Att J YKM-FY19-FAC FOS 2.3.33-Tank 3-FINAL.pdf

US Army Corps of Engineers Center of Expertise for Petroleum, Oils, and Lubricants

(USACE POL‐MCX)

11/26/2018

API 653 Out-Of-Service Inspection November 26, 2018

Yakima Training Center, WA Tank 3 (Facility FOS2.3.33)

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Secondary Containment

2. Tank Construction

3. Tank Foundation

4. Tank Shell

5. Tank Fixed Roof

6. Tank Appurtenances

7. Tank Piping System

8. Fire Protection System

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

3. RECOMMENDED REPAIRS TO FULLY COMPLY WITH UFC 3-460-01, AW 78-24-27

Standards, or as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS

APPENDIX B: ENGINEERING DRAWINGS

APPENDIX C: ENGINEERING DATA

APPENDIX D: API 653 INSPECTION CHECKLIST

APPENDIX E: PHOTOGRAPHS

API 653 Out-Of-Service Inspection November 26, 2018

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

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

API 653 Out-Of-Service Inspection November 26, 2018

GENERAL SUMMARY

Summary of Inspection

An API Standard 653 In-Service inspection of Tank #3 (Facility FOS2.3.33) at Yakima Training Center, WA was completed on November 26, 2018. The shell service life evaluation performed as having greater than 30 years of remaining shell life under current conditions.

Significant Findings (overview)

1. The reinforcement pad of the receipt line measured 2 inches between the reinforcement pad and bottom, which does not conform to the minimum weld spacing requirements of API Standard 653. The minimum weld spacing should be 3 inches.

2. The reinforcement pad of the issue line measured 2 inches between the reinforcement pad and bottom, which does not conform to the minimum weld spacing requirements of API Standard 653. The minimum weld spacing should be 3 inches.

3. The tank bottom to ringwall does not have any sealant, which allows water intrusion underneath the bottom.

4. One of the plugs in the first shell course is weeping.

5. Both manholes are hinged and do not have davit arms.

6. The tank does not have a NFPA 704 fire diamond label affixed to the tank.

7. The tank does not have a datum plate.

8. The tank does not have a facility ID label affixed to the tank.

9. The secondary containment does not satisfy NFPA 30 with an intermediate berm wall height of at least 18 inches between the tanks.

10. The tank is not equipped with an ENRAF automatic tank gauge.

11. The tank is not equipped with a VITO water and temperature probe automatic tank gauge.

12. The tank does not have a dedicated product saver tank. The water draw-off line routes to the product saver tank of Tank #2.

13. The water draw-off line consists of 1-inch threaded carbon steel piping with a 1-inch brass freeze valve as the tank isolation valve.

14. The tank does not have a low suction line. The tank does have a 3-inch drain line that extends to the sump with a camlock fitting on a ball valve. The purpose of a low suction line is to draw the tank completely down.

15. The tank grounding cables are bolted directly to the shell.

16. The thermal relief line on the receipt line consists of 1-inch threaded carbon steel piping with unlockable ball valves. The thermal relief line has a threaded test TEE for annual testing.

17. The thermal relief line on the issue line consists of 1-inch threaded carbon steel piping with unlockable ball valves. The thermal relief line does not have a test TEE for annual testing.

18. The shell has two (2) threaded plugs in the first shell course.

19. The clearance between the high level shut-off tubing and handrail measured 19 inches.

OSHA requires at least a 26-inch unobstructed clearance.

20. The fixed roof does not have any API scaffolding supports.

21. The roof circulation vents/inspection hatches have a bolted bar across the top between the rail posts of the perimeter handrail, which prevents opening without hand tools.

22. The tank is equipped with a sample gauge but does not have a manual winch and floating seal.

INSPECTION DATE

API In-Service Inspection Date: November 26, 2018

Equipment Used: Ultra-Sonic Thickness Meter Manufacturer: General Electric Model: DMS 2 Calibration Methods Used: Zeroing Procedure, Copper Coating

Calibration Procedure, and Two Point Calibration Procedure

Inspector(s): Wayne K. Bailey API 653 Inspector No. 1331

STATE REGULATIONS

API In-Service Tank Inspections: N/A API Out-of-Service Tank Inspections: N/A

NOTE: If there are no state regulations for tank inspections, N/A shall reside in-place of the number of years between inspections. If state regulations reside, the recommended future inspections 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: Unknown (report was not available) API In-Service (External) Inspection Date: Unknown (report was not available)

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

API Out-of-Service (Internal) Inspection Date: Unknown (report was not available) API In-Service (External) Inspection Date: November 2023

Wayne K. Bailey, API‐653 #1331

Owner US Army Location Yakima Training Center Facility Number FOS2.3.33 Tank Number 3 State / Country Washington, United States City Yakima Inspection Date November 26, 2018 Tank Manufacturer Original: Unknown Design Standard API Standard 650 (assumed) Date of Construction Original: Unknown (used 2000 for calculations) Tank Contents Jet A Tank Serial Number Unknown Tank Diameter 31’ Shell Height 24’ Product Height 19’ 01-00/16” Tank Capacity 120,000 Gallons Foundation Concrete Ringwall

Construction

Bottom Lap-Welded Shell Butt-Welded (Cylindrical) Floating Roof Unknown Fixed Roof Lap-Welded

Material

Bottom Carbon Steel, Unknown Grade Shell Carbon Steel, Unknown Grade Floating Roof Aluminum (Unknown Specification) Fixed Roof Carbon Steel, Unknown Grade

Cathodic Protection Impressed Current Interior Coating System Unknown Exterior Coating System Thin Film Epoxy/Polyurethane Level Gauging SHAND&JURS MTG, RONAN ATG, and NO VITO Water & Temp Probe Overfill Protection Automatic Shut-Off (Unknown Set Point)

Piping

Receipt 6" Carbon Steel Issue 6" Carbon Steel Low Suction NA None Water Draw-Off 1" Carbon Steel

Level Alarms Description RONAN ATG Independent High-High Level Alarm: 21’ 03-15/16” 21’ 03-15/16” High-Level Alarm: 19’ 01-00/16” 19’ 01-00/16” Low-Level Alarm: 3’ 04-07/16” 3’ 04-07/16” Low-Low Level Alarm: 1’ 01-08/16” 1’ 01-08/16”

High Level Shut-Off: (Activity Did Not Have Information) Type of Internal Floating Roof Aluminum Honeycomb

API 653 Out-Of-Service Inspection November 26, 2018

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection This project will perform API 653 inspections of various tanks at facilities throughout the United States. 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 inspection was performed for Tank 3 (Facility

FOS2.3.33).

2. Site Information On November 26, 2018, Argus Consulting and our sub-consultant (InterSpec, LLC) performed an API 653 In-Service inspection of Tank 3 (Facility FOS2.3.33), located at Yakima Training Center, WA.

B. TANK INSPECTION COMMENTS

1. Secondary Containment 40 CFR 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.” 40 CFR 112.8(c)(2) and 40 CFR 112.12(c)(2) state that diked areas must be “sufficiently impervious to contain oil.” The purpose of the secondary containment requirement is to prevent discharges, as described in 40 CFR 112.1(b);

therefore, effective secondary containment methods must be able to contain oil until the oil is cleaned up. The secondary containment area consists of concrete floor and concrete vertical walls. An informal containment evaluation was conducted. The containment does appear to be of sufficient size to contain a total tank loss per UFC 3- 460-01 Section 8-14.2.1, “The containment area needs to have sufficient capacity to contain the tank contents plus one foot of freeboard. If the containment has the capacity to contain the tank contents plus one foot of freeboard, the containment area is sufficient.” The secondary containment area appears to be properly graded to drain water away from the tank in accordance with NFPA 30.

2. Tank Construction Tank 3 (Facility FOS2.3.33) is a nominal 120,000 gallon, 31’ diameter by 24’ tall, Jet A, aboveground vertical storage tank. The original construction nameplate was not affixed to the tank.

3. Tank Foundation The tank rests on a concrete ringwall. The tank has an impressed current cathodic protection system, secondary containment, and bottom leak detection. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The tank bottom-to-ringwall sealant was

API 653 Out-Of-Service Inspection November 26, 2018 inspected, and no sealant was observed. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard 653. Settlement results are listed in Appendix A.

4. Tank Shell The shell is constructed of carbon steel material. The shell is a cylindrical design, butt-welded together, consisting of three (3) courses. The shell exterior has a thin film epoxy coating system (new coating in NOV 2018). The coating was inspected for disbonding, adhesion, deterioration, and discoloration; it is in satisfactory condition. 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. A shell service life evaluation performed on all shell courses shows the shell has a remaining life of greater than 30 years under current conditions. The shell service life evaluation is shown in the Shell Service Life Evaluation table in Appendix A. Roundness, plumbness, peaking, and banding of the shell appear to be within the allowable tolerances of API Standard 653.

The tank appears to be stable and does not appear to be in danger of overturning or buckling due to high winds or seismic conditions.

5. Tank Fixed Roof The fixed roof is constructed of carbon steel material. The fixed roof has an epoxy coating system on the exterior (new coating in NOV 2018). The coating was inspected for disbonding, adhesion, deterioration, and discoloration; it is in satisfactory condition.

The topside coating has several areas of cracked coating. The coating underneath was satisfactory. The fixed roof was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Fixed Roof Plate Thickness Measurements table in Appendix C.

1) Water Draw-Off Line: The water draw-off piping consists of 1-inch threaded carbon steel piping. The line has a locking brass ball valve at the shell.

2) Product Saver Tank: The product saver tank (PST) is located adjacent to Tank 2 and services Tank 2 and Tank 3. Tank 3 does not have a dedicated PST.

b. Low Suction System The tank is not equipped with a low suction line. The tank does have a 3-inch drain line adjacent to the issue line.

c. Issue Line The 6-inch issue line is carbon steel. The line is protected from overpressure with a thermal relief system. The thermal relief system consists of 1-inch threaded carbon steel piping and fittings. The system does not have lockable ball valves and a test TEE for annual testing.

API 653 Out-Of-Service Inspection November 26, 2018

d. Receipt Line The 6-inch receipt line is carbon steel. The line is protected from overpressure with a thermal relief system. The thermal relief system consists of 1-inch threaded carbon steel piping and fittings. The system does not have lockable ball valves. test TEE for annual testing is threaded.

e. Automatic Tank Gauging (Fuel Level) The tank is equipped with a RONAN system for electronic fuel level gauging. The tank is not equipped with an ENRAF ATG.

f. Automatic Tank Gauging (Water Level) The tank is equipped with a RONAN system for electronic water level gauging. The tank is not equipped with a VITO water probe ATG.

g. Mechanical Tank Gauging The tank is equipped with a SHAND&JURS mechanical tape level gauge for mechanical fuel level gauging. The tape of the system is attached to the floating roof. The system is in functional condition.

h. Tank Sampling\Manual Gauging The tank is equipped with a sample gauge but does not have a manual winch and floating seal.

i. Level Alarms\High Level Shut‐Off The RONAN system provides low-low, low, high, and high-high level alarms. The tank has independent low-low, low, high, and high-high level alarms. The piping of the low level alarm assemblies consists of 1-inch welded stainless steel piping with flanged connections. The high level alarm assembly and high level shut-off assembly are accessible from extended stairway treads on the circumferential stairway. The piping consists of 1-inch welded stainless steel piping with flanged connections. The high level and low level assemblies do not have piping extending to a product saver tank.

j. Ladder and Platforms The tank’s fixed roof is accessible by a circumferential stairway mounted on the shell of the tank.

k. Grounding The tank has grounding cables that are bolted to the tank shell.

l. Anchoring None.

7. Tank Piping System Fuel is received by trucks and issued to vehicles by remote dispensers.

8. Fire Protection System The fire department provides fire protection.

C. FINDINGS AND RECOMMENDATIONS

The following information identifies the significant findings found during the tank inspection:

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.

a. None

2. REQUIRED REPAIRS to Fully Comply with API 653 or Federal, State, and Local Codes 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. These items may be required by federal, state and local codes, or by military criteria.

If tightening is unsuccessful, then repair in accordance with C.3.i.

22.11.2.6 requirements for an intermediate berm wall height of at least 18 inches between the tanks.

CODE REFERENCE: NFPA 30 Section 22.11.2.6 RECOMMENDATION: Design and install intermediate walls between the tanks to meet the requirements of NFPA 30.

6-inch receipt line and the shell-to-bottom weld. The weld spacing is two inches.

The weld spacing should be at least three inches.

CODE REFERENCE: API Standard 650 Section 5.7.1.1 RECOMMENDATION: Magnetic particle (MT) examination must be performed on the affected welds of the receipt line reinforcement and the shell-to-bottom

6-inch issue line and the shell-to-bottom weld. The weld spacing is two inches.

The weld spacing should be at least three inches.

CODE REFERENCE: API Standard 650 Section 5.7.1.1 RECOMMENDATION: Magnetic particle (MT) examination must be performed on the affected welds of the issue line reinforcement and the shell-to-bottom weld.

inspection.

Detail 3

API 653 Out-Of-Service Inspection November 26, 2018

RECOMMENDATION: Replace the hinge of the manholes with davit arms in accordance with AW 78-24-27 Drawing D.10 Detail 3.

the handrail and the high level controls. The existing clearance is 19 inches. OSHA 1910.24(d) requires a minimum width of 26 inches.

CODE REFERENCE: OSHA 29 CFR 1910.25

RECOMMENDATION: Extend the stairway treads at the high level controls to meet the requirements of OSHA 29 CFR 1910.25.

e. NFPA 704 Diamond Label OBSERVATION: The tank does not have a NFPA 704 diamond label affixed to the tank.

fixed roof in accordance with UFC 3-460-01 Table 8-1 Item (ff).

CODE REFERENCE: API Standard 650 Section 5.8.8 and UFC 3-460-01 Table 8-1 Item (ff) RECOMMENDATION: Install two scaffold cable supports in accordance with API Standard 650 Section 5.8.8.

650 Section 10.

CODE REFERENCE: API Standard 650 Section 10 and AW 78-24-27 Drawing D.10 Detail 2 RECOMMENDATION: Install a datum plate in accordance with API Standard 650 Section 10 and AW 78-24-27 Drawing D.10 Detail C3.

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.

with AW 78-24-27 Drawing D.07 Detail 4 and the ATG policy per the letter issued by the Defense Logistics Agency.

stilling well to meet the ATG policy per the letter issued by the Defense Logistics Agency.

system) to meet the ATG policy per the letter issued by the Defense Logistics Agency.

and stilling well to meet the ATG policy per the letter issued by the Defense Logistics Agency.

draw-off line routes to the product saver tank of Tank #2.

API 653 Out-Of-Service Inspection November 26, 2018

piping with a 1-inch locked brass freeze valve as the tank isolation valve. Brass valves are prohibited in accordance with NFPA 30.

CODE REFERENCE: UFC 3-460-01 Table 8-1 Item (aa), UFC 3-460-01 Section 3-6.7.3 (a), AW 78-24-27 Drawing D.10 Detail 1, and AW 78-24-27 Drawing D.13 Detail 5 RECOMMENDATION: Replace the water draw-off system.

accordance with AW 78-24-27 Drawing G.05 and Drawing D.07 Detail A3 and UFC

UFC 3-460-01 Table 8-1 Item (v) RECOMMENDATION: Tie-in the 3-inch hose connection to the issue line to complete the low suction line circuit in accordance with AW 78-24-27 Drawing G.05 and Drawing D.07 Detail A3 and UFC 3-460-01 Table 8-1 Item (v).

API 653 Out-Of-Service Inspection November 26, 2018

not exothermically welded to ground lug on the shell.

welded connections to ground lugs on the shell.

threaded carbon steel piping with an unlockable ball valve and a check valve. The thermal relief line has a threaded test TEE for annual testing.

CODE REFERENCE: UFC 3-460-01 Section 3-3.1.2 Item (j), AW 78-24-27 Drawing D.10 Detail 4, and NFPA 30 RECOMMENDATION: Install Schedule 80 carbon steel or Schedule 40 stainless steel flanged pressure relief piping on the 6-inch receipt line with socket weld fittings, lockable isolation valves, and a test TEE in accordance with the current AW 78-24-27 Drawing D.10 Detail 4.

carbon steel piping with an unlockable ball valves and a check valve. The thermal relief line does not have a test TEE for annual testing.

CODE REFERENCE: UFC 3-460-01 Section 3-3.1.2 Item (j), AW 78-24-27 Drawing D.10 Detail 4, and NFPA 30 RECOMMENDATION: Install Schedule 80 carbon steel or Schedule 40 stainless steel flanged pressure relief piping on the 6-inch receipt line with socket weld fittings, lockable isolation valves, and a test TEE in accordance with the current AW 78-24-27 Drawing D.10 Detail 4.

Threaded fittings may leak or weep overtime. One of the plugs is weeping. Note:

course and install shell inserts or patch plates in accordance with API Standard 653 Section 9.2.2 or 9.3.

across the top between the rail posts of the perimeter handrail, which prevents opening without hand tools. The carbon steel link locks are seized with rust to prevent opening for routine inspections of the floating roof and seals as required by UFC 3-460-03.

CODE REFERENCE: UFC 3-460-01 Table 8-1 Items (h) and (m), UFC 3-460-03 Section 8-9.1.1, and AW 78-24-27 Drawing D.09 Detail 1 RECOMMENDATION: Remove the bolted bar across the top between the rail posts of the perimeter handrail and install stainless steel link locks.

manual winch and floating seal.

CODE REFERENCE: AW 78-24-27 Drawing D.07 Detail 2 RECOMMENDATION: Reconfigure the sample gauge with a manual winch and floating seal in accordance with AW 78-24-27 Drawing D.07 Detail 2.

allows water intrusion underneath the bottom.

floor and ringwall by removing and re-sealing with a two-component UV and jet fuel-resistant polysulfide sealant. The sealant shall conform to ASTM C 920 and shall be non-sag, Type M, Class 25 Thiokol T-2235M industrial polysulfide sealant manufactured by Polyspec, or approved equivalent.

A-1

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D H

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S i | U i U i-1 U i+1

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R Note: Settlement evaluation must be done using the arc length method.

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Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Yakima Training Center

InterSpec LLC

11/27/18 N/A N/A

Tank #3 S-1Shell Layout

Seam #1 is the first seam left of the first manhole left of the stairway in the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-1

E

DCB

A

Overflow Vent

2-1

3-1

1-2

Overflow Vent

2-2

3-2

1 2 3

A - 23" Manhole B - 6" Issue Line C - 3" Drain D - 1" Water Draw-Off Line E - 1" Plug F - 1" Plug G - 6" Receipt Line

F G

MTG

B -2

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A

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Yakima Training Center

InterSpec LLC

11/27/18 N/A N/A

Tank #3 S-2Shell Layout

Seam #1 is the first seam left of the first manhole left of the stairway in the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-3 H

Overflow Vent

2-3

3-3

1-4

Overflow Vent

2-4

3-4

3 4 1

H - 36" Manhole I - Low Level Control J - Low Level Control K - High level Control L - High Level Control

K

L

I

J

B -3

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Yakim a Training Center, W

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Yakima Training Center

InterSpec LLC

11/27/18 N/A N/A

Tank #3 R-1Fixed Roof Layout

Measured Diameter is 32.8 feet.

Fixed roof has 14 plates.

10543210

GRAPHIC SCALE:

Dimensions are in feet.

y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

5 6

8 9 10

11 12 13 14

A - 10" sample Hatch B - 24" Center Vent C - 36" Hatch D - 2" Cap E - 8" Electronic Indicator F - Hatch G - Roof Circulation Vent/Inspection Hatch

G

G

G

G

A

B

C

E

F

MTG

D

D

D

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API 653 Out-Of-Service Inspection N ovem ber 26, 2018

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Company:

Drawn By:

Date: Rev. No.: Scale:

Drawing Title:

Yakima Training Center

InterSpec LLC

11/27/2018 N/A N/A

Secondary Containment Layout

Tank #1 Diesel

Tank #2 Jet A

Tank #3 Jet A

Tank #5 Diesel

Tank #4

MOGAS

Issue Issue

Receipt Receipt

B -5

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