NSPECT O N OF

HEAT 'EXCHANGERS
!, l ,
 -TABLE OF CONTENTS
Page No.
I. Module Introduction .................... 1
A. Module Objective
B. Module Description
11. Teminal Performance Objective .............. 2
111. Workbook Exercises,
. ~ x e r c i s e s. . . . . . . . . . .
,.
A. How t o u s e the Wprkbook . 3
B. Exercise-. i / l :, . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Exercise#2 ..................... 8
D. Exercise i/3 . . . . . . . . . . . . . . . . . . . . . . 10
E. Exercise i i 4 , . . . . . . . . . . . . . . . . . . . . . . . 14
F. Exercise #5 . . . . . . . . . . . . . . . . . . . . . 16
G. ~ x e r c i s k86 . . . . . . . . . .' . . . . . . . . . 26
L +

v Reference Material
..... L,c,-crence--l---S.tmdard-Cros<Baf
l c
, £19-andSupp-ort -
..
P l a t e Clearvlces' . . . . . . . . . . . . . .. 28 .,
Ref;\rence 2 - F l a t n e s s Tolerance P e r i p h e r i a l Gasket;
, .

Contact Surface . .
' . . . . 29
,

Reference 3 - Typical Anode D e t a i l s . . -.. . . . . . . . .'. . 40'

. . ...
. . '.,.
,

Reference 4 . Tube Bole Diameters and Tolerances . . . . . .

. .. .,.
31
Reference 5 - Tu>e Sheet Ligaments &d Recbmmended
HeaviCSt Tube Gages . . . . . . . . . . . . . . 32
Reference 6 - B a s i c : ~ r e s s : l r e Vessel Design Equations . . . . 33
Reference 7 - in& S h e l l T h i c h e s s . . . . . . . . . . . . 3 4 . .
Reference 8 - C h a r a c t e r i s t i c s of Tubing . . . . . . . . . . . 35
i .,

Reference 9 - I n t e r n a l Working Pressures of Tubes a t

VariousValues of Allowable S t r e s s . . . . . . 36&37
Reference 10 .B a f f l e o r Support P l a t e Thickness . . . . . .
' 38
Rdference 11 - A . Tie Rod Stmdards. . . . . . . . . . . . . 39 ' ,'
t .<

B. Eiinimum Pass P a r t i t i o n P l a t e Thickness

Including Corrosion Allowance ...... 39 I
 MODULE INTRODUCTION

Module Objective
The objective of t h i s module i s t o provide a guide f o r t h e inspector ..
i n h i s &amination of a t y p i c a l s h e l l and tube exchanger f o r d e t e r i o r a t i o n .
I n addition, a discussion on t e s t i n g i s included a s well a s the b a s i c
c a l c u l a t i o n s a s a r e required t o determine t h e r r t i r i n g thiclcness of t h e
pressure p a r t s of an exchanger. The t r a i n e e i s acquainted with t h e
Fixed Equipment Record System as i t p e r t a i n s t o heat exchangers.
Module Description
This module c o n s i s t s f i r s t of a programmed i n s t r u c t i o n presentation
prepared by the Training Division of the Howell Corporation on Heat
Exchangers as p a r t of t h e i r P i l o t Series. This presentation i s t o refresh
you on t h e b a s i c s of heat t r a n s f e r and t h e construction of a b a s i c s h e l l
and tube heat exchanger. The nomenclature of t h e assembly i s given a s well
- . - -- ------..-as-th~~functinn.~of~these~par~ts .-.-, --

(,-~e::.: The second p a r t of t h e module c o n s i s t s of a s l i d e tape presentation

i n .six segments. Segment 1 i s an introductory segmeat covering information
t h a t may be considered b a s i c f o r t h e inspection of any pressure v e s s e l .
Segment 2 is a general guide f o r t h e inspection o f , a heat exchanger on t h e
run. Segment 3 d e a l s with t h e exchanger o u t of s e r v i c e and disassembled.
I n Segment 4, pressure t e s t i n g of t h e equipment i s covered. Equations f o r
t h e c a l c u l a t i o n of the r e t i r i n g thickness of the pressure p a r t s of an
exchanger a r e covered i n Segment 5. The last segment deals with t h e
Fixed Equipment Record System a s i t applies t o heat exchangers.
Following each segment you w i l l be asked t o review the segment with
a workbook exercise designed t o reinforce your i n s t r u c t i o n .
Following each of these presentations t h e r e i s a w r i t t e n examination
covering the m a t e r i a l t h a t has been presented.
TEREIINN. PERFOREMCE OBJECTIVG - BR-EI-60.2
The purpose of t h i s module i s t o teach t h e t r a i n e e xe b a s i c concept of h e a t trans-fer, conduction
and convection, t o i d e n t i f y t h e v a r i o u s p a r t s making up h e a t exchanger and t h e i r functions.. The
t r a i n e e i s then ' i r o v i d i d with g u i d e l i n e s t o enable him ! i n s p e c t a h e a t exchanger f o r d e t e r i o r a t i o n
I
and minimal r e p a i r . ~ e s t i np'rocedures
~ a r e outlined. The s t u d e n t i s presented w i t h t h e b a s i c
e q u a t i o n s r e q u i r e d t o c a l c u l a t e r e t i r i n g t h i c k n e s s of t h eI p r e s s u r e p a r t s . The t r a z n e e is taught t h e
..1

I
minimum i n p u t requirements f o r t h e Fixed Equipment Record System and t h e system output a s i t p e r t a i n s
I
t o h e a t exchangers.
. .. I
I
CONDITIONS
..
-
PERFORMANCE CRITERION
T e s t i/l ., S e l e c t t h e dIo r r e c t answer 1 8 of 20 q u e s t i o n s *-

Given a 20-question m u l t i p l e . from t h e mudtiple choices answered i n a period

..
choice w r i t t e n e x a m i n a t i o n ' given f o r edci1 of t h e q u e s t i o n s of 20 minutes.
I
I
I
T e s t 112 S e l e c t t h e c o r r e c t answer 45 of 50 q u e s t i o n s
I
Given a 50-question m u l t i p l e : from t h e muLtiple choices answered i n a period
choice w r i t t e n examination given f o r
I
each of t h e q u e s t i o n s of 50 minutes.
N

I
 EXERCISE # 1

(QUESTIONS)
SELECT TKE CORRECT ANSWER FROM THE MULTIPLE CHOICES IN THE FOLLOWING
STATEMENTS AND U N D E ~ L N EIT... COMPLETE ALL STATEMENTS BEFORE TURNING m PAGE.

The c o n d i t i o n of equipment can only b e determined by (VISUAL INSPECTION/

RECORDED HISTORY).
The t h i c k n e s s l o s s of m e t a l over a p e r i o d of one y e a r i s c a l l e d i t s
(RATEISPEED) of c o r r o s i o n .
Corrosion-erosion accounts f o r about (20180) % of t h e exchanger
d e t e r i o r a t i o n t h a t w e experience.
When a n exchanger f o u l s we can expect an (INcREASE/DECREASE) i n p r e s s u r e +-
drop through t h e exchanger.
When a n exchanger f o u l s we can expect (REDUCED/INCREASED) h e a t t r a n s f e r . .
-~o~plete-s+_opp;rgpina-tub.e-(CBNk&-NOT) cause thermal s-
t r-
e s s e s i n-- - - - ..........
,

a tube.
When p l a c i n g an exchanger on stream t h e (HOTICOLD) f l u i d i s s t a r t e d
through t h e exchanger f i r s t .
V i b r a t i o n i n a n exchanger tube may t h i n t h e t u b e i n t h e h o l e s i n t h e
(TWE SKEET/BAFFLES).
A v e s s e l w i t h a c o r r o s i o n allowance of .125" has a c o r r o s i o n r a t e
of .005" IPY. The l i f e of t h e v e s s e l i s (15/25/50) y e a r s .
6
-
The d e s i g n t h i c k n e s s of t h e w a l l of a v e s s e l i s .365". The c o r r o s i o n
allowance t h a t must b e provided i s .125". The manufacturer c o n s t r u c t e d
t h e v e s s e l from 112" p l a t e . The t o t a l c o r r o s i o n allowance i s
(.135"/.145"/.150") .
The r e t i r i n g t h i c k n e s s of a v e s s e l (IS/IS NOT) e q u a l t o t h e d e s i g n
t h i c k n e s s of t h e v e s s e l .
The i n t e r v a l of i n s p e c t i o n of a p r e s s u r e v e s s e l i s considered a s ,:;

(ONE-HALFITWO-THIRDS) of t h e remaining l i f e of t h e v e s s e l .
-,.q
Heat Exchanger Nomenclature

TYPE DESIGNATION
 EXERCISE i'l 1

(QUESTIONS)
SELECT !fHE CORRECT ANSWER FROM TEE MULTIPLE CHOICES IN THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURh'ING TKE PAGE.

13. A chang~i n the operating conditions (CAN/CANNOT) e f f e c t the corrosion

r a t e of a vessel.
14. A change i n t h e corrosion r a t e (CAN/CANNOT) e f f e c t v e s s e l ' f i f e .
L5. Vessel l i f e (CANICANNOT) be increased by reducing t h e operating
pressure of t h e vessel.
16. An exchanger i s designed with one pass on t h e s h e l l s i d e with a remov-
able channel and s e p a r a t e cover, p u l l through type tube bundle. The
exchanger would be typed by the designation (EJT) (CFM) (Am).

(TURN TO THE FOLLOWING PAGE)

 EXERCISE i'i 1

(ANSWERS)
COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR WORK.

Visual Inspection
Rate
80%
Increase
Reduced
Can
Cold
Baffles
-25- - - ----.
- -

.135"
fs
One-Half
Can
Can
Can
16. AET
 EXERCISE # 2

(QUESTIONS)
SELECT THE CORRECT ANSWER FROM THE MULTIPLE CHOICES IN THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING TEE PAGE.

I. The exchanger gasket t h a t i f ' i t leaks cannot be observed on the run

i s called t h e gasket.
(CHANNEL COVER TO CHA.NNEL)
(CHANNEL TO STATIONARY TUBE SHEET)
(STATIONARY TUBE SHEET TO SBELL)
(SHELL COVER)
(FLOATING BEAD)
Hot exchangers (MUST/MIJST NOT) be allowed t o s l i d e on i t s cradles.
/&+-
2.
3. I f cradles a r e welded t o t h e exchanger s h e l l s , provision (MUST/MUST NOT)
be provided t o allow f o r thermal expansion.
------4;---The-aost-1-5ke1~r~p1ac~~nr-cracinanexchanger ' s h e l l to occur a r e i n
..
f~..-~: t h e (NOZZLE/SHELL) welds.
5. S h e l l b l i s t e r i n g i s o f t e n associated with (HYDROGENIOXYGEN) attack. -L.L--
6. Thickness readings on exchangers (MAY/MAY NOT) be made with t h e exchanger .
i n service.
7. It (IS/IS NOT) important t h a t thickness readings generally be made
a t t h e same l o c a t i o n on a v e s s e l .
8. The soundness of anchor b o l t s a r e generally checked fo; soundness by &?--
(HAMMER TESTTNG/RADIOGRAPHY).
9. The most l i k e l y p l a c e f o r a cooler t o externally corrode i s
(BETWEEN THE CRADLE AND THE SKELL/BETWEEN TKE INSULATION AND THE SHELL).
10: Coatings including hot and cold i n s u l a t i o n (ARE~ARENOT) to be included
i n an exchanger inspection.

(TURN TO TKE FOLLOWING PAGE)

 (ANSWERS)
COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECT

ANY ERRORS I N YOUR WORK.

1. F l o a t i n g Head
2. Must
3. Must
4, Nozzle
.5. Hydrogen
6. May
7. Is
8. Hammer T e s t i n g
9. Between t h e C r a d l e and t h e S h e l l
.,, -. -- - -
10. Are
( 2. :'
 EXERCISE i'l 3

(QUE~TIONS)
SELECT THE CORRECT ANSWER FROM THE MULTIPLE CHOICES I N THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

The c o r r o s i o n of b r a s s t u b e s h e e t s g e n e r a l l y produces a (GREENIRUST RED)

residue.
Hydrogen b l i s t e r i n g i s sometimes a s s o c i a t e d with a (PRUSSIAN BLUE/
RUSSIAN RED) discoloration..
Too much c l e a r a n c e of a b a f f l e w i t h t h e s h e l l p e r m i t s (CHfQWZINGf
TU~ULLENCE)
of t h e f l u i d w i t h i n t h e s h e l l .
The m a x i m u m recommended c l e a r a n c e recommended f o r t h e b a f f l e i n an
exchanger s h e l l 48" Z.D. is (.25OU/.225").
An exchanger handling an e r r o s i v e f l u i d on t h e s h e l l s i d e i s more
s u b j e c t t o erosion-corrosion on t h e s h e l l i n t h e v i c i n i t y of t h e
-- --
(INLET/ODTLET) n o z z l e .
C o r r o s i v e sludges are most l i k e l y t o c o r r o d e a n exchanger s h e l l .
where they (M)RM/SETTLE).
S h e l l w a l l e r r o s i o n - c o r r o s i o n i s more a p t t o occur (IN BETWEEN/
ADJACENT TO) t h e t u b e b a f f l e s .
An exchanger i n a c o o l e r s e r v i c e h a s water on t h e t u b e s i d e . The
c o r r o s i o n rate of t h e channel s e c t i o n i s most l i k e l y t o be higher
i n t h e (IN'LET/OUTLET) s i d e of t h e channel.
Where two d i s s i m u l a r m e t a l s are i n c l o s e c o n t a c t t h e (LESSfMORE)
n o b l e of t h e two m e t a l s w i l l corrode.
Regardless of t h e i r s i z e , c o n c e n t r a t i o n o r d i s t r i b u t i o n , i t (1SIT.S NOT)
necessary t h a t c o r r o s i v e p i t s b e promptly r e p a i r e d .
An exchanger s h e l l area about 24" s q u a r e i s randomly s c a r r e d w i t h
500 112" p i t s . Under t h e r u l e s such a n a r e a (WOULD~WOULDNOT) r e q u i r e
repairs.
With c r a c k s i n p l a t e s o r welds i t (IS/IS NOT) n e c e s s a r y t h a t they be
4-
gouged o u t b e f o r e rewelding.

-
( . T W TO THE FOLLOWING PAGE)
 EXERCISE $3

(qUESTIONS)
SELECT THE CORRECT ANSWER FROM THE MULTIPLE CHOICES I N THE FOLLOWING
STATEIENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

It ( I S / I S NOT) important t h a t g a s k e t s u r f a c e s be sound.

Warped gasket s u r f a c e s a r e judged u s i n g a (STRAIGHT EDGE/PLUMB BOB).
I n making i n l a y s in t h e r e p a i r of v e s s e l s h e l l s , i t (IS/IS NOT)
permissable t o u s e compatible m a t e r i a l s in l i e u of t h e same o r
e q u i v a l e n t m a t e r i a l s of t h e o r i g i n a l w a l l .
I f a compatible m a t e r i a l i s used i n an i n l a y r e p a i r t h a t has a lower
allowable s t r e s s t h e maximum a l l o w a b l e working p r e s s u r e i s (LESS/MORE).
I f a weld i s made i n t h e r e p a i r w i t h a j o i n t e f f i c i e n c y l e s s than
t h a t of t h e welds i n t h e o r i g i n a l v e s s e l t h e maximum working p r e s s u r e
- r;a-&ESS-/~131tr) ha-~hzt-of - t h ~ - - o r t g L n L ~ . e s s e l .
I n i n s p e c t i n g an exchanger a f t e r 5 y e a r s of o p e r a t i o n , t h e magnesium
anodes have l o s t about one-third of t h e i r bulk. For another 5 y e a r
r u n i t (IS/IS NOT) n e c e s s a r y t o renew t h e anodes.
Erosion on t h e t u b e s i n a t u b e bundle are l i k e l y t o occur i n t h e
a r e a a d j a c e n t t o t h e (IXLET/OUTLET) n o z z l e of t h e s h e l l .
Corrosion i n a tube bundle i s more l i k e l y t o occur where t h e
temperature i s (HIGHEST/LOWEST).
I f v i b r a t i o n occurs i n t u b e s , damage i s most l i k e l y t o occur i n t h e
(BAEFLESITUBE
SHEETS).
Erosion i n t h e i n t e r i o r of t h e t u b e s i s most l i k e l y t o occur a t
t h e tube (ENTWCESIEXITS) .
When a t u b e i s c u t lengthways f o r i n s p e c t i o n i t i s c a l l e d
(SECTIONINGIHALFING) .
Exchanger tubes unsupported i n a bundle i n excess of 36" should n o t
b e more than (1164'' / 1/8") s m a l l e r i n O.D. than t h e tube h o l e i n
t h e b a f f l e o r support p l a t e .

(TURN TO THE FOLLOWING PAGE)

 EXERCISE # 3

(QUESTIONS)
SELECT THE CORRECT ANSWER FROM THE: MULTIPLE CHOICES I N THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

25. There a;e (TWO/THREE/FOTJR)gasket s u r f a c e s t o b e i n s p e c t e d on a

t y p i c a l t u b e bundle.
26. It (IS/IS NOT) important t h a t t u b e b a f f l e s and s u p p o r t s b e s t r a i g h t e n e d .
27. E c c e n t r i c wear o r c o r r o s i o n on a t u b e w a l l (DOES/DOES NOT) have any
e f f e c t on t u b e w a l l c a l c u l a t i o n s .
28. The s t a n d a r d f i t of a 314" OD t u b e in a t u b e s h e e t i s (.760"/.758"/.768").
29. A 3" tube s h e e t t o b e d r i l l e d f o r 314" OD tubes w i t h a t u b e p i t c h of
of 15/16" has a nominal ligament width of (.090"/.122"/.178").
30. A t u b e h o l e i n t h e t u b e s h e e t must be grooved w i t h a minimum of
<ONE~TI?OjTWE)grooves.
(- 31. I n expanding t u b e s i n t h e t u b e s h e e t , i t ( I S / I S NOT) permissable t o
expand t h e t u b e beyond t h e tube s h e e t .
32. Tubes should b e expanded i n t h e s h e e t f o r a l e n g t h n o t less than
(oNE/TWO/THREE) i n c h e s o r t h e t u b e s h e e t t h i c k n e s s less 118" whichever
is less.
33. I f an exchanger is mounted v e r t i c a l l y t h e p r o t r u s i o n of t u b e beyond
t h e top s h e e t should b e (zERO/1/2 TUBE OD).
34. I n an exchanger t h a t i s t o b e mounted h o r i z o n t a l l y , t h e t u b e
p r o t r u s i o n beyond t h e t u b e s h e e t s should n o t exceed (1/2"/1/2 TLTBE OD).
35. Tube w a l l t h i c k n e s s i s g e n e r a l l y measured by s u b t r a c t i n g t h e (IDIOD)
of t h e tube from i t s (ID/OD) d i v i d i n g t h e d i f f e r e n c e by two.
36. There a r e (ONE/TWO) g a s k e t s u r f a c e s on t h e channel s e c t i o n o t h e r
than t h e n o z z l e s .
37. A h e a t exchanger i s t o b e p r o t e c t e d from g a l v a n i c c o r r o s i o n of t h e
channel s e c t i o n w i t h magnesium anodes. The channel s e c t i o n h a s an
I.D. of 30" and i s 20" deep. The channel i s p a r t i o n e d a t i t s c e n t e r
making a two-pass bundle. The t o t a l l e n g t h of 4" X 4" magnesium anodes
t o t h e n e a r e s t i n c h i s (18/20/22) i n c h e s .
(TURN TO THE FOLLOWING PAGE)
 EXERCISE # 3

(ANSWERS)
COMPARE YOUR RESPONSES ON TKE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR WORK.

Green 19. Inlet

prussian ~ l u e 20. Highest
..
Channeling 21. Baffles
.225" 22. Entrances
Inlet 23. Sectioning
Settle 24. 1/64"
Adjacent To 25. Three
Outlet 26. Is
-L-iss- -- -- -
-. ... 27 --Does-

Is Not 28. -760"

Would 29. .178"
Is 30. Two
Is 31. Is Not
S t r a i g h t Edge 32. - Two
Is 33. Zero
Less 34. 112 Tube OD
Less 35. ID-OD
Is Not . 36. Two
37. 20

(STOP)
(QUESTIONS)
SELECT THE CORRECT ANSWER FROM THE MULTIPLE CHOICES IN THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING TEE PAGE.

When t h e test medium i s i n t r o d u c e d i n t o t h e channel t h e test i s

c a l l e d a (TUBEISHELL) test.
When t h e t e s t medium i s introduced i n t o t h e s h e l l t h e t e s t i s c a l l e d
a (TUBE/SHELL) t e s t .
A p r e s s u r e v e s s e l whose normal operating p r e s s u r e i s 100 pounds p e r
s q u a r e i n c h i s t o be g i v e n a t i g h t n e s s test. The p r e s s u r e t o b e
a p p l i e d t o t h e v e s s e l i s (200/150/125) pounds p e r s q u a r e i n c h .
A p r e s s u r e v e s s e l having undergone major r e p a i r s i s t o b e given a
s t r e n g t h test. I f i t s maximum allowable p r e s s u r e i s 150 pounds
--
s q u a r e i n c h t h e t e s t p r e s s u r e t o b e applied t o t h e vessel-is
.- - --
(200/300/225) pounds p e r s q u a r e inch.
A h e a t exchanger may e x p e r i e n c e a l e a k i n (FOUR/TWO/FIVE) p l a c e s .
A t u b e test w i t h t h e s h e l l cover removed p e r m i t s us t o i d e n t i f y a
l e a k a s a (TIJBE LEAK/A ROLL LFAK ON THE STATIONARY TUBE SHEETIA FLOATING
HEAD GASKET).
A s h e l l t e s t w i t h t h e channel cover removed p e r m i t s u s t o p o s i t i v e l y
i d e n t i f y a (TUBE LEAEC/l%OATING READ GASKET LEAKlA ROLL LEAK I N THE
STATIONARY TUBE SHEETIA ROLL LEAK IN TEE FLOATING TUBE SHEET).
I n d i v i d u a l t u b e s t h a t f a i l a r e g e n e r a l l y (PLUGGED~REPUCED).
A s a g e n e r a l r u l e no more t h a n (10/15/25) p e r c e n t of t h e t u b e s i n
any one p a s s may be plugged.
When an exchanger has been @led and i s ready t o b e r e t u r n e d t o
s e r v i c e , i t is g e n e r a l l y g i v e n a tube and a s h e l l t e s t , w i t h t h e
test b e i n g g i v e n f i r s t .
(SHELL~TUBE)
 EXERCISE # 4

(ANSWERS)
. COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECT

ANY ERRORS I N YOUR WORK.

1. T u b e
2. Shell
3. 150
4. 300
5. Four
6. A F l o a t i n g Bead Gasket
7. A ~01.1L e a k i n t h e S t a t i o n a r y Tube S h e e t
8. Plugged
--- - ---- - - --- -- -- -- --- - -.
- -.
.-- - -.
-.- -- - - - -- - -----
9. 10
(-: 10. Tube
 16
EXERCISE 1!5
HEAT EXCHANGER CALCULATIONS
1. Tube Sheet ~ h i c k h e s s
a . The e f f e c t i v e t u b e s h e e t t h i c k n e s s s h a l l b e t h e t h i c k n e s s
measured a t t h e bottom of t h e p a s s p a r t i t i o n groove minus s h e l l
s i d e c o r r o s i o n allowance and c o r r o s i o n allowance on t h e tube s i d e
i n excess of t h e groove depth.
b. Applied f a c i n g s may n o t b e i n c l u d e d i n t h e minimum o r e f f e c t i v e
tube sheet thickness.
c. The t h i c k n e s s of t h e c l a d d i n g material i n i n t e g r a l l y clad p l a t e s
and cladding, d e p o s i t e d by welding may b e included i n t h e e f f e c t i v e
t u b e s h e e t t h i c k n e s s except a s l i m i t e d by t h e Code.

T = E f f e c t i v e t u b e s h e e t thickness i n i n c h e s
S = Allowable t e n s i l e stress of t h e t u b e s h e e t m a t e r i a l a t t h e design
- temperature - , I n pounds p e r s q u a r e i n c h

-
F = 1 f o r s t a t i o n a r y and f l o a t i n g t u b e s h e e t
G = Mean diameter of t h e g a s k e t a t t h e s t a t i o n a r y t u b e s h e e t i n inches

2.
P = Shell side pressure p s i
Tube s i d e p r e s s u r e p s i
Channel Covers
f whichever i s g r e a t e r

a. The e f f e c t i v e t h i c k n e s s of f l a t channel covers s h a l l be t h e thick-

n e s s measured a t t h e bottom of t h e p a s s p a r t i t i o n groove minus t u b e
s i d e c o r r o s i o n allowance i n excess of t h e groove depth. The
r e q u i r e d v a l u e s h a l l b e e i t h e r t h a t determined from t h e a p p r o p r i a t e
Code formula o r from t h e f o l l o w i n g e q u a t i o n , whichever i s g r e a t e r :

where T = E f f e c t i v e channel cover t h i c k n e s s , inches.

P = Design p r e s s u r e , p s i .
G =Mean gasket diameter, inches.
dB= Nominal b o l t diameter, i n c h e s .
%= R a d i a l d i s t a n c e between mean g a s k e t diameter and b o l t c i r c l e , i n c h e s .
A ~ =A c t u a l t o t a l c r o s s - s e c t i o n a l a r e a of b o l t s , square inches.
 E x e r c i s e a5
For g a s k e t s having compression f a c t o r s of 3.0 o r l e s s , t h e v a l u e of
"T" obtained by t h i s formula may b e reduced by 20 per c e n t .
Notes: 1. For h i g h a l l o y steels and nonferrous metals, and f o r carbon
s t e e l at temperatures o t h e r than 650°F, t h e value obtained
from t h i s formula s h a l l b e m u l t i p l i e d by (25,000, O O O / E ) ~ / ~ ,
where "E" i s t h e e l a s t i c modulus of t h e cover m a t e r i a l a t
t h e design temperature.
2. For s i n g l e p a s s channels, o r o t h e r s i n which t h e r e i s no p a s s
p a r t i t i o n g a s k e t s e a l a g a i n s t t h e channel cover, only t h e
code formula a s given below need b e considered:

--- - ------- ----.

--- lil (kl --
-,. Fig. 1
:..
When t h e head, cover, o r b l i n d f l a n g e i s a t t a c h e d by b o l t s causing a n
edge moment ( s k e t c h e s ( j ) and (k)) i n which c a s e t h e thickness s h a l l b e
c a l c u l a t e d by
t d&-
When u s i n g Formula (2), t h e t h i c k n e s s t s h a l l be c a l c u l a t e d f o r both
o p e r a t i n g c o n d i t i o n s and g a s k e t s e a t i n g , and t h e g r e a t e r of t h e two v a l u e s
s h a l l be used. For o p e r a t i n g c o n d i t i o n s , t h e v a l u e of P s h a l l b e t h e
d e s i g n p r e s s u r e , and t h e v a l u e s of S a t t h e design temperature and W from
Formula (3) of UA-49(d) s h a l l b e used. For gasket s e a t i n g , P e q u a l s z e r o ,
and t h e v a l u e s of S a t atmospheric temperature and W from Formula ( 4 ) of
UA-49(d) s h a l l b e used.
C = a f a c t o r depending upon t h e method.of attachment of head,
s h e l l dimensions, and o t h e r items ( s e e Fig. 1 ) .
P = design p r e s s u r e .
S = maximum a l l o w a b l e s t r e s s v a l u e , p s i
t = minimum r e q u i r e d t h i c k n e s s of f l a t head o r cover, e x c l u s i v e of
c o r r o s i o n allowance, i n .
E = joint efficiency
 18
E x e r c i s e #5

d = d i a m e t e r , or. s h o r t s p a n , measured as i n d i c a t e d i n F i g u r e I.
W = t o t a l b o l t l o a d , pounds g i v e n f o r c i r c u l a r heads f o r Formulas (3)
and ( 4 ) , UA-49(d), see page
hG= g a s k e t moment arm, e q u a l t o t h e r a d i a l d i s t a n c e from t h e c e n t e r
l i n e o f t h e b o l t s t o t h e l i n e of t h e g a s k e t r e a c t i o n , as shown i n
F i g u r e 1.
When t h e c o v e r - p l a t e i s grooved f o r a p e r i p h e r a l g a s k e t , as shown i n
s k e t c h ( k ) , t h e n e t c o v e r p l a t e t h i c k n e s s under t h e groove o r between t h e
groove and t h e o u t e r edge of t h e c o v e r p l a t e s h a l l b e n o t less t h a n

f o r c i r c u l a r heads and c o v e r s .

F l a n g e Design B o l t Load W
a. Operating Conditions Formula 3 - UA-49(d)
WY-Q 2 - ----- ---- -- ---- --- -. --
m
4 : :,
I-..'

\,

Formula 4 - UA-49(d)

Sa= a l l o w a b l e b o l t stress a t a t m o s p h e r i c t e m p e r a t u r e , p s i
Ab= c r o s s - s e c t i o n a l a r e a o f t h e b o l t s u s i n g t h e r o o t d i a m e t e r of t h e
t h r e a d o r least d i a m e t e r o f unthreaded p o r t i o n , i f less, i n sq. i n .
A = t o t a l r e q u i r e d c r o s s - s e c t i o n a l a r e a of b o l t s , t a k e n a s t h e g r e a t e r
m
o f & and A& sq. i n .
Aml= t o t a l c r o s s - s e c t i o n a l area o f b o l t s a t r o o t of t h r e a d o r s e c t i o n
of least d i a m e t e r under stress, r e q u i r e d f o r t h e o p e r a t i n g
c o n d i t i o n s , s q . i n . = Wd/Sb-
A = t o t a l c r o s s - s e c t i o n a l a r e a of b o l t s a t r o o t of t h r e a d o r s e c t i o n
m2
of l e a s t d i a m e t e r under stress, r e q u i r e d f o r g a s k e t s e a t i n g , s q . i n .
= Wm2/Sa.
 Exercise #5

B o l t Loads
a. For o p e r a t i n g c o n d i t i o n s - Formula 1 - UA-49(b)

G = diameter a t l o c a t i o n of gasket l o a d r e a c t i o n . Except a s n o t e d

i n Sketch 1 of Fig. UA-48, G i s d e f i n e d a s follows f o r P a r t A
f l a n g e s ( s e e Table UA-49.2) :
When bo 1 1 / 4 i n c h , G = mean d i a m e t e r of g a s k e t c o n t a c t
f a c e , i n . (m)
When bo > 114 inch, G = o u t s i d e d i a m e t e r of gasket c o n t a c t
f a c e less Zb, i n . (mm)
= mean diameter of g a s k e t , i n . (mm) f o r P a r t B f l a n g e s
P = design p r e s s u r e , p s i
b = e f f e c t i v e gasket o r joint-contact-surface s e a t i n g width, in:
bo= b a s i c g a s k e t s e a t i n g width, i n .
.*
--n =-gasket-f ac to=-oh t&n from
W = minimum r e q u i r e d b o l t load f o r t h e o p e r a t i n g c o n d i t i o n s , l b .
(- ml
For f l a n g e p a i r s used t o Eontain a t u b e s h e e t f o r a f l o a t i n g
head f o r a U-tube t y p e of h e a t exchanger, o r f o r any o t h e r
similar d e s i g n , Wml s h a l l b e t h e l a r g e r of t h e v a l u e s a s
i n d i v i d u a l l y c a l c u l a t e d f o r each f l a n g e , and t h a t v a l u e s h a l l
b e used f o r b o t h f l a n g e s .
b. For g a s k e t s e a t i n g - Formula 2 - UA-49(b)
Wd = 3.14bGy

W = minimum r e q u i r e d b o l t load f o r g a s k e t s e a t i n g , 1b (N) ( s e e

m2
UA-49 ( b ) )
b = e f f e c t i v e gasket o r joint-contact-surface s e a t i n g width, i n .
(m) ( s e e Note 1, UA-49(b) (1)).
G = d i a m e t e r a t l o c a t i o n of g a s k e t l o a d r e a c t i o n . Except as n o t e d
i n S k e t c h 1 of Fig. UA-48, G i s d e f i n e d a s follows f o r P a r t A
f l a n g e s ( s e e Table UA-49.2):
When b o 2 114 i n c h , G = mean d i a m e t e r of gasket c o n t a c t f a c e ,
-
i - in. (mm)
 Exercise a5
When bo > 114 inch, G = outside diameter of gasket contact f a c e
l e s s 2b, i n . (mm)
= mean diameter of gasket, i n . (rmn); f o r P a r t B flanges
y = gasket o r joint-contact-surface u n i t seating load, p s i ( B a )
(see Note 1, UA-49(b)).

Bolt Cross Sectional Area ~ e q u i r e d :

a. For operating conditions:

Aml = wmlfSb

Aml= t o t a l cross-sectional area of b o l t s a t r o o t of thread or section

of l e a s t diameter under s t r e s s , required f o r the operating
conditions, s q i n . (mid), = Wml/Sb

Wml= minimum required b o l t load f o r t h e operating conditions, l b . (N)

(see UA-49(b)) For flange p a i r s 'used t o contain a tube sheet f o r
a f l o a t i n g head f o r a U-tube type of heat exchanger, or f o r any
- ---
other s i m i l a r design, Wml s h a l l be t h e l a r g e r of- th--values a r
individually calculated f o r each flange, and t h a t value s h a l l be
used f o r both flanges.
S = allowable b o l t s t r e s s a t design temperature, p s i (ma) (given
b
i n Subsection C)

b. For gasket seating:

Am2 = Wm2/Sa

A = t o t a l cross-sectional a r e a of b o l t s a t root of thread or section

m2 -.
of l e a s t diameter under s t r e s s , required f o r gasket seating, s q i n .

W = minimum required b o l t load f o r gasket s e a t i n g , l b (N) (see

m2
UA-49 (b) )
Sa = allowable b o l t s t r e s s a t atmospheric temperature, p s i ( B a )
(given i n Subsection C )
 Exercise #5

EFFECTIVE GASKET WIDTH

k ' a e i t ~Skc:Ich
~ Basic Casket Scalinr D'idlh. bo
(F.xn~er~trd) Column I Column I1
(1s)
K5.n

(111)'
N
- rv
-
2 2
CiEm '5
77zT27z'
(14 10 - hZm,I w i N
'"rc7LT"'
(Id)' 2

(2)
u, + N
- -
u. + 3!\'
1/64 in. Nubbin' 4 8

-.(31,"..
- ounn. Nubllio-i- ----
3:V -
8

-
(41' 7
Ex3 3N
- -
7,v
8
,?'-txF- 16

(;I'
mi9 -
A'
4
-
3,V
8

((,I
-
W

\Vidllt. "b ''

kXfo:c:liv<~l;a$ht:l Sv:~lir~z
6 = 6,. when 6, 5 ,i n .
!
6 = 4-
+.when 6, ;> !i in.
- .
l . ~ ~ c ~ol'I;x$La.l
li~m 1 , ~ dlLa.zr:Iiot~

G NOTE: T h r ~askct
0. 0 . Contact laclors listed only
apply to llanged
joints i n which t h r
gasket i s contained
entirely within the
inncr cdgcs 01 the
bolt hole*

>ll'l1::
t I t \\lul.n. .~.ttr~t~m-
, I t , t ~ s 1 1i-xl.~~-d
I j6.t it). drl>tltirtd I!:!:!
in. widtll ipacrnc. skrtcl,c~i(ll)and
t1.11 1.1,1 13.. 1,-11.
 22
Exercise #5
I . GASICET MATERIALS AND CONTACT FACINGS1
Gasket Factors ( m ) for Operating Conditions and Minimum Design S e a t i n g Stress ( y )

Min. . Use
Gasket Design Sketches Facing
i Gasket Material Factor Seating and Sketch COtUmn
.. m Stress Notes
Y Aeler to Table UAd9.2

S e l l - E n e r ~ i z i n p ,T y p e s 0 ... ... ...

D Win s, hletallic, ~ l n s t o k or t h e r g a s k e t typcs
I -
cansigered r s sclf-sealing .

E l a s t o m e r s without f a b r i c or a high p e r c e n t a g e o l
i a s b e s t o s fiber:
: Below 7% Shore Dumme(cr
i j A o r higlter Shore Duromcler
' 0.50
1.W 200
0
€2
A s b e s t o s with a s u i t a b l e b i n d e r for
% thick 2.00 1600
,hick 2.75 3700
the operating conditions XI thick 3.50 6500
. Elastomers with.couoo f a b r i c insertion 1.25 400
0
3-ply 2.25 2200
' E l a s t o m e r s with a s b e s t o s fabric inser-
tian, with or without wire reinforce- .. . 2.50
j mcnt 2-ply 290C

SOTES:
( l ) T h i s table rrircsr list or ,n.nr rumrrtcmlyur,.d a s l p l malcrir1s;lnd cc,nln<:l faciltsq wilh
su.upcated d n i z n n l u r s o i m'rnd y tltrl Itxve rmcr311yrrrlvrd u t i r f x c l ~ min . relual awicc
when usit!:: rlfreliw cr.krt r a t i n z widtl! b eivrn in Tat,lc C,\-.l'J?. l'ltr hrsic~)rrlurs 2nd
i - .~..~..t delrils
n .
rr zivrn in tltir vdblr rrr . C U ~ C V S ~ VIIIIIY
~ m d rn: twi mandzttlry.
(2)Thc surface "i r mskcl havim r lap should not 6r strainst the nublrin.
 EXERCISE # 5

(QUESTIONS)
SELECT THE CORRECT ANSWER FROM THE M'ULTIPLE CHOICES I N THE FOLLOWING
STATEMENTS IWD UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

Heat exchangers a r e manufactured i n accordance w i t h s t a n d a r d s a s s e t

I

i
f o r t h by t h e Tubular Exchanger ~ a n u f a c t u r e r ' sAssociation. Much of
t h e design c o n s i d e r a t i o n s and c a l c u l a t i o n s a r e based upon t h e "Code", 1
t h e Code being t h e ASTM B o i l e r and P r e s s u r e Vessel Code, S e c t i o n VIII 1
'I
D i v i s i o n (112).
When w a l l t h i c k n e s s of a p r e s s u r e v e s s e l i s n o t uniform because of
unequal c o r r o s i o n l o s s , t h e w a l l t h i c k n e s s is t h a t averaged over a
d i s t a n c e e q u a l t o (one-halfftwo-thirds) of t h e v e s s e l diameter o r
(20/30/40) i n c h e s , whichever i s less.
The r e t i r i q g t h i c k n e s s of t h e s h e l l of a h e a t exchanger 48" i n
diameter, w i t h a d e s i g n p r e s s u r e of 250 p o u n d y p e r s q u a r e i n i G 5 -
f a b r i c a t e d from a s t e e l w i t h an a l l o w a b l e stress of 15,000 pounds
p e r s q u a r e i n c h and a j o i n t e f f i c i e n c y of .85 i s (.40"/.48"/.6OW).
The m i n i m u m s h e l l t h i c k n e s s permitted by t h e s t a n d a r d s f o r an
exchanger w i t h a s h e l l diameter of 48" f a b r i c a t e d of carbon s t e e l
p l a t e is (3/8"/7/16"/1/2").
The w a l l t h i c k n e s s o f a 314" OD t u b e - 14 BWG low carbon s t e e l is
(.134"/. 083"f. 049") .
I f t h e t u b e w a s made of a d m i r a l t y metal t h e w a l l t h i c k n e s s would
be (.083"/.120"/.035").
A 3/4" OD t u b e - 14 BWG, low carbon steel, has a n allowable stress
of 15,000 pounds p e r s q u a r e inch. I t s maximum allowable i n t e r n a l
working p r e s s u r e i s (3229/3643/3895) pounds per square inch.
If made bf a d m i r a l t y metal w i t h an a l l o w a b l e s t r e s s of 10,000 pounds
p e r s q u a r e i n c h t h e maximum allowable i n t e r n a l working p r e s s u r e
i s (2080/2428/2819).

(TUR.N TO THE FOLLOWING PAGE)

 EXERCISE // 5

(QUESTIONS)
SELECT THE CORRECT BNSWER FROM THE MULTIPLE CHOICES I N THE FOLLOWING
STATDIENTS AND UNDERLINE IT. COMeLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

9. The minimum p l a t e t h i c k n e s s f o r a segmental b a f f l e o r a t u b e support

spaced on 24" c e n t e r s f o r a 36" I D exchanger s h e l l i s (5/1bt'/3/8"/1/2")..
10. An exchanger o v e r 49" i n diameter r e q u i r e s a minimum o f (8/10/12) t i e rod
s p a c e r s each (3/8"/1/2") i n diameter.
11. The minimum t h i c k n e s s p e r m i t t e d i n a carbon s t e e l p a s s p a r t i t i o n
i n c l u d i n g c o r r o s i o n allowance f o r an exchanger over 24" i n diameter
i s (1/4"/3/8"/1/2").
12. The r e t i r i n g t h i c k n e s s of a carbon steel t u b e s h e e t w i t h a mean
g a s k e t diameter of 36"and o p e r a t i n g a g a i n s t 200 pounds p r e s s u r e and
w i t h a n a l l o w a b l e stress of l5,000 pounds p e r s q u a r e i n c h i s

(TIJRN TO THE FOLLOWIh'G PAGE)

 EXERCISE i/ 5

(ANSWERS)
COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO TKE ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR WORK.

I
one-half - 20"
.48"
112"
.083"
.083"
3643
2428
318"
10 - l[zf'---
- - --

1/2"
2.08"

(STOP)
 EXERCISE 6

(QUESTIONS)

SELECT CORRECT ANSWER FROM THE MULTIPLE CHOICES I N THE FOLLOWING

STATmNTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING
THE PAGE.

With r e s p e c t t o t h e Fixed Equipment Record System t h e i n s p e c t o r i s

charged w i t h t h e r e s p o n s i b i l i t y f o r t h e i n p u t d a t a of (4/6/8/10)
b a s i c documents.
The Fixed Equipment Record System i s capable of r e p o r t i n g a F r o n t
Sheet when t h e (BASIC DATA SHEET/TUBE BUNDLE DESIGN DATA~GENERAL
DESIGN DATA/SHELL DESIGN DATA) h a s been e n t e r e d by t h e i n s p e c t o r .
The computer system is s o designed t h a t it (WILLIWILL NOT) a c c e p t
r o u t i n e i n s p e c t i o n d a t a u n t i l it i s capable of reportirrg a f r o n t
check.
Once t h e r e c o r d system h a s banked t h e b a s i c d a t a t h e most important
i n p u t d a t a i s t h e (ROUTINE/SPECLAL)i n p u t of t h e i n s p e c t o r of h i s
o b s e r v a t i o n s and exchanger r e p a i r s . .
The r e c o r d system (DOES/DOES NOT) r e p o r t on Equipment Condition Report.
The r e c o r d system by bundle y a r d number and by exchanger y a r d number
r e p o r t s the.(LOCAT1ON/SERVICE FACTOR) of t h e exchanger bundle.
Thickness measurements o f t h e exchanger components ( I S / I S NOT) t h e
r e s p o n s i b i l i t y of t h e i n s p e c t o r .
Given t h e t h i c k n e s s measurements on t h e components of a h e a t exchanger
t h e r e c o r d system i s c a p a b l e of r e p o r t i n g t h e (REMAINING LIFE/
INSPECTION INTERVAL/FUTURE INSPECTION DATE).

(TURN TO THE FOLLOWLNG PAGE)

 EXERCISE 6

(ANSWERS)

COMPARE YOUR RESPONSES ON TKE PRFVIOUS PAGE TO THE ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR WORK.

8
BASIC DATA SHEET
TUBE BUNDLE DESIGN DATA
GENERAL DESIGN DATA
S E L L DESIGN DATA
WILL NOT
ROUTINE
DOES
LOCATION
IS
- ~ ~ N I N G - ~ ~ - ~ ~ ~ p E C ~ I O i 31"JTDPt---I?:SPECT-IQh!
-~p~RV& DATE
 REFERENCE NO. 1

STANDARD CROSS BAFFLE AND SUPPORT PLATE CLEARANCES

8". 13" lnc. 0.100"

14" - 17" lnc. 0.125"
18" - 23:: Inc. 0.150"
24"-39. Inc. 0.175"
10" .54" lnc. 0.225"
55" and over 0.300"
 REFERFNCE NO. 2

FLATNESS TOLERANCE
PERIPHERAZ. GASKET CONTACT SURFACES

.A. For s p e c i a l applications such a s high pressure, high temperature,

or hydrogen s e r v i c e , the f o l l m i n g requirements s h a l l be met when
s p e c i f i e d by t h e purchaser:
Exchanger Nominal f. Talerance
Diameter, i n inches i n inches

1 5 and l e s s .003
Over L5 t o 30 .006
Over 30 t o 45 .009
Over 45 .OX2

Note: Measurements s h a l l be made with a d i a l i n d i c a t o r .

 REFERENCE NO. 3
57UD f, UCX NIIT, >/O'OSTUD~$HZX NI11 L,OCK. VJk5ULr
\

D . F.-
_-.'-~- -.
A. I L - - A . D E T A I L--B-
- ANODE ~ti:'cisiIRON CHANNEL.
ANODE I N STCEL C H A N N E L

yd 5 T U D ( H E X NUT

.-~/A'FIPE CA5T I N
I. W H C K L P0551BLL A N D D L S ' 3 U A L L
BE, 4 ' X d ' X d :
i MkGNL91UM ANODE ALTLRNCilE ANODE 512E 15 4 ' ~ 4 ' %2
'
j UIGU.
I 2. EDGE. OF A N O D E S M A L L BL A MINIMUM
OF 3'FROM T U B E S H E E T .
~ ' ~ < S U E E TKURIXR OR
3. To det;er~ni!?r t o t a l l e n g t h "L" Of
a l l 4 r 4 MZEnesiurn anodes u h c r e
,3
A ,, i s t t l c s u r f a c e a r e % of the
c h a n n e l box i n t e r i o r , i n c l u d i n g
b o t h s i d e s of t h e p l a t e :
A (Sq2;'in.
L (inches) =
'9/a9 METAL WA4UER 187
!
 Reference No. 4

-TUBE HOLE D!A!CIUERS .fi.F!D-?OLERAF!CES

NomlnJl Tube Hole Dmnxclcr

Ncmlnal
and UnderTolerance-.lncllcr' -
: over Talerancc.lnchc~ (96'; 61
~ ~ meet vslce sn
h o l must
Tvbc S!andard Fit Spcctal Clorc Ftt colunln (cl. Rem38ndcr mas not -
O.D. (a) lbl excccd value in czlumn (dl.)
In:hc$ Eloa8n;ll Undcr Namtnal Undcr
Dtameter Tolerance D#ln,ctcr TOICC~~CC (cl (d)
0.760 .- ' 0.00: 0.758 0.032 0.032 0.OlG-
1.012 0.004 1.010 0.002 0.002 0.010
1 55 1.264 0.006 1.261 0.003 0.003 0.010
1% 1.518 0.007 1.514 0.003 .o.cm . 0.010
2 2.022 0.007 2.018 0.003 O.C?3 0.010
 REFERENCE No. 51

TARLE OF TUBESHEET LIGAMENTS AND RECOM{Y~ENOEDHEAVIEST T"BE GAGES

(All Dirnenslons in Inches)
1 '
tlcav$esl
RCC~III. I
Minlntum Sld. Lt~amenl5 hlini,rtaa?
~ ~ , (965k ~ of
l l l~
g ~ m~c n l must
ll equal or crcccd v ~ l u c sIabelnlcd below)
TuI~E
Dia.
Tube
Pilcll -P
p-d.
tncndcd
Tube
OJRE
$'h
std,
Lifiamcnt
Wldlll I r ~ l l e s h e e lT l % i ~ k ! ~ e ~ s
pEtmir.
siblo
Ll~alllcnl
P do

1
de

I I
0.W.G. 'I' 1 3 4 5 6 Wldll,
2 2
314 15/1G 2 3/16 I3 0.760 0.178 ,144 .142' .I39 ,137 ,135 ,131 127 ,122 .090
I 1.33 114 I2 02rlO ,206 ,204 .201 ,199 ,197 .I93 .I89 .l8.1 ,120
1.Il16 1.42 51IG I2 0.302 .ZGQ .2G6 ,263 ,261 .259 ,295 ,251 ,246 ,150
1.1/8 1.50 3/8 12 0.365 ,331 3 z 9 1 ,326 ,324 322 ,318 314 309 ,185

I :;kfi6
1.318 1.38
6:!;
3/8
'"" :0.363
% 1%
.UO
,203,
,265
,328
,202
,264
227
:%
,329
:%
923
:%
,320
:%
,317
:%
,314
, :;;1
.I85

I.1/4 1-9/16 1.29 5/16 1.264 0.298 - ,264 ,263 ,262 ,260 ,258 ,255 ,253 ,150

1.112 1,718 1.25 318 1.518 0.357 - ,324 ,323 ,322 ,321 ,318 ,316 ,314 ,180
2 2.112 1.25 I12 2.022 0.478 - - ,445 ,444 443 .442 ,480 ,438 ,250
l s based on a llgan'ont talortnco no1 cxcosdlng tho sun, o f twlce the drltl d r l l l
14oTES: 7hn abouc l ~ b l cof minimum slundard l l ~ a m ~ n Is
lalcrmcc plus 0.030 Inchrs.
t3illl DIlft Tolcrunso t 0.0016 X Cfhlskncss of T u b ~ r h o c lIn Tube Dlam.[nrs) Inches.
 ~.
. . . . . .. . . . . . .. . . . . . L $ ~ J $ ~ I ] I ~ L L ~ $. . . . . . ., ....... :. . ";..:. ..
...
. . .. hw.J 'wa.&by .c{~@cl
............. .. . . . . . -
lJ~lui2j~~;& w a K & ....... ..;:,; ;'. +:'::. .
. . . . . --.
. .
'...I --
>ur~T10'. L = ltt&Jc crow^ r:t<Iitts. i ! l c i l c ~ ~ I( = lnsidc n t l i u r . i n c h c r +
= 1 11 okonc. I I,<=Y i l C ~~O I L * ~m~ i . c h i I aY t s i d c radius. inches

/ n = kjbitlo <ib~t:~c~e:.inclws*
n.,= O u ~ s h l cdi;l~nclur. i ~ c l i c s
,!=
I F:tutor..cc lahlc b e l o w
f = LX.sirt_n(~rr.rsttreo r ttmxiinuts
s = Strcss value of rnztcrial, psi.
r = T l ~ i c b l c o inci~u
,
nt'\vcIJr.d ininrs n l l c ~ ~~rrusnlru.
l ~ l ~ psi~. . ~ c n c . t c 1.

I n T n n ~ ~ OISSIDE
l Rlllbular llumnrr In Tern,.Of OUTSIDE Kldlvror Dc~mnrr
i

CI.LISDHlCALSI1ELL rurrnuh f c ~ Lundtudtnrt'*ai..ns [ 0'LIXI)ItICAL SHELL . formula%tor bqitudinal S u m

SPHERE
p=- I
Ri0.21
I SPHERE
Mf p=- 2SEr
R.-0.8I
HEYISPHERIC.<L HEAD IIELIISI'IIERICAL HEAD
.. -

Rl
I'D PD.
...:<:. .>.. I=
2SE-0.2 I = ZSE+ 1.8 P .
I

P=- 2SEr P= 2SEl

0+0.2t D,- 1.8 I
::I ELLIPSOIDIL HEAD 1:1 ELLIPSOIDAL & A D

/ '
!
'=2 cos
I'D
cr ( S E - 0 . 6 P )
, r= PD..
2 cos a (SE+0.4P)
'
P=
ZSEr c o s s i -, P=
2SEr cos a
'I
* D+1.21cosn D,-0.81 cos n
I OSE II. COSICAL SECTIOS 0 wximvm = 30 dm.

PLM
r.
... I PLM
'=ZSE-O.~P 2SE+P(M-0.2)

P=
ZTEI
P=
2.m
~nr+O.Zt ML.-I(M-0.2)
FLAN(;EIl X l l l S l l E l l IIEAD
i('lOHlL.8.r.l 7.0 IJ 8.0 h . 911 YJ IO.IUI 111.5 11.11 11s 11.00 IJ.O I . 1S.O t6.a 16.6
I \I 1.. IX 1.31 21. I.rr. I.rr I.rn I.S> 1.w 156 I . 1.1: 1.61 1.69 1.7: 1.15 1.17 j
VALUES OF FACTOR 1: I
(Use N e a r e s t Value of D/Zk I n t e r p o l a t i o n Unnecessary)
 REFERENCE NO. 7,

MINIMUM SHELL THICKNESS

(All Dimensions in Inches)
. .

Minimum Thickness

Nominal Shell Carbon Stael ?

~lioy
Diameter

8.12 Sclr. 50 - 116

-
13 29
-
3/2 3/2 3/16
-
30 39
- 7/16 1/5
..
-
40 60 1 /2 5/16

I I I I I
? Sclledule SS permissible for 8 inches shell diameter.
REFERENCE No. 8

.. .. . .
CHARACTERISTICS OF TUBING
 REFERENCE No. 9

INTERNAL WORKING PRESSURES (PSI)

OF TUBES AT VARIOUS VALUE5 OF ALLOWABLE STRESS

P R E S S U R E 1
 REFERENCE NO. 9

INTERNAL VJ0Rt:ING PRESSURES (PSI)

01: TUBES AT V A R l 3 U S VALUES O F ALLOWABLE STRESS

Tube
G18c
BWG
 REFERENCE NO. 10

BAFFLE OR SUPPORT PLATE THICKNESS

I Plate Thickness-Inches

Dislance belv,een adiaccnt segmental plates

Nominal '
.or I,$ distance between full supports
Shell
I.D.
12" Over 12" Over 18" Over 2:"
end to to to Over
Under 18" Inc. 24" Inc. 30" lnc. 30"
-.
.
6 " 14" lnc. 118 3/16 114 318 31a
15". 23" Inc. 3/16 114 316 1 12
29.' .38" Inc. 1 114 5/16 318 318
112 5/E
- 39!Lrnd-nrer/ A / 3 / i ,-... >/L
 REFERENCE'NO. 11

TIE ROD STANDARDS

(All Dimensions in inches)

Nominal Minimum
Shell Tie Rod Numberof
- Diameter Diameter Tie Rods
8-15 3/s 4
16-27 6
-
28 33
34 - t18
'h 6
8
lh
49 - 6 0 Ih 10

MINIMUM PASS PARTITION PLATE THICKNESS

(All Dimensions in inches)

Nominal Size Carbon Steel Alloy Material

-
Less than 24 3/8 :A
24 to 6 0 'h %
 MDDULE BR-EI- 60.2

INSPECTION OF H~KJ! MCtJANGERS

SLIDE-TAPE SCXPT

August, 1978

REVISION AFPER REVIEW

P r o p e r t y of E m o n Company, U.S.A.
Not To Be Copied

P r e p a r e d by: 3 . H. Wood
BR-EI-60.2
i
L ,
 MODULE BR-EI-60 - 2
INSPECTION OF HEAT EXCHANGERS
SLIDE-TAPE SCEPT

SEGMENT 1

1-1. ' BLANK

(Music - Hold S l i d e 3 Seconds)

(Music Continues - Hold S l i d e 3 Seconds)

(Music Continues - Hold S l i d e 3 Seconds)

(Music Fades & Out) Welcome t o our Module on the inspection of

tubular h e a t exchangers, one of t h e most common pieces of equipment
making up a r e f i n e r y . It is a l s o one of t h e simplest i n i t s assembly
and operation ...
For a l l of t h e i r s i m p l i c i t y , heat exchangers a r e tricky. They must
c-L
-be :---,-
L W , , +L L ~ d - ~ . ~ e ~ , ~ - ~ z r e f nr-el
~ L L ys-ou-better-w-cc-t t o be embar-
rassed frequently ...
In t h i s segment we want t o cover a few inspection basics t h a t not
only apply t o heat exchangers b u t a r e applicable t o other equipment
a s well.

Inspections a r e f o r t h e s e reasons: One: We want t o determine the

physical condition of t h e equipment - that i s , t h e extent of
deterioration - i f any . ..
Two: We want t o determine t h e r a t e a t which our equipment i s
deteriorating . '. .
Three: We want t o determine the cause of the d e t e r i o r a t i o n . ..
With t h i s d a t a , measures may be taken to: One: To recommend t h e
e x t e n t and methods of r e p a i r s as a r e required - now!
Two: Plan f u t u r e r e p a i r s o r replacements.

Three: To determine t h e cause of t h e d e t e r i o r a t i o n and t o r e c m e n d

steps to stop further deterioration - or a t l e a s t t o slow i t down.
~ r e ~ b e n t lay m a t e r i a l o r design change w i l l f i l l the b i l l .
Four: Avoid mscheduled shutdowns by f o r e c a s t i n g t h e f u t u r e .

Remember t h a t w i t h i n t h e exchanger s h e l l , a l l s u r f a c e s a r e being

a t t a c k e d by t h e f l u i d s p a s s i n g through them. D e t e r i o r a t i o n under
t h e s e circumstances i s caused by c o r r o s i o n , e i t h e r chemical o r
electrochemical ...
O r by impingement with subsequent e r o s i o n o r a combination of both
e r o s i o n and c o r r o s i o n ...
This t y p e of d e t e r i o r a t i o n may b e a c c e l e r a t e d by . . . a rice i n
temperature . . , s t r e s s . . , f a t i g u e . . , or velocity.
Corrosim-erosion accounts f o r about 80% of t h e exchanger d e t e r i o r a -
t i o n t h a t w e experience ...
Mechanical d e t e r i o r a t i o n - i n addition t o corrosion - also contributes
t o exchanger f a i l u r e .

The most common t y p e of mechanical d e t e r i o r a t i o n i s f o u l i n g which

reduces t h e h e a t t r a n s f e r r a t e Zid .Y . ---

I n c r e a s e s t h e p r e s s u r e drop. This r e s u l t s i n a reduced flow r a t e

i n t h e system.

Complete stoppage i n a f o u l e d t u b e can cause thermal s t r e s s e s and

s t r a i n s which may l e a d t o l e a k i n g tube r o l l s and cracked tubes.

F a i l u r e s caused by mechanical d e t e r i o r a t i o n a l s o i n c l u d e l e a k
i n t h e s h e l l due t o f a u l t y welds, u n r e l i e v e d stress concentrations,
i n s u f f i c i e n t reinforcement of openings and thermal stresses at
p a r t i t i o n s i n channels and s h e l l covers.

An example of a problem due t o improper o p e r a t i o n i s t h e i n t r o d u c t i o n

of a very h o t f l u i d i n a c o l d exchanger o r c o l d f l u i d i n a h o t
exchanger without gradual warmup. This can loosen t h e tube r o l l s
i n t h e tube s h e e t causing leaks.

Tubes a r e s u b j e c t t o c u t t i n g o r t h i m i n g ' w h e n r o t a t i n g tube c l e a n e r s

a r e used.

Thin w a l l tubes may c o l l a p s e if c o n s i d e r a b l e d i f f e r e n t i a l p r e s s u r e

e x i s t s between t h e i n s i d e and o u t s i d e of t h e tube.
Binding of t h e bundle within t h e s h e l l may produce buckling of the
tubes i n t h e exchanger bundle.

Vibration i n some of t h e tubes produces a l l kinds of damage - from

b a f f l e c u t s , t o f a t i g u e cracks, t o corrosion f a t i g u e .

Last on our l i s t - but c e r t a i n l y not l e a s t - i s mechanical damage

i n handling the bundle. A,misapplied sLing can collapse a number
of tubes a s i s shown h e r e or c u t through a s i n g l e tube as e a s i l y as
an abrasive saw.

The very a c t of p u l l i n g and r e i n s t a l l i n g a tube bundle i s damaging

by t h e very pature of t h e procedure.

The frequency with which a heat exchanger should be inspected

depends upon t h e r a t e a t which t h e v e s s e l is d e t e r i o r a t i n g o r
corroding. I n other words, what i s t h e metal l o s s ? And What i s
t h e n a t u r e of the l o s s - i s i t general or i s i t p i t t i n g ?
-
This r a t e i s generally measured i n mils per year, a b b r e v i a t r f i - l . F Z ~

The remaining l i f e of a v e s s e l i s i t s measured thickness minus i t s

. ..
r e t i r i n g thiclmess divided by t h e r a t e of corrosion. The r e t i r i n g
thickness i s a l s o c a l l e d t h e calculated minimum thickness.

The minimum thickness of a v e s s e l i s determined f i r s t by t h e thick-

ness needed t o withstand the pressure to which the v e s s e l is
subjected, o r t h a t necessary f o r s t r u c t u r a l strength.

To t h i s thickness i s added a corrosion allowance, CA.

There may he y e t another thickness t h a t must be considered. This

thickness, l e t ' s c a l l i t lagniappe, i s the difference between the
nominal thickness of t h e p l a t e used i n t h e fabricat?& of a v e s s e l
l e s s t h e calculated thickness and t h e corrosion allowance. This
thickness is surplus and may be used f o r additional corrosion
allowance.
(-
1-36. O r t h e surplus thickness may be used a s additional s t r e n g t h f o r
more severe design considerations or f o r nozzle reinforcement.
Under these conditions our lagniappe i s considered t o be on t h e
outside.

1-37. Thus, t h e t o t a l thickness of a w a l l consists of t h e calculated

thickness plus a corrosion allowance plus lagniappe.

1-38. When metal l o s s occurs t o t h e extent t h a t a l l t h a t i s l e f t i s t h e

minimum calculated thickness, then we have reached what i s called
the r e t i r i n g l i m i t and c o r r e c t i v e a c t i o n i s required.

1-39. The time i t takes t o l o s e t h e corrosion allowance and t h e lagniappe

i s c a l l e d t h e remaining L i f e of t h e vessel.

1-40. The amount of metal t h a t i s l o s t every year i n t h e v e s s e l w a l l s

is c a l l e d the corrosion r a t e and i s measured i n mils per year o r
MPY .
--
1-41. The remaining l i f e of a veEZl can then be CdLculated-by-subtractingL-

C t h e r e t i r i n g thickness from t h e b c t u a l thickness and by dividing

this quantity by t h e corrosion r a t e .

1-42. The corrosion r a t e on o l d equipment i s determined from i t s s e r v i c e

h i s t o r y record compiled by the inspector over t h e l i f e of t h e
equipment.

1-43. On new equipment the r a t e of corrosion i s established as follows:

1-44. The inspector may e s t a b l i s h a corrosion r a t e based on accurate

data t h a t has been c o l l e c t e d on equipment i n t h e same o r similar1
service. This i s t h e p r e f e r r e d method.

1-45. Not having t h i s data, t h e inspector may e s t a b l i s h t h e corrosion r a t e

as estimated from his own knowledge and experience with v e s s e l s i n
s i m i l a r service..

1-46. A s a l a s t r e s o r t , on-stream thickness readings should be made a f t e r

about one y e a r ' s operation continuing a t s i m i l a r i n t e r v a l s u n t i l a
corrosion r a t e has been e s t a b l i s h e d .

i
Having determined the remaining l i f e of a v e s s e l t h e i n t e r v a l of
inspection i s generally established a s one-haif of the remaining
life - not t o exceed ten years o r o t h e r l e g a l requirements - which-
ever i s l e s s .

When t h e r e m i n i n g l i f e i s l e s s than four y e a r s , t h e inspection

i n t e r v a l may be t h e f u l l remaining s a f e operating l i f e up t o a
m a x i m u m of two years.

Keep i n mind t h a t a change i n operating conditions may produce a

change i n t h e corrosion r a t e . The inspector must be a l e r t t o these
changes tempering h i s judgement t o conditions, and a l t e r i n g inspec-
t i o n i n t e r v a l s a s a r e appropriate.

With exchangers, t h e frequency of inspection may w e l l be t h a t as

determiqed by t h e frequency with which t h e exchanger f o u l s or gaskets
leak.
-
T l ~ T i T p e c r o rmwirlmvi;-& t l t r r ; o g 5 . - 1 ~ - ~ . ? l e d g ~ - o L t h eeauipment
. he
inspects - from t h e i n s i d e out, including flow p a t t e r n s within t h e
equipment.

The i n s p e c t o r by h i s observational s k i l l s and measurement must be

a l e r t t o any deviation - any change from normal.

The i n s p e c t o r m u s t be a b l e t o describe t h i s deviation i n d e t a i l

and record t h i s i n f o r m a t i o n on t h e condition s h e e t f o r t h a t p a r t i c u l a r
p i e c e of equipment.

The i n s p e c t o r w i l l frequently be asked t o help determine the cause

of any such deviation.

The i n s p e c t o r w i l l frequently be asked to help i n t h e s o l u t i o n to

problems.

The inspect0r.i.s t h e h i s t o r i a n and t h e navigator. H i s records t e l l

you where you have been, where you a r e , where you're going and when
you're going t o g e t there.

The i n s p e c t o r ' s e f f o r t s pay off i n maximum continuity of equipment

operation and s a f e u n i t performance.
. r 1-58. E f f i c i e n t operations a r e the bonus.

1-59. Our next segment covers on-stream inspection of s h e l l and tube

equipment. But f i r s t open your workbook t o Exercise 1 and answer
t h e questions there.

SECXEXT 2

2-1. In this segment of the module w e ' l l cover t h e d e t a i l s of an on-

stream inspection. There i s no p a r t i c u l a r order of inspection but -
2-2. Any leaks - such as the "Smokers" you s e e here - can draw a l o t of
attention. t y p i c a l exchanger has f i v e gaskets - a leak i n four
of them w i l l normally be v i s i b l e .

2-3. The four which may be v i s i b l e a r e : One: t h e channel cover gasket;

Two: t h e channel to s t a t i o n a r y tube sheet gasket; Three: the
s t a t i o n a r y tube sheet t o s h e l l gasket; and Four: t h e s h e l l cover
gasket-.-- --

C 2-4. Now l e t ' s t a l k about foundations . . . Typical foundations usually

c o n s i s t of s t e e l cradles on concrete p i e r s . Visually check the
concrete p i e r s from time t o time f o r cracks, s p a l l i n g , and general
deterioration.. Check f o r evidence of settlement and unusual
distortion. Note the crack i n t h e concrete of t h i s foundation.

2-5. Carefully check t h e crevice formed between t h e exchanger s h e l l and

the c r a d l e support. Moisture trapped here can cause rapid attack
on carbon s t e e l s h e l l s .

2-6. I f t h e cradles a r e s e a l welded t o t h e s h e l l , i n s u r e t h a t on one end

t h e c r a d l e b o l t i n g i s not too t i g h t and t h a t t h e b o l t holes a r e
s l o t t e d t o provide f o r thermal expansion and contraction of the
exchanger. Normally t h i s f e a t u r e i s provided i n t h e f l o a t i n g head
end support.

2-7. Anchor b o l t s should be tapped f o r soundness. Freedom of movement of

the sliding-end support i s important. Bolts a t t h i s location should
be loose t o permit movement of t h e cradle.
Visually c h e c k t h e piping connections f o r external corrosion, signs
of pipe s t r a i n and evidence of leakage.

Look f o r evidence of leaks around nozzle connections. Suspicious

a r e a s may require a closer examination when t h e u n i t i s out of
service. Sandblasting the a r e a followed by magnetic p a r t i c l e o r dye
penetrant methods can then be used t o v e r i f y a v i s u a l examination.

Such a u x i l i a l y equipment with which an exchanger may be equipped

should be checked f o r s a f e t y . This includes pressure gages, tempera-
t u r e i n d i c a t o r s , s i g h t g l a s s e s and s o f o r t h . Undue vibration of
these p a r t s may be i n d i c a t i v e of trouble within.

Check t h e condition of e x t e r n a l coatings. Rust s p o t s , b l i s t e r s , and

f i l m l i f t i n g a r e the most common f a i l u r e s observed.

Rydrogen b l i s t e r s may sometimes be found during an external v i s u a l

inspection i f t h e v e s s e l i s not insulated. T h i s is a piece of p l a t e
-whichwas-rzoved from a v e s s e l showing t h e e f f e c t s of hydrogen
blistering .
I n s u l a t i o n on exchangers should be inspected t o determine i f i t i s
still intact. Areas around nozzles a r e l i k e l y p o i n t s of i n s u l a t i o n
failure.

Check t h e i n s u l a t i o n vapor b a r r i e r on cold u n i t s .

And waterproofing on hot u n i t s . I f t h i s has f a i l e d i t may be

d e s i r a b l e t o remove sample blocks of i n s u l a t i o n and inspect t h e s h e l l .
Atmospheric corrosion under t h e i n s u l a t i o n can cause thinning of the
shell.

And on exchangers t h a t have a tendency t o f o u l , many inspectors

follow t h e change i n heat t r a n s f e r effectiveness by f e e l i n g t h e i n l e t
and o u t l e t l i n e s of both t h e s h e l l and tube s i d e s .

Thickness readings with non-destructive instruments of the various

exchanger components may be made a t your d i s c r e t i o n .

Remember t h a t thickness measurements on a p a r t i c u l a r piece of equip-

ment a r e generally made a t t h e same place each time the measurement
i s made. When t h i s i s done, t h e measurements a r e comparative.
r 2-19. This information should be made a v a i l a b l e to you from t h e h i s t o r i c a l
record of the equipment.

2-20. Now open your workbook t o Exercise 2 and answer the questions there.
(10 Second Pause - Advance)

2-21. ( 3 Second - Stop Pulse)

SEGMENT 3

3-1. I n t h i s segment of t h e module, w e ' l l cover t h e d e t a i l e d inspection

procedures f o r an out-of-service heat exchanger which has had i t s
bundle removed from the s h e l l . Under these conditions t h e r e i s
l i t t l e t h a t can't be closely examined ...
3-2. Inspection should begin as the bundle i s being pulled. The color,
type, amount, and l o c a t i o n of t h e s c a l e and deposits may t e l l a
- s t o r y of corrosion.
-
3 - - 3 7 F o r - i n s t a n c e ~ a - ~ e a ~ 1 a - c " ooz-dcpor;it-cr?-c1pper-hased_materia1~~~
l~

c- l i k e t h i s tube sheet t e l l s us corrosion i s taking place.

t i v e Prussian blue color on a bundle may suggest a ferri-ferrocyanide
Distinc-

compound associated with hydrogen b l i s t e r i n g .

3-4. An o v e r a l l heavy s c a l e buildup of s t e e l tube sheets or tubes i s an

i n d i c a t i o n of general corrosion.

3-5. The lack of any s c a l e o r deposit on tubes near t h e s h e l l i n l e t i s

also significant. It may i n d i c a t e an erosion problem.

3-6. And observe the clearance between t h e b a f f l e s and t h e s h e l l . Too

much clearance permits channeling of the f l u i d through t h e s h e l l ,
decreasing the turbulence of the flow and reducing the heat t r a n s f e r
e f f i c i e n c y of t h e exchanger. Reference 1 i n your workbook tabulates
these clearances based on the exchanger s h e l l i n s i d e diameter.

3-7. With the bundle removed, a degree of cleaning may be i n order prior
t o any inspection of t h e s h e l l . I n most cases hosing t h e p a r t s
down w i l l be a l l the cleaning needed ...
A t other times a scraper or a wire brush can be used t o clean small
areas where a b r i g h t metal s u r f a c e i s not required.

When cracking i s suspected, sandblasting o r other methods of cleaning

may be necessary so t h a t the p a r t can be magnetic p a r t i c l e or dye
penetrant inspected.

Under most s e n r i c e conditions t h e r e a r e s p e c i f i c areas of t h e s h e l l

t h a t a r e most susceptable to trouble. One area i s t h e s h e l l wall a t
t h e i n l e t nozzle due t o the turbulence on t h e tube bundle impingement
baffle.

Also look f o r t h e corrosion-erosion e f f e c t on t h e s h e l l wall a t t h e

locations of t h e tube bundle b a f f l e s .

Check t h e s h e l l in t h e a r e a of t h e tube sheets c a r e f u l l y .

Where t h e r e i s sludge settlement i n t h e exchanger i t accumulates on

t h e bottom. If t h i s sludge contains a corrodent, '.then you may
expect t h e ~ ~ . - c o r r o s i u r r t o - o c c i ; i - ~ ~ n g - t h e - b b + - t ~ m - o L t h e ~ s h e ~ ~
and the bottom tubes i n t h e bundle.

I n water s e r v i c e t h e maximum corrosion w i l l occur where the water

temperature i s h o t t e s t . I f t h e water i s on t h e tube s i d e , maximum
corrosion w i l l occur on t h e o u t l e t s i d e of t h e channel.

Corrosion may occur where d i s s i m i l a r metals a r e i n c l o s e contact.

The l e s s noble of t h e two metals w i l l corrode. Thus we often f i n d
corrosion occurring a t an accelerated r a t e on t h e carbon s t e e l
gasket surfaces adjacent t o b r a s s tube sheets.

Cracks a r e post l i k e l y t o he found near welded seams, where high

s t r e s s e s may be applied. Any nozzle -
o r s h e l l f l a n g e i s s u s c e p t i b l e t o cracks.

With these guidelines i n mind, t h e f i r s t s t e p i n the inspection of

the exchanger s h e l l , channel and s h e l l cover should be a general
v i s u a l inspection of these surfaces f o r p i t s , cracks and grooves.
Look t o the welds. This is where trouble generally begins.
Widely s c a t t e r e d p i t s may be ignored provided t h a t ...
One: The p i t depth is no more than one-half of t h e n e t thiclcness
of t h e v e s s e l wall exclusive of t h e corrosion allowance.

Two: The t o t a l a r e a of p i t s may not exceed seven square inches

within any eight inch diameter c i r c l e .

Three: The sum of t h e i r dimensions along any s t r a i g h t l i n e within

t h e c i r c l e does n o t exceed two inches.

Where p i t t i n g cannot be ignored, i t i s customary t o s t r i p l i n e the

p i t t e d a r e a as i s shown here or i n some cases t o clean the p i t s t o
s o k d metal and f i l l them with weld metal.

Where cracks a r e suspected, v i s u a l examination i s backed up with

penetrant-dye or magnetic p a r t i c l e inspection methods a f t e r thorough
cleaning of t h e suspect area.

Repairs to.cracks i n welds and defects i n p l a t e s a r e generally made

-hycouging the-defect t o i t s f u l l depth and length w i t h a 'U' or
--
'V' shaped groove. As with p i t s , the groove is f i l l e d with weld
metal.

A l l gasket s e a t s must b e v i s u a l l y checked. T h i s includes a l l nozzle

flanges, t h e s h e l l flanges, and those of t h e channel and s h e l l cover.
These surfaces must be of s u f f i c i e n t width i f t h e gasket i s t o s e a l .

Inspect t h e s e a t f i n i s h . Soft gaskets such a s asbestos r e q u i r e a

phonographic f i n i s h , a s you s e e here ...
Whereas a s e a t t h a t is t o take a metal gasket requires a polished
finish. Note t h e deEect i n t h e gasket surface a t t h e lower l e f t .
Depending on where the gasket s e a t s , i t may be cause f o r r e j e c t i o n
of t h i s machining job.

Be watchful of these r a i s e d surfaces on flanged faces. These a r e

c a l l e d nubbins.

And be mindful t h a t i n the i n s t a l l a t i o n of clad gaskets where

nubbins a r e machined i n t h e gasket faces, t h e nubbin must s e a t on
the f l a t s i d e of t h e gasket. The crimped s i d e of t h e gasket s e a t s
on t h e f l a t f a c e of t h e mating flange ...
Where warpage of gasket surfaces is suspected, a s t r a i g h t edge should
be used t o check f l a t n e s s and uniformity. The f l a t n e s s tolerance on
a peripheral gasket contact surface s h a l l not exceed If: 1/32". For
s p e c i a l applications t h i s tolerance i s much l e s s .

Reference 2 i n your workbook covers these tolerances f o r s p e c i a l

applications.

It may be necessary t o shop these p a r t s f o r r e p a i r of the faces.

Corroded f l a n g e faces a r e b e s t repaired by cleaning up the face,
building i t up with weld metal and then machining it t o i t s o r i g i n a l
thickness.

Look f o r s u r f a c e i r r e g u l a r i t i e s i n t h e s h e l l such as bulges, buckles,

and hydrogen b l i s t e r s . A long s t r a i g h t edge placed on t h e surface
may prove useful i n determining t h e extent of such defects.

Check t h e s h e l l next t o t h e impingement b a f f l e f o r erosion.

-. --,-- ,--.-
You may a l s o r m d erosion-arid-eorrosio~ occur~:ng-on-the-sh~Al -

adjacent t o t h e bundle b a f f l e s . Frequently this shows up a s a

s e r i e s of r e g u l a r spaced r i n g s when a f l a s h l i g h t beam i s shown
p a r a l l e l t o t h e s h e l l s u r f a c e or when there i s strong n a t u r a l l i g h t
as t h e r e i s here.

Occasionally patching a v e s s e l by welding an i n l a y i n t h e , w a l l s may

be required.

Where l a r g e r areas must be repaired, t h e replacement of a s h e l l

s e c t i o n i s t h e preferred method of repair.
Preferably the replacement m a t e r i a l should be equivalent to t h e
m a t e r i a l of t h e o r i g i n a l wall.

Other compatible m a t e r i a l s may b e used. However, i f the material

has a lower allowable s t r e s s , t h e maximum permissible operating
pres'sure must be r e c a l c u l a t e d based on the allowable s t r e s s e s
permitted f o r the patch.

J o i n t e f f i c i e n c i e s must be as high as t h e j o i n t e f f i c i e n c i e s i n the

o r i g i n a l v e s s e l i f t h e patch i s t o be i n l a i d i n a vessel with
welded longitudinal j o i n t s .
J o i n t s with lower e f f i c i e n c i e s may be i n s t a l l e d provided t h e maximum
permissible operating pressure i s recalculated. This i s called
de-rating. Patches t o be i n l a i d i n a seamless s e c t t o n m u s t be
welded with a double-vee b u t t j o i n t .

I f the exchanger i s equipped with s a c r i f i c i a l magnesium anodes, then

a judgement must be made a s t o whether o r not they should be removed.

Remember, standard anodes a r e 4" square and t h e t o t a l anode length

i n inches t o b e a i n s t a l l e d i n a channel can be calculated.
I n t e r i o r Area (sq. !inch)
L ( i n inches) =
187 in.

Anode i n s t a l l a t i o n d e t a i l s a r e covered i n b f e r e n c e 3 of your

workbook.

Check a l l small piping connections f o r erosion, corrosion, cracks,

and leakage. -Remember pipe connections under 1-1/2" must be back-
-welded-and gusseted, except where extended body valves a r e used.
-
I n these cases, gusseting may not be required.

Following your v i s u a l inspection, thickness measurements must be

made. This includes t h e channel, s h e l l , s h e l l cover, f l o a t i n g head
and nozzles.

I f t h e equipment i s old, your equipment condition s h e e t %-ill

locate
where these measurements a r e t o he made. On new equipment you must
i n i t i a t e the condition s h e e t l o c a t i n g where these measurements a r e
t o be taken.

The bundle inspection d i f f e r s only i n d e t a i l . Remember we're s t i l l

looking f o r change.

The tube bundle, l i k e t h e s h e l l , has locations where trouble can he

expected. Erosion-corrosion on t h e tubes d i r e c t l y beneath t h e s h e l l
i n l e t i s a most l i k e l y s p o t , p a r t i c u l a r l y i f there i s no impingement
baffle. I f t h e r e i s none, you may consider recornending having one
i n s t a l l e d , provided i t can be done without causing extreme pressure
drop.
 Where a high temperature material flows i n t o the tube i n l e t pass,
t h e backside o,f the s t a t i o n a r y .tube s h e e t or tubes immediately
adjacent t h e r e t o may s u f f e r p r e f e r e n t i a l corrosion.

P r e f e r e n t i a l erosion-corrosion may a l s o occur on the i n t e r i o r of the

tube w d l s a t the tube entrances a t t h e channel and a t the f l o a t i n g
head. I n t h i s s l i d e , n o t e t h e extreme thinning of t h e tubes below
t h e p a r t i t i o n gasket s e a t .

Note how t h i s tube has eroded through a t the tube sheet.

Severe wear can occur a l s o where tubes pass through t h e tube bundle
baffles. Thinning of tubes a t t h i s location i s sometimes observed
and i t is n o t unusual, t o f i n d a tube p a r t i a l l y severed due to
vibration.

A s a f i r s t s t e p i n bundle inspection, v i s u a l l y sweep t h e bundle t o

e s t a b l i s h any general corrosion p a t t e r n s .
--aammer-resi-iug-of-tubss-Icr determining
still-~-t~~-ho~102:ed~way~of
tube thickness. The sound and the rebound i s an i n d i c a t o r but
experience i s a p r e r e q u i s i t e f o r i t s use.

The i n s i d e of t h e tubes can be checked using a t h i n hooked rod, the

t i p of which i s shown here.

The rod i s i n s e r t e d i n the ends of the tubes. As i t i s drawn back

on the i n s i d e w a l l of t h e tubes the f i n g e r s a r e used t o sense t h e
i r r e g u l a r i t i e s , l i k e p i t s or scale.

Removal of one or more tubes a t random w i l l permit sectioning and a

more thorough inspection f o r determining the probahle s e r v i c e l i f e
of the remainder of t h e bundle. Also when the bundle i s retubed,
take the opportunity t o s e c t i o n some tubes t o evaluate cause of
failure.

Other more s o p h i s t i c a t e d means of checking the condition of exchanger

tubes includes the:
* Boroscope, and the
0 Eddy-Current Nonmagnetic-Tube Inspection Instrunient.
For process reasons as well as f o r mechanical support, check the tube
holes i n the b a f f l e s t o s e e i f they a r e not too l a r g e . Too much
clearance w i l l permit channeling of t h e f l u i d i n t h e s h e l l reducing
t h e heat t r a n s f e r efficiency.

These holes a r e normally 1/32" l a r g e r than t h e tube O.D. i f t h e un-

supported length of t h e tube i s l e s s than 36". I f t h e unsupported
length i s g r e a t e r than 36" then these holes. a r e d r i U e 6 1/64" l a r g e r
than t h e tube O.D.

Distorted b a f f l e s need t o be straightened.

And t i e rods and spacers need t o be replaced i f badly corroded or

damaged.

Check t h e gasket surfaces on t h e tube sheets c a r e f u l l y f o r corrosion

and gouge marks. S u f f i c i e n t gasket s u r f a c e should remain t o make a
r i g h t s e a l when t h e j o i n t s a r e made up.
--~emenidrri;liere-are-tFf.iee aces :
s.~ch-g~i~ket-surf --

e One - shown i n red - outboard of the s t a t i o n a r y tube sheet.

0 Two - shown i n green - inboard of t h e s t a t i o n a r y tube sheet, and
0 Three - shown i n yellow - between t h e f l o a t i n g tube sheet and the
f l o a t i n g head.

Tube sheets and covers may be checked f o r d i s t o r t i o n with a s t r a i g h t

edge as shown here. D i s t o r t i o n generally r e s u l t s from over-rolling
o r improper r o l l i n g of tubes, thermal expansion, explosions, or
rough handling.

Thickness measurements of t h e tube s h e e t s must be made although

continuous records a r e n o t usually kept.

Tube w a l l thickness should be measured and recorded. This i s usually

done by measuring the I.D. and the O.D. and dividing t h e difference
by two. I n measuring t h e I . D . be s u r e the measurement i s beyond the
r o l l e d portion of t h e tube sheet - not i n it!!!

Eccentric corrosion o r wear should be noted. This could d r a s t i c a l l y

e f f e c t your calculations.
i
Retubing bundles i s a r o u t i n e p r a c t i c e performed by the mechanical
forces.

Here a r e some things the inspector needs t o know about retubing -

F i r s t , the tube holes i n t h e tube sheets should n o t exceed t h e tube
f i t and tolerances l i s t e d in Reference 4 of your workbook.

The distance between holes i n t h e tube sheets a r e called Ligaments.

Ligaments have permissible minimum l i m i t s to t h e i r widths. Study
t h i s chart i n your workbook when you have time.

The i n s i d e edges of t h e tube holes must be f r e e of burrs t o prevent

c u t t i n g of t h e tubes. I n t e r n a l surfaces should be given a workman-
l i k e finish.

The tube holes f o r expanded j o i n t s a r e machined t o have a t l e a s t

trvjo grooves i n the base metal each appr'oximtely 118" wide x 1/64"
deep. .
--
Tubes X o X L T e qexpan6ed-i11tu-tl1e-t-libe skeet-for a - l e ~ g t hequaLto-_-_--
t h e tube sheet thickness minus 118 of an inch o r two inches, which-
ever i s l e s s .

The expanding procedure s h a l l b e such a s t o provide s u b s t a n t i a l l y

uniform expansion throughout t h e expanded portion of t h e tube, with-
out a sharp t r a n s i t i o n t o t h e unexpanded portion.

Tubes s h a l l b e f l u s h with o r extend by no more than one-half the

tube diameter beyond t h e f a c e of t h e tube sheet. In v e r t i c a l
exchangers t h e tubes should be flush with the top tube sheet t o
f a c i l i t a t e drainage.

Now open your workbook t o Exercise 3 and answer the questions there.
We'll be back to t a l k about t e s t i n g afterward. (10 Second Pause)
(Advance Pulse)

(3 Seconds - Stop Pulse)

 4-1. While t e s t i n g i s a process/mechanical,function, t h e inspector
frequently i s involved i n discussions pertaining t o f i e l d t e s t s of
hdat exchangers. For t h i s reason, he should be a b l e to make sound
recommendations based on a v a i l a b l e information and h i s experience.

4-2. The discussion t h a t follows describes t e s t i n g - what information may

be gained from i t - and what information may not. Field t e s t i n g i s
expensive - time consuming, and i s not always worth t h e time or
effort.

4-3. Let's t a l k about f i e l d t e s t i n g and some of i t s p i t f a l l s s t a r t i n g a t

t h e point where an exchanger has been removed from s e r v i c e , drained
and prepared f o r t e s t i n g ...
4-4. A reasonable beginning would be a tube s i d e t e s t . The t e s t medium,
usually water, i s introduced through t h e channel s e c t i o n ...
-
4-5.
---
If t h e water i s i n t r o d u c a a t a s h e l l nozzTe-~hen-rile-~%ST-is ssl-led--
a shell test.

4-6. Tightness t e s t pressures a r e generally established by t h e operating

personnel and a r e included i n t h e mdts operating i n s t r u c t i o n s .
These pressures normally do not exceed the design pressure or t h e
s a f e t y valve s e t t i n g .

4-7. On t h e other hand, t h e pressure required to t e s t the exchanger f o r

s t r e n g t h has been t r a d i t i o n a l l y determined by t h e inspector. This
value i s one and one h a l f t i m e s t h e design pressure of t h e exchanger.

4-8. With pressure applied, a leak may be detected 'by observing a flow
of water a t a d r a i n point. Ordinarily t h i s i s done by conducting a
tube t e s t and checking f o r leakage a t a s h e l l drain.

4-9. That you've got a l e a k i s . a s u r e thidg. The question which a r i s e s i s

"Do we t r y t o l o c a t e t h e leak and r e p a i r i t i n place o r p u l l t h e
bundle?" L e t ' s look a t your chances.

4-10. This type of leak can be caused by: One: One or more tube r o l l s
- i n t h e s t a t i o n a r y tube sheet.
C"
Two: One o r more tube r o l l s i n the f l o a t i n g tube sheet.

Three: A f l o a t i n g head gasket,

Four: One or more ruptured o r penetrated tubes.

Five: Combinations of these types of f a i l u r e s .

I f we apply a tube s i d e t e s t with t h e s h e l l cover removed, we can

observe: A t point one: Roll leaks i n t h e f l o a t i n g tube s h e e t , and
. . . At point two: A f l o a t i n g head gasket leak.

A tube leak i n s i d e t h e s h e l l o r a r o l l leak a t the s t a t i o n a n tube

s h e e t w i l l show up at a s h e l l nozzle or t h e s h e l l cover flange but
it can't be i d e n t i f i e d ...
A s h e l l test applied t o t h e exchanger with t h e channel cover off
w i l l reveal leaking tube r o l l s i n t h e s t a t i o n a r y head and may
i d e n t i f y a leaking tube.
-
--~r~rhe-brnrdie~s-~10p~.d-do~~i:~rd-ta?~~ar&-th~~~hannel
box,-then-the
tube leakage t h a t is observed i s t h e tube t h a t has ruptured. You
may s u c c e s s f u l l y f i e l d r e p a i r such a l e a k by removing t h e s h e l l
cover and t h e f l o a t i n g head and plugging the tube.

I f however, t h e bundle i s sloped dunward toward t h e f l o a t i n g head,

t h e tube leakage t h a t i s observed i s most l i k e l y a f a l s e i n d i c a t o r
and t h e offending tube cannot be detected.

Another p o s s i b i l i t y i s t h a t t h e so--called leaking tube may b e

carrying water from a leaking f l o a t i n g head gasket or a tube r o l l
i n t h e f l o a t i n g head tube sheet.

Bere i s another thought f o r you. Suppose t h a t you have been lucky

enough t o l o c a t e and plug a d e f e c t i v e tube. How do you know that
t h e r e ' s not another tube ready t o l e t go next week?

Here's a general r u l e . If the s e r v i c e record f o r t h e exchanger

i n d i c a t e s a h i s t o r y of leaking f l o a t i n g head gaskets, then t e s t f o r
this fault.
r 4-23. Otherwise, recommend p u l l i n g the bundle and sending i t t o the shop.
Most of t h e times you w i l l be ahead of t h e game.

I n t h e shop, t h e e n t i r e bundle can be seen during t e s t i n g . The

e x t e r n a l condition of t h e tubes can be noted. Testing w i l l be -more
exact and i n most cases t h e r e p a i r s w i l l be more r e l i a b l e . A s you
can s e e i n t h i s s l i d e , "C" cl&s a r e used t o hold t h e test p l a t e s
i n position.

The shop f a c i l i t i e s include t o o l s t o permit t h e t e s t i n g of individual

tubes a s i s shown here.

Individual leaking tubes a r e not generally replaced, but a r e plugged

with tapered metal plugs.

As a general r u l e , no more than 10%of t h e tubes i n any one pass

should b e plugged. I f more th.an 10%of t h e tube a r e bad ...
.retube t h e bundle.
-
I F i ~ t ~ ~ - t o - f i e i d - ~ e s r i i n - - a c E i a i i g ~ : f ass~~~.hl]r,---Ref
-at m t h k
s h e l l cover i s i n s t a l l e d , a tightness t e s t i s applied t o the tube
s i d e to assure a t i g h t s e a l a t t h e f l o a t i n g head gasket.

A f t e r t h e s h e l l cover i s i n s t a l l e d , a s h e l l t e s t i s conducted.
There should b e no' v i s i b l e leaks. Tightness i s generally judged by
t h e a c t i o n of a pressure gage. A steady gage reading over a period
of a few minutes i n d i c a t e s a t i g h t exchanger.

Be aware t h a t a cold pressure t e s t only means t h a t t h e equipment

was t i g h t when cold. Pressure i s not a s u b s t i t u t e f o r heat. The
thermal s t r e s s e s produced by a few hundred degrees can f a r exceed
those caused by pressure alone.

For those of you i n t e r e s t e d i n more in-depth information about shop

and f i e l d t e s t i n g of heat exchangers, STIP Training Modules 4.66
and 5.20 can be made a v a i l a b l e through your i n s t r u c t o r .

After you've had time t o answer the questions i n Exercise 4 of your

workbook, w e ' l l be back to t a l k about r e t i r i n g thickness and t h e i r
calculations.

( 3 Second Pause - Stop Pulse) ( 2 Second Pause - Advance Pulse)

S' SEGl5NT 5

5-1. I n t h i s segment of our module we w i l l d e a l with the r e t i r i n g thick-

ness of t h e various h e a t exchanger components. We w i l l determine
t h e thickness required t o withstand pressure and discuss standard
corrosion allowances.

5-.2. . Heat exchangers a r e designed and constructed i n accordance w i t h

t h e standards s e t f o r t h by the Tubular Exchanger Manufacturers
Association . . . T R U for short.

This association t o a l a r g e extelit leans heavily on the "Code" i n

t h e design of p.ress&re p a r t s of t h e exchange; assembly. The "Code"
as you learned e a r l i e r i s the ASME Boiler and Pressure Vessel Code,
Section VTII, Division 1.

I n t h i s segment w e ' l l be repeating some of t h e calculations t h a t

we've covered i n e a r l i e r modules. Some of t h e material i s new.
-Xet%~ace-6 -L'~-pcur - ~ ~ z k b o o k ~ e i . n t r o d u c e s - s ~ ~friends,
01d "Fodas
f o r Vessels Under I n t e r n a l Pressure."

Since corrosion i s n o t n e c e s s a r i l y uniform i n i t s attack on metals,

the remaining thickness of a corroded area v a r i e s . I t i s a general
p r a c t i c e t o average t h e l e a s t thickness over a length s p e c i f i e d a s
o n k h a l f t h e v e s s e l diameter o r 20", whichever i s l e s s .

Thus a corroded a r e a of an exchanger with a 36" diameter would be

.measured over a length of t h e l e a s t of: 20 inches or

The Diameter = which int h i s case is o r 18".

2

From. the Code, the r e t i r i n g thickness of the s h e l l wall i s i n accor-

dance with t h e equation expresskd here. Where: t the r e t i r i n g
thickness i n inches equals
t h e pressure (psi) X R -
i n s i d e radius"
max. allowable s t r e s s X j o i n t e f f . - 0.6 X pressure

The same equation i s used i n calculating t h e r e t i r i n g thickness of

the channel s e c t i o n .
 Keep i n mind t h a t TEMA. does not permit the s h e l l thickness t o be
less than t h a t given i n Reference 7 of your workbook.

The same b a s i c code formula i s used to calculate t h e required thick-

ness f o r t h e s h e l l and channel nozzles.

The r e t i r i n g thickness of exchanger tubes i s calculated t h e same

way as any o t h e r c y l i n d r i c a l shaped ~ e s s e l .

- Reference 8 i n your workbook L i s t s the general properties and

c h a r a c t e r i s t i c s of tubing from one-fourth inch t o two inches i n t h e
more popular gage thickness. The outside diameter of tubing i s t h e
same as i t s nominal s i z e .

And Reference 9 computes t h e m a K i m allowable working pressure of

these tubes a t various temperatures and allowable s t r e s s e s .

Some p a r t s of an exchanger a r e not subject t o d i f f e r e n t i a l pressure

-and'_the_minims thickness i s n o t important. However, TEMA has
s p e c i f i e d minimum dimensions f o r them.

Reference 10 i n your workbook l i s t s t h e standard cross b a f f l e and

support p l a t e thickness f o r various s h e l l s i z e s and spans.

And Reference ll lists standard t i e rod dimensions.

And minimum pass p a r t i t i o n p l a t e thickness.

But f o r exchangers with a nominal diameter greater than 36" t h e

pass p a r t i t i o n thickness s h a l l n o t be l e s s than t h e diameter i n
inches divided by 96.

The thickness of t h e channel cover i s t h e thickness measured a t

t h e bottom of t h e pass p a r t i t i o n groove and t h e value i s determined
by t h e TEMA equation o r by the Code form~ula,whichever i s greater.

The b a s i c TEMA equation i s expressed i n t h i s s l i d e . (5 Second Pause)

And the Code equation i s given here. A more d e t a i l e d explanation of

these equations i s covered i n your workbook.

Tube sheet r e t i r i n g thickness i s given i n t h i s TR,fA equation which

i s f u r t h e r explained i n your workbook. .
C i
4-23. I f t h e foregoing equations a r e not h a i r y enough .. . equations on
the calculations f o r flanges can be provided. I f -you a r e faced with
t h i s problem i t is suggested t h a t t h e base d a t a be turned over t o
a computer.

5-24. Now turn t o Exercise 5 i n your workbook.

5-25. (3 second Stop Pulse)

SE- 6

6-1. Maintaining accurate, up-to-date records i s one of the most

important functions of the Equipment Inspector.

For t h i s s e r v i c e , .the Equipment Inspection Section employs a computer

handling system i d e n t i f i e d as the Fixed Equipment Record System, or
FERS f o r Short.
For exchangers,' t h e i n s p e c t o r i s charged with feeding t h e machine
- -
some eight b a s i c documents. --

I n return, t h e computer supplies the inspector with a number of

r e p o r t s and programs.

With t h i s information, we know where we've been . . . we know where

we a r e . . . and we've got a p r e t r p good i d e a where we're going and
when we're going t o g e t there.

The mechanics of preparing t h e input forms as source data f o r the

computer 'is covered i n d e t a i l i n the FERS user's guide. Also, the
use of the FERS system i s covered i n a s e p a r a t e module.

Basic e n t r i e s concerning heat exchangers must be entered i n t o t h e

computer system before i t w i l l accept any other data.

This must include a b a s i c data s h e e t , t h e tube bundle design data,

general design d a t a , and the design d a t a f o r t h e s h e l l .

And with these e n t r i e s the computer develops a f r o n t sheet l i k e t h i s

one f o r t h e exchanger E-10U on the AIAX Unit.
 Another report which can be produced i s a list of fixed equipment by
unit. This report n o t only lists t h e fixed equipment'but a l s o gives
a n u d e r items of design data. A p a r t i a l l i s t i n g of heat exchangers
f o r No. 4 Light Ends West i s shown i n this s l i d e .

The inspector i n h i s r o u t i n e inspection of exchangers reports h i s

observations and r e p a i r s t o the computer. Included i n t h i s r e p o r t
i s t h e need f d r f u t u r e inspections and r e p a i r s . This r e p o r t docu-
ments process u n i t turnarounds and t r a c e s tube bundle movement
through t h e r e f i n e r y n o t i n g i t s location. This e n t r y i s one of the
most important of t h e i n p u t s t o t h e computer.

From t h i s r e p o r t , combined w i t h other b a s i c data, the computer

r e p o r t s t h e following information:

One: Equipment Condition History Report. This one covers exchanger ''.

E-24 on No. 9 PS. .

--A-

Two: OJt-SSjFding w o r k i t e m s - 2 n - p ~ i o r i q - m d e r :-like-this one f o r

No. 10 Pipe S t i l L s .

Three: Turnaround Inspection Report. This one being on a 12 day

turnaround on No. 9 Pipe S t i l l back in 1970.

Four: Tube Bundle H i s t o r y including tube bundle locations by bundle

yard number, tube bundle locations by exchanger yard number, bundles
r e t a i n e d by s t o r e s , bundle locations by process u n i t s .

Five: Downtime logs an8 TA Schedule. The example shown here covers
Nos. 7, 8, & 9 Pipe S t i l l s .

Six: A b a s i c d a t a l i s t i n g by equipment type. '

Thickness measu;ements of t h e various p a r t s making up an exchanger

a r e reported . a f t e r every inspection.

Then taking t h e b a s i c design data and t h e measurements, the computer

determines t h e r e t i r i n g thickness, c a l c u l a t e s t h e minimum remaining
corrosion allowance. With t h e corrosion r a t e known, i t . r e p o r t s the
remaining l i f e , recommends an inspection i n t e r v a l , and gives you a
f u t u r e d a t e f o r t h e inspection.
c-
% . 6-21. The record system, i f p r o p e r l y used, can b e a g e n i e t o serve a s you

6-22. To misuse t h e system i s t o i n v i t e d i s a s t e r . Remember, misinformation

i s worse than none a t a l l .

6-23. P l e a s e t u r n t o E x e r c i s e 6 of your workbook.

6-24. (Nusic) (3 Second Pause - Advance P u l s e )

6-25. Exxon Copyright -3 Second Pause - Advance Pulse.

6-26. P r o p e r t y of &on Company, U.S.A. (Stop P u l s e )

 NSPECT ON OF
STORAGE TANKS
 r -
TABLE- OF.-CONTENTS
P a ~ eNo.
I. Module I n t r o d u c t i o n
A. Moduleobjective. ..................... 1
B. Module Description ..................... 1 .
C. T e d n a l Performance O b j e c t i v e . . . . . . . . . . . . . . . 3

11. Workbook Exercises

A. How To Use The Workbook E x e r c i s e s ............. 4
B. Exercise i:l ........................ 5
C. E x e r c i s e 12 . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Exercisei/3 . . . . . . . . . . . . . . . . . . . . . . . . 10
E. E x e r c i s e i/4 . . . . . . . . . . . . . . . . . . . . . . . . 1 3
F. Exercise U5 . . . . . . . . . . . . . . . . . . . . . . . . 15
.. G. Exercise 116 . . . . . . . . . . . . . . . . . . . . . . . . 17
.-..
-..
-
...
H. Exercise117 . . . . . . . . . . . . . . . . . . . . . . . . . 19
.- I. Exercise 118 . . . . . . . . . . . . . . . . . . . . . . . 21 J
..
-.
-
.- J. Exercisei'f9
. . . . . . . . . . . . . . . . . . . . . . . . . 24
..-- _
-
- K. E x e r c i s e 1/10
. . . . . . . . . . . . . . . . . . . . . . . . .. .-25-.
(\'$ -'
- L. Exercise 1/11 . . . . . . . . . . . . . . . . . . . . . . . . 28
-.
.. . 111. Reference M a t e r i a l -
-- - Bottom Design - Annular
:>
1. Reference i'll Plates

.- Width and Thickness ............. 30

2. Reference $ 2 - Tank Shell - Construction
-
.
Tolerances ................. 31
-
-
-. 3. Reference $3 - Manhole D e t a i l s - Reinforcement
I . Cover P l a t e s ................ 32
! 2OWManhole... . . . . . . . . . . . . . . 33
24" Manhole . . . . . . . . . . . . . . . . . 34
I 30" Manhole . . . . . . . . . . . . . . . . . 35
36" Manhole . . . . . . . . . . . . . . . . . 36
I 4. Reference i;4 - Flanged Nozzles - D e t a i l s Reinforcement . . . 37
Screwed Type Nozzles . . . . . . . . . . . . 38
S h e l l Nozzles - Dimensions . . . . . . . . .
1 S h e l l Nozzles - Welding Schedules . . . . . .
39
40
S h e l l Nozzle Flanges . . . . . . . . . . . .
!( -:-
5. Reference i/5 - S h e l l T e s t - F i l l i n g I n s t r u c t i o n s . . . . . .
41
42
 i.
(1)

M O D U INTRODUCTION

Module Objective

The o b j e c t i v e of t h i s t r a i n i n g module is t o provide you w i t h a guide f o r

t h e i n s p e c t i o n of r e f i n e r y o i l s t o r a g e tanks. Much of t h e module d e a l s with
b a s i c design and c o n s t r u c t i o n of t h e more common types of s t o r a g e tanks found
i n a typical refinery. S h e l l thickness calculations a r e included a s a r e
6
r e t i r e m e n t t h i c k n e s s e s of t h e t a n k components.

Module D e s c r i p t i o n

T h i s module i s a s l i d e / t a p e p r e s e n t a t i o n i n eleven segments. Segment one

i s an i n t r o d u c t o r y segment t o t h e i n s p e c t i o n of s t o r a g e t a n k s . Tank.bottom
d e s i g n and c o n s t r u c t i o n i s d e t a i l e d i n segment 2. In segment 3 s h e l l t h i c k n e s s
c a l c u l a t i o n s a r e taught i n c l u d i n g s h e l l c o n s t r u c t i o n . Refinery t d k s a r e
d.oofed-primarily-k5th f i x e d cone r o o f s - floating roofs - internal.floating
--
covers. Segments 4 , 5 , and 6 c o v e r t h e s e assemblies. S a f e t y as i p p e r t a i n s t o
t a n k i n s p e c t i o n i s covered i n segment 7. A guide t o t a n k i n s p e c t i o n is
p r e s e n t e d i n t h e n e x t two segments. ,Segment 8 covers a t a n k i n s p e c t i o n w i t h
t h e t a n k i n s e r v i c e and 9 covers a n i n t e r n a l i n s p e c t i o n . Segment 10 l a y s down
a b a s i s f o r r e t i r e m e n t of tank components and d e s c r i b e s b a s i c t a n k t e s t i n g
procedures. The l a s t segment d e a l s w i t h t h e Fixed Equipment Record System a s
i t p e r t a i n s t o Tank I n s p e c t i o n .

. A t t h e end of each segment, t h e p r e s e n t a t i o n w i l l be stopped t o r e i n z o r c e

your i n s t r u c t i o n by answering a s e r i e s of q u e s t i o n s i n your Workbook. At
t i m e s , q u e s t i o n and answer p e r i o d s w i t h your i n s t r u c t o r have been a l l o t t e d .

Following t h e p r e s e n t a t i o n , an examination of 4 5 q u e s t i o n s w i l l conclude

t h i s study.

Reference m a t e r i a l a s i s r e q u i r e d t o a i d you i n your work i s included i n

your Workbook.

The Workbook a l s o c o n t a i n s a copy of t h e s l i d e / t a p e s c r i p t o f t h e

p r e s e n t a t i o n which may be used as a r e f r e s h e r course a s may b e r e q u i r e d .
 Pay c l o s e a t t e n t i o n t o the material presented and question your i n s t r u c t o r
on any d i f f i c u l t y you may have.

Bon Chance!
 The o b j e c t i v e of t h i s t r a i n i n g module i s t o teach t h e t r a i n e e t h e
n e c e s s a r y b a s i c design end c o n s t r u c t i o n of t h e more common r e f i n e r y s t o r a g e
t a n k s and t o provide a guide f o r t h e trainee in t h e i n s p e c t i o n of t h e s e
v e s s e l s i n c l u d i n g t h e required i n p u t d a t a i n t o t h e Fixed Equipment Record
System.

Upon completion of t h i s course, t h e s t u d e n t under t h e following c o n d i t i o n s

w i l l be expected t o :

CONDITIONS PERFORMANCE CRITERIA

-
T e s t #l With a c c e s s Select the correct. Answer 40 of t h e 45
t o h i s workbook, and answer from t h e . questions'correctly
given a m u l t i p l e choice multiple choices i n . a ' p e r i o d of 60
w r i t t e n examination of given f o r each of minutes. ..;' .
F--
(- 45 questions. . the questions.
 BOW TO USE THE WORKBOOK FXERCISES

You w i l l p e r i o d i c a l l y b e i n s t r u c t e d t o t u r n t o a s p e c i f i c e x e r c i s e a t
d i f f e r e n t p o i n t s throughout t h i s course. I f you a r e t o l d t o t u r q t o E x e r c i s e
02, you w i l l r e f e r . t o t h e Table of Contents, l o c a t e t h e c o r r e c t page f o r t h e
e x e r c i s e , and t u r n t o it.

The e x e r c i s e itself i s r e l a t i v e l y easy t o use. The f i r s t page c o n t a i n s

q u e s t i o n s on t h e material you have j u s t been p r e s e n t e d . You a r e expected t o
c i r c l e t h e c o r r e c t answer t o each q u e s t i o n on t h e page, w i t h r e f e r e n c e t o t h e
c h a r t s i f required. Upon completion of t h e q u e s t i o n s , you w i l l f o l l o w t h e
i n s t r u c t i o n s i n parentheses on t h e bottom of t h e page. I f i t says, "Turn t o
t h e following page" .... do s o . The second page a g a i n s t t h e answers on t h e
second page. After you have done so, r e f e r t o t h e i n s t r u c t i o n s a t , t h e bottom
of t h e page. I f they t e l l you t o "Stop!', do so; c l o s e your Workbook and
---------
await f u r t h e r i n s t r u c t i o n s . . ...
.
 EXERCISE #1

(QUESTIONS)
SELECI TEE CORRECT ANSWER FROM TEE MULTIPLE CHOICES I N THE FOLLOWING STATEMENTS
.AND UNDERLINE IT. COMPLETE ALL STATEMENTS 'BFIFORE 'TURNING THE PAGE.

1. Atmospheric s t o r a g e v e s s e l design i s i n accordance w i t h (APT.) (ASME)

0
standards. "/
2. F l o a t i n g roof tanks a r e r e p l a c i n g cone roof tanks i n o r d e r t o reduce
LA
(VAPOR) (LIQUID) l o s s e s .

3. The a n n u l a r pontoon f l o a t i n g roof h a s a (SINGLE) (WUBLE) deck. <

+

4. Tank d e t e r i o r a t i o n i s p r i m a r i l y caused by (MECHANICAL DAMAGE) .. .

(C~RROSION).
&

--
. L

C' ,
5. (SULFUR) (CHLORIDES) i n t h e tanks c o n t e n t s i s t h e primary corrodent.

-
6. The vapor s p a c e i n a tank (IS) (IS NOT) immune t o c o r r o s i v e a t t a c k .

7. In new c o n s t r u c t i o n (RIWTING) (WELDING) i s t h e most conrnon means of

joining plates.

8. I n t a n k s w i t h r i v e t e d j o i n t c o n s t t u c t i o n , leakage around t h e r i v e t s (IS)

(IS NOT) uncommon.

9. Tank (BOTTOMS) (RDOFS) a r e s u b j e c t t o g a l v a n i c c o r r o s i o n .

10. I n t e r n a l f l o a t i n g covers a r e p r i m a r i l y used i n (CONE ROOF TANKS) (OPEN

ROOF TANKS).

11. The b a s i c r u l e s of API Standard 650 a p p l y t o tanks having a metal

temperature n o t t o exceed (150) (200) (250) d e g r e e s F. kt---
C
(TURN TO THE FOLLOWING PAGE)
 (ANSWERS)
COMPARE YOUR RESPONSES OK THE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECT
Ah" ERRORS IN YOUR WORK.

i 2. VAPOR

i
I
3. SINGLE

4. CORROSION

,
I
I
(.
6.

7.
I S NOT

WELDING
.

8. I S NOT

I 9. BOTTOMS

.
10. CONE ROOF TANKS
 EXERCISE #2

(QUESTIONS)
SELECT THE CORRECT ANSWERFROM THE MULTIPLE CHOICES IN THE FOLLOWING STATE-
ME3TS AND UNJJERLINE IT, COMPLETE ALI, STATJBEWTS BEFORE TURNING THE PAGE.

1. A b a r r e l of o i l contains (42) (55) g a l l o n s .

2. A tanks dismeter i s measured from t h e (O.D.) (I.D.) (CENTER LINE) of i t s

shell plates.

3. The h e i g h t of a cone roof t a n k i s measured from t h e bottom of t h e s h e l l

t o (THE TOP OF THE TOP ANGLE) MAX^ FILLING FEELGET).

4. A tank bottom desigzed w i t h Bn a n n u l a r r i n g i s g e n e r a l l y used on (SMALL)

,'
5. The t h i c k n e s s of t h e bottom a n n u l a r r i n g p l a t e s i s based on t h e tank

6. The width of the.bottom a n n u l a r r i n g p l a t e s i s based on t h e tank (SHELL

THICKNESS) (DTATQTER).

.7. I f t h e bottom s h e l l course i s 718" t h i c k , t h e minimum a n n u l a r r i n g p l a t e

t h i c k n e s s is (5/1b1') (3/8") (7116").

8. The bottom, i n a tank whose diameter i s 2 9 0 t , i s c a t a g o r i z e d a s a #2

bottom. The width of t h e a n n u l a r p l a t e s may n o t be less than (2) (3)
(6) f t . wide.

9. The minimum t h i c k n e s s of t a n k bottoms i s (3/16) (114) (3/8) inches.

(TURN TO THE FOLLOWING PAGE)

r
.~.
10. The tank bottom i s dimensioned a s t o extend a t l e a s t (112) (1) (2) inches
beyond the outside edge of t h e weld attaching t h e bottom t o the s h e l l
plates.

U. Bottom p l a t e s a r e joined by (LAP) ( B m ) welding.

F-
12. A bottom p l a t e , upon which t h e s h e l l r e s t s , one end of wkich i s &/
rectangular i s called a (sREPCE) (ANNULBR) p l a t e . \

(mTO TKE'FOLLOWING PAGE)

 EXERCISE #2

(ANSWERS)
COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO TEE ANSWERS BELOW. CORRECT
ANY ERRORS I N YOUR WORK.

2. CENTER LINE

3. THE TUP OF TKF: TOP ANGLE

4. LARGE

11. LAPP, B r n
 (QvESTIONS)
SELECT THE CORRECX ANSWER FRO[M. THE MULTIPLE CHOICES I N TKE FOLLOWING STATE-
MENTS AND UNDJ2RLINE IT. COMFLETE ALL STATPIENTS BEFORE TDRNING THE PAGE.

I. The bottom course of s h e l l p l a t e s i s numbered t h e (FIRST) (LAST) course.

2. Tank s h e l l p l a t e s a r e g e n e r a l l y (4) (6) (8) (10) f e e t wide.

3. I n c a l c u l a t i n g t h e p l a t e thickness f o r any p a r t i c u l a r course t h e p r e s s u r e

used i n t h e c a l c u l a t i o n i s t h a t p r e s s u r e e x e r t e d on t h e p l a t e (1) (2)
(3) .(4) from t h e bottom seam of t h e p l a t e .

4. The p r e s s u r e e x e r t e d on t h e second course of a t a n k s h e l l 40 f e e t h i g h

cont-&-~-~~r-"p--ro-.fie ropyinris ~~3~4-2)-(-&~;'5:(-35 ...,c7\ .
,71s~%&-at-
L
.
c. a p o i n t 1' above t h e bottom seam.

5. I f t h e s p e c i f i c g r a v i t y of t h e t&ks c o n t e n t i s 1.17 t h e p r e s s u r e on t h e
second c o u r s e 1' above t h e bottom seam i s (12.65) (14.36) (15.70) p s i g .

6. The minimum s h e l l p l a t e thickness f o r a t a n k w i t h a diameter of 200' i s

(3116) (1/4) (5116) (318) of an inch.

.
7. Given t h e f o l l o w i n g s p e c i f i c a t i o n s :
S t e e l t a n k p l a t e w i t h a y i e l d s t r e n g t h of 43,000 p s i , w i t h a m a x i m u m
t e n s i l e s t r e n g t h of 85,000 p s i .

Joint Efficiency 100%

Tank diameter 240'
Tank h e i g h t 48'
Tank t o s t o r e s e a w a t e r w i t h a s p e c i f i c g r a v i t y o f 1.03.
Corrosion allowance i s .0624

Assume t h e a v a i l a b i l i t y of p l a t e i n t h i c k n e s s increments of 1/16" t h i c k .

(TURN TO THE FOLWWING PAGE)

r
Select p l a t e s for:
A. 1st Course
B. 2nd Course .
C. 3rd Course
D. 4 t h Course
E. 5 t h Course
F. 6 t h Course
G. 7 t h Course
R. 8 t h Course

8. A t a n k 48' high and 290' in diameter, designed t o s t o r e a m a t e r i a l w i t h

a S p e c i f i c Gravity of 1, was constructed of steel p l a t e w i t h an allowable
stress i n t h e bottom plate of 28,0008 p e r s q u a r e i n c h w i t h a j o i n t
e f f i c i e n c y of 100%. The bottom course w a s r o l l e d from a p l a t e 1.250"
tkiick, allowing f o r a c o r r o s i o n allowance of .125 inches. After t h e tank
was
----
constructed a-ecrb&?-to changrthe-se-~-v+ce-and-s-toile~anosher- -

l i q u i d w i t h a s p e c i f i c g r a v i t y of 1.15. If t h e c o r r o s i o n a l l d a n c e i s t o
remain t h e same, we must r e s t r i c t t h e fill l i m i t t o (37.33) (38.47) (39.53) f t .

9. The d e v i a t i o n of t h e s h e l l contour from t h a t of a t r u e c i r c l e i s c a l l e d

(PE.4KIHG) (BANDING).

10. The d e v i a t i o n of t h e s h e l l a t i t s h o r i z o n t a l j o i n t s i s c a l l e d (PEAKING)

. (BANDING).

11. (CONE ROOF) (FLOATING ROOF) t a n k s do not employ a wind g i r d e r i n i t s

design. -1
..
12. Openings i n a t a n k s h e l l l a r g e r than t h a t r e q u i r e d t o a c c o g o d a t e a
(1) (2) (3) inch coupling must be r e i n f o r c e d . P-
13. A t a n k i s constructed w i t h a bottom course of p l a t e steel 1" t h i c k which i s
114 of an inch i n excess of t h a t required f o r t h e h y d r a u l i c loading. Rein-
forcement required f o r any opening i n t h i s course would be (112) (318) (518) -
inches thicker.
(TURNTO THE FOLLOWING PAGE)
 i
(12)

EXERCISE /I3

(ANSWERS)
COMPARE YOUR RESPOXSES ON THE PREVIOUS PAGE TO THE ANSWERS BELOW. CORRECP
ANY ERRORS m YOUR WDRIC.

1. FIRST 8. 37.33

10. BANDING

11. CONE ROOF

12. 2
 EXERCISE #4

(QUESTIONS)
SELECP TIIE CORRECT ANSRER FROMTRE .MULTIPLE CBOICES IN THE FOLLOWING STATE-
AND UNDERLINE IT. COMPLmE ALL STATEXENTS BEPORE TORNING TEIE PAGE.

1. The t h i c k n e s s of a l l cone roof tanks i s (118) (3116) (114) i n c h p l u s a

c o r r o s i o n allowance.

2. Xost Gone r o o f s a r e (SELF-SUPPORTING) (SUPPOmED WITB COLUMNS, GIRDERS

AND RAFTERS).

3. Roof p l a t e s (MUST) ST NEVER) be welded t o t h e i r s u p p o r t i n g r d f t e r s . - .1

4. Roof p l a t e s are'welded t o t h e s h e l l top a n g l e w i t h a continuous f i l l e t
-- ---
weld n o t t o exceed (1/8) (3/16) (114) inch.
..
(-
5. If a vacuum i s p u l l e d on a atmospheric s t o r a g e v e s s e l (ATMOSPHERIC
PRESSURE) (LIQUID PRESSURE) w i l f buckle t h e s h e l l .

6. A t z e r o p r e s s u r e ' i n a t a n k , t h e p a l l e t s of a pressure-vacuum v e n t a r e
(OPENED) (CLOSED).

7. I n t h e event t h a t a vacuum i s p u l l e d on t a n k t h e P-V v e n t opens and

( F ' S E AIR) (NITROGEN) i s admitted t o t h e tank.

8. I n t h e event t h a t t h e r e is a n i n t e r n a l explosion, a t a n k i s designed

t o (SEl2X.L) ROOF) r u p t u r e .
\

(TUlW TO TEE FOLLOWING PAGE)

 2'.
114)

EXERCISE 84

(mSWERS)
WIMPARE YOUR RESPONSES 'ON .THE .PREVIOUS P E E .TO THE ANS- BELOW. C0RR.m

ANY ERRDRS I N YOUR WORK.

I 2. SUPPORTED WITH COLUMNS, GIRDERS AND RAPTERS

I 3. MlST NEYER

5. ATMOSPHERIC PRESSURE'

6. CLOSED

7. FRESH AIR

!I 8. ROOF
 EXERCISE 85

(QUESTIONS)
SELECT TEE CORRECT ANSWER EROH THE HULTIPLE CHOICES I N TEE FOLLOWING S T A T 5
MRiTE AND UNDERLINEIT. COMPLIXE ALL STATEMENTS BEFORE TURNING TKE PAGE. :

1. The f l o a t i n g roof i s designed p r i m a r i l y t o reduce (LIQIJID) (VAPOR) l o s s e s

i n an atmospheric s t o r a g e tank.

#
2. To prevent a f l o a t i n g roof from bottoming on i n t e r n a l t a n k a c c e s s o r i e s
such as p i p i n g o r mixers, t h e f l o a t i n g roof i s equipped w i t h a series of
legs c a l l e d roof (SUPPORICS) (BRACES).

3. When t h e f l o a t i n g roof bottoms, t h e automatic b l e e d e r vent i s (OPENED)

(CLOSED).

4. The f l o a t i n g roof is centered i n t h e s h e l l by t h e (PANTOGXAPH ~ G E R S )

(FABEUC SEAL).
-
5. The r o t a t i o n of t h e f l o a t i n g roof w i t h i n t h e s h e l l i s p r o h i b i t e d by t h e
(GUIDE BAR) (ROLLING LADDER).

6. The f l o a t i n g roof i s gromded t o t h e s h e l l by means of (SHUNTS) (SEALING

7. In a f l o a t i n g roof tank, bouyancy t o f l o a t t h e roof i s provided by

(PONTOONS) (DECKING).

8. A (SINGLE) (DXJBLE) deck i s employed i n t h e pontoon type f l o a t i n g r o o f .

9. The double deck f l o a t i n g roof i s (MORE) (LESS) e f f i c i e n t i n p r e v e n t i n g

vapor l o s s than i s t h e pontoon t y p e f l o a t i n g r o o f .

L 10. The p e r i p h e r i a l space between t h e s e a l i n g r i n g and t h e o u t e r pontoon

rim i s closed w i t h a (FABRIC SEAL) (m SEAL).

(TIJRN TO THE FOLLOWlNG PAGE)

 (ANSWERS)
COMPARE YOUR RESPONSES ON THE PREVIOUS PAGE TO TEE ANSWERS BELOW. CORRECT

ANY ERRDRS I N POUR WORK.

1. VAPOR

2. SUPPORTS

3. OPENED

4. PANTOGRAPH BANGERS

5. GUIDE-BBR

C. 6. SWNTS

7. PONTOONS

8. SINGLE

9. MORE

-
10. FABRIC SEAL
 i.
(17)

EXERCISE U6

(QUESTIONS)
SELECT THE CORRECT ANSWER FROM THE MJLTIPLE CHOICES I N TEE FOLLOWING STATE-
MEhTS AND UNDERLINE IT. COMPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

1. Bouyancy f o r t h e i n t e r n a l f l o a t i n g cover is p r o d d e d by (PIPE) (DECK)

pontoons.

2. The r i m p l a t e i s supported by t h e (MAIN) (D)

pontoons.

3. The decking i s composed of alrrminm s h e e t s named (HIDES) (SKINS).

4. To p r e v e n t t h e i n t e r n a l f l o a t i n g cover from r o t a t i n g w i t h t h e s h e l l (GUIDE

BARS) (AhPfI-ROTATION CABLES)a r e emplbyed. ,
-

r',
\...
5. Grounding of t h i s cover i s accomplished w i t h ground c a b l e s b&;i'e.d t o t h e
tank (SHELL) (ROOF).
-
6. I n t h i s c o n s t r u c t i o n t h e roof s k i n s (DO) (W NOT) rest on t h e c o n t e n t s
of t h e tank.

(TURN TO TEE FOLLOWING PAGE)

(ANSWERS)
COMPARE YOUR RESPONSES ON TE3 PREVIOUS PAGE TO THE ANSWEXS BELOW. CORRECT
ANY ERRDRS I N YOUR WORK.

1. PIPE

2. RIM

4. ANTI-ROTATION CABLES

5. ROOF
 EXERCISE 1/7

(QUESTIONS)
SELECT TEE CORRECT ANSWER FROM THE HULTIPLE CHOICES I N THE FOLWWG STATE-
MENTS AND UNDERLINE IT. COMPLETE ALL STATENINE BEFORE TURNING THE PAGE.

1. It (IS) (IS NOT) important t h a t t h e tank i n s p e c t o r know what is being

s t o r e d i n t h e t a n k t o be i n s p e c t e d .

2. Hydrogen s u l f i d e (IS) (IS NOT) considered a t a x i c m a t e r i a l .

3. A cone roof t a n k being f i l l e d "breaths", (MHALING) (INEALING) vapors.

4. I n s p e c t i o n of a t a n k roof'(WES) (WE3 NOT) r e q u i r e a permit.

--
5. A (RED) (WHI~E)-(~~)=t-is~required--befor~-a-tank-~y-b~--P--~n_te~~erl~ --
...'
.. .
CI' . 6. A t a n k roo£ should b e planked i f : t h e roof has t h i n n e d t o ( 3 1 3 2 ) (118)
inch. -

7. A p e r m i t allowing access t o a f l o a t i n g roof (DOES) (WES NOT) i n c l u d e

e n t r y i n t o a f l o t a t i o n compartment.

8. It (IS) ( I S NOT) n e c e s s a r y t o t a g o u t Mixer Motors when i n s p e c t i n g tanks

c o n t a i n i n g t o x i c vapors.

9. R e s p i r a t o r y p r o t e c t i o n i s r e q u i r e d i n tanks undergoing c l e a n i n g by
(SANDBLASTING)(WATERWASH~NG) .
10. S p e c i a l p r e c a u t i o n s a r e r e q u i r e d when your i n s p e c t i o n i n v o l v e s (TERA
E T H n LEAD) (BYDROGEN SULFIDE).
 (ANSWERS)
COMPARE YOUR RESPONSES ON T H E P R E V I O U S PAGE'TO T H E ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR'WORK.

4. DOES

5. BLUE

7. DOES NOT

9. SANDBLASTING

.
10. TETRA E T m LEAD
BYDROGEN S U L F I D E

(STOP)
 EXERCISE #8

(QUESTIONS)
SELECT THE CORRECP ANSWER FROM T H E m T I P L E CEOICES I N THE FOLLOWING STATE-
MENTS AND UNDERLINE I T . COMPLETE A . STATEkENTS BEFORE TURNING THE PAGE.

1. Tank bottoms submerged i n mud d e t e r i o r a t e (SLOWER) :(FASTER) than i f sealed

on a dry foundation.

2. A tank dyke 5' high and 300' square was cut t o f a c i l i t a t e cleaning and
r e p a i r of t h e tank. Upon completion of t h e work the cut was repaired t o
a height of 4'. The reduction i n capacity of t h e dyke i s (20) (60) (80)
. .
percent.

3. Excessive tank settlement (DOES) (DOES NOT) have any e f f e c t on t h e

.- --.
s t r e s s e s i n t h e piping serving t h e tank. .... .
C 4. Uneven settlement of a tank (DOES) (DOES NGT) e f f e c t the operation of a
..
f l o a t i n g roof.

5. Film coating f a i l u r e i s most l i k e l y t o occur on t h e (SUNNY) ( S W )

s i d e of a tank.

.6. In the Louisiana Gulf Cost area, tank s h e l l corrosion r a t e i s highest on

the (NORTH SIDE) (SODTB SIDE).

7; Piping connections a t tank nozzles a r e l i k e l y p o i n t s of (HIGB) (LOU)

s t r e s s i n t h e welds.

8. S t e e l , unprotected, (RUSTS) (DOES NOT RUST).

.9. Water i n a pontoon more than l i k e l y means t h a t t h e compartment i s holed

through from t h e (TOP) (BOTTOM).
 10. Tank stock i n a pontoon more t h a n l i k e l y means t h a t t h e compartment
i s holed through from t h e (TOP) (BOTTOM).

11. To properly i n s p e c t t h e s u p p o r t l e g s on a f l o a t i n g roof tank, they must

be removed from t h e i r (SLEEVES) CGUmES).

12. The most h i g h l y s t r e s s e d weld on pontoon type f l o a t i n g roof i s t h e deck

weld at t h e pontoon (INNER) (OUTER) rim.

13. F l o a t i n g r o o f s should f l o a t f r e e and (L-) (WEN).

14. A f l o a t i n g roof (MUST) (MUST NOT) r o t a t e w i t h i n t h e s h e l l .

15. Tanks (ARE) (ARE NOT) e l e c t r i c a l l y grounded.

---
16.
--
A r o l l i n g ladder binding i n i t s tracks (LKN)
---,.srvc~cl;i-dmge---------
?..-.-'-I&YIV~TJ
\- -..--..
a f l o a t i n g rdof.
...
.(-
-
17. Heavy r a i n f a l l (CAN) (CANNOT) damage a f l o a t i n g roof i f t h e roof d r a i n s
plug.

(TllRN TO THF FOLLOWING PAGE)

 COXFARE YOUR ItESPONSES ON TRE'PRFVIOVS PAGE TO TIIE ANSWERS BELOW. CORRECI

ANp ERRORS IN YOUR WORK.

1. FASTER 10. BOTTUM

2. 20 11. SLEEVES

3. DOES 12. mE
R

4. DOES 13. LEVEL

5. SUNNY 14. MUST NOT

.. . ..
-
15. ARE .<
6. NORTH SIDE
(-
7. HIGH - 16. CAN

8. RUSTS

9. TOP

(STOP)
 EXERCISE B9

(QUESTIONS)
SELECT THE CORRECT ANSETERFROM TI~EMULTIPLE CHOICESIN TKE FOLLO~TNGSTATE-
MENTS AND UNDERLINE IT. COMPLFL'E ALL STAICEXENTS BEFORE TURNING THE PAGE.

1. A rank map n o t be e n t e r e d w i t h o u t a (RED) (WHITE) (BLUE) permit.

2. Upon e n t e r i n g a tank, t h e f i r s t t h i n g t o be examined i s t h e (OVERHEAD

SPACE) (BOTTOM) (SHELL).

3. I n tanks c o r r o s i o n i s s e v e r e i n / a t (THE TANK BOTTOM) (VAPOR SPACE)

(THE LIQUZD LEVEL).

4. Sunlight through a t a n k roof i n d i c a t e s t h a t t h e t a n k i s ( H O L ~THROUGH)

-- ---
(VENTED OPEN)?- -
. .
, c 5.
.;. .

The h i g h e s t s t r e s s e d j o i n t i n a t a n k s h e l l i s t h e weld j o i n i n g t h e s h e l l
t o t h e (TANR BOTTOX) (CONE ROOFL.

6. A bulged l i n i n g .is a s i g n of d e t e r i o r a t i o n i n t h e (LINING) (BASE >EX.&).

7. The i n s p e c t i o n of a t a n k should proceed from (THE BOTTOM UP) (THE TOP

DOWN).

8. A bottom i n s p e c t i o n may r e q u i r e t h a t t h e bottom b e (COUPONED) (TREPANNED).

9. It ( I S ) ( I S NOT) uncommon f o r a tank bottom t o be holed through and

plugged w i t h t h e products of corrosion.

10. Support eolunms o u t of plumb (CAN) (CANNOT) a f f e c t t h e o p e r a t i o n of an

- i n t e r n a l f l o a t i n g cover.

(TURN TO THE FOLLOhTNG ?AGE)

(ANSWERS)
COMPARE YOUR RESPONSES ON THE PREYTOUS PAGE TO TEE ANS- B m . CORREm
ANY ERRORS I N YQUR WORK.

1. BLUE

2. oVERIIEAD SPACE

3. THE TANK BOTL'OM

THE VAPOR SPACE
THE LIQUID LFoEL

5. TANK BOTTW

6. LINING
BASE MEl?AL

7. THE TOP M)WN

9. I S NOT

(STOP)
 (QUESTIONS)
SELECT THE CORRECP ANSWER FROM THJ3 MULTIPLE CHOICES IN'TKE FOLLOWWG STATE-
MENTS AND UNDERLINE IT. COMPLFTE ALZ. STATR5BQS BEFORE TURNING THE PAGE.

I 1. The r e t i r i n g t h i c k n e s s of tank components t o which an a r b i t r a r y thickness

was given i s (112) (213) (114) of t h a t amount.
I 2. The r e t i r i n g t h i c k n e s s o f a t a n k roof i s (3116) (3132) (3164) of an inch.

I 3. A t a n k bottom should b e r e t i r e d when reduced t o a t h i c k n e s s of (118)

(31163 (114) ".
- 4.-4 tankshell-reaches i t s r-
e t-
i-
r e m e n t l i m i t when t h e c o r r o s i o n allowance
-
i s (GONE) ( 112 GONE).
2.

5. Tank bottoms a r e t e s t e d by (DYKING) (USING A LEAK BOX).

- +-
I 6. The weld attachments on r e i n f o r c i n g pads a r e t e s t e d with air under a
p r e s s u r e of (50) (40) (60) p s i g .

7. I n t e s t i n g a t a n k s h e l l whose bottom course h a s a t h i c k n e s s in excess of

718". t h e f i l l i n g r a t e during t h e top one-third of t h e t a n k should be
I (9) (12) (18) i n c h e s p e r hour.

8. Tank r o o f s must be t e s t e d w i t h extreme c a r e . ALr p r e s s u r e f o r t h e t e s t

s h o u l d n o t exceed (1.25) (1.36) (1.46) inches of water.

9. F l o a t i n g r o o f s a r e t e s t e d by (FLOATING) (SUBMERSION).

10. A t a n k 40' i n h e i g h t and 260' i n diameter s t o r e s a m a t e r i a l w i t h a

s p e c i f i c g r a v i t y of one. I f i t is constructed o f a m a t e r i a l with a n
a l l o w a b l e stress of 23,000 p s i with'a j o i n t e f f i c i e n c y f a c t o r of 1, t h e
r e t i r i n g t h i c k n e s s of t h e bottom course i s (1.173) (1.146) inches.

(TURN TO THE FOLLOWING PAGE)

 (ANSWERS)
COMPARE YOUR RESPONSES ON TEE PREVIOUS PAGE TO TEE ANSWERS BELOV. CORRECl
I
ANY ERRORS I N YOUR WORK.

I 1. 1/2"

a -
4. GONE

>,ijim?G
USING A LEAR BOX

(STOP)
 EXERCISE 1/11

(QUESTIONS)
SELECT TEE CORRECT ANSWER FROM THE MULTIPLE CBOICES I N THE FOLLOWING STATE-
MENTS AND .UNDERLINE I T . COMPLETE ALL STAl'EMEETSS BEFORE TURNING THE PAGE.

1. Tank i n s p e c t i o n r e p o n s a r e e n t e r e d i n t o a computer system i d e n t i f i e d

as (FERS) (ERS).

2. Upon t h e r e c e i p t of Basic Data and General Design Data which i n c l u d e s

component p a r t design, t h e computer system i s a b l e t o produce a (FRONT)
(COVER) s h e e t concerning a s p e c i f i c tank.

3. The Fixed Equipment Record System (DOES) (WES NOT) p r w i d e a tank

-ccfiedrding-f unction.
--

c 4. Tank i n s p e c t i o n d a t a i s r e p o r t e d i n a (EQUEHENT CONDITION HISTORY REPORT)

5. FEFS, using t h i c k n e s s measurements of tanks (DOES) (WES NOT) have t h e

c a p a b i l i t y of c a l c u l a t i n g and r e p o r t i n g c o r r o s i o n r a t e s .

6. The remaining expected l i f e of each i n s p e c t i o n p o i n t (IS) (IS NOT)

c a l c u l a t e d and r e p o r t e d by FERS.

7. F E W (DOES) (DOES NOT) have t h e c a p a b i l i t y of c o r r e c t i n g f a u l t y i n p u t

data.

(TURN TO THE FOLMWD'G PAGE)

 129)

EXERCISE #I1

(ANSWERS)
COMPARE YOUR RESPONSES ON THE P?lEVIOllS PAGE TO THE ANSWERS BELOW. CORRECT
ANY ERRORS IN YOUR WORK.

2. FRONT

3. WES

4. EqTxPMKm CONDITION H.ISSTORY REPom

7. W E S NOT -

(STOP)
 BOTTOM DESIGN

Tank bottom design requirements t o be specified are:

a. Slope "Apex-up" or "Apex-down."
b. Category of bottom required f o r the predicted settlement per Table 3.
c. Spec;fi; location requirements:
1. Baton Rouge, See Table 3.
2. Baytown, See Table 3 , Category 3 .
3. Bayway, See Table 3 . Category 2.
4. Benicia, See Table 3.
5. Billings, SeeTable 3.

TABLE 3
TANK BOTTOI~DESIGNREQUIREMENTS'"

PfiEDtCTED S E R E M E N T 12' . TANK DIAMETER

Cinpov of
bnom kiimum DiHrrrM
st h d l in b n a Oni50ht.3150tt Om 1 W f t
~ i f k d
~..... .
-iiA i i - 6 5 3

1"".
~ - - - - . 4 n n ~ l l ~ r ~ l ~ r t ..~ ~ n f 3 ~ h ~

-1
1 -gi,2m3[) 11
minimum wid*. Bonom
zlares m o w'uMIOM
. with 70% jdinr'cfficicncv.

2 46 in. -L 1 i d 3 3 tt Annutar plarn of 2 11

minimum widtn. Bonom
Annular pla:rr of 3 I f
minimum width. Bonom
-. pbter two W r r -1d.d
with 705 i s i m efficiency.
p l a l ~ 1r 1 0 WLI M l d e d
with 70% joint r f f i c i ~ n w .

3 612 1 2 inJ3D ftf31 Annular p l a t s of 3 f t Annular olarcr of 6 I1 mi*

minimum wkith. BOItom imum wislh. aonom >lam
plater lo mu wrldrd mo mzr (rnin.1 welord
with 70% join1 efficiency. w i n 80% ioinr e.fficicncy.

No*-:
Ill No wccirr rcovircmcntt for mnkx 53 feel a c d undn i n diamner.
I21 PREDICTED SETTLEMENTS ere b d upon the 1ollorrir.l mndixionr:
e. A l l lertlemcnrs i n c l u d ~initial wmtn 1 o d i r . l of I h r tank.
b. D ~ l l r e n t i arl n l e m n t in the ~OIIM) rcfnr to dcrtation f m m s n t i c i ~ w dhhavicrr on uniform will:
I.=..the Bourrimw rolutbn.
c P U r w rilxirg of the tank i r mt mn%aNcd dnrimencsl l o I h r bartorn.
-131 I f .imw of rntrnma i. .r-. w n r bm oi &= imwonnnsnt k r - a u j d p r i m to u n k --ion
sail impro-nt *ill b. d o n by p r d r a m w d w . a x-=il*d.

I Annular p l a t e s per Table 3 s h s l l have thickness as follows:

I-
I Sottom Shell Course Thickness 1 Annulilr Ring Plate Kiniinum Thickness
1 Loss Than o r Eaual t o 1/2" 1
t
l/4"
Over 1/2" t o 718" I 5/16"
I Over 7/8" t o 1-1/4" I 316"
- Over 1-l/4" I 711 6"

1
 REFERENCE 2

TANK SHELLS
Target tolerance f o r peaking i s 1/4 inch. An occasional peaking u p t o 1 / 2 inch
sha;l not be cause f o r rejection.
Target tolerance f o r banding i s 1/4 inch. An occasional banding u p t o 112 inch
shall not be cause f o r rejection.
The radius of the s h e l l measured near t h e bottom of t h e base course s h a l l be
within the following tolerance, which represents deviation from t h e average
radius:

Tank Diameter, Foot Tolerance on Radius, Inch

Less Than 120 1/ 2

120 t o 210 1 -
--
Over 210 1 ~ 1 7 '-
~ J
...
(I The circumf%rence s h a l l be no smaller than t h e theoretical circumference f o r
the specified diameter.
2

The maximum permissible out-of-plumb of any s i n g l e shz7l course, exclusive

of banding e f f e c t s and f l a t n e s s of s t e e l a s furnished, s h a l l be 1/4 inch. An
occasional out-of-plumb of 1/2 inch per course s h a l l not be cause f o r
r e j e c t i o n provided t h a t tank diameter measured across any v e r t i c a l plane
through tank center does not vary more than 4 inches from top t o bottom of
tank.
I .Size of
rncmbcr joincd.
shall c q u d ihc thickness. of thc t h i n c r 3. See Table 3-1: 1)'pa of flangcs and mcihods for atlachins
boiling flanges to manhole n e c k arc iotuchmgcahlc. .
4. Thc shcll nozzles of Fig. 3-7. for manholcs 20 in. in
ditmcter and largcr, may be substitu!cd by agrccrncnt
thc purchaser.
.Vor<s: 5. When ihe shcll n'onlcs of Fig. 3-7 are uwd or whcn
1, Gasket malerial shall bc long-fibcr asbcslos shcct, unless mmtholc Dclails B and C arc uscd. lhc minimum ccnlcrlinc
othcrt\isc spcci5cd. hcighrs above thc tank boaom. as even in Tahlc 3-6, arc
2. Sec Tablcr 5.2 through 3-5. also acccptahlc.

I FIG. 3-&Shell Inanhole (See Tables 3-1 Through 3-5).

 REFERENCE 3 (cont'd)
.. TABLE 3.T-Thickness of shell Manhole Cover piate a n d Bolting Flange (See Fig. 3-61
~ 1 dimensions
1 arc in inchcs unless othciwisc St~lcd.
(3) (4) (5) (6) (7) (8) (9) (10)
(1) (2) ~ i ~ . r h i ~ orh ~a o. l d FI.ncc
n ~ Nm Finirhinr
hfrr. Eguibxlrnt M i i . W i k n a r ~ C O VPhlc U
Tank PWYIC.
' lain, 24". 30.i". >birr ' ' ~ 20.in. ' lli". Sin. 36h.
Hcichl (Poundrpcr mholc M.oholc ht*nhalc Manholr
( F ~ O Squ.rrlmhl M.*.IC M . ~ ~ O I = ~ . n h o l c *nholc

21 9.1 ?46 %
% K
?4
K6
K % '/6
% 'Aa
27 11.7 % $6 %6 %
32 13.9 'As Pnh 'ob % % %6
40 17.4 ?4 'K6

s;s ?4 x % ?46 41 %
45 19.5 % !is 'x6
54 s.4 ?46 1% 'Ks
% 'As ?46
41 % x,
65 26.2 >(s M ?i % % '% l?ia
75 32.5 1x6 '%€ v
'6

Equivalent prcssurc is bascd on water loadins.

TABLE 3-2-20-in. Shell Manhole (See Fig. 3-6)
~ 1 dimensions
1 arc in inches.
0) (10) (11)
(1) (2) (3) (4) 5) (6) (8) ~ (9) ~ ~ ~ B
~ u i l t~* ~ ~ Fi r * ~ ~
~ ~ . ~ ~ U i m ~ a ~ u n DiirnnccPluc
D U ~ C I U Rinn Dic

lnridc M.L
. C
: - lhc
A

l ~ i d ~ D~mcucr
Diman Mar.
. hlin.
NdShWncu
Add
Rcin(cin(rC-C"[
mirknnt of Ao.chmcnt mnpc D h Diamncr
~ ~ or of-
Manhole Holcin ifK&
shcliand
htanholc
Aluchmm'
Si ofFillcl
' wctd wCld . APD'OL
~ ~ d i v l
*qi%or
wdLh ~Fnmc
or or
Shlllt
. o h o t e Hatein
ID* DI*
Fm(0c .
ID, Sktl
Day
nick"=
RrnW ;
I
% :' :
,.nd T A B R L It' 20 21 ? i xs
?C 20 22!i
22 !i
K
><
%6
2?%
5-. %-
.. % 20 22:i K
X& 3;s 20 43. 5;
% 3;6 H
D 21% 25 20 UU K
Kc ?4
I/
y
6
?4 21?4
21%
253.;
25%
20
20 23%
233; MM
M ${
G" ,. 1!6 -
?:. y$ ;?. ax 52%
51?<
221% 25%
2% 20 21
24?.i 316
Y
-% Is6 21:i 25ti 20 21W 3%
h6
x,
1h6 .% M?.;
51%
52 21% 25?< 20 24fi '/is

1 21 26 20 Ifi
25?1
1 I 20% 26 20
IG' 1 20 25%
I% 1 20 25:; %c
I KG 45

I :5
1%
1
1
45
45?4
52W
53
gE
20?4
.26%
26%
26?i
20
20
20
26
26?{
%
%
'hi
I%
I
I%
x6
1
I
45%
4551
4541
53
535;
53!1
::" 26?:
27
20
20 .
26%
265:
27 %
20 27 3.; X,
1Y6 M 27 % '?a
1% 46 20 27% !?k
I1K6 1955 27H A
1>i
~
~
i
i
53%
~ o r bolt
~ circlc
~orcovcr
--
~ u Dsr 26% in.
~ ~platct Dc~ 28?:
r in.
20 28

* ~f a platc thicker than rcquircd is uscd for the hydr* scaffold, hrackcts.
,in, , , ( 3.3,3hC1l Deskn-), lhc S~.II.~I~IC I minimum neck I ~ C ~ ~ Cshall S S fiichcss Of !"c
thickness. within a vcnical disrancc both abovc and below thc shell o r thc allouablc finished t h i c F s of ik bolrlns
ccnlcrlinc of hole in shell plaa. equal 10 t h t . flange (scc Table 5-1 ). u,hichcvcr is lhc ihmncr, but Cay
I I my h shall ~ h ncck
c in a b u i b u p manhole be lhinncr Ihul Ihc ?'lck-
c r l c imcnSon h o e in ncsscs 6ivcn in Column (11). If thc neck !h!ckncss on a built-up
considcrcd as rcinforccmcnt: and the thlclmcss. T, of thc man-
ho. at13rhminl bc dcac.sid auordi"gIy. 1. such rnanbolc is grcalcr than r c b i r c d rnln'mum. Y. m?nbO1c

(_
..
,. form
,he rcinfoximenl and
I csign I
spc;iM in Scct. 33.
T h C Doir in shill
S f

bc
attachmnl.wrld~ng sh.ll-a.n-
r i f o r c c c n t of I o p n
, , . j ~ h horizonta~
attaihm=ni flan!$ may be dccrcaSCd accordin&'
limits specified in S c t33.
,
g crc31cr than l b in. is applicable to Appendix D and G
tanks o d r ; h o m r i ircatcr than 1% i n is a ~ ~ l loi c ~
Ihc

m3jor dianlctcr of 29 in.. where ncccssar). for rcrnoval of rigid Appcndi" only.
 .- , . .. - -.,.-. -.
.. .- - ..
REFEENCE 3 fcont'd)

TABLE 3-3-24-in. Shell Manhole (See Fig. 3-6)

All dimensions arc in inches.
. .
Fmmc U$ingConn)nl- FramcU%in~Conrunt- Fmmc

Thicknnx ot
Shetland Atm:hmntFLrnsc
Diimc~~Rinc
- ,
lmidc Mar
DK

D i m s Diime~cr
Diimcar Plug Wt
lnlidc
DLmner
Mu.
DLmcr
.
Built-up
hlin
KoskTbicknor
Add
Rdnfo-nt
hlnnholc Six ofFilirt C______ d aC or d UNd
Aluihmcnr Aopror Lcnehd Menhole Holcin Mxnholc Holcin Ihid;na%
FLln~c. \\'=Id . Wcld R.diur Sidc Uidth Fmm Shell Fram Shcll l%Lcu
rzndT A B R L 11' ID. DII ID? Drr Thnnt:

Diameter o r bolt circlc Da

Diamctcr o r c o v u platc Dc
-- 30:i i n
32W in.
" I f a shell p h t c thicker than rcquircd is uwd for ihc hydro- $ The minimum neck thickness shall bc the hiclmcrs of &c
static loadin: (Scct. 3.3. "Shell Design-), h c crccss shcll-plate shcll plate o r the allowable finishcd hiclmcsr of thc boltinf
thickness. \taiihin a vcnical distance boih above and bclow the flnngc (we Table 3-1 ). u*hichcvcr is the thinncr, bur in n o czsc
I centcrline of thc hole in thc tank Jlcll plam, cqual lo the vcr-
tical dimension of thc hole in the tank shcll platc may be con-
sidered as rcinforccmenl: and the thickncss. T. of ihc manhole
shall thc neck in n builbup manholc bc thinncr than the h i c k -
ncsses givcn in Column (11). If che ncck thickness on a built-up
manhole is greater than thc rcquircd minimum, 16c manholc
allachmcnt flangc ma)' k dccrcxscd accordincly. I n such cascs. attachmcnt flangc may bc dccrcawd accordinfly wilhin &c
i the reinforccmcnt and thc attachmcnt w c l d i n ~shall conform lo limits spccificd in Scct. 3.3.
! thc dcsifn limits for reinforccmcnt of shcll opcnings spccificd in : I g c a t c r than !5 in. is applicable to Appendix D and G
Sect. 3 3 . tanks only: however, r srcatcr than 1:; in. is applicablc t o
Appendix G only.
 TABLE 3-4-33-in. S h e l l M a n h o l e ( S e e Fig. 3-6)
A:] dimensions arc in ischcs.
(7) 161 (9) (101 (11)
(1) (11 (3) (11 (5) (61
FrameUsincConninv ~ Dhm~lrr
, ~ ~ ~ PivcDic
~ : ~ i ~ ~ C Builg-uo
o n Mi". ~ Frmc~ a n t .
D'lmcln R i n D
~a Xc1Thi:Lncrr
,---'.Inside Mas.
Inlidc Mar -Ade
or
mictncrl *tuchmcntFbn@c Dirmcfrr ~ or i ~~ i or. ~ n~ ~ Rrinrorrcmcnl
r ~ , ~ ~
shdl and
D ~
or
~ C ~ C ~
or irsct
Sl>nholc S i x orFiIlct '-------' ~ . ~ h ~ 0~ 1 l~ i ~n Nanhalc H a i ~ i n Thirkncu
*~lr=hmo~l '
FI~~GC'
, 1
B
Appro&
R
LcncthOr
sidc
L
,Gdth
(I.
~izmr
ID"
Shell
DHI
Framr
ID, ShcI1
D OP
I,, " . I
nan.:
tmdT A 34?.j 30 3l?i
2 'i ?i6 ?" 66 79?i 3% 31 'icI;
. IF l

66 79!4 71% %!4 30

fib !I h 30
<': 22%'
7 - ,

?' I. !G 65?; 78?< 3 34% 30 32!1

'ik
3 IC.
.1'
65% 78?< 33; y?;
-. ?. jc % '/s 30 325 -16
%.
3.;
$16
!.5
'is
?B
%6
)II
6q!'
)II .
6%;
65?<
78
78
32s
32
3d?1
35 30 33 '
(6

3 35 30 33:; 51b
?k 65 7755
-.lc. ?k I ? 3:: 30 33%
a>-<
.-v '%
i 5.
'i ?4 3155 55:;
'i I!+ .I,.< .

NH 76?i 3313.i 30 31
1.: 1;
s:I6
ii
'3-ic
?;
a11r . @?4 76!i . 2534
:j!+ 30
30
3?!;
M?-j
'lb
!>6
li
-.
Yc
1C
if,,
-,
26 61f; 76;; >I!;
3
253,
30 :I
'?ic $11, . '% M:! . 76!i
33; S 3 4

30 35
,
' I<.
36
-I /
l!i! -?6 i.
1
I >;6
1 M
wii -. .i76fi
31-,
G1; - - ' " . C--,
~ Ce .
30:: 36li
30
30
151 .
~ . j b . ~
'It
.-
- , ~ ~
I ?I 14; I 65 77 50:i >h14 50 32,. !I$

I?;' 6 12% I 65 77
30 36 . ,i

I ?i ;!I 1I 65;; 77?i SO!?

?01.{ 36
': 36!4 30 361, ?;
I?,,' I!,c 65?; 77?5 30 36!.$ s+

*.
!?
It4 !6 14; I 6535
65!4
77?4
Ti?$ ' jo:;
3096
56:;
glJ 30 35;i 1'-.I..
I!,, . Plr, 1%~ 1 30 37
I !.i I!..? I 65% 773 30 I
.-
I

65" 77% 197< rr 30 37!i "4

I?,F 9,' l?,i 29ij 30 37:;
37:; 15,;
?.$ I !f I"1% 66 7s
I?.;
66
i8
>9$,.i 37!, 30 . .
!'!I$ ?.$ It! \G 30 38 1
",,, 66:; 761; 29!5 3F
11: ;!I Ibf
~
~ i
i bolt ~circlc D,~
or cover~ p l ~ Dc~ c
-- 36!2 ~~ n . t
3S?I
~ in. ~ :
~
~ ~
~

$.I f 3 shell pla~: lhickrr ~ h n nrcquircd is uscd for the hydro- =,-, l :he ~hictncssof :LC
ntcl: lhickncss ~ h d bc
jllo\vablc finished thickness pf bol:ir.;
s12~ii+~odin:,!Sccr. 3.2. ..Shell Dcsifn-). the crccss shcll-plalc shell plalc or ln no :=s=
thickness. \v,:nin :I vertical rtis~anccboth above 2nd bclokv the ~ ~ 5.1 ).
b whichcvcr
l ~ is thc thjnncr. zu:
thick-
d c hulc in ihc 1anl: shell pl:lle. equal to the \'cr- neck in buill-u2 rnmholc bc thynncr :hzn
cen~crlin: n=sscs ri\.cn in Column t l l ) . :hlikncss on 3 bui~i-IIF
tical dimension o i ihc holc in thc tank shell plate may be con- mnnholc is E:catcr than thc rcquircd n11nml:m IZJ*~!~
sid.rcd :IS rcinlorccrncn~:and th: thickness. T. o i the rnanhol: 211schn,cnl nmEc
may be dccrcascd accordrnfl? within
stw;hmcn~ flanfe may bc dccrc:tscd :~cco:dingly. In such CaSCS. limi:s sp:ci6:d in Sccl. 3 3 .
!hr. rcinrorccnxnt :,nd the ntl:ichn~cnl rtclding sh:111 conform 10
:he d c s i ~ nlinri~sfor rcinforcemcn~,,I shcll opcntnzs sitecified in
,
; srcalc: :ha,, I ) in. is nppliuble l o AprcndiS D and Cj
houcvcr. r z r e ~ ~ cthan
r 1 ' in. is a p ~ l i i a b l cIu
Sccl. 3.3. . ~ n c c n d i sG only.
 _ . . . . . . _ -- .- . . . . .- ..-. - . - . - .. , .- .- ........ , . .
REFERENCE 3 (cont'd)

TABLE 3-5-36-in. Shell Manhole (See Fig. 3-6)

All dimensions arc in inches.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (111

nickn- or
Fnmc Ulinr Contynl.
r
-
Diimefcl R t n ~Dne
Inzidc Mni.
F R ~ C UConsunr-

lmidc
Dimctn
~ ~ S ~
Diimctei PIUSDic
M~li
Dimcts
. 8uill.u. Fmmc
Min.
NectThickncu
Add
Rdd~rumsnt
Shcll.nd ~ttachmrnlFlrnce D i mor
a c r DLmarr
OT or or ir6&
Ltanholc s h or~illa Manhot. Holcin Mznhals Hole in Thiiknm
Attldlmcnc
Fbncc'
\VLtd %$% Lcnnhar
Sidr Wdth Fnmc Shdl Fmmc Shdl I r k
rand T ' A B R L 11' ID" Dyr ID, Dxr h t :

3;s h% % 6'1$ 78 93?i 38% 40!.i 36 37% ?k

% ?la % !i 78 93% 36% 40% 36 38 ?i
I, 7711 935.i 38% 40% 36 38% Vs
%6
M
3;6
?is
$6
36 %
-8
77?f
77!,
93%
92%
38%
38%
40?.<
40%
36
36
3SM
38?< x"/s
75.6 3k 75.6 $j 7 7 92% 38 41 36 39 ?$
.
+ %
%i 36
?k %
?6 %6 77 92 3734 41 36 391;; l/s
N
gi%
!i %
'$6
76!$
76%
91%
91%
37%
37%
41%
41ii
36
36
39%
393: ?6
44;fj 40 M
g, % ?,i ?d .
?<76;s 91 36
g.
k
I!
s?6
46
$6
%la
1% '
i%
76?i
76!i
76!$
9D%
90:
90?$
37%
37%
37
41%
4l?4
42
36
36
36
36
40%
40%
40?,
41
M
M
X6
-,
36
I S/Q I 1 76?: 91M
!4e
I !iu %
.ri:y;-- 1% I
I
761: 91%
77p9:,xp2L3.+fi?1
3634
I-,.
42
-'.
36
l6 .
41?.%.
41%
,.

E-
-us

XS l?ii 1 77 91% 36% 42% 36 41?6

I?is .2. .
l?h % 1% 1 77?.: 91?i 36% 42% 36 41 15.6
iK, -, I 3,s 1 77!i 913i 36% 42!4 36 42:;
1% $j 1% 1 77% 92 36Jg 415; 36
36
42K
42?$ <
!I'
I ?<6 % lI<c I 77% 92 36% -I??< 43 ?.i
1% ?<6 1% 1 77?< 92% 36 43 36

Ilk '6 1% 77:: 92!i 3% 43 36 435; >f

1%, 76
78 92% 35x 43?4 36
36 43!4
13?$ l?iu
92% 35% 43% %
11h6 !$ 11h6
I" 1% 7c!i 92pi 35% 43% 36 M 1
I?; % l?4 . 1%
r bolt circle D.
~ i a m c t c of --
42% in.
Diamctcr of c o w vlatc D C ' M ? i in
" If a shcll platc thicker than rcquircd is urcd for the hydro- + Thc minimum nc;k thiclncss shall bc thc thickness of ihc
slatic loading (Scct. 3.3. "Shcll Design"). the c s c a s shcll-platc shcll plalc or the allowable finished thicknczz of lhc bolting
thi&ncss, within a vcnical distancc both ab0r.c and below thc Ransc [rcc Tablc 3-1). u.hichcvcr is thc rhinncr, bul in n o casc
ccnlcrlinC of thc holc in the o n k shcll platc. cqual 10 ihc rcr- shall ihc ncck in a built-up manholc bc thi?ncr than thc ihick-
tical dimension of the hole in the tank shcll plntc may be con- ncsscs givcn in Column (I I). li the ncck th~ckncsson a built-up
sid-rcd as rcinlorccmen~:and thc thicl:ncss, T, of thc manhole mnnholc is grcatcr than thc rcquircd minimum. lhc .m+olc
attachn,cnt Ranee may bc dccrcnscd accordin;ly. In such casts. attachmcnl Ransc may bc dccrcascd accordin~ly rvlthm thc
thc rcinlurccmcnt znd thc attachmcnr n c l d i n ~shall conform to limits specified in Scct. 3 3 .
thc d c s i ~ nlimits for rcinforcemcnt of shcll openings spccificd in :r ~ r c a t c rthan !; in. is applicable lo Appendix D and G
Scct. 3.3. tanks only; howcrcr. r grcatcr than 1;'. fn. is applicable t o
Appendit G only.
 REFERENCE 4

A CtRCV.hR RZINFORCIM PLATE

MU B E s u Q ~ T V ~ EFOR
D THE
PLATE S W .
OWE ItN.TLLCTALE HOLE IN REINFWICIU:
PL&E .OH HORIZOKTAL CENTERUNE-

ALTERNATIVE SHAPE

FOR BOTTOM EDGE

(SEE DETAILS C AND 01

SINGLE F L A N G E DOUBLE FLANGE

REGULAR-TYPE FLANGED NOZZLES, 3 IN. OR LARGER
BOLT HOLES SHALL STRADDLE
THE FLANGE CENTERLINES

.
I ..s&

I
I DETAIL A DETAIL B DETAIL C
 REFERENCE 4 (cont'd)

DIMENSION A EOUIVALEm
;O SIZE O i FILLET W E D A
(TABLE 3-7sCOLUlAN 6 )

e
TYPE A
SCREWED-TYPE SHELL NOZZLES, 3/4 IN. TO 2 IN.. INCLUSIVE
i
-1 Sores:

i 1. Scc Par. 33.7(f) regarding size of n,clds.

4 ~ h ~ l l - ~ 1 h ~ s ~ a 1 1 ~ r ~ o i ~ ~ ~ ~ i n ~ ( 1 r
cithcr part joined by rhc fill51 wcld:' .

I C 2. Sce Par. j.6.11. "Thrwdcd Connections." regarding Cou-

plings used in shcll n o d e s .
3. r . shall bc no1 less than thc lhictncss of Schcdulc 1 6 0 p i ~ .
5. 3-in noulc rcquircs rctnforccrncnl.
6. Wcldinp bevel dctails ma),
aprecd to hg rhc purchscr.
from thosc shown if

FIG. 3-7-Shell Nozzles (See Tables 3-6,3-7, and 3-8).

 p&mWINCE 4 (cont' d)
TABLE 3-6-Shell N o z z l e s ( s e e Fig. 3-7)
All
. ~~~ dimensions are in inches.
(71: (el: (PI:
(11 (21 (31 (41 (5) (6) ~in.oi%:~n:clram
Botio3oc
or ~ic.~innmc T.DL I o ~ c n t c o~xc:::~
r
Min.
~~~~~d
Thkknnt or Dbmcisroc
~~~~i~
Holcin
~cjnro,cjnc
Lmp'hor
Sidcor .
Rrinrortin~
K;d,h
RcinrorcinL rr~mSh*I!10 c_--
Pi~\C,l!. PLllr Pblc Plllc Rxngc F:; Rr~ularT?~ L r r 7:x
11. J H C
s i . ~ ~ r s ~ ~ . lOD
~ orPipS D" Lt

--
<7 AS'
;6% ;
f
50 ..?
iF
46 i
.-<
;-
40%.
.
-- 24
3:' ;
76'4 923; I? 42
36 :.E - Sec Tablr 7:. Col. (21 3E% 14 40 165.:
36 ...:
35 26% 72>< 88 36 311;
:,-!
831; 13
34 .C( A 96 6S?j
78% 13 36 -i'i ;
32 52 2:%,
0j.s
6-1?5
so=; 735 12 3-1 .- =.
10 ?O
28
26
24
2s
26
2: 0.-%I
. 28%
26%
24%
56?i
52:;
49?4
68?;
61
60
12
12
12
32
30
25 .....
252 6
2hl.
-- -
-- -_
7-.

--
71)
70
--
:-
20
0.50
0.50
,.g
--,
20%
Is;*
41%
551;
50%
II
I1
26
> 24 ZGL;

--
77 1;'F
. 20 16-;
1-F 15.:
...
., '17 :1:
I::?
15
13 --..:
0:
II
9 h::.
S
7
....-
.--.
6

3 4.W Couplinc ??4 11';

2s 2.~75 Coupljnz ...
I?5X 2 . 3 ~ Coupling ?I.; ...
IS I .576 Coupling IIL~G ...
$?:. .- 1.313 Coupling l !+ ...
',' Ehtra.,lronc pip~-for sizcs up :o 12 in.. inclusive, refcr lo
API St:tr.d:rr! 51: for sizcs orcr 12 in. lo 22 in.. inclusi\'c. refcr luca~cdnt minimum d i s ~ ~ n c c .
~ i : , ~:,"d~ scrcst~d
~ d norrlcs in 2-in. pipe sir: o; s w l l c r
lo :he kttest cJi~ionof .+SThl -4 55. .+
133, A 135. o r A 139.
Pipc made from formcd pl:tle elcctrica11y bull xcldcd be d o not rcinforcin; plates. D , will be thc dia.--.c' ; of..
hole in !he shell plx~eand ucld A nil1 be as circa i- G I -
subs:itulcd for any of thc abovcrnen:ioncd pipe scct!ons.
* \ViJlh of sl~cllpl:itc shall hc sufilcicnt l o conlaln reinforc- ,,,,,,,
( 6 ) . ~ : ~ i . 3.7.
: ~ Rcinforcln; p1x:cs ma!. be tlrcd if ?:sired.
: S:rctvcd noulc in :hc 3.in. size requires r:izio;::m:n:.
in":l!e and to provi~k clcamncc from ~ i n hjoint of shell
 -
.. ... . -.20 (401

REFERENCE 4 (c0nt d ) '

TABLE 3-7-Shell Nozzles: Pipe, Plate, and Welding Schedules (See Fig. 3-7)
All dimensions arc in incbcs.

1% 1% IH I ?G x
6
154, l?ii IH I% Xc
II!,~ % 1% I1!.:6 % ?(6
I?: M IH I ?.i % %6

" If a shell platc thickcr than rcquircd is uwd lor thc hydro. Ihc d e s i ~ nlimits lor rcinforccmcnt of shcll o p c n i n ~ sspczifird in
~ t a t i cloading 1Scct. 5.3. "Shcll Design"). thc cxccss shcll-plalc Sccl. 3.5.
thickness. within a vcrtiwl dis1;lncc both abo\*c and b C l 0 ~the t Rclcr to API Standard 5LX; o r to thc lntcn edition of
ccn~crlincof 1hc hole in thc tank shell platc. cqual to the vcr- ASTM .4 1%. A 135. o r A 139. Pipc made from formed plalc
. tical dimension o l thc hole in thc tank shcll platc m=y bc con- clcctrically butt wcldcd map bc submitted for an). of thc above-
sidcicd 3s rcinforccmcnt: and thc thickness. T. o l lhc manhole mentioned pip. x d i o n s .
;litachmm! flange may bc dccrcascd accordin:ly. :n such cascs. :1 ~ r c a l c rthan ?; in. is applicable lo Appcndis D and G
the reinforcrmcn~ and the attachment welding shall conform l o lanks only: howc\.cr. 1 ~ r c a t c rthan ;!I in. is ~pplicablc l o
Appendix G only.
 REFERENCE 4 ( c o n t ' d )

TABLE 3-8-Shell Nozzle Flanges ( S e e Fig. 3-8)'

All dimcnsions arc in inchcs.
(I) (2) 3 (4) (5) (6) (7) (8) (9) (10) (11) (12)
Min
ihiCknns
Diimcln
OT
Dbmctcr
or
DLrnnu orsars
s l i p a n T?m Weldin. .
.I
Min.DiarnctoorHub
slim"
point ~ r \ v ~ l d
urc~dins.
or ODor ~urcd Bolt xumbsr Dtmcci
or
D'umtu
or
Add~ooD
or P i p tirckiyp . TT? K ~ T W
sireor FII~~C %npc ~ a u Circle or B 81 Er
Saulc Q A D C Hola Hola Bolu

6 1
u,
II
9
8%
6
9%
K Bg %
I., .. %
0.10
0.06
4
3
2 :.I
1,, 7
6
5
4
2 @ 0.06
0.07
I ?4 '!is 5 4 3.6 % 0.07
* T h e facinc dimensions for slip-on and urlding-neck flanges iron Aangcs. Thc dimcnsions for flangcs in sizes 22 in.. 2 6 in..
in sizes I!? in, t o 20 in., inclusive, and sire 21 in. are identical 28 in, 32 in.. 34 in.. 36 in.. 40 in, 44 in.. and 46 in. (which
with [how spcctficd in ANSI 516.5 for 150-lb s ~ c c lflanges. arc not included in ihc ASS1 slandards) conform lo 1hc
The facing dirncnsions lor flanges in sizcs 3 0 in.. 36 in.. 42 in. rnanufaclurcr~sstandards.
and 1 8 in. arc in agrccrncnt uilh ANSI 516.1 lor 125-lb cast

PLhTE-RING SLIP-ON HUB SLIP-ON WELDING VIELDING-NECKFLANGE

VIELD!NG FLANGE FLANGE

Thc rt dcsiyn.xcd for weld lhtkncss is ihc minimum pi^ u.all ihi:lness (scc Tablcs ?-6 and 3-71,
FIG. 3-8-Shell Nozzle Flanges ( S e e Table 3-8).

I
 REFERENCE 5

TESTING TANK SHELL

Unless otherwise specified, t h e tank Owner shall furnish and i n s t a l l
temporary water 1ines f o r t e s t i n g t h e tank, f i l l and empty the tank with water,
and remove s i l t from tank bottom a f t e r t e s t i n g . The tank e r e c t o r shall remove
a l l scrap and debris from i n t e r i o r of tank before t e s t i n g and s h a l l witness
t h e t e s t , observe t a n k f o r proper operation d u r i n g t e s t i n g , .and c o r r e c t any
malfunction.
The water f i l l i n g r a t e f o r t e s t i n g s h a l l not exceed the following:

Bottom Course Thickness Tank Portion I F i l l i n g Rate

Less Than 718 Inch Top Course 12 Inches/Hour-

Below Top Course 18 Inches/Hour
7/8 inch and Thicker Top Third 9 Inches/Hodr
, <:ddI e-Thi rd
-I+. 1- Zlnches/Hour --
- Bottom Third 18 Inches/Hoar.
[- J

*Tanks requiring extended f i l l i n g periods, due t o s o i l s t a b i l i t y considerations,

s h a l l be specified.
-
 MODULE BR-EI-60.8

INSPECTION
OF
STORAGE TANKS

SLIDE-TAPE SCRIPT

MAY, 1980

Property of Exxon Company, U.S.A.

Not To Be Copied

Prepared by: 3 . H.-Wood

t, BR-EI-60.8
 MODULE BR-EI-60.8
INSPECTION
OF
STORAGE TANKS

Segment 1 - INTRODUCTION

PRESS ADVANCE

1-1. None. - (BLANK SLIDE)

1-2. None - EXXON LOGO

1-3. None - (EQUIPMENT INSPECTION LOGO)

None (TITLE SLIDE - INSPECTION OF STORAGE TANKS, MODULE BR-EI-60.8)

--'-
Welcome t o o u r t r a i n i n g module on t h e i n s p e c t i ~ ~ t X ~ & - - t a r i K s
.... .
maintained a t e s s e n t i a l l y atmospheric p r e s s u r e .

On January l5, 1919, a l a r g e s t o r a g e tank owned by t h e United S t a t e s

-
I n d u s t r i a l Alcohol Co. of Boston, Mass. i n which was s t o r e d more
than two m i l l i o n g a l l o n s o f mollasses, b u r s t assunder. A t i d a l wave
of t h e b l a c k ' r e e k i n g mass r e l e n t l e s s l y poured down t h e s t r e e t s
a d j a c e n t t o t h e t a n k , i n u n d a t i n g everything i n i t s path. Buried i n
t h e morass and under c o l l a p s i n g b u i l d i n g s were more than twenty men,
women, and c h i l d r e n , along w i t h a l i k e number of d r a y animals.

The i n s p e c t o r s r e s p o n s i b i l i t y , w i t h r e s p e c t t o tankage, i s t o prevent

c a t a s t r o p h i e s such as t h e s e . I n t h i s pursuit, he periodically
determines t h e p h y s i c a l c o n d i t i o n s and r e c o r d s t h e d e t e r i o r a t i o n of
t h e tankage a s h i s t o r i c a l d a t a .

I n t h i s s t u d y , t h e i n s p e c t o r determines t h e r a t e o f d e t e r i o r a t i o n
and i f p o s s i b l e , t h e cause of t h e d e t e r i o r a t i o n .

With t h i s knowledge t h e i n s p e c t o r i s i n a p o s i t i o n to:

8 Reduce t h e p r o b a b i l i t y of f i r e and t h e l o s s of tankage c a p a c i t y .
 1-10. 0 Maintain s a f e working conditions.

1-11. 6 Determine when and t h e extent of tankage repairs.

1-12. e Prevent o r r e t a r d f u r t h e r d e t e r i o r a t i o n .

1-13. r And lessen environmental pollution.

1-14. You w i l l r e c a l l t h a t v e s s e l s operating with an i n t e r n a l pressure

i n excess of 15 pounds per square inch a r e termed pressure vessels
and a r e constructed i n accordance with t h e pressure vessel code.

1-15. Storage v e s s e l s of t h e type t h a t w i l l be covered i n t h i s module

o p e r a t e . a t i n t e r n a l pressures t h a t a r e e s s e n t i a l atmospheric.
Their constuction i s i n accordance with Standard 650 e n t i t l e d
"Welded S t e e l Tanks f o r Oil Storage," published by t h e American
Petroleum I n s t i t u t e .

Unlike process u n i t s t h a t l i v e only as long as t h e i r technology, ,

-.
storage v e s s e l s a r e generally long l i v e d and a r e slow adying.
...- .
Many of your present day tanks a r e over f i f t y years old and a r e
of r i v e t e d construction, a s k i l l not known o r practiced in t h i s
r e f i n e r y s i n c e t h e 30's. -
During t h i s age t h e r e was one type of tank and the geometry of
i t s roof gave it i t s name - cone roof.

In the l a t e 30's welded construction replaced the r i v e t but t h e

shape of t h e tank remained the same.

The cone roof tank was s u f f i c i e n t in i t s c a p a b i l i t y of s t o r i n g

l i q u i d products but i t had one s e r i o u s problem - it breathed.
I n doing so petroleum product vapors, equivalent t o hundreds of
b a r r e l s of o i l , dissappeared out the tank vents every day.

I 1-20. To reduce these evaporation l o s s e s , the l i g h t e r products with

lower vapor pressures a r e being s t o r e d i n tanks t o which t h e

I 1-21.
name " f l o a t i n g roof tank" has been given.

In t h i s type of tank the roof i s s o designed a s to f l o a t on

the tank contents - l i m i t i n g the vapor space.
I(-
Of t h i s type t h e most common i s t h e annular pontoon type
f l o a t i n g roof a s i s shown i n t h e c r o s s s e c t i o n here.

And t h e double deck f l o a t i n g roof shown h e r e .

Now with g r e a t e r emphasis being placed on a c l e a n environment

and more s t r i n g e n t p o l l u t i o n c o n t r o l l e g i s l a t i o n , a new t a n k i s
emerging c a l l e d t h e i n t e r n a l f l o a t i n g roof - a combination of t h e
old cone roof tank t o which has been added an i n t e r n a l f l o a t i n g
cover.

Corrosion i s t h e primary cause of d e t e r i o r a t i o n of s t e e l s t o r a g e

tanks. The a t t a c h i s from a l l q u a r t e r s .

Atmospheric c o r r o s i o n works on t h e e x t e r n a l s u r f a c e s .

Galvanic c o r r o s i o n a t t a c k s t h e tank bottom.

And t h e i n t e r n a l s u r f a c e s must withstand t h e c o r r o s i v e & t a c k

of t h e tanmtZiitsTQith-suiphus rrompotruds-nd-moIsi'~zc-being-
L..
i n t h e van guard.

I n a d d i t i o n t o t h e s u l p h u s a t t a c k , t h e vapor space, p a r t i c u l a r l y
t h a t of t h e cone roof t a n G g e , i s t h r e a t e n e d by t h e water vapor
and oxygen.

Mechanical d e t e r i o r a t i o n of t a n k s is a poor second t o c o r r o s i o n

a s t o t h e causes of tank d e t e r i o r a t i o n . Complete t a n k f a i l u r e
i s r a r e , b u t they have occurred. Embrittlement was t h e cause of
t h i s disaster.

I n r e v e t e d tanks, seepage through t h e j o i n t s o r through t h e r i v e t s

i s n o t uncommon.

Cracks i n welds o r p l a t e s can r e s u l t from manycauses, some of t h e

more common being:
6 F a u l t y welding.

e Unrelieved s t r e s s c o n c e n t r a t i o n s around f i t t i n g s .

6 I n s u f f i c i e n t reinforcement around openings.

e S t r e s s e s caused by s e t t l e m e n t o r e a r t h movement.
1-36. e V i b r a t i o n , and ...
1-37. Poor design of r e p a i r s .

1-38. Now open your workbook t o Exercise 1 and r e i n f o r c e your

i n s t r u c t i o n by answering t h e q u e s t i o n s t h e r e .

1-39. (BLANK) (STOP) (START)

 INSPECTION OF ATMOSPHERIC STORAGE TANKS
TANK NOMENCLATURE 6 CONSTRUCTION

SEGMENT 2

I n t h i s segment of our module w e w a n t t o cover t a n k nomenclature and

t h e d e t a i l s of i t s c o n s t r u c t i o n a s i s covered i n t h e API standard 650
covering welded s t e e l tanks f o r o i l s t o r a g e as amended by Exxon
Engineering Standards.

Tanks a r e s i z e d by t h e i r diameter and h e i g h t and by t h e i r c a p a c i t y i n

b a r r e l s of 42 g a l l o n s each.

The diameter of a t a n k i s measured i n f e e t - center t o c e n t e r of i t s

s h e l l plates.

The h e i g h t of a cone roof t a n k i s measured from t h e bottom of t h e

s h e l l t o t h e top of t h e t o p angle.

The h e i g h t of a f l o a t i n g roof t a n k i s t h e measurement fromJhe bottom

of t h e s h e l l t o t h e maximum f i l l i n g h e i g h t .

A t a n k on i t s bottom. The t a n k bottom may b e s l o p e d t o t h e c e n t e r

w i t h i t s apex "up" - o r apex down. Other t a n k bottoms may be f l a t o r
s l o p e d from one s i d e t o t h e o t h e r .

For s m a l l tanks - with diameters less than 50' - Emon Engineering

Standards a r e n o t s p e c i f i c i n t a n k bottom design. Where t h e s e t t l e -
ment i s p r e d i c t e d t o b e less than 2 " , bottom d e s i g n of t a n k s more than
50' i n diameter but l e s s t h a n 150' must be i n accordance w i t h API
d e s i g n which permits bottoms w i t h s k e t c h p l a t e s . A s k e t c h p l a t e i s any
bottom p l a t e on which t h e s h e l l i s t o r e s t , one end of which i s
rectangular.

Tanks wity diameters exceeding 150' o r where t h e t a n k s e t t l e m e n t i s

expected t o exceed 2 " , r e q u i r e a bottom d e s i g n w i t h a n o u t e r r i n g of
p l a t e s c a l l e d annular plates. When assembled t h e a n n u l a r p l a t e s
comprise a n annular r i n g upon which t h e tank s h e l l i s t o r e s t .
The width of t h e a n n u l a r p l a t e s i s determined by t h e tank diameter
and t h e expected s e t t l e m e n t . The minimum width i s 2 f e e t f o r t h e
s m a l l e r tanks on a f i n n foundation - up t o 6 f e e t for the larger
tanks where s e t t l e m e n t i s expected t o be extreme. Reference i n your
workbook schedules t h e tank bottom design requirements.

The t h i c k n e s s o f t h e bottom a n n u l a r p l a t e s i s determined by t h e

t h i c k n e s s of t h e bottom s h e l l course - t h e minimum t h i c k n e s s is 114"
f o r 112" s h e l l w i t h a maximum t h i c k n e s s of 7/16" f o r a t a n k w i t h a
bottom c o u r s e over 1 114" t h i c k . Reference 1 i n your workbook
a r b i t r a r i l y a s s i g n s t h e s e minimum t h i c k n e s s e s .

The a n n u l a r bottom p l a t e s a r e b u t t welded w i t h complete p e n e t r a t i o n

and f u s i o n .

The remainder of t h e bottom i s composed of r e c t a n g u l a r p l a t e s trimmed

a s r e q u i r e d t o match w i t h t h e annular p l a t e s . These p l a t e s have a
minimum width of 72" and a minimum t h i c k n e s s o f 7 o ~ f o u r t h - l t n c ? r r
.-. . L.

To t h e s e p l a t e t h i c k n e s s e s a c o r r o s i o n allowance must be added.

These p l a t e s may be joined by l a p p i n g with a f i l l e t weld made w i t h

two p a s s e s a s shown h e r e .

O r they may b e b u t t welded with a backing s t r i p . The edge may be

prepared f o r welding e i t h e r by a ' V ' groove o r spaced 1/4" f o r a
square groove.

The t a n k bottom i s dimensioned a s t o p r o j e c t a t l e a s t one i n c h beyond

t h e o u t s i d e edge of t h e weld a t t a c h i n g t h e bottom t o t h e s h e l l p l a t e .

Most t a n k bottoms a r e provided with draw o f f sumps - centered when

t h e bottom apex is down and l o c a t e d on t h e periphery o f ' t h e bottom
when t h e apex i s up.

I n t h e ne*t segment of t h i s module w e ' l l cover t h e c a l c u l a t i o n s

r e q u i r e d t o d e s i g n t h e s h e l l t h i c k n e s s , b u t f i r s t we have some
q u e s t i o n s f o r you i n Exercise 2 of your workbook.

(CHANGE TRAY 6 TAPE) (STOP)

 STORAGE VESSEL SHELL CALCULATIONS
&
TANK COXSTRUCTION

SEGMENT 3

The design of t h e r e f i n e r y ' s s t o r a g e v e s s e l s under p r e s s u r e i s Fn

accordance with o t h e r codes, Tanks s t o r i n g petroleum products at
e s s e n t i a l l y atmospheric p r e s s u r e s a r e b u i l t Fn accordance w i t h API
Standard 650, supplemented and modified by Exxon ~ n ~ i n k e r i n g
Standard 9-4-1-1B.

A s t o r a g e tank s h e l l i s b u i l t of steel p l a t e s o f s t a n d a r d widths

g e n e r a l l y e i t h e r 72" wide o r 96" wide. Thus t a n k h e i g h t s a r e
g e n e r a l l y some m u l t i p l e o f t h e s e widths. T h e r e f o r e , t a n k 24' high
h a s a s h e l l made of r i n g s of t h r e e o r f o u r such p l a t e s . Each r i n g
--..
is c a l l r d a course. it-is-cusru~tai-~-to-'il'~3Ecr-these-cnII-~sewith.-
t h e bottom course being No. 1. ..,

You wil.1-recall t h a t t h e p r e s s u r e e x e r t e d by a l i q u i d w i t h a
s p e c i f i c g r a v i t y of 'G' a t a depth 'h' can b e c a l c u l a t e d by t h e
e q u a t i o n expressed here: P = .433 X h X G .

The p r e s s u r e i n a tank then bas a v a l u e of z e r o a t t h e s u r f a c e of

t h e l i q u i d i n a tank and a maximum p r e s s u r e a t t h e bottom of t h e
tank. To withstand t h i s v a r i a t i o n i n p r e s s u r e you should n o t be
s u p r i s e d t o f i n d t h e top tank s h e l l c o u r s e s t o b e of t h i n n e r p l a t e
t h a n t h e bottom courses.

I n a n a l y z i n g any tank c o u r s e t h e code s p e c i f i e s t h a t t h e p r e s s u r e t o

b e considered i s t h e i n t e n s i t y of t h e p r e s s u r e one f o o t above t h e
bottom seam of t h a t course. Thus, t h e p r e s s u r e t o be considered
on t h e bottom course of t h i s tank which i s twenty f o u r f e e t high
would be t h a t c a l c u l a t e d a t H-1 o r 23 f e e t .

You w i l l r e c a l l t h a t t h e minimum t h i c k n e s s of a t h i n w a l l v e s s e l
a s d e r i v e d from t h e e q u a t i o n f o r hoop stress i s t = p r e s s u r e times
t L e diameter divided by twice t h e a l l o w a b l e stress.
But the. p r e s s u r e on any course i s equal t o .433. X (H - 1 ) X G , and
s u b s t i t u t i n g t h i s v a l u e i n t h e preceeding e q u a t i o n g i v e s us t h e
equation t - .433 X (XZ5- 1 ) G X D.

But remember t h a t D in our equation i s i n i n c h e s and tank diameters

a r e measured i n f e e t s o we must m u l t i p l y D X 12..

Our equation has s t r e t c h e d o u t t o t h e one in t h e top of t h e s l i d e .

S i m p l i f i c a t i o n of t h e equation g i v e s us t h e one a t t h e bottom. This
i s t h e one given t o u s by t h e M I t a n k code.

I n t h i s e q u a t i o n t h e minimum s h e l l w a l l t h i c k n e s s of t h e course under

c o n s i d e r a t i o n i s expressed i n inches.

And r e p e a t i n g ' 8 ' i s in f e e t and i s t h e d i s t a n c e from t h e tank over-

flow o r from t h e t o p r i n g t o t h e bottom seam of t h e course under
consideration.

G i s t h e speFifiTgfaavicy-of-~'ne cun~~ents-of-:h~-t~!~.-C~aeraTly-
G should n e v e r be less than 1 . .. t h e s p e c i f i c g r a v i t y OF water.

D i s t h e diameter of t h e t a n k expressed i n f e e t .
-
'St i s t h e allowable t e n s i l e s t r e s s i n t h e tank s h e l l . Stress is
always expressed i n pounds p e r s q u a r e i n c h .

To t h i s minimum t h i c k n e s s must be added t h e c o r r o s i o n allowance t o

get the design thickness. For atmospheric s t o r a g e v e s s e l s t h e
minimum c o r r o s i o n allowance i s .0625".

Among t h e v a r i o u s r e f i n e r i e s t h e r e i s a d i f f e r e n c e of opinion on
allowable stress v a l u e s , ' S t . The API Code g i v e s an a l l o w a b l e s t r e s s
v a l u e of 21,000 pounds per s q u a r e i n c h l e g s 15% f o r j o i n t e f f i c i e n c y
o r 17,580 pounds p e r s q u a r e inch. Some r e f i n e r i e s a r e i n agreement
with t h i s value.

Other r e f i n e r i e s s p e c i f y maximum a l l o w a h l e stresses as f o l l o w s : For

low s t r e n g t h t a n k s t e e l s - For t h e bottom course - t h e l e s s e r of t h e
following: 42.5% of t h e u l t i m a t e t e n s i l e s t r e n g t h 66% of t h e
minimum y i e l d s t r e n g t h For t h e o t h e r c o u r s e s - t h e lesser of t h e
following: 50% of t h e u l t i m a t e t e n s i l e s t r e n g t h 85% of t h e minimum
yield strength. . .
For high. s t r e n g t h tank s t e e l s : For t h e bottom course t h e l e s s e r
of the following: 42.5% of t h e u l t i m a t e t e n s i l e s t r e n g t h . 66%
of the minimum y i e l d s t r e n g t h . For t h e o t h e r courses t h e l e s s e r
of t h e following: 50% of t h e u l t i m a t e t e n s i l e s t r e n g t h . 60% of. t h e
minimum y i e l d s t r e n g t h .

Low s t r e n g t h t a d s t e e l i s p l a i e whose minimum y i e l d s t r e n g t h i s

i s e q i r k t o o r less t h a n 43,000 pounds p e r square i n c h and t h e maxi-
mum t e n s i l e s t r e n g t h i s e q u a l t o o r l e s s than 85,000 pounds p e r
s q u a r e inch.

Yield s t r e n g t h s g r e a t e r than 43,000 pounds p e r s q u a r e i n c h o r

maximum t e n s i l e s t r e n g t h s e q u a l t o o r less than 100,000 pounds per
s q u a r e i n c h c l a ~ s i f yt h e s t e e l as high s t r e n g t h s t e e l .

The s t a n d a r d s p r o v i d e f o r minimum thickness of s h e l l p l a t e s . For

-~n&~l-tan1cs---Ie~s-than J D 3 . r - d i g g ~ r - t h e minimum nominal .
p l a n t t h i c k n e s s i s 3/16 of an inch. For tanks w i t h diameters of
5 0 ' t o 120' e x c l u s i v e , t h i s minimum thickness i s 114 of an inch.

-
A minimum t h i c k n e s s of 5/16 of an i n c h i s r e q u i r e d f o r tanks w i t h
diameters of 120' t o 200' i n c l u s i v e . Over 200' t h e minimum s h e l l
t h i c k n e s s i s 318 of an i n c h .

The bottom s h e l l c o u r s e i s joined t o t h e bottom.annular r i n g w i t h

a continuous f i l l e t weld l a i d on each s i d e of t h e s h e l l p l a t e . The
weld s i z e may n o t b e l e s s than t h e thickness of t h e bottom a n n u l a r
vertical centerline.

V e r t i c a l j o i n t s i n a d j a c e n t s h e l l courses may n o t a l i g n . The o f f s e t

i n t h e misalignment should be equal t o not less than f i v e t i m e s t h e
t h i c k n e s s of t h e t h i c k e r course.

A l l v e r t i c a l and h o r i z o n t a l s h e l l j o i n t s must be f u l l p e n e t r a t i o n
and f u l l f u s i o n welds.

The t a n k s h e l l i s c r e a t e d t o t h e s e dimentional t o l e r a n c e s t o produce

a tank of a c c e p t a b l e appearance and t o permit t h e p r o p e r f u n c t i o n i n g
of a f l o a t i n g r o o f . These t o l e r a n c e s may be waived by agreement
between t h e owner and b u i l d e r .
 3-27. The maximum o u t of plumbness of the s h e l l may n o t exceed 1/200 of
the t o t a l tank height.

3-28. The t o l e r a n c e of o u t of roundness depends on t h e t a n k s i z e . For

small tanks - up t o 40' in diameter, t h e r a d i a l t o l e r a n c e measured
one f o o t above t h e bottom i s p l u s o r minus 112 inch. For tanks
over 250' i n diameter t h i s t o l e r a n c e i n c r e a s e s t o p l u s o r minus 1
1 / 4 inches. Reference 2 in your workbook provides t h e allowable
o u t of roundness t o l e r a n c e s f o r a l l t a n k s i z e s .

3-29. Peaking i s t h e term a p p l i e d t o t h e d e v i a t i o n of t h e s h e l l contour

from t h a t of a t r u e c i r c l e a t t h e v e r t i c a l j o i n t s . Using a h o r i -
z o n t a l sweep board 36" long and c e n t e r e d on t h e weld, t h e t a r g e t
t o l e r a n c e f o r peaking i s 114". An o c c a s i o n a l peaking of 1/2" i s
n o t t o be cause f o r r e j e c t i o n of t h e work.
... 3---30; --Ba.li~g-is t h e t e r n - a p p l i e d yo t h e d e v i a t i o n of t h e s h e l l . a t t h e
horizontal joints. Using a v e r t i c a l sweep board 36" long.:aud
centered on t h e h o r i z o n t a l weld, t h e t a r g e t t o l e r a n c e . f o r banding
is 114". -
An o c c a s i o n a l banding up t o 112" i s n o t t o be a cause f o r
r e j e c t i o n of t h e work.

3-31. Generally, t a n k s h e l l s a r e topped o f f with a n g l e i r o n s i z e d i n

accordance w i t h t h e t a n k diameter. On open t o p t a n k s o r on tanks
with f l o a t i n g r o o f s , when r e q u i r e d , t h i s a n g l e i s turned outward.

3-32. . On f i x e d roof t a n k s t h e a n g l e i s r e v e r s e d , a s shown h e r e .

3-33. Open top tanks and t a n k s with f l o a t i n g r o o f s a r e d i s t i n g u i s h e d by

t h e wlnd g i r d e r which surrounds t h e t a n k n e a r i t ' s top. The wind
g i r d e r serves t o s t i f f e n t h e s h e l l a g a i n s t wind and wave a c t i o n .

3-34. Depending upon t h e i r s e r v i c e , you may f i n d some tanks equipped with

mixers f o r b l e n d i n g purposes.

3-35. O r c o i l s such as t h i s one. Steam i n t h e c o i l provides h e a t t o t h e

t a n k ' s c o n t e n t s t o p r e v e n t s o l i d i f i c a t i o n of t h e s t o c k , a s would
occur i n w a x t a n k s o r a s p h a l t t a n k s , o r t o improve t h e v i s c o s i t y
of tankage t o e a s e i t ' s handling, a s with r e s i d u a l f u e l o i l s .
 INSPECTION OF
PRESSURE RELiEVING BEVlCES

MODULE BR-E1-60.11
 TABLE OF CONTENTS

Page No.

I. Module Introduction
A. Module Objective
B. Module Description
C. -Terminal Perfom+ce Objective
11. Workbook Exercises
A. How To Use The Workbook Exercises
B. Exercise #l
C. Exercise 102
D. Exercise 83
E; Exercise 84
F. Exercise #5
G. Exercise #6
111. Reference Material -

1. Pressure C h a r a c t e r i s t i c s of a Typical Safety-Relief Valve

2: Nomenclature - Typical Conventional Safety-Relief Valve
3. Nomenclature - Typical ~ a l a n E e dBellows Type ,Safety-Relief
Valve
4. Nomenclature - Typical Liquid Relief Valve
5. Typical Spring Chart
6. S e t Pressure Temperature Adjustment
7. A Glossary
I . Slide/Tape Script
 MODULE INTRODUCTIOX

Module Ob j c c t i v e
The o b j e c t i v e of t h i s t r a i n i n g module i s t o teach you t h e b a s i c 'duty of
p r e s s u r e r e l i e v i n g d e v i c e s , t h e b a s i c types, and a g l o s s a r y of terms used i n
t h e study of s a f e t y v a l v e s . Included i n t h i s i n s t r u c t i o n i s t h e c o n s t r u c t i o n
of t h e more common types t o g e t h e r with a p a r t s nomenclature. You w i l l be
t a u g h t t h e ' b a s i c o p e r a t i o n of t h e s e v a l v e s . Another segment provides a guide
t o - t h e i n s p e c t i o n of a s a f e t y valve. Another t e a c h e s you how t o c a l c u l a t e
bench t e s t p r e s s u r e s . The i n s p e c t o r ' s r e s p o n s i b i l i t y i n r e g a r d s t o t h e
Equipment Record System a s i t p e r t a i n s t o p r e s s u r e r e l i e v i n g d e v i c e s i s
reiterated.

Module D e s c r i p t i o n
This module i s a s l i d e l t a p e p r e s e n t a t i o n i n s i x segments. Segment one
i s an i n t r o d u c t o r y segment and d e a l s p r i m a r i l y w i t h t y p e s of p r e s s u r e r e l i e v -
--5an_e-dev;tces-m4 d e s c r i b e s a number of terms t h a t you must become f a m i l i a r
with. Segment two d e t a i l s t h e c o n s t r u c t i o n of a t y p i c a l s a f e t y v a l v e w
ni-
I t s nomenclature o f p a r t s . The n e x t segment d e a l s w i t h t h e b a s i c o p e r a t i o n
o f a s a f e t y v a l v e followed by a guide t o t h e i n s p e c t i o n of t h e valve. Seg-
s

ment f i v e d e a l s w i t h t h e c a l c u l a t i o n of test p r e s s u r e s . a n d t e s t i n g . The

last segment d e a l s w i t h t h e i n p u t d a t a concerning a p r e s s u r e r e l i e v i n g d e v i c e
t h a t i s t h e r e s p o n s i b i l i t y of t h e i n s p e c t o r and t h e d a t a a v a i l a b l e t o t h e
i n s p e c t o r from t h e record s)'stem.

A t t h e end of each segment t h e p r e s e n t a t i o n w i l l be stopped t o r e i n f o r c e

your i n s t r u c t i o n by answering a s e r i e s of q u e s t i o n s i n your workbook. Gener-
a l l y a t t h i s time., time h a s been a l l o t t e d f o r a q u e s t i o n and answer p e r i o d
w i t h your i n s t r u c t o r . Also t a k e t h e time provided f o r d i s m a n t l i n g t h e s a f e t y
v a l v e s on d i s p l a y .

A w r i t t e n examination of 40 q u e s t i o n s w i l l conclude t h e s t u d y . Refer-

ence m a t e r i a l a s i s r e q u i r e d t o a i d you i n your work i s included i n your
workbook.

Pay c l o s e a t t e n t i o n t o t h e m a t e r i a l presented. Question your i n s t r u c t o r

on any d i f f i c u l t y you may have. Good luck!
 The purpose of t h i s t r a i n i n g module i s t o teach t h e t r a i n e e :

1. Types of p r e s s u r e r e l i e v i n g devices, t h e i r b a s i c .use, and a g l o s s a r y

of terms used i n t h e i r usage.
..
2. Nomenclature of a t y p i c a l s a f e t y valve.
-
3. B a s i c p r i n c i p l e s of o p e r a t i o n of pressure r e l i e v i n g devices.

4. Disassembly and i n s p e c t i o n of a t y p i c a l s a f e r y v a l v e .

5. T e s t i n g o f s a f e t y valves.

6. The Equipment Record System a s i t p e r t a i n s t o s a f e t y v a l v e s .

Upon completion of t h i s course, t h e s t u d e n t under t h e following c o n d i t i o n s

w i l l he expected:

;', T e s t #l, w i t h a c c e s s S e l e c t t h e c o r r e c t answer Answer 36 of t h e 40

t o h i s workbook, and from t h e m-u l t i p l e choices questions correctly
given a m u l t i p l e choice given f o r each of t h e i n a p e r i o d of 60
w r i t t e n examination of questions. minutes.
40 q u e s t i o n s .
 HON TO USE THE WORKBOOK MERCISES

-
A t the end of each s l i d e l t a p e segment, you w i l l be instructed t o turn
t o a s p e c i f i f . e x e r c i s e i n your Workbook. I f you a r e t o l d t o turn t o Exercise
83, you should r e f e r t o t h e Table of Contents i n the f r o n t of t h e book,
l o c a t e t h e c o r r e c t page number f o r t h e e x e r c i s e and turn t o i t .

The exercise i t s e l f i s . r e l a t i v e l y easy t o use. The f i r s t page contains

t h e questions on t h e material j u s t presented. You a r e expected t o complete
a l l of t h e questions on t h e page. Upon completion of the questions, you
should follow t h e i n s t r u c t i o n s i n parentheses a t the bottom of t h e page. If
they t e l l you t o "Turn t o the Following Page" - do so. Check t h e answers
on t h e second page against your responses on the f i r s t page. Make any
corrections t o your work t h a t a r e necessary.

- After your have completed the e x e r c i s e s , r e f e r t o t h e i n s t r u c t i o n s a t

the bottom of t h e second page. I f you a r e directed tT"StTp",-6o so;-now------ -- -

c l o s e your Workbook and await f u r t h e r i n s t r u c t i o n s .

 EXERCISE 1

I: (OUESTIONS)
S n E F P THE CORRECT ANSVER FROX THE MULTIPLE CHOICES I N EAC?I OF THE FOLLOWING
I STATEMENTS AM) UNDERLINE I T . COMPLETE ALL STATEMENTS BEFORE TmWING THE PAGE.

1. A pressure device t h a t operates i n a ste-am, gas, or vapor s e r v i c e

. (&IEF) (SAFETY-RELIEF) valve.

2. L p r e s s u a v i n g device t h a t operates i n l i q u i d service s called a

i
(SAFW (RELIEF (SAFETY-RELIEF) valve.
I
3. A device t h a t i s designed t o maintain a storaxe

I atmospheric pressure i s

1
-I
4. A s a f e t y valve s e t t i n g may not exceed the (OPERATING PRESSURE) (

I"-
AILOWABLE WORKING PRESSURE) of a vessel.
J
5. The pressure a t which a s a f e t y valve pops under s e r v i c e conditions is
c a l l e d the (SET) (TEST) pressure.
-
b-
6. Simmer does not occur i n (SAFETY) (RELIEF) valves.

1 7. The s e t pressure of a s a f e t y psi. I f the simmer i s 2%, t h e

I . valve w i l l s i m e r a t (235)

8. With reference t o t h e valve i n question 7 , the blowdown i s 8%. The valve

w i l l r e s e a t a t (220)

9. Back pressur
s a f e t v valve.
NOT) a f f e c t t h e s e t pressure of a conventional
k
1.0. Back pressure may

11. The bench t e s t same a s s e t pressure.

4
I('- 12. Bench test p r e s s u r e is c o r r e c t e d f o r (BACK PRESSURE) (INLET PRESSTJRE) and
(TEMPERATLIRE) (CAPACITY). i

I 13.. (OVERPRESSURE) (ACCUMULATION) exists when t h e p r e s s u r e i n a vessel exceeds

I t h e s a f e t y v a l v e set p r e s s u r e .

1 4 . (OVERPRESSURE) (ACCIMUIATION) i s t h e tern a p p l i e d , t o t h e e x c e s s p r o s s u r e

. i n a v e s s e l e x c e e d i n g t h e m a d m u m a l l o w a b l e worMng p r e s s u r e .

1 15. If t h e s a f e t y valve set p r e s s u r e i s e q u a l t o t h e maximum a l l m a b l e working

p r e s s u r e the accumulation e q u a l s t h e (OVERPRESSURE) (RESJZ PRESSURE).

I 16. S a f e t y valve c a p a c i t y i s r a t e d i n (POUNDS PER HOUR) (GALLONS PER HINKCE).

I 17: R e l i e f valve c a p a c i t y i s r a t e d i n (POUNDS PER HOUR) (GALLONS PER MINUTE).

-
18. The d i s c h a r g e f l a n g e on a-4" x

19. To a v o i d any u n d e s i r a b l e o p e r a t i o n o f a p r e s s u r e r e l i e v i n g d e v i c e , t h e
nonnal m a r g i n a l d i f f e r e n c e betwgen t h e o p e r a t i n g p r e s s u r e of a vessel and
i t s maxinum a l l o w a b l e working p r e s s u r e i s % or PSIG
... whichever is greatest.

(TURN TO TRE IEMILU)WING PAGE)

7.

8.
245
.,... ....

230'::
. I:+, - .G,ve;$Ri;C/2
.
.
.
.
...,,
.
.
.:.< ....
. .. .
d . : ~

.;, $9.:
: "15; .:.. .:\'.:.
- :':

17. GBLLONS PER MINUTE

. . . ..
1 6 . : ~ ~ ' : p O ~ S $ P ~ ~ H O T J';. R.. :

. . . . . ... . , . .. . . . . ...
I ., . . .
, . a
9. DOES
18. 6"

19. 1 '

25 P S I G
 EXERCISE 2

(QUESTIONS)
SELECT THE CORRECT ANSWER FROM TKE MULTIPLE CEOICES m E A OF
~ THE FOLLOWING
STATEMENTS AND UNDERLINE IT. COMPLETE ' U L STATEMENTS BEFORE TURNING TEE PAGE.

1. The c a p a c i t y of a s a f e t y v a l v e is determined by t h e (NOZZLE) (LNIZT.

FLANGE) w i t h which t h e v a l v e is equipped.

2. The i n l e t f l a n g e of a s a f e t y v a l v e may n o t b e r a t e d less than (150) (300.)

pounds.
6,
3. A s a f e t y v a l v e seats.when t h e (DISK) (DISK HOLDER) mates with t h e
(NOZZLE) (WADI RING) s e a t .

- /---"'.(BUTTONS)) (SEATS) and

-
4.
-
The comprrission s p r i n g is p r e c i s e l y f i t t e d w i t h i
should be replaced a s an assembly.
- 7.
.-.L-,-./,
--

5. The s e t p r e s s u r e of a s a f e t y valve is a d j u s t e d by means of (SPRTNG

-
ADJUSTING SCREW) (JAM NUT).

6. A s a f e t y v a l v e s p r i n g i s (LIMITED) (ONLIMITED) i n i t s range.

7. Backpressure (DOES)-/ ( W E S NOT) q f f e c t t h e pop p r e s s u r e of a conventional

. s a f e t y valve.
- . . . . .I

8. Back ( W E S NOT) a f f e c t t h e pop p r e s s u r e of a bellows t y p e

s a f e t y valve. '-.-

9. The bonnet of a bellows type v a l v e i s p a i n t e d . .

10. A l l bonnets of a 1
0. (BELLOWS) (CONVE~TIONAL)v a l v e s must be vented.

11. The (BL0WM)IJN RIXG) (WAN RING) i s ussd t o a d j u s t t h e p r e s s u r e a t

which t h e d i s k r e s e a t s .

(TURN TO TEE FOLLOLTNG PAGE)

!, c- 12. Alignment of t h e d i s c assembly i s maintained by t h e (SLEEVE GUIDE)
(STM WAINEX).
I

(TURN TO THE FOLLOh'ING PAGE)

 EXERCISE 2

(Ah'SW)
03IQARE YOUR RESPONSES ITITH THE ANSWERS G m BTiLOW. CORRECT YOUR HIST~%ES.

1. NOZZLE

3, DISK, NOZZLE

I 5. SPRING ADJUSTING SCREW

8. DOES NOT

9. RED

12. SLEEVE GUIDE

(STOP
 EXERCISE 3

QUESTION^)
SELECT. THE CORRECT ANSlr'ER FROM THE.XDLTIPLE CHOICES I N EACH OF THE FOLLOWING
STATEMENTS LLND UNDEP.LINE IT. COMPLETE AIL STATEMENTS'BEFORE TURNING THE PAGE.

('.

!.'
I
1. A s a f e t y v a l v e d i s k , 3" Ln d i a m e t e r , 'is s e a t e d on i t s nozzle a g a i n s t an
inlet p r e s s u r e of 150 p s i . Disregarding t h e w i d t h of t h e nozzle s e a t ,
t h e f o r c e on top of t h e d i s k r e q u i r e d t o b a l a n c e t h e bottom f o r c e i s
(1024) (1060) pounds.

I 2. I f t h e back p r e s s u r e on t h e d i s k i s 5 p s i , t h e s p r i n g f o r c e must b e

I (1060) (1024) pounds.

I
3. I n a s a f e t y v a l v e sinmering occurs a t p r e s s u r e s

-1-
I pressure.
--
r-
4. I n a r e l i e f v a l v e , a n -over p r e s s u r e of about (10) (25) p e r c e n t i s

-
r e q u i r e d t o l i f t t h e d i s c f u l l y . o f f i t s seat.

--.\,
5. The r u p t u r e d i s c i s a

I t u r e d i s k i s s o mounted t h a t t h e p r e s s u r e b e a r s
i d e of t h e d i s c .
I
I
.
7. I n a bellows t y p e v a l v e , i f t h e 5ellows ..c.
rup%ures;-unless
\ t h e bonnet i s
vented, t h e back p r e s s u r e - i n t h e the set
pressure.

I 8. A bellows f a i l u r e , u n l e s s t h e bonnet i s v e n t e d ,
p o t e n t i a l l y dangerous c o n d i t i o n .

I 9. A c o i l spring is
....

when i t i s h o t . -%--

. ( T m Y TO Xi?i FOLLVkTkG DAGE)

I
 EXERCISE 3

(ANSWERS)
COMPARE YOUR RESPONSES .ITITEi THE ANSWERS GIVEN BELOW. CORRECT YOUR .MISTAKES.

2. 1024
. .
3. LESS THAN

4. 25

5. NON-RECLOSING

-6. corn-

7. INCREASES

8. IS

9. WEAKER

(STOP)
.,.t
EXERCISE 4 .

(QUESTIONS). .;

SELECP TRE CORRECT ANSWER FROM THE MULTIPLE CHOICES IN EGCH OF THE FOLLOL'LNG
STATEMENTS 'AND iUNDERLINE I T . COXPLETE ALL STATEMENTS BEFORE TURNING THE PAGE.

NOT) possible t o i n s t a l l the wrong valve on a ptessure vessel.

. .
s a f e t y valve piping system n u l l i f i e s t h e function of
(BLOCK VALVE).

3. A l l block valves in a s a f e t y valve system must b

i n i t s proper position.

4. The bonnet of a bellows type s a f e t y va

5. Any s a f e t y valve whose s e a l has been broken

I' inspected and tested.
2

6. An e x t e r n a l f i r (CANNOT) increase the i n t e r n a l pressure of a

pressure vessel.

7. A l l s a f e t y valves a r e tagged giving ( I T S SEX PRESSURE) (INSPECTION DATE)

& LL
. (ITS PV NUMBER).

8. Safety valves on being shopped f o r inspection should be popped f o r t h e i r

,

.m
REcEIVED\(AS I S ) r e l i e v i n g pressure.

9. (CORROSIO (EROSION) is a major enemy t o s a f e t y valves.

L.,/'
10. A ruptured b e l l o w c a (HAS NO) e f f e c t upon t h e s e t pressure oE a
s a f e t y valve w h o s e w p r e s s u r e is superimposed,

(Tm TO THE FOLWTJING PAGE)

 11. A s a f e t y valve spring whose cross
corrosion permits t h e s a f e t y valve
pressure.

1 ( I S NOT) important t h a t t h e valve stem be s t r a i g h t within

I
I
13. The mating surfaces of t h e d i s c and

I
I
maintained t o o p t i c a l precision i f a

14. For proper operation t h e d i s c (MUST NOT) wobble i n i t s holder.

NOT) important t h a t t h e manufacturers i n s t r u c t i o n s on t h e

of valve p a r t s be heeded.

I- 15-.-I-f-thn- ~.rzLxe-stem_r.e.t.ener is frozen i n t h e sleeve guide'the s a f e t y

-1

0.
valve (IS) (IS NOT) inoperable.

(TLW TO THE FOILO\\TNGPAGE)

 ... .
..-;
EXERCISE 4

(ANSlJERs)
CO1PARE YOUR RESPONSES .WITH THE ANSWERS 'G+ BELOW. CORRECT YOUR MISTAKES.

1. IS . 9. CORROSION

2. SAFETY VALVE 10. BAS

3. CAR swm . 11. L o r n

5. SBOP 13. NOZZLE

14. MUST

7. I T S SEZ PRESSURE
INSPECTION DATE
I T S PV NUMBER

(STOP)
 .,.
...
EXERCISE 5

(QUESTIONS)
S ~ E C TTHE CORRECT ANSWER FROM THE MRLTIPLE CBOICES IN W E OF THE F O L U ) ~ G
STATEENTS AND UNDERLINE IT. COMPLmE ALL STATEMERTS'BEFORE TURNING TRE PAGE.

0
i. T y p i c a l l y t h e set p r e s s u r e of a s a f e t y v a l v e i s (10 (90) % h i g h e r than t h e
normal o p e r a t i n g p r e s s u r e of t h e v e s s e l t h a t i t must p r o t e c t .

p r e s s u r e of a s i n g l e s a f e t y v a l v e must never exceed t h e

working p r e s s u r e o f t h e v e s s e l i t s e r v e s t o p r o t e c t .

3. I n bench t e s t i s a f e-&e the ( O W PRESSURE) and

t h e operating ~ 3 ) e ~ ~ " _ - " ) / m u s l . be considered.

- 4. -
The hen& test p r e s s u r e and t h e cold d i f f e r e n t i a l s e t p r e s s u r e ( ( 1 ~ ) (IS NOT)
-- --
t h e same p r e s s u r e .
C
5. The set p r e s s u r e temperature a d j ~ s t m e n tof a s a f e t y v a l v e o p e r a t i n g a t a

I
temperature o f 750°F a t a set p r e s s u r e of 750 p s i i s (48) @(36) pounds
,
6. The temperature adjustment i s always SUBTRACTED FROM) t h e s e t

I p r e s s u r e t o determine t h e s e t pressure.

L------. -
I ' 7. The back p r e s s u r e i s always (ADDED T O ) ~ T R A C L ~ ~ , - & . ~s e; t~ p~r e~s s u r e
t o determine t h e cold d i f f e r e n t i a l s e t p r e s s u r e .

8. The cold d i f f e r e n t i a l s e t p r e s s u r e of a c o n v e n t i o n a l s a f e t y v a l v e with a

s e t p r e s s u r e of 2550 p s i g o p e r a t i n g of 300°F w i t h , a
c o n s t a n t back p r e s s u r e of 150 p s i g

I 9 . . The cold d i f f e r e n t i a l s e t p r e s s u r e of a bellows t y p e s a f e t y v a l v e with a

s e t p r e s s u r e o f 2550 p s i g o p e r a t i n g a t a temperature of 300°F w i t h a
c o n s t a n t back p r e s s u r e of L50 p s i g is (2472 f-3
(2626 , (2515) psig.
l i. L-J
(TLn' TO THE FOLLOVING PAGE)
I
10. For s a f e t y v a l v e s a t 70 p s i g o r less, t h e s e t p r e s s u r e t o l e r a n c e
i s p l u s o r minus pounds p e r s q u a r e i n c h .

. .,.: ,.
valve's set-p r e s s u r e i s 100 p s i g . I f i t pops a t 103 p s i g i t
NOT) w i t l l i n i t s set p r e s s u r e t o l e r a n c e .

L2. When 95% of t h e set p r e s s u r e a s a f e t y v a l v e must show a l e a k a g e

(NOT MORE THAN 20 BUBBLES PER MLNUTE).

The p r e s s u r e r a n g e of a F a r r i s safety valve s p r i n g number 6 6 9 f o r .a

2 1 / 2 x 4 s a f e t y valve w i t h a s i z e K o r i f i c e i s (381-420) (421-460)
(461-510) pounds p e r s q u a r e i n c h .

14. A s p r i n g i n a p r e s s u r e r e l i e f v a l v e i n a service f o r p r e s s u r e up t o and

i n c l u d i n g Z50 p"sig may n o t be reset f o r any p r e s s u r e over o r under
( 5 1 6 3 (15) % o f t h e p r e s s u r e f o r which t h e v a l v e i s marked.
u- - --

15. A s p r i n g i n a p r e s s u r e r e l i e f v a l v e i n service f o r i n excess of

250 p s i g may n o t b e reset f o r any p r e s s u r e over o r
of t h e p r e s s u r e f o r which t h e v a l v e is marked.

(TUILU TO THE F0LZX)VING PAGE)

 (ANSWERS)
COMPARE YOUR RESPONSES WITH TEE ANSI- GrVElJ BELOIJ. CORREFT YOUR MISTAKES.

I 3. BACK P R E S S U a
 -
EXERCISE 6

(QUESTIONS)
SELECT'THE'CORRECT ANSNFR FRm.1 THE MWLTIPLE CHOICES I N EACH OF THE FOLLOWING
STATEMEXTS.AND UNDERLINE IT. COIPLE~E ALL STATEMENTS BEFORE TURNING THE PAGE.

1.
0
It ( I ) ( I S NOT) i m p o r t a n t t h a t a l l s a f e t y valves b e accounted f o r .

2. A s a f e t y v a l v e p u r c h a s e d f o r a h i g h p r e s s u r e i n s t a l l a t i o n and i n s t a l l e d
i n a s y s t e m t o p r o t e c t a v e s s e l w i t h a low d e s i g n p r e s s
(COULD NOT) l e a d t o d i s a s t e r .

3. S a f e t y v a l v e i n s p e c t i o n s c h e d u l e s are an i m p o r t a n t computer r e p o r t . T h i s

I r e p o r t l i s t s s a f e t y v a l v e s t h a t are(PAST DUE FOR INSPECTION) (DUE FOR

INSPECTION THIS MONTH) (DUE FOR INSPECTION NEXT MONTH).

-
4. The NOT) m a i n t a i n s p a r e saf-lve-listings.

NOT) p r o v i d e d in t h e computers s a f e t y v a l v e
-
performance r e p o r t .

(EX': TO THE FOLLQT?T.tiG PAGE)

(AhTS\?E.JERs)
CONYARE YOUR RESPONSES iJITR THE ANSWERS GIVEN BELOl?. - CORRECT YOUR M I S T D S .

2. COULD

3. PAST DUE FOR INSPECTION

DUE FOR INSPECTION THIS MONm
DUE FOR INSPECTION NERT M O W

4. WES

(STOP)
 Reference 2
r'

Bill of rnalerlals-2600 Series / Convenllonal

AISI 303 St. St.

S:rm
~ock ID.H.1 AISI 3C3 51. St.
Eonnet Gasket Soft Iron
Slrsl
 SPRING ADJ. SCREW

SPRING BUTTON '

SPRING BUTTON

BONNET GASKET

LOCK SCREW STUD

BLOV! DOWN R!NG

NOZZLE GASKET
Reference 5

Spring Chart
 15 (30)
Reference 6
_?

TEMPERATURE ADJUSTMENT
Safety relief valves set on air .at atmospheric
ternpcratures and to be used at h~ghertempera-
t u r e s should have the set pressure adjusted. as.
fouo\vs:
increase in
Operating Temperature Set Pressure
-20'F. to 250aF. None
251°F. to '1000°F. 370
The following -table can be used for set pres-
sure adjustment of valves with operating tempera.
tures from 251°F. to 1000°F..
 16 (31)

-.
_#_ Reference 7
Glossary
SAFETY VALVE - an automatic pressure-relieving COLD DIFFERENTIAL TEST.PRESSURE -
this i s the
device actuated by the static pressure upstream of pressure at .:rhich the valve is adjusted to open On
the valve. and characterized by rapid i u l l opening or the test stand. indicated in pounds per squere incn
pop action. I t is used for gas or vapor service. (In the gage. This pressure i n ~ l u d e sthe corrertrons i c r beck
petroleum industry it is normally used for steam or Fressure and or temperature service conditions.
air).
SItAMER -characterized by the audible passzge of
. SAFETY RELIEF VALVE -an automatic Pressure. a gas or vapor across the seating surfaces just prior
relieving device which may be used as either a safety to ,2pop", ~h~ difference betvreen this stad :o opes
or relief valve, depending upon application: A safety pressure and the set pressure is simner. and is gem
relief valve is:used to protect personnel and equip- erally expressed as a percentage of set
ment by preventing excessive accumulation.
ACCUtdULATlON -
pressure increasa over the maxi.
RELIEF VALVE - an automaiic pressure-relieving
device. actuated by static pressure upstream from the
mum all(jv,able working pressure of the vessel during
discharge through the pressure ex.
valve. which opens in proportion t o the increase in pressed as a percentase of that pressure, o: ?ounds
pressure over the opening pressure: a relief valve is
used primarily for liquid service. per square inch.

OVERPRESSURE -a pressure incretse over :he se:

MAXIMUM ALL0':lABLE !'/ORKING ?RESSURE the - pressure o i the primary reli~:,ingdevice. over?:essure
maximum gauge pressure permissible in a vessel at a
is similar to accumulation ::sen the relievins cev!ce
designated temperature. A vessel may not be oper-
ated above this pressure or its equivalent at any is set at the maximum. ali$.:;able working pressure
o i the vessel. Normally. ov5:Dressure is.expressed 2s
-metal_temperature-othe~than used in its design:
consequently. for that metal temperature. i t is t h y
..,.".
,..".
a percentage o,>' %.'aLk p ,LAJL.--.
highest pressure at vrhich the primary pressure safety
r e l ~ evalve
i is set 10 open. BLDJL/DOWN-the differ:!nce between set pressure
and reseating pressure of ;; pressure relie! v3lve. ex.
OPERATING PE'ESSURE -pressure in porrnds per pressed as a percentage of the set pressure. Or
square inch gage to s.vhich the vessel is normally sub- pounds per square inch gage.
jected in service. A suitable margin is provided be-
tween operating press.ure and maximum ailowable
LIFT - the disc rise in pressure relie: valves.
v~orkingpressure. For assured saie operation. the BAC:< PRESSURE - pressure on the disch-rge sia?
oprrzting pressure should be at least 10% under the of a safety relief valve. speciiied as follo:.,~:
rnzxirnum alloxable working pressure or 25 psi. a. Constant - Specify single constant back
v:hichever is greater.
pressure (i.e. -30 psi:).
S<T PRESSURE -expressed in pounds per square b. Variable - Specify variable back preSSUrT
inch gaze. set pressure is the inlet pressure at which range usill: .mi% an(! mas.
the relief valve has been adjusted to open under serv. limits (i.e. 0 lo 20 psi:).
ice conditions. in liquid service. set pressure is de.
lermrned by the inlet nrcssclrc at :*/l1ich the valve
SUTERI:;IPOSED BACK PRESSURE -
the prCsSUr*
starts to d i s c h a r ~ euncler servicc conditions. In gas in the discli3rge header bcforc t I 1 sziety
~ r e l ~ r\al\.r
i
or ./agar service. the sc:t pressure is detcrmincd Ily opens.
t h inlet
~ pressure at .:1l11sh the v;~l:*c will "pop" utlclcr
sersvicccond~tions.
GUILT.UP SAC:( PRESSURE - pressu8.c 'xilic!~ 62,
vclops at the valve outlct 3s a result o l f!o::. alter
the sztciy rrlicf V.-I/VC 11as0pc11C'tl.
GPEf?ATI?.IG ;\I.ID SET PRESStJfiES - DIFFEREN-
TIAL - valvcs in prz.rr:s sr.rwcc *:,il F.'.IIc~:IIIY ;:IVC VALVE T!?It<l - iinclutlcs lhe ricz:lc a!ld disc. S!~nc!.
I:?'; r%SUltSif :il%o?+r:t:lne pr1:5slrrr. itoc.; nr:: oxcccd l ASTirl A152 Gradc F30-1 cta:nlcss
.+rtl trtm m ~ t c r i ais
90'% cf the SE! f?TeESilr':. stecl.
2ATED C,\C :'i I;Y - llle prrccsnlzge o l :::rrsurcc
:.I' .lt :~n.~trthor~zcd ::i'rc"nt o:.c!rpress:rc! prra:tiiZ
I?;. :I;? r::;::cocfr corie. I?.l!ci] c3pzc;tv 3s ;c??r?#'.:
c~c;:$szr.u in p01111:ls ;:tr Il1jllr i!bs ?.TI fzr ::D?I~:
5:3cc.?rz c:;:. !<el w r ?:::I::': 15Ci:.:\<?r ::$ss: 272
tn c.?:lcn; ::I.-: TInuie (G?,'.'! i c r !icv::s.
:s Reference 1
 11 (26)

Reference 2

SPFUNG ADJ. SCREW

'3,)
%
CAP GASKET

SPRING BUTTON

SPRING BUTTON
.. : SLEEVE GUIDE

BODY GASKET

LOCK SCREW O H J
STEM RETAINER

LOCK SCREW GASKET

LOCK SCREW (8.D.R)

BLOW DOWN RING

HEX. NUT (5RR.LsJ

NOZZLE GASKET