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Api 653 Tank Inspection, Tank Maintenance, AND Causes of Tank Failure

The document discusses API 653 tank inspections, maintenance, and causes of tank failure. It emphasizes the importance of proper inspection protocols using certified inspectors to identify issues before catastrophic failure. Common causes of tank failure include insufficient plate thickness, overfilling, improper cutting and rewelding of tanks, and defective welds due to lack of fusion or deterioration. Proper maintenance like regular visual inspections and following API specifications for construction can help prevent leaks and catastrophic failures.

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Arif Priyadi
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105 views43 pages

Api 653 Tank Inspection, Tank Maintenance, AND Causes of Tank Failure

The document discusses API 653 tank inspections, maintenance, and causes of tank failure. It emphasizes the importance of proper inspection protocols using certified inspectors to identify issues before catastrophic failure. Common causes of tank failure include insufficient plate thickness, overfilling, improper cutting and rewelding of tanks, and defective welds due to lack of fusion or deterioration. Proper maintenance like regular visual inspections and following API specifications for construction can help prevent leaks and catastrophic failures.

Uploaded by

Arif Priyadi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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API 653 TANK INSPECTION,

TANK MAINTENANCE,
AND
CAUSES OF TANK FAILURE

Ir. Sadani
API 653 Tank Inspections

Why Inspect Your Tanks?

• Prevent leaks into your secondary containment or to


groundwater (if you do not have a secondary
containment system)

• Establish a baseline of tank condition and corrosion


rates

• Identify problems to perform repairs before you have a


significant leak or release - Maintain your capital asset

• Minimize chance of catastrophic tank failure


PROPER INSPECTION PROTOCOL

INSPECTOR CREDENTIALS

• Certified API 653 Inspector


 Four years minimum experience with storage tanks

 Must pass test conducted by American Petroleum Institute


(API)
 Inspectors receive an individual inspector number
 Inspector testing required every three years
PROPER INSPECTION PROTOCOL

• Visual inspection of welds, plates, and appurtenances

• UT (Ultra-sonic Thickness) testing of shell courses, floor, and


roof

• Vacuum testing of all floor weld seams – unless epoxy coated

• Identify bottom side corrosion on floors

• Settlement Survey
 Checking for planar tilt

 Check for floor bulges or depressions

• Provide calculations for safe or maximum fill height


Weld deterioration

Plate
corrosion
Interior piping
corrosion

Shell
corrosion
Weld deterioration and
four-way junction – NON
API

Four-corner insert with


reinforcing backup – NON
API
Evidence of interior shell
corrosion

Foundation evaluation
Floor plate
corrosion

Lap-welded seam
leak
Floor coupon with bottom
side corrosion

Floor top side


corrosion
Severe roof
corrosion

Star light . . . Star


bright!
TANK INSPECTIONS ARE NOT ALWAYS A BAD THING

THIS IS A HAPPY TANK


TANK MAINTENANCE – COMMON SENSE APPROACH

• Conduct monthly/weekly walk-around of your tank(s)


• Look for stains on steel where leak may be
occurring
• Check valve function and nozzle welds
• Check associated piping
• Check foundation for wash-out/deterioration
• Keep good records of product in and out
TANK MAINTENANCE – COMMON SENSE APPROACH

• Open up your tank a minimum of every two years and conduct


your own visual inspection inside
• Check for weld deterioration and corrosion
• If tank is coated, visually check coating for blisters or cracks
• Keep a record of inspections and results
• If tank has an internal containment liner, check leak monitor
weekly
• Conduct an API-653 inspection of your tank every five years as
recommended by TFI (The Fertilizer Institute)
WHAT IS THE API 650 SPECIFICATION

API - AMERICAN PETROLEUM INSTITUTE


Worldwide Standard for Above Ground Storage Tank Design
and Construction

• Provides requirements for calculations of shell plate


thickness, man-way and nozzle design

• Provides procedures for shell, roof and floor construction

• Specifies material requirements and minimum


thickness requirements

• Specifies weld construction requirements, weld spacing,


and x-ray requirements
CAUSES OF
CATASTROPHI
C TANK
FAILURE
TANK FAILURES – COMMON CAUSES

• Tank shell plates not thick enough for specific gravity of


product stored

• Over-filling of tank – over pressure

• Cut-down and re-erected tanks using improper cutting


and re-welding procedures

• Improper weld procedures


 Lack of full weld penetrations (lack of weld fusion)
 Improper weld seam spacing
 Lack of radiograph (x-ray) of newly constructed tanks or
on repaired tanks
TANK FAILURES – COMMON CAUSES

• Lack of weld fusion - #1 common cause


• Welders not certified and tested to weld procedure

• Weld deterioration/corrosion – especially in lower horizontal


and vertical weld seams

• Brittle fracture of steel

• Lack of proper certified inspections

• Tank erectors who know little about API Specifications and


procedures – these companies attract customers with a
“cheap” price. Make certain your contractor can verify that
your tank meets API Specifications. DO YOUR OWN
HOMEWORK
Cut-down and re-welded
tank

Improper weld
spacing
Double wall 500,000
gallon
tank, Illinois 2008

Cause – overfilling and lack


of fusion on weld seams
Yards of destruction
Original tank
foundation
Weld seam rupture. Force of rupture “pushes
back”. Rupture on side of camera location.
earthquake

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