API 510 Pressure Vessel Inspection (Training Material)

API 510:

Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training Only)

September 4-15, 2004 Abu Dhabi, U.A.E.

Copyright © 2004 by Harvard Technology Middle East. All Rights Reserved

To The Participant The Course notes are intended as an aid in following lectures and for review in conjunction with your own notes; however they are not intended to be a complete textbook. If you spot any inaccuracy, kindly report it by completing this form and dispatching it to the following address, so that we can take the necessary action to rectify the matter.

P. O. Box 26608 Abu Dhabi, U.A.E. Tel: +971 2 627 7881 Fax: +971 2 627 7883 Email: [email protected]

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Disclaimer The information contained in these course notes has been complied from various sources and is believed to be reliable and to represent the best current knowledge and opinion relative to the subject. Harvard Technology offers no warranty, guarantee, or representation as to it’s absolute correctness or sufficiency. Harvard Technology has no responsibility in connection therewith; nor should it be assumed that all acceptable safety and regulatory measures are contained herein, or that other or additional information may be required under particular or exceptional circumstances.

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COURSE OVERVIEW IE100

API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training only) Course Title API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair and Alteration (Training only) Course Date/ Venue March 05-16, 2005/ Al Nakheel 4, Movenpick Hotel, Dubai, UAE Course Reference IE100 Course Duration 10 days (80 hours as per API recommendations) Course Objectives This course is designed to train individuals who are interested in obtaining the API 510 Pressure Vessel Inspector Certification, as well as those who are seeking a better understanding of ASME Section VIII and IX code requirements. Included with the course is a pre-study guide and student classroom workbook. The student receives instruction regarding how to take the test, as well as insight into the intricacies of "real world" situations. Daily tests are designed to gauge students’ proficiency and understanding of the material. Topics include: ƒ ƒ ƒ ƒ ƒ ƒ ƒ

Head and Shell Calculations Hydrostatic Test Pressure Calculations Reinforcement Calculations Shell External Pressure Calculations Impact Test Requirements and Determination Development and Review of Welding Documentation NDE Requirements

Harvard Technology (ITAC) is proud of its 90%+ pass rate, and we hope to include your staff among our successful candidates. Who Should Attend The course is intended for Inspection Engineers who are seeking API-510 certification. Other engineers, managers or technical staffs who are dealing with Pressure Vessel will also benefit. Course Certificate Harvard Technology certificate will be issued to all attendees completing minimum of 75% of the total tuition hours of the course.

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Course Fee US $ 3,750 per Delegate. This rate includes Participant’s Pack (Folder, Manual, Hand-outs, etc.), buffet lunch, coffee/tea on arrival, morning & afternoon of each day. Accommodation Accommodation is not included in course fees. However, any accommodation required can be arranged by Harvard Technology at the time of booking. Required Codes & Standards Listed below are the effective editions of the publications required for the current Vessel Inspector Certification Examination. Each student must have these documents available for use during the class. ƒ A APPII SSttaannddaarrdd 551100, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and Alteration, Eighth Edition, June, 1997; including Addendum 1 (December, 1998), Addendum 2 (December, 2000) and Addendum 3 (December, 2001). Global Engineering Product Code API CERT 510 ƒƒ A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557722, Inspection of Pressure Vessels, Second Edition, February, 2001. Global Engineering Product Code API CERT 572 ƒƒ A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557766, Inspection of Pressure-Relieving Devices,, Second Edition (December 2000). Global Engineering Product Code API CERT 576 ƒƒ G Guuiiddee ffoorr IInnssppeeccttiioonn ooff R Reeffiinneerryy EEqquuiippm meenntt,, C Chhaapptteerr 22**,, Global Engineering Product Code API CERT GUIDE IRE CH2 *NOTE: This publication is a reference document intended only for Inspector Certification applicants. To obtain a copy please inform the person taking your order that you require this publication for the API 510 Inspector Certification exam. ƒƒ A Am meerriiccaann SSoocciieettyy ooff M Meecchhaanniiccaall EEnnggiinneeeerrss ((A ASSM MEE)),, Boiler and Pressure Vessel . Code, 2001 edition. i. ii. iii. iv.

A A S M E S o n D AS SM ME ES Seeeccctttiiio on n IIIIIID D, External Pressure Graphs only. A A S M E S o n V AS SM ME ES Seeeccctttiiio on nV V, Nondestructive Examination, Articles 1, 2, 6, 7 and, Article23 (SE797) A A S M E S o n V AS SM ME ES Seeeccctttiiio on nV VIIIIIIIII, Rules for Construction of Pressure Vessels, Division 1, UG, UW, UCS, UHT, Appendices 1-4, 6, 8 and 12. Optional Appendix L ( has sample problems) A A S M E S o n X AS SM ME ES Seeeccctttiiio on n IIIX X, Welding and Brazing Qualifications

Global Engineering Product Code for the ASME package is API CERT ASME 510. Package includes only the above excerpts necessary for the exam. Future addenda will not be provided. API and ASME publications may be ordered through Global Engineering Documents at 303792-2181 or 800-854-7179. Product codes are listed above. API members are eligible for a 50% discount on all API documents, other exam candidates are eligible for a 20% discount on all API documents. No discounts will be made for ASME documents. When calling to order please identify yourself as an exam candidate.

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For complete sets of ASME documents including future addenda please contact ASME’s publications department at 1-800-843-2763. In Canada, ASME publications are available through Power Engineering Books, Ltd. at 1-800-667-3155 or 780-458-3155. Note: API and ASME publications are copyrighted material. Photocopies of publications are not permitted at the exam. CD-ROM versions of the API documents are issued quarterly by Information Handling Services. Be sure to check your CD-ROM against the editions noted on this sheet.

Course Instructor Mr. Oran T. Lewis, P.E. (Texas, USA) is an Adjunct Instructor with over twenty years experience in the design, erection, maintenance, inspection, fabrication, modification and repair of pressure equipment, as well as presenting educational courses for piping inspection, welding, weld inspection, and pressure equipment inspection Mr. Lewis has a Bsc degree and he is a qualified American National Board Trainer and an NDE Trainer. Further, he is a AWS Certified Welding Inspector, API Certified Pressure Vessel Inspector, API Certified Piping Inspector, a member of the National Board of Boiler and Pressure Vessel Inspectors Commission and a Boiler and Pressure Vessel Inspector - State of Texas. Course Program Day 1 : Saturday 05th of March 2005 0730 - 0800 Registration & Coffee 0800 - 0810 Welcome & Introduction Joint Efficiencies 0810 - 1000 ƒ UW-3 Weld Categories ƒ UW-51 RT Examination of Welded Joints ƒ UW-52 Spot Examination of Welded Joints 1000 - 1015 Break Joint Efficiencies (continued) 1015 - 1230 ƒ UW-11 RT and UT Examinations ƒ UW-12 Maximum Allowable Joint Efficiencies ƒ Exercises UW 3, 11 and 12 1230 - 1330 Lunch Postweld Heat Treatment 1330 - 1515 ƒ UW-40 Procedures for Postweld Heat Treatment 1515 - 1530 Break Postweld Heat Treatment (continued) 1530 - 1700 ƒ UCS-56 Requirements for Postweld Heat Treatment 1700 End of Day One

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Day 2 : Sunday 06th of March 2005 Review of Day 1 0730 - 0830 Vessels Under Internal Pressure 0830 - 1000 ƒ UG-27 Thickness of Shells Under Internal Pressure ƒ UG-32 Formulas and Rules for Using Formed Heads 1000 - 1015 Break Vessels Under Internal Pressure (continued) 1015 - 1230 ƒ UG-34 Unstayed Flat Heads and Covers (Circular) ƒ Exercises UG s-27-32-34 1230 - 1330 Lunch Cylinder under External Pressure 1330 - 1515 ƒ UG-28 Thickness of Shells and Tubes (External Pressure) 1515 - 1530 Break Cylinder under External Pressure (continued) 1530 - 1700 ƒ Exercise UG-28103 1700 End of Day Two Day 3 : Monday 07th of March 2005 Review of Day 1 & 2 0730 - 0930 0930 - 0945 Break Pressure Testing 0945- 1230 ƒ UG-20 Design Temperature ƒ UG-22 Loading ƒ UG-25 Corrosion ƒ UG-98 Maximum Allowable Working Pressure ƒ UG-99 Hydrostatic Test Pressure and Procedure ƒ UG-100 Pneumatic Test Pressure and Procedure ƒ UG-102 Test Gages 1230 - 1330 Lunch Pressure Testing (continued) 1330 - 1515 ƒ Exercises UG s 99-100-102 1515 - 1530 Break Minimum Requirements for Attachment Welds at Openings 1530 - 1730 ƒ UW-16 Weld Size Determination ƒ Exercise UW-16 1730 End of Day Three Day 4 : Tuesday 08th of March 2005 Review of Day 3 0730 - 0830 Reinforcement for Openings in Shells and Heads 0830 - 1000 ƒ UG-36 Openings in Vessels ƒ UG-37 Reinforcement of Openings 1000 - 1015 Break Reinforcement for Openings in Shells and Heads (continued) 1015 - 1230 ƒ UG-40 Limits of Reinforcement IE100 IE100-03-05

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1230 - 1330 1330 - 1515 1515 - 1530 1530 - 1700 1700

ƒ UG-41 Requirements for Strength of Reinforcement ƒ UG-42 Reinforcement of Multiple Openings Lunch Reinforcement for Openings in Shells and Heads (continued) ƒ Exercises UG s 40-41-42-45 Break Reinforcement for Openings in Shells and Heads (continued) ƒ Exercise Reinforcement for Openings in Shells and Heads End of Day Four

Day 5 : Wednesday 09th of March 2005 Review of Day 4 0730 - 0830 Minimum Design Metal Temperature & Exemptions From Impact 0830 - 1000 Testing ƒ UG-84 Charpy Impact Test Requirements ƒ Exercise UG-84 ƒ UCS-66 Materials 1000 - 1015 Break Minimum Design Metal Temperature & Exemptions From Impact 1015 - 1230 Testing (continued) ƒ UCS-67 Impact Testing of Welding Procedures ƒ UCS-68 Design ƒ Exercises UG 20 –UCS 66 – 67 1230 - 1330 Lunch Practical Knowledge 1330 - 1515 ƒ UG-77 Material Identification ƒ UG-93 Inspection of Materials ƒ UG-116 Name Plate Markings 1515 - 1530 Break Practical Knowledge (continued) 1530 - 1700 ƒ UG-119 Name Plates ƒ UG-120 Data Reports 1700 End of Day Five Day 6 : Saturday 12th of March 2005 Review of Day 5 0730 - 0830 Welding on Pressure Vessels (Section IX Overview) 0830 - 1000 ƒ Article I General Requirements ƒ Article II Welding Procedure Qualifications 1000 - 1015 Break Welding on Pressure Vessels (Section IX Overview) … (continued) 1015 - 1230 ƒ Article III Welding Performance Qualifications ƒ Article IV Welding Data 1230 - 1330 Lunch Welding Documentation Review 1330 - 1515 ƒ Welding Procedure Specification (WPS) ƒ Procedure Qualification Record (PQR) IE100 IE100-03-05

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Break Welding Documentation Review (continued) ƒ Practice WPS/PQR reviews End of Day Six

Day 7 : Sunday 13th of March 2005 Review of Day 5 & 6 0730 - 0930 0930 - 0945 Break Advanced Material Example Problems 0945 - 1230 ƒ Static Head of Water ƒ Corrosion Calculations ƒ Cylinders under Internal Pressure ƒ Heads under Internal Pressure ƒ Charpy Impact Test Evaluation WPS/PQR ƒ Quiz Static Head Pressure 1230 - 1330 Lunch Advanced Exercise Problems 1330 - 1515 ƒ Internal Pressure Shell Calculations ƒ Internal Pressure Head Calculations 1515 - 1530 Break Advanced Exercise Problems (continued) 1530 - 1700 ƒ Solutions for Advanced Exercises 1700 End of Day Seven Day 8 : Monday 14th of March 2005 Review of Day 7 0730 - 0830 API 510 Corrosion Rates and Inspection Intervals 0830 - 1000 ƒ Scope ƒ MAWP Determination ƒ Inspection Interval ƒ Corrosion Rate and Remaining Life ƒ Long and Short Term Corrosion Rates ƒ Quiz # 1 1000 - 1015 Break API 576 Pressure Relieving Devices 1015 - 1230 ƒ Scope ƒ Types of pressure relieving devices ƒ Quiz # 2 ƒ Quiz # 3 API 572 Inspection of Pressure Vessels ƒ Scope ƒ Reasons for Inspection ƒ Causes of Deterioration ƒ Methods of Repairs ƒ Inspection Records and Reports 1230 - 1330 Lunch API 572 Inspection of Pressure Vessels (continued) 1330 - 1515 ƒ Quiz # 4 IE100 IE100-03-05

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ƒ Quiz # 5 ƒ Quiz # 6 ƒ Quiz # 7 ƒ Quiz # 8 IRE Chapter 2 Break IRE Chapter 2 (continued)

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Coverage from the API 510 Body of Knowledge ƒ Quiz # 9 End of Day Eight

Day 9 : Tuesday 15th of March 2005 Review of all course materials 0730 - 0930 Administer first half of 150 question API 510 practice examination A. 0730 - 1000 1000 - 1015 Break Administer first half of 150 question API 510 practice examination A 1015 - 1230 (continued) 1230 - 1330 Lunch Administer first half of 150 question API 510 practice examination A 1330 - 1515 (continued) 1515 - 1530 Break Administer first half of 150 question API 510 practice examination A 1530 - 1730 (continued) 1730 End of Nine Day 10 : 0730 - 0830 0830 - 1000 1000 - 1015 1015 - 1230 1230 - 1330 1330 - 1530 1530 - 1545 1545 - 1645 1645 - 1730

Wednesday 16th of March 2005 Review of the first half of the API 510 practice examination A. Administer 2nd half of 150 question API 510 practice examination A. Break Administer 2nd half of 150 question API 510 practice examination A. Lunch Administer 2nd half of 150 question API 510 practice examination A. Break Review of the second half of API 510 practice examination. Pass out API 510 practice examinations B and C with solutions. Closing comments

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Presentation of Certificates End of course

Course Coordinator Ms. Urooj Musheer: [email protected]

Tel:

+971-2-6277881,

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Table of Contents Section 1

API 510 Code, RP’s 576, 572, & Chap. 2

Section 2

ASME Section VIII Div. 1

Section 3

ASME Section IX

Section 4

Advanced Material

Section 5

Practice Exams / Exercises

Section 1 API 510 Code, RP’s 576, 572, & Chap. 2

Section 2 ASME Section VIII Div. 1

Section 3 ASME Section IX

Section 4 Advanced Material

Section 5 Practice Exams / Exercises