Shell Repairs to Storage Tanks Using Lap-Welded Patch Plates

API-653, Tank Repair and Alteration, intends that repairs and alterations
made on an Aboveground Atmospheric Storage Tank (AST) result in general
equivalence to API-650 requirements. Section 9 of API-653, contains specific
requirements that are intended to meet this objective. After the AST has
been in service for some time, thinning due to corrosion may require that
sections of the shell be repaired in order for the tank to have adequate
strength for its next period of operation. Such repairs are generally done by
installing insert plates into the shell using full-thickness butt welds. Before
Addendum 1 issued in December 1996, API-653 did not permit the use of
lap-welded shell patch plates under any circumstances. The primary
concerns with using lap-welded patch plates relate to the quality and
strength of the attachment fillet weld, the possible increased risk of initiating
a brittle fracture at the fillet weld (especially in steels that do not meet
current fracture toughness requirements), and the ease with which the patch
plate is installed (which may lead some individuals to not take it as seriously
as they should). Addendum 1 relaxed this general prohibition on the use of
lap-welded patch plates provided that the owner specifies their use and they
meet requirements stated in API-653. Despite this relaxation, the specified
requirements for lap-welded patch plates will still limit their widespread use.
As noted below, the maximum shell and patch plate thickness limit is a
significant constraint. Lapped patch repairs may be considered permanent
repairs subject to an established inspection and maintenance program. The
requirements specified in API-653 may be used to evaluate pre-existing
lapped patch repairs, except that the various plate thickness limits need not
be applied. The following several highlights of the requirements for using
lap-welded patch plates. This is not an all-inclusive list; so, refer to API-653
for additional details. > All repair material must meet the requirements of
the applicable construction standard and API-653; > Lap patches cannot be
used on any shell course whose original construction thickness is greater
than 1/2 in. (12.5 mm), and cannot be used to replace doorsheets or shell
plates. The 1/2 in. (12.5 mm) thickness limit relates to potential brittle
fracture concerns. There has never been a documented case of a brittle
fracture in plates less than 1/2 in. (12.5 mm) thick. Therefore, limiting patch
plate thickness to 1/2 in. (12.5 mm) minimizes the brittle fracture risk This
maximum thickness limit effectively limits the use of lap patches to small
diameter tanks, or the upper courses of large diameter tanks, where the
shell plate thickness is not over 1/2 in. (12.5 mm); > The lap patch must be
at least 3/16 in. (4.8 mm) thick, but no thicker than the smaller of 1/2 in.
(12.5 mm) or the thickness of the plate to which it is being welded.
Therefore, if the design calculations conclude that a lap patch plate must be
over 1/2 in. (12.5 mm) thick, a butt-welded insert patch must be used
instead; > The shape of the lap patch may be circular, oblong, square, or
rectangular. All corners must be rounded to a 2 in. (50 mm) minimum radius
(except at the bottom-to-shell joint). This reduces local stress
concentrations and facilitates welding; > Minimum spacing limits between
the lap patch welds and shell seams are specified. The size and placement of
the lap patch might require adjustment to respect these limits; > A lap patch
may extend to and intersect with the external bottom-to-shell joint at a 90°
angle. Acceptable attachment details are specified in API-653; > Shell
openings and their reinforcement shall not be positioned within a lapped
patch shell repair. The main concern here is the additional loads that could
be imposed on the lap patch fillet welds; > The area on the shell where the
lap patch welds are to be made must first be ultrasonically examined for
plate defects and remaining thickness. The plate size must be changed
(probably increased) as needed to weld to sound shell plate material; > Lap
patches shall not be lapped on lap-welded shell seams, riveted shell seams,
other lap patch repairs, distorted areas, or unrepaired cracks or defects; >
Minimum and maximum lap patch size limits are specified (see API-653 for
details). The patch plate must be formed to the shell curvature in all cases. -
Repair of Tank Bottoms in Atmospheric Storage Tanks
Tank bottoms in atmospheric storage tanks (AST) are susceptible to both
external and internal corrosion. Repair of corroded tank bottoms in old
tanks is thus a common maintenance undertaking by tank owners. API
Standard 653, Tank Inspection, Repair, Alteration and Reconstruction,
provides guidance on the repair of tank bottoms. The rules in API 653,
however, contain certain restrictions on weld repairs and, in some cases,
require that the shell penetrations be raised. This article will examine
these requirements and discuss safe repair of tank bottoms without
undue costs or prolonged tank downtime.

Repairing a Portion of the Bottom

API 653 restricts welding in the “critical zone” when making repairs to a
portion of the tank bottom. The “critical zone” is defined as: within the
annular plate ring, within 12 inches of the shell, or within 12 inches of
the inside edge of the annular ring. No welding, welded-on patch plates,
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.
If more extensive repairs are required, the bottom plate under the tank
shell would have to be cut out and a new plate installed.

The “critical zone” is supposed to be based on stress considerations. It is

well known that the maximum stress in a tank bottom exists at the toe of
the inside shell-to-bottom fillet weld at the annular plate or sketch plate.
However, this is a very localized bending stress and it decays rapidly
with distance from the shell-to-bottom junction. Indeed, the annular
plate width requirement of API 650 was established by determining the
required distance for the edge moment to damp out completely using the
beam on an elastic foundation approach. Therefore, the "critical zone"
should only be the immediate area of the shell-to-bottom junction. Yet,
API 653 does not prohibit repair of the shell-to-bottom weld.

Weld repairs in the bottom “critical zone” should be treated no

differently than those permitted during construction of new tanks. The
weld restrictions in the “critical zone” are unwarranted, except that if
welded-on patch plates are used, they should be located several inches
away from the shell-to-bottom fillet weld in order to minimize the
compound effect of two stress risers located near each other. All weld
repairs within 12 inches of the shell-to-bottom junction should be
examined by the magnetic particle method.

The following provides examples of what should be permissible. More

than 25 years ago, the author (Mr. Ray Chao) led an effort to relocate
two new 600,000 Bbl (260 ft. diameter by 64 ft. high) floating roof tanks
due to foundation failures that occurred when the tanks were undergoing
hydro static tests. The moves were successfully accomplished by using
the water flotation method which subjected the tank bottoms to much
higher stresses than those under normal operating conditions. In order to
protect the lap weld between the annular plate and the bottom plate from
potential failures, 6-inch wide by 1/4-inch thick patch plates covering
the lap weld over its entire circumference were installed. The tanks were
subsequently placed into service without any ill effects. It may also be
noted that weld overlay to restore base metal thickness for strength
considerations is permitted by the ASME B&PV Code Section VIII for
pressure vessels.
Complete Bottom Replacement

When a tank bottom is corroded beyond repair, a new bottom must often
be installed over the existing corroded bottom. This is done by slotting
the new bottom through the tank shell several inches above the existing
bottom. The rules in API 653 require the spacing between the existing
welds around nozzles and the new bottom-to-shell weld to comply with
the requirements of API 650. Trimming of the existing nozzle
reinforcing plate is permitted to satisfy the weld spacing requirements,
provided that the modified detail complies with the requirements of API
650. In many instances, these requirements would necessitate raising the
existing shell nozzles.

With an API “Regular Type” nozzle, if the weld spacing requirements

cannot be met by trimming the existing reinforcing plate, the lower half
of the existing reinforcing plate can be removed and replaced with a new
plate to form a “tombstone” shaped reinforcing plate. In essence, this
converts the “Regular Type” nozzle to a “Low Type” nozzle. However,
with an API “Low Type” nozzle, the distance from the tank bottom to
the center of the nozzle would be reduced to less than the minimum
required by API 650 and the nozzle would have to be raised. Raising
existing shell nozzles involves cutting and welding of shell plates which
may be of unknown toughness, thereby increasing the risk of a brittle
fracture. One must therefore examine the technical justification for
raising nozzles.

The reason for raising nozzles is to comply with the nozzle details given
in API 650 which provide reinforcement of shell openings generally in
accordance with the well-established area replacement rules of the
ASME Code. However, nozzles in an AST that are located near the tank
bottom are subject to much lower stresses under the hydrostatic head
pressure than those at higher evaluations. In fact, because the bottom of
the shell is restrained from radial displacement by the bottom plates, the
circumferential membrane stress in the tank shell at the bottom of the
tank is essentially zero. Therefore, the requirements for nozzle
reinforcement should be based on stress analysis, considering the cross-
sectional area available in the shell plate for reinforcement, as allowed
by the ASME Code, as well as by API 650. In most cases, there should
be no need to raise the nozzles.

Summary

In summary, the API 653 restrictions on weld repairs and requirements

for raising shell penetrations when making tank bottom repairs should be
re-examined. Relaxation of these rules should be possible to facilitate
tank bottom repairs without affecting tank safety.