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API 510
PRESSURE VESSEL INSPECTOR
CERTIFICATION EXAMINATION
PUSPATRI
JOHOR BAHRU
5TH -9TH NOVEMBER 2007
Course Outlines
DAY 1 - 5th November 2007
Introduction to API 510 Certification
Module 1: ASME Section VIII – Rules For Construction Of
Pressure Vessel
Module 2: Static Head, MAWP & Stress Calculations
Trial Examination
Why Are You Here?
Why API Certification?
- Significant milestone in inspectors’ career
- Additional job opportunities & salary increase
- Widen employment doors – resume with API certificates
- Oil & Gas industry is booming
- Middle East offers USD 500 - 700 per day
ASME Publications
1. Section V, Nondestructive Examination
2. Section VIII, Division 1, Rules for Constructing Pressure Vessels
3. Section IX, Welding and Brazing Qualifications
Don’t Worry About The Exam
The API Examination
- 150 multiple choices with four possible answers
- Exam divided into 2 Parts
(a) Open Book – 50 questions for 4 hours durations
(b) Closed Book – 100 questions for 4 hours durations
If you know these 2 secret, every answer can be found with minimum
effort. That’s much better than paging through 700 pages of the
codes!
Organization of Code
Section VIII- Rules for Construction of Pressure Vessel consists of 2
division;
(a) Division 1 – Routine Vessel
(b) Division 2 – Alternate Rules for special vessel
Mandatory Appendices
U-1(b) “address specific subject not covered elsewhere in this division”
Alternate formulae
QC Manual
NDE Standards
Non-mandatory Appendices
U-1(b) “provides information and suggested good practices”
Completed Sample Problems
Example 1-1 Finding the Right Answer
At what base metal temperature is welding not allowed on
routine pressure vessel?
Example 1-1 Finding the Right Answer
At what base metal temperature is welding not allowed on routine
pressure vessel?
ASME Code
Division 1 Division 2
Routine Other
Hint:
If it’s applicable to all vessel –UG.
If it’s only applicable because it’s welded – UW
If it’s based on metallurgy - UCS
Code’s Purpose
Establish Rules for Construction of Pressure Vessel
One way the Code achieves this is by setting requirements for critical
work assignment. This will involved:
(1) User
(2) Manufacturer
(3) Authorized Inspector
(4) Welder
(5) NDE Technician
Setting The Rules
User Roles & Responsibilities
U-2(a) : The user or his designated agent shall establish the
requirements for pressure vessel …”
- Specify size and shape
- Specify vessel internals; type, spacing
- Determine design pressure and temperature
- Specify the Corrosion Allowance
- Determine whether the PV be classified as “ Lethal Service”
- Specify PWHT if needed for process conditions
Setting The Rules
Manufacturer Roles & Responsibilities
U-2(b)(1) “ The manufacturer of any vessel…has the responsibility of
complying with all of the applicable requirements of this Division ..”
UG-90(b) “ The Manufacturer shall perform his specified duties.”
• Obtain Certificate of Authorization from ASME
• Perform design calculations & develop fabrications drawings
• Identify all material used during fabrication
• Examine materials before fabrication: thickness, ID, defects
• Qualify welding procedures & welders
• Perform NDE test and records result
• Perform vessel hydro or pneumatic test
• Apply the Code Stamp
• Prepare Manufacturer’s Data Report
Setting The Rules
Authorized Inspector Roles & Responsibilities
U-2(f) “The rules of this Division shall serve as the basis for the
inspector to:”
1. Perform required duties
2. Authorize the application of the Code Symbol
3. Sign the Certificate of Shop Inspection
Setting The Rules continued…
Authorized Inspector Roles & Responsibilities
UG-90(c)(1) “ The inspector shall”
• Verify the Manufacturer has a current Certificate of Authorization
• Verify Manufacturer is working to the QC system
• Verify design calculations are available
• Verify materials meet Codes
• Verify weld procedures and welders are qualified
• Verify NDE tests have been performed & are acceptable
• Perform internal & external inspections
• Verify nameplate is attached and has the right markings
• Witness the hydrotest
• Sign the Manufacturer’s Data Report
Setting The Rules
Welders & NDE Techs Roles & Responsibilities
Welder
UW-29(a) “ The welders ..used in welding pressure parts…shall be
qualified in accordance with Section IX”
NDE Technician
UW-51(a)(2) RT “Qualified and certified in accordance with employer’s
written practice. SNT-TC-1A used as a guidelines”
App 12-2 UT “Qualified and certified in accordance with employer’s
written practice. SNT-TC-1A used as a guidelines”
App 6-2 (a&b) MT “ He has vision ..read a Jaeger Type No. 2 Chart ..”
And “is competent in the techniques of the magnetic particle
examination method”
App 8-2 (a&b) MT “ He has vision ..read a Jaeger Type No. 2 Chart ..”
And “is competent in the techniques of the magnetic particle
examination method”
CODE-OLOGY
Code Stamp
UG-117(a&b)
“ A Certificate of Authorization to use the Code U, UM, & UV
symbols…will be granted by the Society …Each applicant must agree
that each Certificate of Authorization and each Code Symbol Stamp are
at all times the property of the Society…”
CODE-OLOGY
Quality Control System
The Code tells the Manufacturer “what must be done” when building a
vessel. The Manufacturer’s Quality Control System tells ASME and the
AI “how things will be done” in the shop to meet the code.
CODE-OLOGY
Data Reports
If a vessel
Is not covered by U-1 (c), (g), (h) & (i)
Is not required to be fully radiographed
Does not have a quick actuating device
Does not exceed either the following limit
5 ft3 and 250 psi
1.5 ft3 and 600 psi
2a 2b 3
854 ft
845 ft x 0.433 psi/ft = 369.8 psig
Exercise 2-1
Answer 2a
2) A vessel is 50’ high. The vessel will be hydrotested
a. When filled with water what is the pressure at the bottom of
the vessel?
0’ 0 psig
Pbtm = 0.433 psi/ft x 50 ft
= 21.7 psig
2a
??
50’ psig
Exercise 2-1
Answer 2b
2) A vessel is 50’ high. The vessel will be hydrotested
b. When the hydrotest pressure at the top of the vessel 100 psi,
what is total pressure at the bottom?
100 psig
0’
Pbtm = Ptop + Psh
= 100 + (0.433x50) 2b
= 121.7 psig
?? psig
50’
Exercise 2-1
Answer 3
3) A 60” vessel is filled with water. The pressure at the
bottom is 210 psi. What is the pressure at the top?
0’ ?? psig
= 184 psig
210 psig
60’
Module 2.2
Design Pressure
Design Pressure
The pressure used in the design of a vessel component together with
the coincident design metal temperature for the purposes of
determining the minimum permissible thickness…static head shall be
added to the design pressure …” App 3-2
Exercise 2-2
Design Pressure
A 50 high vessel has a design pressure of 100 psig. The elevations are
shown in the sketch below.
0’ 100 psig
2’
?? psig
48’ ?? psig
50’ ?? psig
Exercise 2-2
Design Pressure
a. Pshell = Ptop +Psh
= 100 psig + (0.433 psi/ft x 48 ft) 0’ 100 psig
= 120.8 psig 2’
?? psig
b. Ptop head = Ptop + Psh
= 100 psig + (0.433 psi/ft x 2 ft)
= 100.9 psig
c. Pbtm head = Ptop + Psh 48’ ?? psig
Note: Each component should be designed for the highest pressure it will see
at conditions. The highest pressure is at the bottom of the part
Module 2.3
MAWP Calculations
MAWP
Vessel & Vessel Part
UG98(b) “The maximum MAWP for a vessel part is the maximum
pressure… including static head…(based) upon rules and formulae in
this Division…excluding any metal thickness specified as corrosion
allowance”
0’
12’ B
Part A: 343 – 0.433(34) = 328.3 psig
Part B:
MAWP 336 Part B: 336 -0.433(12) = 330.8 psig
Thus, vessel MAWP = 328.3 psig
A
Part A:
MAWP 343
34’
Exercise 2-3
Determining Vessel MAWP
0 ft
40 ft
Bottom Head 336 psig
42 ft
Shell 337 psig
Exercise 2-3
Determining Vessel MAWP
0 ft
1 ft Part Part MAWP Static Head Pressure @ Top
3 ft
Top Nozzle 342 psig 0.433 341.6
Side Nozzle 426 psig 10.4 415.6
Top Head 329 psig 1.3 327.7
24 ft
40 ft
Bottom Head 336 psig 18.2 317.8
42 ft
Shell 337 psig 17.3 319.7
Design Pressure vs. MAWP
Design Pressure – pressure from the system (process + static head)
MAWP – pressure part of the vessel is “good for”
Design
Pressure
MAWP
1) The MAWP of a vessel is 100 psig. Each head depth is 2’ and the
cylindrical portion of the shell is 32’. The shell should be
designed for a pressure of ______ psig.
2) A vessel’s MAWP is limited by the lower shell portion. This shell
part has a MAWP of 87.5 psig. What is the maximum allowed
MAWP for this vessel?
0 ft
1 ft
100 ft
Exercise 2-3
More MAWP & Static Head calculation
1) The MAWP of a vessel is 100 psig. Each head depth is 2’ and the
cylindrical portion of the shell is 32’. The shell should be
designed for a pressure of ______ psig.
100 psig
0 ft
34 ft
Exercise 2-3
More MAWP & Static Head calculation
100 ft
Exercise 2-3
More MAWP & Static Head calculation
3) A 80’ tall pressure vessel is being hydrotested. A pressure gauge
20’ up from the bottom reads 136 psig. What is the pressure at
the top of the vessel.
0 ft
Ptop = Pgauge – Psh
= 136 – (0.433 x 60)
= 110.0 psig
60 ft 136 psig
80 ft
Module 2.4
Calculating Stress
Stress on Welds
S = Load/Area
S = 12,500/(0.25 x 1.0)
S = 50,000 psi
Exercise 2.5
Calculating Stress
The Allowable Stresses for Section VIII Pressure Vessel are provided in
the B&PV Code Section II.
UW-11(a)
Full RT – Required by User
Full RT can be specified by the User:
- If full RT is not required by the Code
- Selected to increase “E” and lower “t”
- Full RT does not mean 100% RT
- The following RT must be performed
- Category A welds -100% RT
- Category A&B welds – Type 1 or 2
- Category B welds – Spot RT
UW-11(a)(5)
The RT Factors
Describe the amount of RT performed
- RT 1&2: Full Radiography
- RT-3: Spot Radiography
- RT-4: Combo Radiography
E = 0.85
When the butt welds are either not spot RT
Or when the welds connecting seamless vessel sections or heads are
type 3,4,5 or 6.
UW-12(d)
Example – Finding “E”
1) A pressure vessel has butt welds which are single welded. No RT has
been performed.
1) “E” for welded shell? _______
2) “E” for the seamless head? _______
2) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-3
1) “E” for welded shell? _______
2) “E” for the seamless head? ________
3) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-2.
1) “E” for welded shell? _______
2) “E for the seamless head? _______
4) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-1
1) “E” for welded shell? _______
2) “E” for the seamless head? _______
Example – Finding “E”
1) A pressure vessel has butt welds which are single welded. No RT has
been performed.
1) “E” for welded shell? 0.6
2) “E” for the seamless head? 0.85
2) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-3
1) “E” for welded shell? 0.85
2) “E” for the seamless head? 1.00
3) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-2.
1) “E” for welded shell? 1.00
2) “E for the seamless head? 1.00
4) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-1
1) “E” for welded shell? 1.00
2) “E” for the seamless head? 1.00
Exercise 2-8
More Joint Efficiencies
1) A pressure vessel has lap welds which are single welded. The
vessel is stamped RT-3
1) “E” for welded shell? _____
2) “E” for the seamless head? ______
2) A pressure vessel has lap welds which are double fillet welded
1) “E” for welded shell? ______
2) “E” for the seamless head? ______
3) A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
1) “E” for welded shell? ______
2) “E” for the welded head? _______
Exercise 2-8
More Joint Efficiencies
1) A pressure vessel has lap welds which are single welded. The
vessel is stamped RT-3
1) “E” for welded shell? 0.45
2) “E” for the seamless head? 0.85
2) A pressure vessel has lap welds which are double fillet welded
1) “E” for welded shell? 0.55
2) “E” for the seamless head? 0.85
3) A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
1) “E” for welded shell? 0.99
2) “E” for the welded head? 0.99
Module 3.2
Tmin Calculations
Successful Calculations
• The 5 steps to calculating Success
1) Always write the formula. Leave space above the formula for step 2
data
2) Write the “Givens” above formula. Put these in the same order as
the formula.
3) Plug-in the values directly below the formula
4) Solve the problem
5) When complete shows the appropriate units e.g. inches, mpy, years
Shell tmin Calculations
t = PR/SE-0.6P
P = SEt/R + 0.6t
___________________________________________________________
• The “Givens”: P=158 psi, R= 36”, S=15,000 psi, E=1.0
___________________________________________________________
2) The formula: t = PR/SE-0.6P
___________________________________________________________
3) The plug-in: t = 158 x 36 / (15,000 x 1) – (0.6 x 158)
___________________________________________________________
4) The solutions with Units t = 0.382”
___________________________________________________________
Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24”. At the design
temperatures the material’s allowable stress is 20,000 psi. The
pressure on the shell is 250 psi (static head is included). The joint
efficiency is 1.0. Determine the minimum required thickness?
___________________________________________________________
• The “Givens”: P= , R= , S=, E=
___________________________________________________________
2) The formula: t = PR/SE-0.6P
___________________________________________________________
3) The plug-in: t =
___________________________________________________________
4) The solutions with Units t =
___________________________________________________________
Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24”. At the design
temperatures the material’s allowable stress is 20,000 psi. The
pressure on the shell is 250 psi (static head is included). The joint
efficiency is 1.0. Determine the minimum required thickness?
___________________________________________________________
• The “Givens”: P= 250 psi , R= 24” , S= 20,000 psi, E= 1.0
___________________________________________________________
2) The formula: t = PR/SE-0.6P
___________________________________________________________
3) The plug-in: t = (250)(24)/(20,000 x 1.0) – (0.6 x 250)
___________________________________________________________
4) The solutions with Units t = 0.302”
___________________________________________________________
Exercise 2-10
Shell Minimum Required Thickness
1) A vertical vessel has an internal radius of 48”. The material
allowable stress is 12,500 psi. The MAWP of the vessel is 120 psi. The
welds are “double-welded” and the nameplate says RT-3. The top of
this shell section is 4 ft from the top of the vessel and the bottom of
this shell section is 52 ft from the top of the vessel. Determine the
minimum required thickness.
t = PD/2SE-0.2P
P = 2SEt/D + 0.2t
t = 0.885PL/SE-0.1P
t = PL/2SE-0.2P
t = d √CP/SE
Exercise 2-12
Flat Head tmin
A flat circular head is made from seamless A-285 Grade B plate with a
corner design illustrated in Figure UG-34 (e). The allowable stress is
12,500 psi. The vessel MAWP is 300 psi. The horizontal vessel is
stamped RT-3. Assume m=1.0. The vessel inside diameter is 60”.
___________________________________________________________
1) The “Givens”: P= ?, D = 60” = 5’, C= 0.33m = 0.33 x 1 =0.33 , S= 12,500
psi, E= 1.0 (Seamless)
Pshell = Ptop + Psh = 300 + (0.433 x 5) = 302.165 psi
___________________________________________________________
2) The formula: t = d √CP/SE
___________________________________________________________
3) The plug-in: t = 60 √C(0.33)(302.165)/(12,500)(1.0)
___________________________________________________________
4) The solutions with Units t = 5.359”
___________________________________________________________
Part MAWP
Part MAWP is the pressure a part is “good for”
Based on knowing the thickness (don’t include the CA)
The a typically used in re-rate calculations
This is not vessel MAWP. Vessel MAWP is based on the “weakest
link” after subtracting Static Head.
Part MAWP formulas are given in the same paragraphs as the tmin
formulas.
No “P” formula for flat heads
Symbols are the same as used in the tmin formulas
t = PD/2SE-0.2P
P = 2SEt/D + 0.2t
Exercise 2-13
Let’s Calculate Part MAWP
1) The thickness of each part is 0.5”. The allowable stress ofte
materials is 15,000 psi. The joint efficiency is 1.0. The inside
diameter is 60”. Calculate the maximum pressure each part is “good
for”. P = 2SEt/D + 0.2t
2:1 Ellipsoidal Head: _______ psi
Torispherical Head: _______ psi P = SEt/0.885L + 0.1t
Pt = Test Pressure
St = Allowable stress at temperature
of hydrotest
Sd = Allowable stress at design
temperature
Note: St/Sd always > 1
Determine the:
• Pneumatic Test Pressure
• Each of the Test Pressure Steps
• Inspection Test Pressure
Exercise 3-2
Hydrotest Solution
a) Pneumatic Test Pressure
Pt = 1.1(MAWP) x (St/Sd) = 1.1x100(18,000/17,000) = 116.5 psi
b) Each of the Test Pressure Steps
0.5Pt – 1st step = 0.5(116.5) = 58.2 psi
0.6Pt – 2nd step = 0.6(116.5) = 69.9 psi
0.7Pt – 3rd step = 0.7(116.5) = 81.5 psi
0.8Pt – 4th step = 0.8(116.5) = 93.2 psi
0.9Pt – 5th step = 0.9(116.5) = 104.8 psi
1.0Pt – at test pressure = 1.0(116.5) = 116.5
Material Curve C
Initial MDMT 260F [SA-516 Gr. 60 as it is not mentioned as normalized]
Ratio Reduction 00F [no reduction ratio given assume no reduction]
PWHT Reduction 00F [no reduction as 2” plate required PWHT by Codes]
Final MDMT 260F
Exercise 3-3
Determine MDMT
2) Material normalized SA-612. Thickness is 0.750”. Reduction ration is 0.85.
vessel was not PWHT.
Curve B
Initial MDMT 31 0F [Either figure UCS-66 or Table UCS-66 for tabular values]
Ratio reduction -12 0F [from figure UCS-66.1]
PWHT reduction -30 0F [P-1 material <1 ½” not required PWHT as per UCS-56]
Final MDMT -11 0F
Impact Testing UG-84
Impact testing of material is required
when minimum operating temperature
is lower than allowed by the UCS-66
MDMT calculations.
1) 18-19-12
2) 17-12-25
3) 17-16-17
4) 18-17-12
More Exercise
Impact Testing
A welding procedure requires impact testing for a thickness range
3/16” – 2”. The specimen is 1” having 45 ksi yield strength. What is
the minimum acceptable impact test values for the three specimens?
From figure UG-84.1 find value required for average of 3 specimen using 2”
the thickest range.
Average = 17 ft-lbs
Min value = 2/3 (17) = 11.3
D0 = Outside diameter
P =4B/3(Do/t) L = Length between supports (inches)
Factors A & B – numbers from graph
t= 0.635” B=11,600
D0=45” A=0.0008
P =4B/3(Do/t)
= 4(11,600)/3(45/0.635)
= 218 psi
We must sail sometimes with the wind and sometimes against it-but we must sail, and
not drift, nor lie at anchor.
-Oliver Wendell Holmes
To
People are always blaming their circumstances for what they are. I don’t believe in
circumstances. The people who get on in this world are the people who get up and look
for the circumstances they want, and if they can’t find them, make them.
-George Bernard Shaw
If we don’t change, we don’t grow. If we don’t grow, we aren’t really living.
-Beverly Sills