api_510_pressure_vessel_vessel_inspection_20130625014813 Flashcards
Internal Vessel Inspection Options
Normally, lesser of 10 years or 1/2 life or 2 years - if life is from 2-4 years, or Full Life - if life is
External Inspection Options
Lesser of 5 years or the inspection interval
Overall responsibility to comply with API 510
Owner
During repairs and alterations - Responsibilities for Quality Control
Repair organization
Assures owner - testing inspection and examination activities meet code ?
Inspector
Develop the inspection plan for vessels and relief devices ?
Inspector or Engineer
Review the inspection plan for equipment operating at elevated temperatures ?
Corrosion specialist
Choice to conduct RBI assessment ?
Owner
Review prior vessel history prior to vessel inspections ?
Inspector
Familiar with characteristics of potential damage mechanisms ?
Inspector
Perform internal inspections ?
Inspector
Determine whether its necessary to remove deposits or lining ?
Corrosion specialist and the inspector
Perform on stream inspection ?
Tech or the inspector
Approve on-stream inspection work performed by examiners ?
Inspector
Perform external inspection ?
Qualified others or the inspector
Take thickness measurements ?
Tech or the inspector
Review corrosion data if short term corrosion rate varies significantly
Corrosion specialist and the inspector
Assure those taking thickness measurements are trained and qualified ?
Owner
Determine locations of CML’s for vessels with localized corrosion ?
Corrosion specialist
Involved if the # of CML’s will be significantly reduced or eliminated ?
Corrosion Specialist
Determine types of expected damage and select NDE method ?
Inspector and the engineer or Corrosion Specialist
Perform UT flaw detection for finding linear flaws ?
QUTE
Determines whether a pressure test is needed after a repair “believes” ?
Inspector
Review use of a component pressure test in Lieu of a complete vessel hydro ?
Engineer
Determine the test pressure for non code related pressure tests ?
Owner
Hydro of 300 stainless steel, verify water quality and that vessel is drained and dried ?
Inspector
Approve substituting NDE for a pressure test ?
Inspector and engineer
Verify new materials are consistent with those specified ?
Inspector
When verifying new materials, determine the sampling percentage ?
Inspector or the owner
PMI of materials during repairs or alterations ?
Inspector or technician
If incorrect materials found in existing vessels, determine the amount of verification ?
Inspector
Asses crack like flaws attributed to environmental cracking ?
Engineer or corrosion specialist
Asses preferential corrosion in welds ?
Inspector
Inspect new vessels at time of installation ?
Inspector
Review and approve RBI assessments that extend intervals beyond 10 years ?
Inspector and engineer
Determine the internal and external inspection interval ?
Inspector or engineer
Approve the use of on stream inspection in leu of internal inspection ?
Inspector
Determine the relief device interval ?
Inspector or engineer
Select which corrosion rate (short term or long term) reflects the current conditions ?
Inspector and corrosion specialist
Maintain vessel and relief device records ?
Owner
Authorize all vessel repairs ?
Inspector
Authorize all repairs to Division II vessels ?
Inspector and the engineer
Authorize all alterations
Inspector and engineer
Designate hold points ? (fabrication approvals)
Inspector
Repairs - Approve all methods of design, material, WPS, NDE and testing
Inspector and engineer
Approve all repair and alteration work at hold points ?
Inspector
Approve all repair and alteration work at completion of work ?
Inspector
Approve all nozzle installations ?
Engineer
Allow temporary weld repairs to remain in place past the next inspection opportunity ?
Inspector and engineer
Determine that a crack will not propagate from under a fillet weld patch ?
Engineer
Approve the use of fillet welded patch repairs ?
Engineer
Approve the use of a lap band repair ?
Inspector and engineer
Authorize the repair welding of cracks at actress concentration ?
Engineer
Review the repair proceeders for stainless steel cladding ?
Inspector and the engineer
Monitor the repairs made to stainless steel cladding ?
Inspector
Maintain records of qualified WPS’s and WPQ’s
Repair organization
Allow exceptions to preheat temperatures ?
Engineer
Monitor preheat temperatures ?
Inspector
Review the use of local PWHT in leu of a full encirclement PWHT ?
Engineer
Review the use of preheat in leu of PWHT ?
Engineer
Approve the use of alternate NDE methods after repairs and alterations ?
Inspector and engineer
Perform calculations for re-rate ?
Engineer or manufacturer
Oversee the attachment of a nameplate after re-rating was performed ?
Inspector
API 579
Fitness for Service (FFS)
API 580
Risk Based Inspection (RBI)
API 660
API Design for Fabrication of Exchangers
API 2201
Welding on In-Service Equipment containing Flamables
ASME Section V
NDE Procedure Guidlines
ASME Section VIII Div II
Alternative Evaluation for pits and LTA’s
ASME Section IX
Welder and Weld Procedure Qualification
ASNT SNT TC 1A
NDE Personnel Qualification
AIRR
API 510 Scope Alteration Inspection Rerate Repair
JUIC
API 510 AI’s Employer Jurisdiction User Insurance Company Contractor
AJOC
API 510 Repair Organization ASME Stamp Holder Authorized by Jurisdiction Owner Contractor
SOPHI
How to Determine Corrosion Rate for New Service or Change in Service Same or Similar Service Owners Experience Published Data Inspect in 1,000 Hours
TIE
Testing Inspection Examination
Weld Procedure acronym ?
WPS
Qualification record of a WPS ?
PQR
Welder’s qualification record (welder’s papers) ?
WPQ’S
Document that must be prepared and maintained for each vessel and relief device ?
Inspection Plan
Manual that must be prepared and maintained by each Owner / User that uses API 510 ?
QA Inspection / Repair Manual
Two documents that are needed by each Repair Organization that repairs relief devices ?
QCManual & Training
Maximum length of a crack or incomplete penetration or incomplete fusion ?
0”
Smoothness of relief device seating surfaces ?
Three light beads of bands
Maximum allowed mill tolerance of a plate ?
Lesser of .010” or 6% T”
Maximum allowed size of an open discontinuity in a bend test ?
1/8”
Minimum distance beyond the area to be examined to clean a part when performing PT examination ?
1”
Minimum distance beyond the area to be examined to clean a part when performing a PT examination ?
1”
Minimum radius of a insert patch ?
1”
Wall thickness of a carbon steel shell that requires PWHT ?
> 1 1/2
Wall thickness of a shell that requires full RT ?
> 1 1/2”
Maximum length of pit allowed in a 8” line ?
2”
Distance beyond a weld that preheat must be maintained when performing preheat in leu of PWHT ?
Greater of 4” or 4T
Vessel inside diameters that are excluded from the scope of ASME Section VIII ?
Minimum length of RT when qualifying a welding operator with RT of a test coupon ?
6”
Minimum length of RT when qualifying a welder with RT ?
6”
Minimum length of spot RT ?
6”
NDE: Distance of eye to part to count as a Visual Examination ?
6” - 24”
Maximum area of pits allowed in an 8”circle ?
7” sq “
Maximum distance on weld between welder’s stamp ?
3’
Minimum length of RT when qualifying a welding operator with RT of the first production weld ?
3’
Maximum overlap for PWHT when using multiple heats ?
5’
Maximum length of weld represented by 1 spot RT ?
50’
Minimum allowed wall thickness at a pit ?
1/2 t min
Welding: Base metal temperature where welding is not recommended ?
Welding: base metal Temperature when preheat to 60 Deg F is recommended ?
0 - 32 Deg F
Corrosion: CUI affects Carbon Steel & LowAlloy Steel (temp range) ?
10 - 350 Deg F
UT Calibration: Calibration block must be within what temperature of the part to be examined ?
25 Deg F
NDE: Standard temperature range for a PT examination ?
40 - 125 Deg F
Corrosion: Temperature where Cooling water corrosion starts to significantly increase ?
140 Deg F
Corrosion: Temperature where chloride stress corrosion cracking becomes a concern ?
140 Deg F
Corrosion: CUI affects Austinetic Stainless Steel (temperature range) ?
140 - 400 Deg F
NDE: Special procedures are needed for UT thickness readings (temperatures) ?
_> 150 Deg F
Corrosion: Temperature when high strength caustic causes serious corrosion in Carbon Steel and 300 series SS
> 150 Deg F
Corrosion: Temperature swings that can cause Thermal Fatigue ?
200 Deg F
Welding: Minimum preheat temperature when preheat is substituted for PWHT ?
300 Deg F
Welding: Minimum preheat temperature when local PWHT is used in leu of a full encirclement PWHT ?
300 Deg F
Corrosion: Starting temperature for Sulfidation on Carbon Steel ?
500 Deg F
Corrosion: Temper Embrittlement for Low Chromes (temperature) ?
650 - 1,100 Deg F
Inspection: If vessel operating temperature is above this consult a Corrosion Specialist when developing an Inspection Plan ?
> 750 Deg F
Corrosion: If operating temperature is above this, check for Creep in Cat Reformer Equipment ?
> 900 Deg F
NDE: Maximum temperature for UT readings ?
1,000 Deg F
Materials: Carbon Steel PWHT temperature ?
1,100 Deg F
Testing: Minimum base metal temperature during hydro testing vessel > 2” Thick ?
MDMT + 30 Deg F
Testing: Minimum base metal temperature during hydro testing vessel
MDMT + 10 Deg F
NDE: Maximum temperature for Magnetic Particles ?
Manufacturer’s recommendations
Design pressure within the scope of ASME Section VIII and API 510 ?
_> 15 PSIG
Design pressure of non- fired boilers (waist heat boilers) that require full RT ?
_> 50 PSIG
Minimum range of pressure gauge used during a hydro / air test ?
1.5 X P test
Preferred range of pressure gauge used during a hydro / air test ?
2.0 X P test
Maximum range of pressure gauge used during a hydro / air test ?
4.0 X P test
Subject to Temper Embrittlement ?
Low Chromes
Subject to Chloride Stress Corrosion Cracking ?
300 Series Stainless Steel
Subject to Polytheonic Acid Stress Corrosion Cracking ?
300 Series Stainless Steel
Common material with an endurance limit (fatigue cracking cannot occur below this stress level) ?
Carbon Steel
Common material without an endurance limit ?
Stainless Steel
P- numbers allowed to use preheat in leu of PWHT ?
P1 & P3
P- numbers allowed to use controlled deposition in leu of PWHT ?
P1, P3 & P4
P-numbers of base metals that should be examined for delayed cracking after repairs to Stainless Steel cladding ?
P3, P4, & P5
Maximum allowed corrosion rate when using an On Stream inspection in leu of an Internal (ipy) ?
.005 ipy
Ratio of Endurance Limit Stress to Ultimate Tensile Stress for Carbon Steel ?
0.4 - 0.5
Static Head Factor (PSIG per height of water in feet ?
0.433 PSIG per ft. of water
Design joint efficiency when using full RT on a type 1 joint ?
1
FFS - Joint efficiency when evaluating corroded area away from a weld by greater of : 1” or 2t
1
NDE : The number of additional RT’s required when spot RT has a defect ?
2
Weld Qualification - Number of tension tests to qualify a WPS ?
2
Weld Qualification - Number of bend tests to qualify a welder or welding operator in welding positions 1G - 4G ?
2
NDE - Minimum number of exposures to RT 360 Deg of a weld using a double wall technique, double wall view (elliptical shot) ?
2
NDE - RT film density range - allowed for the weld & IQI when using a gamma ray source ?
2.0 - 4.0
NDE - Minimum number of exposures to RT 360 Deg of a weld using a double wall technique, single wall view ?
3
Impact Test - Number of test bars required in each set of impact test specimens ?
3
NDE - When using a shim under a hole type IQI, the number of sides of the IQI that must be seen in the RT image ?
3
Design - Current Safety Factor of the ASME Section VIII
3.5
Design - Pre 2000 Safety Factor of ASME Section VIII
4
Weld Qualification - Number of bend tests to qualify a WPS ?
4
Weld Qualification - Number of bend test required to qualify a welder in welding positions 5G & 6G
4
Design - Recommended resistance of grounding system ?
5 ohms
NDE - weight used to check the magnetic strength of an AC Yoke ?
10 lbs
Design - Maximum resistance allowed of grounding system ?
25 ohms
NDE - Min angle of eye to part to count as a visual exam ?
30 Deg
NDE - Weight used to check magnetic strength of a DC Yoke or a permanent Yoke ?
40 lbs
Testing - Maximum Chloride content in hydro test water when testing 300 Series Stainless Steel (ppm)
50 ppm
NDE - Minimum light intensity when performing non fluorescent MT or PT exams ?
100 ft-Candles
NDE - Minimum light intensity when performing MT or PT fluorescent exams ?
1000 mW / cm sq
NDE - Minimum time an examiner should be in a darkened area prior to using a black light for MT or PT ?
5 Min
NDE - Final interpretation of a PT exam after application of developer (time range) ?
10 - 60 Min
NDE - Minimum time to wait for checking for delayed cracking after repairs to Stainless Steel cladding ?
24 Hours
NDE - Max calibrating interval - MT permanent magnet Yoke ?
Daily
NDE - Max calibrating interval RT densitometer ?
90 Days
Welding - Maximum time that a welder or welding operator maintains qualifications for a welding process without using that process ?
6 Months
NDE - Maximum calibrating interval for electro magnetic MT Yoke?
1 Year
Inspection - Maximum interval external inspection ?
Lesser 5 years or interval
Inspection - Maximum interval for relief devices in fouling or corrosive service ?
5 Years
Inspection- Maximum interval for internal or on stream inspection
Lesser of 10 years or 1/2 life
Inspection - Maximum interval for relief device in non fouling or non corrosive service ?
10 Years
RBI - Maximum interval for the RBI re-assessment ?
10 Years
Inspection - Minimum remaining life required when performing an on - stream inspection in leu of an internal inspection ?
10 Years
NDE - Max calibrating interval - checking the light intensity of a black light used in a MT or PT exam ?
Before and after use
Define - Repair (key words)
Restore -Suitable
Define - Alteration
Physical Change
Define - RBI’s two primary factors
Probability and Consequence
Define - Locations on a vessel of vessel MAWP
Top
Define - Imperfection that exceeds the acceptance criteria ?
Defect
Define - A flaw that may or may not exceed the acceptance criteria ?
Imperfection
Design - Joint category of a vessel longitudnal weld ?
A
Design - Joint Category of a vessel circumferential weld ?
B
Design - RT factors representing Full RT ?
RT-1 & RT-2
Design - RT Factors representing spot RT ?
RT-3
Design - Weld Type - Butt Double welded
Type 1
Design - Weld Type - Butt Single Welded with Backing ?
Type 2
Design - Butt Single Welded without Backing ?
Type 3
Design - Vessel service that always requires Full RT ?
Lethal Service
Design - Maximum set pressure for single relief device on a vessel ?
MAWP
Design - Marking on nameplate indicating vessel was PWHT ?
HT
Design - Marking on nameplate indicating vessel is in Lethal Service ?
L
Design - ASME Section VIII stamp for routine vessel ?
U
Design - ASME Section VIII stamp for Miniature Vessels ?
UM
Design - ASME Section VIII stamp for Relief Devices ?
UV
NDE - Number of CML’s to obtain thickness readings during inspection ? (Key word)
Representative
NDE - Number of nozzles to obtain thickness readings during inspection ? (Key word)
Representative
NDE - Lead letter used during RT to check for Backscatter Radiation ?
B
NDE - Lead letter used during RT to indicate a film-side IQI ?
F
NDE - Hole size that must be visible in RT when using a hole-type IQI ?
2T
NDE - Primary gamma-ray RT sources ?
Ir 192, Co 60
RV’s - How relief devices should be transported ?
Upright
RV’s - How relief device intervals are determined ? (Key word)
Performance
Welding - Variables needed on a WPS ?
Essential and Non-Essential
Welding - Variables needed on a PQR ?
Essential
Welding - Processes that can be used when substituting Preheat or controlled deposition welding for a required PWHT ?
SMAW, GMAW, GTAW
Welding - Minimum taper required for shell welds with mismatch ?
3 to 1
Weld Qualification - The “All Position” test coupon ?
6G
Weld Qualification - Rejectable in RT when qualifying a welder ?
Crack, Lack of Fusion, Incomplete Penetration
Weld Qualification - Which welding process can a welder NOT be qualified by RT ?
GMAW - Short Circuit
Weld Qualification - Maximum allowed thickness on a WPS based on the plate thickness (T) of a PQR test coupon ?
2T
RT Film Density - Limits of weld as compared to the IQI ? (Range)
- 15% to + 30%
Maximum percent of Carbon allowed in new materials ?
0.35%
AI - Amount of time inspector must be involved in inspection activities - required to maintain API 510 certification ?
20%
Maximum operational pressure of a conventional rupture disk ? (Percentage of burst pressure)
70%
Center portion of head wen evaluating a LTA using the spherical formula ?
80%
Alteration
A physical change in any component that has design implications that effect the pressure containing capability of a pressure vessel beyond the scope described in existing data reports.
ACFM
Alternating Current Field Measurement.
Not Considered Alterations
Any duplicate, or any duplicate replacement The addition of any reinforced nozzles less than or equal to the size of existing reinforced nozzles The addition of any nozzle not not requiring reinforcement
MAWP
Maximum Allowable Working PressureMaximum pressure at the top of a vessel in its working position (on gauge)
HTHA
High Temperature Hydrogen Attack
Repair
The work necessary to restore a vessel to a condition suitable for safe operation at the design conditions.If restoration work changes the design temperature, MDMT, or MAWP, the work is considered an alteration.
Re-Rating
Required if design temp, MDMT, or WAWP changes.
RBI Risk Based Inspection
Probability of Failure, consequence and probability.
Temper Embrittlement
The reduction in toughness due to a metallurgical change that can occur I some low alloy steels 2 1/4 Cr-1Mo, as a result from long term exposure in the temperature range of about 650–1,100 Deg F
Transition Temperature
The temperature at which a material fracture mode changes from ductile to brittle.
