Tank Basic API 650 PDF

Tank
Basics
API 650 Fabrica3on
www.epcmconsultants.co.za
Tank Basics -‐ API 650 Fabrica3on

The Uniqueness of Tanks ~ Different Components with specific requirements

1) Five Major Components
a. Founda>on
b. BoAom
c. Shell
d. Roof
e. Nozzle
2) Two Major Welds

a. BoAom-‐to-‐Shell
b. Shell-‐to-‐Roof
Each component has specific requirements for; Design, Erec>on, Inspec>on,
and Tes>ng
API 650 -‐ Organiza3on
API 650 is primarily organized by fabrica>on sequence.

Sec>on 1 -‐ Scope (What's covered by this Code)
Sec>on 4 -‐ Materials (What's allowed, restric>ons)
Sec>on 5 -‐ Design (Thickness, joint designs)
Sec>on 6 -‐ Fabrica>on (Cu[ng and Rolling Plate)
Sec>on 7-‐Erec>on (Field Assembly of Components)
Sec>on 8 -‐ Inspec>on (Qualifica>ons, Acceptance Standards)
Sec>on 9 -‐ Welding (Qualifica>ons, Markings)
Sec>on 10 -‐ Markings (Nameplates, Cer>fica>on)
Material Selec3on
API 650 allows specific materials 4.2.1.1

Some>mes need materials with appropriate "toughness“
How to find whether Impact test are required
•  Find Material Group for Plate Table 4-‐4b
•  Determine Minimum Design Metal Temperature Fig. 4-‐1b
•  Determine Lowest One Day Temp Figure 4-‐2
•  Add 15 °F to this Low Temp
•  If this temperature is above the Minimum Design Metal Temperature -‐
Build the tank
•  If not -‐ Either select another material or impact test
Bo>om – Major Concepts
Why is the tank bo3om generally thinner than the bo3om shell course ?
•  The boAom is a membrane to prevent leaks
•  Generally the boAom is a low stresses area
•  Near the boAom-‐to-‐shell weld the stresses are higher
Defini>ons
•  Annular Plate: BoAom plate that the shell rests on that has buA-‐joints.
Generally the annular plates form a donut with the inside edges straight
•  Sketch Plate: BoAom plate that the shell rests on that has lap joints.
Generally the sketch plate is the same thickness as other boAom plates.
•  Three Plate Lap: Intersec>on of right angle boAom welds. (3 plates thick)
•  Plate Extension: Part of boAom plate that extends outside the shell
Bo>om – Design Issues
•  Min. New Thickness -‐6 mm (0.236") 5.4.1

•  Minimum Annular Plate Thick Table 5-‐1b
•  BoAom Plate Extension -‐2" 5.4.2
•  Sketch Plates Joints -‐ Single Fillets 5.1.3.4
•  Annular Plate Joints -‐ BuA 5.1.5.6
•  Other BoAom -‐ Full Single Fillet 5.1.5.4.
•  All welds -‐ complete penetra>on & fusion (generally welded both sides)
5.1.5.2/3
•  Ver>cal joints offset by "5t" 5.1.5.2.b
•  Courses should have a common centerline
Shell – Major Concepts
•  Shell is designed for the "sta>c head" pressure from the product
•  Ver>cal welds are much higher stressed that the horizontal welds

Which shell weld is most cri>cal? – VERTICAL
Shell -‐ Design
•  The wall thickness for each course must be calculated Lower courses are
thicker.
The shell is designed to hold the pressure resul>ng from "sta>c head" (the
pressure resul>ng from the height of the product.) The pressure increases as
the liquid height increase.
Since the pressure near the boAom increases, the shell must be thicker!
Shell -‐ Thickness
•  1-‐Foot Method -‐ used for tanks < 200 feet 5.6.3.1
•  Variable Design Point Method -‐ required on tanks > 200 feet and can be
used on all tanks with purchaser's approval 5.6.4.1 (not in scope )
•  Use greater of "calculated thickness" or the "arbitrary thickness" 5.6.1.1
Note!!! Each course has a unique reGrement thickness. The reGrement
thickness applies to the whole course! A tank shell with 5 courses will
have 5 reGrement thicknesses.
The 1-‐Foot Method is basically a form of "Barlow s formula"!!!
You will use The 1-‐Foot Method on the API Exam. You will not be responsible
to calculate tank shell thickness using the Variable Point Design Method
Shell – Minimum Thickness
API 650 Formula
•  Td= [2.6 D ( H-‐1)]/Sd G + CA
or
•  Tt= [2.6 D ( H-‐1)G]/St
H = Liquid height from boAom of course G = Specific Gravity
Sd = Allowable Stress -‐ Product Design Stress
St = Allowable Stress – Hydrosta>c Design Stress
Here's how to solve a calcula>on.
1. Draw Sketch-‐Useful for determining "H"
2. Copy formula from Code
3. List data
4. Solve problem (input numbers) below the formula
5. Work problem ver>cally down. Don 't jump all over the paper.
6. Highlight your answer. (Don't forget the units!!!)
Shell – NewThickness
New Thickness -‐ Pick largest of the following:

1. Calc -‐ td Based on Product Gravity with CA
2. Calc-‐A Based on Hydrotest without CA
3. Arbitrary thickness 5.6.1.1

Why 2 Formulas? -‐ Product & Hydrotest
1. The tank must be "strong enough " to hold the product in the corroded
condi>on.
2. It must also be "strong enough " to hold the hydrotest in the non-‐corroded
condi>on. Since the hydrotest is a "1 >me event" the allowable stresses
for the hydrotest are a bit higher than for the product condi>on.
Shell -‐ Fabrica3on
•  Cu[ng & Rolling Plates 6.1.2/3

•  Preheat Temperatures Table 7-‐1 b No welding when:
Any Moisture -‐ Atomic hydrogen enters base metal Windy and Unshielded -‐
Lose shielding gas
•  Undercut Limits 8.5.1. b
•  Reinforcement Limits 8.5.1.d& 8.1.3.4
•  Misalignment Limits 7.2.3.1/2
DefiniGons
•  Peaking: Affects ver>cal tank welds. Caused from not ge[ng the end of a
plate rolled. The weld "pooches-‐out".
•  Banding: Affects horizontal tank welds. Distor>on caused from shrinkage
of weld metal as it cools. The weld "sucks-‐in ".
Misalignment Limits
Shell -‐ RT
RT-‐ Primary NDE method for shell welds
Number of Radiographs 8.1.2 & Fig. & Fig 8.1
Requirements same for each Welder
Thicker plate requires more RTs
VerGcal welds more RTs than Horizontals
More RTs at IntersecGons
Minimum diagnosGc length -‐ 6“

•  Ver3cal spot radiograph in accordance with 6.1.2.2, Item a: one in the first 3 m (10 U) and one in each 30 m (100
U) thereaUer, 25% of which shall be at intersec3ons.
•  Horizontal spot radiograph in accordance with 6.1.2.3: one in the first 10 feet and one in each 60 m (200 U)
thereaUer.
•  3Ver3cal spot radiograph in each ver3cal seam in the lowest course (see 6.1.2.2, Item b). Spot radiographs that
sa3sfy the requirements of Note 1 for the lowest course may be used to sa3sfy this requirement.
•  Spot radiographs of all intersec3ons over 10 mm (3/8 in.) (see 6.1.2.2, Item b).
•  Spot radiograph of bo>om of each ver3cal seam in lowest shell course over 10 mm (% in.) (see 6.1.2.2, Item b).
•  Complete radiograph of each ver3cal seam over 25 mm (1 in.). The complete radiograph may include the spot
radiographs of the intersec3ons if the film has a minimum width of 100 mm (4 in.) (see 6.1.2.2, Item c).
NDE General
NDE Technician Qualifica>on

•  RT& UT-‐ASNT (SNT-‐TC-‐IA) 8.1.3.2/8.3.2.4 & App. U
•  MT& PT – Eye vision & Competent 8.2.3/8.4.3
•  Visual -‐ Not specified
•  Vacuum Box -‐ Eye Vision and Competent 8.6.4

NDE Methods per ASME B&PV Sec>on V Acceptance Standards
•  RT -‐ ASME B&PVSec>on VIII 8.1.5
•  UT -‐ Agreement between purchaser & manufacturer 8.3.2.5
•  MT -‐ ASME B&PV Sec>on VIII 8.2.4
•  PT-‐ASME B&PV Sec>on VIII 8.4.4
Shell – Inspec3on & Test
•  Other Weld InspecGon

No cracks, arc strikes 8.5.1.a
Surface Porosity Limits 8.5. 1. c

•  Other InspecGons ( Dimensional InspecGons )
Plumbness 1/200 of tank height 7.5.2
Roundness Table in 7.5.3
Peaking & Banding 1/ 2" 7.5.4

•  Hydrotest or Air/Vacuum Test 7.3.5/6
Tank Roof
•  Primary funcGon -‐ Keep product in and keep the atmosphere out
•  The roof is generally designed for low pressure.
•  Two basic types -‐ Fixed and floaGng
•  FloaGng Roof-‐ Minimize emissions by minimizing the airspace
Floa3ng Roof

Design InformaGon for FloaGng Roofs
•  Appendix C -‐ External Floa>ng
•  Appendix H -‐ Internal Floa>ng
Tank Seals
Primary Seal Secondary Seal
Normally a Mechanical Normally a wiper
Shoe Minimizes most vapor losses

Mechanical Shoes
•  Many companies have special designs for mechanical shoes. Normally the
major design differences pertain to the method used to push the shoe
against the tank shell. Coil springs, lever springs, and weights have been
used. BeAer designs allow for in-‐service maintenance.
•  Shoes can be used on riveted tanks. Obviously there will be more vapor
losses since the shoe travels over the rivets.
Tank Roof
•  Design
Lap welded single full fillet on top 5.1.5.9
Plate thickness -‐ 3/16" + CA 5.10.2.2

•  FabricaGon
Reasonableness 7.2.5

•  InspecGon OpGons 7.3.7
Gas>ght roof-‐ Air test or Vacuum test
Non-‐gas>ght roof -‐ Visual
Shell-‐to-‐Bo>om Weld
•  This weld and surrounding area is one of the highest stressed parts of the
tanks
•  Weld can fail due to seAlement or corrosion
•  Design 5.1.5.7
Fillet weld both sides of the shell. Weld size -‐ Normally
Not less than the thinner of the parts joined or Table in 5.1.5.7
Not greater than ½ "
•  Inspec>on -‐ Various Op>ons 7.2.4.1
Magne>c Par>cle
Various Penetrants (penetrant or light diesel oil)
Right Angle Vacuum Box
Air Test -‐ Pressure Test between the fillets

Roof-‐to-‐Shell Weld
•  On most Cone Roofs this joint is designed to fail It's called a "frangible
joint“ 5.10.2.6
If the roof-‐to-‐shell weld does not fail then the shell-‐to-‐bo3om weld will fail.
•  Design
Fillet weld size does not exceed 3/16"
The roof slope does not exceed 2" rise in 12" run
Design details per Figure F-‐2 a-‐e
•  Inspec>on 7.3.2.2
Visual
•  Tank Overpressure
The tank pressure may increase by:
1. Blocked or non-‐opera>ng vent
2. Product inflow is greater than vent capacity
3. Internal "poof“
Other
•  Welding 9.2/3/4
Procedures & Welders Qualified ASME Sect IX
Weld ID -‐ All welds except roof and flange-‐to-‐nozzle
Stamp weld every 3 feet, or
Weld map

•  Nameplates 10.1.1
A3ach adjacent to manhole
Le3ers not less than 5/32" high

•  Repads 7.3.4
PneumaGc test at I5psig
Tank Inspec3on
API 653Sec3on 1 Thru 6 & App B

Module Objec3ves
Let’s Inspect & Evaluate
At the end of this module you should know:
•  Scope of API 653
•  Types of tank inspecGons and specific requirements for these inspecGons
•  How to evaluate corrosion pa3erns; generalized, localized, and pilng
•  How to evaluate bo3om se3lement ,

And... much more !!!

Most of 653 is on the closed-‐book por>on of the exam. Included in the open-‐
book por>on of the exam:
1. Calcula>ons (except Corrosion Rates & Intervals)
2. Tables & charts (except Minimum BoAom Thickness)
3. Some details (e.g. design stress -‐ reconstructed tanks)
API 653 -‐ Scope
"What is the purpose of API 653?“

•  To decide Tank Inspec>on(How, When, Where )
•  To repair boAoms, shells , roof
•  To decide altera>on ( reducing height or change in specific gravity )
•  Reconstruc>on Requirements

Defini>ons
Repair: Work needed to Restore tank to a Suitable Safe condi>on (RESTORE)
AlteraGon: Work performed that changes Physical Dimensions (PHYSICAL
CHANGE)
Tank Roof Evalua3on
Verify structural integrity of roof

Minimum roof thickness
•  Average thickness 0.090" in any 100 in2
•  No holes
•  Floa>ng roofs -‐ no holes by next inspec>on
Pipe columns -‐ check for inside corrosion
Other evaluaGon criteria
•  External Floaters -‐ API 650 Appendix C
•  Internal Floaters -‐ API 650 Appendix H
What is the basis for this rule? The minimum average thickness can not be less
than 0.090" in any 100 in2?
An area of 100 in2 is about the size of your shoe! They don't want you to fall
through the roof!
Tank Shell Evalua3on
•  How Corrosion Types are Evaluated v Uniform Corrosion

•  Use tmin calcs from API 653 (with "H-‐1")
Localized Corrosion (LTA)
•  Corrosion Averaging and use tmin calcs from
API 653 (with "H" only)
Pi[ng
•  Evaluate both pit depth & ver>cal length

Defini>ons
LTA: Localized Thin Area (a locally corroded area)
This is a common term that found in API 5 79.
(Fitness for Service)
Uniform Corrosion
The tmin for a Shell Course is:

4.3.3.

This is similar to the I-‐foot formula in API 650, but some differences. This
formula includes an "E", and "S" comes from
API 653 ,
Minimum Shell Calc Notes
1. tmin (minimum thickness) -‐ Based on calc, but can not be less that 0.100 "

2. D & G (Diameter and Specific Gravity) -‐ No changes from API 650

3. H (Liquid Height) -‐ Distance from boAom of course to top of product

4. S (Allowable Stress) -‐ See Table 4-‐1. Based on the course.

5. E (Joint Efficiency) -‐ See Table 4-‐2. Based on tank construc>on code
Note! The tmin for a shell course of an exis>ng tank can be calculated using the
tmin formula in 4.3.3.
This formula looks the same as the tmin formula in API 650. But, the allowable
stresses are higher. This results in a thinner tmin as compared to the API 650 tmin
calcula>on.
API 653 has a lower safety factor.
So here’s the work process: During tank design, the designer
calculates tmin using API 650 and adds corrosion allowance. Then
picks appropriate nominal plate thickness. But, once oil is put into
the tank, you can throw away the designer's tmin and recalculate
using the API 653 formula.
Joint Efficiency – “E”
•  Joint Efficiency is a safety factor based on the joint type & amount of
inspec>on of the welds
•  "E"for welded tanks -‐ See Table 4-‐2
•  E = 1.0 when corroded area is away from welds
•  (Greater of 1”or twice the plate thickness)

Joint Efficiency – “E”
Shell Corrosion Averaging
The tmin for a corroded area is:

4.3.3 . 1.b

This is similar to the 1-‐foot formula in API 650, but there are some differences.
This formula includes "E" and does not have an "H-‐l“. Also "S" comes from API
653

H -‐ Liquid Height

Distance from the BOTTOM OF THE CORRODED AREA to
the top of the product
Minimum Shell Calc Notes!

1. tmin (minimum thickness) -‐ Based on calc, but can not be less that
0.100“
2. D & G (Diameter and Specific Gravity) -‐ No changes from API 650
3. H (Liquid Height) -‐ Distance from boAom of "L " to top of product
4. S (Allowable Stress) -‐ See Table 4-‐1. Based on which course.
5. E (Joint Efficiency) -‐ See Table 4-‐2. Based on tank construc>on code
Welded tanks: E = 1.0 when corroded area is away from the weld by the
greater of I" or twice the plate thickness.
6. LTA can also be evaluated by ASME B&PV Code Sec>on VIII Div. 2
1. Find "t2" -‐ minimum thickness in corroded area

2. Calc Cri>cal Length "L " -‐ the ver>cal limits for averaging
3. Select ver>cal line(s) to measure (may need mul>ple lines)
4. Take equally spaced thickness readings along each linefo,
a distance of "L " (at least 5 readings per line)
5. Average the readings for each line.
6. Determine "t/" -‐ the lowest average thickness of the lines
7. Calculate tmin per API 653 4.3.3.1.b
8. Evalua>on criteria:
a. t, > tmiH + (CR x Interval)
and
b. t2 > 0.60 tmin + (CR x Interval)
Cri3cal Length Notes
1.  "L " is always 3.7 (Dt2 ) 1/2. There is no limit to the horizontal dimension
of the corroded area!

2. "L " can not exceed 40 inches

3. Take a minimum of five equally spaced readings along each line. You can
take more. O|en 5 readings are very far apart! The ver>cal line does not
need to include the "t2 " measurement but generally it is taken at center
and then ver>cal lines are drawn.
Liquid Height Calcs -‐ LTA
•  Product Fill Height -‐ LTA

H = Set/2.6 DG

Hydrotest Fill Height –LTA
H = Set/2.6 D

Formula Differences:
1) No Specific Gravity. For water G= 1.0
2) St is hydrotest allowable stress from Table 4-‐1
These "H's" are from boAom of the corroded area. Opera>ons
needs overall fill height. To determine "H,Mi" add the distance
from tank boAom to the boAom of corroded area.
Shell -‐ Pilng
1. Length Evalua>on
a. In 8" verGcal line, sum length of Pits -‐ "Ps"
b. Acceptance Criteria: Ps ≤ 2"

2 Depth Evalua>on
a) Calculate "trem "; (remaining thickness)
trem = tact -‐ tpit
b) Acceptance Criteria: trem ≥ 0.5 tmin
Other Deteriora3on
•  Shell distorGons -‐ Evaluate Other Flaws
•  Cracks -‐ thoroughly examine
•  Cracks in shell-‐to-‐boAom weld -‐ This is cri>cal and must be repaired
Tank Bo>om Evalua3on
Bo3om Leaks – The tank failures are a3ributed to

Top-‐side corrosion
•  Product
•  Water
•  Sediment
Bo3om-‐side corrosion
•  Pad Materials
•  Debris in pad
•  Ground Water
Se3lement issues
BoAom -‐ Rela>vely thin
BoAom-‐side not visible
Inspec3ng Tank Bo>oms
Special tools have been developed for inspec>ng tank boAoms. Commonly used
today are Magne>c Flux Leakage (MFL) tools. MFL can be used to find both
top-‐side and boAom-‐side corrosion. It works using the same principle as a
Magne>c Par>cle examina>on.
The area being is examined is saturated with magne>c flux. If there is a thin area,
some of the flux "pops out" of the material. The bigger the void, the greater the
amount of flux that "pops out". The scanning machine has a device that
measures the amount of flux that pop's out. MFL can not precisely size the
remaining wall, but can provide a good es>mate. O|en UT follow-‐up is
performed at indica>ons found by MFL.
The MFL tools are very specialized. API 653 Appendix G provides a way to qualify
tank scanning tools and tank scanning operators.
Tank Bo>om Calcula3on
Future Thickness (MRT)

MRT = RT – Or (StPr + UPr)

Future Thickness = Current Lowest Thickness – Future Corrosion Loss
MRT = Minimum Remaining Thickness (future)
RT= Current Remaining Thickness
Or = In-‐Service Interval
StPr = Top-‐side Corrosion Rate
UPr = BoAom-‐side Corrosion Rate
&uture = tcurrent -‐ Iinterval (Rtop-‐side + Rbo>omside)
Table 4.4: Bo>om Plate
Minimum Thickness
Min. Bo3om Thickness Tank Bo3om and
FoundaGon Design
0.100” No means to detect and contain a boAom

leak
0.050” Means to detect and contain a boAom

leak
0.050” Applied tank boAom reinforced lining, >

0.050 “ thick, installed per API 652
Bo>om Evalua3on Notes
1. Current Remaining Thickness (RT) -‐ The lowest boAom thickness AFTER
repairs have been completed.
2. Top-‐side Corrosion Rate (SrPr) = 0 ipy IF top-‐side is coated AND coa>ng life
exceed interval.
3. BoAom-‐side Corrosion Rate (Upr) = 0 ipy IF boAom has effec>ve cathodic
protec>on.
4. BoAom-‐side Corrosion Rate -‐ Assume "linear rate " based on age of tank.
5. Acceptance standard:
MRT > minimum allowed per API 653
a. BoAom away from cri>cal zone -‐ Table 4.4 (either 0.100 " or 0.050")
b. Cri>cal zone -‐ Paragraph 4.4.5.4
c. External floor projec>on -‐ Paragraph 4.4.5.7
Tank Bo>om Evalua3on
The CriGcal Zone -‐ Within 3" of shell

•  This is a higher stressed area
•  Minimum thickness
Smaller of: 1/ 2 tOrig (of bo3om) or 'A tmin (of shell)
But must be> 0.100"
•  External ProjecGon
Minimum thickness: 0.100"
Minimum projec>on: 3/8" (0.375")
•  Rest of Bo3om -‐ Table 4-‐4
Either 0.100" or 0.050"
Annular Plates
* Minimum Thickness
•  Specific Gravity <1.0
API 653 Table 4-‐5
•  Specific Gravity >1.0
API 650 Table 3-‐1
S1* Course Thickness "t“
•  Nominal thickness
"f BoAom Course Stress
Tank Founda3on
•  Calcining (loss of water of hydra>on)

Exposed to high temperature
Causes cracks
•  Chemical AAack
•  Cracks
Hairline cracks -‐ liAle affect on strength
Moisture in cracks
Freeze -‐ swell & propagate crack
Corrodes exposed rebar
•  Anchor Bolts Distor>on
SeAlement or overpressure upli|.
Bri>leness and Toughness
•  Bri3leness: "Separa>on of a solid accompanied by liAle or no macroscopic
plas>c deforma>on. Typically, briAle fracture occurs by rapid crack
propagaGon with less expenditure of energy than for duc>le fracture.
•  Toughness: "The ability of a metal to absorb energy and deform plas>cally
before fracturing. It is usually measured by the energy absorbed in a notch
impact test..
Tank materials must have high enough toughness to resist briAle fracture.
Material Selec3on
•  For new materials used during repairs & alteraGon
•  API 653 "must meet requirements of current applicable std”(That's
generally API 650)
•  API 650 Material SelecGon:
•  Sets the tank Minimum Design Temperature -‐ Fig 4-‐2
15 °F above lowest one-‐day Temperature
•  Groups materials with common toughness. (I-‐VI)
•  Determines when impact tes>ng is required -‐ Fig 4-‐1b
Based on thickness & Group Number
•  Sets acceptance stdsfor impact test -‐ Table 4-‐5b

What Affects Toughness?
1. Material Type -‐ Some materials have higher toughness.

2. Metal Temperature -‐ Generally, the lower the temperature, the lower the
toughness.

3. Metal Thickness -‐ Generally, the thinner the material, the higher the
toughness. This doesn 't appear to make sense, but during fabrica>on,
stresses get "locked into " materials. Thicker materials have more stresses
"locked-‐in " and are also less flexible. This tends to make thicker materials
more briAle.

Past Bri>le Failures
•  All reported bri3le fracture failures have occurred at either:

Hydrotest
First filling in cold weather
Change to lower temperature service
A|er repair or altera>on 5.2.2

Key API 653 Premise:
"Experience shows that once a tank has demonstrated the ability to withstand
the combined effects of maximum liquid level and lowest opera>ng
temperature without failing, the risk of failure due to briAle fracture with
con>nued service is minimal."5.2.2
Bri>le Fracture Evalua3on
•  Evaluate bri3le fracture potenGal when changing service to:
lower temperature
higher specific gravity
•  Also consider impacts of:
Non-‐Code repairs & altera>ons
Tank deteriora>on since original hydrotest 5.2.3
A hydrotest may be used to demonstrate the tank's fitness for the new service
•  Safe to use if any of the following are true:
Tank built to API 650 7th EdiGon (1980) or later and operates in same service
Prior hydrotest and all post-‐hydro repairs met Code
Shell thickness is < 0.500"
Operates at temperature > 60 °F
Actual shell stress is < 7000 psi
Steel meets API 650 toughness requirements
Steel meets API 653 Figure 5.2
Tank full at lowest one-‐day temperature
Bri>les Fracture Evalua3on
Internal Alterna3ves
Robo>cs -‐ If only boAom thickness measurements are needed (6.4.1.2)
Risked Based Inspec>on (RBI) (6.4.2.4)
•  Factors -‐ Likelihood & Consequence
•  Can be used to exceed 20 year max. on Internal
•  Can be used to lower Table 6-‐1 minimums
External access to BoAom (6.5)
Scheduled Inspec3ons
Inspec:on Inspec:on Interval Inspector Key Factor
type Qualifica:on
Rou3ne In Service Monthly Operator Check from
Type ground Gross
Problems
External Lesser of 5Years Authorized Not described See
or1/4 Life Inspector Appendix C
of shell
Shell UT New/Unknown CR:5 Code unclear Shell Thickness
Years Known CR: 15 One who is
Years or ½ Life of competent
Shell
Internal New/Unknown CR: Authorized The bo>om
10 Years Known CR: Inspector
Lesser then 20 Years
or full bo>om
–life
Se>lement Surveys
•  SeAlement surveys should periodically be done

The interval is not specified
Use judgment based on soil condi>ons & experience
•  External Measurements
Number of readings: N = D/10
Equally spaced with a minimum of 8 readings
Maximum spacing between readings 32 feet
•  Internal Measurements
At shell, use same spacing as external measurements
Maximum internal spacing 10'

Excessive seAlement increases the stress in the boAom-‐to-‐shell weld.
Excessive seAlement should be corrected by re-‐leveling the tank. This is
expensive and should not be done unless absolutely necessary
Types of Se>lement
Uniform -‐ BoAom stays flat
Minor problems
Pipe alignment
Rigid or Planar Tilt -‐ BoAom is flat but >lted
More problems
Pipe alignment
FloaGng roof
Tank gauge tables
Out-‐of-‐Plane-‐ BoAom is not flat .
Also called "Differen>al“
Most common type
Poten>al Major Problem
Same as Rigid Tilt
Plus overstress the Bo3om-‐to-‐Shell weld
Acceptance Criteria
•  Out-‐of-‐Plane Se3lement
–  Use Cosine Curve to determine deflec>on "S"
–  Use formulas in B.2.2.4

•  Bo3om Se3lement -‐ Depression or Bulges
–  Use formula in B.3.3
BB = 0.3 7R

"R" is in feet
" B" is in inches
Acceptance Criteria

Example: EvaluaGng a Bo3om Depression
Depression Diameter = 10'(Radius is 5')
B = 0.37R = 0.37x5 = 1.85" (Answer is in inches!)

Fig B 10 is a graphic representa>on of the formula.

Note! Most companies have a computer program to calculate acceptance
limits for Out-‐of-‐Plane SeAlement.
Edge Se>lement
•  Edge Se3lement EvaluaGon

Fig. B.I 1 SeAlement is parallel to boAom fillet welds
Fig. B. 12 SeAlement is perpendicular to boAom fillet welds
Edge Se>lement Evalua3on

Note! Many tank floors are
installed with a slope.
Edge seAlement should be
measured from the
original slope. See Figure
B-‐6!
Se>lement Example

Note! What if the seAlement is somewhere between parallel and
perpendicular? The engineer can evaluate using the formula in B.3.4.4. If
you want to evaluate, without using that complex formula, just use Chart
B-‐ll Parallel to the Shell. It is more conserva>ve than the formula. If it
meets B-‐ll criteria, then it will also pass the B3.4.4 formula. If it does not
pass the B-‐ll chart, then see the engineer.
Repairs, Altera>ons &
Reconstruc>on
API 653 -‐ Sec>ons 7 thru 13 API 653
Cer>fica>on
Mobile Objec3ves
In this module you will learn specific requirements for Repairs, Altera>ons &
Reconstruc>on.
•  Materials that can be used
•  Design
•  Fabrica>on & Welding
•  NDE & Tes>ng
•  Record keeping

Defini>ons
Repair: Work necessary to RESTORE a tank to a condi>on SUITABLE for SAFE
opera>on.
AlteraGon: PHYSICAL CHANGE. Work performed that changes the physical
dimensions of a tank
Reconstruc3on Materials
•  Structural
Reused -‐ ASTMA 7 as a minimum
New -‐ ASTMA36 as a minimum
•  Flanges
Meet As-‐built standard
•  Fasteners/BolGng
Current applicable standard
•  Roofs, Bo3om Plate/Wind girders
Check for excessive corrosion
•  As-‐Built Standard?
•  This is the original construc>on standard, (see 3.2)
Which Code?
•  As-‐built (original construc>on) Standard

Exis>ng Welds
Exis>ng Penetra>ons
Flange Material
Roof Design

•  Current Applicable Standard
New Weld Joint Details
Replacement/New Penetra>ons
Wind girder Design
All New Materials
Fasteners Material
Shell Design
•  Shell Welds
BuA Welds with complete Penetra>on/Fusion
•  Allowable Stresses
Per API 650
If not listed; Lesser of: 2Y/3 & 2T/5 (design)
Lesser of: 3Y/4& 3T/7 (hydro)
•  Thickness Readings must be taken within 180
Days
•  Joint Efficiency
New Welds -‐ Based on Design & Inspec>on
Exis>ng Welds -‐ Original Standard
Shell Replacement Plates
•  Plate Thickness
–  ≥to tnominal of thicker neighbor

•  Various Plate Shape
–  Circular
–  Rectangular
–  "Dog-‐house“

•  Corners
–  Rounded
–  Unless corner stops at an exis>ng horizontal weld
Shell Replacement Plates
•  Plate Size Fig. 9-‐1

–  Based on plate thickness
–  Minimum size: 12“
•  Circular shape
–  Minimum radius: 6 “

•  Exis>ng horizontals
–  Cut at least 12" beyond new ver>cal welds
Shell Lap Patches
•  Three applicaGons

1. Cover up holes (9.3.2)
Weld inside & outside

2. Reinforce LTA 's (9.3.3)
Similar to repad

3. Repair small leaks (9.3.4)
Watch out -‐ trapped liquids!
Shell Repairs Op3ons
•  Grind out 9.4
–  O|en done for crack
–  Adequate remaining thickness
–  Smooth contour
•  Grind out & weld buildup 9.4
–  Smooth contour
•  Replacement plate 9.2
–  BuA welded
–  Complete Penetra>on
–  Complete Fusion
–  Weld Spacing Fig. 9-‐1
•  Greater spacing from ver>cal welds
•  Lap patch 9.3
–  Many restric>ons
Shell Repairs Op3ons
Exis3ng Weld Defects
•  Cracks, Lack of Fusion, Rejectable Slag
Evaluate if it needs repaired
If so, grind out completely
•  Excessive Reinforcement -‐ Judgment
•  Undercut -‐ Judgment
•  Corrosion at Weld -‐ Repair by welding if addiGonal thickness is required
•  Arc Strikes – Repair
•  Why repair Arc Strikes?
•  The cool-‐down rate of molten metal significantly affects the mechanical
proper>es of a metal, i.e. Strength, toughness, etc. Steels that cool down
rapidly can form Martensite (a metal phase that is very hard and very briAle.)
•  When an arc strike occurs, a very small bit of molten metal is deposited on the
base metal. This small amount of molten metal cools down very rapidly
causing a hard briAle spot. This is an ideal place for a crack to ini>ate.
•  Since the hard briAle metal is not very deep, arc strikes can be repaired by
removing a few mils from the metal surface.
Penetra3ons
•  Adding Reinforcement Plates to exis>ng

API 650
API 653 Fig. 9.3 & 9.4

•  Repairs API 650
•  New Nozzles API 650

Nozzle Spacing
•  If replacement bo3om causes nozzles to be too close to bo3om
•  Trim the boAom of the repad
•  Replace the repad
•  • Thicker repad, but smaller diameter
•  3. Raise the nozzle assembly -‐ tombstone shape Fig.9-‐5
Why Nozzle Spacing?
Nozzles are actually "holes " in the shell. The code does not want a "hole "
too close to the boAom-‐to-‐shell weld.
API 650 specifies minimum distances between:
Nozzles and boAoms
•  Repads and boAoms
•  The boAom of the shell is rela>vely highly stressed. And the area around a
nozzle is rela>vely higher stressed. The code does not want these higher
stressed areas to overlap.
Bo>om Repairs – Cri3cal Zone
•  The "Cri>cal Zone"
High stressed boAom area
•  Welding 9.10.1.2.1
Widely scaAer pits
2" in 8" length
> 0.100"a‚illetweld
Grind flush and examine Cracks
Shell-‐to-‐boAom weld
•  Lap Patches 9.10.1.1.e
Permanent repairs
Many limita>ons Fig.9-‐9
•  Replace boAom plates
Required 'd if other op>ons
are not acceptable
Bo>om Repairs – Cri3cal Zone
Defini>on:
Cri>cal Zone: Por>on of tank boAom within 3 inch of the inside edge of the
shell.
Measured radially inward.
Bo>om Repairs – Non Cri3cal Zone
•  Weld overlay
Size not limited
Remove surface irregulari>es before welding

•  Lap patches (permanent repairs)
Not as many limita>ons as in cri>cal zone
Can over-‐lap an exis>ng patch
Can not use if excessive seAlement

•  Non-‐welded patches
Do not "add corrosion allowance ", but may
reduce corrosion rate 4.4.5.6
Roofs
•  Fixed Roofs
Replacement plates: 3/16"+ CA
Supports: Don't exceed API 650 stress levels I
Roof-‐to-‐shell joint: Meet API 650 Floa>ng Roofs
•  Floa>ng Roofs
External: Any method acceptable
Internal: Original construcGon std or API 650
Pontoon Repairs: Reweld or lap patch
Tank Seals Repairs: Primary & Secondary
Not much is men>on since seals are regulated by
environmental groups and seal types vary significantly
between vendors
Hot Taps
•  Nozzle size-‐to-‐shell thickness limita>ons Table 9-‐1
•  New Nozzle Loca>on -‐ In tank shell below liquid level
•  Not allowed if welding causes environmental cracking
•  Procedure per API 2201 & Qualified Operator
•  Minimum of 4 UT readings at nozzle loca>on
•  Nozzle thickness -‐ Pipe Extra Strong
•  During welding -‐ Liquid level at least 3 feet above hot tap
•  Welds: Full penetra>on Nozzle-‐to-‐Shell & Pad-‐to-‐ Nozzle
•  Weld Electrode -‐ Low Hydrogen Electrode
•  Test Re-‐pad -‐15 psig pneuma>c test
•  Test Nozzle -‐ pressure test prior to hot tapping
•  Pt = 0.65 x H x G
Hot Taps – Nozzle Spacing
This table applies if any of the following apply:
1. Shell plate has recognized toughness (e.g. meets API 650 requirements or API
653 Figure 5-‐1)
2. Maximum thickness is ½”.

If those condi>ons are not met, then the hot tap is limited to:
1. Maximum size is 4 NPS.
2. During the hot tap the shell material shall be above the minimum design metal
temperature.
3. The nozzle shall be reinforced
4. During the hot tap, the liquid height shall be limited so the shell stress (at hot
tap loca>on) is not over 7000 psi.
Formula to determine the minimum spacing between hot tap and any
adjacent nozzles:
Tank Dismantling
•  Cu[ng the Tank
–  Any Size Pieces
•  Shell Cu[ng Op>ons
–  Shells < ½ " thick can be cut thru welds
–  Shells > than ½ ", Deseam welds including HAZ
HAZ -‐ lesser of ½ " weld width or 1/4“
–  Cut at least 6"from welds
•  BoAom Cu[ng Op>ons
–  Deseam welds
–  Cut at least 2 " away from welds
•  Roof Cu[ng Op>ons
–  Same as Floor
•  Shell-‐to-‐BoAont Weld
–  Various Op>ons
Tank Dismantling
Shell to BoAom Weld Op>ons
1. Cut at "A-‐A " & "B-‐B " if reusing the boAom and not reusing the shell-‐to-‐
boAom weld
2. Cut at "C-‐C" if reusing the boAom-‐to-‐shell weld.
3. Cut at "B-‐B" if reusing an annular ring, or not reusing the boAom

Iden>fying Pieces -‐ Without ID this is a problem
1. Shell, boAom & roof plates should be marked before cu[ng.
2. A drawing showing piece iden>fica>on is helpful.
3. For shell plates use 2 sets of match marks at boAom & top edges
Reconstruc3on -‐ Welding
•  Weld Spacing
Don't align shell ver>cal welds with boAom welds
Spacing of welds per Figure 9-‐1

•  Temperature Limits when Welding
If, Temp < 0 °F, then NO Welding
If, 0°F< Temp < 32 °F, then warm base metal to 140 °F (hand warm)
If, Temp > 32 °F, then Weld

•  Other Climate Condi>ons
If wet, then NO Welding
If raining or snowing on surface, then NO Welding
If high winds, then NO Welding (unless Shielded)
•  Thickness Limits
If, t>l", then warm base to 140 °F.
If,t> 1-‐1/2", then preheat to 200 °F.

•  Underculng Limits
Ver>cal Welds 1/64"
Horizontal Welds 1/32“

•  Bo3om Welding Sequence
Weld shell-‐to-‐boAom joint first
Sequence of floor welding to prevent distor>on
•  Tack Welds
Remove all ver>cal tacks if joint weld is a manual process.
All tacks to be made with a qualified procedure.
All tacks le| in, must be made by qualified welder.
•  Low Hydrogen Electrode
All manual welds for Group I-‐III materials if t > 1/2"
All manual welds for Group IV -‐ VI material welds
•  Misalignment tolerances -‐ See below
•  Reinforcement Limits -‐ Table 10-‐1
Limits of misalignment and Over projec>on
Plate Thickness Ver:cal Welds Horizontal Welds
t < 5/16" 1/16" 1/16"
t<5/8" 1/16" 0.2t
t>5/8" Lesser of: O.lt or 1/8”
1/8”
Welding Misc.
•  ASMESectlX
WPS qualifica>on
Welders qualifica>on
•  Weldability of steel shall be verified
Known material that is weldable
Test coupon for PQR taken from actual plate
•  Weld Iden>fica>on
Each welder assigned iden>fica>on mark
Welder stamps adjacent to the weld, every 3 feet.
Or use a weld map
No ID required
Roof plate welds
Flange-‐to-‐nozzle-‐neck welds
NDE General
•  Procedures: ASME SecGon V

•  Acceptance Criteria: ASME SecGon Via
•  Personnel
RT& UT -‐ ASNT, SNT-‐TC-‐1A
MT&PT
Competent in technique used
Vision -‐ Jaeger 2, contrast colors, annual exam

Note!!! API Sec>on 12 lists NDE methods by field ac>vity (grinding, hot tap,
new plate, etc.) Appendix F lists all field ac>vi>es by NDE method (UT, RT,
etc.) When studying which NDE methods are applicable, it is probably
easier to memorize using Appendix F
MT & PT Methods
•  Cavi>es from grinding and gouging

Nozzle fillet welds;
nozzle-‐to-‐shell
shell-‐to-‐repad
repad-‐to-‐nozzle
•  Complete welds of stress relieved assemblies, a|er stress relief
•  AAachment welds to Group IV-‐VI materials Shellplates thicker than
1" (root & final) 1

See Appendix F for other NDE methods
Tank Bo>oms
•  New Shell-‐to-‐Bo3om Welds

1st weld pass -‐ light diesel oil (4 hour min.)
Complete welds
Right-‐angle vacuum box
Light diesel oil
Air test (ISpsi) space between the both fillets

•  New Bo3om Welds
Vacuum Box
Tracer Gas
Reverse Hydro
NDE -‐ Radiography
•  Follow API 650 PLUS:
New plate-‐to-‐new plate: no addiGon required
New plate-‐to-‐exisGng plate
Verts -‐ one RTon each vert
Horizontals • one RT each 50'
Intersec>ons -‐ RT all
•  New welds in reconstrucGon
25% of intersec>ons of new-‐to-‐old welds
•  Replacement insert plates
Circular-‐I RT
Rectangular-‐ 6RT(1 vert, 1 horizontal, 4 corners) & all intersec>ons between
new-‐to-‐old welds
If over 1"thick -‐100%
Inserts for new Nozzles -‐ 100%
Other RT Data
1. Minimum diagnos>c length ofRT: 6"
2. Exis>ng welds evaluated per construc>on std.
3. Repair work marked with "R ". "Repair work" are welds that had a weld
defect and were repaired. This "repair " does not mean a welding
associated with a tank "repair ". Are you confused?
4. The film should iden>fy the welder. Or a weld may can be used.
Hydrosta3c Tes3ng
•  A hydrotest is required for all:
Reconstructed Tanks (never exempted)
Tanks with Major Repairs & Altera>ons (unless exempted)
•  Held for 24 hours
•  Hydrotest Exemp>ons
Engineer review, and Tank owner authorizes (in wri>ng), and Meet API's
specific requirements for the component Or, a fitness-‐for-‐service evalua>on
supports exemp>on

Defini>on Major Repair & AlteraGon: Not clearly defined, but includes all the
following:
1. Shell nozzles greater than 12 NPS (in liquid por>on of tank).
2. BoAom penetra>on within 12 inches of the shell.
3. Removal/replacement of a shell plate beneath design liquid level.
4. Removal/replacement of an annular plate with a dimension exceeding 12".
5. Removal/replacement of over 12 " of a shell ver>cal weld.
6. Removal/replacement of over 12 " of a annular plate radial weld.
7. Installa>on of a new boAom if the new boAom includes: an annular plate,
or welding to an exis>ng boAom in
the cri>cal zone.
8. Removal/replacement of any part of the shell-‐to-‐boAom weld.
9. Jacking (leveling) a tank shell
Hydrosta3c Tes3ng
•  Perform Se3lement Survey

Before, during, and a|er filling
Acceptance criteria -‐ API 653 Appendix B

•  Number of Survey points
N = D/l 0 (maximum spacing 32')
Marking & Recordkeeping
•  Major Types of Records (6.8)

Construc>on Records
Inspec>on Records
Repair & Altera>on Records
•  Specific Records -‐ Repair, ReconstrucGon
Calcula>ons
Drawings
Inspec>on & NDE
Radiographs (retained I year)
-‐ Etc.
Reconstruc3on Records
•  AddiGonal Nameplate
AAach next to exis>ng
5/32" leAers (minimum)
Common Sense Data -‐ Tank #, Material, Year, "G", "H", etc.
•  Two CerGficaGons
Reconstruc>on was designed to API 653
Tank was Reconstructed to API 653

Defini>on
CerGficaGon: A form must be signed by someone represen>ng the
appropriate company or organiza>on.
Cathodic ProtecGon & Linings
API 651 -‐ CPfor Tanks API 652 -‐

Linings for Tank Bo3oms
CP Objec3ves
•  At the end of this module you should: Know how a corrosion cell works
•  Know how Cathodic Protec>on Systems func>on
•  Understand advantages & disadvantages of Cathodic Protec>on (CP)
Systems
•  Know opera>onal & inspec>on requirements of CP Systems

Purpose of API 651:
•  Present procedures and prac>ces for achieving effec>ve corrosion control
to exis>ng and new storage tank boAoms through the use of cathodic
protec>on.
Corrosion Cell
•  Component of a Corrosion Cell
Anode
Cathode
Metallic path -‐ connects anode & cathode
Electrolyte

•  Defini>ons:
•  Anode -‐ the electrode at which oxida>on (corrosion) occurs.
•  Remember: "A Node Corrodes!"
•  Cathode -‐ the electrode at which a reduc>on reac>on occurs. No corrosion
occurs at this spot. The anode protects the cathode.
•  Metallic Path -‐ connects the anode and the cathode.
•  Electrolyte -‐for tanks, this is the soil or liquid adjacent to and in contact with
the boAom of an aboveground tank. It contains both nega>vely charged ions
and posi>vely charged ions.
Corrosion Cell is an Electrical Circuit
Corrosion Cell
•  Dissimilar materials -‐ See Galvanic Series Differences between: weld,
HAZ, plate
•  Different oxygen concentraGons -‐ clay and debris
•  Soil characterisGcs -‐ moisture, ph, etc.

Cathodic Protec3on (CP)
•  CP provides an anode thus protecGng the anode -‐ the tank bo3om

•  Two Types
Galvanic (sacrificial anode)
Impressed current
Galvanic CP
Anodes are placed around or under tank
Anodes are usually magnesium or zinc
A weak ba3ery, so limited current flow

Advantages:
•  No external power supply required Easy to install
•  Low cost for small diameter tanks Rarely have problems with stray
currents Less frequent monitoring required
Disadvantages:
•  Limited driving poten>al, low current output Limited to low-‐resis>vity soils
Imprac>cal for large tanks Difficult to protect center of tank
Impressed Current CP
•  Electrical current supplied from A.C. source
•  Rec>fier changes A.C. to D.C. current
•  Power can be adjusted to increase current flow
•  Anodes can be place very deep so current covers center of tank

Advantages:
Large driving poten>al available Large structure can be protected Output
current can be varied Can be used with almost any soil resis>vity
Disadvantages:
•  Can have problems with stray currents
•  Power outage causes loss of protec>on
•  Higher maintenance and opera>ng costs
•  Higher installa>on cost
•  Safety issues regarding the use of an external power source in the area
•  More frequent monitoring required
Opera3onal Issues
•  Stray currents
•  Desired current density is 1-‐2 milliamps/|2
•  Desired poten>al (voltage) of at least 850 m V
•  If leads are reversed the tank boAom becomes the anode
•  Polariza>on may take months to achieve once system is ac>vated
Inspec3on Issues
•  Impressed Current System -‐ Quick Check
Every 2 months
System is opera>onal & func>oning, e.g. the lights are on
•  Impressed Current System -‐ Thorough Check
Annually
A thorough electrical check of equipment
•  Cathodic Protec>on Survey
Annually
Check poten>al (voltage) between tank and soil, etc
Linings Objec3ves
At the end of this module you should:

•  Know the types of Lining Systems
•  Understand advantages & disadvantages of Lining Systems
•  Know the installaGon requirements of Lining Systems
•  Know the inspecGon requirements of new Lining Systems

Purpose of API 652:
•  Present prac>ces for achieving effec>ve corrosion control to exis>ng and
new storage tank boAoms by applica>on of boAom linings. Serves only as
a guide.
Corrosion Mechanics
•  Chemical corrosion
•  Concentra>on cell corrosion
Occurs when a surface deposit, mill scale, or crevice creates a localized
area of lower oxygen
•  Galvanic cell corrosion
•  Cathode and Anode Corrosion caused by sulfate-‐reducing bacteria
•  Colonies of bacteria
•  Erosion corrosion
Highly localized metal loss Abrasive par>cles
Thin-‐Film Lining
•  20 mils or less in thickness

•  Apply 2-‐3 coats for thin-‐film systems
•  Less expensive than thick-‐film linings
Easier to apply than thick-‐film linings
•  O€en applied to new bo3oms

Disadvantages: Difficult to apply to corroded boAoms or uneven surfaces
Thick-‐Film Lining
•  Greater than 20 mils in thickness v Apply 1-‐4 coats for thick-‐film systems
•  35-‐55 mil thick linings should be used for tank where only internal
corrosion is expected
•  80-‐120 mil thick linings should be used for tanks where internal and
external corrosion is expected
•  Less suscep>ble to mechanical damage
•  Not as sensi>ve to pi[ng or surface irregulari>es during installa>on

Disadvantages:
•  More difficult to inspect the steel boAom a|er applica>on More expensive
than thin-‐film Harder to install than thin-‐film More prone to cracking
Lining Installa3on
•  Surface prepara>on is the most cri>cal part of the lining opera>on
•  Abrasive blas>ng should extend several inches beyond the area to be
coated
•  All sharp edges and protrusions should be ground smooth
•  Abrasive blas>ng should not be performed when the steel surface
temperature is less than 5°F above the dew point or if the rela>ve
humidity is greater than 80%
Lining Installa3on
•  Surface roughness required is 1.5-‐4 mils
•  and increases with the thickness of the lining
•  Surface finish must "white" or "near-‐white“
•  abrasive blast cleaned
•  Coa>ng should be installed when the temperature is at least 5°F above the
dew point and the rela>ve humidity be below than 80%
Inspec3on
•  All inspectors should be NACE cer>fied or persons who have demonstrated
a thorough knowledge of coa>ng and lining prac>ces
•  Follow inspec>on procedures of NACE RP0288
•  Take wet film thickness measurement
•  Take dry film thickness measurement
•  Determine the coa>ng hardness using the appropriate procedures
•  "Holiday " test linings

Thick-‐film -‐ high voltage detector
Thin-‐film -‐ low voltage detector
ASME B & PV Sec3on V
Module Objec3ves
•  At the end of this module you should know:

•  The purpose of Sec>on V
•  How Sec>on V is organized
•  Specific NDE Terms
•  Know how to quickly find exam answers in
Ar>cle 2 -‐ "RT“
Ar>cle 6 -‐ "PT"
Ar>cle 7 -‐ "MT"
Ar>cle 23 -‐ 797 "UT"
The Codes Purpose
•  Sec>on V sets requirements to assure that a

"quality" NDE examina>on is conducted
Guidance on NDE method
Limits placed on NDE method
Acceptance Criteria for EvaluaGng NDE
Exam
DocumentaGon requirements
•  It does not establish:
The Acceptance Criteria for a weld or
component
Qualifica>ons for the those performing the NDE
Examina>on
Organiza3on of Code
•  Two major Subsec>ons

SubsecGon A: Provides guidance for each Method
SubsecGon B: Non mandatory pracGces

•  Subsec>on A -‐ NDE Ar>cles
Scope & General
Equipment
CalibraGon
ExaminaGon
EvaluaGon
DocumentaGon
Ar3cle 2 -‐ Radiography
Our focus will primarily be on Radiography. There a number of concepts you
need to know:
•  Basic R T Principles
•  Examina>on technique (single or double wall)
•  Viewing mode (single or double wall)
•  Selec>on, Placement & Evalua>on of the IQl
•  BackscaAer Preven>on & Evalua>ons
•  Film Density Evalua>ons
•  Film Iden>fica>on
•  Geometric Unsharpness
Radiography RT
•  Principles of RadiaGon
Radia>on penetrates maAer
Radia>on that strikes film, exposes the film
When developed, the more "exposed", the darker the film
"Mass " of object absorbs or reflects some of the radia>on.
Factors of Mass
Thickness
Material Density

Gamma Rays or X rays Developed RT film
How Radiography Works
1. The film becomes exposed when RTrays (gamma rays) strike the film.
2. The more exposed the film, the darker the image appears on the film.
3. The "mass " of the component determines how much radia>on "gets
through " the component.
4. As the "mass " increases, fewer rays get through. The radia>on is absorbed
or reflected2.
5. The "mass " of a component, is based on the density and the thickness of
the component. So the thinner the component, more rays expose the film,
and the image on the RTis darker
RT Setup Technique
•  Single-‐wall Technique
Radia3on only passes through 1 wall (T-‐271.1)
This is a preferred method (T-‐271)
Must have access to both sides of the part
With a single exposure, can RT with a single film or with mul3ple
film -‐ a 'panoramic “
•  Double-‐wall Technique
Radia3on passes through 2 walls (T-‐271.2)
Used only when access is not available to both sides of the part
RT Setup Teqncique
•  DWTech -‐ Single Wall Viewing

Source is placed on one side of pipe, and the film is
wrapped around other
"Blow away " the wall where the source is placed
A minimum of 3 exposures -‐120 degrees apart

•  DW Tech -‐ Double Wall Viewing
"Ellip>cal shot" which is similar to a "Profile RT"
Source is placed away from pipe, and film is le| flat.
Only for outside diameters < 3-‐1/2 "
Requires 2 exposures 90 degrees offset
Penetrameters -‐ IQIs
•  The funcGon of the Penetrameter
It's how the sensi>vity ofRT is validated
If the "essen>al" hole/wire can be seen, then any discon>nuity the same
size or greater should be visible in the RT
•  Penetrameter Types (T-‐233)
Hole-‐type -‐ small plate with 3 holes (Table T-‐233.1)
Wire-‐type -‐ plas>c holder with 6 sized wires (Table T-‐233.2)
IQIs Size & Number
•  Penetrameter Size
Use Table T-‐276 to select IQI
Watch out-‐-‐-‐
Source side vs. Film side
Hole Type vs. Wire type

•  Number of Penetrameters
(T-‐277.2)
one per film, except...
for panoramic shots –
3 IQI's placed 120
degrees apart
Back Sca>er
•  Backsca3er definiGon
Radia>on bounces off an obstruc>on and strikes the back-‐side of the film.
(Yes this exposes the film!)
BackscaAer will decrease the RT quality

•  How to handle (T-‐223)
If in a congested area, most techs place a lead screen on the back of the
film to prevent backscaAer
Place a lead leAer "B" on the back of the film
A light image of a "B" on the RT indicates
backscaAer
RT Markings
•  RT IdenGficaGon -‐ Each RT marked: (T-‐224)

Contract
Weld Number
Manufacturer's Name or Symbol
Date

•  LocaGon Markings are used to idenGfy
specific locaGons on a specific weld (T-‐275)
Marked on Weld
Marked on Film
Film Evalua3on
•  Previously we have focused on performing the RT examinaGon, now it's
Gme to evaluated the RTfilm. The evaluaGon includes reviewing:
Film density
IQI (Penetrameter)
BackscaAer
Geometric Unsharpness
Other
There are two primary steps in performing Film Interpreta>on.
1. Evaluate the Film Quality
2. Evaluate the Weld (Area of Interest) Quality
This module will cover the first step -‐ Film Quality
Note! Many inspectors miss this step. They go directly to Step Two. But... if
the film quality does not meet the acceptance criteria, defects will be
missed!
Evalua3on Film Density
Film Density is the darkness of the film, Density is measured with either:
Densitometer (most accurate way!) (T-‐225)
Calibrated step wedge film (T-‐225)
Density acceptance standards
For Gamma Ray, IQI & Aol -‐ 2.0 to 4.0 (T-‐282.1)
Aol is within -‐15% to +30% of the IQI (T-‐282.2)
Film Density is the darkness of the film. It is based on how much light passes through a film.
High film density is dark and Low film density is light
What is the technical meaning of the density numbers?
Density Amount of LightPasses Through Film
1.0 10%
2.0 1%
3.0 0.1%
4.0 0.01%
Why are there density lmits?
1) Film too dark or too light can miss defects?
2) Since the IQI is used to determine the sensi>vity of the RT, the density of the IQI and
weld should be similar!
Evalua3on IQI
•  Check IQI Placement

Hole-‐type IQI -‐ adjacent to weld or across the weld
Wire-‐type IQI -‐ perpendicular across the weld

•  Acceptance Standards
Correct IQI used (Table T-‐276)
Hole-‐type IQIMust
see 2T hole (T-‐283 & Table T-‐276)
If shim is used, must see 3 edges of IQI (T-‐277.3)
Wire-‐type IQI -‐ Must see designated wire (T-‐283)
Lead leAer "F" used for film side IQIs
Evalua3on of Backsca>er
•  Backsca3er definiGon
Radia>on bounces off of obstruc>ons and strikes the back-‐side of the film.
(Yes this exposes the film!)
BackscaAer will decrease the RT quality

•  Backsca3er's acceptance standard a-‐284)
Rejectable film -‐ A light "B " appearing in a dark area
Acceptable film -‐ A dark "B " appearing in a light area
Evalua3on Geometric Unsharpness
•  Geometric Unsharpness is the shadow that can be seen around the image
edges.
•  Factors affec>ng Unsharpness include:
Diameter of the RT Source “F”
Source to Object distance “D”
Object to Film distance “d”
•  Unsharpness is usually not an issue with weld quality shots!
•  Acceptance Criteria (T-‐28S)
Other NDE Methods
•  The other NDE Ar>cles are organized similarly to RT.

Equipment... Calibra>on ... Examina>on ... Evalua>on
Documenta>on. Most of the terms will be familiar.
•  Ultrasonics -‐ ArGcle 23 (SE-‐797)
•  Liquid Penetrant -‐ ArGcle 6
•  MagneGc ParGcle -‐ ArGcle 7
Quality Welds
ASME B & PV Sec3on IX

Module Objec3ves
•  At the end of this module you should know:

The purpose of SecGon IX
How SecGon IX is organized
Specific SecGon IX terms; posiGons, SMTS,
How to evaluate a WPQ; welder's papers
How to evaluate a WPS/PQR; weld procedure

•  WPQ -‐ Welder Performance Qualifica>on
•  WPS -‐ Weld Procedure Specifica>on
•  PQR -‐ Procedure Qualifica>on Record

•  "Two "P's" with a Electrode/Rod"
Performance -‐ Welder Skill
Procedure –ProperGes of Weldment
Sec3on IX Qualifica3on
During qualifica>on tes>ng (either welder or procedure), a test weld is
conducted. Sec>on IX specifies:
•  Specific Variables included in the test weld
Welder Qualifica>on -‐ Skill issues (Mtls, thickness, posi>on, etc.)
Procedure Qualifica>on -‐ Metallurgical issues (Mtls, PWHT, etc.)
•  Specific Examina>ons conducted on the completed test weld
Examina>ons for Welder vs. Procedure -‐ Different examina>ons
Type of Exams -‐ Tension Test, Bend Test, RT & Visual
•  The Acceptance Criteria for examina>ons
•  The Limits Qualified -‐ Based on the test weld variables
Passing a qualifica>on test does NOT qualify a welder or procedure for all
Produc>on welds.
E.g. Welder's test coupon -‐ Flat Posi>on. If the test weld passes the exams,
the welder is only qualified for Flat produc>on welds.
Test Posis3ons
Test PosiGons are used during the Welder's Qualifica>on tes>ng. The test posi>on
is indicated by a designa>on like the 3-‐G posi>on. Produc>on welds are NOT
designated by this numbering system.
Component -‐ either Plate or Pipe
Orienta>on (I, 2,3,4...)
From simple to complex, e.g. "1" is a Flat orienta>on
Groove (G) or Fillet (F)
Welder Illustrates the PosiGons "Ahh,,Ahh2,Ahh3,andAhh 4

See QW-‐461.5 for an illustra>on of the different posi>ons
Sec3on IX Tes3ng
•  Tension Test -‐ strength of weld/HAZ-‐ Mandatory for Welding Procedure
Pulls the specimen apart
•  Bend Tests -‐ "Soundness" of weld-‐ Mandatory for Welding Procedure
and “OR” for Welder Performance
Take a specimen & make a "horseshoe “
•  Visual-‐ Mandatory for Welder Performance
Surface weld defects-‐
•  Radiography -‐ “OR” for Welder Performance
Internal weld defects
Note! These tests and their acceptance criteria are used only when qualifying
a welder or a weld procedure. These acceptance standards are NOT used
to evaluate a fabrica>on weld or a repair weld.
Fabrica>on and repair acceptance standards are found in the fabrica>on and
repair Codes!
Welder Qualifica3on -‐ Other
•  ExpiraGon of QualificaGon QW-‐322J

Welder has not used the Process for 6 months
Reason to ques>on welder's ability
•  Fail a QualificaGon Test QW-‐32U/2/3

Retest using same test -‐ Flunked bends, then must pass bends -‐ can't
subs>tute RT
Do twice as much -‐ Originally 6" weld tested, now have to pass 12 " weld
Welder Qualifica3on – The
WPQ
The WPQ (welder‘s papers) records:
1. Welder data -‐ Name, Stamp #
2. "Actual Values" -‐ Data about the Test Weld Process Used, Weld Procedure
Used Essen>al Variables (thickness, posi>on, etc.)
3. Examina>on Data Type of tests performed, & the results -‐ pass vs. fail
4. Ranges Qualified" -‐ Limits on Field Welds
5. Cer>fica>on -‐ Authorizing Signature
Thank You

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Tank

2) Two Major Welds

API 650 is primarily organized by fabrica>on sequence.

API 650 allows speciﬁc materials 4.2.1.1

• Min. New Thickness -­‐6 mm (0.236") 5.4.1

New Thickness -­‐ Pick largest of the following:

• Cu[ng & Rolling Plates 6.1.2/3

NDE Technician Qualiﬁca>on

• Other Weld InspecGon

API 653Sec3on 1 Thru 6 & App B

"What is the purpose of API 653?“

Verify structural integrity of roof

• How Corrosion Types are Evaluated v Uniform Corrosion

The tmin for a Shell Course is:

• "E"for welded tanks -­‐ See Table 4-­‐2

• E = 1.0 when corroded area is away from welds

• (Greater of 1”or twice the plate thickness)

The tmin for a corroded area is:

Minimum Shell Calc Notes!

1. Find "t2" -­‐ minimum thickness in corroded area

• Product Fill Height -­‐ LTA

• Shell distorGons -­‐ Evaluate Other Flaws

• Cracks -­‐ thoroughly examine

Bo3om Leaks – The tank failures are a3ributed to

Future Thickness (MRT)

0.100” No means to detect and contain a boAom

0.050” Means to detect and contain a boAom

0.050” Applied tank boAom reinforced lining, >

The CriGcal Zone -­‐ Within 3" of shell

• Calcining (loss of water of hydra>on)

• All reported bri3le fracture failures have occurred at either:

• SeAlement surveys should periodically be done

• Edge Se3lement EvaluaGon

• As-­‐built (original construc>on) Standard

• Plate Size Fig. 9-­‐1

• Adding Reinforcement Plates to exis>ng

• New Nozzles API 650

• Procedures: ASME SecGon V

• Cavi>es from grinding and gouging

• New Shell-­‐to-­‐Bo3om Welds

• Perform Se3lement Survey

• Major Types of Records (6.8)

API 651 -­‐ CPfor Tanks API 652 -­‐

At the end of this module you should:

• 20 mils or less in thickness

• All sharp edges and protrusions should be ground smooth

• Surface roughness required is 1.5-­‐4 mils

• and increases with the thickness of the lining

• Surface ﬁnish must "white" or "near-­‐white“

• abrasive blast cleaned

• Follow inspec>on procedures of NACE RP0288

• Take wet ﬁlm thickness measurement

• Take dry ﬁlm thickness measurement

• Determine the coa>ng hardness using the appropriate procedures

• "Holiday " test linings

• At the end of this module you should know:

• Sec>on V sets requirements to assure that a

• Two major Subsec>ons

• DWTech -­‐ Single Wall Viewing

• RT IdenGﬁcaGon -­‐ Each RT marked: (T-­‐224)

• Check IQI Placement

• The other NDE Ar>cles are organized similarly to RT.

ASME B & PV Sec3on IX

•  Min. New Thickness -‐6 mm (0.236") 5.4.1

New Thickness -‐ Pick largest of the following:

•  Cu[ng & Rolling Plates 6.1.2/3

•  Other Weld InspecGon

•  How Corrosion Types are Evaluated v Uniform Corrosion

•  "E"for welded tanks -‐ See Table 4-‐2

•  E = 1.0 when corroded area is away from welds

•  (Greater of 1”or twice the plate thickness)

1. Find "t2" -‐ minimum thickness in corroded area

•  Product Fill Height -‐ LTA

•  Shell distorGons -‐ Evaluate Other Flaws

•  Cracks -‐ thoroughly examine

The CriGcal Zone -‐ Within 3" of shell

•  Calcining (loss of water of hydra>on)

•  All reported bri3le fracture failures have occurred at either:

•  SeAlement surveys should periodically be done

•  Edge Se3lement EvaluaGon

•  As-‐built (original construc>on) Standard

•  Plate Size Fig. 9-‐1

•  Adding Reinforcement Plates to exis>ng

•  New Nozzles API 650

•  Procedures: ASME SecGon V

•  Cavi>es from grinding and gouging

•  New Shell-‐to-‐Bo3om Welds

•  Perform Se3lement Survey

•  Major Types of Records (6.8)

API 651 -‐ CPfor Tanks API 652 -‐

•  20 mils or less in thickness

•  All sharp edges and protrusions should be ground smooth

•  Surface roughness required is 1.5-‐4 mils

•  and increases with the thickness of the lining

•  Surface ﬁnish must "white" or "near-‐white“

•  abrasive blast cleaned

•  Follow inspec>on procedures of NACE RP0288

•  Take wet ﬁlm thickness measurement

•  Take dry ﬁlm thickness measurement

•  Determine the coa>ng hardness using the appropriate procedures

•  "Holiday " test linings

•  At the end of this module you should know:

•  Sec>on V sets requirements to assure that a

•  Two major Subsec>ons

•  DWTech -‐ Single Wall Viewing

•  RT IdenGﬁcaGon -‐ Each RT marked: (T-‐224)

•  Check IQI Placement

•  The other NDE Ar>cles are organized similarly to RT.

•  At the end of this module you should know:

•  ExpiraGon of QualiﬁcaGon QW-‐322J

•  Fail a QualiﬁcaGon Test QW-‐32U/2/3