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We eldingFa abricatio onProce edure API65 50Stora ageTank ks

TABLE OF O CONT TENTS

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PURPOSE AND D SCOPE .................................................. ..................................................................... 2 REFERENCES ............................................................... ..................................................................... 2 WELDER QUA ALIFICATION ........................................... ..................................................................... 2 ..................................................................... 2 WELDING PRE EREQUISITES............................................ MATERIALS ................................................................. ..................................................................... 2 BASE MATERI IAL JOINT PRE EPARATION ....................... ..................................................................... 3 BASE MATERI IAL JOINT CLE EANING ............................. ..................................................................... 3 JOINT FIT-UP AND ALIGNM MENT .................................. ..................... ................................................ 3 PREHEAT ..................................................................... ..................................................................... 3 TACK WELDS S .............................................................. ..................... ................................................ 4 BACKPURGE/B BACKING GAS ........................................ ..................................................................... 4 INTER-PASS TEMPERATURE E ........................................ ..................................................................... 4 WELDING TEC CHNIQUE................................................. ..................................................................... 4 INTERRUPTION N OF WELDIN NG ....................................... ..................................................................... 5 INSPECTOR QUALIFICATION U N ........................................ ..................................................................... 5 ACCEPTANCE CRITERIA FO OR COMPLETE ED WELDS ..... ...................... ...................... ...................... ....... 5 WELD REPAIR RS............................................................. ..................................................................... 6 POST WELD HEAT TREATM MENT .................................. ..................................................................... 6 ATTACHMENT T WELDS ................................................. ..................................................................... 6 ATTACHMENT TS................... ...................... ...................... ...................... ...................... ...... 7 ......................


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Weld dingFab brication nProced dure API A 650 0Storag geTanks s


PUR RPOSE AND SCOPE

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This Wel lding Fabrica ation Procedu ure (WFP) sh hall govern th he welding of components s to the requiremen nts of API 650. The Code edition and a addenda for th his procedure e shall be the latest in effect or as s otherwise sp pecified by th he client.

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REFERENCES

1. API 650, Weld Steel Tanks T for Oil Storage S 2. ASME Sec ction IX, We elding and Brazing Qualifi ications

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WEL LDER QUAL LIFICATIO ON


A.

Welder/weld ding operators s shall be currently c cert tified, having g performed qualification n tests in ac ccordance wit th API 650.

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WEL LDING PRE EREQUISITE ES A. All A welding sh hall comply with w the require ements specif fied in the We elding Proced dure Specification S (WPS). (
B. Welding W shall not be perfor rmed when th he ambient tem mperature in t the immediate e vicinity of t the weld is lo ower than 0 F or when sur rfaces are wet t or exposed t to rain, snow, , dust, or high h wind. The w welder and weld w joint shal ll be sufficien ntly protected d from inclem ment condition ns. Care shall be taken to a assure that moisture m has not n been trapp ped between members m that t are to be we elded and that t moisture ha as not been in ntroduced int to previously y fit-up joints prior to fi inal welding. . Preheating g above the minimum te emperature sp pecified in the e Welding Pro ocedure Spec ification (WP PS) may be necessary to re emove any en ntrapped moi isture. The ad dditional preh heat should be e applied if th here is reason n to believe m moisture is pr resent.

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MAT TERIALS A. Base B Materials s


B. Only O the mater rials specified d shall be used d. 1. Filler Mate erials

W filler materials to be b used with this t procedure e are specified d in the Weld ding C. Welding Pr rocedure Specification (W WPS. D. Requirements R for f procurement and contro ol of filler ma aterials shall b be in accordan nce with WPS. W E. Welding W filler materials (ele ectrodes, bare e filler wire, o or consumable e inserts) mus st be utilized b by welders w makin ng weldments with this proc cedure. Weld ders shall not perform weld ds autogenous sly.

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BASE E MATERIA AL JOINT PREPARAT TION


A. The T edges of plates may be b sheared, machined, m chip pped, or mach hine oxygen cut. Shearing g shall be limited to 3/8 in n. thickness of o plates for butt-welded b j joints and 5/8 in thickness for lap- weld ded joints. When W edges of plates are oxygen o cut, th he resulting su urface shall b be uniform an nd smooth and shall be fr ree of scale an nd slag accum mulations befo ore welding. Circumferentia C al edges of ro oof and bottom m plates may y be manually y oxygen cut. . Kerf or gou uge marks

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on n the joint bev vel deeper tha an 1/8 (0.125 5) shall be rep paired prior to o fit-up and ta ack welding.

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BASE E MATERIA AL JOINT CLEANING G A. Pr rior to weldin ng, surfaces fo or welding shall be clean an nd free from p paint, oil, rus st, scale, slag, grease, an nd other forei ign s that are detrimental d to o welding.
B. A fine film of rust r adhered to t the joint ed dges need not be removed p prior to weldi ing. C. Weld-through W primers, e.g., Deoxaluminite, Spatter-w weld, or Carbo oweld 11, need oved d not be remo pr rior to weldin ng.

1. Solvents ap pproved for use u on the base material and d weld materi ials are methy yl alcohol, eth hyl alcohol, iso opropyl alcoh hol, acetone, methyl m ethyl k ketone, toluen ne, Varson 4, Dowanol EB B, and Stoddard solvents. s

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JOIN NT FIT-UP AND ALIGN NMENT A. The T root openi ing and fit-up tolerances sh hall be as spec cified in WPS S. If f the tolerance es cannot be achieved, a the end preparati ions may be b built up by we elding or re- p prepped by y machining or o grinding.
B. Plates to be joi ined by butt welding w shall be b matched ac ccurately and d retained in p position durin ng th he welding op peration (see paragraph p 15.A.3).

C. During D the wel lding operatio on, plates shal ll be held in c close contact a at all lap joint ts.

D. Sh hell plates ma ay be aligned by metal clip ps attached to the bottom plates, and the shell may be e tackwelded w to the bottom b before e continuous welding w is sta arted between the bottom edge of the she ell plate an nd the bottom m plates.

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PREH HEAT A. When W the base e metal temper rature is below w the minimu um preheat te mperature specified in the Welding Pr rocedure Specification (WPS). The bas se metal shall be heated suc ch that the sur rfaces to be w welded are at t or above the e minimum pr reheat temperature prior to welding.
B. The T preheat tem mperature sha all be maintai ined for a dist tance of at lea ast 3 inches on n each side of f the weld jo oint and in adv vance of the welding. w Preh heat temperat ture above 125 F shall be checked by u using a su urface pyrome eter, Tempilstik, or non-mercury-type e thermomete er. Indicating c crayons shall not be us sed directly in n the weld zon ne.

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TAC CK WELDS A. Tack T welds sha all be made by qualified welders w in acco ordance with the Welding P Procedure Sp pecification (WPS.
B. Defective D tack welds shall be b removed or r repaired prio or to welding. C. Tack T welds use ed in the assembly of vertical joints of t tank shells sha all be remove ed and shall no ot re emain in the finished f joint when w the join nts are welded d manually.

D. Tack T welds in the bottom, ro oof, and circu umferential jo oints of the tan nk shell need not be remov ved pr rovided they are a sound and d the subseque ently applied weld beads a are thoroughly y fused into th he ta ack welds.

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1 11.0 BACKPURGE/B BACKING GAS


Not ap pplicable.

1 12.0 INTE ER-PASS TEMPERATU E URE

A. In nter-pass temp perature shall l not exceed th he maximum value specified in the Wel lding Procedu ure Sp pecification (WPS and sha all be checked d on the surfac ce of the com mponent using g a surface pyr rometer, T Tempilstik, or o non-mercu ury-type therm mometer. Indi cating crayon ns shall not be e used directly y in the weld w zone.

B. If f the temperat ture of the we eld is above th he maximum i inter-pass tem mperature specified in the W Welding Pr rocedure Specification (WPS) the weld shall be allow wed to cool do own below th he maximum i interpa ass temperatu ure, but not be elow the minim mum preheat t temperature, , prior to resum mption of welding.

1 13.0 WEL LDING TEC CHNIQUE

A. Welding W voltag ge and amper rage shall be in n accordance e with the limi its specified o on the WPS. V Voltage an nd amperage range r gages located on the e welding pow wer supply are e for reference only and are e not mandatory m che eck or hold po oints. Voltage and amp rang ge checks for r documentati ion purposes s shall be pe erformed by the t inspector using u calibrat ted voltage an nd amp meter rs or approved d welding par rameter re ecording equip pment.

B. Cracks C or blow wholes that ap ppear on the su urface of a we eld bead shall l be removed by filing, gr rinding, chipp ping, or air ca arbon arc goug ging before de epositing the next bead. O Oxygen gouging sh hall not be use ed on quench hed and tempe ered steel.

C. Before B welding g over previou usly deposited d metal, all sl lag and flux shall be remov ved, and the w weld and ad djacent base material m 1 inc ch on either side of the weld d shall be bru ushed clean.

D. For double-we elded butt join nts, before app plying weld m metal on the s second side to o be welded t the root sh hall be prepa ared by suitab ble methods such as chip pping, grindin ng, or air car rbon arc goug ging to as ssure sound metal. m

E. The T recommen nded weld bea ad thickness shall s be 1/16 to o 3/16 inches. P Passes shall b be less than inch th hick unless oth herwise speci ified in the Welding W Proced dure Specification (WPS). b used to con ntrol distortion n or to relieve e residual stre esses. Peening g shall not be e F. Peening may be erformed unti il at least 3/8 in n. depth of be evel has been deposited. P Peening shall n not be applied d to cover pe pa asses, base, or weld layers requiring non ndestructive e examination. Peening shal ll not be used to mask a defect.

G. After A being laid out and tack ked, bottom plates p shall be e joined by we elding the join nts in the se equence provi ided in Attach hment 2, unle ess otherwise specified by t the Client.

H. All A welding pr rocesses may be b single pass s or multiple p passes per sid de unless othe erwise specifi ied in n the Welding g Procedure Sp pecification (WPS).

I.

Welding W shall be performed d single arc un nless otherwis se specified in n the Welding g Procedure Sp pecification (WPS.

1 14.0 INTE ERRUPTION N OF WELD DING

A. Welding W may be b interrupted d without restr riction, unless s otherwise sp pecified in the e Welding Pr rocedure Specification (W WPS).

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1 15.0 INSP PECTOR QUALIFICAT U TION

A. The T Inspector who w performs s welding insp pection for ac cceptance to th this procedure e shall be au uthorized by AL-KARRAR A R and approv ved by client.

1 16.0 ACC CEPTANCE CRITERIA FOR COMP PLETED W ELDS


A. Butt B Welds

1. . As-welded d surfaces are permitted; ho owever, the su urface of weld ds shall be su ufficiently free e from coarse ripp ples, grooves, overlaps, abr rupt ridges, an nd valleys. 2. The surfac ce condition of the finished d welds shall b be suitable for r the proper in nterpretation of radiograph hic and other nondestructiv n ve examination ns when nond destructive ex xaminations ar re required. Butt-welded B joints j to be ra adiographed sh hall be prepar red as follows s:

a. Weld W ripples or r weld surface e irregularities s on both the inside and ou utside shall be e removed by y any suitable mechanical process p to suc ch a degree th hat the radiogr raphic contras st res sulting from any a irregularities cannot m mask or be able defect. co onfused with the t image of any a objectiona

b. Th he weld surfac ce shall merge smoothly in nto the plate s surface.

c. Th he finished su urface of the weld w reinforce ement may be e flush with th he plate or ma ay have a reas sonable unifo orm reinforcem ment not to ex xceed the amo ount shown in n At ttachment 1. . The misali ignment of co ompleted verti ical butt joints s of tank shel lls shall not ex xceed 10% of f the plate 3. 1 thickness or o /16 inch, whichever w is th he larger. s of tank shel 4. . The upper plate in comp pleted horizon ntal butt joints lls shall not pr roject beyond d the face of the lowe er plate at any y point by mo ore than 20% o of the thickne ess of the upp per plate, with ha maximum of 1/8 inch exc cept that a pro ojection of 1/1 missible for up pper plates less than 16 inch is perm 5 /16 inch thi ick.

5. . The edges of welds shal ll merge with the surface o of the plate wi ithout a sharp p angle. There e shall be a maximum m permissible e undercut of 1/64 inch of th he base metal for vertical bu utt joints and 1/32 inch for horizon ntal butt joints s. 6. . The thickn ness of the rein nforcement of the welds on n butt joints o on each side o of the plate shall not ex xceed the amo ount shown in n Attachment 1.

B. Fillet Welds

d surfaces are permitted; ho owever, the su urface of weld ds shall be su ufficiently free e from 1. As-welded coarse ripp ples, grooves, overlaps, abr rupt ridges, an nd valleys. ce condition of the finished d welds shall b be suitable for r the proper in nterpretation of 2. The surfac nondestruc ctive examina ations.

1 17.0 WEL LD REPAIR RS

A. Defects found f in weld ds shall be cal lled to the atte ention Client a and approval obtained pr rior to repair.

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B. Weld W repairs sh hall be perfor rmed using the original We elding Proced dure Specifica ation (WPS) t to re estore a weld to an accepta able condition n. C. Pinhole leaks or o porosity in tank-bottom joints j or roof f joints may be repaired by applying an ad ks in tank bot dditional weld d bead over th he defective area. a Other de efects or crack ttom joints sh hall be re epaired.

D. Cracks C and all defects in she ell joints or sh hell to bottom m joints shall b be removed b by chipping, gr rinding, mach hining, or air carbon c arc go ouging from o one or both sid des of the join nt and re- wel lded.

E. Repairs R of defe ects discovere ed after the tan nk has been f filled with wa ater for test sh hall be made w with the water w level at least l 12 inche es below the point p being rep paired or with h the tank emp pty if the repa airs are on n or near the tank t bottom. Welding sha all not be perfo formed on any y tank unless c connecting lin nes have be een completely blanked of ff.

F. Welded W repairs s shall not be attempted on n a tank filled with oil, or on a tank that h has previousl ly co ontained oil, until u the tank has been emp ptied, cleaned d, and freed of f gas or oil residue in a saf fe manner. m Repairs shall not be b attempted on o a tank that has contained oil, except i in a manner ap pproved in wr riting by the Client. C

1 18.0 POST T WELD HEAT TREA ATMENT

A. Post P weld he eat treatment when indica ated in the W Welding Proc cedure Specif fication (WP PS shall be pe erformed in accordance a wi ith API-650

1 19.0 ATTACHMENT T WELDS


B.

A. Bars, B clamps, temporary t atta achments, etc c. welded to th he base mater rial shall be th he same P- nu umber as s the base material. When W applyin ng attachmen nts to materia als of differen nt thicknesse es, the prehea at requiremen nts of the th hicker materia al shall govern n.

C. When W the engi ineering speci ification requ uires removal of temporary y attachments, a method th hat will not da amage the ba ase material shall be utilize ed, e.g. cut, g grind, or air c carbon arc go ouge the attac chment off an nd grind the area a flush.