The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition

The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

API RP 577

Welding Inspection and Metallurgy

Section 1 Scope

This recommended practice provides guidance to the API authorized inspector on welding inspection as
encountered with fabrication and repair of refinery and chemical plant equipment and piping.
The level of learning and training obtained from this document is not a replacement for the training
and experience required to be an American Welding Society (AWS) Certified Welding Inspector
(CWI), or Canadian and European equivalent schemes such as CWB, CSWIP, PCN, or EFW.

Section 4 Welding Inspection

4.1 GENERAL

Welding inspection is a critical part of an overall weld quality assurance program. Inspectors should
perform specific tasks prior to welding, during welding and upon completion of welding, although it is
usually not necessary to inspect every weld.

4.2 TASKS PRIOR TO WELDING

Drawings, Codes, and Standards

Weldment Requirements
Procedures and Qualification Records
NDE Information
Welding Equipment and Instruments
Heat Treatment and Pressure Testing
Materials
Weld Preparation
Preheat
Welding Consumables

4.3 TASKS DURING WELDING OPERATIONS

Quality Assurance
Welding Paramaters and Techniques
Weldment Examination

4.4 TASKS UPON COMPLETION OF WELDING

Appearance and Finish

NDE Review
Post-weld Heat Treatment
Pressure Testing
Documentation Audit

4.5 NON-CONFORMANCES AND DEFECTS

At any time during the welding inspection, if defects or non-conformances to the specification are
identified, they should be brought to the attention of those responsible for the work or corrected before
welding proceeds further.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 1 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

4.6 NDE EXAMINER CERTIFICATION

If the referencing code does not list a specific standard to be qualified against, qualification may involve
demonstration of competency by the personnel performing the examination or other requirements
specified by the owner-user.

4.7 SAFETY PRECAUTIONS

Inspectors should be aware of the hazards associated with welding and take appropriate steps to
prevent injury while performing inspection tasks.

Section 5 Welding Processes

5.1 GENERAL

These processes include shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), gas
metal arc welding (GMAW), flux cored arc welding (FCAW), submerged arc welding (SAW), and stud
arc welding (SW).

5.2 SHIELDED METAL ARC WELDING (SMAW)

SMAW is the most widely used of the various arc welding processes. SMAW uses an arc between a
covered electrode and the weld pool.

5.3 GAS TUNGSTEN ARC WELDING (GTAW)

GTAW is an arc welding process that uses an arc between a non-consumable tungsten electrode and
the weld pool. DCEN welding offers the advantages of deeper penetration and faster welding speeds.

5.4 GAS METAL ARC WELDING (GMAW)

GMAW is an arc welding process that uses an arc between continuous filler metal electrode and the
weld pool.

5.4.7 Limitations of GMAW

When using the GMAW-S process, the weld is more susceptible to lack of adequate fusion.

5.5 FLUX CORED ARC WELDING (FCAW)

FCAW is an arc welding process that uses an arc between continuous tubular filler metal electrode
and the weld pool.

5.6 SUBMERGED ARC WELDING (SAW)

Submerged arc welding is an arc welding process that uses an arc or arcs between a flux covered
bare metal electrode(s) and the weld pool.

5.7 STUD ARC WELDING (SW)

SW is an arc welding process that uses an arc between a metal stud or similar part and the work
piece.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 2 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

Section 6 Welding Procedure

6.2 WELDING PROCEDURE SPECIFICATION (WPS)

ASME Section IX requires each manufacturer and contractor to develop welding procedures. ASME
B31.3 allows welding procedure qualification by others, provided it is acceptable to the inspector and
meets certain conditions.

6.3 PROCEDURE QUALIFICATION RECORD (PQR)

The PQR should accompany the WPS and be available for review by the Inspector upon request. It
does not need to be available to the welder. One PQR may support several WPSs. One WPS may be
qualified by more than one PQR within the limitations of the code.

6.4 REVIEWING A WPS AND PQR

The initial step is to verify the WPS has been properly completed and addresses the requirements of
Section IX and the construction/repair code.

The second step is to verify the PQR has been properly completed and addresses all the
requirements of Section IX and the construction and repair code.

The third step is to confirm the PQR essential variable values properly support the range specified in
the WPS.

Section 7 Welding Materials

7.1 GENERAL

Welding materials refers to the many materials involved in welding including the base metal, filler
metal, fluxes, and gases, if any.

7.2 P-NUMBER ASSIGNMENT TO BASE METALS

Base metals are assigned P-numbers in ASME Section IX to reduce the number of welding procedure
qualifications required. For ferrous base metals having specified impact test requirements, group
numbers within P-numbers are assigned.

7.3 F-NUMBER ASSIGNMENT TO FILLER METALS

Electrodes and welding rods are assigned F-numbers to reduce the number of welding procedure and
performance qualifications. The F-number groupings are based essentially on their usability
characteristics, which fundamentally determine the ability of welders to make satisfactory welds with a
given process and filler metal.

7.4 AWS CLASSIFICATION OF FILLER METALS

An AWS classification number identifies electrodes and welding rods.

7.5 A-NUMBER

The A-number grouping in ASME Section IX, Table QW-442 is based on the chemical composition of
the deposited weld metal.

7.6 FILLER METAL SELECTION

Appendix D provides a guide of common filler metals for base metals most often used in
petrochemical plants.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 3 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

Section 8 Welder Qualification

8.1 General

Welder performance qualification is to establish the welder’s ability to deposit sound weld metal.

The term welder is intended to apply to both welders and welding operators.

The responsibility for qualifying welders is restricted to be the contractor or manufacturer employing
the welder and cannot be delegated to another organization.

8.2 Welder Performance Qualification (WPQ)

Welder performance qualification expires if the welding process is not used during a six month period.
The welder’s qualification can be revoked if there is a reason to question their ability to make welds

Section 9 Non-destructive Examination

9.1 DISCONTINUITIES

Non-destructive Examination (NDE) is defined as those inspection methods, which allow materials to
be examined without changing or destroying their usefulness.

Brief review of common types of discontinuities as per table 2 and discontinuities commonly
encountered with welding processes as per table 6

9.3 VISUAL EXAMINATION (VT)

9.3.1 General
Direct visual examination is conducted when access is sufficient to place the eye within 6 in. – 24 in.
(150 mm – 600 mm) of the surface to be examined and at an angle not less than 30 degrees to the
surface.

Direct visual examination requirements

9.4 MAGNETIC PARTICLE EXAMINATION (MT)

9.4.1 General

Magnetic particle examination is effective in locating surface or near surface discontinuities of

ferromagnetic materials.

9.5 ALTERNATING CURRENT FIELD MEASUREMENT (ACFM)

The ACFM technique is an electromagnetic non-contacting technique that is able to detect and size
surface breaking defects in a range of different materials and through coatings of varying thickness.

9.6 LIQUID PENETRANT EXAMINATION (PT)

PT is capable of detecting surface-connecting discontinuities in ferrous and nonferrous alloys.

9.7 EDDY CURRENT INSPECTION (ET)

Eddy current inspection is used to detect surface discontinuities, and in some cases subsurface
discontinuities in tubing, pipe, wire, rod and bar stock.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 4 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

9.8 RADIOGRAPHIC EXAMINATION (RT)

RT is a volumetric examination method capable of examining the entire specimen rather than just the
surface.

9.9 ULTRASONIC EXAMINATION (UT)

UT is capable of detecting surface and subsurface discontinuities.

9.9.5 Examination Coverage

Each pass of the transducer will overlap the previous pass by 10% of the transducer element
dimension. The rate of search unit movement will not exceed 6 in. (152 mm) per second unless the
calibration was verified at an increased speed.

9.10 HARDNESS TESTING

Hardness testing of the weld and HAZ is often required to assure the welding process and any PWHT
resulted in an acceptably “soft” result. API RP 582 details hardness test requirements for PQRs and
production welds.

9.11 PRESSURE AND LEAK TESTING (LT)

Codes and most specifications do not indicate the duration of pressure tests. The test must be held
long enough for a thorough visual inspection to be completed to identify any potential leaks. Typically, a
pressure test should be held for at least 30 minutes.

Section 10 Metallurgy
10.1 GENERAL

Metallurgy is a complex science but a general understanding of the major principles is important to the
inspector, due to the wide variety of base metals that may be joined by welding during the repair of
equipment, and the significant impact on the metals resulting from the welding process.

This section is designed to provide an awareness of metallurgical effects important to personnel

performing inspections, but is not to be considered an in depth resource of metallurgy.

10.2 THE STRUCTURE OF METALS AND ALLOYS

Knowledge of cast structures is important since the welding process is somewhat akin to making a
casting in a foundry. Because of the similarity in the shape of its grains, a weld can be considered a
small casting.

10.3 PHYSICAL PROPERTIES

10.3.6 Density

The density of a material is defined as its mass per unit volume.

10.4 MECHANICAL PROPERTIES

10.4.2 Tensile and Yield Strength

Tensile testing is used to determine a metals ultimate tensile strength, yield strength, elongation and
reduction in area. A tensile test is performed by pulling a test specimen to failure with increasing load.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 5 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

10.4.3 Ductility

In tensile testing, ductility is defined as the ability of a material to deform plastically without fracturing,
measured by elongation or reduction of area.

10.4.4 Hardness

The hardness of a material is defined as the resistance to plastic deformation by indentation.

10.4.5 Toughness

The toughness is the ability of a metal to absorb energy and deform plastically before fracturing.

10.5 PREHEATING

Preheating, for our purposes, is defined as heating of the weld and surrounding base metal to a
predetermined temperature prior to the start of welding. The primary purpose for preheating carbon
and low-alloy steels is to reduce the tendency for hydrogen induced delayed cracking.

10.6 POST-WELD HEAT TREATMENT

The primary reason for post-weld heat treatment is to relieve the residual stresses in a welded
fabrication.

10.7 HARDENING

Hardening or hardenability is defined as that property of a ferrous alloy that determines the depth and
distribution of hardness induced by quenching.

10.9 WELDABILITY OF METALS

10.9.2 Metallurgy and Weldability

A primary factor affecting weldability of metals and alloys their chemical composition. Chemical
composition not only controls the range of mechanical properties in carbon steel and alloy steels, it has
the most influence on the effect of welding on the material. The addition of carbon generally makes the
metals more difficult to weld. Carbon content has the greatest effect on mechanical properties, such as
tensile strength, ductility and toughness in the base metal heat affected zone and weldment.
Carbon content influences the susceptibility of the metal to delayed cracking problems from hydrogen.
The carbon content or carbon equivalent of carbon steel that determines the necessity for pre-heat
and post-weld heat treatment.

One tool has been developed to help evaluate the weldability of carbon and alloy steel and that is
carbon equivalent (CE) equation.

Mn (Cr  Mo V ) (Si  Ni  Cu)

CE  C   
6 5 15
Typically, steels with a CE less than 0.35 require no preheat. Steels with a CE of 0.35 – 0.55 usually
require preheating, and steels with a CE greater than 0.55 require both preheating and a PWHT.
However, requirements for preheating should be evaluated by considering other factors such as
hydrogen level, humidity, and section thickness.

10.10.3 Nickel Alloys

One of the main differences between nickel alloy and carbon steels, and austenitic stainless steels, is
there tendency to be sluggish during welding.

API RP 577 for API 510, MSH 4/7/2017 11:30 PM Page 6 of 7

 The topics discussed herewith are summarized from API RP 577 – 2013,Second Edition
The highlighted points are as per outline in the body of knowledge API 510 Pressure Vessel Inspector
Certification examination issued May and September 2016 and January 2017 (Replaces May 2015)

Section 11 Refinery and Petrochemical Plant Welding Issues

11.2 HOT TAPPING AND IN-SERVICE WELDING

Two primary concerns when welding on in-service piping and equipment are burn through and
cracking. Burn through will occur if the unmelted area beneath the weld pool can no longer contain
the pressure within the pipe or equipment. Weld cracking results when fast weld-cooling rates
produce a hard, crack-susceptible weld microstructure. Fast cooling rates can be caused by flowing
contents inside the piping and equipment, which remove heat quickly.

11.2.2 Electrode Considerations

Hot tap and in-service welding operations should be carried out only with low-hydrogen consumables
and electrodes (e.g., E7016, E7018 and E7048).

11.2.4 Other Considerations

To minimize burn through, the first weld pass to equipment or piping less than 1/4 in. (6.35 mm) thick
should be made with 3/32 in. (4.76 mm) or smaller diameter welding electrode to limit heat input. For
equipment and piping wall thicknesses where burn through is not a primary concern, a larger diameter
electrode can be used. Weaving the bead should also be avoided as this increases the heat input.

11.3 LACK OF FUSION WITH GMAW-S WELDING PROCESS

The gas metal arc welding (GMAW) process can utilize various metal transfer modes. When using the
low voltage, short circuiting mode (designated by the -S extension), the molten weld puddle is able to
freeze more quickly.

Review figure A-4 to A-9

Review Appendix D

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