Attachment J.2 - Fac 1340 (Tank 3) OOS 2012.pdf

API STANDARD 653 INSPECTION REPORT

OUT-OF-SERVICE INSPECTION

ARMY CORE OF ENGINEERS, OMAHA DISTRICT

TANK GROUP 15

CONTRACT NUMBER W9128F-10-D-0075-0002

TANK #3/ FACILITY 1340

LITTLE ROCK AFB

LITTLE ROCK, ARKANSAS

Prepared for:

UNITED STATES AIR FORCE

Little Rock Air Force Base

Little Rock, Arkansas 72099

Prepared by:

CAPE Environmental Management, Inc.

4013A Seaboard Court, Suite 1

Portsmouth, Virginia 23701

(757) 405-1291

Project Number: 00075.002.901

April 5, 2012

API Standard 653 recommends this document containing valuable historical information be retained for the life of the tank.

ER-LITTLEROCK-TANK3

EXECUTIVE SUMMARY

An API Standard 653 Out-of-Service Inspection of Tank #3 was completed on March 28, 2012. The purpose of this inspection was to collect data and establish a data base for present and future inspections and evaluations. The evaluation of the shell settlement was satisfactory. The shell nozzle and reinforcement evaluation of the accessible nozzles shows that the nozzles are adequately reinforced and have a minimum remaining life greater than 30 years. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of greater than 30 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to March 2017, and the next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to March 2027 in accordance with API Standard 653. The bottom service life evaluation shows that the in-service interval of operation (years to next internal inspection) to be twenty years under current conditions, thereby, the next internal inspection should be accomplished by a Certified Inspector prior to March 2032 in accordance with API Standard 653. Inspection Results are listed in 4.0.

Significant Findings: The tank had a double bottom installed in 1994. The center of the original floor was cut out to allow for the installation of a new bottom sump. There is no secondary containment under the new tank bottom. There is no leak detection. The current tank bottom slope is approximately 2.5%.

The tank is equipped with one 36 inch manway and one 20 x 36inch manway. Nozzle A 36 inch manway reinforcement pad extends less than the required 6 inches beyond the circumferential weld. Nozzle A 36 inch manway reinforcement pad tell tale hole is plugged.

Nozzle G 20 x 36 inch manway reinforcement pad does not have a tell tale hole installed.

There was no floating roof seal at the time of inspection. The Gauge well is not slotted. The tank does not have a nameplate installed. The original name plate has fallen off and is currently stored in the bulk storage office. There is no nameplate for new construction.

There is no cathodic protection for the tank bottom. The mechanical high level control valve was reported to be non-functional. The tank is equipped with a geodesic dome. The geodesic dome has been reported to be leaking.

The floating roof manway does not have a ground strap installed on the cover. The Varec ATG has moisture inside making the level reading difficult to view. The ATG tape as viewed from the tank floating roof appears to be damaged at several locations

. The bottom-to-foundation sealant has failed. The bottom coating has holes and deterioration.

The sump has coating failure and corrosion. There is coating failure throughout the internal shell coating where plates and the wind girder were welded to the shell externally. The external coating has chalking throughout, and there is minor coating failure throughout. There is also minor coating failure on the topside of the wind girder where visible from the spiral stairway.

ii

The internal floating roof has coating failure with corrosion throughout the top deck and pontoons. The spiral stairway has minor coating failure throughout.

There are no stairs from the roof deck platform to the roof deck. The internal piping for the water draw off , the low point suction and the issue lines have 90 degree elbows into the sump.

The receipt line and water draw off line are not flanged internally.

There is pitting throughout the top of the first shell course and bottom of the second shell course due to the floating roof seal. Recommendations for Compliance with API Standard 653 are made in 5.0, and Other Recommendations are made in 6.0.

iii

TABLE OF CONTENTS

Section Page

Signature Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv List of Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1.0 Introduction

1.1 Purpose

2.0 References

2.1 American Petroleum Institute

2.2 American Society of Mechanical Engineers

2.3 Code of Federal Regulations

2.4 National Association of Corrosion Engineers

2.5 National Fire Protection Association

3.0 Tank Description

4.0 Inspection Results

4.1 Secondary Containment

4.2 Foundation

4.3 Cathodic Protection

4.4 Bottom

4.5 Shell

4.6 Shell Appurtenances

4.7 Accessways

4.8 Floating Roof

4.9 Floating Roof Appurtenances

5.0 Recommendations for Compliance with API Standard 653

5.1 Secondary Containment

5.2 Foundation

5.3 Cathodic Protection

5.4 Bottom

5.5 Shell

5.6 Shell Appurtenances

5.7 Accessways

5.8 Floating Roof

5.9 Floating Roof Appurtenances

iii

TABLE OF CONTENTS

Section Page

6.0 Other Recommendations

6.1 Secondary Containment

6.2 Foundation

6.3 Cathodic Protection

6.4 Bottom

6.5 Shell

6.6 Shell Appurtenances

6.7 Accessways

6.8 Floating Roof

6.9 Floating Roof Appurtenances

7.0 Serviceability

LIST OF APPENDICES

Appendix A Engineering Calculations Appendix B Engineering Drawings Appendix C Engineering Data Appendix D API Standard 653 Checklists for Tank Inspection Appendix E Photographs iv

LIST OF ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BL Barrel

CAPE CAPE Environmental Management, Inc.

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

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

RP Recommended Practice

RT Radiography Testing

TML Thickness Measurement Location

UT Ultrasonic Testing

VT Visual Testing vi

1.0 INTRODUCTION

1.1 Purpose:

1.1.1 The on-site inspection information acquired for this tank, as well as, historical information was analyzed under CAPE Environmental Management, Inc. inspection program Version 3.4, to provide a standardized report format of tank conditions, recommendations, and serviceability requirements to satisfy federal, state and local regulations, in addition to the API Standards and/or construction standards for this tank.

1.1.2 This report provides an engineering evaluation of Tank #3 located at the Little Rock AFB facility in Little Rock, Arkansas. This report summarizes the results of an API Standard 653 Out-of-Service Inspection conducted by CAPE Environmental Management, Inc. Project Number 00075.002.901.

1.1.3 This inspection was completed on March 28, 2012.

1.1.4 Our policy is: "Provide to the storage tank owner and/or manager the most precise and complete inspection and report possible, using experienced inspectors and technicians, advanced technologies, and analytical software."

2.0 REFERENCES

2.1 American Petroleum Institute:

2.1.1 API Recommended Practice 574, Inspection Practices for Piping System Components.

2.1.2 API Recommended Practice 575, Inspection of Atmospheric and Low-Pressure Storage Tanks.

2.1.3 API Standard 650, Welded Steel Tanks for Oil Storage.

2.1.4 API Recommended Practice 651, Cathodic Protection of Aboveground Petroleum Storage Tanks.

2.1.5 API Recommended Practice 652, Lining of Aboveground Petroleum Storage Tank Bottoms.

2.1.6 API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction.

2.2 American Society of Mechanical Engineers Codes:

2.2.1 ASME Boiler and Pressure Vessel Code; Section V, Non-Destructive Examination.

2.2.2 ASME Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications.

2.2.3 ASME Boiler and Pressure Vessel Code; Section VIII, Division 1, Rules for Construction of Pressure Vessels.

2.3 Code of Federal Regulations:

2.3.1 29 CFR 1910, Permit-Required Confined Spaces for General Industry.

2.3.2 40 CFR 112, Oil Pollution Prevention.

2.4 National Association of Corrosion Engineers:

2.4.1 NACE Recommended Practice, RP0184-91, Repair of Lining Systems.

2.4.2 NACE Recommended Practice, RP0193-93, External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms.

2.4.3 NACE Recommended Practice, RP0288-94, Inspection of Linings on Steel and Concrete.

2.5 National Fire Protection Association:

2.5.1 NFPA-30, Flammable and Combustible Liquids Code.

3.0 TANK DESCRIPTION

3.1 Tank Description:

Owner/Operator: Little Rock AFB Location: Little Rock, Arkansas Tank Number: 3 Service: Jet A Specific Gravity: 0.84 Nominal Diameter: 85 feet Nominal Shell Height: 40 feet Maximum Liquid Level: 35.9 feet Low-Low Level Alarm: None Low Level Alarm: None High Level Alarm: None High Level Control Shutoff: None High-High Level Alarm: None Capacity: 1,523,785 gallons; 36,281 barrels Configuration: Vertical Aboveground Storage Tank Foundation: Concrete Pad Construction: Bottom: Lap-Welded

Shell: Butt-Welded Floating Roof: Lap-Welded Fixed Roof: Lap-Welded

Material: Bottom: Carbon Steel, Unknown Grade Shell: Carbon Steel, Unknown Grade Floating Roof: Carbon Steel, Unknown Grade Fixed Roof: Carbon Steel, Unknown Grade

Tank Built: 1954 Tank Age: 58 years Operating Limits: Minimum Metal Temperature: 10oF

Maximum Metal Temperature: Ambient Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product

Seismic Zone: 1 Construction Code: API Standard 650 Inspection Type: Out-of-Service Inspection Inspection Date: March 28, 2012

4.0 INSPECTION RESULTS

4.1 Secondary Containment: The secondary containment area is constructed from concrete with a non permeable liner. The permeability and capacity of the secondary containment area appears to be sufficient to contain and hold the stored product. The secondary containment area appears to be properly graded to drain water away from the tank in accordance with NFPA 30.

The secondary containment area does not have a dike drain system.

4.1.1 Significant Findings: No significant findings were noted during this inspection.

4.2 Foundation: The tank bears on top of a concrete pad and sand. The foundation was evaluated for shell settlement in accordance with API Standard 653 and is in satisfactory condition.

4.2.1 Significant Findings: The bottom-to-foundation sealant has failed.

4.3 Cathodic Protection:

4.3.1 Significant Findings: The tank does not have a cathodic protection system.

4.4 Bottom: The tank is a lap-welded cone-down type bottom. The bottom has a thick film coating that ranged from 8.06 mils to 13.42 mils in thickness. The tank bottom has leak detection and does not have secondary containment under the tank bottom. The nominal thickness of the bottom is 0.3125 inches. The bottom was scanned (approximately 95%) for underside corrosion using Magnetic Flux Leakage (MFL) technology. The MFE 2412 Mark II unit was used for the MFL floor scan. The MFL unit did not reveal any significant underside corrosion from the MFL scan. The bottom topside was not examined with a flashlight held parallel to the floor, since the tank bottom is coated. The general thickness of each bottom plate was measured using ultrasonic technology (UT). The general thickness of the bottom ranged from a minimum of 0.297 inches to a maximum of 0.326 inches, excluding the underside corrosion indications located by the MFL scan. The general thickness measurements and associated thickness measurement locations (TML) are listed in the Bottom Plate Thickness Measurements table in Appendix C. The general thickness of the sump is measured using ultrasonic technology (UT). Vacuum box testing was not be performed, since the welds were coated. Magnetic particle testing was not performed, since the welds were coated. The floor welds were visually examined and are in satisfactory condition. The bottom service life evaluation is shown in Appendix A.

4.4.1 Significant Findings: The tank had a double bottom installed in 1994. The center of the original floor was cut out to allow for the installation of a new bottom sump.

There is no secondary containment under the new tank bottom. There is no leak detection. The current tank bottom slope is approximately 2.5%. There is no cathodic protection for the tank bottom. The bottom coating system has failed throughout. The bottom sump coating system has failed and there is significant corrosion, however the thickness of the bottom sump is 1 inch.

4.5 Shell: The tank consists of five (5) butt-welded courses. The exterior of the shell has a thin coating system that ranged between 7.7 and 20.5 mils in thickness. The interior of the shell has a thin coating system that ranged between 8.03 and 16.61 mils in thickness. The shell was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Shell Plate Thickness Measurements table in Appendix C. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of greater than 30 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to March 2017. The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to March 2027 in accordance with API Standard 653. The shell service life evaluation is shown in the Shell Service Life Evaluation table in Appendix A. Roundness, plumbness, peaking, and banding of the shell are within the allowable tolerances of API Standard 653.

4.5.1 Significant Findings: There is coating failure throughout the internal shell coating where plates and the wind girder were welded to the shell externally. The external coating has chalking throughout, and there is minor coating failure throughout.

There is also minor coating failure on the topside of the wind girder where visible from the spiral stairway. There is pitting throughout the top of the first shell course and bottom of the second shell course due to the floating roof seal. The pitting was coated at the time of inspection making it inactive. Since none of the pitting meets the criteria of API 653 Section 4.3.2.2 they may be ignored.

4.6 Shell Appurtenances: The accessible shell nozzles and reinforcements were evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements are listed in the Shell Nozzle and Nozzle Reinforcement Measurements table in Appendix C.

The shell nozzle and reinforcement evaluation is performed on all accessible nozzles. The ultrasonic thickness measurements on the nozzles revealed no significant loss of metal from corrosion and erosion. All nozzles that were accessible to ultrasonic examination have a minimum remaining life of greater than 30 years. All nozzles were adequately reinforced. The shell nozzle and reinforcement evaluation is shown in the Shell Nozzle and Reinforcement Evaluation table in Appendix A. The nozzles are shown on the Shell Layout drawings in Appendix B, as well as, listed in the Shell Nozzle and Nozzle Reinforcement Measurements table in Appendix C. The product level is monitored by an autogauge (ATG).

4.6.1 Significant Findings: The Varec ATG has moisture inside making the level reading difficult to view. The ATG tape as viewed from the tank floating roof appears to be damaged at several locations. The tank is equipped with one 36 inch Manway and one 20 x 36 inch Manway. Nozzle A 36 inch manway reinforcement pad extends less than the required 6 inches beyond the circumferential weld. Nozzle A 36 inch manway reinforcement pad tell tale hole is plugged. Nozzle G 20 x 36 inch manway reinforcement pad does not have a tell tale hole. The tank does not have a nameplate installed. The original name plate has fallen off and is currently stored in the bulk storage office. There is no nameplate for new construction. The mechanical high level control valve was reported to be non-functional. The internal piping for the water draw off , the low point suction and the issue lines have 90 degree elbows into the sump. The receipt line and water draw off line are not flanged internally.

4.7 Accessways: The fixed roof is accessible via a spiral stairway. The floating roof is accessible via a rolling ladder. The floating roof rolling ladder rolls along a platform on the roof deck.

4.7.1 Significant Findings: The spiral stairway has minor coating failure throughout.

Install a stair way from floating roof platform to roof deck.

4.8 Floating Roof: The floating roof is an internal annular pontoon type. The annular space between the floating roof and the shell measured between 7.25 and 9.125 inches. The floating roof topside coating thickness measured between 9.8 and 16.8 mils and the underside coating thickness measured between 7.56 and 17.54 mils. The floating roof was evaluated for remaining metal thickness using ultrasonic technology. The floating roof thickness ranges from a minimum of 0.169 inches to a maximum of 0.218 inches. The tank is equipped with a geodesic dome fixed roof. Thickness measurements for the floating roof are listed in the Floating Roof Plate Thickness Measurements table in Appendix C.

4.8.1 Significant Findings: There was no floating roof seal at the time of inspection.

The geodesic dome has been reported to be leaking. The internal floating roof has coating failure with corrosion throughout the top deck and pontoons.

4.9 Floating Roof Appurtenances:

4.9.1 Significant Findings: The Gauge well is not slotted. The floating roof manway does not have a ground strap installed on the cover.

5.0 RECOMMENDATIONS FOR COMPLIANCE

WITH API STANDARD 653

5.1 Secondary Containment:

5.1.1 No recommendations at this time.

5.2 Foundation:

5.2.1 No recommendations at this time.

5.3 Cathodic Protection:

5.3.1 No recommendations at this time.

5.4 Bottom:

5.4.1 The bottom should have a fuel-impermeable liner (secondary containment) installed under the new tank bottom. Over the liner, provide a minimum of 6 inches of compacted clean sand or similar material. Leak detection should be installed for the tank bottom.

5.4.2 Re-design the new tank bottom so the slope is 5%.

5.5 Shell:

5.5.1 No recommendations at this time.

5.6 Shell Appurtenances:

5.6.1 Replace Nozzle G 20 x 36 inch manway with a 36 inch manway.

5.6.2 Clean welds of all coatings within one inch of either side of the welds. Perform MT examination through all reinforcement pad welds within 6 inches of the circumferential weld, the shell to bottom weld and 6 inches along the circumferential weld from the intersection of the reinforcement pad and the circumferential weld per API 653 guidelines.

5.6.3 Remove plug from reinforcement pad tell tale hole on Nozzle A.

5.6.4 Install a tell tale hole in nozzle reinforcement pad on Nozzle G.

5.7 Accessways:

5.7.1 No recommendations at this time.

5.9 Floating Roof Appurtenances:

5.9.1 Install new slotted stilling wells for ATG and manual gauging.

6.0 OTHER RECOMMENDATIONS

6.1 Secondary Containment:

6.1.1 No recommendations at this time.

6.2 Foundation:

6.2.1 Install bottom to foundation sealant.

6.3 Cathodic Protection:

6.3.1 Install cathodic protection for the tank bottom.

6.4 Bottom:

6.4.1 Repair the bottom coating, or blast and re-coat the bottom.

6.4.2 Repair the bottom sump coating, or blast and re-coat the bottom sump.

6.5 Shell:

6.5.1 Repair the exterior coating, or blast and re-coat the exterior coating.

6.5.2 Repair the internal coating, or blast and re-coat the internal coating.

6.6 Shell Appurtenances:

6.6.1. Install a nameplate on the tank shell.

6.6.2. Install new mechanical high level control valve with new float assembly and related stainless steel tubing.

6.6.3. Replace Varec ATG and tape.

6.6.4. The internal piping should have 45 degree elbows into the sump.

6.6.5. The water draw and receipt lines should have flanges installed on the inside of the tank.

6.6.6. Maintain coating system to prevent pitting from worsening and continue to monitor this area during all subsequent internal inspections.

6.7 Accessways:

6.7.1. Repair the spiral stairway coating, or blast and re-coat the spiral stairway coating.

6.7.2. Install a stair way from floating roof platform to roof deck.

6.8 Floating Roof:

6.8.1 Repair the leaks in the geodesic dome.

6.8.2 Repair the exterior coating, or blast and re-coat the exterior coating.

6.9 Floating Roof Appurtenances:

6.9.1 Install a ground strap on the floating roof manway cover.

Appendix A

Engineering Calculations

1.

2.

3.

4.

Bottom Service Life Evaluation Internal Shell Settlement Evaluation Shell Service Life Evaluation Shell Nozzle and Reinforcement Evaluation

A-4

Bottom Service Life Evaluation

MRTbc = RTbc - Orbc(StPr + UPr)

MRTip = RTip - Orip(StPr + UPr)

Orbc = RTbc - MRTbc

(StPr + UPr)

Orip = RTip - MRTip

(StPr + UPr)

Where:

MRTbc or MRTip = Minimum remaining thickness at the end of the in-service period of operation, in inches.

Or or Orbc or Orip = In-service interval of operation (years to next internal inspection), in years; however, Or shall not exceed 20 years.

RTbc = Minimum remaining thickness from bottom side corrosion after repairs, in inches.

RTip = Minimum remaining thickness from internal corrosion after repairs, in inches.

StPr = Maximum rate of corrosion not repaired on the top side, in inches per year. StPr = 0 for coated areas of the bottom. The expected service life of the coating must equal or exceed Orip to use StPr = 0.

UPr = Maximum rate of corrosion on the bottom, in inches per year. To calculate the corrosion rate, use the minimum remaining thicknesses after repairs. Assume a linear rate based on the age of the tanks.

UPr = 0 for areas that have effective cathodic protection.

Note: For areas of a bottom that have been scanned by the magnetic flux leakage (or exclusion) process, and do not have effective cathodic protection, the thickness used for calculating UPr must be the lesser of the MFL threshold or the minimum thickness of corrosion areas that are not repaired. The MFL threshold is defined as the minimum remaining thickness to be detected in the areas inspected. The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than 0.04 inches in depth, based on company experience.

Areas of bottom side corrosion that are repaired should be evaluated with the corrosion rate for the repaired area unless the cause of corrosion has been removed. The evaluation is done by using the corrosion rate of the repaired area for UPr, and adding the patch plate (if used) thickness to the term "minimum of RTbc or RTip".

NOTE: The engineering data used to calculate the in-service interval of operation (Or) assumes the tank remains in the same service and all corrosion rates remain constant.

A-5

Bottom Service Life Evaluation

Present Condition: The tank bottom did not have a coating system. The tank bottom did not have a cathodic protection system. The tank bottom has leak detection and did not have secondary containment under the tank bottom.

MRTbc or MRTip

RTip

RTbc

StPr

UPr

0.10 inches

0.3125 inches

0.2725 inches * 0 inches/year

0.0007 inches/year

* The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than

0.040 inches in depth, based on company experience. No significant underside corrosion was detected. Therefore, RTbc is established at 0.2725 inches (original thickness of 0.3125 inches minus the 0.040 inches).

Orbc = RTbc - MRTbc =

0.2725 - 0.10 = 246 years(StPr + UPr) (0 + 0.0007)

Orip = RTip - MRTip =

0.3125 - 0.10 = 303 years(StPr + UPr) (0 + 0.0007)

Therefore, the in-service interval of operation (years to next internal inspection) is:

Or = 20 years

A-6

Internal Shell Settlement Evaluation

Maximum Permissible Out-of-Plane Deflection

| S | < 11L2Y

2EH

Where:

S L Y E H

Maximum permissible out-of-plane deflection, in feet.

Arc length between measurement points, in feet Yield strength, in pounds per square inch (psi) Young's modulus, in pounds per square inch (psi) Tank height, in feet

L Y E H S

26.7 feet 30,000 psi 29,000,000 psi 40 feet

0.1014 feet

A-7

Internal Shell Settlement Evaluation

Out-of-Plane Deflection

Si = Ui - (1/2Ui-1 + 1/2Ui+1)

Where:

S U

Calculated out-of-plane deflection, in feet.

Out-of-Plane settlement of point "i", in feet (+) when above cosine curve (-) when below cosine curve

U1

U2

U3

U4

U5

U6

U7

U8

U9

U10

-0.0114 -0.0600 -0.0314 -0.0089 -0.0111 0.0314 0.0300

-0.0086 -0.0011 0.0311 feet feet feet feet feet feet feet feet feet feet

S1

S2

S3

S4

S5

S6

S7

S8

S9

S10

0.0031 -0.0386 0.0031 0.0123

-0.0223 0.0220 0.0186

-0.0231 -0.0123 0.0373 feet feet feet feet feet feet feet feet feet feet

The out-of-plane deflection is satisfactory since the magnitude of the highest calculated out-of-plane deflection, 0.0386 feet, is less than the magnitude of the maximum permissible out-of-plane deflection, 0.1014 feet.

A-8

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 SS-1Internal Shell Settlement Evaluation

Point #1 is at Seam #1 and each point is 36 degrees apart to the left viewing from the inside.

Seam #1 is the first seam right of the first manway right of the ladder in the first shell course viewing from the inside.

Out-of-Plane Settlement

Shell Settlement

Cosine Function Curve

Feet

Points 7 8 9 10 1 2 3 4 5 6 7

3.31

3.32

3.33

3.34

3.35

3.36

3.37

3.38

3.39

3.40

A -6

Shell Service Life Evaluation

The maximum inspection intervals are determined by the most restrictive shell course in regard to the remaining life and the corrosion rate calculations for each shell course using the following formulas:

tmin=

2.6(H-1)DG

SE

Lr= tact - tmin Cr= tprev - tact Iut= tact - tmin Iv= tact - tmin

Cr DY 2Cr 4Cr

Where:

tmin = The minimum acceptable shell thickness for each course, in inches; however, tmin shall not be less than 0.1 inch for any tank course.

tnorm = The nominal shell thickness, in inches.

tact = The current measured shell thickness, excluding pits and corrosion, in inches.

tprev = The previous measured shell thickness, excluding pits and corrosion or tnorm, in inches.

D = The nominal diameter of the tank, in feet.

H = The height from the bottom of the shell course under considerations to the established maximum liquid level, in feet.

Hc = The calculated safe fill height, in feet, for the current product.

G = The highest specific gravity of the contents.

Y = Specified minimum yield strength of the plate; use 30,000 pounds per square inch if not known (N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch; use 55,000 psi if not known (N/A for riveted tanks).

S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of 0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S=21,000 psi. For elevated temperatures above 200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API-650 Appendix M or the product design stress value listed in Table M-1a or M-1b of API-650.

E = The original joint efficiency for the tank. Use Table 4-2 from API Standard 653 if original E is unknown; E=1.0 when evaluating the retirement thickness in a corroded plate, when away from welds or joints by at least the greater of one inch or twice the plate thickness. For riveted tanks, use E=1.0 for shell plates when greater than 6 inches from rivets; use the value of E from API-653 Table 4-3 when within 6 inches of rivets.

Lr = The remaining life of the shell, in years.

Cr = The shell corrosion rate, in inches per year.

Iut = The inspection interval for the next ultrasonic inspection, in years (not to exceed 15 years).

Iv = The inspection interval for the next visual external inspection, in years (not to exceed 5 years).

DY = The years between the previous measured shell thickness (tprev) and the current measured shell thickness (tact), in years.

A-10

Shell Service Life Evaluation

Present Condition:

Plate Material: Carbon Steel, Unknown Grade

D H G

DY

85 feet

35.9 feet 0.84 58 years

Course No.

Course Height (feet)

Maximum Allowable

Stress (psi) (S)

Joint Efficiency

(E)

Previous Measured Thickness (inches)

(tprev)

Current Measured Thickness (inches)

(tact)

Minimum Acceptable Thickness (inches)

(tmin)

Corrosion Rate

(in./yr) (Cr)

Remaining Life

(years) (Lr)

Next Visual

Inspection (years)

(Iv)

Next Ultrasonic Thickness Inspection

(years) (Iut)

1 6.42 23,595 0.85 0.5000 0.490 0.3230 0.000172 970 5 15

2 8 23,595 0.85 0.4375 0.410 0.2636 0.000474 308 5 15

3 8 25,960 0.85 0.3125 0.302 0.1723 0.000181 716 5 15

4 8.17 25,960 0.85 0.2500 0.248 0.1050 0.000034 4,205 5 15

5 8.17 25,960 0.85 0.2500 0.248 0.1000 0.000034 4,352 5 15

The current measured thickness is based on the lowest ultrasonic thickness measurement for that course. The remaining life of the shell is 308 years under present conditions. The current maximum liquid level is 35.9 feet based on the high-high level alarm, which is satisfactory. The tank level can potentially be filled greater than this level, however, this tank was not evaluated above this level and should not be operated above this level without rerating the maximum liquid level. The next external visual inspection should be accomplished by a Certified Inspector prior to March 2017 in accordance with API Standard 653. The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to March 2027 in accordance with API Standard 653.

A-11

Shell Nozzle and Reinforcement Evaluation nt pD nR rnt

C h

Use smaller value t2.5 or 2.5 tn t2.5 or 2.5 t + ten Use smaller value t rt d et nd +or Rn+ t td +or R + t tnn Use larger value Use larger value

For nozzle wall abutting the vessel wallFor nozzle wall inserting through the vessel wall

A

A

A

= A

= A

= A3

A A1

2A

A3

A

A

= A42

= A5

= 5 ti ti fr2

= 5 ti ti fr2

= 5 ti ti fr2

= 5(tn- trn ) fr2 t = 5(tn- trn ) fr2 tn

= 2( t + tn) (E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)d

(E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)

= +Frt 2 tn (1 - fr1)d tr F

= outward nozzle weld = (leg) fr2

= inward nozzle weld = (leg)2 r f

= Same as A = Same as

, above A1, above

= 5(tn- trn ) fr2 t = 5(t n

- t rn ) f r2 t (2.5t n + t e ) f r2

= Same as A3, above

= outward nozzle weld = (leg) fr3

= outer element weld = (leg) fr4

= inward nozzle weld = (leg) fr2

= ( pD - fr4d - 2 tn)te

If A1 + 2A + A3+ 41A + A42

A If A1 + 2A + A3+ 41A + A42 A

If A1 + 2A + A3+ 41A + A42 A>+ 43A + 5A

Area required

Area available in shell; use larger value

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle; use the smallest value

Area available in outward weld Area available in inward weld

Opening is adequately reinforced Opening is NOT adequately reinforced; reinforcement required

Area required Area available in shell

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle

Area available in outward welds Area available in outer welds Area available in inward welds

Area available in element

Opening is adequately reinforced If A

A + A

A + A

A+

A +

A Opening is NOT adequately reinforced; additional reinforcement required<

Without Reinforcing Element

With Reinforcing Element

A-12

Minimum Required Thickness for Nozzles shall be determined from ASME Section VIII, Division 1, Part UG-27 as follows:

trn = PRn

SE - 0.6P

The remaining life of a tank or any of its components shall be determined using the formulas from API RP 575 as follows:

Cr = tprev - tact Lr = tact - trn

DY Cr

Where:

Dp = Outside diameter of reinforcing element as measured vertically, inches.

D = Outside diameter of pipe, inches.

d = finished diameter of circular opening in shell (inside diameter of nozzle), inches;

Where d = D - 2tn

E = Joint efficiency of nozzle; Use E = 1.0 for API calculations.

F = Correction factor for different plane variations; Use F = 1.0 for API calculations.

h = Distance nozzle projects beyond the inner surface of the wall, inches. Not to exceed 4tn for API calculations.

P = Internal design pressure, psi. Where, P = 0.433GH

Rn = Inside radius of nozzle, inches; Where Rn = d/2 Sn = Allowable stress in nozzle, psi.

fr = Strength reduction factor; Use fr = 1.0 for API calculations.

leg = Weld leg length, inches; Use leg = 0 for API calculations.

t = actual measured thickness of shell, inches; Use tact from Shell Service Life Evaluation.

tact = Actual measured thickness of nozzle, inches.

tprev = Previous measured thickness of nozzle or tn, inches.

te = Thickness of reinforcement plate or thickness of thickened insert less the actual measured thickness of the shell (t), inches.

tr = Minimum required shell thickness at the bottom of the nozzle, inches;

Where, tr = 2.6HDG/SE, however, tr shall not be less than 0.1 inch; Use E = 1.0 for API calculations; Use D and S from Shell Service Life Evaluation.

tn = External nominal pipe wall thickness, inches.

ti = Internal nominal pipe wall thickness, inches; Use ti = tn if nozzle projects inward for

API calculations.

trn = Required thickness of nozzle wall, inches.

G = Product specific gravity; Use G from Shell Service Life Evaluation.

H = Maximum liquid level above bottom of nozzle, feet.

Cr = Corrosion rate of nozzle, inches per year; Use Cr = 0.0002 inches/year, if Cr calculates to be less than 0.0002 inches/year.

LR = Remaining life of nozzle, years.

DY = Years between tprev and tact, in years.

A-13

Nozzle A: 36" Manway (Course #1) d = 36 - 2(0.5) = 35 inches t = 0.49 inches DY = 58 years

Rn = 35/2 = 17.5 inches tr = 0.1146 inches Dp = 77.5 inches

P = 0.433(0.84)(34.07) = 13 psi tn = 0.5 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.494 inches

Minimum Required Thickness Calculation:

trn = PRn =

(13)(17.5) = 0.0118 inches

SE - 0.6P (20,000)(1) - (0.6)(12)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.494 = 0.000103 inches/year

DY 58

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.494 - 0.1 = 1970 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (35)(0.1146) = 4.011 in2

A1

= d(t-tr) = (35)(0.49-0.1146) = 13.139 in2

= 2(t+tn)(t-tr) = (2)(0.49+0.5)(0.49-0.1146) = 0.7433 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.49) = 0.98 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.49)[(2.5)(0.5)+0.5] = 1.715 in2

A3

= 5t ti = (5)(0.49)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [77.5-35-(2)(0.5)](0.5) = 20.75 in2

Area provided by A1 + A2 + A3 + A5 = 13.139 in2 + 0.98 in2 + 0 in2 + 20.75 in2 = 34.869 in2. This is greater than the required area of 4.011 in2, therefore, the reinforcement is adequate.

A-14

Nozzle B: 8" Fire Protection (Course #5) (Nozzle is above liquid level) d = 8.625 - 2(0.5) = 7.625 inches t = 0.248 inches DY = 58 years

Rn = 7.625/2 = 3.8125 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(0) = 0 psi tn = 0.5 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(0)(3.8125) = 0 inches

SE - 0.6P (20,000)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

Reinforcement Calculations:

Formulas are simplified

A = dtr = (7.625)(0.1) = 0.7625 in2

A1

= d(t-tr) = (7.625)(0.248-0.1) = 1.1285 in2

= 2(t+tn)(t-tr) = (2)(0.248+0.5)(0.248-0.1) = 0.2214 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.1) = 0.496 in2

= 5(tn-trn)tn = (5)(0.5-0.1)(0.5) = 1 in2

A3

= 5t ti = (5)(0.248)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

Area provided by A1 + A2 + A3 = 1.1285 in2 + 0.496 in2 + 0 in2 = 1.6245 in2. This is greater than the required area of 0.7625 in2, therefore, the reinforcement is adequate.

A-15

Nozzle C: 10" Product Receipt (Course #1) d = 10.75 - 2(0.5) = 9.75 inches t = 0.49 inches DY = 58 years

Rn = 9.75/2 = 4.875 inches tr = 0.2319 inches Dp = 27 inches

P = 0.433(0.84)(34.9) = 13 psi tn = 0.5 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.495 inches

Minimum Required Thickness Calculation:

trn = PRn =

(13)(4.875) = 0.0032 inches

SE - 0.6P (20,000)(1) - (0.6)(13)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.495 = 0.000086 inches/year

DY 58

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.495 - 0.1 = 1975 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (9.75)(0.2319) = 2.261 in2

A1

= d(t-tr) = (9.75)(0.49-0.2319) = 2.5165 in2

= 2(t+tn)(t-tr) = (2)(0.49+0.5)(0.49-0.2319) = 0.511 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.49) = 0.98 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.49)[(2.5)(0.5)+0.5] = 1.715 in2

A3

= 5t ti = (5)(0.49)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [27-9.75-(2)(0.5)](0.5) = 8.125 in2

Area provided by A1 + A2 + A3 + A5 = 2.5165 in2 + 0.98 in2 + 0 in2 + 8.125 in2 = 11.6215 in2. This is greater than the required area of 2.261 in2, therefore, the reinforcement is adequate.

A-16

Nozzle D: 8" Product Issue (Course #1) d = 8.625 - 2(0.406) = 7.813 inches t = 0.49 inches DY = 58 years

Rn = 7.813/2 = 3.9065 inches tr = 0.2425 inches Dp = 18 inches

P = 0.433(0.84)(35.15) = 13 psi tn = 0.406 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.406 inches

E = 1 tact = 0.389 inches

Minimum Required Thickness Calculation:

trn = PRn =

(13)(3.9065) = 0.0025 inches

SE - 0.6P (20,000)(1) - (0.6)(13)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.406 - 0.389 = 0.000293 inches/year

DY 58

Remaining Life Calculation:

LR =

tact - trn =

0.389 - 0.1 = 986 years

Cr 0.000293

Reinforcement Calculations:

Formulas are simplified

A = dtr = (7.813)(0.2425) = 1.8947 in2

A1

= d(t-tr) = (7.813)(0.49-0.2425) = 1.9337 in2

= 2(t+tn)(t-tr) = (2)(0.49+0.406)(0.49-0.2425) = 0.4435 in2

A2

= 5(tn-trn)t = (5)(0.406-0.1)(0.49) = 0.7497 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.406-0.1)(0.49)[(2.5)(0.406)+0.5] = 1.1358 in2

A3

= 5t ti = (5)(0.49)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [18-7.813-(2)(0.406)](0.5) = 4.6875 in2

Area provided by A1 + A2 + A3 + A5 = 1.9337 in2 + 0.7497 in2 + 0 in2 + 4.6875 in2 = 7.3709 in2. This is greater than the required area of 1.8947 in2, therefore, the reinforcement is adequate.

A-17

Nozzle E: 3" Low Point Suction (Quick Connect) (Course #1) d = 3.5 - 2(0.3) = 2.9 inches t = 0.49 inches DY = 58 years

Rn = 2.9/2 = 1.45 inches tr = 0.2654 inches Dp = 11 inches

P = 0.433(0.84)(35.36) = 13 psi tn = 0.3 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.3 inches

E = 1 tact = 0.31 inches

Minimum Required Thickness Calculation:

trn = PRn =

(13)(1.45) = 0.0009 inches

SE - 0.6P (20,000)(1) - (0.6)(13)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.3 - 0.31 = -0.000172 inches/year

DY 58

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.31 - 0.1 = 1050 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (2.9)(0.2654) = 0.7697 in2

A1

= d(t-tr) = (2.9)(0.49-0.2654) = 0.6513 in2

= 2(t+tn)(t-tr) = (2)(0.49+0.3)(0.49-0.2654) = 0.3549 in2

A2

= 5(tn-trn)t = (5)(0.3-0.1)(0.49) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.3-0.1)(0.49)[(2.5)(0.3)+0.5] = 0.6125 in2

A3

= 5t ti = (5)(0.49)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [11-2.9-(2)(0.3)](0.5) = 3.75 in2

Area provided by A1 + A2 + A3 + A5 = 0.6513 in2 + 0.49 in2 + 0 in2 + 3.75 in2 = 4.8913 in2. This is greater than the required area of 0.7697 in2, therefore, the reinforcement is adequate.

A-18

Nozzle F: 1-1/2" Water Draw Off (Course #1) d = 1.9 - 2(0.2) = 1.5 inches t = 0.49 inches DY = 58 years

Rn = 1.5/2 = 0.75 inches tr = 0.2713 inches Dp = N/A

P = 0.433(0.84)(35.29) = 13 psi tn = 0.2 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.2 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(13)(0.75) = 0.0005 inches

SE - 0.6P (20,000)(1) - (0.6)(13)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-19

Nozzle G: 36" Manway (Course #1) d = 36 - 2(0.375) = 35.25 inches t = 0.49 inches DY = 58 years

Rn = 35.25/2 = 17.625 inches tr = 0.1218 inches Dp = 47 inches

P = 0.433(0.84)(34.98) = 13 psi tn = 0.375 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.375 inches

E = 1 tact = 0.437 inches

Minimum Required Thickness Calculation:

trn = PRn =

(13)(17.625) = 0.0115 inches

SE - 0.6P (20,000)(1) - (0.6)(13)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.375 - 0.437 = -0.001069 inches/year

DY 58

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.437 - 0.1 = 1685 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (35.25)(0.1218) = 4.2935 in2

A1

= d(t-tr) = (35.25)(0.49-0.1218) = 12.9791 in2

= 2(t+tn)(t-tr) = (2)(0.49+0.375)(0.49-0.1218) = 0.637 in2

A2

= 5(tn-trn)t = (5)(0.375-0.1)(0.49) = 0.6738 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.375-0.1)(0.49)[(2.5)(0.375)+0.5] = 0.9685 in2

A3

= 5t ti = (5)(0.49)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [47-35.25-(2)(0.375)](0.5) = 5.5 in2

Area provided by A1 + A2 + A3 + A5 = 12.9791 in2 + 0.6738 in2 + 0 in2 + 5.5 in2 = 19.1529 in2. This is greater than the required area of 4.2935 in2, therefore, the reinforcement is adequate.

A-20

Nozzle H: 2" High High Level Alarm (Course #5) d = 2.375 - 2(0.218) = 1.939 inches t = 0.248 inches DY = 58 years

Rn = 1.939/2 = 0.9695 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(1.4) = 1 psi tn = 0.218 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.218 inches

E = 1 tact = 0.272 inches

Minimum Required Thickness Calculation:

trn = PRn =

(1)(0.9695) = 0 inches

SE - 0.6P (20,000)(1) - (0.6)(1)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.218 - 0.272 = -0.000931 inches/year

DY 58

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.272 - 0.1 = 860 years

Cr 0.0002

A-21

Nozzle I: 2" High Level Alarm (Course #4) d = 2.375 - 2(0.3125) = 1.75 inches t = 0.248 inches DY = 58 years

Rn = 1.75/2 = 0.875 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(6.48) = 2 psi tn = 0.3125 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.3125 inches

E = 1 tact = 0.3 inches

Minimum Required Thickness Calculation:

trn = PRn =

(2)(0.875) = 0.0001 inches

SE - 0.6P (20,000)(1) - (0.6)(2)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.3125 - 0.3 = 0.000216 inches/year

DY 58

Remaining Life Calculation:

LR =

tact - trn =

0.3 - 0.1 = 926 years

Cr 0.000216

A-22

Nozzle J: 8" Fire Protection (Course #5) (Nozzle is above liquid level) d = 8.625 - 2(0.5) = 7.625 inches t = 0.248 inches DY = 58 years

Rn = 7.625/2 = 3.8125 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(0) = 0 psi tn = 0.5 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(0)(3.8125) = 0 inches

SE - 0.6P (20,000)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

Reinforcement Calculations:

Formulas are simplified

A = dtr = (7.625)(0.1) = 0.7625 in2

A1

= d(t-tr) = (7.625)(0.248-0.1) = 1.1285 in2

= 2(t+tn)(t-tr) = (2)(0.248+0.5)(0.248-0.1) = 0.2214 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.1) = 0.496 in2

= 5(tn-trn)tn = (5)(0.5-0.1)(0.5) = 1 in2

A3

= 5t ti = (5)(0.248)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

Area provided by A1 + A2 + A3 = 1.1285 in2 + 0.496 in2 + 0 in2 = 1.6245 in2. This is greater than the required area of 0.7625 in2, therefore, the reinforcement is adequate.

A-23

Appendix B

Engineering Drawings

1.

2.

3.

Bottom Layout Shell Layout Floating Roof Layout

B-4

Electronic Coupon

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 B-1Bottom Layout

Measured Inside Diameter is 85 feet.

Tank bottom has 23 plates.

201086420

GRAPHIC SCALE:

Dimensions are in feet.

NORTH

P L

A N

N O

R T

H y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

4 5

6 7

8 9 10

11 12 13

14 15 16

17 18

19 20

21 22 23

See Bottom Plate Flaw Measurements table for detailed measurements.

See Bottom Electronic Coupon Measurements table for detailed measurements.

V1

V2

V3

V4

V5

V6

V7

V8

V9

A

Shell Nozzles in Course #1 A - 36" Manway

C

C - 10" Product Receipt

D

D - 8" Product Issue

E

B -2

F

E - 3" Low Point Suction F - 1.5" Water Draw Off

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 S-1Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in 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.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-1 A

2-1

3-1

4-1

5-1

1-2

B

2-2

3-2

4-2

5-2

1 2 3

A - 36" Manway B - 8" Fire Protection

B -3

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 S-2Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in 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.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-3

C

2-3

3-3

4-3

5-3

1-4

D

ATG

2-4

3-4

4-4

5-4

3 4 5

C - 10" Product Receipt D - 8" Product Issue

-4

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 S-3Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in 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.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-5

E

H

I

2-5

3-5

4-5

5-5

1-6

F

G

J

2-6

3-6

4-6

5-6

5 6 7

E - 3" Low Point Suction {Quick Connect} F - 1.5" Water Draw Off G - 36" Manway H - 2" High High Level Alarm I - 2" High Level Alarm J - 8" Fire Protection

-5

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 S-4Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in 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.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-7

2-7

3-7

4-7

5-7

1-8

2-8

3-8

4-8 4-9

5-8

7 8 9

-6

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 S-5Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in 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.

10540

GRAPHIC SCALE:

Dimensions are in feet.

1-9

2-9

3-9

5-9

9 1

-7

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

Environmental Technology A Division of CAPE

04/05/12 N/A N/A

Tank #3 FR-1Floating Roof Layout

Measured Diameter is 83.83 feet.

Floating roof has 53 plates.

201086420

GRAPHIC SCALE:

Dimensions are in feet.

NORTH

P L

A N

N O

R T

H y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

3 4

7 8 9 10

11 12 13 14

15 16 17 18 19

20 21 22 23 24

25 26 27 28 29

30 31 32 33 34

35 36 37 38 39

40 41 42 43

44 45 46 47

48 49 50 51 52 53

71 72 73

959697

B -8

MW

Roof Sump

Appendix C

Engineering Data

1.

2.

3.

4.

5.

6.

7.

Bott…