Module 1: Introduction to API 570 Body of Knowledge (1 Hour)
This module introduces the scope of API 570, which covers the inspection, repair, alteration, and rerating of in-service piping systems. It outlines the certification exam structure and key responsibilities of a piping inspector.
- Overview of API 570 certification and its importance in the refining industry.
- Body of Knowledge: Maintenance, inspection, alteration, and repair of metallic piping systems.
- Exam preparation tips and recertification requirements, including CPD hours.
Self-Assessment: What is the primary purpose of API 570? (Answer: To ensure safe and reliable operation of piping systems through proper inspection and maintenance.)
Module 2: Piping Design and Calculations (ASME B31.3) (1 Hour)
Review of ASME B31.3 for process piping design, including calculations for thickness, pressure, and thermal expansion.
- Calculating minimum required thickness of piping and blanks.
- Thermal expansion, contraction, and stress analysis.
- Evaluating existing piping systems for corrosion rates (long and short term).
Self-Assessment: How do you calculate the corrosion rate? (Answer: Difference in thickness divided by time interval.)
Module 3: In-Service Inspection Practices (API 570) (1 Hour)
Detailed review of in-service inspection, including frequency, extent, and data evaluation.
- Inspection intervals and risk-based inspection.
- Corrosion under insulation (CUI) and soil-to-air interfaces.
- Underground piping inspection and documentation requirements.
Self-Assessment: What factors determine inspection frequency? (Answer: Corrosion rate, service conditions, and risk assessment.)
Module 4: Flanges and Components (ASME B16.5) (1 Hour)
Overview of flange standards, bolting, and gasket selection for piping systems.
- Pressure-temperature ratings and material groups.
- Inspection of flanges, valves, and fittings.
- Requirements for low-temperature toughness tests.
Self-Assessment: What does ASME B16.5 cover? (Answer: Pipe flanges and flanged fittings.)
Module 5: Material Verification (API RP 578) (1 Hour)
Material verification programs for new and existing alloy piping systems.
- 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 and Metallurgy (API RP 577 & ASME IX) (1 Hour)
Welding procedures, qualifications, and inspection.
- Welding processes, essential variables, P-Numbers, and F-Numbers.
- Hot tapping, in-service welding, and repairs.
- Heat treatment and preheat requirements.
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 piping 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.
- 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.)