Attachment J.2 Kwajalein-Fac 935 (Tank 14)-Ext Final-2017.pdf

PDF 7 MB Posted Sep 25, 2023

Attached to: POL Tank Inspection KWA - Kwajalein Atoll
Solicitation number: W9128F24Q0001
Issued by: Department of the Army Corps of Engineers Engineering District Omaha

About this file

Written by GovTribe AI · Dec 21, 2023

This document summarizes an API 653 in-service inspection report for an aboveground storage tank (Tank 14) located at U.S. Army Garrison Kwajalein Atoll in the Republic of the Marshall Islands. The inspection evaluated the tank's integrity and collected data to establish a database for future inspections. Key findings include the tank shell having over 30 years of remaining life, and deficiencies related to the secondary containment, piping, coatings, and safety equipment. Recommendations address repairs to comply with standards and improve regular maintenance. The solicitation number and opportunity indicate the U.S. Army Corps of Engineers is seeking inspection services for POL tanks at Kwajalein Atoll.

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US	Army	Corps	of	Engineers
Omaha	District

API	653	In‐Service
Inspection	Report

U.S.	Army	Garrison	Kwajalein	Atoll
Facility	Number	935
Tank	Number	14

Army

Corps

Engineers

Center

Expertise

for

Petroleum,

Oils,

and

Lubricants

(USACE

POL‐MCX)

September

29,

2017

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

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

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

9. Cathodic Protection

C. FINDINGS AND RECOMMENDATIONS

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

2. REQUIRED REPAIRS to Fully Comply with API 653 or Federal, State, and Local Codes…………………………………..11

3. RECOMMENDED REPAIRS as Part of Regular Maintenance………………………………………………………………………….21

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1 SHELL SERVICE LIFE EVALUATION

A.2 SHELL SETTLEMENT EVALUATION

A.3 ULTRASONIC UT DATA

A.4 CONTAINMENT LAYOUT DRAWING

A.5 SHELL LAYOUT DRAWING

A.6 OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ARD Anti‐rotation device

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

VPI Valve Position Indicator

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

GENERAL	SUMMARY
Summary	of	Inspection

API

Standard

653

In‐Service

inspection

Tank

(Facility

935)

USAG

Kwajalein‐Atoll,

Republic

the

Marshall

Islands

was

completed

September

29,

2017

evaluate

the

tank’s

integrity,

collect

data,

and

establish

database

for

future

inspections

and

evaluations.

The

shell

service

life

evaluation

performed

having

greater

than

years

remaining

shell

life

under

current

conditions.

Inspection

Results

are

listed

Section

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

INSPECTION	DATE
API	In‐Service	(External)	Inspection	Date:	29	September	2017

Equipment (s) Used:

Ultrasonic	Thickness	(A‐scan/B‐scan)	Testing
Manufacturer:	General	Electric
Model:	DMS	Go+
Calibration	Methods	Used:	Zeroing	Procedure,	Copper	Coating	Calibration	Procedure,	and	Two	Point

Calibration Procedure

Tank

Settlement

Surveying

Manufacturer:

Northwest

Instrument

Model:

NRL802K

Rotating

with

NLD5G

Laser

Receiver

Calibration

Methods

Used:

Main

and

transverse

horizontal

axes

checks

100

ft.

≤

1/16

inch

Tank

Shell

Surveying

Manufacturer:

Leica

Geosystem

Model:

Disto

Calibration

Methods

Used:

Tilt

sensor

calibration

automatically

performed

with

unit

set

3°

and

crosshairs calibration using target at a distance > 25 m

Inspector(s): Benyam Berhane

STATE	REGULATIONS
State	Regulation	for	API	In‐Service	Tank	Inspections		N/A
State	Regulation	for	API	Out‐of‐Service	Tank	Inspections	N/A

NOTE:

there

are

state

regulations

for

tank

inspections,

then

N/A

shall

reside

in‐place

the

number

years

between

inspections.

state

regulations

reside,

the

recommended

future

inspection

dates

shall

based

whichever

stringent

between

the

API

inspector’s

calculations

and

the

state

regulations.

PREVIOUS	INSPECTION	DATES
API	Out‐of‐Service	(Internal)	Inspection	Date:	11	November	2012
API	In‐Service	(External)	Inspection	Date:	19	March	2010

RECOMMENDED

FUTURE

INSPECTION

DATES

(CALCULATIONS

SHALL

PROVIDED)

API

Out‐of‐Service

(Internal)

Inspection

Date:

November

2032

Per

API

653

Section

6.4.2‐

Subsequent	Internal	Inspection	Interval
(11	November	2022	IAW	UFC)

API In‐Service (External) Inspection Date: 29 September 2022

Benyam	Berhane
Mechanical	Engineer/Sr.	Inspector
InterSpec,	LLC
API	653	Certified	Inspector	No.	28492

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

GENERAL TANK INFORMATION

ITEM

DESCRIPTION

Owner

U.S

Army

Location

U.S.

Army

Garrison

Kwajalein

Atoll;

RMI

Facility

Number

935

Tank

Number

State

Country

Kwajalein

Atoll

/ Republic

Marshall

Islands

City

‐

Inspection

Date

September

2017

Tank

Manufacturer

Chicago

Bridge

and

Iron

(Per

Inspection

Records

Data

plate)

Design

Standard

Unknown

(Assumed

API

STD

12C

Eleventh

Edition)

Date

Construction

1951

Tank

Contents

JP‐5

(F‐44)

Tank

Serial

Number

None

Tank

Diameter

Feet

Shell

Height

Feet

Product

Height

Feet

Tank

Capacity

7,500

BBL

(315,000

gallons)

Foundation

Coral

Bed

and

Perimeter

Asphalt

Pad

(Concrete

Ring

wall

Outer

Edge)

Construction

Bottom Lap‐Welded (Cone‐Down)

Shell Butt‐Welded (Cylindrical)

Floating Roof None

Fixed Roof Aluminum Geodesic Dome

Material

Bottom Carbon Steel (Unknown Specification)

Shell Carbon Steel (Unknown Specification)

Floating Roof NA

Fixed

Roof

Aluminum

(Unknown

Specification)

Cathodic

Protection

Impressed

Current

Interior

Coating

System

Thin

Film

Epoxy

(Bottom

and

Partial

Shell,

Date

Unknown)

Exterior

Coating

System

Thin

Film

Epoxy/

Polyurethane (Partial

2014

First

Course)

Level

Gauging

ENRAF

Automatic

Tank

Gauge

with

Varec

2500

Mechanical

Tape

Gauge

Overfill	Protection
Hydraulically	Operated	High	Level	Shut‐off	Valve	with	Dedicated	Float	(Set	at
26.75	Feet)

Piping	Receipt	6"	Carbon	Steel
		Issue	6"	Carbon	Steel
		Low	Suction	6”	Carbon	Steel
		Water	Draw‐Off	1"	Carbon	Steel

Level Alarms

Low‐Level	Alarm:	4.28 Feet
Low‐Low	Level	Alarm:	1.44	Feet
High‐Level	Alarm:	26.00	Feet
High‐High	Level	Alarm:	28.00	Feet
High‐Level	Control	Shutoff:	26.75	Feet

Type	of	Internal	Floating
Roof	NA

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

A. GENERAL PROJECT INFORMATION

1. API

653

Inspection

This

project

will

perform

API

653

inspections

various

tanks

facilities

throughout

the

United

States/OCONUS.

Additional

consideration

given

federal,

state,

and

local

regulations,

well

applicable

military

criteria

and

general

industry

standards.

An API Standard 653 In‐Service (External) inspection was performed on Tank 14 (FAC 935).

2. Site

Information

September

29,

2017

Burns

McDonnell

and

our

sub‐consultant

(InterSpec)

performed

API

653

In‐Service

(External)

inspection

Tank

(Facility

935)

located

U.S.

Army

Garrison

Kwajalein

Atoll,

RMI.

USAG

Kwajalein

Atoll

(USAG‐KA)

home

the

Ronald

Reagan

Ballistic

Missile

Defense

Test

Site.

The

Reagan

Test

Site

Major

Range

and

Test

Facility

Base

under

the

DoD

with

the

primary

mission

researching,

developing

tests,

and

developing

missile

defense

and

space

programs.

Tank 14 is used as an aboveground JP‐5 fuel storage tank supporting the installation fueling needs.

B. TANK INSPECTION COMMENTS

1. Tank

Construction

Tank

(FAC

935)

nominal

7,500

BBL,

45‐foot

diameter

30‐foot

tall,

F‐44

(JP‐5),

aboveground

vertical

storage

tank.

The

tank

was

constructed

1951

presumably

API

STD

12C

Eleventh

Edition.

There

are

data

name

plates

affixed

the

tank.

The

tank

has

undergone

several

modifications

since

the

original

construction.

The

most

prominent

modification

the

addition

shell

insert

and

patch

plates

the

lower

twelve

inches

the

first

shell

course.

This

was

likely

added

repair

corrosion

these

areas

due

poor

drainage

away

from

the

chime

and

lower

shell

area

(tank

resting

slightly

inside

and

below

the

foundation).

Additionally,

modifications

including

level

alarms,

high

liquid

level

shut‐off

system,

additional

aluminum

stilling

wells,

shell

patch

repairs,

addition

product

saver

tank

(PST),

product

pipe

repair,

reinforcement

pad

repair,

and

the

circumferential

stairway/platform

repairs

were

noted

some

the

alterations.

2. Tank

Foundation

The

tank

sits

coral

bed

and

perimeter

asphalt

pad

foundation

that

approximately

½"

¼"

lower

than

adjacent

concrete

ring

wall

foundation.

The

oldest

available

report

performed

November

1994

indicated

the

concrete

ring

foundation

was

approximately

four‐inches

away

from

the

edge

the

tank

bottom

extension

(chime).

The

concrete

ring

foundation

was

modified

the

past

eliminate

the

gap

between

the

chime

and

the

foundation.

However,

the

current

configuration

still

promotes

rain

water

intrusions

the

chime.

The

concrete

ring

foundation

extends

approximately

21‐inches

from

the

chime

and

elevated

approximately

4‐inches

from

the

dike

floor.

The

flexible

membrane

liner

(FML)

for

the

secondary

containment

attached

the

foundation

with

batten

strips.

Accessible

sections

the

foundation

were

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

against

the

bottom

the

tank.

Moderate

vegetation

was

present

throughout

the

foundation

chime

interface.

The

foundation

chime

interface

not

sealed.

There

minor

vegetation

from

the

earthen

secondary

containment

encroaching

towards

the

top

the

concrete

foundation.

The

foundation

not

designed

with

leak

detection

(tell‐tale)

system.

Shell

settlement

surveys

were

performed

during

the

inspection

accordance

with

Annex

API

Standard

653.

Settlement

results

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

are

listed

Appendix

There

indication

significant

settlement.

Overall,

the

foundation

appears

satisfactory

condition;

however,

repair

with

consideration

direct

water

away

from

the

chime

area

should

considered.

small

section

the

foundation

accessible

for

inspection.

3. Tank

Shell

The

tank

shell

constructed

from

carbon

steel

material

unknown

specification.

The

shell

cylindrical

design,

butt‐welded

together,

and

consisting

five

(5)

courses

with

one

angle

stiffening‐

ring

approximately

from

the

top

the

shell.

Evaluated

the

shell

for

plumbness,

roundness,

peaking,

and

banding;

all

which

were

found

within

the

allowable

tolerances

the

API

Standard

653.

Visually

inspected

the

exterior

the

shell.

Inspected

the

coating

for

dis‐bonding,

adhesion,

deterioration,

and

discoloration.

The

tank

shell

equipped

with

one

30"

manhole

and

one

20"

manhole

(180°

apart).

The

tank

equipped

with

shell

mounted

low

level

alarm

and

high‐high

level

alarms,

well

high‐level

shut‐off.

The

shell

was

evaluated

for

remaining

metal

thickness

utilizing

ultrasonic

technology.

The

ultrasonic

thickness

measurements

and

thickness

measurement

locations

(TML)

are

listed

the

Shell

Plate

Thickness

Measurements

table

Appendix

service

life

evaluation

performed

shows

the

shell

with

greater

than

years

remaining

life

under

current

conditions.

The

engineering

calculations,

per

API

Standard

653,

for

the

service

life

evaluation

are

shown

Appendix

under

“Service

Life

Evaluation.”

The

tank

shell

satisfactory

mechanical

condition.

4. Tank	Appurtenances
a. Geodesic	Dome	Roof

This

tank

retrofitted

with

clear‐span

aluminum

dome

cover

manufactured

Conservatek

Industries.

aluminum

geodesic

dome

roof

that

was

retrofitted

this

tank

circa

1990.

The

dome

joined

with

stainless

steel

fasteners

with

interlocking

panel

that

has

enclosed

gasket

compression

for

mechanical

seal.

The

batten

bars

and

gusset

cover

are

sealed

with

caulking

(external

joint

seals).

There

minor

moderate

caulking

deterioration

geodesic

roof

panel

caulking.

Inspection

the

dome

roof

limited

what

accessible

from

the

platform.

b. Gauging

The

tank’s

Enraf

(Model

854)

ATG

installed

through

8‐inch

carbon

steel

well.

The

stilling

well

slotted.

The

Enraf

system

was

not

working

order

the

time

the

inspection.

There

manual

gauging

and

sampling,

well

but

appears

this

action

performed

via

the

geodesic

roof

access

hatch.

The

ATG

water

probe

installed

the

same

ATG

stilling

well.

The

tank

equipped

with

float

and

tape

type

mechanical

tape

gauge

manufactured

Varec

(Model

2500).

The

system

not

good

working

condition.

c. Level

Alarms

The

high

level

alarm,

the

HLV

float

chamber,

and

the

high‐high

level

alarm

are

mounted

the

shell

and

are

accessible

via

the

circumferential

stairway.

The

tank

equipped

with

low‐level

alarm,

but

independent

low‐low

level

alarm

system

was

installed,

required

military

criteria.

d. Stairs

and

Platforms

The

tank’s

fixed

roof

accessible

circumferential

stairway

mounted

the

shell

the

tank

with

top

platform.

The

stairs

and

platform

were

inspected

for

corrosion

and

structural

soundness.

The

stairway

handrail

constructed

with

1½"

angle

iron

handrails

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

and

coated

steel

plate

treads

with

non‐slip

profile.

The

top

platform

galvanized

grating

type,

and

several

stairway

treads

were

replaced

the

past

with

carbon

steel

grating.

The

overall

general

condition

the

stairs

and

platform

are

mostly

satisfactory

(with

some

exception

–

See

Section

C).

e. Grounding

and

Bonding

There

are

two

grounding

cables

and

two

structure

lead

cables

that

are

mechanically

connected

lugs

the

tank’s

shell.

The

grounding

rod

penetrates

through

the

secondary

containment

floor

liner

and

attached

grounding

cable.

The

tank

not

equipped

with

copper

grounding

bar

for

personnel

static

electric

discharge

(typically

required

military

criteria).

5. Tank

Coating

The

tank

shell,

stairway,

handrails,

piping,

and

appurtenances

are

coated.

The

exterior

tank

coating

epoxy

with

polyurethane

top

completed

December

2014

(on

first

shell

course

and

nozzles;

the

rest

tank’s

coating

date

unknown).

The

exterior

shell

coating

mostly

satisfactory

with

isolated

coating

failures

the

top

shells

and

stiffening

ring.

Isolated

coating

failure

was

noted

the

appurtenances,

circumferential

stairway,

platform,

product

piping,

and

valves

within

the

secondary

containment.

6. Tank

Piping

System

The

fuel

received

through

6‐inch

carbon

steel

piping

and

product

issued

from

the

tank

through

6‐

inch

carbon

steel

pipe.

The

tank

also

equipped

with

other

auxiliary

piping

for

the

water

draw

(NPS

attached

product

saver

tank

(PST)

and

6‐inch

low

suction

piping

that

terminates

Camlock

fitting

adjacent

the

PST.

Inspected

and

evaluated

each

tank

nozzle

accordance

with

API

Standards

650

and

653.

Identified

the

type

and

use

each

shell

nozzle

and

measured

the

nozzle

neck

thickness

all

accessible

shell

nozzles.

Evaluated

all

nozzles

and

reinforcement

plates

for

leaks

and

corrosion.

7. Fire

Protection

System

The

storage

tank

equipped

with

surface

application

fixed

foam

fire

suppression

system

that

uses

mobile

foam

supply.

One

NPS

foam

chamber

mounted

approximately

inches

down

from

the

top

the

tank

shell

course

five.

All

Victaulic

couplings

for

the

fire

suppression

system

piping

have

deteriorated

fasteners.

Serval

locations

have

completely

failed

couplings.

fire

hydrants

were

noted

near

the

tank

during

the

inspection.

8. Secondary

Containment

The

tank

sits

inside

earthen

secondary

containment

basin

with

geotextile

liner

positioned

approximately

eight

ten

inches

below

the

soil

and

concrete

dike

walls.

The

overall

dimension

the

secondary

containment

131.42

feet

131.25

feet,

with

vertical

height

68.5"

(to

top

soil).

The

secondary

containment

equipped

with

drain

inlet

and

drain

valve

that

tie

the

underground

PVC

piping

system

the

OWS.

The

secondary

containment

release

valve

housed

inside

valve

pit

adjacent

the

drain

inlet

within

the

dike.

The

PVC

piping

system

manifolded

together

and

cannot

individually

isolated

outside

the

valve

pit.

The

drain

line,

the

drain

inlet,

and

valve

pit

were

visually

evaluated

determine

the

drainage

system

liquid‐tight.

The

valve

pit

has

rain

covers,

but

standing

water

was

noted

the

valve

pit.

Additional

testing

and

evaluation

may

required

determine

the

valve

pit

liquid‐tight.

The

liquid

the

valve

pit

was

lower

than

the

liquid

the

adjacent

drain

inlet

and

thus

suggests

that

the

drain

inlet

satisfactory.

However,

the

source

the

standing

water

the

valve

pit

should

determined.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

The

secondary

containment

was

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

growth.

Minor

hairline

cracks

(temperature

cracks)

and

some

moderate

cracks

were

noted

the

secondary

containment

wall.

approximate

total

147

linear

feet

cracks

the

secondary

containment

wall

were

identified.

Hairline

cracks

not

seriously

affect

the

strength

the

concrete

structures;

however,

these

cracks

can

potential

access

points

for

moisture

water

seepage

that

could

corrode

the

reinforcing

steel

(rebar).

There

are

several

test

port/anode

access

PVC

openings

around

the

perimeter

the

tank

that

penetrate

the

FML.

Some

these

PVC

openings

have

deteriorated

caulking.

The

secondary

containment

mostly

satisfactory

mechanical

condition,

with

the

exception

the

discrepancies

identified

Section

below.

Field

assessment

indicates

that

the

secondary

containment

sufficient

size

contain

total

tank

loss.

The

secondary

containment

partially

sloped

allow

for

drainage

away

from

the

tank.

formal

secondary

containment

evaluation,

accordance

with

CFR

112,

may

required

order

satisfy

federal,

state,

and

local

requirements.

9. Cathodic

Protection

impressed

current

Cathodic

Protection

(CP)

system

installed

this

tank

that

serves

multiple

ASTs

the

tank

farm

(Tank

13,

and

14).

The

system

manufactured

Corrpower

(Model

COYSE

50‐34R

Serial

CO11956).

This

unit

volt

ampere

air‐cooled

rectifier

unit

(numbered

and

mounted

the

outside

the

pumphouse

the

northeast

end

the

secondary

containment.

The

January

2017

report

provided

indicated

that

Tank

receiving

cathodic

protection

based

NACE

criterion.

The

rectifier,

anode

junction

box,

and

tank

junction

box

all

are

satisfactory

condition.

the

time

the

inspection,

the

rectifier

was

powered

and

serviceable

operation

condition.

Base

personnel

performed

the

required

testing

and

data

logging.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

C. FINDINGS AND RECOMMENDATIONS

The

tank

generally

not

accordance

with

current

military

criteria

for

some

the

tank

design,

appurtenances

and

piping

configuration.

Therefore,

the

recommendations

are

not

meant

bring

the

tank

into

full

compliance

with

UFC

3‐460‐01

78‐24‐27

standards

but

rather

identify

these

items

for

the

owner/user’s

planed

upgrades,

rehabilitation,

and

priority

repairs.

Mandatory

repairs

should

completed

assure

compliance

with

industry

standards,

well

federal

state

jurisdictional

requirements.

During

this

evaluation,

the

tank

was

found

generally

serviceable

condition,

with

imminent

risk

operation

and

overall

integrity.

However,

there

were

several

deficiencies

that

were

noted.

These

noted

deficiencies

are

listed

below

particular

order,

with

repair

recommendations.

All

repairs

and

modifications

should

performed

accordance

with

API

standard

653,

UFC

3‐460‐01,

DoD

Standard

Design

78‐24‐27,

and

applicable

UFGS

specifications.

1. MANDATORY

REPAIRS

per

API

653,

UFC

3‐460‐01,

78‐24‐27

Standards

Mandatory

repairs

represent

items

that

require

immediate

attention,

order

prevent

imminent

risk

system

operators,

equipment

integrity,

the

adjacent

environment.

The

tank

should

remain

out

service

until

these

repairs

are

completed.

No mandatory repairs were identified for this tank.

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

Required

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

These

items

are

required

API‐653

federal,

state,

and

local

codes.

a. Secondary

Containment

Cracks

OBSERVATION:

Unsealed

cracks

were

identified

the

secondary

containment

wall

(this

includes

areas

that

were

previously

sealed).

Code

REFERENCE:

CFR

Section

112.7(c)

states

that

the

entire

secondary

containment

system,

“including

walls

and

floor,

must

capable

containing

oil

and

must

constructed

that

any

discharge

from

primary

containment

system

...

will

not

escape

containment

before

cleanup

occurs.”

§§112.8(c)(2)

and

112.12(c)(2)

state

that

diked

areas

must

“sufficiently

impervious

contain

oil.”

RECOMMENDATION:

Repair

all

exposed

cracks

the

containment

walls

grinding

V‐shape

pattern,

with

least

¼‐inch

width

the

surface

and

depth

least

¼‐inch

and

sealing

with

flexible

urethane

(e.g.

Sikaflex

1c)

similar

approved

sealant

(Quantity:

147

linear

feet).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

b. Secondary

Containment

Expansion

Joint

Sealant

OBSERVATION:

There

are

areas

weathered

and

deteriorated

sealant

the

expansion

joints

for

the

secondary

containment

wall.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Remove

the

damaged

joint

sealant

and

install

new

backer

rods

and

sealant

within

the

containment.

The

sealant

shall

adequate

accommodate

joint

compression

equal

percent

the

width

the

joint.

The

backer

rod

shall

compressible

rod

stock

polyethylene

foam,

polyurethane

foam,

butyl

rubber

foam,

other

flexible,

non‐absorptive

material,

recommended

the

sealant

manufacturer.

Sealant

shall

conform

UFGS

Joint

Sealant

(Quantity:

linear

feet

–

three

locations).

c. Secondary

Containment

Drain

OBSERVATION:

The

valve

pit

has

rain

covers,

but

standing

water

was

noted

valve

pit.

The

liquid

the

valve

pit

was

lower

than

the

liquid

the

adjacent

drain

inlet

and

thus

suggests

that

the

drain

inlet

satisfactory.

However,

the

source

the

standing

water

the

valve

pit

should

determined.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Upgrade

the

concrete

drain

inlet

detailed

78‐24‐27

Drawing

CD.09

Detail

similar.

Use

ductile

iron

piping

lieu

the

PVC

dike

drain

lines.

minimum,

investigate

and

repair

source

water

inside

the

valve

pit.

Slope

dike

basin

surfaces

minimum

for

drainage.

Drainage

swales

should

sloped

flatter

than

0.5%

drainage

inlet

(see

78‐

24‐27).

Secondary Containment Drain

Valve Pit Rain Cover

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

d. Secondary

Containment

Liner

and

Penetration

OBSERVATION:

The

secondary

containment

has

liner

with

earthen

cover.

The

condition

the

liner

unknown,

but

some

penetration

including

the

PVC

cathodic

protection

anode

access

caps

and

the

tank

grounding

rod

sleeves

have

deteriorated

caulking

and

loose

hose

clamps.

The

majority

the

batten

strips

the

perimeter

foundation,

perimeter

dike

wall,

and

the

pipe

support

piers

are

not

accessible

for

inspection.

higher

rate

rain

displacement

was

noted

for

this

secondary

containment

compared

the

other

AST

dike

systems

(Particularly

Tank

and

without

earthen

cover).

Some

the

water

displacement

likely

due

the

water

absorption

rate

the

soil/vegetation.

However,

the

evaporation

the

excess

water

above

grade

expected

constant

for

all

dikes

unless

there

deteriorated

liner.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Reseal

all

PVC

FML

penetrations

and

secure

the

hose

clamps.

See

similar

application

over

concrete

78‐24‐27

Drawing

CD.02

Detail

e. Secondary

Containment

Liner

and

Penetration

OBSERVATION:

There

are

two

NPS

galvanized

pipe

caps

that

are

corroded

off

located

the

dike.

Both

penetrate

the

secondary

containment

floor.

This

potential

breach

the

secondary

containment

this

pipe

extends

outside

the

dike,

with

means

isolation.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Investigate

the

use

and

routing

the

galvanized

pipe.

Either

seal

off

remove

the

pipes.

Drain Valve Drain Inlet

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

f. Secondary

Containment

Wall

Penetration

OBSERVATION:

The

containment

piping

penetrates

through

the

secondary

containment

walls

without

the

use

adequate

pipe

sleeve/seal.

Some

have

been

retrofitted

with

compression

seals

but

not

have

pipe

sleeves

(Quantity:

8).

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Reseal

all

secondary

containment

wall

penetrations.

Consider

upgrading

all

secondary

containment

wall

penetrations

per

78‐24‐27

Drawing

CD.08

Detail

(CONCRETE

WALL

PENETRATION

DETAIL).

g. Foundation

and

Drainage

OBSERVATION:

There

joint

seal

between

the

concrete

foundation

and

the

shell

bottom

projection

(chime).

There

moderate

vegetation

and

isolated

coating

failure

with

corrosion.

The

tank

chime

approximately

½"

¼"

lower

than

adjacent

concrete

ring

wall

foundation.

The

current

configuration

promotes

rain

water

intrusions

the

chime

and

under

the

tank

bottom.

Code

REFERENCE:

API

653

section

4.4.2,

“Inadequate

drainage

resulting

surface

water

flowing

under

the

tank

bottom.”

See

also

78‐24‐27

Drawing

D.04

Detail

RECOMMENDATION:

Remove

all

vegetation

around

the

perimeter

the

chime.

Consider

sealing

the

gaps

between

the

edge

the

chime

and

concrete

direct

water

away

from

the

chime

area.

not

seal

the

top

the

chime.

Note

this

recommendation

not

line

with

78‐24‐27

Drawing

D.04

Detail

but

will

aid

eliminating

the

vegetation

and

water

intrusion

given

the

existing

configuration.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

h. Drips

Tubing

Fittings

OBSERVATION:

Small

drips

were

noted

the

stainless

steel

tubing

compression

fitting

for

the

high

liquid

level

shut‐off

valve.

Code

REFERENCE:

accordance

with

NFPA

30,

paragraph

21.8.6,

“Storage

tanks

and

their

appurtenances,

including

normal

vents,

emergency

vents,

overfill

prevention

devices,

and

devices,

shall

inspected

and

maintained

ensure

that

they

function

intended

accordance

with

written

procedures.”

RECOMMENDATION:

Replace

fittings.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

i. Deteriorated

Victaulic

Coupling

(Associated

with

the

Fire

Suppression

System)

OBSERVATION:

All

Victaulic

couplings

for

the

fire

suppression

piping

have

deteriorated

bolts.

Several

locations

have

completely

failed

Victaulic

couplings.

This

could

result

breach

the

secondary

containment

because

this

pipe

extends

outside

the

secondary

containment,

and

similar

type

corrosion

was

noted

the

coupling

fasteners

outside

the

dike.

section

the

fire

suppression

piping

also

routed

underground

outside

the

dike,

and

the

tightness

the

piping

unknown.

The

fire

suppression

system

will

not

function

with

these

deteriorated

coupling

fasteners.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above).

Also

NFPA

Section

4.7.1.4,

“Where

exposed

corrosive

influences,

the

piping

shall

corrosion

resistant

protected

against

corrosion.”

InterSpec

concludes

the

integrity

the

piping

dependent

the

fasteners

thus

incorporating

the

code

reference

for

the

coupling

fasteners.

RECOMMENDATION:

Replace

all

deteriorated

bolts,

couplings,

and

pipe.

Repair

the

pipe

meet

the

requirements

NFPA

Section

4.7.1.4

installing

stainless

steel

fasteners.

j. Corrosion

and

Pitting

Containment

Piping

OBSERVATION:

Areas

pitting

were

noted

on NPS

section

receipt

piping

the

welded

tee.

Code

REFERENCE:

API

574

Section

7.4.14

(Crevice

Corrosion).

API

574

Section

10.1.6.3

(Loss

thickness)

RECOMMENDATION:

Replace

the

spools

piping

that

have

significant

pitting

and

corrosion.

may

practical

conduct

detailed

API

STD

570

inspection

the

containment

piping

get

overall

condition

assessment.

NDT

tools

such

guided

wave

examination

can

also

employed

get

the

condition

inaccessible

areas

between

the

pipe

supports,

sleeved

piping,

wrapped

piping,

through

the

dike

wall

penetration.

Guided

wave

examination

screening

tool

used

inspect

large

sections

piping

from

single

test

location.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

k. Tank

Grounding

Lug

OBSERVATION:

The

tank

grounding

straps

are

bolted

the

tank

shell

(mechanical

joint

coated

interface)

and

have

reinforcement

plates

grounding

lugs

IAW

78‐24‐27

Drawing

ED.02

Detail

Code

REFERENCE:

78‐24‐27

Drawing

ED.02

Detail

(See

also

API

650

Section

5.8.11.3)

RECOMMENDATION:

Exothermically

weld

the

grounding

cables

the

lugs

and

install

reinforcement

the

shell,

accordance

with

78‐24‐27

Drawing

ED.02

Detail

Note:

repairs

are

elected

not

done,

the

paint

should

removed

where

the

cable

bolts

the

lug,

provide

better

connection

ground

(Quantity:

ground

connections

and

lead

cables).

Note

the

current

edition

API

STD

650

suggests

maximum

lug

spacing

100

ft.

with

minimum

four

lugs.

l. Product

Saver

Tank

(PST)

Grounding

OBSERVATION:

The

Product

Saver

Tank

not

grounded

the

leg

and

does

not

have

vent

installed

accordance

with

78‐24‐27

Drawing

D.13

Detail

A1.

The

PST

stainless

steel

tank

with

top

lid.

The

PST

tank

has

means

grounding.

Code

REFERENCE:

78‐24‐27

Drawing

D.13

Detail

A1.

accordance

with

NFPA

30,

paragraph

6.5.4,

“All

equipment

such

tanks,

machinery,

and

piping

shall

designed

and

operated

prevent

electrostatic

ignitions.

All

metallic

equipment

where

ignitable

mixture

could

present

shall

bonded

grounded.

The

bond

ground

both

shall

physically

applied

shall

inherently

present

the

nature

the

installation.”

RECOMMENDATION:

Install

ground

cable

and

vent

piping

the

Product

Saver

Tank

accordance

with

78‐24‐27

Drawing

D.13

Detail

(Quantity:

ground,

vent

pipe

NPS,

2‐feet

high).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

m. Shell

Manhole

Cover

with

Hinge

Davit

Arm

OBSERVATION:

The

shell

manhole

covers

are

not

equipped

with

hinge

davit

arm

facilitate

the

handling

the

manhole

cover

plates.

Code

REFERENCE:

API

STD

650

Section

5.8.3.5

states,

“Shell

manhole

covers

shall

have

two

handles.

Those

covers

weighing

than

(75

lb)

shall

equipped

with

either

hinge

davit

facilitate

the

handling

the

manhole

cover

plate.

The

davit

support

arm

shall

not

welded

directly

the

shell

without

reinforcing

plate.”

Also

78‐24‐27

drawing

D.10

detail

RECOMMENDATION:

Install

shell

manhole

davit

arm

IAW

with

API

STD

650

and

78‐24‐27

drawing

D.10

detail

(Quantity:

2).

Consider

increasing

shell

manhole

sized

36‐inches

during

the

AST

rehabilitation

project

(See

UFC

3‐460‐01

Chapter

12‐1)

n. Top

Platform

Grating

not

Secured

Down

OBSERVATION:

The

circumferential

stairway

top

platform

does

not

have

anchor/saddle

clips.

Code

REFERENCE:

OSHA

and

78‐24‐27

Drawing

D.11

Detail

“Grating

shall

anchored

with

saddle

clips.”

RECOMMENDATION:

Install

grating

anchors.

o. Circumferential

Stairway

Tread

Spacing

and

Corrosion

OBSERVATION:

The

circumferential

stairway

has

varying

tread

spacing

(rise).

This

was

noted

the

replacement

tread

(7"

9.5"

variance

noted).

Moderate

coating

failure

and

corrosion

were

noted

circumferential

stairway

treads

and

risers.

Code

REFERENCE:

OSHA

CFR

1910,

Subpart

“Stairs

have

uniform

riser

heights

and

tread

depths

between

landings”.

API

STD

650

Section

5.8.10

“Rises

shall

uniform

throughout

the

height

the

stairway.”

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

RECOMMENDATION:

All

future

tread

replacement

should

provide

rises

that

are

uniform

throughout

the

height

the

circumferential

stairway.

Replace

corroded

treads

(3)

and

risers

(5)

p. Circumferential

Stairway

Path

Restricted

OBSERVATION:

There

limited

restricted

path

the

circumferential

stairway

due

the

geodesic

dome

roof

flashing

projection

towards

the

circumferential

stairway.

There

intermediate

platform.

There

approximately

twenty

(20)

inch

clearance

between

the

handrail

and

the

geodesic

dome

roof.

This

reduces

the

existing

tread

width.

REFERENCE:

UFC

3‐460‐01

Section

Table

8‐1

item

OSHA

minimum

required

tread

width

inches

(1920.25(C)(3)).

See

also

API

650

Table

5.18

item

RECOMMENDATION:

Install

intermediate

platform

rework

the

circumferential

stairway

provide

sufficient

path

past

the

geodesic

dome

roof.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

q. Conduit,

Junction

Boxes,

Fittings

and

Mounting

Hardware

OBSERVATION:

The

conduits,

junction

boxes,

fittings,

and

mounting

hardware

within

the

secondary

containment

have

deteriorated.

This

will

not

meet

the

Class

Division

rating

requirements

for

hazardous

locations.

Code

REFERENCE:

All

wiring

and

fittings

Class

location

that

bulk

plant

terminal

must

comply

with

the

applicable

provisions

NEC

Article

501

Article

505

[515.7].

RECOMMENDATION:

Replace

all

corroded/deteriorated

conduits,

junction

boxes,

fittings,

and

mounting

hardware.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

3. RECOMMENDED

REPAIRS

Part

Regular

Maintenance

Recommended

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

a. Exterior

Coating

Failures

Tank

and

Appurtenances

OBSERVATION:

There

isolated

coating

failure

the

exterior

shell

mostly

around

the

stiffening

ring,

top

platform,

circumferential

stairway,

stiffening

ring,

and

shell

manholes.

Similar

isolated

coating

failure

was

noted

the

PST

pump,

HLV

tubing

support

mounting

brace,

and

low

level

and

high

level

sensor

chambers.

There

moderate

coating

failure

and

corrosion

noted

the

LLA,

HLA,

HHLA,

and

HLV

the

pipe

nipples

and

flanges.

Code

REFERENCE:

UFC

3‐460‐01,

Section

8‐3.10

and

Section

9‐10

RECOMMENDATION:

Mechanically

clean

and

recoat

the

areas

coating

failure

the

tank

shell,

circumferential

stairway,

landing,

piping,

and

appurtenances.

Repairs

should

accomplished

using

epoxy

based

coating

system

equivalent.

b. Tank

Marking

(NFPA

Diamond)

OBSERVATION:

The

tank

not

equipped

with

NFPA

marking.

Code

REFERENCE:

Mark

the

tank

accordance

with

NFPA

704.

78‐24‐27

Drawing

D.13

Detail

Note

4) “Provide

hazard

identification

system

labeling

accordance

with

NFPA

704.”

RECOMMENDATION:

Install

NFPA

704

marking.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

c. No

Faded

Confined

Space

Markings

Manholes

OBSERVATION:

The tank

not

equipped

with

confined

space

marking.

Code

REFERENCE:

accordance

with

OSHA

Regulation

CFR

1910.146(c)(2),

“If

the

workplace

contains

permit

spaces,

the

employer

shall

inform

exposed

employees,

posting

danger

signs

any

other

equally

effective

means,

the

existence

and

location

and

the

danger

posed

the

permit

spaces.

NOTE:

sign

reading

DANGER

‐‐

PERMIT‐REQUIRED

CONFINED

SPACE,

NOT

ENTER

using

other

similar

language

would

satisfy

the

requirement

for

sign.”

RECOMMENDATION:

Install

confined

space

markings

all

tank

entry

points.

d. Product

Saver

Tank

(PST)

Pump

and

Level

Alarm

OBSERVATION:

The

Product

Saver

Tank

(PST)

not

equipped

with

electrical

pump

and

does

not

have

high

level

alarms.

The

existing

diaphragm

operated

pump

has

moderate

corrosion

with

deteriorated

appurtenances

(broken

regulator,

corroded

air

filter

housing,

and

corroded

valve

handle).

Code

REFERENCE:

78‐24‐27

Drawing

D.13

Detail

IAW

UFC

3‐460‐01

Section

3‐6.6.7,

“Mount

permanently

installed

pumps

substantial

foundations

reinforced

concrete

designed

accordance

with

Hydraulic

Institute

Standards.”

RECOMMENDATION:

Consider

replacement

the

existing

system

accordance

with

78‐24‐27.

e. Tank

Electronic

ATG

and

Water

Probe

OBSERVATION:

The

tank’s

Enraf

(Model

854)

ATG

installed

through

8‐inch

carbon

steel

well.

The

stilling

well

slotted.

The

Enraf

system

was

reported

non‐working

order

the

time

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

the

inspection.

There

were

broken

conduits

and

exposed

wires.

The

water

probe

not

mounted

over

the

sump

and

installed

the

same

well

the

ATG.

Code

REFERENCE:

UFC

3‐460‐01

Table

8‐1

(item

and

78‐24‐27

Drawing

D.07

Detail

and

RECOMMENDATION:

Replace

repair

the

ATG.

Replace

the

stilling

wells

IAW

with

78‐24‐27.

f. Independent

Low‐Low

Level

Alarm

OBSERVATION:

The

tank

not

equipped

with

independent

low‐low

level

alarm.

There

low

level

alarm

sensor

installed

the

side

the

tank

shell

(see

photo

below).

Code

REFERENCE:

UFC

460

3‐460‐01

Table

8‐1(k)

and

78‐24‐27

Drawing

D.12

Detail

RECOMMENDATION:

Install

independent

low‐low

level

arm.

g. Mechanical

Tape

Gauge

(MTG)

OBSERVATION:

The

tank

equipped

with

float

and

tape

type

mechanical

tape

gauge

manufactured

Varec

(Model

2500).

The

system

not

working

condition.

The

checker

knob

did

not

respond

when

actuated.

The

viewing

window

cloudy

and

has

corroded

fittings.

Code

REFERENCE:

General

maintenance/manufacturer’s

instruction

and

UFC

3‐460‐01

Table

8‐1

(item

RECOMMENDATION:

Consider

replacement

the

existing

system

with

new

MTG.

Consider

increasing

the

elevation

the

gauge

head,

the

product

level

reading

window

“convenient

eye

level”

from

grade.

UFC

3‐460‐01

Section

8‐8.3

(item

lists

liquid

level

gauge

mounted

60”

above

the

walking

surface.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

h. Internal

Ladder

OBSERVATION:

There

internal

ladder

(note

roof

not

equipped

with

floating

roof

and

this

recommendation

may

deferred

until

IFR

installed).

Code

REFERENCE:

UFC

460

3‐460‐01

Table

8‐1(h)

and

78‐24‐27

Drawing

D.08

Detail

RECOMMENDATION:

Install

the

internal

ladder

(in

accordance

with

OSHA

criteria)

for

tanks

5,000

gallons

(19

000

larger

per

UFC

460

3‐460‐01

Table

8‐1(h)

and

78‐24‐27

Drawing

D.08

Detail

i. No

Sample

Gauge

Well

OBSERVATION:

There

manual

sampling/gauging

well.

Code

REFERENCE:

UFC

460

3‐460‐01

Table

8‐1(s)

and

78‐24‐27

Drawing

D.07

Detail

RECOMMENDATION:

Install

10‐inch

roof

nozzle

and

aluminum,

slotted

stilling

well

that

extends

within

inches

the

bottom

the

tank

for

gauging

and

sampling

with

datum

plate

establish

gauging

zero

point.

j. Double

Block

and

Bleed

Valve

Missing

Body

Pressure

Relief

OBSERVATION:

The

product

receipt

and

issue

double

block

and

bleed

valves

not

have

body

pressure

relief

system.

currently

plugged

off.

“Twin

Seal

valves

hold

bubble‐tight,

for

ease

opening

liquid

service,

important

prevent

trapped

body

pressure

from

exceeding

the

working

pressure

the

valve.

Therefore,

relief

system

required

prevent

pressure

buildup

the

body

cavity.”

Code

REFERENCE:

General

maintenance/manufacturer

instruction.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

RECOMMENDATION:	Install	a	differential	thermal	relief	(DTR)	system	with	pressure	discharging
toward	the	flow	path.

k. Product

Piping

Label

Marking

OBSERVATION:

The

majority

the

secondary

containment

piping

has

product

pipe

marking.

Faded

missing

markings

were

noted.

Code

REFERENCE:

78‐24‐27

Drawing

CD.13

Detail

(refer

MIL‐STD‐161G

for

correct

fuel

type)

RECOMMENDATION:

Reapply

the

product

piping

marking.

l. Faded

Tank

Marking

OBSERVATION:

The

tank

markings

have

faded/peeled.

Code

REFERENCE:

Mark

the

tanks

with

easily

discernible

painted

numbers

and

letters

indicating

the

following

addition

the

requirements

stated

MIL‐STD‐161:

Tank

number,

Facility

number,

“No

Smoking”

Class

tanks,

and

“Confined

Space”

Roof

Manhole/Ladder

Hatch

(UFC

3‐460‐01,

Section

2‐18).

RECOMMENDATION:

Replace

the

faded

tank

marking

IAW

NATO

requirements.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

m. Fixed

Roof

Deteriorated

OBSERVATION:

There

minor

moderate

caulking

deterioration

the

geodesic

dome

roof

panels.

Inspection

the

dome

roof

limited

what

accessible

from

the

platform.

Code

REFERENCE:

General

maintenance/

manufacturer

instruction

RECOMMENDATION:

Seal

the

top

side

the

geodesic

dome

roof

needed

eliminate

water

intrusion.

n. Roof	Hatch	Door	Fixed	Roof	Deteriorated	Caulking	Broken	Lid	Hinge
OBSERVATION:	The	geodesic	doom	roof	hatch	lid	has	a	broken	hinge.
Code	REFERENCE:	General	maintenance/	manufacturer	instruction
RECOMMENDATION:	Repair	hinge.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

o. Shell

Pit

and

Gouge

(No

Repair

Recommendation)

OBSERVATION:

There

one

area

isolated

pitting

shell

course

two

and

three

gouge

areas

shell

course

one

(See

Shell

drawing

layout).

The

pitting

depth

0.130"

and

the

max

gouge

depth

0.120"

Code

REFERENCE:

API

653

Section

9.4,

“The

need

for

repairing

indications

such

cracks,

gouges

tears

(such

those

often

remaining

after

the

removal

temporary

attachments),

widely

scattered

pits,

and

corroded

areas

discovered

during

inspection

the

tank

shell

shall

determined

individual

case

basis

accordance

with

Section

4.”

RECOMMENDATION:

repairs

recommend

this

time

(isolate/greater

than

tmin

calculation).

Revaluate

the

API

STD

653

inspection

interval.

Repair

the

API

STD

653

out‐of‐service

inspection.

p. Personnel

Static

Electric

Discharge

OBSERVATION:

The

tank

not

equipped

with

copper

grounding

bar

for

personnel

static

electric

discharge

(typically

required

military

criteria).

Code

REFERENCE:

UFC

3‐460‐03

Section

2‐3.21

and

78‐24‐27

Drawing

D.11

Detail

RECOMMENDATION:

Install

copper

grounding

bar

for

personnel

static

electric

discharge

the

base

the

circumferential

stairway.

q. AST Exterior

Fire

Protection

Water

Systems

OBSERVATION:

The

tank

does

not

appear

meet

the

equipment

requirement

for

AST

exterior

fire

protection

system.

The

stand

post

mounted

water

jet

monitor

was

noted

along

the

facility

fence

line

northeast

corner

the

dike.

Code

REFERENCE:

UFC

3‐460‐03

Section

2‐15.2.1

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

RECOMMENDATION:

Install

additional

services

for

the

tank

exterior

fire

protection

water

systems

IAW

UFC

3‐460‐01

Section

2‐15.2.1

(fire

protection

water

mains,

hydrants,

valves,

pumps,

and

application

devices

outside

dike)

control

brush

and

grass

fires

and

cooling

storage

tanks

the

event

fire

exposure.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1	SHELL	SERVICE	LIFE	EVALUATION
A.2	SHELL	SETTLEMENT	EVALUATION
A.3	ULTRASONIC	UT	DATA
A.4	CONTAINMENT	LAYOUT	DRAWING
A.5	SHELL	LAYOUT	DRAWING
A.6	OSHA	ACCESS	STRUCTURE	REPORT

Where:

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

t nom = nominal shell thickness, in inches.

t act = current measured shell thickness, excluding pits and corrosion, in inches.

t prev = previous measured shell thickness, excluding pits and corrosion or t nom , in inches.

D = nominal diameter of the tank, in feet.

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

H c = calculated safe fill height, in feet, for the current product.

G = specific gravity of the contents.

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

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

S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of 0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S =21,000 psi. For elevated temperatures above

200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API Standard 650 Appendix M or the product design stress value listed in Table M-1a or M-1b of API Standard 650.

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

L r = remaining life of the shell, in years.

C r = shell corrosion rate, in inches per year.

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

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

Y = years between the previous measured shell thickness (t prev ) and the current measured shell thickness (t act ), in years.

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

A.1 Shell Service Life Evaluation tmin =

2.6(H−1)DG

Lr = tact − tmin

Cr Cr = tprev − tact Y Iut = tact − tmin 2Cr

Iv = tact − tmin

4Cr

1) Minimum Required Thickness

D = 45 feet

G = 0.845

𝞓Y = 66 years

Course

No.

Plate

Specification

Course

Height

(feet)

Product

Height

(feet)

(H )

Maximum

Allowable

Stress

(psi)

(S )

Joint

Efficiency

(E )

Minimum

Acceptable

Thickness

(inches)

(t min )

Measured

Thickness

(inches)

(t prev )*

Current

Measured

Thickness

(inches)

(t act )

1 Unknown 6 26 23,600 0.85 0.123 0.2656 0.248

2 Unknown 6 20 23,600 0.85 0.100 0.2656 0.25

3 Unknown 6 14 26,000 0.85 0.100 0.2656 0.249

4 Unknown 6 8 26,000 0.85 0.100 0.2656 0.243

5 Unknown 6 2 26,000 0.85 0.100 0.2656 0.258

*The t prev values were based on t nom .

A.1 Shell Service Life Evaluation

0.000

0.050

0.100

0.150

0.200

0.250

0.300

1 2 3 4 5

In c h e s

Course

Thickness Graph tprev tact tmin

A.1 Shell Service Life Evaluation

2) Corrosion Rate, Remaining Life and Inspection Intervals

Course

No.

Corrosion

Rate

(in./yr)

(C r )

Remaining

Life

(years)

(L r )

Visual

Inspection

(years)

(I v )

Ultrasonic

Thickness

Inspection

(years)

(I ut )

1 0.00027 467 5 15

2 0.00024 634 5 15

3 0.00025 592 5 15

4 0.00034 417 5 15

5 0.00012 1372 5 15

* Let C r =0.0002 inches per year for calculation purposes.

Note: The engineering data used to calculate in-service period of operation (Remaining Life) assumes the tank remains…

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