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Rev. 03 Feb. 26, 05
Haward Technology Middle East
API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training only)
September 3-14, 2005 Abu Dhabi, U.A.E.
Course Instructor(s) Mr. Oran T. Lewis
This document is the property of the course instructor and/or Haward Technology Middle East. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Haward Technology Middle East
To The Participant The Course notes are intended as an aid in following lectures and for review in conjunction with your own notes; however they are not intended to be a complete textbook. If you spot any inaccuracy, kindly report it by completing this form and dispatching it to the following address, so that we can take the necessary action to rectify the matter.
Haward Technology Middle East P. O. Box 26608 Abu Dhabi, U.A.E. Tel: +971 2 627 7881 Fax: +971 2 627 7883 Email:
[email protected]
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Disclaimer The information contained in these course notes has been complied from various sources and is believed to be reliable and to represent the best current knowledge and opinion relative to the subject. Haward Technology offers no warranty, guarantee, or representation as to it’s absolute correctness or sufficiency. Haward Technology has no responsibility in connection therewith; nor should it be assumed that all acceptable safety and regulatory measures are contained herein, or that other or additional information may be required under particular or exceptional circumstances.
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Table of Contents Section 1
Service Restrictions, Joint Efficiencies, Radiography
Section 2
Shell and Head Calculations
Section 3
MAWP
Section 4
Hydrostatic Head Pressure
Section 5
Hydrostatic, Pneumatic Tests
Section 6
Postweld Heat Treatment
Section 7
External Pressure Calculations
Section 8
Charpy Impacts
Section 9
Fillet Welds and Reinforcement
Section 10
Materials, Name Plates, and Data Reports
Section 11
Corrosion Calculations
Section 12
ASME Section IX Overview
Section 13
Writing a Welding Procedure Specification
Section 14
Welder’s Qualification
Section 15
Review of WPS’s and PQR’s
Section 16
Section V NDE
Section 17
RP 577 Welding Inspection and Metallurgy
Section 18
Mechanical and Metallurgical Failures
Haward Technology Middle East COURSE OVERVIEW IE100
API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training only) Course Title API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair and Alteration (Training only) Course Date/ Venue Course : September 03-14, 2005 Exam : December 07,2005 (Optional) Venue : Corniche Room (105), 1st Floor, Millennium Hotel, Abu Dhabi, UAE (For both Course & Exam) Course Reference IE100 Course Duration 10 days (80 hours as per API recommendations) Course Objectives This course is designed to train individuals who are interested in obtaining the API 510 Pressure Vessel Inspector Certification, as well as those who are seeking a better understanding of ASME Section VIII and IX code requirements. Included with the course is a pre-study guide and student classroom workbook. The student receives instruction regarding how to take the test, as well as insight into the intricacies of "real world" situations. Daily tests are designed to gauge students’ proficiency and understanding of the material. Topics include:
Head and Shell Calculations Hydrostatic Test Pressure Calculations Reinforcement Calculations Shell External Pressure Calculations Impact Test Requirements and Determination Development and Review of Welding Documentation NDE Requirements
Haward Technology (ITAC) is proud of its 90% pass rate in API 510/570 examinations Who Should Attend The course is intended for Inspection Engineers who are seeking API-510 certification. Other engineers, managers or technical staffs who are dealing with Pressure Vessel will also benefit. Course Certificate Haward Technology certificate will be issued to all attendees completing minimum of 75% of the total tuition hours of the course. IE100 IE100-09-05
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Haward Technology Middle East Course Fee US $ 3,750 per Delegate. This rate includes Participant’s Pack (Folder, Manual, Hand-outs, etc.), buffet lunch, coffee/tea on arrival, morning & afternoon of each day. Accommodation Accommodation is not included in course fees. However, any accommodation required can be arranged by Haward Technology at the time of booking. Required Codes & Standards Listed below are the effective editions of the publications required for the current Vessel Inspector Certification Examination. Each student must have these documents available for use during the class. A APPII SSttaannddaarrdd 551100, 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 A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557711,, Damage mechanisms affecting fixed equipment in the refining industry, 1st Edition, December 2003 A ATTTTEEN NTTIIO ON N:: 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 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) A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557722,, Inspection of Pressure Vessels, 2nd Edition, February 2001.Global Engineering Product Code API CERT 572 A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557766,, Inspection of Pressure-Relieving Devices, 2nd Edition, December 2000..Global Engineering Product Code API CERT 576 A APPII R Reeccoom mm meennddeedd PPrraaccttiiccee 557777 –– Welding Inspection and Metallurgy, First edition, October 2004.. Global Engineering Product Code API CERT 577 A Am meerriiccaann SSoocciieettyy ooff M Meecchhaanniiccaall EEnnggiinneeeerrss ((A ASSM MEE)),, Boiler and Pressure Vessel , Code, 2001 edition with 2002 and 2003 addenda. i. Section V,
Nondestructive Examination, Articles 1, 2, 6, 7 and 23 (section SE-797)
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Haward Technology Middle East ii. Section VIII,
Rules for Construction of Pressure Vessels, Division 1, UG, UW, UCS, UHT, Appendices 1-4, 6, 8 and 12
iii. Section IX,
Welding and Brazing Qualifications, Welding only
Global Engineering Product Code for the ASME package is API CERT ASME 510. Package includes only the above excerpts necessary for the exam. Future addenda will not be provided. API and ASME publications may be ordered through Global Engineering Documents at 303792-2181 or 800-854-7179. Product codes are listed above. API members are eligible for a 50% discount on all API documents, other exam candidates are eligible for a 20% discount on all API documents. No discounts will be made for ASME documents. When calling to order please identify yourself as an exam candidate. For complete sets of ASME documents including future addenda please contact ASME’s publications department at 1-800-843-2763. In Canada, ASME publications are available through Power Engineering Books, Ltd. at 1-800-667-3155 or 780-458-3155. Note: API and ASME publications are copyrighted material. Photocopies of publications are not permitted at the exam. CD-ROM versions of the API documents are issued quarterly by Information Handling Services. Be sure to check your CD-ROM against the editions noted on this sheet.
Course Instructor Mr. Oran T. Lewis, P.E. (Texas, USA) is an Adjunct Instructor with over twenty years experience in the design, erection, maintenance, inspection, fabrication, modification and repair of pressure equipment, as well as presenting educational courses for piping inspection, welding, weld inspection, and pressure equipment inspection Mr. Lewis has a Bsc degree and he is a qualified American National Board Trainer and an NDE Trainer. Further, he is a AWS Certified Welding Inspector, API Certified Pressure Vessel Inspector, API Certified Piping Inspector, a member of the National Board of Boiler and Pressure Vessel Inspectors Commission and a Boiler and Pressure Vessel Inspector - State of Texas. Course Program Day 1 : Saturday 03rd of September 2005 0730 - 0800 Registration & Coffee 0800 - 0810 Welcome & Introduction Service Restrictions - Joint Efficiencies - Radiography 0810 - 1000 UW-3 Weld Categories UW-51 RT Examination of Welded Joints UW-52 Spot Examination of Welded Joints 1000 - 1015
Break
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Service Restrictions - Joint Efficiencies - Radiography (continued) UW-11 RT and UT Examinations UW-12 Maximum Allowable Joint Efficiencies Exercises UW 3, 11 and 12
1230 - 1330
Lunch
1330 - 1515
Vessels under Internal Pressure – Shell and Head Calculations UG-27 Thickness of Shells under Internal Pressure
1515 - 1530 1530 - 1700
Break Vessels under Internal Pressure – Shell and Head Calculations (Contd…) UG-32 Formulas and Rules for Using Formed Heads End of Day One
1700
Day 2 : Sunday 04th of September 2005 Review of Day 1 0730 - 0830 0830 - 1000
Exercise with Review
1000 - 1015
Break
1015 - 1230
Maximum Allowable Working Pressure UG-98 Maximum Allowable Working Pressure
1230 - 1330
Lunch
1330 - 1515
Hydrostatic Head Pressure Hydrostatic Head Calculations
1515 - 1530
Break
1530 - 1700
Hydrostatic - Pneumatic Tests UG-99 Hydrostatic Test Pressure and Procedure UG-100 Pneumatic Test Pressure and Procedure UG-102 Test Gages End of Day Two
1700
Day 3 : Monday 05th of September 2005 Review of Day 2 0730 - 0830 0830 - 1000
Exercise with Review
1000 - 1015 1015 - 1230
Break Postweld Heat Treatment
1230 - 1330
Lunch
1330 - 1515
Cylinder under External Pressure UG-28 Thickness of Shells and Tubes (External Pressure) Break
1515 - 1530 1530 - 1730
Charpy Impact Testing UCS-66 Materials UCS-67 Impact Testing of Welding Procedures UCS-68 Design
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UG-84 Charpy Impact Test Requirements
End of Day Three
Day 4 : Tuesday 06th of September 2005 Review of Day 3 0730 - 0830 Exercise with Review 0830 - 1000 1000 - 1015 Break Fillet Welds and Reinforcement 1015 - 1230 UW-16 Weld Size Determination UG-36 Openings in Vessels UG-37 Reinforcement of Openings UG-40 Limits of Reinforcement 1230 - 1330 Lunch Materials Name Plates Data Reports 1330 - 1515 UG-77 Material Identification UG-93 Inspection of Materials UG-116 Name Plate Markings 1515 - 1530 Break Materials Name Plates Data Reports (continued) 1530 - 1700 UG-119 Name Plates UG-120 Data Reports 1700 End of Day Four Day 5 : Wednesday 07th of September 2005 Review of Day 4 0730 - 0830 Exercise with Review 0830 - 1000 1000 - 1015 1015 - 1230
Break Corrosion Calculations Inspection Interval Corrosion Rate and Remaining Life Long and Short Term Corrosion Rates
1230 - 1330 1330 - 1515
Lunch ASME Section - IX Overview Article I General Requirements Article II Welding Procedure Qualifications Break ASME Section - IX Overview (continued) Article III Welding Performance Qualifications Article IV Welding Data
1515 - 1530 1530 - 1700
1700
End of Day Five
Day 6 : Saturday 10th of September 2005 Review of Day 5 0730 - 0830 Exercise with Review 0830 - 1000 1000 - 1015 Break IE100 IE100-09-05
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Writing a Welding Procedure Specification Welding Procedures by Essential Variables
1230 - 1330
Lunch
1330 - 1515
Welder’s Qualification Welder Testing and Qualification Break Welder’s Qualification (continued) End of Day Six
1515 - 1530 1530 - 1700 1700
Day 7 : Sunday 11th of September 2005 Review of Day 6 0730 - 0830 Exercise with Review 0830 - 1000 1000 - 1015 Break Review of WPS’s and PQR’s 1015- 1230 Practice WPS/PQR reviews 1230 - 1330 1330 - 1515
1515 - 1530 1530 - 1700
1700
Lunch ASME Section - V NDE Article 1 General Requirements Article 2 Radiographic Testing Appendix 4 - Section VIII Rounded Indications Article 23 SE-797 Standard Practice for measuring thickness by the pulse-echo contact method Appendix 12 - Section VIII Ultrasonic Acceptance Criteria Break ASME Section - V NDE (continued) Article 6 Penetrant Testing Appendix 8 - Section VIII Methods for Liquid Penetrant Exam Article 7 Magnetic Particle Examination Appendix 6 - Section Magnetic Particle Examination End of Day Seven
Day 8 : Monday 12th of September 2005 Review of Day 7 0730 - 0830 Exercise with Review 0830 - 1000 1000 - 1015 Break API RP 577 Welding inspection and Metallurgy 1015 - 1230 Definitions Welding Inspection Welding Processes Welding Procedure Welding Materials 1230 - 1330 1330 - 1515
Lunch API RP 577 Welding inspection and Metallurgy (continued) Welder Qualification Non-Destructive Examination Metallurgy IE100 -
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1515 - 1530 1530 - 1730
1730
Refinery and Petrochemical Welding Issues Terminology and Symbols Break API RP 577 Welding inspection and Metallurgy (continued) Actions to Address Improperly made production welds Welding Procedure review Guide to common filler metals Example report of RT results End of Day Eight
Day 9 : Tuesday 13th of September 2005 Review of Day 8 0730 - 0830 Exercise with Review 0830 -1000 1000 - 1015 1015 - 1230
1230 - 1330 1330 - 1515
1515 - 1530 1530 - 1730
Break API RP 571 Damage Mechanisms Temper Embrittlement Brittle Fracture Thermal Fatigue Erosion/Erosion-Corrosion Mechanical Failure Atmospheric Corrosion Corrosion Under Insulation (CUI) Cooling Water Corrosion Boiler Water Condensate Corrosion Sulfidation Chloride Stress Corrosion Cracking (Cl-SCC) Corrosion Fatigue Caustic Stress Corrosion Cracking (Caustic Embrittlement) Wet H2S Damage (Blistering/HIC/SOHIC/SCC) High Temperature Hydrogen Attack (HTHA) Lunch Overview - API 510 Inspections of Pressure Vessels Scope Organization Types and Definitions of Maintenance Inspections Welding on Pressure Vessels Repairs and Alterations Overview - API 576 Pressure Relieving Devices Scope Types of pressure relieving devices Applications Limitations Break Overview - API 572 Inspection of Pressure Vessels Scope Reasons for Inspection IE100 -
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Day 10 : 0730 - 1030 1030 - 1045
Causes of Deterioration Methods of Repairs Inspection Records and Report End of Day Nine
Wednesday 14th of September 2005 Administer first half of API 510 practice examination #1 Break
1045 - 1345
Administer second half API 510 examination #1
1345 - 1445 1445 -1645
Lunch Review Exam result
1645- 1700 1700 - 1730
Break Pass out API 510 practice examinations 2 and 3 with solutions. Closing comments
1730
Presentation of Certificates End of course
Course Coordinator Ms. Samhar Tadesse: Tel: +971-2-6277881, Fax: +971-2-6277883, Email:
[email protected]
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Section 1 Service Restrictions, Joint Efficiencies, Radiography
Section 2 Shell and Head Calculations
Section 3 MAWP
Section 4 Hydrostatic Head Pressure
Section 5 Hydrostatic, Pneumatic Tests
Section 6 Postweld Heat Treatment
Section 7 External Pressure Calculations
Section 8 Charpy Impacts
Section 9 Fillet Welds and Reinforcement
Section 10 Materials, Name Plates, and Data Reports
Section 11 Corrosion Calculations
Section 12 ASME Section IX Overview
Section 13 Writing a Welding Procedure Specification
Section 14 Welder’s Qualification
Section 15 Review of WPS’s and PQR’s
Section 16 Section V NDE
Section 17 RP 577 Welding Inspection and Metallurgy
Section 18 Mechanical and Metallurgical Failures
