API 510 Training - Pressure Vessel Inspector Course


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Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0086-201703  30 Oct 2017  03 Nov 2017  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale   Register
PST0086-201704  04 Dec 2017  08 Dec 2017  Bandung, Indonesia  SGD 3195  Uday B. Kale   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 
PST0086-201101  19 Sep 2011  23 Sep 2011  Kuala Lumpur, Malaysia  SGD 2995  Uday B. Kale 
PST0086-201102  03 Oct 2011  07 Oct 2011  Kuala Lumpur, Malaysia  SGD 2995  Uday B. Kale 
PST0086-201302  19 Aug 2013  23 Aug 2013  Kuala Lumpur, Malaysia  SGD 2995  Uday B. Kale 
PST0086-201301  02 Dec 2013  06 Dec 2013  Kuala Lumpur, Malaysia  SGD 2995  Uday B. Kale 
PST0086-201401  19 May 2014  23 May 2014  Kuala Lumpur, Malaysia  SGD 2995  Uday B. Kale 
PST0086-201402  01 Sep 2014  05 Sep 2014  Bandung, Indonesia  SGD 2995  Uday B. Kale 
PST0086-201501  09 Mar 2015  13 Mar 2015  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale 
PST0086-201502  08 Jun 2015  12 Jun 2015  Bandung, Indonesia  SGD 3195  Uday B. Kale 
PST0086-201503  05 Oct 2015  09 Oct 2015  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale 
PST0086-201601  04 Apr 2016  08 Apr 2016  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale 
PST0086-201602  14 Nov 2016  18 Nov 2016  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale 
PST0086-201701  06 Mar 2017  10 Mar 2017  Bandung, Indonesia  SGD 3195  Uday B. Kale 
PST0086-201702  15 May 2017  19 May 2017  Kuala Lumpur, Malaysia  SGD 3195  Uday B. Kale 

The course prepares the professional for the API 510 exam. The course is an intensive one-week course with a heavy emphasis on the use of the codes and mathematical calculations.


API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, and alteration of pressure vessels. The API 510 Certification Preparation is designed to equip the professional with such information and understand the exam format. The course will prepare the professional with both parts of the exam, the closed and open book portion.


This is an intense course with daily homework and a final exam (similar to the API 510 exam). A study guide is issued to direct participant’s pre-class study.

DAY 1

Module - 1

    Welcome and Introduction
    Overview of API 510 Course

Module - 2

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

Module - 3

    Thickness Calculations
        a) The required thickness of a cylindrical shell (UG-27(c)(1));
        b) The vessel part MAWP for a cylindrical shell
        c) The required thickness of a head-Hemispherical, Ellipsoidal, Torispherical
        d) The vessel part MAWP for a head

Module - 4

    Static Head
        a) Calculate static head pressure on any vessel part;
        b) Calculate total pressure (MAWP + static head) on any vessel part;
        c) Calculate maximum vessel MAWP given vessel parts MAWP and elevations

Module - 5
    
    External Preasure
        a) Calculate the maximum allowable external pressure;
        b) Calculate whether a cylindrical shell meets Code design for external pressure.
    
    Impact Testing
     a) Determine the minimum metal temperature of a material which is exempt from impact testing (UG-20 (f), UCS-66,UCS-68(c).)
    

DAY 2

Module - 1

    Preasure Testing
        a) Calculate a test pressure compensating for temperature. (UG-99 & UG-100)
        b) The precautions associated with hydrostatic and pneumatic testing,
        c) Steps in a hydrotest Procedure (UG 99 and UG 100)
        d) All steps in a pneumatic test procedure (UG 100 and UG 102)

Module - 2

    Weld Size For Attachment Welds at Openings
        a) Conversion of a fillet weld throat dimension to leg dimension , conversion factor(0.707)
        b) Determine the required size of welds at openings (UW-16).
       
Module – 3

    Nozzle Reinforcement
    Key concepts of reinforcement, such as replacement of strength and limits of reinforcement
    Credit for extra metal in shell and nozzle
    Calculate the required areas for reinforcement
    
Module - 4

    1 Scope of API 510
        1.1 General Application
        1.2 Specific Applications
        1.3 Recognized Technical Concepts
       
    2 references
    
Module - 5

    3 definitions
    4 owner/user inspection organization
        4.1 General
        4.2 Owner/user Organization Responsibilities
       

DAY 3

Module - 1

    5 Inspection, Examination and Pressure Testing Practices
        5.1 Inspection Plans
        5.2 Risk-based Inspection
        5.3 Preparation For Inspection
        5.4 Inspection For Types Of Damage Modes Of Deterioration And Failure
       
Module – 2

        5.5 General Types Of Inspection And Surveillance
        5.6 Condition Monitoring Locations
        5.7 Condition Monitoring Methods
    
Module - 3

        5.8 Pressure Testing
        5.9 Material Verification And Traceability
        5.10 Inspection Of In-service Welds And Joints
        5.11 Inspection Of Flanged Joints
       
Module - 4

    6 interval/frequency and extent of inspection
        6.1 General
        6.2 Inspection During Installation And Service Changes
        6.3 Risk-based Inspection
        6.4 External Inspection
        6.5 Internal And On-stream Inspection
        6.6 Pressure-relieving Devices
       
Module - 5

    7 inspection data evaluation, analysis, and recording
    
        7.1 Corrosion Rate Determination
        7.2 Remaining Life Calculations
        7.3 Maximum Allowable Working Pressure Determination
       
Module - 6

        7.4 Fitness For Service Analysis Of Corroded Regions
        7.5 API RP 579 Fitness For Service Evaluations
        7.6 Required Thickness Determination
        7.7 Evaluation Of Existing Equipment With Minimal Documentation
        7.8 Reports And Records
       

DAY 4

Module - 1

    8 repairs, alterations, and rerating of pressure vessels .
        8.1 Repairs And Alterations
    Authorization
    Approval
    Materials Requirements
    Welding Requirements
    
Module - 2

    Heat Treating Requirements
    Preheating
    Post weld Heat Treating
    Local Postweld Heat treatment
    Repairs to Stainless Steel Weld Overlay and Cladding
    Rerating
    
Module - 3

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

    And determine:
      a) Whether number and type of mechanical test listed on PQR are appropriate
      b) Whether the results of the tests are acceptable
      c) Whether all required essential and non-essential variables have been properly addressed.
 

DAY 5

Module - 1

    API RP 576, Inspection of Pressure-Relieving Devices
    1. Relief Devices
        a) Description of Types -- (API RP-576, Section 2)
        b) Causes of Improper Performance (API RP-576, Section 4)
        c) Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)
        d) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)
       
Module - 2

    A. Article 1, General Requirements:
    B. Article 2, Radiographic Examination
    
Module - 3

    C. Article 6, Liquid Penetrant Examination,
    D. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):
    E. Article 23, Ultrasonic Standards, Section SE–797
    
Module - 4

    API RP 576, Inspection of Pressure-Relieving Devices
    1. Relief Devices
        a) Description of Types -- (API RP-576, Section 2)
        b) Causes of Improper Performance (API RP-576, Section 4)
        c) Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5)
        d) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)
       
Module - 5 ( 1 hour + 1 hour discussion )

    Practice Examination-Open Book
    Practice Examination-Closed Book
    Feed Back and Closing

You Will Learn

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


Bring to Class


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

This course will specifically benefit Engineers, Supervisors, and Managers from the following disciplines:

  • Mechanical Engineering
  • Inspection
  • Maintenance & Operations
  • Technical & Engineering
  • QAQC

and technical personnel with 2-3 years of experience in the management and planning of inspection and maintenance activities of pressure vessel system at upstream oil & gas facilities, refineries, process plants and petrochemical facilities.

Aaron A. Zick, Ph.D.

Founder and President

Biography


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.

 

Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).

 

Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.

 

IMPORTANT PUBLICATIONS

A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).