture surface indicate?

• AFatigue crack growth — concentric marks radiating from the crack origin showing progressi…
• BThe fracture occurred near a beach
• CImpact fracture at high speed
• DCreep rupture at elevated temperature

What is the Failure Assessment Diagram (FAD) used for in FFS evaluation?

• ATo simultaneously evaluate the risk of both brittle fracture and plastic collapse for a c…
• BTo diagram the organizational structure of the inspection team
• CTo assess the failure of inspection equipment
• DTo schedule failure analysis meetings

What type of material is commonly used for high-temperature superheater and reheater tubes?

• ACarbon steel only
• BCopper
• CAluminum
• DFerritic or austenitic alloy steels such as T22 (2.25Cr-1Mo), T91 (9Cr-1Mo-V), or TP304H…

What is the difference between transgranular and intergranular cracking?

• AThere is no difference
• BTransgranular is faster than intergranular
• CTransgranular cracking propagates through the grains; intergranular cracking propagates a…
• DIntergranular only occurs in welds

What is the purpose of a risk matrix in RBI?

• AA matrix for scheduling inspection personnel
• BA matrix for tracking equipment purchase orders
• CA graphical tool that plots equipment items based on their probability of failure and con…
• DA tool for calculating inspection costs

What factors affect the probability of failure (POF) in RBI analysis?

• AOnly the age of the equipment
• BActive damage mechanisms, corrosion rates, current condition, inspection effectiveness, o…
• COnly the cost of the equipment
• DOnly the equipment manufacturer

What factors affect the consequence of failure (COF) in RBI analysis?

• AOnly the repair cost
• BOnly the equipment's appearance
• CFluid toxicity and flammability, inventory released, detection and isolation capability,…
• DOnly the equipment location