Harvard Technology Middle East API 510 Pre-Course Material PO. Box: 26608, Abu Dhabi, United Arab Emirates, Tel: +971-2-6277081, Fax. +971-2-6217663 info@harvardtc hilp/iwwwharvard.teINSTRUCTIONS FOR API 510 PRE-COURSE STUDIES CONTENTS: 1, API 510 Study Questions and Answers 2. ASME Section [IX Welding Exercise 3. ASME Section V NDT Exercise 4. API Study Questions and Answers Audio CD(s) Please begin by reading all API materials including the Body of Knowledge sent with your package from the API. If you do not have the Body of Knowledge you may download it at the API website www.api.org. Continue by reading the API Study Questions and listening to the Audio, follow this by completing the enclosed exercises over ASME IX and V. Please bring to the class the following items, Effective Publications for this Revision: June 4" 2003 Exam * API510 Eighth Ed. June, 1997 with Addendums.1(Dec. 98) & 2 (Dec. 2000) &3 (Dec.2001) API RP 572 Second Edition Feb. 2001 API RP 576 Second Edition (Dec. 2000) AP! Guide to Inspection of Refinery Equipment Chapter 2 ASME Section VIII Div.1 2000 Edition with 01 addenda ASME Section IX 2000 Edition with 01 addenda ASME Section V 2000 Edition with 01 addenda A simple calculator (needs to have the square root function) Highlighters and Tabs The first day of class a short test will be given over the pre-course API 510 Study Questions! THIS PRE-STUDY MATERIAL IS VERY IMPORTANT PLEASE DO NOT NEGLECT THIS WORK. Start Now FAST TRACK TECHINICAL TRAINING - LICENSED TO BASE LINE DATAAPI 510 STUDY QUESTIONS | HOW TO USE THESE QUESTIONS The following questions and answers on the API material are ol for memorization. The API questions will be open book on the first part of the exam and closed book during the second half. Practice remembering the key words as opposed to learning the entire answer.API 510 EIGHTH ED., JUNE, 1997 ADDENDA #1 DEC. 1998, #2 DEC. 2000, #3 Dec. 2001 REVIEW QUESTIONS Section 1 - General Application 1, The primary code for the inspection of pressure vessels after they enter service is? (a) © The API510 Code 2. Relative to pressure vessels, when does API 510 apply? aay © Only applicable to vessels after they have been placed in service, 3. What does the API inspection code cover? (a) ‘+ Maintenance inspection, repair, alteration, and re-rating procedures for pressure vessels used by petroleum and chemical process industries. 4, What type of pressure vessel is exempt from periodic inspection requirements? (1.2.2) ‘© Pressure vessels on movable structures covered by other jurisdictional requirements. ‘© Allclasses listed for exemption from the inspection scope of the ASME Code Section VIN, Division I. © Pressure vessels that do not exceed specified volumes & pressures. Section 3 - Definitions 5, What is an alteration? G1) ‘+A physical change in any component or a re-rating which has design implications which affect pressure-containing capability beyond the scope of existing data reports. 6. What three situations should not be considered alterations? a) ‘Comparable or duplicate replacement + Addition of reinforced nozzle less than or cqual to cxisting reinforced nozzles * Addition of nozzles not requiring reinforcement 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC32) (33) 10. G5) WL 3.6) 12, G8) 1B. ‘In what situation would the term “applicable requirements of ASME Code” be used? ‘When the ASME Code cannot be followed because of its new construction orientation (new or revised material specifications, inspection requirements, certain heat treatments and pressure tests, and stamping and inspection requitemeats), the engineer or inspector shall conform to this inspection code rather than to the ASME Code. If an itera is covered by requirements in the ‘ASME Code and this inspection code or if there is « conflict between the two codes, for vessels that have been placed in service, the requirements of this inspection code shall take precedence over the ASME Code. As an example of the intent of this inspection code, the phrase "applicable requirements of the ASME Code" has been used in this inspection cade instead of the phrase "in accordance with the ASME Code." ‘What is an Authorized Inspector or Inspector? An employee of an Authorized Inspection Agency who is qualified and certified to perform inspection under this inspection code, List 4 examples of an Authorized Inspection Agency. Inspection organization of the jurisdiction in which the pressure vessel is used or; Inspection organization of insurance company which is licensed or registered to write and actually ‘writes pressure vessel insurance. An owner or user of pressure vessels who maintains an inspection organization for activities relating only to his equipment and not for vessels intended for sale or resale. ‘An independent organization or individual licensed or recognized by the jurisdiction in which the pressure vessel is used and employed by or acting under the direction of the owner or user. Define "construction code". ‘The code or standard to which a vessel was originally built, sich as APUASME, API, ot State Special/non-ASME. What does the term "inspection code” refer to in API 510? Shortened title for API 510 used in this publication. Define Jurisdictions. A legally constituted government administration, which may adopt rules relating to pressure vessels. Define Maximum Allowable Working Pressure (MAW) as it relates to API'510. (3.9) and (Sect VII UG-98) ‘The maximum gage pressure permitted at the top of a pressure vessel in its operating position for a designated temperature that is besed on calculations using the minimum (or average pitted) ‘thickness forall critical vessel elements, not including corrosion allowance or loading other than pressure, 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC“a (@.10) 15. Gn 16, al) 17. When determining Minimum Allowable Shell Thickness, what must be considered when making calculations? ‘Temperature, pressure, and all loading. What type of inspection uses nondestructive examination procedures to establish the suitability of Pressure vessels for continued operation? ‘On-stream Inspection ‘What is the key element of an On-stream inspection? Because the vessel may be in operation while an on-stream inspections being carried out, the vessel is not entered for internal inspection, ‘What is a Pressure Vessel? (3.12) and (Seet VIII U-1 (a) ) 18, (3.13) 19. G14) 20. G.15) A container designed to withstand internal or external pressure, which can be imposed by an ‘external source, by the application of heat from a direct or indirect source, or by any combination, ‘thereof. This definition includes unfired steam generators and other vapor generating vessels, ‘which use heat from the operation of a processing system or other indirect heat source. (Specific mits and exemptions of equipment covered by this inspection code are given in Section I and Appendix A.) ‘Who shall be a pressure vessel engineer? ‘Shall be one or more persons or organizations acceptable to the owner-user who are knowledgeable and experienced in the engineering disciplines associated with evaluating mechanical and material characteristics which affect the integrity and reliability of pressure vessels. The pressure vessel engineer, by consulting with appropriate specialists, should be regarded as a composite of all entities needed to properly assess the technical requirements. ‘What is the definition of quality assurance as given in API 510? All planned, systematic, and preventative actions required to determine if materials, equipment, or services will meet specified requirements so that equipment will perform satisfactorily in service. ‘The contents of a quality sssurance inspection manuel are outlined in 4.3, ‘What is a Repait ‘The work necessary to restore a vessel to a condition suitable for safe operations at the design conditions. "TF" design temperature or pressure changes due to restoration, then re-rating requirements shall also be satisfied. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO TTAC21 GB.16) . 23. : Bly 24, G18) 25, G9) List the four examples of a Repair Organization, ‘The holder of a valid ASME Certificate of Authorization forthe use of an appropriate ASME Code symbol stamp ‘An owner or user of pressure vessels who repairs his own equipment in accordance with the API 510 code. A contractor whose qualifications are acceptable to the owner or user of pressure vessels and ‘makes repairs in accordance with this inspection code. ‘A repair concern that is authorized by the legal jurisdiction What is re-rating? A change in either the temperature ratings or the maximum allowable working pressure rating of vessel, or a change in both. The maximum allowable working temperature and pressure of a ‘vessel may be increased or decreased because of a re-rating, and sometimes a re-rating requires a combination of changes. De-rating below original design conditions is « permissible way to provide for comosion. When a re-rating is conducted in which the maximum allowable working ‘pressure or temperature is increased or the minimum temperature is decreased so that additional mechanical tests are required, it shell be considered an alteration. ‘What is a permissible way to provide for corrosion? De-rating below original design conditions. What distinguishes an examiner from and inspector? A person who assists the API authorized pressure vessel inspector by performing specific NDE on pressure vessels but does not evaluate the results of those examinations in accordance with API 510, unless specifically trained and authorized to do so by the owner or user, ‘The examiner need not be certified in accordance with API 510 or be an employee of the owner or user but shall be trained and competent in the applicable procedures in which the examiner is involved. Define Controlled-Deposition Welding Any welding technique used to obtain controlled grain refinement and tempering of the underlying heat affected zone (HAZ)in the base metal. Various controlled-depositioa techniques, such as termper-bead (tempering of the layer below the current bead being deposited) and half-bead (requiring removal of one-half of the first layer), ate included. Controlled-deposition welding requires control ofthe entire welding procedure including the joint detail, preheating and post hhesting, welding technique, and welding parameters. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED 70 IACSection 4 - Owner-User Inspection Organization 26. What are the education and experience requirements for becoming an inspector (4.2 go to Appendix B) ‘+ Degree in engineering & 1 year experience in the design, construction, repait, operation, ot inspection of boilers or pressure vessel. ‘+ 2-year certificate in engineering or technology froma technical college & 2 years of experience in the design, construction, repair, operation, or inspection of boilers or pressure vessels. Equivalent ofa high school education plus 3 years of experience. (and). Five years experience in the inspection of boilers or pressure vessels. 27. Who will be responsible to the owner-user when alterations, inspections, or repairs are performed? (44) © The API authorized pressure vessel inspector. 08/02 Rev 6 FAST TRACK TECHNICAL - LICENSED TO TTACSection 5- Inspection Practices 28. Why are safety precautions important in pressure-vessel inspections? 6. © Because of the limited access to and the confined spaces of pressure vessels. 29. What guidelines must an inspector follow to enter a vessel that has been in service? (5.1) ‘+ OSHA Regulations regarding Confined Space Entry. 30. Explain the safety precautions and procedures that should be taken when performing an internal inspection, 6.0) {Isolate vessel from all sources of liquids, gas or vapors. Drain, purge, clean and ventilate. Gas test. ‘Wear protective equipment es required. ‘Wam all petsons working around the vessel that inspection personnel are inside, ‘Wam all inside the vessel of work that is done outside the vessel. Check all tools and safety equipment needed before inspection. 31. When developing an inspection plan for vessels that operate at elevated temperatures (750 to 1000 °F) what things chould be considered when assessing the remaining life of the vessel? (52) © Creep deformation and stress rupture. Creep crack growth, «Effect of hydrogen on creep, Interaction of creep and fatigue. ‘© Possible metallurgical effects, including a reduction in ductility. 32, Locations where metals of different thermal coefficients of expansion are welded together are susceptible to what? (5.2) © Thermal Fatigue. 33, The actual or estimated levels of what four items snust be considered in any evaluation of Creep? (52) Time Temperature Suess Material Creep Strength 34, Atambient temperatures, cazbon, low alloy, and other femiti steels may be susceptible to what? (5.2) © Brite Failure 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC35. (8.2) 36. 62) 37. (3) 38. 64) 39. G4) 40. (3.5) al. (6.5) 42. (5.5) Define Temper Embrittlement. A loss of ductility and notch toughness due to PWHT or high temperature service above 700 degrees F. (370 degrees C) ‘What kind of steel is prone to Temper Emibrittlement? Low alloy steels, especially 2 1/4-Cr-1 Mo ‘What three methods may be used to determine the probable rate of corrosion? Caleulate rate from data collected from same or similar service ‘Estimate rate from owner-user experience or from published data on comparable service. On-stream determination after 1000 hours of service using a suitable corrosion monitoring device or NDE thickness measurements (UT), subsequent inspections shall be made until the corrosion rate has been established. ‘How should the MAWP for the continued use of a pressure vessel be established? ‘By using the Code to which the vessel was fabricated or by using the appropriate formulas and requirements of the latest edition of the ASME Code to establish the design temperature and pressure. In corrosive service, the wall thickness used in the MAWP calculations shall be the actual thickness obtained by inspection minus ‘Twice the estimated corrosion loss before the date of the next inspection, except as modified in section 6.4 ‘What is the most important and the most universally accepted method of inspection? Careful visual examination ‘What determines the parts of a vessel that should be inspected? ‘The type of vessel and its operating conditions. For proper visual examination, what surface preparation is required? ‘The type of surface preparation depends on individual circumstances, but surface preparstion such as wire brushing, blasting, chipping, grinding, or a combination of these may be required. 08/02 Rey 8 FAST TRACK TECHNICAL - LICENSED 70 ITAC(3) 45, 66) : 66) 47. 67) 48, 67) 49. 7) If distortion is suspected during the inspection of a pressure vessel what is the proper course of action? If any distortion of a vessel is suspected or observed, the overall dimensions of the vessel shall be checked to confirm whether or not the vessel is distorted and, iit is distorted, to determine the extent and seriousness of the distortion. The parts of the vessel that should be inspected most carefully depend on the type of vessel and its operating conditions ‘What type of examiners shall the when the owner/user requires inspection for detection of interior surface breaking planar flaws? Industry-qualified UT Shear Wave examiners. List the inspections, which include the features that are common to most vessels and that are most important. Examine the surfaces of shells and heads carefully for possible cracks, blisters, bulges, and other signs of deterioration. ‘Examine welded joints and the adjacent heat affected zones for service-induced cracks or other defects, Examine the surfaces of all man ways, nozzles, and other openings for distortion, cracks, and other defects. ‘Name two reasons why it is necessary for the API 510 inspector to examine flange faces. To look for distortion To determine the condition of gasket-seating surfaces Corrosion may cause what two forms of loss? Uniform loss - a general, relatively even wastage ofa surface area Pitted appearance - an obvious, irregular surface wastage [Name three ways the minimum thickness of a pressure vessel can be determined. Any suitable nondestructive examination ‘Measurements teken through drilled test holos Gauging from un-corroded surfaces in the vicinity of the corroded area, For a corroded area of considerable size in which the cizcumferential stresses gover, the least thickness along the most critical element of the area may be averaged over a length not exceeding what? For vessels with inside diameters less than or equal to 60 inches (150 centimeters), one half the vvesse] diameter or 20 inches (50 centimeters), whichever is les. For vessels with inside diameters greater than 60 inches, one third the vessel diameter or 40 inches (100 centimeters), whichever is less. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITACSL (6.7) 10 ‘When can widely scattered pits be ignored? ‘No pit depth is more than 1/2 the vessel wall thickness exclusive of corrosion allowance. Total area of pits does not exceed 7 sq. inches in any 8 inch diameter circle. ‘Sum of pit dimensions along any straight line within the circle does not exceed 2 inches. ‘When should the design by analysis methods of Section VIIL, Division 2, Appendix 4, of the ASME Code be used? To determine if components with thinning walls, which are below the minimum required wall thicknesses, are adequate for continued service. ‘To evaluate blend ground areas where defects have been removed. What do you use to determine ifthe thickness at the weld or remote fiom the weld governs the allowable working pressure when the surface at the weld has a joint factor other than 1.02 For this calculation, the surface at a weld includes 1 inch (2.5 centimeters) on either side of the ‘weld, or twice the minimum thickness on either side of the weld, whichever is greater. 08/02 Rev 8 PAST TRACK THCHNICAL - LICENSED TO ITACa |. Describe the governing thickness when measuring the corroded thickness of ellipsoidal and torispherical heads. ‘The thickness of the knuckle region with the head rating calculated by the appropriate head formula. ‘The thickness of the central portion of the dished region, in which case the dished region may be considered a spherical segment whose allowable pressure is calculated by the code formula for spherical shells. ‘What is the spherical segment of both ellipsoidal and torispherical heads? ‘That area located entirely within a circle whose center coincides with the center of the head and whose dismeter is equal to 80% of the shell diameter. On torispherical heads, what is used as the radius of the spherical segment? Radius of the dish. ‘The radius of the spherical segmont of ellipsoidal heads sball be considered to be what? ‘The equivalent spherical radius K,D, where D is the shell diameter (equal to the major axis) end Kis given in Table I. ‘When evaluating metal loss in excess of a vessel’s corrosion allowance what API document should be consulted? APIRP 579 Sections 4.5 and 6 Section 6 - Inspection and Testing of Pressure Vessels and Pressure-Relieving Devices ‘When is an internal field inspection of new vessels not required? ‘When the manufactures’ data report (U1) essuring that the vessels are satisfactory for their intended service is available, ‘Name two factors to be considered when inspection intervals are being determined, ‘The risk associated with operational shutdown and start-up and the possibility of increased corrasion due to exposure of vessel surfaces to air and moisture, ‘What are the essential elements of a risk based assessment inspection? ‘The combination of likelihood of failure and the consequences of failure. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC6 (62) (Cc) 65, (63) 66. (63) o7. (64) 12 . What other factors should be considered in a RBI program? Appropriateness of the materials, vessel design conditions relative to operating conditions, appropriateness of the design codes and standards utilized, effectiveness of corrosion monitoring, programs; and the quality of inspection / quality assurance and maintenance programs ‘What action should be taken after an effective RBI assessment has been finished? ‘Choose the most appropriate inspection tools and methods based on the degradation expected. Set the appropriste frequency for internal and external and on-stream inspections. Determine if pressure testing will be required based on damage or after repairs. Decide on prevention and mitigation steps to reduce the likelihood of a vessel failure. . How often should each above ground vessel be given a visual external inspection? Each vessel aboveground shall be given a visual external inspection, preferably while in operation, at least every 5 years or at the same interval as the required internal or on-stream inspection, ‘whichever is less. ‘When making an external inspection, what shall the inspection include? Condition of the exterior insulation Condition of the supports ‘Allowance for expansion General alignment of the vessel on its supports Buried vessels shall be periodically monitored to determine their external environmental condition. What shall the inspection intervals be based ou? Corrosion rate information obtained during maintenance on adjacent connecting piping of similar material. Information from the interval examination of similarly buried corrosion test coupons of similar material. Information from representative portions of the actual vessel. Information from a vessel in similar circumstances. ‘What is the minimum interval for checking the insulating system or outer jacketing of vessels that are known to have a remaining life of over 10 years or that are protected against external corrosion? Every 5 years and repaired as needed ‘What is the maximum period between internal or on-stream inspection? ‘The maximum period shall not exceed one half the estimated remaining corrosion-rate life or 10 years, whichever is less, 08/02 Rev 6 FAST TRACK TECHNICAL - LICENSED 70 TTAC13 68. Ifthe remaining safe operating life ofa vessel is less than 4 years, what is inspection interval? (64) Interval may be the full remaining safe operating life up to @ maximum of 2 years. 69. Under what conditions would a vessel with a corrosion rate less than 0,005 inch (0.125 millimeter) per year and an estimated remaining life greater than 10 years be exemp! fiom an intemal inspection and inspected externally instead? (64) + When size, configuration, or lack of access makes vessel entry for internal inspection physically impossible, When the general corrosion rate ofa vessel is known to be fess than 0.005 inch (0. 125 millimeter) per year and the estimated remaining life is greater than 10 years, and all of the following conditions are met: The comosive character of the contents, including, the effect of trace components, has been established by at least 5 years of the same or comparable service experience with the type of contents being handled. ‘No questionable condition is disclosed by the external inspection specified in 6.2. ‘The operating temperature of the steel vessel shell docs not exceed the lower temperature limits for the creep-rupture range of the vessel material ‘©The vessel is not considered to be subject to environmental cracking or hydrogen damage from the ‘luid being handled. ‘© The vessel is not strip-lined or plate-ined. 7 70, Write the corrosion rate formula fo be used when determining the safe remaining life of a vessel. (64) ‘actual -tmin, Rem. Life ¥is. = —- corrosion rate © Where: tactual = the thickness, in inches millimeters), measured at the time of inspection for the limiting section used to determine the minimum allowable thickness, tminimum ~ the minimum allowable thickness, in inches (millimeters) for the limiting section or zone. 71, ‘There are two kinds of corrosion rates to be considered when calculating the remaining life of @ vessel. What are these types? (64) © Short Term and Long Term rates. 72. When conducting a pressure test as part ofa periodic inspection, what shall the shell temperature be during the test? (63) © To minimize the risk of brittle fracture during the test, the metal temperature should be maintained at least 30 °F (-1 °C) above the minimum design metal temperature for vessels that are more than 2 inches thick, or 10 °F (-12 °C) above for vessels that have a thickness of 2 inches or less. The test temperature need not exceed 120°F (50 °C) unless there is information on the brittle characteristics of the vessel material indicating that a lower test temperature is acceptable or a higher test temperature is needed, 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC14 73. When should pneumatic testing be done and what are some of the considerations to be taken into account? (6.5) (65) ‘+ Pneumatic testing may be used when hydrostatic testing is impracticable because of temperature, foundation or process reasons, however, the potential personnel and property risks should be considered. ‘74, Should safety relief valves ever be removed from a vessel during pressure testing? «Yes, if pressure testis being conducted in which the test pressure will exceed the set pressure of the safety relief valve with the lowest setting, 75, When a pressure relief valve requires repair, who shall make this repair? (6.6) ‘Testing and repairs shall be made by a repair organization experienced in valve maintenance. The repair organization shall have a written quality control system with the minimum requirements as listed in 4.5 of the API 510 code and maintain a training program to insure the qualifications of the repair personnel. 76. How often shall a safety relief valve be tested? (6.6) ‘©The intervals between pressure relieving device testing or inspection should be determined by the performance of the devices in the particular service concemed. Test or inspection intervals on. pressure-relicving devices in typical process services should not exceed 5 years, unless service experience indicates that a longer interval is acceptable, For clean (non-fouling), non-corrosive services, maxinum intervels may be increased to 10 years, 71. Pressure vessel owners and users are required to maintain permanent and progressive records of their pressure vessels. What things are included in these records? (6.7) Construction and design information, Operating and inspection history. Repair, alteration, and re-rating information. Fitness-for-service assessment documentation. Section 7- Repairs, Alterations, and Re-rating of Pressure Vessels, 78, Who must approve any repairs or alterations? (1.1) Allrepair and alteration work must be authorized by the authorized pressure vessel inspector before the work is started by a repair organization (see 3.13). Authorization for alterations to pressure vessels that comply with Section VIN, Divisions I and 2, of the ASME Code and for repairs to pressure vessels that comply with Section VIII, Division 2, of the ASME Code may not be given until a pressure vessel engineer experienced in pressure vessel design has been consulted about the alterations and repairs and has approved them. The authorized pressure vessel inspector will designate the fabrication approvals thet are required. The authorized pressure vessel inspector ‘may give prior general authorization for limited or routine repairs as long as the inspector is sure that the repairs are the kind that will not require pressure tests, 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC15 79. Who shall approve all specified repair and alteration wock? (71.2) * The API authorized pressure vessel inspector, after the work has been proven to be satisfactory and any required pressure test has been witnessed. 80, What nmst be removed from base material prior to welding? (7.1.3) © Surface irregularities and contamination. 81, All repair and alteration welding shall be in accordance with what code? 72.) + ASME Code, except as permitted in 7.2.11 82. What must be done before Preheat or Controlled Deposition Welding is used in lieu of PWHT? (7.2.3) + Prior to using any alternative method a metallurgical review must be conducted to determine ifthe proposed alternative is suitable for the application. 83, Name the materials allowed when using the alternative preheating method when notch toughness testing is not required. (723.1) r The materials shall be limited to P-Nos. P-No. 1 Group 1,2 and 3 and P-No. 3, Group 1 and 2 {excluding Mn-Mo steels in Group 2). 84, Name the materials allowed for use with the Controlled-Deposition Welding Method. (7.23.2) © ‘The materials shall be limited to P-No. 1, P-No. 3 and P-No. 4. = 85, Can local post weld heat treatment (PWHT) be substituted for 360 degree banding? (725) © YES provided the following conditions are met: ‘© Application is reviewed and procedure developed by engineer experienced in pressure vessel design & PWHT requirements. © Inevaluating the suitability of a procedare, all applicable Zactors (base metal thickness, material properties, etc.) are considered. ‘+ Preheat of 300 degree or higher per WPS is maintained. + PWHT temperature is maintained for distance not less than 2 times base metal thickness measured from weld. A minimum of 2 thermocouples is used. Heat is applied to any nozzle or other attachment in PWHT area. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC16 86. What considerations must be given to the repair of stainless steel overlay and claddings? (726) ‘© Consideration shall be given to factors which may augment the repair sequence such as stress level, P number of base material, service environment, possible previously dissolved hydrogen, type of lining, deterioration of base metal properties (by temper embrittlement of chromium- molybdenum alloys), minimum pressurization temperatures, and ¢ need for future periodic examination. 87. Per API 510, state the design requirements for: Butt Joints, Replacement Parts, New Connections, Fillet Weld Patches, Overlay Patches, Flush patches 7.2.7) + BUTT JOINTS - shall have complete penetration and fusion. «REPLACEMENT PARTS - shall be fabricated in accordance with the applicable requirements of the appropriate code, + NEW CONNECTIONS - design, location, and method of attachment shall be in accordance with the applicable requirements of the appropriate code. * FILLET WELDED PATCHES - require special design considerations, they are temporary repairs. Also it must be true that; (@) The fillet-welded patches provide design safety equivalent to reinforced openings designed according to the applicable section of the ASME Code. (b) The fillet-welded patches are designed to absorb the membrane strain of the parts so that in accordance with the rules of the applicable section of the ASME Code, the following result: + The allowable membrane stress is not exceeded in the vessel parts or the patches. ©The strain in the patches does not result in fillet-weld stresses that exceed allowable stresses for such welds. © OVERLAY PATCHES - shall have rounded comers. FLUSH (insert) PATCHES shall have rounded comers and be installed with full penetration butt joints 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC17 88. Summarize the rules for the use of s full encirclement lap band on a pressure vessel. (2.7) © A fill encirclement lap band repair may be considered a long term repair ifthe design is approved, ‘and documented by the pressure vessel engineer and the authorized API pressure vessel inspector ‘and the following requirements are met: ‘The repair is not being made to a crack in the vessel shell. ‘The band alone is designed to contain the full design pressure. All longitudinal seams in the repair band are full penetration butt welds with the design joint efficiency and inspection consistent with the appropriate code, «The circumferential fillet welds attaching the band to the vessel shell are designed to transfer the full longitudinal load in the vessel shell, using a joint efficiency of 0.45, without counting on the integrity of the original shell material covered by the band. «Fatigue of the attachment welds, such as fatigue resulting from differential expansion of the band relative to the vessel shell, should be considered if applicable. «The band materiel and weld metal are suitable for contact with the contained fluid at the design conditions and an appropriate corrosion allowance is provided in the band. ‘+ The degradation mechanism leading to the need for repair shell be considered in determining the reed for any additional monitoring and future inspection of the repair. Non-penetrating nozzles (Gncluding pipe caps attached as nozzles) may be used as long term repairs for other than cracks ‘when the design and method of attachment comply with the applicable requirements of the appropriate code. The design and reinforcement of such nozzles shall consider the loss of the ‘original shell material enclosed by the nozzle. The nozzle material shall be suitable for contact ‘with the contained fluid at the design conditions and an appropriate corrosion allowance shall be provided. 89. Describe the material suitable for making repairs or alterations. (7.2.8) ‘© Shall conform to the applicable section of the ASME Code, be of known weldable quality and be ‘compatible with the original material. Carbon or allow steel with a carbon content over 0.35, percent shall not be welded. 90. When making a sepair or alteration, what should the acceptance criteria include? (7.2.9) «NDE techniques that are in accordance with the applicable sections of the ASME Code or another ‘applicable vessel rating code. 91. After repairs or alterations, is a pressure test required? (72:10) «Repairs - pressure test only applied if inspector believes oneis necessary. «Alterations - pressure test are normally required. Subject tothe approval of the Juris (where the jurisdiction's approval is required), appropriate nondestructive examinations shall be required where a pressure testis not performed, Substituting nondestructive examination procedures for a pressure test after an alteration may be done only after a pressure vessel engineer experienced in pressure vessel design and the authorized pressure vessel inspector have been consulted. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC92, (72.11) 93. (73) 94, (73) 18 List the minimum tensile strength requirements for filler metals used on vessels weld repairs and the details of this method of repair. ‘The filler metal used for weld repairs should have minimum specified tensile strength equal to or greater than the minimum specified tensile strength of the base metal, Ifa filler metal is used that has a minimum specified tensile strength lower than the minimum specified tensile strength of the base metal, the compatibility of the fller metal chemistry with the base metal chemistry shall be considered regarding weld ability and service degradation. In addition, the following shall be met: ‘The repair thickness shall not be more than 50 percent of the required base metal thickness, excluding corrosion allowance. ‘The thickness of the repair weld shall be increased by a ratio of minimum specified tensile strength of the base metal and minimum specified tensile ofthe filler metal used for the repair. ‘The increased thickness of the repair shall have rounded comers and shall be blended into the base metal using a 3 to 1 taper. ‘The repair shall be made with 2 minimum of two passes. List the requirements associated with re-rating a pressure vessel, Calculations from either the manufacturer or an owner-user pressure vessel engineer (or his designated representative) experienced in pressure vessel design, fabrication, ot inspection shall Justify re-rating. A re-rating shall be established in accordance with the requirements of the constructiori code to ‘which the pressure vessel was built or by computations that are determined using the appropriate formulas in the latest edition of the ASME Code if ail of the essential details comply with the applicable requirements of the code being used. If the vessel was designed to an edition or addendum of the ASME Code earlier than the 1999 Addenda and was not designed to Code Case 2290 or 2278, it may be re-rated to the latest edition/sddendum of the ASME Code if permitted by Figure 7- Current inspection records verify that the pressure vessel is satisfactory for the proposed service conditions and that the corrosion allowance provided is appropriate. An increase in allowable ‘working pressure or temperature shall be based on thickness data obtained from a recent internal or on-stream inspection ‘The pressure vessel has at some time been pressure tested in accordance with the new service conditions, or the vessel integrity is maintained by special nondestructive evaluation inspection techniques in lien of testing. ‘The pressure vessel inspection and re-reting is acceptable to the authorized pressure vessel inspector. ‘When is the re-ating of a pressure vessel considered complete? ‘When the APT authorized pressure vessel inspector oversees the attachment of an additional nameplate or additional stamping that carries the following information: Rerated by: Maximum Allowable Working Pressure ___ psi a degrees F. Date 06/02 Rev € FAST TRACK TECHNICAL - LICENSED TO TTAC19 API RECOMMENDED PRACTICE 576 SECOND EDITION, DECEMBER 2000 ‘REVIEW QUESTIONS Section 1 - General 1. What is the general scope of API RPS76? a = To describe inspection and repair practices for automatic pressure-relieving devices commonly used in the oil and petrochemical industries. Section 2— References 2. What document should be referenced to determine the appropriate size for a pressure relief device? @) ‘+ RP520 Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries Section 3 ~ Definitions 3, Describe a pin-actuated device. 13) © Anonreclosing pressure relief device actuated by static pressure and designed to function by ‘buckling or breaking a pin, which holds a piston or plug in place. 4, What is a huddling chamber? 8.22) » Anannular pressure chamber located downstream of the seat of a pressure relief valve for the ‘purpose of assisting the valve in lifting. 5. Describe “rated relieving capacity”. 63.) ‘+ The relicving capacity used as the basis for the application of a pressure vessel relief device determined using the applicable code or regulation, Section 4 — Pressure-Relieving Devices 6. Whatis the function of pressure-relieving devices? @1) + Toprotect refinery equipment and personnel by automatically opening et predetermined pressures. 7, Name common examples of pressure relieving devices, @) Direct spring loaded Pilot PRV Rupture disks Weight loaded devices Pressure/Vacuum vent valves 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC20 ‘Name the five types of pressure relief valves. 4.4,4.6, 4.7) Safety valve Relief valve Safety relief valve Balanced Safety Relief Valve Pilot-operated safety relief valve 9, Describe a safety valve. (4.2)(Section VI UG-126 foot notes) + Actuated by static pressure upstream ofa valve. Spring fully exposed outside casing to protect from escaping steam. + Normally not pressure tight on their downstream side, 10. Safety valves should not be used in whet situations? (4.2.2) Corrosive refinery services. Any back pressure service. Where discharge is piped to remote locations. Where escape of lading fluid around blowing valves is not desirable In liquid service As pressure control or bypass valves. 11, Describe a relief valve. (4.3)(Section VIII UG-126 foot notes) + Actuated by static pressure upstream of a valve. ‘+ Lifts in proportion tothe inerease in pressure. © Usually reaches full lift at either 10% or 25% overpressure. 12, Why do relief valves have closed bonnets? ‘+ Toprevent the release of corrosive, toxic, flammable or expensive fluids. 13, Relief valves should not be used in what situations? In steam, air, gas, or vapor service. Inservices piped to an enclosed header unless the effects of any constant or variable backpressure shave been accounted for. * As pressure control or bypass valves. 14, There are two types of safety relief valves. What are these two types? (45,46) * Conventional & Balanced 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC15, (4.5) 16 (45.1) 17. (45.2) 18. (4.6) 19. (4.6.1) 20, (4.7(Section VI. 21 (7.1) J 21 Describe # conventional safety relief valve. ‘Opening pressure, closing pressure and relieving capacity are affected by back pressure. Has a closed bonnet ‘The bonnet cavity is vented to the downstream side, Where are conventional safety relief valves used? Refinery process industries that handle flammable, hot, or toxic materials. May a conventional safety relief valve be used on boiler steam drums or super heaters? No Describe a balanced safety relief valve. Balanced safety relief valves are direct spring loaded and incorporate a bellows or other means to minimize the effects of backpressure, ‘What are the proper applications for these pressure balanced safety relief devices: Balance safety relief valves are normally used in applications with flammable, hot or toxic ‘materials, where high pressures are present at the discharge of the valve. ‘What is a t-operated safety relief valve? -126 foot notes) A pressure-relief valve in which the major relieving device is combined with and is contolled by a self-actuated pressure relief valve (called a pilot valve) ‘What are some applications of pilot-operated safety relief valves? ‘Where a large relief area and/or a high pressure is required. ‘Where a low differential exists between normal vessel pressure and set pressure of valves. (On large low-pressure storage tanks (See API Std 620). ‘Where very short blow down required. ‘Where back pressure is very high and a balanced design is required. ‘Where the process requires the sensing of pressure at one location and the relief of fluid at another. ‘Where inlet and outlet frictional losses are high. ‘Where in-situ, in-service, set pressure verification is desired, ‘Name some limitations on the use of pilot-operated safery relief valves. Where fluids are diry. ‘Thick or viscous fluid service. ‘With vapors which polymerize in the valve. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC22 23, What are the three basic categories of pressure and/or vacuum vent valves? (48) Weight-loaded pallet vent valve = Pilot-operated vent valve Spring and weight-loaded vent valve 24, ‘What are the applications and limitations of pressure and/or vacuum vent valves? (4.8.1 and 2 + They are designed to protzct atmospheric and low pressure. storage tanks and are not generally used in applications requiring set pressures above 15 Ibf/in” 25, Describe the parts of a Rupture Disk Device. (49) ‘+The combination of a rupture disk and rupture disk holder is known as a rupture disk device. 26, Name the types of rupture disks. 49) Conventional Rupture Disk. Scored Tension-Loaded Rupture Disk. Composite Rupture disk Reverse-Acting Rupture Disk. Graphite Rupture Disk. 27, What is one advantage of the graphite disk over metal disks? 7 (4.9.1.5) * High corrosion resistance 28, Whatis usually the service life of pre-bulged metal rupture disks installed so that pressure acts against the concave side? (493) * One year - If not replaced periodically they can rupture under normal pressures without warning, 29. Normally the operating pressure of a system protected by # pre-bulged rupture disk is from 65% to 85% of the disk’s predetermined bursting pressure. What determines this pressure range? (49.3) ‘+The exect percentage depends on the disk’s type. 30. What precaution should be taken when a rupture disk is used in combination with another relief device and removed for any reason and will be reused? (49.3) ‘+ They should be handled with care to avoid damage which might cause premature rupture. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC23 Section 5~ Causes of improper Performance 31. What is the basic cause of many the difficulties encountered with pressure relief devices? 1) © Corrosion 32, What effect can the severe over sizing of relief valve bave? (82) + Damaged valve seats 33. List the major causes of improper performance in pressure-relieving devices. Corrosion Damaged seating surfaces Failed springs Improper seating & adjustments Plugging and sticking Misapplication of materials Improper location, history, or identification Rougit handling Improper differential between operating and set pressures Improper piping test procedures 34, To prevent leakage of the lading fluid, what must be maintained in the flatness of seating surfaces on pressure relief valves? 62) ‘© An optical precision on the order of 3 light beads/bands. 35, What are some reasons for damaged valve seats? 62) Corrosion Foreign particles getting into valve Improper or lengthy piping to the valve inlet or obstructions in the line. Carcless handling during maintenance. Leakage past the seating surfaces of a valve after it has been installed. Improper blow down ring settings. Severe over sizing. 36. What almost always causes broken springs in pressure relief valves? (3) © Corrosion (Note: two types - surface & stress) 37. What chemical frequently causes stress-corrosion spring failure in petrochemical plants? (53) ‘+ Hydrogen sulfide (#28) 08/02 Rey 8 FAST TRACK TECHNICAL - LICENSED TO ITAC38, (33) 39. 64) 63) 41. (5.6) (58.1) 43. (5.8.2) (383) 45. (5.10) 24 ‘What may be done to prevent spring failure due to corrosion? Spring material which can resist the action of the corrosive agent. - ‘Spring isolated by a bellows. Spring coated by a coating that can withstand the operating temperature and environment. ‘What medium should be used to set the following pressure relief devices? Safety relief valve - air or other gas. ‘Vapor service valve air or inert gas. ‘Steam service valves — steam but air may be used if suitable corrections are applied. Liquid service valves — water. ‘What is recommended for lubricating sliding parts and threads on valves to prevent fouling? ‘Valve parts should be lubricated with a material that is compatible with the service and temperature. In general, what should be considered in determining the material to be used for pressure-relieving devices? Temperature Pressure Corrosion resistance requirements 7 Atmospheric conditions .. Why should relief valves be shipped in an upright position? ‘When relief valves are laid on their sides, the springs may not exert the same force all around the seating surface. ‘What is one important aspect of the work done to PRDs in the maintenance shop? ‘Rough handling should be avoided such as the application of excessive backpressure to bellows type valves. IERV inlets and outlets are not covered during shipment what provisions should be made? = Provision should be made for such covering during all future shipments ‘What risks are incurred when a hydrostatic test of discharge piping for a PRD is performed? ‘The disk, spring and body area on the discharge side of valve can be fouled, ‘The bellows of a balanced relief valve can be damaged by excessive back pressure. ‘The dome area and/or the pilot assembly of a pilot-operated pressure RV are fouled and damaged by the back flow of the fluid. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC25 Section 6 — Inspection and Testing 46, Name two types of inspections. (6.1) © Shop inspections! overhauls and visual on-stream inspections. 47, When a relief valve is removed for inspection or overhauls what additional inspection should be made? (6.2) ‘+ Inlet and outlet piping should be inspected for intemal deposits and records made of their conditions. 48. Aftera PRV has been reinstalled what should be checked? (62.1) (6. ‘© Afterreinstalling the related piping should be checked to ensure that itis not imposing loads that ‘would cause problems with the pressure relief valve's body such as distortion leading to in-service leakage. 49. A complete operating history of each pressure relief valve should be maintained and should include what? Information on upsets and their effects on the valve, ‘+The extent of any leakage that has occurred in operation. ‘+ Any other evidence of malfunctioning, 50. When a relief device is removed from a system that is in operation, aame a necessary step to prevent an unexpected pressure release. (624) * The space between the relief valve and the adjacent block valve should be vented to release all pressure. S1. What must be done to valves in hydrofluoric acid service as soon as they are removed? (625 «They must be correctly neutralized immediately after removal ‘52, Since inspection of RV piping cannot be done when removing the valve while the system is in service what alternative inspection can be done to check for line any major blockage or fouling? (62.6) + Radiographic Inspection, 53. What can visual inspection of the piping after the removal ofa PRD indicate? (62.6) + The condition of the process piping whose interior is not visible. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC26 54, Why should caution be used with the rigging to remove. large PRD for maintenance? (62.7) + Prevent auxiliary piping and pilot assemblies from being damaged. 55. Prior to performing the as received pop test on a PRD what should be inspected and checked? * Check thatthe seals are intact on the pressure set screw and the blow down ring screw cover. ‘When may the as received pop pressure test be waived by the owner/user? ‘© When the valve is extremely fouled and the test may damage the valve. 57. When unusual corrosion, deposits, or conditions are noted upon receipt of a PRD at the shop what should be done? (6.2.9) ‘©The inspector should participate in the shop inspection of the PRD. 58. When is it not necessary to disassemble at PRD at the shop? (6.2.10) ‘+ Hfthe valve has been tested at the appropriate API 510 interval and the as received pop test shows the valve to be operating properly disassembly is not mandatory. at least four of the steps in the inspection of a relief valve upon disassembly. Measure each part's dimensions, ‘Check components for wear or corrosion. ‘Seating surfaces should be checked for roughness or damage. Springs should be checked for cracking. 60. During re-assembly of a pressure relief valve what should never be done? (6.2.12) +The nozzle and seating surfaces should never be oiled. 61, Afterre-assembly of a relief device how should any blow down rings be set? (62.13) + Inaccordance with the manufacturer's recommendations. 62, Why do some manufactures recommend at least three pop tests before releasing a relief device for installation? (6.2.14) ‘© Itis believed that the first pop test helps to align all of the components and that the successive tests verify the actual set pressure. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO TTAC27 63. Once the valve is set to pop at its CDTP (cold differential test pressure) it should be checked for aa) (6.2.15) © Leakage and seat tightness by increasing the pressure on the test block to 90% of the CDIP. 64, When applying the hydrautic test method to ASME Section VII pressure relief valves while on equipment, what precautions should be taken? (62.17) ‘The potential for failure of the rupture disk in dish/relief valve combinations. Possible introduction of foreign material into the valve seat are from popping. ‘+ Possible release of process material to the atmosphere. 65. May a pilot operated pressure relief valve be tested in place if no block valve exists beneath it? (62.19) ‘© No, it may be inspected and repaired only while the vessel is out of service. 66. Where is « weight loaded pressure and/or a vacuum vent used? (6.2.20) + Onpressure storage tanks. 67. What type of failure are pressure and/or vacuum vent valves prone to? (6.2.20) © Sticking. 68, Is it permissible to reinstall a rupture disk once it has been unbolted and removed from its holder? (62.21) ‘+ No, it may not be possible to geta tight seal and unreliable performance is probable. 69. What are the objectives of a visual on-stream inspection of relief devices? (63) * Make sure the comect device is installed, that the correct pressure can be determined, that there are not any blinds or gags installed, that the seals are intact and that the valve is not leaking. Also boellows if'so equipped are connected and clear and vent piping is routed to a safe location. Any upstream or downstream block valves are sealed or cheined ia the proper position. That discharge piping is supported, valve body drains and vent stacks are open, any required lifting lever is present and properly positioned. Any heat tracing or insulation required is in good condition and ‘operational and if. rupture disk is installed itis properly oriented. 70. API $10 establishes the maximum interval between device inspections or tests of 10 years, what clse should be considered when setting the fequency of inspection and testing? (64) + The performance of the device in a particular service, 08/02 Rev 8 FASE TRACK TECHNICAL - LICENSED TO ITAC28 71. How is the frequency of shop inspection or overhaul normally determined? (6.4.1.1) ‘+ By the operating experience in the valve's present service, corrosion service would be more frequent for example, Section 7- Records and Reports 72. What is the principal objective in keeping records on pressure-relieving devices? aay © Tomnke available the information needed to ensure the performance of the devices meets the requirements of their various installations. 73, What should the record for a pressure-reliving device include? (7.2) Its specification data and a continuously accumulating record of its tests and inspections results, 74. Which of the following per API 576 might be expected to initiate 2 work request on a PRD? The APT inspector or the Process Unit Operator? (73) ‘= Process Unit Operator 08/02 Rev 6 FAST TRACK TECHNICAL - LICENSED TO TTAC29 API RECOMMENDED PRACTICE 572 SECOND EDITION, FEBRUARY 2001 REVIEW QUESTIONS Section 1 - General 1, What are the main points covered in API RP 572? aay Descriptions of the various types of pressure vessels. Standards for construction, Reasons for inspection. Causes of deterioration. Frequency & methods of inspection. Methods of repair. Preparation of records end reports. Sections 3, 4, 5 and 6 contain duplicate information to that found in the API 510. You should still read these sections however, at least once. Section 7 -Reasons for Inspection 2. What are the basic reasons for inspection? cy © To determine the physical condition of the vessel. © Determine the type, rate and causes of deterioration. 3,___List at least four additional reasons for inspections. 17) + Safety maintained + Periods of operation without shutdown extended - well planned maintenance program + Rate of deterioration often reduced Future repair and replacement requirements estimated Section 8 - Causes of Deterioration 4, List the 4 general forms of deterioration. © Blectrochemical © Chemical © Mechanical © Combination of all three 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC@1) ey 10, (8.2.2) 30 List the 4 general classifications of things that cause deteriorstion upon coming into contact with a vessel surface. ‘Organic & inorgenic compounds Contaminated or fresh water Steam Atmosphere ‘Name 6 factors, which accelerate the rate of deterioration. ‘Temperature Stress Fatigue Impingement High velocity Inregularity of flow ‘What is the prime cause of deterioration in a pressure vessel? Corrosion What are the most common intemal corrodents in refineries? Sulfur Salt/Chloride compounds Define erosion. ‘The removal of surface material caused by numerous individual impacts of solid or liquid particles, or cavitation. Erosion is typically found where in a vessel? ‘Downstream of control valves Downstream of orifices ‘Downstream of pump discharges Atany point of flow direction change, such as impingement baffles. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC31 11, Problems with environmental cracking have been experienced of high hardness, areas of high stress or both. Examples of this include + Chloride stess corrosion cracking of austenitic stainless steels due to moisture under insulation. * Polythionic acid stress corrosion cracking (PSCC) © Caustic stress corrosion also know as caustic embrittlement ‘+ Amine stress corrosion cracking in non-stress relieved vessels. © Carbonate stress corrosion cracking in alkaline systems. © Wet hydrogen sulfide stress cracking, hydrogen induced cracking, and hydrogen blistering. 12, Corrosion beneath refractory linings can cause what? + Bulging of the refractory 13, What does fatigue cracking in a vessel result from? © Excessive cyclic stresses the are often below the yield strength of the material such as; © Pressure stresses © Mechanical stresses © Thermal stresses 14, Creep damage may be difficult to detect until ‘© Significant damage hes occured 15, What factor increases susceptibility to high temperature hydrogen attack in a vessel's material? (8.2.7) Ineressing carbon content of the materials 16, In the absence of ., sulfide corrosion rates of arc relatively low at metal temperatures below. (8.2.8) Water 430°F 17. When buried vessels are equipped with adequate cathodic protection when will excavation be required for inspection? (8.29) «When evidence of coating or wrapping damage is revealed 18, What are the most important microorganisms that directly influences the rate of metallic corrosion? (8.2.10) ‘© Sulfate reducing becteria found in may soils 08/02 Rev € FAST TRACK TECHNICAL ~ LICENSED TO ITAC19. (83.7) 20. (8.5) a. (85.1) 2. (852) (8.5.3) 24, (85.4) 25. (85.5) 32 ‘What causes titanium alloys to lose ductility? Absorption of hydrogen Many of the problems that may develop in pressure vessels are traceable to what? Faulty material or fabrication Poor welding, improper heat treatment, fabrication with dimensions outside tolerances allowed by ASME Code, improper installation of internal equipment, and assembly of flanged or threaded Joints are cxamples of what problem? Faulty fabrication List several consequences of improper welding techniques, Incomplete penetration Lack of fusion Cracking Undercutting Slag inclusion Porous welds High residual stresses near welds affecting the physical properties and corrosion resistance of the metal is caused by what? Improper heat treatment ‘Dimensional intolerance can lead to what? Stress concentrations and subsequent failures ‘What are the consequences of improper installation of interns] equipment? Inefficient operation Blockage of passages Displacement of intemal equipment with pressure surges 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC33 26, Improper fitting or tightening of flanges or threaded joints may lead to what? 85.6) + Lesks and possible failure Section 9 — Frequency and Time of Inspection 27. What are the important factors when determining the frequency with which a pressure vessel should be inspected? © Therate of deterioration © The remaining corrosion allowance 28. What event can provide and opportunity for an inspection? (62) © Amunscheduled shutdown 29. What occasional check may locate the cause of functional deterioration? 02) * Acheck of a vessel's operating record 30. What are the most important issues when scheduling a unit for inspections? 9.3) «Safety and reliability Section 10 Inspection Methods and Limitations 31, Before starting inspection of a pressure vessel, what are some basic things the inspector should do? ao.) ‘+ Determine pressure and temperature conditions under which the vessel has operated since last inspection © Ascertain the character of the vessel contents and the function the vessel serves in the process 32, Name at least 8 types of tools required by an inspector to inspect a pressure vessel. (10.22) Portable lights ‘Thin bladed knife Broad chisel or scraper Mirrors Calipers Steel tape measure(50 feet) Hammer ‘Notebooks and pencils 33, Where should the external inspection start? 003.2) ‘+ External inspection should start with ladders, stairways, platforms, or walkways connected to or ‘bearing on the vessel. The condition of most parts can be determined by hammering. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC34 34. What are most foundations constructed of? (10.3.3) ‘+ Foundations for vessels are almost always constructed of steel-reinforced concrete structural steel fireproofed with concrete, 35, Cracks in concrete or fireproofing may be caused by what? (10.3.3) + Excessive heat ‘+ Mechanical shock + Corrosion of reinforcing steel + Freezing of entrapped moisture 36. What types of vessels are most likely to experience uneven settling of their foundations? (10.3.3) + Vessels supported on long concrete slabs or on two or more separate foundations. 37. What is the proper way to check an anchor bolt on a piece of equipment for deterioration below the base plate? (10.3.4) + Asideways blow with a hammer 38. Often corrosion of structural elements can be virtually eliminated by a simple procedure, which is? (10.3.6) + Proper painting 39. A bulge in fireproofing is noted om stee! structural member, what does that indicate? (10.3.6) ‘© Corrosion beneath the fireproofing is present. 40. ‘The inside surface of a skirt is may be subject to corrosion, below what temperature is this ikely? (10.3.6) + 100°F 41, What should you inspect guy wires for? (10.3.7) ‘+ Tightness and correct tension - a visual inspection should be sufficient, 42. ‘What type of corrosion are turnbuckles subject to? (103.7) © Crevice corrosion 08/02 Rey 8 FAST TRACK TECHNICAL - LICENSED TO ITAC35 43, If settling of a vessel has occurred, what should be checked for distortion and cracks? 03.8 © Nozzles. 44, Whatis the recommended resistance for grounding connections? (00.3.9) © Solis orless, not to exceed 25 ohms 45. Unchecked vibrations on auxiliary equipment such as gauge connectors can cause what type of (0.3.1 on + Fatigue failure 46, What type of inspection is usually sufficient for protective coatings and insulation? (103.11) + Visual 47. At what operating temperature does CUI become a concer on externally insulated vessels subject to moisture ingress? (10.3.1) * Between 25 t0.250°F 48, What are the normally required measurements on external metal surfaces of a vessel? (103.12) ‘© Under normal conditions, at least onc measurement in cach shell ring and one on each head. If'n0 history exists for a vessel, then get a reading in each quadrant of each shell ring. 49. What types of corrosion are found on external surfaces of vessel? (103.13) + Atmospheric Caustic Embrittlement © Hydrogen blistering * Soil corrosion 50. Vessels containing acidic corrodents are subject to hydrogen blistering. Where is this normally found in the vessel? (103.13) ‘+ Those areas below the liquid level in vessels containing acidic corredents are more likely than other areas to be subject to hydrogen blistering. Blisters are normally on the inside, but can occur on the outside surface as well, 51, What should a vessel be checked for if a caustic is stored in it? (103.13) © [fa caustic materia! is stored or used in a vessel, the vessel should be checked for caustic embrittlement. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC36 52, Evidence of white salts seeping through cracks will indicate what type of material? (103.13) © Caustic material 53. Unless readily visible, leaks are best found by what means? (103.13) © Pressure or Vacuum testing 54, Describe how you would determine the extent of bulging or buckling on a vessel in service. (03.13) ‘+ By measuring the changes in circumferences or by making profiles of the vessel wall. Profiles are made by taking measurements from a line parallel to the vessel wall. A surveyor’s transit or a 180 degree optical plummet may also be used. 55, The degree of surface preparation needed for internal inspection will vary with several factors. Foremost among these are: (10.4.2) + Type of deterioration expected + Location of any deterioration 56. Cracks in vessels are most likely to occur where? (0.4.3) + Inplaces where there are sharp changes in shape or size or near welded seams, especially if a high stress is applied. 57, What may preliminary inspections reveal? 10.43) ‘+ Unsafe conditions, such as those due to loose internals that may fal! or due to badly corroded or broken internal ladders or platforms. 58, A detailed inspection should start at one end of the vessel and work toward the other end and inclide what? (10.4.4) «A systematic procedure to avoid overlooking obscure but important items. 59. What should all parts of a vessel be inspected for? 10.4.4) + Conesion + Erosion «Hydrogen blistering + Cracking + Laminations 60. Some times the depth of a pit can be estimated by using whal simple method? (1044) + Extending the lead of a mechanical pencil 08/02 Rev € FAST TRACK TECHNICAL - LICENSED TO Z'TAC37 61. What types of methods are used for determining the extent of cracks? 04.4) Dye penetrant © Magnetic-particle (wet or dry) + Ultrasonic shear-wave 62. Explain the difference in appearance between erosion and corrosion. 00.44) ‘+ Erosion is characterized by a smooth, bright appearance: marked by the absence of the erosion product; and metal loss, is usually confined to 2 clearly marked local area * Corroded areas are not often smooth or bright. 63, Shells and heads of vessels should be inspected for deformation. Which is more likely to suffer deformation? (8.4.4) © The shell of a vessel 64, How do you check for (a) small distortions, (b) bulging or buckling (c) out-of-roundness or bulging? (10.4.4) Small distortions - by placing a straight edge against a vessel. Bulging/buckling - measuring the changes in circumference ar by profile (measuring from a tine strung parallel to the vessel). © Outof round/bulge - by measuring the minimum and maxinnum internal deviation at the cross sectional area and comparing the two. (65. What is the best method of locating suspected deformations? (10.4.4) Direct s flashlight beam parallel to the surface to check for shadows in depressions and on the non-light sides of internal bulges. 66, What is the most sensitive method of locating surface cracking? (10.4.4) ‘© Fluorescent Magnetic Particle Method. 67. Whatis the difference between cracks and laminations? (10.44) © Laminations run at e slant to the plate surface, + Cracks run at right angles to the surface. 68, Name three important factors in the inspection of metallic linings (19.43) ‘+ That there is no corrosion. ‘+ That the linings are properly installed. ‘+ Thatno holes or cracks exist. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED 10 ITAC38 69. Explain how the Corrosive Tab Method is used to determine the metal loss on vessel linings. (10.4.5) ‘+ Small 1 by 2 inch tabs of lining that form a right angle are welded onto the lining with one leg extended into the vessel. During inspections the thickness of the protruding leg is measured, and, since both sides of the leg are exposed to corrosive action, the loss in thickness would be twice that of the lining, 70, What is the principle method used to inspect nonmetallic Linings like glass, plastic, rubber, ‘concrete, and carbon block or brick. (10.4.6) ‘+ For the most part all of the above will be visually inspected for discontinuities or physical damage. Specific: For paint, glass plastic, & rubber lining the spark tester method is used to locate holidays. For concrete, brick, tile, or refractory lining the hammer testing method is used to locate lack of bond. 71, Name the factors to consider when selecting tools for thickness measurements. (0.5) Accessibility from both sides. Desire for NDE methods. Accuracy desired. Time available. Economy 72. What is the primary means of obtaining thickness measurements? (10.5) ‘* Ultrasonic instruments. 73. To analyze defects in welded seams that are not visible on the surface of the metal, what two methods are used? (0.6) © Radiography. «© Shear-wave Ultrasonic 74, How does the Hammer Test function in supplementing visual examination of a vessel for the inspector? 00.8.1) "Thin" - Locate thin sections in vessel walls, heads, and attachments. © "Tightness"= Check for tightness of rivets, bolts, brackets. + "Cracks and Lack of Bond” - Check for cracks in metalic linings and lack of bond in concrete linings. + "Scale" - Remove scale accurmulations for spot inspections. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC39 75, When is use of the Hammer Test not recommended? (10.8.1) + When vessels are under pressure, © Onpiping upstream from a catalyst bed. 76. What is pressure testing? (10.8.2) ‘© Filling a vessel with liquid or gas and building up an internal pressure to a desired level. 77. Which isthe preferred method, pressure or vacuum testing, and why? (10.8.2) © Pressure testing. Leaks from an intemal pressure source are more easily located. With vacuum testing you will know if there are leaks, but the location is not evident, 78. What should an inspector examine before applying test pressure to the shell side of an exchanger? (10.8.3) # He should inspect the tube walls to be sure there is sufficient wall thickness to withstand external pressure, 79. Inan exchanger where the cooling water is the lower pressure stream and a hydrocarbon is the higher pressure stream, what is a possible way to detect a leak? (10.8.3) « Itmaybbe possible to assess the hydrocarbon content upstream and downstream of the suspect exchanger. 80, Name the two most limits of corrasion or other deterioration that must be kmown by inspection. (20.9) The retiring thickness of the part considered. The rate of deterioration. 81. Often vessels have excess thickness above that required for pressure. When taking credit for this excess thickness what must always be considered? (10.9) ‘+ Insome eases the excess thickness of the shell or head plates was used by the designer to ‘compensate for nozzle openings. 82, Before determining the limiting or retiring thicknesses of parts of any pressure vessel, what must ‘be known? (20.9) ‘+ Which Code and edition of that Code itis to be rated under. «Ase there specific regulations regarding limits and allowable repairs. 08/02 Rev 6 FAST TRACK TECHNICAL - LICENSED TO ITACSection 83. ay 34, an Section 85. 2.1) 86. (12.2) 40 11 - Methods of Repair ‘When is it required that a repair concern making welded repairs to a vessel have ¢ National Board Restamp? ‘When the jurisdiction dictates that the these repairs are to made by only R stamp holders ‘When is a pressure test of a vessel normally a requirement? ‘After an alteration 12- Records and Reports ‘A-complete record file should contain whet three types of information? Basie data ~ manufacturer's drawings, data reports and specifications, design information, results of any material tests, Field notes - notes and measurements recorded on site including record of condition of all parts inspected and repairs required. Continuous file - all information on the vessel's operating history, previous inspections, corrosion rate tables, records of repairs and replacements. ‘When making reports recommending repairs, who should receive these reports? All management groups. This would normally include engineering, operation, and maintenance departments. Reports should include the location, extent, and reasons for recommended repair. Appendix A - Exchangers 87. (9.1) 88. (A92) 89, {A.10) ‘Why should bundles be checked when they are first pulled from the shells? ‘The color, type, amount, and location of scales and deposits often help to pinpoint corrosion problems. A distinctive Prussian blue on bundle tubes indicates the presence of what? Ferriferrocyanide Coils in open condenser boxes and double-pipe exchanger shells should be inspected according to what API Recommended Practice? RPST4 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC41 CHAPTER TL CONDITIONS CAUSING DETERIORATION OR FAILURES SECOND EDITION, 1973 201 General 1. What are the modes of failure that can be found in refinery equipment? 201.2) ‘© Fatigue Failures - caused by stress reversals. (In machinery these cracks start atthe surface and ‘progress with each stress reversal.) ‘© Distortion Failure - occurs when equipment is subjected to temperatures above design temperature. (Athigh temperatures the metal becomes weaker and distortion occurs Which mey result in failure.) ‘+ Brittle Fracture - carbon steels are susceptible to brite fracture at ambient temperatures and ‘below. (A number of tank failures have been attributed to the britle condition of steel at low tomperatures, combined with high loads that have been imposed by thermal stress set up rapid ‘temperature changes.) © Excessive Metal Loss - may result in failure if remaining wall thickness gets below safety valve settings. This is a rare occurrence. + Wrong Material or Wrong Gaskets - may lead to feilure, 202 - Corrosion 2. Corrosion problems in refining operations can be divided into three major groups. What are these groups? 202.1) ‘* Corrosion from components present in crude oil. ‘© Corrosion from chemical used in refinery processes, ‘+ Environmental corrosion. 3, Name the corrosion compounds found in crude oil, 202.01) ‘Hydrogen Chloride and organic/inorganic chloride. Hydrogen sulfide, mercaptans, & organic sulfur compounds, Carbon dioxide. Dissolved oxygen and water. Organic acids. Nitrogen compounds. 4, What is hydrogen chloride? When does it become a corrosion problem in process streams? (202.022) +A dry hydrochloric acid (aormally not corrosive in process streams). It becomes corosive when ‘water is available to form hydrochloric acid. 5. What do all crade oils contain? (202.022) © Salt 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED 70 TTAC42 6. What is the most active of the sulfur compounds in causing corrosion in refinery equipment? (202.023) © Hydrogen Sulfide 7. At what temperature range does accelerated hydrogen sulfide corrosion occur in refinery equipment? (202.023) © Between 450 and 900°F 8. What makes carbon dioxide corrosive? (202,024) © When it is combined with water, it becomes carbonic acid. 9, Where is corrosion by carbon dioxide found to be most severe? (202.024) © Inbydrogen plants. 10, Dissolved oxygen and water is a corrosion problem in what equipment? (202.025) © Storage tanks 11, When are organic acids very corrosive? (202.026) ‘+ At their boiling temperatures, The most severe form of corrosion occurs upon condensation. 12, What two forms of corrodents are formed when nitrogen is cracked ina cracking or catalytic cracking unit? (202.027)] + Ammonia & Cyanide 13, What is phenol and what is it used for? (202.033) ‘© Catbolic acid - Used im refinery operations in the manufacture of lubricating oils and aromatics. 14, What is caustic and what is it used for in refinery operations? (202.035) ‘+ Sodium Hydroxide - Used for the neutralization of acid components and for grease manufacture. 15, When ammonia is permitted to contact copper base alloys in pH ranges of 8.0 and above, severe corrosion in three form of general metal loss and stress corrosion cracking will occur. How may this attack ‘be identified? (202.037) ‘+ By the appearance ofa blue salt deposit on the metal’s surface. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED 70 ITAC43 16, What is the primary use of aramonia in the refining industry? (202.037) + Asa refrigerant. + For neutralization of acidic components in overhead streams, from pipe stills, and catalytic cracking units, 17, What materials is ammonia harmful to? (202.037) ‘+ Copper base alloys. 18. What is chlorine used for in refinery operations and when does it become very corrosive? (202.038) ‘© Used for treating cooling water and for the manufacture of sodium hypochlorite for treating oils. It becomes very corrosive in contact with small amounts of moisture 19, Aluminum Chloride - What is it used for? What does it form in the presence of water? How does it affect carbon steel and stainless steels? (202.039) © Used as 2 catalyst in isomerization units. It forms hydrochloric acid in the presence of water. ‘Hydrochloric acid causes severe pitting corrosion in carbon steel and intergranular and stress corrosion cracking in stainless. 20, What is the term applied to atmospheric corrosion? (202.041) + Galvanic. 21. What is needed to prevent atmospheric corrosion? (202.041) ‘© Eliminate water from the surface of the metal by means of a protective barrier or coating. 22. At what temperature does hidden corrosion take place under insulation and fireproofing if moisture penetrates through cracks in the insulation? (202.042) + Invessels and piping operating below approximately 250 °F. 23, When does oxygen become destructive? (202.052) + Athigh temperatures oxygen reacts with steel to cause scaling (iron oxide). 24, Why may steam at high temperatures cause scaling? (202,053) + Because the steam may be decomposed to hydrogen and oxygen, and the fiee oxygen may cause severe scaling. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC