API 653 (2020) API 653 Exam (Revised on July, 2022) 1. Scope of API 653 API653 covers in-service inspection, repair, alternation, relocation and reconstruction for steel storage tanks that have been built or constructed to API 650 (1961) & API 12C (1936) Conflict - API 650/12C & API 653-API 653 -API 653 & jurisdiction jurisdiction (More stringent) If the requirements of this code (API 653) are more stringent than the requirements of the regulation, then the requirement of this standard (API 653) shall govern. Recognize codes-FFS-579 & RBI-580 Ultimate/overall/limits of responsibility-owner/operator Personnel Protection (Health and safety)-API 2015 and API 2217A Welding and Hot Work- API 2009 Tank internal inspection- Confined space federal or state safety regulation. 2. Normative References API 2201- Hot tapping API 580- RBI API 579- FFS API 651- CP API 652-Linin API 2003- Hydrocarbon ignition covered API 2009-Welding and hot work API 2015, 2217A - Confined Space ASNT-SNT-TC-1A - (UT/RT- Level-1 & II) NDT examiner’ Technician qualifications, PT/MT/VT- Competent person ASME SEC V- NDT (UT, RT, PT, MT) Procedures NDT examiner Performance test API 650 Atmospheric Storage Tank (Operating pressure-up to 2.5 psig) API 620 Low Pressure storage tank (Operating Pressure >2.5-15 psig) ASME SEC IX Welder, WPS & PQR Qualifications ASME B16.5 Flange (1/2 to 24") ASTM A370 Mechanical/ Impact test procedure API S78 PMI MVPDefinitions Alteration - Any work on a tank that changes its physical dimensions or configuration Authorized inspection agency (JUIC)-Jurisdiction, owner/operator, insurance company, and contractor. Except- Manufacturer Candidate tank - CR unknown Control tank - CR known (Different in between candidate & control tank- CA/Age of tank) Critical zone -The portion of the tank bottom or annular plate within 3" inch of the i measured radially inward. jide edge of the shell, Current applicable standard- the current edition of standard, Examiner-A person who assists the inspector by performing specific nondestructive examination (NDE) on aboveground storage tanks and evaluates to the applicable acceptance criteria, but does not interpret the results of those examinations in accordance with API 653, unless specifically trained and authorized to do so by the owner/operator. FFS - 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, Major alteration/major repair- Installation shell penetration (Nozzle) >12 inch beneath the design liquid level; -Installation bottom penetration <12 inch of the shell; -Removing and Replacing or adding >12 inch shell plate beneath the design liqui -Removing /replacing >12 inch annular ring; -complete or partial > /% WM removal and replace >12 inch vertical weld joining shell plates or radial weld joining the annular plate ring; -Installing a new bottom, (installing portion of new bottom not major Repair/alteration) -Portion replace >50% (1/2) tank bottom a annular plate ring -Jacking a tank shell level; Repair- Suitable for safe operation Repair organization- Jurisdiction, owner/operator, Contractor. Storage tank engineer-persons acceptable to owner/operator and knowledgeable and experienced in engineering/evaluation of mechanical/material of above ground storage tank (AGST). Installing NPS 12" nozzle, (not major repair/alteration)- hydro test no required If FFS evaluation is not performed, which is require hydro tes weld. 2-Remove of 18" of complete shell to bottom4. Suitabil y for servi When the results of a tank inspection show that a change has occurred from the original physical condition of that tank, an evaluation shall be made to determine its suitability for continued use. Roof Plate average thickness < 0.09 inch in any 100 inch? area or hole-repaired/replaced When a frangible roof to shell joint required evaluate (tank bottom to shell joint corrosion/tank roof to shell joint modification)-API 650, Frangible roof to shell slope < 2:12 Floating roof pitted areas evaluated to determine the likelihood of through pitting occurring prior to the next schedule internal inspection affected area-repaired replaced. Tank roof and roof to shell junetion - API 650, Appendix - F Tank roof and Partial vacuum - API 650, Appendix -V Operation at elevated temperatur 100 °F to < 500 °F - API 650, Appendix - M External floating roofs - API 650, Appendix - C Internal floating roofs- API 650, Appendix - H The evaluation of the tank shell (Pressure ~ static, internal and external pressure- wind, seismic load) - Tank engineer Pitting doesn’t normally represent a significant threat to the overall structural integrity of a shell unless present in a severe form with pits in close proximity to one another. Thickness required to finding Height (H) ta-ca Actual thickness determination: Lis the maximum vertical length in inch over which hoop stresses are assume to “average out” (40") around local discontinuities. Critical Length L = 3.7 VDE2 but not more than 40" Thickness determine ~ Authorized inspector Profile measurements shall be taken along each vertical plane for a distance L. Lowest average thickness 11, least thickness 2, averaged over length to L, using at least five equally spaced measurements over length L. The criteria for continued operation is as follows: 1 mmin+CA 12 = 60 % of min +CA Widely scattered pits ignored - pit depth Remaining Thick < > tmin without CA, Sum of thelr dimensions at Vertical line < 2" in 8" length Tank diameter < 200'- One foot method (API 650 & 653) Tank diameter >200'- Variable Design method (API 650)26(-1)06 SE tmin = (Entire shell course/General corrosion) _26HDG tmin = <> (Portion of shell course/Local thinned) Shell tmin 0.1 inch E= | corroded area away from welds, or > 1" or 2T, E = 1 6”away from rivets. Hydrostatic test height Ht= "2" 4 1 (Entire shell) Hydrostatic test height Ht= 2%" (Locally thinned area) ASTM A 516 gr.70 lower shell course S = 33000 psig Table- 4.1 Allowable stresses, Reconstruction/New -API 650 Table 5-2a/5-2b Unknown material MSYS-30,000 psig, Unknown butt welded joint E = 0,70 Thickness determinations consider- Liquid Loading only. Alternative evaluation (ASME Section VIII div-2)/ (Any thinning below thick- design by analysis) Sm= Original design if < 2/3 SMYS or 1/3 MSTS; Sm< 2/3 SMYS or!/, SMTS if > 2/3 SMYS or 1/3 SMTS For tanks with riveted joints, consideration shall be given to whether, and to what extent, corrosion affects such joints. If calculations show that excess thickness exists, this excess may be taken as corrosion allowance. Shell distortions include- out of roundness, buckled areas, flat spots, peaking and banding at welded joints. Except-Out of plumpness or planner tilled. Shell distortions caused by-foundation settlement, over/under pressure, high wind, and poor fabrication, Repairing such as are strikes, gouges, tears from temporary attachment welds must be evaluated- case by case basis. Crack in the shell to bottom weld shell be removed. Excessive weld reinforcement does not require rework if the tank has a satisfactory history of service. If the reinforcement will interfere with floating roof seal operation, it shall be ground as required. Undercut of shell butt welds resulting from original construction shall not require repair if the tank has been hydro tested or will not undergo a change of service. Shell penetration (Nozzle) - thickness components- reinforcing plate, nozzle neck, bolting flange, cover plate except weld buckled. Existing welds on tank shell closer than required by API 650 (Seventh edition or later) acceptable for continued service- Examined by MT or ACFM. Nozzle wall thickness shall be evaluated for pressure and all other loads. Conversion to operation at elevated temperature (API 650, Appendix-M) - shell to bottom joint evaluated for fatigue cracking Periodic assessment of tank bottom integrity shall be perform < the appropriate internal inspection intervalRPB- Placed in the bottom of or under a tank-preventing and containing for leak detection Bottom plate thickness- MFL+UT. Ultrasonic thickness measurement techniques are often used to confirm and further quantify data obtained by MEL examination The use of leak detection tests or monitoring systems (such as double bottoms or liners under tank bottoms with leak detection pipes) will satisfy the requirement for periodic assessment between internal inspections. MRT= ta ~ Interval (R top + R bottom), Interval= mn Rtopt R bottom An Example: CR = 0,0075, ta = 0.298, MRT = 0.1 (no mentioned) MRT= tact- Interval (Rtop+Rbottom) Interval 0.298- 0.1 / 0.0075 = 26.4 = 0.191- 10(0.007+0.006) = 0.181 For the probabilistic method, a statistical analysis is made of thickness data from measurements projecting remaining thickness, based on sample scanning of the bottom. Unless a stress analysis is performed, the minimum bottom plate thickness in the critical zone of the tank bottom defined in 9.10.1.2 shall be the smaller of one-half the original bottom plate thickness (not including the original corrosion allowance) or 50 % of min of the lower shell course per 4.3.3.1 but not less than 0.1 in, Isolated pitting will not appreciably affect the strength of the plate, The repair of internal pitting, when performed to extend the in-service period of operation, shall be by pit 1g, overlay welding, or lap patching, followed by inspection and testing, Critical zone of bottom plate thick- not less than 0.1", shell to bottom fillet weld size > 0.1" Min thick annular plate ring 0.10", (4.4.6.2) Existing Bottom projection = Table 4.4 Bottom plate min, Thick- at next inspection - 0.10 with no means (Maximum Interval 20 years ch.6), 0.05 with means (Maximum Interval 30 years ch.6). Table 4.5 annular plate Thick 1/5 = Stress 23000 psig- 0.17", Stress calculated =°— An example: A 285 gr. C, Dia 100, store product Specific gravity=0.9, First shell $ = 23600, shell thick 0.5", Annular plate thick? Calcining - Loss of water of hydration concrete exposed to high temperature for period of time. Distortion of anchor bolts-uplift condi 5. Brittle Fracture considerations Any change in service must be evaluated to determine if it increases risk of failure due to brittle fracture, Change to a more severe service ~operating at lower temp, handling product higher specific gravity (need for hydro test) deterioration of the tank since original hydrostatic test. ‘No chance for brittle fracture thick -API 650 (Seventh Edition or later) or API 650, Appendix G (Fifth and Sixth Editions) , < 0.5", temp > 60 °F, stress < 7000 psig. Unknown toughness will apart a min temperature 20 °F and thinnest tank shell that can be exempted from addition toughness assessment thick 0.5" for safe operation (Figure 5.2)The owner/operator can also make a more rigorous analysis to determine the risk of failure due to brittle fracture by performing a fracture mechanics analysis based on established principles and practices. The procedures and acceptance criteria for conducting an alternative analysis are not included in this standard. 6. Inspection Routine in service inspection -used inspection from the ground on a routine basis -by owner/operator or authorized inspector or other than authorized inspector. -one month = report not required. - qualification not required External inspection = by authorized inspector < Vy x © or 5, RCA = ta-tmin ,N ce aw : RL or 5 (Whichever is less) Insulated tanks — insulation removal — extent necessary to determine the condition of exterior wall Tank grounding ~ shunts/mechanical connection — visually checked ~ API 2003 UT thickness, measurements — extent/ no of UT measurement requirement-owner/op Inspection Interval: An example: -CR unknown ~ <5 years CR 0.003, ta 44, tmin .301= interval 15 Yrs = CR Known 12" or 12 (circular, square, rectangular except- enter) Existing horizontal welds cut min 12" distance prior to welding vertical welds. Figure 9.1 Find C value >3" or St (Acceptance criteria for detail shell plate replacement) Note. 2,3 To reduce the potential for distortion of an existing tank due to welding a replacement plate into an existing tank shell, fit-up, heat input, and welding sequence must be considered. Shell repairs using Lap welded patch: All repair materials - Current applicable standard and API 653 Lapped patch shell repair not be used on any shell course Thickness >2” Repair Plate - + or corroded shell thick not less than 3/16", radius min 2” - cross butt welded ver Vhorizontal- min overleap 6" (Lap patch) - Vertical and horizontal dimension 48" and 72" (maximum), min- 4" - Prior to application lap patch -UT for detect defect and reaming thick - not installed on existing patch. Outer perimeter of repair plate- hole dia. min 2" min, E= .70, dimension min 4”, overleap min 1" and maximum 8T (T= shell thick) as built Std. 9,5 adding new shell plate- current applicable Std, wind and seismic load. 9.6 Repair of dective Wel Crack, LOF, rejectable slag ete shall be removed completely by gauging and or grinding then welding, Excessive reinforcement shall be repaired by grinding if required by 4.3.8.2. Existing weld undercut unacceptable shall be repaired by additional weld metal, or grinding, as appropriate. Welded joints that have experienced unacceptable loss of metal due to corrosion shall be repaired by grinding and/or welding, Surface defects, such as arc strikes, shall be acceptable if the tank has been hydrotested or will not undergo a change of service Unacceptable surface defects shall be repaired by grinding and/or welding, Are strikes adjacent to welded joints repaired by ~Grinding and/ or welding. Are strikes repaired by welding shall be ground flush with the plate, Fillet weld for penetration (Nozzle) (Figure 9.7) (An example RP T = 15/16 shell t= 15/16 Ans. Fillet weld size tombstone shape (Figure 9.8) (An example t= 11/8, T= 7/16 Ans, 7/16)Replace shell penetration: Insert plate tapered 1:4, unknown materials stress =20,000 psig. Penetration >4" NPS use insert plate (without RP), if shell plate >1/2" and does not meet the current design metal temperature criteria. Insert plate dimension min (circular/ non circular) >2D or D+12" Existing shell perpetration: ‘A new bottom may be installed through an existing tombstone reinforcing plate, provided all weld spacing and reinforcement requirements, as specified in API 650, are met. One of the following methods shall be used, a) Remove only that portion of the existing R.P necessary to weld and test the new bottom shell weld (Fig- 9.10) b) Bevel the shell from the inside to allow for a full penetration weld between the bottom and shell if annular plate or bottom sketche plate thickness > 10 mm (3/8 in.). Fig-9.11 4) Lower portion of existing RP removed and reinstalled after new shell bottom weld completed (Fig- 9.8) e) Existing R.P may be remove, modified and reinstalled after the new shell to bottom weld (Fig- 9.8) Fig-9.12 Find H\J value (installing new bottom through existing tombstone RP) Repair of tank bottoms: Patch min Dimension 12" patch not allowed on tank bottom- global/local dishing NOTE If the tank is still undergoing settlement, the addition of welded-on patch plate may not be advisable, Repair in critical Zone: Maximum patch plate thick + , Minimum dimension between two welded-on patch plates in the critical zone shall be one-half of the dimension approximately parallel to the shell of the smaller patch. Maximum dimension 24”, if <6" of shell plate tombstone 90 perimeter patch plate, spacing greater of 3” or St, two pass welds min, examined -MT\PT (Note, Bottom plate min thick 0.1"), Fig-9.13 tank bottom patch plate, three plate lap shell be extended min12", 45 or 90 degrees Repair in critical zone: No welding or overlay permitted except pits, pinholes, cracking the bottom plate welding not permitted CS @ operating temp >200° F or SS @ temp >100° F Sum of pit dimension <2" in 8" length Replace of tank bottom: For Aluminum Floating roofs, pads way be omitted if the owner/operator approves and new austenitic steel/nonmetallic acceptable. Removing existing tank bottom min of 1/2" above the bottom to shell weld (Fig- 10.1) or removing entire shall to bottom, including any penetration, heat effected zone- are gouging and/grinding. Are gouging area MT and defective area repaired & re-examined. For tanks constructed from materials having 50,000 Ibf/in.2 yield strength or less, the required spacing of the welds may be reduced from the requirements of 9.10.2.4 if the following conditions are met. The blend-ground lengths of welds listed in 9.10.2,7(d) shall be magnetic particle examined before and after hydrostatic test.Supported cone Roof: Min thick of new Roof plate 3/16 (plus any CA) Nominal thick of new roof plate 3/16" or tmintCA (Whichever is greater) If the roof rim thick <0.10" shall be replaced. New roof rim 3/16" min t Hot tapping: API 2201, Known toughness-Table 9.1 Nozzle size $ 18" thick 4", Nozzle thick XS, Low hydrogen electrode. Unknown toughness tank shell pate- Nozzle <4", All Nozzles reinforced, Stress <7000 psi, min height at least 3' liquid above. Hot taps not permitted on roof or gas/vapor space, on pitted/laminated shell plate, cause cracking, and lethal service. Shell plate thick min of four places along the circumference of the proposed nozzle location. NS= WRT D=Dia. T=shell thick, NS Space between Nozzle 1.5 hydrostatic Head (prior hot tap when Nozzle Flange bolted valve) Pipsi)= 1.SH2Gp0 Fig 9.14, distance bet. RP @ vertical weld 12" min, telltale whole %", 1/," Alter the pipe is welded, the reinforcing plate shall be installed either in one piece or two pieces with horizontal weld. 10. Dismantling and Reconstruction Inspection hold points-authorized inspector Bottom-plate cut by de-seaming of lap welds at min 2” away for existing welds. Tank shell plates may be dismantled using one of the following methods or a combination thereof. Shell-dismantled by cutting- HAZ- < 1/y weld width or 1/4" on both side of the weld seam Shell rings may be dismantled by cutting vertical and/or horizontal cuts through the shell a minimum of 6 in. away from existing welds, except where cuts cross existing welds, Vertical joints offset St (min) No welding < 0 "F, if 0-32 °F or, T>1" temp warm to the hand 140"F. > Fe preheat 200 °F Table- Reinforcement height on new welds (Visual) (< 1/y"—at vertical joint 3/3") Dimension tolerance: Plumpness 1/4 9 but maximum 5" (As per 65055), Roundness radii/radius - above | foot roundness < 3x ‘able -10.2 radii tolerance (40 to <150 dia. > + 3/4) tank dia 48" Peaking Horizontal sweep board 36" @ Vertical joint <1/," tolerance given in Banding- Vertical sweep board 36" @ Horizontal/circumferential joint < 1" 11, Welding: PQR, WPS, Welder qualification - ASME Section IX Weldability of steel from existing tanks shell be verified. Welder identification <3’ ( Feet) not required on roof and flange to nozzle neck welds Prior to use any alternative (preheat/CDW alternative to PWHT) metallurgical review by tank engineer.Process SMAW, GTAW, GMAW, FCAW, preheat 300 °F ( 0.35% CDW alternative to PWHT (temper bead/Half bead) reinforcement shalll be flush grind cool to ambient temp |, interpass temp 600 °F (Max), Carbon < 12. Examination and Testing Shell penetration (Nozzle) - UT for shell plate lamination (additing RP & hot tap) Completed welds (Fillet Welds) - nozzle neck to shell, RP to shell, Shell to Nozzles- MT/PT after stress relief but before hydro testing. Completed welds (Butt Welds)- RT/UT Full length of repair Temporary/permanent attachment (not including shell-to-bottom welds) to shell plate- removed- MT/PT Shell to bottom weld- New welding- right angle, vacuum box and solution film/light diesel oil ~ Existing- visual & MT/PT Bottom- New welds- VT, bottom repaired- MT/PT and VB and solution/tracer gas & detector Critical zone- welded patch root and final pass- VT and MT/PT Shell plate- repaired by weld metal deposit or Lap Patch - VT and MT/PT Floating roof- repaired- VT, Air leak, VB, penetrating oil, tracer gas, as an alternative flotation test, Except RT RT- reconstructed tank RT- 25% of all junction joints ‘New and replaced shell plate and door sheet RT- all junction, if defect found 100% RT. Circular replacement min one RT, if thick >1" full RT, Square and rectangular replacement plate- IRT @ vertical joint, IRT@ horizontal j comer, thick >1" vertical full nt and IRT@ each Min diagnostic length RT- 6", RT- all repaired welds- R Insert plate and shell plate- full RT Hydro test required- Full hydro test 24 hours a) Reconstructed tank, b) Major Repair’ alteration, c) Engineering evaluation severity of service increase operating pressure, higher specific gravity and lower temperature. Hydro test exemption repair reviewed and approved by tank engineer & authorization owner/operator exemption writing must agree tank engineer and owner/operator. Stress repair area < 7000 psig, FFS evaluation by tank Engr. 264DG t S: Leak test new or altered RP of shell penetration- Air leak test (15 psig) Settlement- Min no. of evaluation point shall be N min no of settlement > 8 An example 65/49 = 65,8 Settlement Survey- During filling and test water reaches 100%, measurement spacing max 32!Corrosion resistance (SS) > 5 ‘New name plate — shell adjacent to the existing name plate Record keeping- RT at least one year Annexure Annex- A (Tank Std.) API 12C - 1936, API 650- 1961 Annex- B Tank bottom settlement evaluation ~ Personal Experienced, Additional settlement required- local bottom expressions or edge settlements, Max spacing 32' around circumference max spacing 10’ across Dia, (Figure B.2) ‘Additional settlement readings may be required to better define local bottom depressions or edge settlements, to refine shell settlement measurements in areas suspected to have local out-of-plane settlements, or to otherwise improve bottom or shell settlement evaluation. Edge settlement occurs when the tank shell settles sharply around periphery- shell to bottom junction (Figure B.6) Measure the bulge/depression By = 0.37R Here in R= Feet, By = inch Figure- B.10, Repair above this line Edge settlement maximum allowable settlement parallel/ Perpendicular to the shell +20” 2.3% Acceptable str: B.4.2 For tanks with edge settlement exceeding the limits and assumptions given in B.2.3.1 through B.2.3.7, the tank should be repaired. Any plate exceeding acceptable strains (typically 2 % to 3 %) should be replaced. Settlement exceeds 75%- VT and MT/PT (Figure B.11, B.12) An example- Parallel to the Shell, Dia. 120', radius of settlement 48" (4') Answer 4.6" Tank edge settlement exceeding limit tank should be repaired plate exceeding replaced ex C eck. Floating roof drain plugged - Roof drain open or unexpected rain Rock crushed - rock underside corrosion Anchor piping earth movement. Roof insulation- wet insulation under the weathercast. Lower portion/ Roof support legs properly supported (internal inspection primary concern)‘Swing line freedom of movement > 65° Bracket required Annex-D Authorized inspector Certification- Recertification- 20% time spent performing inspection in API 653 Annex- F NDE requirements ~ RT/ UT technician ASNT- SNT- TC- LA. Tracer gas by Purchaser VB 3-5, psig, Duration 5 See Annex- G TBE & PQ- MFL/UT scanning operator training 40 hrs, Requalification- inspection reason to question the ability of the examiner. Tank bottom test sample min 70 ft, Area of general corrosion 100% not coated +/-0.020" £0.05 70-90% +.020" Annex. H, Similar service assessment: Control tank and candidate not match age of the tank considered in the corrosion rate calculation similar service product H — Crude oil. Annex, C Roof drain an external floating roof tanks should be checked? -After a significant rainfall Before inspection of Dec plate near the edge of the roof- blow clean with compressor air, API 650 (2021) API 653 (Revised on July.2022) Section-2 Normative References ASNT-SNT-TC-1A-Personnel Qualification and Certification in Nondestructive Testing Section-4 Materials Ifyou want ASTM A283 instant of A36- require purchaser written approval. ASTM A283 gr. ¢ for plate’s thick <1" F Ib Min Design Metal Temperature (MDMT) without impact testing Figure-4,2 One day mean temperature Los Angeles/coliform. 35°F (same as F-4.2) Min Temp = One day mean temp + 15°F Table 4.4b Material groups (USC) Table 4.5b Impact test- ASTM A370, 03 specimens, average value, and one specimen can break > 2/3x avg Section-5 DESIGN Vertical Shell joints off set > St (t= thicker course thickness) Lap welded bottom joints-Three laps in tank bottoms > 12" from each other Shell to Bottom fillet welds (5.1.5.7) ~An example, nominal thick 1.25” of shell, fillet weld size? =5.3.4 Hardness Testing-one test shall be conducted for each vertical joint and one test shall be conducted for each 100° (3 m) of circumferential’ horizontal joint. An example-Tank Dia 160”, 5 Shell, 22 Vertical joints@ shell. HT@ Horizontal joints = (60x3.14x4) /100=20 and HT @ Vertical joint = 22x5 = 110 Drip ring (5.4.5.3) Dripping shell extend > 3" Table 5.1b Annular Bottom plate thick Required shell thick > design shell thick +CA, Hydrostatic shell thick, Arbitrary 26 D(n-1)g 7 26(h-1) tg + CA,t =O, arbitrary ‘New/ reconstructed tanks, Allowable stress (Table-5,2b) Unknown CS, Yield strength= 30,000 psi Reinforcement required Nozzle size >2" Insert Plate tapered 1:4 Extent of RT for vertical/Horizontal weld if nozzle/Manhole repads cover the existing welds-3D of the opening with owner permission (5.7.3.4) PWHT-temperature min 1100" F, Holding | br. /1" thick (5.7.4.8) Gasket dimension, Manhole flange, and cover-API 620 (Ring Gasket) Rectangular Roof opening Manhole size= (6x 3) Feet Fig-5.17 Min width of stair ways 28" (Table-5.18) Stiffening Ring-thick 1/4» uninshlated tank drain hole >1dia. Insulated have no drain hole/ slot. Roof plate thick 3/;. (Roof to shell fillet weld size), Frangible roof-IF roof to shell joint fail prior to the shell to bottom joint in the event of excessive internal pressure, slope (angle of roof at top) <2:12 Roof support Column-wear plate min thick+/,., welded to the tank bottom weld size 1/4 " Flush type clean out fittings- cover plate, Bolting Flange, Bottom Reinforcing plate. The shell plate in the clean out opening assembly shall be-At least as thick as adjacent shell plate lower course. Section- 6 Fabrication Zine or cadmium coating in the weld area to the pressure boundary distance- %" (.5") Fig- 6.1 shaping of plates-An example, data given, Shell plate thick 3/8", tank Dia. in less than? 60 shaping required Lamination 3" length, depth 1" repair made by edge gouging and relending to seal the lamination. Section- 7 Erection Table 7.1b min preheat temperature.Examination and testing of the tank bottom — vacuum box/ tracer gas test. Vacuum box testing- Pressure 3-5 psi, overleap 2", temperature 40-125"F, Light intensity 100 fe (1000 lux), and time 5 second. Tracer gas- owner/operator) Purchaser Reinforcement pad- Pneumatic test (Air test) <15 psig by manufacturer for the detection of leaks. All attachment welding around the reinforcement, both inside and outside of the tank. 7.3.6.5 Water Filling Rate Plumpness < = of total tank height, roundness — Radii at I', Dia, 150'~ tolerance + 1" Peaking- "vertical weld, horizontal sweep board 36", Bending - 3"Horizontal weld, vertical sweep board 36" 7.5.5.2 Foundation Tolerances. Section-8 Methods of Examination Joints 8.1.2, Figure 8.1 & Notes. RT for Butt welds shell plate > %" But < 1" RT (Spot RT) diagnostic Length min 6" (150 mm) Reinforcement height of RT (8.1.3.4) and for VT (8.5.2), undercut @vertical Joints" undercut @ horizontal joints 1/32" RT acceptance criteria- ASME Section VIII, UW-51 (b) Section 9 WPS and welder qualification PQR, WPS, & WPQ qualification as per ASME Section IX. For vertical joints material design temp 200°F, <500°F Annex-F tank Roof/ Roof to shell junction Annex-V partial Vacuum API 575 (2020) API 653 (Revised on July, 2022) ‘Terms and Difini ns Atmospheric pressure tank/API 650 designed tank operating pressure up to 2.5 psig Crude oil, heavy oils, gas oils, furnace oils, naphtha, gasoline, and nonvolatile chemicals are usually stored in atmospheric storage tanks. Low pressure storage tank/ API 620 designed tank operating pressure > 2.5 to 15 psig Light crude oil, gasoline blending stock, light naphtha, pentane, volatile chemicals, liquefied petroleum gas (LPG), liquefied natural gas (LNG), liquid oxygen, and liquid nitrogen are examples of liquids that should be stored in low-pressure storage tanks. Types of storage tanks Cone Roof, Umbrella Roof, Geodesic Dome Roof, Self-supporting Dome Roof, Pan Type Floating Roof Tanks ete. Floating roof tank designed to n vapor space above the storage liquid. izing filling and breathing losses by eliminating or minimizing the 5. Reason for inspection and causes of deterioration Pressure/ vacuum vents and flame arrestors can failed-the presence of fouling materials Clay, wood, crushed stone as contaminates is a sand pad-Pitting corrosion (etevice) Internal corrosion of tank in the vapor space caused by-Hydrogen sulfide vapor, water vapor, O2 or combination of these. Internal corrosion of tank in the stored liquid caused by-acid salts, hydrogen sulfide or other sulfide components. In the areas in contact with the stored liquid, corrosion is commonly caused by acid salts, hydrogen sulfide or other sulfur compounds, dew point corrosion, or contaminated water that settles out and mixes with solids on the bottom of the tank, typically referred to as BS&W. Exami ion of tank venting devices should be included in - a periodic inspection to ensure that their proper operation and protection are maintained Inoperative drains with installed plugs (or with closed valves) can cause enough rain water to accumulate on the roof to sink a pontoon-type floating roof.In order to calculate bottom plate CR inspection must check past tank inspection reports to obtain in go on?- Min thick and date of measurement 7, Frequency and Extent of inspection An example: 5 years ago thick0.5", tmin 0.4", ta=0.420, CR=? CR==—"*= 0.016 IPY tp-ta_ py _ta-tmin Time? Scr Similar service CR-May be used lieu of, or is addition to, actual measurement of CR. 8, Methods of inspections Tank cleaning methods dependent on the amount type of scale, sediment, solid product/foreign materials, The opening or joint between tank bottom and concrete pad or base ring should be sealed to prevent water from flowing under the tank bottom. Corrosion & suspect conditions- the resistance to be checked. Grounding connection total resistance <25 ohms, Paint blister occurs on roof and tank side the most sun light. Significant corrosion can occur beneath insulation, at points near gaps in the weather protection, and in areas of the lower shell. CUI-most aggressive temperature 170-230°F but can occurs 10-350 °F, significant corrosion occurs beneath insulation near gap lower shell, water contact with surface. tu Tank Shell Inspection Inspection for coating failure to locate corrosion on the extemal surfaces of the tank can be of critical importance. Corrosion may occur on the shell near the bottom due to buildup of soil or other foreign matter and where product leakage occurs, especially if the tank contains corrosive materials, Caustic cracking-Internal heating units or coils, crack star, temp>150°F (>170 °F As per API 571) Hydrogen blister-Flashlight against the shell so the light beam shines parallel to the shell surface. On fixed roof planks long enough to span at least two roof rafters. Drainage systems on floating roofs should be inspected frequently for leakage or blockage. If the drains are blocked, an accumulation of liquid can cause floating roofs to sink or to be severely damaged. Pressure/vacuum vents and breather valves should be inspected in accordance with 5.5 to see that they are not plugged; that the seat and seal are tight; and that all moving parts are free and not significantly worn or corroded. Thickness measurements should be taken where deterioration is located. Plugging of the discharge side screen and buildup of solids on the pallets are common problems. Flame Arrestors should be opened (verified) at appropriate interval. Fouling/ corrosive materials solidification of vapor restrict flow also. Inspectors should also be alert to accumulation of dry pyrophori Ignition substance found at tank bottom or top of rafter. material during inspectionPipe line break out tanks are often susceptible to accelerated corrosion behind —floating roof seals. Tank bottom statistical methods -0.2-10% of the tank bottom should be scan randomly. Depth of pitting can be measured by pit gauge/ mechanical lead pencil If corrosion noted on roof, upper shell-twice the rate of the thinning of the roof or shell, since both side of the structural members are exposed to the corrosive vapors Light hammer taps can be used to test-tightness of bolts or Rivets, and soundness of structural members except cast iron pasts, the coils and supports may be UT/Hammer tested. Testing of tank —Air test using air pressure <2” (0,50 kPa) inch of water pressure may be applied For gauge calibration-dead weight tester or calibrated test gauge 10. Integrity of repair and alteration Typical methods inspection of riveted joints repair-including visual ,penetrating oil, hammer testing and vacuum box /tracer gas techniques. AET/ ACEM: live crack, crack growth, crack formation, crack propagation. Personnel enter, under roof, before a floating roof is landed? -Check floating roof legs for corrosion structural integrity, A tank pipe connection enters the ground immediately after existing tank. How should the pipe be inspected?-MPI the pipe for cracking corrosion at the soil Annex A Dual-element transducers are frequently selected, and they are available with many different operating ranges. Dual-element transducers may have the ability to measure thin sections from 0.050 in, to 1.000 in. (1.3 mm to 25 mm). API 571 (2020) API 653 (Revised on July, 2020) The information for each damage mechanism is provided in a set format as shown-Name of the Mechanism-Description of Damage -Affected Materials-Critical Factors- Affected Units or Equipment-Appearance or Morphology of Damage- Prevention/Mitigation- Inspection and Monitoring- Related Mechanisms- References. Texms Nickel Alloy ~ Nickel Containing > 30%, Example C276Atmospheric corrosion: Marie environments, corrosion rates increase < 250°F and above 250 °F surfaces are usually too dry for corrosion to occur except under insulation, Bimetallic connections such as copper to aluminum electrical connections. Painting/ coating to preventive ATM corrosion. Brittle Fracture: Brittle fracture is the sudden rapid fracture under stress (residual or applied) where the material exhibits little or no evidence of ductility or plastic deformation. CS & Low alloys. In most cases, in materials that exhibit a ductile-to-brittle transition, brittle fracture occurs only at temperatures below the Charpy impact transition temperature (stresses at the crack tip and promotes brittle also called the ductile-to- brittle transition temperature), thicker material wall increases triaxial, Startup, Shutdown & Brittle fracture can occur during ambient temperature hydrotesting due to high stresses and low toughness at the testing temperature. Routine inspection is not normally used to detect or mitigate brittle fracture. Caustic Corrosion/ Caustic Gouging: Caustic/ alkaline (NaOH or KOH) must be present. Temperature. >170° F, Prevented in steam generating equipment through proper design. In process equipment, caustic injection facilities should be designed to allow proper mixing and adequate dilution of caustic in order to avoid the concentration of caustic on hot metal surfaces. Caustic Stress Corrosion Cracking (Caustic Embrittlement): Caustic soda (NaOH) and caustic potash (KOH) at elevated temperature to non-PWHT’d welds in adjacent base metal but also occur in the weld or HAZ. Heating coils and heat transfer equipment’s. Spider web of small cracks at weld flaws as local stress raisers. Prevented by PWHT @CS temperature 1150°P, steamout of non PWHT'd as avoided. WEMT, ACFM, ECT effective techniques to detect surface breaking cracks/ flaws. Proper surface preparation is necessary to ensure cracking is not masked by blending or smearing metal into the cracks. SWUT and PAUT effective techniques to detect and size cracks. AET can be used for locating cracks and monitoring crack growth, Data given, Figure 3-1-1, caustic soda (NaoH) 30% and operating temperature 140°F-CS stress relieve welds Bends. Chloride Stress Corrosions Cracking (CSCC)/ Chloride Cracking (: 300 series SS (304 SS) highly susceptible. The greatest susceptibility occurs in stainless steels with a nickel content of 8 % to 12%. ‘Temperature >140 °F, Nickel >35% highly resistant and >45% nearly immune. CSCC has occurred in water-cooled condensers and in the process side of crude tower overhead condensers. Spider web or craze cracking on the surface. PT, ECT and Angle beam UT (SWUT and PAUT) from the opposite wall can be used for crack detection. Corrosion Under Insulation/ CUI: Corrosion rates increase with increasing metal temperature up to the point where the water evaporates quickly. While water boils or steams off above the boiling temperature, 212° F(100° C), it does not do so instantaneously. Carbon steel and low-alloy steels are subject to localized corrosion, 300 series SS are subject to SCC if chlorides are present. While the duplex steels are less susceptible, SCC failures have occurred in duplex stainless steel due to CUI. CS, Low alloy & 400 series SS 10- 350 °F, 300 series SS 140-350 °F, Duplex SS 280-350 °F, painting/coatings and insulation to prevent moisture ingress. Closed cell foam glass materials will hold less water and less corrosive. If CUL damage is found, the inspector should inspect other susceptible areas. Neutron backscatter (for identifying wet insulation); IR thermography- infrared thermography imaging (for identifying wet insulation). inless Mechanical Fatigue (Including Vibration-induced Fatigue): Initiate at surface at notches or stress raiser under cyclic loading. Signature mark, clam shell, fingerprint, Beach marks, good design. Common surface features that can lead to the initiation of fatigue cracks, because they act as stress concentrations, include: key holes on drive shafts of rotating equipment, mechanical notches (sharp corners or groves), weld joint flaws and/or mismatches, tool markings, grinding marks, lips on drilled holes, thread root notches, and corrosion.Microbiologically induced corrosion (MIC): Localized pitting under deposits or tubercles that shield the organisms (Bacteria/Fungi). Soil corrosion: Operating temperature, moisture, oxygen, soil resistivity coating and cathodic protection, (NACERT 0169), dedicated reference electrode. Sour water corrosion (Acidic): Acidic sour water containing H2S @ pH 4.5-7 H2S content, pH, temperature, velocity and oxygen concentration are all critical factors. pH >4.5, a protective, thin iron sulfide layer limits the CR. In some instances-PH>4,5, a thicker, porous sulfide film layer conform. This can promote pitting under the sulfide deposits. General thinning and can occur localized corrosion, if oxygen is present. Sulfurie Acid Corrosion: Figure 3-62-1, Temp 125°F, Sulfuric acid 85% 50 MPY. Temp 175°F, Sulfuric acid 65% -200 MPY. API 652 (2020) API 653 (Revised on July, 2022) 4, Corrosion Mechanisms Concentration cell corrosion will cause pitting and may result in significant localized metal loss. Concentration cell corrosion occur surface deposit, mill scale-lower oxygen concentration (crevice) Preferential corrosion sulfuric acid corrosion attacks at HAZ (significant localized) MIC Most bacteria found in the petroleum industry are strict anaerobes that do not proliferate in the presence of oxygen; however, the dense bacterial colonies create a local anaerobic condition, even if some oxygen is available, By creating the local anaerobic condition, the bacteria can stay alive in the presence of oxygen, even though the colonies do not expand. 5. Tank Bottom Lining Flexing occurs on all steel floors excessive flexing cause an internal bottom lining to crack (Thick Flim) 6. Tank Bottom Lining Selection Thin Flim < 20 mils Thick Flim > 20 mils Inorganic zine (I0Z), also known as zine silicate, is a type of coating that can be used as a tank lining for ethanol and methanol storage. IOZ is different from organic coatings in many respects. IOZ is typically applied at 3 mils to 5 mils (76 um to 127 tm) dry DFT. Thin Flim lining may be applied to new tanks and to bottom storage tanks that have experienced minimal corrosion. Coal tar epoxy/amine = erude oil “Temp 120-170°F. Advantage of thin flim linings- more accurate MFL floor scans, cost low. Disadvantage of thick film lining-break /erack due to plate flexure may be a concern.Advantages of Thick-film Unreinforced Linings Typically, fast curing, with the ability to be returned to service quickly resulting in a shorter turnaround schedule. Generally, provides greater resistance to moisture permeation due to greater thickness. Reinforced Thick-film Tank Bottom Linings ified to restore he: There are currently two systems being spi ily corroded and pitted tank bottoms: fiberglass reinforced plastic (FRP) laminates and reinforced thick-film linings. FRP laminates and reinforced thick-film linings are methods to extend the life of these types of steel tank bottoms. Asa result, a good quality installation may be difficult to achieve. In service, steam coils create local areas where the temperature can be much greater than that of the bulk product. The resulting thermal effects on a tank bottom lining may cause localized coating damage such as blistering or cracking. 7. Surface preparation Abrasive blast cleaning white and near white metal finish, Min surface cleaning prior to lining. Prior to abrasive blasting- all hydrocarbon residues such as oil, tar and grease removed. Abrasive blasting not effective in the removal of soluble salt. Solvent cleaning is typically required. Anchor pattern (profile) required for lining is typically 1.5-4.0 mils and generally increases with the thickness of the lining Improper application and inadequate curing time are major causes of premature ling failure. 8. Lining Application Surface temperature > 5°F above the dew point temperature and humidity < 80%. Surface preparation lining application and cure duration > 24 hours. 9. Inspector Qualifications All lining inspectors qualified either NACE ot SSPC or demonstrated knowledgeable of coating and lining practices. Inspection shall verify that as the lining is applied, wet film thickness measurements are being made for each coat in accordance with ASTM D4414, Holiday testing of thick flim (More suitable for corroded service)-High voltage detector, RP 0188 Holiday testing of thin flim ~ Low voltage (67.5 volts) wet sponge detector. When testing with high-voltage detectors, it is important that the voltage be properly set in accordance with the manufacturer's recommended volts per mil and that the film thickness properly matches the specified thickness. 10, Evaluation, Repair, and Replacement of Existing LiningsIf lining degradation is detected, the cause and extent of coating degradation must be established, as well as whether 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. API 651 (2014) API 653 (Revised on July, 2022) 3. Terms and Definitions Anode: The electrode of on electrochemical cell at which oxidation loss of electron (Corrosion) occurs. Cathode: the electrode of an electrochemical cell at which a reduction reaction occurs. CP: A technique to reduce corrosion of metal surface b electrochemical cell. making the entire surface the cathode of an Electrolyte: Electrode refers to the soil or water adjacent to and in contact with the bottom of AGST. RPB: Bottom of or under AGST Includes steel bottoms (when used in a double bottom or secondary containment system), synthetic materials, clay liners, and all other barriers or combination of barriers placed in the bottom of, or under an aboveground storage tank, which have the following functions: (a) preventing the escape of stored product, and (b) containing or channeling released material for leak One source of CP interface or stray current that can cause tank bottom corrosion is - Addition of sacrificial magnesium anodes to a nearly UG piping. 4. Corrosion Mechanisms Three major types of corrosion to be considered are general corrosion, localized (pitting) corrosion, and to a lesser extent in tanks, environmental cracking. 5. Determination of need for CP Table- 1 General classification of resistivity ASTM G 57 The sand should be clean, screened, and debris free (i.e. no wood, sticks, vegetation, paper, rocks; clay, orother soil; welding rods or other metallic or non-metallic objects; etc.) A municipal potable water supply may not be acceptable Produce high chloride. CR increase PH < 5.0, Decrease PH > 8.0, ASTM G 51 CR in steel may double with every 18°F increase in temperature >77 °F Cathode protection anodes placed in between external liner and tank bottom,6. Methods of CP for corrosion control Galvanic system (<20°) Galvanic system no external power supply required. Impressed current system her maintenance & operating cost, more frequent monitoring 7. Design of CP system Current density in between 1 MAJ fat ambient temperature (0.5 MA/ ft” for close coupled anode) and 2 MA/ ft? — 8 MA/ ft’ for elevated temperature tanks. 8. Criteria for CP A negative (cathodic) potential of at least 850 MV (8.5 V) for CP current applied standard method of determines the effectiveness of CP on thank bottom is the tank to soil potential measurement (soil resistivity). The actual structural to soil under the tank should be determined by using permanently installed reference electrodes (Anode). 9. Installation of Cathodic Protection Systems Caution—If the leads are reversed, with the positive lead mistakenly attached to the tank, the tank bottom will serve as an anode and rapid corrosion failure can result. 11. Operation and maintenance of CP system IfCP devices are shut off while working on AGST the system should be re-energized as soon as possible to avoid corrosion damage during maintenance period. Annual CP surveys are recommended to ensure effectiveness of CP. All sources of impressed current checked < 2 months. All impressed current protective facilities inspected annually. Records related to the effectiveness of CP retained for 5 years, API 577 (2020) API 510/570/653 (Revised on July, 2022) This RP does not require all welds to be inspected, nor does it require welds to be inspected to speci techniques and extent. ACEM - Electromagnetic inspection method-used to detect and size surface breaking defects in both magnetic and non- magnetic materials. (Monitoring existing crack) ARC Blow- The deflection of an arc from its normal path because of magnetic forces.ARC Length- The distance from the tip of the welding electrode to the adjacent surface of the weld pool. Burn through -Excessive visible root reinforcement or hole through the root a common term used to reflect the act of penetrating a thin component with the welding are while hot tape welding or in service welding. Defect - A flaw/Imperfection/discontinuity of such size, shape, orientation, location or property. Which is reject able. Discontinuity-Lack of homogeneity in its mechanical, metallurgical or physical characteristics. A discontinuity is not necessarily a defect. HAZ -not melted but mechanical properties or microstructure altered. Lamellar Tearing -step like crack, Round Indication - A discontinuity with a length that is substantially <3 times of width, Linear Indication - A discontinuity with a length that is substantially > 3 times of width, Undereu/Overlap-@ weld toe or root, Underfill — incompletely fill or Unfilled weld NDE Examiner certification- ASNT-SNT-TC-1A (RP) / ASNT-CP-189 (Std). 9.2 Task prior to welding... 9.2.1.1 Quality control items to asses GTAW- Gas shielded process in confined space can create - oxygen deficient SMAW-Widely used welding process GMAW-S- Welder cannot be qualified by RT (S-Short Circuit mode) -Lack of Inter pass and sidewall fusion FCAW — Backing material required for root pass welding. SAW — High metal deposition rate, large weldments. SW — Refractory support pins, suitable for CS & Low alloys. WPS — Essential, Nonessential, Supplementary variables If essential variable changed. WPS must be requalified. ‘Non-essential variable changed -WPS not required requalify - revised. Company Business name, supplementary treated as essential variable PQR —Essential variable, signature, Certificate, date PQR, WPS, WQT -reposts/records responsible — Repair org. /Contractor/Manufacturer P no, Base Metals-to reduce the no, of procedure qualification, F no, Electrodes/Fillers. A no. Chemical composition of the deposited weld metal-Essential variables, Titanium and titanium base alloys P51, 52, 53 Any electrodes or fluxes that have become wet should be discarded. Welder Qualification-RT of Test coupon, First Production joint, Bend test. Welder/Operator (SMAW, GTAW, GMAW, SAW) by RT using 6" length, for first production operator -3'(feet) length by RT. (except GMAW-S) Welder qualification expires- Not weld within 6 month with same process Table -4 Applicable inspection method for Tee joint-UT,PT,MT,VT<. Table-5 new model questions Lack of fusion, Lack of side wall fusion- UT VT- Most extensively/universally used NDE method distance 6-24" (150-600mm), Angle > 30° Bridge cam gauge- Bevel angle, Depth of undercut, Welds cap, Fillet weld size, and misalignment. MT- Two inspection performed, One parallel to weld, One across to the weld. Best result line of flux perpendicular to the discontinuity. PT- Temp, 40-125 °F, Penetrant MTC-Chlorine, Sulfur, Halogens. RT- IQI selection based on thickness + reinforcement, not considered backing/strip Iridium 192-Thickness range 0. 250-3.0", Cobalt 1.5-7.0" RIFI- Light Intensity- Specified density range. UG not on RT Report/Records, to av reflections, shadows, or glare on the radiograph Clear film has a zero density Exposed film that allows 10% of the incident light to pass through has a 1.0 film density. A film density of 2.0, 3.0 and 4.0 allows 1%, 0.1% and 0.01% of the incident high to pass through respectively. Back scatter B light image-cause of rejection. A darker density band with straight parallel edges in the center of the width of the weld image - Incomplete/Lack of penetration, UT calibration- Prior and after an examination, In addition, a system check is required with any change in the search unit, cabling, and examiner calibration standard temp 25 °F (Block & part of exam) troublesomeEach pass of transducer overlap- 10% of the transducer element dia. Hardness testing after PWHT acceptably soft result acceptable relative hardness. Welding process- akin to casting, Pre heat- to reduce HICC PWHT ~ to relieve residual stress, BHN CS-200 , 2° Cr Imo - 12 Cr~ 241 The amount of segregation is determined by the chemical composition of the weld and the base metal. ‘Toughness- The ability of metal to absorb energy and deform plastically. 300 SS- solidification cracking, Hot cracking, Nickel alloy > 30 % Nickel. Two primary concerns when welding on in-service Burn through and cracking. Cellulosic electrodes E-7010, 6010, 6011 for root & hot pass, deep penetration, size < 5/32 (4 mm) ER-70 S-6 GMAW/GTAW, E- 70 T-5 FCAW Figure A.4—Standard Weld Symbols in tail: Spec or process or other Ref. 2S Sie oF processor other ASME Section_V (2019) API 510/570/653 (Revised on July, 2022) Article-1 General Requirements, 2-RT, 6-PT, 7MT, 9-VT, 10-LT, 23-SE-797 UTT (Pulse Echo Technique) Article- 1 General Requirements T-130 Who is the responsible that examination equipment requirement as per AMSE Sec. V-Code User T- 190 Examination Records- Date, Name, Identification, Method, Results. Personnel qualification and procedure performance demonstration performed ~ V Article- 2 RT. Table- 1233.2, Wire type IQI, Wire Set-A,B,C,D A source-side wire-type IQI is used on a component that is 0.625” thick. To be an acceptable RT, what is the minimum number of wires that must be visible in the RT? 4 Wires visible; Table- T-276 &233.2 T-2 RTFI- Light intensity used for the specified density range of film. T- 262.1 Densitometers shall be calibrated at least every 90 days/03 month/quarter by national standard step tablet or step wedge calibration film, traceable to a national standard step tablet and having at least five steps with neutral densities from 1.0-4.0 shall be used T-271- SWSI-Plate, SWSI (Panoramic), Pipe-DWDI (Elliptical/Superimposed) < 35", DWSI (touch short) > 32", Latitude- Varying thickness, Location Marker on the part of exam. T- 274.2- UG table <2"- 0,020", 0.030", UG not on RT report/records.Table- 233.2 1QI Selection based on Nominal wall thickness + Reinforcement, Data given, Both-side access - (Source side) Thick 1.250" (T- 276) Hole -type IQI- 30. (T-277) Source is placed on the axis of the component, Single exposure -3 IQIs, Spaced 120 apart. If IQL placed on film side- F Lead letter. Hole-type IQI- 2T, Wire type IQI- 2 wire , Hole type placed adjacent to or on weld, wire type placed on the weld or perpendicular to the weld. Shim under hole-type IQI- 3 sides of IQI visible. ‘T- 282-RT Density- Gamma ray 2-4, X ray 1.8-4, Composite 1.3-4, +£0.05 (5%) Torrance in density allowed. Density variation- 15% (min) + 30 % (max) T- 284 If a light image of the “B,” as described in T-223, appears on a darker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable. A dark image of the “B” on a lighter background is not cause for rejection, T-290 Documentation details- Article- 6 PT Table 621 non-essential variables T- 652 PT surface temp 40-125 F T- 660 Light meters ( Black & Visible) calibration- once a year or not use within one or more year, calibration shall be done prior to it reuse. ° T- 672 Penetration (Dwell) time- note temp 40-50 F- Dwell time 2x value of table T- 676 PT- Final Interpretation 10-60 Minutes. T- 670 PT- Surface preparation, penetrant application, penetration Dwell time, Excess penetration removal, Apply developer time, Interpretation, Post cleaning, Article- 7MT. T 721-Non essential variables T 772 Two Inspections performed, one parallel to weld, one perpend ion to weld. Maximum (T 720) sensitivity the line of flux perpendicular to discontinuity. 731 Magnetic particle temperature limitation range set-by manufacturer. 752 Prod spacing 3"-8" T 756 Alternating magnetizing current- produces over all part in multidirectional, T 756.2 An adequate field shall be obtained in at least two nearly perpendicular directions.T 760 MT yokes, Ammeter, Light meter, units meter, PMI machine, and P.G calibration once a year. If repair or over hauling or not used in within one or more year calibration shall be done prior to first use. Ammeter tolerance +10%, (Light meter calibration-prior to use) 762 Lifting power of yokes AC 10 Ib, DC 40 Ib, each weight shall be weighted with a scale from a reputable manufacturer and stenciled with the applicable nominal weight prior to first use. 1764 Artificial flaw shims- at least one perpendicular to the magnetic field, T778 Residual magnetic field effect during welding-Are deflection 1730 Dry Powder Techniques- Applicators qualified for over-head position may be used in any other/all position. If qualified vertical-used in flat & horizontal, T 793 Examination records/ documentations-equipment, magnetic particles (visible or fluorescent, wet or dry), material, record indication, lighting equipment ovT T 923 Annual vision test- capable of reading standard J-1 letters. T 952 visual examination distance < 24" (600mm), Angle > 30°, light intensity 100 fe (1000Lux). A 10 LT T 1030 Pressure gage range min 1.5 xTP, Preferred 2xTP, Max 4xTP T 1060 All-dial indicating and recording type gages calibrated by standard dead weight tester, a calibrated master gage or a mercury column and re-calibrated at least once a year. je- 23 SE-797 UTT- Pulse Echo Method 4.3 Velocity of materi empirically. Is obtained from Table x 3.1 in practice E 494, NDT hand book or determined 9.3 UT Scanning speed stated in the procedure, 9.5 UTT- measure in materials temperature < 1000 °F, Thumb rule temperature >150 °F correction factor required, every 100 °F factor 1% deduction from metal too thick. Example 1: Data given, instrument standard (Calibration) temperature 68 °F, thickness reading obtain temp 860 °F, (58mm). Temperature (860-68) = 792 =8%, Actual thick = 58- 4.64 (8% of 58) =: 3.36mm, Example 2: Data given, Equipment temperature 700 °F, calibration temp 100 °F-apparent reading reducing by 6%. 9.6 UT CRT readout horizontal li nearity checked by practice E317 11. UT ReportRecords-Procedure, type of instrument, block, size, scanning method, results, location, personnel data, certificate level-ete.ASME SEC. IX (2019) _API.510/570/563 (Revised on July, 2022) Tensile test < 1"-2 specimens, >I" multi specimens, If specimen breaks in the base metal < 5% the specified tensile strength acceptable. Breaks in the weld metal greater or specified tensile strength acceptable. QW- 163 Bend test open discontinuity < 1/4" (3mm) in weld/ HAZ. Acceptance criteria for WPS/PQR/WPQ-as per IX, Elongated slag -QW 191 QW-321 Immediate retest- Welder/Operators to examine- Plate two 6", Pipe- two or more- 12" QW-322 Welder qualification expires- Welder has not used the Process for 6 months -Reason to question welder’s ability to make sound weld Table QW 253 SMAW-Essential variable-09 no’s, Non- Essential variable-17 no's, and Supplementary variable -09 no, s. Table QW 256 GTAW- Essei variable -09 no, s. Preheat Min for WPS can be decreased <100°F from PQR temp value Pro. QW- 422, F no. QW- 432 & Ano. QW-442 During a welder’s qualification test, the welder uses an F3 rod without backing, If the welder passes this test, list the F-numbers(s) this welder is qualified to use with backing. F1, 2, 3 with backing; QW-433 QW 451 WPS, PQR Thickness, Bead test, Tensile test, Deposited weld metal QW 461 Position of welds plate, 1G/F, 2G/F, 3G/F, 4G/F and Pipe- 1G, 2G, 5G, 6G. Table 461.9 Performance qualification QW 452 Performance qualification thickness and test specimens (3/4". R+F Bend test = 0, Side bend test = 2, 5/8" [R+1F or 2 side bend test, 5G/6G — 4 Bend test. 2G+5G - 6 Bend test.) Figure-QW 462.12 for Temper Bead Welding Hardness measures below Imm from surface and above Imm the root. variable-14 no’s, Non- Essential variable-27 no’s, and Supplementary POR WI Preheat 300°F © 200 °F Bend test thick 1" (23/8") 2F+2R or 4 side test and open discontinuity < 1/8"(Only in PQR) Tensile test thick A 516 gr. 60 1"-4 specimens (Only in PQR) Joint Design Bevel Angles, Root Face, Root Gap ete Thickness 1” 3/yg"-2T Welding consumables E-7018 (F no, 4) baking required prior to use and same F no. welder can used without re-qualify the procedure.