API 510 Code Q&A’s.pdf

GoDEWEST API 5{0 PREP COURSE I Apt 5{0 API 5{ 0 Table of Contents Topic Page API 510 Review MathProblems 22.......... Problem Solutions 28 Sample Questions 37 Answer Key... 62.:... PLEASE NOTE: This information is based on the Edition, Addenda, and Supplement(s) of the API, ASME AND AWS Codes and Standards as required for the specific API examination that this text has been prepared for. CodeWest makes no claims as to the accuracy of this information. Use for any other purpose than intended is forbidden and holders of this document are subject to all of the Terms and Conditions of attendance at CodeWest courses as stated on the CodeWest Registration Form. This includes criminal prosecution, civil prosecution, possible prison sentences, and other polsible legal actions that may be brought bJ CodeWest, the State of Texas, The United States of America, or other countries and jurisdictions. Registered trademark no 00003054553. Copyright @ 2018 AII rights reserved. No part of this book covered by the copyright hereon may be reproduced.or used in any form-or by any meani-graphic, electronic, or mechanical, including photogopying, reco$]no, taping, _or information storage anO"reti-ievil systems without the wriften permission of CodeWest. Violators will be prosecuted to the full extent possibte under U. S. Federal copyright laws. Copyright violations are investigated in Federal by the FBl, pros".ut"O by the United States Attorney, and punishable by fines and incarceration prison. Coniact CodeWeit tor further inforrnation or permission to copy this document. DO NOT GOPY WITHOUT WRITTEN PERMISSION FROM CODEWEST GOPYRIGHT @ 201,S C€PE-WEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT a I GoDEWEST API 510 PREP COURSE I API 5{0 APt 5{0 FOREWORD The first edition of the API/ASME Code was approved for publication in 1934. SEGTION 1 - SGOPE 1.1.1 Coverage Covers in-service inspection, repair, alteration, and rerating activities for pressure vessels and the pressure-relieving devices protecting these vessels. This inspection code applies to all refining and chemical process that have been placed in-service. 1.1,2 Intent Application is restricted to owners/users that employ or have access to the following: a. An Authorized lnspection Agency b. A repair organization c. An engineer d. An inspector, and e. Examiners 1.2 Specific Applications Covers the reference to the alternative rules that apply to pressure vessels used for Exploration and Production service set forth in Section 9. Also lists and references the pressure vessels that are excluded from specific requirements of API 510. 1.3 Recognized Technical Goncepts Recognizes fitness-for-seruice concepts in API RP 579 which provides detaits for assessment procedures. Also recognizes RBI concepts. SEGTION 2. REFERENCES Covers the standards referenced in API 510 such as RP 572, RP-574, ASME Code Section V, VI, Vll, VIII, IX, Xl, NACE, WRC, ASNT, and the National Board Inspection Code. SEGTION 3. DEFINITIONS Each one must be understood and memorized. SECTION 4. OWNER-USER INSPECTION ORGANIZATION 4.1 Owner-User responsible for the function of an authorized inspection agency. Owner-User inspection organization shall control activities relating to the maintenance inspection, rating, repair, and alteration of these pressure vessels. GOPYRIGHT O zfiq C.qPEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apr 510 pREp GOURSE I Apr 510. 4.2 Owner-User Organization Responsibilities Responsible for developing, documenting, implementing, executing, and assessing pressure vessel inspection systems in a Quality Assurance lnspection Manual that includes: a) b) c) d) e) 0 g) h) i) j) k) l) m) n) o) p) q) r) s). Organization & reporting structure for inspection personnel Documented inspection & QA procedures Documentation & reports of inspection & test results Developing and documenting inspection plans Developing and documenting risk-based assessments Establishing and documenting he appropriate inspection intervals Corrective action for inspection and test results Internal auditing Review & approval of drawings, calculations & specifications Atljurisdictional requirements met Reporting changes to API Authorized lnspector Training Welding controls Repairs/alterations are performed in accordance with this inspection code NDE controls Material controls Calibration Controls by Owner-User for inspection & repair organizations Auditing of pressure-relieving device QC system SUGGESTED QA MANUAL TABLE OF CONTENTS SEGTION NO, 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0.12.0 13.0 14.0 15.0 4,2.2 TITLE Table of Contents Statement of Authority Organization Document and Data Control Control of Material. Corrective Action Control of Welding Control of NDE Calibration Conirol of Nonconformities Control of lnspections, Alterations and Repairs Jurisdictional Requirements Internal and Pressure-Relieving Device QC System Audits API Authorized lnsPector Training Definitions Engineer Responsible to owner/user for activities involving design, engineering review etc. copyRIGHT @ 2018 CODEU/EST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I coDEwEST API 5f 0 PREP GOURSE I API 510 4,2,3 Repair Organization Responsible to owner/user and shall provide the materials, equipment, quality control and workmanship 4,2,4 Inspeetor Responsible to owner-user for determining that requirements on inspection and testing are met and shall be directly involved in inspection activities. May be assisted in performing visual inspections by other properly trained and qualified individuals who may or may be certified inspectors. All "xamination results must be evaluated and accepted by the lnspector. Examiners Does not need API 510 lnspector certification. lnspecto/s employer shall maintain certification records SEGTION 5 - INSPECTION EXAMINATION AND PRESSURE TESTING PRAGTIGES 5,1 Inspection Plans An inspection plan shall be established for all pressure vessels and pressure-relieving devices within the seope of this code. 5.1,1 Development of an Inspection Plan Shall be developed by the inspector or engineer in consultation with a corosion specialist. Examinations must be scheduled at intervals that consider five items. 5,1,2 Minimum Gontents of an lnspection PIan Shall contain the inspection tasks and schedule required to monitor damage mechanisms and assure mechanical integrity of the equipment. The plan should cover seven items. lndustry generic plans may be used. 5.1.3 Additional Gontents of an Inspection PIan May contain other additional items, three are listed. 5.2 Risked-Based Inspection (RBl) RBI assessment determines risk by combining the probability and the consequence of equipment failure. When conducted by the owner/user it must include a systematic evaluation of both the probability of failure and the consequence of failure per API 580 COPYRIGHT @ 2018 GQDEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT I GODEWEST API 5{0 PREP GOURSE IAPI 5{0 P robability Assessment Several examples of degradation mechanisms are given as well as other factors to be considered. 5,2,2 ConsequenceAssessment Must consider the potential incidents that may occur as a result of fluid release, the size and type of the potential release. such as explosion, fire, or toxic exposure. 5.2.3 Documentation All RBI assessments must be thoroughly documented. The results can be used to establish the vessel inspection plan and better define five items. 5,2,4 Frequency of RBlAssessments They shall be updated after each vessel inspection and after each process or hardware change that could significantly affect damage rates or mechanisms. 5.3 Preparation for lnspection Regulations such as OSHA for confined spaces must be followed in addition to the company safety rules. 5.3.1 Equipment All tools, equipment and personnel protective equipment used should be checked prior to use. Comrnunication Obtain permission to work in the vicinity from operating personnel. ' - 5.3.3 Inform persons working around a vessel of individuals who will be working inside the vessel.and vice versa. Vessel Entry Basic steps prior to confined space entry: Isolate Drain Purge CIean Ventilate Gas Test Obtain entry permit Have person standby at entrance Check tools and personal safety equipment 5.3,4 Records Review Before performing any inspection familiarize yourself with the prior history of the vessel. COPYRIGHT @ 2O{8 EODEWEST I DO NOT GOPY OR DISTRIFUTE THIS DOCUMENT E I GODEWEST API 510 PREP COURSE I APr 5{0 5.4 Inspection for Types of Damage Modes of Deterioration and Failure 5.4.1 A listing of typical damage types and Mechanisms 5.5 General Types of Inspection and Surveillance 5.5.1 General lnternal lnspection On-stream inspection External inspection Thickness inspection Corrosion under insulation (CUl) inspection 5,5.2 lnternal lnspection 5,5.2,1 General Primary goal is to find damage that cannot be found by regular monitoring of external CML's. 5,5,2,2 Vessel Internals Vessels equipped with removable internals may need to be removed to the extent necessary to allow inspection of pressure boundary surfaces. 5.5.2.3 Deposits and Linings lnspector in consultation with the corrosion specialist should determine when necessary to remove deposits or linings. Spot examination at selected areas may be required. 5.5.3 On-stream lnspection May be required by the inspection plan. May be acceptable in lieu of internal inspection for vessels under the specific circumstances defined in 6.5.2. 5.5.4 External lnspection Performed to check the outside condition of the vessel surface. Any signs of leakage should be investigated. 5,5.4,2 Buried Vessels Shall be inspected to determine their external surface condition. The inspection interval shall be based on corrosion rate information obtained from 4listed sources. 5.5.5 Thickness Inspection Thickness measurements taken to verify the thickness of vessel components. copyRIGHT @ 20!8 COqEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST API 510 PREP COURSE I Apr 5{0 lnspeetor should consult with a corrosion specialist when the short term corrosion rate changes significantly from the previous identified rate to determine the cause. 5.5.6 GUI lnspection 5.5.6.1 Susceptible Temperature Range a. 100F and 3500F for carbon and low allow steels. b. 1400F and 4000F for austenitic stainless welds. I 5.5.6.2 Susceptible Locations With carbon and low allow steels CUI usually causes localized corrosion With austenitic stainless steel materials CUI usually is in form of stress corrosion cracking. '5.5.6.3.lnsulation Removal May require removal, however if in good condition and no rebson to suspect damage behind ihen not necessary to remove. 5.6 Condition Monitoring Locations CML's are designated areas on pressure vessels where periodic examinations are conducted to monitor the presence and rate of damage Each pressure vessel shall be monitored by performing a representative number of GML's to satisfy the requirements for an internal or on-steam inspection. CML's and examination points should be permanently recorded to allow for repetitive measurements at the same CML's. 5.7 Gondition Monitoring Methods Inspector should consult with a corrosion specialist or an engineer to help define the type of damage, the NDE technique and extent of examination. Ten techniques are listed. Adequate surface preparation is important and depends on individual circumstances. The ownerluser shall specifiT industry-qualified UT shear wave examiners when owner/user requires the following: a. Detection of interior surface (lD) breaking flaws when inspecting from external surface; or b. Where detection, characterization, and/or through wall sizing is required of defects. Conosion may cause a uniform loss or may cause a pitted appearance. Uniform corrosion may be difficult to detect. Measurements may be obtained by any suitable NDE, such as UT or profile radiographic examination. ' When measurement method produces considerable uncertainty other NDE thickness techniques may be employed such as UT A scan, B scan or C scan. copyRtcHT @ 2018 coDEv.vEgT I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT -7 I GODEWEST API 5{0 PREP GOURSE I API 510 Depth of corrosion may be gauged from the uncorroded surface. UT scanning or radiographic profile techniques are preferred when corrosion is localized or the remaining thickness is approaching the required thickness. lnspectors should be aware of possible sources of measurement inaccuracies Eight factors are listed. 5,8 Pressure Testing Pressure test normally required after an alteration. After repairs a pressure test shall be applied if the inspector believes one is necessary. Pressure tests normally performed on the entire vessel but can be performed on a component or section such as a nazle. An engineer should be consulted to ensure this is suitable. The code hydrostatic test pressure shall be in accordance with the rules of the rating code used to determine the MAWP. Test pressure in psi = 1.5 MAWP X (Stesttemp/ Soesigntemp), priorto 1999 addendum Test pressure in.psi = 1.3 MAWP X (Stesttemp/ Soesigntump), 1999 addendum and later When the test pressure will exceed the set pressure of the pressure relieving devices they should be removed or test clamps installed to hold down the valve disks. Other appurtances incapable of withstanding the test pressure should either by removed or blanked off. Before applying a hydrostatic test the supporting structures and foundation design should be reviewed to assure they are suitable for the hydrostatic load. Hydrostatic tests of components with 300 series stainless steel should be tested with potable water, steam condensate or with a chloride concentration of less than 50 ppm. When a pneumatic test is used the potential for personnel and property risks shall be considered by an inspector or engineer. The minimum precautions in the ASME Code shall be applied. 5.8.6 Test Temperature and Brittle Fracture Considerations Most brittle fractures occur on the first application of a high stress level such as overload or flrst hydrostatic test. To minimize the risk of brittle fracture during a pressure test the metal temperature should be maintained at least 300F above the MDMT for vessels that are more than 2 in. thick and 100F above the MDMT for vessels 2 in. or less. The test temperature need not exceed 1204F unless there is information on the brittle characteristics indicating the need for a higher temperature. Appropriate NDE shall be specified and conducted when a pressure test is not conducted after a major repair or alteration. copyRtGHT @) 2018 CODEIryEST 'o I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST API 5{0 pREp GOURSE I Apt 510 Substituting NDE procedures after an alteration may be done only if approved by the engineer and inspector. For cases where UT is substituted for RT the owner/user shall speciff industry-qualified UT shear wave examiners or the application of Code Case 2235.as applicable for closure welds that have not been pressure tested and for welding repairs identified by the engineer or inspector 5.9 MaterialVerification and Traceability During repairs and alterations, the inspector shall verify that all neW materials, including carbon steel are consistent with the specifications.. At the discretion of the owner/user or the inspector, this assessment can be made by 100% verification checking or by sampling a percentage of the materials in critical situations. API 578 has additional guidance. lf a component experiences accelerated corrosion or should fail because an incorect material was inadvertently substituted, the inspector shall consider the need for further verification of existing materials. 5.{0 lnspection of In-service Welds and Joints lnspection for weld quality is normally accomplished as part of new construction. When preferentialweld corrosion or cracking is noted, additionalwelds should be examined. If crack like flaws are detected while the vessel is in operation further inspection may be used to assess the magnitude of the flaw. Additionally, an effort should be made to determine whether the crack like flaws are from original weld fabrication or are caused by a service related crabking mechanism. Crack like flaws and environmental cracking shall be assessed by and engineer and/or corrosion specialist. Preferentialweld corrosion shall be assessed by the inspector. 5.11 lnspection of Flanged Joints Flanged joints should be examined for leakage. Flanged joints that have been clamped and pumped with sealant should be checked for leakage aqt the bolts. lf re-pumping is contemplated fasteners should be renewed first.. Fasteners should be examined visually for corrosion and thread engagement. Fasteners should be fully engaged. Any fastener failing to do so is considered acceptable if the lack of engagement is not more than one thread. The markings on a representative sample of newly installed fasteners and gaskets should be examined to determine whether they meet specifications CODEWEST COPYRIGHT.@ 2018.".l I DO NOT GOPY OR DISTRIBUTE THI$ DOCUMENT I GODEWEST Apt 5,l0 pREp GOURSE I Apt 5{0 SEGTION 6 6,2 - INTERVAL/FREQUENGY AND EXTENT OF INSECTION Inspection Duringrlnstallation and Seryice Ghanges Pressure vessels shall be inspected at the time of installation. The minimum inspection should cover three listed items. 6.2,2 Vessel Service Ghange lf the service conditions are changed, the inspection intervals shall be established for the new service conditions. lf both the ownership and location are changed, the vessel shall be internally and externally inspected before it is reused. Also the allowable service conditions and the inspection interval shall be established for the new service. 6.3 Risk-based Inspection A RBI assessm"ni ,.y be used to establish the appropriate inspection intervals for internal, onstream, and external inspections. ' 6,4 When a RBI interval for the internal or on-stream inspection exceeds the 10 year limit, the RBI assessment shall be reviewed and approved by the engineer and inspector at intervals not to exceed 10 years or moi'e often if warranted. External lnspection Unless justified by an RBI assessment, each aboveground vessel shall be given a visual external inspection at an interval that does not exceed the lesser of five years or the required internal/onstream inspection. External inspection intervals for vessels in non-continuous service are the same for vessels in continuous service. 6.5 Internal and On-stream Inspection 6.5.1 Inspection lnterval Unless justified by a RBI assessment, the period between internal or on-stream inspections shall not exceed one half the remaining life of the vessel or 10 years whichever is less. When the remaining life is less than four years, the inspection interval may be the full remaining life up to a maximum of two years. The interval is established by the inspector or engineer. For vessels in non-continuous service the interval is based on the number of years of actual service. An alternative method to establish the required inspection interval is by calculating the projected MAWP of each component per 7.3. GOPYR-IGHT O 2018 CODEWEST. I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT.A I GODEWEST APr 510 PREP GOURSE I APr 510 6.5.2 On-stream Inspection At the discretion of the inspector, an on-stream inspection may be substituted for the internal inspection in the following situations: a) b) When size or configuration makes vessel entry physically impossible; When vessel entry for internal inspection is physically possible and following conditions are met: all the 1) When the general corosion rate is known to be less than 0.005 in. per year. 4) 5) 6) 7) established for a five year period of same or comparable service; No questionable condition is disclosed by external inspection in 6.3; Operating temperature does not exceed lower temperature limits for material creep-ru pture range; Vessel not considered subject to environmental cracking hydrogen damage from fluid handled; Vessel does not have a on-integrally bonded liner such as strip-lined or plate- 2) When the remaining life is greater than 10 years. 3) Corrosive character of contents, including effect of trace components Iined. lf the requirements are not met the next inspection shall be an internal inspection. When an on-stream inspection is conducted, the type of extent of NDE should be splcified in the inspection plan. 6,5.3 Multi-Zone Vessels For a large vesselwith two or more zones of differing corrosion rates, each zone may be treated independently. Each zone shall be inspected based on the interval for that zone. 6.6 Pressure-relieving Devices Pressure-retieving devices shall be tested and repaired by a repair organization experienced in valve maintenance. 6.6.{ Quality Gontrol System Each repair organization shall have a fully documented quality control system. As a minimum the QC system shall address 17 features including having a fully documented training program 6.6.2 Testing and Inspection Intervals Pressure-relieving devices shall be tested and inspected at intervals that are frequent enough to verify that the valves perform reliably in the particular service condition. Unless documented experience and/or a RBI assessment indicates that a tonger interval is acceptable, test and inspection intervals for pressure-relieving devices in typical process services should not exceed: a. Five years for typical process services, and b. Ten years for clean (non-fouling) copyRtcHTr@ 201,E coDEwEsT and non-corrosive services. I DO NOT COPY OR DISTRIBUTE THiS DOCUMENT I CoDEWEST API 5{0 PREP COURSE I API 510 SECTION 7 - INSPECTION 7.1 Gorrosion Rate Determination 7,1,1 Existing Pressure Vessels DATA EVALUATION, ANALYSIS, AND REGORDING Long Term corrosion Rate = short rerm corrosion Rate = ti"itia - t'"t.a years between tprevious - tactrial ars between The Inspector in consultation with a corrosion specialist shall select the corrosion rate that best reflects the curent process. (Normally the highest corrosion rate for the exam) 7,1.2 Newly Installed Pressure Vessels or changes in Seruice For new vessel or a service condition change use one of following methods in the order given to determine the vessels probable conosion rate. a) b) Calculated from data collected by owner or user from same or similar service. Estimated using previous experience or published data. 0Q0 hou rs service usi ns N DE th ickness 3I":Hx[f fi:xill?i,Tffi H:' 7,2 Remaining Life Galculations Remaining life calculation to determine the limiting component is calculated per the following formula: Remaining Life (years) = A statistical analysis may taotual - trequired corrosion rate be. used in the corrosion rate and remaining life calculation. However, statistical analysis may not be applicable for vessels with randon but significant localized corrosion. 7,3 Maximum Allowable Working Pressure Determination a) b) c) Established using latest ASME Code edition or original Code edition to which vessel constructed. Certain essential details must be known prior to performing computations. In corrosive service the wall thickness used shall be actual thickness determined by inspection minus twice the estimated corrosion loss before the next inspection. t = Lctuar.- 2(corrosion rate x interval to next inspection) d) e) If the actual thickness determined by inspection is greater than repofted on the Data Report it must be confirmed by multiple thickness measurements taken at areas where the thickness of the component in question was most likely affected by the thinning due to forming. Allowances made for other loadings in accordance with ASME Code. copyRlcHT @ 20{8 C9DEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT 1.1 I GODEWEST API 510 PREP GOURSE I Apt 510 7.4 Fitness For Service Analysis of Corroded Areas The actual thickness and maximum corrosion rate for any part of a vessel can be adjusted at any inspection considering the following: 7.4,2 Evaluation of Locally Thinned Areas For a conoded area of considerable size the wall thicknesses may be averaged over a length not exceeding the following: 1. For inside diameters less than or equal to 60 inches the lesser of 20 in. or 1/2 vessel diameter 2. For inside diameters greater than 60 inches the lesser of 40 in. or 1/3 vessel diameter. Along the designated length the thickness readings should be equally spaced. For areas of considerable size, multiple lines in the corroded area may have to be evaluated to determine which length has the lowest average thickness. When circumferential stress governs critical element is along longitudinal axis. When longitudinal stress governs critical element is circumferential in direction When performing remaining life calculations the lowest average of any length in the corroded area is substituted for 7,4,3 tactual. Evaluation of Pitting During the curent inspection, widely scattered pitting may be ignored as long as all the following are true: 1. - 2. 3. The remaining thickness below the pit is greater than one-half the required thickness. Total area of pits that is deeper than the corrosion allowance does not exceed 7 square in. in any 8 in. circle. The sum of the pit dimensions that is deeper than the corrosion allowance does not exceed 2 in. along a straight 8 inch line. 7.4.4 Alternative Evaluation Methods for Thinning When thinning of walls occurs that is belowthe minimumwall thickness requirements a design by analysis evaluation using Section Vlll, Division2, Appendix4 orAPl 579, Appendix B may be employed. Resultant wall thickness may be less than that determined by calculation using Section Vlll, Division 1. When this approach is used an engineer shall perform the analysis. 7,4,5 Joint EfficiencyAdjustments When conosion of wetd surfaces with joint factor other than 1.0 and surfaces remote from weld occurs, two calculatlons are required to determine which governs the MAWP. For this calculation the surface at a weld (measured from the toe of the weld) includes the greater of 1 in. or twice the minimqm.thickness on either side of weld. COPYRI.GHT O 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOGUMENT I CoDEWEST API s10 PREP COURSE IAPI 5{0 7,4,6 Gorroded Areas in Vessel Heads When measuring corroded thickness of ellipsoidal or torispherical heads the governing thickness may be: 1. Thickness of knuckle region - use appropriate head formula (UG-32(d) or (e). 2. Thickness of central portion (80% of D) - use hemispherical head formula UG-32(0. L for elliptical heads is 0.9D. L for torispherical head is crown radius or Do. 7,5 API 579 Fitness-for-Service Evaluations Pressure containing components found to have degradation that could affect their load carrying capability shall be evaluated for continued service. API RP 579 may be used for this evaluation. The following techniques may be used as an alternative to the evaluation techniques in 7.4. To evaluate metal loss in excess of the corrosion allowance, API 579, Parts 4 or 5 as applicable. To evaluate blisters and laminations, API 579, Parl7. To evaluate weld misalignment and shell distortions, API 579, Part 8. To evaluate crack like flaws, API 579, Part 9. To evaluate the effects of fire damage, API 579, Part 11. 7,6 RequiredThickness Determination The required thickness shall be based on pressure, mechanical, and structural considerations using the appropriate formula and code allowable stress. For services with high potential consequences if failure were to occur the engineer should consider increasing the required thickness above the calculated minimum thickness. 7,7 Evaluation of Existing Equipment With Minimal Documentation For pressure vessels that have no nameplate and minimal or no design and construction documentation, the following steps may be used to verify operating integrity: 1) 2) 3) Perform inspection to determine condition of the vessel. Define design parameters and prepare drawings Perform design calculations based on applicable eodes and standards and condition of tlie vessel following any repairs. Do not use allowable stress values based on design factor of 3.5. See ASME Code Section Vlll, Division 1, paragraph UG-10(c) for guidance on evaluation of unidentified materials. lf UG-10 (c) is not followed, then for carbon steels, use allowable stresses for SA-283 Grade C: and for alloy and nonferrous materials, uie x-ray fluorescence analysis to determine material type on which to base allowable stress values. copyRtcHT @ ?q18 COPEWEST r DO NOT.COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST API 5{0 PREP GOURSE I Apt 5f 0 When extent of RT originally performed is not known, use joint factor of 0.7 for butt welds, or consider performing radiography if a higher joint factor is required. (Recognize that performing radiography on welds in a vessel with minimal or no design and construction documentation may result in the need for a fitness-forservice assessment and significant repairs. 4) 5) 7,8 a nameplate or stamping showing the maximum allowable working pressure and temperature, minimum allowable temperature, and date. Perform pressure test as soon as practical, as required by code of construction used for design calculations. Attach Reports And Records Pressure vessel owners/users shall maintain permanent and progressive records of their pressure vessels and pressure-relieving devices. Pressure vessel and pressure relieving device records shall contain four types of information pertaining to mechanical integrity as follows: :. [;s::,Hl,.;i::::,,', 1,,.n d. Fitness for service assessment documentation. 8.1 SEGTION 8 - REPAIRS, ALTERATIONS, AND RERATING OF PRESSURE VESSELS Repairs and Alterations All repairs and alterations shall be performed by a repair organization in accordance with the applicable principles of the ASME Code or the applicable repair of construction code. 8.1.1 Authorization All alterations or repairs to be authorized by an Inspector prior to work starting. Alterations to all pressure vessels and repairs to Section Vlll, Division 2 vessels must be approved by a pressure vessel engineer The lnspector will designate required fabrication approvals, The lnspector may give prior authorization for certain limited or routine repairs provided no pressure test will be required. 8,1,2 Approval Before any repairs or alterations are performed, all proposed methods of design, execution, materials, welding procedures, NDE and testing must be approved by the inspector, and, if an alteration by an engineer lnspector shall approve all repair and alteration work completion of the work in accordance with the repair plan. 8,1.3 at designated hold pointsand after Design New vessel nozzles, connections, or replacement parts must meet the design requirements of the applicable construction code. An engineer shall approve all nozzle installation. copyRtGHT O 20,!8 COQFWEST I DO NOT COPY OR DISTRIBUTE THIS 1E DoCUMENT I GODEWEST API 510 pREp COURSE I Apr.510 8.1.4 Material Material used shall conform to the applicable construction code. Carbon or alloy steel with carbon content over 0.35% shall not be welded. 8.1.5 - Defect Repairs Repairs to defects found in pressure vessel components may be made by several techniques often dependent upon the size and nature of the defect, the materials of construction, and design requirements of the pressure vessel. 8.1.5.1 Temporary Repairs Temporary repairs shall be removed and replaced with suitable permanent repairs at the next maintenance opportunity. They may remain in place longer if evaluaied, approved and documented by the engineer and inspector. Documentation should include five listed items. 8,1,5,1.2 Fillet-welded Patches. Fillet welded patches may be used to make temporary repairs. Cracks shall not be repaired in this manner unless the engineer determines that the crack will not be expected to propagate from under the patch. Temporary repairs using fillet welded patches shall be approved by an inspector and engineer. Their use may be subject to the acceptance of the governing jurisdiction. Fillet wslded patches require special design considerations and may be applied to internal or external surfaces provided they meet two conditions.. A fillet welded patch shall not be installed on top of an existing fillet welded patch. When installing a fillet welded patch adjacent to another fillet welded patch the distance between the toes of the fillet weld shall not be less than: o= 4rffi Fillet welded patches shall have rounded corners with a minimum radius of 1 inch. 8,1.5.{,3 Lap Band Repairs A full encirclement lap band repair may be considered if nine requirements are met. 8.1.5.1,4 Non-penetrating Nozzles Non-peneirating nozzles may be used for permanent repairs for other than cracks. The damage mechanism leading to the need for repair shall be considered in determining the need for any additional monitoring and future inspection of the repair. copyRtGHT @ 2o{8,.gopEWEST r DO NOT COPY OR DISTRIBUTE THIS QOCUMENT I GoDEWEST API 5{0 pREp GOURSE I Apt 510 8,1,5,2,1 Typical permanent repair techniques include: Five techniques are listed Repairing a crack at a discontinuity, where stress concentrations are high should not be attempted without prior consultation with an engineer. 8,1.5,2.2 Insert Plates Damaged or coroded shell plates may be repaired by removing a section and replacing it with an insert patch (flush) patch) provided three requirements are met. 8.{.5.3 Filler Metal Strength for Overlay and Repairs to Existing Welds Should have minimum specified tensile strength equal to or greater than that of the base metal. lf minimum specified tensile strength is lower than base metal specified conditions must be met. 8.1.5.4 Repairs to Stainless Steel Weld Overlay and Gladding Repair procedure reviewed and approved by the engineer and inspector before implementation. Consideration given to factors that may affect the repair plan. Repairs monitored by inspector. The repair shalt be inspected by the PT method per Section Vlll, Division 1, Appendix 8. Vessels constructed of P-3, P-4 or P-5 base materials should be examined for cracking by UT per ASME Code Section V, Article 4, ParagraphT-473. This inspection is most appropriately conducted following a delay of at least 24 hours after completed repairs for alloys that could be affected by delayed cracking. 8.1.6 Welding and Hot Tapping Refer to API 2201 when making on-stream welds. 8.1.6.2 Procedures, Qualifications and Records The repair organization shall use welders and welding procedures that are qualified. in accordance with the-requirements of the construction code e.g. Section IX.. Repair organization shall maintain records of its qualified welding procedures and its welding performance qualifications. These records are available to lnspector before start of welding. 8.1.6.3 Preheating Preheat temperature shall be in accordance with applicable code and qualified welding procedure. Exceptions must be approved by engineer. 8.{,6,4 Postweld Heat Treatment PWHT of pressure vessel repairs or alterations should be made using the relevant requirements of the ASME Code, the applicable construction code, or an approved alternative PWHT procedure defined in 8.1.6.4.2. copyRtGHT o 2o18.cqDEwEST I DO NOT COPY OR DTSTRTBUTE TH|S DOCUMENT.A' I GoDEWEST API 5{0 PREP GOURSE I APr 510 8.1,6.4,1 Local Postweld Heat Treatment Local PWHT may be substituted for 360 degree banding when specified precautions are taken and requirements met. Application is reviewed and a procedure developed by pressure vessel engineers. Local PWHT temperature shall be monitored by at least two thermocouples. 8,1,6,4.2 Preheat or Gontrolled Deposition Welding Methods as Alternatives to PWHT Preheat and controlled deposition welding, as described in 8.1.6.4.2.2 and 8.1.6.4.2.3 may be used in lieu of PWHT where PWHT is inadvisable or mechanically unnecessary. Prior to using any alternative method, a metallurgical review shall be conducted by an engineer. When reference is made to materials by the ASME designation, P-Number and Group Number, the requirements of this section apply to the applicable materials of the original code of construction, either ASME or other, which conform by chemical composition and mechanical properties to the ASME P-Number and Group Number designations. Vessels constructed of steels otherthan those listed in 8.1.6.4.2.2 and 8.1.6.4.2.3. that initially required PWHT shall be PWHT'd if alterations or repairs involving pressure boundary welding are performed. 8.1,6.4,2,2 Preheating Method (Notch Toughness Testing Not Required) The preheating method, when performed in lieu of PWHT, is limited to the following material and weld processes: a. Materials limited to P-No. 1, Group 1,2,3, and to P-No. 3, Group 1 and 2, excluding Mn-Mo steels in Group 2; b. Welding processes are limited to SMAW, GMAW, and GTAW; Preheat maintained at 3000F during welding The preheat temperature checked to dssure that 4 in. of the material or 4 times the material thickness (whichever is greater) on each side of the groove is maintained; The maximum interpass temperature shall not exceed 6000F; When the weld does not penetrate through the full thickness the minimum preheat and maximum interpass temperatures need only be maintained at a distance of 4 in. or 4 times the depth of the repair, whichever is greater on each side of the joint. 8.1.6,4.2.3 Controlled Deposition Welding Method (Notch Toughness Testing Required) a. Notch toughness testing such as per UG-84 and UCS-66 is necessary when impact tests are required by the original construction code or the construction code applicable to the planned work; b. Materials limited to P-No's 1,3, and 4; c. Welding processes limited to SMAW, GMAW, and GTAW; d. A WPS shall be developed and qualified for each application The WPS shall define preheat. and interpass temperature and include the post heating treatment per the supplementary essential variables in Section lX, QW-250. The test material for the qualification shall be the same material specification, type, grade class, condition of heat treatment as the original material specification for the repair. lf original material is obsolete test material shall conform as much as possible with a maximum carbon content of 0.35%; COPYRIGHT @ 2018 COPEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT 4A I GoDEWEST APr 5{0 pREp COURSE I Apt 510 e. f. PQR shall include sufficient tests to determine if the toughness of the weld metal and the heat affected zone is adequate at the minimum design metal temperature. lf special hardness requirements apply hardness testing shall be applied; The WPS shall include 9 additional specified requirements. f(8). For welds made by SMAW, after completion of welding and without allowing the weldment to cool below the minimum preheat temperature, the temperature of the weldment shall be raised to a temperature of 5000F +/- 500F for a minimum period of 2 hours 8,1.7 NDE of Welds Prior to welding, the area shall be examined using either MT or PT to determine no defects exist. Following completion of welding examine the area using either MT or PT using acceptance standards acceptable to the inspector or applicable construction code. Perform RT on weld if original required by original code of construction. Where not practical to perform RT, accessible surfaces of each new repair or alteration weld shall be fully examined using the most appropriate NDE method to determine that no defects exist. Where use of NDE techniques specified by the construction code is not possible or practical, alternative NDE techniques approved by the engineer and inspector may be used. 8.1.8 Weld Inspection forVessels Subject to Brittle Fracture For vessels constructed of materials that may be subject to brittle fracture from either normal or abnormal service appropriate inspection should be considered after welded repairs or alterations. 8,2 Rerating Rerating a pressure vessel by changing its design temperature, minimum metal design temperature, or its maximum allowable working pressure may be done only after all the following requirements have been met performed by either the manufacturer ' a. Calculations (or his designated representative). b. or an owner/user engineer A rerating shall be performed in accordance with the requirements of the vessels construction code. Current inspection records verify that the pressure vessel is satisfactory for the proposed service conditions and that the corrosion allowance is appropriate. The vessel shall be pressure tested using the applicable testing formula from the code used to perform the rerating calculations unless either of the following are true: (1) The vessel has at some time been pressure tested to a test pressure equal to or higher than the test pressure required by the rerating code. (2) The vessel integrity is confirmed by special nondestructive evaluation techniques in lieu of testing. e. The rerating is acceptable to the engineer. c. d. The rerating will be considered complete when the inspector witnesses the attachment of an additional nameplate or additional stamping that carries the information in Figure 8-1 COPYRIGHT O 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT.A I GoDEWEST Apl 5{0 PREP COURSE I API 5{0 APENDIX A - ASME GODE EXEMPTIONS The following classes of containers and pressure vessels are excluded from the specific requirements of this inspection code: a. Pressure vessels on movable structures covered by jurisdictional regulations. b. All classes of containers listed for exemption from the scope of the ASME Code other than Section Vlll, Division 1. There are 10 classes of containers. c. Pressure vessels that do not exceed the following volumes and pressures. 1. Five ft3 in volume and 250 psi design pressure. 2. Three ft3 in volume and 350 psi design pressure. 3. One-and one-half cubic feet in volume and 600 psi design pressure APPENDIX B - INSPECTOR GERTIFIGATION 8.1 Written examination shall be administered by API based on the current edition of API 510 lnspector Certification Body of Knowledge. 8.2 Certification API 510 authorized pressure vessel certificate issued when applicant successfully passes certification examination and satisfies the education and experience criteria. Education and experience shall be equalto at least one of the following: a) Bachelor of Science degree in engineering or technology plus 1 year experience in supervision of inspection activities or performance of inspection activities as described in API 510. b) A Z-year degree or certificate in engineering or technology, plus 2 years experience in the design, construction, repair, inspection, or operation of pressure vessels, of which one year must be in supervision of inspection activities or performance of inspection activities as described in API 510. c) A high school diploma or equivalent, plus 3 years of experience in the design, construction, repair, inspection, or operation of pressure vessels, of which one year must be in supervision of inspection activities or performance of inspection activities as described in API 510. d) A minimum of five years' experience in the in the design, construction, repair, inspection, or operation of pressure vessels, of which one year must be in supervision of inspection activities or performance of inspection activities as described in API 510. 8.2.2 An API 510 authorized pressure vessel inspector certificate may when issued when applicant provides documented evidence of passing the National Board examination and meets all requirements for education and experience of API 510. 8.2.3 8.2.4 Certificate is valid for three years from date of issue. Certificate is valid in all jurisdictions and any other locations that accepts or otherwise does not prohibit use of API 510. copyRIGHT @ 20{8 CODEWEST I D9 NOT GOPY OR DTSTRIBUTE THIS DOCUMENT I GoDEWEST API 510 PREP COURSE I API 5{0 8.3 Certification Agency API shall be certifying agency. 8.4 Retroactivity Certification requirements of API 510 shall not be retroactive or interpreted as applying before 12 months after date of publication of this edition and addendum Recertification requirements of 8.5.2 shall not be retroactive or interpreted as applying before 3 years after date of publication of this edition and addendum. 8.5 'Recertification B.5.1 Recertification is required 3 years from the date of issuance of the certificate. Recertification by written test is required if Inspector has not. been activeV engaged within previous three years.. 8.5.2 Actively engaged is defined as: a. Minimum of 20% of time spent performing inspection activities or supervision of inspection activities over most recent 3-year certification period. b. Performance of inspection activities or supervision of inspection activities on 75 pressure vessels over most recent 3-year certification period. Note: lnspection activities common to other API inspection documents (NDE, record-keeping, review of welding documents, etc.) may be considered here.. 8.5.3 ":, Once every other recertification period the inspector shall demonstrate knowledge of revisions to API 510 that were instituted in the previous six years. copyRtGHT @ 20iB GoDEWEST I Do NoT coPY oR DISTRIBUTE THIS DoGUMENT I GODEWEST API 510 PREP COURSE I Apt 510 Math Problems: Prohlem #{ A vessel is in service and the lowest thickness reading is.832". The corrosion rate has been calculated to be.012"1yr. A MAWP must be calculated for eight years in the future. What is the projected "f'for the eight year span? 1) 2) 3) 4) 0.593" 0.640" 0.779" 0.616" Problem # 2 An eight foot diameter vessel has a large area of general corrosion (32 in. in length and width) and has thickness readings taken in the circumferential (lettered rows, eg. 1a, 2a,3a,) and longitudinal (numbered rows, 1a, 1b, 1c) directions as shown below. What would be the least thickness along the most critical element considering that circumferential stress governs? 1a-0.298" 2a-0.243" 3a-0. 92" 4a-0. 85" 1b-0.264" 2b-0.230', 3b-0.1 85" 4b-0. 93" 1c-0.223" 2c-0.180" 3c-0.204" 4c-0.210" 1 1 1 1) 2) 3) 4) 5a-0.267" 5b-0.220" 5c-O.246r' 0.206" 0.193" 0.17e" 0.1e5 Problem # 3 A six foot diameter vessel has a large area of general corrosion (24 in. in length and width) and has had thickness readings taken in the longitudinal direction (numbered rows, eg. 1a, 1b, 1c) and in the circumferential direction (lettered rows, eg. h, 2a, 3a,) as shown below. What would be the least thickness along the most critical element considering that longitudinal stress governs? 1a-0.456 2a-A.443 3a-0.388 4a-0.443 1b-0.458 2b-0.423 3b-0.334 4b-A.457 1c-0.398 2c-0.399 3c-0.368 4c-0.447 1) 0.447 in. 2) 0.363 in. 3) 0.388 in. 4) 0.422 in. 5a-0.550 5b-0.589 5c-0.498 Problem # 4 A pressure vesset is 48 in. in diameter. There is some widely scattered pitting present. The wall thickness including a 0.125 in. corrosion allowance is 0.750 in. One group is encircled by an eight inch diameter circle that contains the following. One 1" dia. x 0.20" deep pit, three 314" dia. pits x 0.20" deep pits and, one 1-112" dia. x 0.15' deep pit. A straight line is drawn through the most pits within the circle and includes one of the 3l4",the 1" and the 1.5" pits. '' I r t CODEWEST O 2O{8 4U lC, \'\'IJEYYE;o GOPYRIGHT L'Vf I l\.llgn I \i,' DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT a _ I GoDEWEST APr 510 pREp COURSE I Apr 510 a. What is the total area of the pits within the 8 in. circle? 1) 2) 3) 4) 2.500 in2 3.876 in2 1.325 inz 7.250 inz b. What would have to be done to the pits in the straight 1) 2) 3) 4) line to make them acceptable? Nothing they are acceptable as is Weld repair the 1.5" dia. pit Fill all pits with an epoxy material None of the above applies Problem # 5 A pressure vessel is found to have a corroded area that includes the longitudinal welded seam. An evaluation must be made to determine whether the thickness at the weld or remote from the weld governs. The inside radius is 36 in., which includes a 0.125 in. corrosion allowance. The MAWP is 500 psig, S = 17500 psi, E =.7 and tr is 1.511". What is the width of the band of the weld as a result of the evaluation if the width from toe to toe was 1.000 in? 1) 2) 3) 4) 7 in. 2 in. 3.022in. 7.044 in. Problem # 6 A pressure vessel shell has a measured thickness of 0.678 inches and a required thickness of 0.570 inches. The short term corrosion rate is 0.023 inches per year and the long term corrosion rate is 0.015 inches per year. What is the remaining life of the shell? 1) 2) 3) 4) 7.2OO years 6.000 years 8.123 years 4.695 years Problem # 7 The bottom head of a vessel has had the following thickness readings taken since being put into service in 2001.2004 = 0.750",2005 =0.720",2007 = 0.650",2009 = 0.623". The required thickness is 0.553 in. What is the next inspection interval? 1) 2) 3) 4) 2.0 years 2,755 years 6.2 years 10 years copyRrGHT @ 2or8 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I CoDEWEST API 510 PREP COURSE I Apt 510 Problem # 8 The following readings were taken for a pressdre vessel. New in 2OO2 - 0.689", 2AO4 - A.527",2006 0.500', 2008 - A.467'. What is the short term corosion rate? 1) 2) 3) 4) 0.036 0.006 0.016 0.037 in./year in./year in./year in./year Problem # 9 Using the data in problem # 8 what is the long term corrosion rate? 1) 2) 3) 4) 0.037 in./year 0.0235 in./year 0.100 in./year 0.001 in./year Problem # 10 During the inspeetion of a horizontal pressure vessel a corroded area was found on the inside surface, the thickness at the point was measured to be.906 inches thick. Checking the ASME Data Report for the vessel it was found that the shell plate was 1.0 inch purchased thickness, 48 inch inside diameter, of SA-516 Gr. 70 material, the shell was rolled and welded using a type 1 longitudinal seam with full radiographic examination. Allowable Stress is 20,000 psi and CA is 0.25 in. What would be the maximum pressure permitted for continued operation if CA is fully maintained? 1) 2) 3) 4) 722psi 537 psi 1010 psi 738 psi Problem # 11 a horizontal pressure vessel, 48 inch actual inside diameter, 1.25 inch measured thickness immediately adjacent to the longitudinal weld joint; material is Sfu516 Gr 70 normalized material, S = 20,000 psi, nameplate is stamped RT-3 and no specified corrosion allowance. All vessel seams are type 2 welds. Given the above conditions what is the maximum pressure permitted for this condition? On 1) 2) 3) 4) 543 psi 858 psi 808 psi 225 psi copyRlcHT gopEWEsT @ 20_{g -. '."' I DO NOT COPY OR DTSTRTBUTE THIS DOCUMENT 4' I GoDEWEST API 510 PREP GOURSE I API 510 Problem #{2 Avessel operating in the horizontal position has an inside diameter of 20'and is operated half full of water. CA is.065....no corrosion has occurred. The MAWP is 55 psig with a iemperature of 325 F. The nameplate shows RT 3; Category A weld is a full penetration single vee with backing left in place; allowable stress @325 F = 18,800 psi. What is the minimum required thickness to operate atthe present MAWP? 1) 2) 3) 4) 0.540 0.438 0.475 0.379 in. in. in. in. Problem # 13 During a recent inspection of a horizontal pressure vessel a minimum thickness was measured to be 2.5 inches. Checking the ASME Data Report for the vessel it was found that the shell plate was 2-314 inch purchased thickness of 5A-516 Gr 70 material, S = 20,000 psi, the shell was rolled and welded using a type 1 longitudinal seam with full radiographic examination. The original design defined the inside diameter as 57.00 inches. The design pressure (P) is 875 psig at 4500F. Plant records indicate a corrosion rate of 0.030 inches per year of service on the inside surface of the vessel. With a constant corrosion rate, what is the time interval to the next required internal inspection of this vessel? 1) 2) 3) 4) 30 years 10 years 22 years 3 years Problem # 14 On a horizontal pressure vessel, 60 inch actual inside diameter, made of SA-515 Gr. 70 normalized material, S= 19,400 psi. The vessel nameplate reads MAWP 600 at 350 F., RT-2. All vessel seams are Type 2 with backing left in place. The Data Report shows that a corrosion allowance was not specified. Corrosion rate is.030"/yr. Actual thickness is 1.136 in. What is the remaining life of the vessel? 1) 2) 3) 4) 4.874 yr. 5.073 yr. 2.766 yr. 1.889 yr. Problem # 15 A pressure vessel has just received its second in-service inspection after four years of service. The shelt's.originat inside radius was 26.625". lts current measured thickness is 1.36". The shell's original thickness was 1.433"; a thickness of 1.431 was determined from an inspection at 2 years. lt is made of a material with a stress value of 15000 psi and a joint efficiency of 1.0. The MAWP is 685 psi with a 5 psi static head. No corosion allowance is specified. What is the remaining corosion allowance for the shell? a) 1) 2) 3) 4).250.1o1.303.054 in. in. in. in. copyRtcHT @ 2018 coDEwEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I CoDEWEST API 5{0 PREP COURSE I API 510 b) What is the remaining life of the vessel considering LTCR? 1) 5.5 years 35 years 2) 3) 4) 2.7 years 10 years Problem # 16 An in-service vessel has an area of localized corrosion in the crown region of one of the buo 2:1 ellipsoidal heads. Actual thickness is 0.883", S = 22.5KSI, the lD is 60" and no radiography was performed when the vesselwas manufactured. What maximum pressure is permitted on the locally thinned area? 1) 2) 3) 4) 733 633 702 588 Problem # 17 On this same vessel the other heaO has localized corrosion leaving a thickness of 0.883" on the flange and knuckle of the head. What maximum pressure is permitted on the locally thinned area? 1) 2) 3) 4) 4eB 561 317 3e4 Problem # 18 Using the "MAWP" alternative method for determining the next inspection interval what minimum MAWP stamping on the vessel nameplate would be required based on the following? S=20000psi 0.636" 1) 403 2) 288 3) 377 4) 366 t actual= R=30" E = 1.0 COPYRIGHT O 2O1E CR = 0.004 in/yr Interval desired = 10 yrs qODEWEST I DO NOT qOPY OR DISTRIBUTE THIS DOCUMENT A I GODEWEST API 5{0 PREP COURSE I API 510 Problem # 19 An existing vesselwith no nameplate or MDR is to be included in an API 510 inspection program due to a change of-ownership (new owner disagreed with exclusion by the former owner). A condition assessment deterinined the vessel is in excellent c.-ondition and atfirmed that the shell long seam is a type 1 weld and that construction is carbon steet. The only documentation available is an old fabrication drawing that provided the following dimensions but had iro bill of material. Assume allowable stress (300 D_ for one of ihe foilowing per Aptb10...sA-285 Gr A- 12.9 KSI....SA-283 Gr C 15.1 KSI.....SA 516 Gr 70 - 20 KSI. Considering a.0625 CA is to be maintained what MAWP can be applied to a nameplate? - 1) 2) S=? R = 60"' t nominal= 0.500" E=? 58 76 3) 79 4) 63 Problem # 20 A recent inspection of a pressure vessel disclosed a large surface gouge foyr.ilc_hes long. A weld overlay repair is to be performed after excavation to a depth _of 3_0 milq. Checking the ASME Data Report for the vessel it was found that the pipe shell was SA-106 Gr. G having an ultimate tensile strength of 75 KSI. What is the minimum depth of deposited weld metal if using E-7018 electrodes? 1) 2) 3) 4).033.030.032.035 in. in in. in. Problem # 21 A lap patch.is to be installed on a vessel that is 10 ft long and 5 foot diameter close to another lap patch.. The measured thickness in the area of the patch is 0.55 in. The shell is SA-516 Gr. 70 with an allowable stress of 20,000 PSI. What is the minimum required spacing between patches? 1) 2) 3) 4) 15.50 in. 21.20 in. -17.25 in. 16.25 in. GOPYRIGHT @. 201,8 gO D El/'l/EST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apr 5{0 pREp COURSE I Apt 5{0 Solutions: Problem: 1 Reference - API 510, 7.3.3 The projected o't'o at eight years is: t = tactuar - 2(corrosion rate x interval to next inspection) = 0.832 -2(,012x = 0.832 - 2(.09G) = 0.832 - 0.192 I yrs) = 0.640" Problem: 2 Reference - API 5'|-0,7,4.2,3 ' Gonsidering the longitudinal joint direction the lowest average in the numbered rows is column three with 0.{93" Problem: 3 Reference - API 510, 7,4,2.3 Gonsidering the circumferential direction, the lowest average in the numbered rows is row with 0.422". 3 Problem:4 Reference - API ilA,7,:A.3(b)(c) a) A=d2x0,7854 ({)'x 0.7854 = 0.7854 in2 (0.75)2 x 0.7854 x 3 = 1,325 inz ({.5)2 x 0.7854 = 1,767 inz Total area = A.7854 + 1,325 + 1.767 Total area = 3-877 inz copyRIGHT @ 2018 cgpEwEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT I. GoDEWEST Apr 510 pREp COURSE I Apt 5{0 b) 0,75 + 1 + L5 = 3.2b" are the pit dimensions in a straight line. 3.25" is greater than 2" the pitting in a straight line is unacceptable As a minimum the 1.5" diameter pit must be repaired leaving 1.75" which is less than the 2".'. the pitting would then.be acceptable Problem: 5 Reference - API 510, 7.4,5 1'51"{x 2) = g-022" on each side of the weld. Therefore the total width of the weld is 2 x 3,022 or 6.0M in plus 1.000 in. or 7,044in,, Problem: 6 Reference - API 51A,7,2.1 Remaining Life = t acgreb t required _ Remaining Life = 9-,620. -_9.520, 0.023 Remaining Life = 4.695 years Problem: 7 Reference - API 510,7,1,1,1 torevious - - Lctua1 STCR = years between STCR = 0.650 -_0.623 STCR = 0.0135 in./year LTCR = tioiti*t - Lctual years between LTCR= 0,750-0.623 5 LTCR = 0.0254 in./year GOPYRIGHT O 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT.tfl I coDEwEST APr 510 PREP COURSE I API 5{0 tactual Remaining Life = Remaining Life =c - treErired corosionrate 0,62L - 0.553 0,0254 Remaining Life = 2,755 years The next inspection interval is 2.00 years. Problem: 8 Reference - API 510, sTcR 5 -- tprevious --- - 7 ,1 ,1.1 tactual years between STGR = 0.500 STGR = 0.016 in,/year :0.467 Problem: 9 ] Reference - API 5{0, 7,1.1,1 LTCR = tioitiat - taoaral years between LTGR = 0.689 LTGR = 0.037 in./year :0,467 Problem 10 Giuen 5A-516-70 = 20,000 psi t =.906" GA = ,25" E = 1.OO R=24" copyRtGHT G) 2018 GODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apt 510 pREp COURSE I Apr 510 FORMULA: UG-27(cX1) P SEt - - NOTE: To maintain the R+ A.6t P: full.25" GA subtract from o't" actual 20000 x 1.0 x (.906-.250) 24+[.6x(.906-.2s0)] = 20000 x.656 24+(6x.65Q : p 13L20 24.3936 = 537,845 therefore round down to 537 PSI Problem 11 GIVEN: S = 20,000 spot RT on the Longitudinalweld. Therefore, a type weld yields a.80'E per Table UW {2 E =.80 since RT 3 = t= 2 1.25" (actual) R=24 FORMULA: P SEt = R+- 0.6t UG-27(cX1) NOTE: Use actual "t" x.80 x {.25 24 + (.6X1.251 P = 20000 = 20000 24,75 = 808.08 therefore round down to 808 PSI Problem {2 GTVEN: P= E= 55.8 (RT-3 R = 120" S = 18,800 Static Head = 1O'x.433 = 4.33 psi - vessel meets req. for spot per UW COPYRIGHT @ 2018 CODEWEST I - 11(b) and Table UW -{2 DO NOT COPY OR DISTRIBUTE THIS DOGUMENT I GoDEWEST API 5{0 PREP GOURSE I API 510 FORMULA: PR f= ,sB f= - 0.6P 59.33:x 120 18800x.8-,6x59.33 ' = t= UG-27(cl(11 7119.6 15004,4 O.475" Problem 13 GIVEN: Measured minimum thickness = 2,500* Original thickness = 2,75" S = 20,000 psi E = {.00 28,5 inches Radius for calculation = 57 I 2 P = 875 psi Gorrosion rate/year = 0.030" = FORMULA: UG-27(cl(11 & API 5{0, 6.3 tr = PR _ -* SE _ O.6P tr= (tr never changes over the life of a vessel!) 875x28.5 -.6 x 875 20000 x {.0 = 24938 19475 tr = {.282'minimum required thickness Remaining Life RL= = tactuat :tr:3Y1= corrosion rate - 2.500 -1.28A 1.216.030 RL = 40.5 years therefore the next interval is {0 years per API 5{0, 6.4 copyRtcHT G) 2o1s COpEWEST r.DO NOT COPY OR DISTRIBUTE THIS DOGUMENT I GoDEWEST Apr 510 pREp couRsE Apt 510 I Problem 14 GIVEN: P=600 S = 19,400 lD=60",...R=30" RT-2.,,, E =.90 T (act) = 1,25" GR = 0.030 in./year FORMULA: UcaT(c)(I) PR t.= ^sE tr= - a.6P 600x30 19400 x 0,9 -.G x 600 = 18000 17100 tr = {.053" Remaining Life Remaining Life = = taauat -trequired coruosion - rate {.{36 - ,1.083.030 Remaining Life = 2,766 years Problem 15 GIVEN: S= 15000 to = 1.433" t" = 1.36" E=1.0. PreEent inside R = 26.625" Static head = 5 psi MAWP = 685 psi Vessel €lge = 4 years FORMULA: UG-27(cX1) PR L- ^sE - a.6P COPYRIGHT @ 2018 COqEWEST I DO NOT COPY OR DISTRIBUTE THIS DOGUMENT I CoDEWEST Apr 5{0 pREp GOURSE I Apt 510 [= 690x26.625 15000x1.0-6x690 = 18371 14586 f= 1.259" Therefore: (a) 1.360 1.259 0.101" of metal available for corrosion allowance (b) LTGR tnifiat - = tacna Remaining Life = years LTGR = {.433 - 1.360_ 4 LTGR =.018 in/year tacnal - trequired cr Remaining Life = {.960 - 1.2s9 Remaining Life = 5.8 years.018 Problem 16 Reference -API-510,7,4.6,1(b)...,.corrosion in the crovyn - use the Gode hemi head formula Therefore: Given $ = 22500 psi f = {.0 (ref. API-5.10,7,4.5.,.,not near a weld) = |= { P..883 From Table 7-1,,,,ru = = 0,9 therefore KrD = (.9XG0) = 54,, 2Set L + 0.2t =(2)M (54) + (.2X.883) = = 39735. 54,1766 733.4....round down to 733 psig COPYRIGHT @ 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST API 510 PREP GOURSE I API 510 Problem 17 in the knuckle - API-510,7,4,6,{(a).....corrosion Reference - use the Code ellipsoidal formula Therefore: Given g = 22500 psi f =.85 [ref. UW-{2(d)l f =.883 f)= 60" = P 2SEt D + o.Zt = (2X225001(.85)X.883) (60) + (.2X.883) = = 33774.75 60.1766 561.2...round down to 561 psig Problem 1E - AP I-.5 1 0, 7.3.,,..MAWP Referen ce Determ i n atio n Therefore: Given $ = 20000 f= t.'!,0 actual = ,636" CR =.004 R=30" I-10yrs P= SEt and t=tactuat-2(GRxyears) R + 0.61 t (proiected) = '636 P -2(0A4x 10) =.636 -.080 =.556 = ' 20000({.0X.556) 30 + (.6)(.556) = =. M124. 30.3336 366.69..,round down to 366 psig-,-'and therefore the stamped MAWP must be equal to or greater than 366 in which ease we can apply the desired 10 year inspection interval. "COPYRIGHT O 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT ?tr I GoDEWEST API 5{0 PREP COURSE I API 510 Problem 19 - Reference API-51A,7.7 - Evaluation of Equipment with Minimal Documentation Given S = Use 15100 for SA-283 Gr' G E = Use ,70 since RT is unknown t = 0.50" R=60" GA =.0625 FORMULA: UG-27(cXl) SEt p= R+ 0.6t = - ({5{00X.70X.500-.0625) 60 + (.6)(,500-.0625) = = 4624.375 60,2625 76,73..,,round down to 76 psig Problem 20 Reference - API 510, 8'1 ,5,3.2 Given: d=,030in' Sbase Sritl = = 75 KSI 70 KSI Tfin = dXSnase/Sntt =.030 X75170 = 030 X1,0714 Tfill =.032 in. Problem 21 Reference - API 510, 8.1 ,5-1-2,3' Given: 5 ft dia. "...therefore R = 30 in. Tact = 0'55 in' d=4/Rt d=4 /30x.55 = 16.25 in. spacing between Patches GoPYRIGHT@20IsGoDEWESTIDoNoTcoPYoRDISTRIBUTETHISDoGUMENTI 2A coDEWESTApt 5{0 pREp couRSE JApt 5{0 PRACTICE QUESTIONS SELECT THE BEST ANSWER 1. The application of API 510 is restricted to organizations that: a. fabricate or build pressure vessels according to ASME B&PV code. b. employ or have access to an authorized inspection agency. c. manufacture or inspect pressure vessels according to NBIC. d. hire or have access to an unsanctioned inspection agency. 2. APl510 Inspection Code is only applicable to pressure vessels used by the petroleum and chemical process industries that a. are being fabricaied for the petroleum/chemical industries. b. can be fabricated to ASME B&PV Code and inspected by NBIC inspectors. c. will be place in service after fabrication to the ASME B&PV Code. d. have been placed in service; inspected and/or repaired by an authorized agehcy 3. Which of the following is an example of a pressure vessel covered by API 510. (All of the vessets are 'in-service.) a. Pressure vessel on an ocean-going ship, operates at 100 psig & 1000 F. b. Pressure vessel in a oil refinery, operates at 5 psig and 700 F. c. Pressure vessel in a oil refinery, operates at 100 psig and 2000 F. d. Pressure vessel in a oil refinery, vol. of 4 cu. ft., & operates at70 psig and 700 F. 4. lf there is a conflict between the ASME Code and API 510 for vessels that have been placed in service, the requlrements of: a. API 510 shalltake precedence over the ASME Code. b. ASME Code shall take precedence overAPl 510. c. NBIC shall be used as an arbitration Code. d. the owner/user shall take precedence over both Codes. 5. One type of Authorized Inspection Agency is: a. An inspection organization that does inspections. b. An insurance/inspection agency which does not write pressure vessel insurance. c. An owner/user of pressure vessels who maintains an inspection organization only for his own equipment. d. An independent third party consultant. 6. The term "required thickness" is the thickness: a. essential for the shell and heads of a vessel. b. required for each element of a vessel. c. necessary for the shell of a vessel. d. including the corrosion allowance for the shell of a vessel. COPYRIGHT @ 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST APr 5{0 PREP COURSE I Apt 510 7. Lowering of the maximum allowable working pressure or temperature rating of a vessel or both below the design conditions is: a. not a permissible way to provide for corrosion. b. the preferred way to provide for corrosion. c. the only way to keep a vessel in service when it is corroded. d. a permissible way to provide for corosion. 8. An owner-user is res;ionsible for developing, documenting, implementing, executing, and assessing pressure vessel inspection systems and inspection procedures that will meet the requirements of API 510. These systems and procedures will be: a. maintained in a engineering procedure document. b. kept as a standard procedure. c. contained in a quality assurance inspection manual. d. in hand and available at owner-user headquarters. 9. Who should develop the Inspection PIan?. a. The b. The c. The d. The owner/user. contractor or contractor representative. inspector or engineer. planner or field superintendent. 10. Deleted 11. When developing an inspection plan, equipment shall be evaluated based on damage mechanisms.. _ types of a. estimated or conjectural b. present or potential c. unspecified or assumed d. suspected or supposed 12.Type of damage, rate of damage progression, tolerance of the equipment to the type of damage, probability of the NDE method to identify the damage, and maximum intervals as defined in codes and that sets the time for equipment examinations. standards are all items that help determine the _ a. planning b. operation's schedules c. manpower availability d. interval. COPYRIGHT O 2018 CODEW. EST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I coDEWESTApt 510 pREp COURSE lApt 510 13, When variables that may impact damage mechanisms or deterioration rates are identified, the inspection plan shall be reviewed: a. and modified to fit the expected equipment downtime. b. and amended as needed. c. with maintenance planning to see if it wilr fit their schedule d. and reported to operations for possible changes 14. An inspection plan contains inspection tasks and schedules required to monitor damage mechanisms. What major function does this assure? a. cooperation of maintenance and inspection. b. ontime completion of inspection and maintenance work. c. the mechanical integrity of the equipment. d. Iimited downtime of refinery equipment. 15. lnspection plans may also contain other details to assist in understanding the reasons for establishing and executing the plan. Pick the item listed below that could provide additional contents to an inspection plan. a. List.the codes and standards that the inspection is based upon. b. ldentify the nest inspection date for each inspection type. c. Define any special access requirements. d. Describe any required repairs. 16. An operations manager is looking for a way to keep from shutting a unit down for inspection. He calls in the inspector and-asks him if there is a safe way of extending the inspection interval for a year. The inspector states: a. We cannot extend the unit's inspection interval. b. It is your unit; you can run it as long as you wish. c. We can call in contractors for extra NDE work and use that to justify an extended interval. d. We can run a risk-based inspection on the unit to see if we can extend the interval. 17. Whatother method (otherthan Codes orstandards) may be used to determine inspection intervals and the type and extent of future inspection examinations? a. Risk-based lnspection (RBl). b. Operational directives. scheduling. d. Manpower availability. ' c. Maintenance 18. A RBI assessment determines risk by combining the and the consequence of equipment failure. a. certainty b. probability c. uncertainty - d. confidence COPYRIGHT O 2018 CODEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST API 5{0 PREP COURSE I API 510 1g. During a RBl, considering factors such as correct materials of construction, vessel design conditions relative to operating conditions, design codes and standards utilized effectiveness of corrosion monitoring firograms, and quality of maintenance and inspection quality assurance/quality control programs, are part of a: a. inspection opinion. b. physical estimation. c. condition appraisal. d. probability assessment. 20. When conducting a RBI and you assess what happens when a process leak occurs, (an explosioh, a fire, or toxic fluid) is called a: a. damage appraisal. b. consequence assessment. c. insurance estimation. d. repair estimate. 21.ltisessentialthatallRBlaSSeSSmentsbethoroughIy-inaccordancewithAPl580,Section 16. a. documented b. accepted c. established d. reputable 22. How often shall a RBI assessment be updated? a. The assessment change. b. The assessment change. c. The assessment change. d. The assessment change. shall be updated after each vessel inspection and at each process or hardware shoutd be updated after each vessel inspection and at each process or hardware may be updated after each vessel inspection and at each process or hardware can be updated after each vessel inspection and at each process or hardware 23. Why is it important to update a RBI assessment? a. It is important to have proper paper work to show OSHA that you are safely extending the operating time. b. Records must be kept up to date in order to have excellent records in the event of a failure. c. Any process or hardware change could significantly affect damage rates or damage mechanisms d. Alllurisdictions require the paper work to be done' 24.\Nhy are safety precautions important in pressure vessel inspection and maintenance activities? a. Process fluids may be harmful to some workers' b- Process fluids can cause rash on some workers c. Process fluids are flammable. d. Process fluids are harmful to human health'. copyRreHT @ 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apt 510 pREp COURSE J Apt 510 25. Pick the best example of "other equipment" that is needed for inspection of pressure vessels. a. Scrapers and hammers b. Rules and Levels c. Scaffolding and ladders. d. Ultrasonic testing devices. 26.DuringaninspectionofpressurevesselS,perSonaIprotectiveequipment required either by regulations, the owner/user or the repair organization. a. may b. shall c. should d. can 27. When individuals are working inside a vessel, they should: a. rely on the job foreman to insure communications with workers inside the vessel is adequate. b. be informed when any work is to be done on the outside of the vessel or near the vessel. c. not be concerned with loud noises or disturbances outside the vessel. d. let the entry attendant what type work they will be doing inside the vessel. 28. Pick the item below that is not necessarily required prior to entering a vessel. a. The vessel shall be isolated from all sources of liquids, gases, vapors, radiation, and electricity. b. The vessel should be drained, purged, cteaned, ventilat6d, and gas free before it is entered. c. The vessel's prior fabrication record shall be reviewed d. Continuous safe ventilation should be ensured. 29. Before performing any of the required API 510 inspections, a. inspectors shall familiarize themselves with prior history of the vessel they will inspect. b. inspectors should familiarize themselves with prior history of the vessel they will inspect. c. inspectors may familiarize themselves with prior history of the vessel they will inspect. d. inspectors ought to familiarize themselves with prior history of the vessel they will inspect. 30. Pressure vessels are susceptible to various types of damage by several mechanisms. One type of damage is General and local metal loss. Which of the problems listed below that is not considered general and local metal loss? a. Sulfidation. b: Oxidation. c. Fatigue cracking d. Naphthenic acid corrosion. 31. Which of the damages listed below falls under the classification of subsurface cracking? a. Fatigue cracking b. Caustic stress corrosion cracking. c. Sulfide stress corrosion cracking. d. Hydrogen induced cracking. copyRtGHT @ 2018 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GODEWEST.API 5{0 PREP GOURSE lApt 510 32. Which of the damages listed below falls under the classification of microfissuring/microvoid formation? a. Fatigue cracking. b. Temper embrittlement. c. Graphitization. d. Creep. 33. Vessel material of construction, design, construction and operating conditions are all factors that help determine a. tl're effectiveness of it. b. the efficiency of it. c. the presence or potential of damage in it. d. the necessity for careful monitoring. 34. Detailed information concerning common damage mechanisms (critical factors, appearance, and typical inspection and monitoring techniques) in vessels is found in: a. API 576 b. API 571 c. API 510 d. APt 577 35. Internal inspection, on-stream inspection, external inspection, thickness inspection, and CUI inspection are all different types of inspections and examinations. They are depending on the circumstances and the pressure vessel. all a. inappropriate b. unsuitable c. appropriate d. required 36. A primary goal of the internal inspection is to find: a. damage to trays and tray parts. b. if the inspection plan is accurate. c. internal pressure boundary surface damage. d. damage that cannot be found by regular monitoring of external CMLs. 37. When vessels are equipped with removable internals, internals may need to be removed to allow inspection of pressure boundary surfaces. The internals: a. should be removed completely to assure that no damage is hidden by their presence. b. must be left in place in order to prevent any changes to operational charaeteristics. c. may be removed completely to assure that no damage is hidden by their presence. d. need not be removed completely as long as damage is not hidden by their presence. 38. Delete COPYRIGHT @ 2018 CODEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apt 5{0 pREp GOURSE I Apr 5{0 39. In order to insure the good condition and the reliability of pressure vesset internals (trays, bubble caps, baffles, etc.) inspectors are often requested to check this equipment by: a. inspection supervisors. b. maintenance personnel.. c. operating personnel. d. jurisdictional personnel. 40. An inspector finds evidence that coke or some type of deposit is behind a lining of a pressure vessel. Who should the inspector consult with in determining if it is necessary to remove the linings and/or the deposits? ' a. The pressure vessel engineer. b. A corrosion specialist. c. Operation supervisor. d. The maintenance superuisor. 41. lt a deposit such as coke is permitted to remain on a vessel's internal surface, it is important to determine whether these deposits protect the vessel or possibly cause deterioration of the vessel shell. What would be the minimum way to determine the vessel's surface condition? a. Thoroughly corrosion. b. Thoroughly vessel. c. Thoroughly d. Thoroughly remove 30% of the deposits from the lower part of the vessel shell and check for remove all the deposits from the vessel surface and make a complete inspection of the remove the deposits at selected areas and spot examine the areas for corrosion. remove 5096 of the deposits from the vessel shell and check for corrosion. 42. Without removing a vessel's internal lining, how would an inspector check a vessel shell if he suspected corrosion was taking place beneath the lining? a. Lightly tap on the lining with a small hammer. b. Use external NDE such as UT inspection. c.,Consult a corrosion specialist. d. Drill an inspection hole in the external vessel shell. 43. Who authorizes and approves all on-stream inspection work performed by an examiner. a. The authorized inspector. b. Jurisdictional authorities. c. The maintenance supervisor. d. The operations supervisor. 44.Who conducts all on-stream inspections? a, An inspector b. An inspector or an examiner. c. An examiner. d. An engineer. CoDEWEST APr 510 pREp GOURSE I Apr 5{0 45. When on-stream inspections of the pressure boundary of a pressure vessel are specified, they shall be: a. designed b. designed c. designed d. designed to detect to detect to detect to detect the wall thickness of the pressure vessel. the damage mechanisms identified in the inspection plan. all damage mechanisms identified by API 571. all damage mechanisms that have been identified in past inspections. 46. NDE techniques used in on-stream inspections are chosen for their ability to identify particular internal damage mechanisms from the exterior and their capabilities to perform the on-stream conditions of the pressure vessel. Which of the conditions listed below would be an example of a condition that would provide some difficulty in the use of a NDE tech a. availability of manpower. b. availability of the eorect equipment. c. metal temperatures. d. location of the vessel. 47. During an external inspection particular attention should be given to welds used to attach components and clips for cracking or other defects. Which of the items listed below would the inspector be checking? a. anchor bolts for ladders b. platform handrails. c. reinforcement plates, and clips. d. anchor bolts for vertical vessel base plates. 48. Normally, weep holes in reinforcing plates should remain open to provide visual evidence of leakage as well as to: a. provide operators a heads-up for possible on-stream leakage. b. prevent pressure build-up behind the reinforcing plate. c. provide a threaded hole where a pressure gage may be attached to see if there is pressure present. d. prevent hydrogen build up from any internal corrosion occurring in the vessel. 49. An operator calls an inspector and reports that a vessel on his unit is bulging. What should the inspector do? a. The inspector inspection. b. The inspector problem. c. The inspector d. The inspector should check the vessel records to see if there was a problem at the last vessel should check the overall dimension of the vessel to determine the extent of the should tell the operator to notify the operating foreman or supervisor. should suggest that the vessel should be taken out of service immediately. 50. Buried vessels shall be inspected to determine their exiernal surface condition. This corrosion rate may be arrived at in at least 4 different ways. From the list below, pick the correct way to obtain this corrosion rate. a. Rely on reports from operating personnel. b. Wait until maintenance has to excavate areas around the vessel. c. Rely on metallurgical information from textbooks. d. lnspect representative portions of the actual vessel by excavating. COPYRIGHT 9 2O{8 GODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apt 510 pREp couRsE I Apt 510 51. Thickness measurements are taken to verify the thickness of vessels and their components. What is this data used for? a. The b. The c. The d. The data is used to predict the operating capabilities of the vessel. data is used to provide busy work for the inspector or examiner. data is used to show OSHA that the company is monitoring the thickness of the vessel. data is used to determine the corrosion rates and remaining life of the vessel. 52. An inspector, while conducting an on-stream inspection of an operating pressure vessel, finds that the short-term corrosion rate has accelerated from the identified rate. Who should he consult with? a. A corrosion specialist. b. An operating supervisor. c. A maintenance supervisor. d. A pressure vessel engineer. 53. lnspection for corrosion under insulation (CUl) shall be considered for: a. external-insulated vessels and those that are in intermittent service. - b. any insulated vessel and that those that operate at temperatures above 4000 F. c. austenitic stainless steel vessels operating between 4500 F and 5500 F d. carbon and low alloy steels operating below 00 F 54. CUI on austenitic staintess steel vessels is usually in the form of: a. dealloying. b. graphitization. c. stress corosion cracking. d. ca.rburization. 55. Consideration for insulation removal inctudes several different conditions. Pick the correct one listed below. a. Recommendation of an operating foreman. b. The inspection plan governs the removal of insulation. c. Visual condition of the external covering insulation. d. Analysis of the repair organization. 56. A designated area on pressure vessels where examinations are conducted to monitor the presence and rate of damage is called: a. A condition monitoring location. b. A corosion monitoring location. c. A c-ondensation monitoring location. d. A concentration monitoring location. 57. Using CMLs what may be determined? a. Operating conditions, temperature ranges, and the vessel limitations. b. Corrosion rates, remaining life and the next inspection interval. c. Possible repairs, extent of repairs, and the length of the l&T period. d- Manpower requirements, vessel parameters, and cost of repairs. COPYRIGHT.@ 2O{8 GODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GoDEWEST Apr 510 pREp couRSE l Apt 5{0 58' Pressure vessels with high pote.ntial consequences if failure should occur, and those subject to high co*osion rates' localized corrosion, higilrates or rro, otn* *"cianisms, wl, normary have ;; oi*ri" a. Iess CMLs b. more CMLs c. no CMLs d. average CMLs 59' when thickness measuremgnls. are requi.g ut cMLs, severar different means may be used. which the inspection techniques listed of below iJ ret used ro,- il.,t[n"ss measurements? a. Ultrasonic measurements. b. Hammer testing c. Radiography. d. Electromagnetic techniques. uo ,Y,l;t?"tllr5:::s 3. 1[ readins or readinss are taken with in the area of an examination point, what is readings taken shall be recorded. b. R.ead.ings specifi?d by the inspection engineer. c. The thinnest reading or an average of siverar readings. d' The thinnest readin! found shau 6e recoroeo. 6'1. Repeating thickness readings at the same CMLs accuracy of the calculated damage rate. a. indemnifies b. guarantees c. insures d. improves 62 clYrsc*;$,!fi,:'}jl?Xili* over the vessel to provide adequate monitorins coverase or a. methodically b. systematically c. completely d. appropriately 63' ln circumstances where cMLs are substantially reduced in number or eliminated, a be consulted. _ should a. witch doctor b. inspection engineer c. operations supervisor d. corrosion specialist COPYRIG- HT O 2018 COJEWEST I n rq.i'tiri! -,tr.n!,! ttr!, r! !!_f , !-,! @itn, DO NOT COPY OR DISTRIBUTE THIS DOCUMENT I GODEWEST Apt 510 pREp COURSE I Apr 510 64. An inspector suspects that he may find cracks or other elongated discontinuities that extend to the surface of a carbon steel i:ressure vessel. What type of NDE shoutd he consider using? a. PT b. UT c. MT d. RT 65. What type testing would reveal throughthickness defects efficiently? a. Pressure testing b. Ultrasonic testing c. Magnetic particle testing. d. Thermography. 66. An inspector is preparing to inspect a Hydro-cracker Reactor. The vesselwall'is 7 inches thick. The material is 2.25 % Chrome-0.S% Moly. What type of test would detect structurally significant defects in the welds or structural parts of the heads or walls of this vessel? a. RT b. UT c. AE d. MT 67. What type of testing would you use for determining temperatures of the exierior of a pressure vessel. a. Field metallographic replication. b. Acoustic emission. c. Thermography. d. Ultrasonic testing. 68. The owner/user of a unit shall specify what type of UT shear wave examiners when the following.is required. Detection of interior surface (lD) breaking flaws when inspecting from the external surface (OD) or where detection, characterization, and/or through-wall sizing is required of defects. a. industry-qualified UT shear wave examiners. b. jurisdictional-qualified UT shear wave examiners. c. provisionally-qualified UT shear wave examiners d. conditionally-qualified UT shear wave examiners. 69. What is usually the most accurate means for obtaining thickness measurement of a vessel's pressure containing parts? a. PT b, AE c. UT d. MT 70. What type thickness determining techniques are preferred where corrosion is localized or the : remaining thickness is approaching minimum? a. Acoustic emission will determine areas approaching minimum thickness. b. Ultrasonic shear wave scanning combined with thermography. c. Ultrasonic scanning or radiographic profile. d. Field metallographic replication. copyRIgHT o 2018 coD-EwEST I DO NOT COPY OR DTSTRTBUTE THIS DOGUMENT AA I GoDEWEST API 510 PREP GOURSE l API 5{0 degrees F., corrective procedures should be 71. When vessel metal tempeEtures are above utilized to insure the accuracy of the ihickness measurements obtained. - a. 1500 b. 1250 c. 1000 d.750 72. When is a pressure test normally required? a. lt is required only at a scheduled inspection and test of a unit b. lt is required when operations requqsb it. c. lt is usually required after an altemtion. d. lt is required before any pressurc vessel may be placed back into service. 73. A pressure vessel is to be tested after an alteration. The vessel was designed, built and placed in seruice 2004, The design pressure of the vessel shell is '100 psi at 6000F. The design stress at 6000F is 19400 psi. The vessel is to be tested at 800 F. The allowable stress of the vessel material at 800 F is 20000 psi- What is the test pressure? a. 100 psi b. 150 psi c. 134 psi d. 200 psi 74. Who sets the test pressure for a non-code vessel that has had a major alteration? a. The owner/user determines the test pressure. b. The jurisdiction determines the test pressure. c. The inspector determines the test pressure. d. The repair organization determines the test pressure. 75. A close visual inspection of pressure vessel components should not be performed until: a. the vessel b. the vessel c. the ves$el d. the vessel pressure pressure pressure pre$sure is at 90% of the test pressure. is at full test pressure. is at or below the MAWP. is at 80 % of the test 76. What is the prefened thing to do with a prcssure relieving device when a test pressure exceeds the set pressure of the pressure relieving device?. a. The compression screw of the PRV should be ttrghtened until the valve cannot pop. b. The pressure relieving device should be reset to the maximum test pressure, c. The pressurc relieving device should be removed fTom the vessel d. Nothihg is required. 77. Why do you review supporting shucturcs and foundation designs before applying a hydrostatic test? a. They are reviewed to assure they are suitable for the hydrostatic load. b. They are reviewed to assur€ that there is compleio access to check the vessel for leaks. c. They are reviewed to assure that the structure will carry the pumps, etc. for the pressure test' d. They are reviewed to assure that the laddeF and platforms would not be dangerous to the inspector. COPYRIGHT @ 2O{8 CODEWEST I DO NOT COPY OR DISTRIBUTE THIS DOGUMENT I coDEWESTApt 510 pREp COURSE lApt 510 78. An inspector has scheduled a hydrostatic test of a vessel fabricated from AlSl Type 316 SS The inspectors makes sure that the water or steam condensate has a chloride concentration of less than: a. 100 ppm b. 50 ppm. c. 75 ppm d. B0 ppm 79.To minimize the risk of brittle fracture during a pressure test, the metal temperature should be maintained at least above MDMT for vessels that are more than 2 inches thick. a. 1OoF b. 300F c. 60oF d. 200F 80. To minimize the risk of brittle fracture during a pressure test, the metal temperature should be maintained at least _ above MDMT for vessels that are two inches thick or less. a. 30oF b. 100F c. 40oF d. 200F 81. Appropriate NDE shall be specified and conducted when a pressure test is not performed after a major repair or alteration. Substituting NDE procedures for a pressure test after an alteration may be done only after the: a. examiner and inspector have approved. b. engineer and inspector have approved. c. maintenance supervisor has approved. d. owner/user has approved. 82. Before using a material for repairs or alterations of a pressure vessel the material is consistent with the specifications. a. storehouse supervisor b. owner/user c. inspector d. maintenance supervisor shall veriff that the - 83. Crack-like flaws and environmental cracking shall be assessed by: ' a. a laboratory worker and/or an inspector. b. the owner/user and the job superintendent. c. the inspector and the maintenance supervisor. d'^ an engineer and/or a corrosion specialist..84. Accessible flange faces should be examined for distortion and to: a. determine that the correct gasket is being used. b. determine the condition of gasket-seating surfaces. c. make sure that flange bolts are correct. d. assure that the pressure rating of the flange is correct copyRlcttT @ 201s coDEwEST r DO NOT COPY OR DISTRTBUTE THIS DOCUMENT ar\ I GoDEWEST API 5{0 PREP COURSE I API 510 85. What constitutes complete engagement of a flange fastener (stud bolt)? a. A fastener is considered acceptably engaged if the lack of comptete engagement is not more than 4 - threads. b. A fastener is considered acceptably engaged if the lack of complete engagement is not more than 3 threads. c. A fastener is considered acceptably engaged if the lack of complete engagement is not more than 1 thread. d. A fastener is considered acceptably engaged if the lack of complete engagement is not more than 2 threads. 86. If a probable corrosion rate cannot be determined from reviewing data from the same or similar service vessels or estimated form published data, on-stream determinations shall be made after of service by using NDE methods and a corrosion rate is established. approximately a. 500 Hrs b. 3-6 months c. 5000 Hrs d. 1 year 87. The maximum allowable working pressure for the continued use of a pressure vessel shall be based on computations determined by using the. a. latest edition of the NBIC or the construction code to which the vessel was built. b. latest edition of the ASME Code or the construction code to which the vessel was built. c. latest edition of the API/ASME Code or the construction code to which the vessel was built. d, Iatest edition of the UL Code or the construction code to which the vessel was built. 88. lf external or internal coverings, such as insulation, refractory protective linings, and corrosion resistant linings are in good condition and there is no reason to suspect that an unsafe condition is behind them, inspection. ? a. it is not necessary to remove them for b. it is necessary to remove them completely for inspection. c. it is necessary to partially remove them for inspection. d. it is required to remove them completely for inspection on some set interval. 89. 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 exceeding the following: 89a. For vessels with inside diameters less than or equal to 60 inches- or 5 inches, whichever is less. the vessel diameter or 10 inches, whichever is less. c.114 the vessel diameter or 15 inches, whichever is less. d.1lzthe vessel diameter or 20 inches, whichever is less. a.114 the vessel diameter b 112 89b. For vessels with inside diameters greater than 60 inches- a. 1/3 the vessel diameter b. 114 the vessel diameter c. 1/3 the vessel diameter d. 114 the vessel diameter. copyRIG.t_{T o or 40 inches, whichever is less. or 30 inches, whichever is less. or 50 inches, whichever is less. or 25 inches, whichever is less. 2018 c.opEWEST I DO NOT COPY OR DISTRIBUTE THIS DOCUMENT 50 I CoDEWEST Apt 5{0 pREp COURSE I Apt 510 90. For corrosion calculations the surface of the weld is considered to be: a. 1 inch on either side of the weld or 2 times the tr on either side of the weld, whichever is greater. b. 2 inches on either side of the weld 2 times the tr on either side of the weld, whichever is greater. c, 4 inches on either side of the weld or 4 times the tr on either side of the weld, whichever is greater. d. 6 inches on either side of the weld or 6 times the tr on either side of the weld, whichever is greater. 91. Under what conditions is an internal field inspection of a newly installed pressure vessel waived?. a. The contractor installing the vessel assures the owner-user that the vessel is satisfactory for its intended service. b. A manufacturers data report assuring the vessel is satisfactory for its intended service is available. c. The owner-user assures the inspector that the vessel is satisfactory for its intended service. d. The manufacturer orally assures the owner-user that the vessel is iatisfactory for its intended service. 92. An above ground pressure vessel shall be given a visual external inspection, preferably while in operation, at least years or at the same interval as the internal, whichever is less. every a.2 b.3 c.5 d. 10 93. The period between internal or on-stream inspections for a' remaining life of four years or greater shall not exceed one-half the estimated remaining life of the vessel based on corrosion rate or years whichever is less. a. 10 b. 15 c.5 d. 12 94. ln cases where the remaining safe operating life is estimated to be less than 4 years, ,n" ,n"O"ction. years. interval may be the full remaining safe operating life up to a maximum of a. 1 b.2 c.3 d.4 95. lf both the ownership and the location of a vessel are changed, what must happen before it is reused? a. lt must be internally and externally inspected b. All the records must be revievred. c. lt must be thoroughly ultrasonically checked. d. lt must have all the paper work transferred to the new owner. 96. A pressure vessel has been in service tor 12 years and has shown a history of corrosion over its service life. The original thickness was 1.9375" thick and the present thickness is 1.405". What is the corrosion rate for this vessel? a. 0.266 inches/year b. 0.532 inchesiyear c. 0.088 inches/year d. 0.044 inches/year cqpyB.lcHT g 20,!s copEWEST r DO NOT COPY OR DTSTRTBUTE THIS DOCUMENT 5,1 I GoDEWEST APt 510 pREp GOURSE I Apr 5{0 97. When must a pressure test be performed on a pressure vessel? a. When the contractor working on the vessel deems it is necessary. b. When the API authorized pressure vessel inspector believes that it is necessary. c. When the safety group of the owner-user requests it. d. When the NFPA requests it. 98. Who is authorized to test and repair a pressure relief valve? a. An organization experienced in PRV maintenance. b. A valve repair shop. c. A certified pressure vessel inspector. d. A contractor with valve mechanics. 99. What is the maximum inspection or testing interval of a pressure-relieving device? a. 15 years. b. 12 years, c. 10 years. d. 20 years. 100. Who determines the inspection interual of pressure-relieving devices? a. The interval b. The interval c. The interval d. The interval is determined is determined is determined is determined by the authorized pressure vessel inspector. by the owner-user. by the inspector or engineer or other qualified individual by the engineer 101. deleted 102. A 12in. nozzle is being installed in a vessel where the largest existing opening is 10 in. This is considered: a. A repair b. An alteration c. A rerating d. A maintenance activity 103. May the API 510 lnspector be assisted by non-certified individuals when visual inspections are performed? a. Yes, when authorized by API b. Yes c. No d. Yes, when properly trained and qualified copyRtGHT o 2ol.8.coDEwEST ! DO NOT COPY OR DISTRIBUTE THIS DOCUMENT E' I GODEWEST Apt 510 pREp GOURSE I Apt 510 104. Which of the following conditions must be met to qualify vessels for on-stream inspections when the general corrosion rate is less than 0.005 in. per year and has a remaining life greater than 10 years? a. The vessel is strip lined b. The corrosive character of the contents has been established for at least S years c. Not more than iwo questionable conditions were disclosed at the previous external inspection d. The operating temperature exceeds the lower temperature limits ior the materials creeprupture range ' 105. The definition of trequireo isl a. Minimum nominal thickness in inches for a given location or component b. Minimum actual thickness in inches for a given location or component e. Minimum thickness in inches for a given location or component d. Minimum allowable thickness in inches for a given location or component 106. Which of the following widely scattered pitting cannot be ignored? ' a. The total area of the pits does not exceed 7 square inches within a 9 inch diameter circle b. A single pit depth is less than Tz trequired. c. The sum of the pit dimensions along any straight line within the circle is 2.1 inches d, The total area of the pits does not exceed 7 square inches within an 8 inch diameter circle 107. You have a corroded area which is 0.900 in. thick. The minimum thickness is calculated to be 1.000 in. the corrosion rate is 0.01 in. per year. Assuming a constant corosion rate how much weld overlay must be applied to have a 10 year life? a. 0.10 in. b. 0.20 in. c. 1.300 in. d. repair not permitted by API 510 108. All repairs and alterations shall be performed by a repair organization in accordance with: a. the applicable b. the applicable c. the applicable d. the applicable principles principles principles principles of the National Boiler and Pressure Vessel Code. of the API Standard 510 latest edition. of the ASME Code, or the applicable construction or repair code. of the U.S. Department of Transportation CFR part 4g. 109. Repairs to pressure-relieving devices should follow: ' a. API 576 b. APt 653 c. API 571 d. API 572 110. All repair and alteration work must be authorized by the repair organization. _ before the work is started by a a. corrosion specialist b. inspector c. maintenance supervisor d. operations manager COPY.RIGHT @ 2018 GODEWEST I DO NOT GOPY OR DISTRIBUTE THIS DOCUMENT 53 I GoDEWEST Apr 5{0 PREP COURSE I API 5{0 111. Authorization for alterations to pressure vessels that comply with ASME Section Vlll, Divisions 1 and 2 and for repairs to pressure vessels that comply with ASME Section VIll, Division 2, may not be given until_ has also authorized the work. a. a jurisdictionai representative. b. an examiner c. a corrosion specialist d. an engineer 112. All proposed methods of design, execution, materials, welding procedures, NDE, and testing must be approved by the inspector. must approve an alteration. a. The inspector b. An inspector or engineer c. A corrosion specialist d. lnspector and engineer copyRIGHT O 2018 COP-EWEST I DO NOT COPY OR DTSTRIBUTE THIS DOCUMENT I GoDEWEST Apr 510 pREp couRSE lApt 510 113. New vessel nozzles, connections, or replacement parts must meet the design requirements of the: a. latest edition of National Boiler and lnspection Code. b. latest edition of the ASME Code. c. applicable construction code. d. applicable ASTM specifications. 114. Carbon or alloy steel with carbon content over _ shall not be welded. a.0.15% b.0.1a% c. 0.35% d.0.2

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