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API - 510 COURSE NOTESm

VOLUME - 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. API 510.

6. Case Studies ASME See. IX.

7. Reference Documents.

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

• Points to recall Day-1
Design of Dished heads. (Contd.)
Design of Flat unstayed heads
• Depths of dished heads

Session 2

External pressure calculations
Case Studies
Impact testing requirements

Session 3

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

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

I DAY-3.
l
Session 1

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

Session 2

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

Session 3

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

~------------------------------------------,
I DAY 4. I

Session 1

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

Session 2

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

Session 3

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

.•.-------------------. --------.-.•.--_.. --------------------- Session 1 • Points to recall Day-3 • API-510 contd . I Session 1 Points to recall Day-3 API-510 contd ... [DAYS..._-------~---_. _-_ _-.••..-_ . ---------..-. -_ -_ -_ -_ ..Defect repairs Pressure tests Documentation and Records Session 2 • Welding requirements Pre-heating and PWHT Weld overlay and cladding NOT for repairs and alterations Session 3 Alterations and re-rating Re-rating documentation and stamping Review of Mid-session Exam-Open book._ .. ...Defect inspection • Inspection of parts • Minimum thickness Evaluation • Pitting corrosion • Localised corossion Session 2 • API-510 Inspection practices • Corrosion rate determination • MAWP determination for Vessels in service Numerical Examples Session 3 • API-510 contd ..------. External inspection Internal and on-stream inspection Inspection interval • Remaining service life Illustrative calculations Review of Practice Exam-4 r DA-Y_ -_6-. . Closed book._----.

IX • Procedure Qualifications • PQR tests. Session 1 • Points to recall Day-6 • Introduction to ASME SEC. NEVs. ASME Sec.I DAY 7. Session 1 Points to recall Day-7 Article 2: Radiographic Examination Radiograpic procedure Selection of penetrameter • Radiographic technique Interpretation & documentation Session 2 • Article 6: Liquid Penetrant Examination • LPE procedure • Selection of penetrants LPE technique • Interpretation & documentation Article 7: Magnetic particle Examination Session 3 SE-797 UT measurememt Pulse-Echo contact method Single and dual crystal techniques Review of NDE Requirements ASME See VIII & API 510 Review of Practice Exam-7 .v Nondestructive Examination • Article 1: General Requirements • Review of Practice Exam-6 I t DAY 8. WPS/PQR documentation • WPQ tests & their validity Session 3 • Detailed road-map for review of WPS/PQR documentation Case Studies for WPS/PQR review. Limits of PQR Qualificatios I validity. SEVs.and evaluation of results Session 2 Welding variables-EVs.

.I DAY 9. • 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. procedures for PRDs.---. • Testing of PRDs on test bench. Session 1 • Points to recall Day-8 • Introduction to IRE Chap. ---------.--------- Session 1 • Points to recall Day-9 • API RP-576 Inspection of Pressure relieving Devices Types of PRDs • Causes for malfunctioning • Inspection intervals &insp. 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 -.

a minimum of one question from each category listed within tl1is Body of Knowledge will be included on the API certification exan1ination. A. and supplements ofilie reference publications tl1at are effective for your ex. 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. 05105 .C. Damage Mechanisms Affecting Equipment in Refilling Industry API RP 572. Inspection of Pressure Vessels API RP 576. Division I. D. Only inspection information covered in one of the references outlined in this body of knowledge will be utilized for the examination questions..ao 1220 L Street. Northwest Washington. repair. and altcration of pressure vessels. REFERENCE PUBLICATIONS: API publications and ASME codebooks must be brought to the examination site to be used as reference materials for the open-book part of the examination. ASME Publications: Section V. inspection.:". Inspection of Pressure-Relieving Devices API RP 577. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such knowledge.nspector should bc knowledgeable. Rules for Constructing Pressure Vessels Section lX.am date. The closed book part tests the candidate on knowledge and tasks requiring everyday working knowledge of API Standard 510 and the applicable reference documents. Welding Inspection and Metallurgy B. Welding and Brazing Qualifications Note: Refer to the Publications Effectivity Sheet in the application package for a list of specific editions. Pressure Vessel Inspection Code API RP 571. The following is a list of specific topics in which the API Authorized Pressure Vessell. To determine whether the applicants have this broad base of inspection knowledge. but would not nonnally be COllunitted to memory. API Publications: API 510. addenda. 20005-4070 reln-dcum 202-682-8161 Institute 202-682-8348 (Fax) ~ICP BODY OF KNOWLEDGE API-SIO PRESSURE VESSEL INSPECTOR CERTIFICATION EXAMINATION May 2005 (Replaces June 2004) API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance. Nondestructive Examination Section VIII. The examination consists of two parts. " ~ .

d. Code calculation questions will be oriented toward existing pressure vessels. Remaining Corrosion Allowance (API-51O. CORROSION RATES AND INSPECTION INTERVALS The Inspector should be able to take inspection data and deternline the internal and external inspection intervals. RT-2. d) Calculate total pressure (MA WP + static head) on any vessel part. 2. etc. c. The Inspector must be able to calculate: a. Para 5. Joint efficiency for seamless heads and vesscls Sections per UW -12 (d). or none) performed basis the nameplate markings (RT-I. THICKNESS MEASUREMENTS. Joint efficiency for weldcd pipe and tubing per UW. JOINT EFFICIENCIES The inspector must be able to detennine the joint efficiency "E" of a vessel weld. 6. I. not new pressure vessels. Para 6. Inspector should be able to detennine: a. e) Calculate maximum vessel MA WP given vessel parts MA WP and elevations Static head calculations may also be required during the internal pressure calculations if static head data is given in the examination problem. rerates.).4) e. The inspector should be able to: a) List the static head/pressure conversion factor (0. INSPECTION INTERVALS AND VESSEL INTEGRITY A. All static head wiIl be based upon a Specific Gravity of 1. repairs.433 psilft). The following categories describe the minimum necessary knowledge and skills: I.4) The fonnulas for perfonning the above calculations and rules for setting the inspection intervals may be "closed-book" during the exam. API Authorized Pressure Vessellnspcctors should be able to check and perfonn calculations relative to in-service deterioration.0. d) b. Weld Joint Categories from UW-3. Para 6. b) Know the difference between vessel MA WP and vessel part MAWP (UG-98). or alterations.4) c. Type of radiography (full. Metal Loss (including corrosion averaging) (API-51O. c) Calculate static head pressure on any vessel part. Para.4) d. Inspection Interval (API-SIO. Joint efficiency by reading Table UW-12. Remaining Service Life (API-510. STATIC HEAD The inspector must be able to compensate for the pressure resulting from static head. spot. Corrosion Rates (API-SIG.12 (e). Para. Only internal and external pressure loadings will be considered for the API 510 examination. and e. 6. 05/05 2 . b. 3.7. Detenllining joint efficiency may be part of the internal pressure problem since joint efficiency "E" is used in the formulas for deternlining required thickness or Vessel Part MA WP.

Note: Factors from the external pressure charts will be given in the wording of the question. (UG-32 (d).n a pre-. The inspector should also be able to compensate for thc corro_i0n d1l0wanee: add or subtract based on requirements of tbe exam problem. The Appendix I fonnula for cylinders. (f) and (g). c) Be familiar with all steps in a hydrotest Procedure (UG 99 and UG 100) d) Be fanliliar with all steps in a pneumatic test procedure (UG 100 and UG 102) 7. can be used. and b) Calculate whether a cylindrical shell or tube meets Code design for external pressure given a wall thickness and a pressure (UG 28 (c )( I). PRESSURE TESTING The inspector should be able to: a) Calculate a test pressure compensating for temperature. given a metal thickness (UG-27(c)(I)). Use of the actual charts is not required. using conversion factor (0. IMPACT TESTING The inspector should be able to: a) Determine the minimum metal temperature of a material which is exempt from irnpacttesting (UG-20 (f). (e). and b) Detennine the required size of welds at openings (UW -16). c) The rcquircd thickncss ofa head (ellipsoidal. such as minimum test temperatures.d) ~i"en a -neta\ thickness.tr<:ss gi. (UG-32 (d). (UG-99 & UG-IOO) b) Be familiar with the precautions associated with hydrostatic and pneumatic testing.Ti<a: I mect.'<:n a pr<:ssure (UG-27(c)(l »)i b) The vessel part MA WP for a cylindrieal shell ba. 6. The Appendix I fonnulas for non-standard heads will not be required. The inspector should be able to detennine: a) The rcquired thickness of a cylindrical shell based (In circllnlferel\ti.) 8.707)..surc. (e).:umtcr. UCS-66. 5.:nllal strcs. (f) and (g). which IS bascd on outside diamcter. (f) and (g)) d) The vessel part MAWP for a head (ellipsoidal. ( ode rcquiremcnts given both prcssure and metal thickness (UG 32(d). The inspector should be able to: a) Convert a fillet weld throat dimension to leg dimension or visa versa.d . and hCOlisphcrh. and hCOlisphcn-:.al) ~i\(.cd on cir. EXTERNAL PRESSURE The inspector should be able to: a) Calculate the maximum allowable external pressure (specific MaterialfTemperature Charts supplied with the examination) (UG-28(c)(l). protection against overpressure etc. WELD SIZE FOR ATTACHMENT WELDS AT OPENINGS The inspector must be able to determine if weld sizes meet Code requirements. UCS-68(c). 05/05 3 . e) Whether a head (ellipsoidal. torispherical or hcmlsph. (e).

22. API-5 10. UNF. Code Cases and interpretations. Thc inspector should: a) Undcrstand thc kcy conccpts of reinforcement. The following are typical ASME code engineering requirements that API certification candidates will NOT be expected to know for purposes of the certification examination... 4. and 23. Nozzle calculations for external loads. and other secondary stress loadings. Lifting lug and other structural type calculations. and non-metallic vessels and assemblies. Credit can be takcn for cxtra metal in shell and nozzle b) Be able to calculate the required areas for reinforcement or check to ensure that a designed pad 1S large enough. gas tungsten arc welding (OT A W). 7. To simplify the problem: All fr = 1. \V elding process requirements other than shielded metal arc welding (SMA W). Supplementary design formulas and calculations for non-cylindrical shell components. except as they apply to alterations and repairs. ULW. jacketed. 19. embossed. e) Weld strength calculations are excluded. Required thickness calculations for wind. I. Flange calculations. ASME Sections UF. UCL. UHT (except UHT-6). Relief valve sizing. earthquake.. 6. UHA.0 All F = \. Most external pressure calculations. 15. Brazing requirements. 17. Tubesheet calculations (stayed or unstayed) and tube to tubesheetjoints and loads. 2. Required inspections for new construction. Cryogenic vessels (below -50 f). 3. 5. and ULT. 16. 05/05 4 . Stayed flat heads and sizing of stays. 20. Proof testing requirements. Rules for natural resource vessels. 14.0 All E = 1. 2 \ . 18. DB. UCD. 8. 13. Ligament calculations. 9. gas metal arc welding (OMA W). UCI. eddy current. 12. or submerged arc welding (SAW). such as replacement of strength removed and limits of rcinforccmcnt. Zick analysis. Dimpled. Section 8. Integrally forged pressure components. B. NDE requirements for acoustic emission. and motion radiography. 10.0 All required thicknesses are given c) There will be no nozzle projecting inside the shell d) Be able to compensate for corrosion allowances. II. Requirements for pressure vessels for human occupancy.

GT A W. • Special weld processes such as corrosion-resistant weld metal overlay. and name of testing lab. 1. BOILER AND PRESSURE VESSEL CODE. Welding Procedure Specification (WPS). Div. The following limitations or conditions will apply: • Base metals limited to PI. 2.lrca . al\: .. The wcld procedure review may include: SMA W... are excluded. ASME Scction VIII. The inspector should be able to determine: a) Whether numbcr and type of mechanical test listed on PQR arc appropriate b) Whether the results of the tests are acceptable c) Whether all required essential and non-essential variables have been properly addressed. c) Thc PQR will be the supporting PQR for thc WPS. The inspector shall be familiar with all the requirements of and infonnation in API RP 577. the candidate is to be tested on. GTAW. (Supplemental essential variables will not bc a part of the WPS). P3. Section VIII. • Dissimilar base metal joints. and P8. WELD PROCEDURE REVIEW I. Howcver. This includes items such as the revision level of the WPS. Proccdure Qualification Record (PQR). and dissimilar thicknesses of base metals are excluded. I The inspector should be familiar with and understand the general rules for welding in ASME Section VIII. II.mJ the wrs 10 bc rcviewcd will bc supported by a single PQR. company name. API510 Thc inspector should be familiar with and understand any rules for welding in API-51O. GMA W. Parts UW and UCS such as: a) Typical joints and definitions b) Weld sizes c) Rcstrictions on joints d) Maximum allowable reinforcement c) Inspection requirements f) Heat treatmcnt 2. SECTION IX /\. P5. P3. and dissimilar metal are excluded • Welds with buttering of ferritic member are excluded. or ~A W. I. ASME Section VIII. hard-facing overlay. and P5. • Supplemental powdered filler metals and consumable inserts are excluded. for the purpose of the examination the lower transfonnation temperature will be o 13330F and the upper transformation tempcrature will be 1600 F.n . Div. the API 510 applicants shall know tbat the PQR must be certified by signing and dating. P4. The weld procedurc review may include: a. b) filler metals limited to one-pcr-proccss for SMAW. WPS numbcr and date.::ation record. B. ""ilh thl f(llhm ing Iimiwtions: a) No more than one process will be included on a single WPS or PI)R. The inspector should be able to detern1ine if procedure and qualtfi.••S\It. • For PI. OK SA \\ . 05/05 5 .::olllpliance with applicable ASME boiler and pressure vessel code and any additional requirem<:nt$ . . GMA \\'.tl . Div. C. Div. P4. "Editorial" and non-technical requirements for the welding subject matter. I and API-51O: GENERAL WELDING REOUIREMENTS: I. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASEl) 0" .. and b. Any rules for welding given in API-510 shall take precedence over those covering the same areas in ASME.f API 5 10 (\ 1'1·51 (I requirements will take preccdencc ovcr any ASME requirements covcring the same technic.. 3.

2. Definitions of "inspection" and examination". Article 2. Record keeping requirements. Records C. but not linlited to. and of subcontractors. 5.uring thickness by manual ultrasonic pulse-echo contact method: 05105 6 . Rules for use of Section Vas a referenced Code. The Scope of Article 6. Required marking b. number. 4. 1. I. The rules for radiography as typically applied on pressure vessels such as. except as noted A. Radiographic Examination: The inspector should be familiar with and understand. Calibration. Techniques (Yoke and Prod only) c. General Requirements: The inspector should be familiar with and understand. selection. Examination e. 6. 1Il. but not limited to. but not limited to: a. Interpretation 2. Type. Responsibilities of the Owner / User. Procedures b. The general rules for applying and using the liquid penetrant method such as.Standard practice for mea<. Magnetic Particle Examination (Yoke and Prod techniques only): The inspector should bc fanliliar with and understand the general rules for applying and using the magnetic particle method such as. 3. Location markers 3.NONDESTRUCTlVE EXAMINATION A~ME Section V. Article 6. 8. 2. Section SE-797 only . a) Procedures b) Contaminants c) Techniques d) Examination e) Interpretation f) Documentation and g) Rccord keeping D. Ultrasonic Standards. c. 2. and placement ofIQI's. 2. Article 7. Article I. The Scope of Article 7. Allowable density d. l'J9ndestluctive Examination NOTE: The examination will cover ONLY the main body of each referenced Article. including Mandatory Appendices II and III: The inspector should be familiar with and understand: I. Calibration d. The Scope of Article 2 and general requirements. 1. The Scope of Section V. Liquid Penetrant Examination. General requirements such as but not limited to requirements for: a. Article 23. Documentation and record keeping E. Control of backscatter radiation e.

U)dthe general rules for NDE in API-51 O. 5. 14. 4. 9. Types of Process Corrosion and Deterioration.:a. 15. Inspection Records and Reports.fDE (UG. API 510. 7. 10.ure!a'nl JS' ontallled in paragraph 7. I and API-510 Genna.GENERAL The following topics may be covered in the examination. [K)p(k-. 13. Div. IV.ASME Section VIII.u. Pressure Vessel Materials and Fabrication Problems. PRACTICAL KNOWLEDGE .ti\c e\amillJtion requirements: I. Corrosion and Minimum Thickness Evaluation. The inspector should be famiiiar \. 6. 6. and High Temperature Dcterioration. Section SE-797. 3. 8. Modes of Mechanical. UW.u1\1 unl~r-. PRACTICAL KNOWLEDGE .r><:ral ruk.. Maintenance Inspcction Safety Practices. Types and Definitions of Maintenance Inspections.SPECIFIC 1.d :hc F. Appendices 4. Repairs/Alterations to Pressure Vessels. 2) The general rules for applying and using th<:ll(lra~llir ll't. I) The Scope of Article 23. More infonnation relative to each of the categories is contained in section V. 11.'it~ . Thennal. Nondestructive Examination (NDE) Methods. 2. 12. Alterations. Relief Devices. Pressure Testing After Repairs. for \.t. 16. 1: The inspector should be familiar Withand u!xkrs:aI. Div. or Rerating 05/05 7 . Inspection Interval Determination and Issues Affecting Intervals. 8. AS ME Section VIII. Organization and Certification Requirements. The inspector should be familiar wnh and und<:rsland.:t:)od 3) The specific procedures for Ultrasonic thldness lTl<. Rerating Pressure Vessels. Estimated Remaining Life. Welding on Pressure Vessels. and 12) 2.t.

5. Section 4.SPECIFIC A PI-51 0.r ()rga:linllons (API-510.2) b) Internal or On-Stream Inspection Intervals (API 510.2 and Appcndix B).4) c) Intcrnal and On-stream inspection Intervals for Estimated Life (API 510. 5. Inspection Interval Determination and Issues Affecting Intervals a) Rjsk-based inspection (API 510.6 & 7.5l.4) b) Defcct Inspection (API-51O.6. 6.3 & 6.5. I.4) h) Change in Location and Ownership (API 510.510.5 & 5.rc \ ~s. Section 3..cllcles (AP -: 1('.7) c) Widely Scattered Pitting (API 510.5) h) Thickness Measurements (API-51O. Typcs and Dcfinitions of Maintcnance Inspcction a) Internal Inspection (API 5 10.2) f) Different Zones of a Vessel (API 510. Estimated Remaining Life and Corrosion rate (API 510. 5. 6. Relief Devices 05'05 8 . 6. 5. 6.-ss s[}Ccifically cxcluded. 6.4) g) Change of Service Conditions (API 510.6.3. PRACTICAL KNOWLEDGE . and may be required to make calculations using these principles. ror cxample: Scction 8 and Appcndix E arc excludcd.4) i) Nondestructive Examination (API-5 I 0.6) d) External Inspection & Buried Vessels (API 510. '\ection 3.\/--.1 I & 6.3) b) Corrosion Averaging (API 510.3) e) Dcterioration Other Than Metal Loss (API 510. 5.1-6. a) Corrosion Rate Determination (API 510.liremc'll~ a) Certification for API A ulh0roe(! Pce-.2) 4.4) 6. >n Rcq.4) 7.5.. 6. Section 6.7) d) Surfaccs Remote From a Weld (API.7. Pressure Vessclluspc'crio. 5. 5.r Code \fOTE: All of A PI 510 is applic able 10 Ih~ "XdDlm. Corrosion and Minimum Thickness Evaluation The inspector should havc a general knowledge of the following principles. b) Authorized Inspeni011 . 5.7) e) Corrosion in Central Portion of Dished Heads (API 510.6) 2. (API.6.3) e) Atmospheric Corrosion and Corrosion Undcr Insulation (API-5 10. Organization and ('ertiflcati. 6.4) g) Visual Examination (API-51O.4) d) External Inspection Intervals «API-51O.7) 5. V.ll"Jll unk.8) 3. 6.7) j) Assessment of Inspection Findings (5. Welding on Pressure Vessels a) Welding Inspection Requirements (API-51O.4) c) Vessel Repair Organlzati'Jn'. 5. 5.16) d) Relief Device Testing and Repa.3) 1) On-Stream Inspcction (API-51O. 6. 3.cl Insrectors (API-510.5.5) c) Inspcction of Parts (API-51O.

2.1.3.3) j) Pressure Testing After Repairs.5.4.2) c) Design Requirements (API 510.2.7.1) 9.3 .Cooling Water Corrosion 4.2.Temper Embrittlement 4.8) e) Welding Requirements (API 510.2.2.2. Section 6.6) c) Maximum Service Intervals (API-51O.Thermal Fatigue 4.. 7.3.2. 7.2.2. Maintenancc Inspcction Safety Practices a) Pressurc Vcssel Inspection (API-51O. 7.9 .1.9) i) Rerating of Pressure Vessels (API 510.2 .1.High Temperaturc Hydrogen Attack (HTHA) API RP-572.5) g) Repairs to Stainless Steel Weld Overlay and Cladding (API 510.3) • Post weld Heat Treating (API 510.6.2.Boiler Water Condensate Corrosion 4. 7.2.!! Industry ATTN: Test questions will be based on the following mechanisms only: Par.10) k) Nondestructive Examination of Welds (API 510.3) • Local Postweld Heat treatment (API 510.2. Inspcction Rccords and Reports a) Permanent and Progressive Inspection Records (API-510. including • Preheating (API 510. Section 5. 6.4) API RP 571.2.6) b) Minimum Requirements for Quality Control Systems (API 510.Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5.Mechanical Failure 4.5 and 7.Atmospheric Corrosion 4.5 . If/sf/eetio" of Pressure Vessels 05/05 9 .2 .Brittle Fracture 4. 7. 6.3. 7. 4.2.2. Damaf!e Mechanisms Affectinf! Fixed equipment in the Refini.3.4 .2.2.3 .Chloride Stress Corrosion Cracking (CrscC) 4.6.7 .1 .2. & 7.Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.5.7) 10.2.7) d) Materials Requirements (API 510.1) b) Approval (API 510.Corrosion Fatigue 4.3. 7.Erosion/Erosion-Corrosion 4. 7.5. 7. 6. Alterations or Rerating (API-51 0.3 .2 . 7.1. 7.3 .7. to Pressure Vessels a) Authorization (API 510.2.3.Corrosion Under Insulation (CUI) 4. a) Repair Organizations (API-51O.6) 8.1 . 7.Sulfidation 4. Repairs and Alterations. \.2. 7.6) h) Inspection (API 510.11) f) Heat Treating Requirements.16 .14 .

General Knowledge of Application and Limitations (API RP-576. Section 7) e) Causes of Detcnoration (API RP-572. Section 2) b) Causes of Improper Performance (API RP-576. Section 9) g) Internal Inspection (API RP-572. Ternlinology and symbols II.1. 10. Types and Definitions of Maintenance Inspections a) Types of Pressure Vessels (API RP-572. Sections 3 & 5) d) Inspection and Test Service Procedures (API RP-576. Weldine Inspection alld Metallurf!1J I. Welding procedure 5. 8. Welding Inspection 3. Actions to Address improperly made production welds 12. Inspection Records and Reports (API RP-572. lOA) 11) External Inspection. Welder qualifications 7.10) f) Frequency and Time of Inspection (API RP-572. Refinery and Petrochemical Plant Welding Issues 10. Non-destructive examination 8. Welding procedure review 13. Definitions 2. Inspection of Pressure-RelievinF! Devices: 1. Section 12) API RP 576. Section 6) f) Inspection Records and Reports (API RP-576. Section 10) j) Thickness Measurements and Limits (API RP-572.2) 2. Section 10) \) Repair Methods (API RP-572.5) 3. Section 5) c) Maintenance Inspection (API RP-572. Section 4) c) Reasons for Inspection and Frequency Detennination (API RP 576. 10. Pressure Vessel Materials and Fabrication Problems a) Material and Fabrication Problems (API RP-572. I. Section 10) k) Nondestructive Examination (API RP-572. Typical Items Checked (API RP-572. Welding Processes 4. Guide to common filler metal selection 14. Example report ofRT results OS/OS 10 . Section 6) d) Reasons for Inspection (API RP-572. Maintenance Inspection Safety Practices a) Pressure Vessel Inspection (API RP-572. Metallurgy 9. Section 4) b) Construction Standards (API RP-572. Section 11) 2. Sections 6 and 7) e) Maintenance Inspection Safety Practices (API RP 576. 8A & 8. Section 8) API RP 577. Welding Materials 6.3) i) Visual Examination (API-RP-572. Relief Devices a) Description of Types -.8.

14 .4. Photocopies of API and ASME publications are not pennitted. Appendices 1-4.2. Pressure Vessel Inspection Code: Maintenance Inspection.High Temperature Hydrogen Attack (HTHA) • AP I Recommended Practice 572. and Alteration.3 .3.2.Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.3. Nondestructive Examination. 6.3 . Global Engineering Product Code API CERT 577 • American Society of Mechanical Engineers (ASME). We/ding OIlZF Global Engineering Product Code for the ASME package API CERT 510 ASME. 1" Edition.5 . 2001 edition with 2002 and 2003 addenda. please identify yourself as an exam candidate and/or API membcr. Publications Effectivity Sheet API 510. Section lX. 2nd Edition.Atmospheric Corrosion 4. Global Engineering Product Code API CERT 572 • API Recommended Practice 576.3 .1. Rules for Construction of Pressure Vessels.3 and 4 (August 2003). Section V. 6.global. 2nd Edition. Inspection of Pressure Vessels. Boiler and Pressure Vessel Code. June 1997.Temper Embrittlement 4.Brittle fracture 4. Orders may also be faxed to 303-397-2740. 8th Edition.3.16 .7 . Package includes only the above excerpts necessary for the exam.Cooling Water Corrosion 4. API members are eligible for a 50% discount on all API documents.2 .3 . UCS.Corrosion fatigue 4.Mechanical failure 4. Addenda 1. 7 and 23 (section S£-797) ii. Division 1.ihs.com.2.9 . Welding and Brazing Qualifications. December 2003 A TTENTION: Only the following mechanisms to be included: Par. 1.] .2005 Examination. Be sure to check your CD-ROM against the editions noted on this sheet. 2005 Listed below are the effective editions of the publications required for the December 7.3. Inspection of Pressure-Relieving Devices. Rating.Chloride Stress Corrosion Cracking (CrscC) 4.4 . December 2000. 8 Gnd 12 Ill. Product codes are listed above. When calling to order. API and ASME publications may be ordered through Global Engineering Documents at 303-397-7956 or 800-854- 7179.2. CD-ROM versions of the API documents are issued quarterly by Information Handling Services and are pemlitted. Prices quoted will reflect the applicable discounts.2 . Pressure Vessel Inspector Certification Exam For Exam Administration: December 7.Caustic Stress Corrosion Cracking (Caustic Embrittlement) 5. Global Engineering Product Code API CERT 576 • API Recommended Practice 577 .Boiler Water Condensate Corrosion 4. 2.5. . \. October 2004. Section VIII.Thennal Fatigue 4.2.Welding Inspection and Metallurgy. 4. exam candidates are eligible for a 20% discount on all API documents. Articles 1. Global Engineering Product Code API CERT 510 • API Recommended Practice 571.2.1 . Repair. First edition. More infonnation is available at hUp://www.Erosion/Erosion-Corrosion 4. Damage mechanisms Affecting fIXed equipment in the refining industry.5. • API Standard 510. No discounts will be made for ASME documents. UHT.2.Corrosion Under Insulation (CUI) 4. UG.3. February 200 I. Note: API and ASME publications are copyrighted material.2 .Sulfidation 4.5. urv.

ladder clips c. API 510 PREPARP. tray support rings 5 Replacement of heat exchanger tube sheets in accordance with the original design. Weld repairs or replacement of pressure parts or (' attachments that have failed in a weld or in the base material: 2. having loading Y"hich do not affect the design of the pressure retaining item to which they are attached d. The addition of welded attachments to pressure parts. rs Replacement of boiler and heat exchanger tubes where welding is involved. such as. Weld bUildup of wasted areas. brackets. repair organizations and Inspectors the assistance in evaluating whether contemplated work on a pressure retaining item should be categorized as a repair or alteration. Corrosion resistance strip lining or weld overlay: :. EXAMPLES OF REPAIRS J. a.TORY COURSE EXAMPLES OF REPAIRS AND ALTERATIONS INTRODUCTION The following examples are intended to provide owners. 7 The installation of a flush patch to a pressure retaining Itern 1 . 4. studs for insulation or refractory lining b. users.

replacement of a shell or head in accordance with the original design. Installation of new nozzles or openings of such a size that reinforcement is not a consideration {for example the ( installation of a 3 NPS nozzle to a shell or head of 3/8 in. Replacement of pressure parts identical to those existing on the pressure retaining item f such as. 8. b. a. Re-welding a circumferential or longitudinal seam in a shell or head c. equal to or greater tn allowable stress from that used in the or-iginal design. i o. 11. or less in thickness or the addition of a 2 NPS nozzle to a shell of head of any thi~kness}. Welding of wasted or distorted flange faces: 13. 15 The repai r or replacement of a pressure part with a Code accepted material that has a normal composition and strength that is equivalent to the original material. Seal welding of butt straps and rivets. The addition of a nozzle where reinforcement is a consideration may be considered to be a repair if the nozzle is identical to one in the original design. 2 . Replacement of slip-on flanges with weld neck flanges 01- ( vice-versa: 14. Replacement of nozzles of a size whet~e reinforcement is not a consideration 9. 16 Replacement of a pressure retaining part with material of different nominal composition. The replacement of a shell course in a cylindrical pr·essure vessel: 12. located in a similar part of the vessel.

an increase in the heating surface or steaming capacity such that increase in the relieving capacity is required. c. The addition of a braCket Or an increase in ioading on an existing bracket which affects the design of the pressure retaining item to which it is attached. A change in the dimensions or contour of a pressu re retaining item. 7. The addition of pressurized jacket to a pressure vessel. The addition of new nozzles or opening (in a bOiler or pressure vessel) of new sizes other than existing sizes and requiring new reinforcement calculations 4. In a boiler. 3. An increase in the maximum allowable working pressure (internal or external) Or temperature of a pressure retaining item regardless of whether or not a physical change was made to the pressure retaining item. 5. 6. repiacement of a pressure retaining part in a presSure retaining item with a material of different allowable stress or nominal composition from that used in the presSure retaining item to which it is attached. provided the replacement material satisfies the material and design requirements of the original code of construction under which the vessel was built. Except as permitted in Repair. A decrease in the minimum temperature such that additional ( mechanical tests are required. 2. EXAMPLES OF ALTERATIONS 1. 8. ') J .

Time Management During the Examination .-------------_.~- GUIDELINES FOR API 510 CERllFICA liON EXAMINA liON Contents 1. API-510 -Chapter wise Tips for Maximizing the Score 6."----~ . How to Prepare for the Examination 5._-------_.~~"~~. Salient Features of the Examination 4. Distribution of Marks 3. Examination Scheme 2..

1. 2 session examination. please note the followinq: • Fill only one circle out of four given 2 . however the total is always 150 questions. The correct answer is to be indicated by blackening (filling) the relevant circle by a pencil. 8-hour. The candidate has to pick-up the correct choice. The distribution of 50 and 100 questions respectively for open-book and closed-book examinations is approximate. comprising of pre-lunch session (4 hours) for "open- book" examination and post-lunch session (4 hours) for "closed-book" examination. In the answer sheet you will find four blank circles for each question. Only ONE out of these four is the correct choice. Each correct answer will carry one mark.( in open book as well as closed book part ) is multiple- choice question with given FOUR possible choices. There is no set passing percentage. split into open-book (approximately 50 questions) and c1osed- book (approximately 100 questions). API 510 examination is one-day.2 Total marks: There are a total of 150 questions carrying 1 mark each. and indicate the same on separate answer sheet.3 Question pattern: Each question. 1. (total of 150 marks). However a score of about 100 to 110 out of 150 is a good estimate of passing score. EXAMINATION SCHEME 1. The answer sheet along with the question paper should be returned back to the Supervisor. 1.1 General: As per the present scheme.

8 or 28 pencils and eraser • Non-programmable calculator • Photo identity (passport.. • 2 Nos. Do not miss them. underlined or notes in margin of the pages are accepted. 3 .J) the circles. Always carry the following to the exam hall.-_.._--------------------~-~-~~---~------== • Fill the circle fully and completely.) • Exam confirmation letter Be present in the exam hall at least 15 minutes prior to scheduled start of exam. driving license. The Supervisor announces important instructions during this period. etc. Now relax and attempt the exam calmly. • Never indicate the answers by ticking (. highlightened. Half or less than half blackened circle is not reckoned for answer. • There is no negative marking. you are permitted to refer to the codes and other documents as per "Effectivity Sheets". Additional new pages to codes are not accepted. Time is always more than enough. During the "open-book" session. Code pages may be tabbed..

- __ 8 General Knowledge 2 3 ~-. there are total 7 codes prescribed for examination. 2.N. all of them are not equally important and do not therefore require equal emphasis.---------------- -- ______ L___ 4 . 18 4 ASME Sec. Approx.{ .. Weightage Approx. l: 0- . About 45 percent questions are asked from one code API 510 which is hardly a total of 20 pages.Questions S. while all other 6 codes contribute 55% marks which are more than 1. DISTRIBUTION OF MARKS 2.vlll Div." ( b( J . However.1 20-22 30-33 3 ASME Sec IX 12 . Code (in %) Out of Total 150 1 API 510 Code 42-45 63 ."' ~' . 2. V 12 18 5 API RP 572 4 6 6 API RP 576 5 8 ~ IRE Chap II 1 c.68 2 ASME Sec.' I -' 2 .500 pages.2 Code-wise marks distribution: Following distribution scheme will help the participant to decide how much time he should spend for each document during preparation..1 Codes for Study: As per the Effectivity Sheet for API-510 exam.

important definitions and well-known inspection principles will constitute such questions. 5 . To answer open-book questions. specific "DO" and "DON'T" statements. Thus.e. Here the participant is expected not to remember the information but should know where to find it in the body of the Code. a closed book question may be expected on it. (i.. Closed-book part of the exam (100 marks) can be finished in 2 to 2"12 hours. important quantified statements. large paragraphs.. The closed-book examination includes such questions which the inspectm is normally expected to know without referring the Codes. SALIENT FEATURES OF THE EXAMINATION 3. The Code information which is not short and crisp. though 4 hours are allotted. the basic requirements of a code.e._ 3. Whenever you find a very definitive or quantitative statement in body of the Code. While "open-book" part (50 marks) takes a little longer and may require all the 4 hours that are allotted. it will always be an "open-book" question. highlighting the paragraphs or additional explanatory notes in page margins is useful for saving time. i. "awareness level" questions. one only needs to know where to find the answer in the code and therefore tabbing of Code pages. the examination comprises of open book and closed book parts. All calculation oriented questions will normally be "open-book" type. the questions are .1 How the questions are set: As stated earlier.___________________________ ~ ~' ~="o=~=·. several descriptive statements clubbed together) will normally be asked in "open-book" part.."_. The questions asked in closed book part are straight forward statements directly taken form Code without much of the modifications and therefore are easy to answer. Where the student is required to refer to the diagrams or formulas or tables or graphs and curves from the Codes.

the Open book Questions from these can always be found out and answered plus the points to recall can help to answer other questions. An overall "awareness" level knowledge of these 3 Codes may be okay.. These contribute only 10% weightage. HOW TO PREPARE FOR EXAM: A ) If your aim is only to get "certified" only.2 distribution of marks. Chap. Still. Serial No. IX and ASME Sec.If your objective is to get certified and also to obtain a good score.e. However. VIII Oiv. V should be such that it can cover the topics mentioned in the "Body of Knowledge". i.) may be adequate. to obtain just around 110- 115 marks. then joint discussions and one putting question to another and vice versa has been found very effective during preparation. 4. 1 to 4 above (Ref.5 to 7).1.5 to 7) may be studied in detail if there is additional preparation time available. then. one should try to remember all the "Points to Recall" given each day during the preparatory course and review the mock examinations attempted during the Preparatory Course. It is worthwhile to study the 3 Codes also. 6 . (say 135+) then prepare for exam as follows: In addition to preparation as per 1&2 above. ASME Sec. If two or more participants from same organization are appearing for exam. while study of ASME Sec. (Serial No. Follow the steps given below 1) . please remember that study of API 510 has to be "thorough" and total. B) .Detailed study of documents nos.. 2) Additionally. 3) Other 3 codes (Le.

************ 7 .. In the last week of preparation. If you are about two weeks away from the exam. A very "thorough" study of these documents however will not result in "gains" commensurate with the efforts put in. focus on Points to Recall and and highlighted text from the codes. _.~='-~- The last 3 Codes should be read at least once and note the important points. read all the Codes at least once and concentrate on highlighted text in the Codes and also try to solve the question bank. concentrate on highlighted text as well as the mock examinations conducted during the course.. If you are about a month away from examination.----------------------~-------~'~-.

In the last week of preparation. A very "thorough" study of these documents however will not result in "gains" commensurate with the efforts put in.. If you are about two weeks away from the exam._ .. _._. read all the Codes at least once and concentrate on highlighted text in the Codes and also try to solve the question bank. focus on Points to Recall and and highlighted text from the codes._. ************ 7 .-=- The last 3 Codes should be read at least once and note the important points. ~..~-~~ .------------------------~------~=. concentrate on highlighted text as well as the mock examinations conducted during the course.. If you are about a month away from examination.

B for certification requirements. Concentrate on responsibilities clause. about 6 to 8 questions ( both open & close book) are asked. application and . usually closed book. This is only four page chapter and almost all chapter is important. F rom Chapter 7 also 15-18 questions are asked. usually 2 or 3 questions are asked. From Chapter 6.2 to 5. b. At the most one question is asked from this chapter c. just note the scope.6. From Chapter 5. e. about 15-18 questions are asked. API-510 CHAPTERWISE TIPS FOR MAXIMIZING THE SCORE a.7. f.Chapter 3. Two questions will be asked from these. average of 1 or 2 questions are asked while on para 5. which attracts at least 5 to 6 questions and they could be either open book or closed book. g. Normally 3 to 4 definitions are asked in closed-book exam. About 10-12 in closed book and 4-S in open book. Chap. about 15-18 questions are asked. Para 5. From Chapter 4. d. exclusions. There are only 5 or 6 important definitions from Chapter 3 of API 510. Also see App. 2 lists only the reference documents. From Chapter 1. Pay 8 . Particularly pay attention to Inspection intervals.5.

and inspection requirements. the course content is categorised in 9 categories. particular attention to authorisation. Chapter 8 as well as App. 7 of them are listed under calculations while 8 and 9 are listed under welding and NOT . E are excluded from examination. h. You may expect at least one open book and one closed book question on each of these. J. you may expect 4 open book questions one each for thickness calculation for the 4 types of end closures. VIII Oiv. I. Additionally. under the category internal pressure. defect repair. As regards ASME Sec.1. ******** 9 . There may be 2 or 3 questions on overall API-510 code for the purpose of assessing the overall under standing of code.

Go on like this till say last 10-15 minutes are remaining.e. I.. *********** ------------------------------. however. -----.. a) You may start from Question NO. you are behind the required rate..1 and proceed. d) If there are still some questions where you have no clue at all just mark the answer at random in last 10-15 minutes. Do not leave any question unanswered whose answer you know.•• ~ _ 6.::." .T---=~. For proper time management following are useful suggestions. deleting whose answer you.'----------.'_""L·_ . This may give you few chance marks. Do not leave any question unattempted. start jumping the questions. start attempting those questions you can answer._-_'r~..r><. If after 1 hour you feel that you are maintaining the required progress as mentioned above proceed serially._=. i.~. c) Then come back to "deleted" questions and attempt them using your "feel" factor. TIME MANAGEMENT DURING EXAM Both "open" and "closed" book sessions are 4 hours each.. e) After completion of writing exam.... This means about 25 to 28 questions per hour for closed book and 12 to 15 questions per hour for open book.. Proceed like this till the end.. ·----------·~~~~. do not know. b) If. if you have still time (which you normally have) you may go through your answers just to check quickly if you have filled a wrong circle..._.. _ 10 .

per the owner's specifications.api. Division 1. length of time since the last inspection. Hydrogen blistering near the liquid level - 4.org. Hydrogen embrittlement in the vapor space 3. A pressure vessel is scheduled for pneumatic testing using the methodology of ASME Code. 65 material and is neither enameled nor lined. availability of certified . type. How many pressurization steps are needed to . 3. Section VIII. Hydrogen blistering in the vapor space 2. In planning for an internal inspection of a vessel that has contained acidic corrodents. what type and location of corrosion would you ·expect to find on the vessel shell. 1. away from the welds? 1. Hydrogen embrittlement below the liquid level Correct Answer: 1 C. 4. 2. age of the component to be inspected.NDE examiners. Correct Answer: 3 B. with the maximum allowable working pressure = 635 psig at 375 F. The test metal temperature will 0 be a minimum of 50 F. The vessel is 0 constructed of SA-516 Gr. location. and orientation of the expected flaws. Reproduced here for guidance to the students Correct Answer: 4 A The nondestructive examination method to be used for a particular inspection should be determined by the: 1. The questions are furnished by API web site www. SAMPLE API-510 EXAM QUESTIONS The Questions below are examples of what exam question might look like.

635 psig 2. 635 psig 4. 9 steps. 6 steps. the spring coil diameter. 3. A pressure vessel has been in service for 12 years and has a history of corrosion over its service life. 0. 9 steps. achieve the minimum required test pressure. 0. 2.532 inch per year Correct Answer: 3 F. the body thickness.044 inch per year 2. The original thickness was 1. What is the corrosion rate for this vessel? 1. and a corrosion thickness currently near the minimum required thickness? . a joint efficiency of less than 1. What can be done to extend the life of a vessel with a corroded area in the shell plate 6 inches from the weld. 6 steps.405 inches. Correct Answer: 1 E. 4. 793. The principal reason for inspecting a pressure relief device is to determine: 1. 0. 0. the remaining life.089 inch per year 3.266 inch per year 4. if it is functioning properly.9375 inches. and at what minimum pressure will the visual examillation be performed? 1. the current thickness is 1. 793.75 psig 3.75 psig Correct Answer: 4 D.

Correct Answer: 2 H. The WPS and the PQR are used to determine: . - Correct Answer: 2 G. Recalculate t minimum for design conditions using E = 1. 2. Temporary repairs to pressure vessels: 1. 4. may remain in place for long periods if approved by the API-authorized pressure vessel inspector. 1 . The National Board inspector 4. Who must be consulted before the repair of a crack at a discontinuity where stress concentrations may be serious? 1. Monitor the thickness during the run. 2. The vessel manufacturer Correct Answer: 4 I. must be replaced with permanent repairs during the next scheduled shutdown. The owner-user 2. Recalculate t minimum for current operating conditions = using E 1. Recalculate t minimum for current operating conditions using E < 1. The pressure vessel engineer 3. may remain in place permanently if approved by the pressure vessel engineer and the API authorized pressure vessel inspector. 3. ~~~------~-. 3. may remain in place for long periods if approved by the pressure vessel engineer. 4.