Volume 1 API 510 Exam

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7. Reference Documents.

1 Program Daily Schedule.

6. Case Studies

ASME See. IX.

COURSE

NOTESm

- IE

API - 510

VOLUME

Allowable Stress Tables

Solved Examples, ASME Sec. VIII,

Div. 1

Materials of Construction

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.

API 510.

8. Daily Practice Exams

&

Answer Keys

9. Daily Points to Recall.

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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.

Session 1

• Points to recall Day-1

Design of Dished heads. (Contd.) Design of Flat unstayed heads • Depths of dished heads

Session 2

External pressure calculations Case Studies

Impact testing requirements

Session 3

Pressure testing -Hydrostatic Pressure testing-Pneumatic Review of Practice Exam-1

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DAY-3.

Session 1

• Weld size for attachment welds at openings. • Case studies.

• Reinforcement of Openings-Concepts

Session 2

• Reinforcement pad Calculations • Case studies.

• Typical weld joints for Pressure Vessels Restrictions on joints -mismatch tolerances

Session 3

• Allowable weld reinforcements

• Inspection requirements for Pressure Vessels • Heat treatment

Code stamping and Data-reports • Review of Practice Exam-2

l

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I

DAY 4. I

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

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..•..••..

_-_

.•.

_-._---~---_.

[DAYS.

---

---Session 1

• API-510 contd ..Defect inspection • Inspection of parts

• Minimum thickness Evaluation • Pitting corrosion • Localised corossion Session 2

•

API-510 Inspection practices Corrosion rate determination

MAWP determination for Vessels in service Numerical Examples

Session 3

• API-510 contd .... External inspection Internal and on-stream inspection Inspection interval

• Remaining service life Illustrative calculations Review of Practice Exam-4

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r

DA-Y_ -_6-._--- -- -- --- -_ -_ -_ -_ - . I

Session 1

API-510 contd ...Defect repairs Pressure tests

Documentation and Records

Session 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

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I

DAY 7.

Session 1

• Introduction to ASME SEC. IX • Procedure Qualifications

• PQR tests- and evaluation of results

Session 2

Welding variables-EVs, NEVs, SEVs. Limits of PQR Qualificatios I validity. WPS/PQR documentation

• WPQ tests & their validity

Session 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

I

DAY 8.

t

Session 1

Article 2: Radiographic Examination Radiograpic procedure

Selection of penetrameter • Radiographic technique

Interpretation & documentation

Session 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

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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

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---.---Session 1

• 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.

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" ~ ..: ",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 VESSEL INSPECTOR

CERTIFICATION 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 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 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 Pressure Vessels Section lX, Welding and Brazing Qualifications

Note: Refer to the Publications Effectivity Sheet in the application package for a list of specific editions, addenda, and supplements ofilie reference publications tl1at are effective for your ex.am date.

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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. Metal Loss (including corrosion averaging) (API-51O, Para 5.7, d) b. Corrosion Rates (API-SIG, Para 6.4)

c. Remaining Corrosion Allowance (API-51O, Para 6.4) d. Remaining Service Life (API-510, Para, 6.4) e. Inspection Interval (API-SIO, Para, 6.4)

The fonnulas for perfonning the above calculations and rules for setting the inspection intervals may be "closed-book" during the exam.

2. JOINT EFFICIENCIES

The inspector must be able to detennine the joint efficiency "E" of a vessel weld. Inspector should be able to detennine: a. Weld Joint Categories from UW-3;

b. Type of radiography (full, spot, or none) performed basis the nameplate markings (RT-I, RT-2, etc.); c. Joint efficiency by reading Table UW-12;

d. Joint efficiency for seamless heads and vesscls Sections per UW -12 (d); and e. Joint efficiency for weldcd pipe and tubing per UW- 12 (e).

Detenllining joint efficiency may be part of the internal pressure problem since joint efficiency "E" is used in the formulas for deternlining required thickness or Vessel Part MA WP.

3. STATIC 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) List the static head/pressure conversion factor (0.433 psilft);

b) Know the difference between vessel MA WP and vessel part MA WP (UG-98); c) Calculate static head pressure on any vessel part;

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

e) Calculate maximum vessel MA WP given vessel parts MA WP and elevations

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

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The inspector should be able to detennine:

a) The rcquired thickness of a cylindrical shell based (In circllnlferel\ti.d ,tr<:ss gi,'<:n a pr<:ssure (UG-27(c)(l »)i b) The vessel part MA WP for a cylindrieal shell ba.,cd on cir.:umtcr.:nllal strcs, given a metal thickness (UG-27(c)(I)); c) The rcquircd thickncss ofa head (ellipsoidal. and hCOlisphcrh;al) ~i\(;n a pre-;surc. (UG-32 (d), (e), (f) and (g)) d) The vessel part MAWP for a head (ellipsoidal. and hCOlisphcn-:;d) ~i"en a -neta\ thickness. (UG-32 (d), (e), (f) and

(g).

e) Whether a head (ellipsoidal, torispherical or hcmlsph,Ti<a: I mect. ( ode rcquiremcnts given both prcssure and metal thickness (UG 32(d), (e), (f) and (g).

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 TESTING The inspector should be able to:

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

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 fanliliar with all steps in a pneumatic test procedure (UG 100 and UG 102) 7. IMPACT TESTING

The inspector should be able to:

a) Determine the minimum metal temperature of a material which is exempt from irnpacttesting (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

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Thc inspector should:

a) Undcrstand thc kcy conccpts of reinforcement, such as replacement of strength removed and limits of rcinforccmcnt.

Credit can be takcn for cxtra metal in shell and nozzle

b) Be able to calculate the required areas for reinforcement or check to ensure that a designed pad 1S large enough. To simplify the problem:

All fr= 1.0 All F=\.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.

I. 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 tubesheetjoints and loads; 10. Relief valve sizing;

II. 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, DB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT; 20. Code Cases and interpretations;

2 \ .\Velding 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.

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II. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASEl) 0" ..••S\It. BOILER

AND PRESSURE VESSEL CODE, SECTION IX

/\. WELD PROCEDURE 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 \\ . ""ilhthl 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 will bc supported by a single PQR.

b) filler metals limited to one-pcr-proccss for SMAW, GTAW, GMA W. or ~A W. c) Thc PQR will be the supporting PQR for thc WPS.

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 essential 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 the lower transfonnation temperature will be 13330F and the upper transformation tempcrature will be 1600oF.

B. ASME Section VIII. Div. I and API-51O: GENERAL WELDING REOUIREMENTS: I. 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) Typical joints and definitions b) Weld sizes

c) Rcstrictions on joints

d) Maximum allowable reinforcement c) Inspection requirements

f) Heat treatmcnt 2. 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.

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 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.

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1Il.NONDESTRUCTlVE EXAMINATION A~ME Section V. l'J9ndestluctive Examination

NOTE: The examination will cover ONLY the main body of each referenced Article, except as noted A. Article I, General Requirements:

The inspector should be familiar with and understand; I. The Scope of Section V,

2. Rules for use of Section Vas a referenced Code,

3. Responsibilities of the Owner / User, and of subcontractors, 4. Calibration,

5. Definitions of "inspection" and examination", 6. Record keeping requirements.

8. 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 II and III: The inspector should be familiar with and understand:

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. 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 for: a. Procedures

b. Techniques (Yoke and Prod only) c. Calibration

d. Examination e. Interpretation 2. Documentation and record keeping

E. Article 23, Ultrasonic Standards, Section SE-797 only - Standard practice for mea<;uring thickness by manual ultrasonic pulse-echo contact method:

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The inspector should be familiar wnh and und<:rsland. I) The Scope of Article 23, Section SE-797,

2) The general rules for applying and using th<:ll(lra~llir ll't.:t:)od

3) 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 :hcF,;r><:ralruk, for \,fDE (UG, UW, Appendices 4, 6, 8, and

12)

2. API 510, The inspector should be famiiiar \.'it~.u1\1unl~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.

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V. PRACTICAL KNOWLEDGE - SPECIFIC

A PI-51 0, Pressure Vessclluspc'crio,r Code

\fOTE: All of A PI 510 is applic able 10Ih~"XdDlm..ll"Jll unk.-ss s[}Ccifically cxcluded. ror cxample: Scction 8 and Appcndix E arc excludcd.

I. Organization and ('ertiflcati. >n Rcq,liremc'll~

a) Certification for API A ulh0roe(! Pce-.5l,rc \ ~s.;cl Insrectors (API-510, Section 4.2 and Appcndix B). b) Authorized Inspeni011 ,\/--,cllcles (AP -: 1('. '\ection 3.4)

c) Vessel Repair Organlzati'Jn'; (API- 510. Section 3.16)

d) Relief Device Testing and Repa,r ()rga:linllons (API-510, Section 6.6) 2. Typcs and Dcfinitions of Maintcnance Inspcction

a) Internal Inspection (API 5 10,6.4) b) Defcct Inspection (API-51O, 5.5) c) Inspcction of Parts (API-51O, 5.6)

d) External Inspection & Buried Vessels (API 510, 6.3)

e) Atmospheric Corrosion and Corrosion Undcr Insulation (API-5 10, 6.3)

1) On-Stream Inspcction (API-51O, 3.1 I & 6.4) g) Visual Examination (API-51O, 5.5)

h) Thickness Measurements (API-51O, 5.3, 5.7, 6.3 & 6.4) i) Nondestructive Examination (API-5 I 0,5.5 & 5.7) j) Assessment of Inspection Findings (5.8)

3. Welding on Pressure Vessels

a) Welding Inspection Requirements (API-51O, 5.6 & 7.2) 4. Corrosion and Minimum Thickness Evaluation

The inspector should havc a general knowledge of the following principles, and may be required to make calculations using these principles.

a) Corrosion Rate Determination (API 510, 5.3) b) Corrosion Averaging (API 510, 5.7) c) Widely Scattered Pitting (API 510,5.7) d) Surfaccs Remote From a Weld (API, 5.7)

e) Corrosion in Central Portion of Dished Heads (API 510,5.7)

5. Estimated Remaining Life and Corrosion rate (API 510,6.4) 6. Inspection Interval Determination and Issues Affecting Intervals

a) Rjsk-based inspection (API 510, 6.2)

b) Internal or On-Stream Inspection Intervals (API 510, 6.4)

c) Intcrnal and On-stream inspection Intervals for Estimated Life (API 510, 6.4) d) External Inspection Intervals «API-51O, 6.1-6.3)

e) Dcterioration Other Than Metal Loss (API 510, 5.2) f) Different Zones of a Vessel (API 510, 6.4)

g) Change of Service Conditions (API 510, 6.4) h) Change in Location and Ownership (API 510,6.4) 7. Relief Devices

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a) Repair Organizations (API-51O, Section 6.6)

b) Minimum Requirements for Quality Control Systems (API 510, 6.6) c) 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) Authorization (API 510, 7.1.1) b) Approval (API 510, 7. \.2)

c) Design Requirements (API 510, 7.2.7) d) Materials Requirements (API 510, 7.2.8)

e) Welding Requirements (API 510, 7.2.1, 7.2.2,7.2.3,7.2.6, &7.2.11) f) 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)

g) Repairs to Stainless Steel Weld Overlay and Cladding (API 510, 7.2.6) h) Inspection (API 510, 7.2.9)

i) Rerating of Pressure Vessels (API 510, 7.3)

j) Pressure Testing After Repairs, Alterations or Rerating (API-51 0, 6.5 and 7.2.10) k) Nondestructive Examination of Welds (API 510, 7.2.4)

API RP571, 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)

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I. 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 Detcnoration (API RP-572, 8.1- 8.10)

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

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

2. Pressure Vessel Materials and Fabrication Problems

a) Material and Fabrication Problems (API RP-572, 8A & 8.5) 3. Maintenance Inspection Safety Practices

a) Pressure Vessel Inspection (API RP-572, 10.2) 2. Inspection Records and Reports (API RP-572, Section 12)

API RP 576, Inspection of Pressure-RelievinF! Devices:

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 Detennination (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, Weldine Inspection alld Metallurf!1J

I. 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. Ternlinology and symbols

II. Actions to Address improperly made production welds 12. Welding procedure review

13. Guide to common filler metal selection 14. Example report ofRT results

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Publications Effectivity Sheet

API 510, Pressure Vessel Inspector

Certification

Exam

For Exam Administration:

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, 8th Edition,

June 1997, Addenda 1,2,3 and 4 (August 2003). Global Engineering Product Code API CERT 510

• API Recommended Practice 571, Damage mechanisms Affecting fIXed equipment in the refining industry, 1"Edition,

December 2003

A TTENTION: Only the following mechanisms 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 Vessels, 2nd Edition, February 200 I.

Global Engineering Product Code API CERT 572

• API Recommended Practice 576, Inspection of Pressure-Relieving Devices, 2ndEdition, December 2000.

Global Engineering Product Code API CERT 576

• API Recommended Practice 577 - Welding Inspection and Metallurgy. First edition, October 2004.

Global Engineering Product Code API CERT 577

• American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2001 edition with 2002 and

2003 addenda.

1. Section V, Nondestructive Examination, Articles 1. 2, 6, 7 and 23 (section S£-797)

ii. Section VIII, Rules for Construction of Pressure Vessels, Division 1, UG,

urv,

UCS, UHT, Appendices 1-4, 6, 8

Gnd 12

Ill. Section lX, Welding and Brazing Qualifications. We/ding OIlZF

Global Engineering Product Code for the ASME package API CERT 510 ASME. Package includes only the above excerpts necessary for the exam.

API and ASME publications may be ordered through Global Engineering Documents at 303-397-7956 or 800-854-7179. 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

(18)

('

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

or

replacement

of

pressure

parts

or

attachments

that

have failed

in a weld

or in the

base

material:

2.

Corrosion resistance strip lining or weld overlay:

:;

Weld bUildup of wasted areas;

4.

The addition

of welded

attachments

to pressure

parts,

such as;

a. studs for insulation

or refractory

lining

b. ladder clips

c. brackets,

having

loading

Y"hich do not

affect

the

design of the pressure retaining

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

retaining

(19)

(

8. Replacement

of pressure

parts identical

to those existing

on the pressure

retaining

item

f

such as,

a. replacement

of a shell or head in accordance

with

the original

design.

b. Re-welding

a circumferential

or longitudinal

seam in

a shell or head

c. Replacement

of

nozzles

of

a

size

whet~e

reinforcement

is not a consideration

9.

Installation

of new nozzles or openings

of such a size that

reinforcement

is not

a consideration

{for

example

the

installation

of a 3 NPS nozzle to a shell or head of

3/8

in.

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

of

a

nozzle

where

reinforcement

is

a

consideration

may

be considered

to be a repair

if

the

nozzle is identical

to one in the original

design,

located

in

a similar

part of the vessel.

11. The replacement

of a shell course in a cylindrical

pr·essure

vessel:

12. Welding

of wasted or distorted

flange faces:

13. Replacement

of slip-on

flanges with weld neck flanges

01-vice-versa:

14.

Seal welding

of butt straps and rivets;

15 The repai r or replacement

of a pressure

part with

a Code

accepted

material

that

has a normal

composition

and

strength

that

is equivalent

to the original

material,

16

Replacement

of a pressure

retaining

part with

material

of

different

nominal

composition,

equal

to

or

greater

tn

allowable

stress

from

that

used

in the

or-iginal

design,

(20)

c.

provided

the replacement

material

satisfies

the material

and

design

requirements

of

the

original

code

of

construction

under which the vessel

was built.

EXAMPLES OF ALTERATIONS

(

1. An increase

in the

maximum

allowable

working

pressure

(internal

or external)

Or temperature

of a pressure retaining

item

regardless

of whether

or not a physical

change

was

made to the pressure retaining item;

2. A decrease in the minimum

temperature

such that additional

mechanical tests are required.

3. The addition

of

new

nozzles or opening

(in

a bOiler

or

pressure vessel)

of new sizes other than existing

sizes and

requiring

new reinforcement

calculations

4. A

change

in

the

dimensions

or

contour

of

a

pressu re

retaining

item;

5. In a boiler, an increase

in the heating

surface or steaming

capacity

such

that

increase

in

the

relieving

capacity

is

required;

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

of

different

allowable

stress or nominal composition

from that

used in the presSure retaining item to which it is attached.

8. The addition

of a braCket Or an increase

in ioading

on an

existing

bracket

which

affects the design

of the

pressure

retaining

item to which it is attached.

(21)

---_._---_."----~

..

".~-GUIDELINES FOR

API 510 CERllFICA liON EXAMINA liON

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

(22)

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

"open-book" examination and post-lunch session (4 hours) for "closed-"open-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

c1osed-book (approximately

100 questions). The distribution of 50 and 100

questions respectively for open-book and closed-book examinations

is

approximate; however the total is always 150 questions.

1.3 Question pattern:

Each question,( in open book as well as closed book part ) is

multiple-choice question with given FOUR possible multiple-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:

(23)

-_._---~-~-~~---~---==---•

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

to refer to the codes

and

other

documents

as per "Effectivity

Sheets".

Code

pages

may

be

tabbed.

highlightened,

underlined

or notes

in margin

of the pages

are

accepted.

Additional

new pages to codes are not accepted.

Always

carry

the following

to the exam hall.

• 2 Nos. 8 or 28 pencils and eraser

• Non-programmable

calculator

• Photo identity (passport,

driving license, etc.)

• Exam confirmation

letter

Be present

in the exam hall at least 15 minutes prior to scheduled

start of

exam. The Supervisor announces

important instructions

during this period.

Do not miss them. Now relax and attempt the exam calmly. Time is always

more than enough.

(24)

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

Approx.Questions

S.N.

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

_-

₁₈

4 ASME Sec. V

₁₂

₁₈

5 API RP 572

₄

₆

6 API RP 576

₅

₈

~

IRE Chap II

1

c;' I -'

2 ."

( ,{ ;,"' ~'

b (

, l:0- __

,.-8

J

General Knowledge

2

3 ~-- ---

--

______

L___

(25)

___________________________ ~ ~' ~="o=~=·.,"_._

3. 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

oriented questions will normally be "open-book" type. The Code

information

which

is not short and crisp, (i.e., large paragraphs,

several

descriptive

statements clubbed together) will normally be asked in "open-book"

part. Here the participant is expected not to remember the information but should

know where to find it in the body of the Code.

The questions asked in closed book part are straight forward statements directly

taken form Code without much of the modifications and therefore are easy to

answer. To answer open-book questions, one only needs to know where to find

the answer in the code and therefore tabbing of Code pages, highlighting

the

paragraphs or additional explanatory notes in page margins is useful for saving

time. Closed-book

part of the exam (100 marks) can be finished in 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.

(26)

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

Preparatory

Course.

If two or more

participants

from

same

organization

are appearing for exam, then joint discussions and one putting

question

to another and vice versa has been found very effective

during

preparation.

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".

(27)

-

_.---~---~'~-.,~='-~-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.

(28)

-

---~---~=,~-~~

..

~._._._

...

_,-=-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.

(29)

5. API-510 CHAPTERWISE TIPS FOR

MAXIMIZING THE SCORE

a.

From

Chapter

1, just

note

the

scope,

application

and

. exclusions.

Two questions

will be asked from these, usually

closed book.

b.

Chap. 2 lists only the reference

documents.

At the most one

question

is asked from this chapter

c.Chapter

3. There are only 5 or 6 important

definitions

from

Chapter

3 of API 510. Normally 3 to 4 definitions

are asked

in closed-book

exam.

d.

From

Chapter

4, usually

2 or

3 questions

are

asked.

Concentrate

on responsibilities

clause.

Also see App. B for

certification

requirements.

e.

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

6,

about

15-18

questions

are

asked.

Particularly

pay

attention

to

Inspection

intervals,

which

attracts

at least 5 to 6 questions

and they could

be either

open book or closed book.

(30)

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.

(31)

---.'---

·---·~~~~._=.;...::..._-_'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.

(32)

Volume 1 API 510 Exam

7.

Reference Documents.

1

Program Daily Schedule.

6.

Case Studies

ASME See. IX.

COURSE

NOTESm

- IE

CONTENTS

API - 510

VOLUME

Allowable Stress Tables

Solved Examples, ASME Sec. VIII,

Div. 1

Materials of Construction

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.

API 510.

8.

Daily Practice Exams

&

Answer Keys

9.

Daily Points to Recall.

API 510 PRESSURE VESSEL INSPECTOR COURSE

PROGRAM SCHEDULE

Venue:

Hotel Kohinoor Executive,

Pune, INDIA.

I

---_

-

~.---I

l

~

I

--_._

..

,-_

_-_

_-._---~---_.

[DAYS.

•

•

•

r

I

1:

I

I

~ICP

wrs

Publications Effectivity Sheet

API 510, Pressure Vessel Inspector

Certification

Exam

For Exam Administration:

December 7, 2005

urv,

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

('

API 510 PREPARP,TORY COURSE

EXAMPLES OF REPAIRS AND ALTERATIONS

INTRODUCTION

The

following

examples