API 653 Certification Module 2 Homework Name: Open Book - Show your work when performing calculations. (you may need extra paper for some of the longer calculations) D) 2) 3) 4) srs During an internal tank inspection, a locally corroded area is found on the tank shell. The minimum thickness in the wasted area is 0.543". The diameter of the tank is 140°. Calculate the “critical length” for this wasted area. What is the maximum allowable stress that should be used when calculating the minimum. thickness for a wasted area on a tank shell’s 3" course? The shell material is SA-516 Grade 65, During an internal tank inspection, an 18” locally corroded area is found on the shell’s bottom course. The bottom of the corroded area is 4° above the tank floor and is 3” away from a vertical weld. The tank shell material is SA-285-C. The tank diameter is 120°. The tank was built to API 650 the 2” Edition. The specific gravity of the product is 0.9. The maximum liquid level in the tank is 36 feet above the tank bottom, Determine the minimum acceptable thickness in this corroded area. ‘What is the allowable stress that should be used when calculating the minimum thickness for a riveted tank for a, Upper courses made of A-283-C? b. Bottom courses of unknown material? insisens Anarea of edge settlement is discovered during a tank survey. The tank is 50 ft in diameter. In this area, the settlement is parallel with the shell. ‘The distance from the shell to the floor break- point is 48”. What is the maximum allowed edge settlement? A 140° gasoline tank has an annular plate. The bottom shell course is 0.875” thick and has a stress level of 26,000 psi. The retirement thickness for an annular plate is ” Det a. Riveted tank with corroded area 2” away from a rivet row. The rivet connection is a butt joint with butt straps. ‘There are 4 rivet rows on each side of the joints. b. Welded tank corroded area 3” away from weld. Tank built to 4" edition of API 650 (Basic Standard). Riveted tank shell course. Butt joint with butt straps and 6 rows of rivets d. Welded tank shell course. Tank has butt joints and built to APE 12C 1950. ine the joint efficiency for the following calculations Riveted tank shell course. Lap joint with 4 rows of rivets, 1 APL 653 Training8) % 10) 1) 12) 13) la) API 653 Certification Module 2 Homework ‘The bottom tank course has a minimum thickness of 0.420”. The tank floor was originally 0.250". What is the minimum allowable bottom thickness in this critical zone? _ A settlement survey is performed on a 140° tank. How many settlement readings are required around the outside edge? ndiameter. What is the During an internal inspection a bottom depression is found that is 72” maximum allowed depth of this depression? During the evaluation of a corroded area the Critical Length (L) is calculated. The Cri Length can never exceed inches. A140" tank has a corroded area in the 2"! course that crosses a vertical weld and extends within 2 feet of the bottom of this course. All courses are 8° and the tank's fill height is 40°. The shell ‘material is A-283-C, The tank was built to 8" edition of API 650. Product specific gravity is 0.95, The minimum thickness in the corroded area is 0.322”. The corroded area is corroding at 0,002 ipy. ‘The desired interval is 15 years. a. Whatis the maximum critical length? b. For this corroded area, what is the liquid height “H"? c. What is the calculated minimum thickness for the LTA? d, How much corrosion allowance is needed? The average thickness (1) must be > what thickness? £ ‘The minimum thickness (1:) must be > what thickness? Determine the retirement thickness of the 1 course of a 160° tank. All courses are 8° and the tank’s liquid fill height is 40°. The shell material is A-516-60, The tank was built to the 4" edition of API 650 (Basic Std). Product specific gravity is 0.80. ‘An 80" diameter tank has a corroded area that extends within 3° of the tank bottom. Overall product height is 38°. All shell courses are 8°. Shell material is A-516-60, E = 0.85 and product specific gravity is 0.87. The average thickness along the critical length is 0.266". The shell is corroding at 0,001 ipy. ‘The desired interval is 20 years. (for “a” use formulas in manual) a. Whatis the product fill height from the bottom of the corroded are: b. What is the overall tank product fill height? = cc, What is the hydro fill height from the bottom of the corroded area? d, Whats the overall tank hydro fill height? MISTS 2 APL 653 TrainingAPI 653 Certification Module 2 Homework 15) Determine the tank bottom thickness at the next inspection. Data from the current inspection includes: Inspection Interval: 20 years Top-side Corrosion Rate: 0.0005 ipy Current Thickness: 0.170" Bottom-side Corrosion Rate: 0.002 ipy MRT = Is this Acceptable? 16) Determine the tank bottom thickness at the next inspection. During this tank outage a new thick-film coating was installed. Data from the current inspection includes: Inspection Interval: 16 years hickness before repairs: 0.130" Thickness after repairs. 0.166 Top-side Corrosion Rate 0.002 ipy Bottom-side Corrosion Rate: 0.003 ipy MRT = Is this Acceptable? 17) An internal inspection has just been completed. Calculate the maximum internal inspection interval based on the tank bottom thickness. ‘The tank is not coated. Formula is provided! ; Current Remaining Thickness: 0,145" distil Leh Top-side Corrosion Rate: 0.001 ipy ; Bottom-side Corrosion Rate: 0,002 ipy MISTS 3 APL 653 TrainingAPI 653 Certification Module 2 Homework Closed Book 1. The Fitness for Service code is 2, List the 4 organizations that can be an Authorized Inspection Ageney for tanks, a ©. b, a What is the minimum number of thickness readings that should be taken along the Critical Length of a locally corroded area? 4. The arbitrary retirement shell plate thickness is inch. 5. The Variable Design Point method should be used to calculate the minimum shell thickness for tanks larger than feet. 6. The minimum thickness of a cone roof tank is: a. 0,050" b. 0.090" 0.100" d. average thickness of 0,090” in 100 sq inches. ©. average thickness of 0.100” in 100 sq inches 7. ‘The Owner/Operator decides to increase the internal pressure in an API 650 tank. This change should be evaluated per the requirements of: API 620 API 650 Appendix C API 650 Appendix API 650 Appendix HL API 650 Appendix M eaoge 8. ‘The Owner/Operator decides to increase the tank temperature from 150°F to 250°P. This change should be evaluated per the requirements of: API620 APL650 Appendix C APL.650 Appendix F APL.650 Appendix H API 650 Appendix M peers srs 4 APL 653 TrainingAPI 653 Certification Module 2 Homework 10. ne 12, 14. ‘The type of tank settlement that places the most stress on the bottom-to-shell weld is called? settlement Pits on floating roof should be repaired if ’. they are expected to hole-through before the next inspection they ate deeper than % minimum thickness the remaining thickness is less than Ye minimum thickness the remaining thickness is less than 0,090” Complete the following table concerning the various tank inspections. Who Inspects Interval Major Emphasis Routine-in-Service External UT of Shell ‘Coonan Rae Unknow Coroson Rae Kron Internal Consion Rate Uaknow Coston Rate Known List the 3 types of inspection records a b. c ‘The shell plate thickness in January 1980 was 0.750”. In January 2005 the same shell thickness is 0.675”. The renewal thickness is 0.627". Calculate the following: a, ‘The corrosion rat b. ‘The External Inspection interval The Shell UT measurements interval An external settlement survey is performed on a 60" tank? How many settlement readings are required? srs s APL 653 Training16. 20. 21 22. API 653 Certification Module 2 Homework ‘The minimum shell thickness is being calculated for a corroded area on a riveted tank. The joint efficiency used is 1.0 only if the corroded area is: a. away from the rivets by at least 1” b. away from the rivets by the greater of 1” or twice the plate thickness ¢. away from the rivets by at least 6” part ofa tank shell made of normalized steel ‘The minimum allowed thickness for a non-coated tank bottom away from the critical zone is: a, 0,050" b. 0,090" ce. 0.100" d 0,125" Who has ultimate responsibility for complying with API 653? a. Authorized Inspector b. Engineer c. Jurisdiction d. Owner / Operator e. Repair Organization Deep pits are discovered in a shell course, The nominal thickness of shell plate is 0.500" and the shell course retirement thickness is 0.400”. What is the maximum allowed pit depth? a. 0.100" b. 0.200" c. 0.300" d. 0.400" During the External inspection the inspector examines the bottom plate extension a. The minimum projection is b. The minimum plate thickness at the toe of the bottom-to-shell weld is: A brittle fracture evaluation considers the tank is safe to use provided the: shell thickness is < 0.500” operating temperature is < 60°F stress in the shell > 7000 psi bottom-to-shell weld is fully examined by MT ae se A common tool that is used to examine the entire tank bottom is: ‘The maximum interval for a tank internal inspection is: MSTS 6 API 653 TrainingAPI 653 Certification Module 2 Homework 23, 24, 25. 26. 21, 28. 29. MSTS During a tank repair, if AP1653 conflicts with API 650 requirements, the owner should follow: a API 650 b. API 65 ©. most stringent 4. either based on engineering judgement Calcining affects concrete foundations and is a result of: a, low temperatures b. high temperatures acid attack d. caustic attack RBI assessments shall be reviewed and approved by: a. the authorized inspector b. the tank engineer © the Owner / Operator doth the authorized inspector and tank engineer AILNDE results should be reviewed by: a, the authorized inspector b. the tank engineer ¢, the Owner / Operator d. both the authorized inspector and tank engineer List the 2 primary factors that impact Risk. a b, Corroded areas can be evaluated by API 653 criteria, or using criteria fr a, ASME Section VIII Div. 1 b. ASME Section VIII Div. 2 cc. API2201 d. API.S77 Pitting in the shell must be repair is the sum of the pitting lengths exceeds: a 2” in any 8” vertical length b. 2” in any 8” length c. 4” in any 8” vertical length 4. 4 inany 8” length 7 API 653 Training30, 31 32, 33, 34, API 653 Certification Module 2 Homework Cracks in which of the following welds must always be repaired? a b. ¢, a. e, Shell butt weld Novzle neck to flange weld Roof-to-shell weld Bottom-to-shell weld All cracks must be repaired Internal inspections are done primarily to determine the condition of the: aose shell bottom roof roof support system ‘The critical zone is: aes the portion of the bottom plates within 3” of the bottom-to-shell weld the portion of the bottom and shell plates within 3” of the bottom-to-shell weld the portion of the bottom plates within 12” of the bottom-to-shell weld the portion of the bottom and shell plates within 12” of the bottom-to-shell weld What property of materials can be defined as, “The ability of « material to absorb energy and deform plastically before fracturing”? a, b. G a. A brittle fracture evaluation considers the tank i b. el a. Brittleness Hardness Strength Toughness {fe to use provided the: shell thickness is > 0.500” operating temperature is > 60°F siress in the shell < 21,000 psi shell weld is air tested The scope of API 653 covers all the following activities except tank: MSTS. alterations, inspection operation reconstructions 8 API 653 TrainingAPI 653 Certification Module 2 Homework - Answers Open Book 1 323” Ref 43.216 L=3.7140%0543_ = 32.3” 2 30,700psi_— Ref. Table 4-1 3 0.381" Ref. 4.3.3.1.b D=120" 900 (Table 4-1) H=36-4= 32" (over 1 away from weld) G=0.90 nn =2.6DHG/SE fn = 2.6. 120. 32 x 0.9/23,600 x 1.0 on = 0381" 4. a 26,000 psi b. 21,000 psi Ref. Table 4-1 5. Ref. Fig. BeLL 6. 0,220” Ref. Table 4-5 # a. 0.90 Ref. Table 4-2 & 4-3 b. 1.00 (away from weld) © 085 (6 rivet rows, but 3 on either side of joint) d. 085 e 0.75 8. 0.125” Ref. 4.4.5.4 Smaller of: ¥2 twin of bottom course (0.210") or % torisina Of bottom (0.125") 9 14 Ref. 125.12 N=D/10 = 140/10 = 14 10. LMI” Ref. B3.3 B=0.37R = 0.37x3= 111 (72” diameter has a 36"radius = 3 feet) 1, 40” Ref. 4.3.2.1.) 12, a, 24.8" — Ref. 4.3.2.1.b L=3.7 140x032, = 24.8" b. 30° H=40~(8 +2) =30" © 0440" — Ref. 43.3.1.b Inn = 2.0HDG /SE = 2.6 x 30 x 140 x 0.95/23,600 x 1 = 0.440" d. 0.030" — Ref. 4.3.2.1eiti — CAyeea = Rate x Interval = 0,002.x 15 = 0.030" e. 0.470" Ref. 4.3.2.1Le.i 1 2 tnin + CAneea = 0.440 + 0.030 = 0.470 f 0.294" — Ref. 43.2.1eii > O.6tqix + CAnet = 0.6(0.440) + 0.030 = 0.294” 13. 0.596" Ref. 43.3.La ti = 2.6(H-I)DGISE = 2.6 x 39 x 160 x 0.80/25,600 x 0.85 = 0.596" srs 9 APL 653 TrainingAPI 653 Certification Module 2 Homework - Answers 14, a, 29.6" Class manual = Rate x Interval = 0.001 x 20 = 0.020" 1 = fay ~ CAneg = 0.266 -0.020 = 0.246" H = (SE1/2.6DG) = (25,600 x0.85 x 0.246 /2.6 x 80x 0.87) = 29.6" b, 32.6? dwg sketch! Hira + Hrrtorem = 29.6 + 3 = 32.6 c. 30.7? Ref. 4.3.3.2.b (SEt/2.6D) = (28,200 x0.85 x 0.266 / 2.6 x 80) = 30.7 d. 33.7" dwg sketch! Hoveutt = Hera + Hrotugon = 30.7 + 3 = 33.7" 15. 0.120" Ref. 4.4.5.1 44a = fooner =I (Ry + Riso) = 0.170 20(0.0005 + 0.002) = 0.120 Yes, this is acceptable 16, 0.112” Ref. 4.4.5.1 {hr = tara ~ Il (Rap + Rinna) = 0.160 16(0.0 + 0.003) = 0.112" Yes, this is acceptable Note! Top-side corrosion is 0.0 ipy since new coating was installed. 17. IS years Ref. 4.4.5.1 It. (tan tad Ap + Rea) = (0.145-0.100) 40.001 40.002) = 15 rs Closed Book I. APIS79 2. SJUIC” Insp organization of: Jurisdiction, User (Owner/Operator), Insurance Comp. Contractor. 5 4 0.100” 200 feet 4d, average thickness of 0.090” in 100 sq inches. c. APL 650 Appendix F. 8 — @ API650 Appendix M. 9. Out-or-plane settlement or Differential settlement 10. a they are expected to hole-through before the next inspection. MSTS 7 API 653 TrainingAPI 653 Certification Module 2 Homework - Answers i. 22 13. M4. 15, 16. 17. 18, 19, 20, 21, 22, 23, 24. 25. 26. 27. Inspection Schedules Who Inspects Interyal Major Emphasis Routine-in-Service Operator Tmonth Major changes “from the ground!” External Authorized | Lesser of: Outside Inspector W life or 5 years components UT of Shell ? Car Rae Tako Determine Shell (Code Unclear ‘| Gauigeten Corrosion Rate Lesser of Yelife or 15 yrs Internal Authorized ‘Corr Rate Unknown Bottom thickness Inspector 10 years Bottom settlement Corr Rate Known years Bottom condition Construction, Inspection History, Repairs/Alterations 4. Corrosion Rate 0.003 ipy or 3 mpy CR = 0.750 ~0.675 /25 = 0.003 ipy b. External Interval 4 years Interval = lesser of 5 yrs or life Life = (0.675 ~ 0.627)/ 0.003 = 16 yrs W Life = 16/4 = 4 years Shell UT 8 years Lesser of Ys Life (8 years) or IS years eight settlement readings c. away from the rivets by at least 6”. c. 0.100" d. Owner / Operator 6. 0.300" Remaining thickness must be tun (15x 0.400 = 0.200") Pit dept: 0500 - 0.200 = 0.300" a. 3/8” -b, 0.100" a. shell thickness is < 0.500" MEL (Magnetic Flux Leakage) lesser of Full Bottom life or 20 years b. API 653 b. high temperatures d. both the authorized inspector and tank engineer. a. the authorized inspector Likelihood of Failure, and Consequence of Failure u API 653 Training28. 29. 30. 31 32, 33. M. 35. srs API 653 Certification Module 2 Homework - Answers b, ASME Section VIII Div. 2 a, 2” in any 8” vertical length d. Bottom-to-shell weld b, Bottom a the portion of the bottom plates within 3” of the bottom-to-shell weld d, Toughness b. operating temperature is > 60°F operations 2 API 653 Training