Introduction

This course is designed for professionals aiming to succeed in the API 570 examination. The API has developed the Piping Inspector Certification Program to enhance safety through rigorous standards for inspectors specializing in process piping. The course on API 570: Process Piping Inspection Standards not only advocates for industry self-regulation but also helps in establishing uniform criteria to aid governmental bodies at various levels in regulating process piping systems. Mastering the content required to pass this examination is a formidable task, as it encompasses a broad spectrum of topics including in-service piping inspection, methodologies for welding procedure and welder performance qualifications, various refinery damage mechanisms (such as Corrosion Under Insulation (CUI), Galvanic corrosion, and atmospheric corrosion), inspection protocols for pressure relief devices (including PRVs, PSVs, and rupture disks), as well as welding, metallurgy, material verification programs, and maintenance practices per ASME PCC-2 post-construction standards. Furthermore, candidates must acquire proficiency in locating and applying specific formulas, equations, and tables from relevant codes, standards, and recommended practices to solve calculation problems and answer questions effectively during the open-book portion of the API examination.

Course Objectives

• Mastery of utilizing tables within ASME B31.3 process piping codes
• Comprehending methodologies for calculating both long-term and short-term corrosion rates in piping systems
• Determining piping system remaining life and Maximum Allowable Working Pressure (MAWP)
• Gaining insights into prevalent piping damage mechanisms within refineries
• Learning detailed aspects of welding procedures, qualifications, and metallurgical considerations
• Applying suitable Non-Destructive Examination (NDE) techniques for in-service inspections
• Understanding how to interpret corresponding inspection strategies

Target Audience

• Piping Inspectors
• Non-Destructive Examination (NDE) Specialists
• Piping Inspection Engineers
• Plant Inspection Professionals
• Piping and Mechanical Engineers
• Corrosion Engineers

Course Outline

DAY 1 Focus on API RP 577, ASME BPVC Section V, and ASME IX:

• Initial Steps - Examination and Study Guidelines
• Overview of API RP 577 covering Welding Processes, Inspection, and Metallurgy
• Detailed exploration of ASME Section V regarding Non-destructive Testing Methods, specifically Articles 1, 2, 6, 7, 9, 10, and 23
• Examination of Weld Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ)
• Review of essential and non-essential welding variables
• Discussion on the variety and type of mechanical tests required in PQR documentation

DAY 2 Exploration of ASME B16.5, API 578, and API 576:

• Analysis of Flange Pressure-Temperature Ratings and Markings
• Review of Flange Materials and Dimensional Specifications
• Testing Procedures for Flanges
• Implementation of Material Verification Programs for both New and Existing Assets as per API 578
• Case studies on material failures due to inadequate Material Verification Programs (MVP)
• Detailed sections from API 576 focusing on inspection and maintenance protocols

DAY 3 Dive into ASME B31.3:

• Scope and limitations of the code
• Calculation of Casting Quality Factors and Weld Joint Quality Factors from specific ASME B31.3 tables
• Methods to enhance Joint Quality Factors through additional NDE
• Formulas for determining the minimum necessary thickness for both straight pipe sections under internal pressure and for permanent blank installations based on design pressure
• Evaluations of MAWP for corroded pipes, factoring in expected corrosion at future inspections
• Analysis of thermal material expansion and the minimum temperature requirements exempt from impact testing
• Guidelines for calculating mandatory Charpy V-notch impact values for specific materials
• Requirements for preheating, post-weld heat treatment (PWHT), and specific NDE and inspection protocols
• Procedures for both hydrostatic and pneumatic leak testing, including calculations for test pressures

DAY 4 Concentrate on API 570:

• Definitions, Terms, Acronyms, and Abbreviations used within the scope of API 570
• Structure and responsibilities of Owner/User Inspection Organizations
• Best practices for Inspection, Examination, and Pressure Testing
• Guidelines on the Timing, Frequency, and Scope of Inspections
• Methods for Inspection Data Evaluation, Analysis, and Documentation
• Standards for Repairs, Modifications, and Re-rating of Piping Systems
• In-depth review of Annexes A, C, & D
• Problem-solving exercises focused on corrosion rates, MAWP, and remaining lifespan calculations

DAY 5 Study of API RP 571, API RP 547, & ASME PCC-2:

• Identification and management of various corrosion types including Amine and Chloride Stress Corrosion Cracking, Atmospheric Corrosion, and others
• Insight into Mechanical Fatigue and Microbiologically Influenced Corrosion
• Review of API 574's inspection practices for piping system components
• Detailed examination of ASME PCC-2 articles related to weld repairs, flange repairs, mechanical clamps, and other repair techniques
• Comprehensive overview of alternatives to Post-weld Heat Treatment and in-service welding practices on carbon steel pressure components or pipelines