API 510: Pressure Vessel Inspection Code:

Maintenance, Inspection, Rating, Repair, and Alteration

(Training Only)

September 4-15, 2004 Abu Dhabi, U.A.E.

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Copyright © 2004 by Harvard Technology Middle East. All Rights Reserved

To The Participant

The Course notes are intended as an aid in following lectures and for review in conjunction with your own notes; however they are not intended to be a complete textbook. If you spot any inaccuracy, kindly report it by completing this form and dispatching it to the following address, so that we can take the necessary action to rectify the matter.

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Abu Dhabi, U.A.E.

Tel: +971 2 627 7881 Fax: +971 2 627 7883

Email: info@harvard.tc

Disclaimer

The information contained in these course notes has been complied from various sources and is believed to be reliable and to represent the best current knowledge and opinion relative to the subject. Harvard Technology offers no warranty, guarantee, or representation as to it’s absolute correctness or sufficiency. Harvard Technology has no responsibility in connection therewith; nor should it be assumed that all acceptable safety and regulatory measures are contained herein, or that other or additional information may be required under particular or exceptional circumstances.

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COURSE OVERVIEW IE100

API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training only)

Course Title API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair and Alteration (Training only) Course Date/ Venue March 05-16, 2005/ Al Nakheel 4, Movenpick Hotel, Dubai, UAE Course Reference IE100 Course Duration 10 days (80 hours as per API recommendations) Course Objectives This course is designed to train individuals who are interested in obtaining the API 510 Pressure Vessel Inspector Certification, as well as those who are seeking a better understanding of ASME Section VIII and IX code requirements. Included with the course is a pre-study guide and student classroom workbook. The student receives instruction regarding how to take the test, as well as insight into the intricacies of "real world" situations. Daily tests are designed to gauge students’ proficiency and understanding of the material. Topics include:

Head and Shell Calculations Hydrostatic Test Pressure Calculations Reinforcement Calculations Shell External Pressure Calculations Impact Test Requirements and Determination Development and Review of Welding Documentation NDE Requirements

Harvard Technology (ITAC) is proud of its 90%+ pass rate, and we hope to include your staff among our successful candidates. Who Should Attend The course is intended for Inspection Engineers who are seeking API-510 certification. Other engineers, managers or technical staffs who are dealing with Pressure Vessel will also benefit. Course Certificate Harvard Technology certificate will be issued to all attendees completing minimum of 75% of the total tuition hours of the course.

Harvard Technology Middle East

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Course Fee US $ 3,750 per Delegate. This rate includes Participant’s Pack (Folder, Manual, Hand-outs, etc.), buffet lunch, coffee/tea on arrival, morning & afternoon of each day. Accommodation Accommodation is not included in course fees. However, any accommodation required can be arranged by Harvard Technology at the time of booking. Required Codes & Standards Listed below are the effective editions of the publications required for the current Vessel Inspector Certification Examination. Each student must have these documents available for use during the class.

AAAPPPIII SSStttaaannndddaaarrrddd 555111000 , Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and Alteration, Eighth Edition, June, 1997; including Addendum 1 (December, 1998), Addendum 2 (December, 2000) and Addendum 3 (December, 2001). Global Engineering Product Code API CERT 510

AAAPPPIII RRReeecccooommmmmmeeennndddeeeddd PPPrrraaaccctttiiiccceee 555777222 , Inspection of Pressure Vessels, Second Edition, February, 2001. Global Engineering Product Code API CERT 572

AAAPPPIII RRReeecccooommmmmmeeennndddeeeddd PPPrrraaaccctttiiiccceee 555777666 , Inspection of Pressure-Relieving Devices,, Second Edition (December 2000). Global Engineering Product Code API CERT 576

GGGuuuiiidddeee fffooorrr IIInnnssspppeeeccctttiiiooonnn ooofff RRReeefffiiinnneeerrryyy EEEqqquuuiiipppmmmeeennnttt,,, CCChhhaaapppttteeerrr 222***,,, Global Engineering Product Code API CERT GUIDE IRE CH2 *NOTE: This publication is a reference document intended only for Inspector Certification applicants. To obtain a copy please inform the person taking your order that you require this publication for the API 510 Inspector Certification exam.

AAAmmmeeerrriiicccaaannn SSSoooccciiieeetttyyy ooofff MMMeeeccchhhaaannniiicccaaalll EEEnnngggiiinnneeeeeerrrsss (((AAASSSMMMEEE))),,, Boiler and Pressure Vessel Code, 2001 edition...

i. AAASSSMMMEEE SSSeeecccttt iiiooonnn III IIIDDD , External Pressure Graphs only. ii. AAASSSMMMEEE SSSeeecccttt iiiooonnn VVV , Nondestructive Examination, Articles 1, 2, 6, 7 and, Article23 (SE-

797) iii. AAASSSMMMEEE SSSeeecccttt iiiooonnn VVVIII III III , Rules for Construction of Pressure Vessels, Division 1, UG, UW,

UCS, UHT, Appendices 1-4, 6, 8 and 12. Optional Appendix L ( has sample problems) iv. AAASSSMMMEEE SSSeeecccttt iiiooonnn IIIXXX , Welding and Brazing Qualifications

Global Engineering Product Code for the ASME package is API CERT ASME 510. Package includes only the above excerpts necessary for the exam. Future addenda will not be provided.

API and ASME publications may be ordered through Global Engineering Documents at 303-792-2181 or 800-854-7179. Product codes are listed above. API members are eligible for a 50% discount on all API documents, other exam candidates are eligible for a 20% discount on all API documents. No discounts will be made for ASME documents. When calling to order please identify yourself as an exam candidate.

Harvard Technology Middle East

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For complete sets of ASME documents including future addenda please contact ASME’s publications department at 1-800-843-2763. In Canada, ASME publications are available through Power Engineering Books, Ltd. at 1-800-667-3155 or 780-458-3155.

Note: API and ASME publications are copyrighted material. Photocopies of publications are not permitted at the exam. CD-ROM versions of the API documents are issued quarterly by Information Handling Services. Be sure to check your CD-ROM against the editions noted on this sheet. Course Instructor Mr. Oran T. Lewis, P.E. (Texas, USA) is an Adjunct Instructor with over twenty years experience in the design, erection, maintenance, inspection, fabrication, modification and repair of pressure equipment, as well as presenting educational courses for piping inspection, welding, weld inspection, and pressure equipment inspection Mr. Lewis has a Bsc degree and he is a qualified American National Board Trainer and an NDE Trainer. Further, he is a AWS Certified Welding Inspector, API Certified Pressure Vessel Inspector, API Certified Piping Inspector, a member of the National Board of Boiler and Pressure Vessel Inspectors Commission and a Boiler and Pressure Vessel Inspector - State of Texas. Course Program

Day 1 : Saturday 05th of March 2005 0730 - 0800 Registration & Coffee 0800 - 0810 Welcome & Introduction 0810 - 1000 Joint Efficiencies

UW-3 Weld Categories UW-51 RT Examination of Welded Joints UW-52 Spot Examination of Welded Joints

1000 - 1015 Break 1015 - 1230 Joint Efficiencies (continued)

UW-11 RT and UT Examinations UW-12 Maximum Allowable Joint Efficiencies Exercises UW 3, 11 and 12

1230 - 1330 Lunch 1330 - 1515 Postweld Heat Treatment

UW-40 Procedures for Postweld Heat Treatment 1515 - 1530 Break 1530 - 1700 Postweld Heat Treatment (continued)

UCS-56 Requirements for Postweld Heat Treatment 1700 End of Day One

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Day 2 : Sunday 06th of March 2005 0730 - 0830 Review of Day 1 0830 - 1000 Vessels Under Internal Pressure

UG-27 Thickness of Shells Under Internal Pressure UG-32 Formulas and Rules for Using Formed Heads

1000 - 1015 Break 1015 - 1230 Vessels Under Internal Pressure (continued)

UG-34 Unstayed Flat Heads and Covers (Circular) Exercises UG s-27-32-34

1230 - 1330 Lunch 1330 - 1515 Cylinder under External Pressure

UG-28 Thickness of Shells and Tubes (External Pressure) 1515 - 1530 Break 1530 - 1700 Cylinder under External Pressure (continued)

Exercise UG-28103 1700 End of Day Two

Day 3 : Monday 07th of March 2005 0730 - 0930 Review of Day 1 & 2 0930 - 0945 Break 0945- 1230 Pressure Testing

UG-20 Design Temperature UG-22 Loading UG-25 Corrosion UG-98 Maximum Allowable Working Pressure UG-99 Hydrostatic Test Pressure and Procedure UG-100 Pneumatic Test Pressure and Procedure UG-102 Test Gages

1230 - 1330 Lunch 1330 - 1515 Pressure Testing (continued)

Exercises UG s 99-100-102 1515 - 1530 Break 1530 - 1730 Minimum Requirements for Attachment Welds at Openings

UW-16 Weld Size Determination Exercise UW-16

1730 End of Day Three Day 4 : Tuesday 08th of March 2005 0730 - 0830 Review of Day 3 0830 - 1000 Reinforcement for Openings in Shells and Heads

UG-36 Openings in Vessels UG-37 Reinforcement of Openings

1000 - 1015 Break 1015 - 1230 Reinforcement for Openings in Shells and Heads (continued)

UG-40 Limits of Reinforcement

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UG-41 Requirements for Strength of Reinforcement UG-42 Reinforcement of Multiple Openings

1230 - 1330 Lunch 1330 - 1515 Reinforcement for Openings in Shells and Heads (continued)

Exercises UG s 40-41-42-45 1515 - 1530 Break 1530 - 1700 Reinforcement for Openings in Shells and Heads (continued)

Exercise Reinforcement for Openings in Shells and Heads 1700 End of Day Four

Day 5 : Wednesday 09th of March 2005 0730 - 0830 Review of Day 4 0830 - 1000 Minimum Design Metal Temperature & Exemptions From Impact

Testing UG-84 Charpy Impact Test Requirements Exercise UG-84 UCS-66 Materials

1000 - 1015 Break 1015 - 1230 Minimum Design Metal Temperature & Exemptions From Impact

Testing (continued) UCS-67 Impact Testing of Welding Procedures UCS-68 Design Exercises UG 20 –UCS 66 – 67

1230 - 1330 Lunch 1330 - 1515 Practical Knowledge

UG-77 Material Identification UG-93 Inspection of Materials UG-116 Name Plate Markings

1515 - 1530 Break 1530 - 1700 Practical Knowledge (continued)

UG-119 Name Plates UG-120 Data Reports

1700 End of Day Five Day 6 : Saturday 12th of March 2005 0730 - 0830 Review of Day 5 0830 - 1000 Welding on Pressure Vessels (Section IX Overview)

Article I General Requirements Article II Welding Procedure Qualifications

1000 - 1015 Break 1015 - 1230 Welding on Pressure Vessels (Section IX Overview) … (continued)

Article III Welding Performance Qualifications Article IV Welding Data

1230 - 1330 Lunch 1330 - 1515 Welding Documentation Review

Welding Procedure Specification (WPS) Procedure Qualification Record (PQR)

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1515 - 1530 Break 1530 - 1700 Welding Documentation Review (continued)

Practice WPS/PQR reviews 1700 End of Day Six

Day 7 : Sunday 13th of March 2005 0730 - 0930 Review of Day 5 & 6 0930 - 0945 Break 0945 - 1230 Advanced Material Example Problems

Static Head of Water Corrosion Calculations Cylinders under Internal Pressure Heads under Internal Pressure Charpy Impact Test Evaluation WPS/PQR Quiz Static Head Pressure

1230 - 1330 Lunch 1330 - 1515 Advanced Exercise Problems

Internal Pressure Shell Calculations Internal Pressure Head Calculations

1515 - 1530 Break 1530 - 1700 Advanced Exercise Problems (continued)

Solutions for Advanced Exercises 1700 End of Day Seven

Day 8 : Monday 14th of March 2005 0730 - 0830 Review of Day 7 0830 - 1000 API 510 Corrosion Rates and Inspection Intervals

Scope MAWP Determination Inspection Interval Corrosion Rate and Remaining Life Long and Short Term Corrosion Rates Quiz # 1

1000 - 1015 Break 1015 - 1230 API 576 Pressure Relieving Devices

Scope Types of pressure relieving devices Quiz # 2 Quiz # 3

API 572 Inspection of Pressure Vessels Scope Reasons for Inspection Causes of Deterioration Methods of Repairs Inspection Records and Reports

1230 - 1330 Lunch 1330 - 1515 API 572 Inspection of Pressure Vessels (continued)

Quiz # 4

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Quiz # 5 Quiz # 6 Quiz # 7 Quiz # 8

IRE Chapter 2 1515 - 1530 Break 1530 - 1730 IRE Chapter 2 (continued)

Coverage from the API 510 Body of Knowledge

Quiz # 9 1730 End of Day Eight

Day 9 : Tuesday 15th of March 2005 0730 - 0930 Review of all course materials 0730 - 1000 Administer first half of 150 question API 510 practice examination A. 1000 - 1015 Break 1015 - 1230 Administer first half of 150 question API 510 practice examination A

(continued) 1230 - 1330 Lunch 1330 - 1515 Administer first half of 150 question API 510 practice examination A

(continued) 1515 - 1530 Break 1530 - 1730 Administer first half of 150 question API 510 practice examination A

(continued) 1730 End of Nine

Day 10 : Wednesday 16th of March 2005 0730 - 0830 Review of the first half of the API 510 practice examination A. 0830 - 1000 Administer 2nd half of 150 question API 510 practice examination A. 1000 - 1015 Break 1015 - 1230 Administer 2nd half of 150 question API 510 practice examination A. 1230 - 1330 Lunch 1330 - 1530 Administer 2nd half of 150 question API 510 practice examination A. 1530 - 1545 Break 1545 - 1645 Review of the second half of API 510 practice examination. 1645 - 1730 Pass out API 510 practice examinations B and C with solutions.

Closing comments Presentation of Certificates

1730 End of course

Course Coordinator Ms. Urooj Musheer: Tel: +971-2-6277881, Fax: +971-2-6277883, Email: urooj@harvard.tc

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Table of Contents

Section 1 API 510 Code, RP’s 576, 572, & Chap. 2

Section 2 ASME Section VIII Div. 1 Section 3 ASME Section IX Section 4 Advanced Material Section 5 Practice Exams / Exercises

Section 1

API 510 Code, RP’s 576, 572, & Chap. 2

Section 2

ASME Section VIII Div. 1

Section 3

ASME Section IX

Section 4

Advanced Material

Section 5

Practice Exams / Exercises