API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration (Training Only) September 4-15, 2004 Abu Dhabi, U.A.E. Iv.vìì Iv.vìì Iv.vìì Iv.vìì, ,, , ^·. ^·. ^·. ^·. O·vn £c.i. O·vn £c.i. O·vn £c.i. O·vn £c.i. 1v·.v·v Ic.nnoìo¡, ^ivvìc 1v.ì 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. Name: --------------------------------------------------------------------------------------- Address: --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- Email: --------------------------------------------------------------------------------------- Course Title: --------------------------------------------------------------------------------------- Course Date: --------------------------------------------------------------------------------------- Course Location: --------------------------------------------------------------------------------------- Description of Inaccuracy: --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- 1 11 1v·.v·v v·.v·v v·.v·v v·.v·v Ic.nnoìo¡, ^ivvìc 1v.ì Ic.nnoìo¡, ^ivvìc 1v.ì Ic.nnoìo¡, ^ivvìc 1v.ì Ic.nnoìo¡, ^ivvìc 1v.ì P. O. Box 26608 Abu Dhabi, U.A.E. Tel: +971 2 627 7881 Fax: +971 2 627 7883 Email:
[email protected] 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. ********************************************** IE100 - Page 1 of 7 . IE100-03-05 Rev. 5 22 February 2005 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 IE100 - Page 2 of 7 . IE100-03-05 Rev. 5 22 February 2005 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. A A A P P P I I I S S S t t t a a a n n n d d d a a a r r r d d d 5 5 5 1 1 1 0 0 0 , 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 A A A P P P I I I R R R e e e c c c o o o m m m m m m e e e n n n d d d e e e d d d P P P r r r a a a c c c t t t i i i c c c e e e 5 5 5 7 7 7 2 2 2 , Inspection of Pressure Vessels, Second Edition, February, 2001. Global Engineering Product Code API CERT 572 A A A P P P I I I R R R e e e c c c o o o m m m m m m e e e n n n d d d e e e d d d P P P r r r a a a c c c t t t i i i c c c e e e 5 5 5 7 7 7 6 6 6 , Inspection of Pressure-Relieving Devices,, Second Edition (December 2000). Global Engineering Product Code API CERT 576 G G G u u u i i i d d d e e e f f f o o o r r r I I I n n n s s s p p p e e e c c c t t t i i i o o o n n n o o o f f f R R R e e e f f f i i i n n n e e e r r r y y y E E E q q q u u u i i i p p p m m m e e e n n n t t t , , , C C C h h h a a a p p p t t t e e e r r r 2 2 2 * * * , , , 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. A A A m m m e e e r r r i i i c c c a a a n n n S S S o o o c c c i i i e e e t t t y y y o o o f f f M M M e e e c c c h h h a a a n n n i i i c c c a a a l l l E E E n n n g g g i i i n n n e e e e e e r r r s s s ( ( ( A A A S S S M M M E E E ) ) ) , , , Boiler and Pressure Vessel Code, 2001 edition. . . i. A A A S S S M M M E E E S S S e e e c c c t t t i i i o o o n n n I I I I I I D D D , External Pressure Graphs only. ii. A A A S S S M M M E E E S S S e e e c c c t t t i i i o o o n n n V V V , Nondestructive Examination, Articles 1, 2, 6, 7 and, Article23 (SE- 797) iii. A A A S S S M M M E E E S S S e e e c c c t t t i i i o o o n n n V V V I I I I I I I I I , 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. A A A S S S M M M E E E S S S e e e c c c t t t i i i o o o n n n I I I X X X , 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 IE100 - Page 3 of 7 . IE100-03-05 Rev. 5 22 February 2005 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 05 th 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 Harvard Technology Middle East IE100 - Page 4 of 7 . IE100-03-05 Rev. 5 22 February 2005 Day 2 : Sunday 06 th 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 07 th 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 08 th 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 Harvard Technology Middle East IE100 - Page 5 of 7 . IE100-03-05 Rev. 5 22 February 2005 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 09 th 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 12 th 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) Harvard Technology Middle East IE100 - Page 6 of 7 . IE100-03-05 Rev. 5 22 February 2005 1515 - 1530 Break 1530 - 1700 Welding Documentation Review (continued) Practice WPS/PQR reviews 1700 End of Day Six Day 7 : Sunday 13 th 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 14 th 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 Harvard Technology Middle East IE100 - Page 7 of 7 . IE100-03-05 Rev. 5 22 February 2005 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 15 th 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 16 th of March 2005 0730 - 0830 Review of the first half of the API 510 practice examination A. 0830 - 1000 Administer 2 nd half of 150 question API 510 practice examination A. 1000 - 1015 Break 1015 - 1230 Administer 2 nd half of 150 question API 510 practice examination A. 1230 - 1330 Lunch 1330 - 1530 Administer 2 nd 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:
[email protected] Harvard Technology Middle East 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