api510 pre-course rev. 01 - part 1

8/3/2019 API510 Pre-Course Rev. 01 - Part 1

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INSTRUCTIONS FOR API 510 PRE-COURSE STUDIES

CONTENTS:1. API 510 Body Of Knowledge2. API 510 Study Questions and Answers3. ASME Section IX Welding Exercise4. ASME Section V NDE Exercise5. ASME Section VIII ExercisePlease begin by reading all API materials including the Body ofKnowledge sent with this package. Continue by reading the API StudyQuestions; follow this by completing the enclosed exercises over ASMEVIII~ IX and, V.Please bring to the class the following items.

Effective Publications for this Revision: June 4th 2004 Exam API 510 Eighth Ed. June, 1997 with Addendums.1 (Dec. 98) & 2 (Dec. 2000)& 3 (Dec.2001) API RP 572 Second Edition Feb. 2001 API RP 576 Second Edition (Dec. 2000) API Guide to Inspection of Refinery Equipment Chapter 2 ASME Section VIII Div.1 2000 Edition with 02 addenda ASME Section IX 2000 Edition with 02 addenda ASME Section V 2000 Edition with 02 addenda

A simple calculator (needs to have the square root function)Highlighters and TabsThe first day of class a short test will be given over the pre-course API510 Study Questions!THIS PRE-STUDY MATERIAL IS VERY IMPORTANT PLEASE DONOT NEGLECT THIS WORK. START Now

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BODY OF KNOWLEDGEAPI-SI0 PRESSURE VESSEL INSPECTOR

CERTIFICATION EXAMINATIONNovember 2003 (Replaces June 2003)

API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, andalteration of JTessure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed todetermine if individuals have such knowledge. The following is a list of specific topics in which the API Authorized PressureVessel Inspector should be knowledgeable.To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from eachcategory listed will be included on the API certification examination. Only inspection information covered in one of thereferences outlined in this body of knowledge will be utilized for the examination questions.The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring everydayworking knowledge of API Standard 510 and the applicable reference documents. The open book portion of the examinationrequires the use of more detailed information that the inspector is expected to be able to find in the documents, but would notnormally be committed to memory.

REFERENCE PUBLICATIONS:API publications and ASME codebooks must be brought to the examination site to be used as reference materials for theopen-book part of the examination.A. API Publications:

API 510, Pressure Vessel Inspection CodeAPI RP-572 , Inspection of Pressure VesselsAPI RP 576, Inspection of Pressure-Relieving DevicesAPI Guide For Inspection of Refinery Equipment, Chapter II

B. ASME Publications:Section V, Nondestructive ExaminationSection VIII, Division I, Unfired Pressure VesselsSection IX, Welding and Brazing Qualifications

Note: Refer to the Publications Effectivity Sheet in the application package for a list of specific editions, addenda, andsupplements of the reference publications that are effective for your exam date.

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I. THICKNESS MEASUREMENTS, INSPECTION INTERVALS AND VESSEL INTEGRITYA. Code calculation questions will be oriented toward existing pressure vessels, not new pressure vessels. APIAuthorized Pressure Vessel Inspectors should be able to check and perform calculations relative to in-service deterioration,repairs, rerates, or alterations. Only internal and external pressure loadings will be considered for the API 510 examination.The following ten categories describe the minimum necessary knowledge and skills:

1. CORROSION RATES AND INSPECTION TNTERVALSThe Inspector should be able to take inspection data and determine the internal and external inspection intervals.The Inspector must be able to calculate:a. Metal Loss (including corrosion averaging) (API-51O, Para 5.7, d)b. Corrosion Rates (API-5ID, Para 6.4)c. Remaining Corrosion Allowance (API-510, Para 6.4)d. Remaining Service Life (API-510, Para, 6.4)e. Inspection Interval (API-510, Para, 6.4)

The formulas for performing the above calculations and rules for setting the inspection intervals may be "closed-book"during the exam.2. JOINT EFFICIENCIESThe inspector must be able to determine the joint efficiency "E" of a vessel weld. Inspector should be able to determine:a. Weld Joint Categories from UW -3;b. Type of radiography (full, spot, or none) perfonncd basis the nameplate markings (RT -1, RT -2, etc.);c. Joint efficiency by reading Table UW -12;d. Joint efficiency for seamless heads and vessels Sections per UW -12(d); ande. Joint efficiency for welded pipe and tubing per UW -12(e).

Determining joint efficiency may be part of the internal pressure problem since joint efficiency "E" is used in the formulusfor determining required thickness or Vessel Part MA WP.3. STATIC HEADThe inspector must be able to compensate for the pressure resulting from static head. All static head will be based upon aSpecific Gravity of 1.0. The inspector should be able to:a) List the static head/pressure conversion factor (0.433 psi/ft);b) Know the difference between vessel MAWP and vessel part MAWP (UG-98);c) Calculate static head pressure on any vessel part;d) Calculate total pressure (MA WP + static head) on any vessel part;e) Calculate maximum vessel MA WP given vessel parts MA WP and elevations; and1) Determine the head depth for fanned heads given the vessel diameter (UG-32(1) &UG-32(d.

Static head calculations may also be required during the internal pressure calculations if static head data is given in theexamination problem.

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4. INTERNAL PRESSUREThe inspector should be able to determine:

a) The required thickness ofa cylindrical shell based on circumferential stress given a pressure (UO-27(c)(I));b) The vessel part MA WP for a cylindrical shell based on circumferential stress given a metal thickness (UO-27(c)(I));c) Whether a cylindrical shell meets Code requirements given both pressure and metal thickness (UO 27(c)(1))d) The required thickness of a head (ellipsoidal, torispherical, and hemispherical) given a pressure. (UO-32(d), eel, (f)

and (g))e) The vessel part MAWP for a head (ellipsoidal, torisphericaland hemispherical) given a metal thickness. (UO-32 (d),

(e), (f) and (g)).f) Whether a head (ellipsoidal, torispherical or hemispherical) meets Code requirements given both pressure and metal

thickness (VO 32(d), (e), (f) and (g)).g) The required thickness for a flat unstayed circular head given a pressure. (UO-34(c)(2)) Formula I only).

The inspector should also be able to compensate for the corrosion allowance: add or subtract based on requirementsof the exam problem. The Appendix 1 formula for cylinders, which is based on outside diameter, can be used. TheAppendix 1 formulas for non-standard heads will not be required.5. EXTERNAL PRESSUREThe inspector should be able to:a) Calculate the maximum allowable external pressure based on material from ASME B&PV Section II, Part D

(Figure 0& specific Material/Temperature Charts supplied with the examination) UO-28(c)(l); andb) Calculate whether a cylindrical shell or tube meets Code design for external pressure given a wall thickness and

a pressure (ASME B & PV, Section II, Part D; UO 28 (c )(1).6. PRESSURE TESTINOThe inspector should be able to:a) Calculate a test pressure compensating for temperature. (UO-99 & VO-l 0 0)b) Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test

temperatures, protection against overpressure etc.c) Write a hydrotest Procedure (VO 99 and UO 100)d) Write a pneumatic test procedure (VO 100 and UO 102)

7. IMPACT TESTINOThe inspector should be able to:a) Determine the minimum metal temperature of a material which is exempt from impact testing (UO-20 (f), UCS-66,

UCS-68(c).8. WELD SIZE FOR ATTACHMENT WELDS AT OPENINOSThe inspector must be able to determine if weld sizes meet Code requirements. The inspector should be able to:

1. Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707); anda) Determine the required size of welds at openings (UW -16).

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9 . N O Z Z L E R E IN F OR C EM E N TThe inspector should:

b) Understand the key concepts of reinforcement, such as replacement of strength removed and limits of reinforcement.Credit can be taken for extra metal in shell and nozzlec) Be able to calculate the required areas for reinforcement or check to ensure that a designed pad is large

To simplify the problem:enough.

Allfr=1.0All F = 1.0All E= 1.0All required thicknesses are given

d) There will be no nozzle projecting inside the shell Be able to compensate for corrosion allowances. Weldstrength calculations are excluded.

B. The following are typical ASME code engineering requirements that API certification candidates will NOT beexpected to know for purposes of the certification examination.

1. Required thickness calculations for wind, earthquake, and other secondary stress loadings;2. Supplementary design formulas and calculations for non-cylindrical shell components;3. Most external pressure calculations;4. Nozzle calculations for external loads;5. Flange calculations;6. Brazing requirements;7. Ligament calculations;8. Stayed flat heads and sizing of stays;9. Tubeshcct calculations (stayed or unstayed) and tube to tubeshect joints and loads;10. Relief valve sizing;11. Lifting lug and other structural type calculations;12. Proof testing requirements;13. Required inspections for new construction, except as they apply to alterations;14. Zick analysis;15. Integrally forged pressure components;16. Cryogenic vessels (below -50 I);17. Dimpled, embossed, jacketed, and non-metall ic vessels and assemblies;18. NDE requirements for acoustic emission, eddy current, and motion radiography;19. ASMESectionsUF, UB, UNF, UHA, UCI, UCL, trcn, UHT (exceptUHT-6), ULW, and ULT;20. Code Cases and interpretations;21. Welding process requirements other than shielded metal arc welding (SMA W), gas tungsten arc welding (OT AW),

gas metal arc welding (OMA W), or submerged arc welding (SAW);22. Requirements for pressure vessels for human occupancy; and23. Rules for natural resource vessels, API-5iD, Section 8.

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II. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILERAND PRESSURE VESSEL CODE, SECITON IX

A. WELD PROCEDURE REVIEWL The inspector should be able to determine if prccedure and qualification records are in compliance with applicable ASMEboiler and pressure vessel code and any additional requirements of API-SlO (API-SID requirements will take precedence overany ASME requirements covering the same technical area).The weld procedure review may include:

a. Welding Procedure Specification (WPS); andb. Procedure Qualification Record (PQR).

The weld procedure review may include: SMAW, GTAW, GMAW, OR SAW, with the following limitations:a) No more than one process will be included on a single WPS or PQR, and the WPS to be reviewed win be

supported by a single PQR.b) Filler metals limited to one-per-process for SMA W, GTAW, GMAW, or SAW.c) The PQR will be the supporting PQR for the WPS.

1. The inspector should be able to determine:a) Whether number and type of mechanical test listed on PQR are appropriateb) Whether the results of the tests are acceptablec) Whether all required essential and non-essential variables have been properly addressed. (Supplemental essential

variables will not be a part of the WPS). The following limitations or conditions will apply: Base metals limited to PI, P3, P4, PS, and P8. Dissimilar base metal joints, and dissimilar thicknesses of'base metals are excluded. Supplemental powdered filler metals and consumable inserts are excluded. Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and dissimilar

metal Welds with buttering of ferritic member arc excluded. For PI t P3, P4, and PS, for the purpose ofthe examination the lower transition temperature will bel3330F and the upper transformation temperature will be 1600F,

B . ASME Section VIII. Div. I and API-5ID: GENERAL WELDING REQUIREMENTS:I. ASME Section VIII, Div. I

The inspector should be familiar with and understand the general rules for welding inASME Section VIII, Div. I, Parts UW and UCS such as:a) typical joints and definitionsb) weld sizesc) restrictions on jointsd) maximum allowable reinforcemente) inspection requirements1 ) .hea t treatment

2. API510The inspector should be familiar with and understand any rules for welding in API-5ID. Any rules for welding given inAPI-SID shall take precedence over those covering the same areas in ASME, Section VIII, Div. I.

3. "Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are excluded.This includes items such as the revision level of the WPS, company name, WPS number and date, and name of testing lab,However, the API 5lD applicants shall know that the PQR must be certified by signing and dating.

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m.NONDESTRUCfIVE EXAMINATIONASME Section V, Nondestructive ExaminationNOTE: Information contained in Mandatory or Nonmandatory Appendices or referenced ASTM specifications will not be

covered on the examination. The examination will cover only the main body of each referenced Article. Whenparagraphs are specifically noted only those paragraphs will be covered. This listing is based on ASME Section V,

A. Article I, General Requirements:The inspector should be familiar with and understand;

1.The Scope of Section v,2. Rules for use of Section V as a referenced Code,3. Responsibili ties of the Owner / User, and of subcontractors,4. Calibration,5. Definitions of "inspection" and examination",6. Record keeping requirements.

B. Article 2, Radiographic Examination:The inspector should be familiar with and understand;

I. The Scope of Article 2 and general requirements,2. The rules for radiography as typically applied on pressure vessels such as, but not limited to:

a. required markingb. type, selection, number, and placement ofIQI's,c. allowable densityd. control of backscatter radiatione. location markers

3. Records

C. Article 6, Liquid Penetrant Examination:The inspector should be familiar with and understand:

I. The Scope of Article 6,2. The general rules for applying and using the liquid penetrant method such as, but not limited to;

a) proceduresb) contaminantsc) techniquesd) examinatione) interpretation1) documentation andg) record keeping

D. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):The inspector should be familiar with and understand the general rules for applying and using the magnetic particlemethod such as, but not limited to;

1,The Scope of Article 7,2, General requirements such as but not limited to requirements for:

a, proceduresb. techniques (Yoke and Prod only)c. calibrationd. examination

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e. interpretation4. Documentation and record keepingE. Article 23, Ultrasonic Standards, Section SE-797 only - Standard practice for measuring thickness by manual ultrasonicpulse-echo contact method:The inspector should be familiar with and understand;

1) The Scope of Article 23, Section SE-797,2) The general rules for applying and using the Ultrasonic method3) The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.

ASME Section VIlT. Div. 1 and API-51O. General nondestructive examination requirements:l.ASNIE Section VIII, Div. I:

The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4, 6, 8, and(2 )

2. API 510, The inspector should be familiar with and understand the general rules for NDE in API-51O.

IV. PRACITCAL KNOWLEDGE - GENERALThe following topics may be covered in the examination. More information relative to each of the categories is contained insection V. PRACTICAL KNOWLEDGE - SPECIFIC

1. Organization and Certification Requirements.2. Types and Definitions of Maintenance Inspections.3. Types of Process Corrosion and Deterioration.4. Modes of Mechanical, Thermal, and High Temperature Deterioration.5. Pressure Vessel Materials and Fabrication Problems.6. Welding on Pressure Vessels.7. Nondestructive Examination (NDE) Methods.8. Corrosion and Minimum Thickness Evaluation.9. Estimated Remaining Life.10. Inspection Interval Determination and Issues Affecting Intervals.11. Relief Devices.12. Maintenance Inspection Safety Practices.13. Inspection Records and Reports.14. Repairs/Alterations to Pressure Vessels.15. Rerating Pressure Vessels.16. Pressure Testing After Repairs, Alterations, or Rerating

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V. PRACTICAL KNOWLEDGE - SPECIFICEach reference publication relative to study for the examination is listed below. A list of to pies, which may be covered, islisted for each publication. Some topics may be listed under more than one publication. For example; ASME Section IX isthe basic document for welding requirements as referenced by ASME Section VlIl, Division 1 and API 510. The ASME andAPI documents contain additional welding requirements and exceptions to those contained in ASME Section IX. Thereforewelding requirements may be listed under all three documents and all three documents may be listed under the generalheading of "Welding on Pressure Vessels".

API-510. Pressure Ve.~,H!lInspection CodeNOTE: All of API 510 is applicable to the examination unless specifically excluded. For example: Section 8 and AppendixEare excluded.

I. Organization and Certification Requirementsa) Certification for API Authorized Pressure Vessel Inspectors (API-SID, Section 4.2 and Appendix B).b) Authorized Inspection Agencies (API-SID, Section 3.4)c) Vessel Repair Organizations (API-SID, Section 3.16)d) Relief Device Testing and Repair Organizations (API-51 0, Section 6.6)

2. Types and Definitions of Maintenance Inspectione) Internal Inspection (API 510, 6.4)f) Defect Inspection (API-5lO, 5.5)g) Inspection ofParts (API-5ID, 5.6)b) External Inspection & Buried Vessels (API 510, 6.3)i) Atmospheric Corrosion and Corrosion Under Insulation (API-5lD, 6.3)j) On-Stream Inspection (API-SID, 3.11 & 6.4)k) Visual Examination (API-5IO, 5.5)I) Thickness Measurements (API-51D, 5.3,5.7,6.3 & 6.4)m) Nondestructive Examination (API-51 0, 5.5 & 5.7)n) Assessment of Inspection Findings (5.8)

3. Welding on Pressure VesselsWelding Inspection Requirements (API-51O, 5.6 & 7.2)

4. Corrosion and Minimum Thickness EvaluationThe inspector should have a general knowledge of the following principles, and may be required to makecalculations using these principles.0) Corrosion Rate Determination (API 510, 5.3)p) Corrosion Averaging (API 510,5.7)q) Widely Scattered Pitting (API 510,5.7)r) Surfaces Remote From a Weld (API, 5.7)s) Corrosion in Central Portion of Dished Heads (API 510,5.7)

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5. Estimated RemainingLifeRemainingLife ""Corrosion Allowance (CA) (API510,6.3)

Corrosion rateCA = Actual Thickness Minus Required ThicknessCorrosion Rate =Metal Loss

TimeMetal Loss =Previous or Initial Thickness Minus Present Thickness depending onwhether corrosion rate is short or

long termTime= Time Period Between Inspections

6. Inspection Interval Determination and Issues Affecting Intervalst) Internal or On-Stream Inspection Intervals (API 510,6.4)u) Internal and On-stream inspection Intervals for Estimated Life (API 510,6.4)v) External Inspection Intervals API-51O,6.1-6.3)w) Deterioration Other Than Metal Loss (API 510, 5.2)x) Different Zones ofa Vessel (API 510,6.4)y) Change of Service Conditions (API 510,6.4)z) Change in Location and Ownership (API 510,6.4)

7.ReliefDevicesaa) Repair Organizations (API-SID, Section 6.6)bb) Minimum Requirements for Quality Control Systems (API 510,6.6)cc) Maximum Service Intervals (API-51O,6.6)

8. Maintenance Inspection Safety Practicesa. Pressure Vessel Inspection (API-SID, Section 5.1)

9. Inspection Records and Reportsa. Permanent and Progressive Inspection Records (API-5tD, 6.7)

10. Repairs, and Alterations, to Pressure Vesselsdd) Authorization (API 510,7.1.1)eel Approval (API SID,7.1.2)ff) Design Requirements (API 510,7.2.7)gg) Materials Requirements (API 510, 7.2.8)hh) WeldingRequirements (API SID,7.2.1, 7.2.2, 7.2.3,7.2.6,& 7.2.11)ii) Heat Treating Requirements, including Preheating (API 510, 7.2.3)

Post weld Heat Treating (API SID,7.2.3) Local Postweld Heat treatment (API 510, 7.2.5)

a) Repairs to Stainless Steel Weld Overlay and Cladding (API 510,7.2.6)b) Inspection (API 510, 7.2.9)c) Rerating of Pressure Vessels (API 510,7.3)d) Pressure Testing After Repairs, Alterations orRerating (API-51O,6.5 and 7.2.10)e) Nondestructive Examination ofWelds (API 510,7.2.4)

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API RP-572, Inspectioll ofPres.mre Ve.~.~ds

1.Types and Definitions ofMaintenance Inspections1) Types of Pressure Vessels (API RP-572, Section 4)g) Construction Standards (API RP-572, Section 5)h) Maintenance Inspection (API RP-572, Section 6)i) Reasons for Inspection (API RP-572, Section 7)j) Causes of Deterioration (API RP-572, 8.1- 8.10)k) Frequency and Time oflnspection (API RP-572, Section 9)1) Internal Inspection (API RP-572, lOA)m) External Inspection, Typical Items Checked (API RP-572, 10.3)n) VisualExamination (API-RP-572,Section 10)0) Thickness Measurements and Limits (API RP-572, Section 10)p) Nondestructive Examination (API RP-572, Section 10)q) Repair Methods (API RP-572, Section 11)

2. Pressure Vessel Materials and Fabrication ProblemsMaterial and Fabrication Problems (API RP-572, 8 0 4 & 8.5)

3. Maintenance Inspection Safety PracticesPressure Vessel Inspection (API RP-572, 10.2)

2. Inspection Records and Reports (API RP-572, Section 12)

API RP 576. Illspectioll o(Pressllre-Relievblf! Devices:1 .Relief Devices

a) Description of Types - General Knowledge of Application and Limitations (APIRP-576, Section 2)b) Causes ofImproper Performance (APIRP-576, Section 4)c) Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)d) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)e) Maintenance Inspection Safety Practices (API RP 576, Section 6)1) Inspection Records and Reports (API RP-576, Section 8)

Chapter II, API Gliide for Inspection ofRe(inen' Equipment aRm, Conditiolls Cal/slllT: Deterioratioll orFailllres

Note: The above reference applies to refinery equipment other than pressure vessels (e.g., piping, heaters, andOnly portions applicable to pressure vessels will be covered on the examination.

tanks.

I. Types of Process Corrosion and Deteriorationa) Corrosive Components of Crude Oils (API IRE, Chapter II, Section 202.02)b) Corrosion By Other Process Fluids (API IRE, Chapter II, Section 202.03)c) Deterioration Due ToHydrogen (API IRE, Chapter 11,202.023)d) Stress Corrosion Cracking (API IRE, Chapter II, 202.064)e) Atmospheric Corrosion and Corrosion Under Insulation (API IRE, Chapter 11,202.04)1) Erosion and Erosion-Corrosion (API IRE, Chapter11,203)g) Corrosion byWaters (API IRE, Chapter II, 202.025)

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h) Other Types of Corrosion (API IRE, Chapter II, Section 202.06)

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2. Modes of Mechanical, Thermal, and High Temperature Deteriorationa) Mechanical and Thermal Problems (API IRE, Chapter II, 205-209)b) High Temperature Problems (API IRE, Chapter Il,Section 204)

3. Pressure Vessel Materials andFabrication Problemsa) Faulty Material and Equipment (API IRE, Chapter II, Section 210)b) Known Problems Associated With Design and Fabrication (API IRE, Chapter II, 210.02)

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API 510 STUDY QUESTIONS

HOW TO USE THESE QUESTIONS

The following questions and answers on the API material arefor memorization. The API questions will be open book on thefirst part of the exam and closed book during the second half.Practice remembering the key words as opposed to learning theentire answer.


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API 510 EIGHTH ED., JUNE, 1997 ADDENDA # 1 DEC. 1998, # 2 DEC. 2000, # 3 Dec. 2001REVIEW QUESTIONS

Section 1 - General Application1. The primary code for the inspection of pressure vessels after they enter service is?

(Ll) The API 510 Code2. Relative to pressure vessels, when does API 510 apply?

(Ll) Only applicable to vessels after they have been placed in service.3. What does the API inspection code cover?

(Ll) Maintenance inspection, repair, alteration, and re-rating procedures for pressure vessels used bypetroleum and chemical process industries.4. What type of pressure vessel is exempt from periodic inspection requirements?

(1.2.2) Pressure vessels on movable structures covered by other jurisdictional requirements. All classes listed for exemption from the inspection scope of the ASME Code Section VIII,

Division I. Pressure vessels that do not exceed specified volumes & pressures.

Section 3 - Definitions5. What is an alteration?

(3.1) A physical change in any component or a re-rating which has design implications which affect

pressure-containing capability beyond the scope of existing data reports.6. What three situations should not be considered alterations?

(3.1)

Comparable or duplicate replacement Addition of reinforced nozzle less than or equal to existing reinforced nozzles Addition of nozzles not requiring reinforcement

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7. In what situation would the term "applicable requirements of ASME Code" be used?(3.2)

When the ASME Code cannot be followed because of its new construction orientation (new orrevised material specifications, inspection requirements, certain heat treatments and pressure tests,and stamping and inspection requirements), the engineer or inspector shall conform to thisinspection code rather than to the ASME Code. Ifan item is covered by requirements in theASME Code and this inspection code or if there is a conflict between the two codes, for vesselsthat have been placed in service, the requirements of this inspection code shall take precedenceover the ASME Code. As an example of the intent of this inspection code, the phrase "applicablerequirements of the ASME Code" has been used in this inspection code instead of the phrase "inaccordance with the ASME Code."

8. What is an Authorized Inspector or Inspector?(3.3)

An employee of an Authorized Inspection Agency who is qualified and certified to performinspection under this inspection code.9. List 4 examples of an Authorized Inspection Agency.(3.4) Inspection organization of the jurisdiction in which the pressure vessel is used or; Inspection organization of insurance company which is licensed or registered to write and actually

writes pressure vessel insurance. An owner or user of pressure vessels who maintains an inspection organization for activities

relating only to his equipment and not for vessels intended for sale or resale. An independent organization or individual licensed or recognized by the jurisdiction in which the

pressure vessel is used and employed by or acting under the direction of the owner or user.10. Define "construction code".

(3.5) The code or standard to which a vessel was originally built, such as APVASME, API, or State

SpeciaVnon-ASME.

11. What does the term "inspection code" refer to in API 51O?(3.6)

Shortened title for API 510 used in this publication.12. Define Jurisdictions.

(3.8) A legally constituted government administration, which may adopt rules relating to pressure

vessels.13. Define Maximum Allowable Working Pressure (MAWP) as it relates to API 510.

(3.9) and (Sect VIII UG-98) The maximum gage pressure permitted at the top ofa pressure vessel in its operating position for a

designated temperature that is based on calculations using the minimum (or average pitted)thickness for all critical vessel elements, not including corrosion allowance or loading other thanpressure.

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14. When determining Minimum Allowable Shell Thickness, what must be considered when makingcalculations?

(3.10) Temperature, pressure, and all loading.15. What type of inspection uses nondestructive examination procedures to establish the suitability of

pressure vessels for continued operation?(3.11)

On-stream Inspection16. What is the key element of an On-stream inspection?

(3.11) Because the vessel may be in operation while an on-stream inspections being carried out, the

vessel is not entered for internal inspection.17. What is a Pressure Vessel?

(3.12) and (Sect VIII U-l (a) ) A container designed to withstand internal or external pressure, which can be imposed by an

external source, by the application of heat from a direct or indirect source, or by any combinationthereof. This definition includes unfired steam generators and other vapor generating vessels,which use heat from the operation ofa processing system or other indirect heat source. (Specificlimits and exemptions of equipment covered by this inspection code are given in Section I andAppendix A.)

18. Who shall be a pressure vessel engineer?(3.13)

Shall be one or more persons or organizations acceptable to the owner-user who areknowledgeable and experienced in the engineering disciplines associated with evaluatingmechanical and material characteristics which affect the integrity and reliability of pressurevessels. The pressure vessel engineer, by consulting with appropriate specialists, should beregarded as a composite of all entities needed to properly assess the technical requirements.

19. What is the definition of quality assurance as given in API 510'1(3.14)

All planned, systematic, and preventative actions required to determine if materials, equipment, orservices will meet specified requirements so that equipment will perform satisfactorily in service.The contents of a quality assurance inspection manual are outlined in 4.3.

20. What is a Repair?(3.15)

The work necessary to restore a vessel to a condition suitable for safe operations at the designconditions. "IF" design temperature or pressure cbanges due to restoration, then re-ratingrequirements shall also be satisfied.

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21. List the four examples of a Repair Organization.(3.16)

The holder of a valid ASME Certificate of Authorization for the use of an appropriate ASMECode symbol stamp

An owner or user of pressure vessels who repairs his own equipment in accordance with the API510 code.

A contractor whose qualifications are acceptable to the owner or user of pressure vessels andmakes repairs in accordance with this inspection code.

A repair concern that is authorized by the legal jurisdiction22. What is re-rating?

(3.17) A change in either the temperature ratings or the maximum allowable working pressure rating of a

vessel, or a change in both. The maximum allowable working temperature and pressure of avessel may be increased or decreased because of a re-rating, and sometimes a re-rating requires acombination of changes. De-rating below original design conditions is a permissible way toprovide for corrosion. When a re-rating is conducted in which the maximum allowable workingpressure or temperature is increased or the minimum temperature is decreased so that additionalmechanical tests are required, it shall be considered an alteration.

23. What is a permissible way to provide for corrosion?(3.17)

De-rating below original design conditions.24. What distinguishes an examiner from and inspector?

(3.18) A person who assists the API authorized pressure vessel inspector by performing specific NDE on

pressure vessels but does not evaluate the results of those examinations in accordance with API510, unless specifically trained and authorized to do so by the owner or user. 'The examiner neednot be certified in accordance with API 510 or be an employee of the owner or user but shall betrained and competent in the applicable procedures in which the examiner is involved.

25. Define Controlled-Deposition Welding(3.1.9)

Any welding technique used to obtain controlled grain refmement and tempering of the underlyingheat affected zone (HAZ)in the base metaL Various controlled-deposition techniques, such astemper-bead (tempering of the layer below the current bead being deposited) and half-bead(requiring removal of one-half of the first layer), are included. Controlled-deposition weldingrequires control of the entire welding procedure including the joint detail, preheating and postheating, welding technique, and welding parameters.



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Section 4 - Owner-User Inspection Organization26. What are the education and experience requirements for becoming an inspector?

(4.2 go to Appendix. B) Degree in engineering & 1 year ex-perience in the design, construction, repair, operation, or

inspection of boilers or pressure vessels. 2-year certificate in engineering or technology from a technical college & 2 years of experience in

the design, construction, repair, operation, or inspection of boilers or pressure vessels. Equivalent of a high school education plus 3 years of experience. (and). Five years experience in the inspection of boilers or pressure vessels.27. Who will be responsible to the owner-user when alterations, inspections, or repairs are performed?

(4.4)

The API authorized pressure vessel inspector.



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Section 5- Inspection Practices28. Why are safety precautions important in pressure-vessel inspections?

(5.l) Because of the limited access to and the confined spaces of pressure vessels.29. What guidelines must an inspector follow to enter a vessel that has been in service?

(5.1) OSHA Regulations regarding Confined Space Entry.30. Explain the safety precautions and procedures that should be taken when performing an internal

inspection.(5.1)

Isolate vessel from all sources ofliquids, gas or vapors. Drain, purge, clean and ventilate. Gas test. Wear protective equipment as required. Warn all persons working around the vessel that inspection personnel are inside. Warn all inside the vessel of work that is done outside the vessel. Check all tools and safety equipment needed before inspection.31. When developing an inspection plan for vessels that operate at elevated temperatures (750 to 1000

o F) what things should be considered when assessing the remaining life of the vessel?( 5 . 2 )

Creep deformation and stress rupture. Creep crack growth. Effect of hydrogen on creep. Interaction of creep and fatigue. Possible metallurgical effects, including a reduction in ductility.

32. Locations where metals of different thermal coefficients of expansion are welded together aresusceptible to what?

( 5 . 2 ) Thermal Fatigue.33. The actual or estimated levels of what four items must be considered in any evaluation of Creep?

(5.2) Time Temperature Stress Material Creep Strength34. At ambient temperatures, carbon, low alloy, and other ferritic steels may be susceptible to what?

( 5 . 2 )

Brittle Failure



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35. Define Temper Embrittlement.(5.2)

A loss of ductility and notch toughness due to PWHT or high temperature service above 700degrees F. (370 degrees C)

36. What kind of steel is prone to Temper Embrittlement?(5.2)

Low alloy steels, especially 2 1I4-Cr-l Mo37. What three methods may be used to determine the probable rate of corrosion?

(5.3) Calculate rate from data collected from same or similar service. Estimate rate from owner-user experience or from published data on comparable service. On-stream determination after 1000 hours of service using a suitable corrosion monitoringdevice or NDE thickness measurements CUT), subsequent inspections shall be made until the

corrosion rate has been established.38. How should the MAWP for the continued use of a pressure vessel be established?(5 A) By using the Code to which the vessel was fabricated or by using the appropriate formulas and

requirements of the latest edition of the ASME Code to establish the design temperature andpressure.

39. In corrosive service, the wall thickness used in the MAWP calculations shall be the actualthickness obtained by inspection minus _(SA)

Twice the estimated corrosion loss before the date of the next inspection, except as modified insection 6.440. What is the most important and the most universally accepted method of inspection?

(5.5) Careful visual examination41. What determines the parts of a vessel that should be inspected?

(5.5)

The type of vessel and its operating conditions.42. For proper visual examination, what surface preparation is required?

(5.5) The type of surface preparation depends on individual circumstances, but surface preparation such

as wire brushing, blasting, chipping, grinding, or a combination of these may be required.



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43. If distortion is suspected during the inspection of a pressure vessel what is the proper course ofaction?

(5.5) If any distortion of a vessel is suspected or observed, the overall dimensions of the vessel shall bechecked to confirm whether or not the vessel is distorted and, ifit is distorted, to determine the

extent and seriousness of the distortion. TIle parts of the vessel that should be inspected mostcarefully depend on the type of vessel and its operating conditions

44. What type of examiners shall the when the owner/user requires inspection for detection of interiorsurface breaking planar flaws?

(5.5) Industry-qualified UT Shear Wave examiners.45. List the inspections, which include the features that are common to most vessels and that are most

important.(5.6) Examine the surfaces of shells and heads carefully for possible cracks, blisters, bulges, and other

signs of deterioration. Examine welded joints and the adjacent heat-affected zones for service-induced cracks or other

defects. Examine the surfaces of all man ways, nozzles, and other openings for distortion, cracks, and other

defects.46. Name two reasons why it is necessary for the API 510 inspector to examine flange faces.

(5.6) To look for distortion To determine the condition of gasket-seating surfaces47. Corrosion may cause what two forms ofloss?

( 5 . 7 ) Uniform loss - a general, relatively even wastage ofa surface area Pitted appearance - an obvious, irregular surface wastage48. Name three ways the minimum thickness of a pressure vessel can be determined.

( 5 . 7 ) Any suitable nondestructive examination Measurements taken through drilled test holes Gauging from un-corroded surfaces in the vicinity of the corroded area.49. For a corroded area of considerable size in which the circumferential stresses govern, the least

thickness along the most critical element of the area may be averaged over a length not exceedingwhat?

( 5 . 7 ) For vessels with inside diameters less than or equal to 60 inches (150 centimeters), one half the

vessel diameter or 20 inches (50 centimeters), whichever is less. For vessels with inside diameters greater than 60 inches, one third the vessel diameter or 40 inches

(100 centimeters), whichever is less.

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50. When can widely scattered pits be ignored?(5.7.)

No pit depth is more than 112 the vessel wall thickness exclusive of corrosion allowance. Total area of pits does not exceed 7 sq. inches in any 8 inch diameter circle. Sum of pit dimensions along any straight line within the circle does not exceed 2 inches.51. When should the design by analysis methods of Section VIII, Division 2, Appendix 4, of the

ASME Code be used?( 5 . 7 )

To determine if components with thinning walls, which are below the minimum required wallthicknesses, are adequate for continued service.

To evaluate blend ground areas where defects have been removed.52. What do you use to determine ifthe thickness at the weld or remote from the weld governs the

allowable working pressure when the surface at the weld has a joint factor other than I.O?( 5 . 7 . g ) For this calculation, the surface at a weld includes I inch (2.5 centimeters) on either side of the

weld, or twice the minimum thickness on either side of'the weld, whichever is greater.



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53. Describe the governing thickness when measuring the corroded thickness of ellipsoidal andtorispherical heads.

(5.7.h) The thickness of the knuckle region with the head rating calculated by the appropriate headformula. The thickness of the central portion of the dished region, in which case the dished region may be

considered a spherical segment whose allowable pressure is calculated by the code formula forspherical shells.

54. What is the spherical segment of both ellipsoidal and torispherical heads?(5.7.h)

That area located entirely within a circle whose center coincides with the center of the head andwhose diameter is equal to 80% of the shell diameter.

55. On torispherical heads, what is used as the radius of the spherical segment?(5.7.h)

Radius of the dish.56. The radius of the spherical segment of ellipsoidal heads shall be considered to be what?

(5.7.h) The equivalent spherical radius KID, where D is the shell diameter (equal to the major axis) and

KI is given in Table 1.57. When evaluating metal loss in excess ofa vessel's corrosion allowance what API document

should be consulted?(5.8)

API RP 579 Sections 4.5 and 6Section 6 - Inspection and Testing of Pressure Vessels and Pressure-Relieving Devices

58. When is an internal field inspection of new vessels not required?(6.1)

When the manufactures' data report (VI) assuring that the vessels are satisfactory for theirintended service is available.

59. Name two factors to be considered when inspection intervals are being determined.(6.1)

The risk associated with operational shutdown and start-up and the possibility of increasedcorrosion due to exposure of vessel surfaces to air and moisture.

60. What are the essential elements of a risk based assessment inspection?(6.2)

The combination of likelihood offailure and the consequences of failure.



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61. What other factors should be considered in a RBI program?(6.2)

Appropriateness of the materials, vessel design conditions relative to operating conditions,appropriateness of the design codes and standards utilized, effectiveness of corrosion monitoringprograms; and the quality of inspection / quality assurance and maintenance programs

62. What action should be taken after an effective RBI assessment has been finished?(6.2)

Choose the most appropriate inspection tools and methods based on the degradation expected. Set the appropriate frequency for internal and external and on-stream inspections. Determine ifpressure testing will be required based on damage or after repairs. Decide on prevention and mitigation steps to reduce the likelihood ofa vessel failure.63. How often should each above ground vessel be given a visual external inspection?

(6.3) Each vessel aboveground shall be given a visual external inspection, preferably while in operation,

at least every 5 years or at the same interval as the required internal or on-stream inspection,whichever is less.

64. When making an external inspection, what shall the inspection include?(6.3)

Condition of the exterior insulation Condition of the supports Allowance for expansion General alignment of the vessel on its supports65. Buried vessels shall be periodically monitored to determine their external environmental

condition. What shall the inspection intervals be based on?(6.3)

Corrosion rate information obtained during maintenance on adjacent connecting piping of similarmaterial.

Information from the interval examination of similarly buried corrosion test coupons of similarmaterial.

Information from representative portions of the actual vessel. Information from a vessel in similar circumstances.66. What is the minimum interval for checking the insulating system or outer jacketing of vessels thatare known to have a remaining life of over 10 years or that are protected against external

corrosion?(6.3)

Every 5 years and repaired as needed.67. What is the maximum period between internal or on-stream inspection?

(6.4) The maximum period shall not exceed one half the estimated remaining corrosion-rate life or 10

years, whichever is less.



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68. If the remaining safe operating life of a vessel is less than 4 years, what is inspection interval?(6.4)

Interval may be the full remaining safe operating life up to a maximum of 2 years.69. Under what conditions would a vessel with a corrosion rate less than 0.005 inch (0.125

millimeter) per year and an estimated remaining life greater than 10 years be exempt from aninternal inspection and inspected externally instead?

(6.4) When size, configuration, or lack of access makes vessel entry for internal inspection physically

impossible. When the general corrosion rate ofa vessel is known to be less than 0.005 inch (0. 125 millimeter)

per year and the estimated remaining life is greater than 10 years, and all of the followingconditions are met:

The corrosive character of the contents, including, the effect of trace components, has beenestablished by at least 5 years of the same or comparable service experience with the type ofcontents being handled.

No questionable condition is disclosed by the external inspection specified in 6.2. The operating temperature of the steel vessel shell does not exceed the lower temperature limits

for the creep-rupture range of the vessel material. The vessel is not considered to be subject to environmental cracking or hydrogen damage from the

fluid being handled. The vessel is not strip-lined or plate-lined.70. Write the corrosion rate formula to be used when determining the safe remaining life of a vessel.

(6.4)tactual -tmin.

Rem. Life Yrs. :;;;:-----------------corrosion rate

Where: tactual= the thickness, in inches millimeters), measured at the time of inspection for thelimiting section used to determine the minimum allowable thickness. tminimum =the minimumallowable thickness, in inches (millimeters), for the limiting section or zone.

71. There are two kinds of corrosion rates to be considered when calculating the remaining life of avessel. What are these types?

(6.4)

Short Term and Long Term rates.

72. When conducting a pressure test as part ofa periodic inspection, what shall the shell temperaturebe during the test?

(6.5) To minimize the risk of brittle fracture during the test, the metal temperature should be maintainedat least 30 0 F (-1 DC ) above the minimum design metal temperature for vessels that are more than

2 inches thick, or 10 0 F (-12 DC ) above for vessels that have a thickness of 2 inches or less, Thetest temperature need not exceed 120 D F (50 DC ) unless there is information on the brittlecharacteristics of the vessel material indicating that a lower test temperature is acceptable or ahigher test temperature is needed.



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73. When should pneumatic testing be done and what are some of the considerations to be taken intoaccount?

(6.5)

Pneumatic testing may be used when hydrostatic testing is impracticable because of temperature,foundation or process reasons, however, the potential personnel and property risks should beconsidered.

74. Should safety relief valves ever be removed from a vessel during pressure testing?(6.5)

Yes, if a pressure test is being conducted in which the test pressure will exceed the set pressure ofthe safety relief valve with the lowest setting.

75. When a pressure relief valve requires repair, who shall make this repair?(6.6)

Testing and repairs shall be made by a repair organization experienced in valve maintenance. Therepair organization shall have a written quality control system with the minimum requirements aslisted in 4.5 of the API 510 code and maintain a training program to insure the qualifications of therepair personnel. .

76. How often shall a safety relief valve be tested?(6.6)

The intervals between pressure relieving device testing or inspection should be determined by theperformance of the devices in the particular service concerned. Test or inspection intervals onpressure-relieving devices in typical process services should not exceed 5 years, unless serviceexperience indicates that a longer interval is acceptable. For clean (non-fouling), non-corrosiveservices, maximum intervals may be increased to 10 years.

77. Pressure vessel owners and users are required to maintain permanent and progressive records oftheir pressure vessels. What things are included in these records?

(6.7) Construction and design information. Operating and inspection history. Repair, alteration, and re-rating information. Fitness-for-service assessment documentation.

Section 7-Repairs, Alterations, and Re-rating ofPressure Vessels78. Who must approve any repairs or alterations?(7.1.1) All repair and alteration work must be authorized by the authorized pressure vessel inspector

before the work is started by a repair organization (see 3.13). Authorization for alterations topressure vessels that comply with Section VIII, Divisions I and 2, of the ASME Code and forrepairs to pressure vessels that comply with Section VID, Division 2, of the ASME Code may notbe given until a pressure vessel engineer experienced in pressure vessel design has been consultedabout the alterations and repairs and has approved them. The authorized pressure vessel inspectorwill designate the fabrication approvals that are required. The authorized pressure vessel inspectormay give prior general authorization for limited or routine repairs as long as the inspector is surethat the repairs are the kind that will not require pressure tests.



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79. Who shall approve all specified repair and alteration work?(7.1.2)

- The API authorized pressure vessel inspector, after the work has been proven to be satisfactoryand any required pressure test has been witnessed.

80. What must be removed from base material prior to welding?(7.1.3)

- Surface irregularities and contamination.81. All repair and alteration welding shall be in accordance with what code?

(7.2.)- ASME Code, except as permitted in 7.2.11

82. What must be done before Preheat or Controlled Deposition Welding is used in lieu ofPWHT?(7.2.3)- Prior to using any alternative method a metallurgical review must be conducted to determine ifthe

proposed alternative is suitable for the application.83. Name the materials allowed when using the alternative preheating method when notch toughness

testing is not required.(7.2.3.1)

-The materials shall be limited to P-Nos. P-No. 1 Group 1,2 and 3 and P-No. 3, Group 1 and 2(excluding Mn-Mo steels in Group 2).

84. Name the materials allowed for use with the Controlled-Deposition Welding Method.(7.2.3.2)- The materials shall be limited to P-No. 1, P -No. 3 and P-No. 4.85. Can local post weld heat treatment (PWHT) be substituted for 360 degree banding?

(7.2.5)- YES provided the following conditions are met:- Application is reviewed and procedure developed by engineer experienced in pressure vessel

design & PWHT requirements.- In evaluating the suitability of a procedure, all applicable factors (base metal thickness, materialproperties, etc.) are considered.- Preheat of 300 degree or bigher per WPS is maintained.- PWHT temperature is maintained for distance not less than 2 times base metal thickness measured

from weld. A minimum of2 thermocouples is used. Heat is applied to any nozzle or otherattachment in PWHT area.



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86. What considerations must be given to the repair of stainless steel overlay and claddings?( 7 . 2 . 6 )

Consideration shall be given to factors which may augment the repair sequence such as stresslevel, P number of base material, service environment, possible previously dissolved hydrogen,type oflining, deterioration of base metal properties (by temper embrittlement ofchromiurn-molybdenum alloys), minimum pressurization temperatures, and a need for future periodicexamination.

87. Per API 510, state the design requirements for:Butt Joints, Replacement Parts,New Connections, Fillet Weld Patches,Overlay Patches, Flush patches

( 7 . 2 . 7 ) BUTT JOINTS - shall have complete penetration and fusion. REPLACEMENT PARTS - shall be fabricated in accordance with the applicable requirements

of the appropriate code. NEW CONNECTIONS - design, location, and method of attachment shall be in accordance with

the applicable requirements of the appropriate code. FILLET WELDED PATCHES - require special design considerations, they are temporary

repairs. Also it must be true that;(a) The fillet-welded patches provide design safety equivalent to reinforced openings

designed according to the applicable section of the ASME Code.(b) The fillet-welded patches are designed to absorb the membrane strain of the parts so that

in accordance with the rules of the applicable section of the ASME Code, the followingresult:

The allowable membrane stress is not exceeded in the vessel parts or thepatches. The strain in the patches does not result in fillet-weld stresses that exceed

allowable stresses for such welds. OVERLAY PATCHES - shall have rounded comers. FLUSH (insert) PATCHES shall have rounded comers and be installed with full penetration butt

joints.



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88. Summarize the rules for the use of a full encirclement lap band on a pressure vessel.(7.2.7)

A full encirclement lap band repair may be considered a long term repair if the design is approved,and documented by the pressure vessel engineer and the authorized API pressure vessel inspectorand the following requirements are met:

The repair is not being made to a crack in the vessel shell. TIle band alone is designed to contain the full design pressure. All longitudinal seams in the repair band are full penetration butt welds with the design joint

efficiency and inspection consistent with the appropriate code. The circumferential fillet welds attaching the band to the vessel shell are designed to transfer the

full longitudinal load in the vessel shell, using a joint efficiency of 0,45, without counting on theintegrity of the original shell material covered by the band.

Fatigue of the attachment welds, such as fatigue resulting from differential expansion of the bandrelative to the vessel shell, should be considered if applicable. The band material and weld metal are suitable for contact with the contained fluid at the designconditions and an appropriate corrosion allowance is provided in the band.

TIle degradation mechanism leading to the need for repair shall be considered in determining theneed for any additional monitoring and future inspection of the repair. Non-penetrating nozzles(including pipe caps attached as nozzles) may be used as long term repairs for other than crackswhen the design and method of attachment comply with the applicable requirements of theappropriate code. The design and reinforcement of such nozzles shall consider the loss of theoriginal shell material enclosed by the nozzle. The nozzle material shall be suitable for contactwith the contained fluid at the design conditions and an appropriate corrosion allowance shall beprovided.

89. Describe the material suitable for making repairs or alterations.(7.2.8)

Shall conform to the applicable section of the ASMECode, be of known weldable quality and becompatible with the original material. Carbon or allow steel with a carbon content over 0.35percent shall not be welded.

90. When making a repair or alteration, what should the acceptance criteria include?(7.2.9)

NDE techniques that are in accordance with the applicable sections of the ASME Code or anotherapplicable vessel rating code.

91. After repairs or alterations, is a pressure test required?(7.2.10) Repairs - pressure test only applied ifinspector believes one is necessary. Alterations - pressure test are normally required. Subject to the approval of the Jurisdiction

(where the jurisdiction'S approval is required), appropriate nondestructive examinations shall berequired where a pressure test is not performed. Substituting nondestructive examinationprocedures for a pressure test after an alteration may be done only after a pressure vessel engineerexperienced in pressure vessel design and the authorized pressure vessel inspector have beenconsulted.



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92. List the minimum tensile strength requirements for filler metals used on vessels weld repairs andthe details of this method of repair.

(7.2.11)

The filler metal used for weld repairs should have minimum specified tensile strength equal to orgreater than the minimum specified tensile strength of the base metaL If a filler metal is used thathas a minimum specified tensile strength lower than the minimum specified tensile strength of thebase metal, the compatibility of the filler metal chemistry with the base metal chemistry shall beconsidered regarding weld ability and service degradation. In addition, the following shall be met:

The repair thickness shall not be more than 50 percent of the required base metal thickness,excluding corrosion allowance.

The thickness of the repair weld shall be increased by a ratio of minimum specified tensilestrength of the base metal and minimum specified tensile of the filler metal used for the repair.

The increased thickness of the repair shall have rounded comers and shall be blended into the basemetal using a 3 to 1 taper.

The repair shall be made with a minimum of two passes.93. List the requirements associated with re-rating a pressure vessel,

(7.3) Calculations from either the manufacturer or an owner-user pressure vessel engineer (or his

designated representative) experienced in pressure vessel design, fabrication, or inspection shalljustify re-rating.

A re-rating shall be established in accordance with the requirements of the construction code towhich the pressure vessel was built or by computations that are determined using the appropriateformulas in the latest edition of the ASME Code ifail of the essential details comply with theapplicable requirements of the code being used. If the vessel was designed to an edition oraddendum of the ASME Code earlier than the 1999 Addenda and was not designed to Code Case2290 or 2278, it may be re-rated to the latest edition/addendum of the ASME Code ifpermitted byFigure 7-

Current inspection records verify that the pressure vessel is satisfactory for the proposed serviceconditions and that the corrosion allowance provided is appropriate. An increase in allowableworking pressure or temperature shall be based on thickness data obtained from a recent internalor on-stream inspection.

The pressure vessel has at some time been pressure tested in accordance with the new serviceconditions, or the vessel integrity is maintained by special nondestructive evaluation inspectiontechniques in lieu of testing.

The pressure vessel inspection and re-rating is acceptable to the authorized pressure vesselinspector.94. When is the re-rating of a pressure vessel considered complete?

(7.3) When the API authorized pressure vessel inspector oversees the attachment of an additional

nameplate or additional stamping that carries the following information:Rerated by:,.,.-:::_.....,...,=--==-::--::-:c_-::- _Maximum Allowable Working Pressure __ psiat degrees F. Date _



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API RECOMMENDED PRACTICE 576SECOND EDITION, DECEMBER 2000REVIEW QUESTIONSSection 1 - General

1. What is the general scope of API RP576?(1)

To describe inspection and repair practices for automatic pressure-relieving devices commonlyused in the oil and petrochemical industries.

Section 2 - References2. What document should be referenced to determine the appropriate size for a pressure relief

device?(2)

RP 520 Sizing, Selection, and Installation of Pressure-Relieving Devices in RefineriesSection 3 - Definitions

3. Describe a pin-actuated device.(3.1.3)

A non-reclosing pressure relief device actuated by static pressure and designed to function bybuckling or breaking a pin, which holds a piston or plug in place.

4. What is a huddling chamber?(3.2.2)

An annular pressure chamber located downstream of the seat of a pressure relief valve for thepurpose of assisting the valve in lifting.

5. Describe "rated relieving capacity".(3.3.6)

The relieving capacity used as the basis for the application of a pressure vessel relief devicedetermined using the applicable code or regulation.

Section 4 - Pressure-Relieving Devices6. What is the function of pressure-relieving devices?

(4.1) To protect refinery equipment and personnel by automatically opening at predetermined pressures.7. Name common examples of pressure relieving devices.

( 4 ) Direct spring loaded PilotPRV Rupture disks Weight loaded devices PressureNacuum vent valves



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8. Name the five types of pressure relief valves.(4.2,4.3,4.4,4.6,4.7)

Safety valve Relief valve Safety relief valve Balanced Safety Relief Valve Pilot-operated safety relief valve9. Describe a safety valve.

(4.2)(Section VIII UG-126 foot notes) Actuated by static pressure upstream of a valve. Spring fully exposed outside casing to protect from escaping steam. Normally not pressure tight on their downstream side.

10. Safety valves should not be used in what situations?(4.2.2) Corrosive refinery services. Any back pressure service. Where discharge is piped to remote locations. Where escape of lading fluid around blowing valves is not desirable Inliquid service As pressure contra] or bypass valves.11. Describe a relief valve.

(4.3)(Section VIII UG-126 foot notes) Actuated by static pressure upstream of a valve. Lifts in proportion to the increase in pressure. Usually reaches full lift at either 10% or 25% overpressure.12. Why do relief valves have closed bonnets?

(4.3) To prevent the release of corrosive, toxic, flammable or expensive fluids.13. Reliefvalves should not be used inwhat situations?

(4.3.2) Insteam, air, gas, or vapor service. Inservices piped to an enclosed header unless the effects of any constant or variable backpressure

have been accounted for. As pressure control or bypass valves.14. There are two types of safety relief valves. What are these two types?

(4.5,4.6) Conventional & Balanced

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15. Describe a conventional safety relief valve.(4.5)

Opening pressure, closing pressure and relieving capacity are affected by back pressure. Has a closed bonnet The bonnet cavity is vented to the downstream side.16. Where are conventional safety relief valves used?

(4.5.1) Refinery process industries that handle flammable, hot, or toxic materials.17. Maya conventional safety relief valve be used on boiler steam drums or super heaters?

(4.5.2) No18. Describe a balanced safety relief valve.(4.6) Balanced safety relief valves are direct spring loaded and incorporate a bellows or other means to

minimize the effects ofbackpressure.19. What are the proper applications for these pressure balanced safety relief devices:

(4.6.1) Balance safety relief valves are normally used in applications with flammable, hot or toxic

materials, where high pressures are present at the discharge of the valve.20. What is a pilot-operated safety relief valve?

(4.7)(Section VIII UG-126 footnotes) A pressure-relief valve in which the major relieving device is combined with and is controlled by a

self-actuated pressure relief valve (called a pilot valve).21. What are some applications of pilot-operated safety relief valves?

(4.7.1) Where a large relief area and/or a high pressure is required. Where a low differential exists between normal vessel pressure and set pressure of valves. On large low-pressure storage tanks (See API Std 620). Where very short blow down required. Where back pressure is very high and a balanced design is required. Where the process requires the sensing of pressure at one location and the relief of fluid at another. Where inlet and outlet frictional losses are high. Where in-situ, in-service, set pressure verification is desired.22. Name some limitations on the use of pilot-operated safety relief valves.(4.7.2) Where fluids are dirty. Thick or viscous fluid service. With vapors which polymerize in the valve.



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23. What are the three basic categories of pressure and/or vacuum vent valves?(4.8)

Weight-loaded pallet vent valve Pilot-operated vent valve Spring and weight-loaded vent valve24. What are the applications and limitations of pressure and/or vacuum vent valves?

(4.8.1 and.2 They are designed to protect atmospheric and low pressure storage tanks and are not generally

used in applications requiring set pressures above 15 Ibfi'in225. Describe the parts of a Rupture Disk Device.

( 4 . 9 )

The combination of a rupture disk and rupture disk holder is known as a rupture disk device.26. Name the types of rupture disks.

( 4 . 9 ) Conventional Rupture Disk. Scored Tension-Loaded Rupture Disk. Composite Rupture disk. Reverse-Acting Rupture Disk. Graphite Rupture Disk.27. What is one advantage of the graphite disk over metal disks?

( 4 . 9 . 1 . 5 ) High corrosion resistance28. What is usually the service life of pre-bulged metal rupture disks installed so that pressure acts

against the concave side?( 4 . 9 . 3 )

One year - If not replaced periodically they can rupture under normal pressures without warning.29. Normally the operating pressure ofa system protected by a pre-bulged rupture disk is from 65% to

85% of the disk's predetermined bursting pressure, What determines this pressure range?(4.9.3)

The exact percentage depends on the disk's type.30. What precaution should be taken when a rupture disk is used in combination with another relief

device and removed for any reason and will be reused?(4.9.3)

They should be handled with care to avoid damage which might cause premature rupture.

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Section 5 - Causes of improper Performance31. What is the basic cause of many the difficulties encountered with pressure relief devices?

(5.1) Corrosion32. What effect can the severe over sizing ofa relief valve have?

(5.2) Damaged valve seats.33. List the major causes of improper performance in pressure-relieving devices.

(5) Corrosion Damaged seating surfaces Failed springs Improper seating & adjustments Plugging and sticking Misapplication of materials Improper location, history, or identification Rough handling Improper differential between operating and set pressures Improper piping test procedures34. To prevent leakage of the lading fluid, what must be maintained in the fla tness of seating surfaces

on pressure relief valves?(5.2)

An optical precision on the order on light beadslbands.35. What are some reasons for damaged valve seats?

(5.2) Corrosion Foreign particles getting into valve Improper or lengthy piping to the valve inlet or obstructions in the line. Careless handling during maintenance. Leakage past the seating surfaces ofa valve after it has been installed. Improper blow down ring settings. Severe over sizing.36. What almost always causes broken springs in pressure relief valves?

(5.3) Corrosion (Note: two types - surface & stress)37. What chemical frequently causes stress-corrosion spring failure in petrochemical plants?

(5.3) Hydrogen sulfide (H2S)

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38. What may be done to prevent spring failure due to corrosion?(5.3)

Spring material which can resist the action of the corrosive agent. Spring isolated by a bellows. Spring coated by a coating that can withstand the operating temperature and environment.39. What medium should be used to set the following pressure relief devices?

(5.4) Safety relief valve - air or other gas. Vapor service valve - air or inert gas. Steam service valves - steam but air may be used if suitable corrections are applied. Liquid service valves - water.40. What is recommended for lubricating sliding parts and threads on valves to prevent fouling?

(5.5) Valve parts should be lubricated with a material that is compatible with the service and

temperature.41. In general, what should be considered in determining the material to be used for pressure-relieving

devices?(5.6)

Temperature Pressure Corrosion resistance requirements Atmospheric conditions42. Why should relief valves be shipped in an upright position?

(5.8.1) When relief valves are laid on their sides, the springs may not exert the same force all around the

seating surface.43. What is one important aspect of the work done to PRDs in the maintenance shop?

(~.8.2) Rough handling should be avoided such as the application of excessive backpressure to bellows

type valves.44. IfRV inlets and outlets are not covered during shipment what provisions should be made?

(5.8.3) Provision should be made for such covering during all future shipments.45. What risks are incurred when a hydrostatic test of discharge piping for a PRD is performed?

(5.10) The disk, spring and body area on the discharge side of valve can be fouled. The bellows of a balanced relief valve can be damaged by excessive back pressure. The dome area and/or the pilot assembly ofa pilot-operated pressure RV are fouled and damaged

by the back flow of the fluid.



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Section 6 - Inspection and Testing46. Name two types of inspections.

(6.1) Shop inspections/ overhauls and visual on-stream inspections.47. When a relief valve is removed for inspection or overhauls what additional inspection should be

made?(6.2)

Inlet and outlet piping should be inspected for internal deposits and records made of theirconditions.

48. After a PRY has been reinstalled what should be checked?(6.2.1)

After reinstalling the related piping should be checked to ensure that it is not imposing loads thatwould cause problems with the pressure relief valve's body such as distortion leading to in-serviceleakage.

49. A complete operating history of each pressure relief valve should be maintained and shouldinclude what?

(6.2.3) Information on upsets and their effects on the valve. The extent of any leakage that has occurred in operation. Any other evidence of malfunctioning.50. When a relief device is removed from a system that is in operation, name a necessary step to

prevent an unexpected pressure release.(6.2.4)

The space between the relief valve and the adjacent block valve should be vented to release allpressure.

51. What must be done to valves in hydrofluoric acid service as soon as they are removed?(6.2.5

They must be correctly neutralized immediately after removal.52. Since inspection ofRY piping cannot be done when removing the valve while the system is inservice what alternative inspection can be done to check for line any major blockage or fouling?

(6.2.6) Radiographic Inspection.53. What can visual inspection of the piping after the removal of a PRD indicate?

(6.2.6) The condition of the process piping whose interior is not visible.

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54. Why should caution be used with the rigging to remove a large PRD for maintenance?(6.2.7)

Prevent auxiliary piping and pilot assemblies from being damaged.55. Prior to performing the as received pop test on a PRD what should be inspected and checked?

(6.2.8) Check that the seals are intact on the pressure set screw and the blow down ring screw cover.56. When may the as received pop pressure test be waived by the owner/user?

(6.2.8) When the valve is extremely fouled and the test may damage the valve.57. When unusual corrosion, deposits, or conditions are noted upon receipt of a PRD at the shop what

should be done?(6.2.9)

The inspector should participate in the shop inspection ofthe PRD.58. When is it not necessary to disassemble at PRD at the shop?

(6.2.10) If the valve has been tested at the appropriate API 510 interval and the as received pop test shows

the valve to be operating properly disassembly is not mandatory.59. List at least four of the steps in the inspection of a relief valve upon disassembly.

(6.2.11) Measure each part's dimensions. Check components for wear or corrosion. Seating surfaces should be checked for roughness or damage. Springs should be checked for cracking.60. During re-assembly of a pressure relief valve what should never be done?

(6.2.12) The nozzle and seating surfaces should never be oiled.61. After re-assembly of a relief device how should any blow down rings be set?

(6.2.13) In accordance with the manufacturer's recommendations.62. Why do some manufactures recommend at least three pop tests before releasing a relief device for

installation?(6.2.14)

It is believed that the first pop test helps to align all of the components and that the successive testsverify the actual set pressure.

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63. Once the valve is set to pop at its CDTP (cold differential test pressure) it should be checked for?

(6.2.15) Leakage and seat tightness by increasing the pressure on the test block to 90% of the CDTP.64. When applying the hydraulic test method to ASl\1E Section VIII pressure relief valves while on

equipment, what precautions should be taken?(6.2.17)

The potential for failure of the rupture disk in disk/relief valve combinations. Possible introduction of foreign material into the valve seat are from popping. Possible release of process material to the atmosphere.65. Maya pilot operated pressure relief valve be tested in place if no block valve exists beneath it?

(6.2.19) No, it may be inspected and repaired only while the vessel is out ofservice.66. Where is a weight loaded pressure andlor a vacuum vent used?

(6.2.20) On pressure storage tanks.67. What type of failure are pressure and/or vacuum vent valves prone to?

(6.2.20) Sticking.68. Is it permissible to reinstall a rupture disk once it has been unbolted and removed from its holder?

(6.2.21) No, it may not be possible to get a tight seal and unreliable performance is probable.69. What are the obj ectives of a visual on-stream inspection of relief devices?

(6.3) Make sure the correct device is installed, that the correct pressure can be determined, that there are

not any blinds or gags installed, that the seals are intact and that the valve is not leaking. Alsobellows if so equipped are connected and clear and vent piping is routed to a safe location. Anyupstream or downstream block valves are sealed or chained in the proper position. That dischargepiping is supported, valve body drains and vent stacks are open, any required lifting lever ispresent and properly positioned. Any heat tracing or insulation required is in good condition andoperational and if a rupture disk is installed it is properly oriented.

70. API 510 establishes the maximum interval between device inspections or tests of 10 years, whatelse should be considered when setting the frequency of inspection and testing?

(6.4) The performance of the device in a particular service.

api510 pre-course rev. 01 - part 1

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