Attachment J.1 - Facility 123_Internal_2 July 2014.pdf

ACOE CONTRACT W911KB-10-D-0006, TASK ORDER 0026

TANK 123

API 653 OUT-OF-SERVICE INSPECTION

AND SUITABILITY FOR SERVICE

EVALUATION

FINAL

(PRE-REPAIR)

Eareckson Air Station, Shemya Island, Alaska

September 2014

Contract Agency:

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

Prepared By:

Michael B. Morris, API 570 Certificate No. 51732 Adam W. Ludemann, P.E., API 653 Certificate No. 44035

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 8117

Page Intentionally Left Blank

SUITABILITY FOR SERVICE STATEMENT – TANK 123

Enterprise Engineering, Inc. (EEI) has completed an out-of-service external and internal inspection and suitability for service evaluation of Tank 123 at Eareckson Air Station, Shemya, Alaska. The inspection was performed on June 30 - July 2, 2014 in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work.

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 summer 2019 (5 years from this 2014 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 summer 2024 (10 years from this 2014 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.

September 4, 2014 Adam W. Ludemann, P.E.

API 653 AST Inspector Certificate No. 44035

This tank inspection has determined that mandatory repairs are required for continued long term service. Due to the fall barge delivery, Tank 123 has been returned to service prior to interior repairs being completed. Mandatory repairs can be completed when the tank is in service or when the tank is removed from service for cleaning and repairs (spring 2015) but no later than summer 2016.

Additional recommended repairs have been identified, and if possible, should be completed in conjunction with the mandatory repair.

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 for Long Term Serviceability

COATING SYSTEM

Coating Removal Coating System at Localized Repair Locations Only

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEM

Gauge Tubes Wind Evaluation

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

Tank 123 – API 653 Inspection TABLE OF CONTENTS Eareckson Air Station, Shemya Island, Alaska September 2014 EEI Project No.: 8117

TANK 123

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 123 at Eareckson Air Station, Shemya Island, Alaska. The inspection was performed on June 30 - July 2, 2014. 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 123 is a field erected aboveground storage tank. The tank was originally fabricated and erected in 1965. The tank is 73 feet 3 inches in diameter and 38 feet 11 inches 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 near center sump. The nominal shell capacity is 30,000 Bbls and includes a column supported fixed cone roof and is not equipped with a floating pan. Tank 123 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 for continued long term service.

Due to the fall barge delivery, Tank 123 has been returned to service prior to interior repairs being completed. Mandatory repairs can be completed while the tank is in service or when the tank is scheduled for cleaning and repairs (spring 2015) but no later than summer 2016. The following are significant findings of the inspection.

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 thick-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.

Tank 123 – API 653 Inspection Page 1

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 the each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

Visual inspection found non-compliant weld clearances at nozzle reinforcing plates, insert plates, and doubler plates.

Tank 123 will be suitable for long term service pending the examination of non-compliant weld clearances.

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 summer 2019 (5 years from 2014 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.

The State may or may not require a reduced inspection interval based on the conditions above.

EEI recommends the next API 653 out-of-service inspection be performed no later than summer 2024 (10 years from this 2014 inspection). The next out-of-service inspection should be performed sooner if a change in condition or a change in service occurs.

It should be noted that a maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

Tank 123 – API 653 Inspection Page 2

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 123 to service.

1. Non-compliant weld clearances have been identified with respect to the nozzle reinforcing plates and shell insert plate.

• The clearance from the underside of the reinforcing plates at the 3-inch water draw and 4-inch spare nozzles to the floor-to-shell weld, are less than the required API minimum. Provide additional inspection per API 653 4.3.9.1.

• Non-compliant weld clearances have been identified with respect to the shell insert plate.

Specifically, the clearance from the underside of the 7-inch insert plate to the floor-to-shell weld, are less than the required API minimum. Figure 9.1 of API 653 requires a minimum of 6-inches of clearance between the insert plate and the floor-to-shell weld. Provide additional inspection.

The following additional inspection is required:

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

It is recommended to 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 bottom edge of the insert plate, reinforcing plates, and the shell-to-floor welds on the exterior of the tank at these locations.

Existing welds (i.e. welds along the periphery of the insert plate and reinforcing plates) 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 weld defects are observed.

• 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.

• Provide surface preparation and recoat all exterior repair areas and areas that are damaged as a result of repairs in accordance with Coating Requirements.

Tank 123 – API 653 Inspection Page 3

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 since 1965 and has performed adequately. There is no compelling reason to repair the condition other than it is a gross violation of API 653. This repair can be deferred to spring 2015 in conjunction with other scheduled repairs, but no later than summer 2016. This repair can also be performed while the tank is in service.

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. The bolts on the 4-inch spare nozzle are too short.

• Provide bolts that are long enough to fully engage the nuts.

2. The fill, issue, low fuel, and water draw line plug valve body cavity relief (BCR) relieves to the tank side of the valve. This configuration is of concern due to the inherent lower strength material, and any failure would subject the entire tank volume to leaking.

• Re-pipe the fill, issue, and 6-inch low fuel BCR to the pipeline side of the valve.

• Remove existing BCR piping in its entirety on the fill, issue, low fuel, and water draw double block and bleed plug valves. Provide carbon steel schedule 80 pipe nipples, carbon or stainless steel bar stock gate, or ball valves, and stainless steel tubing with 25 psid relief/check.

3. The concrete ringwall under the prior location of the flush cleanout has been notched. The sealant at this area has failed.

• Remove sealant and assumed 6-inches of grout at ringwall elevation gap. If grout is in good condition, removal is not necessary.

• Provide grout (if required) and jet fuel resistant polysulfide sealant at location.

4. Approximately 70 linear feet of failed sealant between the floor projection (chine) and the concrete ringwall was identified.

• Remove the sealant and organics from the perimeter of the tank.

• Clean the surfaces to be sealed.

• Provide jet fuel-resistant polysulfide sealant between the floor projection and the ringwall.

5. The tank is equipped with a wind girder on the 5th course. Coating failure and corrosion were identified.

• Provide surface preparation and coating of the wind girder. See Coating Requirements.

6. The hand pump on the product saver tank has reportedly seized up and no longer operates properly.

This is reportedly due to corrosion of the internal components. Corrosion and coating failure were identified on the piping associated with the product saver tank.

• Provide a new hand pump.

• The life of the pump may be extended by taking additional steps to ensure that no water is allowed to remain in the pump when not in use.

Tank 123 – API 653 Inspection Page 4

• Perform surface preparation and recoat affected areas piping. Utilize an epoxy coating system compatible with the existing system.

7. The test plunger and the two ball valves have seized on the Cla-Val high level shutoff float assembly.

Coating failure and corrosion were also observed on the threaded ball valves.

• Remove the high level shutoff float assembly and provide a stainless steel Cla-Val high level shutoff float assembly.

• Remove the two ball valves and provide flanged stainless steel ball valves.

• Provide two weldneck flanges at the existing tank nozzle locations to allow for installation of flanged ball valves above. Note this will also require exterior coating repairs.

• Provide schedule 80 stainless steel piping and appurtenances to the shutoff float assembly.

• Provide flange protectors and bolt caps at the flange set between the stainless steel and carbon steel piping.

8. Operations personnel indicated that the level alarm on the Magnetrol System is not functional. The system has both HI and HI-HI displacers. EEI exercised the manual test lever and the alarm sounded (for one of two levels) as expected. The problem may exist within the electrical control system.

• Contact the DLA-E Help Desk (800) 446-4950) for support under the SPAWAR service contract.

9. The existing roof nozzles were evaluated for compliance with DESC/DLA Memorandum. The tank is not equipped with a slotted stilling well for the ATG Probe. There is a significant amount of flex in the roof plates. The tank was overfilled in the past which resulted in significant deformation of roof plates. Operations personnel reported that the bouncing of roof plates causes the ENRAF ATG system to go out of calibration.

• Provide a 10-inch nozzle with an 8-inch slotted gauge tube for the ENRAF ATG which is supported from the floor and extends through the roof plates with a collar. The ATG flange shall be attached to the gauge tube, and not the roof. Provide weather shielding between gauge tube and roof nozzle. This design will allow the roof flex without compromising the calibration of the ATG. Gauge tube shall meet the intent of DLA-E ATG directives.

• Refer to “Gauge Tube Recommendations” below.

10. Coating failure and corrosion were identified on the flanges and bolts of the pressure vacuum vent nozzles (2) and the ENRAF ATG nozzles (2).

• Provide surface preparation and coating of the affected areas on the flanges and provide new nut and bolt sets.

11. The tank is equipped with two 8-inch pressure/vacuum vents.

• Disassemble and clean the pressure/vacuum vents.

12. The hinge on the ENRAF ATG case is broken.

• Provide a new hinge for the ATG case.

13. Tank 123 is not equipped with a dedicated sampling hatch for manual gauging and sampling. Manual gauging is currently performed at the nozzle containing the displacer for the ENRAF ATG.

• Provide an 8-inch slotted stilling well with a 10-inch roof nozzle as required by UFC 3-460-01.

Also provide a striker plate under the gauge hatch. This must be completed before the tank receives scheduled calibration and preparation of new gauge tubes.

Tank 123 – API 653 Inspection Page 5

• Installation shall be fully floor supported, and not roof supported, same as ATG gauge tube noted above.

14. The roof structural columns are equipped with weep holes approximately 3-inches up from the floor.

The bottom 3-inches of the columns have no drain.

• Provide a 3/8-inch drain hole near the tank floor which allows the entire volume of the column to drain.

15. The tank internal issue piping is not consistent with the current definitive design.

• Repipe the issue line to 18-feet from the tank shell, parallel to tank floor, with elbow and anti-vortex plate. Maintain 6-inches of clearance between the elbow and the tank floor.

16. The 6-inch low fuel piping does not extend to the tank sump.

• Extend the piping to 4-inches (minimum) of the bottom of the sump.

17. The hinges on the two manways are corroded and pose a risk of failure.

• Remove the existing hinges for each of the two tank manways.

• Consider adding davit support arms to aide in handling of the manway covers. This will require reinforcing plates on the tank shell as well as coating repairs.

18. The tank is not equipped with a diffuser on the internal fill piping.

• Compliance with UFC 3-460-01 and the current Tank Definitive Design can be met by installing a diffuser, oriented counter clockwise. Given the limited number of fills per year and ability to control submergence velocity, the installation of diffuser is considered less critical.

19. Coating failure and corrosion was identified on the minor piping at low point drains.

• Clean and recoat the affected areas. Provide an epoxy coating system compatible with the existing coating.

20. Several weld anomalies were identified on or near the internal horizontal course welds.

• Closely examine weld anomalies during next internal inspection for changes in condition.

21. Organics were identified in the containment area.

• Remove the organics from the containment area.

22. A mechanical anomaly was identified on the interior shell plate of the first course.

The following additional inspection is recommended:

• Remove the coating from the mechanical anomaly area prior to performing magnetic particle testing. It is recommended to remove the coating by high pressure water or chemical stripping methods and not by mechanical or sandblasting methods.

• Perform magnetic particle testing of the anomaly. The mechanical anomaly does not pose a threat to the integrity of the tank if no rejectable defects or indications are found.

• Contact EEI for further direction if defects are observed.

• 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.

• Provide surface preparation and recoat all interior areas that are damaged as a result of testing.

Tank 123 – API 653 Inspection Page 6

23. Several coating failures were identified on the tank floor (5 sf.).

• Clean and recoat the affected areas. Refer to coating requirements below.

24. Random locations of coating failure were observed on the roof exterior (5 sf.), shell exterior (5 sf.), stair attachments (10 sf.), exterior floor projection (15 sf.).

• Same as above.

25. Water ponding was observed on perimeter roof plates. Over time, this condition may cause coating failure and corrosion.

• Repair action is not recommended at this time. Monitor for coating failure and corrosion during routine maintenance.

26. The existing roof nozzles were evaluated for compliance with DESC/DLA Memorandum. The tank is not equipped with a nozzle located directly over the sump for the temperature/water probe.

• Provide a 6-inch roof nozzle riser for the temperature/water probe directly over the sump. Note due to the radial rafters, the nozzle may need to be located slightly offset from the tank sump.

27. The ball valves on the high point vents are corroded rendering some inoperable.

• Remove existing ball valves including the forged fittings on the main lines.

• Provide carbon steel forged fittings, and XS or XXS carbon steel nipples up to the first flange. All other piping, flanges, and ball valves shall be stainless steel.

• This will also require a pipeline drain down.

28. Coating failure and active corrosion were identified on the pressure relief valves (PRVs), ball valves, and piping of the pressure relief loops.

• Remove the existing pressure relief loops to within 3-inches of the forged fittings on the main lines.

• Provide XS or XXS carbon steel nipples up to the first flange. All other piping, flanges, and ball valves shall be stainless steel. Provide flanged ball valves and flanged test tees. No threaded fittings are permitted. Provide carbon steel flanged PRVs with flange protectors and bolt caps at the carbon/stainless flange connections.

• Provide an epoxy coating system compatible with the existing system.

• This repair should happen concurrently with replacement of the high point vents above.

29. Corrosion was identified at the soil-to-air interfaces on the fill and issue lines.

• Remove liner material and excavate 12 to 18-inches of the dike material. Clean surface of pipe and inspect for corrosion following the provisions of API 570.

• Provide a flood coat epoxy system designed for submergence service. Re-bed the piping and repair the liner material.

30. The internal water draw piping was bent however the integrity of the piping was not compromised and operations personnel reported that the water draw functioned as required.

• Closely evaluate during next internal inspection for changes in condition.

Tank 123 – API 653 Inspection Page 7

31. Based on MFL and UT examination, bottom-side pitting/corrosion is prevalent on the tank floor.

• Short Term Recommendation: MFL Scanning of the tank floor is crucial detecting and monitoring backside corrosion on the tank floor. Recommend performing MFL scanning on a 10-year interval.

• Long Term Recommendation: Consideration should be given to adding cathodic protection to the tank floor in order to limit or prevent the present corrosion from progressing. Testing of the tank floor should be performed during the next CP inspection to see if cathodic protection would be effective due to the presence of the oil sand bedding. The CP CMP should address this issue.

32. 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. When welding on the shell or roof, the coating on the opposite side from the weld shall be inspected and repaired when damaged.

Recommended Repairs for Long Term Serviceability

1. Program the tank for the next API 653 in-service external inspection no later than summer 2019 and the next API 653 out-of-service internal and external inspection no later than summer 2024.

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

COATING SYSTEM

Coating Removal

All repairs involving steel surface grinding, cutting, and welding shall be preceded by proper coating removal. Unless specifically indicated elsewhere, it is not known if the existing coatings have lead or other hazardous materials. The repair contractor shall be responsible for testing coating systems for hazardous materials. If the repairs involve removal or disturbance of paint containing hazardous materials, such work shall be performed in accordance with UFGS Section 02 82 33.13 20 “Removal/Control and Disposal of Paint with Lead”.

Coating System at Localized Repair Locations Only

General

Repair localized areas of failed/damaged coatings identified herein and areas affected by the repair work.

SSPC QP 1 and SSPC QP 5 Requirements At localized repair locations (less than 250 square feet total of repair locations) the requirements for ISO 9001 or SSPC QP 1 and SSPC QS 1 contractor and SSPC QP 5 coating inspection company will be waived.

Exterior Repair Coating System

The existing coating system on Tank 123 at Eareckson AS is a moisture curing urethane manufactured by The Sherwin-Williams Company. The system was installed in 2001 and consists of a Corothane I PrePrime, Corothane I Ironox B intermediate coat, and a Corothane I Ironox A topcoat. Contact Sherwin- William, Mike Zack, 907-229-7018 for repair coating system compatible with the system provided in 2001. Follow manufacturer’s recommendations to ensure compatibility and adhesion of the repair coating system. Protect adjacent areas from damage and overspray.

Tank 123 – API 653 Inspection Page 8

Interior Repair Coating System (Floor)

The existing floor coating system is a thick film liner installed in 2001. Repair coating shall be compatible with the existing system. Follow manufacturer’s recommendations to ensure compatibility and adhesion of the repair coating system. Protect adjacent areas from damage and overspray.

Interior Repair Coating System (Shell and Roof)

Provide interior coating system as specified in UFGS Section 09 97 13.17 “Three Coat Epoxy Interior Coating of Welded Steel Petroleum Fuel Tanks”. This specification covers the requirement for a three coat epoxy system for interiors of Air Force bulk fuel storage tanks.

Follow manufacturer’s recommendations to ensure compatibility and adhesion of the repair coating system. Observe all requirements for soluble salts contamination, cleanliness between coats, and application conditions. Protect adjacent areas from damage and overspray.

Tank interior coatings shall cure for not less than 14 days prior to introducing fuel into the tank. Provide longer cure time when recommended by manufacturer.

Provide dehumidification and temperature control when required to prevent dew point condensation and to obtain satisfactory surface preparation and coating results. Note that this may be localized as necessary for small coated areas.

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: 0.00259 inches per year

Shell: 0.00060 inches per year

Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rate for the floor was calculated using an assumed original metal thickness and a 1965 year of construction. It is believed that the onset of corrosion began sometime after the tank was installed due to the degradation of the oil sand bed. The actual corrosion rate may be more aggressive which prompts the recommended 10-year internal inspection interval in 2024. The corrosion rate should be updated during the 2024 internal inspection. Corrosion rates for the shell and roof were calculated using an assumed original metal thickness and a 1965 year of construction.

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 37.3 mils, is a thick-film lining. The floor coating is 13 years old. A product-side pitting survey was unable to be performed.

Bottom side corrosion with small volumetric metal loss may be present and not detected by magnetic flux leakage (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.

Tank 123 – API 653 Inspection Page 9

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 not equipped with the means to detect and contain a bottom leak. No record of a liner below the tank floor was found. Based on this information, the MRT used in the calculations is

0.100 inch for general floor plates. The MRT at the critical zone shall be the smaller of one-half the original floor thickness or 50% of the minimum thickness of the lower shell course, but not less than

0.100 inches. Based on this information, the MRT used in the calculations is 0.15625 inch at the critical zone.

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 123:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 123 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Non-compliant weld clearances were identified at reinforcing plates that may affect the structural integrity of the tank.

Acceptable – no further action required.

Shell Non-compliant weld clearances were identified at shell nozzle reinforcing plates and insert plates that may affect the structural integrity of the tank.

Acceptable after examinations and repairs if necessary.

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

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): No, constructed in 1965.

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.

Tank 123 – API 653 Inspection Page 10

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

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 design liquid level of 33 feet 9 3/8 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 = 1.275, S1 = 0.4910, an importance factor of 1.15.

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, unanchored tank is at risk of overturning and/or sliding.

Evaluation of the shell buckling determined that the shell requires a stiffener. The tank was retrofitted with an intermediate shell stiffener.

The wind evaluation indicates that an empty, unanchored tank is at risk of overturning. Maintain minimum product level of 5 feet as determined by previous calculations.

ADDITIONAL DISCUSSION ITEM

Gauge Tubes

Gauge Tube Requirements

The requirements for stilling wells have been reviewed. These requirements are based on the DESC/DLA-E Memorandum “Automated Tank Gauge (ATG) Installation Policy” of December 2009.

The comments below represent concept solutions based on the memorandum. It is recommended that the concept be submitted to DESC/DLA-E for ratification or redirection. Field verification of constructability by the prime contractor is also recommended.

Tank 123 Existing Conditions

Tank 123 is an AST with a cone-down floor with a near center sump. The tank is not equipped with a floating pan. The tank does not have a gauge tube used for manual gauging and sampling. The temperature probe for the ENRAF ATG is located in an 8-inch nozzle approximately 22 feet from the shell. The ENRAF ATG displacer is located in an 8-inch nozzle that is approximately 3 feet from the shell. The displacer is not located in a gauge tube.

Gauge Tube Recommendations

The following are recommended for compliance with the DESC/DLA-E Memorandum (for ATG) and UFC 3-460-01 (for operations) based on continuing to use the existing ENRAF ATG system:

• Provide a 10-inch nozzle with an 8-inch slotted gauge tube for the ENRAF ATG which is supported from the floor and extends through the roof plates with a collar.

Tank 123 – API 653 Inspection Page 11

• Provide an 8-inch slotted stilling well with a 10-inch roof nozzle for manual gauging. Support stilling well from the floor and extend through the roof plates with a collar. Also provide a striker plate under the gauge hatch.

• Provide a 6-inch roof nozzle riser for the temperature/water probe directly over the sump.

Note: These recommendations must be validated by DLA-E.

Wind Evaluation

API 653 states that where conditions might adversely affect the performance or structural integrity of the shell of an existing tank, an evaluation and determination must be made regarding suitability for intended service. The analysis shall take into consideration all anticipated loading conditions and combinations, including pressure due to fluid static head, internal and external pressure, wind loads, seismic loads, roof live loads, nozzle loads, settlement and attachment loads.

Although formulas are provided for calculating the minimum thickness for welded tank shells, they only consider liquid loading. API 653 states that all other loads shall be evaluated according to the original standard of construction and engineering judgment shall be used to evaluate different conditions or new information. There is no mandatory requirement to upgrade an existing tank to current API 650 standards as compared to the other proscriptive repair requirements found in API 653.

The wind evaluation determined that an empty unanchored tank is at risk of overturning.

The evaluation was performed using the current design wind speed of 178 mph. At the time of construction, the design wind speed was likely less than 110 mph.

The tank design was likely suitable for the criteria in force at that time. However, it is not recommended to leave the tank empty in the event that a major wind storm has been predicted.

EEI takes no formal position as to repairing the tank, or accepting the risk of failure and consequence of release, beyond advising the owner of cases such as this where the engineering analysis finds that the original design does not meet current tank design and construction standards.

As part of a previous project, it was determined that a minimum product level of 5-feet was suitable to resist sliding/overturning during a high wind event. The decision to maintain a minimum product level is entirely up to the tank owner and the level of risk they are willing to assume.

The installation of tank anchors into a foundation of sufficient mass would eliminate the risk of overturning due to wind forces. However it is not known if the ring wall has sufficient mass. The use of anchoring is not considered practical compared to the ease of having liquid in the tank.

CLOSURE

Conclusions

Mandatory repairs were identified for continued long term service. Tank 123 may be returned to service for a short duration not to exceed summer 2016. The mandatory repairs shall be completed within the two year interval. Pending completion of the mandatory repair items noted, Tank 123 will be suitable for continued service.

Tank 123 – API 653 Inspection Page 12

Project Team

Site Team

Adam W. Ludemann, P.E. Mechanical Engineer, API 653 AST Inspector Certificate No. 44035, API Inspector of Record.

Michael B. Morris Tank Technician, API 570 Piping Inspector Certificate No. 51732

Support Team

Stacy M. Kaplan-McMillan Project Manager

Stephen S. Brooks, P.E. Technical Advisor, QA Review API 653 AST Inspector Certificate No. 17

Tank 123 – API 653 Inspection Page 13

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Shemya Island, Alaska Tank No. 123

Inspection Date(s): June 30 – July 2, 2014 Tank Type: Vertical AST

Type of Inspection: Internal & External w/ Suitability for Service Evaluation Contract Number, Task Order: W911KB-10-D-0006, 0026

Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: Adam W. Ludemann, P.E.

API-653 AST Inspector Certificate No. 44035

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard Unknown, 1965, API 650 2nd Ed. (Assumed) Diameter: 73'-3"

Shell Height: 39'-11" Product, Specific Gravity: JP-8, 0.84

Design Pressure / Temperature: Unknown Nominal Capacity: 30,000 Bbls

Safe Fill Height: 30 feet 1-5/8 inches (from facility) GPS Latitude & Longitude: 52 Deg 43’ 51.80” N, 174 Deg 05’ 33.61” E (Source – Google Earth) Foundation Configuration: Concrete Ringwall

Shell Configuration: Butt Welded, 7 courses Roof: Fixed, column supported cone roof

Cathodic Protection: None Still Wells: None

Last Inspection (Type, Date): In-service: September 2011, Out-of-Service: June 2005 Last Coated Internally (Product): Lower 40-inches of shell and entire floor: 2001, Unknown thick film liner. Upper shell courses: unknown, Unknown product Last Coated Externally (Product): 2001, Moisture-cured Urethane

INSPECTION RESULTS

Can tank return to service? Yes, see paragraph titled “Mandatory Repairs” in body of report

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: summer 2019 (5 Years) Out-of-Service: summer 2024 (10 Years)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: None available

Tank 123 – API 653 Inspection Appendix A, TANK SUMMARY SHEET Eareckson Air Station, Shemya, Alaska

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

COATINGS

APPURTENANCES

PIPING

Tank 123 – API 653 Inspection Appendix A, TABLE OF CONTENTS

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

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

FOUNDATION

Type The tank is supported by a concrete ringwall. The ringwall is notched below the abandoned flush cleanout. Remove sealant and evaluate grout condition.

Assume 6-inches of grout removal at location. If grout is in acceptable condition, removal is not necessary.

Levelness Tank 123 is relatively level. The maximum measured differential between max and min elevations is 0.11 feet.

Tank 123 passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt Tank 123 is slightly tilted. The amount of tilt is

0.72 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The tank floor is approximately 5-inches above the containment dike floor.

Material Below Tank Floor

The material below the tank floor could not be inspected. Cathodic protection reports indicate that the material below the tank floor is oil saturated sand.

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

Tank Anchors Tank is not equipped with anchors. Calculations show that tank meets the requirements for a self-anchored tank at the current fill height of 30 feet 1 5/8 inches.

Secondary Containment The secondary containment consists of a membrane liner covered with a rock ballast.

Vegetation was observed growing throughout the containment dike.

Recommend removing all vegetation.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were

Sealed at Foundation

The floor extension is sealed to the ringwall with an elastomeric sealant. The sealant has failed in several locations.

Provide jet fuel-resistant polysulfide sealant between the floor projection and the ringwall at areas of failed sealant.

Additional Foundation Items, Comments or Notes:

None.

Tank 123 – API 653 Inspection Appendix A, Page 1

FLOOR

Comments/Recommendations

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

TANK FLOOR

Type The tank floor configuration is cone down with a center sump. The plates are orientated in rows and are lap welded. There are butt-welded circumferential sketch plates around the perimeter of the tank.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.244 inch.

Sketch Plates/Annular Ring Plates

The tank has 29 circumferential sketch plates.

Thickness The average thickness of the floor plates based on 2 UT readings per floor plate is 0.312 inch.

Interior Width See floor drawing.

Floor seam welds The thick-film coating system on the floor prevented inspection of the floor seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found 2 locations requiring an ultrasonic test (UT) prove-up. The UT prove-up identified the minimum thickness at these locations. The lowest UT measurement on the interior floor plates was 0.218 inch. The lowest UT measurement on the sketch plates was 0.266 inch.

No repairs are required.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, bottom side pitting/corrosion is prevalent. The extent of the corrosion is not at the level of severity that would reduce the next inspection interval to less than 20-years.

The lack of a cathodic system was not uncommon at the time of the tank construction, but is no longer a supported position. Thus, the periodic floor scanning for backside corrosion is critical for this circumstance. Consideration should be given to installing a cathodic protection system to arrest corrosion as a long term solution.

Top Side Floor Pitting/Corrosion

No top side pits or corroded areas were identified for repair.

Patch Plates There are four 6.5-inch diameter plates.

Each plate is in close proximity of each of the four columns.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted.

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

Tank 123 – API 653 Inspection Appendix A, Page 2

FLOOR

Comments/Recommendations

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

Doubler/Striker Plates Doubler plates are installed below the columns, fill piping, issue piping, and low fuel piping.

There are non-compliant weld clearances between the doubler plates listed above and the adjacent floor welds.

Due to the positive service history of the tank, no action is required at this time.

Plug Welds No plug welds were observed.

Weld Artifacts No weld artifacts were observed.

Vacuum Box Testing Vacuum box testing was not performed.

Helium Leak Testing Helium leak testing was not performed.

Floor Critical Zone No corrosion or deflection was observed within the critical zone.

Floor Profile The floor is cone down with one sump near the center of the tank. The tank floor has a 1% slope to the sump.

Sumps The tank is equipped with a 34-inch diameter near center sump.

Secondary Liner Below

There is no record of a secondary liner below the tank floor.

Leak Detection Below

No leak detection standpipes were located.

Cathodic Protection The tank is not equipped with cathodic protection of the tank floor.

Based on MFL and UT examination, bottom side pitting/corrosion is prevalent.

Consideration should be given to adding cathodic protection to the tank floor.

Testing of the tank floor should be performed during the next CP inspection to see if cathodic protection would be affective due to the presence of the expected oil sand bedding.

Additional Floor Items, Comments, Notes:

Tank 123 – API 653 Inspection Appendix A, Page 3

SHELL

Comments/Recommendations

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

TANK SHELL

Nominal Thickness UT Thickness Coating

1st Course 0.442 inch 20.5 mils

2nd Course 0.364 inch 21.6 mils

3rd Course 0.318 inch 19.3 mils

4th Course 0.276 inch 24.1 mils

5th Course 0.247 inch 27.4 mils 6th Course 0.249 inch 18.6 mils

7th Course 0.251 inch 16.2 mils

Rim Angle 0.295 inch

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

Roundness Measurements indicated minor out-of-roundness but within acceptable limits.

Dents/Buckles 17 dents were observed on the 7th shell course.

The dents appear minor in nature and are likely a result of repairs performed on the tank as a result of the overfill.

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.

A mechanical anomaly was identified on the first shell course.

Perform magnetic particle testing of the anomaly to confirm the area is free of cracking or other defects.

Stencil date and label UT tested per API

Exterior Shell pitting/corrosion

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

Insert plates One 7-inch diameter insert plate 1-inch from floor to shell weld, one insert plate on the upper shell course and one insert plate at old flush cleanout. The 7-inch diameter insert plate does not meet weld spacing requirements for insert plates.

Perform magnetic particle testing of the weld around the insert plate and the shell-to-floor weld on the exterior of the tank.

Stencil date and label UT tested per API

Welded Patch Plates No welded patch plates were observed.

Floor Projection The floor projection extends an average of 1.75-inches beyond the tank shell. The average thickness is 0.324-inch.

Interior Shell Welds Visual inspection of the interior shell welds found four locations of weld anomalies.

Indications include undercut and lack of weld cap. The indications are between the first and second shell courses.

Due to the positive service history of the tank, no action is required at this time.

Closely examine the welds for changes in condition during the next internal inspection.

Tank 123 – API 653 Inspection Appendix A, Page 4

Comments/Recommendations

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

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

Door sheet No door sheets were observed.

Floor-to-Shell Weld – Interior

The interior floor-to-shell weld was covered in a heavy sealant and was not accessible. The sealant appeared to be in excess of ½” thick in some locations. The sealant appeared to be continuous and free from defects.

Floor-to-Shell Weld – Exterior

Visual inspection of the exterior floor-to-shell weld found no indications for further inspections or examinations.

Shell Manholes The tank is equipped with two 30-inch shell manholes.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Shell Reinforcing Plates

Manhole-1

(Size, Thickness, Telltale Hole)

Size: 30-inch diameter nozzle, 0.431 inch thick

(UT).

Reinforcing Plate: Tombstone, 60-inch x 64-inch x 0.429-inch thick (UT).

Telltale hole is packed with grease.

The hinge on the manhole is corroding and at risk of failure.

Consider adding a davit support arm to aide in handling the manhole cover.

Note, this will require reinforcing plates on the tank shell as well as coating repairs.

The use of hinges, particularly in corrosive climates, is no longer…