Attachment J.3 Arnold-Fac 807 (Tank 11)-FINAL-2018.pdf

US Army Corps of Engineers Omaha District

API 653 Out-of-Service Inspection Report

Arnold AFB, Tennessee Facility No. 807

Tank No. 11

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

(USACE POL-MCX)

May 2018

API 653 Out-of-Service Inspection Report Arnold AFB, TN

TABLE OF CONTENTS

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

CONTAINMENT SUMP, DRAIN PIPE AND DRAIN VALVE

TANK BOTTOM INSPECTION

INTERVAL TO NEXT INSPECTION

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ENCLOSED IN APPENDIX B)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Evaluation Items

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, UFC 3-460-01, or AW 78-24-27 Standards

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

D. INSPECTION INTERVALS

1. Routine In-Service Inspection

2. External (In-Service) Inspection

3. Ultrasonic Thickness Inspection

4. Internal (Out-of-Service) Inspection

APPENDIX A: TANK EVALUATION ITEMS

APPENDIX B: ENGINEERING CALCULATIONS AND DRAWINGS

1. FLOOR DRAWING

2. INTERIOR FLOOR UT AND COATING

3. INTERIOR FLOOR CRITICAL ZONE UT

4. FLOOR PROJECTION

5. TILT CALCULATIONS

6. SETTLEMENT CALCULATIONS

7. SHELL ELEVATION DRAWING

8. EXTERIOR SHELL UT AND COATING

9. EXTERIOR 1ST SHELL COURSE UT

10. INTERIOR 1ST SHELL COURSE COATING

11. SHELL MANHOLE AND NOZZLE UT

12. SHELL CORROSION CALCULATIONS

13. ROOF DRAWING

14. ROOF EXTERIOR UT AND COATING

15. ROOF CORROSION CALCULATIONS

16. EMERGENCY VENTING CALCULATIONS

17. TANK EVALUATION SPREADSHEET

18. OSHA ACCESS STRUCTURE REPORT

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

AFB Air Force Base

API American Petroleum Institute

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DBB Double Block and Bleed

DFT Dry Film Thickness

FML Flexible Membrane Liner

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LF Linear Feet

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NDT Non-Destructive Testing

NFPA National Fire Protection Association

OOS Out-of-Service

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

SF Square Feet

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UTT Ultrasonic Thickness Testing

VT Visual Testing

GENERAL SUMMARY

Enterprise Engineering Inc. (EEI) was retained by the United States Army Corps of Engineers (USACE), Omaha District, under Contract No. W9128F-17-D-0021 Delivery Order W9128F17F0168 to perform an out-of service (OOS) API 653 inspection of Tank 11 (Facility 807) at Arnold Air Force Base, Tennessee.

The OOS API 653 inspection was performed 26-27 February 2018 in accordance with the applicable portions of API Standard 653, UFC 3-460-01, UFC 3-460-03 and the Statement of Work (SOW).

Tank 11 is a field erected, vertical, aboveground storage tank. The tank was constructed in 1956. The nominal tank diameter is 20 feet and the shell height is 18 feet. The tank is of welded construction with butt-welded shell, floor and roof plates. The nominal shell capacity is 1,000 Bbls. The tank is not equipped with a floating pan and is currently in Jet A service. Secondary containment is provided by a reinforced concrete dike floor and walls. The south and west containment walls are covered with a flexible membrane liner.

The tank floor is covered with a thick-film epoxy. The surface profile is extremely rough, thus preventing MFL floor scanning and limiting UT scanning. The tank floor is not inspectable and its condition is indeterminate. However, the thick-film liner is in good condition and the tank may be returned to service in the short term. On 27 February 2018, the facility was directed by the USACE and AFPET to leave Tank 11 out of service pending coating removal and re-inspection of the floor. Additional noted deficiencies are discussed in Section C and should be addressed in a timely manner. Photographs of the deficiencies are also included in Section C. Additional photographs are included in Appendix D.

CONTAINMENT SUMP, DRAIN PIPE AND DRAIN VALVE

The sump failed hydrostatic testing. The drain piping and drain valve were found to be acceptable.

TANK BOTTOM INSPECTION

The thick-film liner was removed from the tank floor and lower portion of the first shell course at the direction of the USACE. Pond was retained by the United States Army Corps of Engineers (USACE) to perform an out-of-service (OOS) API 653 inspection of the tank floor. The inspection was performed by Pond on 10 April 2018. Pond prepared an Internal Bottom Inspection Report dated April 2018.

INTERVAL TO NEXT INSPECTION

The next API 653 In-Service (external) Inspection should be performed by February 2023 (5 years).

The next API 653 Out-of-Service (internal) Inspection, as recommended by Pond, should be performed by April 2038 (20 years) if all mandatory repairs are completed. EEI takes no exception to the recommended interval to the next internal inspection.

INSPECTION DATE

API Out-of-Service (Internal) Inspection Date: 26-27 February 2018

Equipment Used:

Manufacturer: MFE Enterprises Tank Floor Scanner Model Number: MFE 2412 Mark 2 Calibration Method: Calibration plate with known defects

Manufacturer: Positector Dry Film Thickness (DFT) Gauge

Model Number: 6000

Calibration Method: Calibration to know thickness standard

Manufacturer: Pro Shot Rotary Laser Level

Model Number: L3

Calibration Method: Manual leveling

Inspectors:

David A. Stchyrba, P.E.

Shaun C. Wilson

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections N/A

State Regulation for API Out-of-Service Tank Inspections N/A

The Tennessee Department of Environment and Conservation does not regulate aboveground storage tanks.

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: August 2008

API In-Service (External) Inspection Date: Unknown

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ENCLOSED IN APPENDIX B)

API Out-of-Service (Internal) Inspection Date: 10 April 2038 (20 years)

API In-Service (External) Inspection Date: 26 February 2023 (5 years)

David A. Stchyrba, P.E.

Project Manager – Structural

Enterprise Engineering Inc.

API 653 Certified Inspector No. 27187 sjd Line

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Air Force Location Arnold Air Force Base Facility Number 807 Tank Number 11 State / Country Tennessee / United States City Manchester Inspection Date 26-27 February 2018 Tank Manufacturer Unknown Design Standard API Standard 12C Date of Construction 1956 Tank Contents Jet A Tank Serial Number None present Tank Diameter 20’-0” Shell Height 18’-0” Product Height 16’-8” Tank Capacity 42,000 gallons (1,000 BBLS) Foundation Concrete Ringwall

Construction

Bottom Flat, slight cone-up to side sump / butt welded Shell Butt-welded / 3 courses Floating Roof N/A Fixed Roof Cone-up self-supported / butt welded

Material

Bottom Steel / Unknown grade Shell Steel / Unknown grade Floating Roof N/A Fixed Roof Steel / Unknown grade

Cathodic Protection Not present

Interior Coating System Floor: Thick-film epoxy Shell: Thin-film epoxy Roof: Uncoated

Exterior Coating System Shell: Thin-film epoxy Roof: Thin-film epoxy

Level Gauging Varec tape gauge system ENRAF ATG system

Overfill Protection High level shut off valve on Fill piping Piping Receipt 6 inch reduced to 4 inch Carbon steel

Issue 6 inch reduced to 4 inch Carbon steel Low Suction Not equipped Water Draw-Off 4 inch drain in floor plate Carbon steel

Level Alarms Scully high-high, high, low and low-low level alarms; ENRAF ATG alarms Type of Internal Floating Roof Not equipped

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection An OOS API 653 inspection was performed 26-27 February 2018 on Tank 11 (Facility 807). Results of this inspection identified mandatory repairs, recommended repairs and upgrades required to comply with API 650, API 653, UFC 3-460-01, UFC 3-460-03, AW 78-24-27 and industry standards.

2. Site Information Arnold AFB is located in Tennessee. The base is home to the Arnold Engineering Development Complex (AEDC). The facility operates aerodynamic and propulsion wind tunnels, rocket and turbine engine test cells, space environmental chambers and other specialized units.

B. TANK INSPECTION COMMENTS

1. Tank Construction Tank 11 (Facility 807) is a field erected, vertical, aboveground storage tank. The tank was constructed in 1956. The nominal tank diameter is 20 feet and the shell height is 18 feet. The tank is of welded construction with butt-welded shell, floor and roof plates. The nominal shell capacity is 1,000 Bbls and the design liquid level is 16-feet 8-inches. The tank is not equipped with a floating pan and is currently in Jet A service. Design drawings for the 2008 installation of the stilling wells, partial roof handrails and access ladder were available for review.

2. Tank Evaluation Items Refer to Appendix A for a discussion of the tank evaluation items. The information has been provided in a tabular format for reference.

C. FINDINGS AND RECOMMENDATIONS

The following subsections outline the tank repairs/upgrades. Repairs and upgrades shall be completed in accordance with API requirements and usual and customary engineering practice.

1. MANDATORY REPAIRS per API 653, UFC 3-460-01, or AW 78-24-27 Standards Mandatory repairs represent items that require immediate attention, in order to prevent imminent risk to system operators, equipment integrity, or the adjacent environment. The tank should remain out of service until these repairs are completed.

a. Backside Corrosion of Tank Floor OBSERVATION: The tank floor was covered with a thick-film epoxy. The surface profile was extremely rough and prevented MFL floor scanning and limited UT scanning at the time of the February 2018 inspection. As backside corrosion was identified at adjacent Tanks 5 and 9, which are of similar vintage and construction, potential backside corrosion was a concern at Tank 11.

REFERENCE: API 653 4.4.4 Bottom Plate Thickness Measurements

RECOMMENDATION: Remove the coating from the tank floor and perform MFL scanning with UT prove up of any indications that are detected. The thick-film liner was removed from the tank floor and lower portion of the first shell course at the direction of the United States Army Corps of Engineers (USACE). Pond was retained by the USACE to perform an out-of-service (OOS) API 653 inspection of the tank floor. The inspection was performed by Pond on 10 April 2018 and an Internal Bottom Inspection Report dated April 2018 was prepared. A total of 16 topside pits were identified. Pond identified ten pits for mandatory repair in order to permit an interval of 20 years to the next out-of-service inspection. The repair recommendations included a combination of weld overlay and lapped patch plates. Upon completion, provide a coating system in accordance with UFGS 09 97 13.15 Low VOC Polysulfide Interior Coating of Welded Steel Petroleum Fuel Tanks.

EEI COMMENT: The topside pits identified by Pond were relatively shallow compared to the thickness of the floor plate. The corrosion of the topside pits can be considered to be arrested with the installation of a thin-film liner. It is EEI’s opinion that repair of the topside pits is not required if the floor is recoated; EEI, however, takes no exception to repairing the pits at this time as a preventative measure.

2. REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Required repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment. These items may be required by Federal, State and Local Codes or by Military Criteria.

a. Non-Compliant Weld Clearances OBSERVATION: The weld clearance between the underside of the reinforcing plate at manways 1 and 2 to the floor-to-shell weld, between the reinforcing plate at the fill nozzle to the anchor strap and between the pressure relief nozzle to the reinforcing plate at the transfer nozzle is less than the 3-inch minimum required per API 650.

REFERENCE: API 650 Figure 5.6

RECOMMENDATION: Provide magnetic particle (MT) examination of the welds with non-compliant clearance. Inspect the shell-to-floor weld and weld along the bottom of the reinforcing plate for cracks, lack of fusion, incomplete penetration, and other rejectable defects. Repair rejectable defects by grinding to remove the defect. Examine the repair using MT. Provide surface preparation and coating repairs at the repair locations.

Note: Contact the Government for further direction if grinding to eliminate the weld defects will exceed the base thickness and weld size requirements. Contact the Government for direction on appropriate repair procedure if cracks are found.

b. Emergency Venting OBSERVATION: The tank is equipped with a 6-inch atmospheric vent and a 3-inch P/V vent. The total capacity of the existing vents is less than the required venting capacity of 546,000 CFH based on tank geometry.

REFERENCE: NFPA 30 ¶ 22.7

RECOMMENDATION: Remove the existing 6-inch atmospheric vent. Provide an 8-inch emergency vent with a minimum capacity of 504,818 CFH.

c. Containment Drain Inlet OBSERVATION: The containment area includes a sump with a drain line to the containment area north of the tank. The sump was constructed with brick and mortar and has not been lined. The sump failed hydrostatic testing.

REFERENCE: SOW 2.3.1 h

RECOMMENDATION: Line the sump to make it liquid-tight to maintain the integrity of the secondary containment.

d. Floor Projection Sealant OBSERVATION: There is no sealant between the underside of the tank floor projection and the concrete ringwall. Moss and organics were observed growing within the space.

REFERENCE: AW 78-24-27 Sheet D.04, Detail 3

RECOMMENDATION: Remove all of the organics. Clean and prime surfaces. Provide jet fuel resistant polysulfide sealant. Estimated quantity: 63 L.F.

e. Pitting in Receipt Piping OBSERVATION: There is pitting that ranges from 1/16-inch to 1/8-inch on the 4-inch receipt piping. The nominal pipe wall thickness for schedule 40 pipe is 0.237-inches. This represents a wall loss of up to 53%. The corrosion was arrested and fully coated at the time of the inspection.

The pitted area extends from the containment wall to 4-feet 6-inches inward towards the tank.

Additionally, there is staining at the containment wall that indicates that there is corrosion on the pipe segment within the wall.

REFERENCE: Usual and customary engineering practice

RECOMMENDATION: Provide an engineered design to remove the section of pitted piping through the containment wall and provide new 4-inch piping with an 8-inch casing. The casing shall include a segmented elastomeric seal and any required support/anchoring provisions.

f. Tank Anchors OBSERVATION: The tank is equipped with four anchors. The anchor spacing of 15-feet 8-inches exceeds the API 650 maximum spacing of 10-feet. They are a variation of an anchor strap but were not constructed in accordance with the requirements of API 650. The straps are bolted to the side of the concrete instead of embedded within the concrete foundation. The straps do not contain a taper to ensure that the strap will yield before the tank shell. The concrete ringwall did not exhibit cracking at the bolts at the time of the inspection. However, cracks were observed in the concrete at Tank 5 which is of similar construction.

REFERENCE: API 650 ¶5.12

RECOMMENDATION: Monitor the concrete at each of the anchor bolts for diagonal shear cracking as part of routine inspections. Overturning calculations were performed considering the tank as unanchored. It was found that the tank is stable and not subject to sliding or overturning due to wind or seismic forces. No additional repairs are recommended.

g. Tank Floor Coating Failures OBSERVATION: Coating failures were observed on the interior tank floor. The failures appear to be the result of welding that occurred during the installation of the stilling wells in 2008.

REFERENCE: UFC 3-460-03 ¶8-3

RECOMMENDATION: If the tank floor coating is not removed per Mandatory Repair a. Backside Corrosion of Tank Floor, provide surface preparation and recoat. Estimated quantity: 10 S.F.

h. Interior Roof Plate Coating OBSERVATION: The tank interior is fully coated except for the underside of the roof plate. The outer perimeter has been coated as result of overspray from the tank shell. The underside of the roof plate exhibits widespread rust.

REFERENCE: UFC 3-460-01, Chapter 12 – Major Rehabilitation and Chapter 8 ASTs

RECOMMENDATION: ¶12-3.6 states that when tanks are taken out of service for inspection or repairs, inspect the underside of the roof for rust. If conditions merit, coat the underside of the roof in conformance with Chapter 8. ¶ 8-3.9 requires that the underside of the roof shall be coated for tanks in aviation service. Coat the underside of the tank roof in accordance with UFGS 09 97 13.15 Low VOC Polysulfide Interior Coating of Welded Steel Petroleum Fuel Tanks.

i. ATG Displacer OBSERVATION: The tank is equipped with an ENRAF ATG system that includes a displacer. The displacer is located within an 8-inch stilling well. The displacer was not retracted at the time of the inspection.

REFERENCE: Usual and customary engineering practices

RECOMMENDATION: Contact SPAWAR to review the ATG system to verify accuracy.

j. Thermal Relief OBSERVATION: The fill piping has been equipped with thermal relief. The issue piping and the transfer piping to Tank 9 have not been equipped with thermal relief piping.

REFERENCE: AW 78-24-27 Sheet D.10, Detail 4

RECOMMENDATION: Perform a thermal relief analysis of the piping to determine if additional thermal relief piping is required.

Fill Issue Transfer

TRV

k. Stainless to Carbon Steel Piping OBSERVATION: There is a stainless steel to carbon steel weld at the 4”x6” reducer on the issue piping.

REFERENCE: UFGS 33 52 43 ¶3.1.1.2

RECOMMENDATION: These types of connections are common in industry following properly developed welding procedures for the metals involved. There is no record of the procedure that was followed for this connection. It is recommended to remove the coating from the weld and perform PT inspection of the weld. For long term repair, it is recommended that a flanged connection with isolation kits be provided.

l. Roof Manholes OBSERVATION: The tank is not equipped with roof manholes.

REFERENCE: UFC 3-460-01 Table 8-1 Item e

RECOMMENDATION: There is no compelling reason to provide a roof manhole(s). During cleaning of the tank, the ventilation unit was bolted to the nozzle containing the manual gauge hatch. The tank is not equipped with a floating pan requiring inspection nor is there an internal ladder.

This item has been included for completeness to document a non-conformance condition with military criteria.

m. Shell Manholes OBSERVATION: The tank is equipped with one 24-inch and one 30-inch manhole which is less than the current requirement for two 36-inch manholes.

REFERENCE: UFC 3-460-01 Table 8-1 Item f

RECOMMENDATION: There is no compelling reason to provide larger shell manholes. The installation of a shell manhole would require a full height hydrostatic test. This item has been included for completeness to document a non-conformance condition with military criteria.

n. Nozzle for Water Bottom Sensor OBSERVATION: The tank is not equipped with one 8-inch flanged roof nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor above the floor drain.

REFERENCE: UFC 3-460-01 Table 8-1 Item s and AW 78-24-27 Sheet D.07, Detail 3

RECOMMENDATION: Provide one 8-inch flanged roof nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor above the floor drain. It should be noted that the corresponding location on the tank roof is not protected by the partial handrail system.

Although this is a non-conformance issue with military criteria, it is further recommended to review the need for bottom water sensing with facility personnel based on existing tank service and operations.

o. Fill Piping OBSERVATION: The tank is not equipped with interior fill piping or a diffuser.

REFERENCE: UFC 3-460-01 Table 8-1 Item u and AW 78-24-27 Sheet D.08, Detail 1

RECOMMENDATION: Provide interior piping, including a diffuser. It should be noted that the existing 6-inch nozzle may require complete replacement since it extends inward less than 1-inch past the shell. The tank has been in service without interior piping since 1956. Although this is a non-conformance issue with military criteria, it is further recommended to review the need for interior piping with facility personnel based on existing tank service and operations.

p. Main Suction and Low Suction OBSERVATION: The tank is not equipped with interior issue piping. The tank is not equipped with a low suction nozzle or interior low suction piping.

REFERENCE: UFC 3-460-01 Table 8-1 Item v and AW 78-24-27 Sheet D.08, Detail 4

RECOMMENDATION: Provide interior issue piping. It should be noted that the existing 6-inch nozzle may require complete replacement since it extends inward less than 2-inches past the shell. Given the tank volume and floor drain construction, there is no compelling reason to provide low suction piping. The tank has been in service without interior piping since 1956.

Although this is a non-conformance issue with military criteria, it is further recommended to review the need for interior piping with facility personnel based on existing tank service and operations.

q. Water Draw-Off OBSERVATION: The tank is not equipped with a shell mounted water draw-off.

REFERENCE: UFC 3-460-01 Table 8-1 Item aa and AW 78-24-27 Sheet D.13, Detail 5

RECOMMENDATION: No repair is recommended at this time. The tank is equipped with a 4-inch floor drain. There is no compelling reason to provide a separate water draw-off system. This item has been included for completeness to document a non-conformance condition with

r. Ball Joints OBSERVATION: The tank piping is not equipped with ball joints to relieve strain caused by tank settling or seismic activity.

REFERENCE: UFC 3-460-01 Table 8-1 Item ee

RECOMMENDATION: No repair is recommended at this time. It has been the experience of EEI that the integrity of ball joints is suspect and that leaks have been known to occur. It is the opinion of EEI that it is not necessary to retrofit the piping to include ball joints. This item has been included for completeness to document a non-conformance condition with military criteria.

s. Cable Supports OBSERVATION: The tank is not equipped with scaffold cable supports.

REFERENCE: UFC 3-460-01 Table 8-1 Item ff

RECOMMENDATION: No repair is recommended at this time. There is no compelling reason to provide scaffold cable supports. This item has been included for completeness to document a non-conformance condition with military criteria.

t. Cathodic Protection OBSERVATION: The tank is not equipped with a cathodic protection system to protect the tank floor.

REFERENCE: UFC 3-460-01 Chapter 2 General Design Info and Chapter 12 Major Rehabilitation

RECOMMENDATION: ¶2-13.1 states that for all underground steel tanks and tank bottoms of aboveground vertical tanks, provide cathodic protection. ¶12-8 states that when rehabilitating any fuel system, install or upgrade cathodic protection. Backside corrosion was identified at Tanks 5 and 9 and may be present at Tank 11. The installation of a CP system is not recommended. To install a CP system, the shell would have to be slotted and a double bottom with sand pad provided. The installation of a double bottom would require a hydrostatic test.

This item has been included for completeness to document a non-conformance condition with

u. Roof Handrail OBSERVATION: The tank has been equipped with a partial roof handrail. Two partial segments were installed in 2008 on each side of the roof access ladder. Two partial segments were installed at the center of the roof at an earlier date.

REFERENCE: AW 78-24-27 Sheet D.11, Detail 5 and UFGS 33 56 13.13 ¶2.13.9

RECOMMENDATION: Provide a full perimeter handrail to allow unrestrained access to all portions of the roof.

v. Circumferential Stairway OBSERVATION: The tank is not equipped with a circumferential stairway. The roof is accessed by a ladder.

REFERENCE: AW 78-24-27 Sheet D.11, Detail 4 and UFGS 33 56 13.13 ¶2.13.7

RECOMMENDATION: Although AW and UFGS specify a circumferential stairway, there is no compelling reason to provide one at this time. This item has been included for completeness to document a non-conformance condition with military criteria.

w. Manway Davits OBSERVATION: The tank is equipped with two shell manways. Neither manway has been equipped with a davit to assist with cover plate removal.

REFERENCE: AW 78-24-27 Sheet D.10, Detail 3 and UFGS 33 56 13.13 ¶2.13.16

RECOMMENDATION: Provide manway davits.

x. Shell Valves OBSERVATION: The 6-inch transfer line is equipped with a 6-inch x 4-inch internal emergency valve and a 4-inch ¼-turn ball valve instead of double block and bleed plug valve. The 4-inch drain piping is equipped with a 4-inch gate valve instead of a DBB valve.

REFERENCE: AW 78-24-27

RECOMMENDATION: At the transfer line, remove the existing valves and provide a 6-inch DBB valve and a 6-inch x 4-inch concentric reducer. At the drain nozzle, remove the existing valve and provide a 4-inch DBB valve.

3. RECOMMENDED REPAIRS as Part of Regular Maintenance Recommended repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Exterior Tank Coating OBSERVATION: Moss and dirt were observed on the exterior tank shell and roof

REFERENCE: DUFC 3-460-03 ¶8-3

RECOMMENDATION: Pressure wash the entire tank to remove the organics.

b. Exterior Coating Failure OBSERVATION: Coating failure and corrosion was observed on the tank floor projection, valve flanges, actuator handles, level alarm floats and roof appurtenances.

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Provide surface preparation and recoat. Provide stainless steel hardware for all roof appurtenances.

c. Concrete Ringwall Deterioration OBSERVATION: The tank is on a reinforced concrete ringwall. Past concrete delamination was observed at one location.

REFERENCE: API 653 ¶4.5.2.2

RECOMMENDATION: Repair the deteriorated concrete to maintain support of the tank shell and floor projection. Estimated quantity: 2 S.F.

d. Manway Reinforcing Plate Telltale Holes OBSERVATION: The telltale hole in the nozzle reinforcing plate at manway 1 is open. A minor amount of rust is streaking from the hole. It is an API requirement that the holes remain open.

REFERENCE: API 650 ¶5.7.2.10

RECOMMENDATION: Remove the rust streak. Do not provide a threaded plug. The usual repair is to pack the hole with white grease. However, facility personnel reported that the grease fails due to extreme temperatures. Re-packing the hole is not recommended.

e. Chain to P/V Vent OBSERVATION: The tank is equipped with a 6-inch atmospheric vent and a 3-inch lever loaded pressure/vacuum vent with a flame arrestor. Facility personnel reported that the internal components of the flame arrestor have been removed. A chain is connected to the weight actuated pressure/vacuum vent and extends to grade. The chain is abrading the coating on the tank shell

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Remove the combination 3-inch vent and provide a pressure/vacuum vent.

Remove the chain as soon as possible to stop abrasion of the coating.

f. Organic Growth on Piping OBSERVATION: Organic growth was observed on the exterior piping at the 6 o’clock position.

REFERENCE: UFC 3-460-03 ¶8-3.1

RECOMMENDATION: Pressure wash the piping.

g. Secondary Containment Sealant OBSERVATION: The tank is located within a concrete containment area. Scattered failure of the sealant in the dike floor and walls was observed.

REFERENCE: UFC 3-460-03, ¶8-10.2

RECOMMENDATION: It is recommended to replace all of the sealant at one time to prevent having sealant of different ages. Remove the sealant from the joints. Clean and prepare concrete surfaces by mechanical means to achieve desired surface profile. Prime surfaces in accordance with manufacturer recommendations. Provide jet fuel resistant polysulfide sealant. Note:

Facility personnel reported that a project is in place to execute sealant repairs.

Estimated quantities:

Ringwall-to-Floor Joint: 63 L.F.

Concrete Walls: 30 L.F.

Wall-to-Floor Joint: 140 L.F.

Floor Joints: 310 L.F.

h. Testing

OBSERVATION: The tank is equipped with an ENRAF ATG system, a high level shut off valve and an independent level alarm system.

REFERENCE: UFC 3-460-03 Appendix C

RECOMMENDATION: Test all level alarms, switches and overfill prevention devices as part of the on-going maintenance program.

D. INSPECTION INTERVALS

Intervals between tank inspection (both internal and external) should be determined by the tank service history, corrosion rates, and regulatory requirements. Listed below are the recommended inspection intervals.

1. Routine In-Service Inspection Facility personnel shall perform a visual inspection of the tank exterior surfaces and associated piping.

Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (including tank floor projection-to-foundation interface), coating, and appurtenances.

Interval: Monthly

2. External (In-Service) Inspection An API certified inspector shall perform this inspection every five (5) years or RCA/4N years (where RCA is the difference between the measured shell thickness and the minimum required thickness and N is the shell corrosion rate) whichever is less. This inspection includes inspection requirements of the routine in-service inspection as well as a visual inspection of the tank grounding systems (shunts and cables) for damage.

Interval: Five (5 years); 26 February 2023

3. Ultrasonic Thickness Inspection An external UT inspection of the tank shell and roof shall be performed by an API certified inspector every fifteen (15) years or RCA/2N, whichever is less. The inspection may be performed in conjunction with the external in-service inspection.

Interval: Fifteen (15) years; 26 February 2033

4. Internal (Out-of-Service) Inspection An API certified inspector shall perform a visual inspection of the tank interior surfaces and associated piping. The inspection shall include an evaluation of the tank bottom via NDT methods.

Interval: Twenty (20 years); 26 February 2038

APPENDIX A: TANK EVALUATION ITEMS

Tank 11 (807) – API 653 Inspection APPENDIX A, TABLE OF CONTENTS Arnold AFB, TN

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

COATINGS

APPURTENANCES

PIPING

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 30

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FOUNDATION

Type Concrete ringwall

Levelness The tank is relatively level. The maximum measured differential between max and min elevations is 0.48 inches.

The tank passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt The tank is slightly tilted. The amount of tilt is

0.43 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The concrete ringwall is approximately 22-inches above the containment dike floor.

Material Below Tank Floor The material below the tank floor could not be inspected.

Drainage Around Tank Drainage around the tank appears to be adequate.

Tank Anchors The tank is equipped four non-standard anchor straps. The upper end of the strap is welded to the tank shell. The lower end is attached to the face of the concrete pad with a single 1-inch bolt. The concrete does not appear to be cracked at any of the bolt locations.

Since the anchor strap is of non-standard design, the evaluation calculations were performed assuming that it was unanchored. It was found that the tank is stable and does not requiring anchoring to resist wind or seismic forces.

Secondary Containment Tank is located within a concrete lined containment area that includes reinforced concrete walls. Scattered failure of the sealant in the dike floor and walls was observed.

Calculations indicate that the containment area has a storage capacity of 1,327 BBLS.

Remove the sealant in its entirety and replace.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were

Sealed at Foundation

There is no sealant between the tank floor projection and the concrete slab to prevent the intrusion of water below the tank floor. Moss and organics were observed growing within the space.

Remove the organics and provide jet fuel resistant sealant for the full perimeter of the tank.

Additional Foundation Items, Comments or Notes:

The concrete ringwall exhibits a worn appearance. A spall was observed 33’-9” clockwise from manway 1. The spalled area is covered with the same coating as the remainder of the ringwall, suggesting that it is old. Repair is recommended to maintain support of the tank shell.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 31

FLOOR

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type Butt welded floor.

Annular Ring Plates Tank is not equipped with annular ring plates.

Nominal Thickness Floor consists of 1/4-inch (0.250) thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.233-inch.

Interior Width See floor drawing.

Floor seam welds The profile of the thick-film coating prevented examination of the floor seam welds for relevant indications.

MFL Floor Scan The extremely rough surface profile of the floor coating prevented MFL scanning of the tank floor. The floor is not inspectable and its condition is indeterminate.

Remove the coating from the tank floor and perform MFL scanning with UT prove up of any anomalies that are detected.

Bottom Side Floor Pitting/Corrosion

Based on the inability to perform MFL scanning, the extent of backside corrosion is unknown.

Top Side Floor Pitting/Corrosion

No top side pitting or corrosion was observed on the tank floor.

Patch Plates No lapped patch plates were observed on the tank floor.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted.

Floor Bulges, Depressions No relevant bulges or depressions were noted.

Doubler/Striker Plates Doubler plates were provided at each of the two stilling wells.

Plug Welds No plug welds were observed on the tank floor.

Weld Artifacts No weld artifacts were observed on the tank floor.

Floor Critical Zone No evidence of significant back side corrosion or thinning was observed within the critical zone.

Floor Projection The floor projection extends an average of 1.163-inches beyond the tank shell. The average thickness is 0.237-inch.

Floor Profile The floor is flat with a slight slope to the near shell floor drain.

Sumps The tank is not equipped with a sump. There is a 4-inch floor drain.

Vacuum Box Testing Vacuum box testing was not performed since

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 32

FLOOR

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

the floor is coated.

Secondary Liner Below Floor

No drawings were available for review. It is not known if there is a secondary liner below the floor plate.

Leak Detection Below Floor

There are four equally spaced leak detection ports in the concrete ringwall.

Cathodic Protection The tank floor is not equipped with cathodic protection. Since the floor could not be inspected by MFL, it is not known if there is backside corrosion.

Additional Floor Items, Comments, Notes:

None.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 33

SHELL

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK SHELL

Average Thickness UT Thickness

1st Course 0.165 inch

2nd Course 0.169 inch

3rd Course 0.186 inch

Rim Angle Unable to measure. Angle is internal.

Plumbness Visual observations found no noticeable out-of-plumbness.

Roundness No noticeable out-of-roundness was observed.

Dents/Buckles No significant dents or buckles requiring repairs were observed.

Banding/Peaking No significant banding or peaking was

Interior Shell pitting/corrosion

No pits or significant corrosion were observed on the interior of the shell.

Exterior Shell pitting/corrosion

No pits or significant corrosion were observed on the exterior of the shell

Insert plates No insert plates were observed.

Welded Patch Plates No welded patch plates were observed.

Interior Shell Welds Visual inspection of accessible interior shell welds found no indications for further inspections or examinations.

Exterior Shell Welds Visual inspection of accessible exterior shell welds found no indications for further

Door sheet None present.

Shell-to Floor Weld – Interior

Visual inspection of the interior floor-to-shell weld found no indications for further

Shell-to Floor Weld – Exterior

Visual inspection of the exterior floor-to-shell weld found no indications for further

Shell Manholes The tank is equipped with one 30-inch manhole and one 24-inch manhole in the 1st shell course.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Temperature Probe Tank is not equipped with a shell mounted temperature probe.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 34

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Shell Reinforcing Plates

Manholes

(Size, Thickness, Telltale Hole)

Manhole 1:

Size: 30-inch diameter nozzle, 0.489-inch thick

(UT).

Reinforcing Plate: Diamond shaped, 81-inch x wide x 66-inch tall x 0.232-inch thick (UT). The clearance between the underside of the reinforcing plate to the floor-to-shell weld is less than the API requirement of 3-inches.

The telltale hole is open.

Manhole 2:

Size: 24-inch diameter nozzle, 0.175-inch thick

(UT).

Reinforcing Plate: Diamond shaped, 65-inch x wide x 54-inch tall x 0.179-inch thick (UT). The clearance between the underside of the reinforcing plate to the floor-to-shell weld is less than the API requirement of 3-inches.

The telltale hole is open.

Provide magnetic particle examination of the non-compliant welds.

Floor Drain

(Size, Thickness, Telltale Hole)

Size: 4-inch diameter nozzle, 0.233-inch thick

(UT).

Reinforcing Plate: 10-inch diameter x 0.329-inch thick (UT) welded to the underside of the tank floor.

Issue

Telltale Hole)

Size: 6-inch nozzle, 0.414-inch thick (UT).

Reinforcing Plate: Diamond shaped, 20-inch x wide x 16-inch tall x 0.377-inch thick (UT).

The telltale hole is open.

Fill

Telltale Hole)

Size: 6-inch nozzle, 0.423-inch thick (UT).

Reinforcing Plate: Diamond shaped, 20-inch x wide x 16-inch tall x 0.176-inch thick (UT).

Pressure Relief for Fill Piping

(Size, Thickness, Telltale Hole)

Size: 3/4-inch diameter nozzle, unable to measure UT since nozzle is a threaded half coupling.

Reinforcing Plate: None.

A reinforcing plate is not required.

Transfer Piping to Tank 11

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.417-inch thick (UT).

Reinforcing Plate: Diamond shaped, 20-inch x wide x 16-inch tall x 0.173-inch thick (UT).

Shell Vents Tank is not equipped with shell vents.

Overflow Ports Tank is not equipped with overflow ports. Overflow ports are not required since the tank is not equipped with a floating pan.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 35

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Wind Girders and Shell Stiffeners (Size & Elevation)

Tank is not equipped with wind girders or shell stiffeners.

Calculations indicate that a shell stiffener is not required.

Tank Nameplate Data:

Repaired/Altered by CAPE

Installed (2) 8” gauge poles, level alarms, ladder and handrails.

Original year of construction: 1956

Year completed: 2008

Nominal diameter: 20’-0”

Nominal height: 18’-0”

Design liquid level: 16’-8”

Maximum capacity: 1,000 BBL

Design specific gravity: 0.84

Maximum design temperature: 200 deg. F.

Additional Shell Items, Comments or Notes:

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 36

ROOF

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK ROOF (See Tank Appurtenances for ATG, Gauging, Level Alarms, etc.)

Type Self-supported fixed cone up roof.

Roof Plate Thickness The roof consists of 1/4-inch (0.250) thick butt welded roof plates. Average measured thickness is 0.244-inch (UT).

Roof Joints Visual inspection from below the roof found no indications of leakage.

Roof Topside Pitting/corrosion

No significant pitting or corrosion was identified on the topside of the roof.

Roof Topside Condition No significant distortions present. No water ponding areas were observed.

Roof Welds Visual inspection of roof topside plate welds found no significant indications requiring further examination.

Frangible Joint (Size/Condition)

Tanks with a diameter in excess of 50 feet and designed with a frangible joint to API 650, are considered adequate for emergency venting. Since the diameter of the tank is only 20 feet and does not meet the construction requirements of API 650 5.10.2.6, it is not considered to have a frangible joint.

The tank is equipped with a 6-inch atmospheric vent but no emergency vent.

Calculations indicate that the total capacity of the existing atmospheric vent and the pressure/vacuum vent is less than required.

Remove the existing 6-inch atmospheric vent and provide an 8-inch emergency vent.

Roof Vents (Size & Type) The tank is equipped with one 6-inch atmospheric vent and one 3-inch lever loaded pressure/vacuum vent with flame arrestor.

Facility personnel reported that the internal components of the flame arrestor have been removed.

Roof Manhole The tank is not equipped with any roof manholes.

Roof Hatch The tank is not equipped with a roof hatch. A roof hatch is not required since the tank is not equipped with a floating pan.

Roof Nozzles (3) 1.5-inch for tape gauge and guide wires

Roof Framing/Roof Underside Condition

Visual inspection of the underside of the roof from the tank floor found no indication of leaks and no areas of significant corrosion or other degradation.

Interior Columns The tank is not equipped with any support columns. The roof is self-supporting.

Additional Roof Items, Comments or Notes:

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 37

COATINGS

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Exterior Coatings

Shell

Type/age Thin-film epoxy. The age of the coating system is not known.

General Condition The coating is generally in good condition.

Moss and dirt were observed.

There is a chain that extends from grade to the top of the tank at the lever loaded pressure/vacuum vent. The chain is abrading the coating on the tank shell.

Pressure wash the entire tank to remove the organics.

Remove the chain.

Nominal Thickness The average thickness of the shell coating is

12.6 mils; with a maximum thickness of 20.6 mils and a minimum thickness of 7.8 mils.

Lead and Chromate Testing Not performed.

Roof

Type/age Thin-film epoxy. The age of the coating system is not known.

General Condition The coating is generally in satisfactory condition. Minor coating failure and corrosion was observed on the roof appurtenances.

Moss and dirt were observed.

Provide surface preparation and recoat affected areas.

Pressure wash the entire tank to remove the organics.

Nominal Thickness The average thickness of the roof coating is

16.3 mils; with a maximum thickness of 23.5 mils and a minimum thickness of 11.3 mils.

Interior Coatings

Floor

Type/age Thick-film epoxy. Installation date is not known. Excerpts from the 1999 OOS reports indicate that the floor was uncoated at that time.

General Condition The interior floor coating is generally in good condition. However, the surface profile is extremely rough and prevented MFL scanning of the floor.

Minor coating failures were observed. The failures appear to be the result of welding that occurred during the installation of the stilling wells in 2008.

Nominal Thickness The average thickness of the floor coating is

57.7 mils; with a maximum thickness of 75.1 mils and a minimum thickness of 42.6 mils.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 38

COATINGS

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Lead and Chromate Testing Not performed.

Shell

Type/age Thin-film epoxy. Installation date is not known. Excerpts from the 1999 OOS reports indicate that the shell was uncoated at that time.

General Condition The coating is generally in good condition.

Nominal Thickness The average thickness of the 1st shell coating is 15.9 mils; with a maximum thickness of 24.4 mils and a minimum thickness of 8.4 mils.

Underside Roof

Type/age Uncoated. Recommend coating the underside of the roof plate.

Additional Coating Items, Comments or Notes:

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 39

APPURTENANCES

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK APPURTENANCES

Float Gauge The tank is equipped with a Varec tape gauge system. Facility personnel did not report any concerns with the system.

ATG (Automatic Tank Gauging) or RTG (Remote Tank Gauging) System

The tank is equipped with an ENRAF ATG system.

HI/HI-HI Level Alarms The high and high-high level alarms are integrated into the ENRAF ATG system.

Low/Low-Low Level Alarms The low level alarms are integrated into the ENRAF ATG system.

Independent Level Alarms The tank is equipped with an independent level alarm system.

Facility personnel reported that the alarm levels are set at the same elevations as the ENRAF system.

Temperature Probe The tank has a temperature probe that is part of the ENRAF ATG system.

Stilling Wells

ATG The ATG displacer is located within an 8-inch near-shell stilling well. The displacer was not retracted at the time of the inspection.

Contact SPAWAR to review the ATG system to verify accuracy.

Sampling/Testing/Hand Gauging

Manual gauging and sampling is performed at an 8-inch near-shell stilling well.

Water/Temperature Probe

The temperature probe is not located within a 6-inch stilling well as required by current military criteria.

Provide a 6-inch slotted stilling well above the near shell floor drain.

Confirm need for bottom water sampling with facility personnel.

Fire Suppression System The tank is not equipped with a fire suppression system.

Product Saver Tank (PST) Tank is equipped with a product saver tank.

Tank Grounding The tank is equipped with two ground wires attached to tank shell.

Internal Ladders The tank is not equipped with an internal ladder.

An internal ladder is not required since the tank is not equipped with a floating pan.

Roof Access from Ground (Stairs)

Roof access is via a ladder that is supported from the shell.

Roof Access from Adjacent Tanks

There is no roof access to adjacent tanks.

Roof Handrails The tank is equipped with a partial perimeter roof handrail.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 40

APPURTENANCES

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Additional Appurtenance Items, Comments or Notes:

Strapping charts were available for review. The tank was strapped in 2008 and the charts have 1/16-inch gradations.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 41

PIPING

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

PIPING

Drain

Interior Piping Size: 4-inch nozzle, 0.233-inch thick welded to the tank floor. (UT).

There is no interior piping.

Exterior Piping Size: 4-inch diameter

Valve (Type/Condition) Valve: 4-inch, class 150, Hamer gate valve with manual operator. Minor coating failure and corrosion.

Remove the gate valve and provide a 4-inch DBB steel plug valve.

Provide coating repairs.

Pressure Relief Piping None present. Not required.

Issue

Interior Piping Size: 6-inch nozzle, unable to record UT due to lack of pipe extension inward from shell.

The nozzle is not equipped with interior piping.

Provide interior piping. Review need for piping with facility personnel based on existing operations.

Exterior Piping Size: 6-inch nozzle reduces to 4-inch diameter piping upstream of the shell valve.

Valve (Type/Condition) Valve: 4 General Twin Seal, DB&B steel plug valve, class 150 with manual actuator. Minor coating failure and corrosion.

Provide coating repairs.

Pressure Relief Piping The piping is not equipped with a pressure relief loop.

Perform a thermal relief analysis to determine if additional thermal relief piping is required.

Fill

Interior Piping Size: 6-inch nozzle, unable to record UT due to lack of pipe extension inward from shell.

There is no interior piping.

Provide interior piping, including a diffuser. Review need for piping with facility personnel based on existing operations.

Exterior Piping Size: 6-inch nozzle reduces to 4-inch diameter piping upstream of the shell valve.

Valve (Type/Condition) Valve: 4 General Twin Seal, DB&B steel plug valve, class 150 with manual actuator. Minor coating failure and corrosion.

Provide coating repairs.

High Level Shut-Off Valve (Type/Condition)

Tank is equipped with a Cla-Val hydraulically operated high level shut off valve on the exterior piping.

Tank 11 (807) – API 653 Inspection APPENDIX A, Page 42

PIPING

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Pressure Relief Piping 3/4-inch steel piping with threaded connections, a thermal safety relief valve set at 166 psi and a…