Tank Inspection: Examination & Testing, API 653 Sec 12

12.1 General Nondestructive examination shall be performed as per API 650 by the qualified examiner. The acceptance criteria shall as per API 650. 12.1.2 Shell Penetration Ultrasonic examination of shell plate shall be done to check any lamination in the area where reinforcing plate has been planned to reinforce an opening. Area of hot tap connection shall also be examined. Cavities resulting from gouging and grinding to remove attachment welds of the existing reinforcing plate shall be examined by Magnetic particle (MP) or liquid penetrant (LP) tests. Completed weld attaching nozzle neck to shell and the reinforcing plate shall be examined by MP or LP. Completed welds of stress relieved assemblies shall also be examined using MP & LP, but before the hydro test.

Tank Inspection: Examination & Testing, API 653 Sec 12

12.1.3 Repaired Weld Flaws Cavities resulting from gouging and grinding to remove weld defects shall be examined by MP or LP. Completed repairs of butt welds shall be examined for full length by Radiographic (RT) or Ultrasonic (UT) methods. 12.1.4 Temporary & Permanent Attachments to Shell They shall be visually examined followed by MP or DP Methods. 12.1.5 Shell Plate to Shell Plate welds They shall be examined by RT. When the plate thickness is greater than 1 in (25 mm) and welds are back gouged at the root pass and final pass, they shall be examined additionally by MP or LP.

Tank Inspection: Examination & Testing, API 653 Sec 12

12.1.6 Shell to Bottom Weld New welding on the shell to bottom joint shall be inspected for full length by using right angle vacuum box and a solution film, or by applying light diesel oil. The first weld pass shall be inspected by applying light diesel oil to side opposite the first weld pass. The shall be allowed to stand at least for 4 hours and then the weld inspected for wicking action. The oil shall be removed before the weld is completed. As alternative, such welds shall be cleaned of all slag and non- metals and weld is examined visually. After completion of the inside and outside fillet weld or partial penetration weld, the weld shall be tested by pressurizing the volume between outside and inside weld with pressure of 15 psig (1 bar) and applying a solution film to both sides. The air supply must be connected at one end and the pressure gage to farther end to a coupling. Existing welds at shell to bottom joints shall be inspected visually as well as by MP or LP for full length under a welded on patch plate. Additional 6 in (150 mm) weld lengths on either side shall be examined before placement of the repair plate.

Tank Inspection: Examination & Testing, API 653 Sec 12

12.1.7 Bottoms Welding done on the tank bottom shall be visually examined. Particular attention shall apply to sumps, dents, gouges, three plate laps, bottom plate breakdown, arc strikes, temporary attachments removal area and weld lead arc burns. Leaking area shall be repaired by grinding and re-welding and repaired area shall be retested. Root and final pass welds on welded on patch plate in critical zone shall be visually examined followed by MP or LP. Bottom plates repaired by welding shall be examined by MP or LP. Vacuum box and solution test shall also be conducted or tracer gas detectors may be used. 12.1.8 Shell Plate Area repaired by weld shall be visually examined followed by MP or LP Test.

Tank Inspection: Examination & Testing, API 653 Sec 12

12.2 Radiographs 1. Vertical Joints: New shall plate welding radiographs shall be as per API 650. New replacement shell plate to existing shell welds shall require one additional radiograph each joint Repaired joints in existing shell plate shall have one additional radiograph each joint. 2. Horizontal joints: New replacement shell plate to existing shell welds shall have one additional radiograph for each 50 ft (15 m) repaired horizontal weld. Similar criteria applies for repaired joints of the existing shell plate. 3. Intersections of Vertical and Horizontal joints: New replacement shell plate to existing shell welds shall require one radiograph each intersection. All repaired intersections shall be radiographed. All junctions between repair and existing welds shall be radiographed. If defects were found, it shall be 100% radiographed. For circular replacement plate, at least one radiograph shall be taken. In case the plate thickness is above 25 mm, weld shall be fully radiographed. For square and rectangular plates, one radiograph each for vertical and horizontal joints shall be taken. For plated above 25 mm, it shall be full radiograph. Minimum length of each radiograph shall be 6 in (150 mm).

Tank Inspection: Examination & Testing, API 653 Sec 12

12.3 Hydrostatic Testing Full hydrostatic test held for 24 hours shall be performed on: 1. Reconstructed Tank: 2. Any tank with major repairs and alteration, unless exempted. 3. Also incase where re-rating has been done, or service condition severity has been increased. 4. Full hydro test may be exempted in cases as determined by the design engineer.

Tank Inspection: Examination & Testing, API 653 Sec 12

12.3.2.2 Shell repair New material shall meet the code requirements. Existing tank material in repair area shall meet at least the following; Fall within safe use area, Stress in repair area shall not exceed 7000 psi; S = 2.6 H D G/ t Where H is the tank fill height in ft above the bottom of repair or alteration, t is shall thickness in inch in the area, D is tank diameter in ft, G is specific gravity of product. 12.3.2.6 Fitness for service evaluation shall be done by qualified engineer 12.5 Settlement Measurements This shall be done during and after the hydro test. Tank settlement shall be surveyed with tank empty using number of bottom plate projections points. This shall be N and at least one for each 32 ft circumference of the shell. N = D/10 where D is tank dia in ft. Settlement shall be measured during filling and when water reaches 100 % of test level. This shall be properly reported and excessive and non-uniform settlement reported.