API-SIRE Source Inspector Rotating Equipment Exam Preparation Resources

1. During a Factory Acceptance Test (FAT) for a centrifugal pump, it was observed that the pump was vibrating at higher amplitudes than specified. Upon investigation, it was determined that the misalignment between the motor and the pump was the cause. As a source inspector, what should be your next step to ensure the issue is resolved properly before acceptance?

2. Which of the following strategies is most effective in minimizing erosion in rotating equipment used in slurry pumping applications?

3. During a routine inspection closeout for a high-speed turbine, the source inspector notices that one of the components was replaced with an alternative part not originally specified in the design. This part has a slightly different specification but is claimed to be equivalent by the supplier. The inspector is required to document this deviation before finalizing the inspection report.

What is the most appropriate action for the inspector to take to ensure compliance with the API SIRE guidelines?

4. When conducting an inspection, maintaining impartiality is essential to avoid conflict of interest. The API SIRE code of ethics requires inspectors to prioritize over personal or professional relationships.

5. During the documentation review phase of a rotating equipment inspection, an inspector is responsible for verifying that all calibration certificates for measuring instruments used during manufacturing are current and valid.

6. When completing an inspection closeout, the source inspector must ensure that all discrepancies noted during the inspection are documented in the.

7. When inspecting the fabrication and assembly of rotating equipment, which standard provides guidelines on the tolerances and clearances for components like bearings and seals?

API 612

8. During the final assembly of a centrifugal pump, a source inspector notices that the alignment check between the pump and the driver is not within the specified tolerance. The equipment was previously aligned, but some adjustments were necessary to accommodate thermal expansion.

Considering the fabrication and assembly stages, what step should the inspector prioritize to ensure compliance with the alignment criteria before commissioning?

9. In a failure modes and effects analysis (FMEA) for rotating equipment, the likelihood of a specific failure mode occurring is assessed through the parameter known as.

10. In a risk-based inspection framework for rotating equipment, the likelihood of failure and the consequence of failure are both equally important factors in determining inspection intervals.

11. Which of the following actions would most likely be considered a conflict of interest for a source inspector of rotating equipment?

12. You are tasked with reviewing the documentation for a centrifugal pump before conducting an inspection. During the review, you notice that the material test reports (MTRs) for the impeller are missing, and the heat treatment records indicate a discrepancy in the temperature range used. Additionally, the manufacturer's data report does not include the correct serial number for the components.

Considering these issues, what should be your immediate course of action before proceeding with the inspection?

13. When conducting a heat treatment process on a high-strength alloy rotor, which factor is most critical to ensuring the desired outcome?

14. Which of the following is the most important step in reducing the risk of bearing failure in rotating equipment?

15. Which of the following best describes the role of a source inspector during a witness point inspection for rotating equipment?

16. What is the primary purpose of conducting a Factory Acceptance Test for rotating equipment?

17. What is the primary purpose of conducting a risk assessment before inspecting rotating equipment?

18. When inspecting impellers for signs of erosion, which factors are most likely to contribute to this type of damage?

19. During a routine inspection of a rotating equipment manufacturing facility, you notice that a colleague is accepting gifts from a vendor whose products are being inspected. This behavior could potentially compromise the integrity of the inspection process.

As a source inspector, what should be your first course of action to address this situation?

20. In eddy current testing, the ability to detect smaller defects is primarily influenced by the of the probe.

21. In the context of hardness testing, a is used to measure the depth of penetration under a specific load, providing an indication of material hardness.

22. Cavitation erosion in rotating equipment is often characterized by pitting and a rough surface texture.

23. Which of the following is a critical consideration when selecting the test medium for a hydrostatic test of rotating equipment?

24. Functional testing of rotating equipment focuses primarily on verifying mechanical integrity rather than operational performance.

25. Which of the following is the most important consideration when evaluating the results of a performance test on a gas compressor?

26. During a final inspection of a centrifugal pump, you notice that the rotor assembly has not been balanced. The manufacturer's documentation specifies that balancing is required to ensure proper functionality and longevity of the equipment.

What should be your course of action as a source inspector to ensure compliance with the specifications before the release of the equipment?

27. The primary factor that differentiates erosion from wear in rotating components is the presence of.

28. During a documentation review, it is essential to ensure that the equipment's design specification aligns with the applicable standards.

29. What is the primary purpose of reviewing the quality control plan during the documentation review phase of a rotating equipment inspection?

30. Which of the following is a crucial element to verify during the inspection closeout for rotating equipment?

31. According to API standards, which of the following best describes the primary purpose of performing a hydrostatic test on rotating equipment?

32. In hazard identification for rotating equipment, which standard practice is utilized to predict potential failures by examining past performance data?

33. During a site visit, you are performing an inspection on a newly installed centrifugal pump. The manufacturer has specified several hold points in the fabrication and assembly process. However, during the inspection, you notice that one of the critical hold points was not documented in the inspection records.

What is the most appropriate action to take in this situation?

34. It is considered ethical for a source inspector to provide consulting services to the same company whose rotating equipment they are inspecting.

35. During the inspection of rotating equipment, it is essential to assess the condition of the to ensure safe and efficient operation.

36. Heat treatment processes must account for factors such as material composition, component thickness, and to ensure optimal results.

37. Dry gas seals in rotating equipment are designed to operate effectively even if the seal gas pressure is slightly lower than the process gas pressure.

38. During a routine inspection of a centrifugal pump, the source inspector notices increased vibration levels and a sharp drop in pump efficiency. Upon further investigation, it is found that the pump's impeller has cavitation damage.

What is the most likely initial cause of this failure mode?

39. Which of the following factors would most likely cause a false indication of a defect during eddy current testing of a rotor shaft?

40. During the final inspection and release of rotating equipment, it is acceptable to bypass certain specified tests if the equipment has passed similar tests at earlier stages.

41. During the inspection of a dry gas seal system, it is essential to verify the condition of the to ensure the integrity of the seal assembly.

42. During a routine inspection at a manufacturing facility, you notice that a centrifugal pump is emitting an unusual noise, and there is a slight vibration. Upon further investigation, it is found that the pump's impeller is slightly worn out. The facility's maintenance team suggests continuing its operation until the next scheduled maintenance. Considering hazard identification principles, what is the most appropriate course of action?

43. During the inspection of a multi-stage pump, you are tasked with measuring the clearance between the impeller and the pump casing. The clearance measurement is critical to ensure optimal pump performance and prevent operational issues.

The recommended clearance for this specific pump model is.

44. During a routine inspection of a centrifugal pump within a chemical processing plant, the source inspector observes significant wear patterns on the impeller blades. The wear is most pronounced on the leading edges, and there are signs of pitting and material loss.

Considering the environment and the operational conditions, what is the most likely cause of this erosion?

45. Which of the following is a key benefit of conducting a rotor dynamic analysis during the fabrication stage of rotating equipment?

46. Effective documentation control in rotating equipment inspections requires that all records be stored electronically to ensure accessibility and security.

47. When implementing a risk-based inspection strategy for a fleet of pumps in an industrial facility, which action should be taken first to effectively assess and manage risk?

48. During a hydrostatic test for a recently manufactured centrifugal pump, the inspector notices a slight pressure drop over a 30-minute period. The equipment manual specifies a permissible pressure drop rate, and the test gauge is calibrated correctly. The inspector suspects a minor leak in the system.

Which step should the inspector take next to ensure compliance with API test procedures?

49. During Factory Acceptance Testing, it is acceptable to bypass certain tests if the equipment has previously passed similar tests in another facility.

50. The Leeb Hardness Test is particularly suitable for testing the hardness of very large and heavy components because it is portable and non-destructive.

51. During a routine inspection, you are tasked with verifying the performance of a centrifugal pump that is crucial for a refinery's operations. The pump has recently been overhauled, and part of your job is to ensure it meets the operational parameters specified in the maintenance documentation. You notice that the pump's discharge pressure is slightly below the expected value, and vibration levels are at the upper limit of acceptable tolerance.

Which step should you prioritize to ensure compliance with performance standards before the pump is cleared for continuous operation?

52. During the inspection of a rotor assembly, you are required to perform a witness point activity. The purpose of a witness point is to allow the inspector to the process without mandating work stoppage.

53. When performing eddy current testing on rotating equipment, an inspector observes that the phase angle of the signal has shifted unexpectedly.

What is the most probable cause of this change?

54. Which of the following is the primary purpose of maintaining accurate documentation and record control during the inspection of rotating equipment?

55. During a routine inspection of centrifugal pump impellers in a chemical processing plant, you notice that some impellers exhibit signs of cavitation damage. The damage appears as pitting on the leading edges of the impeller blades. You also observe that the plant has recently switched to a new process fluid with different properties. As a source inspector, it is crucial to determine the root cause and recommend corrective actions.

What should be the first step in addressing this issue?

56. When inspecting a turbine, the source inspector notices unusual wear patterns on the blades that point towards erosion.

What is the most appropriate initial action to further investigate this issue?

57. The Factory Acceptance Test should include testing of the equipment under various operational conditions. This is important to ensure the equipment can handle different.

58. In the context of rotating equipment inspection, a hold point is a stage where work must stop until an inspection or approval is obtained.

59. The use of a laser alignment tool during the assembly of rotating equipment is critical to ensuring precision in component alignment.

60. During an inspection of a centrifugal pump, an eddy current test reveals indications of potential cracking in the impeller blades. The inspection team must determine the severity and exact location of these discontinuities.

Which technique should be employed to enhance the accuracy of the results and ensure reliable assessment of the impeller's condition?

61. What is the primary purpose of an inspection closeout meeting in the context of rotating equipment inspection?

62. A critical part of hazard identification involves recognizing potential risks associated with the lubrication system of rotating equipment. Inadequate lubrication can lead to.

63. During the inspection of a centrifugal pump, the source inspector discovers that certain critical records related to the equipment's performance tests are missing. These records are essential for verifying the pump's compliance with industry standards. The inspection is part of a larger quality assurance process, and the client has emphasized the importance of thorough documentation. The source inspector needs to address this issue following appropriate documentation control procedures to ensure all necessary records are accounted for.

What should be the inspector's first step in resolving this issue?

64. During a routine inspection of a dry gas seal system in a centrifugal compressor, you observe that the seal gas supply pressure is lower than the manufacturer's recommended minimum. This scenario raises concerns about the potential for process gas infiltration into the seal area, which could lead to seal damage.

Given this situation, what should be the immediate course of action to prevent equipment failure?

65. During the heat treatment process, it's essential to ensure that all parts of the rotating equipment reach the same temperature simultaneously to avoid thermal distortion.

66. When conducting performance testing on a newly installed turbine, it is essential to measure its efficiency, vibration levels, and to ensure optimal functionality.

67. Which of the following documents is most crucial for verifying the quality and specifications of rotating equipment during a final inspection and release process?

68. A source inspector is reviewing the reliability analysis of a turbine. They are tasked with identifying the component with the highest failure rate.

Which analysis tool would be most suitable for this task?

69. During a final inspection of rotating equipment, the inspector must verify that all safety devices are operational, including.

70. What is the primary difference between a hold point and a surveillance activity in the context of rotating equipment inspection?

71. During an inspection, an impeller was found to have uneven wear that was more pronounced on one side.

What is the most likely cause of this uneven wear pattern?

72. When reviewing documentation for a rotating equipment inspection, the source inspector notices discrepancies between the test results and the documented acceptance criteria’.

What is the most appropriate action to take in this situation?

73. Hydrostatic testing of rotating equipment requires maintaining a pressure equal to 1.5 times the maximum allowable working pressure for a specified duration.

74. During a hydrostatic test, the pressure must be raised gradually to avoid.

75. During the documentation review, you notice that the welding procedure specifications (WPS) have not been included in the documentation package.

What should be your next step to resolve this issue?

76. The final stage in the fabrication and assembly of rotating equipment involves a to ensure the equipment meets all operational requirements.

77. Which of the following hardness tests is most suitable for evaluating the hardness of thin coatings or surface layers?

78. In the context of risk-based inspection, the term "criticality" refers to the combination of the probability of failure and the of that failure.

79. During the inspection of a centrifugal pump casing, you find that the component has undergone a post-weld heat treatment (PWHT) process. Upon reviewing the documentation, you notice that the temperature was maintained at 620°C for 2 hours. The material in question is a low-alloy steel.

According to standard heat treatment procedures, what should be your primary concern regarding this treatment?

80. Which of the following best describes a potential conflict of interest scenario for a source inspector working in the rotating equipment industry?

81. Which of the following factors is most critical for the effective operation of a dry gas seal system?

82. Which of the following statements is correct regarding the cooling phase of the heat treatment process for rotating equipment components?

83. Vibration analysis is a critical tool for identifying early signs of failure in rotating equipment.

84. You are tasked with inspecting the hardness of a newly manufactured shaft intended for a high-speed compressor. The client has specified that the hardness should be verified at multiple points along the shaft to ensure uniformity. The shaft is composed of an alloy steel known for its toughness and wear resistance. During the inspection, you notice that the shaft's surface is slightly rough, which may affect the hardness readings.

Given these conditions, which hardness testing method would be the most appropriate to ensure accurate and reliable results?

85. Impeller wear rings are primarily used to minimize leakage and maintain efficiency in centrifugal pumps.

86. When inspecting rotating equipment, wearing appropriate personal protective equipment (PPE) is mandatory, regardless of the equipment's operational status.

87. During an inspection, you encounter a component composed of a very soft polymer material. You need to determine its hardness to ensure it meets the specifications for a non-load-bearing application.

Which hardness testing method would be most appropriate for this soft material?

88. It is acceptable for a source inspector to finalize the inspection documentation without verifying the calibration status of the measuring instruments used during the inspection.

89. During a routine inspection of a petrochemical plant, you notice that a critical compressor in a high-pressure system has a history of minor failures that have not been adequate. The compressor plays a vital role in maintaining plant safety and operational continuity. Given the potential consequences of its failure, a detailed risk-based inspection (RBI) analysis is warranted.

As a source inspector, how should you prioritize this piece of documented equipment within the RBI framework to ensure both safety and efficiency are optimized?

90. Which of the following factors is least likely to be a concern during the hazard identification process for rotating equipment in manufacturing facilities?

91. When performing functional testing on a gear-driven pump, which aspect is crucial to verify to ensure the pump operates effectively and within safe limits?

92. The final inspection of a gearbox requires a review of its lubrication system. The inspector must ensure that the lubrication system complies with the manufacturer's specifications. This includes verifying that all lubrication points are accessible and that the correct type and amount of lubricant are used. During your inspection, you find a discrepancy in the lubricant type used. The gearbox documentation specifies the use of synthetic oil, but mineral oil is present.

What should your inspection report indicate?

93. During a routine inspection of a centrifugal pump in a chemical processing facility, the source inspector notices unusual vibration and noise levels. The equipment is crucial for maintaining the plant's output. The inspector must decide whether to halt operations for further investigation, which could impact production schedules, or continue monitoring while taking immediate corrective actions.

Considering health and safety regulations, what should be the inspector's primary course of action?

94. When conducting a hazard identification assessment in a facility with rotating equipment, it is essential to consider the potential for misalignment in shafts.

95. In the context of rotating equipment inspection, the document that outlines the specific inspection procedures, acceptance criteria, and documentation control requirements is known as the.

96. Which of the following is NOT typically included in a Factory Acceptance Test for rotating equipment like pumps and compressors?

97. Which of the following factors is least likely to influence the determination of equipment criticality in a risk-based inspection program for rotating equipment?

98. When conducting a thorough inspection of a dry gas seal, which component's wear pattern is most indicative of potential seal face misalignment?

99. Eddy current testing can be effectively used to detect both surface and subsurface defects in non-conductive materials like plastics.

100. Which of the following is not a common hazard associated with inspecting rotating equipment?

101. When inspecting a gas turbine as per API standards, which document should you refer to for guidance on the mechanical integrity and testing procedures?

102. You are assigned to inspect a newly manufactured centrifugal pump that must comply with the latest ASME standards for its pressure-containing components. During the inspection, you notice that the manufacturer has used a material that is not listed in the ASME Code for the construction of the casing. The manufacturer claims that the material meets the required mechanical properties and provides a test certificate.

How should you proceed?

103. According to ASME B73.1, which of the following components of a centrifugal pump must adhere to specific dimensional standards to ensure interchangeability?

104. During an inspection of a centrifugal pump, the source inspector notices that the impeller exhibits signs of cavitation damage. The equipment manufacturer has provided an acceptance criterion that specifies allowable cavitation marks must not exceed a depth of 0.5 mm. The inspector measures several cavitation marks and finds the deepest is 0.7 mm.

What should the inspector do next based on the acceptance and rejection criteria?

105. During an NDE inspection using magnetic particle testing (MPT) on a ferromagnetic component, you observe a cluster of indications.

Which action should be taken according to the acceptance criteria?

106. Which of the following types of misalignment is characterized by the angle between two shafts?

107. When verifying the concentricity of a rotor shaft, which method provides the most accurate results?

108. Which of the following is a critical advantage of using remote surveillance systems during rotating equipment inspections?

109. When balancing rotating assemblies, the addition of balance weights should always be performed on the same plane as the detected imbalance.

110. Which tool is most commonly used to ensure precise alignment of rotating equipment couplings?

111. During an inspection of a newly installed centrifugal pump, you discover that the vibration levels exceed the acceptable limits specified by the manufacturer. After consulting with the engineering team, you determine that the misalignment of the pump and motor is the primary cause. To prevent recurrence, you decide to implement a corrective action plan.

Which of the following steps should be prioritized to address and prevent this issue from happening again in the future?

112. API 618 provides standards and guidelines specifically for reciprocating compressors used in petroleum, chemical, and gas service industries.

113. During an audit, you find that the supplier uses an outdated version of a critical quality standard in their processes.

What is the most appropriate action to ensure compliance with the current standards?

114. During a dimensional inspection of a centrifugal pump, you notice that the shaft length and diameter are not within the specified tolerances. The pump is intended for high-pressure applications, and any deviation from the specifications could lead to significant operational issues.

As a source inspector, which method would you prioritize to ensure the dimensional accuracy of this critical component?

115. Which of the following is a key responsibility of a source inspector when working with procurement teams to ensure the quality of rotating equipment?

116. In the context of ISO 13709/API 610, a Source Inspector is reviewing the documentation for a centrifugal pump. The pump's performance test results show that the pump is operating at 120% of its best efficiency point (BEP).

What should the inspector consider regarding this observation?

117. During a routine inspection, a source inspector identifies pitting corrosion on the impeller blades of a centrifugal pump. The equipment is operating in a petrochemical plant where the process fluid contains high levels of chlorides. The inspector is tasked with determining the primary cause of this corrosion mechanism to recommend appropriate mitigation strategies.

What is the most likely cause of the pitting corrosion observed in this scenario?

118. In the identification of alloy materials, the process involves the use of a portable device to analyze the elemental composition of metals in the field.

119. In the context of defect detection in forged components, ultrasonic testing is more effective than radiographic testing for identifying subsurface discontinuities.

120. The identification of alloy materials in rotating equipment is crucial for ensuring compatibility and performance. The presence of incorrect alloy materials can lead to significant equipment failure and safety hazards.

121. During an inspection of a centrifugal pump's components, you notice a series of linear indications on the surface of a cast impeller. These indications are visible to the naked eye and seem to align along the casting flow lines. The customer is concerned about the potential impact on performance and longevity.

Which of the following is most likely the cause of these defects?

122. In vibration analysis of rotating equipment, which of the following is a primary indicator of potential imbalance in the equipment?

123. When conducting an audit of a supplier's quality system, one of the critical elements to evaluate is their process for, which involves ensuring that all products and services meet specified requirements.

124. In the context of communicating with suppliers and stakeholders, a source inspector should prioritize technical jargon over clarity to maintain professional standards.

125. What is the primary purpose of establishing rejection criteria for rotating equipment during the inspection process?

126. Calibration drift in instruments measuring rotating equipment parameters is primarily influenced by ambient temperature changes.

127. A flexible coupling can accommodate both angular and parallel misalignments between two rotating shafts.

128. A new supplier claims to have a robust quality management system compliant with API SIRE standards. However, during your audit, you realize that their corrective and preventive action (CAPA) process is not well-documented.

Which of the following is the best immediate step to take during the audit?

129. A gas turbine has been experiencing frequent shutdowns due to high exhaust temperature alarms. Upon inspection, you discover that the combustion chamber has significant carbon buildup.

Which of the following actions should be prioritized to address this issue effectively?

130. According to API SIRE standards, a supplier's quality management system should include processes for continuous improvement and risk management.

131. Internal defects in cast components can include a variety of issues such as porosity, inclusions, and.

132. During a routine inspection of a centrifugal pump, you find that the vibration levels are exceeding the acceptable limits as defined by API standards. As a source inspector, you must determine the most appropriate course of action to address this issue. The pump is crucial for the plant's operations, and downtime needs to be minimized.

Which API standard should guide your decision on the corrective measures to take?

133. During a routine inspection of a centrifugal pump, you notice that the coating on the casing is showing signs of blistering and delamination. The pump is located in a coastal environment, which is highly corrosive due to the presence of salt and moisture. The equipment was coated using a standard epoxy primer and polyurethane topcoat, which are said to be suitable for such environments. However, the damage is evident and affecting the equipment's performance.

What is the most likely reason for this coating failure?

134. During a routine inspection, you observe that a centrifugal pump has been recently reassembled after maintenance. The pump's alignment needs to be verified before it is put back into service.

What is the most appropriate tool to use for checking the alignment of the pump and its driver to ensure optimal performance and avoid premature wear?

135. According to API standards, the recommended practice for assessing the integrity of critical rotating equipment components includes the use of non-destructive examination techniques. A common technique used is.

136. Which of the following is a primary objective of implementing preventive actions in the maintenance of rotating equipment?

137. Which of the following corrosion mechanisms is most likely to occur in rotating equipment exposed to alternating wet and dry conditions?

138. During the inspection of a newly manufactured centrifugal pump, you observe that the vibration levels exceed the acceptable limits outlined in the ISO 10816 standard. It appears that the imbalance is due to improper distribution of mass along the rotor. To address this, you decide to perform a balancing process.

Which of the following techniques is most appropriate for balancing a high-speed rotor in this scenario?

139. Which API standard provides the guidelines for the lubrication systems of rotating equipment, ensuring optimum performance and reliability?

140. While inspecting a piece of rotating equipment, you notice that the remote surveillance system is showing inconsistent data compared to the on-site inspection readings. The equipment is critical, and downtime must be minimized.

What is the best course of action to ensure both the accuracy of the data and the integrity of the inspection process?

141. Which of the following tools is most suitable for performing an accurate dimensional inspection of a turbine blade's complex surface geometries?

142. During the procurement phase of a new rotating equipment project, the engineering team discovers a discrepancy between the technical specifications provided by the supplier and the project requirements. As a source inspector, it is crucial for you to ensure alignment between the procurement and engineering teams to resolve this issue.

What is your first step in coordinating this effort?

143. Which of the following methods is primarily used to determine the amount and location of imbalance in a rotor during the balancing process?

144. During a quality inspection of a gearbox, the inspector finds that the backlash between gears is slightly above the maximum allowable limit specified in the manufacturer's documentation.

What should the inspector do in this situation?

145. Which of the following methods is most suitable for detecting surface-breaking cracks in forged components during in-service inspections?

146. In coordinating with engineering and procurement teams, the source inspector uses various tools and frameworks. One such tool is the, which helps in tracking and managing procurement activities.

147. When implementing a digital inspection system for rotating equipment, it is crucial to ensure the system is compliant with standards to maintain data integrity and operational safety.

148. In rotating equipment, corrosion fatigue is more likely to occur when mechanical stresses are cyclic in nature and the environment is corrosive.

149. Which lubrication method is most effective for bearings operating under high-speed conditions?

150. An axial displacement of a rotor shaft that exceeds the specified tolerance can lead to operational inefficiencies and potential equipment failure.