EAGLE TESTING Jim Blankenship Sr. NDE Technician Mechanical Integrity Specialist API-510 Pressure Vessel Inspector SNT TC-1A L-III (MT, PT, VT & UT)

Experience 30+ years in the NDE industry Employed with Eagle Testing – 10 years 1992-2002 Velsicol Chemical 2007 – Certification API-510 2007 forward… 30+ years in the NDE industry – RECEIVED INITIAL NDE TRAINING IN 1980 AT OAK RIDGE Y-12 PLANT THROUGH UNION CARBIDE 1992-2002 Velsicol – ADMINISTERED A TANK AND VESSEL MECHANICAL INTEGRITY PROGRAM FOR VELSICOL CHEMICAL 2007 – Certification API-510 – ACHIEVED API-510 PRESSURE VESSEL INSPECTOR CERTIFICATION IN 2007 THROUGH THE AMERICAN PETROLEUM’S INDIVIDUAL CERTIFICATION PROGRAM ADMINSTERED BY CODE WEST, HOUSTON, TX 2007 forward… - SINCE 2007 HAVE WORKED FULL TIME AT A MAJOR GEORGIA ENERGY COMPANY – PERFORMING NDE INSPECTIONS AND LEADING A SMALL GROUP OF NDE INSPECTORS DURING MAINTENANCE OUTAGES ON BOILER, TURBINE AND AUXILLIARY COMPONENTS. CURRENTLY ASSISTING CHEMICAL PROCESSING COMPANIES IN DALTON, GA AND WELLFORD, SC WITH MECHANICAL INTEGRITY INSPECTIONS AND API-510 PRESSURE VESSEL REVIEWS.

API-510 PRESSURE VESSEL INSPECTION CODE In-Service Inspection, Rating, Repair and Alteration API-510 code covers the in-service inspection repair, alteration, and re-rating activities for pressure vessels and the pressure relieving devices protecting these vessels. Application of this inspection code is restricted to owner/users that employ or have access to the following technically qualified individuals or organizations. An authorized inspection agency A repair organization An engineer An inspector Examiner API-510 code covers……. VESSELS CONSTRUCTED IN ACCORDANCE WITH AN APPLICABLE CONSTRUCTION CODE. VESSELS CONSTRUCCTED WITHOUT A CONSTRUCTION CODE (NON-CODE)-A VESSEL NOT FABRICATED TO A RECOGNIZED CONSTRUCTION CODE AND MEETING NO KNOWN RECOGNIZED STANDARD. VESSELS CONSTRUCTED AND APPROVED AS JURISDICATIONAL SPECIAL BASED UPON JURISDICTION ACCEPTANCE OF PARTICULAR DESIGN, FABRICATION, INSPECTION, TESTING AND INSTALLATION. NON-STANDARD VESSELS – A VESSEL FEBRICATED TO A RECOGNIZED CONSTRUCTION CODE BUT HAS LOST THE NAMEPLATE OR STAMPING.

American Petroleum Industry ASME Section VIII Why did the American Petroleum develop its own pressure vessel inspection code and how does it relate to ASME Section VIII? Inspections Industry questions Problems/Challenges API-510 wrote Inspection Code with ASME Section VIII as the basis for comparing in- service vessels Why did the American Petroleum develop its own…….. MOST OF THE PRESSURE VESSELS USED IN THE PRODUCTION OF PETROLEUM, NATURAL GAS AND CHEMICAL PROCESSING ARE CONSTRUCTED TO ASME SECTION VIII OR OTHER NEW CONSTRUCTION CODES. DURING INSPECTION ACTIVITIES VARIOUS PROBLEMS WERE ENCOUNTERED INCLUDING CORROSION, EROSION, SHELL OR HEAD DISTORTIONS, THERMAL OR PROCESS CHEMISTRY CRACKING. These had to be evaluated to determine what repairs were necessary. THE INDUSTRY SOUGHT TO ANSWER QUESTIONS SUCH AS: How can we evaluate vessels that have been in service for many years to determine if they still meet the critical safety standards that they were originally manufactured to? For vessels that were not constructed to a construction code or have minimal or no documentation, how to evaluate those vessels in the context of providing operating limitations (pressure, temperature or vacuum)? How do we evaluate and provide operating limitations for vessels that have lost their manufacturer’s name plate? API – 510 wrote Inspection Code with ASME…………. THE ASME CODE AND OTHER CONSTRUCTION CODES ARE WRITTEN FOR NEW CONSTRUCTION; HOWEVER, MOST OF THE TECHNICAL REQUIREMENTS FOR DESIGN, WELDING, NDE, AND MATERIALS CAN BE APPLIED TO THE INSPECTION, RE-RATING, REPAIR, AND ALTERATION OF IN-SERVICE PRESSURE VESSELS.

API-510 – Additional Services R-stamp repair company oversight Required documents include: Weld Procedure Specification (WPS) Procedure Qualification Record (PQR) Welder Performance Qualification (WPQ) & welder currency documentation Material Test Reports (MTR) for all materials, plate, nozzle, flanges and filler metals. NDE Testing of repair welding R-stamp repair company oversight – TO MAKE SURE PROPER DOCUMENTATION IS IN PLACE PRIOR TO THE WELDER STRIKING AN ARC ON THE VESSEL. NDE Testing of repair welding – DYE PENETRANT, X-RAY OR AS APPLICABLE) TO APPLICABLE CODES

API-510 – Additional Services Pressure Test Calculations Pressure Test Required Nozzle Reinforcement Integral Reinforcement Pressure Test Required – IF A PRESSURE TEST IS REQUIRED BY THE API-510 AUTHORIZED INSPECTOR, THE TEST PRESSURE IS DETERMINED THROUGH APPLICABLE CALCULATIONS (AS PRESCRIBED IN ASME SEC VIII AND THE API-510 CODES) Nozzle Reinforcement – NOZZLE REINFORCEMENT CALCULATIONS ON VESSEL NOZZLES OR PENETRATIONS (USUALLY NOZZLES LARGER THAN 3” NPS) THAT DO NOT HAVE REINFORCEMENT PADS . Integral Reinforcement - PER ASME SEC VIII DIV 1 TO DETERMINE IF ACCEPTABLE “INTEGRAL” REINFORCEMENT EXISTS (EXCESS MATERIAL IN THE HEAD OR SHELL AND NOZZLE) THAT MEETS THE REQUIREMENTS OF THE ASME CODE NOT INCLUDING THICKNESS REQUIRED FOR PRESSURE, VACUUM AND TEMPERATURE

API-510 BENEFITS Corrosion addressed Corrosion rate Shell loss – remaining wall 0.385” Required wall – 0.418” WHAT TO DO? An answer can be found through the API-510 process. RE-RATING Corrosion rate Remaining Service Life Next Inspection Interval Name Plate Corrosion addressed – IF EXTENSIVE CORROSION HAS REDUCED THE SHELL, HEAD OR NOZZLE THICKNESS BELOW MINIMUM WALL VALUES REQUIRED IN ASME SEC VIII, DIV 1 – IN THIS EXAMPLE LET’S SAY WE ARE LOOKING AT A CARBON STEEL SHELL MATERIAL THAT IS/WAS 0.500” THICK AND THE VESSEL IS RATED FOR 150 PSI AT 500 DEGREES F. AN ULTRASONIC THICKNESS SURVEY OF THE SHELL, HEADS AND NOZZLES HAS DETERMINED THE WALL THICKNESS TO BE 0.385” ASME DETERMINES THE REQUIRED THICKNESS IS 0.418”. OBVIOUSLY THE VESSEL DOES NOT MEET THE REQUIREMENTS FOR ITS DESIGN LIMITATIONS (OR RATINGS). WHAT SHOULD BE DONE – ORDER A REPLACEMENT VESSEL? !! ANSWER – THE ACTUAL OPERATING CONDITIONS FOR THIS VESSEL ARE NO MORE THAN 90 PSI AT 350 DEGREES F. THROUGH THE API-510 RE-RATING PROCESS, CALCULATIONS ARE AGAIN PERFORMED; THIS TIME FOR A RATING OF 100 PSI AT 400 DEGREES F. THIS SET OF CALCULATIONS REVEAL THAT A WALL THICKNESS OF 0.323” IS ACCEPTABLE. Corrosion rate – Remaining Service Life – Next Inspection Internal – During the process of inspection the API-510 INSPECTOR WILL COMPLETE CALCULATIONS ACCORDING TO THE API-510 CODE FOR: Corrosion rate, Remaining Service Life and Next Inspection Interval. IF ACCEPTABLE TO THE VESSEL’S OWNER AND ENGINEER, AN OWNER/USER NAME PLATE IS PRODUCED, STAMPED WITH DATE AND AUTHORIZATION (API-510 INSPECTOR CERFICIATION) AND IS ATTACHED TO THE VESSEL. THE ORIGINAL NAME PLATE IS VOIDED. CHANGE IN SERVICE OUTSIDE OF THE NAME PLATE LIMITATIONS – A DESIRED INCREASE OF TEMPERATURE AND/OR PRESSURE…

PREPARATION VESSEL INSPECTION Lock-Out, Tag-Out for vessel entry Vessel clean-out for inspection Insulation removal Insulation plug cutting Insulation removal – MIGHT BE NEEDED FOR SOME NOZZLES – TO AID IN EXTERNAL INSPECTION AND NOZZLE THICKNESS TESTING Insulation plug cutting – TO PROVIDE POINTS FOR EXTERNAL VISUAL ACCESS AND ULTRASONIC THICKENSS TESTING (UNLESS ULTRASONIC MEASUREMENTS CAN BE TAKEN INTERNALLY).

DOCUMENTATION REQUIRED (copies) Manufacturer’s Data Reports U-1, U-1A, U2 & U4 Manufacturer’s Construction Drawings Repair or Alteration Documentation R-1 Operating Conditions Pressure, Temperature, Vacuum, etc. Information on each Vessel Dates of inspection, etc. Information on each Vessel – PRESSURE RELIEF VALVES OR OTHER PROTECTIVE DEVICES, DATES OF INSPECTION PRESSURE RELIEF CALCULATIONS (INTERNAL OR EXTERNAL ENGINEERING KNOWN UPSET EVENTS OR CONDITIONS VESSEL INSPECTION SHELL, HEAD OR NOZZLE DISTORTIONS

REFERENCES Available upon request The most recent editions of the following standards, codes, and specifications are cited in this inspection code. API: RP571 Damage Mechanisms Affecting Fixed Equipment in the Refining Industry RP572 Inspection of Pressure Vessels RP 576 Inspection of Pressure-Relieving Devices RP577 Welding Inspection and Metallurgy RP 578 Material Verification Program for New and Existing Alloy Piping Systems RP579 Fitness-For Service RP 580 Risk-Based Inspection Publ581 Risk-Based Inspection- Base Resource Document RP 582 Recommended Practice and Supplementary Welding Guidelines/or the Chemical, Oil, and Gas Industries Publ2201 Procedures for Welding or Hot Tapping on Equipment in Service API 510 Inspector Certification Examination Body of Knowledge   ASME1. Boiler and Pressure Vessel Code Section V: Non Destructive Examination Section VIII: Division 1, Rules for Construction of Pressure Vessels Section VIII: Division 2, Rules for Construction of Pressure Vessels-Alternative Rules Section IX: Welding and Brazing Qualifications PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly ASNT2 / CP-189 Standard for Qualification and Certification of Nondestructive Testing Personnel SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing NACE3 / RP0472 Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments In Corrosive Petroleum Refining Environments MR 0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments National Board4 National Board Inspection Code NB-23 / WRC5 Bulletin 412 Challenges and Solutions in Repair Welding for Power and Processing Plants OSHA6 29 CFR Part 1910 Occupational Safety and Health Standards OSHA6 29 CFR Part 1910 Occupational Safety and Health Standards 1. ASME International, Three Park Avenue, New York, New York 10016-5990, www.asme.org 2. The American Society for Nondestructive Testing, 1711 Arlingate Lane, Columbus Ohio 43228-0518, www.asnt.org 3. NACE International, 440 South Creek Drive, Houston, Texas 77084, www.nace.org.. 4. The National Board ofBoi1er and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229, www.nationalboard.org 5. Welding Research Council, P.O. Box 201547, Shaker Heights, Ohio 44120, www.Jorengineers.org 6. Occupational Safety and Health Administration, 200 Constitution Avenue, NW, Washington, DC 20210, www.osha. gov