BODY OF KNOWLEDGEAPI-570 PIPING INSPECTOR2

II. WELDING PROCEDURE AND QUALIFICATION EVALUATION

 

A. ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX
The inspector should have the knowledge and skills required to review a Procedure Qualification Record, Welding Procedure Specification and Welder Performance Qualification to determine the following:
 

  1. Determine if procedure and qualification records are in compliance with applicable ASME Boiler and Pressure Vessel Code and any additional requirements of API-570. The weld procedure review will include:
    • Weld Procedure Specification (WPS)
    • Procedure Qualification Record (PQR)
    • Welder Performance Qualification (WPQ)

 

  2. 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)
 

  3. Determine that the number and type of mechanical tests that are listed on PQR are the proper tests, and whether the results are acceptable.

 

  4. Determine that the welder is qualified to make a production weld according to the WPS
WELD PROCEDURE REVIEW MAY INCLUDE SMAW, GTAW, GMAW, OR SAW, WITH THE FOLLOWING LIMITATIONS:
    1. 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.
    2. Filler metals will be limited to one-per-process for SMAW, GTAW, GMAW, or SAW
    3. The PQR will be the supporting PQR for the WPS.
    4. The WPQ test coupon is to be welded in accordance with a qualified WPS.
    5. Base metals will be limited to P1, P3, P4, P5, and P8.
    6. Dissimilar base metal joints, and dissimilar thicknesses of base metals will be excluded.
    7. 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.
    8. 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.

 

B. ASME B31.3
The inspector should be familiar with and understand the general rules for welding in ASME B31.3, Chapter V such as:
  1. Typical joints and definitions
  2. Weld sizes
  3. Restrictions on joints
  4. Maximum allowable reinforcement
  5. Inspection requirements
  6. Preheating and Heat Treatment

 

C. API Standard 570
The inspector should be familiar with and understand any rules for welding in API-570. Any rules for welding given in API-570 shall take precedence over those covering the same areas in ASME, B31.3.
Note: "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 Authorized Piping Inspector should know that the PQR and WPQ must be signed and dated.

 

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

 

III. NONDESTRUCTIVE EXAMINATION

 

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

   1. Article 1, General Requirements:
The inspector should be familiar with and understand;
    a) The Scope of Section V
    b) Rules for use of Section V as a referenced Code
    c) Responsibilities of the Owner / User, and of subcontractors
    d) Calibration
    e) Definitions of "inspection" and examination"
    f) Record keeping requirements
 

   2. Article 2, Radiographic Examination:
The inspector should be familiar with and understand;
    a) The Scope of Article 2 and general requirements,
    b) The rules for radiography as typically applied on butt welded seams such as, but not limited to:
     • Required marking
     • Type, selection, number, and placement of IQI’s,
     • Allowable density and density ranges
     • Control of backscatter radiation
    c) Records
 

  3. Article 6, Liquid Penetrant Examination (Including mandatory appendices II and III):
The inspector should be familiar with and understand the general rules for applying and using the liquid penetrant method, including but not limited to the following:
    a) The Scope of Article 6,
    b) General requirements such as but not limited to:
     • Procedures
     • Contaminants
     • Techniques
     • Examination
     • Interpretation
     • Documentation and record keeping

 

  4. 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 including, but not limited to the following:
    a) The Scope of Article 7,
    b) General requirements such as but not limited to:
     • Procedures
     • Techniques (Yoke and Prod only)
     • Calibration
     • Examination
     • Interpretation
    c) Documentation and record keeping

 

  5. Article 9, Visual Examination:
The inspector should be familiar with and understand the general rules for applying and using the visual examination method including, but not limited to the following:
    a) The scope of Article 9,
    b) General requirements such as but not limited to:
     • Procedures
     • Physical requirements
     • Procedure/technique
     • Evaluation
    c) Documentation and record keeping

 

  6. Article 10, Leak Testing (Including Mandatory Appendix I Bubble Test –Direct Pressure Technique):
The inspector should be familiar with and understand the general rules for applying and using the leak testing method including, but not limited to the following:
    a) The scope of Article 10,
    b) General requirements such as but not limited to:
     • Procedures
     • Equipment
     • Calibration
     • Test
     • Evaluation
    c) Documentation and record keeping
 

 

  7. 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;
    a) The Scope of Article 23, Section SE-797,
    b) The general rules for applying and using the Ultrasonic method
    c) The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.

 

B. ASME B31.3 and API-570: General nondestructive examination requirements:
ASME B31.3: The inspector should be familiar with and understand the general rules for NDE (Chapter VI).
API Standard 570: The inspector should be familiar with and understand the general rules for NDE in API-570.

 

V. PRACTICAL KNOWLEDGE - SPECIFIC
  • API-570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems – the entire document is subject to testing
  • API RP 571, Damage mechanisms Affecting Fixed equipment in the Refining Industry
  • ATTN: Examination questions will be based on the following portions of the document only:

 

Section 3 – Definitions
  4.2.14 – Erosion/Erosion Corrosion
  4.2.16 – Mechanical Fatigue
  4.3.1 – Galvanic Corrosion
  4.3.2 – Atmospheric Corrosion
  4.3.3 – Corrosion Under Insulation (CUI)
  4.3.5 – Boiler Water Condensate Corrosion
  4.3.8 – Microbiological Induced Corrosion (MIC)
  4.3.9 – Soil 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 (Acidic)
  5.1.2.2 - Amine Stress Corrosion Cracking
   • API RP-574, Inspection of Piping, Tubing, Valves, and Fittings – the entire document is subject to testing
   • API RP 577, Welding Inspection and Metallurgy – the entire document is subject to testing
   • API Recommended Practice 578 – Material Verification program for New and Existing Alloy piping Systems-
   • the entire document is subject to testing
   • ASME B16.5, Pipe Flanges and Flanged Fittings
     o Scope
     o Pressure Temperature Ratings
     o Markings
     o Materials
     o Dimensions
     o Test
     o Limiting Dimensions of Gaskets
     o Methods for Establishing Pressure-Temperature Ratings