TANK INSPECTION, REPAIR, ALTERATION, AND RECONSTRUCTION 9-9

9.6.3 Existing weld undercut deemed unacceptable based on suitability for service considerations shall be repaired
by additional weld metal, or grinding, as appropriate.

9.6.4 Welded joints that have experienced loss of metal due to corrosion may be repaired by welding.

9.6.5 Arc strikes discovered in or adjacent to welded joints shall be repaired by grinding and/or welding. Arc strikes
repaired by welding shall be ground flush with the plate.

9.6.6 After repairing weld defects listed in API 653, Section 9.6, the repaired areas shall be examined in accordance
with the requirements of API 653, Section 12.1.3.

9.7 Repair of Shell Penetrations

9.7.1 Repairs to existing shell penetrations shall be in compliance with API 650, Section 5.7.

9.7.2 Reinforcing plates may be added to existing unreinforced nozzles when deemed appropriate. The reinforcing
plate shall meet all dimensional and weld spacing requirements of API 650, Section 5.7. See Figure 9.7 and Figure
9.8 for acceptable details.
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9.7.3 As an alternative, the reinforcing plates may be added to the inside of the tank provided that sufficient nozzle
projection exists.

9.8 Addition or Replacement of Shell Penetrations

9.8.1 New shell penetrations (addition or replacement) shall be in accordance with material, design, and stress relief
requirements of API 650, Section 5.7 and in accordance with 9.8.2 through 9.8.6 of this standard.

A 1 /4
in. tell tale hole, drill and
t tap for 1/8-in. pipe thread
T

T or t
(1.5 in. max) Tank Greater
shell of
2 in. or 6T

1/16 in.

A SECTION A-A

t and T
A
(maximum)
9/16 in. 1/4 in.

3/4 in. 5/16 in.

15/16 in. 3/8 in.

1 1/8 in. 7/16 in.

1 5/16 in. 1/2 in.

1 9/16 in. 9/16 in.

1 3/4 in. 5/8 in.

NOTE All details, dimensions, and weld spacing shall be in accordance

with the requirements of API 650.

Figure 9.7—Typical Details for Addition of Reinforcing Plate to Existing Shell Penetration

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 9-10 API STANDARD 653

1/4-in.telltale hole, drill and

A
t tap for 1/8-in. pipe thread
T

T or t Greater
Tank
(1.5 in. max) of
shell
2 in. or 6T

1/16 in.

B
A SECTION A-A

t and T
A B
(maximum)
9/16 in. 1/4 in. 1/4 in.

3/4 in. 5/16 in. 1/4 in.

15/16 in. 3/8 in. 5/16 in.

1 1/8 in. 7/16 in. 5/16 in.

1 5/16 in. 1/2 in. 3/8 in.

1 9/16 in. 9/16 in. 3/8 in.

1 3/4 in. 5/8 in. 3/8 in.

NOTE All details, dimensions, and weld spacing shall be in accordance

with the requirements of API 650.

Figure 9.8—Typical Details for Addition of “Tombstone” Shape Reinforcing Plate to Existing Shell Penetration

9.8.2 The required penetration reinforcement area of API 650, Section 5.7.2, shall be determined using the required
shell thickness calculated by the equation in 4.3.3.1 b) of this standard except the variable S shall be the allowable
design stress from API 650, Table 5-2a or Table 5-2b for the existing shell plate; use 20,000 lbf/in.2 if of unknown
material. A joint efficiency of 1.0 may be used (see 9.8.5). The variable H shall be the height from the centerline of the
penetration to the maximum liquid level, in ft.

9.8.3 Penetrations shall be prefabricated in thermally stress relieved insert assemblies when required by API 650,
Section 5.7.4. API 650, Section 4.1.5, may be used when reinforcing material is from API 650 Group-IV through
Group-VI and the existing shell is a Group-I through Group-IIIA material.

9.8.4 The following erection requirements shall be met:

a) if an integral reinforcement design is used, the insert plate at its periphery shall have a 1:4 reduction taper to match
the shell plate thickness when the insert plate exceeds the shell plate thickness by more than 1/8 in.;
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b) spacing of welds shall be in accordance with Figure 9.1;

c) the new insert plate shall be joined to existing shell plate with full penetration and full fusion butt welds.

9.8.5 Examinations shall be per Section 12, except penetrations located on a shell joint shall receive additional shell
radiography in accordance with API 650, Section 5.7.3.

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 TANK INSPECTION, REPAIR, ALTERATION, AND RECONSTRUCTION 9-11

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.

9.9 Alteration of Existing Shell Penetrations

9.9.1 Existing shell penetrations may be altered if the altered details comply with the requirements of API 650,
Section 5.7 including the requirements for minimum reinforcing area and the requirements for spacing of welds
around connections.

9.9.2 When installing a new tank bottom above the existing bottom, it may be necessary to alter existing shell
penetrations in the bottom course of a tank shell. If the new bottom is slotted through the tank shell several inches
above the existing bottom, the spacing between existing welds around penetrations and the new bottom-to-shell weld
may not comply with API 650 requirements. Options for altering the penetrations and/or reinforcing plates are given in
9.9.2.1 through 9.9.2.3.

9.9.2.1 The existing reinforcing plate may be trimmed to increase the spacing between the welds provided that the
altered detail complies with the requirements of API 650, Section 5.7. Care must be exercised during the trimming
operation to avoid damaging the shell material beneath the reinforcing plate. The existing weld attaching the portion
of the reinforcing plate to be removed shall be completely removed by gouging and grinding.

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).

9.9.2.3 The existing penetration may be moved by cutting the section of the shell containing the fitting and
reinforcing plate, and raising the entire assembly to the correct elevation (see Figure 9.9).

9.9.3 Any components of the penetration (neck, flange, and reinforcing plate) that are in serviceable condition after
removal may be reused.

9.9.4 A new bottom may be installed through an existing tombstone reinforcing plate, provided all weld spacing and
reinforcement requirements, as specified in API 650, are met. One of the following methods shall be used.

a) Remove only that portion of the existing reinforcing plate necessary to weld and test the new bottom-to-shell weld.
The lower edge of the reinforcing plate shall be cut reasonably straight and horizontal and beveled to facilitate
welding. See Figure 9.10 for weld joint details.
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No reproduction or networking permitted without license from IHS