Module 1: Introduction to API 510 Body of Knowledge (1 Hour)

This module introduces the scope of API 510, which covers the in-service inspection, repair, alteration, and rerating of pressure vessels. It outlines the certification exam structure and key responsibilities of a pressure vessel inspector.

• Overview of API 510 certification and its importance in the petrochemical industry.
• Body of Knowledge: Maintenance, inspection, alteration, and repair of pressure vessels.
• Exam preparation tips and recertification requirements, including CPD hours.

Self-Assessment: What is the primary purpose of API 510? (Answer: To ensure safe and reliable operation of pressure vessels through proper inspection and maintenance.)

Module 2: Pressure Vessel Design and Calculations (ASME VIII Div 1) (1 Hour)

Review of ASME Section VIII Div 1 for pressure vessel design, including calculations for thickness, MAWP, and hydrostatic head.

• Calculating minimum required thickness and maximum allowable working pressure (MAWP).
• Joint efficiencies, impact testing, and toughness requirements.
• Evaluating existing vessels for corrosion rates and remaining life.

Self-Assessment: How do you calculate the corrosion rate? (Answer: Difference in thickness divided by time interval.)

Module 3: In-Service Inspection Practices (API 510 & API RP 572) (1 Hour)

Detailed review of in-service inspection, including frequency, extent, and data evaluation for pressure vessels.

• Inspection intervals, risk-based inspection, and thickness measurements.
• Corrosion under insulation (CUI) and external inspections.
• Documentation, reports, and nameplate stamping requirements.

Self-Assessment: What factors determine inspection frequency? (Answer: Corrosion rate, service conditions, and risk assessment.)

Module 4: Pressure Relieving Devices (API RP 576) (1 Hour)

Overview of inspection and maintenance of pressure relieving devices.

• Types of pressure relieving devices and their inspection intervals.
• Testing, repair, and documentation requirements.
• Causes of improper performance and prevention strategies.

Self-Assessment: What does API RP 576 cover? (Answer: Inspection of pressure-relieving devices.)

Module 5: Material Verification (API RP 578) (1 Hour)

Material verification programs for new and existing alloy pressure vessels.

• Positive Material Identification (PMI) techniques.
• Evaluation of materials and prevention of mix-ups.
• Documentation and traceability requirements.

Self-Assessment: Why is PMI important? (Answer: To ensure correct alloy materials are used to prevent failures.)

Module 6: Welding Inspection and Metallurgy (API RP 577 & ASME IX) (1 Hour)

Welding procedures, qualifications, and inspection for pressure vessels.

• Welding processes, essential variables, P-Numbers, and F-Numbers.
• Repairs, alterations, and post-weld heat treatment.
• Preheat requirements and metallurgy basics.

Self-Assessment: What is an essential variable in welding? (Answer: A change that affects mechanical properties and requires requalification.)

Module 7: Non-Destructive Examination (ASME Section V) (1 Hour)

NDE methods for pressure vessel inspection.

• Radiographic, liquid penetrant, magnetic particle, ultrasonic, and visual testing.
• Procedures, calibration, and evaluation criteria.
• Articles 1, 2, 6, 7, 9, 10, and 23 from ASME Section V.

Self-Assessment: What is the purpose of NDE? (Answer: To detect defects without damaging the component.)

Module 8: Damage Mechanisms (API RP 571) (1 Hour)

Common damage mechanisms in refining and petrochemical industries affecting pressure vessels.

• Brittle fracture, thermal fatigue, erosion/corrosion, and sulfidation.
• Affected materials, critical factors, appearance, prevention, and inspection methods.
• Corrosion beneath linings and deposits.

Self-Assessment: How can erosion/corrosion be prevented? (Answer: Through material selection, design, and protective coatings.)