Attachment I - API External Inspection Report Template.docx

API 653 In-Service Inspection Report Installation, State

US Army Corps of Engineers Omaha District API 653 In-Service Inspection Report

[Location] [Facility Number] [Tank Number]

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

(USACE POL-MCX)

[DATE]

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

Summary of Inspection

INSPECTION DATE

API In-Service (External) Inspection Date: 1 January 20XX Equipment Used:

Inspector(s):

STATE REGULATIONS

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 inspections dates shall be based on whichever is more stringent between the API inspector’s calculations and the State regulations.

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

[Name] [Title] [Company] API 653 Certified Inspector No. [XXXX]

GENERAL TANK INFORMATION

Owner

Location

Facility Number

Tank Number

State / Country

City

Inspection Date

Tank Manufacturer

Design Standard

Date of Construction

Tank Contents

Tank Serial Number

Tank Diameter

Shell Height

Product Height

Tank Capacity

Foundation

Shell

Floating Roof

Fixed Roof

Shell

Floating Roof

Fixed Roof

Cathodic Protection

Interior Coating System

Exterior Coating System

Level Gauging

Overfill Protection

Issue

Low Suction

Water Draw-Off

Level Alarms

Type of Internal Floating Roof

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

XXXX

2. Site Information

XXXX

B. TANK INSPECTION COMMENTS

1. Tank Construction

XXXX

2. Tank Foundation

XXXX

3. Tank Shell

XXXX

4. Tank Appurtenances

a. Geodesic Dome Roof

XXXX

b. Gauging

XXXX

c. Level Alarms

XXXX

d. Stairs and Platforms

XXXX

e. Grounding and Bonding

XXXX

5. Tank Coating

XXXX

6. Tank Piping System

XXXX

7. Fire Protection System

XXXX

8. Secondary Containment

XXXX

C. FINDINGS AND RECOMMENDATIONS

XXXX.

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.

1. Title Observation: Description Reference: Description Recommendation: Description

Title Observation: Description Reference: Description Recommendation: Description

2. REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 StandardsSHORT TERM REPAIRS Recommended Short-term Repairs that directly relate to the long-term preservation of the asset. Short-term 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.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.

1. Title Observation: Description Reference: Description Recommendation: Description

Title Observation: Description

3. RECOMMENDED REPAIRS as Part of Regular MaintenanceLONG TERM REPAIRS Recommended Long-term Repairs that directly relate to repair/upgrade of an asset to bring it up to the current standard from the standard at time of construction. Long-term 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. 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.

1. Title Observation: Description Reference: Description Recommendation: Description

Title Observation: Description

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATION

SHELL UT MEASUREMENTS

ROOF UT MEASUREMENTS

SHELL NOZZLE / REPAD UT MEASUREMENTS

CRITICAL ZONE SHELL THICKNESS

SHELL LAYOUT DRAWING

ROOF LAYOUT DRAWING

NEXT INSPECTION

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3-D DOCUMENTATION AND ANALYSIS

The purpose of this study is to determine the tank shell out-of-roundness, locations of buckled areas, flat spots, and peaking and banding at weld joints. Shell distortion can be caused by many conditions such as foundation settlement, over- or under-pressuring, high wind, poor shell fabrication, or various repair techniques or tank modifications.

Out-of-Plumbness (Verticality) - The measured out-of-plumbness for this tank is x.xx in. in the worst area located at xxx degrees. Refer to the Out-of-Plumbness (Verticality) diagram.

Out-of-Roundness –Measurements for out-of-roundness were taken in x to x-ft increments along the shell. The worst area among the measurements was an out-of-roundness of xxx-in. The shell lower that xx-ft. was not measured. Laser setup was performed along the floating roof. Refer to Out-of-Roundness diagram.

Isolated Shell distortion – Isolated measurements were also taken along the external shell adjacent to the shell manway and 12-in receipt near the 0 degree mark. . Refer to the Isolated Shell Distortion diagram.

Tank Bottom Elevation – Laser scans were also performed along the tank bottom. Refer to the diagram below for details. Bottom slope is made evident by the point cloud system. No significant edge settlement was noted.

OUT OF PLUMBNESS (VERTICALLY)

ISOLATED SHELL DISTORTION

OUT-OF-ROUNDNESS

OUT-OF-ROUNDNESS AT XX FT

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

Tank In-Service Inspection Checklist

X

Measure foundation levelness and bottom elevations (see Annex B for extent of measurements).

Check for settlement into the base which would direct runoff rain water under the tank rather than away from it.

Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

Inspect the area for buildup of trash, vegetation, and other inflammables buildup.

Review cathodic protection potential readings.

Visually inspect for grooving, corrosion, pitting, and coating failures.

Tank In-Service Inspection Checklist Continued

X

Tank In-Service Inspection Checklist Continued

X

Inspect condensate drain for presence of oil indicating leakage.

Check for leaks at threaded and flanged joints.

Check for significant difference in stock specific gravity.

Check for water or gravity differences that would indicate a leaking swing joint.

Target should indicate direction of swing opening (up or down) and height above bottom where suction will be lost with swing on bottom support.

For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. (Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck.

Look for indication of standing water. (Significant sagging of fixed roof deck indicates potential rafter failure. Large standing water areas on a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons.)

Tank In-Service Inspection Checklist Continued

X

At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a nonlevel roof with possible shell out-of-round, out-of-plumb, leaking pontoons, or hang-up. On small diameter tanks, an unlevel condition can indicate unequal loading at that level.

Test for explosive gas on top of the internal floating roof. Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

NOTE Inspection of the seal and measurement of the rim spaces and seal-to-shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

Tank In-Service Inspection Checklist Continued

X

Inspect scaffold support for corrosion, wear, and structural soundness.

Check condition of screens, locking and pivot pins.

On fixed roof tanks with drip rings under the gauging platform or sampling area, inspect for plugged drain return to the tank.

Inspect vapor plugs for emergency drain: that seal fabric discs are slightly smaller than the pipe ID and that fabric seal is above the liquid level.

Check for leg racks on roof.

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

Tank In-Service Inspection Checklist Continued

X

See Tank Out-of-service Inspection Checklist, Item C.2.12.

NOTES:

APPENDIX E: PHOTOGRAPHS

E.1: Tank XX North View E.2: Tank XX South View

E.3: Tank XX East View E.4: Tank XX West View

E.5: Picture Description E.6: Picture Description

E.7: Picture Description E.8: Picture Description

E.9: Picture Description E.10: Picture Description

E.11: Picture Description E.12: Picture Description

E.13: Picture Description E.14: Picture Description

E.15: Picture Description E.16: Picture Description image3.jpeg image4.jpeg image5.jpeg image1.png image2.jpeg image6.gif