BODY OF KNOWLEDGE API-510 PRESSURE VESSEL INSPECTOR 2

II. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX

 

WELD PROCEDURE REVIEW

 

The inspector should have the knowledge and skills required to review a Procedure Qualification Record, a Welding Procedure Specification and a Welder Performance Qualification to be able to determine the following:

 

           a) Determine if procedure and qualification records are in compliance with applicable ASME Boiler and

             Pressure Vessel Code and any additional requirements of API- 510

             The weld procedure review will include:
             • Weld Procedure Specification (WPS)
             • Procedure Qualification Record (PQR)
             • Welder Performance Qualification (WPQ)
            b) Determine if all required essential and non-essential variables have been properly addressed.

             (Supplemental essential variables will not be a part of the WPS/PQR)
            c) Determine that the number and type of mechanical tests that are listed on PQR are the proper tests, and

              whether the results are acceptable.
            d) Determine that the welder is qualified to make a production weld according to the WPS

 

WELD PROCEDURE REVIEW WILL ONLY INCLUDE SMAW, GTAW, GMAW, OR SAW, WITH THE FOLLOWING LIMITATIONS:
            a) No more than one process will be included on a single WPS,PQR or WPQ and the WPS to be reviewed

             will be supported by a single PQR.
            b) Filler metals will be limited to one-per-process for SMAW, GTAW, GMAW, or SAW
            c) The PQR will be the supporting PQR for the WPS.
            d) The WPQ test coupon is to be welded in accordance with a qualified WPS.
            e) Base metals will be limited to P1, P3, P4, P5, and P8.
            f) Dissimilar base metal joints, and dissimilar thicknesses of base metals will be excluded.
            g) Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and dissimilar

             metal welds with buttering of ferritic member will be excluded.
            h) For P1, P3, P4, and P5, for the purpose of the examination the lower transition temperature will be 1330°

             F and the upper transformation temperature will be 1600°F.

 

ASME Section VIII, Div. 1 and API-510: GENERAL WELDING REQUIREMENTS:
 

1. ASME Section VIII, 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:
         a) Typical joints and definitions
         b) Weld sizes
         c) Restrictions on joints
         d) Maximum allowable reinforcement
         e) Inspection requirements
         f) Heat treatment

 

2. API 510 The inspector should be familiar with and understand any rules for welding in API 510. Any rules for welding given in API 510 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 is to 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 and WPQ must be certified by signing and dating.

 

The inspector shall be familiar with all the requirements of and information in API RP 577.

 

III. NONDESTRUCTIVE EXAMINATION

 

ASME Section V, Nondestructive Examination
    NOTE: The examination will cover ONLY the main body of each referenced Article, except as noted
    

   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:
            a) Required marking
            b) Type, selection, number, and placement of IQI’s,
            c) Allowable density
            d) Control of backscatter radiation
            e) Location markers
       3. Records

 

  C. Article 6, Liquid Penetrant Examination, including Mandatory Appendices II and III: The inspector should be

   familiar with and understand:
    1. 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) Record keeping
 

  D. 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:
      a. Procedures
      b. Techniques (Yoke and Prod only)
      c. Calibration
      d. Examination
      e. Interpretation
      f. Documentation and record keeping

 

  E. Article 23, Ultrasonic Standards, Section SE–797 only – Standard practice for measuring thickness by manual

  ultrasonic pulse-echo contact method: The inspector should be familiar with and understand;

    1. The Scope of Article 23, Section SE-797,
    2. The general rules for applying and using the Ultrasonic method
    3. The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.

 

ASME Section VIII, Div. 1 and API 510. General nondestructive examination requirements: ASME Section VIII, Div.
The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4, 6, 8, and 12)

 

API 510: The inspector should be familiar with and understand the general rules for NDE in API-510.

 

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.
  11. 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

 

VI. PRACTICAL KNOWLEDGE - SPECIFIC

 

API-510, Pressure Vessel Inspection Code
All of API 510 is applicable to the examination unless specifically excluded. For example: Section 9 and Appendix E are excluded.

 

API RP 571, Damage Mechanisms Affecting Fixed equipment in the Refining Industry
  ATTN: Test questions will be based on the following portions of the document only:
   Section 3 - Definitions
     4.2.7 – Brittle Fracture
     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
     4.3.10 – Caustic Corrosion
     4.4.2 – Sulfidation
     4.5.1 – Chloride Stress Corrosion Cracking (Cl-SCC)
     4.5.3 – Caustic Stress Corrosion Cracking (Caustic Embrittlement)
     5.1.1.4 – Hydrochloric Acid (HCl) Corrosion
     5.1.1.10 --Sour Water Corrosion
     5.1.2.2 – Amine Stress Corrosion Cracking
     5.1.2.3 – Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
     5.1.3.1 – High Temperature Hydrogen Attack (HTHA)

 

API RP-572, Inspection of Pressure Vessels – Entire document is subject to testing, including Annex B. All other Annexes are not subject to testing.

 

API RP 576, Inspection of Pressure-Relieving Devices - Entire document is subject to testing with the exception of annexes

 

API RP 577, Welding Inspection and Metallurgy – Entire document is subject to testing