Api si source inspector certification the quoted references

Guide for Source Inspection and QualitySurveillance of Fixed EquipmentAn API Approach _ The Referred Standards2014-October My Self Study Exam Preparatory Notes

Charlie Chong/ Fion Zhang


Offshore Installations





Expert at works


Fion Zhang2014/October

http://meilishouxihu.blog.163.com/Charlie Chong/ Fion Zhang


Dennis Tong2014/October

Technical


Remember few keypoints. The rest is common sense!


The best keypoints learning is practicing the magical Q&A & thru forum discussion


The Magical Journey Starts……


12.ASNT SNT-TC-1A13.SSPC-PA 214.SSPC Surface preparation

guide

6. ASME IX7. ASME VIII8. ASME V9. ASME II10.ASME B16.511.ASME B31.3

1. API SI 2. API 510/5723. API 5774. API 5785. API 598

Contents:


1. The Main Document: API SIGuide for Source Inspection and QualitySurveillance of Fixed Equipment


Key points:Section 2: IntroductionLike most business processes, the Source Inspection work process follows the “ Plan–Do–Check–Act” circular process first popularized in the 1950’s by Edward Deming.

Section 3: References

RP 577 Welding Inspection and Metallurgy RP 578 Material Verification Program for New and Existing Alloy Piping

Systems (PMI) API Std 598 Valve Inspection and Testing


ASME BPVC Section II—MaterialsPart A—Ferrous Material SpecificationsPart B—Nonferrous Material SpecificationsPart C—Specifications for Welding Rods, Electrodes and Filler MetalsPart D—Materials Properties


ASME BPVC Section VIII, Division 1—Rules for the Construction of Pressure Vessels.

ASME BPVC Section VIII, Division 2—Rules for the Construction of Pressure Vessels - Alternative Rules.

ASME B16.5—Pipe Flanges and Flanged Fittings- NPS ½ to NPS 24

SSPC-PA 2 Coating Applications Standard No. 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements.

SSPC Surface Preparation Guide:SSPC-SP1—Solvent CleaningSSPC-SP3—Power Tool CleaningSSPC-SP5 or NACE 1—White Metal Blast CleaningSSPC-SP6 or NACE 3—Commercial Blast CleaningSSPC-SP7 or NACE 4—Brush-Off Blast CleaningSSPC-SP10 or NACE 2—Near-White Blast CleaningSSPC-SP11—Power Tool Cleaning to Bare Metal


9.2.1 Mechanical Testing- ASME SA-370

11.7.6.2 Typically heating rates for pressure equipment and piping above 800°F must be controlled to no more than 400°F per hour with no variation permitted of more than 250°F in any 15 foot segment of the equipment.

PWHT is covered in API RP 577, Section 10.6; ASME BPVC Section VIII, Division 1, UCS-56; and B31.3, 331.

12.3.5 For example, acceptable methods of traceability for plates used in the fabrication of vessels include:

　 Plate number　 Lot number　 Heat number


12.7.6 In the U.S., heat exchangers and condensers are designed and built in accordance with ASME BPVC, TEMA Standards, API 660—Shell-and-Tube Heat Exchangers, and API 661- Air-Cooled Heat Exchangers for General Refinery Services.

Marking on valves at a minimum shall comply with the requirements of MSS-SP-25, Standard Marking System for Valves, Fittings, Flanges and Unions

ASME PCC-1, Guidelines for Pressure Boundary Bolted Flange Joint Assembly.

13.3.2 Pipe flanges that are made to standards such as ASME B16.5 (see 8.2.5.3) or ASME B16.47 are typically made from forged materials and have machined surfaces for gaskets.

13.3.3 ASME B16.5 covers NPS’s from ½″ to 24″ and ASME B16.47 covers NPS’s from 26" to 60".


Materials for flanges are usually covered in ASME designation: SA-105 (Specification for Carbon Steel Forgings for Piping Applications), SA-266 (Specification for Carbon Steel Forgings for Pressure Vessel Components), or SA-182 (Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service).

14.6 ASTM A6 specification covers a group of common requirements for structural steel

14.7 ASTM A325, A325M, A490 and A490M are used for high strengthstructural bolts.

14.9 Galvanizing should be in accordance with ASTM A123 or A153 unless otherwise specified in the purchase order documents


ASME & NB Symbol Stamps


ASME & NB Symbol Stamps

R: Repair & alteration

VR: Repair of safety valves


“V” Day for Safety Valves


“S” Superman for Power Boiler


“S” Superwomen for Power Boiler



2. The Reference Document: API 510Pressure Vessel Inspection Code:In-Service Inspection, Rating, Repair, and Alteration

www.slideshare.net/slideshow/embed_code/38469969


3. The Reference Document: API 577Welding Inspection and Metallurgy



4. The Reference Document: API 578Material Verification Program for Newand Existing Alloy Piping Systems



5. The Reference Document: API 598Valve Inspection and Testing


Valve Inspection and Testing

Downstream SegmentAPI STANDARD 598EIGHTH EDITION, MAY 2004


Scopes & Coverage Seat Types:

1.1.1 This standard covers inspection, examination, supplementary examinations, and pressure test requirements for (1) resilient-seated, (2) nonmetallic-seated (e.g., ceramic), and (3) metal-to-metal-seatedvalves of the gate, globe, plug, ball, check, and butterfly type.

Valve Standard:1.1.1 API Std 598 supplements the API standards that reference it, but it may also be applied to other types of valves by agreement between the purchaser and the valve manufacturer.


1.1.3 The following tests and examinations are specified in this standard: a. Shell test. b. Backseat test. c. Low-pressure closure test. d. High-pressure closure test. e. Visual examination of castings. f. High-pressure pneumatic shell test.


Gate Valve


Gat

e Va

lve


Sliding Gate Valve


Globe Valve

http://www.ctgclean.com/tech-blog/2012/03/valves-manual-valves-globe-valves/


Globe Valve


Globe Valve

http://www.bellowseal.com/products.html


Globe Valve


Globe Valve


Plug Valve


Plug Valve


Plug Valve


Check Valve


Check Valve


Floating Ball Valve


Floating Ball Valve


Floating Ball Valve


Floating Ball Valve


Floating Ball Valve


Floating Ball Valve


Butterfly Valve


Butterfly Valve


Butterfly Valve


Trunnion Mounted Ball Valve



http://www.c-a-m.com/forms/Product.aspx?prodID=81fecf80-6b0e-41cd-87da-49a7b65e8ecc




Table 1-A—Pressure Tests Valves:NPS ≤ 4 & ASME Class ≤ 1500, NPS > 4 & ASME Class ≤ 600

A The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature.

B For lubricated plug valves, the high-pressure closure test is mandatory and the low-pressure closure test is optional.

C When the purchaser specifies an “optional” test, the test shall be performed in addition to the required tests.

D The high-pressure closure test of resilient-seated valves may degrade subsequent sealing performance in low-pressure service.

E For power-operated and manually operated gear actuated globe valves, including non-return type globe valves, the high-pressure closure test shall be performed at 110% of the design differential pressure used for sizing of the operator.

F A high-pressure closure test is required for all valves specified to be double block and bleed valves.


Comments on Table A-1

Shell test - All. Back Seat Test - Gate & Globe Valve only. Low Pressure Closure Test - Gate, Plug, Ball Valves only. High Pressure Closure Test - Globe, Check Valves only.


3.1 TEST LOCATION Pressure tests shall be performed by the valve manufacturer at the valve manufacturer’s plant.

Company Written Procedure: 3.3.1 The pressure tests listed in Table 1-A or 1-B shall be performed on each valve in accordance with written procedures that comply with this standard.

Back Seat Test Choice: 3.3.2 At the manufacturer’s option, the backseat test for valves that have the backseat feature may be either a high pressure or a low-pressure test unless stated otherwise in the purchase order.(Why?)


Discussion: Topic:3.4 HIGH-PRESSURE CLOSURE TESTThe high-pressure closure test is required for several valve types, as shown in Table 1-A and 1-B. For the valve types for which, according to Table 1-A and 1-B, the high-pressure closure test is optional, the valves are still requiredto be able to pass the test (as a test of the design of the valve closure structure). Results of tests confirming the capacity of the valve design to pass the high-pressure closure test shall be supplied when requested in the inquiry purchase requisition, or by the purchaser.

Hints: Valve features


3.5 HIGH-PRESSURE PNEUMATIC SHELL TEST The pneumatic shell test pressure shall be 110% of the maximum allowable pressure at 100°F (38°C) or as specified in the purchase order. Visible leakage is not allowed.

3.6 TEST FLUID 3.6.1 For shell, high-pressure backseat, and high-pressureclosure tests, the test fluid shall be air, inert gas, kerosene, water, or a non-corrosive liquid with a viscosity not higher than that of water. Unless otherwise specified in the purchase requisition, the test fluid temperature shall be within the range 41°F (5°C) to 122°F (50°C).

3.6.2 For the low-pressure closure and low-pressure backseat tests, the test fluid shall be air or inert gas.


3.6.4 For testing of austenitic stainless steel valves, water with chloride content not exceeding 100 parts per million shall be used. The valve manufacturer shall be able to document the chloride content.

3.9.1.1 For shell tests, visually detectable leakage through the pressure boundary walls and any fixed body joint is not permitted.

3.9.1.2 For backseat tests, visually detectable leakage isnot permitted.


4.2 BACKSEAT TEST4.2.1 The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature and shall be performed by applying pressure inside the assembled valve with the valve ends closed, the valve fully open, and the packing gland loose or packing not installed. If the backseat test is performed after the shell test, the packing shall be installed and/or packing glands re-tightened after the backseat test.

The successful completion of the backseat test shall not be construed as a recommendation by the valve manufacturer that, while the valve is pressurized, the valve stuffing box may be repacked or the packing may be replaced. (SAFETY Consideration during in-service)

4.2.2 For valves 4 in. NPS and smaller, the backseat test may be combined with the shell test when volumetric devices are used to monitor leakage from the shell and backseat. When tested by this method, the packing shall be loose. The manufacturer shall be responsible for demonstrating that the packing will not leak at the valve’s rated pressure at 100°F (38°C).


Seat Test


Bellow Sealed Valve


Bellow Sealed Valve


What is Bellow Sealed

http://www.bellowseal.com/products.html


Bellow Sealed


Bellow Sealed Valve


Bellow Sealed Valve


Discussion Time: Why the followings were mark NA

a The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature.


Why Marked “NA” for Ball Valve?


Why Marked “NA” for Plug Valve?


4.4 LOW-PRESSURE CLOSURE TEST: 4.4.3 For a valve designed to close against pressure from one direction only and so marked, the pressure shall be applied on the pressure side of the valve only. For a check valve, the pressure shall be applied on the downstream side


4.4 LOW-PRESSURE CLOSURE TEST: 4.4.3 …For a check valve, the pressure shall be applied on the downstream side

Process flow direction

Pressurized here


4.5 HIGH-PRESSURE CLOSURE TEST4.5.1 The procedure for the high-pressure closure test shall be the same as the procedure for the low-pressure closure test except that, in the case of a liquid test, leakage shall be detected when drops, not bubbles as described in 4.4 are observed.


All The Best for your API SI Exam!


6. The Reference Document: ASME IIMaterial Verification Program for Newand Existing Alloy Piping Systems


ASME BPVC Section II - Materials. This section of the BPVC is divided into four parts covering materials for the construction of piping and pressure vessels.

■ Part A - Ferrous Material Specifications.

This part contains the individual specifications for ferrous materials that are allowed in the construction of pressure vessels and piping designed to the ASME BPVC. Part A covers all forms of ferrous material products like wrought, castings, forgings, plates, piping valves, bolting, etc.


The issues addressed by each ferrous material specification vary based on the characteristics of the material and final use for which it is intended. Some examples of issues covered include: ordering information, heat treatment, chemical composition, mechanical properties, tests and examinations, dimensions and tolerances and the steel making practice. The source inspector should be familiar with the contents of whichever materials are specified in the contractual agreements. The only three specifications covered in ASME BPVC Section II, Part A that the SI need to be familiar with for purposes of the examination are:

SA-20, General Requirements for Steel Plates SA-370, Test Methods and Definitions of Mechanical Testing Steel

Products SA-6, Thickness Tolerances for Steel Plate


■ Part B - Nonferrous Material Specifications.

This part contains the individual specifications for nonferrous materials that are allowed in the construction of pressure vessels and piping designed to the ASME BPVC. Part B covers all forms of nonferrous material products like wrought, castings, forgings, plates, piping valves, bolting, etc. allowed for in the construction of ASME BPVC equipment.

The types of nonferrous material alloys included in Part B are: aluminum, copper, nickel, titanium, and zirconium. The issues addressed by each nonferrous material specification vary based on the characteristics of the material and final use for which it is intended. Some examples of issues covered include: ordering information, heat treatment, chemical composition, mechanical properties, tests and examinations, dimensions and tolerances and the steel making practice. The source inspector should be familiar with the contents of whichever materials are specified in the contractual agreements. However there will be no specific questions on the core examination out of Part B, but the SI should be familiar with what the standard covers.


■ Part C - Specifications for Welding Rods, Electrodes and Filler Metals.

Part C covers material specifications for the manufacture, acceptability, chemical composition, mechanical usability, surfacing, testing, operating characteristics and intended uses of welding rods, electrodes and filler materials. The material specifications are designated by SFA numbers derived from AWS specifications. The source inspector would typically reference these specifications for whichever welding materials are specified in the contractual agreements to ensure that the right materials are being used in fabrication. However there will be no specific questions on the core examination out of Part C, but the SI should be familiar with what the standard covers.


■ Part D - Materials Properties.

Part D provides tables for design stress values, tensile strength, yield strength, and other important chemical and physical properties for all the material specifications contained in Parts A and B. This section is primarily intended for designers of ASME BPVC equipment. As such, there will be no specific questions on the core examinations out of Part D, but the SI should be familiar with what the standard covers.


7. The Reference Document: ASME VNondestructive Examination


8. The Reference Document: ASME VIIIRules for Construction ofPressure Vessels


9. The Reference Document: ASME IXQualification Standard for Welding and Brazing Procedures,Welders, Brazers, and Welding and Brazing Operators


10. The Reference Document: ASME B16.5Pipe Flanges and Flanged FittingsNPS 1/2 Through NPS 24 Metric/Inch Standard



11. The Reference Document: ASME B31.3Process PipingASME Code for Pressure Piping, B31


12. The Reference Document: ASNT SNT-TC-1AASNT Standard Topical Outlines for Qualification of Nondestructive Testing Personnel (Includes ANSI/ASNT CP-105-2011)


13. The Reference Document: SSPC-PA 2SSPC-PA 2 Procedure for Determining Conformance to Dry Coating Thickness Requirements


14. The Reference Document: SSPC Guide to Surface Preparation


SSPC Surface Preparation Guide. This guideline briefly describes the scope of the 7 different SSPCand NACE Surface Preparation Standards with application to source inspection. The source inspector should be familiar with the scope of the 7 standards listed below that are included in this guide, but need not be familiar with the details in the specific standards for examination purposes.

■ SSPC-SP1 - Solvent Cleaning■ SSPC-SP3 - Power Tool Cleaning■ SSPC-SP5 or NACE 1 - White Metal Blast Cleaning (SA3)■ SSPC-SP6 or NACE 3 - Commercial Blast Cleaning (SA2)■ SSPC-SP7 or NACE 4 - Brush-Off Blast Cleaning (SA1)■ SSPC-SP10 or NACE 2 - Near-White Blast Cleaning (SA2 ½)■ SSPC-SP11 - Power Tool Cleaning to Bare Metal


Documents

Api si source inspector certification the quoted references