QAF011 Rev. 02 Dec.

04, 04

Harvard Technology Middle East

API 653: Tank Inspection Code:

Inspection, repair, alteration, and
reconstruction of steel aboveground storage
tanks used in the petrochemical industry
(Training only)

January 8-12, 2005

Abu Dhabi, U.A.E.

Course Instructor(s)
Mr. Ron VanArsdale

To The Participant
The Course notes are intended as an aid in following lectures and for review in
conjunction with your own notes; however they are not intended to be a complete
textbook. If you spot any inaccuracy, kindly report it by completing this form and
dispatching it to the following address, so that we can take the necessary action
to rectify the matter.

P. O. Box 26608
Abu Dhabi, U.A.E.
Tel: +971 2 627 7881
Fax: +971 2 627 7883
Email: [email protected]

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Disclaimer
The information contained in these course notes has been complied
from various sources and is believed to be reliable and to represent
the best current knowledge and opinion relative to the subject.
Harvard Technology offers no warranty, guarantee, or representation
as to its absolute correctness or sufficiency.
Harvard Technology has no responsibility in connection therewith; nor
should it be assumed that all acceptable safety and regulatory
measures are contained herein, or that other or additional information
may be required under particular or exceptional circumstances.

**********************************************

Harvard Technology Middle East

COURSE OVERVIEW IE400

API 653: Tank Inspection Code: Inspection, repair, alteration, and

reconstruction of steel aboveground storage tanks used in the
petrochemical industry (Training only)
Course Title
API 653: Tank Inspection Code: Inspection, repair, alteration, and reconstruction of
steel aboveground storage tanks used in the petrochemical industry (Training only)
Course Date / Venue
January 08 -12, 2005 / Al Hosn suite, 2nd Floor, Le Royal Meridien, Abu Dhabi, UAE.
Course Reference
IE400
Course Duration
Five days (40 hours as per API regulations)
Course Objectives
In order to meet the needs of today's fast changing inspection industry, Harvard
Technology has developed the "Tank Inspection Course with API 653 Exam Prep..
The course textbook includes notes and summaries on the tank inspection standards
referenced in the API 653 Body of Knowledge.
This comprehensive 40 hour course consists of five 8-hour teaching days. It is
designed to accomplish a two-fold training agenda:
(1)

To train those individuals who are interested in obtaining the API 653 Tank
Inspection Certification.

(2)

Train those who require a working knowledge of the intricacies

encountered in the working environment.

Additionally, quizzes are given at the end of each section; homework is handed out
at the end of each class day, which consists of 30 questions per day and is reviewed
at the beginning of the following day, and a practice exam is administered at the
end of the course. Harvard Technology is proud of the 90%+ pass rate attained
by its students who have sat for the API 653 certification exam.
Who Should Attend
The course is intended for Inspection Engineers who are seeking API-653
certification. Other engineers, managers or technical staffs who are dealing with
Steel Aboveground Storage Tanks used in the Petrochemical Industry will also
benefit.

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Harvard Technology Middle East

Course Instructor
Mr. Ron VanArsdale, PE, USA, is the founder of Inspection Training And Consulting
Company (ITAC). His duties include conducting training courses for Harvard
Technology and ITAC, creating new courses for inspection and other related
activities, creating course material, as well as developing custom training programs,
customized written practices and providing trouble-shooting consulting services. In
the past, Mr. VanArsdale was employed by SGS Industrial Services as the
Training Director and the American Welding Society (AWS) as the Curricula
and Course Development Manager. In this position he developed various training
courses dealing with the AWS Certified Welding Inspector program. He planned,
organized, and developed all phases of educational activities for AWS.
In addition to these functions, he is a member of the API 653 Questions
Committee which devised the API 653 Tank Inspector Certification
Examination; as well as a member of the API 570 Questions Committee which is
charged with developing the API 570 Piping Inspector Certification
Examination.
Ron attended San Jacinto College and Texas A&M University, and has a Lifetime
Teaching Certificate from the State of Texas.
He is an AWS Certified Welding Inspector (CWI), ITAC Level III, an API Certified
Aboveground Storage Tank Inspector, and API Certified Piping Inspector, an
AWS Certified Welding Educator (CWE) and is an internationally recognized
Presenter/Instructor. Additionally, he received the AWS Distinguished Member
Award in March, 1989, the AWS CWI of the Year District Award in January,
1993, as well as the AWS District 18 Meritorious Award in September, 1993.
He has thirty-three years experience in the erection, maintenance and inspection
of buildings, petrochemical facilities, vessels, above-ground storage tanks, piping
systems, in addition to teaching welding/inspection education courses.
Mr. VanArsdale is professionally affiliated with the American Welding Society,
American Society for Nondestructive Testing, American Petroleum Institute,
Vocational Industrial Clubs of America, Harvard Technology, American
Inspection Society, the National Job Core and has been appointed a Kentucky
Colonel by the Governor of Kentucky in recognition of his lifetime contribution
to his fellow man.
Course Certificate
Harvard Technology certificate will be issued to all attendees completing minimum of
75% of the total tuition hours of the course.
Course Fee
US $2,750 per Delegate. This rate includes Participants Pack (Folder, Manual,
Hand-outs, etc.), buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

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Harvard Technology Middle East

Accommodation
Accommodation is not included in course fees. However, any accommodation
required can be arranged by Harvard Technology at the time of booking.
Required Codes And Standards:
Listed below are the effective editions of the publications required for the current
Tank Inspector Certification Examination. Each student must purchase and have
these documents available for use during the class. The course fee doesnt include
the cost of those codes & standards.
API Recommended Practice 575, Inspection of Atmospheric and LowPressure Storage Tanks, First Edition, November, 1995. Global Engineering
Product Code API CERT 575
API Standard 650, Welded Steel Tanks for Oil Storage, Tenth Edition,
November 1998, including Addendum 1 (March 2000) and Addendum 2
(November 2001), Addendem 3 ( September 2003). Global Engineering
Product Code API CERT 650
API Recommended Practice 651, Cathodic Protection of Aboveground
Petroleum Storage Tanks, Second Edition (December 1997). Global
Engineering Product Code API CERT 651
API Recommended Practice 652, Lining of Aboveground Petroleum
Storage Tank Bottoms, Second Edition (December 1997). Global Engineering
Product Code API CERT 652
API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction,
Third Edition, December 2001 and Addendum 1(September 2003). Global
Engineering Product Code API CERT 653
American Society of Mechanical Engineers (ASME), Boiler and Pressure
Vessel Code, 2001 Edition with 2002 and 2003 Addenda.
i.

ASME Section V, Nondestructive Examination, Articles 1, 2, 6, 7

and 23 (Section SE-797 only).

ii.

ASME Section IX, Welding and Brazing Qualifications

Global Engineering Product Code for the ASME package is API CERT ASME 653. Package includes
only the above excerpts necessary for the exam. Future addenda will not be provided.
API and ASME publications may be ordered through Global Engineering Documents at +1-303792-2181 or +1-800-854-7179. Product codes are listed above. API members are eligible for a 50%
discount on all API documents, other exam candidates are eligible for a 20% discount on all API
documents. No discounts will be made for ASME documents. When calling to order please identify
yourself as an exam candidate. For complete sets of ASME documents including future addenda
please contact ASMEs publications department at +1-800-843-2763. In Canada, ASME publications
are available through Power Engineering Books, Ltd. at +1-800-667-3155 or +1-780-458-3155.

Note: API and ASME publications are copyrighted material. Photocopies of publications are
not permitted at the exam. CD-ROM versions of the API documents are issued quarterly by
Information Handling Services. Be sure to check your CD-ROM against the editions noted on
this sheet.
IE400 - Page 3 of 8
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Harvard Technology Middle East

Course Program
Day 1

0730 - 0800
0800 - 0815
0815 - 0900
0900 - 0930
0930 - 1000
1000 - 1015
1015 - 1045
1045 - 1230
1230 - 1330
1330 - 1445

1445 - 1500
1500 - 1620

1620 - 1720
1720 - 1730
1730
Day 2

0730 - 0830
0830 - 1000

1000 - 1015
1015 - 1130

1015 - 1130

Saturday 08th January 2005

Registration & Coffee

Welcome
Introduction
Students Take Initial Math Quiz
Review Math Quiz Answers
Break
Overview of Course Outline
Review of API 653 Body of Knowledge
Lunch
API 653 - Section 1 Introduction:
General, Compliance With This Standard, Jurisdiction, Safe Working
Practices, Definitions, Referenced Publications
API 653 - Section 2 References
API 653 - Section 3 Definitions
Break
API 653 - Section 4 - Suitability For Service:
General, Tank Roof Evaluation, Tank Shell Evaluation, Tank Bottom
Evaluation, Tank Foundation Evaluation
API 653 - Section 5 - Brittle Fracture Considerations:
General, Basic Considerations, Assessment Procedure
Distribute Homework
End of Day One
Sunday 09th January 2005

Review Homework Answers

API 653 - Section 6 - Inspection
General, Inspection Frequency Considerations, Inspections from the
Outside of the Tank, Internal Inspection, Alternative to Internal
Inspection to Determine Bottom Thickness, Preparatory Work for
Internal Inspection, Inspection Checklists, Records, Reports, NonDestructive Testing
Break
API 653 - Section 7 - Materials
General, New Materials, Original Materials for Reconstructed Tanks,
Welding Consumables
API 653 - Section 8 - Design Considerations for Reconstructed
Tanks
General, New Weld Joints, Existing Weld Joints, Shell Design, Shell
Penetrations, Wind Girders and Shell Stability, Roofs, Seismic Design
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Harvard Technology Middle East

1230 - 1330
1330 - 1500

1500 - 1515
1515 - 1545

1545 - 1615
1615 - 1645

1645 - 1700
1700 - 1725
1725 - 1735
1735 - 1745
1745
Day 3

0730 - 0800
0800 - 0830
0830 - 0900
0900 - 0945

0945 - 1000
1000 - 1030
1030 - 1100

1100 - 1145

Lunch
API 653 - Section 9 - Tank Repair And Alteration
General, Removal and Replacement of Shell Plate Material, Shell
Repairs Using Lap-Welded Patch Plates, Repair of Defects in Shell Plate
Material, Alteration of Tank Shells to Change Shell Height, Repair of
Defective Welds, Repair of Shell Penetrations, Addition or Replacement
of Shell Penetrations, Alteration of Existing Shell Penetrations, Repair
of Tank Bottoms, Repair of Fixed Roofs, Floating Roofs, Repair or
Replacement of Floating Room Perimeter Seals, Hot Taps
Break
API 653 - Section 10 - Dismantling And Reconstruction
General, Cleaning and Gas Freeing, Dismantling Methods,
Reconstructions, Dimensional Tolerances
API 653 - Section 11 - Welding
Welding Qualifications, Identification and Records
API 653 - Section 12 - Examination And Testing
Nondestructive Examination, Radiographs, Hydrostatic Testing, Leak
Tests, Measured Settlement During Hydrostatic Testing
API 653 - Section 13 - Marking And Recordkeeping
Nameplates, Recordkeeping, Certification
API 653 Appendices B F
Administer API 653 Section Quiz
Distribute Homework
End of Day Two
Monday 10th January 2005

Review Homework Answers

API 650 - Section 1 - Scope
General, Limitations, Compliance, Referenced Publications
API 650 - Section 2 - Materials
General, Plates, Welding Electrodes
API 650 - Section 3 - Design
Joints, Bottom Plates, Annular Bottom Plates, Shell Design, Shell
Openings, Shell Attachments and Tank Appurtenances, Roofs, Wind
Load on Tanks (Overturning Stability)
Break
API 650 - Section 4 - Fabrication
API 650 - Section 5 - Erection
General, Details of Welding, Inspection, Testing and Repairs, Repairs to
Welds, Dimensional Tolerances
API 650 - Section 6 - Methods Of Inspecting Joints
Radiographic Method, Magnetic Particle Examination, Ultrasonic
Examination, Liquid Penetrant Examination, Visual Examination
IE400 - Page 5 of 8

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Harvard Technology Middle East

1145 - 1230
1230 - 1330
1330 - 1345
1345 - 1435
1435 - 1445
1445 - 1500
1500 - 1515
1515 - 1530

1530 - 1600

1600 - 1615

1615 - 1625
1625 - 1715

1715 - 1730
1730 - 1735
1735
Day 4

0730 - 0800
0800 - 0805
0805 - 0815
0815 - 0825

0825 - 0830
0830 - 0845

API 650 - Section 7 - Welding Procedure & Welder Qualifications

Definitions, Qualification of Welders
Lunch
API 650 - Section 8 - Marking
Nameplates, Division of Responsibility, Certification
API 650 - Appendices B - S
Administer API 650 Section Quiz
Break
API RP 575 - Section 1 - Scope
API RP 575 - Section 3 - Selected Nondestructive Examination
(NDE) Methods
Ultrasonic-Thickness Measurement, Magnetic Floor Testing
API RP 575 - Section 4 - Types Of Storage Tanks
General, Storage Tanks with Linings and/or Cathodic Protection,
Storage Tanks with Leak Detection Systems, Low-Pressure Storage
Tanks
API RP 575 - Section 5 - Reasons For Inspection and Causes of
Deterioration
Reasons for Inspection, Corrosion of Steel Tanks
API RP 575 - Section 6 - Frequency Of Inspection
API RP 575 - Section 7 - Methods Of Inspection And Inspection
Scheduling
External Inspection of In-Service Tanks, Foundation Inspection, Anchor
Bolt inspection, Grounding Connection Inspection, Thickness
Measurements, Caustic Cracking, Tank Bottoms, Inspection
Scheduling, Inspection Checklists
Pose Thought Questions to Class for Group Discussion
Distribute Homework
End of Day Three
Tuesday 11th January 2005

Review Homework Answers

API RP 651 - Section 1 - Scope
API RP 651 - Section 3 - Definitions
API RP 651 - Section 4 - Corrosion of Aboveground Steel Storage
Tanks
Introduction, Corrosion Mechanisms
API RP 651 - Section 5 - Determination of Need for Cathodic
Protection
API RP 651 - Section 6 - Methods of Cathodic Protection for
Corrosion Control
Introduction, Galvanic Systems, Impressed Current Systems, Cathodic
Protection Rectifiers
IE400 - Page 6 of 8

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Harvard Technology Middle East

0845 - 0900

0900 - 0905
0905 - 0915

0915 - 0920
0920 - 0925
0925 - 0930
0930 - 0935
0935 - 0945

0945 - 1000

1000 - 1015
1015 - 1030

1030 - 1040
1040 - 1045
1045 - 1100
1045 - 1100
1100 - 1110
1110 - 1115
1115 - 1120
1120 - 1125
1125 - 1130
1130 - 1135
1135 - 1140
1140 - 1145

API RP 651 - Section 7 - Design Of Cathodic Protection Systems

Barriers to Cathodic Protection, Tank Bottom Replacement, Impervious
Membrane Lining, Effects of Impermeable Membrane Secondary
Containment Systems
API RP 651 - Section 8 - Criteria For Cathodic Protection
API RP 651 - Section 9 - Installation Of Cathodic Protection
Systems
Introduction, Galvanic Anode Systems, Impressed Current Systems
API RP 651 - Section 10 - Interference Currents
API RP 651 - Section 11 - Operation and Maintenance of
Cathodic Protection Systems
API RP 652 - Section 1 - Introduction
API RP 652 - Section 3 - Definitions
API RP 652 - Section 4 - Corrosion Mechanisms
Chemical Corrosion, Concentration Cell Corrosion, Corrosion Caused
by Sulfate-Reducing Bacteria, Erosion-Corrosion in Water Treatment
API RP 652 - Section 5 - Determination of The Need for Tank
Bottom Lining
General, Design Considerations and Tank Internals, Tank History,
Environmental Considerations, Flexibility for Service Change
Break
API RP 652 - Section 6 - Tank Bottomlining Selection
General, Thin-Film Tank Bottom Linings, Thick-Film Tank Bottom
Linings
API RP 652 - Section 7 - Surface Preparation
General, Precleaning
API RP 652 - Section 9 - Inspection
API RP 652 - Section 10 - Repair Of Tank Bottom Linings
General, Types of Repairs
API RP 652 - Section 11 - Safety
Tank Entry, Manufacturer's Material Safety Data Sheets
Administer API RP 652 Section Quiz
API 2207 - Section 1 - Introduction
API 2207 - Section 3 - Precautions
API 2207 - Section 6 - Safe Work Procedures
Administer API 2207 Section Quiz
API 2015 - Section 1 - General
Scope, Definitions
API 2015 - Section 2 - Administrative Controls
General, Qualified Person
API 2015 - Section 3 - Storage Tank Hazards
General, Oxygen Deficiency and Enrichment, Toxic Substances,
Physical and Other Hazards
IE400 - Page 7 of 8

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Harvard Technology Middle East

1145 - 1150
1150 - 1155

1155 - 1200
1200 - 1205
1210 - 1215
1215 - 1225
1225 - 1230
1230 - 1330
1330 - 1430

1430 - 1530
1530 - 1545
1545 - 1615
1615 - 1715
1715 - 1720
1720
Day 5

0730 - 0800
0800 - 1000
1000 - 1015
1015 - 1230
1230 - 1330
1330 1530
1530 - 1545
1545 - 1600
1600

API 2015 - Section 4 - Preparing the Tank for Entry and Cleaning
API 2015 - Section 5 - Testing The Tank Atmosphere
Oxygen Analyzers, Flammable Vapor Analyzers, Toxic Substance
Indicators, Testing the Atmosphere
API 2015 - Section 6 - Hazard Assessment for Entry Permits
API 2015 - Section 8 - Entering And Working Inside The Tank
Entry Permit, Attendant, Emergency Plan
API 2015 - Section 9 - Hot Work And Tank Repairs
General, Hot Work Permit
API 2015 Appendices A F
Administer API 2015 Section Quiz
Lunch
ASME Section V - Nondestructive Test Methods
Ultrasonic Thickness Testing, Liquid Penetrant Testing, Magnetic
Particle Testing, Radiographic Film Interpretation
ASME Section V - WPS and PQR requirements
Break
Review Procedure Exercise
ASME Section IX - Welder Certification
Distribute Homework
End of Day Four
Wednesday 12th January 2005

Review Homework Answers

Question and Answer Session
Break
API 653 Sample Exam
Lunch
Review API 653 Exam Answers
Break
Presentation of Certificates
End of Course

Course Coordinator
Ms. Arine Dmello:
[email protected]

Tel:

+971-2-6277881,

IE400 - Page 8 of 8
IE400-01-05

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Fax:

+971-2-6277883,

Email:

.
21 December 2004

Section 1
API 653
Tank Inspection, Repair, Alteration, and
Reconstruction

API - 653
TANK INSPECTION, REPAIR
ALTERATION AND RECONSTRUCTION
THIRD EDITION - DECEMBER 2001
ADDENDUM 1 - SEPTEMBER 2003
SECTION 1 - INTRODUCTION
1.1

General
1.1.1

This standard covers carbon and low alloy steel tanks built to API-650 and
12C standards. These standard provide minimum requirements for
maintaining the integrity of welded or riveted, non-refrigerated,
atmospheric pressure, above ground storage tanks after they have been
placed in service.

1.1.2 Scope coverage

Foundation, bottom, shell, structure, roof, attached appurtenances and
nozzles to the face of the first flange, first threaded joint or first welded
end connection.
NOTES:

1.
2.

1.1.6
1.2

Many API-650 requirements apply that will satisfy

this new code.
In case of conflict (for in-service tanks) between API12C; 650; and 653, this latest Code governs.

API 653 now recognizes API RP 579, Recommended Practice for Fitnessfor-Service. Under API 653 , the owner may use fitness-for-service criteria.

Compliance
The owner/operator has ultimate responsibility for complying with API 653
provisions.

1.3

Jurisdiction
Statutory Regulation (i.e., local, state or federal) shall govern, unless the
requirements of this standard are more stringent than Statutory Regulation.

1.4

Safe Working Practices

Safety procedures according to guidelines given in API publications 2015, 2016,
and 2217A are suggested for potential hazards involved when conducting
internal inspections, making repairs or dismantling tanks.
NOTE:

Procedures must comply with any state or federal safety

regulation involving "confined space" entry.

API 650 Summary, 2005

Page 1-1

SECTION 3 - DEFINITIONS
3.1
alteration: Any work on a
tank involving cutting, burning,
welding or heating operation that
changes the physical dimensions
and/or configuration of a tank.
Typical examples of alterations
include:
a. The addition of manways and
nozzles greater than 12-inch
(NPS).
b. An increase or decrease in
tank shell height.
3.2
applicable standard: The
original standard of construction,
such as API standards or
specifications or Underwriter
Laboratories (UL) standards,
unless the original standard of
construction has been superseded
or withdrawn from publication;
in this event, applicable standard
means the current edition of the
appropriate standard. See
Appendix A for background on
editions of API welded storage
tank standards.
3.3
atmospheric pressure:
Used to describe tanks designed
to withstand an internal pressure
up to but not exceeding 2.5
lbs./sq. in. gauge.
3.4
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 or operator of
one or more aboveground
storage
tank(s) who maintains an
inspection organization for
activities
relating only to its equipment,
and not for aboveground storage
tanks intended for sale or resale.
d.
An independent
organization or individual under
contract to and under the
direction of an owner or operator
and recognized or otherwise not
prohibited by the jurisdiction in
which the aboveground storage
tank is operated. The owner or
operators inspection program
shall provide the controls
necessary for use by Authorized
Inspectors contracted to inspect
above ground storage tanks.
3.5
authorized inspector: An
employee of an authorized inspection
agency and is certified as an
Aboveground Storage Tank Inspector
per Appendix D of this standard.
3.6
breakover point: The area on a
tank bottom where settlement begins.
3.7
change in service: A change
from previous operating condition
involving different properties of the
stored product such as specific gravity
or corrositivity and/or different service
conditions of temperature and/or
pressure.
3.8
corrosion rate The total metal
loss divided by the period of time over
which the metal loss occurred.

API 650 Summary, 2005

Page 1-2

NOTE:
Alteration/Repair
items may be closely related and
could even be a matter of
personal description (See also
Section 12).

3.9
critical zone: The portion of the
bottom or annular plate within 3 inches
of the inside edge of the shell, measured
radially inward.
3.10 hot tap: Identifies a procedure
for installing a nozzle in the shell of a
tank that is in service.
3.11 inspector: A representative of an
organizations mechanical integrity
department who is responsible for
various quality control, and assurance
functions, such as welding, contract
execution, etc.

3.16 repair organization: An

organization that meets any of the
following:
a. An owner/operator of aboveground
storage tanks who repairs or alters its
own equipment in accordance with this
standard.

3.12 owner/operator: The legal entity

having both control of and/or
responsibility for the operation and
maintenance of an existing storage tank.

b. A contractor whose qualifications are

acceptable to the owner/operator of
aboveground storage tanks and who
makes repairs or alterations in
accordance with this standard.

3.13 reconstruction: Any work

necessary to reassemble a tank that has
been dismantled and relocated to a new
site.

c. One who is authorized by, acceptable

to, or otherwise not prohibited by the
jurisdiction, and who makes repairs in
accordance with this standard.

3.14 reconstruction organization: The

organization having assigned
responsibility by the owner/operator to
design and/or reconstruct a tank.

3.17 storage tank engineer: One or

more persons or organizations
acceptable to the owner/operator who
are knowledgeable and experienced in
the engineering disciplines associated
with evaluating mechanical and material
characteristics that affect the integrity
and reliability of aboveground storage
tanks. The storage tank engineer, by
consulting with appropriate specialists,
should be regarded as a composite of all
entities needed to properly assess the
technical requirements.

3.15 repair: Any work necessary to

maintain or restore a tank to a condition
suitable for safe operation. Typical
examples of repairs includes:
a. Removal and replacement of material
(such as roof, shell, or bottom material,
including weld metal) to maintain tank
integrity.
b. Re-leveling and/or jacking of a tank
shell, bottom, or roof.
c. Addition of reinforcing plates to
existing shell penetrations.

3.18 external inspection: A formal

visual inspection, as supervised by an
authorized inspector, to assess all
aspects of the tank as possible without
suspending operations or requiring tank
shutdown (see 6.4.1).

d. Repair of flaws, such as tears or

gouges, by grinding and/or gouging
followed by welding.
API 650 Summary, 2005

Page 1-3

3.19 internal inspection: A formal,

complete inspection, as supervised by
an authorized inspector of all accessible
internal tank surfaces (see6.4.1).

3.20 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.

API 650 Summary, 2005

Page 1-4

SECTION 4 - SUITABILITY FOR SERVICE

4.1

General
4.1.1

When inspection indicates a change from original physical condition,

evaluate to determine suitability for continued service.

4.1.2 This section covers:

a.
b.
4.1.3

Factors for consideration: (plus engineering analysis and judgment)

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.

4.2

Evaluation for continued service.

Decisions relative to repairs, alterations, dismantling, relocating,
or reconstruction.

Internal corrosion (products or water bottom).

External corrosion (environmental exposure).
Allowable stress levels.
Stored product properties (i.e., Specific Gravity, temperature,
corrositivity).
Metal design temperatures (at service location).
External roof live load, wind and seismic loading.
Foundation, soil and settlement conditions.
Chemical analysis/mechanical properties (construction. material).
Existing tank distortions.
Operating conditions (i.e., filling/emptying rates and frequency).

Tank Roof Evaluation (General)

4.2.1.2

Roof plates corroded to an average "t" of less than 0.09" (in

any 100 sq. in) Repair or Replace.

4.2.2 Fixed Roofs

Determine condition of roof support system (i.e., rafters, girders,
columns, bases and out of plumb columns). Corrosion and/or damaged
members - Evaluate for repair or renewal.
NOTE:

Pipe columns require special attention. Severe internal

corrosion may not be evidenced by external visual
inspection.

4.2.3 Floating Roofs

4.2.3.1

Cracks/punctures - Repair or replace.

4.2.3.2

Pitting/corrosion - Evaluate for potential penetration before

the next scheduled internal inspection.

4.2.3.3

Roof support system, perimeter seals, drain system, venting,

other appurtenances. Evaluate.
API 650 Summary, 2005

Page 1-5

4.2.3.4

See API-650 (Appendix C and H) for evaluation guidance.

NOTE:

4.2.4

4.3

Upgrading - Not mandatory to meet those

guidelines on floating roofs.

Change of Service
4.2.4.1

Internal pressure: Refer to API-650 (Appendix F) when

evaluating/modifying roof or roof-to-shell junction.

4.2.4.2

External pressure: Roof support structure and roof-to-shell

junction. Evaluate for effect of design partial vacuum. Refer
to API-620.

4.2.4.3

All requirements of API-650 (Appendix M) shall apply before

a change of service to operation at temperature above 200F
is considered.

4.2.4.4

See API-650 (or applicable standard) if operation is to be at

lower temperature than original design.

4.2.4.5

Evaluate if change of service will effect normal or

emergency venting.

Tank Shell Evaluation

4.3.1.1

Flaws, deterioration, (greater than CA) must be evaluated

for continued use suitability.

4.3.1.2

The shell condition, analysis and evaluation shall take into

consideration the anticipated loading conditions and
combinations including:
a.
b.
c.
d.
e.

Pressure due to fluid static head.

Internal and external pressure.
Wind and seismic loads.
Roof live loads.
Nozzle, settlement and attachment loads.

4.3.1.3

Shell corrosion occurs in many forms and varying degrees

of severity resulting in a generally uniform loss of metal
over a large surface area or in localized areas. Pitting may
also occur, but does not normally represent a significant
threat to overall structural integrity unless present in a
severe form with pits in close proximity to one another.

4.3.1.4

Methods for determining the minimum shell "t" suitable for

continued operation are given in 4.3.2, 4.3.3, and 4.3.4.
(see page 1-8 below for minimum shell t formula.)

API 650 Summary, 2005

Page 1-6

4.3.2

Actual Thickness Determination

This section deals with the averaging of corroded areas. This is not an exact
science and should be used only when an area is questionable for repair. For exam
purposes, you will be supplied with 't2 " and the diameter of the tank.

API 650 Summary, 2005

Page 1-7

Minimum Thickness Calculation for

Welded Tank Shell
(API 653 Section 4.3.3.1)
tmin = 2.6 (H-1)DG
SE
tmin = the minimum acceptable thickness, in inches, for each course as
calculated from the above formula; however, tmin shall not be less
than 0.1 inch for any tank course.
D=

nominal diameter of tank, in feet.

H = height from the bottom of the shell course under consideration to the
maximum liquid level when evaluating an entire shell course, in ft; or
height, from the bottom of the length L (see 4.3.2.1) from the lowest point
of the bottom of L of the locally thinned area to the maximum liquid level,
in ft; or
height from the lowest point within any location of interest to the
maximum liquid level, in ft.
G=

Highest specific gravity of the contents.

S=

Maximum allowable stress in pounds per square inch; use the

smaller of 0.80Y or 0.429T for bottom and second course; use the
smaller of 0.88Y or 0.472T for all other courses. Allowable shell stresses
are shown in Table 4-1 for materials listed in the current and previous
editions of API Std. 12C and Std. 650. Note: For reconstructed tanks,
S shall be per the current applicable standard.

Y=

Specified minimum yield strength of the plate; use 30,000 psi if not
known.

T=

The smaller of the specified minimum tensile strength of the plate

or 80,000 psi; use 55,000 psi if not known.

E=

Original joint efficiency for the tank. Use Table 4-2 if original E is
unknown. E=1.0 when evaluating the retirement thickness in a
corroded plate, when away from welds or joints by at least the
greater of one inch or twice the plate thickness.

API 650 Summary, 2005

Page 1-8

FOR UNKNOWN MATERIAL

Maximum Allowable Stress (in PSI)

NOTE:

Use the smaller of:

First or Second Course

Other Courses

(Yield)
.80Y = .80 X 30,000 = 24,000
or
(Tensile)
.429T = .429 X 55,000 = 23,595

(Yield)
.88Y = .88 X 30,000 = 26,400
or
(Tensile)
.472T = .472 X 55,000 = 25,960

The Third Edition of API 653 has added a new table, Table 4-1,
Maximum Allowable Shell Stresses (not for use for reconstructed
tanks). This will make stress calculations much easier.

Sample problem for minimum thickness of a welded tank shell.

An inspection of a welded, 138 foot diameter tank, 50 feet tall, 48 feet fill height shows
some scattered pitting in the first course. What is the minimum shell thickness required
for this tank, if the specific gravity of the product is 0.9?

tmin = ?
D = 138'
H = 48'
G = .9
S = 23,600 (from Table 4-1)
E=1

tmin = 2.6 (H-1) DG

SE

tmin = 2.6 (48-1)((138)(.9)

23,600(1)
15,177.24
23,600
tmin = .643"

API 650 Summary, 2005

Page 1-9

Practice Problem
tmin = 2.6 (H-1) DG
SE
A 190' diameter tank has a pit that measures 5/16" deep in the first course, what is the
min t, if the fill is 42 feet and the specific gravity is 0.6? (The pit is not in a weld seam or
HAZ.) The material is unknown.
S=

Maximum allowable stress in pounds per square inch; use the

smaller of 0.80Y or 0.429T for bottom and second course; use the
smaller of 0.88Y or 0.472T for all other courses.

Y=

Specified minimum yield strength of the plate; use 30,000 psi if not
known.

T=

The smaller of the specified minimum tensile strength of the plate or

80,000 psi; use 55,000 psi if not known.

E=

Original joint efficiency for the tank. Use Table 4-2 if original E is unknown.
E = 1.0 when evaluating the retirement thickness in a corroded plate, when away
from welds or joints by at least the greater of one inch or twice the plate
thickness.

Explanation of Practice Problem

tmin = 2.6 (H-1) DG
SE

tmin = ?

D = 190
S = 23,600

H = 42
E=1

G = .6

tmin = 2.6 (42-1) (190) (.6)

23,600(1)
tmin = 12,152.4
23,600
tmin = .515 inches

API 650 Summary, 2005

Page 1-10

The Exam recognizes a variation of the minimum thickness formula, even though the
formula does not appear directly in the API 653 Standard. The calculation is for
Maximum Allowable Fill Height based on a minimum thickness and can be found in the
API 653 Body of Knowledge.

Maximum Allowable Fill Height

Calculation
(API 653 Body of Knowledge)
H=

S x E x t min
2.6 x D x G

tmin = The minimum acceptable thickness, in inches, as calculated

from the above formula; however, tmin shall not be less than 0.1
inch for any tank course.
D=

Nominal diameter of tank, in feet.

H=

Height, in feet, from the bottom of the length L for the most severely
corroded area in each shell course to the maximum design liquid
level.

G=

Highest specific gravity of the contents.

S=

Maximum allowable stress in pounds per square inch; use the

smaller of 0.80Y or 0.429T for bottom and second course; use the
smaller of 0.88Y or 0.472T for all other courses.
Note: For reconstructed tanks, S shall be per the current applicable
standard.

Y=

Specified minimum yield strength of the plate; use 30,000 psi if not
known.

T=

The smaller of the specified minimum tensile strength of the plate or

80,000 psi; use 55,000 psi if not known.

E=

Original joint efficiency for the tank. Use Table 4-2 if original E is
unknown. E=1.0 when evaluating the retirement thickness in a
corroded plate, when away from welds or joints by at least the
greater of one inch or twice the plate thickness.

Note: The + 1 was removed from this formula because of a change in the base
formula in API 653, Second Edition, Second Addenda. The API Body of
Knowledge has not yet made the correction.

API 650 Summary, 2005

Page 1-11

Sample problem for maximum allowable

fill height of a welded tank shell.
An inspection of a welded, 138 foot diameter tank, 55 feet tall, shows some scattered
pitting in the first course, minimum remaining thickness is .72. The product specific
gravity is 0.9 What is the maximum fill height required for this tank?
H=

S x E x t min
2.6 x D x G

H=?
S = 23,600
E=1
t min = .72
D = 138'
G = .9
H=

23,600(1)x.72
2.6(138)(.9)

H=

16,992.0
322.92

H = 52.620 or 52 6

Sample problem for maximum allowable

fill height of a welded tank shell.
H=

S x E x t min
2.6xDxG

What is the fill height of a welded tank 112 diameter, that has a
minimum thickness of .115 inches? The specific gravity of the product is .5
H=

23,600 x .115
2.6 x 112 x .5

H=

2,714.0
145.6

H = 18.640 or 18 6-3/8

API 650 Summary, 2005

Page 1-12

The 3rd Edition of API 653 takes a two step approach for hydrostatic testing height H,
Ht.
STEP A: Controlling Thickness
Ht = StEtmin
2.6D + 1
STEP B: Locally Thinned Areas
Ht = StEtmin
2.6D
4.3.1.5

If the "t" requirements cannot be satisfied, the corroded or

damaged areas shall be:
a.
b.
c.

Repaired, or
Allowable liquid level reduced, or
Tank retired.

NOTE:
4.3.2

The maximum design liquid level shall not be

exceeded.

Actual "t" Determination:

a.
b.
4.3.2.2

See Inspection of Corrosion Areas (Fig. 4-1, Page 4-2).

The controlling thickness in each shell course, where corroded
areas of considerable size occur, must be determined.
Widely scattered pits may be ignored if:
a.

b.

No pit results in the remaining shell "t" being less than

one-half (1/2) of the minimum acceptable tank shell
"t" (exclusive of the CA);
And
The sum (total) of their dimensions along any vertical
line does not exceed two inches (2") in an eight inch
(8") length. (See Fig. 4-2).
EXAMPLE:
Three (3) pits in close proximity. Dimension
(measure) vertically - each pit. Add the sum (total
dimensions) together.
* d1 + d2 + d3 ---
2"
NOTE:

API 650 Summary, 2005

If the pit dimension totals (measured

vertically) exceed 2" in an 8" length, then
these pits must be considered as
strength factors.
Page 1-13

Special Note:
1.
2.
3.
4.

4.3.4

Old method of evaluating pit problem.

Draw or imagine an 8" diameter circle.

Within the circle, measure all of the pit surface areas, individually.
Add all of the pit values together.
* Unit of Measure = Sq. In.
If the sum total of all the pit surface areas exceed 7 sq. in. within that
8" diameter circle, then the pits must be considered as strength factors.

Minimum "t" calculation for Riveted Tank Shell

4.3.4.1

Use the same formula as 4.3.3.1, except that the following

allowable stress criteria and joint efficiency shall be used:
a.
b.

S = 21,000 lbs./sq./in.
E - 1.0 for shell plate 6" or more away from rivets.

NOTE:
4.3.4.3

See Table 4-3 for joint efficiencies for locations

within 6" of rivets.

Evaluate to what extent, if any, riveted joints have been

affected by corrosion. Relate "bulging" condition between
internal butt-straps and shell plates with stress placed on
rivets.

INTERNAL CORROSION - OBSERVATIONS/COMMENTS

Based on experience and personal observations only, the following is presented for
field data survey and evaluation.
A.

Tank Bottoms
1.

2.
3.

For tanks with potential sour water present, check closely for accelerated
corrosive attack around outer periphery. This is usually found at the
lowest point and at the water collection point. Also applies to lower 4" - 6"
of internal shell.
Some product services specifically attack weld seams and the adjacent
HAZ
Not Internal, but related, corrosion often occurs to the underside of tank
bottoms. If bottom leak is suspected as a result of underside corrosion, be
prepared for a slow, long duration, expensive operation to verify and/or
locate problem areas. * Later reference under Bottom Evaluation.

API 650 Summary, 2005

Page 1-14

B.

Tank Shells
1.
2.
3.
4.
5.

C.

See prior comment on lower shell area with potential for sour water
attack. * Sour Crude tanks very susceptible to this type corrosion.
The theory that the hot side (i.e., west side thermal input) is more
corrosive has not been justified or verified.
Preferential attack on weld seams, HAZ, scaffold lug removal areas, etc., is
not uncommon.
Extreme upper, non-wetted shell area often experiences accelerated
corrosion. This is a very real possibility in sour crude or No. 6 fuel oils
due to high sulfur content in the vapor phase.
Watch for accelerated metal loss (usually smooth, perhaps even grooved)
at the normal product high liquid level in weak acid service.

Tank Roofs/Support Structure

Should corrosion be found in the upper shell, the potential for a like loss should
be suspected on the internal roof plates, the rafter/structural members and the
roof support columns. These specific areas are exposed to the same
environment as the upper, non-wetted shell surface.
If only the two (2) lower shell rings show accelerated corrosion, closely check the
roof support columns. Problems to the same degree and elevation may be
present.
4.3.5

Distortions
4.3.5.1

Includes out-of-roundness, buckled areas, flat spots, peaking

and banding at welded joints.

4.3.5.2

Potential causes:
a.
b.
c.
d.
e.

4.3.6

Foundation settlement
Over or under-pressuring
High winds
Poor shell fabrication/erection
Repair Techniques

Flaws cracks and laminations

a.

Examine/evaluate to determine need, nature or extent of repair. If

repair is required, develop procedure (with sketch as necessary).
Evaluate all issues on a case-by-case basis.

b.

Cracks in the shell-to-bottom (corner) weld are critical. Removal,

not weld-over, is required.

API 650 Summary, 2005

Page 1-15

4.3.9 Shell Penetrations

Consideration details include:
a.
b.
c.
d.
e.
4.4

Type and extent of reinforcement.

Weld spacing.
Proximity of reinforcement to shell weld seams.
Thickness of component parts.
Deterioration (internal/external).

Tank Bottom Evaluation

4.4.1

General
RBI is now a basis of this paragraph. All aspects of corrosion phenomena,
all potential leak or failure mechanisms must be examined. Assessment
period shall be less than or equal to the appropriate internal inspection
interval.
NOTE:

4.4.2

Excessive foundation settlement can have a serious impact

on the integrity of shell and bottoms. Refer to Appendix "B"
for tank bottom settlement techniques.

Causes of Bottom Leaks

Consider cause/effect/repair:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.

4.4.6

Internal pitting.
Corrosion of weld seams and HAZ
Weld joint cracking.
Stresses (roof support loads and settlement).
Underside corrosion (i.e., normally pitting).
Inadequate drainage.
Lack of an annular plate ring, when required.
Uneven settlement (with resultant high stress).
Roof support columns (or other supports) welded to bottom
without allowance for adequate movement.
Rock or gravel foundation pads.
Non-homogeneous fill under bottom (i.e., shell, rock, clay,
wood stakes, etc.).
l.
Inadequately supported sumps.

Bottom Measurements Methods (Appendix G may apply)

a.
b.
c.
d.
e.
f.

Spot U. T. measurement.
Visual, internal survey with hammer test.
UT "B" scan.
MFE or MFLT
Section removal (i.e., coupon).
Abrasive blast (scan for capillary wicking).

API 650 Summary, 2005

Page 1-16

4.4.7

Minimum "t" for Tank Bottom Plate

Two (2) Methods:
a.
b.

4.4.8

4.4.7.3

If the minimum bottom "t", at the end of the in-service

period of operation, are calculated to be less than the bottom
renewal thickness given in Table 6-1 (page 6-3), the bottom
shall be repaired as follows: Lined, repaired, replaced or the
interval to the next internal inspection shortened. Unless an
RBI program is in place.

4.4.7.4

Critical zone thickness is redefined in this paragraph. Note

the plate thickness in the critical zone shall be the smaller of
1/2 the original bottom plate thickness or 50% of tmin of the
lower shell course, but not less than 0.1 inch.

4.4.7.7

The bottom extension shall be no less than 0.1 inch thick and
must extend beyond the outside toe of the shell-to-bottom
weld at least 3/8 inch.

Minimum "t" - Annular Plate Rings

1.
2.
3.

4.5

Deterministic (See 4.4.7.1) - A long, drawn out formula/data

process. Not normally used.
Probabilistic (See 4.4.7.2) - Normal process. Statistical
analysis based on thickness data resulting from visual,
mechanical or UT survey.

See Visual Aide of Table 4-4 (page 4 - 9).

With product SG less than 1.0 that require annular plates for
other than seismic loading consideration -- Also see Table 4-4.
SG greater than 1.0: Refer to Table 3-1 of the API-650 standard.

Tank Foundation Evaluation

4.5.1 General - (causes of foundation deterioration):
a.
b.
c.

Settlement
Erosion
Cracking of concrete (i.e., calcining, underground water,
frost, alkalies and acids).

API 650 Summary, 2005

Page 1-17

4.5.1.2

4.5.2 and 4.5.3

Description - concrete deterioration mechanisms.

a.

Calcining - (loss of water of hydration).

Normally occurs when concrete has been exposed to
high temperature for a period of time. During
intermediate cooling periods, the concrete absorbs
moisture, swells, loses its strength and cracks.

b.

Chemical attack: cyclic changes in temperature

and by freezing moisture.

c.

Expansion in porous concrete caused by

freezing moisture - Spalling or serious structural
cracks.

d.

Concrete bond deterioration - Attack by

sulfate-type alkalies or even chlorides.

e.

Temperature cracks (hairline with uniform

width). Not Normally serious.* Potential moisture
entry points with resulting corrosion of the
reinforcing steel.

General
a.
b.
c.

For repair or renewal (See 10.5.6).

Prevent water entry.
Distortion of anchor bolts and excessive cracking of
the concrete structure in which they are embedded
may indicate:
(i)
(ii)

Serious foundation settlement.

Tank over pressure uplift condition.

API 650 Summary, 2005

Page 1-18

SECTION 5 - BRITTLE FRACTURE CONSIDERATIONS

5.1

General
Provides a procedure to assess the risk of failure due to brittle fracture, plus
establishes general guidance for avoiding this type failure.

5.2

Basic Considerations
See Fig. 5-1 "Decision Tree" as the assessment procedure to determine failure
potential. Prior incident data whereby brittle fracture has 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
failure has primarily occurred in welded tanks.
5.2.1 Reported conditions involving failures (primarily involving welded tanks):
a.
b.
c.
d.

Hydro test at initial erection.

First filling in cold weather.
After a change to lower temperature service.
After a repair-alteration.

5.2.2 Any change in service must be evaluated to determine if it

increases the risk of failure due to brittle fracture. For example, the
change to a more severe service involving one of the following:
a.
b.

Lower operating temperature (especially below 60F).

Product with a higher specific gravity.
* Consider need for hydrostatic test when any repair or alteration
does not meet all requirements of the 653 standard or
deterioration of the tank has occurred since the original hydrostatic
test.

General Comments:
1.

Fracture assessment would most likely be conducted by a metallurgist or

design specialist.

2.

Several options exist based on the most severe combination of

temperature and liquid level experienced by the tank during its life,
whereby an increased potential for brittle fracture failure exists:
a.
b.
c.
d.

3.

Restrict the liquid level.

Restrict the minimum metal temperature
Change service to a lower Specific Gravity. product.
A combination of the three areas listed above.

Remember: Reducing the storage temperature,- Increases the potential

for failure. Shell stresses are increased and potential for failure is greater
with a stored product change to a higher specific gravity.
API 650 Summary, 2005

Page 1-19

SECTION 6 - INSPECTION
46.1

General - In-service Inspection of Tanks

6.2

Inspection Frequency Considerations

6.2.1 Some factors determining inspection frequency:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.

Nature of stored product.

Visual inspection/maintenance results.
Corrosion rates and/or allowances.
Corrosion prevention systems.
Previous inspection results.
Methods-materials of construction or repair.
Tank location (i.e., isolated, grouped, high risk areas).
Potential for air, water or soil pollution.
Leak detection systems.
Change in operating mode.
Jurisdictional requirements.
Changes in service (including water bottoms).
The existence of a double bottom or a release prevention
barrier.

6.2.2 The interval between inspections (internal/external) is most

influenced by its service history, unless special reasons indicate an
earlier inspection is required.
6.2.3

6.3

Local jurisdictional regulations (i.e., vapor loss values, seal condition,

leakage, proper diking and repair procedures) should be known by
inspection personnel in their own locality, or should be furnished by
owner-user to inspectors who function at remote locations.

External Inspection (Routine In-Service Type)

6.3.1.1 through 6.3.1.3
Routine external in-service inspection may be done by owner-user
operator personnel. Routine requirements include:
a.
b.
c.

Visual inspection from the ground.

Intervals shall not exceed one month.
External check for leaks, distortion, settlement, corrosion,
foundation, paint, insulation, etc.

API 650 Summary, 2005

Page 1-20

6.3.2

6.3.3

Scheduled Inspections (All tanks)

6.3.2.1

Formal visual external inspection at least every five (5) years

or RCA/4N years (where RCA is the difference between the
measured shell thickness and the minimum required
thickness in mills, and N is the shell corrosion rate in mills
per year), whichever is less, by an Authorized Inspector.
Tank may be in operation.

6.3.2.2

Remove insulation to extent necessary to determine

condition of roof and shell.

6.3.2.3

Tank grounding system components, shunts, cable

connection, etc., shall be visually checked.

6.3.2.4

Visually check tank grounding components.

In-service UT "t" measurement of shell.

6.3.3.1

Extent of UT survey - Determined by owner-user.

6.3.3.2

When UT is used as inspection method, intervals shall not

exceed the following:
a.
b.
c.

Five (5) years from commissioning new tank.

At five year intervals (existing tanks where corrosion
rate is not known.
When the corrosion rate IS known, the maximum
interval shall be the smaller of RCA/2N years (where
RCA is the difference between the measured shell
thickness and the minimum required thickness in
mils, and N is the shell corrosion rate in mils per year)
or fifteen (15) years.

6.3.3.3

Internal tank shell inspection (out-of-service condition) can

be substituted for a program of external UT measurements
made during in-service condition.

6.3.4.1

Cathodic Protection System -- Survey in accordance with

API RP 651.

API 650 Summary, 2005

Page 1-21

6.4

Internal Inspection
6.4.1

General
Internal inspection is primarily designed to:
a.
b.

Determine that bottom is not severely corroded or leaking.

Gather data necessary to determine minimum "t" of shell
and bottom for proper evaluation.
NOTE:

c.
6.4.1.2

6.4.2

Prior in-service UT data may be used as criteria in the

assessment process.

Identify/evaluate any tank bottom settlement.

New item. The Authorized Inspector who is responsible for
evaluation of a tank must visually examine each tank and
review the NDE results.

Inspection Intervals
6.4.2.1

Internal inspection intervals are determined by:

a.
b.

Corrosion rates established during prior surveys.

Anticipated corrosion rates based on experience with
tanks in similar service.

NOTES:

1.
2.
3.

6.4.2.2

6.4.3

Normally, bottom corrosion rates will

control.
Set interval so that bottom plate
minimum "t"(at the next inspection) are
not less than the values listed in Tbl 6-1.
In No case, shall the internal inspection
interval exceed twenty (20) years.

If corrosion rates are not known and similar service data is

not available (to determine bottom plate "t" at next
inspection), the actual bottom "t" shall be determined by
inspection(s), interval shall not exceed ten (10) years of
operation to establish corrosion rates.

Alternative Internal Inspection Interval

For unique combinations of service, environment and construction, the
owner/operator may establish the interval using an alternative
procedure. This method includes:
a.
b.
c.
d.

Determining bottom plate "t".

Consideration of environmental risk.
Consideration of inspection quality.
Analysis of corrosion measurements.
API 650 Summary, 2005

Page 1-22

As an alternative an RBI program may be used.

NOTE: Must be documented and made part of permanent record.
6.5

Alternative to Internal Inspection to Determine Bottom "t"

In cases where construction, size or other aspects allow external access to
bottom, an external inspection (in lieu of internal) is allowed to meet
requirements of Table 6-1. Documentation also required.

6.7

Inspection Checklists
Appendix "C" provides sample checklists of items for consideration for in or outof-service inspections. A similar checklist also exists in API RP 575.
NOTES:

6.8

1.
2.
3.
4.

Would be very expensive and time consuming.

Would require support personnel/equipment.
Plant personnel could check a number of items.
All are not necessary, unless special condition exists.

Records
6.8.1

General
a.
b.

Records form the basis of any scheduled inspection/maintenance

program. If no records exist, judgment may be based on tanks in
similar service.
Owner/operator must maintain a complete record file on each tank
consisting of three (3) types:
i.
ii.
iii.

6.8.2

Construction Records
Inspection History
Repair/Alteration History

Construction Records
May include the following:
a.
b.
c.
d.
e.
f.
g.

Nameplate information
Drawings
Specifications
Construction completion report
NDE performed
Material analysis
Hydro data

API 650 Summary, 2005

Page 1-23

6.8.3

Inspection History
a.

b.
c.
6.8.4

Includes all measurements taken, condition of all parts inspected

and a record of all examination and tests. Include a complete
description of any unusual condition with probable reason for
problem and recommendation for corrections.
Sketches and detailed repair procedure should be provided if
so desired by the customer.
Corrosion rate and inspection interval calculations should be
furnished and made a part of the permanent file.

Repair/Alteration History
Includes all data accumulated from initial erection with regard to repairs,
alterations, replacements, plus data associated with service changes (i.e.,
specific gravity and temperature). Include results of coating-lining
experience.

6.9

Reports
6.9.1

Recommended repairs shall include:

a.
b.

6.9.2

General inspection reports shall include:

a.
b.
c.
d.
e.

6.10

Reason for the repair.

Sketches showing location and extent.

Metal thickness measurements

Conditions found
Repairs
Settlement data
Recommendations

Non-Destructive Examinations
NDE personnel shall meet the qualifications identified in 12.1.1.2, but need
not be certified in accordance with Appendix D. However, the results
must be reviewed by an Authorized Inspector.

API 650 Summary, 2005

Page 1-24

SECTION 7 - MATERIALS
7.1

General
This section provides general requirements for materials when tanks are
repaired, altered or reconstructed. (See Section 9 for specific data).

7.2

New Materials
Shall conform to current applicable tank standards.

7.3

Original Materials for Reconstructed Tanks

7.3.1

All shell plates and bottom plates welded to the shell shall be identified.
Original contract drawings, API nameplate or other suitable
documentation do not require further identification. Materials not
identified must be tested.(See 7.3.1.2.).
7.3.1.2

7.3.1.3

7.3.3

If plates are not identified, subject plate to chemical analysis

and mechanical tests, as required in ASTM-A6 and A370
(including Charpy V-Notch). API-650 impact values must be
satisfied.
For known materials, plate properties (at a minimum) must
meet chemical and mechanical API-650 requirements with
regard to thickness and design metal temperature.
Flanges, fasteners, structural, etc., must meet current
standards. Welding consumables must conform to the AWS
classification that is applicable.

API 650 Summary, 2005

Page 1-25

SECTION 8 - DESIGN CONSIDERATIONS

RECONSTRUCTED TANKS
8.2

New Weld Joints

a.
b.

8.3

Must meet applicable standard.

Butt-weld joint with complete fusion and penetration.

Existing Joints
Must meet original construction standard.

8.4

Shell Design
8.4.1

When checking design criteria, the "t" for each shell course shall be based
on measurements taken within 180 days prior to relocation.

8.4.2

Determining maximum design liquid level for product is determined by:

a.
b.
c.
d.

8.5

Calculate the maximum liquid level (each course) based on

product specific gravity.
Actual "t" measured for each course.
Material allowable stress for each course. (See Table 3-2 - API-650).
Selected design method.

Shell Penetrations
8.5.1

New/replacement penetrations must be designed, detailed, welded

and examined to meet current applicable standard.

8.5.2

Existing penetrations must be evaluated for compliance with the

original construction standard.

API 650 Summary, 2005

Page 1-26

SECTION 9 - TANK REPAIR AND ALTERATION

9.1

General
Basis for repair/alteration shall be equivalent to API-650 standard.
9.1.3 All repairs must be authorized by the Authorized Inspector or an
engineer. The Authorized Inspector will establish hold points.
9.1.4 All proposed design, welding procedures, testing methods, etc., must be
approved by the Authorized Inspector or an engineer.
9.1.5 Appendix F summarizes the requirements by method of examination and
provides the acceptance standards, inspector qualifications, and procedure
requirements. This is a good summary of NDT requirements and includes
procedures from API 650, but it should not be used alone.

9.2

Removal and Replacement - Shell Plate

9.2.1 Thickness of the replacement shell plate shall not be less than the greatest
nominal "t" of any plate in the same course adjoining the replacement
plate except thickened insert plate.
NOTE:

9.2.2

When evaluating plate suitability, any change from the

original design condition (i.e., specific gravity, pressure,
liquid level and shell height) must be considered.

Minimum Dimensions of Replacement Shell Plate

9.2.2.1

Twelve inches (12"), or 12 times the "t" of the replacement,

whichever is greater.
NOTE:

9.2.2.2

The replacement plate may be circular, oblong,

square with rounded corners or rectangular
with rounded corners, except when an entire
plate is replaced. (See Fig. 9-1 for details).

When replacing entire shell plates, it is permissible to cut and

reweld along the existing horizontal weld joints. Maintain
weld spacing as per established API-650 values.
NOTE:

Prior to welding the new vertical joints, the

existing horizontal weld must be cut for a
minimum distance of twelve inches (12")
beyond the new vertical joints. As normal,
weld verticals before roundseams.

API 650 Summary, 2005

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9.2.3

Weld Joint Design

9.2.3.1

Replacement Shell Plates - Butt joints with complete

penetration and fusion. Fillet welded lapped patch plates are
permitted.

9.2.3.2

Weld Joint Design

a.
b.
c.

9.2.3.3

See API-650 (3.1.5.1 through 3.2.5.3).

Joints in existing lap-weld shells may be repaired
according to original construction standard
Weld details - See API-650(5.2) and API-653
(Section 11).

Refer to Figure 9-1 for Minimum weld spacing dimensions.

NOTE:

9.3.1

Special requirements for shell plates of

unknown toughness, not meeting the
exemption curve for brittle fracture: The new
vertical weld must be at least 3 or 5T from
bottom joints.

Lapped patch shell repairs are now an acceptable form of repair, API 653,
Second Edition, Addenda 1. Existing patch plates may be evaluated to this
Standard.
9.3.1.2

Lap patches may not be used on plate thicker than 1/2" or to

replace door sheets.

9.3.1.3

Lap patch plates are not to be thicker than 1/2 or thinner

than 3/16.

9.3.1.4

All lap patch plates may be circular, oblong, square,

rectangular or meet the nozzle reinforcing plate shapes of
API 650.

9.3.1.5

Lap patch plates may cross welds. See figure 9-1 for weld
spacing details.

9.3.1.6

Lap patch plates may extend to and intersect with the

external shell-to-bottom joint. Internal lap patches shall
have 6 toe-to-toe weld clearance between the patch and the
shell-to-bottom weld.

9.3.1.7

Maximum size of lap patch plates is 48 x 72, minimum 4.

9.3.1.8

Shell openings are not allowed within a lapped patch repair.

9.3.1.9

UT required in the areas to be welded, searching for plate

defects and remaining thickness.
API 650 Summary, 2005

Page 1-28

9.3.1.10

9.3.2

9.3.3

Lapped patch plates may be used to close holes.

9.3.2.1

The lap patch plate must be seal-welded, including the inner

perimeter of the hole. The minimum hole diameter is 2.

9.3.2.2

Nozzle necks and reinforcing plates shall be entirely

removed prior to installation of a repair plate.

9.3.2.3

The overlap of a repair plate shall not exceed 8 times the

shell thickness, minimum overlap is 1. The minimum
repair plate dimension shall be 4 inches.

9.3.2.4

The repair plate thickness shall not exceed the nominal

thickness of the shell plate adjacent to the repair.

Lapped patch plates may be used for thinning shells, below retirement
thickness.
9.3.3.1

9.3.4

9.6

Repair plates shall not be lapped onto lap-welded shell

seams, riveted shell seams, other lapped patch repair plates,
distorted areas, or unrepaired cracks or defects.

Full fillet weld required on lap patch plates.

Lapped patch repair plates may be used to repair small shell leaks or
minimize the potential from leaks.
9.3.4.4

This repair method shall not be used if exposure of the fillet

welds to the product will produce crevice corrosion or if a
corrosion cell between the shell plate and repair plate is
likely to occur.

9.3.4.5

This repair method shall not be used to repair shell leaks if

the presence of product between the shell plate and repair
plate will prevent gas freeing from the tank to perform hot
work.

Repair of Defective Welds

9.6.1

Cracks, lack of fusion and rejectable slag/porosity require repair.

Complete removal by gouging-grinding and the cavity properly prepared
for welding.

9.6.2

Generally, it is not necessary to remove existing weld reinforcement in

excess of that allowed in API-650.

API 650 Summary, 2005

Page 1-29

9.6.3

Unacceptable weld undercut can be repaired by additional weld

metal (or grinding), as appropriate.
NOTE:

Maximum allowable depth of undercut:

a.
b.

1/64" on vertical seams

1/32" on horizontal seams

9.6.4

Weld joints that have experienced loss of metal by corrosion may be

repaired by welding.

9.6.5

Arc strikes
Repair by grinding or welded. If welded, grind flush.

9.7

9.8

9.9

Repair of Shell Penetrations

9.7.2

Reinforcing plates may be added but they must meet API-650 for
dimensions and weld spacing.

9.7.3

Reinforcement plates can be installed to the inside wall, provided

that sufficient nozzle projection exists for proper weld tie-in.

Addition/Replacement of Shell Penetrations

9.8.1

The December 1998 Addenda requires both API 653 and API 650
requirements be met for shell penetrations.

9.8.2

Penetrations larger than 2" NPS shall be installed with the use of an insert
plate if the shell "t" is greater than 0.50" and the material does not meet
the current design metal temperature criteria. Additionally, the minimum
diameter of the insert plate shall be at least twice the diameter of the
penetration or diameter plus twelve inches (12"), whichever is greater.

Alteration of Existing Shell Penetrations

9.9.1

Altered details must comply with API-650.

9.9.2

New bottom installation (above old bottom) and using the "slotted"
method through the shell may not now meet spacing requirements.
Options for alternate compliance include the following three (3) items:
9.9.2.1

Existing reinforcement plate may be "trimmed" to increase

the spacing between the welds, provided the modification
still meets API-650.

9.9.2.2

Remove existing reinforcement and install a new pad.

"Tombstone" shapes are acceptable.

9.9.2.3

The existing penetration (nozzle and pad) may be removed

and the entire assembly relocated to the correct elevation.
API 650 Summary, 2005

Page 1-30

9.10

Repair of Tank Bottoms (Definition see paragraph 3.9)

9.10.1.1

See figure 9-5 for details for welded-on patch plates

9.10.1.2.1

No welding or weld overlays are permitted

within the critical zone, except for welding of:
a.
b.
c.
d.
e.
d.

Widely scattered pits.

Pinholes
Cracks in the bottom plates.
Shell-to-bottom weld.
Welded-on patch plates
Replacement of bottom or annular
plate.

9.10.1.2.4

If more extensive repairs are required within the

critical zone (than as listed in 9.10.1.2.), the bottom
plate (under the shell) shall be cut out and a new plate
installed.

9.10.1.2.5

This is a new paragraph that gives the requirements

for reinforcement plates.

REVIEW NOTE: Weld Spacing requirements must meet

API-650 (3.1.5.4 and 3.1.5.5) requirements. No 3 plate laps
closer than twelve inches (12") from each other, from the
tank shell, from butt weld annular joints and from joints of
the annular ring to normal bottom plates.
9.10.2 Replacement - Entire Bottom
9.10.2.1.1

Non-corrosive material cushion (i.e., sand, gravel or

concrete) 3"-4" thick shall be used between the old
and new bottoms.

9.10.2.1.2

The shell shall be "slotted" with a uniform cut made

parallel to the tank bottom.

9.10.2.1.3

Voids in the foundation (below the old bottom) shall

be filled with sand, crushed limestone, grout or
concrete.

9.10.2.1.4

Raise elevation of existing penetrations if the new

bottom elevation requires a cut through the
reinforcement.

9.10.2.1.5

On floating roof tanks, keep in mind that the floating

roof support legs may require revision to conform to
new bottom elevation.

API 650 Summary, 2005

Page 1-31

9.10.2.1.6

9.10.2.2

New bearing plates are required for floating roof leg

supports and for fixed roof support columns.
Column length revisions are also required on fixed
roof tanks.

Consider removal of old bottom, or of providing protection

from potential galvanic corrosion.
NOTE:

9.10.2.3

9.10.3.1

See API-RP 651. Also see API-653

(4.4.5.) regarding bottom leak detection.

New weld joints in the tank bottom or annular ring shall be

spaced at least the greater of 3 inches or 5t from existing
vertical weld joints in the bottom shell course.

Additional Welded-on Plates

New inspection requirements, plates must be MT or PT if the weld
spacing requirements can not be met.

9.11

Repair of Fixed Roofs

9.11.1.1 and 9.11.2.2
Same criteria as previously noted/discussed in API-650
relative to:
a.
b.
c.
d.

9.12

External and Internal Floating. Roofs

a.
b.

9.13

Plate "t"
Roof support structure
Loading
Roof-to-shell junction

Repair in accordance to original construction drawings.

If no original drawings available, use criteria from API-650,
Appendix C and H.

Repair/Replacement of Floating Roof Seals

9.13.1 Rim mounted seals can be removed, repaired or replaced. Items for
consideration are:
a.
b.
c.

Minimize evaporation/personnel exposure by limiting seal

segment removal to 1/4 of the seal at one time.
Use temporary spacers to keep roof centered.
In-service repair may be limited to seal component parts or
high positioned vapor seals.

9.13.2 Secondary seals can normally be "in-service" repaired or replaced.

API 650 Summary, 2005

Page 1-32

9.13.3 Seal-to-Shell Gap

Corrective action includes:
a.
b.
c.
d.
e.

Adjusting hanger system or primary shoe seal types.

Adding foam filler to toroidal seals.
Increasing length of rim mounted secondary seals.
Replacement (all or part) of the primary system.
Adding a rim extension to install secondary seal.

9.13.4 Mechanical Damage: Repair or replace.

NOTE:

Buckled parts require replacement, not straightening.

9.13.6 Minimum Allowable roof rim "t" = 0.10"

Minimum "t" of new rim plate = 0.1875"
9.14

Hot Taps
Installation on existing in-service tanks with shell material that does not require
post-weld heat treatment.
NOTE:

Connection size and shell "t" limitations are:

a.
b.
c.
d.

Six inches (6) and small-minimum shell t 0.1875

Eight inches (8") and smaller-minimum shell "t" 0.25"
Fourteen inches (14") and smaller-minimum shell "t" 0.375"
Eighteen inches (18") and smaller-minimum shell "t" 0.50"

9.14.1.2

Use low hydrogen electrodes.

9.14.1.3

Hot taps are not permitted on:

a.
b.

Tank roof
Within the gas/vapor space of a tank.

9.14.2 Hot Tap Procedure Requirements

a.
b.

Use customer/owner developed-documented procedure.

If no documentation is available, API Pub. 2201 applies.

9.14.3 Preparatory Work

9.14.3.1

Minimum spacing in any direction (toe-to-toe of welds)

between the hot tap and adjacent nozzles shall be equivalent
to the square root of RT (where "R" is tank shell radius, in
inches, and "T" is the shell plate "t", in inches.

API 650 Summary, 2005

Page 1-33

9.14.3.2

Shell plate "t" shall be taken in a minimum of four (4)

places along the circumference of the proposed nozzle
location.

9.14.5 Installation Procedure

9.14.5.1

Pre-cut pipe nozzle to shell contour and outside bevel for full
penetration weld. (See Fig. 9-6, page 9-12 for details).

9.14.5.2

After pipe nozzle is welded, install the reinforcement (1 piece

or 2 pieces). A two piece pad requires a horizontal weld).
NOTES:

9.14.5.3

Full penetration weld - pad to nozzle.

Limit weld heat input as practical.

Upon weld completion:

a.
b.
c.

9.14.5.4

1.
2.

Conduct NDE as required by procedure.

Pneumatically test per API-650 procedure.
After valve installation, pressure test (at least 1.5
times the hydrostatic head) the nozzle prior to
mounting the hot-tap machine.

Following the hot-tap machine manufacturer's procedure,

only qualified operators can make the shell cut.

API 650 Summary, 2005

Page 1-34

SECTION 10 - DISMANTLING AND RECONSTRUCTION

10.1

General
10.1.1 Provides for dismantling and reconstruction of existing welded tanks
relocated from their original site.
10.1.2 See Section 12 for hydrostatic and weld requirements.

10.3

Dismantling Methods
Cut into any size pieces that are readily transportable to new site.
10.3.2 Bottoms
10.3.2.1

Deseam lapwelds, or cut alongside existing seams (a

minimum of 2" from existing welds), except where cuts cross
existing weld seams.

10.3.2.2

If most of the bottom is to be reused, cut from shell along

line A-A (Fig. 10-1), or if entire bottom is salvaged intact, cut
shell along line B-B.

10.3.3 Shells
10.3.3.1

Cut shell by one, or a combination, of the following

methods:
a.

Cuts made to remove existing welds and HAZ, the

minimum HAZ to be removed will be one-half of the
weld metal width or 1/4 inch, which ever is less, on
both sides of the weld seam.

b.

Any shell ring 1/2 inch thick or thinner may be

dismantled by cutting through the weld without
removing the HAZ.

c.

Cuts made a minimum of 6" away from existing weld

seams, except where cuts cross existing welds.

10.3.3.2

Shell stiffeners, wind girders and top angles may be left

attached to shell or cut at attachment welds. If temporary
attachments are removed, grind area smooth.

10.3.3.3

Cut shell from bottom plate along line B-B (see Fig. 10-1).
The existing shell-to-bottom weld connection shall not be
reused unless the entire bottom is to be salvaged intact.

API 650 Summary, 2005

Page 1-35

10.3.4 Roofs
10.3.4.1

Cut roof by lapweld deseaming or alongside (a minimum of

2" from) the remaining welds.

10.3.4.2

Roof structure
Remove bolts or deseaming at structural welds.

10.3.5 Piece Marking

10.3.5.1

Shell bottom and roof plates

Mark prior to dismantling for ready identification and
reconstruction placement.

10.3.5.2

10.4

Punch mark (minimum 2 sets) at matching centers located

on top and bottom edges of each shell segment for future
proper alignment.

Reconstruction
10.4.2.1

Welding notes as follows:

a.
b.
c.

10.4.2.2

Vertical weld joints should not aligned with joints

located in bottom plates.
No welding over heat affected zones (from original
tank welds), except where new joints cross original
joints.
Refer to Fig. 9-1 for weld spacing.

Tank and Structural Attachment Welding

Use processes specified in API-650.

10.4.2.3

Specific welding notes:

a.

No welding is allowed when parts to be welded are

wet from rain, snow or ice or when rain or snow is
falling, or during high wind conditions (unless the
work is shielded). Caution this is a common practice
and should be avoided.

b.

No welding is permitted when the base metal is

below 0F.

c.

If the base metal temperature is between 0 and 32F

or the metal "t" is in excess of 1", the base metal
within 3" of welding shall be pre-heated to
approximately 140F.

API 650 Summary, 2005

Page 1-36

10.4.2.4

As normal, each layer of weld deposit is to be cleaned of slag

or other deposits.

10.4.2.5

As in API-650, the maximum acceptable undercutting is

1/64" for vertical butt joints and 1/32" for horizontal butt
joints.

10.4.2.7

Same tack weld provisions as API-650, i.e.:

a.
b.

Vertical , manual tacks - Remove.

Vertical, submerged tacks - If sound, clean only.

NOTE:
10.4.2.8

If weldable primer coatings exist, they must be included in

procedure qualification tests.
NOTE:
welding.

10.4.2.9

Tack welds left in place must have been applied

by a qualified welder.

All other coating must be removed prior to

Low-hydrogen electrodes required on manual metal-arc

welds, including the shell to bottom attachment or annular
plate ring.

10.4.3 Bottoms
10.4.3.2

Weld shell to bottom first (except for door sheets) before

weldout of bottom plates is started.

10.4.4 Shells
10.4.4.1

Same fit-up/welding procedures and values as allowed in

API-650 for vertical joints:
a.
b.

Over 5/8" thick - misalignment shall not exceed 10%

of "t" (maximum 0.125").
Under 0.625" thick - misalignment shall not exceed
0.06".
NOTE:

10.4.4.2

Complete vertical welding before

roundseam below is welded.

Horizontal joints
Upper plate shall not project over lower by more than 20%
of upper plate "t"(with 0.125" maximum).

10.4.4.3

Material over 1.50" thick a minimum pre-heat of 200F is

required.

API 650 Summary, 2005

Page 1-37

10.4.5 Roofs
There are no special stipulations, except that structural members must be
reasonably true to line and surface.
10.5

Dimensional Tolerances
10.5.2.1

Allowable maximum out-of-plumbness (top of shell relative

to shell bottom) shall not exceed 1/100 of total tank height,
with a maximum of 5" this dimension also applies to roof
columns.

10.5.3 Roundness
See values and measurement locations on Table 10-2.
10.5.4 Peaking
Shall not exceed 0.50".
10.5.5 Banding
Shall not exceed 1.00".
NOTE: Somewhat more lax than API-650.
10.5.6 Foundations
Same specifications as listed under API-650.

API 650 Summary, 2005

Page 1-38

SECTION 11 - WELDING
11.1

Welding Qualifications
11.1.1

Weld procedure specifications (WPS), welders and operators shall

be qualified in accordance with Section IX of the ASME Code.

11.1.2

Weldability of steel from existing tanks must be verified. If the

material specification is unknown or obsolete, test coupons for the
procedure qualification shall be taken from the actual plate to be
used.
SECTION 12 - EXAMINATION AND TESTING
12.1.1.1

NDE shall be performed in accordance with API 650, plus

API 653 supplemental requirements.

12.1.1.2

Personnel performing NDE shall be qualified in accordance

with API 650.

12.1.1.3

Acceptance criteria shall be in accordance with API 650.

NOTE: Appendix "F" is not mentioned.

12.1.1.5

Appendix G is mentioned fro qualifying personnel and

procedures when using MFL.

12.1.2 Shell Penetrations

12.1.2.1

UT lamination check required for:

a.
b.

Adding reinforcement plate to an unreinforced

penetration.
Installing a hot-tap connection.

12.1.2.2

Cavities from gouging or grinding to remove reinforcement

pad welds require either a magnetic particle or liquid
penetrant test.

12.1.2.3

Completed welds attaching nozzle to shell or pad to shell

and nozzle neck shall be examined by a magnetic particle or
liquid penetrate test. Consideration should be given for
extra NDE on hot taps.

12.1.2.4

Complete welds in stress relieved components require

magnetic particle or liquid penetrate testing (after stress
relief, but before hydrostatic test).

API 650 Summary, 2005

Page 1-39

12.1.3 Repaired Weld Flaws

12.1.3.1

Cavities from gouging or grinding to remove weld defects

shall be either a magnetic particle or liquid penetrate tested.

12.1.3.2

Completed repair of butt welds shall be examined over their

full length by UT or radiographic methods.

12.1.4 Temporary and Permanent Attachments to Shell Plates

12.1.4.1

A ground area resulting from the removal of attachments

requires a visual test.

12.1.4.2

Completed welds on permanent attachments shall be

examined by MT or PT, groups IV-VI, excluding the shell to
bottom weld.

12.1.5 Shell-to-Shell Plate Welds

New welds attaching shell plate to shell plate require visual and
radiographic examination. Additionally, plate greater than 1", the backgouged surface of root pass and final pass (each side) shall be examined
over its full length by a magnetic particle or liquid penetrate test.
12.1.5.2

New welds on new shell plate to new shell plate are to be

examined and radiographed to API 650.

12.1.6 Shell-to Bottom

12.2

12.1.6.1

Joints shall be inspected over its entire length by a right

angle vacuum box and a solution film, or by applying light
diesel oil. (Diesel test technique).

12.1.6.2

An air pressure test may be used to check the shell-tobottom weld.

12.1.8.2

(New Paragraph) deals with lap welded shell patches.

Radiographs
Number and location - Same as API-650, plus the following additional
requirements:
12.2.1.1

Vertical Joints
a.
b.
c.

New plate to new plate: Same as API 650.

New plate to existing plate: Same as API 650,
plus one (1) additional radiograph.
Existing plate to existing plate: Same as API 650,
plus one (1) additional radiograph.

API 650 Summary, 2005

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12.2.1.2

Horizontal Joints
a.
b.
c.

12.2.1.3

New plate to new plate: Same as API 650.

New plate to existing plate: Same as API 650, plus
one (1) additional radiograph for each 50 feet of
horizontal weld.
Existing plate to existing plate: Same as API 650,
plus one (1) additional radiograph for each 50
of horizontal weld..

Intersections
a.
b.
c.

New plate to new plate: Same as API 650.

New plate to existing plate: Shall be radiographed.
Existing plate to existing plate: Shall be radiographed.

12.2.1.4

Each butt-weld annular plate joint - Per API-650.

12.2.1.5

For reconstructed tanks 25 percent of all junctions shall be

radiographed.

12.2.1.6

New and replaced shell plate or door sheet welds:

12.2.1.6.1

Circular - Minimum one (1) radiograph

12.2.1.6.2

Square or Rectangular:

One (1) in vertical, one (1) in horizontal, one (1) in

each corner.
NOTE:

12.2.1.8

All junctions between repair and existing weld

shall be radiographed. If defects are found,
100% is required on weld repair area.

For penetrations installed using insert plates as described in

9.8.2, the completed butt welds between the insert plate and
the shell plate shall be fully radiographed.

12.2.2 Criteria Acceptance

If a radiograph of an intersection between new and old weld detects
unacceptable flaws (by current standards) the weld may be evaluated
according to the original construction standard.

API 650 Summary, 2005

Page 1-41

12.3

Hydrostatic Testing
12.3.1.1

A full hydrostatic test, held for 24 hours, is required on:

a.
b.

c.
12.3.1.2

A reconstructed tank.
Any tank that has had major repairs or alterations
(See 12.3.1.2.) unless exempted by 12.3.2 for the
applicable combination of materials, design and
construction features.
A tank where an engineering evaluation indicates the
need for the hydrostatic test.

Major Repair/Alteration
Operations that require cutting, addition, removal and/or
replacement of annular plate ring, shell to bottom weld or a
sizable shell segment. Major would therefore include:
a.

The installation of any shell penetration (beneath the

design liquid level) larger than 12" or any bottom
penetration within 12" of the shell.

b.

Any shell plate (beneath design liquid level) or any

annular plate where the longest dimension of plate
exceeds 12".

c.

The complete or partial ( more than "1/2 t" of the

weld thickness) or more than 12" of vertical seams, or
radial annular plate welds.

d.

New bottom installation if the foundation under the

new bottom is not disturbed.
1.
2.

e.

The Annular ring remains intact

The welding repair does not result in welding
on the existing bottom within the critical zone.

Partial of complete jacking of a tank shell.

12.3.2 Hydrostatic not Required Conditions

12.3.2.1

A full hydrostatic test of the tank is not required for major

repairs and major alterations when:
a.
b.

The repair has been reviewed and approved by an

engineer, in writing.
The tank owner or operator has authorized the
exemption in writing.

API 650 Summary, 2005

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12.3.2.2

Shell Repair

12.3.2.2.1

Weld procedures for shell repair must include impact

testing.

12.3.2.2.3

New requirements, new shell materials must API 650

7th edition or later, must meet requirements for
brittle fracture, stress must not be more than 7,000 psi
as calculated from the new formula given in this
paragraph.
S = 2.6 H D G
t
S=
H=

shell stress in pounds per square foot

tank fill height above the bottom of
repairs or alteration in feet
shell thickness at area of interest in
inches
tank mean diameter in feet
specific gravity of product

t=
D=
G=
12.3.2.2.5

New radiography requirements, the finished weld in

the shell plates shall be fully radiographed.

12.3.2.2.8

A big change in this section, door sheets shall comply

with the requirements for shell plate installation,
except they shall not extend to or intersect the
bottom-to-shell joint.

12.3.2.3

Bottom Repair Within the Critical Zone

12.3.2.3.1
12.5

Now allows UT to be used on annular plate butt

welds

Measured Settlement (During Hydro)

12.5.1.1

When settlement is anticipated, the tank being hydrotested must have a settlement survey.

API 650 Summary, 2005

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12.5.1.2

Initial Settlement Survey:

With tank empty, using the number of bottom plate
projections as elevation measuring points (N), uniformly
distributed around the circumference.
FORMULA: N=D/10
Where:
a.

N=

b.

D=

NOTE:

minimum number of measurement points (not

less than 8). The Maximum spacing between
measurement points shall be 32 feet.
tank diameter (in feet).
See Appendix B for evaluation and
acceptance.

12.5.2 Survey During Hydro

Measure at increments during filing and at 100% test level.
NOTE:

Excessive settlement (per Appendix B) shall be cause to

stop test, investigate and/or repair.

API 650 Summary, 2005

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SECTION 13 - MARKING AND RECORD KEEPING

13.1.1 API-653 reconstructed tanks require nameplate with letters and
numerals must be a minimum of 5/32" high. The following information
is required
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.

Reconstructed to API-653.
Edition/revision number.
Year reconstruction completed.
If known, the original applicable standard and original date.
Nominal diameter
Nominal height.
Design specific gravity of product stored.
Maximum permissible operating liquid level.
Contractor's serial and/or contract number.
Owner/operator identification number.
Material for each shell course.
Maximum operating temperature.
Allowable stress used in calculations for each course.

13.1.2 New nameplate

Shall be attached to the tank shell adjacent to existing nameplate.
13.2

Record keeping
Tanks evaluated, repaired, altered or reconstructed to API-653 require the
following owner/operator records:
a.
b.
c.

Component integrity evaluation, including brittle fracture

considerations.
Re-rating data (including liquid level).
Repair and alteration considerations.

API 650 Summary, 2005

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13.2.1.3

Additional support data including, but not limited to,

information pertaining to:
a.
b.
c.
d.
e.
f.
g.
h.
i.

13.3

Certification

j.
k.
l.
m.

Inspections (including "t" measurements).

Material test reports/certifications.
Tests.
Radiographs (to be retained for at least one year).
Brittle fracture considerations.
Original construction data.
Location and identification (owner/operator number,
serial number).
Description of tank (diameter, height and service).
Design conditions (i.e., liquid level, specific gravity,
stress and loading).
Shell material and thickness (by course).
Tank perimeter elevations.
Construction completion record.
Basis for hydrostatic test exemption

Documentation of reconstruction in accordance with API-653 is required. (See

Fig. 13-2).
APPENDIX B
EVALUATION OF TANK BOTTOM SETTLEMENT
B.1.1 Common methods to monitor potential problem:
a.
b.
c.

Initial settlement survey, at erection and hydro.

Planned frequency, per soil settlement predictions
For existing tanks (with no settlement history), monitoring
should be based on visual observations and prior service history.

B.1.2 Excessive settlement requires evaluation/interpretation of survey

data. Tank should be emptied and releveling repair conducted.

B.1.3 Correcting shell and bottom settlement problems include the

following techniques:
a.
b.
c.

B.2

Localized bottom plate repair.

Partial releveling of tank periphery.
Major releveling of shell and bottom.

Types of Settlement
API 650 Summary, 2005

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B.2.1 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.
B.2.2 Shell Settlement Evaluation
Tank settlement results from either one or a combination of the following
three (3) settlement components:
B.2.2.1

Uniform settlement. May vary in magnitude, depending on

soil characteristics. It is the least severe or threatening
settlement problem. It does not introduce stress in tank
structure, but does present a potential problem for piping,
nozzles and attachments.

B.2.2.2

Planar Tilt (rigid body tilting). 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.
This may be visible in the form of elongation of top shell
ring in floating roof tanks. Can affect tank nozzles that have
piping attached to them.

B.2.2.3

Differential Settlement (out of plane). Due to a tank shell

being a rather flexible structure, non-planer configuration
type settlement often occurs.
Potential Problems:
a.
b.
c.
d.
e.

B.2.2.4

Increased stress levels.

Elongation of upper shell.
Floating roof travel interference and potential seal
damage or roof "hang-up".
Development of shell flat spots.
High nozzle/piping stress levels.

Uniform and rigid body tilt can cause problems as noted,

overall integrity of the shell and bottom are more likely to
be impacted by differential settlement. Therefore, this type
problem becomes very important to determine severity and
evaluate properly.
Common approach for settlement survey:
a.
b.
c.

Obtain transit survey from the correct number of evenly

spaced points.
Determine magnitude of uniform and rigid body tilt from
each point on tank periphery.
Develop a graphic line point representation of the
involved data.
API 650 Summary, 2005

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NOTE:

B.2.2.5

Develop values (showing elevation differences)

by comparing transit measurement readings by
use of provided decimal chart. A stress analysis
method is now included in this paragraph.

Refer to B.3.2 for method of determining acceptable

settlement condition or values.

B.2.3 Edge settlement

B.2.3.1

Occurs when tank shell settles sharply around the periphery,

resulting in deformation of the bottom plate near the shell
junction. (See Fig. B-4 for pictorial view).

B.2.5 Localized Bottom Settlement (Remote from Shell)

B.2.5.1

Depressions/bulged that occur in a random matter, remote

from shell.

B.2.5.2

Acceptability dependent upon:

a.
b.
c.

Localized bottom plate stresses.

Design/quality of lap welds.
Void severity below the bottom plate.

NOTES:

B.3

1.
2.

Not normally seen as extreme problem.

When occurring, normally associated
with new tank where no or insufficient
load bearing soil test borings have been
made.

Determination of Acceptable Settlement

B.3.1 General
Greater settlement may be acceptable in tanks with a successful service
history than new construction standards allow. Each condition must be
evaluated, based on service conditions, construction materials, soil
characteristics, foundation design and prior service history.

B.3.2 Shell Settlement

Determine the maximum out-of-plane deflection. The formula for
calculating the maximum permissible deflection is shown on page B-4.
Requires technical assistance.

API 650 Summary, 2005

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B.4

Repairs
If conditions beyond acceptable conditions are found, a rigorous stress analysis
should be performed to evaluate the deformed profile, or repairs conducted.
Various repair techniques are acceptable. (See Section 9.10 for helpful details).
Several new figures have been added to Appendix B, however the bases for the
new figures and requirements have been challenged. There is no bases for the
information in the figures.. The user is left to his own devices as how to use this
information.
APPENDIX C
CHECKLISTS FOR TANK INSPECTION

Tables C-1 and C-2 are sample checklists illustrating tank components and auxiliary
items that deserve consideration during internal/external inspections. Use these as
guidance items only. Numerous items need not be checked by the inspector, but rather
by plant personnel.
Table C-1 (In Service Inspection checklist) includes 111 separate items.
Table C-2 (Out-of-Service Inspection Checklist) includes 248 separate items.
APPENDIX D
AUTHORIZED INSPECTOR CERTIFICATION
This Appendix was rewritten in the 4th Addenda to API 653.
D.1

Written exam. based on the current API 653 Body of Knowledge.

D.2

Educational requirements for the API 653 Authorized Inspector.

D.5

Recertification requirements for the API 653 Authorized Inspector.

D.5.3 The requirements for re-examination are listed, after two re-certifications,
6 years, each inspector shall demonstrate knowledge of revisions to API
653.
APPENDIX E
TECHNICAL INQUIRIES

This section is a listing of how to contact the API 653 committee. The Technical Inquiry
Responses have also been listed, but are not a part of the exam. This information is
useful in actual application of API 653.

API 650 Summary, 2005

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APPENDIX F
NDE REQUIREMENTS SUMMARY
This section is a summary of the requirements for NDE personnel and procedures, API
650, ASME Section V and VIII, and ASNT are listed. This is a very good section that will
be useful to the user.
APPENDIX G
QUALIFICATION OF TANK BOTTOM EXAMINATION PROCEDURES
AND PERSONNEL
This appendix was established in the first addenda to edition three of API 653 and
outlines procedure and qualifications for floor scanning,
G.2 Definitions
G.2.1 essential variables: Variables in
the procedure that cannot be changed
without the procedure and scanning
operators being re-qualified.
G.2.2 examiners: Scanning operators
and NDE technicians who prove-up
bottom indications.
G.2.3 bottom scan: The use of
equipment over large portions of the
tank bottom to detect corrosion in a
tank bottom. One common type of
bottom scanning equipment is the
Magnetic Flux Leakage (MFL) scanner.
G 2.4 authorized inspection agency:
Organizations that employ an
aboveground storage tank inspector
certified by API (see 3.4).
G.2.5 non-essential variables:
Variables in the procedure that can be
changed without having to re-qualify
the procedure and/or scanning
operators.
G.2.6 qualification test: The
demonstration test that is used to prove
that a procedure or examiner can
successfully find and prove-up tank
bottom metal loss.

G.2.7 scanning operator (or operator):

The individual that operates bottomscanning equipment.
G.2.8 sizing (or prove-up): The activity
that is used to accurately determine the
remaining bottom thickness in areas
where indications are found by the
bottom scanning equipment. This is
often accomplished using the UT
method.
G.2.9 tank bottom examination: The
examination of a tank bottom using
special equipment to determine the
remaining thickness of the tank bottom.
It includes both the detection and proveup of the indications. It does not include
the visual examination that is included in
the internal inspection.
G.2.10 tank bottom examination
procedure (TBP): A qualified written
procedure that addresses the essential
and non-essential variables for the tank
bottom examination. The procedure
can include multiple methods and tools,
i.e., bottom scanner, hand scanner, and
UT prove-up.

API 650 Summary, 2005

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G.2.11 tank bottom examiner

qualification record (TBEQ): A record
of the qualification test for a specific
scanning operator. This record must
contain the data for all essential
variables and the results of the
qualification test.
G.2.12 tank bottom procedure
qualification record (TBPQ): A record
of the qualification test for a tank
bottom examination procedure. This

record must contain the data for all

essential variables and the results of the
qualification test.
G.2.13 variables or procedure
variables: The specific data in a
procedure that provides direction and
limitations to the scanning operator.
Examples include; plate thickness,
overlap of adjacent bottom scans,
scanning speed, equipment settings. ect.

G.3

An explanation of Tank Bottom Examination procedures

G.4

Requirements for Tank Bottom Examiners

G.5

Qualification Testing, including test plates, standards and variables.

API 650 Summary, 2005

Page 1-51

API 653 CODE QUIZ

1.

In case of conflict between API-12C, API-650 and API-653 standards

involving "in-service" AST's, which of the three codes will govern?
a.
b.
c.

2.

Which of the following have the ultimate responsibility for complying

with API-653 standard provisions?
a.
b.
c.
d.

3.

On-site Inspector
Contractor Involved
Owner/operator of equipment
Relevant State or Federal Agency

Internal pressures inside tanks may vary. Which of the following

pressures represent the maximum amount and is still considered to be
atmospheric storage?
a.
b.
c.
d.

4.

API-12C
API-650
API-653

3 oz. psig
1.0 lb. psig
1.5 lb. psig
2.5 lb. psig

What is the joint efficiency of a lap riveted joint with one (1) row of
rivets?
a.
b.
c.
d.

45%
60%
75%
80%
API 650 Summary, 2005

Page 1-52

5.

All prior reported brittle fracture tank failures have occurred under which
of the following conditions/situations?
a.
b.
c.
d.

6.

When external UT "t" measurements are used to determine a rate of

general, uniform corrosion (relevant to shell integrity) which of the following
values cannot be exceeded?
a.
b.
c.
d.

7.

10 years maximum
20 years maximum
5 years (after commissioning), or at 5 year intervals (where
corrosion rate is not known).
Five years or RCA/4N, whichever is more.

What primary factor determines the interval between internal and

external inspections?
a.
b.
c.
d.

8.

Atmospheric temperature of 20F or lower.

During a hydro test where the test water was 50F or colder.
Shortly after erection, following a repair/alteration, first cold
weather filling or change to lower temperature service.
Where a testing medium other than water was used.

Jurisdictional regulations
Tank service history, unless special reasons indicate an earlier
inspection is required.
Known (or suspected) corrosion activity of product.
Change of service to a product with a specific gravity 10% higher
than prior stored product.

What is the minimum dimension for a shell ring replacement piece or

segment?
a.
b.
c.
d.

The actual area requiring renewal, plus 6" on all four surrounding
sides.
12" or 12 times the "t" of the replacement plate, whichever is
greater.
10% of the individual ring segment involved.
20% of the individual ring segment involved.

API 650 Summary, 2005

Page 1-53

9.

Which of the areas described below are considered to be the

"critical zone" involving tank bottom repair?
a.
b.
c.
d.

10.

Select the minimum number of "t" measurements required (along the

circumference of any proposed "hot-tap" nozzle location):
a.
b.
c.
d.

11.

One (1) on horizontal centerline (3" from edge) on each side of

proposed shell opening cut.
Four (4)
Eight (8)
Establishment of both a minimum and average "t" over the entire
nozzle installation area.

What type of contour cut (if any) and what degree of bevel (if any) is
required on the nozzle "barrel" end that is to be joined to shell during a "hot-tap".
a.
b.
c.
d.

12.

Within the annular ring, within 12" of shell, or within 12" of inside
edge of annular plate ring.
Any area where 3plate laps are located
Within 36" (measured vertically) from any shell penetration above.
Within 3" from the shell on the bottom plates

No contour cut required, 30 outside bevel.

No contour cut required, 45 outside bevel.
Cut to shell contour and outside beveled for full penetration
attachment weld.
No contour cut required. 1/8" corner radius (minimum).

When reconstructing tank shells with a material "t" exceeding 1.50", what
minimum pre-heat is specified?
a.
b.
c.
d.

No preheat required, if air temperature exceeds 70F.

200F.
225F.
300F.

API 650 Summary, 2005

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13.

In re-erecting a tank shell, what length "sweep-board" and what are

maximum allowable values for weld seam peaking?
a.
b.
c.
d.

14.

Welding procedure Specs (WPS) are established in Section 11 of API-653.

Welders/operators must be qualified in accordance with which of the codes
listed.
a.
b.
c.
d.

15.

0.50" (1/2") with 36" horizontal sweep board?

0.25" (1/4") on verticals; 0.50" (1/2") on horizontal with 36" board
0.75" (3/4") with 48" board.
1.00" (1") with 48" board.

AWS
Section V ASME
Section VIII ASME
Section IX ASME

API-653 (Section 12) requires greater radiographic examination of tank

shell welds than does API-650. Relevant to new or repaired vertical joints in
existing shell plates, how many radiographs are required?
a.
b.
c.
d.

Twice those required by API-650.

API 650 requirements plus one (1) in every joint.
One (1) for each welder or operator involved on each ring.
Two (2) for each welder or operator involved on each ring for all
plate thicknesses.

The following information applies for questions 16 through 20 below:

An internal inspection is performed on an aboveground storage tank 44 feet tall, 40 foot
fill height, 112 feet diameter, light oil (specific gravity = 1) service, sand pad with a
reinforced concrete ring wall foundation. There is one area of general corrosion on the
north side of the shell 38 inches wide and 20 inches tall. (The tank was built to API 650,
7th Edition).
16.

Calculate the minimum thickness for the first course based on

product alone.
a.
b.
c.
d.

7/8"
3/4"
5/8"
1/2"
API 650 Summary, 2005

Page 1-55

17.

Calculate the "L" length for an area of general corrosion found ten feet
from the bottom on the north side of the shell, t2 = .125 inches.
a.
b.
c.
d.

18.

There are four pits lined vertically on the south side of the tank in the first
course. The pits measure 1", 1.250", 1." and .500" in length along a vertical line 8"
long. The pit depth is approximately 0.255" each.
a.
b.
c.
d.

19.

A repair is required.
Because of the vertical pits, no repair is required.
If the pit depth is only .130 inches the pits may be ignored.
Scattered pits may be ignored.

A bulge is found on the tank floor, the diameter of the bulge is 30 inches,
what is the maximum permissible height for the bulge?
a.
b.
c.
d.

20.

3.7"
10"
13.84"
40"

11.1"
.463"
.962
1.11"

An area of edge settlement in the tank bottom 6 feet from the tank shell
has sloped down and settled. The settlement measures 2 inches at the deepest
point. The edge settlement area has bottom lap welds approximately parallel to
the shell.
a.
b.
c.
d.

A more rigorous stress analysis must be performed.

The area must be repaired.
Sloped edge settlement is usually no problem
The area should be documented and checked during the next
inspection.

API 650 Summary, 2005

Page 1-56

API 653 CODE QUIZ

ANSWER KEY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

c
c
d
a
c
c
b
b
d
b
c
b
a
d
b
d

{Paragraph 1.1.2 page 1-1}

{Paragraph 1.2 page 1-1}
{Paragraph 3.3 page 3-1}
{Table 4-3 page 4-7}
{Paragraph 5.2.1 page 5-1}
{Paragraph 6.3.3.2 (b) page 6-1 and 6-2}
{Paragraph 6.2.2 page 6-1}
{Paragraph 9.2.2.1 page 9-1}
{Paragraph 3.9 page 3-1}
{Paragraph 9.14.3.2 page 9-11}
{Paragraph 9.14.5.1 page 9-11}
{Paragraph 10.4.4.3 page 10-3}
{Paragraph 10.5.4 page 10-3}
{Paragraph 11.1.1 page 11-1}
{Paragraph 12.2.1.1 page 12-2}
(1/2") {Paragraph 4.3.3 page 4-3}
tmin = 2.6 (H-1) DG
SE
tmin = ?
D = 112
H = 40
G=1
S = 23,600
E=1
tmin = 2.6 (40-1) (112) (1)
23,600
tmin = 11,356.8
23,600
tmin = .481 inches (rounded to 1/2 inch)

API 650 Summary, 2005

Page 1-57

17.

L = 3.7

Dt2

L = 3.7
(112)(.125) L = 3.7

18.
a
(A repair is required.) Paragraph4.3.2.2 Page 4-3)
Add the pit diameters 1+ 1.25 + 1 + .500 = 3.75 (More than allowed in an 8 area)
The pit depth exceeds one-half the minimum acceptable tank shell thickness.
19.
b
(.463") (Paragraph B.3.3 Page B7)
R = Diameter divided by 2, in feet, 30 divided by 2 - 15 divided by 12 = 1.25 feet.
B = .37R
B = .37 (1.25)
B = .463 inches
20.

(The area should be documented and checked during the next

inspection.) Figure B-10
Using figure B-10 the area is acceptable, it should be documented.

API 650 Summary, 2005

Page 1-58

Section 2
API 650
Welded Steel Tanks for Oil Storage

API STANDARD 650

WELDED STEEL TANKS FOR OIL STORAGE
Tenth Edition, November, 1998
Addendum 1, January, 2000
Addendum 2, November, 2001
Addendum 3, September 2003
SECTION 1 - SCOPE
1.1

General
1.1.1

This standard covers material, design, fabrication, erection and testing

requirements for vertical, cylindrical, aboveground, closed and open-top,
welded steel storage tanks in various sizes and capacities for internal
pressures approximating atmospheric pressure.

NOTE 1:

This standard covers only tanks whose entire bottom is uniformly

supported and only tanks in non-refrigerated service that have a
maximum operating temperature of 200 F.

NOTE 2:

A bullet () at the beginning of a paragraph indicates that there is

an expressed decision or action required of the purchaser.

APPENDIXES:

1.1.3

Listed below apply to specifics that most often apply to new

tank erections whereby Inspector knowledge must be
reasonably thorough.

The purchaser will specify SI dimensions or US customary dimensions.

1.1.6 Appendix B: Design and construction of foundations under flat bottom

oil storage tanks.
1.1.7 Appendix C: Requirements for pan-type, pontoon-type and double decktype external floating roofs.
1.1.12 Appendix H: Requirements for an internal roof in a tank that has a fixed
roof at the top of the tank shell.
1.1.14 Appendix J: Requirements covering the complete shop assembly of tanks
not more than 20 feet in diameter.
1.1.15 Appendix K: An example of the application of the variable-design-point
method to determine shell-plate thickness.
NOTE:

In larger tanks (over 200 feet in diameter), use of higher

tensile strength steel, plus increased NDE procedures
reduces plate "t".
1.1.17 Appendix M: Requirements for elevated temperature product storage up
API 650 Summary, 2005

Page 2-1

to 500 F.
NOTE:

Appendixes A, D, E, F, L, N, O and P cover requirements on

specifics that apply much less frequently from an inspection
perspective.

1.1.21 Appendix S: Requirements for the construction of austenitic stainless steel

tanks.
1.1.22 Appendix T: Requirements for inspection (summary).
1.1.23 Appendix U: Requirements for UT examination, in lieu of radiography.
1.2

Limitations
a.
b.
c.
d.

API 650 stops at the face of the first flange.

API 650 stops at the first sealing surface.
API 650 stops at the first threaded connection.
API 650 stops at the first circumferential weld.
SECTION 2: MATERIALS

2.1

General Material Requirements

2.2.1.1

Refer to 2.2.2 ASTM Standards for acceptable tank steel plate

requirements.

2.2.1.2

Plate for shells, roofs and bottoms may be on an edgethickness basis or on a weight (pounds per square foot)
basis. Example: 3/16" plate (0.1875" or 7.65 lbs.) or 1/4" plate
(0.250" or 10.4 lbs.), etc.
2.2.1.2.3

Whether an edge-thickness or a weight basis is used,

an underrun of not more than 0.01" from the
computed design thickness or the minimum
permitted thickness is acceptable.

NOTE:

Most common plates used:

1.
2.
3.

ASTM A-283 Gr. C

ASTM A-36
Alternate Design Basis (ADB) tanks (See
Appendix K) require higher tensile
strength material.

2.2.2

New ASTM specification used.

2.2.8

Special plate requirement or testing:

API 650 Summary, 2005

Page 2-2

a.
Customer may require a set of charpy v-notch impact specimens.
b.
Special toughness requirements may be specified.
2.2.9.3
Normal design metal temperature shall be assumed to be
15F above the lowest 1-day mean ambient temperature in
the locality where the tank is to be installed. (See Fig. 2-2).
2.2.9.4

Plate used to reinforce shell openings shall be of the same

material as the shell plate to which it is attached.
NOTE:

2.2.10.4
2.8

Also must be at least as thick as primary plate! Shell

nozzles and manway materials shall be equal or
greater yield and tensile strength and shall be
compatible with the shell material.

The manufacturer must furnish mill test data, including the

required toughness at design metal temperature.

Welding Electrodes
For welding materials with a minimum tensile strength less than 80 kips per
square inch, manual arc-welding electrodes shall conform to the E60 and E70
series, AWS 5.1.
SECTION 3: DESIGN

3.1

Joints (Tank Design)

3.1.1-3.1.1.8 No detailed discussion. Be knowledgeable about the eight (8) types
listed.

3.1.4

3.1.3.2

Tack welds are not considered as having any strength value

in the finished structure.

3.1.3.3

On plates 3/16" thick, a full fillet weld is required. On plates

thicker than 3/16", the weld shall not be less than one-third
the "t" of the thinner plate at the joint, with minimum of
3/16".

3.1.3.4

Single lap welds - bottom and roof plates only.

3.1.3.5

Lap-weld joints shall be lapped not less than "5t" of the

thinner plate, but need not exceed 1".

AWS weld symbols are required on drawings.

3.1.5.2

Vertical Shell Joints

API 650 Summary, 2005

Page 2-3

3.1.5.3

a.

Verticals shall be butt joints with complete

penetration and fusion that will provide the same
quality of deposited metal on both outside and inside
weld surfaces.

b.

Vertical joints (in adjacent shell courses) shall not be in

alignment. An off-set from each other of "5t"(where
"t" is the thickest course at the point of offset).

Horizontal shell joints

Same criteria as for verticals above, except that top angles
may be double-lap welded.

3.1.5.4

Lap-welded Bottom Joints

a.

3-plate laps shall not be closer than 12" from each

other, from the tank shell, from butt-welded annular
plate joints and from joints between annular plate and
bottom.

b.

Welded on top side only (full fillet only).

c.

On other than annular (doughnut) rings the plate

under the shell must have the outer end of the joint
fitted and welded to form a smooth bearing for the
shell plate. Note: Called a "BREAK-OVER."
(Fig 3.3.b)

NOTE:

3.1.5.5

Butt-weld bottom joints (i.e., normally annular ring)

a.
b.
c.
d.

3.1.5.6

Parallel edges - either square or v-grove beveled.

If square, root opening not less than 1/4".
Minimum 1/8" thick back-up strip required.
A 12" minimum space from each other or tank shell
also applies.

Annular ring joints - complete penetration and fusion

NOTE:

3.1.5.7

A 2" minimum projection beyond outside edge

of shell (i.e., bottom extension). See Par. 3.5.2).

Shell-to-Bottom Fillet Welds

a.
b.

3.1.5.9

When annular plates are used or required, butt

welding is required with a minimum distance of
24" between shell and any bottom lap seam.

If shell is 1/2" thick or less - Fillets not more than 1/2"

or less than the nominal "t" of the thinner plate joined.
Two (2) weld passes (minimum) are required.

Roof and Top-Angle Joints

API 650 Summary, 2005

Page 2-4

a.
b.

Welded top side only with continuous full-fillet. Butt

welds are also permitted.
Top angle (horizontal leg) may extend either inside or
outside.

API 650 Summary, 2005

Page 2-5

3.2.5 Tank Capacity

Three new paragraphs that describe the requirements for stating the
capacity for a new tank.
3.4

Bottom Plates
a.
b.

3.5

Annular Bottom Plates

a.
b.

3.6

A minimum nominal "t" of 1/4" (10.2 lbs. per sq. ft.), exclusive of any
corrosion allowance (CA).
A 1" minimum width to project beyond outside edge of shell, on lap weld
bottoms (i.e., bottom extension).

Annular bottom plates must be 24 inches wide.

A 2 inch projection beyond the outside of the shell.

Shell Design
Shell designed on basis that tank is filled to a level "H" (fill level) with a specific
gravity (SG) product value furnished by customer.
NOTE:

Normally designed to be filled with water (i.e., SG of 1.0).

3.6.1.7

Manufacturer must furnish drawing that lists:

a.
b.
c.
d.

3.6.2

Allowable Stress - Be familiar with Table 3-2 for plate specifications,

yield/tensile strength and stress involved.
NOTE:

3.6.3

Required shell "t" (including CA) for design product

and hydro test.
Nominal "t" used, (i.e.; shell "t" as constructed).
Material specification.
Allowable stresses.

ASTM A-283, A-285 (GR. C.) and A-36 are the most
common.

One Foot Method - Calculates the "t" required at design points 1 foot
above the bottom of each shell course. *Not allowed for shells greater
than 200 feet in diameter.
Formula: td = 2.6D(H-1)G + CA (Design Shell Thickness)
Sd
Formula: tt = 2.6D(H-1)
St
NOTE:

See 3.6.3.2 for details as to actual values or relationship of

items shown in the formula above.

API 650 Summary, 2005

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3.7

Shell Openings
3.7.1.6

Manway necks, nozzle necks and shell plate openings shall

be uniform and smooth, with the corners rounded, except
where the surfaces are fully covered by attachment welds.
NOTE:

1/8" corner radius for 2" and smaller nozzle.

1/4" corner radius for larger nozzle sizes.

3.7.2.1

No reinforcement required for nozzles 2" and smaller.

3.7.2.2

By design, nozzle necks (i.e., outside extension, within the

shell plate "t" and inside extension) may provide the
necessary reinforcement.
NOTE:

For manway and nozzle design

values/fabrication details, be familiar with and
able to select the proper values from the
following data sheets:
1.
2.

Fig. 3-4A, 3-4B, 3-5 and 3-6.

Tables 3-3, 3-4, 3-5, 3-6, 3-7, 3-8, 3-9 and
3-10.

3.7.3 Spacing of Welds Around Connections

This paragraph and the next three paragraphs confuse the weld spacing
issue. A great deal of confusion has been relieved with the addition of
figure 3-22, minimum weld requirements for openings in shells according
to section 3.7.3, see page 3-49.

3.8

3.7.4.2

Paragraphs on stress relief of materials.

3.7.4.5

Hold times for stress relieving temperatures.

Shell Attachments (i.e., surface items such as angles, clips and stair treads).
3.8.1.2

3.8.5

Roof Nozzles - See Fig. 3-12, 3-13 and 3-14.

NOTE:

3.9.6
and
3.9.7

Permanent attachment welds shall not be closer than 3" from

horizontal shell joint seams, nor closer than 6" from vertical
joints, insert-plate joints or reinforcement-plate fillet welds.

Remember note on bottom of Fig. 3-14. "When the roof

nozzle is used for venting, the neck shall be trimmed flush
with the roof line".

Primary/Secondary Wind Girders or Stiffeners:

See Fig. 3-17 for typical stiffening ring sections.

API 650 Summary, 2005

Page 2-7

NOTE:
3.10

Intermediate wind girders cannot be attached within 6" of a

horizontal shell joint.

Roofs
3.10.1 Refer to fixed roof types.
3.10.2.1

Roofs and structure designed to support dead load (i.e., roof

deck and appurtenances), plus a uniform live load of not less
than 25 lbs. per sq. ft. of projected area.

3.10.2.2

Roof plates - minimum nominal "t" of 3/16" (7.65 lbs. per sq.
ft., 0.180" plate or 7 gauge sheet).
NOTE:

Self-supported roofs may require thicker plate.

3.10.2.3

Supported cone roof plates shall not be attached to the

supporting members.

3.10.2.4

Internal-External structural members must have a minimum

nominal "t" (in any component) of 0.17".

3.10.2.5

Roof plate weld attachment to top angle.

NOTE:

Refer to Glossary, Frangible Joint, Items "a, b

and c" -See weld size restrictions/conditions.
(3/16")

3.10.2.6

Frangible roof general information.

3.10.2.7

Roof plates may be stiffened by welded sections, but not

connected to girders-rafters.

3.10.4.1

Supported cone roofs slope 3/4" in 12" (or greater).

3.10.4.4

Rafters shall be spaced so that in the outer ring, their centers

are not more than 2
ft. (6.28 feet), measured along the
circumference. The maximum spacing for inner ring rafters
(i.e., "Jack" rafters) is 5.5 feet.
NOTE:

3.10.4.5

In earthquake zones, where specified, 3/4"

diameter tie rods (or equivalent) shall be
placed between the outer ring rafters (i.e.,
"Long" rafters). Not necessary if "I" or "H"
sections are used as rafters.

Roof Columns
Structural shapes or steel pipe is acceptable. If pipe, it must
be sealed (or provisions for draining or venting made).

API 650 Summary, 2005

Page 2-8

3.10.4.6

Rafter and Column Base Clips

a.
b.
c.

3.11

Outer row rafter clips - welded to tank shell.

Column-base clip guides - welded to tank bottom to
prevent lateral shift.
Other structural attachments - welded, bolted or
riveted.

Wind Load on Tanks (Overturning Stability)

3.11.1 Where specified, overturn stability values are and the wind load (or
pressure) shall be assumed to be:
a.
b.
c.

Vertical plane surfaces - 30 lbs. per sq. foot.

Projected areas - Cylindrical surfaces - 18 lbs.
Conical-double curved surfaces - 15 lbs.

NOTE:

All based on wind velocity of 100 m.p.h.

3.12.3 Anchor spacing - maximum of 10 feet apart.

SECTION 4 - FABRICATION
4.1

Fabrication (General)
4.1.1.2

When material requires straightening:

a.
b.

Pressing or non-injurious method required (prior to

any layout or shaping).
Heating or hammering not permitted, unless heated
to a forging temperature.
SECTION 5 - ERECTION

5.1

Erection (General)
5.1.1

Subgrade shall be uniform and level (unless otherwise specified) i.e.,

sloped (1 way) bottoms.

5.1.5

Erection lugs shall be removed, noticeable projections or weld metal

removed, torn or gouge areas repaired.

API 650 Summary, 2005

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5.2

Welding (General)
5.2.1.1

Acceptable weld processes

a.
b.
c.
d.
e.
f.

Shielded metal-arc
Gas metal-arc
Flux-cored arc
Submerged-arc
Electroslag
Electrogas

May be performed manually, automatically or semiautomatically. Complete fusion with base metal required.
NOTE:
5.2.1.2

Welding prohibited when:

a.
b.
c.
d.

Surfaces are wet or moisture falling on surfaces.

During high winds (unless shielded).
When base metal temperature is less than 0 F.
Base metal temperature is between 0 - 32 F and "t"
exceeds 1 1/4" pre-heat of metal within 3" of weld is
required.

5.2.1.3

Multilayer welds require slag and other deposit removal

before next layer applied.

5.2.1.4

All weld edges must merge with plate surface without a

sharp angle.
a.
b.

5.2.2

Procedures described in ASME Section IX.

Maximum acceptable undercut - 1/64" (0.016") vertical

butt joints.
Maximum acceptable undercut - 1/32" (0.031")
horizontal butt joints.

5.2.1.8

Tack welds, used in vertical joints, shall be removed and not

remain in finished joint - when manually welded. If sound,
cleaned and fused, tack welds can remain when the
submerged-arc process is used.

5.2.1.10

Low-hydrogen electrodes shall be used for manual metal-arc

welds, including shell to bottom junction for all shell courses
over 0.5" thick of Group I-III material.

5.2.1.11

Stud welding is recognized.

Bottoms
5.2.2.2

After layout/tacking, weld out may proceed with some

shrinkage seams left open.

API 650 Summary, 2005

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5.2.2.3
5.2.3

Shells

Shell to bottom welding shall be practically completed,

before shrinkage openings (in 5.2.2.2. above) are welded.

5.2.3.1

Misalignment in completed vertical joints over 5/8" thick,

shall not exceed 10% of plate "t", with a maximum of 0.125".
Misalignment in completed vertical joints 5/8" thick and less
thick shall not be greater than 0.06".

5.2.3.3

The reverse side of double-welded joints (prior to the

application of the first bead to the second side), must be
cleaned by chipping, grinding or melting out.

5.2.3.4

Joints exceeding 1 1/2" base metal "t"

a.
b.

5.3

No pass over 3/4" thick is permitted.

Minimum preheat of 200F is required.

5.2.3.5

New requirement for a procedure that minimizes the

potential for underbead cracking, in group IV through VI
material.

5.2.3.6

After any stress relief (but before hydro), welds attaching

nozzles, manways and cleanout openings shall be visually
and magnetic particle or die penetrant tested.

5.2.4.1

Shell-to-bottom welds, inside, may be checked by visual and

any of the following: magnetic particle, PT solvent, PT water
washable, diesel test or right angle vacuum box.

5.2.4.2

New paragraph, a new procedure as an alternative to

paragraph 5.2.4.1, allows for pressure testing the volume
between the inside and outside welds to 15 psi and applying
a soap solution to the face of the fillet welds.

INSPECTION, TESTING, AND REPAIRS

5.3.2.1 Butt welds, must be inspected visually, radiographic or
ultrasonic method.
5.3.3

Examination and testing of the tank bottom:

a.
b.
c.

Vacuum box
Tracer gas test
External "float" test

NOTE: Vacuum text procedure removed from this paragraph. The

procedure is now in paragraph 6.6, as well as a procedure for
tracer gas testing.

API 650 Summary, 2005

Page 2-11

5.4

5.3.5

Reinforcing. pads tested by up to 15 PSIG pneumatic pressure between

tank shell and reinforcement on each opening.

5.3.6

Shell Testing - Be familiar with procedure.

Weld Repair
5.4.2 Pinhole or porosity bottom leaks - weld over.
5.4.3 All defects in shell or shell-to-bottom joints.
NOTE:

5.5

See Specifics - 6.1.7.

Dimensional Tolerances
The maximum out-of-plumbness of the top (relative to bottom of shell)
may not exceed 1/200 of the total tank height.
5.5.2

The 1/200 criteria shall also apply to fixed roof columns.

5.5.4a Weld "peaking" - shall not exceed 1/2".

5.5.4b Weld "banding" - shall not exceed 1/2".
5.5.5

Foundations (General)
5.5.5.2a

For concrete ring walls - Top shall be level within 1/8" in

any 30 foot circumference. and within 1/4" in the total
circumference (measured from average elevation).
NOTE:

5.5.5.3

Non-concrete ring walls the values change to

1/8" in any 10 feet and 1/2" in total
circumference.

Sloped foundations - Same criteria.

SECTION 6 - METHODS OF INSPECTING JOINTS

6.1

Radiographic (Number-Location)
6.1.2.2

Requirements for vertical shell welds

a.

Butt-weld joints with the thinner plate 3/8" or less:

One spot in the first 10 feet of each type and thickness
welded by each welder or operator. Thereafter, one
additional spot in each additional 100 feet.

API 650 Summary, 2005

Page 2-12

NOTE:

b.

Plates greater than 3/8" and through 1" thickness same as thinner plate above plus all junctions.
Additionally, two spots in all bottom ring verticals
(one as near to bottom as practical, the other
random).

c.

Plates thicker than 1" - full radiography of all verticals,

plus all junctions.
Butt weld around periphery of insert nozzles and
manways complete radiography.

d.
6.1.2.3

At least 25% of spots must be at

junctions of verticals and roundseam
joints - minimum 2 per tank.
Additionally, one random spot in each
bottom ring vertical.

Requirements for horizontal shell welds

One spot in the first 10 feet (same type) thickness without
regard to welder or operator. Thereafter, one spot in each
additional 200 feet.

6.1.2.4

Multi-tank erection (at same location) may use aggregate

footage values of same type and thickness.
NOTE: See Fig. 6-1 Radiographic Layout.

6.1.2.8

Each radiograph must clearly show 6" minimum weld

length.
NOTE: Each film must show Identifier, plus "t" gauge or
penetrometer.

6.1.2.9

Tank bottom annular ring (See 3.5.1), the radial joints shall
be radiographed as follows:
a.
b.

Double-butt-weld joints - one spot on 10% of radial

joints.
Single weld joints with back-up bar - one spot on 50%.
of radial joints.

NOTE:
6.1.3

Preferable spot - at the outer edge, near shell.

Technique - Radiography
6.1.3.1

ASME method, Section V NDE, Article 2.

6.1.3.2

Radiographers meet ASNT - SNT - TC - 1A requirements.

API 650 Summary, 2005

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6.1.5
6.1.6

Radiography Standards - Acceptability to be in accordance

with Section VIII, Div. 1, Par. UW-51(B), ASME.

Unacceptable radiographs (under 6.1.5), or the limits of the deficient

radiograph are not defined, 2 adjacent shots are required.
NOTE:

6.1.7

6.2.1
6.3

6.4

If adjacent spots are still unacceptable, additional spots are

examined until weld is acceptable.

Weld defects shall be repaired by chipping or melting out from one or

both sides, and rewelded.
6.1.7.2

When all welds are repaired, repeat original inspection

procedure.

6.1.8.1

The manufacturer shall prepare an as-built radiograph map

showing the location of all radiographs taken along with the
film identification marks.

Magnetic Particle - ASME Section V, Article 7.

Ultrasonic Examination
6.3.1

Ultrasonic Method in lieu of radiography see Appendix U.

6.3.2

UT not in lieu of radiography - ASME Section V, Article 5

6.3.2.4

Must be ASNT-SNT-TC-1A requirements

6.3.2.5

Acceptance standards shall be agreed upon by the purchaser

and the manufacturer.

Liquid Penetrant Examination

6.4.1

ASME Section V, Article 6 must be followed.

6.4.2

Must have written procedure

6.4.3

Manufacturer determines qualifications

6.4.4

Acceptance standards, ASME Section VIII, Appendix 8, paragraphs 8-3, 8-4

and 8-5.

6.5.1

Visual acceptability based on following:

a.
b.

No visible crater or surface cracks or arc strikes.

Undercut does not exceed limits given in 5.2.1.4 for vertical
and horizontal butt joints.

API 650 Summary, 2005

Page 2-14

NOTE:

c.

6.5.2

1/64" maximum allowable undercut on

attached nozzles, manways, cleanout openings
and permanent attachments.

Frequency of surface porosity does not exceed one "cluster"

in any 4" of length and the diameter of each cluster does not
exceed 3/32" (0.094).

All welds failing to meet 6.5.1 requirements must be reworked

prior to hydro-testing.
SECTION 7 - WELDING PROCEDURE/QUALIFICATIONS

* No specifics
SECTION 8 - MARKING (NAMEPLATE)
* No specifics

API - 650 (APPENDIX REVIEW)

Appendix. A - Optional Design Basis For Small Tanks (Do not use Appendix A on the
API 653 Exam).
A.1.4 The overturning effect of wind load should be considered.
A.1.5 Consider Tables A-1 through A-4 for sizes, capacities, shell plate thickness, etc.
A.2.1 Shell plate thickness limited to 1/2".
A.5.1 Vertical and horizontal joints, bottom, shell-to-bottom, roof and top angle - same
provisions as normal size.
A.5.2 Normal weld spacing restrictions are relaxed.
A.5.3 Radiograph inspection - slightly relaxed.
Appendix B - Foundation Construction
B.2.1 Requires soil coring to determine sub-surface conditions.

API 650 Summary, 2005

Page 2-15

B.2.3 Varying conditions that require special engineering considerations

a.
b.
c.
d.
e.
f.

Sites on hillsides.
Sites on swampy or filled ground.
Sites underlain by layers of plastic clay.
Sites adjacent to water courses or deep excavations.
Sites immediately adjacent to heavy structures.
Sites exposed to floodwaters.

B.2.4 General methods to improve non-acceptable subsoil

a.
b.
c.
d.
e.
f.

Removal and replacement with suitable, compacted subsoil.

Compacting with short piles - preloading with an overburden of
suitably drained earth.
Removing water content then compacting.
Stabilizing by chemical methods or grout injection.
Driving bearing piles/foundation piers.
Load distribution over a extra large area.

B.2.5 Fill material must be sound and durable (i.e., at least equivalent to fill
used in good highway construction), free from vegetation, organic matter
or other corrosive substances.
B.3.1 Suggested grade/surface elevation - 1'.
B.3.2

Finished grade (i.e., surface next to bottom)

a.
b.
c.

Top 3"-4" - Clean sand, gravel, crushed stone (maximum size 1"), or
other suitable inert material.
Equipment and material movement will cause damages. Correct
before bottom plates are installed.
Oiled/stabilized finished grade.

B.3.3 Finished tank grade

Crowned from outer edge to center - 1" in 10'.
B.4.2.1

Concrete foundation ringwall advantages

a.
b.
c.
d.
e.

Better distribution of concentrated load.

Provides a level, solid starting plane for erection.
Provides better means to level tank during erection.
Retains subsoil fill and finished top surface.
Minimizes moisture under tank bottom.

Fig. B-1 - Foundation with Concrete Ringwall.

Fig. B-2 - Foundation with Crushed Stone Ringwall.
NOTE:

Have familiarity with above types.

API 650 Summary, 2005

Page 2-16

B.4.3 Earth Foundations (without concrete ringwall)

a.
b.
c.
e.

A 3' shoulder and berm - protected from weathering.

Smooth, level surface for bottom plates.
Adequate drainage.
Surface true to specified plane (tolerances specified in 5.5.6).

Appendix C - External Floating Roofs

C.3.1 General
If a windskirt or top-shell extension is used for the purpose of containing
roof seal at its highest point of travel, appropriate alarm devices are
required.
C.3.2 Joints
Same as required in 3.1 (i.e., single lap, full fillet, 1" minimum lap, etc.).
C.3.3. On the bottom side, where flexure is anticipated adjacent to girders,
support legs, or other relatively rigid members, full-fillet welds (not
less than 2" long on 10" centers) shall be used on any plate laps that
occur within 12" of any such member.
C.3.3.4

Decks (double and diaphragm) designed for drainage, shall have a

minimum slope of 3/16" in 12".

C.3.4. Pontoon roofs shall have sufficient buoyancy to remain afloat on a specific
gravity product of 0.7 and with primary drains inoperative for following
conditions:
a.
b.

A 10" of rainfall in a 24 hour period with roof intact, except for double
deck floating roofs that have emergency drains.
Single-deck (i.e., diaphragm) and any 2 adjacent compartments punctured
in single-deck pontoon types and any 2 adjacent compartments punctured
in double-deck roofs Both types with no water or live load.

C.3.5 Pontoon Openings

a.
b.
c.

Each compartment provided with liquid tight manway.

Manway covers provided with suitable hold-down fixture.
Compartments vented against internal/external pressure.

API 650 Summary, 2005

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C.3.8 Roof Drains

a.
b.
c.
d.

Primary drains may be hose, jointed or siphon type.

Check valve required (hose and jointed pipe type) on pontoon and pan
type roofs.
Hose drain types designed to permit replacement without personnel
entering the tank (* Not Normal).
Minimum roof drain size - 3" for a tank 120 in diameter and less; 4" for a
tank greater than 120 feet in diameter.

C.3.9 Vents
Purchaser furnishes fill and withdrawal flow rates. Fabricator sizes accordingly.
C.3.10.1 and 3.10.2 Roof support leg requirements
a.
b.
c.
d.
e.

Pipe legs - notched or perforated at bottom.

Adjustable length from roof top side.
Designed to support roof and a uniform live load of at least 25
lbs./sq. ft.
Sleeves, gussets, etc., required at deck entry points.
Load distribution members required on tank bottom.

NOTE: If pads used, continuous weld required.

C.3.11 Manways
Minimum of 1 with 24" access, with gasket and bolted cover.
C.3.12 Centering/anti-rotation devices required.
C.3.13 Seals
a.
b.

The space (rim) between outer roof periphery and shell - sealed by flexible
device providing a reasonable close fit to shell surfaces.
No plain (i.e., bare) carbon steel shoes allowed.
NOTE:

c.
d.

Adequate expansion joints (i.e., secondary seal strips) required.

Must be durable to environment and must not contaminate the product.
NOTE:

C.4

Must be galvanized or coated See API RP 2003.

Aviation fuel restrictions.

Fabrication, Erection, Welding, Inspection And Testing

C.4.2 Deck and other joint seams tested for leaks with vacuum box, penetrating oil,
etc.

API 650 Summary, 2005

Page 2-18

C.4.3 Water flotation test required at initial erection. Weld repair can be seal-weld
type.
C.4.5 50 PSIG hydro test required on drain system.
Appendix D - Technical Inquiries
(No specific comments)
Appendix E - Seismic Design of Storage Tanks
(No specific comments)
Appendix F - Design of Tanks for Small Internal Pressures
F.1.3 Internal pressures that exceed the weight of the shell, roof and framing but do
not exceed 2 1/2 pounds per square inch gauge when the shell is anchored to a
counterbalancing weight, such as a concrete ringwall.
Appendix G - Structurally Supported Aluminum Dome Roofs
(No specific comments)
Appendix H - Internal Floating Roofs
H.1

Scope
Subsection 3.10 of standard. is applicable except as modified in this
appendix.
H.2.2 Types
a.
b.
c.
d.
e.
f.
g.

H.3

Metallic pan internal - liquid contact with two peripheral rims.

Metallic open top bulkhead - liquid contact/peripheral rim and
open top bulkheads.
Metallic pontoon - liquid contact/closed pontoons.
Metallic double deck.
Metallic on floats - deck above liquid.
Metallic sandwich-panel - liquid contact, surface-coated honeycomb
panels.
Hybrid internal floating roofs.

Materials
H.3.2 Steel
H.3.3 Aluminum
API 650 Summary, 2005

Page 2-19

H.3.4 Stainless Steel

Same general provisions as for open top floating roofs.
H.3.5.2/3.5.7 - Seal types
a.
b.
c.
d.
e.
H.4

Flexible foam contained in an envelope

Liquid fill (in an envelope)
Wiper type (resilient)
Metallic Shoe
Other mutually agreeable types (fabrication and customer)

General Requirements and Design

H.4.4 Peripheral Seals
H.4.5.1 through 4.5.3 - Design Features
a.
b.
c.
d.

Accommodate 4" local deviation between roof and shell.

Tank shell free of internal projections, burrs, etc.
Envelope seals to be liquid tight. Field joints, minimum 3" lap.
Mechanical shoe types - Galvanized steel (16 ga.) - Stainless Steel
(18 ga).

H.4.5 Roof Penetrations

Columns, ladders and other rigid vertical appurtenances that penetrate
the deck shall have a seal permitting a local deviation of 5".
NOTE:

Appurtenances require a vertical plumbness of 3".

H.4.6 Roof Supports

H.4.6.1 through H.4.6.8 - Specific requirements
a.
b.
c.
d.

Both fixed and adjustable supports are acceptable.

Supports/attachments designed to support a uniform live load of
12.5 lbs./sq. ft., unless roof is equipped with drains to prevent
liquid accumulation.
Same underside tack-weld required on seams as on conventional
floating roofs. (See C.3.3.3.).
Same requirements on notching pipe legs, welding support pads to
bottom, etc., as on conventional.
NOTE:

H.5

Pads may be omitted with purchaser approval.

Openings and Appurtenances

API 650 Summary, 2005

Page 2-20

H.5.1 Ladder Specifics

H.5.2 Vents
H.5.2.2

Circulation Vents
a.
b.
c.

H.5.2.2.2

Located on shell or fixed roof (above seal in full

tank).
Maximum spacing - 32". No fewer than 4 total.
Sized equal to or greater than 0.2 sq. ft. per ft.
of tank diameter. Covered with corrosion
resistant screen and weathershield.

Open vent required at center of fixed roof minimum

area of 50 sq. in.

NOTE:

Pressure-vacuum vents (rather than air

openings) required on gas blanketed tanks.

H.5.3 Overflow Slots

H.5.4 Antirotation Devices
H.5.5 Manholes and Inspection Hatches
H.6

Fabrication, Erection, Welding, Inspection and Testing

Appendix I - Undertank Leak Detection and Subgrade Protection

(No specific comments) Refer to API RP 652 and 651 for more guidelines.
Appendix J - Shop Assembled Storage Tanks
(No specific comments)
Appendix K - Engineering Data
(No specific comments)
Appendix L - Data Sheets
(No specific comments) In the real world use these sheets as a guide only.
Appendix M - Requirements for Tanks Operating at Elevated Temperatures
(No specific comments)

API 650 Summary, 2005

Page 2-21

Appendix N - Use of New Materials That are Not Identified

(No specific comments)
Appendix O - Recommendations for Under-Bottom Connections
(No specific comments)
Appendix P - Allowable External Loads on Tank Shell Openings
(No specific comments)
Appendix S - Austenitic Stainless Steel Storage Tanks
S.1.1 This section covers tank construction of material grades 304, 304L, 316,
316L, 317, and 317L.
S.1.2 Ambient temperature tanks shall have a design temperature of 1000 F
Appendix T - NDE Requirements Summary
Appendix U - Ultrasonic Examination in Lieu of Radiography
(This is a new section, no specific comments)

API 650 Summary, 2005

Page 2-22

NAME:

DATE:

The first part of the exam is "Open Book.

API 650 Tenth Ed. CODE QUIZ

(Select The Best Answer)

1.

A peripheral seal, on an internal floating roof, shall be designed to accommodate

_____ of local deviation between the floating roof and the shell.
a.
b.
c.
d.

2.

Welders shall be qualified in accordance with

a.
b.
c.
d.

3.

API 1104
ASME Section V
ASME Section IX
AWS D1.1

A new tank will hold a product with the specific gravity of 1.05. The corrosion
allowance is .10. The thickness of the first course is 1.25 inches; The hydrostatic
test stress is 25,000 PSI. What is the thickness required for the annular plate?
(Note: Include corrosion allowance).
a.
b.
c.
d.

4.

the manufacturer's standard

+ 100 mm
+ 1/8 inch
the inspector's experience

5/16"
11/16"
3/8"
7/16"

In order to comply with API 650, the finished surface of a weld reinforcement on
plate 1/2" thick, horizontal butt joints, may have a reasonably uniform crown not to
exceed ________, for radiographic examination.
a.
b.
c.
d.

1/4"
3/16"
1/8"
1/16"

API 650 Summary, 2005

Page 2-23

5.

What is the design thickness for the first course of a new tank 60 tall, with a fill
height of 58 and a diameter of 804? The material of construction is A516M
485. Specific gravity of .6
a.
b.
c.
d.

6.

What is the hydrostatic test shell thickness of the tank in question 5?

a.
b.
c.
d.

7.

.281
.416
.500
1.00

If the first course of a new tank is 12.5 mm and the design metal temperature is
-7oC, what is the material group?
a.
b.
c.
d.

9.

.416
.281
.117
.500

To what thickness should the tank in question 6 be constructed?

a.
b.
c.
d.

8.

.097
.416
28.1
.281

Group I
Group II
Group III
Group IV

What is the maximum reinforcement on a vertical butt joint, if the plate is .625 in.
thick?
a.
b.
c.
d.

3/32
1/8
3/16
1/4

API 650 Summary, 2005

Page 2-24

Please close all materials.

The remainder of the Quiz
is Closed Book.

API 650 Summary, 2005

Page 2-25

The second part of the quiz is "Closed Book."

10.

According to API 650, which of the following types of connections shall be stress
relieved?
a.
b.
c.
d.

11.

Upon completion, the roof of a tank designed to be gas tight shall be tested by
which one of the following methods?
a.
b.
c.
d.

12.

erection/fabrication manufacturer
purchaser
Nuclear Regulatory Commission
certified inspector

Per API 650, external floating roof deck plates having support leg or other rigid
penetrations closer than ____ inches to lap weld seams must be full fillet welded
not less than 2 inches on 10 inch centers.
a.
b.
c.
d.

14.

Magnetic particle testing of all welds

Application of internal air pressure not exceeding the weight of the roof
plates and applying a solution suitable for the detection of leaks
Penetrant testing the weld joints
Visual inspection of the weld joints

Each welder making welds on a tank shall be certified by the _______.

a.
b.
c.
d.

13.

All nozzles
All Group I, II, III or IIIA opening connections less than 12 inches
All Group IV, IVA, V or VI opening connections requiring reinforcement
All connections requiring reinforcement

6
12
14
18

Upon completion of welding of the new tank bottom, the welds shall be
inspected by which one of the following methods?
a.
b.
c.
d.

Radiographs
Vacuum or air pressure
Penetrant testing
Hammer testing

API 650 Summary, 2005

Page 2-26

15.

The maximum reinforcement thickness for vertical butt joints, less than or equal to
1/2" thick is
.
a.
b.
c.
d.

16.

Annular bottom plates shall have a radial width that provides at least _____
inches between the inside of the shell and any lap-welded joint in the remainder
of the bottom.
a.
b.
c.
d.

17.

c.
d.

a joint between two abutting parts lying in approximately the same plane
a joint between two abutting parts lying in approximately the same plane
that is welded from both sides
a joint between two overlapping members in which the overlapping
edges of both members are welded with fillet welds
a fillet weld whose size is equal to the thickness of the thinner joined
member

Openings in tank shells larger than required to accommodate an NPS _____ inch
flanged or threaded nozzle shall be reinforced.
a.
b.
c.
d.

20.

3/32
1/8
1/64
3/64

A double-welded butt weld is ______.

a.
b.

19.

10
30
24
18

The maximum acceptable undercutting of the base metal for vertical butt joints is
___ inch.
a.
b.
c.
d.

18.

1/16"
1/8"
3/32"
3/16"

one
two
three
four

The acceptability of welds examined by radiography shall be judged by the

standards in
.
a.
b.
c.
d.

ASME Section V, Division 7

ASME Section IX, Paragraph QW-191
ASME Section VIII, Division 1, Paragraph UW-51(b)
API 1104
API 650 Summary, 2005

Page 2-27

21.

When bottom annular plates are required by paragraph 3.5.1 of API 650, the
radial joints shall be radiographed. For single welded butt joints using a backup
bar, one spot radiograph shall be taken on _____ percent of the radial joints.
a.
b.
c.
d.

22.

Annular bottom plates must extend a minimum of _______ inches outside the
tank shell.
a.
b.
c.
d.

23.

Manufacturer
Purchaser
State Inspector
API 653 Inspector

A new tank is under construction. How many radiographs are required on the first
course vertical welds if the shell is 35 mm thick?
a.
b.
c.
d.

26.

500 F
500 C
200 F
200 C

Who is responsible for compliance with the API 650 standards?

a.
b.
c.
d.

25.

1 1/2
2
3
4

The maximum operating temperature for tanks constructed to API 650 (not
including appendices) is _______.
a.
b.
c.
d.

24.

10
30
50
100

One radiograph shall be taken in every vertical joint

100% of the vertical joint
Two radiographs shall be taken in the vertical joint
No radiographs required

All bottom plates shall have a minimum nominal thickness of _____ inch,
exclusive of any corrosion allowance specified by the purchaser for the bottom
plates.
a.
b.
c.
d.

3/8
.250
.516
.325

API 650 Summary, 2005

Page 2-28

27.

Repairs of defects shall not be attempted on a tank that is filled with _____ or on
a tank that has contained ____ until the tank has been emptied, cleaned and gas
freed in a safe manner.
a.
b.
c.
d.

28.

Misalignment in completed vertical joints over 5/8" shall not exceed what
percentage of the plate thickness?
a.
b.
c.
d.

29.

ASME Section VIII

ASME Section V
ASME Section XI
Agreed upon by the purchaser and the manufacturer

Column-based clip-guides shall be welded to the tank bottom to prevent

__________.
a.
b.
c.
d.

32.

diesel
air
stress
gas

Ultrasonic acceptance standards, in accordance with API 650, shall be ______.

a.
b.
c.
d.

31.

25% with a maximum of 1/16"

2% with a maximum of 3/64"
5% with a maximum of 3/8"
10% with a maximum of 1/8"

Reinforcing plates of shell penetrations shall be given a(n) ________ test, in

accordance with API Standard 650.
a.
b.
c.
d.

30.

nitrogen
oil
water
grain

internal erosion
structural uplifting
lateral movement of column bases
lateral expansion and contraction

Who is responsible for specifying whether the dimensions of a tank will be given
in SI units or US customary units?
a.
b.
c.
d.

Industrial requirements
U.S. Government mandates
The purchaser
The manufacturer

API 650 Summary, 2005

Page 2-29

33.

When performing a vacuum test, the gauge should register a partial vacuum of at
least
?
a.
b.
c.
d.

34.

When reviewing a radiograph of an intersection, 2 inches of weld length must be

shown on each side of the vertical intersection. How much of the vertical weld
must be shown?
a.
b.
c.
d.

35.

1
1 1/2
1 3/4
2

Which electrodes are in the AWS A5.1 specification?

a.
b.
c.
d.

38.

the purchaser specifies the requirement.

API mandates the requirement
the manufacturer approves the requirement
required by jurisdictional requirements

Shell plates are limited to a maximum thickness of

a.
b.
c.
d.

37.

2 inches
50 mm
3 inches
No API 653 requirement

An appendix becomes a requirement only when

a.
b.
c.
d.

36.

2 lbf/in.2
3 lbf/in.2
4 lbf/in.2
5 lbf/in.2

E-9018
E-8518
E-8018
E-6010

What is the minimum size fillet weld that can be installed on a new tank?
a.
b.
c.
d.

1/8
3/16
1/4
5/16

API 650 Summary, 2005

Page 2-30

39.

Roof plates shall have a minimum nominal thickness, in addition to any required
corrosion allowance, of
.
a.
b.
c.
d

40.

The slope of a supported cone roof shall be at least

a.
b.
c.
d.

41.

10%
15%
20%
25%
.

the floor only

the roof only
shell welds greater than 1/2
shell welds less than 1/2

Which of the following NDE methods is not acceptable for the inspection of new
shell-to-bottom welds.
a.
b.
c.
d.

44.

1 m in 6 m
19 mm in 300 mm
.75 mm in 12 mm
7.5 mm in 1.2 mm

Low hydrogen electrodes shall be used for weld on

a.
b.
c.
d.

43.

Misalignment in completed vertical joints for plates greater than 5/8 thick shall not
exceed
.
a.
b.
c.
d.

42.

3/16
1/4
7-Gauge
both a and c

Magnetic particle
Liquid Penetrant
Vacuum Box
Radiography

A tank construction crew is using a vacuum box constructed of clear plastic and
a sponge-rubber gasket.
a.
b.
c.
d.

This is an acceptable practice.

This is a good vacuum test.
This vacuum box is not recognized by API 650.
The crew can use any style vacuum box.

API 650 Summary, 2005

Page 2-31

45.

Floor plates may be tested by vacuum box testing or

a.
b.
c.
d.

46.

1/4
1/2
3/4
1

the contractor
API 1104
ASME Section IX
ASME Section VIII

A joint between two members that intersect at an angle between 0o (a butt joint)
and 90o (a corner joint) is called a(n)
.
a.
b.
c.
d.

50.

Welds examined by radiography shall be judged as acceptable or

unacceptable by
.
a.
b.
c.
d.

49.

6.5
5.4
3.9
2.0

Banding at horizontal weld joints shall not exceed

a.
b.
c.
d

48.

air pressure test

tracer gas and compatible detector
explosion-bulge test
acoustic emission test

What is the maximum out-of-plumbness of the top of the shell relative to the
bottom of the shell of a new tank that is 65 tall?
a.
b.
c.
d.

47.

fillet joint
butt joint
angle joint
joint that requires backing

The client has requested the top course of a tank to be 1/2 thick. The maximum
thickness of all the other courses is 3/8 thick.
a.
b.
c.
d.

The client wants it, do it.

The top course is usually 1/2 thick.
No shell course shall be thinner than the course above it.
The thickness of each course is based on the design thickness of the tank
not including corrosion allowance.

API 650 Summary, 2005

Page 2-32

API 650 Tenth Ed. CODE QUIZ

Answer Key
1.
b
2.
c
3.
c
4.
d
5.
d
Solution:

(Page H-4, Par. H.4.4.3) API 650

(Page 7-2, Par. 7.3.2) API 650
(Page 3-6, Par. 3.5.3) API 650
(Page 6-3, Par. 6.1.3.4) API 650
(Page 3-7, Par. 3.6.3.2) API 650
td = 2.6D(H-1)G + CA
Sd
td = 2.6(80)(58-1)(.6)
25,300
td = 7113.6
25,300

6.
a
Solution:

td = .281
(Page 3-7, Par. 3.6.3.2) API 650
tt = 2.6D(H-1)
St
tt = 2.6 (80) 58 - 1
28,500
tt = 11,856
28,500

7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

b
a
b
c
b
a
b
b
c
c
c

tt = .416
(Page 3-6, Par. 3.6.1.1) API 650
(Page 2-2, Fig. 2-1) API 650
(Page 5-1, Par. 5.2.1.5) API 650
(Page 3-17, Par. 3.7.4.3) API 650
(Page 5-4, Par. 5.3.6.1) API 650
(Page 7-2, Par. 7.3.1) API 650
(Page C-1, Par. C.3.3.3) API 650
(Page 5-4, Par. 5.3.3) API 650
(Page 5-1, Par. 5.2.1.5) API 650
(Page 3-5, Par. 3.5.2) API 650
(Page 5-1, Par. 5.2.1.4) API 650
API 650 Summary, 2005

Page 2-33

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.

b
b
c
c
b
c
a
b
b
b
d
b
d
c
c
b
c
a
c
d
b
d
b
a
c
d
a
b
c
b
d
c
c

(Page 3-1, Par. 3.1.1.1) API 650

(Page 3-11, Par. 3.7.2.1) API 650
(Page 6-3, Par. 6.1.5) API 650
(Page 6-3, Par. 6.1.2.9b) API 650
(Page 3-5, Par. 3.5.2) API 650
(Page 1-1, Par. 1.1.1) API 650
(Page 1-2, Par. 1.3) API 650
(Page 6-1, Par. 6.1.2.2c) API 650
(Page 3-5, Par. 3.4.1) API 650
(Page 5-4, Par. 5.4.4) API 650
(Page 5-2, Par. 5.2.3.1) API 650
(Page 5-4, Par. 5.3.4) API 650
(Page 6-4, Par. 6.3.4) API 650
(Page 3-48, Par. 3.10.4.6) API 650
(Page 1-1, Par. 1.1.3) API 650
(Page 6-5, Par. 6.6.3) API 650
(Page 6-1, Par. 6.1.2.2b) API 650
(Page 1-1, Par. 1.1.4) API 650
(Page 2-1, Par. 2.2.1.4) API 650
(Page 2-10, Par. 2.8.1) API 650
(Page 3-1, Par. 3.1.3.3) API 650
(Page 3-44, Par. 3.10.2.2) API 650
(Page 3-48, Par. 3.10.4.1) API 650
(Page 5-2, Par. 5.2.3.1) API 650
(Page 5-2, Par. 5.2.1.10) API 650
(Page 5-2, Par. 5.2.4.1) API 650
(Page 6-4, Par. 6.6.1) API 650
(Page 5-3, Par. 5.3.3) API 650
(Page 5-5, Par. 5.5.2) API 650
(Page 5-5, Par. 5.5.4(b) API 650
(Page 6-3, Par. 6.1.5) API 650
(Page 7-1, Par. 7.1.1) API 650
(Page 3-6, Par. 3.6.1.5) API 650

API 650 Summary, 2005

Page 2-34

Section 3
API RP 575
Inspection of Atmospheric
& Low-Pressure Storage Tanks

API RECOMMENDED PRACTICE 575

INSPECTION OF
ATMOSPHERIC AND LOW-PRESSURE STORAGE TANKS
First Edition, November, 1995
SECTION 1 - SCOPE
Atmospheric and low-pressure storage tanks that have been in service.
SECTION 3 - SELECTED NONDESTRUCTIVE EXAMINATION
(NDE) METHODS
3.1

Ultrasonic Thickness Measurement

This section is a discussion of thickness measurements and Dual-element verses
single-crystal transducers. The doubling phenomena is mentioned.

3.4

Magnetic Floor Testing

RP 575 now recognizes magnetic floor scanning. MFLT (Magnetic Flux Leakage
Testing) is one of the more common types of floor tests. It can be used on bare
floor or on some coatings. The principal is basically flooding the area with a
magnetic field and measuring any changes in the field. This display will appear
on a CRT (Cathode Ray Tube). One of the main limitations of this type of testing
is the problem of distinguishing between surface roughness and a through floor
pin hole. The process will not evaluate the welds or weld areas. Even with those
problems, this is one of the fastest, best methods for inspecting the bottom side
or soil side of most tanks.
SECTION 4 - TYPES OF STORAGE TANKS

4.1

General
Storage tanks are used in a wide variety of industries for a wide range of
products. Basically, our discussion will deal primarily with those that store crude
oil, intermediate and finished products, chemicals, water and a general
assortment of other products.
For our purposes, the inspection, evaluation and comments dealing with future
service conditions and limitations can all be generally categorized together, since
conditions that would change the serviceability or repair needs for a tank are
basically identical, regardless of the product stored. Other than diameter and
height, the only other two (2) service factors to be considered are the specific
gravity and temperature of the product.
4.1.1

Linings as covered in API RP 652 and cathodic protection API RP 651.

AP I RP 575 S umma ry, 1998

P a ge 3-1

4.2

Atmospheric Storage Tanks

Those that have been designed to operate in their gas and vapor spaces at
internal pressures which approximate atmospheric pressure.
4.2.2

Use of Tanks
Atmospheric storage tanks are used to store materials having a true
vapor pressure (at storage temperature) which is substantially less than
atmospheric pressure.
NOTE:

4.3

Vapor Pressure is the pressure on the surface of the liquid

caused by the vapors of the liquid. Vapor pressure varies
with temperature, inasmuch as that more of the liquid
vaporizes as the temperature rises.

Low-Pressure Storage Tanks

4.3.1

Description and Design of Low-Pressure Storage Tanks

Low-pressure storage tanks are those designed to operate at pressures in
their gas or vapor spaces exceeding the 2.5 pounds per square inch gauge
pressure permissible in API Standard 540, but not exceeding 15 pounds
per square inch gauge. Low-pressure tanks are usually built to API
Standard 620.
SECTION 5 - REASONS FOR INSPECTION
AND CAUSES OF DETERIORATION

5.1

Reasons for Inspection

a.

Reduce the potential for failure and the release of stored products.

b.

Maintain safe operating conditions.

c.

Make repairs or determine when repair or replacement of a tank may be

necessary.

d.

Determine whether any deterioration has occurred and, if so, prevent or

retard further deterioration.

e.

Keep ground water, nearby waterways and the air free of hydrocarbon
and chemical pollution.

5.2.1

External Corrosion
a.

External (underside) tank bottom corrosion results from

contamination in the pad. Cinders contain sulfur compounds that
become very corrosive when moistened.
AP I RP 575 S umma ry, 1998

P a ge 3-2

b.

Electrolytic corrosion (pitting type) results when clay, rocks, oyster

shell, wooden grade stakes, etc., come in contact with the underside
bottom, as they attract and hold moisture.

c.

Poor drainage from faulty pad preparation.

d.

Lower external shell corrosion due to:

i.
ii.
iii.

e.
5.2.2

Settlement, with corrosion at soil grade line

Casual water collection point
Insulation moisture wicking.

Shell appurtenances are subject to crevice corrosion at non-seal

welded joints (angles/flats).

Internal Corrosion
a.

Primarily dependent on product stored.

b.

Corrosion resistant linings are most common preventative.

c.

Normal locations and causes are:

i.
ii.

d.

Vapor space (above the liquid). Most commonly caused by

H2 S vapor, water vapor, oxygen or a combination of the
three.
Liquid area. Most commonly caused by acid salts, H2 S or
other sulfur compounds.

Other forms of internal attack, considered as forms of corrosion

are:
i.
ii.
iii.
iv.
v.

Electrolytic corrosion.
Hydrogen blistering.
Caustic Embrittlement.
Graphitic corrosion (cast iron parts).
Dezincification (brass parts).

In the areas covered by the stored liquid, corrosion is commonly

caused by acid salts, hydrogen sulfide or bottom sediment and
water (BS&W).
5.3

Deterioration of Non-Steel Tanks

a.

Both wooden and concrete tanks may require inspection.

b.

Potential problem areas:

i.
ii.

Wood - subject to rotting, attack by termites, subject to shrinkage,

corrosion of the steel bands.
Concrete - internal corrosion, cracking due to settlement or
temperature change, spalling (exposes reinforcement and corrodes
due to atmosphere).
AP I RP 575 S umma ry, 1998

P a ge 3-3

5.4

c.

Tanks constructed of other materials (i.e., alloy or aluminum) can present

special problems, but are subject to the same mechanical damage potential
as steel tanks.

d.

Other nonmetallic tanks (i.e., plastic, fiberglass or glass reinforced epoxy)

may present special problems, but will not be discussed in this
presentation.

Leaks, Cracks and Mechanical Deterioration

a.

Leaks, whatever the cause, can cause serious economic losses or

environmental damage resulting in fines or penalties by governmental
agencies. These, however, pale in comparison to the problems associated
with the instantaneous (catastrophic) failure of a shell with resulting loss
of the entire tank, the product stored, plus perhaps all surrounding
structures.

b.

Plate cracking is always of prime importance when inspecting tanks.

Cracks can result from a wide variety of causes. The more frequent
causes are:
i.
ii
iii.
iv.
v.

Faulty welding.
Unrelieved stress concentrations (i.e., stress raisers) around fittings
or appurtenances.
Stress caused by settlement or earth movement, especially
differential settlement
Vibration
Poorly designed repair or sloppy craftsmanship.

The most likely points of occurrence are:

i.
ii.
iii
iv.
v.
NOTE:

Shell to bottom junction.

Around nozzle and manway connections.
.Around rivet holes.
At welded brackets.
At welded seams.
The lower shell to bottom sketch plate is especially critical in
relatively larger or hot tanks. It can act as a plastic hinge with the
potential for cracking. See API 650 (Appendix M).

c.

Many other kinds of mechanical deterioration can develop. In earthquake

areas, sloshing damage may occur to roofs. Shell buckling (directly above
bottom) can occur in tanks having relatively large height to diameter
ratios.

d.

Another form of mechanical deterioration is settlement. Frequent causes

are:
i.
ii.
iii.

Freezing/thawing of the ground.

Unusually high tides in tidal areas.
Slow lateral flowing of the soil.
AP I RP 575 S umma ry, 1998

P a ge 3-4

5.5

Failure of Auxiliary Equipment

a.

Frequent problem areas are associated with pressure/vacuum

conservation vents.

b.

Most common problems are:

i.
ii.
iii.
iv.
v.
vi.
vii.

Collection of gummy residue on pallets.

Moving parts, guide and seat corrosion.
Foreign deposits (by birds or insects).
Ice formation.
Tampering.
Adding extra weights to pallets (which changes release point of
vapor).
Lay-down of sand from abrasive blasting.

NOTE:
c.

Quite often, vents are the only safety relief device available
to prevent pressure or vacuum damage.

Other potential auxiliary problem areas:

i.
ii.
iii.

Malfunction of gauging system.

Floating roof drains.
Plugged drain sumps (debris or ice).
SECTION 6 - FREQUENCY OF INSPECTION

API Standard 653 provides requirements for inspection frequency, including factors to
consider in determining inspection frequency.
SECTION 7 - METHODS OF INSPECTION AND INSPECTION SCHEDULING
The first part of this section deals with safety aspects of entry. The next section is a
current list of tools commonly used in tank inspection and a suggested list of equipment
that might be needed in tank inspection.
7.2

External Inspection of In-Service Tank

See Appendix C, Table C-1 and C-2 of this RP.
7.2.3

Foundation Inspection
Refer to API Standard 653 for limitation.

7.2.4

Anchor Bolt Inspection

The condition of anchor bolts can usually be determined by visual
inspection. The hammer and UT thickness methods are also described in
this section.
AP I RP 575 S umma ry, 1998

P a ge 3-5

7.2.6

Grounding Connection Inspection

The total resistance from tank to earth should not exceed approximately
25 ohms.

7.2.8

Insulation Inspection
Under insulation corrosion is now considered to be a more severe
problem than previously thought.
a.

A visual examination is usually, but not always, sufficient to spot

problem areas.

b.

Areas to be more closely checked include:

i.
ii.
iii.
iv.
v.

7.2.9.1

Around all nozzles and appurtenances, especially if the

caulking bond is loose or points for casual water entry is
evident.
Around saddles where movement or expansion may have
damaged insulation or seal.
Around open-bubbles on polyurethane foam systems.
Along bottom edge where moisture wicking may have
occurred.
Along roof to shell junction, unless this area is protected by
an overhand rat-guard type insulation support brackets
(where block insulation is used).
Thickness Measurements
Ultrasonic-thickness measurements should be conducted
only by trained personnel using a properly calibrated
thickness measurement instrument and an appropriate
thickness measurement procedure.

7.2.9.3

Caustic Cracking
If caustic or amine is stored in a tank, the tank should be
checked for evidence of damage from caustic stress
corrosion cracking, sometimes referred to as caustic
embrittlement.

7.4.4

Tank Bottoms
This section suggests inspection of the entire tank bottom by using
Magnetic Flux Leakage, looking for bottom side corrosion. Other UT type
techniques may also be used. A-scan or shear wave ultrasonic testing
may be used under specific conditions. Hammer-testing is also mentioned
as a testing technique.

AP I RP 575 S umma ry, 1998

P a ge 3-6

7.4.6

Testing for Leaks

The usual types of tests are mentioned, hydrostatic tests, vacuum box
tests, external water bottom tests and tracer gas tests. Another method
being used successfully is the injection of inert gas with a tracer gas under
the tank. Instruments capable of detecting a few parts per million (PPM)
of the tracer gas are then used for sniffing for leaks on the topside of
the tank floor. An advantage of such a method is that welded repairs can
be made immediately with the inert gas under the bottom and a re-check
can be made immediately after repairs.

7.5

Testing of Tanks
The word testing, as used in this subsection, applies only to the process of filling
the tank with a liquid or gaseous fluid, at the appropriate level or pressure,
test the tank for strength or leaks.

7.6

Inspection Scheduling
The two main aspects to consider when inspecting a tank:
a.
b.

the rate at which deterioration is proceeding; and

the safe limit of deterioration.

The following may be used for most common forms of deterioration, metal
corrosion, the rate of metal loss and the remaining life of a tank component.
t actual - t minimum
corrosion rate

Remaining life =
Where:

Remaining life = the remaining life of a tank component, in years

t actual =

the thickness measured at the time of the inspection for a given

location or component used to determine the minimum allowable
thickness, in inches.

t minimum = the minimum allowable thickness for a given location or

component, in inches.
Corrosion rate

t previous -= t actual
in years between
t actual and t previous

t previous =- thickness at the same location as t actual measured during a

previous inspection, in inches.

AP I RP 575 S umma ry, 1998

P a ge 3-7

7.7

Inspection Checklists
Inspection checklists should be used judiciously by the inspector as memory
joggers for issues and items to be checked during inspection, both internal and
external.

AP I RP 575 S umma ry, 1998

P a ge 3-8

Section 4
API RP 651
Cathodic Protection Aboveground
Petroleum Storage Tanks

API-RP-651
CATHODIC PROTECTION OF ABOVEGROUND
PETROLEUM STORAGE TANKS
SECOND EDITION, DECEMBER 1997
SECTION 1 - GENERAL
1.1

Scope
Recommended practices covered by this presentation is to present procedures,
practices, information and guidance for achieving effective corrosion control on
above ground hydrocarbon storage tank bottoms. It contains provisions for the
application of cathodic protection to existing and new storage tanks.
Corrosion control methods based on chemical control of the environment and
the use of protective coatings are not covered in detail. Certain recommended
practices may also be applicable to tanks in other than hydrocarbon service. This
is intended to serve only as a guide. Specific cathodic protection design is not
provided. Every tank condition is not covered. Standardization is precluded
because of the varied conditions for field application.

2.0

Referenced Publications

3.0

Definitions
Definitions in this section reflect the common usage among practicing corrosion
control personnel. In many cases, in the interests of brevity and practicality, the
strict scientific definitions have been abbreviated or
paraphrased.
3.1

aboveground storage tank: A stationary container of greater than 500

barrel capacity, usually cylindrical in shape, consisting of a metallic roof,
shell, bottom, and support structure where more than 90 percent of the
tank volume is above surface grade.

3.2

anode: An electrode of an electrochemical cell at which oxidation

(corrosion) occurs. Antonym: cathode.

3.3

backfill: Material placed in a hole to fill the space around anodes,

vent pipe, and buried components of a cathodic protection system.
Anodes can be prepackaged with backfill material for ease of installation.

3.4

breakout piping: All piping associated with the transfer of products in

and out of storage tanks.

3.5

cathode: An electrode of an electrochemical cell at which a reduction

reaction occurs. Antonym: anode.
cathodic protection: A technique for preventing corrosion by making the

3.6

API 651 Summary, 1998

Page 4-1

entire surface of the metal to be protected act as the cathode of an

electrochemical cell.
3.7

coke breeze: A carbonaceous backfill material.

3.8

continuity bond: A metallic connection that provides electrical continuity.

3.9

corrosion: The deterioration of a material, usually a metal, that results

from a reaction with its environment.

3.10

current density: The current per unit area flowing to or from a metallic
surface.

3.11

current requirement test: Creates direct current flow from a temporary

ground bed to the structure to be protected to determine the amount of
current necessary to protect that structure.

3.12

deep anode groundbed: One or more anodes installed vertically at a

nominal depth of 15m (50 ft) or more below the earths surface in a single
drilled hole for the purpose of supplying cathodic protection.

3.13

differential aeration cell: An electrochemical cell the electromotive force

of which is due to a difference in air (oxygen) concentration at one
electrode as compared with that at another electrode of the same material.

3.14

electrical isolation: The condition of being electrically separated from

other metallic structures and the environment.

3.15

electrical isolation cell: An electrical circuit where electrical current flows

from certain areas of a metal to other areas through a solution capable of
conducting electricity (electrolyte).

3.16

electrochemical cell: An electrochemical system consisting of an anode

and a cathode immersed in an electrolyte so as to create an electrical
circuit. The anode and cathode may be separate metals or dissimilar areas
on the same metal. The cell includes the external circuit which permits the
flow of electrons from the anode toward the cathode.

3.17

electrode potential: The potential of an electrode as measured against a

reference electrode. (The electrode potential does not include any
resistance losses in potential in either the electrolyte or the external circuit.
It represents the reversible work required to move a unit charge from the
electrode surface through the electrolyte to the reference electrode).

3.18

electrolyte: A chemical substance containing ions that migrate in an

electric field. For the purposes of this recommended practice, electrolyte
refers to the soil or liquid adjacent to and in contact with the bottom of an
aboveground petroleum storage tank, including the moisture and other
chemicals contained therein.

3.19

environmental cracking: The brittle fracture of a normally ductile

API 651 Summary, 1998

Page 4-2

material in which the corrosive effect of the environment is a causative

factor.
3.20

external circuit: Consist of the wires, connectors, measuring devices,

current sources, etc., that are used to bring about or measure the desired
electrical conditions within an electrochemical cell. It is this portion of the
cell through which electrons travel.

3.21

foreign structure: Any metallic structure that is not an intended part of

the system in question.

3.22

galvanic anode: A metal that, because of its relative position in the

galvanic series, provides sacrificial protection to another metal that is
more noble, when coupled in an electrolyte. These anodes are the source
of current in one type of cathodic protection.

3.23

galvanic series: A list of metals and alloys arranged according to their

relative potentials in a given environment.

3.24

groundbed: Consists of one or more anodes installed below the earths

surface for the purpose of supplying cathodic protection.

3.25

holiday: A discontinuity in a protective coating that exposes unprotected

surface to the environment.

3.26

impressed current: An electric current supplied by a device employing a

power source that is external to the electrode system. (An example is
direct current for cathodic protection).

3.27

insulating coating system: All components of the protective coating, the

sum of which provides effective electrical insulation of the coated
structure.

3.28

interference bond: A metallic connection designed to control electrical

current interchange between metallic systems.

3.29

IR drop: The voltage generated across a resistance by an electrical

current in accordance with Ohm's Law: E=I X R. For the purpose of this
recommended practice, IR drop is the portion of a structure-to-soil
potential caused by a high resistance electrolyte between the structure and
the reference electrode or by current flow from the anodes to the tank
bottom.

3.30

isolation: Electrical isolation.

3.31

liner: A system or device, such as a membrane, installed beneath a

storage tank in or on the tank dike, to contain any accidentally escaped
product.

3.32

membrane: A thin, continuous sheet of non conductive synthetic material

API 651 Summary, 1998

Page 4-3

used to contain and/or separate two different environments.

3.33

oxidation: The loss of electrons by a constituent of chemical reaction.

3.34

polarization: The change from the open circuit potential of an electrode

resulting from the passage of current. (In this recommended practice, it is
considered to be the change of potential of a metal surface resulting from
the passage of current directly to or from an electrode).

3.35

rectifier: A device for converting alternating current to direct current.

Usually includes a step-down AC transformer, a silicon or selenium stack
(rectifying elements) , meters and other accessories when used for
cathodic protection purposes.

3.36

reduction: The gain of electrons by a constituent of a chemical reaction.

3.37

reference electrode: A device whose open circuit potential is constant

under similar conditions of measurement.

3.38

resistor: A device used within an electrical circuit to control current flow.

3.39

sacrificial anode: Another name commonly used for a galvanic anode.

3.40

sacrificial protection: The reduction or prevention of corrosion of a

metal in an electrolyte by galvanically coupling it to a more anodic metal.

3.41

secondary containment: A device or system used to control the accidental

escape of a stored product so it may be properly recovered or removed
from the environment. For the purposes of the recommended practice,
secondary containment refers to an impermeable membrane.

3.42

shallow anode groundbed: A group of cathodic protection anodes

installed individually, spaced uniformly, and typically buried less than 20
feet below grade.

3.43

shunt: A conductor of a known electrical resistance through which

current flow may be determined by measurement of the voltage across
the conductor.

3.44

stationary: Something that is permanently installed on the ground or on

a foundation.

3.45

stray current: Current flowing through paths other than the intended
circuit.

3.46

stray current corrosion: Corrosion resulting from direct current flow

through paths other than the intended circuit.

3.47

stress corrosion cracking: The fracture of a metal by the combined action

API 651 Summary, 1998

Page 4-4

of corrosion and tensile stress that may be well below the tensile strength
or even the yield strength of the material.
3.48

structure-to-electrolyte voltage (also structure-to-soil potential or pipeto-soil potential): The voltage difference between a metallic structure and
the electrolyte which is measured with a reference electrode in contact
with the electrolyte.

3.49

structure-to-structure voltage (also structure-to-structure potential): The

difference in voltage between a metallic structures in a common
electrolyte.

3.50

tank cushion: The material immediately adjacent to the exterior steel

bottom of an aboveground storage tank.

3.51

tank pad: Another name for a tank cushion.

3.52

test lead: An electrically conductive cable attached to a structure and

leading to a convenient location. It is used for the measurement of
structure-to-electrolyte potentials and other measurements.

3.53

test station: A small enclosed box-like housing and the usual termination
point of one or more test leads.

3.54

voltage: Refers to an electromotive force, or a difference in electrode

potentials expressed in volts. Also known as a potential.

3.55

water bottom: A water layer in the bottom of a tank caused by

separation of water and product due to differences in solubility and
specific gravity.

SECTION 4- CORROSION OF ABOVEGROUND

API 651 Summary, 1998

Page 4-5

STEEL STORAGE TANKS

4.1.1

Corrosion may be defined as the deterioration of a metal due to a reaction

to its environment. Corrosion of steel structures is an electrochemical
process. The corrosion process occurs when:
a.
b.
c.

Areas with different electrical potentials exist on the metal surface.

These areas must be electrically connected.
Areas must be in contact with an electrolyte. Moist soil is the most
common electrolyte for external surfaces of the tank bottom.
Water and sludge are, generally, the electrolytes for internal
surfaces.
NOTE:

There are four (4) components in each corrosion cell:

1.
2.
3.
4.

4.1.2

An anode
A Cathode
A metallic path connecting the anode and
cathode. (See Fig. 1)
An electrolyte

Many forms of corrosion exist. The two (2) most common (relative to
tank bottoms) are general and pitting corrosion.
a.
b.

General type: Thousands of microscopic corrosion cells occur on an

area of the metal surface resulting in relatively uniform metal loss.
Pitting type: Individual cells are larger and distinct anode and
cathode areas can be identified.
NOTE:

Corrosion occurs at the Anode. Metal loss may be

concentrated within relatively small areas with
substantial surface areas unaffected.

4.1.3 through 4.1.5

Conditions that influence which areas of a surface become anodic or
cathodic and/or corrosion cells are:
a.
b.
c.
d.
e.
f.
g.

4.2

Composition of the metal.

Differences in electrochemical potential (i.e., uneven distribution of
alloying elements or contaminates within the metal structure).
Differences between the weld bead, the heat affected zone and the
parent metal.
Physical and chemical properties of the electrolyte.
Differences in oxygen concentrations.
Soil characteristics (i.e., dissolved salts, moisture content, pH, etc.).
Clay, wood or other debris in bottom contact.

Corrosion Mechanisms
API 651 Summary, 1998

Page 4-6

4.2.1

Stray current corrosion occurs when stray currents (also known as

interference currents) travel through the soil electrolyte and on to
structures for which they are not intended.
NOTE:

The most common, and potentially more damaging,

stray currents are direct currents (i.e., grounded DC
electric power systems) such as electric railroads, subways,
welding machines, impressed current cathodic protection
systems and thermoelectric generators.

The severity of corrosion resulting from interference currents depend on

the following:
a.
b.
c.
d.
4.2.2

Separation and routing of the interfering and affected structures

and the location of the interfering current source.
Magnitude and density of the current.
Quality of or absence of a coating on the affected structure.
Presence and location of mechanical joints having high electrical
resistance.

Bimetallic Corrosion occurs when two (2) metals with different

compositions (thus different electrolytic potentials) are connected in an
electrolyte (usually soil). (See Fig. 4).
NOTE:

4.2.3

Current flows from the more active metal (anode) to the less
active metal (cathode) with resulting accelerated attack at the
anode. Examples: Bronze check valve to steel piping.
Stainless Steel or Copper pipe to steel tank.

Internal Corrosion may occur on the inside surface of a tank bottom.

Factors influencing severity are:
a.
b.
c.
d.

Conductivity (2 function of dissolved solids).

Suspended solids
pH level
Dissolved gases such as CO2, H2S or O2.

SECTION 5 - DETERMINATION OF NEED FOR CATHODIC PROTECTION

API 651 Summary, 1998

Page 4-7

5.1.4

Limitations
Cathodic protection is an effective means of corrosion control only if it is
possible to pass electrical current between the anode and cathode (i.e.,
tank bottom). Many factors can either reduce or eliminate the flow of
electrical current, reducing protection effectiveness. Such factors include:
a.
b.
c.
d.

Foundations such as concrete, asphalt or oiled sand.

An impervious lining between the tank bottom and anodes such as
in secondary containment systems.
High resistance soil or rock foundations.
Old storage tank bottoms left in place when a new bottom is
installed.

SECTION 6 - METHODS OF CATHODIC PROTECTION FOR CORROSION

CONTROL
6.1

Introduction
Cathodic protection is a technique for preventing corrosion by making the entire
surface of the metal act as the cathode of an electrochemical cell. The two (2)
methods of protection are:
a.
b.

6.2

Sacrificial anode
Impressed current.

Galvanic Systems
6.2.1

Use of a metal more active than the structure to be protected to supply

the current required to stop corrosion. See Table 3 (Page 10 code) for a
partial galvanic series. The more active metal is called a sacrificial anode.
Example: The anode is electrically connected to the structure and buried
in the soil. A galvanic corrosion cell develops and the active metal anode
corrodes (is sacrificed) while the metal structure (cathode) is protected.
NOTE:

Metals commonly used as sacrificial anodes in soil are

magnesium and zinc (in either cast or ribbon form). Usually
distributed around the perimeter of the tank or buried
beneath the bottom.

6.2.2

Advantages of Galvanic Systems

6.2.3

a.
No external power supply is required.
b.
Installation is easy.
c.
Capital investment is low.
d.
Minimum maintenance costs.
e.
Interference problems (stray currents) are rare.
f.
Less frequent monitoring required.
Disadvantages of Galvanic Systems
API 651 Summary, 1998

Page 4-8

a.
b.
c.
d.
6.3

Driving potential is limited.

Current output is low.
Method is limited to use in low-resistivity soils.
Not practical for protection of large bare structures.

Impressed Current Systems

6.3.1

Uses DC usually provided by a rectifier (i.e., device for changing AC into

DC). DC flows from the rectified to the buried impressed current anode.

6.3.2

Advantages of Impressed Current Systems

a.
b.
c.
d.

6.3.3

Disadvantages of Impressed Current Systems

a.
b.
c.
d.
e.
f.
g.

6.3.4

Availability of large driving potential.

High current output for protecting large structures.
Capability of variable current output.
Applicable to almost any soil resistivity.

Interference problems (i.e., stray currents) on foreign structures.

Loss of AC power causes loss of protection.
Higher costs (maintenance and operating).
Higher capital costs.
Safety aspects of rectifier location.
Safety aspects of negative lead connections.
More frequent monitoring.

Rectifiers - Two (2) major components:

a.
b.

Step-down transformer (reduces AC supply voltage).

Rectifying elements to provide DC output.

NOTE:

6.3.5

Silicon rectifiers are more efficient, but are troubled by

power surges, (i.e., lightening prevention devices required).
Selenium rectifiers are used, but have decreased life span if
ambient temperature exceeds 130F.

Impressed Current Anode materials are graphite, steel, high silicon cast
iron or mixed metal oxides on titanium. Usually buried in a coke breeze
backfill (reduces circuit resistance), in remote groundbeds, distributed
around or under the tank or installed in deep groundbeds.

SECTION 7 - DESIGN OF CATHODIC PROTECTION SYSTEMS

API 651 Summary, 1998

Page 4-9

When dealing with your client/customer, be aware of certain conditions that may
influence your job assessment/evaluation. These items include:
7.2.1

Anything that acts as a barrier to the flow of current will prevent the
application of cathodic protection.

7.2.2

Tank bottom replacement has a significant impact on protection

effectiveness. If cathodic systems exist, or installation is planned for the
new bottom, the old bottom must be removed.
NOTE:

If the old bottom remains in place, even with cathodic

systems installed between the old and new bottoms, future
problems may occur. If a conductive electrolyte exists
between the bottoms, the current flow and metal loss will be
from the new bottom.

7.2.5.1

Secondary containment systems between bottoms (i.e.,

impermeable membranes) have both good and bad features
relative to cathodic protection.
7.2.5.1.1

Advantages
a.
b.
c.

7.2.5.1.2

Contains leaks and prevents ground

contamination.
Eliminates current flow between bottoms.
Prevents ground water wicking into sand pad.

Disadvantages
a.
b.
c.

Future addition of cathodic protection

impossible.
Membrane acts as a basin to contain
electrolyte.
With leak, traps hydrocarbon, becomes "hotwork" issue.

SECTION 8 - CRITERIA FOR CATHODIC PROTECTION:

API 651 Summary, 1998

Page 4-10

When has adequate protection been achieved and does it still exist?
8.2

Protection Criteria
Developed from lab experiments or from existing, successful systems.
Minimum requirements are listed below.
8.2.2.1 A negative (cathodic) potential of at least 850 mV with the cathodic
protection current applied.
8.2.2.2 A negative polarized potential of at least 850 mV relative to a CSE.
8.2.2.3 A minimum of 100 mV of cathodic polarization measured between
the tank bottom metallic surface and a stable reference electrode
contacting the electrolyte.

8.3

Measurement Techniques
8.3.1

The standard method of determining the effectiveness of cathodic

protection on a tank bottom is the tank-to soil potential measurement.
NOTE:

1.

2.

Measurement is performed using a high-impedance

(i.e., resistance) voltmeter and a stable, reproducible
reference electrode contacting the electrolyte.
(See Fig. 10)
Perimeter measurement may not represent potential
at the center of the tank bottom.

SECTION 9 - INSTALLATION OF CATHODIC PROTECTION SYSTEMS

(No specific notes)
SECTION 10 - INTERFERENCE CURRENTS
(No specific notes)

SECTION 11 - OPERATION AND MAINTENANCE OF CATHODIC PROTECTION

SYSTEMS
API 651 Summary, 1998

Page 4-11

11.1

Introduction
Coupled with operation and maintenance, Field inspection surveys (to determine
that cathodic protection has been established and that it is currently effective)
should be established. A few items that should be considered include:
a.
b.
c.

Conditions that affect protection are subject to change with time.

Changes may be required to maintain (or even establish) protection.
If tanks are empty, large areas of the bottom may not be in contact
with underlying soil. Potential surveys, may therefore, be misleading.

NOTE:
d.

Potential surveys should be made with sufficient product gauge so

as to maximize bottom-cushion contact.

Initial surveys (on new installation) should not be conducted until

after adequate polarization (i.e., a positive or negative condition) has
occurred. This is generally 6-18 months after system energized.

11.3.1 Surveys should include one or more of the following:

a.
b.
c.
d.
e.
f.
g.
h.
11.4

Structure-to-soil potential.
Anode current.
Native structure-to-soil potentials.
Structure-to-structure potential.
Piping to tank isolation (if protected separately).
Effect an adjacent structures.
Continuity of structures (if protected as single structure).
Rectifier DC volts, DC amps, efficiency and tap settings.

Cathodic Protection Records

Depending on need, circumstance and customer direction, the following
should be considered as permanent record needs:
a.
b.
c.
d.
e
f.
g.

Design and location of insulating devices.

Results of current requirement tests, where made and procedures
used.
What was native structure-to-soil potential before current was
applied.
Results of soil resistivity (resistance) test at the site, where made and
procedures used.
Type of system (i.e., sacrificial anode, impressed current, etc. ).
Repair of rectifiers, other DC power sources required.
Repair/renewal of anodes, connections or cable.

API 651 Summary, 1998

Page 4-12

Section 5
API RP 652
Lining of Aboveground Petroleum
Storage Tank Bottoms

API RP - 652
LINING OF ABOVEGROUND PETROLEUM STORAGE TANK BOTTOMS
SECOND EDITION, DECEMBER 1997
SECTION 1 - GENERAL
1.1

Scope
This recommended practice describes the procedures and practices for achieving
effective corrosion control in aboveground storage tanks by application of tank
bottom linings to existing and to new storage tanks.
This recommended practice also provides information and specific guidance for
tanks in hydrocarbon service. Some of the practices may also be applicable for
other services.
NOTES:
1.
2.
3.

This does not designate specific bottom linings for all situations
because of the wide variety of service environments.
This recommended practice is a guide only.
Detailed lining specifications are not included.

2.0

Referenced Publications

3.0

Definitions
3.1

aboveground storage tank: A stationary container, usually cylindrical in

shape, consisting of a metallic roof, shell, bottom and support structure
where more than 90% of the tank volume is above surface grade.

3.2

adduct: A curing agent, generally an amine, that has been combined with
a portion of the resin, usually an epoxy.

3.3

amine: An organic compound having amino functional groups which

provide chemical reactivity and utility as a curative for epoxy and other
resins.

3.4

anchor pattern: Surface profile or roughness.

3.5

anode: The electrode of an electrochemical cell at which oxidation

(corrosion) occurs. Electrons flow away from the anode in the external
circuit. Corrosion usually occurs and metal ions enter the solution at the
anode. * Antonym: cathode.

3.6

aromatics: Strong hydrocarbon solvents whose chemical structure has an

API RP-652 Summary, 1998

Page 5-1

unsaturated ring with delocalized pi electrons. Benzene, toluene and

xylene are common examples of aromatic solvents.
3.7

bisphenol-A polyester: A polyester whose chemical structure

incorporates Bisphenol-A into the resin molecule in place of some or all of
the glycol. The solid resin is generally provided a solution in styrene,
which acts as a solvent and as a cross-linking agent for the resin.

3.8

cathode: An electrode of an electrochemical cell as which a reduction

is the principle reaction. Electrons flow toward the cathode in the external
circuit. * Antonym: anode

3.9

cathodic protection: A technique for to reduce corrosion of a metal

surface by making that surface the cathode of an electrochemical cell.

3.10

coal tar: A black hydrocarbon residue remaining after coal is distilled.

3.11

coal tar epoxy: A coating in which the binder is a combination of coal

tar and epoxy resin.

3.12

copolymer: A large molecule whose chemical structure consists of at

least two (2) different monomers.

3.13

corrosion: The deterioration of a material, usually a metal, because of a

reaction with its environment.

3.14

curing: The setting up, or hardening, generally due to a polymerization

reaction between two (2) or more chemicals (resin and curative).

3.15

dew point: Pertains to the temperature at which moisture condenses

from the atmosphere.

3.16

differential aeration cell: An electrochemical cell , the electromotive

force of which is due to a difference in air (oxygen) concentration at one
electrode as compared with that at another electrode of the same material.

3.17

electrochemical cell: A system consisting of an anode and a cathode

immersed in an electrolyte so as to create an electrical circuit. The anode
and the cathode may be different metals or dissimilar areas on the same
metal surface.

3.18

electrolyte: A chemical substance containing ions that migrate in an

electric field.

3.19

epoxy: Resin containing epoxide (oxirane) functional groups that allow

for curing by polymerization with a variety of curatives. Epoxy resins are
usually made from Bisphenol-A and epichlorohydrin.

3.20

forced-curing: Acceleration of curing by increasing the temperature

above ambient, accompanied by forced air circulation.
holiday: A discontinuity in a coating film that exposes the metal surface

3.21

API RP-652 Summary, 1998

Page 5-2

to the environment.
3.22

isophthalic polyester: A resin polymerized from isophthalic acid (or

anhydride), ethylene or propylene glycol and malaic acid (or anhydride).
The solid resin is generally provided as a solution in styrene, which acts as
a solvent and as a cross-linking agent for the resin.

3.23

lining: A coating bonded to the internal surfaces of a tank to serve as a

barrier to corrosion by the contained fluids.

3.24

mil: One one-thousandth of an inch (0.001").

3.25

mill scale: An oxide layer formed on steel during hot forming

operations.
NOTE: Appearance: slick, smooth, shiny surface area.

3.26

phenolic: A resin of the phenol-formaldehyde type.

3.27

polyamide: A resin whose chemical structure contains adjacent carbonyl

and amino functional groups that is often used as a curative for epoxy
resins. Commercially available polyamides are reaction products of
dimerized and trimerized fatty acids and polyamines.

3.28

polyamidoamine: : A resin whose chemical structure contains adjacent

carbonyl and amino functional groups that is often used as a curative for
epoxy resins. Commercially available polyamides are reaction products
of dimerized and trimerized fatty acids and polyamines.

3.29

resin: A natural or synthetic substance that may be used as a binder in

coatings.

3.30

vinyl-ester: A polyester that usually contains Bisphenol-A in the resin

backbone and two vinyl groups for reactivity. The solid resin is generally
provided as a solution in styrene, which acts as a solvent and as a crosslinking agent for the resin.

3.31

vinyl group: A functional group on a resin molecule that contains a

carbon-to-carbon double bond at the end of the molecule.

SECTION 4 - CORROSION MECHANISMS

API RP-652 Summary, 1998

Page 5-3

4.1

General
The common mechanisms of internal storage tank bottom corrosion
include:
a.
b.
c.
d.
e.

Chemical corrosion
Concentration cell corrosion
Galvanic cell corrosion
Corrosion caused by sulfate-reducing bacteria
Erosion corrosion.

NOTES:

1.
2.

Example:

4.2

Water collection on tank bottoms may contain salt and

sediment that "settles out" on bottom plates. The chlorides
and other soluble salts may provide a strong electrolyte
which can promote corrosion.

Chemical Corrosion
a.

Normally seen in environmental and product clean-up tanks.

Concentrated acids, added to water (with heat) to break emulsion of oil
and water, becomes deluded. Diluted acid is much more corrosive than
stronger acids.
b.

4.3

Carbon steel corrosion rates in various hydrocarbon

services have been established. Refer to NACE 510700.
These apply only if there are no accelerating mechanisms
present.

Chemical attack also occurs in caustic, sulfuric acid, ballast water

and water neutralization services.

Concentration Cell Corrosion

Occurs in lower oxygen concentration areas (i.e., surface deposit, mill scale or
crevice).
NOTE:

4.4

Recognized as pitting or in a significant localized metal loss area.

Galvanic Cell Corrosion

Formation of a bi-metallic corrosion couple due to the presence of an electrolyte
(i.e., dissolved oxygen). The common locations for occurrence are:
a.
b.

Breaks in mill scale.

HAZ adjacent to welds

NOTE: Also noted by significant localized metal loss.

4.5

Corrosion Caused by Sulfate-Reducing Bacteria

API RP-652 Summary, 1998

Page 5-4

a.
b.
c.
4.6

Phenomenon recognized but not understood.

Usually negligible, occasionally service.
Thought to be associated with concentrated cell corrosion, due to deposits
forming a barrier to the diffusion of dissolvedoxygen.

Erosion Corrosion
Normally occurs in mixing tanks where soil particles or small aggregate are
present and movement occurs (i.e., waste water treating or mixing, adjacent to
mixers in crude tanks). The movement of aggregate causes abrasive attack.
Normally seen as "well defined" loss pattern.
SECTION 5 - DETERMINATION OF NEED for TANK BOTTOM LININGS

5.1

General
Tank bottoms normally fabricated from carbon steel plate sections typically 1/4"
(6 mm) thick. Annular floor plate rings may be thicker (up to 1/2" (12 mm).
Sketch plates (under shell) of 5/16" plate may often be found in older tanks. The
need for an internal tank bottom lining is generally based upon one or more of
the following:
a.
b.
c.
d.
e.
f.
g.

5.2

Corrosion prevention
Tank design
Tank history
Environmental considerations
Flexibility for service change
Upset conditions
Federal, State or local regulations.

Linings for Corrosion Prevention

Proper selection and application of bottom linings can prevent internal bottom
corrosion.
NOTE:

5.3

If the tank bottom measurements indicate that a "t" of 0.100"

exists, or will be present prior to the next schedule turnaround,
then a recommendation for applying a lining should be strongly
considered.

Design Considerations and Tank Internals

Design or fabrication details that would jeopardize the integrity, or limit the life
expectancy or effectiveness, may exist.
Example:

5.4

Steam coils limit accessibility for surface preparation. The resulting

thermal effects effect may cause localized failure by blistering or
cracking.
Tank History
API RP-652 Summary, 1998

Page 5-5

a.
b.
c.

Consider corrosion history when determining need for lining.

Consider history of other tanks in similar service.
Some important considerations are:
i.
ii.
iii.
iv.
v.

5.4.1

Where is corrosion problem occurring (product side, soil side, outer

periphery, etc.)?
How fast is corrosion proceeding?
Has there been a significant change in corrosion rate?
What type of corrosion is occurring?
Has through-bottom penetration occurred?

Tank Foundation
Inadequate foundation can cause tank settlement, bottom flexing may
occur, causing the internal lining to fail by cracking.

5.4.2

Methods of Construction
a.
b.
c.

Irregular surfaces (i.e., rivets, butt straps and skip welding) are
difficult to cover and protect with a lining.
Older tank lining application may be complicated by chemical
contaminates.
Column bases and roof leg support pads may present application
problems.

5.4.2.1

If a prior liner is present, and a portion is to be salvaged and

reused, the new liner application and material must be
compatible.

5.4.2.2

Previous Repairs: Prior mechanical repair/additions must

be considered. Such as, are there odd-shaped patches to
cover, support-angles to seal, no back-welded or hot-taps
that will require special crevice sealing solutions?

5.4.2.3

Prior Storage: Special cleaning techniques, or degree of

cleaning required must be considered when evaluating
which type of coating is most effective.
NOTE:

5.5

Most major material suppliers have data and

technical expertise that can be requested. The
data should be free, the technical help will add
to costs.

Environmental Considerations
Properly applied internal linings reduce the chance of external
environmental contamination. Cathodic protection also usually reduces
underside bottom loss.
5.5.1

Location
API RP-652 Summary, 1998

Page 5-6

When considering the need for an internal lining, always consider:

a.
b.
c.
d.
5.6

Flexibility for Service Change

a.
b.
c.

5.7

The potential for ground water contamination in hydrogeologically

sensitive areas.
Proximity to populated areas or public roads.
Proximity to rivers, lakes, parks or scenic areas.
Presence/location of containment dikes.

Changes in service may drastically affect the performance of existing

liners.
If "swing-service" is expected of the tank involved, then all potential
services and their compatibility with internal lining being considered must
be carefully and fully evaluated.
Remember: Tank linings do not offer universal resistance. Product makeup varies. Therefore, properties of the lining must vary. Again, technical
assistance from the liner supplier can be of great value.

Upset Conditions
Don't forget the impact involved. Consult customer as to potential for
occurrence.
SECTION 6 - TANK BOTTOM LINING SELECTION

6.1

General:
Tank bottom linings can generally be divided into two (2) classes:
a.
b.

Thin films (20 mils or less).

Thick films (greater than 20 mils).

NOTES:

1.
2.
3.

6.2

Linings are installed at tank erection or after some period of

service.
Generally, thin-film is applied when some minimal corrosion
has occurred.
Other liner discussion includes:

Thin-film types
Frequently based on epoxy or epoxy-copolymer resins. See Table 1 (Lining
Systems) for generic types and their suitability for various services.
NOTE:

6.2.1

All linings that are employed to protect tank bottoms must be

resistant to water.

Advantages - Disadvantages (Thin Film Type)

API RP-652 Summary, 1998

Page 5-7

a.

Advantages:
i.
ii.

b.

New plate provides a smooth surface that can easily be

made ready for coating application.
Lower cost (due to ease of application).

Disadvantage:
Corrosion creates a rough/pitted surface that is difficult to
completely coat and protect.

6.3

Thick-Film types
Commonly reinforced with glass flake, chopped glass fibers, glass mat, glass
cloth or organic fibers.
a.

Generic types and where used. (See Table 2)

NOTE:
b.

Specific notes relative to thick-film types:

i.
ii.
iii.
iv.
v.
vi

6.3.1

Additional data available in NACE Publication 6A187.

All applied over a white or near-white abrasive blast.

Primer frequently required.
Dependent upon thickness required - multiple coats needed.
Resin-rich topcoat required.
Polyesters require wax addition to ensure timely cure.
Check with manufacturer for specifics (chemical immersion,
elevated temperature tolerance, limitations in specific products,
etc.).

Advantages (thick-film types):

Advantages:
a.
b.
c.
d.

6.3.2

Less susceptible to mechanical damage.

Provides additional strength to bridge over small bottom
perforations.
Not as sensitive to pitting and other surface irregularities
during installation.
Less need for removal of sharp corners, edges, offsets and
weld spatter.

Disadvantages (thick-film types):

Disadvantages:

6.4

a.
Require more time and effort to apply.
b.
More expensive.
c.
Makes future inspections more difficult.
Design of Storage Tank Bottom Linings
API RP-652 Summary, 1998

Page 5-8

a.

Normal data or knowledge required:

i.
ii.
iii.
iv.
v.
vi.

b.

More specific data:

i.
ii.

6.5

Linings should extend 18-24 inches up the shell.

Transition area (from bottom horiz. to shell vert.), is a common
failure area. Proper support, especially with thick-films are critical
in this area.
With thin-film types, desired film thickness normally requires 2-3
coats.
Thick-films range from 1-4 coats.
New tanks, or where only internal loss has occurred may require
35-55 mils.
Older bottoms, corroded on both sides may require 80-120 mils
(usually reinforced).

"White" (SSPC-SP5/NACE #1) or a "near-white" (SSPCSP10/NACE #2) abrasive blast cleaner.

Anchor pattern (surface roughness) required is generally between
1.5 and 4 mils, depending on lining selection.

Exceptional Circumstances Affecting Selection

Be sure to take into consideration:
a.
b.
c.
d.

Corrosion history or corrosion potential

Elevated temperatures. Above 160F is critical.
Product purity. Thin-films may be sufficient.
Liner may contaminate product.

NOTE:

NACE Publ. TMO174 or Military Spec MIL-C-4556D may be of

assistance if manufacturer cannot furnish special data.

SECTION 7 - SURFACE PREPARATION

API RP-652 Summary, 1998

Page 5-9

7.1

General

b.

a.
Surface preparation is a critical part of lining operation. Surface
preparation is performed to provide the appropriate combination of
surface cleanliness/surface profile (anchor profile) required to establish
good chemical and mechanical adhesion of the coating resin to the
substrate (i.e., steel). Inadequate surface preparation is a major cause of
lining failure. However, a well prepared surface becomes meaningless if
all of the abrasive material (i.e., sand, etc.) is not removed prior to
primer/liner application. In such event, a lack of adhesion, future peeling
or disbonding failure can be expected.
Continuous immersion presents a sever exposure.

NOTE:
7.2

Precleaning
a.
b.

7.3.

SP5 #1 (white metal finish) or SP10 #2 (near-white) is

often specified as the minimum degree of surface cleanliness.

Before blasting, all contaminants (i.e., oil, tar, grease, salt, etc.) must be
removed.
Solvent cleaning (SSPC-SP1), high pressure water or steam cleaning
should be considered. Fresh water wash after solvent cleaning, may be
required to remove soluble salts and cleaning chemicals.

Bottom Repair - Weld Preparation

a.
Most common repair of perforations is welded steel patches.
Another repair method is to epoxy a 12 gauge steel plate over the bottom
perforation prior to thick-film (reinforced) linings being installed.
SAFETY NOTE:
b.

7.4

Weld repair may be disallowed if tank pad has been

contaminated with flammable materials.

Remove sharp edges, corners and protrusions. Chipping or power

grinding most common removal method.

Abrasive Blasting
Do Not Blast when steel temperature is less than 5F(3C) above the dew
point or if the relative humidity is greater than 80%. In particularly humid areas,
such as coastal regions, potential solutions might be selective timing, which may
influence work schedules, or perhaps the use of forced air injection.
NOTE:

7.5

Liner applications must be conducted when surface condition is

appropriate. Delay (between blast and application) will produce
poor results. When in doubt, restore surface preparation to the
necessary degree.

Surface Profile or Anchor Pattern

API RP-652 Summary, 1998

Page 5-10

a.
b.
c.
7.6

Match profile to accommodate selected liner.

Refer to material manufacturer's recommendation.
Typical anchor pattern is 1.5 to 4 mils. This generally increases with liner
thickness.

Types and Quality of Abrasives

SECTION 8 - LINING APPLICATION

8.1

General
a.
b.
c.
d.

8.2

Application Guidelines
a.
b.
c.
d.

8.4

SSPC-PA1 and NACE 6F164 - Good painting practice.

Establish and adhere to proper mixing practices.
If conflicts arise (between owner/user; liner applicator or material
manufacturer) over any aspect of the job, resolve them prior to beginning
the project.
Consider restraints imposed by steel temperature and relative humidity.

Lining Thickness
a.
b.

8.5

Avoid disbonding or delamination by following manufacturer's

recommendations.
Stick to time interval (between coats) recommended by owner's
specifications or manufacturer.
SSPC-PA1 is a dependable procedure to follow.
Establish and adhere to recommended drying (curing) period. Customers
often get impatient.

Insufficient film thickness will not provide adequate coverage or

protection.
Excessive thickness can compromise adhesion and integrity. Thicker is
not always better.

Lining Curing
a.

Lining failure is attributed to:

i.
ii.
iii.

NOTE:
b.

Improper preparation.
Improper application.
Inadequate curing.
Adhesion and film integrity depend upon above listed items.

Proper curing conditions may be aided by force-curing (i.e., circulating

warmed, dehumidified air).
Notes
API RP-652 Summary, 1998

Page 5-11

API RP 652
(Reinforced Glass-epoxy Internal Lining 65 Mils Thick)
Clean and repair the tank bottom (install lap weld steel plate patches 3/16" or 1/4" and
weld build-up).
Abrasive blast per API 652 specifications, remove all residue (air blow, broom sweep
and vacuum) remove all moisture.
Hand trowel epoxy in the corner area and radius all transitions, and around patch
plates.
Consult a "Technical Representative" for the product being installed, include a job site
visit.
If the following conditions are correct:
Proper blast profile
Proper material mixture
Application equipment properly functioning
Material specifications correct
Proper thickness applied
Proper curing procedure followed
Weather restraints are observed
The lining will be satisfactory and last 10 - 20 years.
SECTION 9 - INSPECTION
Items 7.1 (General) through 7.3.2.4 (Discontinuities) list some qualifications, parameters
and procedures to assist or guide in the area of Inspection. Without going into detail or
explanation, some or all of the following should provide guidelines or assistance.
9.2

Personnel NACE certified

9.3

Recommended Inspection Parameters

Refer to NACE RP-02-88
9.3.1.2

Cleanliness and Profile: Refer to SSPC-VIS1 (reference

photos) and NACE TMO175 (sealed steel reference panels
NACE RPO287 provides a method of measuring surface
profile.

9.3.1.3

Film thickness
API RP-652 Summary, 1998

Page 5-12

a.
b.
9.3.1.4

Hardness: As applicable, refer to the following procedures:

a.
b.
c.
d.

9.3.1.5

Soon after application, wet film "t" measurement

should be made. Refer to ASTM D4414.
After curing, dry film "t". Refer to SSPC PA2.

ASTM D 2583
ASTM D 2240
ASTM D 3363
Solvent wipe test

Discontinuities
a.
b.

Linings exceeding 20 mils "t" shall be holiday tested

with a high voltage detector (see NACE RPO188).
Linings less than 20 mils should be tested with a low
voltage (67.5 volts) wet sponge detector.

SECTION 10 - REPAIR OF TANK BOTTOM LININGS

10.1

General
a.
b.

10.2

Properly selected/applied liners should provide a service life of 10-20

years.
Any bottom mechanical repair should be complete prior to any liner
installation or repair.

Determine Cause of Failure

Before deciding how to make a lining failure repair, the cause or extent should be
established by visual inspection and a review of the operating history. Attempt
to determine if:
a.
b.
c.

10.3

Failure was due to mechanical damage.

Environmental attack was responsible.
Improperly installed.

Types of Repair
a.
b.
c.

Spot repairs for localized failure (blisters, pinholes or mechanical damage)

Topcoating for more extensive failure but where adhesion and integrity is
still good. Make sure topcoat is compatible with existing liner.
Complete replacement when existing liner is beyond repair.

SECTION 11 - SAFETY
API RP-652 Summary, 1998

Page 5-13

11.2

Tank Entry
Permits for tank entry and hot work should be issued and enforced.
Follow guidelines for issuing permits and preparing a tank or confined space for
entry, as detailed in API Publication 2015.

11.3

Surface Preparation and Lining Application

Use respiratory equipment and protective clothing as found in:
a.
b.
c.
d.
e.

11.4

OSHA Standard for Abrasive Blasting.

SSPC PA 3.
NACE 6D163.
Any relevant federal or state regulation.
As required on tank entry permit.

Manufacturer's Material Safety Data Sheets

a.
b.
c.

Indicates the "chemical make-up" that can present health hazards to

personnel.
MSDS inform about materials so that they can protect themselves and
how to respond properly to emergency situations.
Purpose of MSDS is to inform personnel of:
i.
ii.
iii.
iv.
v.

A Material's physical properties which make it hazardous to

handle.
The type of personal protective equipment needed.
First aid treatment necessary ( if exposed).
Safe handling under normal conditions and during emergencies
such as fires and spills.
Appropriate response to accidents.

API RP-652 Summary, 1998

Page 5-14

API-652 (LINING TANK BOTTOMS)

"QUIZ"
1.

Which of the following pertains to or establishes the "dew point"?

a.
b.
c.
d.

2.

Difference (in F) between the relative humidity value and the

internal tank air temperature.
Difference (in F) between the internal tank air temperature and
the substrate (steel) temperature
The temperature at which moisture condenses from the
atmosphere.
The moisture content value at which adhesion between the liner
and the substrate cannot be achieved.

Indicate the most correct definition for "a holiday".

a.
b.
c.

A lamination that develops between coating layers.

A discontinuity in a coating film that exposes the metal surface
to the environment.
Any thin liner area where an additional film "t" layer is required.

3.

,
are common examples of aromatic solvents.

4.

A
during hot forming operations.

5.

There are five (5) common mechanisms normally associated with internal
tank bottom corrosion. List any three (3) of the five (5) causes below.

and

is an oxide layer formed on steel

a.
b.
c.
6.

Match the following SSPC surface preparation to the metal finish

specification, as specified in Section 5. Draw Arrow to Connect.
White Metal Finish
Near-White Metal Finish

SSPC-SP5 NACE #1
SSPC-SP10 NACE #2

API RP-652 Summary, 1998

Page 5-15

7.

Select the general rule normally followed relative to liner application vs.
temperature and humidity restrictions.
a.
b.
c.
d.

8.

5F (3C) above dew point, with relative humidity below 80%

10F (5.5C) above dew point, with relative humidity below 80%
Stop application when visually, adhesion and bonding is not
being achieved.
Any substrate temperature when moisture is visible.

What is the typical range required on anchor pattern (i.e., depth profile)
prior to liner installation.
Answer:

9.

is a natural or synthetic substance that may be

used as a binder in coatings.

10.

When considering the need for an internal lining, make selections from
below as some of the more important.
A.

B.
C.
D.

a.
Where is corrosion occurring?
b.
How fast is it proceeding.
c.
Have there been significant corrosion rates changes.
d.
What type of corrosion is occurring.
e.
Have bottom perforations occurred.
Sub-items "b", "c" and "d" only.
All of the above.
Primarily cost and out-of service time frame involved.

API RP-652 Summary, 1998

Page 5-16

API 652 CODE QUIZ

ANSWER KEY
1.

"c" (Temperature at which moisture condenses from atmosphere.

2.

"b" (Discontinuity exposing surface to environment).

3.

Benzene, Toluene and Xylene.

4.

Mill Scale

5.

Any of the following:

Chemical Corrosion
Concentration cell corrosion
Galvanic Cell Corrosion
Erosion Corrosion
Corrosion caused by sulfate-reducing bacteria.

6.

White --------- SP5 #1

Near-White ---- SP10 #2

7.

"a" (5F above dew point with relative humidity below 80%).

8.

1.5 to 4 mils

9.

Resin

10.

A - All 5 considerations.

API RP-652 Summary, 1998

Page 5-17

Section 6
API Publication 2207
Preparing Tank Bottoms for Hot Work

API PUBLICATION 2207

PREPARING TANK BOTTOMS FOR HOT WORK
FIFTH EDITION - SEPTEMBER 1998
PREFACE
This publication outlines safety precautions for preventing accidental fires and
explosions when hot work is performed on tank bottoms.
SECTION 1 - GENERAL
1.1

Introduction and Scope

a.
b.
c.

The term hot work, as used here, is defined as an operation that can
produce a spark or flame hot enough to ignite flammable vapors.
Tanks that have contained flammable or combustible liquids, regardless of
age or type, must be considered unsafe for hot work until safety
inspections prove otherwise.
A primary consideration is that the oxygen content must be between
19.5% and 22.5%.
SECTION 3 - PRECAUTIONS

3.1

General Precautions
3.1.1

The tank must be isolated, cleaned, ventilated and tested for toxic and
flammable vapors, plus oxygen deficiency.
NOTE:

Test in accordance with applicable national, state and local

regulations, plus recognized industry practices (i.e., OSHA
Part 1910 and API Publications 2015 and 2217.

3.1.2 and 3.1.3

The following is required prior to hot-work:
a.
b.
c.
d.
e.
3.2

Visual survey of area.

Trained, experienced person to authorize hot-work.
Precautions designated.
First aid and fire-fighting equipment.
Personnel instructed in use of equipment.

Specific Precautions
3.2.1

Permits (i.e., job, entry, work): signed and issued.

3.2.2

Appropriate air mover in operation continuously.

AP I 2207 S umma ry, 1998

P a ge 6-1

3.2.3

Attached pipe systems disconnected, blanked off or isolated during all

entry or hot-work.

3.2.4

Leaded surfaces should be scraped down to bare metal or, alternatively,

supplied air respiratory equipment can be used. For surfaces that are to
be excessively heated, an area of at least 12" (30 centimeters) should be
scraped down to bare metal on all sides.
NOTE:

Scraping may be waived if frequent air-quality tests indicate

a safe atmosphere. This applies only to other personnel in
area. If not scraped, Welders must wear supplied air
respirators.

3.2.5

Grounding leads from welding machine should be attached directly to

bare tank shell surface. Also, welding leads to be checked for abrasions,
cuts, scuffs or breaks.

3.2.6

Cutting equipment
a.
b.
c.

3.2.7

Compressed-gas cylinders: Fastened in an upright position and

located outside the tank manhole.
Cutting torches/hose (when not in use): Closed-off at cylinder and
kept outside tank.
Gas supply hoses: Protected from outside damage and from
internal source of problems (i.e., burns, cuts or breaks).

Periodic Checks
All work areas must be monitored for oxygen deficiency or combustible
or toxic atmospheres.
SECTION 4 - INSPECTION PROCEDURES

4.1

General
When repairs are planned, tank bottom must be inspected, regardless of its
suspected condition.

4.2

Specific Procedures
a.
b.

Holes cold-cut or drilled (in hot-work area) to provide an underside inert

atmosphere and should be monitored. Apply coolant when installing
hole. Do not use an electric drill.
Oil-soaked insulation (ext. hot-work) should be removed. Determine type
so it can be handled properly.

AP I 2207 S umma ry, 1998

P a ge 6-2

SECTION 5 - SAFE WORK PROCEDURES

5.1

General
Safe work procedures should be written and approved by a competent, trained
or experienced person. The work procedures adopted will depend on:
a.
b.
c.

5.2

The tank bottom condition.

The type and extent of the hot work repairs.
The inspection results (at the bottom).

Minor Repairs
a.
b.

Usually consist of welding corrosion pits, installing patches or welding

supports or braces.
To establish a below bottom inert atmosphere:
i.
ii.
iii.
iv.
v.
vi.

5.3

Drill or tap a 1/2" pipe size hole in bottom.

Connect a supply of CO2 (or other inert gas) to the 1/2" nipple
with metal tubing. A pressure control valve with a flow indictor
should be used to prevent bottom overpressure.
Prior to hot work, establish a flow of inert gas under the bottom in
the vicinity of the hot-work.
Continuously monitor oxygen content.
When hot-work (local area) is complete, stop the inert gas flow.
Remove the nipple and plug the hole with a tapered pin or other
device and back weld promptly - Before moving to another area.

Major Repairs
When repairs involve most of the tank bottom, it may be desirable to displace
the flammable liquids beneath the tank by water flooding.
a.
b.
c.
d.
e.
f.
g.

5.4

Construct an earthen dike.

Drill or tap bottom vent holes. (and/or couplings).
Install vent pipe nipples.
Fill dike and allow for complete water coverage on underside.
Watch for bottom leaks. Plug-stop as necessary.
When repairs are complete, remove vents, plug and weld.
Break water dike.

Perimeter Repairs
a.
b.
c.
d.
e.
f.
g.

Excavate under the tank for a minimum of 12" beyond the hot-work area.
Monitor for oxygen content.
Seal-off between bottom plate and foundation by mud-packing or other
non-corrosive material.
Check for explosive or toxic vapor in excavation.
Monitor for airborne concentrations of chemical contaminants.
As necessary, ventilate with a portable air blower.
Back-fill and compact excavation to prevent future damage to foundation.
AP I 2207 S umma ry, 1998

P a ge 6-3

5.5

Double Bottoms
Install 4" (10 centimeters) of sand or other sealing material over the
existing bottom.
Install new bottom by welding.
NOTE: This is a poor practice

5.6

Sectional Repairs
When sectional repairs are made on tank bottoms, the following methods may
be used:
a.
b.
c.
d.

Cold-cut segment to be replaced. Remember, a coolant should be applied

continuously to the cutting edge of the tool to reduce the heat of friction.
Remove the sand from the area of replacement and refill with tamped
sand. Seal the perimeter area.
Monitor for oxygen deficiency and combustible or toxic atmospheres.
Larger areas should be inert gas blanketed while patch is being installed.

AP I 2207 S umma ry, 1998

P a ge 6-4

API - PUBL. 2207

"QUIZ"
1.

Of the following, which is the correct range of oxygen content necessary for
entry into confined spaces (without special breathing equipment)?
a.
b.
c.
d.

2.

As used in this Publication, which of the following best describes the term
"Hot Work"?
a.
b.
c.
d.

3.

18.0 to 20.0%
19.0 to 21.0%
19.5 to 22.5%
20.0 to 23.0%

Any external heat greater than 200F.

An operation producing a spark or flame hot enough to
ignite flammable vapors.
Weld arcs, air arcs or cutting torches only.
Any external or internal heat greater than 200F.

When scraping metal (with lead contamination) where excessive heating

will be applied, what is the minimum measurement (away from the heat area)
recommended?
a.
b.
c.
d.

12" on each side of heat line.

24" on each side of heat line.
24" diameter circle around outside edge of heat line.
Dependent on tested lead contamination value.

4.

While work is in progress (inside tank), all work areas must be monitored
for oxygen deficiency and ____________________.

5.

Which specific inert gas is suggested for injection under tank bottom
when hot-work is in progress?
a.
b.
c.
d.

Nitrogen
Oxygen
Helium
Carbon dioxide
AP I 2207 S umma ry, 1998

P a ge 6-5

API PUBL. 2207 QUIZ

ANSWER KEY
1.

"c" (19.5 to 22.5%)

2.

"b" (spark or flame that will ignite flammable vapors).

3.

"a" (12" on each side of heat line).

4.

Combustible and toxic atmospheres

5.

"d" (carbon dioxide) i.e., CO2.

AP I 2207 S umma ry, 1998

P a ge 6-6

Section 7
API 2015
Safety Entry & Cleaning Petroleum
Storage Tanks

API Standard 2015

Sixth Edition, August 2001
SAFE ENTRY AND CLEANING OF PETROLEUM STORAGE TANKS
This new Edition contains many changes and introduces API RP 2016, which was information
contained within API 2015
SECTION 1 - GENERAL
1.1

Scope and applicability

This standard is applicable to cleaning stationary atmospheric and low-pressure
(up to and including 15 psig) ASTs.

1.2

Non-applicability and other tank cleaning applications

The tanks that this standard does not apply is listed here.

1.3

ANSI/API Recommended Practice 2016

A large section of the Fifth Edition of API 2015 is now in this
Recommended Practice.

1.4

Regulatory Requirements
This standard is intended to be consistent with Title 29 of the U.S. Code of
Federal Regulations (Occupational Safety and Health Administration). Other
regulations, federal state local etc. may also apply and should be consulted.

1.5

Tank cleaning overview

This entire section outlines a method for thinking about, pre-cleaning,
cleaning and post cleaning plans.

SECTION 2 - REFERENCES

API 2015 Summary, 2003 Page 7-1

SECTION 3 - DEFINITIONS
Note: The student should read each definition and have a basic working knowledge of the
following.
3.2.2

attendant: A qualified employee stationed outside one or more permit required

confined spaces who monitors the entrants and who performs all attendant's
duties in accordance with the employer's (owner/operator and contractor)
permit required confined space program. Attendants may also perform the
duties of standby personnel when entrants use respiratory protective
equipment.

3.2.3

blanking: The absolute closure of a pipe or line by fastening a solid, flat plate
(designed to retain the pressure of the pipeline), between two flanges, using two
gaskets and fully engaged bolts or stud bolts in all flange bolt-holes. Blanks have
handles extending beyond the flange with a 1/4-inch (6.3 mm) minimum hole in
the handles (see ASME B31.3 for additional information).

3.2.4

blinding: The absolute closure of the open end of a pipe, line or pressure vessel
opening by fastening a solid, flat plate (designed to retain the pressure) across
the opening, using a gasket and fully engaged bolts or stud bolts in all flange
bolt-holes (see ASME B16.5 and B16.47 for additional information).

3.2.5

bonding: The joining of metal parts to form an electrically conductive path that
ensures electrical continuity and has the capacity to safely conduct any current
likely to be generated.

3.2.8

combustible liquid: A liquid having a closed cup flash point equal to or greater
than 100oF (38oC).

3.2.9

confined space: Any tank or space that meets all three of the following
requirements:
*Is large enough and so configured that an employee can bodily
enter and perform assigned work, and
*Has limited or restricted means for entry or exit (for example,
tanks and vessels, storage bins, hoppers, vaults, and pits are spaces
that may have limited means of entry or exit), and
*Is not designed for or meant to be continuously occupied by employees.

3.2.9.1 permit-required confined space: A confined space that has all three of the
confined space requirements and also has one or more of the following four
characteristics:
*Contains or has the potential to contain a hazardous atmosphere.
*Contains a material with the potential to engulf an entrant.
*Has an internal configuration such that an entrant could become
trapped or asphyxiated by inwardly converging walls or by floors
that slope downward, tapering to smaller cross-sections.
*Contains any other recognized serious safety or health hazard.
API 2015 Summary, 2003 Page 7-2

3.2.9.2 non-permit required confined space: A confined space (a space

that meets all three of the confined space requirements) but has been
checked, inspected and its atmosphere has been monitored and it does
not have (or does not have the potential to have) any of the characteristics
required to be classified as a permit required confined space.
3.2.9.3 non-confined space: A space (previously classified as a permit
required confined space or a non-permit required confined space) that
no longer meets any of the requirements for either a permit required
confined space or a non-permit required confined space.
Note: An example of a non-confined space is a tank that has
been cleaned, tested as gas and vapor free and has a large
opening (door sheet) cut into the side of the tank to provide
unrestricted access and egress.
3.2.11 double block and bleed: The positive closure of a line or pipe by
closing and locking or tagging two in-line valves and by opening and locking
or tagging a drain or vent valve in the line or pipe between the two closed
valves.
Note: Employers may evaluate and designate a single valve
that uses two sealing surfaces within a drain orifice between
them as satisfying double block and bleed requirements.
3.2.15 employer: An owner, operator, contractor, or subcontractor whose
respective employees are performing a task, or activity described in this
standard.
3.2.15.1

owner/operator: The company or person responsible

for the facility in which the tank to be cleaned is located.

3.2.15.2

contractor: A company or person selected and hired by

the owner/operator to conduct tank cleaning operations
and activities in accordance with the contract and tank
cleaning agreements. There may be more than one
contractor on a job at the same time.

3.2.15.3

sub-contractor: A company or person selected and hired

by a contractor to conduct specific tank cleaning related
operations and activities in accordance with sub-contract
agreements. There may be more than one sub-contractor
on a job at the same time.

API 2015 Summary, 2003 Page 7-3

3.2.21 entry supervisor: The qualified person (employee, foreman, supervisor, crew
chief, etc.) designated by the employer (owner/operator and contractor) to be
responsible for determining the requirements and whether or not acceptable
entry conditions exist at permit required confined spaces and non-permit
required confined spaces, where entry is contemplated. Entry supervisors shall
authorize entry, oversee entry operations and terminate entry as required by
the permit or conditions. An entry supervisor, who is properly qualified, trained
and equipped, may serve as an attendant or as an entrant. The duties of entry
supervisor may be passed from one entry supervisor to another entry
supervisor, during the course of an entry operation.
3.2.24 flammable liquid: A liquid having a closed cup flash point below 100oF (38oC).
3.2.32 hot work: Any work that has the potential to produce enough thermal energy
to provide an ignition source in an area where a potential exists for a flammable
gas or vapor-in-air atmosphere in the explosive (flammable) range to occur.
3.2.34 immediately dangerous to life or health (IDLH): Any condition that poses an
immediate or delayed threat to life or that would cause irreversible adverse
health effects or that would interfere with an entrant's ability to escape unaided
from a permit required confined space. For example, an oxygen deficient
atmosphere is considered IDLH> Some toxic materials, such as hydrogen
fluoride gas and cadmium vapor, may produce immediate transient effects that
even if severe, may pass without medical attention, but are followed by sudden,
possibly fatal collapse 12 to 72 hours after exposure. The exposed worker "feels
normal" from recovery from transient effects until collapse. Such materials in
hazardous quantities are considered to be "immediately" dangerous to life or
health (IDLH). Other toxic substances, such as hydrogen sulfide, immediately
desensitize a person so that continued exposure is not longer noticed. Certain
irritation effects may also impede the entrant's ability to escape permit required
confined spaces.
3.2.39 lockout/tagout: The condition when electrical, hydraulic and mechanical
switches are open in the de-energized position and locked out and/or
mechanical linkages are set, tagged and sealed or locked out to preclude the
input of product or energy into a permit required confined space, non-permit
confined space or non-confined space. Where required by regulation or
employer procedures, the system shall be tested to assure isolation.
3.2.40 material safety data sheet (MSDS): Written or printed material prepared in
accordance with applicable regulations and standards (for example, OSHA 29
CFR 1910.1200) concerning hazardous chemicals. MSDSs provide physical
properties, safety, fire prevention and protection, personal protection, and health
data.
3.2.50 product: The liquid petroleum hydrocarbon or other material stored in tanks.
3.2.52 pyrophoric iron sulfide: A material capable of rapid spontaneous ignition when
exposed to air.

API 2015 Summary, 2003 Page 7-4

3.2.54 qualified person: A person designated by an employer (owner/operator and

contractor) as having the necessary training, education and competence to
perform assigned tank cleaning and entry related tasks or activities in accordance
with the employer's (owner/operator and contractor) policy, procedures, and
programs.
3.2.70 worker: A qualified person working in or around a tank during tank cleaning.
A worker, working inside a tank, may or may not be an entrant depending on
the classification of the tank.

API 2015 Summary, 2003 Page 7-5

SECTION 4 - ADMINISTRATIVE CONTROLS AND PROCEDURES

4.1

General Requirements
The owner, operator, or contractor must develop written plans for all tank work.

4.3

Qualified Persons
Qualified persons are: testers, entry supervisors, hot and cold work permit
issuers, attendants, entrants, standby persons, workers and rescuers.

SECTION 5 - PREPARING THE TANK FOR ENTRY AND CLEANING

A general plan for cleaning the tank, including MSDS, special requirements,
decommissioning and returning the tank to service.

SECTION 6 - TESTING THE TANK ATMOSPHERE

The tank must be tested, by a qualified person, for oxygen levels, combustible gas, toxic
substance, and general atmosphere.

API 2015 Summary, 2003 Page 7-6

SECTION 7 - STORAGE TANK HAZARDS

7.1

General
"All" tanks present one or more of the following hazards during some
of tank entry and work:
a.
b.
c.
d.

7.2

phase

Fires and explosions.

Oxygen deficiency
Toxic liquids, vapors and dust.
Physical and other hazards.

Oxygen Deficiency
NOTES:

1.
2.

3.

Internal atmosphere may be stratified (i.e., layered).

Potential hazards:
i.
Fire and asphyxiation
ii.
Toxic substances.
"Sneaky" Oxygen deficiency is usually not noticed and
little or no warning is given. The effects are
compounding (i.e., loss of reasoning ability, followed
by unconsciousness.

7.3

Fire and Explosion Hazards

7.4

Toxic substances
a.
b.
c.

d.

Can cause injury, acute or delayed illness or death.

Toxicants can enter the body by inhalation, ingestion and skin
contact (including eyes).
Toxic substances occur in several forms:
i.
Irritants - minor, transient, but possibly painful. Many
hydrocarbons/polar solvents are irritants.
ii.
Corrosives - destroy tissue/leave permanent scars. These
include hydrofluoric acid, sulfuric acid, caustics.
iii.
Acutely toxic - single dose/short term exposure. The results
of exposure to these toxins i.e., hydrogen sulfide (H2 S) range
from headache or nausea to disablement or death.
iv.
Chronically toxic - physiological impairment with long
latency such as cancer, pulmonary obstruction or
reproduction.
Toxic substances which are likely to be found in entering and
clearing petroleum storage tanks are:
i.
H2 S
ii.
Leaded gasoline
iii.
Dusts
iv.
Petroleum substances
v.
Welding fumes
vi.
Various chemical hazards
API 2015 Summary, 2003 Page 7-7

SECTION 8 - HAZARD ASSESSMENT FOR ENTRY PERMITS

8.1

General
After testing for flammable vapors, oxygen content and toxic substances,
tank entry conditions will fall into one of the following categories:
permit required confined space
Non-permit required confined space
8.2.1.1 Permit Required Confined Space
1.
2.
3.
4.

Has potential to contain hazardous atmosphere.

Contains a material with the potential to engulf an entrant.
Physical hazards or asphyxiate hazards.
Any other safety or health hazard.

8.2.1.2 Non-Permit Required Confined Space

1. Large enough that entrants can enter and work.
2. Limited means for entry or exit.
3. Not designed to be continuously occupied by employees.
8.3

Entry into Tanks Classified as Permit Required Confined Spaces

The rules for permit requires spaced are listed in these paragraphs.

8.4

Entry into Tanks Classified as Non-Permit Required Confined Spaces

The rules for non-permit required spaces are listed in these paragraphs.

SECTION 9 - PERSONAL PROTECTIVE EQUIPMENT

This section covers:
a.
b.
c.
d.
e.
f.
g.
h.

Clothing
Shower facilities
Respiratory protection
OSHA Regulations
Breathing air
Air lines
Fit testing
Facepiece maintenance

API 2015 Summary, 2003 Page 7-8

SECTION 10 - TANK CLEANING PERSONNEL

This section covers:
a.
b.
c.
d.
e.
f.

Responsibilities
Requirements
Entry Supervisors
Entrants
Attendants
Qualified Persons

SECTION 11 - ENTERING AND WORKING INSIDE THE TANK

This section covers:
a.
b.
c.
d.

Entry permit
Ventilation
Vapor and Gas sources
Potential hazards

SECTION 12 - HOT WORK AND TANK REPAIRS

12.1

General
If hot work is involved, the flammable vapor concentration must not exceed ten
percent (10%) of the lower flammable limit.
NOTE:

Hot work is any work that produces enough heat to be a

potential ignition source (i.e., welding, burning, grinding,
drilling and abrasive blasting.

12.2

Hot Work Permits

12.3

Hot Work Hazards

12.4

Hot Work in Leaded Service Tanks

API 2015 Summary, 2003 Page 7-9

SECTION 13 - EMERGENCY PLANNING

No specific notes.

SECTION 14 - RECOMMISSIONING
No specific notes.

SECTION 15 - TRAINING
No specific notes.

API 2015 Summary, 2003 Page 7-10

Section 8
ASME Section V, Section VIII, Div. 1
Nondestructive Examination

API 653
Nondestructive Examination
API Paragraph 12.1.1.1
Nondestructive Examination procedures, qualifications and acceptance criteria
shall be prepared for visual, magnetic particle, liquid penetrant, ultrasonic, and
radiographic methods in accordance with API Standard 650 and the
supplemental requirements given herein.
API 653 Paragraph 12.1.1.2
Personnel performing nondestructive examinations shall be qualified in
accordance with API 650 and the supplemental requirements given herein.
API 653 Paragraph 12.1.1.3
Acceptance Criteria is based on API 650 and supplemental requirements of API
653.
API 653 Paragraph 12.1.1.5
New Appendix G is introduced. The requirements for MFL, procedures,
operator qualifications, training and equipment calibration is listed in this
appendix.
API 653 uses API 650 requirements for nondestructive testing procedures and
personnel certification.
The American Society for Nondestructive Testing, Inc. Recommended Practice SNT-TC1A is recognized for technician qualifications in some NDE techniques.
SNT-TC-1A is a document that outlines requirements for Personnel Qualification and
Certification in Nondestructive Testing, the main items listed are:
a.
b.
c.
d.

Work Experience
Training
Education
Testing

In order to qualify as an ASNT Level II, Radiographers must have:

a.
b.
c.
d.

12 Months Job Experience

79 Hours Formal Training
High School Graduation
Level II Exam, General, Specific and Practical

NDE Summary, 2005 Page 8-1

In order to qualify as an ASNT Level II, Ultrasonic Technicians must have:

a.
b.
c.
d.

12 Months Job Experience

80 Hours Formal Training
High School Graduation
Level II Exam, General, Specific and Practical
API 650 does not require MT or PT Technicians to be certified to
ASNT-SNT-TC-1A.

Nondestructive Examination
API 650
Magnetic Particle Method

MT Principles of Operation
Basically, an object or localized area is magnetized through the use of AC or DC
current. Once the area is magnetized lines of flux are formed, see above. Dry
iron powder, or iron powder held in suspension is added to the surface of the
test piece. Any interruption in the lines of flux will create an indication which can
be evaluated. The process may be used on any material that is ferromagnetic.
This method of NDE can be used in visible light or with special powders, under
black light. Surface discontinues are the most commonly detected indications
using this process.

NDE Summary, 2005 Page 8-2

API 653 requirements

API 653 directs the user to API 650 Paragraph 6.2.1 - 6.2.3
When magnetic particle examination is specified, the method of examination
shall be in accordance with the ASME Boiler and Pressure Vessel Code, Section V,
Nondestructive Examination, Article 7.
API 650 Paragraph 6.2.2
Magnetic particle examination shall be performed in accordance with a written
procedure that is certified by the manufacturer to be in compliance with the
applicable requirements of Section V, of the ASME Code.
API 650 Paragraph 6.2.3
No ASNT Certification Required, Manufacturer Determined
Magnetic Particle Method Acceptance Standards per API 650
API 650 Paragraph 6.2.4
Acceptance standards and removal and repair of defects shall be per Section VIII,
Appendix 6, Paragraphs 6-3 and 6-4, of the ASME Code.
ASME Section VIII, Appendix 6, Paragraph 6-3
Definition of indication. Must be larger than 1/16.
ASME Section VIII, Appendix 6, Paragraph 6-4
Acceptance Standards
All surfaces to be examined shall be free of:
a.
b.
c.

relevant linear indications;

relevant rounded indications greater than 3/16
four or more relevant rounded indications in line separated by
1/16 or less, edge to edge.

API 650 Paragraph 6.2.4

Acceptance standards and removal and repair of defects shall be per Section VIII,
Appendix 6, Paragraphs 6-3 and 6-4, of the ASME Code.
ASME Section VIII, Appendix 6, Paragraph 6-3
Definition of indication. Must be larger than 1/16.

NDE Summary, 2005 Page 8-3

ASME Section VIII, Appendix 6, Paragraph 6-4

Acceptance Standards
All surfaces to be examined shall be free of:
a.
b.
c.

relevant linear indications;

relevant rounded indications greater than 3/16
four or more relevant rounded indications in line separated by
1/16 or less, edge to edge.

Study Notes:

Page Number:

Standard/Code

Calibration requirements

_____________

________________

Yoke weight requirements,

both AC and DC

_____________

________________

General MT procedure
requirements

_____________

________________

Know where to find:

NDE Summary, 2005 Page 8-4

Nondestructive Examination
API 650
Liquid Penetrant Method

PT Principles of Operation
Penetrant testing is a family of testing that can be divided in to two major groups,
visible light and fluorescent or Black Light detectable groups. the basic steps of the
operation can be seen above. Step 1 the test piece must be cleaned. Step two the
penetrant is applied, a dwell time or soaking time waited. Step three the excess
penetrant is removed. Step four the developer applied. Step five the part is inspected,
any indication is evaluated. Step six the part is post cleaned.
This inspection technique relays on the penetrant being pulled in to all surface
irregularities by capillary action. When the developer is applied the penetrant is blotted
back to the surface making the irregularities visible. The irregularities are then
evaluated into three groups, false indications, commonly called handling marks, nonrelevant indications and defects. The defects are evaluated to a given standard for
acceptance.
This process will detect:

Surface defects only!

NDE Summary, 2005 Page 8-5

Nondestructive Examination
API 650
Liquid Penetrant Method
API 650 Paragraph 6.4.1
When liquid penetrant examination is specified, the method of examination shall
be in accordance with the ASME Boiler and Pressure Vessel Code, Section V,
"Nondestructive Examination, Article 6
API 650 Paragraph 6.4.2
Liquid Penetrant examination shall be performed in accordance with a written
procedure that is certified by the manufacturer to be in compliance with the
applicable requirements of Section V, of the ASME Code.
API 650 Paragraph 6.4.3
No ASNT Certification Required, Manufacturer Determined
API 650 Paragraph 6.4.4
Acceptance standards and removal and repair of defects shall be per Section VIII,
Division 1, Appendix 8, Paragraphs 8-3 , 8-4 and 8-5, of the ASME Code
ASME Section VIII Division 1
Liquid Penetrant Examination - Acceptability
Appendix 8 paragraph 8-3 Evaluation of Indications
An indication is the evidence of a mechanical imperfection. Only indications with
major dimensions greater than 1/16 in. shall be considered relevant.
a.
b.
c,

A linear indication is one having a length greater than three times

the width.
A rounded indication is one of circular or elliptical shape with the
length equal to or less than three times the width.
Any questionable or doubtful indications shall be reexamined to
determine whether or not they are relevant.

Appendix 8 paragraph 8-4 Acceptance Standards

All surfaces shall be free of :
a.
b.
c.

relevant linear indications

relevant rounded indications greater than 3/16
four or more relevant rounded indications separated by 1/16

Appendix 8 paragraph 8-5 Repair Requirements

NDE Summary, 2005 Page 8-6

Nondestructive Examination
API 650
Liquid Penetrant Method
Study Notes
Read ASME Section V, Article 6

Study Notes:

Page Number:

Standard/Code

Test temperatures

_____________

_______________

Surface temperatures

_____________

_______________

General PT procedure
requirements

_____________

_______________

Know where to find:

NDE Summary, 2005 Page 8-7

Nondestructive Examination
API 650
Ultrasonic Method
(Weld Quality)

API 650 Paragraph 6.3.1

Introduction of the new Appendix U. This appendix sets requirements for UT
inspection when performed in lieu of radiography.
API 650 Paragraph 6.3.2.2 (Ultrasonic requirements not in lieu of radiography)
When ultrasonic examination is specified, the method of examination shall be in
accordance with the ASME Boiler and Pressure Vessel Code, Section V,
"Nondestructive Examination," Article 5.
API 650 Paragraph 6.3.2.3
Ultrasonic examination shall be performed in accordance with a written
procedure that is certified by the manufacturer to be in compliance with the
applicable requirements of Section V, of the ASME Code.
API 650 Paragraph 6.3.2.4
Examiners performing ultrasonic examinations under this section shall be
qualified and certified by the manufacturers as meeting the requirements of
certification as generally outlined in Level II or Level III of ASNT Recommended
Practice SNT-TC-1A (including applicable supplements).

Note: "Acceptance standards shall be agreed upon by the purchaser and

the manufacturer." API 650 Paragraph 6.3.2.5
The API 653 Effectivity Sheet has listed ASME Section V, Article 23 (Section SE-797 only).
This section deals with Standard Practice for Measuring Thickness by Manual
Ultrasonic Pulse-Echo Contact Method. The section includes the general procedure
requirements for thickness readings.

NDE Summary, 2005 Page 8-8

Nondestructive Examination
API 650
Radiographic Examination

IQI

Shim
17

Weld

1 ASTM B

API 650 Paragraph 6.1.3.1

Except as modified in this section, the radiographic examination method
employed shall be in accordance with Section V, Nondestructive Examination,"
Article 2., of the ASME Code.
API 650 Paragraph 6.1.3.2
Personnel who perform and evaluate radiographic examinations according to
this section shall be qualified and certified by the manufacturers as meeting the
requirements of certification as generally outlined in Level II or Level III of ASNT
Recommended Practice SNT-TC-1A (including applicable supplements).
API 650 Paragraph 6.1.3.3
The requirements of T-285 in Section V, Article 2, of the ASME Code are to be
used only as a guide. Final acceptance of radiographs shall be based on whether
the prescribed penetrameter image and the specified hole can be seen.

NDE Summary, 2005 Page 8-9

Radiographic Examination
Acceptability
API 650 Paragraph 6.1.5
The acceptability of welds examined by radiography shall be judged by the
standards in Section VIII, Division I, Paragraph UW-51(b), of the ASME Code.
UW-51 Radiographic and Radioscopic Examination of Welded Joints
(b)
This section requires indications shown on the radiographs to be repaired.
The repairs may be radiographed or optionally, examined by ultrasonic
examination.
Indications that are unacceptable:
Any crack
Zone of incomplete fusion
Zone of incomplete penetration
Any other elongated indication which is longer than:
1/4 in for t up to 3/4 in
1/3 t for t from 3/4 in to 2 1/4 in
3/4 in for t over 2 1/4 in
UW-51 Radiographic and Radioscopic Examination of Welded Joints
(subparagraph 3)
Any group of aligned indications that have an aggregate length between the
successive imperfections exceeds 6L where L is the length of the longest
imperfection in the group.
Rounded indications in excess of that specified by the acceptance standards given
in Appendix 4.

NDE Summary, 2005 Page 8-10

Nondestructive Examination
API 650
Radiographic Examination Study Notes

Read ASME Section V, Article 2

Study Notes:

Page Number:

Standard/Code

Backscatter acceptability

_____________

________________

Geometric Unsharpness

_____________

________________

IQI information

_____________

________________

Density

_____________

________________

Location Markers

_____________

________________

General RT procedure
requirements

_____________

________________

Know where to find:

NDE Summary, 2005 Page 8-11

Section 9
ASME Section IX
Procedures & Qualifications

API 653
ASME Section IX
API 653 - Section 11 - Welding
11.1.1 Welding procedure specifications (WPS) and welders and welding
operators shall be qualified in accordance with Section IX of the ASME
Code. This includes welding procedure qualification records (PQR).
ASME Section IX is a document that outlines the requirements for welding
procedures and welder qualifications. Other organizations that have the
requirements for procedures are AWS (American Welding Society) and API
(American Petroleum Institute) (API 1104). While both organizations have excellent
rules, the only origination required by API 653 is ASME Section IX.
A welding procedure shows compatibility of:
a.
b.
c.
d.

Base metals
Filler metals
Processes
Technique

The general approaches to procedure qualification is usually in one of two forms:

a.

Prequalified procedures:
These are AWS welding procedures used only for structural welding
and do not require testing. The user is limited to specific weld joints
and specific weld processes (see AWS D 1.1).

b.

Procedure qualification testing:

These are API and ASME requirements. Both require actual welding to
be performed and destructively tested.

ASME procedure qualification testing uses a listing of essential variables in the

creation of weld procedures. Essential variables are those in which a change is
considered to affect the mechanical properties of the weldment, and shall require
requalification of the WPS, ASME IX Paragraph QW - 251.2.
Under ASME rules the welding procedure begins with the creation of the WPS. This
information is taken from ASME IX and outlines the ranges of materials, electrodes
and other general aspects. Then the PQR is created, performed and tested and used
as proof for the WPS. The WPS can have many supporting PQRs.

Locations of weld specimens from plate procedure qualification.

ASME IX Summary, 2003 Page 9-1

Locations of weld specimens from pipe procedure qualification.

ASME IX Summary, 2003 Page 9-2

ASME IX Summary, 2003 Page 9-3

Weld procedure specimens, guided bends are also used for welder qualification
tests.

Square

Tensile Specimens

Round

Guided Bends
Face

Root

Side

ASME IX Summary, 2003 Page 9-4

The tests commonly required by ASME Section IX are:

a.
b.

Tensile
Bends
1.
2.
3.

Face
Root
Side

Table QW -451 is the Procedure qualification thickness limits and test specimens
requirements. Each groove weld must pass tension tests and transverse bend tests.
This table is where the requirements for testing are listed..
After the procedure qualification testing the Welding Inspector must check
production welding to ensure welds are being made in compliance with the
approved and tested weld procedure. Remember the weld procedure is proof that
the weld can be successfully made.
The general sequence for procedure qualification testing is as follows:

Select welding variables (write the WPS and PQR)

Check equipment and materials for suitability

Monitor weld joint fit-up as well as actual welding,

recording all important variables and observations

Select, identify and remove required test specimens

Test and evaluate specimens

Review test results for compliance with applicable

code requirements

Release approved procedure for production

Qualify individual welders in accordance with this procedure

Monitor production welding for procedure compliance

ASME IX Summary, 2003 Page 9-5

QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS

(WPS)
(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)
Company Name:
Welding Procedure Specification No.
Revision No.
Welding Process(es):

By:
Supporting PQR No.(s)

Date:
Date:
Type(s):

Automatic, Manual, Machine, or Semi-Auto

JOINTS (QW-402)
Joint Design
Backing (Yes)
Backing Material (Type)

Details
(No)
(Refer to both backing and retainers)

Metal
Nonmetalic

Nonfusing Metal
Other

Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be
welded. Where applicable, the root spacing and the details of
weld groove may be specified.
(At the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g., for
notch toughness procedures, for multiple process procedures,
etc.)

*BASE METALS (QW-403)

P-No.
Group No.
OR
Specification type and grade
to Specification type and grade
OR
Chem. Analysis and Mech. Prop.
to Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal:
Groove
Pipe Dia. Range:
Groove
Other:

to P-No.

Group No.

Fillet
Fillet

*FILLER METALS (QW-404)

Spec. No. (SFA)
AWS No. (Class)
F-No.
A-No.
Size of Filler Metals
Weld Metal
Thickness Range:
Groove
Fillet
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert
Other
*Each base metal-filler metal combination should be recorded individually

ASME IX Summary, 2003 Page 9-6

QW-482 (Back)
WPS No.

POSITIONS (QW-405)

Rev.

POSTWELD HEAT TREATMENT (QW-407)

Position(s) of Groove
Welding Progression: Up
Position(s) of Fillet

Temperature Range
Time Range

Down

GAS (QW-408)
PREHEAT (QW-406)

Percent Composition

Preheat Temp. - Min.

Interpass Temp. - Max.
Preheat Maintenance

Gas(es)

(Mixture)

Flow Rate

Shielding

(Continuous or special heating where applicable should be recorded)

Trailing
Backing

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC
Amps (Range)

Polarity
Volts (Range)

(Amps and volts range should be recorded for each

position, and thickness, etc. This information may
be listed in a tabular form similar to that shown below.
Tungsten Electrode Size and Type
(Pure Tungsten, 2% Thorated, etc.)
Mode of Metal Transfer for GMAW
(Spray arc, short-circuiting arc, etc.)
Electrode Wire feed speed range

TECHNIQUE (QW-410)
String or Weave Bead
Orifice or Gas Cup Size
Initial and Interprass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrodes
Travel Speed (Range)
Peaning
Other

Filler Metal
Weld
Layer(s)

Process

Class

Dia.

Current
Type
Polar

Amp
Range

Volt
Range

ASME IX Summary, 2003 Page 9-7

Travel
Speed
Range

Other
(e.g., Remarks, Comments,
Hot Wire Addition,Technique,
Torch Angle, Etc.)

QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD

(PQR)
(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Conditions Used to Weld Test Coupon
JOINTS (QW-402)

Company Name
Procedure Qualification Record No.
WPS No.
Welding Process(es)
Types (Manual, Automatic, Semi-Auto.)

Date

Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness will be required for each filler metal or process used.)

BASE METALS (QW-403)

Material Spec.
Type or Grade
P. No.
Thickness of Test Coupon
Diameter of Test Coupon
Other

POST WELD HEAT TREATMENT (QW-407)

to P-No.

Temperature
Time
Other

GAS(QW-408)
Gas(es)

FILLER METALS (QW-404)

SFA Specification
AWS Classification
Filler Metal F-No.
Weld Metal Analysis A-No.
Size of Filler Metal
Other
Weld Metal Thickness

Percent Composition
(Mixture)
Flow Rate

Shielding
Trailing
Backing

ELECTRICAL CHARACTERISTICS (QW-409)

Current
Polarity
Amps.
Volts
Tungsten Electrode Size
Other

POSITION (QW-405)

TECHNIQUE (QW-410)

Position of Groove
Weld Progression (Uphill, Downhill)
Other

Travel Speed
String or Weave Bead
Oscillation
Multipass or Single Pass (per side)
Single or Multiple Electrodes
Other

PREHEAT (QW-406)
Preheat Temp.
Interpass Temp.
Other

ASME IX Summary, 2003 Page 9-8

QW-483 (Back)
PQR No.
Tensile Test (QW-150)
Specimen
No.

Width

Thickness

Area

Ultimate
Total Load
lb.

Ultimate
Unit Stress
psi

Type of
Failure &
Location

Guided-Bend Tests (QW-160)

Type and Figure No.

Toughness Tests (QW-170)

Specimen
No.

Notch
Location

Notch
Type

Test
Temp.

Impact
Values

Lateral Exp.
% Shear
Mils

Drop Weight
Break
No Break

Fillet-Weld Test (QW-180)

Result- Satisfactory:
Macro - Results

Yes

No

Penetration into Parent Metal: Yes

No

Other Tests
Type of Test
Deposit Analysis
Other
......................................................................................................................................................
Welders Name
Tests conducted by:

Clock No.

Stamp No.
Laboratory Test No.

We certify that the statements in this record are correct and that the test welds were prepared, welded, and
tested in accordance with the requirements of Section IX of the ASME Code.
Manufacturer
Date

By

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of test required by the Code.)

ASME IX Summary, 2003 Page 9-9

ASME Section IX
Welder Qualification
Welder qualification establishes the skill level for the welder. The test positions are
similar to the welding procedure positions. The essential variables for welder
qualification are as follows:
Position
Joint Configuration
Electrode Type and Size
Process
Base Metal Type
Base Metal Thickness
Technique (Up-hill or Down-hill)

(d) 4G

(b) 2G

(a) 1G

(c) 3G
QW-461.3 Groove Welds in Plate -- Test Positions

Throat of weld
vertical

Axis of weld
horizontal

Axis of weld
vertical

Axis of weld
horizontal

45 deg.

QW-461.5 Fillet Welds in Plate - Test Positions

(a) 1F

(b) 2F

(c) 3F

ASME IX Summary, 2003 Page 9-10

(d) 4F

(a) 1G Rotated

(c) 5G

(b) 2G

(d) 6G
QW-461.4 Groove Welds in Pipe -- Test Positions

PERFORMANCE QUALIFICATION - POSITION AND DIAMETER

LIMITATIONS
(Within the Other Limitations of QW-303)
Position and Type Weld Qualified [Note (1)]
Qualification Test
Weld

Groove

Position

Plate and Pipe

Over 24 in. O.D.

Plate - Groove

1G
2G
3G
4G
3G and 4G
2G, 3G and 4G
Special Positions m(SP)

Plate - Fillet

1F
2F
3F
4F
3F and 4F
Special Positions (SP)

F
F,H
F,V
F,O
F,V,O
All
SP,F

Fillet

Pipe

24 in. O.D.
F [Note (2)]
F,H [Note (2)]
F [Note (2)]
F [Note (2)]
F [Note (2)]
F,H [Note (2)]
SP,F

...
...
...
...
...
...

ASME IX Summary, 2003 Page 9-11

...
...
...
...
...
...

Plate
and Pipe
F
F,H
F,H,V
F,H,O
All
All
SP,F
F [Note (2)]
F,H [Note (2)]
F,H,V [Note (2)]
F,H,O [Note (2)]
All [Note (2)]
SP, F [Note (2)]

PERFORMANCE QUALIFICATION - POSITION AND DIAMETER

LIMITATIONS
(Within the Other Limitations of QW-303)
Position and Type Weld Qualified [Note (1)]
Qualification Test
Weld

Position

Groove
Plate and Pipe
Over 24 in. O.D.

Pipe - Groove [Note (3)] 1G

2G
5G
6G
2G and 5G
Special Positions (SP)

Fillet

Pipe

24 in. O.D.

F
F,H
F,V,O
All
All
SP,F

Pipe - Fillet [Note (3)]

1F
2F
2FR
4F
5F
Special Positions (SP)

...
...
...
...
...
...

F
F,H
F,V,O
All
All
SP,F
...
...
...
...
...
...

Plate
and Pipe
F
F,H
All
All
All
SP,F
F
F,H
F,H
F,H,O
All
SP,F

NOTES:
(1)
Positions of welding as shown in QW-461.1 and QW-461.2.
F = Flat
H = Horizontal
V = Vertical
O = Overhead
(2)
Pipe 2 7/8 in. O.D. and over.
(3)
See diameter restrictions in QW-452.3, QW-452.4 and QW-452.6

The general sequence for Welder qualification testing is as follows:

Identify essential variables

Check equipment and materials for suitability

Check test coupon configuration and position

Monitor actual welding, to assure that it complies with applicable

welding procedure

Select, identify and remove required test specimens

Test and evaluate specimens

Complete necessary paperwork

Monitor production welding

ASME IX Summary, 2003 Page 9-12

QW-484 SUGGESTED FORMAT FOR MANUFACTURERS RECORD OF WELDER OR

WELDING OPERATOR QUALIFICATION TESTS (WPQ)
See QW-301, Section IX, ASME Boiler and Pressure Vessel Code

Welders name
Clock no.
Stamp no.
Welding process(es) used
Type
Identification of WPS followed by welder during welding of test coupon
Base material(s) welded
Thickness
Manual or Semiautomatic Variables for Each Process (QW-350)

Actual Values Range Qualified

Backing (metal, weld metal, welded from both sides, flux, etc.) (QW-402)
ASME P-No.
to ASME P-No. (QW-403)
( ) Plate ( ) Pipe (enter diameter, if pipe)
Filler metal specification (SFA):
Classification (QW-404)
Filler metal F-No.
Consumable insert for GTAW or PAW
Weld deposit thickness for each welding process
Welding position (1G, 5G, etc.) (QW-405)
Progression (uphill/downhill)
Backing gas for GTAW, PAW or GMAW, fuel gas for OFW (QW-408)
GMAW transfer mode (QW-409)
GTAW welding current type/polarity
Machine Welding Variables for the Process Used (QW-360)

Actual Values

Range Qualified

Direct/remote visual control

Automatic voltage control (GTAW)
Automatic joint tracking
Welding position (1G, 5G, etc.)
Consumable insert
Backing (metal, weld metal, welded from back sides, flux, etc.)
Guided-Bend Test Results
Guided-Bend Tests Type

( )QW-462.2(Side) Results

( )QW-462.3(a) (Trans. R &F ) Type

( )QW-462.3(b) (Long R & F) Results

Visual examination results (QW-302.4)

Radiographic test results (QW-304 and QW-305)
(For alternative qualification of groove welds by radiography)
Fillet Weld - Fracture test
Length and percent of defects
Macro test fusion
Fillet leg size
in. x
in. Concavity/convexity
Welding test conducted by
Mechanical tests conducted by
Laboratory test no.

in.
in.

We certify that the statements in this record are correct and that the test coupons were prepared, welded and
tested in accordance with the requirements of Section IX of the ASME Code.
Organization
Date

By

ASME IX Summary, 2003 Page 9-13

Section 10
Welding Metallurgy

WELDING METALLURGY
Admixture: The interchange of filler metal and base metal during welding, resulting in
weld metal of composition borrowed from both. Limited admixture is necessary to
complete metallurgical union across the joint.
Aging: The recrystallization that occurs over an extended period of time, resulting
form austenite or other normally elevated-temperature structure being retained at a
temperature and under conditions where it has no permanent stability. The result may
be a change in properties or dimension. Under some circumstances, aging can be
advantageous.
Blowhole: A defect in metal caused by hot metal cooling too rapidly when excessive
gaseous content is present. Specifically, in welding, a gas pocket in the weld metal,
resulting from the hot metal solidifying without all of the gases having escaped to the
surface.
Crater cracks: Cracks across the weld bead crater, resulting form hot shrinkage.
Heat-affected zone: The portion of the base metal, adjacent to a weld, the structure or
properties of which have been altered by the heat of welding.
Hot shrinkage: A condition where the thin weld crater cools rapidly while the
remainder of the bead cools more slowly. Since metal contracts or shrinks as it cools,
and shrinkage in the crater area is restrained by the larger bead, the weld metal at the
crater is stressed excessively and may crack.
Lamination: An elongated defect in a finished metal product, resulting from the rolling
of a welded or other part containing a blowhole. Actually, the blowhole is stretched out
in the direction of rolling.
Pick-up: The absorption of base metal by the weld metal as the result of admixture.
Usually used specifically in reference to the migration of carbon or other critical alloying
elements from the base metal into the weld metal. Depending upon the materials
involved, this can be an asset and not a liability.
Segregation: The tendency of alloying elements, under certain heat conditions, to
separate from the main crystalline constituent during transformation and to migrate
and collect at the grain boundaries. There they often combine into undesirable
compounds.
Stringers: The tendency of segregated atoms of alloying elements or their compounds
to attach to one another in thread-like chains.
The problems encountered in welding can be better understood through a basic
understanding of metallurgy. The metallurgical effects of welding are the effects of
heat. Whether the welds are made by a gas flame, a metal arc, or electrical resistance,
the effects on the parent metal are due to heat.

Welding, Metallurgy, 1995 Page 1010-1

Every fusion welding operation involves a logical sequence of thermal or heat events.
These include:
1.
2.
3.
4.

Heating of the metal

Manipulation of the electrode or torch flame to deposit weld metal
Cooling of the weld deposit as well as the base metal
Reheating of the entire structure for stress-relieving purposes, in some
instances

In every weld, the metal immediately under the flame or arc is in a molten state; the
welded section is in the process of cooling off; and the section to be welded has not yet
been heated and so is comparatively cool. These various conditions are encountered at
the very same instant. See Figure M-1.
As a result of welding, the structure of the welded ferrous metal may become
martensitic, pearlitic or even austenitic in nature. The welder who knows metallurgy
can predict which structure will be found when the weld has cooled. It is most
important to know this because the final condition of the structure after welding is the
one that determines the strength, hardness, ductility, resistance to impact, resistance to
corrosion and similar mechanical and physical properties of the metal. All these
properties may be affected by conditions that exist during the welding operation, so it is
well to become acquainted with possible difficulties and see how they may be avoided.
To avoid confusion, this discussion will be confined to steel. The effects of heating and
cooling will not necessarily be the same for the non-ferrous metals and alloys. In some
cases, a considerable difference in temperature ranges and other characteristics exist.
The arc welding of steel involves very high temperatures. The resultant weld is
essentially cast steel. Since the base metal very close to the weld is comparatively cool,
a considerable variation in the grain structure develops within the weld area. The ironcarbon diagram, Figure M-2 shows how the rate at which the weld cools will alter the
grain structure in both the weld itself and the immediately adjacent base metal, known
technically as the heat -affected zone.
Danger from the Air
Unless extreme care to shield the weld metal is exercised during welding, the possibility
exists that oxygen or nitrogen or both will be absorbed from the air. What either of
these gases can do to weld metal is pitiful. An oxide or nitride coating will form along
the grain boundaries. Oxidation along the grain boundaries greatly weakens the weld
metal, and greatly reduces the impact strength and also the fatigue resistance of the
welded part. Nitrogen forms iron nitrides in chemical composition with the iron, and
these make the weld extremely brittle.

Welding, Metallurgy, 1995 Page 10-2

10-

The extent to which oxides and nitrides penetrate a steel will depend upon the type of
steel, the temperature to which it is heated and the length of time it is held at this
temperature. Extreme care should be exercised to prevent the penetration of air into
high-temperature welding regions. The most satisfactory way to prevent oxide or
nitride contamination in metal-arc welding is to make sure that the electrode has a
coating that provides adequate shielding. The arc and weld metal may also be shielded
by carbon dioxide (CO2) or vapor. In gas tungsten arc welding (GTAW) or gas metal
arc welding (GMAW) (inert-gas-arc welding), the inert gas will provide the shielding.
With submerged-arc welding, the molten flux that covers the arc does the job. Fluxes
or a reducing flame provide the needed protection during gas welding.
When the oxyacetylene torch is used for cutting, it is desirable to oxidize the steel. It is
rapid oxidation that makes it possible for the flame to sever steel.
Besides oxygen or nitrogen, another gas absorbed during welding may have harmful
effects on some types of metals and alloys. This gas is hydrogen, and usually comes
from moisture in the electrode coating or from the use of hydrogen in the welding
flame. The presence of hydrogen in the weld metal will weaken the structure and lead
to cracking of the weld. Hydrogen is a contributing cause of underbead cracking. To
avoid this harmful weld defect, use low-hydrogen electrodes of the E-xx15, E-xx16 and
E-xx18 series.
Heat-Affected Zone
Figure M-2 shows the close relationship that exists between thermal conditions, grain
structure and hardness in the arc weld. So that this relationship might be clearly
established, a photomicrograph of a section through a welded 0.25% carbon steel plate
has been inserted in an iron-carbon diagram. This diagram was split on the 0.25%
carbon line and opened up to allow insertion of the photomicrograph.
The photomicrograph is of a single automatic weld bead. The bead as deposited on the
1/2 inch plate produced a heat-affected zone that extended for about 1/8 in. adjacent to
the weld. This zone shows a variation in grain structure adjacent to the weld. This zone
shows a variation in grain structure (staring at the bottom) from the normal base metal
structure into a band of finer grain structure between the lower and upper critical
temperature points and then to a coarse overheated grain structure adjacent to the
weld.
The extent of the change in the grain structure depends upon the maximum
temperature to which the metal is subjected, the length of time this temperature exists,
the composition of the steel, and the rate of cooling. The cooling rate will not only
affect grain size but it will also affect physical properties.
As a rule, faster cooling rates produce a slightly harder, less ductile and stronger steel.
For low-carbon steels, the relatively small differences found in practice make
insignificant changes in these values. However, with higher carbon content in
appreciable amounts of alloying material, the effect may become serious.

Welding, Metallurgy, 1995 Page 10-3

The speed of welding and the rate of heat input into the joint effects change in structure
and hardness. On a given mass of base metal, at a given temperature, a small bead
deposited at high speed produces a greater hardening than a larger bead deposited at a
higher heat input per unit length of joint. This is because small high speed beads cool
more rapidly than the larger high heat beads.
The effect that heat from welding has on the base metal determines to a great degree
the weldability of a metal and its usefulness in fabrication. A metal that is sensitive to
heat conditions or heat changes, as in the case of high-carbon and some alloy steels,
may require heat treatment both before and after welding.
Admixture or Pick-up
When a base metal is welded with a filler metal of different composition, the two metals
will naturally mix and blend together in the molten weld pool. Consequently, the weld
metal will be a mixture of two materials. it will not necessarily be an average of them,
however.
The amount of base metal picked up in the molten weld pool varies greatly relative to
the amount of deposited electrode metal. Some welds are made up principally of base
metal, while others are primarily deposited electrode metal. The specific process of
welding, the rate of electrode travel, the current selected, the width of the joint, the base
metal composition, the plate thickness -- all these factors determine the volume of base
metal brought to a molten temperature, and therefore the amount of base metal pick-up
or admixture into the weld.
In some cases, the deposited metal and the base metal are sufficiently alike in
composition that the amount of admixture is of little significance. At other times,
admixture is an advantage in that the weld metal is made stronger or otherwise
improved by a pick-up of carbon or other needed elements from the base metal.
Unfortunately, under some conditions alloying elements or chemical combinations of
the base metal tend to concentrate -- to precipitate, or to segregate during the heating
and cooling cycle and reform into stringers or other arrangements that harden,
embrittle, weaken or otherwise cause inferior welds. Sometimes, the stringer itself is a
source of weakness. At other times, the segregation of an element or its loss into the
slag or atmosphere "starves" the newly formed weld microstructure of elements
needed for certain physical properties.
In general, admixture should be limited unless the metals and the processes involved
justify a procedure that calls for a specific amount of pick-up. This is discussed further
in later chapters on the welding of specific metal groups. To minimize the effects of
pick-up, electrode coatings or fluxes are often treated with alloying elements that bring
the deposited metal up to the desired composition. These alloying elements replace
those that might be destroyed or lost to either parent metal or weld metal during the
high-temperature welding operation.

Welding, Metallurgy, 1995 Page 10-4

Carbide Precipitation
Sometimes, because of rapid cooling, steels, particularly stainless steels, are not given
time to go through all of the temperature changes indicated in the iron-carbon diagram.
As a result, a concentration of the solid solution (austenite) is retained at a temperature
where it simply has no business existing. This being against nature, so to speak, the
dissolved elements will eventually recrystallize. This type of recrystallization is known
as aging. Suppose, however, the metal is reheated before recrystallization can occur. In
this event, the carbon will crystallize out of the austenite as iron carbide. This
phenomena is known as carbide precipitation.
Stainless steels of the nickel-chromium variety are austenitic in nature even at room
temperatures. When such steels are heated, as by welding operations, carbide
precipitation is apt to occur. The carbides, or carbon compounds, are chromium as well
as iron. When chromium is used up in this way, in chemical union with the precipitated
carbon, the remaining austenite is deficient in the chromium element. The result is a
serious reduction in the corrosion-resisting properties of the stainless steel.
When the carbides are precipitated in stainless steel, they appear mainly at the grain
boundaries. If subjected to corrosion, the carbides along the grain boundaries will be
attacked readily. Severe corrosive conditions will cause the grains to lose their
coherence and the steel to fail.
In making a weld on stainless, there will always be a region some distance back from
the weld where the base metal will be at the exact temperature of the precipitation
range: 800-1500F. Consequently, the stainless qualities of the structure will be lost
unless steps are taken to prevent precipitation.
Austenitic stainless steels may be stabilized against carbide precipitation by the addition
of elements known as stabilizers. Such elements are columbium and titanium. These
elements have a ready affinity for carbon; they will grab and hold fast the carbon that
might otherwise have been attracted to the chromium. Moreover, both titanium and
columbium carbide resemble stainless steel in having high resistance to corrosion.
Stabilized stainless steels, therefore, will not fail under the combination of heat and
corrosive attack. Austenitic stainless steels also are available in several grades with
extra low carbon (ELC). Since there is less carbon, the possibility of chromium
migration to the grain boundaries is minimized.
It is well to remember that the stabilized and ELC austenitic steels will resist carbide
precipitation. If the welded stainless is to be subjected to corrosive conditions,
particularly at elevated temperatures, the base metal should be a stabilized steel and it
should be welded with electrodes or filler rods that have also been stabilized.

Welding, Metallurgy, 1995 Page 10-5

Crater Cracks
In some instances, both arc welds and gas welds develop crater cracks. These come
from hot shrinkage. The crater cools rapidly while the remainder of the bead is cooling
slowly. Since the crater solidifies from all sides toward the center, the conditions are
favorable to shrinkage cracks. Such crater cracks may lead to failures under stress -brittle failures since there is an inclination towards fracture without deformation. The
remedy is to manipulate the electrode to fill up the craters when you are welding.
Blowholes, Gas Pockets and Inclusions
Other common welding defects known as blowholes, gas pockets and inclusions
involve problems of electrode manipulation rather than metallurgy. These difficulties
are created because of the welder's failure to retain the molten weld pool for sufficient
time to float entrapped gas, slag and other forms of material.
A blowhole or gas pocket represents a bubble of as in the liquid weld metal. A gas
pocket is one that did not reach the surface before the metal began to freeze.
Consequently, the gas remains entrapped in the solidified metal.
Some gases, particularly hydrogen, are absorbed by the molten metal and are then
given off as the metal beings to cool. If the metal is in a molten condition, the gas
bubbles make their way to the surface and disappear. If the bubbles are trapped in the
growing grains of solid metal, blowholes are the result.
Blowholes are particularly prevalent in steels high in sulphur. In this case the entrapped
gas is either sulphur dioxide or hydrogen sulphide, the hydrogen being supplied from
moisture, the fuel gas (in gas welding), the electrode coating or the hydrogen
atmosphere that surrounds the weld in atomic-hydrogen welding.
Blowholes may be minimized in the weld area by using a continuous welding technique
so that the weld metal will solidify continuously. Most welding operators, through
practice, learn to develop welding techniques that will produce a relatively gas-free
weld. One of the secrets of such a technique is to keep the molten weld pool at the
temperature necessary for the rapid release of absorbed gases. At the same time an
unbroken protective atmosphere must be provided over the pool. Modern electrode
coatings aid in this problem, for they contain scavenging elements that cleanse the weld
pool while it is in molten condition.
Inclusions of slag and other foreign particles in the weld present a type of problem
similar to gas pockets and blowholes. These inclusions tend to weaken the weld. Slag is
frequently entrapped because of the operator's failure to manipulate torch, filler rod or
electrode so as to maintain a molten condition long enough to float out all the foreign
material. Ordinarily, the liquid slag freezes and forms a protective coating for the weld
deposit. On some occasions, however, because of the force of the flame or arc, it is
blown into the molten weld pool. The pool freezes before the slag particle or particles
can float to the top, thus producing a defective weld.

Welding, Metallurgy, 1995 Page 10-6

Slag inclusions are more common in welds made in the overhead position. The lower
density of the slag tends to keep it afloat on the weld pool. In overhead welding, the
weld pool first forms at the narrow part of the vee, which is uppermost in the weld.
Since the pool tends to drip if kept molten too long, the welder works to have it solidify
as rapidly as possible. As a result, inclusions are frequent. This problem in overhead
welding can be overcome by using gaseous, non-slagging types of electrodes.
Faulty plate preparation contributes to slag inclusions. If edges of V-joints are beveled
at too steep an angle and the gap between plates is too small, the weld metal bridges
the gap and leaves a pocket at the root in which slag tends to collect. If back of joint is
accessible, slag can be removed by back gouging; however, if this operation is omitted,
the result is a defective weld. With a J-joint or U-joint, improper arc manipulation may
burn back the inside corners and form pockets that can entrap slag or gases.
In repair of a broken surface, a groove along the break line should be burned out or
ground so as to provide clean surfaces properly angled and spaced. Failure to do so
may leave an overhang of base metal or an unfilled crack that can entrap slag or gases.
Surfaces to be welded should be thoroughly cleaned of scale, dirt, paint, lubricants, and
other chemicals that might contribute to formation of gas or dirt inclusions in the weld.
Welds that contain blowholes, gas pockets and inclusions may develop other defects
upon hot work. By the action of hot working, the basic defects are exaggerated to form
larger defects. For example, if a piece of weld metal containing a blowhole is rolled, the
tendency is to flatten and elongate the hole. This develops a long fibrous defect
running in the same direction as the piece that is rolled. Such a condition, known as a
lamination, will reduce the strength of the metal, particularly in directions at right angles
to the lamination.

Welding, Metallurgy, 1995 Page 10-7

Section 11
Technical Report Writing

TECHNICAL REPORT WRITING

LEGAL IMPLICATIONS
I.

Preamble Comments
A.

The completeness, factual data transmitted and final validity of any

equipment inspection depends on the depth and scope of the officially
submitted Inspection Report.

B.

The customer's perception of You as a qualified professional is

always strongly influenced by what is contained in the report. Remember
the "Image" comments earlier? Your report may well be "the make or
break" factor about whether you or your company will be favorably
considered for future inspection activities.

C.

An unknown factor usually exists relative to the "likes, dislikes and

preferences" of the person who receives or acts on your inspection report.
Some factors include:
1.
2.
3.
4.
5.
6.

D.

When developing the Inspection Report, consider:

1.
2.
3.

II.

Organization of data
Length of report
Factual versus theoretical
Precise details or general statement.
Recommendations or suggestion.
Line-item coverage or report by exceptio.

Who will read and/or react to its contents, such as project

engineers, superintendents, managers, supervisors, foremen,
craftsmen, etc.?
Can the report be understood, or will a translator be needed?
If repair recommendations or sketches are submitted, how
much "hand-holding" is required for them to be understood?

Date and Signature

For a report to be auditable (legitimate by law), it must be dated and signed by
the inspector/person involved. Basically, any item worth reporting is worthy of
legal validation.

III.

Report Format/Descriptive Contents

Tech. Report Writing, 1997

Page 11-1

A.

Many of those reading/reacting to your report simply do not have

time to attempt to grasp or correlate those items most useful to their
response. Therefore, the report should be factual, concise and reasonably
easy to grasp or understand.

B.

An "attention getter", up front statement is always helpful. Simple

statement examples could be one of the following or some reasonably
similar comment:
1.

Based on my inspection survey of Tank ______ on

____________, this equipment is considered to be in good condition
and structurally sound for long term service.

or

2.

My findings/evaluation of this equipment indicates that minor,

general internal corrosion of the bottom is occurring, but is of no
near term concern. The remainder of this equipment is considered
to be in good condition with no corrosion noted.

or

3.

The inspection survey indicates that moderate to sever internal

corrosion exists. Component part thickness measurements, plus
visual observations reflect the following conditions and
recommendations:

NOTE:

C.

Remember that the person to whom you submit a report is

a Client. It may be an "in-house" client for those inspecting
equipment owned by their respective employer, or it may
be a contract-owner relationship.

Many, if not most, clients will not appreciate, nor perhaps even
tolerate, a report that contains "inflammatory" comments. In this context,
inflammatory words, comments, opinions or predictions could be
anything that, in the event of some future legal action, would place the
equipment owner in a precarious, defensive position. Some examples are:
1.
2.
3.
4.
5.

Dangerous
Explosion
Hazardous
Health Problem
Unsafe

A simpler explanation would be any comment or wording that could be twisted

or used out of context by lawyers in a negligence trial situation.

Tech. Report Writing, 1997

Page 11-2

Certainly, the comments listed above are not meant or intended to cause an
inspector to prostitute himself or his profession by "soft-pedaling" or ignoring
serious problems, plus informing the client whenever problems exist. Each client
deserves a true, factual evaluation and condition report. It is possible, however,
to structure your report comments in such a fashion that problems can be stated
(or client informed) so as to impart various degrees of urgency or concern
involving areas or component items requiring immediate or near term
corrective action.
IV.

Report Vocabulary
A.

Each individual most probably has already established, or will

establish, his own vocabulary (or word usage) to identify or project his
evaluation of conditions noted during the inspection survey. Degrees of
corrosion/deterioration exist, plus varying stages or phases of problems
involving mechanical equipment, safety, environment, etc., must be
described and/or commented upon. Some common descriptive
phrases/comments I have become comfortable with are listed below.
You will note that it is possible to make many combination statements by
grouping certain descriptive words into comments that best describe your
personal evaluation.
1.
2.
3.
4.
5.
6.
7.

B.

Very minor, general corrosion.

Minor to moderate, etc., etc.
Moderate, etc., etc.
Moderate to severe, etc., etc.
Severe, etc., etc.
The results of this inspection survey indicate that repair as
follows is recommended.
Inspection/evaluation of this equipment indicates it to be in
good condition and is considered OK for long term service.

Owner/client user Expectations

You are hired (or used) to determine existing conditions of equipment,
assess and evaluate the impact on future reliability, determine
corrosion/metal thickness limitations or minimum requirements.
You are expected to use your best judgment, expertise, experience and
training to develop (perhaps even to recommend), the most cost
effective, safest, operationally reliable method/degree of repair necessary
to achieve the above conditions.

V.

Report Structure
A.

Recall earlier comments regarding those who will receive your

report plus those who will eventually react to your comments and/or
recommendations.

Tech. Report Writing, 1997

Page 11-3

B.

Methods, data organization, component part separation, etc.,

suggested for your strong consideration include:
1.

Method of presentation
a.
b.
c.
d.

2.

Keep the report as brief( but complete) as possible or

practical.
Keep it factual. If theorizing is required, make sure
that this approach is recognized.
Avoid, whenever possible, inflammatory words or
comments.
Be conscious of the economics involved. Don't
recommend complete item renewal, when 50% renewal will
provide the desired results.

Data Organization/Component Part Separation

In reporting conditions found, separate into component tank
parts (i.e., shell, bottom, fixed roof, I.F.R., etc.)

NOTE:

Do not intermingle comments/conditions, so that a thought

pattern is established in the report readers mind on one component
of the tank (i.e., shell) and then refer to the bottom in mid-stream.
Keep comments separated in the report body and on the repair
items recommended.

Ideally, repair items should be arranged in order, clearly defined and

explicit enough, that the list can be given to maintenance personnel who
can make proper repairs from the list.
VI.

Review Comments
The following are "Basic" in nature, but occasionally can be flexible to fit the
needs of a particular situation:
A.

Do's
1.
2.
3.
4.
5.

Keep as brief as possible, but present all factual data. A wide

flexibility is necessary because of the range of comments required
to satisfy numerous conditions.
Provide suggestions or recommendations relative to repair if
the client requests. Sketches involving repair or procedure details
are a mark of competence.
Be conscious of the economics involved that could result
from your recommendations.
Arrange data in an orderly fashion, separated into
component parts for ease of reading and understanding.
Sign and date report.

Tech. Report Writing, 1997

Page 11-4

B.

Don'ts
1.
2.
3.
4.
5.

Use inflammatory word, statements or opinions.

Present a mass of data all intermingled in one statement.
Make it a practice to theorize or guess as to problem cause.
Present condition comments or data involving one major
tank component into the same statement as data is presented on a
completely different major component.
Diminish your competency or professional image by a failure
to submit a comprehensive, factual, readable report that will, by
itself, be a future auditable document.

Tech. Report Writing, 1997

Page 11-5