Attachment J.1 - Tank 101 A(Facility 8314A)Ft Riley FINAL 2019.pdf

US Army Corps of Engineers Omaha District

API 653 In‐Service (Visual) Inspection Report

FORT Riley, KS Tank 101A (Facility 8314A)

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

(USACE POL‐MCX)

12/3/2019

Table of Contents ACRONYMS AND ABBREVIATIONS .......................................................................................................... …...3

GENERAL SUMMARY

INSPECTION DATE

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Secondary Containment

2. Tank Construction

3. Tank Foundation

4. Tank Bottom

5. Tank Shell

6. Tank Floating Roof

7. Tank Fixed Roof

8. Tank Appurtenances

9. Tank Piping System

10. Fire Protection System

C. FINDINGS AND RECOMMENDATIONS

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

2. REQUIRED REPAIRS to Fully Comply with API 653, or, Federal, State, and Local Codes

3. RECOMMENDED REPAIRS TO FULLY COMPLY WITH UFC 3‐460‐01, AW 78‐24‐27 Standards or as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS

APPENDIX B: ENGINEERING DRAWINGS

APPENDIX C: ENGINEERING DATA

APPENDIX D: API STANDARD 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX E: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

GENERAL SUMMARY

Summary of Inspection

An API Standard 653 In‐Service (Visual) inspection of Tank 101 A (Facility 8314 A) at Ft. Riley, KS was completed on December 3, 2019. Tank 101 A (Facility 8314 A) is a 2,500 barrel above ground storage tank containing F‐24 jet fuel. The tank was constructed in 1984 to API Standard 650 with a nominal diameter of 28 feet and a nominal shell height of 24 feet. The significant findings (overview) is summarized below.

MANDATORY REPAIRS per API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards:

1. None

REQUIRED REPAIRS to Fully Comply with API 653, Federal, State, or Local Codes:

1. The bottom‐to‐foundation seal is deteriorated around the entire circumference of the tank.

(Approximately 88‐linear feet)

2. The concrete ring‐wall has approximately 30 linear feet of hairline cracks.

3. The foundation has a 12‐inch area of broken concrete around the 3/4‐inch pipe penetration in the ringwall.

4. The support base for the ENRAF’s electronic readout is bolted to the top of the foundation.

The support partially extends under the bottom projection allowing a potential access point for water to enter the underside of the tank.

5. The fixed roof, shell, shell nozzles, and tank appurtenances have general coating deterioration throughout the entire tank. (Approximately 2,800ft²)

6. The (Varec) mechanical tape gauge is seized and not functioning. The ENRAF readout has the tank level at 14’ 8‐15/16” and the MTG has the tank level at 24’ 2”.

7. The NFPA placard is worn and weather faded.

8. The tank is equipped with two (2) grounding lugs welded to the bottom projection. There is inadequate weld spacing between the grounding lug and the shell‐to‐bottom weld. The minimum distance between the edge of any permanent attachment weld and a horizontal weld is 3‐inches IAW API‐650. The grounding lugs are not configured to API‐650, and a minimum of four (4) grounding lugs shall be provided IAW API‐650. Note: The grounding lugs are bolted and not exothermically welded IAW AW 78‐24‐27.

9. The lens cover for the light that is attached to the perimeter guardrail on the fixed roof is filled with water.

10. The product receipt line’s isolation valve and the high liquid level shut‐off valve (Cla‐Val) are bolted directly to each other not allowing a means of thermal relief. Even though there is no piping, pressure can build a possibly cause a leak.

RECOMMENDED REPAIRS TO FULLY COMPLY WITH UFC 3‐460‐01, AW 78‐24‐27 Standards or as Part of Regular Maintenance:

1. The facility number is not attached to the tank, and the tank stencils are faded and barely legible. Tanks should be marked with easily discernible painted numbers and letters IAW MIL‐STD‐161 and UFC 3‐460‐01.

2. The piping stencils are faded and weathered. The piping should have easily discernable banding, product name, and flow direction IAW MIL‐STD‐161 and UFC 3‐460‐01.

3. The valves within the secondary containment are not marked with easily discernable painted numbers or numbered corrosion‐resistant metal or plastic tags as recommended

IAW UFC 3‐460‐01.

4. The pipe penetrations through the secondary containment berm for the 6‐inch issue line and 4‐inch receipt line for Tanks 101A and 101B are wrapped for underground protection.

The piping is not equipped with a sleeve, a sleeve seal, and a nitrile boot seal that is clamped to the piping as recommended IAW 78‐24‐27. (two 4‐inch and two 6‐inch pipe penetrations)

5. The five (5) sets of pipe supports within the containment are pipe hangers. The receipt line does not have any pipe supports on the shell. The 30‐foot section of receipt line and conduit are supported by the bolted flange at the top of Shell Course three and the pipe hanger. It is not recommended to use pipe hangers IAW UFC 3‐460‐01.

6. The 36‐inch x 36‐inch secondary containment drain basin is not equipped with a link seal around the piping as recommended IAW AW 78‐24‐27.

7. The product issue and receipt line are not equipped with a fuel sample connector as recommended IAW 78‐24‐27.

8. The 4‐inch product receipt line is not equipped with an isolation valve before the Cla‐Val

IAW AW 78‐24‐27.

9. The low suction line/stripper line is a 2‐inch valve that is welded to the 4‐inch shell overflow. The shell overflow pipe has no supports or shell attachments and is only supported by the bolted 4‐inch flange connection at the top of Shell Course three and the bolted 2‐inch low suction flange connection. The low suction is near the water draw‐off system and does not tie into the issue line or have a CAM type connection.

10. The conventional TRVs for the 4‐inch receipt line and 6‐inch issue line are not equipped with a test tee as recommended in UFC 3‐460‐01.

11. The water draw‐off nozzle is a ¾‐inch coupling welded to ¾‐inch stainless steel piping. A 2‐ inch nozzle with a DBB valve with an eccentric flat on bottom (FOB) reducer is recommended. The water draw‐off system is not equipped with a product return nozzle.

The piping is configured to tie into the existing water draw‐off nozzle. An additional return nozzle with an eccentric flat on bottom (FOB) reducer attached to a 2‐inch nozzle with a DBB valve is recommended to meet the specifications described in AW 78‐24‐27.

12. The PST ground cable is bolted to the PST leg and not exothermically welded IAW

AW 78‐24‐27.

13. The tank is equipped with one (1) 24‐inch shell manhole. The manhole is not hinged or equipped with a davit arm as recommended IAW AW78‐24‐27. Two 36‐inch manholes are recommended IAW UFC 3‐460‐01.

14. The tank is not equipped with a shell mounted low level alarm and low‐low level alarm as described in AW 78‐24‐27. The alarms are provided through a (Magnatrol) electronic level sensor located on the fixed roof.

15. The tank is not equipped with a shell mounted high level alarm and high‐high level alarm as described in AW 78‐24‐27. The alarms are provided through a (Magnatrol) electronic level sensor located on the fixed roof.

16. The high level shut off is not equipped with an intermediate platform. The high level shut off’s piping is constructed of threaded carbon steel and not equipped with lockable ball valves as described in AW 78‐24‐27.

17. The tank is equipped with a 3‐inch (Varec) center vent and flame arrestor. Flame arrestors are not recommended unless required by host‐nation and/or NATO regulations IAW UFC 3‐460‐01. The product issue is a 6‐inch line, and the product receipt is a 4‐inch line.

Alternatively, the normal vent shall be at least as large as the largest fill or withdrawal connection, unless sized IAW API‐2000. A 24‐inch center vent is recommended IAW AW 78‐ 24‐27.

18. The tank is not equipped with sample gauge well as recommended IAW UFC 3‐460‐01 and AW 78‐24‐27. The only means to manually gauge the tank is through the ENRAF hatch.

19. The tank is not equipped with two (2) cable scaffold supports IAW UFC 3‐460‐01.

20. The conduit supports on the fixed roof are not properly secured. The supports freely rest on the tank top and pose the potential risk as a trip hazard and can rub and wear the coating.

INSPECTION DATE

API In‐Service (Visual) Inspection Date: December 3, 2019 Inspector(s): Stephen M. Hollenzer API 653 Inspector No. 80182

PREVIOUS INSPECTION DATES

API Out‐of‐Service (Internal) Inspection Date: March 18, 2015 API In‐Service (Visual) Inspection Date: March 18, 2015 API In‐Service (Ultrasonic) Inspection Date: March 18, 2015

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

API Out‐of‐Service (Internal) Inspection Date: March 18, 2025 (Based on the last API Out‐of‐Service Summary of findings)

API In‐Service (Visual) Inspection Date: December 3, 2024 API In‐Service (Ultrasonic) Inspection Date: March 18, 2030(Based on the last

API Out‐of‐Service Summary of findings)

Stephen M. Hollenzer, API‐653 #80182

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner US Army

Location Ft. Riley

Facility Number 8314 A

Tank Number 101 A

State / Country Kansas, United States

City Fort Riley

Inspection Date December 3, 2019

Tank Manufacturer Webco Tank, Inc.

Design Standard API Standard 650

Date of Construction 1984

Tank Contents F‐24 Jet Fuel

Tank Serial Number Unknown

Tank Diameter 28’

Shell Height 24’

Product Height 14’ 08‐15/16”

Tank Capacity 2,500 barrels (105,000 gallons)

Foundation Concrete Pad

Construction

Bottom Lap‐Welded (Flat)

Shell Butt‐Welded (Cylindrical)

Floating Roof None

Fixed Roof Lap‐Welded

Material

Bottom Carbon Steel, A‐36

Shell Carbon Steel, A‐36

Floating Roof NA

Fixed Roof Carbon Steel, A‐36

Cathodic Protection Impressed Current

Interior Coating System Thin Film Epoxy/Polyurethane (Assumed)

Exterior Coating System Thin Film Epoxy/Polyurethane (Assumed)

Level Gauging ENRAF ATG

Overfill Protection Cla‐Val Hydraulic Control Valve

Piping

Receipt 4" Carbon Steel

Issue 6" Carbon Steel

Low Suction 2" Carbon Steel

Water Draw‐Off 3/4" Stainless Steel

Level Alarms & Controls

Description ENRAF ATG Independent (Electronic Sensor)

High‐High Level Alarm: 22’ 9‐5/8” 95%

High‐Level Alarm: 20’ 4‐7/8” 85%

Low‐Level Alarm: 3’ 7‐1/8” 15%

Low‐Low Level Alarm: 1’ 2‐3/8” 5%

High‐Level Control Shut‐Off: 95,500 gallons

Type of Internal Floating Roof

None

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

This project will perform API 653 inspections of various tanks at facilities throughout the United States. Additional consideration is given to federal, state, and local regulations, as well as applicable military criteria and general industry standards.

An API Standard 653 In‐Service (Visual) inspection was performed for Tank 101 A

(Facility 8314 A).

2. Site Information

On December 3, 2019, Argus Consulting and our sub‐consultant (InterSpec, LLC) performed an API 653 In‐Service (Visual) inspection of Tank 101 A (Facility 8314 A), located at Ft. Riley, KS.

B. TANK INSPECTION COMMENTS

1. Secondary Containment

40 CFR 112.7(c) states that the entire secondary containment system, “including walls and floor, must be capable of containing oil and must be constructed so that any discharge from a primary containment system ... will not escape containment before cleanup occurs.” 40 CFR 112.8(c)(2) and 40 CFR 112.12(c)(2) state that diked areas must be “sufficiently impervious to contain oil.” The purpose of the secondary containment requirement is to prevent discharges, as described in 40 CFR 112.1(b);

therefore, effective secondary containment methods must be able to contain oil until the oil is cleaned up. The secondary containment area consists of a geomembrane floor and sloped berm walls. An informal containment evaluation was conducted. Based on visual observation, the containment does appear to be of sufficient size to contain a total tank loss per UFC 3‐460‐01 Section 8‐14.2.1, “The containment area needs to have sufficient capacity to contain the tank contents plus one foot of freeboard. If the containment has the capacity to contain the tank contents plus one foot of freeboard, the containment area is sufficient.” Based on visual observation, the secondary containment area appears to be properly graded to drain water away from the tank in accordance with NFPA 30.

2. Tank Construction

Tank 101 A (Facility 8314 A) is a nominal 2,500 barrel, 28’ diameter by 24’ tall, F‐24

Jet Fuel, aboveground vertical storage tank. The original construction nameplate is affixed to the tank but is not legible.

3. Tank Foundation

The tank rests on top of a concrete ringwall. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The concrete pad has minor exposed hairline cracks. The tank bottom‐to‐foundation sealant was inspected; it is not in satisfactory condition.

A shell settlement survey was performed during the inspection in accordance with

Appendix B of API Standard 653. Settlement results are listed in Appendix A.

4. Tank Bottom

Not evaluated during this inspection.

5. Tank Shell

The shell is constructed of A‐36 carbon steel material. The shell is a cylindrical design, butt‐welded together, consisting of three (3) courses. The shell exterior has a thin film epoxy coating system (assumed). The coating was inspected for disbonding, adhesion, deterioration, and discoloration; it is in unsatisfactory condition. Based on visual observation, roundness, plumbness, peaking, and banding of the shell appear to be within the allowable tolerances of API Standard 653. Based on visual observation, the tank is stable and does not appear to be in danger of overturning or buckling due to high winds or seismic conditions.

6. Tank Floating Roof

The tank is not equipped with an internal floating roof.

7. Tank Fixed Roof

The fixed roof is a supported cone roof constructed of carbon steel material. The fixed roof has an epoxy coating system (assumed) on the exterior. The coating was inspected for disbonding, adhesion, deterioration, and discoloration; it is in unsatisfactory condition.

8. Tank Appurtenances

a. Water Draw‐Off System

1) Water Draw‐Off Line: The tank is equipped with a 3/4‐inch water draw‐off line. The water draw‐off line does not comply with UFC 3‐460‐01 and

AW 78‐24‐27 standards.

2) Product Saver Tank: The product saver tank (PST) complies with

UFC 3‐460‐01 and AW 78‐24‐27 standards, except for the lack of having the ground strap exothermically welded.

b. Low Suction Line

The tank is equipped with a 2‐inch low suction line.

c. Issue Line

The 6‐inch issue line is carbon steel. The line is protected from overpressure with a thermal relief system. The thermal relief system does not comply with

UFC 3‐460‐01 and AW 78‐24‐27 standards.

d. Receipt Line

The 4‐inch receipt line is carbon steel. The line is protected from overpressure with a thermal relief system; however, the high liquid control shut‐off valve is bolted directly to the isolation valve. The thermal relief system does not comply with UFC 3‐460‐01 and AW 78‐24‐27 standards.

e. Automatic Tank Gauging (Fuel Level)

The tank is equipped with an ENRAF system for electronic fuel level gauging and complies with UFC 3‐460‐01 and AW 78‐24‐27 standards.

f. Automatic Tank Gauging (Water Level)

The tank is equipped with an ENRAF VITO system for electronic water level gauging and complies with UFC 3‐460‐01 and AW 78‐24‐27 standards.

g. Mechanical Tank Gauging

The tank is equipped with a SHAND&JURS mechanical tape level gauge (MTG) for mechanical fuel level gauging. The MTG level reads 24’ 2” and does not match the ENRAF ATG level of 14’ 8‐15/16”

h. Tank Sampling\Manual Gauging

The tank is not equipped with a separate stilling well for sampling and manual gauging and does not comply with UFC 3‐460‐01 and AW 78‐24‐27 standards.

i. Level Alarms\High Level Shut‐Off

The ENRAF system provides low‐low, low, high, and high‐high level alarms. The tank is equipped with electronic independent low, low‐low, high, and high‐high level alarms and does not comply with UFC 3‐460‐01 and AW 78‐24‐27 standards. The high level shut‐off assembly is not accessible from the external ladder and does not have an intermediate platform.

j. Ladder and Platforms

The tank’s fixed roof is accessible by an external caged ladder mounted on the shell of the tank.

k. Grounding

The tank has two (2) grounding straps around the circumference of the tank.

The tank grounding lugs are welded directly to the bottom projection and are not exothermically welded to a ground lug with a pad on the shell.

l. Anchoring

The tank does not have anchors around the circumference of the tank.

9. Tank Piping System

Fuel is received by trucks and is issued to trucks.

10. Fire Protection System

The fire department provides fire protection. Fire hydrants were located near the tank.

C. FINDINGS AND RECOMMENDATIONS

The following information identifies the significant findings found during the tank inspection:

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

Mandatory repairs represent items that require immediate attention, in order to prevent imminent risk to system operators, equipment integrity, or the adjacent environment. The tank should remain out of service until these repairs are completed.

a. None

2. REQUIRED REPAIRS to Fully Comply with API 653, or, Federal, State, and Local

Codes

Recommended repairs represent items that should be addressed in a timely manner, in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment. These items may be required by federal, state and local codes, or by military criteria.

a. Secondary Containment Floor Cracks

OBSERVATION: The bottom‐to‐foundation seal is deteriorated around the entire circumference of the tank. (Approximately 88 linear feet)

CODE REFERENCE: 40 CFR 112.7(c); 40 CFR 112.8(c)(2), 40 CFR 112.12(c)(2), 40 CFR

112.1(b) and ASTM C 920

RECOMMENDATION: Replace the sealant on the exterior of the tank between the foundation and ring‐wall by removing and resealing. Consider resealing the bottom to foundation in accordance with AW 78‐24‐27 Drawing D.04 Detail 3.

(Quantity: 88 LF)

b. Ring‐Wall Cracks

OBSERVATION: The ring‐wall has approximately 30 linear feet of minor hairline cracks.

CODE REFERENCE: 40 CFR 112.7(c); 40 CFR 112.8(c)(2), 40 CFR 112.12(c)(2), 40 CFR

112.1(b)

RECOMMENDATION: Repair all hairline cracks and chips in the foundation and reseal with flexible urethane (e.g. Sikaflex 1c) or a similar approved sealant.

(Quantity: 30 LF)

c. Foundation Spalling

OBSERVATION: The foundation has a 12‐inch area of broken concrete around the

3/4‐inch pipe penetration in the ring‐wall.

CODE REFERENCE: 40 CFR 112.7(c); 40 CFR 112.8(c)(2), 40 CFR 112.12(c)(2), 40 CFR

112.1(b)

RECOMMENDATION: Repair the foundation around the ¾‐inch pipe penetration.

d. ENRAF Support

OBSERVATION: The support base for the ENRAF’s electronic readout is bolted to the top of the foundation. The support partially extends under the bottom projection allowing a potential access point for water to enter the underside of the tank.

CODE REFERENCE: 40 CFR 112.7(c); 40 CFR 112.8(c)(2), 40 CFR 112.12(c)(2), 40 CFR

112.1(b)

RECOMMENDATION: Relocate the support base for the electronic readout.

Replace the sealant between the foundation and ring‐wall where the support base was located.

e. NFPA Placard

OBSERVATION: The NFPA placard is worn and weather faded.

CODE REFERENCE: NFPA 30 paragraph 21.7.2.1. and UFC 3‐460‐01 Section 2‐17(c)

RECOMMENDATION: Replace the deteriorated NFPA placard on the tank shell.

f. Coating Deterioration

OBSERVATION: The fixed roof, shell, shell nozzles, and tank appurtenances have general coating deterioration throughout the entire tank. (Approximately 2,800ft²)

CODE REFERENCE: UFC 3‐460‐01 Section 8‐3.10(a) and UFGS 09 97.13.27 (Exterior

Coating of Steel Structures).

RECOMMENDATION: Mechanically clean and recoat any coating failure on the shell, shell nozzles, fixed roof, and tank appurtenances. (Approximately 2,800ft²)

g. Mechanical Tape Level Gauge

OBSERVATION: The (Varec) mechanical tape gauge is seized and not functioning. The

ENRAF readout has the tank level at 14’ 08‐15/16” and the MTG has the tank level at 24’ 2”.

CODE REFERENCE: API‐653 Section C.1.3.3, UFC 3‐460‐01 Table 8‐1(q), and

AW 78‐24‐27 Drawing D.07 Detail 1

RECOMMENDATION: Provide a working mechanical tape gauge in accordance with UFC 3‐460‐01 Table 8‐1(q).

NOTE: If the tape gauge is no longer in use, consider removing the MTG assembly from the tank.

h. Grounding Lugs

OBSERVATION: The tank is equipped with two (2) grounding lugs welded to the bottom projection. The grounding lug is welded ½‐inch from the shell‐to‐bottom weld. A minimum of four (4) grounding lugs shall be provided IAW API‐650. Note:

The grounding lugs are bolted and not exothermically welded IAW AW 78‐24‐27.

CODE REFERENCE: API‐650 5.8.11.3

RECOMMENDATION: Provide four grounding lugs in accordance with API‐650.

Exothermically‐weld the grounding cables to the grounding lug and install reinforcement at the shell in accordance with AW 78‐24‐27 Drawing ED.02 Detail 2.

i. Light on Fixed Roof

OBSERVATION: The lens cover for the light that is attached to the perimeter guardrail on the fixed roof is filled with water.

CODE REFERENCE: General Maintenance

RECOMMENDATION: Remove the water from the lens cover. If the light is no longer in use consider removing the lighting assembly from the tank.

j. Thermal Relief on the Receipt Line

OBSERVATION: The product receipt line’s isolation valve and the high liquid level shut‐off valve (Cla‐Val) are bolted directly to each other not allowing a means of thermal relief. Even though there is no piping, pressure can build and potentially cause a leak.

CODE REFERENCE: API‐576 Section 6.1.1 & UFC 3‐460‐01 Section 3‐3.1.2(j)

RECOMMENDATION: Provide a means for thermal relief between the isolation valve and the high liquid level shut‐off valve.

3. RECOMMENDED REPAIRS TO FULLY COMPLY WITH UFC 3‐460‐01, AW 78‐24‐27

Standards or as Part of Regular Maintenance

Recommended repairs represent items that should be addressed in a timely manner, in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Tank Labels and Markings

OBSERVATION: The facility number is not attached to the tank, and the tank stencils are faded and barely legible. Tanks should be marked with easily discernible painted numbers and letters IAW MIL‐STD‐161 and UFC 3‐460‐01.

CODE REFERENCE: UFC 3‐460‐01 Section 2‐17 and MIL‐STD‐161

RECOMMENDATION: Mark tanks with easily discernible painted numbers and letters in accordance with UFC 3‐460‐01 and MIL‐STD‐161.

b. Piping Identification

OBSERVATION: The piping stencils are faded and weathered. The piping should have easily discernable banding, product name, and flow direction IAW MIL‐STD‐161 and UFC 3‐460‐01.

CODE REFERENCE: UFC 3‐460‐01 Section 2‐17 & MIL‐STD‐161

RECOMMENDATION: Mark the piping with easily discernible painted numbers and letters in accordance with UFC 3‐460‐01 and MIL‐STD‐161.

c. Valve Markings

OBSERVATION: The valves within the secondary containment are not marked with easily discernable painted numbers or numbered corrosion‐resistant metal or plastic tags as recommended IAW UFC 3‐460‐01.

CODE REFERENCE: UFC 3‐460‐01 Section 2‐17(a)

RECOMMENDATION: Mark the valves within the secondary containment in accordance with UFC 3‐460‐01.

d. Secondary Containment Pipe Penetrations

OBSERVATION: The pipe penetrations through the secondary containment berm for the 6‐inch issue line and 4‐inch receipt line for Tanks 101A and 101B are wrapped for underground protection. The piping is not equipped with a sleeve, a sleeve seal, and a nitrile boot seal that is clamped to the piping as recommended IAW

AW 78‐24‐27. (two 4‐inch and two 6‐inch pipe penetrations)

CODE REFERENCE: AW 78‐24‐27 Drawing CD.10

RECOMMENDATION: Provide a sleeve for the pipes penetrating the secondary containment berm wall in accordance with AW 78‐24‐27.

e. Pipe Supports

OBSERVATION: The five (5) sets of pipe supports within the containment are pipe hangers. The receipt line does not have any pipe supports on the shell. The 30‐foot section of receipt line and conduit are supported by the bolted flange at the top of

Shell Course three and the pipe hangers. The dead‐end on the 4‐icnh receipt line appears to be and attachment welded on to the elbow of the receipt line to extend to the pipe hanger. It is not recommended to use pipe hangers IAW UFC 3‐

460‐01.

CODE REFERENCE: UFC 3‐460‐01 Section 9‐3.2

RECOMMENDATION: Provide pipe supports in accordance with UFC 3‐460‐01. Ensure the piping is adequately supported and not putting any unnecessary stress on the shell nozzle.

f. Secondary Containment Drain Basin

OBSERVATION: The 36‐inch x 36‐inch secondary containment drain basin is not equipped with a link seal around the piping as recommended IAW AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing CD.09 Detail 3

RECOMMENDATION: Reconfigure the secondary containment drain basin in accordance with AW 78‐24‐27.

g. Fuel Sample Connector

OBSERVATION: The product issue and receipt line are not equipped with a fuel sample connector as recommended IAW AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing D. 13 Detail 4

RECOMMENDATION: Provide a fuel sample connector as recommended in accordance with AW 78‐24‐27.

h. Isolation Valve on the Product Receipt Line

OBSERVATION: The 4‐inch product receipt line is not equipped with an isolation valve before the high liquid control shut‐off valve (Cla‐Val) IAW AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing D.12 Detail 3

RECOMMENDATION: Provide an isolation valve before the high liquid control shut‐ off valve (Cla‐Val) in accordance with AW Standard 78‐24‐27.

i. Conventional TRVs within the Secondary Containment

OBSERVATION: The conventional TRVs for the 4‐inch receipt line and 6‐inch issue line are not equipped with a test tee as recommended in UFC 3‐460‐01.

CODE REFERENCE: UFC 3‐460‐01 Section 9‐3.5.1.

RECOMMENDATION: Provide a test tee for the conventional TRVs within the secondary containment IAW UFC 3‐460‐01. Consider reconfiguring the TRV lines in accordance with AW 78‐24‐27 Drawing D.10 Detail 4.

j. Low Suction Line

OBSERVATION: The low suction line/stripper line is a 2‐inch valve that is welded to the 4‐inch shell overflow. The shell overflow pipe has no supports or shell attachments and is only supported by the bolted 4‐inch flange connection at the top of Shell Course three and the bolted 2‐inch low suction flange connection. The shell overflow pipe ends just above a 3‐inch pipe which runs into the secondary containment sump. The low suction is near the water draw‐off system and does not tie into the issue line or have a CAM type connection.

CODE REFERENCE: UFC 3‐460‐01 Table 8‐1(z) and AW 78‐24‐27 Drawing G.05.

RECOMMENDATION: Provide a low suction line that meets the criteria described in

UFC 3‐460‐01 and AW 78‐24‐27. All repairs shall be in accordance with API‐653.

k. Water Draw‐off Piping

OBSERVATION: The water draw‐off nozzle is a ¾‐inch coupling welded to ¾‐inch stainless steel piping. A 2‐inch nozzle with a DBB valve with an eccentric flat on bottom (FOB) reducer is recommended. The water draw‐off system is not equipped with a product return nozzle. The piping is configured to tie into the existing water draw‐off nozzle. An additional return nozzle with an eccentric flat on bottom (FOB) reducer attached to a 2‐inch nozzle with a DBB valve is recommended to meet the specifications described in AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing D.13 Detail 5

RECOMMENDATION: Reconfigure the water draw‐off piping in accordance with

AW 78‐24‐27.

l. Product Saver Tank

OBSERVATION: The PST ground cable is bolted to the PST leg and not exothermically welded IAW AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing D.13 Detail 5

RECOMMENDATION: Exothermically weld the grounding cable for the product saver tank in accordance with AW 78‐24‐27.

m. Shell Manholes

OBSERVATION: The tank is equipped with one (1) 24‐inch shell manhole. The manhole is not hinged or equipped with a davit arm as recommended IAW

AW 78‐24‐27. Two 36‐inch manholes are recommended IAW UFC 3‐460‐01.

CODE REFERENCE: UFC 3‐460‐01 Table 8‐1(f) and AW 78‐24‐27 Drawing D.10

Detail 3

RECOMMENDATION: Provide two 36‐inch manholes with davit arms in accordance with UFC 3‐460‐01 and AW 78‐24‐27.

n. Low and Low‐Low Level Alarm

OBSERVATION: The tank is not equipped with a shell mounted low level alarm and low‐low level alarm as described in AW 78‐24‐27. The alarms are provided through a (Magnatrol) electronic level sensor located on the fixed roof.

CODE REFERENCE: AW 78‐24‐27 Drawing D.12 Detail 1 and UFC 3‐460‐01 Table

8‐1(l)

RECOMMENDATION: Provide a low and low‐low independent level alarm in accordance with AW Standard 78‐24‐27.

o. High and High‐High Level Alarm

OBSERVATION: The tank is not equipped with a shell mounted high level alarm and high‐high level alarm as described in AW 78‐24‐27. The alarms are provided through a (Magnatrol) electronic level sensor located on the fixed roof.

CODE REFERENCE: AW 78‐24‐27 Drawing D.12 Detail 2 and UFC 3‐460‐01 Table

8‐1(l)

RECOMMENDATION: Reconfigure the high and high‐high level alarm in accordance with AW Standard 78‐24‐27.

p. High‐Level Shut Off Valve

OBSERVATION: The high level shut off valve is not equipped with an intermediate platform. The high level shut off’s piping is constructed of threaded carbon steel instead of a flanged connection to storage tank, is not equipped with flanged ball valves, and does not have any means to test the system as described in AW

78‐24‐27.

CODE REFERENCE: UFC 3‐460‐01 Table 8‐1(l) & AW 78‐24‐27 Drawing D.12 Detail 2

RECOMMENDATION: Provide an intermediate platform for the high level shut off valve in accordance with UFC 3‐460‐01 and reconfigure the piping for the high‐ level shut off valve in accordance with AW 78‐24‐27.

q. Center Vent

OBSERVATION: The tank is equipped with a 3‐inch (Varec) center vent and flame arrestor. Flame arrestors do not allow the tank to breathe properly and are not recommended unless required by host‐nation and/or NATO regulations IAW UFC

3‐460‐01. The screen around the vent is disengaged and not seated properly. The product issue is a 6‐inch line, and the product receipt is a 4‐inch line. Alternatively, the normal vent shall be at least as large as the largest fill or withdrawal connection, unless sized IAW API‐2000. A 24‐inch center vent is recommended

IAW AW 78‐24‐27.

CODE REFERENCE: AW 78‐24‐27 Drawing D.09 Detail 2 and UFC 3‐460‐01 Table

8‐1(o).

RECOMMENDATION: Remove the flame arrestor in accordance with UFC 3‐460‐01.

Adjust or replace the screen for the center vent to prevent animals and insects from entering the tank. Provide a center vent in accordance with AW 78‐24‐27.

r. Sample Gauge

OBSERVATION: The tank is not outfitted with a thief and reel sample gauge to manually gauge the tank. The tank is being manually gauged through the ENRAF hatch.

CODE REFERENCE: UFC 460 3‐460‐01 Table 8‐1(x), AW 78‐24‐27 Drawing D.07

Detail 2

RECOMMENDATION: Provide a 10‐inch roof nozzle and an aluminum, slotted stilling well for gauging and sampling with a datum plate to establish a gauging zero point.

Design in accordance with AW 78‐24‐27 Drawing D.07 Detail 2.

s. No Scaffold Cable Supports

OBSERVATION: The tank is not equipped with two (2) cable scaffold supports IAW

UFC 3‐460‐01.

CODE REFERENCE: 3‐460‐01 Table 8‐1(jj).

RECOMMENDATION: Provide two (2) scaffold cable supports IAW API‐650 Figure 5.22 and UFC 3‐460‐01.

t. Conduit Supports

OBSERVATION: The conduit supports on the fixed roof are not properly secured. The supports freely rest on the tank top and pose the potential risk as a trip hazard and can damage the coating and appurtenances.

CODE REFERENCE: General Maintenance and AW 78‐24‐27 Drawing D.10 Detail 5.

RECOMMENDATION: Secure the conduit supports on the fixed roof to prevent a potential trip hazard and damage to the coating and appurtenances in accordance with AW 78‐24‐27.

Appendix A

Engineering Calculations

1. Shell Settlement Evaluation

Shell Settlement Evaluation

Where:

S max = maximum permissible out-of-plane deflection, in feet.

L = ΠD /N = arc length between measurement points, in feet.

D = tank diameter, in feet N = number of survey points.

Y = yield strength, in pounds per square inch (psi).

E = young's modulus, in pounds per square inch (psi) H = tank height, in feet

D = 28 feet N = 8 L = 3.14(28)/8 = 10.9956 feet Y = 36,000 psi E = 29,000,000 psi H = 24 feet

L 2 = 120.9027 square feet

11(120.9027)(36,000) 2(29,000,000)(24)

1) Maximum Permissible Out-of-Plane Deflection Calculation

S max = = 0.0344 feet

𝑆𝑚𝑎𝑥 11𝐿 𝑌

2𝐸𝐻

|S i | = U i - (1/2U i-1 + 1/2U i+1 ) Where:

|S i | = magnitude of the calculated out-of-plane deflection, in feet.

U i = Out-of-Plane settlement of point "i ", in feet

(+) when above cosine curve (-) when below cosine curve

Point Actual Curve

Fit U i U i+1 U i-1 S i |S i |

1 0.05208 0.00000 0.05208 0.02210 0.01168 0.01168 0.03519

2 0.02083 0.00915 0.01168 0.05208 -0.03125 -0.03125 0.00126

3 0.00000 0.03125 -0.03125 0.01168 -0.00126 -0.00126 0.03646

4 0.05208 0.05335 -0.00126 -0.03125 -0.01042 -0.01042 0.01957

5 0.05208 0.06250 -0.01042 -0.00126 0.00915 0.00915 0.01436

6 0.06250 0.05335 0.00915 -0.01042 0.02083 0.02083 0.00394

7 0.05208 0.03125 0.02083 0.00915 0.02210 0.02210 0.00521

8 0.03125 0.00915 0.02210 0.02083 0.05208 0.05208 0.01436

R 2 = 0.54 Note: Settlement evaluation must be done using the arc length method.

1) Out-of-Plane Deflection Calculation

Shell Settlement Graph

4 5

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

0.05

0.055

0.06

0.065

0.07

2 3 4 5 6 7 8 1 2

E le va ti on s

(f ee t)

Data PointsShell Settlement

Optimum Cosine Curve

Min. Settlement at (Pt 1)

Max. Settlement at (Pt 4)

Where:

S arc = settlement arc length between start and end point, in feet.

S i = maximum out-of-plane settlement within the settlement arc length, in inches.

K = factor based on tank roof type (per B.3.2.2).

Roof TypeFixed Roof K = 10.5

Sarc # Start Pt End Pt End Pt Sarc (ft) Si (in) Smax (in)

1 6 1 8 32.9867 0.2917 0.5016 Pass

2 1 6 3 54.9779 0.6750 0.8360 Pass

Evaluation of the settlement by the arc length method is within acceptable limits.

API 653 B.2.2.5 Evaluation by Settlement Arc Length Method (For R 2 less than 0.9)

Si < Smax →

Si < Smax →

Arc Length Evaluation

𝑆 𝑚𝑖𝑛 𝑘 𝑆 𝐷 𝐻

𝑌 𝐸

, 4.0

4 5

0.75

0.625

0.25

0.5

0.75

6 7 8 1 2 3 4 5 6

E le va ti on s

(i nc he s)

Data Points

Appendix B

Engineering Drawings

1. Shell Layout Drawing

2. Roof Layout Drawing

3. Containment Layout Drawing

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

InterSpec, LLC.

12/3/2019 N/A N/A

Tank 101A (Facility 8314A) S-1Shell Layout [1 of 2]

Remarks/Legend:

Seam #1 is the first shell seam left of the manway on the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

A - 24" Manhole B - 4" Receipt C - 1" High Level Shut-Off D - 1" High Level Shut-Off E - 6" Product Issue F - 3/4" Water Draw Off G - 2" Low Suction H - 4" Overflow

US Air Force - Fort Riley; Fort Riley, KS

A

B C

D

E

1-1 1-2 1-3

2-1 2-2

3-1 3-2 3-3

Grounding Lug

Manual Tank Gauge

ENRAF

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

InterSpec, LLC.

12/3/2019 N/A N/A

Tank 101A (Facility 8314A) S-2Shell Layout [2 of 2]

Remarks/Legend:

Seam #1 is the first shell seam left of the manway on the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

A - 24" Manhole B - 4" Receipt C - 1" High Level Shut-Off D - 1" High Level Shut-Off E - 6" Product Issue F - 3/4" Water Draw Off G - 2" Low Suction H - 4" Overflow

US Air Force - Fort Riley; Fort Riley, KS

F G

H

1-4

3-4 3-5

1-5

2-3 2-4 2-5

Remarks/Legend:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

US Air Force - Fort Riley; Fort Riley, KS

InterSpec, LLC.

12/3/2019 N/A N/A

Tank 101A (Facility 8314A) R-1Roof Layout [1 of 1]

The measured tank diameter is 28 feet.

The roof consists of 14 plates.

A - 3" Vasec Vent B - 8" Vito Probe C - 20" Manhole D - 4" Electronic Level Gauge E - 1" Manual Tank Gauge Wire F - 1 1/2" Manual Tank Gauge Float G - 1" Manual Tank Gauge Wire

H - 8" ENRAF

2 3 4

5 6 7

8 9 10

11 12 13

A

B

C D

E F

HG

Remarks/Legend:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

US Air Force - Fort Riley; Fort Riley, KS

InterSpec, LLC.

12/3/2019 N/A N/A

Tank 101A (Facility 8314A) C-1Containment Layout [1 of 1]

The secondary containment consists of a gravel floor and gravel walls.

- 6" Issue Piping (101 A)

- 4" Receipt Piping (101 A)

- 4" Receipt Piping (101 B)

- 6" Issue Piping (101 B)

- Pipe Support

36" x 36" Sump

Stairway

101 B 101 A

Concrete Sidewalk

Appendix C

Engineering Data

1. Shell Settlement Measurements

Shell Settlement Measurements

1 56 3/8

2 56 3/4

3 57

4 56 3/8

5 56 3/8

6 56 1/4

7 56 3/8

8 56 5/8

NOTE: The Rod Heights are based on the actual height of the transit at the time of the data collection. This data should only be used for this report. Point #1 is located at Vertical Shell Seam #1.

Point No. Rod Height (inches)

Appendix E

Photographs

E.1: General View of Tank E.2: General View of Tank

E.3: General View of Tank E.4: General View of Tank

E.5: General View of Fixed Roof E.6: General View of Fixed Roof

E.7: General View of Roof Appurtenances E.8: General View of Roof Appurtenances

E.9: External Caged Ladder E.10: External Caged Ladder

E.11: 24‐inch Manhole E.12: Tank Nameplate

E.13: MTG and Enraf Readout E.14: 8‐inch Receipt

E.15: 8‐inch Receipt Piping E.16: 8‐inch Receipt Piping

E.17: High‐Level Shut‐off E.18: 6‐inch issue

E.19: Product Saver Tank E.20: Water Draw‐Off Piping

E.21: 4‐Inch Shell Overflow E.22: Shell Overflow Piping

E.23: 2‐inch Low Suction tied into Overflow E.24: Overflow Drain

E.25: Secondary Containment Drain Basin E.26: Piping from overflows to Drain

E.27: Containment Drain Valve E.28: General View of Secondary Containment

E.29: General View of Secondary Containment E.30: General View of Secondary Containment

E.31: General View of Secondary Containment E.32: General View of Secondary Containment

E.33: Tank 101A Piping E.34: Interior Berm Wall Pipe Penetration

E.35: General View of Berm Wall E.36: Exterior Berm Wall Pipe Penetration

E.37: Emergency Shutoff E.38: Audible Level Alarms

E.39: Audible Level Alarms E.40: Cathodic Protection Housing

E.41: Cathodic Protection Bath E.42: Cathodic Protection Gauges