Ss sAN ene API 510 PREPARATCRY COURSE Points To Recall - Day 1 ASME codes edition Is issued once in 3 years and addenda, once a year - both on 1 July. Edition and addenda become effective ‘on 1* January of next year ( i.e. 6 months after issue). ASME Sec VIII Div.1 is Unfired Pressure Vessel and is applicable fofoy to pressures exceeding 15 psig, up to 3000 psig and diameters Intrcbehory above 6.0”. Pump and turbine casings are excluded. Thickness of cylindrical shell t= PR SE-0.6P Longitudinal weld is more critical because it is subjected to double the stress than Circ. Weld. ‘Weld joint categories’ A,B,C,D - are based on joint locations in the vessel and stress levels encountered. ‘weld Types’ ( type 1,2,3...etc) describe the weld it self. Depths of 2:1 Ellip and hemisph. heads are D/4 and D/2 respectively. (D= Head diameter.) Weld Joint categories: Category A: - All fongitudinal welds in shell and nozzles. - All welds in heads, Hemisph-head to shell weld joint Category B: - All circumferential welds in shell and nozzles, - Head to shell joint (other than Hemisph.) Category C and D are flange welds and nozzle attachment welds respectively.10. 11. 12. 13. 14. Weld Types: Type 1: Full penetration welds ( Typically Double welded) Type 2: Welds with Backing strip. Type 3: Single welded partial penetration welds. Type 4,5,6 are various Lap welds ( rarely used) For full penetration welds (type 1), Joint efficiency, E= 190%, 85%, 70%, For the radiography = Full, Spot, Nil respectively. Radiography marking on name plates ( typically for Type-1 welds) RT-1: (E=1) All butt welds - full length radiography. RT-2: (E=1.0) All Cat. A Butt welds Full length , Cat B, spot. RT-3: (E=0:85) Spot radiography of both Cat A and B welds RT-4: (E=0.7) Partial / No radiography For Welded Heads for E=1, all welds within the head require full h radi ince th 1 Cat, : length radiography (since they are all Cat, A welds) For seamless heads , E=1, If a) head to shell weld is fully radiographed ( if Cat A), and at least spot radiographed ( if Cat, B) ari RZ Compared to Cylindrical shell, thickness of 2:1 Ellipsoidal head is approx. same as shell, Hemisph. head approx. half and Torisph head is 77% higher. MAWP is calculated for: Working condition (Hot & Corroded). Vessel MAWP is always taken at the Top of the Vessel and is lowest of all part MAWPs adjusted for static pressure.SATE API 510 PREPARATORY COURSE Points To Recall - Day 2. Hydro-Test Is Standard Pressure test on Completed Vessels. Hyd. Test Pr. = 1.3 x MAWP x stress ratio Min Insp. Pressure (hydro) = test pr./1.3 Min. Test temp = MDMT + 30 deg.F Max. Inspection W. = 120 deg. F Temp Pneumatic test is performed if Hydro is not possible due to design or process reasons . Prior to the test, NOT as per UW-50 is mandatory. Pneumatic Test pr = 1.1 x x Stress ratio, Pressure should be Increased in steps (Total 6). 1* step - 50% of Test pr. 2" to 6 step - 10% of Test for Insp. Pr. (pneumatic) = Test pr,/1.1 Pressure Gauge range should be about twice the Test Pressure, However, in any case it shall not be lower than 1.5 times and not higher than 4 times the Test Pressure. Vessel MAWP represents the Maximum Safe Pressure holding capacity of the vessel .vessel MAWP is Measured at top-most point. And is lowest of vessel part MAWPs. For vertical vessels, Hydrostatic pressure caused due to liquid with specific gravity = 1, 1ft of height = 0.43 psig. Or 1 mtr of height = 0.1 Bar 43311. 12. Total pressure at any point of Vertical vessel is given by: Total Pr. = Vessel MAWP +(h x 0.433) (h= height from top in ft.) If part MAWP and elevations are known, Vessel MAWP can be calculated by {i deducting hydrostatic pressure from part MAWP. Ext. pressure is worked out on basis of Geometric factor A (which depends on L/Do and Do/t ratios) and factor B ( depends on A, ) ane Allowable Ext. Pressure, Pa = 3(Do/t) For values of A falling to left of material line in the material chart, pa = 248 3(Do/1) Name plate shows The Code stamping, MAWP, design temp., MDMT, and Extent of Radiography. For the impact test requirement, UCS 66 curve. If MDMT-thickness combination falls on or above the curve, impact testing is exempted Additional Exemptions are given as per UG-20(f) and UCS=68 (c ). ASME materials (SA) shall be used for code stamped vessel fabrication instead of ASTM (A) materials.we SAW API 510 PREPARATORY COURSE Points To Recall — Day 3 Reinforcement pad is not required, if the size of finished opening is — Not exceeding 2 3/8” for all thicknesses of vessel — Not exceeding 3 1/2", if vessel thickness is < 3/8” Reinforcement pad with OD = 2d and thk = vessel thk is always safe (d= dia of finished opening) Reinforcement Limit along vessel wall = 2d Reinf. Limit normal to vessel wall = smaller of: 2.5 t or 2.5 tn In reinforcement pad calculations, credit can be taken for area available in shell and nozzle. Fillet weld Throat dimension = 0.707 x leg of weld Adequacy of weld sizes shall be checked as required by UW-16. The nozzles construction shall be one of the Code acceptable types. The maximum permitted ovality tolerance (D max - D min) shall not exceed 1% of nominal diameter of vessel. If there is opening, then the tolerance can be increased by 2% x d (d = diameter of opening) if measurement is taken within a distance of ‘d’ from axis of opening.10. it. 12. 13. 14, 15. 16. The mis-match tolerances and the maximum allowable weld reinforcement is more strict on longitudinal welds compared to circumferential welds (UW-35). Principle of reinforcement: Area removed = Area compensated. Compensation area shall be within reinforcement li its. For use as pressure parts, the plates shall be fully identified. Maximum permitted under tolerance on plates is 0.01" (0.3 mm) or 6% of ordered thickness, whichever is less. All Welding (including tack, seal etc.) shall be done using Qualified procedures and welders Mandatory Full Radiography is required for all welding with thickness exceeding Table UCS-57, and also for lethal service vessels and Unfired boilers with Design Pr. More than 50 psig. PWHT is Code Requirement if thickness exceeds those given in tables UCS-56 (given in notes under the tables). These tables also give min. PWHT temperature and min. holding time (soaking period) based on P-nos. and thickness respectively. For Furnace PWHT, Loading Temperature shall not exceed 800 deg.F, heating rate 400 deg F/hr/inch of thickness, Cooling rate 500 deg.F /hr/inch of thickness. Still air cooling permitted below 800 deg.F. During Soaking period, temp difference between hottest and coldest part shall not exceed 150 deg.F Min. Overlap for PWHT in multiple heats = 5 ft.SAN API 510 PREPARATORY COURSE Points To Recall - Day 4 1, API 510 Is applicable to Vessels that have been placed in service, and It can not be adopted for New constructions. 2. Following are excluded from scope of API 510: ~> a. All mobile vessels ~> b. All exclusions of ASME Sec VIII Div, 1 >. Vessels not exceeding 5 cubic feet and 250 psi design pressure or 1.5 cubic feet and 600 psi design pressure 3. Alteration: It is change in component that has design implications affecting pressure and/or temperature rating. 4. — Repair: It is restoring vessel suitable for operations at the Present design conditions. Repairs do not change Pr-Temp rating of vessel. 5. Authorized inspection agency: Any one of following: a. Jurisdiction organization b, Insurance company which under writes insurance of pressure vessels ¢. Inspection organization of owner-user d. Inspection organization under contract with owner user 6. Repair Organization: Any one of following: a. Holder of ASME certificate & appropriate code symbol stamp. b. Owner-user c. Contractor under contract with owner-user d. Organization authorized by jurisdictionOn-stream inspection means NDT inspection done on Vessel without entering Inside vessel. This inspection Is basically to know process side deterioration. Re-rating: A change in either MAWP or temperature rating or change in both. 9. Owner-User bears Ultimate responsibility for all activities (inspection, Engineering, repairs etc.) under API 510. te 10. Authorised Inspector is responsible to Owner-User to: a). b). °. Determine that all work (inspection, repairs ,alteration) is carried out as per requirements of API-510 By getting Involved In the actual activities performed Evaluate & accept/reject results of NDT and other tests. 11. Modes of failure: a. Chemical corrosion: - uniform corrosion ~ pitting corrosion Fatigue : - due to stress reversals Creep:- At elevated temp. below Yield point. Erosion: - Due to high fluid velocity, turbulence & suspensions Failure due to freezing of aqueous solutions. Brittle failure - due to loss of impact strength at lower temperature Loss of ductility in Cr-Steels due to improper PWHT or service at high temperature (>700°F)API 510 PREPARATORY COURSE Points To Recall - Day 5 1. For new service, or for changed service, if corrosion rate is not known, on-stream determination after 1000 hours shall be made to establish or confirm corrosion rate. 2. MAWP = *"/easo.ct) Where t = t acta: - 2x Cn Cn = metal loss upto next inspection 3. For corrosion area of considerable size; thickness averaging along most critical element shall not exceed following length (1): a. Vessel 1.D. < 60”. b. Vessel I.D. > 60”. | = D/2 or 20” use smaller value = D/3\40" use smaller value OR ‘The widely scattered pits, can be ignored if: q “The min the auaikible @ the bottem of te pit Shall be holt the a, No pit depth in greater than half wall thickness ‘4? seq sireof excluding C.A. b. Total pit arexdoes not exceed 7 square inches (refer Cede tor within 8 inch diameter circle Cosredt Gate mert) ¢. Total sum along any line in circle does not exceed 2 inches For surface remote from weld, (weld E < 1), shell thickness can be recalculated with E = 1. Shell area is considered remote from weid if it lies on either side weld beyond 1” or 2 times thickness (whichever Is greater). For dished Heads, the Crown portion lies within circle concentric to dish infer ci. = 0.8 x shell dia With For Ellipsoldal or Torispherical heads, crown portion thickness can be recalculated considering crown as part of sphere of radius equal to D, (for std, Torispherical) or Ki D (for Ellipsoidai). For ellipsoidal head Ki depends on D/2h ratio (h=head depth) For 2:1 Ellipsoidal Head, K1 = 0.9ANNE API 510 PREPARATORY COURSE Points To Recall - Day 6 1. Frequency of inspection: a. External visual: 5 years or same as internal (or on-s@am) inspection, use smaller duration b. Internal / on-stream: Smaller of half remaining life or 10 years, but if remaining life is < 4 years full remaining life up to max. of 2 years. ¢. For non-continuous service - external same as (a) above but internal will be after 10 years of actual exposed life for non corrosive, where as for corrosive it will be smailer of half remaining life or 10 years, 2. — Remaining life = Remaining C.A / Corrosion rate Corrosion rate = metal loss over a period period oF metal Toss 3. Pressure test - Test at temp above MDMT + 30°F (thickness># 2”) MDMT + 109F (thickness < 2”) Perform Pneumatic test, if hydro is impractical 4. Inspection records shall have Devoe of information a. Design & Construction (permanent) records —~ b. Running (progressive) inspection records “ c. Repair and alteration (modification) records a Fitness for Service araly sis \Snert ed RBI wilt be inducted5. For Vessels whose material is not known, MAWP can be calculated assuming Stess value for A 285 Gr. C material and Joint Efficiency equal to0.7. 283 6. Pressure relieving devices: Inspection interval not to exceed 5 years normally but for clean non-corrosive service may be 10 years. 7. Authorization for repairs/alteration of vessels constructed as per: a. ASME Sec. VII, Div. 1: Repairs — API inspector b. Alterations — API inspector and P.V. Engineer c. Sec. VII, Div. 2: Repairs & Alterations — API inspector & P.V. Engineer 8. If PWHT Is impracticable, materials under P No. 4 (gr 1, 2, 3) and P No. (gr 1, 2) shall be repair welded as follows (If impact testing is not required). a. Preheat to 30P°degrees F for a distance 4” or Mt on either side of groove (t = weld metal thickness) b. Welding process shall be SMAW, GMAW, or eae G Control interpass temperature not to exceed 600 degrees F10. in. 12. 13. 14. If impact testing is required and PWHT is impracticable, the materials under P No. 1, 3, 4 shall be welded as follows: a. Adopt SMAW/GMAW/GTAW process — with temper bead $Phaif bead technique b. — Requalify the procedures as per table 7-1 o-f API-S10 €. Use low Hydrogen Electrodes. Carry out Sith eee et Hydrogen bake out treatment if required (Electrodes designation > H4) For all other materials other than 8 and 9 above, PWHT shall be carried out after repair if it was carried out originally as per code of construction. The welding area of weld preparation before welding, and the completed weld shall be checked by PT or MT. Pressure test is required after repair/alterations, if Authorised Inspector thinks it necessary. Pressure Test is normally requiéd after Alteration and Major Repairs. Insert patches must be with full penetration welds. Fillet —Ee0hs patches shall be approved by P.V. Engineer. Normally a fillet patch equivalent to reinforced openi ing. is okay. Re-rating calculations shall be done by Pressure Vessel Engineer, and New Stamping or New Name plate showing Rerating ( New MAWP , temp, ) shall be attached to vessel. eeAPI 510 PREPARATORY COURSE Points To Recall - Day 7 Procedure qualifications give suitability of weld for required mechanical properties (i.e., strength, ductility), while Performance qualifications show ability of the welder to make sound weld. Tension test gives Tensil Value, while bend test shows ductility and soundness. Radiography also indicates soundness. Thus, Proc. Qual.: Tension test + Bend test Perf. Qual. : Bend test or Radiography Tensile test for procedure qualification is passed if failure is in: a. Weld metal at strength>= Base metal SMTS or b. Base metal at strength>= 95% of base metal SMTS. Bend test crack shall not exceed 1/8” in any direction. Radiography criteriaJare more strict than radiography for job. feqnitjohn P - Numbers represent parent metal classification of similar composition and properties, i.e., similar strength and ductility. F - numbers give similar usability aspects of filler material. A - numbers give similar chem. comp. In “As welded” condition.10. 11. 12. 13 Essential variables (EV), if changed require new procedure wes qualification. Non-essential variables (NEV) may be changed without new procedure qualification. = Supplementary essential variables (SEV) are considered as (EV) only if there is impact strength requirement. Otherwise they are “non-essential” variables. EV and SEV are included in PQR document. EV,SEV and NEV are included in WPS document. PQR document gives data used in PQR test and test results, and cannot be revised. WPS gives parameters to be used in production job, and must be within ranges qualified by the PQR test. WPS may be revised within the EVs qualified. The NEVs can always be revised without affecting validity of PQR. For performance, 1G is flat, 2G is horizontal, 3G is vertical and 4G in. Pipe 5G qualifies 1G,,3G and 4G, but pipe 6G qualifies all positions. is overhead posi ASME Sec. V is NDT procedure/methods code and is applicable only if it is referenced by the Reference code (Construction Code). The extent of NDT and acceptance standards are stipulated in Reference Code.14. For RT (Art.2): a. Backscatter Control: Light image of 8 on dark background —Unacceptable b. Density Limitations: Min 1.8 for x Ray / 2.0 for G-Ray Max 4.0 for x / G Ray Density Variation = —-15 % to + 30% Anat Double wall viewing (DWDI)- —_up to 3.5" dia. O0 Penetrameter ( IQI ) Selection : - As per Table T-276. Thickness includes weld reinforcement, But not backing. - Penetrameter should be placed on Source side. Film side (with letter F) is permitted if there Is no acess tplace IQI on source side - At least one penetrameter image shall appear on each film ( with 2T hole for Hole-type or Designated wire for wire type)API 510 PREPARATORY COURSE Points To Recall - Day 8 For PT (Art.6) : a. Control of Contaminants: Sulphur or (chlorine+ fluorine) shall not exceed 1% Standard procedures(penetrant time,Developing time etc.) are applicable for temp. range 10 °C to 52 °C,. New procedure shall be qualified for outside this range. Penetrants are Colur(visible) type and Fluoroscent type. Each of these have 3 types of penetrants Water Washable, Post Emulsifying, Solvent Removable. PE type may be - Lipopholic, Hydro-pholic, Penetration Time, Developing time, Table T-672 Final interpretation within 7 to 60 minutes. For MT ( Art.7): a. Yoke Type: Electromagnet or Permanent Magnet. Suitable for Surface defects. b. Prod Type: Electro-magnet wear’ Suitable for Surface/ Sw-surface Defects c. Examination Medium: Dry powder or Wet Powder Dry Powder Suitable for higher temperatures. d. For Electromagnets: Equipment Ammeters shall be checked anually with a Master Ammeter. 3 Readings to be taken and should be within +- 10% of full scale. e. Lifting Power of Yokes + AC shall have lifting power of at least 4.5 Kg /folbs + OC shall have lifting power of at least 18.1 K9 /40 lox = Weight too shall be checked prior to first use f. Min. two examinations on each area, the second is perpendicular to first g. Prod Spacing - Not exceed 8” and not less than 3"3. SE-797UT Measurement: a. Pulse- Echo method can be adopted up to 200 deg. F. Not suitable on Coarse-Grain Castings. b. Apparatus : - 3 types ~ CRT read out - CRT + direct read out - Direct thickness read out c. Search Units: 3 types - Straight beam contact type - Delay line type. (delay block to minimize dead zone). Suitable for Low thickness - Dual element type. (two crystals in one unit). Low roof angle used for higher thickness range and vice-versa. Low thicknesses measurements require Vee-error correction. d. High thickness measurement: Use of multiple echo is made by using thinner calibration block. The second last back-echo coinsides to zero, the last echo to the end of screen,the screen is thus calibrated to thickness of the calibration block. e. While taking measurement for high temperature condition a positive error of 1% per 55 deg C (100 deg F) will results. Hence temperature correction is necessary. f. CRT read out is recommended when reflecting surface is corroded or rough . sels 4. Acceptance Criteria is to be applied to indications and not actual size of discontinuity. 5. Spot radiography of Pressure vessels (as per ASME Sec. VIII Div.1) is 1% .(1 spot of Ginches per 5Oft) If the spots in spot radiography are ok complete weldlength represented by that weld is accepted. For every unaccepted spot, take 2 more spots. Both additional spots shall be ok. Otherwise reject weld 6. UT is permitted only if RT cannot be performed on the closing weld. PT shall be done for MT only if MT cannot be done (i.e. non magnetic material) ®7. API 576 provides practical guidelines to meet API 510 requirements for pressure relieving devices. (PRDs) It does not cover training requirements 8. Inspection of PRDs is essential for : a. protection of equipments and safety of personnel, b. to determine condition of device itselfzaae- 9. __ Inspection frequency a. Inspection and shop maintenance - normal frequency Is 5 years (max) but may be up to 10 years for clean, non-corrosive, non-fouling medium b. Visual on-line survey — 5 years max 10. Safety valve is pop-opening valije, used on gases and vapors. Relief valve is “proportional opening” valve used on liquids. Safety relief valves can function both ways , Back-pressure correction is done on balanced safety relief valves , 11. After the valve is removed from service, first action is to check its relieving pressure (pop pressure) in the “as received” condition. Subsequently, carry out detailed visual examination, dismantling, cleaning, and lapping of valve seat. Set the pop at desired pressure and confirm the same at least once. Carry out leak test. 12. Leak test is carried out (at 90% of relieving pressure) by monitoring air bubbles appearing per minute under head of ¥2" and comparing with acceptance chart.API 510 PREPARATORY COURSE Points To Recall - Day 9 & 10 The chloride salts in Crude, in the presence of water (or during steam stripping) produces HCI acid which can attack the steel and in presence of H2S, the HCI is regenerated continuing the corrosion of steel equipments Fe+2HCl --> FeCl2+ 2H. FeCl: + 4@24,S--> lq 2HcI OLS ete. ‘Atomic Hydrogen can cause Hydrogen Induced Cracking (HIC) and Hydrogen Blistering (HB) At high temp (> 800 degrees F) In 2 addition to HIC and HB, the steel becomes spongy as Methane gas formation takes place by combining Hydrogen with free Carbon which is coming from decomposition of Cementite. 2S will cause RBIBnd §ildue to formation of Atomic Hydrogen during sulphide corrosion of steel (Fe + H2S --> FeS + @# and H:S also SENERRONE in Cf above. Erosion is caused due to high velocity flow of solid suspensions in liquids and gases or liquid suspensions in gases. R.O.E. varies as Cube of velocity. Inte lal if of aan SS. is ed di te Intergranular corrosion S. is caus jue to it Chromium carbide precipi 1a aeiapeiniibltisise cc2 the areas close to grain boundries stainiesS Ay 12.7, Vessel inspections are for The safety, continuity, reliability. Graphitization in Carbon Steels takes place due to prolonged exposure in 825 to 1400 deg. F ae in decomposition of Steel into Ferrite Crystals and /Graphite Nodules. In-situ Metallography is used to detect the Graphitization External inspection of Pr. Vessels and Exchangers should start with ladders, platforms, stairways connected to or bearing on vessel. External surfaces of vessels shall be examined for not only for corrosion but also for leaks, cracks, buckles, etc. L g2sF10. 1. 12. 13. 18. 19. 20. 21. If any settling is seen on vessel, nozzles and adjacent shell area shall be inspected for distortion and cracking. Hammer test shail be followed by suitable NDT. Grounding connection resistance shall not exceed 25 ohms but 5 ohms is normally preferred. In presence of acidic co rodents (PH < 7) hydrogen blistering is expected above and below (close to) liquid level. Auxiliary equipments ( Pr. gauges, sight glass, safety vaives etc. may be visually inspected while in service. Undue vibrations shall be arrested by providing additional supports or qualified engineer should determine if these could lead to fatigue failure. First step for Internal inspection Is review of previous records. For Heavy wall vessels at high pressure, major concern is crack damage particularly at the welds ( Weld & HAZ) 0 ce idic PLAC) hydros istering ts a {close to) liquid Yeuef. Laminations run siant while cracks run normal to surface. ‘Spark testing is effective method for breaks/leaks in paint, glass, plastic and rubber lining. UT is the primary means of obtaining thickness measurements. Other methods like profile radiography, Step-wedge comparison radiographs, Corrosion buttons, test holes and depth drilling are some other methods tetl tale pH = 7 represents Neutral fluid . pH > 7 indicates Basic while PH < 7 indicates Acidic fluid. depth awl ns