Attachment J.3 Fac 88044 (Tank 111)-FINAL-2021.pdf

API 653 In-Service Inspection Report Ft Hood / Killeen, TX

Facility ID: 88044/Tank ID: 111

Prepared for:

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

(USACE POL-MCX)

07/02/2021

Inspection Report Prepared by:

API Standard 653 recommends this document containing valuable historical information be retained for the life of the tank.

ii

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ARE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction / Shell

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

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

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

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS SHELL SETTLEMENT SURVEY

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATION

SHELL UT MEASUREMENTS

ROOF UT MEASUREMENTS

SHELL NOZZLE / REPAD UT MEASUREMENTS

CRITICAL ZONE SHELL THICKNESS

SHELL DROP UT MEASUREMENTS

OSHA ACCESS STRUCTURE REPORT

iii

APPENDIX B: 3-D DOCUMENTATION AND ANALYSIS

OUT OF PLUMBNESS (VERTICALLY)

ISOLATED SHELL DISTORTION

TANK BOTTOM ELEVATION

APPENDIX C: TANK DRAWINGS

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX E: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute ASME American Society of Mechanical Engineers ASNT American Society of Non-Destructive Testing ATG Automatic Tank Gauge BBL Barrel CFR Code of Federal Regulations CP Cathodic Protection 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

GENERAL SUMMARY

An API 653 In-Service inspection of Tank # 111 was completed on July 2, 2021 to evaluate the tank’s integrity, collect data, and establish a database for future inspections and evaluations. The tank meets the requirements for structural integrity in accordance with the API 653. The project scope required the inspection to include the evaluation of many aspects of the tank and its ancillary equipment to address tank integrity, including but not limited to, secondary containment, spill prevention, military standards related issues as directed by UFC 3-460-01 Table 8-1 and other applicable industry standards.

API 653 provides inspection and evaluation criteria required to determine the suitability for continued service of an AST until the next scheduled inspection. The purpose of conducting inspections is to identify the condition of and changes to the AST.

INSPECTION DATE

API In-Service (External) Inspection Date: 28 June 2021 Equipment Used:

Manufacturer: Olympus Model Number:38DL Calibration Method:

Steel Calibration Wedge SN 107514

Manufacturer: Trimble Model Number: SX10 Calibration Method: N/A

Manufacturer: Spectra Precision Model Number: LL300N Calibration Method: Self Leveling

Inspector(s): Daniel Elliott

STATE REGULATIONS

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

NOTE: If there are no state regulations for tank inspections then N/A shall reside in-place of the number of years between inspections. If state regulations reside, the recommended future inspections dates shall be based on whichever is more stringent between the API inspector’s calculations and the State regulations.

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: May 2008 (Assumed) API In-Service (External) Inspection Date: 5 May 2016

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS ARE PROVIDED)

API Out-of-Service (Internal) Inspection Date: May 2028 API 653: 653 6.4.2.1 / UFC 3-460-03: 8-4.1(e)

API Ultrasonic Thickness Inspection Date: 28 June 2036

API 653: API 653 6.3.3.2 / UFC 3-460-03: N/A

API In-Service (External) Inspection Date: 28 June 2026 API 653: 6.3.2.1 / UFC 3-460-03: 8-4.1(d)

Daniel Elliott Project Manager Pacific Engineering & Consulting, Inc.

API 653 Certified Inspector No. 70788

Jared Shuman, PE Principal Engineer Pacific Engineering & Consulting, Inc.

API 653 Certified Inspector No. 56100

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner United States Army Location Fort Hood, TX 76544 Facility Number 88044 Tank Number 111 State / Country Texas City Killeen Inspection Date June 28th – July 1st Tank Manufacturer American Tank & Vessel Design Standard API 650 Date of Construction 1985 Tank Contents Jet Fuel F-24 Tank Serial Number Unknown Tank Diameter 52’ Shell Height 40’ Product Height 29’ 1-1/8” Tank Capacity 630,000 gallons Foundation Concrete Ring wall Construction Bottom External Inspection Only

Shell Vertical, cylindrical – consisting of (4) 10’ courses

Floating Roof N/A Fixed Roof Lap Welded, Shallow, fixed cone

Material Bottom Carbon Steel Shell Carbon Steel Floating Roof N/A Fixed Roof Carbon Steel

Cathodic Protection N/A Interior Coating System Unknown Exterior Coating System Standard epoxy coatings; date unknown Level Gauging Manual and electronic gauging Overfill Protection High Level Shut-Off Valve Piping Receipt 6” Carbon Steel

Issue 10” Carbon Steel Low Suction N/A N/A Water Draw-Off 2” Carbon Steel

Level Alarms HHLA, HLA, LLA, LLLA Type of Internal Floating Roof N/A

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection This project will perform API 653 Inspections of various tanks at facilities throughout the United States.

Additional consideration is given to Federal, State, and Local regulations as well as applicable Military Criteria and general industry standards.

For Tank 111, an API Standard 653 In‐service (External) Inspection was performed.

2. Site Information On June 28, 2021 Pacific Engineering & Consulting, Inc. performed API 653 In‐Service (External) Inspection of Tank 111 located at Ft Hood, Killeen, Texas. Fort Hood has nearly 65,000 soldiers and family members and serves as a home for the following units: Headquarters III Corps; First Army Division West; the 1st Cavalry Division; 13th Sustainment Command (formerly 13th Corps Support Command); 89th Military Police Brigade; 504th Battlefield Surveillance Brigade; 85th Civil Affairs Brigade; 1st Medical Brigade; and the 69th Air Defense Artillery Brigade. Fort Hood is the Army's premier installation to train and deploy heavy forces. A 214,968-acre installation, Fort Hood is the only post in the United States capable of stationing and training two armored divisions.

B. TANK INSPECTION COMMENTS

1. Tank Construction / Shell Tank 111 is a nominal 15,000 bbl, 52’ diameter by 40’ tall, F-24 (Jet-A additized), aboveground vertical cylindrical storage tank. The tank was constructed in 1985 by American Tank & Vessel as indicated by the information on the tank data plate. The information stenciled on the manhole indicated that the tank was last inspected out-of-service and cleaned in 2008. As‐built drawings of the original construction were not available to the inspector.

2. Tank Foundation The tank rests on a raised concrete ring wall foundation with six (6) inches visible above the containment floor. The foundation was visually evaluated for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The tank chime-to-foundation seal is deteriorating and must be replaced to prevent water intrusion. A tell-tale leak detection system is installed at the perimeter of the ring wall. No water or fuel was found during the inspection. A shell settlement survey, in accordance with Appendix B of API Standard 653, found settlement within tolerance. Settlement results are listed in Appendix A.

3. Tank Shell The vertical cylindrical shell consists of four butt‐welded courses constructed of A-283-C carbon steel.

The exterior of the shell was visually inspected and evaluated for plumbness, roundness, peaking and banding. A 3D-scan of the exterior tank shell demonstrated that roundness was within tolerances established by API 650 7.5.3. See Appendix B. The critical zone and accessible shell plates were examined using an ultrasonic thickness meter. No general corrosion issues were found during the inspection. The results are listed in Appendix A.

4. Tank Appurtenances

a. Tank Roof

The coating system on the tank roof and appurtenances appear to be in good to moderate condition with moderate coating failure and corrosion observed on the roof, deck plate, inspection hatches, nozzle flanges, nuts, and bolts, etc. Evidence of water ponding was observed in isolated depressions along roof perimeter. The roof plates were examined using an ultrasonic thickness meter. No general corrosion issues were found during the inspection. The results are listed in Appendix A. A single scaffold-cable support, as described in API 650 Fig 5-22, is installed on the roof. UFC 3-460-01 Table 8-1 requires two (2) scaffold-cable supports. No floating roof or inspection hatches are installed on this tank. Floating roofs are required per UFC 3-460-01 and AW 078-24-27. The tank has an atmospheric vent with a weather hood and bird screen installed in the 24-inch manway, which also functions as a gauge hatch. The vent is not located in the center of the tank and the bird screen is not well attached, which leaves sizable gaps. A 6-inch Shand & Jurs Pressure Vacuum vent is also installed on the roof. The re-enforcing pad also has a hole that should be removed to prevent water accumulation between the repad and the roof plate.

b. Gauging An MTS M-series magnetostrictive probe provides product, water level and temperature data to the Red Lion ATG. The probe is installed in a 10‐inch nozzle on the roof as required in UFC 3- 460-01. The tank also has a Varec 2500 Tape Level Gauge whose reading does align with the ATG installed on the tank and is has 1/16th of an inch graduations. The manual gauging hatch is combined into the 24-inch manway, and vent. There is no 10-inch nozzle with an established datum plate or 8-inch nozzle dedicated for temperature and bottom water sensor as required by UFC 3-460-01 Table 8-1.

c. Level Alarms The high and high-high level alarms are mounted on the shell approximately 48” and 4” below the roof-to-shell weld, respectively. The HLA and HHLA are accessible from the circumferential stairway. The low and low-low level alarms are mounted on the shell 23” and 40” above the tank bottom, respectively. A SOR 704 series mechanical level switch is installed in a 10-inch nozzle on the roof. Overfill prevention is provided by a Cla-Val Co float switch connected to an hydraulically operated diaphragm control valve on the receipt piping.

d. Manways

There are two (2) 24 inch manways on the shell located 180 degrees across from each other, and one (1) 24 inch manway on the roof. The manways are required to be 36-inches in diameter and shall have davit arms to support the manway covers as required by AW 078-24-27.

e. Water Draw-Off The tank has a water separator/product return system installed, but it is not compliant with AW-078-24-27. A manual 3-inch low point water drain is also provided for water/low product removal. Both appurtenances were in the closed position and locked.

f. Stairs and Platforms The fixed steel roof is accessible by a circumferential stairway mounted on the shell of the tank.

There are several areas of coating failure and corrosion on the stairway and the platforms. The bottom stair of the circumferential stairway is approximately 13 ½ inches above the landing.

OSHA requires the rise to be consistent with the rest of the stairs. Stairs are constructed of bar grating stair tread and have checkered plate non-slip nosing. See stair report in Appendix A.

g. Grounding and Bonding There are two grounding cables connected to ground lugs welded to the tank shell.

5. Tank Coating

The external coating system appeared to be a standard military coating system (epoxy-epoxy-polyurethane). Localized minor coating failure and corrosion was observed on the surface of the circumferential stairway, reinforcing plate weep holes, tank roof and roof appurtenances.

6. Tank Piping System Fuel is received through a 6‐inch carbon steel piping system from the truck off-loading area and is issued through a 10-inch carbon steel piping system. No low-suction system is installed.

The 6-inch receipt piping consists of two block valves and a high liquid level shut-off valve. A 1-inch carbon steel thermal relief system is installed to prevent thermal expansions. AW 078-24-27 requires stainless steel thermal relief piping. No calibration information was visible on the thermal relief valve.

No blind flange for sidestream filtration as required by AW 078-24-27.

The 10-inch carbon steel issue piping is equipped with a General Valve Twin Seal double-block and bleed valve. No thermal relief is installed on the issue piping as indicated in AW 078-24-27.

7. Fire Protection System There are fire hydrants noted within 300 feet of this tank.

8. Secondary Containment Secondary containment is provided by a concrete containment basin that is connected with the containment basins of the other fuel tanks in the tank farm. The containment was visually evaluated during the inspection for structural damage and adequate drainage controls. There is minor to moderate cracking throughout the containment area in addition to vegetation growth. There is evidence of ponding water accumulating around the ring wall foundation. Drainage control system appears adequate and capable for retaining water, however the containment drain valve is not compliant with AW 078-24-27. Pipe penetrations into concrete basin floor do not have sleeve seals as required by AW 078-24-27.

FINDINGS AND RECOMMENDATIONS

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.

None.

2. REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Short-term Repairs that directly relate to the long-term preservation of the asset. Short-term 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. TITLE: Required Manway Size

OBSERVATION: The current manways installed are 24”.

REFERENCE: UFC 3-460-01 Table 8-1 Manhole (f) RECOMMENDATION: The two (2) manways should be increased in size to 36 inches and have a davit arm installed.

b. TITLE: Carbon Steel Thermal Relief Piping OBSERVATION: Thermal Relief system on receipt piping is not stainless steel as required.

REFERENCE: AW-78-24-27 Page D.10 Figure 4 RECOMMENDATION: Install thermal relief system as described in AW-78-24-27 Page D.10 Figure 4.

c. TITLE: Bottom Stair Height

OBSERVATION: Bottom stair is approximately 13 ½” above the containment floor.

REFERENCE: AW-78-24-27 Page D.11 Figure 4 / OSHA 1917.120 Fixed Stairways RECOMMENDATION: Install concrete approach step.

d. TITLE: Water Separator/Product Return OBSERVATION: Combined inlet/outlet water draw-off system, no 2-inch product return.

REFERENCE: AW 78-24-27 Page G.05 Note 2 / AW 78-24-27 Page D.13 Figure 5 RECOMMENDATION: Add nozzle and water draw-off system as indicated in AW 78-24-27.

e. TITLE: Single Scaffold Support

OBSERVATION: Only one (1) scaffold support is provided on the tank.

REFERENCE: UFC 3-460-01 Table 8-1 Cable Supports (jj) RECOMMENDATION: Add additional scaffold support per API 650 near the center of the tank.

f. TITLE: 10-inch Issue Thermal Relief System OBSERVATION: Thermal Relief system on issue piping is not stainless steel as required.

REFERENCE: AW-78-24-27 Page D.10 Figure 4 RECOMMENDATION: Install thermal relief system as described in AW-78-24-27 Page D.10 Figure 4.

g. TITLE: Tell-tale hole on Roof Re-pad OBSERVATION: There is a tell-tale hole on a roof repad for 6-inch P/V vent.

REFERENCE: API 650

RECOMMENDATION: Repair by welding hole shut.

h. TITLE: No Full Circumference Rail on Roof OBSERVATION: The roof does not have a full circumference rail attached.

REFERENCE: AW-78-24-27 Page D.11 Figure 5 RECOMMENDATION: A full circumference rail must be added to the roof.

i. TITLE: Repair Hairline Cracking in Dike Containment Area

OBSERVATION: The are several locations where the secondary containment has cracked, and several locations where the joint sealant between slabs has failed. Cracks in the concrete can create areas where a containment breach could occur without detection, as well as allow vegetation to grow.

REFERENCE: UFC 3-460-01, paragraph 8-14.5 requires concrete dikes to resist and contain the full hydrostatic load when filled to capacity, which cracks in the dike may impede. All concrete surfaces in a diked enclosure should be sealed with a flexible, UV-resistant, fuel-resistant coating if required by State or local regulations.

RECOMMENDATION: Repair the approximate 4560’ of linear cracking throughout the entire containment area and seal the exposed joint material to prevent the intrusion of water and degradation of the concrete dike.

3. RECOMMENDED REPAIRS as Part of Regular Maintenance Long-term Repairs that directly relate to repair/upgrade of an asset to bring it up to the current standard from the standard at time of construction. Long-term 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. TITLE: Provide NFPA Hazard Label

OBSERVATION: The tank is not labeled with a NFPA hazard warning label.

REFERENCE: NFPA 30, paragraph 21.7.2.1 requires ASTs to be labeled in accordance with

NFPA 704.

RECOMMENDATION: Provide a new NFPA hazard warning label in accordance with NFPA 704.

b. TITLE: Monitor Roof Drainage OBSERVATION: There is evidence of water ponding in areas on the roof.

REFERENCE: DoD AST Standard Design, AW 78-24-27 requires roofs to be sloped to prevent water from ponding to prevent coating deterioration and plate corrosion.

RECOMMENDATION: Monitor the roof to ensure any water that may pond is not causing deterioration of the roof.

c. TITLE: Monitor Ringwall Foundation Drainage

OBSERVATION:. There is evidence of water ponding near the concrete ringwall foundation.

There is no sign currently of coating failure or corrosion.

REFERENCE: DoD AST Standard Design, AW 78-24-27 requires tanks to be significantly elevated to ensure that every portion of the tank bottom underside is elevated out of groundwater in order to reduce the risk of bottom side plate corrosion.

RECOMMENDATION: Monitor the ring wall foundation and routinely monitor tell tale drains

d. TITLE: Bird Screen Damaged

OBSERVATION: The bird screen on the atmospheric vent is damaged.

REFERENCE: UFC 3-460-01 Table 8-1 RECOMMENDATION: Repair/Replace bird screen.

4. SIGNIFICANT FINDINGS per API 653, UFC 3-460-01, or AW 78-24-27 Standards The following information identifies the significant findings found during the tank inspection.

j. TITLE: Repair Coating System on Tank Roof, Roof Appurtenances, Stairway and Associated Piping OBSERVATION: Localized minor coating failure and corrosion was observed on the surface of the circumferential stairway, tank roof and roof appurtenances, etc.

REFERENCE: UFC 3-460-01, Section 8-3.10, requires the exterior of fuel storage tanks and appurtenances to be coated.

RECOMMENDATION: Remove corrosion from all isolated areas of deterioration. Clean and prep all the areas that require coating repairs, approximately 55 sqft, and apply a compatible coating system that meets military criteria. Corroded nuts and bolts should be removed and replaced with corrosion resistant nuts and bolts.

k. TITLE: Repair Bottom-to-Foundation Seal

OBSERVATION: The tank bottom-to-foundation seal has numerous areas where the sealant has completely failed.

REFERENCE: UFC 3-460-03, Section 8-4.10 B, requires the seal to be maintained in good working order to prevent corrosion of the underside of the tank bottom.

RECOMMENDATION: Replace the approximate 87’ of failed tank bottom-to-foundation seal with a new seal.

l. TITLE: Repair Joint Sealant in Ringwall Foundation OBSERVATION: The joint sealant in the concrete ringwall foundation has failed in several areas.

REFERENCE: UFC 3-460-03, Section 8-4.3.1 and 8-10.2.1 require all cracks to be cleaned and sealed with a fuel resistant sealant.

RECOMMENDATION: Replace the approximate 95’ of failed concrete ringwall foundation sealant with a fuel resistant sealant.

APPENDIX A: ENGINEERING CALCULATIONS

AND DRAWINGS SHELL SETTLEMENT

SURVEY

SHELL SETTLEMENT SURVEY

Tank Specification Unit D Diameter 52 ft.

C Circumference 163.4 ft.

H Height 40 ft.

ΔY Age 36 years N Data Point Taken 8

Nmin Minimum of Data Points required 8 API-653 12.5.2 L Arc Length between measurement points 20.42 ft.

Y Specified Minimum Yield Strength 23595 psi API 653 Table 4-1

R2 Coefficient of determination 0.9245 API 653 B.2.2.4(e)

|S|Max Maximum permissible out-of-plane deflection 0.0466 ft.

|S| Largest Calculated |S| 0.0068 ft.

Data Points, N

Actual (ft)

Optimum

(ft) Ui Ui+1 Ui-1 Si |S| Result

1 5.5417 5.5391 0.002558 0.001098 -0.00433 0.004176 0.004176 PASS

2 5.5417 5.5406 0.001098 -0.00265 0.002558 0.001144 0.001144 PASS

3 5.5313 5.5339 -0.00265 0.003032 0.001098 -0.00472 0.004715 PASS

4 5.5260 5.5230 0.003032 -0.00386 -0.00265 0.006287 0.006287 PASS

5 5.5104 5.5143 -0.00386 0.002808 0.003032 -0.00678 0.00678 PASS

6 5.5156 5.5128 0.002808 0.001348 -0.00386 0.004064 0.004064 PASS

7 5.5208 5.5195 0.001348 -0.00433 0.002808 0.002111 0.002111 PASS

8 5.5260 5.5304 -0.00433 0.002558 0.001348 -0.00629 0.006287 PASS

5.54 5.54

5.53

5.53

5.51

5.52

5.52 5.53

5.54

5.5

5.505

5.51

5.515

5.52

5.525

5.53

5.535

5.54

5.545

5.55

1 2 3 4 5 6 7 8 1

N Data Points, Equally Sapced Apart Tank Circumference (πD)

Shell Settlement Evaluation

Actual Edge Settlement Optimum Cosine Curve

SHELL THICKNESS CALCULATION

Tank Information Reference Owner/Operator United States Army Facility ID 88044 Tank ID 111 Inspection Date 6/28/2021 Plate Specification A 283-C Material Carbon Steel Manufactured Date 1975

Tank Specification Units D Diameter 52 ft.

H Height 40 ft.

G Specific Gravity 0.84 N/A ΔY Age 36 years

Shell Plate Properties Units T Specified Minimum Tensile Strength 55000 psi API 653 Table 4-1 Y Specified Minimum Yield Strength 30000 psi API 653 Table 4-1 S Maximum Allowable Stress (Course 1 &2) 23595 psi API 653 4.3.3.1 S Maximum Allowable Stress (All Other Courses) 25960 psi API 653 4.3.3.1

Course No.

Plate Specification

Course Height (ft)

Product Height (ft)

Maximum Allowable Stress (psi) Joint Efficiency

Previous Measured Thickness (in)

Current Measured Thickness (in)

Minimum Acceptable Thickness (in)

1 A 283-C 10 40 23595 1 0.250 0.256 0.188 2 A 283-C 10 30 23595 1 0.250 0.253 0.140 3 A 283-C 10 20 25960 1 0.250 0.259 0.100 4 A 283-C 10 10 25960 1 0.250 0.252 0.100

Corrosion Rate (in/yr)

Remaining Life (yrs)

Next Visual Inspection (yrs)

Next Ultrasonic Inspection (yrs)

0.0002* 341.42 5.00 15.00 0.0002* 567.08 5.00 15.00 0.0002* 795.00 5.00 15.00 0.0002* 760.00 5.00 15.00

*Let Cr=0.0002 inches per year for calculation purposes.

0.050

0.100

0.150

0.200

0.250

0.300

1 2 3 4

Th ic kn es s (in

Course

Shell Life Evaluation

Previous Measured Thickness (in)

Current Measured Thickness (in)

Minimum Acceptable Thickness (in)

SHELL UT MEASUREMENTS

Location No. Thickness (in) 1-1 0.250 1-1 0.250 1-1 0.237 1-1 0.237 1-1 0.250 1-2 0.240 1-2 0.241 1-2 0.239 1-2 0.235 1-2 0.240 1-3 0.236 1-3 0.224 1-3 0.232 1-3 0.243 1-3 0.245 1-4 0.251 1-4 0.254 1-4 0.247 1-4 0.252 1-4 0.237 1-5 0.251 1-5 0.250 1-5 0.248 1-5 0.250 1-5 0.249 1-6 0.255 1-6 0.247 1-6 0.246 1-6 0.246 1-6 0.247

ROOF UT MEASUREMENTS

Roof Ultrasonic Thickness Readings

Plate No

Thickness (in)

Plate Type Point Numbers

1 2 3 4 5 1-1 0.19 0.19 0.211 0.189 0.189 B 1-2 0.189 0.19 0.191 0.191 0.19 E 1-3 0.198 0.224 0.199 0.198 0.199 E 1-4 0.191 0.192 0.192 0.192 0.192 E 1-5 0.193 0.193 0.192 0.193 0.192 A 2-1 0.19 0.191 0.189 0.189 0.19 E 2-2 0.191 0.192 0.191 0.191 0.191 E 2-3 0.193 0.193 0.193 0.193 0.193 E 3-1 0.191 0.191 0.19 0.19 0.199 E 3-2 0.198 0.198 0.198 0.198 0.198 E 3-3 0.19 0.19 0.187 0.187 0.189 E 3-4 0.189 0.19 0.19 0.189 0.189 E

Roof Ultrasonic Thickness Readings

Plate No

Thickness (in)

Plate Type Point Numbers

1 2 3 4 5 4-1 0.196 0.196 0.196 0.195 0.196 E 4-2 0.194 0.195 0.195 0.196 0.195 E 4-3 0.193 0.195 0.195 0.194 0.195 E 5-1 0.196 0.196 0.196 0.195 0.195 E 5-2 0.195 0.193 0.193 0.193 0.197 E 5-3 0.197 0.196 0.195 0.195 0.195 E 5-4 0.196 0.196 0.196 0.196 0.195 E 6-1 0.196 0.196 0.195 0.195 0.194 E 6-2 0.192 0.192 0.197 0.197 0.196 E 6-3 0.195 0.194 0.194 0.197 0.197 E 7-1 0.197 0.194 0.194 0.196 0.196 D 7-2 0.195 0.194 0.195 0.193 0.196 E 7-3 0.195 0.195 0.195 0.195 0.195 E 7-4 0.195 0.195 0.195 0.195 0.193 E 7-5 0.193 0.196 0.196 0.196 0.195 C

SHELL NOZZLE / REPAD UT MEASUREMENTS

Nozzle Size (in)

Description 0° 90° 180° 270° Average Repad Repad Type

Top Right Botto m

Left Average

A 3 Low Point Drain

0.295 0.294 0.295 0.295 0.295 Yes B 0.253 0.310 0.309 0.310 0.296

B 24 Manway 0.381 0.384 0.384 0.381 0.383 Yes B 0.260 0.312 0.312 0.312 0.299 C 3/4 Sampling

Port

0.112 0.113 0.113 0.112 0.113 No N/A N/A N/A N/A N/A N/A

D 6 Receipt 0.428 0.436 0.429 0.430 0.431 Yes B 0.260 0.306 0.306 0.307 0.295 E 8 Issue 0.371 0.391 0.370 0.367 0.375 Yes B 0.240 0.309 0.318 0.310 0.294 G 2 Plugged

Nozzle

0.248 0.249 0.247 0.239 0.246 No N/A N/A N/A N/A N/A N/A

H 24 Manway 0.389 0.388 0.382 0.389 0.387 Yes B 0.258 0.309 0.308 0.309 0.296

CRITICAL ZONE SHELL THICKNESS

1 0.254 2 0.254 3 0.256 4 0.256 5 0.256 6 0.256 7 0.256 8 0.256 9 0.256

10 0.256 11 0.248 12 0.248 13 0.246 14 0.246 15 0.245 16 0.249 17 0.238 18 0.238 19 0.235 20 0.235 21 0.238 22 0.235 23 0.235 24 0.236 25 0.236 26 0.236 27 0.244 28 0.244 29 0.244 30 0.244 31 0.235 32 0.235 33 0.235 34 0.235 35 0.235 36 0.230 37 0.230 38 0.242 39 0.242 40 0.242 41 0.242

Location No. Thickness (in) 42 0.241 43 0.252 44 0.252 45 0.253 46 0.253 47 0.253 48 0.253 49 0.249 50 0.249 51 0.241 52 0.241 53 0.246 54 0.246 55 0.246 56 0.246 57 0.238 58 0.239 59 0.237 60 0.239 61 0.240 62 0.240 63 0.240 64 0.240 65 0.241 66 0.239 67 0.240 68 0.242 69 0.245 70 0.240 71 0.245 72 0.246 73 0.249 74 0.249 75 0.249 76 0.249 77 0.249 78 0.249 79 0.249 80 0.249 81 0.249 82 0.249

83 0.258 84 0.255 85 0.256 86 0.259 87 0.251 88 0.255 89 0.255 90 0.254 91 0.255 92 0.256 93 0.256 94 0.252 95 0.252 96 0.252 97 0.254 98 0.253 99 0.253

100 0.253 101 0.253 102 0.253 103 0.252 104 0.252 105 0.252 106 0.252 107 0.253 108 0.253 109 0.252 110 0.252 111 0.252 112 0.252 113 0.252 114 0.252 115 0.253 116 0.253 117 0.252 118 0.252 119 0.252 120 0.253 121 0.253 122 0.253 123 0.252 124 0.252 125 0.251

Location No. Thickness (in) 126 0.251 127 0.251 128 0.252 129 0.252 130 0.252 131 0.252 132 0.252 133 0.245 134 0.247 135 0.247 136 0.247 137 0.247 138 0.247 139 0.247 140 0.247 141 0.247 142 0.247 143 0.247 144 0.245 145 0.245 146 0.248 147 0.248 148 0.248 149 0.247 150 0.247 151 0.246 152 0.246 153 0.246 154 0.246 155 0.248 156 0.248 157 0.248 158 0.246 159 0.246 160 0.246 161 0.248 162 0.248 163 0.248 164 0.247 165 0.247

SHELL DROP UT MEASUREMENTS

4-5 0.254 4-5 0.253 4-5 0.256 4-5 0.248 4-5 0.248 3-6 0.257 3-6 0.258 3-6 0.260 3-6 0.259 3-6 0.261 2-6 0.261 2-6 0.263 2-6 0.263 2-6 0.264 2-6 0.263 1-1 0.253 1-1 0.256 1-1 0.256 1-1 0.257 1-1 0.257

OSHA ACCESS STRUCTURE REPORT

OSHA Stairway Data

Handrail Actual (in) OSHA Req'd min (in) max (in)

Handrail Height 31 SAT 30 34 Step Width 30 SAT 22 N/A Step Rise 8.5 SAT N/A N/A Bottom Step Rise 13.5 UNSAT 6.5 9.5

APPENDIX B: 3-D DOCUMENTATION AND

ANALYSIS

The purpose of this study is to determine the tank shell locations of buckled areas, flat spots, and peaking and banding at weld joints. Shell distortion can be caused by many conditions such as foundation settlement, over- or under-pressuring, high wind, poor shell fabrication, or various repair techniques or tank modifications.

ISOLATED SHELL DISTORTION

Roundness Report Course 1: Weld 1 +0.7500 ft

Station Radius Delta(ft) Pass/Fail 0.0625ft

1 -0.0031 PASS

2 -0.0203 PASS

3 -0.0188 PASS

4 0.0162 PASS

5 0.0143 PASS

6 0.0177 PASS

7 -0.0012 PASS

8 -0.0322 PASS

9 0.0171 PASS

10 0.0156 PASS

11 -0.0061 PASS

12 -0.0189 PASS

APPENDIX C: TANK DRAWINGS

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AutoCAD SHX Text A. 4" BLIND FLANGE 4" BLIND FLANGE B. 6" SHAND & JURS VACUUM 6" SHAND & JURS VACUUM C. 10" ATG 10" ATG D. 24" MANWAY WITH A 12" VENT 24" MANWAY WITH A 12" VENT E. 10" SOR 704 MECHANICAL 10" SOR 704 MECHANICAL LEVEL SWITCH F. 1 " CAPPED NOZZLE 1 " CAPPED NOZZLE 34" CAPPED NOZZLE G. 2" VAREC LEVEL GAUGE 2" VAREC LEVEL GAUGE H. 1 " CAPPED NOZZLE1 " CAPPED NOZZLE34" CAPPED NOZZLE

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AutoCAD SHX Text A. 3" LOW POINT DRAIN 3" LOW POINT DRAIN B. 24" DIAMETER MANWAY 24" DIAMETER MANWAY C. " WATER SEPARATOR/PRODUCT 34" WATER SEPARATOR/PRODUCT RETURN SYSTEM D. 6" RECEIPT 6" RECEIPT E. 10" ISSUE 10" ISSUE F. 2" ATG 2" ATG G. 2" PLUGGED NOZZLE 2" PLUGGED NOZZLE H. 24" DIAMETER MANWAY 24" DIAMETER MANWAY I. 1" LOW LEVEL ALARMS 1" LOW LEVEL ALARMS J. 1" HIGH LEVEL ALARMS 1" HIGH LEVEL ALARMS K. ATG BRACKETS ATG BRACKETS L. LLD BRACKETS LLD BRACKETS M. BRACKET BRACKET N. BRACKET WITH GROUND WIREBRACKET WITH GROUND WIRE

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Tank 111 Fort Hood Killeen, TX 76544

APPENDIX D: API 653 CHECKLISTS FOR TANK

INSPECTIONS

Tank In-Service Inspection Checklist

Item Completed

X C.1.1 Foundation

Measure foundation levelness and bottom elevations (see Annex B for extent of measurements). X C.1.1.1 Concrete Ring a Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell.

X b Inspect drain openings in ring, back of waterdraw basins and top surface of ring for indications of bottom leakage. X c Inspect for cavities under foundation and vegetation against bottom of tank. X d Check that runoff rainwater from the shell drains away from tank. X e Check for settlement around perimeter of tank. X

C.1.1.2 Asphalt a Check for settling of tank into asphalt base which would direct runoff rain water under the tank instead of away from it.

b Look for areas where leaching of oil has left rock filler exposed, which indicates hydrocarbon leakage. N/A

C.1.1.3 Oiled Dirt or Sand

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

N/A

C.1.1.4 Rock

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

Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

N/A

C.1.1.5 Site Drainage a Check site for drainage away from the tank and associated piping and manifolds. X b Check operating condition of the dike drains. X

C.1.1.6 Housekeeping Inspect the area for buildup of trash, vegetation, and other inflammables buildup. X

C.1.1.7 Cathodic Protection Review cathodic protection potential readings. N/A

C.1.2 Shells C.1.2.1 External Visual Inspection a Visually inspect for paint failures, pitting, and corrosion. X b Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X c Inspect the bottom-to-foundation seal, if any. X

Completed

X C.1.2.2 Internal (Floating Roof Tank)

Visually inspect for grooving, corrosion, pitting, and coating failures. N/A C.1.2.3 Riveted Shell Inspection a Inspect external surface for rivet and seam leaks. N/A b Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A c Inspect rivets for corrosion loss and wear. N/A d Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A e If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern: number of rows, rivet size, pitch length, and note whether the joint is butt-riveted or lap-riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks) a Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds. N/A b Check support welds to shell for pitting, especially on shell plates. N/A c Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 Shell Appurtenances C.1.3.1 Manways and Nozzles a Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates. X b Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X c Inspect for flange leaks and leaks around bolting. X d Inspect sealing of insulation around manways and nozzles. X e Check for inadequate manway flange and cover thickness on mixer manways. X

C.1.3.2 Tank Piping Manifolds a Inspect manifold piping, flanges, and valves for leaks. X b Inspect fire fighting system components. X c Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement. X d Check for adequate thermal pressure relief of piping to the tank. X e Check operation of regulators for tanks with purge gas systems. N/A f Check sample connections for leaks and for proper valve operation. X g Check for damage and test the accuracy of temperature indicators. X h Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System a Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X b Inspect autogauge head for damage. X c Bump the checker on autogauge head for proper movement of tape. X d Identify size and construction material of autogauge tape guide (floating roof tanks). N/A e Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). N/A

Completed

X f Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X g On floating roof tanks, when the roof is in the lowest position, check that no more than two ft of tape are exposed at the end of the tape guide. N/A h Inspect condition of board and legibility of board-type autogauges. X i Test freedom of movement of marker and float. X

C.1.3.4 Shell-Mounted Sample Station a Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line. X b Check circulation pump for leaks and operating problems. N/A c Test bracing and supports for sample lines and equipment. X

C.1.3.5 Heater (Shell Manway Mounted) Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer a Inspect for proper mounting flange and support. N/A b Inspect for leakage. N/A c Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation a Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly. N/A b Floating. With tank half full or more, lower the swing line, then let out cable and check if swing has pulled cable tight, indicating that the winch is operating properly. N/A c Indicator. Check that the indicator moves in the proper direction: Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite.

N/A

C.1.3.8 Swing Lines: External Guide System Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition a For nonstainless steel cable, check for corrosion over entire length. N/A b All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison Check for water or gravity differences that would indicate a leaking swing joint. N/A

C.1.3.12 Swing Lines: Target

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

Completed

X C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

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

X

C.1.4.2 Deck Plate External Corrosion Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck. X

C.1.4.3 Roof Deck Drainage

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

C.1.4.4 Level of Floating Roof

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

N/A

C.1.4.5 Gas Test Internal Floating Roof

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

C.1.4.6 Roof Insulation a Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation. N/A b Inspect for wet insulation under the weather coat. N/A c Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area. N/A

C.1.4.7 Floating Roof Seal Systems a Inspect the condition of the seal, measure and record maximum rim spaces and seal to- shell gaps around the full roof circumference at the level of inspection. N/A

Completed

X NOTE Inspection of the seal and measurement of the rim spaces and seal-to-shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

b Measure and record annular space at 30-ft spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly opposite pairs. N/A

1) _______ _______ Opposite pair 1. N/A

2) _______ _______ Opposite pair 2. N/A c Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough). N/A d Inspect fabric for deterioration, holes, tears, and cracks. N/A e Inspect visible metallic parts for corrosion and wear. N/A f Inspect for openings in seals that would permit vapor emissions. N/A g Inspect for protruding bolt or rivet heads against the shell. N/A h Pull both primary and secondary seal systems back all around the shell to check their operation. N/A i Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow. N/A j Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. N/A C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch a Inspect condition and functioning of sample hatch cover. X b On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover. N/A c Check for corrosion and plugging on thief and gauge hatch cover. X d Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance. N/A e Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X f On floating roof sample hatch and recoil systems, inspect operation of recoil reel and condition of rope. N/A g Test operation of system. N/A h On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample). N/A

C.1.5.2 Gauge Well a Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. X b Check for a hold-off distance marker and tab with hold-off distance (legible). N/A c On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving. N/A d If accessible, check the distance from the gauge well pipe to the tank shell at different levels. N/A e If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange. N/A

C.1.5.3 Fixed Roof Scaffold Support Inspect scaffold support for corrosion, wear, and structural soundness. X

Completed

X C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof) a Check the hatch for corrosion and missing bolts. X b Look for corrosion on the tape guide’s and float guide’s wire anchors. X

C.1.5.5 Autogauge: Float Well Cover a Inspect for corrosion. X b Check tape cable for wear or fraying caused by rubbing on the cover. X

C.1.5.6 Sample Hatch (Internal Floating Roof) a Check overall conditions. N/A b When equipped with a fabric seal, check for automatic sealing after sampling. N/A c When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-mounted Vents (Internal Floating Roof) Check condition of screens, locking and pivot pins. N/A

C.1.5.8 Gauging Platform Drip Ring

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

C.1.5.9 Emergency Roof Drains

Inspect vapor plugs for emergency drain: that seal fabric discs are slightly smaller than the pipe ID and that fabric seal is above the liquid level. N/A

C.1.5.10 Removable Roof Leg Racks Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position. N/A

C.1.5.12 Rim Vents a Check condition of the screen on the rim vent cover. N/A b Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. N/A

C.1.5.13 Pontoon Inspection Hatches a Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A b Test for explosive gas (an indicator of vapor space leaks). N/A c If pontoon hatches are equipped with locked down coves, check for vent tubes. Check that vent tubes are not plugged up. Inspect lock-down devices for condition and operation. N/A

C.1.6.1 Accessways See Tank Out-of-service Inspection Checklist, Item C.2.12. X

NOTES:

APPENDIX E: PHOTOGRAPHS

E.1: Tank 111 North View E.2: Tank 111 South View

E.3: Tank 111 East View E.4: Tank 111 West View

E.5: 24” South Manway E.6: 24” North Manway

E.7: 10” Issue E.8: 6” Receipt

E.9: 2” Low Point Drain E.10: Ground Wire

E.11 Nameplate E.12: Ground Wire

E.13: 1” Low Level Alarms E.14: 1” High Level Alarms & High Level Shut-off

E.15: 4” Blind Flange and Scaffold Support E.16: 24” Manway with atmospheric Vent

E.17: ATG E.18: 6” High Level Alarm

E.19: 6” Shand & Jurs Pressure Vacuum Vent E.20: 2” Varec Level Gauge

E.21: Varec Level Gauge