Guide for Source Inspection and Quality Surveillance of Fixed Equipment An API Approach _ The Referred Standards 2014-October My Self Study Exam Preparatory Notes
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Fion Zhang 2014/October
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http://meilishouxihu.blog.163.com/
Dennis Tong 2014/October
Technical
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Remember few keypoints. The rest is common sense!
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The best keypoints learning is practicing the magical Q&A & thru forum discussion
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The Magical Journey Starts……
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Contents: 1. API SI
6. ASME IX
12.ASNT SNT-TC-1A
2. API 510/572
7. ASME VIII
13.SSPC-PA 2
3. API 577
8. ASME V
4. API 578
9. ASME II
14.SSPC Surface preparation guide
5. API 598
10.ASME B16.5 11.ASME B31.3
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1. The Main Document: API SI Guide for Source Inspection and Quality Surveillance of Fixed Equipment
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Key points: Section 2: Introduction Like 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
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ASME BPVC Section II—Materials Part A—Ferrous Material Specifications Part B—Nonferrous Material Specifications Part C—Specifications for Welding Rods, Electrodes and Filler Metals Part D—Materials Properties
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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 Cleaning SSPC-SP3—Power Tool Cleaning SSPC-SP5 or NACE 1—White Metal Blast Cleaning SSPC-SP6 or NACE 3—Commercial Blast Cleaning SSPC-SP7 or NACE 4—Brush-Off Blast Cleaning SSPC-SP10 or NACE 2—Near-White Blast Cleaning SSPC-SP11—Power Tool Cleaning to Bare Metal Charlie Chong/ Fion Zhang
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
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12.7.6 In the U.S., heat exchangers and condensers are designed and built in accordance with ASME BPVC, TEMA Standards, API 660—Shelland-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".
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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 strength structural bolts. 14.9 Galvanizing should be in accordance with ASTM A123 or A153 unless otherwise specified in the purchase order documents
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ASME & NB Symbol Stamps
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ASME & NB Symbol Stamps
R: Repair & alteration VR: Repair of safety valves
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“V” Day for Safety Valves
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“S” Superman for Power Boiler
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“S” Superwomen for Power Boiler
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2. The Reference Document: API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration
www.slideshare.net/slideshow/embed_code/38469969 Charlie Chong/ Fion Zhang
3. The Reference Document: API 577 Welding Inspection and Metallurgy
www.slideshare.net/slideshow/embed_code/38134553 Charlie Chong/ Fion Zhang
4. The Reference Document: API 578 Material Verification Program for New and Existing Alloy Piping Systems
www.slideshare.net/slideshow/embed_code/38134583 Charlie Chong/ Fion Zhang
5. The Reference Document: API 598 Valve Inspection and Testing
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Valve Inspection and Testing Downstream Segment
API STANDARD 598 EIGHTH EDITION, MAY 2004
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Scopes & Coverage ď Ž 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-seated valves of the gate, globe, plug, ball, check, and butterfly type. ď Ž 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.
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ď Ž 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.
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Gate Valve
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Gate Valve Charlie Chong/ Fion Zhang
Sliding Gate Valve
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Globe Valve
http://www.ctgclean.com/tech-blog/2012/03/valves-manual-valves-globe-valves/
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Globe Valve
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Globe Valve
http://www.bellowseal.com/products.html
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Globe Valve
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Globe Valve
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Plug Valve
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Plug Valve
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Plug Valve
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Check Valve
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Check Valve
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Floating Ball Valve
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Floating Ball Valve
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Floating Ball Valve
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Floating Ball Valve
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Floating Ball Valve
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Floating Ball Valve Charlie Chong/ Fion Zhang
Butterfly Valve
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Butterfly Valve
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Butterfly Valve
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Trunnion Mounted Ball Valve
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Trunnion Mounted Ball Valve
http://www.c-a-m.com/forms/Product.aspx?prodID=81fecf80-6b0e-41cd-87da-49a7b65e8ecc
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Trunnion Mounted Ball Valve
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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.
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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.
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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 1A 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?)
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Discussion: Topic:3.4 HIGH-PRESSURE CLOSURE TEST The 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 required to 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
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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-pressure closure tests, the test fluid shall be air, inert gas, kerosene, water, or a noncorrosive 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.
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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 is not permitted.
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4.2 BACKSEAT TEST 4.2.1 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).
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Seat Test
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Bellow Sealed Valve
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Bellow Sealed Valve
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What is Bellow Sealed
http://www.bellowseal.com/products.html
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Bellow Sealed
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Bellow Sealed Valve
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Bellow Sealed Valve
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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.
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Why Marked “NA” for Ball Valve?
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Why Marked “NA” for Plug Valve?
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ď Ž 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
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4.4 LOW-PRESSURE CLOSURE TEST: 4.4.3 …For a check valve, the pressure shall be applied on the downstream side
Pressurized here
Process flow direction
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ď Ž 4.5 HIGH-PRESSURE CLOSURE TEST 4.5.1 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.
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All The Best for your API SI Exam!
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6. The Reference Document: ASME II Material Verification Program for New and Existing Alloy Piping Systems
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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. â– 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.
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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
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â– 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.
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â– 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.
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â– 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.
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7. The Reference Document: ASME V Nondestructive Examination
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8. The Reference Document: ASME VIII Rules for Construction of Pressure Vessels
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9. The Reference Document: ASME IX Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators
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10. The Reference Document: ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard
www.slideshare.net/slideshow/embed_code/39835586 Charlie Chong/ Fion Zhang
11. The Reference Document: ASME B31.3 Process Piping ASME Code for Pressure Piping, B31
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12. The Reference Document: ASNT SNT-TC-1A ASNT Standard Topical Outlines for Qualification of Nondestructive Testing Personnel (Includes ANSI/ASNT CP-105-2011)
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13. The Reference Document: SSPC-PA 2 SSPC-PA 2 Procedure for Determining Conformance to Dry Coating Thickness Requirements
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14. The Reference Document: SSPC Guide to Surface Preparation
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SSPC Surface Preparation Guide. This guideline briefly describes the scope of the 7 different SSPC and 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
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