Attachment J.2 - Facility 123_External_18July2019.pdf

ACOE CONTRACT W911KB-15-D-0001, DELIVERY ORDER W911KB19F0059

TANK 123 (FACILITY NO. 77525)

API 653 IN-SERVICE INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

DRAFT FINAL REPORT (PRE-REPAIR)

Eareckson Air Station, Alaska

September 2019

Date of Inspection: July 2019

Contract Agency

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

Prepared By

2525 Gambell Street, Suite 200 Anchorage, AK 99503

George M. Markland IV API 653 Certificate No. 54131

Submitted By

Kelly B. Waring, P.E.

Principal, API 653 Certificate No. 21992

EEI Project No. 9457

Page Intentionally Left Blank

SUITABILITY FOR SERVICE TESTAMENT

TANK 123 (FACILITY NO. 77525)

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, in-service external and suitability for service evaluation of Tank 123 at Eareckson Air Station, Alaska. The inspection was performed July 18, 2019. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, UFC 3-460-03, and the Statement of Work.

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

EEI recommends the next API 653 external in-service inspection be scheduled no later than July 2024 (5 years from 2019 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API 653 internal out-of-service inspection be scheduled no later than Summer of 2024 (10 years from July 2014 inspection), or sooner if a change in condition has occurred.

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

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

September 3, 2019 George M. Markland IV Date API 653 AST Inspector Certificate No. 54131

Tank 123 – API 653 Inspection TABLE OF CONTENTS Eareckson Air Station, Alaska September 2019 EEI Project No.: 9457

TABLE OF CONTENTS

Page

SUMMARY

Scope

General

INSPECTION ASSESSMENT

Hydraulic Integrity

Structural Integrity

Next Inspection

REPAIR ITEMS

Standard of Care

COATING SYSTEM

Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Tank Shell Corrosion Rates

Hydraulic and Structural Integrity Summary

CLOSURE

Conclusions

EEI Project Team

APPENDICES

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

Tank 123 – API 653 Inspection Page 1

EEI Project No.: 9457

TANK 123

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

EARECKSON AIR STATION, ALASKA

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an in-service external integrity inspection of Tank 123 at Eareckson Air Station, Alaska. The inspection was performed July 18, 2019.

The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3- 460-01, UFC 3-460-03 and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. Inspection findings and recommended repairs are provided below.

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

General

Tank 123 is a field erected, vertical aboveground storage tank. The tank was fabricated and erected in 1965. The tank is 73 feet 3 inches in diameter and 39 feet 11 inches high. It is of welded construction with butt-welded shell plates and lap welded floor and roof plates. The tank has a fixed column supported cone up roof. The tank is not equipped with a floating pan. The nominal shell capacity is 30,000 Bbls and the tank is currently in JP-8 service.

An out-of-service inspection was performed August 2014 by Enterprise Engineering Inc. Repairs were identified in the API 653 report dated September 2014. Repairs were completed prior to the current inspection effort including:

• Magnetic particle inspection of weld with non-compliant clearances.

• Installation of an 8 inch stilling well for the ENRAF ATG displacer.

• Installation of an 8 inch stilling well for manual gauging.

For a complete list of completed repairs, refer to Appendix H

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 123 is considered suitable to remain in service.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Tank 123 – API 653 Inspection Page 2

EEI Project No.: 9457

Inspection of the tank shell and roof found no holes or indications of leaks. As the tank was in service at the time of inspection, the condition of the floor is unknown.

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

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof, and their attachments.

Ultrasonic inspections of the shell were performed on the first course and on each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

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

Next Inspection

API 653 requires an in-service inspection by an authorized inspector be performed every 5 years or RCA/4N years, whichever is less. RCA is the remaining corrosion allowance of the shell (i.e. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. When shell corrosion rates are unknown, API 653 requires the in-service inspection interval not exceed 5 years.

EEI recommends the next API 653 external in-service inspection be scheduled no later than July 2024 (5 years from this 2019 inspection), or sooner if a change in condition or change in service has occurred.

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires the interval until the next internal inspection be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years for tanks without a release prevention barrier or 30 years for tanks with a release prevention barrier.

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

(a) The storage tank is older than 30 years,

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

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

(d) After a significant seismic event.

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

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 recommendations for long term serviceability, and recommended for non-tank inspection items. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

Tank 123 – API 653 Inspection Page 3

EEI Project No.: 9457

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 (MANDATORY)

Findings Repair Photo

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank and may require the removal of a tank from service.

No mandatory repairs were identified.

RECOMMENDED REPAIRS (NON-MANDATORY)

Findings Repair Photo

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank but should be performed if approved by the Government for the long-term preservation and integrity of the tank.

1. The tank has not been provided with an NFPA emergency responder diamond and is not labeled per UFC 3- 460-01.

Provide an NFPA emergency responder diamond on the tank shell and label tank in accordance with UFC 3-460-01 and MIL-STD- 161.

2. Vegetation was observed growing in the containment area and on the liner batten strips affixed to the concrete ring.

Remove vegetation and monitor during routine inspections.

3. Localized coating failure was observed on the outer projection of the tank floor, piping, and roof plates.

Remove the coating from the affected areas. Clean and provide surface preparation in accordance with the coating manufacturer’s written recommendations and recoat the affected areas.

Quantity: 150 SF

Tank 123 – API 653 Inspection Page 4

EEI Project No.: 9457

RECOMMENDED REPAIRS (NON-MANDATORY)

Findings Repair Photo

4. Cracking was observed in the concrete ringwall foundation.

Seal the cracks in the ringwall that are wider than 1/64-inch with epoxy injection.

Quantity: 10 LF

5. The sealant between the tank floor projection and the concrete ring wall has failed in multiple locations.

Remove the sealant from the entire perimeter of the tank.

Clean the surfaces to be sealed.

Provide fuel resistant polysulfide sealant between the floor projection and the concrete ringwall.

Quantity: 230 LF

6. General coating failures were observed on all of the valves associated with Tank 123.

Remove the coating from the affected areas. Clean and provide surface preparation in accordance with the coating manufacturer’s written recommendations and

Quantity: 100 SF

7. The grease packing the telltale holes in the nozzle reinforcement pads has dried out.

Remove the grease currently in the telltale holes and repack with white grease to prevent moisture migration between the reinforcement plate and the shell.

Quantity: 7 locations

8. Coating failures and corrosion were observed at multiple locations on the tank shell and appurtenances (stair supports, wind girder, tape gauge supports, etc.).

Remove the coating from the affected areas. Clean and provide surface preparation in accordance with the coating manufacturer’s written recommendations and

Quantity: 200 SF

Tank 123 – API 653 Inspection Page 5

EEI Project No.: 9457

RECOMMENDED REPAIRS (NON-MANDATORY)

Findings Repair Photo

9. Coating failures and corrosion were observed at multiple locations on the tank roof and appurtenances (roof nozzles, roof plates, handrails, etc.).

Remove the coating from the affected areas. Clean and provide surface preparation in accordance with the coating manufacturer’s written recommendations and

Quantity: 100 SF

10. A hinge on the ENRAF ATG access panel is broken.

Repair or replace the hinge.

11. Tank 123 is equipped with an 8 inch

Manual Gauging Hatch.

The locking mechanism is currently cracked and likely to fail.

Repair or replace the mechanism.

12. Tank 123 is currently not equipped with a tank nameplate.

Recommend affixing a nameplate meeting the requirements of current API standards above the manway MH-1.

13. Tank 123 is equipped with two 8-inch pressure vacuum vents.

Disassemble and clean both pressure/vacuum vent pallets and screens.

Replace any soft goods if found to be worn

Tank 123 – API 653 Inspection Page 6

EEI Project No.: 9457

RECOMMENDED REPAIRS (NON-MANDATORY)

Findings Repair Photo

14. Facility personnel reported that the current safe fill height is 30 feet 1-5/8 inches while the overall shell height is 39 feet 11 inches. The safe fill height was provided by EEI as a result of seismic calculations performed during an earlier tank inspection.

Seismic calculations have changed from the time of the earlier inspection. Specifically, seismic forces are now calculated based on spectral accelerations rather than by zones.

Calculations indicate that the tank may be capable of supporting an increase in product level.

Refer to “Additional Discussion Items-Fill Height” for further discussion.

15. The 8 inch fill, 6 inch Left & Right issue, 4 inch water draw, and 3 inch product recovery tank nozzles are less than the API minimum.

It is not recommended to replace the nozzles at this time. It is recommended to monitor the nozzles for changes in condition during routine maintenance inspections. Should the government wish to replace the nozzles at a future date, it should be noted that replacement with thicker wall nozzles would not require a hydrostatic test.

RECOMMENDED REPAIRS FOR LONG TERM SERVICEABILITY

1. Program the tank for the next API 653 in-service inspection no later than July 2024 (5 years)

2. Program the tank for the next API 653 out-of-service inspection no later than the Summer 2024 (10 years from 2014 inspection).

3. Test all level alarms and switches as part of ongoing maintenance.

4. Tank 123 is not equipped with ice/snow shields above the tank nozzles. From past experience, it is the recommendation of EEI to provide ice/snow shields above the nozzles to prevent damage from falling ice. This recommended repair can be deferred until the next out-of-service interval.

COATING SYSTEM

Coating Requirements

Coating materials and application requirements for type and location of repair items shall be in accordance with the applicable UFGS specification.

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: 0.000430 inches per year

Tank 123 – API 653 Inspection Page 7

EEI Project No.: 9457

Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates were calculated using an assumed original metal thickness and a 1965 year of construction.

Tank Shell Corrosion Rates

API 653 4.3.1.3 states that tank shell corrosion can occur in many forms and varying degrees of severity and may result in a generally uniform loss of metal over a large surface area or in localized areas. The corrosion rate for the tank shell was calculated based on the original nominal shell thickness and the minimum recorded shell thickness during the inspection.

UT readings of the shell were obtained at the bottom shell course and accessible locations from the spiral stairs at the upper shell courses. The shell plate thickness will not be reduced below the minimum value at a 5 year inspection interval.

Hydraulic and Structural Integrity Summary

The following table summarizes the hydraulic and structural integrity of the tank:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

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

Acceptable

Floor Projection

No conditions were found that affect the hydraulic or structural integrity of the floor projection.

Acceptable

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

Acceptable

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

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

Hydrostatic Test

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

Acceptable

Tank 123 – API 653 Inspection Page 8

EEI Project No.: 9457

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

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

1. Does the tank meet API 650(7th edition or later, 1980): No, constructed in 1965.

2. Has a prior hydrotest been performed demonstrating fitness: Unknown.

3. Is the tank shell thickness < 0.5 inch: Yes.

4. Does the tank operate at metal temperature above

60 deg F?: No.

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

6. Tank steel exempt per API 650, Figure 4.1b or API 653 Figure 5.2: Yes.

7. Tank full at lowest one day temperature per API 650 Figure 4.2: Unknown, but likely.

The tank, with a first shell course thickness less than 0.5 inches, does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

The tank is not anchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that tank shell stresses are within limits at the existing operational fill height of 30 feet 1 5/8 inches.

Calculations were performed utilizing the specific gravity for JP-8 (S.G. = 0.84), a concrete ringwall, seismic parameters Ss = 1.500, S1 = 0.600, an importance factor of 1.1.

Acceptable

Wind Evaluation

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

Calculations were performed using a wind velocity of 160 mph (Risk Category III).

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

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

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

Based on previous calculations, it is recommended that a minimum of 5 feet of product be maintained in the tank.

Refer to “Additional Discussion Items-Wind Evaluation” for further discussion.

ADDITIONAL DISCUSSION ITEMS

Wind Evaluation

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

Although formulas are provided for calculating the minimum thickness for welded tank shells, they only consider liquid loading. API 653 states that all other loads shall be evaluated according to the original standard of construction and engineering judgment shall be used to evaluate different conditions or new

Tank 123 – API 653 Inspection Page 9

EEI Project No.: 9457 information. There is no mandatory requirement to upgrade an existing tank to current API 650 standards as compared to other proscriptive repair requirements found in API 653.

The wind evaluation determined that an empty unanchored tank is at risk of overturning. The evaluation was performed using the current design wind speed of 160 mph. At the time of construction, the design wind speed was likely less than 110 mph. The tank design was likely suitable for the criteria in force at the time. However, it is not recommended to reduce the fill height below the previously calculated product height of 5 feet.

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

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

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

Fill Height

Facility personnel reported that the current operating fill height is 30 feet 1-5/8 inches. The height of the tank shell is 39 feet 11 inches. Assuming that the depth of the roof framing members is 12 inches, the distance between the underside of the framing to the fill height is 8.78 feet. The calculated height of the sloshing wave based on the current fill height is 5.13 feet. UFGS and the standard design AW 78-24-27 require a minimum freeboard clearance of 12 inches between the underside of the roof framing and the top of the sloshing wave. The available freeboard is 8.78 feet – 5.13. feet -12 inches = 2.65 feet. This available freeboard represents a potential increase in the operational fill level.

Calculations were performed increasing the fill height 2.5 feet for a revised fill height of 32 feet 7-5/8 inches. The height of the potential sloshing wave is 5.25 feet or elevation 37 feet 10-5/8 inches. The clearance between the underside of the roof framing and the top of the sloshing wave is 38 feet 11 inches

– 37 feet 10-5/8 inches = 1.03 feet, which is slightly greater than the minimum clearance requirement of 12 inches.

The decision to increase the fill height is entirely up to the government. Although these preliminary calculations support an increase in fill height, the final results are dependent upon the actual depth of the existing roof framing structure.

Tank 123 – API 653 Inspection Page 10

EEI Project No.: 9457

CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 123 is considered suitable to remain in service.

EEI Project Team

Site Team

George M. Markland IV Mechanical Integrity Specialist, API Inspector of Record

Nick Beeker, E.I.T. Design Engineer, Tank Technician

Support Team

Stacy M. Kaplan-McMillan Project Manager

David A. Stchyrba, P.E. Structural Engineer, QC Review API 653 AST Inspector Certificate No. 27187

Kelly Waring, P.E. Principal Engineer, QA Review API 653 AST Inspector Certificate No. 21992 API 570 Piping Inspector Certificate No. 23160

APPENDIX A

Tank Inspection Data Sheet and

Evaluation Items

Tank 123 – API 653 Inspection Appendix A, TANK SUMMARY SHEET

EEI Project No.: 9457

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Eareckson Air Station, Shemya Island, Alaska Tank No. 123

Facility No. 77525 Inspection Date(s): July 18, 2019

Tank Type: Vertical Above Ground Storage Tank Type of Inspection: External w/ Suitability for Service Evaluation

Contract Number, Task Order: W911KB-15-D-0001, Delivery Order W911KB19F0059 Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: George M. Markland IV

API-653 AST Inspector Certificate No. 54131

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

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

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

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

Safe Fill Height: 30’-1.625” (Per Facility) GPS Latitude & Longitude: 52 Deg 43’ 51.80” N, 174 Deg 5’ 33.61” E (Source – Google Earth) Foundation Configuration: Concrete Ringwall

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

Cathodic Protection: None Stilling Wells: 8 inch at ENRAF ATG displacer

8 inch for manual gauging and sampling Last Inspection (Type, Date): Out-of-Service, June 30 – July 2, 2014 by EEI

Last Coated Internally (Product): Lower 40 inches of shell and entire floor: 2001, Unknown thick film liner. Upper shell courses: Unknown, Unknown product

Last Coated Externally (Product): 2001, Moisture-cured Urethane

INSPECTION RESULTS

Can tank remain in service? Yes.

Deficiencies identified as mandatory repairs: No mandatory repairs identified

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 API Inspections (Type, Date): API 653 In-Service: July 2024 (5 Years)

API 653 Out-of-Service: Summer 2024 (10 Years from the OOS inspection performed in 2014)

ADDITIONAL ITEMS

Change in Service: None As-Built Drawings, Specifications: None available

API STANDARD 653

TANK IN-SERVICE INSPECTION CHECKLIST

Tank 123 – API 653 Inspection APPENDIX A, Page 1

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

Location: Eareckson Air Stn., AK Date: 7/22/2019

EEI Project No.: 9457

Item Completed Comments

C. 1.1 FOUNDATION

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

✓ Survey completed.

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.

✓ Minor cracking observed in the concrete ringwall.

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

N/A

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

No cavities were observed.

d. Check that runoff rainwater from the shell drains away from tank. ✓

Drains away from tank.

e. Check for settlement around perimeter of tank. ✓ None 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.

N/A

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.

N/A

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.

N/A In-service inspection. Backside corrosion will be checked at next out-of-service inspection.

C.1.1.5 Site Drainage

a. Check site for drainage away from the tank and associated piping and manifolds. ✓

Drains adequately.

b. Check operating condition of the dike drains.

Operation of the drain was not performed.

Operations personnel stated the drain functions properly.

Tank 123 – API 653 Inspection APPENDIX A, Page 2

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

C.1.1.6 Housekeeping

Inspect the area for buildup of trash, vegetation, and other flammables buildup. ✓

Vegetation observed around the perimeter of the tank.

C.1.2 SHELLS

C.1.2.1 External Visual Inspection

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

✓ Coating failures and corrosion were observed.

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

✓ Corrosion observed at locations of coating failures.

c. Inspect the bottom-to-foundation seal, if any. ✓ Seal is cracked and damaged.

Recommend replacing damaged sections.

C.1.2.2 Internal (Floating Roof Tank) Tank is not equipped with an internal floating roof.

Visually inspect for grooving, corrosion, pitting and coating failures.

N/A

C.1.2.3 Riveted Shell Inspection

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.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks)

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.

Wind Girder is in fair condition. Coating failures with corrosion were observed.

b. Check support welds to shelf for pitting, especially on shell plates. ✓

No evidence of pitting observed at welds

c. Note whether supports have reinforcing pads welded to shell. ✓

Wind girder is welded directly to the tank shell.

C.1.3 SHELL APPURTENANCES

C.1.3.1 Manways and Nozzles

Tank 123 – API 653 Inspection APPENDIX A, Page 3

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

a. Inspect for cracks or signs of leakage in weld joint at nozzles, manways, and reinforcing plates. ✓

None observed.

b. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. ✓

None observed.

c. Inspect for flange leaks and leaks around bolting. ✓ None observed.

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.

N/A

The tank is not equipped with mixer manways.

C.1.3.2 Tank Piping Manifolds

a. Inspect manifold piping, flanges, and valves for leaks. ✓

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.

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

The fill and issue lines are equipped with pressure relief loops.

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

f. Check sample connections for leaks and for proper valve operation.

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

N/A Temperature recorded with ENRAF ATG.

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

C.1.3.3 Autogauge System

The tank is equipped with an ENRAF ATG system mounted on the roof and a Varec tape gauge. The tape gauge display head is mounted to the tank shell.

a. Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. ✓

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

c. Bump the checker on autogauge head for proper movement of tape. ✓

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

Tank 123 – API 653 Inspection APPENDIX A, Page 4

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

e. Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). ✓

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.). ✓

Tape gauge reading matches ENRAF ATG.

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.

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.

c. Test bracing and supports for sample lines and equipment.

C.1.3.5 Heater (Shell Manway Mounted)

Inspect condensate drain for presence of oil indicating leakage.

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.

C. 1.3.7 Swing Lines: Winch Operation

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 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.

Tank 123 – API 653 Inspection APPENDIX A, Page 5

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

C.1.3.8 Swing Lines: External Guide System

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

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity.

C.1.3.10 Swing Lines: Cable Material and Condition

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

b. All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison

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

C.1.3.12 Swing Lines: Target

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.)

C.1.4.2 Deck Plate Exterior Corrosion

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

✓ Minor coating failures and corrosion.

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).

✓ Roof is cone-up design. Undulations observed in the roof plates. Evidence of standing water present.

No repairs recommended at this time.

C.1.4.4 Level of Floating Roof

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 Tank is not equipped with a floating roof.

Tank 123 – API 653 Inspection APPENDIX A, Page 6

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

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.

N/A

C.1.4.6 Roof Insulation

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

N/A

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.

N/A

C.1.4.7 Floating Roof Seal System Tank is not equipped with an internal floating roof

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

N/A

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.

N/A

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).

N/A

d. Inspect fabric for deterioration, holes, tears, and cracks.

e. Inspect visible metallic parts for corrosion and wear.

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

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

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

Tank 123 – API 653 Inspection APPENDIX A, Page 7

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

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.

C.1.5 ROOF APPURTENANCES

C.1.5.1 Sample Hatch

a. Inspect condition and functioning of sample hatch cover. ✓

Hatch locked at the time of inspection.

Locking mechanism damaged/cracked.

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.

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. ✓

Reinforcement plate installed at 8 inch Manual Gauging Hatch.

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

a. Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. ✓

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

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.

Tank 123 – API 653 Inspection APPENDIX A, Page 8

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

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.

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

a. Check the hatch for corrosion and missing bolts.

One hinge on the Autogauge inspection hatch is broken

b. Look for corrosion on the tape guide’s and float guide’s wire anchor. ✓

OK

C.1.5.5 Autogauge: Float Well Cover

a. Inspect for corrosion. ✓

b. Check tape cable for wear or fraying caused by rubbing on the cover. ✓

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.

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

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

Check condition of screens, locking, and pivot pins. N/A

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 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.

Tank is equipped with two 8 inch Pressure Vacuum Vents.

Tank 123 – API 653 Inspection APPENDIX A, Page 9

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

C.1.5.12 Rim Vents

a. Check condition of the screen on the rim vent cover.

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

C.1.5.13 Pontoon Inspection Hatches

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

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

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 item C.2.12 below.

C. 2.12 ACCESS STRUCTURES

C. 2.12.1 Handrails

a. Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails.

The roof handrail is constructed with 2” pipe.

The stair handrail is constructed with 2” x 2” galvanized structural angles.

b. Inspect for pitting and holes, paint failures.

Paint failures and crevice corrosion observed where toe board is welded to the roof handrail system

c. Inspect attachment welds.

Corrosion present, no evidence of cracking

d. Identify cold joints and sharp edges. Inspect the handrails and midrails. ✓

e. Inspect safety drop bar (or safety chain) for corrosion, functioning, and length.

N/A

f. Inspect the handrail between the rolling ladder and the gaging platform for a hazardous opening when the floating roof is at its lowest level.

C. 2.12.2 Platform Frame

a. Inspect frame for corrosion and paint failure.

b. Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure. ✓

Paint failures and corrosion present.

c. Check reinforcing pads where supports are attached to shell or roof. ✓

d. Inspect the surface that deck plate or grating rests on, for thinning and holes. ✓

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Tank No.: 123 Prepared by: GMM

e. Check that flat-surface-to flat-surface junctures are seal welded. ✓

C. 2.12.3 Deck Plate and Grating

a. Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure. ✓

b. Inspect plate-to –frame wells for rust scale buildup. ✓

c. Inspect grating for corrosion-caused thinning of bars and failure of welds. ✓

d. Check grating tie down clips. Where grating had been retrofitted to replace plate, measure the rise of the step below and above the grating surface and compare with other risers on the stairway.

C. 2.12.4 Stairway Stringers

a. Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. Inspect attachment of stairway treads to stringer.

b. Inspect stairway supports to shell welds and reinforcing pads. ✓

Paint failures and crevice corrosion observed at reinforcing pads.

c. Inspect steel support attachment to concrete base for corrosion. ✓

C.2.12.5 Rolling Ladder

a. Inspect rolling ladder stringers for corrosion. N/A

b. Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment to stringers and corrosion, particularly where angle rungs are welded to stringers.

c. Check for wear and corrosion where rolling ladder attaches to gaging platform.

N/A

d. Inspect pivot bar for wear and secureness. N/A

e. Inspect operation of self-leveling stairway treads. N/A

f. Inspect for corrosion and wear on moving parts. N/A

g. Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle.

N/A

h. Inspect alignment of rolling ladder with roof track.

N/A

i. Inspect top surface of rolling ladder rack for wear by wheels to assure at least 18 in. of unworn track (track long enough).

j. Inspect rolling ladder track welds for corrosion. N/A

k. Inspect track supports on roof for reinforcing pads seal-welded to deck plate.

Tank 123 – API 653 Inspection APPENDIX A, Page 11

EEI Project No.: 9457

Tank No.: 123 Prepared by: GMM

l. Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs.

Max angle __________________.

m. If rolling ladder track extends to within 5 ft. of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

Additional Notes:

None.

APPENDIX B

Assessment of Compliance with

Military Criteria

Tank 123 – API 653 Inspection Appendix B, Page 1

EEI Project No.: 9457

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1 (Complete UFC available at www.wbdg.org)

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

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT

COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

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.

✓ Tank is not equipped with an IFR.

Manhole above the floating pan is not required.

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.

✓ The roof is equipped with two 24” manways.

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 two 30” manholes.

Manhole covers are not supported by davits.

There is no compelling reason to upgrade the tank with 36 – inch manholes.

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 not equipped with an IFR.

There is no compelling reason to provide a cover.

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 not equipped with an IFR.

There is no compelling reason to install hatches.

LADDER/STAIRS

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

✓ Tank is not equipped with an IFR.

An internal ladder is not required.

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.

LEVEL ALARMS

l 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.

✓ Tank is equipped with a shell mounted level alarm system independent of the ATG.

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

Tank 123 – API 653 Inspection Appendix B, Page 2

EEI Project No.: 9457

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1 (Complete UFC available at www.wbdg.org)

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

ITEM

APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT

COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

VENTS

m Open atmospheric vents with weather hoods and bird screens or pressure/vacuum vents in lieu of open vents. 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.

✓ Tank is equipped with two 8-inch pressure/vacuum vents with weather hoods and bird screens.

Screens and bolting show minor corrosion.

Disassemble and clean the pressure/vacuum vent pallets and screens.

n Emergency relief venting with capacity in accordance with NFPA 30 and UL 142, as applicable or a weak roof-to-shell seam, as specified in API Std 650.

✓ Tank has a frangible roof joint.

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 Varec tape gauge system.

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.

✓ Tank is equipped with an ENRAF ATG.

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.

✓ Tank has been provided with an 8” stilling well that contains the ENRAF ATG displacer and the temperature probe.

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.

✓ 6-inch roof nozzle has been installed over the sump to allow for the installation of a water probe per recommendation in 2014 OOS report. The probe has not been installed.

Note: A stilling well was not required for a water probe in a tank without an IFR at the time of the OOS inspection. A stilling well is required per current requirements.

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.

✓ Tank is equipped with a 10-inch nozzle and 8-inch stilling well for manual gauging.

PIPE CONNECTION

u Inlet fill connection. See Facility Plates 016, 017, and 018, as applicable.

✓ Tank is equipped with an inlet fill connection that meets UFC 3-460-01.

v Main suction and low suction.