Attachment J.1 Fac 88071 (Tank 211) - OOS - 2008.pdf

ATMOSPHERIC STORAGE TANK

INTERNAL / EXTERNAL & ULTRASONIC

API 653 OUT-OF-SERVICE INSPECTION REPORT

CAPE FUEL SYSTEMS GROUP

TANK NO. 211

FORT HOOD

KILLEEN, TX

MARCH 5-13, 2008

Prepared by:

HMT Inspection A Division of HMT Inc.

8979 Market Street Rd.

Houston, TX 77029

(713) 676-6150

APIRPT2007.DOT REV 1 222-23960-211r2.doc 3/31/2008 2:22:41 PM

INTRODUCTION

Cape Fuel Systems Group contracted with HMT Inspection, a division of HMT Inc. to provide inspection services for Tank No. 211. The tank is located at the Cape Fuel Systems Facility in Killeen, TX (Fort Hood).

This report documents the findings of the examinations performed on March 5-13, 2008 and provides an evaluation of the inspection results per the applicable criteria of API Standard 653.

The owner / user is responsible for establishing the suitability for service of Tank No.

211 based on the applicable criteria of API 653. This report provides details on current condition from inspection that can be used as a basis in satisfying this requirement if the following conditions are met:

1 The recommendations in Section 2.0 Summary and Repair Recommendations of this report are reviewed, evaluated and implemented (or a decision is made by responsible owner / user representatives to take no further action) prior to return to service and documentation of actions taken (or not taken) is provided for in tank records.

2 The safe fill height recommendations in Section 2.0 Summary and Repair recommendations of this report are adhered to.

HMT Inspection provided the following personnel:

Mike Master API 653 Aboveground Storage Tank Inspector Certification Number 29451

Nestor Vidal, Freylan Brown Level I Technicians

TABLE OF CONTENTS

1.0 DESCRIPTION

2.0 SUMMARY AND REPAIR RECOMMENDATIONS

3.0 DRAWINGS

3.1 BOTTOM LAYOUT

3.2 SHELL LAYOUT

3.3 FIXED ROOF LAYOUT

4.0 INSPECTION REPORT

4.1 FOUNDATION

4.1.1 FOUNDATION INSPECTION CHECKLIST

4.1.2 FOUNDATION SETTLEMENT EVALUATION

4.1.3 FOUNDATION SETTLEMENT SURVEY

4.2 BOTTOM

4.2.1 BOTTOM INSPECTION CHECKLIST

4.2.2 SERVICE INTERVAL

4.3 SHELL

4.3.1 SHELL INSPECTION CHECKLIST

4.3.2 SHELL THICKNESS CALCULATIONS

4.4 NOZZLES AND APPURTENANCES

4.4.1 NOZZLE AND APPURTENANCE INSPECTION CHECKLIST

4.4.2 NOZZLE AND APPURTENANCE TABLE

4.4.2 NOZZLE AND APPURTENANCE TABLE CONT’D

4.5 FIXED ROOF

4.5.1 FIXED ROOF INSPECTION CHECKLIST

4.5.2 FIXED ROOF NOZZLE TABLE

5.0 NDE INSPECTION

5.1 NDE INSPECTION SCOPE

5.2 SIGNIFICANT FINDINGS

5.3 BOTTOM EXAMINATION

5.4 SHELL READINGS

5.5 NOZZLE READINGS

5.6 FIXED ROOF READINGS

5.7 SUMP READINGS

6.0 EQUIPMENT

6.1 MAGNETIC FLUX LEAKAGE

6.2 ULTRASONIC

6.3 LEVEL

6.4 PIT GAUGE

7.0 TABLES

TABLE A BOTTOM REDUCTION

TABLE B BOTTOM PLATE UT READINGS

TABLE C SHELL READINGS

TABLE D FIXED ROOF UT READINGS

TABLE E SUMP READINGS

8.0 WARRANTY

9.0 PHOTOGRAPHS

API 653 Out-of-Service Inspection Report for Cape Fuel Systems Group

Tank No. 211 Killeen, TX

Inspection

March 5-13, 2008

1.0 DESCRIPTION

GENERAL:

TANK NUMBER: 211

OWNER: Cape Fuel Systems Group

DESIGN STANDARD: API 650

TANK LOCATION: Killeen, TX (Fort Hood) MANUFACTURER: American Tank & Vessel, Inc.

PRODUCT: JP-8 (Jet Fuel) DESIGN SPECIFIC GRAVITY: Data Not Available DESIGN PRESSURE: Data Not Available CATHODIC PROTECTION: No DATA PLATE PRESENT: Yes DOT REGULATED TANK: Yes

DIMENSIONS:

DIAMETER: 34.0 ft.

HEIGHT: 32.0 ft.

CAPACITY GROSS: 5,178 bbls.

OPERATING HEIGHT: Data Not Available CAPACITY NOMINAL: 5,000 bbls. (per data plate)

GEOMETRY:

FOUNDATION: Concrete Ringwall w/ Leak Detection BOTTOM: Lap Welded (Cone Down) SHELL: Butt Welded FIXED ROOF: Lap Welded Cone w/ Framing

FLOATING ROOF: N/A

DATES:

YEAR BUILT: 1985

LAST COATED: Data Not Available LAST INSPECTION: April 2004

ACCESS:

STAIRWAY: Spiral (CCW-Up)

FLOATING ROOF ACCESS: N/A

COATINGS:

BOTTOM: Thin-Film Epoxy SHELL: External - White Paint

Internal – Thin-Film Epoxy FIXED ROOF: External - White Paint

Internal – Thin-Film Epoxy

Cape Fuel Systems Group

2.0 SUMMARY AND REPAIR RECOMMENDATIONS

The following is a summary of the significant findings of the inspection.

FOUNDATION: The survey found the tank to be out of level by 0.24 inch. API 653 calculation for deflection of this tank is 0.08 inch. API 653 maximum deflection permitted for this tank is calculated to be 0.38 inch (ref. API 653, Appendix B, Para. B.2.2).

Differential settlement for this tank does not exceed the API allowable (ref. API 653, Appendix B, Para. B.2.2).

Evidence of sealant failure was found at several locations around the concrete ringwall and surrounding containment area. Cracks leading to possible spalling have occurred at two (2) anchor bolt locations due to bending of the bolts and identified as Items N and Y, (ref. Shell Nozzle and Appurtenance Table). Consideration should be given to re-sealing the concrete as needed to protect against moisture intrusion. Continue to monitor the concrete ringwall at future inspection intervals.

The nut for each anchor bolt was found to lack 1 turn to 2 turns from the anchor chairs.

Two (2) bolts were found to be noticeably bent. No visible corrosion was noted at any of these details.

BOTTOM: Tank No. 211 was built by American Tank & Vessel, Inc. in 1985. The tank design is in accordance with API 650. Nominal bottom plate thickness is 0.250 inch.

Magnetic Flux Leakage (MFL) scanning located zero (0) areas of soil side corrosion with a remaining thickness at or below 0.195 inch. Visual (VT) inspection, in conjunction with Magnetic Flux Leakage (MFL) scanning, revealed one (1) area of product side corrosion pitting 0.055 inch deep or more. The epoxy coating is in acceptable condition over this isolated pit and corrosion has been arrested. Additionally, one (1) area of plate lamination was identified. This is provided as information only, as the imperfection occurs mid-thickness and does not break either surface.

The next internal inspection should be conducted within 20 years if all areas of soil side corrosion resulting in a remaining thickness of 0.195 inch or below are repaired and all areas of internal corrosion with a pit depth of 0.055 inch or greater are repaired. If all such areas are repaired and the bottom is internally coated, the next inspection should be conducted within 20 years, provided that the expected life of the coating meets or exceeds this interval. If all such areas are repaired and reinforced lining is installed, the next inspection should be conducted within 20 years (ref. API 653, Para. 4.4.7).

NOTE: If the bottom is to retain thin-film epoxy coating (integrity verified), repair of the single product side pit is unnecessary for a 20-year service life.

Cape Fuel Systems Group

BOTTOM (CONT’D.): Holiday testing of the thin-film epoxy bottom coating and of the same coating extending 18 inches up the shell found less than 2% to be in need of replacement. Areas are primarily located at welds and are identified by red marker.

Ultrasonic (UT) thickness readings of the bottom consist of five (5) areas per plate, seventeen (17) areas equally spaced at 2.5 feet from the shell with two (2) of these areas being 12-inch x 12-inch grids. No significant metal loss was detected.

SHELL: Shell thickness calculations indicate the hydrostatic test height, or storage of product with specific gravities up to 1.0, should be restricted to 32.0 feet. For products with a specific gravity over 1.0, additional calculations should be performed (ref. API 653, Para. 4.3.3.1). These calculations do not take into account operational restrictions from such items as high-level alarms or owner / operator-imposed safe fill restrictions.

The shell-mounted vent elevations were not taken into account.

Shell thickness Ultrasonic (UT) thickness readings were taken as follow:

Four (4) equally spaced full height vertical drops with the distance between readings not exceeding 6 inches.

Nine (9) readings per plate (3 rows of 3 readings) of shell Course 1 with an additional reading at 3.167 feet above the shell-to-bottom joint.

Nine (9) readings per Course 2 shell plate located 2 inches to 4 inches above the Course 1 to Course 2 horizontal weld.

The automatic gauge supports do not have reinforcing plates underneath. Visual (VT) inspection of these supports found them to be in acceptable condition. This is provided as information only and no corrective action is required at this time. Consideration should be given to installing seal welded reinforcing plates under each support the next time major repairs are made to the shell or when a hydrostatic test is required for other reasons.

There are two (2) previous shell vents that have been sealed off by lap welded plates on the shell interior. The hoods and screens remain on the exterior shell giving the appearance of open atmospheric shell venting. A joint efficiency of 0.35 is used on this entire shell course with minimal effect on the maximum safe fill height. This is provided as information only.

The spiral stairway tread-to-shell attachments are flat plate welded on the top side only.

Consideration may be given to seal welding these supports.

Inspection noted light creases of the shell plate at Stations 22.0 and 35.0 (measured in feet circumferentially counterclockwise from Manway A). The creases are located away from shell plate butt welds and no immediate action is required. The shell should be monitored at future inspection intervals.

Cape Fuel Systems Group

SHELL (CONT’D.): Holiday testing of the thin-film epoxy coating extending 18 inches up the interior shell showed less than 1% of the area to need re-coating. Areas are primarily located at welds and are identified by red marker.

The next external API 653 inspection should be conducted within 5 years and no later than March 2013 (ref. API 653, Para. 6.3.2.1).

NOZZLES AND APPURTENANCES: Manways A and O and Nozzles F and AA have a weld spacing between their reinforcing plates and the shell-to-bottom weld less than that required by API 650, Para. 5.7.3. Such practice results in areas of increased stress concentration and possible accelerated corrosion. Visual (VT) inspection of these manway / nozzle details did not identify any such corrosion at this time and no action is required.

Manways A and O are each 24 inches diameter. Consideration should be given to the need for two (2) 36-inch manways with hinge mounted covers as suggested by MIL- HDBK-1022A, Item e.

Items F and I (the fill / suction lines) lack internal piping details specified by MIL-HDBK- 1022A, Items s and t (ref. Plates 16 and 17 respectively).

Nozzle I has a reinforcing plate that does not meet the minimum thickness requirements of API 650 (ref. Table 5-7, Column 1). This nozzle should be replaced with an API standard nozzle detail the next time this tank has welded repairs to the shell.

Nozzle I has an incorrect placement of the telltale hole. The hole should be at the horizontal centerline elevation per API 650, Figure 5-8.

Operation of the high-level alarm routed through the automatic level gauge is to be verified prior to returning the tank to service. Consideration should be given to verification by physically retracting the float itself. The manual tape retraction knob is missing at this time and should be found and / or replaced.

An additional automatic tank gauge is freely routed from the roof to sensors attached by magnet to the tank bottom. An 8-inch stilling well / gauge pole is specified to contain these sensors per MIL-HDBK-1022A, Item r. This detail is thought to include back-up alarms for high, high-high, low, and low-low level conditions in addition to the features detailed in Item n of MIL-HDBK-1022A. Means of verification of this detail were not known at the time of this inspection and the system is to be replaced by a tank radar gauge (per client).

Cape Fuel Systems Group

FIXED ROOF: The coating was found to be weathered and chalking. Areas of scrapes, minor chipping and surface rust of the top coat were noted. Consideration should be given to re-coating the roof plates and appurtenances.

The roof has one (1) 6-inch gauge / sample hatch and one (1) 8-inch sample / gauge hatch. The hinged hatch cover is missing the hold-down device. The 6-inch hatch is bolted to the roof to accommodate the level gauge, temperature instrumentation and the level alarms. Consideration should be given to installing an additional 8-inch gauge hatch and replacing the bolted nozzle with an 8-inch flanged nozzle to accommodate Items p through r of MIL-HDBK-1022A.

There roof includes a 16-inch pressure / vacuum hatch (providing the only tank ventilation) and a 24-inch diameter manway. MIL-HDBK-1022A, Item d suggests two (2) 24-inch square manholes for fixed roofs in tanks not including a floating pan.

The 16-inch pressure / vacuum vent is rated at 1.5 oz. pressure, 0.5 oz. vacuum. The need for additional venting should be considered.

The roof does not presently include a scaffold hitch. MIL-HDBK-1022A, Item cc suggests two (2) scaffold cable supports (designed in accordance with API 650, Figure 5-22).

There is a 25-inch diameter x 9-inch high seal welded node present at the roof center.

This detail is open to the tank interior beneath. This is provided as information only. The use for this detail is unknown.

No reportable metal loss was found by Visual (VT) inspection and Ultrasonic (UT) testing.

Cape Fuel Systems Group

4.0 INSPECTION REPORT

4.1 FOUNDATION

4.1.1 FOUNDATION INSPECTION CHECKLIST

# DESCRIPTION COMMENTS

Y 1 Inspect foundation for damage. Reference Section 2.0 Y 2 Search for indications of bottom leakage. Acceptable Y 3 Inspect for cavities and vegetation under foundation.

Acceptable

Y 4 Check for proper water runoff and drainage away from the tank.

Acceptable

Y 5 Check for grade or other material covering the shell-to-bottom junction. Detail findings.

Acceptable

Y 6 Check for settlement around the perimeter of the tank.

Reference Sections 2.0 and 4.1.2.

Y 7 Check for presence or condition of moisture barrier.

Reference Section 2.0

Y 8 Check for anchorage. Record sizes, spacing between anchors and condition.

Reference Section 2.0

Cape Fuel Systems Group

4.1.2 FOUNDATION SETTLEMENT EVALUATION

Shell Settlement (Survey Data) Vs.

Planar Settlement (Cosine Curve)

0.24

0.00

0.05

0.10

0.15

0.20

0.25

0.30

40 53 67 80 93 0 13 27 40

Distance Around Tank (ft)

Se ttl em en t ( in

Survey Cosine

Differential Settlement Evaluation

-0.5 -0.4 -0.3 -0.2 -0.1

0.1 0.2 0.3 0.4 0.5

40 53 67 80 93 0 13 27 40

Distance Around Tank (ft)

D ef le ct io n

(in

Calculated Deflection Positive Permissible Negative Permissible

Cape Fuel Systems Group

4.1.3 FOUNDATION SETTLEMENT SURVEY

The survey was conducted counterclockwise from the reference Shell Manway A located at Station 0.0. The circumferential distance between the readings is 13.35 feet.

Distance from Shell (ft.)

Point Shell 1’ 2’ 3’ 4’ 5’ 6’ 10’ Center No. Rod Readings (ft.)

1 3.60 3.64 3.64 3.64 3.61 3.55 3.61 3.59 3.44 2 3.59 3.59 3.59 3.60 3.56 3.55 3.54 3.51 -- 3 3.59 3.57 3.54 3.53 3.49 3.49 3.49 3.56 -- 4 3.58 3.56 3.59 3.57 3.58 3.60 3.64 3.61 -- 5 3.59 3.60 3.62 3.64 3.61 3.54 3.51 3.51 -- 6 3.59 3.62 3.65 3.64 3.64 3.66 3.65 3.45 -- 7 3.59 3.64 3.69 3.72 3.71 3.68 3.66 3.53 -- 8 3.60 3.61 3.61 3.62 3.61 3.61 3.61 3.49 --

Cape Fuel Systems Group

4.2 BOTTOM

4.2.1 BOTTOM INSPECTION CHECKLIST

Y 1 Conduct Visual Inspection of bottom/ bottom coating. Record all findings.

Reference Section 2.0

N 2 Conduct Vacuum Box Bubble Test Inspection of lap welds and internal shell-to-bottom weld. Record all findings.

N/A

N 3 Conduct Magnetic Particle Inspection of the internal shell-to-bottom weld. Record all findings.

N/A

Y 4 Conduct Visual Inspection on bottom lap and shell-to-bottom weld. Record all finding

Reference Sections 2.0 and 5.0

Y 5 Conduct Ultrasonic Thickness readings of bottom plates. Record all data.

Reference Section 5.0

Y 6 Conduct Magnetic Flux Leakage Inspection of bottom. Quantify all findings.

Reference Sections 2.0 and 5.0

Y 7 Locate unacceptable voids beneath bottom.

Record the locations.

Acceptable

Y 8 Conduct Visual Inspection of reinforcement. Acceptable Y 9 Conduct Visual Inspection of fixed roof support column, base plates and lateral clips.

Acceptable

N 10 Conduct Visual Inspection of sump(s), sump welds and condition of sump coating.

Record all findings.

N/A

N 11 Conduct Ultrasonic Thickness readings of sump(s). Record all data. Perform additional NDE if necessary.

N/A

Cape Fuel Systems Group

4.2.2 SERVICE INTERVAL

The next internal inspection should be conducted within 20 years if all areas of soil side corrosion resulting in a remaining thickness of 0.195 inch or below are repaired and all areas of internal corrosion with a pit depth of 0.055 inch or greater are repaired (ref. API 653, Para. 4.4.7).

The next external API 653 inspection should be conducted within 5 years and no later than March 2013 (Ref. API 653, Para. 6.3.2.1).

Nominal Bottom Plate Thickness (inches) 0.250 inch Maximum Underside Corrosion Depth 0.035 inch Maximum Internal Corrosion Depth 0.055 inch Minimum Remaining Thickness at Next Inspection (MRT) 0.100 inch Year of Inspection (Yi) 2008 year Year of Construction (Yo) 1985 year Minimum Remaining Thickness from Underside Corrosion after Repairs (RTbc) 0.195 inch Minimum Remaining Thickness from Internal Corrosion after Repairs (RTip) 0.195 inch Underside Corrosion Rate (UPr) 0.0024 inch/yr Internal Corrosion Rate (StPr) 0.0024 inch/yr

Repaired Underside Corrosion Evaluation (assume 0.25 patch): 0.250 in Patch Plate Acceptable (per API 653 4.4.7.1, UPr Def.)

Interval to next inspection 20 Years (RRT-0.10)/(Int + US C.R.)

O RT orRT MRT

S P UPr bc ip t r r

(min )

Cape Fuel Systems Group

4.3 SHELL

4.3.1 SHELL INSPECTION CHECKLIST

Y 1 Inspect external shell for coating failure, corrosion or leaks.

Acceptable

Y 2 Inspect external shell-to-bottom weld area for corrosion, defects, or thinning on weld, shell, or bottom.

Reference Section 2.0

Y 3 Inspect internal shell surface for corrosion or leaks.

None found

Y 4 Inspect weld seams for corrosion or defects Visually inspect rivet joint details and record findings.

Joint Efficiency = 0.85 Butt Welded Acceptable

N 5 Inspect wind girder for corrosion or damage. N/A Y 6 Check support welds to shell for corrosion or defects.

Acceptable

Y 7 Note whether supports have reinforcing pads welded to shell.

Reference Section 2.0

N 8 Conduct Visual Inspection of shell insulation inspect for damage.

N/A

Y 9 Visually inspect shell for out-of-roundness Reference Section 2.0 Y 10 Shell mounted vents, Check for debris covering or condition of screens.

Reference Section 2.0

Screen Present: Yes

Approx. dimensions:

10 inches X 10 inches.

Cape Fuel Systems Group

4.3.2 SHELL THICKNESS CALCULATIONS

The minimum acceptable shell plate thickness for tanks with a diameter equal to or less than two-hundred (200) feet is calculated as follows (Ref. API 653, Para. 4.3.3.1):

SE

DGHt )1(6.2 min

Where:

S = See Table = Allowable Stress (psi) D = 34.00 = Nominal Diameter of Tank (ft.)

G = 1.00 = Highest Specific Gravity of Contents H = See Table = Product Height (ft.)

E = See Table = Joint Efficiency

Course

Course Height

(in.)

Product Height

(ft.)

Allowable Stress (psi)

Joint Efficiency

Average Thickness

(in.)

Required Thickness

(in.)

1 96 32.00 23,600 0.85 0.190 0.137 2 96 24.00 23,600 0.85 0.196 0.101 3 96 16.00 26,000 0.85 0.195 0.100 4 96 8.00 26,000 0.85 0.193 0.100

Shell thickness calculations indicate the hydrostatic test height, or storage of product with specific gravities up to 1.0, should be restricted to 32.0 feet. For products with a specific gravity over 1.0, additional calculations should be performed (ref. API 653, Para.

4.3.3.1). These calculations do not take into account operational restrictions from such items as high-level alarms or owner / operator-imposed safe fill restrictions. The shell-mounted vent elevations were not taken into account.

Cape Fuel Systems Group

4.4 NOZZLES AND APPURTENANCES

4.4.1 NOZZLE AND APPURTENANCE INSPECTION CHECKLIST

Y 1 Inspect for signs of corrosion or other defects around all manways, nozzles, and attachments.

Acceptable

Y 2 Inspect for flange leaks and leaks around bolts.

None found

N 3 Check piping and valves for leaks, thermal relief or signs of damage.

N/A

Y 4 Inspect condition of stairway ladder and platform.

Acceptable

N 5 Check welds on shell mounted davit clips above large valves or equipment.

N/A

Y 6 Describe and verify operability of gauging devices, if applicable.

Type: Varec 2500 B Reference Section 2.0

N 7 Inspect mixer for support, leakage, and defects.

N/A

Y 8 Check for adequate reinforcement around nozzles and appurtenances.

Acceptable

Y 9 Verify adequate weld spacing around nozzles and appurtenances.

Reference Section 2.0

N 10 Check floating suction for damage and proper support. Check condition of shell mounted angle limiting brackets or angle limiting chains mounted to bottom

N/A

4.4.2 NOZZLE AND APPURTENANCE TABLE Page 20 of 52

Reinforcing Plate

Item

Description Pipe Size (in.)

Station

(ft.)

CL

Elev.

Width

Height

Thick

Shape

Neck

(in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

Comments

A Manway 24 0.0 30 54 54 0.263 B 0.591 0.435 0.438 Y 2 B Grounding Lug --- 2.1 9 typ. --- --- --- --- --- --- --- --- 5.5 typ. w/ Cable C Shell Vent NA --- 8.8 --- --- --- --- --- --- --- --- --- --- 10 in. x 10 in.

Sealed Off D Anchor Block --- 13.6 5 typ. --- --- --- --- --- --- --- --- --- 1 ¼ in. Bolt typ.

E Nozzle 2 20.3 7 --- --- --- --- 0.228 0.740 --- --- 5 F Nozzle 6 23.8 11.5 16 16 0.274 B 0.433 0.998 --- Y 2 Fill G Conduit Riser ¾ 25.7 --- --- --- --- --- --- --- --- --- --- To Item H H Nozzle 2 26.6 --- --- --- --- --- --- --- --- --- --- Course 4 I Nozzle 8 26.9 15 17 17 0.195 B 0.343 1.164 --- Y* 5 Suction , *ITL J Grounding Lug --- 28.2 --- --- --- --- --- --- --- --- --- --- w/o Cable K Automatic Gauge --- 29.8 --- --- --- --- --- --- --- --- --- --- Varec Fig. 2500

Model B L Anchor Block --- 31.1 --- --- --- --- --- --- --- --- --- --- M Stairway --- 34.5 --- --- --- --- --- --- --- --- --- --- Bottom N Anchor Block --- 48.8 --- --- --- --- --- --- --- --- --- --- O Manway 24 53.5 30 56 56 0.264 B 0.392 0.431 0.524 Y 2 P Grounding Lug --- 55.4 --- --- --- --- --- --- --- --- --- --- w/ Cable Q Coupling 1 ½ 59.4 --- --- --- --- --- --- --- --- --- --- Course 4 R Coupling 1 ½ 59.4 --- --- --- --- --- --- --- --- --- --- Course 4 S Coupling 1 59.4 40 --- --- --- --- --- --- --- --- 38.5 Hot Tap T Coupling 1 59.4 25 --- --- --- --- --- --- --- --- 23.5 Hot Tap U Grounding Cable --- 62.1 --- --- --- --- --- --- --- --- --- --- To Tank 311 V Anchor Block --- 65.6 --- --- --- --- --- --- --- --- --- --- W Stairway --- 66.0 --- --- --- --- --- --- --- --- --- --- Top X Grounding Lug --- 81.6 --- --- --- --- --- --- --- --- --- --- w/o Cable Y Anchor Block --- 84.5 --- --- --- --- --- --- --- --- --- --- Z Shell Vent NA --- 93.2 --- --- --- --- --- --- --- --- --- --- 10 in. x 10 in.

Sealed Off The stations are measured circumferentially counterclockwise from Manway A.

4.4.2 NOZZLE AND APPURTENANCE TABLE CONT’D Page 21 of 52

Reinforcing Plate

Size

Station

(ft.)

CL

Elev.

Width

Height

Neck

(in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

AA Nozzle 3 93.6 7.5 10 10 0.262 B 0.329 0.329 --- Y 1 BB Anchor Block --- 102.4 --- --- --- --- --- --- --- --- --- --- CC Ground Cable --- 104.6 --- --- --- --- --- --- --- --- --- --- To Outside

Containment The stations are measured circumferentially counterclockwise from Manway A.

IWS = Inadequate Weld Spacing *ITL = Incorrect Telltale Location VERTICAL WELD SEAM LOCATIONS: (Measured in feet circumferentially counterclockwise from Manway A)

1) 8.2 2) 34.95 3) 61.7 4) 88.4 5) 6) 7) 8) 9) 10) 11) VERTICAL WELD OFFSET FOR COURSES 2,3,4 etc.:

2) 21.5 3) 8.2 4) 21.5 5) 6) 7) 8) 9)

Total Strapped Circumference = 107.0 ft.

Cape Fuel Systems Group

4.5 FIXED ROOF

4.5.1 FIXED ROOF INSPECTION CHECKLIST

Y 1 Describe condition of fixed roof Acceptable Y 2 Visually inspect low spots on roof for external corrosion. Locate on layout.

Acceptable

Y 3 Conduct Visual Inspection of roof nozzles and appurtenances. Locate on layout.

Reference Section 2.0

Y 4 Conduct Visual Inspection of frangible joint. Acceptable N 5 Conduct Visual Inspection of roof insulation.

Inspect for damage.

N/A

Y 6 Conduct Visual Inspection of cone roof coating system.

Acceptable

Y 7 Check condition of vents, missing or clogged screens, pallets and gaskets. Condition of vent or gauge hatch etc.…. Note possible insufficient venting

Acceptable

Y 8 Conduct Visual Inspection of internal roof supports, rafters, columns, and bases.

Record sizes and located supports on layout.

# fixed roof supports: 1 Type of Support: Pipe Column

Number of rafters ( Row 1: 17

Reference Section 2.0

Y 9 Record sizes of fixed roof Supports and Base Plate.

Pipe Diameter: 8 in.

Thickness: 0.326 in.

X-I-Beam:

6 width x 6 depth

Base plate: 10 in. X 10 in.

Thickness: 0.507 in.

Cape Fuel Systems Group

4.5.2 FIXED ROOF NOZZLE TABLE

Size (in.)

Location Plate No.

Neck

A Coupling 1 ¼ 8 -- Float guide B Coupling 1 ½ 8 -- Tape guide C Coupling 1 ¼ 8 -- Float guide D Center Hub / Node 25x9 0.338 Fully seal welded E Vacuum Pressure Hatch 16 12 0.249 Groth Mfg

Pres=1.5 Vac-.5 oz

F Manway/Hatch 24 11 0.308 -- G Sample/Gauge Hatch 6 11 0.190 Flanged and bolted to deck. Caulking applied

H Sample/Gauge Hatch 8 14 0.141 Pres. Only 2 oz.

Cape Fuel Systems Group

5.0 NDE INSPECTION

5.1 NDE INSPECTION SCOPE

The following Nondestructive Examinations (NDE) were conducted to evaluate the physical characteristics of the tank:

A) Magnetic Flux Leakage (MFL) scan of the tank bottom for the detection of significant internal or underside metal loss. Performed in accordance with HMT Inspection MFL Procedure No. 1611.4, Revision No. 6. (MK1A)

B) Quantitative remaining thickness measurements in any area of significant metal loss. Performed in accordance with HMT Inspection UT Procedure No. 1611.1, Revision No. 4.

C) Visual Inspection (VT) of areas restricted from MFL coverage for the detection of anomalies or significant internal metal loss which may affect the integrity.

Performed in accordance with HMT Inspection VT Procedure No. 1611.9, Revision No. 2.

D) Random Ultrasonic (UT) bottom/sump plate readings. Performed in accordance with HMT UT Procedure No. 1611.1, Revision No. 4.

E) Random Ultrasonic (UT) readings on shell / fixed roof plates. Performed in accordance with HMT Inspection UT Procedure No. 1611.1, Revision No. 4.

F) Random Ultrasonic (UT) readings on shell / fixed roof nozzles. Performed in accordance with HMT Inspection UT Procedure No. 1611.1, Revision No. 4.

5.2 SIGNIFICANT FINDINGS

Magnetic Flux Leakage (MFL) scanning located zero (0) areas of soil side corrosion with a remaining thickness at or below 0.195 inch. Visual (VT) inspection, in conjunction with Magnetic Flux Leakage (MFL) scanning, revealed one (1) area of product side corrosion pitting 0.055 inch deep or more. The epoxy coating is in acceptable condition over this isolated pit and corrosion has been arrested. Additionally, one (1) area of plate lamination was identified. This is provided as information only, as the imperfection occurs mid-thickness and does not break either surface (Ref. Table A).

Cape Fuel Systems Group

5.3 BOTTOM EXAMINATION

The tank bottom plates were examined utilizing MFL, UT and VT inspection methods.

The bottom was examined for the detection of both internal and underside metal loss.

Areas identified by the MFL as exceeding or closely approaching the critical thickness were quantified by UT and pit gauge measurements. Recording criteria was set by the client at 0.195 inch or less remaining thickness (Ref. Table A). Nominal bottom plate thickness is 0.250 inch.

Areas of restricted access to MFL examination coverage included: near the shell-to-bottom weld, plate-to-plate lap welds, fixed roof supports, near the automatic gauge base, sump, gauge pole and under internal piping.

The bottom lap welds were examined utilizing VT inspection method.

The internal / external shell-to-bottom weld was examined utilizing VT inspection methods.

Bottom plate UT data was collected utilizing random readings. Five (5) readings per bottom plate were taken (Ref. Table B). Seventeen (17) areas equally spaced at 2.5 feet from the shell with two (2) of these areas being 12-inch x 12-inch grids.

5.4 SHELL READINGS

The tank shell plate UT data was collected utilizing random readings. Sixteen (16) readings were taken per course along four (4) vertical drops, evenly spaced, around the shell. Nine (9) readings per plate (3 rows of 3 readings) of shell Course 1 with an additional reading at 3.167 feet above the shell-to-bottom joint. Nine (9) readings per Course 2 shell plate located 2 inches to 4 inches above the Course 1 to Course 2 horizontal weld (Ref. Table C).

5.5 NOZZLE READINGS

The tank shell and roof nozzle UT data was collected utilizing random readings. One (1) reading per nozzle was taken (Ref. Sections 4.4.2 and 4.5.2)

5.6 FIXED ROOF READINGS

The fixed roof deck plate UT data was collected utilizing random readings. Five (5) readings per plate were taken (Ref. Table C). There were no readings less than 0.090 inch identified (Ref. API 653, 4.2.1.2).

Cape Fuel Systems Group

5.7 SUMP READINGS

The sump was examined utilizing random readings. Sixteen (16) readings were taken along the wall, and ten (10) readings were taken across the bottom in an X pattern (Ref.

Table D). There were no readings that deviated significantly from nominal thickness.

Cape Fuel Systems Group

6.0 EQUIPMENT

6.1 MAGNETIC FLUX LEAKAGE

MFL equipment utilized consisted of an RTD Floorscanner Type Mk1A (S/N: 2K504).

6.2 ULTRASONIC

The UT equipment utilized for the inspection was a NDT 400 Flaw Detector.

The transducer utilized was a Britek, 7.5 MHz, 0.312 inch dual element, and a Technisonic CF-0503-GP, 5.0 MHz, 0.250 inch dual element.

The calibration block utilized was a 5 step, 4340 steel test block.

Echogel 20 and water was used as a couplant.

6.3 LEVEL

The level utilized was a Zip Level.

6.4 PIT GAUGE

The pit gauge utilized was a W.R. Thorpe Co. standard pipe pit gauge.

Cape Fuel Systems Group

7.0 TABLES

TABLE A

BOTTOM REDUCTION

(in inches) SW reference corner unless otherwise indicated.

REMAINING X Y Soil NE PLATE

NO./ID

PIT

DEPTH THICKNESS LOCATION LOCATION INT side REF COMMENTS

13 0.055 95 19 1

15 Lamination 51-57 20-32 Midwall, 0.178 in.

NOTES:

US = UNDERSIDE CZ = CRITICAL ZONE

INT = INTERNAL NE = NORTHEAST REFERENCE CORNER

Cape Fuel Systems Group

TABLE B

BOTTOM PLATE UT READINGS

(in inches)

PLATE NO. Reading

Reading

Reading

Reading

Reading

1 0.242 0.249 0.250 0.249 0.242 2 0.243 0.242 0.241 0.242 0.243 3 0.242 0.243 0.243 0.245 0.243 4 0.238 0.238 0.241 0.239 0.239 5 0.238 0.238 0.239 0.239 0.239 6 0.245 0.244 0.243 0.244 0.243 7 0.237 0.238 0.240 0.239 0.239 8 0.240 0.245 0.245 0.244 0.245 9 0.242 0.243 0.241 0.243 0.244

10 0.242 0.238 0.235 0.237 0.239 11 0.252 0.252 0.253 0.254 0.252 12 0.251 0.250 0.250 0.251 0.251 13 0.247 0.246 0.245 0.246 0.241 14 0.245 0.242 0.242 0.241 0.242 15 0.245 0.243 0.238 0.243 0.244 16 0.249 0.249 0.249 0.248 0.249

Min: 0.235 Avg: 0.244

Bottom Plate Readings at 2’6” from shell

Reading No.

UT

Reading

Reading No.

UT

Reading

1 0.252 10 0.247 2 0.248 11 0.249 3 0.249 12 0.246 4 0.245 13 0.245 5 0.238 14 0.241 6 0.249 15 0.243 7 0.248 16 0.246 8 0.250 17 0.253 9 0.248 -- --

Cape Fuel Systems Group

TABLE B (CONT’D)

BOTTOM UT READINGS

(in inches) 12-inch x 12-inch GRIDS

Location Reading

Reading

Reading

Reading

Reading

Reading

1 0.248 0.247 0.245 0.244 0.243 0.243 2 0.245 0.244 0.246 0.241 0.248 0.245 3 0.239 0.238 0.241 0.242 0.245 0.248 4 0.248 0.247 0.245 0.244 0.249 0.249 5 0.248 0.247 0.248 0.246 0.247 0.245 6 0.248 0.245 0.247 0.248 0.245 0.248

MIN. 0.238 AVG. 0.245

Location Reading

Reading

Reading

Reading

Reading

Reading

1 0.248 0.246 0.245 0.248 0.246 0.245 2 0.244 0.243 0.248 0.249 0.244 0.243 3 0.242 0.242 0.241 0.239 0.238 0.239 4 0.238 0.239 0.237 0.235 0.238 0.238 5 0.240 0.243 0.244 0.246 0.248 0.248 6 0.248 0.246 0.247 0.249 0.246 0.245

MIN. 0.235 AVG. 0.243

Cape Fuel Systems Group

TABLE C

SHELL READINGS

Course 1

LOCATION Drop 1 Drop 2 Drop 3 Drop 4 1 0.188 0.190 0.189 0.187 2 0.190 0.189 0.190 0.188 3 0.190 0.191 0.188 0.188 4 0.191 0.190 0.189 0.188 5 0.191 0.187 0.189 0.188 6 0.191 0.190 0.189 0.189 7 0.190 0.190 0.189 0.189 8 0.190 0.191 0.189 0.190 9 0.190 0.191 0.190 0.190

10 0.191 0.190 0.188 0.189 11 0.190 0.189 0.189 0.191 12 0.188 0.190 0.190 0.191 13 0.191 0.190 0.190 0.191 14 0.190 0.191 0.190 0.191 15 0.190 0.192 0.190 0.190 16 0.190 0.189 0.190 0.190

Min: 0.187 Avg: 0.190

Cape Fuel Systems Group

TABLE C (CONT’D)

(in inches)

Course 2

LOCATION Drop 1 Drop 2 Drop 3 Drop 4 1 0.199 0.189 0.191 0.189 2 0.200 0.190 0.192 0.191 3 0.201 0.191 0.193 0.192 4 0.201 0.190 0.194 0.193 5 0.201 0.199 0.190 0.194 6 0.201 0.189 0.190 0.195 7 0.201 0.189 0.190 0.196 8 0.201 0.192 0.192 0.197 9 0.200 0.199 0.193 0.198

10 0.203 0.198 0.193 0.196 11 0.202 0.198 0.193 0.198 12 0.203 0.198 0.193 0.199 13 0.202 0.198 0.194 0.197 14 0.203 0.196 0.193 0.198 15 0.202 0.197 0.193 0.198 16 0.202 0.197 0.193 0.197

Min: 0.189 Avg: 0.196

Cape Fuel Systems Group

Course 3

1 0.189 0.198 0.193 0.195 2 0.192 0.199 0.195 0.194 3 0.192 0.196 0.195 0.194 4 0.192 0.198 0.195 0.194 5 0.192 0.197 0.196 0.194 6 0.192 0.197 0.197 0.195 7 0.194 0.197 0.198 0.195 8 0.194 0.198 0.199 0.194 9 0.194 0.199 0.198 0.195

10 0.195 0.196 0.197 0.196 11 0.196 0.195 0.196 0.195 12 0.195 0.195 0.196 0.194 13 0.193 0.195 0.196 0.195 14 0.194 0.195 0.196 0.194 15 0.195 0.194 0.197 0.195 16 0.196 0.194 0.196 0.195

Min: 0.189 Avg: 0.195

Cape Fuel Systems Group

Course 4

1 0.191 0.193 0.190 0.193 2 0.192 0.192 0.191 0.193 3 0.191 0.194 0.191 0.193 4 0.192 0.194 0.191 0.192 5 0.191 0.194 0.191 0.194 6 0.193 0.194 0.191 0.193 7 0.193 0.192 0.190 0.195 8 0.194 0.193 0.191 0.194 9 0.194 0.193 0.190 0.193

10 0.193 0.193 0.190 0.194 11 0.192 0.193 0.192 0.195 12 0.197 0.192 0.193 0.194 13 0.197 0.193 0.193 0.193 14 0.197 0.192 0.193 0.194 15 0.196 0.192 0.193 0.193 16 0.195 0.192 0.194 0.193

Min: 0.190 Avg: 0.193

Cape Fuel Systems Group

(Additional UT at 3’2” above shell/bottom weld) Course 1-Plate 1

Location Drop 1 Drop 2 Drop 3 1 0.194 0.192 0.192 2 0.195 0.196 0.196 3 0.198 0.197 0.197

Additional 0.194 0.194 0.199

MIN. 0.192 AVG. 0.195

Course 1-Plate 2

Location Drop 1 Drop 2 Drop 3 1 0.191 0.192 0.194 2 0.190 0.193 0.196 3 0.193 0.194 0.198

Additional 0.195 0.193 0.195

MIN. 0.190 AVG. 0.194

Course 1-Plate 3

1 0.191 0.191 0.191 2 0.195 0.192 0.194 3 0.196 0.193 0.195

Additional 0.194 0.194 0.198

MIN. 0.191 AVG. 0.194

Course 1-Plate 4

1 0.192 0.192 0.195 2 0.192 0.194 0.194 3 0.194 0.195 0.198

Additional 0.198 0.196 0.196

MIN. 0.192 AVG. 0.195

Cape Fuel Systems Group

(UT-2” to 4” above 1st Horizontal Weld)

Course 2-Plate 1 Location Stairway

1 0.189 2 0.189 3 0.190 4 0.191 5 0.185 6 0.185 7 0.179 8 0.186 9 0.183 10 0.185

Average: 0.186 Minimum: 0.179 Maximum: 0.191

Course 2-Plate 2

1 0.184 2 0.184 3 0.185 4 0.185 5 0.186 6 0.185 7 0.186 8 0.188 9 0.187 10 0.186

Average: 0.186 Minimum: 0.184 Maximum: 0.188

Cape Fuel Systems Group

Course 2-Plate 3

1 0.187 2 0.186 3 0.187 4 0.187 5 0.188 6 0.189 7 0.188 8 0.188 9 0.187 10 0.186

Average: 0.187 Minimum: 0.186 Maximum: 0.189

Course 2-Plate 4

1 0.184 2 0.184 3 0.187 4 0.185 5 0.185 6 0.186 7 0.186 8 0.186 9 0.186 10 0.186

Average: 0.186 Minimum: 0.184 Maximum: 0.187

Cape Fuel Systems Group

TABLE D

FIXED ROOF UT READINGS

PLATE NO. Reading

Reading

Reading

Reading

Reading

1 0.188 0.187 0.186 0.188 0.187 2 0.186 0.187 0.188 0.186 0.184 3 0.184 0.183 0.184 0.185 0.186 4 0.190 0.190 0.189 0.191 0.192 5 0.190 0.191 0.188 0.192 0.190 6 0.190 0.191 0.190 0.189 0.190 7 0.190 0.191 0.192 0.190 0.191 8 0.199 0.198 0.197 0.199 0.197 9 0.190 0.191 0.191 0.190 0.192

10 0.195 0.195 0.196 0.197 0.198 11 0.189 0.188 0.189 0.190 0.190 12 0.188 0.188 0.187 0.186 0.187 13 0.189 0.190 0.188 0.189 0.188 14 0.187 0.189 0.188 0.190 0.189 15 0.188 0.187 0.188 0.190 0.190 16 0.186 0.187 0.186 0.187 0.188

Min: 0.183 Avg: 0.190

Cape Fuel Systems Group

TABLE E

SUMP READINGS

WALL

N READING S READING

1 0.305 1 0.298 2 0.306 2 0.300 3 0.307 3 0.302 4 0.304 4 0.301

E READING W READING

1 0.305 1 0.301 2 0.304 2 0.305 3 0.305 3 0.306 4 0.305 4 0.305

BOTTOM

LOCATION READING READING

N 0.322 0.321 S 0.321 0.321 E 0.321 0.320 W 0.322 0.321

CENTER -- --

Cape Fuel Systems Group

8.0 WARRANTY

WARRANTY

HMT Inspection, a division of HMT, Inc. has evaluated the condition of this tank based on the observations and measurements made by the HMT Inspection tank Inspector.

While our evaluation accurately describes the condition of the tank at the time of inspection, the tank owner/operator must independently assess the inspection information/report provided by HMT Inspection and any conclusions reached by the tank owner/operator and any action taken or omitted to be taken are the sole responsibility of the owner/operator. With respect to inspection and testing, HMT Inspection warrants only that the services have been performed in accordance with accepted industry practice. If any such services fail to meet the foregoing warranty, HMT Inspection shall re-perform the service to the same extent and on the same conditions as the original service.

The preceding paragraph sets forth the exclusive remedy for claims based on failure or of defect in materials or services, whether such claim is made in contract or tort (including negligence) and however instituted, and, upon expiration of the warranty period, all such liability shall terminate. The foregoing warranty is exclusive and in lieu of all other warranties, whether written, oral, implied or statutory. NO IMPLIED

WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE SHALL APPLY,

nor shall HMT Inspection be liable for any loss or damage whatsoever by reason of its failure to discover, report, repair or modify latent defects or defects inherent in the design of any tank inspected. In no event, whether a result of breach of contract, warranty or tort (including negligence) shall HMT Inspection be liable for any consequential or incidental damages including, but not limited to, loss of profit or revenues, loss of use of equipment tested or services by HMT Inspection or any associated damage to facilities, down-time costs or claims of other damages.

9.0 PHOTOGRAPHS Page 41 of 52

APIRPT.DOT REV 2 222-23960-211r2.doc 3/31/2008 2:22:41 PM

View of Tank View of Tank

View of Tank View of Tank

9.0 PHOTOGRAPHS Page 42 of 52

Manway A Ground Typ.

Shell vent sealed off Anchor chair Typ.

9.0 PHOTOGRAPHS Page 43 of 52

Nozzle E Nozzle F

Nozzle I Automatic gauge K.

9.0 PHOTOGRAPHS Page 44 of 52

Stairway base Manway O

Couplings S, T Ground cable to tank 311

9.0 PHOTOGRAPHS Page 45 of 52

Stairway platform Nozzle AA

Nozzles E, F, I Stilling well

9.0 PHOTOGRAPHS Page 46 of 52

Water draw Water draw to sump

Sump, center column detail Roof view

9.0 PHOTOGRAPHS Page 47 of 52

Interior view_1 Interior view_2

Hatches H, G PV Hatch E

9.0 PHOTOGRAPHS Page 48 of 52

Roof view_1 Couplings A, B, C

Hatch H Manway F

9.0 PHOTOGRAPHS Page 49 of 52

Hatch G PV Hatch E detail.

Center node D ATG data plate

9.0 PHOTOGRAPHS Page 50 of 52

Tanks 310, 31 Couplings Q, R

Stair treads not seal welded. Cracks leading to spalling

9.0 PHOTOGRAPHS Page 51 of 52

Plate lamination Data plate

Bottom detail_1 Bottom detail_2

9.0 PHOTOGRAPHS Page 52 of 52

Prior inspection & cleaning ATG w/FAS

Certificate of Qualification

This is to Certify

Mike Master

August 14, 2006 John Hazel Date

ASNT Level III

Method Level Expiration Date UT(t) II 04/24/2009 MT(y) II 04/24/2009

MFL II 08/31/2009

is qualified in accordance with the HMT Procedure for Qualification and Certification of Nondestructive Examination Personnel which is in compliance with the requirements of the American Society for Nondestructive Testing Recommended Practice SNT-TC-1A-2001 ed.

Certificate of Qualification

This is to Certify

Freylan Brown

November 30, 2007 John Hazel Date

ASNT Level III

Method Level Expiration Date

LT/BT II 11/01/2012

is qualified in accordance with the HMT Procedure for Qualification and Certification of Nondestructive Examination Personnel which is in compliance with the requirements of the American Society for Nondestructive Testing Recommended Practice SNT-TC-1A-2006 ed.