Attachment J.4 - Fac 1344 (Tank 2) OOS 2013.pdf

API STANDARD 653 INSPECTION REPORT

OUT-OF-SERVICE INSPECTION

TANK #2 (Facility No: 1344)

LITTLE ROCK AIR FORCE BASE

JACKSONVILLE, ARKANSAS

Prepared for:

United States Army Corps of Engineers Omaha District

1616 Capitol Avenue Omaha, Nebraska 68192-4901

Prepared by:

CAPE Environmental, Inc.

4013A Seaboard Court, Suite 1

Portsmouth, Virginia 23701

(757) 405-1291

Project Number: 00075.002.901

May 6, 2013

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

ER-LITTLEROCKAFB-2

EXECUTIVE SUMMARY

An API Standard 653 Out-of-Service Inspection of Tank #2 was completed on April 25, 2013. The purpose of this inspection was to collect data and establish a data base for present and future inspections and evaluations. The evaluation of the shell settlement was satisfactory. The shell nozzle and reinforcement evaluation of the accessible nozzles shows that the nozzles are adequately reinforced and have a minimum remaining life of greater than 50 years. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of greater than 30 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to April 2018, and the next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to April 2028 in accordance with API Standard 653. The bottom service life evaluation shows that the in-service interval of operation (years to next internal inspection) to be twenty years under current conditions, thereby, the next internal inspection should be accomplished by a Certified Inspector prior to April 2033 in accordance with API Standard 653. Inspection Results are listed in 4.0. Recommendations for Compliance with API Standard 653 are made in 5.0, and Other Recommendations are made in 6.0.

API Standard 653 Compliance Findings:

1.) The reinforcement plates for the 36-inch manway (Shell Nozzle C) and the 8-inch product (Shell Nozzle N) are within 3-inches of the shell-to-bottom weld.

2.) The floating roof peripheral seal has completely deteriorated.

3.) The penetration seal on the floating roof for the internal vertical ladder is torn and deteriorated.

4.) The floating roof has two pontoons that are weeping product.

UFC 3-460-1 Compliance Findings:

5.) The 8-inch product issue piping (Shell Nozzle D) extends to the center of the tank.

6.) The tank does not have a low level or low-low level alarm installed.

7.) The product recovery system does not have a 2-inch stainless steel DBBV installed.

8.) The tank does not have a shell mounted manway installed above the floating roof.

9.) The pressure relief piping does not have test Tee's to test the valves for proper operation.

10.) The fixed roof does not have scaffold supports.

11.) The manway covers lack a support system such as davit arms.

12.) The fixed roof does not have a 4-inch stilling well for water probe.

13.) The fixed roof does not have an 8-inch slotted aluminum stilling well.

14.) The fixed roof does not have an 8-inch gauge hatch for water sampling near the tank center.

15.) The fixed roof does not have a safety railing around the entire roof circumference.

Other Significant Findings:

16.) The containment area liner is torn near the containment drain.

17.) The leak detection tell-tale drains do not have valves installed.

18.) The bottom-to-foundation is not evident along the entire ringwall circumference. (Approximately

270 LF).

19.) The three anti-rotation device anchors are welded directly to the tank bottom plates.

ii

20.) The tank shell does not have a data plate installed.

21.) The external tank shell coating system has visible cracks and a chalky surface. Minor visible coating failures are evident over the entire external shell.

22.) The reinforcement plate for the 24 x 36-inch oval manway does not have a tell-tale hole installed.

23.) The manual ATG tape is twisted just above the deck level of the floating roof.

24.) The auto actuator on the 8-inch DBBV product (Shell Nozzle N).

25.) The 3-inch low point suction does not have a quick disconnect Cam Lock type fitting.

26.) The tank is not electronically isolated from the product piping cathodic protection system.

27.) The fire fighting piping and foam chamber have coating failure and corrosion.

28.) The spiral stairway platform has minor visible coating failures and corrosion.

29.) The internal vertical ladder does not have a safety climb installed.

30.) The floating roof does not sit level upon its support legs and several legs no longer align with their striker plates on the tank bottom.

31.) The floating roof has 15 pontoons that are dented on the bottom and 9 pontoons that are crushed from above.

32.) The floating roof has two missing water drain tubes.

33.) The floating roof ground cable is not attached.

34.) The floating roof does not have a data plate installed listing manufacturer, roof type, date of installation, and weight.

35.) One fixed roof ARD anchor support has light visible along the edge of the nozzle indicating a hole in the anchor cap or roof plate. The edge of the roof is not accessible.

36.) The fixed roof has coating failure and vegetation growth on the roof plates and nozzles.

37.) The hinges on the 30 x 30-inch access hatch cover do not have a locking mechanism.

38.) The existing safety railing for the 30 x 30-inch access hatch does not have room for a safety tripod to be installed over the hatch when personnel enter the tank through the access hatch.

iii

TABLE OF CONTENTS

Section Page

Signature Page Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v List of Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

1.0 Introduction

1.1 Purpose

2.0 References

2.1 American Petroleum Institute

2.2 American Society of Mechanical Engineers

2.3 Code of Federal Regulations

2.4 National Association of Corrosion Engineers

2.5 National Fire Protection Association

2.6 Unified Facilities Criteria 4

3.0 Tank Description

4.0 Inspection Results

4.1 Secondary Containment

4.2 Foundation

4.3 Cathodic Protection

4.4 Bottom

4.5 Shell

4.6 Shell Appurtenances

4.7 Accessways

4.8 Floating Roof

4.9 Floating Roof Appurtenances

4.10 Fixed Roof

4.11 Fixed Roof Appurtenances

5.0 Recommendations for Compliance with API Standard 653

5.1 Secondary Containment

5.2 Foundation

5.3 Cathodic Protection

5.4 Bottom

5.5 Shell

5.6 Shell Appurtenances

iv

TABLE OF CONTENTS

Section Page

5.7 Accessways

5.8 Floating Roof

5.9 Floating Roof Appurtenances

5.10 Fixed Roof

5.11 Fixed Roof Appurtenances

6.0 Other Recommendations

6.1 Secondary Containment

6.2 Foundation

6.3 Cathodic Protection

6.4 Bottom

6.5 Shell

6.6 Shell Appurtenances

6.7 Accessways

6.8 Floating Roof

6.9 Floating Roof Appurtenances

6.10 Fixed Roof

6.11 Fixed Roof Appurtenances

7.0 Serviceability

LIST OF APPENDICES

Appendix A Engineering Calculations Appendix B Engineering Drawings Appendix C Engineering Data Appendix D API Standard 653 Checklists for Tank Inspection Appendix E Photographs v

LIST OF ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

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

RP Recommended Practice

RT Radiography Testing

TML Thickness Measurement Location

UT Ultrasonic Testing

VT Visual Testing vi

1.0 INTRODUCTION

1.1 Purpose:

1.1.1 The on-site inspection information acquired for this tank, as well as, historical information was analyzed under CAPE Environmental, Inc.'s inspection program Version 3.4, to provide a standardized report format of tank conditions, recommendations, and serviceability requirements to satisfy federal, state and local regulations, in addition to the API Standards and/or construction standards for this tank.

1.1.2 This report provides an engineering evaluation of Tank #2 located at the Little Rock Air Force Base facility in Jacksonville, Arkansas. This report summarizes the results of an API Standard 653 Out-of-Service Inspection conducted by CAPE Environmental, Inc. , Project Number 00075.002.901.

1.1.3 This inspection was completed on April 25, 2013.

1.1.4 Our policy is: "Provide to the storage tank owner and/or manager the most precise and complete inspection and report possible, using experienced inspectors and technicians, advanced technologies, and analytical software."

2.0 REFERENCES

2.1 American Petroleum Institute:

2.1.1 API Recommended Practice 574, Inspection Practices for Piping System Components.

2.1.2 API Recommended Practice 575, Inspection of Atmospheric and Low-Pressure Storage Tanks.

2.1.3 API Standard 650, Welded Steel Tanks for Oil Storage.

2.1.4 API Recommended Practice 651, Cathodic Protection of Aboveground Petroleum Storage Tanks.

2.1.5 API Recommended Practice 652, Lining of Aboveground Petroleum Storage Tank Bottoms.

2.1.6 API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction.

2.2 American Society of Mechanical Engineers Codes:

2.2.1 ASME Boiler and Pressure Vessel Code; Section V, Non-Destructive Examination.

2.2.2 ASME Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications.

2.2.3 ASME Boiler and Pressure Vessel Code; Section VIII, Division 1, Rules for Construction of Pressure Vessels.

2.3 Code of Federal Regulations:

2.3.1 29 CFR 1910, Permit-Required Confined Spaces for General Industry.

2.3.2 40 CFR 112, Oil Pollution Prevention.

2.4 National Association of Corrosion Engineers:

2.4.1 NACE Recommended Practice, RP0184-91, Repair of Lining Systems.

2.4.2 NACE Recommended Practice, RP0193-93, External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms.

2.4.3 NACE Recommended Practice, RP0288-94, Inspection of Linings on Steel and Concrete.

2.5 National Fire Protection Association:

2.5.1 NFPA-30, Flammable and Combustible Liquids Code.

2.6 Unified Facilities Criteria:

2.6.1 UFC 3-460-01, August 2010, Petroleum Fuel Facilities.

2.6.2 UFC 3-460-03, January 2003, Operation and Maintenance: Maintenance of Petroleum Systems.

3.0 TANK DESCRIPTION

3.1 Tank Description:

Owner/Operator: Little Rock Air Force Base Location: Jacksonville, Arkansas GPS Coordinates: Latitude: N 34o 54.3120; Longitude: W 92o 7.7857 Facility Number: 1344 Tank Number: 2 Service: Jet A Specific Gravity: 0.84 Nominal Diameter: 85 feet Nominal Shell Height: 38 feet, 10 inches Maximum Liquid Level: 29 feet, 7 inches Low-Low Level Alarm: None Low Level Alarm: None High Level Alarm: None High Level Control Shutoff: None High-High Level Alarm: None Shell Overflow Height: 34 feet, 2 inches Nominal Capacity: 1,230,913 gallons; 29,307 barrels Configuration: Vertical Aboveground Storage Tank Foundation: Concrete Ringwall Construction: Bottom: Lap-Welded

Shell: Butt-Welded Floating Roof: Aluminum Skin w/ Log Type Pontoons Fixed Roof: Lap-Welded

Material: Bottom: Carbon Steel, Unknown Grade Shell: Carbon Steel, Unknown Grade Floating Roof: Aluminum, Unknown Grade Fixed Roof: Carbon Steel, Unknown Grade

Tank Built: 1954 Tank Age: 59 years Tank Upgrades: 2004: Coating Repairs on Bottom Plates

August 1995: Slotted Bottom, Secondary Containment, Leak Detection, and Cathodic Protection Installed September 1985: ATG Gauge Tape and Pressure Relief Piping Installed August 1982: Floating Roof Installed

Operating Limits: Minimum Metal Temperature: 12oF Maximum Metal Temperature: Ambient Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product

Seismic Zone: 1 Construction Code: API Standard 12C Inspection Type: Out-of-Service Inspection w/ MFL Bottom Scan Inspection Date: April 25, 2013 Last External Visual Inspection Year: 2004 Last External Ultrasonic Thickness Inspection Year: 2004 Last Out-of-Service Inspection Year: 2004

4.0 INSPECTION RESULTS

4.1 Secondary Containment: The secondary containment area is constructed of earthen walls and floor with an HDPE liner. The capacity of the secondary containment area appears to be sufficient to contain the stored product and appears to be properly graded to drain water away from the tank in accordance with NFPA 30. The secondary containment drain system is in satisfactory condition.

4.1.1 Significant Findings: The HDPE liner is torn near the containment drain (see UFC 3-460-01, Section 8.14.2.1 and Photographs in Appendix E).

4.2 Foundation: The tank bears on top of a concrete ringwall. The tank has a secondary containment liner and leak detection underneath the bottom. The foundation was evaluated for shell settlement in accordance with API Standard 653 and is in satisfactory condition.

4.2.1 Significant Findings: The bottom-to-foundation sealant has failed along the entire perimeter of the foundation (see API Standard 653, Annex C, Section C.1.2.1(c), and Photographs in Appendix E). The leak detection tell-tale drains do not have valves installed (no reference; see Photographs in Appendix E).

4.3 Cathodic Protection: The tank has an impressed current cathodic protection system.

4.3.1 Significant Findings: No significant findings were noted during this inspection.

4.4 Bottom: The tank is a lap-welded cone-down type bottom. The bottom has a thin film coating that ranged from 16.3 mils to 23.4 mils in thickness. The tank has leak detection and secondary containment under the bottom. The nominal thickness of the bottom is 0.3125 inches.

The bottom was scanned (approximately 95%) for underside corrosion using Magnetic Flux Leakage (MFL) technology. The MFE 2412 Mark II unit was used for the MFL floor scan. The MFL unit did not reveal any significant underside corrosion from the MFL scan. The bottom has no significant stockside (top side) pitting. The general thickness of each bottom plate was measured using ultrasonic technology (UT). The general thickness of the bottom ranged from a minimum of 0.304 inches to a maximum of 0.320 inches. The general thickness measurements and associated thickness measurement locations (TML) are listed in the Bottom Plate Thickness Measurements table in Appendix C. The general thickness of the sump is measured using ultrasonic technology (UT) and is in satisfactory condition. The floor welds were visually examined and are in satisfactory condition. The bottom service life evaluation shows that the in-service interval of operation (years to next internal inspection) to be twenty years under current conditions, thereby, the next internal inspection should be accomplished by a Certified Inspector prior to April 2033 in accordance with API Standard 653. The bottom service life evaluation is shown in Appendix A.

4.4.1 Significant Findings: The three anti-rotation device anchors are welded directly to the tank bottom plates (see API Standard 653, Annex C, Section C.2.3(l), and Photographs in Appendix E).

4.5 Shell: The tank shell consists of five (5) butt-welded courses. The exterior of the shell has a thin coating system that ranged between 9.87 and 21.8 mils in thickness. The interior of the shell has a thin coating system that ranged between 15.1 and 37 mils in thickness. The interior coating of the shell is in satisfactory condition. The shell was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Shell Plate Thickness Measurements table in Appendix C. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of greater than 30 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to April 2018, and the next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to April 2028 in accordance with API Standard 653. The shell service life evaluation is shown in the Shell Service Life Evaluation table in Appendix A. Roundness, plumbness, peaking, and banding of the shell are within the allowable tolerances of API Standard 653.

4.5.1 Significant Findings: The exterior coating of the shell has isolated failures, visible cracks, and a chalky surface (see API Standard 653, Annex C, Section C.1.2.4(f), and Photographs in Appendix E). The tank does not have a data plate installed (see API Standard 653, Section 13, and Photographs in Appendix E).

4.6 Shell Appurtenances: The accessible shell nozzles and reinforcements were evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements are listed in the Shell Nozzle, Nozzle Reinforcement and Insert Measurements table in Appendix C. The shell nozzle and reinforcement evaluation is performed on all accessible nozzles. The ultrasonic thickness measurements on the nozzles revealed no significant loss of metal from corrosion and erosion. All nozzles that were accessible to ultrasonic examination have a minimum remaining life of greater than 50 years. All nozzles were adequately reinforced. The shell nozzle and reinforcement evaluation is shown in the Shell Nozzle and Reinforcement Evaluation table in Appendix A. The 12-inch product issue (Shell Nozzle C), the 3-inch low point suction (Shell Nozzle F), and the 8-inch product (Shell Nozzle N) are internal elbow-down nozzles. The 12-inch product issue (Shell Nozzle C) and the 8-inch product issue (Shell Nozzle D) have over-pressure protection. The nozzles are shown on the Shell Layout drawings in Appendix B, as well as, listed in the Shell Nozzle, Nozzle Reinforcement and Insert Measurements table in Appendix C. The product level is monitored by an autogauge (ATG).

The product level is electronically monitored.

4.6.1 Significant Findings: The reinforcement plates for the 36-inch manway (Shell Nozzle B) and the 8-inch product (Shell Nozzle N) are within 3-inches of the bottom-to-shell weld. Minimum spacing is 3-inches (see API Standard 650, Section 5.7.3.3, and Figure 5-6, and Photographs in Appendix E). The 8-inch product issue (Shell Nozzle C) piping extends to the center of the tank directly over the sump (see AW-78-24-27, Drawing D.08-A1 and Photographs in Appendix E). The pressure relief piping lacks the necessary valves, fittings, and test Tee's to conduct testing of the relief valve(s) (see UFGS Guidelines). The ball valves on the product recovery piping does not meet the current UFGS guidelines (see UFGS Guidelines). No davit arms for the manway covers are installed (see UFGS Guidelines). The tank does not have a low level alarm (LLA) or a low-low level alarm (LLLA) installed (see UFC 3-460-01, Table 8-1(k) and Photographs in Appendix E). The 24 x 36-inch oval manway (Shell Nozzle P) reinforcement plate does not have a tell-tale hole installed (see API Standard 650, Section

5.7.2.10 and Photographs in Appendix E). The ATG tape is twisted near the deck of the floating roof (see API Standard 653, Annex C, Section C.2.10.10(d), and Photographs in Appendix E). The tank does not have a manway installed on the shell above the level of the floating roof (see UFC 3-460-01, Table 8-1(c)). The Owner/Operator reports that the auto actuator for the 8-inch DBBV for the product nozzle (Shell Nozzle N) is not functioning properly (see API Standard 653, Annex C, Section C.1.3.2(a) and Photographs in Appendix E). The 3-inch low point suction (Shell Nozzle F) does not have a quick disconnect such as a Cam Lock fitting (see Photographs in Appendix E).

The tank is not electronically isolated from the product piping cathodic protection system.

4.7 Accessways: The fixed roof is accessible via a spiral stairway. The floating roof is accessible via an internal vertical ladder.

4.7.1 Significant Findings: The spiral stairway platform has visible coating failures and surface corrosion (see API Standard 653, Annex C, Section C.2.12.4(a) and Photographs in Appendix E). The internal vertical internal ladder does not have a safety slide installed (see AW-78-24-26).

4.8 Floating Roof: The floating roof is constructed of aluminum skin and log type pontoons.

The maximum rim spacing measured 13.5-inches. The maximum seal-to-shell gap measured

13.5 inches. The annular space between the floating roof and the shell measured between 6.5 and 13.5 inches. The pontoons are vapor tight.

4.8.1 Significant Findings: Two pontoons have minor weeps (see API Standard 653, Annex C, Section C.2.8.2(a) and Photographs in Appendix E). The floating roof does not sit level upon its support legs (see API Standard 653, Annex C, Section C.1.4.4 and Photographs in Appendix E). The floating roof has 15 pontoons that are dented on the bottom and 9 pontoons that are crushed from above (see Photographs in Appendix E).

The floating roof aluminum sheet has five holes (see Photographs in Appendix E).

4.9 Floating Roof Appurtenances:

4.9.1 Significant Findings: The roof peripheral foam log primary seal is torn and deteriorated and has absorbed product (see API Standard 650, Section H.4.4, and Photographs in Appendix E). The penetration seal for the internal vertical ladder has torn and deteriorated (see API Standard 650, Section H.4.5 and Photographs in Appendix E).

The floating roof has two missing water drain tubes (see API Standard 653, Annex C, Section C.2.10.5(c) and Photographs in Appendix E). The floating roof ground cable is not attached (see Photographs in Appendix E). The floating roof does not have a data plate installed listing manufacturer, roof type, date of installation, and weight.

4.10 Fixed Roof: The topside coating of the floating roof measured between 14.4 and 20.6 mils in thickness. The fixed roof was evaluated for remaining metal thickness using ultrasonic technology. The fixed roof thickness ranged from a minimum of 0.178 inches to a maximum of

0.205 inches. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Fixed Roof Plate Thickness Measurements table in Appendix C.

4.10.1 Significant Findings: The fixed roof does not have scaffold supports installed (see API Standard 653, Annex C, Section C.1.5.3 and UFC 3-460-01, Table 8-1(ee)).

There is visible coating failures and surface corrosion on the fixed roof plates and roof nozzles (see Photographs in Appendix E and API Standard 653, Annex C, Section C.2.12.1(b)). One fixed roof ARD anchor support has light visible along the edge of the nozzle indicating a hole in the anchor cap or roof plate. The edge of the roof is not accessible (see Photographs in Appendix E and API Standard 650, Annex C, Section C.1.4.2). The existing safety railing for the 30 x 30-inch access hatch does not have room for a safety tripod to be installed over the hatch when personnel enter the tank through the access hatch (see Photographs in Appendix E). The fixed roof does not have a safety railing installed along the entire roof circumference (see Photographs in Appendix E and UFC 3-460-01, Table 8-1(j)).

4.11 Fixed Roof Appurtenances:

4.11.1 Significant Findings: The fixed roof does not have any 8-inch gaugewells or gauge hatches installed (see UFC 3-460-01, Table 8-1(q and r)). The hinges on the 30 x 30-inch access hatch cover do not have a locking mechanism. The four roof vent covers do not have locking mechanisms installed (see API Standard 653, Annex C, Section C.2.7.1(b)).

5.0 RECOMMENDATIONS FOR COMPLIANCE

WITH API STANDARD 653

5.1 Secondary Containment:

5.1.1 No recommendations at this time.

5.2 Foundation:

5.2.1 No recommendations at this time.

5.3 Cathodic Protection:

5.3.1 No recommendations at this time.

5.4 Bottom:

5.4.1 No recommendations at this time.

5.5 Shell:

5.5.1 No recommendations at this time.

5.6 Shell Appurtenances:

5.6.1 Due to the successful operating history of the tank, and that no shell deflection or deformation is evident on the shell near shell nozzles B and N no repairs are recommended at this time to repair the insufficient weld spacing. Should shell deflection or deformation become evident in the future, repairs should be considered to bring the reinforcement plates into compliance with API Standards.

5.7 Accessways:

5.7.1 No recommendations at this time.

5.8 Floating Roof:

5.8.1 Repair or replace the two weeping pontoons in accordance with the manufacturers specifications.

5.9 Floating Roof Appurtenances:

5.9.1 Replace the roof peripheral seal.

5.9.2 Replace the penetration seal for the vertical ladder.

5.10 Fixed Roof:

5.10.1 No recommendations at this time.

5.11 Fixed Roof Appurtenances:

5.11.1 No recommendations at this time.

6.0 OTHER RECOMMENDATIONS

6.1 Secondary Containment:

6.1.1 Repair the HDPE liner near the containment drain.

6.2 Foundation:

6.2.1 Replace the bottom-to-foundation sealant.

6.2.2 Install valves on the four leak detection tell-tale drains.

6.3 Cathodic Protection:

6.3.1 No recommendations at this time.

6.4 Bottom:

6.4.1 Install reinforcement plates on the bottom between the anti-rotation device anchors and bottom plates.

6.5 Shell:

6.5.1 Install a data plate on the tank shell.

6.5.2 Repair the coating failures on the tank shell.

6.6 Shell Appurtenances:

6.6.1 Modify the product issue piping so that it extends 1/2 the tank radius.

6.6.2 Install manway cover support systems, such as davit arms, to properly and safely support the manway covers when they are removed for tank cleaning and inspection.

6.6.3 Install low and low-low level alarms to the tank shell.

6.6.4 Install a tell-tale hole on the reinforcement plate for the 24 x 36" oval manway.

6.6.5 Repair or replace the ATG float tape.

6.6.6 Install a 36-inch floating roof manway on the shell above the level of the floating roof when the roof is in a high leg position.

6.6.7 Repair or replace the auto actuator on the 8-inch product DBBV.

6.6.7 Replace the existing pressure relief piping with socket weld SCH 80 pipe and fittings, and lockable ball valves. Install test Tee's for testing the pressure relief valves.

6.6.8 Install a quick disconnect on the 3-inch low point suction nozzle.

6.6.9 Install isolation kits to isolate the tank from the product piping cathodic protection system.

6.6.10 Remove the corrosion and repair the coating system on the fire fighting piping and repair or replace the foam chamber.

6.7 Accessways:

6.7.1 Install a safety climb on the internal vertical ladder per AW-78-24-26.

6.7.2 Remove the corrosion and repair the paint failures on the spiral stairway platform.

6.8 Floating Roof:

6.8.1 Due to the age and condition of the floating roof no repairs to the roof legs are recommended at this time.

6.8.2 Replace the crushed and bent pontoons.

6.8.3 Repair the five holes on the floating roof deck.

6.9 Floating Roof Appurtenances:

6.9.1 Replace the two missing roof drain tubes.

6.9.2 Attach the floating roof ground cable.

6.9.3 Install a data plate on the floating roof.

6.10 Fixed Roof:

6.10.1 Install scaffold supports on the fixed roof.

6.10.2 Repair the hole near the ARD anchor cap.

6.10.3 Remove the vegetation growth and replace the fixed roof coating system.

6.10.4 Expand the safety railing around the vertical ladder hatch to allow for a safety tripod.

6.10.5 Install a safety railing around the perimeter of the roof edge.

6.11 Fixed Roof Appurtenances:

6.11.1 Install locking hinges on the vertical ladder hatch cover.

6.11.2 Install locking mechanisms on the four roof vent covers.

6.11.3 Install an 8-inch gauge hatch for water sampling and an 8-inch aluminum slotted stilling well for manual gauging.

Appendix A

Engineering Calculations

1.

2.

3.

4.

Bottom Service Life Evaluation Internal Shell Settlement Evaluation Shell Service Life Evaluation Shell Nozzle and Reinforcement Evaluation

A-1

Bottom Service Life Evaluation

MRTbc = RTbc - Orbc(StPr + UPr)

MRTip = RTip - Orip(StPr + UPr)

Orbc = RTbc - MRTbc

(StPr + UPr)

Orip = RTip - MRTip

(StPr + UPr)

Where:

MRTbc or MRTip = Minimum remaining thickness at the end of the in-service period of operation, in inches.

Or or Orbc or Orip = In-service interval of operation (years to next internal inspection), in years; however, Or shall not exceed 20 years.

RTbc = Minimum remaining thickness from bottom side corrosion after repairs, in inches.

RTip = Minimum remaining thickness from internal corrosion after repairs, in inches.

StPr = Maximum rate of corrosion not repaired on the top side, in inches per year. StPr = 0 for coated areas of the bottom. The expected service life of the coating must equal or exceed Orip to use StPr = 0.

UPr = Maximum rate of corrosion on the bottom, in inches per year. To calculate the corrosion rate, use the minimum remaining thicknesses after repairs. Assume a linear rate based on the age of the tanks.

UPr = 0 for areas that have effective cathodic protection.

Note: For areas of a bottom that have been scanned by the magnetic flux leakage (or exclusion) process, and do not have effective cathodic protection, the thickness used for calculating UPr must be the lesser of the MFL threshold or the minimum thickness of corrosion areas that are not repaired. The MFL threshold is defined as the minimum remaining thickness to be detected in the areas inspected. The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than 0.04 inches in depth, based on company experience.

Areas of bottom side corrosion that are repaired should be evaluated with the corrosion rate for the repaired area unless the cause of corrosion has been removed. The evaluation is done by using the corrosion rate of the repaired area for UPr, and adding the patch plate (if used) thickness to the term "minimum of RTbc or RTip".

NOTE: The engineering data used to calculate the in-service interval of operation (Or) assumes the tank remains in the same service and all corrosion rates remain constant.

A-2

Bottom Service Life Evaluation

Present Condition: The tank bottom has a thin film coating system. The tank has an impressed current cathodic protection system, leak detection, and secondary containment under the bottom.

MRTbc or MRTip

RTip

RTbc

StPr

UPr

0.050 inches

0.3125 inches

0.2725 inches *

0.0002 inches/year **

0.0002 inches/year **

* The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than

0.040 inches in depth, based on company experience. No significant underside corrosion was detected. Therefore, RTbc is established at 0.2725 inches (original thickness of 0.3125 inches minus the 0.040 inches).

** A corrosion rate of 0.0002 inches/year was assumed for StPr and UPr for calculation purposes.

Orbc = RTbc - MRTbc =

0.2725 - 0.050 > 20 years(StPr + UPr) (0.0002 + 0.0002)

Orip = RTip - MRTip =

0.3125 - 0.050 > 20 years(StPr + UPr) (0.0002 + 0.0002)

Therefore, the in-service interval of operation (years to next internal inspection) is:

Or = 20 years

A-3

Internal Shell Settlement Evaluation

Maximum Permissible Out-of-Plane Deflection

| S | < 11L2Y

2EH

Where:

S L Y E H

Maximum permissible out-of-plane deflection, in feet.

Arc length between measurement points, in feet Yield strength, in pounds per square inch (psi) Young's modulus, in pounds per square inch (psi) Tank height, in feet

L Y E H S

26.7 feet 30,000 psi 29,000,000 psi

38.83 feet

0.1045 feet

A-4

Internal Shell Settlement Evaluation

Out-of-Plane Deflection

Si = Ui - (1/2Ui-1 + 1/2Ui+1)

Where:

S U

Calculated out-of-plane deflection, in feet.

Out-of-Plane settlement of point "i", in feet (+) when above cosine curve (-) when below cosine curve

U1

U2

U3

U4

U5

U6

U7

U8

U9

U10

-0.0042 -0.0067 0.0100 0.0233

-0.0142 -0.0158 -0.0233 0.0000 0.0067

-0.0258 feet feet feet feet feet feet feet feet feet feet

S1

S2

S3

S4

S5

S6

S7

S8

S9

S10

0.0121 -0.0096 0.0017 0.0254

-0.0179 0.0029

-0.0154 0.0083 0.0196

-0.0271 feet feet feet feet feet feet feet feet feet feet

The out-of-plane deflection is satisfactory since the magnitude of the highest calculated out-of-plane deflection, 0.0271 feet, is less than the magnitude of the maximum permissible out-of-plane deflection, 0.1045 feet.

A-5

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock Air Force Base, Jacksonville, AR

CAPE Environmental, Inc.

05/06/13 N/A N/A

Tank #2 SS-1Internal Shell Settlement Evaluation

Point #1 is at Seam #1 and each point is 36 degrees apart to the left viewing from the inside.

Seam #1 is the first seam right of the first manway right of the ladder in the first shell course viewing from the inside.

Out-of-Plane Settlement

Shell Settlement

Cosine Function Curve

Feet

Points 3 4 5 6 7 8 9 10 1 2 3

2.85

2.86

2.87

2.88

2.89

2.90

2.91

2.92

A -6

Shell Service Life Evaluation

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

tmin=

2.6(H-1)DG

SE

Lr= tact - tmin Cr= tprev - tact Iut= tact - tmin Iv= tact - tmin

Cr Y 2Cr 4Cr

Where:

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

tnorm = The nominal shell thickness, in inches.

tact = The current measured shell thickness, excluding pits and corrosion, in inches.

tprev = The previous measured shell thickness, excluding pits and corrosion or tnorm, in inches.

D = The nominal diameter of the tank, in feet.

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

Hc = The calculated safe fill height, in feet, for the current product.

G = The highest specific gravity of the contents.

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

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

S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of 0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S=21,000 psi. For elevated temperatures above 200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API-650 Appendix M or the product design stress value listed in Table M-1a or M-1b of API-650.

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

Lr = The remaining life of the shell, in years.

Cr = The shell corrosion rate, in inches per year.

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

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

Y = The years between the previous measured shell thickness (tprev) and the current measured shell thickness (tact), in years.

A-7

Shell Service Life Evaluation

Present Condition:

Plate Material: Carbon Steel, Unknown Grade

D H G

Y

85 feet

29.58 feet 0.84 59 years

Course No.

Course Height (feet)

Maximum Allowable

Stress (psi) (S)

Joint Efficiency

(E)

Previous Measured Thickness (inches)

(tprev)

Current Measured Thickness (inches)

(tact)

Minimum Acceptable Thickness (inches)

(tmin)

Corrosion Rate

(in./yr) (Cr)

Remaining Life

(years) (Lr)

Next Visual

Inspection (years)

(Iv)

Next Ultrasonic Thickness Inspection

(years) (Iut)

1 6.5 23,595 0.85 0.5000 0.487 0.2645 0.000220 1,011 5 15

2 8 23,595 0.85 0.4375 0.417 0.2044 0.000347 612 5 15

3 8 25,960 0.85 0.3125 0.301 0.1185 0.000195 935 5 15

4 8.17 25,960 0.85 0.2500 0.253 0.1000 0.0002* 765 5 15

5 8.17 25,960 0.85 0.2500 0.255 0.1000 0.0002* 775 5 15

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

The current measured thickness is based on the lowest ultrasonic thickness measurement for that course. The remaining life of the shell is greater than 30 years under present conditions. The current maximum liquid level is 29.58 and set by the Owner/Operator. The tank level can potentially be filled greater than this level, however, this tank was not evaluated above this level and should not be operated above this level without rerating the maximum liquid level. The next external visual inspection should be accomplished by a Certified Inspector prior to April 2018 in accordance with API Standard 653. The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to April 2028 in accordance with API Standard 653.

A-8

Shell Nozzle and Reinforcement Evaluation nt pD nR rnt

C h

Use smaller value t2.5 or 2.5 tn t2.5 or 2.5 t + ten Use smaller value t rt d et nd +or Rn+ t td +or R + t tnn Use larger value Use larger value

For nozzle wall abutting the vessel wallFor nozzle wall inserting through the vessel wall

A

A

A

= A

= A

= A3

A A1

2A

A3

A

A

= A42

= A5

= 5 ti ti fr2

= 5 ti ti fr2

= 5 ti ti fr2

= 5(tn- trn ) fr2 t = 5(tn- trn ) fr2 tn

= 2( t + tn) (E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)d

(E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)

= +Frt 2 tn (1 - fr1)d tr F

= outward nozzle weld = (leg) fr2

= inward nozzle weld = (leg)2 r f

= Same as A = Same as

, above A1, above

= 5(tn- trn ) fr2 t = 5(t n

- t rn ) f r2 t (2.5t n + t e ) f r2

= Same as A3, above

= outward nozzle weld = (leg) fr3

= outer element weld = (leg) fr4

= inward nozzle weld = (leg) fr2

= ( pD - fr4d - 2 tn)te

If A1 + 2A + A3+ 41A + A42

A If A1 + 2A + A3+ 41A + A42 A

If A1 + 2A + A3+ 41A + A42 A>+ 43A + 5A

Area required

Area available in shell; use larger value

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle; use the smallest value

Area available in outward weld Area available in inward weld

Opening is adequately reinforced Opening is NOT adequately reinforced; reinforcement required

Area required Area available in shell

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle

Area available in outward welds Area available in outer welds Area available in inward welds

Area available in element

Opening is adequately reinforced If A

A + A

A + A

A+

A +

A Opening is NOT adequately reinforced; additional reinforcement required<

Without Reinforcing Element

With Reinforcing Element

A-9

Minimum Required Thickness for Nozzles shall be determined from ASME Section VIII, Division 1, Part UG-27 as follows:

trn = PRn

SE - 0.6P

The remaining life of a tank or any of its components shall be determined using the formulas from API RP 575 as follows:

Cr = tprev - tact Lr = tact - trn

Y Cr

Where:

Dp = Outside diameter of reinforcing element as measured vertically, inches.

D = Outside diameter of pipe, inches.

d = finished diameter of circular opening in shell (inside diameter of nozzle), inches;

Where d = D - 2tn

E = Joint efficiency of nozzle; Use E = 1.0 for API calculations.

F = Correction factor for different plane variations; Use F = 1.0 for API calculations.

h = Distance nozzle projects beyond the inner surface of the wall, inches. Not to exceed 4tn for API calculations.

P = Internal design pressure, psi. Where, P = 0.433GH

Rn = Inside radius of nozzle, inches; Where Rn = d/2 Sn = Allowable stress in nozzle, psi.

fr = Strength reduction factor; Use fr = 1.0 for API calculations.

leg = Weld leg length, inches; Use leg = 0 for API calculations.

t = actual measured thickness of shell, inches; Use tact from Shell Service Life Evaluation.

tact = Actual measured thickness of nozzle, inches.

tprev = Previous measured thickness of nozzle or tn, inches.

te = Thickness of reinforcement plate or thickness of thickened insert less the actual measured thickness of the shell (t), inches.

tr = Minimum required shell thickness at the bottom of the nozzle, inches;

Where, tr = 2.6HDG/SE, however, tr shall not be less than 0.1 inch; Use E = 1.0 for API calculations; Use D and S from Shell Service Life Evaluation.

tn = External nominal pipe wall thickness, inches.

ti = Internal nominal pipe wall thickness, inches; Use ti = tn if nozzle projects inward for

API calculations.

trn = Required thickness of nozzle wall, inches.

G = Product specific gravity; Use G from Shell Service Life Evaluation.

H = Maximum liquid level above bottom of nozzle, feet.

Cr = Corrosion rate of nozzle, inches per year; Use Cr = 0.0002 inches/year, if Cr calculates to be less than 0.0002 inches/year.

LR = Remaining life of nozzle, years.

Y = Years between tprev and tact, in years.

A-10

Nozzle A: 6" Fire Fighting (Course #5) (Nozzle is above liquid level) d = 6.625 - 2(0.432) = 5.761 inches t = 0.255 inches Y = 18 years

Rn = 5.761/2 = 2.8805 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(0) = 0 psi tn = 0.432 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.432 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(0)(2.8805) < 0.1 inches

SE - 0.6P (20,000)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-11

Nozzle B: 36" Reference Manway (Course #1) d = 36 - 2(0.375) = 35.25 inches t = 0.487 inches Y = 18 years

Rn = 35.25/2 = 17.625 inches tr = 0.1 inches Dp = 78 inches

P = 0.433(0.84)(27.5) = 10 psi tn = 0.375 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.375 inches

E = 1 tact = 0.39 inches

Minimum Required Thickness Calculation:

trn = PRn =

(10)(17.625) = 0.0088 inches

SE - 0.6P (20,000)(1) - (0.6)(10)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.375 - 0.39 < 0.0002 inches/year

Y 18

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.39 - 0.1 > 50 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (35.25)(0.1) = 3.525 in2

A1

= d(t-tr) = (35.25)(0.487-0.1) = 13.6418 in2

= 2(t+tn)(t-tr) = (2)(0.487+0.375)(0.487-0.1) = 0.6672 in2

A2

= 5(tn-trn)t = (5)(0.375-0.1)(0.487) = 0.6696 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.375-0.1)(0.487)[(2.5)(0.375)+0.5] = 0.9626 in2

A3

= 5t ti = (5)(0.487)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [78-35.25-(2)(0.375)](0.5) = 21 in2

Area provided by A1 + A2 + A3 + A5 = 13.6418 in2 + 0.6696 in2 + 0 in2 + 21 in2 = 35.3114 in2. This is greater than the required area of 3.525 in2, therefore, the reinforcement is adequate.

A-12

Nozzle C: 12" Product Receipt (Course #1) d = 12.75 - 2(0.5) = 11.75 inches t = 0.487 inches Y = 18 years

Rn = 11.75/2 = 5.875 inches tr = 0.1737 inches Dp = 27 inches

P = 0.433(0.84)(28.58) = 10 psi tn = 0.5 inches te = 0.5 inches h = 2 inches ti = 0.5 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.459 inches

Minimum Required Thickness Calculation:

trn = PRn =

(10)(5.875) = 0.0029 inches

SE - 0.6P (20,000)(1) - (0.6)(10)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.459 = 0.002278 inches/year

Y 18

Remaining Life Calculation:

LR =

tact - trn =

0.459 - 0.1 > 50 years

Cr 0.002278

Reinforcement Calculations:

Formulas are simplified

A = dtr = (11.75)(0.1737) = 2.041 in2

A1

= d(t-tr) = (11.75)(0.487-0.1737) = 3.6813 in2

= 2(t+tn)(t-tr) = (2)(0.487+0.5)(0.487-0.1737) = 0.6185 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.487) = 0.974 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.487)[(2.5)(0.5)+0.5] = 1.7045 in2

A3

= 5t ti = (5)(0.487)(0.5) = 1.2175 in2

= 5ti ti = (5)(0.5)(0.5) = 1.25 in2

= 2hti = (2)(2)(0.5) = 2 in2

A5 = (Dp-d-2tn)te = [27-11.75-(2)(0.5)](0.5) = 7.125 in2

Area provided by A1 + A2 + A3 + A5 = 3.6813 in2 + 0.974 in2 + 1.2175 in2 + 7.125 in2 = 12.9978 in2. This is greater than the required area of 2.041 in2, therefore, the reinforcement is adequate.

A-13

Nozzle D: 8" Product Issue (Course #1) d = 8.625 - 2(0.5) = 7.625 inches t = 0.487 inches Y = 18 years

Rn = 7.625/2 = 3.8125 inches tr = 0.1921 inches Dp = 20 inches

P = 0.433(0.84)(28.74) = 10 psi tn = 0.5 inches te = 0.5 inches h = 2 inches ti = 0.5 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.513 inches

Minimum Required Thickness Calculation:

trn = PRn =

(10)(3.8125) = 0.0019 inches

SE - 0.6P (20,000)(1) - (0.6)(10)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.513 < 0.0002 inches/year

Y 18

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.513 - 0.1 > 50 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (7.625)(0.1921) = 1.4648 in2

A1

= d(t-tr) = (7.625)(0.487-0.1921) = 2.2486 in2

= 2(t+tn)(t-tr) = (2)(0.487+0.5)(0.487-0.1921) = 0.5821 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.487) = 0.974 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.487)[(2.5)(0.5)+0.5] = 1.7045 in2

A3

= 5t ti = (5)(0.487)(0.5) = 1.2175 in2

= 5ti ti = (5)(0.5)(0.5) = 1.25 in2

= 2hti = (2)(2)(0.5) = 2 in2

A5 = (Dp-d-2tn)te = [20-7.625-(2)(0.5)](0.5) = 5.6875 in2

Area provided by A1 + A2 + A3 + A5 = 2.2486 in2 + 0.974 in2 + 1.2175 in2 + 5.6875 in2 = 10.1276 in2. This is greater than the required area of 1.4648 in2, therefore, the reinforcement is adequate.

A-14

Nozzle E: 3/4" Plug (Course #1) d = 1.05 - 2(0.154) = 0.742 inches t = 0.487 inches Y = 18 years

Rn = 0.742/2 = 0.371 inches tr = 0.2213 inches Dp = N/A

P = 0.433(0.84)(28.53) = 10 psi tn = 0.154 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.154 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(10)(0.371) < 0.1 inches

SE - 0.6P (20,000)(1) - (0.6)(10)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-15

Nozzle F: 3" Low Point Suction (Course #1) d = 3.5 - 2(0.3) = 2.9 inches t = 0.487 inches Y = 18 years

Rn = 2.9/2 = 1.45 inches tr = 0.215 inches Dp = 10 inches

P = 0.433(0.84)(28.96) = 11 psi tn = 0.3 inches te = 0.5 inches h = 1.2 inches ti = 0.3 inches

Sn = 20,000 psi tprev = 0.3 inches

E = 1 tact = 0.306 inches

Minimum Required Thickness Calculation:

trn = PRn =

(11)(1.45) = 0.0008 inches

SE - 0.6P (20,000)(1) - (0.6)(11)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.3 - 0.306 < 0.0002 inches/year

Y 18

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR =

tact - trn =

0.306 - 0.1 > 50 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (2.9)(0.215) = 0.6235 in2

A1

= d(t-tr) = (2.9)(0.487-0.215) = 0.7888 in2

= 2(t+tn)(t-tr) = (2)(0.487+0.3)(0.487-0.215) = 0.4281 in2

A2

= 5(tn-trn)t = (5)(0.3-0.1)(0.487) = 0.487 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.3-0.1)(0.487)[(2.5)(0.3)+0.5] = 0.6088 in2

A3

= 5t ti = (5)(0.487)(0.3) = 0.7305 in2

= 5ti ti = (5)(0.3)(0.3) = 0.45 in2

= 2hti = (2)(1.2)(0.3) = 0.72 in2

A5 = (Dp-d-2tn)te = [10-2.9-(2)(0.3)](0.5) = 3.25 in2

Area provided by A1 + A2 + A3 + A5 = 0.7888 in2 + 0.487 in2 + 0.45 in2 + 3.25 in2 = 4.9758 in2. This is greater than the required area of 0.6235 in2, therefore, the reinforcement is adequate.

A-16

Nozzle G: 3/4" Plug (Course #2) d = 1.05 - 2(0.154) = 0.742 inches t = 0.417 inches Y = 18 years

Rn = 0.742/2 = 0.371 inches tr = 0.1511 inches Dp = N/A

P = 0.433(0.84)(19.61) = 7 psi tn = 0.154 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.154 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(7)(0.371) < 0.1 inches

SE - 0.6P (20,000)(1) - (0.6)(7)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-17

Nozzle H: 3/4" Plug (Course #3) d = 1.05 - 2(0.154) = 0.742 inches t = 0.301 inches Y = 18 years

Rn = 0.742/2 = 0.371 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(10.61) = 4 psi tn = 0.154 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.154 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(4)(0.371) < 0.1 inches

SE - 0.6P (20,000)(1) - (0.6)(4)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-18

Nozzle I: 3/4" Plug (Course #4) d = 1.05 - 2(0.154) = 0.742 inches t = 0.253 inches Y = 18 years

Rn = 0.742/2 = 0.371 inches tr = 0.1 inches Dp = N/A

P = 0.433(0.84)(1.78) = 1 psi tn = 0.154 inches te = N/A h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.154 inches

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(1)(0.371) < 0.1 inches

SE - 0.6P (20,000)(1) - (0.6)(1)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-19

Nozzle J: 6" Fire Fighting (Course #5)…