Attachment J.1 - ERK-FAC 77526-Tank 124-Final-2016.pdf

ACOE CONTRACT W911KB-15-D-0001, TASK ORDER 0004

TANK 124 (FACILITY NO. 77526)

API 653 OUT-OF-SERVICE INSPECTION

AND SUITABILITY FOR SERVICE

EVALUATION

FINAL

(PRE-REPAIR)

Eareckson Air Station, Shemya Island, Alaska

July 2016

Contract Agency:

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

Prepared By:

Michael B. Morris, P.E., API 653 Certificate No. 56148 Bill Brookins, P.E.

Submitted By:

Kelly B. Waring, P.E.

Principal, API 653 Certificate No. 21992 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 8691

Page Intentionally Left Blank

SUITABILITY FOR SERVICE STATEMENT – TANK 124

Enterprise Engineering, Inc. (EEI) has completed an out-of-service external and internal inspection and suitability for service evaluation of Tank 124 at Eareckson Air Station, Shemya, Alaska. The inspection was performed in two mobilizations, the first occurring April 13 – 18, 2016 for the external inspection (performed concurrently with a separate project, prior to tank cleaning) and the second occurring May 16

– 18, 2016 for the internal inspection.

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 no later than April 2021 (5 years from this 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 May 2036 (20 years from this 2016 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653 and ADEC Regulation 18AAC75, this report satisfies the requirement for an out-of-service, tank 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.

July 22, 2016 Michael B. Morris, P.E.

API 653 AST Inspector Certificate No. 56148

This tank inspection has determined that mandatory repairs are required for continued long term service. Following completion of the mandatory repairs, Tank 124 will be considered suitable for continued service.

FNC1052

Highlight

FNC1052

Highlight

Tank 124 – API 653 Inspection TABLE OF CONTENTS Eareckson Air Station, Shemya Island, Alaska July 2016 EEI Project No.: 8691

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs (Mandatory) Recommended Repairs (Non-Mandatory) Recommended Repairs and Upgrades for Long Term Serviceability

COATING SYSTEM

Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

CLOSURE

Conclusions Project Team

APPENDICES

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

Tank 124 – API 653 Inspection Page 1

EEI Project No.: 8691

TANK 124

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

EARECKSON AIR STATION (ERK), ALASKA

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an out-of-service internal and external inspection of Tank 124 at Eareckson Air Station, Shemya Island, Alaska. The inspection was performed in two mobilizations, the first occurring April 13 – 18, 2016 for the external inspection (performed concurrently with a separate project, prior to tank cleaning) and the second occurring May 16 – 18, 2016 for the internal inspection. The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 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

Tank 124 is a field erected aboveground storage tank. The tank was originally fabricated and erected in 1988. The tank is 100 feet in diameter and 40 feet high and is of welded construction with butt-welded shell plates and lap welded floor and roof plates. The tank floor is cone down with a center sump. The nominal shell capacity is 55,000 Bbls and includes a column supported fixed cone roof. The tank is not equipped with a floating pan. Tank 124 is currently in JP-8 service.

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.

This tank inspection has determined that mandatory repairs are required prior to returning the tank to service. Following completion of the mandatory repairs, Tank 124 will be suitable for continued 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 floor, shell, and roof found no holes or indications of leaks. A thin-film liner prevented a topside pit survey. A magnetic flux leakage (MFL) scan of the floor found no relevant indications of corrosion on the bottom side of the floor requiring repair.

Visual inspection of the floor found non-compliant weld clearances at four locations between patch plates and radial column doubler plates. Additional inspection by magnetic particle testing is required at these

Tank 124 – API 653 Inspection Page 2

EEI Project No.: 8691 locations. Following completion of the additional inspection the hydraulic integrity of the tank will be acceptable (assuming no indications are found; contact EEI for further direction if indications are found).

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 attachment.

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

Next Inspection

API 653 requires an in-service inspection 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.

EEI recommends that the next external in-service inspection be scheduled no later than April 2021 (5 years from 2016 inspection), or sooner if a change in condition has occurred.

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires the interval until the next internal in section 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. When RBI procedures are used the interval shall not exceed 25. If the tank has a release prevention barrier and leak detection designed in accordance with API 650 Appendix I and RBI procedures are used, the interval shall not exceed 30 years. As an RBI assessment is not included in the scope of this inspection, the interval until the next out-of-service inspection was determined using corrosion rates.

It should be noted that ADEC may reduce the inspection interval for a specific storage tank if:

(a) The storage tank is older than 30 years,

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion or foundation problems, or

(d) After a significant seismic event.

EEI recommends the next API 653 out-of-service inspection be performed no later than May 2036 (20 years from this 2016 inspection) or sooner if a change in condition or a change in service occurs.

Tank 124 – API 653 Inspection Page 3

EEI Project No.: 8691

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) and recommended for long term serviceability. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

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 are repairs that are critical to the hydraulic and structural integrity of the tank and are required prior to returning Tank 124 to service.

1. Non-compliant weld clearances have been identified with respect to floor patch plates and the radial column doubler plates on columns R1, R2, R4, and R5. Figure 9.13 of API 653 requires a minimum distance of 2-inch between patch plates and other fillet welds. Additional inspection is required per API 653 9.10.3.1. Additionally, non-compliant weld clearances were identified with respect to the shell door sheet. Specifically, the door sheet does not intersect the vertical weld seam at a 90-degree angle. Additional inspection is required per API 653 4.3.9.1.

• Remove the coating from the non-compliant welds prior to performing magnetic particle testing.

Remove the coating by high pressure water or chemical stripping methods and not by mechanical or sandblasting methods.

• Perform magnetic particle testing of the weld along the edge of the patch plates and the edge of the doubler plate at these locations. Existing welds that are not modified or affected by repairs are acceptable for continued service if the welds have no rejectable defects or indications.

• Contact EEI for further direction if any weld defects are observed.

• Repair coatings at affected areas.

• Provide stenciling on the tank indicating the date and type of testing performed. A record of the testing shall be placed in the tank file in the Fuels Building.

Although the inspection step is considered mandatory under API 653 provisions, it is very unlikely such testing will result in any work other than light grinding of the weld, MT testing and restoration work. The tank has been in service in its present condition for over 20 years and has performed adequately. There is no compelling reason to repair the condition other than it is a violation of API 653.

Tank 124 – API 653 Inspection Page 4

EEI Project No.: 8691

2. The internal fill piping is equipped with one pipe support. The pipe support consists of an 8-inch diameter piece of pipe with a 2-foot square base plate. The base plate is not seal welded to the tank floor. The condition of the tank floor below the base plate is indeterminate. Provide one of the following repairs:

• Option 1: Provide a 1/4-inch thick by 28-inch square carbon steel doubler plate with rounded corners below the base plate. Remove dirt/debris below the base plate prior to installing the doubler plate. Maintain 2-inch clearance from floor plate lap weld seams. Coat all affected areas following completion of repairs.

• Option 2: Cut the piping free from the base plate. Cut piping free one foot from tank shell and set aside. Round the corners on the existing 2-foot square base plate (2-inch radius). Clean the area below the base plate. Seal weld the base plate to the tank floor. Provide a new 12-inch diameter by 3/8-inch thick base plate for the pipe support base. Reconnect piping with slip on flanges. Coat all affected areas following completion of repairs.

Recommended Repairs (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends performing these repairs for the long term preservation and integrity of the tank.

1. Coating failure and corrosion was identified on the support brackets for the high level piloting and conduit.

• Remove the existing support brackets and provide welded brackets to tank shell at five (5) locations.

• Perform interior and exterior coating repairs at these locations.

2. A 32-inch long portion of the tape gauge conduit is corroded on the tank roof.

• Remove corroded portion of piping and provide a new piping segment. Provide an exterior coating system on the new piping segment.

3. Remove existing corroded mechanical coupling on 6-inch roof ATG nozzle.

• Provide new 6-inch carbon steel roof nozzle and flange. Protect the floor from falling debris and welding/grinding sparks while performing repairs.

• Provide an exterior coating system on the topside of the roof. Repair affected areas of coating on the underside of the affected roof plates where welding damaged the coating system.

• Note: Coordinate with stilling well recommendations.

4. Coating failure and minor corrosion was identified on the roof hand railing.

• Provide surface preparation and recoat the entire perimeter handrail on the tank roof.

5. Aggressive corrosion was identified on the level alarm module on the tank roof.

• Remove the existing module and provide a Magnetrol level alarm system to match existing.

Model: B15-1E2E-AOB. SN: 545994-01-001.

6. The bolts on the two 30-inch roof manways were experiencing coating failure and corrosion.

• Provide new bolts on both 30-inch manways.

Tank 124 – API 653 Inspection Page 5

EEI Project No.: 8691

7. The pressure relief loop piping was experiencing coating failure and corrosion (two pressure relief valves total; the discharge of the relief valves for the issue line and fill line are manifolded together).

• Provide two 3/4-inch flanged PSV valves, three stainless steel ball valves for isolation, ANSI class 150 stainless steel flanges, and two blind flanges (for test tees).

8. The 3-inch DB&B plug valve located on a tee off of the issue line (used for localized tank low fuel drain down) was experiencing aggressive corrosion.

• Remove existing valve and provide ANSI class 150 carbon steel DB&B plug valve with stainless steel body cavity relief piping.

• Note: Due to long lead times and the accelerated schedule for placing the tank back in to service due to the fall fuel barge delivery, a ball valve with blind flange will be provided in lieu of a plug valve.

9. The telltale hole in the fill line reinforcing plate is open to the atmosphere.

• Pack the telltale hole with White grease to prevent moisture ingress between the reinforcing plate and the tank shell.

10. Remove corroded body cavity relief piping on five DB&B valves. Remove corroded LRDTR piping on one (1) DB&B valve.

• Provide stainless steel valves, piping and tubing. Install the BCR piping to relieve away from the tank.

11. Replace bolts on (6) 8-inch flanges, (3) 6-inch flanges, (1) 3-inch flange, and (1) 2-inch flange. Four of the 8-inch flanges are located in the northeast end of the containment area and two are located on the east end of the containment area near the soil-to-air interfaces. The 6-inch flanges are located on the fill, issue, and low fuel nozzles on the set closest to the tank shell. The 3-inch flange is located on the water-draw off nozzle on the set closest to the tank shell. The 2-inch flange is located in the low point drain pit at the east end of the containment area.

• Provide Grade B7 carbon steel bolts.

12. Remove two high point vents and three low point drains on the fill and issue piping.

• Provide two 3/4-inch flanged stainless steel ball valves, two 3/4-inch stainless steel flanges, and two flanged camlocks.

• Provide three 1-1/2-inch flanged stainless steel ball valves, three stainless steel flanges and three flanged camlocks.

13. The sealant between the floor projection (chine) and concrete ringwall has disbonded (360o).

• Remove all of the sealant, clean the surfaces in accordance with sealant manufacturer’s instructions, and provide jet fuel-resistant polysulfide sealant.

14. Coating failure and corrosion was identified on the edge of the floor projection (chine).

• Provide surface preparation and recoat the edge of the floor projection (360o).

15. Coating failure and corrosion was identified on the anchor bolts and anchor chairs (36 anchors).

• Provide surface preparation and recoat the anchor bolts and chairs.

16. Coating failure and corrosion was identified on the shell wind girder (approximately 15 sq. ft.).

• Provide surface preparation and recoat the affected areas of the wind girder.

Tank 124 – API 653 Inspection Page 6

EEI Project No.: 8691

17. Over time, the dike aggregate that is ballast for the liner system has been displaced from its original location due to wind and vehicles driving in the containment area. Water ponding adjacent to the ringwall was observed.

• Recommend re-grading the aggregate to direct water away from the tank.

18. Organics were observed on the lower 12” to 18” of the tank shell, the wind girder, and on the tank roof.

• Power wash the tank shell.

19. Coating failure and corrosion was identified on the abandoned temperature probes (2 total).

• Remove the abandoned temperature probes and provide lapped patch plates. Patch plates shall be 7/16-inch thick by 6-inch diameter. The welding shall be continuous on the outer perimeter of the repair plate and the inner perimeter of the hole in the shell plate. The minimum hole diameter is 2-inch. Shell openings due to plate removal shall have a minimum corner radius of 2-inch.

Provide a minimum overlap of 1-inch and a maximum overlap of 3.5-inch. Nozzle necks shall be entirely removed prior to installation of a repair plate. The welds of the repair plate shall be full fillet welds.

20. Twenty-five abandoned conduit supports were identified on the tank shell.

• Remove the abandoned supports. Repair coatings at the affected areas.

21. Rigid conduit associated with the Magnetrol level alarm is not secured to the tank roof (approximately 5 feet).

• Secure the conduit to the tank roof at one location. Provide seal welded channel mounting pads with seal welded stainless steel bolting studs for mounting channel to support conduit.

22. Coating failure and corrosion was identified on the tank roof plates (approximately 50 sq. ft.).

• Provide surface preparation and recoat the affected areas.

23. Coating failure and corrosion was identified on the 8x6 nozzle and flange for the Vito probe (for the ATG system) on the 30-inch roof manway.

• Provide surface preparation and recoat the affected areas.

24. The stainless steel latches on the ATG nozzle cover have failed.

• Replace the latches.

25. Coating failure and corrosion was identified on the atmospheric roof vents on the flange, screen, and mounting hardware (two roof vents total).

• Provide surface preparation and recoat the affected areas.

• Replace the screens and mounting hardware.

26. The conduit for the ATG on the roof is equipped with unistrut pipe supports however the supports are not secured to the tank roof.

• Secure the conduit to the tank roof. Provide seal welded channel mounting pads with seal welded stainless steel bolting studs for mounting channel to support conduit.

27. The clamps securing the ATG conduit to the roof railing kick plates are corroded.

• Replace clamps.

Tank 124 – API 653 Inspection Page 7

EEI Project No.: 8691

28. Coating failure and corrosion was identified on the painters post on the roof (6-inch nozzle).

• Provide surface preparation and recoat the affected areas.

29. Coating failure and corrosion was identified on the backside of shell manhole-1.

• Provide surface preparation and recoat the affected areas.

30. Coating failure and corrosion was identified on the rim angle (approximately 10 linear feet).

• Provide surface preparation and recoat the affected areas.

31. Coating failure and corrosion was identified on the product saver tank and the product saver tank piping and appurtenances.

• Provide surface preparation and recoat the affected areas.

32. The hand pump on the product saver tank is reportedly non-functional.

• Replace the hand pump.

33. The tape gauge system float is not retracting properly.

• Service the tape gauge system so it retracts properly.

34. Coating failure was identified on the interior of the tank on the tank floor plates, column base plates, interior piping, shell, and at the sump. An approximately 4-foot square area of coating failure was identified in the tank sump. Five locations of coating failure were approximately 1 square foot and approximately 50 chips (1-inch diameter) were identified.

• Provide surface preparation and recoat the affected areas.

35. The existing stilling wells were evaluated for compliance with the DESC/DLA Memorandum and

UFC 3-460-01.

• Water Probe: Provide an 8-inch roof nozzle located as close as feasible to the tank sump.

o Note: There is a cap plate at the top of the center column approximately 70-inch diameter which may prevent placing the nozzle directly over the sump.

• ATG Displacer: Provide slotted 8-inch diameter aluminum stilling well with 10-inch roof nozzle.

• Manual Gauging and Sampling: Provide slotted 8-inch aluminum stilling well with 10-inch roof nozzle.

• Provide an exterior coating system on new roof nozzles. Repair coatings at underside of tank roof at affected areas. Protect the floor from falling debris while performing repairs.

36. The tank is not equipped with a nameplate.

• Provide the tank with a nameplate.

37. The tank is not equipped with grounding lugs.

• Provide two grounding lugs with grounding rods located 180 degrees apart in accordance with the AST definitive design. Repair the containment area liner at grounding rod location.

38. Provide surface preparation and recoat all interior and exterior repair areas and areas that are damaged as a result of repairs in accordance with Coating Requirements (Appendix H). When welding on the shell or roof, the coating on the opposite side from the weld shall be inspected and repaired when damaged.

Tank 124 – API 653 Inspection Page 8

EEI Project No.: 8691

Recommended Repairs and Upgrades for Long Term Serviceability

1. Program the tank for the next API 653 in-service external inspection no later than April 2021 and the next API 653 out-of-service internal and external inspection no later than May 2036.

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

3. Tank 124 last received an exterior recoat circa 2000. The exterior coating system is generally in acceptable condition. Continue to monitor coating system every five years at in service inspections.

4. At the next out-of-service interval, or sooner if the tank can be removed from service, provide the ability to test the high level alarms and high level shutoff valve test capabilities with the use of the product saver pump. Repair includes routing tubing from the product saver pump to the float piping.

Weld brackets on the tank shell to secure the tubing.

5. The tank issue line extends inwards approximately 30-inches and is not equipped with an anti-vortex plate. The tank issue line does not meet the current definitive design. Extend the issue line inwards to 1/2 of the tank radius and provide an anti-vortex plate. Due to the accelerated timeline of placing the tank back in service due to the fall fuel barge delivery, it is recommended this repair be performed when the tank can be removed from service.

6. The tank is equipped with a roof mounted Magnetrol high level alarm. The tank high level alarms do not meet the definitive design. Provide shell mounted high and high-high level alarms floats and nozzles per the definitive design. The level alarms shall be located so that they may be accessed by the shell spiral stairway. Due to the accelerated timeline of placing the tank back in service due to the fall fuel barge delivery, it is recommended this repair be performed when the tank can be removed from service.

COATING SYSTEM

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.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

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

Floor: 0.002707 inches per year

Shell: Negligible – Plate thickness is within mill tolerance

Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates for the floor, shell, and roof were calculated using an assumed original metal thickness and a 1988 year of construction.

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 12.5 mils, is a thin-film lining. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The floor coating is 16 years

Tank 124 – API 653 Inspection Page 9

EEI Project No.: 8691 old. Since the coating was in good condition, a nominal unrepaired pit depth was not assumed in the calculations. No pits on the floor plates requiring repair were identified.

Bottom side corrosion with small volumetric metal loss may be present and not detected by MFL scanning. The metal loss used to calculate the bottom side corrosion rate was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits. The MFL floor scanner is not configured to indicate (alarm) for minor metal loss. The tank is not equipped with a cathodic protection (CP) system. For tanks without effective CP, the bottom side corrosion rate (UPr) is the lesser of the MFL threshold or the minimum thickness of a corroded area.

The minimum remaining thickness (MRT) used in the calculations is based on API 653 Section 4.4.5 and Table 4.4. The tank is equipped with the means to detect and contain a bottom leak. It was reported (confirmed with historical design drawings) that there is a liner beneath the sand cushion. Based on this information, the MRT used in the calculations is 0.050-inch.

It was found that the tank floor plate thickness will not be reduced below the limiting MRT at a 20-year inspection interval.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 124:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 124 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Visual inspection of the floor plate joints found no relevant indications. MFL scanning of the floor found no indication of active corrosion on the bottom side. A pit survey was conducted for topside corrosion and no pits were identified requiring repair.

Non-compliant weld clearances were identified with respect to floor patch plates and the radial column doubler plates on columns R1, R2, R4, and R5.

Additional inspection is required per API 653 9.10.3.1.

Based upon the calculated corrosion rate, the floor plate thickness will not be reduced below the requirements for minimum floor plate thickness of 0.05 inch at a 20-year inspection interval.

Acceptable after repair.

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 Spot ultrasonic testing of the roof plates found no noticeable thinning of the plates.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

Tank 124 – API 653 Inspection Page 10

EEI Project No.: 8691

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Hydrostatic Test

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

Acceptable

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): Yes, constructed in 1988.

2. Has a prior hydrotest been performed demonstrating fitness: Unknown

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, with a first shell course thickness less than 0.5 inches does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank shell stresses are within limits at the current fill height of 38 feet 6 inches. Tank resistance to seismic sliding satisfies criteria. There is no required minimum fill height to prevent uplift.

Calculations were performed utilizing the specific gravity for JP-8 (S.G. = 0.84), seismic parameters Ss = 1.5, S1 = 0.6, an importance factor of 1.25.

Acceptable

Wind Evaluation

A wind analysis was performed per API 650, Section

5.11. Calculations were performed using an importance

factor of 1.15 and a wind velocity of 178 mph.

The evaluation determined that an empty tank is not at risk of overturning. A minimum fill level of 4 3/4-inches of product is required in addition to the anchors to prevent the tank from sliding.

Evaluation of the shell buckling determined that the shell requires a wind stiffener. The tank is equipped with an intermediate shell stiffener.

The wind evaluation indicates that an empty tank is at risk of sliding.

Based on the past performance of the tank, a change in tank use is not required.

CLOSURE

Conclusions

Mandatory repairs were identified for Tank 124. Following completion of the mandatory repairs, Tank 124 will be suitable for continued service.

Tank 124 – API 653 Inspection Page 11

EEI Project No.: 8691

Project Team

Site Team (Trip 1)

Adam W. Ludemann, P.E. Mechanical Engineer, API 653 AST Inspector Certificate No. 44035, API 570 Piping Inspector Certificate No. 37927

Site Team (Trip 2)

Michael B. Morris, P.E. Mechanical Engineer, API 653 AST Inspector Certificate No. 56148, API 570 Piping Inspector Certificate No. 51732 API Inspector of Record

Bill Brookins, P.E. Structural Engineer, Tank Technician

Kristopher R. Homerding Tank Technician

Support Team

Stacy M. Kaplan-McMillan Project Manager

David A. Stchyrba, P.E. Structural Engineer, API 653 AST Inspector Certificate No. 27187

Kelly B. Waring, P.E. Principal Engineer, QA Review, API 653 AST Inspector Certificate No.

21992

APPENDIX A

Tank Inspection Data Sheet and

Evaluation Items

Tank 124 – API 653 Inspection Appendix A, TANK SUMMARY SHEET Eareckson Air Station, Shemya Alaska EEI Project No.: 8691

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Eareckson Air Station, Shemya, Alaska Tank No. 124

Facility No. 77526 Inspection Date(s): April 13 to April 18 (external) and May 16 to May 18 (internal), 2016

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

Contract Number, Task Order: W911KB-15-D-0001, Task Order 0004 Inspector, Certificate #: Michael Morris, P.E.

API-653 AST Inspector Certificate No. 56148

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard Rockford Corporation, 1988, API 650 7th Ed. (Assumed) Diameter: 100’-0" (nominal)

Shell Height: 40'-0" (nominal) Product, Specific Gravity: JP-8, 0.84

Design Pressure / Temperature: Unknown (Missing nameplate). Assumed atmospheric.

Gross Capacity / Nominal Capacity: 55,000 Bbl (nominal)

Safe Fill Height: 38’-6” (Per Facility) GPS Latitude & Longitude: 52 Deg 43’ 55.47” N, 174 Deg 05’ 20.57” W (Source – Google Earth) Foundation Configuration: Concrete Ringwall

Shell Configuration: Butt Welded, 5 courses Roof: Fixed cone up, column supported roof

Cathodic Protection: The tank is not equipped with a CP system. An oiled sand bed and liner is present below the tank floor.

Still Wells: One stilling well present for ATG displacer Last Inspection (Type, Date): In-Service, September 19, 2011 by Enterprise Engineering, Inc.

Last Coated Internally (Product): Epoxy polyamide topcoat, circa 2000.

Last Coated Externally (Product): Corothane 1, circa 2000.

INSPECTION RESULTS

Can tank return to service? Yes, following completion of mandatory repair.

Deficiencies identified as mandatory repairs: Yes, see paragraph titled “Mandatory Repairs” in body of report 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 2021 (5 Years) Out-of-Service: May 2036 (20 Years)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Drawings were available for review.

Tank 124 – API 653 Inspection Appendix A, TABLE OF CONTENTS Eareckson Air Station, Shemya, Alaska EEI Project No.: 8691

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

INTERNAL FLOATING PAN

COATINGS

APPURTENANCES

PIPING

Tank 124 – API 653 Inspection Appendix A, Page 1

EEI Project No.: 8691

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

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

TANK FOUNDATION

Type Concrete ringwall.

Levelness The tank is relatively level. The maximum measured differential between max and min elevations is 0.07 feet (0.84 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

0.34 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The concrete ringwall averages 6 1/8-inches above the containment dike floor.

Material Below Tank Floor The material below the tank floor could not be inspected. Previous inspection reports indicate an oil sand base.

Drainage Around Tank Drainage around the tank appears to be adequate. Some pooling water is visible where truck tires have packed down the dike floor material.

Recommend re-grading the soils within the dike area to original configuration.

Tank Anchors Tank 124 is equipped with 36 anchors equidistant around the tank perimeter.

The anchor bolt diameter is 3-inches with 43-inch high chairs. The anchor at the door insert sheet has been cut and re-welded.

Minor coating failure was identified on the anchor chairs. Recommend cleaning and recoating the affected areas.

Secondary Containment Tank sits within an earthen dike with a membrane liner.

Settlement Tank 124 rests on a concrete ringwall. No concerns.

Erosion/Washouts No indications of washouts or erosion were observed.

Sealed at Foundation

The floor projection is sealed to the concrete ring wall with an elastomeric sealant. The sealant is cracked and failing.

Recommend removing the sealant around the entire perimeter of the tank, clean the surfaces and apply a jet-fuel resistant sealant.

Additional Foundation Items, Comments or Notes:

None.

Tank 124 – API 653 Inspection Appendix A, Page 2

FLOOR

Evaluation Item Finding(s) Comments/Recommendations

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

TANK FLOOR

Type Lap welded steel floor plates.

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

Nominal Thickness Floor consists of 5/16-inch (0.313-inch) thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.306 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 no indications requiring an ultrasonic test (UT) prove-up.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, bottom side pitting/corrosion is not prevalent.

Top Side Floor Pitting/Corrosion

The floor is coated. 6 minor pits/gouges were located, however the coating system was installed over the pits and the coating was well adhered.

No repairs required on floor pits with adhered coatings.

Patch Plates Six 4-inch diameter lapped patch plates were observed on the floor. It was previously reported by Operations personnel that the patches were placed over test holes cut into the floor to allow examination of the sub-base material. The plates are seal welded to the floor, do not exhibit any signs of distress and are not in the vicinity of either floor lap welds or the critical zone.

Non-compliant weld clearances have been identified with respect to floor patch plates and the radial column doubler plates on columns R1, R2, R4, and R5. Additional inspection is required per API 653. See Main Body for additional information.

The patch plates do not meet minimum 6-inch dimension per 9.10.1.1b of API 653.

No repairs are recommended at this time.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted. Measurements taken for edge settlement at 10 equidistant locations pass API 653, Appendix B criteria.

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

Doubler/Striker Plates The base plates for the eight perimeter roof support columns rest on 1/4-inch thick by 40-inch square doubler plates. The base plate for the center roof support column rests on a doubler plate 1/4-inch thick x 13-inch diameter.

A 20-inch diameter doubler plate is located below the 6-inch diameter gauge tube.

The interior piping supports for the fill line, low

Provide a 3-foot square by 1/4-inch thick doubler plate under the diffuser support.

See Main Body for additional information.

Tank 124 – API 653 Inspection Appendix A, Page 3

EEI Project No.: 8691

FLOOR

Evaluation Item Finding(s) Comments/Recommendations

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

fuel line and water draw-off line have legs that are welded to the floor with support plates.

Visual inspection of the support plate welds found no indications for further examination.

A doubler plate is needed under the under the diffuser support plate. Currently the 2-foot square by 1/4-inch thick plate rests on the floor plate and the tank floor underneath cannot be inspected.

Plug Welds No plug welds were observed.

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 2.10-inches beyond the tank shell. The average thickness is 0.298-inch.

Coating failure and corrosion are evident.

Recommend cleaning and recoating the affected areas.

Floor Profile The floor is sloped with one center sump. The differential height from the center of the tank is 3.87 feet. The tank floor has an average slope of 5.13% from the tank shell to the center of the tank.

Sumps Tank 124 has one 71-inch diameter center sump that is 17.5-inches deep.

The sump has a 2-inch diameter water draw-off and 6-inch diameter low fuel line that sit 2-inches and 5 1/2-inches above the bottom of the sump respectively. UT thickness readings of the sump plate wall averaged 0.313-inches.

The center roof support column is located in the center of the sump.

Coating failure was noted in the areas beneath the water draw-off and the low fuel lines.

Primarily in the top coat.

Recommend providing coating repairs in the areas affected.

Vacuum Box Testing Vacuum box testing was not performed. The tank floor is coated and no suspect areas were noted.

Secondary Liner Below Floor

Per design drawings secondary liner is present below the tank floor. The liner is not visible from the interior or exterior of the tank and could not be inspected or verified.

Leak Detection Below Floor

Four leak detection standpipes are located equidistant around the perimeter of the tank.

No water was present when viewed by the inspection team.

Tank 124 – API 653 Inspection Appendix A, Page 4

EEI Project No.: 8691

FLOOR

Evaluation Item Finding(s) Comments/Recommendations

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

Cathodic Protection The tank is not equipped with a CP system. An oiled sand bed and liner is present below the tank floor per design drawings.

Additional Floor Items, Comments, Notes:

Tank 124 – API 653 Inspection Appendix A, Page 5

SHELL

Comments/Recommendations

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

TANK SHELL

Average Thickness UT Thickness

1st Course 0.393 inch

2nd Course 0.307 inch

3rd Course 0.248 inch

4th Course 0.248 inch

5th Course 0.245 inch

Rim Angle 0.368 inch

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

Roundness The tank was measured across two diagonal locations with no out-of-roundness noted.

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

Banding/Peaking No significant banding or peaking was

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 as viewed from the ground elevation.

Insert plates No insert plates were observed.

Welded Patch Plates No welded patch plates were observed on the exterior or interior shell surfaces.

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 found no indications for further

Door sheet Tank 124 is equipped with a door sheet. The door sheet was installed as part of the original construction and was improperly installed in the first and second course. The dimensions are 0.390-inches thick, 11-feet wide and 12-feet tall.

The door sheet violates API criteria for replacement shell plate and weld spacing;

additional inspection is required per API 653 (see main body for additional details).

It has been previously reported that a hydrostatic test was performed on the tank shell after the installation of the door sheet (2006 Out of Service Report).

In addition, an engineering evaluation was performed during the 1997 internal inspection and found no concerns for the installation.

Tank 124 – API 653 Inspection Appendix A, Page 6

EEI Project No.: 8691

SHELL

Evaluation Item Finding(s) Comments/Recommendations

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

Shell-to Floor Weld – Interior

Visual inspection of the interior floor-to-shell weld found no indications for further

Shell-to Floor Weld – Exterior

Visual inspection of the exterior floor-to-shell weld found no indications for further

Shell Manholes The tank is equipped with two 30-inch diameter manways.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Water Draw-Off The tank is equipped with a 3-inch diameter, water draw off nozzle. This nozzle is reduced to a 2-inch pipe running into the sump approximately 6-inches after entering the tank.

Temperature Probe The tank was previously equipped with two temperature probes. The two probes have been removed and the nozzles plugged.

Coating failure and corrosion was observed on the abandoned nozzles. Temperature measurements are incorporated as part of the ATG system.

Recommend removing the two abandoned temperature probe nozzles.

See Main Body for additional details

Shell Reinforcing Plates

Manholes

(Size, Thickness, Telltale Hole)

Manhole 1:

Size: 30-inch diameter nozzle, 0.444-inch thick (UT). Severe corrosion was noted on the back side of the flange.

Reinforcing Plate: Tombstone shaped, 64-inch x 68-inch x 0.390-inch thick (UT).

Telltale hole is present on the left side and is packed full of all-purpose grease.

Manhole 2:

Size: 30-inch diameter nozzle, 0.396-inch thick (UT). Severe corrosion was noted on the back side of the flange.

Reinforcing Plate: Tombstone shaped, 64-inch x 68-inch x 0.388-inch thick (UT).

Telltale hole is present on the left side and is packed full of all-purpose grease.

Provide coating repairs to the manhole nozzle flanges.

Fill

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.439-inch thick (UT).

Reinforcing Plate: Diamond shaped, 16-inch x 0.376-inch thick (UT).

Telltale hole is present on the right side and is open to the atmosphere.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Tank 124 – API 653 Inspection Appendix A, Page 7

EEI Project No.: 8691

SHELL

Evaluation Item Finding(s) Comments/Recommendations

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

Issue

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.461-inch thick (UT).

Reinforcing Plate: Diamond shaped, 16-inch x 0.379-inch thick (UT).

Telltale hole is present on the right side and is packed full of all-purpose grease.

Water Draw-Off

(Size, Thickness, Telltale Hole)

Size: 3-inch nozzle, 0.269-inch thick (UT).

Reinforcing Plate: Circular shaped, 10-inch diameter x 0.504-inch thick (UT).

Telltale hole is present on the right side and is packed full of all-purpose grease.

Shell Vents Tank is not equipped with shell vents.

Overflow Ports Tank is not equipped with overflow ports.

Wind Girders and Shell Stiffeners (Size & Elevation)

Tank 124 is equipped with an intermediate shell stiffener. The stiffener is made of a 10-inch x 2 3/4-inch channel (C10x20), with one leg of the channel welded to the tank shell.

The stiffener is located 14-feet 2-inches down from the roof edge. Coating failure and corrosion was identified on the wind girder (approximately 15 sq ft).

Recommend cleaning and recoating the affected areas.

Tank Nameplate Data:

No name plate is present. Recommend providing a tank name plate.

Additional Shell Items, Comments or Notes:

Twenty-five abandoned conduit supports were identified on the tank shell. Recommend removing the abandoned supports.

Organics were identified on the lower 12” to 18” of the tank shell. Recommend removing the organics by power washing.

Stenciled on the tank shell:

Safe fill height:

38’-6”

Tank 124 – API 653 Inspection Appendix A, Page 8

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 Column supported fixed cone roof.

Roof Plate Thickness The roof consists of 1/4 inch (0.25) thick roof plates. Average measured thickness is 0.255 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. Minor organics growth was found around the roof perimeter.

Recommend removing the organics by pressure washer.

Roof Topside Condition

No distortions present. No water ponding areas were observed. Minor oil canning was observed.

The conduits are not secured to the roof and are rubbing the coating off at support locations.

Provide coating repairs at conduit support locations.

Provide positive attachment of the conduit supports to the roof.

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

Frangible Joint (Size/Condition)

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

A separate emergency vent is not required.

Roof Vents (Size & Type) The tank is equipped with two 10-inch atmospheric vent on the tank roof. Coating failure and corrosion was identified on the vent flanges and mounting hardware.

Recommend cleaning and recoating the affected areas. Recommend replacing the mounting hardware.

Roof Hatch/Manholes The roof is equipped with two 30-inch diameter manholes. The bolts on the manholes are corroding.

Recommend replacing the bolts.

Tank 124 – API 653 Inspection Appendix A, Page 9

EEI Project No.: 8691

ROOF

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of…