February 2013

Upcoming Training Course

Shell Repairs to Aboveground Atmospheric Storage held in our NJ offices
Tanks Using Lap-Welded Patch Plates
 Course 607, Design and
By Vincent A. Carucci Maintenance of Aboveground
Atmospheric Storage Tanks,
API-653, Tank Repair and Alteration, intends that repairs and alterations made on an April 9 - 11, 2013
Aboveground Atmospheric Storage Tank (AST) result in general equivalence to API-650
requirements. Section 9 of API-653, contains specific requirements that are intended to meet See our website for details
this objective. After the AST has been in service for some time, thinning due to corrosion may
require that sections of the shell be repaired in order for the tank to have adequate strength for Work Highlights
its next period of operation. Such repairs are generally done by installing insert plates into the
shell using full-thickness butt welds. Mechanical Engineering
 Mechanical engineering design
Before Addendum 1 issued in December 1996, API-653 did not permit the use of lap-welded audits were made of piping
shell patch plates under any circumstances. The primary concerns with using lap-welded patch systems, pressure vessels, heat
exchangers, and packaged
plates relate to the quality and strength of the attachment fillet weld, the possible increased risk equipment being supplied for
of initiating a brittle fracture at the fillet weld (especially in steels that do not meet current fracture onshore and offshore facilities for
toughness requirements), and the ease with which the patch plate is installed (which may lead “upstream” projects.
Considerable effort was made to
some individuals to not take it as seriously as they should). Addendum 1 relaxed this general help ensure that the contractors
prohibition on the use of lap-welded patch plates provided that the owner specifies their use and were using appropriate
they meet requirements stated in API-653. Despite this relaxation, the specified requirements for procedures to correct potential
lap-welded patch plates will still limit their widespread use. As noted below, the maximum shell acoustically induced piping
vibration issues that were
and patch plate thickness limit is a significant constraint. identified.
Lapped patch repairs may be considered permanent repairs subject to an established inspection
Process, Operations & Safety
and maintenance program. The requirements specified in API-653 may be used to evaluate pre-
 Provided patent review and
existing lapped patch repairs, except that the various plate thickness limits need not be applied. technical consultation regarding
fuels hydroprocessing.
The following highlights several of the requirements for using lap-welded patch plates. This is
 Providing long-term facilities/
not an all-inclusive list; so, refer to API-653 for additional details. equipment layout optimization
support services for various
 All repair material must meet the requirements of the applicable construction standard and locations.
API-653.
 Performing ongoing process
 Lap patches cannot be used on any shell course whose original construction thickness is planning support for domestic
refinery and miscellaneous
greater than 1/2 in. (12.5 mm), and cannot be used to replace doorsheets or shell plates. The related consultation.
1/2 in. (12.5 mm) thickness limit relates to potential brittle fracture concerns. There has never
been a documented case of a brittle fracture in plates less than 1/2 in. (12.5 mm) thick.
Therefore, limiting patch plate thickness to 1/2 in. (12.5 mm) minimizes the brittle fracture risk.

Carmagen Engineering, Inc. – Industry Leading Engineering Consulting and Training

4 West Main Street, Rockaway, NJ 07866  973-627-4455  www.carmagen.com
 This maximum thickness limit effectively limits the use of lap patches to small diameter tanks, or the upper courses of
large diameter tanks, where the shell plate thickness is not over 1/2 in. (12.5 mm).
 The lap patch must be at least 3/16 in. (4.8 mm) thick, but no thicker than the smaller of 1/2 in. (12.5 mm) or the
thickness of the plate to which it is being welded. Therefore, if the design calculations conclude that a lap patch plate
must be over 1/2 in. (12.5 mm) thick, a butt-welded insert patch must be used instead.
 The shape of the lap patch may be circular, oblong, square, or rectangular. All corners must be rounded to a 2 in.
(50 mm) minimum radius (except at the bottom-to-shell joint). This reduces local stress concentrations and facilitates
welding.
 Minimum spacing limits between the lap patch welds and shell seams are specified. The size and placement of the lap
patch might require adjustment to respect these limits.
 A lap patch may extend to and intersect with the external bottom-to-shell joint at a 90° angle. Acceptable attachment
details are specified in API-653.
 Shell openings and their reinforcement shall not be positioned within a lapped patch shell repair. The main concern
here is the additional loads that could be imposed on the lap patch fillet welds.
 The area on the shell where the lap patch welds are to be made must first be ultrasonically examined for plate defects
and remaining thickness. The plate size must be changed (probably increased) as needed to weld to sound shell plate
material.
 Lap patches shall not be lapped on lap-welded shell seams, riveted shell seams, other lap patch repairs, distorted
areas, or unrepaired cracks or defects.
 Minimum and maximum lap patch size limits are specified (see API-653 for details). The patch plate must be formed to
the shell curvature in all cases.
The following Table highlights additional requirements that must be met when lapped patch repairs are used for particular
situations.

Repair Situation Additional Requirements

Closure of holes caused by removal  Continuous fillet welds in outer perimeter of plate and inner perimeter of hole.
of:
 2 in. (50 mm) minimum hole diameter.
 Existing shell openings
 2 in. (50 mm) minimum corner radius of shell hole.
 Thinned areas of shell
 Complete removal of original nozzle neck and any associated reinforcement
plate.
 Repair plate thickness calculated based on E  0.7, where E is the weld joint
efficiency of the double fillet weld. Note that using this weld joint efficiency
may result in the lap patch being thicker than the shell plate. If this results in
a thickness greater than 1/2 in. (12.5 mm), a lap patch cannot be used.
 Repair plate thickness  nominal thickness of shell plate adjacent to repair.
 Full-thickness fillet welds.
 4 in. (100 mm) minimum repair plate dimension.
 Repair Situation Additional Requirements
Reinforce thinned areas of shell  Repair plate thickness calculated using E  0.35. Here again, using this weld
without removal joint efficiency may result in the lap patch being thicker than the shell plate. If
this results in a thickness greater than 1/2 in. (12.5 mm), a lap patch cannot
be used.
 Full-thickness fillet weld.
 Repair plate thickness cannot exceed:
- Shell plate thickness by more than one-third, but by no more than 1/8 in.
(3 mm)
- 1/2 in. (12.5 mm)
 Strength of remaining shell under repair plate cannot be considered effective
in carrying calculated service or hydrotest loads. 

Repair small leaks or minimize  Existing shell thickness meets minimum thickness requirements.
potential for leaks at isolated or
widely scattered pits  Repair plate thickness calculated using E  0.35 (same comments as above
regarding resulting patch plate thickness).
 Full-thickness fillet weld.
 Repair plate thickness cannot exceed:
- Shell plate thickness by more than one-third.
- 1/2 in. (12.5 mm)
 Minimum repair plate thickness  3/16 in. (4.8 mm)
 Cannot be used if:
- Crevice corrosion or concentration cell corrosion is a concern if fillet weld
is exposed to stored liquid.
- Presence of stored liquid between shell and repair plate will prevent tank
gas freeing for hot work.
 Thickness of shell plate under repair plate must be evaluated for acceptability
during future inspections. 

As is evident from the above summary, many of the lap-welded patch plate requirements can easily be met. However,
others [e.g., the maximum 1/2 in. (12.5 mm) thickness limit] effectively precludes their use for tank shell repairs.

About the Author

Vincent Carucci, President of Carmagen Engineering, Inc., also provides mechanical engineering expertise in the areas of pressure vessels, heat
exchangers, piping systems, and storage tanks to the process and power industries, insurance companies, and attorneys. If you would like more
information, please contact Vince at [email protected].