Attachment J.2 - Fac 738 External Final Report 2014.pdf

ACOE CONTRACT W911KB-10-D-0006, TASK ORDER 0024

TANK 738 (FACILITY NO. 738)

API 653 IN-SERVICE INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

FINAL REPORT

(PRE-REPAIR)

Joint Base Elmendorf-Richardson (JBER), Alaska

August 2014

Contract Agency:

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

Prepared By:

David A. Stchyrba, P.E., API 653 Certificate No. 27187

Submitted By:

Stephen S. Brooks, P.E.

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

EEI PROJECT 8115

Page Intentionally Left Blank

SUITABILITY FOR SERVICE STATEMENT – TANK 738 (FACILITY NO. 738)

Enterprise Engineering, Inc. (EEI) has completed an in-service external inspection and suitability for service evaluation of Tank 738 at JBER, Alaska. The inspection was performed on June 18, 2014 in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair. Recommendations for continued long-term service are also provided.

EEI recommends performing the next in-service external inspection no later than June 2019 (5 years from 2014 inspection), or sooner if a change in condition has occurred.

EEI recommends performing the next out-of-service internal inspection no later than September 2025 (15 years from 2010 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653 and ADEC Regulation 18AAC75, this report satisfies the requirement for an in-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

August 5, 2014 David A. Stchyrba, P.E.

API 653 AST Inspector Certificate No. 27187

No deficiencies were observed in the field requiring the removal of Tank 738 from service. Tank 738 is suitable to remain in service.

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs Prior to Return to Service (Mandatory) Recommended Repairs Prior to Return to Service (Non-Mandatory) Recommended Repairs for Long Term Serviceability

COATING SYSTEM

Exterior Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Hydraulic and Structural Integrity

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Checklist ............................................................... Tab A Assessment of Compliance with Military Criteria ...................................................... Tab B Non-Destructive Examination (NDE) and Evaluation Criteria ...................................Tab C Tank Drawings .........................................................................................................Tab D Tank Photographs .................................................................................................... Tab E NDE Results ............................................................................................................. Tab F Calculations ............................................................................................................. Tab G Coating Requirements ............................................................................................ Tab H

Tank 738 – API 653 Inspection TABLE OF CONTENTS JBER, Alaska August 2014 EEI Project No. 8115

TANK 738

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

JOINT BASE ELMENDORF-RICHARDSON (JBER), ALASKA

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an in-service external inspection of Tank 738 at JBER, Alaska. The inspection was performed on June 18, 2014. The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 and the Statement of Work.

The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible.

Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 738 is a field erected, vertical aboveground storage tank. The tank was fabricated and erected in 1998. The tank is 112 feet in diameter and 51 feet 6 inches high. It is of welded construction with butt-welded shell plates and lap welded floor and roof plates. The nominal shell capacity is 80,000 Bbls. Tank 738 is currently in JP-8 service and is equipped with an aluminum honeycomb floating pan.

INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Tank 738 is considered suitable to remain in service. The following are significant findings of the inspection.

Hydraulic Integrity

The in-service inspection and evaluation found no conditions affecting the hydraulic integrity of the tank.

As the tank is in-service, the condition of the floor is unknown.

Structural Integrity

The in-service inspection and evaluation found no conditions affecting the structural integrity of the tank.

Next Inspection

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires that an in-service inspection be performed every 5 years or RCA/4N years, whichever is less. RCA is the remaining corrosion allowance of the shell (ie. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. The measurements of the fully coated shell found only minor plate thickness variations resulting in a negligible corrosion rate.

It should be noted that ADEC may reduce the inspection interval for a specific storage tank if

(a) The storage tank is older than 30 years, Tank 738 – API 653 Inspection Page 1

EEI Project No.: 8115

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion or foundation problems, or

(d) After a significant seismic event.

EEI recommends that the next in-service inspection should be performed no later than June 2019 (5 years from 2014 inspection), or sooner if a change in condition or a change in service occurs.

EEI recommends that the next out-of-service inspection should be performed no later than September 2025 (15 years from 2010 inspection), or sooner if a change in condition has occurred.

REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory) and recommended for long term serviceability. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements.

Required Repairs Prior to Return to Service (Mandatory)

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank and are required prior to placing Tank 738 in service.

• The inspection of Tank 738 found no mandatory repairs that would require removing the tank from service.

Recommended Repairs Prior to Return to Service (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends these repairs for long-term preservation and integrity of the tank.

1. The sealant between the floor projection (chine) and the concrete ringwall has failed. Moss was observed growing within the space.

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

• Clean the surfaces of the concrete ringwall and the underside of the floor projection in accordance with sealant manufacturer’s instructions.

• Provide jet fuel-resistant polysulfide sealant.

2. The tank is equipped with six perimeter roof vent/inspection hatches. The jeep style hold down latches are corroding and most have failed.

• Replace the latches on all of the roof vents.

3. Localized coating failure was observed on the stairs, landings, floor projection at the cathodic protection (CP) connections, roof appurtenances and the toe plate on the roof handrail.

• Remove the coating from the affected areas.

Tank 738 – API 653 Inspection Page 2

• Clean and provide proper surface preparation on 100% of the areas to be recoated in accordance with coating manufacturer’s written recommendations.

• Recoat affected areas.

4. The telltale holes in the reinforcing plates for the three shell manways, Fill, Issue, Low Fuel and Water Draw-Off nozzles contain a threaded plug.

• Remove the plug from the telltale holes as API criteria require telltale holes to be open to the atmosphere.

• Pack the open telltale hole with general purpose grease to prevent moisture migration between the reinforcing plate and the shell.

5. Black moss was observed on the roof of the tank. The coating is in otherwise good condition.

• Remove the moss by power washing or other suitable non-mechanical means.

• Note: Since the material will travel down the tank shell during cleaning, it is recommended to power wash the entire exterior of the tank.

6. The stainless steel pilot tubing for the high level shutoff valve is routed such that contact is made at the wind girder. Vibration of the tubing may cause abrasion resulting in failure of the tubing.

• Provide Teflon sheet shields wrapped around the tubing to eliminate metal to metal contact between the tubing and the wind girder.

7. The grounding cable connecting the roof manway cover plate to the roof plate has been severed.

• Replace the grounding connection.

8. Minor piping (LR/DTR) is present on the DB&B valve at the 6 inch Low Fuel nozzle. The piping is open to the elements and there is a risk of damage from falling ice/snow. The tank would have to be removed from service and drained in order to complete any repairs.

• Provide an ice/snow shield at the next out-of-service interval.

9. There are only 2 bolts present in the flange of the 36 inch diameter roof manway.

• Replace the missing bolts.

10. Hairline cracks were noted in the concrete ringwall including areas with hold down anchor bolts.

• Repair action is not recommended at this time. Monitor the cracks during routine maintenance.

11. Water ponding was observed on several of the perimeter roof plates and at the weld seams. The roof plates appear to have been shingled in the wrong direction. Over time, this condition may cause coating failure and corrosion.

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

12. The tank was evaluated for compliance with current military criteria. The following is noted:

• The tank has been equipped with all of the recommended appurtenances that were observable in an external inspection.

• Refer to Appendix B “Assessment of Compliance with Military Criteria” for further discussion.

13. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Tab H - Coating Requirements. When welding on the shell or roof, the coating on the opposite side from the weld shall be inspected and repaired if damaged.

Tank 738 – API 653 Inspection Page 3

Recommended Repairs for Long Term Serviceability

1. Program the tank for an API 653 in-service inspection no later than June 2019.

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

3. It is the opinion of EEI that water is infiltrating the joint between the ringwall and the floor projection and entering the sand cushion. From the sand cushion, it migrates into the leak detection ports. An alternative to replacing the sealant, it is recommended to provide a drip ring per section 5.4.5 of API

650. The drip ring would consist of a steel ring, welded to the floor projection along the perimeter of the tank. It would extend past the concrete foundation and would prevent moisture from being wicked into the sand cushion.

4. Based on the 2010 out-of-service inspection, the aluminum honeycomb floating pan is equipped with a foam filled wiper seal. At the time of the inspection, the jacket had been compromised and that the foam was retaining product. It has been the experience of EEI that the long term service life of this type of seal is suspect. Recommend programming the seal for replacement with a solid urethane wiper at the next out-of-service interval.

COATING SYSTEM

Exterior Coating Requirements

Refer to Appendix H for complete coating materials and application requirements for type and location of coating repair items identified by the inspection.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank shell and roof were calculated using thickness measurements that were obtained during the inspection and are as follows:

Shell: Negligible – Plate thickness is within mill tolerance Roof: 0.000940 inches per year The corrosion rates were calculated using an assumed original metal thickness and a 1998 year of construction.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 738:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 738 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Projection

Moss was found growing within the space between the floor projection and the concrete ringwall.

Acceptable after repairs

Shell Visual inspection of the accessible shell joints found no relevant indications. A pit survey was conducted and no locations were identified for repair.

Acceptable

Tank 738 – API 653 Inspection Page 4

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Roof Spot ultrasonic testing of the roof plates found no significant thinning of the plates.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

Hydrostatic Test

Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980): Yes, constructed in 1998.

2. Has a prior hydrotest been performed demonstrating fitness: Yes, likely when the tank was constructed in 1998.

3. Is the tank shell thickness < 0.5 inch: No.

4. Does the tank operate at metal temperature above 60 deg F?: No.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4.1 or API

653 Figure 4.1: Yes.

7. Tank full at lowest one day temperature per API 650

Figure 4.1: Unknown.

The tank, having exempt steel and a hydrotest in 1998, does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Tank 738 is anchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank anchors are adequate and that the shell stresses are within limits at the current fill height of 41 ft 9 inches.

Calculations were performed utilizing the specific gravity for JP-8 (S.G. = 0.84), a ringwall foundation, seismic parameters Ss = 1.50, S1 = 0.68, an importance factor of 1.25.

Acceptable

Wind Evaluation

A wind analysis was performed per API 650, Section 5.11.

Calculations were performed using an importance factor of

1.15 and a wind velocity of 100 mph.

The evaluation determined that an empty tank is stable and not at risk of overturning or sliding.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 100 mph.

Acceptable

Tank 738 – API 653 Inspection Page 5

CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 738 is considered suitable to remain in service.

Project Team

Site Team

David A. Stchyrba, P.E. Structural Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 27187, API Inspector of Record

Travis W. Snyder Mechanical Engineer, Tank Technician

Support Team

Stacy M. Kaplan-McMillan Project Manager

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

Tank 738 – API 653 Inspection Page 6

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Joint Base Elmendorf-Richardson (JBER), Alaska Tank No. 738

Facility No. 738 Inspection Date(s): June 18, 2014

Tank Type: Vertical AST Type of Inspection: In-Service External Inspection

Contract Number, Task Order: W911KB-10-D-0006, 0024 Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: David A. Stchyrba, P.E.

API-653 AST Inspector Certificate No. 27187

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard Morse Construction Group, 1998, API 650 9th Edition, Appendices A, E & H

Diameter: 112'-0" Shell Height: 51'-6"

Product, Specific Gravity: JP-8, 0.84 Design Pressure / Temperature: Atmospheric / -15 Deg. F. Design Metal Temperature

Gross Capacity / Nominal Capacity: 83,286 BBLS / 80,000 BBLS Safe Fill Height: 47’–6” (Tank Nameplate), 41’-9” (from facility)

GPS Latitude & Longitude: 61 Deg 15’ 46.02” N, 149 Deg 48’ 45.90” E (Source – Google Earth)

Foundation Configuration: Concrete Ringwall Shell Configuration: Butt Welded w/ 7 courses

Roof: Fixed, column supported cone up Cathodic Protection: Present

Still Wells: Based on 2010 out-of-service inspection, 8” combination ladder/gauge tube for manual gauging and 8” gauge tube for ATG

Last Inspection (Type, Date): Out-of-Service, August 2010 Last Coated Internally (Product): Original coating Last Coated Externally (Product): Original coating

INSPECTION RESULTS

Can tank remain in service? Yes.

Deficiencies identified as mandatory repairs: No.

Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term Serviceability” in body of report

Next Scheduled Inspections (Type, Date): Out-of-Service: June 2019 (5 Years) In-Service: Concurrent with out-of-service inspection.

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Design drawings available

Tank 738 – API 653 Inspection Appendix A, Page 1 JBER, Alaska

API STANDARD 653

TANK IN-SERVICE INSPECTION CHECKLIST

Tank No.: 738 Prepared by: ADL

Location: JBER, AK Date: 7/14/2014

Item Completed Comments

C. 1.1 FOUNDATION

Measure foundation levelness and bottom elevations (see Appendix B for extent of measurements) X

Tank 738 is relatively level. The maximum measured differential between max and min elevations is 0.040 feet.

C. 1.1.1 Concrete Ring

a. Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell.

X

Hairline cracks were noted in the concrete ringwall including areas with hold down anchor bolts.

Repair action is not recommended at this time. Monitor the cracks during routine maintenance.

b. Inspect drain openings in ring, back of waterdraw basins and top surface of ring for indications of bottom leakage.

X No indications observed.

c. Inspect for cavities under foundation and vegetation against bottom of tank. X

Sealant has failed and moss is present.

Recommend removing sealant, clean surfaces and provide new sealant.

d. Check that runoff rainwater from the shell drains away from tank. X Drainage appears adequate.

e. Check for settlement around perimeter of tank. X No settlement observed.

C.1.2 Asphalt

a. Check for settling of tank into asphalt base which would direct runoff rain water under the tank rather than away from it.

N/A

b. Look for areas where leaking of oil has left rock filler exposed, which indicates hydrocarbon leakage.

C.1.1.3 Oiled Dirt or Sand

Check for settlement into the base which would direct runoff rain water under the tank rather than away from it.

C. 1.1.4 Rock

Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when tank is out of service.

X

Underside corrosion will be checked during the next internal inspection.

C.1.1.5 Site Drainage

a. Check site for drainage away from the tank and associated piping and manifolds. X Drainage around the tank and piping appears adequate.

Tank 738 – API 653 Inspection APPENDIX A, Page 2

b. Check operating condition of the dike drains. X Operation of the drains was not performed.

C.1.1.6 Housekeeping

Inspect the area for buildup of trash, vegetation, and other flammables buildup. X None observed.

C.1.2 SHELLS

C.1.2.1 External Visual Inspection

a. Visually inspect for paint failures, pitting, and corrosion.

X

Localized coating failure was observed on the stairs, landings, floor projection at the cathodic protection (CP) connections, roof appurtenances and the toe plate on the roof handrail.

Recommend recoating the affected areas.

b. Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X

The floor projection extends an average of 2.6 inches beyond the tank shell. The average thickness is 0.316-inch.

c. Inspect the bottom-to-foundation seal, if any. X See C1.1.1(c)

C.1.2.2 Internal (Floating Roof Tank)

Visually inspect for grooving, corrosion, pitting and coating failures. N/A

C.1.2.3 Riveted Shell Inspection The shell is of welded construction.

a. Inspect external surface for rivet and seam leaks. N/A

b. Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A

c. Inspect rivets for corrosion loss and wear. N/A

d. Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A

e. If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern; number of rows, rivet size, pitch length, and note whether the joint is butt-riveted or lap-riveted.

C.1.2.4 Wind Girder (Floating Roof Tanks) Tank has a fixed roof.

a. Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds.

Tank 738 – API 653 Inspection APPENDIX A, Page 3

b. Check support welds to shelf for pitting, especially on shell plates. N/A

c. Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 SHELL APPURTENANCES

C.1.3.1 Manways and Nozzles

a. Inspect for cracks or signs of leakage in weld joint at nozzles, manways, and reinforcing plates. X None visually noticed.

b. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X No dimpling detected.

c. Inspect for flange leaks and leaks around bolting. X None detected.

d. Inspect sealing of insulation around manways and nozzles. N/A The tank is not insulated.

e. Check for inadequate manway flange and cover thickness on mixer manways.

The tank is not equipped with mixer manways.

C.1.3.2 Tank Piping Manifolds

a. Inspect manifold piping, flanges, and valves for leaks. X None observed.

b. Inspect firefighting system components. N/A

c. Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X None observed.

d. Check for adequate thermal pressure relief of piping to the tank. X

The thermal relief for the tank fill and issue lines is accomplished through pressure relief loops. The pressure relief settings are 40 psi.

e. Check operation of regulators for tanks with purge gas systems. N/A

f. Check sample connections for leaks and for proper valve operation. N/A

g. Check for damage and test the accuracy of temperature indicators. N/A

h. Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System

a. Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X Visual inspection was not available through the roof manway.

b. Inspect autogauge head for damage. X No damage was observed.

Tank 738 – API 653 Inspection APPENDIX A, Page 4

c. Bump the checker on autogauge head for proper movement of tape. X No deficiencies observed.

d. Identify size and construction material of autogauge tape guide (floating roof tanks). N/A

e. Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X Facility personnel did not report any difficulties with the tape gauge.

f. Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). N/A

g. On floating roof tanks, when the roof is in the lowest position, check that no more than two ft.

of tape are exposed at the end of the tape guide.

h. Inspect condition of board and legibility of board-type autogages. N/A

i. Test freedom of movement of marker and float. N/A

C.1.3.4 Shell-Mounted Samples Station

a. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

b. Check circulation pump for leaks and operating problems. N/A

c. Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted)

Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer

a. Inspect for proper mounting flange and support. N/A

b. Inspect for leakage. N/A

c. Inspect condition of power lines & connection to mixer. N/A

C. 1.3.7 Swing Lines: Winch Operation None Present.

a. Nonfloating. Raise, then lower the swing line with winch, and check for cable tightness to confirm that swing line lowered properly.

b. Floating. With tank half full or more, lower the swing line, then let out cable and check if swing line has pulled cable tight, indicating that the winch is operating properly.

c. Indicator. Check that the indicator moves in the N/A

Tank 738 – API 653 Inspection APPENDIX A, Page 5 proper direction: Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite.

C.1.3.8 Swing Lines: External Guide System None Present.

Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need None Present.

Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition None Present.

a. For nonstainless steel cable, check for corrosion over entire length. N/A

b. All cable: check for wear or fraying.

C.1.3.11 Swing Lines: Product Sample Comparison None Present.

Check for water or gravity differences that would indicate a leaking swing joint. N/A

C.1.3.12 Swing Lines: Target None Present.

Target should indicate direction of swing opening (up or down) and height above bottom where suction will be lost with swing on bottom support.

C.1.4 ROOFS

C.1.4.1 Deck Plate Internal Corrosion

For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. (Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

X

C.1.4.2 Deck Plate Exterior Corrosion

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck.

X Black moss was observed on the roof of the tank. The coating is in otherwise good condition.

C.1.4.3 Roof Deck Drainage

Look for indication of standing water. (Significant sagging of fixed roof deck indicates potential rafter failure. Large standing water areas in a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons).

X Water ponding was observed on several of the perimeter roof plates and at weld seams. This condition may cause coating failure and corrosion. Recommend monitoring ponding locations during routine inspections.

C.1.4.4 Level of Floating Roof

Tank 738 – API 653 Inspection APPENDIX A, Page 6

At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a nonlevel roof with possible shell out-of –round, out-of-plumb, leaking pontoons, or hang-up. On small diameter tanks, an unlevel condition can indicate unequal loading at that level.

N/A

C.1.4.5 Gas Test Internal Floating Roof

Test for explosive gas on top of the internal floating roof. Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

C.1.4.6 Roof Insulation The tank is not insulated.

a. Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation.

b. Inspect for wet insulation under the weather coat. N/A

c. Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

C.1.4.7 Floating Roof Seal System

a. Measure and record maximum seal-to-shell gaps at: N/A

Entry above the floating pan was not performed. Inspection limited to examination from hatches.

1. Low pump out N/A

2. Mid-shell N/A

3. High liquid level N/A

b. Measure and record annular space at 30-ft.

spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly apposite pairs.

1. __________ _________ Opposite pair 1. N/A

2. __________ _________ Opposite pair 2. N/A

c. Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough).

d. Inspect fabric for deterioration, holes, tears, and cracks. N/A

e. Inspect visible metallic parts for corrosion and wear. N/A

Tank 738 – API 653 Inspection APPENDIX A, Page 7

f. Inspect for openings in seals that would permit vapor emissions. N/A

g. Inspect for protruding bolt or rivet heads against the shell. N/A

h. Pull both primary and secondary seal systems back all around the shell to check their operation. N/A

i. Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

j. Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. N/A

C.1.5 ROOF APPURTENANCES

C.1.5.1 Sample Hatch

a. Inspect condition and functioning of sample hatch cover. X Sample hatch is operable.

b. On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

c. Check for corrosion and plugging on thief and gauge hatch cover. X None observed.

d. Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance.

e. Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X

The manual gauge hatch is located in the 36-inch diameter manhole nozzle. The manhole nozzle has a reinforcing pad.

f. On floating roof sample hatch and recoil systems, inspect operation of recoil reel and condition of rope.

g. Test operation of system. N/A

h. On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample).

C.1.5.2 Gauge Well The gauge well was not visible from the tank exterior.

a. Inspect visible portion if the gauge well for thinning, size of slots, and cover condition. N/A

b. Check for a hold-off distance marker and tab with hold-off distance (legible). N/A

Tank 738 – API 653 Inspection APPENDIX A, Page 8

c. On floating roof, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

d. If accessible, check the distance from the gauge well pipe to the tank shell at different levels.

e. If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

C.1.5.3 Fixed Roof Scaffold Support

Inspect scaffold support for corrosion, wear, and structural soundness. N/A

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof)

a. Check the hatch for corrosion and missing bolts. N/A

b. Look for corrosion on the tape guide’s and float guide’s wire anchor. N/A

C.1.5.5 Autogauge: Float Well Cover

c. Inspect for corrosion. N/A

d. Check tape cable for wear or fraying caused by rubbing on the cover. N/A

C.1.5.6 Sample Hatch (Internal Floating Roof)

a. Check overall conditions. N/A

b. When equipped with a fabric seal, check for automatic sealing after sampling. N/A

c. When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check condition of screens, locking, and pivot pins.

X

Tank is equipped with six perimeter vent/inspection hatches. Hold down latches have failed at several locations.

Recommend replacing all of the latches on all hatches.

C.1.5.8 Gauging Platform Drip Ring

On fixed roof tanks with drip rings under the gauging platform or sampling area, inspect for plugged drain return to the tank.

C.1.5.9 Emergency Roof Drain

Inspect vapor plugs for emergency drain: that seal N/A

Tank 738 – API 653 Inspection APPENDIX A, Page 9 fabric discs are slightly smaller than the pipe ID and that fabric seal is above the liquid level.

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

Report size, number, and type of vacuum breakers.

Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

C.1.5.12 Rim Vents

a. Check condition of the screen on the rim vent cover. N/A

b. Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. N/A

C.1.5.13 Pontoon Inspection Hatches

a. Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A

b. Test for explosive gas (an indicator of vapor space leaks). N/A

c. If pontoon hatches are equipped with locked down covers, check for vent tubes. Check that vent tubes are not plugged-up. Inspect lock-down devices for condition and operation.

C.1.6 Accessways

See Tank Out-of-Service Inspection Checklist, item C.2.12 X Platforms, stairs, and handrails are in good condition.

Additional Notes:

1. Telltale holes at the shell reinforcing plates for the three manways, fill, issue, low fuel and water draw-off nozzles contain a threaded plug. Recommend removing the plugs as API criteria require telltale holes to be open to atmosphere. Recommend packing the holes with general purpose grease to prevent moisture migration between plate and shell.

2. The stainless steel pilot tubing for the high level shutoff valve is routed such that contact is made at the wind girder.

Vibration of the tubing may cause abrasion resulting in failure of the tubing. Provide Teflon sheet shields wrapped around the tubing to eliminate metal to metal contact between the tubing and the wind girder.

3. The grounding cable connecting the roof manway cover plate to the roof plate has been severed. Replace the grounding connection.

4. Minor piping (LR/DTR) is present on the DB&B valve at the 6 inch Low Fuel nozzle. The piping is open to the elements and there is a risk of damage from falling ice/snow. The tank would have to be removed from service and drained in order to complete any repairs. Provide an ice/snow shield at the next out-of-service interval.

5. There are only 2 bolts present in the flange of the 36 inch diameter roof manway. Replace the missing bolts.

Tank 738 – API 653 Inspection APPENDIX A, Page 10

APPENDIX B

Assessment of Compliance with Military Criteria

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01 Table 8-1

Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMMENTS/RECOMMENDATION

MANHOLE

c A shell manhole located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals as required by DoD Standard

AW 78-24-27.

The tank is not equipped with a shell manhole above the internal floating pan’s high position. The area above the pan can be accessed from the roof manway or from the manway in the floating pan.

There is no compelling reason to provide an additional manway.

e Roof manholes in accordance with API Std 650. Locate the roof manholes near the perimeter of the roof at opposite ends of a diameter and approximately 90 degrees from the shell manholes.

Tank is equipped with one 36-inch roof manhole;

meets UFC 3-460-01.

f Shell manholes in accordance with API Std 650. Two 36-inch shell manholes 180 degrees from each other. Align shell manholes parallel with prevailing wind direction.

Support shell manhole covers by davits.

Tank is equipped with three 36-inch shell manholes;

meets UFC 3-460-01.

g A bolted cover in the roof for installation and removal of the internal floating pan as required by the tank supplier based on the pan manufacturer.

Tank is equipped with a roof hatch for installation and removal of the floating pan; meets UFC 3-460-01.

INSPECTION HATCHES

h A minimum of four 24-inch square inspection hatches on fixed roof tanks with floating pans. Inspection hatches are not required for tanks without floating pans.

Tank is equipped with six inspection hatches at the perimeter of the tank; meets UFC 3-460-01.

LADDER/STAIRS

i Internal ladders (in accordance with OSHA criteria) for tanks of 5,000 gallons or larger.

* with floating pans

Tank is equipped with a combination internal ladder/gauge tube; meets UFC 3-460-01.

k Ladders, railings, toeboards, a spiral stairway, top platform, and handrail in accordance with API Std 650 and OSHA requirements. Provide stairways to access high level shut-off and alarms. Provide metal bar grating stair tread and platforms. Provide stair tread with non-slip nosings.

Tank is equipped with a spiral stairway, platforms, and handrails in accordance with API 650 and OSHA requirements; meets UFC 3-460-01.

Tank is equipped with metal bar grating treads with non-slip nosings on stairs and platforms; meets UFC 3- 460-01.

Tank 738 – API 653 Inspection Appendix B, Page 1

Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMMENTS/RECOMMENDATION

LEVEL ALARMS

l 1. Tanks Greater ≥ 30,000 gallons:

An individual automatic level alarm system, independent of the gauging device or system for each tank. Include high, high-high, low and low-low level alarms. On aboveground tanks: provide a means to manually test each alarm sensor to ensure system operability without a full tank; locate level alarm equipment for ready access from ground level, stairway platforms, or roof access. On aboveground vertical tanks set level alarms as defined in AW 78-24-27. For underground tanks, high and high-high will be 90 and 95 percent, respectively (although this may have to be adjusted downwards for horizontal tanks). On tanks without floating pans, set the low level alarm no less than 5 percent before loss of suction to avoid pump cavitation, and the low-low level alarm as defined in AW 78-24-27. In determining the low level, consider the time it would take for the pump or system to shut down. Provide both audible and visible alarms in a manned area responsive to the alarm. Review facility size and operating method to determine the most desirable location for audible and visible alarms, this will usually be in the tank farm or near the operations building. Interface the alarm output to stop issue pump on low level alarm and receipt pump/valve on high-high level alarm. Install alarms on winter sun side of the tank. Comply with most stringent of federal, state, or local regulations. For vertical aboveground tanks, see Facility Plates 014 and 015.

Tank is equipped with a level alarm system independent of the ATG system; meets UFC 3-460-01.

VENTS

m Open atmospheric vents with weather hoods and bird screens for tanks to be used for products with true vapor pressure of 0.75 psig or less. For higher vapor pressure, or if a vapor recovery system is used, provide pressure/vacuum vents in lieu of open vents. Consider using pressure/vacuum vents if product quality is at risk by blowing sand, dust, or snow. Comply with NFPA 30, host nation requirements, Chapter 2 of this UFC, API Std 650, API Std 2000, 29 CFR Part 1910.106, and DoD Standard Design AW 78-24-27, where applicable. Do not use flame arrestors.

Tank is equipped with atmospheric vents with weather hoods and bird screens; meets UFC 3-460-01.

n Emergency relief venting with capacity in accordance with NFPA 30 and UL 142, as applicable. For vertical aboveground tanks, a floating roof or weak roof-to-shell seam, as specified in API Std 650, may be used to fulfill emergency relief requirements.

Tank is equipped with a frangible roof to shell joint in accordance with API 650 requirements; meets UFC 3- 460-01.

Tank 738 – API 653 Inspection Appendix B, Page 2

Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMMENTS/RECOMMENDATION

GAUGE/GAUGE HATCH/STILLING WELLS

o A liquid level gauge calibrated in 1/16-inch graduations mounted at 60 inches above the walking surface.

Tank is equipped with a liquid level gauge; meets UFC 3-460-01.

p Automatic Tank Gauging (ATG) for all tanks with fuel managed through the Defense Logistics Agency's Business Modernization {BSM Enterprise Resource Programs (ERP) - Fuels section}, that complies with API MPMS Chapter 3. Key features include: measures fluid level to ±0.05 inch; measures standard volume ±0.1 percent; measures average product temperature ±1 F;

measures product density ±1 percent; detects water in the tank sump to a level equal to or slightly above the water draw-off pipe; converts volume to API standard conditions; local tank readout; For tanks that are 30,000 gallons or less certain ATG systems (Veeder- Root and Ronan) can provide backup alarms for high, high-high, low, and low-low level conditions; meet American Standard Code for Information Interchange (ASCII) interface.

The tank is equipped with an ITT Barton automatic tank gauging system; meets UFC 3-460-01.

r One 10-inch roof flanged nozzle with an 8-inch aluminum, fully slotted, stilling well for ATG near the edge of the roof near the top of the stairway platform.

Gauge tubes will be addressed at the next out-of-service inspection.

s One 8-inch roof flanged nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor, as close to or in the tank sump as possible. See DoD Standard Design AW 78-24-27.

Gauge tubes will be addressed at the next out-of-service inspection.

t One 10-inch roof nozzle and an aluminum, slotted stilling well extended to within 3 inches of the bottom of the tank* for gauging and sampling. A datum plate to establish a gauging zero point.

Gauge tubes will be addressed at the next out-of-service inspection.

PIPE CONNECTION

u Inlet fill connection. See Facility Plates 016, 017, and 018, as applicable. For H-A tanks, Facility Plate 017 applies to single wall tanks only.

Based on the previous out-of-service inspection report, the tank is equipped with an inlet fill connection that meets UFC 3-460-01 criteria; meets UFC 3-460-01.

v Main suction and low suction. See DoD Standard Design

AW 78-24-27.

Based on the previous out-of-service inspection report, the tank is equipped with main and low suction; meets

UFC 3-460-01.

Tank 738 – API 653 Inspection Appendix B, Page 3

Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMMENTS/RECOMMENDATION

OVERFILL PROTECTION

x Overfill protection with a hydraulically operated diaphragm control valve. Tanks connected to commercial pipelines or marine offload systems with restrictions on shut-off may require diversion to additional tankage. On vertical tanks, valve typically closes midway between high and high-high levels, but ensure valve closes no later than on high-high level. For underground tanks, (per NFPA 30) and in aboveground horizontal tanks, automatically shut off the flow into the tank when the tank is no more than 95 percent full.

Comply with most stringent of federal, state, or local regulations. Include a solenoid on the control valve to close the valve as a backup. Use API RP 2350 to establish the proper overfill level setting. On gravity drop fills, replace valve with an integral high level shut-off valve in the drop tube. Prior to designing automatic valve closure features, conduct a surge analysis on pressure filled systems. See Plates 017 and 018.

Provide on a horizontal underground tank if pressure-filled.

Tank is equipped with a hydraulically operated diaphragm control valve; meets UFC 3-460-01.

WATER DRAWOFF

aa Water draw-off connections. See DoD Standard Design

AW 78-24-27.

Tank is equipped with a water draw-off connection;

meets UFC 3-460-01.

BALL JOINTS

ee Ball joints on pipes to relieve strain caused by tank settling or seismic activity. Ensure that contract specifications do not allow piping connections to be made until after the tank has been completely tested and allowed to settle. As an alternative, settlement calculations can be made and piping flexibility can be designed to account for settling. In this case, pipe can be connected prior to testing.

* May be required on tanks 25,000 gallons and larger.

The piping is not equipped with ball joints. It has been the experience of EEI that the integrity of ball joints is suspect and that leaks have been known to occur. It is the opinion of EEI that it is not necessary to retrofit the piping to include ball joints.

CABLE SUPPORTS

ff On the fixed roof of all tanks, provide two scaffold cable supports in accordance with API Std 650. Locate the supports near the center of the tank so that supported cables will have maximum range and flexibility of operation with minimum interference with other tank fittings.

The tank does not have scaffold cable supports. There is no compelling reason to provide scaffold cable supports.

STRIKER PLATES

gg Striker plates under all openings used for manual gauging in steel tanks and all openings in fiberglass tanks.

Based on the previous out-of-service inspection report, there is a datum plate within the gauge tube used for manual gauging; meets UFC 3-460-01.

Tank 738 – API 653 Inspection Appendix B, Page 4

Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMMENTS/RECOMMENDATION

Additional Military Criteria Items, Comments or Notes:

None.

END OF DATA

Tank 738 – API 653 Inspection Appendix B, Page 5

APPENDIX C

Non-Destructive Examination (NDE) and Evaluation Criteria

APPENDIX C - NDE and Evaluation Criteria (In-Service Inspection) Page 1

IN-SERVICE INSPECTION

CODES AND STANDARDS

API Standard 653, April 2009, Fourth Edition, Addendum 2, January 2012

API Standard 650, 12th Edition, March 2013

UFC 3-301-01 Structural Engineering, June 2013

NON DESTRUCTIVE EXAMINATION (NDE)

Tank Inspection (General)

API Standard 653 as applicable.

Visual Inspection

1. Inspection Items

In accordance with API Standard 653 and EEI STD for API 653 In-Service Inspection

Shell and roof plate welded joints (where accessible).

Shell and roof plate surfaces.

Items affecting structural and hydraulic integrity

2. Method

In accordance with API Standard 653.

Ultrasonic Testing (UT)

Ultrasonic thickness measurements were taken to establish floor, shell, and roof plate thicknesses.

1. Inspection Items

In accordance with EEI NDE Procedure, EEI-UT-002, Ultrasonic Thickness Examination.

Shell plates

Roof plates

Tank appurtenances

2. Equipment

Olympus 38DL Plus / Panametrics 37DL Plus

APPENDIX C - NDE and Evaluation Criteria (In-Service Inspection) Page 2

3. Method

Perform on a spot basis to determine thickness.

Perform in areas of low UT thickness readings to determine the nature of the low reading that is backside corrosion, lamination, or inclusion within the parent material.

Echo/Echo (E/E) or Thru Coat mode for determining metal thickness and backside corrosion on coated surfaces without including thickness of coating in reading.

Pit Survey

1. Inspection Items

Tank shell

Tank roof

2. Equipment

Mechanical pit gauges

Tank Bottom Settlement Measurements

1. Equipment

Laser level

2. Method

In accordance with API Standard 653 Appendix B, measure the floor profile at a minimum of eight locations around the tank perimeter not greater than 30 feet apart.

Coating Thickness Measurements

1. Equipment

Olympus 38DL Plus (Thru Coat mode) / PosiTector 6000 Thickness Gauge

2. Method

Measurements taken at UT locations.

APPENDIX D

Tank Drawings

APPENDIX E

Tank Photographs

All photographs in this report, unless otherwise noted, were taken by Enterprise Engineering, Inc.

Enterprise Engineering, Inc. hereby grants permission to the U.S. Government and its contractors to publish/republish these photos.

Tank 738 North Elevation

Tank 738 East Elevation

APPENDIX E – Tank Photographs Page 1 Tank 738 – API 653 Inspection

Tank 738 South Elevation

Tank 738 West Elevation

APPENDIX E – Tank Photographs Page 2

36” Manway #1

Tank Nameplate

APPENDIX E – Tank Photographs Page 3

Typical Tank Anchor

Tab with Ground Wire

APPENDIX E – Tank Photographs Page 4

Concrete Ringwall and Tank Floor Projection

(Note: Failed sealant and moss/organics within space.)

Leak Detection Standpipe (Typical of 2)

APPENDIX E – Tank Photographs Page 5

Varec Tape Gauge Display

Cathodic Protection Box

APPENDIX E – Tank Photographs Page 6

2” Leak Detection Pipe below Tank Floor (Typical of 4)

Nozzles and Float for Low Level Alarm

APPENDIX E – Tank Photographs Page 7

Roof Access…