API 653: Tank Assessment, Restoration, Alteration, and Refurbishment

Introduction:

The API 653 Tank Inspection, Repair, Alteration, and Reconstruction course is designed to equip participants with a thorough understanding of core engineering principles related to the inspection, repair, alteration, and reconstruction of aboveground storage tanks. The course covers critical aspects of API standards, focusing on the in-service storage tanks outlined by API 653.

Participants will explore the API 653 regulations, gaining the ability to apply technical insights to make informed decisions in their professional roles.

Earning the API 653 certification enhances the career prospects of inspectors and engineers working with storage tanks, reflecting a deep understanding of the relevant standards for tank inspection, maintenance, modification, and rehabilitation.

This course offers detailed coverage of API 653, with a strong focus on tank inspection, repair, and maintenance. Participants will be introduced to non-destructive testing and effective inspection, repair, and safety management systems, ensuring compliance with API 653 regulations for tank inspection, repair, and alteration.

Objectives:

Upon completing this API 653 Tank Inspection, Repair, Alteration, and Reconstruction course, participants will be able to:

• Define the API 653 standard in terms of content, including applicability, serviceability, and tank shell integrity, addressing minimum allowed thickness and maximum fill height.
• Assess tank bottoms, settlement issues, and Release Prevention Systems (RPS).
• Understand key inspection requirements and identify common causes of tank deterioration.
• Evaluate the need for cathodic protection and the methods used for its implementation.
• Perform post-weld heat treatments and understand the importance of normalization and Charpy impact testing.
• Interpret welding defects and discuss ASME Section IX, including WPS, WPQ, and PQR.

Training Methodology:

• Workshops and interactive sessions
• Self-evaluation reports and case studies
• Simulations
• Problem-based learning
• Expert presentations
• Issue resolution exercises
• Investigation of real-world conditions

Course Outline:

Unit 1: Introduction and Overview of API 653

• Scope and definitions of API 653 and its suitability for use
• Tank shell evaluation and shell thickness calculations for welded tanks
• Computation of maximum allowable fill height
• Tank bottom analysis and release prevention systems (RPS)
• Assessment of tank base and annular plate ring minimums
• Internal/external inspections and ultrasonic thickness measurements
• Tank reconstruction and design aspects
• Tank reclamation and alteration processes

Unit 2: Practical API 653 Procedures for Tank Dismantling and Reinstatement

• Testing of flanges, welds, and tank examination requirements
• Tank base settlement assessments
• Application of API 650 scope
• Material specifications and tank joint design
• Fabrication and welding of tanks
• Tank inspections, testing, and maintenance
• Joint inspection methodologies

Unit 3: API 575 and API 651 Scope and Definitions

• Types of storage tanks and reasons for inspection
• Causes of deterioration in structures and equipment
• Health inspections and maintenance of structures
• Encyclopedia of steel aboveground storage tank corrosion
• Cathodic protection system design and implementation

Unit 4: ASME IX Welding Procedure Qualifications (WPS, WPQ, and PQR)

• Welding processes and essential variables
• P-Numbers, S-Numbers, F-Numbers, and A-Numbers
• Welder test positions and qualification requirements
• API 571: Identifying damage mechanisms in refining equipment

Unit 5: Damage Mechanisms and Non-Destructive Testing

• Welding inspection and metallurgy based on API 577
• Hot tapping and in-service welding
• ASME Section V: Non-destructive testing (X-ray, liquid penetrant, magnetic particle testing)