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 pressure loadings will be considered for the API 510 examination.
Note: Candidates are expected to understand the US customary units (inches, feet, PSI, etc.) and the SI units (metric system) and to use both system formulas.
The following categories describe the minimum necessary knowledge and skills:
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 510, 7.4)
b) Corrosion Rates (API 510, 7.1)
c) Remaining Corrosion Allowance (API 510, 7.1)
Remaining Corrosion Allowance = tactual – trequired
d) Remaining Service Life (API 510, 7.2)
e) Inspection Interval (API 510, Section 6)
The formulas for performing the above calculations and rules for setting the inspection intervals may be “closed-book” during the examination.
The inspector must be able to determine the joint efficiency “E” of a vessel weld. Inspector should be able to determine:
a) Weld Joint Categories (ASME Section VIII, UW-3);
b) Type of radiography (full, spot, or none) performed basis the nameplate markings (RT-1, RT-2, etc.); (UW-11)
c) Joint efficiency by reading Table UW-12;
d) Joint efficiency for seamless heads and vessels sections per UW-12(d); and
e) Joint efficiency for welded pipe and tubing per UW-12(e).
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.
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 (ASME Section VIII, UG-98)
c) Calculate static head pressure on any vessel part;
d) Calculate total pressure (MAWP + static head) on any vessel part;
e) Calculate maximum vessel MAWP given vessel parts MAWP and elevations
Static head calculations may also be required during the internal pressure calculations if static head data is given in the examination problem.
The inspector should be able to determine:
a) The required thickness of a cylindrical shell based on circumferential stress given a pressure (UG-27(c)(1));
b) The required thickness of a spherical shell based on circumferential stress given a pressure (UG-27(d))
c) The vessel part MAWP for a cylindrical shell based on circumferential stress given a metal thickness (UG27(c)(1));
d) The required thickness of a head (ellipsoidal, and hemispherical) given a pressure. (UG-32(c), and (e))
e) The vessel part MAWP for a head (ellipsoidal, and hemispherical) given a metal thickness. (UG-32(c), and (e)).
f) Whether a head (ellipsoidal or hemispherical) meets Code requirements given both pressure and metal thickness. (UG 32(c) and (e)).
The inspector should also be able to compensate for the corrosion allowance: add or subtract based on requirements of the examination problem. The Section VIII, Appendix 1 formula for cylinders, which is based on outside diameter, can be used.
The Appendix 1 formulas for non-standard heads will not be required.
The inspector should be knowledgeable of the rules for design of shells and tubes under external pressure (UG-28). The inspector will not be required to perform external pressure calculations.
The inspector should be able to:
a) Calculate a test pressure compensating for temperature. (UG-99 and UG-100)
b) Be familiar with the precautions associated with hydrostatic and pneumatic testing, such as minimum test temperatures, protection against overpressure etc.
c) Be familiar with all steps in a hydrotest procedure (UG-99 and UG-100)
d) Be familiar with all steps in a pneumatic test procedure (UG-100 and UG-102)
a) The inspector should understand impact testing requirements and impact testing procedure (UG-84)
b) The inspector should be able to determine the minimum metal temperature of a material which is exempt from impact testing (UG-20(f), UCS-66, UCS-68(c))
The inspector must be able to determine if weld sizes meet Code requirements. The inspector should be able to:
a) Convert a fillet weld throat dimension to leg dimension or vice versa, using conversion factor (0.7); and
b) Determine the required size of welds at opening (UW-16)
The inspector should understand the key concepts of reinforcement, such as replacement of strength removed and limits of reinforcement.
B. The following are typical ASME code engineering requirements that API certification candidates will NOT be expected to know for purposes of the certification examination.
1. Required thickness calculations for wind, earthquake, and other secondary stress loadings;
2. Supplementary design formulas and calculations for non-cylindrical shell components;
3. External pressure calculations (but should understand the rules governing external pressure noted in Section 5);
4. Nozzle calculations for external loads;
5. Flange calculations;
6. Brazing requirements;
7. Ligament calculations;
8. Stayed flat heads and sizing of stays;
9. 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 as they apply to alterations and repairs;
14. Zick analysis;
15. Integrally forged pressure components;
16. Cryogenic vessels (below -50°F);
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, ULW, ULT, UHX and UIG;
20. Code Cases and interpretations;
21. Requirements for pressure vessels for human occupancy; and
22. Rules for natural resource vessels, API 510, Section 9.
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 P-No. 1, P-No. 3, P-No. 4, P-No. 5, and P-No. 8.
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 P-No. 1, P-No. 3, P-No. 4, and P-No. 5, for the purpose of the examination the lower transition temperature will be 1330°F and the upper transformation temperature will be 1600°F.
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.
API RP 577: The inspector shall be familiar with all the requirements of and information in API RP 577.
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, 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.
The following topics may be covered in the examination. More information relative to each of the categories is contained in section.
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
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.
ATTN: Test questions will be based on the following portions of the document only:
Section 2 Terms and Definitions
3.3 Amine Stress Corrosion Cracking
3.8 Atmospheric Corrosion
3.11 Brittle Fracture
3.14 Caustic Corrosion
3.15 Caustic Stress Corrosion Cracking
3.17 Chloride Stress Corrosion Cracking
3.20 Cooling Water Corrosion
3.22 Corrosion Under Insulation (CUI)
3.27 Erosion/Erosion-Corrosion
3.36 High Temperature Hydrogen Attack
3.37 Hydrochloric Acid Corrosion
3.43 Mechanical Fatigue (including Vibration-induced Fatigue)
3.58 Sour Water Corrosion
3.61 Sulfidation
3.67 Wet H2S Damage (Blistering/HIC/SOHIC/SCC)
Entire document is subject to testing, including Annex B. All other Annexes are not subject to testing.
Entire document is subject to testing with the exception of annexes.
Entire document is subject to testing
Entire document is subject to testing
ATTN: Test questions will be based on the following portions of the document only:
Article 201: Butt-Welded Insert Plates in Pressure Components
Article 202: External Weld Buildup to Repair Internal Thinning
Article 209: Alternatives to Postweld Heat Treatment
Article 210: In-Service Welding Onto Carbon Steel Pressure Components or Pipelines
Article 211: Weld Buildup, Weld Overlay, and Clad Restoration
Article 212: Fillet Welded Patches
Article 215: Repair Welding Considerations for Cr-Mo Steel Pressure Vessels
Article 216: Welded Hot Taps in Pressure Equipment or Pipelines
Article 304: Flaw Excavation and Weld Repair
Article 305: Flange Repair and Conversion
Article 312: Inspection and Repair of Shell and Tube Heat Exchangers
Article 501: Pressure and Tightness of Piping and Equipment
Article 502: Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alternations
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