Points to Recall API653

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Professional Training and Consultation

API 653PREPARATORY COURSE

Points To Recall

26'h upto 31s' August 2006AI-Khobar, Saudi Arabia

MR. HASAN ATIYAH HASAN ALGHAMDISABle

Saudi Arabia

8'1, FloorI Al-Subeaei Towers. King Abdul aziz cor . Prince Falsal Rin Fahd Streets , AI- Khobar , Saudi Arabia

• TEL (966J 3 B8i 66 33 . FAX (966) 3 887 6565 • [email protected] a www.qot ouc.com

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DAilY POINTSTO RECAll (DAY 6)

1. GENERAL:

a. ASME Sec. V is NDT procedure/methods code and isapplicable only if it is referenced by the relevantconstruction code. The extent of NDT and acceptancestandards is given in relevant construction code.

b. NDT equipment and their calibration shall be as per ASMESec. V.

c. Examiner is NDT person in employment of fabricator orrepair organization. Inspector means Authorized Inspectorwho finally accepts/rejects NDT results.

2. FOR RT:

a. Satisfactory radiograph shall meet requirements of density andIQI image (2T hole for hole type and designated wire for wiretype).

b. Backscatter:Light image of B on dark background - Unacceptable

c. Density Limitations:

Min 1.8 for X Ray / 2.0 for G-RayMax 4.0 for X / GRayDensity Variation = -15 % to + 30%

d. Double wall viewing (DWDI) - Up to 3.5" outside diameter

e. Penetrameter Selection: Tab le T-276. Thickness includesweld reinforcement. But not backing.

f . Penetrameter shall be normally placed on source side. If notpossible, it may be placed on film side with lead letter "F".

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DAILY POINTS TO RECAll (DAY 6)

3 . FOR PT :

a. Control of Contaminants : Sulphur (for Nickel alloys)

shall not exceed 1% of residue. Chlorine + Fluorine (for

5.5. and Titanium) shall not exceed 1% of residue.

b. Temp. shall be between lOoC to 52°C, for standard

procedures.

c. Penetrants are colour (v isible) type and fluorescent

type. Each of these have:

• water washable

• post emulsifying

• solvent removable

Thus, total 6 categories of penetrant are available.

Emulsifier is applied after applying penetrant and

required dwell t ime is completed. Lipopholic emulsifier

is app lied without pre-rinsing. Hydropholic emulsifier is

applied after pre-rinsing.

For dwell time for penetrant and developer refer Table

T-672.

f. After applying developer, interpretation shall be done

within 10 to 60 minutes.

g. All penetrant materials should be from same

manufacturer .

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DAi l Y POINTS TO RECAll (DAY 6)

4. FOR MT:

a. Prod Technique:- Use direct (rectified) current for magnetization- Prod spacing 3" to 8"- Useful for surface and sub-surface defects.

b. Yoke Techn ique:- Use D.C. or A.C. or permanent magnet- Suitable for·surface defects only.

c. Calibration :Equipment Ammeter to be calibrated once a yearcomparing with standard Ammeter, take 3readings. Devia t ion shall not exceed ± 10% of fullscale.

d. Lifting Power of Yokes- AC shall have lifting power of at least 4 .5 kg (10 Ibs.)- DC shall have lifting power of at least 18.1 kg(40 Ibs.)

e. Minimum t wo exam inations on each area , the second isperpendicu lar to f irst

s. SE-797 UT MEASUREMENT:

a. Pulse-echo method can be adopted up to 200°F

b. Apparatus: 3 types- CRT read out- CRT + direct read out- Direct thickness read out

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DAILY POINTSTO RECAll (DAY 6)

c. Search Units: 3 types- Straight beam contact type- Delay line type (delay block to minimize dead zone)- Dual element type. There are two crystals set at

a small range. Low roof angle used for higherrange and higher angle for low range .

d. High thickness measurement:

Use of multiple echoes is made. (i.e., for thickness between50 mm and 60mm, use 10mm calibration block then 5th

back echo will be 50 mm and 6th will be 60mm. Set the 5th

echo to zero and 6th at the screen range. The screen iscalibrated to 50-60mm.

e. While taking measurement for high temperature condition apositive error of 1% per 55°C (100°F) results. Hencetemperature correction is necessary.

f. CRT read out is recommended on corroded and rough surface.

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DAILY POINTS TO RECALL (DAY 5)

1. WPS gives parameters to be used in production job, and must bewith in ranges qualified by the PQR test.

2. Essential variables (EV), if changed require new procedurequalification. Non-essentia l variables (NEV) may be changedwithout new procedure qualification.

3. Bend test crack shall not exceed 1/8" in any direction fo r facebend, root bend or side bend .

4. Suppl ementary essent ial variables (SEV) are considered as (EV)only if there is impact strength requirement. Otherwise they are"non-essential" variables.

5. Tensile test for procedure qualification is passed if failure is in :a. Weld meta l at strength>= Base metal SMTS orb. Base metal at strength>= 95% of base metal SMTS.

5. P-numbers represent parent meta l groupings of similarcomposit ion and properties, l.e ., similar strength and ductility.F-numbers give sim ila r usability aspects of fi ller material. A~

numbers give sim ilar chem. cornp . In "As welded" condition

7. For performance, 1G is f lat, 2G is horizontal, 3G is vertical and4G is overhead position . Pipe 5G qual ifies 1G, 3G and 4G, butpipe 5G qual ifies all positions.

8. Welders who have not welded for more than 5 months on aprocess, th eir qualification wi ll expire for that process.

9. In Galvanic corrosion , current flows from anode to cathode,therefore anode will lose metal and cathode will gain . If we makethe "component to be protected" cathod ic with respect tosurrounding, it wil l not lose metal, thus will be protected.

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10. As soil resistivity goes up, soil is less corrosive and vice-versa. (Soilresist iv ity < 500 ohm-em is highly corrosive, > 10,000 ohm-em, isleast corrosive.) Ref. Table l-API 651

11. Cathodic protection methods: Galvanic and impressed current

Galvanic current: Easy to install, cheap, easy to maintain, butlim ited use. (Not suitable for large structure)

I mp ressed curre nt: Expensive, but more effective, suitable for largestructures. Requires cons tant monitoring .

12. CP system survey intervals:

Impressed current:

Rectifier (power source) - Max. 2 monthsOth er components - Max. 1 year

Galva nic System (sacrific ial anode system) : AnnuallyCP survey reco rds shou ld be maintained normally for 5 years.

13. There are two main classes of lin ings :

a. Equal to or less than 20 mils (thin film linings) andb. Greater than 20 mils (thick f ilm linings).

14. The principal advantages for th in-film lining are lower cost and easeof application compared to t hick-fi lm lining systems.

15. Thick-f ilm, rei nforced lining are less susceptible to mechanicaldamage than thin film linings. They can prov ide sufficient strengthto bridge over small perforations of the supporting steel bottomthat may develop due to external corrosion.

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16. Temperatu re during blast cleaning and applying the linings shall be3°C (5°F) above the dew-point temperature and relative humiditynot to exceed 80%.

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1. For tank relocation, the bottom, shell or roof may be cut in any sizefrom exist ing tank so that the pieces are suitable for transportation.

2. For dismantling the tank the bottom may be cut 12" away fromshell to bottom weld, if entire bottom plates are to be used.

3. Alternatively cut the bottom and shell at 1/2" from toe of shell tobottom weld and discard the weld portion.

4 . For rest of the bottom, de-seaming of welds or cutting 2" awayfrom weld may be done.

5. Shell plates :5 '12" thk may be dismantled by cutting through weldwithout removing HAZ. If shell plate thk > V2", discard welds +HAZ.

6. Alternatively, shell plates may be cut 6" away from ex isting welds.

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7. NOT for Repair / Alteration:

PT / MT: For all fillet welds and fill-up (weld-build up) during repairor alteration

8. Radiography : ,a. New welds during repair or alteration between the plates such

as:

( i) New to new plates - same as API 650( ii) New to old plates or old to old plates. Additional

examination:1 spot for each 50 feet for horizontal weld1 spot on each vertical weld1 radiograph on each T-joint

b. Repair of old butt-welds - entire length of repair

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16. Ultrasonic thickness measurements as a minimum must bemade on at least one TML on each shell course. TMLs also shallbe established on top uncoated portion of shell for floating rooftanks.

17 . For internal inspection of tank bottoms, a preliminary randomt hickness scanning survey is carried out in X pattern across thetank and along the circumference. If significant corrosion isdetected, entire bottom shall be scan ned .

18. For internal inspecti on of shell, the major areas of focus shall bethe vapour space, liquid -vapour interface and the bottom area.

19. Leak tes t ing of shell may be done hydrostatically or by usingdiesel t est or by vacuum box test.

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'('>' 20. Leak test ing of bottom may be done by :

i

a.b.

c.

d.

Using vacuum box testBy construction of clay dam around tank and fill ing underside by water (observe seepage inside)Apply seal to tank outer perimeter and introducecompressed air below tank bottom, check welds byapplying soap solution or by observing bubbles by fillinginside of tank by water for 6" heightBy injecting inert gas with tracer gas under the tank andusing "sn iffers" inside to detect leakage

21. Hammer test is never carried out on cast iron parts.

22. Corrosion rate curves are helpful as an important record ofcorrosion behavior of tank in past and anticipated remaining lifein future.

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DAILY POINTS TO RECALL ( DAY 3)

1. Inspection Frequency (External) shall not exceed following

a. Routine-in Service inspection every one month.b. External inspect ion (visual by authorized inspector): Lower of

one-fourth remaining life (RCA/4N) or 5 years.c. Ultrasonic thickness inspection (external) of shell.

(i) when corrosion rate is not known - maximum 5yea rs

(ii) when corrosion rate is known - lower of :- half remaining life (RCA/2N) or- 15 years

2. Inspection Frequency (Internal) shall not exceed:

a. Based on MRT calculations, as per " Or" calculated but notexceeding 20 years

b. If corrosion rates are not known: Actual bottom thicknesssha ll be determ ined not later than 10 years.

3. Alternative to point no. 2 above for internal inspect ion interval maybe altered based on RBI. The RBI basis shall be reviewed atintervals not exceed ing 10 years by authorized inspector and tankengineer.

4. If there is access to tank bottom to determine bottom thickness,externally, such inspect ion may be used in lieu of internalinspection. (Point No.2)

5. I nspect ion reco rds include:

a. Permanent Records (Tank construction data)b. Inspection history (Progressive Records)c. Repair/ alteration history (Repair/alteration records)

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9. A full hydrostatic test (held for 24 hours) is required on majorrepairs and major alterations which include:

a. Installation of nozzles larger than NPS 12 below liquid levelb. Repair / Replacement of more than 12" length of vertical weld

in shell or rad ial weld in anular platesc. Any repair / replacement on shell to bottom weldd. Jacking of tank shell

Exemption for hydrotest is possible only if owner / operator and thetank engineer give the exemption in writing .

10. Hydrostatic test of reconstructed tank is compulsory.

11. Out of plumbness for reconstructed tank is 1/100 of the tank heightsubject to maximum 5 inches.

12. For tank settlement survey, the number of elevation measurementpoints for tank diameter D ft . is given by: N=D/l0, but minimum 8.

13 . Permitted internal settlement (for bulge or depression) is given by:

B = 0.37 RWhere B = Max. height of bulge or depth of settlement (inches)And R = Radius of largest inscribing circle (feet)

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14.

15.

Based on Fig. B-l0, and B-11 maximum allowable edge settlementis worked out depending on settled area being approximatelyparallel or perpendicular to shell.

As per API RP 575, the grounding connection inspect ion shall beincluded is external visual inspect ion. Total resistance from tankto soil should not exceed approximately 25 ohms.

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6. New materials for repair/alteration/ reconstruction: All platematerial used for shell and the bottom plates welded to shell shallbe ident ified.

7. Thickness of shell plates to be used for checking the tank designshall be within 180 days before relocation.

8. The strength values Sd and St for reconstructed tank shall be on thebasis of allowable stress as per table 3-2 of API 650.

9. The replacement shell plate thickness ~ th ickness of the shellcourse where rep lacement is proposed and dimensions and spacingshall be as per Figure 9-1.

s-:;/;o. 10. Lap-welded patch plates can be used only if:' \', ' .""l~t~';f

a. owner specifiesb. only on shell plates S; '/2 inchc. must be within spacing requ irements as per Fig. 9-1d. maximum size 48" vertical x 72 horizontal and minimum

dimension 4"e. areas on which lap patch is to be put shall be UT checkedf . lap on lap is not permitted

11. All shell plate defects like the cracks, gauges, tears, Widelyscattered .pits and corroded areas shall be evaluated case by caseas per chapter 4 of API 653 .

12. New reinforcements can be added to existing unreinforced nozzlesas per Fig. 9-3a and 9-3b.

13. Repairs within critical zone of the bottom require additionalprecautions like "Tombstone" type patch and additional PT or MPItesting after v isual examination of patch welds, and weld shall bemade by minimum 2 passes .

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API 653 Preparatory26"' upto 31" upto August 2006, Af-Khobar, KSA.

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DAILY POINTS TO RECALL ( DAY 3)

14. If impact test was not done on original tank material, the hot tapsshall be limited to NPS 4 (max) .

15. Toe-to-toe minimum spacing between hot tap and adjacent nozzleshall be = .JRT where R= tank shell radius in inches T is shell platethickness in inches.

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S" noor. .3..1 SuueaeuIowers. Ktnq Abdutaztz COf . Pnnce Fdi ~al Bm Fahd Stree ts . AI-Khobar. Saudi Arabia.. n. l i'1t1ul 3 5S; 66 3 3 • f AX 19GG} 3 Mti 7 G56~ • lnfo:flgot oitc.com • www.qotottc.com

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1. Accord ing to API 653, " Repairs" means any work necessary tomaintain or restore the safe operating conditions (as per originaldesign). "Alteration" means any work that changes the dimensionsand/or configuration of ta nk (changing origina l safe operatingcondit ions) .

2. "Aut horized inspection agency" is anyone of the following (whoemploy API tank inspector) :

a. An owner operatorb. Subcontractor to owner operatorc. Inspection organization of jurisdictiond. Inspection organization of insurance company

3. " Break-over point" means area of tank bottom where settlementbegins.

4. "Change of service" means change in flu id stored and havingdifferent specific gravity or corrosivity or different temperature orpressu re.

5'. "Cr itical zone" means portion of tank bottom within 3 inches ofshell inside and measured radically i nward~.

6. " Repa ir o rganiza t ion" means any of the following who carries outrepairs / alterat ions according to API 653.

a. Owner-userb. Subcontractor to owner-userc. Subcontractor authorized or approved by jurisdiction

7. Tank roof plates which are so corroded that there are through holesor the average thickness is less than 0.09 inch in any 100 sq. incharea, then plates must be repaired or rep laced , l .e., tank cannot bepermitted to continue operat ion .

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8. If tank service is to be changed resu lting in increase of internalpressure or operation above 900 C (2000 F), then requirements ofAPI Appendix .F and M must be fulfilled respectively. If servicechanges lower temperature then material must be suitable as perimpact test requ irements of API 550.

9. Tan k shell evaluation: 5 step method.

a. Determine the min imum thickness (t2) at corroded area.

b. Calcula te vertical critical length L for tank diameter D (in ft.)

L=3 .7 ~Dt, or 40" whichever is less

c.

d.

Determine t 1 which is minimum of tav (tav is average thicknessof at least 5 readings over wea kest L)

Determine t min by formula, tmin = 2.5 DHG for local area .. SE

D(H -1)GOr tmin = 2.5 for full shell course.

SETake '5' from Table 4-1 of API 553 code.

e. ( i) Then t1 ~ tm in + (CR x lntervalj. i and

(Ii ) t2 ~ 0 . 5 x tmin + (CR x interval) if condi tions (i) and (ii)are okay - accept. If no repair, or replace or reducethe liqu id height t ill repa ir/ replacement can be done.

10 , Widely scattered pits can be ignored if:

a. No pit depth results in shell t hickness being less than half therequired th k - excluding C. A.

D. Sum of pit dimensions along any vertical line does not exceed2 inches in a to ta l length of 8".

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11. Minimum thickness for bottom plates is given by :

a. Anular plates (product sp. gr. < 1.0): Table 4-3 (API 653)b. (Product sp. gr. ;:: 1.0): Table 3-1 (API 650)c. Other bottom plates : Table 6-1 (API 653)

12. Min. thickness in " cr iti cal zone" is smaller of:(but not less than 0.1 ")a. Half of orig inal bottom thickness in critical zone, andb. Half of tm in for first shell course.

13. Tanks designed prior to API 650 (7th edition, 1980) may beassessed for brittle failure as per Fig. 5.2.

14. Tanks are not likely to fail in brittle failure if th ickness is not morethan '12" or shell temperature is not less than 600 F or stress level isless than 7,000 psi.

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API 653 Preparatory26 t h upto 31 st August, AI-Khobar, KSA.

Page 1 of 3

DAI LY POI NTS TO RECALL(DAY 1 )

1. API 653 is code used for inspection, repair, and alteration for theaboveground storage tanks w hich are placed in Service. API650 is the basic construction code for making New Tanks.

2. API 650 and API 653 are used for aboveground storage tanks atatmospheric pressure (maximum 2.5 psi above atmospheric) andtemperatures not exceeding 90°e.

3. Design metal temperature of tank is assumed to be 80C (150 F)above the lowest one day mean temperature of tank site.

4. Where necessary, as per Fig. 2-1 (API 650), the tank materialsshall be checked against brittle fai lure by conducting impacttesting. Acceptance criteria shall be as per Table 2-4.

5. If average value of 3 specimen is < specified average value(SAV) - reject. But if average value of 3 specimen <': SAVand,

a. Value of one specimen is < SAV but <': 2/3 SAV - acceptb. Value of one specimen is < SAV and also < 2/3 SAV - retestc. Value of two specimen is < SAV - retest

On retest for band c all three specimen <': SAV - accept

6. The required thickness of shell plates for tanks up to 60 m (200feet) diameter shall be greater of l:ci or tt:

t. 4.9D(H -0.3)G +CA and t 4.9D(H -0.3) (metric)Sd ' St

::::: ::..<»

_ 2.6D(H -l)G CAd _ 2.6D(H -1)t ,j - Sd + . . all t, - St

---_._------------ -_.

(US units)

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Proressional Training and ConsultationAPI 653 Preparatory

26 th upto 31st August, AI-Khobar, KSA.Page 2 of 3

DAILY POINTS TO RECALL(DAY 1)

Where:

D = Tank Diameter m (ft)H = Height shell course from top liquid level in m (ft)G = Specific Gravity of liquid to be storedSd and St = Allowable stress for design and

hydrostatic conditions in Mpa (psi)CA. = Corrosion allowance in mm (in)

7. Shell thickness calculated above (point no. 6) shall not be lessthan that required by Diameter - Thickness table in API 650.(3.6.1.1)

8. Values of Sd and St are taken from Table 3-2 of API 650. Forunlisted material:Sd = Lower of 2/3 (Y.S) or 2/5 (T.S.) andSt = Lower of 3f4 (Y.S) or 3/7 (T.S .)

9. Minimum nominal thickness excluding corrosion allowance forroof plate shall be 5 mm (3/16") and for bottom plate shall be 6mm (1/4").

10. All nozzles, manholes and other open ings shall 'have dimensionsthickness, reinforcement plates and weld sizes as per tables 3-6and 3-7 of API 650.

11. Radiography inspection is required for all shell butt welds andannular plate butt welds and insert plates for manhole andnozzles.

12. For shell plat es the number of rad iographs requ ired depend onwhether the plate thickness is up to 10 mm (3/8), or above 10mm to 25 mm (3/8" - 1") or above 25 mm (1"). (Fig . 6-1 of API650) .

:'" i- !lIO: . " J- ~ ( l t 'coe l I ewers . King Abuutaztz cor. Purtee Faisal Bin Fahd Streets. At-Khobar . Saudi Arabia

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Profe ssiona l Trai ning and Consu ltationAPI 653 Preparatory

26 th upto 31 st August, AI· Khobar, KSA.Page 3 of 3

DAILY POINTS TO RECALL(DAY 1)

13. Radiography is also required on:(i) 100% length of butt welds joining insert

plate to shell, and(Ii) Annular bottom plate radial joints (1 spot on

10% of radial welds if double butt weldedand 1 spot on 50% of radial welds if singlewelded with backing strip.)

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Points to Recall API653