Pressure Vessels Inspection or International Welding Inspectors

Introduction

Maintenance, inspection, repair, and alteration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such Knowledge. The following is a list of specific topics in which the API Authorized Pressure Vessel Inspector should be knowledgeable.

To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each category listed within this Body of Knowledge will be included on the API certification examination. Only inspection information covered in one of the references Outlined in this body of knowledge will be utilized for the examination questions. The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring an everyday working knowledge of API Standard 510 and the applicable Reference documents. The open book portion of the examination requires the use of more detailed information that the inspector is expected to be able to find in the documents, but would not normally be committed to memory.

Reference publications:

• API 510, Pressure Vessel Inspection Code
• API RP 571, Damage Mechanisms Affecting Equipment in Refining Industry
• API RP 572, Inspection of Pressure Vessels
• API RP 576, Inspection of Pressure-Relieving Devices
• API RP 577, Welding Inspection and Metallurgy
• ASME Publications:
• Section V, Nondestructive Examination
• Section VIII, Division 1, Rules for Constructing Pressure Vessels
• Section IX, Welding and Brazing Qualifications

Objectives

The course covers the following knowledge

• Thickness Measurements, Inspection Intervals and Vessel Integrity
• Code calculation oriented toward existing pressure vessels
• Perform calculations relative to in-service deterioration, repairs, rerates, or alterations.
• Corrosion Rates and Inspection Intervals Inspection data and determination of the internal and external inspection intervals. Calculation of Metal Loss, Corrosion Rates, Remaining Corrosion Allowance, Remaining Service Life and Inspection Interval.
• Joint Efficiencies Determination of joint efficiency "E" including: Weld Joint Categories, Type of radiography, Joint Efficiency, Joint efficiency for seamless heads and vessels, and Joint efficiency for welded pipe And tubing.
• Internal Pressure Determining the required thickness of a cylindrical shell based on circumferential stress, The vessel part MAWP, The required thickness of a head, the vessel part MAWP for ahead, whether a head meets Code requirements given both pressure and metal thickness.
• External Pressure Calculation of the maximum allowable external, Calculate whether a cylindrical shell or tube Meets Code design for external pressure.
• Pressure Testing Calculate a test pressure compensating for temperature, precautions associated with hydrostatic and pneumatic testing, such as minimum test temperatures, is familiar with all steps in a Pneumatic test procedure.
• Impact Testing Determining the minimum metal temperature of a material which is exempt from impact testing,
• Weld Size for Attachment Welds at Openings Determining if weld sizes meet Code requirements.
• Nozzle Reinforcement
• Understanding the key concepts of reinforcement, such as replacement of strength removed and Limits of reinforcement, calculate the required areas for reinforcement.
• Welding Procedure And Qualification Evaluation Based On Asme Section Ix
• Weld Procedure Review
• ASME Section Viii, Div. 1 And Api-510: General Welding Requirements
• Nondestructive Examination

Training Methodology

The course will be conducted along with workshop principles with formal lectures and interactive worked examples and with an active contribution by all delegates during workshops and discussions and teamwork. Real-life examples will be selected to illustrate the procedure for control of good performance of gas turbines. The emphasis will be on the explanation of technical phenomena and providing answers to problems that are encountered in everyday industrial practice. There will be ample opportunities for problem solving and workshops with active open discussion and sharing professional experiences on the operation, maintenance and troubleshooting. All course materials will be provided.

Who Should Attend?

The course is intended for beginners as well as experienced individuals who desire to update their knowledge of the latest industry and Code requirements for pressure vessel design and the longer-term aspects and issues of inspection and repair. The course will benefit individuals involved in design, fabrication, inspection or purchase of pressure vessels and those responsible safety and integrity of in-service pressure vessels

Course Outline

• Introduction to API 510 certification
• Introduction to ASME Code System
• Introduction to ASME Sec VIII Div 1
• Design Fundamentals
• Allowable Stresses
• Joint Category, Joint Type
• Joint Efficiencies
• Design Of Cylindrical Shells
• Calculations of Vessel MAWP, Part MAWP
• Static Head Calculations
• Design Of Dished Heads
• Case Studies
• Design of Dished Heads (Continue…)
• Depth Of Dished Heads
• Introduction to External Pressure Calculations
• Case Studies
• Impact Testing Requirements
• Pressure Testing – Hydrostatic
• Pressure Testing – Pneumatic
• Weld size for attachment welds at openings
• Case Studies
• Reinforcement of Openings - Concepts
• Reinforcement Pad Calculations
• Case Studies
• Typical Weld Joints For Pressure Vessels
• Restrictions on Joints – mismatch tolerances
• Allowable Weld Reinforcements
• Inspection Requirements For Pressure Vessels
• Heat Treatment
• Code Stamping and Data Reports
• Introduction To API 510 Code: Scope and Applications
• Reference Codes and Standards
• Specific Definitions
• API 510 (Continued..): Inspection Organization
• Owner- User Responsibilities
• Quality Control Manual
• Certification Requirements
• Modes of Deterioration
• Corrosion, Fatigue, Creep
• Freeze Damage, Brittle Fracture,
• Temper embrittlement
• Review of Practice Exam 3.
• API 510 (continued…) Defect Inspection
• Inspection Of Parts
• Minimum Thickness Evaluation
• Pitting Corrosion, Localized Corrosion
• API 510 Inspection Practices
• Corrosion Rate Determination
• MAWP Determination For Vessels In-Service
• Numerical Examples
• External Inspection
• Internal and On-stream Inspection
• Inspection Intervals
• Remaining Service Life
• Illustrative Calculations
• API 510 (continued…) Defect Repairs
• Pressure Tests
• Documentation and Records
• API 510 (Continued..): Welding Requirements
• Pre- Heating and PWHT
• Weld Overlay and Cladding
• NDT For Repairs and Alterations
• Alterations and Rerating
• Rerating Documentations and Stamping
• Introduction To ASME Sec IX
• Procedure Qualification
• PQR Tests and Evaluations of Results
• Welding Variables – Evs, NEVs and SEVs
• Limits Of PQR Qualifications/ validity
• WPS/PQR Documentation
• WPQ Tests and Their Validity
• Detail Road map For Review Of WPS and PQR Documentation
• Case Study For WPS/PQR Review
• Introduction To ASME Sec V: Non-destructive Examination
• Article 1: General Requirements
• Article 2: Radiographic Examination
• Radiographic Procedure
• Selection Of IQI (Pentameter)
• Radiographic Technique
• Interpretation and Documentation
• Article 6: Liquid Penetrant Examination
• LPE Procedure
• Selection Of Penetrants
• LPE Technique
• Interpretation and Documentation
• Article 7: Magnetic Particle Examinations
• Se – 797 UT Measurements
• Pulse- Echo Contact Method
• Single and Dual Crystal Techniques
• Review Of NDE Requirements ASME Sec VIII & API 510
• Introductions To API 571
• Corrosive Components in Crude
• Deterioration Due To Hydrogen
• Deterioration Due To H2S
• Other Factors Of Corrosion
• API RP 572 Review
• Types Of Pressure Vessels
• Construction Standards
• Causes of Deterioration
• Internal Inspection
• External Inspection
• Inspection Record and Reports
• API RP 576 Inspection of Pressure Relieving Devices
• Types Of PRDs
• Causes Of Malfunctioning
• Inspection Intervals and Inspection Procedures for PRDs
• Testing Of PRDs on Test Bench
• Inspection Records & reports
• Final Open Book Examination
• Final Close Book Examination
• Feedback On Tests