PELATIHAN

INSPEKTUR BEJANA TEKAN

November – 2019

API 510

Rev. 7 – Aug 2019

Purwidiatmo
OVERVIEW OF API 510
 OVERVIEW OF API 510

Pressure Vessel Inspection Code :

• In-service Inspection,
• Rating,
Purwidiatmo

• Repair,
• Alteration

TENTH EDITION, MAY 2014/2017 Add.

 OVERVIEW OF API 510
• 1931  Created Joint API/ASME Committee on Unfired PV
• 1934  1st edition API/ASME Code for Unfired PV approved
for publication
• 1956  API/ASME Code discontinued
(demand arose – need to have uniform maintenance
Purwidiatmo

and inspection practices)

• 1958  1st publication of API 510
• Each edition may be used at the date of issuance
• Becomes effective 6 months after the date of issuance
• During the 6-months (date of issuance – eff. Date)  the user
shall specify which edition, revision or addenda will be used
• API standards are review & revised at least every 5 years
 OVERVIEW OF API 510
Addendum 2017
Purwidiatmo
 CONTENTS
1. Scope
2. References
3. Definitions
OVERVIEW OF API 510

4. Owner-User Inspection Organization

5. Inspection, Examination and Press. Test Practices
6. Interval / Frequency and Extent of Inspection
7. Inspection Data Evaluation, Analysis and Recording
8. Repairs, Alterations, and Rerating of Press. Vessel
9. Alternative Rules for E&P Press. Vessel
Appendix : A ~ E
OVERVIEW OF API 510
1. SCOPE

• GENERAL APPLICATION

• SPECIFIC APPLICATIONS

• RECOGNIZED TECHNICAL CONCEPT

 1. SCOPE
GENERAL APPLICATION
COVERAGE :
 In-service inspection, Repair, Alteration, Re-rating activities
OVERVIEW OF API 510

for PV and PRD

 Hydrocarbon and chemical process PV that have been
placed in service (existing)
 Also applies to PV constructed to:
• An applicable construction code (ASME Code),
• Without a construction code (non-code vessel)
• Approved as jurisdictional special based upon jurisdiction
acceptance of particular design, fabrication, inspection, testing
and installation.
• Non-standard Vessels – Recognized code, but lost name plate
or stamping
Most technical requirement of ASME Code can be applied ( if conflict –
API 510 mandatory)
 1. SCOPE
GENERAL APPLICATION
INTENT :
 Application of this code is restricted to owner/user that
employ or have access to the following technically qualified :
OVERVIEW OF API 510

• An authorized inspection agency,

• A repair organization,
• An engineer,
• An Inspector,
• Examiners

 Inspector shall be certified  see annex B.

 To specify the in-service & condition-monitoring, to determine the

integrity of PV & PRD. Owner/user shall respond to any require
corrective action, to assure the continued safe operation of PV &
PRD

 Limitations : No conflict with regulatory requirements. If the code is

stringent, than the code is govern.
 1. SCOPE
SPECIFIC APPLICATIONS
 PV used for E&P (drilling, transporting, lease processing, treating: liquid, gas, etc)
• Alternative rules – section 9
OVERVIEW OF API 510

 Excluded & Optional

• PV on moveable structure ( see annex A)
• Containers exempted from applicable constr. Code ( see App. A)
• PV that do not exceed the volumes and pressures ( see App. A)
- 5 cu ft in volume and 250 psi design pressure
- 3 cu ft in volume and 350 psi design pressure
- 1.5 cu ft in volume and 600 psi design pressure
 1. SCOPE
RECOGNIZED TECHNICAL CONCEPTS
• Fitness-for-service (FFS) Concept for evaluating in-service damage
API 579-1 / ASME FFS-1
RBI Concept  determining the inspection intervals  API 580
OVERVIEW OF API 510

•
 3. DEFINITIONS
AUTHORIZED PV INSPECTOR (Inspector)
An Employee of an authorized inspection agency who is qualified and
certified to perform inspection under this inspection code, including
OVERVIEW OF API 510

annex B

ALTERATION
Physical change in any component that has design implications that
affect the pressure-containing capacity of PV beyond its existing data
reports.
Not considered alteration :
• Duplicate replacement
• Addition of any reinforced nozzles less than or equal to the
existing size
• Additional nozzles not requiring reinforcement
 3. DEFINITIONS
REPAIR
Restore a vessel to a condition for safe operation at the design
conditions
Any restorative work results  change the MDMT or MAWP, the
OVERVIEW OF API 510

work considered an Alteration & rerating requirements shall be

satisfied.

RERATING
• A change in either the des temp. rating, MDMT or MAWP (may be
increased or decreased)
• Derating below original design  permissible way to provide
additional CA
 3. DEFINITIONS

PRESSURE VESSEL
A container designed to withstand internal or external
pressure, may be imposed external source, application of
OVERVIEW OF API 510

heat or combination of them.

Limits : Annex A

MAWP
The maximum gauge pressure permitted at the top of a PV in its
operating position for a designated temperature

See 3.1.44
 3. DEFINITIONS
QUALITY ASSURANCE
All planned, systematic, and preventative actions specified to
determine if materials, equipment or services will meet
specified requirements. (minimum content of QA  4.1.2)
OVERVIEW OF API 510

QUALITY CONTROL
Physical activities to check conformance with specifications
in accordance to QA plan

FITNESS-FOR SERVICE
A methodology whereby flaws and conditions contained
within an equipment item are assessed in order to determine
the integrity of the equipment for continued service.
 4. OWNER-USER INSP. ORGANISATION
OWNER-USER ORGANIZATION RESPONSIBILITIES

 General
• Shall exercise PV & PRD insp program, frequencies & maintenance,
• Responsible for the function of an AI
OVERVIEW OF API 510

• Control activities of rerating, alteration & engineering assessment.

 Systems & Procedure

• Developing
• Documenting QA Insp. Manual To meet the
• Implementing a ~ t (20 items) reqmn’t of 510
• Executing
• Assessing Insp,
system & proc.
 4. OWNER-USER INSP. ORGANISATION
 Management of Change (MOC)
OWNER-USER ORGANIZATION RESPONSIBILITIES

• to be able to address issues concerning the adequacy of the

pressure equipment design and current condition for the proposed
changes,
• to anticipate changes in corrosion or other types of damage, and
• to update the inspection plan and records to account for those
changes.

 Integrity Operation Windows (IOWs)

To avoid unanticipated impact on pressure equipment integrity.
• should implement and maintain an effective program for creating,
establishing, and monitoring integrity operating windows
• Future inspection plans and intervals have historically been based
on prior measured corrosion rates resulting from past operating
conditions
• modify or create new inspection plans depending upon the
seriousness of the exceedance.
 4. OWNER-USER INSP. ORGANISATION
 ENGINEER
OWNER-USER ORGANIZATION RESPONSIBILITIES

Responsible for Activities involving : Design, engineering review,

analysis, evaluation of PV and PRD
 REPAIR ORGANIZATION
• All repairs and Alterations shall be by qualified repair organization
• Provide : Mat. , equip. , QC, workmanship to code requirements.
(see 3.1.62)
 INSPECTOR
• Assure that API 510 requirements are met.
(Inspection, NDE, repair & testing are met )
 Examiners
• Shall perform NDE according to Job requirements, NDE procedure
& Owner/user specifications
 Other Personnel  see 4.6
 Inspection Organization Audits  see 4.7
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
INSPECTION PLAN
 To be developed by Inspector and/or Engineer (cunsult. w/ Corr.
Specialist – to designate potential damage mechanisms & specific
location where damage mechanisms may occur)
 To be developed from several sources of data (present or potential types
OVERVIEW OF API 510

of damage mechanisms, extent of NDE adequate to identify the damage mechanisms)

 Examinations shall be scheduled at intervals that consider the:
• type of damage;
• rate of damage progression;
• tolerance of the equipment to the type of damage;
• probability of the NDE method to identify the damage;
• maximum intervals as defined in codes and standards;
• extent of previous examination;
• recent operating history, including IOW exceedances;
• MOC records that may impact inspection plans; and
• RBI assessments (where available).
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
 Shall be developed using the most appropriate sources of
information & shall be reviewed and amended as needed
 Minimum Content of an Inspection Plan:
Tasks and schedule required to monitor damage mechanisms and
assure the mechanical integrity of the equipment
INSPECTION PLAN

• define the type(s) of inspection needed (e.g. internal, external);

• identify the next inspection date for each inspection type;
• describe the inspection and NDE techniques;
• describe the extent and locations of inspection and NDE;
• describe the surface cleaning requirements needed for inspection
and examinations;
• describe the requirements of any needed pressure test (e.g. type of
test, test pressure, and duration); and
• describe any previously planned repairs.type
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
 Additional Contents
• describing the types of damage anticipated or experienced in the
equipment,
• defining the location of the damage, and
• defining any special access requirements.
INSPECTION PLAN

RISK BASED INSPECTION (RBI)

 Probability of Failure vs. Consequence of Failure
 Can be used to determine inspection intervals and extent of
future inspection/examinations
 RBI assessment in accordance with API 580
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES

PREPARATION FOR INSPECTION

OVERVIEW OF API 510

General
Follow OSHA - Occupational Safety and Health Administration

Equipment
Use safe equipment - shall comply to Owner/User’s safety requirements

Communication
Inform / notify that people are working inside PV
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Vessel Entry
• Obtain permission to work (work permit) Prior to start the inspection
• Wear required PPE – Personal Protective Equipment
PREPARATION FOR INSPECTION

• Vessel shall be :
Isolated from Other sources (Gas, liquid, vapor, electricity, etc.), Drained,
Purged, Cleaned, Ventilated, Gas tested
• Prior to perform inspections, Inspectors shall familiar with vessel
history and review :
Previous inspection results, prior repair, current inspection plan, Eng.
Calculations

Inspection for Different Types of Damage Mechanisms and

Failure Modes
Pressure vessels are susceptible to various types of damage by several
mechanisms. Inspection techniques for each of the potential damage
mechanisms that exist for each pressure vessel should be part of the inspection
plans. See API 571
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
TYPES OF INSPECTION AND SURVEILLANCE

Internal Inspection
OVERVIEW OF API 510

• Primary goal  to find damage that can not be found by regular monitoring
of external, specific NDE may be required.
• Removal of internal equipment may be needed to provide access of
inspection

On-stream Inspection
• On-stream inspection may substitute internal inspection (see 6.5.2)
• Shall be authorized and approve by the Inspector
• Shall be designed to detect damage mechanism identified in the insp. plan
• May include several NDE techniques to check various types of damage
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
External inspection of Pressure Vessel
• By Inspector or other qualified personnel acceptable to the inspector
TYPES OF INSPECTION AND SURVEILLANCE

• To check the external condition of vessel :

o Insulation, Painting & Coating system
o Supports and associate structures
o Any leakage, vibration, allowance for expansion and general alignment
o Visual insp. for bulging, sagging, out of roundness, distortion, etc.
Any leakage shall be investigated to establish the source  weep hole
/teltale hole on repad should remain open to provide evidence of leakage

More information  API 572

• Buried vessel
Inspection interval for external surface condition shall be based on
corrosion rate information obtained from:
o Maintenance activity on connecting pipe
o Periodic exam. Of similar buried corrosion test coupon material
o Vessel on similar circumstances
o Etc.
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Thickness Inspection
• To verify thickness of vessel components
TYPES OF INSPECTION AND SURVEILLANCE

• To determine the corrosion rate and remaining life of the vessel

• Is primary method of monitoring corrosion rate

CUI (Corrosion Under Insulation) Inspection

• For vessel with operating temp. between :
o 10 0F (-12 0C) and 350 0F (177 0C)  for carbon & low alloy steels
o 140 0F (60 0C) and 350 0F (177 0C)  for austenitic stainless steels
o 280 0F (133 0C) and 350 0F (1770C)  for duplex stainless steels

• Insulation removal
o If insulation in good cond. and no reason to suspect damage, no need to
remove the insulation.
o Alternatively, thickness measurement from inside during internal
inspection.
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Condition Monitoring Locations (CMLs)
• CMLs is designated area where periodic examinations are performed.
TYPES OF INSPECTION AND SURVEILLANCE

• To monitor the presence and rate of damage

• For localized corrosion, examination shall use scanning methods
• To allow repetitive measurement at same locations  CMLs location shall be
permanently recorded (marked on insp. Drawing and/or on equipment - to
improve accuracy of the damage rate)

CML selection
• Type, number and location should consider results from previous inspection
• CMLs should be distributed to provide adequate monitoring coverage of
major components and nozzles.
• A minimum number of CMLs is acceptable if probability and/or consequence
of failure is low and not localized.
• Consult with corrosion specialist for placement and number of CMLs
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Condition Monitoring Methods
• Examination Technique Selection  based on possible type of damage for
TYPES OF INSPECTION AND SURVEILLANCE

each vessel. (inspector should consult with corr. specialist & engineer to
define the type of damage, NDE technique and extent of examination)
• Various NDE techniques and pressure testing may be use to establish the
damage.
• Surface preparation (brushing, blasting, chipping, grinding, etc) shall be
performed prior to NDE.
• Thickness measurement methods
o To determine the minimum thickness of vessel components
o Uniform corrosion is difficult to detect visually, pitted surfaces may be
thinner than it appear visually  UT thickness gauge is commonly used.
o UT scanning are preferred where corrosion is localized.
o Inspector and examiner shall aware of possible measurement accuracy.
(calibration, temperature effect, surface roughness, surface coating, etc.)
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing
• Not part of routine inspection
TYPES OF INSPECTION AND SURVEILLANCE

• After repair  pressure test shall be applied (if Inspector believes it is

necessary)
• Test Pressure
For vessel constructed to ASME VIII div.1
o Test Press = 1.5 MAWP X (S Test temp / S Des. temp)  ASME prior to 99 addm.
o Test Press = 1.3 MAWP X (S Test temp / S Des. temp)  ASME 99 addm & later

• Press Testing alternative

Substituting NDE for press test after a major repair or alteration  only if
Engineer and Inspector approved.

Inspection of in-service welds

• Welds and HAZ are also part of in-service Inspections
• Flanged joints shall be examined for leakage, stains, deposits, or drips and
distortion
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

GENERAL
To determine that the equipment is safe to operate until next scheduled
inspection  All PV & PRD shall be inspected at the intervals by the
code
OVERVIEW OF API 510

INSPECTION DURING INSTALLATION AND SERVICE CHANGE

Vessel Installation
• To verify the vessel is safe for operation
• To provide base line information & obtain thickness reading at
designated CMLs
o Verify the name plate information against MDR
o Verify vessel installed correctly and appurtenances are secured
o Verify the PRD is provided (correct device & set pressure)

Vessel Service Change

• If Service change 
Insp. Intervals shall be established for the new service conditions
• If both ownership & location changed 
Internal & external insp. , Intervals shall be established for the new
service conditions
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

RISK BASED INSPECTION

• RBI assessment may be used to establish appropriate insp. intervals
• Insp. intervals may exceed the intervals specified in 6.4 & 6.5
OVERVIEW OF API 510

• If insp. intervals exceeds 10 year limit, the RBI shall be approved by

the engineer and inspector at 10 year interval.

EXTERNAL INSPECTION
• Unless justified by an RBI, Visual external insp. Is 5 years or
required interval of Internal/on-stream inspection (which ever is less)
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

INTERNAL & ON-STREAM INSPECTION

Inspection Intervals
Unless justified by an RBI,
OVERVIEW OF API 510

• The lesser of ½ remaining life or 10 years

• If remaining life < 4 years → full remaining life up to max. 2 years.
• The intervals is established by inspector or engineer in accordance
with owner’s QA system
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

On-stream Inspection in lieu of Internal Inspection

Internal Inspection may be substituted if: (Discretion of Inspector)
• Size or configuration not permit to enter the vessel
INTERNAL & ON-STREAM INSPECTION

• If internal inspection is possible, but the following conditions are met:

o General Corrosion Rate < 0.005 inch (0.125 mm) / year
o Remaining life > 10 years
o Corrosive character of the contents has been established at least 5 years of
same or similar service
o No questionable condition during external inspection
o Temperature operation < creep-rupture range temperature (400 ~ 540 deg C)
o Vessel is not subject to environment cracking or hydrogen damage
o No non-integral lining

Multi-Zone Vessel
Vessel having two or more zones of differ corr. Rate  to determine the inspection
interval, each zone may be treated independently
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

Pressure Relieving Devices

• Inspection, testing & maintenance  API 576
• Testing & Inspection Interval
OVERVIEW OF API 510

o 5 years for typical process services

o 10 years for clean & noncorrosive services
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

CORROSION RATE DETERMINATION

Existing PV
t initial – t actual
OVERVIEW OF API 510

Corrosion Rate (LT) = ——————————————————

(Long -Term) time between t initial and t actual
t previous – t actual
Corrosion Rate (ST) = ——————————————————
(Short-Term) time between t previous and t actual

t initial = Initial thickness at the same CML (first thick. measured at this CML)
t actual = Actual thick measured during most recent inspection
t previous = Previous thickness measured during prior inspection, it is at the same
location as t actual measured during previous insp.

LT & ST should be compared, Inspector (consult with corr. Specialist) shall

select the corrosion rate that best reflect the current conditions.
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

CORROSION RATE DETERMINATION

Newly installed PV or change in service

OVERVIEW OF API 510

• May be calculated from Data collected by the owner on same or similar

service vessels
• May be estimated from owner experience
• May be estimated from publish data of same or similar vessels
• If items above not available, on-stream determination shall be made after
3 to 6 months of service by using suitable corrosion monitoring devices
or actual thickness measurements.
If later found that above corrosion rate is inaccurate, the corrosion rate
in the remaining life calculation shall be changed to the actual corrosion
rate
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

REMAINING LIFE CALCULATIONS

t actual – t required
Remaining Life (year) = ————————
corrosion rate
OVERVIEW OF API 510

t actual = Actual thick. measured during most recent inspection

t required = required thickness excluding CA & manufacturer tolerances

MAXIMUM ALLOWABLE WORKING PRESSURE DETERMINATION

Used ASME latest edition or construction code PV was built
• Shall not greater than original MAWP
• Thickness used = Ta – 2 x ( corrosion loss before next inspection)
 Ta = actual thick determined by inspection ( See 5.7)
 If Ta greater than thickness reported in MTR or MDR  recheck
 Thickness measurement Procedure shall be approved by Inspector
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

FFS ANALYSIS OF CORRODED REGIONS

Evaluation of Locally Thinned Areas

• Thickness may be averaged over a length (L) not exceeding :
→ L = ½ ID or 20” whichever is less
OVERVIEW OF API 510

- ID < 60”
- ID > 60” → L = ⅓ ID or 40” whichever is less
- If falls on opening → L = limit of reinforcement

Along the designated length, the thickness readings should be equally

spaced. For areas of considerable size, multiple lines in the corroded
area may have to be evaluated to determine which length has the lowest
average thickness. The following criteria must be met in order to use
thickness averaging:
• the region of metal loss has relatively smooth contours without notches (i.e.
negligible local stress concentrations),
• the equipment does not operate in the creep range,
• the component is not in cyclic service,
• a minimum of 15 thickness readings should be included in the data set,
• minimum reading must be included in the thickness average;
• lowest individual reading cannot be less than 50 % of t required.
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

Evaluation of Pitting
• Pitting may be ignored if :
- Remaining thick > ½ t required (excl CA)
FSS ANALYSIS OF CORRODED REGIONS

- Total pits area < 7 sq in within any 8” diameter circle

- The sum of their dimensions along any straight 8” line < 2”
Alternative Evaluation Methods for Thinning
• Use ASME Sect VIII Div. 2 of ASME code (localize assess)
- Des Stress < 2/3 SMYS → Stress value = Sm
- Des Stress > 2/3 SMYS → Stress value = 2/3 SMYS

Further detail  API 579

• Joint efficiency Adjustment.
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

Inside PV
A B
CA
A = OK
OVERVIEW OF API 510

tr B = Not OK

Outside PV
A

• Sum of A max. 7 Sq in

• In any 8” straight line

Sum of A max. 2”

8” Circle
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

EVALUATING OF EXISTING EQUIPMENT WITH MINIMAL DOCUMENTATION

If vessel has no name plate and minimal or no design & constr.

documents, steps to verify operating integrity are :
OVERVIEW OF API 510

• Perform inspection to determine PV condition

• Define design parameters, prepare drawings
• Perform calculation based on applicable code, do not used design factor of
3.5
• If UG-10(c) not follow, for carbon steel use stress value for SA-283 Gr.C
• If no info on RT, use E = 0.7
• Attach a name plate or stamping showing MAWP, MDMT and date.
• Perform pressure test as soon as practicable

Reports and Records

Owner / user shall maintain permanent and progressive records for PV & PRD
• Construction & Deign Information.
• Inspection history
• Repair, alteration and re-rating information
• Fitness-for-service assessment document