Attachment J.2 Fac 3036 - Insp Report - Oct 2017.pdf

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Andrews Air Force Base, Maryland Facility 3036

Tank 8

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

USACE POL-MCX

5 March 2018

API 653 In-Service Inspection Report Andrews AFB, MD

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

THIS INSPECTION

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

3. Future Projects

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs

2. SIGNIFICANT FINDINGS per API 653, UFC 3-460-01, or AW 78-24-27 Standards

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

4. REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

SHELL THICKNESS CALCULATIONS

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

TANK DRAWINGS,

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX C: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

AFFF Aqueous Film Forming Foam

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

CS Carbon Steel

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFE Magnetic Flux Eddy Current

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NA Not Applicable

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

PTFE Polytetrafluoroethylene (e.g., TEFLON)

P/V Pressure/Vacuum

PST Product Saver Tank

SS Stainless Steel

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UG Underground

UT Ultrasonic Testing

GENERAL SUMMARY

Austin Brockenbrough & Associates, LLP (Brockenbrough) was retained by Omaha District USACE under Contract

No. W9128F-12-D-0006 Delivery Order 0036 to perform SPCC Mandated AST/UST Inspections at various locations. As required by this task, Brockenbrough executed a tank inspection site visit to Andrews Air Force Base located in Morningside, Maryland. An API 653 In-service (visual external) Inspection was conducted for Tank

Facility No. 3036 on October 5, 2017. This inspection was performed in accordance with API Standard 653, “Tank

Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. In addition to the inspection requirements of API 653, the shell was ultrasonic thickness inspected for remaining thickness and surveyed for roundness. All observations made during this in-service (visual external) inspection were made from the exterior of the tank.

Facility 3036 is a 42-foot and 6-inch diameter by 38-foot and 9 1/2-inch tall, single wall, vertical, field-erected tank with a nominal storage capacity of 9,800 barrels of jet fuel (F-24). The tank has a steel double deck internal floating roof. The repair organization nameplates indicate the tank was constructed in 1958 and substantial repairs were completed in 2004 and 2015. The original tank erector is unknown. The Base’s SPCC plan indicates a date of construction of 1960. Repair drawings are not available at this time. The tank has a second bottom installed by the shell slotting method, which was likely part of the 2004 repairs. The 2015 repair organizations nameplate indicates a MTG (likely meaning “mechanical tape gauge”) and level alarms were installed at that time.

Details of tank construction and appurtenances are included in the General Tank Information table on page 6 and comments in Section ‘B’.

There are no Mandatory Repairs noted that need immediate attention. Additional noted deficiencies are discussed in more detail in Section ‘C’, and should be addressed in a timely manner. Photographs of the tank are included in

Appendix ‘C’.

The next API Standard 653 In-service (visual external) Inspection should be performed by October 2022. The next ultrasonic thickness inspection of the shell should be performed by October 2032. The guidance provided in the current UFC 3-460-03 includes out-of-service inspection at least every 10 years of service. An upcoming revision allows the frequency to be extended as determined by a certified API 653 tank inspector. As recommended in the

June 2014 API 653 inspection report, the next API Standard 653 Out-of-service (internal and external) Inspection should be performed by June 2034. This inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology, and a thorough code compliance evaluation.

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Air Force

Location Andrews Air Force Base

Facility Number 3036

Tank Number Tank 8

State / Country Maryland / U.S.A.

City Morningside

Inspection Date October 5, 2017

Tank Manufacturer Unknown

Design Standard API 12C (assumed)

Date of Construction 1958 per repair nameplate. 1960 per SPCC Plan

Tank Contents Jet Fuel (F-24)

Tank Serial Number unknown

Tank Diameter 42’-6”

Shell Height 38’-9 1/2” (second bottom to rim angle)

Product Height 38’-9 1/2” (to rim angle)

Tank Capacity 9,800 bbl (411k gal) nominal (second tank bottom to rim angel).

8,000 bbl (337k gal) useable (low level alarm to high level alarm)

Foundation Double bottom; concrete foundation 6” above dike basin.

Construction

Bottom 5/16-inch lap welded plate (14 inches above original).

Shell

(5) shell courses of 1/4-inch butt-welded carbon steel.

Floating Roof Steel double deck.

Fixed Roof Corrugated sheet metal barn style.

Material

Bottom Carbon steel of unknown grade.

Shell Carbon steel of unknown grade.

Floating Roof Carbon steel

Fixed Roof Corrugated sheet metal (steel).

Cathodic Protection Impressed current

Interior Coating System Interior 100% coated, likely epoxy.

Exterior Coating System Epoxy/polyurethane assumed.

Level Gauging Enraf servo ATG, Vito water probe, manual gauging well, Shand and Jurs tape autogauge.

Overfill Protection Independent High and high-high level alarms, ATG Alarms, Float operated high level control valve.

Piping Receipt 8” Welded carbon steel

Issue 10” Welded carbon steel

Low Suction 4” No piping

Water Draw-off 1” Welded stainless steel

Level Alarms Shell mounted (independent) Scully high, high-high, low, and low-low level alarms; and ATG level alarms.

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.

For Facility 3036 an API Standard 653 In‐service (external) Inspection was performed, which included a shell settlement survey and a shell UT inspection. In addition, a shell roundness survey was performed.

2. Site Information

On October 5, 2017 Brockenbrough performed API 653 In‐Service (External) Inspection of Facility

3036 (Tank 8) located at Andrews Air Force Base, which is located in Morningside, Prince George's

County, Maryland. The facility is under the jurisdiction of the United States Air Force 11th Wing, Air

Force District of Washington. In 2009, Andrews Air Force Base and Naval Air Facility Washington were merged to form Joint Base Andrews. The Base is named for Lieutenant General Frank Maxwell

Andrews (1884–1943), former Commanding General of United States Armed Forces in the European

Theater of Operations during World War II. The Base is widely known for serving as the home base of two Boeing VC-25 aircraft which have the call sign Air Force One while the President of the United

States is on board. As of the 2010 census, the resident population was 2,973. The host unit at Andrews is the 11th Wing, assigned to the Air Force District of Washington. The Wing is responsible for maintaining emergency reaction rotary-wing airlift and other National Capital Region contingency response capabilities critical to national security, and for organizing, training, equipping and deploying combat-ready forces for Air and Space Expeditionary Forces (AEFs). The Wing also provides installation security, services and airfield management to support the President, Vice President, other

U.S. senior leaders and more than 50 tenant organizations and federal agencies. The list of the types of aircraft that fly out of Andrews Air Force Base is extensive, as are the list of the branches of the military that fly out of Andrews Air Force Base.

3. Future Projects

There are no projects in the near future or that are currently on-going that affect the operation or maintenance of the tank. A project to erect new tanks adjacent to the Tank Facility 3036 is currently under construction.

B. TANK INSPECTION COMMENTS

1. Tank Construction

Tank Facility 3036 is a nominal 9,800 bbl, 42‐foot and 6-inch diameter by 38-foot and 9 1/2-inch tall, aboveground, vertical, jet fuel, storage tank. The tank has a steel double deck internal floating roof, which was converted from external when the corrugated sheet metal, barn style roof was installed. The tank also has a lap welded steel cone-down second bottom. The perimeter of the second bottom is approximately 14 inches above the original. The original bottom rests on a concrete ringwall with an average projection above the dike basin of approximately 6 inches. Two repair organization nameplates and the previous inspection report indicate a date of construction of 1958. The SPCC Plan indicates the tank was constructed in 1960.

https://en.wikipedia.org/wiki/United_States_Air_Force https://en.wikipedia.org/wiki/11th_Wing https://en.wikipedia.org/wiki/Air_Force_District_of_Washington https://en.wikipedia.org/wiki/Air_Force_District_of_Washington https://en.wikipedia.org/wiki/Andrews_Air_Force_Base https://en.wikipedia.org/wiki/Naval_Air_Facility_Washington https://en.wikipedia.org/wiki/Lieutenant_General https://en.wikipedia.org/wiki/Frank_Maxwell_Andrews https://en.wikipedia.org/wiki/Frank_Maxwell_Andrews https://en.wikipedia.org/wiki/United_States_Armed_Forces https://en.wikipedia.org/wiki/European_Theater_of_Operations https://en.wikipedia.org/wiki/European_Theater_of_Operations https://en.wikipedia.org/wiki/World_War_II https://en.wikipedia.org/wiki/Boeing_VC-25 https://en.wikipedia.org/wiki/Aircraft https://en.wikipedia.org/wiki/Air_Force_One https://en.wikipedia.org/wiki/President_of_the_United_States https://en.wikipedia.org/wiki/President_of_the_United_States https://en.wikipedia.org/wiki/2010_United_States_Census https://en.wikipedia.org/wiki/Population https://en.wikipedia.org/wiki/11th_Wing https://en.wikipedia.org/wiki/Air_Force_District_of_Washington

2. Tank Foundation

The tank rests on a concrete ringwall foundation with an average projection above the dike basin of 6 inches. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. Concentric spalling and cracking on the top of the concrete foundation was noted centered about the north by northwest quarter. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard 653. The shell settlement evaluation indicates the settlement of the bottom of the shell and perimeter of the tank bottom is acceptable.

3. Tank Shell

The vertical and cylindrical shell consists of five butt‐welded courses. The ultrasonic thickness measurements of the shell and calculations included in Appendix A indicate the shell has more than 30 years of remaining life. API 653 recommends ultrasonic thickness measurements of the shell be taken at least every 15 years.

a. Plumbness, Roundness, Peaking, and Banding

The exterior of the shell was visually inspected and evaluated for plumbness, roundness, peaking and banding.

1) API 650, paragraph 7.5.2 allows a maximum out-of-plumb of the top of a new tank shell, relative to the bottom of the shell, of 1/200 of the height of the shell, a difference of 2 3/8 inches for this

38-foot and 9 1/2-inch tall tank. The maximum measured out-of-plumbness was 1 1/2 inches away from the tank center as measured on the northeast side. The shell also leans toward the tank center approximately 7/8 inch on the opposite side (the southwest side) of the tank. The out-of-plumbness of the shell appears to be within that allowed by API 650 for new construction. The horizontal shell seam between the first and second shell courses measures higher on the southwest side than on the northeast side by 3/8 inch, which indicates little settlement of the foundation.

2) The shape of the shell appears to exceed the allowable API 650 tolerance of plus or minus 1/2-inch of a new tank shell radius. No localized shell distortions were noted. The tank bottom should restrain the shell from deflection near the bottom. That there did not appear to be any significant distortion of the shell, would seem to suggest the tank was built slightly out-of-round. As measuring the out-of-roundness using laser survey methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time.

3) While some minor peaking and banding of the butt-welded shell seams was observed, the peaking-and-banding appeared to be within limits allowed by API 650.

4. Tank Appurtenances

a. Tank Roof

The tank is covered with a corrugated sheet metal, barn style roof. Access for inspecting the roof is limited to visual observations made from the top of the stairs and from the outside as viewed through the rolling ladder access door.

b. Venting

Evaporation of the fuel is controlled by a double deck steel internal floating roof. The overhang of the barn style roof is vented all around the perimeter of the tank.

c. Gauging

The tank has an Enraf ATG and a water probe installed in separate aluminum wells. There is also a

Shand and Jurs autogauge (mechanical tape level gauge), and an 8-inch aluminum manual gauging well with a floating plug retriever. The upper end of the ATG, water probe, and manual gauging wells are all only accessible by performing a confined space entry through the barn style roof access door, and the manual gauging well is accessible only from the rolling ladder.

d. Level Alarms

The tank has shell mounted (independent) high, high-high, low and low-low level alarms, as well as

ATG level alarms.

e. Stairs and Platforms

The tank’s barn style roof access door is accessible by a circumferential stairway, which includes a landing for accessing the high-level alarms, and controls.

f. Grounding and Bonding

The tank has two grounding cables which are bolted to the tank’s original bottom and appeared to be in good condition. There are also four ground cables connected to the barn style roof and penetrate the dike basin through unsealed PVC pipe.

5. Tank Coating

The coating was evaluated for deterioration. The exterior of the shell appears to be in good condition.

However, there is some isolated coating failure and corrosion on the stairway handrails, and top platform frame. The interior appears to be 100% coated.

6. Tank Piping System

Tank Facility 3036 is a bulk tank and receives fuel from the nearby New Star commercial terminal via a combination of aboveground and underground piping and the facility’s filter/separators. Fuel is issued from the tank to the local pumphouse via aboveground piping. The local pumphouse issues the fuel from the tank via the pumphouse filter/separators and a system of underground pipelines to tanks serving three hydrant systems. The 8-inch aboveground carbon steel receipt piping and the 10-inch aboveground carbon steel issue piping connect to the tank nozzles through offset piping runs to limit nozzle stress due to thermal expansion. The tank’s low suction is remote from and not connected to the main suction. The product saver tank piping is welded stainless steel and is connected to water draw-off and return nozzles as well as the alarm and control test piping. The pipe coatings and supports appear to be in good condition. However, there is some coating failure on the pipe flanges, double block and bleed isolation valves, and issue piping TRV. The integral TRVs on the receipt and issue nozzle isolation valves discharge away from the tank. The receipt and issue TRV nameplates indicate set pressures for both of 200 psi.

7. Fire Protection System

There are three fire hydrants within 300 feet of this tank.

8. Secondary Containment

Secondary containment is provided by concrete covered earthen berms and basin. Secondary containment is shared with Tank 10 (FAC 3035). The secondary containment was visually evaluated during the inspection. The drainage control valve is located outside the dike area and should be accessible in the event of a fire. The dike basin is sloped to a swale approximately 20 feet from the tank on the north side. The piping runs over the north swale and near the dike drain. NFPA 30 paragraph

22.11.2.1 requires the dike basin to slope away from the tank a minimum of 50 feet or to the dike berm.

NFPA 30 paragraph 22.12.2.1 requires the dike basin to slope away from piping for at least 50 feet. The secondary containment appears otherwise to be in good condition. A conservative evaluation of the volume of the secondary containment, not including the secondary containment of the adjacent tank, which borrows some secondary containment from Tank Facility 3036, indicates it is sufficient to hold the contents of the tank full to the top of the shell as required by NFPA 30 plus approximately 14 inches of freeboard. Additional freeboard may be provided by the swale and the secondary containment of the adjacent tank. Guidance for new construction provided in UFC 3-460-01 paragraph 8-14.2.1 includes one foot of freeboard.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 3036 was found to be in generally good condition. The tank is fully serviceable, with no mandatory deficiencies that would require immediate removal of the tank from service. However, there were several items observed that could be addressed to reduce long term maintenance, to improve operability, and to more clearly comply with federal, state, and local regulations or military criteria.

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs

Mandatory repairs represent items that require immediate attention in order to prevent imminent risk to system operators, equipment, or the adjacent environment. The tank would have to be taken out-of-service to complete these repairs. No Mandatory Repairs are required to be performed.

2. SIGNIFICANT FINDINGS per API 653, UFC 3-460-01, or AW 78-24-27 Standards

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

a. Ground Product Saver Tank

OBSERVATION: The product saver tank stainless steel piping is isolated from the tank by the isolation flange kit on the shell nozzle isolation valve. An electric motor is mounted on the product saver tank skid, but the skid and product saver tank are not grounded.

REFERENCE: Guidance provided in DoD Standard Design AW 78-24-27 and UFC 3-460-01 paragraph

2-12.3 include grounding for new product saver tanks. Paragraph 9-8 i) includes isolation flanges for connecting dissimilar metals.

RECOMMENDATION: Provide a grounding system for the product saver tank. Do not bond the product saver tank to the same grounding system as that on the tank in order to maintain some degree of electrical isolation and inhibit galvanic corrosion.

b. Repair and Resurface the Exposed Concrete of the Foundation

OBSERVATION: The foundation is spalled and cracked in a concentric pattern and concentrated in the north by northwest quarter of the foundation. Water entering the foundation through the cracks in the concrete may lead to corrosion of the reinforcing steel. The water in the cracks may expand upon freezing, further widening the cracks and leading to more spalling.

Reference: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require secondary containment to be liquid tight. API 650 paragraph 5.3.1 and API 653 Appendix B require foundations to provide adequate support.

RECOMMENDATION: Repair, resurface, and seal the exposed surfaces of the tank foundation.

c. Provide Ball Valves or PVC Plugs on Leak Detection Tell-Tales

OBSERVATION: The tank bottom leak detection tell-tale port/drain threaded plugs are too tight and painted over. The ports/drains were not capable of being opened to be checked for sign of a bottom leak by application of approximately 220 ft-lbs of torque using an 18-inch pipe wrench.

Reference: Guidance for new construction included in DoD Standard Design AW 78-24-27 includes threaded ball valves on tank bottom leak detection tale tell ports/drains.

RECOMMENDATION: Provide ball valves or PVC plugs on the four (4) tank bottom leak detection tell-tale ports so that checking for signs of bottom leaks may be completed monthly.

d. Seal Cracks Dike Basin

OBSERVATION: There are unsealed cracks in the dike basin showing efflorescence in about 30 places totaling approximately 40 feet, most of which are in the shared dike area of the sister tank.

Reference: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require secondary containment to be liquid tight.

RECOMMENDATION: Seal the efflorescent cracks in the dike basin in about 30 places and totaling approximately 40 feet mostly in dike area of sister tank with which the tank shares secondary containment.

e. Provide Dike Access

OBSERVATION: Personnel access to the dike area is by climbing the gravel over the geotextile covered dike berm from the outside of the dike and at some risk of falling due to the gravel rolling out from under personnel.

Reference: NFPA 30 paragraph 22.11.2.5 requires provisions be made for normal and emergency access. Guidance for the design of new tanks provided in UFC 3-460-01 paragraph 8-14.8 includes steps for passage over dike berms.

RECOMMENDATION: Provide dike access steps for accessing the dike area from outside of the dike.

Dike Access Steps Only on Inside of Dike

3. RECOMMENDED REPAIRS 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. Clean the Shell Manhole Covers

OBSERVATION There is sign of previous leaks around the shell manhole cover bolts as evidenced by the dirt that had collected on the fuel stain.

REFERENCE: Guidance for operation and maintenance of fuel storage tanks provided in UFC 3-460-

03 includes visually inspecting the exterior of the tank for leaks at shell manhole covers.

RECOMMENDATION: Remove the fuel stains and dirt from the shell manhole covers to provide indication of current leaks.

b. Continue to Remove Vegetation

OBSERVATION: The tank shares secondary containment with the adjacent tank. There is soil and algae in the secondary containment, and a small amount of plants growing out of the concrete secondary containment expansion joints of the sister tank.

Reference: Guidance for maintenance of fuel storage facilities provided in UFC 3-460-03 paragraph 8-10.3.1 includes inspection of concrete secondary containment for cleanliness and removal of vegetation.

RECOMMENDATION: Continue to remove the soil and algae from the shared dike areas, and continue to remove the vegetation growing out of the concrete secondary containment expansion joints.

c. Label CP Rectifier Control Box

OBSERVATION There are several cathodic protection (CP) rectifier control boxes in the area near the tank. The CP rectifier control box for the tank is not labeled to indicate which tank it is associated with.

REFERENCE: Guidance for the design of new construction provided in UFC 3-460-01 paragraph 8-8.5 includes cathodic protection for tank bottoms. Paragraph 2-18 includes marking equipment to correspond with the installations drawings.

RECOMMENDATION: Mark the cathodic protection rectifier control box to identify which tank it is associated with.

d. Service or Replace the Issue Piping Thermal Relief Valve

OBSERVATION: The issue piping thermal relief valve is corroded. The data plate indicates a set pressure of 200 psi. The maximum actual operating pressure is approximately 14 psi.

REFERENCE: Guidance for new construction provided in UFC 3-460-01 paragraph 9-3.5.1 recommends a set pressure of 10 % above pump deadhead.

RECOMMENDATION: Service the issue thermal relief valve. Adjust the set pressure to 40 psi and install car seals. Replace the issue thermal relief valve coating. Provide a manufacturer’s nameplate with the new set pressure indicated. Alternatively, replace the issue thermal relief valve with a valve factory set at 40 psi.

e. Provide Bottom to Foundation Seal

OBSERVATION: While the bottom to foundation seal shows little sign of deterioration, the bottom reinforcing plate for the demolished flush cleanout is not sealed to the tank bottom. The lack of a complete seal between the tank bottom and the foundation may allow fuel to escape the secondary containment in the event of a spill.

Reference: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require secondary containment to be liquid tight. Guidance for new construction included in UFC 3-460-01 and DoD Standard Design include a tank bottom to foundation seal. NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require secondary containment to be liquid tight.

RECOMMENDATION: Abrasive blast and coat the underside of the bottom reinforcing plate of the demolished flush cleanout and provide a tank bottom to foundation seal under the reinforcing plate of the demolished flush cleanout.

f. Spot Repair Appurtenance Coatings

OBSERVATION: There is isolated coating failure and corrosion on the circumferential stairway handrails, attachment welds, and platform frame. There is also isolated coating failure and corrosion on the issue piping flange.

REFERENCE: Guidance for the design of new storage tanks provided in UFC 3-460-01 paragraph 8-

3.10 includes exterior coatings.

RECOMMENDATION: Spot repair the coatings on the issue piping flange and circumferential stairway handrails, attachment welds, and platform frame.

g. Seal the Roof and CP Ground Cable Dike Basin Penetrations

OBSERVATION: The CP and four roof ground cables penetrate the dike basin through unsealed PVC pipe. The PVC pipes are broken-up and held together with black electrical tape.

REFERENCE: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require dikes to be liquid tight.

RECOMMENDATION: Eliminate the aboveground portion of the PVC pipes, through which the CP and four roof ground cables penetrate the dike basin. Seal the CP and four roof ground cable penetrations through the dike basin.

4. REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards

These items represent repairs and/or upgrades that could be performed to bring the tank into full compliance with current standards, but that do not represent potential risks to system operators, equipment integrity, or the adjacent environment. Our recommendations to perform, or not to perform these repairs and/or upgrades, take into consideration the cost of the repair, the operational benefit of the repairs, the age of the tank/system, operator safety, environmental risks, and equipment integrity.

a. Provide Low Suction and Internal Piping

OBSERVATION: The low suction is not on the same side of the tank as the main suction and is not connected to the main suction.

REFERENCE: Guidance for the design of new storage tanks provided in DoD Standard Design AW 78-

24-27 and UFC 3-460-01 table 8-1 item v) indicate a low suction nozzle located adjacent to the main suction nozzle and connected to the main suction by piping and isolation valves.

RECOMMENDATION: When other major repairs are performed, provide a low suction nozzle adjacent and connected to the main suction and relocate the isolation valve and internal low suction piping to the new low suction nozzle. The low suction thus connected to the main suction may be used to recirculate the tank bottoms from the sump through the pumphouse filter/separators to clean and dry the fuel. The new low suction internal piping and nozzle, thus connected, can also be used to prepare the tank for cleaning without the use of vacuum trucks and with significantly less loss of fuel and less risk of a spill.

Main Suction

Low Suction

b. Modify Secondary Containment

OBSERVATION: The concrete dike basin is sloped away from the tank to a swale approximately 25 feet from the tank on the north and east sides. The piping is routed along and over the north swale and near the dike drain.

REFERENCE: NFPA 30 paragraph 22.11.2.1 requires secondary containment to be sloped away from the tank for 50 feet or to the dike berm, whichever is less. Paragraph 22.12.2.1 requires secondary containment to be sloped away from piping for at least 50 feet.

RECOMMENDATION: Modify the secondary containment to slope way from the tank and piping for at least 50 feet or to the dike berm.

c. Replace Top Landing Guardrail

OBSERVATION: The landing guardrail at the top of the circumferential stairway is fabricated from 1

1/4-inch steel angle with single bolt splices. The splices create uncoatable flat surface-to-flat surface connections that promote corrosion. The strength of the single bolt spliced handrails is questionable and is susceptible to corrosion.

REFERENCE: 29 CFR 1910.23 (e) requires railings to be able to withstand a force of 200 pounds.

RECOMMENDATION: Replace the landing guardrails at the top of the circumferential stairway with

OSHA compliant guardrails.

Dike Drain

Dike Drain

Bolt piping

Swale

Swale

d. Provide a Cone Roof

OBSERVATION: The tanks roof is a corrugated sheet metal, barn style roof. Access to the manual gauging well and other appurtenances is by permit required confined space entry only. There is not access to the roof. Walking on the tank roof is not permitted.

REFERENCE: While API 650 paragraph 5.10.2.8 allows alternative roof designs, the roof generally does not meet API 650 paragraph 5.10.2. for thickness, member attachment, structural member thickness, safety, and structural stability.

RECOMMENDATION: Provide a lap welded cone roof per API 650 and UFC 3-460-01.

e. Modify Stairway

OBSERVATION The rise of the stairway below the intermediate landing is typically 9 inches. The rise of the bottom step above the dike basin is 7 1/2 inches.

REFERENCE: 29 CFR 1910.24 (f) requires the rise of stair steps to be uniform throughout any flight of stairs including a foundation used as a step.

RECOMMENDATION: Provide a landing at the bottom of the circumferential stairway at approximately the same level as the bottom step.

Floating Plug Retriever

Rolling Ladder

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 1/2-inch of a new tank shell radius. Based on the circumference of the shell measured near the bottom, the radius of the shell should be 21 feet and 3 inches. However, the measured radii of the shell, varies at the bottom from 21 feet and 1

3/4 inches in the southwest to 21 feet and 4 1/4 inches in the North. Also, the measured radii of the shell, varies at the top from 21 feet and 7/8 inches in the southwest to 21 feet and 4 1/2 inches in the northeast. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top. That there did not appear to be any significant distortion of the shell, would seem to suggest the tank was built slightly out-of-round. It is noted that the tolerance for out-of-roundness has been included in API 650 since at least before 1993. API 650 1st

Edition was published in 1960. However, it has not been until later years that the industry has had the laser surveying technology and methods available to it to measure it in the upper shell courses. It should be noted that

API 653,10.5.3 – 3rd Edition (published in 2001), and later editions, allow the shell out-of-roundness (radial deviation), at higher than one foot above a bottom of a reconstructed tank, to be as much as three times greater (1

1/2 inches), a subject not addressed in API 653 prior to the year 2001. As measuring the out-of-roundness using such methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time.

Austin Brockenbrough & Associates, L.L.P. Job No. 17-050.01

Location: Andrews AFB Date: 9/18/2017

Subject: Tank Fac 3036 - Shell Settlement Evaluation By: Mike O'Connor

API 653 Appendix B

Optimum cosine curve, B 2.2.4.e) Z = a + b x cos(theta + c)

Diameter (D) = 42.5 (ft)

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 16.69

Tank Height (H) = 38.8 (ft)

Relative elevation of lowest horizontal weld seam.

* Z U S

0 106.77 0.00 0.01 0.01 -0.01

1 106.80 0.03 0.05 0.02 -0.02

2 106.84 0.07 0.12 0.05 -0.01

3 106.87 0.10 0.20 0.10 0.01

4 106.88 0.11 0.23 0.12 0.16

5 107.14 0.37 0.20 -0.17 -0.14

6 107.07 0.30 0.12 -0.18 -0.11

7 106.78 0.01 0.05 0.04 0.12

8 106.77 0.00 0.01 0.01 0.00

Maximum out-of-plane deflection = 0.16

* = measured elevation

*HI (Height of Instrument)

Z = calculated ridged body tilt (in)

U = out-of-plane settlement

S = out-of-plane deflection

Y = yield sterength of shell material (PSI) = 30,000 (CS, unknown grade)

E = Youngs modulas of elasticity (lbf/in2) = 29*10^6

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH)*12 = 0.49 in

R^2 = (Syy - SSE) / Syy = 0.38 not >=0.9 therefore cosine curve is invalid.

Evaluation by the Arc Length Method described in API 653 B.2.2.5.1 is required.

Austin Brockenbrough & Associates, L.L.P. Job No. 17-050.01

Location: Andrews AFB Date: 9/18/2017

Subject: Tank Fac 3036 - Shell Settlement Evaluation By: Mike O'Connor

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

* Open top (yes/no) = yes Per B.3.2.2, K = 28.7

Settlement arc length (ft), Sarc

Out of plate settlement at Point i (Si)

Allowable settlement at point i (Smax) = MIN[K*Sarc*(D/H)*(Y/E), 4]

Point Sarc (ft) Si (in) Smax

4 83.4 0.19 2.71 OK

7 33.4 0.14 1.09 OK

* For the purpose of this evaluation tanks with geodesic domes and barn roofs are consided to be open top, as those types of roofs do not significantly restrain shell deformation.

Si < Smax →

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

Si < Smax →

-0.10

0.00

0.10

0.20

0.30

0.40

0 2 4 6 8 10

Si7 Si4

Measured Elevation (in)

Austin Brockenbrough & Associates, L.L.P. 17-043.01

Location: FAC 3036 (Tank 8) Andrews AFB Date: 10/12/17

Subject: Shell Radius Survey Page 1 of 4

Measured Circumference at Bottom = 133.52

Calculated Diameter = 42.50

Calculated Radius = 21.25

Distance Height Out

From Radial Radial Above of

Centerline Deviation Deviation Bottom Plumb

(ft) (ft) (in) (ft) (in)

South 21.22 -0.03 -0.42 36.5 S+N 0.08 0.31

21.22 -0.03 -0.41 33.8 0.35

21.21 -0.04 -0.54 29.5 0.56

21.20 -0.05 -0.60 27.5 0.30

21.16 -0.09 -1.14 24.5 0.32

21.16 -0.09 -1.07 21.5 0.28

21.16 -0.09 -1.10 18.5 0.30

21.16 -0.09 -1.04 15.5 0.13

21.17 -0.08 -0.91 12.5 0.14

21.17 -0.08 -0.91 9.5 0.12

21.19 -0.06 -0.67 6.5 0.31

21.19 -0.06 -0.67 3.5 0.53

21.19 -0.06 -0.73 0.5 *

107.07

Southeast 21.32 0.07 0.90 36.2 SE+NW 0.72 1.84

21.32 0.07 0.82 33.2 0.93

21.31 0.06 0.72 30.2 1.06

21.31 0.06 0.76 27.2 0.92

21.31 0.06 0.72 24.2 0.89

21.29 0.04 0.45 21.2 0.58

21.28 0.03 0.32 18.2 0.39

21.25 0.00 0.02 15.2 -0.03

21.26 0.01 0.14 12.2 0.14

21.28 0.03 0.34 9.2 0.42

21.27 0.02 0.19 6.2 0.05

21.22 -0.03 -0.36 3.2 -0.14

21.17 -0.08 -0.94 0.2 -0.66

Weld Elevation 106.78

* Diameter deviation is not calculated where there are obstructions.

Weld Elevation

Diameter Deviation

(in)

Subject: Shell Radius Survey Page 2 of 4

Distance Height Out

From Radial Radial Above of

Centerline Deviation Deviation Bottom Plumb

(ft) (ft) (in) (ft) (in)

East 21.29 0.04 0.42 36.2 E+W 0.43 0.97

21.28 0.03 0.30 33.2 0.58

21.27 0.02 0.23 30.2 0.48

21.29 0.04 0.43 27.2 0.70

21.31 0.06 0.67 24.2 0.95

21.31 0.06 0.68 21.2 1.20

21.29 0.04 0.52 18.2 1.22

21.29 0.04 0.47 15.2 1.12

21.30 0.05 0.59 12.2 1.44

21.29 0.04 0.48 9.2 1.30

21.28 0.03 0.34 6.2 1.06

21.26 0.01 0.06 3.2 0.70

21.20 -0.05 -0.55 0.2 0.43

Weld Elevation 106.77

Northeast 21.38 0.13 1.50 36.1 NE+SW 0.62 1.50

21.36 0.11 1.27 33.1 0.76

21.35 0.10 1.20 30.1 0.94

21.35 0.10 1.15 27.2 0.93

21.33 0.08 0.92 24.2 1.04

21.34 0.09 1.14 21.2 0.60

21.35 0.10 1.22 18.2 0.48

21.36 0.11 1.37 15.2 1.85

21.36 0.11 1.27 12.2 0.27

21.34 0.09 1.08 9.2 0.10

21.32 0.07 0.89 6.2 0.30

21.31 0.06 0.70 3.2 0.39

Weld Elevation 106.80

* Radius was not be measured where there are obstructions.

Diameter Deviation

(in)

Subject: Shell Radius Survey Page 3 of 4

Distance Height Out

From Radial Radial Above of

Centerline Deviation Deviation Bottom Plumb

(ft) (ft) (in) (ft) (in)

North 21.28 0.03 0.34 36.2 0.34

21.31 0.06 0.76 33.2

21.34 0.09 1.10 30.2

21.33 0.08 0.90 27.2

21.32 0.07 0.82 24.2

21.32 0.07 0.79 21.2

21.32 0.07 0.80 18.2

21.33 0.08 0.91 15.2

21.34 0.09 1.06 12.2

21.34 0.09 1.03 9.2

21.33 0.08 0.98 6.2

21.35 0.10 1.20 3.2

Weld Elevation 106.84

Northwest 21.24 -0.01 -0.18 36.2 -0.46

21.26 0.01 0.11 33.2

21.28 0.03 0.34 30.2

21.26 0.01 0.16 27.2

21.26 0.01 0.17 24.2

21.26 0.01 0.13 21.2

21.26 0.01 0.07 18.2

21.25 0.00 -0.05 15.2

21.25 0.00 0.00 12.2

21.26 0.01 0.08 9.2

21.24 -0.01 -0.14 6.2

21.27 0.02 0.22 3.2

21.27 0.02 0.28 0.2

Weld Elevation 106.87

* Radius was not be measured where there are obstructions.

Subject: Shell Radius Survey Page 4 of 4

Distance Height Out

From Radial Radial Above of

Centerline Deviation Deviation Bottom Plumb

(ft) (ft) (in) (ft) (in)

West 21.25 0.00 0.01 36.2 -0.11

21.27 0.02 0.28 33.2

21.27 0.02 0.25 30.2

21.27 0.02 0.26 27.2

21.27 0.02 0.28 24.2

21.29 0.04 0.52 21.2

21.31 0.06 0.71 18.2

21.30 0.05 0.65 15.2

21.32 0.07 0.85 12.2

21.32 0.07 0.82 9.2

21.31 0.06 0.72 6.2

21.30 0.05 0.64 3.2

21.26 0.01 0.12 0.2

Weld Elevation 106.88

Southwest 21.07 -0.18 -2.12 36.5 -0.82

21.08 -0.17 -2.03 33.5

21.07 -0.18 -2.15 30.5

21.08 -0.17 -2.08 27.5

21.09 -0.16 -1.95 24.5

21.11 -0.14 -1.74 21.5

21.11 -0.14 -1.71 18.5

21.29 0.04 0.48 15.5

21.12 -0.13 -1.54 12.5

21.15 -0.10 -1.18 9.5

21.15 -0.10 -1.19 6.5

21.16 -0.09 -1.09 3.5

21.14 -0.11 -1.30 0.5

Weld Elevation 107.14

SHELL THICKNESS CALCULATIONS

Job No.: 17-043.01

Job Title: Andrews AFB

Subject: FAC 3036 Shell Calculations

By: Mike O'Connor Date: 10/11/17

API-12C

API 653

SHELL CALCULATIONS

Diameter 42.5 feet Wind Velocity 125 mph

Shell Height 38.79 feet

Freeboard 0 feet Nom Shell Thk

Design Fill Height 38.79 feet

Specific Gravity 0.80 API 12C JP-4 Maximum allowable height

0.84 API 653 Jet A of unstiffened shell: 62.4 feet

Joint Efficiency 0.85 API 12C

Material unknown

Yield Strength 30,000 psi (assumed)

Tensile Strength 55,000 psi (assumed)

Original Design Corrosion Allowance

0.031 in

Required thickness

Lower Upper

Two

CoursesCourses

Allowable Stress 23595 25960

Height Product Required Thickness

Course (feet) Depth 1/4" min

5 8.00 8.00

4 8.00 16.00

3 8.00 24.00

2 8.00 32.00

1 6.79 38.79 min 2017 Corrosion Estimated UTM Visual current net 1958 Rate Service Life Inspection Inspection

Course UTM* thick Thickness * in/yr yrs. Interval Interval

5 0.246 0.246 0.260 0.000 >30 15 5

4 0.242 0.242 0.260 0.000 >30 15 5

3 0.238 0.238 0.260 0.000 >30 15 5

2 0.258 0.258 0.260 0.000 >30 15 5

1 0.242 0.242 0.260 0.000 >30 15 5

* The original thicknesses are assumed based on required design thicknessess, overtolerance and the range of the UTMs.

P.O. Box 4800 4800 W. Hundred Road Chester, Virginia 23831 Phone: 804-748-8746 Fax: 804-748-7849 www.brockenbrough.com

0.250

0.175

0.143

2.6(H-1)DG

0.133

0.069

0.179

0.218

0.157

0.113

0.100

0.238

0.201

0.040

0.087

API-653

Original

Design

0.100

0.100

2.6HDG

SESESE

(psi)

2.6(H-1)D

API-650

Original

Hydro

2250020000

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

Job No.: 17-043.01

Job Title: Andrews AFB

Subject: Tank 3036 UT Data

By: Mike O'Connor Date: 10/11/17

SHELL UTM DATA (0.001 inches)

1 4 7

2 5 8

3 6 9

Typical Shell Plate UTMs.

1 2 3 4 5 6 7 8 9

1-1 255 253 253 250 250 251

1-2 250 251 253 249 251 250 250 253 251

1-3 256 268 258 259 262 257 255 260 255

1-4 242 250 249 252 257 253 252 255 252

1-5 242 243 244 242 246 245 243 244 243

1-6 256 257 256 253 255 256 251 255 252

Insert Plates

I1 501 497 498 498

I2 498 498 498 501

UTMs Taken From Stairway

2-1 269 267 258

2-2

2-3

2-4

2-5

2-6

3-1 242 245 238 4-1 242 250 249 5-1 250 246 256

3-2 4-2 5-2

3-3 4-3 5-3 3-4 4-4 5-4 3-5 4-5 5-5

3-6 4-6 5-6

Roof UTMs

NA

P.O. Box 4800 4800 W. Hundred Road Chester, Virginia 23831 Phone: 804-748-8746 Fax: 804-748-7849 www.brockenbrough.com

TANK DRAWINGS,

The following drawings are pages extracted from the 2014 out-of-service tank inspection report.

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Andrews Air Force Base, Maryland

CAPE Environmental Management, Inc.

06/23/14 N/A N/A

Tank #8 B-1Bottom Layout

Measured Inside Diameter is 42.5 feet.

Tank bottom has 19 plates.

10543210

GRAPHIC SCALE:

Dimensions are in feet.

y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

6 7 8

9 10 11

12 13 14

15 16 17 18 19

V1

V2

V3

V4

V5

A

Shell Nozzles in Course #1

A - 36" Reference Manway

B

B - 4" Low Point Suction

C

C - 2" Product Recovery

H

H - 2" Low Level Alarm

I

I - 2" Low Level Alarm

L

L - 36" Manway

M

M - 6" Product Receipt

P

P - 10" Product Issue

V# - Vertical Seam Number of Shell Course #1

B -2

8" Gaugewells

- Floating Roof Leg Striker Plate

- Vacuum Breaker Stem Striker Plate

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Andrews Air Force Base, Maryland

CAPE Environmental Management, Inc.

06/23/14 N/A N/A

Tank #8 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

ATG

2-1

3-1

4-1

5-1

1-2

B

2-2

3-2

4-2

5-2

1 2 3

A - 36" Reference Manway

B - 4" Low Point Suction

B -3

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Andrews Air Force Base, Maryland

CAPE Environmental Management, Inc.

06/24/14 N/A N/A

Tank #8 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

D

E

F

G

H

I

J

K

2-3

3-3

5-3

1-4

L

2-4

3-4

4-4

5-4

3 4 5

C - 2" Product Recovery

D - 2" High Level Alarm

E - 2" High Level Alarm

F - 2" High High Level Alarm

G - 2" High High Level Alarm

H - 2" Low Level Alarm

I - 2" Low Level Alarm

J - 2" High Level Control Shut Off

K - 2" High Level Control Shut Off

L - 36" Manway

B -4

4-3

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Andrews Air Force Base, Maryland

CAPE Environmental Management, Inc.

06/29/14 N/A N/A

Tank #8 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

M

N

O

P

2-5

3-5

4-5

5-5

5 1

M - 6" Product Receipt

N - 1" Open

O - 1" Plug

P - 10" Product Issue

B -5

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Andrews Air Force Base, Maryland

CAPE Environmental Management, Inc.

06/23/14 N/A N/A

Tank #8 FR-1Floating Roof Layout

Measured Diameter is 41 feet.

Floating roof has 24 plates.

10543210

GRAPHIC SCALE:

Dimensions are in feet.

y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

2 3

5 6 7

8 9 10

11 12 13 14

15 16 17

18 19 20

21 22 23 24

B -6

P

P

P

P

P

P

P

P

P

P

P

P

P

Rolling Ladder Track

24" Manway

Vacuum Breaker Stem

Emergency Roof Drain

20" MTG Float Well 20" Pontoon Cover

8" Stilling Well

8" Electronic Stilling Well

6" Rim Vent

Floating Roof Sump

- 20" Pontoon Cover

- Floating Roof Leg

OSHA ACCESS STRUCTURE REPORT

OSHA Circumferential Stairway Data

Intermediate landing to top landing OSHA Rq’d

Actual (in) min (in) max (in)

Handrail Height 34 OK 30 34 Step Width 24 OK 22 NA

Step Rise 10 OK NA NA Bottom Step Rise 9 1/2 *OK 9 11

From Ground Level to Intermediate Landing OSHA Rq’d

Actual (in) min (in) max (in)

Handrail Height 29 1/2 OK 30 34 Step Width 30 OK 22 NA

Step Rise 9 OK NA NA Bottom Step Rise 7 1/2 NOT OK 8 10

* The rise of the bottom step, exceeds an arbitrary tolerance of 1-inch as established by Brockenbrough.

BOTTOM STEP

RISE

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

carbon steel End Conn: Size: 8" Material: carbon steel End Conn: Size: 10"

Issue To:

Release Prevention Barrier

Overfill Protection / Level Alarms:

High-high, High, low, and low-low high & high-high level alarms & hydraulic operated control valve

Receipt Piping Configuration Issue Piping Configuration

Tank Piping

Secondary Containment

June 2014

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

Inspection Date:

Design Std

Horizontal

Mike O'Connor

Exterior Coating:

Epoxy - Polyurethane

Epoxy

Receipt From:

Inspector Certification Number:

Tank Construction and Configuration

Rectangular

Double Wall

Fire Resistant

Secondary Containment, Overfill, and CRDM

Welded

Three pumphouses via local pumphouse

42'-6" dia by 38'-9 1/2" tall

NA

commercial pipeline

FML under tank bottom

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

(8" Well, 1" level alarms, 2" WDO)

API 653 EXTERNAL INSPECTION CHECKLIST

Andrews AFBProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

SPCC Mandated AST Inspections

Various Locations

General Inspection Information

17-043.01

Submitted to:

Contract No.:

USACE - Omaha

W9128F-12-D-0006

Tank Facility No.:

Local Tank ID No.:

October 5, 2017

Tank Manufacturer:

Tank Construction Date:

Tank 8 Tank Inspector Name:

Jet Fuel (F-24)

9,800 bbl

7,500 bblTank Outside Dimensions: Useable Capacity:

2004 (assumed)

(4) leak detection ports

2004 (assumed)

Overfill Protection:

Insulated

Nominal Capacity:

Open Type DikeVertical

Single Wall

Interior Coating:

Double Bottom

Unknown

1958-1960

Concrete

48 1/2" x 141' x 141' and

45 1/2 x 143 x 140 (sister tank)

Level Alarms:

Material: Welded

Coated

Plastic / Fiberglass

Other:

API 653 EXTERNAL INSPECTION CHECKLIST

Andrews AFBProject Site:Project Name: SPCC Mandated AST Inspections

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Cracking and spalling of foundation in concentric pattern centered on north-northwest quarter.

Unable to open tell-tale drain plugs due to being too tight and painted over.

Check for:

Tank Settlement

COMMENTS

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand

e) Settlement around perimeter of tank

Check for:

STATUS

C.1.1.1 Concrete Ring

Proper operation of dike drains

Check for:

Check for:

Piping runs over swale and near drain.

Indications of bottom leakage at drain openings in ring, back of water-draw basins, and top surface of ring a) b)

Measure foundation levelness and bottom elevations (See Annex B) See settlement survey.

ITEM

C.1.1 Foundation

TASK

Check for:

Presence of crushed rock under the steel bottom which usually results in severe underside corrosion.

C.1.1.4 Rock

C.1.1.5 Site Drainage

C.1.1.7 Cathodic Protection a) b)

C.1.1.6 Housekeeping

Buildup of trash, vegetation, and other inflammables

Settlements into the base

C.1.1.2 Asphalt d) a)

22V, 0.7A b)

c) Cavities under foundation; vegetation against bottom of tank

Broken concrete, spalling, and cracks, especially under backup bars used in welding butt-welded annular rings under the shell

Leaching of oil which has left rock filler exposed indicating hydrocarbon leakage

Tank settlement into asphalt base

Review cathodic protection potential readings

Site drainage away from the tank, associated piping, and manifolds

C.1.2.1 External Visual Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.2.3 Riveted Shell Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Observed from access door.

Paint failures, pitting, and corrosion

Check for:

e) Drawings of riveted seams if available. Otherwise, dimension and sketch (or photograph) the rivet pattern: no. of rows, rivet size, pitch length, butt-riveted or lap-riveted joints

C.1.2. Shells

Check for:

Grooving, corrosion, pitting, and coating failures c)

Broken welds and corrosion damage

(paint failure, pitting, corrosion, product builup), especially where it occurs at tack-welded junction

Reinforcing pads welded to shell at supports

Leaks and identify the location by sketch or photo

C.1.2.4 Wind Girder (Floating

Roof Tanks) a)

There is no seal between the tank bottom reinforcing plate and the tank foundation at the location where the flush cleanout was demolished when the second bottom was provided.

Check for:

Rivet and seam leaks on external surface

Check for:

Corrosion and thinning on plate and weld after cleaning the bottom angle area a) b) c)

Full fillet lap-welded vertical seams to increase joint efficiency b)

Corrosion loss and wear on the rivets

C.1.2.2 Internal (Floating Roof

Tank)

Bottom-to-Foundation Seal c) a)

Pitting on support welds to shell, especially on shell plates d) b)

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail…