Pressure Vessel Inspection Code:

In-service Inspection, Rating, Repair, and Alteration

API 510

TENTH EDITION, MAY 2014

ADDENDUM 1, MAY 2017

ADDENDUM 2, MARCH 2018

Date of Issue: March 2018

Affected Publication: API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration, Tenth Edition, May 2014

Addendum 2

Page v (Table of Contents): Changed title in the entry for Section 6.7 to the following:

Page 6: Added “deferral” term and definition:

3.1.16

deferral

An approved and documented postponement of an inspection, test, or examination. See 6.7.

Page 6: Added “due date” term and definition:

3.1.19

due date

The date established by the owner-user and in accordance with this code, whereby an inspection, test, examination, or inspection recommendation falls due or is to be completed. The date may be established by rule-based inspection methodologies (e.g. fixed intervals, retirement half-life interval, retirement date), risk-based methodologies (e.g. RBI target date), fitness-for-service analysis results, owner-user inspection agency practices/procedures/guidelines, or any combination thereof.

Page 8: Deleted “inspection deferral” definition. Page 16: Section 4.3 shall read:

All repairs and alterations shall be performed by a qualified repair organization. The repair organization is responsible to the owner/user and shall provide the materials, equipment, QC, and workmanship that is necessary to maintain and repair the vessel or pressure-relieving device in accordance with the requirements of this inspection code. See definition of a repair organization in 3.1.63.

Page 38: Section 6.6.1 shall read:

Pressure-relieving devices shall be tested and repaired by a repair organization qualified and experienced in relief valve maintenance per definitions in 3.1.63. Pressure-relieving devices should be inspected, tested, and maintained in accordance with API 576.

Page 39: Section 6.7 shall read:

1. 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 requirements in the following sub-sections.

   Pressure vessels or pressure-relieving devices that are operated beyond the due date without a valid deferral in accordance with these requirements are not permitted by this code. Deferrals should be the occasional exception, not a frequent occurrence. All deferrals shall be documented. Pressure vessels or pressure-relieving devices that were granted a deferral can be operated to the new due date without being considered overdue for the deferred inspections, tests, or examinations.

   
   

   1. Simplified Deferral

      
      

      A simplified short-term deferral may be approved by the owner-user if all of the following conditions are met:

      
      

      1. The current due date for the inspection, test, or examination has not been previously deferred.

         
         

      2. The proposed new due date would not increase the current inspection/servicing interval or due date by more than 10 % or six months, whichever is less.

         
         

      3. A review of the current operating conditions, as well as the pressure vessel or pressure- relieving device history, has been completed, with results that support a short-term/one- time deferral.

         
         

      4. The deferral request has the consent of the inspector representing or employed by the owner-user and an appropriate operations management representative(s).

         
         

      5. Updates to the pressure vessel or pressure-relieving device records with deferral documentation are complete before it is operated beyond the original due date.

      
      

   2. Deferral

Deferral requests not meeting the conditions of a simplified deferral shall follow a documented deferral procedure/process that includes all of the following minimum requirements:

1. Perform a documented risk assessment or update an existing RBI assessment to determine if the proposed deferral date would increase risk above acceptable risk threshold levels as defined by the owner-user. The risk assessment may include any of the following elements as deemed necessary by the owner/user.

   
   

   • fitness-for-service analysis results;

     
     

   • consequence of failure;

     
     

   • applicable damage mechanism susceptibilities and rates of degradation;

     
     

   • calculated remaining life;

     
     

   • historical conditions/findings from inspections, tests, and examinations and their technical significance;

     
     

   • extent and/or probability of detection (i.e. effectiveness) of previous inspections, tests, or examinations, as well as the amount of time that has elapsed since they were last performed;

   • considerations for any previous changes to inspection or test intervals (e.g. reductions in interval due to deteriorating conditions);

     
     

   • disposition(s) of any previous requests for deferral on the same pressure vessel or pressure-relieving device;

     
     

   • historical conditions/findings for pressure vessels or pressure-relieving devices in similar service if available

     
     

2. Determine if the deferral requires the implementation of, or modification to, existing integrity operating windows or operating process control limits.

   
   

3. Review the current inspection plan to determine if modifications are needed to support the deferral.

   
   

4. 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).

   
   

5. Updates to the pressure vessel or pressure-relieving device records with deferral documentation are complete before it is operated beyond the original due date.

Page numbers in the Table of Contents have been updated to account for the above changes.

Special Notes

API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.

Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of API's employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.

API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.

Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.

Users of this Standard should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.

Work sites and equipment operations may differ. Users are solely responsible for assessing their specific equipment and premises in determining the appropriateness of applying the Standard. At all times users should employ sound business, scientific, engineering, and judgment safety when using this Standard.

All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.

Copyright © 2014 American Petroleum Institute

Foreword

In December 1931, API and the American Society of Mechanical Engineers (ASME) created the Joint API/ASME Committee on Unfired Pressure Vessels. This committee was created to formulate and prepare for publication a code for safe practices in the design, construction, inspection, and repair of pressure vessels to be used in the petroleum industry. Entitled API/ASME Code for Unfired Pressure Vessels for Petroleum Liquids and Gases (commonly called the API/ASME Code for Unfired Pressure Vessels or API/ASME Code), the First Edition of the API/ASME Code was approved for publication in 1934. From its inception, the API/ASME Code contained Section I, which covered recommended practices for vessel inspection and repair and for establishing allowable working pressures for vessels in service. Section I recognized and afforded well-founded bases for handling various problems associated with the inspection and rating of vessels subject to corrosion. Although the provisions of Section I (like other parts of the API/ ASME Code) were originally intended for pressure vessels installed in the plants of the petroleum industry, especially those vessels containing petroleum gases and liquids, these provisions were actually considered to be applicable to pressure vessels in most services. ASME’s Boiler and Pressure Vessel Committee adopted substantially identical provisions and published them as a nonmandatory appendix in the 1950, 1952, 1956, and 1959 editions of Section VIII of the ASME Boiler and Pressure Vessel Code.

After the API/ASME Code was discontinued in 1956, a demand arose for the issuance of Section I as a separate publication, applicable not only to vessels built in accordance with any edition of the API/ASME Code but also to vessels built in accordance with any edition of Section VIII of the API/ASME Code. Such a publication appeared to be necessary to assure industry that the trend toward uniform maintenance and inspection practices afforded by Section I of the API/ASME Code would be preserved. API 510, first published in 1958, is intended to satisfy this need.

The procedures in Section I of the 1951 edition of the API/ASME Code, as amended by the March 16, 1954 addendum, have been updated and revised in API 510. Section I of the API/ASME Code contained references to certain design or construction provisions, so these references have been changed to refer to provisions in the API/ ASME Code. Since the release of the 1960 edition of the National Board Inspection Code, elements of the API/ASME Code have also been carried by the National Board Inspection Code.

It is the intent of API to keep this publication up to date. All pressure vessel owners and operators are invited to report their experiences in the inspection and repair of pressure vessels whenever such experiences may suggest a need for revising or expanding the practices set forth in API 510.

This edition of API 510 supersedes all previous editions of API 510. Each edition, revision, or addendum to this API code may be used beginning with the date of issuance shown on the cover page for that edition, revision, or addendum. Each edition, revision, or addendum to this API code becomes effective six months after the date of issuance for equipment that is rerated, reconstructed, relocated, repaired, modified (altered), inspected, and tested per this code. During the six-month time between the date of issuance of the edition, revision, or addendum and the effective date, the user shall specify to which edition, revision, or addendum the equipment is to be rerated, reconstructed, relocated, repaired, modified (altered), inspected, and tested.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.

Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the specification.

This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which

this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the Director.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.

Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org.

1. Scope 1

   1. General Application 1

   2. Specific Applications 2

   3. Recognized Technical Concepts 2

2. Normative References 2

3. Terms, Definitions, Acronyms, and Abbreviations 4

   1. Terms and Definitions 4

   2. Acronyms and Abbreviations 13

4. Owner/User Inspections Organization 14

   1. Owner/User Organization Responsibilities 14

   2. Engineer 16

   3. Repair Organization 16

   4. Inspector 16

   5. Examiners 16

   6. Other Personnel 16

   7. Inspection Organization Audits 17

5. Inspection, Examination, and Pressure Testing Practices 17

   1. Inspection Plans 17

   2. Risk-Based Inspection (RBI) 19

   3. Preparation for Inspection 20

   4. Inspection for Different Types of Damage Mechanisms and Failure Modes 21

   5. Types of Inspection and Surveillance for Pressure Vessels 23

   6. Condition Monitoring Locations (CMLs) 27

   7. Condition Monitoring Methods 29

   8. Pressure Testing 31

   9. Material Verification and Traceability 33

   10. Inspection of In-service Welds 33

   11. Inspection and Repair of Flanged Joints 34

   12. Inspection of Shell and Tube Heat Exchangers 34

6. Interval/Frequency and Extent of Inspection 34

   1. General 34

   2. Inspection During Installation and Service Changes 35

   3. RBI 35

   4. External Inspection 36

   5. Internal, On-stream, and Thickness Measurement Inspections 36

   6. Pressure-relieving Devices 38

   7. Deferral of Inspections, Examinations, and Tests 39

   8. Deferral of Inspection Repair Recommendation Due Dates 40

   9. Review of Inspection Repair Recommendations 41

7. Inspection Data Evaluation, Analysis, and Recording 41

   1. Corrosion Rate Determination 41

   2. Remaining Life Calculations 42

      
      

   3. Maximum Allowable Working Pressure (MAWP) Determination 42

   4. FFS Analysis of Corroded Regions 43

   5. FFS Evaluations 45

   6. Required Thickness Determination 46

   7. Evaluation of Existing Equipment with Minimal Documentation 46

   8. Reports and Records 47

8. Repairs, Alterations, and Rerating of Pressure Vessels and Pressure-relieving Devices 48

   1. Repairs and Alterations 48

   2. Rerating 57

9. Alternative Rules for E&P Pressure Vessels 59

   1. Scope and Specific Exemptions 59

   2. Definitions 59

   3. Inspection Program 60

   4. Pressure Test 64

   5. Safety Relief Devices 64

   6. Records 64

Annex A (normative) Code Exemptions 65

Annex B (normative) Inspector Certification 67

Annex C (informative) Sample Pressure Vessel Inspection Record 69

Annex D (informative) Sample Repair, Alteration, or Rerating of Pressure Vessel Form 71

Annex E (informative) Technical Inquiries 73

Figures

1. Rerating Vessels Using the Latest Edition or Addendum of the ASME Code Allowable Stresses 58

2. Sample Additional Nameplate 59

Tables

7.1 Values of Spherical Radius Factor K1 46

8.1 Qualification Limits for Base Metal and Weld Deposit Thicknesses for the CDW Method 56

Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration

1. Scope

   1. General Application

      1. Coverage

         
         

         This inspection code covers the in-service inspection, repair, alteration, and rerating activities for pressure vessels and the pressure-relieving devices protecting these vessels. This inspection code applies to all hydrocarbon and chemical process vessels that have been placed in service unless specifically excluded per 1.2.2; but it could also be applied to process vessels in other industries at owner/user discretion. This includes:

         
         

         1. vessels constructed in accordance with an applicable construction code [e.g. ASME Boiler and Pressure Vessel Code (ASME Code)];

            
            

         2. vessels constructed without a construction code (noncode vessels)—a vessel not fabricated to a recognized construction code and meeting no known recognized standard;

            
            

         3. vessels constructed and approved as jurisdictional special based upon jurisdiction acceptance of particular design, fabrication, inspection, testing, and installation;

            
            

         4. nonstandard vessels—a vessel fabricated to a recognized construction code but has lost its nameplate or stamping.

         
         

         However, vessels that have been officially retired from service and abandoned in place (i.e. no longer are an asset of record from a financial/accounting standpoint) are no longer covered by this “in-service inspection” code.

         
         

         The ASME Code and other recognized 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, rerating, repair, and alteration of in-service pressure vessels. If for some reason an item that has been placed in service cannot follow the construction code because of its new construction orientation, the requirements for design, material, fabrication, and inspection shall conform to API 510 rather than to the construction code. If in-service vessels are covered by requirements in the construction code and API 510 or if there is a conflict between the two codes, the requirements of API 510 shall take precedence. As an example of the intent of API 510, the phrase “applicable requirements of the construction code” has been used in API 510 instead of the phrase “in accordance with the construction code.”

         
         

      2. Intent

The application of this inspection code is restricted to owner/users that employ or have access to the following technically qualified individuals and organizations:

1. an authorized inspection agency,

   
   

2. a repair organization,

   
   

3. an engineer,

   
   

4. an inspector, and,

   
   

5. examiners.

1