INSTRUCTIONS FOR API 510 PRE-COURSE STUDIES CONTENTS: 1. API/ASME Code Book List 2, API 510 Body of Knowledge 3. API 510 Study Questions and Answers 4, ASME Section IX Welding Exercise 5, ASME Section V NDT Exercise 6. API Study Questions and Answers Audio CD(s) Please begin by reading all API materials including the Body of Knowledge sent with your package from the API. If you do not have the Body of Knowledge you may download it at the API website www.api.org. Continue by reading the API Study Questions and listening to the Audio, follow this by completing the enclosed exercises over ASME IX and V. Please bring to the class the following items. Effective Publications for this Revision: Dec. 3 2003 Exam See the enclosed API Effectivity list! A simple calculator (needs to have the square root function) Highlighters and Tabs The first day of class a short test will be given over the pre-course API 510 Study Questions! THIS PRE-STUDY MATERIAL IS VERY IMPORTANT PLEASE DO NOT NEGLECT THIS WORK. START Now FAST TRACK TECHINICAL TRAINING ~ LICENSED TO ITAC_Publications Effectivity Sheet API 510, Pressure Vessel Inspector Certification Exam For Exam Administration: December 3, 2003 Listed below are the effective editions ofthe publications required forthe December 3, 2003 API S10, Pressure Vessel Inspector Certification Examination, + API Standard 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration, Eighth Edition, June 1997, Addendum { (December 1998), Addendum 2 (December 2000) and Addendum 3 (December 2001). Global Engineering Product Code API CERT 510 + API Recommended Practice 572, inspection of Pressure Vessels, Second Euition, February 2001, Global Engineering Product Code API CERT $72 ‘+ API Recommended Practice 876, /nspection of Pressure-Relieving Devices, Second Edition, December 2000, Global Engineering Product Code API CERT $76 + Guide for Inspection of Refinery Equipment, Chapter 2° Global Engineering Product Code API CERT GUIDE IRE CH2 Note: This publication isa reference document intended only for Inspector Certification applicants. To obtain a copy please inform the person taking your order that you require this publication forthe API 510 Inspector Certification exam. + American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2001 edition with 2002 Addenda, i, ASME Section IID, External Pressure Graphs only ji, ASME Section V, Nondestructive Examination, Articles I, 2,5, 6and 7 iti. Section VII, Rules for Construction of Pressure Vessels, Division 1, UG, UW, UCS, UHT, Appendices 1-4, 6,8 and 12 iv, Section IX, Welding and Brazing Qualifications Global Engineering Product Code for the ASME package API CERT 510 ASME. Package includes only the above excerpts necessary forthe exam. ‘API and ASME publications may be ordered through Global Engineering Documents at 303-792-2181 or 800-854 7179. Product codes are listed above. Orders may also be faxed to 303-397-7935. More information is available at hitovwiew.glohaLihs.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 member. Prices quoted will reflect the applicable discounts. No discounts will be made for ASME documents. For the 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. st 1-800-667-3155 or 403-458-3155. Note: API and ASME publications are copyrighted material. Photocopies of API and ASME publications are not permitted. CD-ROM versions of the API documents are issued quarterly by Information Hand! ‘Services and are permitted. Be sure to check your CD-ROM against the editions noted on this sheet.BODY OF KNOWLEDGE APIS10 PRESSURE VESSEL INSPECTOR CERTIFICATION EXAMINATION June 2003 (Replaces August 1998) API Authorized Pressure Vessel Inspectors must have a broad knowledge base relating to maintenance, inspection, repair, and alteration of pressure vessels. The API Authorized Pressure Vessel Inspector Certification Examination is designed to determine if individuals have such knowledge. The following is alist of specific topics in which the API Authorized Pressure ‘Vessel Inspector should be knowledgeable. To determine whether the applicants have this broad base of inspection knowledge, « minimum of one question from each ‘category listed will be included on the API certification examination. Only inspection information covered in one of the references outlined in this body of knowledge will be utilized forthe 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 more detailed information that the inspector is expected to be able to find in the documents, but would not ‘normally be committed to memory 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 ofthe examination. ‘A. API Publications: [APIS10, Pressure Vessel Inspection Code APIRP.572, Inspection of Pressure Vessels API RP 576, Inspection of Pressure-Relieving Devices API Guide For Inspection of Refinery Equipment, Chapter Il B. ASME Publications Section V, Nondestructive Examination Section VIM, Division 1, Unfred Pressure Vessels Section 1X, Welding and Brazing Qualifications Note: Refer to the Publications Effectivity Sheet in the application package for alist of specific editions, addenda, and supplements ofthe reference publications that are effective for your exam 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 Vessel Inspectors should be able to check and perform 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 ten categories describe the minimum necessary knowledge and skills: L.CORROSION RATES AND INSPECTION INTERVALS ‘The Inspector should be able to take inspection data and determine the internal and external inspection intervals. ‘The Inspector must be able to calculate: ‘a. Metal Loss (including corrosion averaging) (API-S10, Para 5.7, 4) ’. Corrosion Rates (API-S10, Para 64) «Remaining Corrosion Allowance (API-SI0, Para 64) 4. Remaining Service Life (API-S1O, Para, 6.4) ¢. Inspection Interval (API-510, Para, 6.4) ‘The formulas for performing the above calculations and rules for seting the inspection intervals may be “closed-book” during the exam. ‘2.JOINT EFFICIENCIES ‘The inspector must be able to determine the joint efficiency "E" ofa vessel weld. Inspector should be able to determine: ‘a. Weld Joint Categories from UW-3; ', Type of radiography (full, spot, or none) performed basis the nameplate markings (RT-1, RT «. Joint efficiency by reading Table UW-12; 4. Joint efficiency for seamless heads and vessels Sections per UW-12(4); and €. Joint efficiency for welded pipe and tubing per UW-12(). , ee.) Determining joint efficiency may be part of the internal pressure problem since joint efficiency “E" is used in the formulas for determining required thickness or Vessel Part MAWP. ‘LSTATICHEAD ‘The inspector must be able to compensate for the pressure resulting from static head. All static head will be based upon a ‘Specific Gravity of 1.0. The inspector should be able to: a) List the static head/pressure conversion factor (0.433 psi/ft); b) Know the difference between vessel MAWP and vessel part MAWP (UG-98); ©) Caleulate static head pressure on any vessel part; 4) Calculate total pressure (MAWP + static head) on any vessel part; ) Calculate maximum vessel MAWP given vessel parts MAWP and elevations; and +1 Determine the head depth for formed heads given the vessel diameter (UG-32(0) & UG-32(4) jons if static head data is given in the Static head calculations may also be required during the intemal pressure calcul ‘examination problem.INTERNAL PRESSURE ‘The inspector should be able to determine: a) » ° 4) 2 9 2 “The required thickness of cylindrical sell based on circumferential stress given a pressure (UG-27(¢X1)}; ‘The vessel part MAWP for a cylindrical shell based on circumferential stress given a metal thickness (UG-276)(1); ‘Whether a cylindrical shell meets Code requirements given both pressure and metal thickness (UG 27(¢X) “The required thickness ofa head (ellipsoidal, torisphercal, and hemispherical) given a pressure. (UG32(0), (9, (9) and (@)) ‘The vessel part MAWP for a head (elipsidal, torisphericaland hemispherical) given « metal thickness. (UG-32 (4), (@,@and(g). ‘Whether a head (ellipsoidal, torispherical or hemispherical) meets Code requirements given both pressure and metal thickness (UG 32(@, (9), (8 and (8) ‘The required thickness for a flat unstayed circular head given a pressure. (UG-34(¢\2)) Formula! only). ‘The inspector should also be able to compensate forthe corrosion allowance: add or subtract based on requirements ‘of the exam problem. The Appendix | formula for cylinders, which is based on outside diameter, can be used. The “Appendix I formulas for non-standard heads will not be required. SLEXTERNAL PRESSURE ‘The inspector should be able to 8) Calculate the maximum allowable external pressure based on material from ASME B&PV Section Il, Part D (igure G & specific Material/Temperature Charts supplied withthe examination) UG-28(c)(1); and 'b) Calculate whether a cylindrical shell or ube meets Code design for external pressure given a wal thickness and a pressure (ASME B & PV, Section II, Part D; UG 28 (¢ X1). 4. PRESSURE TESTING ‘The inspector should be able to: 2) ») 2) 4 Calculate atest pressure compensating for temperature. (UG-99 & UG-100) ‘Be familiar withthe precautions associated with hydrostatic and pneumatic testing, such as minimum test temperatures, protection against overpressure et Write a hydrotest Procedure (UG 99 and UG 100) ‘Write a pneumatic test procedure (UG 100 and UG 102) ‘LIMPACT TESTING ‘The inspector should be able to » Determine the minimum metal temperature ofa material which is exempt from impact testing (UG-20 (9), UCS-66, UCS-68(0). 4S.WELD SIZE FOR ATTACHMENT WELDS AT OPENINGS ‘The inspector must be able to determine if weld sizes meet Code requirements. The inspector should be able to: 1 a Convert fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707); and. Determine the required size of welds at openings (UW-16).‘NOZZLE REINFORCEMENT ‘The inspector should: ) Understand the key concepts of reinforcement, such as replacement of strength removed and limits of reinforcement. CCredit can be taken for extra metal in shell and nozzle ©) Beable to calculate the required areas for reinforcement or check to ensure that a designed pad is large enough To simplify the problem: All f= 1.0 AIF=10 AIE=10 All required thicknesses are given 4) ‘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. Required thickness calculations for wind, earthquake, and other secondary stress loadings; Supplementary design formulas and calculations for non-cylindrical shell components; Most external pressure calculations; |. Nozzle calculations for external loads; 5. Flange calculations; 5. Brazing requirements; Ligament calculations; Stayed flat heads and sizing of stays; ‘Tubesheet calculations (stayed or unstayed) and tube to tubesheet joints and loads; 10. Relief valve sizing, 11 Lifting lug and other structural type calculations; 12. Proof testing requirements; 13, Required inspections for new construction, except a they apply to alterations; 14 Zick analysis; 15. Integrally forged pressure components; 16. Cryogenic vessels (below -50 9; 17. Dimpled, embossed, jacketed, and non-metallic vessels and assemblies; 18. NDE requirements for acoustic emission, eddy current, and motion radiography; 19, ASME Sections UF, UB, UNF, UHA, UCI, UCL, UCD, UHT (except UHT-6), ULW, and ULT; 20. Code Cases and interpretations; 21, Welding process requirements other than shielded metal arc welding (SMA W), gas tungsten are welding (GTAW), ‘gas metal arc welding (GMAW), or submerged are welding (SAW); 22. Requirements for pressure vessels for human occupancy; and 23, Rules for natural resource vessels, API-510, Section 8, 1 2 3. 4 5. 6 1 8 9.Il WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX A. WELD PROCEDURE REVIEW. 1. The inspector should be able to determine if procedure and qualification records are in compliance with applicable ASME boiler and pressure vessel code and any additional requirements of API-S1O (API-510 requirements wil take precedence over any ASME requirements covering the same technical area). ‘The weld procedure review may include: ‘a. Welding Procedure Specification (WPS); and b, Procedure Qualification Record (PQR). ‘The weld procedure review may include: SMAW, GTAW, GMAW, OR SAW, withthe following limitations: 1a) Nomore than one process will be included on a single WPS or PQR, and the WPS to be reviewed will be supported by a single PQR. ')_ Filler metals limited to one-per-process for SMAW, GTAW, GMAW, or SAW. ©) The PQR will be the supporting PQR forthe WPS. 1. The inspector should be able to determine: 8) Whether number and type of mechanical test listed on PQR are appropriate b) Whether the results of the tests are acceptable €) Whether all required essential and non-essential variables have been properly addressed. (Supplemental essential variables will not be a part ofthe WPS). The following limitations or conditions will apply: ‘Base metals limited to Pl, P3,P4, PS, and P. 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 corrosionsesistant weld metal overlay, hard-facing overlay, and dissimilar metal Welds with buttering of fertic member are excluded + ForPI, P3, Pd and PS, forthe purpose of the examination the lower transition temperature will be 1333°F andthe upper transformation temperature wil be 1600. 'B_ASME Section Vill Div. | and API-510:_ GENERAL WELDING REQUIREMENTS: |, ASME Section VII, Div. 1 ‘The inspector should be familiar with and understand the general rules for welding in ‘ASME Section VIII, Div. 1, Parts UW and UCS such as: 8) typical joints and definitions b) weld sizes €) restrictions on joints 4) maximum allowable reinforcement ©) inspection requirements 1) cheat treatment 2 APrsio ‘The inspector should be familiar with and understand any rules for welding in API-S10. Any rules for welding given in ‘API-S10 shall take precedence over those covering the same areas in ASME, Section VIII, Div. 1 3. "Editorial" and non-technical requirements for the welding subject matter, the candidate isto be tested on, are excluded, ‘This includes items such as the revision level of the WPS, company name, WPS number and date, and name of testing lab. However, the API 510 applicants shall know that the PQR must be certified by_ signing and dating,TILNONDESTRUCTIVE EXAMINATION ASME Section V, Nondestructive Examination NOTE: Information contained in Mandatory or Nonmandatory Appendices or referenced ASTM specifications will not be covered on the examination. The examination will cover only the main body of each referenced Article. When paragraphs are specifically noted only those paragraphs will be covered. This listing is based on ASME Section V. A. Article 1, General Requirements: ‘The inspector should be familiar with and understand; 1. The Scope of Section V, 2. Rules for use of Section V as a referenced Code, 3. Responsibilities of the Owner/ User, and of subcontractors, 4. Calibration, 5. Definitions of "inspection" and examination", 6. Record keeping requirements. B. 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: 2. required marking ‘type, selection, number, and placement of IQI's, «allowable density 4. control of backscatter radiation «location markers 3. Records . Article 5, Ultrasonic Examination Methods for Materials and Fabrication (general rules forall methods and specific rules for welds and thickness measurement): ‘The inspector should be familiar with and understand: 1. The Scope of Antcle 5, 2. The general rules for applying and using the Ultrasonic method such as those contained in paragraphs T-520 through T-534 3. The specific rules for Ultrasonic thickness measurement and welds as contained in paragraphs T-542, and T-544 through T5443 4. The general rules for evaluation and record keeping in paragraphs T-580 through T-553 D. Article 6, Liquid Penetrant Examination: ‘The inspector should be familiar with and understand: 1. The Scope of Antcle 6, 2. The general rules for applying and using the liquid penetrant method such a) procedures ) contaminants ©) techniques 4) examination ) interpretation 9) documentation and 8) record keeping Dut not limitedE_ Article 7, Magnetic Particle Examination (Yoke and Prod techniques only): ‘The inspector should be familiar with and understand the general rules for applying and using the magnetic particle ‘method such as, but not limited to; 1. The Scope of Article 7, 2. General requirements such as but not limited to requirements for: 1. procedures '. techniques (Yoke and Prod only) «calibration 4. examination «. interpretation 3, Documentation and record keeping, _ASME Section VIII Div, | and API-S10. General nondestructive examination requirements: |LASME Seetion VII, Div. | ‘The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4, 6 8, and 12) 2. API'510, The inspector should be familiar with and understand the general rules for NDE in API-S10. IV. PRACTICAL KNOWLEDGE - GENERAL ‘The following topics may be covered in the examination. More information 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, Thermal, and High Temperature Deterioration, 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. 1 Relief Devices. 12. Maintenance Inspection 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\V. PRACTICAL KNOWLEDGE - SPECIFIC Each reference publication relative to study for the examination is listed below. A list of topics, which may be covered, is listed for each publication. Some toptes may be listed under more than one publication. For example; ASME Section IX is the basie document for welding requirements as referenced by ASME Section VIII, Division 1 and API 510. The ASME and ‘API documents contain additional welding requirements and exceptions to those contained in ASME Section [X. Therefore ‘welding requirements may be listed under all three documents and all three documents may be listed under the general heading of "Welding on Pressure Vessels”. APL-S10, Pressure Vessel Inspection Code NOTE; All of API 510 is applicable to the examination unless specifically excluded. For example: Section 8 and Appendix E are excluded 1. Organization and Certification Requirements 8) Certification for API Authorized Pressure Vessel Inspectors (API-S10, Section 4.2 and Appendix B). b) Authorized Inspection Agencies (API-510, Section 3.4) ©) Vessel Repair Organizations (API-510, Section 3.16) 4) Relief Device Testing and Repair Organizations (API-510, Section 6.6) 2. Types and Definitions of Maintenance Inspection ) Internal inspection (API 510, 64) 1) Defect Inspection (API-SI0, 55) 1) Inspection of Parts (API-SI0,5.6) ‘h) Extemal Inspection & Buried Vessels (API 510, 6:3) 3) Atmospheric Corrosion and Corrosion Under Insulation (API-510, 63) 4) On-Stream Inspection (API-SI0, 3.11 & 64) Visual Examination (API-S10, 55) 1) Thickness Measurements (API-510,53,5:7,63 & 64) re) Nondestructive Examination (API-510,5.5 & 57) 1) Assessment of Inspection Findings (5.8) 3. Welding on Pressure Vessels ‘Welding Inspection Requirements (API-S10, 568 72) 44, Corrosion and Minimum Thickness Evaluation ‘The inspector should have a general knowledge of the following principles, and may be required to make calculations using these principles. 2) Corrosion Rate Determination (API 510, 5.3) ) Corrosion Averaging (API 510, 5.7) 4) Widely Scattered Piting (API 510, 5.7) ') Surfaces Remote From a Weld (API, 5.7) 8) Corrosion in Central Portion of Dished Heads (API 510, 5.7)5. Estimated Remaining Life Remaining Life = Comrasion Allowance (CA) (API10, 63) Corrosion rate CA-= Actual Thickness Minus Required Thickness Corrosion Rate = Metal Loss Time Metal Loss = Previous or Initial Thickness Minus Present Thickness depending on whether corrosion rate is short or tong term ‘Time = Time Period Between Inspections 6. Inspection Interval Determination and Issues Affecting Intervals ')_Imemal or On-Stream Inspection Intervals (API S10, 6.4) Internal and On-stream inspection Intervals for Estimated Life (API 510, 6.4) ¥)_Extemal Inspection Intervals ((API-SI0,6.1-63) \W) Deterioration Other Than Meta Loss (API 510, 5.2) x) Different Zones of a Vessel (API 510, 6.4) ¥) Change of Service Conditions (API S10, 64) 2) Change in Location and Ownership (API 51 64) 7. Relief Devices aa) Repair Organizations (API-510, Section 6.6) bbb) Minimum Requirements for Quality Control Systems (API 510, 6.6) ec) Maximum Service Intervals (API-S10, 6.6) 8. Maintenance Inspection Safety Practices 1, Pressure Vessel Inspection (API-510, Section 5.1) 9. Inspection Records and Reports ‘8. Permanent and Progressive Inspection Records (API-510, 67) 10. Repairs, and Alterations, to Pressure Vessels. dd) Authorization (API-S10, 7.1.1) ee) Approval (API 510, 7.1.2) Design Requirements (API $10, 7.2.7) 18g) Materials Requirements (API 510, 7.2.8) hhh) Welding Requirements (API $10, 72.1, 72.2, 723,726, &72.11) ii) Heat Treating Requirements, including ‘© Preheating (API S10, 7.23) ‘© Post weld Heat Treating (API 510, 72.3) ‘© Local Postweld Heat treatment (API 510, 7.2.5) a) Repairs to Stainless Stel Weld Overlay and Cladding (API 510, 72.6) ) Inspection (API 510, 729) ©) Rerating of Pressure Vessels (API 510, 7.3) ) Pressure Testing After Repairs, Alterations or Rerating (API-S10, 6.5 and 7.2.10) ©) Nondestructive Examination of Welds (API S10, 72.4)APLRP-572, Inspection of Pressure Vessels |. Types and Definitions of Maintenance Inspections £) Types of Pressure Vessels (API RP-S72, Section 4) 8) Construction Standards (API RP-572, Section 5) fh) Maintenance Inspection (API RP-572, Section 6) {Reasons for Inspection (API RP-572, Section 7) 4) Causes of Deterioration (API RP-572, 8.1 ~ 8.10) k)_ Frequency and Time of Inspection (API RP-572, Section 9) 1) Inmemal Inspection (API RP-572, 10.8) 1m) External Inspection, Typical Items Checked (API RP-572, 10:3) 1) Visual Examination (API-RP-572, Section 10) (0). Thickness Measurements and Limits (API RP-S72, Section 10) ) Nondestructive Examination (API RP-572, Section 10) 4) Repair Methods (API RP-S72, Section 11) 2. Pressure Vessel Materials and Fabrication Problems Material and Fabrication Problems (API RP-S72, 84 & 85) 3. Maintenance Inspection Safety Practices Pressure Vessel Inspection (APIRP-S72, 102) 2. Inspection Records and Reports (API RP-S72, Section 12) 1. Relief Devices 8) Description of Types ~ General Knowledge of Application and Limitations (API RP-576, Section 2) 'b) Causes of Improper Performance (API RP-576, Section 4) €) Reasons for Inspection and Frequency Determination (API RP 576, Sections 3 & 5) 4) Inspection and Test Service Procedures (API RP-576, Sections 6 and 7) ) Maintenance Inspection Safery Practices (API RP 576, Section 6) {Inspection Records and Reports (API RP-576, Section 8) ter IL, API Guide for Inspection of i rioration Failures Note: The above reference applies to refinery equipment other than pressure vessels (e.g. piping, heaters, and tanks. Only portions applicable to pressure vessels will be covered on the examination, 1. Types of Process Corrosion and Deterioration 8) Corrosive Components of Crude Oils (API IRE, Chapter Il, Section 202.02) b) Corrosion By Other Process Fluids (API IRE, Chapter Il, Sestioy 202.03) ©) Deterioration Due To Hydrogen (APIIRE, Chapter Il, 202.03 4) Stress Corrosion Cracking (API IRE, Chapter Il, 202.064) ) Atmospheric Corrosion and Corrosion Under Insulation (API [RE, Chapter Il, 202.04) 1) Erosion and Erosion-Comrosion (API IRE, Chapter Il, 203) 8) Corrosion by Waters (API IRE, Chapter Il, 202.025)‘h) Other Types of Corrosion (API IRE, Chapter Il, Section 202.06)2. Modes of Mechanical, Thermal, and High Temperature Deterioration 2) Mechanical and Thermal Problems (API IRE, Chapter Il, 205-208) 'b) High Temperature Problems (APLIRE, Chapter Il, Section 204) 3. Pressure Vessel Materials and Fabrication Problems a) Faulty Material and Equipment (APIIRE, Chapter If, Section 210) ) Known Problems Associated With Design and Fabrication (API IRE, Chapter Il, 210.02)19 a API RECOMMENDED PRACTICE 576 SECOND EDITION, DECEMBER 2000 REVIEW QUESTIONS Section 1 - General 1. What is the general scope of API RPS76? a ‘To describe inspection and repair practices for automatic pressure-relieving devices commonly used in the oil and petrochemical industries. Section 2 - References 2. What document should be referenced to determine the appropriate size for a pressure relief device? @ ‘+ RF 52q Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries Section 3 - Definitions 3. Describe a pin-actuated device @.13) + Anon-reclosing pressure relief device actuated by static pressure and designed to function by ‘buckling or breaking a pin, which holds a piston or plug in place. 4. What isa huddling chamber? 3.22) ‘+ Anannular pressure chamber located downstream of the seat of a pressure relief valve for the purpose of assisting the valve in lifting. 5. Describe “rated relieving capacity”. 6.3.6) ‘+ The relieving capacity used as the basis for the application of a pressure vessel relief device determined using the applicable code or regulation. ~ _ Section 4 ~ Pressure-Relieving Devices 6. What is the function of pressure-relieving devices? > 40) ‘+ Toprotect refinery equipment and personnel by automatically opening at predetermined pressures 7. Name common examples of pressure relieving devices. 4) Direct spring loaded Pilot PRV Rupture disks Weight loaded devices Pressure/Vacuum vent valves 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC20 8, Name the five types of pressure relief valves. (4.2,43,44, 4.6, 4.7) 7 Safety valve Relief valve Safety relief valve Balanced Safety Relief Valve Pilot-operated safety relief valve 9. Describe a safety valve. (4.2\Section VIII UG-126 foot notes) + Actuated by static pressure upstream of a valve + Spring fully exposed outside casing to protect from escaping steam. + Normally not pressure tight on their downstream side. 10. Safety valves should not be used in what situations? (4.2.2) ‘+ Cortosive refinery services. + Any back pressure service. ‘+ Where discharge is piped to remote locations, ‘+ Where escape of lading fluid around blowing valves is not desirable * Inliquid service ‘* As pressure control or bypass valves. 11. Describe a relief valve. (4.3) Section VIII UG-126 foot notes) ‘© Actuated by static pressure upstream of a valve. ‘+ Lifts in proportion to the increase in pressure. ‘© Usually reaches full lift at either 10% or 25% overpressure. 12, Why do relief valves have closed bonnets? (43) ‘© Toprevent the release of corrosive, toxic, flammable or expensive fluids. 13. Relief valves should not be used in what situations? (43.2) + In steam, air, gas, or vapor service. ‘ _Inservices piped to an enclosed header unless the effects of any constant or variable backpressure hhave been accounted for. ‘* As pressure control or bypass valves. 14, There are two types of safety relief valves. What are these two types? 45,4.) ‘* Conventional & Balanced 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC(45.1) 17, (45.2) 18, 46) 19. (46.1) 20. 21 5. Describe a conventional safety relief valve. Opening pressure, closing pressure and relieving capacity are affected by back pressure. Has a closed bonnet ‘The bonnet cavity is vented to the downstream side, 3. Where are conventional safety relief valves used? Refinery process industries that handle flammable, hot, or toxic materials. May a conventional safety relief valve be used on boiler steam drums or super heaters? No Describe a balanced safety relief valve. Balanced safety relief valves are direct spring loaded and incorporate a bellows or other means to minimize the effects of backpressure. ‘What are the proper applications for these pressure balanced safety relief devices: Balance safety relief valves are normally used in applications with flammable, hot or toxic materials, where high pressures are present a the discharge ofthe valve. ‘What is a pilot-operated safety relief valve? (4.7)Section VIII UG-126 foot notes) 21 47.) (4.72) A pressure-relief valve in which the major relieving device is combined with and is controlled by a self-actuated pressure relief valve (called a pilot valve). ‘What are some applications of pilot-operated safety relief valves? Where a large relief area and/or a high pressure is required Where a low differential exists between normal vessel pressure and set pressure of valves. On large low-pressure storage tanks (See API Std 620). Where very short blow down required. Where back pressure is very high and a balanced design is require. ‘Where the process requires the sensing of pressure at one location and the relief of fluid at another. Where inlet and outlet fictional losses are high Where in-situ, in-service, set pressure verification is desired. Name some limitations on the use of pilot-operated safety relief valves. Where fluids are dirty. Thick or viscous fluid service. With vapors which polymerize in the valve. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC22 23, What are the three basic categories of pressure and/or vacuum vent valves? (48) ‘Weight-loaded pallet vent valve Pilot operated vent valve Spring and weight-loaded vent valve 24, What are the applications and limitations of pressure and/or vacuum vent valves? (4.8.1 and 2 ‘+ They are designed to protect atmospheric and low pressure storage tanks and are not generally used in applications requiring set pressures above 15 Ibfin® 25. Describe the parts of a Rupture Disk Device. 49) ‘+The combination of a rupture disk and rupture disk holder is known as a rupture disk device, 26. Name the types of rupture disks. 49) * Conventional Rupture Disk. ‘Scored Tension-Loaded Rupture Disk. + Composite Rupture disk. * Reverse-Acting Rupture Disk. + Graphite Rupture Disk. 27. What is one advantage of the graphite disk over metal disks? (49.1.5) + High corrosion resistance 28, What is usually the service life of pre-bulged metal rupture disks installed so that pressure acts against the concave side? (493) ‘© One year - If not replaced periodically they can rupture under normal pressures without warning. 29. Normally the operating pressure of a system protected by a pre-bulged rupture disk is from 65% to 85% of the disk’s predetermined bursting pressure. What determines this pressure range? (493) + The exact percentage depends on the disk’s type. 30, What precaution should be taken when a rupture disk is used in combination with another relief device and removed for any reason and will be reused? (493) ‘© They should be handled with care to avoid damage which might cause premature rupture. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC23 Section 5 - Causes of improper Performance 31. What is the basic cause of many the difficulties encountered with pressure relief devices? (Sl) © Corrosion > 52. whateffectcan the severe over sizing of a relief valve have? (2) 6) © Damaged valve seats 33. List the major causes of improper performance in pressure-relieving devices. Corrosion Damaged seating surfaces Failed springs Improper seating & adjustments Plugging and sticking Misapplication of materials Improper location, history, or identification Rough handling Improper differential between operating and set pressures Improper piping test procedures 34. To prevent leakage of the lading fluid, what must be maintained in the flamess of seating surfaces on pressure relief valves? (5.2) ‘© An optical precision on the order of 3 light beads/bands. 35. What are some reasons for damaged valve seats? (5.2) Corrosion Foreign particles getting into valve Improper or lengthy piping to the valve inlet or obstructions in the line. Careless handling during maintenance. Leakage past the seating surfaces of a valve after it has been installed. Improper blow down ring settings. Severe over sizing. 36. What almost always causes broken springs in pressure relief valves? (3) + Corrosion (Note: two types - surface & stress) 37. What chemical frequently causes stress-corrosion spring failure in petrochemical plants? 63) ‘© Hydrogen sulfide (#28) 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC38. (53) 39, (5.4) 40. (5.5) al. 6.6) (58.1) 48. (682) 44, (583) 4s. (5.10) 24 ‘What may be done to prevent spring failure due to corrosion? Spring material which can resist the action of the corrosive agent. Spring isolated by a bellows. Spring coated by a coating that can withstand the operating temperature and environment. ‘What medium should be used to set the following pressure relief devices? Safety relief valve - air or other gas. Vapor service valve ~ air or inert gas. ‘Steam service valves ~ steam but air may be used if suitable corrections are applied. Liquid service valves - water. ‘What is recommended for lubricating siding parts and threads on valves to prevent fouling? Valve parts should be lubricated with a material that is compatible with the service and temperature. In general, what should be considered in determining the material to be used for pressure-relieving devices? Temperature Pressure Corrosion resistance requirements Atmospheric conditions .. Why should relief valves be shipped in an upright position? ‘When relief valves are laid on their sides, the springs may not exert the same force all around the seating surface. ‘What is one important aspect of the work done to PRDs in the maintenance shop? Rough handling should be avoided such as the application of excessive backpressure to bellows type valves, IERV inlets and outlets are not covered during shipment what provisions should be made? Provision should be made for such covering during all furure shipments. ‘What risks are incurred when a hydrostatic test of discharge piping for a PRD is performed? ‘The disk, spring and body area on the discharge side of valve can be fouled. ‘The bellows of a balanced relief valve can be damaged by excessive back pressure. ‘The dome area and/or the pilot assembly of a pilot-operated pressure RV are fouled and damaged by the back flow of the fluid. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC25 Section 6 — Inspection and Testing 46, ) 47. (6.2) (62.1) 49. (623) (624) 5 (62.5 52, (62.6) 33. (62.6) [Name two types of inspections. Shop inspections/ overhauls and visual on-stream inspections. When a relief valve is removed for inspection or overhauls what additional inspection should be made? Inlet and outlet piping should be inspected for internal deposits and records made of their conditions. ‘After a PRV has been reinstalled what should be checked? ‘After reinstalling the related piping should be checked to ensure that itis not imposing loads that ‘would cause problems with the pressure relief valve’s body such as distortion leading to in-service leakage. A complete operating history of each pressure relief valve should be maintained and should include what? Information on upsets and their effects on the valve. ‘The extent of any leakage that has occurred in operation, Any other evidence of malfunctioning. When a relief device is removed from a system that is in operation, name a necessary step to prevent an unexpected pressure release. ‘The space between the relief valve and the adjacent block valve should be vented to release all pressure. ‘What must be done to valves in hydrofluoric acid service as soon as they are removed? ‘They must be correctly neutralized immediately after removal. Since inspection of RV piping cannot be done when removing the valve while the system is in service what alternative inspection can be done to check for line any major blockage or fouling? Radiographic Inspection. ‘What can visual inspection of the piping after the removal of a PRD indicate? ‘The condition of the process jing whose interior is not visible. 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC26 54, Why should caution be used with the rigging to remove a large PRD for maintenance? (62.7) - ‘+ Prevent auxiliary piping and pilot assemblies from being damaged. 55. Prior to performing the as received pop test on a PRD what should be inspected and checked? (628) Check that the seals ae intact on the pressure set screw and the blow down ring screw cover. 56, When may the as received pop pressure test be waived by the owner/user? (6.2.8) + When the valve is extremely fouled and the test may damage the valve. 57. When unusual corrosion, deposits, or conditions are noted upon receipt of a PRD at the shop what should be done? (629) ‘+ The inspector should participate in the shop inspection of the PRD. 58. When is it not necessary to disassemble at PRD at the shop? (6.2.10) ‘© Ifthe valve has been tested atthe appropriate API 510 interval and the as received pop test shows the valve to be operating properly disassembly is not mandatory. 59, List at least four ofthe steps in the inspection of a relief valve upon disassembly. (62.11) ‘+ Measure each part’s dimensions. ‘+ Check components for wear or corrosion. Seating surfaces should be checked for roughness or damage. ‘+ Springs should be checked for cracking. 60. During re-assembly of a pressure relief valve what should never be done? (62.12) ‘© The nozzle and seating surfaces should never be oiled. 61. After re-assembly of a relief device how should any blow down rings be set? (62.13) + Inaccordance with the manufacturer's recommendations. 62, Why do some manufactures recommend at least three pop tests before releasing a relief device for installation? (62.14) ‘© It is believed that the first pop test helps to align all of the components and that the successive tests verify the actual set pressure. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC27 63, Once the valve is set to pop at its CDTP (cold differential test pressure) it should be checked for 2 (62.15) — ero ‘+ Leakage and seat tightness by increasing the pressure on the test block to 90% of the CDTP.. (64, When applying the hydraulic test method to ASME Section VIII pressure relief valves while on ‘equipment, what precautions should be taken? (62.17) ‘+ The potential for failure of the rupture disk in diskirelief valve combinations. Possible introduction of foreign material into the valve seat are from popping. Possible release of process material to the atmosphere. 65. May a pilot operated pressure relief valve be tested in place if no block valve exists beneath it? (6.2.19) * No, it may be inspected and repaired only while the vessel is out of service. (66. Where is a weight loaded pressure and/or a vacuum vent used? (6.2.20) © Onpressure storage tanks. 67. What type of failure are pressure and/or vacuum vent valves prone to? (6.2.20) © Sticking. 68. Is it permissible to reinstall a rupture disk once it has been unbolted and removed from its holder? 2.21) ‘+ No, it may not be possible to get.a tight seal and unreliable performance is probable. 69. What are the objectives ofa visual on-stream inspection of relief devices? (63) ‘© Make sure the correct device is installed, that the correct pressure can be determined, that there are not any blinds or gags installed, thatthe seals are intact and that the valve is not leaking. Also bellows if so equipped are connected and clear and vent piping is routed to a safe location. Any upstream or downstream block valves are sealed or chained in the proper position. That discharge ing is supported, valve body drains and vent stacks are open, any required lifting lever is present and properly positioned. Any heat tracing or insulation required isin good condition and operational and if a rupture disk is installed itis properly oriented. 70. API510 establishes the maximum interval between device inspections or tests of 10 years, what else should be considered when setting the frequency of inspection and testing? (6.4) ‘* The performance of the device in a particular servi 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC28 71. How is the frequency of shop inspection or overhaul normally determined? (64.1.1) + By the operating experience in the valve’s present service, corrosion service would be more frequent for example. Section 7- Records and Reports 72. What is the principal objective in keeping records on pressure-relieving devices? 7.) © Tomake available the information needed to ensure the performance of the devices meets the ‘requirements of their various installations. 73, What should the record for a pressure-reliving device include? (7.2) ‘+ Its specification data and a continuously accumulating record of it tests and inspections results. 74, Which of the following per API 576 might be expected to initiate a work request on a PRD? The API inspector or the Process Unit Operator? (73) * Process Unit Operator 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC29 API RECOMMENDED PRACTICE 572 SECOND EDITION, FEBRUARY 2001 REVIEW QUESTIONS Section 1 - General 1. What are the main points covered in API RP $72? (aa Descriptions of the various types of pressure vessels. Standards for construction. Reasons for inspection. ‘Causes of deterioration. Frequency & methods of inspection. Methods of repair. Preparation of records and reports. Sections 3, 4, 5 and 6 contain duplicate information to that found in the API 510. You should still read these sections however, at least once. Section 7 - Reasons for Insp 2. What are the basic reasons for inspection? ay ‘+ To determine the physical condition ofthe vessel + Determine the type, rate and causes of deterioration. 3._List atleast four additonal reasons for inspections. 7.172) ‘+ Safety maintained ‘+ Periods of operation without shutdown extended - well planned maintenance program ‘+ Rate of deterioration often reduced ‘+ Future repair and replacement requirements estimated Section 8 - Causes of Deterioration 4. List the 4 general forms of deterioration. (8.1) Electrochemical Chemical Mechanical © Combination of all three 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC(8.22) 30 List the 4 general classifications of things that cause deterioration upon coming into contact with a vessel surface, Organic & inorganic compounds Contaminated or freshwater Steam Atmosphere [Name 6 factors, which accelerate the rate of deterioration. Temperature Stress Fatigue Impingement High velocity Irregularity of flow ‘What is the prime cause of deterioration in a pressure vessel? Corrosion ‘What are the most common internal corrodents in refineries? Sulfur Salt(Chloride compounds Define erosion. The removal of surface material caused by numerous individual impacts of solid or liquid particles or cavitation. ). Erosion is typically found where in a vessel? Downstream of control valves Downstream of orifices Downstream of pump discharges Atany point of flow direction change, such as impingement baffles. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC31 11, Problems with environmental cracking have been experienced of high hardness, areas of high stress or both. Examples of this include (823) Chloride stress corrosion cracking of austenitic stainless steels due to moisture under insulation, Polythionic acid stress corrosion cracking (PSCC) Caustic stress corrosion also know as caustic embrittlement ‘Amine stress corrosion cracking in non-stress relieved vessels. Carbonate stress corrosion cracking in alkaline systems. Wet hydrogen sulfide stress cracking, hydrogen induced cracking, and hydrogen blistering. . Corrosion beneath refractory linings can cause what? * Bulging of the refractory 13, What does fatigue cracking in a vessel result from? + Excessive cyclic stresses the are often below the yield strength of the material such as; + Pressure stresses ‘+ Mechanical stresses © Thermal stresses 14, Creep damage may be dfflelt to detect until ‘+ Significant damage has oocured > 15. What factor increases susceptibility to high temperature hydrogen attack in a vessels material © Increasing carbon content of the materials 7 In the absence of | , sulfide corrosion rates of are relatively low at metal temperatures below + Water + 450°F 17, When buried vessels ate equipped with adequate cathodic protection when will excavation be required for inspection? 629) + Whenevidence of coating or wrapping damage is revealed txtatraale G-(2 LAP 18, What are the most important microorganisms tha directly influences the rate of metallic corrosion? (82.10) ‘Sulfate reducing bacteria found in may soils 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC19. (837) 20. (8.5) 2 (85.1) 2. (852) 2s. (855) 32 ‘What causes titanium alloys to lose ductility? Absorption of hydrogen Many of the problems that may develop in pressure vessels are traceable to what? Faulty material or fabrication Poor welding, improper heat treatment, fabrication with dimensions outside tolerances allowed by ASME Code, improper installation of internal equipment, and assembly of flanged or threaded joints are examples of what problem? Faulty fabrication List several consequences of improper welding techniques. Incomplete penetration Lack of fusion Cracking Undereutting Slag inclusion Porous welds . High residual stresses near welds affecting the physical properties and corrosion resistance of the ‘metal is caused by what? Improper heat treatment |. Dimensional intolerance can lead to what? ‘Stress concentrations and subsequent failures ‘What are the consequences of improper installation of internal equipment? Inefficient operation Blockage of passages Displacement of internal equipment with pressure surges 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO TTAC33 26, Improper fitting or tightening of flanges or threaded joints may lead to what? (85.6) © Leaks and possible failure Section 9 — Frequency and Time of Inspection 27. What are the important factors when determining the frequency with which a pressure vessel should be inspected? © The rate of deterioration © The remaining corrosion allowance 28. What event can provide and opportunity for an inspection? (92) + Anunscheduled shutdown 29, What occasional check may locate the cause of functional deterioration? (9.2) © Acheck of a vessel's operating record 30. What are the most important issues when scheduling a unit for inspections? (9.3) © Safety and reliability Section 10 Inspection Methods and Limitations 31. Before starting inspection of a pressure vessel, what are some basic things the inspector should do? (10.1) + Determine pressure and temperature conditions under which the vessel has operated since last inspection + Ascertain the character ofthe vessel contents and the function the vessel serves inthe process 32, Name at least 8 types of tools required by an inspector to inspect a pressure vessel. (10.2.2) Portable lights Thin bladed knife Broad chisel or scraper Mirrors Calipers Steel tape measure(50 feet) Hammer Notebooks and pencils 33." Where should the external inspection start? (103.2) ‘+ Extemal inspection should start with ladders, stairways, platforms, or walkways connected to or bearing on the vessel. The condition of most parts can be determined by hammering 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC34 34. What are most foundations constructed of? (103.3) + Foundations for vessels are almost always constructed of steel-einforced concrete structural steel fireproofed with concrete. 35. Cracks in concrete or fireproofing may be caused by what? (10.3.3) + Excessive heat ‘* Mechanical shock * Corrosion of reinforcing steel «Freezing of entrapped moisture 36. What types of vessels are most likely to experience uneven settling of their foundations? (103.3) ‘+ Vessels supported on long concrete slabs or on two or more separate foundations. "37. What is the proper way to check an anchor bolt ona piece of equipment for deterioration below the base plate? (103.4) + Assideways blow with a hammer 38. Often corrosion of structural elements can be virtually eliminated by a simple procedure, which is? (103.6) ‘+ Proper painting, 39. A bulge in fireproofing is noted on steel structural member, what does that indicate? (103.6) ‘© Corrosion beneath the fireproofing is present. 40. The inside surface of a skirt is may be subject to corrosion, below what temperature is this likely? (103.6) + 100°F 41. What should you inspect guy wires for? 03.7) ‘+ Tightness and correct tension - a visual inspection should be sufficient. 42. What type of corrosion are turnbuckles subject to? (203.7) © Crevice corrosion 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC35 43, If settling of a vessel has occurred, what should be checked for distortion and cracks? (03.8 © Nozzles. 44, What is the recommended resistance for grounding connections? (103.9) ‘© Scohms or less, not to exceed 25 ohms 45. Unchecked vibrations on auxiliary equipment such as gauge connectors can cause what type of failure? (103.10) © Fatigue failure 46, What type of inspection is usually sufficient for protective coatings and insulation? (103.11) © Visual 47. At what operating temperature does CUI become a concern on externally insulated vessels subject to moisture ingress? (103.11) + Between 25 to 250° F 48, What are the normally required measurements on external metal surfaces of a vessel?” (103.12) ‘© Under normal conditions, a least one gneasurement in each shell ring and one on each head. Ifno history exists for a vessel, then get a reading in each quadrant ofeach shell ring. 49. What types of corrosion are found on external surfaces of vessel? (103.13) + Atmospheric + Caustic Embrittlement + Hydrogen blistering + Soil corrosion 50. Vessels containing acidic corrodents are subject to hydrogen blistering. Where is this normally found in the vessel? (103.13) © Those areas below the liquid level in vessels containing acidic corrodents are more likely than other areas to be subject to hydrogen blistering. Blisters are normally on the inside, but can occur on the outside surface as well. * 51. What should a vessel be checked for if a caustic is stored in it? (103.13) ‘© Ifa caustic material is stored or used in a vessel, the vessel should be checked for caustic embrittlement, 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC36 —h 52. Evidence of white salts seeping through cracks will indicate what type of material? (103.13) © Caustic material 53. Unless readily visible, leaks are best found by what means? (003.13) ‘Pressure or Vacuum testing 54. Describe how you would determine the extent of bulging or buckling on a vessel in service. (103.13) ‘+ By measuring the changes in circumferences or by making profiles of the vessel wall. Profiles are rade by taking measurements from alin parallel to the vessel wall. A surveyors titra 18D degree gotical plumes may also be used 55. The degree of surface preparation needed for internal inspection will vary with several factors. Foremost among these are: (10.42) ‘© Type of deterioration expected ‘© Location of any deterioration °S6. Gracks'in vessels are most likely to occur where? (10.43) ‘+ Inplaces where there are sharp changes in shape or size or near welded seams, espe stress is applied. 57. What may preliminary inspections reveal? (1043) ‘© Unsafe conditions, such as those due to Idose internals that may fall or due to badly corroded or ‘broken intemal ladders or platforms. 58. A detailed inspection should start at one end of the vessel and work toward the other end and. include what? (10.4.4) ‘+A systematic procedure to avoid overlooking obscure but important items. 59. What should all parts of a vessel be inspected for? (10.4.4) © Corrosion © Erosion © Hydrogen blistering © Cracking © Laminations 60, Some times the depth ofa pit can be estimated by using what simple method? aoa) © Extending the lead of a mechanical pencil 08/02 Rev 8 FAST TRACK TECHNICAL - LICENSED TO ITAC37 61. What types of methods are used for determining the extent of cracks? (10.4.4) © Dye penetrant © Magnetic-particle (wet or dry) Ultrasonic shear-wave (62. Explain the difference in appearance between erosion and corrosion. (10.4.4) ‘+ Erosion is characterized by a smooth, bright appearance: marked by the absence of the erosion product; and metal loss, is usually confined to a clearly marked local area. ‘© Corroded areas are not often smooth or bright. 63. Shells and heads of vessels should be inspected for deformation. Which is more likely to suffer deformation? (8.4.4) © The shell ofa vessel 64, How do you check for (a) small distortions, (b) bulging or buckling (c) out-of:roundaess or bulging? (10.4.4) ‘+ Small distortions - by placing a straight edge against a vessel ‘+ Bulging/buckling - measuring the changes in circumference or by profile (measuring from a line strung parallel to the vessel). + Out-of round/bulge - by measuring the minimum and maximum internal deviation at the cross sectional area and comparing the two. 65. What is the best method of locating suspected deformations? (10.4.4) ‘+ Direct a flashlight beam parallel to the surface to check for shadows in depressions and on the non-light sides of internal bulges. ‘66. What is the most sensitive method of Incating surface cracking? (10.44) © Fhaorescent Magnetic Particle Method. - 67. What is the difference between cracks and laminations? 0.44) © Laminations run at a slant to the plate surface. © Cracks run at right angles to the surface. (68. Name three important factors in the inspection of metallic linings. (10.4.5) ‘+ That there is no corrosion. + That the linings are properly installed. ‘© Thatno holes or cracks exist. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC38 69. Explain how the Corrosive Tab Method is used to determine the metal foss on vessel linings. (10.45) ‘+ Small 1 by 2 inch tabs of lining that form a right angle are welded onto the lining with one leg ‘extended into the vessel. During inspections the thickness of the protruding leg is measured, and, since both sides of the leg are exposed to corrosive action, the loss in thickness would be twice that ofthe lining. 70. What is the principle method used to inspect nonmetallic linings like glass plastic, rubber, concrete, and carbon block or brick. (10.4.6) ‘+ For the most part all of the above will be visually inspected for discontinuities or physical damage. Specifi For paint, glass, plastic, & rubber lining the spark tester method is used to locate holidays. For concrete, brick, tile, or refractory lining the hammer testing method is used to locate lack of bond, 71. Name the factors to consider when selecting tools for thickness measurements. ~ (0.5) Accessibility from both sides. Desire for NDE methods. Accuracy desired. Time available. Economy 72. What is the primary means of obtaining thickness measurements? (10.5) © Ultrasonic instruments. 73. To analyze defects in welded seams that are not visible on the surface of the metal, what two ‘methods are used? (10.6) Radiography. ‘Shear-wave Ultrasonic. : 74, How does the Hammer Test function in supplementing visual examination of a vessel for the inspector? (10.8.1) ‘+ “Thin” - Locate thin sections in vessel walls, heads, and attachments. "Tightness"- Check for tightness of rivets, bolt, brackets, “Cracks and Lack of Bond" - Check for cracks in metalic linings and lack of bond in concrete linings. "Seale Remove scale accumulations for spot inspections. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC39 75. When is use of the Hammer Test not recommended? (10.8.1) + When vessels are under pressure. + Onpiping upstream from a catalyst bed. 76. What is pressure testing? (10.8.2) © Filling a vessel with liquid or gas and building up an internal pressure to a desired level 77. Which isthe preferred method, pressure or vacuum testing, and why? (10.8.2) ‘© Pressure testing. Leaks from an internal pressure source are more easily located. With vacuum testing you will know if there are leaks, but the location is not evident. ‘78. What should an inspector examine before applying test pressure to the shell side of an exchanger? (1083) ‘© He should inspect the tube walls to be sure there is sufficient wall thickness to withstand external pressure, 79, Inan exchanger where the cooling water is the lower pressure stream and 2 hydrocarbon is the higher pressure stream, what is a possible way to detect a leak? (10.8.3) ‘It may be possible to assess the hydrocarbon content upstream and downstream of the suspect exchanger. 80, Name the two most limits of corrosion or other deterioration that must be known by inspection. (10.9) ‘+The retiring thickness of the part considered. © The rate of deterioration, BI. Often vessels have excess thickness above that required for pressure. When taking credit for this excess thickness what must always be considered? (0.9) ‘+ Insome cases the excess thickness of the shell or head plates was used by the designer to ‘compensate for nozzle openings. 82. Before determining the limiting or retiring thicknesses of parts of any pressure vessel, what must bbe known? (10.9) Which Code and edition of that Code itis to be rated under. ‘Are there specific regulations regarding limits and allowable repairs. 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC40 Section 11 - Methods of Repair 83. When is it required that a repair concem making welded repairs to a vessel have a National Board Rstamp? qa) ‘+ When the jurisdiction dictates thatthe these repairs are to made by only R stamp holders 84. When is a pressure test of a vessel normally a requirement? ay + Afteran alteration Section 12 - Records and Reports 85. A complete record file should contain what three types of information? (2a) + Basic data — manufacturer's drawings, data reports and specifications, design information, results of any material tests. Fleld notes - notes and measurements recorded on site including record of condition of all parts inspected and repairs required. + Continuous file - all information on the vessel's operating history, previous inspections, corrosion rate tables, records of repairs and replacements 86. When making reports recommending repairs, who should receive these reports? (2.2) = Allmanagement groups. This would normally include engineering, operation, and maintenance departments. Reports should include the location, extent, and reasons for recommended repair. Appendix A - Exchangers 87. Why should bundles be checked when they are first pulled from the shells? (A9.1) + Thecolor, type, amount, and location of scales and deposits often help to pinpoint corrosion problems. ~ 88. A distinctive Prussian blue on bundle tubes indicates the presence of what? (92) © Ferriferrocyanide 89. Coils in open condenser boxes and double-pipe exchanger shells should be inspected according to what API Recommended Practice? (alo) = RPS74 08/02 Rev @ FAST TRACK TECHNICAL - LICENSED TO ITAC