SP031 Standard for the

Repair of Aboveground
Storage Tanks
 SP031 Tank Repair Standard

 Standard covers the repair and modification of atmospheric

tanks made of carbon or stainless steel
 Intended for tanks storing flammable and combustible
liquids
 Written for tanks constructed to a nationally recognized
standard, but can be applied to any tank at the owner’s risk
 Covers the tank and supports only. Does not cover
platforms, walkways, piping systems, etc.
 SP031 Tank Repair Standard

 Primary sections of the standard

 Safety
 Personnel Qualifications
 Materials and Welding
 Modification
 Repair
 Testing and Inspection
 SP031 Safety

 The standard is not an all inclusive standard for safety

 Investigate local codes and regulations
 Plan for safety
 Hot work requires cleaning the tank.
 NFPA 326, Standard for the Safeguarding of Tanks and Containers for
Entry, Cleaning or Repair
 API RP 2015, Requirements for Safe Entry and Cleaning of Petroleum
Storage
 API RP 2016, Guidelines and Procedures for Entering and Cleaning
Petroleum StorageTanks
 SP031 Safety

 The level of planning and protection for modification or

repair to the tank is higher that what is required for
inspection
 Modification or repair will almost always include “Hot Work”
where an ignition source will be present, therefore
monitoring for explosive conditions is critical
 Personnel Qualifications

 Personnel qualified to make repairs:

 Company qualified welding personnel of a facility which
manufacturers STI, API, UL, ULC, or SwRI tanks
 ASME Section IX qualified welders
 AWS D1.1 qualified welders
 Additional certifications as may be required by individual states or
other governing bodies
 Personnel Qualifications

 Personnel qualified to perform testing

 Experience with the test procedure to be utilized
 Necessary training and/or certification by the manufacturer of the
equipment used in the procedure
 Meet certification standards imposed by regulatory bodies or other
overseeing authorities
 Certified under ASNT TC-1A for the test being performed
 Personnel Qualifications

 Personnel qualified to perform the inspections

 Steel Tank Institute (STI) SP001 Certified Inspector
 API 653 Certified Inspector
 Personnel employed by a manufacturer of STI, API, UL, ULC, or
SwRI tanks
 The final inspection is important to ensure the repairs were
performed correctly and the corrections noted in the
inspection prior to work have been made
 Modifications

 NOT COVERED
 Shell height modification or other change in tank dimensions
 Addition of anchor chairs for code requirements
 Change of service
 Pipe penetrations larger than 12 inches below maximum liquid level
 Pipe connections with external loads
 These modifications require engineering assistance
 Modifications Covered

 Addition of a new pipe penetration

 Addition or replacement of a manway
 Installation of a second bottom
 Removing a shell penetration
 Adding a Pipe Penetration

 Minimum Schedule 40
 Minimum ANSI Class 150 raised face flanges
 Verify the type of connection meets local code
 Vents must be flush on the inside of the roof or shell
 Minimum continuous welding from the exterior of the tank
is required!
 Adding a Pipe Penetration
 Reinforcing plates are not required when:
 Penetration is above the liquid level
 Penetration is less than 2”
 Reinforcing plate must be
 at least 3” wide, with 2” minimum radius corners
 the same thickness as the shell
 have and OD that is twice the diameter of the opening
 Minimum spacing of 3” from the toe of an existing weld or must overlap the weld by
3”
 ¼” threaded tell tale or test hole if welded inside and out to allow testing of the
welds
 Installing a Second Bottom

 Intended to describe how to upgrade a vertical tank to

include secondary containment of the tank floor
 The new floor plates must meet the requirements of the
original standard of construction or ¼” whichever is greater
 All welds must be continuous welds
 Installing a Second Bottom
 Lift the tank an place new bottom
plate
 Bottom plate must extend at least 1
½” beyond the existing tank shell or
floor plate
 Vertical flat bar extension is needed
when tank has a knuckle bottom.
The flat must extend at least 3”
above the existing shell to floor joint.
 Removing a Penetration
 The tank shell or roof must be cut at least 1” away from
the existing weld
 The cut can be round, oval or rectangular, but no sharp
corners. Minimum radius is 2”
 Cut must remain at least 1” from an existing weld seam
or extend 3” beyond it
 The cut must be at least 3” from any rolled knuckle
 A section of knuckle can not be removed
 Repairs

 Typically repairs are performed as recommendations from

an SP001 inspection
 Weld Deposition
 Lap Patch Plates
 Insert Patch Plate
 Which repair is needed depends upon the type of problem
and the size…
 Weld Deposition
 Weld deposition is used to repair the following
 Cracks
 Lack of fusion
 Rejectable slag
 Porosity
 Excessive weld undercut
 Corroded weld joints
 Broken welds on attachments to the shell
 It can also be used to repair pitting corrosion
 Weld Deposition

 Weld deposition is the only

repair allowed to the knuckle
joint in a tank
 Limited to corrosion pitting not
exceeding 2” in 8”
 Lap Patches
 Lap patches are often used to repair areas where corrosion has resulted in
thinning of the shell
 They do not have to be applied to the side with corrosion, but they must
extend beyond the corroded area by 1”
 Lap patch must be the same material and thickness as the plate being
repaired
 Minimum plate thickness that can be repaired is 0.100”
 NO lap patches over lap patches!
 Minimum size is 6” - Maximum size is 48” x 72” (but orientation is limited by tank
orientation)
 Lap Patches
 Formed to match the contour of the
tank
 Minimum corner radius of 2”
 Extend a minimum of 1” beyond the
defect
 Must remain 3” away from the shell to
knuckle joint or existing weld
 Insert Plates

 Like the lap patch, must be the same material and thickness
as the plate being repaired
 Same size limitations as lap patches
 Same shape limitations. No sharp corners
 To reduce the potential for distortion in the tank shell, fit-
up, heat input and welding sequence must be considered
 Insert plates require a full penetration weld
 Insert Plates
 Same rules for intersecting the shell
to floor joint
 12” minimum cut back of the shell to
floor joint is required (except for
rectangular tanks)
Patch Plates
 Bottom Repairs

 Bottom repair is typically using a lap patch

 Patch plates must be the same as the original thickness or
¼” which ever is greater
 The minimum size is 6” diameter
 The patch must overlap the defect by at least 1”
 The floor plate under a weld must be at least 0.100” thick
 Bottom Repairs

 Overlapping patches is not allowed.

 Repair by weld deposition is recommended for
 Cracks or porosity in welds
 Internal pitting
 Corrosion losses in the knuckle
 Repair by full plate replacement is the only other method of
repair in the knuckle
 Bottom Replacement

 Remove the entire bottom by cutting at least ½” above the

existing shell to bottom joint
 New bottom plate must meet the requirements of the
current version of original standard of construction. If the
standard is not known, then the plate shall be ¼”
 The new bottom can be connected using either a knuckle or
T joint
Bottom Replacement
 Roofs and Supports
 Roof Repairs/Modifications
 No pooling of water
 Spacing limitations from weld seams is not applicable
 Venting (N&E) must be maintained
 Supports Repairs/Modifications
 Must meet original standard or current version of UL142
 Wind and Seismic loads must be considered
 If damage affects structural integrity, remove damaged section
and replace
 If welding to the shell, testing is required
 Testing and Inspection

 Testing of all repairs and modifications is required

 All inspection results, repairs, modifications, and
recommendations shall be documented and maintained in
the tank records
 A visual examination of all repairs and modifications is
required
Testing and Inspection
 Testing and Inspection

 A pressure or vacuum test is required for a tank that has

undergone a “Significant Repair”
 Significant Repair
 A complete replacement of a tank bottom or installation of a double
bottom in a tank
 A patch plate or insert plate is installed with a total area greater
than 12 square feet
 New openings or penetrations greater than 12 inches diameter that
are installed below the maximum normal liquid level
 Final Inspection

 A final inspection by a qualified inspector must be

performed before returning the tank to service
 The repair or modification was made appropriately
 Appropriate testing was performed successfully
 Current standard and code compliance,
 General overview of application of repair or modification
 Documentation completed