2023DataSheetAnswers510.pdf

API 510 Certification Data Sheets Answer Reference Reference Documents 1 API 579 510: 1.2.3, 7.5 Fitness for Service (FFS) 2 API 580 510: 1.2.3, 5.2.1 R...

API 510 Certification Data Sheets Answer Reference Reference Documents 1 API 579 510: 1.2.3, 7.5 Fitness for Service (FFS) 2 API 580 510: 1.2.3, 5.2.1 Risked Based Inspection 3 API 660 572: 4.6 API Design for Fabrication of Exchangers 4 API 2201 510: 8.4.1 Welding on In-Service Equipment containing Flammables 5 ASME Sect V 510: 5.7.1.1 NDE Procedure Guidelines 6 ASME Sect 510: 8.4.2.1 Welder & Weld Procedure Qualification IX 7 ASNT SNT- 510: 4.5.2 NDE Personnel Qualification (RT & UT Flaw Detection) TC-1A Answer Reference Class Abbreviations 1 AIRR 510: 1.1.1 API 510 Scope (Alteration, Inspection, Repair, Rerate) 2 JOIC 510: 3.1.5 API 510 AI’s Employer (Jurisdiction, Owner, Insurance company, Contractor) API 510 Repair Organization (ASME stamp holder, authorized by 3 A JOC 510: 4.3 Jurisdiction, Owner, Contractor) How to determine Corrosion Rate for New Service or Change in 4 SPUCE 510: 7.1.2 Service (Similar Service, Published Data, UT Sensors, Corrosion Specialist, or Exam w/in 6 months) Primary responsibilities of API 510 AI (Repairs, Alterations, 5 RAT-IE 510: 4.4 Testing, Inspection, Examination) Answer Reference Key Words Physical 1 Change 510: 3.1.2 Define – Alteration Restore - 2 Suitable 510: 3.1.70 Define – Repair Probability & 3 Consequence 510: 5.2.1 Define – RBI’s two Primary Factors Qualified & 4 Experienced 510: 6.6.1 PRD’s – Requirements for Relief Device Repair Organization 5 Performance 510: 6.6.3.1 PRD’s - How relief device intervals are determined MSTS 1 May 2023  API 510 Certification Data Sheets Answer Reference Dimensions VIII: UW-51.b.1 Maximum length of Crack, Incomplete Penetration or 1 0” & 52.c.1 Incomplete Fusion allowed on a new weld 2 3 light beads 576: 5.2 Smoothness of relief device seating surfaces Lesser: 0.010” 3 or 6% of T” VIII: UG-16.c Maximum allowed mill tolerance of a plate 4 1/8” IX: QW-163 Maximum allowed size of open discontinuity in a Bend Test 5 0.25 – 3.0” 577: 8.8.3 NDE – Typical thickness range for RT using Iridium 192 VIII: UW-51.a.4 Thickness for using UT in lieu of RT for: 1) Inspection of 6 > 1/4” IX: QW-191.2.1.a new vessel welds or, 2) to qualify welder V: T-642.b / Minimum distance beyond the area to be examined to clean a 7 1” T-741.1.b part when performing a MT or PT examination 8 1” 510: 8.2.2.4 Minimum radius of insert patch or fillet weld patch Greater of: 9 1” or 2T 510: 7.4.5 Evaluate LTA – Distance from the weld in for: E = 1.0 10 1.5 – 7.0” 577: 8.8.3 NDE – Typical thickness range for RT using Cobalt 60 VIII: Table 11 > 1-1/2” Wall thickness of CS shell that requires PWHT UCS-56, Note 2.a 12 > 1-1/2” VIII: UW-11.a.2 Wall thickness of shell that requires Full RT 13 2” 510: 7.4.3.c Maximum length of pits allowed in 8” line 14 2” 510: 3.1.7 Maximum diameter of a CML VIII: U-1.c.2.i Vessel inside diameters that are excluded from the scope of 15 < 6” 510: App A b.9 Section VIII IX: QW-302.2/ Weld Qualify - Minimum weld length when qualifying a welder 16 6” 304.1 with RT/UT using a coupon or 1st production weld Weld Qualify - Minimum weld length when qualifying a 17 6” IX: QW-302.2 welding operator with RT/UT of a test coupon 18 6” VIII: UW-52.c Minimum length of Spot RT 19 6-24” 577: 8.3.1.f NDE – Distance of eye-to-part to count as a Visual Exam 20 3’ VIII: UW-37.f.1 Maximum distance on weld between welder’s stamp Weld Qualify - Minimum weld length when qualifying a 21 3’ IX: QW-305.1 welding operator with RT/UT of first production weld 22 5’ VIII: UW-40.a.2 Minimum overlap for vessel PWHT when using multiple heats 23 50’ VIII: UW-52.b.1. Maximum length of weld represented by 1 Spot RT 24 ½ tmin 510: 7.4.3.a Minimum allowed wall thickness at a pit MSTS 2 May 2023  API 510 Certification Data Sheets Answer Reference Temperatures 1 < 0 oF VIII: UW-30 Welding - Base metal temp where welding is not recommended 2 0 - 32 oF VIII: UW-30 Welding - Base metal temp, pre-heat to 60 oF is recommended 3 10 - 350 oF 510: 5.5.6.1.a Corrosion - CUI affects Carbon Steel & low alloy (temp range) UT Calibration - Calibration Block must be within what 4 25 oF 577: 8.9.3.1 temperature of the part to be examined 5 40 - 125 oF V: T-652/653 NDE - Standard temperature range for a PT exam Corrosion - Temperature where Cooling Water corrosion starts 6 140 oF 571: 3.20.3.b to significantly increase Corrosion - Temperature where chloride stress corrosion 7 > 140 oF 571: 3.17.3.d cracking becomes a concern 8 140 - 350 oF 510: 5.5.6.1.b Corrosion - CUI affects Austenitic SS (temp range) 9 > 150 oF 510: 5.7.2.3 NDE - Special procedures are needed for UT thickness rdgs Corrosion - Temperature when high strength caustic causes 10 > 170 oF 571: 3.14.3.b serious corrosion in CS 11 280–350 oF 510: 5.5.6.1.c Corrosion - CUI affects Duplex SS (temp range) Welding - Minimum pre-heat temperature, when pre-heat is 12 300 oF 510: 8.6.2.2.a substituted for PWHT Welding - Minimum pre-heat temperature, when a local PWHT 13 300 oF 510: 8.5.2.c is used in lieu of a full encirclement PWHT 14 500 oF 571: 3.61.3.f Corrosion - Temp when Sulfidation becomes a concern on CS 15 650–1070 oF 510: 3.1.78 Corr - Temper embrittlement for low chromes (temp range) Corrosion – If operating temp is above this, check for Creep in 16 > 900 oF 572: 9.3.9 Cat Reformer equipment 17 1000 oF V: SE-797 9.5 NDE - Maximum temperature for UT readings VIII: Table 18 1100 oF UCS-56 Materials - Carbon Steel normal PWHT temperature 19 > 1350 oF 577: 10.2.4 Mtls – Carbon Steel temp of base metal to create HAZ 20 MDMT + 10 oF 510: 5.8.7.2 Testing – Min. base metal temp during hydro vessels < 2” thick 21 MDMT + 30 oF 510: 5.8.7.2 Testing - Min base metal temp during hydro vessels > 2” thick Manufacturer 22 Recommend V: 731.c NDE - Maximum temperature for magnetic particles 23 24 MSTS 3 May 2023  API 510 Certification Data Sheets Answer Reference Documents 1 WPS IX: Various Weld Procedure 2 PQR IX: Various Qualification Record of a Weld Procedure 3 WPQ IX: Various Welders Qualification Record (the welder’s paper) Inspection Document that must be prepared and maintained for each 4 510: 5.1.1 Plan vessel and relief device QA Insp/ Manual that must be prepared and maintained by each 5 Repair Manual 510: 4.1.2 Owner/Operator that uses API 510 QA Manual Two documents that are needed by each Repair Organization 6 510: 6.6.2.1/2 & Training that repairs relief devices Answer Reference Pressures VIII: U-1.c.2.h.1 1 > 15 psig Design pressures within scope of ASME Sect VIII & API 510 510: Ap A b.7.1 2 1.5 x Ptest VIII: UG-102.b Minimum range of pressure gauge used during a test 3 2.0 x Ptest VIII: UG-102.b Preferred range of pressure gauge used during a test 4 4.0 x Ptest VIII: UG-102.b Maximum range of pressure gauge used during a test 5 Answer Reference Materials Low 1 510: 3.1.78 Subject to temper-embrittlement Chromes 2 300 SS 571: 3.17.2.a Subject to chloride stress-corrosion cracking 3 300 SS 572: 9.4.1 Subject to polytheonic acid stress-corrosion cracking Common material with an endurance limit (fatigue cracking cannot 4 CS 571: 3.43.3.c.1 occur below this stress level) 5 Aust. SS 571: 3.43.3.c.3 Common material without an endurance limit 6 P1 & P3 510: 8.6.2.1.a P-numbers allowed to use pre-heat in lieu of PWHT 7 P1, P3 & P4 510: 8.6.3.b P-numbers allowed to use CDW in lieu of PWHT P-numbers of base metal that should be examined for delayed 8 P3, P4 & P5 510: 8.3.4.4 cracking after repairs to SS cladding MSTS 4 May 2023  API 510 Certification Data Sheets Answer Reference Miscellaneous Numbers Maximum allowed corrosion rate when using an On-stream 1 0.005 ipy 510: 6.5.2.1.b.1 inspection in lieu of an Internal (in ipy) Ratio of Endurance Limit Stress to Ultimate Tensile Stress 2 0.4 – 0.5 571: 3.43.3.c.2 for Carbon Steel 0.433 Body of 3 Knowledge Static Head Factor (psig per height of water in feet) psig/ft 4 1.0 VIII: Tb UW-12 Design - Joint efficiency when using Full RT on a Type 1 joint FFS – Joint efficiency when evaluating corroded area away 5 1.0 510: 7.4.5 from a weld by greater of: 1” or 2t NDE - The # of additional RTs required when a Spot RT has a 6 2 VIII: UW-52.d.2 defect 7 2 IX: Tbl QW451.1 Weld Qualification - Number of tension tests to qualify a WPS IX: Table Weld Qualification - Number of bend tests to qualify a welder 8 2 QW452.1.a or welding operator in welding positions 1G-4G NDE - Minimum # of exposures to RT 360o of a weld using a 9 2 V: T-271.2.b.1 double-wall technique, double-wall view (elliptical shot) NDE - RT film Density Range - allowed for the weld & IQI 10 2.0 – 4.0 V: T-282.1 when using a gamma ray source NDE - Minimum # of exposures to RT 360o of a weld using a 11 3 V: T-271.2.a double-wall technique, single-wall view Impact Test - Number of test bars required in each set of 12 3 VIII: UG-84.c.1 impact test specimens NDE - When using a shim under a hole-type IQI, the number 13 3 V: T-277.3 of sides of the IQI that must be seen in the RT image 14 3.5 510: 7.7 Tbl 2 Design - Current Safety Factor of ASME Section VIII 15 4.0 510: 7.7 Tbl 2 Design - Pre-2000 Safety Factor of ASME Section VIII 16 4 IX: Tbl QW451.1 Weld Qualification - Number of bend tests to qualify a WPS IX: Tbl QW452. Weld Qualification - Number of bend tests to qualify a welder 17 4 1.a Note 1 or welding operator in welding positions 5G & 6G 18 5 ohms 572: 9.3.10 Design - Recommended resistance of grounding systems 19 7 in2 510: 7.4.3.b Maximum area of pits allowed in an 8” circle 20 10 lb V: T-762.b NDE - Weight used to check magnetic strength of an AC yoke 21 25 ohms 572: 9.3.10 Design - Maximum resistance allowed of grounding systems 22 30 degrees 577: 8.3.1.f NDE – Min angle of eye-to-part to count as a Visual Exam MSTS 5 May 2023  API 510 Certification Data Sheets Answer Reference Miscellaneous Numbers (cont.) 23 40 lb. V: T-762.c NDE - Weight used to check magnetic strength of a DC yoke or permanent magnet yoke Testing - Maximum chloride content in hydrotest water when 24 50 ppm 510: 5.8.5.2 testing 300 series SS (ppm) 100 ft- V: T-676.3 & NDE - Minimum light intensity when performing non- 25 T-777.1 candles fluorescent MT or PT exams 100 ft- 26 577: 8.3.2.2.a NDE - Minimum light intensity when performing VT candles 1000 V: T-676.4.d & NDE - Minimum black light intensity when performing MT or PT 27 μW/cm2 T-777.2.d fluorescent exams Answer Reference Percentages NDE - Limits of RT Film Density of weld as compared to IQI 1 -15 to +30% V: T-282.2.a.1 (range) 2 0.35% 510: 8.1.4 Maximum percent of carbon allowed in new materials 3 9% 571: 2.1.11 Mtls - Max amount of chrome to be considered low-alloy steel 4 10.5% 571: 2.1.17 Mtls - Min amount of chrome to be considered stainless steel AI – Amount of time inspector must be involved in inspection 5 20% 510: B.3.2.a activities - required to maintain API 510 certification Mtls – Amount of nickel required for a material to be 6 > 30% 571: 2.1.16 considered a nickel alloy Center portion of head when evaluating a LTA using the 7 80% 510: 7.4.6.1.b spherical formula MSTS 6 May 2023  API 510 Certification Data Sheets Answer Reference Time Intervals V: T-676.4.b NDE - Minimum time an examiner should be in a darkened area 1 5 minutes & T-777.2.b prior to using a black light for MT & PT exams 10-60 NDE - Final interpretation of a PT exam after application of 2 V: T-676.1 minutes developer (time range) 3 30 minutes 577: 8.11 Testing – Typical minimum duration for a pressure test NDE - Minimum time to wait to check for delayed cracking 4 24 hours 510: 8.3.4.4 after repairs to SS cladding Records – Max time to post inspect results in Insp Data 5 90 days 510: 7.8.4. System 6 3 months V: T-262.1 NDE - Max Calibrating Interval - RT densitometer Welding – Max Time a Welder or Welding Operator maintains 7 6 months IX: QW322.1.a qualifications for a process without using that process 510: 4.1.2.t 8 1 year 577: 8.3.1.3 NDE - Maximum Interval for a visual examiner’s eye exam Lesser 2 yr Insp - Maximum Interval for Internal Inspection if Remaining 9 510: 6.5.1.1 or Full Life Life is less than 4 Years Lesser 5 yr 10 510: 6.4.1 Insp - Maximum Interval - External Inspection or Internal Insp - Maximum Interval for Relief devices in fouling or 11 5 year 510: 6.6.3.2.a corrosive service Lesser 10 yr Insp - Maximum Interval for Internal or On-Stream 12 510: 6.5.1.1 or ½ Life Inspection Insp - Maximum Interval for Relief devices in non-fouling or 13 10 years 510: 6.6.3.2.b non-corrosive service 14 10 years 510: 6.3.2 RBI - Maximum Interval for the RBI Reassessment Insp - Minimum Remaining Life required when performing an 15 > 10 years 510: 6.5.2.1.b.2 On-stream inspection in lieu of an Internal Inspection 16 Before use V: T-762.a NDE - Max Calibrating Interval – For all MT Magnetic Yokes Before & V: T-676.4.f & NDE - Max Calibrating Interval - Check the light intensity of a 17 after use T-777.2.f black light used in a MT or PT exam MSTS 7 May 2023  API 510 Certification Data Sheets Answer Reference Miscellaneous Other VIII: UG-98.a 1 Top 510: 3.37 Define - Location on a vessel of Vessel MAWP 2 Defect 510: 3.1.18 Define – Imperfection that exceeds the acceptance criteria 3 Imperfection 510: 3.1.33 Define – A flaw that may or may not exceed the acceptance criteria 4 A VIII: Fig UW-3 Design - Joint Category of a vessel longitudinal weld 5 B VIII: Fig UW-3 Design - Joint Category of a vessel circumferential weld VIII: UG-116. 6 RT-1, RT-2 e.1 & 2 Design - RT Factors representing Full RT VIII: UG-116. 7 RT-3 e.3 Design - RT Factors representing Spot RT 8 Type 1 VIII: Fig UW-12 Design - Weld Type – Butt double welded 9 Type 2 VIII: Fig UW-12 Design - Weld Type – Butt single welded with backing 10 Type 3 VIII: Fig UW-12 Design - Weld Type – Butt single welded without backing 11 Lethal VIII: UW-11.a.1 Design - Vessel service that always requires Full RT Design - Maximum set pressure for single relief device on a 12 MAWP VIII: UG-155.a vessel 13 HT VIII: UG-116.f.1 Design - Marking on Nameplate indicating vessel was PWHT Design - Marking on Nameplate indicating vessel is in Lethal 14 L VIII: UG-116.c Service VIII: UG-116.a. 15 U 1.a Design - ASME Sect VIII stamp for routine vessels VIII: UG-116.a. 16 UM 1.b Design - ASME Sect VIII stamp for miniature vessels Represent- NDE - Number of CMLs to obtain thickness readings during 17 510: 5.6.2.1 ative inspection (key word) Represent- NDE - Number of Nozzles to obtain thickness readings during 18 510: 5.6.2.1 ative inspection (key word) NDE - Lead letter used during RT to check for backscatter 19 B V: T-223 radiation 20 F V: T-277.b NDE - Lead letter used during RT to indicate a film-side IQI NDE - Hole size that must be visible in RT when using a hole- 21 2T V: Tbl T-276 type IQI Ir 192, Co 22 577: 8.8.3 NDE - Two primary gamma-ray RT sources 60 23 Upright 576: 5.9.2 RV’s - How relief devices should be transported MSTS 8 May 2023  API 510 Certification Data Sheets Answer Reference Miscellaneous Other (continued) Essential & 24 IX: QW200.1.b Welding - Variables needed on WPS Non-Essent. 25 Essential IX: QW200.2.b Welding - Variables needed on PQR SMAW, 510: 8.6.3.2.1.b Welding - Processes to use when substituting Preheat or 26 GMAW, & 8.6.3.c Controlled Deposition Welding for a required PWHT GTAW Welding - Minimum taper required for shell welds with 27 3 to 1 VIII: UW 9.c mismatch 28 6G IX: QW461.9 Weld Qualification – The “all-position” test coupon Crack, LoF, IX: QW191.1. 29 2.2.a.1 Weld Qualification – Rejectable in RT when qualifying a welder IP Weld Qualification – Which welding process can a welder NOT 30 GMAW - SC IX: QW-304 be qualified by RT Weld Qualification - Maximum allowed thickness on a WPS 31 2T IX: Tbl QW451.1 based on the plate thickness (T) of a PQR test coupon 32 Jaeger J-1 510: 4.1.2.t Test for inspector Eye Exam 33 34 35 SDG MSTS 9 May 2023