API 510, PRESSURE

VESSEL INSPECTOR
CERTIFICATION
EXAMINATION
 BODY OF KNOWLEDGE
 REFERENCE PUBLICATIONS:
 API publications and ASME codebooks must be brought to the
examination site to be used as reference materials for the open-book
part of the examination.
 A. API Publications:
 API 510, Pressure Vessel Inspection Code
 API RP 571, Damage Mechanisms Affecting Equipment in Refining
Industry
 API RP 572, Inspection of Pressure Vessels (except Appendix B)
 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 1, Rules for Constructing Pressure Vessels
 Section IX, Welding and Brazing Qualifications
 MODULE – 1

Introduction
 Scope
 This inspection code covers the maintenance
inspection, repair, alteration, and rerating
procedures for pressure vessels used by the
petroleum and chemical process industries.
 REPAIR
 Repair: The work necessary to restore a
vessel to a condition suitable for safe
operation at the design conditions. If any
repair changes the design temperature or
pressure, the requirements for rerating shall
be satisfied. A repair can be the addition or
replacement of pressure or nonpressure
parts that do not change the rating of the
vessel.
 ALTERATION
 Alteration: A physical change in any component or
a rerating that has design implications that affect the
pressure-containing capability of a pressure vessel
beyond the scope of the items described in existing
data reports. The following should not be considered
alterations: any comparable or duplicate
replacement, the addition of any reinforced nozzle
less than or equal to the size of existing reinforced
nozzles, and the addition of nozzles not requiring
reinforcement.
 RERATING
 Rerating: A change in either the temperature ratings
or the maximum allowable working pressure rating of a
vessel, or a change in both. The maximum allowable working
temperature and pressure of a vessel may be increased
or decreased because of a rerating, and sometimes a rerating
requires a combination of changes. Derating below
original design conditions is a permissible way to provide
for corrosion. When a rerating is conducted in which the maximum
allowable working pressure or temperature is
increased or the minimum temperature is decreased so that
additional mechanical tests are required, it shall be considered
an alteration.
MODULE – 2
JOINT EFFICIENCIES
 UW-3 weld joint category
The term “Category” as used herein defines the location
of a joint in a vessel, but not the type of joint.
Category A. Longitudinal and spiral welded joints
within the main shell, communicating chambers, transitions
in diameter, or nozzles; any welded joint within a
sphere, within a formed or flat head, or within the side
plates of a flat-sided vessel; circumferential welded joints
connecting hemispherical heads to main shells, to transitions
in diameters, to nozzles, or to communicating
Category B. Circumferential welded joints
within the main shell, communicating
chambers, nozzles, or transitions in diameter
including joints between the transition and a
cylinder at either the large or small end;
circumferential welded joints connecting
formed heads other than hemispherical to
main shells, to transitions in diameter, to
nozzles, or to communicating chambers.
Category C.
Welded joints connecting flanges, Vanstonelaps, tubesheets, or
flat heads to main shell, to formed heads, to transitions in
diameter, to nozzles, or to communicating chambers any welded
joint connecting one side plate to another side plate of a flat-
sided vessel.

Category D.
Welded joints connecting communicating
chambers or nozzles to main shells, to spheres, to
transitions in diameter, to heads, or to flat-sided vessels,
and those joints connecting nozzles to communicating
chambers (for nozzles at the small end of a transition in
diameter, see Category B).
FIG. UW-3 ILLUSTRATION OF WELDED JOINT LOCATIONS TYPICAL
OF CATEGORIES A, B, C, AND D
 types of radiograph (UW11)
 Full radiography
 Item 1: All butt welds in vessels used to contain a lethal
substance (UW-11(a)).Lethal substances have specific
definitions in ASME Code in UW-2 and it is the responsibility of
the end user to determine if they ordered a vessel that contains
lethal substances.
 Item 2: All butt welds in vessels in which the nominal thickness
exceeds specified values (UW-11(a). You can find these values
in subsection C, in UCS-57, UNF-57, etc. For example, this value
for P-No.1 in UCS-57 is 38 mm.
 Item 3: All butt welds in an unfired steam boiler with
design pressure > 50 psi (UW-11(a)).

 Item 4: all butt welds in nozzles, communication

chambers, etc., attached to vessel sections or
heads that are required to be fully radiographed
under (1) or (3) above; however, except as required
by UHT-57(a), Categories Band C butt welds in
nozzles and communicating chambers that neither
exceed NPS 10 (DN 250) nor 11⁄8 in. (29 mm)
wall thickness do not require any radiographic
examination
 Spot radiography

 No radiography
the RT symbols are used in Code (UG-116).
 RT 1: Items 1, 2 and 3, (E=1), All butt welds-full

length radiography
 RT 2: when the complete vessel satisfies the

requirements of UW-11(a)(5) and when the spot

radiography requirements of UW-11(a)(5)(b) have
been applied.
 RT 3: (E=0.85), Spot radiography butt welds

 RT 4: (E=0.7), Partial / No radiography

Joint efficiency by reading Table UW-12
Joint efficiency for seamless heads and vessels Sections perUW-12 (d); and e.
Joint efficiency for welded pipe and tubing per UW-12 (e).

 Seamless vessel sections or heads shall be considered

equivalent to welded parts of the same geometry in
which all Category A welds are Type No. 1. For calculations
involving circumferential stress in seamless vessel
sections or for thickness of seamless heads, E = 1.0 when
the spot radiography requirements of UW-11(a)(5)(b) are
met. E = 0.85 when the spot radiography requirements
of UW-11(a)(5)(b) are not met, or when the Category A
or B welds connecting seamless vessel sections or heads
are Type No. 3, 4, 5, or 6 of Table UW-12.
 Welded pipe or tubing shall be treated in the
same manner as seamless, but with
allowable tensile stress taken from the
welded product values of the stress tables,
andthe requirements of UW-12(d) applied.
 - A new pressure vessel should be inspected to which of the
following codes?
a. API 510 ,
b. ASME Sec. 1,
c. ASME Sec. VIII Div. 1,
d. None of these

- Code rules for testing vessels in service are detailed in:

a. API 510
b. API 570
c. ASME Section VIII Div.1
d. None of above
- Identify category A joints from following:
a. Longitudinal joints
b. Circumferential joints, shell to shell
c. Shell to hemispherical head joint
d. a and c above
- A Pressure Vessel is designed for 0.85 joint efficiency
with full penetration welds. RT requirement will be:
a. Nil
b. Spot
c. 100 %
d. T-joints radiography
-For a vessel constructed with Type 1 welds:
a. RT3 means E = 1
b. RT2 means E = 0.85
c. RT1 and RT2 may mean E = 1
d. RT4 means spot radiography
- Two head to shell joints, one joining a seamless Hemisph,
head to shell was radiographed for full length and the
other joint joining seamless std. torisph. head to shell was
spot radiographed, The weld joint efficiency for each of
these heads respectively will be:
a. 1, 0.85
b. 1, 1
c. 0.85, 1
d. 0.85, 0.85
- ASME Sec. VIII Div. 1 recommends use of U.T. in place of R.T.
(for a fully radiographed vessel) for:
a. All butt welds in vessel
b. All butt and fillet welds in vessel
c. For closing seams only
d. The code does not permit use of U.T. at all
 MODULE – 3
Internal pressure
UG(27), (32)
 Cylindrical Shells. The minimum thickness or maximum
allowable working pressure of cylindrical shells shall
be the greater thickness or lesser pressure as given by (1)
or (2) below.

(1) Circumferential Stress (Longitudinal Joints). When the thickness

does not exceed one-half of the inside radius, or P does not
exceed 0.385SE, the following formulas shall apply:
 E = joint efficiency
 P = internal design pressure (see UG-21)
 R = inside radius of the shell course under
consideration,
 S = maximum allowable stress value (see
UG-23 and
 t = minimum required thickness of shell
 Spherical Shells. When the thickness of the shell of a wholly
spherical vessel does not exceed 0.356R, or P does not exceed
0.665SE, the following formulas shall apply:
FORMED HEADS, AND SECTIONS,
PRESSURE ON CONCAVE SIDE
 Hemispherical Heads:
 Torispherical heads made of materials having a
specified Minimum tensile strength exceeding
70,000 psi (500 MPa)
shall be designed using a value of S equal to 20,000
psi(150 MPa) at room temperature and reduced in
proportion to the reduction in maximum allowable
stress values at temperature for the material (see
UG-23).
- If all other conditions are remains same the design thickness
of which dished end (Torispherical, Hemispherical, Ellipsoidal)
will be maximum?
a. Torispherical
b. Hemispherical
c. Ellipsoidal
d. All will be same
-In thickness formula for internal pressure for shell, term ‘E’ refers
to:
a. Modules of Elasticity of material
b. Thermal Expansion
c. Joint efficiency of the weld
d. None of above
- A standard seamless , ASME F & D head (Torispherical) is used for the
following conditions:
 Material of Construction = SA 515 gr 60
 Design Pressure = 250 psig
 Design temp = 580ºF
 Inside Crown Radius = 72 inches
 Minimum available thk. = 1.14 inches
 Category B welds are spot radiographed.
 Corrosion allowance = 0.125 inches
 Allowable stress at design temp. = 16400 psig

 Your assessment is:

a. The head does not meet code requirements.
b. The head meets the code requirements.
c. Suitability would depend on decision of pressure vessel inspector.
d. Data are not adequate.
 For a certain pressure vessel with spot
radiography, and all Welds type 1,
Vessel diameter = 72 inch I.D.
M.O. C = SA 515 gr 70
Design temp. = 600°F
Allowable stress at design temp. = 20,000 psi
If shell thk. = 5/8" and C. A = 1/8", the MAWP for the
shell will be:
a. 234 psi
b. 168 psi
c. 256 psi
d. None of the above
 MODULE – 4
 UG-28 THICKNESS OF SHELLS AND
TUBES UNDER EXTERNAL PRESSURE
Do = outside diameter of cylindrical shell course or tube
L = total length, in. (mm),
P = external design pressure
t = minimum required thickness of cylindrical shell
or tube, or spherical shell, in. (mm)
Cylinders having Do /t values ≥ 10:
Step 1. Assume a value for t and determine the ratios
L/Do and Do /t.
Step 2. Enter Fig. G in Subpart 3 of Section II, Part D
at the value of L/Do determined in Step 1. For values of
L/Do greater than 50, enter the chart at a value of L/Do =50.
For values of L/Do less than 0.05, enter the chart at a
value of L/Do = 0.05.
Step 3. Move horizontally to the line for the value of
Do /t determined in Step 1. Interpolation may be made for
intermediate values of Do /t; extrapolation is not permitted.
From this point of intersection move vertically downward
to determine the value of factor A.
Step 4. Using the value of A calculated in Step 3, enter
the applicable material chart in Subpart 3 of Section II,
Part D for the material under consideration.
Step 5. From the intersection obtained in Step 4, move
horizontally to the right and read the value of factor B.
Step 6. Using this value of B, calculate the value of the
maximum allowable external working pressure Pa using
the following formula:
Step 7. For values of A falling to the left of the applicable
material /temperature line, the value of Pa can be calculated
using the following formula:

Step 8. Compare the calculated value of Pa obtained in

Steps 6 or 7 with P. If Pa is smaller than P, select a larger value for t and
repeat the design procedure until a value
of Pa is obtained that is equal to or greater than P.
 A pressure vessel (M.O.C. 516 gr. 70) has external jacket spread
over 72 inches length of the shell. (Jacket pressure = 180 psi,
Jacket temperature = 350°F) the vessel OD = 36 inches. Shell
thickness= 0.5 inch, C.A. = Nil. Decide which of the following are
applicable in the present case.
 
a. Shell thickness is OK.
b. Shell thickness is NOT OK.
c. Data are not adequate.
d. Acceptance of shell thickness depends on opinion of vessel
engineer.
 In a pressure vessel one of the 2:1 ellipsoidal dished head is
removed and a new seamless dished head of same type is
installed with a single ‘V’ joint with backing strip and full
radiography. What is the joint category, type and efficiency of
the joint now?
a. Category-B, Type-1 & E-0.9
b. Category-B, Type-2 & E-0.9
c. Category-A, Type-2 & E-1.0
d. Category-B, Type-2 & E-1.0
 For external pressure calculations, the value of “E” is worked out
on the basis of:
a. E = 1 for full radiography
b. E = 0.85 for spot radiography
c. E = 0.7 for no radiography
d. E is modulus of elasticity and does not depend on radiography

 In external pressure calculations for cylindrical shell, the Factor –

A, depends on:
a. O.D. and thickness of shell
b. Design temperature
c. Safe stress value ‘S’ of material
d. All of the above
 MODULE – 5
hydrostatic and pneumatic test
UG (99) , (100)
 - a hydrostatic test pressure that at every point in the
vessel is at least equal to 1.3 times the maximum allowable
working pressure multiplied by the lowest stress ratio
(LSR) for the materials of which the vessel is constructed.
The stress ratio for each material is the stress value S
at its test temperature to the stress value S at its design
temperature .

- The hydrostatic test pressure at the top of the vessel shall be

the minimum of the test pressures calculated by multiplying the
basis for calculated test pressure
.
- Any nonhazardous liquid at any temperature may be used for the
hydrostatic test if below its boiling point. Combustible liquids
having a flash point less than 110°F (43°C), such as petroleum
distillates, may be used only for near atmospheric temperature
tests.

- It is recommended that the metal temperature during hydrostatic

test be maintained at least 30°F (17°C) above the minimum
design metal temperature, but need not exceed 120°F (48°C), to
minimize the risk of brittle fracture.
 Pneumatic Test

 a pneumatic test prescribed in this paragraph may be used in

lieu of the standard hydrostatic test prescribed in UG-99 for
vessels:
(1) that are so designed and/or supported that theycannot safely
be filled with water;
(2) not readily dried, that are to be used in service

- The Pneumatic test shall be at least equal to 1.1 times the

MAWP multiply by (LSR)
- The metal temperature during pneumatic test shall be maintained
at least 30°F (17°C) above the minimum design metal
temperature to minimize the risk of brittle fracture.

- The pressure in the vessel shall be gradually increased to not

more than one-half of the test pressure. Thereafter, the test
pressure shall be increased in steps of approximately one-tenth
of the test pressure until the required test pressure has been
reached
 What will be the minimum inspection pressure if pneumatic
testing was carried out at 220 psig, as per code:
a. 220 psi
b. 250 psi
c. 200 psi
d. 260 psi
 Hydrostatic pressure test of vessels may be replaced by
pneumatic test:
a. At the option of vessel manufacturer
b. At the option of vessel inspector
c. Permitted only if water is not available in the region and client
approves
d. Permitted only if design or operating conditions do not permit use
of water as test medium
- Choose correct Pneumatic test pressure for a vessel with the
following data:
 Design Pressure = 160 psi
 Design temp. = 675ºF
 Allow stress (Ambient) = 20000 psi
 Allow stress (675ºF) = 19200 psi
a. 176.0 psig
b. 215.6 psig
c. 183.3 psig
d. None of above
 - Part MAWP for lower dished head in vertical vessel will
generally be:
a. Lower than top head
b. Lower than shell
c. Higher than both shell and top head
d. Same as both top head and shell

- Pneumatic test should be carried out on a vessel at

300 psig. The design temperature and the test
temperature are same. What is the test pressure
and in how many steps the pressure should be
applied.
a. 350 psig, 6 steps
b. 330 psig, 6 steps
c. 350 psig, 2 steps
d. 330 psig, 2 steps
 The material not requiring PWHT by code
requirement has been heat-treated. The PWHT
carried out on this material is most likely due to:
a. Due to process requirement
b. Because of the material
c. As per authorized inspector requirement
d. Because of welding process.
 MODULE – 6
Low Temperature Operation
UCS (66)
 Components, such as shells, heads, nozzles,
manways,reinforcing pads, flanges, tubesheets,
flat cover plates, backing strips which remain in
place, and attachments which are essential to
the structural integrity of the vessel when welded
to pressure retaining components, shall be
treated as separate components. Each
component shall be evaluated for impact test
requirements based on its individual
material classification, thickness
 UCS-68(c) If postweld heat treating is performed
when it is not otherwise a requirement of this
Division, a 30°F(17°C) reduction in impact
testing exemption temperature may be given to
the minimum permissible temperature from Fig.
UCS-66 for P-No. 1 materials. The resulting
exemption temperature may be colder than
−55°F (−48°C).
 A pressure vessel is to be constructed with
MDMT = +20°F, M.O.C = SA 515 gr 60 . Impact
testing not performed.
Required shell thickness = ¾ , dished head thk. =
1-⅛ " ( torisph. head). Determine if this material
is suitable for:
 
a. Both shell as well as dished head
b. Suitable for head but not for shell
c. Suitable for shell only but not for head
d. Not suitable for either
Impact test requirement for the two plates is to be
assessed for MDMT = 0ºF, to be used for Vessel which
will be hydrotested and used for steady operation.
 
Plate A. Plates 537 class 1, 2.0 inch thick
Plate B. Plates 515 gr 60, 0.75 inch thick
 
Your assessment is:
 
A. Plate (A) and plate (B) both require impact test.
B. Only (A) requires, (B) is exempt.
C. Only (B) requires, (A) is exempt.
D. Both do not require impact testing.
MODULE – 7
Heat treatment