Attach 11 - Tower 7 Inspection Report (91134).pdf

Hurlburt Field, FL Tank No. 91134 Tank Inspection Report Project No.:49-060

Tank Name: 91134 Tank Type: Elevated (Pedestal) Location: Hurlburt AFB Tank Capacity: 250,000 gallons State: FL Type of Construction: Steel Built By: Unknown Location:

Year Built: Unknown (Data plate painted over) Inspected By:

Inspection Date: 2/22/19

GENERAL SUMMARY

Overall the tank is in fair condition with corrosion at most sharp edges and scattered throughout the tank surface, particularly on roof fixtures, ladders and floor of platforms. Coating system is beginning to show signs of failure with cracking and lifting of the multi-layer coatings throughout the tank surface.

RECOMMENDATIONS

Blast and repaint entirety of tank within next two years to prevent steel loss and protect long term integrity of the tank

Blast and clean anchor bolts and area inside bolt enclosures as thoroughly as possible. Re-coat and cover front of enclosure with welded steel plate with grease fitting. Fill void around bolts with grease for maximum long-term protection.

Install safety grating over valve pit in floor of tank.

Repair or replace lighting through dry access tube of tank.

Seal open holes on platforms with welded steel plates during next repaint to remove trip/fall hazard.

Replace wet area ladder and safety climb equipment during next repaint.

STANDARDS

The inspection of the tank was performed with the tank nearly full and no cleaning was performed. The inspection consisted of a visual observation of the tank’s interior (as feasible with water present) and exterior components and coating system. Interior and exterior assessment was documented using digital still photography, representative samples of which are included in the Appendix of this report.

CONDITION OBSERVATIONS

Conditions noted in this report are documented in the following pages and supported by color photographs in the Appendix. Condition ratings used to describe field findings are defined as follows:

Excellent No deficiencies noted.

Good Minor deficiencies noted. Structure is functioning as designed.

Fair Major deficiencies noted. Structure is in need of repair (or replacement) to continue functioning as designed.

Poor Repair or replacement required immediately. Item no longer functioning as designed

CONTAMINATION, HEALTH & SAFETY REPORT

Contamination & Health Overall Condition: Excellent

Overflow pipe is equipped with screen, gasket and flapper to prevent access for insects

All manways and hatches fit properly and were closed Roof vent is properly screened to prevent access for insects

Facility Safety Compliance Overall Condition: Fair

Tank is located inside locked, fenced area at secure military site Dry area ladders and safety climb in good condition but require coating replacement within next 1-2 years to avoid replacement.

Wet area ladder is heavily corroded and safety climb equipment has been painted over and is unusable. Both should be replaced at next repaint.

Valve pit in floor of tank has no safety grid over it, creating a fall/trip hazard Platforms have open holes that are a fall/trip hazard.

INTERIOR RESERVOIR INSPECTION REPORT

Interior Reservoir Roof Overall Condition: Poor

Most of ceiling coating in poor condition Ceiling coating has completely failed and ceiling is corroding throughout the tank Undetermined if cathodic protection system is working

Interior Reservoir Walls Overall Condition: Fair

Coating on walls in area of water surface showing consistent corrosion and coating failure

Coating on walls throughout showing signs of cracking and beginning to release from steel walls

Corrosion is evident on areas of walls below the water surface

Interior Reservoir Floor Overall Condition: Undetermined

Sediment and corrosion can be seen on floor of bowl, but complete inspection not possible without tank drained.

Interior Reservoir Plumbing Components Overall Condition: Good

Overflow pipe assembly is in good condition with corrosion along piping from water line up.

Interior Riser Overall Condition: Good

Wet side of access tube is in generally good shape with coating in better condition than that of ceiling and walls.

EXTERIOR RESERVOIR INSPECTION REPORT

Exterior Reservoir Roof Overall Condition: Fair

Coating on tank roof is in overall fair condition with scattered spots of minor corrosion, particularly along roof seams. Coating is beginning to crack and lift over the entirety of the tank roof, which will expose steel to the elements if coating is allowed to continue to degrade.

Roof vent is in good condition and is properly screened, but the tank/vent connection seam is showing minor to heavy corrosion around its perimeter.

Cathodic appear sealed but are corroding and staining top of tank Lip of primary hatch is corroded and should be rehabbed soon.

Exterior Reservoir Walls Overall Condition: Fair

Coating on exterior walls in fair condition with signs of corrosion and/or coating failures

Heavier corrosion along all sharp edges (painter’s ring, hatches), which is typical

Exterior Pedestal Overall Condition: Fair

Pedestal is heavily mildewed and coating is starting to crack through to the base metal over the entirety of the exterior of the tank. The coating system has reached the end of its useful tank and needs to be replaced soon to protect the integrity of the tank.

Exterior Plumbing Structures Overall Condition: Good

Overflow pipe assembly in good condition and properly braced. Coating is starting to fail, as evidenced on remainder of tank, but piping is still salvageable.

Overflow splash pad and riprap are adequate and functioning properly.

Foundation Overall Condition: Good

Foundation of pedestal in good condition with minor grout loss between base and foundation

Interior of anchor bolt enclosures and threads of anchor bolts have coating failure and corrosion that needs to be addressed.

GENERAL TANK SECURITY

Security Overall Condition: Excellent

Tank is located inside locked, fenced area at secure military site All ladders are inside tank with locked door.

Cathodic Protection System

Type, size, material and # of anodes: Overall Condition: N/A

Present but condition unknown.

TABLE 1 – Recommended Coatings Schedule

Coating System Surface Prep

Prime6 (mils - DFT)

Product4

Intermediate #1 (mils - DFT)

Product4

Intermediate #2 (mils - DFT)

Product4

Final (mils - DFT)

Product4

Total System (mils - DFT) Min 5 - Max 5

OCS-4

(Modified)

SSPC-10 Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro- Zinc

Epoxy 3.0-5.0

N140 - 1255 Pota-Pox Plus

Polyurethane

2.0 - 3.0

1075 Endura-Shield

Fluoropolymer Urethane

2.0 - 3.0

Series 700 HydroFlon

9.5 - 14.5

ICS-3

(Modified)

ICS-5

(Modified)

SSPC-10 (Immersion)

SSPC-6 (Interior Dry - Except bottom of bowl)

SSPC-6 (Interior Dry – Tank Bowl)

Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro-Zinc

Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro- Zinc

Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro- Zinc

Epoxy

4.0 - 6.0

Series 20HS Pota-Pox

Acrylic Insulation 150 mils

Series 971 Aerolon

100% Solids Epoxy2

25.0 - 35.0

Series FC22 Epoxoline

Epoxy

6.0 - 8.0

Series 20HS Pota-Pox

Epoxy

2.0 - 4.0

Series 20HS Pota-Pox

27.5 - 37.5 (42.5 - 52.5)3

12.5 - 17.5

154.5 – 157.5

Concrete SSPC-7 Acrylic Elastomeric

4.0 - 6.0

Series 156 Enviro-Crete

Acrylic Elastomeric

4.0 - 6.0

Series 156 Enviro-Crete

10.0

1 A stripe coat of epoxy shall be applied by brush to all weld seams, ladders, edges, etc., prior to receiving first intermediate coat on exterior surfaces and prior to the finish coat on interior surfaces.

2 All interior roof beams, sharp edges and other difficult to coat areas shall receive 35.0 – 45.0 mils of epoxy lining 3 Total Dry Film Thickness for roof beams, sharp edges and other difficult to coat areas 4 All products are as manufactured by Tnemec Company, Inc.

5 Mil thicknesses for individual coats shall not exceed manufacturer’s written recommendation.

6 An additional coat of zinc-rich primer shall be shop-applied to the replacement ladders and other replacement parts.

Appendix

Photos

1-Base of pedestal covered with heavy mildew

2-Heavy mildew around entirety of base of pedestal

3-Overflow splash pad and riprap runoff area is adequate and performing as designed with no excess washing

4-Interior of mouth of overflow pipe is heavily corroded, screen is intact with debris partially clogging screen from interior

5-Overflow flapper working properly, but coating is failing and peeling

6-Floor drain screen is intact but corroding

7-All sharp edges on interior of door and door frame corroding

8-Coating beginning to fail on painter's rings allowing corrosion to form

9-Mildew widespread nearly to top of tank pedestal

10-Coating failing on anchor bolts and corrosion forming, particularly in area behind bolts. Should be blasted, tool cleaned and front covered with welded seal plate (with grease fitting installed). Then void in box should be filled with grease.

11-Closer view of anchor bolt

12-Tank data plate painted over

13-Interior light at base of pedestal operational

14-Underside of bottom platform

15-Coatings on interior dry areas of tank in generally good condition

16-Safety grating should be installed over valve pit to prevent fall/trip hazard

17-Coating on floor of first platform is failing and cracking. Discoloration is combination of mildew, dirt and scattered corrosion.

18-Piping through dry tube of tank is properly braced with room for expansion and contraction of piping.

19-Lighting through dry tube not operational

20-Bolts on fill pipe beginning to corrode

21-Fill pipe bolts

22-Ladder and safety climb properly aligned and functional. No lighting in dry tube.

23-Expansion joint in top of fill pipe in good condition

24-Interior coatings in generally good condition

25-Floor of top platform showing coating failure, with heaviest corrosion on weld seams and sharp edges.

26-Open holes in platform floor should be covered with plate during next repaint to alleviate trip hazard.

27-Top coat of paint in good condition, but coating system is beginning to crack and fail from base coat.

28-More cracking of coating in dry interior and corrosion forming along rough weld seams

29-Blisters in coating on dry interior wall

30-Exterior of tank through painter's hatch at top of pedestal

31-Corrosion of weld seams as viewed from painter's hatch

32-Downward view of exterior from painter's hatch

33-Exterior coating beginning to fail. Small stress cracking throughout exterior. Difficult to photograph.

34-Small cracks throughout coatings as paint is beginning to fail. Difficult to photograph.

35-General paint fatigue evident at top of dry tube into bowl.

36-Coating is rough with bubbles and drips and beginning to crack.

37-Very rough finish on current coatings. Poor workmanship during prior coating installations. Each coat should have been applied smoothly with any drips, runs or irregularities sanded out.

38-Ladder and safety climb through dry tube in good condition.

39-Ladder through dry tube

40-Cracking and blistering of paint more visible at top of dry tube (interior).

41-More blistering and cracking of interior coating at top of dry tube.

42-Clips and other appurtenances on roof of tank are corroding.

43-Widespread cracking and coating failure on top of tank. Most evident at cathodic protection caps.

44-Scattered rust spots where coating is failing

45-Severe cracking and corrosion forming near hatch on top of tank.

46-Coating on top of tank discolored, cracking and blistering. Has reached end of useful life.

47-Widespread cracking with rust forming in areas where coating has completely released from steel.

48-Up close view of cracking. Difficult to photograph.

49-Discoloration and coating failure around base of tank vent.

50-Vent screen is intact but coating failing on tank vent, most severely along flange edges.

51-Broken conduit and heavy corrosion on top of tank.

52-Corrosion at cathodic protection cover.

53-Interior wet ladder has widespread coating failure and should be blasted and coated soon or will require replacement. Safety climb equipment has been painted and is not usable. Should be replaced.

54-Corrosion on interior walls visible through water.

55-Major coating failure and rust forming at and above customary waterline throughout tank. Rust also visible on tanks walls below water line.

56-Junction of dry tube and roof inside wet area of tank showing heavy corrosion along seam.

57-Closer view of complete coating failure in area of water line.

58-Complete failure of coating system in large areas of tank ceiling.

59-More tank ceiling with complete coating failure.

60-Widespread coating failure on tank wall above water line.

61-Stain, minor sediment and corrosion in floor of tank visible through the water.

62-Another view of tank roof and dry tube junction with heavy corrosion at seam.

63-Underside of vent inside tank is corroding. Also clips and seams inside wet area exhibiting coating failure.

64-Ceiling of tank and dry tube seam, corroding at seam and staining adjoining areas.

65-Complet coating failure at top of flanged dry riser on exterior top of tank.

66-Vent in adequate condition but widespread paint fatigue and failure on top of tank.

67-Widespread scattered coating failure with spots of corrosion forming where paint has completely separated from the steel top of tank.

68-Heavy runs in existing coating is sign of poor workmanship. Should have been sanded smooth.

69-Floor of platform is corroding most heavily at thick, rough weld seams.

70-Underside of belly of tank (view from interior platform). Final coat is rough and uneven with cracks beginning to form.

71-Platforms are skip welded, which is acceptable, but welds are very thick and rough, difficult to coat properly.

72-Fill pipe through landing. Properly braced with allowance for expansion and contraction.

73-Widespread "alligator" cracking is visible on underside of hatch to top of tank. Coating system in this condition has reached end of usable life. Not a candidate for overcoating.

74-Close up view of fatigued coating cracking.

75-Uneven thicknesses with heavy runs and drips in existing coating. Poor workmanship in prior paintings.

76-Appears to be a plate welded to cover a hole in side of tank. Very rough weld and coating is cracking at seams and in general area.

77-Close up of blistering, failing paint.

78-Interior view of underside of tank belly.

79-Blistering and rusting on fill pipe.