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Tank Bottom Inspection Criteria
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The article will discuss the added requirements for the training and testing of NDT personnel who inspect storage tank floors during an API 653 out of service inspection. The America Petroleum Institute added Appendix G to the 653 code in 2003 to describe the precise requirements for this training and testing. It describes the number of training hours, the types of test questions and even details the construction of a tank floor mock-up with manufactured defects.
Most out of service inspections use magnetic flux leakage (MFL) as a great detector for locating underside floor corrosion. This is often referred to as soil side corrosion caused by the contact of the steel floor with the moisture and chemical make up of the soils underneath the tank. MFL however cannot give an accurate assessment of the remaining wall thickness due to some of the limitations imposed by the inspection environment. The only reliable and accurate quantitative assessment must be obtained by using ultrasonic thickness techniques. These techniques include appropriate operator training and not just the ability to take digital thickness measurements.
It is essential that a quality A-scan be used to assess any corrosion detected. This equipment must be capable of determining location, size and the accurate measurement of remaining floor thickness. A 5 Megahertz dual crystal focused contact transducer of either .375" or .500" in diameter should be used. Either water or a gel type couplant should be used. It is essential that the amplitude of the signal from the corroded back wall must be raised to at least the same screen height as the calibration reflector. While it is true that a reflector from a straight back wall will give a clean signal the same is not true for a corroded surface. Since there is an irregular profile the energy being reflected back will be wider at the base and have much lower amplitude. In this case the operator's experience in adjusting the ultrasonic equipment is essential. This is the reason that code book now requires the advanced training for ultrasonic prove-up operators.
Here is a summary of the requirements now in place for API 653 tank bottom examiners.
1. A written procedure that address the essential and non-essential variables for a tank bottom inspection.
2. A record of the qualification test for a specific scanning operator.
3. A record of the qualification test for a tank bottom procedure.
4. Each scanning operator shall receive 40 hours of training. The training will include NDT principles and scanning equipment operation and calibration.
5. Specific dimensions of the tank bottom sample (70 square feet) and a minimum number and size of pits to be located during the operator testing.
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