ATT D - ROB-FY11-FAC 4302-Tank 23-FINAL.pdf

Final Report

Region 1 API 653 Out-of-Service Tank Inspections & Repairs

Tank 23: Robins Air Force Base, Georgia

Prepared for

Air Force Civil Engineer Support Agency

Prepared by

Weston Solutions, Inc.

70 NE Loop 410, Suite 600 San Antonio, Texas 78216

Contract No. FA3002-08-D-0023 Delivery Order: 0003

November 2010

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EXECUTIVE SUMMARY

Weston Solutions, Inc. (WESTON) was contracted by the Air Force Civil Engineer Support Agency (AFCESA) to conduct an API 653 tank inspection on Tank 23 (Facility 4302) at Robins Air Force Base (AFB) in Georgia under the AFCESA Contract No. FA3002-08-D-0023, Delivery Order (DO)-0003. The purpose of the project was to clean, perform an API 653 Out-of- Service tank inspection to determine suitability for service, and perform the approved recommended repairs in accordance with the Notice to Proceed (NTP) requests dated 29 July 2009, 6 November 2009, and 19 March 2010.

Tank 23 (Facility 4302), located at Robins AFB, is a vertical all welded steel aboveground storage tank (AST) fabricated of carbon steel that is currently in service as a Jet Propellant 8 (JP-8) bulk storage tank. At the time of the inspection, the tank was emptied and taken out of service by the bulk storage operators. WESTON isolated the tank, removed the residual fuel, and cleaned and

The testing and inspection was performed in accordance with API 653, by Nova Data Testing Services, Inc. (NOVA), and a subsequent review of the inspection report was performed by WESTON to identify the repairs. The results of this API 653 inspection identified service.

Nondestructive Examination (NDE), and the conclusions derived from the inspection, examinations, and calculations. Also included is a list of recommendations for repairs and/or upgrades that were identified by the inspection and those items that were completed. Through these activities and corresponding report (this document), WESTON has satisfied the contractual requirements of this project.

Storage Tank No. 23

SUITABILITY FOR SERVICE MEMORANDUM

Out of Service API 653 Tank Inspection and Repair Contract No. FA 3002-08-D-0023/DO-003

Robins AFB, GA

Tank No. 23 was inspected May 21 and 22, 2009. An out-of-service inspection was performed by Nova Data Testing Services, Inc. (Nova) for Weston Solutions, Inc., under contract to Air Force Civil Engineer Support Agency.

The tank is in suitable condition for return to service. Mandatory repairs and examinations have been completed.

Mandatory Repairs

Mandatory repairs and examinations have been completed. The tank is suitable for continued service for a period of 5 years until the next in-service inspection.

Other Repairs and Maintenance

Near-Term and Long-Term maintenance and repair items have been identified by the inspection.

Completion of these items within the suggested times is recommended to assure successful long term service. Detailed recommendations are included in the Summary of Inspection Recommendations.

Inspection Intervals

The next in-service inspection with UT thickness measurements should occur in five years in accordance with API 653.

The next out-of-service inspection should occur in not more than 10 years.

This storage tank suitability for service evaluation has been completed in accordance with the requirements of API STD 653, Third Edition, Addendum 3, February 2008.

Region 1 API-653 Inspection & Repair

Tank 23 Robins AFB, SC

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TABLE OF CONTENTS

Section Page Title Page ......................................................................................................................................... i Table of Contents ............................................................................................................................ ii List of Acronyms and Abbreviations ............................................................................................. iv

1.0 INTRODUCTION.......................................................................................................... 1-1

1.1 PROJECT OBJECTIVES AND SCOPE OF WORK ................................................ 1-2

1.1.1 Project Objectives ................................................................................................ 1-2

1.2 BACKGROUND ....................................................................................................... 1-2

1.2.1 Hydraulic Integrity ............................................................................................... 1-3

1.2.2 Structural Integrity ............................................................................................... 1-3

1.2.3 Next Inspection .................................................................................................... 1-3

1.2.4 Foundation ........................................................................................................... 1-3

1.2.5 Dike/Containment ................................................................................................ 1-3

1.2.6 Cathodic Protection .............................................................................................. 1-3

1.2.7 Internal Floating Roof .......................................................................................... 1-3

1.2.8 Stilling Wells ....................................................................................................... 1-4

2.0 FIELD ACTIVITIES ..................................................................................................... 2-4

2.1 MOBILIZATION AND SITE PREPARATION ....................................................... 2-4

2.2 FIELD TASKS........................................................................................................... 2-4

2.2.1 Tank Cleaning ...................................................................................................... 2-4

2.2.2 API 653 Tank Inspection ..................................................................................... 2-4

2.2.3 Tank Repairs ........................................................................................................ 2-5

2.2.3.1 MT-1: Seal Welded Wear Plates ............................................................... 2-5

2.2.3.2 MT-2, 4, 5, 6: Conducted Magnetic Particle Testing ................................ 2-5

2.2.3.3 MT-3: Conducted Radiographic Testing ................................................... 2-5

2.2.3.4 MT-7: Seal Welded Patch Plates ............................................................... 2-5

2.2.3.5 MT-8: Reconfigured Lines with DB&B Valves ....................................... 2-5

2.2.3.6 NT-1: Recoated Roof Plates ...................................................................... 2-5

2.2.3.7 NT-2: Recoated Areas of Tank Interior .................................................... 2-5

2.2.3.8 NT-3: Inspected for Buckling .................................................................... 2-6

2.2.3.9 NT-4: Repaired Roof Hatch ...................................................................... 2-6

2.2.3.10 NT-5: Replaced ATG ........................................................................... 2-6

2.2.3.11 NT-6: Replaced Pressure Relief Valves ............................................... 2-6

2.2.3.12 NT-7: Repaired Secondary Containment .............................................. 2-6

2.2.3.13 NT-8: Replaced Chime Sealant ............................................................ 2-6

2.2.3.14 NT-9: Installed Bird Screens ................................................................ 2-6

2.2.3.15 NT-10: Replaced Gauge Gaskets .......................................................... 2-6

2.2.3.16 NT-11: Installed Grounding Lugs ........................................................ 2-6

2.2.3.17 NT-12: Investigate High Level Alarm Operation ................................. 2-6

2.2.3.18 LT-3: Cathodic Protection .................................................................... 2-7

Tank 23 Robins AFB, SC Contract No. FA3002-08-D-0023

Page iii

2.2.3.19 LT-4: Installed Stilling Well with Internal Ladder............................... 2-7

2.2.3.20 LT-5: Installed Stilling Well................................................................. 2-7

2.2.3.21 LT-6: Installed Anchor Bolt ................................................................. 2-7

2.2.3.22 LT-7: Installed Manway Davits............................................................ 2-7

2.2.3.23 NTP-007(22): Lead Based Paint Safety Measures ............................... 2-7

2.2.3.24 NTP-010(34): Installed Conduit and Cable for High Level Sensors.... 2-8

2.3 SITE RESTORATION AND DEMOBILIZATION ................................................. 2-8

LIST OF APPENDICES

Appendix Title A API 653 Inspection Report B Tank Calibration Charts C Tank History and Assessment D Photo Documentation E NDE Documentation F QC Documentation G Cathodic Protection Report H Buckling Inspection Report I Paint Sampling Results J Waste Documentation K Transfer and Acceptance

Tank 23 Robins AFB, SC

Page iv

LIST OF ACRONYMS AND ABBREVIATIONS

AFCESA Air Force Civil Engineer Support Agency AFB Air Force Base API American Petroleum Institute AST Aboveground Storage Tank ATG Automatic Tank Gauge DO Delivery Order DB&B Double Block and Bleed GA Georgia IFP Internal Floating Pan JP-8 Jet Propellant 8 LBP Lead Based Paint LEL Lower Explosive Limit LF Linear Feet MFL Magnetic Flux Leakage MT Magnetic Particle NDE Nondestructive Examination NOVA Nova Data Testing Services, Inc.

NTP Notice to Proceed QC Quality Control SF Square Feet SOW Statement of Work UT Ultrasonic Thickness Examination UV Ultraviolet VT Visual Examination WESTON Weston Solutions, Inc.

Tank 23 Robins AFB, GA

Page 1-1

1.0 INTRODUCTION

Under contract agreement [Contract No. FA3002-08-D-0023, Delivery Order (DO)-0003] with the Air Force Civil Engineer Support Agency (AFCESA), Weston Solutions, Inc. (WESTON) has prepared this Final Report for the recommended repairs of Tank 23 (Facility 4302) based on the testing and inspection performed in accordance with American Petroleum Institute (API) 653, by Nova Data Testing Services, Inc. (NOVA) at Robins Air Force Base (AFB), Georgia (GA).

A comprehensive API 653 Out-of-Service Tank Inspection and suitability for service evaluation following the applicable criteria of API 653 and in accordance with the AFCESA Statement of Work (SOW) was conducted on 21-22 May 2009. Upon completion of the API 653 Inspection, field measurements of the tank were executed to produce Tank Calibration Charts (strapping tables) attached in this Final Report. Through these activities and corresponding Final Report, WESTON has satisfied the contractual requirements of this project.

The original Notice to Proceed (NTP) request, dated 29 July 2009, for recommended repairs followed the API 653 preliminary inspection summary in order to accomplish the objectives of the project. Two additional NTP s dated 6 November 2009 and 19 March 2010 were requested after repairs started to account for Lead Based Paint (LBP) and high level alarm system repairs.

The associated repairs of Tank 23 are summarized as follows:

NTP-005(15): Tank 23 Repairs o Seal Welded Wear Plates o Conducted Magnetic Particle Testing o Conducted Radiographic Testing o Seal Welded Patch Plates o Reconfigured Lines with Double Block and Bleed (DB&B) Valves o Recoated Roof Plates o Recoated Areas of Tank Interior o Inspected for Buckling o Repaired Roof Hatch o Replaced Automatic Tank Gauge (ATG) o Replaced Pressure Relief Valves o Repaired Secondary Containment o Replaced Chime Sealant o Installed Bird Screens o Replaced Gauge Gaskets o Installed Grounding Lugs o Investigated High Level Alarm Operation o Cathodic Protection o Installed Stilling Well with Internal Ladder o Installed Stilling Well o Installed Anchor Bolt o Installed Manway Davits

NTP-007(22): Lead Based Paint Safety Measures NTP-010(34): Installed Conduit and Cable for High Level Sensors

Tank 23 Robins AFB, GA

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1.1 PROJECT OBJECTIVES AND SCOPE OF WORK

The scope of the project was to complete an API 653 out-of-service inspection to determine the suitability for service and structural and hydraulic conditions of the tank, provide written recommendations for repairs, and develop recommendations for long-term service based on visual inspection and Nondestructive examination (NDE).

The purpose of this document is to report that WESTON has completed the contract requirements to clean, inspect in accordance with API 653 guidance, and repair Tank 23 (Facility 4302) at Robins, GA.

1.1.1 Project Objectives

WESTON completed the following site-specific tasks to accomplish the objectives outlined in the

AFCESA NTP:

1) Mobilized all construction materials, personnel, vehicles, and equipment as necessary.

2) Established, erected, and maintained the appropriate construction work area perimeter and associated safety features such as warning signs, barricades, and barrier tape.

3) Blind flanged all issue and receipt piping to the tank and isolated all electrical components through lock-out and tag-out.

4) Performed tank cleaning.

5) Performed an API 653 Out-of Service Tank Inspection.

6) Performed field measurement of the tank to produce tank calibration charts.

7) Performed tank repairs based on the NTP request.

8) Upon completion of repair activities, performed site restoration and examination to verify the tank repairs.

9) Performed tank closure, removed all evidence of construction activities and debris from the site, and demobilized from the project location.

1.2 BACKGROUND

Robins AFB is located in Houston County, GA and is home of Warner Robins Air Logistics Center, the 78th Air Base Wing. It is situated adjacent to the city of Warner. Robins AFB is about 100 miles southeast of Atlanta and is the largest industrial complex in GA.

Tank 23 (Facility 4302), located at Robins AFB Bulk Storage, is a vertical all welded steel aboveground storage tank (AST) fabricated of carbon steel that is currently in service as a Jet Propellant 8 (JP-8) bulk storage tank. The tank is 112 - in diameter and 52 - high with a self supported cone fixed roof and an aluminum pontoon internal floating pan (IFP). The existing tank bottom is of lap-welded bottom plate construction, and the shell is constructed of butt-welded shell plates. There are six (6) shell courses for a height of 52 - and a Nominal Capacity of 88,095 barrels (3,700,000 gallons).

Tank 23 Robins AFB, GA

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1.2.1 Hydraulic Integrity

A Magnetic Flux Leakage (MFL) scan of the tank bottom was conducted which revealed twenty relevant indications that were followed up with ultrasonic thickness examination (UT) scans. A pit survey was conducted for topside corrosion which identified indications from soil side pitting.

Based on the inspection results and calculations, performed repairs and a new impressed current cathodic protection system, the tank is in acceptable hydraulic condition for continued service.

1.2.2 Structural Integrity

The structural integrity of the tank is based on the condition of the tank bottom, shell, fixed roof, and attachments to the tank. To determine the structural integrity of this tank, ultrasonic testing (thickness measurements) of the shell was performed on each course of the shell. From interpretation of the UT readings recorded, only minor plate thickness variances were noticed and three locations were found where the remaining floor thickness was .190-inches or less. Based on the inspection results and calculations and performed repairs, the tank is in acceptable structural condition for continued service.

1.2.3 Next Inspection

service history. Therefore, the next In-Service Inspection with UT measurements should be performed in five (5) years, in 2014, in accordance with API 653, and the next API 653 Out-of- Service Inspection should be performed in ten (10) years, in 2019.

1.2.4 Foundation

Currently, the foundation consists of a reinforced concrete ringwall within a containment (concrete splash-wall) at the bottom.

1.2.5 Dike/Containment

The existing containment is a reinforced concrete wall with a poly lining which is underneath a sand and gravel base. The total containment size is approximately 88,000 square feet (SF) with seven (7) unequal walls. The dike has an average depth of 6 ent is constructed with vertical ncrete.

1.2.6 Cathodic Protection

Tank 23 had no cathodic protection system installed at the time of inspection. An impressed current cathodic protection was designed and installed to provide protection to the soil side of the tank floor as a part of the tank repairs.

1.2.7 Internal Floating Roof

Tank 23 has a self supported cone and an aluminum pontoon internal floating pan. There was no access ladder through or to the roof at time of inspection. An 8-inch slotted stilling well with an internal ladder assembly was installed as a part of the tank repairs.

Tank 23 Robins AFB, GA

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1.2.8 Stilling Wells

There was no stilling well through or to the roof at time of inspection. An 8-inch fully slotted aluminum stilling well with an internal ladder assembly and another aluminum stilling well was installed as a part of the tank repairs.

2.0 FIELD ACTIVITIES

The field tasks that were performed are described in the following subsections. The total duration of field activities continued from 17 April 2009 to 15 May 2010.

2.1 MOBILIZATION AND SITE PREPARATION

SWS, mobilized to the site on 17 April 2009 inclusive of all equipment, material, and personnel set up for tank cleaning.

2.2 FIELD TASKS

Tank availability to execute the project was primarily contingent upon fueling operations, mission requirements, and coordination for tank availability. The subsequent sections describe field tasks to complete this project.

2.2.1 Tank Cleaning

Tank 23 (Facility 4302 -the potential for environmental and safety impact during the site execution. The major activities performed for the task are summarized as follows:

Before cleaning the tank, all electrical components and fuel lines were isolated. A forced air ventilation system was set up to maintain a safe Lower Explosive Limit (LEL), and air monitoring was conducted during field operation.

The inside of the tank was cleaned with high-pressure washers.

The cleaning water rinsate was processed through the oil-water separator in accordance with Robins AFB guidelines.

2.2.2 API 653 Tank Inspection

Once cleaned and certified safe for entry, the tank was inspected in accordance with applicable guidelines of API 653 Out-of-Service tank inspection requirements. The major activities performed for the task are summarized as follows:

Installed lighting sufficient to perform tank inspection and continued air monitoring during field operation.

Nova Data Testing Services, Inc. (NOVA) performed a tank inspection inclusive of a visual examination (VT) of the tank interior and exterior, an API 653 evaluation of the tank (using applicable methods and guidance from the current version of API 653), review of the existing coating condition, pit survey on tank bottom and shell, tank bottom profile and edge settlement measurement, flooring, mapping, and structural analysis.

Tank 23 Robins AFB, GA

Page 2-5

An API 653 Tank Inspection for suitability for service evaluation was conducted on 21 and 22 May 2009, and the final inspection report is provided as Appendix A. Upon completion of the API 653 Out-of-Service inspection, field measurement of the tank was executed to produce tank calibration charts (strapping tables). Calibration charts for Tank 23 (Facility 4302), in English and Metric units, are provided as Appendix B of this report.

2.2.3 Tank Repairs

Based upon the original NTP request dated 29 July 2009, 6 November 2009 and 19 March 2010, WESTON performed the tank repairs as outlined below:

2.2.3.1 MT-1: Seal Welded Wear Plates

Carbon steel wearing plates (approximately 50) were seal welded to the floor under the floating roof legs, anti-rotation cable connections, low suction and water draw off piping. All welded wear plates were coated and vacuum box tested.

2.2.3.2 MT-2, 4, 5, 6: Conducted Magnetic Particle Testing

Magnetic Particle (MT) examination was conducted of the welds: (1) between N1 and bottom reinforcement plates, (2) between anchors A-4 and A-24 and the vertical seams, (3) between N-3 and A-2, and (4) between N-2 and A-1. NDE is attached as Appendix E.

2.2.3.3 MT-3: Conducted Radiographic Testing

Radiographic Testing (RT) examination was conducted of the welds on the shell plate inserts at the first and second shell course intersections. NDE is attached as Appendix E.

2.2.3.4 MT-7: Seal Welded Patch Plates

Three (3) carbon steel patch plates were seal welded where the remaining floor thickness is .190-inches or less. All welded patch plates were coated and vacuum box tested.

2.2.3.5 MT-8: Reconfigured Lines with DB&B Valves

The existing issue, receipt, water draw, and low suction ball valves and stab-in connections were replaced with new nozzle connections and new DB&B plug valves.

2.2.3.6 NT-1: Recoated Roof Plates

The roof plates displaying severe corrosion (approximately 50 SF) were abrasive blasted and recoated.

2.2.3.7 NT-2: Recoated Areas of Tank Interior

Tank interior areas having coating failure at welds and other repair areas were abrasive blasted and recoated.

Tank 23 Robins AFB, GA

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2.2.3.8 NT-3: Inspected for Buckling

The shell distortion at the upper shell courses was closely inspected. No corrective action was recommended. Report is attached as Appendix H.

2.2.3.9 NT-4: Repaired Roof Hatch

New hinges and hatch hardware were installed as a part of this repair.

2.2.3.10 NT-5: Replaced ATG

The float gauge was removed and replaced with a Shand and Jurs tank gauge before returning tank to service. The ATG was tested for proper operation.

2.2.3.11 NT-6: Replaced Pressure Relief Valves

The inlet and outlet pressure relief valves were removed and replaced before returning tank to service.

2.2.3.12 NT-7: Repaired Secondary Containment

The existing deteriorated joint sealant was removed and replaced with approximately 200 LF of UV/JP-8 resistant joint sealant.

2.2.3.13 NT-8: Replaced Chime Sealant

The existing deteriorated chime sealant was removed and replaced with UV/JP-8 resistant chime sealant.

2.2.3.14 NT-9: Installed Bird Screens

Bird screens were installed on the six (6) atmospheric vents.

2.2.3.15 NT-10: Replaced Gauge Gaskets

The existing gauge hatch gaskets were replaced with new ones prior to returning to service.

2.2.3.16 NT-11: Installed Grounding Lugs

Grounding lugs for the tank shell were installed to ensure proper electrical bonding.

2.2.3.17 NT-12: Investigate High Level Alarm Operation

The inconsistent operation of the high level alarm was investigated. The wiring from the high level alarm to the control panel was compromised. Additionally, the lower junction box inside the building was completely filled with water and the upper control panel / cabinet had water inside it up to the level of the panel door and water ran out into the floor. During the investigation, it was determined the wiring for Tanks 24 and 27 was also compromised. These were the causes for the intermittent operation of the high level alarm.

Tank 23 Robins AFB, GA

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2.2.3.18 LT-3: Cathodic Protection

A cathodic protection system plan was provided after evaluating existing conditions. Significant soil side corrosion was found on the tank floor plates. An impressed current cathodic protection system was designed and installed to provide protection to the soil side of the tank floor. The system consists of an air cooled manually controlled rectifier with a distributed anode bed;

approximately (8) eight anodes installed at 20 foot depths around the ring wall perimeter. The compliance report which contains all field data and analysis, as-built drawings and calculated anode service life is attached as Appendix G.

2.2.3.19 LT-4: Installed Stilling Well with Internal Ladder

An 8-inch fully slotted aluminum stilling well with an internal ladder assembly was installed prior to returning the tank to service.

2.2.3.20 LT-5: Installed Stilling Well

An 8-inch fully slotted aluminum stilling well was installed before putting tank back to service.

2.2.3.21 LT-6: Installed Anchor Bolt

An expansion anchor bolt between anchors A-48 and A-49 was installed by rotary hammer drilling.

2.2.3.22 LT-7: Installed Manway Davits

The manway covers were modified and davit arms were installed for all three (3) manways.

2.2.3.23 NTP-007(22): Lead Based Paint Safety Measures

After the original NTP dated 29 July 2009 was approved and the repairs begun, it became known that the tank coatings contained lead. Due to the strict occupational health, safety and environmental requirements when working with Lead Based Paint (LBP), a second NTP dated 6 November 2009 was requested to ensure full worker safety and environmental compliance.

After approval, a decontamination station including hand and face wash (with water collection/storage for testing prior to disposal) was installed. Air was supplied in positive pressure hoods for the abrasive blasting workers inside the tank. Proper PPE was provided to keep lead off of the workers clothes. Dust monitoring devices were used and the blast area was kept contained and the pressure kept neutral so that there was not a significant release to the environment. HEPA filtration of the air was performed within the contained area to reduce the airborne concentrations of the contaminants.

Lead abatement was performed on the annular ring as shown in quality control (QC) documentation attached as Appendix F. All waste disposals were coordinated and handled by Robins AFB and the labels are attached as Appendix I.

Tank 23 Robins AFB, GA

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2.2.3.24 NTP-010(34): Installed Conduit and Cable for High Level Sensors AFCESA was notified of the recommended repairs from the high level alarm investigation and a subsequent NTP dated 19 March 2010 was requested. After approval, the existing conduit was replaced by new conduit and cable for fuel tank high level sensors on fuel tanks 23, 24, and 27.

The existing wire and conduit associated with the high level alarms was demolished and disposed.

A new Quazite enclosure at the current control panel location was installed and the system was tested and re-commissioned by Scully.

2.3 SITE RESTORATION AND DEMOBILIZATION

The site activities were completed and the site was restored to the original conditions on 15 May 2010. The Transfer and Acceptance Form (DD 1354), submitted to the Base Fuel Management representative and confirming the acceptance of work performed, is provided as Appendix J.

Demobilization of subcontractors was an on-going process as various stages of work were completed. Site restoration consisted of demobilizing subcontractors and equipment from the site and returning the site to pre-construction conditions.

WESTON and its subcontractors completed the cleaning, inspection, and repairs of Tank 23 (Facility 4302) at Robins AFB, GA. Photo documentation has been attached to this Final Report as Appendix D for records. WESTON recommends that the facility keep this report on file for future reference.

APPENDIX A

API 653 INSPECTION REPORT

Robins AFB Tank 23 Page 1 of 5

Storage Tank No. 23

SUMMARY OF INSPECTION RECOMMENDATIONS

Out of Service API 653 Tank Inspection and Repair

Contract No. FA 3002-08-D-0023/DO-003 Robins AFB, Georgia

Tank No. 23 was inspected May 21 and 22, 2009. An API 653 out-of-service inspection was performed by Nova Data Testing Services, Inc. (Nova) for Weston Solutions, Inc., under contract to Air Force Civil Engineer Support Agency.

The tank is in suitable condition for return to service. Mandatory repairs and examinations have been completed.

TANK DATA

Diameter 112’-0” Height 52’-0” Nominal Capacity 3,700,000 Gallons Product Stored JP-8 Construction Vertical AST, welded steel, self-supported cone fixed roof, aluminum floating pan Built 1980’s Construction Std. Unknown Foundation Concrete Ring Wall

INSPECTION

Type API 653 out-of-service Shell Ultrasonic thickness (UT) and visual inspection (VT) Bottom MFL scan, ultrasonic thickness (UT) and visual inspection (VT) Roof Ultrasonic thickness (UT) and visual inspection (VT) General General visual inspection

INSPECTION INTERVALS

The following are the maximum inspection intervals allowed per API 653 for this storage tank based on corrosion rate considerations. The owner may elect to inspect more frequently. UFC 3-460-03 requires API 653 out-of-service inspection every 10 years.

Inspection Type Interval Complete no later than:

In-Service with Thickness Measurement 5 years May 2014 Out-of-Service (internal) 10 years May 2019

Robins AFB Tank 23 Page 2 of 5

MANDATORY ITEMS

Mandatory repairs are those necessary to preserve or restore the structural or hydraulic integrity of the tank, or to comply with applicable codes, standards and regulations.

1. High level alarm assembly, anti-rotation cable connection, and floating roof legs have no seal-welded bearing plates attached to tank floor.

API 653 requires that wear plates be attached by welding to tank bottom.

Recommend to provide welded steel pads and to seal weld all bearing plates to tank floor. [Repair completed, with acceptable NDE results.]

2. The distance between the shell manway nozzle N-1 and N-8 bottom reinforcement plates and shell weld seam is insufficient.

Recommend providing Magnetic Particle examination in accordance with API 653, Par. 4.3.9.1 prior to returning the tank in service (removal of coatings required.)

[Repair completed, with acceptable NDE results.]

3. Shell plate inserts do not have required spacing distances at cleanout nozzle on first and second shell courses intersection.

The welds associated with these shell insert plates should be further examined prior to returning the tank to service. Recommend radiographing all welds that do not meet weld spacing requirements. [NDE completed with existing welds found acceptable.]

4. Anchor A-4 and A-24 is welded over shell vertical seams.

Provide weld examination of affected portions of shell vertical seam welds using the magnetic particle method to demonstrate suitability for service in accordance with API 653, Par. 4.3.9.1. The weld examination will require removal of coatings, possible repair of defects, and coating touch-up. [NDE completed with existing welds found acceptable.]

5. The distance between shell nozzle N-3 and anchor angle A-2 welds is insufficient.

Provide weld examination of affected portions of reinforcing plate weld using the magnetic particle method to demonstrate suitability for service in accordance with API 653, Par. 4.3.9.1. The weld examination will require removal of coatings, possible repair of defects, and coating touch-up. [NDE completed with existing welds found acceptable.]

6. Nozzle N-2 reinforcement plate and anchor A-1 are welded to manway nozzle N-1 reinforcement plate.

Provide weld examination of affected portions of reinforcing plate weld using the magnetic particle method to demonstrate suitability for service in accordance with API 653, Par. 4.3.9.1. The weld examination will require removal of coatings, possible repair of defects, and coating touch-up. [NDE completed with existing welds found acceptable.]

Robins AFB Tank 23 Page 3 of 5

7. Three locations on the tank bottom were found with remaining metal thickness below 0.190-inch thickness.

Repair with welded patch plates in accordance with API 650 before return to service. [Repair completed, with acceptable NDE results.]

8. Existing issue, receipt, water draw off and low suction lines have ball valves, however there are reducers and stab-in connections between the ball valves and the tank.

Recommend reconfiguration of the issue, receipt, low suction line and nozzle to incorporate a proper nozzle connection and new DB&B plug valves based on NFPA 30 (Para 22.13) and UFC 3-460-01. This should be done prior to returning the tank to service. [Repair completed, with acceptable NDE results.]

9. Random buckling and distortion of shell at weld connections and on the West side of tanks.

Recommend a detailed examination be conducted to examine shell distortion prior to return to service. [Deformations have been further investigated and evaluated.

No corrective action was required. Deformations should be monitored as part of future inspections.]

NEAR-TERM RECOMMENDATIONS

Repairs and upgrades based on good engineering and maintenance practices or compliance with policy or criteria.

1. Various areas of active corrosion of roof plates.

Recommend touch up coating repair as soon as practical, to extend the service life of the tank.

2. Various internal coating failures of floor plate welds and 3-inches on floor and shell adjacent to floor to shell weld.

Recommend blasting and recoating repair before return to service, to extend the service life of the tank.

3. Northeast roof hatch will not open.

Recommend repair of inoperable roof hatch as soon as practical based on good engineering practice.

4. Shand & Jurs automatic tank gauge (ATG) is inoperable, Recommend repair or replacement of ATG before return to service based on UFC guidelines and good engineering practices.

5. Inlet and outlet pressure relief valves (PRV) have no seals or tags.

Recommend removal of valves and testing to reconfirm set pressure of valves before return to service based on good engineering practice.

Robins AFB Tank 23 Page 4 of 5

6. Tank containment has numerous areas where sealant between concrete slabs and previously repaired cracks have failed.

Recommend that existing caulk be removed and concrete slabs and resealed in failed areas to prevent water migration through containment area as soon as practical.

7. Circumferential floor to shell protrusion (chime) to foundation sealant shows evidence of degradation and failure.

Recommend that existing caulk be removed and shell to foundation resealed in failed areas to prevent water migration under tank as soon as practical.

8. Roof atmospheric vents do not meet current UFC standards for roof vents to be equipped with bird screens.

Recommend providing bird screens on atmospheric vents to be installed based on UFC guidelines and good engineering practices as soon as practical.

9. Manway and gauge hatch gaskets need replacement.

Recommend replacement of manway and gauge hatch gaskets before return to service.

10. Tank contains no shell grounding lugs.

Recommend installation of grounding lugs as soon as practical based on good engineering practice.

11. The tank does not have an operational high level alarm.

Recommend repairing high level alarm as soon as practical. This is consistent with UFC 3-460-01 guidance and will provide additional protection from operational error based on good engineering practice.

12. The tank does not have an operational high level alarm.

Recommend repairing high level alarm as soon as practical. This is consistent with UFC 3-460-01 guidance and will provide additional protection from operational error based on good engineering practice.

13. The tank does not have NFPA standard labeling for flammable liquids.

Provide labeling as soon as practical.

Robins AFB Tank 23 Page 5 of 5

LONG-TERM RECOMMENDATIONS

Repairs and upgrades intended to extend the service life of the tank, ensure continued compliance with codes, standards and regulations, and discretionary improvements.

1. Continue providing modified API 653 inspection at required intervals.

Provide in accordance with API 653 and Service Headquarters policy.

2. No tank cathodic protection system exists.

An evaluation of the soil resistivity and consideration of corrosion rates and need for cathodic protection system may be considered when the tank is out of service for scheduled maintenance, repairs or upgrades.

3. Roof is not equipped with an interior access ladder.

Installation of an interior ladder may be considered when the tank is out of service for scheduled maintenance, repairs or upgrades.

4. Tank is not equipped with stilling wells for ATG.

Installation of a stilling well for ATG may be considered when the tank is out of service for scheduled maintenance, repairs or upgrades.

5. Anchor spacing between anchor A-48 and anchor A-49 does not meet current UFC standards with maximum distance between anchors of ten-feet.

Installation of an additional anchor may be considered when the tank is out of service for scheduled maintenance, repairs or upgrades.

6. 36-inch shell manways are not equipped with davits or hinges for quick opening and closing.

Installation of davits or hinges for shell manways may be considered when the tank is out of service for scheduled maintenance, repairs or upgrades.

7. Annular ring plates 3 and 4 line up with the seam in adjacent bottom plates.

Recommend monitoring these locations for any change in condition during future inspections.

8. Fire water piping support brackets to shell do not have bearing plates.

Monitor condition during future inspections. Repair if necessary as part of any tank repair or alteration project.

November 18, 2009

Tim Towers Project Manager Weston Solutions, Inc.

70 N.E. Loop 410, Suite 600 San Antonio, TX 78216-5842

Subject: Robins AFB tank 23 final inspection report Purchase Order: 0065391 Job Number: Y9056 Revision: 0

Mr. Towers, Please find this to be the final inspection report for Robins AFB tank 23 located in Warner Robins, Georgia. The inspections were performed on May 21 and 22, 2009.

Should you have any further questions, please contact us at the information provided below.

Report prepared by:

Jeff Barksdale Operations Manager API-653 Inspector #36130 jbarksdale@novadatatesting.com

(866) 674-6806 ext. 743

Authorized API-653 Inspector:

John G. Taylor ASNT Level III API-653 Inspector #2250 jtaylor@novadatatesting.com

(866) 674-6806 ext. 741

Y9056r0 – Robins AFB tank 23 final inspection report Page 2 of 34

TABLE OF CONTENTS

Methods of Inspection……………………………………………………………………. Page 03

Introduction………………………………………………………………………………. Page 04

Record of Tank Data……………………………………………………………………… Page 05

General Observations…………………………………………………………………….. Page 06

Recommendations………………………………………………………………………… Page 09

Figures (Referenced Photographs)……………………………………………………….. Page 11

ATTACHMENTS

Planar Tilt and Settlement Graph

Minimum Wall Calculations

Y9056-D-01 – Shell layout and thickness data

Y9056-D-02 – Floor layout and thickness data

Y9056-D-03 – Fixed roof layout and thickness data

Y9056r0 – Robins AFB tank 23 final inspection report Page 3 of 34

METHODS OF INSPECTION

MFL Floor Scan – Magnetic Flux Exclusion was performed on 100% of accessible floor areas. The equipment used was the MFE Enterprises 2412, Mark II. The areas excluded are the sump area, floor attachments, and under internal piping.

Ultrasonic Thickness – The ultrasonic thickness equipment used for the roof, floor, and shell inspection was a Krautkramer Branson DMS2 (this unit is capable of obtaining thickness readings through applied coatings; it has a digital CRT screen and numeric readout). A 560TC - ", 5.0 MHz quad-element transducer was used. This transducer allows the thickness gauge read the velocity and thickness of the coating, thus eliminating the coating thickness from the thickness of the metal. All thickness testing was performed as outlined in our procedure #A-401, revision 8 (Ultrasonic Testing for Metal Thickness and/or Soundness). Refer to the attached drawing for all thickness values.

Y9056r0 – Robins AFB tank 23 final inspection report Page 4 of 34

INTRODUCTION

General – The tank was out of service at the time of this inspection. Based on the inspection requirements of API-653, this tank meets the criteria for continuation of service.

Next Inspections – Due to no supplied previous inspection data, the next recommended in-service ultrasonic thickness inspection should be performed in 5 years (2014). Due to no supplied previous inspection data, the next out-of-service inspection should be performed in 10 years (2019).

Maximum Fill Height – According to the attached minimum wall calculations, the maximum fill height exceeds the height of this tank.

Robins AFB tank 23

Y9056r0 – Robins AFB tank 23 final inspection report Page 5 of 34

TANK INFORMATION

Tank Owner: Robins AFB – Georgia Tank Identification: 23 Diameter: 112’ Height: 52’ Nom. Capacity: 3,700,000 gal. (Unrestricted est.)

Product: JP-8 Manufacturer: Unknown Construction Date: Reportedly 1980’s Construction Code: Unknown Design Pressure: Unknown Design Temperature: Unknown Fixed Roof: Self-supported Cone Floating Roof: Aluminum Pontoon Foundation Type: Concrete Ring Cathodic Protection: None Anchoring: 71x 1” diameter bolts Floor Sump: Center ATG: Yes Float Gauge: Shand & Jurs 92021 (not operational) Alarms: Unknown High Level Valve: Yes Roof Gauge Hatch: Yes Painters Hitch: No Shell Manways: 2 x 36” Roof Manways: 4 x 24” square hatches

Supplied Documentation: No nameplate mounted on tank

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OBSERVATIONS

1. Shell – consists of 6 carbon steel, butt-welded courses

1.1. Both 1st course shell manway nozzle reinforcements (N-1 and N-8) are 2” from the floor to shell weld (see Fig. A, B)

1.2. Nozzle N-2 reinforcement plate and Anchor angle A-1 are welded to Manway nozzle N-1 reinforcement plate (see Fig. A, C)

1.3. All three manway nozzles are 36” and should have davits or hinges for safety (see Fig. D)

1.4. There are 54 (10” flange – 4” web – approx. 14’ long) stiffeners on the upper shell, there is random buckling over most of the tank at welded connections and on the West side (see Fig. E, F, G)

1.5. Nozzle N-3 and anchor angle A- 2 welds are only ” apart (see Fig. H)

1.6. Anchor angle is welded over vertical weld at A-4 and A-24 (see Fig. I, J)

1.7. Anchor bolts are 19’ apart between A-48 and A-49 at cleanout nozzle (see Fig. K)

1.8. Three shell insert plates at cleanout nozzle have square corners (see Fig. L, M, N)

1.9. Fire water piping support brackets are connected to the shell with no repads (see Fig. O)

2. Floor – consists of 41 carbon steel, lap-welded plates, with an annular ring consisting of 38 plates

2.1. MFE of the floor revealed twenty relevant indications that were followed up with UT scans.

Indication #10 was .190” tm, #15, was .167” tm and #16 was .188” tm and located on floor plate #7. All other indications were above .200”. (see Fig. P, Q, R)

2.2. Center sump is approximately 16” in diameter (see Fig. S)

2.3. Annular ring plates 3 and 4 line up with the seam in adjacent floor plate (four plate connection)

(see Fig. T)

2.4. No wear plates on floor under forty-five floating roof legs (see Fig. U)

2.5. Approx 3” on the floor and shell adjacent to the floor to shell weld has coating failure. (see Fig.

V)

2.6. Various areas at the welds on the interior floor have coating failure (see Fig. W)

2.7. No repad under anti-rotation cable connections to floor (see Fig. AF)

2.8. No wear plate under high-level alarm assembly (see Fig. AG)

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3. Floor Protrusion

3.1. Floor to concrete ring seal has failed. (see Fig. X)

4. Floating Roof

4.1. No stilling well or access ladder through or too roof (see Fig. Y)

4.2. Metal shoe (hinged) and fabric seal appears in good condition ( see Fig. Z, AL)

5. Fixed Roof

5.1. Roof rafters and supports appear to be in good condition (see Fig. AA)

5.2 There are several locations where the roof has active corrosion (see Fig. AB)

5.3 Manway and gauge hatch gaskets need replacing (see Fig. AC)

5.4 There are no screens in the roof vents. (see Fig. AD)

5.5 NE roof hatch would not open (see Fig. AE)

6. Appurtenances

6.1. Inlet and outlet lines have PRV’s with no seals or tags (see Fig. AH, AI)

7. Other

7.1. High-level alarm reportedly does not work

7.2. Shand & Jurs model 92021 float gauge does not work (see Fig. AJ)

8. Foundation – seal needs renewing between floor and concrete ring (see Fig. X)

9. Secondary Containment – Containment Area has numerous areas where the seal between concrete slabs and previously fixed cracks need re-sealing (see Fig. AK)

10. Grounding / Cathotic Protection

10.1. This tank does not have cathodic protection

10.2. This tank does not visually appear to be grounded

11. Tank Plumbness/Out of Round/Tilt/Settlement – Planar tilt and differential settlement readings

Y9056r0 – Robins AFB tank 23 final inspection report Page 8 of 34 are within the specifications of API 653, appendix B. Please refer to the attached planar tilt and settlement graph. No significant edge deflection was noted at the time of inspection.

12. Brittle Fracture – Based upon this tank demonstrating the ability to withstand hydrostatic and operating levels during low operating temperature, API-653 Section 5.2 and figure 5-1 recommends continuation of service. Brittle fracture considerations should be taken upon a change of service.

13. Overturning – Wind and Seismic loads –Overturning considerations should be taken upon a change of service.

14. Identification – The tank number and the contents are identified on this tank. There is no NFPA label.

Y9056r0 – Robins AFB tank 23 final inspection report Page 9 of 34

RECOMMENDATIONS

Consideration should be given to the following near term recommendations –

1. Remove the coating on the manway reinforcing plates, the nozzles and attachments welded to those plates that do not meet API weld spacing requirements, perform magnetic particle testing of the welds and pressure test the reinforcing pads (N-1, N-2, N-3, N-8 A-1, A-2, A-4, A-24)

2. Install davits or hinged manways on the three manways

3. Perform engineering evaluation of anchor angles and specifically the distance between anchor bolts near the cleanout nozzle (A-48 and 49)

4. Remove the coating on the shell insert plates above the cleanout nozzle that do not meet API spatial requirements (square corners and weld spacing issues), perform magnetic particle testing of the welds

5. Install shell re-pads at all fire water bracket locations

6. Perform engineering evaluation of four plate connection at annular ring weld joint for repair and/or remove coating on the weld seams and perform magnetic particle and vacuum box testing

7. Install wear plates under the 45 roof legs, under the anti-rotation cable attachments, and larger pads under the low suction and water drain pipe brackets ** it should be noted numerous roof support legs and the anti-rotation attachment clips are in the critical zone (near the shell) and will require tombstone style plates**

8. Install grounding cables per API requirements

9. Evaluate the need for cathodic protection

10. Install new gaskets at all hatches and connections prior to returning to service

11. Consideration should be made to media blast and recoat the floor to shell weld area and numerous other floor plate areas where the old coating has failed **protect floating roof seal fabric during any internal blasting evolutions**

12. Repair or replace ATG and high level alarm

13. Install stilling well and ladder assembly

14. Install screen on roof vents

15. Check mechanical latches on roof hatches for proper operation, install gaskets

16. Spot blast and recoat roof coating where needed

Y9056r0 – Robins AFB tank 23 final inspection report Page 10 of 34

17. Replace or test inlet and outlet PRV’s

18. Remove and replace seal between tank floor protrusion and concrete ring

Consideration should be given to the following long term recommendations –

19. Monitor shell buckles and deformations

20. Monitor or repair soil-side pitting areas #10, #15, & #16

21. Patch secondary containment seals

Nova Data Testing Services, Inc. makes no implied or expressed warranty that these recommendations would return any tank to serviceability.

Please contact Nova Data Testing Services at the numbers below for information on detailed repair specifications or quality assurance for this, or any other project.

Y9056r0 – Robins AFB tank 23 final inspection report Page 11 of 34

Fig. A – Shell manway N-1 is 2” from floor weld, Anchor angle A-1 is welded to N-1 repad

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Fig. B – Shell manway N-8 is 2” from floor weld

Fig. C – Nozzle N-2 repad and Anchor angle A-1 are welded to Manway N-1 repad

Y9056r0 – Robins AFB tank 23 final inspection report Page 13 of 34

Fig. D – Manways (3 typical) are 36” without davits or hinges for safe opening

Fig. E – There are 54 Shell stiffeners, and numerous random buckles on the shell (Southside)

Y9056r0 – Robins AFB tank 23 final inspection report Page 14 of 34

Fig. F –There are 54 Shell stiffeners, and numerous random buckles on the shell (Northeast side)

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Fig. G – There are 54 Shell stiffeners, and numerous random buckles on the shell (West side)

Fig. H – 1” Nozzle N-3 and anchor angle A-2 are ” apart

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Fig. I – Anchor angle A-4 welded on vertical shell weld

Y9056r0 – Robins AFB tank 23 final inspection report Page 17 of 34

Fig. J – Anchor angle A-24 welded on vertical shell weld

Fig. K – Anchor bolts are 19’ apart at cleanout nozzle

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Fig. L – Shell plate inserts with square corners at cleanout nozzle

Fig. M – Shell plate inserts with square corners at cleanout nozzle middle of 1st course

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Fig. N – Shell plate inserts with square corners at cleanout nozzle 1st to 2nd course

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Fig. O – Fire water system support brackets connected to shell with no repads (typ. All)

Fig. P – MFE indications revealed area .190” tm from soil side pitting

Y9056r0 – Robins AFB tank 23 final inspection report Page 21 of 34

Fig. Q – MFE indications revealed area .167” tm from soil side pitting

Y9056r0 – Robins AFB tank 23 final inspection report Page 22 of 34

Fig. R – MFE indications revealed area .188” tm from soil side pitting

Fig. S – Sump is small, approx 16” wide

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Fig. T – Four plate connection at annular ring and floor plates near North Manway

Fig. U – No floor wear plates under floating roof legs

Y9056r0 – Robins AFB tank 23 final inspection report Page 24 of…