API - 510
COURSE
VOLUME
NOTESm
- IE
CONTENTS
1
Program Daily Schedule.
2. Body of Knowledge & Effectivity Sheet. 3. Examples of Repairs and Alterations 4. Guidelines for API 510 Certification Exam. 5.
Case Studies.
ASME Sec. VIII.
6.
Case Studies
7.
Reference Documents.
API 510.
ASME See. IX.
Allowable Stress Tables Solved Examples, ASME Sec. VIII, Div. 1 Materials of Construction 8.
Daily Practice Exams & Answer Keys
9.
Daily Points to Recall.
10. Add itiona I Information
API 510 PRESSURE VESSEL INSPECTOR COURSE
PROGRAM SCHEDULE Venue:
Hotel Kohinoor Executive, Pune, INDIA.
\ DAY 1.
Session
1
Introduction to API-510 Certification. ASME code system introduction to ASME SEC. VIII, Div. 1. Session
2
Design fundamentals Allowable Stresses, Joint Category, Joint types Joint efficiencies Session
3
Design of Cylindrical shells Calculation of vessel MAWP, part MAWP Static head calculations Design of Dished heads Case Studies
I DAY 2.
J Session
1
•
to recall Day-1 of Dished heads. (Contd.) of Flat unstayed heads of dished heads
•
Points Design Design Depths
Session
2
External pressure calculations Case Studies Impact testing requirements Session
3
Pressure testing -Hydrostatic Pressure testing-Pneumatic Review of Practice Exam-1
------------------_ - ~.-------..
I
DAY-3.
Session • • • •
l 1
Points to recall Day-2 Weld size for attachment welds at openings. Case studies. Reinforcement of Openings-Concepts
Session • • •
Reinforcement pad Calculations Case studies. Typical weld joints for Pressure Vessels Restrictions on joints -mismatch tolerances
Session • • • •
2
3
Allowable weld reinforcements Inspection requirements for Pressure Vessels Heat treatment Code stamping and Data-reports Review of Practice Exam-2
~------------------------------------------,
I
DAY 4.
Session 1 Points to recall Day-3 Introduction to API-510 code - Scope & Applications Reference Codes and Standards Specific definitions Session 2
•
API-510 contd ...lnspection Organizations Owner-User responsibilities Quality control manual Certification requirements
Session
•
3
Modes of Deterioration Corrosion, Fatigue, Creep Freeze damage, Brittle failure, Temper embrittlement Review of Practice Exam-3
I
--_._ ..,-_
..•..••..
_-_ _-._-------~---_. .•.
[DAYS. Session • • • • • •
•
r
1
2
API-510 Inspection practices Corrosion rate determination MAWP determination for Vessels in service Numerical Examples
Session •
---------------------
Points to recall Day-3 API-510 contd ..Defect inspection Inspection of parts Minimum thickness Evaluation Pitting corrosion Localised corossion
Session
• • •
----------
3
API-510 contd .... External inspection Internal and on-stream inspection Inspection interval Remaining service life Illustrative calculations Review of Practice Exam-4
DA-Y_ -_6-._----- -- -- -------
Session
-_ -_ -_ -_ -
--------.-------------------., .
1
Points to recall Day-3 API-510 contd ...Defect repairs Pressure tests Documentation Session •
and Records
2
Welding requirements Pre-heating and PWHT Weld overlay and cladding NOT for repairs and alterations
Session
3
Alterations and re-rating Re-rating documentation and stamping Review of Mid-session Exam-Open book. Closed book.
I
I DAY 7. Session • • • •
Points to recall Day-6 Introduction to ASME SEC. IX Procedure Qualifications PQR tests- and evaluation of results
Session
Session •
• • t
2
Welding variables-EVs, NEVs, SEVs. Limits of PQR Qualificatios I validity. WPS/PQR documentation WPQ tests & their validity
•
I
1
3
Detailed road-map for review of WPS/PQR documentation Case Studies for WPS/PQR review. ASME Sec.v Nondestructive Examination Article 1: General Requirements Review of Practice Exam-6
DAY 8.
Session
•
Points to recall Day-7 Article 2: Radiographic Examination Radiograpic procedure Selection of penetrameter Radiographic technique Interpretation & documentation
Session • • • •
1
2
Article 6: Liquid Penetrant Examination LPE procedure Selection of penetrants LPE technique Interpretation & documentation Article 7: Magnetic particle Examination
Session
3
SE-797 UT measurememt Pulse-Echo contact method Single and dual crystal techniques Review of NDE Requirements ASME See VIII & API 510 Review of Practice Exam-7
I DAY
9.
Session • • • • • •
1
Points to recall Day-8 Introduction to IRE Chap. II Corrosive components in crude Deterioration due to Hydrogen Deterioration due to H2S Other factors of Corrosion
Session • • • •
2
API RP-572 review Types of Pressure Vessels Construction Standards Causes of deterioration
Session • • • •
3
Internal inspection External inspection Inspection records and reports Review of Practice Exam-8
-- ----
Session • • • • • •
---------.---------
1
Points to recall Day-9 API RP-576 Inspection of Pressure relieving Devices Types of PRDs Causes for malfunctioning Inspection intervals &insp. procedures for PRDs, Testing of PRDs on test bench. Inspection records & reports
Session
2
Review of Practice Exam-8 Final Open- book Test Session
3
Final close book test Feed-back on tests Close-down.
" ~ ..:",ao
reln-dcum Institute
1220 L Street. Northwest Washington, D.C. 20005-4070 202-682-8161 202-682-8348 (Fax)
~ICP BODY OF KNOWLEDGE API-SIO PRESSURE CERTIFICATION
VESSEL
INSPECTOR
EXAMINATION
May 2005 (Replaces June 2004) API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, and altcration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such knowledge. The following is a list of specific topics in which the API Authorized Pressure Vessell.nspector
should bc knowledgeable.
To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each category listed within tl1is Body of Knowledge will be included on the API certification exan1ination. Only inspection information covered in one of the references outlined in this body of knowledge will be utilized for the examination questions. The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring everyday working knowledge of API Standard 510 and the applicable reference documents. The open book portion of the examination requires the use of morc detailed information that the inspector is expected to be able to find in the documents, but would not nonnally
be COllunitted to memory.
REFERENCE
PUBLICATIONS:
API publications open-book
and ASME codebooks
must be brought to the examination
site to be used as reference materials for the
part of the examination.
A. API Publications: API 510, Pressure Vessel Inspection Code API RP 571, Damage Mechanisms Affecting Equipment
in Refilling Industry
API RP 572, Inspection of Pressure Vessels API RP 576, Inspection of Pressure-Relieving Devices API RP 577, Welding Inspection and Metallurgy B. ASME Publications: Section V, Nondestructive Examination Section VIII, Division I, Rules for Constructing Section lX, Welding and Brazing Qualifications Note: Refer to the Publications supplements
05105
Effectivity
ofilie reference publications
Pressure Vessels
Sheet in the application package for a list of specific editions, addenda, and tl1at are effective for your ex.am date.
I. THICKNESS
MEASUREMENTS,
INSPECTION
INTERVALS
AND VESSEL
INTEGRITY
A. Code calculation questions will be oriented toward existing pressure vessels, not new pressure vessels. API Authorized Pressure Vessellnspcctors should be able to check and perfonn calculations relative to in-service deterioration, repairs, rerates, or alterations. Only internal and external pressure loadings will be considered for the API 510 examination. The following categories describe the minimum necessary knowledge and skills: I. CORROSION
RATES AND INSPECTION
INTERVALS
The Inspector should be able to take inspection data and deternline the internal and external inspection
intervals.
The Inspector must be able to calculate: a. b. c. d. e.
Metal Loss (including corrosion averaging) (API-51O, Para 5.7, d) Corrosion Rates (API-SIG, Para 6.4) Remaining Corrosion Allowance (API-51O, Para 6.4) Remaining Service Life (API-510, Para, 6.4) Inspection Interval (API-SIO, Para, 6.4)
The fonnulas for perfonning during the exam.
the above calculations
and rules for setting the inspection
intervals may be "closed-book"
2. JOINT EFFICIENCIES The inspector must be able to detennine a. Weld Joint Categories b. Type c. Joint d. Joint e. Joint
"E" of a vessel weld. Inspector should be able to detennine:
from UW-3;
of radiography (full, spot, or none) performed basis the nameplate markings (RT-I, RT-2, etc.); efficiency by reading Table UW-12; efficiency for seamless heads and vesscls Sections per UW -12 (d); and efficiency for weldcd pipe and tubing per UW- 12 (e).
Detenllining formulas 3. STATIC
the joint efficiency
joint efficiency may be part of the internal pressure problem for deternlining required thickness or Vessel Part MA WP.
since joint
efficiency
"E" is used in the
HEAD
The inspector must be able to compensate for the pressure resulting from static head. All static head wiIl be based upon a Specific Gravity of 1.0. The inspector should be able to: a) b) c) d) e)
List the static head/pressure conversion factor (0.433 psilft); Know the difference between vessel MA WP and vessel part MAWP (UG-98); Calculate static head pressure on any vessel part; Calculate total pressure (MA WP + static head) on any vessel part; Calculate maximum vessel MA WP given vessel parts MA WP and elevations
Static head calculations examination problem.
05/05
may also be required during the internal pressure calculations
2
if static head data is given in the
The inspector a) b) c) d) e)
should be able to detennine:
The rcquired thickness of a cylindrical shell based (In circllnlferel\ti.d ,tr<:ss gi,'<:n a pr<:ssure (UG-27(c)(l »)i The vessel part MA WP for a cylindrieal shell ba.,cd on cir.:umtcr.:nllal strcs, given a metal thickness (UG-27(c)(I)); The rcquircd thickncss ofa head (ellipsoidal. and hCOlisphcrh;al) ~i\(;n a pre-;surc. (UG-32 (d), (e), (f) and (g)) The vessel part MAWP for a head (ellipsoidal. and hCOlisphcn-:;d) ~i"en a -neta\ thickness. (UG-32 (d), (e), (f) and (g). Whether a head (ellipsoidal, torispherical or hcmlsph,Ti
The inspector should also be able to compensate for thc corro_i0n d1l0wanee: add or subtract based on requirements of tbe exam problem. The Appendix I fonnula for cylinders, which IS bascd on outside diamcter, can be used. The Appendix I fonnulas for non-standard heads will not be required. 5. EXTERNAL
PRESSURE
The inspector should be able to: a) Calculate the maximum allowable external pressure (specific MaterialfTemperature Charts supplied with the examination) (UG-28(c)(l); and b) Calculate whether a cylindrical shell or tube meets Code design for external pressure given a wall thickness and a pressure (UG 28 (c )( I). Note: Factors from the external pressure charts will be given in the wording of the question. Use of the actual charts is not required.
6. PRESSURE The inspector a) b) c) d)
should be able to:
Calculate a test pressure compensating for temperature. (UG-99 & UG-IOO) Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test temperatures, protection against overpressure etc. Be familiar with all steps in a hydrotest Procedure (UG 99 and UG 100) Be fanliliar with all steps in a pneumatic test procedure (UG 100 and UG 102)
7. IMPACT The inspector a)
TESTING
TESTING should be able to:
Determine the minimum metal temperature UCS-68(c).)
8. WELD SIZE FOR ATTACHMENT
of a material which is exempt from irnpacttesting
WELDS AT OPENINGS
The inspector must be able to determine if weld sizes meet Code requirements. a) b)
05/05
(UG-20 (f), UCS-66,
The inspector should be able to:
Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion (0.707); and Detennine the required size of welds at openings (UW -16).
3
factor
Thc inspector should: a)
Undcrstand
thc
kcy
conccpts
of reinforcement,
such
as replacement
b)
rcinforccmcnt. Credit can be takcn for cxtra metal in shell and nozzle Be able to calculate the required areas for reinforcement
of
strength
or check to ensure
removed
that a designed
and
pad
limits
1S
of
large
enough. To simplify the problem:
c) d) e)
B.
All fr = 1.0 All F = \.0 All E = 1.0 All required thicknesses are given There will be no nozzle projecting inside the shell Be able to compensate for corrosion allowances. Weld strength calculations are excluded.
The following are typical ASME code engineering requirements that API certification candidates will NOT be expected to know for purposes of the certification examination.
I. Required thickness calculations for wind., earthquake, and other secondary stress loadings; 2. Supplementary design formulas and calculations for non-cylindrical shell components; 3. 4. 5. 6. 7. 8. 9.
Most external pressure calculations; Nozzle calculations for external loads; Flange calculations; Brazing requirements; Ligament calculations; Stayed flat heads and sizing of stays; Tubesheet calculations (stayed or unstayed) and tube to tubesheetjoints
10. II. 12. 13.
Relief valve sizing; Lifting lug and other structural type calculations; Proof testing requirements; Required inspections for new construction, except as they apply to alterations and repairs;
14. 15. 16. 17. 18. 19.
Zick analysis; Integrally forged pressure components; Cryogenic vessels (below -50 f); Dimpled., embossed., jacketed, and non-metallic vessels and assemblies; NDE requirements for acoustic emission, eddy current, and motion radiography; ASME Sections UF, DB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT;
and loads;
20. Code Cases and interpretations; 2 \ . \V elding process requirements other than shielded metal arc welding (SMA W), gas tungsten arc welding (OT A W), gas metal arc welding (OMA W), or submerged arc welding (SAW); 22. Requirements for pressure vessels for human occupancy; and 23. Rules for natural resource vessels, API-5 10, Section 8.
05/05
4
II. WELDING
PROCEDURE
AND PRESSURE /\.
VESSEL
WELD PROCEDURE
AND QUALIFICATION CODE, SECTION
EVALUATION
BASEl) 0"
..••S\It.
BOILER
IX
REVIEW
I. The inspector should be able to detern1ine if procedure and qualtfi.::ation record., al\: .n ,::olllpliance with applicable ASME boiler and pressure vessel code and any additional requirem<:nt$ .,f API 5 10 (\ 1'1·51 (I requirements will take preccdencc
ovcr any ASME requirements
covcring the same technic.tl .lrca ..
The weld procedurc review may include: a. Welding Procedure Specification (WPS); and b. Proccdure Qualification Record (PQR). The wcld procedure review may include: SMA W, GT A W, GMA \\'. OK SA \\ . ""ilh thl f(llhm ing Iimiwtions: a) No more than one process will be included on a single WPS or PI)R, ..mJ the wrs 10 bc rcviewcd b) c)
2. The inspector should be able to determine: a) Whether numbcr and type of mechanical test listed on PQR arc appropriate b) Whether the results of the tests are acceptable c) Whether all required essential and non-essential variables have been properly addressed. (Supplemental variables will not bc a part of the WPS). The following limitations or conditions will apply:
Base metals limited to PI, P3, P4, P5, and P8. Dissimilar base metal joints, and dissimilar thicknesses of base metals are excluded. Supplemental powdered filler metals and consumable inserts are excluded. Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and dissimilar
• •
metal are excluded Welds with buttering of ferritic member are excluded. For PI, P3, P4, and P5, for the purpose of the examination tempcrature
B. ASME Section VIII. Div. I and API-51O: GENERAL
3.
the lower transfonnation o will be 1600 F.
WELDING
temperature
will be
REOUIREMENTS:
ASME Scction VIII, Div. I The inspector should be familiar with and understand the general rules for welding in ASME Section VIII, Div. I, Parts UW and UCS such as: a) b) c) d) c) f)
2.
essential
• • • •
13330F and the upper transformation
I.
will bc
supported by a single PQR. filler metals limited to one-pcr-proccss for SMAW, GTAW, GMA W. or ~A W. Thc PQR will be the supporting PQR for thc WPS.
Typical joints and definitions Weld sizes Rcstrictions on joints Maximum allowable reinforcement Inspection requirements Heat treatmcnt
API510 Thc inspector should be familiar with and understand any rules for welding in API-51O. Any rules for welding given in API-510 shall take precedence over those covering the same areas in ASME, Section VIII, Div. 1. "Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are excluded. This includes items such as the revision level of the WPS, company name, WPS numbcr and date, and name of testing lab. Howcver, the API 510 applicants shall know tbat the PQR must be certified by signing and dating.
C. The inspector
05/05
shall be familiar with all the requirements
5
of and infonnation
in API RP 577.
1Il.NONDESTRUCTlVE
EXAMINATION
A~ME Section V. l'J9ndestluctive NOTE: The examination A.
will cover ONLY the main body of each referenced
Article, except as noted
Article I, General Requirements: The inspector should be familiar with and understand; I. 2. 3. 4. 5. 6.
8.
Examination
The Scope of Section V, Rules for use of Section Vas a referenced Code, Responsibilities of the Owner / User, and of subcontractors, Calibration, Definitions of "inspection" and examination", Record keeping requirements.
Article 2, Radiographic Examination: The inspector should be familiar with and understand; 1. The Scope of Article 2 and general requirements, 2. The rules for radiography as typically applied on pressure vessels such as, but not limited to: a. Required marking b. Type, selection, number, and placement ofIQI's, c. Allowable density d. Control of backscatter radiation e. Location markers 3. Records
C.
Article 6, Liquid Penetrant Examination, including Mandatory Appendices The inspector should be familiar with and understand:
II and III:
I. The Scope of Article 6, 2. The general rules for applying and using the liquid penetrant method such as, but not limited to; a) Procedures b) Contaminants c) Techniques d) Examination e) Interpretation f) Documentation and g) Rccord keeping
D.
2.
Article 7, Magnetic Particle Examination (Yoke and Prod techniques only): The inspector should bc fanliliar with and understand the general rules for applying and using the magnetic particle method such as, but not linlited to; 1. The Scope of Article 7, 2. General requirements such as but not limited to requirements a. Procedures b. Techniques (Yoke and Prod only) c. Calibration d. Examination e. Interpretation Documentation and record keeping
for:
E. Article 23, Ultrasonic Standards, Section SE-797 only - Standard practice for mea<;uring thickness pulse-echo contact method:
05105
6
by manual ultrasonic
The inspector should be familiar wnh and und<:rsland. I) 2) 3)
The Scope of Article 23, Section SE-797, The general rules for applying and using th<:ll(lra~llir ll't.:t:)od The specific procedures for Ultrasonic thldness lTl<.:a,ure!a'nl JS' ontallled in paragraph 7.
AS ME Section VIII, Div. I and API-510
Genna; [K)p(k-;t;u,ti\c e\amillJtion requirements:
I.ASME Section VIII, Div. 1: The inspector should be familiar Withand u!xkrs:aI,d :hc F,;r><:ral ruk, for \,fDE (UG, UW, Appendices 4, 6, 8, and 12)
2. API 510, The inspector should be famiiiar \.'it~ .u1\1 unl~r-;t.U)dthe general rules for NDE in API-51 O.
IV. PRACTICAL KNOWLEDGE - GENERAL The following topics may be covered in the examination. More infonnation relative to each of the categories is contained in section V. PRACTICAL KNOWLEDGE - SPECIFIC 1. Organization and Certification Requirements. 2. Types and Definitions of Maintenance Inspections. 3. Types of Process Corrosion and Deterioration. 4. Modes of Mechanical, Thennal, and High Temperature Dcterioration. 5. Pressure Vessel Materials and Fabrication Problems. 6. Welding on Pressure Vessels. 7. Nondestructive Examination (NDE) Methods. 8. Corrosion and Minimum Thickness Evaluation. 9. Estimated Remaining Life. 10. Inspection Interval Determination and Issues Affecting Intervals. 11. Relief Devices. 12. Maintenance Inspcction Safety Practices. 13. Inspection Records and Reports. 14. Repairs/Alterations to Pressure Vessels. 15. Rerating Pressure Vessels. 16. Pressure Testing After Repairs, Alterations, or Rerating
05/05
7
V. PRACTICAL
A PI-51 0, Pressure
KNOWLEDGE - SPECIFIC
Vessclluspc'crio,r
\fOTE: All of A PI 510 is applic able Appcndix E arc excludcd. I. Organization a) b) c) d)
Code 10
Ih~
1)
g) h) i) j)
unk.-ss s[}Ccifically cxcluded.
ror cxample: Scction 8 and
and ('ertiflcati. >n Rcq,liremc'll~
Certification for API A ulh0roe(! Pce-.5l,rc \ ~s.;cl Insrectors (API-510, Section 4.2 and Appcndix Authorized Inspeni011 ,\/--,cllcles (AP -: 1('. '\ection 3.4) Vessel Repair Organlzati'Jn'; (API- 510. Section 3.16) Relief Device Testing and Repa,r ()rga:linllons (API-510, Section 6.6)
2. Typcs and Dcfinitions of Maintcnance a) b) c) d) e)
"XdDlm..ll"Jll
B).
Inspcction
Internal Inspection (API 5 10,6.4) Defcct Inspection (API-51O, 5.5) Inspcction of Parts (API-51O, 5.6) External Inspection & Buried Vessels (API 510, 6.3) Atmospheric Corrosion and Corrosion Undcr Insulation (API-5 10, 6.3) On-Stream Inspcction (API-51O, 3.1 I & 6.4) Visual Examination (API-51O, 5.5) Thickness Measurements (API-51O, 5.3, 5.7, 6.3 & 6.4) Nondestructive Examination (API-5 I 0,5.5 & 5.7) Assessment of Inspection Findings (5.8)
3. Welding on Pressure Vessels a) 4. Corrosion
Welding Inspection
(API-51O, 5.6 & 7.2)
Requirements
and Minimum Thickness
Evaluation
The inspector should havc a general knowledge of the following principles, calculations using these principles. a) b) c) d) e)
Corrosion Rate Determination (API 510, 5.3) Corrosion Averaging (API 510, 5.7) Widely Scattered Pitting (API 510,5.7) Surfaccs Remote From a Weld (API, 5.7) Corrosion in Central Portion of Dished Heads (API 510,5.7)
5. Estimated
Remaining Life and Corrosion
6. Inspection
Interval Determination
a) b) c) d) e) f) g) h)
rate
(API 510,6.4)
and Issues Affecting Intervals
Rjsk-based inspection (API 510, 6.2) Internal or On-Stream Inspection Intervals (API 510, 6.4) Intcrnal and On-stream inspection Intervals for Estimated Life (API 510, 6.4) External Inspection Intervals «API-51O, 6.1-6.3) Dcterioration Other Than Metal Loss (API 510, 5.2) Different Zones of a Vessel (API 510, 6.4) Change of Service Conditions (API 510, 6.4) Change in Location and Ownership (API 510,6.4)
7. Relief Devices
05'05
and may be required to make
8
a) b) c)
Repair Organizations (API-51O, Section 6.6) Minimum Requirements for Quality Control Systems (API 510, 6.6) Maximum Service Intervals (API-51O, 6.6)
8. Maintenancc Inspcction Safety Practices a)
Pressurc Vcssel Inspection (API-51O, Section 5.1)
9. Inspcction Rccords and Reports a)
Permanent and Progressive Inspection Records (API-510,6.7)
10. Repairs and Alterations, to Pressure Vessels a) b) c) d) e) f)
g) h) i) j)
k)
Authorization (API 510, 7.1.1) Approval (API 510, 7. \.2) Design Requirements (API 510, 7.2.7) Materials Requirements (API 510, 7.2.8) Welding Requirements (API 510, 7.2.1, 7.2.2,7.2.3,7.2.6, & 7.2.11) Heat Treating Requirements, including • Preheating (API 510, 7.2.3) • Post weld Heat Treating (API 510, 7.2.3) • Local Postweld Heat treatment (API 510, 7.2.5) Repairs to Stainless Steel Weld Overlay and Cladding (API 510, 7.2.6) Inspection (API 510, 7.2.9) Rerating of Pressure Vessels (API 510, 7.3) Pressure Testing After Repairs, Alterations or Rerating (API-51 0, 6.5 and 7.2.10) Nondestructive Examination of Welds (API 510, 7.2.4)
API RP 571, Damaf!e Mechanisms Affectinf! Fixed equipment in the Refini,,!! Industry ATTN: Test questions will be based on the following mechanisms only: Par. 4.2.3 - Temper Embrittlement 4.2.7 - Brittle Fracture 4.2.9 - Thermal Fatigue 4.2.14 - Erosion/Erosion-Corrosion 4.2.16 - Mechanical Failure 4.3.2 - Atmospheric Corrosion 4.3.3 - Corrosion Under Insulation (CUI) 4.3.4 - Cooling Water Corrosion 4.3.5 - Boiler Water Condensate Corrosion 4.4.2 - Sulfidation 4.5.1 - Chloride Stress Corrosion Cracking (CrscC) 4.5.2 - Corrosion Fatigue 4.5.3 - Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5.1.2.3 - Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 - High Temperaturc Hydrogen Attack (HTHA)
API RP-572, If/sf/eetio" of Pressure Vessels
05/05
9
I. Types and Definitions a) b) c) d) e) f)
g) 11)
i) j) k) \) 2.
Pressure Vessel Materials and Fabrication Problems Material and Fabrication Problems (API RP-572, 8A & 8.5)
Maintenance
Inspection Safety Practices a)
2.
Inspections
Types of Pressure Vessels (API RP-572, Section 4) Construction Standards (API RP-572, Section 5) Maintenance Inspection (API RP-572, Section 6) Reasons for Inspection (API RP-572, Section 7) Causes of Detcnoration (API RP-572, 8.1- 8.10) Frequency and Time of Inspection (API RP-572, Section 9) Internal Inspection (API RP-572, lOA) External Inspection, Typical Items Checked (API RP-572, 10.3) Visual Examination (API-RP-572, Section 10) Thickness Measurements and Limits (API RP-572, Section 10) Nondestructive Examination (API RP-572, Section 10) Repair Methods (API RP-572, Section 11)
a) 3.
of Maintenance
Inspection
Pressure Vessel Inspection (API RP-572, 10.2) Records and Reports (API RP-572, Section 12)
API RP 576, Inspection
of Pressure-RelievinF!
Devices:
1. Relief Devices a) b) c) d) e) f)
Description of Types -- General Knowledge of Application and Limitations (API RP-576, Section 2) Causes of Improper Performance (API RP-576, Section 4) Reasons for Inspection and Frequency Detennination (API RP 576, Sections 3 & 5) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7) Maintenance Inspection Safety Practices (API RP 576, Section 6) Inspection Records and Reports (API RP-576, Section 8)
API RP 577, Weldine Inspection I. 2. 3. 4. 5. 6. 7. 8. 9. 10. II. 12. 13. 14.
OS/OS
alld Metallurf!1J
Definitions Welding Inspection Welding Processes Welding procedure Welding Materials Welder qualifications Non-destructive examination Metallurgy Refinery and Petrochemical Plant Welding Issues Ternlinology and symbols Actions to Address improperly made production welds Welding procedure review Guide to common filler metal selection Example report ofRT results
10
Publications Effectivity Sheet API 510, Pressure Vessel Inspector For Exam Administration:
Certification Exam
December 7, 2005
Listed below are the effective editions of the publications
required for the December
7,2005
Examination.
•
API Standard 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair. and Alteration, June 1997, Addenda 1,2,3 and 4 (August 2003). Global Engineering Product Code API CERT 510
8th Edition,
•
API Recommended December 2003
1" Edition,
A TTENTION:
Practice 571, Damage mechanisms
Only the following mechanisms
Affecting fIXed equipment
in the refining
industry,
to be included:
Par. 4.2.3 - Temper Embrittlement 4.2.7 - Brittle fracture 4.2.9 - Thennal Fatigue 4.2.14 - Erosion/Erosion-Corrosion 4.2.16 - Mechanical failure 4.3.2 - Atmospheric Corrosion 4.3.3 - Corrosion Under Insulation (CUI) 4.3.4 - Cooling Water Corrosion 4.3.5 - Boiler Water Condensate Corrosion 4.4.2 - Sulfidation 4.5.1 - Chloride Stress Corrosion Cracking (CrscC) 4.5.2 - Corrosion fatigue 4.5.3 - Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5. \.2.3 - Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.] - High Temperature Hydrogen Attack (HTHA) •
AP I Recommended Practice 572, Inspection of Pressure Global Engineering Product Code API CERT 572
•
API Recommended Practice 576, Inspection of Pressure-Relieving Global Engineering Product Code API CERT 576
•
API Recommended Practice 577 - Welding Inspection and Metallurgy. Global Engineering Product Code API CERT 577
•
American
Society of Mechanical
Vessels, 2nd Edition, February 200 I. Devices, 2nd Edition, December 2000. First edition, October 2004.
Engineers (ASME), Boiler and Pressure
Vessel Code, 2001 edition
with 2002 and
2003 addenda. 1.
Section V, Nondestructive
Examination,
ii.
Section VIII, Rules for Construction Gnd 12
Ill.
Section lX, Welding and Brazing
Articles 1. 2, 6, 7 and 23 (section S£-797)
of Pressure
Qualifications.
Vessels, Division 1, UG, We/ding
urv, UCS,
UHT, Appendices
1-4, 6, 8
OIlZF
Global Engineering Product Code for the ASME package API CERT 510 ASME. necessary for the exam.
Package includes only the above excerpts
API and ASME publications may be ordered through Global Engineering Documents at 303-397-7956 or 800-8547179. Product codes are listed above. Orders may also be faxed to 303-397-2740. More infonnation is available at hUp://www.global.ihs.com. API members are eligible for a 50% discount on all API documents; exam candidates are eligible for a 20% discount on all API documents. When calling to order, please identify yourself as an exam candidate and/or API membcr. Prices quoted will reflect the applicable discounts. No discounts will be made for ASME documents.
Note: API and ASME publications are copyrighted material. Photocopies of API and ASME publications are not pennitted. CD-ROM versions of the API documents are issued quarterly by Information Handling Services and are pemlitted. Be sure to check your CD-ROM against the editions noted on this sheet.
API 510 PREPARP,TORY COURSE
EXAMPLES OF REPAIRS AND ALTERATIONS INTRODUCTION The following examples are intended to provide owners, users, repair organizations and Inspectors the assistance in evaluating whether contemplated work on a pressure retaining item should be categorized as a repair or alteration.
EXAMPLES OF REPAIRS J.
('
Weld
repairs
attachments material:
or that
replacement
of
pressure
parts
or
have failed in a weld or in the base
2.
Corrosion resistance strip lining or weld overlay:
:;
Weld bUildup of wasted areas;
4.
The addition such as;
of welded attachments
a. studs for insulation or refractory
to pressure
parts,
lining
b. ladder clips c. brackets,
having
loading Y"hich do not affect
design of the pressure retaining
the
item to which they
are attached d. tray support rings 5
Replacement of heat exchanger tube sheets in accordance with the original design.
rs
Replacement
of boiler and heat exchanger
tubes
where
welding is involved. 7
The installation
of a flush patch to a pressure
Itern
1
retaining
8. Replacement
of pressure
parts identical
on the pressure retaining a. replacement the original b. Re-welding
item
f
to those existing
such as,
of a shell or head in accordance
with
design. a circumferential
or longitudinal
seam in
a shell or head c. Replacement
of
reinforcement 9.
Installation
of
a
size
whet~e
is not a consideration
of new nozzles or openings
reinforcement
of such a size that
is not a consideration
{for
example
the
of a 3 NPS nozzle to a shell or head of 3/8 in.
installation
(
nozzles
or less in thickness
or the addition
of a 2 NPS nozzle to a
shell of head of any thi~kness}. i o.
The
addition
consideration
of
nozzle
where
may be considered
nozzle is identical a similar
a
reinforcement to be a repair
to one in the original
is if
design, located
a
the in
part of the vessel.
11. The replacement
of a shell course in a cylindrical
pr·essure
vessel: 12. Welding
(
of wasted or distorted
13. Replacement
of slip-on
flange faces:
flanges with weld neck flanges
01-
vice-versa: 14.
Seal welding
of butt straps and rivets;
15 The repai r or replacement
accepted strength 16
material
that
of a pressure has a normal
that is equivalent
Replacement
to the original
of a pressure retaining
different
nominal
allowable
stress
composition, from
that
part with a Code composition material,
part with material
equal
to
or greater
used in the or-iginal
2
and
of tn
design,
provided and
the replacement material
design
construction
c.
requirements
of
satisfies
the
under which the vessel
the material
original
code
of
was built.
EXAMPLES OF ALTERATIONS 1. An increase (internal
in the maximum
or external)
item regardless
allowable
Or temperature
working
pressure
of a pressure retaining
of whether or not a physical
change was
made to the pressure retaining item;
(
2. A decrease in the minimum temperature mechanical tests are required. 3. The addition
of new
pressure vessel)
such that additional
nozzles or opening
(in
a bOiler
of new sizes other than existing
requiring new reinforcement 4. A change in the retaining item;
or
sizes and
calculations
dimensions
or contour
of
a pressu re
5. In a boiler, an increase in the heating surface or steaming capacity required;
such that
increase in the
relieving
capacity
is
6. The addition of pressurized jacket to a pressure vessel; 7. Except as permitted
in Repair, repiacement
of a pressure
retaining
part in a presSure retaining item with a material
different
allowable
stress or nominal composition
of
from that
used in the presSure retaining item to which it is attached. 8. The addition
of a braCket Or an increase
existing
bracket
which
affects the design
retaining
item to which it is attached.
')
J
in ioading
on an
of the pressure
-------------_._-------_."----~
GUIDELINES FOR API 510 CERllFICA liON EXAMINA liON
Contents
1.
Examination Scheme
2.
Distribution of Marks
3.
Salient Features of the Examination
4.
How to Prepare for the Examination
5.
API-510 -Chapter wise Tips for Maximizing the Score
6.
Time Management During the Examination
..~~"~~.~-
1.
EXAMINATION SCHEME
1.1 General: As per the present scheme, API 510 examination is one-day, 8-hour, 2 session examination, comprising of pre-lunch session (4 hours) for "openbook" examination and post-lunch session (4 hours) for "closed-book" examination.
1.2 Total marks: There are a total of 150 questions carrying 1 mark each, (total of 150 marks), split into open-book (approximately 50 questions) and c1osedbook (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.
1.3 Question pattern: Each question,( in open book as well as closed book part ) is multiplechoice question with given FOUR possible choices. Only ONE out of these four 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. In the answer sheet you will find four blank circles for each question. The correct answer is to be indicated by blackening (filling) the relevant circle by a pencil. Each correct answer will carry one mark. There is no set passing percentage. However a score of about 100 to 110 out of 150 is a good estimate of passing score.
please note the followinq: •
Fill only one circle out of four given 2
-_._--------------------~-~-~~---~------== •
Fill the circle fully and completely. Half or less than half blackened circle
is not reckoned for answer.
•
Never indicate the answers by ticking (....J) the circles.
•
There is no negative marking.
During the "open-book"
session.
you are permitted
and other documents
as per "Effectivity
tabbed.
underlined
highlightened,
Sheets".
to refer to the codes Code
or notes in margin
2 Nos. 8 or 28 pencils and eraser
•
Non-programmable
•
Photo identity (passport,
•
Exam confirmation
may be
of the pages
accepted. Additional new pages to codes are not accepted. the following to the exam hall.
•
pages
Always
are carry
calculator driving license, etc.)
letter
Be present in the exam hall at least 15 minutes prior to scheduled exam. The Supervisor announces
important instructions
start of
during this period.
Do not miss them. Now relax and attempt the exam calmly. Time is always more than enough.
3
2.
DISTRIBUTION OF MARKS
2.1 Codes for Study: As per the Effectivity Sheet for API-510 exam. there are total 7 codes prescribed for examination. However. all of them are not equally important and do not therefore require equal emphasis. About 45 percent questions are asked from one code API 510 which is hardly a total of 20 pages, while all other 6 codes contribute 55% marks which are more than 1.500 pages.
2.2 Code-wise marks distribution: Following distribution scheme will help the participant to decide how much time he should spend for each document during preparation.
Approx. Weightage S.N.
Approx.Questions
Code (in %)
Out of Total 150
1
API 510 Code
42-45
63 - 68
2
ASME Sec.vlll Div.1
20-22
30-33
3
ASME Sec IX
12
4
ASME Sec. V
12
18
5
API RP 572
4
6
6
API RP 576
5
8
IRE Chap II
1
~
J ~-- ----------------______ L___ 8
General Knowledge
-
c;' I ,{
2
18
;,"'
~'
-'
b(
2
."
l:
,
( 0-
,.-
__
3
4
___________________________
3.
~
~'
~="o=~=·.,"_._
SALIENT FEATURES OF THE EXAMINATION
3.1 How the questions are set:
As stated earlier, the examination comprises of open book and closed book parts. The closed-book examination includes such questions which the inspectm 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 information
oriented questions will normally be "open-book" type. The Code 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 2 to 2"12 hours, 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.
5
4.
HOW TO PREPARE FOR EXAM:
A ) If your aim is only to get "certified"
only, i.e., to obtain just around 110-
115 marks, then, Follow the steps given below
1) .Detailed study of documents nos. 1 to 4 above (Ref. Chap.2 distribution of marks,) may be adequate. 2) Additionally, one should try to remember all the "Points to Recall" given each day during the preparatory course and review the mock examinations attempted during
the
organization
Preparatory
Course. If two or more participants
from
same
are appearing for exam, then joint discussions and one putting
question to another and vice versa has been found very effective during preparation. 3) Other 3 codes (Le., Serial No.5 to 7) may be studied in detail if there is additional preparation time available. An overall "awareness" level knowledge of these 3 Codes may be okay. These contribute only 10% weightage. Still, the Open book Questions from these can always be found out and answered plus the points to recall can help to answer other questions.
B) .If your objective is to get certified and also to obtain a good score, (say
135+) then prepare for exam as follows:
In addition to preparation as per 1&2 above, It is worthwhile to study the 3 Codes also. (Serial No.5 to 7). However, please remember that study of API 510 has to be "thorough" and total, while study of ASME Sec. VIII Oiv.1, ASME Sec. IX and ASME Sec. V should be such that it can cover the topics mentioned in the "Body of Knowledge".
6
-
_.----------------------~-------~'~-.,~='-~The last 3 Codes 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 and highlighted text from the codes.
************
7
- ------------------------~------~=,~-~~ .. ~._._._ ... _,-=The last 3 Codes 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 and highlighted text from the codes.
************
7
5.
API-510 CHAPTERWISE TIPS FOR MAXIMIZING THE SCORE
a.
From
Chapter
. exclusions.
1, just
note
the
scope,
application
and
Two questions will be asked from these, usually
closed book.
b.
Chap. 2 lists only the reference documents. question
c.Chapter Chapter
is asked from this chapter
3. There are only 5 or 6 important definitions 3 of API 510. Normally 3 to 4 definitions
in closed-book
d.
From
certification
from
are asked
exam.
Chapter
Concentrate
e.
At the most one
4, usually
2 or 3 questions
on responsibilities
clause.
are
asked.
Also see App. B for
requirements.
From Chapter
5, about 15-18 questions
are asked.
About
10-12 in closed book and 4-S in open book. Para 5.2 to 5.6, average
of 1 or 2 questions are asked
while on para
5.7,
about 6 to 8 questions ( both open & close book) are asked.
f.
From
Chapter
Particularly attracts
pay
6,
about
attention
15-18 to
questions
Inspection
at least 5 to 6 questions
are
asked.
intervals,
which
and they could be either
open book or closed book.
g.
F rom Chapter 7 also 15-18 questions are asked. This is only four page chapter and almost all chapter is important.
Pay
8
particular attention to authorisation,
defect
repair,
and
inspection requirements.
h.
There may be 2 or 3 questions on overall API-510 code for the purpose of assessing the overall under standing of code.
I.
Chapter 8 as well as App. E are excluded from examination.
J.
As regards ASME Sec. VIII Oiv.1, the course content is categorised in 9 categories. 7 of them are listed under calculations while 8 and 9 are listed under welding and NOT . You may expect at least one open book and one closed book question on each of these. Additionally,
under the
category internal pressure, you may expect 4 open book questions one each for thickness calculation for the 4 types of end closures.
********
9
-----.'-----------
·----------·~~~~._=.;.....::..._-_'r~." ... I..'_""L·_ .•• ~
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.
***********
------------------------------.T---=~._..r><,~, 10
_
1. SAMPLE API-510 EXAM QUESTIONS The Questions below are examples of what exam question might look like. The questions are furnished by API web site www.api.org. Reproduced here for guidance to the students Correct Answer: 4
A The nondestructive examination method to be used for a particular inspection should be determined by the: 1. availability of certified .NDE examiners. 2. length of time since the last inspection. 3. age of the component to be inspected. 4. type, location, and orientation of the expected flaws.
Correct Answer: 3 B. In planning for an internal inspection of a vessel that has contained acidic corrodents, what type and location of corrosion would you ·expect to find on the vessel shell, away from the welds? 1. Hydrogen blistering in the vapor space 2. Hydrogen embrittlement in the vapor space 3. Hydrogen blistering near the liquid level 4. Hydrogen embrittlement below the liquid level
Correct Answer: 1 C. A pressure vessel is scheduled for pneumatic testing using the methodology of ASME Code, Section VIII, Division 1, with the maximum allowable working pressure = 635 psig at 375 F. The vessel is constructed of SA-516 Gr. 65 material and is neither enameled nor lined. The test metal temperature will be a minimum of 50 F, per the owner's specifications. How many pressurization steps are needed to 0
0
achieve the minimum required test pressure, and at what minimum pressure will the visual examillation be performed? 1. 6 steps; 635 psig 2. 6 steps; 793.75 psig 3. 9 steps; 635 psig 4. 9 steps; 793.75 psig
Correct Answer: 4 D. The principal reason for inspecting a pressure relief device is to determine: 1. the remaining life. 2. the spring coil diameter. 3. the body thickness. 4. if it is functioning properly.
Correct Answer: 1 E. A pressure vessel has been in service for 12 years and has a history of corrosion over its service life. The original thickness was 1.9375 inches; the current thickness is 1.405 inches. What is the corrosion rate for this vessel? 1. 0.044 2. 0.089 3. 0.266 4. 0.532
inch per year inch per year inch per year inch per year
Correct Answer: 3 F. What can be done to extend the life of a vessel with a corroded area in the shell plate 6 inches from the weld, a joint efficiency of less than 1, and a corrosion thickness currently near the minimum required thickness?
1 . Recalculate t minimum for current operating conditions using E < 1. 2. Recalculate t minimum for current operating conditions using E 1. 3. Recalculate t minimum for design conditions using E = 1. 4. Monitor the thickness during the run.
=
~~~------~--
-
Correct Answer: 2 G. Temporary repairs to pressure vessels: 1. must be replaced with permanent repairs during the next scheduled shutdown. 2. may remain in place for long periods if approved by the pressure vessel engineer. 3. may remain in place for long periods if approved by the API-authorized pressure vessel inspector. 4. may remain in place permanently if approved by the pressure vessel engineer and the API authorized pressure vessel inspector.
Correct Answer: 2 H. Who must be consulted before the repair of a crack at a discontinuity where stress concentrations may be serious?
1. The 2. The 3. The 4. The
owner-user pressure vessel engineer National Board inspector vessel manufacturer
Correct Answer: 4 I. The WPS and the PQR are used to determine:
