ATT G-KWA-FY12-FAC 962-Tank 6-FINAL.pdf

NFESC CONTRACT N62583-09-D-0130, TASK ORDER 0002

TANK 6

API 653 TANK INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

(POST -REPAIR)

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

August 2012

Prepared For:

Naval Facilities Engineering Command Engineering Service Center 1100 23rd Avenue, Code 232 Port Hueneme, California 93043-4370

Presented By:

Shaw Environmental Inc.

6330 Commerce, Suite 190 Irving, Texas 75063

Prepared By:

David A. Stchyrba, P.E., API 653 Certificate No. 27187

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 7161

larisa.zdeb Text Box All photographs contained in this report were taken by Shaw Environmental & Infrastructure, Inc. and their subcontractors. The U.S. Government has permission to publish these photographs.

ABSTRACT

Enterprise Engineering, Inc. (EEI) completed an out-of-service inspection of Tank 6 at U.S.

Army Kwajalein Atoll, Republic of Marshall Islands on March 17-21, 2011. Subsequently, Shaw E&I completed repairs that were identified in the Pre-Repair Inspection Report dated April 2011. A new floor was installed by Shaw E&I in February 2012. A Post-Repair Inspection was performed by EEI on February 29 – March 2, 2012 and July 25, 2012.

This report provides a summary of the original identified repairs, completion status and inspection findings, a revised DLA-E Tank Condition Form and the original API 653 Pre- Inspection Report. Long term items requiring programming have been included where applicable.

EEI recommends the next API external in-service inspection be scheduled no later than July 2017 (5 years from 2012 construction inspection), or sooner if a change in condition has occurred.

EEI recommends the next API internal out-of-service inspection be scheduled no later than July 2022 (10 years from the 2012 construction inspection), or sooner if a change in condition has occurred.

This report has been prepared for the benefit of the government and the next API 653 inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

August 27, 2012 David A. Stchyrba, P.E.

API 653 AST Inspector Certificate No. 27187

Based on a review of the completed tank repairs, this post-repair inspection has determined that Tank 6 is suitable to return to service.

Tank 6 – Post-Repair Inspection TABLE OF CONTENTS Kwajalein Atoll August 2012 EEI Project No. 7161

TABLE OF CONTENTS

Page

SUMMARY

Scope General Next Inspection

TANK REPAIRS

ADDITIONAL DISCUSSION ITEMS

Dike Liner Gauge Tubes

CLOSURE

Conclusions Project Team

APPENDICES

DLA-E Tank Condition Form .................................................................................... Tab A Pertinent Repair Information .................................................................................... Tab B API 653 Pre-Repair Inspection Report .....................................................................Tab C

Tank 6 – Post-Repair Inspection Page 1

EEI Project No.: 7161

TANK 6

API 653 POST-REPAIR TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

SUMMARY

Scope

Enterprise Engineering, Inc. (EEI) has completed a Post-Repair inspection of Tank 6 at U.S.

Army Kwajalein Atoll, Republic of Marshall Islands. The inspection was performed on February 29 to March 2, 2012 and July 25, 2012 and included a review of completed repairs and contractor furnished repair documentation.

The scope of this project is to determine the status of the originally identified repairs and determine long term items requiring programming. This report has been prepared for the benefit of the government and the next API 653 inspection organization.

General

Tank 6 is a field erected above ground storage tank. The tank was constructed in 1954. Tank 6 failed a volumetric test after the out-of-service API 653 Tank inspection that was completed March 2011. Subsequent inspection efforts were unsuccessful in locating the source of the loss.

A new floor was installed on February 2012. The tank is 60 feet in diameter and the revised height is 53 feet 3 inches.

Tank 6 is of the open top style, welded construction with butt-welded shell plates and lap-welded floor plates. The tank was originally equipped with an external floating roof. The floating roof has since been removed and an aluminum geodesic dome provided. No aluminum floating pan was installed. The original floor was cone up with a perimeter sump. The new tank floor is cone down with a center sump. The majority of the original floor was removed during the installation of the new floor. The nominal shell capacity is 25,000 Bbls. Tank 6 is currently in JP-5 service.

Next Inspection

API 653 requires an in-service inspection be performed every 5 years or RCA/4N years whichever is less. RCA is the remaining corrosion allowance of the shell (i.e. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. An out-of-service inspection was performed March 2011. Based on the corrosion calculations, it was found that the remaining life of the shell exceeds 5 years. The tank has remained out-of-service since the inspection date.

Based on the published interpretations of API 653, the in-service inspection interval shall be measured from the date of the last inspection.

EEI was on site for the construction review and found that no changes had occurred from the 2011 inspection. EEI recommends the next external in-service inspection be scheduled no later than July 2017 (5 years from July 2012 construction inspection), or sooner if a change in condition has occurred.

Tank 6 – Post-Repair Inspection Page 2

EEI Project No.: 7161

Section 6.4.2.1 of API 653 provides two approaches for determining the out-of-service inspection interval for a refurbished tank. The first approach dictates that the interval from initial service date to the first out-of-service inspection shall not exceed 10 years unless a tank has been provided with one or more of the tank safeguards listed in Table 6.1. The initial inspection date may be based on incremental credits for the additional safeguards and are cumulative. The interval is capped at 20 years for tanks that are not equipped with a release prevention barrier, or 30 years for tanks with a release prevention barrier. Tank 6 has been equipped with an internal thin-film coating (2 years), a cathodic protection system (5 years) and a release prevention barrier (10 years) for a total of 27 years.

As an alternative to the first approach, the inspection interval may be determined using Risk Based Inspection (RBI). The interval shall not exceed 20 years for tanks that are not equipped with a release prevention barrier, or 30 years for tanks with a release prevention barrier.

Based upon EEI inspection of government tanks with new floors, there have been isolated near-failures at the 10 year inspection. Although a longer inspection interval is allowed by API 653, we recommend not exceeding 10 years based upon the corrosion pressures at Kwajalein Atoll.

EEI recommends the next out-of-service inspection should be performed no later than July 2022 (10 years from July 2012 construction inspection), or sooner if a change in condition or a change in service occurs. This inspection interval will be in sync with the in-service inspection cycle and is in keeping with the 10 year inspection interval commonly used in many government and commercial facilities.

TANK REPAIRS

The original out-of-service API 653 inspection report (Pre-Repair) classified repairs as Mandatory, Recommended and Long Term. An assessment for compliance with current military standards was also provided. The Pre-Repair report identified several repairs associated with the tank floor and acknowledged that a leak had yet to be located. Many of these repairs were no longer applicable with the installation of the new floor.

Item No.

Repair Description Status Comments

Mandatory Repairs

1. Identification of leak in tank floor. N/A Item superseded with the installation of the new floor.

2. Replace corroded winder girder supports. Completed

3. Magnetic particle testing of non-compliant weld clearance at Manway #1.

N/A Item superseded with the installation of the new floor. Manway #1 was removed and replaced with a larger manway that included a full height insert plate.

4. General comment with respect to recoating areas that are affected by repairs.

N/A

Tank 6 – Post-Repair Inspection Page 3

EEI Project No.: 7161

Recommended Repairs

1. Provide tell tale holes in the reinforcing plates at the Manway #2, Manway #3, Fill, Issue and the two blind flanges.

Completed Telltale holes were provided in the reinforcing plates for all new nozzles.

2. Pack the open tell tale hole at the reinforcing plate at Manway #1 with grease.

Completed

3. Recoat areas of failed coating on the shell, shell stiffener, manway flanges, shell valves, stair treads, handrails and platform.

N/A The exterior of Tank 6 was completely recoated April 2012.

4. Provide new handles for the manway cover plates.

N/A The manways were replaced in their entirety.

5. Recoat areas of failed coating on the floor projection. Replace sealant between the concrete ringwall and the floor projection

N/A The exterior of Tank 6 was completely recoated April 2012.

6. Remove the wood cross over stair within the containment area and replace with non-combustible construction.

Incomplete It was reported that a separate project has been programmed to address the cross over stairs at the facility. This does not impact tank return to service.

7. Remove the rivet artifact from the former tank identification plate at manway #1.

N/A Item superseded with the installation of the new floor. Manway #1 was removed and replaced with a larger manway that included a full height insert plate.

8. Repair holes in aluminum dome roof adjacent to the stair platform.

Completed

9. Replace the nozzle in the dome roof that contains the ENRAF ATG displacer.

Completed The nozzle has been replaced and provided with a blind flange.

10. Remove the damaged thermometer and backweld a threaded plug in the nozzle.

Completed

11. Remove and replace the existing tape gauge in its entirety.

Completed

12. Replace the flat plate pipe closure on the tee segment downstream of the issue nozzle.

Completed

13. Remove and replace the caulking in the concrete containment dike wall.

Completed

14. Remove the square patch plates from the tank floor.

N/A Item superseded with the installation of the new floor.

15. Provide magnetic particle testing of the non-compliant weld spacing at the old sump.

N/A Item superseded with the installation of the new floor.

16. Provide magnetic particle testing of the non-compliant weld spacing at the welded-on patch plate in the critical zone.

N/A Item superseded with the installation of the new floor.

Tank 6 – Post-Repair Inspection Page 4

EEI Project No.: 7161

17. Remove the steel bars from the perimeter of each octagonal doubler plate on the floor.

N/A Item superseded with the installation of the new floor.

18. Perform integrity inspection of the threaded plug adjacent to the Low Fuel Nozzle.

N/A Item superseded with the installation of the new floor.

19. Recoat areas of failed interior floor. N/A Item superseded with the installation of the new floor.

20. General comment with respect to recoating areas that are affected by repairs.

N/A

21. Replace the gate valve at the 6 inch sump drain with a double block & bleed plug valve.

Completed Due to small pipe diameter, a ¼-turn ball valve was provided.

22. Perform integrity inspection of the three-plate laps that do not meet API 650 requirements for weld spacing.

N/A Item superseded with the installation of the new floor.

23. Perform integrity inspection of shell insert plates that do not meet API 650 requirements for minimum size.

N/A Item superseded with the installation of the new floor.

24. Provide weld overlay at locations of weld undercuts in the interior shell-to-floor weld.

N/A Item superseded with the installation of the new floor.

25. Provide a Tank ID number and product type on the shell.

Completed

26. Comment with respect to gauge tubes. Completed Refer to “Additional Discussion Item – Gauge Tubes” for further commentary.

27. Commentary on the results of seismic calculations.

N/A

28. Recommendation to prepare a Post-Repair Inspection Report.

Completed

29. Provide a mounting bracket on the underside of the dome roof for the water probe.

N/A Tank 6 was provided with a standalone water draw-off system.

Military Criteria

1. Provide an individual automatic level alarm system independent of the gauging system.

Completed Tank 6 has been provided with a Magnatrol system including HI-HI, HI and Low level alarms.

2. Comment with respect to gauge tube for ATG. N/A Refer to “Additional Discussion Item – Gauge Tubes” for further commentary.

3. Comment with respect to bottom water sampling.

N/A Refer to “Additional Discussion Item – Gauge Tubes” for further commentary.

4. Comment with respect to locating a gauge tube above the low point.

N/A Refer to “Additional Discussion Item – Gauge Tubes” for further commentary.

5. Provide a product recovery tank. Completed

Tank 6 – Post-Repair Inspection Page 5

EEI Project No.: 7161

Long Term Repairs

1. Program the tank for an in-service inspection no later than July 2017.

N/A To be scheduled by the government.

2. General comment to test all level alarms and switches as part of on-going maintenance.

N/A Maintenance item.

ADDITIONAL DISCUSSION ITEMS

Dike Liner

The secondary containment around the tank is composed of a concrete containment wall and secondary membrane liner dike floor. The secondary liner is not visible and is located under the grass and soil ballast. A representative number of areas within the containment area were excavated to permit assessment of the liner and liner to wall attachments.

The condition of the dike liner was addressed under separate cover in a report dated March 13, 2012 and a clarification letter dated August 2, 2012. The condition is summarized below.

Dike Liner Inspection

For the inspection of the dike liner, the ballast was excavated at each quadrant of the tank where the liner is connected to the ringwall foundation, at random locations where the liner is connected to the concrete containment wall and at random locations in the middle of the dike floor.

Ringwall

An average burial depth of 9¼ inches was recorded. The liner is covered by a geotextile fabric.

The geotextile fabric was pulled back to allow examination of the attachment connection. The dike liner is secured to the ringwall with a metal strip and 1½ inch flat plates with rounded head fasteners. A sealant has been placed in the gap between the concrete and the metal strip.

Overall, it appears that the connection is in serviceable condition at exposed locations.

Although, gaps were observed in the sealant, they are not believed to compromise the integrity of the connection.

Containment Wall

An average burial depth of 8¾ inches was recorded. The liner is covered by a geotextile fabric.

The geotextile fabric was pulled back to allow examination of the attachment connection. The dike liner is secured to the containment wall in the same manner as the tank ringwall. In general, the connection appears to be in serviceable condition.

Random Dike Floor Locations

Random locations were excavated at the dike floor between the ringwall and the containment wall. An average burial depth of 7½ inches was recorded. The liner is covered by the geotextile fabric which prevents direct examination. Rather than damage the geotextile fabric, it was not

Tank 6 – Post-Repair Inspection Page 6

EEI Project No.: 7161 cut or removed. The condition of the liner is not known but it is not suspect. At the time of the inspection, the liner appeared to retain rainwater.

Major Findings It was determined that there were no issues with the liner within the containment area for Tank 6.

Gauge Tubes

The gauge tubes that were provided for Tank 6 were based on a combination of the DLA-E Memorandum “Automated Tank Gauge (ATG) Installation Policy” of December 2009 and historical practices at the facility.

Tank 6 Current Conditions

Tank 6 is an AST with a cone-down floor and includes a 24 inch center sump. There are no interior roof columns as the tank is equipped with a self-supporting aluminum geodesic roof.

Access on the dome roof is limited to a platform at the top of the spiral stairs and a partial perimeter roof handrail. Prior to the installation of the new floor, the tank was equipped with the following:

1. One 6 inch slotted carbon steel gauge tube for the ENRAF ATG displacer and temperature probe. The gauge tube is located approximately 2 feet from the tank shell.

Gauge Tube Modifications

The following was provided as part of the gauge tube modifications:

1. The 6 inch carbon steel gauge tube was retrofitted with an 8 inch aluminum nozzle penetrating the geodesic dome roof. The gauge tube will be used for manual gauging (UFC criteria.) The 6 inch size, which is less than the preferred 8 inch size, was accepted by the government.

2. A 6 inch aluminum slotted gauge tube with an 8 inch aluminum nozzle at the dome roof was provided. The gauge tube will be used for the ENRAF ATG displacer (DLA directive). The 6 inch size, which is less than the preferred 8 inch size, was accepted by the government.

3. Based on the configuration of Tank 6, the DLA directive calls for the installation of a 6 inch topside riser located over the low point sump for the water/temperature probe. It was not possible to install the riser in the center of the dome roof. Since the low point is not located below the access platform, no additional nozzles were provided in the dome roof. Tank 6 was equipped with a standalone water draw-off system that was accepted by the government.

CLOSURE

Conclusions

Based on a review of the completed repairs and repair documentation, Tank 6 is suitable to return to service.

Tank 6 – Post-Repair Inspection Page 7

EEI Project No.: 7161

Project Team

Site Team

David A. Stchyrba, P.E. Structural Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 27187, API Inspector of Record.

Support Team

Stephen S. Brooks, P.E. Technical Advisor, QA Review, API 653 Aboveground Storage Tank Inspector Certificate No. 17

APPENDIX A

DLA-E Tank Condition Form

Tank 6 – Post-Repair Inspection Appendix A, Page 1 Kwajalein Atoll, RMI August 2012 EEI Project No.: 7161

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Reagan Test Site (RTS), Kwajalein Atoll

Republic of Marshall Islands (RMI) Tank No. 6

Facility No. 962 Inspection Date(s): March 17-21, 2011 (Post-Repair Feb 29-Mar 2 & July 25, 2012)

Tank Type: Vertical AST Type of Inspection: Internal & External w/ Suitability for Service

Contract Number, Task Order: N62583-09-D-0130, Task Order 0002 Prime Contractor Name: Shaw Environmental, Inc.

Inspector, Certificate #: David A. Stchyrba

ANSI/API-653 AST Inspector Certificate No. 27187

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard: Unknown, 1954, Not Specified; Assume API 12C, 11th Ed.

Repair, Manufacturer, Date, Design Standard: Installation of a new bottom, Shaw Environmental, Feb 2012, API

650 11th Ed. June 2007 Add #2 Nov. 2009, API 653 4th Ed. April 2009 Add #1 Aug 2010.

Diameter: 60'-0" Shell Height: 53'-3"

Product, Specific Gravity: JP-5, 0.84 Design Pressure / Temperature: Unknown

Maximum Strapped Capacity / Nominal Capacity: 26,926 Bbls / 25,000 Bbls Safe Fill Height: 49' – 6” (High Level Alarm)

GPS Latitude & Longitude: 8 Deg 43’ 40.24” N, 167 Deg 44’ 12.56” E (Source – Google Earth)

Foundation Configuration: Concrete Ringwall Shell Configuration: Butt Welded w/ 8 courses Floor Configuration: Double bottom at shell, cone down w/ lap welded plates oriented in rows with center sump Roof: Aluminum Geodesic Dome Roof

Cathodic Protection: Present and operational Still Wells: 6” carbon steel slotted gauge tube for manual gauging (existing)

6” aluminum slotted gauge tube for ATG displacer Last Inspection (Type, Date): Out-of-Service March 2011

Last Coated Internally (Product): May 2012, Sherwin Williams – 3 coat epoxy Last Coated Externally (Product): April 2012, Sherwin Williams – 2 coat epoxy with polyurethane topcoat

INSPECTION RESULTS

Can tank be returned to service? Yes.

Next Scheduled Inspections (Type, Date:) In-Service: July 2017 (5 years from 2012 inspection) Out-of-Service: July 2022 (10 years from 2012 inspection)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Floor Replacement Project per EEI Project 7161, Jan 6, 2012

APPENDIX B

Pertinent Repair Information

• Phased array shear wave UT results

• Tank hydrotest settlement survey at 53 ft

Ultrasonic Inspection Report

DATE MARCH 18, 2012 CLIENT SHAW – KWAJALEIN

Item Description (Specific) TANK 6 – MANWAY 1 & 2

Insert to old shell welds, Left, Top & Rights (view from outside facing manway)

SCANNER: OLYMPUS FLEX SCANNER

INSPECTION SURFACE OUTSIDE (12” – INSIDE)

Material carbon steel Material Thickness

0.470” – 0.500”

Weld Width 7/16”-1/2”

M ISC. INFO SMAW PROCESS

Mfr. and Model No. olympus mx-pa

PA 16/128

Serial No. 10436

200681

TRANSDUCER FREQUENCY 5MHZ SIZE 16 PULSERS, 32, 64 ELEMENTS

Serial No. G2256

G2218

Angle 45-70 sectorial, B & C

Calibration Std. No.

COUPLANT ULTRAGEL CALIBRATION BLOCK TYPE DSC,

ASME

TEST PROCEDURE TGR-UT REV 2 ACCEPTANCE STD. API 605, APP-

U

DISCONTINUITIES

N O

DISTANC

E

L E

N G

T H

DEPTH

A M

P L.

B E

A M

D

IR

A C

C . O

R

J.

RECEIVED BY DATE 3-16,17

JOB ORDER NO. M ISC. INFO. ACCEPT

REJECT

REMARKS : SEE PHOTO’S AND SCANS ATTACHED

Inspector: Gary Mathis Level: III Date: MARCH 17, 2012

SCAN PLANS

Phased Array inspection (Automated Scanner) was conducted on the Manway 1 & 2 welds: Left side, Right side and Top (Top weld is 3 separate scans, 2 from outside, 1 inside due to repad). Dry Powder MT was conducted on all nozzle repad welds as well as the new floor to shell welds, inside and out. Inside repads under piping. One area was found on the outside ring splice, repaired – acceptable.

Manway 1

Left Side Scan (90 ͦview) 270 ͦview

Top (Left) (90 ͦview) 270 ͦview

Top (Center) (90 ͦview) 270 ͦview

Top (Right) (90 ͦview) 270 ͦview

Right Side Scan (90 ͦview) 270 ͦview

Manway 2

Left Side Scan (90 ͦview) 270 ͦview

Top (Left) (90 ͦview) 270 ͦview

Top (Center) (90 ͦview) 270 ͦview

Top (Right) (90 ͦview) 270 ͦview

Right Side (90 ͦview) 270 ͦview

Ultrasonic Inspection Report

DATE MARCH 5, 2012 CLIENT SHAW – KWAJALEIN

Item Description (Specific) TANK 6 - INSERT PLATES, AND PIPE

BUTT WELDS

EXISTING 6” INSERT; 2-12” INSERTS; 8” FILL W-2, W-3, W-4,

W-5; 6” ISSUE W-2, W-3, W-4

THE EXISTING 6” INSERT WAS REJECTED – REPAIRED FROM

BOTH INSIDE AND OUTSIDE – RETESTED ACCEPTABLE

INSPECTION SURFACE OUTSIDE (12” – INSIDE)

Material carbon steel Material Thickness

0.230” – 0.500”

Weld Width 7/16”-1/2”

M ISC. INFO TIG, SMAW PROCESS

Mfr. and Model No. olympus mx-pa

PA 16/128

Serial No. 10436

200681

TRANSDUCER FREQUENCY 5MHZ SIZE 16 PULSERS, 32, 64 ELEMENTS

Serial No. G2256

G2218

Angle 45-70 sectorial, B & C

Calibration Std. No.

COUPLANT ULTRAGEL CALIBRATION BLOCK TYPE DSC,

ASME, 6” PIPE STANDARD

TEST PROCEDURE TGR-UT REV 2 ACCEPTANCE STD. API 605, APP-

U, B31.3

DISCONTINUITIES

N O

DISTANC

E

L E

N G

T H

DEPTH

A M

P L.

B

A M

D

IR

A C

C . O

J.

EXISTING

6”

INSERT

0.180”

0.300”

90 REJ

RECEIVED BY DATE 2-28 3-5

JOB ORDER NO. M ISC. INFO. ACCEPT

REJECT

REMARKS : SEE PHOTO’S AND SCANS ATTACHED

Inspector: Gary Mathis Level: III Date: MARCH 5, 2012

SCAN PLANS

90 DEGREE VIEW IS DOWNSTREAM, 270 DEGREE VIEW IS UPSTREAM SIDE OF WELD. SCAN DIRECTION IS CLOCKWISE LOOKING UPSTREAM.

Initial scan of existing 6” insert (Reject) After repair scan of existing 6” insert

12” Insert - 1

90 Degree view 270 Degree view

Geometric reflector, outside of weld

12” Insert - 2

Geometric reflector, outside of weld

8” Fill – W-2

90 Degree view - N/A Flange 270 Degree view

8” Fill – W-3

90 Degree view 270 Degree view - N/A Flange

8” Fill – W-4

8” Fill – W-5

6” Issue – W-2

6” Issue – W-3

6” Issue W-4

Kwajalein Atoll – Tank # 6 Magnetic Particle Inspections

MAGNETIC PARTICLE EXAMINATION RECORD

Client: Shaw Location: Kwajalein Date: March 17, 2012

P.O. No. Job No.:

Procedure: MT Code: API 650

TANK # 6

MATERIAL MAGNETIZING TECHNIQUE MAGNETIZING

EQUIPMENT

Type: CFe Yoke: AC DC Spacing 4-6 inches Mfg. Serial #: 778 Thickness: Amps 4 Coil Dia.

Longitudinal Turns Amp Turns Direct Circular Central Conductor Amps

Calibration Date: 2-15-2012 Geometry

Pipe Plate Rod Other

Field Verification By:

UV Meter :

Item: MODEL: S/N# Stage of Mfg.: Inspection Medium Dry Powder ColorRED

Wet Fluorescent Type Batch No.

Surface Cond.: As welded Illumination White Ultraviolet

Item(s)

Accept R e j e c t

Item(s) Accept Reject Sketch/Notes

MW-1 (Repad and inside nozzle to shell weld)

One indication was found on outside ring splice, see photos.

MW-2 (Repad and inside nozzle to shell weld)

New Floor to Shell Inside and Out

Fill Issue Mod – Nozzle Repads

Inside floor repads for piping

Sump

Preformed By : GARY MATHIS Level III Date 3-17-2012 Reviewed By Date Page 1 of 1

API 653 TANK SETTLEMENT EVALUATION

TANK NO. INPUT BY: P. Cavanaugh

LOCATION: DATE: 3/25/2012

EEI Project No.

SURVEY DATE: 3/25/2012 TANK SETTLEMENT REL: 1/18/2000

REV: 7/31/2007

INPUT DATA

TANK HEIGHT H = 53.000 FT MAX. ELEV: 9.800

TANK DIAMETER D = 60.000 FT MIN. ELEV: 9.790

YIELD STRENGTH Y = 30000.000 PSI

NO. OF SURVEY POINTS N = 8.000 (Input number of points, up to 30 max)

MODULUS OF ELASTICITY E = 29000000.000 PSI

LOCATION OF SURVEY POINT NO. 1 =

ARC LENGTH BETWEEN PT L = (PI)D/N = 23.56 FT

S(ALLOW) = L2 x Y x 11 = 0.0596 FT

2[EH]

SURVEY ELEV. THETA RIGID BODY OUT OF PLANE OUT OF PLANE S(ALLOW)

POINT TILT ELEV. SETTLEMENT DEFLECTION

NO. Ui Si 0.0596

(DEGREES) (FT) (FT) (FT) (FT)

1 9.790 270.00 9.790 0.000 0.0015 0.0596 PASS

2 9.790 315.00 9.792 -0.002 0.0010 0.0596 PASS

3 9.790 0.00 9.795 -0.005 MAX. -0.0050 0.0596 PASS

4 9.800 45.00 9.799 0.002 0.0040 0.0596 PASS

5 9.800 90.00 9.800 0.000 -0.0015 0.0596 PASS

6 9.800 135.00 9.799 0.002 -0.0010 0.0596 PASS

7 9.800 180.00 9.795 0.005 MAX. 0.0050 0.0596 PASS

8 9.790 225.00 9.792 -0.002 -0.0040 0.0596 PASS

1 9.790 270.00 9.790 0.000 0.0015 0.0596 PASS

USAKA

ENTERPRISE ENGINEERING, INC.

Printed: 8/22/2012 Page 1

Tank Settlement App B Tank 6 Part 2 Hydrotest.xlsx

API 653 TANK SETTLEMENT EVALUATION

TANK NO. 6 INPUT BY: P. Cavanaugh

LOCATION: USAKA DATE: 3/25/2012

EEI Project No. 7161

SURVEY DATE: 3/25/2012 TANK SETTLEMENT REL: 1/18/2000

REV: 7/31/2007

TANK SHELL SETTLEMENT

NOTES: 1. THE HIGHEST SURVEY POINT NUMBER N SHOWN ON THE ABOVE GRAPH CORRESPONDS TO POINT NUMBER 1 ON THE TANK

2. 3 (Input starting point no. of rigid body tilt curve)

RIGID BODY TILT

MAXIMUM DIFFERENTIAL SETTLEMENT BETWEEN MAX. ELEV. AND MIN. ELEVATION:

MAX. ELEVATION = 9.800

MIN. ELEVATION = 9.790

DELTA = 0.010 FT = 0.12 IN.

ANGLE OF SLOPE

THETA = SIN -1 (DELTA / D) = SIN -1 (0.01/60) = 0.01 deg.

ANGLE OF TILT

PHI = THETA = 0.01 deg.

AMOUNT OF TILT

e = 53 SIN(PHI)= 0.01 FT = 0.11 IN

9.788

9.790

9.792

9.794

9.796

9.798

9.800

9.802

1 2 3 4 5 6 7 8 9 10

E

LE

V A

TI

O

N

(F T)

SURVEY POINT N

SURVEY (ACTUAL) ELEVATION RIGID BODY TILT MEAN ELEVATION

ENTERPRISE ENGINEERING, INC.

Printed: 8/22/2012 Page 2

Tank Settlement App B Tank 6 Part 2 Hydrotest.xlsx

APPENDIX C

API 653 Pre-Repair Inspection Report

NFESC CONTRACT N62583-09-D-0130, TASK ORDER 0002

TANK 6

API 653 TANK INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

(PRE-REPAIR)

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

April 2011

Prepared For:

Naval Facilities Engineering Command Engineering Service Center 1100 23rd Avenue, Code 232 Port Hueneme, California 93043-4370

Presented By:

Shaw Environmental Inc.

6330 Commerce, Suite 190 Irving, Texas 75063

Prepared By:

David A. Stchyrba, P.E., API 653 Certificate No. 27187

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 10-5452

larisa.zdeb

All photographs contained in this report were taken by Shaw Environmental & Infrastructure, Inc. and their subcontractors. The U.S. Government has permission to publish these photographs.

ABSTRACT

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, out-of-service inspection and suitability for service evaluation of Tank 6 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. The inspection was performed on March 17-21, 2010.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair, prior to returning the tank to service. Recommendations for continued long-term service are also provided. It should be noted that prior to the inspection, the facility reported an inventory loss from the tank. This was confirmed by a third party certified leak detection procedure by MassTech. The API 653 tank inspection was unsuccessful in identifying the source of the leak.

EEI recommends the next API external in-service inspection be scheduled no later than March 2016 (5 years from 2011 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API internal out-of-service inspection be scheduled no later than March 2021 (10 years from 2011 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653, this report satisfies the requirement for an out-of-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

April 27, 2011 David A. Stchyrba, P.E.

API 653 AST Inspector Certificate No. 27187

This tank inspection has determined that mandatory repairs are required prior to return to service. Following completion of the identified repairs and resolution of the reported inventory loss, Tank 6 will be suitable for service.

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

Typewritten Text

DAS

The Pre-Repair Abstract has been superseded by the Post-Repair Inspection Report

Tank 6 – API 653 Inspection TABLE OF CONTENTS Kwajalein Atoll April 2011 EEI Project No. 10-5452

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs Prior to Return to Service (Mandatory) Recommended Repairs Prior to Return to Service (Non-Mandatory) Recommended Repairs per Current Military Criteria Recommended Repairs for Long Term Serviceability

COATING REQUIREMENTS

Coating System at Localized Repairs (Interior and Exterior) Interior Coating System – Out of Service Concerns

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEMS

Seismic Evaluation Gauge Tubes New Floor

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ................................................... Tab A Non-Destructive Examination (NDE) and Evaluation Criteria ................................... Tab B Tank Drawings ........................................................................................................ Tab C Tank Photographs ................................................................................................... Tab D NDE Results ............................................................................................................. Tab E Calculations .............................................................................................................. Tab F Repair Documentation ............................................................................................. Tab G Field Inspection Report ........................................................................................... Tab H

Tank 6 – API 653 Inspection Page 1

EEI Project No.: 10-5452

TANK 6

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

SUMMARY

Scope

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, out-of-service inspection and suitability for service evaluation of Tank 6 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. The inspection was performed on March 17-21, 2011.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 6 is a field erected above ground storage tank. The tank was constructed in 1954. The tank is 60 feet in diameter and 54 feet high and is of the open top style, welded construction with butt-welded shell plates and lap-welded floor plates. The tank was originally equipped with an external floating roof. The floating roof has since been removed and an aluminum geodesic dome provided. No aluminum floating pan was installed. The tank floor is of cone up (original) style, with perimeter sump. The nominal shell capacity is 27,000 BBLS. Tank 6 is currently in JP-5 service.

Facility personnel reported an inventory loss from the tank on January 2011 and the tank was subsequently removed from service. Prior to arrival on site, a hydraulic leak test using a 3rd party certified procedure was performed, with water, by a DLA-E approved testing company (Mass Technology). The hydraulic leak test indicated that the tank was leaking at a rate of approximately 3 gallons per hour. EEI performed a visual examination and magnetic particle testing (MT) on all floor welds. Vacuum box testing was performed on all accessible welds including the patch plates, reinforcing plates, floor seams and breakdown welds at the tank shell.

Vacuum box testing was also performed on the floor plate where MFL suspect locations were identified. It should be noted that all of the NDE was performed with the coating in place. The tank inspection was unsuccessful in identifying the leaking site.

An additional test was conducted by Shaw, consisting of filling the tank with approximately 3 ft.

of water, and injecting compressed air under the floor. A close inspection of the floor, by individuals inside the tank, could not discover any bubbles, thus the leak site remains unidentified. Consideration should be made to replace the floor of Tank 6. If this is accomplished, many of the repair items noted below are no longer required.

Tank 6 – API 653 Inspection Page 2

EEI Project No.: 10-5452

INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Tank 6 is considered suitable for service after all required repairs are completed. The following are significant findings of the inspection.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Visual inspection of the tank shell found no indications of leakage. A pit survey was conducted for topside corrosion on the floor and no pits were identified requiring repair. Magnetic particle testing (MT) of the floor welds did not identify any areas of possible leakage. A magnetic flux leakage (MFL) scan of the tank floor found evidence of active corrosion on the bottom side of the floor plates. No locations were identified requiring repair. A leak was reported by facility personnel January 2011 and the tank was subsequently removed from service. As of the preparation of this report, the location of the leak has not been identified. Discussions are currently taking place between EEI, Shaw and NFESC as to next appropriate steps. Upon completion of the required repairs and resolution of the reported leak, Tank 6 will be in acceptable hydraulic condition.

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor and shell and their attachments. Ultrasonic inspections of the shell were performed on the accessible courses. From interpretation of ultrasonic test (UT) readings recorded, only plate thickness variances were noticed. Based on this inspection of the accessible components, Tank 6 is in acceptable structural condition. However, additional NDE has been recommended. Refer to “Repair Items” identified below.

Next Inspection

API 653 recommends the interval to the next internal inspection be determined based on known corrosion rates, but in no case shall the interval exceed 20 years from the date of inspection.

When corrosion rates are not known or well established, API 653 recommends that the tank be inspected within 10 years. A maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

EEI recommends that the next external in-service inspection be scheduled no later than March 2016 (5 years from 2010 inspection), or sooner if a change in condition has occurred.

EEI recommends the next internal out-of-service inspection be scheduled no later than March 2021 (10 years from 2010 inspection), or sooner if a change in condition has occurred. The 10 year inspection is based on active and aggressive corrosion observed throughout the facility.

Tank 6 – API 653 Inspection Page 3

EEI Project No.: 10-5452

REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory), recommended per military criteria, recommended for long term serviceability and client requested repairs.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor, and shall consider the tank has been in jet fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs Prior to Return to Service (Mandatory)

Mandatory refers to those API 653 items that are considered critical to the hydraulic or structural integrity of the tank, or are required to meet code, prior to placing Tank 6 back into service.

1. As of the writing of this report, the location of the leak within Tank 6 remains unidentified.

Additional testing is not recommended as it would most likely also be indeterminate. It is recommended to provide a new floor to eliminate the leak.

2. Severe corrosion and through holes were observed on the wind girder support angle near the spiral access stair. The remaining portions of the wind girder are inaccessible for inspection.

The following is required:

Remove and replace the angle support to maintain the stability of the wind girder.

Inspect the remaining inaccessible portions of the wind girder. Construction of scaffolding may be necessary to complete inspection. It is likely that additional repairs will be necessary including coating removal, corrosion abatement, steel replacement and recoating.

3. The weld clearance between the threaded plug at the water draw-off nozzle and the reinforcing plate for the sump drain nozzle do not meet API 653 clearance requirements. The following repair is required per API 653 4.3.9.1:

Examine the welds by magnetic particle testing (MT).

Note: It may be necessary to remove the coating from the affected areas in order to complete the inspection. We recommend removal by high pressure water or paste methods, and not by mechanical or sandblasting methods.

Although this inspection step is considered mandatory under API 653 provisions, as it is very unlikely such testing will result in any work other than light grinding (per API 653 criteria) the coating stripping, MT testing, and restoration work can be provided after the tank is returned to service with relatively low risk of creating any problems.

Tank 6 – API 653 Inspection Page 4

EEI Project No.: 10-5452

4. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Coating Requirements. When welding on the shell, the opposite side from the weld shall be inspected and repaired if damaged.

Recommended Repairs Prior to Return to Service (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends these repairs for long-term preservation and integrity of the tank, and believes that the repairs should be performed concurrently with required repairs noted above.

1. The reinforcing plates for two manways, fill and issue nozzles are not equipped with tell tale holes. The following repair is recommended:

Provide tell tale holes in the reinforcing plates in accordance with API 653 requirements.

Pressure test reinforcing plate welds to a pressure of 15 psig. In the event the welds do not pass, notify government for direction.

Pack the tell tale hole with general purpose grease to prevent moisture migration between the reinforcing plate and the shell.

2. The tell tale hole in the reinforcing plate at the Low Fuel nozzle is open. The following repair is recommended:

Pack the tell tale hole with general purpose grease to prevent moisture migration between the reinforcing plate and the shell.

3. Coating failure and corrosion was observed on the exterior tank shell, shell stiffener, the manway flanges, shell valves, stair treads, handrails, platform and support for the fire piping.

The following repair is recommended:

Remove the coating from the affected areas and recoat to prevent further degradation.

4. Corrosion and severe metal loss is present on the manway cover plate handles. The following repair is recommended:

Provide new cover plate handles.

5. Coating failure and corrosion was observed on approximately 40% of the floor projection.

The following repairs are recommended:

Remove the sealant between the floor projection and the concrete ringwall.

Remove the coating from the entire floor projection and the lower 6 inches of the tank shell.

Clean the surfaces of the concrete ringwall and underside of the floor to be sealed.

Provide jet-fuel resistant sealant and recoat as required.

6. A wood pipeline cross over stair is present within the containment area. Structures are to be constructed of noncombustible materials per section 4.3.2.3.4.5 of NFPA 30. The following repair is recommended:

Remove the wood stair and provide a new access stair. Suggested materials of construction include galvanized steel, aluminum or fiberglass.

Tank 6 – API 653 Inspection Page 5

EEI Project No.: 10-5452

7. An API tank identification plate was formerly located in the reinforcing plate at manway #1.

The plate was subsequently removed but one of the rivet-type attachments remains. The following repair is recommended:

Remove the rivet-type attachment.

Repair the location by providing additional weld passes.

Perform integrity inspection of the entire weld by visual examination and either dye penetrant testing (PT) or magnetic particle testing (MT).

8. Tank 6 is equipped with an aluminum dome roof. Holes were observed in the top of the roof adjacent to the access stair platform, the tape gauge appurtenance, and on the east side of the roof. The following repair is recommended:

Repair the damaged roof by providing an aluminum patch plate.

9. The portion of the steel gauge tube above the dome roof containing the ENRAF ATG is severely corroded and has through-holes. The ATG is currently disconnected. The following repair is recommended:

Replace the steel gauge tube with an aluminum gauge tube including the roof reinforcing pad and boot seal. Gauge tube recommendations have been provided in “Additional Discussion Items – Gauge Tubes.”

Notify SPAWAR of status of ATG system. Contact DLA-E help desk at (800) 446-4950 to schedule SPAWAR authorized technician for re-connection of ATG components.

10. Tank 6 has been provided with a thermometer in the first shell course. The glass display is cracked and debris has accumulated inside. The following repair is recommended:

Temperature measurements are incorporated as part of the ATG system. Remove the thermometer and backweld a threaded plug in the existing nozzle.

11. Tank 6 is equipped with a Varec tape gauge. The cover plate on the tape gauge display is open to the weather. It is likely that it has been infiltrated by water. The following repair is recommended:

Provide a new tape gauge head, tape, tension springs, float, conduit and guide wires.

This recommendation is based on historical observations by EEI at multiple government facilities. A Varec or Shand & Jurs tape gauge is recommended.

12. A tee segment is present downstream of the shell valve on the issue nozzle. The pipe closure consists of a flat plate welded to a flange. The following repair is recommended:

Replace the closure with a rated blind flange.

13. Tank 6 is located within a reinforced concrete containment dike. The dike walls include expansion and construction joints. The caulking within the joints is cracked and failing. The following repair is recommended:

Remove the caulking and backer rods, if present, from the joints.

Clean and prepare the concrete surfaces.

Provide jet-fuel resistant sealant and backer rod, if required, due to width.

Tank 6 – API 653 Inspection Page 6

EEI Project No.: 10-5452

14. Six test port patch plates are present on the tank floor. The plates are 6 inch square and are each topped with a 1-1/2 inch nipple with welded plug. The square plates do not have rounded corners. The following repair is recommended, but considered optional:

Remove the patch plates.

Remove the coating from the affected surfaces and prep surfaces for welding.

Provide 5/16 inch thick x 8 inch square steel plates with radius corners.

Weld the plates to the floor with a full fillet weld, continuous on all edges of each plate.

The completed welds shall have no cracks, porosity or lack of fusion.

In preparation for recoating, remove edge on topside of plate by grinding a 45-degree chamfered rounded edge.

Perform integrity inspection of the entire weld by vacuum box testing (BT) and either dye penetrant testing (PT) or magnetic particle testing (MT).

15. The old sump patch plate is 4 ½ inches from chine within the critical zone resulting in a weld clearance issue. API 653, 9.10.1.2 calls for a minimum of 6 inch spacing between floor-to-shell weld and a patch plate. The following is recommended:

Remove the coating over the patch plate welds and perform integrity inspection of the welds by either dye penetrant testing (PT) or magnetic particle testing (MT).

Advise EEI for repair direction if cracks are detected.

16. The tombstone patch plate at Manway 1 exceeds maximum dimension along the shell for welded-on patch plate in the critical zone. The patch plate is 31 inches along shell; the maximum permitted length is 24 inches (API 653, 9.10.1.2). The following is recommended:

Remove the coating over the patch plate welds and perform integrity inspection the welds by either dye penetrant testing (PT) or magnetic particle testing (MT).

Advise EEI for repair direction is cracks are detected.

17. Eight 1 inch diameter bars are welded around the perimeter of each octagonal doubler plate.

The bars prohibit floor scanning and may be a possible leak source The following repair is recommended:

Grind the bars flush with the floor surface at each octagonal plate.

Upon completion of grinding, perform integrity inspection of the bars by vacuum box testing and either dye penetrant testing (PT) or magnetic particle testing (MT).

18. Tank 6 is not equipped with a water draw-off line at the sump. A threaded plug is present in the shell nozzle. The following repair is recommended:

Perform integrity inspection of the existing nozzle weld by either dye penetrant testing (PT) or magnetic particle testing (MT).

Provide a 1¼-inch water draw-off line with ¼-turn ball valve in the existing water draw-off nozzle.

Tank 6 – API 653 Inspection Page 7

EEI Project No.: 10-5452

19. Approximately 110 sq. ft. of coating failure was observed at multiple locations on the tank floor plates. The following repair is recommended:

Remove the coating from the affected areas and recoat to prevent further degradation.

Note: The locations and quantities are provided in Appendix G.

20. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Coating Requirements.