Volume 1 API 510 Exam

API - 510

COURSE

VOLUME

NOTESm

- IE

CONTENTS

1

Program Daily Schedule.

2. Body of Knowledge & Effectivity Sheet. 3. Examples of Repairs and Alterations 4. Guidelines for API 510 Certification Exam. 5.

Case Studies.

ASME Sec. VIII.

6.

Case Studies

7.

Reference Documents.

API 510.

ASME See. IX.

Allowable Stress Tables Solved Examples, ASME Sec. VIII, Div. 1 Materials of Construction 8.

Daily Practice Exams & Answer Keys

9.

Daily Points to Recall.

10. Add itiona I Information

API 510 PRESSURE VESSEL INSPECTOR COURSE

PROGRAM SCHEDULE Venue:

Hotel Kohinoor Executive, Pune, INDIA.

\ DAY 1.

Session

1

Introduction to API-510 Certification. ASME code system introduction to ASME SEC. VIII, Div. 1. Session

2

Design fundamentals Allowable Stresses, Joint Category, Joint types Joint efficiencies Session

3

Design of Cylindrical shells Calculation of vessel MAWP, part MAWP Static head calculations Design of Dished heads Case Studies

I DAY 2.

J Session

1

•

to recall Day-1 of Dished heads. (Contd.) of Flat unstayed heads of dished heads

•

Points Design Design Depths

Session

2

External pressure calculations Case Studies Impact testing requirements Session

3

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

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

I

DAY-3.

Session • • • •

l 1

Points to recall Day-2 Weld size for attachment welds at openings. Case studies. Reinforcement of Openings-Concepts

Session • • •

Reinforcement pad Calculations Case studies. Typical weld joints for Pressure Vessels Restrictions on joints -mismatch tolerances

Session • • • •

2

3

Allowable weld reinforcements Inspection requirements for Pressure Vessels Heat treatment Code stamping and Data-reports Review of Practice Exam-2

~------------------------------------------,

I

DAY 4.

Session 1 Points to recall Day-3 Introduction to API-510 code - Scope & Applications Reference Codes and Standards Specific definitions Session 2

•

API-510 contd ...lnspection Organizations Owner-User responsibilities Quality control manual Certification requirements

Session

•

3

Modes of Deterioration Corrosion, Fatigue, Creep Freeze damage, Brittle failure, Temper embrittlement Review of Practice Exam-3

I

--_._ ..,-_

..•..••..

_-_ _-._-------~---_. .•.

[DAYS. Session • • • • • •

•

r

1

2

API-510 Inspection practices Corrosion rate determination MAWP determination for Vessels in service Numerical Examples

Session •

---------------------

Points to recall Day-3 API-510 contd ..Defect inspection Inspection of parts Minimum thickness Evaluation Pitting corrosion Localised corossion

Session

• • •

----------

3

API-510 contd .... External inspection Internal and on-stream inspection Inspection interval Remaining service life Illustrative calculations Review of Practice Exam-4

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

Session

-_ -_ -_ -_ -

--------.-------------------., .

1

Points to recall Day-3 API-510 contd ...Defect repairs Pressure tests Documentation Session •

and Records

2

Welding requirements Pre-heating and PWHT Weld overlay and cladding NOT for repairs and alterations

Session

3

Alterations and re-rating Re-rating documentation and stamping Review of Mid-session Exam-Open book. Closed book.

I

I DAY 7. Session • • • •

Points to recall Day-6 Introduction to ASME SEC. IX Procedure Qualifications PQR tests- and evaluation of results

Session

Session •

• • t

2

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

•

I

1

3

Detailed road-map for review of WPS/PQR documentation Case Studies for WPS/PQR review. ASME Sec.v Nondestructive Examination Article 1: General Requirements Review of Practice Exam-6

DAY 8.

Session

•

Points to recall Day-7 Article 2: Radiographic Examination Radiograpic procedure Selection of penetrameter Radiographic technique Interpretation & documentation

Session • • • •

1

2

Article 6: Liquid Penetrant Examination LPE procedure Selection of penetrants LPE technique Interpretation & documentation Article 7: Magnetic particle Examination

Session

3

SE-797 UT measurememt Pulse-Echo contact method Single and dual crystal techniques Review of NDE Requirements ASME See VIII & API 510 Review of Practice Exam-7

I DAY

9.

Session • • • • • •

1

Points to recall Day-8 Introduction to IRE Chap. II Corrosive components in crude Deterioration due to Hydrogen Deterioration due to H2S Other factors of Corrosion

Session • • • •

2

API RP-572 review Types of Pressure Vessels Construction Standards Causes of deterioration

Session • • • •

3

Internal inspection External inspection Inspection records and reports Review of Practice Exam-8

-- ----

Session • • • • • •

---------.---------

1

Points to recall Day-9 API RP-576 Inspection of Pressure relieving Devices Types of PRDs Causes for malfunctioning Inspection intervals &insp. procedures for PRDs, Testing of PRDs on test bench. Inspection records & reports

Session

2

Review of Practice Exam-8 Final Open- book Test Session

3

Final close book test Feed-back on tests Close-down.

" ~ ..:",ao

reln-dcum Institute

1220 L Street. Northwest Washington, D.C. 20005-4070 202-682-8161 202-682-8348 (Fax)

~ICP BODY OF KNOWLEDGE API-SIO PRESSURE CERTIFICATION

VESSEL

INSPECTOR

EXAMINATION

May 2005 (Replaces June 2004) API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, and altcration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such knowledge. The following is a list of specific topics in which the API Authorized Pressure Vessell.nspector

should bc knowledgeable.

To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each category listed within tl1is Body of Knowledge will be included on the API certification exan1ination. Only inspection information covered in one of the references outlined in this body of knowledge will be utilized for the examination questions. The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring everyday working knowledge of API Standard 510 and the applicable reference documents. The open book portion of the examination requires the use of morc detailed information that the inspector is expected to be able to find in the documents, but would not nonnally

be COllunitted to memory.

REFERENCE

PUBLICATIONS:

API publications open-book

and ASME codebooks

must be brought to the examination

site to be used as reference materials for the

part of the examination.

A. API Publications: API 510, Pressure Vessel Inspection Code API RP 571, Damage Mechanisms Affecting Equipment

in Refilling Industry

API RP 572, Inspection of Pressure Vessels API RP 576, Inspection of Pressure-Relieving Devices API RP 577, Welding Inspection and Metallurgy B. ASME Publications: Section V, Nondestructive Examination Section VIII, Division I, Rules for Constructing Section lX, Welding and Brazing Qualifications Note: Refer to the Publications supplements

05105

Effectivity

ofilie reference publications

Pressure Vessels

Sheet in the application package for a list of specific editions, addenda, and tl1at are effective for your ex.am date.

I. THICKNESS

MEASUREMENTS,

INSPECTION

INTERVALS

AND VESSEL

INTEGRITY

A. Code calculation questions will be oriented toward existing pressure vessels, not new pressure vessels. API Authorized Pressure Vessellnspcctors should be able to check and perfonn calculations relative to in-service deterioration, repairs, rerates, or alterations. Only internal and external pressure loadings will be considered for the API 510 examination. The following categories describe the minimum necessary knowledge and skills: I. CORROSION

RATES AND INSPECTION

INTERVALS

The Inspector should be able to take inspection data and deternline the internal and external inspection

intervals.

The Inspector must be able to calculate: a. b. c. d. e.

Metal Loss (including corrosion averaging) (API-51O, Para 5.7, d) Corrosion Rates (API-SIG, Para 6.4) Remaining Corrosion Allowance (API-51O, Para 6.4) Remaining Service Life (API-510, Para, 6.4) Inspection Interval (API-SIO, Para, 6.4)

The fonnulas for perfonning during the exam.

the above calculations

and rules for setting the inspection

intervals may be "closed-book"

2. JOINT EFFICIENCIES The inspector must be able to detennine a. Weld Joint Categories b. Type c. Joint d. Joint e. Joint

"E" of a vessel weld. Inspector should be able to detennine:

from UW-3;

of radiography (full, spot, or none) performed basis the nameplate markings (RT-I, RT-2, etc.); efficiency by reading Table UW-12; efficiency for seamless heads and vesscls Sections per UW -12 (d); and efficiency for weldcd pipe and tubing per UW- 12 (e).

Detenllining formulas 3. STATIC

the joint efficiency

joint efficiency may be part of the internal pressure problem for deternlining required thickness or Vessel Part MA WP.

since joint

efficiency

"E" is used in the

HEAD

The inspector must be able to compensate for the pressure resulting from static head. All static head wiIl be based upon a Specific Gravity of 1.0. The inspector should be able to: a) b) c) d) e)

List the static head/pressure conversion factor (0.433 psilft); Know the difference between vessel MA WP and vessel part MAWP (UG-98); Calculate static head pressure on any vessel part; Calculate total pressure (MA WP + static head) on any vessel part; Calculate maximum vessel MA WP given vessel parts MA WP and elevations

Static head calculations examination problem.

05/05

may also be required during the internal pressure calculations

2

if static head data is given in the

The inspector a) b) c) d) e)

should be able to detennine:

The rcquired thickness of a cylindrical shell based (In circllnlferel\ti.d ,tr