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Hydro-test Exemptions

Tuesday, April 18, 2017   By: ADI HAR-SHOSHAN [93] 4 Stars
Does Para in API-653 relate to any all size nozzles ,or only to nozzles of 12 and above?

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Tuesday, April 18, 2017   By: davidr@fast.net [39] 5 Stars
The section as written does not include any qualifications or limitations. A literal reading would be that no nozzles are exempt regardless of size.

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Wednesday, April 19, 2017   By: ADI HAR-SHOSHAN [93] 4 Stars
let put the question this way : if we add a new 8 nozzle with out welding it in full penetration , does the tank need to be hydro-test?

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Wednesday, April 19, 2017   By: Tankee [235] 4 Stars
It has been my experience that in order to waive the hydro-test, you must perform 100% full penetration weld to perform the extra NDE requirements. You also have to have an engineer review all documentation and sign off on it.

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Thursday, April 20, 2017   By: DavidR@Fast.net [39] 5 Stars
That is a much different question. You may qualify for a hydrotest exemption. What is the shell thickness and grade?

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Thursday, April 20, 2017   By: ADI HAR-SHOSHAN [93] 4 Stars
Thr shell THK = 16.0 MM and the steel grade is unknown

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Saturday, April 22, 2017   By: davidr@fast.net [39] 5 Stars
You will need a hydrotest unless a fitness for service evaluation is made passes.

The steel is over 1/2 thick and does not meet current toughness requirements. The nozzle will therefore need to be installed using an insert plate 9.8.6. The insert plate will be larger than 12. The work is classified as a major repair and hydrotest is required 12.3. To avoid a hydrotest you have to meet all of through which includes CJP for the neck-to-shell welds.

Of course, this is my opinion only ...

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Sunday, April 23, 2017   By: ADI HAR-SHOSHAN [93] 4 Stars
Thanks David,
Please clarify the following with regard to your answer:
1. API-653 Para 3.20 a say only NPS larger than 12 is a Major repair
2. API-653 Para 9.8.6 b is confusing regarding reinforcing plates, can reinforcing plate be used or only insert plate is aloud?

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Sunday, April 23, 2017   By: davidr@fast.net [39] 5 Stars
Your question: API-653 Para 3.20 a say only NPS larger than 12 is a Major repair - Read further: 3.20.c says removing or replacing a shell plate larger than 12 inches is a major repair.

Your question: API-653 Para 9.8.6 b is confusing regarding reinforcing plates, can reinforcing plate be used or only insert plate is allowed? - My reading of this section is: if the nozzle is over 2 inches your is over 2 inches AND the shell is over 0.5 inch thick yours is over 0.5 inch thick AND it does not meet current toughness yours does not meet current toughness because it is unknown, see 3.31 then you have to use a shell insert plate this section does not distinguish between single-thick or a thickened insert, just says an insert plate must be used.

So, no - you can not use just a reinforcing plate and must use an insert plate.

The rest of the section describes the minimum size of the insert plate. The minimum size is the greater of penetration x 2 or penetration + 12. This would apply to a nozzle and a single thick or thickened insert plate you determine the thickness based on reinforcement requirements.

If you use a nozzle and a reinforcing plate and a shell insert plate usually this insert plate thickness is equal to the shell thickness the minimum size of the shell insert plate is the size of the reinforcing plate plus 12 inches.

Because you are forced into using an insert plate, and the insert plate will be larger than 12 inches in at least one direction, it is a major repair per 3.20.c and you need a hydrotest or an exemption that meets the criteria in 12.3.2.

Again - my reading and interpretation only...

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Sunday, April 23, 2017   By: ADI HAR-SHOSHAN [93] 4 Stars
Thank you David .

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Sunday, April 23, 2017   By: davidr@fast.net [39] 5 Stars
All is not lost however: section a, b and c give you three ways to demonstrate toughness.

Determine that the steel is tough enough - 1 cut out the shell plate for the nozzle neck as if a repad were to be used instead of an insert plate and get this coupon tested for toughness or 2 establish the material grade from a non-destructive test and determine if the shell material is tough enough.

Another possibility is to evaluate your tank for Figure 5.2 and if you fall into the safe for use area of the curve your steel is tough enough without any other testing.

Another possibility is to evaluate the shell stress and see if it falls under 7,000 psi

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