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)