1. CORROSION RATES AND INSPECTION INTERVALS

The Inspector should be able to understand inspection data and determine the thickness measurement and visual external inspection intervals.

The Inspector must be able to calculate:

a) Corrosion Rates (API 570, 7.1.2)

b) Remaining Life (API 570, 7.2)

c) Inspection Interval (API 570, 6.3.3 & Table 1)

The formulas for performing the above calculations and rules for setting the inspection intervals may be “closed-book” during the exam.

2. WELD JOINT QUALITY FACTORS AND CASTING QUALITY FACTORS

The inspector should be able to determine the weld joint quality factor “Ej” of a longitudinal pipe weld joint. The inspector should be able to determine:

a) Casting Quality factor, Ec from ASME B31.3, 302.3.3(b) and Table A-1A

b) Weld Joint Quality factors from ASME B31.3, 302.3.4 and Table A-1B;

c) Increased Joint Quality Factors by performing supplemental NDE from ASME B31.3, Table 302.3.4;

Determining weld joint quality factor may be part of an internal pressure problem since the joint factor Ej is used in the formulas for determining required thickness or internal design pressure.

3. INTERNAL PRESSURE / MINIMUM THICKNESS OF PIPE

The inspector should be able to determine:

a) The minimum required thickness or pressure design thickness of a straight pipe section for internal pressure only (ASME B31.3, 304.1.1 and 304.1.2);

b) The minimum required thickness of a permanent blank for a given design pressure (ASME B31.3, 304.5.3);

c) The “MAWP” of corroded pipe, compensating for expected corrosion loss at the next inspection (API 570, 7.5)

The inspector should also be able to compensate for the corrosion allowance. (Add or subtract based on requirements from the exam problem).

4. PRESSURE TESTING

The inspector should be able to:

a) Demonstrate knowledge concerning hydrostatic leak testing (ASME B31.3, 345.4)

b) Demonstrate knowledge concerning pneumatic leak testing (ASME B31.3, 345.5)

c) Calculate a hydrostatic or pneumatic leak test pressure (ASME B31.3, 345.4 and 345.5)

5. IMPACT TESTING

The inspector should be able to:

a) Determine the minimum metal temperature of a material, which is exempt from impact testing (ASME B31.3, 323.2.2, Figure 323.2.2A and Table A-1).

b) Determine the minimum required Charpy V-notch impact values of a given material. (ASME B31.3, 323.3 and Table 323.3.5)

6. PREHEATING AND HEAT TREATMENT REQUIREMENTS

The inspector should be able to determine which weld sizes require preheating and/or heat treatment.

The inspector also should be able to determine what is the required or recommended preheat temperature (ASME B31.3, 330 and Table 330.1.1).

7. THERMAL EXPANSION

The inspector should be able to determine the total thermal expansion of a material between temperatures (ASME B31.3, Appendix C, Table C-1).

8. MINIMUM WALL THICKNESS & WORKING PRESSURES FOR FLANGES

The inspector should be able to determine the minimum wall thickness and working pressure requirements for flanges.

The inspector should also be able to:

a) Determine the working pressure and minimum/maximum system hydrostatic test pressure for a flange of specified material and temperature (ASME B16.5, Section 2 and Table 1.1-1 and Tables 2-1.1 through 2-3.19 and Tables 2- 1.1C through 2-3.19C).

b) Determine the minimum dimensions of a given flange (ASME B16.5, Tables 7 through 22 and Tables 7 C through 22 C).

c) Determine maximum working pressure of a flange when given the design temperature, flange material and flange class.

d) Determine maximum temperature of a flange when given the design pressure, flange material and flange class.

e) Determine most cost-effective flange when given the design pressure, design temperature, and flange material.

9. MINIMUM REQUIRED THICKNESS OF A PERMANENT BLANK (ASME B31.3, 304.5.3)

II. WELDING PROCEDURE AND QUALIFICATION EVALUATION

A. ASME BPVC 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 P-No. 1, P-No. 3, P-No. 4, P-No. 5, and P-No. 8

.

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 P-No. 1, P-No. 3, P-No. 4, and P-No. 5, for the purpose of the exam 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 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 exam will cover only the main body of each referenced Article, except as noted.

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

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

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

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

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

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

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, 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 exam requirements:

ASME B31.3: The inspector should be familiar with and understand the general rules for NDE (Chapter VI).

API 570: The inspector should be familiar with and understand the general rules for NDE in API 570.

 PRACTICAL KNOWLEDGE

IV. PRACTICAL KNOWLEDGE – GENERAL

The following topics may be covered:

1. Organization and Certification Requirements.

2. Types and Definitions of Maintenance Inspections.

3. Welding on Piping

4. Corrosion and Minimum Thickness Evaluation.

5. Estimated Remaining Life.

6. Inspection Interval Determination and Issues Affecting Intervals.

7. Maintenance Inspection Safety Practices.

8. Inspection Records and Reports.

9. Repairs/Alterations/Reratings to Piping.

10. Rerating Piping.

11. Pressure Testing After Repairs, Alterations, or Rerating

12. Pressure Temperature Ratings

13. Markings

14. Materials

15. Dimensions

16. Test

17. Limiting Dimensions of Gaskets

18. Methods for Establishing Pressure-Temperature Ratings

19. Methods of performing positive material identification and related record keeping.

V. PRACTICAL KNOWLEDGE – SPECIFIC

• API 570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems – Entire document is subject to testing

• API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

ATTN: Exam questions will be based on the following portions of the document only:

Section 2 Definitions

Par. 3.3 Amine Stress Corrosion Cracking

3.8 Atmospheric Corrosion

3.9 Boiler Water and Stream Condensate Corrosion

3.14 Caustic Corrosion

3.15 Caustic Stress Corrosion Cracking

3.17 Chloride Stress Corrosion Cracking

3.22 Corrosion Under Insulation

3.27 Erosion/Erosion – Corrosion

3.31 Galvanic Corrosion

3.37 Hydrochloric Acid Corrosion

3.43 Mechanical Fatigue (Including Vibration-induced Fatigue)

3.45 Microbiologically Influenced Corrosion

3.57 Soil Corrosion

3.58 Sour Water Corrosion (Acidic)

3.61 Sulfidation

API RP 574, Inspection of Piping, Tubing, Valves, and Fittings

Entire document is subject to testing

• API RP 576, Inspection of Pressure-Relieving Devices

ATTN: Exam questions will be based on the following portions of the document only:

Sections 5

Sections 6.1-6.3

Section 8

Sections 10.1-10.3

API RP 577, Welding Inspection and Metallurgy

Entire document is subject to testing

API RP 578, Material Verification program for New and Existing Alloy piping Systems

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

ASME PCC-2, Repair of Pressure Equipment and Piping

ATTN: The examination will cover each referenced Article and its Appendices.

Article 201: Butt-Welded Insert Plates in Pressure Components

Article 206: Full Encirclement Steel Reinforcing Sleeves for Piping

Article 209: Alternatives to Postweld Heat Treatment

Article 210: In-Service Welding on to Carbon Steel Pressure Components or Pipelines

Article 211: Weld Buildup, Weld Overlay, and Clad Restoration

Article 212: Fillet Welded Patches

Article 304: Flaw Excavation and Weld Repair

Article 305: Flange Repair and Conversion

Article 306: Mechanical Clamp Repair

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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API 570 Piping Inspector Examination – Body of Knowledge and Scoring Areas – YouTube