API 510 Pressure Vessel Inspection — Code Application & Practice

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Module 1 — API 510 Scope and Inspector Authority

Lesson 1: Scope and Application of API 510 Identify what pressure vessels are covered. Understand exclusions and jurisdictional boundaries. Owner-operator responsibilities. Determining when a vessel falls under API 510 vs. other codes. References: API 510 March 2023

Lesson 2: Inspector Qualifications and Authorized Inspectors Authorized Inspector certification requirements. Inspector independence. Third-party inspection arrangements. Document control and reporting responsibilities. References: API 510 March 2023

Module 2 — Inspection Intervals and Risk-Based Inspection

Lesson 3: Inspection Intervals and Risk Based Inspection Default inspection intervals. Half-life rule calculations. RBI implementation per API 580/581. Documentation requirements for extended intervals. Common audit findings. References: API 510, API 580, API 581

Lesson 4: External Visual Inspection Requirements External visual inspections per API 510. Insulation removal requirements. CUI screening. Inspecting supports, foundations, and grounding. Documentation standards. References: API 510, API 583

Module 3 — Internal Inspection and Thickness Monitoring

Lesson 5: Internal Inspection Procedures On-stream vs. out-of-service inspections. Confined space prep. NDE methods during internal inspections. Documentation to code requirements. References: API 510, API 572

Lesson 6: Thickness Measurement Locations and Strategy TML selection based on damage mechanism predictions. Minimum number per API 510. Documenting locations and history. When to add or retire TMLs. References: API 510, API 572

Module 4 — Corrosion Rates and Pressure Testing

Lesson 7: Corrosion Rate Calculation and Application Short-term vs. long-term rates. Statistical treatment of thickness data. Choosing the right rate for intervals and remaining life. Adjusting when rates change. References: API 510

Lesson 8: Pressure Testing Requirements and Procedures When pressure tests are required. Hydrostatic vs. pneumatic. Test pressure calculation. Temperature considerations and exemptions. References: API 510

Module 5 — Repairs, Alterations, and Welding

Lesson 9: Repairs vs. Alterations vs. Re-Rating Code definitions. Authorization requirements for each type. Documentation requirements. When re-rating is required and how to verify design. References: API 510

Lesson 10: Welding Repairs and Heat Treatment Welder/procedure qualifications per code. PWHT requirements and exemptions. Controlled deposition welding as PWHT alternative. Documentation. References: API 510

Module 6 — Fitness for Service and Vessel Identification

Lesson 11: Fitness for Service Assessment Triggers When FFS evaluation is required. How API 510 references API 579. Level 1/2/3 progression. Common FFS scenarios in vessel inspection. References: API 510, API 579

Lesson 12: Nameplate, Stamp, and Identification Requirements Original nameplate retention. When repair stamps are required. Alteration nameplate requirements. Maintaining identification through service life. References: API 510

Module 7 — Documentation and Vessel-Specific Damage

Lesson 13: Records, Documentation, and Audit Readiness Inspection records per API 510. Retention periods. Audit-ready documentation. What records must be available during inspection. References: API 510

Lesson 14: Damage Mechanisms Specific to Pressure Vessels HIC and SOHIC in vessel service. Shell stress corrosion cracking patterns. Liquid metal embrittlement. Weld decay in austenitic components. References: API 571, API 510

Module 8 — Code Application and Practice

Lesson 15: Common Code Misinterpretations and Pitfalls The most common API 510 inspector mistakes. How auditors find documentation errors. Misinterpreted code clauses in field practice. Best practices to avoid failures. References: API 510

Lesson 16: Building a Complete Inspection Plan Real-world scenario walkthrough. Building an inspection plan from scratch. Integrating intervals, NDE methods, and TMLs. Applying RBI principles. Documenting for code compliance. References: API 510, API 580