API - 510

COURSE

VOLUME

NOTESm

- IE

CONTENTS

Program Daily Schedule.

2. Body of Knowledge & Effectivity Sheet.

3. Examples of Repairs and Alterations
4. Guidelines for API 510 Certification Exam.
5.

Case Studies.

ASME Sec. VIII.

6.

Case Studies

7.

Reference Documents.

API 510.

ASME See. IX.

Allowable Stress Tables

Solved Examples, ASME Sec. VIII, Div. 1
Materials of Construction
8.

Daily Practice Exams & Answer Keys

9.

Daily Points to Recall.

10. Add itiona I Information

API 510 PRESSURE VESSEL INSPECTOR COURSE

PROGRAM SCHEDULE
Venue:

Hotel Kohinoor Executive, Pune, INDIA.

\ DAY 1.

Session

Introduction to API-510 Certification.

ASME code system
introduction to ASME SEC. VIII, Div. 1.
Session

Design fundamentals
Allowable Stresses,
Joint Category, Joint types
Joint efficiencies
Session

Design of Cylindrical shells

Calculation of vessel MAWP, part MAWP
Static head calculations
Design of Dished heads
Case Studies

I DAY 2.

J
Session

to recall Day-1
of Dished heads. (Contd.)
of Flat unstayed heads
of dished heads

Points
Design
Design
Depths

Session

External pressure calculations

Case Studies
Impact testing requirements
Session

Pressure testing -Hydrostatic

Pressure testing-Pneumatic
Review of Practice Exam-1

------------------_ - ~.-------..

DAY-3.

Session

l
1

Points to recall Day-2

Weld size for attachment welds at openings.
Case studies.
Reinforcement of Openings-Concepts

Session

Reinforcement pad Calculations

Case studies.
Typical weld joints for Pressure Vessels
Restrictions on joints -mismatch tolerances

Session

Allowable weld reinforcements

Inspection requirements for Pressure Vessels
Heat treatment
Code stamping and Data-reports
Review of Practice Exam-2

~------------------------------------------,

DAY 4.

Session 1
Points to recall Day-3
Introduction to API-510 code - Scope & Applications
Reference Codes and Standards
Specific definitions
Session 2

API-510 contd ...lnspection Organizations

Owner-User responsibilities
Quality control manual
Certification requirements

Session

Modes of Deterioration
Corrosion, Fatigue, Creep
Freeze damage, Brittle failure,
Temper embrittlement
Review of Practice Exam-3

--_._ ..,-_

......

_-_ _-._-------~---_.
..

[DAYS.
Session

API-510 Inspection practices

Corrosion rate determination
MAWP determination for Vessels in service
Numerical Examples

Session

---------------------

Points to recall Day-3

API-510 contd ..Defect inspection
Inspection of parts
Minimum thickness Evaluation
Pitting corrosion
Localised corossion

Session

----------

API-510 contd .... External inspection

Internal and on-stream inspection
Inspection interval
Remaining service life
Illustrative calculations
Review of Practice Exam-4

DA-Y_ -_6-._----- -- -- -------

Session

-_ -_ -_ -_ -

--------.-------------------.,
.

Points to recall Day-3

API-510 contd ...Defect repairs
Pressure tests
Documentation
Session

and Records

Welding requirements
Pre-heating and PWHT
Weld overlay and cladding
NOT for repairs and alterations

Session

Alterations and re-rating

Re-rating documentation and stamping
Review of Mid-session Exam-Open book. Closed book.

I DAY 7.
Session

Points to recall Day-6

Introduction to ASME SEC. IX
Procedure Qualifications
PQR tests- and evaluation of results

Session

Session

Welding variables-EVs, NEVs, SEVs.

Limits of PQR Qualificatios I validity.
WPS/PQR documentation
WPQ tests & their validity

Detailed road-map for review of WPS/PQR documentation

Case Studies for WPS/PQR review.
ASME Sec.v Nondestructive Examination
Article 1: General Requirements
Review of Practice Exam-6

DAY 8.

Session

Points to recall Day-7

Article 2: Radiographic Examination
Radiograpic procedure
Selection of penetrameter
Radiographic technique
Interpretation & documentation

Session

Article 6: Liquid Penetrant Examination

LPE procedure
Selection of penetrants
LPE technique
Interpretation & documentation
Article 7: Magnetic particle Examination

Session

SE-797 UT measurememt
Pulse-Echo contact method
Single and dual crystal techniques
Review of NDE Requirements ASME See VIII & API 510
Review of Practice Exam-7

I DAY

9.

Session

Points to recall Day-8

Introduction to IRE Chap. II
Corrosive components in crude
Deterioration due to Hydrogen
Deterioration due to H2S
Other factors of Corrosion

Session

API RP-572 review

Types of Pressure Vessels
Construction Standards
Causes of deterioration

Session

Internal inspection
External inspection
Inspection records and reports
Review of Practice Exam-8

-- ----

Session

---------.---------

Points to recall Day-9

API RP-576 Inspection of Pressure relieving Devices
Types of PRDs
Causes for malfunctioning
Inspection intervals &insp. procedures for PRDs,
Testing of PRDs on test bench.
Inspection records & reports

Session

Review of Practice Exam-8

Final Open- book Test
Session

Final close book test

Feed-back on tests
Close-down.

" ~ ..:",ao

reln-dcum
Institute

1220 L Street. Northwest

Washington, D.C. 20005-4070
202-682-8161
202-682-8348 (Fax)

~ICP
BODY OF KNOWLEDGE
API-SIO PRESSURE
CERTIFICATION

VESSEL

INSPECTOR

EXAMINATION

May 2005 (Replaces June 2004)

API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair,
and altcration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to
determine if individuals have such knowledge. The following is a list of specific topics in which the API Authorized Pressure
Vessell.nspector

should bc knowledgeable.

To determine whether the applicants have this broad base of inspection knowledge, a minimum of one question from each
category listed within tl1is Body of Knowledge will be included on the API certification exan1ination. Only inspection
information covered in one of the references outlined in this body of knowledge will be utilized for the examination
questions.
The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring everyday
working knowledge of API Standard 510 and the applicable reference documents. The open book portion of the examination
requires the use of morc detailed information that the inspector is expected to be able to find in the documents, but would not
nonnally

be COllunitted to memory.

REFERENCE

PUBLICATIONS:

API publications
open-book

and ASME codebooks

must be brought to the examination

site to be used as reference materials for the

part of the examination.

A. API Publications:
API 510, Pressure Vessel Inspection Code
API RP 571, Damage Mechanisms Affecting Equipment

in Refilling Industry

API RP 572, Inspection of Pressure Vessels

API RP 576, Inspection of Pressure-Relieving
Devices
API RP 577, Welding Inspection and Metallurgy
B. ASME Publications:
Section V, Nondestructive Examination
Section VIII, Division I, Rules for Constructing
Section lX, Welding and Brazing Qualifications
Note: Refer to the Publications
supplements

05105

Effectivity

ofilie reference publications

Pressure Vessels

Sheet in the application package for a list of specific editions, addenda, and
tl1at are effective for your ex.am date.

I. THICKNESS

MEASUREMENTS,

INSPECTION

INTERVALS

AND VESSEL

INTEGRITY

A.
Code calculation questions will be oriented toward existing pressure vessels, not new pressure vessels. API
Authorized Pressure Vessellnspcctors
should be able to check and perfonn calculations relative to in-service deterioration,
repairs, rerates, or alterations. Only internal and external pressure loadings will be considered for the API 510 examination.
The following categories describe the minimum necessary knowledge and skills:
I. CORROSION

RATES AND INSPECTION

INTERVALS

The Inspector should be able to take inspection data and deternline the internal and external inspection

intervals.

The Inspector must be able to calculate:

a.
b.
c.
d.
e.

Metal Loss (including corrosion averaging) (API-51O, Para 5.7, d)

Corrosion Rates (API-SIG, Para 6.4)
Remaining Corrosion Allowance (API-51O, Para 6.4)
Remaining Service Life (API-510, Para, 6.4)
Inspection Interval (API-SIO, Para, 6.4)

The fonnulas for perfonning

during the exam.

the above calculations

and rules for setting the inspection

intervals may be "closed-book"

2. JOINT EFFICIENCIES
The inspector must be able to detennine
a. Weld Joint Categories
b. Type
c. Joint
d. Joint
e. Joint

"E" of a vessel weld. Inspector should be able to detennine:

from UW-3;

of radiography (full, spot, or none) performed basis the nameplate markings (RT-I, RT-2, etc.);
efficiency by reading Table UW-12;
efficiency for seamless heads and vesscls Sections per UW -12 (d); and
efficiency for weldcd pipe and tubing per UW- 12 (e).

Detenllining
formulas
3. STATIC

the joint efficiency

joint efficiency may be part of the internal pressure problem

for deternlining required thickness or Vessel Part MA WP.

since joint

efficiency

"E" is used in the

HEAD

The inspector must be able to compensate for the pressure resulting from static head. All static head wiIl be based upon a
Specific Gravity of 1.0. The inspector should be able to:
a)
b)
c)
d)
e)

List the static head/pressure conversion factor (0.433 psilft);

Know the difference between vessel MA WP and vessel part MAWP (UG-98);
Calculate static head pressure on any vessel part;
Calculate total pressure (MA WP + static head) on any vessel part;
Calculate maximum vessel MA WP given vessel parts MA WP and elevations

Static head calculations

examination problem.

05/05

may also be required during the internal pressure calculations

if static head data is given in the

The inspector
a)
b)
c)
d)
e)

should be able to detennine:

The rcquired thickness of a cylindrical shell based (In circllnlferel\ti.d ,tr<:ss gi,'<:n a pr<:ssure (UG-27(c)(l )i
The vessel part MA WP for a cylindrieal shell ba.,cd on cir.:umtcr.:nllal strcs, given a metal thickness (UG-27(c)(I));
The rcquircd thickncss ofa head (ellipsoidal. and hCOlisphcrh;al) ~i\(;n a pre-;surc. (UG-32 (d), (e), (f) and (g))
The vessel part MAWP for a head (ellipsoidal. and hCOlisphcn-:;d) ~i"en a -neta\ thickness. (UG-32 (d), (e), (f) and
(g).
Whether a head (ellipsoidal, torispherical or hcmlsph,Ti<a: I mect. ( ode rcquiremcnts given both prcssure and metal
thickness (UG 32(d), (e), (f) and (g).

The inspector should also be able to compensate for thc corro_i0n d1l0wanee: add or subtract based on requirements of
tbe exam problem. The Appendix I fonnula for cylinders, which IS bascd on outside diamcter, can be used. The
Appendix I fonnulas for non-standard heads will not be required.
5. EXTERNAL

PRESSURE

The inspector should be able to:

a) Calculate the maximum allowable external pressure (specific MaterialfTemperature
Charts supplied with the
examination) (UG-28(c)(l); and
b) Calculate whether a cylindrical shell or tube meets Code design for external pressure given a wall thickness and
a pressure (UG 28 (c )( I).
Note: Factors from the external pressure charts will be given in the wording of the question. Use of the actual
charts is not required.

6. PRESSURE
The inspector
a)
b)
c)
d)

should be able to:

Calculate a test pressure compensating for temperature. (UG-99 & UG-IOO)

Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test
temperatures, protection against overpressure etc.
Be familiar with all steps in a hydrotest Procedure (UG 99 and UG 100)
Be fanliliar with all steps in a pneumatic test procedure (UG 100 and UG 102)

7. IMPACT
The inspector
a)

TESTING

TESTING
should be able to:

Determine the minimum metal temperature

UCS-68(c).)

8. WELD SIZE FOR ATTACHMENT

of a material which is exempt from irnpacttesting

WELDS AT OPENINGS

The inspector must be able to determine if weld sizes meet Code requirements.
a)
b)

05/05

(UG-20 (f), UCS-66,

The inspector should be able to:

Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion
(0.707); and
Detennine the required size of welds at openings (UW -16).

factor

Thc inspector should:

a)

Undcrstand

thc

kcy

conccpts

of reinforcement,

such

as replacement

b)

rcinforccmcnt.
Credit can be takcn for cxtra metal in shell and nozzle
Be able to calculate the required areas for reinforcement

of

strength

or check to ensure

removed

that a designed

and

pad

limits

1S

of

large

enough. To simplify the problem:

c)
d)
e)

B.

All fr = 1.0
All F = \.0
All E = 1.0
All required thicknesses are given
There will be no nozzle projecting inside the shell
Be able to compensate for corrosion allowances.
Weld strength calculations are excluded.

The following are typical ASME code engineering requirements that API certification candidates will NOT be
expected to know for purposes of the certification examination.

I. Required thickness calculations for wind., earthquake, and other secondary stress loadings;
2. Supplementary design formulas and calculations for non-cylindrical shell components;
3.
4.
5.
6.
7.
8.
9.

Most external pressure calculations;

Nozzle calculations for external loads;
Flange calculations;
Brazing requirements;
Ligament calculations;
Stayed flat heads and sizing of stays;
Tubesheet calculations (stayed or unstayed) and tube to tubesheetjoints

10.
II.
12.
13.

Relief valve sizing;

Lifting lug and other structural type calculations;
Proof testing requirements;
Required inspections for new construction, except as they apply to alterations and repairs;

14.
15.
16.
17.
18.
19.

Zick analysis;
Integrally forged pressure components;
Cryogenic vessels (below -50 f);
Dimpled., embossed., jacketed, and non-metallic vessels and assemblies;
NDE requirements for acoustic emission, eddy current, and motion radiography;
ASME Sections UF, DB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT;

and loads;

20. Code Cases and interpretations;

2 \ . \V elding process requirements other than shielded metal arc welding (SMA W), gas tungsten arc welding (OT A W),
gas metal arc welding (OMA W), or submerged arc welding (SAW);
22. Requirements for pressure vessels for human occupancy; and
23. Rules for natural resource vessels, API-5 10, Section 8.

05/05

II. WELDING

PROCEDURE

AND PRESSURE
/\.

VESSEL

WELD PROCEDURE

AND QUALIFICATION
CODE, SECTION

EVALUATION

BASEl) 0"

..S\It.

BOILER

IX

REVIEW

I.
The inspector should be able to detern1ine if procedure and qualtfi.::ation record., al\: .n ,::olllpliance with applicable
ASME boiler and pressure vessel code and any additional requirem<:nt$ .,f API 5 10 (\ 1'151 (I requirements will take
preccdencc

ovcr any ASME requirements

covcring the same technic.tl .lrca ..

The weld procedurc review may include:

a. Welding Procedure Specification (WPS); and
b. Proccdure Qualification Record (PQR).
The wcld procedure review may include: SMA W, GT A W, GMA \\'. OK SA \\ . ""ilh thl f(llhm ing Iimiwtions:
a) No more than one process will be included on a single WPS or PI)R, ..mJ the wrs 10 bc rcviewcd
b)
c)

2. The inspector should be able to determine:

a) Whether numbcr and type of mechanical test listed on PQR arc appropriate
b) Whether the results of the tests are acceptable
c) Whether all required essential and non-essential variables have been properly addressed. (Supplemental
variables will not bc a part of the WPS). The following limitations or conditions will apply:

Base metals limited to PI, P3, P4, P5, and P8.

Dissimilar base metal joints, and dissimilar thicknesses of base metals are excluded.
Supplemental powdered filler metals and consumable inserts are excluded.
Special weld processes such as corrosion-resistant
weld metal overlay, hard-facing overlay, and dissimilar

metal are excluded

Welds with buttering of ferritic member are excluded.
For PI, P3, P4, and P5, for the purpose of the examination
tempcrature

B. ASME Section VIII. Div. I and API-51O: GENERAL

3.

the lower transfonnation

o
will be 1600 F.

WELDING

temperature

will be

REOUIREMENTS:

ASME Scction VIII, Div. I

The inspector should be familiar with and understand the general rules for welding in
ASME Section VIII, Div. I, Parts UW and UCS such as:
a)
b)
c)
d)
c)
f)

2.

essential

13330F and the upper transformation

I.

will bc

supported by a single PQR.

filler metals limited to one-pcr-proccss for SMAW, GTAW, GMA W. or ~A W.
Thc PQR will be the supporting PQR for thc WPS.

Typical joints and definitions

Weld sizes
Rcstrictions on joints
Maximum allowable reinforcement
Inspection requirements
Heat treatmcnt

API510
Thc inspector should be familiar with and understand any rules for welding in API-51O. Any rules for welding given in
API-510 shall take precedence over those covering the same areas in ASME, Section VIII, Div. 1.
"Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are excluded.
This includes items such as the revision level of the WPS, company name, WPS numbcr and date, and name of testing
lab. Howcver, the API 510 applicants shall know tbat the PQR must be certified by signing and dating.

C. The inspector

05/05

shall be familiar with all the requirements

of and infonnation

in API RP 577.

1Il.NONDESTRUCTlVE

EXAMINATION

A~ME Section V. l'J9ndestluctive

NOTE: The examination
A.

will cover ONLY the main body of each referenced

Article, except as noted

Article I, General Requirements:

The inspector should be familiar with and understand;
I.
2.
3.
4.
5.
6.

8.

Examination

The Scope of Section V,

Rules for use of Section Vas a referenced Code,
Responsibilities of the Owner / User, and of subcontractors,
Calibration,
Definitions of "inspection" and examination",
Record keeping requirements.

Article 2, Radiographic Examination:

The inspector should be familiar with and understand;
1. The Scope of Article 2 and general requirements,
2. The rules for radiography as typically applied on pressure vessels such as, but not limited to:
a. Required marking
b. Type, selection, number, and placement ofIQI's,
c. Allowable density
d. Control of backscatter radiation
e. Location markers
3. Records

C.

Article 6, Liquid Penetrant Examination, including Mandatory Appendices

The inspector should be familiar with and understand:

II and III:

I. The Scope of Article 6,

2. The general rules for applying and using the liquid penetrant method such as, but not limited to;
a) Procedures
b) Contaminants
c) Techniques
d) Examination
e) Interpretation
f) Documentation and
g) Rccord keeping

D.

2.

Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

The inspector should bc fanliliar with and understand the general rules for applying and using the magnetic particle
method such as, but not linlited to;
1. The Scope of Article 7,
2. General requirements such as but not limited to requirements
a. Procedures
b. Techniques (Yoke and Prod only)
c. Calibration
d. Examination
e. Interpretation
Documentation and record keeping

for:

E. Article 23, Ultrasonic Standards, Section SE-797 only - Standard practice for mea<;uring thickness
pulse-echo contact method:

05105

by manual ultrasonic

The inspector should be familiar wnh and und<:rsland.

I)
2)
3)

The Scope of Article 23, Section SE-797,

The general rules for applying and using th<:ll(lra~llir
ll't.:t:)od
The specific procedures for Ultrasonic thldness lTl<.:a,ure!a'nl JS' ontallled in paragraph 7.

AS ME Section VIII, Div. I and API-510

Genna; [K)p(k-;t;u,ti\c e\amillJtion requirements:

I.ASME Section VIII, Div. 1:

The inspector should be familiar Withand u!xkrs:aI,d :hc F,;r><:ral
ruk, for \,fDE (UG, UW, Appendices 4, 6, 8, and
12)

2. API 510, The inspector should be famiiiar \.'it~ .u1\1 unl~r-;t.U)dthe general rules for NDE in API-51 O.

IV. PRACTICAL KNOWLEDGE - GENERAL

The following topics may be covered in the examination. More infonnation relative to each of the categories is contained in
section V. PRACTICAL KNOWLEDGE - SPECIFIC
1. Organization and Certification Requirements.
2. Types and Definitions of Maintenance Inspections.
3. Types of Process Corrosion and Deterioration.
4. Modes of Mechanical, Thennal, and High Temperature Dcterioration.
5. Pressure Vessel Materials and Fabrication Problems.
6. Welding on Pressure Vessels.
7. Nondestructive Examination (NDE) Methods.
8. Corrosion and Minimum Thickness Evaluation.
9. Estimated Remaining Life.
10. Inspection Interval Determination and Issues Affecting Intervals.
11. Relief Devices.
12. Maintenance Inspcction Safety Practices.
13. Inspection Records and Reports.
14. Repairs/Alterations to Pressure Vessels.
15. Rerating Pressure Vessels.
16. Pressure Testing After Repairs, Alterations, or Rerating

05/05

V. PRACTICAL

A PI-51 0, Pressure

KNOWLEDGE - SPECIFIC

Vessclluspc'crio,r

\fOTE: All of A PI 510 is applic able

Appcndix E arc excludcd.
I. Organization
a)
b)
c)
d)

Code
10

Ih~

1)

g)
h)
i)
j)

unk.-ss s[}Ccifically cxcluded.

ror cxample: Scction 8 and

and ('ertiflcati. >n Rcq,liremc'll~

Certification for API A ulh0roe(! Pce-.5l,rc \ ~s.;cl Insrectors (API-510, Section 4.2 and Appcndix
Authorized Inspeni011 ,\/--,cllcles (AP -: 1('. '\ection 3.4)
Vessel Repair Organlzati'Jn'; (API- 510. Section 3.16)
Relief Device Testing and Repa,r ()rga:linllons
(API-510, Section 6.6)

2. Typcs and Dcfinitions of Maintcnance

a)
b)
c)
d)
e)

"XdDlm..ll"Jll

B).

Inspcction

Internal Inspection (API 5 10,6.4)

Defcct Inspection (API-51O, 5.5)
Inspcction of Parts (API-51O, 5.6)
External Inspection & Buried Vessels (API 510, 6.3)
Atmospheric Corrosion and Corrosion Undcr Insulation (API-5 10, 6.3)
On-Stream Inspcction (API-51O, 3.1 I & 6.4)
Visual Examination (API-51O, 5.5)
Thickness Measurements (API-51O, 5.3, 5.7, 6.3 & 6.4)
Nondestructive Examination (API-5 I 0,5.5 & 5.7)
Assessment of Inspection Findings (5.8)

3. Welding on Pressure Vessels

a)
4. Corrosion

Welding Inspection

(API-51O, 5.6 & 7.2)

Requirements

and Minimum Thickness

Evaluation

The inspector should havc a general knowledge of the following principles,

calculations using these principles.
a)
b)
c)
d)
e)

Corrosion Rate Determination (API 510, 5.3)

Corrosion Averaging (API 510, 5.7)
Widely Scattered Pitting (API 510,5.7)
Surfaccs Remote From a Weld (API, 5.7)
Corrosion in Central Portion of Dished Heads (API 510,5.7)

5. Estimated

Remaining Life and Corrosion

6. Inspection

Interval Determination

a)
b)
c)
d)
e)
f)
g)
h)

rate

(API 510,6.4)

and Issues Affecting Intervals

Rjsk-based inspection (API 510, 6.2)

Internal or On-Stream Inspection Intervals (API 510, 6.4)
Intcrnal and On-stream inspection Intervals for Estimated Life (API 510, 6.4)
External Inspection Intervals API-51O, 6.1-6.3)
Dcterioration Other Than Metal Loss (API 510, 5.2)
Different Zones of a Vessel (API 510, 6.4)
Change of Service Conditions (API 510, 6.4)
Change in Location and Ownership (API 510,6.4)

7. Relief Devices

05'05

and may be required to make

a)
b)
c)

Repair Organizations (API-51O, Section 6.6)

Minimum Requirements for Quality Control Systems (API 510, 6.6)
Maximum Service Intervals (API-51O, 6.6)

8. Maintenancc Inspcction Safety Practices

a)

Pressurc Vcssel Inspection (API-51O, Section 5.1)

9. Inspcction Rccords and Reports

a)

Permanent and Progressive Inspection Records (API-510,6.7)

10. Repairs and Alterations, to Pressure Vessels

a)
b)
c)
d)
e)
f)

g)
h)
i)
j)

k)

Authorization (API 510, 7.1.1)

Approval (API 510, 7. \.2)
Design Requirements (API 510, 7.2.7)
Materials Requirements (API 510, 7.2.8)
Welding Requirements (API 510, 7.2.1, 7.2.2,7.2.3,7.2.6, & 7.2.11)
Heat Treating Requirements, including
Preheating (API 510, 7.2.3)
Post weld Heat Treating (API 510, 7.2.3)
Local Postweld Heat treatment (API 510, 7.2.5)
Repairs to Stainless Steel Weld Overlay and Cladding (API 510, 7.2.6)
Inspection (API 510, 7.2.9)
Rerating of Pressure Vessels (API 510, 7.3)
Pressure Testing After Repairs, Alterations or Rerating (API-51 0, 6.5 and 7.2.10)
Nondestructive Examination of Welds (API 510, 7.2.4)

API RP 571, Damaf!e Mechanisms Affectinf! Fixed equipment in the Refini,,!! Industry
ATTN: Test questions will be based on the following mechanisms only:
Par. 4.2.3 - Temper Embrittlement
4.2.7 - Brittle Fracture
4.2.9 - Thermal Fatigue
4.2.14 - Erosion/Erosion-Corrosion
4.2.16 - Mechanical Failure
4.3.2 - Atmospheric Corrosion
4.3.3 - Corrosion Under Insulation (CUI)
4.3.4 - Cooling Water Corrosion
4.3.5 - Boiler Water Condensate Corrosion
4.4.2 - Sulfidation
4.5.1 - Chloride Stress Corrosion Cracking (CrscC)
4.5.2 - Corrosion Fatigue
4.5.3 - Caustic Stress Corrosion Cracking (Caustic Embrittlement)
5.1.2.3 - Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
5.1.3.1 - High Temperaturc Hydrogen Attack (HTHA)

API RP-572, If/sf/eetio" of Pressure Vessels

05/05

I. Types and Definitions

a)
b)
c)
d)
e)
f)

g)
11)

i)
j)
k)
\)
2.

Pressure Vessel Materials and Fabrication Problems

Material and Fabrication Problems (API RP-572, 8A & 8.5)

Maintenance

Inspection Safety Practices

a)

2.

Inspections

Types of Pressure Vessels (API RP-572, Section 4)

Construction Standards (API RP-572, Section 5)
Maintenance Inspection (API RP-572, Section 6)
Reasons for Inspection (API RP-572, Section 7)
Causes of Detcnoration (API RP-572, 8.1- 8.10)
Frequency and Time of Inspection (API RP-572, Section 9)
Internal Inspection (API RP-572, lOA)
External Inspection, Typical Items Checked (API RP-572, 10.3)
Visual Examination (API-RP-572, Section 10)
Thickness Measurements and Limits (API RP-572, Section 10)
Nondestructive Examination (API RP-572, Section 10)
Repair Methods (API RP-572, Section 11)

a)
3.

of Maintenance

Inspection

Pressure Vessel Inspection (API RP-572, 10.2)

Records and Reports (API RP-572, Section 12)

API RP 576, Inspection

of Pressure-RelievinF!

Devices:

1. Relief Devices
a)
b)
c)
d)
e)
f)

Description of Types -- General Knowledge of Application and Limitations (API RP-576, Section 2)
Causes of Improper Performance (API RP-576, Section 4)
Reasons for Inspection and Frequency Detennination (API RP 576, Sections 3 & 5)
Inspection and Test Service Procedures (API RP-576, Sections 6 and 7)
Maintenance Inspection Safety Practices (API RP 576, Section 6)
Inspection Records and Reports (API RP-576, Section 8)

API RP 577, Weldine Inspection

I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
13.
14.

OS/OS

alld Metallurf!1J

Definitions
Welding Inspection
Welding Processes
Welding procedure
Welding Materials
Welder qualifications
Non-destructive examination
Metallurgy
Refinery and Petrochemical Plant Welding Issues
Ternlinology and symbols
Actions to Address improperly made production welds
Welding procedure review
Guide to common filler metal selection
Example report ofRT results

10

Publications Effectivity Sheet

API 510, Pressure Vessel Inspector
For Exam Administration:

Certification Exam

December 7, 2005

Listed below are the effective editions of the publications

required for the December

7,2005

Examination.

API Standard 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair. and Alteration,
June 1997, Addenda 1,2,3 and 4 (August 2003).
Global Engineering Product Code API CERT 510

8th Edition,

API Recommended
December 2003

1" Edition,

A TTENTION:

Practice 571, Damage mechanisms

Only the following mechanisms

Affecting fIXed equipment

in the refining

industry,

to be included:

Par. 4.2.3 - Temper Embrittlement

4.2.7 - Brittle fracture
4.2.9 - Thennal Fatigue
4.2.14 - Erosion/Erosion-Corrosion
4.2.16 - Mechanical failure
4.3.2 - Atmospheric Corrosion
4.3.3 - Corrosion Under Insulation (CUI)
4.3.4 - Cooling Water Corrosion
4.3.5 - Boiler Water Condensate Corrosion
4.4.2 - Sulfidation
4.5.1 - Chloride Stress Corrosion Cracking (CrscC)
4.5.2 - Corrosion fatigue
4.5.3 - Caustic Stress Corrosion Cracking (Caustic Embrittlement)
5. \.2.3 - Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
5.1.3.] - High Temperature Hydrogen Attack (HTHA)

AP I Recommended Practice 572, Inspection of Pressure

Global Engineering Product Code API CERT 572

API Recommended Practice 576, Inspection of Pressure-Relieving

Global Engineering Product Code API CERT 576

API Recommended Practice 577 - Welding Inspection and Metallurgy.

Global Engineering Product Code API CERT 577

American

Society of Mechanical

Vessels, 2nd Edition, February 200 I.

Devices, 2nd Edition, December 2000.
First edition, October 2004.

Engineers (ASME), Boiler and Pressure

Vessel Code, 2001 edition

with 2002 and

2003 addenda.
1.

Section V, Nondestructive

Examination,

ii.

Section VIII, Rules for Construction

Gnd 12

Ill.

Section lX, Welding and Brazing

Articles 1. 2, 6, 7 and 23 (section S-797)

of Pressure

Qualifications.

Vessels, Division 1, UG,

We/ding

urv, UCS,

UHT, Appendices

1-4, 6, 8

OIlZF

Global Engineering Product Code for the ASME package API CERT 510 ASME.
necessary for the exam.

Package includes only the above excerpts

API and ASME publications may be ordered through Global Engineering Documents at 303-397-7956 or 800-8547179. Product codes are listed above. Orders may also be faxed to 303-397-2740. More infonnation is available at
hUp://www.global.ihs.com.
API members are eligible for a 50% discount on all API documents; exam candidates
are eligible for a 20% discount on all API documents. When calling to order, please identify yourself as an exam
candidate and/or API membcr. Prices quoted will reflect the applicable discounts. No discounts will be made for
ASME documents.

Note: API and ASME publications are copyrighted material. Photocopies of API and ASME publications
are not pennitted. CD-ROM versions of the API documents are issued quarterly by Information Handling
Services and are pemlitted. Be sure to check your CD-ROM against the editions noted on this sheet.

API 510 PREPARP,TORY COURSE

EXAMPLES OF REPAIRS AND ALTERATIONS

INTRODUCTION
The following examples are intended to provide owners, users,
repair organizations and Inspectors the assistance in evaluating
whether contemplated work on a pressure retaining item should be
categorized as a repair or alteration.

EXAMPLES OF REPAIRS
J.

('

Weld

repairs

attachments
material:

or
that

replacement

of

pressure

parts

or

have failed in a weld or in the base

2.

Corrosion resistance strip lining or weld overlay:

:;

Weld bUildup of wasted areas;

4.

The addition
such as;

of welded attachments

a. studs for insulation or refractory

to pressure

parts,

lining

b. ladder clips
c. brackets,

having

loading Y"hich do not affect

design of the pressure retaining

the

item to which they

are attached
d. tray support rings
5

Replacement of heat exchanger tube sheets in accordance

with the original design.

rs

Replacement

of boiler and heat exchanger

tubes

where

welding is involved.
7

The installation

of a flush patch to a pressure

Itern

retaining

8. Replacement

of pressure

parts identical

on the pressure retaining

a. replacement
the original
b. Re-welding

item

to those existing

such as,

of a shell or head in accordance

with

design.
a circumferential

or longitudinal

seam in

a shell or head
c. Replacement

of

reinforcement
9.

Installation

of

size

whet~e

is not a consideration

of new nozzles or openings

reinforcement

of such a size that

is not a consideration

{for

example

the

of a 3 NPS nozzle to a shell or head of 3/8 in.

installation

nozzles

or less in thickness

or the addition

of a 2 NPS nozzle to a

shell of head of any thi~kness}.

i o.

The

addition

consideration

of

nozzle

where

may be considered

nozzle is identical
a similar

reinforcement
to be a repair

to one in the original

is
if

design, located

the
in

part of the vessel.

11. The replacement

of a shell course in a cylindrical

pressure

vessel:
12. Welding

of wasted or distorted

13. Replacement

of slip-on

flange faces:

flanges with weld neck flanges

01-

vice-versa:
14.

Seal welding

of butt straps and rivets;

15 The repai r or replacement

accepted
strength
16

material

that

of a pressure
has a normal

that is equivalent

Replacement

to the original

of a pressure retaining

different

nominal

allowable

stress

composition,
from

that

part with a Code

composition
material,

part with material

equal

to

or greater

used in the or-iginal

and

of
tn

design,

provided
and

the replacement material

design

construction

c.

requirements

of

satisfies

the

under which the vessel

the material

original

code

of

was built.

EXAMPLES OF ALTERATIONS
1. An increase
(internal

in the maximum

or external)

item regardless

allowable

Or temperature

working

pressure

of a pressure retaining

of whether or not a physical

change was

made to the pressure retaining item;

2. A decrease in the minimum temperature

mechanical tests are required.
3. The addition

of new

pressure vessel)

such that additional

nozzles or opening

(in

a bOiler

of new sizes other than existing

requiring new reinforcement

4. A change in the
retaining item;

or

sizes and

calculations

dimensions

or contour

of

a pressu re

5. In a boiler, an increase in the heating surface or steaming

capacity
required;

such that

increase in the

relieving

capacity

is

6. The addition of pressurized jacket to a pressure vessel;

7. Except as permitted

in Repair, repiacement

of a pressure

retaining

part in a presSure retaining item with a material

different

allowable

stress or nominal composition

of

from that

used in the presSure retaining item to which it is attached.

8. The addition

of a braCket Or an increase

existing

bracket

which

affects the design

retaining

item to which it is attached.

')

in ioading

on an

of the pressure

-------------_._-------_."----~

GUIDELINES FOR
API 510 CERllFICA liON EXAMINA liON

Contents

1.

Examination Scheme

2.

Distribution of Marks

3.

Salient Features of the Examination

4.

How to Prepare for the Examination

5.

API-510 -Chapter wise Tips for Maximizing the Score

6.

Time Management During the Examination

..~~"~~.~-

1.

EXAMINATION SCHEME

1.1 General:
As per the present scheme, API 510 examination is one-day, 8-hour, 2
session examination, comprising of pre-lunch session (4 hours) for "openbook" examination and post-lunch session (4 hours) for "closed-book"
examination.

1.2 Total marks:

There are a total of 150 questions carrying 1 mark each, (total of 150
marks), split into open-book (approximately 50 questions) and c1osedbook (approximately

100 questions). The distribution of 50 and 100

questions respectively for open-book and closed-book examinations

is

approximate; however the total is always 150 questions.

1.3 Question pattern:

Each question,( in open book as well as closed book part ) is multiplechoice question with given FOUR possible choices. Only ONE out of these
four is the correct choice. The candidate has to pick-up the correct choice,
and indicate the same on separate answer sheet. The answer sheet along
with the question paper should be returned back to the Supervisor. In the
answer sheet you will find four blank circles for each question. The correct
answer is to be indicated by blackening (filling) the relevant circle by a
pencil. Each correct answer will carry one mark. There is no set passing
percentage. However a score of about 100 to 110 out of 150 is a good
estimate of passing score.

please note the followinq:

Fill only one circle out of four given

2

-_._--------------------~-~-~~---~------==

Fill the circle fully and completely. Half or less than half blackened
circle

is not reckoned for answer.

Never indicate the answers by ticking (....J) the circles.

There is no negative marking.

During the "open-book"

session.

you are permitted

and other documents

as per "Effectivity

tabbed.

underlined

highlightened,

Sheets".

to refer to the codes

Code

or notes in margin

2 Nos. 8 or 28 pencils and eraser

Non-programmable

Photo identity (passport,

Exam confirmation

may be

of the pages

accepted. Additional new pages to codes are not accepted.

the following to the exam hall.

pages

Always

are
carry

calculator
driving license, etc.)

letter

Be present in the exam hall at least 15 minutes prior to scheduled

exam. The Supervisor announces

important instructions

start of

during this period.

Do not miss them. Now relax and attempt the exam calmly. Time is always
more than enough.

2.

DISTRIBUTION OF MARKS

2.1 Codes for Study:

As per the Effectivity Sheet for API-510 exam. there are total 7 codes prescribed
for examination. However. all of them are not equally important and do not
therefore require equal emphasis. About 45 percent questions are asked from
one code API 510 which is hardly a total of 20 pages, while all other 6 codes
contribute 55% marks which are more than 1.500 pages.

2.2 Code-wise marks distribution:

Following distribution scheme will help the participant to decide how much time
he should spend for each document during preparation.

Approx. Weightage
S.N.

Approx.Questions

Code
(in %)

Out of Total 150

API 510 Code

42-45

63 - 68

ASME Sec.vlll Div.1

20-22

30-33

ASME Sec IX

12

ASME Sec. V

12

18

API RP 572

API RP 576

IRE Chap II

J
~-- ----------------______
L___
8

General Knowledge

c;' I
,{

18

;,"'

~'

-'

b(

."

l:

(
0-

,.-

__

___________________________

3.

~'

~="o=~=.,"_._

SALIENT FEATURES OF THE EXAMINATION

3.1 How the questions are set:

As stated earlier, the examination comprises of open book and closed book
parts. The closed-book examination includes such questions which the inspectm
is normally expected to know without referring the Codes, i.e., the questions are

"awareness level" questions. Whenever you find a very definitive or quantitative

statement in body of the Code, a closed book question may be expected on it.
Thus, the basic requirements of a code, specific "DO" and "DON'T" statements,
important quantified statements, important definitions and well-known inspection
principles will constitute such questions.
Where the student is required to refer to the diagrams or formulas or tables or
graphs and curves from the Codes, it will always be an "open-book" question. All
calculation
information

oriented questions will normally be "open-book" type. The Code

which

is not short and crisp, (i.e., large paragraphs,

several

descriptive statements clubbed together) will normally be asked in "open-book"

part. Here the participant is expected not to remember the information but should
know where to find it in the body of the Code.

The questions asked in closed book part are straight forward statements directly
taken form Code without much of the modifications and therefore are easy to
answer. To answer open-book questions, one only needs to know where to find
the answer in the code and therefore tabbing of Code pages, highlighting the
paragraphs or additional explanatory notes in page margins is useful for saving
time. Closed-book part of the exam (100 marks) can be finished in 2 to 2"12
hours, though 4 hours are allotted. While "open-book" part (50 marks) takes a
little longer and may require all the 4 hours that are allotted.

4.

HOW TO PREPARE FOR EXAM:

A ) If your aim is only to get "certified"

only, i.e., to obtain just around 110-

115 marks, then, Follow the steps given below

1) .Detailed study of documents nos. 1 to 4 above (Ref. Chap.2 distribution of

marks,) may be adequate.
2) Additionally, one should try to remember all the "Points to Recall" given each
day during the preparatory course and review the mock examinations attempted
during

the

organization

Preparatory

Course. If two or more participants

from

same

are appearing for exam, then joint discussions and one putting

question to another and vice versa has been found very effective during
preparation.
3) Other 3 codes (Le., Serial No.5 to 7) may be studied in detail if there is
additional preparation time available. An overall "awareness" level knowledge of
these 3 Codes may be okay. These contribute only 10% weightage. Still, the
Open book Questions from these can always be found out and answered plus
the points to recall can help to answer other questions.

B) .If your objective is to get certified and also to obtain a good score, (say

135+) then prepare for exam as follows:

In addition to preparation as per 1&2 above, It is worthwhile to study the 3

Codes also. (Serial No.5 to 7). However, please remember that study of API 510
has to be "thorough" and total, while study of ASME Sec. VIII Oiv.1, ASME Sec.
IX and ASME Sec. V should be such that it can cover the topics mentioned in the
"Body of Knowledge".

_.----------------------~-------~'~-.,~='-~The last 3 Codes should be read at least once and note the important points. A
very "thorough" study of these documents however will not result in "gains"
commensurate with the efforts put in.

If you are about a month away from examination, read all the Codes at least
once and concentrate on highlighted text in the Codes and also try to solve the
question bank.

If you are about two weeks away from the exam, concentrate on highlighted text
as well as the mock examinations conducted during the course.

In the last week of preparation, focus on Points to Recall and and highlighted text
from the codes.

************

- ------------------------~------~=,~-~~
..
~._._._
...
_,-=The last 3 Codes should be read at least once and note the important points. A
very "thorough" study of these documents however will not result in "gains"
commensurate with the efforts put in.

If you are about a month away from examination, read all the Codes at least
once and concentrate on highlighted text in the Codes and also try to solve the
question bank.

If you are about two weeks away from the exam, concentrate on highlighted text
as well as the mock examinations conducted during the course.

In the last week of preparation, focus on Points to Recall and and highlighted text
from the codes.

************

5.

API-510 CHAPTERWISE TIPS FOR

MAXIMIZING THE SCORE

a.

From

Chapter

. exclusions.

1, just

note

the

scope,

application

and

Two questions will be asked from these, usually

closed book.

b.

Chap. 2 lists only the reference documents.

question

c.Chapter
Chapter

is asked from this chapter

3. There are only 5 or 6 important definitions

3 of API 510. Normally 3 to 4 definitions

in closed-book

d.

From

certification

from

are asked

exam.

Chapter

Concentrate

e.

At the most one

4, usually

2 or 3 questions

on responsibilities

clause.

are

asked.

Also see App. B for

requirements.

From Chapter

5, about 15-18 questions

are asked.

About

10-12 in closed book and 4-S in open book. Para 5.2 to 5.6,
average

of 1 or 2 questions are asked

while on para

5.7,

about 6 to 8 questions ( both open & close book) are asked.

f.

From

Chapter

Particularly
attracts

pay

6,

about

attention

15-18
to

questions

Inspection

at least 5 to 6 questions

are

asked.

intervals,

which

and they could be either

open book or closed book.

g.

F rom Chapter 7 also 15-18 questions are asked. This is only

four page chapter and almost all chapter is important.

Pay

particular attention to authorisation,

defect

repair,

and

inspection requirements.

h.

There may be 2 or 3 questions on overall API-510 code for

the purpose of assessing the overall under standing of code.

I.

Chapter 8 as well as App. E are excluded from examination.

J.

As regards ASME Sec. VIII Oiv.1, the course content is

categorised in 9 categories. 7 of them are listed under
calculations while 8 and 9 are listed under welding and NOT
. You may expect at least one open book and one closed
book question on each of these. Additionally,

under the

category internal pressure, you may expect 4 open book

questions one each for thickness calculation for the 4 types
of end closures.

********

-----.'-----------

----------~~~~._=.;.....::..._-_'r~." ...
I..'_""L_ . ~

6.

TIME MANAGEMENT DURING EXAM

Both "open" and "closed" book sessions are 4 hours each. This means about
25 to 28 questions per hour for closed book and 12 to 15 questions per hour
for open book. For proper time management following are useful suggestions.

a) You may start from Question NO.1 and proceed. If after 1 hour you
feel that you are maintaining the required progress as mentioned
above proceed serially.

b) If, however, you are behind the required rate, start jumping

the

questions, i.e., start attempting those questions you can answer,

deleting whose answer you, do not know. Proceed like this till the end.
Do not leave any question unanswered whose answer you know.

c) Then come back to "deleted" questions and attempt them using your
"feel" factor. Go on like this till say last 10-15 minutes are remaining.

d) If there are still some questions where you have no clue at all just mark
the answer at random in last 10-15 minutes. This may give you few
chance marks. Do not leave any question unattempted.

e) After completion of writing exam, if you have still time (which you
normally have) you may go through your answers just to check quickly
if you have filled a wrong circle.

***********

------------------------------.T---=~._..r><,~,
10

1. SAMPLE API-510 EXAM QUESTIONS

The Questions below are examples of what exam question might look like. The questions are
furnished by API web site www.api.org. Reproduced here for guidance to the students
Correct Answer: 4

A The nondestructive examination method to be used for a

particular inspection should be determined by the:
1. availability of certified .NDE examiners.
2. length of time since the last inspection.
3. age of the component to be inspected.
4. type, location, and orientation of the
expected flaws.

Correct Answer: 3
B. In planning for an internal inspection of a vessel
that has contained acidic corrodents, what type and
location of corrosion would you expect to find on the
vessel shell, away from the welds?
1. Hydrogen blistering in the vapor
space
2. Hydrogen embrittlement in the vapor
space
3. Hydrogen blistering near the liquid
level
4. Hydrogen embrittlement below the
liquid level

Correct Answer: 1
C. A pressure vessel is scheduled for pneumatic
testing using the methodology of ASME Code,
Section VIII, Division 1, with the maximum allowable
working pressure = 635 psig at 375 F. The vessel is
constructed of SA-516 Gr. 65 material and is neither
enameled nor lined. The test metal temperature will
be a minimum of 50 F, per the owner's specifications.
How many pressurization steps are needed to
0

achieve the minimum required test pressure, and at

what minimum pressure will the visual examillation be
performed?
1. 6 steps; 635 psig
2. 6 steps; 793.75 psig
3. 9 steps; 635 psig
4. 9 steps; 793.75 psig

Correct Answer: 4
D. The principal reason for inspecting a pressure
relief device is to determine:
1. the remaining life.
2. the spring coil diameter.
3. the body thickness.
4. if it is functioning properly.

Correct Answer: 1
E. A pressure vessel has been in service for 12 years
and has a history of corrosion over its service life. The
original thickness was 1.9375 inches; the current
thickness is 1.405 inches. What is the corrosion rate
for this vessel?
1. 0.044
2. 0.089
3. 0.266
4. 0.532

inch per year

inch per year
inch per year
inch per year

Correct Answer: 3
F. What can be done to extend the life of a vessel
with a corroded area in the shell plate 6 inches from
the weld, a joint efficiency of less than 1, and a
corrosion thickness currently near the minimum
required thickness?

1 . Recalculate t minimum for current operating conditions

using E < 1.
2. Recalculate t minimum for current operating conditions
using E 1.
3. Recalculate t minimum for design conditions using E = 1.
4. Monitor the thickness during the run.

~~~------~--

Correct Answer: 2
G. Temporary repairs to pressure vessels:
1. must be replaced with permanent repairs during the
next scheduled shutdown.
2. may remain in place for long periods if approved by
the pressure vessel engineer.
3. may remain in place for long periods if approved by
the API-authorized pressure vessel inspector.
4. may remain in place permanently if approved by the
pressure vessel engineer and the API authorized
pressure vessel inspector.

Correct Answer: 2
H. Who must be consulted before the repair of a crack
at a discontinuity where stress concentrations may be
serious?

1. The
2. The
3. The
4. The

owner-user
pressure vessel engineer
National Board inspector
vessel manufacturer

Correct Answer: 4
I. The WPS and the PQR are used to determine: