Attachment J.1 Arnold-Fac 802 (Tank 5)-FINAL-2018.pdf

API 653 Out-of-Service Inspection Report Arnold AFB, TN

US Army Corps of Engineers Omaha District

API 653 Out-of-Service Inspection Report

Arnold AFB, Tennessee Facility No. 802

Tank No. 5

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

(USACE POL-MCX)

May 2018

TABLE OF CONTENTS

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

CONTAINMENT SUMP, DRAIN PIPE AND DRAIN VALVE

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ENCLOSED IN APPENDIX B)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Evaluation Items

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS per API 653, UFC 3-460-01, or AW 78-24-27 Standards

2. REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

D. INSPECTION INTERVALS

1. Routine In-Service Inspection

2. External (In-Service) Inspection

3. Ultrasonic Thickness Inspection

4. Internal (Out-of-Service) Inspection

APPENDIX A: TANK EVALUATION ITEMS

APPENDIX B: ENGINEERING CALCULATIONS AND DRAWINGS

1. FLOOR DRAWING

2. INTERIOR FLOOR UT AND COATING

3. INTERIOR FLOOR CRITICAL ZONE UT

4. FLOOR PROJECTION

5. FLOOR CORROSION CALCULATIONS

6. FLOOR REPAIR LOCATIONS

7. TILT CALCULATIONS

8. SETTLEMENT CALCULATIONS

9. SHELL ELEVATION DRAWING

10. EXTERIOR SHELL UT AND COATING

11. EXTERIOR 1ST SHELL COURSE UT

12. INTERIOR 1ST SHELL COURSE COATING

13. SHELL MANHOLE AND NOZZLE UT

14. SHELL CORROSION CALCULATIONS

15. ROOF DRAWING

16. ROOF EXTERIOR UT AND COATING

17. ROOF CORROSION CALCULATIONS

18. EMERGENCY VENTING CALCULATIONS

19. TANK EVALUATION SPREADSHEET

20. OSHA ACCESS STRUCTURE REPORT

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

AFB Air Force Base

API American Petroleum Institute

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DBB Double Block and Bleed

DFT Dry Film Thickness

FML Flexible Membrane Liner

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LF Linear Feet

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NDT Non-Destructive Testing

NFPA National Fire Protection Association

OOS Out-of-Service

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

SF Square Feet

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UTT Ultrasonic Thickness Testing

VT Visual Testing

GENERAL SUMMARY

Enterprise Engineering Inc. (EEI) was retained by the United States Army Corps of Engineers (USACE), Omaha District, under Contract No. W9128F-17-D-0021 Delivery Order W9128F17F0168 to perform an out-of-service (OOS) API 653 inspection of Tank 5 (Facility 802) at Arnold Air Force Base, Tennessee.

The OOS API 653 inspection was performed 22-23 February 2018 in accordance with the applicable portions of API Standard 653, UFC 3-460-01, UFC 3-460-03 and the Statement of Work (SOW).

Tank 5 is a field erected, vertical, aboveground storage tank. The tank was constructed in 1954. The nominal tank diameter is 20 feet and the shell height is 18 feet. The tank is of welded construction with butt-welded shell and floor and lap-welded roof plates. The nominal shell capacity is 1,000 Bbls. The tank is not equipped with a floating pan and is currently in Jet A service. Secondary containment is provided by a reinforced concrete dike floor and walls. The south containment wall is covered with a flexible membrane liner.

CONTAINMENT SUMP, DRAIN PIPE AND DRAIN VALVE

Tank 5 is not equipped with a containment sump or drain piping. There is a 4 inch drain opening in the north concrete containment wall. A gate valve is located on the exterior side of the wall. Since the wall is only 8 inches thick, it was not possible to hydrotest the gate valve.

This inspection has determined that mandatory repairs are not required. Locations of backside corrosion were detected on the floor plate. Based on corrosion calculations, the tank may be returned to service for a period not to exceed 8.1 years, if repairs are not performed. The government has elected to return the tank to service until repairs can be completed within the 8.1-year period. Additional noted deficiencies are discussed in Section C and should be addressed in a timely manner. Photographs of the deficiencies are also included in Section C. Additional photographs are included in Appendix D.

The next API 653 In-Service (external) Inspection should be performed by February 2023 (5 years).

If no repairs are performed at this time, the next API 653 Out-of-Service (internal) Inspection should be performed by February 2026 (8 years). If repairs are performed, the service next inspection should be performed by February 2038 (20 years).

INSPECTION DATE

API Out-of-Service (Internal) Inspection Date: 22-23 February 2018

Equipment Used:

Manufacturer: MFE Enterprises Tank Floor Scanner Model Number: MFE 2412 Mark 2 Calibration Method: Calibration plate with known defects

Manufacturer: Olympus Model Number: 45MG Calibration Method: 2-point calibration using a single material standard

Manufacturer: Positector Dry Film Thickness (DFT) Gauge Model Number: 6000 Calibration Method: Calibration to know thickness standard

Manufacturer: Pro Shot Rotary Laser Level

Model Number: L3

Calibration Method: Manual leveling

Inspectors:

David A. Stchyrba, P.E.

Shaun C. Wilson

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections N/A

State Regulation for API Out-of-Service Tank Inspections N/A

The Tennessee Department of Environment and Conservation does not regulate aboveground storage tanks.

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: June 2008

API In-Service (External) Inspection Date: Unknown

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ENCLOSED IN APPENDIX B)

API Out-of-Service (Internal) Inspection Date without Repairs: 22 February 2026 (8 Years)

API Out-of-Service (Internal) Inspection Date with Repairs: 22 February 2038 (20 years)

API In-Service (External) Inspection Date: 22 February 2023 (5 years)

David A. Stchyrba, P.E.

Project Manager – Structural

Enterprise Engineering Inc.

API 653 Certified Inspector No. 27187

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Air Force Location Arnold Air Force Base Facility Number 802 Tank Number 5 State / Country Tennessee / United States City Manchester Inspection Date 22-23 February 2018 Tank Manufacturer Unknown Design Standard API Standard 12C Date of Construction 1954 Tank Contents Jet A Tank Serial Number None present Tank Diameter 20’-0” Shell Height 18’-0” Product Height 16’-8” Tank Capacity 42,000 gallons (1,000 BBLS) Foundation Concrete Pad

Construction

Bottom Flat, slight cone-up to side sump / lap welded Shell Butt-welded / 3 courses Floating Roof N/A Fixed Roof Cone-up self-supported / lap welded

Material

Bottom Steel / Unknown grade Shell Steel / Unknown grade Floating Roof N/A Fixed Roof Steel / Unknown grade

Cathodic Protection Not present

Interior Coating System Floor: Thick-film epoxy Shell: Thin-film epoxy Roof: Uncoated

Exterior Coating System Shell: Thin-film epoxy Roof: Thin-film epoxy

Level Gauging Varec tape gauge system ENRAF ATG system

Overfill Protection High level shut off valve on Fill piping Piping Receipt 6 inch reduced to 4 inch Carbon steel Issue 6 inch reduced to 4 inch Carbon steel Low Suction Not equipped

Water Draw-Off 4 inch drain in floor plate Carbon steel Level Alarms Scully high-high, high, low and low-low level alarms; ENRAF ATG alarms Type of Internal Floating Roof Not equipped

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection An OOS API 653 inspection was performed 22-23 February 2018 on Tank 5 (Facility 802). Results of this inspection identified recommended repairs and upgrades required to comply with API 650, API 653, UFC 3-460-01, UFC 3-460-03, AW 78-24-27 and industry standards.

2. Site Information Arnold AFB is located in Tennessee. The base is home to the Arnold Engineering Development Complex (AEDC). The facility operates aerodynamic and propulsion wind tunnels, rocket and turbine engine test cells, space environmental chambers and other specialized units.

B. TANK INSPECTION COMMENTS

1. Tank Construction Tank 5 (Facility 802) is a field erected, vertical, aboveground storage tank. The tank was constructed in 1954. The nominal tank diameter is 20 feet and the shell height is 18 feet. The tank is of welded construction with butt-welded shell and floor and lap-welded roof plates. The nominal shell capacity is 1,000 Bbls and the design liquid level is 16-feet 8-inches. The tank is not equipped with a floating pan and is currently in Jet A service. Design drawings for the 2008 installation of the stilling wells, partial roof handrails and access ladder were available for review.

2. Tank Evaluation Items Refer to Appendix A for a discussion of the tank evaluation items. The information has been provided in a tabular format for reference.

C. FINDINGS AND RECOMMENDATIONS

The following subsections outline the tank repairs/upgrades. Repairs and upgrades shall be completed in accordance with API requirements and best engineering practice.

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.

No conditions requiring mandatory repairs were identified.

2. REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Required 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.

a. Backside Corrosion of Tank Floor OBSERVATION: MFL floor scanning detected five locations of backside corrosion. Since the locations were not identified during the 2008 inspection, it has been assumed that the corrosion has occurred since 2008 and not the 1954 year of construction. If left unrepaired, the service interval will be limited to 8.1 years. If repaired, the service interval can be extended to 20 years.

REFERENCE: API 653 4.4.5 Minimum Thickness for Tank Bottom Plate

RECOMMENDATION: Provide ¼-inch thick x 6-inch square lapped patch plates with rounded corners. Weld the patch plates to the floor with a ¼-inch fillet weld. Perform integrity inspection of the entire weld by vacuum box testing. Remove edge on topside of plates for recoating by grinding a 45-degree chamfered rounded edges.

b. Non-Compliant Weld Clearances OBSERVATION: The weld clearance between the underside of the reinforcing plate at manways 1, 2 and the fill nozzle to the floor-to-shell weld is less than the 3-inch minimum required per API 650.

REFERENCE: API 650 Figure 5.6

RECOMMENDATION: Provide magnetic particle (MT) examination of the welds with non-compliant clearance. Inspect the shell-to-floor weld and weld along the bottom of the reinforcing plate for cracks, lack of fusion, incomplete penetration, and other rejectable defects. Repair rejectable defects by grinding to remove the defect. Examine the repair using MT. Provide surface preparation and coating repairs at the repair locations.

Note: Contact the Government for further direction if grinding to eliminate the weld defects will exceed the base thickness and weld size requirements. Contact the Government for direction on appropriate repair procedure if cracks are found.

c. Emergency Venting OBSERVATION: The tank is equipped with a 6-inch Oceco emergency vent and a 3-inch P/V vent.

The total capacity of the existing vents is less than the required venting capacity of 546,000 CFH based on tank geometry.

REFERENCE: NFPA 30 ¶ 22.7

RECOMMENDATION: Remove the existing 6-inch vent. Provide an 8-inch emergency vent with a minimum capacity of 504,818 CFH.

d. Tank Labelling OBSERVATION: The label identifying the tank number has detached from the tank shell.

REFERENCE: AW 78-27-27 Sheet D.13, Detail 3, Note 3

RECOMMENDATION: Provide tank labelling.

e. Floor Projection Sealant OBSERVATION: There is no sealant between the underside of the tank floor projection and the concrete ringwall. Moss and organics were observed growing within the space.

REFERENCE: AW 78-24-27 Sheet D.04, Detail 3

RECOMMENDATION: Remove all of the organics. Clean and prime surfaces. Provide jet fuel resistant polysulfide sealant. Estimated quantity: 63 L.F.

f. Tank Grounding OBSERVATION: The tank is equipped with one ground wire. It appears that the installation of a second ground wire was started but not completed.

REFERENCE: AW 78-24-27 Sheet ED.02

RECOMMENDATION: Complete the installation of the ground wire.

g. Tank Anchors OBSERVATION: The tank is equipped with four anchors. The anchor spacing of 15-feet 8-inches exceeds the API 650 maximum spacing of 10-feet. They are a variation of an anchor strap but were not constructed in accordance with the requirements of API 650. The straps are bolted to the side of the concrete instead of embedded within the concrete foundation. The tank floor projection was cut out at each strap. The straps do not contain a taper to ensure that the strap will yield before the tank shell. Since the concrete is cracked at multiple locations, the tank can no longer be considered anchored.

REFERENCE: API 650 ¶5.12

RECOMMENDATION: Repair the concrete by epoxy injection or similar means to prevent the ingress of water and deterioration of reinforcing steel. Overturning calculations were performed considering the tank as unanchored. It was found that the tank is stable and not subject to sliding or overturning due to wind or seismic forces. No additional repairs are recommended.

h. Nozzle Reinforcing Plates OBSERVATION: Manway 2, issue and receipt nozzles are not equipped with reinforcing plates.

REFERENCE: API 650 ¶ 5.7.2.1

RECOMMENDATION: The precursor to API 650 was API 12C. The oldest edition of API 12C available for review was the 15th edition issued in 1958. It was a requirement of API 12C to provide a reinforcing plate for nozzles greater than NPS 2. It is not known why the nozzles were not provided with reinforcing plates. However, no repair is recommended at this time. The tank has demonstrated satisfactory service since 1954. The addition of new reinforcing plates to the existing tank nozzles may result in buckling or similar damage to the tank shell.

i. Tank Floor Coating Failures OBSERVATION: Coating failures were observed on the interior tank floor. The failures appear to be the result of welding that occurred during the installation of the stilling wells in 2008.

REFERENCE: UFC 3-460-03 ¶8-3

RECOMMENDATION: Provide surface preparation and recoat. Estimated quantity: 50 S.F.

j. Coating at Pressure Relief Piping OBSERVATION: The fill and issue nozzles are each equipped with a ¾-inch pressure relief loop.

The interior nozzles are partially blocked with coating.

REFERENCE: UFC 3-460-03 ¶8-3

RECOMMENDATION: Remove the excess coating.

k. Interior Roof Plate Coating OBSERVATION: The tank interior is fully coated except for the underside of the roof plate. The outer perimeter has been coated as result of overspray from the tank shell. The underside of the roof plate exhibits widespread rust.

REFERENCE: UFC 3-460-01, Chapter 12 – Major Rehabilitation and Chapter 8 ASTs

RECOMMENDATION: ¶12-3.6 states that when tanks are taken out of service for inspection or repairs, inspect the underside of the roof for rust. If conditions merit, coat the underside of the roof in conformance with Chapter 8. ¶ 8-3.9 requires that the underside of the roof shall be coated for tanks in aviation service. Coat the underside of the tank roof in accordance with UFGS 09 97 13.15 Low VOC Polysulfide Interior Coating of Welded Steel Petroleum Fuel Tanks.

l. ATG Displacer OBSERVATION: The tank is equipped with an ENRAF ATG system that includes a displacer. The displacer is located within an 8-inch stilling well. The displacer was not retracted at the time of the inspection.

REFERENCE: Best practices

RECOMMENDATION: Contact SPAWAR to review the ATG system to verify accuracy.

m. Pressure Relief Loop Isolation Valve OBSERVATION: There is a pressure relief loop around the tank issue nozzle that is not equipped with an isolation valve.

REFERENCE: AW 78-24-27 Sheet D.10, Detail 4

RECOMMENDATION: Provide a ¾-inch ¼-turn ball valve.

n. Roof Manholes OBSERVATION: The tank is not equipped with roof manholes.

REFERENCE: UFC 3-460-01 Table 8-1 Item e

RECOMMENDATION: There is no compelling reason to provide a roof manhole(s). During cleaning of the tank, the ventilation unit was bolted to the nozzle containing the manual gauge hatch. The tank is not equipped with a floating pan requiring inspection nor is there an internal ladder. This item has been included for completeness to document a non-conformance condition with military criteria.

o. Shell Manholes OBSERVATION: The tank is equipped with one 18-inch and one 30-inch manhole which is less than the current requirement for two 36-inch manholes.

REFERENCE: UFC 3-460-01 Table 8-1 Item f

RECOMMENDATION: There is no compelling reason to provide larger shell manholes. The installation of a shell manhole would require a full height hydrostatic test. This item has been included for completeness to document a non-conformance condition with military criteria.

p. Nozzle for Water Bottom Sensor OBSERVATION: The tank is not equipped with one 8-inch flanged roof nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor above the floor drain.

REFERENCE: UFC 3-460-01 Table 8-1 Item s and AW 78-24-27 Sheet D.07, Detail 3

RECOMMENDATION: Provide one 8-inch flanged roof nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor above the floor drain. It should be noted that the corresponding location on the tank roof is not protected by the partial handrail system.

Although this is a non-conformance issue with military criteria, it is further recommended to review the need for bottom water sensing with facility personnel based on existing tank service and operations.

q. Fill Piping OBSERVATION: The tank is not equipped with interior fill piping or a diffuser.

REFERENCE: UFC 3-460-01 Table 8-1 Item u and AW 78-24-27 Sheet D.08, Detail 1

RECOMMENDATION: Provide interior piping, including a diffuser. It should be noted that the existing 6-inch nozzle may require complete replacement since it extends inward less than 1-inch past the shell. The tank has been in service without interior piping since 1954. Although this is a non-conformance issue with military criteria, it is further recommended to review the need for interior piping with facility personnel based on existing tank service and operations.

r. Main Suction and Low Suction OBSERVATION: The tank is not equipped with interior issue piping. The tank is not equipped with a low suction nozzle or interior low suction piping.

REFERENCE: UFC 3-460-01 Table 8-1 Item v and AW 78-24-27 Sheet D.08, Detail 4

RECOMMENDATION: Provide interior issue piping. It should be noted that the existing 6-inch nozzle may require complete replacement since it extends inward less than 2-inches past the shell. Given the tank volume and floor drain construction, there is no compelling reason to provide low suction piping. The tank has been in service without interior piping since 1954.

Although this is a non-conformance issue with military criteria, it is further recommended to review the need for interior piping with facility personnel based on existing tank service and operations.

s. Water Draw-Off OBSERVATION: The tank is not equipped with a shell mounted water draw-off.

REFERENCE: UFC 3-460-01 Table 8-1 Item aa and AW 78-24-27 Sheet D.13, Detail 5

RECOMMENDATION: No repair is recommended at this time. The tank is equipped with a 4-inch floor drain. There is no compelling reason to provide a separate water draw-off system. This item has been included for completeness to document a non-conformance condition with military criteria.

t. Ball Joints OBSERVATION: The tank piping is not equipped with ball joints to relieve strain caused by tank settling or seismic activity.

REFERENCE: UFC 3-460-01 Table 8-1 Item ee

RECOMMENDATION: No repair is recommended at this time. 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. This item has been included for completeness to document a non-conformance condition with military criteria.

u. Cable Supports OBSERVATION: The tank is not equipped with scaffold cable supports.

REFERENCE: UFC 3-460-01 Table 8-1 Item ff

RECOMMENDATION: No repair is recommended at this time. There is no compelling reason to provide scaffold cable supports. This item has been included for completeness to document a non-conformance condition with military criteria.

v. Cathodic Protection OBSERVATION: The tank is not equipped with a cathodic protection system to protect the tank floor.

REFERENCE: UFC 3-460-01 Chapter 2 General Design Info and Chapter 12 Major Rehabilitation

RECOMMENDATION: ¶2-13.1 states that for all underground steel tanks and tank bottoms of aboveground vertical tanks, provide cathodic protection. ¶12-8 states that when rehabilitating any fuel system, install or upgrade cathodic protection. Although backside corrosion requiring repair was identified at five locations, it is the opinion of EEI that the floor remains in serviceable condition. The installation of a CP system is not recommended. In order to provide a CP system, the tank shell would have to be slotted and a double bottom with sand pad provided. The installation of a double bottom would require a hydrostatic test. This item has been included for completeness to document a non-conformance condition with military criteria.

w. Roof Handrail OBSERVATION: The tank has been equipped with a partial roof handrail. Two partial segments were installed in 2008 on each side of the roof access ladder. Two partial segments were installed at the center of the roof at an earlier date.

REFERENCE: AW 78-24-27 Sheet D.11, Detail 5 and UFGS 33 56 13.13 ¶2.13.9

RECOMMENDATION: Provide a full perimeter handrail to allow unrestrained access to all portions of the roof.

x. Circumferential Stairway OBSERVATION: The tank is not equipped with a circumferential stairway. The roof is accessed by a ladder.

REFERENCE: AW 78-24-27 Sheet D.11, Detail 4 and UFGS 33 56 13.13 ¶2.13.7

RECOMMENDATION: Although AW and UFGS specify a circumferential stairway, there is no compelling reason to provide one at this time. This item has been included for completeness to document a non-conformance condition with military criteria.

y. Manway Davits OBSERVATION: The tank is equipped with two shell manways. Neither manway has been equipped with a davit to assist with cover plate removal.

REFERENCE: AW 78-24-27 Sheet D.10, Detail 3 and UFGS 33 56 13.13 ¶2.13.16

RECOMMENDATION: Provide manway davits.

z. Shell Valves OBSERVATION: The 6-inch fill and 6-inch issue nozzles are each equipped with a 6-inch x 4-inch internal emergency valve and a 4-inch ¼-turn ball valve instead of double block and bleed plug valves. The flanges on the fill and issue nozzles do not appear to be Class 150. The 4-inch drain piping is equipped with a 4-inch gate valve instead of a DBB valve.

REFERENCE: AW 78-24-27

RECOMMENDATION: At the fill and issue nozzles, remove the existing valves and nozzle flanges.

Provide each with a Class 150 weld neck flange, 6-inch DBB valve and a 6-inch x 4-inch concentric reducer. At the drain nozzle, remove the existing valve and provide a 4-inch DBB valve.

aa. Stilling Wells OBSERVATION: The tank is equipped with two 8-inch stilling wells. The first one contains the ATG displacer and the second is used for manual gauging and sampling. The guides that are welded to the tank floor have also been welded to the stilling well. Current criteria is to provide a gap between the guides and stilling wells to allow for movement resulting from filling and issuing.

REFERENCE: AW 78-24-27

RECOMMENDATION: Remove the welds that secure the guides to the stilling wells.

3. RECOMMENDED REPAIRS as Part of Regular Maintenance Recommended repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Exterior Tank Coating OBSERVATION: Moss and dirt were observed on the exterior tank shell and roof

REFERENCE: DUFC 3-460-03 ¶8-3

RECOMMENDATION: Pressure wash the entire tank to remove the organics.

b. Exterior Coating Failure OBSERVATION: Coating failure and corrosion was observed on the tank floor projection, tank shell at the labels, valve flanges, actuator handles, roof plate, level alarm floats and roof appurtenances.

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Provide surface preparation and recoat. Roof quantity: 30 S.F.

c. Manway Reinforcing Plate Telltale Hole OBSERVATION: The telltale hole in the nozzle reinforcing plate at manway 1 is open. Grease and rust is streaking from the hole.

REFERENCE: API 650 ¶5.7.2.10

RECOMMENDATION: Remove the grease and rust streak. Do not provide a threaded plug. The usual repair is to pack the hole with white grease. However, facility personnel reported that the grease fails due to extreme temperatures. Re-packing the hole is not recommended.

d. Chain to P/V Vent OBSERVATION: The tank is equipped with a 6-inch emergency vent and a 3-inch lever loaded pressure/vacuum vent with a flame arrestor. Facility personnel reported that the internal components of the flame arrestor have been removed. A chain is connected to the weight actuated pressure/vacuum vent and extends to grade. The chain is abrading the coating on the tank shell.

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Remove the combination 3-inch vent and provide a pressure/vacuum vent.

Remove the chain as soon as possible to stop abrasion of the coating.

e. Organic Growth on Piping OBSERVATION: Organic growth was observed on the exterior piping at the 6 o’clock position.

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Pressure wash the piping.

f. Low Point Drain OBSERVATION: The low point drain is in contact with the floor of the concrete secondary containment. Additionally, the piping downstream of the ball valve is cast iron.

REFERENCE: UFC 3-460-03

RECOMMENDATION: Remove the cast iron piping and provide coated carbon steel components.

g. Secondary Containment Sealant OBSERVATION: The tank is located within a concrete containment area. Scattered failure of the sealant in the dike floor and walls was observed.

REFERENCE: UFC 3-460-03, ¶8-10.2

RECOMMENDATION: It is recommended to replace all of the sealant at one time to prevent having sealant of different ages. Remove the sealant from the joints. Clean and prepare concrete surfaces by mechanical means to achieve desired surface profile. Prime surfaces in accordance with manufacturer recommendations. Provide jet fuel resistant polysulfide sealant. Note: Facility personnel reported that a project is in place to execute sealant repairs.

Estimated quantities:

Ringwall-to-Floor Joint: 63 L.F.

Concrete Walls: 75 L.F.

Wall-to-Floor Joint: 140 L.F.

Floor Joints: 310 L.F.

h. Drain Piping OBSERVATION: There is a ¾-inch drain pipe that is open to the atmosphere.

REFERENCE: Best practices

RECOMMENDATION: Provide a ¾-inch threaded plug.

i. Sealant at Dike Wall Penetrations OBSERVATION: The sealant at the dike wall penetrations is cracked and starting to deteriorate.

REFERENCE: UFC 3-460-03, ¶8-10.2

RECOMMENDATION: Remove the degraded sealant at the four dike wall penetrations and provide jet fuel resistant sealant.

j. Testing OBSERVATION: The tank is equipped with an ENRAF ATG system, a high level shut off valve and an independent level alarm system.

REFERENCE: UFC 3-460-03 Appendix C

RECOMMENDATION: Test all level alarms, switches and overfill prevention devices as part of the on-going maintenance program.

k. Nozzle Thickness OBSERVATION: The thickness of the 6-inch Fill and the 6-inch Issue nozzles is schedule 40 instead of the minimum requirement of extra strong (XS).

REFERENCE: API 650 Table 5.6b

RECOMMENDATION: The tank has demonstrated suitable service since 1954 in its current condition. Removal and replacement of the nozzles is not recommended since the tank shell may end up with damage, such as buckling, as a result of the repair effort. The shell thickness is 3/16-inch. It is recommended to monitor the nozzles for changes in condition during routine monthly inspections.

D. INSPECTION INTERVALS

Intervals between tank inspection (both internal and external) should be determined by the tank service history, corrosion rates, and regulatory requirements. Listed below are the recommended inspection intervals.

1. Routine In-Service Inspection Facility personnel shall perform a visual inspection of the tank exterior surfaces and associated piping.

Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (including tank floor projection-to-foundation interface), coating, and appurtenances.

Interval: Monthly

2. External (In-Service) Inspection An API certified inspector shall perform this inspection every five (5) years or RCA/4N years (where RCA is the difference between the measured shell thickness and the minimum required thickness and N is the shell corrosion rate) whichever is less. This inspection includes inspection requirements of the routine in-service inspection as well as a visual inspection of the tank grounding systems (shunts and cables) for damage.

Interval: Five (5 years); 23 February 2023

3. Ultrasonic Thickness Inspection An external UT inspection of the tank shell and roof shall be performed by an API certified inspector every fifteen (15) years or RCA/2N, whichever is less. The inspection may be performed in conjunction with the external in-service inspection.

Interval: Fifteen (15) years; 23 February 2033

4. Internal (Out-of-Service) Inspection An API certified inspector shall perform a visual inspection of the tank interior surfaces and associated piping. The inspection shall include an evaluation of the tank bottom via NDT methods. The inspection identified backside corrosion requiring repair. The interval to the next inspection has been provided below based on whether repairs are performed at this time or deferred until a later date.

Interval: Eight (8) years without repairs; 23 February 2026 Twenty (20) years with repairs; 23 February 2038

APPENDIX A: TANK EVALUATION ITEMS

TANK 5 (802) – API 653 INSPECTION

ARNOLD AFB, TN

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

COATINGS

APPURTENANCES

PIPING

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FOUNDATION

Type Concrete pad

Levelness The tank is relatively level. The maximum measured differential between max and min elevations is 0.48 inches.

The tank passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt The tank is slightly tilted. The amount of tilt is 0.43 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The concrete pad is approximately 18.4-inches above the containment dike floor.

Material Below Tank Floor The material below the tank floor could not be inspected.

Drainage Around Tank Drainage around the tank appears to be adequate.

Tank Anchors The tank is equipped four non-standard anchor straps. The upper end of the strap is welded to the tank shell. The lower end is attached to the face of the concrete pad with a single 1-inch bolt. The concrete is cracked at several of the anchor bolt locations.

Since the concrete is cracked, the tank can no longer be considered as anchored.

Provide repairs to the concrete to prevent the ingress of water and deterioration of the reinforcing steel.

Secondary Containment Tank is located within a concrete lined containment area that includes reinforced concrete walls. Scattered failure of the sealant in the dike floor and walls was observed.

Calculations indicate that the containment area has a storage capacity of 1,068 BBLS.

Remove the sealant in its entirety and replace.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were

Sealed at Foundation

There is no sealant between the tank floor projection and the concrete slab to prevent the intrusion of water below the tank floor. Moss and organics were observed growing within the space.

Remove the organics and provide jet fuel resistant sealant for the full perimeter of the tank.

Additional Foundation Items, Comments or Notes:

None.

FLOOR

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type Lap welded floor.

Annular Ring Plates Tank is not equipped with annular ring plates.

Nominal Thickness Floor consists of 1/4-inch (0.250) thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.229-inch.

Interior Width See floor drawing.

Floor seam welds No relevant indications were found on the floor plate seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found five locations requiring UT prove up.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, five locations of bottom side pitting/corrosion were identified for repair.

Provide lapped patch plates at each location.

Refer to Appendix B for repair locations.

Top Side Floor Pitting/Corrosion

No top side pitting or corrosion was observed on the tank floor.

Patch Plates No patch plates were observed on the tank floor.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted.

Floor Bulges, Depressions No relevant bulges or depressions were noted.

Doubler/Striker Plates Doubler plates were provided at each of the two stilling wells.

Plug Welds No plug welds were observed on the tank floor.

Weld Artifacts No weld artifacts were observed on the tank floor.

Floor Critical Zone No evidence of back side corrosion or thinning was observed within the critical zone.

Floor Projection The floor projection extends an average of 0.825-inches beyond the tank shell. The average thickness is 0.239-inch.

Floor Profile The floor is flat with a slight slope to the near shell floor drain.

Sumps The tank is not equipped with a sump. There is a 4-inch floor drain.

Vacuum Box Testing Vacuum box testing was not performed since the floor is coated.

Secondary Liner Below Floor

No drawings were available for review. It is not known if there is a secondary liner below the floor plate.

Leak Detection Below Floor

The tank is not equipped with leak detection ports below the floor.

FLOOR

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Cathodic Protection The tank floor is not equipped with cathodic protection. Backside corrosion was detected as part of the inspection.

The installation of a CP system is not recommended at this time.

Additional Floor Items, Comments, Notes:

SHELL

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK SHELL

Average Thickness UT Thickness

1st Course 0.172 inch

2nd Course 0.178 inch

3rd Course 0.174 inch

Rim Angle 0.242 inch

Plumbness Visual observations found no noticeable out-of-plumbness.

Roundness No noticeable out-of-roundness was observed.

Dents/Buckles No significant dents or buckles requiring repairs were observed.

Banding/Peaking No significant banding or peaking was observed.

Interior Shell pitting/corrosion

No pits or significant corrosion were observed on the interior of the shell.

Exterior Shell pitting/corrosion

No pits or significant corrosion were observed on the exterior of the shell

Insert plates No insert plates were observed.

Welded Patch Plates No welded patch plates were observed.

Interior Shell Welds Visual inspection of accessible interior shell welds found no indications for further inspections or examinations.

Exterior Shell Welds Visual inspection of accessible exterior shell welds

Door sheet None present.

Shell-to Floor Weld – Interior

Visual inspection of the interior floor-to-shell weld

Shell-to Floor Weld – Exterior

Visual inspection of the exterior floor-to-shell weld

Shell Manholes The tank is equipped with one 30-inch manhole and one 18-inch manhole in the 1st shell course.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Temperature Probe Tank is not equipped with a shell mounted temperature probe.

Shell Reinforcing Plates

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Manholes

(Size, Thickness, Telltale Hole)

Manhole 1:

Size: 30-inch diameter nozzle, 0.483-inch thick (UT).

Reinforcing Plate: Diamond shaped, 81-inch x wide x 66-inch tall x 0.236-inch thick (UT). The clearance between the underside of the reinforcing plate to the floor-to-shell weld is less than the API requirement of 3-inches.

The telltale hole is open.

Manhole 2:

Size: 18-inch diameter nozzle, 0.181-inch thick (UT).

Reinforcing Plate: None

Provide magnetic particle examination of the non-compliant welds.

Refer to the report body for further discussion on the lack of nozzle reinforcing plate.

Floor Drain

(Size, Thickness, Telltale Hole)

Size: 4-inch diameter nozzle, 0.225-inch thick (UT).

Reinforcing Plate: None.

Refer to the report body for further discussion on the lack of nozzle reinforcing plate.

Pressure Relief for Issue Piping

(Size, Thickness, Telltale Hole)

Size: 3/4-inch diameter nozzle, unable to measure UT since nozzle is a threaded half coupling.

Reinforcing Plate: None.

A reinforcing plate is not required.

Issue

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.272-inch thick (UT). The thickness is less than the API minimum requirement of extra strong (0.432-inch).

Reinforcing Plate: None.

Replacement of the nozzle is not recommended at this time. Monitor the nozzle for changes in condition during routine maintenance

Refer to the report body for further discussion on the lack of nozzle reinforcing plate.

Fill

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.266-inch thick (UT). The thickness is less than the API minimum requirement of extra strong (0.432-inch). The clearance between the underside of the nozzle to the floor-to-shell weld is less than the API requirement of 3-inches

Reinforcing Plate: None.

Replacement of the nozzle is not recommended at this time. Monitor the nozzle for changes in condition during routine maintenance

Provide magnetic particle examination of the non-compliant welds.

Refer to the report body for further discussion on the lack of nozzle reinforcing plate.

Pressure Relief for Fill Piping

(Size, Thickness, Telltale Hole)

Size: 3/4-inch diameter nozzle, unable to measure UT since nozzle is a threaded half coupling.

Reinforcing Plate: None.

A reinforcing plate is not required.

Shell Vents Tank is not equipped with shell vents.

Overflow Ports Tank is not equipped with overflow ports. Overflow ports are not required since the tank is not equipped with a floating pan.

Wind Girders and Shell Stiffeners (Size & Elevation)

Tank is not equipped with wind girders or shell stiffeners.

Calculations indicate that a shell stiffener is not required.

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Tank Nameplate Data:

Repaired/Altered by CAPE

Installed (2) 8” gauge poles, level alarms, ladder and handrails.

Original year of construction: 1954

Year completed: 2008

Nominal diameter: 20’-0”

Nominal height: 18’-0”

Design liquid level: 16’-8”

Maximum capacity: 1,000 BBL

Design specific gravity: 0.84

Design pressure: atmospheric

Maximum design temperature: 200 deg. F.

Additional Shell Items, Comments or Notes:

The label identifying the tank number has detached from the tank shell. Provide tank labelling.

ROOF

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK ROOF (See Tank Appurtenances for ATG, Gauging, Level Alarms, etc.)

Type Self-supported fixed cone up roof.

Roof Plate Thickness The roof consists of 3/16-inch (0.188) thick lap welded roof plates. Average measured thickness is 0.184-inch (UT).

Roof Joints Visual inspection from below the roof found no indications of leakage.

Roof Topside Pitting/corrosion

No significant pitting or corrosion was identified on the topside of the roof.

Roof Topside Condition No significant distortions present. No water ponding areas were observed.

Roof Welds Visual inspection of roof topside plate welds found no significant indications requiring further examination.

Frangible Joint (Size/Condition)

Tanks with a diameter in excess of 50 feet and designed with a frangible joint to API 650, are considered adequate for emergency venting.

Since the diameter of the tank is only 20 feet and does not meet the construction requirements of API 650 5.10.2.6, it is not considered to have a frangible joint.

The tank is equipped with a 6-inch Oceco emergency vent. Calculations indicate that the total capacity of the existing emergency and pressure/vacuum vent is less than required.

Remove the existing 6-inch emergency vent and provide an 8-inch emergency vent.

Roof Vents (Size & Type) The tank is equipped with one 6-inch emergency vent and one 3-inch pressure/vacuum vent with flame arrestor.

Facility personnel reported that the internal components of the flame arrestor have been removed.

Roof Manhole The tank is not equipped with any roof manholes.

Roof Hatch The tank is not equipped with a roof hatch. A roof hatch is not required since the tank is not equipped with a floating pan.

Roof Nozzles (3) 1.5-inch for tape gauge and guide wires

Roof Framing/Roof Underside Condition

Visual inspection of the underside of the roof from the tank floor found no indication of leaks and no areas of significant corrosion or other degradation.

Interior Columns The tank is not equipped with any support columns. The roof is self-supporting.

Additional Roof Items, Comments or Notes:

COATINGS

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Exterior Coatings

Shell

Type/age Thin-film epoxy. The age of the coating system is not known.

General Condition The coating is generally in good condition.

Moss and dirt were observed.

There is a chain that extends from grade to the top of the tank at the lever loaded pressure/vacuum vent. The chain is abrading the coating on the tank shell.

Pressure wash the entire tank to remove the organics.

Remove the chain.

Nominal Thickness The average thickness of the shell coating is

14.9 mils; with a maximum thickness of 20.1 mils and a minimum thickness of 11.3 mils.

Lead and Chromate Testing Not performed.

Roof

Type/age Thin-film epoxy. The age of the coating system is not known.

General Condition The coating is generally in good condition.

Minor coating failure and corrosion was observed on the roof plate.

Moss and dirt were observed.

Provide surface preparation and recoat affected areas.

Pressure wash the entire tank to remove the organics.

Nominal Thickness The average thickness of the roof coating is

13.0 mils; with a maximum thickness of 18.0 mils and a minimum thickness of 7.3 mils.

Interior Coatings

Floor

Type/age Thick-film epoxy. Installation date is not known. Excerpts from the 1999 OOS reports indicate that the floor was uncoated at that time.

General Condition The interior floor coating is generally in good condition. Minor coating failures were observed. The failures appear to be the result of welding that occurred during the installation of the stilling wells in 2008.

Provide coating repairs.

Nominal Thickness The average thickness of the floor coating is

55.4 mils; with a maximum thickness of 75.9 mils and a minimum thickness of 35.1 mils.

Shell

Type/age Thin-film epoxy. Installation date is not known. Excerpts from the 1999 OOS reports indicate that the shell was uncoated at that time.

COATINGS

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

General Condition The coating is generally in good condition.

The interior nozzles for the ¾-inch pressure relief piping are partially blocked with coating.

Remove the excess coating.

Nominal Thickness The average thickness of the 1st shell coating is 26.5 mils; with a maximum thickness of

39.2 mils and a minimum thickness of 13.0 mils.

Underside Roof

Type/age Uncoated. Recommend coating the underside of the roof plate.

Additional Coating Items, Comments or Notes:

APPURTENANCES

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK APPURTENANCES

Float Gauge The tank is equipped with a Varec tape gauge system. Facility personnel did not report any concerns with the system.

ATG (Automatic Tank Gauging) or RTG (Remote Tank Gauging) System

The tank is equipped with an ENRAF ATG system.

HI/HI-HI Level Alarms The high and high-high level alarms are integrated into the ENRAF ATG system.

Low/Low-Low Level Alarms The low level alarms are integrated into the ENRAF ATG system.

Independent Level Alarms The tank is equipped with an independent level alarm system.

Facility personnel reported that the alarm levels are set at the same elevations as the ENRAF system.

Temperature Probe The tank has a temperature probe that is part of the ENRAF ATG system.

Stilling Wells

ATG The ATG displacer is located within an 8-inch near-shell stilling well. The displacer was not retracted at the time of the inspection.

Contact SPAWAR to review the ATG system to verify accuracy.

Sampling/Testing/Hand Gauging

Manual gauging and sampling is performed at an 8-inch near-shell stilling well.

Water/Temperature Probe

The temperature probe is not located within a 6-inch stilling well as required by current military criteria.

Provide a 6-inch slotted stilling well above the near shell floor drain. Confirm need for bottom water sampling with facility personnel.

Fire Suppression System The tank is not equipped with a fire suppression system.

Product Saver Tank (PST) Tank is equipped with a product saver tank.

Tank Grounding The tank is equipped with one grounding wire attached to tank shell. It appears that the installation of a second ground was started but not completed.

Complete the installation of the ground wire.

Internal Ladders The tank is not equipped with an internal ladder.

An internal ladder is not required since the tank is not equipped with a floating pan.

Roof Access from Ground (Stairs)

Roof access is via a ladder that is supported from the shell.

Roof Access from Adjacent Tanks

There is no roof access to adjacent tanks.

Roof Handrails The tank is equipped with a partial perimeter roof handrail.

Additional Appurtenance Items, Comments or Notes:

Strapping charts were available for review. The tank was strapped in 2008 and the charts have 1/16-inch gradations.

PIPING

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

PIPING

Drain

Interior Piping Size: 4-inch nozzle, 0.310-inch thick welded to the tank floor. (UT).

There is no interior piping.

Exterior Piping Size: 4-inch diameter

Valve (Type/Condition) Valve: 4-inch, class 150, Hamer gate valve with manual operator. Minor coating failure and corrosion.

Remove the gate valve and provide a 4-inch DBB steel plug valve.

Provide coating repairs.

Pressure Relief Piping None present. Not required.

Issue

Interior Piping Size: 6-inch nozzle, unable to record UT due to lack of pipe extension inward from shell.

The nozzle is not equipped with interior piping.

Provide interior piping. Review need for piping with facility personnel based on existing operations.

Exterior Piping Size: Reduces to 4-inch diameter at emergency valve.

Valve (Type/Condition) Valve: 6x4 emergency valve and a 4-inch, class 150, ¼-turn ball valve with manual actuator. Minor coating failure and corrosion.

Remove the valves and provide a 6-inch DBB steel plug valve.

Provide coating repairs.

Pressure Relief Piping 3/4-inch steel piping with threaded connections thermal safety relief valve set at 166 psi. The piping is not equipped with an isolation valve.

Provide a ¾-inch ¼-turn ball valve.

Fill

Interior Piping Size: 6-inch nozzle, 0.260-inch thick (UT).

There is no interior piping.

Provide interior piping, including a diffuser.

Review need for piping with facility personnel based on existing operations.

Exterior Piping Size: Reduces to 4-inch diameter at emergency valve.

Valve (Type/Condition) Valve: 6x4 emergency valve and a 4-inch, class 150, ¼-turn ball valve with manual actuator. Minor coating failure and corrosion.

Remove the valves and provide a 6-inch DBB steel plug valve.

Provide coating repairs.

High Level Shut-Off Valve (Type/Condition)

Tank is equipped with a Cla-Val hydraulically operated high level shut off valve on the exterior piping.

Pressure Relief Piping 3/4-inch steel piping with threaded connections, a thermal safety relief valve set at 166 psi and a ¼-turn ball valve for isolation.

Additional Piping Items, Comments or Notes:

END OF DATA

APPENDIX B: ENGINEERING CALCULATIONS AND DRAWINGS

1. FLOOR DRAWING

2. INTERIOR FLOOR UT AND COATING

3. INTERIOR FLOOR CRITICAL ZONE UT

4. FLOOR PROJECTION

5. FLOOR CORROSION CALCULATIONS

6. FLOOR REPAIR LOCATIONS

7. TILT CALCULATIONS

8. SETTLEMENT CALCULATIONS

9. SHELL ELEVATION DRAWING

10. EXTERIOR SHELL UT AND COATING

11. EXTERIOR 1ST SHELL COURSE UT

12. INTERIOR 1ST SHELL COURSE COATING

13. SHELL MANHOLE AND NOZZLE UT

14. SHELL CORROSION CALCULATIONS

15. ROOF DRAWING

16. ROOF EXTERIOR…