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API 653 Client Awareness Session by SGS
API 653 Client Awareness Session by SGS
ON
API 653 ABOVE GROUND STORAGE
TANKS INSPECTION, REPAIR,
ALTERATION AND RECONSTRUCTION
Cause of Concern
1
Objectives of Awareness Session
Table of Contents
◊ 1. Scope of API 653
◊ 2. Relevant Codes and References
◊ 3. Some Important Definitions
◊ 6. Inspection
◊ 4. Suitability for service
◊ 5. Brittle fracture considerations
◊ 9. Tank repair and alteration
◊ 7. Materials
◊ 10. Dismantling and reconstruction
◊ 8. Design Consideration for Reconstructed Tank
◊ 11. Welding
◊ 12. Examination and testing
◊ 13. Marking and recordkeeping
◊ Appendix B Evaluation of Tank Bottom Settlement
2
Scope of API 653
◊ The scope of API 653 is limited to the tank foundation, bottom, shell,
structure, roof, attached appurtenances, and nozzles to the face of the
first flange, first threaded joint, or first welding - end connection.
3
Scope of API 653 (Cont’d)
COMPLIANCE WITH THIS STANDARD
JURISDICTION
API 652
API 575 API 650
ASME ASME
API 651
V IX
4
Relevant Codes And References
Alteration:
Any work on a tank that changes its physical dimensions or
configuration.
As-Built Standard:
The standard used for the construction of the tank component
Atmospheric pressure:
Used to describe tanks designed to withstand an internal pressure
up to but not exceeding 2 ½ lbf/in2 gauge.
Authorized inspector:
A Person who is certified as an Aboveground Storage Tank
Inspector per Appendix D of API 653
10
5
Some Important Definitions (Cont’d)
11
Candidate tank:
The tank for which corrosion rates are not known.
Change in service:
A change from previous operating conditions involving different
properties of the stored product such as specific gravity or corrosivity
and/or different service conditions of temperature and/or pressure.
Corrosion rate:
The total metal loss divided by the period of time over which the metal
loss occurred.
12
6
Some Important Definitions (Cont’d)
Control tank:
The tank for which corrosion rates and service history are known and
documented.
Critical zone:
The portion of the tank bottom or annular plate within 3 in. of the inside
edge of the shell, measured radially inward.
Reconstruction:
Any work necessary to reassemble a tank that has been dismantled and
relocated to a new site.
Repair:
Work necessary to maintain or restore a tank to a condition suitable for
safe operation. Repairs include both major repairs (see 3.21) or repairs
that are not major repairs. Examples of repairs include:
Removal and replacement of material to maintain tank integrity.
◊ Re-leveling and/or jacking of a tank shell, bottom, or roof.
◊ Addition of reinforcing plates to existing shell penetrations.
◊ Repair of flaws, such as tears or gouges, by grinding and / or
gouging followed by welding.
13
14
7
Some Important Definitions (Cont’d)
Fitness for service assessment:
A methodology whereby flaws contained within a structure are
assessed in order to determine the adequacy of the flawed
structure for continued service without imminent failure.
Hot tap:
Identifies a procedure for installing a nozzle in the shell of a tank
that is in service
Product side:
The side of the tank that is in contact with the stored liquid
product.
Reconstruction:
Any work necessary to reassemble a tank that has been
dismantled and relocated to a new site
15
8
Some Important Definitions (Cont’d)
Major alteration/or major repair: An alteration or repair that includes
any of the following:
◊ Installing a new bottom. This does not include new bottoms in tanks
where the foundation under the new bottom is not disturbed and either
of the following conditions is met:
1. For tanks with annular rings, the annular ring remains intact; or,
2. For tanks without annular rings, the alteration does not include
welding on the existing bottom within the critical zone.
◊ Removing and replacing part of the weld attaching the shell to the
bottom, or to the annular plate ring, in excess of the amounts listed in
12.3.2.4.1a.
◊ Jacking a tank shell.
Soil Side:
The side of the tank bottom that is in contact with the ground.
Unknown toughness:
A condition that exists when it cannot be demonstrated that material of a
component satisfies the definition of recognized toughness
17
◊ GENERAL
◊ Storage tanks are used to store fluids such as crude oil,
intermediate and refined products, gas, chemicals, waste
products, water, and water/product mixtures. Important factors
such as the volatility of the stored fluid and the desired storage
pressure result in tanks being built of various types, sizes, and
materials of construction.
◊ At the moment we will discuss only atmospheric and low
pressure storage tanks..
18
9
Atmospheric Storage Tanks
19
◊ Additional uses for atmospheric storage tanks can include liquid (both
hydrocarbon and non-hydrocarbon) storage in horizontal vessels,
storage of process liquids or granular solids in skirt-supported or
column-supported tanks with elevated cone bottoms (non-flat bottom)
and process water / liquids in open-top tanks.
20
10
Types Of Atmospheric Storage Tanks
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22
11
Cone Roof Tank
24
12
Steel Dome Roof Tank
25
• Annular-pontoon
Floating-roof Tank
26
13
Internal Floating Roof
27
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14
SUITABILITY FOR SERVICE
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15
Tank Roof Evaluation
Plates shall be repaired or replaced if:
Fixed Roofs
Inspection should be performed to check the soundness of :
◊ Roof Support members (rafters, girders, columns, and bases)
◊ Particular attention must be given to the possibility of severe
internal corrosion of pipe columns (corrosion may not be
evidenced by external visual inspection).
◊ Roof to shell frangible joint (when required)
31
32
16
Change of Service:
Internal Pressure
As per API 650 Appendix F regarding evaluation and subsequent
modifications to the tank and roof to shell junction.
External Pressure
As per API 620 regarding roof support structure (if any) and the
roof to shell junction shall be evaluated for the effects of a design
partial vacuum.
Operation at Elevated Temperature
As per API 650 Appendix M, shall be considered before changing
o
the service of a tank to operation at temperatures above 200 F.
Operation at Lower Temperature than Original Design
As per API 650.
Normal and Emergency Venting
Effects of change of service on Normal and Emergency Venting
shall be considered.
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17
Tank Shell Evaluation: (Contd)
◊ Many forms of corrosion at shell occurs , generally uniform loss
of metal over a large surface area or in localized area.
35
36
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Inspection Of Corroded Areas
37
38
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Tank Shell Evaluation: (Cont’d)
Pits Evaluation:
39
PIT MEASUREMENT
40
20
Minimum Thickness Calculation for Tank Shell
When determining the minimum acceptable thickness for an
entire shell course, tmin is calculated as follows:
41
42
21
43
44
22
Minimum Thickness Calculation for Tank Shell
45
46
23
Minimum Thickness Calculation for Riveted Tank Shell
S is 21000 lbf/in°
E is 1.0 for shell plate 6 in. or more away from rivets. See
table 4.3 for joint efficiencies for location within 6 in. of
rivets
47
48
24
Shell Distortions
Shell distortions include out of roundness, buckled areas,
flat spots, and peaking and banding at welded joints.
Causes:
◊ Foundation settlement
◊ Over or under pressuring
◊ High wind
◊ Poor shell fabrication or repair techniques
Evaluation
49
Flaws
25
Shell Penetrations
51
Elevated Temperature
52
26
Tank Bottom Evaluation:
Causes of Bottom Failure:
53
54
27
Tank Bottom Evaluation:
55
56
28
Minimum Thickness for Tank Bottom Plate
57
58
29
Tank Bottom Evaluation: (Cont’d.)
59
60
30
ABOTTOM PLATE MINIMUM THICKNESS
61
◊ Settlement
◊ Erosion
◊ Cracking
◊ Calcining
◊ Attack by underground water
◊ Attack by alkalies and acids
62
31
Tank Foundation Evaluation:
63
Anchor Bolts:
64
32
Brittle Fracture Considerations
65
66
33
Brittle Fracture Considerations (Contd.)
67
A decision Tree
68
34
Exemption Curve
69
INSPECTION
70
35
INSPECTION
71
36
Inspection Intervals
73
Types Of Inspection
External Inspections
Internal Inspections
74
37
Routine In-service Inspections
75
38
External Inspections
(Tank may be in operation during this inspection)
RCA/4N
Where as
RCA difference between the measured shell thickness and the minimum
77
◊ Appendix “C” of API 653 provides the sample checklist for In-service
tank inspection.
the roof.
78
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Ultrasonic Thickness Inspection
79
80
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Internal Inspection
Internal Inspection is primarily required to:
◊ Ensure that the bottom is not severely
corroded and leaking.
82
41
Internal Inspection Intervals
Tank Safe Guards Max Inspection
Interval
i) Original nominal bottom thickness 5/16 in. or greater 12 years
ii) Cathodic protection of the soil-side of the primary tank bottom per Note 1 12 years
iii) Thin-film lining of the product-side of the tank bottom per Note 2 12 years
iv) Fibreglass-reinforced lining of the product-side of the tank bottom per Note 2 13 years
v) Cathodic protection plus thin-film lining 14 years
viii) Release prevention barrier per Note 3 (when RBI assessment performed) 25 years
NOTE 1 For purposes of 6.4.2.1, effective cathodic protection of the soil-side of the primary tank bottom
means a system installed and maintained in accordance with API 651.
NOTE 2 For purposes of 6.4.2.1, lining of the product-side of the tank bottom means a lining installed,
maintained and inspected in accordance with API 652.
NOTE 3 For purposes of 6.4.2.1, a release prevention barrier means an under-bottom leak detection and
containment system designed in accordance with API 650, Appendix I.
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Alternative Internal Inspection Interval
RBI (Risk Based Inspection):
◊ An owner / operator may establish the internal
inspection interval using risk based inspection (RBI)
procedures.
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Records Of Inspection
◊ The owner / operator shall maintain a complete
record file consisting of three types of records,
namely:
◊ Construction records
◊ Inspection history
◊ Repair / Alteration history.
87
Materials
88
44
MATERIALS
New Material:
89
Structural:
90
45
Materials (Contd.)
Flanges and Fasteners:
◊ Flanges – Minimum requirement of the material
specifications in the original standard of construction
◊ Fasteners – Material specifications of current applicable
standard.
Welding Consumables:
92
46
Design Considerations For Reconstructed Tanks
94
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Tank Repair And Alteration
95
96
48
Minimum Dimensions of replacement shell plate
Minimum Dimensions for a replacement shell plate is:
◊ 12 in. or 12 times the thickness of the replacement plate,
whichever is greater.
97
98
49
Shell Repairs Using Lap Welded Patch Plates
99
◊ The repair plate may cross any butt welded vertical or horizontal
shell seam that have been ground flush, but must overlap a
minimum of 6’’.
100
50
Weld Joint Design
101
102
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Weld Joint Spacing (Contd.)
103
104
52
Lapped Patch Repair Plates at Shell to Bottom Joint
105
53
Repair of Defective Welds
◊ Cracks, lack of fusion, and rejectable slag and porosity that
need repair shall be removed completely by gouging and or
grinding and resulting cavity properly repaired by welding.
107
For acceptable details fig. 9-3 and 9-4 are referred here.
108
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Repair of Shell Penetration
109
110
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Repair of Shell Penetration
Addition or replacement of shell penetration
◊ New shell penetration shall be in accordance API-650
Additionally
111
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Repair of Shell Penetration
113
114
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Repair of Tank Bottoms
The use of welded-on patch plates for repairing a portion of
uniformly supported tank bottoms is permitted within the limitations
given in the following.
◊ The minimum dimension for a welded-on patch plate that
overlaps a bottom seam or existing patch is 12”.
◊ The welded-on patch plate may be circular, oblong, or
polygonal with rounded corners.
◊ Welded-on patch plates shall not be placed over areas of the
tank bottom that have global dishing, local dishing, settlement
or distortion greater than the limits in Appendix B of the API
653, except a welded-on patch plate may be placed over a
mechanical dent or local dishing if its un-supported dimension
does not exceed 12in. in any direction, it is at least ¼in. thick, it
is at least as thick as the existing bottom, and does not overlap
seams nor other patches, except for tanks designed in
accordance with API 650.
115
116
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Typical Welded – on Patch Plates on The Tank Bottom
117
118
59
Replacement of Entire Tank Bottom
When removing an existing bottom, the tank shell shall be
separated from tank bottom either by:
119
120
60
Replacement of Entire Tank Bottom
The following shall be considered for tanks with cathodic
protection and under-bottom leak detection:
121
Self-Supporting Roofs
◊ The nominal thickness of new roof plate shall be 3/16in. or the
required thickness given in API 650 , plus specified corrosion
allowance whichever is greater.
122
61
Hot Taps
◊ The requirement in API 653 cover the installation of radial hot
tap connections on existing in-service tanks constructed with shell
material that does not require post weld heat treatment.
◊ The minimum height of tank liquid above the hot tap location
shall be at least 3 ft. during the hot tapping operation.
◊ Hot taps are not permitted on the roof of a tank or within the
gas/vapor space of the tank.
◊ Hot taps are not permitted on tanks where the heat of welding
may cause environmental cracking (such as caustic cracking or
stress corrosion cracking).
123
Hot Taps
For material having unknown toughness
124
62
Hot Taps
Table 9.1- Hot tap connection sizes and shell plate thicknesses
125
126
63
DISMANTLING AND
RECONSTRUCTION
127
Dismantling Methods
◊ Roof, Shell and bottom plates may be cut in to any size pieces
that are readily transportable to the new site for reconstruction.
Bottom:
◊ The bottom plates may be cut from the shell along a line A-A
and line B-B.
64
Tank Shell and Bottom Cut Locations
129
◊ The shell shall be cut from the bottom plate along line B-B as
shown in figure 10-1. The existing shell to bottom connection shall
not be reused unless the entire bottom is to be reused intact.
130
65
Dismantling Methods (contd.)
Roofs:
Piece Marking:
131
Reconstruction
Shells – Plates to be joined by butt welding shall be matched
accurately and retained in position during welding.
Misalignment shall not exceed the following:
Vertical Joints - > 5/8in. 10% of thickness or 1/8 max.
Vertical Joints - ≤ 5/8in. 1/16in. max.
Horizontal Joints -
◊ Upper plate projection to lower plate 20% thk. of upper plate,
maximum projection 1/8in. except that a projection of 1/16in. is
acceptable for upper plates less than 5/16in.
◊ For the horizontal and vertical joints in tank shell courses constructed
of material over 1 ½ in. thick (based on the thickness of the thicker
plate at the joint), multi-pass weld procedures are required, with no
o
pass more than 3/4in. thick permitted. A minimum preheat of 200 F is
required of these welds.
◊ the reinforcement of new weld on all butt joints on each side of the
plate shell not exceed the thickness shown in table 10.1
132
66
Reconstruction
133
Reconstruction (contd.)
Dimensional Tolerances:
Plumbness – From top of the shell to the bottom of the shell –
1/
100 of total height (max. 5in.)
Same criteria can be used for fixed roof columns.
134
67
Reconstruction (contd.)
135
Reconstruction (contd.)
Table 10.2 – Radii Tolerance
Tank Diameter (ft) Radius Tolerance (in)
≤ 40 ± 1/2
≥ 250 ± 11/4
136
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Reconstruction (contd.)
Foundations:
137
WELDING
138
69
Welding
Welding Qualification:
139
Welding (contd.)
Identification and Records:
◊ Roof plate welds and flange to nozzle neck welds do not require
welder identification.
140
70
Design Considerations For Reconstructed Tanks
141
Shell Design
◊ Maximum design liquid level for product and hydrostatic test
– based on thickness, specific gravity and max. design liquid
level of each course.
◊ For material not listed in the standard API 650 (Table 3-2),
an allowable stress value of the lesser of 2/3 yield strength or
3/8 tensile strength shall be used for maximum design liquid
level for product and lesser of ¾ yield strength or 2/5 tensile
strength shall be used for maximum design liquid level for
hydrostatic test.
142
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EXAMINATION AND
TESTING
143
144
72
Repaired Weld Flaws
◊ Cavities resulting from gouging or grinding etc. MPI or
DPT.
◊ Shell plate to shell plate welds (new welds joining new shell
plate material to new shell plate material) VI + RT
146
73
Radiographs (Number and location of Radiographs)
Shall be in accordance with API 650 with following additional
requirement with the minimum diagnostic length of 6in.
Vertical Joints:
◊ New replacement shell plates to new shell plates No additional
◊ New replacement shell plates to existing shell plates One
additional in each joint
◊ Repaired joints in existing shell plates One additional in each joint.
Horizontal Joints:
◊ New replacement shell plates to new shell plates No additional
◊ New replacement shell plates to existing shell plates One
additional radiograph for each 50ft. of repaired horizontal weld
◊ Repaired joints in existing shell plates One additional radiograph
for each 50ft. of repaired horizontal weld.
147
148
74
Hydrostatic Testing
◊ After reconstruction
149
Shell Repair
◊ Welds to existing metal – PQR, Impact testing as per API
650.
◊ Existing tank materials in the repair area shall meet at least
one of the following:
● API 650 requirement (7th edition or later)
● Fall within the “safe for use” area of fig. 5.2.
● Stress in repair area shall not exceed 7000 lbf/in2
◊ New vertical and horizontal shell butt-welds complete
penetration and fusion
◊ Finished weld shall be fully radiographed
150
75
151
152
76
Marking and Record Keeping
153
Name Plates:
154
77
Marking and Record Keeping (contd.)
Record Keeping:
◊ Calculations for component evaluation for integrity, including Re-
rating (incl. liquid level), Repair and Alteration Considerations
◊ Construction and repair drawings
◊ Additional support data including, but not limited to, information
below:
● Inspections, Material test reports / certifications, Tests
● Radiographs (shall be retained at least one year), Brittle Fracture
consideration
● Original tank construction data
● Location and Identification, Description of tank (dia., height,
service)
● Design conditions, Shell material and thickness by course
● Tank perimeter elevations, Construction completion record
● Basis for hydrostatic test exemption (if proposed)
155
APPENDIX “B”
EVALUATION OF TANK BOTTOM
SETTLEMENT
156
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Types of Settlement
Elevation Measurements:
Elevation measurements around the circumference and across
the tank diameter are the best method for evaluating shell and
bottom settlement problems. Local depressions may require
other techniques.
Uniform settlement:
May vary in magnitude, depending on soil characteristics. It is the
least severe threatening settlement problem. It does not
introduce stress in tank structure, but does present a potential
problem for piping, nozzles and attachments.
157
Types of Settlement
Rigid body Tilt (Planar Tilt):
Rotates the tank in a tilted plane. This tilt will cause an increase
in the liquid level and an increase in the shell hoop stress. Can
also cause binding of peripheral seals in a floating roof and
inhibit roof travel.
158
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Types of Settlement
Rigid body Tilt (Planar Tilt):
Rotates the tank in a tilted plane. This tilt will cause an increase
in the liquid level and an increase in the shell hoop stress. Can
also cause binding of peripheral seals in a floating roof and
inhibit roof travel.
159
Types of Settlement
160
80
Settlement Survey
161
Settlement Survey
162
81
Localized Bottom Depression
163
164
82
Localized Bottom Settlement Evaluation
165
Edge Settlement
166
83
Edge Settlement Evaluation
167
168
84
Edge Settlement Evaluation
169
170
85
SGS Capabilities with reference to
STORAGE TANKS INSPECTION
171
172
86
SGS at work
173
174
87
CHEVRON TANK TK # 1 , KARACHI
175
176
88
SHELL TANK SSH-03 SHERSHAH MULTAN
177
178
89
SHELL TANK SP – 13 KAEMARI KARACHI
179
180
90
SHELL TANK SP – 07, KARACHI
181
182
91
SHELL TANK S – 28 , KARACHI
183
Gratitude
184
92
For Customized Courses at Client’s Site
◊ Zafar Hussain
Assistant Manager AIM
Industrial Services
API 510,570,653,580 & 577 Certified
◊ M. Sabahat Noor
Inspection Engineer
Industrial Services
API 510 & 653 Certified
185
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