Lap Patches

Considerations:

Does the owner prohibit the use of a lap patch? (Para. 9.3.1)

Will the repair prevent gas freeing the tank to perform hot work, at a later date?
(Para. 9.3.4.5)

Will crevice corrosion or a corrosion cell between the shell plate and repair plate
likely occur? (Para. 9.3.4.4)

An affirmative answer to any of the above is cause to stop planning on a lap patch. Since
the inception of API 653, Tank Inspection, Repair, Alteration, And Reconstruction, the fillet
weld lap patch has been prohibited, until the Second Edition, 1995, First Addenda, 1996.
The owner/user may now use paragraph 9.3, Shell Repairs Using Lap Welded Patch
Plates under certain conditions and size limitations.

The first 11 paragraphs apply to lap patches generally.

1. The lap patch is considered a permanent repair and subject to ongoing inspection
and maintenance. (Para. 9.3.1)

2. All the repair material must conform to the requirements of API 653, which will
reference API 650, Welded Steel Tanks for Oil Storage.

3. A lap patch may not be used on any shell course thickness that exceeds 1/2 inch or
to replace doorsheets or shell plates. (Para 9.3.1.2)

4. Patch plates may be from 3/16 to 1/2 inches thick, depending to the thickness of the
shell plate to be repaired. (Para. 9.3.1.3)

5. The repair plate may be circular, oblong, square, or rectangular with rounded
corners, except at the shell to bottom joint. The radius of the corners shall be 2 in.
minimum. (Para. 9.3.1.4)

6. The butt welded seams that are covered, by the patch, must be ground flush and
must over lap a minimum of 6 inches, use Figure 9-1 as a guide. (Para. 9.3.1.5)

Figure 9-1 is on the next page.

Notes on Patch Plates, 2003 Page 1

Figure 9-1 - Acceptable Details for Replacement of
Shell Plate Material

Notes on Patch Plates, 2003 Page 2

7. Refer to Figure 9-2 for details on welding the lap patch to the shell to bottom joint.
Note: An internally installed patch must be located such that the toe-to-toe weld
clearances are a minimum of 6 inches to the shell to bottom weld. (Para. 9.3.1.6)

T T
Tank Shell
W
3/16
Repair Plate

3/16
W

Trim repair
plate to clear
Shell-to-bottom
weld

8. The maximum size of a patch plate is 48 inches by 72 inches, the minimum size is 4
inches. The patch shall be formed to the shell radius. (Para. 9.3.1.7)

9. Shell openings and reinforcements shall not be positioned within a lapped patch
shell repair. (Para. 9.3.1.8)

10. An ultrasonic inspection for laminations and other plate defects shall be performed
on the shell plate in the areas to be welded. (Para. 9.3.1.9)

11. Repair plates shall not be lapped on lap welded shell seams, riveted shell seams,
other lapped patch repair plates, distorted areas, or unrepaired cracks or defects.
(Para. 9.3.1.10)

Notes on Patch Plates, 2003 Page 3

The next 5 paragraphs apply to the use of lap patches to close holes in the shell.

12. A lap patch may be used for the closure of holes, where openings have been
removed or the removal of severely corroded/eroded areas, but there are special
requirements. (Para. 9.3.2)

13. The weld shall be continuous on the inside and outside of the patch plate, the
removed opening must be at least 2 inches in diameter, a minimum corner radius of
2 inches is required for plate removal. (Para. 9.3.2.1)

14. Nozzles and reinforcement pads must be removed entirely before the repair plate is
installed. (Para. 9.3.2.2)

15. Repair plates, for opening repairs, shall be of a design that conforms to API 653,
using a joint efficiency not exceeding 0.70. All fillet welds shall be full (equal leg)
fillet welds. The overlap of the repair plate shall not exceed 8 times the shell
thickness, minimum overlap is 1 inch. The minimum repair plate dimension shall be
4 in. (Para. 9.3.2.3)

16. The repair plate shall not exceed the nominal thickness of the shell plate adjacent to
the repair. (Para. 9.3.2.4)

The next 4 paragraphs apply to the use of lap patches to repair areas of thinned
shells due to deterioration.

17. Lap patches may be used to reinforce areas of deteriorated shell plates and to
reinforce shell plates that are below retirement thickness. (Para. 9.3.3)

18. The repair plate thickness shall be based on API 653, using a joint efficiency not
exceeding 0.35, the perimeter weld shall be full fillet (equal leg) weld. (Para. 9.3.3.1)

19. The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker
repair plate than the existing shell plate is allowed. (Para. 9.3.3.2)

20. The remaining strength of the deteriorated areas under the repair plate shall not be
considered as effective in carrying the calculated service or hydrotest loads.
(Para. 9.3.3.3)

The next 4 paragraphs apply to the use of lap patches to repair leaks or potential
leaks in the shell.

21. Lap patches may be used to repair leaks or minimize the potential leaks form pitting.
(Para. 9.3.4)

22. To install a lap patch over a leak, the existing shell thickness, excluding holes and
pits, must meet the minimum acceptable shell thickness (t min.). (Para. 9.3.4.1)

23. The repair plate must be designed to withstand the hydrostatic pressure load
between the repair plate and the shell assuming a hole exists in the shell using a joint
efficiency of 0.35. (Para. 9.3.4.2)

24. The repair plates for this repair shall not exceed 1/2 inch thick, only a 1/8 in thicker
repair plate than the existing shell plate is allowed. A full (equal leg) fillet perimeter
weld is required. (Para. 9.3.4.3)

Notes on Patch Plates, 2003 Page 4

The last 3 paragraphs apply to safety warnings and inspection requirements of lap
patches.

25. Do not use a lap patch if corrosion between the shell plate and repair plate is likely
to occur. (Para. 9.3.4.4)

26. Do not use a lap patch if the repair plate will prevent gas freeing the tank to perform
future hot work, remember a penetration is not allowed in the patch. (Para. 9.3.4.5)

27. Future inspection must be performed on the patch plates. (Para. 9.3.4.6)

Notes on Patch Plates, 2003 Page 5