American Petroleum Institute)

What Is Static Equipment? Fundamental, Types, and Design

17 April, 2024

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There are two types of equipment in the oil and gas industry: static equipment and rotating equipment. Static
equipment refers to machinery or devices that stay in one place and do not have moving parts during normal
operation. Let’s explore the importance, functions, and applications of static equipment in different sectors of the oil
and gas industry.
Table of Contents
• What Is Static Equipment?
• How Many Types of Static Equipment Are There?
• What Is The Difference between Static and Rotating Equipment?
• What Are Some FAQs About Static Equipment?
What Is Static Equipment?
Static equipment refers to machinery or devices that stay in one place, do not have moving parts like pumps or
compressors, and do not move during normal operation. These are usually used in industries like manufacturing, oil
and gas, and power generation.
Examples of static equipment include tanks, pressure vessels, heat exchangers, and pipes. They are designed to
handle specific tasks like storing liquids, containing high-pressure gasses, or transferring heat between fluids. Static
equipment plays a crucial role in various industrial processes by providing necessary infrastructure for production
and operations.
How Many Types of Static Equipment Are There?
There are several types of static equipment used in various industries. Some common types include tanks, pressure
vessels, heat exchangers, columns, and piping systems. These static equipment types serve different purposes such as
storing liquids, handling high-pressure gasses, and transferring heat between fluids.
1. Heat Exchangers
A heat exchanger is a system used to transfer heat between a source and a working fluid, without them mixing
together. This means that heat can move between the two fluids without any physical contact between them.
It is considered part of static equipment because heat exchangers are typically designed to stay in one place and do
not have moving parts during normal operation. They are stationary and are used in various industries such as power
plants, chemical processing, and HVAC systems to control temperatures and transfer heat efficiently between fluids
like water, air, or gasses. Their stationary nature and specialized design make them an essential component of static
equipment used in industrial processes.
2. Pressure Vessels
A pressure vessel is a container designed to hold gasses or liquids at a pressure substantially different from the
ambient pressure and is made to withstand high pressures safely without leaking or rupturing.
Pressure vessels are considered part of static equipment because they do not have moving parts during normal
operation. Unlike dynamic equipment like pumps or compressors, pressure vessels remain stationary while
performing their function of containing pressurized substances. They are vital in various industries for storing and
transporting gasses or liquids under pressure, such as in chemical processing plants, oil refineries, and power
generation facilities.
3. Distillation Column
A column is a tall, vertical structure typically used in industrial processes, produced for the chemical and
petrochemical industry, for refineries, and for the gas and food industry. It works by allowing different components
of a mixture to rise or fall based on their properties like density or volatility.

Distillation column is
one of the static equipment in oil and gas industry. (Credit: Freepik)
Columns are considered part of static equipment because they do not have moving parts during regular operation.
Unlike pumps or compressors that actively move fluids, columns rely on natural forces like gravity and phase
separation to perform their function. They are stationary components that play a vital role in various industries such
as oil refining, chemical processing, and wastewater treatment, aiding in the separation and purification of substances
for production purposes.
4. Atmospheric Storage Tank
An atmospheric storage tank is a type of container that stores products at the same pressure as the atmosphere at the
location of the tank, and it is used to store liquids or gasses at atmospheric pressure, which means it is not
pressurized. These tanks are commonly used in industries like oil and gas, chemical processing, and water treatment.
Atmospheric storage tanks are considered part of static equipment because they remain stationary and do not have
moving parts during their normal operation. They are designed to store materials like crude oil, water, chemicals, or
natural gas without needing additional pressure to keep the contents inside. This distinguishes them from pressurized
vessels like boilers or high-pressure cylinders, which require pressure to contain their contents safely.
Because atmospheric storage tanks do not rely on pressurization, they are simpler in design and typically easier to
maintain compared to pressurized equipment. They are an essential part of static equipment used in various industries
for storing and handling liquids or gasses under normal atmospheric conditions.
5. Aboveground Storage Tank
An aboveground storage tank is a large container used to store liquids such as oil, chemicals, or water above the
ground level. These tanks are usually made of steel and have a fixed position in a facility or an outdoor area. They are
different from underground tanks, which are buried beneath the ground.
Aboveground storage tanks are considered part of static equipment because they are designed to remain stationary
and hold substances without the need for constant movement or agitation. This static nature distinguishes them from
dynamic equipment like pumps or compressors, which are used to move fluids or gasses.
6. Air cooled exchangers
An air-cooled exchanger, also known as heat rejection equipment where the excess process heat is rejected to the
atmosphere, is a type of equipment used to cool fluids, such as water or oil, by using ambient air. It consists of a
series of tubes or fins through which the hot fluid flows, while cool air is blown over the tubes or fins to remove heat
and lower the temperature of the fluid.
Air heat exchangers are fixed in place within industrial facilities and serve the specific purpose of heat exchange
without requiring mechanical movement. This static nature makes them suitable for applications where continuous
cooling or heat exchange is needed without the complexity of dynamic components.
7. Boilers
Power boilers are large vessels designed to generate steam or hot water for various industrial processes or heating
purposes by taking the chemical energy stored in fuel, converting it to heat energy in the combustion process, and
transferring that heat energy to water to produce steam. They are typically used in power plants, manufacturing
facilities, and other industries that require a significant amount of steam or hot water.
Unlike pumps or compressors that are part of dynamic equipment and involve mechanical motion, power boilers rely
on the static containment of pressurized fluids (such as water or steam) to generate energy. They are stationary
devices that are integral to the production of steam or hot water, playing a key role in providing thermal energy for
industrial processes and heating systems.
8. Filters
Filters in static equipment are devices used to remove impurities or contaminants from fluids flowing through the
equipment. These impurities can include solid particles, debris, or other substances that may affect the performance
or integrity of the equipment. Filters help to ensure that the fluid remains clean and free from harmful substances,
thus maintaining the efficiency and reliability of the static equipment.
9. Fired heaters
Fired heaters, serving as a primary source of thermal energy for process heating operations in petroleum refining and
chemical plants, are devices used in industries like oil and gas to generate heat by burning fuels like natural gas or
oil. They are used to heat up fluids or gasses in processes such as refining, petrochemical production, and power
generation. Fired heaters are considered part of static equipment because, unlike rotating machinery like pumps or
compressors, fired heaters remain stationary during operation.
10. Furnace
A furnace is an appliance used to generate heat for all or part of a building, commonly found in homes and industries
to provide warmth and heat for various applications. Furnaces work by burning fuel such as gas, oil, or coal to
produce heat, which is then distributed throughout a building or used for specific processes like melting metals or
drying materials.
A furnace is considered part of static equipment because it typically remains in one place and doesn’t have moving
parts during its normal operation. Unlike machinery like pumps or compressors that involve mechanical motion,
furnaces are stationary and designed to provide consistent heat output without the need for continuous movement.
This static nature makes furnaces fall into the category of static equipment used in industrial and residential heating
systems.
11. Pig receiver
A pig receiver is a type of equipment used in pipelines to receive and collect cleaning devices called pigs, which are a
device that “catches” the cleaning device (“pig”) after it has passed through the pipeline. These pigs are used for
maintenance and cleaning purposes inside the pipeline. The pig receiver is designed to safely and efficiently capture
the pig as it travels through the pipeline during maintenance activities.
12. Piping
A piping system, which is a network of pipes, fittings, and valves intended to perform a specific job i.e. to transport
fluids or gasses within a facility or industrial plant. These pipes are interconnected to form a system that can carry
materials like water, chemicals, oil, steam, or air from one place to another.
Piping systems play a crucial role in various industrial activities such as refineries, petrochemical plants, and power
plants. In refineries, piping systems are used to transport crude oil, refined products, and various chemicals
throughout the facility, enabling different refining processes such as distillation, cracking, and blending. In
petrochemical plants, these systems facilitate the movement of raw materials, intermediates, and final products like
plastics, solvents, and fuels.
Moreover, in power plants, piping systems are essential for circulating water, steam, and other fluids required for
electricity generation, cooling systems, and steam turbines. These systems also include safety features such as valves,
pressure gauges, and control systems to ensure efficient and safe operation.
13. Valves
A valve is a device or natural object that regulates, directs, or controls the flow of a fluid (gasses, liquids, fluidized
solids, or slurries) by opening, closing, or partially obstructing passages within a system. It is like a door that can be
opened or closed to regulate the flow of liquids or gasses through pipes or channels.
Valves play a crucial role in the oil and gas industry by regulating the flow of fluids and gasses throughout the
production, refining, and distribution processes. They are used in various applications such as controlling the flow of
crude oil, natural gas, and refined products like gasoline and diesel.
What Is The Difference between Static and Rotating Equipment?
The main difference between static and rotating equipment lies in their functionality and movement during operation.
Static equipment, which is without moving parts, is comparatively more reliable, such as tanks, pressure vessels, heat
exchangers, and pipes.
On the other hand, rotating equipment includes machinery that has moving parts and rotates during operation, such as
pumps, compressors, turbines, and motors. Rotating equipment is designed to convert energy and move fluids or
gasses, while static equipment provides infrastructure for storage, containment, or transfer of substances without
moving parts. Both types of equipment serve distinct purposes in industrial processes and are essential for various
applications in different industries.
What Are Some FAQs About Static Equipment?
1. Is Valve A Static Equipment?
Yes, a valve is considered a static equipment because it typically remains stationary and does not have moving parts
like pumps or compressors. Valves are fixed in place within a system and are used to regulate, control, or stop the
flow of fluids or gases by opening, closing, or partially obstructing passages. They are an essential component of
pipelines, industrial processes, and systems where fluid or gas flow needs to be managed.
2. Is A Separator Static Equipment?
Yes, a separator is considered static equipment because it remains in one place and does not have moving parts
during normal operation. Separators are used in various industries, such as oil and gas, to separate different
components of a mixture, such as oil, gas, and water.
They work by utilizing gravity, centrifugal force, or other separation mechanisms to achieve the desired separation of
substances. Separators play a crucial role in processing and refining operations by separating and recovering valuable
components efficiently.
3. Is A Compressor Static or Rotary?
A compressor is a rotary equipment because it has moving parts that rotate during operation. Compressors are used to
increase the pressure of gasses or air by compressing and reducing their volume.
They work by drawing in gas or air and then mechanically compressing it to a higher pressure before releasing it.
Rotary compressors are designed with rotating components such as rotors or blades that create the compression
action, distinguishing them from static equipment that remains stationary during operation.
4. What Is Static Equipment Engineering?
Static equipment engineering refers to the specialized field of engineering focused on the design, analysis,
construction, and maintenance of static equipment used in various industries, including the stationary components
used in various processes of oil and gas exploration, production, refining, and transportation.
This discipline involves applying engineering principles to develop equipment such as tanks, pressure vessels, heat
exchangers, and pipes that do not have moving parts during normal operation.
Static equipment engineers ensure that these devices are designed to withstand specific pressures, temperatures, and
environmental conditions while meeting safety, regulatory, and performance standards. They also oversee the
installation, testing, and ongoing maintenance of static equipment to ensure reliable and efficient operation
throughout its service life.
5. What Are The Static Equipment Used in Refinery?
The static equipment used in a refinery includes tanks, pressure vessels, heat exchangers, columns and towers, piping
systems, and valves.
In conclusion, static equipment plays a vital role in the oil and gas industry by providing essential infrastructure for
storage, containment, and transfer of substances without moving parts. The design, creation, and inspection of static
equipment are governed by strict standards to ensure safety, reliability, and compliance with industry requirements.
Two prominent standards in this regard are the American Petroleum Institute (API) standards and the American
Society of Mechanical Engineers (ASME) codes.
In addition to the standards set by API and ASME, it is essential for engineers and professionals in the oil and gas
industry to have thorough knowledge and expertise in handling static equipment.
PetroSync offers API training and ASME training programs specifically designed to equip you with the necessary
skills and understanding to work effectively with static equipment. These training courses cover topics such as design
principles, inspection techniques, maintenance practices, and compliance with industry regulations. You can invest in
your own professional development through API and ASME training with PetroSync.

WHAT are Hold Points, and how to manage them?

 Home QShop Software » Q.Shop Data Collection » What are Hold Points, and how to manage them?
Table of Contents
What are Inspection Hold Points or Witness Points?
Hold points are stages and checkpoints in production where the work progress is temporarily stopped until certain
inspection criteria are met. The production will resume after an inspector, an engineer, or a quality assurance
personnel approves the checkpoint and releases it.
Hold points aim to ensure quality standards and conditions before proceeding further in production.
During the Inspection Test Plan (ITP) process on the shop floor, the inspector will release the hold point after
ensuring that the Quality Assurance standards are met.
During shop floor inspection, there are often stages of the process that cannot continue without inspection approval.
These inspections are called hold points or witness points.
Examples of hold points could be doing a minor check during the inspection or performing a First Article Inspection
(FAI) before production begins. In both cases, the production stops until the results are approved by a supervisor or a
QA manager.
The Quality Assurance department is in charge of making sure the final product is made according to the proper
standards.
Shop Floor Inspection and Hold Points
Collecting shop floor inspection data is directly linked to the quality of the inspection process and management of
hold points. A unified shop floor data collection system ensures that all your data is collected quickly and managed
accurately.
With a data collection system in place, when reaching an inspection point, managers or supervisors will be notified
automatically. This can greatly improve the efficiency and quality of communication throughout your business.
At the same time, a unified ITP system brings all your production data together and makes sure that your products
meet the quality standards at each stage of your production.
Similarly, a shop floor inspection system with automated witness points can immensely speed up your inspection and
test plan data collection saving you money.

Why Hold Points are needed?

A hold point can be placed for a number of reasons, depending on your industry or Inspection and Test Plan (ITP)
process. For example, a critical inspection point for manufacturers could be to make sure that incoming goods match
their order before beginning production.
No matter your shop floor inspection process, a hold point results in a stop of your operation. On your shop floor,
placing hold points comes with the cost of slowing production to a halt and idling technicians.
The question is, how is there a better way to make the hold point move forward faster? Here are two major factors
during your shop floor inspection that slow down the release of hold points:
1. Slow Communication: Between the shop operator or the technicians and the shop supervisor, engineer, or quality
assurance inspector. For example, it is not uncommon that the inspector isn’t there or takes a long time to be notified.
2. Work instructions: Finding the right work instructions and process manuals related to a certain hold point. As
paperwork is often difficult to locate on the shop floor.

How to reduce Hold Time?

With many industries having deadlines and backed-up orders, hold points begin to become costly. Being able to
speed up the inspection of a hold point would make the delays shorter.
It saves money and allows the operators to use most of their time. The question here is how.
If your shop floor inspection process is a paperless system, the operator can send a photo of the inspection area along
with an alert to notify the inspector.
 The notification is sent to their phone or computer, without them needing to physically be on the shop floor.
The inspector can attend the inspection point if needed or even release the hold point from their desk. This way the
shop floor inspection process becomes faster and more efficient.
Why consider an electronic Inspection Test Plans (ITP) system?
Having automated inspection points as part of the paperless manufacturing Inspection Test Report (ITR) system
saves you time by easing communication between inspectors and operators. It also makes an easier process for all
people involved in the inspection of a hold point.
Don’t let hold points delay your production, make the switch to an online data collection system. Let Q.Shop house
all test reports and inspection forms online. Hold points and inspections are just one of the daily tasks made easier
with the use of a data collection system.
Hold point in itp
An ITP is an Inspection Test Plan document with specific inspection activities and criteria. These criteria are required
to meet quality standards and comply with industry standards.
Following Inspection Test Plans also include hold points. These are the critical checkpoints in the quality inspection
process. Hold points are defined while designing an Inspection Test Plan. Here are some key components that should
be considered when identifying hold points in ITP:
• Identification: Hold points are critical points in the production where verification is essential. Identifying hold points
is based on risk assessment and industry-specific requirements and industry standards followed in the productions.
• Determining the Criteria for Inspection: Each hold point determines the criteria that must be met before the
production can move ahead. Quality standards and customer requirements dictate the verification points.
• Authorities: Part of the inspection ITP development is to identify the role of stakeholders and supervisors in the
approval process. Subsequently, this means putting procedures in place to ensure the smooth handling of witness
points during the inspection.
• Communication: When designing ITP forms, it’s important to consider the communication process and this means
of notifying the relevant personnel when a hold point is reached. For example, in a digital place, a hold point can
automatically send a message to the related supervisor to ensure a speedy inspection process.

Asme Section VIII

ASME Section VIII is a globally recognized standard for pressure vessel design, ensuring safety and reliability across
energy, oil and gas, and other industries. Pressure vessels play a critical role in storing and transporting gases or
liquids under pressure, making compliance with ASME essential for safe operations.
Table of Contents
• What is ASME Section VIII?
• What Is Code ASME Section VIII?
• How Many Divisions Are In ASME Section VIII?
• ASME Section VIII Division 1?
• ASME Section VIII Division 2?
• What Is ASME Section VIII Division 3?
• What Are The Differences Between ASME Section VIII Div 1 and 2?
• What Are The Advantages of ASME Section VIII?
• Join PetroSync Training: Master ASME Section VIII Standards
In this article, we will explore the fundamentals of ASME Section VIII, the key differences between Division 1 and
Division 2, and the benefits of following this standard.
What is ASME Section VIII?
ASME Section VIII is a widely recognized industry standard providing guidelines for pressure vessel constructions,
including tanks, boilers, and heat exchangers. Regulated by ASME, this code provides guidelines for safe operation
at different pressure and temperature conditions.
Section VIII code also modulates design and fabrication standards, testing procedures, and inspection methods to
ensure that pressure vessels are reliable for various industries such as chemical, oil and gas, and pharmaceutical.
Compliance with Section VIII is often mandatory for companies operating in the mentioned sectors as it prevents
safety risks and legal liabilities.
Related to Section VIII, there is API 579 that provides guidelines for fitness-for-service assessments for equipment
and piping. It is related to Section VIII as it provides a methodology for assessing the integrity of pressure vessels
and other equipment.
What Is Code ASME Section VIII?
Sometimes known as the “Pressure Vessel Code,” is part of the American Society of Mechanical Engineers’ (ASME)
Boiler and Pressure Vessel Code (BPVC). This section explains the regulations for designing, fabricating, testing,
and certifying pressure vessels to ensure that they fulfill safety standards.
Engineers, manufacturers, and safety experts worked together to develop the code, which addresses all aspects of
pressure vessel design. It defines design criteria, permissible stress limits, and testing processes to ensure the vessel’s
integrity under a variety of operating conditions.
The code is regularly revised to reflect advances in technology, materials, and safety standards, ensuring that it
remains current and helpful for modern industrial applications.
How Many Divisions Are In ASME Section VIII?
ASME Section VIII is organized into three major sections, each customized to a different type of pressure vessel
based on design criteria, material attributes, and industry applications. The divisions are:
ASME Section VIII Division 1?
This category includes vessels that operate at low pressures and temperatures. It is the most popular division because
of its thorough yet flexible design standards, which allow for a variety of materials and construction methods.
ASME Section VIII Division 2?
An engineer inspects pressure vessel following the rule from ASME Section VIII (Credit: Bassett Mechanical)
Known as the alternative rules division, it addresses vessels operating under higher stress levels. It provides more
strict criteria for material selection, testing, and design requirements than Division 1. This division is commonly
employed for vessels in which weight and material costs are crucial, such as in offshore applications.
What Is ASME Section VIII Division 3?
This division includes vessels that operate under extremely high pressures, such as those used in the oil and gas or
petrochemical industries. It establishes recommendations for designing pressure vessels that operate at pressures
above those generally covered in Divisions 1 and 2, often exceeding 10,000 psi.
Each of these departments guarantees that pressure vessels are designed to satisfy the specific needs of their
individual applications, which range from standard storage tanks to highly specialized, high-pressure equipment.
What Are The Differences Between ASME Section VIII Div 1 and 2?
ParameterASME Section VIII Div 1 ASME Section VIII Div 2

Section 1 applies to the design and

construction of pressure vessels with
Scope and a maximum allowable working pressure ASME VIII Section 2 applies to pressure vessels with a MAWP of
Applicability
(MAWP) above 15 psi 15,000 psi or less.

Design and Section 2 has more detailed design requirements and stress analysis
Testing Section 1 has less rigorous design methods, including the use of finite element analysis (FEA) for more
Requirements
requirements compared to Section 2,complex
as it designs. Section 2 also has more stringent testing
 relies more on established design practices
requirements, including additional non-destructive examination
and standard formulae. (NDE) methods.

Section 1 allows for a broader range of

materials than Section 2. Section 1 permits
Material the use of materials such as cast ironSection
and 2 allows for the use of thinner materials, which can result in
Requirements
ductile iron cost savings.

Section 2 requires more frequent and extensive inspections during

Quality Control
Section 1 has less stringent requirements
fabrication and testing, as well as more comprehensive documentation
and Assurance
for quality control and assurance. of the fabrication process.

The cost may be higher due to the usage

The cost
of may be higher due to more detailed design requirements and
Cost thicker materials and fabrications more rigorous testing requirements

What Are The Advantages of ASME Section VIII?

ASME Division VIII benefits users, designers, and manufacturers the most. It provides detailed requirements for
pressure vessel design, fabrication, erection, testing, assembly, inspection, and certification that bring several
advantages, such as:
1. Safety Prioritization
Engineers and manufacturers widely accept this code as the standard for pressure vessel design and fabrication.
Using Section VIII ensures the vessel meets regulatory requirements. This includes the capability to withstand the
intended operating conditions.
2. Quality Assurance
Quality assurance that modulates materials, fabrication process, and quality control measures. validates how a vessel
is of a high quality that meets design criteria.

3. Cost Effective
Following Section VIII can prevent any expensive testing and design modifications. It also reduces the risk of
accidents or equipment.
To sum up, the usage of Section VIII leads to standardized pressure vessels with a reliable approach to designing,
building, and testing. Not just safe, compliant, and of high quality, the pressure vessels can be flexible in design to
meet specific needs.
Join PetroSync Training: Master ASME Section VIII Standards
Enrolling in ASME Section VIII Division 1 & 2 Pressure Vessel training course can help individuals understand and
comply with the standard, reducing the risk of accidents and failures. PetroSync provides ASME Section VIII
training covering both the stated and implied requirements of the codes, as well as the mechanics of implementing
the code rules and design formulas for various design conditions and services.
We craft our 5 days training to equip participants with the comprehensive knowledge and practical skills required for
designing, fabricating, testing new vessels, and evaluating the durability of the existing ones. The ASME VIII
Division 1 & 2 training will also employ numerous case studies to illustrate how to implement code regulations.
Enroll now and advance your knowledge of pressure vessels with PetroSync!

ASME HYDROSTATIC TEST REQUIREMENTS

HYDROSTATIC TESTING IS A RELIABLE WAY TO ENSURE YOUR PIPELINE IS FREE OF LEAKS AND
OTHER DISRUPTIVE DAMAGE. OPERATORS CAN PERFORM HYDROSTATIC TESTS WITHOUT
COMPLETELY DISRUPTING SERVICE OR CAUSING DAMAGE TO THE PIPELINE SYSTEM, MAKING IT
AN EFFICIENT AND COST-EFFECTIVE METHOD OF TESTING. THAT SAID, HYDROSTATIC TESTS ARE
ONLY EFFECTIVE WHEN YOU PERFORM THEM CORRECTLY. THAT’S WHY THE AMERICAN SOCIETY
OF MECHANICAL ENGINEERS HAS THE ASME B31 PRESSURE PIPING CODE FOR PRESSURE AND
LEAK TESTS. THIS CODE ENSURES THAT PIPELINE OPERATORS FOLLOW THE PROPER
REQUIREMENTS AND PROCEDURES WHEN CONDUCTING PRESSURE OR PNEUMATIC TESTS, SUCH
AS THE HYDROSTATIC TEST. BRUSH UP ON EVERYTHING YOU NEED FOR A SUCCESSFUL PIPE
INSPECTION WITH THIS OVERVIEW OF ASME HYDROSTATIC TEST REQUIREMENTS.
GENERAL PRESSURE TEST REQUIREMENTS
EVERY PIPING SYSTEM IS DIFFERENT, SO MAKE SURE YOU ACCOUNT FOR ALL THE DETAILS
WHEN YOU PERFORM YOUR HYDROSTATIC TESTS. IF THE SYSTEM IS SUBJECT TO LOW TEST
TEMPERATURES OR THERMAL EXPANSION, MAKE SURE YOU TAKE THE NECESSARY
PRECAUTIONS AGAINST DAMAGE OR EXCESSIVE PRESSURE. YOU SHOULD ALSO FOCUS ON
PERSONNEL PROTECTION. THE RIGHT EQUIPMENT AND MEASURES CAN HELP ELIMINATE INJURY
IN THE EVENT OF A RUPTURE OR OTHER ACCIDENT. YOU MUST ALSO FOLLOW THE PROPER
PROCEDURES WHEN PREPARING FOR THE TEST. ISOLATE THE SECTION OF PIPE YOU ARE TESTING
AND USE QUALITY PIPE STOPPLES AND OTHER MATERIALS TO ENSURE YOU CAN SAFELY AND
EFFECTIVELY CLOSE OFF AND PRESSURIZE THE AREA. ENSURE ANY SUPPORT POINTS ALONG THE
PIPE—INCLUDING TEMPORARY SUPPORTS—CAN SUSTAIN THE PRESSURIZED HYDROSTATIC
LOAD. ADDITIONALLY, OPEN VENTS AND OTHER HIGH POINT CONNECTIONS AS YOU SLOWLY
FILL THE LINE WITH WATER. THIS WILL ALLOW THE DISPLACED AIR TO ESCAPE AND HELPS YOU
REMOVE AS MUCH AIR AS POSSIBLE FROM THE PIPE. FINALLY, KEEP A PROPER RECORD OF THE
TEST. THIS RECORD SHOULD INCLUDE THE DATE, THE SPECIFIC PIPELINE SYSTEM YOU TEST, THE
FLUID AND PRESSURE YOU USE, AND THE EXAMINER’S CERTIFICATION OF THE RESULTS.
HYDROSTATIC TEST STRESS AND PRESSURE REQUIREMENTS
YOU CAN FIND SPECIFIC ASME HYDROSTATIC TESTING REQUIREMENTS FOR PROCESS PIPING IN
ASME B31.1 AND ASME B31.3. THESE CODES STATE THAT THE PRESSURE DURING THE
HYDROSTATIC TEST SHOULD NEVER FALL BELOW ONE AND A HALF TIMES THE PRESSURE THAT
THE SYSTEM IS DESIGNED TO HOLD. THE EXCEPTION TO THIS RULE IS WHEN THE SYSTEM’S
DESIGN TEMPERATURE IS HIGHER THAN THE TEST TEMPERATURE. IN THIS CASE, YOU CAN
CALCULATE THE MINIMUM PRESSURE REQUIREMENT WITH THE EQUATION 1.5PST DIVIDED BY S,
WHERE P EQUALS THE DESIGN PRESSURE, ST EQUALS THE ALLOWABLE STRESS AT THE TEST
TEMPERATURE, AND S EQUALS THE ALLOWABLE STRESS AT THE DESIGN TEMPERATURE. DURING
THE HYDROSTATIC TEST, YOU MUST MAINTAIN THIS PRESSURE FOR AT LEAST TEN MINUTES.
AFTER THIS PERIOD, YOU CAN REDUCE THE TEST PRESSURE TO MATCH THE DESIGN PRESSURE,
THEN INSPECT THE SYSTEM FOR LEAKS AND OTHER DAMAGE.
YOU WILL FIND A VARIETY OF HYDROSTATIC TEST TOOLS AND EQUIPMENT ON PETERSEN
PRODUCTS WEBSITE. ANY QUESTIONS OR NEED ADDITIONAL INFORMATION JUST CONTACT US.
THE INFORMATION MAY BE USED BUT WITH NO WARRANTY OR LIABILITY. THIS INFORMATION IS
BELIEVED TO BE CORRECT BUT SHOULD ALWAYS BE DOUBLE CHECKED WITH ALTERNATIVE
SOURCES. STRICTLY ADHERE TO AND FOLLOW ALL APPLICABLE NATIONAL AND LOCAL REGULATIONS
AND PRACTICES.
 API 510 KEY POINTS

>Key Points from API 510 (2022) - Pressure Vessel Inspection Code

#>1. Scope & Application

- Covers in-service inspection, repair, alteration, and rerating of pressure vessels (PVs) and pressure-relieving devices
(PRDs).
- Applies to hydrocarbon/chemical process vessels (ASME, non-code, jurisdictional-special, nonstandard).
- Exemptions: Decommissioned vessels (unless abandoned-in-place), portable vessels, small containers (Annex A).

#>2. Inspection Organization & Responsibilities

- Owner-Operator : Must maintain QA systems, inspection plans, and records.
- Inspector : Certified per Annex B, oversees inspections, evaluates NDE results.
- Engineer : Approves design changes, rerating, and FFS assessments.
- Repair Organization : Must hold ASME/NB stamps or meet API 510 qualifications.

#>3. Inspection Types & Intervals

- Internal Inspection : Max 10 years or ½ remaining life (whichever is less).
- On-stream Inspection : Can replace internal inspection if corrosion rate <0.125 mm/year and no cracking risk.
- External Inspection : Every 5 years (or per RBI).
- Thickness Monitoring : Required for corrosion rate calculation.
- Risk-Based Inspection (RBI) : Can extend intervals if risk is managed (API RP 580/581).

#>4. Key Damage Mechanisms

- General/localized corrosion, cracking (SCC, fatigue), hydrogen damage, CUI/CUF, erosion.
- Refer to API RP 571 for detailed mechanisms and inspection methods.

#>5. Condition Monitoring Locations (CMLs)

- Designated areas for thickness measurements/exams.
- Must represent worst-case corrosion zones.

#>6. Fitness-for-Service (FFS) Assessments

- Use API 579-1/ASME FFS-1 to evaluate flaws (e.g., thinning, cracks, blisters).
- Allows continued operation with defects if criteria are met.

#>7. Repairs & Alterations

- Repairs : Restore integrity (e.g., weld overlay, insert plates).
- Alterations : Change design (e.g., new nozzles, rerating).
- Temporary Repairs : Must be documented and replaced ASAP.
- PWHT Alternatives : Controlled-deposition welding (CDW) or preheat may be used with engineering approval.

#>8. Rerating
- Requires recalculation per ASME BPVC, pressure test, and updated nameplate.
- MAWP/Temperature changes must be justified.
#>9. Pressure Testing
- Required after major repairs/alterations.
- Hydrostatic (preferred) or pneumatic (with safety precautions).
- Test pressure = 1.3–1.5 × MAWP (adjusted for temperature).

#>10. Records & Documentation

- Maintain permanent records: design data, inspection results, repairs, FFS assessments.
- Inspection reports must be approved and filed within 90 days.

#>11. Exploration & Production (E&P) Vessels

- Alternative rules in Section 9 (simplified intervals, class-based inspections).

#>12. Deferrals
- Inspections can be deferred with risk assessment and documentation.

>Critical Standards Referenced

- API RP 571 : Damage mechanisms.
- API RP 580/581 : RBI methodology.
- API 579-1/ASME FFS-1 : Fitness-for-service.
- ASME BPVC Sections V, VIII : NDE and construction rules.

Note : Always comply with jurisdictional requirements where stricter than API 510.

HERE’S A DETAILED BREAKDOWN OF KEY ASPECTS FROM API 510 (2022) FOR
COMPREHENSIVE UNDERSTANDING:

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>1. SCOPE & APPLICATION

- Coverage :
- Applies to in-service PVs & PRDs in hydrocarbon/chemical industries (ASME Div. 1/2, non-code, jurisdictional-
special).
- Excluded : Decommissioned vessels (unless abandoned-in-place), portable equipment (e.g., truck-mounted tanks),
small containers (volumes <0.14m³ at ≤1.7 MPa).
- Intent : Ensure integrity via inspections, repairs, alterations, and rerating.
- Limitations : Overrides construction codes if conflicts arise; stricter than regulations if required.

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>2. INSPECTION ORGANIZATION ROLES
| Role | Responsibilities |
|-------------------------|--------------------------------------------------------------------------------------|
| Owner-Operator | QA systems, inspection plans, MOC (Management of Change), IOWs (Integrity Operating
Windows), records. |
| Authorized Inspector | Certified (Annex B), approves repairs/alterations, evaluates NDE, sets hold points. |
| Engineer | Validates FFS, rerating, weld procedures, material compatibility. |
| Repair Organization | Must hold ASME/NB stamps (R/VR) or meet API 510 qualifications (Section 4.3). |
| Examiners | Perform NDE; ASNT CP-189/SNT-TC-1A certified. |

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>3. INSPECTION PLANNING & METHODS

- Inspection Plan :
- Based on RBI, damage mechanisms (API RP 571), vessel history, IOWs.
- Specifies techniques: UT, RT, PT, MT, ET, PAUT, TOFD.
- Types :
- Internal : Entry-based; verifies internal surfaces, internals, linings. Max. interval: 10 years or ½ remaining life.
- On-stream : External NDE; substitutes internal if corrosion rate <0.125 mm/yr, no cracking risk (Section 6.5.2).
- External : Visual/NDE; checks supports, insulation, leaks. Every 5 years.
- Thickness Monitoring : At CMLs; calculates corrosion rates (LT/ST).
- CUI Inspection :
- Required for insulated vessels in susceptible temp ranges (e.g., -12°C to 177°C for carbon steel).
- Techniques: Insulation removal, UT, radiography.

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>4. DAMAGE MECHANISMS & ASSESSMENT

- Key Mechanisms (API RP 571):
- Corrosion (general/pitting/CUI/sulfidation), cracking (SCC/fatigue/creep), hydrogen damage (HIC/HTHA),
erosion.
- Fitness-for-Service (FFS) :
- API 579-1/ASME FFS-1 used for:
- Thinning (Level 1/2/3), cracks, blisters, dents.
- Accepts flaws if remaining strength factor (RSF) ≥ 0.9.
- Remaining Life Calculation :
```plaintext
Remaining Life (yrs) = (t_actual - t_min) / Corrosion Rate
```
- t_min = required thickness (pressure + structural loads).

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>5. REPAIRS, ALTERATIONS & RERATING

- Repairs :
- Permanent : Weld overlay, insert plates, nozzle replacements. Follow ASME PCC-2.
 - Temporary : Fillet-welded patches, nonmetallic wraps (ASME PCC-2 Art. 401/402); max. 2-year duration.
- Alterations :
- Physical changes affecting pressure boundary (e.g., new nozzles); requires engineer approval.
- Rerating :
- Steps:
1. Recalculate MAWP per ASME BPVC (Figure 1).
2. Pressure test at 1.3–1.5 × new MAWP (temp-adjusted).
3. Update nameplate (Figure 2).
- Welding Alternatives to PWHT :
- Preheat (150°C min.) or CDW (Controlled-Deposition Welding) for P-No. 1/3/4 steels (Table 3).

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>6. PRESSURE TESTING

- When Required : After major repairs/alterations.
- Methods :
- Hydrostatic : Preferred; test pressure = 1.3 × MAWP (post-1999 ASME) or 1.5 × MAWP (pre-1999).
- Pneumatic : High-risk; requires engineer approval.
- Brittle Fracture Prevention :
- Metal temp ≥ (MDMT + 17°C) for thick vessels (>50 mm).

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>7. RECORDS & DOCUMENTATION

- Mandatory Records :
- Design specs, inspection reports, FFS assessments, repair/alteration forms (Annex D), RBI documentation.
- Pressure test results, thickness readings, corrosion rates.
- Retention : Lifecycle of equipment.

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>8. RISK-BASED INSPECTION (RBI)

- Methodology (API RP 580/581):
- Risk = Probability (damage rate) × Consequence (safety/environmental impact).
- Outputs : Inspection intervals, techniques, extent.
- Updates : After inspections, process changes, or failures.

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>9. EXPLORATION & PRODUCTION (E&P) VESSELS

- Alternative Rules (Section 9):
- Longer intervals: External every 5 years; internal/on-stream every 10–15 years.
- Class-based risk grouping (low/high risk).

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>10. CRITICAL REFERENCES
- API RP 571 : Damage mechanisms.
- API 579-1/ASME FFS-1 : FFS assessments.
- API RP 580/581 : RBI.
- ASME BPVC Section V/IX : NDE/welding.
- ASME PCC-2 : Repair standards.

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Key Takeaway : API 510 emphasizes proactive integrity management via RBI, FFS, and strict documentation.
Always prioritize jurisdictional requirements where stricter.