Attachment 08 - Shaw B1921 Annex Upgrade - Shaw AFB Tanks Design Standard updated March 2025.docx

March 2025

SHAW AFB SHOP-FABRICATED TANK INSTALLATION GUIDE

POC- 20 CES/CEIEC, Tanks Program Manager 803-895-9987

BLUF-All shop-fabricated ASTs shall be UL 2085 double wall, coated steel (inside with fuel-compatible coating) and (outside with a durable weather-proof coating with top coat, incorporating industry standard coating materials and application). Tanks and equipment must be properly UL listed, compliant with applicable industry standards and codes of practice, and any regulatory requirements from federal/state/local Authority Having Jurisdiction (AHJ) for Shaw AFB. Tank design and installation must comply with all NFPA 30, UFC 3-460-01, other applicable military standards, and Air Force guidance requirements for shop-fabricated aboveground tanks. Each tank must be installed and equipped to meet STI SP001 requirements for STI Category 1 with Spill/overfill/CRDM. All tanks and equipment shall be verified by a Certified STI SP001 Inspection. Tanks shall be pressure tested or vacuum equivalent proving the primary tank and secondary shell are intact prior to introducing fuel for commissioning, in accordance with UFC 3-460-01, chapter 8. Tank system shall be designed with input from 20 CES/CEIEC with ergonomic utilization by end user in mind with respect to tank location, orientation, location of fill port, gauge, emergency generator stop button, signage (as applicable), and access to the tank for deliveries and maintenance of generator (as applicable).

Shop-Fabricated ASTs shall meet the industrial standards for construction and installment. The following standards/requirements shall be used but not limited to:

· 40 CFR part 112,

· American Petroleum Institute (API)

· National Fire Protection Agency (NFPA) including but not limited to:

· UL 2085, Protected Aboveground Tanks for Flammable and Combustible Liquids

· Unified Facilities Criteria (UFC) 3-460-01 – Design: Petroleum Fuel Facilities

· Unified Facilities Guide Specification (UFGS) 33 56 10 Factory-Fabricated Fuel Storage Tanks

· DAFMAN 32-1067

· Steel Tank Institute SP001

· Tank Manufacturer's Instructions

NOTE: Issue tanks shall be elevated horizontal cylindrical tanks and shall also have other ancillary equipment requirements not provided with this list but included in NFPA 30A.

NOTE: No vertical shop-fabricated tanks are permissible.

NOTE: 72-hour notification of tank arrival on-base must be provided to 20 CES/CEIEC to allow verification of tank condition prior to unloading and placement. Leaving a phone message is not considered proper verification. Email response from the government or speaking with a 20 CES/CEIEC employee is considered adequate notification.

NOTE: NO FUEL DELIVERY SHALL BE ALLOWED WITHOUT WRITTEN AUTHORIZATION BY THE 20 CES/CEIEC POC. That will only happen after all installation and compliance requirements are met and verified by the government.

At a minimum, the following UL listed ancillary equipment and actions shall be required for proper installation:

· Secondary containment

· must be integral to tank by design and

· must have interstitial/rupture basin containment,

· which is pressure testable,

· verifiable, and

· continuously monitored.

· Spill box/bucket on fill

· 5-gallon capacity with lockable lid

· When a sub-base tank is chosen, and exposed tank top is available, spill bucket with fill should be located outside the genset housing

· Overfill Prevention Valve (OPV)

· Installed at fill point

· Set to activate at 95% volumetrically with a drop leg installed to allow deliveries below product level

· Overfill Alarm (liquid level float switch with annunciator with audible and visual alarms installed in clear view and close proximity to be easily heard at fill port area with generator running under load conditions and delivery truck running)

· With external alarms not contained within generator/genset housing

· Must easily be heard and seen at fill area with generator running

· Low alarm set to activate at 5% before loss of suction

· High level alarm set to activate at 90% volumetrically

· High-High level alarm set to activate at 95% volumetrically

· No battery powered overfill alarm units

· Power must be supplied to overfill alarm when commercial power is off, and generator is providing power

· Level float switch shall be designed with a magnet float that actuates a hermetically sealed dry-reed switch and have an external test lever

· Annunciator box will be weatherproof, have lights and sound for each alarm, be equipped with test button and reset button, have easy-to-open housing for ease of maintenance, and be labeled with tank number on engraved, plaque-type nameplate pop-riveted to front of housing.

· Fill riser adaptor

· Pressurized Tight-fill connection required (ex… cam and groove lock style liquid-tight)

· 2-inch male size with open nozzle prevention and matching locking female cam and groove fill cap

· Tank Bungs

· No plastic factory/shipping plugs shall remain installed, and no bungs shall remain open.

· Bungs with no equipment installed shall be plugged with cast iron threaded plugs with fuel compatible pipe thread sealant

· Manholes

· Shall be installed with one (1) for tanks up to 5,000 gallons, and

· Two (2) for tanks larger than 5,000 gallons

· Weather resistant tank shell coating with no holidays (i.e., scratches or defects)

· Any damage to coating from transport or installation shall be repaired IAW manufacturer’s specifications and/or industry standard codes of practice prior to commissioning.

· Tank gauge

· Shall be mechanical, testable design, and accurate to 1/8 inch

· Shall be vapor tight and fog-free construction

· Shall be easy to install and calibrate in 2-inch tank opening with float install through a 2-inch schedule 40 or 80 pipe nipple

· Gauge clock style shall be installed on all horizontal cylindrical tanks with stainless steel float and cable that is designed to swivel 360 degrees and be read from 30 feet away

· Sight window for tank gauge shall be UV rated and not be made of plastic

· Electronic tank gauges may be used in addition to the tank gauge requirements above

· Primary vent

· Vents must be extended outside buildings for Class I and Class II liquids

· Vents should be a minimum of 5 feet from any building structure

· If tank is inside the building, vent must be extended outside and sloped so no low point traps can be created with liquid and extend at least 3 feet above the roof line and meet industry standard spacing requirements from structure/roof openings and power ventilation openings.

· Class III liquids can currently be vented inside a building/shop (subject to change)

· With vapor diverter/rain cap

· Class I liquids require testable pressure/vacuum vent cap (valved to only open when tank must breathe in and out)

· Class II and Class III liquids can have open to atmosphere vent cap (subject to change)

· With applicable vent line riser height depending on Class liquid contained

· Class I liquids require minimum 12-ft. riser from finished grade above tank top.

· Class II and Class III liquids must be vented above tank top with no minimum height from finished grade but must be higher than the fill riser height.

· Emergency Vents

· Both primary and secondary containment emergency venting is required

· Adequate vent diameters are driven individually by volume of primary and secondary tank capacities.

· Weighted-cap emergency vents with O-ring seals should be chosen over spring driven models.

· All vents shall be UL listed and meet the industry standard emergency ventilation requirements with equal or greater relief than emergency venting parameters stated on the tank label as specified by tank manufacturer.

· Anti-siphon valve

· Must be installed at tank top on any supply/issue line where piping extends below tank top.

· If generator fuel pump is not strong enough to pull fuel through anti-siphon valve, a solenoid valve may be used but must be designed to have automatic and manual operational valve

· Anti-siphon valve is not necessary for belly tanks with no lines below tank top

· Return lines are not required to have an anti-siphon valve unless the return line begins from a tank (like a day tank) higher than the tank top where it drops back into the tank in question

· Leak detection sensor in the annular/interstice/rupture basin

· Electronic (typically top mounted) with audible and visual alarm, or

· Mechanical with external visibility

· Design with minimal plastic parts to prevent UV damage

· General provisions- All tanks shall be provided with, but not be limited to the following components:

· Lifting lugs

· Manual drain valve for rupture basin

· Interior striker plate if equipped with gauging port

· Ladders (interior and exterior as applicable)

· Strapping charts/tables

· Water removal

· Hand pumps for water removal shall be installed for all horizontal cylindrical tanks up to 1,000 gallons

· Tanks greater than 1,000 gallons shall have a water removal tube installed to within ½-inch of tank bottom with 2-inch cam and groove style adaptor and locking, weather-proof female cap

· Placarding/signage shall meet all industry standards and military codes (government will provide photographic examples to meet industry and military standards)

· All signage shall be contrasting to tank color and large enough for first responders to read at a distance

· NFPA placarding as appropriate in accordance with NFPA 704

· Numbers shall be minimum 3” in height with minimum 15” placard

· Class I liquid (example: MOGAS (1-3-0))

· Class II liquid (example: Diesel/Jet/Fuel Oil (1-2-0))

· Class III and Used Oil with no contaminants (0-1-0)

· Off-Spec fuel shall show highest level that may be contained

· (example: If Class I liquids may be present then Class I signage is required)

· UN Placarding- in accordance with MIL-STD-161H (universal coding with vertical yellow bars)

· As appropriate for liquid contained

· Minimum 3” lettering

· Fuel designation

· Provided by government

· Minimum 3” lettering

· Flammability/Combustible Placarding

· Standard 12” diamond signage

· Class I liquids require “Flammable” placarding

· Class II liquids require “Combustible” placarding

· No ignition source within 50 feet placarding

· Both Class I and Class II required

· Minimum 2” lettering

· Tank number

· The numeric values will be provided by government (will be building number with a dash and chronological order of the newest tank installed at current location), (example: 250-2) (building #250 and -2 is the second tank replacing the original tank at that location)

· Minimum 3” lettering

· Tank capacity in gallons

· Minimum 3” lettering

· UL label for the tank

· Manufacturer information including model number, serial number, tank capacity, and other industry standard information

· Tank access ports must be labeled to include but not limited to; fill port, vent ports, monitoring ports, and any other feature on the tank.

· Supply and Return line indicators, as applicable

· Bollard/traffic protection

· Must be installed in accordance with industry standard codes of practice

· Bollards are required (UFC 3-460-01) unless surrounded by a ballistic barrier wall, dike wall, or surrounded by building(s) where no traffic can reach the tank location

· No more than 48 inches on center spacing

· At least 48 inches high

· At least 6 inches diameter tubular steel (Schedule 40 or greater) filled with concrete with smooth domed finish

· Buried to standard depth 3 feet set in 18 inches square excavation with ¼ yard of concrete

· Located on all sides easily accessible by motor vehicle

· Elevated tanks

· All horizontal cylindrical tanks shall be designed and installed as elevated tanks

· No sub-base/belly tanks greater than 3,999 gallons shall be installed.

· All tanks over 4,000 gallons shall be horizontal cylindrical tanks designed by manufacturer to be installed as “elevated”, (at least 12 inches above concrete pad in accordance with UFC 03-460-01)

· Tank spacing/location

· Tanks shall have 3 feet, minimum, of separation from each other

· Tanks shall have at least 5 feet from any other structures and any surrounding equipment, except that:

· Tanks shall be located at least 50 feet from open flame or ignition sources

· Anchoring

· Tanks shall be anchored in accordance with manufacturer design and specifications

· Each anchoring point shall be properly utilized

· Tank saddles/stands should be affixed to the tank (welded) and coated with same coating as the tank shell and designed/equipped for proper anchoring

· Tank should be properly anchored to adequately sized and properly engineered concrete pad such that weight of tank and fuel to capacity will not compromise pad integrity and proper anchoring does not reduce concrete pad integrity

· After anchoring, proper tank support base bedding shall be required for filling voids between the tank support bases and the concrete pad with concrete as directed by the government

· Grounding

· Tank must have at least one visible grounding strap of adequate size from tank base/saddle to grounding rod installed close to concrete pad for lightning protection in accordance with NFPA 780.

· Grounding rod must be at least 5/8” diameter solid copper and at least standard 10-foot length

· Sub-base tanks with generator mounted on top must also be grounded to the generator chassis and the building common ground bus

· Piping

· At least schedule 40 cast iron and shall be coated similarly to the tank shell protective coating in accordance with: Clean all piping in accordance with (Society for Protective Coatings) SSPC-SP1 with a bio-degradable degreaser. Prep all piping in accordance with SSPC-SP2 and SP3. Install 2 coats of Sherwin Williams 646 Macropoxy to achieve 3 to 5 mil thickness. Topcoat with Sherwin Williams Hi Solids polyurethane (2 coats). All prime coats shall be of different shades to ensure proper coverage. Inspections shall be performed by a (National Association of Corrosion Engineers) NACE certified quality control inspector and documented.

· This includes any fuel lines for fuel cleaning/scrubbing/polishing devices

· This includes any fuel piping associated with issue lines or supply and return lines from horizontal cylindrical or any other tank where the generator or dispenser are lower than the top of the tank

· Sub-base/belly tanks with generator(s) on top with weather-resistant housing may have UL listed, fuel compatible rubber supply and return lines, provided those lines are not exposed to UV rays and do not extend below the top of the tank.

· To allow for on-site observation by the Environmental flight, 48-hour notification of date and time of STI SP001 testing/inspection must be given to 20 CES/CEIEC Tanks Program Manager. (803-895-9987)

· Alternate: Chief of Environmental Quality (803-895-5006)

· With all testing records and all forms from STI SP001 completed and strapping charts from manufacturer provided at commissioning submitted to 20 CES/CEIEC Tanks Program Manager for approval.

· All tanks shall be inspected prior to commissioning and before any fuel delivery, in accordance with UFC 3-460-01 and STI SP001, by a STI SP001 Certified Inspector.

· Results must show tank is fit for service, verifying Category 1 tank status, and note when next testing event is required, assuming monthly and annual inspections will be completed in timely fashion by tank owner/custodian.

· With pressure testing after installation/tank anchoring, to ensure integrity, per STI SP001 (most current edition to date of installation).

· Factory established vacuum on closed interstice/rupture basin with vacuum gauge still attached may be used in lieu of pressure testing if verified by CEIEC within allowable parameters when compared to factory-shipped vacuum and maintained until tank is set and anchored to concrete pad.

· Vacuum testing of the primary and/or secondary, in accordance with tank manufacturer specifications, may also be used instead of pressure testing after being set and anchored.

· The following STI SP001 forms will be completed and submitted with testing records and the inspection results: STI SP001 AST Record, Monthly AST Inspection Checklist, and Annual AST Inspection Checklist.

NOTE: When the shop-fabricated AST meets all the following compliance criteria:

· Conforms to all requirements of the Shaw design standard, and

· Has been inspected/tested in accordance with manufacturer specifications, industry standard codes of practice, and military guidance, and

· Has all STI SP001 forms completed with strapping charts submitted and verified by 20 CES/CEIEC Only then can coordination for commissioning begin with notification to the 20 CES/CEN (engineering) and 20 CES/CEOFP (Power Pro) POCs as applicable. Commissioning shall include use-training of the tank and any associated systems and equipment operations check to be performed and provided. The government must verify compliance with the installation requirements and provide written authorization for fuel delivery to be requested.

Engineering Program Manager Chief 803-895-9618 Exterior Electrician Supervisor 803-895-5252