ATT F - Previous Inspection Report-Martin State-Fac 3030.pdf

Tank 3030 Inspection Report API 653 In-Service (External) Inspection

Martin State ANG

Baltimore County, Maryland

Prepared For:

U.S. Army Corps of Engineers

Omaha District 106 South 15th Street

Omaha, Nebraska 68102

Submitted By:

Pond and Company

3500 Parkway Lane, Suite 600 Atlanta, GA 30092

Telephone: 678 336 7740 Facsimile: 678 336 7744 www.pondco.com

August 2015

Tank 3030 – API 653 Inspection Report Pond and Company Martin State ANG 1150068 i

Preface

Pond & Company, Inc. was under contract to the U.S. Army Corps of Engineers (USACE), Omaha

District to provide an in-service (external) tank inspection on Tank 3030 at the Air National Guard

(ANG) facility at Martin State Airport in Baltimore County, Maryland.

There are no mandatory repairs required to remove Tank 3030 from service; however, additional repairs and upgrades have been identified to prolong tank integrity and maintain product quality.

This document presents findings of the tank inspection and testing, as well as the recommendations regarding repairs and upgrades.

Brian Lunsford, P.E. and Roger Jochum performed the API-653 in-service (external) inspection and

Brian Lunsford, P.E. developed the API 653 inspection report.

11 August 2015

Brian W. Lunsford, P.E. Date Sr. Project Manager Integrity Engineer API 653 Inspector # 28526 ii

Table of Contents

Section 1

Executive Summary .......................................................................................................................... 1-1

Section 2

Tank Physical and Historical Data ..................................................................................................... 2-1

Section 3

Non-Destructive Testing (NDT) ......................................................................................................... 3-1

3.1 NDT Inspection Scope of Work .................................................................................... 3-1

3.2 Equipment Used .......................................................................................................... 3-1

3.3 NDT Significant Findings ............................................................................................. 3-1

3.4 Bottom-to-Shell Weld Examination .............................................................................. 3-1

3.5 Shell Examination ........................................................................................................ 3-1

3.6 Shell Nozzle Examination ............................................................................................ 3-2

3.7 Fixed Roof Examination ............................................................................................... 3-2

3.8 Fixed Roof Nozzle Examination ................................................................................... 3-2

Section 4

Significant Findings ........................................................................................................................... 4-1

4.1 Tank Bottom and Foundation ....................................................................................... 4-1

4.2 Tank Shell, Nozzles and Appurtenances ..................................................................... 4-1

4.3 Fixed Roof, Nozzles and Appurtenances ..................................................................... 4-1

4.4 High Level Alarms and Gauging System ...................................................................... 4-1

Section 5

Recommendations and Inspection Intervals ...................................................................................... 5-1

5.1 Repair and Upgrade Recommendations ...................................................................... 5-1

5.1.1 Mandatory Repairs Required to Remove Tank from Service ............................. 5-1

5.1.2 Repairs Required to Fully Comply with API 653 / 650 ........................................ 5-1

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03 ...................... 5-1

5.1.4 Recommended Repairs as Best Management Practice ..................................... 5-1

5.2 Inspection Intervals ...................................................................................................... 5-2

Appendices Appendix A (CAD Drawings) ............................................................................................................. A-1

Appendix B (Tank Inspection Data) ................................................................................................... B-1

Appendix C (API 653 Inspection Checklist) ....................................................................................... C-1

Appendix D (Calculations) ................................................................................................................. D-1

Appendix E (Photographs) ................................................................................................................ E-1 iii

Abbreviations and Acronyms

ANG Air National Guard

AFFF Aqueous Film Forming Foam

API American Petroleum Institute

ATG Automatic Tank Gauge

AVG Average

BBL Barrels

CAD Computer Aided Design

CP Cathodic Protection

DB&B Double Block & Bleed Valve

DFT Dry Film Thickness

EFSO Emergency Fuel Shut-Off

FML Flexible Membrane Liner

FT Foot/Feet

GE General Electric

HHLA High-High Level Alarm

HLA High Level Alarm

HLCV High Level Control Valve

IAW In Accordance With

LLA Low Level Alarm

LLLA Low-Low Level Alarm

N/A Not Applicable

NDT Non Destructive Testing

NFPA National Fire Protection Association

PE Professional Engineer

PPS Project Planning Study

PRT Product Recovery Tank

PVC Polyvinyl Chloride

RCA Remaining Corrosion Allowance

TRV Thermal Relief Valve

TYP Typical

UFC Unified Facilities Criteria

USACE U.S. Army Corps of Engineers

UTT Ultrasonic Thickness Testing

VT Visual Testing

1-1

Section 1

Executive Summary

Tank 3030 located at the ANG facility at Martin State Airport is a welded, steel, vertical aboveground jet fuel (F-24) storage tank. The tank was fabricated by Witherup Fabrication and Construction and erected by Summit City Construction in 1985 in accordance with (IAW) the 7th edition of API 650. Tank

3030 is 31’-0” in diameter and 42’-3” high with a maximum liquid level of 37’-5”. The nominal capacity of the tank is 5,000 barrels (bbls). The in-service inspection was performed 25 June 2015. The results of this inspection will provide recommendations for repairs and upgrades which are required to comply with applicable industry and military standards.

The testing and inspection was performed IAW the applicable sections of the Fifth Edition of API 653.

Contained in this report is a detailed account of the tank inspection, a summary of the non-destructive testing, and the conclusions derived from the inspection and testing. The findings of this inspection are further detailed in Section 4 of this report. Repairs and upgrades identified in this section are further classified and listed in Section 5 of this report.

Foundation and Containment

Tank 3030 is located within a concrete containment dike. The concrete dike floor exhibits minor cracking at various locations. The tank rests on an elevated, stained concrete ring wall. The tank is grounded at three (3) locations. The grounding cables and tank connections are in good condition.

The containment dike is not provided leak detection pipes to monitor for product under the tank bottom.

Tank Shell

The tank shell consists of six (6) butt-welded steel shell courses. The external coating on the tank shell is in good overall condition with only one minor flaking. The tank is provided standard product identification IAW MIL-STD-161G and National Fire Protection Agency (NFPA) emergency responder diamond. The tank shell is provided two (2) overflow ports with screens.

The tank shell is equipped with a spiral staircase and upper platform for fixed roof access.

Fixed Roof

The roof is a lap-welded, steel, cone-up, self-supported fixed roof. The fixed roof is equipped with a full perimeter handrail. The external coating is in good overall condition with various minor locations of coating failure. The locations are located mostly around the perimeter of the fixed roof where water collects. The roof is provided with a center vent and perimeter roof vents (floating pan inspection hatches) with screens.

The tank is equipped with an aluminum pontoon internal floating pan with double wiper seals.

Nozzles and Appurtenances

Piping within the containment dike consists of aboveground stainless steel piping. The piping is supported by adjustable pipe supports and axial guide supports. The receipt and issue piping includes

1-2 carbon steel slip-on flanges instead of welded connections. The carbon steel slip-on flanges exhibit minor surface corrosion. A 2 ½” aqueous film forming foam (AFFF) pipe is routed to the tank from outside the containment dike. The pipe is not provided support inside the dike. The receipt and issue double block and bleed (DB&B) skin valves are provided with thermal relief valves (TRVs) and associated crossover piping.

The water draw-off piping is connected to a product recovery tank (PRT) located inside the containment dike.

Gauges and Alarms

The tank is currently equipped with a roof mounted ITT Barton/Cameron system for automatic tank gauging (ATG). The ATG probe is located in a slotted stilling well. An 8” gauging hatch is provided a stilling well for manual gauging activities. An 8” sampling assembly with a winch and 6” blind flange equipped with a slotted stilling well are also located on the fixed roof. The 6” blind-flanged nozzle is located adjacent to the center vent. A high-high level alarm (HHLA), high level alarm (HLA), and low level alarm (LLA) are mounted on the tank shell. A high level control valve is provided on the receipt piping into the tank and the float is mounted on the tank shell. A Varec 2500B tape level gauge is utilized for reading liquid level from grade.

Cathodic Protection

The tank bottom is not provided cathodic protection (CP) to protect the tank bottom from underside corrosion. The original construction of the tank foundation consists of a liner and oiled sand. This type of corrosion protection is not ideal and an impressed current CP system should be provided.

Recommendations for Repair and Upgrade

Below is a summary of the repair and upgrade recommendations identified during the external API 653 inspection:

1. Spot repair external tank shell coating.

2. Spot repair external tank roof coating.

3. Enlarge existing tell-tale holes in both manways and the flush clean-out nozzle reinforcing pads.

4. Monitor the tank shell between the chime and lower shell manway in future inspections.

5. Repair approximately 120 linear feet of minor cracking in the concrete dike floor.

6. Coat the existing AFFF piping and chamber red IAW MIL-STD-161G.

7. Replace all carbon steel slip-on flanges with welded connection. The existing piping in the dike is stainless steel.

8. Replace existing ITT Barton ATG with an Enraf ATG system (to include VITO probe).

9. Provide standard under-tank details, to include a FML, clean sand bedding, and impressed current

CP system.

10. Provide leak detection to monitor for product under tank bottom.

11. Provide a pipe support in the containment dike for the 2 ½” AFFF piping.

1-3

Recommended Inspections and Intervals

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector w/ UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector (1): API: Twenty (20) Years; April 2031

UFC: Ten (10) Years; April 2021

(1) Internal inspection intervals were based on the previous out-of-service inspection performed April 2011.

Internal inspection intervals required by UFC are more stringent and therefore should govern the next internal inspection.

2-1

Section 2

Tank Physical and Historical Data

Owner: Air National Guard Tank Number: Tank 3030

Location: Martin State Airport Baltimore County, Maryland

Fabricated By: Witherup Fabrication and Erection Erected by Summit City Construction

Design Standard: API 650, 7th edition

Year Built: 1985 Product: Jet Fuel (F-24)

Product Specific Gravity: 0.84

Diameter: 31’-0” Height: 42’-3”

Maximum Liquid Level: 37’-5”

Nominal Capacity: 5,000 bbls Foundation: Concrete Ring Wall in Concrete Dike

Bottom Construction: Cone Down*

Shell Construction: Butt-Welded A36* Steel Plates / 6 Shell Courses

Fixed Roof Construction: Lap-Welded Steel Plates / Cone-Up / Self- Supported

Cathodic Protection (CP): None Bottom Coating: Thin Film Coating*

Shell Coating Internal: Thin Film Coating*

Shell Coating External: Epoxy Fixed Roof Internal Coating: Unknown

Fixed Roof External Coating: Epoxy

Stairway Construction: Spiral Stairway with Upper Platform Last Inspection: Out-of-Service Inspection Performed April 2011

Average Floor Plate Thickness: 0.250”*

Average Shell Plate Thickness: Shell Course 1: 0.255” Shell Course 2: 0.245” Shell Course 3: 0.248” Shell Course 4: 0.245” Shell Course 5: 0.244” Shell Course 6: 0.249”

Average Fixed Roof Plate Thickness: 0.185”

GPS Coordinates: N 39° 19' 57.51" W 76° 24’ 52.19"

Notes:

*information based on inspection performed April 2011 and report dated May 2011.

3-1

Section 3

Non-Destructive Testing (NDT)

3.1 NDT Inspection Scope of Work

The following NDT examinations were performed to evaluate the tank integrity.

• A Visual Test (VT) was performed on the tank containment, as well as piping and valves located inside containment.

• VT was performed on the external surfaces of the tank shell and fixed roof.

• VT was performed on the tank nozzles, coatings, appurtenances, and ancillary equipment.

• Ultrasonic thickness testing (UTT) measurements were taken on the tank nozzles, reinforcement pads, shell plates, and fixed roof plates.

• Dry Film Thickness (DFT) measurements were taken on the external tank shell and fixed roof coatings.

• An external settlement survey was performed on the tank foundation.

3.2 Equipment Used

• GE Krautkramer Ultrasonic Thickness Gauge w/ Topcoat o M/N DMS GO+

• Fisher Technologies Dry Film Thickness Gauge o M/N Dual Scope MPOR

3.3 NDT Significant Findings

The UTT measurements indicated no significant metal thinning on the tank shell and fixed roof. The external shell and roof coatings are in good overall condition with minor locations of failure.

3.4 Bottom-to-Shell Weld Examination

The external bottom-to-shell weld was examined using VT methods. There were no significant findings. The examination was limited due to the external coating.

3.5 Shell Examination

The shell plates were examined using UTT and VT methods. Nine (9) UTT measurements were taken on each plate of the 1st shell course. Ten (10) UTT measurements were taken on the remaining shell course plates using the spiral stairs and upper platform for access. No areas of significant metal loss were identified.

Refer to Drawing A-1, “Shell Layout” for plate locations and Table B-1, “Shell Plate Ultrasonic

Thickness Readings” for thickness data.

3-2

3.6 Shell Nozzle Examination

The shell nozzles and reinforcement pads were inspected by UTT and VT testing methods and were found to be in good overall condition. The reinforcement pad tell-tale holes for the manway and flush clean-out nozzles are undersized.

Refer to Drawings A-1, “Shell Layout” for nozzle locations and Table B-3, “Nozzles and

Appurtenances” for nozzle data.

3.7 Fixed Roof Examination

The fixed roof plates were examined using UTT and VT methods. Five (5) thickness measurements were taken on each roof plate and four (4) measurements were taken on each sketch plate. No areas of significant metal loss were identified.

Refer to Drawing A-2, “Fixed Roof Layout” for plate locations and Table B-2, “Roof Plate Ultrasonic

Thickness Readings” for thickness data.

3.8 Fixed Roof Nozzle Examination

The fixed roof nozzles and reinforcement pads were examined using UTT and VT methods. The nozzles are in good overall condition.

Refer to Drawing A-2, “Fixed Roof Layout” for nozzle locations and Table B-3, “Nozzles and

Appurtenances” for nozzle data.

4-1

Section 4

Significant Findings

4.1 Tank Bottom and Foundation

• The tank rests on a concrete ring wall inside a concrete containment dike.

• Staining was observed on the ring wall from previous weeping.

• The concrete dike floor exhibits minor cracking.

• There is no leak detection to monitor for product under the tank bottom.

• The tank bottom is not provided CP. The existing foundation is a liner with oiled sand.

4.2 Tank Shell, Nozzles and Appurtenances

• The shell is equipped with six (6) fully coated butt-welded steel shell courses.

• The external tank shell coating is in good overall condition with only 2 ft2 of flaking topcoat.

• The tank is equipped with three (3) shell mounted grounding lugs. The cables and clips are in good overall condition.

• The shell is equipped with a spiral stairway for fixed roof access with an upper platform.

• The tank shell is equipped with standardized identification, product designation, and NFPA emergency responder diamond.

• The stainless steel issue and receipt piping are connected with carbon steel slip-on flanges.

The flanges exhibit general surface corrosion.

• Tell-tale holes for both manways and the flush clean-out nozzle reinforcing pads are undersized (1/8” instead of ¼”).

• The AFFF piping inside the containment dike is not supported.

4.3 Fixed Roof, Nozzles and Appurtenances

• The fixed roof is a self-supporting cone-up roof. The plates are fully coated and lap-welded.

• The roof coating is in good condition with minor failure at perimeter low spots. The low spots exhibit water staining.

• The roof is equipped with a full perimeter handrail.

• The internal floating pan is of aluminum pontoon construction. The pan is provided double wiper seals.

• There is no internal ladder to provide for pan access.

4.4 High Level Alarms and Gauging System

• The tank is equipped with an ITT Barton/Cameron ATG System located in a slotted stilling well.

• An 8” manual gauging hatch with slotted stilling well is provided for manual gauging activities.

• The receipt is equipped with a HLCV for overfill protection.

• HHLA, HLA, and LLA wells are mounted on the tank shell.

4-2

• A Varec 2500B tape level gauge is mounted on the tank shell.

• A sampling assembly is located on the fixed roof. The assembly includes a hand crank.

• A 6” blind-flanged nozzle with a slotted stilling well is located adjacent to the center vent.

5-1

Section 5

Recommendations and Inspection Intervals

5.1 Repair and Upgrade Recommendations

The following subsections outline the itemized tank repairs/upgrades.

5.1.1 Mandatory Repairs Required to Remove Tank from Service

No mandatory repairs required to remove tank from service.

5.1.2 Repairs Required to Fully Comply with API 653 / 650

Recommendation 1: Spot repair external tank shell coating. Approximate coating repair is 2 ft2.

Recommendation 2: Spot repair external tank roof coating. Approximate coating repair is 20 ft2.

Recommendation 3: Enlarge existing 1/8” tell-tale holes in both manways and the flush clean-out nozzle reinforcing pads to 1/4”.

Recommendation 4: Monitor the tank shell between the shell manway and tank chime. The existing weld clearance is not fully compliant with API 650/653; however, no indications of stress or distortion were observed during the inspection.

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03

Recommendation 5: Repair approximately 120 linear feet of minor cracking in the concrete dike floor.

Recommendation 6: Coat the existing AFFF piping and chamber red IAW MIL-STD-161G.

Recommendation 7: Replace all carbon steel slip-on flanges with welded connection. The existing piping in the dike is stainless steel. There are two (2)-10” and two (2)-6” slip-on flanges for replacement.

Recommendation 8: Replace existing ITT Barton ATG with an Enraf ATG system (to include VITO probe).

Recommendation 9: Provide standard under-tank details, to include a FML, clean sand bedding, and impressed current CP system.

Recommendation 10: Provide leak detection to monitor for product under tank bottom.

5.1.4 Recommended Repairs as Best Management Practice

Repairs required as Best Management Practice are recommended to extend the tank service life and maintain product quality, but are not necessarily part of a design or inspection standard.

Recommendation 11: Provide a pipe support in the containment dike for the 2 ½” AFFF piping.

5-2

5.2 Inspection Intervals

The interval between inspections of a tank (both internal and external) should be determined by its service history. Inspection intervals can be adjusted based on the known corrosion rates. The corrosion rates can only be determined when a comparison can be made between measurements taken over an interval of time. The previous API 653 out-of-service inspection was performed April

2011 and the report is dated May 2011. The inspection report was reviewed and provided data for comparison.

API 653 and UFC 3-460-03 provides recommendations for inspection intervals which are identified below. UFC 3-460-03 provides a maximum internal inspection interval for military facilities. The UFC guidelines should be used as they are more stringent.

• Routine monthly inspections to monitor the external condition of the tank and associated piping. Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (includes tank chime to foundation interface), coatings, and appurtenances. The roof should be visually inspected for signs of damage.

• Formal visual external inspection by an API certified inspector every 5 years or RCA/4N years

(where RCA is the difference between the measured shell thickness and the minimum required thickness and N is the shell corrosion rate), whichever is less. Based on the review of shell and roof thickness measurements, the 5-year interval will govern the next formal external visual inspection.

• Ultrasonic thickness measurements of the shell plates can be performed with the tank in service and can be scheduled at a maximum interval of fifteen (15) years or RCA/2N, whichever is less.

Based on this data, the recommended interval for the UTT measurements on the tank shell is fifteen (15) years.

• Bottom corrosion rates govern the internal inspection interval. Per API 653, the next internal inspection should be performed within twenty (20) years of the previous inspection; however, UFC 3-460-03 requires a maximum internal inspection interval of ten (10) years. The internal inspection interval required by UFC is more stringent and therefore should govern when to perform the next internal inspection. The previous internal inspection was performed April 2011.

The recommended inspections and intervals are:

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector w/ UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector: API: Twenty (20) Years; April 2031

UFC: Ten (10) Years; April 2021

Appendix A

CAD Drawings

8'-0"

8'-0"

7'-0"

7'-0"

7'-0"

1-1

1-2

1-3

1-4 1-5

2-1 2-2

2-3 2-5

3-1 3-2

3-3

4-1

4-2 4-3 4-4 4-5

5-1

5-2 5-3 5-4

6-1

6-2

6-3

6-4

6'-3"

STAIR LANDING GROUND (TYP 3)

N1

N2

N3

N4

C/O

MW1

MW2

N5

N6

N7

N10

N9

N8

6-5

5-5

3-43-5

2-4

SHELL OVERFLOW

PORT (TYP 2)

UPPER PLATFORM

FLAKING

TOPCOAT

BALTIMORE, MARYLAND

MARTIN STATE AIRPORT

SCALE:

SHEETNOT TO SCALE AUGUST 2015

REVISED BY:

EHY

TANK 3030

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 39° 19’ 57.51”

W 76° 24’ 52.19”

MANUFACTURER:

SUMMIT CITY CONSTRUCTION

DESIGN STANDARD:

API 650 7TH ED

YEAR BUILT:

PRODUCT:

JET FUEL

PRODUCT SPECIFIC GRAVITY:

0.84

TANK DIAMETER:

31'

TANK HEIGHT:

42'-3" (6 SHELL COURSES)

CAPACITY:

5,000 BBLS

NOTES:

1. REFER TO TABLE B-1, SHELL PLATE ULTRASONIC

THICKNESS READINGS IN APPENDIX B FOR THE

INDIVIDUAL SHELL PLATE ULTRASONIC THICKNESS

READINGS.

2. REFER TO TABLE B-3, NOZZLES AND APPURTENANCES,

FOR NOZZLE DATA.

SHELL LAYOUT

A1 OF A2

LEGEND:

- COATING FAILURE

5 6

N11

PERIMETER VENTS/

PAN INSPECTION HATCHES

(TYP 2)

N11

N13

N12

N17

N16

H2

N15

N14

HANDRAIL

BALTIMORE, MARYLAND

MARTIN STATE AIRPORT

SCALE:

SHEETNOT TO SCALE AUGUST 2015

REVISED BY:

EHY

TANK 3030

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 39° 19’ 57.51”

W 76° 24’ 52.19”

MANUFACTURER:

SUMMIT CITY CONSTRUCTION

DESIGN STANDARD:

API 650 7TH ED

YEAR BUILT:

PRODUCT:

JET FUEL

PRODUCT SPECIFIC GRAVITY:

0.84

TANK DIAMETER:

31'

TANK HEIGHT:

42'-3" (6 SHELL COURSES)

CAPACITY:

5,000 BBLS

NOTES:

1. REFER TO TABLE B-2, ROOF PLATE ULTRASONIC THICKNESS READINGS IN

APPENDIX B FOR THE INDIVIDUAL FIXED ROOF PLATE ULTRASONIC THICKNESS

READINGS.

2. REFER TO TABLE B-3 NOZZLES AND APPURTENANCES, FOR NOZZLE DATA.

FIXED ROOF LAYOUT

A2 OF A2

Appendix B

Tank Inspection Data

Table B-1: Shell Plate Ultrasonic Thickness Readings

Roof

Shell Course

Plate 6-1 Plate 6-2 Plate 6-3 Plate 6-4 Plate 6-5

.249 .249 .247

.253 .251 .250

.248 .248 .251

.247

Avg. .249

Circumferential weld C6

Shell Course

Plate 5-1 Plate 5-2 Plate 5-3 Plate 5-4 Plate 5-5

.245 .244 .244

.244 .246 .243

.247 .242 .245

.243

Avg. .244

Circumferential weld C5

Shell Course

Plate 4-1 Plate 4-2 Plate 4-3 Plate 4-4 Plate 4-5

.244 .245 .246

.247 .242 .246

.248 .245 .246

.245

Avg. .245

Circumferential weld C4

Shell Course

Plate 3-1 Plate 3-2 Plate 3-3 Plate 3-4 Plate 3-5

.244 .249 .248

.248 .249 .250

.247 .249 .248

.246

Avg. .248

Circumferential weld C3

Shell Course

Plate 2-1 Plate 2-2 Plate 2-3 Plate 2-4 Plate 2-5

.241 .248 .243

.246 .246 .245

.245 .247 .247

.246

Avg. .245

Circumferential weld C2

Shell Course

Plate 1-1 Plate 1-2 Plate 1-3 Plate 1-4 Plate 1-5

.260 .261 .259 .251 .248 .243 .258 .256 .247 .253 .254 .254 .256 .257 .251

.260 .263 .264 .257 .247 .249 .261 .258 .247 .247 .258 .263 .260 .261 .253

.256 .259 .257 .247 .248 .245 .255 .253 .250 .255 .256 .260 .257 .256 .248

Avg. .260 .248 .254 .256 .255

Circumferential weld C1

Thicknesses represented in inches.

Average shell plate thickness: Shell Course 1: 0.255 Shell Course 2: 0.245 Shell Course 3: 0.248 Shell Course 4: 0.245 Shell Course 5: 0.244 Shell Course 6: 0.249 Refer to Drawing A-1 in Appendix A for plate numbers.

Table B-2: Roof Plate Ultrasonic Thickness Readings

Plate 1 Plate 2 Plate 3 Plate 4 Plate 5

.195 .185 .180 .193 .182 .183 .177 .177

.193 .191 .195 .194 .191

.182 .179 .185 .179 .186 .183 .179 .178 .179 .189

Avg. .187 .184 .189 .183 .183

Plate 6 Plate 7 Plate 8 Plate 9 Plate 10

.181 .185 .186 .187 .185 .181 .180 .182 .181 .180

.192 .184 .193 .193 .188

.184 .186 .181 .182 .178 .182 .179 .177 .177 .178

Avg. .186 .184 .184 .182 .181

Plate 11 Plate 12 Plate 13 Plate 14

.180 .180 .181 .184 .186 .182 .190 .201

.191 .197 .191 .202

.183 .182 .184 .184 .181 .190

Avg. .183 .187 .185 .196

Thicknesses represented in inches.

Average roof plate thickness: 0.185 Refer to Drawing A-2 in Appendix A for plate numbers.

Table B-3: Tank Shell Nozzles and Appurtenances

NOZZLE

NOZZLE SIZE

(Diameter or

Width/Height)

REPAD

SHAPE

REPAD SIZE

(W X H)

REPAD

THICKNESS

NOZZLE

THICKNESS

H1 H2

NOZZLE

LOCATION

(Measured circumferentially from Manway A)

NOTES

MW1 36" A 7'-0" x 6'-0" .235 .270 3'-0" 2 1/2" 0'-0" Shell Manway

N1 1" - - - Threaded 5'-3" - 5'-2" LLA

N2 1" - - - Threaded 3'-3" - 5'-2" LLA

N3 1" - - - Threaded 4'-0" - 9'-9" Shell Thermometer

N4 6" B 1'-4" .245 .267 1'-7" 10" 17'-6" Receipt

MW2 36" A 7'-0" x 6'-0" .236 .280 9'-5" 6'-8" 21'-8" Manway

C/O 2'-0" x 2'-0" D 6'-0" x 3'-0" .310 .296 - - 50'-11" Flush Clean-Out

N5 3" B 11" .258 .181 1'-0" 6" 88'-0" Low Suction

N6 10" A 2'-4' x 2'-0" .244 .364 1'-6" 6" 92'-0" Issue (Main Suction)

N7 2" - - - - 4 1/2" - 94'-9" Water Draw-off

N8 1" - - - - 34'-7" - 48'-6" HLA / HLCV

N9 1" - - - - 37'-2" - 48'-6" HLA / HLCV

N10 4" - - - - - - - AFFF

N11 1 3/4" - - - Roof Tape Gauge

N12 6" B 1'-2" .246 .258 Roof Blind Flange

N13 24" - - - .249 Roof Center Vent

N14 2" - - - .125 Roof Pan Anti Rotation

N15 10" B 2'-0" .251 .326 Roof Sampling Assembly w/ Winch

N16 8" B 1'-0" .519 .181 Roof Gauging Hatch

N17 10" B 2'-0" .252 .325 Roof ATG

H1 24"x24" - - - .242 Roof Hatch

H2 24"x24" - - - .243 Roof Hatch

Thickness measurements are in inches.

H1 = C/L of pipe to edge of roof or chime.

H2 = Edge of tank or chime to nearest weld toe.

Repad Shapes:

Table B-4: Coating Thickness Measurements

External Shell Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

15.46 2.939 20 11.04 21.99

Roof Coating Thickness (External)

Average Standard Deviation Number of Readings Minimum Maximum

16.48 3.420 20 11.21 22.44

Appendix C

API 653 Inspection Checklist

Foundation Inspection

Item Description Comments

1 Foundation description Tank rests on an elevated concrete ring wall within a concrete containment dike.

2 Inspect for foundation damage or cracking.

Minor cracking in dike floor.

3 Evidence of bottom leakage or stains.

Ring wall is stained from previous issues with water ingress under tank bottom and product loading. A previous study mentions staining is due to oiled sand weeping from between tank chime and ring wall. The chime has been sealed and is in good condition.

4 List all significant cavities or erosion around the foundation.

None noted.

No erosion or cavities noted.

5 Inspect for vegetation under and around tank perimeter.

None noted.

Does tank have proper water runoff and drainage away from the tank?

Yes. Tank is elevated.

Is grade or other material covering the floor-to-shell weld or chime bottom plate?

No. Tank rests on an elevated concrete ring wall.

Is any visual settlement noted around the tank perimeter?

None noted.

What is the general condition of the dike area?

Minor cracking in dike floor.

Notes:

No leak detection.

The tank rests on oiled sand inside the ring wall.

Shell Inspection

1 Inspect shell ladders, stairways, platforms and walkways.

Good overall condition.

2 Inspect shell for significant distortions, creases and/or buckling.

None noted.

3 Visually inspect shell for out-of-roundness.

Acceptable.

4 Inspect shell support welds for corrosion or damage.

None noted.

5 Inspect wind girder for corrosion or damage.

N/A – The tank is not equipped with a wind girder.

6 Inspect external shell for leaks or significant corrosion areas.

None noted.

7 Inspect exterior shell-to-bottom weld area for corrosion, defects or thinning of the chime bottom plate.

Good overall condition.

8 Inspect shell coating for failure, peeling or fading.

Coating is in good overall condition with only a minor location of topcoat flaking.

9 Inspect the internal shell for pitting, corrosion, rubbing or grooving.

N/A – External Inspection

10 Inspect horizontal and vertical seams for weld or rivet joint details.

Acceptable.

11 Inspect shell overflows for corrosion and screening.

Acceptable.

12 Inspect shell for any lap patches. None noted.

13 Is the tank grounded?

Are the cables and clips in good condition?

Yes. The tank shell is equipped with three (3) grounding lugs and cables in good condition.

14 Does the tank have a legible data plate?

Yes.

Nozzle and Appurtenance Inspection

1 Inspect nozzle flanges and bolting for leaks and corrosion.

None noted.

2 Inspect nozzles for pipe strain or misalignment.

No signs of visual pipe strain or misalignment.

3 Inspect valves for leaks or damage. None noted.

4 Do nozzles, which require pressure relief, have crossovers at the valve?

Yes, acceptable.

Is Tank equipped with High Level Control Valve and High Level Alarms?

Yes. The tank is provided with a shell mounted HHLA, HLA, LLA, and HLCV chamber.

6 Verify operation of gauging system.

• Manual Stilling Well?

• Type of Float Gauge?

• Type of Automatic Gauging System?

8” manual gauging hatch with a slotted stilling well.

Varec 2500B tape level gauge.

ITT Barton/Cameron ATG with slotted stilling well.

7 Inspect manways, nozzles and attachments for signs of corrosion or defects.

Acceptable.

8 Do all nozzle reinforcement pads have tell-tale holes? Are they plugged?

All reinforcement pads are provided tell-tale holes.

None are plugged. The tell-tale holes for both manways and the flush clean-out reinforcing pads are undersized (≤1/8”).

9 Verify adequate reinforcement around nozzles and appurtenances.

Acceptable.

10 Verify adequate nozzle and appurtenances weld spacing.

Acceptable.

11 Verify interior nozzles have been back welded to the shell.

N/A – External Inspection

12 Check reinforcement pads for adequate fillet welds around pads.

Acceptable.

13 Visually inspect welds for defects on all nozzles and appurtenances.

Acceptable.

14 Does the inlet nozzle have a diffuser?

N/A – External Inspection

Carbons steel slip-on flanges inside the containment dike connecting the stainless steel piping.

Fixed Roof Inspection

1 Inspect fixed roof protective coating system.

The coating is in good overall condition. There are perimeter locations of damage. Water is collecting at these locations.

2 Inspect frangible joint / eave angle for corrosion, defects and coating failure.

Acceptable.

3 Inspect fixed roof for low spots and external corrosion.

Low spots evident at the roof perimeter.

4 Conduct visual / UT inspection on roof nozzles and appurtenances.

Acceptable.

5 Visual inspection of internal roof supports, girders, columns and bases.

N/A – External Inspection

6 Verify open roof vents have screens and covers.

Acceptable.

7 Verify handrails and tie-off supports are in good condition.

Acceptable.

8 Measure any significant bulges and creases in the roof plates.

None noted.

9 Do any roof nozzles or appurtenances have bolt-on type reinforcement pads?

None noted.

Notes:

The tank is equipped with an aluminum pontoon internal floating pan with primary and secondary wiper seals.

There is no internal ladder to access the topside of the pan.

Appendix D

Calculations

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

1150068

Initials

BWL

Client

USACE, Omaha

Tank No

Date 08/12/2015

The above evaluation results are not in accordance with API 653, Appendix B; however, the evaluation is not entirely applicable for smaller tanks (small arc length). There were no indications of significant settlement at the time of inspection. The measurements from this inspection should be used in future inspections for comparison.

Notes:

Y

30000

E

29000000 0.02 S - Max Permissible

0.020

H

42.25

-0.005 0.000 0.011 0.000 0.022 -0.008 -0.036 -0.050

U

0.020 -0.003 0.011 -0.017 0.026 -0.001 -0.007 -0.030

S

UNSAT

SAT

SAT

SAT

UNSAT

SAT

SAT

UNSAT

Results

Point 1 Point 2 Point 3 Point 4 Point 5 Point 6 Point 7 Point 8

U = Measured out-of-plane settlement in relation to a cosine curve, in feet S = Deflection, in feet, (out-of-plane distortion) (with 0.38" allowable threshold considering fnd and survey instrument tolerances) L = Arc length between measurement points, in feet Y = Yield strength, in pounds per square inch (psi) E - Young's modulus, in pounds per square inch (psi) H = Tank height, in feet

S <= 11L^2Y/2EH

Feet

0.66 0.64 0.68 0.72 0.79 0.78 0.73 0.67

0.64High Point

0.79Low Point

0.15

Planar Tilt

Ft

Ft

Ft

L

12.17

D

1.80 In.

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

1150068

Initials

BWL

Client

USACE, Omaha

Tank No

Date 08/12/2015

API653 Survey Calculation

0.642

0.675

0.717

0.792 0.783

0.733

0.667 0.658 0.642

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

2 3 4 5 6 7 8 1 2

Survey Point

D ep th f

File No

Report No

1150068

Initials

BWL

Client

USACE, Omaha

Tank No

Date 08/12/2015

Temp. °F

Tank Shell Minimum Thickness and Remaining Life Calculations

Material Crs H (ft)

37.4

H (ft)

29.4 22.4 15.4 8.4 1.4 tmin (in)

0.1 0.1 0.1 0.1 0.1 0.1

0.1A 36M A 36M A 36M A 36M A 36M A 36M

31 0.84 1.00D (ft) G E 37.4Fill Height (ft)

2.6D(H-1)G

SE

tmin =

Where:

H = The height above the bottom of the course of study to the maximum liquid level height of the product, in feet. For corroded or pitted areas, H = the height from the bottom of the corroded or pitted area to the maximum liquid level height of the product, in feet.

tmin = The calculated minimum acceptable shell thickness, in inches (can not be less than 0.100 inch for any course). The minimum acceptable shell thickness allowed by API-653 and STI-SP001 for tank size, in inches .

D = Nominal diameter of tank, in feet.

G = Highest specific gravity of the contents (including test water if tank will, or may, be tested in the future).

S = Maximum allowable stress, in psi. For welded tanks; use the smaller of 0.80Y of 0.429T for bottom and second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks; S = 21,000 psi. For STI Tank Inspections S = 26000 (E = 1)

Y = Specified minimum yield strength of the plate, in psi; use 30,000 psi if not known (N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80,000 psi; use 55,000 psi if not known (N/A for riveted tanks).

E = Original joint efficiency for the tank. For welded tanks; use API-653, Table 2-1 ; use E = 1.0 when evaluating the retirement thickness in a corroded plate, when away from welds or joints by at least the greater of one inch or twice the plate thickness. For riveted tanks; use E = 1.0 for shell plates greater than 6 inches away from rivets; use the value of E from API-653 Table 2-1 when within 6 inches of rivets. For STI Tank Inspections E = 1 where S = 26000.

3.25

Course 1 Course 2 Course 3 Course 4 Course 5 Course 6

SHELL MINIMUM THICKNESS CALCULATIONS

S (psi)

24900 24900 27400 27400 27400 27400

0.100 0.100 0.100 0.100 0.100

0.100

Report No 1150068

File No

Report No

1150068

Initials

BWL

Client

USACE, Omaha

Tank No

Date 08/12/2015

Temp. °F

Tank Shell Minimum Thickness and Remaining Life Calculations

The previous report states the shell material is A36 steel.

The age is the previous date of inspection to present (2015-2011).

tmin

0.100 0.100 0.100 0.100 0.100

0.1000.255 0.245 0.248 0.245 0.244 0.249 tact

0.249 0.247 0.248 0.240 0.245 0.252 tprev Ca

0.145 0.148 0.145 0.144 0.149

0.155

Cr

0.0000

RL

>40 0.0005 0.0000 0.0000 0.0003 0.0008

>40 >40

Where:

Ca = Remaining corrosion allowance of the shell course under consideration, in inches.

Cr = Corrosion rate of the shell course under consideration, in inches per year.

FHc = Calculated fill Height = (SEtact/2.6DG+1) + (product height below course of interest), in feet.

tact = Minimum thickness measurement of the shell course under consideration, as recorded at the time of inspection, in inches.

tmin = minimum required thickness of shell course, at the maximum allowable fill height, in inches.

tprev = previous thickness measurement of shell course under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches.

RL = Estimated remaining life of the shell course under consideration, in years.

Y = Time span between thickness readings or age of the tank if nominal thickness is used for tprev, in years.

SHELL REMAINING LIFE CALCULATIONS

Ca = tact-tmin = Remaining Corrosion Allowance (inches)

Cr = tprev-tact / Y = Corrosion Rate (inches per year)

RL = Ca / Cr = Remaining Life (years)

4Y = = Tank age (years)

Course 1 Course 2 Course 3 Course 4 Course 5 Course 6

Course FHc

94.78 99.11

116.37 122.15 128.75 137.77

Report No 1150068

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-650 ATMOSPHERIC STORAGE TANK FIXED ROOF EVALUATION

File No

Report No

1150068

Initials

BWL

Client

USACE, Omaha

Tank No

Date 08/12/2015

Temp. °F

Where;

Ca = remaining corrosion allowance of the tank component under consideration, in inches (t act - t min).

Cr = corrosion rate of the tank component under consideration, in inches per year (t prev - t act / Y).

oz = unit of measurement, (weight, in ounces, per square inch), (16 oz per pound) psi = unit of measurement, (weight, in pounds, per square inch) RL = estimated remaining life of the tank component under consideration, in years (Ca / Cr).

t act = actual thickness measurement of the tank component under consideration, as recorded at the time of inspection, in inches.

t min = minimum required thickness of tank component, at the design MAWP at the design temperature (200°F for atm AST's), in inches (greater of psi/wt or 0.090").

t nom = design nominal thickness of tank component under consideration, in inches.

t prev = previous thickness measurement of the tank component under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches.

t yn = thickness of the tank component under consideration at the next inspection at twice the calculated corrosion rate, in inches (t act - (2*Cr*Yn).

wt = weight of plate per cubic inch.

wc = unit of measurement, (height, in inches, of water column bearing on 1 square inch area), (27.7 wc per pound) Y = time span between thickness readings or age of the tank component if tnom is used for tprev, in years.

Yn = estimated time span to next inspection of the tank component under consideration, in years.

Y t prev

0.188 t act

0.185 t min

0.090

Cr

0.00010

RL

psi

0.052

Yn

ROOF PLATES - REMAINING LIFE

ROOF MAXIMUM ALLOWABLE INTERNAL PRESSURE

Ca

0.095

0.2833 wc

1.44 oz.

0.834 t yn

0.184

Relief setting is satisfactory

Setting

RELIEF VALVE SETTING EVALUATION

Max Allowed

0.834

Unit oz(psi)= wtMaterial Catagory

CS/Crom. Stl

Appendix E

Photographs

Tank 3030 and Containment

Typical Concrete Dike Floor Cracking

Nameplates

Tank 3030 Stained Ring Wall

Receipt and Issue Nozzles

Slip-on Flange PRT

AFFF Piping and Foam Chamber

Shell Coating Failure

Low and High Level Alarms

Fixed Roof

Center Vent and ATG

Existing Gauging Hatch

Typical Perimeter Low Spots and Corrosion

Internal Floating Pan