API 510 - Pressure Vessel Inspector Course

Chintamani M. Khade

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

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).)
    

DAY 2

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
       

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 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.
 

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. 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)


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)

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.

Chintamani M. Khade

International Certified Trainer

Chintamani M. Khade is a specialist on Materials & Damage Mechanisms. He has more than 19 years experience as Department Head of NDT, Welding Inspection, In Service Inspection in India, Middle East, Southeast Asia & Africa. Currently, he is the technical director of Empirical Technocrats.

He conducted training for various API Certification Preparatory, NDE methods, ASNT & ISNT Level III, advanced NDT Methods, welding inspection, Construction codes, ASME Sections II, Section IX, Section V, ASME Sec. VIII div. 1, ASME B31.1, ASME B31.3, AWS D1.1, UT, MT, PT, VT, RT & Basic for ISO 9712 level 2 & level 3.

He has been a team leader of 100+ multidiscipline NDT technicians, metallurgists & Welding inspectors during various shutdown jobs in Qatar Petroleum, Massaid refinery, Qatar in March – June 2005, March - April 2009 & October November 2009. Executed in service inspection of nearly 800 pressure vessels, Static & rotary equipments, Plant process piping & storage tanks as shutdown coordinator.

WorldOils
Code Start Date End Date Locations Cost Instructor Register
PST0086-202301 03 Jul, 2023 07 Jul, 2023 Jakarta, Indonesia USD 3150 Chintamani M. Khade Register
PST0086-202302 27 Nov, 2023 01 Dec, 2023 Kuala Lumpur, Malaysia USD 3150 Chintamani M. Khade Register
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