Toaz - Info Api 653 Vol 1 PR

API 653 Preparatory Introduction & Workbook
API 653 CERTIFICATION COURSE FOR
* STORAGE TANK INSPECTOR *
COURSE NOTES
VOLUME - 1
CONDUCTED FOR
Reliance Industries Limited

Navi Mumbai
CONDUCTED BY
Asian Training Academy, Pune.

19/ A-4 Sarita Vihar, S No 119/3/1 Parvati, Off Sinhgad Road, Pune 411030. India
Tel: + 91-20-24252214, 24308068, E-mail: asiantraining.academy@gmail.com
© Asian Training Academy. Pune, India 1

API 653- STORAGE TANK INSPECTOR

PREPARATORY COURSE
CONDUCTED BY
Statement
This course manual has been prepared by Asian Training Academy, Pune; INDIA., strictly for the use
of attendees to API-653 Examination Preparation Course from Reliance Industries Ltd. This manual
is to be used as an aid to assist those persons wishing to take the API-653 Aboveground Storage Tank
Inspector Certification Examination. This manual is not all-inclusive and should not be used in place
of any recognized Code or Standard. The information contained in this manual was obtained from the
author’s research and experience and is intellectual property of the author.
This manual or any part of it shall not be reproduced by any means without the written consent
of Asian Training Academy, Pune.

API 653- STORAGE TANK INSPECTOR PREPARATORY COURSE
VOLUME-1
CONTENTS
1. Program Schedule
2. PART 1 - Examination/Certification Information from API.
3. PART II- Guidelines and useful tips for Examination
4. PART III- Case Studies- WPS/PQR Roadmap & Examples
5. PART IV- Mathematics in API 653 Exam.
6. PART –V Questions on API 653-Tank Inspection Code

API 653- STORAGE TANK INSPECTOR PREPARATORY COURSE

PROGRAMME SCHEDULE
API 653 ABOVEGROUND STORAGE TANK INSPECTOR PREPARATORY COURSE DAILY TIME
TABLE
Session I Session II Session III Session IV

• Introduction API 650 – cont’d API 650 – cont’d • API 650 – cont’d
• API 653: Design temperature Shell design • Inspection
Examination Scheme Tank Materials Bottom & roof design requirements
Day Impact Testing of Fabrication
• Question Types • Extent of Radiography
1 Materials requirements
• API 650 Design • Introduction to API 653
Aspects Weld sizes for shell and – Sec. 1
roof openings • Quiz (Day 1)
• Points to Recall-Day 1 Evaluating of corrosion API 653 – Sec. 6 API 653 – Sec. 7
• Review of Quiz-Day 1 on bottom plates Inspection frequency API 653 – Sec. 8
• Introduction to API Foundation evaluation (routine inspection) API 653 – Sec. 9
653 API 653 – Sec. 5 Brittle External Inspection Tank repair and
Day fracture Internal Inspection alteration
• API 653 Sec. 4
2 Inspection Intervals Repair of Shell
• Existing tank shell
thickness evaluation Inspection Records Quiz (Day 2)
• Evaluation of pitting
Points to Recall API 653 – Sec 11 API 653 – Sec. 13 API RP 575
Day2 Welding API 653 – App. B Types of Tanks
Review Quiz -Day 2 API 653 – Sec. 12 Evaluation of Tank Procedures and
Day Repair of Tank Examination & Testing Bottom Settlement evaluations of internal
3 Bottom Reports & Records and external inspection
API 653 – Sec. 10 Quiz (Day 3)
Dismantling and
reconstruction
Points to Recall (Day 3) API RP 651 ASME Sec. V – NDT ASME Sec. V – NDT
Review of Quiz Cathodic Protection RT Examination Magnetic Particle,
(Day 3) Requirement Penetrant Testing, UT Examination
Day
Evaluation of change of Methods of Cathodic Quiz (Day 4)
4 service Protection
Evaluation of flaws and
distortions
Points to Recall (Day 4) Review of WPS/PQR API RP 652 API 571
Day Review of Quiz (Day 4) documents Tank Bottom Lining Damage Mechanisms
5 ASME Sec. IX Road map for document Types of linings Quiz (Day 5)
Welding Qualifications review Selection and
WPS/PQR Case studies in WPS/PQR Application of Linings
Points to Recall (Day 5) API 577 Final Simulated Test Final Simulated Test
Review of Quiz (Day 5) Welding, NDT and (Close Book) (Open Book)
Day
API 571 metallurgy. - Test Feedback Test Feedback
6 Degradation mechanisms Concluding Session


PREPARATORY COURSE
PART I
EXAMINATION/CERTIFICATION
INFORMATION
FROM API.


API 653 CERTIFICATIN FOR IN-SERVICE INSPECTION
INTRODUCTION
1. Preamble:
Storage Tanks are the major installations in Petroleum Refineries, Petrochemical

plants, Oil terminals and other process plants. They store variety of fluids, which
may be Explosive, Corrosive or Toxic in nature. The equipments are also subjected to
fluid head pressures and moderate temperatures. All these factors may cause
corrosion and other damages to the vital equipments.
The corrosion may cause thinning, pitting or cracking of tank walls. The internal
head will tend to bulge the tanks or piping at the corroded locations, releasing the
explosive or toxic contents resulting in serious consequences to the plant, personnel
and the people at large. It is therefore essential that during the planned shutdowns,
the degradation and damages inflicted to the Plant equipment, Piping and Tanks
should be monitored and evaluated so as to arrive at the ‘3R’ decisions. i.e.’ Run-
Repair-Replace” decisions.
More specifically, these courses describe the essentials of what to inspect, where to
inspect, how much to inspect and what to accept so as to evaluate the safety and
mechanical integrity of in-service equipments. The courses also cover methods of
repair, alteration, re-rating and replacements of affected equipments.

2. Course objectives:
The API Courses provide the participants the guidelines and methodology of
carrying out inspection of “in-service” equipments. It also provides techniques for
the assessment of the wear and tear of the equipments as well as to measure de-
gradation and damages caused to the process equipments due to the process
conditions.
If the assessment indicates that the equipment is safe to run, the participants are
further taught how to estimate the safe remaining life and the methods to extend the
useful life of the equipments.
If the decision is that the equipment needs repair, the course teaches the
participants, how to carry out such repairs of the damaged part without causing
damage to the whole equipment. It also covers the methods of re-rating the
equipment by evaluating the mechanical integrity if it is not possible to restore the
equipment to its original design conditions.

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Examination Information
1. API 653 examination consists of 150 multiple-choice questions with an open and closed
book sections. The examination is administered by participating members of the National
Board of Boiler and Pressure Vessel Inspectors and by the Professional Examination
Service (PES). Total length of examination is 8 hours. Individual jurisdictions may
charge a sitting fee to take the examination in their jurisdiction. Please contact the
jurisdiction you select for an exact amount. There is no additional sitting fee at the
locations where examination is administered by PES.
2. If you pass the examination, and all sections of your application are complete, you will be
certified and receive a wallet card and a certificate approximately 3 months after the
examination date.
3. API grants each applicant three consecutive attempts during the 18-month period to sit
and pass the test, starting with the first exam administration the applicant registers for. If
you fail the examination on your first attempt, you may retake it twice. If you fail to
appear for the test, it will still count as an official attempt.
4. If you do not pass the examination on the first attempt, you need to submit a $50.00
rescheduling fee. If you do not pass it on the second attempt, you must also submit an
updated Employment Reference form. If the candidate is unsuccessful on the third
attempt, a new application must be submitted with a new application fee.
5. Examination results will be mailed to you approximately 8 weeks after you have taken
the exam. DO NOT call API, PES, or your jurisdiction for examination results; these
results WILL NOT be given over the telephone.
What to Bring to the Examination
o No. 2 pencils;
o A non-programmable calculator (a calculator with only simple functions);
o The applicable API and ASME reference publications. Please note: highlighting,
underlining, page tabs, and notes written in margins of the code books are
acceptable. However, loose pages inserted in the code books are not acceptable.
Note: API and ASME publications are copyrighted material. Photocopies of
publications are not permitted at the exam;
o Your examination site confirmation letter;
o A picture ID (i.e. driver’s license).

Step-by-step certification process

Please complete the following steps in order to get certified:
1. Check out minimum qualification requirements for your chosen certification

program, and confirm your eligibility for certification.
2. Review API's testing and certification policies.
3. Determine the most convenient location, test date and application deadline for
your chosen program.
4. Download the application for your program or request the application package
to be sent to you via mail.
5. Fill out your application completely.
6. Mail your application, supporting documentation and payment to API by the

deadline indicated.
7. Download the Body of Knowledge for your chosen program.
8. Obtain necessary technical documents and publications. Effective publication

dates are listed in the application package.
9. Prepare for examination. Training programs are optional and not provided by
API.
10. Take the examination.

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PREPARATORY COURSE
PART II
GUIDELINES AND USEFUL TIPS FOR
API 653 CERTIFICATION
EXAMINATION


Preface
This examination preparation course is designed to prepare the participant to

successfully sit for the API-653 exam. Through your concentrated effort, and
the material provided in this course, you should have sufficient information to
pass the examination.
The majority of the classroom study will focus on the “Open Book” portion of
the exam. The goal, since this is open book, is to obtain a perfect score in this
section. Study for the practical questions (Closed Book) will be included in the
daily classroom activity and assigned homework.
The material contained in this manual is to be thoroughly studied and practiced

prior to attending the course. The math examples and practice problems are
based on the types of questions given on the API-653 exam. Through the use of
these examples, you will be exposed to many of the formulas used during the
course.
Remember, this is a very intense course. There will be eight hours of classroom
study each day. The instructor will be available to answer questions or to assist
any participant having difficulty with the homework assignments or any topic
discussed during class. There will be from two to three hours of homework
assignments each day. Daily quizzes are given and one practice API-653
examination is provided. The pace is fast and focused.
The participant is responsible for making all arrangements for taking the
examination including confirming your eligibility and applying to the American
Petroleum Institute.
No reference material of any kind will be permitted during the closed book
portion; some examining proctors may permit language translation dictionaries.
There will be some common knowledge mathematical questions on the
practical portion of the exam - remember to have your calculator available for
this part of the exam.

During this course, we will attempt to duplicate actual examination conditions

including using a separate answer sheet during the practice examination.
1. EXAMINATION SCHEME
As per the present scheme, API 653 examination is one-day, 8-hour, 2

session examination, comprising of pre-lunch session (4 hours) for
“open-book” examination and post-lunch session (4 hours) for “closed-
book” examination.
There are a total of 150 questions carrying 1 mark each (total of 150
marks), split into open-book (approximately 50 questions) and closed-
book (approximately 100 questions). The distribution of 50 and 100
questions respectively for open-book and closed-book examinations is
approximate; however the total is always 150 questions.
Each question is multiple choice questions with given 4 possible choices.

Only one is the correct choice. The candidate has to pick-up the correct
choice and indicate the same on separate answer sheet. The answer sheet
along with the question paper should be returned back to the Supervisor.
The correct answer is to be indicated by blackening (filling) the relevant
circle by a pencil. There is no set passing percentage. However a score of
about 95 to 105 out of 150 is a good estimate of passing score.
Please note the following:
• Fill only one circle out of four given

• Fill the circle fully and completely. Half or less than half
blackened circle area is not reckoned for answer.
• Never indicate the answers by ticking (√) the circles.
• There is no negative marking.

During the “open-book” session, you are permitted to refer to the codes
and other documents as per “Effectivity Sheets”. Code pages may be
tabbed, highlightened, underlined or notes in margin of the pages are
accepted. Additional new pages to codes are not accepted. Always carry
the following to the exam hall.
• 2 Nos. B or 2B pencils and eraser

• Non-programmable calculator
• Photo identity (passport, driving license, etc.)
• Exam confirmation letter
Be present in the exam hall at least 15 minutes prior to scheduled start of

exam. The supervisor announces important instructions during this
period. Do not miss them. Now relax and attempt the exam calmly. Time
is always more than enough.
Good luck, friends!

2. DISTRIBUTION OF MARKS
As per the Effectivity Sheet, there are total 9 codes prescribed for examination.
However, all of them are not equally important and do not therefore require
equal emphasis. About 50 percent questions are asked from one code API 653
which is hardly 40 pages, while all other 8 codes contribute 50% marks which
are more than 1,000 pages. Following distribution scheme will help the
participant to decide how much time he should spend for each document during
preparation.
3. Codes and Standards for study and their weight age:

Note: The weight age indicated is approximate and for guidance only.
A . API Publications:
API RP 650 Vertical storage tanks Construction code 20 %
API 653, Aboveground tanks Inspection Code 45 %
API RP 575, Inspection of Storage tanks 06 %
API RP 651 Cathodic Protection of Storage tanks 05 %
API RP 562 Lining of Tank bottom 03 %
API RP 571, Damage Mechanisms 03 %
API RP 577, Welding Inspection and Metallurgy 03 %
B. ASME Publications:
Section V, Nondestructive Examination 07 %
Section IX, Welding and Brazing Qualifications 08 %

3. SALIENT FEATURES OF THE EXAMINATION
As stated earlier, the examination comprises of open book and closed book
parts. The closed-book examination includes such questions which the inspector
is normally expected to know without referring the Codes, i.e., the questions are
“awareness level” questions.
Whenever you find a very definitive or quantitative statement in body of the

Code, a closed book question may be expected on it. Thus, the basic
requirements of a code, specific “DO” and “DON’T” statements, important
quantified statements, important definitions and well-known inspection
principles will constitute such questions.
Where the student is required to refer to the diagrams or formulas or tables or

graphs and curves from the Codes, it will always be an “open-book” question.
All calculation oriented questions will normally be “open-book” type. The Code
information which is not short and crisp, (i.e., large paragraphs, several
descriptive statements clubbed together) will normally be asked in “open-book”
part. Here the participant is expected not to remember the information but
should know where to find it in the body of the Code.
The questions asked in closed book part are straight forward statements directly
taken form Code without much of the modifications and therefore are easy to
answer. To answer open-book questions, one only needs to know where to find
the answer in the code and therefore tabbing of Code pages, highlighting the
paragraphs or additional explanatory notes in page margins is useful for saving
time. Closed-book part of the exam (100 marks) can be finished in hardly 2 to 2
½ hour though 4 hours are allotted. While “open-book” part (50 marks) takes a
little longer and may require all the 4 hours that are allotted.

4. HOW TO PREPARE FOR EXAM:
If your aim is only to get “certified”, i.e., to obtain just around 100-110 marks,
detailed study of documents nos. 1 to 4 above (Chapter 2) may be adequate.
Additionally, one should try to remember all the “Points to Recall” and review
the mock examinations attempted during the Preparatory Course. If two or more
participants from same organization are appearing for exam, then joint
discussions and one putting question to another and vice versa has been found
very effective during preparation. Other 5 codes (i.e., Serial No. 5 to 9) may be
studied in detail if there is additional preparation time available. An overall
“awareness” level knowledge of these 5 Codes may be okay.
If your objective is to get certified and also to obtain a good score, (say 125+)
then it is worthwhile to study the 5 Codes (Serial No. 5 to 9). However, please
remember that study of API 653 has to be “thorough” and total, while study of
API 650, ASME Sec. IX and ASME Sec. V should be such that it can cover the
topics mentioned in the “Body of Knowledge”. The last 5 Codes (Serial No. 5
to 9) should be read at least once and note the important points. A very
“thorough” study of these documents however will not result in “gains”
commensurate with the efforts put in.
If you are about a month away from examination, read all the Codes at least
once and concentrate on highlighted text in the Codes and also try to solve the
question bank.
If you are about two weeks away from the exam, concentrate on highlighted
text as well as the mock examinations conducted during the course. In the last
week of preparation, focus on Points to Recall and mock exams.

5. TIPS FOR MAXIMIZING THE SCORE
a. There are only 5 or 6 important definitions from Chapter 3 of API

653. Normally 3 to 4 definitions are asked in closed-book exam.
b. From Chapter 4 of API 653, nearly 15 questions are asked (7 to 8

closed book and 7 to 8 open book). Concentrate more on clauses
4.2.1.2, 4.2.3.1, 4.2.4.3 to 4.3.7.
c. Chapter 5, knowing figure 5-2 and only 3 clauses 5.3.5 to 5.3.7 is

enough.
d. From Chapter 6, about 10 questions are asked. It is only 3 page

chapter. Particularly pay attention to Inspection intervals.
e. From Chapter 7 and Chapter 8, generally 2 or 3 questions are

asked.
f. Chapter 9, about 7 to 8 questions are asked. Concentrate more on

Figure 9-1 and hot tap (Clause 9.14).
g. Chapter 10, about 3 or 4 questions are asked and those generally

“open book” type. So you can refer to the code and get answers.
h. Chapter 11, it is hardly 8 to 10 lines chapter but 1 or 2 questions are

asked
i. .Chapter 12, about 7 to 8 questions are asked. Normally the

questions are on NDT. The participant is expected to know that
NDT procedures shall be as per relevant article of ASME Sec. V,
the NDT extent shall be as per API 650 or 653 while acceptance
criteria is as per API 650 or ASME Sec. VIII, Div. 1. he should
also know that qualification standard of NDT personnel is ASNT
SNT-TC 1A (or API 650). This chapter is better explained in
Appendix F (API 653) as NDE Summary or in Appt. (API 650)

j. Chapter 13, generally 1 question covering name plate stamping is

asked.
k. Appendices: App. A. Here note that API 650 was introduced in

1961 (prior to this was API 12C) and seventh edition (1980)
onwards the joint efficiency (E) is taken as 1.
App. B: The important topics are number of settlement monitoring points

(Figure B-1, B-2) and formula B = 0.37 R (R in feet while B is in
inches)
App. C: This being item wise inspection checklist concerning what to check
where. Normally, 1 or 2 open book questions are set. No need to
remember this table.
App. D: Note certification requirement (Clauses D.2 and D.5)
From API 650.
Normally, two questions are asked on materials. (Fig. 2-1, Table 2-3, Table 2-4
and Clause 2.8).
Usually 5 to 6 questions are asked on Chapter 3 concerning shell, bottom and

roof thickness, attachment welds.
From Chapter 5, normally 2 or 3 questions will be asked. Focus on weld

reinforcement, undercuts, use of low-H electrodes and inspection pressure for
pad-test and vacuum box test.
From Chapter 6, generally 3 questions covering number of radiographs (Fig. 6-

1) and acceptance standards and personnel qualifications are asked.
Since there is no negative marking, there is no harm in making guess.

Generally, do not go against your first impulse, unless you are sure you were
wrong in the first place. If some questions are still remaining unanswered
mark the answers you “feel” may be right. Do not leave any question
unanswered.

6. TIME MANAGEMENT DURING EXAM:
Both “open” and “closed” book sessions are 4 hours each. This means about
25 to 28 questions per hour for closed book and 12 to 15 questions per hour
for open book. For proper time management following are useful
suggestions.
a) You may start from Question No. 1 and proceed. If after 1 hour you
feel that you are maintaining the required progress as mentioned
above proceed serially.
b) If, however, you are behind the required rate, start jumping the
questions, i.e., start attempting those questions you can answer,
deleting whose answer you do not know. Proceed like this till the end.
Do not leave any question unanswered whose answer you know.
c) Then come back to “deleted” questions and attempt them using your
“feel” factor. Go on like this till say last 10-15 minutes are remaining.
d) If there are still some questions where you have no clue at all just
mark the answer at random in last 10-15 minutes. This may give you
few chance marks. Do not leave any question unattempted.
After completion of writing exam, if you have still time (which you normally
have) you may go through your answers just to check quickly if you have filled
a wrong circle.

TEST TAKING TIPS
● Don’t read too much into a question. Do not get too

elaborate and ruin your answer.
● If two choices are very similar, the answer is probably not

either of them.
● If two choices are opposite, one of then is probably

correct.
● Don’t go against your first impulse unless you are very

sure you were wrong.
● Check for negatives and other words that can throw you
off.
● The answer is usually wrong if it contains “all,” “always,”

“never,” or “none.”
● The answer has a great chance of being right if it has

“sometimes,” “probably,” or “some.”
● When you don’t know the answer, look for the wrong ones.
● If you are supposed to read a long passage and then answer

questions about it, read the question first. That will tell you
what you are looking for and affect the way you read the
passage.
● Be suspicious of choices that seem obvious.
● Don’t give up on a question that, after one reading,

seems complicated. Looking at it from a different angle,
restating it in your own words, drawing a picture, or
breaking it down, etc., may help you realize that it’s not as
hard as you thought.

API 653 Preparatory Course

IMPORTANT CLOSED BOOK QUESTIONS
No. QUESTION CODE CLAUSE

1 Definition of the Critical zone API653 3.7
2 Definition of Change of Service API653 3.9
3. Minimum thickness of corroded roof plate API653 4.2.1.2
4. Limits of L API653 4.3.2.1
5. Definition of widely scattered pits API653 4.3.2.2
6. Causes for shell distortion API653 4.3.5.2
7. Cracks in the shall to bottom weld – what should be done API653 4.3.6
8. What is the reason for the distortion of anchor bolts & API653 4.5.3
excessive cracking of concrete structures
9. Tanks fabricated from steels of unknown toughness, API653 5.3.7
thickness less than ½” can be operated at above what
minimum shell metal temperature
10. Interval for routine In-service inspection API653 6.3.1.2
11. Who shall carry out External Inspection API653 6.3.2.1
12. Interval for External inspection API653 6.3.2.1
13. How is the external inspection of Insulated tank carried API653 6.3.2.2
out
14. What is the method of external inspection of Tank API653 6.3.2.3
grounding system
15. Interval for ultrasonic thickness inspection API653 6.3.3
16. If internal inspection is solely for the purpose of API653 6.4.1.2
determining the condition & integrity of tank bottom what
is the method of inspection
17. alternative Internal Inspection method API653 6.4.3
18. What is the bottom plate minimum thickness API653 Table
6-1
19. Construction records shall include the following API653 6.8.2
information
20. New material for tank reconstruction shall comply to which API653 7.2
standard
21. Welding consumables shall conform to which specification API653 7.4
22. What are the minimum dimensions for a replacement shell API653 9.2.2.1
23. The corners of a repair plate shall be rounded to what API653 9.3.1.4
minimum radius
24. Insert plate having higher thickness than the shall plate shall API653 9.8.2(c)
be tapered to

API 653 Preparatory Course

IMPORTANT CLOSED BOOK QUESTIONS
(Cont…)

25. Minimum thk. of new roof to be used for repair for a fixed API653 9.11.1.1
roof shall be
26. The minimum height of tank liquid above hot tap location API653 9.14.1.2
shall be at least
27 During hot tapping operation welding will be done using API653 9.14.2.3
which electrodes
28. Are hot taps permitted on the roof of a tank API653 9.14.2.4
29. The maximum allowed undercutting for horizontal joints of API653 10.4.2.5
a reconstructed tank is
30. If the material specification for the steel from an existing API653 11.1.2
tank is unknown or obsolete, how do you qualify the
welding procedure
31. At what intervals Welders identification shall be marked API653 11.2.2
adj. to welds
32. What alternative methods are used to inspect the integrity API653 12.1.7.1
of the welded bottom joint
33. Areas of bottom plate repaired by welding in addition to API653 12.1.7.3
MT/PT are any other testing done.
34. The minimum diagnostic length of each radiograph is API653 12.2.1.7
35. For penetration installed using insert plates , butt weld API653 12.2.1.8
between the insert plate & shell plate shall be radiographed
to what extent
36. Hydrostatic test of a reconstructed tank shall be held for API653 12.3.1.1
how long time.
37. At what intervals shall settlement be measured during API653 12.5.2
hydrotest
38. The maximum spacing across diameter over which API653 Fig. B-2
measurements of bottom settlement are taken is
39. Internal Bottom settlement formula API653 B-3-3
40. What is the NDT Inspector Qualification requirement for API653 F 4.3
carrying out UT during tank repair?
41 UT procedure shall follow which Code/Standard API653 F 4.4

API 653 PREPARATORY

IMPORTANT OPEN BOOK QUESTIONS

1 Calculate the t min. welded tank shell API653 4.3.3.1
2 What is the maximum allowable stress for bottom & second
API653 4.3.3.1
course
3. To change the service of the tank to above 200°F what
API653 4.2.4.4
requirements are to be met
4. What is the maximum allowable stress for reconstructed
API653 4.3.3.1
tank
5. What is the maximum allowable stress for revited tank API653 4.3.4.1
6. Annular bottom plate thickness (Sp. Gr. < 1.0) API653 Table 4-4
7. Assessment of the safe use of a tank constructed of
API653 Fig. 5.2
unknown materials
8. What records shall be maintained by the Owner / Operator API653 6.8.1
9. What are the material specifications for structural materials API653 7.3.2
10. Shell design for a reconstructed tank, with materials whose
allowable stresses are not given in Table 3-2 of API 650, API653 8.4.2
what allowable stresses are to be taken
11. After the valve has been installed on the flange at what
API653 9.14.5.3
pressure the pressure test shall be performed
12. In tank re-construction, new vertical joints in adjacent shell
API653 10.4.2.1
courses shall be offset by what minimum distance
13. During tank reconstruction / repair what is the maximum
API653 10.4.2.5
allowed undercutting for vertical joints
14. What is the maximum reinforcement allowed for horizontal
API653 Table 10-1
joint of ¾” plate
15. In completed horizontal butt joints, the upper plate shall not
API653 10.4.4.2
project beyond the lower plate by how much
16. Calculation of Internal Bottom settlement or bulges API653 B.3.3
17. Problem on edge settlement API653 Fig B-10
18. For welding A516 Gr 70 materials what electrode
API650 2.8
classification shall be used


PREPARATORY COURSE
PART III
CASE STUDIES


API 653 TRAINING COURSE

Case Study 1: Impact Testing of Plates
(Question)
An Aboveground Storage Tank is to be constructed using ASTM A 516 gr 60

plates. The plates are normalized. The plates were tested for impact value and
the following were the test results. The test results are presented for 32 mm thk
plates (Lot A) and 30 mm thk plates (Lot B).
A) Longitudinal Specimen:
Three specimens failed at 13 ft-lb, 15 ft-lb and 18 ft-lb respectively
B) Transverse Specimen:
Three specimens failed at 12 ft-lb, 14ft-lb and 14ft-lb respectively
Your assessment is:

a. Plate A is okay. B is not.
b. Plate B is okay. A is not.
c. Both A and B are okay.
d. Both A and B are not okay.


Case Study 1: Impact Testing of Plates
(Solution)
The material belongs to Group III A.
The thicknesses are within acceptable limits.

(Ref: 2.2.2, 516 gr60 can be used up to 40 mm thickness)
Plate A (Longitudinal):
13 + 15 + 16
Average of 3 specimen = = 14.66 ft. lb.
3
Average of 3 specimen, 14.66 ft. lb is less than required average of 15 ft. lb. —
Reject.
Plate B (Transverse):
12 + 14 + 14
Average of 3 specimen = = 13.33
3
Average of 3 specimen, 13.33 is greater than required average of 13 ft. lb.
Also only one specimen (12 ft. lb) is below average and its value is greater than
2/3 x 13, i.e., greater than 8.66.
4.2.9.3 An impact test shall be performed on three specimens taken from a
Accept Plate B. single test coupon or test location. The average value of the specimens (with
no more than one specimen value being less than the specified minimum
value) shall comply with the specified minimum value. If more than one value
is less than the specified minimum value, or if one value is less than
Correct answer: b two-thirds the specified minimum value, three additional specimens shall be
tested, and each of these must have a value greater than or equal to the
specified minimum value.
API650 Table 4.5b—Minimum Impact Test

Requirements for Plates (USC) (See Note)


Case Study 2: Shell Design of AST (New Tank)
(Question)
The following data are presented for an Aboveground Storage Tank:

1) Code of construction: API 650
2) Tank diameter = 60ft
3) Tank height = 48ft; width of plates used = 8ft
4) Maximum fill height = 48ft
5) Product specific gravity = 0.92
6) Material of construction; ASTM A 516 gr 60
7) Corrosion allowance = 1/8 in
Determine:
a. Required thickness for bottom course (first course)
b. Required thicknesses for courses 2 to 6


Case Study 2: Shell Design of AST (New Tank)
(Solution)
2.6 D(H − 1)G 2.6 D(H − 1)

td = + CA tt =
a. Sd or St
From table 3.2, S d = 21,300 psi , S t = 24,000 psi
2.6 × 60 × (48 − 1) × 0.92 1

∴ td = + in
21300 8
∴ t d = 0.3167 + 0.125 = 0.4417"
2.6 × 60 × (48 − 1)
tt = = 0.3055"
24000
0.4417" > 0.3055"
Select 0.4417” thick plate, i.e. 11.22 mm
Use 12 mm thick plate
b. It is obvious that for all other courses, td will govern, since td will be
greater than tt
2.6 D(H − 1)G

td = + CA
Sd
• For the 2nd Course, H = 40ft
2.6 × 60 × (40 − 1) × 0.92 1

∴ td = + in
21300 8

∴ t d = 0.2628 + 0.125 = 0.3878" = 9.85mm Use 10mm plate
• For the 3rd Course, H = 32ft
2.6 × 60 × (32 − 1) × 0.92 1

∴ td = + in
21300 8
∴ t d = 0.2089 + 0.125 = 0.3339" = 8.48mm Use 10mm plate
• For the 4th Course, H = 24ft
2.6 × 60 × (24 − 1) × 0.92 1

∴ td = + in
21300 8
∴ t d = 0.1550 + 0.125 = 0.2800" = 7.11mm Use 8mm plate
• For the 5th Course H = 16ft
2.6 × 60 × (16 − 1) × 0.92 1

∴ td = + in
21300 8
∴ t d = 0.1011 + 0.125 = 0.2261" = 5.74mm Use 6mm plate
• For the 6th Course H = 8ft
2.6 × 60 × (8 − 1) × 0.92 1
∴ td = + in
21300 8
∴ t d = 0.0472 + 0.125 = 0.1722" = 4.37 mm 5mm plate may be OK
But, As per table 3.6.1, (Diameter-Thickness Table) minimum thickness

(for D = 60ft) is 6mm. Use 6mm plate


Case Study 3: Tank Shell Thickness Evaluation (Old Tank)
(Question)
Data: Code of Constr. API 650 – Basic. Year of Constr. 1984
1) Tank diameter = 100 feet

2) Tank height = Maximum liquid height = 56 feet
3) Course width = 8 feet
4) Product specific gravity = 0.98
5) Corrosion rate = 0.1 mm / year
6) Thickness provided = 20mm (new)
7) M. O. C. = ASTM-A-36
8) After 20 years, a patch was observed on the second shell course, at
46 feet from the top (i.e. in 2nd course). Least thickness in the area
of corrosion was 15.25mm (0.6”). The next interval for inspection
is 10 years.
9) Readings in vertical planes a, b, c, d over the length L were:
No. a b c d
1 19 18.5 18 18.5
2 18 18 17.75 17.5
3 18 17.5 15.25 17.5
4 17 18 16.5 18
5 19 18.5 17.5 18.5
Is the tank safe until next inspection?


Case Study 3: Tank Shell Thickness Evaluation (Old Tank)
(Solution)
1) t 2 = 0.6" = 15.25
2) L = 3.7 D × t 2 = 3.7 100 × 0.6 = 28.66"
3) tavg for plane a = 91/5 = 18.2 mm. (Total of 5 readings = 91)
tavg for plane b = 90.5/5 = 18.1 mm (Total of 5 readings = 90.5)
tavg for plane c = 85/5 = 17.0 mm (Total of 5 readings = 85)
tavg for plane d = 90/5 = 18.0 mm (Total of 5 readings = 90)
So, the weakest plane is c. And lowest of tavg = 17 mm

∴ t1 = 17 mm
2.6 × D × H × G 2.6 × 100 × 46 × 0.98

4) t min = = = 0.471" = 11.965mm
SE 24900
For safe operation:
t1 ≥ t min + (CR × Interval ) and t 2 ≥ 0.6 × t min + (CR x int erval )
17 ≥ 11.965 + 0.1 × 10 15.25 ≥ 0.6 × 11.965 + 1
17 ≥ 12.965 OK 15.25 ≥ 8.179 OK
Therefore the tank is safe.


Case Study 4: Minimum Thickness of Bottom Tank Evaluation
(Question)
An aboveground storage tank provided with sketch plate type bottom

construction was observed to be having following thickness readings on bottom
plate by UT measurement. (The tank does not have leak detection system on
bottom.)
Bottom thickness provided when tank was new (excluding corrosion allowance
= 10 mm. Maximum depth of corrosion pits from inside of tank on the tank
bottom = 3.5 mm. Maximum corrosion from bottom side (metal loss) = 4.5 mm.
Rate of corrosion on topside of bottom = 100 microns / year. Rate of corrosion
on bottom side = 150 microns / year.
Calculate when the next inspection interval should be due.


Case Study 4: Minimum Thickness of Bottom Tank Evaluation
(Solution)
RTbc = 10 – 4.5 = 5.5 mm
RTip = 10 – 3.5 = 6.5 mm
M RT = 0.1” (from Table 6-1) = 2.5 mm
M RT = (Minimum of RTbc or RTip ) – Or (StPt + U Pr)
2.5 = 5.5 - Or (0.1 + 0.15)
Or x 0.25 = 3.0
Or = 3.0 / 0.25 = 12 years
Answer: 12 years
Note: In examination, problems will be simple. Out of the various terms in

formula for MRT, all data except one will be given and you will be asked to
find the missing one.

Review of WPS/PQR (Road Map)
Start at Front side of PQR.
No Do the P, F & A Nos. match

with mtl. Spec No & filler AWS
Go to back side of PQR.Are the results (QW 140)

No for tensile, and bend tests stated.
Ye
No For tensile test are qty of
specimen, area and unit stress (QW –
calculation right
Ye
No
Is location of failure stated
Ye
R No Is unit stress > SMTS
(QW – 153)
of base metal
Start Ye Was break
Ye
in weld
No
Is the WPS supported by E No Is unit stress >
No
PQR. Does WPS show 95% of SMTS (QW – 153)
reference No. of the of base metal
supporting PQR Ye
Ye No Is bend test Qty, type
Ye (QW –
Has PQR been revised J stated and correct
Ye
No
No (QW – 163)
Is PQR signed and Yes
Ye No Are results for toughness
(QW – 172)
test (if any) OK
Accept for
E Yes
detailed Place WPS & PQR side by
review
Go to tables as follows
C SMAW - QW 253
SAW – QW 254
No
Check WPS/PQR for QW 402
to QW 410 for the following
WPS: EV, NEV, PQR: EV,
T
No If the welder is to be qualified on the
basis of PQR. Is his Identifying code.
Position of welding recorded on
Ye
Accept
WPS / PQR PRACTICE QUIZ - OPEN BOOK

(Refer to Attached PQR / WPS Documents)
Note: Encircle the letter of only one alternative which you think is most appropriate.
1. Choose correct statement from the following:

a. The PQR shows root spacing of 1/8” and same shall be followed in
production welding.
b. PQR shows beval angle 37°. It shall be followed in production
welding without change.
c. PQR does not show backing ring, hence production weld also can
not be with backing ring
d. None of above is correct statement.
2. What condition below describes the results of the guided bend test?
a. The three bend tests are acceptable and the fourth one is not
acceptable
b. The test result overall is acceptable
c. The test result is not acceptable due to the linear indication
d. The bend test result is indeterminable, carry out retest.
3. What welding process is qualified by this PQR?
a. GTAW
b. SMAW
c. GMAW
d. SAW
4. What is the P number and the tensile strength of SA-106-C?
a. P No. 1 and 70 ksi

b. P No. 1 and 60 ksi
c. P No. 3 and 70 ksi
d. P No. 3 and 60 ksi

5.. In accordance with the PQR, the WPS is qualified for what welding
positions?
a. Flat and horizontal

b. Flat, vertical, overhead and horizontal
c. Vertical and overhead
d. All positions
6. What is the F No. of an E 7010 electrode?
a. F no. 4
b. F No. 3
c. F No. 2
d. F No. 1
7. The welder who welded the test plate for PQR 101 is qualified to weld in
what position?
a. Flat
b. Flat and horizontal
c. Flat and vertical
d. Flat, vertical and horizontal
8. The bend test specimen used are side bend. They are:
a. Not accepted since 2 face bend and 2 root bend must be used
b. Accepted since as alternative to (a) 4 side bend may be used
c. Accepted since only 2 bend tests are required where as 4 bend tests are
performed
d. Not accepted since all 3 types of bend tests (face, root, side) are
required.
9. As far as thickness ranges for Base Metal (B.M.) and weld metal (W.M.)
as shown on WPS are concerned, your decision about the qualified range
is:
a. B.M. is okay and W.M. is not okay.

b. Both B.M. and W.M. are okay.
c. Both B.M. and W.M. are not okay.
d. W.M. is okay and B.M. is not okay.

PREPARATORY COURSE
PART IV
CALCULATIONS IN
API 653 EXAMINATION


CALCULATIONS IN API 653 EXAM
Calculation questions found on the API-653 examination are oriented toward existing tanks and not
new tanks. API authorized above ground storage tank inspectors are expected to be able to check and
perform calculations necessary to ensure compliance with appropriate Codes and standards. For this
reason, the inspector must have a thorough understanding of the formulas and procedures used to
calculate the following:
Corrosion Rates and Inspection Intervals

Remaining Life determination
Joint Efficiencies
Maximum Height (Hydrostatic Testing)
Determining appropriate weld sizes for shell opening
Minimum spacing between existing and new hot tap nozzles
Settlement evaluation including the number of survey points
Minimum Thickness for Existing Tank and Reconstructed Tank Shells
Corroded areas of tank shells including evaluation of pitting
Bottom plate thickness determination and evaluation
Reinforcement of opening
The American Petroleum Institute does not permit the use of programmable calculators while taking
the exam; therefore, programmable calculators will not be permitted during the course.
Mathematics Fundamentals:
As we all know, mathematics has a language of its own, made up of signs, symbols, and characters.
During this course of study many common mathematical signs, symbols, and characters, which you
must be familiar with, will be used. Some of these are listed below.
+ Addition
− Subtraction
∗× () Multiplication
÷ Division
π Pi Expressed as 3.14
< Less than
> Greater than
∴ Therefore
≤ Less than or equal to
≥ Greater than or equal to
= Equal
X2 Number squared
Square root

Pre-Test:
1. Find the minimum acceptable shell plate thickness of the first course of an AST.
tmin = Minimum acceptable thickness ?

D = Nominal diameter of tank, in feet 120
H = Height of tank in feet 48
G = Specific gravity of contents 1
S = Maximum allowable stress 21000
E = Joint efficiency of tank .85
2.6 D( H − 1)G
t min =
SE
2. Find the corrosion rate of an AST given the following information.
Original thickness = .875”

Measured thickness = .625
Years since last thickness measurement = 11
t original − t last
CR =
Time
3. Using the corrosion rate determined in problem number 2, what would the remaining life
expectancy of this tank be if the minimum required thickness is 0.436”?
t actual − t min imum

RL =
CR
4. Shell settlement evaluation measurements are to be taken on a 146 feet diameter AST. Given the
following formula, how many elevation measurements would be required?
D
N=
10
5. Using the information in number four, does this number meet the requirements of API-653, which
does not permit the measurement points to exceed 32 feet?
πD
Dis tan ce =
N

Pre-Test continued:
6. Find the throat of a right angle fillet weld with a weld leg length of .4375 inches.
7. Using the following information, what is the maximum vertical length (also known as critical
length), in inches, over which hoop stresses are assumed to “average out” around local
discontinuities? Diameter of the tank is 136 feet, the least thickness in an area of corrosion,
exclusive of pits, is determined to be .563”
L = 3.7 Dt 2
8. A 6 inch nozzle is to be placed in the tank shell of an AST. The shell course where the nozzle will
be installed is .875” thick. What is the required area of reinforcement?
A = ODnozzle t shell
9. The maximum ultrasonic thickness measurement interval shall be five years when the corrosion
rate is not known. What is the interval based on a known corrosion rate? The tank information is
as follows: Initial thickness of the tank was 1.0625”, the actual thickness is .815”, the calculated
required thickness is .473”, the tank has been in service for 16 years with no measurements taken
since it was installed.
RCA = .342
N = .015
RCA
Interval =
2N
10. What is the circumference of an AST that is 96 feet in diameter?

Practice problems #1:
Problem #1
Find “S” when tmin, D, H, G, and E are known where: D=78, H=29, G = 1, E=.85, and tmin =.602
2.6 DHG
t min =
SE
Problem #2
Find E when D, H, G, S, G, and tmin are known where: D =128, H=60, S = 22,300 G = .87, and tmin =
1.125
2.6 DHG
t min =
SE
Problem #3
Find “D” when H, E, S, G, and tmin are known where: H=45, E=.90, S=22500, G= .7 and tmin =.9375
2.6 DHG
t min =
SE
Problem #4
Find “St” when E, Ht, D, G, and tmin are know where: E = .80, Ht = 54, D= 70, G = 1 and tmin =.4325
S t Et min
Ht =
2.6 D
Problem #5
Find “C” when D and H are know where D = 60, H = 54
C = 014
. D2 H

Pre-Test: ANSWERS
1. Find the minimum acceptable shell plate thickness of the first course of an AST.
Tmin = Minimum acceptable thickness ?

D = Nominal diameter of tank, in feet 120
H = Height of tank in feet 48
G = Specific gravity of contents 1
S = Maximum allowable stress 21000
E = Joint efficiency of tank .85
2.6 D( H − 1)G (2.6)(120)(48 − 1)(1) 14664

t min = t min = t min = =.8215"
SE (21000)(.85) 17850
2. Find the corrosion rate of an AST given the following information.
Original thickness = .875”

Measured thickness = .625
Years since last thickness measurement = 11
t original − t last .875−.625

CR = CR = CR =.023
Time 11
3. Using the corrosion rate determined in problem number 2, what would the remaining life
expectancy of this tank be if the minimum required thickness is 0.436”?
t actual − t min imum .625−.436

RL = RL = RL = 8.2 years
CR .023
4. Shell settlement evaluation measurements are to be taken on a 146 feet diameter AST. Given the
following formula, how many elevation measurements would be required?
D 146
N= N= N = 14.6 = 15
10 10
5. Using the information in number four, does this number meet the requirements of API-653, which
does not permit the measurement points to exceed 32 feet?
πD (314
. )(146)
Dis tan ce = Dis tan ce = Distance = 30.5ft. yes meet requirements
N 15
Reference: API-653 Paragraph 10.5.1.2 definition of N

6. Find the throat of a right angle fillet weld with a weld leg length of .4375 inches.
Throat =.707Wleg Throat = (.707)(.4375) Throat = .309”
7. Using the following information, what is the maximum vertical length (also known as critical
length), in inches, over which hoop stresses are assumed to “average out” around local
discontinuities? Diameter of the tank is 136 feet, the least thickness in an area of corrosion,
exclusive of pits, is determined to be .563”
L = 3.7 Dt 2 L = 3.7 (136)(.563) L = 3.7 76.568 L = (3.7)(8.75) L = 32.375"
8. A 6 inch nozzle is to be placed in the tank shell of an AST. The shell course where the nozzle will
be installed is .875” thick. What is the required area of reinforcement?
A = ODnozzle t shell A = (6.75)(.875) = 5.906 square inches API-650 3.7.2.1 & 3.7.2.2
9. The maximum ultrasonic thickness measurement interval shall be five years when the corrosion
rate is not known. What is the interval based on a known corrosion rate? The tank information is
as follows: Initial thickness of the tank was 1.0625”, the actual thickness is .815”, the calculated
required thickness is .473”, the tank has been in service for 16 years with no measurements taken
since it was installed.
RCA = .342
N = .015
RCA .342
Interval = Interval = = 114
. years API-653 4.3.3.2 b.
2N (2)(.015)
10. What is the circumference of an AST that is 96 feet in diameter?
Circumference = πD Circumference = (3.14)(96) = 301.44 feet.

Answers of Practice problems #1:
Problem #1
Find “S” when tmin, D, H, G, and E are known where: D=78, H=29, G = 1, E=.85, and tmin =.602
2.6 DHG 2.6 DHG (2.6)(78)(29)(1) 58812

.
t min = S= S= S= S = 11493.4
SE Et min (.85)(.602) .5117
Problem #2
Find E when D, H, G, S, G, and tmin are known where: D =128, H=60, S = 22,300 G = .87, and
tmin = 1.125
2.6 DHG 2.6 DHG (2.6)(128)(60)(.87) 17372.16

t min = E= E= E= E = .692
SE St min (22300)(1125
. ) 25087.5
Problem #3
Find “D” when H, E, S, G, and tmin are known where: H=45, E=.90, S=22500, G= .7 and tmin =.9375
2.6 DHG t SE
t min = D = min
SE 2.6 HG
Problem #4
Find “St” when E, Ht, D, G, and tmin are know where: E = .80, Ht = 54, D= 70, G = 1 and tmin =.4325
S t Et min
Ht =
2.6 D
Problem #5
Find “C” when D and H are know where D = 60, H = 54

Post Test Questions.
1. What is the required hydrostatic test height (Ht) of an AST given the following data?
Maximum allowable hydrostatic stress (St)= 21350
Diameter of the tank = 110 feet
Hydrostatic test shell thickness (tmin) is .625”
Shell joint efficiency = 70%
Use API-653 2.3.3.1 formula for tanks to be hydrostatically tested.
2. What is the area of a tank bottom that is 121 feet in diameter?
3. A reinforcing plate is installed around a nozzle installed in the first course of an AST. What is the
throat dimension of the ½” leg fillet weld around the periphery of the reinforcing plate.
4. What is the minimum acceptable thickness of the bottom course of an existing AST that is 135
feet in diameter, maximum fill height is 56.5 feet? The product stored in the tank has a specific
gravity of .87 and all shell butt-welds were 100% radiographically examined. The yield strength
of the material is 28,000 and the tensile strength is 60,000. Use API-653 paragraph 2.3.3.1.
2.6 DHG
t min =
SE
5. What is the required area of reinforcement for a 14 NPS nozzle installed in a shell course that is
1.0625” thick. Use API 650 Paragraph 3.7.2.1
6. A bulge is noted in a tank bottom, what is the maximum height of the bulge permitted if the
radius of the inscribed circle is 10.8 feet? Use API-653 Appendix B 3.3
7. If the throat of a fillet weld is .309, what is the leg length of the weld?
8. An AST is 175 feet in diameter. How many tank settlement survey points are required? Use API-
653 paragraph 10.5.1.2.
9. Do the number of settlement measurement locations and maximum spacing comply with API –
653? Use API –653 Paragraph 10.5.1.2
10. What is the design liquid level of an AST that is 140 feet in diameter, thickness of the bottom or
first course is .765”, stress of the material is 21300. The specific gravity of the product to be
stored is 1 and no corrosion allowance is needed nor provided.
2.6 D( H − 1)G  t S 
td = + CA ➪ H =  d d  +1
Sd  2.6 DG 

Post Test Answers
1. What is the required hydrostatic test height (Ht) of an AST given the following data?
Maximum allowable hydrostatic stress (St)= 21350
Diameter of the tank = 110 feet
Hydrostatic test shell thickness (tmin) is .625”
Shell joint efficiency = 70%
Use API-653 2.3.3.1 formula for tanks to be hydrostatically tested.
S t Et min (21350)(.7)(.625) 9340.625

Ht = ➪ Ht = = = 32.6 ft
2.6 D (2.6)(110) 286
2. What is the area of a tank bottom that is 121 feet in diameter?
A = πR 2 A = (3.14)(60.5)2 A = (3.14)(3660.25) A = 11493 sqft
3. A reinforcing plate is installed around a nozzle installed in the first course of an AST. What is the
throat dimension of the ½” leg fillet weld around the periphery of the reinforcing plate.
Throat = .707Wleg Throat = (.707)(.5) = .3535
4. What is the minimum acceptable thickness of the bottom course of an existing AST that is 135
feet in diameter, maximum fill height is 56.5 feet? The product stored in the tank has a specific
gravity of .87 and all shell butt-welds were 100% radiographically examined. The yield strength
of the material is 28,000 and the tensile strength is 60,000. Use API-653 paragraph 2.3.3.1.
2.6 DHG (2.6)(135)(56.5)(.87) 17253.405

t min = ➪ t min = ➪ t min = =.7"
SE (24640)(1) 24640
S = (.8)(28000) = 24640 S = (.429)(60000) = 25740
5. What is the required area of reinforcement for a 14 NPS nozzle installed in a shell course that is
1.0625” thick.
Area = (14)(1.0625) = 14.875 square inches
6. A bulge is noted in a tank bottom, what is the maximum height of the bulge permitted if the
radius of the inscribed circle is 10.8 feet?
B = .37R ➪ B = (.37)(10.8) = 3.996 inches or 4 inches
7. If the throat of a fillet weld is .309, what is the leg length of the weld?
Throat .309
Throat =.707Wleg ➪ Wleg = ➪ Wleg = =.437"
.707 .707

8. An AST is 175 feet in diameter. How many tank settlement survey points are required? Use API-
653 paragraph 10.5.1.2.
D 175
N= ➪ N = = 17.5
10 10
9. Do the number of settlement measurement locations and maximum spacing comply with API –
653?
Yes ➪ (175)(3.14) = 549.3 ➪ 549.3 ÷ 18 = 30.5 feet spacing
10. What is the design liquid level of an AST that is 140 feet in diameter, thickness of the bottom or
first course is .765”, stress of the material is 21300. The specific gravity of the product to be
stored is 1 and no corrosion allowance is needed nor provided.
2.6 D( H − 1)G  t S   (.765)(21300) 

td = + CA ➪ H =  d d  + 1 ➪ H =   +1 ➪
Sd  2.6 DG   (2.6)(140)(1) 
 16294.5
H=  + 1 H = 44.76 + 1 ➪ H = 45.76 feet
 364 


PREPARATORY COURSE
PART V
QUESTIONS ON API 653

Tank Inspection Code


QUESTIONS ON API 653 -Tank Inspection Code

Section 1, 2, 3 – Introduction
1. API-653 covers which of the following types of tanks?

a) Carbon and low alloy steel tanks built to ASME Section VIII, Div.1
b) Carbon and low alloy steel tanks built to ASME Section X
c) Carbon and low alloy steel tanks built to API - 650 and 12C
d) Carbon and low alloy steel tanks built to API - 510
Reference: API-653 Paragraph 1.1.1
2. API-653 provides the requirements for construction of which of the following?

a) Process pressure vessels
b) Aboveground petroleum storage tanks
c) LNG Storage spheres
d) This standard does not provide construction requirements
3. API-653 provides for all but which of the following with regard to aboveground storage tanks?
a) Repair
b) Operation
c) Relocation
d) Alteration
4. The scope of API-653 is limited to all of the following except?

a) Tank foundation
b) Tank Bottom
c) Tank roof
d) Tank mixing motor
5. The API-653 standards states that many of the requirements for design, welding, and materials of
API-650 and API-12C can be applied with regard to _____.
a) Repair, inspection, rating, and alteration.
b) Repair, personnel assignment, maintenance, and inspection.
c) Inspection, product in storage, rating, and alteration.
d) Alteration, refinery equipment, electrical controls, and repair.

6. In the application of the requirements for welding, design, and materials of API-650 or API-12C
to in-service aboveground storage tanks (AST), which of the following code or standard takes
precedence?
a) ASME Section VIII, Pressure Vessels
b) API-12C
c) API-653
d) API-650
7. The API-653 Standard may only be applied to aboveground storage tanks (AST) that have been
constructed to and meet the requirements of API-650.
a) True
b) False
8. The use of API-653 is intended for organizations that have personnel who are technically trained
and experienced in which of the following?
a) All ASME, AWS, ASNT, and API Codes and Standards
b) Tank design, fabrication, repair, construction, and inspection
c) Refinery operations, safety requirements, personnel management, and refinery design
d) Mechanical integrity program, OSHA regulations compliance program, and Process Safety
Management
9. When design and construction details are not given and not available in the original construction
standard, then details that will provide a level of integrity equal to the current edition of what
Code or Standard must be used?
a) ASME Section VIII, Division 1, Pressure Vessels
b) ASME Section VIII Division 2, Alternative Rules for Pressure Vessels
c) API- 650, Welded Steel Tanks for Oil Storage
d) API-12C Steel Storage Tanks for Oil Storage
10. Ultimate responsibility for compliance with this standard rests with ____?
a) The Owner/Operator
b) The Owner/Operator’s Inspector
c) The repair organization of the Owner/Operator
d) The manufacturer of the AST
Reference: API-653 Paragraph 1.2

11. According to API-653, if any provision presents a direct or implied conflict with any statutory
regulation, the regulation governs. What governs if API-653 requirements are more stringent than
the statutory regulation?
a) The statutory regulation applies in all cases
b) The conflict must be submitted to the American Petroleum Institute for resolution
c) The owner/operator has the option of applying the requirement best suited to the situation
d) The API-653 requirements shall govern
12. Safe working practices shall comply with what requirements concerning confined space entry?
a) Procedures must comply with any trade developed safety precautions
b) Procedures must comply with any federal or state regulations
c) Procedures need only comply with owner/operator/s requirements
d) Procedures need only comply with NFPA requirements
Answers to API-653 Section 1, 2, 3 Introduction
Question Number Answer

1 C
2 D
3 B
4 D
5 A
6 C
7 B
8 B
9 C
10 A
11 D
12 B

Section 4 – Suitability for Service

1. When must an evaluation, to determine the suitability for continued use, be conducted?
a) Evaluations shall be conducted when a tank inspection reveals a change has occurred
from the original physical condition of the tank.
b) Evaluations shall be conducted at least annually
c) Evaluations shall be conducted at an interval not to exceed the calculated tank inspection
frequency.
d) Evaluations shall be conducted once each ten years of service
2. What factors are required for consideration when performing an evaluation for continued use of an
AST?
a) Only those listed in API-653
b) The recommended list of considerations provided in API-510 can be modified to suit this
purpose
c) Engineering analysis and judgement required for each situation
d) Only those items requested by the Certified Aboveground Storage Tank Inspector
3. Roof plates corroded to an average thickness of less that ____ inch in any ___ square inch area
shall be repaired of replaced.
a) 0.9 inch in any 100 square inch area
b) 0.09 inch in any 10 square inch area
c) 0.09 inch in any 144 square inch area (1 square foot)
d) 0.09 inch in any 100 square inch area
Reference: API-653 Paragraph 4.2.1.2
4. The method of inspecting roof support members shall be acceptable to whom?

a) The manufacturer of the AST
b) The responsible inspector
c) The Owner/Operator’s design engineering department
d) The operations manager
5. During the inspection of fixed roof support members, particular attention must be given to .
a) Severe external corrosion of the roof plate where support structures are attached
b) Severe internal corrosion of pipe columns
c) Severe internal corrosion of the roof plate where support structures are attached
d) Deterioration of wind girders at the point of attachment

6. Inspection of floating roofs is limited to roof plates and pontoons.

a) True
b) False
7. Evaluation of existing floating roofs shall be based on the criteria of

a) API-650, Appendix C for external floating roofs and Appendix H for internal floating
roofs
b) API-510 Paragraph 6.4.3 for external floating roofs and 6.5.3 for internal
c) ASME Section VIII, Div 1 Appendix C for external floating roofs and Appendix H for
internal
d) ASME Section VIII, Div. 2 Alternative Rules
8. What API Standard or Recommended Practice must be used for evaluating the effects of design
partial vacuum on tank roofs?
a) API Standard 620
b) API Standard 650
c) API Recommended Practice 651
d) API Recommended Practice 652
9. Above what operating temperature shall API Standard 650, Appendix M, be considered before
changing the service of a tank?
a) 500°F
b) 400°F
c) 300°F
d) 200°F
10. Under what conditions may a tank be operated at a temperature lower than the original design?
a) When the requirements for impact testing of ASME Section VIII, Div, 1 have been met
b) When the requirements of the applicable standard or API Standard 650 have been met
c) When the requirements of ASTM Specification A-370 have been met
d) When the requirements of ASTM Specification A-20 have been met
11. Flaws, deterioration, or other conditions that might adversely affect the performance or structural
integrity of the shell of an existing tank must be evaluated. Personnel experienced in tank design
shall conduct the evaluation. This analysis shall take into account any of the following except
a) Fluid static head
b) Internal and external pressure
c) Organization that manufactured the tank
d) Seismic loads

12. Of the following, which is not an option available to the owner/operator if it is not possible to
satisfy the requirements for minimum thickness calculations for a welded tank?
a) Repair damaged areas
b) Reduce allowable liquid level
c) Retire the tank
d) Reduce the fill rate so the tank fills slower and applies pressure gradually
13. Out-of-roundness, buckled areas, flat spots, and peaking and banding of welded joints are all
examples of _____.
a) Shell Distortions
b) Flaws
c) Discontinuities
d) Severe damage
14. Shell distortions require the tank to be immediately removed from service and inspected.
a) True
b) False
15. Flaws such as cracks or laminations shall be thoroughly examined to determine their nature and
extent and the need for repairs.
a) True
b) False
16. What if anything should be done with cracks in the shell-to-bottom weld?
a) These cracks can be sealed with caulking and the tank returned to service
b) The welds can have a cover weld pass applied over them to prevent leakage
c) Cracks of this type are critical and the tank must be retired from service since repairs are
prohibited.
d) Cracks in the shell-to-bottom weld are critical and shall be removed and repaired
17. Internal pitting and pitting rates in the anticipated service, corrosion of weld joints (weld and heat
affected zone), weld joint cracking history, and stresses placed on the bottom plates by roof
support loads and shell settlement are all examples of causes of what type of failure?
a) Annular ring failure
b) Shell plate failure at first shell course
c) Bottom failure
d) Fatigue failure due to repeated jacking of floor plates

18. Underside corrosion (normally in the form of pitting), inadequate drainage resulting in surface
water flowing under the tank bottom, lack of an annular plate ring when required, uneven
settlement that results in high localized stresses in the bottom plates, and inadequate provision for
movement of roof support columns and other supports are all examples of causes of what type of
failure?
a) Shell plate failure at first course
b) Bottom failure
c) Failure of support columns due to hydraulic compression
d) Creep cracking failure
19. Of the following what has historically not been a cause of bottom failures?
a) Non-homogeneous fill under the tank bottom
b) Rock or gravel foundation pads with inadequately filled-in surface voids
c) Inadequate inspection frequency
d) Inadequately supported sumps
20. Where would you look to find the basis for cathodic protection systems for the underside of tank
bottoms?
a) API Recommended Practice 651
b) API Recommended Practice 652
c) API Standard 2015
d) API Standard 2207
21. Where would you look to find procedures and practices for protecting tank bottoms with internal
lining?
a) API Recommended Practice 651
b) API Recommended Practice 652
c) API Standard 2015
d) API Standard 2207
22. What two methods may be used in quantifying the remaining thickness of tank bottoms?
a) Drilling and actual measurement
b) Ultrasonic and radiography
c) Deterministic and probabilistic
d) Detailed stress analysis and plate deformation measurement

23. Unless a stress analysis is performed, what is the minimum thickness of bottom plates in the
critical zone?
a) Smaller of ½ the original bottom plate thickness or 50% of tmin of the lower shell course
but not less than 0.1 inch.
b) Smaller of ¼ the original bottom plate thickness or 25% of tmin of the lower shell course
c) Smaller of ¾ the original bottom plate thickness or 75% of tmin of the lower shell course
d) Smaller of ½ the original bottom plate thickness or 50% of tmin of the lower shell course
24. When repairing internal pitting for the extension of in-service operating period, the repair shall be
by any of the following methods except.
a) Pit welding
b) Brazing
c) Overlay welding
d) Lap Patching
25. The thickness of the bottom plate projection beyond the shell, measured at the toe of the weld of
the outside bottom-to-shell fillet weld shall be not less than?
a) 0.25 inch
b) 0.01 inch
c) 0.50 inch
d) 0.10 inch
26. The projection of the bottom plate beyond the toe of the shell-to-bottom weld shall be at least?
a) 0.125 inch
b) 0.250 inch
c) 0.375 inch
d) 0.500 inch
27. An aboveground storage tank contains a fluid with a specific gravity of less than one. The
thickness of the plate in the first course is 7/8”. What is the minimum thickness of the annular
plate ring, seismic loading is not a consideration, and the stress in the first course is 27,850 pound
per square inch?
a) 0.22 inch
b) 0.31 inch
c) 0.20 inch
d) 0.23 inch
Reference: API-653 Paragraph 4.4.8.2 and Table 4-4

28. An aboveground storage tank contains a fluid with a specific gravity of greater than one. The
thickness of the plate in the first course is 7/8”. What is the minimum thickness of the annular
plate ring, seismic loading is not a consideration, and the hydrostatic test stress in the first shell
course is 27,850 pound per square inch?
a) 1 / 4 inch
b) 3 / 8 inch
c) 9 / 32 inch
d) 11 / 32 inch
Reference: API-653 Paragraph 4.4.8.3 and Table 3-1 API-650
29. Settlement, erosion, cracking, and deterioration of concrete are all examples of which of the
following principle modes of failure or deterioration?
a) Annular plate ring failure
b) Shell-to-bottom weld failure
c) Deterioration of walkways and roadways
d) Deterioration of foundations
30. To ensure suitability for service, what is the minimum permitted frequency of tank foundation
inspection?
a) Annually
b) Every five years
c) Monthly
d) Periodically
Reference: API-653 Paragraphs 4.5.1.1 & 4.3.1.2
31. Distortion of anchor bolts and excessive cracking of concrete structures may be indications of
what two conditions?
a) Serious foundation settlement of a tank overpressure uplift condition
b) Inferior material used in the anchor bolts and the concrete structure
c) Over tightening of the anchor bolts and improper mixing of the concrete
d) The tank was struck by lightning and wind caused movement of the tank

Answers to API-653 Section 4 Suitability for Service

1 A
2 C
3 D
4 B
5 B
6 B
7 A
8 A
9 D
10 B
11 C
12 D
13 A
14 B
15 A
16 D
17 C
18 B
19 C
20 A
21 B
22 C
23 A
24 B
25 D
26 C
27 B
28 C
29 D
30 C
31 A

Section 5 – Brittle Fracture Considerations
1. Incidents of tank failure due to brittle fracture have occurred shortly after erection during
hydrostatic testing or in all but which of the following incidents?
a) On the first filling in cold weather
b) After a change to a higher temperature service
c) After a change to a lower temperature service
d) After a repair or alteration
2. The risk of tank failure due to brittle fracture is minimal after what condition(s)?
a) The tank has demonstrated its ability to withstand the combined effects of maximum
liquid level (highest stresses) and highest operating temperature
b) The tank has demonstrated its ability to withstand the combined effects of intermediate
liquid level (highest stresses) and lowest operating temperature
c) The tank has demonstrated its ability to withstand the combined effects of maximum
liquid level (highest stresses) and lowest operating temperature
d) The tank has demonstrated its ability to withstand the combined effects of maximum
liquid level (highest stresses) and intermediate operating temperature
3. If it is decided to change the service to a more severe service, it is necessary to

a) Consider the need for pneumatically testing the entire tank
b) Consider the need to recalculate the effectiveness of all reinforcement of openings
c) Consider the need for hydrostatic testing
d) Consider removing all previous welded repairs and have them redone
4. If a tank shell thickness is less than _____ inch, and an evaluation in accordance with Section 5 of
API-653 has been performed, the risk of brittle fracture is considered to be minimal.
a) 0.01
b) 0.10
c) 0.05
d) 0.50
5. No known tank failures attributed to brittle fracture have occurred at shell metal temperatures of
_____°F and above.
a) -20
b) 20
c) 40
d) 60

6. According to industry experience and laboratory tests, what membrane stress is required to
caused failure due to brittle fracture?
a) 6 ksi
b) 7 ksi
c) 10 ksi
d) 12 ksi
7. What is the lowest temperature that a tank, constructed of carbon steel of unknown toughness,
may be used? The maximum thickness of the shell is .625”
a) 40°F
b) 45°F
c) 50°F
d) 55°F
Reference: API-653 Paragraph 5.3.8 and Figure 5-2
8. What is the purpose of Figure 5-1 of API-653?

a) Provides a procedure to be used in the evaluation of the remaining life of tank bottom
plates
b) Provides a procedure to be used in the evaluation of the likelihood of floating roof
pontoon failure
c) Provides an assessment procedure for evaluating aboveground storage tanks operating at
15 psi
d) Provides an assessment procedure for evaluating atmospheric aboveground storage tanks
Reference: API-653 Paragraph 5.2.1 and Figure 5-1
Answers to API-653 Section 3, Brittle Fracture Considerations

1 B
2 C
3 C
4 D
5 D
6 B
7 A
8 D

Section 6 – Inspection
1. What is the purpose of periodic in-service inspection?

a) The purpose of periodic in-service inspection, assure job security for inspectors
b) The purpose of periodic in-service inspection, assure proper operation of AST
c) The purpose of periodic in-service inspection is to assure continued tank integrity
d) The purpose of periodic in-service inspection is to assure OSHA compliance
2. Of the following, which is not a consideration that must be addressed in determining inspection
intervals for ASTs?
a) Corrosion prevention systems
b) Inspection interval of other equipment located near the tank under consideration
c) Changes in service (including changes in water bottoms)
d) Previous inspection results
3. What methods of inspection must be considered when establishing inspection frequencies?

a) On-stream core sample inspection
b) On-stream nondestructive inspection
c) In-service aerial inspection
d) In-service groundwater inspection
4. Close visual inspections of aboveground storage tanks, from the ground, may be made by other
than the Authorized Inspector , The interval of such inspections shall not exceed:
a) At least every five years or 1/4 the corrosion rate life of the shell whichever is less
b) 12 months
c) 6 months
d) 1 month
5. All tanks shall be given a visual external inspection, by an Authorized Inspector, at what
frequency?
a) Inspection conducted at least every 20 years or at the quarter corrosion rate of the bottom
whichever is less
b) Inspection conducted at least every 5 years or at the quarter corrosion rate of the bottom
whichever is less
c) Inspection conducted at least every 5 years or at the quarter corrosion rate of the shell
whichever is less
d) Inspection conducted at least every 20 years or at the quarter corrosion rate of the shell
whichever is less

6. External ultrasonic thickness measurements of the shell, while the tank is in service, can be a
means of determining rate of uniform corrosion. The extent of UT measurements shall be
determined by the owner/operator. What is maximum interval of such thickness measurements
when the corrosion rate is not known?
a) Five years
b) Three years
c) One year
d) Every three months until the corrosion rate is established
Reference: API-653 Paragraph 6.3.3.2a.
7. The minimum thickness of a tank was established at 0.585 inch. The shell was fabricated from
3/4 inch plate and included a 0.125 inch corrosion allowance. The tank has been in service for
eight years and current ultrasonic thickness measurements reveal an average thickness of 0.712
inch. Based on this information determine when the next ultrasonic thickness measurements will
be required.
a) Fifteen years
b) Thirteen years
c) Eleven years
d) Nine years
Reference: API-653 Paragraph 6.3.3.2b.
8. Internal inspections are primarily required to do all but which of the following?
a) Ensure the internal surfaces of the tank are thoroughly cleaned periodically
b) Identify and evaluate any tank bottom settlement
c) Ensure that the bottom is not severely corroded and leaking
d) Gather data necessary for the minimum bottom and shell thickness assessments
9. When can the required internal inspection be performed by some method other than visual
inspection?
a) Substitution of the visual inspection is never permitted
b) If the internal inspection is required solely for determining the condition and integrity of
the tank bottom
c) If the internal inspection is required solely for determining the condition and integrity of
the tank critical zone
d) If the internal inspection is required solely for determining the condition and integrity of
the tank roof support structure
10. According to API-653, all tanks shall have a formal internal inspection conducted at intervals
defined by this standard. Who is required to conduct the visual inspection?
a) The corrosion engineer
b) The person designated by the Authorized Inspector
c) The authorized Inspector
d) The person designated by the owner user

11. Intervals between internal inspections shall be determined by the corrosion rates measured during
previous inspections or anticipated based on experience with tanks in similar service. The internal
inspection interval shall not exceed how many years?
a) Ten years
b) Fifteen years
c) Twenty years
d) Twenty-five years
12. What is the minimum thickness permitted at the next inspection for a tank bottom designed with a
means to provide detection and containment of a bottom leak?
a) 0.01 inch
b) 0.10 inch
c) 0.50 inch
d) 0.05 inch
Reference: API-653 Paragraph 6.4.2.1 & Table 6.1
13. In cases where corrosion rates are not known and similar service experience is not available, the
bottom plate actual thickness shall be determined by inspection(s) within how many years?
a) 25 years
b) 20 years
c) 15 years
d) 10 years
14. Which of the following is a recognized alternative to internal inspection interval described in
API-653?
a) Risk-based Inspection procedures (RBI)
b) Hydrostatically testing the tank every five years
c) Performing complete calculations for minimum required thickness of the tank shell and
bottom
d) API-653 does not permit any alternatives to the internal inspection intervals
15. Of the following, which would not be a factor to be considered in a Risk-based assessment of a
tank?
a) Availability and effectiveness of inspection methods and quality of data collected
b) The methods used for determining the thickness of the shell and bottom plates
c) Effectiveness of corrosion mitigation methods
d) Names of all operators since the initial start-up of the tank

16. The owner/operator is required to maintain complete record file consisting of three types of
records. Which of the following is not one of the three types of records.
a) Repair/alteration history
b) Fill cycles
c) Construction
d) Inspection
17. General inspection reports shall include which of the following?

a) Metal thickness measurement, repairs, conditions found, settlement measurements, and
recommendations
b) Metal thickness measurement, repairs, operational upsets, settlement measurements, and
recommendations
c) Metal thickness measurement, repairs, conditions found, name of organization
performing environmental impact study, and recommendations
d) Metal thickness measurement, list of all personnel who have worked on the tank since the
last inspection, conditions found, settlement measurements, and recommendations
Answers to API-653 Section 6, Inspection
Question Number Answer Question Number Answer

1 c 10 c
2 b 11 c
3 b 12 d
4 d 13 d
5 c 14 a
6 a 15 d
7 b 16 b
8 a 17 a
9 b

Section 7 – Materials
1. All new materials used for repair, alteration, and reconstruction shall conform to which of the
following?
a) The existing material code at the time of original construction
b) The latest NFPA Code
c) The current applicable tank standards
d) Any ASME Code specification for P-1 material
Reference: API-653, Paragraph 7.2
2. All shell plates and bottom plates welded to the shell shall be identified. Material identified by
any of the following except _____ does not require further identification?
a) Original contract drawings
b) API name plates
c) Suitable documentation
d) Owner/operator's experience with similar tanks in similar service constructed of similar
material
Reference: API-653, Paragraph 7.3.1.1
3. Each individual plate for which adequate identification can not be made; the plate shall be
_______.
a) Subjected to chemical analysis and mechanical tests as required in ASTM A6 and A370
including Charpy V-Notch
b) Subjected to chemical analysis and mechanical tests as required in ASTM A20 and A333
including Charpy V-Notch
c) Subjected to Brinell hardness analysis and mechanical tests as required in ASTM A6 and
A370 including Charpy V-Notch
d) Subjected to Brinell hardness analysis and mechanical tests as required in ASTM A20
and A333 including Charpy V-Notch
4. Under what condition does API-653 require two tension specimens shall be taken at right angles
to each other from a corner of each plate? One of those specimens must meet the specification
requirements.
a) When the direction of rolling is not definitely known
b) When the welding will be conducted at a temperature less than 32ºF
c) When the plate is not a full size plate and may be installed with the grain running vertical
d) When the material is not a P-1 material

5. Even when a material is identified, all shell plates and bottom plates welded to the shell shall meet
what minimum requirements?
a) The chemistry and mechanical properties of material specified for the application with
regard to thickness and design temperature given in ASME Section II, Part A
b) The chemistry and mechanical properties of material specified for the application with
regard to thickness and design temperature given in API Standard 650
c) The chemistry and mechanical properties of material specified for the application with
regard to thickness and design temperature given in the owner/operator's engineering
design
d) The chemistry and mechanical properties of material specified for the application with
regard to thickness and design temperature given in the contract for the tank repair,
alteration, or reconstruction
6. Is it permissible to reuse existing rolled structural shapes? If so what specification applies?

a) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-20 as a
minimum
b) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-370 as a
minimum
c) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-6 as a
minimum
d) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-7 as a
minimum
Reference: API-653, Paragraph 7.3.2
7. Flange material must meet the minimum requirements of the material specifications of the current
applicable standard.
a) True
b) False
8. Fasteners shall meet the material specifications of the current applicable standard.
a) True
b) False

9. If existing plates are to be used to reconstruct the tank, they shall be checked for which of the
following?
a) Chemical compatibility with other plates used in the reconstruction
b) Excessive corrosion and pitting
c) Mechanical strength including impact properties
d) Inadequately reinforced openings

Answers to API-653 Section 7, Materials

1 C
2 D
3 A
4 A
5 B
6 D
7 B
8 A
9 B

Section 8 – Design Considerations for Reconstructed Tanks

1. Design considerations other than normal product loading shall be specified by the _____.
a) Organization performing the reconstruction
b) Authorized Inspector
c) Owner/operator
d) Registered professional engineer contracted by the repair organization
Reference API 653 Paragraph 8.1
2. Weld joint details shall meet the requirements of which of the following?
a) API Standard 650
b) ASME Section IX only
c) The applicable standard
d) AWS D1.1 Structural Welding Code
Reference API 653 Paragraph 8.2.1
3. The thickness to be used for each shell course when checking tank design shall be based on:
a) Measurements taken within 30 days prior to relocation
b) Measurements taken within 60 days prior to relocation
c) Measurements taken within 120 days prior to relocation
d) Measurements taken within 180 days prior to relocation
4. The maximum liquid level for hydrostatic test shall be determined by using which of the
following?
a) The nominal thickness of each shell course at the time of original construction
b) The actual thickness measured for each shell course
c) The anticipated thickness for each shell course at the time of next thickness
measurements
d) Twice the anticipated thickness for each shell course at the time of next thickness
measurements
5. The joint efficiency and allowable stress levels for existing welded joints that are not to be
removed and replaced shall be based on which of the following?
a) Original construction standard
b) Original degree and type of inspection
c) Current construction standard
d) Current degree and type of inspection

6. Replacement and new penetrations shall be designed, detailed, welded, and examined to meet
what requirements?
a) The current applicable standard
b) The original standard of construction
c) The requirements of the Authorized Inspector
d) The requirements of the owner/operator
7. Existing penetrations shall be evaluated for compliance with what requirements?

a) The current applicable standard
b) The original standard of construction
c) The requirements of the Authorized Inspector
d) The requirements of the owner/operator
8. With regard to seismic design, reconstructed tanks shall be built to meet the stability requirements
of:
a) The requirements of the owner/operator
b) The requirements of the Authorized Inspector
c) The original standard of construction
d) The applicable standard
Reference API 653 Paragraph 8.8
Answers to API-653 Section 8, Design

1 C
2 C
3 D
4 B
5 B
6 A
7 B
8 D

Section 9 – Tank Repair and Alteration

1. The basis for repairs and alterations shall be equivalent to which of the following?
a) API-653
b) API-650
c) API-510
d) API-570
Reference API-653, Paragraph 9.1.1
2. The minimum dimension for a replacement shall plate shall be _____ inches or ____ times the
thickness of the replacement plate whichever is ______.
a) 12, 12, greater
b) 12, 12, lesser
c) 18, 18, greater
d) 18, 18, lesser
Reference API-653, Paragraph 9.2.2.1
3. Unless an entire shell plate is replaced, the replacement plate may be circular, oblong, square or
rectangular provide the corners are
a) Provided with a radius of at least 1 inch
b) Provided with a radius of at least 3% of the short dimension of the plate
c) Provided with a radius of at least 3 inches
d) Provided with rounded corners
4. Prior to welding the new vertical joints, the existing horizontal joints shall be cut for a minimum
distance of _____ inches beyond the new vertical joints.
a) Six
b) Eight
c) Twelve
d) Sixteen
5. Vertical joints shall be welded before the horizontal joints.

a) True
b) False

6. For existing shell plates over ½” thick, the outer edge of the butt weld, attaching the replacement
shell plate shall be at least _____ times the weld thickness or _____ inches whichever is greater
from the outer edge of any existing butt-welded shell joints.
a) 12, 10
b) 10, 12
c) 8, 10
d) 10, 8
7. For existing shell plates ½” thick and less, the outer edge of the butt weld, attaching the
replacement shell plate may be reduced to _____ inches from the outer edge of vertical joints or
_____ inches from the outer edge of horizontal joints.
a) 10, 8
b) 9, 6
c) 6, 9
d) 6, 3
8. For existing shell plates over ½” thick, the outer edge of the butt weld, attaching the replacement
shell plate shall be at least _____ times the weld size or _____ inches, whichever is greater, from
the edge (toe) of the fillet weld attaching the bottom shell course to the bottom. This rule does not
apply if the replacement shell plate extends to and intersects with the bottom-to-shell joint at
approximately _____ degrees.
a) 8, 10, 45
b) 8, 10, 90
c) 8, 10, 60
d) There are no exceptions
9. The edge of any vertical weld joint attaching a replacement plate shall be at least how far from
the edge of the weld joint in the annular plate ring or sketch plate?
a) Eight inches
b) Ten inches
c) Twelve inches
d) Six inches
10. Lapped patch shell repairs are an acceptable form of repair for butt-welded, lap-welded, and
riveted tank shell only when specified by:
a) The Authorized Inspector
b) Repair organization
c) The insurance company
d) The owner/operator

11. Lapped patch shell repairs are not permitted on shell courses exceeding what thickness?
a) ½ inch
b) ¾ inch
c) 1 inch
d) 1 ¼ inch
12. When a lapped patch shell repair is used, what is the minimum thickness permitted for the repair
plate?
a) Not less than .25 inch
b) Not less than .1875 inch
c) Not less than .50 inch
d) Not less than .375 inch
13. Repair plates for lapped patch repairs may square or rectangular in shape. These plates must be
provided with a corner radius of at least what dimension?
a) They shall be rounded to a minimum radius of 1 inch
b) They shall be rounded to a minimum radius of 2 inches
c) They shall be rounded to a minimum radius of 3 inches
d) They shall be rounded to a minimum radius of 4 inches
14. The maximum dimension of the lapped patch repair plate vertically and horizontally shall not
exceed:
a) 24 inches vertically and 36 inches horizontally
b) 36 inches vertically and 48 inches horizontally
c) 48 inches vertically and 72 inches horizontally
d) There are no maximum dimensions
15. The minimum lapped patch repair plate dimension is what length?
a) 6 inches
b) 8 inches
c) 10 inches
d) 12 inches
16. Is it permissible to install a shell opening and its reinforcement within a properly designed lapped
patch shell repair?
a) Yes
b) No

17. When a lapped patch repair plate is used to reinforce the thickness of a shell, which of the
following is correct?
a) The repair plate thickness shall be based on the latest edition of API-650 and 653 using a
joint efficiency not exceeding 0.35
b) The repair plate thickness shall be based on the applicable standard of construction and
API Standard 653 using a joint efficiency not exceeding 0.35
c) The repair plate thickness shall be based on the latest edition of API-650 and 653 using a
joint efficiency not exceeding 0.70
d) The repair plate thickness shall be based on the applicable standard of construction and
API Standard 650 using a joint efficiency not exceeding 0.70
18. With regard to the thickness of the repair plate at the perimeter of the repair plate, when a lapped
patch repair plate is used to reinforce the thickness of a shell, which of the following is correct?
a) The repair plate shall not exceed the thickness of the shell plate by more than 1/4th but no
more than 1/8th inch. The maximum repair plate thickness is 1/2inch.
b) The repair plate shall not exceed the thickness of the shell plate by more than 1/3rd but no
c) The repair plate shall not exceed the thickness of the shell plate by more than 1/3rd but no
d) The repair plate shall not exceed the thickness of the shell plate by more than 1/4th but no
more than 1/3rd inch. The maximum repair plate thickness is 1/2inch.
19. Lapped patch repair plates may be used to repair small leaks or minimize the potential of leaks
from isolated pitting. The requirements for thickness and design are the same as for reinforcement
of shell thickness. This type of repair may not be used to repair small leaks if what condition(s)
exists?
a) The leak is located anywhere in the first shell course within 12 inches of a vertical joint
b) The leak of pit is in an area of the shell where there is a product to atmosphere interface
c) There is a possibility of severe environmental impact should the repair fail
d) If exposure of the fillet weld to the product would produce crevice corrosion or if a
corrosion cell is likely to occur between the shell plate and the repair plate
20. An alteration to a tank shell by the addition of new plate material shall be performed in
accordance with what standard?
a) Current API 650 and latest addenda
b) API 650 edition and addenda applicable at the time of original tank construction
c) Applicable standard
d) Tanks may not be altered by increasing height
Reference API-653, Paragraph 9.5

21. Repairs to existing shell penetrations shall be in accordance with

a) API Standard 650
b) API Standard 653
c) API Standard 510
d) National Board Inspection Code
22. API 653 permits the addition of reinforcing plates to existing un-reinforced nozzles. What
requirement is necessary to add this reinforcement to the inside of the tank?
a) The reinforcement plate may not be added to the inside of the plate
b) A telltale hole shall be drilled through the shell opposite the reinforcement plate
c) The reinforcement plate is the same material as the nozzle and is attached to the nozzle
by full penetration weld
d) Sufficient nozzle projection exists
23. The addition or replacement of shell penetrations shall be in accordance with

a) API-650
b) API-650 and API 653
c) API-650 and API 510
d) API-650 and AMSE Section VIII, Division 2
24. Installation or replacement of shell penetrations greater than 2 inches shall be installed with the
use of an insert plate if what condition(s) exists?
a) The penetration is no closer than 12 inches to an existing penetration
b) The shell plate is greater than ½” thickness and the shell plate material does not meet
current metal temperature criteria
c) The penetration is no closer than 10 inches to an existing penetration
d) The shell plate is greater than 3/16” thickness and the shell plate material does not meet
current metal temperature criteria
25. An 8 inch diameter penetration is to be installed in a shell which requires an insert plate. What is
the minimum permitted diameter of the insert plate?
a) Eight inches
b) Twelve inches
c) Sixteen inches
d) Twenty inches
Reference API-653, Paragraph 9.8.2(a)

26. An insert plate containing an opening with a reinforcing plate is to be installed in a tank. The
reinforcing plate diameter is thirty-two inches. What is the minimum diameter of the insert plate?
a) The insert plate must be 32 inches in diameter
b) The insert plate must be 44 inches in diameter
c) The insert plate must be 32 inches in diameter plus the diameter of the opening
d) The insert plate must be 32 inches in diameter plus twice the diameter of the opening
Reference API-653, Paragraph 9.8.2(b)
27. If an integral reinforcement design is used, the thickness of the insert plate, at its periphery and for
a distance of 2t from the edge of the weld, shall be the same thickness as the shell. If it is not, the
insert plate shall have a ______ taper to match the shell plate thickness.
a) 1:2
b) 1:3
c) 1:4
d) 1:5
Reference API-653, Paragraph 9.8.2(c)
28. When it is necessary to install a new tank bottom above an existing bottom, it may be necessary to
alter existing shell penetrations. This procedure may require the existing reinforcing plate to be
removed and a new reinforcement plate added. This is not permitted when what condition exists?
a) The assembly was originally hardness tested
b) The existing assembly was not impact tested
c) The existing assembly was fabricated from re-claimed material
d) The existing assembly was stress relieved
29. New reinforcing plates shall be installed in accordance with Fig. 7-2a of API-653. In order to
maintain weld spacing, what shape reinforcing plate is permitted?
a) Oval
b) Diamond
c) Tombstone
d) Circular is the only permitted shape
30. No welding or weld overlays are permitted within the “Critical Zone” except for welding of
widely scattered pits, cracks in the bottom plates, the shell-to-bottom weld, or where the bottom
or annular plate is being replaced.
a) True
b) False
Reference API-653, Paragraph 9.10.1.2.1

31. API Standard 653 defines the “Critical Zone” for repairs to tank bottoms as what?
a) That portion of the bottom or annular plate within 3" from the inside edge of the shell,
measured radially inward
b) Within the annular plate ring, within 12 inches of the shell, or within 12 inches of the
inside edge of the annular plate ring
c) That portion of the bottom or annular plate within 6" from the inside edge of the shell,
measured radially inward
d) Within the annular plate ring, within 3" of the shell, or within 12 inches of the inside edge
of the annular plate ring
32. If more extensive repairs are required within the “Critical Zone” than those listed in 7.10.1.2,
what must be done with the bottom plate?
a) As long as the repairs do not involve the bottom plate, nothing needs to be done
b) The bottom plate welded to the shell shall be cut out and a new plate installed
c) The bottom plate shall be subjected to suitable nondestructive examination to ensure it
has not be adversely affected by the repair
d) The bottom plate and the bottom shell course shall be replaced as an assembly
33. When it is necessary to install a new bottom plate over an existing bottom plate, a suitable ______
material cushion such as sand, gravel or concrete shall be used between the old bottom and the
new bottom.
a) Drainage
b) Compacted
c) Non-corrosive
d) Non-conductive
34. When a new tank bottom has been installed in a floating roof tank, what consideration must given
to the floating roof level?
a) The floating roof will find its own level
b) The support legs can be jacked up or shortened by the same amount as the thickness of
the cushion and new bottom plate
c) The support legs can be jacked up or shortened by the same amount as the thickness of
the cushion
d) The support legs can be jacked up or shortened by the same amount as the thickness of
the new bottom plate

35. Which of the following is not acceptable when removing an existing tank bottom, with regard to
the separation of the shell from the tank bottom?
a) Cutting the shell parallel to the tank bottom a minimum of ½” above the bottom to shell
weld
b) Removing the entire shell to bottom attachment weld including penetration and heat
affect zone
c) Removing the entire shell to bottom attachment weld by arc gouging and/or grinding
d) Cutting the shell parallel to the tank bottom a minimum of ¼” above the bottom to shell
weld
Reference API-653, Paragraph 9.10.2.2(a) and (b)
36. For installation of a new tank bottom in a tank with shell plates of unknown toughness, not
exempted in Table 10-1 of API-653, new welds in the bottom or annular ring shall be spaced at
least the greater of _____ inches or ____t from existing vertical weld joints in the bottom shell
course. (t is the thickness of the bottom shell course)
a) three, five
b) six, five
c) five, three
d) five, six
37. What is the minimum thickness of new roof plates for supported cone roofs?
a) 7/16”
b) 5/16”
c) 3/16”
d) 1/16”
38. The nominal thickness of new roof plates for self-supporting roofs shall be equal to or greater
than _____ inch not to exceed _____ inch.
a) 1/4th, 5/8th
b) 5/16th, 1/2
c) 3/16th, 5/16th
d) 3/16th, 1/2
Reference API-653, Paragraph 9.11.2.1 and API-650 3.10.5 or 3.10.6
39. Repairs to internal floating roofs shall be made in accordance with the original construction
drawings. To what requirements shall repairs be made if the original construction drawings are
not available?
a) The original construction standard
b) Appendix H of API Standard 650
c) Appendix G of API Standard 650
d) Appendix C of API Standard 650

40. To minimize evaporation losses and reduce potential hazard to workers, no more than ____ of the
roof seal system should be out of an in-service tank at one time.
a) One-eighth
b) One-fourth
c) One-half
d) Three-quarters
41. Mechanical damage to floating roof perimeter seals shall be repaired or replaced. How are
buckled parts handled?
a) They shall be replaced
b) They may be straightened in place
c) They may be heated and bent back into position
d) They may be removed straightened and re-installed
42. With regard to installation of primary and secondary seals, what must be done if the roof rim
thickness is less than 0.10 inch.
a) The roof rim shall be thoroughly inspected for damage and corrosion, if it is satisfactory
then nothing further needs to be done
b) It shall be replaced. The new roof rim shall be 3/16 inch thickness minimum
c) It shall be replaced. The new roof rim shall be 1/4 inch thickness minimum
d) The tank must be condemned and dismantled
43. What is the maximum hot tap connection permitted in an in-service tank with a minimum shell
thickness of 3/8 inch? The material is of recognized toughness.
a) NPS 6
b) NPS 8
c) NPS 14
d) NPS 18
Reference API-653, Paragraph 9.14.1.1(a) and Table 9-1
44. The owner/operator requires a connection to be made in an in-service tank. The shell material is
of unknown toughness and the thickness is 1.25”. The minimum design metal temperature is
45°F. What is the maximum diameter hot tap connection that may be installed in this tank?
a) NPS 18
b) NPS 14
c) NPS 8
d) NPS 4
Reference API-653, Paragraph 9.14.1.1(b)(1) and Fig. 9-6

45. The minimum height of tank liquid relative to the hot tap location shall be at least ______ during
the hot tapping operation.
a) The tank liquid shall be at least 3 feet below the hot tap location
b) The tank liquid shall be at least 1 foot above the hot tap location
c) The tank liquid shall be at least 3 feet above the hot tap location
d) The tank liquid shall be at least 1 foot below the hot tap location
46. It is permissible to perform hot taps on the roof of a tank or within the gas/vapor space.
a) True
b) False
47. The owner/operator requires an NPS 3 ½ nozzle to be installed in an in-service tank. The tank is
110 feet in diameter, 60 feet maximum fill height, shell thickness at the point of hot tap is .75”,
and the material is of unknown toughness with a minimum design metal temperature of 38°F.
This nozzle is to be installed adjacent to an existing nozzle. What is the minimum spacing
between these nozzles?
a) Minimum distance is 22.24”
b) Minimum distance is 9.08”
c) Minimum distance is 19.08”
d) Minimum distance is 2.24”
48. When installing a pipe nozzle into an in-service tank, how shall the pipe nozzle be prepared?
a) The pipe nozzle must be cut to the contour of the tank and prepared for full fillet welding
b) The pipe nozzle shall be cut to the contour of the tank and beveled to a depth of not more
than 1/3 the nozzle thickness to ensure partial penetration groove welding
c) The pipe nozzle shall be cut to the contour of the tank and beveled to a depth of not less
than 1/3 the nozzle thickness to ensure partial penetration groove welding
d) The pipe nozzle shall be cut to the contour of the tank and beveled from the outside for a
full penetration weld
49. After the reinforcing pad is installed, the pad shall be subjected to a pneumatic test.
a) True
b) False

50. After the valve has been installed on the flange, a pressure test of at least ______ shall be
performed on the nozzle prior to mounting the hot tap machine.
a) The same pressure as the pneumatic test of the reinforcing pad
b) 1.25 times the hydrostatic head
c) 1.5 times the hydrostatic head
d) 2.0 times the hydrostatic head (to account for the added stress of the machine)
Answers to API-653 Section 9, Repair/Alteration

1 B
2 A
3 D
4 C
5 A
6 C
7 D
8 B
9 C
10 D
11 A
12 B
13 B
14 D
15 A
16 B
17 B
18 C
19 D
20 C
21 A
22 D
23 B
24 B
25 D

Answers to API-653 Section 9, Repair and Alteration Continued:

26 B
27 C
28 D
29 C
30 A
31 A
32 B
33 C
34 B
35 D
36 A
37 C
38 D
39 C
40 B
41 A
42 B
43 C
44 D
45 C
46 B
47 A
48 D
49 A
50 C

Section 10 – Dismantling and Reconstruction
1. Bottom plates that will be reused shall be cut by de-seaming of lap-welds or by cutting alongside
of the remaining welds at a minimum of _______ away from existing welds.
a) One inch
b) Two inches
c) Four inches
d) Six inches
2. Shell plates may be cut by any of the following methods except

a) Shell rings ½” thick or thinner can be dismantled by cutting through the weld without
removing the heat affected zone
b) Cuts made a minimum of 6” away from existing welds except where cuts cross existing
welds
c) Cuts made a minimum of 2” away from existing welds except where cuts cross existing
welds
d) Any shell ring may be dismantled by cutting out existing weld seams and the heat
affected zone of the weld
3. API-653 requires that new vertical joints in adjacent shell courses not be in alignment. What is
the minimum offset dimension of these joints?
a) Vertical joints shall be offset a minimum of 5 inches or 5t which ever is greater
b) Vertical joints shall be offset a minimum of 5t where t is the plate thickness of the thicker
course at the point of offset
c) Vertical joints shall be offset a minimum of 5t where t is the plate thickness of the thinner
course at the point of offset
d) Vertical joints shall be offset a minimum of 5 inches or 5t which ever is less
4. Roof plates shall be cut by de-seaming of lap-welds or by cutting alongside of the remaining
welds at a minimum of _______ away from existing welds.
a) One inch
b) Two inches
c) Four inches
d) Six inches

5. In the reconstruction of aboveground storage tanks, welding shall be by any of the following
welding processes except.
a) Submerged arc welding
b) Oxyfuel
c) Gas metal-arc
d) Forging
Reference API-653, Paragraph 10.4.2.2 and API-650 5.2.1
6. No welding of any kind may be performed when the surfaces to be welded are wet from rain,
snow, or ice. When rain or snow is falling or during high wind conditions, welding is permitted
provided:
a) The welder is secured to an anti-fall device and the work is properly grounded
b) The welder has agreed to work in such conditions
c) The welder and the work are properly shielded
d) The owner/operator takes full responsibility for the safety of the welder and the quality of
the welds
7. According to API-653, no welding is permitted when the temperature of the base metal is below
what value?
a) Base metal temperature below -20°F
b) Base metal temperature below 0°F
c) Base metal temperature below 20°F
d) Base metal temperature below 30°F
8. If the base metal is greater than 1” thickness or the temperature of the base metal is between 0°F
and 32°F what requirement does API-653 stipulate?
a) The base metal within 3 inches of the weld area shall be heated to a temperature that is
warm to the hand (approximately 180°F)
b) The base metal within 8 inches of the weld area shall be heated to a temperature that is
c) The base metal within 3 inches of the weld area shall be heated to a temperature that is
d) The base metal within 8 inches of the weld area shall be heated to a temperature that is
9. What is the maximum permissible undercut of the base metal for vertical joints?
a) 1/64
b) 1/32
c) 1/19
d) 1/16

10. What is the maximum permissible undercut of the base metal for horizontal joints?
a) 1/64
b) 1/32
c) 1/19
d) 1/16
11. What is the maximum weld reinforcement thickness permitted on each side of the plate for a
plate, which is 7/8” thick?
Vertical joints Horizontal joints
a) 3/32” 1/8”
b) 1/8” 3/16”
c) 3/16” 1/4
d) 1/4 5/16”
Reference API-653, Paragraph 10.4.2.6 & Table 10-1
12. Tack welds used in the assembly of vertical joints in tank shells may remain in place when the
joints are welded manually provided:
a) They are properly cleaned of all weld slag
b) They are sound
c) Liquid Penetrant or Magnetic Particle examination is performed
d) They shall not remain
13. What are the requirements for making tack welds according API-653?
a) If the tack weld is to be removed, it must be made using qualified weld procedure and
qualified welder
b) If the tack weld is to remain in place, it must be made using qualified weld procedure and
qualified welder
c) If the tack weld is to remain in place, it may be made using any weld procedure
acceptable to the owner/operator
d) If the tack weld is to be removed, it may be made by any welder wishing to gain
experience provided the process is the SMAW process
14. All coatings must be removed from the weld area prior to welding except weldable primer
coatings. What must done if these primer coatings are used?
a) Weldable primer coatings must also be removed
b) If the coating is applied by brush it may remain provided the application is performed to a
written procedure
c) They shall be included in welding procedure qualification tests for brand, formulation,
and maximum thickness of primer applied
d) They shall be included in welding procedure qualification tests for the method of
application either by brushing or by spraying or a combination of the two.

15. When welding tank bottoms, when should the shell-to-bottom weld be completed?
a) This joint (except for door sheets) can be welded as soon as the bottom plates are laid out
and welded
b) This joint (except for door sheets) shall be welded as soon as the first bottom weld joint is
completed to prevent distortion
c) This joint (except for door sheets) shall be welded as work progresses around the tank
bottom
d) This joint (except for door sheets) shall be completed before the welding of bottom joints
16. What is the maximum permissible misalignment of vertical joints in shell plates that are .9375”
thick?
a) .125”
b) .09375”
c) .009375”
d) .0125”
17 What is the maximum permissible misalignment of vertical joints in shell plates that are .625”
thick?
a) .0625”
b) .00625”
c) .125”
d) .0125”
18. Vertical joints shall be completed before the lower horizontal weld is made.
a) True
b) False
19. In completing horizontal joints, what is the maximum projection of the upper plate, beyond the
face of the lower plate, at any point for plate thickness of 1.125”
a) .25”
b) .225”
c) .125”
d) .0125”

20. When welding horizontal and vertical joints constructed of material that is over 1.5” thick, based
on the thickness of the thicker part, what is the required preheat temperature?
a) Preheating is not required
b) 140°F
c) 200°F
d) 300°F
21. When shall measurements be taken to verify tolerances of reconstructed tanks?

a) After hydrostatic testing
b) Before hydrostatic testing
c) After lay out of all plates
d) After fit-up and tack welding used for alignment purposes
22. What is the maximum out-of-plumbness of the top of the shell relative to the bottom of the shell
of a tank with a total height of 62.25 feet?
a) 7.47”
b) .6225”
c) 6.25”
d) 5”
23. An aboveground storage tank is 115 feet in diameter. What is the maximum or minimum radius
permitted measured at one foot above the shell-to-bottom weld?
Maximum Minimum
a) 115.75” 114.25”
b) 690.75” 689.25”
c) 1380.75” 1379.25”
d) 115.5” 114.5”
24. An aboveground reconstructed tank is 126.5 feet in diameter. What is the maximum or minimum
radius permitted measured at the second shell course up from the bottom?
Maximum Minimum
a) 759.75” 758.25
b) 761.25” 756.75”
c) 1520.25” 1515.75”
d) 128.75” 124.25”

25. Peaking shall not exceed ½”. This is measured using a horizontal sweep board of what
dimensions?
a) The sweep board shall be 48” long and made to the true outside radius of the tank
b) The sweep board shall be 48” long and made to the true inside radius of the tank
c) The sweep board shall be 36” long and made to the true outside radius of the tank
d) The sweep board shall be 36” long and made to the true inside radius of the tank
26. Banding shall not exceed ____ with a vertical 36” long sweep board.
a) One half inch
b) Three quarter inch
c) One inch
d) One and one eighth inch
27. The top of the concrete ring wall of a reconstructed tank, that is 115 feet in diameter, must be
level within ± 1/8” in any 30 feet of circumference. What is the tolerance measured from the
average elevation?
a) ±1/8”
b) ±3/16”
c) ±1/2”
d) ±1/4”
Reference API-653, Paragraph 10.5.6.2(a)
28. Where concrete ring walls are not provided, the foundation under the shell shall be level to within
what tolerances?
a) ±1/8” in any 30’ of the circumference and ±1/2” in the total circumference measured
from the average elevation
b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference measured
c) ±1/8” in any 10’ of the circumference and ±1/4” in the total circumference measured
d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference measured
Reference API-653, Paragraph 10.5.6.2(b)
29. For foundations specified to be sloped from a horizontal plane, the actual elevation shall not
deviate from the calculated differences by more than which of the following where concrete ring
walls are provided?
b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference
d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference
Reference API-653, Paragraph 10.5.6.3(a)

30. For foundations specified to be sloped from a horizontal plane, the actual elevation shall not
deviate from the calculated differences by more than which of the following where concrete ring
walls are not provided?
b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference
d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference
Reference API-653, Paragraph 10.5.6.3(b)
Answers to API-653 Section 10, Dismantling & Reconstruction

1 b
2 c
3 b
4 b
5 d
6 c
7 b
8 c
9 a
10 b
11 b
12 d
13 b
14 c
15 d
16 b
17 a
18 a
19 c
20 c
21 b
22 d
23 b
24 b
25 c
26 c
27 d
28 b
29 d
30 b

Section 11 – Welding
1. Welding procedure specifications and welders and welding operators shall be qualified in
accordance with __________.
a) Original code of construction
b) Owner/operator’s specification
c) Section IX of the ASME Code
d) Repair organization’s specifications
2. According to API Standard 653, if the material specification for the steel from an existing tank is
unknown or obsolete what must be done?
a) The material can not be used for tank reconstruction
b) Test coupons for the WPS shall be taken from the actual plate to be used
c) Test coupons for the WPS may be taken from a similar material of known specification
d) Test coupons for the WPS shall only be taken from weld filler metal and not from the
base metal
3. Each welder and welding operator shall be assigned ________.

a) Only one joint to ensure traceability
b) A specific welding machine
c) An identifying number, letter, or symbol
d) Weld joints on only one side of the tank
4. How does each welder and welding operator identify the welds produced by them?
a) Each welder and welding operator’s identification mark shall be hand or machine
stamped adjacent to each completed weld.
b) Each welder and welding operator shall inform the owner/operator which welds he or she
completed
c) Each welder and welding operator shall show the inspector exactly which welds they
completed
d) Each welder and welding operator shall inform the owner/operator which welds they will
be making prior to the start of such welding
5. At what intervals must the welder and welding operator’s identification be stamped adjacent to
the completed welds?
a) Identification shall be at intervals not to exceed 9 feet
b) Identification shall be at intervals not to exceed 7.5 feet
c) Identification shall be at intervals not to exceed 6 feet
d) Identification shall be at intervals not to exceed 3 feet

6. In lieu of stamping, a record may be kept that identifies the welder or welding operator for each
welded joint.
a) True
b) False
7. What welds do not require welder’s identification?

a) All welds require identification
b) Vertical welded joints which are located within the final shell course since this course
will be subjected to relatively low stresses
c) Roof plate welds and flange-to-nozzle-neck welds
d) Roof plate welds and bottom plate welds
Answers to API-653 Section 11, Welding

1 C
2 B
3 C
4 A
5 D
6 A
7 C

Section 12 – Examination and Testing
1. Nondestructive examination procedures, qualifications, and acceptance criteria is required for

VT, MT, UT, PT, and RT methods and must be in accordance with what Code or Standard?
a) ASME Code Section V, Nondestructive examination
b) API Standard 650 only
c) API Standard 650 and the supplements given in API-653
d) Owner/operator’s specifications
2. Personnel performing nondestructive examination shall be qualified in accordance with _____.

a) API Standard 650 and the supplemental requirements of API-653
b) ASME Code Section V, Nondestructive Examination
c) SNT-TC-1A
d) The owner/operator’s specifications
3. When it is necessary to install a hot tap connection or add a reinforcing plate to an existing un-
reinforced penetration, API 653 requires what type, extent, and purpose of examination.
a) Magnetic particle examination for slight sub-surface discontinuities shall be performed in
an area equal to twice the diameter of the opening
b) Radiographic examination for cracking shall be performed in the immediate area
c) Ultrasonic examination for cracking shall be performed in the immediate area
d) Ultrasonic examination for lamination shall be performed in the immediate area
4. Completed welds attaching nozzle neck to shell, and reinforcing plate to shell and nozzle neck,
shall be examined by _______.
a) Ultrasonic or Radiography
b) Magnetic Particle or Liquid Penetrant
c) Visual examination or Liquid Penetrant
d) Ultrasonic or Magnetic Particle

5. How and when does API Standard 653 require the examination of welds of completed stress
relieved assemblies?
a) Completed welds of stress relieved assemblies shall be examined visually only after
stress relief and hydrostatic test
b) Completed welds of stress relieved assemblies shall be examined visually as well as by
ultrasonic methods after stress relief but before hydrostatic test
c) Completed welds of stress relieved assemblies shall be examined visually as well as by
magnetic particle or liquid penetrant methods after stress relief but before hydrostatic test
d) Completed welds of stress relieved assemblies shall be examined visually or by
radiography after stress relief but before hydrostatic test
6. Completed butt welds between insert plates and the shell require what type and extent of
examination?
a) Complete radiography
b) Spot Radiography
c) Random Radiography
d) Random Spot Radiography
7. In repairing butt weld flaws, what type and extent of examination is required by API-653?
a) Random examination by radiography or ultrasonic methods of the full length of repair
b) Examined full length of the repair by liquid penetrant or magnetic particle methods
c) Examined at three foot intervals by radiography or ultrasonic methods
d) Examined full length of the repair by radiography or ultrasonic methods
8. Completed repairs of fillet welds shall be examined over their full length by the appropriate
nondestructive method listed in API-653.
a) True
b) False
9. With regards to new welds attaching shell plate to shell plate, what method(s) of examination
is/are required on the completed weld?
a) Visual
b) Visual and Radiography
c) Visual and magnetic particle or liquid penetrant
d) Visual and ultrasonic

10. With regards to new welds attaching shell plate to shell plate for plate thickness greater than one
inch, what additional extent and method of examination is required by API-653?
a) The back gouged surface of the root and final pass (each side) shall be examined for its
complete length by the Inspector
b) The back gouged surface of the root and final pass (each side) shall be examined for its
complete length visually
c) The back gouged surface of the root and final pass (each side) shall be examined for its
complete length by magnetic particle or liquid penetrant
d) The back gouged surface of the root and final pass (each side) shall be examined for its
complete length by ultrasonic
11. New welding on the shell-to-bottom joint shall be inspected for its entire length by _____ and
_______ or ________.
a) Visual examination, liquid penetrant , magnetic particle
b) Right-angle vacuum box and solution film, light diesel oil
c) Visual examination, ultrasonic, eddy current
d) Visual examination, wet fluorescent magnetic particle, helium tracer gas
12. In applying light diesel oil to the opposite side of the first pass of new shell-to-bottom joints, how
long must the oil remain on the weld and what is the weld inspected for?
a) The oil shall be allowed to stand at least four hours and the weld inspected for wicking
action
b) The oil shall be allowed to stand at least three hours and the weld inspected for wicking
action
c) The oil shall be allowed to stand at least two hours and the weld inspected for wicking
action
d) The oil shall be allowed to stand at least one hour and the weld inspected for wicking
action
13. The existing weld at the shell-to-bottom joint shall be examined visually and magnetic particle or
liquid penetrant methods, for the full length under a welded-on patch plate. How much additional
shell-to-bottom joint must be examined?
a) Three inches on each side of the patch plate
b) Six inches on each side of the patch plate
c) nine inches on each side of the patch plate
d) twelve inches on each side of the patch plate

14. How and to what extent are newly welded bottom joints tested?
a) Newly welded bottom joints shall be tested their entire length using liquid penetrant
b) Newly welded bottom joints shall be tested their entire length using a vacuum box and a
solution film, or a tracer gas and detector
c) Newly welded bottom joints shall be tested their entire length using visual and ultrasonic
examination
d) Newly welded bottom joints shall be tested their entire length using wet fluorescent
magnetic particle examination
15. What are the requirements, regarding examination, of a welded-on patch plate in the critical
zone?
a) The final weld shall be examined by radiography over its entire length
b) Root and final pass shall be examined by radiography over its entire length
c) The root and final pass shall be examined visually over its entire length
d) The root and final pass shall be examined visually and by magnetic particle of liquid
penetrant method over its entire length
16. API-653 requires the number and location of radiographs to in accordance with API-650. In
addition, API-653 requires how many and what location for new or repaired shell vertical joints?
a) For new or repaired shell vertical joints one radiograph shall be taken in each fifty foot
length
b) For new or repaired shell vertical joints one radiograph shall be taken in each twenty-five
foot length
c) For new or repaired shell vertical joints one radiograph shall be taken in every joint
d) For new or repaired shell vertical joints one radiograph shall be taken in every other joint

17. API-653 requires the number and location of radiographs to in accordance with API-650. In
addition, API-653 requires how many and what location for new or repaired shell horizontal
joints?
a) For new or repaired shell horizontal joints one radiograph shall be taken in each twenty-
five feet of horizontal joint including those required at intersections of vertical and
horizontal joints
b) For new or repaired shell horizontal joints one radiograph shall be taken in each twenty-
five feet of horizontal joint not including those required at intersections of vertical and
horizontal joints
c) For new or repaired shell horizontal joints one radiograph shall be taken in each fifty feet
of horizontal joint including those required at intersections of vertical and horizontal
joints
d) For new or repaired shell horizontal joints one radiograph shall be taken in each fifty feet
of horizontal joint not including those required at intersections of vertical and horizontal
joints
18. API-653 requires two radiographs to be taken at each new or replacement intersection between
vertical and horizontal joints. One to comply with the requirement for vertical joints and one to
comply with the requirements for horizontal joints.
a) True
b) False
19. For reconstructed tanks, each butt-welded annular plate joint shall be radiographed in accordance
with which of the following?
a) API-650
b) ASME - Section V
c) API-653 and API-575
d) Owner/operator's specifications
20. For reconstructed tanks, radiographic examination is required for what percentage of all junctions
of new welds over existing seams?
a) 100%
b) 75%
c) 50%
d) 25%

21. Radiographic examination is required for new and replaced shell insert plate and door shell
welds. What are the minimum number and location of such radiographs?
a) Circular plates - four radiographs are required, one at each quadrant
b) Square or rectangular - two radiographs are required in each vertical joint and one in a
horizontal joint
c) Circular plates - one radiograph and for square or rectangular - one in a vertical joint, one
in a horizontal joint, and one in each corner
d) Circular and square of rectangular new or replaced insert plates require 100%
examination
22. What is the minimum diagnostic length of each radiograph?

a) The minimum diagnostic length of each radiograph shall be six inches
b) The minimum diagnostic length of each radiograph shall be three inches
c) The minimum diagnostic length of each radiograph shall be nine inches
d) The minimum diagnostic length of each radiograph shall be twelve inches
23. If the radiograph of an intersection between a new and old weld discloses discontinuities, which
are unacceptable by current standards, what must be done?
a) The unacceptable welds must be removed and made in accordance with current standards
b) The unacceptable welds shall be repaired to bring them in to compliance
c) The existing welds may be evaluated according to the original standard of construction
d) The existing welds shall be evaluated using the acceptance criteria of ASME Section VIII
24. Radiographs and radiograph records of all repaired welds shall be marked with what letter(s)?
a) "RW" (Repaired Weld)
b) "WR" (Weld Repair)
c) "A" (Accepted repair)
d) "R"
25. Hydrostatic testing is required for reconstructed tanks and tanks that have undergone major
repairs or alterations. What is the minimum length of time the hydrostatic test must be held?
a) The time is up to the discretion of the Inspector
b) Twenty-four hours
c) The time is up to the discretion of the owner/operator
d) Twelve hours

26. Major repair and major alteration is defined by API-653 by which of the following?
a) Cutting, addition, removal and/or replacement of the annular plate ring only if the plate is
less than 1/2" thick
b) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom
weld, or a sizeable portion of the shell
c) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom
weld, or a 100 square inch portion of the shell
d) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom
weld, or a sizeable portion of the shell in shell material greater than 3/4" thick
27. Of the following, which would not be considered a major repair or alteration?
a) The installation of a shell penetration NPS 12 above the design liquid level
b) The installation of a shell penetration NPS 12 below the design liquid level
c) Jacking of a tank shell
d) The complete of partial removal and replacement of more than 12 inches of vertical weld
joining shell plates, or radial weld joining the annular plate ring
28. A full hydrostatic test of the tank is not required for major repairs and alterations when certain
conditions are met. Where would you look for these conditions?
a) API-650 Paragraph 5.3.6
b) API-RP-575 Paragraph 7.5
c) API-510 Paragraph 6.4
d) API-653 Paragraph 12.3.2
29. Hydrostatic testing is not required for shell repairs when all but which of the following are
complied with?
a) Impact test requirements shall follow appropriate portions of API-650 and must be
specified in the repair procedure
b) New vertical and horizontal shell butt-welds must have complete penetration and fusion
c) New materials shall meet the current edition of ASME Section II Part A
d) Finished weld must be examined by radiography
30. If the owner/operator elects to utilize a fitness-for-service evaluation to exempt a repair form
hydrostatic testing, who perform the evaluation?
a) Fitness-for-service evaluations may not be used to exempt hydrostatic testing following a
repair
b) The Authorized Inspector
c) Engineer experienced in storage tank design and the evaluation methods used
d) Exemption of hydrostatic testing for repairs can only be given by the jurisdiction

31. When settlement is anticipated, a tank that is to be hydrostatically tested shall:

a) Have the plumbness checked
b) Have the water tested to ensure it is potable
c) Have the perimeter dike system checked
d) Have the foundation checked for settlement
32. The tank settlement shall initially be surveyed with the tank empty. What is the minimum number
of settlement measurement points for a tank which is 110 feet in diameter?
a) Minimum number of settlement points is 11
b) Minimum number of settlement points is 32
c) Minimum number of settlement points is 8
d) Minimum number of settlement points is 12
33. The tank settlement shall initially be surveyed with the tank empty. What is the minimum number
of settlement measurement points for a tank which is 60 feet in diameter?
a) Minimum number of settlement points is 12
b) Minimum number of settlement points is 6
c) Minimum number of settlement points is 8
d) Minimum number of settlement points is 4
34. Regardless of the minimum number of settlement measurement points required, what is the
maximum spacing between settlement measurement points?
a) 24 feet
b) 32 feet
c) 36 feet
d) 40 feet
35. When shall settlement be measured?

a) Settlement shall be measured after the water reaches 100% of test level and again when
the tank is emptied
b) Settlement shall be measured during filling and when the water reaches 80% of test level
c) Settlement shall be measured during filling and when the water reaches 100% of test
level
d) Settlement shall be measured during filling and when the water reaches 100% of test
level and during emptying of the tank

Answers to API-653 Section 12, Examination and Testing

1 c
2 a
3 d
4 b
5 c
6 a
7 d
8 a
9 b
10 c
11 b
12 a
13 b
14 b
15 d
16 c
17 d
18 b
19 a
20 d
21 c
22 a
23 c
24 d
25 b
26 b
27 a
28 d
29 c
30 c
31 d
32 a
33 c
34 b
35 c

Section 13 – Marking
1. Tanks that are reconstructed, in accordance with API-653 shall be identified by a corrosion-
resistant metal nameplate. What is the size requirement for the letters and numerals to be used on
this nameplate and how are they applied to the nameplate?
a) Letters and numerals not less than 1/2" high shall be embossed, engraved, or stamped in
the plate
b) Letters and numerals not less than 1/4" high shall be embossed, engraved, or stamped in
the plate
c) Letters and numerals not less than 5/32" high shall be painted on the plate or embossed,
engraved, or stamped in the plate
d) Letters and numerals not less than 5/32" high shall be embossed, engraved, or stamped in
the plate
2. Where should the new nameplate be attached and what should be done with the existing
nameplate
a) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate.
The existing nameplate shall be cleaned or suitably reconditioned
b) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate.
The existing nameplate shall be left attached to the tank
c) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate.
The existing nameplate shall be removed and placed in the tank record file
d) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate.
The existing nameplate shall then be discarded
3. All but which of the following information shall be made part of the owner/operator's records for
aboveground storage tanks?
a) Names of all operators of the tank
b) Calculations
c) Construction and repair drawings
d) Additional supporting data
Reference: API-653, Paragraph 13.2.1, 13.2.2, 13.2.3
Answers to API-653 Section 13, Marking

1 D
2 B
3 A

Appendix B – Evaluation of Tank Bottom Settlement

1. External measurements for tank settlement shall be taken at points having a maximum spacing of
____ around the circumference.
a) 24 feet
b) 28 feet
c) 32 feet
d) 36 feet
Reference: API-653 Appendix B, Paragraph B.2.1 and Figure B-1
2. Regardless of tank size, what is the minimum number of settlement point measurements?
a) Four
b) Eight
c) Twelve
D
d) Based on the formula N =
10
3. Internal measurement for tank bottom settlement taken across the diameter of the tank must be
taken at what maximum spacing?
a) 10 feet
b) 24 feet
c) 32 feet
d) 4 feet
4. Which of the following is not listed as settlement component?

a) Uniform settlement
b) Rigid body tilting of a tank (planar tilt)
c) Out-of-plane settlement (differential settlement)
d) Soil undermining (total tank sinking)
Reference: API-653 Appendix B, Paragraph B.2.2
5. What type of settlement is depicted here? ➪

a) Bottom settlement near tank shell
R
b) Edge settlement
c) Localized bottom remote from tank shell
d) Planar settlement
Original
bottom
Reference: API-653 Appendix B & Fig. B-5 position

6. Using the formula in B-3.2, determine the maximum permissible deflection (out of plane
distortion) for a tank with the following data reported.
Diameter 110 feet

Height 60 feet
Material Carbon Steel (Young's modulus = 29,000,000 psi)
Yield strength 30,000psi
Arc length between measurements 31.4 feet
a) S = .09 feet
b) S = .9 feet
c) S = 9 feet
d) S = .009 feet
Reference: API-653 Appendix B Paragraph B.3.2
7. What is the maximum depth of a local depression in a tank bottom if the radius of an inscribed
circle is equal to 7.5 feet?
a) BB = .2775 inches
b) BB = 2.775 inches
c) BB = 27.75 inches
d) BB = .02775 inches
Reference: API-653 Appendix B Paragraph B.3.3
Answers to API-653 Appendix B, Tank Bottom Settlement

1 C
2 B
3 A
4 D
5 B
6 A
7 B

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API 653 Preparatory Introduction & Workbook

API 653 CERTIFICATION COURSE FOR

* STORAGE TANK INSPECTOR *

Reliance Industries Limited

Asian Training Academy, Pune.

© Asian Training Academy. Pune, India 1

API 653- STORAGE TANK INSPECTOR

Asian Training Academy, Pune.

© Asian Training Academy. Pune, India 2

API 653- STORAGE TANK INSPECTOR PREPARATORY COURSE

2. PART 1 - Examination/Certification Information from API.

3. PART II- Guidelines and useful tips for Examination

4. PART III- Case Studies- WPS/PQR Roadmap & Examples

5. PART IV- Mathematics in API 653 Exam.

6. PART –V Questions on API 653-Tank Inspection Code

© Asian Training Academy. Pune, India 3

API 653- STORAGE TANK INSPECTOR PREPARATORY COURSE

Session I Session II Session III Session IV

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API 653- STORAGE TANK INSPECTOR

Asian Training Academy, Pune.

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API 653 CERTIFICATIN FOR IN-SERVICE INSPECTION

Storage Tanks are the major installations in Petroleum Refineries, Petrochemical

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