Questions from my memory- (API-653- SEPTEMBER-26-2012 EXAM)

Open book (total 52 questions)

1. Maximum radial spacing for settlement measurement inside tank – 10’ (10 feet).

Appendix B Figure … Figure B.2 … 10 feet … Also know maximum circumferential = 32 feet (Fig B.1)

Expect these open or closed book … especially the 32 feet rule for closed book

2. Maximum weld reinforcement of 1” weld joint (Vertical or Horizontal) for reconstructed tank as per
API-653 - The answer options includes 1/8” and ¼”, this seems to be a tricky question… in my
opinion the answer shall include reinforcements on both side of the joint if you look at the definition
of reinforcement in API.

Section 10, 10.4.2.6 & Table 10.1 🡪 Easy easy 🡪 Reconstructed Tanks 🡪 1/8 inch (vert) & 3/32 (Horiz)

3. Spacing for stiffening ring drain holes for un-insulated tank.

Design / welding question 🡪 Use your BRAIN 🡪 650 Index 🡪 Section 5.9 …

5.9.3.3 Rings that may trap liquid shall be provided with adequate drain holes. Uninsulated tanks having rings shall
have small water-shedding slopes and/or drain holes or slots unless the Purchaser approves an alternate means of
drainage. If drain holes are provided, they shall be at least 25 mm (1 in.) diameter (or slot width) on 2400 mm (8 ft)
centers or less. Insulated tanks where the rings function as insulation closures shall have no drain holes or slots.

4. Length of area to be cleaned from galvanized attachments to be welded to tanks.

A) 3mm B) 12mm C) 25mm D) None of these

VERY TRICKY … Likely a new question in the 25 not counted … Arguable, unless
6.1.1.3 Materials used to aid in the fabrication of tanks shall not have a detrimental effect on the structural integrity
of the tank. Lubricants, crayons, adhesives, and anti-weld spatter compounds shall not contain materials that will be
detrimental to the tank, e.g., sulfur and chloride compounds for stainless steel materials. Attachments that will be
welded to the pressure boundary shall not have a zinc or cadmium coating in the weld area within 12 mm (0.5
in.) of the weld.
API 653 Section 7.2 & Section 9 (WPS/PQR) … Must also know … 7.2.1.9 If protective coatings are to be
used on surfaces to be welded, the coatings shall be included in welding-procedure qualification tests for the
brand formulation and maximum thickness of coating to be applied. 9.2.1.4 Welding variables (including
supplementary essential variables when impact tests are required by 9.2.2), as defined by QW-250 of Section IX of
the ASME Code, shall be used to determine the welding procedure specifications and the procedure qualification
records to be instituted. In addition, when impact tests of the heat-affected zone are required, the heat-treated
condition of the base material shall be a supplementary essential variable. Plates produced by the controlled-rolled
process are not to be considered as having received any heat treatment. If a protective coating has been applied to
weld edge preparations, the coating shall be included as an essential variable of the welding procedure specification,
as required by 7.2.1.9.

Answer: B is correct … But expect also D is correct … AS STATED ON WPS/PQR

Questions from my memory- (API-653- SEPTEMBER-26-2012 EXAM) Open book (total 52 questions)

5. Minimum preheat to be used for given PQR … 🡪MUST determine PQR T value + MAT’L GROUP ☺

See Table 7-1a & 7-1b listing minimum preheat … EASY AS EATING PIE ☺☺☺☺☺☺☺

6. Check whether the A number provided in the WPS was correct or not? WPS provided, SMAW
welding with 7018 electrodes……

ASME IX … QW-253 SMAW ESSENTIAL VARIABLES = 10 🡪 Easy as PIE 🡪 A-1 (PQR) qualifies A-1 (WPS) … A-
2 🡪 A-2, etc … SAME RULE APPLIES FOR P-NUMBERS & F-Numbers

7. Which is suitable coating for tank to store crude oil at temperature 880C?

API 652 🡪 Section 6, Table 1 (Thin Film) & Table 2 (Thick Film) 🡪 Temperature & Coating type tables

Epoxy phenolic/amine Light products, distillates, aromatics, high purity water, sour products, crude 🡪 180–220 (82–104)
Epoxy/amine Water, light products, distillates, aromatics, crude, and gasoline 🡪 160–220 (71–104)
Vinyl Ester Water, crude oil, aromatics, solvents, alcohols, gasohol, oil, and chemicals 🡪 180 – 220 (82 – 104)

Three options exist … Depending on the question

6.3 THICK-FILM, REINFORCED TANK BOTTOM
LININGS 🡪 Thick-film, reinforced linings may be used as tank bottom linings for both new and old storage tanks.
Table 2 lists generic types of resins typically used in such linings.
8. Minimum number of radiographs required for a rectangular shell plate replacement shell (also
known as a DOORSHEET by 653 definition) as per API-653? MUST KNOW THICKNESS
(Assume 1 inch plate 40 feet long & 3 intersecting welds)

API 653 Section 12.2 🡪 Figure 8.1 BY THICKNESS & Notes 🡪 650 required + 653 Added shots = 4 (650
Vertical) shots + 2 (added 653 vertical) shots = 6 vertical shots total
= 2 (650 Horizontal ) shots + 1 (added 653 horizontal) shots = 3 horizontal shots total
= All intersections = 3 shots (650) … All intersections 3 shots (653) = 3 intersecting shots total
9. What is the maximum size of rectangular opening at the roof of a fixed conical roof tank?

650 … 5.8.6 Rectangular Roof Openings

5.8.6.1 Rectangular roof openings shall conform to Figures 5-17 and 5-18 and/or this section.

900 mm (3') max

10. To check swing lines scribe the flexible joint across the two moving faces and raise end of swing line
to check the joint’s ___________. Ans> freedom of movement.

API 575, 7.4.9 (end of 2nd Para) 🡪 653 Annex C 🡪 Inspection Checklist 🡪 OUT OF SERVICE CHECKLIST
11. Name plate information, drawings, specification, results of test and analysis shall be part of which
type of records. Ans: Repair/alteration history, operational records, construction records.

6.8.2 🡪 CONSTRUCTION RECORDS = CORRECT ANSWER

SMART TIP 🡪 HIGHLIGHT CHAPTER 13 653 & REMIND YOURSELF GO TO 6.8 for RECORDS

12. If corrosion is noted on tank roof and top of shell which statement is true…….. Ans: structural
members may be twice the rate of thinning of the roof.

INTERNAL INSPECTION QUESTION 🡪 API 575 🡪 7.4.8 covers the area discussed!!!

API 575 … 7.4.8 Roof and Structural Members

Ordinarily, a visual inspection of the interior roof plates, framing system and column supports is sufficient. When
corrosion or distortion is evident or heavy under-side roof corrosion is indicated by external thickness
measurements, access scaffolding should be erected so that measurements can be taken internally. If corrosion is
noted on the roof and upper shell, then structural members may also be thinning, possibly at as much as
twice the rate of the thinning of the roof or shell, since both sides of the structural members are exposed to
the corrosive vapors. See API Std 653, Appendix C, for
guidance that is more detailed. Figure 57 shows an example of internal corrosion of roof plates & rafters.

13. Radius tolerance shall be measured at what distance from the bottom to shell joint…….

Bad Q???? … Must say whether tank is new (being repaired) or reconstructed … does it matter????
If new or REPAIRED (per API 653) 🡪 See API 650, 7.5.3
If reconstructed ONLY 🡪 see API 653 Table 10.2
THEY ARE SOMETIMES IDENTICAL REQMTS 🡪 But not ALWAYS

653 Table 10.2

 650 Table 7.5.3

SMART TIP … Place Dimensional tolerances for REPAIRED

TANKS AS 650 Section 7.5 … Place NOTE NEXT TO TABLE 10.2 🡪
ALWAYS SEE 650 SECTION 7.5 IF TANK IS NOT
RECONSTRUCTED
14. Find out the hydrostatic stress for A 516 – 65 bottom shell course 🡪 API 653 Chapter 4 exam Q …

Tmin will be given … But you can easily determine it if needed … S = 30,700 … E = Table 4.2, & D = given

15. One of the conditions for not conducting hydro test is stress in the repair area
shall not exceed ----------- Ans: 7000 PSI.

12.3.2.3.3.c 🡪 7 ksi rule … When Hydrotesting is NOT REQUIRED

16. In a frangible roof design the slope of the roof at the top angle attachment shall not exceed --------
Ans : 2:12

API 653 Para 4.2.2.2 🡪 API 650 5.10.2.6.a.1

17. Typical anchor profile required for lining?

API 652 … Section 7.5

7.5 SURFACE PROFILE OR ANCHOR PATTERN

The abrasive used for blasting should be selected to produce the necessary profile depth, or anchor pattern, for the
lining to be applied. The lining manufacturer’s recommendation for surface profile depth must be achieved in order
to optimize the mechanical adhesion of the lining to the steel tank bottom. The anchor pattern required for linings is
typically 1.5 – 4.0 mils (38 – 102 (m) and generally increases with the thickness of the lining. To achieve adhesion
necessary for long-term performance, it is important that the anchor pattern is sharp and angular.

18. Prior to blasting surface shall be essentially cleaned from ___________. Ans: Oil,tar, grease must be
removed.

7.2 PRE-CLEANING
Prior to abrasive blasting, all hydrocarbon residues such as oil, tar, and grease, must be removed from the area
to be lined.

19. T min. thickness calculation- all parameters given directly in the question.

Too easy … Select the correct formula in section 4

20 … 652 possible question … 4.4 GALVANIC CELL CORROSION

Hot-rolled carbon steel, typically used for the construction of petroleum storage tanks, is covered with a thin layer of
oxide called mill scale, which is cathodic to the base steel. In the presence of a corrodent (such as dissolved oxygen)
and an electrolyte, a galvanic corrosion couple forms at breaks in the mill scale. Accelerated pitting corrosion of the
steel at breaks in the mill scale can result. Mill scale may be removed from both sides of the tank bottom plate by
abrasive blast cleaning or by pickling, but removal of mill scale from the underside of the steel bottom is not
commonly done.
In some cases, welding can produce large differences in the microstructure of a steel bottom plate resulting in
a built-in galvanic couple. In the presence of a corrodent and an electrolyte, preferential corrosion can occur
at the heat-affected zones (HAZ) of the base metal near the welds. This type of corrosion can cause significant
localized metal loss. SULFURIC ACID CORROSION ATTACKS WELD HAZ 🡪 See Also 575 & 571

21. What action to be taken if you notice a flat spot of size 1” deep X 50 ft wide X 30 ft length on a 200 ft
diameter tank.

Ans: accept since it is within tolerance, refer to engineer, provide patch plate etc.

TIP : FLAT SPOT Question 🡪 USE 650 ROUNDNESS TOLERANCE

22. Per API 650, what action is to be taken if the opening in a tank shell is larger than required to
facilitate 2” nozzle?

5.7.2 Reinforcement and Welding

5.7.2.1 Openings in tank shells larger than required to accommodate a NPS 2 flanged or threaded nozzle shall be
reinforced.

Open & Closed book Mixed

1. Maximum circumferential spacing for settlement measurement. … LOL, 32 Feet Figure B.1
2. What is the maximum period for RBI re-assessment? 10 years … 6.4.2.2.2 (4th para)
3. Which standard refers for design of partial vacuum condition of tanks? 650 Appendix V

API 650 … 5.2.5 External Pressure 🡪APP. V

See Appendix V for the provisions for the design of tanks subject to partial internal vacuum exceeding 0.25 kPa (1
in. of water). Tanks that meet the requirements of this Standard may be subjected to a partial vacuum of 0.25 kPa (1
in. of water), without the need to provide any additional supporting calculations.
API 2000 … Section 2

4. Inspection interval for UT thickness measurements. 🡪 6.3.3.2 (two rules corrosion rate unknown = 5
years maximum … Corrosion rate known = Lesser 0f 15 or RCA/2N
5. When an internal inspection may be waived? Ans: If the content freezes when leaks, access to
bottom side of tank, not required for authorized inspector etc.

6. One question to find out the “H” used to calculate t min for a tank which has corroded area on
certain distance from the bottom of the tank.
BOTTOM OF LENGTH “L” TO MAXIMUM LIQUID LEVEL … USE 4.3.3.1.b

7. Procedure qualification thickness limits, procedure is qualified in 5/8” thickness plate what is the
maximum thickness can be welded with this PQR. … Table 451.1 🡪 2T = 1-1/4 inches
8. What information a PQR must have …… answer options include…signature and date, current
revision, thickness range etc?

API BODY OF KNOWLEDGE PART 2 WELDING …

API 577 … 6.4.2 Items to be Included in the PQR … See also ASME IX QW-200.2

c. WPS(s) that the PQR supports. … v. Certification signature and date.

9. The thickness of plate to be used for shell replacement shall be the maximum thickness of the
adjoining member except in which condition…..

The thickness of the replacement shell plate shall not be less than the greatest nominal thickness
of any plate in the same course adjoining the replacement plate except where the adjoining plate

is a thickened insert plate.

10. Correct statement regarding hot tapping……. Answer was hot tapping shall not be done at roof top.

Expect one of these 3 on the exam … Section 9 question

11. What is important while considering internal cleaning of tanks…. Answer includes the assessment of
amount/types of sludge inside the tank, facility to mobilize cleaning equipment inside the tank,
obstructions inside the tank etc.

API 653 Section 1.4 🡪 API 575 Section 7.1 & 7.4.1

A tank shall be sufÞciently clean to allow adequate inspection. Tank cleaning methods will be dependent on
the amount of scale, sediment, solid product, or other foreign material that is present on the surfaces to be
inspected. For relatively clean product services, water-washing the internal surfaces may result in adequate
cleanliness for inspection but it may be necessary to grit-blast or high-pressure water-blast internal surfaces and
weld seams to achieve sufÞcient cleanliness for inspection.

12. Which alternative method can be used if internal inspection is required only to assess the bottom
plate … Ans: Scanning of bottom using robotic equipment.

653 … 6.4.1.2 All tanks shall have a formal internal inspection conducted at intervals defined by 6.4.2.
Authorized inspector who is responsible for evaluation of a tank must conduct a visual inspection and
assure the quality and completeness of the nondestructive examination (NDE) results. If the internal
inspection is required solely for the purpose of determining the condition and integrity of the tank
bottom, the internal inspection may be accomplished with the tank in-service UTILIZING VARIOUS
ULTRASONIC ROBOTIC THICKNESS MEASUREMENT and other onstream inspection methods
capable of assessing the thickness of the tank bottom, in combination with methods capable of assessing
tank bottom integrity as described in 4.4.1.

13. What is the minimum length of radiograph to be taken for a reconstructed tank?

Chapter 12 … 12.2.1.7

14. Minimum number of RT spots required for 1” thick rectangular replacement shell as per API-653?
Option includes – 4 spots, full radiography, 8 spots etc.

Minimum number of radiographs required for a rectangular shell plate replacement shell (also known as
a DOORSHEET by 653 definition) as per API-653? MUST KNOW THICKNESS
 (Assume 1 inch plate 40 feet long & 3 intersecting welds)

API 653 Section 12.2 🡪 Figure 8.1 BY THICKNESS & Notes 🡪 650 required + 653 Added shots = 4 (650
Vertical) shots + 2 (added 653 vertical) shots = 6 vertical shots total
= 2 (650 Horizontal ) shots + 1 (added 653 horizontal) shots = 3 horizontal shots total
= All intersections = 3 shots (650) … All intersections 3 shots (653) = 3 intersecting shots total

15. What is the frequency of a UT equipment calibration?

API 577, Chapter 9 … BEFORE & AFTER RULE

16. How a RT densitometer is calibrated?

ASME V ARTICLE 2
17. When a welder is qualified as per an approved WPS under what conditions a requalification is
required…. Option include ‘when an essential variable changes’.

When the variables of QW-350 change 🡪 SAME AS

18. An existing tank 200 ft dia, 50 ft height, 3l4” thick , material not known requires hot tapping of 4”,
6”, 8” and 10” dia nozzles. Which of the following statement is true….. Option includes only 4” dia
can be made.

19. Type of fasteners used for floating roof seals ….options…cs. ss. Nonmetallic etc.

20. Welder symbol is not required for which type of joints?

CHAPTER 11 API 653 … easy … see question and reference below

21. What distance the welder symbol shall be stamped?

Every 3 feet

22. What is the maximum pressure of pneumatic test of reinforcement pads?

7.3.4 Inspection of Reinforcing-Plate Welds

After fabrication is completed but before the tank is filled with test water, the reinforcing plates shall be tested by
the Manufacturer by applying up to 100 kPa (15 lbf/in.2) gauge pneumatic pressure between the tank shell and the
reinforcement plate on each opening using the telltale hole specified in 5.7.5.1. While each space is subjected to
such pressure, a soap film, linseed oil, or another material suitable for the detection of leaks shall be applied to all
attachment welding around the reinforcement, both inside and outside the tank.

23. Who should carry out RBI assessment? Option includes original manufacturer, owner, authorized
inspector, person who is experienced in RBI methodology and design of tank.

653 🡪 6.4.2.2.2
24. Recertification requirements of Authorized inspector… option contains 20% of time spent
performing the inspection activities, inspection of 50 tanks etc..

20% Insp activity time & 75 tank rule 🡪 Recertification requirement

25. To check the hydrogen blisters hold the flash light against the shell so that the light beam runs
-------------- to the shell. Ans: Perpendicular, parallel etc.

Parallel to shell 🡪 Figure 40 & 41

26. Type of corrosion most likely to occur around heating coil connections at the tank wall? Ans: Caustic
stress corrosion cracking, hydrogen blisters etc.
 ALSO EXPECT WHITE SALTS QUESTION

27. While altering the tank shell by adding new plates what loadings should be considered…

Ans: wind and seismic …..i don’t remember other

options since I directly marked this option.

28. While replacing a shell plate on a horizontal joint what is the minimum length of horizontal joint to
be cut on either side of new vertical joint? Ans: 8”, 12” etc….

See Note 2 below 🡪 12 in

 , >2000F
29. Appendix M shall be used for tanks at what temperature? Ans: 100 0F , 200 0F etc.

30. Maximum interval for routine in service inspection?

31. When tank grounding system components will be checked? Ans: Routine in-service inspection,

external inspection by AI etc…

SEE API 575 🡪 7.2 & 7.3 🡪 25 OHMS = ANSWER (RESISTANCE MEASUREMENT with Ohm meter)
32. What is the number of locations where UT thickness measurement shall be taken in tank?
readings, as determined by owner/operator etc….

33. If No RBI is carried out what is the maximum interval of internal inspections?

QUESTION SHOULD LIST SAFEGUARDS 🡪 IF ANY …

Ans: 15 yrs, 20 years, 25 years etc. 🡪 MAXIMUM POSSIBLE = 30 years

34. Special safety procedures must comply with any federal or safety regulations pertaining to
---------Ans: Excavation, work permit, only exploration, confined space entry.
 LAST SENTENCE SECTION 1.4 🡪 API 653

35. To measure settlement where the bottom lap weld is parallel to shell _______. Ans : + 200.

FIGURE B.11 🡪 Floor Parallel to shell rule (+/- 20 degrees)

FIGURE B.12 🡪 Floor Perpendicular to shell rule (+/- 20 degrees)

See figure B.13 for clarification 🡪 Arbitrary angle (not parallel, not perpend)

36. No of settlement measurement points for 65 ft diameter tank? Ans: 6, 8, 10 etc.

37. Where the name plates shall be attached to re-constructed tank? Ans: Adjacent to the existing
name plate.

38. Inspection reports along with inspector recommendations and documentation for disposition shall
be kept up to ______ Ans: 10 years, 5 years, life of the tank etc.
39. How many years’ radiographs shall be retained? Ans: 5 years, 1 year, 10 years etc.

40. Material used for fasteners of floating roof seals? Ans: CS, Stainless steel, nonmetallic etc.

41. Major reasons for coating failure of tanks? Ans: Improper specification, curing etc.
API 652 … SURFACE PREPARATION 7.1 … Surface preparation is a critical part of the lining application.
Continuous immersion is a severe exposure. Inadequate surface preparation is a major cause of lining failure.

10.5 DETERMINING THE CAUSE OF LINING DEGRADATION/FAILURE

If lining degradation is detected, the cause and extent of coating degradation must be established, as well as whether
or not the existing lining is suitable for a repair. When evaluating the condition of an existing lining, one should
consider whether deterioration is premature or whether the lining has achieved its anticipated performance life.
If degradation or failure of a lining is premature, it is important to understand and address the cause of such
degradation prior to determining whether the lining should be allowed to be repaired or refurbished vs. be
completely replaced. A review of the tank’s operating history and a visual examination of the lining should be
conducted to determine whether the problems were a result of environmental attack, local mechanical
damage, and/or if inadequate surface preparation or improper lining installation were contributing factors.

42. Welding procedures shall be qualified as per which code?

43. RT requirement for circular replacement shell plate. 🡪 653 12.2.1.6.1

NOTE: ALSO REPORTED WAS 12.2.1.6.2 🡪 ¾ inch thickness 🡪 apply the rules below Up to 6 shots

TWO RULES … 1 (6 inch shot) for T ≤ 1 inch or 100% RT for T > 1 inch

44. What is the primary purpose of post weld heat treatment? Ans: To relieve residual stresses.

API 577 CHAPTER 10.5 & 10.6 🡪 LALA’s THREE STAR TEST Qs

Know primary purpose for BOTH PREHEATING & PWHT

45. Abrasive blasting climate condition requirement, steel temperature shall be ______?

… 652 … 7.4 ENVIRONMENTAL CONDITIONS DURING BLASTING

Abrasive blasting should not be performed if the temperature of the steel surface is LESS THAN 5°F (3°C)
ABOVE THE DEW POINT or if the relative humidity is greater than 80% (see 8.3).

46. On a fixed roof, planks long enough to span at least----------------- rafters should laid to use as
walkways for inspection? Ans: 2.

7.2.9 Tank Roof Inspection

The roof or top head of a tank can be inspected for significant thinning by ultrasonic thickness examination or even
by MFL scanning (if the roof condition is thought sound enough to withstand the weight of the equipment). Hammer
testing may dislodge scale from the internal plate surfaces into stored
product and is not a recommended method of establishing roof plate integrity for personnel loading. Suitable fall
protection should be used when working on roofs. On a fixed roof, planks long enough to span at least two roof
rafters should be laid and used as walkways, at least until the safety of the roof is determined. In general, the
inspector should always walk on weld seams if they are present, because of the extra thickness available to support
body weight. On a floating roof of unknown or questionable condition (e.g., insulated roof decks), the same
precautions should be taken. In addition,
because of the possible existence of harmful vapors, the floating roof should be as high as possible if volatile liquid
is in the tank at the time of inspection.

47. Seams of riveted tank can be checked by -------------------- Ans: By running a thin blade scraper or
knife along the riveted seam.

575 Chapter 7.4.4 …

Pits can sometimes be found by scratching suspected areas with a pointed scraper. When extensive and deep pitting
is located and measurements in the pits are necessary, the areas may be abrasive-blasted Þrst, although it should be
noted that this process can also create holes or open existing holes. The
depth of pitting can be measured with a pit gauge or with a straight edge and steel rule (in large pits). An estimated
depth can be found by extending the lead of a mechanical pencil as a simulated depth gauge. Seams of riveted
tanks can be checked by running a thin-bladed scraper or knife along the riveted seam. If the seam is open, the
scraper will pass into the opening and disclose the separation. Rivets should be checked at random for tightness.
Rivet heads should be checked visually for corrosion (see 7.2.9). This may involve considerable scraping and
picking to clean corrosion products from the rivet head. Consideration should be given to determining whether
enough of the rivet head remains to last until
the next inspection. Figure 52 shows a special case of severe corrosion near a tank bottom seam. The tank contents
were acidic and were kept in motion with an agitator. This deterioration, a combination of corrosion and mixing
erosion, would be further accelerated by the high stresses in the area of the riveted seam.

48. Brittle fracture least likely for ------------- Ans: Thickness <1/2” rule.
API 653 Chapter 5 … Step # 3