BIMTEK

INSPEKTUR BEJANA TEKAN

API 510

Purwidiatmo
Rev. 10 – June 2024

1
OVERVIEW OF API 510

2
 OVERVIEW OF API 510
History :

• 1931  Created Joint API/ASME Committee on Unfired PV

• 1934  1st edition API/ASME Code for Unfired PV approved
for publication
• 1956  API/ASME Code discontinued
Purwidiatmo

(demand arose – need to have uniform maintenance

and inspection practices)
• 1958  1st publication of API 510
• Each edition may be used at the date of issuance
• Becomes effective 6 months after the date of issuance
• During the 6-months (date of issuance – eff. Date)  the user
shall specify which edition, revision or addenda will be used
• API standards are review & revised at least every 5 years
3
 OVERVIEW OF API 510

Objective of In-service Inspection:

To ensure Vessel integrity
(safe to operate until next scheduled inspection)

 Determine current conditions

Purwidiatmo

 Determine Remaining Life

 Determine Inspection Plans & Intervals

4
 CONTENTS
1. Scope
2. References
3. Definitions
4. Owner- Operator Inspection Organization
Purwidiatmo

5. Inspection, Examination and Press. Testing Practices

6. Interval / Frequency and Extent of Inspection
7. Inspection Data Evaluation, Analysis and Recording
8. Repairs, Alterations, and Rerating of Press. Vessel
9. Alternative Rules for E&P Press. Vessel

Appendix : A ~ E
5
OVERVIEW OF API 510
1. SCOPE

• GENERAL APPLICATION

• SPECIFIC APPLICATIONS

• RECOGNIZED TECHNICAL CONCEPT

6
 1. SCOPE
GENERAL APPLICATION
COVERAGE :
 In-service inspection, Repair, Alteration, Re-rating activities
for PV and PRD
OVERVIEW OF API 510

 Hydrocarbon and chemical process PV that have been

placed in service (existing)
 Also applies to PV in other industries (at owner discretion)
that is constructed to:
• An applicable construction code (ASME Code),
• Without a construction code (non-code vessel)
• Approved as jurisdictional special based upon jurisdiction
acceptance of particular design, fabrication, inspection, testing
and installation.
• Non-standard Vessels
Most technical requirement of ASME Code can be applied ( if conflict –
API 510 mandatory)
7
 1. SCOPE
GENERAL APPLICATION
INTENT :
 Application of this code is restricted to owners-operators
that employ or have access to the following technically
OVERVIEW OF API 510

qualified :
• An authorized inspection agency,
• A repair organization,
• An engineer,
• An Inspector,
• Examiners
 Inspector shall be certified  see annex B.
 To specify the in-service & condition-monitoring, to determine the
integrity of PV & PRD. Owners-operators shall respond to any
require corrective action, to assure the continued safe operation of
PV & PRD
 Limitations : No conflict with regulatory requirements. If the code is
stringent, than the code is govern. 8
 1. SCOPE
SPECIFIC APPLICATIONS
 PV used for E&P (drilling, transporting, lease processing, treating: liquid, gas, etc)
• Alternative rules – section 9
OVERVIEW OF API 510

 Excluded & Optional

• PV on moveable structure ( see annex A)
• Containers exempted from ASME VIII Div.1 ( see annex A)
• PV that do not exceed the volumes and pressures ( see annex A)
- 5 cu ft in volume and 250 psi design pressure
- 3 cu ft in volume and 350 psi design pressure
- 1.5 cu ft in volume and 600 psi design pressure

9
 1. SCOPE
RECOGNIZED TECHNICAL CONCEPTS
• Fitness-for-service (FFS) Concept for evaluating in-service damage
API 579-1 / ASME FFS-1
OVERVIEW OF API 510

• RBI Concept  determining the inspection intervals  API 580

10
 3. DEFINITIONS
AUTHORIZED PV INSPECTOR (Inspector)
An Employee of an authorized inspection agency who is qualified and
certified to perform inspection under this inspection code, including
OVERVIEW OF API 510

annex B (Inspector Certification)

ALTERATION
Physical change in any component that has design implications that
affect the pressure-containing capacity of PV beyond its existing data
reports.
Not considered alteration :
• Duplicate replacement
• Addition of any reinforced nozzles less than or equal to the
existing size
• Additional of nozzles not requiring reinforcement

11
 3. DEFINITIONS
REPAIR
Restore a vessel to a condition for safe operation at the design
conditions
Any restorative work results  change the MDMT or MAWP, the
OVERVIEW OF API 510

work considered an Alteration & rerating requirements shall be

satisfied.

RERATING
• A change in either the des temp. rating, MDMT or MAWP (may be
increased or decreased)
• Derating below original design  permissible way to provide
additional CA

12
 3. DEFINITIONS

PRESSURE VESSEL
A container designed to withstand internal or external
pressure, may be imposed external source, application of
OVERVIEW OF API 510

heat or combination of them.

Limits : Annex A

MAWP
The maximum gauge pressure permitted at the top of a PV in its
operating position for a designated temperature

13
 3. DEFINITIONS
QUALITY ASSURANCE
All planned, systematic, and preventative actions specified to
determine if materials, equipment or services will meet
specified requirements. (minimum content of QA  4.1.2)
OVERVIEW OF API 510

QUALITY CONTROL
Physical activities to check conformance with specifications
in accordance to QA plan

FITNESS-FOR SERVICE
A methodology whereby flaws and conditions contained
within an equipment item are assessed in order to determine
the integrity of the equipment for continued service.

14
 4. OWNER-OPERATOR INSP. ORGANISATION

OWNER-OPERATOR ORGANIZATION RESPONSIBILITIES

 General
• Shall exercise PV & PRD insp program, frequencies & maintenance,
• Responsible for the function of an AI Agency
OVERVIEW OF API 510

• Control activities of rating, repair, alteration & engineering

assessment.

 Systems & Procedure

• Developing QA Insp. Manual To meet the
• Documenting a ~ t (20 items) reqmn’t of 510
• Implementing
• Executing
• Assessing Insp,
system & proc.

15
Overview API 510Rev.9 – Sep .2022 16
 4. OWNER-OPERATOR INSP. ORGANISATION
 Management of Change (MOC)
OWNER-USER ORGANIZATION RESPONSIBILITIES

• to be able to address issues concerning the adequacy of the

pressure equipment design and current condition for the proposed
changes,
• to anticipate changes in corrosion or other types of damage, and
• to update the inspection plan and records to account for those
changes.

 Integrity Operation Windows (IOWs)

To avoid unanticipated impact on pressure equipment integrity.
• should implement and maintain an effective program for creating,
establishing, and monitoring integrity operating windows
• Future inspection plans and intervals have historically been based
on prior measured corrosion rates resulting from past operating
conditions
• modify or create new inspection plans depending upon the
seriousness of the exceedance.

17
 4. OWNER-OPERATOR INSP. ORGANISATION
 ENGINEER
OWNER-USER ORGANIZATION RESPONSIBILITIES

Responsible for Activities involving : Design, engineering review,

analysis, evaluation of PV and PRD
 REPAIR ORGANIZATION
• All repairs and Alterations shall be by qualified repair organization
• Provide : Mat. , equip. , QC, workmanship to code requirements.
(see 3.1.62)
 INSPECTOR
• Assure that API 510 requirements are met.
(Inspection, NDE, repair & testing are met )
 Examiners
• Shall perform NDE according to Job requirements, NDE procedure
& Owner-operator specifications
 Other Personnel  see 4.6
 Inspection Organization Audits  see 4.7

18
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
INSPECTION PLAN
 To be developed by Inspector and/or Engineer (consult. w/ Corr.
Specialist – to designate potential damage mechanisms & specific
location where damage mechanisms may occur)
 To be developed from several sources of data (present or potential types
OVERVIEW OF API 510

of damage mechanisms, extent of NDE adequate to identify the damage mechanisms)

 Examinations shall be scheduled at intervals that consider the:
• type of damage;
• rate of damage progression;
• tolerance of the equipment to the type of damage;
• probability of the NDE method to identify the damage;
• maximum intervals as defined in codes and standards;
• extent of previous examination;
• recent operating history, including IOW exceedances;
• MOC records that may impact inspection plans; and
• RBI assessments (where available).

19
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
INSPECTION PLAN (cont’d)

 Shall be developed using the most appropriate sources of

information & shall be reviewed and amended as needed
 Minimum Content of an Inspection Plan:
OVERVIEW OF API 510

Tasks and schedule required to monitor damage mechanisms and

assure the mechanical integrity of the equipment
• define the type(s) of inspection needed (e.g. internal, external);
• identify the next inspection date for each inspection type;
• describe the inspection and NDE techniques;
• describe the extent and locations of inspection and NDE;
• describe the surface cleaning requirements needed for inspection
and examinations;
• describe the requirements of any needed pressure test (e.g. type of
test, test pressure, and duration); and
• describe any previously planned repairs.

20
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
 Additional Contents
• describing the types of damage anticipated or experienced in the
equipment,
• defining the location of the damage, and
OVERVIEW OF API 510

• defining any special access requirements.

RISK BASED INSPECTION (RBI)

 Probability of Failure vs. Consequence of Failure
 Can be used to determine inspection intervals and extent of
future inspection/examinations
 RBI assessment in accordance with API 580 & API 581
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES

PREPARATION FOR INSPECTION

General
OVERVIEW OF API 510

Follow OSHA - Occupational Safety and Health Administration

Equipment
Use safe equipment - shall comply to Owner/User’s safety requirements

Communication
Inform / notify that people are working inside PV

22
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Vessel Entry
• Obtain permission to work (work permit) Prior to start the inspection
• Wear required PPE – Personal Protective Equipment
• Vessel shall be :
OVERVIEW OF API 510

Isolated from Other sources (Gas, liquid, vapor, electricity, etc.), Drained,
Purged, Cleaned, Ventilated, Gas tested  obtain the certificate
• Prior to perform inspections, Inspectors shall familiar with vessel
history and review :
Previous inspection results, prior repair, current inspection plan, Eng.
Calculations

23
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Inspection for Different Types of Damage Mechanisms and
Failure Modes
• Pressure vessels are susceptible to various types of damage by
several mechanisms. Inspection techniques for each of the potential
OVERVIEW OF API 510

damage mechanisms that exist for each pressure vessel should be part
of the inspection plans.  API 571 - describes common damage
mechanisms and inspection techniques to identify them.
• Some example damage mechanisms are as follows:
a. General and localized metal loss and pitting corrosion:
b. Surface-connected cracking:
c. Subsurface cracking
d. High-temperature microfissuring/microvoid formation and eventual
macro cracking
e. Metallurgical changes
f. Blistering:

24
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
TYPES OF INSPECTION AND SURVEILLANCE

Internal Inspection
• Conducted from inside the PV by Inspector, if PV to small,
borescope, drones & robotic crawler may be used.
OVERVIEW OF API 510

• Primary goal  to find damage that can not be found by regular

monitoring of external CML during on-stream inspection, specific
NDE may be required.
• Removal of internals, deposits & linings may be needed to provide
access of inspection

On-stream Inspection
• All work perform by examiner, Shall be authorized and approved by
the Inspector
• Shall be designed to asses damage mechanism identified in the
insp. plan
• May include several NDE techniques to check various types of
damage
• On-stream inspection may substitute internal inspection (see 6.5.2)
25
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
External inspection of Pressure Vessel
• By Inspector or other qualified personnel acceptable to the inspector
• To check the external condition of vessel :
o Insulation, Painting & Coating system
OVERVIEW OF API 510

o Supports and associate structures

o Any leakage, vibration, allowance for expansion and general
alignment
o Visual insp. for bulging, sagging, out of roundness, distortion, etc.
Any leakage shall be investigated to establish the source  weep hole
/teltale hole on repad should remain open to provide evidence of
leakage.  More information  API 572

• Buried vessel
Inspection interval for external surface condition shall be based on
corrosion rate information obtained from:
o Maintenance activity on connecting pipe
o Periodic exam. of similar buried corrosion test coupon material
o Representative portions of the actual vessel
o Vessel on similar circumstances
Scanning NDE methods to determine the external surface condition
can be performed from the inside of the PV.
26
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Thickness Examination
• Shall be obtained as required and scheduled by the inspection plan.
• Thickness measurement data is used to determine corrosion rate &
remaining life of PV
OVERVIEW OF API 510

• Is the primary method for corrosion rates monitoring.

• The inspector shall review & consult with a corrosion specialist when
the short-term corrosion rate changes significantly from the previous
rate to determine the cause. Additional thickness readings may be
required, UT scans in suspect areas, corrosion/ process monitoring,
and revisions to the vessel’s inspection plan
• CMLs on insulated vessel: CML plugs shall be kept in place to provide
adequate sealing & prevent CUI

27
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
CUI (Corrosion Under Insulation) /CUF (Corrosion Under Fire proofing) Insp.
• For vessel with operating temp. between :
o -12 0C (10 0F) and 177 0C (350 0F )  for carbon & low alloy steels
o 60 0C (140 0F ) and 177 0C (350 0F )  for austenitic stainless steels
o 133 0C (280 0F ) and 177 0C (350 0F )  for duplex stainless steels
OVERVIEW OF API 510

• Insulation removal
o May require removal of some or all insulation (i.e., removing
selected windows in the insulation).
o If external cover are in good cond. and no reason to suspect
damage, no need to remove the insulation.
o For small diameter PV, removal of insulation may be required
o See API RP 583 for guidance NDE method of CUI/CUF under
insulation
• Operator Surveillance
Operator should report to the Inspector for anything unusual with PV &
PRD. (vibration, signs of leakage, unusual noises, insulation
deterioration, relief device having opened, distortion, denting,
temperature excursions, presence of rust stain…etc) 28
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Condition Monitoring Locations (CMLs)
• CMLs is designated areas where periodic examinations are performed.
• To monitor the presence and rate of damage
• For localized corrosion, examination shall use scanning methods – UT or RT
OVERVIEW OF API 510

• To allow repetitive measurement at same locations  CMLs location shall be

permanently recorded (marked on insp. Drawing and/or on equipment - to
improve accuracy of the damage rate)

CML selection
• Type, number and location should consider results from previous inspection
• CMLs should be distributed to provide adequate monitoring coverage of
major components and nozzles.
• If localized corrosion is suspected, consult with corrosion specialist for
placement and number of CMLs
• More CMLs for higher risk PV  High corr. rate, localized corrosion …etc
• Less CMLs for lower risk PV  non corrosive content, uniform corrosion ..

29
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Condition Monitoring Methods
• Examination Technique Selection  based on possible type of damage for
each vessel. (inspector should consult with corr. specialist & engineer to
define the type of damage, NDE technique and extent of examination)
• Various NDE techniques may be use to establish the damage.
OVERVIEW OF API 510

• Surface preparation (brushing, blasting, chipping, grinding, etc) shall be

performed prior to NDE.

• Thickness measurement methods

o To determine the minimum thickness of vessel components
o Uniform corrosion is difficult to detect visually, pitted surfaces may be
thinner than it appear visually  UT thickness gauge is commonly used.
o UT measuring instruments are the most accurate means for obtaining
thickness measurements.
o UT scanning / Radiographic profile technique are preferred where
corrosion is localized.
o Inspector and examiner shall aware of possible measurement accuracy.
(calibration, temperature effect, surface roughness, surface coating, etc.)

30
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing
• Not part of routine inspection
• After an Alteration or Major repair  pressure test shall be applied
(if Inspector believes it is necessary).
• May be the entire PV or component being repaired (when practical)
OVERVIEW OF API 510

• Test Pressure
For vessel constructed to ASME Sec. VIII div.1
o Test Press = 1.5 MAWP X (S Test temp / S Des. temp)  ASME prior to
99 addm.
o Test Press = 1.3 MAWP X (S Test temp / S Des. temp)  ASME 99 addm
& later
• Press Testing Preparation
o Safety precaution to personnel involve
o In-service PV may have experienced metallurgical degradation or
a cracking phenomenon.
o Close visual inspection shall not be performed until the vessel
pressure is at or below the MAWP.
o PRD(s), gauge glass, pressure gauge & rupture disk should be
removed
31
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing (cont’d)
• Hydrostatic Test
o Support structure and foundation design should be reviewed.
o May be the entire PV or component being repaired (when
OVERVIEW OF API 510

practical)
o For stainless steel type 300 series, potable water, steam
condensate or other fluid with chloride content less than 50 ppm
o Upon completion of pressure test, Inspector should verify: the
specified water is used and the PV has been drained & dried.

• Pneumatic Test
o When hydrostatic test is impracticable, pneumatic test may be
used.
o Pneumatic test procedure should be developed by the engineer
following steps in AME PCC-2, Article 501

32
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing (cont’d)
• Test Temp & Brittle Fracture Consideration
At ambient temperatures, carbon, low-alloy, and other ferritic steels
may be susceptible to brittle failure.
o low-alloy steels, especially 2 1/4 Cr-1Mo, because they may be
OVERVIEW OF API 510

prone to temper embrittlement, or

o any other metal that may be prone to embrittlement per the
damage mechanisms listed in API RP 571

• To minimize the risk of brittle fracture during pressure test, metal

temp. should be maintained :
o PV > 5 cm (2 in.) Thk  at least 17°C (30°F) above MDMT / MAT
o PV < 5 cm (2 in.) Thk  6°C (10°F) above MDMT / MAT
The test temperature need not exceed 50°C (120°F)

o For solid weld overlaid or clad austenitic stainless steel, the water
temperature should not exceed 50°C (120°F) to avoid possible
chloride stress corrosion cracking.

33
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing (cont’d)
• Press Testing alternatives
o Substituting NDE for press test after a major repair or alteration 
only if Engineer and Inspector approved.
o Advisable to conduct FSS assessment  critical flaw size 
OVERVIEW OF API 510

NDE(s) acceptance criteria . Refer to ASME PCC-2, Article 502

(guidance on NDE in lieu of pressure test)
o Where manual UT is used the owner-operator shall specify
qualified angle beam examiners.
o For use of UT in lieu of RT, ASME BPVC Case 2235 or ASME
BPVC Section VIII, Division 2, 7.5.5 shall be followed.

• Material Verification and Traceability

During repairs or alterations of pressure vessels,
o The inspector shall verify all new materials are in compliance with the
specifications.
o This assessment can be made by 100 % verification checking, 100 %
positive material identification (PMI), or by sampling a percentage of the
materials depending upon the criticality of each service.
o PMI testing can be done using suitable methods such as optical emission
spectrographic analyzers or X-ray fluorescence analyzers.
o See API 578 for guidance on material verification 34
35
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Pressure Testing (cont’d)
Inspection of in-service welds
• Welds and HAZ are also part of in-service Inspections
• Profile radiography, density radiography, and UTs may reveal what
appears to be a flaw in an existing weld.
OVERVIEW OF API 510

• If crack-like flaws are detected while the pressure vessel is in

operation, further inspection may be used to assess the magnitude
of the flaw.
• Crack-like flaws, environmental cracking and preferential weld
corrosion shall be assessed by the inspector and either an engineer
or corrosion specialist (refer to API 579-1/ASME FFS-1).
• Dissimilar metal welds (DMW) may be prone to cracking or
preferential in-service corrosion, the inspection plan should
include techniques to identify cracking or corrosion damage at the
DMWs. See API RP 572 for guidance on DMW
Inspection and repair of flange joints
• Flanged joints shall be examined for evidence of leakage, stains,
deposits, or drips.
Inspection of Shell and Tube Heat Exchangers
• API RP 572, for more information on inspection of several types of HE
• ASME PCC-2 Article 312 for guidance on the inspection and repair of HE
• API RP 586 Part 1 for guidance on selecting inspection techniques. 36
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES

GENERAL

 To ensure vessel integrity, all PV and PRD shall be inspected and

tested at the intervals/frequencies provided in this section.
OVERVIEW OF API 510

 Inspection shall provide information necessary to determine that the

equipments is safe to operate until next scheduled inspection

37
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
INSPECTION DURING INSTALLATION & SERVICE CHANGE

Vessel Installations
• To verify the vessel is safe for operation & no damage occurerd
during transportation.
OVERVIEW OF API 510

o Verify the name plate information against MDR

o Verify vessel installed correctly and appurtenances are secured
o Verify the PRD is provided (correct device & set pressure)
• To provide baseline information & obtain thickness reading at
designated CMLs
• Internal field inspection of new vessels is not required

Vessel Service Change

• If Service change 
Insp. Intervals shall be established for the new service conditions
• If both ownership & location changed 
o Internal & external insp. shall be done & should include baseline
examination for the new service
o Intervals shall be established for the new service conditions
38
 5. INSPECTION, EXAMINATION &
PRESSURE TESTING PRACTICES
Risk Based Inspection (RBI)
• RBI assessment in compliance with API RP 580 may be used to
establish appropriate insp. Intervals for internal, on-stream &
external inspection
OVERVIEW OF API 510

• Insp. intervals may exceed the intervals specified in 6.4 & 6.5
• If insp. intervals exceeds 10 year limit, the RBI shall be approved by
the engineer and inspector at intervals not to exceed 10 year
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

External Inspection
• Unless justified by an RBI, Visual external insp. Is 5 years or the required
interval of Internal/on-stream inspection (which ever is less)

Internal, On-stream & Thickness Measurement Inspections

OVERVIEW OF API 510

Inspection Intervals
• Unless justified by an RBI, the period between internal or on-stream insp.
o The lesser of ½ remaining life or 10 years
o If remaining life < 4 years → full remaining life up to max. 2 years.
o The intervals is established by inspector or engineer in accordance
with owner’s QA system
• Unless justified by an RBI, the period between thick. measurement insp
o The lesser of ½ remaining life or 10 years
o If remaining life < 4 years → full remaining life up to max. 2 years.
• Alternative method to establish insp interval is by calculating the
projected MAWP  as per 7.3
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

On-stream Inspection in lieu of Internal Inspection

May be substituted if:
• Size or configuration not possible to enter the vessel.
• If internal inspection is possible, but all of the following conditions are
OVERVIEW OF API 510

met:
o General Corrosion Rate < 0.005 inch (0.125 mm) / year
o Remaining life > 10 years
o Corrosive character of the contents has been established at least 5
years of same or similar service
o No questionable condition during external inspection
o Temperature operation < creep-rupture range temperature (400 ~ 540
deg C)  see API 579-1 / ASME FFS-1
o Vessel is not subject to environment cracking or hydrogen damage
o No nonintegrally bonded liner

• If the above limitations are not meet, the next inspection shall be internal
inspection.

41
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

On-stream Inspection in lieu of Internal Inspection (cont’d)

• Same and Similar Service Equipment
Internal inspection results can be used to determine whether an on-
stream inspection can be substituted for an internal inspection on a
similar operating condition pressure vessel
OVERVIEW OF API 510

The inspection of one vessel (preferably the worst case) may be taken as
representative of the whole train when the following conditions are
observed:
o two or more pressure vessels are installed in series and no potentially
corrosive contaminants are introduced
o the operating conditions in any part of the train are the same;

o sufficient corrosion history has been accumulated.

RBI analysis may be useful when considering the extent of same service
applicability in determining internal and on-stream inspection requirements.
If the vessel is subject to environmental cracking or hydrogen damage, the
results of an internal inspection on a similar service pressure vessel cannot
be used to substitute an on-stream inspection for an internal inspection.
Multi-Zone Vessels
Vessel having two or more zones of differ corrosion rate  to determine the
inspection interval, each zone may be treated independently 42
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

Pressure Relieving Devices

• Inspection, testing & maintenance  API 576 and API 510
• Testing & Inspection Intervals
OVERVIEW OF API 510

Unless documented experience and/or a RBI assessment indicates that a

longer interval is acceptable, test and inspection intervals for PRD should
not exceed:
o 5 years for typical process services
o 10 years for clean & noncorrosive services

43
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

Deferral of Inspections, Tests, and Examinations

Inspections, tests, or examinations for pressure vessels and associated
pressure-relieving devices that cannot be completed by their due date may
be deferred for a specified period, subject to the followings.
OVERVIEW OF API 510

(Deferrals should be the occasional exception, not a frequent occurrence)

Simplified Deferral
A simplified short-term deferral may be approved by the owner-operator if
all of the following conditions are met:
a. The current due date for the inspection has not been previously deferred.
b. The new due date would not increase the inspection interval by more than 10% or
six months, whichever is less.
c. A review of the current operating conditions has been completed, with results
that support a short-term/one-time deferral.
d. The deferral request has the consent of the inspector representing or employed
by the owner-operator and an appropriate operations management
representative(s).
e. Updates to the pressure vessel or pressure-relieving device records with deferral
documentation are complete before it is operated beyond the original due date.44
 6. INTERVAL / FREQUENCY & EXTENT OF INSPECTION

Deferral of Inspections, Tests, and Examinations ( cont’d)

Deferral
Deferral requests not meeting the conditions of a simplified deferral shall
follow a documented deferral procedure/process that includes all of the
OVERVIEW OF API 510

following minimum requirements:

a. Perform risk assessment or update an existing RBI, to determine if the
proposed deferral date would increase risk above acceptable risk threshold
levels as defined by the owner-operator. (may include 9 elements: FFS,
Consequent of failure, Remaining life… etc)
b. Determine if the deferral requires the implementation of, or modification to,
existing IOWs or operating process control limits.
c. Review the current inspection plan to determine if modifications are needed
to support the deferral.
d. Obtain the consent and approval of appropriate pressure vessel personnel,
including the inspector representing or employed by the owner-user and
appropriate operations management representative(s).
e. Updates to the pressure vessel or pressure-relieving device records with
deferral documentation are complete before it is operated beyond the
original due date 45
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

CORROSION RATE DETERMINATION

Existing PV
t initial – t actual
Corrosion Rate (LT) = ——————————————————
OVERVIEW OF API 510

(Long -Term) time between t initial and t actual

t previous – t actual
Corrosion Rate (ST) = ——————————————————
(Short-Term) time between t previous and t actual

t initial = Initial thickness at the same CML as t actual (first thick. measured at this
CML)
t actual = Actual thick of a CML, measured during most recent inspection
t previous = Previous thickness measured during prior inspection, it is at the same
location as t actual measured during previous insp.

Inspector (consult with corr. Specialist) shall select the corrosion rate that
best reflect the current conditions.

46
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

CORROSION RATE DETERMINATION (cont’d)

Newly installed PV or change in service

• May be calculated from Data collected by the owner on same or similar

OVERVIEW OF API 510

service vessels
• May be determined through appropriately placed ultrasonic sensors
• May be estimated by corrosion specialist
• May be estimated from publish data of same or similar vessels

If items above not available, on-stream determination shall be made after 6

months of service by direct measurement techniques.

If it is later determined that an inaccurate corrosion rate was assumed, the

corrosion rate in the remaining life calculations shall be changed to the
actual corrosion rate.

47
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

REMAINING LIFE CALCULATIONS

t actual – t required
Remaining Life (year) = ————————
corrosion rate
t actual = Actual thick. Of a CML measured during most recent inspection
OVERVIEW OF API 510

t required = required thickness at the same CML, excluding CA &

manufacturer tolerances

MAXIMUM ALLOWABLE WORKING PRESSURE DETERMINATION

Used ASME latest edition or construction code PV was built

• Shall not be greater than the original MAWP

• Thickness used = Ta – 2 x ( Crate x Iinterval)
 Ta = actual thick determined by inspection (In)  See 5.6.2 - CML)
If Ta greater than thickness reported in MTR or MDR  recheck
 Crate = Corrosion rate (in / year)
 Iinterval = The interval of the next inspection (year)

48
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

ANALYSIS OF CORRODED REGIONS

This section outlines methodologies that can be used when a vessel
thickness is below the required thickness

Evaluation of Locally Corroded Areas

OVERVIEW OF API 510

For locally corroded areas, refer to API 579-1/ ASME FFS-1, which
provides assessment methodology.

49
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING
OVERVIEW OF API 510

50
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

Evaluation of Pitting
• Pits may be ignored if :
- Remaining thick > ½ t required and greater than 1.6 mm (0.062 in)
2 2
- Total area of pits deeper than CA < 45 cm (7 in ) within any 20
OVERVIEW OF API 510

cm (8 in) diameter circle

- Pits deeper than CA  the sum of their diameter along any
straight 20 cm (8 in) line < 5 cm (2 in)

Alternative Evaluation Methods for Thinning

• General and local metal loss may be evaluated following API 579-
1/ASME FFS-1

Joint efficiency Adjustment.

Corroded area in Vessel Heads

Use appropriate head formula (SE, Torispherical, Hemispherical ..)

51
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

Inside PV Excess mat thk (New cond.)

A B
CA A = OK

tr B = Not OK
OVERVIEW OF API 510

Outside PV
½ tr

2 2
• Sum of A max. 45 cm (7 in )

• In any 20 cm (8 in) straight line

Sum of A max. 2 in

8 in Circle 52
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING
OVERVIEW OF API 510

SHELL
Weld toe

Greater of 1 In or 2 x Treq

Corroded area

If E design < 1 (e.g. 0.85)  E =1 may be used to calculate the Treq

at thinning area

53
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING
OVERVIEW OF API 510

54
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

FFS Evaluations
Damage pressure components shall be evaluated for continued service in
accordance with API 579-1 / ASME FFS-1
Damage types:
OVERVIEW OF API 510

• Corrosion /Thinned area

• Blister, HIC, Laminations, etc..
• Weld misalignment, shell distorsion
• Crack-like flaw
• Creep
• Fire, dent, gouge
• Fatigue
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

EVALUATING OF EXISTING EQUIPMENT WITH MINIMAL DOCUMENTATION

If vessel has no name plate and minimal or no design & constr.

documents, steps to verify operating integrity are :
• Perform inspection to determine PV condition
OVERVIEW OF API 510

• Define design parameters, prepare drawings

• Perform calculation based on applicable code, do not used design factor of 3.5
o If UG-10(c) not follow, for carbon steel use stress value for SA-283 Gr.C
o Allowable stress value  do not used ASME BPVC current edition.
Determined the construction year (by reasonable assumption), the select
ASME BPVC edition.
o If no info on RT, use E = 0.7 for Type No.1, 0.65 for Type No.2 butt weld
and 0.85 for seamless shell
• Attach a name plate or stamping showing MAWP, MDMT and date.
• Perform pressure test as soon as practicable

56
7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

57
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING
OVERVIEW OF API 510

58
 7. INSPECTION DATA EVALUATION, ANALYSIS & RECORDING

Reports and Records

Owner – operator shall maintain permanent and progressive records for

PV & PRD
OVERVIEW OF API 510

• Construction & Design Information.

• Inspection history
• Repair, alteration and re-rating information
• Fitness-for-service assessment document
• Etc….

59