API 653 AWARENESS SESSION

ON
API 653 ABOVE GROUND STORAGE
TANKS INSPECTION, REPAIR,
ALTERATION AND RECONSTRUCTION

API STD 653 PRESENTATION

Venue: SGS Head Office, Karachi
Date: September 20th & 21st , 2010

Cause of Concern

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 Objectives of Awareness Session

◊ Understand common Tanks terms

◊ Perform required calculations

◊ Be able to use codes to find required information

◊Increase your inspection knowledge & skills

Table of Contents
◊ 1. Scope of API 653
◊ 2. Relevant Codes and References
◊ 3. Some Important Definitions
◊ 6. Inspection
◊ 4. Suitability for service
◊ 5. Brittle fracture considerations
◊ 9. Tank repair and alteration
◊ 7. Materials
◊ 10. Dismantling and reconstruction
◊ 8. Design Consideration for Reconstructed Tank
◊ 11. Welding
◊ 12. Examination and testing
◊ 13. Marking and recordkeeping
◊ Appendix B Evaluation of Tank Bottom Settlement

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 Scope of API 653

◊ API 653 covers steel storage tanks built to

API Standard 650 and its predecessor API 12C.

◊ It provides minimum requirements for maintaining the

integrity of such tanks after they have been placed in
service.

◊ API 653 addresses inspection, repair, alteration,

relocation, and reconstruction.

Scope of API 653 (Cont’d)

◊ The scope of API 653 is limited to the tank foundation, bottom, shell,
structure, roof, attached appurtenances, and nozzles to the face of the
first flange, first threaded joint, or first welding - end connection.

◊ When design and construction details are not available in the

standard to which the tank was originally constructed, then details that
will provide a level of integrity equal to the level provided by the current
edition of API Std 650 must be used.

◊ In the case of any conflicts between the requirements of this

standard and API Std 650 or its predecessor API 12C, API 653 Shall
be govern for tanks that have been placed in service.

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 Scope of API 653 (Cont’d)
COMPLIANCE WITH THIS STANDARD

◊ The owner/operator has ultimate responsibility for complying

with the provisions of this standard.

◊ The application of this standard is restricted to organizations

that employ or have access to an authorized inspection agency

JURISDICTION

◊ If any provision of this standard presents a direct or implied

conflict with any statutory regulation, the regulation shall govern.

◊ If the requirements of this standard are more stringent than the

requirements of the regulation, then the requirements of this
standard shall govern.
7

Relevant Codes And References

API 652
API 575 API 650

API 571 API 653 API 577

ASME ASME
API 651
V IX

4
 Relevant Codes And References

◊ API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks

◊ API STD 650, Welded Steel Tanks for Oil Storage

◊ API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks

◊ API RP 652, Lining of Aboveground Petroleum Storage Tank Bottoms

◊ API RP 577, Welding Inspection and Metallurgy

◊ API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining

Industry

◊ ASME Section V, Non Destructive Examination

◊ Section IX, Welding and Brazing Qualifications

◊ EEMUA 159, User’s Guide to the Inspection, Maintenance and Repair of

Aboveground Vertical Cylindrical Steel Storage Tanks
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Some Important Definitions

Alteration:
Any work on a tank that changes its physical dimensions or
configuration.

As-Built Standard:
The standard used for the construction of the tank component

Atmospheric pressure:
Used to describe tanks designed to withstand an internal pressure
up to but not exceeding 2 ½ lbf/in2 gauge.

Authorized inspector:
A Person who is certified as an Aboveground Storage Tank
Inspector per Appendix D of API 653

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 Some Important Definitions (Cont’d)

Authorized inspection agency:

One of the following organizations that employ an aboveground
storage tank inspector certified by API.

a. The inspection organization of the jurisdiction in which the

aboveground storage tank is operated.

b. The inspection organization of an insurance company

which is licensed or registered to and does write aboveground
storage tank insurance.

c. An owner/operator who maintains an inspection organization for

activities relating only to his/her equipment and not for aboveground
storage tanks intended for sale or resale.

d. An independent organization or individual.

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Some Important Definitions (Cont’d)

Break over point:

The area on a tank bottom where settlement begins.

Candidate tank:
The tank for which corrosion rates are not known.

Change in service:
A change from previous operating conditions involving different
properties of the stored product such as specific gravity or corrosivity
and/or different service conditions of temperature and/or pressure.

Corrosion rate:
The total metal loss divided by the period of time over which the metal
loss occurred.

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6
 Some Important Definitions (Cont’d)
Control tank:
The tank for which corrosion rates and service history are known and
documented.
Critical zone:
The portion of the tank bottom or annular plate within 3 in. of the inside
edge of the shell, measured radially inward.
Reconstruction:
Any work necessary to reassemble a tank that has been dismantled and
relocated to a new site.
Repair:
Work necessary to maintain or restore a tank to a condition suitable for
safe operation. Repairs include both major repairs (see 3.21) or repairs
that are not major repairs. Examples of repairs include:
Removal and replacement of material to maintain tank integrity.
◊ Re-leveling and/or jacking of a tank shell, bottom, or roof.
◊ Addition of reinforcing plates to existing shell penetrations.
◊ Repair of flaws, such as tears or gouges, by grinding and / or
gouging followed by welding.

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Some Important Definitions (Cont’d)

Repair organization: An organization that meets any of the
following:

a. An owner/operator of aboveground storage tanks who repairs

or alters his/her own equipment in accordance with API 653.

b. A contractor whose qualifications are acceptable to the

owner/operator of aboveground storage tanks and who makes
repairs or alterations in accordance with API 653.

c. One who is authorized by, acceptable to, or otherwise not

prohibited by the jurisdiction, and who makes repairs in
accordance with API 653.

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7
 Some Important Definitions (Cont’d)
Fitness for service assessment:
A methodology whereby flaws contained within a structure are
assessed in order to determine the adequacy of the flawed
structure for continued service without imminent failure.

Hot tap:
Identifies a procedure for installing a nozzle in the shell of a tank
that is in service

Product side:
The side of the tank that is in contact with the stored liquid
product.

Reconstruction:
Any work necessary to reassemble a tank that has been
dismantled and relocated to a new site
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Some Important Definitions (Cont’d)

Major alteration/or major repair: An alteration or repair that includes
any of the following:

◊ Installing a shell penetration larger than NPS 12 beneath the design

liquid level.

◊ Installing a bottom penetration within 12 in. of the shell.

◊ Removing and replacing or adding a shell plate beneath the design

liquid level

◊ Removing or replacing annular plate ring material where the longest

dimension of the replacement plate exceeds 12 in.

◊ Complete or partial (more than one-half of the weld thickness) removal

and replacement of more than 12 in. of vertical weld joining shell plates
or radial weld joining the annular plate ring.
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8
 Some Important Definitions (Cont’d)
Major alteration/or major repair: An alteration or repair that includes
any of the following:
◊ Installing a new bottom. This does not include new bottoms in tanks
where the foundation under the new bottom is not disturbed and either
of the following conditions is met:
1. For tanks with annular rings, the annular ring remains intact; or,
2. For tanks without annular rings, the alteration does not include
welding on the existing bottom within the critical zone.
◊ Removing and replacing part of the weld attaching the shell to the
bottom, or to the annular plate ring, in excess of the amounts listed in
12.3.2.4.1a.
◊ Jacking a tank shell.
Soil Side:
The side of the tank bottom that is in contact with the ground.
Unknown toughness:
A condition that exists when it cannot be demonstrated that material of a
component satisfies the definition of recognized toughness
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Types of Storage Tank

◊ GENERAL
◊ Storage tanks are used to store fluids such as crude oil,
intermediate and refined products, gas, chemicals, waste
products, water, and water/product mixtures. Important factors
such as the volatility of the stored fluid and the desired storage
pressure result in tanks being built of various types, sizes, and
materials of construction.
◊ At the moment we will discuss only atmospheric and low
pressure storage tanks..

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 Atmospheric Storage Tanks

CONSTRUCTION MATERIAL AND DESIGN STANDARDS

◊ Atmospheric storage tanks are designed to operate with their gas and vapour spaces at
internal pressures approximating atmospheric pressure. Such tanks are usually
constructed of carbon steel, alloy steel, aluminium or other metals, depending on service.
USE OF ATMOSPHERIC STORAGE TANKS
◊ Atmospheric storage tanks in the petroleum industry are normally used for fluids having a
true vapour pressure that is less than atmospheric pressure.
◊ Crude oil, heavy oils, gas oils, furnace oils, naphtha, gasoline, and non-volatile chemicals
are usually stored in atmospheric storage tanks.
◊ Many of these tanks are protected by pressure-vacuum vents that maintain the pressure
difference between the tank vapour space and the outside atmosphere to just a few ounces
per square inch.

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Use Of Atmospheric Storage Tanks

◊ Non-petroleum industry uses of atmospheric tanks include storage of a

variety of chemicals and other substances operated in closed-loop
systems not vented to atmosphere and with pressure control and relief
devices as required.

◊ Additional uses for atmospheric storage tanks can include liquid (both
hydrocarbon and non-hydrocarbon) storage in horizontal vessels,
storage of process liquids or granular solids in skirt-supported or
column-supported tanks with elevated cone bottoms (non-flat bottom)
and process water / liquids in open-top tanks.

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 Types Of Atmospheric Storage Tanks

◊ The most common type of atmospheric storage tanks are ;

◊ Fixed Cone Roof Tanks
• Dome Roof Tank
• The Umbrella Roof Tank
◊ Floating Roof Tanks
• Single Steel Deck
• Double Steel Deck
• Annular Pontoon Tanks

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Types Of Atmospheric Storage Tanks (Cont’d)

◊ The floating-roof tank is another common type of atmospheric storage tank.

◊ The floating-roof tank is designed to minimize filling and breathing losses by
eliminating or minimizing the vapor space above the stored liquid. The shell and
bottom of this type of tank are similar to those of the fixed roof tanks, but in this
case, the roof is designed to float on the surface of the stored liquid. Older styles
of floating roofs include single steel deck details without annular pontoons . Such
roofs have no reserve buoyancy and are susceptible to sinking in service.
◊ Some floating-roof tanks have fixed aluminum geodesic dome roofs installed on
top of the tank shell to reduce product vapor loss or to eliminate the need to drain
rainwater from the roof. These are considered internal floating roofs as is a tank
with a fixed steel cone roof over a floating roof.

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 Cone Roof Tank

• The most common type of

atmospheric storage tank is the
fixed cone roof tank, shown in
attached Figure.
• Fixed cone roof tanks may
typically be up to 300 ft (91.5 m) in
diameter and 64 ft (19.5 m) in
height (although larger diameter
tanks have been built, mostly
outside the U.S.).
• These roofs are normally
supported by internal structural
rafters, girders and columns but
can be fully self- supporting in
smaller diameters (typically, 60 ft
[3 m] diameter or less).
• Geodesic domes may be applied
to any diameter tank without the
need for internal supporting
columns.
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Umbrella Dome Roof Tank

• The umbrella roof tank,

shown in attached Figure
is a variation of the fixed
roof tank.
• The umbrella roof has
radially-arched segmental
plates with integral
framing support members
(usually without internal
support columns).

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12
Steel Dome Roof Tank

• In the steel dome roof

tank shown in attached
Figure, the roof plates are
usually formed with
curved segments joined
to be self-supporting.

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Floating Roof Tanks

• Pan Type Floating

Roof Tank

• Annular-pontoon
Floating-roof Tank

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 Internal Floating Roof

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Components of Internal Floating Roof

1. Roof Deck 8.Vacuum Relief Device

2. Support Leg 9. Overflow Vent
3. Seal 10. Peripheral Roof Vent
4. Anti Rotation Device 11. Centre Roof Vent
5. Column Negotiating Device 12. Anti Static Grounding
6. Manway 13. Roof Hatch
7. Gauge Float well 14. Gauge Funnel

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 SUITABILITY FOR SERVICE

When the results of a tank inspection show

that a change has occurred from the original
physical condition of that tank, an evaluation
shall be made to determine its suitability for
continued use.

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Factors For Consideration

◊ Internal corrosion due to the product stored or water bottoms.

◊ External corrosion due to environmental exposure.
◊ Stress levels and allowable stress levels.
◊ Properties of the stored product such as specific gravity, temperature
and corrosivity.
◊ Metal design temperatures at the service location of the tank.
◊ Chemical analysis and mechanical properties of the materials of
construction.
◊ Operating conditions such as filling / emptying rates and frequency.
◊ External roof live load, wind, and seismic loadings.
◊ Tank foundation, soil, and settlement conditions.
◊ Distortions of the existing tank.

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 Tank Roof Evaluation
Plates shall be repaired or replaced if:

◊ Roof Plates corroded to an average thickness of less

than 0.09in. in any 100sq.in. area
◊ Roof plates with any holes through the roof plates

Fixed Roofs
Inspection should be performed to check the soundness of :
◊ Roof Support members (rafters, girders, columns, and bases)
◊ Particular attention must be given to the possibility of severe
internal corrosion of pipe columns (corrosion may not be
evidenced by external visual inspection).
◊ Roof to shell frangible joint (when required)

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Tank Roof Evaluation

Floating Roofs

Attention should be given to :

◊ Pontoons for damage or cracks
◊ Roof support systems
◊ Perimeter seal systems
◊ Appurtenances such as a roof rolling ladder, anti-
rotation devices, water drain systems, and venting
systems
Guidance for the (design) evaluation of existing floating
roofs shall be based on the criteria of API 650.

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 Change of Service:
Internal Pressure
As per API 650 Appendix F regarding evaluation and subsequent
modifications to the tank and roof to shell junction.
External Pressure
As per API 620 regarding roof support structure (if any) and the
roof to shell junction shall be evaluated for the effects of a design
partial vacuum.
Operation at Elevated Temperature
As per API 650 Appendix M, shall be considered before changing
o
the service of a tank to operation at temperatures above 200 F.
Operation at Lower Temperature than Original Design
As per API 650.
Normal and Emergency Venting
Effects of change of service on Normal and Emergency Venting
shall be considered.

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Tank Shell Evaluation

◊ Flaws, deterioration, or other conditions (for example, change

of service, relocation, corrosion greater than the original corrosion
allowance) that might adversely affect the performance or
structural integrity of the shell of an existing tank must be
evaluated and determination made regarding suitability for
intended service.

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 Tank Shell Evaluation: (Contd)
◊ Many forms of corrosion at shell occurs , generally uniform loss
of metal over a large surface area or in localized area.

◊ Pitting does not normally represent a significant threat to the

overall structural integrity of a shell unless present in a severe
form with pits in close proximity to one another. General corrosion
and pitting should be evaluated separately.

◊ If the minimum requirement of the standard cannot be

satisfied, the corroded or damaged areas shall be repaired or the
allowable liquid level of the tank reduced or the tank retired.

◊ The actual thickness, as determined by inspection, minus the

corrosion allowance shall be used to establish the liquid level limit.
The maximum design liquid level shall not be exceeded.

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Actual Thickness Determination: (Shell)

For determining the controlling thickness in each shell course when
there are corroded areas of considerable size, measured thickness shall
be averaged in accordance with the following procedure:

◊ For each area, the authorized inspector shall determine the

minimum thickness, t2, at any point in the corroded area, excluding
widely scattered pits.

◊ Calculate critical length L.

◊ The authorized inspector shall visually or otherwise decide which

vertical plane(s) in the area is likely to be most affected by
corrosion. Profile measurements shall be taken along each vertical
plane for a distance, L. In the plane(s), determine the lowest
average thickness, t1, averaged over a length of L, using at least
five equally spaced measurements over length L.

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18
 Inspection Of Corroded Areas

37

Tank Shell Evaluation: (Contd)

Criteria for continued operation:

◊ The value t1 (tavg) shall be greater than or equal to tmin,

subject to verification of all other loading (such as wind
induced buckling, seismic loads, operation at temperature over
200oF, vacuum induced external pressure, external loads
caused by piping, tank mounted equipment, hold down lugs,
etc., wind induced overturning, loads due to settlement)

◊ The value t2 shall be greater than or equal to 60% of tmin;

and

◊ Any corrosion allowance required for service until the time

of the next inspection shall be added to tmin and 60% of tmin.

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 Tank Shell Evaluation: (Cont’d)

Pits Evaluation:

Widely scattered pits may be ignored provided that:

◊ No pit depth results in the remaining shell thickness

being less than one-half the minimum acceptable tank
shell thickness exclusive of the corrosion allowance; and

◊ The sum of their dimensions along any vertical line

does not exceed 2in. in any 8 in. length (Fig 4-2)

39

PIT MEASUREMENT

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 Minimum Thickness Calculation for Tank Shell
When determining the minimum acceptable thickness for an
entire shell course, tmin is calculated as follows:

tmin should not be less than 0.1in in any case

When determining the minimum acceptable thickness for any

other portions of a shell course (such as locally thinned areas
or any other location of interest), tmin is calculated as follows:

41

Hydrostatic Test Height (Shell)

After determining the controlling thickness of an entire shell
course, Ht calculated as follows:

After determining the controlling thickness for a locally thinned

area, or any other location of interest within a shell course, Ht
is calculated as follows:

42

21
 43

Minimum Thickness Calculation for Tank Shell

44

22
Minimum Thickness Calculation for Tank Shell

45

Minimum Thickness Calculation for Tank Shell

46

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Minimum Thickness Calculation for Riveted Tank Shell

◊The minimum acceptable thickness for riveted shell shall

be calculated by given equation except that following
allowable stress criteria and joint efficiencies shall be used:

S is 21000 lbf/in°

E is 1.0 for shell plate 6 in. or more away from rivets. See
table 4.3 for joint efficiencies for location within 6 in. of
rivets

47

Minimum Thickness Calculation for Riveted Tank Shell

48

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 Shell Distortions
Shell distortions include out of roundness, buckled areas,
flat spots, and peaking and banding at welded joints.
Causes:
◊ Foundation settlement
◊ Over or under pressuring
◊ High wind
◊ Poor shell fabrication or repair techniques

Evaluation

◊ Shell distortions shall be evaluated on an individual

basis to determine if specific conditions are considered
acceptable for continuing tank service and/or the extent
of corrective action.

49

Flaws

The evaluation of an existing tank shell for suitability for

service must also consider the details and condition of the
following:

◊ Flaws such as cracks or laminations

◊ Scars such as arc strikes, gouges
◊ Tears from temporary attachment welds
◊ Critical if in shell-bottom weld
◊ Shell Welds for pits or any other discontinuities
◊ Wind girders and shell stiffeners
◊ Shell Penetrations – (Nozzles, man-ways, clean
out openings, etc.)
50

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 Shell Penetrations

◊ The condition and details of existing shell penetrations

(nozzles, manways, cleanout openings, etc.) shall be reviewed
when assessing the integrity of an existing tank shell.

◊ Nozzle wall thickness shall be evaluated for pressure and all

other loads.

◊ Existing welds on the tank shell that are not to be modified or

affected by repairs and are closer than required by API Std 650
(seventh edition or later) are acceptable for continued service if
the welds are examined by the magnetic particle method and
have no rejectable defects or indications.

51

Elevated Temperature

Operation at elevated temperature:

◊Tank of welded construction that operate at elevated
temperature (200 °F ~ 500 °F) shall be evaluated as per API-650
Appendix M.

Continued operation at elevated temperature:

◊ shall be evaluate as per API-653 Para 4.3.10.1.1.

Conversion operation at elevated temperature:

◊ Tank shell shall be evaluated in conformance with API-650
Appendix M.
◊ Butt-welded annular ring shall be determined in conformance
with API-650 Appendix M.
◊ Shell-to-bottom joint shall be evaluated for fatigue condition.

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 Tank Bottom Evaluation:
Causes of Bottom Failure:

◊ Internal pitting and pitting rates.

◊ Corrosion of weld joints (weld and heat effected zone)
◊ Weld joint cracking.
◊ Stresses placed on the bottom plates by roof support
loads and shell settlement.
◊ Underside corrosion (normally in the form of pitting).
◊ Inadequate drainage resulting in surface water flowing
under the tank bottom.
◊ The lack of an annular plate ring when required.

53

Causes of Bottom Failure: (Cont’d.)

◊ Uneven settlement that results in high localized

stresses in the bottom plates.
◊ Roof support columns or other supports welded to
the tank bottom where adequate allowance for
movement was not made.
◊ Rock or gravel foundation pads with inadequately
filled-in surface voids.
◊ Non-homogeneous fill under the tank bottom (for
example, a lump of clay in a sand foundation pad).
◊ Inadequately supported sumps.

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27
 Tank Bottom Evaluation:

Bottom Leak Detection:

If bottom is to be replaced, consideration should be

given to installing a leak detection system that will
channel any leak in the bottom to a location where
it can be readily observed from outside of the tank.

Bottom Plate Thickness Measurements:

Various methods for determining tank bottom plate

underside corrosion are available. The methods vary
by the extent that they can reliably measure general
corrosion and pitting.

55

Minimum Thickness for Tank Bottom Plate

56

28
Minimum Thickness for Tank Bottom Plate

57

Tank Bottom Evaluation

58

29
 Tank Bottom Evaluation: (Cont’d.)

If the minimum bottom thickness, at the end of

the in-service period of operation, are calculated
to be less than the minimum bottom renewal
thicknesses given in Table 4-4, the bottom shall
be lined, repaired, replaced, or the interval to
the next internal inspection shortened.

59

BOTTOM PLATE MINIMUM THICKNESS

60

30
 ABOTTOM PLATE MINIMUM THICKNESS

61

Tank Foundation Evaluation:

Causes of Foundation Failure:

◊ Settlement
◊ Erosion
◊ Cracking

Deterioration of concrete initiated by:

◊ Calcining
◊ Attack by underground water
◊ Attack by alkalies and acids

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 Tank Foundation Evaluation:

Foundation Repair or Replacement:

Concrete pads, ring walls, and piers, showing

evidence of spalling, structural cracks, or general
deterioration, shall be repaired to prevent water
from entering the concrete structure and
corroding the reinforcing steel.

63

Tank Foundation Evaluation:

Anchor Bolts:

Distortion of anchor bolts and excessive cracking

of the concrete structures in which they are
embedded may be indications of either serious
foundation settlement or a tank overpressure
uplift condition.

64

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 Brittle Fracture Considerations

65

Brittle Fracture Considerations

◊ In all reported incidents of tank failure due to brittle

fracture, failure occurred either shortly after erection
during hydrostatic testing or on the first filling in
cold weather, after a change to lower temperature
service, or after a repair / alteration

◊ This experience shows that once a tank has

demonstrated the ability to withstand the combined
effects of maximum liquid level (highest stresses) and
lowest operating temperature without failing, the
risk of failure due to brittle fracture with continued
service is minimal.

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 Brittle Fracture Considerations (Contd.)

Chances of Brittle Fracture are minimum if:

◊ Tank Shell Thk. ≤ 0.5 inch

◊ Operate at metal Temperature ≥ 60oF

◊ Membrane Stress < 7 ksi

67

A decision Tree

68

34
Exemption Curve

69

INSPECTION

70

35
 INSPECTION

The purpose of tank inspection is to assure continued tank integrity.

For the 100% code compliance, it is the mandatory requirement
of API 653 to conduct inspections under the supervision of
API 653 certified / authorized inspector
according to appendix “D” of the standard.

71

Inspection Frequency Considerations

Several Factors must be considered when determining Inspection
interval for storage tanks. These include but not limited to the following:

◊ The nature of product stored.

◊ Corrosion allowance and corrosion rate.
◊ Corrosion preventive system.
◊ Condition at previous inspection.
◊ The location of tanks, such as those in isolated or high risk areas.
◊ The potential risk of air and water pollution.
◊ Leak detection system.
◊ Change in operating mode.
◊ Chang in service.
◊ The results of visual maintenance checks.
◊ The existence of a double bottom or RPB
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36
 Inspection Intervals

◊ Based on service history

◊ A history of the service of a given tank or a tank in

similar service (preferably at the same site) should be
available so that complete inspections can be scheduled with
a frequency according to the corrosion rate of the tank.

◊ Jurisdictional regulations, in some cases, control

the frequency and interval of the inspections. These
regulations may include vapor loss requirements,
seal condition, leakage, proper diking, and repair
procedures

73

Types Of Inspection

Routine In-service Inspections

External Inspections

Ultrasonic Thickness Inspection

Internal Inspections

74

37
 Routine In-service Inspections

◊ The external condition of the tank shall be monitored by close

visual inspection from the ground on a routine basis

◊ This inspection may be done by owner/operator personnel, and

can be done by other than authorized inspectors

◊ Personnel performing this inspection should be knowledgeable

of the storage facility operations, the tank, and the characteristics
of the product stored.

75

Routine In-service Inspections (Cont’d)

Interval Shall not Exceeds
One Month
This routine in-service inspection shall include a visual external
inspection, Following shall be considered:
◊ Evidence of leaks
◊ Shell distortions
◊ Signs of settlement
◊ Corrosion
◊ Condition of the foundation
◊ Paint coatings
◊ Insulation systems
◊ Appurtenances

Records of routine in-service inspection should be documented for

follow-up action by an authorized inspector.
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38
 External Inspections
(Tank may be in operation during this inspection)

Visual External Inspection shall be conducted by an Authorized

Inspector at least 5 years or following which ever is less:

RCA/4N
Where as

RCA
difference between the measured shell thickness and the minimum

required thickness in mils,

N
is the shell corrosion rate in mils per year

77

External Inspections (Contd.)

◊ Appendix “C” of API 653 provides the sample checklist for In-service

tank inspection.

◊ Insulated tanks need to have insulation removed only to the extent

necessary to determine the condition to the exterior wall of the tank or

the roof.

◊ Tank grounding system components such as shunts or mechanical

connections of cables shall be visually checked.

◊ CP Surveys
API 651

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 Ultrasonic Thickness Inspection

◊ Corrosion rate not known
Maximum interval

shall be 5 years

◊ Corrosion rate known
RCA/2N years or 15

years which ever is less

◊ Corrosion rates may be estimated from tanks in

similar service based on thickness measurements
taken at an interval not exceeding 5 years

79

Cathodic Protection Survey

◊ where exterior tank bottom corrosion is

controlled by a cathodic protection system,
periodic survey of the system shall be conducted
in accordance with API- 651.

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 Internal Inspection
Internal Inspection is primarily required to:
◊ Ensure that the bottom is not severely
corroded and leaking.

◊ Gather the data necessary for the minimum

bottom and shell thickness assessments.

◊ Check Internal Condition of tank for Shell,

Internal Structure and Roof.

◊ Identify and evaluate any tank bottom

settlement
81

Internal Inspection Intervals

◊ The interval from initial service until the initial
internal inspection shall not exceed 10year.

◊If tank has one of the following leak prevention,

detection, or containment safeguards. The initial
internal inspection interval shall not exceed the
applicable maximum interval as shown below

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 Internal Inspection Intervals
Tank Safe Guards Max Inspection
Interval
i) Original nominal bottom thickness 5/16 in. or greater 12 years
ii) Cathodic protection of the soil-side of the primary tank bottom per Note 1 12 years
iii) Thin-film lining of the product-side of the tank bottom per Note 2 12 years

iv) Fibreglass-reinforced lining of the product-side of the tank bottom per Note 2 13 years
v) Cathodic protection plus thin-film lining 14 years

vi) Cathodic protection plus Fibreglass-reinforced lining 15 years

vii) Release prevention barrier per Note 3 (when similar service assessment performed) 20 years

viii) Release prevention barrier per Note 3 (when RBI assessment performed) 25 years

NOTE 1 For purposes of 6.4.2.1, effective cathodic protection of the soil-side of the primary tank bottom
means a system installed and maintained in accordance with API 651.
NOTE 2 For purposes of 6.4.2.1, lining of the product-side of the tank bottom means a lining installed,
maintained and inspected in accordance with API 652.
NOTE 3 For purposes of 6.4.2.1, a release prevention barrier means an under-bottom leak detection and
containment system designed in accordance with API 650, Appendix I.

83

Internal Inspection Intervals

◊ The interval between subsequent internal
inspections shall be determined in accordance with
either the corrosion rate or RBI procedure and shall not
exceed the applicable maximum intervals as shown
below

Procedure Used Max. Interval

i) Corrosion rate procedures in 6.4.2.3 20 years
ii) RBI assessment per 6.4.2.4 25 years
iii) RBI assessment per 6.4.2.4 and a release prevention barrier per Note 30 years
NOTE For purposes of 6.4.2.2, a release prevention barrier means an under-bottom leak detection and
containment system designed in accordance with API 650, Appendix I.

84

42
 Alternative Internal Inspection Interval
RBI (Risk Based Inspection):
◊ An owner / operator may establish the internal
inspection interval using risk based inspection (RBI)
procedures.

◊ The RBI process may be used to establish as

acceptable the risk of a minimum bottom plate
thickness at the next inspection interval.

◊ The RBI assessment may also increase or decrease

the 20 years inspection interval.

◊ API RP 580 - Risk Based Inspection

85

RBI (Risk Based Inspection) Cont’d

◊ The initial RBI assessment shall be reviewed and approved

by an authorized inspector and an engineer, knowledgeable
and experienced in tank design (including tank foundations)
and corrosion.

◊ The RBI assessment shall subsequently be reviewed and

approved by an authorized inspector and an engineer,
knowledgeable and experienced in tank design (including
tank foundations) and corrosion, at intervals not to exceed
10 years.

86

43
 Records Of Inspection
◊ The owner / operator shall maintain a complete
record file consisting of three types of records,
namely:

◊ Construction records
◊ Inspection history
◊ Repair / Alteration history.

◊ It is recognized that records may not exist for

older tanks and judgments must be based on
experience with tanks in similar services

87

Materials

88

44
 MATERIALS
New Material:

All new material used for repair, alterations, or

reconstruction shall conform to current applicable tank
standards

89

Original Materials for Reconstructed tanks

Shell and Bottom Plates Welded to the shell:

◊ All material shall be identified.

◊ After identification, determination shall be made as to

suitability of the material for intended service.

Structural:

◊ Existing rolled structural shapes that are to be reused shall

meet the requirement of *ASTM A7 as a minimum. New
structural material shall meet the requirements of ASTM A 36 or
A 992 as a minimum.

90

45
 Materials (Contd.)
Flanges and Fasteners:
◊ Flanges – Minimum requirement of the material
specifications in the original standard of construction
◊ Fasteners – Material specifications of current applicable
standard.

Roof, Bottom and Plate Wind girders:

◊ If existing plates are to be used to reconstruct the tank,

they shall be checked for excessive corrosion and pitting (for
further details Sect. 4 and 6 of API 653)

Welding Consumables:

◊ Welding consumables shall conform to AWS classification

that is applicable to the intended use.
91

DESIGN CONSIDERATIONS FOR

RECONSTRUCTED TANKS

92

46
 Design Considerations For Reconstructed Tanks

New Weld Joints:

Weld joint details shall meet the welding requirements of the
current applicable standard.
All new shell joints shell be butt welded joints with complete
fusion
Existing Weld Joints:
Existing weld joints shall meet the requirements of the as-built
standard.
Shell Design:
1. Thickness to be used for each shell course when checking
tank design shall be based on measurements taken within
180 days prior to relocation.

2. The maximum liquid level for hydrostatic test shall be

determined by using the actual thickness measured for each
shell course.
93

TANK REPAIR AND

ALTERATION

94

47
 Tank Repair And Alteration

◊ Basis for repairs and alterations shall be

API 650.

◊ All repair work and quality plan must be

authorized by the Authorized Inspector
(API 653’s requirement).

95

Removal and replacement of shell plate material

Minimum thickness of replacement shell plate:

◊ Shall be calculated according to API 650.

◊ The thickness of the replacement shell plate shall not be

less than the greatest nominal thickness of any plate in the
same course adjoining the replacement plate except where
the adjoining plate is thickened insert plate.

◊ Any change from the original design conditions, such as

specific gravity, design pressure, liquid level, and shell
height shall be considered.

96

48
 Minimum Dimensions of replacement shell plate
Minimum Dimensions for a replacement shell plate is:
◊ 12 in. or 12 times the thickness of the replacement plate,
whichever is greater.

◊ May be circular, oblong, square with rounded corners, or

rectangular with rounded corners except when entire shell plate is
replaced.

◊ Prior to welding the new vertical joints, the existing horizontal

welds shall be cut for a minimum distance of 12in. beyond the new
vertical joints. The vertical joints shall be welded prior to welding the
horizontal joints.

97

Minimum Dimensions of replacement shell plate

98

49
 Shell Repairs Using Lap Welded Patch Plates

Lapped patch plates may be used:

◊ For the closure of holes caused by the removal of existing shell

openings.
◊ For the removal of corroded or eroded areas.
◊ To reinforce areas of severely deteriorated shell plates that are
unable to resist the service loads to which the tank is to be
subjected.
◊ To repair small shell leaks, or minimize the potential from leaks
from severely isolated or widely scattered pitting.

99

Minimum Dimensions of Lap Welded Patch Plates

◊ Thickness shall not exceed ½’’ and not less than 3/16’’ .

◊ The maximum vertical and horizontal dimension of repair plate is

48’’ and 72’’.

◊ The minimum repair plate dimension is 4’’.

◊ The repair plate shall be formed to shell radius.

◊ All corners, except at the shell to bottom joint, shell be rounded

to a minimum radius of 2’’.

◊ The repair plate may cross any butt welded vertical or horizontal
shell seam that have been ground flush, but must overlap a
minimum of 6’’.

100

50
 Weld Joint Design

◊ Shell replacement plates shall be welded with butt joints

with complete penetration and complete fusion, except as
permitted for lapped patch shell repairs.

◊ Weld joint design for replacement shell plates shall

meet the original standard of construction – API 650

◊ Repair plates positioned on the shell interior shall be

located such that the toe-to-toe weld clearance are a
minimum of 6 in. to the shell to bottom weld

101

Weld Joint Spacing

There are various rules for maintaining the weld joint

spacing between existing welds and welds of replacement
shell plates. For example:

◊ For existing shell plates over ½ in., thick, the outer

edge of the butt weld attaching the replacement shell
plate shall be at least the greater of 8 times the weld
thickness or 10 in. from the outer edge of any existing
butt-welded shell joints.

102

51
 Weld Joint Spacing (Contd.)

◊ For existing shell plates ½ in., thick and less, the

spacing may be reduced to 6in. from the outer edge of
vertical joints or 3 in. from outer edge of horizontal
joints. (fig. 9-1 of API 653 for minimum dimensions as
shown below)

◊ To reduce the potential for distortions of an existing

tank due to welding a replacement into an existing tank
shell, fit-up, heat input, and welding sequence must be
considered.

103

Acceptable Details For Replacement Of Shell Plates

104

52
Lapped Patch Repair Plates at Shell to Bottom Joint

105

Repair of Defects In Shell Plate Material

◊ The need for repairing indication such as Cracks, gouges or
tears (such as those often remaining after the removal of
temporary attachments), widely scattered pits, and corroded
areas discovered during an inspection of the tank shell shall be
determined on individual case basis in accordance with the
standard API 653.

◊ In areas where the shell plate thickness exceeds that required

by design considerations, it is permissible to grind surface
irregularities to a smooth contour so long as the remaining
thickness is adequate for the design conditions.

◊ Where grinding to a smoothly contoured surface will result in

unacceptable shell plate metal thickness, the shell plate may be
required by deposition of weld metal, followed by examination
and testing.
106

53
 Repair of Defective Welds
◊ Cracks, lack of fusion, and rejectable slag and porosity that
need repair shall be removed completely by gouging and or
grinding and resulting cavity properly repaired by welding.

◊ Existing weld undercut deemed unacceptable based on

suitability for service considerations shall be repaired by additional
weld metal or grinding.

◊ Welded joints that have experienced loss of metal due to

corrosion may be repaired by welding.

◊ Arc strikes discovered in or adjacent to welded joints shall be

repaired by grinding and or welding. Arc strikes repaired by
welding shall be ground flush with the plate.

107

Repair of Shell Penetration

◊ Repairs to existing shell penetrations shall be in
compliance with API 650.

◊ Reinforcing plates may be added to existing un-

reinforced nozzles when deemed appropriate.

◊ The reinforcing plate shall meet all dimensional and

weld spacing requirement of API 650.

◊ Reinforcing plate may added inside provided sufficient

nozzle projection exists.

For acceptable details fig. 9-3 and 9-4 are referred here.

108

54
Repair of Shell Penetration

109

Repair of Shell Penetration

110

55
 Repair of Shell Penetration
Addition or replacement of shell penetration
◊ New shell penetration shall be in accordance API-650
Additionally

◊ periphery shall have a 1:4 reduction taper to match shell

plate thickness when the insert plate exceed the shell plate
thickness by more than 1/8 in.

◊ spacing of welds shell be in accordance with figure 9.1.

◊The new insert plate shall be joined to existing shell plate

with full penetration and full fusion butt welds

111

Repair of Shell Penetration

Alteration of existing shell penetration
◊ Existing shell penetration may altered in accordance API-650
◊When installing a new tank bottom, the spacing between
existing weld around penetration and new shell to bottom join
may not comply with API-650 requirement.
◊The existing reinforcing plate may be trimmed to increase the
spacing between the welds provided that the altered detail
complies with the requirements of API-653.
OR
◊The existing plate may be removed a new reinforcing plate
added except that reinforcement plate replacement is not
permitted on existing stress relieved assemblies
OR
◊The existing penetration may be moved by cutting the section of
the shell containing the fitting and reinforcing plate, and raising
the entire assembly to the correct elevation.
112

56
Repair of Shell Penetration

113

Repair of Shell Penetration

114

57
 Repair of Tank Bottoms
The use of welded-on patch plates for repairing a portion of
uniformly supported tank bottoms is permitted within the limitations
given in the following.
◊ The minimum dimension for a welded-on patch plate that
overlaps a bottom seam or existing patch is 12”.
◊ The welded-on patch plate may be circular, oblong, or
polygonal with rounded corners.
◊ Welded-on patch plates shall not be placed over areas of the
tank bottom that have global dishing, local dishing, settlement
or distortion greater than the limits in Appendix B of the API
653, except a welded-on patch plate may be placed over a
mechanical dent or local dishing if its un-supported dimension
does not exceed 12in. in any direction, it is at least ¼in. thick, it
is at least as thick as the existing bottom, and does not overlap
seams nor other patches, except for tanks designed in
accordance with API 650.
115

Repair of Tank Bottoms

A welded on patch plate smaller than 12’’ in diameter is permitted,

if:

◊ It is equal to or exceed 6’’ in diameter.

◊ It does not overlap a bottom seam.

◊ It does not placed fully or partially over an existing patch.

◊ It extends beyond the corroded bottom area if any by at

least 2’’.

116

58
Typical Welded – on Patch Plates on The Tank Bottom

117

Replacement of Entire Tank Bottom

Installation of a replacement bottom over an existing bottom:

◊ A suitable non-corrosive material cushion such as sand, gravel,

or concrete shall be used between the old bottom and the new
bottom.

◊ The shell shall be slotted with a uniform cut made parallel to

the tank bottom. The cut edges in the slot shall be ground to
remove all slag and burrs from the cutting operation. The new
bottom plate shall be extended outside the shell as required by
API 650. All rules for weld spacing shall be followed.

◊ Voids in the foundation below the old bottom shell be filled

with sand, crushed limestone, grout or concrete.

118

59
 Replacement of Entire Tank Bottom
When removing an existing bottom, the tank shell shall be
separated from tank bottom either by:

◊ Cutting the shell parallel to the tank bottom a minimum of ½’’

above the bottom to shell welding.

◊ Removing the entire shell to bottom attachment weld including

any penetration and heat affected zone by suitable methods such
as arc gouging and grinding.

◊ All arc gouge areas of tank shell to bottom weld shall be

magnetic particle examined and defective areas repaired and re
examined.

◊ Spacing requirement shall be consider

119

Replacement of Entire Tank Bottom

120

60
 Replacement of Entire Tank Bottom
The following shall be considered for tanks with cathodic
protection and under-bottom leak detection:

a. For tanks having cathodic protection (CP) installed under the

existing bottom, consideration shall be given to removal of the
entire bottom and unused dead shell to prevent shielding of CP
current to the new bottom.

b. Removal of the old bottom is also important in preventing

galvanic corrosion (refer to API RP 651).

c. Consideration shall be given to installing under-bottom leak

detection at this time (such as a RPB) to contain and channel
any bottom leak to a location where it can readily be
observed from outside of the tank.

121

Repair of Fixed Roofs

Supported Cone Roofs
◊ The minimum thickness of new roof plates shall be 3/16in. plus
any corrosion allowance as specified in the repair specifications.
◊ In the event roof live loads in excess of 25lbf/ft2 are specified
(such as insulation, operating vacuum, high snow loads), the plate
thickness shall be based on analysis using the allowable stresses in
conformance with API 650, sect. 5.10.3 (see 9.11.2.2)
◊ The roof supports (rafters, girders, columns, and bases) shall be
repaired or altered such that under design conditions the resulting
stresses do not exceed the stress levels given in sect. 3.10.3 of API
650.

Self-Supporting Roofs
◊ The nominal thickness of new roof plate shall be 3/16in. or the
required thickness given in API 650 , plus specified corrosion
allowance whichever is greater.
122

61
 Hot Taps
◊ The requirement in API 653 cover the installation of radial hot
tap connections on existing in-service tanks constructed with shell
material that does not require post weld heat treatment.

◊ The minimum height of tank liquid above the hot tap location
shall be at least 3 ft. during the hot tapping operation.

◊ Welding shall be done with low hydrogen electrodes.

◊ Hot taps are not permitted on the roof of a tank or within the
gas/vapor space of the tank.

◊ Hot taps are not permitted on tanks where the heat of welding
may cause environmental cracking (such as caustic cracking or
stress corrosion cracking).

123

Hot Taps
For material having unknown toughness

◊ Nozzle shall be limited to a maximum diameter 4 in.

NPS

◊ Shell plate temperature shall be at or above MDMT for

the entire hot tapping operation

◊ All nozzle reinforce as per API-650 section 5.7.2.

◊ Hydrostatic tank shell stress is less than 7000 lbf/in°

124

62
 Hot Taps

Table 9.1- Hot tap connection sizes and shell plate thicknesses

Connection Size NPS (in) Minimum shell plate thickness

(in)
≤6 3/16
≤8 ¼
≤ 14 3/8
≤ 18 ½

125

Hot Taps Connection

126

63
 DISMANTLING AND
RECONSTRUCTION

Cleaning and Gas freeing:

The tank shall be cleaned and gas-freed prior to commencement of

dismantling.

127

Dismantling Methods
◊ Roof, Shell and bottom plates may be cut in to any size pieces
that are readily transportable to the new site for reconstruction.

Bottom:

◊ 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 2in. away from existing welds, except where cuts
cross existing weld seams.

◊ The bottom plates may be cut from the shell along a line A-A
and line B-B.

◊ If the entire bottom is to be reused, the bottom may be cut

from the shell on the line C-C leaving the shell with part of the
bottom attached.
128

64
 Tank Shell and Bottom Cut Locations

129

Dismantling Methods (contd.)

Shell:
◊ Any shell ring may be dismantled by cutting out existing weld
seams and the heat effected zone (HAZ) of the weld. The minimum
HAZ to be removed will be 1/2 of the weld metal width or 1/4in.
which ever is less, on both sides of the weld seam.

◊ Any shell ring 1/2in. thick or thinner may be dismantled by cutting

through the weld without removing the HAZ.

◊ Shell rings may be dismantled by cutting vertical and / or

horizontal cuts through the shell a minimum of 6in. away from
existing welds, except where cuts cross existing welds.

◊ The shell shall be cut from the bottom plate along line B-B as
shown in figure 10-1. The existing shell to bottom connection shall
not be reused unless the entire bottom is to be reused intact.

130

65
 Dismantling Methods (contd.)
Roofs:

◊ Roof plates shall be cut by de-seaming of lap welds, or by

cutting alongside of the remaining welds at a minimum of 2in.
away from existing welds, except where cuts cross existing welds.

◊ Roof supporting structures shall be dismantled by removing

bolts (if bolted) or de-seaming the structural attachment welds.

Piece Marking:

◊ Shell, bottom, and roof plates shall be marked prior to

dismantling for ready identification and placement when the tank
is reconstructed. Marking material shall be of a durable type.
Drawings showing piece mark locations are also a useful tool.

131

Reconstruction
Shells – Plates to be joined by butt welding shall be matched
accurately and retained in position during welding.
Misalignment shall not exceed the following:
Vertical Joints - > 5/8in.
10% of thickness or 1/8 max.
Vertical Joints - ≤ 5/8in.
1/16in. max.
Horizontal Joints -
◊ Upper plate projection to lower plate 20% thk. of upper plate,
maximum projection 1/8in. except that a projection of 1/16in. is
acceptable for upper plates less than 5/16in.
◊ For the horizontal and vertical joints in tank shell courses constructed
of material over 1 ½ in. thick (based on the thickness of the thicker
plate at the joint), multi-pass weld procedures are required, with no
o
pass more than 3/4in. thick permitted. A minimum preheat of 200 F is
required of these welds.
◊ the reinforcement of new weld on all butt joints on each side of the
plate shell not exceed the thickness shown in table 10.1

132

66
 Reconstruction

Table 10.1 – Maximum thickness on new welds

Plate thickness (in) Maximum Reinforcement thickness (in)

Vertical Joint Horizontal Joint

≤ 1/2 3/32 1/8

½ ≥ through 1 1/8 3/16
≥1 3/16 1/4

133

Reconstruction (contd.)
Dimensional Tolerances:
Plumbness – From top of the shell to the bottom of the shell –
1/
100 of total height (max. 5in.)
Same criteria can be used for fixed roof columns.

Roundness – Radii measured above 1ft. above shell to bottom

weld shall not exceed the tolerances shown in Table 10-2,
however, for above 1ft. shall not exceed three times the
tolerances in Table 10-2

Peaking – Horizontal sweep board 36in. long – 1/2in. max

(for vertical joints)

Banding – Straight edge Vertical sweep board 36in. long – 1 in.

max. (for horizontal joints)

134

67
 Reconstruction (contd.)

135

Reconstruction (contd.)
Table 10.2 – Radii Tolerance
Tank Diameter (ft) Radius Tolerance (in)

≤ 40 ± 1/2

> 40 to 150 ± 3/4

> 150 to 250 ±1

≥ 250 ± 11/4

136

68
 Reconstruction (contd.)

Foundations:

Details are discussed in API 653 e.g.: Where concrete ring

walls are provided under the shell, the top of the ring wall
shall be level within + 1/8in. in any 30ft. of the
circumference and within +1/4in. in the total
circumference from the average elevation.

137

WELDING

138

69
 Welding

Welding Qualification:

◊ Welding procedure specifications (WPS) and welders

and welding operators shall be qualified in accordance with
section IX of the ASME code.

◊ Weldability of steel from existing tanks shall be verified.

If the material specifications for the steel from an existing
tank is unknown or obsolete, test coupons for the welding
procedure qualification shall be taken from actual plate to
be used.

139

Welding (contd.)
Identification and Records:

◊ Each welder and welding operator shall assigned an identifying

number, letter, or symbol. Records of this identification, along with
the date and results of the welder’s qualification tests shall be
accessible to the inspector.

◊ The welder or welding operator’s identification mark shall be

hand or machine stamped adjacent to and at intervals not
exceeding 3 ft. along the completed welds. In lieu of stamping, a
record may be kept that identifies the welder or welding operator
employed for each welded joint; these records shall be accessible to
the inspector.

◊ Roof plate welds and flange to nozzle neck welds do not require
welder identification.

140

70
Design Considerations For Reconstructed Tanks

New weld joints:

◊ shall meet the welding requirement of the applicable
standard.

◊ All new shell joints shall be butt welded joints with

complete penetration and complete fusion.

Existing weld joints:

◊ Shall meet the requirement of the original standard of
construction for the tank.

141

Design Considerations For Reconstructed Tanks

Shell Design
◊ Maximum design liquid level for product and hydrostatic test
– based on thickness, specific gravity and max. design liquid
level of each course.

◊ API 650 shall be used for the design parameters.

◊ For material not listed in the standard API 650 (Table 3-2),
an allowable stress value of the lesser of 2/3 yield strength or
3/8 tensile strength shall be used for maximum design liquid
level for product and lesser of ¾ yield strength or 2/5 tensile
strength shall be used for maximum design liquid level for
hydrostatic test.

142

71
 EXAMINATION AND
TESTING

Personnel qualification, acceptance criteria and NDT

shall be performed according to API 650 and any
supplemental requirements in API 653.

143

Examination And Testing

Shell Penetrations
◊ Ultrasonic Examination for Plate Lamination
adding a
reinforcing plate or adding a hot tap connection.

◊ Cavities resulting from gouging or grinding etc.
MPI

or DPT.

◊ Completed welds attaching nozzle neck to shell,

reinforcing plate and nozzle neck
MPI or DPT

◊ Completed welds of stress relieved assemblies shall be

examined by visual as well as by MPT or DPT after stress
relief, but before hydrostatic test.

144

72
 Repaired Weld Flaws
◊ Cavities resulting from gouging or grinding etc.
MPI or
DPT.

◊ Completed repairs of butt-welds over full length
RT or

UT (flaw detection).

◊ Completed repairs of fillet welds over full length

appropriate NDT method.

◊ Temporary and Permanent attachment to shell plates

(excluding shell to bottom welds)
VI
MPI / DPT.

◊ Shell plate to shell plate welds (new welds attaching existing

shell plate to existing or new shell material
VI + RT + for
plates > 1in. back gouged surface of root and final pass (each
side) of entire length
MPI / DPT.
145

Repaired Weld Flaws

◊ Shell plate to shell plate welds (new welds joining new shell
plate material to new shell plate material)
VI + RT

Shell to bottom weld

◊ New welding – entire length
Right angle Vacuum box

+ solution film
or
Light diesel oil

◊ Existing welding
VI + MPI / DPT

additionally 6in. on each side before placement of repair
plate
MPI / DPT

146

73
Radiographs (Number and location of Radiographs)
Shall be in accordance with API 650 with following additional
requirement with the minimum diagnostic length of 6in.

Vertical Joints:
◊ New replacement shell plates to new shell plates
No additional
◊ New replacement shell plates to existing shell plates
One
additional in each joint
◊ Repaired joints in existing shell plates
One additional in each joint.

Horizontal Joints:
◊ New replacement shell plates to new shell plates
No additional
◊ New replacement shell plates to existing shell plates
One
additional radiograph for each 50ft. of repaired horizontal weld
◊ Repaired joints in existing shell plates
One additional radiograph
for each 50ft. of repaired horizontal weld.

147

Radiographs (Number and location of Radiographs)

For intersections of vertical and horizontal joints

◊ New replacement shell plates to new shell plates
No

additional.

◊ New replacement shell plates to existing shell plates

each intersection.

◊ Repaired joints in existing shell plates
each intersection.

148

74
 Hydrostatic Testing

When Hydrostatic Testing is Required

◊ After reconstruction

◊ Major repairs or major alterations

◊ Change in service for increased severity

◊ Conditions defining major repair and major alterations are

described in detail in API 653.

149

When Hydrostatic Testing is Not Required

A full hydrostatic test is not required when conditions given in API
653 are met.
Example conditions:

Shell Repair
◊ Welds to existing metal – PQR, Impact testing as per API
650.
◊ Existing tank materials in the repair area shall meet at least
one of the following:
● API 650 requirement (7th edition or later)
● Fall within the “safe for use” area of fig. 5.2.
● Stress in repair area shall not exceed 7000 lbf/in2
◊ New vertical and horizontal shell butt-welds
complete
penetration and fusion
◊ Finished weld shall be fully radiographed

150

75
 151

Measured Settlement During Hydrostatic Testing

N = D / 10

N = Minimum required number of settlement measurement

points, but no less than eight. All fraction values shall be
rounded to the next higher whole number. The maximum
spacing between settlement measurement points shall be 32 ft.

D = Tank diameter, in ft.

◊ For settlement evaluation, Appendix “B” of API 653 can be

further consulted.

◊ Survey shall be measured during filling and when water

reaches 100 %.

152

76
 Marking and Record Keeping

153

Marking and Record Keeping

Name Plates:

◊ Corrosion resistant name plate

◊ Letters and Numerals not less than 5/32in.

◊ Embossed, engraved or stamped to indicate the

Reconstruction information.

154

77
 Marking and Record Keeping (contd.)

Record Keeping:
◊ Calculations for component evaluation for integrity, including Re-
rating (incl. liquid level), Repair and Alteration Considerations
◊ Construction and repair drawings
◊ Additional support data including, but not limited to, information
below:
● Inspections, Material test reports / certifications, Tests
● Radiographs (shall be retained at least one year), Brittle Fracture
consideration
● Original tank construction data
● Location and Identification, Description of tank (dia., height,
service)
● Design conditions, Shell material and thickness by course
● Tank perimeter elevations, Construction completion record
● Basis for hydrostatic test exemption (if proposed)

155

APPENDIX “B”
EVALUATION OF TANK BOTTOM
SETTLEMENT

156

78
 Types of Settlement
Elevation Measurements:
Elevation measurements around the circumference and across
the tank diameter are the best method for evaluating shell and
bottom settlement problems. Local depressions may require
other techniques.

Shell Settlement Evaluation:

Tank settlement results from either one or a combination of the
following three (3) settlement components:

Uniform settlement:
May vary in magnitude, depending on soil characteristics. It is the
least severe threatening settlement problem. It does not
introduce stress in tank structure, but does present a potential
problem for piping, nozzles and attachments.

157

Types of Settlement
Rigid body Tilt (Planar Tilt):
Rotates the tank in a tilted plane. This tilt will cause an increase
in the liquid level and an increase in the shell hoop stress. Can
also cause binding of peripheral seals in a floating roof and
inhibit roof travel.

Out-of-plane settlement (Differential Settlement):

Since a tank is a rather flexible structure, non-planer
configuration type settlement often occurs.
Potential Problems:
1. Increased stress levels.
2. Lack of circularity of upper shell.
3. Extent of the induced ovality may impede the proper functioning of the
floating roof.
4. Development of shell flat spots.
5. could affect nozzles that have piping attached to them.

158

79
 Types of Settlement
Rigid body Tilt (Planar Tilt):
Rotates the tank in a tilted plane. This tilt will cause an increase
in the liquid level and an increase in the shell hoop stress. Can
also cause binding of peripheral seals in a floating roof and
inhibit roof travel.

Out-of-plane settlement (Differential Settlement):

Since a tank is a rather flexible structure, non-planer
configuration type settlement often occurs.
Potential Problems:
1. Increased stress levels.
2. Lack of circularity of upper shell.
3. Extent of the induced ovality may impede the proper functioning of the
floating roof.
4. Development of shell flat spots.
5. could affect nozzles that have piping attached to them.

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Types of Settlement

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Settlement Survey

161

Settlement Survey

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81
 Localized Bottom Depression

163

Localized Bottom Settlement Evaluation

The following formula can be used to evaluate localized
settlement remote from the tank shell. These limits are
applicable to tank bottoms that have single-pass lap-welded
joints.

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 Localized Bottom Settlement Evaluation

Example: Evaluating a Bottom Depression

Depression Diameter = 10’ (Radius is 5’)

B = 0.37R = 0.37 x 5 = 1.85”

(Answer is in inches)

Note Figure B.9 is a graphic representation of this formula.

165

Edge Settlement

Edge settlement occurs when the tank shell settles sharply

around the periphery, resulting in deformation of the bottom
plate near the shell-to-bottom corner junction. Figure B-5
illustrates this settlement.

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Edge Settlement Evaluation

167

Edge Settlement Evaluation

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Edge Settlement Evaluation

169

Edge Settlement Evaluation

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 SGS Capabilities with reference to
STORAGE TANKS INSPECTION

◊ SGS Pakistan (Pvt) Limited is leader & Trend setter in Storage

Tank Inspection in Pakistan. Corrosion resistant name plate
◊ Our work philosophy is Client’s satisfaction. Corrosion resistant
name plate Corrosion resistant name plate
◊ Having Two API 653 Certified Inspectors, further five inspector
to appear in forthcoming API 653 Certification Examination.
◊ Having expertise in Routine , Shutdowns & Turnaround
Inspections of Storage Tanks.
◊ Having complete assistance for conducting Non Destructive
Testing as per API 653 requirements.

171

SGS Capabilities with reference to

STORAGE TANKS INSPECTION

◊ Having full range of inspection equipment necessary for executing

the Tank inspection job. These include;
◊ Ultrasonic Flaw detector, Ultrasonic Thickness Gauging Meter,
Magnetic Particle Testing Equipment, Ultraviolet light, Dye Penetrant
Testing Kit. Full range of visual inspection tools.
◊ Busy in market since 2003 serving different sectors of industry.
◊ So far have inspected more than 300 tanks.
◊ The list of Clients include:
◊ M/S Shell, Chevron, British Petroleum, OMV , Engro Asahi , Engro
VoPack, ICI PPTA, International Power , Unilever , Eni Pakistan and
many more.

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 SGS at work

◊ Inspection photographs of various Tanks inspected by SGS

Pakistan (Pvt) Limited nationwide.

173

CHEVRON TANK TK # 1 , KARACHI

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 CHEVRON TANK TK # 1 , KARACHI

175

SHELL TANK SSH-03 SHERSHAH MULTAN

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SHELL TANK SSH-03 SHERSHAH MULTAN

177

SHELL TANK SP – 13 KAEMARI KARACHI

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SHELL TANK SP – 13 KAEMARI KARACHI

179

SHELL TANK SP – 07, KARACHI

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90
SHELL TANK SP – 07, KARACHI

181

SHELL TANK S – 28 , KARACHI

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 SHELL TANK S – 28 , KARACHI

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Gratitude

◊ Thank you very much for your kind

appearance & let us give opportunity to
express our expertise to you & sharing
experience with one another

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 For Customized Courses at Client’s Site

◊ Zafar Hussain
Assistant Manager AIM
Industrial Services
API 510,570,653,580 & 577 Certified

◊ M. Sabahat Noor
Inspection Engineer
Industrial Services
API 510 & 653 Certified

◊ SGS Pakistan (Private) Ltd.

H 3/3 , Sector 5 Korangi Industrial Area,
Karachi - 74900, Pakistan
Phone: +92 21 5121388 - 97
Fax +92 21 51231325
mail to : zafar_hussain@sgs.com
: muhammad.sabahat@sgs.com

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