Attachment I Tank 7 Final Report.pdf

ACOE CONTRACT W911KB-15-D-0001, TASK ORDER 0007

TANK 7 (FACILITY NO. 961)

API 653 IN-SERVICE INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

FINAL REPORT

U.S. Army Kwajalein Atoll (KWA)

November 2016

Date of Inspection: April 2016

Prepared For:

U.S. Army Engineer District, Alaska P.O. Box 6898 Elmendorf AFB AK 99506-6898

Prepared By:

ENTERPRISE ENGINEERING, INC.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

James E. Hall, P.E.

API 653 Certificate No. 46418

Submitted By:

Kelly B. Waring, P.E.

Principal, API 653 Certificate No. 21992

EEI Project No. 8694

Page Intentionally Left Blank

SUITABILITY FOR SERVICE TESTAMENT

TANK 7 (FACILITY NO. 961)

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, in-service external integrity inspection and suitability for service evaluation of Tank 7 at U.S. Army Kwajalein Atoll on April 20 through April 21, 2016. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, UFC 3-460-03, and the Statement of Work.

Based on findings of the in-service inspection, Tank 7 is considered suitable for service. No mandatory repairs are required. The inspection identified Recommended (non-mandatory) API Repairs, Recommended Non-API Repairs, and recommended repairs for long term serviceability.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair. Recommendations for continued long-term service are also provided.

EEI recommends the next API 653 external in-service inspection be scheduled concurrently with the next out-of-service inspection no later than March 2020 (4 years from 2016 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API 653 internal out-of-service inspection be scheduled no later than March 2020 (10 years from 2010 inspection), or sooner if a change in condition has occurred. This inspection interval was taken from the last Tank 7 API 653 out-of-service report dated May 2010.

In accordance with API Standard 653, this report satisfies the requirement for an out-of-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

James E. Hall, P.E.

API 653 AST Inspector Certificate No. 46418 API 570 Piping Inspector Certificate No. 55566

This tank inspection did not identify any mandatory repairs. Based on the extent of this inspection and lack of mandatory repairs, Tank 7 is considered suitable to remain in service. Recommended repairs have been identified, and if possible, should be completed.

Tank 7 – API 653 Inspection TABLE OF CONTENTS U.S. Army Kwajalein Atoll (KWA) November 2016 EEI Project No.: 8694

TABLE OF CONTENTS

Page

1.0 SUMMARY

Scope General and Historical Information

2.0 INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

3.0 REPAIR ITEMS

Standard of Care Required Repairs (Mandatory) Recommended Tank Repairs (Non-Mandatory) Recommended Non-Tank Inspection Repairs Recommended Repairs for Long Term Serviceability

4.0 COATING SYSTEM

Coating Requirements

5.0 SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Shell Corrosion Rates Hydraulic and Structural Integrity Summary

6.0 CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ..................................................................... Appendix A Assessment of Compliance with Military Criteria ..................................................................... Appendix B Non-Destructive Examination (NDE) and Evaluation Criteria .................................................. Appendix C Tank Drawings .......................................................................................................................... Appendix D Tank Photographs .......................................................................................................................Appendix E NDE Results ............................................................................................................................... Appendix F Calculations ............................................................................................................................... Appendix G Coating Requirements ............................................................................................................... Appendix H

Tank 7 – API 653 Inspection Page 1

EEI Project No.: 8694

TANK 7

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

U.S. ARMY KWAJALEIN ATOLL (KWA)

1.0 SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an in-service external integrity inspection of Tank 7 at U.S. Army Kwajalein Atoll. The inspection was performed on April 20 through April 21, 2016.

The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3- 460-01, UFC 3-460-03 (April 2016), and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs, and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General and Historical Information

Tank 7 is a field erected above ground storage tank. The tank was constructed in 1954. The tank is 60 feet in diameter and 54 feet high and is of the open top style, welded construction with butt-welded shell plates and lap-welded floor plates. The tank was originally equipped with an external floating roof. The floating roof has since been removed and an aluminum geodesic dome provided. No aluminum floating pan was installed. The original tank floor was of cone up style, with perimeter sump. A second floor was installed in 2012. The second floor is cone up and parallel to the original floor in 2012. The nominal shell capacity is 27,000 BBLS. Tank 7 is currently in JP-5 service.

2.0 INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Tank 7 is considered suitable to remain in service.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Inspection of the tank shell, and accessible areas of the tank roof found no holes or indications of leaks. A pit survey was conducted of the exterior of the tank shell and no pits were identified requiring repair.

The in-service inspection and evaluation found no conditions that affect the hydraulic integrity of the tank.

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EEI Project No.: 8694

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof, and their attachments.

Ultrasonic inspections of the shell were performed on the first course and on each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

The in-service inspection and evaluation found no conditions that affect the structural integrity of the tank.

Next Inspection

In-Service Inspection Interval

API 653 requires an in-service inspection by an authorized inspector be performed every 5 years or RCA/4N years, whichever is less. RCA is the remaining corrosion allowance of the shell (i.e. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. When shell corrosion rates are unknown, API 653 requires the in-service inspection interval not exceed 5 years. Based on the corrosion calculations, it was found that the remaining life of the shell exceeds 5 years.

EEI recommends the next API 653 external in-service inspection be scheduled concurrently with the next out-of-service inspection no later than March 2020 (4 years from 2016 inspection), or sooner if a change in condition has occurred.

Out-of-Service Inspection Interval

API 653 requires the interval until the next internal inspection be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years for tanks without a release prevention barrier and 30 years for tanks with a release prevention barrier. The tank is equipped with a release prevention barrier. The corrosion rate procedure was used.

UFC 3-460-03 Final Document dated April 11, 2016, Appendix C, Storage Tanks, Aboveground Field- Erected Tanks (Section 8-4) recommends an interval of 10 years between inspections or as determined by an API 653 inspector. Calculated corrosion rates for the tank have determined that the remaining life of the tank shell exceeds 30 years. The previous out-of-service inspection in 2010 recommended the next out-of-service inspection to be performed no later than March 2020.

EEI recommends the next API 653 internal out-of-service inspection be performed no later than March 2020 (10 years from 2010). The next out-of-service inspection should be performed sooner if a change in condition or a change in service occurs.

3.0 REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory), recommended for long term serviceability, and recommended for non-tank inspection items. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

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Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor, and shall consider the tank has been in petroleum fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs (Mandatory)

Mandatory repairs refer to those items that are critical to the hydraulic or structural integrity of the tank and are required prior to placing the tank back into service.

The out-of-service inspection of the tank found no significant deficiencies that would require mandatory repair or require the tank be removed from service for repair.

Recommended Tank Repairs (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. The tank has been evaluated for compliance with UFC criteria. EEI highly recommends these repairs for tank integrity, ATG and operational compliance, and for the long-term preservation of the tank. To realize cost saving, these repairs should be performed while the tank is out-of-service.

Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Appendix titled “Coating Requirements”. When welding on the shell, the coating on the opposite side from the weld shall be inspected and repaired if damaged.

While the Tank is In-Service

1. Coating failure and corrosion was observed on the tank shell, spiral stairs, spiral stair handrail, stair platform and framing, wind girder, nozzle flanges and bolts, and shell valves.

• Remove the coating from the affected areas and recoat to prevent further degradation. It is estimated that approximately 600 square feet of the tank shell is in need of recoating.

2. The telltale holes at both shell manholes, low fuel, fill, issue, and blinded nozzles are open to the atmosphere.

• Re-pack the telltale holes with general purpose grease to prevent moisture migration between the reinforcing plate and the tank shell.

3. One-inch Stainless steel ball valves at the high and low level alarms are equipped with carbon steel handles. Severe corrosion of the handles was observed.

• Replace 8 carbon steel handles with stainless steel handles. Alternatively, replace entire valve with a stainless steel valve and handle at the next time the tank is taken out of service.

4. The one-inch thermal safety valves (TSV) in the pressure relief loops at the fill and issue nozzles are equipped with carbon steel caps.

• Replace TSV carbon steel caps with stainless steel caps.

5. The body cavity relief (BCR) valves and tubing are carbon steel. The low fuel, fill, and issue valves are all equipped with BCR.

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• Replace existing BCR with fully stainless steel BCR kits. The BCR shall relieve to the line side of the valve at the fill and issue valves. The BCR at the low fuel BCR shall relieve toward the tank. The low fuel BCR shall be deferred until the next time that the tank is taken out of service.

6. Three 3/8-inch ball valves on the product saver system are equipped with carbon steel handles. Severe corrosion was observed on the handles.

• Replace the carbon steel actuators (handles) with stainless steel handles. Alternatively, replace entire valve with a stainless steel valve and handle.

Deferred until the Next Tank Outage

1. The tank is equipped with spiral stairs. Moderate corrosion was observed on many of the stair treads.

Stair treads have been replaced in the past. Ten stair treads have through holes and areas of severe corrosion. Four handrail posts have areas of moderate to severe corrosion.

• Replace 10 stair treads with serrated steel bar grating treads.

• Replace 4 handrail posts.

2. The stair platform connection to the shell at the top of the spiral stairs is severely corroded.

• Replace corroded section of platform framing at shell.

3. An abandoned 4-inch nozzle is equipped with a custom non-rated blind flange that consists of a flange with a welded plate.

• Replace the custom non-rated blind with an ANSI Class 150 blind flange at the next out-of-service inspection.

Recommended Non-Tank Inspection Repairs

The following recommendations are outside the scope of an API 653 inspection as they do not affect the structural or hydraulic integrity of the tank. Where items have not been mandated for inspection by the scope of work, they have been added as good engineering practice.

1. The tank is located within a containment dike with reinforced concrete walls. The dike walls include expansion and construction joints. The caulking at one joint is cracked and failing.

• Remove the existing caulking and backer rod from the joint, clean and prepare the concrete surfaces, and provide jet-fuel resistant sealant and backer rod. Approximately 6 linear feet of joint is in need of repair.

2. Localized concrete spalls were observed on the concrete containment wall.

• It is recommended to rebuild the damaged areas with a polymer modified repair mortar or similar compatible material. Approximately 100 square feet of spalled concrete is in need of repairs.

3. Twelve of the band clamps at the liner connections to the CP anode ports have failed.

• Provide band clamps or other mechanical device at the failed locations.

4. Coating failure and corrosion was observed on the fire foam and fuel piping within the containment dike. Victaulic fitting bolts have severe corrosion and four fittings have separated. The sealant at the nine fire foam piping penetrations in the containment wall have failed.

• Program the fire foam piping for a complete recoat. There is approximately 700 LF of 4-inch piping to be recoated.

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• Program the 6-inch and 8-inch fuel piping for recoating at localized areas. There is approximately 20 LD of 6-inch piping and 20 LF of 8-inch piping to be recoated.

• Recommend replacing approximately 96 fitting bolts and 6 fittings.

• Remove the existing sealant, clean and prepare the concrete surfaces, and provide jet-fuel resistant sealant

5. The pipe supports within the containment dike with concrete piers and tees connected to the pipe with two pipe clamps with steel slide pads. Minor to severe corrosion was observed on the steel components of all pipe supports.

• Replace bolted tees and steel slide pads. There are two 8-inch pipe supports and two 6-inch pipe supports to be replaced. The concrete piers may be reused. Provide non-shrink grout beneath supports if required.

6. The distance between pipe supports exceeds normal maximum spans for 6-inch and 8-inch piping (based on the common criteria of a maximum of 0.10-inch sag between supports).

• Recommend replacing the existing six pipe supports with nine new pipe supports with spacing not exceeding 17 feet on center.

• (Note: This repair is included in the API 570 recommended “Pipe Support Rejuvenation” project).

7. Two pits were observed in the 6-inch schedule 40 JP-5 pipe between the shared containment wall with Tanks 13 and 14 and the first pipe support. Each pit is approximately two inches in diameter and measures 7/32” deep. The remaining wall thickness is below the minimum required structural thickness.

• Remove the corroded section of pipe, a minimum of two inches beyond the corroded areas, and no less than 12 inches minimum. An alternative of a full encirclement sleeve may be provided with the final report.

• Provide a schedule 40 carbon steel pipe pup.

• Provide 100% visual inspection and phased array UT of the completed welds.

• Pressure test the section of piping in accordance with ASME 31.3. The pressure test segment shall terminate at double block and bleed plug valves.

8. A crack was observed in the West concrete containment wall.

• It is recommended to repair the crack. The crack repair method will vary with the actual field conditions but would most likely consist of saw cutting the joint, cleaning and filling with sealant.

Smaller cracks only need to be filled with sealant. Approximately 6 linear feet of crack is in need of repair.

Recommended Repairs for Long Term Serviceability

1. Test all level alarms and switches as part of on-going maintenance.

2. Test the operability of the high level control valve during tank fillings to ensure proper operation.

3. Program the tank for the next API 653 out-of-service internal and external inspection no later than March 2020.

4.0 COATING SYSTEM

fhp0370 Highlight fhp0370 Highlight

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EEI Project No.: 8694

Coating Requirements

Refer to Appendix H for complete coating materials and application requirements for type and location of coating repair items identified by the inspection.

5.0 SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank shell was calculated using thickness measurements that were obtained during the inspection and are as follows:

Shell: 0.00079 inches per year

The corrosion rates were calculated using an assumed original metal thickness and a 1954 year of construction.

Tank Shell Corrosion Rates

API 653 4.3.1.3 states that tank shell corrosion can occur in many forms and varying degrees of severity and may result in a generally uniform loss of metal over a large surface area or in localized areas. The corrosion rate for the tank shell was calculated based on the original nominal shell thickness and the minimum recorded shell thickness during the inspection.

UT readings of the shell were obtained at the bottom shell course and accessible locations from the spiral stairs at the upper shell courses. The shell plate thickness will not be reduced below the minimum value for a period in excess of 30 years.

Hydraulic and Structural Integrity Summary

The following table summarizes the hydraulic and structural integrity of the tank:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Foundation Tank sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Shell Visual inspection of the accessible shell joints found no relevant indications. A pit survey was conducted and no locations were identified for repair.

Acceptable

Roof Tank is equipped with an aluminum geodesic dome roof.

The geodesic dome roof is in good condition.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

Hydrostatic Test

Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

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EEI Project No.: 8694

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980): No, constructed in 1954.

2. Has a prior hydrotest been performed demonstrating fitness: Yes, 2012.

3. Is the tank shell thickness < 0.5 inch: Yes.

4. Does the tank operate at metal temperature above

60 deg F?: No.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4.1 or API 653 Figure 4.1: Yes.

7. Tank full at lowest one day temperature per API 650 Figure 4.1: Unknown.

The tank, having a prior hydrotest and shell thickness less than 0.5 inches thick does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Tank 7 is not anchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that at a fill height of 49’-6”, the tank is uplifting, but stable as the longitudinal shell stresses are acceptable Calculations were performed utilizing the specific gravity for JP-5 (S.G. = 0.84), a ringwall foundation, seismic parameters Ss = 1.25, S1 = 0.60.

Acceptable

Wind Evaluation

A wind analysis was performed per API 650, Section 5.11.

Calculations were performed using an importance factor of

1.0 and a wind velocity of 105 mph.

The evaluation determined that an empty tank is stable and not at risk of overturning or sliding.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 105 mph.

Acceptable

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EEI Project No.: 8694

6.0 CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 7 is considered suitable to remain in service.

Project Team

James E. Hall, P.E. Structural Engineer, Inspector of Record API 653 AST Inspector Certificate No. 46418 API 570 Piping Inspector Certificate No. 55566

Travis W. Snyder Tank Technician API 570 Piping Inspector Certificate No. 51982

Kelly B. Waring, P.E. Project Manager, QA Review API 653 AST Inspector Certificate No. 21992 API 570 Piping Inspector No. 23160

APPENDIX A

TANK INSPECTION DATA SHEET AND

EVALUATION ITEMS

Tank 7 – API 653 Inspection Appendix A, TANK SUMMARY SHEET

EEI Project No.: 8694

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Reagan Test Site, Kwajalein Atoll (KWA) Tank No. 7

Facility No. 961 Inspection Date(s): April 20 to 21, 2016

Tank Type: Vertical Above Ground Storage Tank Type of Inspection: External w/ Suitability for Service Evaluation

Contract Number, Task Order: W911KB-15-D-0001, Task Order 0007 Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: James E. Hall, P.E.

API-653 AST Inspector Certificate No. 46418

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard: Unknown, 1954, Not Specified (Assumed API Standard 12C 11th Ed.)

Diameter: 60'-0"

Shell Height: 54'-0" Product, Specific Gravity: JP-5, 0.788 to 0.845

Design Pressure / Temperature: Unknown Gross Capacity / Nominal Capacity: 26,915 Bbls / 27,000 Bbls

Safe Fill Height: 49’-6” (Per Facility) GPS Latitude & Longitude: 8 Deg 43’ 41.34” N, 167 Deg 44’ 13.22” E (Source – Google Earth) Foundation Configuration:

Floor Configuration:

Concrete Ringwall Cone-Up. Second floor was installed in 2012

Shell Configuration: Butt Welded, 8 courses Roof: Aluminum Geodesic Dome Roof

Cathodic Protection: Impressed Current Stilling Wells: Yes

Last Inspection (Type, Date): Out-of-Service, March 2010 Last Coated Internally (Product): 2006, White Epoxy Polyamide Last Coated Externally (Product): 2010, White Epoxy System

INSPECTION RESULTS

Can tank remain in service?: Yes.

Deficiencies identified as mandatory repairs: No.

Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term Serviceability” in body of report

Next Scheduled Inspections (Type, Date): In-Service: April 2020 (4 Years from 2016 inspection) Out-of-Service: April 2020 (10 Years from 2010 inspection)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: None available

API STANDARD 653

TANK IN-SERVICE INSPECTION CHECKLIST

Tank 7 – API 653 Inspection APPENDIX A, Page 1

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

Location: Kwajalein Atoll Date: 5/25/16

EEI Project No.: 8694

Item Completed Comments

C. 1.1 FOUNDATION

Measure foundation levelness and bottom elevations (see Appendix B for extent of measurements) X

C. 1.1.1 Concrete Ring

The tank bears on a concrete ringwall and 10-inches of sand filled interstice within a dead shell.

a. Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell.

X

b. Inspect drain openings in ring, back of water draw basins and top surface of ring for indications of bottom leakage.

X

c. Inspect for cavities under foundation and vegetation against bottom of tank. X

d. Check that runoff rainwater from the shell drains away from tank. X

e. Check for settlement around perimeter of tank. X

C.1.2 Asphalt

a. Check for settling of tank into asphalt base which would direct runoff rain water under the tank rather than away from it.

N/A

b. Look for areas where leaking of oil has left rock filler exposed, which indicates hydrocarbon leakage.

N/A

C.1.1.3 Oiled Dirt or Sand

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

N/A

C. 1.1.4 Rock

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 tank is out of service.

N/A

A 10-inch thick sand cushion was installed in 2012 along with a second bottom.

C.1.1.5 Site Drainage

a. Check site for drainage away from the tank and associated piping and manifolds. X

b. Check operating condition of the dike drains. N/A

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Tank No.: 7 Prepared by: James Hall

C.1.1.6 Housekeeping

Inspect the area for buildup of trash, vegetation, and other flammables buildup. X The liner ballast for the containment system includes soil and grass.

C.1.2 SHELLS

C.1.2.1 External Visual Inspection

a. Visually inspect for paint failures, pitting, and corrosion. X Spot locations of coating failure at wind girder, nozzles, and stairs.

b. Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X

c. Inspect the bottom-to-foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank)

Visually inspect for grooving, corrosion, pitting and coating failures. N/A

C.1.2.3 Riveted Shell Inspection

a. Inspect external surface for rivet and seam leaks. N/A

b. Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A

c. Inspect rivets for corrosion loss and wear. N/A

d. Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A

e. If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern; number of rows, rivet size, pitch length, and note whether the joint is butt-riveted or lap-riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks)

a. Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds.

X

b. Check support welds to shelf for pitting, especially on shell plates. X

c. Note whether supports have reinforcing pads welded to shell. X No reinforcing pads.

C.1.3 SHELL APPURTENANCES

C.1.3.1 Manways and Nozzles There are two 36-inch shell manholes.

a. Inspect for cracks or signs of leakage in weld joint at nozzles, manways, and reinforcing plates. X

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Tank No.: 7 Prepared by: James Hall

b. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X

c. Inspect for flange leaks and leaks around bolting. X

d. Inspect sealing of insulation around manways and nozzles. N/A

e. Check for inadequate manway flange and cover thickness on mixer manways. N/A

C.1.3.2 Tank Piping Manifolds

a. Inspect manifold piping, flanges, and valves for leaks. X

b. Inspect firefighting system components. X See body of report for recommendations.

c. Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X

d. Check for adequate thermal pressure relief of piping to the tank. X

e. Check operation of regulators for tanks with purge gas systems. N/A

f. Check sample connections for leaks and for proper valve operation. N/A

g. Check for damage and test the accuracy of temperature indicators. N/A

h. Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System There is a Varec Tape Gauge.

a. Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X

b. Inspect autogauge head for damage. X

c. Bump the checker on autogauge head for proper movement of tape. X

d. Identify size and construction material of autogauge tape guide (floating roof tanks). X

e. Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X

f. Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X

g. On floating roof tanks, when the roof is in the lowest position, check that no more than two ft.

of tape are exposed at the end of the tape guide.

N/A

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Tank No.: 7 Prepared by: James Hall

h. Inspect condition of board and legibility of board-type autogauges. N/A

i. Test freedom of movement of marker and float. X

C.1.3.4 Shell-Mounted Samples Station

a. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

N/A

b. Check circulation pump for leaks and operating problems. N/A

c. Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted)

Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer

a. Inspect for proper mounting flange and support. N/A

b. Inspect for leakage. N/A

c. Inspect condition of power lines & connection to mixer. N/A

C. 1.3.7 Swing Lines: Winch Operation

a. Nonfloating. Raise, then lower the swing line with winch, and check for cable tightness to confirm that swing line lowered properly.

N/A

b. Floating. With tank half full or more, lower the swing line, then let out cable and check if swing line has pulled cable tight, indicating that the winch is operating properly.

N/A

c. Indicator. Check that the indicator moves in the proper direction: Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite.

N/A

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity. N/A

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Tank No.: 7 Prepared by: James Hall

C.1.3.10 Swing Lines: Cable Material and Condition

a. For nonstainless steel cable, check for corrosion over entire length. N/A

b. All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison

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

C.1.3.12 Swing Lines: Target

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

C.1.3.13 Other - Alarms

There are low level and high level (Hi and Hi-Hi) level alarms mounted on the tank shell.

C.1.4 ROOFS Tank is equipped with an aluminum geodesic dome roof.

C.1.4.1 Deck Plate Internal Corrosion

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.)

N/A

Aluminum geodesic roofs are not suitable for walking on. The inspection team did not walk on the roof.

C.1.4.2 Deck Plate Exterior Corrosion

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck. X Tank is equipped with an aluminum geodesic dome roof.

C.1.4.3 Roof Deck Drainage

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

X

C.1.4.4 Level of Floating Roof

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.

Tank 7 – API 653 Inspection APPENDIX A, Page 6

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

C.1.4.5 Gas Test Internal Floating Roof The tank is not equipped with an internal floating roof.

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.

N/A

C.1.4.6 Roof Insulation

a. Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation.

N/A

b. Inspect for wet insulation under the weather coat. N/A

c. Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

N/A

C.1.4.7 Floating Roof Seal System The tank is not equipped with an internal floating roof.

a. Measure and record maximum seal-to-shell gaps at: N/A

1. Low pump out N/A

2. Mid-shell N/A

3. High liquid level N/A

b. Measure and record annular space at 30-ft.

spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly opposite pairs.

N/A

1. __________ _________ Opposite pair 1. N/A

2. __________ _________ Opposite pair 2. N/A

c. Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough).

N/A

d. Inspect fabric for deterioration, holes, tears, and cracks. N/A

e. Inspect visible metallic parts for corrosion and wear. N/A

f. Inspect for openings in seals that would permit vapor emissions. N/A

g. Inspect for protruding bolt or rivet heads against the shell. N/A

Tank 7 – API 653 Inspection APPENDIX A, Page 7

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

h. Pull both primary and secondary seal systems back all around the shell to check their operation. N/A

i. Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

N/A

j. Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. N/A

C.1.5 ROOF APPURTENANCES

C.1.5.1 Sample Hatch

a. Inspect condition and functioning of sample hatch cover. N/A Tank is not equipped with a manual gauge nozzle.

b. On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

N/A

c. Check for corrosion and plugging on thief and gauge hatch cover. N/A

d. Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance.

N/A

e. Check for reinforcing pad where sample hatch pipe penetrates the roof deck. N/A

f. On floating roof sample hatch and recoil systems, inspect operation of recoil reel and condition of rope.

N/A

g. Test operation of system. N/A

h. On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample).

N/A

C.1.5.2 Gauge Well

a. Inspect visible portion if the gauge well for thinning, size of slots, and cover condition. N/A

b. Check for a hold-off distance marker and tab with hold-off distance (legible). N/A

c. On floating roof, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

N/A

d. If accessible, check the distance from the gauge well pipe to the tank shell at different levels.

Tank 7 – API 653 Inspection APPENDIX A, Page 8

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

e. If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

N/A

C.1.5.3 Fixed Roof Scaffold Support

Inspect scaffold support for corrosion, wear, and structural soundness. N/A

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof)

The tape gauge penetrates through the geodesic aluminum roof. There is no inspection hatch in the geodesic dome roof.

a. Check the hatch for corrosion and missing bolts. N/A

b. Look for corrosion on the tape guide’s and float guide’s wire anchor. N/A

C.1.5.5 Autogauge: Float Well Cover

c. Inspect for corrosion. N/A

d. Check tape cable for wear or fraying caused by rubbing on the cover. N/A

C.1.5.6 Sample Hatch (Internal Floating Roof)

a. Check overall conditions. N/A

b. When equipped with a fabric seal, check for automatic sealing after sampling. N/A

c. When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check condition of screens, locking, and pivot pins. N/A

C.1.5.8 Gauging Platform Drip Ring

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

N/A

C.1.5.9 Emergency Roof Drain

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.

N/A

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

Tank 7 – API 653 Inspection APPENDIX A, Page 9

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

C.1.5.11 Vacuum Breakers

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.

N/A

C.1.5.12 Rim Vents

a. Check condition of the screen on the rim vent cover. X Screens are in good condition.

b. Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. X

C.1.5.13 Pontoon Inspection Hatches

a. Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A

b. Test for explosive gas (an indicator of vapor space leaks). N/A

c. If pontoon hatches are equipped with locked down covers, check for vent tubes. Check that vent tubes are not plugged-up. Inspect lock-down devices for condition and operation.

N/A

C.1.6 Accessways X See item C.2.12 below.

C. 2.12 ACCESS STRUCTURES

There is a spiral stair case welded to the shell of the tank. The stair ends at a top landing platform.

C. 2.12.1 Handrails

There is a hand rail section approximately 1/3 the perimeter of the roof. The geodesic doom roof structure is not designed for walking on.

a. Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails. X Handrail posts are round rod. Top rail is a

2” x 2” x 1/4" structural angle.

b. Inspect for pitting and holes, paint failures. X

c. Inspect attachment welds. X

d. Identify cold joints and sharp edges. Inspect the handrails and midrails. X

e. Inspect safety drop bar (or safety chain) for corrosion, functioning, and length. N/A

f. Inspect the handrail between the rolling ladder and the gaging platform for a hazardous opening when the floating roof is at its lowest level.

N/A

C. 2.12.2 Platform Frame

a. Inspect frame for corrosion and paint failure. X

Tank 7 – API 653 Inspection APPENDIX A, Page 10

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

b. Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure. X Severe corrosion was observed at the connection to the tank shell.

c. Check reinforcing pads where supports are attached to shell or roof. N/A

d. Inspect the surface that deck plate or grating rests on, for thinning and holes. X

e. Check that flat-surface-to flat-surface junctures are seal welded. X

C. 2.12.3 Deck Plate and Grating

a. Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure. X

b. Inspect plate-to –frame wells for rust scale buildup. X

c. Inspect grating for corrosion-caused thinning of bars and failure of welds. X

d. Check grating tie down clips. Where grating had been retrofitted to replace plate, measure the rise of the step below and above the grating surface and compare with other risers on the stairway.

X

C. 2.12.4 Stairway Stringers

a. Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. Inspect attachment of stairway treads to stringer. X

Moderate to severe corrosion was observed on several stair treads and handrail posts. See body of report for recommendations.

b. Inspect stairway supports to shell welds and reinforcing pads. X

c. Inspect steel support attachment to concrete base for corrosion. N/A

C. 2.12.5 Rolling Ladder

a. Inspect rolling ladder stringers for corrosion. N/A

b. Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment to stringers and corrosion, particularly where angle rungs are welded to stringers.

N/A

c. Check for wear and corrosion where rolling ladder attaches to gaging platform. N/A

d. Inspect pivot bar for wear and secureness. N/A

e. Inspect operation of self-leveling stairway treads. N/A

f. Inspect for corrosion and wear on moving parts. N/A

g. Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle. N/A

Tank 7 – API 653 Inspection APPENDIX A, Page 11

EEI Project No.: 8694

Tank No.: 7 Prepared by: James Hall

h. Inspect alignment of rolling ladder with roof track. N/A

i. Inspect top surface of rolling ladder rack for wear by wheels to assure at least 18 in. of unworn track (track long enough).

N/A

j. Inspect rolling ladder track welds for corrosion. N/A

k. Inspect track supports on roof for reinforcing pads seal-welded to deck plate. N/A

l. Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs.

Max angle __________________.

N/A

m. If rolling ladder track extends to within 5 ft. of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

N/A

Additional Notes:

None.

APPENDIX B

ASSESSMENT OF COMPLIANCE WITH

MILITARY CRITERIA

Tank 7 – API 653 Inspection Appendix B, Page 1

EEI Project No.: 8694

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

MANHOLE

c A shell manhole located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals as required by DoD Standard AW 78-24-27.

X

N/A, tank is not equipped with a floating pan.

e Roof manholes in accordance with API Std 650.

Locate the roof manholes near the perimeter of the roof at opposite ends of a diameter and approximately 90 degrees from the shell manholes.

X f Shell manholes in accordance with API Std 650.

Two 36-inch shell manholes 180 degrees from each other. Align shell manholes parallel with prevailing wind direction. Support shell manhole covers by davits.

g A bolted cover in the roof for installation and removal of the internal floating pan as required by the tank supplier based on the pan manufacturer.

X N/A, tank is not equipped with a floating pan.

INSPECTION HATCHES

h A minimum of four 24-inch square inspection hatches on fixed roof tanks with floating pans.

Inspection hatches are not required for tanks without floating pans.

X

N/A, tank is not equipped with a floating pan.

LADDER/STAIRS

i Internal ladders (in accordance with OSHA criteria) for tanks of 5,000 gallons or larger with floating pans.

X

N/A, tank is not equipped with a floating pan.

Unknown as only an in-service inspection was performed.

k Ladders, railings, toeboards, a spiral stairway, top platform, and handrail in accordance with API Std 650 and OSHA requirements. Provide stairways to access high level shut-off and alarms. Provide metal bar grating stair tread and platforms. Provide stair tread with non-slip nosings.

X

See “Appurtenances” section of Appendix A for repair recommendations.

LEVEL ALARMS

l An individual automatic level alarm system, independent of the gauging device or system for each tank. Include high, high-high, low and low-low level alarms.

X

See “Appurtenances – Independent Level Alarms” section of Appendix A for repair recommendations.

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

Tank 7 – API 653 Inspection Appendix B, Page 2

EEI Project No.: 8694

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

VENTS

m Open atmospheric vents with weather hoods and bird screens or pressure/vacuum vents in lieu of open vents. Comply with NFPA 30, host nation requirements, Chapter 2 of this UFC, API Std 650, API Std 2000, 29 CFR Part 1910.106, and DoD Standard Design AW 78-24-27, where applicable.

n Emergency relief venting with capacity in accordance with NFPA 30 and UL 142, as applicable or a weak roof-to-shell seam, as specified in API Std 650.

GAUGE/GAUGE HATCH/STILLING WELLS

o A liquid level gauge calibrated in 1/16-inch graduations mounted at 60 inches above the walking surface.

p Automatic Tank Gauging (ATG) for all tanks with fuel managed through the Defense Logistics Agency's Business Modernization {BSM Enterprise Resource Programs (ERP) - Fuels section}, that complies with API MPMS Chapter 3.

r One 10-inch roof flanged nozzle with an 8-inch aluminum, fully slotted, stilling well for ATG near the edge of the roof near the top of the stairway platform.

X

Gauge tubes will be addressed at the next out-of-service inspection.

s One 8-inch roof flanged nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor, as close to or in the tank sump as possible. See DoD Standard Design AW 78-24-27.

X

Gauge tubes will be addressed at the next out-of-service inspection.

t One 10-inch roof nozzle and an aluminum, slotted stilling well extended to within 3 inches of the bottom of the tank* for gauging and sampling. A datum plate to establish a gauging zero point.

X

Gauge tubes will be addressed at the next out-of-service inspection.

PIPE CONNECTION

u Inlet fill connection. See Facility Plates 016, 017, and 018, as applicable. X Unknown as only an in-service inspection was performed.

v Main suction and low suction. See DoD Standard Design AW 78-24-27. X

OVERFILL PROTECTION

x Overfill protection with a hydraulically operated diaphragm control valve. X

Tank 7 – API 653 Inspection Appendix B, Page 3

EEI Project No.: 8694

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

WATER DRAW-OFF

aa Water draw-off connections. See DoD Standard Design AW 78-24-27. X

BALL JOINTS

ee Ball joints on pipes to relieve strain caused by tank settling or seismic activity.

X

It has been the experience of EEI that the integrity of ball joints is suspect and that leaks have been known to occur. It is the opinion of EEI that it is not necessary to retrofit the piping to include ball joints.

CABLE SUPPORTS

ff On the fixed roof of all tanks, provide two scaffold cable supports in accordance with API Std 650. X N/A, tank is equipped with an aluminum geodesic dome roof.

STRIKER PLATES

gg Striker plates under all openings used for manual gauging in steel tanks and all openings in fiberglass tanks.

X Unknown as only an in-service inspection was performed.

Additional Military Criteria Items, Comments or Notes:

None.

END OF DATA

APPENDIX C

NON-DESTRUCTIVE EXAMINATION (NDE) AND

EVALUATION CRITERIA

Tank 7 – API 653 Inspection APPENDIX C, Page 1

IN-SERVICE INSPECTION

CODES AND STANDARDS

API Standard 653, 5th Edition, November 2014

API Standard 650, 12th Edition, March 2013, Addendum 2, January 2016

UFC 3-301-01 Structural Engineering, June 2013, Change 1 May 2014

UFC 3-460-03 Operation and Maintenance: Maintenance of Petroleum Systems, Final…