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Professional Training an d Consultation

API 653PREPARATORY COURSE

Points To Recall

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

MR. HASAN ATIYAH HASAN ALGHAMDISABle

Saudi Arabia

8'1, Floor I Al-S ube ae i T ower s Kin g Abdul aziz cor . Princ e Fal sal Rin Fahd S treets AI- Khobar , Saudi Ara b ia TEL (9 66J 3 B8 i 66 33 . FAX (9 66) 3 8 87 6 56 5 in fo@goroitc. com www .qoto u c.com

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Prof ess ional Training and Consul tationAPI 5 70 P reparatory

26 '" upto August 2006, AI - Khobar, KSA .Page 2 of 4

DAILY POINTS TO RE CAll (DAY 6)

3 . FOR PT :

a . Cont rol of Contaminants : Sulphur (for Nickel alloys)

shall not exceed 1% of residue. Chlorine + Fluorine (for5.5. and Titanium) shall not exceed 1% of res idue.

b . Temp . shall be between lO oC to 52 C, for standard

procedur es.

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

type. Each of these have:

water washable

post emuls ifying

so lvent 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 -r insing.

For dwell time for penetrant and developer refer Table

T -672 .

f. After apply ing developer, interpretat ion shall be done

within 10 to 60 minutes.

g . All penetrant materia ls should be from same

manu facture r .

- - - - - - - -- - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - -- - - - - - - - - - - - - -- - - -- - - - - - - - - ~ .. It oor . At - Sub eae r Iew ers . KlOg Abd u tazi z c or. Pnnce f 3 887 I n f o g o l O i t ( . c o m www .gotoitc .com

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Prof essio nal Tr ai ning a nd C on sultatio nAPI 570 P reparatory

6 upta 3 August 2006 , AI-Khobar, KSA.

Page 3 of 4

DAi l Y POINTS TO RECA l l (DAY 6)

4. FOR MT:

a. Prod Technique:- Use direct (rectified) current for magnet ization- 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- Su itable for surface defects only.

c. Calibration :Equipment Ammeter to be calibrated once a yearcomparing with standard Ammeter , ta ke 3readings . Devia tion shall no t exceed 10% of fullsca le.

d. Lift ing Power of Yo kes- AC shall have lifting power of a t least 4 .5 kg (10 Ibs.)- DC shall have lifting power of at least 18.1 kg(40 Ibs.)

e. Min imum two exam inat ions on eac h area , t he second isperpendicu lar t o first

s . SE -797 UT MEA SUREMENT:

a . Pulse-echo met hod can be adopted up to 200F

b. Appara tus: 3 types- CRT read out- CRT + d irect read out- Direct thickness read out

----------- ---------- ------ ---- ------ -- ----- ---------- --- -------- -------- -- ----- ------ --- ------------S f 1001, Al- Subeaer T owe rs. King Abdu laziz co r. Pnn ce Fa lsa l BIO Fah d Stree ts, AI-K ho b ar . Sa udi Arabia TEL i 966J 3 887 6633 FAX (9 66 ) 3 887 G 56S o g o loltc. com www .g o to itc .c om

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Professional Training an d Consult at ionAPI 570 Preparatory

26 Ul upto 31 st August 2006, AI-Khobar, KSA .

Page 4 0(4

DAILY PO INTS TO RECA l l (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 fo r higherrange and higher angle for low range .

d. High th ickness measurement :

Use of multiple echoes is made. (i.e., fo r thickness between50 mm and 60mm, use 10mm calibration block then 5 t h

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

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

e . While ta king measurement for high temperature condition apositive e rror of 1% per 55C (100F) results. Hence

t emperature correction is necessary.

f. CRT read ou t is recommended on corroded and rough surface .

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- - - - - - - - - - - - - -Professtona l T rai ning a nd Consu ltat ion

API 653 Pre paratory26 t /l u pt o 3 Aug us t 2 006, A I-Khobar , K SA.

Pag e 1 of 3

DAILY PO INTS TO RE CALL (DAY 5)

1. WPS gives parameters to be used in product ion job, and must bewithin ranges qualified by the PQR test.

2. Essential va r iables (EV), if changed require new procedurequalificat ion. Non-essent ia l var iables (NEV) may be changedwithout new procedure qualificat ion.

3. Bend t est crac k shall not exceed 1/8 " in any direct ion for facebend, roo t bend o r s ide bend .

4 . Suppl em entary essen tial variables (SEV) are considered as (EV)only if there is impact strength requirement . Otherwise they are"non -essential" variab les .

5 . Tensile test fo r procedure quali fication i s passed if failure is in :a. Weld me ta l at strength>= Base me tal S MTS orb . Base meta l at strength>= 95% of base metal S MTS.

5. P-numbers represent parent meta l groupings of similarcomposit ion and properti es, l.e ., similar strength and ducti lity.F-numb ers give s imilar usabil ity aspec ts of filler material. ~numb ers give sim ilar chem. cornp . In "As welded" cond it ion

7 . For pe rformance, 1 G is f lat, 2G is ho rizontal, 3 G is vert ical and4G is o verhead position . Pipe 5G qual ifies 1G, 3G and 4G, bu tpipe 5G qual ifies all pos itions.

8 . We lders w ho have no t welded fo r m ore than 5 mon ths on aproc ess, th e ir qu alifica tion will exp ire for that process.

9 . In Gal vanic corros ion, current flows from anode to cathode ,t herefore anode w ill lose meta l and cathode will gain . If we maket he "component to be protected " cathod ic with respect tosurround ing, it will no t lose m etal, thus will be protected.

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Pro fessio n a l Train in g and C onsultationAPI 653 Preparatory

26 t h u pto 31 st Augu st 2006, AI Khobar , KSA.

Pa ge 2 of 3

DA ILY POINT S TO RECALL (DA Y 5)

10 . As soil res istiv ity goes up, soil is less corrosive and vice-versa. (Soilresistivity < 500 ohm-em is highly corrosive, > 10,000 ohm-em, isleast cor rosive.) Ref. Table l-API 651

11. Cathodic pro tect ion methods: Gal vanic and impressed current

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

Impressed cu rre nt: Expensive, but more effect ive, suitable fo r larges truc tures . Requ ires cons tant monitor ing.

12 . CP system survey intervals:

Imp ressed current:

Re ctifier (power sourc e) - Max. 2 months

Oth er components - Max. 1 year

Gal vanic System (sacr ificial anode system) : AnnuallyCP survey reco rds shou ld be main tained normally fo r 5 years.

13. There are two main classes of linings :

a . Equal to or less than 20 m ils (thin film linings) andb . Grea te r than 20 mi ls (t hick f ilm linings).

14. The princ ipal ad vantages fo r th in -film lining a re lower cost and easeof application c ompared to t hick-film lining systems .

15 . Thick-film, rei nforced lining a re less susceptible to mechan icaldamage than th i n film linings. They c an pro vide sufficient strengthto bridge over small perforat ions of the support ing steel bottomtha t ma y develop due to e xternal corrosion.

8' t t oo r . I- S t l : i P I Towe rs , King A bdu ta z rz cor. P nnce Fa is al Bin Fahd Street s, AI - KholJar I Saud i Arabia H. .. eG 3 i 66 33 fA X {966 3 5 8 65 6 5 mf o t i:gotoll C.COITI www .q c to rtc.c orn

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Prof ession al Training and ConsultationAPI 6 53 Preparatory

6 upt o s t " August 200 6, AI-Khobar , K SA.Page 3 of 3

DAILY POINTS T O RECALL (DAY 5)

16. Tempera tu re during blast cleaning and applying the linings shall be3C (5F) above the dew-point temperature and relative humidityno t to e xceed 80%.

------------------------ End ------------------------

8'" Floor. Al- Su b eaer Towers . King Abdul az rz cor . Prin ce Faisa l But Fah d Street s, Al-Khoba r , Saudi Arabia I (L G G ~3 8 876633 .. FAX (96 3 887 6565 m f o m t o o m www.qot cn c.com

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26 fh upt o 31 s t Au gust 2 006, AI-Khob ar , KSA.

P age 1 of 3

DA ILY POINTS TO RECALL (DAY 4 )

1. For tan k relocat ion, the bottom, shell o r roof may be cut in any sizefrom existing tank so that the pieces are suitable for transportation .

2. For d ismantling 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 o f the bottom, de-seaming of welds or cutt ing 2" awayfrom weld may be done .

5. Shell plates :5 12 thk may be dismantled by cutting through weldw ithout removing HAZ. If shell plate thk > V 2", discard welds +HAZ.

6. Alternat ively, shell p lates may be cut 6" away from ex is t ing welds.

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7. NOT for Repair / Alteration:

PT / MT : For a ll fillet welds and f ill-up (weld-build up) during repairor a lteration

8. Radiography: ,a. New welds during repair or alterat ion 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

e xamination:1 spot for each 50 feet fo r horizontal weld1 spot on each vertical weld1 radiograph on each T-joint

b. Repair of o ld butt- welds - entire length of repair

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Professio nal Tr aining a nd Con sultation

API 653 P reparatory 2 6 u pt o 3 1 u pt o Augus t 2 006, AI-K hobar, KS A.

Pa ge 2 of 3

DAILY POINTS TO RECALL (DAY 3)

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

7. Thickness of shell plates to be used for checking the tank design

shall be w ithin 180 days before relocation.8. The strength values Sd and S t for reconstructed tank shall be on the

basis 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 F igure 9-1.

s :; o 10. Lap- welded patch plates can be used only if:\ .

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a. owne r specifiesb. only on shell plates S; /2 inchc. must be with in spacing requ irements as per Fig. 9-1d . ma ximum size 48" vertical x 72 horizontal and minimum

dimens ion 4"e. areas on wh ich 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, W idelyscattered .p its and co rroded areas shall be evaluated case by caseas per chapter 4 of API 653 .

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

13. Repairs w ith in critical zone of the bottom require ad ditionalprecautions like "Tombstone" type patch and additional PT or MPItest ing after visual examination of patch welds, and weld shall bemade by mini mum 2 passes.

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API 65 3 Prep aratory 26 u pto 3 1 upto Augu st 2 006, A f-Khobar , K SA.

P age 3 of 3

DAILY POINT S TO RECALL ( DAY 3)

14 . If impact test was not done on or iginal tank mater ial, the hot tapsshall be limited to NPS 4 (ma x) .

15 . Toe-to -toe min imum spac ing between hot tap and adjacent nozzle

shall be = RT where R= tank shell radius in inches T is shell platethic kness in inches.

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S " no or. 1 Su ueae uIowe rs . Ktnq Abd utaztz COf . Pn nce F i ~ a Bm Fa h d St reets . A I- K h o bar . S audi A rabia

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Professio nal Traini ng and C on sultationAPI 653 P r epara tory

up t o sr ' August 2006 , AI- Kh obar , K SAPage. J of3

DAILY PO INTS TO RECALL (DAY 2)

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

2. "A ut ho rize d inspe cti o n age ncy" is anyone of the following (whoemplo y API tan k inspector) :

a . An owner opera to rb. Subcontractor to owne r operatorc. Inspection organization of jurisdictiond . Inspection organization of insurance company

3. " Break-over po in t" means area of tan k bottom where settlementbeg ins.

4 . "C ha n ge o f se rv ice" means change in flu id stored and havingdifferent spec ific grav ity or corrosivity or different tempera ture orpressu re .

5'. "C r iti c al zo ne" means port ion of tan k bottom within 3 inches ofshell inside an d measured radically in r d ~

6. " Repa ir o rga nizat ion" means any of the following who carries outrepai rs / a lterations according to API 653.

a. O wn er-userb. Subcontractor to owner-userc. Subco ntractor authori zed or approved by jurisdiction

7 . Ta nk roof plates wh ich are so co rroded that there are through holesor the average th ickness i s less than 0.09 inc h in any 100 sq. incharea, then p lates mus t be rep air ed or rep laced, l.e., tan k cannot beperm itted to con t inue ope rat ion .

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. 8 Ftoo r. Al- Suu ea et Towe rs, Ki ng Abdulaztz co r . Prince r arsat Btn Fahd Streets, Al-Khc bar , Sa u di Ara b ia.. Tf t i 9 ,6) ~ S S 7 6 633 F AX (96 6) 3 SS 7 6 565 n f o ~j o t o i r o www.qo toitc .co rn

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- - - - - Pro fe ssional Tra ining and C onsultation

API 653 P r epa ra t o ry th u pto sr ' Au gu st 20 06 , AI-Khob ar , KS A

P ag e 2 of 3

DA ILY POINTS T O RECALL (DAY 2)

8. If tank service is to be changed resu lting in increase of internalpressure or operation above 90 0 C (200 0 F) , then requirements ofAPI Appendi x .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 evaluat ion: 5 step method.

a. De t erm ine the min imum th ickness (t2) at corroded area.

b . Calcula te vert ical cr it ica l length L for tan k diameter D (in ft.)

L=3 .7 ~D t or 40" whichever is less

c.

d.

De termine t1 wh ich is min imum of t a v (t av is average thic knessof at leas t 5 readings over wea kest L)

Determ ine t min by fo rmu la, tmin = 2.5 DHG fo r local area . S E D( H -1)G

Or t min = 2.5 for full shell course.SE

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

e . (i) Then t 1 ~ t m + (CR x lntervalj. iand

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

10 , Widely scatter ed pits can be ignored if:

a . No p it depth resu lts in shell thickness being less than half thereq ui red th k - excluding C. A.

Su m of pit d imensio ns alo ng a ny vertical line does no t exceed2 inches in a to tal length of 8" .

S'' r O I . ,\ I- Su bt J 1Towe r's , King Abdulaz t z cor . P rince Fai sa l Bin Fa l1d Stree t s, Ai-Kh obar , Sa udi Arabia

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Professi onal Trai ning and ConsultationAPI 653 Pre pa r at ory

ti1 upt o sr' Aug u st 2006 / AI - Khobar , K SAPa g e . ] of 3

DAILY POINTS TO RECA LL (DAY 2)

11. Minimum thickness fo r 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. th ickness i n "critical zone " is smalle r of:(but not less than 0.1 ")a. Hal f of orig inal bottom thickness in critical zone, andb. Half o f tm in for first shell course.

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

14 . Tan ks are no t likely to fail in br ittle failure if th ickness is not morethan 2 or sh ell temperature is not less than 60 0 F or stress level isless than 7 ,000 ps i.

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t. 1 ~ . 1 J \ ~ 1 _ l I . , - -- -- --- - - _ .Professional Training and Con sultati on

API 653 Preparatory 26 th upto August, AI-Khobar, KSA.

Page 1 of 3

DA I LY PO I NTS TO R ECALL(D AY 1 )

1. API 653 is code used fo r inspection, repair, and alteration for theaboveground storage tanks w hic h a re place d in Serv ice. API650 is the basic construction code fo r making New Tan ks .

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

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 pe r 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 bu t < 2/3 SAV - acceptb. Value of one specimen is < SAV and also < 2/3 SAV - retestc. Value of two spec imen 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

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J N T R A T E D1 ;. I ~ I ~ ...- j, 1 . ~ . ,. ~ _ . J ,,,r f ... ~ I I I

Profe ssiona l Training an d Consu ltationAPI 653 r ep r tory

6 t upto 3 t August, AI Khobar , K SA.

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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W F loor. AlSu neaer Towers, King Ab dulaztz cor . P rince Fmsa! Bin Fahd St reets . AI-Khobar. Saudi Arabia lLl, i9 tll 3 8 8 7 6 6 3 3 F AX 966) ] 887 GS65 Info ;- oto tc corY www .qcroit c.com