Guidelines for API 653 Certification Examination

1. EXAMINATION SCHEME
As per the present scheme, API 653 examination is one-day, 8-hour, 2 session examination, comprising of pre-lunch session (4 hours) for “open-book” examination and post-lunch session (4 hours) for “closed-book” examination.

There are a total of 150 questions carrying 1 mark each (total of 150 marks), split into open-book (approximately 50 questions) and closed-book (approximately 100 questions). The distribution of 50 and 100 questions respectively for open-book and closed-book examinations is approximate; however the total is always 150 questions.

Each question is multiple choice questions with given 4 possible choices. Only one is the correct choice. The candidate has to pick-up the correct choice and indicate the same on separate answer sheet. The answer sheet along with the question paper should be returned back to the Supervisor. The correct answer is to be indicated by blackening (filling) the relevant circle by a pencil. There is no set passing percentage. However a score of about 95 to 105 out of 150 is a good estimate of passing score.

Please note the following
Fill only one circle out of four given

Fill the circle fully and completely. Half or less than half blackened circle area is not reckoned for answer.

Never indicate the answers by ticking (√) the circles.

There is no negative marking.
During the “open-book” session, you are permitted to refer to the codes and other documents as per “Effectivity Sheets”. Code pages may be tabbed, highlightened, underlined or notes in margin of the pages are accepted. Additional new pages to codes are not accepted. Always carry the following to the exam hall.

2 Nos. B or 2B pencils and eraser

Non-programmable calculator

Photo identity (passport, driving license, etc.)

Exam confirmation letter

Be present in the exam hall at least 15 minutes prior to scheduled start of exam. The supervisor announces important instructions during this period. Do not miss them. Now relax and attempt the exam calmly. Time is always more than enough.

2. DISTRIBUTION OF MARKS 

As per the Effectivity Sheet, there are total 7 codes prescribed for examination. However, all of them are not equally important and do not therefore require equal emphasis. About 50 percent questions are asked from one code API 653 which is hardly 40 pages, while all other 8 codes contribute 50% marks which are more than 1,000 pages. Following distribution scheme will help the participant to decide how much time he should spend for each document during preparation.

S.N.	Code	Approx. Weightage (in %)	Questions Asked Out of Total 150
1	API 653	45 – 50	68 – 75
2	API 650	15 – 18	22 - 27
3	ASME Sec. IX	10 -12	15 - 18
4	ASME Sec. V	10 – 12	15 - 18
5	API RP 575	5	7
6	API RP 651	3	4
7	API RP 652	3	5
8	General Knowledge	2	3

3. SALIENT FEATURES OF THE EXAMINATION 

As stated earlier, the examination comprises of open book and closed book parts. The closed-book examination includes such questions which the inspector is normally expected to know without referring the Codes, i.e., the questions are “awareness level” questions.

Whenever you find a very definitive or quantitative statement in body of the Code, a closed book question may be expected on it. Thus, the basic requirements of a code, specific “DO” and “DON’T” statements, important quantified statements, important definitions and well-known inspection principles will constitute such questions.

Where the student is required to refer to the diagrams or formulas or tables or graphs and curves from the Codes, it will always be an “open-book” question. All calculation oriented questions will normally be “open-book” type. The Code information which is not short and crisp, (i.e., large paragraphs, several descriptive statements clubbed together) will normally be asked in “open-book” part. Here the participant is expected not to remember the information but should know where to find it in the body of the Code.

The questions asked in closed book part are straight forward statements directly taken form Code without much of the modifications and therefore are easy to answer. To answer open-book questions, one only needs to know where to find the answer in the code and therefore tabbing of Code pages, highlighting the paragraphs or additional explanatory notes in page margins is useful for saving time. Closed-book part of the exam (100 marks) can be finished in hardly 2 to 2 ½ hour though 4 hours are allotted. While “open-book” part (50 marks) takes a little longer and may require all the 4 hours that are allotted.

4. HOW TO PREPARE FOR EXAM 

If your aim is only to get “certified”, i.e., to obtain just around 100-110 marks, detailed study of documents nos. 1 to 4 above  (Chapter 2) may be adequate. Additionally, one should try to remember all the “Points to Recall” and review the mock examinations attempted during the Preparatory Course. If two or more participants from same organization are appearing for exam, then joint discussions and one putting question to another and vice versa has been found very effective during preparation. Other 5 codes (i.e., Serial No. 5 to 9) may be studied in detail if there is additional preparation time available. An overall “awareness” level knowledge of these 5 Codes may be okay.

If your objective is to get certified and also to obtain a good score, (say 125+) then it is worthwhile to study the 5 Codes (Serial No. 5 to 9). However, please remember that study of API 653 has to be “thorough” and total, while study of API 650, ASME Sec. IX and ASME Sec. V should be such that it can cover the topics mentioned in the “Body of Knowledge”. The last 5 Codes (Serial No. 5 to 9) should be read at least once and note the important points. A very “thorough” study of these documents however will not result in “gains” commensurate with the efforts put in.

If you are about a month away from examination, read all the Codes at least once and concentrate on highlighted text in the Codes and also try to solve the question bank.

If you are about two weeks away from the exam, concentrate on highlighted text as well as the mock examinations conducted during the course. In the last week of preparation, focus on Points to Recall and mock exams.

5. TIPS FOR MAXIMIZING THE SCORE

Remember the below given tips will be useful.

1. There are only 5 or 6 important definitions from Chapter 3 of API 653. Normally 3 to 4 definitions are asked in closed-book exam.
2. From Chapter 4 of API 653, nearly 15 questions are asked (7 to 8 closed book and 7 to 8 open book). Concentrate more on clauses 4.2.1.2, 4.2.3.1, 4.2.4.3 to 4.3.7.
3. Chapter 5, knowing figure 5-2 and only 3 clauses 5.3.5 to 5.3.7 is enough.
4. From Chapter 6, about 10 questions are asked. It is only 3 page chapter. Particularly pay attention to Inspection intervals.
5. From Chapter 7 and Chapter 8, generally 2 or 3 questions are asked.
6. Chapter 9, about 7 to 8 questions are asked. Concentrate more on Figure 9-1 and hot tap (Clause 9.14).
7. Chapter 10, about 3 or 4 questions are asked and those generally “open book” type. So you can refer to the code and get answers.
8. Chapter 11, it is hardly 8 to 10 lines chapter but 1 or 2 questions are asked.
9. Chapter 12, about 7 to 8 questions are asked. Normally the questions are on NDT. The participant is expected to know that NDT procedures shall be as per relevant article of ASME Sec. V, the NDT extent shall be as per API 650 or 653 while acceptance criteria is as per API 650 or ASME Sec. VIII, Div. 1. he should also know that qualification standard of NDT personnel is ASNT SNT-TC 1A (or API 650). This chapter is better explained in Appendix F (API 653) as NDE Summary or in Appt. (API 650)
10. Chapter 13, generally 1 question covering name plate stamping is asked.
11. Appendices:

• App. A. Here note that API 650 was introduced in 1961 (prior to this was API 12C) and seventh edition (1980) onwards the joint efficiency (E) is taken as 1.
• App. B: The important topics are number of settlement monitoring points (Figure B-1, B-2) and formula B = 0.37 R (R in feet while B is in inches)
• App. C: This being item wise inspection checklist concerning what to check where. Normally, 1 or 2 open book questions are set. No need to remember this table.
• App. D: Note certification requirement (Clauses D.2 and D.5)

12. From API 650. Normally, two questions are asked on materials. (Fig. 2-1, Table 2-3, Table 2-4 and Clause 2.8). Usually 5 to 6 questions are asked on Chapter 3 concerning shell, bottom and roof thickness, attachment welds. From Chapter 5, normally 2 or 3 questions will be asked. Focus on weld reinforcement, undercuts, use of low-H electrodes and inspection pressure for pad-test and vacuum box test. From Chapter 6, generally 3 questions covering number of radiographs (Fig. 6-1) and acceptance standards and personnel qualifications are asked.
13. Since there is no negative marking, there is no harm in making guess. Generally, do not go against your first impulse, unless you are sure you were wrong in the first place. If some questions are still remaining unanswered mark the answers you “feel” may be right. Do not leave any question unanswered.

6. TIME MANAGEMENT DURING EXAM:

Both “open” and “closed” book sessions are 4 hours each. This means about 25 to 28 questions per hour for closed book and 12 to 15 questions per hour for open book. For proper time management following are useful suggestions.

a)  You may start from Question No. 1 and proceed. If after 1 hour you feel that you are maintaining the required progress as mentioned above proceed serially.

b)  If, however, you are behind the required rate, start jumping the questions, i.e., start attempting those questions you can answer, deleting whose answer you do not know. Proceed like this till the end. Do not leave any question unanswered whose answer you know.

c)   Then come back to “deleted” questions and attempt them using your “feel” factor. Go on like this till say last 10-15 minutes are remaining.

d)  If there are still some questions where you have no clue at all just mark the answer at random in last 10-15 minutes. This may give you few chance marks. Do not leave any question unattempted.

e)   After completion of writing exam, if you have still time (which you normally have) you may go through your answers just to check quickly if you have filled a wrong circle.

7. TEST TAKING TIPS

• Don’t read too much into a question. Do not get too elaborate and ruin your answer.
• If two choices are very similar, the answer is probably not either of them.
• If two choices are opposite, one of then is probably correct.
• Don’t go against your first impulse unless you are very sure you were wrong.
• Check for negatives and other words that can throw you off.
• The answer is usually wrong if it contains “all,” “always,” “never,” or “none.”
• The answer has a great chance of being right if it has “sometimes,” “probably,” or “some.”
• When you don’t know the answer, look for the wrong ones.
• If you are supposed to read a long passage and then answer questions about it, read the question first. That will tell you what you are looking for and affect the way you read the passage.
• Be suspicious of choices that seem obvious.
• Don’t give up on a question that, after one reading, seems complicated. Looking at it from a different angle, restating it in your own words, drawing a picture, or breaking it down, etc., may help you realize that it’s not as hard as you thought.

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BGAS Painting Study Material Chapter 2 continuation

Profile measurement

If a profile requirement is specified, it is the inspector’s duty to ensure that the specification requirements are met. This can be done in two ways.

1. By measuring – using gauges with and without replica tape.
2. By assessing – using surface comparators.

The dial gauges are still very often used.  The dial gauges fall into two categories

1. Surface Profile Needle Gauge
2. Dial Micrometers with Replica Tape.

Surface Profile Needle Gauge.

The gauge is applied to the blasted substrate and the needle can be felt to locate a trough.  Then by applying a slight pressure to allow the flat ‘foot’ of the gauge to sit firmly on the peaks of the blasted substrate, the needle will pass into the trough as far as it can.

Surface profile needle gauge.

1. We need to zero the gauge when the point of the needle is on the same plane as the flat foot, i.e. on a smooth piece of glass.
2. Applying slight pressure to the foot to ensure that it is perfectly flat on the glass.
3. By loosening the locking screw, the bezel can now be moved.  The bezel should be moved till the zero on the gauge is immediately behind the needle.
4. Then tighten the locking screw and the gauge is ready for use.
5. Several readings are taken, usually more than ten, in random Positions over the substrate, and the average Calculated. This type of gauge is not ideally suited for curved areas such as pipes.
6. It is normal to work to an average figure.

Continue..............

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Painting Defects

Viscosity Drop

Low viscosities may be simply due to incomplete stirring or the addition of too much solvent. The viscosity may decrease on standing in water-borne paints due to enzymic attack on the thickeners used. Modern latex paints use thickeners that are not readily attacked by bacteria. Changes in the orientation of the pigments (for example partial flocculation) may reduce the viscosity.

Wrinkling, Webbing, Frosting and Gas Checking

Wrinkling is the development of wrinkles in the paint film as it dries, usually due to the formation of a skin. Defects similar to wrinkling are webbing, frosting and gas checking. Webbing is the development of wrinkles, usually in a well defined pattern and if it occurs in an oven it is called gas checking. Frosting is the formation a haze which is due to fine wrinkles and it occurs in gas fired drying ovens.

The causes can be:

• Due to the paint's being applied too thick, especially with high oil-length alkyds, varnishes with wood oil and too much cobalt drier, enamels based on alkyd or phenolic resins with drying oils and black enamels containing bitumen.
• Stoving paints containing bitumen.
• Frosting may be due to the products combustion in the oven reacting with the surface of the film or may be due to high humidity.
• Too much cobalt drier.

Sometimes the wrinkle pattern may be induced into the paint to produce films that will hide surface defects.

Another type of defected related to wrinkling are crocodiling or alligatoring where the wrinkle pattern resembles the hide of one of these reptiles.

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Painting Defects

Settling

This is the separation of the pigments and occurs to a certain extent in all paints. It becomes a serious defect when the pigment is difficult to reincorporate into the paint by stirring.

The defect occurs due to the high densities of some pigments and can be accelerated by a drop in viscosity, the paint being stored at high ambient temperatures or by being subjected to vibration for example on long transportation by rail.

The control of settling lies in selection of suitable pigments and the addition of additives that increase the viscosity of the paint.

Slow Drying

Slow drying occurs when the paint remains tacky for an extended period of time. This will result in the film picking up insects or dirt before it is hard and will make repainting difficult.

The main causes are:

• Too thick of an application of the paint when using air-drying paints. As these paints require oxygen to penetrate the film to produce dying, if the film is too thick oxygen will not penetrate.
• The viscosity of the paint is too high for the application. This can occur in cold weather and can be overcome by reducing the viscosity with the recommended thinners for the paint.
• The paint was applied at too cold a temperature. This will cause the chemical reaction that takes place to cause the film to cure slowly.
• High humidity due to rain or the like will reduce the evaporation of the solvent, the first step in drying.
• The surface to which the paint is applied is not clean and has traces of wax or paint removed on it.
• The coat to which the paint is being applied has not dried when the next coat is applied.

Staining

Contamination of many surfaces with water, soot, smoke, tannins and tobacco can result in color coming through the paint surface to cause stains. Stains caused by water will leave a tide mark and after drying, the paint around the stain can be removed and the surface repainted. If the surface may become damp again, remove the source of the water or paint with chlorinated rubber or a hard varnish. Patches of soot or smoke should be removed before coating. Use of an insulating paint before the final coat can help. Nicotine should be removed with an alkaline cleaner (bleach) before coating. Remember to wash off all the alkali before attempting to paint.

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Painting Defects

Orange Peel

This defect gives the paint finish the rough appearance similar to the outside of an orange. The defect is found in spray painting and is generally due to having the wrong solvent. It can also be due to an incorrectly adjusted spray gun.

The solution is to use the manufacturers recommended thinner and to adjust and use the gun correctly.

Peeling

Peeling is simply another type of flaking where the amount of paint film removed is greater.

Pin holing

The defect is the appearance of small holes in dried paint film. The problem is most probably caused by too thick a coat trapping solvents into the film, or by air bubbles. The defect may be due to not cleaning the surface before painting, using the wrong solvents in spray painting or incorrect air pressure. The problem can be solved by addressing the above causes.

Poor Flow

Poor flow can manifest itself in two ways: if the paint is too thick and will not flow out this will show up as a rough surface or orange peel where the surface resembles the skin of an orange; if the paint flows too much the result will be runs, sags and wave formation. This defect is remedied by proper formulation and when thinning the paint to use the right solvent and the correct amount.

Poor Hiding or Lack of Opacity

Opacity is the ability of a paint film, when applied to a given surface, to hide or obliterate the surface or the undercoat. Poor hiding power can be due to too thin a coat being applied or to the formulation using a poor quality pigment.

Runs and Sags

As the name suggests this is the formulation of runs or sages on the finished paint film.

The defect can be caused by a number of things:

• Too thick of a film.
• Too much thinners.
• Not allowing the first coat to dry before applying the top coat. 

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Painting Defects

Floatation and Flooding

Floatation or floating occurs when a paint has been incorrectly formulated with two or more different colored pigments when one of the pigments floats to the surface giving different differences. On close examination the surface appears mottled with regular shaped cells.

Flooding is similar to floatation in that one of the pigments migrates to the surface when the paint is produced using two pigments with different densities.

These defects are corrected mainly by better paint formulation.

Gassing

This is the formation of a gas, usually by hydrogen, by the reaction of reactive pigments, like Zinc and Aluminum, with acidic materials in the resin. It can be overcome by better formulation or packaging the paint separate from the pigment and mixing the ingredients prior to application.

Mould

The growth of mould on a paint film causes severe discoloration. Mould is a plant growth that requires moisture, the presence of food and the correct temperature for growth. The defect can occur on most types of paint but is most prevalent in bathrooms, kitchens and exterior walls that are in shady positions. The paints that are most susceptible are soft oil-based paints or varnishes and emulsions, especially if they are low gloss where dirt can be trapped in the film.

Often the mould growth can be killed and color removed by washing with dilute sodium hypochlorite solution taking due care as this preparation is alkaline. Safety glasses and gloves have to be worn. Before repainting, susceptible surfaces should be prepared with anti-mould preparations, like sodium pentachlorophenate and by using either paints prepared with mould inhibiting pigments, like Zinc oxide, or by using high gloss finishes. In extreme cases it may be necessary to remove the high humidity in the room by using exhaust fans.

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Painting Defects

Dirt Retention

This is the deposition of dirt and dust on the paint film. For certain types of paint, the dirt may become entrained into the surface. The paints that resist dirt retention are high-gloss enamels while the low gloss latexes are the most susceptible to this defect.

Fading

Fading is the decrease in the intensity of the color after exposure. It should be tested for after removal of any chalking that may have occurred as this will tend to mask the actual fade of the pigment. In general organic pigments, especially those of low cost, will fade more than pigments that are inorganic. More expensive coatings especially prepared for exterior exposure will resist fading more than less expensive paints.

Fish Eye

This defect is indicated by small round imperfections in the top coat. The defect is caused by traces of silicone or oil on the surface prior to painting. The remedy is to thoroughly clean the surface and if spray painting, to ensure that there is an oil filter on the air line.

Flaking

Flaking is the lifting of small-to-large sections of the paint and is due to poor adhesion and to the brittleness of the paint. The causes can be varied, for example the defect could be caused by efflorescence or the migration of soluble salts to the paint-media interface which can cause the paint to be forced off the surface. The paint may react with moisture and any traces of alkali to decompose the paint - this is called saponification. It may be due to failure to remove millscale from the steel before painting.

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Painting Defects

Bronzing

This is a defect that was often observed on cars painted red or blue where after a period of time a characteristic red tone developed on the paint surface. The cause was older types of pigments like phthalocyanine or Prussian blues. The defect is not common with the pigments available today.

Chalking

Chalking is the powdery deposit on the surface of the paint which dulls the gloss and appears after exposure. This defect is usually associated with long exposures to sunlight and is a natural degradation of the paint film. Some combinations and types of pigments and resins show more pronounced chalking than others.

Checking

Checking is the appearance of wide splits with round edges that occur in the top coat. The cause is usually due to the surface not being clean (could be old paint) or too high a film build or the materials not being mixed properly. The remedy is to remove the old paint, cleaning the surface and mixing the paint ingredients properly.

Cracking or Crazing

This defect is a series of irregular cracks in the surface of the paint.

The cause of this defect can be:

• Application of the top coat before the previous coat is dried
• Too thick of a top coat
• Impurities on the surface or the effect of impurities on the applied coat.

The remedy is the let the intermediate coats dry before the top coat is applied, clean the surface well, remove the previous coat or ensure that the top coat is not applied too thickly.

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Painting Defects

Blistering

This defect is the appearance of irregular blisters on the paint finish.

This defect can be caused by:

• Not correctly cleaning substrate
• Contamination of the brush, air gun, line etc.
• Using wrong thinner or incorrect amount of thinners
• Old paint surface
• Excess film thickness
• In timber finishes, not allowing the solvent, particularly paint removers , to evaporate before repainting

This defect may be overcome by:

• Cleaning all surfaces free of grease and allowing the solvent to evaporate.
• Using recommended thinner at correct ratio.
• In spray applications, inspect so that water does not build up in the traps, especially in humid weather.
• Check that the new paint is compatible with the old surface.
• Do not apply paint films too quickly and allow solvents to evaporate before re-coating.

Blooming

This defect gives a bloom or white deposit, like the bloom on a grape or plum, after the paint has dried. The cause is the rising of soluble fractions of the pigment rising to the surface on the paint's drying. The remedy for spray paints is to rub the surface down.

Blushing

This is a white deposit appearing on the surface of lacquer films only. The defect is caused by painting with lacquers in high humidity conditions where the water contained in the air condenses on the paint film The remedy is not to paint in humid conditions or to add a strong, active solvent that may stop the blushing.

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Painting Defects

BGAS Painting Inspector Exam Painting Defects Name and Definition

Banding

This defect is found in spray applications where there is heavy application of paint on the outside of the spray pattern with little paint in the canter of the fan.

The cause can be:

• Too much air pressure
• Uneven lapping of the spray gun
• Having the gun too close to the job

The remedy may be found from:

• Use at correct air pressure
• Ensure that the overlap of each stroke is 50% over the previous coat
• Hold gun at the correct distance from the job - about 15 cm for lacquers and 25 cm for enamels. To correct a coat that has been applied, re-coat with double coat using thinner that has been specifically recommended for the paint using indicated solvent ratio and pressure, and ensuring that the gun is held at the correct distance.

Bleeding

This is the migration of the color from a previous coat into the freshly applied top coat. This defect usually occurs when a light color is applied over a dark color, particularly reds and maroons which are prepared by using organic pigments not resistant to solvents or application over a surface contaminated with bitumen where the solvents in the fresh paint dissolve the bitumen.

The remedy is:

• Use a bleed sealer before application of the light color
• Wash the surface with mineral turps if it is contaminated with bitumen.

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BGAS Painting Study Material Chapter 2 continuation

Profile

Surface profile, Anchor pattern, key, Peak to trough height and Amplitude are all expression meaning the cross section of a blasted area, as measured from the top of the peaks to the bottom of the troughs.  The surface profile requirements are given on the specification for the job, e.g. for B. Gas 30 – 75 microns.

Shot blasted profile

Figure 2.1 Terms relating to preparing surfaces

Grit blasted profile 

Figure 2.2 Grit blasted profile

*Hackle – A small surface lamination, which stands upright like a needle after blasting.  Approximately ≤ 13 mm.  Easily removed.

*Lamination (slivers) – Appears to be a longitudinal ‘crack’, one lip curling back, any laminations found must be referred to engineer for ultrasonic check.

continue............

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