Understanding API ICP653 Worksheet-02.pdf

Q&A API 653 Tank Inspection Code

Reading V- My self study note, 29th Dec 2015

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Section 1, 2, 3 – Introduction Q1. 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 API510 Reference: API-653 Paragraph 1.1.1 Q2. 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

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Q3. API-653 provides for all but which of the following with regard to aboveground storage tanks? a) Repair b) Operation c) Relocation d) Alteration Reference: API-653 Paragraph 1.1.1 Q4. 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

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Q5. 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 Q6. 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 Reference: API-653 Paragraph 1.1.2

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Q7. 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 Reference: API-653 Paragraph 1.1.3 Q8. 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 Reference: API-653 Paragraph 1.1.4

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Q9. 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 Q10. 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 Reference: API-653 Paragraph 1.2

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Q11. 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 Q12. 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

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

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Section 4 – Suitability for Service Q1. 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 4.1.1

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Q2. 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 4.1.3

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Q3. 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 4.2.1.2 Q4. 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 Reference: API-653 Paragraph 4.2.2

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Q5. 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 Reference: API-653 Paragraph 4.2.2 Q6. Inspection of floating roofs is limited to roof plates and pontoons. a) True b) False Reference: API-653 Paragraph 4.2.3.3

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Q7. 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 4.2.3.4 Q8. 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 4.2.4.2

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API650-2013 Welded Tanks for Oil Storage Annex C (normative) External Floating Roofs Annex H (normative) Internal Floating Roofs API Std 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks, Twelfth Edition

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Q9. 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 Reference: API-653 Paragraph 4.2.4.3 Q10. 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, Div, 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 4.2.4.4

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Q11. 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 Reference: API-653 Paragraph 4.3.1.2

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Q12. 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 4.3.1.5 Q13. 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 Reference: API-653 Paragraph 4.3.5.1

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Q14. Shell distortions require the tank to be immediately removed from service and inspected. a) True b) False Reference: API-653 Paragraph 2.3.5.3 Q15. 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 Reference: API-653 Paragraph 4.3.6

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Q16. 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 repaired Reference: API-653 Paragraph 2.3.6 Q17. 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 4.4.2 Charlie Chong/ Fion Zhang

Q18. 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 Reference: API-653 Paragraph 4.4.2 Q19. 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 4.4.2

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Q20. 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 4.4.3 Q21. 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 4.4.4

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Q22. 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 4.4.7 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. Reference: API-653 Paragraph 4.4.7.4 Charlie Chong/ Fion Zhang

API653: 4.4.5.4 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 tmin 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.

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Q24. 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 Reference: API-653 Paragraph 4.4.7.5 Q25. 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 Reference: API-653 Paragraph 4.4.7.7

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API653: 4.4.5.7 The thickness of the projection of the bottom plate beyond the shell as measured at the toe of the outside bottom-to-shell fillet weld shall not be less than 0.1 in. The projection of the bottom plate beyond the outside toe of the shell-to-bottom weld shell shall be at least 3/8 in.

3/8 in. 0.1 in.

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Q26. The projection of the bottom plate beyond the toe of the shell-to-bottom weld shall be at least? a) 0.125 inch b) 0.250 inch c) 0.375 inch d) 0.500 inch Reference: API-653 Paragraph 4.4.7.7 Q27. 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? a) 0.22 inch b) 0.31 inch c) 0.20 inch d) 0.23 inch Reference: API-653 Paragraph 4.4.8.2 and Table 4-4

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API653: 4.4.6 Minimum Thickness for Annular Plate Ring 4.4.6.1 Due to strength requirements, the minimum thickness of annular plate ring is usually greater than 0.10 in. Isolated pitting will not appreciably affect the strength of the plate. Unless a stress analysis is performed, the annular plate thickness shall be in accordance with 4.4.6.2 or 4.4.6.3, as applicable. 4.4.6.2 For tanks in service with a product specific gravity less than 1.0, which require annular plates for other than seismic loading considerations, the thickness of the annular plates shall be not less than the thicknesses given in Table 4.5, plus any specified corrosion allowance. Interpolation is allowed within Table 4.5 based on shell stress determined per Note b of Table 4.5. 4.4.6.3 For tanks in service with a product specific gravity of 1.0 or greater, which require annular plates for other than seismic loading considerations, the thickness of the annular plates shall be in accordance with API 650, Table 5-1a or 5-1b, plus any specified corrosion allowance. Interpolation is allowed within API 650, Table 5-1a or 5-1b based on shell stress determined per Note b of API 650, Table 5-1.

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API653: Table 4.5—Annular Bottom Plate Thicknesses (in.) (Product Specific Gravity < 1.0)

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Q27A. An aboveground storage tank contains a fluid with a specific gravity of 1.1. 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? a) 0.22 inch b) 0.31 inch c) 0.20 inch d) 0.23 inch Answer: 9/32” Reference: API-653 Paragraph 4.4.8.2 and Table 4-4

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API650: Table 5.1b—Annular Bottom-Plate Thicknesses (tb) (USC)

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Q28. 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 4.4.8.3 and Table 3-1 API-650 Q29. 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 Reference: API-653 Paragraph 4.5.1.1

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Q29. 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 Reference: API-653 Paragraph 4.5.1.1

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Q30. 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 4.5.1.1 & 4.3.1.2

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API653: 4.5 Tank Foundation Evaluation 4.5.1 General 4.5.1.1 The principal causes of foundation deterioration are settlement, erosion, cracking, and deterioration of concrete initiated by: calcining, attack by underground water, attack by frost, and attack by alkalies and acids. To ensure suitability for service, all tank foundations shall be inspected periodically (see 6.3). API653: 6.3 Inspections from the Outside of the Tank 6.3.1 Routine In-service Inspections 6.3.1.1 The external condition of the tank shall be monitored by close visual inspection from the ground on a routine basis. This inspection may be done by owner/operator personnel, and can be done by other than authorized inspectors as defined in 3.4. Personnel performing this inspection should be knowledgeable of the storage facility operations, the tank, and the characteristics of the product stored. 6.3.1.2 The interval of such inspections shall be consistent with conditions at the particular site, but shall not exceed one month.

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Q31. 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 4.5.3

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Answers to API-653 Section 4 Suitability for Service 1A

11 C

21 B

2C

12 D

22 C

3D

13 A

23 A

4B

14 B

24 B

5B

15 A

25 D

6B

16 D

26 C

7A

17 C

27 B

8A

18 B

28 C

9D

19 C

29 D

10 B

20 A

30 C

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31 A

Section 5 – Brittle Fracture Considerations Q1. 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 Reference: API-653 Paragraph 5.2.2

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Q2. The risk of tank failure due to brittle fracture is 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 5.2.2

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Q3. 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 5.2.3 Q4. If a tank shell thickness is less than _____ inch, and an evaluation in accordance with Section 5 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 Reference: API-653 Paragraph 5.3.5

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Q5. 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 Reference: API-653 Paragraph 5.3.6 Q6. 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 Reference: API-653 Paragraph 5.3.7

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Q7. 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 5.3.8 and Figure 5-2 Q8. What is the purpose of Figure 5-1 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 for brittle fracture Reference: API-653 Paragraph 5.2.1 and Figure 5-1 Charlie Chong/ Fion Zhang

Figure 5.2—Exemption Curve for Tanks Constructed from Carbon Steel of Unknown Material Specification

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Answers to API-653 Section 3, Brittle Fracture Considerations Question Number Answer 1B 2C 3C 4D 5D 6B 7A 8D

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Section 6 – Inspection Q1. 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 6.1

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Q2. 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 6.2.1

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Q3. 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 6.2.2 Q4. Close visual inspections of aboveground storage tanks, from the ground, may be made by other than the Authorized Inspector , 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 Reference: API-653 Paragraph 6.3.1.2

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Q5. 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 shellwhichever is less Reference: API-653 Paragraph 6.3.2.1

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Q6. 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 6.3.3.2a.

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Q7. 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 6.3.3.2b. Initial thickness= 0.75” Present thickness= 0.712 Interval= 8 year Corrosion rate= 0.00475”/year Next interval= 15 years or RCN/2N = 0.127/0.00475 = 26.7 year, which ever is less. Used= 15 years Charlie Chong/ Fion Zhang

Q8. 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 Reference: API-653 Paragraph 6.4.1.1 Q9. 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 Reference: API-653 Paragraph 6.4.1.2 Charlie Chong/ Fion Zhang

Q10. 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 6.4.1.2

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Q11. 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 Reference: API-653 Paragraph 6.4.2.1

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Q11A. 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, for tanks with a Release Prevention Barrier.? a) Ten years b) Fifteen years c) Thirty years d) Twenty-five years Reference: API-653 Paragraph 6.4.2.1

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6.4.2.1 Initial Internal Inspection Interval The initial internal inspection intervals for newly constructed tanks and/or refurbished tanks shall be established either per 6.4.2.1.1 or 6.4.2.1.2. 6.4.2.1.1 The interval from initial service date until the first internal inspection shall not exceed 10 years unless a tank has one or more of the leak prevention, detection, corrosion mitigation, or containment safeguards listed in Table 6.1. The initial internal inspection date shall be based on incremental credits for the additional safeguards in Table 6.1 which are cumulative.

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Table 6.1—Tank Safeguard

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6.4.2.2 Subsequent Internal Inspection Interval The interval between subsequent internal inspections shall be determined in accordance with either the corrosion rate procedures of 6.4.2.2.1 or the risk based inspection procedures as outlined in 6.4.2.2.2. 6.4.2.2.1 The subsequent inspection interval (beyond the initial inspection) can be determined using the measured tank bottom corrosion rate and the minimum remaining thickness in accordance with 4.4.5. During any examination to determine corrosion rates the owner/operator should ensure they understand the effectiveness of the inspection techniques employed for detecting and measuring potential damage mechanisms. When changing service, an owner/operator may decide to use internal corrosion rates obtained from similar service assessment (performed per Annex H of API 653) when setting subsequent internal inspection dates. When using the corrosion rate procedures of 6.4.2.2.1 the maximum subsequent internal inspection interval shall be 20 years for tanks without a Release Prevention Barrier, or 30 years for tanks with a Release Prevention Barrier.

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Q12. 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? a) 0.01 inch b) 0.10 inch c) 0.50 inch d) 0.05 inch Reference: API-653 Paragraph 6.4.2.1 & Table 6.1 Q13. 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 Reference: API-653 Paragraph 6.4.2.2

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Q14. 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 6.4.3 Q15. Of the following, which would not be a factor to be considered in a Riskbased 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 6.4.3 Charlie Chong/ Fion Zhang

Q16. 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 Reference: API-653 Paragraph 6.8.1

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Q17. 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 Reference: API-653 Paragraph 6.9.2

Charlie Chong/ Fion Zhang

Answers to API-653 Section 6, Inspection 1c

11 c

2b

12 d

3b

13 d

4d

14 a

5c

15 d

6a

16 b

7b

17 a

8a 9b 10 c

Charlie Chong/ Fion Zhang

Section 7 – Materials Q1. 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 7.2 Q2. 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 7.3.1.1

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Q3. 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 Reference: API-653, Paragraph 7.3.1.2

Charlie Chong/ Fion Zhang

Q4. 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 7.3.1.2

Charlie Chong/ Fion Zhang

Q5. 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 Reference: API-653, Paragraph 7.3.1.3

Charlie Chong/ Fion Zhang

Q6. 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 7.3.2 Note: ASTM A6 / A6M - 14 Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling API653: 7.3.2 Structural Existing rolled structural shapes that are to be reused shall meet the requirement of ASTM A7 as a minimum. New structural material shall meet the requirements of ASTM A36 or ASTM A992 as a minimum. NOTE ASTM A7 was a steel specification that was discontinued in the Fourth Edition of API 650, 1970. Charlie Chong/ Fion Zhang

API653: 7.3.2 Structural Existing rolled structural shapes that are to be reused shall meet the requirement of ASTM A7 as a minimum. New structural material shall meet the requirements of ASTM A36 or ASTM A992 as a minimum. NOTE ASTM A7 was a steel specification that was discontinued in the Fourth Edition of API 650, 1970.

Charlie Chong/ Fion Zhang

Q7. Flange material must meet the minimum requirements of the material specifications of the current applicable standard. a) True b) False Reference: API-653, Paragraph 7.3.3.1 API653: 7.3.3 Flanges and Fasteners 7.3.3.1 Flange material shall meet the minimum requirements of the material specifications in the as-built standard. 7.3.3.2 Fasteners shall meet the material specifications of the current applicable standard.

Charlie Chong/ Fion Zhang

Q8. Fasteners shall meet the material specifications of the current applicable standard. a) True b) False Reference: API-653, Paragraph 7.3.3.2

Charlie Chong/ Fion Zhang

Q9. 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 Reference: API-653, Paragraph 7.3.4

Charlie Chong/ Fion Zhang

Answers to API-653 Section 7, Materials Question Number Answer 1C 2D 3A 4A 5B 6D 7B 8A 9B

Charlie Chong/ Fion Zhang

Section 8 – Design Considerations for Reconstructed Tanks Q1. Design considerations other than normal product loading shall be specified by the _____. a) Organization performing the reconstruction b) Authorized Inspector c) Owner/operator d) Registered professional engineer contracted by the repair organization Reference API 653 Paragraph 8.1 Q2. Weld joint details shall meet the requirements of which of the following? a) API Standard 650 b) ASME Section IX only c) The applicable standard d) AWS D1.1 Structural Welding Code Reference API 653 Paragraph 8.2.1

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Q3. The thickness to be used for each shell course when checking tank design shall be based on: a) Measurements taken within 30 days prior to relocation b) Measurements taken within 60 days prior to relocation c) Measurements taken within 120 days prior to relocation d) Measurements taken within 180 days prior to relocation Reference API 653 Paragraph 8.4.1 Q4. The maximum liquid level for hydrostatic test shall be determined by using which of the following? a) The nominal thickness of each shell course at the time of original construction b) The actual thickness measured for each shell course c) The anticipated thickness for each shell course at the time of next thickness measurements d) Twice the anticipated thickness for each shell course at the time of next thickness measurements Reference API 653 Paragraph 8.4.3

Charlie Chong/ Fion Zhang

Design Considerations for Reconstructed Tanks API653: 8.4.3 The maximum liquid level for hydrostatic test shall be determined by using the actual thickness measured for each shell course, the allowable stress for the material in each course, and the design method to be used. The allowable stress for the material shall be determined using API 650, Table 5- a or Table 5-2b. For material not listed in Table 5-2a or Table 5-2b, an allowable stress value of the lesser of 3/4 yield strength or 3/7 tensile strength shall be used.

Charlie Chong/ Fion Zhang

Q5. The joint efficiency and allowable stress levels for existing welded joints that are not to be removed and replaced shall be based on which of the following? a) Original construction standard b) Original degree and type of inspection c) Current construction standard d) Current degree and type of inspection Reference API 653 Paragraph 8.4.5 Q6. Replacement and new penetrations shall be designed, detailed, welded, and examined to meet what requirements? a) The current applicable standard b) The original standard of construction c) The requirements of the Authorized Inspector d) The requirements of the owner/operator Reference API 653 Paragraph 8.5.1

Charlie Chong/ Fion Zhang

Q7. Existing penetrations shall be evaluated for compliance with what requirements? a) The current applicable standard b) The original standard of construction c) The requirements of the Authorized Inspector d) The requirements of the owner/operator Reference API 653 Paragraph 8.5.2 Q8. With regard to seismic design, reconstructed tanks shall be built to meet the stability requirements of: a) The requirements of the owner/operator b) The requirements of the Authorized Inspector c) The original standard of construction d) The applicable standard Reference API 653 Paragraph 8.8

Charlie Chong/ Fion Zhang

Answers to API-653 Section 8, Design Question Number Answer 1C 2C 3D 4B 5B 6A 7B 8D

Charlie Chong/ Fion Zhang

Section 9 – Tank Repair and Alteration Q1. The basis for repairs and alterations shall be equivalent to which of the following? a) API-653 b) API-650 c) API-510 d) API-570 Reference API-653, Paragraph 9.1.1 Q2. The minimum dimension for a replacement shall plate shall be _____ inches or ____ times the thickness of the replacement plate whichever is ______. a) 12, 12, greater b) 12, 12, lesser c) 18, 18, greater d) 18, 18, lesser Reference API-653, Paragraph 9.2.2.1

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Q3. Unless an entire shell plate is replaced, the replacement plate may be circular, oblong, square or rectangular provide the corners are a) Provided with a radius of at least 1 inch (2”) b) Provided with a radius of at least 3% of the short dimension of the plate c) Provided with a radius of at least 3 inches d) Provided with rounded corners Reference API-653, Paragraph 9.2.2.1 9.3.1.4 The shape of the repair plate may be circular, oblong, square, or rectangular. All corners, except at the shell to bottom joint, shall be rounded to a minimum radius of 2 in. The nozzle reinforcing plate shapes of API 650, Figure5-8, are also acceptable.

Q4. Prior to welding the new vertical joints, the existing horizontal joints shall be cut for a minimum distance of _____ inches beyond the new vertical joints. a) Six b) Eight c) Twelve d) Sixteen Reference API-653, Paragraph 9.2.2.2

Charlie Chong/ Fion Zhang

Q5. Vertical joints shall be welded before the horizontal joints. a) True b) False Reference API-653, Paragraph 9.2.2.2 Q6. For existing shell plates over ½” thick, the outer edge of the butt weld, attaching the replacement shell plate shall be at least _____ times the weld thickness or _____ inches whichever is greater from the outer edge of any existing butt-welded shell joints. a) 12, 10 b) 10, 12 c) 8, 10 d) 10, 8 Reference API-653, Paragraph 9.2.3.3

8t or 10” Charlie Chong/ Fion Zhang

API653: 9.2.3.3 For existing shell plates over 1/2-in. thick, the outer edge of the butt weld attaching the replacement shell plate shall be at least the greater of 8 times the weld thickness or 10 in. from the outer edge of any existing buttwelded shell joints. For existing shell plates 1/2-in. thick and less, the spacing may be reduced to 6 in. from the outer edge of vertical joints or 3 in. from the outer edge of horizontal joints. See Figure 9.1 for minimum dimensions.

8t or 10” For t> ½”, d1 = greater of 8 times the weld thickness or 10 in.

Charlie Chong/ Fion Zhang

API653: 9.2.3.3 For existing shell plates over 1/2-in. thick, the outer edge of the butt weld attaching the replacement shell plate shall be at least the greater of 8 times the weld thickness or 10 in. from the outer edge of any existing buttwelded shell joints. For existing shell plates 1/2-in. thick and less, the spacing may be reduced to 6 in. from the outer edge of vertical joints or 3 in. from the outer edge of horizontal joints. See Figure 9.1 for minimum dimensions.

8t or 10” For t> ½”, d1 = greater of 8 times the weld thickness or 10 in.

Charlie Chong/ Fion Zhang

API653: 9.2.3.3 For existing shell plates over 1/2-in. thick, the outer edge of the butt weld attaching the replacement shell plate shall be at least the greater of 8 times the weld thickness or 10 in. from the outer edge of any existing buttwelded shell joints. For existing shell plates 1/2-in. thick and less, the spacing may be reduced to 6 in. from the outer edge of vertical joints or 3 in. from the outer edge of horizontal joints. See Figure 9.1 for minimum dimensions.

d1 = 3”

3” & 6” d2 = 6”

Charlie Chong/ Fion Zhang

For t≤ ½”

API653: 9.2.3.3 For existing shell plates over 1/2-in. thick, the outer edge of the butt weld attaching the replacement shell plate shall be at least the greater of 8 times the weld thickness or 10 in. from the outer edge of any existing buttwelded shell joints. For existing shell plates 1/2-in. thick and less, the spacing may be reduced to 6 in. from the outer edge of vertical joints or 3 in. from the outer edge of horizontal joints. See Figure 9.1 for minimum dimensions. d1 = 3”

3” & 6” d2 = 6”

Charlie Chong/ Fion Zhang

For t≤ ½”

Figure 9.1—Acceptable Details for Replacement of Shell Plate Material

Charlie Chong/ Fion Zhang

Q7. For existing shell plates ½” thick and less, the outer edge of the butt weld, attaching the replacement shell plate may be reduced to _____ inches from the outer edge of vertical joints or _____ inches from the outer edge of horizontal joints. a) 10, 8 b) 9, 6 c) 6, 9 d) 6, 3 Reference API-653, Paragraph 9.2.3.3

3” & 6” Charlie Chong/ Fion Zhang

Q8. For existing shell plates over ½” thick, the outer edge of the butt weld, attaching the replacement shell plate shall be at least _____ times the weld size or _____ inches, whichever is greater, from the edge (toe) of the fillet weld attaching the bottom shell course to the bottom. This rule does not apply if the replacement shell plate extends to and intersects with the bottom-toshell joint at approximately _____ degrees. a) 8, 10, 45 b) 8, 10, 90 c) 8, 10, 60 d) There are no exceptions Reference API-653, Paragraph 9.2.3.3

Charlie Chong/ Fion Zhang

Q9. The edge of any vertical weld joint attaching a replacement plate shall be at least how far from the edge of the weld joint in the annular plate ring or sketch plate? a) Eight inches b) Ten inches c) Twelve inches d) Six inches Reference API-653, Paragraph 9.2.3.3 Q10. Lapped patch shell repairs are an acceptable form of repair for buttwelded, lap-welded, and riveted tank shell only when specified by: a) The Authorized Inspector b) Repair organization c) The insurance company d) The owner/operator Reference API-653, Paragraph 9.3.1

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Q11. Lapped patch shell repairs are not permitted on shell courses exceeding what thickness? a) ½ inch b) ¾ inch c) 1 inch d) 1 ¼ inch Reference API-653, Paragraph 9.3.1.2 Q12. When a lapped patch shell repair is used, what is the minimum thickness permitted for the repair plate? a) Not less than .25 inch b) Not less than .1875 inch (4.76mm) c) Not less than .50 inch d) Not less than .375 inch Reference API-653, Paragraph 9.3.1.3

Charlie Chong/ Fion Zhang

9.3 Shell Repairs Using Lap-welded Patch Plates 9.3.1.3 Except as permitted in 9.3.3.2 and 9.3.4.3, the repair plate material shall be the smaller of 1/2 in. or the thickness of the shell plate adjacent to the repairs, but not less than 3/16 in (0.187”). 9.3.3.2 The repair plate thickness shall not exceed the shell plate thickness at the perimeter of the repair plate by more than one-third, but no more than 1/8 in. The repair plate thickness shall not exceed 1/2 in. 9.3.4.3 The repair plate thickness shall not exceed the shell plate thickness at the perimeter of the repair plate by more than one-third, but no more than 1/8 in. The repair plate thickness shall be no thinner than 3/16 in. nor thicker than 1/2 in. A full fillet perimeter weld is required.

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Q13. Repair plates for lapped patch repairs may square or rectangular in shape. These plates must be provided with a corner radius of at least what dimension? a) They shall be rounded to a minimum radius of 1 inch b) They shall be rounded to a minimum radius of 2 inches c) They shall be rounded to a minimum radius of 3 inches d) They shall be rounded to a minimum radius of 4 inches Reference API-653, Paragraph 9.3.1.4 Q14. The maximum dimension of the lapped patch repair plate vertically and horizontally shall not exceed: a) 24 inches vertically and 36 inches horizontally b) 36 inches vertically and 48 inches horizontally c) 48 inches vertically and 72 inches horizontally d) There are no maximum dimensions Reference API-653, Paragraph 9.3.1.7

Charlie Chong/ Fion Zhang

Q15. The minimum lapped patch repair plate dimension is what length? a) 6 inches (4”) b) 8 inches c) 10 inches d) 12 inches Reference API-653, Paragraph 9.3.1.7 API653: 9.3.1.7 The maximum vertical and horizontal dimension of the repair plate is 48 in. and 72 in., respectively. The minimum repair plate dimension is 4 in. The repair plate shall be formed to the shell radius. Q16. Is it permissible to install a shell opening and its reinforcement within a properly designed lapped patch shell repair? a) Yes b) No Reference API-653, Paragraph 9.3.1.8 API653: 9.3.1.8 Shell openings and their reinforcements shall not be positioned within a lapped patch shell repair.

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Q17. When a lapped patch repair plate is used to reinforce the thickness of a shell, which of the following is correct? a) The repair plate thickness shall be based on the latest edition of API-650 and 653 using a joint efficiency not exceeding 0.35 b) The repair plate thickness shall be based on the applicable standard of construction and API Standard 653 using a joint efficiency not exceeding 0.35 c) The repair plate thickness shall be based on the latest edition of API-650 and 653 using a joint efficiency not exceeding 0.70 d) The repair plate thickness shall be based on the applicable standard of construction and API Standard 650 using a joint efficiency not exceeding 0.70 Reference API-653, Paragraph 9.3.3.1 9.3.3.1 The selection of the repair plate thickness shall be based on a design that conforms to the as-built standard and API 653, using a joint efficiency not exceeding 0.35. The perimeter weld shall be a full fillet weld.

Charlie Chong/ Fion Zhang

Q18. With regard to the thickness of the repair plate at the perimeter of the repair plate, when a lapped patch repair plate is used to reinforce the thickness of a shell, which of the following is correct? a) The repair plate shall not exceed the thickness of the shell plate by more than 1/4th but no more than 1/8th inch. The maximum repair plate thickness is 1/2inch. b) The repair plate shall not exceed the thickness of the shell plate by more than 1/3rd but no more than 1/4th inch. The maximum repair plate thickness is 1/2inch. c) The repair plate shall not exceed the thickness of the shell plate by more than 1/3rd but no more than 1/8th inch. The maximum repair plate thickness is 1/2inch. d) The repair plate shall not exceed the thickness of the shell plate by more than 1/4th but no more than 1/3rd inch. The maximum repair plate thickness is 1/2inch. Reference API-653, Paragraph 9.3.3.1

Charlie Chong/ Fion Zhang

Q19. Lapped patch repair plates may be used to repair small leaks or minimize the potential of leaks from isolated pitting. The requirements for thickness and design are the same as for reinforcement of shell thickness. This type of repair may not be used to repair small leaks if what condition(s) exists? a) The leak is located anywhere in the first shell course within 12 inches of a vertical joint b) The leak of pit is in an area of the shell where there is a product to atmosphere interface c) There is a possibility of severe environmental impact should the repair fail d) If exposure of the fillet weld to the product would produce crevice corrosion or if a corrosion cell is likely to occur between the shell plate and the repair plate Reference API-653, Paragraph 9.3.4.4

Charlie Chong/ Fion Zhang

Q20. An alteration to a tank shell by the addition of new plate material shall be performed in accordance with what standard? a) Current API 650 and latest addenda b) API 650 edition and addenda applicable at the time of original tank construction c) Applicable standard d) Tanks may not be altered by increasing height Reference API-653, Paragraph 9.5 9.5 Alteration of Tank Shells to Change Shell Height Tank shells may be altered by adding new plate material to increase the height of the tank shell. The modified shell height shall be in accordance with the requirements of the current applicable standard and shall take into consideration all anticipated loadings such as wind and seismic.

Q21. Repairs to existing shell penetrations shall be in accordance with a) API Standard 650 b) API Standard 653 c) API Standard 510 d) National Board Inspection Code Reference API-653, Paragraph 9.7.1

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Q22. API 653 permits the addition of reinforcing plates to existing unreinforced nozzles. What requirement is necessary to add this reinforcement to the inside of the tank? a) The reinforcement plate may not be added to the inside of the plate b) A telltale hole shall be drilled through the shell opposite the reinforcement plate c) The reinforcement plate is the same material as the nozzle and is attached to the nozzle by full penetration weld d) Sufficient nozzle projection exists Reference API-653, Paragraph 9.7.3 Q23. The addition or replacement of shell penetrations shall be in accordance with a) API-650 b) API-650 and API 653 c) API-650 and API 510 d) API-650 and AMSE Section VIII, Division 2 Reference API-653, Paragraph 9.8.1

Charlie Chong/ Fion Zhang

Q24. Installation or replacement of shell penetrations greater than 2 inches shall be installed with the use of an insert plate if what condition(s) exists? a) The penetration is no closer than 12 inches to an existing penetration b) The shell plate is greater than ½” thickness and the shell plate material does not meet current metal temperature criteria c) The penetration is no closer than 10 inches to an existing penetration d) The shell plate is greater than 3/16” thickness and the shell plate material does not meet current metal temperature criteria Reference API-653, Paragraph 9.8.2 API653: 9.8.6 Penetrations larger than 2 in. NPS shall be installed with the use of an insert plate if the shell plate thickness is greater than 1/2 in. and the shell plate material does not meet the current design metal temperature criteria. In addition, the following requirement shall be met: a) the minimum diameter of the insert plate shall be at least twice the diameter of the penetration or the diameter plus 12 in., whichever is greater; b) when reinforcing plates are used, the minimum diameter of the insert plate shall equal the diameter of the reinforcing plate plus 12 in. Charlie Chong/ Fion Zhang

Q24. Installation or replacement of shell penetrations greater than 2 inches shall be installed with the use of an insert plate if what condition(s) exists? a) The penetration is no closer than 12 inches to an existing penetration b) The shell plate is greater than ½” thickness and the shell plate material does not meet current metal temperature criteria c) The penetration is no closer than 10 inches to an existing penetration d) The shell plate is greater than 3/16” thickness and the shell plate material does not meet current metal temperature criteria Reference API-653, Paragraph 9.8.2 API653: 9.8.6 Penetrations larger than 2 in. NPS shall be installed with the use of an insert plate if the shell plate thickness is greater than 1/2 in. and the shell plate material does not meet the current design metal temperature criteria. In addition, the following requirement shall be met: a. the minimum diameter of the insert plate shall be at least twice the diameter of the penetration or the diameter plus 12 in., whichever is greater; b. when reinforcing plates are used, the minimum diameter of the insert plate shall equal the diameter of the reinforcing plate plus 12 in. Charlie Chong/ Fion Zhang

Q25. An 8 inch diameter penetration is to be installed in a shell which requires an insert plate. What is the minimum permitted diameter of the insert plate? a) Eight inches b) Twelve inches c) Sixteen inches d) Twenty inches Reference API-653, Paragraph 9.8.2(a) Q26. An insert plate containing an opening with a reinforcing plate is to be installed in a tank. The reinforcing plate diameter is thirty-two inches. What is the minimum diameter of the insert plate? a) The insert plate must be 32 inches in diameter b) The insert plate must be 44 inches in diameter c) The insert plate must be 32 inches in diameter plus the diameter of the opening d) The insert plate must be 32 inches in diameter plus twice the diameter of the opening Reference API-653, Paragraph 9.8.2(b) Charlie Chong/ Fion Zhang

Q27. If an integral reinforcement design is used, the thickness of the insert plate, at its periphery and for a distance of 2t from the edge of the weld, shall be the same thickness as the shell. If it is not, the insert plate shall have a ______ taper to match the shell plate thickness. a) 1:2 b) 1:3 c) 1:4 d) 1:5 Reference API-653, Paragraph 9.8.2(c) Q28. When it is necessary to install a new tank bottom above an existing bottom, it may be necessary to alter existing shell penetrations. This procedure may require the existing reinforcing plate to be removed and a new reinforcement plate added. This is not permitted when what condition exists? a) The assembly was originally hardness tested b) The existing assembly was not impact tested c) The existing assembly was fabricated from re-claimed material d) The existing assembly was stress relieved Reference API-653, Paragraph 9.9.2.2 Charlie Chong/ Fion Zhang

Q29. New reinforcing plates shall be installed in accordance with Fig. 7-2a of API-653. In order to maintain weld spacing, what shape reinforcing plate is permitted? a) Oval b) Diamond c) Tombstone d) Circular is the only permitted shape Reference API-653, Paragraph 9.9.2.2

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9.9.2.2 The existing reinforcing plate may be removed and a new reinforcing plate added except that reinforcing plate replacement is not permitted in existing stress relieved assemblies unless the requirements of 11.3 are met. If it is not known whether the assembly was thermally stressed relieved, then the alteration shall meet the requirements of API 650, Section 5.7.4. Care must be exercised when removing the existing reinforcing plate to avoid damaging the shell plate beneath the reinforcing plate. When the upper half of the existing reinforcing plate meets all requirements of API 650, it can be left in place with approval of the purchaser. In this case, only the lower half of the existing reinforcing plate need be removed and replaced with the new one. The existing upper half of the reinforcing plate and the new lower section shall be provided with new a telltale hole, if needed, or drilled hole, and a welded pipe coupling for the pneumatic test. The shell plate thickness under the telltale hole or drilled hole shall be checked after drilling and the thickness shall not be less than 1/2 tmin, as calculated in 4.3.3.1, plus any required corrosion allowance. The welds to be replaced around the perimeter of the reinforcing plate and between the reinforcing plate and neck of the penetration shall be completely removed by gouging and grinding. The new reinforcing plate shall be in accordance with Figure 9.7. If required to maintain weld spacing, a tombstone shaped reinforcing plate may be used (see Figure 9.8).

Charlie Chong/ Fion Zhang

Q30. No welding or weld overlays are permitted within the “Critical Zone” except for welding of widely scattered pits, cracks in the bottom plates, the shell-to-bottom weld, or where the bottom or annular plate is being replaced. a) True b) False Reference API-653, Paragraph 9.10.1.2.1

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9.10.1.2 Repairs within the Critical Zone The use of welded-on patch plates is permitted for repairing a portion of tank bottoms within the critical zone (see 3.10 for definition) provided 9.10.1.1 requirements and the following additional requirements are met. a) Maximum plate thickness for welded-on patch plates within the critical zone is 1/4-in. and must meet the toughness requirements of API 650, Section 4.2.10. b) When a welded-on patch plate is within 6 in. of the shell, the welded-on patch plate shall be tombstone shaped. The sides of the tombstone shaped welded- n patch plate shall intersect the shell-to-bottom joint at approximately 90°. c) Perimeter welds on welded-on patch plates within the critical zone shall be two-pass, minimum, and examined per 12.1.1.3 and 12.1.7.2. d) Installation of a welded-on patch plate by butt-welding to an adjacent existing patch is not permitted in the critical zone. e) Welded-on patch plates over existing patches are not allowed in the critical zone. f) The bottom plate under the perimeter of a welded-on patch plate shall meet the thickness requirements in 4.4. g) For tanks with shell plate of unknown toughness as defined in Section 3, new fillet welds utilized to install a tombstone patch plate in the critical zone shall be spaced at least the greater of 3 in. or 5t from existing vertical weld joints in the bottom shell course, where t is the thickness of the bottom shell course, in inches. See Figure 9.13 for further guidance on weld spacing. NOTE The bottom plate thickness at the attachment weld must be at least 0.1-in. thick before welding the welded-on patch plate to the bottom plate. Refer to API 2207 for further information.

Charlie Chong/ Fion Zhang

9.10.1.2.1 No welding or weld overlays are permitted within the critical zone except for the welding of: widely scattered pits (see 4.3.2.2), pinholes, cracks in the bottom plates, the shell-to-bottom weld, welded-on patch plates, or where the bottom plate welded to the shell is being replaced.

Charlie Chong/ Fion Zhang

Q31. API Standard 653 defines the “Critical Zone” for repairs to tank bottoms as what? a) That portion of the bottom or annular plate within 3" from the inside edge of the shell, measured radially inward b) Within the annular plate ring, within 12 inches of the shell, or within 12 inches of the inside edge of the annular plate ring c) That portion of the bottom or annular plate within 6" from the inside edge of the shell, measured radially inward d) Within the annular plate ring, within 3" of the shell, or within 12 inches of the inside edge of the annular plate ring Reference API-653, Paragraph 9.10.1.1

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Q32. If more extensive repairs are required within the “Critical Zone” than those listed in 7.10.1.2, what must be done with the bottom plate? a) As long as the repairs do not involve the bottom plate, nothing needs to be done b) The bottom plate welded to the shell shall be cut out and a new plate installed c) The bottom plate shall be subjected to suitable nondestructive examination to ensure it has not be adversely affected by the repair d) The bottom plate and the bottom shell course shall be replaced as an assembly Reference API-653, Paragraph 9.10.1.2.4 9.10.1.2.4 If more extensive repairs are required within the critical zone than those listed in 9.10.1.2, the bottom plate welded to the shell shall be cut out and a new plate shall be installed. Weld spacing requirements shall be in accordance with 9.10.2.4, and API 650, Section 5.1.5.4 and Section 5.1.5.5. The shell-to-bottom weld shall be removed and replaced for a minimum distance of 12 in. on each side of the new bottom plate. Charlie Chong/ Fion Zhang

Q33. When it is necessary to install a new bottom plate over an existing bottom plate, a suitable ______ material cushion such as sand, gravel or concrete shall be used between the old bottom and the new bottom. a) Drainage b) Compacted c) Non-corrosive d) Non-conductive Reference API-653, Paragraph 9.10.2.1.1

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Q34. When a new tank bottom has been installed in a floating roof tank, what consideration must given to the floating roof level? a) The floating roof will find its own level b) The support legs can be jacked up or shortened by the same amount as the thickness of the cushion and new bottom plate c) The support legs can be jacked up or shortened by the same amount as the thickness of the cushion d) The support legs can be jacked up or shortened by the same amount as the thickness of the new bottom plate Reference API-653, Paragraph 9.10.2.1.5

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Q35. Which of the following is not acceptable when removing an existing tank bottom, with regard to the separation of the shell from the tank bottom? a) Cutting the shell parallel to the tank bottom a minimum of ½” above the bottom to shell weld b) Removing the entire shell to bottom attachment weld including penetration and heat affect zone c) Removing the entire shell to bottom attachment weld by arc gouging and/or grinding d) Cutting the shell parallel to the tank bottom a minimum of ¼” above the bottom to shell weld Reference API-653, Paragraph 9.10.2.2(a) and (b) 9.10.2.3 When removing an existing tank bottom, the tank shell shall be separated from tank bottom either by: a) cutting the shell parallel to the tank bottom a minimum of 1/2 in. above the bottom-to-shell weld (cut line B-B as shown in Figure 10.1), or b) removing the entire shell-to-bottom attachment weld, including any penetration and heat affected zone by suitable methods such as arc gouging and/or grinding. All arc-gouged areas of the tank shell-to-bottom weld shall be magnetic particle examined, and defective areas repaired and re-examined.

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Figure 10.1—Tank Shell and Bottom Cut Locations

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Q36. For installation of a new tank bottom in a tank with shell plates of unknown toughness, not exempted in Table 10-1 of API-653, new welds in the bottom or annular ring shall be spaced at least the greater of _____ inches or ____t from existing vertical weld joints in the bottom shell course. (t is the thickness of the bottom shell course) a) three, five b) six, five c) five, three d) five, six Reference API-653, Paragraph 9.10.2.3 API653: 9.10.2.4 Installation of a new tank bottom, after removal of the existing tank bottom, shall meet all requirements of API 650. Except as permitted in 9.10.2.7, existing shell penetrations shall be raised or their penetration reinforcing plates modified if the elevation of the new bottom results in inadequate nozzle reinforcement (see Figure 9.8 and API 650, Section 5.7.2) or if the weld spacing requirements given in API 650, Section 5.7.3 are not met. For tanks with shell plate of unknown toughness as defined in Section 3, new weld joints in the bottom or annular ring shall be spaced at least the greater of 3 in. or 5t from existing vertical weld joints in the bottom shell course, where t is the thickness of the bottom shell course, in inches.

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Q37. What is the minimum thickness of new roof plates for supported cone roofs? a) 7/16” b) 5/16” c) 3/16” d) 1/16” Reference API-653, Paragraph 9.11.1.1

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9.11.2 Supported Cone Roofs 9.11.2.1 The minimum thickness of new roof plates shall be 3/16 in. (4.76mm) plus any corrosion allowance as specified in the repair specifications. In the event roof live loads in excess of 25 lbf/ft2 are specified (such as insulation, operating vacuum, high snow loads), the plate thickness shall be based on analysis using the allowable stresses in conformance with API 650, Section 5.10.3 (see 9.11.2.2).

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Q38. The nominal thickness of new roof plates for self-supporting roofs shall be equal to or greater than _____ inch not to exceed _____ inch. a) 1/4th, 5/8th b) 5/16th, 1/2 c) 3/16th, 5/16th d) 3/16th, 1/2 Reference API-653, Paragraph 9.11.2.1 and API-650 3.10.5 or 3.10.6 Q39. Repairs to internal floating roofs shall be made in accordance with the original construction drawings. To what requirements shall repairs be made if the original construction drawings are not available? a) The original construction standard b) Appendix H of API Standard 650 c) Appendix G of API Standard 650 d) Appendix C of API Standard 650 Reference API-653, Paragraph 9.12.2

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API653: 9.11.3 Self-supporting Roofs 9.11.3.1 The nominal thickness of new roof plate shall be 3/16 in. or the required plate thickness given in API 650, Section 5.10.5 or Section 5.10.6, plus any specified corrosion allowance, whichever is greater. 9.11.3.2 The details of the roof-to-shell junction shall meet the requirements of API 650, Section 5.10.5, Section 5.10.6, or Annex F of this standard, as applicable, for the intended service. 9.12 Repair of Floating Roofs 9.12.1 External Floating Roofs Any method of repair is acceptable that will restore the roof to a condition enabling it to perform as required. 9.12.2 Internal Floating Roofs Repairs to internal floating roofs shall be made in accordance with the original construction drawings, if available. If the original construction drawings are not available, the roof repairs shall be in compliance with the requirements of API 650, Annex H.

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Q40. To minimize evaporation losses and reduce potential hazard to workers, no more than ____ of the roof seal system should be out of an in-service tank at one time. a) One-eighth b) One-fourth c) One-half d) Three-quarters Reference API-653, Paragraph 9.13.1 Q41. Mechanical damage to floating roof perimeter seals shall be repaired or replaced. How are buckled parts handled? a) They shall be replaced b) They may be straightened in place c) They may be heated and bent back into position d) They may be removed straightened and re-installed Reference API-653, Paragraph 9.13.4

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9.13 Repair or Replacement of Floating Roof Perimeter Seals 9.13.1 Primary Seals Rim-mounted primary shoe seals and toroidal seal systems can be removed, repaired, or replaced. To minimize evaporation losses and reduce potential hazard to the workers, no more than one-fourth of the roof seal system should be out of an in-service tank at one time. Temporary spacers to keep the roof centered shall be used during the repairs. Primary seal systems mounted partly or fully below the bolting bar or top of the rim usually cannot be reached to allow removal in service. In this case, in-service repairs are limited to replacement of the primary seal fabric. 9.13.4 Mechanical Damage Damaged parts shall be repaired or replaced. Prior to taking this action, the cause of the damage shall be identified and corrected. Buckled parts shall be replaced, not straightened. Torn seal fabric shall be replaced.

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Q42. With regard to installation of primary and secondary seals, what must be done if the roof rim thickness is less than 0.10 inch. a) The roof rim shall be thoroughly inspected for damage and corrosion, if it is satisfactory then nothing further needs to be done b) It shall be replaced. The new roof rim shall be 3/16 inch thickness minimum c) It shall be replaced. The new roof rim shall be 1/4 inch thickness minimum d) The tank must be condemned and dismantled Reference API-653, Paragraph 9.13.6.2 Q43. What is the maximum hot tap connection permitted in an in-service tank with a minimum shell thickness of 3/8 inch? The material is of recognized toughness. a) NPS 6 b) NPS 8 c) NPS 14 d) NPS 18 Reference API-653, Paragraph 9.14.1.1(a) and Table 9-1

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API653: 9.13.6.2 If the roof rim thickness is less than 0.10-in. thick, it shall be replaced. The new roof rim shall be 3/16-in. thickness, minimum.

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Q44. The owner/operator requires a connection to be made in an in-service tank. The shell material is of unknown toughness and the thickness is 1.25”. The minimum design metal temperature is 45°F. What is the maximum diameter hot tap connection that may be installed in this tank? a) NPS 18 b) NPS 14 c) NPS 8 d) NPS 4 Reference API-653, Paragraph 9.14.1.1(b)(1) and Fig. 9-6 Q45. The minimum height of tank liquid relative to the hot tap location shall be at least ______ during the hot tapping operation. a) The tank liquid shall be at least 3 feet below the hot tap location b) The tank liquid shall be at least 1 foot above the hot tap location c) The tank liquid shall be at least 3 feet above the hot tap location d) The tank liquid shall be at least 1 foot below the hot tap location Reference API-653, Paragraph 9.14.1.2

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9.14 Hot Taps 9.14.1 General 9.14.1.1 The requirements given herein cover the installation of radial hot tap connections on existing in-service tanks. Hot taps are not permitted on shell material requiring thermal stress relief as specified in API 650, Section 5.7.4. a) For tank shell plates of recognized toughness, as defined in Section 3, the connection size and shell thickness limitations are shown in Table 9.1. b) For tank shell plates of unknown toughness, as defined in Section 3, the following limitations apply. 1) Nozzles shall be limited to a maximum diameter of 4 in. NPS. 2) The shell plate temperature shall be at or above the minimum shell design metal temperature for the entire hot tapping operation. 3) All nozzles shall be reinforced. The reinforcement shall be calculated per API 650, Section 5.7.2. The minimum thickness of the reinforcing plate shall be equal to the shell plate thickness, and the minimum reinforcing plate diameter shall not be less than the diameter of the shell cutout plus 2 in. 4) The maximum height of tank liquid above the hot tap location during the hot tapping operation shall be such that the hydrostatic tank shell stress is less than 7,000 lbf/in.2 at the elevation of the hot tap. 9.14.1.2 The minimum height of tank liquid above the hot tap location shall be at least 3 ft during the hot tapping operation.

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9.8 Addition or Replacement of Shell Penetrations ….. 9.8.6 Penetrations larger than 2 in. NPS shall be installed with the use of an insert plate if the shell plate thickness is greater than 1/2 in. and the shell plate material does not meet the current design metal temperature criteria. In addition, the following requirement shall be met: a) the minimum diameter of the insert plate shall be at least twice the diameter of the penetration or the diameter plus 12 in., whichever is greater; (Dinsert = 2D or D+12”) b) when reinforcing plates are used, the minimum diameter of the insert plate shall equal the diameter of the reinforcing plate plus 12 in. (Dinsert = Dreinforce + 12”)

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Q46. It is permissible to perform hot taps on the roof of a tank or within the gas/vapor space. a) True b) False Reference API-653, Paragraph 9.14.1.4 Q47. The owner/operator requires an NPS 3 ½ nozzle to be installed in an inservice tank. The tank is 110 feet in diameter, 60 feet maximum fill height, shell thickness at the point of hot tap is .75”, and the material is of unknown toughness with a minimum design metal temperature of 38°F. This nozzle is to be installed adjacent to an existing nozzle. What is the minimum spacing between these nozzles? a) Minimum distance is 22.24” b) Minimum distance is 9.08” (6.422) √(RT) c) Minimum distance is 19.08” d) Minimum distance is 2.24” Reference API-653, Paragraph 9.14.3.1

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Q47A. The owner/operator requires an NPS 3 ½ nozzle to be installed in an in-service tank. The tank is 110 feet in diameter, 60 feet maximum fill height, shell thickness at the point of hot tap is .75”, and the material is of unknown toughness with a minimum design metal temperature of 38°F. This nozzle is to be installed adjacent to an existing nozzle. What is the minimum spacing between these nozzles? Note: Data: Material is of unknown toughness with a minimum design metal temperature of 38°F. Comments: NPS 3 ½ nozzle: not allowed Height above tap point assumed 3’ Skin stress: t= 2.6(3x110)/SE, E= 1566psi (1.566Ksi): OK

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9.14.3 Preparatory Work 9.14.3.1 Minimum spacing in any direction (toe-to-toe of welds) between the hot tap and adjacent nozzles shall be equivalent to the square root of RT where R (D/2!) is the tank shell radius, in inches, and T is the shell plate thickness, in inches.

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Q48. When installing a pipe nozzle into an in-service tank, how shall the pipe nozzle be prepared? a) The pipe nozzle must be cut to the contour of the tank and prepared for full fillet welding b) The pipe nozzle shall be cut to the contour of the tank and beveled to a depth of not more than 1/3 the nozzle thickness to ensure partial penetration groove welding c) The pipe nozzle shall be cut to the contour of the tank and beveled to a depth of not less than 1/3 the nozzle thickness to ensure partial penetration groove welding d) The pipe nozzle shall be cut to the contour of the tank and beveled from the outside for a full penetration weld Reference API-653, Paragraph 9.14.5.1 49. After the reinforcing pad is installed, the pad shall be subjected to a pneumatic test. a) True b) False Reference API-653, Paragraph 9.14.5.3 Charlie Chong/ Fion Zhang

Q50. After the valve has been installed on the flange, a pressure test of at least ______ shall be performed on the nozzle prior to mounting the hot tap machine. a) The same pressure as the pneumatic test of the reinforcing pad b) 1.25 times the hydrostatic head c) 1.5 times the hydrostatic head d) 2.0 times the hydrostatic head (to account for the added stress of the machine) Reference API-653, Paragraph 9.14.5.3 API653: 9.14.5.3 After the reinforcing plate has been welded to the shell and NDE performed, the pad shall be pneumatically tested by the procedure described in API 650, Section 7.3.4. After the valve has been installed on the flange, a pressure test at least 1.5 times the hydrostatic head shall be performed on the nozzle prior to mounting the hot tap machine, which shall be bolted to the valve. The required pressure for the pressure test shall be at least the value computed by the following equation: P(psi) = 1.5H2Gγw

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Answers to API-653 Section 9, Repair/Alteration 1B

13 B

26 B

37 C

46 B

2A

14 D

27 C

38 D

47 A

3D

15 A

28 D

39 C

48 D

4C

16 B

29 C

40 B

49 A

5A

17 B

30 A

41 A

50 C

6C

18 C

31 A

42 B

7D

19 D

32 B

43 C

8B

20 C

33 C

44 D

9C

21 A

34 B

45 C

10 D

22 D

35 D

11 A

23 B

36 A

12 B

24 B 25 D

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Section 10 – Dismantling and Reconstruction Q1. Bottom plates that will be reused shall be cut by de-seaming of lap-welds or by cutting alongside of the remaining welds at a minimum of _______ away from existing welds. a) One inch b) Two inches c) Four inches d) Six inches Reference API-653, Paragraph 10.3.2.1 10.3.2 Bottoms 10.3.2.1 Bottom plates that will be reused shall be cut by deseaming of lapwelds; or by cutting alongside of the remaining welds at a minimum of 2 in. away from existing welds, except where cuts cross existing weld seams.

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Q2. Shell plates may be cut by any of the following methods except a) Shell rings ½” thick or thinner can be dismantled by cutting through the weld without removing the heat affected zone b) Cuts made a minimum of 6” away from existing welds except where cuts cross existing welds c) Cuts made a minimum of 2” away from existing welds except where cuts cross existing welds d) Any shell ring may be dismantled by cutting out existing weld seams and the heat affected zone of the weld Reference API-653, Paragraph 10.3.3.1 10.3.3 Shells 10.3.3.1 Tank shell plates may be dismantled using one of the following methods or a combination thereof. a) Any shell ring may be dismantled by cutting out existing weld seams and the heat affected zone (HAZ) of the weld. For the purpose of this method, the minimum HAZ to be removed will be ½ of the weld metal width or 1/4 in. (6.35mm) , whichever is less, on both sides of the weld seam.

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Q3. API-653 requires that new vertical joints in adjacent shell courses not be in alignment. What is the minimum offset dimension of these joints? a) Vertical joints shall be offset a minimum of 5 inches or 5t which ever is greater b) Vertical joints shall be offset a minimum of 5t where t is the plate thickness of the thicker course at the point of offset c) Vertical joints shall be offset a minimum of 5t where t is the plate thickness of the thinner course at the point of offset d) Vertical joints shall be offset a minimum of 5 inches or 5t which ever is less Reference: API-653, Paragraph 10.4.2.1 10.4.2 Welding 10.4.2.1 Provisions shall be made during the reconstruction of a tank to ensure that weld spacing requirements of Figure 9.1 are maintained. New vertical joints in adjacent shell courses, made in accordance with 10.3.3.1, shall not be aligned but shall be offset from each other a minimum distance of 5t, where t is the plate thickness of the thicker course at the point of the offset.

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Q4. Roof plates shall be cut by de-seaming of lap-welds or by cutting alongside of the remaining welds at a minimum of _______ away from existing welds. a) One inch b) Two inches c) Four inches d) Six inches Reference API-653, Paragraph 10.3.4.1 Q5. In the reconstruction of aboveground storage tanks, welding shall be by any of the following welding processes except. a) Submerged arc welding b) Oxyfuel c) Gas metal-arc d) Forging Reference API-653, Paragraph 10.4.2.2 and API-650 5.2.1

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Q6. No welding of any kind may be performed when the surfaces to be welded are wet from rain, snow, or ice. When rain or snow is falling or during high wind conditions, welding is permitted provided: a) The welder is secured to an anti-fall device and the work is properly grounded b) The welder has agreed to work in such conditions c) The welder and the work are properly shielded d) The owner/operator takes full responsibility for the safety of the welder and the quality of the welds Reference API-653, Paragraph 10.4.2.3 Q7. According to API-653, no welding is permitted when the temperature of the base metal is below what value? a) Base metal temperature below -20°F b) Base metal temperature below 0°F c) Base metal temperature below 20°F d) Base metal temperature below 30°F Reference API-653, Paragraph 10.4.2.3

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10.4.2.3 No welding of any kind shall be performed when the surfaces of the parts to be welded are wet from rain, snow, or ice; when rain or snow is falling on such surfaces; or during periods of high winds unless the welder and the work are properly shielded. No welding of any kind shall be performed when the temperature of the base metal is less than 0°F. When the temperature of the base metal is between 0°F and 32°F or the thickness is in excess of 1 in., the base metal within 3 in. of the place where welding is to be started shall be heated to a temperature warm to the hand (approximately 140°F) before welding. (See 10.4.4.3 for preheat requirements for shell plates over 1 1/2-in. thick.)

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Q8. If the base metal is greater than 1” thickness or the temperature of the base metal is between 0°F and 32°F what requirement does API-653 stipulate? a) The base metal within 3 inches of the weld area shall be heated to a temperature that is warm to the hand (approximately 180°F) b) The base metal within 8 inches of the weld area shall be heated to a temperature that is warm to the hand (approximately 140°F) c) The base metal within 3 inches of the weld area shall be heated to a temperature that is warm to the hand (approximately 140°F) d) The base metal within 8 inches of the weld area shall be heated to a temperature that is warm to the hand (approximately 180°F) Reference API-653, Paragraph 10.4.2.3

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Q9. What is the maximum permissible undercut of the base metal for vertical joints? a) 1/64 b) 1/32 c) 1/19 d) 1/16 Reference API-653, Paragraph 10.4.2.5 Q10. What is the maximum permissible undercut of the base metal for horizontal joints? a) 1/64 b) 1/32 c) 1/19 d) 1/16 Reference API-653, Paragraph 10.4.2.5

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API650: 8.5.2 A weld shall be acceptable by visual examination if the inspection shows the following. a) There are no crater cracks, other surface cracks or arc strikes in or adjacent to the welded joints. b) Maximum permissible undercut is 0.4 mm (1/64 in.) in depth for vertical butt joints, vertically oriented permanent attachments, attachment welds for nozzles, manholes, flush-type openings, and the inside shell-to-bottom welds. For horizontal butt joints, horizontally oriented permanent attachments, and annular-ring butt joints, the maximum permissible undercut is 0.8 mm (1/32 in.) in depth.

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Q11. What is the maximum weld reinforcement thickness permitted on each side of the plate for a plate, which is 7/8” thick? Vertical joints Horizontal joints a) 3/32” 1/8” b) 1/8” 3/16” c) 3/16” 1/4 d) 1/4 5/16” Reference API-653, Paragraph 10.4.2.6 & Table 10-1 Q12. Tack welds used in the assembly of vertical joints in tank shells may remain in place when the joints are welded manually provided: a) They are properly cleaned of all weld slag b) They are sound c) Liquid Penetrant or Magnetic Particle examination is performed d) They shall not remain Reference API-653, Paragraph 10.4.2.7

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Q13. What are the requirements for making tack welds according API-653? a) If the tack weld is to be removed, it must be made using qualified weld procedure and qualified welder b) If the tack weld is to remain in place, it must be made using qualified weld procedure and qualified welder c) If the tack weld is to remain in place, it may be made using any weld procedure acceptable to the owner/operator d) If the tack weld is to be removed, it may be made by any welder wishing to gain experience provided the process is the SMAW process Reference API-653, Paragraph 10.4.2.7

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Q14. All coatings must be removed from the weld area prior to welding except weldable primer coatings. What must done if these primer coatings are used? a) Weldable primer coatings must also be removed b) If the coating is applied by brush it may remain provided the application is performed to a written procedure c) They shall be included in welding procedure qualification tests for brand, formulation, and maximum thickness of primer applied d) They shall be included in welding procedure qualification tests for the method of application either by brushing or by spraying or a combination of the two. Reference API-653, Paragraph 10.4.2.8

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Q15. When welding tank bottoms, when should the shell-to-bottom weld be completed? a) This joint (except for door sheets) can be welded as soon as the bottom plates are laid out and welded b) This joint (except for door sheets) shall be welded as soon as the first bottom weld joint is completed to prevent distortion c) This joint (except for door sheets) shall be welded as work progresses around the tank bottom d) This joint (except for door sheets) shall be completed before the welding of bottom joints Reference API-653, Paragraph 10.4.3.2

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10.4.3 Bottoms 10.4.3.1 After the bottom plates are laid out and tacked, they shall be joined by welding the joints in a sequence that results in the least distortion from shrinkage and provides, as nearly as possible, a plane surface.

10.4.3.2 The welding of the shell to the bottom (except for door sheets) shall be completed prior to the welding of bottom joints. 10.4.3.3 Plates shall be held in close contact at all lap joints during welding.

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Q16. What is the maximum permissible misalignment of vertical joints in shell plates that are .9375” thick? a) .125” b) .09375” c) .009375” d) .0125” Reference API-653, Paragraph 10.4.4.1 10.4.4 Shells 10.4.4.1 Plates to be joined by butt welding shall be matched accurately and retained in position during welding. Misalignment in completed vertical joints over 5/8-in. thick shall not exceed 10 % of the plate thickness, with a maximum of 1/8 in. (0.125”) Misalignment in joints 5/8-in. thick or less shall not exceed 1/16 in. Vertical joints shall be completed before the lower horizontal weld is made.

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Q17. What is the maximum permissible misalignment of vertical joints in shell plates that are .625” thick? a) .0625” b) .00625” c) .125” d) .0125” Reference API-653, Paragraph 10.4.4.1 Q18. Vertical joints shall be completed before the lower horizontal weld is made. a) True b) False Reference API-653, Paragraph 10.4.4.1

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Q19. In completing horizontal joints, what is the maximum projection of the upper plate, beyond the face of the lower plate, at any point for plate thickness of 1.125” a) .25” b) .225” c) .125” d) .0125” Reference API-653, Paragraph 10.4.4.2 10.4.4.1 Plates to be joined by butt welding shall be matched accurately and retained in position during welding. ■ Misalignment in completed vertical joints (>) over 5/8-in. thick shall not exceed 10 % of the plate thickness, with a maximum of 1/8 in. ■ Misalignment in joints (≤) 5/8-in. thick or less shall not exceed 1/16 in. ■ Vertical joints shall be completed before the lower horizontal weld is made.

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Q20. When welding horizontal and vertical joints constructed of material that is over 1.5” thick, based on the thickness of the thicker part, what is the required preheat temperature? a) Preheating is not required b) 140°F c) 200°F d) 300°F Reference API-653, Paragraph 10.4.4.3

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Preheating  10.4.2.3 1) No welding of any kind shall be performed when the temperature of the base metal is less than 0°F. 2) When the temperature of the base metal is between 0°F and 32°F the base metal within 3 in. of the place where welding is to be started shall be heated to a temperature warm to the hand (approximately 140°F) before welding. 3) When the temperature of the base metal is between 0 °F and 32 °F or the thickness is in excess of 1 in., the base metal within 3 in. of the place where welding is to be started shall be heated to a temperature warm to the hand (approximately 140°F) before welding. or the

thickness is in excess of 1 in.,

 10.4.4.3 4) For horizontal and vertical joints in tank shell courses constructed of material over 1½ in. thick (based on the thickness of the thicker plate at the joint), multi-pass weld procedures are required, with no pass more than 3/4-in. thick permitted. A minimum preheat of 200°F is required of these welds. Charlie Chong/ Fion Zhang

Preheat  



0°F 0°F - 32°F ”: 140°F >1”: 140°F >1½”: 200°F

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Stewed Lamb at 200°F

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Grilled Lamb at 200°F

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Grilled Lamb at 200°F

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Afghanistan Grilled Chicken Rice

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Afghanistan Stewed Lamb c/w Rice

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Q21. When shall measurements be taken to verify tolerances of reconstructed tanks? a) After hydrostatic testing b) Before hydrostatic testing c) After lay out of all plates d) After fit-up and tack welding used for alignment purposes Reference API-653, Paragraph 10.5.1.2 Q22. What is the maximum out-of-plumbness of the top of the shell relative to the bottom of the shell of a tank with a total height of 62.25 feet? a) 7.47” b) .6225” c) 6.25” d) 5” Reference API-653, Paragraph 10.5.2.1 10.5.2 Plumbness 10.5.2.1 The maximum out-of-plumbness of the top of the shell relative to the bottom of the shell shall not exceed 1/100 of the total tank height, with a maximum of 5 in. The 1/100 criteria, with a maximum of 5 in., shall also apply to fixed roof columns. For tanks with internal floating roofs, apply the criteria of this section or API 650, Section 7.5.2 and Annex H, Section H.4.1.1, whichever is more stringent. Charlie Chong/ Fion Zhang

Q23. An aboveground storage tank is 115 feet in diameter. What is the maximum or minimum radius permitted measured at one foot above the shellto-bottom weld? Maximum/ Minimum a) 115.75” 114.25” b) 690.75” 689.25” (Radius!) c) 1380.75” 1379.25” d) 115.5” 114.5” Reference API-653, Paragraph 10.5.3 Q24. An aboveground reconstructed tank is 126.5 feet in diameter. What is the maximum or minimum radius permitted measured at the second shell course up from the bottom? Maximum/ Minimum a) 759.75” 758.25 b) 761.25” 756.75” (Radius!) c) 1520.25” 1515.75” d) 128.75” 124.25” Reference API-653, Paragraph 10.5.3

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10.5.3 Roundness Radii measured at 1 ft above the shell-to-bottom weld shall not exceed the tolerances shown in Table 10.2. Radius tolerances measured higher than one foot above the shell-to-bottom weld shall not exceed three times the tolerances given in Table 10.2.

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Q25. Peaking shall not exceed ½”. This is measured using a horizontal sweep board of what dimensions? a) The sweep board shall be 48” long and made to the true outside radius of the tank b) The sweep board shall be 48” long and made to the true inside radius of the tank c) The sweep board shall be 36” long and made to the true outside radius of the tank d) The sweep board shall be 36” long and made to the true inside radius of the tank Reference API-653, Paragraph 10.5.4 Q26. Banding shall not exceed ____ with a vertical 36” long sweep board. a) One half inch b) Three quarter inch c) One inch d) One and one eighth inch Reference API-653, Paragraph 10.5.5

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Q27. The top of the concrete ring wall of a reconstructed tank, that is 115 feet in diameter, must be level within ± 1/8” in any 30 feet of circumference. What is the tolerance measured from the average elevation? a) ±1/8” b) ±3/16” c) ±1/2” d) ±1/4” Reference API-653, Paragraph 10.5.6.2(a) 10.5.6.2 Where foundations true to a horizontal plane are specified, tolerances shall be as follows: a) where concrete ringwalls are provided under the shell, the top of the ringwall shall be level within ±1/8 inches in any 30 ft of the circumference and within ±1/4 inches in the total circumference measured from the average elevation; b) where concrete ringwalls are not provided, the foundation under the shell shall be level within ±1/8 in. in any 10 ft of circumference and within ±1/2 in. in the total circumference measured from the average elevation.

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Q28. Where concrete ring walls are not provided, the foundation under the shell shall be level to within what tolerances? a) ±1/8” in any 30’ of the circumference and ±1/2” in the total circumference measured from the average elevation b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference measured from the average elevation c) ±1/8” in any 10’ of the circumference and ±1/4” in the total circumference measured from the average elevation d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference measured from the average elevation Reference API-653, Paragraph 10.5.6.2(b)

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Q29. For foundations specified to be sloped from a horizontal plane, the actual elevation shall not deviate from the calculated differences by more than which of the following where concrete ring walls are provided? a) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference measured from the average elevation b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference c) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference measured from the average elevation d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference Reference API-653, Paragraph 10.5.6.3(a)

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10.5.6.3 For foundations specified to be sloped from a horizontal plan, elevation differences about the circumference shall be calculated from the specified high point. Actual elevation differences about the circumference shall be determined from the actual elevation of the specified high point. The actual elevation differences shall not deviate from the calculated differences by more than the following tolerances: a) where concrete ringwalls are provided ±1/8 inches in any 30 ft of circumference and ±1/4 inches in the total circumference; b) where concrete ringwalls are not provided, ±1/8 inches in any 10 ft of circumference and ±1/2 inches in the total circumference.

Charlie Chong/ Fion Zhang

Q30. For foundations specified to be sloped from a horizontal plane, the actual elevation shall not deviate from the calculated differences by more than which of the following where concrete ring walls are not provided? a) ±1/8” in any 30’ of the circumference and ±1/2” in the total circumference measured from the average elevation b) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference c) ±1/8” in any 10’ of the circumference and ±1/2” in the total circumference measured from the average elevation d) ±1/8” in any 30’ of the circumference and ±1/4” in the total circumference Reference API-653, Paragraph 10.5.6.3(b)

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Answers to API-653 Section 10, Dismantling & Reconstruction 1b

11 b

21 b

2c

12 d

22 d

3b

13 b

23 b

4b

14 c

24 b

5d

15 d

25 c

6c

16 b

26 c

7b

17 a

27 d

8c

18 a

28 b

9a

19 c

29 d

10 b

20 c

30 b

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Section 11 – Welding Q1. Welding procedure specifications and welders and welding operators shall be qualified in accordance with __________. a) Original code of construction b) Owner/operator’s specification c) Section IX of the ASME Code d) Repair organization’s specifications Reference API-653, Paragraph 11.1.1 Q2. According to API Standard 653, if the material specification for the steel from an existing tank is unknown or obsolete what must be done? a) The material can not be used for tank reconstruction b) Test coupons for the WPS shall be taken from the actual plate to be used c) Test coupons for the WPS may be taken from a similar material of known specification d) Test coupons for the WPS shall only be taken from weld filler metal and not from the base metal Reference API-653, Paragraph 11.1.2

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11.1 Welding Qualifications 11.1.1 Welding procedure specifications (WPSs) and welders and welding operators shall be qualified in accordance with Section IX of the ASME Code, the additional requirements of API 650, Section 9, and this standard. Welding procedures for ladder and platform assemblies, handrails, stairways, and other miscellaneous assemblies, but not their attachments to the tank, shall comply with either AWS D1.1, AWS D1.6, or Section IX of the ASME Code, including the use of SWPSs. 11.1.2 Weldability of steel from existing tanks shall be verified. If the material specification for the steel from an existing tank is unknown or obsolete, test coupons for the welding procedure qualification shall be taken from the actual plate to be used.

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Q3. Each welder and welding operator shall be assigned ________. a) Only one joint to ensure traceability b) A specific welding machine c) An identifying number, letter, or symbol d) Weld joints on only one side of the tank Reference API-653, Paragraph 11.2.1 Q4. How does each welder and welding operator identify the welds produced by them? a) Each welder and welding operator’s identification mark shall be hand or machine stamped adjacent to each completed weld. b) Each welder and welding operator shall inform the owner/operator which welds he or she completed c) Each welder and welding operator shall show the inspector exactly which welds they completed d) Each welder and welding operator shall inform the owner/operator which welds they will be making prior to the start of such welding Reference API-653, Paragraph 11.2.2

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Q5. At what intervals must the welder and welding operator’s identification be stamped adjacent to the completed welds? a) Identification shall be at intervals not to exceed 9 feet b) Identification shall be at intervals not to exceed 7.5 feet c) Identification shall be at intervals not to exceed 6 feet d) Identification shall be at intervals not to exceed 3 feet Reference API-653, Paragraph 11.2.2 Q6. In lieu of stamping, a record may be kept that identifies the welder or welding operator for each welded joint. a) True b) False Reference API-653, Paragraph 11.2.2

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Q7. What welds do not require welder’s identification? a) All welds require identification b) Vertical welded joints which are located within the final shell course since this course will be subjected to relatively low stresses c) Roof plate welds and flange-to-nozzle-neck welds d) Roof plate welds and bottom plate welds Reference API-653, Paragraph 11.2.2

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Answers to API-653 Section 11, Welding Question Number Answer 1C 2B 3C 4A 5D 6A 7C

Charlie Chong/ Fion Zhang

Section 12 – Examination and Testing Q1. Nondestructive examination procedures, qualifications, and acceptance criteria is required for VT, MT, UT, PT, and RT methods and must be in accordance with what Code or Standard? a) ASME Code Section V, Nondestructive examination b) API Standard 650 only c) API Standard 650 and the supplements given in API-653 d) Owner/operator’s specifications Reference: API-653, Paragraph 12.1.1.1

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Q2. Personnel performing nondestructive examination shall be qualified in accordance with _____. a) API Standard 650 and the supplemental requirements of API-653 b) ASME Code Section V, Nondestructive Examination c) SNT-TC-1A d) The owner/operator’s specifications Reference: API-653, Paragraph 12.1.1.2 Q3. When it is necessary to install a hot tap connection or add a reinforcing plate to an existing unreinforced penetration, API 653 requires what type, extent, and purpose of examination. a) Magnetic particle examination for slight sub-surface discontinuities shall be performed in an area equal to twice the diameter of the opening b) Radiographic examination for cracking shall be performed in the immediate area c) Ultrasonic examination for cracking shall be performed in the immediate area d) Ultrasonic examination for lamination shall be performed in the immediate area Reference: API-653, Paragraph 12.1.2.1 Charlie Chong/ Fion Zhang

Q4. Completed welds attaching nozzle neck to shell, and reinforcing plate to shell and nozzle neck, shall be examined by _______. a) Ultrasonic or Radiography b) Magnetic Particle or Liquid Penetrant c) Visual examination or Liquid Penetrant d) Ultrasonic or Magnetic Particle Reference: API-653, Paragraph 12.1.2.3 API653: 12.1.1.2 Personnel performing NDE shall be qualified in accordance with API 650, Section 8, and any supplemental requirements given herein.

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Q5. How and when does API Standard 653 require the examination of welds of completed stress relieved assemblies? a) Completed welds of stress relieved assemblies shall be examined visually only after stress relief and hydrostatic test b) Completed welds of stress relieved assemblies shall be examined visually as well as by ultrasonic methods after stress relief but before hydrostatic test c) Completed welds of stress relieved assemblies shall be examined visually as well as by magnetic particle or liquid penetrant methods after stress relief but before hydrostatic test d) Completed welds of stress relieved assemblies shall be examined visually or by radiography after stress relief but before hydrostatic test Reference: API-653, Paragraph 12.1.2.4 Keywords:  VI  UT  RT  MT/DP Charlie Chong/ Fion Zhang

Q6. Completed butt welds between insert plates and the shell require what type and extent of examination? a) Complete radiography b) Spot Radiography c) Random Radiography d) Random Spot Radiography Reference: API-653, Paragraph 12.1.2.5 Q7. In repairing butt weld flaws, what type and extent of examination is required by API-653? a) Random examination by radiography or ultrasonic methods of the full length of repair b) Examined full length of the repair by liquid penetrant or magnetic particle methods c) Examined at three foot intervals by radiography or ultrasonic methods d) Examined full length of the repair by radiography or ultrasonic methods Reference: API-653, Paragraph 12.1.3.2

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Q8. Completed repairs of fillet welds shall be examined over their full length by the appropriate nondestructive method listed in API-653. a) True b) False Reference: API-653, Paragraph 12.1.3.3 Q9. With regards to new welds attaching shell plate to shell plate, what method(s) of examination is/are required on the completed weld? a) Visual b) Visual and Radiography c) Visual and magnetic particle or liquid penetrant d) Visual and ultrasonic Reference: API-653, Paragraph 12.1.5

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Q10. With regards to new welds attaching shell plate to shell plate for plate thickness greater than one inch, what additional extent and method of examination is required by API-653? a) The back gouged surface of the root and final pass (each side) shall be examined for its complete length by the Inspector b) The back gouged surface of the root and final pass (each side) shall be examined for its complete length visually c) The back gouged surface of the root and final pass (each side) shall be examined for its complete length by magnetic particle or liquid penetrant d) The back gouged surface of the root and final pass (each side) shall be examined for its complete length by ultrasonic Reference: API-653, Paragraph 12.1.5

Charlie Chong/ Fion Zhang

Q11. New welding on the shell-to-bottom joint shall be inspected for its entire length by _____ and _______ or ________. a) Visual examination, liquid penetrant , magnetic particle b) Right-angle vacuum box and solution film, light diesel oil c) Visual examination, ultrasonic, eddy current d) Visual examination, wet fluorescent magnetic particle, helium tracer gas Reference: API-653, Paragraph 12.1.6.1 12.1.6 Shell-to-bottom Weld 12.1.6.1 New welding on the shell-to-bottom joint shall be examined for its entire length by using a right-angle vacuum box and a solution film, or by applying light diesel oil. Additionally, the first weld pass shall be examined by applying light diesel oil to the side opposite the first weld pass made. The oil shall be allowed to stand at least 4 hours (preferably overnight) and then the weld examined for wicking action. The oil shall be removed before the weld is completed.

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Q12. In applying light diesel oil to the opposite side of the first pass of new shell-to-bottom joints, how long must the oil remain on the weld and what is the weld inspected for? a) The oil shall be allowed to stand at least four hours and the weld inspected for wicking action b) The oil shall be allowed to stand at least three hours and the weld inspected for wicking action c) The oil shall be allowed to stand at least two hours and the weld inspected for wicking action d) The oil shall be allowed to stand at least one hour and the weld inspected for wicking action Reference: API-653, Paragraph 12.1.6.2

Charlie Chong/ Fion Zhang

Q13. The existing weld at the shell-to-bottom joint shall be examined visually and magnetic particle or liquid penetrant methods, for the full length under a welded-on patch plate. How much additional shell-to-bottom joint must be examined? a) Three inches on each side of the patch plate b) Six inches on each side of the patch plate c) nine inches on each side of the patch plate d) twelve inches on each side of the patch plate Reference: API-653, Paragraph 12.1.6.2

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12.1.6.3 The existing weld at the shell-to-bottom joint shall be examined by visual, as well as by magnetic particle or liquid penetrant methods, for the full length under a welded-on patch plate. An additional 6 in. of the shell-tobottom joint on each side of the welded-on patch plate shall be examined similarly before placement of the repair plate to assure weld integrity and to confirm the absence of weld cracks.

Charlie Chong/ Fion Zhang

Q14. How and to what extent are newly welded bottom joints tested? a) Newly welded bottom joints shall be tested their entire length using liquid penetrant b) Newly welded bottom joints shall be tested their entire length using a vacuum box and a solution film, or a tracer gas and detector c) Newly welded bottom joints shall be tested their entire length using visual and ultrasonic examination d) Newly welded bottom joints shall be tested their entire length using wet fluorescent magnetic particle examination Reference: API-653, Paragraph 12.1.7.1 Q15. What are the requirements, regarding examination, of a welded-on patch plate in the critical zone? a) The final weld shall be examined by radiography over its entire length b) Root and final pass shall be examined by radiography over its entire length c) The root and final pass shall be examined visually over its entire length d) The root and final pass shall be examined visually and by magnetic particle of liquid penetrant method over its entire length Reference: API-653, Paragraph 12.1.7.3 Charlie Chong/ Fion Zhang

Q16. API-653 requires the number and location of radiographs to in accordance with API-650. In addition, API-653 requires how many and what location for new or repaired shell vertical joints? a) For new or repaired shell vertical joints one radiograph shall be taken in each fifty foot length b) For new or repaired shell vertical joints one radiograph shall be taken in each twenty-five foot length c) For new or repaired shell vertical joints one radiograph shall be taken in every joint d) For new or repaired shell vertical joints one radiograph shall be taken in every other joint Reference: API-653, Paragraph 12.2.1.1

Charlie Chong/ Fion Zhang

Q17. API-653 requires the number and location of radiographs to in accordance with API-650. In addition, API-653 requires how many and what location for new or repaired shell horizontal joints? a) For new or repaired shell horizontal joints one radiograph shall be taken in each twenty five feet of horizontal joint including those required at intersections of vertical and horizontal joints b) For new or repaired shell horizontal joints one radiograph shall be taken in each twenty five feet of horizontal joint not including those required at intersections of vertical and horizontal joints c) For new or repaired shell horizontal joints one radiograph shall be taken in each fifty feet of horizontal joint including those required at intersections of vertical and horizontal joints d) For new or repaired shell horizontal joints one radiograph shall be taken in each fifty feet of horizontal joint not including those required at intersections of vertical and horizontal joints Reference: API-653, Paragraph 12.2.1.2

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12.2.1.2 For horizontal joints: a) new replacement shell plates to new shell plates, no additional radiographs required, other than those required by API 650, Section 8.1.2.3 and Figure 8-11 for new construction; b) new replacement shell plates to existing shell plates, one additional radiograph for each 50 ft of repaired horizontal weld; c) repaired joints in existing shell plates shall have one additional radiograph taken for each 50 ft of repaired horizontal weld.

Charlie Chong/ Fion Zhang

Q18. API-653 requires two radiographs to be taken at each new or replacement intersection between vertical and horizontal joints. One to comply with the requirement for vertical joints and one to comply with the requirements for horizontal joints. a) True b) False Reference: API-653, Paragraph 12.2.1.3 Q19. For reconstructed tanks, each butt-welded annular plate joint shall be radiographed in accordance with which of the following? a) API-650 b) ASME - Section V c) API-653 and API-575 d) Owner/operator's specifications Reference: API-653, Paragraph 12.2.1.4

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Q20. For reconstructed tanks, radiographic examination is required for what percentage of all junctions of new welds over existing seams? a) 100% b) 75% c) 50% d) 25% Reference: API-653, Paragraph 12.2.1.5 12.2.1.5 For reconstructed tanks, radiographic examination is required for 25 % of all junctions of new welds over existing seams. The owner/operator shall, with the consent of the contractor, determine the extent of further examination and repair that may be required. Any further examination or repair of existing welds will be handled by contractual agreement between the owner/ operator and tank reconstruction contractor.

Charlie Chong/ Fion Zhang

Q21. Radiographic examination is required for new and replaced shell insert plate and door shell welds. What are the minimum number and location of such radiographs? a) Circular plates - four radiographs are required, one at each quadrant b) Square or rectangular - two radiographs are required in each vertical joint and one in a horizontal joint c) Circular plates - one radiograph and for square or rectangular - one in a vertical joint, one in a horizontal joint, and one in each corner d) Circular and square of rectangular new or replaced insert plates require 100% examination Reference: API-653, Paragraph 12.2.1.6 12.2.1.6.1 For circular replacement plates, a minimum of one radiograph shall be taken regardless of thickness. When the circular replacement plate is located in a shell plate with thickness exceeding 1 in., the weld shall be fully radiographed. 12.2.1.6.2 For square and rectangular replacement plates, at least one radiograph shall be taken in a vertical joint, and at least one in a horizontal joint, and one in each corner. When the square or rectangular replacement plate is located in a shell plate with thickness exceeding 1 in., the vertical joints shall be fully radiographed.

Charlie Chong/ Fion Zhang

Q22. What is the minimum diagnostic length of each radiograph? a) The minimum diagnostic length of each radiograph shall be six inches b) The minimum diagnostic length of each radiograph shall be three inches c) The minimum diagnostic length of each radiograph shall be nine inches d) The minimum diagnostic length of each radiograph shall be twelve inches Reference: API-653, Paragraph 12.2.1.7 Q23. If the radiograph of an intersection between a new and old weld discloses discontinuities, which are unacceptable by current standards, what must be done? a) The unacceptable welds must be removed and made in accordance with current standards b) The unacceptable welds shall be repaired to bring them in to compliance c) The existing welds may be evaluated according to the original standard of construction d) The existing welds shall be evaluated using the acceptance criteria of ASME Section VIII Reference: API-653, Paragraph 12.2.2 Charlie Chong/ Fion Zhang

Q24. Radiographs and radiograph records of all repaired welds shall be marked with what letter(s)? a) "RW" (Repaired Weld) b) "WR" (Weld Repair) c) "A" (Accepted repair) d) "R" Reference: API-653, Paragraph 12.2.3.2 Q25. Hydrostatic testing is required for reconstructed tanks and tanks that have undergone major repairs or alterations. What is the minimum length of time the hydrostatic test must be held? a) The time is up to the discretion of the Inspector b) Twenty-four hours c) The time is up to the discretion of the owner/operator d) Twelve hours Reference: API-653, Paragraph 12.3.1.1

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Q26. Major repair and major alteration is defined by API-653 by which of the following? a) Cutting, addition, removal and/or replacement of the annular plate ring only if the plate is less than 1/2" thick b) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom weld, or a sizeable portion of the shell (?) c) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom weld, or a 100 square inch portion of the shell d) Cutting, addition, removal an/or replacement of the annular plate ring, the shell-to-bottom weld, or a sizeable portion of the shell in shell material greater than 3/4" thick Reference: API-653, Paragraph 12.3.1.2

Charlie Chong/ Fion Zhang

Q27. Of the following, which would not be considered a major repair or alteration? a) The installation of a shell penetration NPS 12 above the design liquid level b) The installation of a shell penetration NPS 12 below the design liquid level c) Jacking of a tank shell d) The complete of partial removal and replacement of more than 12 inches of vertical weld joining shell plates, or radial weld joining the annular plate ring Reference: API-653, Paragraph 12.3.1.2 Q28. A full hydrostatic test of the tank is not required for major repairs and alterations when certain conditions are met. Where would you look for these conditions? a) API-650 Paragraph 5.3.6 b) API-RP-575 Paragraph 7.5 c) API-510 Paragraph 6.4 d) API-653 Paragraph 12.3.2 Reference: API-653, Paragraph 12.3.2.1 Charlie Chong/ Fion Zhang

Q29. Hydrostatic testing is not required for shell repairs when all but which of the following are complied with? a) Impact test requirements shall follow appropriate portions of API-650 and must be specified in the repair procedure b) New vertical and horizontal shell butt-welds must have complete penetration and fusion c) New materials shall meet the current edition of ASME Section II Part A d) Finished weld must be examined by radiography Reference: API-653, Paragraph 12.3.22

Charlie Chong/ Fion Zhang

Q30. If the owner/operator elects to utilize a fitness-for-service evaluation to exempt a repair form hydrostatic testing, who perform the evaluation? a) Fitness-for-service evaluations may not be used to exempt hydrostatic testing following a repair b) The Authorized Inspector c) Engineer experienced in storage tank design and the evaluation methods used d) Exemption of hydrostatic testing for repairs can only be given by the jurisdiction Reference: API-653, Paragraph 12.3.2.6

Charlie Chong/ Fion Zhang

Q31. When settlement is anticipated, a tank that is to be hydrostatically tested shall: a) Have the plumbness checked b) Have the water tested to ensure it is potable c) Have the perimeter dike system checked d) Have the foundation checked for settlement Reference: API-653, Paragraph 12.5.1.1 Q32. The tank settlement shall initially be surveyed with the tank empty. What is the minimum number of settlement measurement points for a tank which is 110 feet in diameter? a) Minimum number of settlement points is 11 b) Minimum number of settlement points is 32 c) Minimum number of settlement points is 8 d) Minimum number of settlement points is 12 Reference: API-653, Paragraph 12.5.1.2

Charlie Chong/ Fion Zhang

N is the minimum required number of settlement measurement points, but no less than eight. All values of N shall be rounded to the next higher even whole number. The maximum spacing between settlement measurement points shall be 32 ft.

Charlie Chong/ Fion Zhang

Q33. The tank settlement shall initially be surveyed with the tank empty. What is the minimum number of settlement measurement points for a tank which is 60 feet in diameter? a) Minimum number of settlement points is 12 b) Minimum number of settlement points is 6 c) Minimum number of settlement points is 8 d) Minimum number of settlement points is 4 Reference: API-653, Paragraph 12.5.1.2 Q34. Regardless of the minimum number of settlement measurement points required, what is the maximum spacing between settlement measurement points? a) 24 feet b) 32 feet c) 36 feet d) 40 feet Reference: API-653, Paragraph 12.5.1.2

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Q35. When shall settlement be measured? a) Settlement shall be measured after the water reaches 100% of test level and again when the tank is emptied b) Settlement shall be measured during filling and when the water reaches 80% of test level c) Settlement shall be measured during filling and when the water reaches 100% of test level d) Settlement shall be measured during filling and when the water reaches 100% of test level and during emptying of the tank Reference: API-653, Paragraph 12.5.2

Charlie Chong/ Fion Zhang

Answers to API-653 Section 12, Examination and Testing 1c

11 b

21 c

31 d

2a

12 a

22 a

32 a

3d

13 b

23 c

33 c

4b

14 b

24 d

34 b

5c

15 d

25 b

35 c

6a

16 c

26 b

7d

17 d

27 a

8a

18 b

28 d

9b

19 a

29 c

10 c

20 d

30 c

Charlie Chong/ Fion Zhang

Section 13 – Marking Q1. Tanks that are reconstructed, in accordance with API-653 shall be identified by a corrosion resistant metal nameplate. What is the size requirement for the letters and numerals to be used on this nameplate and how are they applied to the nameplate? a) Letters and numerals not less than 1/2" high shall be embossed, engraved, or stamped in the plate b) Letters and numerals not less than 1/4" high shall be embossed, engraved, or stamped in the plate c) Letters and numerals not less than 5/32" high shall be painted on the plate or embossed, engraved, or stamped in the plate d) Letters and numerals not less than 5/32" high shall be embossed, engraved, or stamped in the plate Reference: API-653, Paragraph 13.1.1 13.1.1.1 Tanks reconstructed in accordance with this standard shall be identified by a corrosion-resistant metal nameplate similar to that shown in Figure 13.1. Letters and numerals not less than 5/32 in. high shall be embossed, engraved, or stamped in the plate to indicate information as follows: Charlie Chong/ Fion Zhang

Q2. Where should the new nameplate be attached and what should be done with the existing nameplate a) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate. The existing nameplate shall be cleaned or suitably reconditioned b) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate. The existing nameplate shall be left attached to the tank c) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate. The existing nameplate shall be removed and placed in the tank record file d) The new nameplate shall be attached to the tank shell adjacent to the existing nameplate. The existing nameplate shall then be discarded Reference: API-653, Paragraph 13.1.2

Charlie Chong/ Fion Zhang

Q3. All but which of the following information shall be made part of the owner/operator's records for aboveground storage tanks? a) Names of all operators of the tank b) Calculations c) Construction and repair drawings d) Additional supporting data Reference: API-653, Paragraph 13.2.1, 13.2.2, 13.2.3

Charlie Chong/ Fion Zhang

Answers to API-653 Section 13, Marking Question Number Answer 1D 2B 3A

Charlie Chong/ Fion Zhang

Appendix B – Evaluation of Tank Bottom Settlement Q1. External measurements for tank settlement shall be taken at points having a maximum spacing of ____ around the circumference. a) 24 feet b) 28 feet c) 32 feet d) 36 feet Reference: API-653 Appendix B, Paragraph B.2.1 and Figure B-1

Charlie Chong/ Fion Zhang

Q2. Regardless of tank size, what is the minimum number of settlement point measurements? a) Four b) Eight c) Twelve d) Based on the formula N = D/10 Reference: API-653 Appendix B, Paragraph B.2.1 and Figure B-1

Charlie Chong/ Fion Zhang

Q3. Internal measurement for tank bottom settlement taken across the diameter of the tank must be taken at what maximum spacing? a) 10 feet b) 24 feet c) 32 feet d) 4 feet Reference: API-653 Appendix B, Paragraph B.2.1 and Figure B-2 Q4. Which of the following is not listed as settlement component? a) Uniform settlement b) Rigid body tilting of a tank (planar tilt) c) Out-of-plane settlement (differential settlement) d) Soil undermining (total tank sinking)

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Q5. What type of settlement is depicted here? a) Bottom settlement near tank shell b) Edge settlement c) Localized bottom remote from tank shell d) Planar settlement Reference: API-653 Appendix B & Fig. B-5 ➪

Charlie Chong/ Fion Zhang

Q6. Using the formula in B-3.2, determine the maximum permissible deflection (out of plane distortion) for a tank with the following data reported. ■ D?: Diameter 110 feet ■ H: Height 60 feet ■ E: Material Carbon Steel (Young's modulus = 29,000,000 psi) ■ Y: Yield strength 30,000psi ■ L: Arc length between measurements 31.4 feet a) S = .09 feet b) S = .9 feet c) S = 9 feet d) S = .009 feet Reference: API-653 Appendix B Paragraph B.3.2 Smax in feet = 31.42 x 30000 x 11/ 2(29 x106 x 60) = 0.093’

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Q7. What is the maximum depth of a local depression in a tank bottom if the radius of an inscribed circle is equal to 7.5 feet? a) BB = .2775 inches b) BB = 2.775 inches c) BB = 27.75 inches d) BB = .02775 inches Reference: API-653 Appendix B Paragraph B.3.3 B.3.3 Internal Bottom Settlements or Bulges Measure the bulge or depression. The permissible bulge or depression is given by the following equation (see Note). BB = 0.37R where BB is maximum height of bulge or depth of local depression, in inches; R is radius of inscribed circle in bulged area or local depression, in feet.

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Answers to API-653 Appendix B, Tank Bottom Settlement Question Number Answer 1C 2B 3A 4D 5B 6A 7B

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Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

https://www.yumpu.com/en/browse/user/charliechong Charlie Chong/ Fion Zhang