API-653 PPT

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API-653 - Inspection, Repair,

Alteration, & Reconstruction

API-650 - Welded Steel

Storage Tanks

API-651 - Cathodic

Protection

API-652 - Lining

Aboveground Tanks

API - 2207 - Preparing for

Hot Work

API-2015 - Safe Entry &

Cleaning of Tanks

API-575 - Inspection of

Storage Tanks

ASME Section IX - Welding

Qualifications

ASME Section V -

Nondestructive Examination

Pre-Course

Workbook

and

Examination Study

Guide

Hellier

Codes & Standards

Training

and

BAY Technical

Associates, Inc.

(610) 594-9036

Presented by:

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Statement

This course manual has been prepared by BAY Technical Associates, Inc., strictly for the use of attendees to this Hellier/BAY Tech API-653 Examination Preparation Course. This manual is to be used as an aid to assist those persons wishing to take the API-653 Aboveground Storage Tank Inspector Certification Examination. This manual is not all-inclusive and may not be used in place of any recognized Code or Standard.

The information contained in this manual was obtained from the author’s research and experience and through numerous published resources including:

American Petroleum Institute Codes, Standards, and Recommended Practices: API-653, Tank Inspection, Repair, Alteration, and Reconstruction

API-650, Welded Steel Tanks for Oil Storage

API-575, Inspection of Atmospheric and Low Pressure Storage Tanks API-651, Cathodic Protection of Aboveground Petroleum Storage Tanks API-652, Lining of Aboveground Petroleum Storage Tank Bottoms API-2015, Cleaning Petroleum Storage Tanks

API-2207, Preparing Tank Bottoms for Hoe Work

American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Codes: ASME Section V, Nondestructive Examination

ASME Section IX, Welding and Brazing Qualifications

“The Procedure Handbook of Arc Welding”, Twelfth Edition: The Lincoln Electric Co. “Metals and How to Weld Them”, Second Edition: The James F. Lincoln Arc Welding Foundation.

This manual may not be reproduced by any means without the express written consent of BAY Technical Associates, Inc.

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Preface

The API-653 Aboveground Storage Tank Inspector Certification Examination consists of two parts; an “Open Book” part and a “Closed Book part. The open book portion of the

examination contains approximately forty to fifty-five (40 to 55) questions. This part of the examination requires the use of detailed information that the inspector must be able to research in the permitted documents, and is not expected to have committed to memory. Not all open book questions are mathematical in nature. The closed book portion of the

examination represents the remaining questions. Some of the closed book questions require the applicant to perform basic math; remember to have your calculator available. The closed book portion tests the inspector on knowledge and tasks requiring everyday working

knowledge of API Standard 653 and the applicable reference documents.

This examination preparation course is designed to prepare the participant to successfully sit for the API-653 exam. Through your concentrated effort, and the material provided in this course, you should have sufficient information to pass the examination.

The majority of the classroom study will focus on the “Open Book” portion of the exam. The goal, since this is open book, is to obtain a perfect score in this section. Study for the

practical questions (Closed Book) will be included in the daily classroom activity and assigned homework.

The material contained in this manual is to be thoroughly studied and practiced prior to attending the course. The math examples and practice problems are based on the types of questions given on the API-653 exam. Through the use of these examples, you will be exposed to many of the formulas used during the course.

Remember, this is a very intense course. There will be eight hours of classroom study each day. The instructor will be available by phone, fax, or e-mail each evening between 7:00pm and 9:00pm to answer questions or to assist any participant having difficulty with the homework assignments or any topic discussed during class. Typically, there will be two to three hours of homework assignments each day. Daily quizzes are given and one practice API-653 examination is provided. The pace is fast and focused.

The participant is responsible for making all arrangements for taking the examination including confirming your eligibility and applying to the American Petroleum Institute.

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Introduction:

Objective for this section:

At the end of this section, you should be able to:

1. List the required reference manuals you must bring to the course 2. List the reference material permitted during the exam

3. Know where you can obtain ASME and API Code books 4. List what material will be provided during the course 5. Explain the structure of the API-653 Exam

How to use this Pre-Course Study Guide:

1. Review the basic math skills section and complete the practice math test. 2. Complete the reading assignments,

3. Research and answers the questions in the "Practical Questions" section of this study guide (chapters 2 through 10).

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Required Reference Material

You must bring the following API Standards, API Recommended Practices (RP), ASME Code books, and material with you to the course:

1. API Standard 650, Welded Steel Tanks for Oil Storage, 10th Edition

2. API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction, 2nd Edition, December 1995; including Addendum 1, 2, & 3

3. API Standard 2015, Safe Entry and Cleaning of Petroleum Storage Tanks, 5th Edition (May 1994)

4. API Publication 2207, Preparing Tank Bottoms for Hot Work, 5th Edition (September 1998)

5 API RP - 575, Inspection of Atmospheric & Low Pressure Storage Tanks, 1st Edition, (November, 1995)

6. API RP - 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, 2nd Edition (December 1997)

7. API RP - 652, Lining of Aboveground Storage Tank Bottoms, 2nd Edition (December 1997)

8. ASME Section V, Nondestructive Examination, 1998 Edition & 1999 Addenda 9. ASME Section IX, Welding and Brazing Qualifications, 1998 Edition & 1999

Addenda

10. This Study Manual

11. Non-Programmable Calculator

To order ASME Code books, you may call the ASME at 1(800) THE-ASME (843-2763) or you can write them at:

ASME Order Department 22 Law Drive

Box 2300

Fairfield, NJ 07007-2300

To order API Documents, you may call them at: 1(202) 682-8375 or you can write them at: American Petroleum Institute

Order desk 1220 L Street

Washington, DC 20005

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Hellier and BAY Technical Associates, Inc. will provide:

1. Pre-course Study Manual

2. Student Reference Manual (Provided on Day-one) 3. Certificate of Completion

Hellier and BAY Technical Associates, Inc. will have available for reference:

1. Welding reference books 2. Overhead transparencies

3. Various applicable reference documents

The structure of the API-653 Examination:

The API-653 Examination is given on Saturday September 23,2000. The exam consists of an open book portion and a closed book portion You will have not more than five hours to complete the entire examination. The questions consist of multiple choice and true/false type questions.

You are permitted and required to use the following Reference books during the open book portion of the exam:

1. API Standard 650, Welded Steel Tanks for Oil Storage, 10th Edition

2. API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction, 2nd Edition, December 1995; including Addendum 1 - 3

3. API Standard 2015, Safe Entry and Cleaning of Petroleum Storage Tanks, 5th Edition (May 1994)

4. API Publication 2207, Preparing Tank Bottoms for Hot Work, 5th Edition (September 1998)

5 API RP - 575, Inspection of Atmospheric & Low Pressure Storage Tanks, 1st Edition, (November, 1995)

6. API RP - 651, Cathodic Protection of Aboveground Petroleum Storage Tanks, 2nd Edition (December 1997)

7. API RP - 652, Lining of Aboveground Storage Tank Bottoms, 2nd Edition (December 1997)

8. ASME Section V, Nondestructive Examination, 1998 Edition & 1999 Addenda 9. ASME Section IX, Welding and Brazing Qualifications, 1998 Edition & 1999

Addenda

No reference material of any kind will be permitted during the closed book portion; some examining proctors may permit language translation dictionaries. There will be some

common knowledge mathematical questions on the practical portion of the exam - remember to have your calculator available for this part of the exam.

During this course, we will attempt to duplicate actual examination conditions including using a separate answer sheet during the practice examination.

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Reading Assignments:

At the end of this section, you should:

1. Have completed the reading assignments

2. Be familiar with the layout and structure of each API Standards, API

Recommended Practices, and ASME Code Books used in the course and on the exam. (These Standards, RPs, and Code books will be referred to as "Reference books" in this section)

3. Compile a list of questions concerning paragraphs/subjects you do not understand. The classroom portion of this American Petroleum Institute examination preparation course is focused on the "open book" portion of the exam. A thorough understanding each reference book is also essential in order to answer the closed book questions on the exam. All

Reference books will be reviewed and discussed during the course. Many hours of the homework assignments will be reading selected portions of each Reference book. The course begins up-to-speed on day one and continues until the practice exam. It is essential that you complete the "pre-course" reading assignments. You are not expected understand all that you read, but the familiarity gained will assist you in keeping up and not becoming overwhelmed on the first day of class. If during the course of reading this material you have questions, do not dwell too long on the subject. Write your question down and be sure to ask for clarification during the course.

Do not try to memorize Reference book paragraphs at this time, selected portions will be pointed out for highlighting and memorization during the course. Studying and researching the example questions and answers provided in the "Pre-Course Workbook and Study Guide" should be sufficient for exam purposes. The first thing one realizes, when they begin working with these Reference books, is that they are dynamic and change constantly. An inspector should never rely on memorized passages, but should instead always research the answer to a question; that is why understanding the structure of the Reference books is imperative.

Reading Assignments:

It is highly recommended that you obtain a set of tabs or binder index pages. The API permits tabs, indexes, highlighting, underlining, and some written notes in the margins; they do not permit any type of inserted pages in the Reference books.

API Standard 650, Welded Steel Tanks for Oil Storage:

Title Paragraph(s) Pages(s)

Foreword All iii

Asbestos Information All iv

Required Ordering Information All xiii

Section 1 - Scope All 1-1 through 1-4

Section 2 - Materials All 2-1 through 2-8

Section 4 - Fabrication All 4-1

Section 7 - Welding All 7-1 through 7-2

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API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction:

Entire document must be read. You should be thoroughly familiar with this standard.

API Standard 2015, Safe Entry and Cleaning of Petroleum Storage Tanks

Read this entire document - remember this is a safety code to help ensure your ability to survive your daily work. The API takes a dim view of your answers to questions if they could result in injury to yourself or others.

API Publication 2207, Preparing Tank Bottoms for Hot Work

Entire document must be read. You should be thoroughly familiar with this publication

API Recommended Practice 651, Cathodic Protection of Aboveground Petroleum Storage Tanks

Sections 1 through 6 - Pages 1 through paragraph 6.3.5 on page 11.

Recommended Practice 652, Lining of Aboveground Petroleum Storage Tank Bottoms

Entire document must be read. You should be thoroughly familiar with this RP.

Recommended Practice 575, Inspection Atmospheric and Low Pressure Storage Tanks

Entire document must be read. You should be thoroughly familiar with this RP

ASME Section V – Nondestructive Examination:

Title Paragraph(s)

Subsection A - Article 1 All

Subsection A - Article 2 T-210 through T-292

ASME Section IX, Welding and Brazing Qualifications:

Title Paragraph(s)

Foreword All

Introduction All

Part QW - Article I QW-100 through QW-196.2.2

Part QW - Article II QW-200 through QW-251.4

Part QW - Article III QW-300 through QW-361.2(h)

Part QW - Article IV QW-400 through QW-401.5

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Pre-Course Workbook Practice Mathematics Objective:

At the end of this section, you should:

1. Be familiar with the basic types of mathematics used on the exam. 2. Have taken and “self graded” the pre and post math tests

3. Have reviewed the basic mathematical functions 4. Worked the practice problems

A Pre-Test is provided on pages 15 & 16 with the answers on page 20 & 21

Practice problems are provided on pages 17 through 19 with the answers on pages 22 & 23 A Post-Test is provided on page 24 with answers on pages 25 & 26

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MATH

Calculation questions found on the API-653 examination are oriented toward existing tanks and not new tanks. API authorized above ground storage tank inspectors are expected to be able to check and perform calculations necessary to ensure compliance with appropriate Codes and standards. For this reason, the inspector must have a thorough understanding of the formulas and procedures used to calculate the following:

Corrosion Rates and Inspection Intervals Remaining Life determination

Joint Efficiencies

Maximum Height (Hydrostatic Testing)

Determining appropriate weld sizes for shell opening

Minimum spacing between existing and new hot tap nozzles Settlement evaluation including the number of survey points Minimum Thickness for Existing and Reconstructed Tank Shells Corroded areas of tank shells including evaluation of pitting Bottom plate thickness determination and evaluation

Reinforcement of openings

The American Petroleum Institute does not permit the use of programmable calculators while taking the exam; therefore, programmable calculators will not be permitted during the course. A recommended answer sheet layout format for use during the course is provided in this section. Using the layout will help keep your procedures straight and make it easier for you to check your work. This format is only recommended.

The remainder of this section deals with the typical mathematical skill level required. It is divided into modules: Pre-Test, Basic Math Functions, and Post-Test. Typically, if a formula requires transposing, the appropriate formula is given in the examination question however, you should have a basic understanding of Algebra. Completion and understanding of this portion of the pre-course manual will increase your chances of passing the exam as well as enhancing your ability to keep up with the pace during the course. Should you have difficulty with any portion of this math section, you should obtain assistance. In any case, you should complete all the problems and practice them until you are comfortable with them.

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Recommended Math Page Layout

Name Page Number

Answer (a) Problem Number Page ____of_____ Answer (b) Answer (c) Answer (d) Drawing if Applicable

Given Information: Final Formula

Formula with Variables Plugged In

Show all Work

Find: Reference: Formula to use: Formula Transposition Answer:

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Recommended Math Page Layout

Name: Page Number

Answer (a) Problem Number Page ____of_____ Answer (b) Answer (c) Answer (d) Drawing if Applicable

Given Information: Final Formula

Formula with Variables Plugged In

(Note:) At this point make sure you have: a value for each variable, included the correct sign, and included the correct information within any parentheses or brackets)

Show all Work

Find: (what does the question ask)

Reference: (Code book and paragraph)

Formula to use:

Formula Transposition

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Mathematics Fundamentals:

As we all know, mathematics has a language of its own, made up of signs, symbols, and characters. During this course of study many common mathematical signs, symbols, and characters, which you must be familiar with, will be used. Some of these are listed below.

+ Addition − Subtraction ∗

×

( ) Multiplication

÷

Division π Pi Expressed as 3.14 < Less than > Greater than ∴ Therefore

≤ Less than or equal to

≥ Greater than or equal to

= Equal

X2 Number squared

Square root

In addition to the symbols, we will use the common Arabic numerals 1,2,3,4, (etc) and the letters of the alphabet to develop our mathematical problems and solutions. How we use this language is determined by the structure of the question.

In our use of the language of math, all equations must be complete and retain their equality throughout in order to be useful. One of the first things that must be clear is the order in which operations must be performed. An operation is a function caused by the sign in the equation. For instance, the + sign tells us to add two or more characters together. In the following statement 12+87 doesn’t tell us anything; just two numbers separated by an addition sign. If we add the = sign, now the statement asks a question: 12+87=X, when we replace the X with the correct answer we have completed the equation ∴ 12+87=99 is a true statement and meets all the requirements of an equation for our purposes.

Order of Operations and Grouping:

Operation Grouping

1. Addition 1. Parentheses ( )

2. Subtraction 2. Brackets [ ]

3. Multiplication 3. Braces { }

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Clarification:

At this point, it is assumed that the participant is already familiar with the basics of addition, subtraction, multiplication, and division.

Finding areas of shapes will follow customary rules. The area of a circle can be found using A = π R2

or A = (.7854)(d2). Algebra

The first rule in algebraic statements is the equality of the equation must remain throughout the steps leading to the final solution. In other words, the left side of the equal sign must always equal the right side of the equal sign. In order to ensure this, always remember:

“whatever you do to one side of the equal sign, you must also do to the other side of the equal sign”.

Lets look at the following equation: c

t t_m = +

If we know all the variables except the minimum required design thickness, we can

transpose the formula to solve for the thickness.

t c t_m − = c t t = m − 0625 . 3165 . − = t " 254 . = t

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Pre-Test:

1. Find the minimum acceptable shell plate thickness of the first course of an existing AST. tmin = Minimum acceptable thickness ?

D = Nominal diameter of tank, in feet 120

H = Height of tank in feet 48

G = Specific gravity of contents 1 S = Maximum allowable stress 21000 E = Joint efficiency of tank .85

SE DHG tmin = 2.6

2. Find the corrosion rate of an AST given the following information. Original thickness = .875”

Measured thickness = .625

Years since last thickness measurement = 11

CR t t

Time original last

= −

3. Using the corrosion rate determined in problem number 2, what would the remaining life expectancy of this tank be if the minimum required thickness is 0.436”?

RL t t

CR

actual imum

= − min

4. Shell settlement evaluation measurements are to be taken on a 146 feet diameter AST. Given the following formula, how many elevation measurements would be required?

N = D 10

5. Using the information in number four, does this number meet the requirements of API-653, which does not permit the measurement points to exceed 32 feet?

Dis ce D

N

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Pre-Test continued:

6. Find the throat of a right angle fillet weld with a weld leg length of .4375 inches.

7. Using the following information, what is the maximum vertical length (also known as critical length), in inches, over which hoop stresses are assumed to “average out” around local discontinuities? Diameter of the tank is 136 feet, the least thickness in an area of corrosion, exclusive of pits, is determined to be .563”

L= 3 7. Dt₂

8. A 6 inch nozzle is to be placed in the tank shell of an AST. The shell course where the nozzle will be installed is .875” thick. What is the required area of reinforcement? A=ODnozzle shellt

9. The maximum ultrasonic thickness measurement interval shall be five years when the corrosion rate is not known. What is the interval based on a known corrosion rate? The tank information is as follows: Initial thickness of the tank was 1.0625”, the actual thickness is .815”, the calculated required thickness is .473”, the tank has been in service for 16 years with no measurements taken since it was installed.

RCA = .342 N = .015 Interval RCA N = 2

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Practice problems #1:

Problem #1

Find “S” when tmin, D, H, G, and E are known where: D=78, H=29, G = 1, E=.85, and tmin =.602 t DHG SE min . = 2 6 Problem #2

Find E when D, H, G, S, G, and tmin are known where: D =128, H=60, S = 22,300 G = .87, and tmin = 1.125 t DHG SE min . = 2 6 Problem #3

Find “D” when H, E, S, G, and tmin are known where: H=45, E=.90, S=22500, G= .7 and tmin =.9375 t DHG SE min . = 2 6 Problem #4

Find “St” when E, Ht, D, G, and tmin are know where: E = .80, Ht = 54, D= 70, G = 1 and tmin =.4325 H S Et D t t = min . 2 6 Problem #5

Find “C” when D and H are know where D = 60, H = 54 C= 014. D H2

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Let’s go a step farther:

What do we do when our Unknown is inside a radical (square root symbol)? We know all the values except for the “d”

d a= .7854 d a2 =.7854 7854 . 2 = da 2 7854 . a d = Practice Problems #2 Problem # 1

Find “d” when a=1.0755 2 7854 . d a= Problem # 2 Find “D” when t=.875, L=32.5 L= 3 7. Dt2 Problem # 3

Find tinitial when LlongtermCR=.015, Tyears = 19 and tlast = 1.134

CR t t

T initial last

years

= −

Step 1 -To eliminate the radical, we must do the opposite of its function. The opposite function of extracting a square root is to square the variable. We square both sides of the equation. Step 2 - .7854 is divided by “d”. The opposite of division is

multiplication; therefore we multiply both sides by the “d” Step 3 - “a2” is multiplied by “d”. We perform the opposite function

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Practice Problems # 3

Problem # 1 ⇒ Exponents:

(a) 43 = ? (b) (23)(24) = ? (c) Calculator display 1.0137-3 would be written as ?

Problem # 2 ⇒ Square Root:

(a) X = 3+9 (b) X = 1 96 0013. −. (c) Find “t” L = 3 7. Dt2 Problem # 3 ⇒ Fractions: (a) 3 7 5 7 1 7 + + = (b) 1 3 5 6 + = (c) 21 6 3 3 8 + = (d) 5 6 3 6 − = (e) 4 7 1 2 − = (f) 13 4 2 5 − = (g) 3 8 7 9 × = (h) 3 10 2 3 3 4 × × = (i) 13 8 2 5 11 × × = (j) 2 3 5 8 ÷ = (k) 13 4 2 1 2 ÷ = (l) 31 3 1 1 6 ÷ =

Problem # 4 ⇒ Ratios and Proportions:

(a) N N 9 2 3 = ∴ = (b) 3 4 = 12∴ = N N (c) 2 3 15 K = ∴ =K Problem # 5 ⇒ Area:

A 24-inch nozzle is to be installed in a 1.0625” thick shell course. What is the required area of reinforcement?

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Pre-Test: ANSWERS

1. Find the minimum acceptable shell plate thickness of the first course of an AST. Tmin = Minimum acceptable thickness ?

D = Nominal diameter of tank, in feet 120

H = Height of tank in feet 48

G = Specific gravity of contents 1 S = Maximum allowable stress 21000 E = Joint efficiency of tank .85

SE DHG tmin = 2.6 ) 85 )(. 21000 ( ) 1 )( 48 )( 120 )( 6 . 2 ( min = t .839" 17850 14976 min = = t

2. Find the corrosion rate of an AST given the following information. Original thickness = .875”

Measured thickness = .625

Years since last thickness measurement = 11

CR t t

Time original last

= − CR= .875 625−.

11 CR=.023

3. Using the corrosion rate determined in problem number 2, what would the remaining life expectancy of this tank be if the minimum required thickness is 0.436”?

RL t t CR actual imum = − min RL=. −. . 625 436 023 RL= 8 2. years

4. Shell settlement evaluation measurements are to be taken on a 146 feet diameter AST. Given the following formula, how many elevation measurements would be required?

N = D

10 N = 146

10 N =14 6. =15

5. Using the information in number four, does this number meet the requirements of API-653, which does not permit the measurement points to exceed 32 feet?

Dis ce D

N

tan = π Distance= ( .314 146)( )

15 Distance = 30.5ft. yes meet requirements Reference: API-653 Paragraph 10.5.1.2 definition of N

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Pre-Test continued: ANSWERS

6. Find the throat of a right angle fillet weld with a weld leg length of .4375 inches. Throat =.707W_leg Throat = (.707)(.4375) Throat = .309”

7. Using the following information, what is the maximum vertical length (also known as critical length), in inches, over which hoop stresses are assumed to “average out” around local discontinuities? Diameter of the tank is 136 feet, the least thickness in an area of corrosion, exclusive of pits, is determined to be .563”

L= 3 7. Dt2 L= 3 7 136 563. ( )(. ) L= 3 7 76568. . L= ( . )( . )3 7 8 75 L= 32 375. "

8. A 6 inch nozzle is to be placed in the tank shell of an AST. The shell course where the nozzle will be installed is .875” thick. What is the required area of reinforcement?

A=ODnozzle shellt A = (6.75)(.875) = 5.906 square inches API-650 3.7.2.1 & 3.7.2.2

9. The maximum ultrasonic thickness measurement interval shall be five years when the corrosion rate is not known. What is the interval based on a known corrosion rate? The tank information is as follows: Initial thickness of the tank was 1.0625”, the actual thickness is .815”, the calculated required thickness is .473”, the tank has been in service for 16 years with no measurements taken since it was installed.

RCA = .342 N = .015 Interval RCA N = 2 Interval= = years . ( )(. ) . 342 2 015 114 API-653 4.3.3.2 b.

10. What is the circumference of an AST that is 96 feet in diameter? Circumference = πD Circumference = (3.14)(96) = 301.44 feet.

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Practice problems #1:

Problem #1

Find “S” when tmin, D, H, G, and E are known where: D=78, H=29, G = 1, E=.85, and tmin =.602 t DHG SE min . = 2 6 S DHG Et = 2 6. min S = ( . )( )( )( ) (. )(. ) 2 6 78 29 1 85 602 S = 58812 5117 . . S = 11493.4 Problem #2

Find E when D, H, G, S, G, and tmin are known where: D =128, H=60, S = 22,300 G = .87, and tmin = 1.125 t DHG SE min . = 2 6 E DHG St = 2 6. min E= ( . )( )( )(. ) ( )( . ) 2 6 128 60 87 22300 1125 E = 17372 16 25087 5 . . E = .692 Problem #3

Find “D” when H, E, S, G, and tmin are known where: H=45, E=.90, S=22500, G= .7 and tmin =.9375 t DHG SE min . = 2 6 D t SE HG = min . 2 6 Problem #4

Find “St” when E, Ht, D, G, and tmin are know where: E = .80, Ht = 54, D= 70, G = 1 and tmin =.4325 H S Et D t t = min . 2 6 Problem #5

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Practice Problems #2 Problem # 1

Find “d” when a=1.0755 2 7854 . d a= Problem # 2 Find “D” when t=.875, L=32.5 ⇒ L= 3 7. Dt₂ Problem # 3

Find tinitial when LlongtermCR=.015, Tyears = 19 and tlast = 1.134

CR t t T initial last years = − Practice Problems # 3 Problem # 1 ⇒ Exponents:

(a) 43 = 64 (b) (23)(24) = 27 or 128 (c) Calculator display 1.0137-3 is written as .0010137 Problem # 2 ⇒ Square Root:

(a) X = 3+9 = 3.4641 (b) X = 1 96 0013. −. =1.3993 (c) Find “t2” L= 3 7. Dt2 2 2 2 ) 7 . 3 ( D L t = or D L t 2 2 7 . 3      = Problem # 3 ⇒ Fractions: (a) 3 7 5 7 1 7 + + = 7 2 1 (b) 1 3 5 6 + = 6 1 1 (c) 21 6 3 3 8 + = 24 13 5 (d) 5 6 3 6 − = 3 1 (e) 4 7 1 2 − = 14 1 (f) 13 4 2 5 − = 20 7 1 (g) 3 8 7 9 × = 24 7 (h) 3 10 2 3 3 4 × × = 20 3 (i) 13 8 2 5 11 × × = 4 1 1 (j) 2 3 5 8 ÷ = 15 1 1 (k) 13 4 2 1 2 ÷ = 10 7 (l) 31 3 1 1 6 ÷ = 7 6 2 Problem # 4 ⇒ Ratios and Proportions:

(a) N N 9 2 3 = ∴ = 6 (b) 3 4 = 12∴ = N N 9 (c) 2 3 15 K = ∴ = 10 K Problem # 5 ⇒ Area:

A 24-inch nozzle is to be installed in a 1.0625” thick shell course. What is the required area of reinforcement? API-650 Para. 3.7.2.1 & 3.7.2.2 (24)(1.0625) = 25.5 sq in

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Post Test:

1. What is the required hydrostatic test height (Ht) of an AST given the following data? Maximum allowable hydrostatic stress (St)= 21350

Diameter of the tank = 110 feet

Hydrostatic test shell thickness (tmin) is .625” Shell joint efficiency = 70%

Use API-653 2.3.3.1 formula for tanks to be hydrostatically tested. 2. What is the area of a tank bottom that is 121 feet in diameter?

3. A reinforcing plate is installed around a nozzle in the first course of an AST. What is the throat dimension of the ½” leg fillet weld around the periphery of the reinforcing plate. 4. What is the minimum acceptable thickness of the bottom course of an existing AST that

is 135 feet in diameter, maximum fill height is 56.5 feet? The product stored in the tank has a specific gravity of .87 and all shell butt-welds were 100% radiographically

examined. The yield strength of the material is 28,000 and the tensile strength is 60,000. Use API-653 paragraph 2.3.3.1.

t DHG

SE

min .

= 2 6

5. What is the required area of reinforcement for a 14 NPS nozzle installed in a shell course that is 1.0625” thick. Use API 650 Paragraph 3.7.2.1

6. A bulge is noted in a tank bottom, what is the maximum height of the bulge permitted if the radius of the inscribed circle is 10.8 feet? Use API-653 Appendix B 3.3

7. If the throat of a fillet weld is .309, what is the leg length of the weld?

8. An AST is 175 feet in diameter. How many tank settlement survey points are required? Use API-653 paragraph 10.5.1.2.

9. Do the number of settlement measurement locations and maximum spacing, calculated in problem 8, comply with API – 653? Use API –653 Paragraph 10.5.1.2

10. What is the design liquid level of an AST that is 140 feet in diameter, thickness of the bottom or first course is .765”, stress of the material is 21300. The specific gravity of the product to be stored is 1 and no corrosion allowance is needed nor provided.

t D H G S CA d d = 2 6. ( −1) +  H t S DG d d =_ _{ +} 2 6. 1

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Post Test Answers

1. What is the required hydrostatic test height (Ht) of an AST given the following data? Maximum allowable hydrostatic stress (St)= 21350

Diameter of the tank = 110 feet

Hydrostatic test shell thickness (tmin) is .625” Shell joint efficiency = 70%

Use API-653 2.3.3.1 formula for tanks to be hydrostatically tested.

H S Et D t t = min . 2 6  Ht = = = ft ( )(. )(. ) ( . )( ) . . 21350 7 625 2 6 110 9340 625 286 32 6

2. What is the area of a tank bottom that is 121 feet in diameter?

A=πR2 A = (3.14)(60.5)2 A = (3.14)(3660.25) A = 11493 sqft

3. A reinforcing plate is installed around a nozzle in the first course of an AST. What is the throat dimension of the ½” leg fillet weld around the periphery of the reinforcing plate. Throat = .707Wleg Throat = (.707)(.5) = .3535

4. What is the minimum acceptable thickness of the bottom course of an existing AST that is 135 feet in diameter, maximum fill height is 56.5 feet? The product stored in the tank has a specific gravity of .87 and all shell butt-welds were 100% radiographically

examined. The yield strength of the material is 28,000 and the tensile strength is 60,000. Use API-653 paragraph 2.3.3.1.

t DHG SE min . = 2 6  t_min ( . )( )( . )(. ) ( )( ) = 2 6 135 56 5 87 24640 1  tmin . . " =17253 405 = 24640 7 S = (.8)(28000) = 24640 S = (.429)(60000) = 25740

5. What is the required area of reinforcement for a 14 NPS nozzle installed in a shell course that is 1.0625” thick.

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Post Test Answers

6. A bulge is noted in a tank bottom, what is the maximum height of the bulge permitted if the radius of the inscribed circle is 10.8 feet?

BB = .37R  BB = (.37)(10.8) = 3.996 inches or 4 inches

7. If the throat of a fillet weld is .309, what is the leg length of the weld?

Throat =.707Wleg  W Throat leg = .707  Wleg = = . . . " 309 707 437

8. An AST is 175 feet in diameter. How many tank settlement survey points are required? Use API-653 paragraph 10.5.1.2.

N = D

10  N = = 175

10 17 5.

9. Do the number of settlement measurement locations and maximum spacing, calculated in problem 8, comply with API – 653?

Yes  (175)(3.14) = 549.3  549.3 ÷ 18 = 30.5 feet spacing

10. What is the design liquid level of an AST that is 140 feet in diameter, thickness of the bottom or first course is .765”, stress of the material is 21300. The specific gravity of the product to be stored is 1 and no corrosion allowance is needed nor provided.

t D H G S CA d d = 2 6. ( −1) +  H t S DG d d =_ _{ +} 2 6. 1  H =    + (. )( ) ( . )( )( ) 765 21300 2 6 140 1 1  H =_16294 5_{ +} 364 1 . H = 44.76 + 1  H = 45.76 feet

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Section 1 - Introduction

1. API-653 covers which of the following types of tanks?

a) Carbon and low alloy steel tanks built to ASME Section VIII, Div.1 b) Carbon and low alloy steel tanks built to ASME Section X

c) Carbon and low alloy steel tanks built to API - 650 and 12C d) Carbon and low alloy steel tanks built to API - 510

Reference: API-653 Paragraph 1.1.1

2. API-653 provides the requirements for construction of which of the following? a) Process pressure vessels

b) Aboveground petroleum storage tanks c) LNG Storage spheres

d) This standard does not provide construction requirements Reference: API-653 Paragraph 1.1.1

3. API-653 provides for all but which of the following with regard to aboveground storage tanks?

a) Repair b) Operation c) Relocation d) Alteration

4. The scope of API-653 is limited to all of the following except? a) Tank foundation

b) Tank Bottom c) Tank roof

d) Tank mixing motor Reference: API-653 Paragraph 1.1.2

5. The API-653 standards states that many of the requirements for design, welding, and materials of API-650 and API-12C can be applied with regard to _____.

a) Repair, inspection, rating, and alteration.

b) Repair, personnel assignment, maintenance, and inspection. c) Inspection, product in storage, rating, and alteration.

d) Alteration, refinery equipment, electrical controls, and repair. Reference: API-653 Paragraph 1.1.2

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6. In the application of the requirements for welding, design, and materials of API-650 or API-12C to in-service aboveground storage tanks (AST), which of the following code or standard takes precedence?

a) ASME Section VIII, Pressure Vessels b) API-12C

c) API-653 d) API-650

7. The API-653 Standard may only be applied to aboveground storage tanks (AST) that have been constructed to and meet the requirements of API-650.

a) True b) False

8. The use of API-653 is intended for organizations that have personnel who are technically trained and experienced in which of the following?

a) All ASME, AWS, ASNT, and API Codes and Standards b) Tank design, fabrication, repair, construction, and inspection

c) Refinery operations, safety requirements, personnel management, and refinery design

d) Mechanical integrity program, OSHA regulations compliance program, and Process Safety Management

9. When design and construction details are not given and not available in the original construction standard, then details that will provide a level of integrity equal to the current edition of what Code or Standard must be used?

a) ASME Section VIII, Division 1, Pressure Vessels

b) ASME Section VIII Division 2, Alternative Rules for Pressure Vessels c) API- 650, Welded Steel Tanks for Oil Storage

d) API-12C Steel Storage Tanks for Oil Storage Reference: API-653 Paragraph 1.1.5

10. Ultimate responsibility for compliance with this standard rests with ____? a) The Owner/Operator

b) The Owner/Operator’s Inspector

c) The repair organization of the Owner/Operator d) The manufacturer of the AST

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11. According to API-653, if any provision presents a direct or implied conflict with any statutory regulation, the regulation governs. What governs if API-653 requirements are more stringent than the statutory regulation?

a) The statutory regulation applies in all cases

b) The conflict must be submitted to the American Petroleum Institute for resolution c) The owner/operator has the option of applying the requirement best suited to the

situation

d) The API-653 requirements shall govern Reference: API-653 Paragraph 1.3

12. Safe working practices shall comply with what requirements concerning confined space entry?

a) Procedures must comply with any trade developed safety precautions b) Procedures must comply with any federal or state regulations

c) Procedures need only comply with owner/operator/s requirements d) Procedures need only comply with NFPA requirements

Reference: API-653 Paragraph 1.4

Answers to API-653 Section 1, Introduction

Question Number Answer

1 C 2 D 3 B 4 D 5 A 6 C 7 B 8 B 9 C 10 A 11 D 12 B

Should you find a mistake or disagree with any answer listed, please bring it to our attention for correction or clarification.

BAY Technical Associates, Inc. has attempted to provide answers developed from paragraphs of the respective Code, Standard, or Recommended Practice.

You can reach BAY Tech by phone at (610) 594-9036, by fax at (610) 594-2612, or by e-mail at [email protected].

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Section 2 – Suitability for Service

1. When must an evaluation, to determine the suitability for continued use, be conducted? a) Evaluations shall be conducted when a tank inspection reveals a change has

occurred from the original physical condition of the tank. b) Evaluations shall be conducted at least annually

c) Evaluations shall be conducted at an interval not to exceed the calculated tank inspection frequency.

d) Evaluations shall be conducted once each ten years of service Reference: API-653 Paragraph 2.1.1

2. What factors are required for consideration when performing an evaluation for continued use of an AST?

a) Only those listed in API-653

b) The recommended list of considerations provided in API-510 can be modified to suit this purpose

c) Engineering analysis and judgement required for each situation

d) Only those items requested by the Certified Aboveground Storage Tank Inspector Reference: API-653 Paragraph 2.1.3

3. Roof plates corroded to an average thickness of less that ____ inch in any ___ square inch area shall be repaired of replaced.

a) 0.9 inch in any 100 square inch area b) 0.09 inch in any 10 square inch area

c) 0.09 inch in any 144 square inch area (1 square foot) d) 0.09 inch in any 100 square inch area

Reference: API-653 Paragraph 2.2.1.2

4. The method of inspecting roof support members shall be acceptable to whom? a) The manufacturer of the AST

b) The responsible inspector

c) The Owner/Operator’s design engineering department d) The operations manager

5. During the inspection of fixed roof support members, particular attention must be given to .

a) Severe external corrosion of the roof plate where support structures are attached b) Severe internal corrosion of pipe columns

c) Severe internal corrosion of the roof plate where support structures are attached d) Deterioration of wind girders at the point of attachment

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6. Inspection of floating roofs is limited to roof plates and pontoons. a) True

b) False

7. Evaluation of existing floating roofs shall be based on the criteria of

a) API-650, Appendix C for external floating roofs and Appendix H for internal floating roofs

b) API-510 Paragraph 6.4.3 for external floating roofs and 6.5.3 for internal

c) ASME Section VIII, Div 1 Appendix C for external floating roofs and Appendix H for internal

d) ASME Section VIII, Div. 2 Alternative Rules Reference: API-653 Paragraph 2.2.3.4

8. What API Standard or Recommended Practice must be used for evaluating the effects of design partial vacuum on tank roofs?

a) API Standard 620 b) API Standard 650

c) API Recommended Practice 651 d) API Recommended Practice 652 Reference: API-653 Paragraph 2.2.4.2

9. Above what operating temperature shall API Standard 650, Appendix M, be considered before changing the service of a tank?

a) 500°F b) 400°F c) 300°F d) 200°F

10. Under what conditions may a tank be operated at a temperature lower than the original design?

a) When the requirements for impact testing of ASME Section VIII, Division 1 have been met

b) When the requirements of the applicable standard or API Standard 650 have been met

c) When the requirements of ASTM Specification A-370 have been met d) When the requirements of ASTM Specification A-20 have been met Reference: API-653 Paragraph 2.2.4.4

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11. Flaws, deterioration, or other conditions that might adversely affect the performance or structural integrity of the shell of an existing tank must be evaluated. Personnel

experienced in tank design shall conduct the evaluation. This analysis shall take into account any of the following except

a) Fluid static head

b) Internal and external pressure

c) Organization that manufactured the tank d) Seismic loads

12. Of the following, which is not an option available to the owner/operator if it is not possible to satisfy the requirements for minimum thickness calculations for a welded tank?

a) Repair damaged areas

b) Reduce allowable liquid level c) Retire the tank

d) Reduce the fill rate so the tank fills slower and applies pressure gradually Reference: API-653 Paragraph 2.3.1.5

13. Out-of-roundness, buckled areas, flat spots, and peaking and banding of welded joints are all examples of _____.

a) Shell Distortions b) Flaws

c) Discontinuities d) Severe damage

14. Shell distortions require the tank to be immediately removed from service and inspected. a) True

b) False

15. Flaws such as cracks or laminations shall be thoroughly examined to determine their nature and extent and the need for repairs.

a) True b) False

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16. What if anything should be done with cracks in the shell-to-bottom weld?

a) These cracks can be sealed with caulking and the tank returned to service b) The welds can have a cover weld pass applied over them to prevent leakage c) Cracks of this type are critical and the tank must be retired from service since

repairs are prohibited.

d) Cracks in the shell-to-bottom weld are critical and shall be removed and the weld repaired

17. Internal pitting and pitting rates in the anticipated service, corrosion of weld joints (weld and heat affected zone), weld joint cracking history, and stresses placed on the bottom plates by roof support loads and shell settlement are all examples of causes of what type of failure?

a) Annular ring failure

b) Shell plate failure at first shell course c) Bottom failure

d) Fatigue failure due to repeated jacking of floor plates Reference: API-653 Paragraph 2.4.2

18. Underside corrosion (normally in the form of pitting), inadequate drainage resulting in surface water flowing under the tank bottom, lack of an annular plate ring when required, uneven settlement that results in high localized stresses in the bottom plates, and

inadequate provision for movement of roof support columns and other supports are all examples of causes of what type of failure?

a) Shell plate failure at first course b) Bottom failure

c) Failure of support columns due to hydraulic compression d) Creep cracking failure

19. Of the following what has historically not been a cause of bottom failures? a) Non-homogeneous fill under the tank bottom

b) Rock or gravel foundation pads with inadequately filled-in surface voids c) Inadequate inspection frequency

d) Inadequately supported sumps Reference: API-653 Paragraph 2.4.2

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20. Where would you look to find the basis for cathodic protection systems for the underside of tank bottoms?

a) API Recommended Practice 651 b) API Recommended Practice 652 c) API Standard 2015

d) API Standard 2207 Reference: API-653 Paragraph 2.4.3

21. Where would you look to find procedures and practices for protecting tank bottoms with internal lining?

a) API Recommended Practice 651 b) API Recommended Practice 652 c) API Standard 2015

d) API Standard 2207 Reference: API-653 Paragraph 2.4.4

22. What two methods may be used in quantifying the remaining thickness of tank bottoms? a) Drilling and actual measurement

b) Ultrasonic and radiography c) Deterministic and probabilistic

d) Detailed stress analysis and plate deformation measurement Reference: API-653 Paragraph 2.4.7

23. Unless a stress analysis is performed, what is the minimum thickness of bottom plates in the critical zone?

a) Smaller of ½ the original bottom plate thickness or 50% of tmin of the lower shell course but not less than 0.1 inch.

b) Smaller of ¼ the original bottom plate thickness or 25% of tmin of the lower shell course but not less than 0.1 inch.

c) Smaller of ¾ the original bottom plate thickness or 75% of tmin of the lower shell course but not less than 0.1 inch.

d) Smaller of ½ the original bottom plate thickness or 50% of tmin of the lower shell course but not less than 0.01 inch.

24. When repairing internal pitting for the extension of in-service operating period, the repair shall be by any of the following methods except.

a) Pit welding b) Brazing

c) Overlay welding d) Lap Patching

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25. The thickness of the bottom plate projection beyond the shell, measured at the toe of the weld of the outside bottom-to-shell fillet weld shall be not less than?

a) 0.25 inch b) 0.01 inch c) 0.50 inch d) 0.10 inch

26. The projection of the bottom plate beyond the toe of the shell-to-bottom weld shall be at least?

27. An aboveground storage tank contains a fluid with a specific gravity of less than one. The thickness of the plate in the first course is 7/8”. What is the minimum thickness of the annular plate ring, seismic loading is not a consideration, and the stress in the first course is 27,850 pound per square inch?

Reference: API-653 Paragraph 2.4.8.2 and Table 2-3

28. An aboveground storage tank contains a fluid with a specific gravity of greater than one. The thickness of the plate in the first course is 7/8”. What is the minimum thickness of the annular plate ring, seismic loading is not a consideration, and the hydrostatic test stress in the first shell course is 27,850 pound per square inch?

a) 1 / 4 inch b) 3 / 8 inch c) 9 / 32 inch d) 11 / 32 inch

Reference: API-653 Paragraph 2.4.8.3 and Table 3-1 API-650

29. Settlement, erosion, cracking, and deterioration of concrete are all examples of which of the following principle modes of failure or deterioration?

a) Annular plate ring failure b) Shell-to-bottom weld failure

c) Deterioration of walkways and roadways d) Deterioration of foundations

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30. To ensure suitability for service, what is the minimum permitted frequency of tank foundation inspection?

a) Annually

b) Every five years c) Monthly

d) Periodically

Reference: API-653 Paragraphs 2.5.1.1 & 4.3.1.2

31. Distortion of anchor bolts and excessive cracking of concrete structures may be indications of what two conditions?

a) Serious foundation settlement of a tank overpressure uplift condition b) Inferior material used in the anchor bolts and the concrete structure c) Over tightening of the anchor bolts and improper mixing of the concrete d) The tank was struck by lightning and wind caused movement of the tank Reference: API-653 Paragraph 2.5.3

Message to the student:

API-653 Paragraph 2.5.1.2 contains descriptions of some mechanisms of concrete deterioration. It would be in your best interest to read these descriptions carefully and

understand them. The examination may contain questions that would require you to know the definition of one or more of these modes of deterioration.

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Answers to API-653 Section 2, Suitability for Service

1 A 2 C 3 D 4 B 5 B 6 B 7 A 8 A 9 D 10 B 11 C 12 D 13 A 14 B 15 A 16 D 17 C 18 B 19 C 20 A 21 B 22 C 23 A 24 B 25 D 26 C 27 B 28 C 29 D 30 C 31 A

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Section 3 – Brittle Fracture Considerations

1. Incidents of tank failure due to brittle fracture have occurred shortly after erection during hydrostatic testing or in all but which of the following incidents?

a) On the first filling in cold weather

b) After a change to a higher temperature service c) After a change to a lower temperature service d) After a repair or alteration

2. The risk of tank failure due to brittle fracture is considered minimal after what condition(s)?

a) The tank has demonstrated its ability to withstand the combined effects of maximum liquid level (highest stresses) and highest operating temperature b) The tank has demonstrated its ability to withstand the combined effects of

intermediate liquid level (highest stresses) and lowest operating temperature c) The tank has demonstrated its ability to withstand the combined effects of

maximum liquid level (highest stresses) and lowest operating temperature d) The tank has demonstrated its ability to withstand the combined effects of

maximum liquid level (highest stresses) and intermediate operating temperature Reference: API-653 Paragraph 3.2.1

3. If it is decided to change the service to a more severe service, it is necessary to a) Consider the need for pneumatically testing the entire tank

b) Consider the need to recalculate the effectiveness of all reinforcement of openings c) Consider the need for hydrostatic testing

d) Consider removing all previous welded repairs and have them redone Reference: API-653 Paragraph 3.2.2

4. If a tank shell thickness is less than _____ inch, and an evaluation in accordance with Section 2 of API-653 has been performed, the risk of brittle fracture is considered to be minimal.

a) 0.01 b) 0.10 c) 0.05 d) 0.50

5. No known tank failures attributed to brittle fracture have occurred at shell metal temperatures of _____°F and above.

a) -20 b) 20 c) 40 d) 60

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6. According to industry experience and laboratory tests, what membrane stress is required to caused failure due to brittle fracture?

a) 6 ksi b) 7 ksi c) 10 ksi d) 12 ksi

7. What is the lowest temperature that a tank, constructed of carbon steel of unknown toughness, may be used? The maximum thickness of the shell is .625”

a) 40°F b) 45°F c) 50°F d) 55°F

Reference: API-653 Paragraph 3.3.7 and Figure 3-2 8. What is the purpose of Figure 3-1 of API-653?

a) Provides a procedure to be used in the evaluation of the remaining life of tank bottom plates

b) Provides a procedure to be used in the evaluation of the likelihood of floating roof pontoon failure

c) Provides an assessment procedure for evaluating aboveground storage tanks operating at 15 psi

d) Provides an assessment procedure for evaluating atmospheric aboveground storage tanks

Reference: API-653 Paragraph 3.3 and Figure 3-1

Answers to API-653 Section 3, Brittle Fracture Considerations

1 B 2 C 3 C 4 D 5 D 6 B 7 A 8 D

Should you find a mistake or disagree with any answer listed, please bring it to our attention for correction or clarification. BAY Technical Associates, Inc. has attempted to provide answers developed from paragraphs of the respective Code, Standard, or Recommended Practice.

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Section 4 – Inspection

1. What is the purpose of periodic in-service inspection?

a) The purpose of periodic in-service inspection, assure job security for inspectors b) The purpose of periodic in-service inspection, assure proper operation of AST c) The purpose of periodic in-service inspection is to assure continued tank integrity d) The purpose of periodic in-service inspection is to assure OSHA compliance Reference: API-653 Paragraph 4.1

2. Of the following, which is not a consideration that must be addressed in determining inspection intervals for ASTs?

a) Corrosion prevention systems

b) Inspection interval of other equipment located near the tank under consideration c) Changes in service (including changes in water bottoms)

d) Previous inspection results Reference: API-653 Paragraph 4.2.1

3. What methods of inspection must be considered when establishing inspection frequencies?

a) On-stream core sample inspection b) On-stream nondestructive inspection c) In-service aerial inspection

d) In-service groundwater inspection Reference: API-653 Paragraph 4.2.2

4. Close visual inspections of aboveground storage tanks, from the ground, are required. Owner/operator personnel who may be other than the Authorized Inspector may perform this inspection. The interval of such inspections shall not exceed:

a) At least every five years or 1/4 the corrosion rate life of the shell whichever is less b) 12 months

c) 6 months d) 1 month

5. All tanks shall be given a visual external inspection, by an Authorized Inspector, at what frequency?

a) Inspection conducted at least every 20 years or at the quarter corrosion rate of the bottom whichever is less

b) Inspection conducted at least every 5 years or at the quarter corrosion rate of the bottom whichever is less

c) Inspection conducted at least every 5 years or at the quarter corrosion rate of the shell whichever is less

d) Inspection conducted at least every 20 years or at the quarter corrosion rate of the shell whichever is less

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6. External ultrasonic thickness measurements of the shell, while the tank is in service, can be a means of determining rate of uniform corrosion. The extent of UT measurements shall be determined by the owner/operator. What is maximum interval of such thickness measurements when the corrosion rate is not known?

a) Five years b) Three years c) One year

d) Every three months until the corrosion rate is established

Reference: API-653 Paragraph 4.3.3.2a.

7. The minimum thickness of a tank was established at 0.585 inch. The shell was fabricated from 3/4 inch plate and included a 0.125 inch corrosion allowance. The tank has been in service for eight years and current ultrasonic thickness measurements reveal an average thickness of 0.712 inch. Based on this information determine when the next ultrasonic thickness measurements will be required.

a) Fifteen years b) Thirteen years c) Eleven years d) Nine years

Reference: API-653 Paragraph 4.3.3.2b.

8. Internal inspections are primarily required to do all but which of the following? a) Ensure the internal surfaces of the tank are thoroughly cleaned periodically b) Identify and evaluate any tank bottom settlement

c) Ensure that the bottom is not severely corroded and leaking

d) Gather data necessary for the minimum bottom and shell thickness assessments

9. When can the required internal inspection be performed by some method other than visual inspection?

a) Substitution of the visual inspection is never permitted

b) If the internal inspection is required solely for determining the condition and integrity of the tank bottom

c) If the internal inspection is required solely for determining the condition and integrity of the tank critical zone

d) If the internal inspection is required solely for determining the condition and integrity of the tank roof support structure

10. According to API-653, all tanks shall have a formal internal inspection conducted at intervals defined by this standard. Who is required to conduct the visual inspection?

a) The corrosion engineer

b) The person designated by the Authorized Inspector c) The authorized Inspector

d) The person designated by the owner user Reference: API-653 Paragraph 4.4.1.2

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11. Intervals between internal inspections shall be determined by the corrosion rates measured during previous inspections or anticipated based on experience with tanks in similar service. The internal inspection interval shall not exceed how many years?

a) Ten years b) Fifteen years c) Twenty years d) Twenty-five years

12. What is the minimum thickness permitted at the next inspection for a tank bottom designed with a means to provide detection and containment of a bottom leak?

Reference: API-653 Paragraph 4.4.2.1 & 2.4.7.4

13. In cases where corrosion rates are not known and similar service experience is not available, the bottom plate actual thickness shall be determined by inspection(s) within how many years?

a) 25 years b) 20 years c) 15 years d) 10 years

14. Which of the following is a recognized alternative to internal inspection interval described in API-653?

a) Risk-based Inspection procedures (RBI)

b) Hydrostatically testing the tank every five years

c) Performing complete calculations for minimum required thickness of the tank shell and bottom

d) API-653 does not permit any alternatives to the internal inspection intervals Reference: API-653 Paragraph 4.4.3

15. Of the following, which would not be a factor to be considered in a Risk-based assessment of a tank?

a) Availability and effectiveness of inspection methods and quality of data collected b) The methods used for determining the thickness of the shell and bottom plates c) Effectiveness of corrosion mitigation methods

d) Names of all operators since the initial start-up of the tank Reference: API-653 Paragraph 4.4.3

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16. The owner/operator is required to maintain complete record file consisting of three types of records. Which of the following is not one of the three types of records.

a) Repair/alteration history b) Fill cycles

c) Construction d) Inspection

17. General inspection reports shall include which of the following?

a) Metal thickness measurement, repairs, conditions found, settlement measurements, and recommendations

b) Metal thickness measurement, repairs, operational upsets, settlement measurements, and recommendations

c) Metal thickness measurement, repairs, conditions found, name of organization performing environmental impact study, and recommendations

d) Metal thickness measurement, list of all personnel who have worked on the tank since the last inspection, conditions found, settlement measurements, and

recommendations

Note to Student: Be sure to know all the requirements for Inspector Qualifications. Questions can appear on the exam requiring you to know one, two, or all of these qualification requirements. You will find these requirements are similar to those found in Inspector Certification programs for API-510 and API-570.

Answers to API-653 Section 4, Inspection

Question Number Answer Question Number Answer

1 c 10 c 2 b 11 c 3 b 12 d 4 d 13 d 5 c 14 a 6 a 15 d 7 b 16 b 8 a 17 a 9 b

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Section 5 – Materials

1. All new materials used for repair, alteration, and reconstruction shall conform to which of the following?

a) The existing material code at the time of original construction b) The latest NFPA Code

c) The current applicable tank standards

d) Any ASME Code specification for P-1 material Reference: API-653, Paragraph 5.2

2. All shell plates and bottom plates welded to the shell shall be identified. Material identified by any of the following except _____ does not require further identification?

a) Original contract drawings b) API name plates

c) Suitable documentation

d) Owner/operator's experience with similar tanks in similar service constructed of similar material

Reference: API-653, Paragraph 5.3.1.1

3. Each individual plate for which adequate identification can not be made; the plate shall be _______.

a) Subjected to chemical analysis and mechanical tests as required in ASTM A6 and A370 including Charpy V-Notch

b) Subjected to chemical analysis and mechanical tests as required in ASTM A20 and A333 including Charpy V-Notch

c) Subjected to Brinell hardness analysis and mechanical tests as required in ASTM A6 and A370 including Charpy V-Notch

d) Subjected to Brinell hardness analysis and mechanical tests as required in ASTM A20 and A333 including Charpy V-Notch

4. Under what condition does API-653 require two tension specimens shall be taken at right angles to each other from a corner of each plate? One of those specimens must meet the specification requirements.

a) When the direction of rolling is not definitely known

b) When the welding will be conducted at a temperature less than 32ºF

c) When the plate is not a full size plate and may be installed with the grain running vertical

d) When the material is not a P-1 material Reference: API-653, Paragraph 5.3.1.2

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5. Even when a material is identified, all shell plates and bottom plates welded to the shell shall meet what minimum requirements?

a) The chemistry and mechanical properties of material specified for the application with regard to thickness and design temperature given in ASME Section II, Part A b) The chemistry and mechanical properties of material specified for the application

with regard to thickness and design temperature given in API Standard 650 c) The chemistry and mechanical properties of material specified for the application

with regard to thickness and design temperature given in the owner/operator's engineering design

d) The chemistry and mechanical properties of material specified for the application with regard to thickness and design temperature given in the contract for the tank repair, alteration, or reconstruction

6. Is it permissible to reuse existing rolled structural shapes? If so what specification applies?

a) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-20 as a minimum

b) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-370 as a minimum

c) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-6 as a minimum

d) Yes, existing rolled structural shapes shall meet the requirement of ASTM A-7 as a minimum

Reference: API-653, Paragraph 5.3.2

7. Flange material must meet the minimum requirements of the material specifications of the current applicable standard.

a) True b) False

8. Fasteners shall meet the material specifications of the current applicable standard. a) True

b) False

9. If existing plates are to be used to reconstruct the tank, they shall be checked for which of the following?

a) Chemical compatibility with other plates used in the reconstruction b) Excessive corrosion and pitting

c) Mechanical strength including impact properties d) Inadequately reinforced openings

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Answers to API-653 Section 5, Materials

1 C 2 D 3 A 4 A 5 B 6 D 7 B 8 A 9 B