Module 1: Introduction to API 653 Body of Knowledge (1 Hour)

This module introduces the scope of API 653, which covers the inspection, repair, alteration, and rerating of aboveground storage tanks. It outlines the certification exam structure and key responsibilities of a tank inspector.

• Overview of API 653 certification and its importance in the petrochemical industry.
• Body of Knowledge: Maintenance, inspection, alteration, repair, and reconstruction of aboveground storage tanks.
• Exam preparation tips and recertification requirements, including CPD hours.

Self-Assessment: What is the primary purpose of API 653? (Answer: To ensure safe and reliable operation of aboveground storage tanks through proper inspection and maintenance.)

Module 2: Tank Design and Calculations (API 650) (1 Hour)

Review of API 650 for welded tanks, including calculations for thickness, hydrostatic testing, and settlement.

• Calculating minimum required thickness and maximum fill height.
• Joint efficiencies, impact testing, and settlement evaluation.
• Evaluating existing tanks for corrosion rates and remaining life.

Self-Assessment: How do you calculate the corrosion rate? (Answer: Difference in thickness divided by time interval.)

Module 3: In-Service Inspection Practices (API 653 & API RP 575) (1 Hour)

Detailed review of in-service inspection, including frequency, extent, and evaluation for aboveground storage tanks.

• Inspection intervals, risk-based inspection, and thickness measurements.
• Evaluation of distortions, flaws, corrosion, and leaks.
• Documentation, reports, and safety practices.

Self-Assessment: What factors determine inspection frequency? (Answer: Corrosion rate, service conditions, and risk assessment.)

Module 4: Cathodic Protection (API RP 651) (1 Hour)

Overview of cathodic protection systems for tank bottoms.

• Corrosion mechanisms, need for cathodic protection, and methods.
• Operation, maintenance, and interference currents.
• Design and installation considerations.

Self-Assessment: What does API RP 651 cover? (Answer: Cathodic protection of aboveground petroleum storage tank bottoms.)

Module 5: Tank Bottom Linings (API RP 652) (1 Hour)

Lining of aboveground storage tank bottoms.

• Corrosion mechanisms and lining selection.
• Surface preparation, application, and inspection of linings.
• Advantages, disadvantages, and quality control.

Self-Assessment: Why are tank bottom linings used? (Answer: To prevent corrosion and extend tank life.)

Module 6: Welding Inspection and Metallurgy (API RP 577 & ASME IX) (1 Hour)

Welding procedures, qualifications, and inspection for storage tanks.

• Welding processes, essential variables, P-Numbers, and F-Numbers.
• Repairs, hot tapping, and post-weld heat treatment.
• Preheat requirements and metallurgy basics.

Self-Assessment: What is an essential variable in welding? (Answer: A change that affects mechanical properties and requires requalification.)

Module 7: Non-Destructive Examination (ASME Section V) (1 Hour)

NDE methods for tank inspection.

• Radiographic, liquid penetrant, magnetic particle, ultrasonic, and visual testing.
• Procedures, calibration, and evaluation criteria.
• Articles 1, 2, 6, 7, 9, 10, and 23 from ASME Section V.

Self-Assessment: What is the purpose of NDE? (Answer: To detect defects without damaging the component.)

Module 8: Damage Mechanisms (API RP 571) (1 Hour)

Common damage mechanisms affecting aboveground storage tanks.

• Brittle fracture, thermal fatigue, erosion/corrosion, and sulfidation.
• Affected materials, critical factors, appearance, prevention, and inspection methods.
• Soil corrosion and mechanical fatigue.

Self-Assessment: How can soil corrosion be prevented? (Answer: Through cathodic protection and coatings.)