API 510 - Pressure Vessel Inspector Course

Day 1 of API 510 Training

Module 1

• Welcome and Introduction Overview of API 510 Course

Module 2: Joint Efficiency

• Weld Joint Categories from UW-3;
• Type of radiography (full, spot, or none, RT-1, RT-2, etc.)
• Joint efficiency by reading Table UW-12)
• Joint efficiency for seamless heads and vessels Sections per UW-12 (d); and
• Joint efficiency for welded pipe and tubing per UW-12 (e)

Module 3: Thickness Calculations

• The required thickness of a cylindrical shell (UG-27(c)(1));
• The vessel part MAWP for a cylindrical shell
• The required thickness of a head-Hemispherical, Ellipsoidal, torispherical
• The vessel part MAWP for a head

Module 4: Static Head

• Calculate static head pressure on any vessel part
• Calculate total pressure (MAWP + static head) on any vessel part
• Calculate maximum vessel MAWP given vessel parts MAWP and elevations

Module 5: External Pressure and Impact Testing

• Calculate the maximum allowable external pressure
• Calculate whether a cylindrical shell meets the Code design for external pressure.
• Determine the minimum metal temperature of a material that is exempt from impact testing (UG-20 (f), UCS-66, UCS-68(c).

Day 2 of API 510 Training

Module 1: Pressure Testing

• Calculate a test pressure compensating for temperature. (UG-99 & UG-100)
• The precautions associated with hydrostatic and pneumatic testing,
• Steps in the hydro test procedure (UG 99 and UG 100)
• All steps in a pneumatic test procedure (UG 100 and UG 102)

Module 2: Weld Size For Attachment Welds at Openings

• Conversion of a fillet weld throat dimension to leg dimension, the conversion factor(0.707)
• Determine the required size of welds at openings (UW-16).

Module 3: Nozzle Reinforcement

• Key concepts of reinforcement, such as replacement of strength and limits of reinforcement.
• Credit for the extra metal in the shell and nozzle
• Calculate the required areas for reinforcement

Module 4: Scope of API 510

• General Application
• Specific Applications
• Recognized Technical Concepts
• References

Module 5

• Definitions and Owner/user inspection organization
• General
• Owner/User Organization Responsibilities

Day 3 of API 510 Training

Module 1: Inspection, Examination, and Pressure Testing Practices

• Inspection Plans
• Risk-based Inspection
• Preparation For Inspection
• Inspection For Types Of Damage Modes Of Deterioration And Failure

Module 2

• General Types Of Inspection And Surveillance
• Condition Monitoring Locations
• Condition Monitoring Methods

Module 3

• Pressure Testing
• Material Verification And Traceability
• Inspection Of In-service Welds And Joints
• Inspection Of Flanged Joints

Module 4: Interval/frequency and extent of inspection

• General
• Inspection During Installation And Service Changes
• Risk-based Inspection
• External Inspection
• Internal And On-stream Inspection
• Pressure-relieving Devices

Module 5: Inspection data evaluation, analysis, and recording

• Corrosion Rate Determination
• Remaining Life Calculations
• Maximum Allowable Working Pressure Determination

Module 6

• Fitness For Service Analysis Of Corroded Regions
• API RP 579 Fitness For Service Evaluations
• Required Thickness Determination
• Evaluation Of Existing Equipment With Minimal Documentation
• Reports And Records

Day 4 of API 510 Training

Module 1: Repairs, alterations, and rerating of pressure vessels

• Repairs And Alterations
• Authorization
• Approval
• Materials Requirements
• Welding Requirements

Module 2

• Heat Treating Requirements
• Preheating
• Post-weld Heat Treating
• Local Post-Weld Heat treatment
• Repairs to Stainless Steel Weld Overlay and Cladding
• Rerating

Module 3

• Introduction to ASME Sec. IX
• Welding Procedure tests
• Performance qualification tests
• Acceptance criteria
• Welding positions
• P-No, F-No, and A-No.
• Review of Welding Procedure Specification (WPS); and Procedure Qualification Record (PQR)
• Determine:

              - Whether the number and type of mechanical test listed on PQR  are appropriate

              - Whether the results of the tests are acceptable

              - Whether all required essential and non-essential variables have been properly addressed.

Day 5 of API 510 Training

Module 1: API RP 576, Inspection of Pressure-Relieving Devices

• Description of Types -- (API RP-576, Section 2)
• Causes of Improper Performance (API RP-576, Section 4)
• Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)
• Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)

Module 2

• Article 1, General Requirements:
• Article 2, Radiographic Examination

Module 3

• Article 6, Liquid Penetrant Examination
• Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):
• Article 23, Ultrasonic Standards, Section SE–797

Module 4: API RP 576, Inspection of Pressure-Relieving Devices

• Description of Types (API RP-576, Section 2)
• Causes of Improper Performance (API RP-576, Section 4)
• Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)
• Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)

Module 5 (1 hour + 1 hour discussion)

• Practice Examination-Open Book Practice Examination-Closed BookFeedback and Closing

What is API 510 training course objective?

• Successfully pass the API 510 pressure vessel inspector certification exam
• Effectively use major codes: ASME B&PV Sections V, VIII, & IX
• Perform all basic vessel calculations needed for the API exam (e.g. min, test pressure, MAWP, static head, MDMT, corrosion rates, remaining life, etc.)
• Use API’s requirements during inspection, repairs, and alterations of pressure vessels
• Review welding procedures (WPS/PQR) and welder performance qualifications (WPQ)

What you must bring to class

Students should bring to class: a calculator, a straight edge (or triangle), pencils, highlighters, lots of questions, and a “can-do” attitude. Also, participants must bring the appropriate codes required for the API exam (see API website: www.api.org/icp)