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API, ASME, ASTM, AWS, CSA, NACEPiping, Pressure Vessels, Tanks, Materials, Welding, NDE, Corrosion

Engineering Information: Training and Publishing

Codes and Standards Training InstituteSuite 205, 10544 106 Street, Edmonton, AB T5H 2X6phone: 780-424-2552 fax: 780-421-1308website: www.casti.ca email: [email protected]

API 510Pressure Vessel Inspector

Exam PreparationPrepared for iTC Skills Development Sdn Bhd (Kuala Lumpur, Malaysia)

April 5-10, 2010

CASTICodes and Standards Training Institute

CASTILEARNINGADVANTAGE

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CODES AND STANDARDS TRAINING INSTITUTE (CASTI) Suite 205, 10544106 Street, Edmonton, Alberta T5H 2X6 Canada

Tel: 780-424-2552 Fax: 780-421-1308 E-mail: [email protected] Website: www.casti.ca

API 510 Pressure Vessel Inspector Exam Preparation Prepared for iTC Skills Development Sdn Bhd (Kuala Lumpur, Malaysia)

April 5-10, 2010

COPYRIGHT This material is printed for the sole purpose as training material for the API 510 Pressure Vessel Inspector Exam Preparation training course presented by Codes and Standards Training Institute (CASTI) on April 5-10, 2010 for iTC Skills Development Sdn Bhd in Kuala Lumpur, Malaysia. This notebook material is copyrighted 2010, and shall not be reproduced without the written permission of the copyright holders, Codes and Standards Training Institute (CASTI) and CASTI Publishing Inc.

IMPORTANT NOTICE The material presented herein has been prepared for the general information of the reader and should not be used or relied upon for specific applications without first securing competent technical advice. Nor should it be used as a replacement for current complete engineering codes and standards. In fact, it is highly recommended that the appropriate current engineering codes and standards be reviewed in detail prior to any decision making. While the material in this book was compiled with great effort and is believed to be technically correct, Codes and Standards Training Institute (CASTI) and its staff do not represent or warrant its suitability for any general or specific use and assume no liability or responsibility of any kind in connection with the information herein. Nothing in this book shall be construed as a defense against any alleged infringement of letters of patents, copyright, or trademark, or as defense against liability for such infringement. All rights reserved. No part of this notebook covered by the copyright hereon may be reproduced or used in any form or by any meansgraphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systemswithout the written permission of Codes and Standards Training Institute (CASTI).


Codes and Standards Training Institute (CASTI)

About Your CASTI Notebook

The material outlined in your CASTI notebook will be covered in detail by the instructor during the

in-classroom portion of the training course. Your instructor will review this notebook material in a

dynamic format allowing for participants to ask questions about exam topics as they are raise in the

classroom discussion.

Your CASTI notebook highlights portions of the various code documents that are most likely to be a

source of exam questions. It is intended to focus your attention on areas that have been covered by

past exam questions. While working through the sample problems in this notebook, you may wish to

highlight (or otherwise note) the Code paragraphs where you referenced solutions to the sample

problems. These highlighted Code paragraphs will be important areas of study.

You are encouraged to ask questions and actively participate in the classroom and evening tutorial

sessions. Make any notes in your CASTI notebook that you believe will help you prepare for the API

ICP examination. Explanations of key concepts, possible exam topics, and specific areas of post-

classroom study are all beneficial items to take note of.

Exam Preparation Guidance

As you review the content of this notebook, you will notice several boxes similar to the one shown

below:

These guidance boxes are provided to help direct candidates to specific areas of study during

preparation for the API ICP examination. Some guidance comes in the form of notes about specific

sections of the Code documents covered in the API ICP examination. Some guidance comes in the

form of notes about specific types of questions used in past exams. Some guidance will draw

attention to important concepts that must be clearly understood. And some guidance will highlight

problematic exam questions used in past exams.

Examples and Practice Problems

Examples and Practice Problems can be found throughout this CASTI Notebook. In most cases,

Examples will include detailed solutions to illustrate the methodology used to solve a particular

problem. Each Example is followed by a Practice Problem that can be used as exam practice. The

Practice Problems help reinforce the learning of concepts and procedures illustrated in the Example.

Solve the Practice Problem using the information discussed in this notebook and any required

reference documents. Then check the solutions provided at the end of each tabbed notebook section.

If your answer does not match the solution provided, be sure to investigate the reason(s). Learning

the correct methodology to solve the Practice Problems will help you to solve questions on the API

ICP examination. If you do not understand the solutions, ask for clarification from the instructor

during the in-classroom review of these Examples and Practice Problems and/or during the evening

tutorial sessions.



Examination Information

1. The API examination consists of 150 multiple-choice questions with an open and closed book

sections. The examination is administered by participating members of the National Board of

Boiler and Pressure Vessel Inspectors and by the Professional Examination Service (PES).

Total length of examination is 8 hours. Individual jurisdictions may charge a sitting fee to

take the examination in their jurisdiction. Please contact the jurisdiction you select for an

exact amount. There is no additional sitting fee at the locations where examination is

administered by PES.

2. If you pass the examination, and all sections of your application are complete, you will be

certified and receive a wallet card and a certificate approximately 3 months after the

examination date.

3. API grants each applicant three consecutive attempts during the 18-month period to sit and

pass the test, starting with the first exam administration the applicant registers for. If you

fail the examination on your first attempt, you may retake it twice. If you fail to appear for

the test, it will still count as an official attempt.

4. If you do not pass the examination on the first attempt, you need to submit a $50.00

rescheduling fee. If you do not pass it on the second attempt, you must also submit an

updated Employment Reference form. If the candidate is unsuccessful on the third attempt, a

new application must be submitted with a new application fee.

5. Examination results will be mailed to you approximately 8 weeks after you have taken the

exam. DO NOT call API, PES, or your jurisdiction for examination results; these results

WILL NOT be given over the telephone.

What to Bring to the Examination:

No. 2 pencils;

A non-programmable calculator (a calculator with only simple functions);

The applicable API and ASME reference publications. Please note: highlighting, underlining,

page tabs, and notes written in margins of the code books are acceptable. However, loose

pages inserted in the code books are not acceptable. Note: API and ASME publications are

copyrighted material. Photocopies of these publications are not permitted at the exam;

Your examination site confirmation letter;

A picture ID (i.e. driver's license).



How to Answer Exam Questions and Navigate the Exam Documents

For each exam question, you must first identify the key word(s) and key concept in the exam

question.

Step 1. Read Each Exam Question and All Answers Slowly

Read each question and all the answers slowly at least twice. You will have enough time to complete

the exam, so do not rush! There are no bonus points for being the first person to finish the exam.

Note: look out for not or only or other exclusive wording in the questions.

Each set of 4 answers will contain a distracter answer, which will be close to the correct answer,

but not the correct answer. So do not select the first answer you think is correct, before reading all

of the answers.

Read the question and all of the answers slowly!

Step 2. Identify Key Word(s) and Key Concepts in the Exam Question

Step 2 is to find the key word(s) in the question to determine which exam document (code book) to

use. The following are examples of key words:

1. new equipment or in-service equipment or existing equipment:

a) for new equipment go to Sec. VIII-1

b) for in-service or existing equipment go to API 510 or 572

2. failure mechanisms, go to API 571 first, then to API 572 if required

3. NDE test details or procedures, go to ASME Sec. V

4. WPS/PQR review and rules, go to ASME Sec. IX

5. valves, go to API 576

6. specific welding inspection details, go to API 577

Note: the question may not use the term new equipment, in-service, failure mechanism, etc.,

but will include information with the same meaning.

Step 3. Use Code Book Tabs, Table of Contents, and Subject Indexes

The API ICP exam rules allows the exam candidate to highlight, underline, write short notes in the

margin, and tab their Code books to assist with navigating them.

In the course, as you answer the notebook practice questions and the practice exam questions, you

should highlight and underline each answer, but be very mindful not to over mark your Code books

since it can be a distraction during the exam.

You will also want to add sticky tabs to commonly used pages in the Code books, for example pages

with important tables.



Each exam document includes a Table of Contents and each ASME Codes also includes a Subject

Index. Note: the API exam documents do not contain a Subject Index. These two reference sources

will be very useful during the open book exam, so take advantage of them by studying them.

Note: see next section on exam document tabbing.

Step 4. Remember to:

- choose the most correct answer, since there may be two correct answer, where one answer is

more complete or accurate than another; be mindful of the distractor answer;

- use the process of elimination to find the most correct answer, for example: a) after slowly reading the question and all of the answers, mark an X next to the most

obvious wrong question b) slowly read the remaining 3 answers again, then eliminate the most obvious answer c) slowly read the question and two remaining answers again, then choose the most correct

answer d) do not change your answer later unless you are absolutely positive that the change is

correct!

Step 5. Handling Difficult Questions

If you do not know the answer to a difficult question, especially math questions, do not waste time,

move to the next question.

Place a question mark (?) next to the unanswered question in your exam booklet, so that you can go

back after answering all of the other the exam questions, to answer the difficult questions.

Even if you cannot answer 2 or 3 or more questions in a row, dont panic! Just simply move to the

next question and keep calm. You will be surprised that if you remain calm and answer a few

questions in a row correctly, your memory will improve and you will be able to go back to the earlier

missed questions and answer them a lot easier the second time.

Step 6. General Tips

- use practice questions in your notebook to highlight areas of special attention in the exam

documents

- do not over highlight!

- underline details that need to be memorized (e.g., temperatures)

- repetition is a good practice for learning, so do the notebook practice questions and exam

questions several times



Exam Document Tabbing

The following are suggestions for tabbing your exam documents. Use sticky tabs that can be

purchased from any office supply store.

Write reference paragraph and short title with a pencil on bright fluorescent coloured tabs, since it

will give you the best contrast for reading.

Do not over tab! If you cannot fit all of your tabs on the long side of the page, then you have too many

tabs. Do not place tabs on the top or bottom of page.

Exam Document Tabbing Suggestions

API 510 Section VIII-1 Section IX Section V

Table of Contents Table of Contents Table of Contents Table of Contents

3 Definitions UG27 Shell QW100 Gen./Tests Article 2 - RT

4 Owner/User UG28 - Ext Press QW200 WPS Table T-276 IQI

5.1 Insp. Practices UG32 Heads QW253 SMAW WPS Article 6 - PT

5.8 Hydro UG34 Flat Head QW-300 WPQ T-672 Dwell Time

6.1 Inspection UG37.1 Repad QW416 WPQ Var. Article 7 - MT

6.5 Inspect Int. UG99 Hydro QW422 P-No. Article 23 - UT

7.1 Corr. Rate UW16.1 Fillets QW432 F-No. Subject Index

7.2 Rem. Life Table UCS66 MDMT QW451 WPS Thick/Tests

7.3 MAWP UG84 Impact tests QW452 WPQ Thick/Tests

7.4 FFS UG125 Relief Valves QW461.3 Positions

8.1 Repairs UW11 RT QW461.9 Welder Qual.

8.1.5.1.2 Patches UW12 Eff Factor Subject Index

8.1.5.3 Filler Metal UW51 RT

8.1.6 Weld repair Table UCS56 PWHT

8.1.6.4.1 PWHT Subject Index

8.1.6.4.2 Preheat

8.1.6.4.2.3 PWHT Lieu

8.2 Rerating

Appendix B

Exam Document Tabbing Suggestions

API 571 API 572 API 576 API 577

Table of Contents Table of Contents Table of Contents Table of Contents

Each damage

mechanism on

effectivity sheet


API Individual Inspector Certification Examination Instructions

These instructions have been designed by API to help you understand the requirements to apply for certification in the programs.

Length of Certification Term

When API receives your completed application and confirms that all the requirements have been met and you passed the exam, you will be certified as an Authorized Inspector. The certification is for a three year period.

Admission Letters

Once the review and processing of all the submitted applications is completed, we create rosters for each examination site. Those rosters are then sent to our test administrating company to ensure adequate number of seats at each site. The test administrating company then creates and mails admission letters for each applicant. Admission letters include applicants test ID, the exact exam location, time and other details. The admission letters are usually mailed 3 weeks before the examination date. Please look for it in your mail.

Test Locations

API does not guarantee you the test location of your choice. In some locations seating may be limited and the seats are assigned on the first come first serve basis. The only way to improve your chances of getting into your desired exam location is to apply for the exam early in the registration campaign. We encourage you not to wait until the registration deadline apply early.

Changing Your Testing Location

You may request a site change, if it is necessary but it must be requested within 3 weeks after the application deadline. However, there is no guarantee that your site may be changed. API reserves the right to deny requests to change exam site. Room sizes are limited and we may not be able to accommodate your request. Requests for site changes must be submitted in writing by mail, fax or email.

API Exams Grading

We do not utilize the popular "curve" method because it means comparing the scores of one candidate to all the other candidates who took the exam and assigning grades or passing status according to a fixed percentage. The implication is that whether an individual passes the exam or not might depend on the ability level (or preparation) of all the other candidates who took the exam. This would not be fair for a credentialing exam. Instead, API uses a statistical method called Equating to score the exams. The original passing point of the exam is set by a committee of experts and it represents an absolute standard of knowledge the minimum amount that a competent inspector should know in order to be certified. Each exam has different questions in it. Equating process then adjusts the passing point of each exam to compensate for differences in the difficulty level of those questions. Thus, the passing point always represents the minimum knowledge required and the absolute knowledge standard is held constant. The test results of candidates only reflect whether they have this minimum amount of knowledge or not. Passing the exam is not affected by any other candidate's performance.


Exam Results Notification

Approximately eight weeks after taking the examination you will receive an official Exam Score Report generated by our test administration company. The exam results are sent electronically to API at the same time, so please do not call API before that time. If you passed the exam and your application is complete, you will receive a wallet card and certificate from API approximately four weeks after receipt of your score report. Under no circumstances will scores be given over the telephone.

Grievances or Appeals of Exam Scores

During the examination the candidates will have an opportunity to challenge individual exam questions. All challenges regarding the questions on the exam must be submitted at the conclusion of each section of the exam. After the exam has been administered, a panel of subject matter experts will review all the challenges submitted. As a result of this review, if challenges were found to be legitimate, the scoring may be adjusted, effective for all candidates taking the same exam.

Challenges or complaints regarding the conditions or environment of the exam administration must be submitted to API in writing no later than 7 business days after the date of the exam. No adjustment to scores will be made due to site conditions or environment. Exams are graded using a computerized system. You will receive a score report that indicates the passing score on the exam, the maximum possible score within an activity domain, your score within an activity domain, and a percent correct score in each activity domain within the exam. You may request a manual scoring of your exam for an additional fee of $75. Requests for manual scoring of exams should be submitted in writing by mail, fax or email.

Challenging Questions at the Exam

If you believe an exam question or answer was written improperly, you will given the opportunity to challenge the question at the exam site by filling our a Question Challenge Form. Just ask one of the exam monitors for the form after you have written the exam. You will not be allowed to challenge an exam question after you leave the exam.


API 510 June 2010 Exam Publications Effectivity Sheet

Publications Effectivity Sheet API 510 Pressure Vessel Inspector Certification Exam

For Exam Administration: June 2, 2010

Listed below are the effective editions of the publications required for the June 2, 2010 API 510 Pressure Vessel Inspector Certification Examination:

API Standard 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration, Ninth Edition, June 2006

API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, First Edition, December 2003

Attention: Only the following mechanisms to be included: 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 Fatigue 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 (Cl-SCC) 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 Temperature Hydrogen Attack (HTHA)

API Recommended Practice 572, Inspection of Pressure Vessels, Second Edition, February 2001

API Recommended Practice 576, Inspection of Pressure-Relieving Devices, Second Edition, December 2000

API Recommended Practice 577, Welding Inspection and Metallurgy, First Edition, October 2004

American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2007 Edition with 2008 Addenda i. ASME Section V, Nondestructive Examination, Articles 1, 2, 6, 7, 9 and 23 (Section SE-797 only) ii. ASME Section VIII, Rules for Construction of Pressure Vessels, Division 1, U, UG, UW, UCS, UHT, Appendices 1-4, 6, 8 and 12 iii. ASME Section IX, Welding and Brazing Qualifications, Welding Only

The above API and ASME publications are available, as a package, from CASTI (Codes and Standards Training Institute). Package includes only the above excerpts necessary for the exam.

CASTI (Codes and Standards Training Institute) is a licensed distributor of API and ASME exam documents. Only CASTI course registrants may purchase documents directly from CASTI. CASTI reproductions are stamped for exam use and are binder-ready. Binder is not supplied. No returns are accepted on exam documents.

Note: API and ASME publications are copyrighted material. Photocopies of API and ASME publications are not permitted.


01/09 1

BODY OF KNOWLEDGE

API-510 PRESSURE VESSEL INSPECTOR

CERTIFICATION EXAMINATION

January 2009 (Replaces June 2007)

API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair,

and alteration 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 Vessel Inspector should be knowledgeable.

To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each

category listed within this Body of Knowledge will be included on the API certification examination. 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 more detailed information that the inspector is expected to be able to find in the documents,

but would not normally be committed to memory.

REFERENCE PUBLICATIONS:

API publications and ASME codebooks must be brought to the examination site to be used as reference materials for the

open-book part of the examination.

A. API Publications:

API 510, Pressure Vessel Inspection Code

API RP 571, Damage Mechanisms Affecting Equipment in Refining Industry

API RP 572, Inspection of Pressure Vessels (except Appendix B)

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 1, Rules for Constructing Pressure Vessels

Section IX, Welding and Brazing Qualifications

Note: Refer to the Publications Effectivity Sheet in the application package for a list of specific editions, addenda, and

supplements of the reference publications that are effective for your exam date.


01/09 2

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 Vessel Inspectors should be able to check and perform calculations relative to in-service

deterioration, repairs, rerates, or alterations. Only internal and external pressure loadings will be considered

for the API 510 examination.

Note: Candidates are expected to understand the SI units (metric system) and the US customary units (inches,

feet, PSI, etc.) and to use both system formulas.

The following categories describe the minimum necessary knowledge and skills:

1. CORROSION RATES AND INSPECTION INTERVALS

The Inspector should be able to take inspection data and determine the internal and external inspection intervals.

The Inspector must be able to calculate:

a. Metal Loss (including corrosion averaging) (API-510, Para 7.4) b. Corrosion Rates (API-510, Para 7.1)

c. Remaining Corrosion Allowance (API-510, Para7.1)

d. Remaining Service Life (API-510, Para, 7.2)

e. Inspection Interval (API-510, Section 6)

The formulas for performing the above calculations and rules for setting the inspection intervals may be "closed-book

during the examination.

2. JOINT EFFICIENCIES

The inspector must be able to determine the joint efficiency "E" of a vessel weld. Inspector should be able to determine:

a. Weld Joint Categories (ASME Section VIII, UW-3);

b. Type of radiography (full, spot, or none) performed basis the nameplate markings (RT-1, RT-2, etc.); (UW -11)

c. Joint efficiency by reading Table UW-12;

d. Joint efficiency for seamless heads and vessels Sections per UW-12 (d); and

e. Joint efficiency for welded pipe and tubing per UW-12 (e).

Determining joint efficiency may be part of the internal pressure problem since joint efficiency "E" is used in the

formulas for determining required thickness or Vessel Part MAWP.

3. STATIC HEAD

The inspector must be able to compensate for the pressure resulting from static head. All static head will be based upon a

Specific Gravity of 1.0. The inspector should be able to:

a) List the static head/pressure conversion factor (0.433 psi/ft);

b) Know the difference between vessel MAWP and vessel part MAWP (UG-98);

c) Calculate static head pressure on any vessel part;

d) Calculate total pressure (MAWP + static head) on any vessel part;

e) Calculate maximum vessel MAWP given vessel parts MAWP and elevations

Static head calculations may also be required during the internal pressure calculations if static head data is given in the

examination problem.


01/09 3

4. INTERNAL PRESSURE

The inspector should be able to determine:

a) The required thickness of a cylindrical shell based on circumferential stress given a pressure (UG-27(c)(1));

b) The vessel part MAWP for a cylindrical shell based on circumferential stress given a metal thickness (UG-

27(c)(1));

c) The required thickness of a head (ellipsoidal, and hemispherical) given a pressure. (UG-32 (d), (e), (f) and (g))

d) The vessel part MAWP for a head (ellipsoidal, and hemispherical) given a metal thickness. (UG-32 (d), (e), (f) and

(g)).

e) Whether a head (ellipsoidal, torispherical or hemispherical) meets Code requirements given both pressure and

metal thickness (UG 32(d), (e), (f) and (g)).

The inspector should also be able to compensate for the corrosion allowance: add or subtract based on requirements of

the examination problem. The Section VIII, Appendix 1 formula for cylinders, which is based on outside diameter, can

be used. The Appendix 1 formulas for non-standard heads will not be required.

5. EXTERNAL PRESSURE

The inspector should be able to:

a) Calculate the maximum allowable external pressure; 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 )(1).

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 TESTING


a) Calculate a test pressure compensating for temperature. (UG-99 & UG-100)

b) Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test

temperatures, protection against overpressure etc.

c) Be familiar with all steps in a hydrotest procedure (UG 99 and UG 100)

d) Be familiar with all steps in a pneumatic test procedure (UG 100 and UG 102)

7. IMPACT TESTING


a) Determine the minimum metal temperature of a material which is exempt from impact testing (UG-20 (f), UCS-

66,

UCS-68(c).)

8. WELD SIZE FOR ATTACHMENT WELDS AT OPENINGS

The inspector must be able to determine if weld sizes meet Code requirements. The inspector should be able to:

a) Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707); and

b) Determine the required size of welds at openings (UW-16).


01/09 4

9. NOZZLE REINFORCEMENT

The inspector should:

a) Understand the key concepts of reinforcement, such as replacement of strength removed and limits of

reinforcement.

Credit can be taken for extra metal in shell and nozzle

b) Be able to calculate the required areas for reinforcement or check to ensure that a designed pad is large

enough. To simplify the problem:

All fr = 1.0

All F = 1.0

All E = 1.0

All required thicknesses are given

c) There will be no nozzle projecting inside the shell

d) Be able to compensate for corrosion allowances.

e) Weld strength calculations are excluded.

B. The following are typical ASME code engineering requirements that API certification candidates will NOT

be expected to know for purposes of the certification examination.

1. Required thickness calculations for wind, earthquake, and other secondary stress loadings;

2. Supplementary design formulas and calculations for non-cylindrical shell components;

3. Most external pressure calculations;

4. Nozzle calculations for external loads;

5. Flange calculations;

6. Brazing requirements;

7. Ligament calculations;

8. Stayed flat heads and sizing of stays;

9. Tubesheet calculations (stayed or unstayed) and tube to tubesheet joints and loads;

10. Relief valve sizing;

11. Lifting lug and other structural type calculations;

12. Proof testing requirements;

13. Required inspections for new construction, except as they apply to alterations and repairs;

14. Zick analysis;

15. Integrally forged pressure components;

16. Cryogenic vessels (below -50 f);

17. Dimpled, embossed, jacketed, and non-metallic vessels and assemblies;

18. NDE requirements for acoustic emission, eddy current, and motion radiography;

19. ASME Sections UF, UB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT;

20. Code Cases and interpretations;

21. Welding process requirements other than shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW),

gas metal arc welding (GMAW), or submerged arc welding (SAW);

22. Requirements for pressure vessels for human occupancy; and

23. Rules for natural resource vessels, API-510, Section 9.


01/09 5

II. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILER

AND PRESSURE VESSEL CODE, SECTION IX

A. WELD PROCEDURE REVIEW

1. The inspector should be able to determine if procedure and qualification records are in compliance with applicable

ASME boiler and pressure vessel code and any additional requirements of API-510 (API-510 requirements will take

precedence over any ASME requirements covering the same technical area).

The weld procedure review may include:

a. Welding Procedure Specification (WPS); and

b. Procedure Qualification Record (PQR).

The weld procedure review may include: SMAW, GTAW, GMAW, OR SAW, with the following limitations:

a) No more than one process will be included on a single WPS or PQR, and the WPS to be reviewed will be

supported by a single PQR.

b) Filler metals limited to one-per-process for SMAW, GTAW, GMAW, or SAW.

c) The PQR will be the supporting PQR for the WPS.

2. The inspector should be able to determine:

a) Whether number and type of mechanical tests listed on PQR are appropriate

b) Whether the results of the tests are acceptable

c) Whether all required essential and non-essential variables have been properly addressed. (Supplemental essential

variables will not be a part of the WPS). The following limitations or conditions will apply:

Base metals limited to P1, 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 P1, P3, P4, and P5, for the purpose of the examination the lower transformation temperature will be

13330F and the upper transformation temperature will be 16000F.

B. ASME Section VIII, Div. 1 and API-510: GENERAL WELDING REQUIREMENTS:

1. ASME Section VIII, Div. 1

The inspector should be familiar with and understand the general rules for welding in

ASME Section VIII, Div. 1, Parts UW and UCS such as:

a) Typical joints and definitions

b) Weld sizes

c) Restrictions on joints

d) Maximum allowable reinforcement

e) Inspection requirements

f) Heat treatment

2. API 510

The inspector should be familiar with and understand any rules for welding in API-510. Any rules for welding given in

API-510 shall take precedence over those covering the same areas in ASME, Section VIII, Div. 1.

3. "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 number and date, and name

of testing lab. However, the API 510 applicants shall know that the PQR must be certified by signing and dating.

C. The inspector shall be familiar with all the requirements of and information in API RP 577.


01/09 6

III.NONDESTRUCTIVE EXAMINATION

ASME Section V, Nondestructive Examination

NOTE: The examination will cover ONLY the main body of each referenced Article, except as noted

A. Article 1, General Requirements:

The inspector should be familiar with and understand;

1. The Scope of Section V,

2. Rules for use of Section V as a referenced Code,

3. Responsibilities of the Owner / User, and of subcontractors,

4. Calibration,

5. Definitions of "inspection" and examination",

6. Record keeping requirements.

B. Article 2, Radiographic Examination:


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 of IQIs,

c. Allowable density

d. Control of backscatter radiation

e. Location markers

3. Records

C. Article 6, Liquid Penetrant Examination, including Mandatory Appendices II and III:

The inspector should be familiar with and understand:

1. 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) Record keeping

D. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

The inspector should be familiar with and understand the general rules for applying and using the magnetic

particle method such as, but not limited to;

1. The Scope of Article 7,

2. General requirements such as but not limited to requirements for:

a. Procedures

b. Techniques (Yoke and Prod only)

c. Calibration

d. Examination

e. Interpretation

f. Documentation and record keeping


01/09 7

E. Article 23, Ultrasonic Standards, Section SE797 only Standard practice for measuring thickness by manual

ultrasonic pulse-echo contact method:


1) The Scope of Article 23, Section SE-797,

2) The general rules for applying and using the Ultrasonic method

3) The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.

ASME Section VIII, Div. 1 and API-510. General nondestructive examination requirements:

1. ASME Section VIII, Div. 1:

The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4, 6, 8, and

12)

2. API 510:

The inspector should be familiar with and understand the general rules for NDE in API-510.

IV. PRACTICAL KNOWLEDGE - GENERAL

The following topics may be covered in the examination. More information 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, Thermal, and High Temperature Deterioration.

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 Inspection 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


01/09 8

V. PRACTICAL KNOWLEDGE - SPECIFIC

API-510, Pressure Vessel Inspection Code

NOTE: All of API 510 is applicable to the examination unless specifically excluded. For example: Section 9 and

Appendix E are excluded.

1. Organization and Certification Requirements

a) Certification for API Authorized Pressure Vessel Inspectors (API-510, Appendix B).

b) Authorized Inspection Agencies (API-510, Section 3.6)

c) Vessel Repair Organizations (API-510, Section 3.54)

d) Relief Device Testing and Repair Organizations (API-510, Section 4.2.3 and 6.6)

2. Types and Definitions of Maintenance Inspection

a) Internal Inspection (API 510, 5.5.2)

b) Damage Inspection (API-510, 5.7)

c) Inspection of Parts (API-510, 5.10, 5.11)

d) External Inspection & Buried Vessels (API 510, 5.5.4)

e) On-Stream Inspection (API-510, 3.43, 5.5.3 & 6.5.2)

f) Thickness Measurements (API-510, 5.5.5, 5.7.2,)

g) Nondestructive Examination (API-510, 5.7.1)

h) Assessment of Inspection Findings (Section 7)

i) Risk-based Inspecion (API 510, 5.2 )

j) CUI Inspection (API 510, 5.5.6)

3. Welding on Pressure Vessels

a) Welding Inspection Requirements (API-510, 5.10 )

4. Corrosion and Minimum Thickness Evaluation

The inspector should have a general knowledge of the following principles, and may be required to make

calculations using these principles.

a) Corrosion Rate Determination (API 510, 7.1)

b) Corrosion Averaging (API 510, 7.4.2)

c) Widely Scattered Pitting (API 510, 7.4.3)

d) Surfaces Remote from a Weld (API, 7.4.5.)

e) Corrosion in Central Portion of Dished Heads (API 510, 7.4.6)

5. Estimated Remaining Life and Corrosion rate (API 510, 7.2)

6. Inspection Interval Determination and Issues Affecting Intervals

a) Risk-based inspection (API 510, 6.3)

b) Internal or On-Stream Inspection Intervals (API 510, 6.5)

c) Internal and On-stream inspection Intervals for Estimated Life (API 510, 6.5)

d) External Inspection Intervals ((API-510, 6.4)

e) Deterioration Other Than Metal Loss (API 510, 5.4)

f) Different Zones of a Vessel (API 510, 6.5.3)

g) Change of Service Conditions (API 510, 6.2.2)

h) Change in Location and Ownership (API 510,6.2.2)


01/09 9

7. Relief Devices

a) Repair Organizations (API-510, Section 6.6)

b) Minimum Requirements for Quality Control Systems (API 510, 6.6)

c) Testing and Inspection Intervals (API-510, 6.6)

8. Maintenance Inspection Safety Practices

a) Pressure Vessel Inspection (API-510, Section 5.3)

9. Inspection Records and Reports

a) Permanent and Progressive Inspection Records (API-510, 7.8)

10. Repairs, Alterations and Rerating of Pressure Vessels

a) Authorization (API 510, 8.1.1)

b) Approval (API 510, 8.1.2)

c) Design Requirements (API 510, 8.1.3)

d) Materials Requirements (API 510, 8.1.4)

e) Welding Requirements (API 510, 8.1.6)

f) Heat Treating Requirements, including

Preheating (API 510, 8.1.6.4.2)

Post weld Heat Treating (API 510, 8.1.6.4)

Local Postweld Heat treatment (API 510, 8.1.6.4.1)

g) Repairs to Stainless Steel Weld Overlay and Cladding (API 510, 8.1.5.4)

h) Inspection (API 510, 8.1.7 & 8.1.8)

i) Rerating of Pressure Vessels (API 510, 8.2)

j) Pressure Testing After Repairs, Alterations or Rerating (API-510,5.8)

k) Nondestructive Examination of Welds (API 510, 8.1.7)

API RP 571, Damage Mechanisms Affecting Fixed equipment in the Refining Industry

ATTN: Test questions will be based on the following mechanisms only:

Par. 3. - Definitions (included as a frame of reference only)

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 (Cl-SCC)

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 Temperature Hydrogen Attack (HTHA)


01/09 10

API RP-572, Inspection of Pressure Vessels Entire document is subject to testing with the exception of Appendix B.

1. Types and Definitions of Maintenance Inspections

a) Types of Pressure Vessels (API RP-572, Section 4)

b) Construction Standards (API RP-572, Section 5)

c) Maintenance Inspection (API RP-572, Section 6)

d) Reasons for Inspection (API RP-572, Section 7)

e) Causes of Deterioration (API RP-572, 8.1 8.5)

f) Frequency and Time of Inspection (API RP-572, Section 9)

g) Internal Inspection (API RP-572, 10)

h) External Inspection, Typical Items Checked (API RP-572, 10.3)

i) Visual Examination (API-RP-572, Section 10)

j) Thickness Measurements and Limits (API RP-572, Section 10)

k) Nondestructive Examination (API RP-572, Section 10)

l) Repair Methods (API RP-572, Section 11)

2. Pressure Vessel Materials and Fabrication Problems

a) Material and Fabrication Problems (API RP-572, 8.4 & 8.5)

3. Maintenance Inspection Safety Practices

a) Pressure Vessel Inspection (API RP-572, 10.2)

4. Inspection Records and Reports (API RP-572, Section 12)

API RP 576, Inspection of Pressure-Relieving Devices ( Entire document is subject to testing with the exception for

appendices):

1. Relief Devices

a) Description of Types -- General Knowledge of Application and Limitations (API RP-576, Section 2)

b) Causes of Improper Performance (API RP-576, Section 4)

c) Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)

d) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)

e) Maintenance Inspection Safety Practices (API RP 576, Section 6)

f) Inspection Records and Reports (API RP-576, Section 8)

API RP 577, Welding Inspection and Metallurgy

1. Definitions

2. Welding Inspection

3. Welding Processes

4. Welding procedure

5. Welding Materials

6. Welder qualifications

7. Non-destructive examination

8. Metallurgy

9. Refinery and Petrochemical Plant Welding Issues

10. Terminology and symbols

11. Actions to Address improperly made production welds

12. Welding procedure review

13. Guide to common filler metal selection

14. Example report of RT results



API 510 PRESSURE VESSEL INSPECTION CODE

TABLE OF CONTENTS

1 SCOPE ...............................................................................................................................................1-1

1.1 General Application ...................................................................................................................1-1

1.1.1 Coverage..........................................................................................................................1-1

1.1.2 Intent...............................................................................................................................1-1

1.1.3 Limitations......................................................................................................................1-1

1.2 Specific Applications..................................................................................................................1-1

1.2.1 Exploration and Production Vessels .............................................................................1-1

1.2.2 Excluded and Optional Services ....................................................................................1-2

1.3 Recognized Technical Concepts.................................................................................................1-2

2 REFERENCES...................................................................................................................................2-1

3 DEFINITIONS ...................................................................................................................................3-1

ACFM to ET ...............................................................................................................................3-1

Engineer to On-Stream..............................................................................................................3-2

On-Stream Inspection to Risk-Based Inspection (RBI) ...........................................................3-3

Strip Lining to Transition Temperature ..................................................................................3-4

4 OWNER/USER INSPECTION ORGANIZATION ...........................................................................4-1

4.1 General .......................................................................................................................................4-1

4.2 Owner/User Organization Responsibilities..............................................................................4-1

4.2.1 Owner/User Organization ..............................................................................................4-1

4.2.2 Engineer ..........................................................................................................................4-1

4.2.3 Repair Organization .......................................................................................................4-1

4.2.4 Inspector..........................................................................................................................4-1

4.2.5 Examiners .......................................................................................................................4-2

4.2.6 Other Personnel..............................................................................................................4-2

5 INSPECTION, EXAMINATION AND PRESSURE TESTING PRACTICES ...............................5-1

5.1 Inspection Plans.........................................................................................................................5-1

5.1.1 Development of an Inspection Plan...............................................................................5-1

5.1.2 Minimum Contents of an Inspection Plan ....................................................................5-1

5.1.3 Additional Contents of an Inspection Plan ...................................................................5-1

5.2 Risk-Based Inspection (RBI) .....................................................................................................5-1

5.2.1 Probability Assessment..................................................................................................5-2

5.2.2 Consequence Assessment...............................................................................................5-2

5.2.3 Documentation................................................................................................................5-2

5.2.4 Frequency of RBI Assessments .....................................................................................5-2

5.3 Preparation for Inspection.........................................................................................................5-2

5.3.1 Equipment.......................................................................................................................5-3

5.3.2 Communication...............................................................................................................5-3

5.3.3 Vessel Entry....................................................................................................................5-3

5.3.4 Records Review...............................................................................................................5-3

5.4 Inspection for Types of Damage Modes of Deterioration and Failure....................................5-3



5.5 General Types of Inspection and Surveillance.........................................................................5-4

5.5.1 General ............................................................................................................................5-4

5.5.2 Internal Inspection .........................................................................................................5-4

5.5.2.1 General .............................................................................................................5-4

5.5.2.2 Vessel Internals ...............................................................................................5-4

5.5.2.3 Deposits and Linings .......................................................................................5-4

5.5.3 On-Stream Inspection ....................................................................................................5-5

5.5.4 External Inspection ........................................................................................................5-5

5.5.4.1 General .............................................................................................................5-5

5.5.4.2 Buried Vessels..................................................................................................5-5

5.5.5 Thickness Inspection ......................................................................................................5-6

5.5.6 CUI Inspection................................................................................................................5-6

5.5.6.1 Susceptible Temperature Range.....................................................................5-6

5.5.6.2 Susceptible Locations ......................................................................................5-6

5.5.6.3 Insulation Removal..........................................................................................5-6

5.6 Condition Monitoring Locations ...............................................................................................5-7

5.6.1 General ............................................................................................................................5-7

5.6.2 CML Monitoring .............................................................................................................5-7

5.6.3 CML Selection.................................................................................................................5-7

5.7 Condition Monitoring Methods .................................................................................................5-7

5.7.1 Examination Technique Selection.................................................................................5-7

5.7.1.1 Surface Preparation.........................................................................................5-8

5.7.1.2 UT Shear Wave Examiners.............................................................................5-8

5.7.2 Thickness Measurement Methods.................................................................................5-8

5.8 Pressure Testing ........................................................................................................................5-9

5.8.1 When to Perform a Pressure Test .................................................................................5-9

5.8.2 Test Pressure ..................................................................................................................5-9

5.8.3 Pressure Test Preparation .............................................................................................5-9

5.8.4 Hydrostatic Pressure Tests..........................................................................................5-10

5.8.5 Pneumatic Pressure Tests ...........................................................................................5-10

5.8.6 Test Temperature and Brittle Fracture Considerations............................................5-10

5.8.7 Pressure Testing Alternatives .....................................................................................5-10

5.9 Material Verification and Traceability ...................................................................................5-10

5.10 Inspection of In-Service Welds and Joints .............................................................................5-11

5.11 Inspection of Flanged Joints ...................................................................................................5-11

6 INTERVAL/FREQUENCY AND EXTENT OF INSPECTION.......................................................6-1

6.1 General .......................................................................................................................................6-1

6.2 Inspection During Installation and Service Changes..............................................................6-1

6.2.1 Vessel Installations ........................................................................................................6-1

6.2.2 Vessel Service Change....................................................................................................6-1

6.3 Risk-Based Inspection ...............................................................................................................6-1

6.4 External Inspection....................................................................................................................6-1

6.5 Internal and On-Stream Inspection.......................................................................................... 6-2

6.5.1 Inspection Interval .........................................................................................................6-2

6.5.2 On-Stream Inspection ....................................................................................................6-2

6.5.3 Multi-Zone Vessels .........................................................................................................6-3



6.6 Pressure-Relieving Devices .......................................................................................................6-3

6.6.1 Quality Control System..................................................................................................6-3

6.6.2 Testing and Inspection Intervals...................................................................................6-3

7 INSPECTION DATA EVALUATION, ANALYSIS, AND RECORDING.......................................7-1

7.1 Corrosion Rate Determination ..................................................................................................7-1

7.1.1 Existing Pressure Vessels ..............................................................................................7-1

7.1.2 Newly Installed Pressure Vessels or Changes in Service ............................................7-1

7.2 Remaining Life Calculations.....................................................................................................7-1

7.3 Maximum Allowable Working Pressure Determination .........................................................7-2

7.4 Fitness for Service Analysis of Corroded Regions ...................................................................7-2

7.4.1 General ............................................................................................................................7-2

7.4.2 Evaluation of Locally Thinned Areas............................................................................7-2

7.4.3 Evaluation of Pitting ......................................................................................................7-3

7.4.4 Alternative Evaluation Methods for Thinning .............................................................7-3

7.4.5 Joint Efficiency Adjustments.........................................................................................7-3

7.4.6 Corroded Areas in Vessel Heads ...................................................................................7-3

7.5 API RP 579 Fitness-for-Service Evaluations ...........................................................................7-3

7.6 Required Thickness Determination..........................................................................................7-4

7.7 Evaluation of Existing Equipment with Minimal Documentation.........................................7-4

7.8 Reports and Records ..................................................................................................................7-5

8 REPAIRS, ALTERATIONS, AND RERATING OF PRESSURE VESSELS..................................8-1

8.1 Repairs and Alterations.............................................................................................................8-1

8.1.1 Authorization ..................................................................................................................8-1

8.1.2 Approval ..........................................................................................................................8-1

8.1.3 Design..............................................................................................................................8-1

8.1.4 Material...........................................................................................................................8-1

8.1.5 Defect Repairs.................................................................................................................8-1

8.1.5.1 Temporary Repairs ..........................................................................................8-1

8.1.5.1.1 General ...........................................................................................8-1

8.1.5.1.2 Fillet-Welded Patches....................................................................8-2

8.1.5.1.3 Lap Band Repairs ..........................................................................8-2

8.1.5.1.4 Non-Penetrating Nozzles...............................................................8-3

8.1.5.2 Permanent Repair............................................................................................8-3

8.1.5.2.1 Typical Permanent Repair Techniques ........................................8-3

8.1.5.2.2 Insert Plates ...................................................................................8-3

8.1.5.3 Filler Metal Strength for Overlay and Repairs to Existing Welds ...............8-3

8.1.5.4 Repairs to Stainless Steel Weld Overlay and Cladding ................................8-4

8.1.6 Welding and Hot Tapping ..............................................................................................8-4

8.1.6.1 General .............................................................................................................8-4

8.1.6.2 Procedures, Qualifications and Records.........................................................8-4

8.1.6.3 Preheating ........................................................................................................8-4

8.1.6.4 Postweld Heat Treatment ...............................................................................8-4

8.1.6.4.1 Local Postweld Heat Treatment ...................................................8-5



8.1.6.4.2 Preheat or Controlled Deposition Welding Methods as

Alternatives to Postweld Heat Treatment ...................................8-5

8.1.6.4.2.1 General ......................................................................8-5

8.1.6.4.2.2 Preheating Method ...................................................8-5

8.1.6.4.2.3 Controlled-Deposition Welding Method ..................8-6

8.1.7 NDE of Welds..................................................................................................................8-7

8.1.8 Weld Inspection for Vessels Subject to Brittle Fracture..............................................8-7

8.2 Rerating ......................................................................................................................................8-7

9 ALTERNATIVE RULES FOR EXPLORATION AND PRODUCTION PRESSURE

VESSELS............................................................................................................................................9-1

9.1 Scope and Specific Exemptions .................................................................................................9-1

9.2 Definitions ..................................................................................................................................9-1

9.3 Inspection Program....................................................................................................................9-1

9.4 Pressure Test..............................................................................................................................9-4

9.5 Safety Relief Device ...................................................................................................................9-4

9.6 Records..........................................................................................................................................9-4

APPENDIX A ASME CODE EXEMPTIONS.................................................................................... A-1

APPENDIX B INSPECTOR CERTIFICATION ............................................................................... B-1

B.1 Examination...................................................................................................... B-1

B.2 Certification ...................................................................................................... B-1

B.3 Recertification................................................................................................... B-1

APPENDIX C SAMPLE PRESSURE VESSEL INSPECTION RECORD...................................... C-1

Sample Pressure Vessel Inspection Record .................................................... C-2

APPENDIX D SAMPLE REPAIR, ALTERATION, OR RERATING OF PRESSURE

VESSEL FORM.......................................................................................................... D-1

Sample Repair Alteration or Rerating of Pressure Vessels Form................. D-2

APPENDIX E TECHNICAL INQUIRIES......................................................................................... E-1

E.1 Introduction ...................................................................................................... E-1

E.2 Inquiry Format ................................................................................................. E-1

E.3 Technical Inquiry Responses ........................................................................... E-1

Tables 7-1 Values of Spherical Radius Factor K1 ......................................................................................7-4

8-1 Welding Methods as Alternatives to Postweld Heat Treatment Qualification

Thickness for Test Plates and Repair Grooves ........................................................................8-7

Figures

8-1 Rerating Vessels Using the Latest Edition or Addendum of the ASME Code

Allowable Stresses .....................................................................................................................8-9



API 510 Pressure Vessel Inspection Code

Purpose of API 510

Exam

GuidancePreparation


Exam Note: All of API 510 is applicable to the examination, except Section 9 and

Appendix E are excluded.

API 510 provides users with a set of rules to inspect and maintain pressure vessels and the pressure-

relieving devices protecting these vessels for continued safe operation after they have entered

service. This code resulted from the need by industry for an in-service inspection code applicable to

pressure vessel systems originally constructed to constructed to ASME B&PV Code Section VIII

Div. 1 and other similar codes. For refineries and petrochemical plants, API 510 is complimented by

many other codes and standards, with some of the API documents listed as follows


API RP 571 Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

API RP 572 Inspection of Pressure Vessels

API RP 576 Inspection of Pressure-Relieving Devices

API RP 577 Welding Inspection and Metallurgy

API RP 578 Material Verification Program for New and Existing Piping Systems

API RP 579 Fitness-For-Service

API RP 580 Risk-Based Inspection

API Publ. 581 Risk-Based Inspection Base Resource Document

API RP 582 Recommended Practice and Supplementary Welding Guidelines for the

Chemical, Oil, and Gas Industries

API Publ 2201 Procedures for Welding or Hot Tapping on Equipment in Service

API 510 Review of Table of Contents

Refer to API 510 Table of Contents

1. Scope

2. References

3. Definitions

4. Owner/User Inspection Organization

5. Inspection, Examination, and Pressure Testing Practices

6. Interval/Frequency and Extent of Inspection

7. Inspection Data Evaluation, Analysis, and Recording

8. Repairs, Alterations, and Rerating of Pressure Vessels

9. Alternative Rules for Exploration and Production Pressure Vessels (excluded in the API 510

ICP exam Body of Knowledge)

Appendix A ASME Code Exemptions

Appendix B Inspector Certification

Appendix C Sample Pressure Vessel Inspection Record

Appendix D Sample Repair, Alteration, or Rerating of Pressure Vessel Form

Appendix E Technical Inquiries



Certification

Exam

GuidancePreparation


These sections of API 510 are listed in the API Body of Knowledge:

Practical Knowledge General

Organization and Certification Requirements.

Organization and Certification Requirements:

Certification for API Authorized Pressure Vessel Inspectors (API 510,

Appendix B).

To qualify for the API 510 ICP examination, the applicants education and experience, when

combined, shall be equal to at least one of the following:

Education

Minimum Experience in the

Design, Construction, Repair,

Inspection, or Operation of

Pressure Vessels

As Part of Minimum

Experience, Time Required

in Supervision of

Inspection Activities or

Performance of Inspection

Activities

bachelor of science degree in

engineering or technology --- 1 year

two-year degree or certificate

in engineering or technology 2 years 1 year

high school diploma or

equivalent 3 years 1 year

not a high school graduate 5 years 1 year

Practice Problem Q001: API 510 ICP Minimum Experience To qualify to write the API 510 ICP certification examination, what is the inspection experience

requirement for a high school graduate?

a) three years of experience in inspection of pressure vessels

b) two years of experience in inspection of pressure vessels, of which one year must be in

supervision of inspection activities or performance of inspection activities

c) three years of experience in inspection of pressure vessels, of which one year must be in


d) five years of experience in inspection of pressure vessels, of which two years must be in


See the answer key at the end of this CASTI Notebook section.



API 510 Section 1

Scope

Coverage

1.1.1 defines coverage of the API 510 document to include inspection, repair, alteration, and

rerating procedures for in-service pressure vessel systems, including pressure-relieving devices.

When API 510 references the ASME Code, it is referring to the ASME Boiler and Pressure Vessel

Code (B&PVC), including its addenda and code cases. Most pressure vessel built to the ASME Code

would have been designed to ASME B&PVC, Sec. VIII Division 1 Rules for Construction of

Pressure Vessels. Two other common pressure vessel design and construction codes are the

European Pressure Equipment Directive (PED) and BS PD 5500 Specification for Unfired Fusion

Welded Pressure Vessels.

1.1.1 explains that the original pressure vessel code of construction, such as ASME Sec. VIII Div. 1,

were written for new construction and not for in-service requirements. However, much of the

technical requirements in the original construction code can still be used for in-service pressure

vessels applied to the inspection, rerating, repair, and alteration.

Note: 1.1.1 warns the user that if an item cannot follow the ASME Code because of its new

construction orientation, then API 510 must be followed. If in-service vessels are covered by

requirements in the ASME Code and API 510, or if there is a conflict between the two codes, the

requirements of API 510 shall take precedence.

Intent

To be in compliance API 510, the owner/user must employ or have access to appropriately trained

and qualified technical staff and support organizations, which include:

a. an authorized inspection agency

b. a repair organization

c. an engineer

d. an inspector, and

e. examiners.

Limitations

The safe operation of pressure vessels is commonly governed by local jurisdiction laws and

regulations that in most cases will supercede codes and standards. However, these same laws and

regulations typically reference codes and standards, such as the ASME Code and API 510.

Note: 1.1.3 warns the user that adoption and use of API 510 does not permit it to be in conflict with

any prevailing regulatory requirements. However, if the requirements of API 510 are more stringent

than the requirements of the regulation, then the requirements of API 510 shall govern.



Practice Problem Q002: Scope What activities does the API 510 pressure vessel inspection code cover?

a) in-service inspection, repair, alterations

b) rerating activities for pressure vessels

c) pressure-relieving devices protecting pressure vessels

d) all of the above


Practice Problem Q003: Intent The application of API 510 is restricted to owner/users that employ which of the following?

a) an authorized inspection agency and a repair organization

b) an engineer

c) an inspector and examiners

d) all of the above


Practice Problem Q004: Limitations When the use of API 510 is in conflict with prevailing regulatory requirements, how shall pressure

vessel inspection conformance be carried out?

a) inspection shall be modified to suit API 510 in accordance with the inspection plan with

the owner/user's approval

b) inspection shall be modified to suit the ASME Code in accordance with the inspection

plan with the owner/user's approval

c) inspection shall be modified to suit API 510 in accordance with the inspection plan with

the owner/user's and engineer's approval

d) inspection shall conform to regulatory requirements rather than to API 510




API 510 Section 3

Definitions

Recognized Technical Concepts of API RP 579 and RP 580

API 510, 1.3 recognizes the concepts of fitness-for-service and risk-based inspection (RBI), and as

such, references API RP 579 and RP 580, respectively.

Notable Definitions

Exam

GuidancePreparation


These sections of API 510 are listed in the API Body of Knowledge:

Practical Knowledge General

Types and Definitions of Maintenance Inspections.

Organization:

Authorized Inspection Agencies (API 510, 3.6)

Vessel Repair Organizations (API 510, 3.54)

Section 3 contains a list of definitions applicable to API 510. It is important to note that there are

differences between the definitions in API 510 and API 570 for the same terms. Some notable API

510 definitions include:

3.2 alteration: A physical change in any component that has design implications that affect

the pressure-containing capability of a pressure vessel beyond the scope described in existing

data reports. The following should not be considered alterations: any comparable or duplicate

replacement, the addition of any reinforced nozzle less than or equal to the size of existing

reinforced nozzles, and the addition of nozzles not requiring reinforcement.

3.6 authorized inspection agency: Any one of the following:

a. The inspection organization of the jurisdiction in which the pressure vessel is used.

b. The inspection organization of an insurance company that is licensed or registered to

write and does write pressure vessel insurance;

c. The inspection organization of an owner or user of pressure vessels who maintains an

inspection organization for his equipment only and not for vessels intended for sale

or resale; or

d. An independent organization or individual that is under contract to and under the

direction of an owner/user and that is recognized or otherwise not prohibited by the

jurisdiction in which the pressure vessel is used. The owner/users inspection

program shall provide the controls that are necessary when contract inspectors are

used.



3.9 condition monitoring locations (CMLs): Designated areas on pressure vessels where

periodic examinations are conducted. Previously, they were normally referred to as

thickness monitoring locations (TMLs).

3.21 external inspection: A visual inspection performed from the outside of a pressure

vessel to find conditions that could impact the vessels ability to maintain pressure integrity

or conditions that compromise the integrity of the supporting structures, e.g. ladders,

platforms. This inspection may be done either while the vessel is operating or while the

vessel is out-of-service.

3.34 internal inspection: An inspection performed from the inside of a pressure vessel

using visual and/or NDE techniques.

3.43 on-stream inspection: An inspection performed from the outside of a pressure vessel

while it is on-stream using NDE procedures to establish the suitability of the pressure

boundary for continued operation.

3.53 repair: The work necessary to restore a vessel to a condition suitable for safe operation

at the design conditions. If any of the restorative work results in a change to the design

temperature, MDMT, or MAWP, the work shall be considered an alteration and the

requirements for rerating shall be satisfied. Any welding, cutting or grinding operation on a

pressure-containing component not specifically considered an alteration is considered a

repair.

3.54 repair organization: Any one of the following who makes repairs in accordance with

the inspection code:

a. The holder of a valid ASME Certificate of Authorization that authorizes the use of an

appropriate ASME Code symbol stamp (e.g. U-stamp).

b. The holder of a valid R-stamp issued by the National Board.

c. An owner or user of pressure vessels who repairs his or her own equipment.

d. A contractor whose qualifications are acceptable to the pressure-vessel owner or user.

e. An individual or organization that is authorized by the legal jurisdiction.

3.56 rerating: A change in either the design temperature rating, the MDMT or the MAWP

rating of a vessel. The design temperature and maximum allowable working pressure of a

vessel may be increased or decreased because of a rerating. Derating below original design

conditions is a permissible way to provide for additional corrosion allowance.



Practice Problem Q005: Definitions Which of the following are not considered to be alterations?

a) any comparable or duplicate replacement

b) the addition of any reinforced nozzle less than or equal to the size of existing reinforced

nozzles

c) the addition of nozzles not requiring reinforcement

d) all of the above


Practice Problem Q006: Definitions What is the main function of an examiner within API 510?

a) a person who assists the inspector by performing spe

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