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API 653API 653

Section 7, MaterialsSection 7, Materials

Section 11, WeldingSection 11, Welding

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API 653API 653MaterialsMaterials

This section provides generalThis section provides generalrequirements for the selection ofrequirements for the selection of

materials for the repair, alteration, andmaterials for the repair, alteration, and

reconstruction of existing tanks.reconstruction of existing tanks.

Specific requirements for repairs andSpecific requirements for repairs and

alterations are covered in Section 9.alterations are covered in Section 9.

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API 653API 653 Section 7, MaterialsSection 7, Materials

New MaterialsNew Materials

All new materials used forAll new materials used forrepair, alterations, orrepair, alterations, or

reconstruction shall conform toreconstruction shall conform tocurrent applicable tankcurrent applicable tank

standards.standards.

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API 653API 653 Section 7, MaterialsSection 7, MaterialsShell And Bottom Plates Welded To TheShell And Bottom Plates Welded To The

ShellShell

All shell plate materials and bottom platesAll shell plate materials and bottom plates

welded to the shell shall be identified.welded to the shell shall be identified.

Materials identified by original contractMaterials identified by original contract

drawings, API name plates, or other suitabledrawings, API name plates, or other suitable

documentation do not require furtherdocumentation do not require further

identification.identification.

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Shell And Bottom Plates Welded ToShell And Bottom Plates Welded ToThe ShellThe Shell

Material not identified shall be tested andMaterial not identified shall be tested andidentified by the requirements as outlined inidentified by the requirements as outlined in

7.3.1.2.7.3.1.2.

After identification, determination shall beAfter identification, determination shall be

made as to suitability of the material formade as to suitability of the material forintended service.intended service.

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API 653API 653 Section 7, MaterialsSection 7, MaterialsStructuralStructural

Existing rolled structural shapes that are toExisting rolled structural shapes that are to

be reused shall meet the requirements ofbe reused shall meet the requirements of

ASTM A7 as a minimum.ASTM A7 as a minimum.

New structural material shall meet theNew structural material shall meet the

requirements of ASTM A36or A 992 as arequirements of ASTM A36or A 992 as a

minimumminimum

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Roof, Bottom, and Plate WindgirdersRoof, Bottom, and Plate Windgirders

If existing plates are to be used to reconstructIf existing plates are to be used to reconstruct

the tank, they shall be checked for excessivethe tank, they shall be checked for excessivecorrosion and pitting. (See Sections 4 and 6.)corrosion and pitting. (See Sections 4 and 6.)

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Welding ConsumablesWelding Consumables

Welding consumables shall conform to theWelding consumables shall conform to theAmerican Welding Society (AWS) classificationAmerican Welding Society (AWS) classification

that is applicable to the intended use.that is applicable to the intended use.

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99

API 653API 653

WeldingWelding

Section 11Section 11

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WeldingWelding

Qualified per ASME Section IXQualified per ASME Section IX Welding Procedure Specifications (WPS)Welding Procedure Specifications (WPS)

Procedure Qualification Records (PQR)Procedure Qualification Records (PQR)

Welders / Welding OperatorsWelders / Welding Operators

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WeldingWelding

Must also meet additional requirements ofMust also meet additional requirements ofAPIAPI--650, Section 7650, Section 7 unstated hereunstated here

WeldabilityWeldability of steel must be verifiedof steel must be verified

If material is unknown, must use plateIf material is unknown, must use platesample for WPS/PQRsample for WPS/PQR

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Additional WPS/PQR WeldingAdditional WPS/PQR Welding

Requirements of APIRequirements of API--650650

API-650 is the Referencing Code Section API-650, Section 7.2 Qualification of Welding

Procedures

specifies impact testing requirements supplementary essential variable in ASME IX

based of DMT

protective coatings addressed as an essential variable all other requirements are same as ASME IX

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Additional WPS/PQR WeldingAdditional WPS/PQR Welding

Requirements of APIRequirements of API--650650 contcont

Impact test HAZ if base metal impact tested andImpact test HAZ if base metal impact tested andwelded by auto or semiwelded by auto or semi--auto processauto process

Impact test for vertical seams if DMT < 50FImpact test for vertical seams if DMT < 50F

impact test weld metalimpact test weld metal

include HAZ if auto or semiinclude HAZ if auto or semi--auto processauto process

Impact test for all seams if DMT

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Identification and Records 9.2Identification and Records 9.2

For each welder / welding operatorFor each welder / welding operator must have identification number, letter, etcmust have identification number, letter, etc

identification number must be recordedidentification number must be recorded

WPQ available to AIWPQ available to AI

welder ID markwelder ID mark

applied to work at interval or 3 ftapplied to work at interval or 3 ft or recordedor recorded record (rollrecord (roll--out maps?) available to AIout maps?) available to AI

not required on roof plates or flangenot required on roof plates or flange--toto--neck weldsneck welds

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1515

API 653API 653

Examination and TestingExamination and Testing


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GeneralGeneral

The following shall be in accordance with API Std 650The following shall be in accordance with API Std 650 NDENDE

NDE PersonnelNDE Personnel

Acceptance criteriaAcceptance criteria

Plus any additional requirements given in API 653Plus any additional requirements given in API 653

Appendix F, NDE Requirements SummaryAppendix F, NDE Requirements Summary

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Shell PenetrationsShell Penetrations

UT examination of shell plate forUT examination of shell plate forlaminationslaminations

Adding a reinforcing plate to an existingAdding a reinforcing plate to an existing

unreinforced penetrationunreinforced penetration

Adding a hot tap connectionAdding a hot tap connection

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Cavities resulting from gouging or grindingCavities resulting from gouging or grindingto remove attachment welds of existingto remove attachment welds of existing

reinforcing plates shall be examined by:reinforcing plates shall be examined by:

VisualVisual

MT or PTMT or PT

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Completed welds shall be examinedCompleted welds shall be examined

MT or PTMT or PT

Consider additional examination for plates ofConsider additional examination for plates of

unknown toughnessunknown toughness

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Stress relieved assemblies shall beStress relieved assemblies shall beinspected by MT or PTinspected by MT or PT

After Stress reliefAfter Stress relief

Before hydrostatic testBefore hydrostatic test

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Repaired Weld FlawsRepaired Weld Flaws

Cavities from gouging or grinding toCavities from gouging or grinding toremove a weld defectremove a weld defect

VisualVisual

MT or PTMT or PT

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Repaired Weld FlawsRepaired Weld Flaws

Completed repairs of buttCompleted repairs of butt--welds shall bewelds shall beexamined radiographic or ultrasonicexamined radiographic or ultrasonic

methodsmethods

Repairs of fillet welds shall be examinedRepairs of fillet welds shall be examinedby the appropriate NDE methodby the appropriate NDE method

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Temporary & PermanentTemporary & Permanent

Attachments to Shell PlatesAttachments to Shell Plates

Visual examination of permanentVisual examination of permanentattachments and areas where temporaryattachments and areas where temporary

attachments are removed.attachments are removed.

Group IV, IV4, V, or VI materials shall alsoGroup IV, IV4, V, or VI materials shall also

include MT or PTinclude MT or PT

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Shell Plate to Shell Plate WeldsShell Plate to Shell Plate Welds

Existing Shell Plate to New orExisting Shell Plate to New orExisting Shell Plate WeldsExisting Shell Plate Welds

VTVT

RTRT

Additionally if Shell Plate > 1 inchAdditionally if Shell Plate > 1 inch

BackBack--gouged surface of root and finalgouged surface of root and finalpass (each side) examined by MT or PTpass (each side) examined by MT or PT

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ShellShell--ToTo--Bottom WeldBottom Weld

New welding shall be inspectedNew welding shall be inspected RightRight--angle vacuum boxangle vacuum box

Diesel test opposite side after first weld passDiesel test opposite side after first weld pass

AlternativelyAlternatively

11stst weld pass examined visuallyweld pass examined visually

Pressure interstice to 15 PSIPressure interstice to 15 PSIgg

Apply solution film to both weldsApply solution film to both welds

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ShellShell--ToTo--Bottom WeldBottom Weld

WeldWeld--on Patch Plateson Patch PlatesVT and MT or PT existing weldVT and MT or PT existing weld

Full length of pad + 6 in either sideFull length of pad + 6 in either side

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BottomsBottoms

VT all new welds for entire lengthVT all new welds for entire lengthAttention to sumps, dents, gouges, 3Attention to sumps, dents, gouges, 3--plateplate

laps, breakdowns, arc strikes, attachmentslaps, breakdowns, arc strikes, attachments

One of the methods listed in API Std 650,One of the methods listed in API Std 650,

5.3.35.3.3

Vacuum boxVacuum box

Tracer gasTracer gas

Water floodWater flood

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BottomsBottoms Additionally Patch plates in the criticalAdditionally Patch plates in the critical

zonezone

VTVT

MT or PTMT or PT

Bottom plates restored by weldingBottom plates restored by welding

VTVT

MT or PTMT or PT

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Shell PlatesShell Plates

Weld Metal DepositWeld Metal DepositVTVT

MT or PTMT or PT

Lap Welded PatchesLap Welded Patches

VTVT MT or PTMT or PT

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RoofsRoofs

Newly welded roof joints and repairs shallNewly welded roof joints and repairs shallbe examined in accordance with API Stdbe examined in accordance with API Std

650 5.3.2.2 and 5.3.6650 5.3.2.2 and 5.3.6

VTVT

GastightGastight

Internal PressureInternal PressureVacuum BoxVacuum Box

Non gastightNon gastight

VTVT

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RadiographsRadiographs

The number and location of radiographsThe number and location of radiographs

shall be in accordance with API Std 650shall be in accordance with API Std 650

and the following additional requirementsand the following additional requirements

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For Vertical JointsFor Vertical Joints

New to NewNew to New no additionalno additional

requirementsrequirements

New to ExistingNew to Existing 1 extra in each joint1 extra in each joint

ExistingExisting 1 extra in each joint1 extra in each joint

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For Horizontal JointsFor Horizontal Joints

New to NewNew to New no additional requirementsno additional requirements

New to ExistingNew to Existing 1 extra for each 50 ft of1 extra for each 50 ft of

weldweld

ExistingExisting 1 extra for each 50 ft of weld1 extra for each 50 ft of weld

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For Intersections of Vertical and HorizontalFor Intersections of Vertical and HorizontalJointsJoints

New to NewNew to New no additional requirementsno additional requirements

New to ExistingNew to Existing Each intersection shall beEach intersection shall be

radiographerradiographer ExistingExisting Each intersection shall beEach intersection shall be

radiographerradiographer

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For Reconstructed TanksFor Reconstructed Tanks Each buttEach butt--welded annular platewelded annular plate

25% of all junctions of new welds over25% of all junctions of new welds over

existing seamsexisting seams

The owner/operator and contractor shallThe owner/operator and contractor shalldetermine extent of further inspectionsdetermine extent of further inspections

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Shell Plate Inserts / Door SheetsShell Plate Inserts / Door Sheets

CircularCircular

1 radiograph regardless of thickness1 radiograph regardless of thickness

Square or rectangularSquare or rectangular 1 in a vertical joint1 in a vertical joint

1 in a horizontal joint1 in a horizontal joint

Each cornerEach corner

All junctions between new and old weldsAll junctions between new and old welds

If defects found, 100% of repaired weldIf defects found, 100% of repaired weld

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The minimum diagnostic length is 6The minimum diagnostic length is 6inchesinches

Penetrations installed using insert plates,Penetrations installed using insert plates,

100% of butt100% of butt--weld shall be RTweld shall be RT

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Acceptance criteria shall be based on theAcceptance criteria shall be based on the

current standard.current standard.

Existing welds can be judged on theExisting welds can be judged on the

original standard of constructionoriginal standard of construction

d i iH d i T i

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Hydrostatic TestingHydrostatic Testing

When a Hydrostatic Test is RequiredWhen a Hydrostatic Test is Required

A full hydrostatic test, held for 24 hoursA full hydrostatic test, held for 24 hoursshall be performed on:shall be performed on:

Reconstructed TankReconstructed Tank

Any tank that has undergone major or majorAny tank that has undergone major or major

alterations, unless exempted by 12.3.2alterations, unless exempted by 12.3.2

A tank where an engineering evaluationA tank where an engineering evaluation

indicates the need for a hydrostatic test.indicates the need for a hydrostatic test.

H d i T iH d t ti T ti

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Major repair or major alteration refer toMajor repair or major alteration refer tooperations that require cutting, addition,operations that require cutting, addition,

removal and/or replacement ofremoval and/or replacement of

The annular plate ringThe annular plate ring

The shellThe shell--toto--bottom weldbottom weld

A sizeable portion of the shellA sizeable portion of the shell

H d t ti T tiH d t ti T ti

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Major repair or major alteration includes:Major repair or major alteration includes:

The installation of any shell penetrationThe installation of any shell penetration

beneath the design liquid level larger than 12beneath the design liquid level larger than 12inches NPS, or any bottom penetrationinches NPS, or any bottom penetration

located within 12 inches of the shelllocated within 12 inches of the shell

H d t ti T tiH d t ti T ti

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Major repair or major alterationMajor repair or major alterationincludes:includes:

The removal and replacement or addition ofThe removal and replacement or addition ofany shell plate beneath the design liquidany shell plate beneath the design liquid

level, or any annular plate ring materiallevel, or any annular plate ring material

where the longest dimension of thewhere the longest dimension of the

replacement plate exceeds 12 inches.replacement plate exceeds 12 inches.

H d t ti T tiH d o t ti Te ti

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The complete or partial (more than oneThe complete or partial (more than one--halfhalf

of the weld thickness) removal andof the weld thickness) removal and

replacement of more than 12 inches ofreplacement of more than 12 inches of

vertical weld joining shell plates, or radialvertical weld joining shell plates, or radial

weld joining the annular plate ring.weld joining the annular plate ring.

H d t ti T tiHydrostatic Testing

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The installation of a new bottom. This does not includeThe installation of a new bottom. This does not include

new bottoms in tanks where the foundation under thenew bottoms in tanks where the foundation under the

new bottom is not disturbed and either condition 1) ornew bottom is not disturbed and either condition 1) or

2) are met below:2) are met below:

1)1) For tanks with annular rings, the annular ringFor tanks with annular rings, the annular ring

remains intact.remains intact.

2)2) For tanks without annular rings, the repair does notFor tanks without annular rings, the repair does notresult in welding on the existing bottom within theresult in welding on the existing bottom within the

critical zone.critical zone.


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Major repair or major alterationMajor repair or major alterationincludes:includes:

The removal and replacement of any partThe removal and replacement of any partof the weld attaching the shell to theof the weld attaching the shell to the

bottom or to the annular plate ring.bottom or to the annular plate ring.

Jacking of a tank shellJacking of a tank shell

H d ostatic TestingHydrostatic Testing

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When a Hydrostatic Test is Not RequiredWhen a Hydrostatic Test is Not Required

A hydrostatic test is not required when:A hydrostatic test is not required when:

The repair has been reviewed and approved byThe repair has been reviewed and approved by

an engineer and the engineer must concur inan engineer and the engineer must concur in

writing.writing. The owner/operator has authorized theThe owner/operator has authorized the

exemption in writing.exemption in writing.

And Sections 12.3.2.2 through 12.3.2.5 orAnd Sections 12.3.2.2 through 12.3.2.5 or

12.3.2.6 are met.12.3.2.6 are met.

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Shell RepairShell Repair Welding ProceduresWelding Procedures

Based on existing material chemistryBased on existing material chemistry

Qualified with existing or similar materialQualified with existing or similar material

Include impact testingInclude impact testing

New Material meet current API Std 650New Material meet current API Std 650requirementsrequirements

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Shell RepairShell Repair Existing Material shall meet at least one ofExisting Material shall meet at least one of

the following:the following:

API Std 650 requirements (7API Std 650 requirements (7thth edition oredition orlater)later)

Fall within the safe to use area ofFall within the safe to use area ofFigure 5Figure 5--22

Stress in the repair area shall notStress in the repair area shall notexceed 7,000 PSIexceed 7,000 PSI

t

HDGS

6.2=

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Shell RepairShell Repair

New vertical and horizontal shell buttNew vertical and horizontal shell butt--welds shall have complete penetrationwelds shall have complete penetration

and fusionand fusion Root Pass shall be examinedRoot Pass shall be examined

100% Radiography100% Radiography

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Shell RepairShell Repair

The root pass of nozzle attachment weldsThe root pass of nozzle attachment welds

shall be backshall be back--gouged and examined bygouged and examined by

MT or PT and by UTMT or PT and by UT

Door sheets shall not intersect theDoor sheets shall not intersect the

bottombottom--toto--shell jointshell joint

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Bottom Repair Within the Critical ZoneBottom Repair Within the Critical Zone

Examined visually prior to weldingExamined visually prior to welding

Examined after the root pass & finalExamined after the root pass & final

pass by VT and MT or PTpass by VT and MT or PT

Annular Plate buttAnnular Plate butt--welds examinedwelds examined

by UTby UT

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ShellShell--ToTo--Bottom RepairBottom Repair A portion may be removed an replaced providedA portion may be removed an replaced provided

that:that:

No more than 50% of the required weld crossNo more than 50% of the required weld cross

required sectional area is removedrequired sectional area is removed

100% not exceeding 12 inches and spacing100% not exceeding 12 inches and spacing

between repairs is at least 12 inches apartbetween repairs is at least 12 inches apart

VT and MT or PT of root pass and final weldVT and MT or PT of root pass and final weld

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Minor Shell JackingMinor Shell Jacking Tank Shell and critical zone materials shallTank Shell and critical zone materials shall

meet requirements of 12.3.2.2.3meet requirements of 12.3.2.2.3

Engineering evaluation consideringEngineering evaluation considering

pertinent variables.pertinent variables.

Careful consideration shall be given toCareful consideration shall be given to

potential stresses and damage that maypotential stresses and damage that may

result from jacking.result from jacking.

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FitnessFitness--ForFor--Service EvaluationService Evaluation The owner/operator may utilize fitnessThe owner/operator may utilize fitness--forfor--

service or other appropriate evaluationservice or other appropriate evaluationmethodologies based on established principlesmethodologies based on established principles

and practices.and practices.

The analysis shall be performed by an Engineer.The analysis shall be performed by an Engineer.

The procedures and acceptance criteria are notThe procedures and acceptance criteria are not

included in API Std 653.included in API Std 653.

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Leak TestsLeak Tests

New or altered reinforcingNew or altered reinforcing

plates or shell penetrationsplates or shell penetrationsshall be given a leak test.shall be given a leak test.

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Settlement SurveySettlement Survey When settlement is anticipated, a tankWhen settlement is anticipated, a tank

receiving a hydrostatic test shall have thereceiving a hydrostatic test shall have thefoundation checked for settlement.foundation checked for settlement.

Surveyed emptySurveyed empty

During fillingDuring filling

At 100% test levelAt 100% test level

Appendix B used for acceptance criteriaAppendix B used for acceptance criteria

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5959

API 653API 653

Marking and RecordkeepingMarking and Recordkeeping


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NameplatesNameplates Required for reconstructed tanks onlyRequired for reconstructed tanks only

attached adjacent to existing nameplateattached adjacent to existing nameplate

Fig 13Fig 13--11 required nameplate informationrequired nameplate information

existing nameplate remains in placeexisting nameplate remains in place

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RecordkeepingRecordkeeping Records are required forRecords are required for

evaluationevaluation repair and alterationrepair and alteration

reconstructionreconstruction

RecallRecall Per 6.8Per 6.8 three types of recordsthree types of records

constructionconstruction

inspectioninspection

repair and alterationrepair and alteration

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RecordkeepingRecordkeeping Calculations required forCalculations required for

component integrity, including brittle fracturecomponent integrity, including brittle fracture

reratingrerating

repair and alteration considerationsrepair and alteration considerations

Construction drawingsConstruction drawings

Repair drawingsRepair drawings

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RecordkeepingRecordkeeping Inspection data, UTMsInspection data, UTMs

MTRsMTRs & certifications tests& certifications tests

Radiographs (1 year)Radiographs (1 year)

Brittle fracture issuesBrittle fracture issues

Construction dataConstruction data

Location & ID numberLocation & ID number

Tank descriptionTank description

Tank serviceTank service

Design conditionsDesign conditions

ShellShell matmatll & thickness& thickness

Tank elevationsTank elevations

Construction recordsConstruction records

Basis ofBasis ofhydrotesthydrotestexemptionexemption

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CertificationCertification Documentation of reconstructionDocumentation of reconstruction

Certifications required forCertifications required for

DesignDesign

ReconstructionReconstruction Inspection and testingInspection and testing

Figure 13Figure 13--22

Certification for Tank Reconstructed to APICertification for Tank Reconstructed to API--653653

Certification for Tank Designed to APICertification for Tank Designed to API--653653

Appendix AAppendix A

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Appendix AAppendix A

3. api 653-pt2

Documents