Harvard Technology Middle East April 3-14, 2004 Dubai, U.A.E. Faculty Mr. Oran Lewis 0. Box: 26606, Abu Dhabi, United Arab Emirates, Tel: +071-2-6277881, Fax: +071-2-6277663 info@harvard.tc htip/www.harvard.:To The Participant The Course notes are intended as an aid in following lectures and for review in conjunction with your own notes; however they are not intended to be a complete textbook. If you spot any inaccuracy, kindly report it by completing this form and dispatching it to the following address, so that we can take the necessary action to rectify the matter. Harvard Technology Middle East P. O. Box 26608 Abu Dhabi, U.A.E. Tel: +971 2 627 7881 Fax: +971 2 627 7883 Email: info@harvard.te Address: Email: Course Title: ee Course Date: Course Location: | ——————— Description of inaccuracy:Disclaimer The information contained in these course notes has been complied from various sources and is believed to be reliable and to represent the best current knowledge and opinion relative to the subject. Harvard Technology offers no warranty, guarantee, or representation as to it's absolute correctness or sufficiency. Harvard Technology has no responsibility in connection therewith; nor should it be assumed that all acceptable safety and regulatory measures are contained herein, or that other or additional information may be required under particular or exceptional circumstances.Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Table of Contents API 510 Code, RP’S 576 & Chapter I ASME Section VIII Div. 1 ASME Section IX Advanced Material Practice Exams API 510 Pre - Course StudiesHarvard Technology Middle East COURSE OVERVIEW IE100 API 510: Pressure Vessel Inspection Code Pressure Vessel Maintenance, Inspection, Rating, Repair & Alteration (API Exam Preparation Training) API 510; Pressure Vessel Inspection Code: Pressure Vessel Maintenance, Inspection, Rating, Repair and Alteration (API Exam Preparation) Course Date/ Venue April 03-14, 2004 / Palm 9 , Fairmont Hotel, Dubai, UAE. Course Reference 1E100 Course Duration 10 days (80 hours as per API recommendations) Course Objectives This course is designed to train individuals who are interested in obtaining the API 510 Pressure Vessel Inspector Certification, as.well as those who are seeking a better understanding of ASME Section Vill and IX code requirements. Included with the course is a pre-study guide and student classroom workbook, The student receives instruction regarding how to take the test, as well as insight into the intricacies of "real world" situations. Daily tests are designed to gauge students’ proficiency and understanding of the material. Topics include: «Head and Shell Calculations Hydrostatic Test Pressure Calculations Reinforcement Calculations Shell External Pressure Calculations Impact Test Requirements and Determination Development and Review of Welding Documentation NDE Requirements Who Should Attend The course is intended for Inspection Engineers who are seeking API-510 cettification. Other engineers, managers or technical staffs who are dealing with Pressure Vessel will also benefit. Course Certificate Harvard Technology certificate will be issued to all attendees. Course Fee US $ 3,750 per Delegate. This rate includes Participant's Pack (Folder, Manual, Hand-outs, etc.), buffet lunch, coffee/tea on arrival, morning & afternoon of each day. (iE100_- Page 1 of 7 P.O. Bor: 26608, Abu Dhabi, United Arab Emirates, Tel +877-2-6077881, Fax: +971-2-6277863 info@harvard.te hifpy/waw.harvard.16Accommodation Kecommodation is not included in course fees. However, any accommodation required can be arranged by Harvard Technology at the time of booking, Required Codes & Standards Listed below are the effective editions of the publications required for the current Vessel inspector Certification Examination. Each student must have these documents available for use during the class. = APL Standard 810, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and Alteration, Eighth Edition, June, 1997; including Addendum 1 (December, 1998), Addendum 2 (December, 2000) and Addendum 3 (December, 2001). Global Engineering Product Gode API CERT 510 « API Racermmended Practice 672, Inspection of Pressure Vessels, Second Edition, February, 2001. Global Engineering Product Code API CERT 572 «APL Recommended Practice §76, Inspection of Pressure-Relieving Devices, Second Edition (December 2000). Global Engineering Product Code AP! CERT 576 = Guide fer Inspection of Refinery Equipment, Chapter 2, Global Engineering Product Code API CERT GUIDE IRE CH2 *NOTE: This publication is a reference document intended only for Inspector Certification applicants. To obtain a copy please inform the person taking your order that you require this publicetion for the API 510 Inspector Certification exam. © American Society of Mechanical Engineers (ASME}, Boiler and Pressure Vossel Code, 2001 edition. i ASME Section WD, External Pressure Graphs only. ASME Seetion V, Nondestructive Examination, Articles 1, 2, 5, 8 and 7 iii. ASME Section VIU, Rules for Construction of Pressure Vessels, Division 1, UG, UW, UCS, UHT, Appendices 1-4, 6, 8 and 12. iv. ASME Section IX, Welding and Brazing Qualifications Global Engineering Product Code for the ASME package is API CERT ASME 510. Package includes only the above excerpts necessary for the exam. Future addenda will not be provided. ‘API and ASME publications may be ordered through Global Engineering Documents at 303 792-2481 or 800-854-7179. Product codes are listed above. API members are eligible for a 50% discount on all API documents, other exam candidates are eligible for a 20% discount on all API documents. No discounts will be made for ASME documents. When calling to order please identify yourself as an exam candidate, For complete sets of ASME documents including future addenda please contact ASME's publications department at 1-800-843-2763. In Canada, ASME publications ere available through Power Engineering Books, Ltd. at 1-800-687-3155 or 780-458-3155, Note: AP|and ASME publications are copyrighted material. Photocopies of publications are not permitted at the exam, CD-ROM versions of the API documents are issued quarterly by Information Handling Services, Be sure to check your CD-ROM against the editions noted on this sheet. E100 = Page 207 7Course Faculty Mr, Oran T. Lewis, P.E. (Texas, USA) is an Adjunct Instructor with over twenty years experience in the design, erection, maintenance, inspection, fabrication, modification and repair of pressure equipment, as well as presenting educational courses for piping inspection, welding, weld inspection, and pressure equipment inspection Mr. Lewis has a Bsc degree and he is a qualified American National Board Trainer and an NDE Trainer. Further, he is a AWS Certified Welding Inspector, API Certified Pressure Vessel Inspector, API Certified Piping Inspector, a member of the National Board of Boiler and Pressure Vessel Inspectors Commission and a Boiler and Pressure Vessel Inspector - State of Texas. Course Program Day1: Saturday 3” of April 2004 0730-0800 _| Registration & Coffee 0800-0810 _ | Welcome & Introduction 0810-1000 _| Joint Efficiencies = UW-3 Weld Categories = UW-51 RT Examination of Welded Joints + _UW-52Spot Examination of Welded Joints 1000-7015 | Break 1015-1230 __| Joint Hificiencies (continued) = UW-11 RT and UT Examinations + UW-12 Maximum Allowable Joint Efficiencies + Exercises UW 3, 11 and 12 7230-1330 __| Lunch 1330-1515 | Postweld Heat Treatment + _UW-40 Procedures for Postweld Heat Treatment 1515 -1530_| Break 1530-1700 | Postweld Heat Treatment (continued) + _UCS-56 Requirements for Postweld Heat Treatment 1700 End of Day One Day2: Sunday 4” of April 2004 0730-0830 _| Review of Day1 (0830-1000 __| Vessels Under Internal Pressure + UG-27 Thickness of Shells Under Internal Pressure + _UG-32 Formulas and Rules for Using Formed Heads 1000-1015 __| Break 1015-1230 _ | Vessels Under Internal Pressure (continued) + UG-34 Unstayed Flat Heads and Covers (Circular) + Exercises UG s-27-32-34 1230-1330 _| Lunch 1330-1515 _ | Cylinder under External Pressure + _UG-28 Thickness of Shells and Tubes (External Pressure) i100 = Page 30f 71515 - 1530 Break 1530-1700 | Cylinder under External Pressure (continued) » Exercise UG-28103 1700 End of Day Two Day3: Monday 5" of April 2004 0730-0930 __| Review of Day 1&2 0930-0945 _| Break 0945-1250 | Pressure Testing = UG-20 Design Temperature = UG-22 Loading + UG25 Corrosion * UG-98 Maximum Allowable Working Pressure = UG-99 Hydrostatic Test Pressure and Procedure * UG-100 Pneumatic Test Pressure and Procedure = __UG-102 Test Gages 1230-7330 [Lunch 1330-1515 | Pressure Testing (continued) +__Exercises UG s 99-100-102 1515-1530 _| Break 1530-1730 | Minimum Requirements for Attachment Welds at Openings * UW-16 Weld Size Determination «Exercise UW-16 1730 End of Day Three Day 4: Tuesday 6" of April 2004 (0730-0830 _| Review of Day 3 (0830-1000 | Reinforcement for Openings in Shells and Heads = UG-36 Openings in Vessels + _UG-37 Reinforcement of Openings 1000-1015 | Break 1015-1230 _ | Reinforcement for Openings in Shells and Heads (continued) "= UG-40 Limits of Reinforcement = UG-41 Requirements for Strength of Reinforcement + _UG-42 Reinforcement of Multiple Openings 1230-1330 __| Lunch 1330-1515 | Reinforcement for Openings in Shells and Heads (continued) + Exercises UG s 40-41-42-45 7515-1530_| Break [530-1700 | Reinforcement for Openings in Shells and Heads (continued) + _ Exercise Reinforcement for Openings in Shells and Heads 1700 End of Day Four 1100 - Page 4 of 7Day 5: Wednesday 7" of April 2004 0730 - 0830 Review of Day 4 (0830 - 1000 Minimum Design Metal Temperature & Exemptions From Impact Testing = UG-84 Charpy Impact Test Requirements + Exercise UG-84 + UCS-66 Materials 1000-1015, Break 1015 - 1230 Minimum Design Metal Temperature & Exemptions From Impact Testing (continued) + UCS-67 Impact Testing of Welding Procedures = UCS-68 Design + Exercises UG 20 -UCS 66 ~ 67 1230 - 1330 Lunch 1330 - 1515 Practical Knowledge *UG-77 Material Identification + UG-93 Inspection of Materials + _UG-116 Name Plate Markings 1515 - 1530 Break 1530 - 1700 Practical Knowledge (continued) + UG-119 Name Plates, + _UG-10 Data Reports 1700 End of Day Five Day 6: Saturday 10" of April 2004 0730-0830 __[ Review of Day 5 (0830-1000 _ | Welding on Pressure Vessels (Section IX Overview) + Article I General Requirements + _ Article I’ Welding Procedure Qualifications 1000-1015 __| Break 1015-1230 | Welding on Pressure Vessels (Section IX Overview) ... (continued) «Article III Welding Performance Qualifications + _ Article IV Welding Data 1230-1330_| Canch 1330-1515 | Welding Documentation Review + Welding Procedure Specification (WPS) + _ Procedure Qualification Record (POR) 1515 - 1530 | Break 1530-1700 _ | Welding Documentation Review (continued) = _ Practice WPS/POR reviews 1700 End of Day Six 16100 = Page 507 7Day7: Sunday 11" of April 2004 0730-0930__| Review of Day5 & 6 0930-0945 | Break ‘0945-1230 | Advanced Material Example Problems Static Head of Water * Corrosion Calculations + Cylinders under Internal Pressure «Heads under Internal Pressure = Charpy Impact Test Evaluation WPS/PQR + Quiz Static Head Pressure 1230-1330 _[ Lunch 1330-1515 | Advanced Exercise Problems = Internal Pressure Shell Calculations +» _ Internal Pressure Head Calculations 1515-1530 _| Break 1530-1700 | Advanced Exercise Problems (continued) = Solutions for Advanced Exercises 1700 End of Day Seven Day 8: Monday 12" of April 2004 0730-0830 __| Review of Day 7 (0830-1000 | API 510 Corrosion Rates and Inspection Intervals Scope MAWP Determination Inspection Interval Corrosion Rate and Remaining Life Long and Short Term Corrosion Rates Quiz #1 1000-1015 | Break 1015-1230 | API576 Pressure Relieving Devices = Scope = Types of pressure relieving devices = Quiz #2 = Quiz#3 API572 Inspection of Pressure Vessels = Scope Reasons for Inspection Causes of Deterioration Methods of Repairs Inspection Records and Reports 1230-1330 | Lunch E100 - Page 6 oF 71380-1515 | API572 Inspection of Pressure Vessels (continued) = Quiz #4 = Quiz#5 "Quiz #6 * Quiz#7 + Quiz#s IRE Chapter 2 1515 -1530_| Break 1530-1730 | IRE Chapter 2 (continued) Coverage from the API 510 Body of Knowledge + Quiz #9 1730 End of Day Fight Day 9: Tuesday 13" of April 2004 0730-0930 | Review of all course materials 0730-1000 __| Administer first half of 150 question API 510 practice examination A. 1000-1015 _ | Break 1015-1230 | Administer first half of 150 question API 510 practice examination A (continued) 1230-1330 | Lunch 1330-1515 | Administer first half of 150 question API 510 practice examination A (continued) 1515 -1530__| Break 1530-1730 | Administer first half of 150 question API 510 practice examination A (continued) 1730. End of Nine Day 10 Wednesday 14” of April 2004 0730-0830 __| Review of the first half of the API510 practice examination A. (0830-1000 | Administer 2»! half of 150 question API 510 practice examination A. 1000-1015 | Break 1015-1230__| Administer 2-4 half of 150 question API510 practice examination A. 1230-1330 | Lunch 1330-1530 | Administer 2-4 half of 150 question API 510 practice examination A. 1530-1545 _ | Break 1545-1645 | Review of the second half of API510 practice examination. 1645-1730 _ | Pass out API5I0 practice examinations B and C with solutions. Closing comments Presentation of Certificates 1730 End of course Course Coordinator Ms. Yana Spichak, Tel: +971-2-6277881, Fax: +971-2-6277883, Email: yana@harvard.te Tor 7 1100INTRODUCTION TEXTBOOK ‘The textbook table of contents follows the AP! 510 Body of Knowledge that was in effect at the time of its writing, Each area can be studied as a stand alone Modules for those who do not intend to set for the API 510 exam, but want to obtain a better understanding on a given Code subject. ‘The process found to most effective for general use is to study each subject of interest and complete the quizzes at the end of those Modules, As regards calculations, after mastering the given ‘material, refer to the Advanced Material section to increase the depth of understanding. The Advanced Material covers the calculations required for some actual circumstances that might be encountered in the field. Effective Publications for this Revision: Intended for the June 2004 Exam API 510 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) API Guide to Inspection of Refinery Equipment Chapter 2 ASME Section VIll Div.1. 2000 Edition with 02 addenda ASME Section IX 2000 Edition with 02 addenda ASME Section V 2000 Edition with 02 addenda‘API 510 MODULES Table of Contents SECTION 1 - API CODES AND RECOMMENDED PRACTICES API510 Corrosion Rates and Inspection Intervals Scope 5 MAWP Determination 6 Inspection Interval 9 Corrosion Rate and Remaining Life 15 Long and Short Term Corrosion Rates 15 Quiz #1 7 APL 576 Pressure Relieving Devices Scope 1B ‘Types of pressure relieving devices 18 Quiz #2 21 Quiz #3 2 API S72 Inspection of Pressure Vessels Scope 23 Reasons for Inspection 4 Causes of Deterioration 4 Methods of Repairs 30 Inspection Records and Repoxts 30 Quiz#4 3 Quiz#5 2 Quiz #6 3 Quiz#7 34 Quiz #8 35 IRE Chapter 2 Coverage from the API 510 Body OF Knowledge 36 Quiz #9 39 2 11/03 REV 12SECTION 2 - ASME Section VIII Div. 1 Joint Efficiencies UW-3 Weld Categories 4 UW-S1 RT Examination of Welded Joints 4B UW-52 Spot Examination of Welded Joints ot) UW-11 RT and UT Examinations 51 UW-12 Maximum Allowable Joint Efficiencies 58 Exercises UW 5-3-11-12 41, 57,76 Postweld Heat Treatment UW-40 Procedures for Postweld Heat Treatment B ‘UCS-S6 Requirements for Postweld Heat Treatment B Vessels under Internal Pressure UG-27 Thickness of Shells Under Internal Pressure 80 ‘UG-32 Formulas and Rules for Using Formed Heads 91 UG-34 Unstayed Flat Heads and Covers (Circular) 96 Exercises UG 5-27-32-34 90, 95, 100 Cylinder under External Pressure UG-28 Thickness of Shells and Tubes (Extemal Pressure) 101 Exercise UG-28 103 Pressure Testing UG-20 Design Temperature 106 UG-22 Loading 107 UG-25 Corrosion 107 ‘UG-98 Maximum Allowable Working Pressure 108 UG.99 Hydrostatic Test Pressure and Procedure 109 UG-100 Pneumatic Test Pressure and Procedure 2 UG-102 Test Gages 14 Exercises UG s 99-100-102 us ‘Minimum Requirements for Attachment Welds at Openings UW-16 Weld Size Determination us Exercise UW-16 120 Reinforcement for Openings in Shells and Heads UG-36 Openings in Vessels 121 UG-37 Reinforcement of Openings 122 UG-40 Limits of Reinforcement 122 UG-4I Recuirements for Strength of Reinforcement 122 UG-42 Reinforcement of Multiple Openings 123 Exercises UG s 40-41-42-45 125 Exercise Reinforcement for Openings in Shells and Heads 132 11/03 REV 12