Area of Examination & Reference Documents
In this module, you shall learn about:
Reference documents,
In this module, you shall learn about:
Certified API 570 Piping Inspector must have a broad knowledge in inspection and repair of piping.
As an API 570 Piping Inspector, you should know about Piping Inspection Code (API 570) and Piping Inspection Practices (API 574).
You should also know about Process Piping (ASME B31.3); Pipe Flanges and Fittings (ASME B16.5); Welding Inspection and WPS (ASME Sec IX & API 577), Positive Material Identification (API 578); NDT (ASME Sec V); damage mechanism (API 571), PRD (API 576); Repair of Piping (PCC-2), and finally have general knowledge of safety.
The API 570 examination has two sets of references as study materials:
One set contains ASME codes (Section IX (Welding) and Section (V Non-destructive Testing); Process Piping (ASME B31.3), Flanges and Fittings (ASME B16.5) as well as the all-important Piping Inspection Code (API 570).
The other set of reference materials are API Recommended Practices (API 571, 574, 576, 577 & 578) and PCC-2, Repair of Pressure Equipment and Piping.
Most calculation type of questions from the API and ASME codes are in the open book part of the examination. You need not memorize the formulas but should know where to look for when solving the open book questions.
You should have an idea how to navigate through them during open book part since the “search button” is disabled during the exam.
When reading a code and standard; donāt immediately dive into the details.Ā Get the bigger picture.
First, understand what the code covers by reviewing the opening paragraphs of each code. This is called the Scope or purpose.
We have flagged important pages of codes and also brought important information in the flash cards that should be treated as potential exam questions.
Our timed mock exams and practice questions are also designed to test your knowledge, and help you understand how to interpret and answer exam questions.
Those closed book exam questions that are coming straight from API and ASME codes and RPs or within a context/scenario; are the ones that an inspector would be using on daily basis and therefore, you need to memorize them. API calls them āāpractical questionsāā.
But donāt worry; we shall supply you with enough presentation, mock question and flash cards to ensure that you would not forget them during the exam.
The second set of reference documents contains the recommended practices (API 571, 574, 576, 577, 578 & PCC-2).
Again, we have summarized them; highlighted important information and explained the underlying reasons whenever necessary, so you understand the concepts.
Please note that only API 570 is an inspection code and therefore, mandatory, while the rest of API documents are recommended practices (RP) and hence not mandatory as the name RP suggests.
Closed book questions mostly come from API 570 code and RPs because this type of information is supposed to be used by piping inspectors on daily basis.
For open book questions that need referring to tables, graphs and formulas, you shall have access to both the API RPs, API 570 & ASME codes.
We shall summarize and explain the concepts of these Reference Materials within the next 9 modules complete with flash cards and mock exams.
Note: A Code document is mandatory while a Recommended Practice as the name suggest, is advisory which means you can deviate from it based on circumstances and sound engineering judgement while the code cannot be violated under any circumstances.
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Codes are based on engineering design and calculations while recommended practices are mostly the result of past experience gathered over the years showing the trends and good practices.
Thatās why; you may observe that the formulas brought within RPs are empirical. The empirical formulas have no sound scientific backing and are merely formulated to show the trends and relationship between various parameters.
Why? Because, to turn an empirical formula into a scientific formula necessitates including many more parameters of less importance and this would unnecessarily complicate the equation where as empirical formulas are like rule of thumbs that can be of everyday use especially when you do not need to be that accurate.
The analogy would be the difference between a WPS and a Welding Instruction. The welder does not need to know about all the essential and non essential parameters or the PQR and itās associated test reports. All the welder needs to know is the range of amperage & voltage, the welding speed, the type and size of electrode, the welding position, the number of passes and whether any pre heat required.
Empirical formulas are used when a very high accuracy is not important. They are basically the mathematical representation of trends. For example, as a rule of thumb, you need to preheat 4āā or 4t from each side of the weld whichever is more. You do not really need complicated formulas to come to the right number that you cannot even implement in practice.
Before going to the relevant section, you need to know which document you need to look at in order to find a particular topic.
Therefore, you need to know what is covered in each code and recommended practice. If you are in doubt, look at the table of contents.
If it does not help, look at the list of figures or list of tables.Ā It shall give you an idea where you can find the topic.
Try reading the PDF format of documents on a desktop or laptop so your eyes and mind-set gets used to them. Practice actually solving closed book calculation type of questions to simulate an actual exam.
Reading soft copies of reference documents help acclimatize oneself while searching for a topic.
A little practice is necessary to get it right. It is particularly useful for bigger codes such as ASME Sec V & IX and ASME B31.3 & 16.5.
Also try to memorize the topics of codes and RPs so you know where to look for. If you canāt find the relevant section after a couple of minutes, flag off the question and note the question number on a piece of paper.
There is a high chance that you shall find it when looking for answers to other questions. Once found, you can go back to the flagged off question and solve it within seconds.
API code 570 and API RP 571, 574, 576, 577, 578, PCC-2 should not be a problem navigating as they are much smaller compared to ASME.
A. Code calculation questions will be oriented toward existing in-service piping, not new piping.
API Authorized Piping Inspectors should be able to check and perform calculations relative to in-service deterioration, repairs, rerates, or alterations, such as those included in the following eight categories.
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 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-bookā during the exam.
The inspector should be able to determine the weld joint quality factor āEjā 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.
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).
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)
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)
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).
The inspector should be able to determine the total thermal expansion of a material between temperatures (ASME B31.3, Appendix C, Table C-1).
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 7C through 22C).
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)
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:
ā¢ Weld Procedure Specification (WPS)
ā¢ Procedure Qualification Record (PQR)
ā¢ 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 1330Ā°F and the upper transformation temperature will be 1600Ā°F.
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
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.
A. ASME Section V, Nondestructive Examination
Note: The exam will cover only the main body of each referenced Article, except as noted.
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
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:
ā¢ Required marking
ā¢ Type, selection, number, and placement of IQIās,
ā¢ Allowable density and density ranges
ā¢ Control of backscatter radiation
c) Records
(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:
ā¢ Procedures
ā¢ Contaminants
ā¢ Techniques
ā¢ Examination
ā¢ Interpretation
ā¢ Documentation and record keeping
(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:
ā¢ Procedures
ā¢ Techniques (Yoke and Prod only)
ā¢ Calibration
ā¢ Examination
ā¢ Interpretation
c) Documentation and record keeping
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:
ā¢ Procedures
ā¢ Physical requirements
ā¢ Procedure/technique
ā¢ Evaluation
c) Documentation and record keeping
(Including Mandatory Appendix I Bubble Test āDirect 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:
ā¢ Procedures
ā¢ Equipment
ā¢ Calibration
ā¢ Test
ā¢ Evaluation
c) Documentation and record keeping
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.
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.
ā¢ API 570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems ā Entire document is subject to testing
ā¢ 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 ā 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
Entire document is subject to testing
ā¢ 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
Entire document is subject to testing
Entire document is subject to testing
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
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