Api 510 Notes

API 510 for quickly review
1- Applicators qualified for the overhead position may be used in any other position.
2- Table QW/QB-422 in ASME IX for Ferrous and Nonferrous P-Numbers Grouping of Base
Metals for Qualification.
3- Table QW/QB-432 in ASME IX for Ferrous and Nonferrous F-Numbers Grouping of Base
Metals for Qualification
4- Table QW-442 A-Numbers Classification of Ferrous Weld Metal Analysis for Procedure
Qualification.
5- Table QW-451.1 Groove-Weld Tension Tests and Transverse-Bend Tests be informed that Note:
5 (Four side-bend tests may be substituted for the required face- and root-bend tests when
thickness T is 3/8 in. (10mm) and over.
6- Applicators Qualified for the vertical position may be used in the horizontal and flat positions.
7- For atmospheric corrosion .Corrosion rates increase with temperature up to about 250 °F (120
°C).
Above 250 °F (120 °C), surfaces are usually too dry for corrosion to occur except under
insulation.
8- One of the main differences between nickel-alloy and carbon steels and austenitic stainless steels
is the tendency for nickel-alloy welds to be sluggish during welding. This means for nickel
alloys that the molten weld pool will not move as easily as it does for other metals. This sluggish
tendency means the welder should move the weld pool with a weave or oscillation pattern to
ensure good sidewall fusion API 577
9- HTHA or High temperature creep (angle beam spectral analysis (ABSA) & Automated
ultrasonic backscatter testing (AUBT)
10- When a change in the damage rate occurs or is anticipated, the recommended inspection interval
should be changed accordingly. API 572
11- Non penetrating nozzles (including pipe caps attached as nozzles) may be used as permanent
repairs for other than cracks when the design and method of attachment comply with the
applicable requirements of the appropriate code. API 510
12- For PT Surface temperature outside 40°F to 125°F (5°C to 52°C) or as previously qualified
ENG/Abdelhamid Muhammad 01223986267

13- For temperature range from 50°F to 125°F (10°C to 52°C). For temperatures from 40°F (5°C) up
to 50°F (10°C), minimum penetrant dwell time shall be 2 times the value listed.
14- Densitometers shall be calibrated at least every 3 months
15- The step wedge calibration film shall have been verified within the last year by comparison with
a national standard step tablet unless, prior to first use, it was maintained in the original light-
tight and waterproof sealed package as supplied by the manufacturer.
16- If a light image of the “B,” as described in T-223, appears on a darker background of the
radiograph, protection from backscatter is insufficient and the radiograph shall be considered
unacceptable
17- Frequency. Magnetizing equipment with an ammeter shall be calibrated at least once a year, or
whenever the equipment has been subjected to major electric repair, periodic overhaul, or
damage.
18- One spot shall be examined on each vessel for each 50 ft. (15 m)
19- RADIOGRAPHIC EXAMINATION OF WELDED JOINTS UW-51 as following
 1/4 in. (6 mm) for t up to 3/4 in. (19 mm)
 1/3t for t from 3/4 in. (19 mm) to 21/4 in.
 3/4 in. (19 mm) for t over 21/4 in. (57 mm)
 For rounded indication see APENDIX 4 Table 4.1
20- Welds having indications characterized as slag inclusions or cavities are unacceptable when the
indication length exceeds 2/3t
21- For all thicknesses, indications less than1/4 in. (6 mm) are acceptable, and indications greater
than 3/4 in. (19 mm) are unacceptable.
22- Table 4—Capability of the Applicable Examination Method for Weld-Type Joints
23- Table 5—Capability of the Applicable Method vs. Discontinuity
24- Table 11—Brinell Hardness Limits for Steels in Refining Services
25- Terminology and Symbols API RP 577 Annex A.
26- Guide to Common Filler Metal Selection API RP 577 Annex D
27- Bridge cam gauge Can be used to determine the weld preparation angle prior to welding

28- Weld size gauge Measures the size of fillet welds, the actual throat size of convex and concave
fillet welds, the reinforcement of butt welds, and root openings.
29- Digital or infrared pyrometer or temperature sensitive crayons: Measures preheat and interpass
Temperatures.
30- UT to detect incomplete fusion
31- API 577 Table 11—Brinell Hardness Limits for Steels in Refining Services(Carbon Steel 200)
32- Several resources recommend a minimum of 5 % to 20 % ferrite content to prevent cracking.
API 577
33- To minimize burn-through, the first weld pass to equipment or piping less than 1/4 in. (6 mm)
thick should be made with a 3/32 in. (5 mm) or smaller diameter welding electrode to limit heat
input. API 577
34- Lack of Fusion with GMAW-S Welding Process.
35- Although caustic stress corrosion cracks may be seen visually, crack detection is best performed
with WFMT, ET, RT, or ACFM techniques. Surface preparation by grit blasting, high-pressure
water blasting, or other methods is usually required. Guidelines for when PWHT is required for
carbon steels may be found in NACESP0403 and API 571.
36- Tolerance The unit’s meter reading shall not deviate by more than ±10% of full scale, relative to
the actual current value as shown by the test meter.
37- Heating the vessel in more than one heat in a furnace, provided the overlap of the heated sections
of the vessel is at least 5 ft. (1.5 m). UW-40
38- maximum permitted offset for a repaired Table UW-33
39- The bottom head and shell of fractionators processing high-sulfur crude oils are susceptible to
sulfide corrosion. This corrosion will usually be most intense around the inlet lines. In general,

high-temperature sulfur corrosion tends to be uniform compared to more localized corrosion

from high naphthenic acid
40- 9.7.7 Film Side Penetrometer (IQI)—In the case where the penetrameter (IQI) cannot be
physically placed on the source side and the use of a separate block technique is not
practical,penetrameters (IQI) placed on the film side may be used.
41- Alignment tolerance- UW-33
42- Visual on-stream inspections are intended to find problems with the maintenance and operating
practices surrounding pressure-relieving devices.
The interval selected should vary with circumstances, based on the results of previous on-stream
inspections.
The maximum interval for visual on-stream inspections should be five years. Although not
always a full visual on-stream inspection, some companies perform inspections for leakage and
vibration damage each time a relief device operates.
43- Pressure-relieving devices shall be tested and inspected at intervals that are frequent enough to
verify that the devices perform reliably in the particular service conditions.
44- Other pressure-relieving devices (e.g. rupture disks and vacuum-breaker valves) shall be
inspected at intervals based on service conditions.
45- After maintenance of the valve(s) is completed, a full visual on-stream inspection shall be
performed before
Startup
46- Storage vessels subject to internal pressures up to 15 lbf /in.2 (103 kPa) are covered in API RP
575.]
47- Deaerators in boiler feed water systems can be susceptible to cracking from a corrosion fatigue
mechanism.
48- Examination for cracking should include pressure boundary welds and heat-affected zones up to
4" from the welds.
49- In addition, examination for internal cracking of the pressure boundary at locations of external
attachment welds should be considered.
50- WFMPT is the primary recommended internal examination method.

51- When evaluating corrosion rates as part of the data assessment, the inspector, in consultation
with a corrosion specialist, shall select the corrosion rate that best reflects the current conditions.
52- A corrosion rate may be estimated by a corrosion specialist (Newly Installed Pressure Vessels
or Changes in Service)
53- The inspection plan shall be developed by the inspector and/or engineer. A corrosion specialist
shall be consulted when needed to designate potential damage mechanisms and specific
locations where damage mechanisms may occur.
54- The inspector, in consultation with the corrosion specialist, should determine when it is
necessary to remove deposits or linings to perform adequate inspections.
55- The inspector shall review the results of the thickness inspection data to look for possible
anomalies and should consult with a corrosion specialist when the short-term corrosion rate
changes significantly from the previous identified rate to determine the cause.
56- The inspector should consult with a corrosion specialist or an engineer to help define the type of
damage.
57- Crack-like flaws and environmental cracking shall be assessed by an engineer (refer to API 579-
1/ASME FFS-1, Part 9) and/or corrosion specialist.
58- On occasion, radiographic profile and ultrasonic examinations may reveal what appears to be a
flaw in an existing weld. If crack-like flaws are detected while the pressure vessel is in
operation, further inspection may be used to assess the magnitude of the flaw. Additionally, an
effort should be made to determine whether the crack-like flaws are from original weld
fabrication or caused by a service-related cracking mechanism.
59- Inspection for weld quality is normally accomplished as a part of the requirements for new
construction, repairs, or alterations. However, welds and weld heat-affected zones are often
inspected for corrosion and/or service induced cracking as part of the in-service inspections.
60- When preferential weld corrosion or cracking is noted, additional welds of the pressure vessel
should be examined to determine the extent of damage.
61- If bulging or separation of the refractory lining is detected, then portions of the refractory may
be removed to permit inspection of the metal beneath the refractory. Alternatively, UT thickness
scanning may be made from the external metal surface.

62- Bulges and buckling often occur in metallic linings and usually indicate that cracks or leaks exist
in the bulged section of the lining or that pin holes exist in the adjacent welds
63- Thermography may also be useful in detecting refractory or lining damage.
64- Careful selection of insulating materials is important. Both water absorption properties and water
retention characteristics are important and should be considered. Some insulating materials
absorb little water but still trap water against the pipe or equipment for an extended time because
water removal is slow.
65- While closed cell Foam glass materials will hold less water and, therefore, might be less prone to
causing CUI,
66- All welded joints in Category A (see UW-3) shall be in accordance with Type No. (1) Of Table
UW-12, and all welded joints in Category B, when the thickness exceeds5/8 in. (16 mm), shall
be in accordance with Type No. (1) or No. (2) Of Table UW-12. No welded joints of Type No.
(3) Of Table UW-12 are permitted for either Category A or B joints in any thickness. UW-2
67- In steam-generating equipment, caustic corrosion is best prevented through proper design
68- Advanced metallographic analysis of damaged areas can detect the early stages of micro
fissuring.
69- Automated ultrasonic backscatter testing (AUBT) and angle beam spectral analysis (ABSA)
have had some success finding fissuring,
70- Susceptibility to this form of sulfidation increases with increasing nickel content.
71- Sulfidation (H2-free) of iron-based alloys begins at metal temperatures above 450 °F (230 °C)
but normally only becomes a practical concern above 500 °F (260 °C).
72- As a minimum, the soak band shall contain the weld, heat-affected zone, and a portion of base
metal adjacent to the weld being heat treated.
73- The minimum width of this volume is the widest width of weld plus 1t or 2 in. (50 mm),
whichever is less, on each side or end of the weld. The term t is the nominal thickness as defined
in.UW-40
74- Valves in acid or caustic service should be handled very carefully adhering to rigorous handling
procedures prior to pre-pop testing of the “as-removed” pressure-relief valve.

75- Pop testing in the as-received condition for valves in acid/caustic/toxic services can be
accomplished by utilizing a pop test stand built on site in the area where the valve is installed or
by contracting with a service supplier that has a portable test stand that can be brought on site.
76- Valves in acid or caustic service should be handled very carefully adhering to rigorous handling
procedures prior to pre-pop testing of the “as-removed” pressure-relief valve.
77- After pre-popping, pressure-relief valves should be immediately neutralized.
78- The interval between shop inspection/overhaul of pressure-relieving devices should not exceed
that necessary to maintain the device in satisfactory operating condition.
79- Eddy current inspection is used to detect surface imperfections. Inspection method that applies
primarily to non-ferromagnetic materials.
80- If the test shall be accepted as meeting the requirements provided the strength is not more than
5% below the minimum specified tensile strength of the base metal.
81- Acceptance criteria for bend tests the guided‐bend specimens shall have no open discontinuity
in the weld or heat‐affected zone exceeding 1/8 in. Lowest accepted value for bend test? Crack
3mm
82- Impact test procedures and apparatus shall conform to the applicable paragraphs of SA-370
83- The radiographic density throughout the area of interest is no more than minus 15% from
(lighter than) the radiographic density through the designated IQI adjacent to the essential hole.
vary by more than minus 15% or plus 30%
84- Caustic stress corrosion cracking observed on the steel surface is sometimes described as a
spider web
85- Caustic SCC is characterized by surface-initiated cracks that occur in piping and equipment
exposed to caustic (alkaline hydroxide solutions) at elevated temperature, primarily adjacent to
non-PWHT’d welds.
86- Caustic SCC can be effectively prevented by means of a stress-relieving heat treatment (e.g.
PWHT).
A heat treatment at 1150 °F (620 °C) minimum with a minimum holding time of 1 hr. is
considered an effective stress relieving heat treatment for carbon steel.

Steam out of non-PWHT’d carbon steel piping and equipment should be avoided, where
necessary, equipment should be water washed before steaming out.
87- WFMT, ACFM, and ECT can be effective techniques to detect these surface-breaking cracks
88- PT may not be effective for finding tight cracks, because the cracks are oxide filled in case of
caustic stress corrosion cracking.
89- Chloride Stress Corrosion cracking usually occurs at metal temperatures above about 140 °F
(60 °C)
To 400 °F, the potential for cracking increases at lower pH, Cl− SCC usually does not occur at
pH values below 2.
90- Nickel content of the alloy has a major effect on resistance. The greatest susceptibility occurs in
stainless Steels with a nickel content of 8 % to 12 %.
91- Alloys with nickel contents above 35 % are highly resistant, and alloys above 45 % are nearly
immune in refining applications, but cracking can still occur in severe conditions
92- Chloride cracking has occurred in water-cooled condensers and on the process side of crude
tower overhead condensers.
93- Characteristic of Cl- stress corrosion cracks have many branches and may be visually detectable
as spider web or craze cracking on the surface.
94- Metallography of cracked samples typically shows branched transgranular cracks.
95- Carbon steels, low-alloy steels, and 400 series SS are not susceptible to Cl− SCC.
96- PT can be used for Cl- SCC. However, extremely fine cracks may be difficult to detect with PT.
Special surface preparation methods, including polishing or high-pressure water blast, may
be require in some cases, especially in high-pressure services.
97- In case of HTHA the C-½Mo material is not recommended for new construction in hot
hydrogen services.
98- Non-stress-relieved carbon steel welds have also shown a higher susceptibility to HTHA
compared to stress-relieved welds and non-welded components.
99- Experience has shown that removal of metal up to 0.1 in. (2 mm) may be needed for finding
HTHA damage.

100- Damage in refineries is most often associated with dew point corrosion in which vapors
containing water and hydrogen chloride condense from the overhead stream of a distillation,
fractionation, or stripping tower. The first water droplets that condense can be highly acidic (low
pH) and promote high corrosion rates.
101- Carbon steel and low-alloy steels are subject to excessive corrosion when exposed to any
concentration of HCl acid that produces a pH below about 4.5
102- Alloy 400, titanium, and some other nickel-based alloys have good resistance to dilute HCl acid
in many refinery applications.
103- In the atmospheric tower overhead system, corrosion from HCl acid occurs as the first droplets
of water condense from the vapor stream off the top of the tower.
104- Caustic injection downstream of the desalter is another common method used to reduce the
amount of HCl going overhead. Proper design and operating guidelines should be followed to
avoid caustic SCC
(3.15) and fouling in the feed preheat train.
105- Mechanical Fatigue (Including Vibration-induced Fatigue) Pressure swing absorber vessels in
hydrogen purification units& Safety-relief valves that are subject to chatter, premature pop-off,
fretting, and failure to operate properly.
106- pressure swing absorption(HTHA)
107- Mechanical Fatigue (Including Vibration-induced Fatigue)the signature mark of a fatigue failure
is a “clam-shell”-type fingerprint that has concentric rings called “beach marks” emanating
108- The best defense against fatigue cracking is good design
109- Corrosion of steel (primarily) due to acidic sour water (SW) containing H2S at a pH between 4.5
and 7.0
110- Sulfidation. Sulfidation will refer to high-temperature sulfidic environments without hydrogen.
111- Nickel-based alloys are also affected to varying degrees depending on composition, especially
chromium content.
112- Above 1193 °F (645 °C), alloys containing high nickel contents can suffer a form of sulfidation
and metal loss associated with the formation of nickel sulfides beneath the metal surface. This
has also been referred to as hot corrosion. Susceptibility.

113- The silicon content of carbon steel can significantly affect its susceptibility to sulfidation.
114- Carbon steels with Si content less than 0.10 % have been found to suffer variable and often
higher sulfidation corrosion rates than carbon steel with silicon content above this level. (Higher-
Si carbon steels are still susceptible to sulfidation, but steel with low Si content may suffer
higher rates.)
115- Silicon-killed steel has greater than 0.10 % Si, while non-killed steels generally do not.
116- Sulfidation (H2-free) of iron-based alloys begins at metal temperatures above 450 °F (230 °C)
but normally only becomes a practical concern above 500 °F (260 °C). Experience has shown
500 °F (260 °C) to be the most useful service temperature above which to focus inspection,
monitoring, and corrosion mitigation efforts.
117- Resistance to sulfidation is generally achieved by upgrading to a higher-chromium steel such as
9Cr-1Mo.
118- Proactive and retroactive MVPs (materials verification programs) can be used for alloy
verification and to check for alloy mix-ups in services where sulfidation is anticipated.
119- Hydrogen Blistering form bulges primarily on the ID surface of pressure vessels. Hydrogen
blistering is rare in seamless pipe but can occur in seam-welded pipe
120- Hydrogen-induced Cracking (HIC)
121- Stress-oriented Hydrogen-induced Cracking (SOHIC) SOHIC most often occurs in the base
metal adjacent to weld HAZs
122- Sulfide Stress Cracking (SCC) SSC is the cracking of a susceptible metal under the combined
action of tensile stress and corrosion in the presence of water and H2S.SSC occurs in high-
strength (high-hardness) steels but can also initiate in highly localized zones of high hardness in
weld metal and HAZs.
123- The difference between the maximum and minimum inside diameters at any cross section shall
not exceed1% of the nominal diameter at the cross section under consideration
124- The metal temperature during pneumatic test shall be maintained at least 30°F (17°C) above the
minimum design metal temperature to minimize the risk of brittle fracture.UG 100 C
125- To minimize errors in the testing and handling of pressure-relief valves, each should carry an
identifying tag, Stencil, plate, or other means to show its company equipment number. This
number readily identifies the device’s unit, the equipment that the device should be installed on,
the device’s set pressure, and the date of its last test. 6.2.3 Valve Identification API 576
126- The maximum content of iron in a nonferrous metal is 50%. SEE ASME/NBIC Q&A

127- Demonstration of acceptable density on radiographic films and the ability to see the prescribed
image quality indicator (IQI) image and the specified hole or the designated wire of a wire IQI
shall be considered satisfactory evidence of compliance with Section V, Article 2.
128- Rounded indications are not a factor in the acceptability of welds not required to be fully
radiographed.in spot radiograph.
129- The inability to draw the product of fractionation or distillation from certain trays may indicate
fouling or loss of tray parts in a process tower.
130- The condition of the protective coating or insulation on a vessel shell should be determined. Rust
spots, blisters, and film lifting are the types of paint failures usually found. Rust spots and
blisters are easily found by visual examination
131- Film lifting is not easily seen unless the film has bulged appreciably or has broken.
132- Substituting NDE procedures for a pressure test after an alteration or major repair may be done
only after the engineer and inspector have approved
133- For cases where manual UT is used to examine welds in lieu of pressure test, the owner/user
shall specify industry qualified angle beam examiners.
134- Internal field inspection of new vessels is not required provided appropriate documentation (e.g.
manufacturer’s data reports) assures that the vessels comply with the specified design and
specification requirements.
135- The spark tester method of inspection for leaks in paint, glass, plastic, and rubber linings is quite
thorough.
136- A high-voltage, low-current, brush-type electrode is passed over the nonconductive lining.
137- The interval between shop inspection/overhaul of pressure-relieving devices should not exceed
that necessary to maintain the device in satisfactory operating condition.
138- The frequency of shop inspection/overhauls is normally determined by operating experience in
the various services involved.
139- The ideal time to inspect pressure-relief devices is when the inspection least interferes with the
process and maintenance manpower is readily available. API 576 Routine inspection
140- The caustic material seeping through the cracks will often deposit white salts that are readily
visible.

141- Vessels shall be examined for visual indications of bulging, out-of-roundness, sagging, and
distortion.
142- If any distortion of a vessel is suspected or observed, the overall dimensions of the vessel shall
be checked to determine the extent of the distortion.
143- Catalytic reformer equipment operating at temperature more than 900 °F (482 °C) may
experience creep embrittlement damage during operation Replication is a useful technique in
detecting this damage).
144- The bottom head and shell of fractionators processing high-sulfur crude oils are susceptible to
sulfide corrosion.
145- Local chemical tests may be used to detect the installation of materials other than those
specified. Chemicals such as nitric acid in varying concentrations are used
146- Hydrogen sulfide (H2S) frequently causes SCC of springs.
147- When galling of the metal in the guiding surfaces is not due to corrosion or foreign particles, it is
often due to valve chatter or flutter caused by improper piping at the valve inlet or outlet or by
severe oversizing of the valve.
148- Galling may also occur if the system operates too close to the set pressure resulting in frequent
relieving.
149- Sticking of pressure-relief valves may also be caused by poor alignment of the valve disc holder
150- The most important considerations to welding austenitic stainless steels are solidification
cracking, hot cracking, distortion, and maintaining corrosion resistance Solidification cracking
151- Which increases triaxial stresses at the crack tip and promotes brittle, rather than ductile,
fracture.
152- The min spacing for the center of nozzle’s must be not less than the sum of their diameter.
153- A small liquid relief valve set to 11/3 times the test pressure is recommended for the pressure
test system, in case a vessel, while under test, is likely to be warmed up materially with
personnel absent.
154- The visual inspection of the vessel at the required test pressure divided by 1.3.
155- If the joint radiographed as per UW (11) (a) (5) (b) these mean that the joint have spot
radiographed.

156- For the requirements of PWHT see table UCS-56-1 in ASME IIIV DIV 1
157- To determine the no-off test required for test coupon when qualify the WPS according to ASME
IX see table QW-451.1
158- If the valve initially opens at the cold differential test pressure (CDTP), no further testing to
determine the “as-received” pop pressure is needed.
159- If the initial pop is at a pressure higher than the CDTP, the valve should be tested a second time.
160- The rupture disk is used to prevent corrosive materials from contacting the pressure-relief valve
internals during normal operating conditions.
161- Bellows can protect moving parts from the corrosive substance, especially in closed systems.
162- Pilot-operated pressure-relief valve are generally used
 Where a large relief area and/or high set pressures are required
 Where a low differential exists (operating margin) between the normal pressure
equipment (vessel and piping) operating pressure and the set pressure of the or the
operating pressure is close to the set pressure.
163- High inlet pressure drop cause a valve chatter
164- A safety valve is normally used with compressible fluids
165- A safety valve is a pressure-relief valve that is actuated by the static pressure upstream of the
valve and characterized by rapid opening or pop action.
166- A rupture disk device is a non-reclosing pressure-relief device actuated by the static differential
pressure
167- A forward-acting conventional rupture disk is a formed (domed), solid metal disk designed to
burst at a rated pressure applied to the concave side this rupture disk typically has an angular
seat design.
168- Reverse-acting rupture disks are generally designed to be non-fragmenting and are frequently
installed upstream of pressure-relief valve These disks provide satisfactory service life when
operating pressures are 90 % or less of marked burst pressure (90 % operating ratio).
169- Causes of Improper Performance of PRV
1. Corrosion

2. Damage seating surface which can a result of (corrosion, foreign particles, high inlet
pressure drop’’ chattering’’, Improper handling during maintenance and/or transport, such
as bumping, dropping, jarring, or scratching of the valve parts, leakage Improper blow
down ring setting
3. Failed spring in two forms (a weakening of the springe & the second is a mechanical
failure (complete break) of the spring, which causes uncontrolled valve opening
4. Improper Setting and Adjustment
5. Plugging and Fouling due to Process solids and contaminants such as coke, sand, or
solidified products can sometimes plug various parts of the valve and connected piping.
6. Sticking of pressure-relief valves may also be caused by poor alignment of the valve disc
holder
7. Galling when galling of the metal in the guiding surfaces is not due to corrosion or
foreign particles, it is often due to valve chatter or flutter caused by improper piping at the
valve inlet or outlet or by severe oversizing of the valve.
Galling may also occur if the system operates too close to the set pressure resulting in
frequent relieving.
8. Misapplication of Materials
9. Improper Location, History, or Identification
10.Improper Handling can occur during shipment, maintenance, or installation. This
improper handling of the relief valve can cause a change of the set pressure, damage
lifting levers, damage tubing and tubing fittings, damage pilot assemblies, or cause
internal leakage when the valve is in service.
11.Improper Differential Between Operating and Set Pressures
12.Improper Inlet/Outlet Piping Test Procedures
170- Pressure-relief valves with lifting levers should not be moved or carried via the lever
171- A graphite rupture disk is manufactured from graphite impregnated with a binder material and
designed to burst by bending or shearing

172- If any settling of the vessel has occurred, nozzles and adjacent shell areas should be inspected
for distortion and cracking, if there is any evidence of distortion or cracks in the area around the
nozzles, all seams and the shell in this area should be examined for cracks
173- Laminations in vessel plates have an appearance similar to cracks, but they run at a slant to the
plate surface, while cracks run at right angles to the surface
174- If open sufficiently for a thin feeler to be inserted, the angle of the lamination can be observed. If
a lamination is suspected but not open enough for a feeler to be inserted, heating to
approximately 200 °F (93 °C) with a torch will usually cause the edge of the lamination to lip
upward.
175- Erosion usually differs in appearance from corrosion. Erosion is characterized by a smooth,
bright appearance, marked absence of the erosion product, and metal loss, usually confined to a
clearly marked local area. On the other hand, corroded areas are not commonly smooth or bright.
176- The size (length and width) of the patch plate is governed by the requirement that all attachment
welds be located on sound base metal completely encompassing the damaged area(s).
ASMEBCC-2
177- The patch plate should overlap sound base metal by at least 25 mm (1 in.).
178- Pneumatic testing is potentially much more hazardous than hydrostatic testing due to the higher
levels of potential energy in the pressurized system;
179- Pressure and tightness testing are not substitutes for proof testing a design.
180- Tightness testing may be considered when structural integrity does not need to be verified but
leak tightness must be verified prior to start-up. And the consequences of a leak during start-up
are acceptable, or when permitted by the applicable construction code or post-construction code.
181- Pressure test of equipment or a piping system should be considered if an alteration or repair has
been performed, the equipment has been rerated, or it needs to be recertified to determine
integrity.
182- Pressure testing should be performed hydrostatically unless one of the following conditions
apply:
 The equipment, piping, and/or supports, including foundations, cannot adequately support
the liquid weight

 The equipment or piping cannot be dried and traces of the test liquid may result in
contamination of the system or its contents after returning to service.
 The equipment or piping contains internal linings that could be damaged by the test
medium.
183- If a hydrostatic test cannot be performed, then a pneumatic pressure test should be considered.
184- In order to reduce the risk of brittle fracture during the test, the temperature of the metal during
the pressure test of pressure vessels should be maintained at a minimum of 17°C (30°F) above
the ( M D M T )
185- If the MDMT is unknown, the minimum allowable temperature (MAT) of the component or
system should be determined using a fitness-for-service evaluation.
186- When pressure testing piping systems, the ambient temperature should be greater than 2°C
(35°F).
187- At ambient temperatures, carbon, low-alloy, and other ferritic steels may be susceptible to brittle
failure. API 510
SO When pressure testing piping systems, the ambient temperature should be greater than 2°C
(35°F).
188- Special attention should be given when testing low-alloy steels, especially 2 1/4 Cr-1Mo,
because they may be prone to temper embrittlement or any other metal that may be prone to
embrittlement per the damage mechanisms listed in API 571 or because of high triaxial stresses
due to thickness or geometry considerations.
189- The test temperature need not exceed 120 °F (50 °C) unless there is information on the brittle
characteristics of the vessel material indicating a higher test temperature is needed
190- The set pressure of a pressure relief device should be no more than the lesser of:
 the test pressure plus 345 kPa (50 psi), or110% of the test pressure
191- Pressure vessels and/or piping systems that will hold the test water for more than 10 days,
whether or not the test liquid is pressurized, should be treated with a corrosion inhibitor and
biocide. A corrosion engineer should be consulted.
192- The applied Tightness Test pressure for vessels and piping should not exceed 35% of the design
pressure.

193- Considerations Prior to Welding. Once the area to be repaired has been mapped and the pressure
component surface cleaned, welding may be initiated on the first layer. Welding parameters
should provide as low of a heat input as possible while maintaining fusion. This not only reduces
the potential for burn-through but also reduces the width of the finished heat-affected zone.
ASME BCC-2
194- Crack when discovered, stop drilling may need to be performed if weld repair is not performed.
195- Tray support ring upper attachment welds are prone to cracking,
196- The large number of internal attachment welds, coupled with the numerous horizontal surfaces,
creates conditions that promote service type defects such as environmental cracking and/or
corrosion at the tray support ring attachment welds, the down comer attachment welds, and on
both the upper and lower surfaces of the tray
197- Supplemental NDE, such as WFMPT, may be required in certain services (i.e. amine or caustic).
198- As a general rule, the upper third or the lower third of the tower is where the most corrosive
environment is typically found.
199- Where cladding is provided for corrosion protection, interface welds between the cladding and
shell should be carefully inspected for localized/preferential corrosion .
200- Other locations to inspect for damage are as follows:
 the area of the feed inlet and five to ten trays above and below the feed inlet
 the reflux inlet, the adjacent shell/head, and the first 5 to 10 trays below the reflux inlet
 The shell across from and adjacent to the inlet from the reboiler (if present).
 The bottom head, bottoms nozzles and the head to shell seam.
201- Visual examination performance as per ASME IX shall show that :
 Test coupons shall show no cracks and Complete joint penetration with complete fusion
of weld metal and base metal
202- Ultrasonic System. Calibrations shall include the complete ultrasonic system and shall be
performed prior to use of the system in the thickness range under examination (each shift). Asme
v
203- Calibration system checks are required to be performed prior to and at the completion of an
examination. APIN 577 (Ultrasonic Examination System Calibration)

204- In addition, a system check is required with any change in the search unit, cabling, and
examiner, and after a specified time frame, such as four hours.
205- The C-scan display shows a plan view of the test object.
206- The temperature of the calibration standard should be within 25 °F (14 °C) of the part to be
examined. ASME V
207- Applications of Rupture Disk Devices
 Single Relieving Device
 Supplemental Relieving Device
 Combination with Pressure-relief Valve
208- The primary reasons for applying rupture disks upstream of pressure-relief valves include the
following:
 Prevent plugging of pressure-relief valve
 Prevent corrosion of pressure-relief valve
 Prevent leakage through pressure-relief valve
209- Damaged Seating Surface of relief valve due to (Corrosion., High inlet pressure drop, Severe
oversizing…….) Very important
210- Failed spring although springs may weaken and fail due to the use of improper materials in
high-temperature service, failed springs are almost always caused by corrosion.
211- Improper Setting and Adjustment (Incorrect calibration of pressure gauges is a frequent cause of
improper valve setting.
212- Lap joint flanges or slip flanges such as Van Stone flanges should be checked for corrosion
between the flange and the pipe. API 572
213- The grooves of ring-joint flanges should be checked for cracks due to excessive bolt tightening.
Also, stainless steel ring joint grooves should be checked for stress corrosion cracking
214- SA-516 Gr 60 not normalized curve C
215- Thickness of cylindrical head from UG-27 and spherical shells as per mandatory appendix
1supplementary design formulas.
216- Thickness of other heads from UG-32.

217- PMI within the warehouse should not be regarded as an alternative to PMI of the fabricated
assets when PMI is specified.
218- The owner/user is responsible to assure that all individuals performing PMI are trained and
qualified in accordance with the applicable procedure used during the examination. Certification
and qualification are two of the most effective methods to prove requirements are met.
219- Owner/user-approved material analysis laboratories (Laboratory Chemical Analysis) using X-ray
emission spectrometry, optical emission spectrometry, or wet chemical analysis can provide the
most accurate analytical results for all elements.
220- Laboratory Chemical Analysis are typically slower than field PMI techniques due to Laboratory
analysis may involve the removal of significant amounts of material but the accuracy of
laboratory chemical analysis are typically higher than field analysis.
221- Chemical Spot Testing he chemical spot test is typically accomplished by electrochemically
removing a minute amount of surface metal and depositing it onto moistened filter paper.
Reagents dropped onto the paper produce distinct colors that are indicative of the presence of
specific elements in the sample tested.
222- Chemical spot testing is much slower than the other field PMI methods, and interpretation is
subjective.
223- Resistivity testing heated junction of dissimilar metal is created when the heated probe [300 °F
(150 °C)] and the metal being tested are in contact with each other and have not proved to be
consistently capable of sorting low-alloy (< 5 % Cr) and austenitic stainless steels and able to
sort wide range of ferrous and non-ferrous materials .
224- Spectrometer Technology (Portable X-ray Fluorescence) or XRF
225- When PMI indicates that alloying elements are outside the ranges indicated in the material
specification, the owner/user may still choose to allow the use of the tested materials in
situations where a person
226- For atmospheric Corrosion the corrosion rates increase with temperature up to about 250 °F
(120 °C). Above 250 °F (120 °C), surfaces are usually too dry for corrosion to occur except
under insulation.

227- What is the difference between ACFM &WFMPT

 The 1st one is ACFM
 The ACFM technique is an electromagnetic, non-contacting technique that is able to
detect and size surface breaking imperfections in a range of different materials and
through coatings of varying thicknesses. It requires minimal surface preparation and can
be used at elevated temperatures up to 900 °F (480 °C).
 it is less sensitive and more prone to operator errors than WFMT
 The 2nd one is WFMPT
 WFMT is used for the evaluation and monitoring of existing cracks
228- When weld metal buildup is required, post weld heat treatment shall be performed prior to flange
face machining if required by an applicable new construction or post-construction code. ASME
BCC-2(Article 305Flange Repair and Conversion)
229- Post weld heat treatment is not required if the thickness of the weld metal buildup is less than the
limits prescribed in the applicable new or post construction code or standard unless dimensional
stability is an issue, or post weld heat treatment is required for process reasons.
230- During Conversion of Flange Facing from Ring-Type Joint to Raised Face consideration shall be
given to the impact of such a change on the system design bases and specifications, including
such negative potential consequences as sealing difficulties and gasket blowout .
231- total replacement of the tube bundle when tubes inspected indicate a wall loss of 40% or more of
the initial, nominal thickness
232- tube bundle replacement or individual tube replacement when tubes inspected indicate a wall
loss of 20% to 40% of the initial, nominal thickness
233- There are two primary concerns when performing in service welding.
 The first concern is “burn-through, also referred to as blowout so welding onto pressure
components or pipelines with thin walls [4.8 mm (3/16 in.) or less for set-on-type fittings
used for hot tap connections] and 4 mm (5∕32 in.) for forged pressure retention tee type
connections is possible as long as precautions are taken. Precautions include controlling
the heat input or penetration of the welding process and using smaller diameter electrodes
[e.g. 2.4 mm (0.094in.)] when the wall thickness is less than 6.4 mm (0.250in.).

 The second concern is hydrogen cracking Hydrogen cracking occurs when tensile stresses
are acting on the weld, hydrogen is present in the weld and, when the weld solidifies, the
resultant weld microstructure is crack susceptible. Precautions include reduced by using
proper low hydrogen welding processes such as shielded metal arc welding withEXX18 or
EXX15 type electrodes. Crack-susceptible microstructures typically have high
microstructure hardness and are controlled by the carbon equivalence of the material and
the rate at which the weld cools.
234- Before inspection and any repairs on pressure-relieving devices are executed, general
precautions should be taken to maintain the safety of the equipment protected by the devices,
especially if the equipment is in operation. When inspection and repairs on an operating unit are
required, the unit operations should be normal and the proper authority and permits for the work
should be obtained. API 576
235- Prod spacing shall not exceed 8 in. (200 mm) and Shorter spacing may be 3 in
236- Preheat and CDW may be used in lieu of PWHT where PWHT is inadvisable or mechanically
unnecessary. Prior to using any alternative method, a metallurgical review conducted by an
engineer shall be performed to assure the proposed alternative is suitable for the application
237- When PWHT is performed for environmental-assisted cracking resistance, metallurgical review
shall be conducted to assess whether the procedure is acceptable
238- The thickness on which the IQI is based is the nominal single-wall material thickness plus the
weld reinforcement thickness estimated to be present on both sides of the weld (I.D. and O.D.)
and the Backing rings or strips shall not be considered as part of the thickness in IQI selection.
239- The specific type and amount of surface and/or volumetric NDE that should be specified in lieu
of pressure testing is at the owner–user’s discretion. ASME BCC-2
240- To prevent brittle fracture during the pressure test when required on CR-MO steel after repair
the pressure test shall be performed at a temperature higher than the fracture appearance
241-
242- transition temperature (FATT) and at or above the minimum temperature specified by the
applicable construction code,

243- If the valve initially opens at the cold differential test pressure (CDTP), no further testing to
determine the “as-received” pop pressure is needed.
244- If the initial pop is at a pressure higher than the CDTP, the valve should be tested a second time.
245- If it then pops near the CDTP, the valve may not have originally popped at the CDTP because of
deposits.
246- If on the second try the valve does not pop within the tolerances allowed by the ASME BPVC,
either the valve setting may have been originally in error or it changed during operation.
247- Pressure-relief valves that do not pop at inlet pressures of 150 % of CDTP should be considered
as stuck shut.
248- If the initial pop is at a pressure lower than the CDTP, the spring may have become weakened,
the valve may have been set improperly at its last testing, the seat may have been damaged, or
the setting changed during operation.
249- What is the required area of reinforcement= d*t(required) where the d refer to the opening
250- Joint Efficiency Adjustments when the surface at a weld includes 1 in. (2.5 cm) on either side of
the weld (measured from the toe) or twice the required thickness on either side of the weld,
whichever is greater.
251- The fluorescence excitation light intensity shall be measured with a suitable fluorescence
excitation light light’s meter prior to use, whenever the power source is interrupted or changed,
and at the completion of the examination or series of examinations.
252- Welders may be qualified by volumetric NDE per QW-191 when making a groove weld using
SMAW, SAW,GTAW,PAW,andGMAW(except short‐circuiting mode for radiographic
examination)
253- If temperatures in the creep range are suspected, an experienced metallurgist or engineer should
be consulted. API 572
254- UG-27 Thickness of Shells under Internal Pressure
255- UG-32 Formed Heads, and Sections, Pressure on Concave Side
256- Hydrostatic head press calculation ( only the trick to convert inch > feet )
257- For welding position of welder Table QW-461.9

258- For P. No see table 422

259- For F.No See table 432
260- A welder qualified by welding in the 5G position, the welder can’t weld: horizontal.
261- In case of Wet H2S Hydrogen permeation and diffusion rates in steel have been found to be
minimal at pH 7 and increase at both higher and lower pH.
262- Prevention/Mitigation of HTHA by Using alloy steels with chromium and molybdenum will
increase carbide stability.
263- CUI Damage is aggravated by contaminants that may be leached out of the insulation, such as
chlorides.
264- Erosion and erosion-corrosion are typically characterized by a localized loss in thickness in the
form of grooves, gullies, waves, rounded holes, valleys, or simply a greater amount of thinning
in a localized area such as the outer radius of a piping elbow.
265- In wet H2S damage the Sulfur acts as a recombination poison
266- It is the responsibility of the Code User to ensure that the examination equipment being used
conforms to the requirements of this Code Section. ASME V
267- For cylindrical components where the source is placed on the axis of the component for a single
exposure at least three IQIs, spaced approximately 120 deg. ASME V
268- One spot shall be examined on each vessel for each 50 ft. (15 m)
269- Confirm recalibration of equipment and instruments.
270- Corrective action for a nonconformance depends upon the nature of the nonconformance and its
impact on the properties of the weldment.
271- Advantages of GTAW produces high purity welds, generally free from defects.
272- Limitations of FCAW the equipment is more complex, more costly, and less portable than that
for SMAW.
273- Any electrodes or fluxes that have become wet should be discarded.
274- Prior to any welding, inspectors should review welders’ WPQ to verify that they are qualified to
perform the welding given its position, process, and other limitations
275- During PWHT Multiple thermocouples are necessary to ensure proper PWHT of all components.
Adequate support should be provided during any PWHT to prevent sagging.

276- Guide to Common Filler Metal Selection Annex DAPI 577

277- Table QW-256 Welding Variables Procedure Specifications(WPS) — Gas Tungsten-Arc
Welding (GTAW) be informed that ϕ Single, mixture, or %
278- Potential Actions by Inspector at Various Stages of the Work Preparation and Execution API
577 Annex F
279- The film is required to be of a sufficient length and width to allow a minimum of 1 in. (25 mm)
on consecutive circumferential exposures, and 3/4 in. (19 mm) coverage on either side of the
weld.
280- A radiograph with any blemishes in the area of interest shall be discarded and the area
radiographed again
281- Shear wave or angle beam techniques are employed for resolution of discontinuities in welds
282- Eddy current inspection is used to detect surface imperfections
283- Weep holes in reinforcing plates should remain open to provide visual evidence of leakage as
well as to prevent pressure buildup behind the reinforcing plate.
284- The owner/user should receive a report of the audit team’s findings. When nonconformance’s
are found, the owner/ user authorized inspection agency shall take the necessary corrective
actions.
285- Visual on-stream inspections over PRV are intended to find problems with the maintenance and
operating practices surrounding pressure-relieving devices.
286- Amine concentration does not appear to have a significant effect on the propensity for cracking.
287- The appearance of the Caustic stress cc&cl scc are spider web
288- Amine Stress Corrosion Cracking &Caustic Stress Corrosion Cracking more susceptible on
Carbon steel non PWHT
289- Caustic Corrosion as localized gouging corrosion best prevented throughout prober design
290- Caustic Stress Corrosion (Coustic service chart) Cracking& chloride stress corrosion cracking
described as a spider web.
291- Sour Water Corrosion (Acidic) susceptible at PH from 4.5 to 7 (oxygen concentration increase
acidic water corrosion increase).

292- Mechanical Fatigue (Including Vibration-induced Fatigue Damage is usually in the form of a
crack emanating from a point of high stress concentration or discontinuity such as thread, a weld
& the signature mark of a fatigue failure is a “clam-shell”-type fingerprint that has concentric
rings called “beach marks “or called “ratchet markings.
293- A valve may be tested on-stream with a lift assist device that will determine the set pressure of
the valve. API 576
294- Pilot-operated Pressure-relief Valves used in case of where a low differential exists (operating
margin) between the normal pressure equipment (vessel and piping) operating pressure and the
set pressure of the valve
295- When foreign material enter to the inlet of PRV, which part may be damaged seat-to-nozzle
contact required for tightness in most pressure-relief valves.
296- High inlet pressure drop may be caused by improper piping design or lengthy piping to the valve
inlet or obstructions in the line and may cause a valve to chatter
297- Geometric unsharpness
298- The primary difference between the internal visual inspection of trayed towers and packed
towers is the trays themselves and their support rings.
299- B.4.6.2 Internal Manways Removed for areas which inspected internally. API 572
300- Hot spots that have developed on the shell or heads of vessels that are internally insulated should
be inspected at frequent intervals while the vessel is in service .
301- The upper shell and the top head of the fractionation and distillation towers are sometimes
subject to chloride attack.
302- Table 210-4.2.1-1 Type and Number of Test Specimens Required for an In-Service Welding
Procedure Qualification ASME BCC-2 for in service PQR.

303- When damage is slight, one thickness measurement on each head and each shell course may be
sufficient on small vessels, but more measurements should be taken on large vessels.
304- To minimize burn-through, the first weld pass to equipment or piping less than 1/4 in. (6
mm)thick should be made with a 3/32 in. (5 mm) or smaller diameter welding electrode to limit
heat input As per API 577
305- Balanced Direct Spring-operated Pressure-relief Valve: Bellows or other means for minimizing
the effect of backpressure on the operational characteristics of the valve.
306- ET Similar to MT, this technique provides the greatest probability of detection when the
circulating currents are perpendicular to the discontinuity.

Api 510 Notes

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API 510 for quickly review

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high-temperature sulfur corrosion tends to be uniform compared to more localized corrosion

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ENG/Abdelhamid Muhammad 01223986267

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ENG/Abdelhamid Muhammad 01223986267

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ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

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ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

227- What is the difference between ACFM &WFMPT

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ENG/Abdelhamid Muhammad 01223986267

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258- For P. No see table 422

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276- Guide to Common Filler Metal Selection Annex DAPI 577

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ENG/Abdelhamid Muhammad 01223986267

ENG/Abdelhamid Muhammad 01223986267

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