Introduction
The API 653 Inspection Report Builder is a comprehensive tool designed for creating, managing, and reviewing API 653 inspection reports for Aboveground Storage Tanks (ASTs). It streamlines the inspection process by integrating data entry, calculations, and report generation into one seamless platform. This article serves as a step-by-step guide to navigating and utilizing the report builder efficiently, ensuring compliance with industry standards.
Aboveground Storage Tanks play a critical role in storing oil, chemicals, and other industrial fluids. Over time, these tanks are subject to various forms of wear, including corrosion, thinning, and structural damage, which can lead to potential safety hazards and environmental impacts. Regular inspection and evaluation, guided by API 653 standards, are essential to maintain the integrity of these tanks and extend their operational life.
The API 653 Inspection Report Builder offers a structured approach to recording inspection data, analyzing corrosion rates, calculating remaining life, and providing actionable recommendations. This tool simplifies the reporting process while ensuring accuracy and compliance with industry regulations.
Accessing the Tool
To access the API 653 Inspection Report Builder, follow these steps:
Setting Up Reports
- Navigate to the API 653 Module:
- From the main interface, choose the [API 653 Insp.] option. Then, click on the [Report Builder] button at the bottom of the page.
- Creating a New Report:
- Select [New Report +] to create a new inspection report.
- Input a unique “Report No.” in the designated field. This number serves as the unique identifier for the report.
- Selecting an Existing Report:
- To edit or continue an existing report, use the dropdown menu labeled “Select Report.” Choose the desired report from the list of previously saved inspections.
Data Entry and Customization
- Choosing the Unit System:
- In the upper-right corner of the screen, select the desired unit system: either US or Metric. This setting will apply to all numerical data entered into the report.
- Data Entry for New Reports:
- Enter all required data into the available fields, such as tank dimensions, original plate thickness, and service environment details.
- Ensure that numerical data (e.g., Design Pressure) is entered as a raw value without signifiers (e.g., 5000, not 5000 psi).
- Numerical Data Requirements
- Much of the numerical data entered on the report builder front page will be used in subform calculations. Therefore:
- Enter all numerical data without signifiers (e.g., “25” instead of “25’” or “25 ft”).
- The Original Plate Thickness in the lower-left corner will display values to the thousandths place for a professional appearance in the final report (e.g., [0.500]).
- Much of the numerical data entered on the report builder front page will be used in subform calculations. Therefore:
- Age and Previous Inspection Input
- The Age/Prev Insp. field requires a numerical value (e.g., 9, 20, 34) and not a date. This value is used to calculate corrosion rates and must correspond with the Original Plate Thickness.
- Field Customization Options:
- For dropdown menus, such as Inspector or Service, use the [ * ] button to add custom entries that are not available by default.
- These custom entries will allos the user to build the data base with data for future usage.
- Require approval from the development team to ensure accuracy and compliance with national standards (e.g., material stress values, product data values, etc.).
- For dropdown menus, such as Inspector or Service, use the [ * ] button to add custom entries that are not available by default.
- Access to Resources
- A link to the PDF Codes/Standards, File Cabinet Libraries, and Engineering Data is available in the upper-left corner for quick access to these resources.
Advanced Features and Final Steps
- Adding User Signatures
- Click on the [Signature] button at the bottom of the form to add a user signature to the report.
- Note: Changing the signature is not global. Each report requires the signature to be uploaded individually.
- Click on the [Signature] button at the bottom of the form to add a user signature to the report.
- Material Selection
- The material selection accesses a material list compliant with API-650 standards.
- Deleting Records
- A record may be deleted by clicking the delete icon in the upper-right corner and confirming the action.
- Printing Options
- Preview and Print:
- To preview and print the front-page section of the report (first four pages in PDF or Word format), click the Limited Print icon (printer icon with no designation) in the upper-right corner.
- Note: Always save your progress before previewing.
- To preview and print the front-page section of the report (first four pages in PDF or Word format), click the Limited Print icon (printer icon with no designation) in the upper-right corner.
- Full Report Print:
- To print the full report, click the printer icon with the “F” designation. Choose either the PDF or Word file type. The full report includes all appendices and any attached files.
- Preview and Print:
- Access to Additional Calculations
- To access extraneous AST calculations outside of the report, navigate to the Engineering Data tab and select the desired calculation.
- Cover Text Customization
- The cover text initially updates automatically based on front-page inputs.
- After the first save, users can manually edit the cover text. Avoid saving the base page until all cells are populated. Alternatively, users may delete the default text and enter custom text after saving.
- Saving Progress
- Always click the Save icon before navigating away from any page to ensure data changes are not lost.
- Spell Checking
- To perform a spell check, hover the cursor over any redlined text, right-click, and select from the suggested corrections.
- Pipe/Nozzle Practical Thickness Table
- As users scroll down the base page, the “Pipe/Nozzle Practical tmins” table will appear.
- These values default to program-generated practical thickness values but can be overwritten by users. These values will be referenced throughout the program for evaluating nozzle remaining life.
- Additional Static Data Input
- Farther down the base page, users will find empty data cells for entering additional static data.
- These entries will appear on data page 4 of the report and may be customized to suit the user’s needs.
- Progressing to Appendices
- Once all front-page data cells are populated, users can proceed to the appendices for evaluations, write-ups, recommendations, and other report-building functions.
- Always progress from left to right (Appendix A to H) when entering data in subforms, as the program cascades information progressively.
- Copy Report Feature
- To duplicate a report, click the [Copy Report] button. Enter a new name for the duplicated report.
- Note: Only front-page data and write-ups are copied. Appendices must be created separately.
- To duplicate a report, click the [Copy Report] button. Enter a new name for the duplicated report.
- Adding Company Logos
- Click the [Logo] button at the top of the form to upload the company logo for the report.
- Note: Changing the logo is not global. Each report requires the logo to be uploaded individually. To streamline this process, save logos and signatures in a dedicated folder (e.g., “AA Toolbox Support”) under My Documents for quick access.
- Click the [Logo] button at the top of the form to upload the company logo for the report.
Report Configuration / Appendix
To access the Report Config. / Appendix page, start from the front page of the tool. Choose [API 653 AST], then click on the [Report Builder] button located at the bottom of the page. Select an existing report from the dropdown menu, then click on the [Report Config. / Appendix] button at the bottom left of the interface.
Appendix Overview and Functionality
The Report Appendix automatically populates with the most common appendix subjects associated with an API 653 Out-Of-Service (OOS) inspection. The section is divided into separate windows for building and editing the appendices.
- Sequential Data Entry
- Always progress from Appendix A to H when entering data into subforms. The program cascades information sequentially, ensuring accuracy as the report is completed.
- Default Text Editing
- Each appendix comes pre-filled with default text that needs to be edited to reflect the specific details of the inspection.
- Alternatively, users can delete the default text and input custom information as required.
- Pull-Down Menus
- Data cells in the appendices feature pull-down menus with user options. To add additional options, click the [App. Subject] or [App. Text] button and enter the desired details.
Customizing Appendices
Before entering data, users should review each appendix to customize its contents according to the needs of the inspection report. Specific actions include:
- Selecting and Deselecting Subjects
- Customize appendix content by selecting or deselecting relevant subjects.
- To remove a specific subject, click the pull-down arrow, select the “Please Select” option, and deselect the text.
- If an entire appendix is not applicable, uncheck the “Applicable” checkbox in the upper-right corner of that appendix.
- Adding New Subjects or Text
- To add new options to the pull-down menus:
- Click the [App. Subject] or [App. Text] button in the upper-right corner.
- Select the appendix of interest, write in the new subject or text, and click Add New Subject/Text.
- Click the Refresh icon (two circular arrows) in the upper-right corner to apply the changes.
- To add new options to the pull-down menus:
Navigation and Saving
- Save Progress Frequently
- Always click the Save icon before navigating away from any page to ensure that data and changes are not lost.
- Returning to the Base Page
- To move back to the base page from the appendix, click the Back Arrow located in the upper-right corner of the interface.
Report Component Corrosion Monitoring location (TML) Record
The Corrosion Monitoring Location (CML) Record section in the API 653 Inspection Report Builder allows users to document and analyze data specific to components and their corrosion rates. This feature supports efficient tracking and evaluation of key inspection data points for Aboveground Storage Tanks.
Accessing the CML Data Form
To access the CML Data Form:
- From the front page, choose [API 653 AST] and click the [Report Builder] button at the bottom of the page.
- Select an existing report from the dropdown menu, navigate to the [Report Appendix] section, and click the [Component TML Record] button under Appendix A.
- Begin entering data into the “Component TML Record” data section as prompted.
CML Data Structure
- Auto-Populating CML Data
- The CML Records will auto-populate with data as entries are added.
- “Component” entries should reflect a single description per component (e.g., all data from shell course one should have “Shell Crs 1” entered in this field).
- Location Descriptions
- The Location field should describe the specific area where thickness measurements were taken (e.g., “Chime Q1-Q2,” where “Chime” is the bottom 6 inches of the first shell course, and Q1 represents the first quadrant as defined on CAD drawings).
- Thickness Measurements
- Each CML can receive up to six thickness measurement (TML) points. The final entry is typically the lowest reading, which will be used to calculate corrosion rates and remaining life.
- The CML Descriptions appear at the top of the form to identify the CML being edited.
Entering and Managing CML Data
- New, Save, Duplicate, and Delete Records
- Add records individually or use the Duplicate function to create multiple entries. Select a CML, check the box next to it, and click the duplicate icon to create additional entries.
- Records may be deleted by clicking the delete icon in the top-right corner.
- Actual Plate Thickness Determination
- For each component, determine the Actual Plate Thickness (t act) at the top of the form. This value should represent the lowest reading across the component unless an average thickness (e.g., for hoop stress evaluation) is more appropriate.
- Editing and Correcting Data
- Use the [Edit Component Data] or [Edit CML] buttons to modify values or text. Adjustments can include deleting erroneous values or reducing decimal placements for clarity.
Importing and Exporting CML Data
- Exporting CML Data
- Click the [Export CML’s] button to export data into an Excel spreadsheet. The exported file can be used to populate additional data via copy-paste from a data log file.
- Importing CML Data
- Use the [Import CML’s] button to import data from an updated spreadsheet. Attach the file by clicking the [Choose File] button and then selecting the [Import CML’s] option.
- The imported data will overwrite any CMLs with identical numbers. Ensure the Report Number column in the spreadsheet matches the report it is being imported into.
- Transferring Data Between Reports
- Export a dataset from one report, update the report number in the spreadsheet to the desired report, and re-import the data to transfer it seamlessly.
Final Steps and Navigation
- Printing and Saving
- Save progress regularly by clicking the Save icon in the upper-right corner.
- To print the CML records, click the print icon in the upper-right corner. Always save before selecting print preview.
- Returning to Appendix Page
- To return to the Appendix page, click the Back Arrow in the upper-right corner.
Report Nozzle Corrosion Monitoring location (CML) Record
The Nozzle CML Data Form in the API 653 Inspection Report Builder enables users to document corrosion monitoring locations specific to nozzles and pipe components, ensuring accurate tracking of thickness measurements and supporting critical calculations such as corrosion rates and remaining life.
Accessing the Nozzle CML Data Form
- Navigate to [API 653 AST
]
from the front page and click on the [Report Builder] button. - Select an existing report from the dropdown menu, proceed to the [Report Appendix] section, and click on the [Nozzle TML Record] button under Appendix A.
- Begin entering data in the “AST Nozzle/Pipe TML Record” data section as required.
Key Features of Nozzle CML Data
- Auto-Populated CML Numbers
- The CML numbers will auto-populate and continue from the last Component CML entry, ensuring a seamless transition between component and nozzle records.
- Data Field Requirements
- Comp ID: Enter a clear description for the nozzle (e.g., “24″ MW” or “4” Nozzle”).
- Size: Input all numerical data without unit signifiers (e.g., enter
6
instead of6"
or 6 in). - Location: Use identifiers (e.g., A, B, C, or MW1, N1) to locate nozzles on drawings. The default value is “A” but can be customized.
- t Nominal: Enter the nominal thickness as derived from the original nozzle specifications. Users may replace this with a previous thickness measurement for more accurate corrosion rates.
- Thickness Measurement Locations (TMLs)
- Each nozzle CML can include up to four TML points, with the final entry typically representing the lowest reading. This value is used for corrosion rate and remaining life calculations.
- Editing and Customization
- Use the [Edit CML] button to correct or replace values if needed.
- Fields with [ * ] buttons allow users to add options, such as new Component IDs or Services, to build a reusable database for future inspections.
- Pipe Specifications Reference
- The [Pipe Specs] button provides access to nominal thickness standards for nozzles, ensuring accurate data entry.
Importing and Exporting Nozzle CML Data
- Exporting CML Data
- Click the [Export CML’s] button to export data into an Excel spreadsheet. Populate the spreadsheet with additional data from a data log file using copy-paste functionality.
- Importing CML Data
- To import data, click the [Import CML’s] button, attach the spreadsheet via the [Choose File] option, and click [Import CML’s].
- The imported data will overwrite existing CMLs with matching numbers. Ensure the Report Number in the spreadsheet matches the current report.
- Data Sharing Between Reports
- Export a dataset, modify the report number in the spreadsheet to the target report, and re-import it into the program.
- Adding, Duplicating, and Deleting Records
- Add records individually or use the Duplicate function to create multiple entries based on the number of CML points or similar components.
- Records can be deleted by clicking the delete icon in the upper-right corner and confirming the action.
Best Practices for Nozzle CML Data
- Enter all numerical data precisely, using at least the ones place and to the thousandths for professional formatting (e.g., [0.500]).
- Use the lowest thickness value for remaining life calculations unless an average thickness, such as one derived for hoop stress evaluation, is appropriate.
- Regularly review imported and exported data for consistency, ensuring report numbers and CML identifiers are accurate.
Final Steps and Navigation
- Save Progress
- Always click the Save icon before navigating away from the page to ensure that all entered data and changes are preserved.
- Deleting Records
- Records can be deleted by clicking the delete icon in the upper-right corner and confirming the action.
- Printing Options
- To print the shell calculations report, click the print icon in the upper-right corner. Always save your work before selecting the print preview.
- Navigation
- After completing the Nozzle CML Data, click the Back Arrow in the upper-right corner to return to the Appendix page and proceed to the next step.
Report Shell Calculations
The Shell Calculations section in the API 653 Inspection Report Builder is designed to assist users in performing detailed calculations for tank shell courses, ensuring compliance with API 653 standards. These calculations consider variables such as fill height, material stress, and joint efficiency to determine the structural integrity of the tank.
Accessing the Shell Calculations
- From the front page, choose [API 653 AST] and click on the [Report Builder] button.
- Select an existing report from the dropdown menu, navigate to the [Appendix Builder] section, and click the [Shell Calculations] button under Appendix B.
- Begin performing the shell calculations by entering data in the required fields in accordance with the unit designation selected on the base page.
Shell Calculation Features
- Variable Definitions
- Definitions for calculation variables are provided in the table at the bottom-right corner.
- Use the pull-down menu and vertical scroll within the definition box to read the full text for each variable.
- Fill Height and Governing Course
- The fill height is typically the full height of the tank but may be reduced if the remaining life or tmin value is unacceptable for any course.
- When fill height adjustments are made, the governing course and fill height changes should be documented in the note section at the bottom of the page.
- Joint Efficiency
- Joint efficiency can be determined using Table 4-2, located in the lower-left corner of the form.
- Material Selection
- Materials can be selected from the API-650 material list.
- If a material is not listed, the user can enter its stress value manually by using the yellow cell under [Alt S] (next to the default stress cell).
- Clicking the [Alt S] button accesses the program’s material table (based on ASME Section 2 Part D). Select the desired material, and the form will automatically calculate its stress values for the applicable courses.
- To use a material not on the default list, add it via the Engineering Data module on the front page, ensuring it becomes available for future shell calculations.
- Alternate tmin Values
- When an alternate tmin (e.g., nominal thickness minus corrosion allowance) is required, users can enter this value in the yellow cell under Alt tmin, which will override the calculated tmin.
- Course Height (Crs H)
- Enter the measured height of the product up the course of interest (in feet) in the Crs H field. For example, if an eight-foot course contains product up to 6.5 feet, enter 6.5. Do not use tick marks (
'
) to denote feet; enter the number as a decimal. - The program uses this data to calculate the H value (fill height minus the sum of all Crs H values below the course of interest).
- Enter the measured height of the product up the course of interest (in feet) in the Crs H field. For example, if an eight-foot course contains product up to 6.5 feet, enter 6.5. Do not use tick marks (
- Age Variable
- The Age variable is entered as a single number (e.g.,
4
, 10, 13), not a date, and is carried over from the main page entry.
- The Age variable is entered as a single number (e.g.,
- Notes Section
- Users can add notes in the lower-right corner to document observations or clarifications. These notes will appear at the bottom of the second page of the calculation report.
Final Steps and Navigation
- Save Progress
- Always click the Save icon before navigating away from the page to ensure that all entered data and changes are preserved.
- Deleting Records
- Records can be deleted by clicking the delete icon in the upper-right corner and confirming the action.
- Printing Options
- To print the shell calculations report, click the print icon in the upper-right corner. Always save your work before selecting the print preview.
- Navigation
- After completing the shell calculations, click the Back Arrow in the upper-right corner to return to the Appendix page and proceed to the next step.
Report Floor MRT Calculations
The Floor Minimum Remaining Thickness (MRT) Calculations section in the API 653 Inspection Report Builder provides tools for evaluating tank floor thickness, enabling accurate assessments for inspection and repair planning. This section includes variable definitions, threshold adjustments, and practical guidelines to ensure comprehensive calculations.
Accessing Floor MRT Calculations
To access the Floor MRT Calculations section:
- From the front page, choose [API 653 AST] and click on the [Report Builder] button.
- Select an existing report from the dropdown menu.
- Navigate to the [Appendix Builder] section and click on the [Floor MRT Calculations] button under Appendix B.
Floor MRT Calculation Features
- Variable Definitions
- Definitions for calculation variables are provided in a table located in the upper-right corner.
- Use the pull-down menu and vertical scroll within the definition box to read the full text for each variable.
- Threshold Setting for MFE Floor Exams
- Thresholds for bottom-side corrosion (RTbc) and top-side pitting (RTip) should be determined based on tank conditions and prior inspection results.
- Consult the client for historical data or previous inspection findings to set a starting basis for the threshold. Adjust variables as the inspection progresses, considering predominant findings such as:
- For clean bottoms with no relevant indications, start with a minimum of 40 mil material loss (e.g., a 0.250″ plate would set RTbc = 0.210″).
- If the bottom has few significant indications and the top has numerous indications, aim for a minimum of 40 mil material loss for RTbc.
- For numerous bottom-side indications and few top-side issues, aim for 50–70 mil material loss for RTip.
- When both sides have significant issues, balance cost-effective repairs between top and bottom pitting thresholds.
- If severe damage necessitates floor plate replacement, communicate with the client early to avoid unnecessary inspections.
- Consider coatings or CP systems as viable alternatives and how they affect results.
- Adjust the next inspection period (Or) to optimize repair scopes when feasible for the client.
- Editing CML Data
- Use the [Edit Comp. CML] button to modify CML data if a value was entered incorrectly or requires alternate adjustments.
- Notes Section
- Add any observations or clarifications in the Notes section at the bottom-right corner of the data page. These notes will appear at the bottom of the calculation report.
Final Steps and Navigation
- Save Progress
- Always click the Save icon before navigating away from the page to ensure that all entered data and changes are preserved.
- Deleting Records
- To delete a record, click the delete icon in the upper-right corner and confirm the action.
- Printing Options
- To print the floor MRT calculations report, click the print icon in the upper-right corner. Save your progress before selecting print preview.
- Navigation
- After completing the floor MRT calculations, click the Back Arrow in the upper-right corner to return to the Appendix page and proceed to the next step.
Report Nozzle Calculations
The Nozzle Remaining Life (RL) Calculations section in the API 653 Inspection Report Builder provides tools for evaluating nozzle thickness, ensuring compliance with API 570 standards. This section incorporates practical minimum thicknesses (tmin) derived from the program’s Practical tmin module, as well as options for user-defined customization.
Accessing Nozzle Calculations
To access the Nozzle RL Calculations section:
- From the front page, choose [API 653 AST] and click on the [Report Builder] button.
- Select an existing report from the dropdown menu.
- Navigate to the [Appendix Builder] section and click on the [Nozzle RL Calculations] button under Appendix B.
Nozzle Calculations Features
- Nozzle Evaluations
- Evaluations are based on previously entered data and practical tmin values recommended in API 570 for pipe thicknesses.
- The tmin values in this program are derived from the Practical tmin module (see page 75 for additional details).
- Per API 570 (Section 7.3), retirement thickness determination suggests using a greater thickness than the calculated tmin to account for:
- General and localized corrosion.
- Unanticipated loadings.
- Resistance to normal metal loss.
- Overriding Default tmin Values
- Default tmin values can be overridden using the User Defined yellow data cell at the top of the page.
- To modify, click on the CML of interest, enter the new tmin value, and repeat for all CMLs requiring updates.
- Editing CML Data
- Use the [Edit CML] button to modify or delete CML data if needed. This allows for corrections or alternate values with fewer decimal places.
- NPS per Nozzle ID Reference
- The [NPS per Noz ID] button provides quick access to pipe size details for the selected nozzle.
- Select the CML of interest, then click the [NPS per Noz ID] button in the top-left corner to view outer diameter (OD), pipe schedules, and wall thicknesses for the chosen nozzle size.
- Nozzle Standards Reference
- The [Nozzle Standards] button offers a comprehensive reference to pipe and nozzle data.
- Click on the button, then select the subject matter of interest for more information (see page 67 for details).
Final Steps and Navigation
- Save Progress
- Always click the Save icon before navigating away from the page to ensure that all entered data and changes are preserved.
- Deleting Records
- To delete a record, click the delete icon in the upper-right corner and confirm the action.
- Printing Options
- To print the nozzle calculations report, click the print icon in the upper-right corner. Save your progress before selecting print preview.
- Navigation
- After completing the nozzle calculations, click the Back Arrow in the upper-right corner to return to the Appendix page and proceed to the next step.
Report Shell Settlement Survey Calculations
Report AST Checklists
Report Shell AutoCAD Inspection Drawings
Report Roof/Floor AutoCAD Inspection Drawings
Report Inspection Photograph
All other Appendices
Report Write-up and Recommendations
To access the Write-up and Recommendations page, start from the front page of the tool. Navigate to [API 653 AST], click on the [Report Builder] button at the bottom of the page, and select the desired report from the dropdown menu. Finally, click on the [Report Write-up] button to proceed.
This section provides detailed functionality for documenting findings and recommendations for the inspected components. It includes tools and windows to ensure thorough and accurate reporting.
Key Features
- Quick Access to Codes
- The [Codes] button offers fast navigation to referencing codes, enabling users to align their recommendations with API standards.
- Next Inspection Date Calculation
- The [Calculate Next Inspection Dates (API max)] button calculates inspection intervals based on the maximum allowed by code. This interval may be adjusted if corrosion rates suggest a shorter timeline.
- Default Write-up Text
- The page includes default write-up and recommendation text. Users can edit this text to reflect specific findings or delete it entirely to input custom recommendations.
- To correct spelling errors, place the cursor over red-highlighted text, right-click, and select from suggested corrections.
- Inspection Interval and Governing Component
- Cells across the top of the page allow for determining next inspection dates and identifying the governing component (typically the component with the least remaining life).
- The “Years to Next Insp.” field requires a numerical value without signifiers (e.g.,
2
,4
,5
), typically defaulting to 5 years.
- UT Results Summary and Recommendations
- This section should address all calculation results and highlight any issues identified during component evaluations.
Executive Summary (ES)
- Editing Default Text
- The Executive Summary (ES) text includes default content, which should be reviewed and edited to reflect associated information. Users may delete the default text and enter new details as needed.
- Common discrepancies addressed in the Executive Summary include:
- Items with significant cost implications.
- Issues that limit tank operating parameters.
- Copying from the Body of the Report
- Items detailed in the body of the report can be summarized in the ES with minor edits for clarity.
- Display Location
- The Executive Summary does not appear in the Report Write-up preview but is visible on the main page preview.
Additional Notes
- Save Progress
- Always click the Save icon before navigating away from the page to prevent data loss.
- Deleting Records
- Records may be deleted by clicking the Delete icon in the upper-right corner and confirming the action.
- Printing Options
- To print, click the Printer icon in the upper-right corner. Save the report before printing to ensure all changes are included.
References
FAQ
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