L089 API 653 Certification Module 3 Homework Name: Open Book - Show your work when performing calculations. (you may need extra paper for some of the longer calculations) 1. A repad is added to an existing nozzle. The pad extends down to the bottom-to-shell weld. The shell plate thickness is 0.875”, the repad thickness is 0.500" and the nozzle thickness is 0.375”. Determine the: a. Minimum repad-to-shell weld, . Minimum repad-to-nozzle weld. c. Minimum repad-to-bottom weld. a Gap between the nozzle O.D. and the repad LD. e Distance between “telltale” holes and the repad horizontal weld. a 2. Two lap patches are installed on a tank bottom. Both patches go to the wall of the shell. Determine the following. Minimum radius on these patches, Maximum thickness of patches. Maximum width of either patch. Minimum distance between patches (patch widths are 14” and 20”) pegs 3. A tank thatis made of A-285-C is being reconstructed. The designer must calculate the required thickness for each course. What allowable stress should be used to calculating the thickness of the bottom course when considering the: a product b hydrotest 4, Anew 8 NPS nozzle (8.625” O.D.) is installed in an old tank shell of unknown toughness. An insert plate will be used. The repad is 14” in diameter, The minimum diameter of the insert plate a 16 b, 17.2". c 24", d. 26" e. 28”. 5. A hydrotest is performed on a 160° tank. How many settlement readings are required around the outside edge? 6. During an internal inspection a bottom depression is found that is 48” in diameter. What is the maximum allowed depth of this depression? MISTS i APL 653 Training9, 10. 12 API 653 Certification Module 3 Homework A portion of a shell plate is being replaced. The replacement plate is 0.875”. Determine the nimum distances between the specified adjacent welds Minimum distance to a vertical weld? a b. Minimum distance to a horizontal weld? c imum coer radius of the replacement plate? a imum distance to the bottom-to-shell weld? c. Minimum width of plate? Hae £Ifplate stops ata horizontal weld, distance to cut horizontal? g. With a “tombstone”, min, distance from vert to a bottom weld? A tank that is being reconstructed. The material is not listed in API 653 or API 650, but has a tensile strength of 62,000 psi and a yield strength of 34,000 psi. What allowable stress should be used to calculating the thickness of the 3rd course when considering the: a product b. —_hydrotest A 30° tank is being reconstructed. The tank is 70° high. What is the maximum out-of- plumbness allowed for this tank? Determine the retirement thickness of the 3" course of an existing 180° tank. The overall liquid height is 38° and each course is 8" high. The shell material is SA-516-55 and the speci gravity of the tank’s product is 0.94. The tank was built to API 650 edition 5 (Basic Standard), Retirement thickness: . A portion of a shell plate is being replaced. ‘The replacement plate is 0.375”. Determine the minimum distances between the specified adjacent welds, a, Minimum distance to a vertical weld? b. Minimum distance to a horizontal weld? ©. Minimum comer radius of the replacement plate? d. Minimum distance to the bottom-to-shell weld? e. Minimum width of plate? f. _Ifplate stops ata horizontal weld, distance to cut horizontal? 2 Witha “tombstone”, min. distance from vert to a bottom weld? Determine the tank bottom thickness at the next inspection. The current inspection includes: Inspection Interval: 15 years Thickness before repairs 0.130" Thickness after repairs: 0.160" Top-side Corrosion Rate: 0.001 ipy Bottom-side Corrosion Rate: 0.002 ipy MRT eee Is this Acceptable? Eee MSTS 2 API 653 TrainingAPI 653 Certification Module 3 Homework 13. An 8 NPS nozzle will be hot tapped into a 3/8” tank shell that has a diameter of 120 feet. The shell material has acceptable toughness. The product liquid height from the bottom of the hot tap is 32°. The product has a maximum specific gravity of 0.90. Determine the following. Minimum shell thickness for this hot tap b. Minimum nozzle hydrotest pressure c. Minimum liquid height above nozzle during hot tap Minimum distance (© adjacent nozzle 14, Which of the following nozzle installations requires the use of an insert plate? a 8 NPS nozzle in a 3/8” shell of unknown toughness b. 4 NPS nozzle in a 5/8” shell of unknown toughness ©. _.2NPS nozzle in a 1.000” shell of unknown toughness 4. 12 NPS nozzle in a 1.250” shell which has acceptable toughness 15. A 160° tank is being reconstructed. The tank is 40" high. The bottom course is 0.750" thick, the 2nd course is 0.625” thick. A new concrete ringwall is built for the tank, Determine the following: 4. Maximum allowed weld reinforcement on bottom course vertical welds b. Maximum allowed weld reinforcement on the horizontal weld ¢. Maximum allowed misalignment on the 2nd course vertical welds d. Maximum allowed projection of the 2nd course over bottom course e. Maximum allowed peaking of the 2nd course vertical welds i Maximum allowed banding of the horizontal welds &. Maximum allowed out-of-plumbness. h. Maximum allowed out-of-roundness at the bottom cece i, Maximum allowed out-of-roundness at the 2" course j- Maximum tolerance for overall foundation 16. What is the imum height for the letters on a new tank nameplate? 17. When a shell lap patch is used to cover a leak. ‘The patched should be designed using a joint efficiency of MTS API 653 TrainingAPI 653 Certification Module 3 Homework Closed Book ie A thickened insert plate with a taper is used to during the installation of a new nozzle. The steepest taper allowed is: 30 degrees. b. 45 degrees. c. one-to-three. d.— one-to-four Anew botto talled on a tank. The new repad-to-bottom distance does nof meet APL650 spacing requirements, Which of the following is naf an acceptable solution? a Raise the nozzle b. Remove the repad ¢. Replace the repad with a smaller diameter repad . ‘Trim the repad. ‘The Critical Zone is the portion of the: tank bottom within 3” of the shell. b. tank bottom within 12” of the shell. ¢. tank bottom and shell within 3” of the bottom-to-shell weld. d. tank bottom and shell within 12” of the bottom-to-shell weld. Lap patches cannot be used on any shell course that exceeds thick. What is the minimum dimension of a lap patch on a tank bottom that crosses a bottom weld? ete 8 ©, 1" 4. Unlimited ‘The minimum diagnostic length of a radiograph shall be inches. A nozzle will be welded and hot tapped on a tank shell. What is the minimum number of UT readings to be taken around a nozzle circumference prior to welding on the nozzle? A hot tap should never be performed on a tank in which of the following services? a Acid b. Caustic c. Crude d. Heavy Gas Oil e Lube Addi MSTS 4 API 653 TrainingAPI 653 Certification Module 3 Homework 10. 1 13, 4 MsTS ‘When hot tapping is performed, the requirements of which of the following codes should be followed? a ASME Section VIII b. API652 ©, API 2001 d. APL2015 ce. API2201 Radiographs are performed during a repair to a tank shell. Which of the following is not correct? Radiographs must be retained for 1 year. Radiographs are evaluated to ASME Section IX. Radiographs are performed by someone qualified to ASNT SNT-TC-1A. 100% of vertical welds over 1” thick must be radiographed. Which of the following is not considered a major repair or alteration? a ‘The addition of a 10 NPS nozzle. b. ‘The repair of 18” of a vertical weld. Repair depth is 60% of the weld thickness, ¢. The removal and replacement of 8” of the bottom-to-shell weld. d.—— Reveling the tank. When a bottom lap patch covers a corroded area, the minimum distance from the corroded area to the edge of the patch is inches. A tank shell has a remaining life of 16 years. When are the following inspections due? a. External Inspection b. UT of the Shell During the design of a reconstructed tank, the thickness of each shell course must be known, ‘The thickness readings, used during design calculations, must have been taken within: a 60days. b. 90 days. 180 days, a Lyear During a tank repair, who has 10 approve the work at designated hold points? ‘The authorized inspector ‘The tank engineer Either the authorized inspector or the tank engineer Both the authorized inspector or the tank engineer 5 API653 Training20. 2 API 653 Certification Module 3 Homework ‘When reconstructing a tank, the existing welds joints shall meet the requirements of: API650. Applicable standard. Current applicable standard. Original construction code. ees A repair is the work done on a tank that: a. restores the tank to a new condition, b. restores the tank to a suitable safe condition. ©. physically alters the tank. 4. requires no hot work, ‘An inspection is performed on an existing tank. Which of the following discontinuities must always be repaired when found? a. Are strikes b. Excessive weld reinforcement c. Surface Porosity d.— Undercut A lap patch on a tank bottom crosses a bottom weld. ‘The lap patch must overlap the bottom weld by at least: ata bot ce 6" a 12", An RT is taken at the intersection of an existing weld anda new weld. The existing weld may be evaluated per: a APL650. b. the original construction code. ©. the applicable standard. 4. the current applicable standard. A non-coated bottom plate is 0.150" thick. ‘The overall corrosion rate is 0.004 ipy. When should the next internal inspection be scheduled?” a 6.25 years b. 10 years c. 12.5 years 20 years e. 25 years sts 6 APL 653 TrainingAPI 653 Certification Module 3 Homework 22. 23, 24, 25. 26. 21. 28. MSTS A tank is being reconstructed, During the dismantling, which of the following is the mini acceptable requirements for cutting a shell course that is 0.375” thick? a, Cut through the welds Deseam the weld, Cut out at both toes of the weld, Deseam the weld and cut out the heat affected zone. d.— Cutat least 2 “ away from a weld. ‘The maximum size of a shell lap patch is: a. vertical b. horizontal ‘When a hydrotest is performed on a tank, it should be held for: a 8 hours, b. 12 hours. ce. 24 hours. d. _asufficient time to perform the bottom inspection, What is the minimum allowed thickness for a coated tank bottom away from the critical zone? ‘The coating is a reinforced liner that is 0.060" thick. a 0,050" b. 0,090" c. 0.0100" ad 0.125" Who has ultimate responsibility for complying with APL 653? a. Authorized Inspector b. Engineer c.—_Iurisdiction Owner / Operator e.— Repair Organization Deep pits ate discovered in a shell course. The nominal thickness of shell plate is 0.750" and the shell course retirement thickness is 0.560". What is the maximum allowed pit depth? a 0.100" b. 0.190" c 0.375" 4d 0.470" e 0,560" What is the minimum replacement thickness of a plate for a cone roof tank? 7 APL 653 TrainingAPI 653 Certification Module 3 Homework 29. A hydrotest is always required after all: a. Repairs and Alterations. b. Major Alterations. c, Major Repairs & Alterations. 4d. Reconstruetions. ¢. _Reconstructions and all Major Repairs & Alterations, 30, ‘The maximum amount of pitting that can be welded overlaid in the critical zone is: 2” in any 8” length. 3/32” in any 4” length, °4” in diameter with no limit on the extent of the pitting. 1” in diameter with no limit on the extent of the pitting. aece 31. A tank is being reconstructed. During the dismantling which of the following can be done to cut a shell course that is 0.625” thick? Cut through the welds Deseam the weld. Cut out at both toes of the weld. Descam the weld and cut out the heat affected zone. Cut at least 2 “ away from a weld. pose 32. ‘The maximum interval for a tank internal inspection is: 33. Buckled seal parts must be: a. replaced b. inforced. c. straightened. d. stiffened with weld overlay. 34, Determine the following plate dimensions. a, Maximum dimension of lap patch on a roof zee Minimum dimension of lap patch on a roof Maximum vertical dimension of lap patch on a s Minimum dimension of lap patch on a shell Maximum dimension of insert plate on a shell Minimum dimension of insert plate on a shell Max dimension of lap patch on bottom not in critical zone Max dimension of lap patch on bottom in critical zone Min dimension of lap patch on bottom not in critical zone rem oe ees 35, How many radiographs are required when using a rectangular replacement plate (butt welded) on a 0.500” tank shell? #of RT's: MsTS 8 API 653 TrainingAPI 653 Certification Module 3 Homework 36. 38, 39, 40, AL. 42. During a tank repair, if API 653 conflicts with legal requirements, the owner should follow: a The legal requirements. b. — API653. c. the most stringent requirements. Gd. either set of requirements based on engineering judgment. AIL NDE results should be reviewed by: the authorized inspector. the tank engineer. the Owner / Operator both the authorized inspector and tank engineer aege During a tank alteration, a new weld radiographed and a defect is found. The weld is repaired and radiographed again. This repair radiograph should be marked with a(n) In which situation are lap patches not allowed” a In the critical zone on carbon steel tanks that operate over 10°F, b. Bottom lap patches that cross any lap joint. c. Shell lap patches that cross any riveted joint. d. On shell plates less than 0.500” thick. All new materials used in tank alterations must meet the requirements of a API650. b. ASME Section VITI-Division 1. c_ ASME Section VIT-Division 2. d. the current applicable standard. the original construction standard. The upper two courses of a tank are replaced. How much RT is required on the new vertical welds? Only need to meet the requirements of API 650 One in every vertical weld One in every 10” of vertical weld One in every 200° of weld. eege During a tank alteration, which of following new welds should be inspected by MT or PT? a. Bottom-to-shell welds b. —_Nozzle-to-shell welds c. Bottom lap welds d. Shell plate welds greater than 0.500” thick MISTS 9 API 653 TrainingAPI 653 Certification Module 3 Homework 43. 44, 45. 46, 41. 48. 49. During a tank reconstruction, welders should stamp their identification symbol by the welds, they make. They should stamp every feet of weld made. List the two tanks welds that do not need to be stamped by the welder. a b. ‘The scope of API 653 covers all the following activities excep tank: a. alterations b. inspection. c. fabrication d. reconstructions. e. repairs. ‘What are the qualification requirements for personnel performing MT examinations? Correct vision and competent in the technique used. ASNT SNT-TC-1A ASME B&PY Code - Section V ASME B&PY Code - Section VIII Div. 1 aese Certification of work is required after all: Repairs Alterations. Repairs and Alterations Major Repairs and Alterations Reconstructions Reconstruetions and Major Repairs & Alterations reap ss During a reconstruction, which materials need to be identified (determine plate material)? a, All reused plates b. Only plates in the shell ¢. All shell and bottom plates d All shell plates and bottom plates welded to the shell 1g a tank repair, before the work begins who has to authorize the work a, The authorized inspector b. The tank engineer c. Either the authorized inspector or the tank engineer d. Both the authorized inspector or the tank engineer srs 0 API 653 TrainingAPI 653 Certification Module 3 Homework - Answers Open Book - Answers 1 4. 5. 6. 7. 10. b 4. a b. a. b, 0.500” 3” site" 1/16” » ” 4” a4” 20,000 22,500 26” 16 0.74” 10" 0” o 10” 1 a 4.375” 22,667 psi lesser of 2/3 (22,667) or 2/ST (24,800) 25,500 psi lesser of 3/4Y (25,500) or 3/7T (26,571) 5” D=(Hx 12100 1.37xR (Rin feet) B=037x2 '4 but don’t exceed 5” 1.85 tnin = 2.6 (22-1) 180x094 = 0.418" 26,000 x 0.85 u API 653 TrainingAPI 653 Certification Module 3 Homework - Answers Bit sas 6% ” eta ien ase eID fae & a” n. MRT = 0.113" bg = leur * Int (RT + RB) gg = 0.160 - 0.045 = 0.115” Is this Acceptable? Yes 15, i bd. —.20.8 psig P= 0.65.x 32x 10 (since G < 1.0 use a Gof 1.0) eta a 164" 14, b, 4 NPS in 5/8” shell of unknown toughness 4S. a. as” b v6” « 1/16” d. is” ema re 48” h. 41” i a” i aM” 16. 5/32” 17. 0.35 Closed Book - Answers 1d one-to-four. 2 remove the repad. 3. tank bottom within 3” of the shell 4 Ke Se aa 6 6" m4 8b Caustic STS 2 Sj = 0.160 ~ 15 (0.001 + 0.002) APL653 TrainingAPI 653 Certification Module 3 Homework - Answers 9 10. ML, 2. B. M4. 15, 16. 17. 18. 19. 20. 21. 22, 23. 24, 2s. 26. 27, 28, 29, 30, 3 32, 33, MSTS a. d. d. API 2201 Radiographs are evaluated to ASME Section IX the addition of a 10 NPS nozzle 2 inches yrs. 8 yrs 180 days either the authorized inspector or the tank engineer original construction code restores the tank to a suitable safe condition care strikes » the original construction code 12.5 yrs. cut through welds 4” ma 24 hrs, 0.050” ownerfoperator 0.470" ante” reconstructions 2” in any 8” length Deseam the weld and cut out the heat affected zone 20 yrs replaced 13 APL 653 Trainingi. 45, 46, 47. 48. 49. MsTS 6 4. a API 653 Certification Module 3 Homework - Answers unlimited unlimited 4” ” unlimited RD unlimited 2 o” 6 the most stringent requirements the authorized inspector R Shell lap patches that cross any riveted joint the current applicable standard Only need to meet the requirements of API 650 Nozzle-to-shell welds 3 feet roof plates lange-to-nozzle Jabrication Correct vision and competent in the technique used Reconstructions All shell plates and bottom plates welded to shell Either the authorized inspector or the tank engineer 7 API 653 Training