API 510 - Pressure Vessel Inspector Course

Uday B. Kale (M. Eng. Mechanical)

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 codes and mathematical calculations.

API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to the 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 participants’ pre-class study.

DAY 1 - Introduction

Module - 1

    Welcome and Introduction
    Overview of API 510 Course

Module - 2

    Joint Efficiencies
        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 per UW-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 Pressure
        a) Calculate the maximum allowable external pressure;
        b) Calculate whether a cylindrical shell meets the Code design for external pressure.
    Impact Testing
     a) Determine the minimum metal temperature of a material that is exempt from impact testing (UG-20 (f), UCS-66, UCS-68(c).)


Module - 1

    Pressure 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 the hydro test 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, the 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 the extra metal in the 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


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


Module - 1

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

    Heat Treating Requirements
    Post-weld Heat Treating
    Local Postweld Heat treatment
    Repairs to Stainless Steel Weld Overlay and Cladding
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 the 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.


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

What is API 510 training course objective?

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

What you must bring to class

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

Who should join API 510 training course by PetroSync?

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 systems at upstream oil & gas facilities, refineries, process plants, and petrochemical facilities.

Uday B. Kale (M. Eng. Mechanical)

Technical Director - KUB Quality Services

Uday B. Kale is a Post Graduate Mechanical Engineer with experience in Inspection, Welding and NDE/NDT projects for last 19 years. Currently he is the technical director of M/s KUB Quality Services. He has involved in inspection, welding and NDT projects in the Middle East, Africa and India on offshore production platform and petrochemical refineries. He has vast experience in Manufacturing and In Service Inspection of Static Equipment used in Oil and Gas.

Mr. Uday is very well-versed in international Codes and Standards. He performed and led the shutdown teams in performing NDE, internal and external inspection of equipments in central processing plant, ammonia plant, FCCU, SRU, SWS and amine treating units for Code stamp facilities of ADCO, Qatar Petroleum, Oil India, QAFAC, Banagas, Al Jubail Fertilizer Company, and other various units of Refineries, Petrochemicals, Gas Plant and Fertilizer Plant and so on.

He was a lead API inspector for various shutdown and Turnaround. He was also the appointed plant inspector for BP (GUPCO) in asset integrity management, who took charge of 9 offshore production complex, 75 Satellites and Onshore process units involving Close Visual Inspection of piping, equipments, NDT co-ordination, Baseline and Corrosion Monitoring. Furthermore, as an Inspector in GASCO OAG pipeline project, he conducted and witnessed Ultrasonic Examination of first 50 production weld joints of pipeline done by PWT (Pipe Welding Technology, GMAW).

With his extensive involvement in various projects, Mr. Uday is also an enthusiastic and knowledgeable mentor, who has been a faculty in training, examination, qualification and certification of API 510 & 570, ASME B31.3, API653, welding and NDT in the Middle East, Africa and Asia. He is a charted engineer with 25+ International certification in Welding, NDE and In Service Inspection.

  • Code PST0086-202301
  • Start Date 03 Jul, 2023
  • End Date 07 Jul, 2023
  • Locations Jakarta, Indonesia
  • Cost USD 3150
Code Start Date End Date Locations Cost Instructor Register
PST0086-202301 03 Jul, 2023 07 Jul, 2023 Jakarta, Indonesia USD 3150 Chintamani M. Khade