API 510 [exercise]

Repairing a crack on a vessel requires expertise in pressure vessel design to ensure that the repair is done correctly and safely. A pressure vessel engineer with experience in pressure vessel design would have the knowledge and understanding of the structural integrity of the vessel and the necessary repair techniques. Consulting with the original manufacturer, production manager, or the company writing the insurance on the vessel may not provide the specific expertise required for repairing a crack on a pressure vessel.

A progressive record for a pressure vessel should contain construction and design information as well as the operating and inspection history. This record is important for ensuring the safety and integrity of the pressure vessel. It allows for easy access to information about the vessel's construction, design specifications, and any modifications that have been made over time. Additionally, the operating and inspection history provides a record of the vessel's performance and any maintenance or repairs that have been done. This information is crucial for monitoring the condition of the pressure vessel and ensuring that it meets regulatory requirements.

The correct answer is a. The authorized pressure vessel inspector. Before any repairs or alterations can begin, the authorization of a qualified pressure vessel inspector is required. This is because pressure vessels are subject to strict regulations and safety standards, and only an authorized inspector has the expertise to ensure that the repairs or alterations are done correctly and in compliance with these standards. The inspector's authorization is crucial in order to maintain the integrity and safety of the pressure vessel.

Liquid penetrant inspection is a nondestructive testing method used to detect surface discontinuities. It involves applying a liquid penetrant to the surface of a material and allowing it to seep into any cracks or open defects. The excess penetrant is then removed, and a developer is applied to make the penetrant visible. This method is effective in finding cracks that are open to the surface, as the liquid penetrant can easily seep into and highlight these defects. Therefore, option a is the correct answer.

The correct answer is d because the type of surface preparation required for proper internal or external visual inspections depends on individual circumstances. It could be any of the options mentioned, such as hydro blasting, grit blasting to SA 2, or wire brushing. The specific method chosen would depend on factors like the condition of the surface, the type of material being inspected, and the desired level of cleanliness and preparation. Therefore, there is no one-size-fits-all approach, and the choice of surface preparation method will vary based on the specific circumstances.

After a vessel has been placed in service, API 510 is used to evaluate it. API 510 is a standard that provides guidelines for the inspection, repair, alteration, and rerating of in-service pressure vessels. It covers various aspects such as inspection intervals, methods, and criteria for assessing the condition of the vessel. This code ensures that the vessel remains safe and meets the required standards throughout its service life. ASME Section VIII and ASME Section V are not specifically designed for evaluating vessels after they have been placed in service, while API 572 focuses on inspection practices for pressure vessels during construction.

The correct answer is a. A container designed to withstand internal or external pressure. This definition accurately describes pressure vessels as containers that are specifically designed to handle and withstand both internal and external pressure. These vessels are engineered to safely contain substances or fluids under high pressure, ensuring that they do not leak or rupture. The ability to withstand pressure is a crucial characteristic of pressure vessels, making option a the correct choice.

The API-510 Inspection Code applies to vessels after they have been placed in service. This means that the code is applicable to vessels that are already in operation and not during the fabrication or construction process. The code provides guidelines and requirements for the inspection, repair, alteration, and rerating of in-service pressure vessels. It ensures that these vessels are maintained and operated safely, and helps in identifying any potential issues or defects that may affect their integrity and performance.

A construction code refers to the specific set of regulations and standards that were followed during the initial construction of a vessel. This code ensures that the vessel is built to meet certain safety and quality standards. It includes guidelines for materials, design, construction techniques, and other aspects of the vessel's construction process. The construction code serves as a reference point for assessing the vessel's compliance with the original standards and ensuring its structural integrity and safety.

The probable corrosion rate for a new vessel can be determined by analyzing data collected from other vessels that have been in the same or similar service. This data can provide valuable insights into the corrosion rates experienced by similar vessels and can help estimate the probable corrosion rate for the new vessel. Additionally, published data on vessels providing comparable service can also be used to determine the probable corrosion rate. By comparing the new vessel with existing data, a reasonable estimate of the corrosion rate can be made without the need for an internal inspection.

The correct answer is b. A metallurgical review conducted by an engineer shall be performed to assure the proposed alternative is suitable for the application. This is because when using the half bead or temper bead technique of repair, it is important to assess the metallurgical aspects of the repair. Conducting a review by an engineer will help determine if the proposed alternative is appropriate and will ensure the repair is suitable for the specific application.

The owner/user is responsible for ensuring that the Authorized Inspection Agency functions in accordance with the requirements of API 510. This means that the owner/user is accountable for overseeing and ensuring that the inspection agency is following the necessary guidelines and standards set forth by API 510. They must ensure that the agency is conducting inspections and assessments correctly and accurately, and that they are following all the necessary protocols and procedures. Ultimately, it is the responsibility of the owner/user to ensure that the inspection agency is fulfilling their obligations in accordance with API 510.

The maximum inspection interval for a vessel with a remaining safe operating life of less than four years is the full remaining safe operating life up to a maximum of 2 years. This means that the vessel should be inspected at least once within the remaining safe operating life, but no later than 2 years from the current inspection.

The pressure vessel engineer must be consulted before the repair of a crack at a discontinuity where stress concentrations may be serious because they have the expertise and knowledge to assess the severity of the crack and determine the appropriate repair method. They can evaluate the potential risks and ensure that the repair is done correctly to prevent any further damage or failures in the pressure vessel. The owner-user, National Board inspector, and vessel manufacturer may also be involved in the repair process, but the pressure vessel engineer is the most relevant and essential consultant in this situation.

The correct answer is b. The corners shall be rounded 1 inch minimum radius. This means that when flush (insert) patches are installed with full penetration butt joints, the corners of the patches should have a minimum radius of 1 inch. This ensures that the corners are smooth and rounded, reducing the risk of sharp edges or corners that could cause injury or damage. The rounded corners also help to distribute stress and prevent stress concentrations, improving the overall strength and durability of the patches.

When a vessel is subjected to temperatures above its design limit, the material of the vessel may undergo a phenomenon known as creep. Creep refers to the gradual deformation or elongation of a material under constant stress at high temperatures. This can lead to a loss of structural integrity and potentially cause the vessel to fail or rupture. Therefore, option d is the correct answer as it accurately identifies the potential consequence of subjecting a vessel to temperatures above its design limit.

When both the ownership and location of a pressure vessel are changed, it is necessary to conduct external and internal inspections of the vessel before it can be used again. This is important to ensure that the vessel is in good condition and does not pose any safety risks. Inspections help identify any potential damage or defects that may have occurred during the ownership and location change, allowing necessary repairs or maintenance to be carried out before reusing the vessel. This helps maintain the integrity and safety of the pressure vessel.

When rerating a pressure vessel, one of the important steps is to document the calculations from the manufacturer or the owner-user's engineer. This is necessary to ensure that the vessel is being rerated correctly and can safely handle the desired operating conditions. The calculations provide the necessary technical information and analysis to determine the vessel's new design parameters and its ability to withstand the required pressure and temperature conditions. This documentation serves as a reference for future inspections, maintenance, and regulatory compliance.

The correct answer is d. If insulation is in good condition and the vessel operates within the high and low temperatures stated in API 510, removal of insulation is not necessary for inspection of the vessel. This means that if the insulation is in good condition and the vessel is operating within the specified temperature range, there is no need to remove the insulation for inspection. This is because the insulation is not likely to affect the inspection process or the condition of the vessel.

Risk-based Inspection combines the assessment of the likelihood of failure and the consequence of failure. This means that it takes into account both the probability of a failure occurring and the potential impact or consequences of that failure. By considering both factors, risk-based inspection allows for a more comprehensive evaluation of the risks associated with a particular inspection or maintenance activity. This approach helps prioritize resources and efforts towards areas that have a higher likelihood and consequence of failure, ultimately improving safety and efficiency.

The correct answer is c. One half the estimated remaining life or 10 years whichever is less. This means that the inspection interval should be determined by taking into account one half of the estimated remaining life of the equipment or a maximum of 10 years, whichever is less. This ensures that regular inspections are conducted to identify any potential issues or defects in the equipment and take necessary actions to maintain its integrity and safety.

Both an internal and external inspection must always be performed whenever the vessel's ownership and location changes. This is important because a change in ownership and location can potentially affect the condition and integrity of the vessel. An internal inspection helps identify any internal damage or deterioration that may have occurred during the change, while an external inspection ensures that the vessel is still in compliance with safety and regulatory standards. These inspections help ensure the safety and reliability of the vessel in its new ownership and location.

The maximum interval for internal inspection of the vessel should be less than or equal to the remaining life of the vessel. Since the remaining life of the vessel is 24 years, the maximum interval for internal inspection should be less than or equal to 24 years. Among the given options, the only option that satisfies this condition is option c, which states a maximum interval of 10 years. Therefore, option c is the correct answer.

Preheating is not to be less than 300˚F as an alternative to post-weld heat treatment (PWHT) for vessels made of P-1 and P-3 materials. This means that if alterations or repairs are being done on these vessels, preheating to a temperature of at least 300˚F can be used instead of subjecting the vessel to PWHT. Preheating helps to reduce the risk of cracking and other issues that can occur during welding or repairs.

When a vessel is to be entered for an internal inspection, it is important to review and follow OSHA rules. OSHA (Occupational Safety and Health Administration) sets regulations and standards to ensure the safety and health of workers. By reviewing and following OSHA rules, the necessary precautions can be taken to prevent accidents, ensure proper safety equipment and procedures are in place, and minimize potential hazards during the inspection. This helps to protect the workers and maintain a safe working environment.

The correct answer is a. 1000 hours. According to API-510, when the corrosion rate for a new vessel cannot be determined by available data or experience, on-stream determination should be made. API-510 recommends a minimum length of service of 1000 hours for this purpose.

Before non-destructive procedures are used in lieu of hydrostatic testing, it is necessary to consult with an engineer experienced in pressure vessel design and the API inspector. This is important because these individuals have the expertise and knowledge to assess the safety and integrity of the pressure vessel. They can evaluate the suitability of non-destructive procedures and ensure that they meet the necessary standards and regulations. Consulting with both an engineer and the API inspector helps to ensure a thorough and comprehensive evaluation of the pressure vessel before alternative testing methods are employed.

According to API-510, the function of an authorized inspection agency is the responsibility of the owner-user. This means that the owner-user is responsible for ensuring that an authorized inspection agency is appointed to carry out inspections in accordance with the API-510 standards. The authorized inspection agency plays a crucial role in conducting inspections and ensuring compliance with the standards, but it is ultimately the responsibility of the owner-user to ensure that this function is fulfilled.

In order to accept a new vessel for operation, a first internal inspection must be conducted. However, if a manufacturer's data report (U1) is available and assures that the vessel is satisfactory for its intended service, the first internal inspection may be waived. This means that if the manufacturer's report provides sufficient evidence that the vessel meets all necessary requirements, there is no need for the additional inspection.

Vessel rerating involves calculations from either the manufacturer or an owner-user engineer experienced in pressure vessels. This means that in order to determine the new rating for the vessel, calculations need to be done by someone who has knowledge and expertise in pressure vessels. These calculations are essential to ensure that the vessel can safely operate at the proposed service conditions. The involvement of either the manufacturer or an experienced engineer allows for accurate and reliable calculations to be made, taking into account the specific design and operating conditions of the vessel.

To exempt a vessel from internal inspections, the corrosion rate that cannot be exceeded is 0.005" per year. This means that the rate of corrosion should not exceed 0.005 inches per year for the vessel to be exempt from internal inspections.

The correct answer is a. Call in a pressure vessel engineer. When a crack is discovered in a vessel in a highly stressed area, it is important to consult a pressure vessel engineer. They are experts in assessing the integrity of the vessel and can recommend the appropriate course of action to correct the flaw. This may involve further inspections, repairs, or even replacement of the vessel if necessary. Their expertise ensures that the correct steps are taken to address the issue and prevent any potential hazards or failures.

An engineer competent in pressure vessel design and the API authorized inspector determine if a temporary fillet weld patch may be used in a repair. This is because the engineer is knowledgeable about the design requirements for pressure vessels and can assess whether the temporary patch meets the necessary criteria. The API authorized inspector provides oversight and ensures that the repair is conducted in accordance with industry standards and regulations. Together, they have the expertise to make an informed decision regarding the use of a temporary fillet weld patch in a repair.

The correct answer is b. Minimum temperature shall be at least 30˚F above the minimum design metal temperature. This means that during the pressure test of a 2.125" thick vessel, the minimum temperature of the metal should be at least 30˚F higher than the minimum design metal temperature. This requirement ensures that the metal can withstand the pressure and temperature conditions during the test without any risk of failure or damage.

The correct answer is d. The Code the vessel was constructed to including non-standard and jurisdictional special vessels. This means that when discussing repairs to a pressure vessel, the construction codes refer to the specific code that was followed during the vessel's original construction. This includes any non-standard requirements and jurisdictional regulations that were applicable at the time of construction.

The selection of inspection techniques for a pressure vessel should consider both the condition of the vessel and the environment in which it operates. The condition of the vessel will determine the level of inspection required and the specific techniques needed to identify any potential defects or damage. The environment in which the vessel operates, such as high temperature or corrosive conditions, will also impact the choice of inspection techniques as certain methods may be more effective in detecting specific types of damage. Therefore, considering both the vessel's condition and operating environment is crucial in selecting the appropriate inspection techniques.

The correct answer is b. If a pressure test is being conducted in which the test pressure will exceed the set pressure of the safety relief valve with the lowest setting. This means that if the pressure being tested is higher than the lowest set pressure of any safety relief valve, it is necessary to remove the safety relief device to prevent it from opening and releasing pressure during the test. This ensures that the pressure test is conducted accurately and safely.

The recommended shell temperature during a hydrostatic test of a vessel that is 1" thick is 10°F above the Minimum Design Metal Temperature (MDMT). This temperature ensures that the vessel is tested under conditions that are representative of its intended service temperature range, while still allowing for a safety margin.

Temper embrittlement refers to the loss of ductility and notch toughness of a material when it is exposed to temperatures ranging from 650°F to 1100°F. This means that the material becomes more brittle and prone to cracking, especially under low temperature service conditions. It does not refer to cracking due to high temperatures or flaking of metal surfaces.

A review of the internal inspection interval does not need to be conducted when the operating pressure decreases. This is because a decrease in operating pressure would typically have a positive effect on the degradation of the vessel, reducing the likelihood of damage or deterioration. Therefore, there is no need to review the inspection interval in this situation.

During vessel repairs or alterations, the repair organization owner/user is required to maintain the welding records. This responsibility falls on them as they are directly involved in the repair process and have the necessary knowledge and authority to ensure that the welding records are properly maintained. The repair organization owner/user is responsible for documenting and keeping track of all welding activities, including the type of welding performed, the materials used, and any inspections or tests conducted. This helps to ensure that the repairs or alterations are carried out in compliance with industry standards and regulations.

The re-rating of a pressure vessel will be considered complete only when the authorized pressure vessel inspector witnesses the attachment of an additional nameplate or stamping. This indicates that the re-rating process has been completed and the vessel is ready for use. The pressure test required by the code, the final painting of the vessel, and the stamping of welds by each welder may be important steps in the re-rating process, but they alone do not signify the completion of the re-rating.

The responsibility for rerating calculations for a vessel lies with the manufacturer or an owner-user engineer (or his designated representative). This means that either the manufacturer of the vessel or an engineer designated by the owner-user is responsible for performing these calculations. The chief inspector and the unit engineer may be involved in the process, but the ultimate responsibility lies with the manufacturer or owner-user engineer. The API authorized inspector and a professional engineer are not the only ones allowed to perform these calculations.

API 510 covers vessels constructed to any fabrication code, meaning it is not limited to a specific code such as ASME B&PV Section VIII or the API/ASME Code for Unfired Pressure Vessels. This allows for flexibility in the types of vessels that can be covered under API 510.

Inspection for corrosion under insulation (CUI) is necessary for externally insulated vessels that are subject to moisture ingress. This is particularly important for vessels that operate within a temperature range of 10°F and 350°F for carbon and low alloy steels. This temperature range is specified because CUI is more likely to occur in vessels operating within this range, and therefore regular inspection is necessary to identify and mitigate any corrosion issues.

The most severe stress caused by internal pressure in a cylindrical shell is the circumferential stress acting along the longitudinal axis. This stress is caused by the pressure pushing outward on the curved surface of the shell, resulting in a tensile stress that is highest in the circumferential direction. This stress is critical because it can lead to failure or rupture of the shell if it exceeds the material's strength.

When a RBI assessment is used to increase the typical 10 year inspection limit, it means that the assessment is being used to extend the time between inspections for a pressure vessel. In this case, the assessment should be reviewed by a pressure vessel engineer and authorized inspectors at intervals not exceeding 10 years. This ensures that the assessment remains accurate and up to date, and any potential risks or issues with the pressure vessel can be identified and addressed in a timely manner.

When developing an inspection plan for equipment operating at elevated temperatures, it is important to consult a corrosion specialist. This is because elevated temperatures can have significant impacts on the metallurgical properties of the vessel materials, leading to increased corrosion rates and potential degradation. A corrosion specialist will have the knowledge and expertise to understand these effects and recommend appropriate inspection and maintenance strategies to ensure the integrity and safety of the equipment.

Prior to carrying out the special inspection procedures, it is important to make sure that it is allowed according to any jurisdictional rules that may be in place. This ensures that the inspection procedures are conducted in compliance with legal requirements. Additionally, consulting with an engineer experienced in pressure vessel design and the Authorized Pressure Vessel Inspector helps to ensure that the inspection is carried out correctly and effectively. This step is crucial in maintaining the safety and integrity of the pressure vessel after the alteration.

An on-stream inspection is a type of inspection that is conducted while the equipment or system is still in operation. It is typically less invasive and less time-consuming compared to an internal inspection, which involves physically accessing the internal components of the equipment or system. However, for equipment or systems with a remaining life of less than 10 years, an internal inspection is necessary to ensure a thorough assessment of its condition and to identify any potential issues that may not be detected through an on-stream inspection. Therefore, an on-stream inspection cannot be substituted for an internal inspection unless the remaining life exceeds 10 years.