“CintegratedTraining API 570 PREPARATORY COURSE NOTES 1 CONTENTS Program Daily Schedule Body of Knowledge Publication Effectivity Sheet Case Study: Teaser 2 A. B, A Case Study: Teaser 1 B, s Case Study: Teaser 3 D. Case Study: Teaser 4 £. Case Study: Teaser 5 F. Case Study: Teaser 6 Examples of Repairs and Alterations API 570 Examination Sample Items Reference Documents and Tables WPS/PQR (Road Map) Guidelines for API 570 Certification Exam Piping Materials Copies of TransparenciesPT Introduction to API 570 TIME TABLE Design of piping components Pressure tests Certification examination — ASME B 31.3 - Hydrostatic information Thickness calculations for - Pneumatic Body of Knowledge — API 570 pipes and blanks Pre-heating and PWHT requirements: Introduction to Piping Code, B 31.3 Impact testing requirements for piping Daily Quiz Points to recall Review of Quiz Selection of flanges Pr-temp. ratings & Pressure testing of flanges Evaluation of flanged fittings | Material for pipes and fittings Common ASTM specifications Introduction to API 570 ‘API 570 Scope, applicability & limitations QA Manual. Organisation and responsibilities ‘Authorised inspection agency Repair organization Inspection practices; RBI inspection Daily Quiz ‘API 570 Continued ~ Points to recall, Review of Quiz - Deteriorating of piping components - CUI, SCC, creep and fatigue failures - Inspection methods Determining inspection frequencies Extent of inspection Corrosion under insulation Inspection data evaluation Evaluation of thinned areas Evaluation of pitted areas Determining safe MAWP Daily QuizSession 1 API 570 Continued - Points to recall, Review of Quiz - Repairs, alterations, re-rating of piping systems - Repair and alteration procedures Inspection of buried piping Corrosivity tests Cathodic protection of buried piping Session 3 Leak testing of piping - Retirement thickness Inspection records Daily Quiz ‘API 570 Continued - Points to recall, Review of Quiz - API 574 — Piping components - Inspection practices = Selection of TMLs - Retirement thickness calculation for valves and flanged fittings ‘ASME Section 1X Requirements Welding qualifications WPS/PQR tests and documentation Performance qualifications Review of WPS/PQR documents Additional WPS/PQR requirements as per ASME B 31.3 and API 570 Welding Inspection requirements as per B 31.3 Daily Quiz = Points to recall, Review of Quiz - ASME Section V Requirements - Non-destructive testing procedures - Procedural requirements for RT, PT, MT, UT NDT procedures - visual testing - bubble test Final Simulated Exam - (closed book) ial Simulated Exam - (open book) Review of open book and closed book exams Test taking tips - Discussion on planning and preparation for the actual exam Feedback - Concluding SessionCintegnatedirainin: API 570 PREPARATORY COURSE TEASER 1: Design of Pipes for Internal Pressure (Question) Choose correct pipe schedule for a piping with the following design conditions: Design Pressure = 400 psig Design Temperature = 750 degrees F M.0.C. 8” ND pipes, A 106 gr. B seamless Corrosion Allowance = 3.0mm Assume standard mill tolerance. Solution: 15Cintegratediainin API 570 PREPARATORY COURSE TEASER 1: Design of Pipes for Internal Pressure (Solution) Design Pipe Thickness, t = PD/2 (SE + PY) + C 400 psig -~ 8.625” (219.08 mm) given from pipe dimension tables - Table A-1 (Stress Table) Table A-18 (Quality Factor Table) Table 304.1.1 (Y Table) Now, t= 400 x 219.08 / 2 (13,000 x 1 + 400 x 0.4) +3 3.329 +3 = 6.329 mm Allowing standard negative mill tolerance of - 12.5% Nominal thickness (i.e. ordered thickness) = 6.329 / 0.875 = 7.23 Referring pipe tables again, choose 8” Sch. 40 pipe. 16“Cintegratedirainin. API 570 PREPARATORY COURSE TEASER 2: Design of Pipes for Internal Pressure (Question) Choose correct pipe schedule for a pi conditions: with the following design Design Pressure 60 Bar (9) = 882 psig Design Temperature 550 degrees F M.0.C. 6” ND pipes, A 53 gr. B (ERW) Corrosion Allowance = 3.0mm Assume standard mill tolerance. Solution 17Kintegrated rain API 570 PREPARATORY COURSE TEASER 2: Design of Pipes for Internal Pressure (Solution) Design Pipe Thickness, t = PD/2 (SE + PY) + C Here, P = 882 psig ~ D= 6.625" (168.28 mm: given from pipe dimension tables ‘Table A-1 (Stress Table ~ by interpolation) Table A-18 (Quality Factor Table) Table 304.1.1 (¥ Table) Now, t= 882 x 168,28 / 2 (18,100 x 0.85 + 882 x 0.4) +3 .715 +3 Allowing standard negative mill tolerance of - 12.5% Nominal thickness (i.e. ordered thickness) = 7.715 / 0.875 817 Referring pipe tables again, choose 6” Sch. 80 pipe 18Cintegrated renin: API 570 PREPARATORY TEASER 4: Case Study on Hydro and Pneumatic Testing (Question) A plant piping system, (M.O.C.: A106 gr C) has design Pressure = 100 psi. Design temperature 00°F is to be subjected to hydrostatic and pneumatic testing a 2. 3. What shall be the minimum hydrostatic test pressure? What shall be the minimum pneumatic test pressure? How much minimum time the test pressure should be held before examining leakage in case of hydrostatic and pneumatic test? Instead of water if oil is to be used for hydrostatic test what shall be the minimum flash point of oil? a. 100°F b. 100°C c. 120°F d. 120°C For pneumatic test, what shall be the setting of pressure relief valve? a. 121 psi minimum b. 121 psi maximum c. 150 psi minimum d. 150 psi maximum What will be first stage of pressurization for pneumatic test? a. 50 psi b. 55 psi c. 25 psi d. 27.5 psi What will be inspection pressure for pneumatic test? a. 110 psi b. 100 psi c. 150 psi d. 125 psi If choice of both tests (hydro and pneumatic) is available which one will you prefer? 21“Cintegrated Tainins API 570 PREPARATORY Case Study on Hydro and Pneumatic Testing (Answer) 1. Refer Table A-1, Stress at test temperature (Ambient temperature) = 23,300 psi Stress at design temperature (600°F) = 19,700 psi 23, ea = fee fim |ems wer [ean te ue aie 3 = = ete tim{ses ser [oars = She Be a = fae anlage ise |oan ~ tee ae oy] 2 = 18h Glee Se [ean IS ' =r yeh Gn fes ue [ean oe tan - om osm wen te 7% ta an eeAly ENICAN NATIONAL STANDARD STEEL PIPE FLANGES, FL ANGEO VALVES ANO FITTINGS Atisi 816-97: APPENDIX G PRESSURE-TEMPERATURE RAT! METRIC UNITS “his appendix contains the mettie version of the presiure-temperature ratings, Tables 2. The tables in (his appendix were calculated using the same stress values as were used for Tables 2. The stress values fed (linearly) to obtain the selected were interpols were used to calculate the pressure ratings as show in bars. The tabulated values are in bars (gage). The pressure unit of | bar is equal to 100,000 Newto: per square meter, The conversion: actor is | bar iz equal to 14.5038 pounds per square inch. stress at temperature, T, in degrees Celsius. These MATERIALS: GROUP 1.1 aos A106-c% Alss-cm70 Alss.cears Als5-Kc70 ALSS-KCF70 Aaso.Lr2 = AIsoUr> aziewee A203:8 Az03-€ ASis70 As16.70 TABLE G1 Terafenatune WORKING PRESSURES IN BARS N°C 150 300 ‘00 200 800 133 sre cao Tera Tea 19 50.0 66.7 10011 1501 13 Pre 92.7 138.0, 173 a8 1356 16.7 ae anne | as.9 aur 125.1 Tae 337 78 Te 1a 36.9 73.8 nos 13.9 ae 73.9 109.3 133 ot 38: Toe 7 ao 2a7 574 26.2 | zs | 200 40.0 0.0 ar 133 37-0 40.6 33 ar is 26.3 Ao si Joa 1538 ar To 38 3 34se it Tei API 570 - PREPARATORY COURSE API 570 — INSPECTION INTERVALS (IN YEARS) 20- 25 Novernber 2006 SAMREF - Yanbu Piping Remaining Life in Years S.N. | EPMO | inspection Type Criteria Thickness Shorter of R.L/2 or 5 1 lease 1| Measurement Years Visual External 5 Years Thickness Shorter oF R172 or 10 > class 2} Measurement Years Visual External 5 Years “Thickness Shorter of R.L/2 or 10 3 [crass 3] Measurement Years Visual External 10 Years Thickness Shorter of R.L/2 or 3 Measurement Years a | to Points By Class 1,2 Visual External By Class 3 S/A By Class 1,2 5 ]interfa) Visual external oe By Class 3. API S #0 p. ows 2001 SECTION Ix Page Yq ‘aW-482 SUGGESTED FORIMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) ~__(Seo 0200.1, Section IX, ASME Boller and Pressure Vessel Code) Company name Woking roceeues) GT AW rye ; ems ona Vets ty Pipinging WithTIG weld rr) Stetnes roducon Orange, Wald Symls ar Writan Deseiion ‘houidshow te general ananpemettoltheparaobe wel Where ‘poleable, the root spacing nd the deta of wel prove mary be Species (At option of te Mgr. sketches maybe arached to eae ot design wel lyers nd bead sequence gor oth toughoes prooe Gre, or multe process procedures =) “BASE METALS (QW-203) Pike ‘rove Ne. TALLER METALS raW00) Spe ne sre. VR | si Ne Ce) ER F654} nae SF See oie Sy “ewes tange V6 1 Ba PB row eared har ens omer 7 | -_ ade Meck Trt for GUAM, ao Win nt enn was aoe | Ae. vet taveiat | rece | cm | om | roar | nto | nee wy KGraw|restl Yc" Desp} Gon7g) (22. nile lm Bla 70-80 20-24 ” | . i “ TY Ma | las Gu zeal Lu i 4 38 (Bock 4 becle Jwae 2001 SECTION 1X (QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (POR) (See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon, CXNB Sch 4O ake. : 32 Mave soe, fd tO Cre Pr te inlay} one. —-2.20°F 0K 39 (Beck +0 Bawle )Ie rr NONMANDATORY APPENDIX B cay Lomo + by Agen = 0S (0W-483 (Back) ABe/ pag, ja ‘Teraile Test (W-150) LoL Tae Tana Treat Fourtere | nag ator Thommen el son oo Woh ras worse Malsanishi WT=0 Secon Wty Imevtements at secvon Kotte ASME Coats oe a “ C. — on __ 44-10-2001 __ Eyer Fist ae cea eh mee 40 (Back to Back J 4cee eren verre ores (IKOaG Map) START at font side of POR. Are P.F,A Nos Ok? ‘Are Preheat and PWHT as, ‘er const. Codes? I "Are the results for tensile, and bend test stated No _| Toughness st only when | (QW 140) [ inpeeieing regi | T | Lo _[ Forteasie testare ay of ' Specimen, are andunit | (QW — 451.1) | sess calculation right, | [rs No Trial of fare aed | Yes | Nef Ts unit stress > | | [ Ts oFbase meta} (2-159) | Ye | ve T af ee Tsthe WPS supponedby] | | np feats) unt sess] POR. Does WPS show | No, Seonnconrral | (QW = 133 reference No.of the fie cemiees supporting POR | 7 {E| ys. 1 . {Is bend test Qty, t ee Has POR been revised “2 [xe mail No Tithe result stated & OK ] (QW~ 163) Ts POR signed and dated J vai ve ‘re esl for toughness . (neni | er etaite |

a a N Contents . Examination Scheme Distribution of Marks Salient Features of the Examination How to Prepare for the Examination . API 570 — Chapter wise Tips for Maximizing the Score . Time Management During the Examination . Test Taking Tips 46Cintegratediii 1, EXAMINATION SCHEME As per the present scheme, API 570 examination is one- day, 8-hour, 2 session examination, comprising of pre- lunch session (4 hours) for “open-book” examination and postlunch session (4 hours) for “closed-book" examination. There are a total of 150 questions carrying 1 mark each (tofal of 150 marks}, split into open-book (approximately 50 questions) and closed-book (approximately 100 questions). The distribution of 50 and 100 questions respectively for open-book and _closed-book examinations is approximate; however the total is always 150 questions. Each question is multiple-choice question with given 4 possible choices. Only one is the comect choice. The candidate has to pick-up the correct choice, and indicate the same on separate answer sheet. The answer sheet along with the question paper should be returned back to the Supervisor. The correct answer is to be indicated by blackening (filing) the relevant circle by a pencil. There is no set passing percentage. However a score of about 95 to 105 out of 150 is a good estimate of passing score. Please note the following: Fill only one circle out of four given Fill the circle fully and completely. Half or less than half blackened circle area is not reckoned for answer. Never indicate the answers by ticking (¥) the circles. There is no negative marking. 47“Clategrated renin During the “open-book" session, you are permitted to refer to the codes and other documents as per “Effectivity Sheets". Code pages may be tabbed, highlightened, underlined or notes in margin of the pages are accepted. Additional new pages to codes are not accepted. Always carry the following to the exam hall. * 2Nos. B or 2B pencils and eraser * Non-programmable calculator * Photo identity (passport, driving license, etc.) * Exam confirmation letter Be present in the exam hall at least 15 minutes prior to scheduled start of exam. The supervisor announces important instructions during this period. Do not miss them. Now relax and attempt the exam calmly. Time is always more than enough. Good luck, friends! 48Cintegratectirainins 2. DISTRIBUTION OF MARKS As per the Effectivity Sheet for December 3, 2003 exam, there are total 7 codes prescribed for examination. However, all of them are not equally important and do not therefore require equal emphasis. About 45 percent questions are asked from one code API 570 which is hardly 20 pages, while all other 6 codes contribute 55% marks which are more than 1,500 pages. Following distribution scheme will help the participant to decide how much time he should spend for each document during preparation. 1 | ‘Approx. ] | Approx. | S.N. Code Questions Out of | | | Weightage (in %) | Total 150 | T | API570 40-42 00-63 } | — 2 | ASMEB313 20-22 30-33 i . 3 | ASME Sec. ik 1213 1819 4 | ASME Sec. V 12-13 ie19 ] 5 | APIRP 574 45 58 | EE EE ee 6 | APIRP 578 3 45 | 7 | ASMEBI6.5 2 “3s 8 General Knowledge 2 49Cintegrated liainin: 3. SALIENT FEATURES OF THE EXAMINATION As stated earlier, the examination comprises of open book and closed book parts. The closed-book examination includes such questions which the inspector is normally expected to know without referring the Codes, i.e., the questions are “awareness level” questions. Whenever you find a very definitive or quantitative statement in body of the Code, a closed book question may be expected on it. Thus, the basic requirements of a code, specific "DO" and “DON'T” statements, important quantified — statements, important definitions and well-known inspection principles wil constitute such questions. Where the student is required to refer to the diagrams or formulas or tables or graphs and curves from the Codes, it will always be an “open-book" question. All calculation oriented questions will normally be “open-book" type. The Code information which is not short and crisp, (i.e.. large paragraphs, several descriptive statements clubbed together) will normally be asked in “open-book” part. Here the participant is expected t to remember the information but should know where to find in the body of the Code. 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. To answer open-book questions, one only needs to know where to find the answer in the code and therefore tabbing of Code pages, highlighting the paragraphs or additional explanatory notes in page margins is useful for saving time. Closed-book part of the exam (100 marks) can be finished in hardly 2 to 2 % hour though 4 hours are allotted. While “open-book" part (50 marks) takes a little longer and may require all the 4 hours that are allotted. 50Kintegratedivai 4. HOWTO PREPARE FOR EXAM: A) If your aim is only to get “certified” only, i.e., to obtain just around 110-115 marks, then, 1) Detailed study of documents nos. 1 to 4 above (Ref. The weightage list given above.) may be adequate. 2) Additionally, one should try to remember all the “Points to Recall" and review the mock examinations attempted during the Preparatory Course. If Wo or more participants from same 6rganization are appearing for exam, then joint discussions and ‘éne putting question to another and vice versa has been found very effective during preparation. 3} Other 3 codes (ie., Sefial No. 5 to 7) may be studied in detail if there is additional preparation time available. An overall “awareness” level knowledge of these 3 Codes may be okay. These contribute only 10% weightage. Still, the Open book Questions from these can always be found out and answered plus the points to recall can help to answer other questions. 8) If your objective is to get certified and also to obtain a good score, (say 135+) then, In addition to preparation as per 1&2 above, It is worthwhile to. study the 3 Codes also. (Serial No. 5 to 7). However, please remember that study of API 570 has to be "thorough" and total, while study of ASME Sec. V, ASME Sec. IX and ASME B31.1 and 16.5 should be such that it can cover the topics mentioned in the "Body of Knowledge”. The last 3 Codes should be read at least once and note the important points. A very “thorough” study of these documents 51Clotegratedirsinin: however will not result in “gains” commensurate with the efforts put in. If you are about a month away from examination, read all the Codes at least once and concentrate on highlighted text in the Codes and also try to solve the question bank. If you are about two weeks away from the exam, concentrate on highlighted text as well as the mock examinations conducted during the course. In the last week of preparation, focus on Points to Recall and highlighted text. 52Cntegrated trainin: 5. API 570 CHAPTERWISE TIPS FOR MAXIMIZING THE SCORE From Chapter 1, just note the scope, application and exclusions. Chap. 2 lists only the reference documents. There are only 8 or 10 important definitions out of total 55 from Chapter 3 of API 570. Normally 3 to 4 definitions are asked in closed-book exam. From Chapter 4, usually 2 or 3 questions are asked. Concentrate on responsibilities clause. Also see App. B for Certification requirements. From Chapter 5, about 15-18 questions are asked. About 10-12 in closed book and 4-6 in open book. Para 5.2 to 5.6, average of 1 or 2 questions are asked while on para 5.7, about 6 to 8 questions ( both open & close book) are asked. From Chapter 6, about 15-18 questions are asked. Particularly pay attention to Inspection intervals, which attracts at least 5 to 6 questions and they could be either open book or closed book. From Chapter 7 also 15-18 questions are asked. This is only four page chapter and almost all paras should be studied thoroughly. 53Cintegmtedivainin: There may be 2 or 3 questions on overall API- 570 code for the purpose of assessing the overall under standing of code. Chapter 8 as well as App. E are excluded from examination, As regards ASME Sec. V and IX, the course content is categorised in 10 categories. 8 of them are listed under calculations while 9 and 10 are listed under welding and NDT . You may expect at least one open book and one closed book question on each of these. Additionally, under the category intemal pressure, you may expect 4 open book questions one each for thickness calculation for the 4 types of end closures. 54Cintegratediivinins 6. TIME MANAGEMENT DURING EXAM: Both “open” and “closed” book sessions are 4 hours each This means about 25 to 28 questions per hour for closed book and 12 to 15 questions per hour for open book. For proper time management following are useful suggestions. ) You may start from Question No. 1 and proceed. If after 1 hour you feel that you are maintaining the required progress as mentioned above proceed serially. b) If, however, you are behind the required rate, start jumping the questions, i.e., start attempting those questions you can answer, deleting whose answer you do not know. Proceed like this till the end. Do not leave any question unanswered whose answer you know. cc) Then come back to “deleted” questions and attempt them using your “feel” factor. Go on like this till say last 10-15 minutes are remaining. d) If there are still some questions where you have no clue at alll just mark the answer at random in last 10-15 minutes. This may give you few chance marks. Do not leave any question unattempted. e) After completion of writing exam, 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. 55Cintegratediisinins 7. TEST TAKING TIPS * Don't read too much into a question. Do not get too elaborate and ruin your answer. * If two choices are very similar, the answer is probably not either of them. * If two choices are opposite, one of them is probably correct. * Don't go against your first impulse unless you are very sure you were wrong. * Check for negatives and other words that can throw you off. « The answer is usually wrong if it contains “all,” “always,” “never,” or “none.” « The answer has a great chance of being right if it has “sometimes,” probably" or “some.” * When you don't know the answer, look for the wrong ones. * If you are supposed to read a long passage and then answer questions about it, read the question first. That will tell you what you are looking for and affect the way you read the passage. * Be suspicious of choices that seem obvious. * Don't give up on a question that, after one reading, seems complicated. Looking at it from a different angle. restating it in your own words, drawing a picture, or breaking it down, etc., may help you realize that it's not as hard as you thought.PIPING MATERIALS ‘SPEC NOM. COMP. ROPERTIES | REMARKS | —_ SS soars | |-Maybede- | A53GrA | 0.25% C (max) 48,000 | 30,000 | oxidised -Seamless or GrB | 0.3%C (max) 60,000 | 35,000 | ERW Temp up to (Plain c) 300°C A106 Gr.A | 0.25%C(max),0.1%Si(min) | 48,000 } 30,000 | Seamless conly(No ERW) Gr.B | 0.3%C(max),0.1%Si(min) | 60,000 | 38,000 | Killed. Gr.C | 0.35%C(max)0.1%Si(min) | 70,000 | 40,000 (C-Si Steel) \ -Temp. up to a APIBL GrA | 0.25% 48,000 | 30,000 | -Line pipes Gr.B | 0.3% 60,000 | 35,000 (Plain C) i A335 | P11 | 4.25 Cr-0.5 Mo 60000 | 30000 | High Temp. Up to 650°C P22 | 2.25 Cr-1 Mo 60000 | 30000 (Cr-Mo St. | A333 Grit [0.3C-1 Mn 55000 | 30000 | Up to -88 deg c | Gr3 |3.5%Ni | 60000 | 36000 | Up to -100 degc Gr8 | 9%Ni 100000 |s000 | Up to -195 degcTENSILE STRENGTH (N/mm) «HARDNESS, io DEPENDANCE GF EGNIBERIN G PROPERTIES ON SACARDON, 58)) Hitachi Zosen Printed [Avra 1979 As ppearent from thie figure, in order to increase toughness of carbon steel, thé inclease of tin/C 300 (kgf-m) Absorbed Energy , 2vEo ig 30 7 IZ |By Fukuhoro et. 0 | T.S, : 50~58kgf/rrr2(490-568 oe | | |_MPo) A: ASTM AS5I5 Gr.70 B! ASTM ASI6 Gr.60 C: ASTM AS5I6Gr.70 20 : | + 15 -——_ t | 10-——— { t 7 [ k } | 5,-———-« 7 a hg | t | | | ° . . tJ ° 5. !0 Mn/c tio is effectiv — | Effect of Mn/C on absorbed energy of Carbon steels 2) . _ HITACHI SHIPBUILDING & ENGHIEERING CO, (70 59FHKE ce FECT OF ALLOYING ELEMENTS ON THE PROPERTIES OF STEEL — Wechanical propert~r T Ty tt Tel ¢ 2 2 2 g toying A iz] ¢ t 3 z 3| = 3 fs A ‘eleraent g Es) 2 i 23 a ! e 3 a Hg g Suen tptinpiy- tpofupi fe adalat Manganese mperit steele Ty -1=f- tt d- ~{uyt fit ]= Manganese inavsien steels mls}? huf-|-[-[-[e]-[- palma = oi magnetic Chromiam We pape pet ep papa ee ar it TH 3 | Nicketin pein stecis trl feel ee ee Wat Wicket in austeni steels wha [a farfar fry = pan fa [= [= ffi] = [at | rotmaonese ‘Rison =e eT THe ee a inf - uli Tungsten Ta T= {afin ra = init : i Uy afer (=f a ft cs tip ya a= = in = = T fifi | cisodenum Taye = fe ra a a 1 Seppe tital-{-{-{- ={= [T= = Sulohwe -|-J- ia -f- =[-fiatin[=Tr Phosphorous Tre fin = f= |e r= -]- Te increase Te Reduction __~= constara ~ not characievatic orwitnown Several arrows = marelntensve effect Bo 0919 THE EFFECT. OF ALLO.WNG ELEMENTS IN STEEL (CONTO.) SOLID SOLUBILITY INFLUENCE INFLUENCE EXERTED THROUGH ELEMENT mruuence Spon Etnawe in in UPON AUSTENITE PRINCIPAL FUNCTION OF SYMBOL Geuma Fe Alpha Fe FERRITE {HAROEN- Carbide forming Action during ELEMENT ABT) Tendency Tempering actions 3% in a75% Pee Strong. Grester Opposes 1, Ralees coarsening Mo 0.05% C (less with ing effect in herdenability than Cr. softening by temperature of austenite, steels 8%) lowered mgnMore wont Seltpinna paleo temp hardening avdening 3, Raises hot and creep strength, rad hardness, 4. Enhances corrosion resis- tance in stainless steels. 5. Forms abrasion resistant partes, Suhel Unlimited = 10%indepen- Strengthens Increases Grephiices —_Verylitlein 1. Strengthens unquenched NE dentofC & toughens hardenability less than Fe. ‘small per- or annealed steels. content bysola Signy austenite Ecntages, 2 Toughens pearlitic ferttc Seition retention wth Hecke leapectlly st low Foher carbon temperatures) 3. Renders high Cr/Fe alloys tustenite, Tungsten, 6% (in 33% (less Age-harden. Increases Strong Opposes soften. 1%. Forms hard, abrasion w Ae lowered ‘ing system in hardenability ing by secondary resistant particles in tool steels 11%) temperetures) high Wife Stonglyin sna hardening Steels, high speed steels, Aoys. queries " 2. Promotes redhardness Snanot strength Vanadium 1.0% + Unlimited Hardens Increases Very strong Maximum 1. Promotes fine grain, ‘ v (in 0.2% ¢ moderately hardenability ry eree foreecondary - elevatescosrsening steels 2%) inset very strongly hardening. temperature of austenite solution ss olssolved 2. Increases hardenabiity when dissolved, 3. Resists tempering and causes marked secondary hardening79 MOLYBDENUM Molybdenum, when added to chromium-nicke! austenitic’ steels, improves resistance to pitting corrosion especially by chlorides and sulphur chemicals. When added to low alloy stwels, molybdenum improves high temperature strength and hot hardness. When added to chromium steels it greatly diminishes the tendency of steels to embrittle in service or in heat treatment. Also see Pitting Resistance Equivalent PITTING RESISTANCE EQUIVALENT The specific benefits of Chromium, Molybdenum and, more recently, Nitrogen in conferring resistance to pitting in corrosive environments has been recognised its various formulae. The most common of these is the PRE(N) which includes Nitrogen and is PREIN) = %Cr + (3.3 x 9Mo) + (16 x %6N) 13.62. Like nickel, Vanadium is a very important grain refiner in steels and as little as 0.1", is effective in restricting grain growth during normal hardening, processes. Vanadium is present in the microstructure as finely dispersed carbides and nitrides and since these do not dissolve at normal heat-treatment (emperatures, their presence acts as a burrier to grain growth. [f the steel is over -heated so that the particles of carbide and nitride go into solution, then grain growth immediately takes place rapidly.€9 MATERIAL SELECTION CHART - ( CS, AS, SS ) (BASE ) ON SERVICE TEMPERATURE) TEMPERATURE TEMPERATURE SUITASLE MATERIAL TYF{CAL ASTM SPEC. RANGE SCALE 250°C (-428-F) ~~ : CRYOGENIC SS 300 SERIES A 240 TYPE 304, 3041, 347 HIGH Ni STEEL (Ni A353 — + 100% (-150.F) Low- Temp A203 GrATOD A (Ni UP TO 3 1/2%) A350 LF1, LF3 t- 45°C (50 -F) -- ee PLAIN “G” STEEL (FG) A516 Gr 60/70 0". (32 F) = - MODERATE | AIN“C” A285 GrATOC INTERMEDIATE (CUP TO 0.28%) A515 Gr 60/70 A . A516 Gr 60/70 40d c(778F) ~~ ELEVATED Cr-Mo STL (Cr UP TO 8%, MoUP — A387Gr 1 TO 22 ° . TO 1%) A182 F1 TO F22 —-600".C (1100 F) HIGH TEMP SS 300 SERIES, A240 TYPE 304, 316, 347 e ° PLAIN/ H GRADES A182 Gr 304H, 316H, 347H +800" 0 (1500. FF) ~~--~-~-= == -+-- 22-2 -- === 2 VERY HIGH F162 Ge 3044, 31041, Sau ABOVE 808 C == (1690" F) TYPE 310 , INCOLOY HASTELOY NB : MATERIAL SELECTION FOR NON CORROSIVE SERVICEOBJECTIVES OF API - 570 CERTIFICATION To provide accreditation to inspectors who: Possess adequate level of specialised knowledge and skill to draw up and execute quality systems and inspection programs, e Soas to provide high level of integrity, and « Improve management control for safe operation of the Piping Systems. ¢ The rules given in this standard are minimum requirements. . Each edition, revision, or addenda to this API standard may be used beginning with the date of issuance 2. Each edition, revision, or addendum to this API standard becomes effective six months after the date of issuance 3. If any federal, state, or municipal regulation which may conflict with API standard then the regulations shall prevail over API standard. 64API570 EXAMINATION DETAILS The examination is in an all multiple choice format and currently consists of two parts — Open Book & Closed Book: 1. EXAM FORMAT — The format for the API 570 exam is 150 multiple choice questions. Each question has four possible answers with only one correct answer. 2. OPEN BOOK - 40 TO 50 QUESTIONS: ASME/API pipe evaluation calculations, ASME Section IX WPS & PQR review and general questions covering any other areas listed in the API 570 "Body of Knowledge". You will be allowed to use all the codes and standards referenced during the open book portion of the exam. 3. CLOSED BOOK — 100 TO 110 QUESTIONS: This part will consist of general questions covering all the codes and standards required. Memory will be very important on this portion of the exam.wo API Examination Information Questions for the examination will be multiple choice with an open and closed book sections. Total approx. 150 Questions. Total length of examination is 8 hours. Four hours open book (approx. 40-50 questions) and 4 hours closed book (approx. 100-110 questions). The multiple choice questions will be having 4 choices, and only one correct option. lf you pass the examination, and all sections of your application are complete, you will be certified and receive a wallet card and certificate approximately 3 months after the examination date. Test results will be mailed to you approximately 8 weeks after you have taken the exam. 66What to Bring to the Exam No. 2 pencils; A non-programmable calculator (a calculator with only simple functions); The applicable API and ASME _ reference publications. Highlighting, underlining, page tabs, and notes written in margins of the code books are acceptable. Loose pages inserted in the code books are not acceptable. Your test site confirmation letter A picture ID (i.e. driver's license). 67Fluid Service Categories Category D Service | Category M Service High Pressure (K) | Service by the Code and includes piping not classified within the other fluid services listed below Service in which the fluid is nonflammable, nontoxic, and not damaging to human tissue; the design pressure does not exceed 150 psig (1030 kPag); and the design temperature is from -20°F (-29°C) TO 366°F (186°C) Service in which a_ single exposure to a very small quantity of toxic fluid can produce serious irreversible harm on breathing or body contact, even when prompt restorative measures are taken \Service which applies when designated by the owner, typically for pressures in excess of that allowed by ASME B16.5 Class 2500 rating, for the specified design temperature and material group 68Levels of Generic Classification of Materials Simple Intermediate Complex Carbon Low Carbon Steel | Fully Killed, © Low Steel | Carbon Steel Low Alloy |Cr-Mo Steel 2% Cr-1Mo Steel \ Steel j Stainless | Austenitic |300 Series Austenitic } Steel Stainless Steel Stainless Steel Nickel High Nickel Alloy | NiCrMo Alloy Alloy Common ASTM Carbon Steel Piping Material Specifications and Grades ASTM Materials without Impact Tests ASTM Materials with Impact Tests A53Gr.B A106 Gr.B A 333 Gr. 1 A333 Gr. 6 &} A105 A 350 Gr. |LF2 A 234 Gr. WPB A 420 WPL6 69WELD JOINT QUALITY FACTOR, E, BASIC QUALITY FACTORS. The weld joint quality factors E; tabulated in Table A- 1B are basic factors for straight or spiral longitudinal welded joints for pressure-containing components as shown in Table 302.3.4 INCREASED QUALITY FACTORS. Table 302.3.4 also indicates higher joint quality factors which may be substituted for those in Table A-1B for certain kinds of welds if additional examination is performed beyond that required by the product specification. 70PRESSURE DESIGN OF COMPONENTS : Straight Pipe (330.1.1) The required thickness of pipe shall be : tm=tte The minimum thickness T for the pipe considering manufacturer's minus tolerance, shall be tn... The following nomenciature is used in the equations for pressure design of straight pipe. tm = minimum required thickness, including, corrosion, erosion & mech allowances. t = pressure design thickness. c = the sum of the thickness allowances. T = __ pipe wall thickness as ordered. d = __ inside diameter of pipe. = __ internal design gage pressure. D = __ outside diameter of pipe 71E = quality factor from Table A-1A or A-1B S = __ stress value of materials. Y = coefficient from Table 304.1.1, valid for t < D/6 and for materials shown. For t> D/6, d+2c You — D+d+2c Straight Pipe Under internal Pressure : For t < D/6, the internal pressure design thickness for straight pipe shall be not less than : PD t Se 2(SE + PY) Following Equation may be used instead of above equation 72For t> D/6, or for P/SE > 0.385, calculation of pressure design thickness for straight pipe requires special consideration.. Blanks (304.5.3) The minimum required thickness of a permanent blank (representative configurations shown in Fig. 304.5.3) shall be calculated in accordance with Eq. (15) tm = where- dg = _ inside diameter of gasket for raised or flat face flanges, E = same as defined earlier. P = design gage pressure S = same as defined earlier c = sum of allowances defined earlier. 73BUTT-WELDED FITTINGS Welded fittings are used primarily in systems meant to be permanent. Advantages of butt welded systems are the following : 1. Smooth inner surface,.offer gradual direction change with minimum turbulence. 2. They require much less space for constructing and hanging the pipe system. They form leak-proof constructions. They are almost maintenance free. They have a higher temperature and pressure limit. They form a self-contained system. They are easy to insulate They offer a uniform wall thickness through- out the system. One of the major disadvantages of butt-welded systems is that are not easy to dismantle. 74SOCKET WELDED FITTINGS Socket welded fittings have certain advantages over butt-welded fittings. They are easier to use on small-size pipelines and the ends of the pipes need not be beveled.The advantages of the socket-welded system are : 1. The pipe does not need to be beveled. 2. No tack welding is necessary for alignment since joint and the pipe are self -aligning. 3. Weld material can not extend into the pipeline. 4. It can be used in place of threaded fittings, therefore, reducing the likelihood of leaks, which usually accompany the use of threaded fittings. One of the major disadvantages of this type of fitting is the possibility of a mismatch inside the fitting where improperly aligned or mated parts may create a recess where corrosion could start. 75FLANGED FITTINGS Flanged connections are most common on piping that are a minimum of 2 in.(5.08 cm ) in diameter. e . An assortment of facings, raised, flat, ring joint grooves, etc.are available in flange variations. * One advantage of flanged systems is that they are easily dismantled and assembled. « One of the disadvantages is that they are considerably expensive than an equally rated butt-welded system, « Flanged fittings occupy far more space than the butt-welded or screwed equivalents. e Because of this higher weight load, a flanged system becomes far more expensive to support or hang from the existing structure. 76Wall thk.of flanged fittings(B 16.5 Par- 6.1) For inspection purposes the minimum wall thickness tn of flanged fittings at the time of manufacture shall be as shown in Tables 10, 13, 16, 19, 22, 25 and 28, except as provided in para 6.1.1. See Annex D for the basis used to establish values of tn. .Par-6.1.1Local areas having less than minimum wall thickness will be acceptable provided that : a. the area of subminimum thickness can be enclosed by a circle whose diameter is no greater than 0.35v dtm where d is the inside diameterof fitting and tm is the minimum wall thickness as shown in the tables listed in para 6.1; and b. measured thickness is not less than 0.75 tm; and c. enclosure circles are separated each other by an edge-to-edge distance of more than 1.75v dtm, 77System Hydrostatic Test for flanges. Flanged joints and flanged fittings may be subjected to system hydrostatic tests at a pressure not to exceed 1.5 times the 100°F rating rounded off to the next higher 25 psi. 80MINIMUM THICKNESS OF FLANGE FACE e . Classes 150 and 300 fittings and companion flanges are furnished with a 0.06 in. raised face which is included in the minimum flange thickness C. * Classes 400, 600, 900, 1500 and 2500 fittings and flanges are furnished with 0.25 in. raised face which is additional to the minimum flange thickness C. e Any other facing than the above, when required for any class, shall be furnished as follows.: 1. No metal shall be cut from the minimum flange thickness specified herein. 2. In the case of the 0.25 in. raised face, tongue or male face (other than 0.06 in. raised face for Classes 150 and 300), the minimum flange thickness C shall be first provided and then the raised face, tongue or male face shall be added thereto by providing additional material. 78FLANGE FACINGS Either a serrated concentric or spiral finish having a surface finish from 125 u in. To 250 u in. average roughness shall be furnished. The cutting tool employed should have an approx. 0.06 in. radius, and there should be 45 grooves/in. through 55 grooves/in. Flange Facing Finish Imperfections « Imperfections in the flange facing finish shall not exceed the dimensions shown in Table 3. « Adjacent imperfections shall be separated by at least four times the maximum radial projection. A radial projection shall be measured by the difference between an outer radius and an inner radius encompassing the imperfection where the radii are struck from the centerline of the bore. « Imperfections less than half the depth of the serrations shall not be considered cause for rejection. Protrusions above the serrations are not permitted. 79SPECIFIC APPLICATIONS Included Fluid Services: API 570 applies to piping systems for process fluids, hydrocarbons, and similar flammable or toxic fluid services, such as the following. a. Raw, intermediate, and finished petroleum products. b. Raw _ intermediate, and finished chemical products. Catalyst lines. Hydrogen, natural gas, fuel gas, and flare systems. e. Sour water and hazardous waste streams above threshold limits, as defined by jurisdictional regulations. f. Hazardous chemicals above threshold limits, as defined by jurisdictional regulations. 81AUTHORIZED INSPECTION AGENCY: Defined as any of the following. : a. The inspection organization of the jurisdiction in which the. piping system is used. b. The inspection organization of insurance company licensed to write insurance for piping systems. c. An owner or user of piping systems who maintains an inspection organization for activities relating only to his installation and not intended for sale or resale. d. An independent inspection organization employed / contracted by owner or user for activities relating only to his installation and not intended for sale or resale. e. An independent inspection organization licensed or recognized by the jurisdiction in which the piping system is used. AUTHORIZED PIPING INSPECTOR: An employee of an authorized inspection agency who is qualified and certified to perform the functions specified in API 570. A nondestructive (NDE) examiner is not required to be an authorized piping inspector. Whenever the term inspector is used in API 570, it refers to an authorized piping inspector.PIPING ENGINEER The piping engineer is responsible to the owner/user for activities involving design, engineering review, analysis, or evaluation of piping systems covered by API 570. REPAIR ORGANIZATION The repair organization shall be responsible to the owner/user and shall provide the materials, equipment, quality control, and workmanship necessary to maintain and repair the piping systems in accordance with the requirements of API 570. AUTHORIZED PIPING INSPECTOR: When inspections, repairs, or alterations are being conducted on piping systems, an API authorized piping inspector shall be responsible to the owner/user for determining that the requirements of API 570 on inspection, examination, and testing are met, and shall be directly involved in the inspection activities. 83RISK BASED INSPECTION (RBI) RBI is identifying and evaluating potential degradation consequence of which may be a risk of creation of unsafe conditions (for plant, process, people ) and / or likely failure of component. RBI involves following essential elements : . Expected type of degradation ie. type of degradation process as well as environmental factors may cause. Likely areas affected i.e. identifying the most prone areas and possible locations to look for the type of degradation. Measurement of degradation i.e. quantifying the amount of degradation. Assessment and evaluation i.e. analysis of degradation and likely consequences. Above all effectiveness of inspection practices, tools techniques employed have a great bearing of success of RBI program. 84INSPECTION FOR SPECIFIC TYPES OF CORROSION AND CRACKING Each owner/ user should provide specific attention to the need for inspection of piping system that are susceptible to the following specific types & areas of deterioration: Injection points. Deadlegs. Corrosion under insulation ( CUI ). Soil-to-air (S/A ) interfaces. Services specific & localized corrosion. Erosion &c orrosion/erosion. Environmental cracking. Fenmoaoso Corrosion beneath linings & deposits. Fatigue cracking . Creep cracking. k. — Brittle fracture. I Freeze damage. 852 API570 (Qvernead vapor tna 12" medmum, whichever is ‘*Typicat neinees measurement ‘ccatons (TMs) witanifecton pant crete Figure 5-1—Typicalnjacion Point Piping Circuit ‘pore appropriate to extend this circuit to the next piece of pressure equipment, as shown in Figure 51. ‘The selection of thickness measurement locations (TMLs) ‘within injection point circuits subject to localized currorion should be in accordance withthe folowing guidelines: a. Establish TMLs on appropriate fittings within the injection point circuit. b. Establish TMLs on the pipe wall at the location of expected pipe wall impingement of injected fd. ‘¢. TMLs at intermediate locations along the longer straight Piping within te injection point circuit may be required. dd. Establish TMLs at both tbe upstream and downstream lim its of the injection point cenit. “The prefered methods of inepecting injection paints ae radiography and/or ultnsonics, as eppropite, to establish the minimum thickness at each TML, Close grid ultrasonic measurements or scanning may be wed, as long as tempert- tures are appropriate. ‘For some spplicadoas, itis beneficial to remove piping spools to faclitwe a visual ingpecton of the inside surface. However, thickness measuremeats will sil be required to determine the remaining thickness, During periodic scheduled inspections, more extensive {inspection should be applied to an area beginning 12 inches (200 mm) upstream of the injection nozze and continuing for atleast ten pipe diameter downstream of the injection point Additionally, measure wod record tbe thickness at all TMLs Within tbe injection point circuit. 53.2 Deadiegs ‘The corrosion re in deadlegs can vary significantly from Adjacent active piping. The inspector should monitor wall thickness on selected deadlegs, incinding both the smgnant 86