ATT H-KWA-FY17-FAC 962-Tank 6-FINAL.pdf
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| US | Army | Corps | of | Engineers |
| Omaha | District |
| API | 653 | In‐Service |
| Inspection | Report |
| U.S. | Army | Garrison | Kwajalein | Atoll |
| Facility | Number | 962 | ||
| Tank | Number | 6 |
| US | Army | Corps | of | Engineers | Center | of | Expertise | for | Petroleum, | Oils, | and | Lubricants |
| (USACE | POL‐MCX) | |||||||||||
| September | 29, | 2017 |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| Table | of | Contents |
| ACRONYMS | AND | ABBREVIATIONS .............................................................................................................................................. 3 |
GENERAL SUMMARY
INSPECTION DATE
STATE REGULATIONS
PREVIOUS INSPECTION DATES
RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)
GENERAL TANK INFORMATION
A. GENERAL PROJECT INFORMATION
1. API 653 Inspection
2. Site Information
B. TANK INSPECTION COMMENTS
1. Tank Construction
2. Tank Foundation
3. Tank Shell
4. Tank Appurtenances
5. Tank Coating
6. Tank Piping System
7. Fire Protection System
8. Secondary Containment
9. Cathodic Protection
C. FINDINGS AND RECOMMENDATIONS
1. MANDATORY REPAIRS per API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards
2. REQUIRED REPAIRS to Fully Comply with API 653 or Federal, State, and Local Codes…………………………………..11
3. RECOMMENDED REPAIRS as Part of Regular Maintenance………………………………………………………………………….23
APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS…………………………………………………………………………...32
A.1 SHELL SERVICE LIFE EVALUATION
A.2 SHELL SETTLEMENT EVALUATION
A.3 ULTRASONIC UT DATA
A.4 CONTAINMENT LAYOUT DRAWING
A.5 SHELL LAYOUT DRAWING
A.6 OSHA ACCESS STRUCTURE REPORT
APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS
APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS
APPENDIX D: PHOTOGRAPHS
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
ACRONYMS AND ABBREVIATIONS
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASNT American Society of Non‐Destructive Testing
ARD Anti‐rotation device
ATG Automatic Tank Gauge
BBL Barrel
CFR Code of Federal Regulations
CP Cathodic Protection
DFT Dry Film Thickness
HLA High Level Alarm
HLCS High Level Control Shutoff
HHLA High‐High Level Alarm
LLA Low Level Alarm
LLLA Low‐Low Level Alarm
MFL Magnetic Flux Leakage
MT Magnetic Particle Testing
NACE National Association of Corrosion Engineers
NDT Non‐Destructive Testing
NFPA National Fire Protection Association
PSI Pounds per Square Inch
PT Penetrant Testing
P/V Pressure/Vacuum
RP Recommended Practice
PST Product Saver Tank
RT Radiography Testing
TML Thickness Measurement Location
TRV Thermal Relief Valve
UFC Unified Facilities Criteria
UFGS Unified Facilities Guide Specifications
ULS Ultra Low Sulfur
UT Ultrasonic Testing
VT Visual Testing
VPI Valve Position Indicator
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| GENERAL | SUMMARY | |
| Summary | of | Inspection |
| An | API | Standard | 653 | In‐Service | inspection | of | Tank | 6 | (Facility | 962) | at | USAG | Kwajalein‐Atoll, | Republic | of | the | |
| Marshall | Islands | was | completed | on | September | 29, | 2017 | to | evaluate | the | tank’s | integrity, | collect | data, | and | establish | a |
| database | for | future | inspections | and | evaluations. | The | shell | service | life | evaluation | performed | as | having | greater | than | ||
| 30 | years | of | remaining | shell | life | under | current | conditions. | Inspection | Results | are | listed | in | Section | C. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| INSPECTION | DATE | ||||||
| API | In‐Service | (External) | Inspection | Date: | 29 | September | 2017 |
Equipment (s) Used:
| Ultrasonic | Thickness | (A‐scan/B‐scan) | Testing | ||||||||
| Manufacturer: | General | Electric | |||||||||
| Model: | DMS | Go+ | |||||||||
| Calibration | Methods | Used: | Zeroing | Procedure, | Copper | Coating | Calibration | Procedure, | and | Two | Point |
Calibration Procedure
| Tank | Settlement | Surveying | ||||||||||||
| Manufacturer: | Northwest | Instrument | ||||||||||||
| Model: | NRL802K | Rotating | with | NLD5G | Laser | Receiver | ||||||||
| Calibration | Methods | Used: | Main | and | transverse | horizontal | axes | checks | at | 100 | ft. | ≤ | 1/16 | inch |
| Tank | Shell | Surveying | ||||||||||||
| Manufacturer: | Leica | Geosystem | ||||||||||||
| Model: | 3D | Disto | ||||||||||||
| Calibration | Methods | Used: | Tilt | sensor | calibration | automatically | performed | with | unit | set | at | < | 3° | and |
crosshairs calibration using target at a distance > 25 m
Inspector(s): Benyam Berhane
| STATE | REGULATIONS | |||||||
| State | Regulation | for | API | In‐Service | Tank | Inspections | N/A | |
| State | Regulation | for | API | Out‐of‐Service | Tank | Inspections | N/A |
| NOTE: | If | there | are | no | state | regulations | for | tank | inspections, | then | N/A | shall | reside | in‐place | of | the | number | of | years |
| between | inspections. | If | state | regulations | reside, | the | recommended | future | inspection | dates | shall | be | based | on | |||||
| whichever | is | more | stringent | between | the | API | inspector’s | calculations | and | the | state | regulations. |
| PREVIOUS | INSPECTION | DATES | ||||||||||
| API | Out‐of‐Service | (Internal) | Inspection | Date: | 21 | March | 2010 | |||||
| API | In‐Service | (External) | Inspection | Date: | 21 | March | 2010 | (No | record | of | 2015 | Inspection) |
| RECOMMENDED | FUTURE | INSPECTION | DATES | (CALCULATIONS | SHALL | BE | PROVIDED) | |||||
| API | Out‐of‐Service | (Internal) | Inspection | Date: | 21 | March | 2037 | Per | API | 653 | Section | 6.4.2‐Initial |
service for refurbished AST (21 March 2020 IAW
UFC)
API In‐Service (External) Inspection Date: 29 September 2022
| Benyam | Berhane | ||||
| Mechanical | Engineer/Sr. | Inspector | |||
| InterSpec, | LLC | ||||
| API | 653 | Certified | Inspector | No. | 28492 |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
GENERAL TANK INFORMATION
| ITEM | DESCRIPTION | |||||||
| Owner | U.S | Army | ||||||
| Location | U.S. | Army | Garrison | Kwajalein | Atoll; | RMI | ||
| Facility | Number | 962 | ||||||
| Tank | Number | 6 | ||||||
| State | / | Country | Kwajalein | Atoll | / Republic | of | Marshall | Islands |
| City | ‐ | |||||||
| Inspection | Date | 29 | September | 2017 | ||||
| Tank | Manufacturer | Unknown | ||||||
| Design | Standard | Unknown | (Assumed | API | STD | 12C | Eleventh | Edition) |
| Date | of | Construction | 1954 | |||||
| Tank | Contents | JP‐5 | (F‐44) | |||||
| Tank | Serial | Number | None | |||||
| Tank | Diameter | 60 | Feet | |||||
| Shell | Height | 54 | Feet | |||||
| Product | Height | 49.5 | Feet | |||||
| Tank | Capacity | 27,500 | BBL | (1,134,000 | gallons) | |||
| Foundation | Concrete | Ring | Wall |
Construction
Bottom Lap‐Welded (Cone‐Down)
Shell Butt‐Welded (Cylindrical)
Floating Roof None
Fixed Roof Aluminum Geodesic Dome
Material
Bottom Carbon Steel (Unknown Specification)
Shell Carbon Steel (Unknown Specification)
Floating Roof NA
| Fixed | Roof | Aluminum | (Unknown | Specification) | ||||||||||
| Cathodic | Protection | Impressed | Current | |||||||||||
| Interior | Coating | System | Thin | Film | Epoxy | (Completed | April | 2012) | ||||||
| Exterior | Coating | System | Thin | Film | Epoxy/ | Polyurethane (Completed | May | 2012) | ||||||
| Level | Gauging | ENRAF | Automatic | Tank | Gauge | with | Shand | & | Jurs | 92021 | Mechanical | Tape |
| Overfill | Protection | |||||||||
| Hydraulically | Operated | High | Level | Shut‐Off | Valve | with | Dedicated | Float | (Set | at |
| 48.375 | Feet) |
| Piping | Receipt | 8" | Carbon | Steel | ||
| Issue | 6" | Carbon | Steel | |||
| Low | Suction | 6” | Carbon | Steel | ||
| Water | Draw‐Off | 1" | Carbon | Steel |
Level Alarms
| Low‐Level | Alarm: | 7.20 Feet | ||
| Low‐Low | Level | Alarm: | 2.40 | Feet |
| High‐Level | Alarm: | 47.875 | Feet | |
| High‐High | Level | Alarm: | 48.875 | Feet |
| High‐Level | Control | Shutoff: | 48.375 | Feet |
Type of Internal Floating Roof
NA
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
A. GENERAL PROJECT INFORMATION
| 1. API | 653 | Inspection | ||||||||||||
| This | project | will | perform | API | 653 | inspections | of | various | tanks | at | facilities | throughout | the | United |
| States/OCONUS. | Additional | consideration | is | given | to | federal, | state, | and | local | regulations, | as | well | as | |
| applicable | military | criteria | and | general | industry | standards. |
An API Standard 653 In‐Service (External) inspection was performed on Tank 6 (FAC 962).
| 2. Site | Information | ||||||||||||||||||
| On | September | 29, | 2017 | Burns | & | McDonnell | and | our | sub‐consultant | (InterSpec) | performed | an | API | 653 | |||||
| In‐Service | (External) | inspection | of | Tank | 6 | (Facility | 962) | located | at | U.S. | Army | Garrison | Kwajalein | Atoll, | |||||
| RMI. | USAG | Kwajalein | Atoll | (USAG‐KA) | is | home | to | the | Ronald | Reagan | Ballistic | Missile | Defense | Test | Site. | ||||
| The | Reagan | Test | Site | is | a | Major | Range | and | Test | Facility | Base | under | the | DoD | with | the | primary | mission | of |
| researching, | developing | tests, | and | developing | missile | defense | and | space | programs. |
Tank 6 is used as an aboveground JP‐5 fuel storage tank supporting the installation fueling needs.
B. TANK INSPECTION COMMENTS
| 1. Tank | Construction | |||||||||||||||
| Tank | 6 | (FAC | 962) | is | a | nominal | 27,500 | BBL, | 60‐foot | diameter | by | 54‐foot | tall, | F‐44 | (JP‐5), | aboveground |
| vertical | storage | tank. | The | tank | was | constructed | in | 1954 | presumably | to | API | STD | 12C | Eleventh | Edition. | |
| There | are | no | data | or | name | plates | affixed | on | the | tank. | The | tank | has | undergone | several | modifications, |
| including | the | addition | of | a | new | tank | bottom | in | 2012. | Additionally, | modifications | including | level | alarms, | ||
| a | high | liquid | level | shut‐off | system, | additional | aluminum | stilling | wells, | shell | patch | repairs/removal, | and | |||
| internal | pipe | support | modification | were | noted | as | some | of | the | alterations. |
| 2. Tank | Foundation | ||||||||||||||||||
| The | tank | sits | on | a | concrete | ring | wall | foundation | that | is | approximately | 10" | above | the | containment | floor. | |||
| The | foundation | is | designed | with | a | leak | detection | (tell‐tale) | system | that | presumably | extends | to | the | |||||
| center | of | the | tank | (design | drawings | were | not | available | at | the | time | of | the | inspection). | It | is | reported | as | |
| having | a | flexible | membrane | liner | (FML) | for | the | secondary | containment | attached | to | the | foundation | with | |||||
| batten | strips. | Accessible | sections | of | the | foundation | were | visually | evaluated | during | the | inspection | for | ||||||
| broken | concrete, | spalling, | cracks, | and | vegetation | against | the | bottom | of | the | tank. | No | spalling | and | |||||
| vegetation | were | present. | There | is | minor | vegetation | from | the | earthen | secondary | containment | ||||||||
| encroaching | towards | the | foundation‐to‐bottom | interface. | The | foundation | to | chime | interface | is | sealed, | ||||||||
| and | no | caulking | deterioration | was | identified. | Shell | settlement | surveys | were | performed | during | the | |||||||
| inspection | in | accordance | with | Annex | B | of | API | Standard | 653. | Settlement | results | are | listed | in | Appendix | A. | |||
| There | is | no | indication | of | significant | settlement. | Overall, | the | foundation | appears | to | be | is | in | satisfactory | ||||
| condition | (A | small | section | of | the | foundation | is | accessible | for | inspection). |
| 3. Tank | Shell | ||||||||||||||||
| The | tank | shell | is | constructed | from | carbon | steel | material | of | an | unknown | specification. | The | shell | is | of | |
| cylindrical | design, | butt‐welded | together, | and | consisting | of | eight | (8) | courses | with | one | angle | stiffening‐ | ||||
| ring | approximately | 15" | from | the | top | of | the | shell. | Evaluated | the | shell | for | plumbness, | roundness, | peaking, | ||
| and | banding; | all | of | which | were | found | to | be | within | the | allowable | tolerances | of | the | API | Standard | 653. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| Visually | inspected | the | exterior | of | the | shell. | Inspected | the | coating | for | dis‐bonding, | adhesion, | |||||||
| deterioration, | and | discoloration. | The | tank | shell | is | equipped | with | two | 36" | manholes | (180° | apart) | and | an | ||||
| additional | 30" | manhole. | The | tank | is | equipped | with | a | shell | mounted | low | level | alarm | and | high‐high | level | |||
| alarms, | as | well | as | a | high‐level | shut‐off. | The | shell | was | evaluated | for | remaining | metal | thickness | utilizing | ||||
| ultrasonic | technology. | The | ultrasonic | thickness | measurements | and | thickness | measurement | locations | ||||||||||
| (TML) | are | listed | in | the | Shell | Plate | Thickness | Measurements | table | in | Appendix | A. | Three | areas | of | ||||
| laminations | were | located | on | tank | shell | on | plate | number | 1‐2 | (See | Shell | Layout | Drawing | in | Appendix | A | |||
| for | location). | Lamination | is | formed | within | the | metal | sheet | when | a | discontinuity | present | in | the | metal, | ||||
| such | as | porosity | or | inclusions | trapped | in | the | slab, | are | elongated | in | the | direction | of | rolling | during | the | ||
| steel | manufacturing | process. | The | laminations | are | all | less | than | 0.75" | based | on | the | B‐Scan | ultrasonic | data | ||||
| and | are | within | acceptable | limits | of | the | current | API | STD | 650 | section | 6.2.4. | Evaluate | if | any | hot | work | is | |
| performed | at | these | location | in | the | future; | otherwise, | monitor | at | the | next | API | STD | 653 | UT | inspection | |||
| interval. | A | service | life | evaluation | performed | shows | the | shell | with | greater | than | 30 | years | of | remaining | ||||
| life | under | current | conditions. | The | engineering | calculations, | as | per | API | Standard | 653, | for | the | service | life | ||||
| evaluation | are | shown | in | Appendix | A | under | “Service | Life | Evaluation.” | The | tank | shell | is | in | satisfactory | ||||
| mechanical | condition. |
| 4. Tank | Appurtenances | |
| a. Geodesic | Dome | Roof |
| This | tank | is | retrofitted | with | a | clear‐span | aluminum | dome | cover | manufactured | by | ||||
| Conservatek | Industries. | It | is | an | aluminum | geodesic | dome | roof | that | was | retrofitted | to | this | ||
| tank | sometime | in | 1994. | The | dome | is | joined | with | stainless | steel | fasteners | with | an | ||
| interlocking | panel | that | has | an | enclosed | gasket | in | compression | for | a | mechanical | seal. | The | ||
| batten | bars | and | gusset | cover | are | sealed | with | caulking | (external | joint | seals). | There | is | minor | |
| to | moderate | caulking | deterioration | and | signs | of | standing | water | on | the | geodesic | roof | panels. | ||
| Inspection | of | the | dome | roof | is | limited | to | what | is | accessible | from | the | platform. |
b. Gauging
| The | tank’s | Enraf | (Model | # | 854) | ATG | is | installed | through | an | 8‐inch | aluminum | stilling | well. | |||
| The | stilling | well | is | slotted. | The | Enraf | system | was | not | in | working | order | at | the | time | of | the |
| inspection. | There | is | no | manual | gauging | and | sampling | well, | but | it | appears | this | action | is | |||
| performed | via | the | geodesic | roof | access | hatch. | A | separate | slotted | 8‐inch | carbon | steel | well | is | |||
| used | for | the | ATG | water | probe. | The | tank | is | equipped | with | a | float | and | tape | type | mechanical | |
| tape | gauge | manufactured | by | Shand | & | Jurs | (Model | 92021). | The | system | is | not | in | good | |||
| working | condition. |
| c. Level | Alarms | ||||||||||||||
| The | high | level | alarm, | the | HLV | float | chamber, | and | the | high‐high | level | alarm | are | mounted | on |
| the | shell | and | are | accessible | via | the | circumferential | stairway. | The | tank | is | equipped | with | a | |
| low‐level | alarm, | but | no | independent | low‐low | level | alarm | system | was | installed, | as | required | |||
| by | military | criteria. |
| d. Stairs | and | Platforms | |||||||||||||
| The | tank’s | fixed | roof | is | accessible | by | a | circumferential | stairway | mounted | on | the | shell | of | the |
| tank | with | a | top | platform. | The | stairs | and | platform | were | inspected | for | corrosion | and | ||
| structural | soundness. | The | stairway | handrail | is | constructed | with | 1½" | angle | iron | handrails | ||||
| and | coated | steel | plate | treads | with | non‐slip | profile. | The | top | platform | is | a | galvanized | grating |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| type, | and | several | stairway | treads | were | replaced | in | the | past | with | carbon | steel | grating. | The |
| overall | general | condition | of | the | stairs | and | platform | are | mostly | satisfactory | (with | some | ||
| exception | – | See | Section | C). |
| e. Grounding | and | Bonding | ||||||||||||
| There | is | one | grounding | cable | mechanically | connected | to | lug | on | the | tank’s | shell. | The | |
| grounding | rod | penetrates | through | the | secondary | containment | floor | liner | and | is | attached | to | ||
| a | grounding | cable. | The | tank | is | not | equipped | with | a | copper | grounding | bar | for | personnel |
| static | electric | discharge | (typically | required | by | military | criteria). |
| 5. Tank | Coating | |||||||||||||||
| The | tank | shell, | stairway, | handrails, | piping, | and | appurtenances | are | coated. | The | exterior | coating | is | an | ||
| epoxy | with | a | polyurethane | top | completed | in | May | 2012. | The | exterior | shell | coating | is | mostly | satisfactory | |
| with | isolated | coating | failures | near | the | appurtenances. | Isolated | coating | failure | was | noted | on | the | |||
| appurtenances, | product | piping, | and | valves | within | the | secondary | containment. |
| 6. Tank | Piping | System | ||||||||||||||||
| The | fuel | is | received | through | 8‐inch | carbon | steel | piping | , | and | product | is | issued | from | the | tank | through | a |
| 6‐inch | carbon | steel | pipe. | The | tank | is | also | equipped | with | other | auxiliary | piping | for | the | water | draw | (NPS | |
| 1) attached | to | a | product | saver | tank | (PST) | and | a | 6‐inch | low | suction | piping | that | terminates | to | a | Camlock | |
| fitting | adjacent | to | the | PST. | Inspected | and | evaluated | each | tank | nozzle | in | accordance | with | API | Standards | |||
| 650 | and | 653. | Identified | the | type | and | use | of | each | shell | nozzle | and | measured | the | nozzle | neck | thickness | |
| on | all | accessible | shell | nozzles. | Evaluated | all | nozzles | and | reinforcement | plates | for | leaks | and | corrosion. |
| 7. Fire | Protection | System | |||||||||||||||
| The | storage | tank | is | equipped | with | a | surface | application | fixed | foam | fire | suppression | system | that | uses | a | |
| mobile | foam | supply. | One | NPS | 8 | foam | chamber | is | mounted | approximately | 24 | inches | down | from | the | top | |
| of | the | tank | on | shell | course | eight. | All | Victaulic | couplings | for | the | fire | suppression | system | piping | have | |
| deteriorated | fasteners. | Serval | locations | have | completely | failed | couplings. | No | fire | hydrants | were | noted | |||||
| near | the | tank | during | the | inspection. |
| 8. Secondary | Containment | |||||||||||||||||||
| The | tank | sits | inside | an | earthen | secondary | containment | basin | with | a | geotextile | liner | positioned | |||||||
| approximately | eight | to | ten | inches | below | the | soil | and | concrete | dike | walls. | The | overall | dimension | of | the | ||||
| secondary | containment | is | 189.67 | feet | x | 129.33 | feet, | with | a | vertical | height | of | 72.125" | (to | top | soil). | The | |||
| secondary | containment | is | equipped | with | a | 6" | drain | inlet | and | a | drain | valve | that | tie | to | the | underground | |||
| PVC | piping | system | to | the | OWS. | The | secondary | containment | release | valve | is | housed | inside | a | valve | pit | ||||
| adjacent | to | the | drain | inlet | within | the | dike. | The | PVC | piping | system | is | manifolded | together | and | cannot | be | |||
| individually | isolated | outside | of | the | valve | pit. | The | drain | line, | the | drain | inlet, | and | valve | pit | were | visually | |||
| evaluated | to | determine | if | the | drainage | system | is | liquid‐tight. | The | valve | pit | has | rain | covers, | but | standing | ||||
| water | was | noted | in | the | valve | pit. | Additional | testing | and | evaluation | may | be | required | to | determine | if | the | |||
| valve | pit | is | liquid‐tight. | The | liquid | in | the | valve | pit | was | lower | than | the | liquid | in | the | adjacent | drain | inlet | |
| and | thus | suggests | that | the | drain | inlet | is | satisfactory. | However | the | source | of | the | standing | water | in | the | |||
| valve | pit | should | be | determined. |
| The | secondary | containment | was | visually | evaluated | during | the | inspection | for | broken | concrete, | spalling, | |||||
| cracks, | and | vegetation | growth. | Minor | hairline | cracks | (temperature | cracks) | and | some | moderate | cracks | |||||
| were | noted | in | the | secondary | containment | wall. | An | approximate | total | of | 183 | linear | feet | of | cracks | in | the |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| secondary | containment | wall | were | identified. | Hairline | cracks | do | not | seriously | affect | the | strength | of | the | ||
| concrete | structures; | however, | these | cracks | can | be | potential | access | points | for | moisture | or | water | |||
| seepage | that | could | corrode | the | reinforcing | steel | (rebar). | There | are | several | CP | test | port/anode | access | ||
| PVC | openings | around | the | perimeter | of | the | tank | that | penetrate | the | FML. | Some | of | these | PVC | openings |
| have | deteriorated | caulking. | The | secondary | containment | is | in | mostly | satisfactory | mechanical | condition, | |||||
| with | the | exception | of | the | discrepancies | identified | in | Section | C | below. | Field | assessment | indicates | that | ||
| the | secondary | containment | is | of | sufficient | size | to | contain | a | total | tank | loss. | The | secondary | containment | |
| is | partially | sloped | to | allow | for | drainage | away | from | the | tank. |
| A | formal | secondary | containment | evaluation, | in | accordance | with | 40 | CFR | 112, | may | be | required | in | order |
| to | satisfy | federal, | state, | and | local | requirements. |
| 9. Cathodic | Protection | ||||||||||||||||||
| A | new | impressed | current | Cathodic | Protection | (CP) | system | was | installed | on | this | tank | during | the | tank | ||||
| bottom | repair | project | in | 2012. | The | CP | system | is | manufactured | by | Universal | Rectifiers, | Inc. | (Model | OSOI | ||||
| Serial | # | 114453). | This | unit | is | a | 50 | volt | 6 | ampere | oil‐cooled | rectifier | unit | (numbered | CP | 4) | and | is | |
| mounted | on | the | outside | of | the | pumphouse | on | the | northeast | end | of | the | secondary | containment. | The | CP | |||
| test | box | is | mounted | on | the | secondary | containment | wall | adjacent | to | the | rectifier. | The | tank | appears | to | |||
| have | a | mixed | metal | oxide | anode | (total | of | 9) | laid | under | the | tank | bottom | that | lead | to | an | explosion | proof |
| junction | box | mounted | on | the | side | of | the | tank. | The | tank | is | also | equipped | with | three | permanently | |||
| installed | reference | cells | buried | beneath | the | new | bottom. |
| At | the | time | of | the | inspection, | the | rectifier | was | powered | on | and | in | serviceable | operation | condition. | Base |
| personnel | performed | the | required | testing | and | data | logging. | The | January | 2017 | report | provided | ||||
| indicated | that | Tank | # | 6 | is | receiving | cathodic | protection | based | on | NACE | criterion. | The | rectifier, | anode | |
| junction | box, | and | tank | junction | box | are | all | in | satisfactory | condition. |
C. FINDINGS AND RECOMMENDATIONS
| The | tank | is | generally | not | in | accordance | with | current | military | criteria | for | some | of | the | tank | design, |
| appurtenances | and | piping | configuration. | Therefore, | the | recommendations | are | not | meant | to | bring | the | tank | into | ||
| full | compliance | with | UFC | 3‐460‐01 | or | AW | 78‐24‐27 | standards | but | rather | to | identify | these | items | for | the |
| owner/user’s | planned | upgrades, | rehabilitation, | and | priority | repairs. | Mandatory | repairs | should | be | completed | |||||
| to | assure | compliance | with | industry | standards, | as | well | as | federal | or | state | jurisdictional | requirements. |
| During | this | evaluation, | the | tank | was | found | to | be | in | a | generally | serviceable | condition, | with | no | imminent | risk | to |
| operation | and | overall | integrity. | However, | there | were | several | deficiencies | that | were | noted. | These | noted | |||||
| deficiencies | are | listed | below | in | no | particular | order, | with | repair | recommendations. |
| All | repairs | and | modifications | should | be | performed | in | accordance | with | API | Standard | 653, | UFC | 3‐460‐01, | DoD |
| Standard | Design | 78‐24‐27, | and | applicable | UFGS | specifications. |
| 1. MANDATORY | REPAIRS | per | API | 653, | UFC | 3‐460‐01, | or | AW | 78‐24‐27 | Standards | ||||
| Mandatory | repairs | represent | items | that | require | immediate | attention, | in | order | to | prevent | imminent | risk | |
| to | system | operators, | equipment | integrity, | or | the | adjacent | environment. | The | tank | should | remain | out | of |
| service | until | these | repairs | are | completed. |
No mandatory repairs were identified for this tank.
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
2. REQUIRED REPAIRS to Fully Comply with API 653 or Federal, State, and Local Codes
| Required | repairs | represent | items | that | should | be | addressed | in | a | timely | manner, | in | order | to | prevent |
| future | potential | risks | to | system | operators, | equipment | integrity, | or | the | adjacent | environment. | These | |||
| items | are | be | required | by | API‐653 | or | federal, | state, | and | local | codes. |
| a. Secondary | Containment | Cracks | ||||||||||||||||
| OBSERVATION: | Unsealed | cracks | were | identified | in | the | secondary | containment | wall | (this | includes | |||||||
| areas | that | were | previously | sealed). | ||||||||||||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | states | that | the | entire | secondary | containment | system, | ||||||
| “including | walls | and | floor, | must | be | capable | of | containing | oil | and | must | be | constructed | so | that | any | ||
| discharge | from | a | primary | containment | system | ... | will | not | escape | containment | before | cleanup | occurs.” | |||||
| §§112.8(c)(2) | and | 112.12(c)(2) | state | that | diked | areas | must | be | “sufficiently | impervious | to | contain | oil.” | |||||
| RECOMMENDATION: | Repair | all | exposed | cracks | in | the | containment | walls | by | grinding | in | a | V‐shape | |||||
| pattern, | with | at | least | ¼‐inch | width | at | the | surface | and | a | depth | of | at | least | ¼‐inch | and | sealing | with |
| flexible | urethane | (e.g. | Sikaflex | 1c) | or | a | similar | approved | sealant | (Quantity: | 183 | linear | feet). |
| b. Secondary | Containment | Expansion | Joint | Sealant | ||||||||||||
| OBSERVATION: | There | are | areas | of | weathered | and | deteriorated | sealant | at | the | expansion | joints | for | the | ||
| secondary | containment | wall. | ||||||||||||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above) | |||||||
| RECOMMENDATION: | Remove | the | damaged | joint | sealant | and | install | new | backer | rods | and | sealant | within | |||
| the | containment. | The | sealant | shall | be | adequate | to | accommodate | a | joint | compression | equal | to | 50 | ||
| percent | of | the | width | of | the | joint. | The | backer | rod | shall | be | compressible | rod | stock | of | polyethylene |
| foam, | polyurethane | foam, | butyl | rubber | foam, | or | other | flexible, | non‐absorptive | material, | as | |||||
| recommended | by | the | sealant | manufacturer. | The | sealant | shall | conform | to | UFGS | 07 | 92 | 00 | Joint | Sealant | |
| (Quantity: | 28 | linear | feet | – | four | locations). |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| c. Secondary | Containment | Drain | ||||||||||||||||||
| OBSERVATION: | The valve | pit | has | rain | covers, | but | standing | water | was | noted | in | the | valve | pit. | The | liquid | ||||
| in | the | valve | pit | was | lower | than | the | liquid | in | the | adjacent | drain | inlet | and | thus | suggests | that | the | drain | |
| inlet | is | satisfactory. | However, | the | source | of | the | standing | water | in | the | valve | pit | should | be | determined. | ||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above) | |||||||||||
| RECOMMENDATION: | Upgrade | the | concrete | drain | inlet | as | detailed | in | AW | 78‐24‐27 | Drawing | CD.09 | ||||||||
| Detail | 3 | or | similar. | Use | ductile | iron | piping | in | lieu | of | the | PVC | dike | drain | lines. | At | a | minimum, | ||
| investigate | and | repair | the | source | of | water | inside | the | valve | pit. | Slope | dike | basin | surfaces | a | minimum | ||||
| of | 1% | for | drainage. | Drainage | swales | should | be | sloped | no | flatter | than | 0.5% | to | drainage | inlet | (see | AW |
78‐24‐27
Drain Valve
Secondary Containment Drain
Valve Pit Rain Cover
Drain Inlet
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| d. Secondary | Containment | Liner | and | Penetration | |||||||||||||
| OBSERVATION: | The | secondary | containment | has | a | liner | with | an | earthen | cover. | The | condition | of | the | |||
| liner | is | unknown, | but | some | penetration, | including | the | PVC | cathodic | protection | anode | access | caps | and | |||
| the | tank | grounding | rod | sleeve, | have | deteriorated | caulking | and | loose | hose | clamps. | The | majority | of | the | ||
| batten | strips | on | the | perimeter | of | the | foundation, | the | perimeter | of | the | dike | wall, | and | the | pipe | support |
| piers | are | not | accessible | for | inspection. | A | higher | rate | of | rain | displacement | was | noted | for | this | ||
| secondary | containment | compared | to | the | other | AST | dike | systems | (Particularly | Tank | 8 | and | 9 | without | |||
| earthen | cover). | Some | of | the | water | displacement | is | likely | due | to | the | water | absorption | rate | of | the | |
| soil/vegetation. | However, | the | evaporation | of | the | excess | water | above | grade | is | expected | to | be | constant | |||
| for | all | dikes | unless | there | is | a | deteriorated | liner. | |||||||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above) | ||||||||
| RECOMMENDATION: | Reseal | all | PVC | FML | penetrations | and | secure | the | hose | clamps. | See | similar | |||||
| application | over | concrete | in | AW | 78‐24‐27 | Drawing | CD.02 | Detail | 2. |
| e. Secondary | Containment | Liner | and | Penetration | ||||||||||||
| OBSERVATION: | There | is | an | open | six‐inch | PVC | pipe | in | the | dike | that | penetrates | the | secondary | ||
| containment | floor. | This | is | a | potential | breach | in | the | secondary | containment | if | this | pipe | extends | ||
| outside | of | the | dike, | with | no | means | of | isolation. | ||||||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above) | |||||||
| RECOMMENDATION: | Investigate | the | use | and | routing | of | the | PVC | pipe. | Either | cap | or | remove | the | pipe. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| f. Secondary | Containment | Wall | Penetration | ||||||||
| OBSERVATION: | The | fire | suppression | piping | penetrates | through | the | secondary | containment | wall | |
| without | the | use | of | an | adequate | pipe | sleeve/seal | (Quantity: | 3). | ||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above) | ||
| RECOMMENDATION: | Reseal | all | secondary | containment | wall | penetrations. | Consider | upgrading | all | ||
| secondary | containment | wall | penetrations | per | AW | 78‐24‐27 | Drawing | CD.08 | Detail | NA | (CONCRETE |
| WALL | PENETRATION | DETAIL). |
| g. Foundation | Cracking/Spalling | |||||||||||||
| OBSERVATION: | There | are | spalling | and | breaks | in | the | foundation | (approximately | 4” | x | 18” | section). | |
| Code | REFERENCE: | API | 653 | section | 4.5.2.2, | “Concrete | pads, | ring | walls, | and | piers, | showing | evidence | of |
| spalling, | structural | cracks, | or | general | deterioration, | shall | be | repaired | to | prevent | water | from | entering | |
| the | concrete | structure | and | corroding | the | reinforcing | steel.” | |||||||
| RECOMMENDATION: | Repair | the | spalling | area | (Quantity: | 1). |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| h. Foam | Chamber | “Fixed | Foam | Discharge | Outlets” | |||||||||||
| OBSERVATION: | The | foam | chamber | air | inlet | screen | on | the | fire | suppression | system | is | coated. | The | foam | |
| chamber | may | not | produce | the | required | foam | when | the | air | inlet | is | blocked | due | to | the | coating. |
| Code | REFERENCE: | NFPA | 11 | Section | 5.2.5.1.2.2, | “Each | outlet | shall | be | sized | to | deliver | foam | at | the | |
| minimum | application | rate | or | higher.” | ||||||||||||
| RECOMMENDATION: | Replace | with | a | new | stainless | steel | screen. |
| i. Deteriorated | Victaulic | Coupling | (Associated | with | the | Fire | Suppression | System) | ||||||||
| OBSERVATION: | All | Victaulic | couplings | for | the | fire | suppression | piping | have | deteriorated | bolts. | Several | ||||
| locations | have | completely | failed | Victaulic | couplings. | This | could | result | in | a | breach | in | the | secondary | ||
| containment | because | this | pipe | extends | outside | of | the | secondary | containment, | and | a | similar | type | of | ||
| corrosion | was | noted | on | the | coupling | fasteners | outside | of | the | dike. | A | section | of | the | fire | suppression |
| piping | is | also | routed | underground | outside | of | the | dike, | and | the | tightness | of | the | piping | is | unknown. |
| The | fire | suppression | system | will | not | function | with | these | deteriorated | coupling | fasteners. | |||||
| Code | REFERENCE: | 40 | CFR | Section | 112.7(c) | (See | reference | from | above). | Also | NFPA | 11 | Section | 4.7.1.4, | ||
| “Where | exposed | to | corrosive | influences, | the | piping | shall | be | corrosion | resistant | or | protected | against | |||
| corrosion” | InterSpec | concludes | the | integrity | of | the | piping | is | dependent | on | the | fasteners, | thus | |||
| incorporating | the | code | reference | for | the | coupling | fasteners. | |||||||||
| RECOMMENDATION: | Replace | all | deteriorated | bolts, | couplings, | and | pipe. | Repair | the | pipe | to | meet | the | |||
| requirements | of | NFPA | 11 | Section | 4.7.1.4 | by | installing | stainless | steel | fasteners. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| j. Corrosion | on | Piping | and | Pipe | Supports | |||||||||||||
| OBSERVATION: | The | piping | and | pipe | supports | within | the | tank’s | secondary | containment | have | moderate | ||||||
| to | major | corrosion. | The | majority | of | the | pipe | supports | have | completely | deteriorated. | |||||||
| Code | REFERENCE: | API | RP | 574 | Section | 7.4.14 | (Contact | Point | Corrosion) | API | RP | 574 | Section | 8.2 | ||||
| (Proper | position | and | function | of | supports, | hangers, | and | anchors). | In | accordance | with | API | 570 | Section | ||||
| 7.5, | “Piping | shall | be | supported | and | guided | so | that | (a) | its | weight | is | carried | safely, | (b) | it | has | sufficient |
| flexibility | for | thermal | expansion | or | contraction, | and | (c) | it | does | not | vibrate | excessively.” | ||||||
| RECOMMENDATION: | Repair | the | coating | failure | on | the | piping. | Replace | the | deteriorated | piping | supports | ||||||
| per | AW | 78‐24‐27 | Drawing | CD.13 | Detail | 1 | and | 2. |
| k. Corrosion | and | Pitting | on | Containment | Piping | |||||||||||
| OBSERVATION: | There | were | areas | of | pitting | noted | on NPS | 8 | receipt | piping. | ||||||
| Code | REFERENCE: | API | RP | 574 | Section | 7.4.14 | (Crevice | Corrosion). | API | RP | 574 | Section | 10.1.6.3 | (Loss | ||
| in | thickness) | |||||||||||||||
| RECOMMENDATION: | Replace | the | spools | of | piping | that | have | significant | pitting | and | corrosion. | It | may | be | ||
| practical | to | conduct | a | detailed | API | STD | 570 | inspection | of | the | containment | piping | to | get | an | overall |
| condition | assessment. | NDT | tools | such | as | guided | wave | examination | can | also | be | employed | to | get | the | |
| condition | of | inaccessible | areas | between | the | pipe | supports, | sleeved | piping, | wrapped | piping, | or | the | |||
| through | dike | wall | penetration. | Guided | wave | examination | is | a | screening | tool | used | to | inspect | large | ||
| sections | of | piping | from | a | single | test | location. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| l. Corroded | Fasteners | on | HLV | ||||||||||||
| OBSERVATION: | There | is | significant | corrosion | on | the | body | cover | fastener | on | the | High | Liquid | Level | |
| shut‐off | valve | (HLV). | The | fasteners | do | not | appear | to | have | sufficient | thread | engagement | due | to | the |
corrosion.
| Code | REFERENCE: | API | 570 | Section | 5.15, | “Flange | fasteners | should | be | examined | visually | for | corrosion | ||
| and | thread | engagement. | Fasteners | should | be | fully | engaged. | Any | fastener | failing | to | do | so | is | considered |
| acceptably | engaged | if | the | lack | of | complete | engagement | is | not | more | than | one | thread.” | ||
| RECOMMENDATION: | Replace | the | corroded | studs | and | bolts. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| m. Tank | Grounding | Lug | ||||||||||||||||
| OBSERVATION: | The | tank | grounding | straps | are | bolted | to | the | tank | shell | (mechanical | joint | on | a | coated | |||
| interface) | and | have | no | reinforcement | plates | or | grounding | lugs | IAW | AW | 78‐24‐27 | Drawing | ED.02 | |||||
| Detail | 2. | |||||||||||||||||
| Code | REFERENCE: | AW | 78‐24‐27 | Drawing | ED.02 | Detail | 2. | (See | also | API | 650 | Section | 5.8.11.3) | |||||
| RECOMMENDATION: | Exothermically | weld | the | grounding | cables | to | the | lug | and | install | reinforcement | at | ||||||
| the | shell, | in | accordance | with | AW | 78‐24‐27 | Drawing | ED.02 | Detail | 2. | Note: | if | repairs | are | elected | not | to | |
| be | done, | the | paint | should | be | removed | where | the | cable | bolts | to | the | lug, | to | provide | a | better | connection |
| to | ground | (Quantity: | 1 | ground | connections). | Note | the | current | edition | of | API | STD | 650 | suggests | a | |||
| maximum | lug | spacing | of | 100 | ft. | with | a | minimum | of | four | lugs. |
| n. Product | Saver | Tank | (PST) | Grounding | |||||||||||||||
| OBSERVATION: | The | Product | Saver | Tank | is | not | grounded | at | the | leg | and | does | not | have | a | vent | installed | ||
| in | accordance | with | AW | 78‐24‐27 | Drawing | D.13 | Detail | A1. | The | PST | is | a | stainless | steel | tank | with | a | top | |
| lid. | The | PST | tank | has | no | means | of | grounding. | |||||||||||
| Code | REFERENCE: | AW | 78‐24‐27 | Drawing | D.13 | Detail | A1. | In | accordance | with | NFPA | 30, | paragraph | ||||||
| 6.5.4, | “All | equipment | such | as | tanks, | machinery, | and | piping | shall | be | designed | and | operated | to | prevent | ||||
| electrostatic | ignitions. | All | metallic | equipment | where | an | ignitable | mixture | could | be | present | shall | be | ||||||
| bonded | or | grounded. | The | bond | or | ground | or | both | shall | be | physically | applied | or | shall | be | inherently | |||
| present | by | the | nature | of | the | installation.” | |||||||||||||
| RECOMMENDATION: | Install | a | ground | cable | and | vent | piping | to | the | Product | Saver | Tank | in | accordance | |||||
| with | AW | 78‐24‐27 | Drawing | D.13 | Detail | 5 | (Quantity: | 1 | ground, | 1 | vent | pipe | (1 | ¼ | NPS, | 2‐feet | high). |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| o. Shell | Manhole | Cover | with | no | Hinge | or | Davit | Arm | ||||||||||
| OBSERVATION: | The | shell | manhole | covers | are | not | equipped | with | a | hinge | or | davit | arm | to | facilitate | the | ||
| handling | of | the | manhole | cover | plates. | |||||||||||||
| Code | REFERENCE: | API | STD | 650 | Section | 5.8.3.5 | states, | “Shell | manhole | covers | shall | have | two | handles. | ||||
| Those | covers | weighing | more | than | 34 | kg | (75 | lb) | shall | be | equipped | with | either | a | hinge | or | davit | to |
| facilitate | the | handling | of | the | manhole | cover | plate. | The | davit | support | arm | shall | not | be | welded | directly | ||
| to | the | shell | without | a | reinforcing | plate.” | Also | AW | 78‐24‐27 | drawing | D.10 | detail | 3 | |||||
| RECOMMENDATION: | Install | a | shell | manhole | davit | arm | IAW | with | API | STD | 650 | and | AW | 78‐24‐27 | ||||
| drawing | D.10 | detail | 3 | (Quantity: | 2) |
| p. Top | Platform | Grating | Not | Secured | Down | |||||||||
| OBSERVATION: | The | stairway | top | platform | does | not | have | anchor/saddle | clips. | Tack | welds | were | noted, | |
| but | some | are | cracked. | |||||||||||
| Code | REFERENCE: | OSHA | and | AW | 78‐24‐27 | Drawing | D.11 | Detail | 1, | “Grating | shall | be | anchored | with |
| saddle | clips.” | |||||||||||||
| RECOMMENDATION: | Install | grating | anchors. |
| q. Cracked | Gasket | |||||||||||||||
| OBSERVATION: | The | TRV | test | Tee | blind | flange | for | the | product | issue | nozzle | has | a | cracked | gasket. | |
| Code | REFERENCE: | API | RP | 574 | Section | 10.3.5.1, | “Sites | should | have | a | program | to | assure | that | flanges | are |
| made | up | properly. | Proper | make‐up | of | every | flange | in | a | piping | system | is | important | for | reliability. | |
| Proper | make‐up | includes | the | use | of | the | proper | gasket | and | fastener | material, | type | and | size, | proper |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| positioning | of | the | gasket | and | proper | torquing | of | the | fasteners. | The | assurance | program | should | include |
| procedures | for | gasket | and | fastener | selection | and | for | fastener | torquing.” | |||||
| RECOMMENDATION: | Replace | the | gasket | (3/4” | flange). |
| r. Circumferential | Stairway | Path | Restricted | ||||||||||||
| OBSERVATION: | There | is | a | limited | or | restricted | path | on | the | circumferential | stairway | due | to | the | |
| geodesic | dome | roof | flashing | projection | towards | the | circumferential | stairway. | There | is | no | ||||
| intermediate | platform. | There | is | an | approximately | sixteen | (16) | inch | clearance | between | the | handrail | |||
| and | the | geodesic | dome | roof. | This | reduces | the | existing | tread | width. | |||||
| REFERENCE: | UFC | 3‐460‐01 | Section | Table | 8‐1 | item | j. | OSHA | minimum | required | tread | width | is | 22 | inches |
| (1920.25(C)(3)). | See | also | API | 650 | Table | 5.18 | item | 3. | |||||||
| RECOMMENDATION: | Install | an | intermediate | platform | or | rework | the | circumferential | stairway | to | |||||
| provide | a | sufficient | path | past | the | geodesic | dome | roof. |
| s. No | or | Faded | Confined | Space | Markings | at | Manholes | ||||||||||
| OBSERVATION: | The | tank | is | not | equipped | with | a | confined | space | marking. | |||||||
| Code | REFERENCE: | In | accordance | with | OSHA | Regulation | 29 | CFR | 1910.146(c)(2), | “If | the | workplace | |||||
| contains | permit | spaces, | the | employer | shall | inform | exposed | employees, | by | posting | danger | signs | or | by | |||
| any | other | equally | effective | means, | of | the | existence | and | location | of | and | the | danger | posed | by | the | permit |
| spaces. | NOTE: | A | sign | reading | DANGER | ‐‐ | PERMIT‐REQUIRED | CONFINED | SPACE, | DO | NOT | ENTER | or | ||||
| using | other | similar | language | would | satisfy | the | requirement | for | a | sign.” | |||||||
| RECOMMENDATION: | Install | confined | space | markings | on | all | tank | entry | points. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| t. Tank | Marking | (NFPA | Diamond) | ||||||||||||
| OBSERVATION: | The | tank | is | not | equipped | with | an | NFPA | marking | ||||||
| Code | REFERENCE: | Mark | the | tank | in | accordance | with | NFPA | 704. | AW | 78‐24‐27 | Drawing | D.13 | Detail | 3 |
| Note | 4) “Provide | hazard | identification | system | labeling | in | accordance | with | NFPA | 704.” | |||||
| RECOMMENDATION: | Install | an | NFPA | 704 | marking. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| u. Conduit, | Junction | Boxes, | Fittings, | and | Mounting | Hardware | ||||||||||||
| OBSERVATION: | The | conduits, | junction | boxes, | fittings, | and | mounting | hardware | within | the | secondary | |||||||
| containment | have | deteriorated. | This | will | not | meet | the | Class | 1, | Division | 1 | rating | requirements | for | ||||
| hazardous | locations. | |||||||||||||||||
| Code | REFERENCE: | All | wiring | and | fittings | in | a | Class | I | location | that | is | a | bulk | plant | or | terminal | must |
| comply | with | the | applicable | provisions | of | NEC | Article | 501 | or | Article | 505 | [515.7]. | ||||||
| RECOMMENDATION: | Replace | all | corroded/deteriorated | conduits, | junction | boxes, | fittings, | and | ||||||||||
| mounting | hardware. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| 3. RECOMMENDED | REPAIRS | as | Part | of | Regular | Maintenance | ||||||||
| Recommended | repairs | represent | items | that | should | be | addressed | in | a | timely | manner, | in | order | to |
| prevent | future | potential | risks | to | system | operators, | equipment | integrity, | or | the | adjacent | environment. |
| a. Exterior | Coating | Failures | on | Tank | and | Appurtenances | |||||||||||
| OBSERVATION: | There | is | isolated | coating | failure | on | the | exterior | shell | mostly | around | the | stiffening | ring, | |||
| top | platform, | circumferential | stairway | wind | girder, | and | shell | manholes. | Similar | isolated | coating | ||||||
| failure | is | noted | on | the | PST | pump, | HLV | tubing | support | mounting | brace, | and | low | level | and | high | level |
| sensor | chambers. | There | is | moderate | coating | failure | and | corrosion | noted | on | the | LLA, | HLA, | HHLA, | and | ||
| HLV | on | the | pipe | nipples | and | flanges. | |||||||||||
| Code | REFERENCE: | UFC | 3‐460‐01, | Section | 8‐3.10 | and | Section | 9‐10 | |||||||||
| RECOMMENDATION: | Mechanically | clean | and | recoat | the | areas | of | coating | failure | on | the | tank | shell, | ||||
| circumferential | stairway, | landing, | piping, | and | appurtenances. | Repairs | should | be | accomplished | using | |||||||
| an | epoxy | based | coating | system | or | equivalent. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| b. Missing | Leak | Detection | Plugs | |||||||||||||||
| OBSERVATION: | The | leak | detection | plugs | are | missing | on | the | fitting | mounted | between | the | old | and | new | |||
| bottom. | Water | intrusion | is | likely | during | a | heavy | rain | event | or | if | the | containment | fills | with | rain | water | |
| up | to | the | new | tank | bottom | fittings. | ||||||||||||
| Code | REFERENCE: | API | 650 | section | I.5.5 | “If | specified | by | the | owner, | the | undertank | drains | shall | be | fitted | ||
| with | a | valve | or | piped | to | leak | detection | well | as | shown | in | Figure | I.10.” | The | figure | details | the | leak |
| detection | with | rain | cover | or | positioned | above | the | maximum | high | water | level | within | the | dike. | AW | |||
| 78‐24‐27 | Drawing | D.03 | Detail | 2 | shows | the | leak | detection | with | a | pipe | cap). | ||||||
| RECOMMENDATION: | Install | plugs | (Quantity: | 2). |
| c. Water | in | Leak | Detection | Well | |||||||||||||||
| OBSERVATION: | A | small | amount | of | water | was | noted | in | the | NPS | 4 | stainless | steel | leak | detection | well. | |||
| Code | REFERENCE: | General | maintenance | ||||||||||||||||
| RECOMMENDATION: | Remove | the | water | and | monitor. | Compare | with | the | rain | water | accumulation | ||||||||
| within | the | dike | to | ensure | the | source | of | water. | Some | water | due | to | condensation | is | normal | and | may | be |
disregarded.
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| d. Tank | Electronic | ATG | and | Water | Probe | |||||||||||||
| OBSERVATION: | The | tank’s | Enraf | (Model | # | 854) | ATG | is | installed | through | an | 8‐inch | aluminum | steel | ||||
| well. | The | stilling | well | is | slotted. | The | Enraf | system | was | reported | to | be | in | non‐working | order | at | the | |
| time | of | the | inspection. | The | water | probe | is | not | mounted | over | the | sump | and | is | installed | via | an | eight |
| inch | carbon | steel | well. | The | water | probe | is | not | installed | over | the | tank | bottom | sump | through | a | water | |
| probe | well | (separate | well). | |||||||||||||||
| Code | REFERENCE: | UFC | 3‐460‐01 | Table | 8‐1 | (item | p | and | s) | and | AW | 78‐24‐27 | Drawing | D.07 | Detail | 3, | 4 | |
| and | 5) | |||||||||||||||||
| RECOMMENDATION: | Replace | or | repair | the | ATG. | Modify | the | stilling | wells | IAW | with | AW | 78‐24‐27. | |||||
| Mounting | plate | welding | per | API | STD | 653 | Section | 9.10.3 |
| e. Independent | Low‐Low | Level | Alarm | |||||||||||||
| OBSERVATION: | The | tank | is | not | equipped | with | an | independent | low‐low | level | alarm. | There | is | a | low | |
| level | alarm | sensor | installed | on | the | side | of | the | tank | shell | (see | photo | below). | |||
| Code | REFERENCE: | UFC | 460 | 3‐460‐01 | Table | 8‐1(k) | and | AW | 78‐24‐27 | Drawing | D.12 | Detail | 1 | |||
| RECOMMENDATION: | Install | an | independent | low‐low | level | alarm. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| f. Product | Saver | Tank | (PST) | Pump | and | Level | Alarm | ||||||||
| OBSERVATION: | The | Product | Saver | Tank | (PST) | is | not | equipped | with | an | electrical | pump | and | does | not |
| have | high | level | alarms. | The | existing | diaphragm | operated | pump | has | moderate | corrosion | with | |||
| deteriorated | appurtenances | (broken | regulator, | corroded | air | filter | housing, | and | corroded | valve |
handle)
| Code | REFERENCE: | AW | 78‐24‐27 | Drawing | D.13 | Detail | 5. | IAW | UFC | 3‐460‐01 | Section | 3‐6.6.7, | “Mount | |
| permanently | installed | pumps | on | substantial | foundations | of | reinforced | concrete | designed | in | ||||
| accordance | with | Hydraulic | Institute | Standards.” | ||||||||||
| RECOMMENDATION: | Consider | replacement | of | the | existing | system | in | accordance | with | AW | 78‐24‐27. |
| g. Mechanical | Tape | Gauge | (MTG) | |||||||||||||||
| OBSERVATION: | The | tank | is | equipped | with | a | float | and | tape | type | mechanical | tape | gauge | manufactured | ||||
| by | Shand | & | Jurs | (Model | 92021). | The | system | is | not | in | good | working | condition. | The | checker | knob | did | |
| not | respond | when | actuated. | |||||||||||||||
| Code | REFERENCE: | General | maintenance/manufacturer’s | instruction | and | UFC | 3‐460‐01 | Table | 8‐1 | |||||||||
| (item | o) | |||||||||||||||||
| RECOMMENDATION: | Consider | replacement | of | existing | system | with | new | MTG. | Consider | increasing | the | |||||||
| elevation | of | the | gauge | head, | so | the | product | level | reading | window | is | at | “convenient | eye | level” | from | ||
| grade. | UFC | 3‐460‐01 | Section | 8‐8.3 | (item | o) | lists | a | liquid | level | gauge | mounted | at | 60” | above | the | ||
| walking | surface. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| h. Internal | ladder | |||||||||||||||
| OBSERVATION: | There | is | no | internal | ladder | (note | roof | is | not | equipped | with | floating | roof, | and | this | |
| recommendation | may | be | deferred | to | until | IFR | is | installed). | ||||||||
| Code | REFERENCE: | UFC | 460 | 3‐460‐01 | Table | 8‐1(h) | and | AW | 78‐24‐27 | Drawing | D.08 | Detail | 2 | |||
| RECOMMENDATION: | Install | the | internal | ladder | (in | accordance | with | OSHA | criteria) | for | tanks | of | 5,000 | |||
| gallons | (19 | 000 | L) | or | larger | per | UFC | 460 | 3‐460‐01 | Table | 8‐1(h) | and | AW | 78‐24‐27 | Drawing | D.08 |
| Detail | 2 |
| i. No | Sample | Gauge | Well | ||||||||||||||||
| OBSERVATION: | There | is | no | manual | sampling/gauging | well. | |||||||||||||
| Code | REFERENCE: | UFC | 460 | 3‐460‐01 | Table | 8‐1(s) | and | AW | 78‐24‐27 | Drawing | D.07 | Detail | 2 | ||||||
| RECOMMENDATION: | Install | a | 10‐inch | roof | nozzle | and | an | aluminum, | slotted | stilling | well | that | extends | to | |||||
| within | 3 | inches | of | the | bottom | of | the | tank | for | gauging | and | sampling | with | a | datum | plate | to | establish | a |
| gauging | zero | point. |
| j. Double | Block | and | Bleed | Valve | Missing | Tube | |||||||||||
| OBSERVATION: | The | product | receipt | double | block | and | bleed | valve | is | missing | the | manual | bleed | valve | |||
| goose | neck | tube. | Coating, | water, | and | some | corrosion | were | noted | inside | the | differential | thermal | relief | |||
| (DTR) | valves, | and | long | term | exposure | to | the | internal | section | of | DTR | valve | could | cause | the | system | to |
| not | perform | as | designed. | ||||||||||||||
| Code | REFERENCE: | General | maintenance/manufacturer | drawing. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| RECOMMENDATION: | Reinstall | the | goose | neck | tube | to | prevent | drainage | of | body | liquid | and | to | prevent | |||
| water | and | debris | from | entering | the | DTR | valve. | The | tube | should | be | above | the | highest | point | of | the |
| body | cavity. | A | steel | plug | can | also | be | used | to | prevent | water | intrusion. |
| k. Broken | Valve | Handle | on | Double | Block | and | Bleed | Valve | DTR | ||||
| OBSERVATION: | The | product | receipt | double | block | and | bleed | valve | has | a | broken | differential | thermal |
| relief | (DTR) | valve | and | corrosion | on | the | DTR | tubing | compression | fitting. | |||
| Code | REFERENCE: | General | maintenance/manufacturer | drawing. | |||||||||
| RECOMMENDATION: | Replace | the | DTR | valve | and | corroded | tube | fitting. |
| l. Product | Piping | Label | Marking | |||||||||||
| OBSERVATION: | The | majority | of | the | secondary | containment | piping | has | product | pipe | marking. | Faded | or | |
| missing | marking | was | noted. | |||||||||||
| Code | REFERENCE: | AW | 78‐24‐27 | Drawing | CD.13 | Detail | x. | (refer | to | MIL‐STD‐161G | for | correct | fuel | type) |
| RECOMMENDATION: | Reapply | product | piping | marking. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| m. Fixed | Roof | Deteriorated | Caulking | |||||||||||
| OBSERVATION: | There | is | minor | to | moderate | caulking | deterioration | on | the | geodesic | dome | roof | panels. | |
| Inspection | of | the | dome | roof | is | limited | to | what | is | accessible | from | the | platform. | |
| Code | REFERENCE: | General | maintenance/ | manufacturer | instruction | |||||||||
| RECOMMENDATION: | Seal | the | top | side | of | the | geodesic | dome | roof | as | needed | to | eliminate | water |
intrusion.
| n. Roof | Hatch | Door | |||||||||
| OBSERVATION: | The | geodesic | doom | roof | hatch | lid | was | in | the | open | position. |
| Code | REFERENCE: | General | maintenance/ | manufacturer | instruction | ||||||
| RECOMMENDATION: | Secure | roof | hatch. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| o. Shell | Lamination | (No | Repair | Recommendation) | |||||||||||||
| OBSERVATION: | Three | areas | of | laminations | were | located | on | tank | shell | on | plate | number | 1‐2 | (See | Shell | ||
| Layout | Drawing | in | Appendix | A | for | location). | Lamination | is | formed | within | the | metal | sheet | when | a | ||
| discontinuity | present | in | the | metal, | such | as | porosity | or | inclusions | trapped | in | the | slab, | are | elongated | in | |
| the | direction | of | rolling | during | the | steel | manufacturing | process. | The | laminations | are | all | less | than | 0.75" | ||
| based | on | the | B‐Scan | ultrasonic | data | and | are | the | within | acceptable | limits | of | the | current | API | STD | 650 |
| section | 6.2.4. | ||||||||||||||||
| Code | REFERENCE: | API | 653 | Section | 4.3.6, | “Flaws | such | as | cracks | or | laminations | shall | be | thoroughly | |||
| examined | and | evaluated | to | determine | their | nature | and | extent | and | need | for | repair.” | |||||
| RECOMMENDATION: | No | repairs | recommend. | Evaluate | if | any | hot | work | is | performed | at | these | location | in | |||
| the | future; | otherwise, | monitor | at | the | next | API | STD | 653 | UT | inspection | interval. |
| p. Personnel | Static | Electric | Discharge | |||||||||||
| OBSERVATION: | The | tank | is | not | equipped | with | a | copper | grounding | bar | for | personnel | static | electric |
| discharge | (typically | required | by | military | criteria). | |||||||||
| Code | REFERENCE: | UFC | 3‐460‐03 | Section | 2‐3.21 | and | AW | 78‐24‐27 | Drawing | D.11 | Detail | 4 | ||
| RECOMMENDATION: | Install | a | copper | grounding | bar | for | personnel | static | electric | discharge | at | the | base | |
| of | the | circumferential | stairway. |
| q. AST Exterior | Fire | Protection | Water | Systems | ||||||||||||
| OBSERVATION: | The | tank | does | not | appear | to | meet | equipment | requirement | for | AST | exterior | fire | |||
| protection | system. | The | stand | post | mounted | water | jet | monitor | was | noted | along | the | facility | fence | line | |
| northeast | corner | of | the | dike. |
API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll
| Code | REFERENCE: | UFC | 3‐460‐03 | Section | 2‐15.2.1 | ||||||||||||||
| RECOMMENDATION: | Install | additional | services | for | tank | exterior | fire | protection | water | systems | IAW | ||||||||
| UFC | 3‐460‐01 | Section | 2‐15.2.1 | (fire | protection | water | mains, | hydrants, | valves, | pumps, | and | application | |||||||
| devices | outside | of | dike) | to | control | of | brush | and | grass | fires | and | cooling | of | storage | tanks | in | the | event | of |
| a | fire | exposure. |
API 653 In-Service Inspection Report USAG Kwajalein-Atoll
APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS
A.1 SHELL SERVICE LIFE EVALUATION
A.2 SHELL SETTLEMENT EVALUATION
A.3 ULTRASONIC UT DATA
A.4 CONTAINMENT LAYOUT DRAWING
A.5 SHELL LAYOUT DRAWING
A.6 ROOF LAYOUT DRAWING
A.7 OSHA ACCESS STRUCTURE REPORT
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Shannon T Gray Typewritten Text
Where:
t min = minimum acceptable shell thickness for each course, in inches; however, t min shall not be less than 0.1 inch for any tank course.
t nom = nominal shell thickness, in inches.
t act = current measured shell thickness, excluding pits and corrosion, in inches.
t prev = previous measured shell thickness, excluding pits and corrosion or t nom , in inches.
D = nominal diameter of the tank, in feet.
H = height from the bottom of the shell course under considerations to the established maximum liquid level, in feet.
H c = calculated safe fill height, in feet, for the current product.
G = specific gravity of the contents.
Y = specified minimum yield strength of the plate; use 30,000 pounds per square inch if not known (N/A for riveted tanks).
T = smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch; use 55,000 psi if not known (N/A for riveted tanks).
S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of 0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S =21,000 psi. For elevated temperatures above
200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API Standard 650 Appendix M or the product design stress value listed in Table M-1a or M-1b of API Standard 650.
E = original joint efficiency for the tank. Use Table 4-2 from API Standard 653 if original E is unknown; 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.
This is the start of the file's text. The full file is on GovTribe.
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