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API 653API 653
Section 7, MaterialsSection 7, Materials
Section 11, WeldingSection 11, Welding
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API 653API 653MaterialsMaterials
This section provides generalThis section provides generalrequirements for the selection ofrequirements for the selection of
materials for the repair, alteration, andmaterials for the repair, alteration, and
reconstruction of existing tanks.reconstruction of existing tanks.
Specific requirements for repairs andSpecific requirements for repairs and
alterations are covered in Section 9.alterations are covered in Section 9.
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API 653API 653 Section 7, MaterialsSection 7, Materials
New MaterialsNew Materials
All new materials used forAll new materials used forrepair, alterations, orrepair, alterations, or
reconstruction shall conform toreconstruction shall conform tocurrent applicable tankcurrent applicable tank
standards.standards.
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API 653API 653 Section 7, MaterialsSection 7, MaterialsShell And Bottom Plates Welded To TheShell And Bottom Plates Welded To The
ShellShell
All shell plate materials and bottom platesAll shell plate materials and bottom plates
welded to the shell shall be identified.welded to the shell shall be identified.
Materials identified by original contractMaterials identified by original contract
drawings, API name plates, or other suitabledrawings, API name plates, or other suitable
documentation do not require furtherdocumentation do not require further
identification.identification.
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API 653API 653 Section 7, MaterialsSection 7, Materials
Shell And Bottom Plates Welded ToShell And Bottom Plates Welded ToThe ShellThe Shell
Material not identified shall be tested andMaterial not identified shall be tested andidentified by the requirements as outlined inidentified by the requirements as outlined in
7.3.1.2.7.3.1.2.
After identification, determination shall beAfter identification, determination shall be
made as to suitability of the material formade as to suitability of the material forintended service.intended service.
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API 653API 653 Section 7, MaterialsSection 7, MaterialsStructuralStructural
Existing rolled structural shapes that are toExisting rolled structural shapes that are to
be reused shall meet the requirements ofbe reused shall meet the requirements of
ASTM A7 as a minimum.ASTM A7 as a minimum.
New structural material shall meet theNew structural material shall meet the
requirements of ASTM A36or A 992 as arequirements of ASTM A36or A 992 as a
minimumminimum
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API 653API 653 Section 7, MaterialsSection 7, Materials
Roof, Bottom, and Plate WindgirdersRoof, Bottom, and Plate Windgirders
If existing plates are to be used to reconstructIf existing plates are to be used to reconstruct
the tank, they shall be checked for excessivethe tank, they shall be checked for excessivecorrosion and pitting. (See Sections 4 and 6.)corrosion and pitting. (See Sections 4 and 6.)
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API 653API 653 Section 7, MaterialsSection 7, Materials
Welding ConsumablesWelding Consumables
Welding consumables shall conform to theWelding consumables shall conform to theAmerican Welding Society (AWS) classificationAmerican Welding Society (AWS) classification
that is applicable to the intended use.that is applicable to the intended use.
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99
API 653API 653
WeldingWelding
Section 11Section 11
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WeldingWelding
Qualified per ASME Section IXQualified per ASME Section IX Welding Procedure Specifications (WPS)Welding Procedure Specifications (WPS)
Procedure Qualification Records (PQR)Procedure Qualification Records (PQR)
Welders / Welding OperatorsWelders / Welding Operators
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WeldingWelding
Must also meet additional requirements ofMust also meet additional requirements ofAPIAPI--650, Section 7650, Section 7 unstated hereunstated here
WeldabilityWeldability of steel must be verifiedof steel must be verified
If material is unknown, must use plateIf material is unknown, must use platesample for WPS/PQRsample for WPS/PQR
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Additional WPS/PQR WeldingAdditional WPS/PQR Welding
Requirements of APIRequirements of API--650650
API-650 is the Referencing Code Section API-650, Section 7.2 Qualification of Welding
Procedures
specifies impact testing requirements supplementary essential variable in ASME IX
based of DMT
protective coatings addressed as an essential variable all other requirements are same as ASME IX
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Additional WPS/PQR WeldingAdditional WPS/PQR Welding
Requirements of APIRequirements of API--650650 contcont
Impact test HAZ if base metal impact tested andImpact test HAZ if base metal impact tested andwelded by auto or semiwelded by auto or semi--auto processauto process
Impact test for vertical seams if DMT < 50FImpact test for vertical seams if DMT < 50F
impact test weld metalimpact test weld metal
include HAZ if auto or semiinclude HAZ if auto or semi--auto processauto process
Impact test for all seams if DMT
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Identification and Records 9.2Identification and Records 9.2
For each welder / welding operatorFor each welder / welding operator must have identification number, letter, etcmust have identification number, letter, etc
identification number must be recordedidentification number must be recorded
WPQ available to AIWPQ available to AI
welder ID markwelder ID mark
applied to work at interval or 3 ftapplied to work at interval or 3 ft or recordedor recorded record (rollrecord (roll--out maps?) available to AIout maps?) available to AI
not required on roof plates or flangenot required on roof plates or flange--toto--neck weldsneck welds
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1515
API 653API 653
Examination and TestingExamination and Testing
Section 12Section 12
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GeneralGeneral
The following shall be in accordance with API Std 650The following shall be in accordance with API Std 650 NDENDE
NDE PersonnelNDE Personnel
Acceptance criteriaAcceptance criteria
Plus any additional requirements given in API 653Plus any additional requirements given in API 653
Appendix F, NDE Requirements SummaryAppendix F, NDE Requirements Summary
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Shell PenetrationsShell Penetrations
UT examination of shell plate forUT examination of shell plate forlaminationslaminations
Adding a reinforcing plate to an existingAdding a reinforcing plate to an existing
unreinforced penetrationunreinforced penetration
Adding a hot tap connectionAdding a hot tap connection
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Shell PenetrationsShell Penetrations
Cavities resulting from gouging or grindingCavities resulting from gouging or grindingto remove attachment welds of existingto remove attachment welds of existing
reinforcing plates shall be examined by:reinforcing plates shall be examined by:
VisualVisual
MT or PTMT or PT
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Shell PenetrationsShell Penetrations
Completed welds shall be examinedCompleted welds shall be examined
MT or PTMT or PT
Consider additional examination for plates ofConsider additional examination for plates of
unknown toughnessunknown toughness
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Shell PenetrationsShell Penetrations
Stress relieved assemblies shall beStress relieved assemblies shall beinspected by MT or PTinspected by MT or PT
After Stress reliefAfter Stress relief
Before hydrostatic testBefore hydrostatic test
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Repaired Weld FlawsRepaired Weld Flaws
Cavities from gouging or grinding toCavities from gouging or grinding toremove a weld defectremove a weld defect
VisualVisual
MT or PTMT or PT
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Repaired Weld FlawsRepaired Weld Flaws
Completed repairs of buttCompleted repairs of butt--welds shall bewelds shall beexamined radiographic or ultrasonicexamined radiographic or ultrasonic
methodsmethods
Repairs of fillet welds shall be examinedRepairs of fillet welds shall be examinedby the appropriate NDE methodby the appropriate NDE method
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Temporary & PermanentTemporary & Permanent
Attachments to Shell PlatesAttachments to Shell Plates
Visual examination of permanentVisual examination of permanentattachments and areas where temporaryattachments and areas where temporary
attachments are removed.attachments are removed.
Group IV, IV4, V, or VI materials shall alsoGroup IV, IV4, V, or VI materials shall also
include MT or PTinclude MT or PT
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Shell Plate to Shell Plate WeldsShell Plate to Shell Plate Welds
Existing Shell Plate to New orExisting Shell Plate to New orExisting Shell Plate WeldsExisting Shell Plate Welds
VTVT
RTRT
Additionally if Shell Plate > 1 inchAdditionally if Shell Plate > 1 inch
BackBack--gouged surface of root and finalgouged surface of root and finalpass (each side) examined by MT or PTpass (each side) examined by MT or PT
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ShellShell--ToTo--Bottom WeldBottom Weld
New welding shall be inspectedNew welding shall be inspected RightRight--angle vacuum boxangle vacuum box
Diesel test opposite side after first weld passDiesel test opposite side after first weld pass
AlternativelyAlternatively
11stst weld pass examined visuallyweld pass examined visually
Pressure interstice to 15 PSIPressure interstice to 15 PSIgg
Apply solution film to both weldsApply solution film to both welds
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ShellShell--ToTo--Bottom WeldBottom Weld
WeldWeld--on Patch Plateson Patch PlatesVT and MT or PT existing weldVT and MT or PT existing weld
Full length of pad + 6 in either sideFull length of pad + 6 in either side
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BottomsBottoms
VT all new welds for entire lengthVT all new welds for entire lengthAttention to sumps, dents, gouges, 3Attention to sumps, dents, gouges, 3--plateplate
laps, breakdowns, arc strikes, attachmentslaps, breakdowns, arc strikes, attachments
One of the methods listed in API Std 650,One of the methods listed in API Std 650,
5.3.35.3.3
Vacuum boxVacuum box
Tracer gasTracer gas
Water floodWater flood
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BottomsBottoms Additionally Patch plates in the criticalAdditionally Patch plates in the critical
zonezone
VTVT
MT or PTMT or PT
Bottom plates restored by weldingBottom plates restored by welding
VTVT
MT or PTMT or PT
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Shell PlatesShell Plates
Weld Metal DepositWeld Metal DepositVTVT
MT or PTMT or PT
Lap Welded PatchesLap Welded Patches
VTVT MT or PTMT or PT
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RoofsRoofs
Newly welded roof joints and repairs shallNewly welded roof joints and repairs shallbe examined in accordance with API Stdbe examined in accordance with API Std
650 5.3.2.2 and 5.3.6650 5.3.2.2 and 5.3.6
VTVT
GastightGastight
Internal PressureInternal PressureVacuum BoxVacuum Box
Non gastightNon gastight
VTVT
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RadiographsRadiographs
The number and location of radiographsThe number and location of radiographs
shall be in accordance with API Std 650shall be in accordance with API Std 650
and the following additional requirementsand the following additional requirements
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RadiographsRadiographs
For Vertical JointsFor Vertical Joints
New to NewNew to New no additionalno additional
requirementsrequirements
New to ExistingNew to Existing 1 extra in each joint1 extra in each joint
ExistingExisting 1 extra in each joint1 extra in each joint
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RadiographsRadiographs
For Horizontal JointsFor Horizontal Joints
New to NewNew to New no additional requirementsno additional requirements
New to ExistingNew to Existing 1 extra for each 50 ft of1 extra for each 50 ft of
weldweld
ExistingExisting 1 extra for each 50 ft of weld1 extra for each 50 ft of weld
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RadiographsRadiographs
For Intersections of Vertical and HorizontalFor Intersections of Vertical and HorizontalJointsJoints
New to NewNew to New no additional requirementsno additional requirements
New to ExistingNew to Existing Each intersection shall beEach intersection shall be
radiographerradiographer ExistingExisting Each intersection shall beEach intersection shall be
radiographerradiographer
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RadiographsRadiographs
For Reconstructed TanksFor Reconstructed Tanks Each buttEach butt--welded annular platewelded annular plate
25% of all junctions of new welds over25% of all junctions of new welds over
existing seamsexisting seams
The owner/operator and contractor shallThe owner/operator and contractor shalldetermine extent of further inspectionsdetermine extent of further inspections
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RadiographsRadiographs
Shell Plate Inserts / Door SheetsShell Plate Inserts / Door Sheets
CircularCircular
1 radiograph regardless of thickness1 radiograph regardless of thickness
Square or rectangularSquare or rectangular 1 in a vertical joint1 in a vertical joint
1 in a horizontal joint1 in a horizontal joint
Each cornerEach corner
All junctions between new and old weldsAll junctions between new and old welds
If defects found, 100% of repaired weldIf defects found, 100% of repaired weld
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RadiographsRadiographs
The minimum diagnostic length is 6The minimum diagnostic length is 6inchesinches
Penetrations installed using insert plates,Penetrations installed using insert plates,
100% of butt100% of butt--weld shall be RTweld shall be RT
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RadiographsRadiographs
Acceptance criteria shall be based on theAcceptance criteria shall be based on the
current standard.current standard.
Existing welds can be judged on theExisting welds can be judged on the
original standard of constructionoriginal standard of construction
d i iH d i T i
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
A full hydrostatic test, held for 24 hoursA full hydrostatic test, held for 24 hoursshall be performed on:shall be performed on:
Reconstructed TankReconstructed Tank
Any tank that has undergone major or majorAny tank that has undergone major or major
alterations, unless exempted by 12.3.2alterations, unless exempted by 12.3.2
A tank where an engineering evaluationA tank where an engineering evaluation
indicates the need for a hydrostatic test.indicates the need for a hydrostatic test.
H d i T iH d t ti T ti
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alteration refer toMajor repair or major alteration refer tooperations that require cutting, addition,operations that require cutting, addition,
removal and/or replacement ofremoval and/or replacement of
The annular plate ringThe annular plate ring
The shellThe shell--toto--bottom weldbottom weld
A sizeable portion of the shellA sizeable portion of the shell
H d t ti T tiH d t ti T ti
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alteration includes:Major repair or major alteration includes:
The installation of any shell penetrationThe installation of any shell penetration
beneath the design liquid level larger than 12beneath the design liquid level larger than 12inches NPS, or any bottom penetrationinches NPS, or any bottom penetration
located within 12 inches of the shelllocated within 12 inches of the shell
H d t ti T tiH d t ti T ti
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alterationMajor repair or major alterationincludes:includes:
The removal and replacement or addition ofThe removal and replacement or addition ofany shell plate beneath the design liquidany shell plate beneath the design liquid
level, or any annular plate ring materiallevel, or any annular plate ring material
where the longest dimension of thewhere the longest dimension of the
replacement plate exceeds 12 inches.replacement plate exceeds 12 inches.
H d t ti T tiH d o t ti Te ti
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alteration includes:Major repair or major alteration includes:
The complete or partial (more than oneThe complete or partial (more than one--halfhalf
of the weld thickness) removal andof the weld thickness) removal and
replacement of more than 12 inches ofreplacement of more than 12 inches of
vertical weld joining shell plates, or radialvertical weld joining shell plates, or radial
weld joining the annular plate ring.weld joining the annular plate ring.
H d t ti T tiHydrostatic Testing
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alteration includes:Major repair or major alteration includes:
The installation of a new bottom. This does not includeThe installation of a new bottom. This does not include
new bottoms in tanks where the foundation under thenew bottoms in tanks where the foundation under the
new bottom is not disturbed and either condition 1) ornew bottom is not disturbed and either condition 1) or
2) are met below:2) are met below:
1)1) For tanks with annular rings, the annular ringFor tanks with annular rings, the annular ring
remains intact.remains intact.
2)2) For tanks without annular rings, the repair does notFor tanks without annular rings, the repair does notresult in welding on the existing bottom within theresult in welding on the existing bottom within the
critical zone.critical zone.
Hydrostatic TestingHydrostatic Testing
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required
Major repair or major alterationMajor repair or major alterationincludes:includes:
The removal and replacement of any partThe removal and replacement of any partof the weld attaching the shell to theof the weld attaching the shell to the
bottom or to the annular plate ring.bottom or to the annular plate ring.
Jacking of a tank shellJacking of a tank shell
H d ostatic TestingHydrostatic Testing
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Hydrostatic TestingHydrostatic Testing
When a Hydrostatic Test is Not RequiredWhen a Hydrostatic Test is Not Required
A hydrostatic test is not required when:A hydrostatic test is not required when:
The repair has been reviewed and approved byThe repair has been reviewed and approved by
an engineer and the engineer must concur inan engineer and the engineer must concur in
writing.writing. The owner/operator has authorized theThe owner/operator has authorized the
exemption in writing.exemption in writing.
And Sections 12.3.2.2 through 12.3.2.5 orAnd Sections 12.3.2.2 through 12.3.2.5 or
12.3.2.6 are met.12.3.2.6 are met.
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Shell RepairShell Repair Welding ProceduresWelding Procedures
Based on existing material chemistryBased on existing material chemistry
Qualified with existing or similar materialQualified with existing or similar material
Include impact testingInclude impact testing
New Material meet current API Std 650New Material meet current API Std 650requirementsrequirements
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Shell RepairShell Repair Existing Material shall meet at least one ofExisting Material shall meet at least one of
the following:the following:
API Std 650 requirements (7API Std 650 requirements (7thth edition oredition orlater)later)
Fall within the safe to use area ofFall within the safe to use area ofFigure 5Figure 5--22
Stress in the repair area shall notStress in the repair area shall notexceed 7,000 PSIexceed 7,000 PSI
t
HDGS
6.2=
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Shell RepairShell Repair
New vertical and horizontal shell buttNew vertical and horizontal shell butt--welds shall have complete penetrationwelds shall have complete penetration
and fusionand fusion Root Pass shall be examinedRoot Pass shall be examined
100% Radiography100% Radiography
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Shell RepairShell Repair
The root pass of nozzle attachment weldsThe root pass of nozzle attachment welds
shall be backshall be back--gouged and examined bygouged and examined by
MT or PT and by UTMT or PT and by UT
Door sheets shall not intersect theDoor sheets shall not intersect the
bottombottom--toto--shell jointshell joint
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Bottom Repair Within the Critical ZoneBottom Repair Within the Critical Zone
Examined visually prior to weldingExamined visually prior to welding
Examined after the root pass & finalExamined after the root pass & final
pass by VT and MT or PTpass by VT and MT or PT
Annular Plate buttAnnular Plate butt--welds examinedwelds examined
by UTby UT
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ShellShell--ToTo--Bottom RepairBottom Repair A portion may be removed an replaced providedA portion may be removed an replaced provided
that:that:
No more than 50% of the required weld crossNo more than 50% of the required weld cross
required sectional area is removedrequired sectional area is removed
100% not exceeding 12 inches and spacing100% not exceeding 12 inches and spacing
between repairs is at least 12 inches apartbetween repairs is at least 12 inches apart
VT and MT or PT of root pass and final weldVT and MT or PT of root pass and final weld
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Minor Shell JackingMinor Shell Jacking Tank Shell and critical zone materials shallTank Shell and critical zone materials shall
meet requirements of 12.3.2.2.3meet requirements of 12.3.2.2.3
Engineering evaluation consideringEngineering evaluation considering
pertinent variables.pertinent variables.
Careful consideration shall be given toCareful consideration shall be given to
potential stresses and damage that maypotential stresses and damage that may
result from jacking.result from jacking.
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FitnessFitness--ForFor--Service EvaluationService Evaluation The owner/operator may utilize fitnessThe owner/operator may utilize fitness--forfor--
service or other appropriate evaluationservice or other appropriate evaluationmethodologies based on established principlesmethodologies based on established principles
and practices.and practices.
The analysis shall be performed by an Engineer.The analysis shall be performed by an Engineer.
The procedures and acceptance criteria are notThe procedures and acceptance criteria are not
included in API Std 653.included in API Std 653.
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Leak TestsLeak Tests
New or altered reinforcingNew or altered reinforcing
plates or shell penetrationsplates or shell penetrationsshall be given a leak test.shall be given a leak test.
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Settlement SurveySettlement Survey When settlement is anticipated, a tankWhen settlement is anticipated, a tank
receiving a hydrostatic test shall have thereceiving a hydrostatic test shall have thefoundation checked for settlement.foundation checked for settlement.
Surveyed emptySurveyed empty
During fillingDuring filling
At 100% test levelAt 100% test level
Appendix B used for acceptance criteriaAppendix B used for acceptance criteria
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5959
API 653API 653
Marking and RecordkeepingMarking and Recordkeeping
Section 13Section 13
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NameplatesNameplates Required for reconstructed tanks onlyRequired for reconstructed tanks only
attached adjacent to existing nameplateattached adjacent to existing nameplate
Fig 13Fig 13--11 required nameplate informationrequired nameplate information
existing nameplate remains in placeexisting nameplate remains in place
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RecordkeepingRecordkeeping Records are required forRecords are required for
evaluationevaluation repair and alterationrepair and alteration
reconstructionreconstruction
RecallRecall Per 6.8Per 6.8 three types of recordsthree types of records
constructionconstruction
inspectioninspection
repair and alterationrepair and alteration
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RecordkeepingRecordkeeping Calculations required forCalculations required for
component integrity, including brittle fracturecomponent integrity, including brittle fracture
reratingrerating
repair and alteration considerationsrepair and alteration considerations
Construction drawingsConstruction drawings
Repair drawingsRepair drawings
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RecordkeepingRecordkeeping Inspection data, UTMsInspection data, UTMs
MTRsMTRs & certifications tests& certifications tests
Radiographs (1 year)Radiographs (1 year)
Brittle fracture issuesBrittle fracture issues
Construction dataConstruction data
Location & ID numberLocation & ID number
Tank descriptionTank description
Tank serviceTank service
Design conditionsDesign conditions
ShellShell matmatll & thickness& thickness
Tank elevationsTank elevations
Construction recordsConstruction records
Basis ofBasis ofhydrotesthydrotestexemptionexemption
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CertificationCertification Documentation of reconstructionDocumentation of reconstruction
Certifications required forCertifications required for
DesignDesign
ReconstructionReconstruction Inspection and testingInspection and testing
Figure 13Figure 13--22
Certification for Tank Reconstructed to APICertification for Tank Reconstructed to API--653653
Certification for Tank Designed to APICertification for Tank Designed to API--653653
Appendix AAppendix A
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Appendix AAppendix A