NOTES
1. API 510 is applicable to vessels that have been placed in service,
and it can not be adopted for new constructions.
2. Following are excluded from scope of API 510:
a. All mobile vessels
b. All exclusions of ASME Sec VIII, Div. 1
c. Vessels not exceeding 5 cubic feet and 250 psi design
pressure or 1.5 cubic feet and 600 psi design pressure
3. Alteration: It is change in component that has design
implications affecting pressure and/or temperature rating.
4. Repair: It is restoring vessel suitable for operations at the
present design conditions. Repairs do not change Pr-Temp
rating of vessel.
5. Authorized inspection agency. Any one of following:
a. Jurisdiction organization
b. Insurance company which under writes insurance of pressure
vessels
c. Inspection organization of owner-user
d. Inspection organization under contract with owner user
6. Repair Organization: Any one of following:
a. Holder of ASME certificate & appropriate code symbol stamp
b. Owner-user
c. Contractor under contract with owner-user
d. Organization authorized by jurisdiction
7. On-stream inspection means NDT inspection done on Vessel
without entering inside vessel. This inspection is basically to
know process side deterioration.
8. Re-rating: A change in either MAWP or temperature rating or
change in both.
9. Owner-User bears Ultimate responsibility for all activities
(inspection, Engineering, repairs etc.) under API 510.
NOTES
10. Authorised Inspector is responsible to Owner-User to:
a. Determine that all work (inspection, repairs ,alteration) is
carried out as per requirements of API-510
b. By getting involved in the actual activities performed
c. Evaluate & accept/reject results of NDT and other tests.
11. Repair Organisation is responsible to Owner-User for the use
of proper materials, Quality Control, Workmanship during the
repair work performed by them.
12. Prior to any inspection, safety rules (OSHA or other) shall be
reviewed and followed. NDT equipment shall be as per Safety
rules and Protective clothing shall be used where required.
13. Modes of failure:
a. Chemical corrosion due to contaminants in fluid
handled.
b. Fatigue: Due to stress reversals (vibration, changes
of temperature or pressure)
c. Creep: At elevated temp (in areas of stress
concentration)
d. Freeze Damage: Failure due to freezing and
expansion of water/aqueous solutions.
e. Brittle failure: Due to loss of impact strength at
lower temperature
f. Tamper Embrittlement: Loss of ductility in Cr-Steels
due to improper PWHT or service at high
temperature (>700ºF)
14. For new service, or for changed service, if corrosion rate is
not known, The corrosion rate may be calculated based on
corrosion data for similar service, or based on published
data. If both are not available, on-stream determination
NOTES
after 1,000 hours shall be made to establish the corrosion
rate.
SEt
15. MAWP = /(R+0.6t)
Where t = t actual – 2 x Cn
Cn = metal loss up to next inspection
16. For corrosion area of considerable size; thickness averaging
along most critical element shall not exceed following length
(l) measured longitudinally:
a. Vessel I.D. < 60”... l = D/2 or 20” use smaller value
b. Vessel I.D. > 60”... l = D/3 or 40” use smaller value
17. The widely scattered pits, can be ignored if:
a. Remaining thickness below the pit is greater than half the
required thickness.
b. Total pit area does not exceed 7 square inches within 8 inch
diameter circle.
c. Total sum along any line in circle does not exceed 2 inches.
18. As alternative, evaluation of thinning of pressure retaining
walls
may be performed by employing methods outlined in ASME Sec.
VIII Div. 2, in consultation with the Pr. Vessel Engineer.
19. For surface remote from weld, (weld E < 1), shell thickness
can be recalculated with E = 1. Shell area is considered
remote from weld if it lies on either side weld beyond 1” or 2
times the thickness (whichever is greater).
20. For dished Heads, the Crown portion lies within a circle
concentric to dish but with circle dia. = 0.8 x shell dia.
21. For Ellipsoidal or Torispherical heads, crown portion thickness
can be recalculated considering the Crown as part of sphere
of radius equal to D, (for standard Torispherical) or K 1 D (for
Ellipsoidal). Where, D is shell diameter
NOTES
22. For ellipsoidal head K1 depends on D/2h ratio (h=head depth)
For 2:1 Ellipsoidal Head, K1 = 0.9
23. Fitness for Service evaluations are performed as per API RP
579.
24. RBI methodology is based on assessment of Likelihood of
failure
(LOF) and Consequence of Failure (COF) and is conducted and
documented as per API RP 580.
25. RBI assessment may be used as an alternative to establish
the
Frequency of Internal and External Inspections.
26. If 10 year limit Is increased based on RBI, the RBI
assessment shall be reviewed and approved by both Pressure
Vessel Engineer and Inspector at intervals not exceeding 10
years or more often if LOF or COF changes.
27. Frequency of inspection:
a. External visual: 5 years or same as internal (or on-steam)
inspection, use smaller duration.
b. Internal/on-stream: Smaller of half remaining life or 10
years, if remaining life is < 4 years full remaining life up to
maximum of 2 years.
a. For non-continuous service – external same as (a) above
but internal will be after 10 years of actual exposed life for
non corrosive, where as for corrosive it will be smaller of
half remaining life or 10 years.
28. For Insulated vessels, CUI is likely to occur If there is
possibility of moisture ingress and operate between 25 to 250
degrees F.
29. On-Stream inspection may be substituted for internal
inspection if:
NOTES
a. There is no access to enter.
b. If Corrosion rate is less than 5 mpy and R. L. is more than 10
years there are no questionable conditions found during
external inspection. Also, the vessel is not subject to
Environmental damage or Strip/plate lined.
30. Remaining life = Remaining C.A. / Corrosion rate
Corrosion rate =
31. Pressure test:
Min. Test temp. = MDMT + 30ºF (thickness > 2”)
= MDMT + 10ºF (thickness ≤ 2”)
Perform Pneumatic test, if hydro is impractical.
32. If service conditions are changed, the allowable service
conditions (Max. pressure, max. and min. temperature) and
inspection intervals shall be determined for new condition.
33. If both ownership and location are changed vessel shall be
cleaned internally and externally and allowable conditions of
service and next period of inspection shall be established.
34. Inspection records shall have 4 type of information:
a. Design and Construction (permanent) records
b. Running (progressive) inspection records
c. Repair and alteration (modification) records
d. Fitness for service records
35. For vessels whose material is not known, MAWP can be
calculated assuming stress value for A 283 Gr. C material and
Joint Efficiency equal to 0.7.
NOTES
36. Pressure relieving devices: Inspection interval not to exceed 5
years normally but for clean non-corrosive service may be 10
years.
37. Authorization for repairs/alteration of vessels constructed as
per:
ASME Sec. VIII, Div. 1:
Repairs — API inspector
Alterations — API inspector and P.V. engineer
ASME Sec. VIII, Div.2:
Repairs & Alterations — API inspector and P.V. engineer
38. 12. If PWHT is impracticable, materials under P No. 1 (group
1, 2, 3) and P No. 3 (group 1, 2) shall be repair welded as
follows (if impact testing is not required).
a. Preheat to 300 degrees F for a distance 4” or 4t on
either side of groove (t = weld metal thickness)
b. Welding process shall be SMAW, GMAW, or GTAW
c. Control interpass temperature not to exceed 600
degrees F
39. 13. If impact testing is required and PWHT is impracticable,
the materials under P No. 1, 3, 4 shall be welded as follows:
a. Adopt SMAW/GMAW/GTAW process — with temper bead of
half bead technique
b. Requalify the procedures as per table 7-1
c. Use low Hydrogen Electrodes. Carry out Hydrogen bake out
treatment if required (Electrodes designation > H4)
40. For all other materials other than 12 and 13 above, PWHT
shall be carried out after repair if it was carried out originally
as per code of construction.
41. Local PWHT may be substituted for 360-degree banding if:
a. Original PWHT was not due to service requirement
NOTES
b. Effects of Local strains/distortions are considered
c. Pre-heat & maintainance of 300 deg. F during welding
d. PWHT temp is maintained beyond the weld upto twice base
metal thickness
e. Heat is applied to any nozzles /attachments within PWHT area.
42. For repairs of following :
a. Cracks: By preparing V or U-shaped groove and depositing
weld metal
— Cracks at area of stress concentrations (i.e., nozzle
welds) shall not be repaired without consulting the
pressure vessel engineer.
b. Localized corroded area: By weld deposit. Low strength
electrodes may be used if thickness of deposit is increased by
ratio of B.M. strength to W.M. strength and
— Depth of deposit does not exceed half of thickness
— Increased thickness is blended with 3:1 taper
43. For repair welds, the weld preparation before welding, and
the completed weld shall be checked by PT or MT.
Additionally, the butt-welds shall be radiographed by the rules
of original Code of construction (depending on joint
efficiency).
44. The carbon and alloy steel materials used in making repairs
and alterations shall not have carbon content over 0.35%.
45. Pressure test is required after repair/alterations, if authorised
inspector thinks it necessary. Pressure test is normally
required after alteration.
46. Insert patches must be with full penetration welds. Fillet
patches shall be approved by P.V. Engineer. Normally, a fillet
patch equivalent to reinforced opening is okay.
47. Normally, temporary repairs are replaced by permanent
repairs at next available maintenance opportunity. But
temporary repairs can remain for longer period if approved by
P.V. engineer.
NOTES
48. Non-penetrating nozzles (including pipe caps) are accepted
method of long term repairs for other than cracks.
49. Full encircle lap band is considered as long term repair for
other than cracks.
50. Full encircle lap band is considered as long term repair for
other than cracks.
51. Re-rating calculations shall be done by pressure vessel
engineer, and the inspector shall oversee the new stamping
or New name plate showing rerating (new MAWP, temp.) is
attached to vessel.
