Attachment J.5 Kwajalein-Fac 955 (Tank 15)-Ext Final-2017.pdf

PDF 7 MB Posted Sep 25, 2023

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

About this file

Written by GovTribe AI · Dec 21, 2023

This document is an API 653 in-service inspection report for an aboveground storage tank located at U.S. Army Garrison Kwajalein Atoll in the Republic of the Marshall Islands. The inspection was conducted on September 29, 2017 to evaluate the tank's integrity and establish a database for future inspections. Key findings and recommendations are provided for the 45-foot diameter tank, including the need for repairs to cracks in the secondary containment, deteriorated couplings on the fire suppression system piping, coating repairs, and installation of safety equipment like confined space markings and a grounding bar. Calculations determine the tank shell has over 30 years of remaining life. Appendices provide engineering data, drawings, photographs, and checklists documenting the inspection results.

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US	Army	Corps	of	Engineers
Omaha	District

API	653	In‐Service
Inspection	Report

U.S.	Army	Garrison	Kwajalein	Atoll
Facility	Number	955
Tank	Number	15

Army

Corps

Engineers

Center

Expertise

for

Petroleum,

Oils,

and

Lubricants

(USACE

POL‐MCX)

September

29,

2017

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

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

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

9. Cathodic Protection

C. FINDINGS AND RECOMMENDATIONS

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

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

3. RECOMMENDED REPAIRS as Part of Regular Maintenance…………………………………………………………………………..22

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1 SHELL SERVICE LIFE EVALUATION

A.2 SHELL SETTLEMENT EVALUATION

A.3 ULTRASONIC UT DATA

A.4 CONTAINMENT LAYOUT DRAWING

A.5 SHELL LAYOUT DRAWING

A.6 ROOF LAYOUT DRAWING

A.7 OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ARD Anti‐rotation device

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

VPI Valve Position Indicator

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

GENERAL	SUMMARY
Summary	of	Inspection

API

Standard

653

In‐Service

inspection

Tank

(Facility

955)

USAG

Kwajalein‐Atoll,

Republic

the

Marshall

Islands

was

completed

September

29,

2017

evaluate

the

tank’s

integrity,

collect

data,

and

establish

database

for

future

inspections

and

evaluations.

The

shell

service

life

evaluation

performed

having

greater

than

years

remaining

shell

life

under

current

conditions.

Inspection

Results

are

listed

Section

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

INSPECTION DATE

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

Equipment (s) Used:

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

Calibration Procedure

Tank

Settlement

Surveying

Manufacturer:

Northwest

Instrument

Model:

NRL802K

Rotating

with

NLD5G

Laser

Receiver

Calibration

Methods

Used:

Main

and

transverse

horizontal

axes

checks

100

ft.

≤

1/16

inch

Tank

Shell

Surveying

Manufacturer:

Leica

Geosystem

Model:

Disto

Calibration

Methods

Used:

Tilt

sensor

calibration

automatically

performed

with

unit

set

3°

and

crosshairs calibration using target at a distance > 25 m

Inspector(s): Benyam Berhane

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

NOTE:

there

are

state

regulations

for

tank

inspections,

then

N/A

shall

reside

in‐place

the

number

years

between

inspections.

state

regulations

reside,

the

recommended

future

inspection

dates

shall

based

whichever

stringent

between

the

API

inspector’s

calculations

and

the

state

regulations.

PREVIOUS	INSPECTION	DATES
API	Out‐of‐Service	(Internal)	Inspection	Date:		16	June	2011
API	In‐Service	(External)	Inspection	Date:	19	March	2010

RECOMMENDED

FUTURE

INSPECTION

DATES

(CALCULATIONS

SHALL

PROVIDED)

API

Out‐of‐Service

(Internal)

Inspection

Date:

June

2031

Per

API

653

Section

6.4.2‐

Subsequent	Internal	Inspection	Interval
(16	June	2021	IAW	UFC)

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

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

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

GENERAL TANK INFORMATION

ITEM	DESCRIPTION
Owner	U.S	Army
Location	U.S.	Army	Garrison	Kwajalein	Atoll;	RMI
Facility	Number	955
Tank	Number	15
State	/	Country	Kwajalein	Atoll	/ Republic	of	Marshall	Islands
City		‐
Inspection	Date	29	September	2017
Tank	Manufacturer	Unknown
Design	Standard	Unknown	(Assumed	API	STD	12C	Eleventh	Edition)
Date	of	Construction	1954
Tank	Contents	Diesel	(F‐76)
Tank	Serial	Number	None
Tank	Diameter	45	Feet
Shell	Height	47.83	Feet
Product	Height	46	Feet
Tank	Capacity	13,500	BBL	(567,000	gallons)
Foundation	Concrete	Ring	Wall

Construction

Bottom Lap‐Welded (Cone‐Down)

Shell Butt‐Welded (Cylindrical)

Floating Roof None

Fixed Roof Lap‐Welded (Cone‐Down)

Material

Bottom Carbon Steel (Unknown Specification)

Shell Carbon Steel (Unknown Specification)

Floating Roof NA

Fixed

Roof

Carbon

Steel

(Unknown

Specification)

Cathodic

Protection

Impressed

Current

Interior

Coating

System

Unknown

Exterior

Coating

System

Thin

Film

Epoxy/

Polyurethane (Date

Completed

Unknown)

Level

Gauging

ENRAF

Automatic

Tank

Gauge

with

Varec

2500

Mechanical

Tape

Gauge

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

Piping	Receipt	8"	Carbon	Steel
Issue	8"	Carbon	Steel
Low	Suction	4"	Carbon	Steel
Water	Draw‐Off	‐	‐

Level Alarms

Low‐Level	Alarm:	7.172	Feet
Low‐Low	Level	Alarm:	2.39	Feet
High‐Level	Alarm:	46.00	Feet
High‐High	Level	Alarm:	48.00	Feet
High‐Level	Control	Shutoff:	46.00	Feet

Type of Internal Floating Roof

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

A. GENERAL PROJECT INFORMATION

1. API

653

Inspection

This

project

will

perform

API

653

inspections

various

tanks

facilities

throughout

the

United

States/OCONUS.

Additional

consideration

given

federal,

state,

and

local

regulations,

well

applicable

military

criteria

and

general

industry

standards.

An API Standard 653 In‐Service (External) inspection was performed on Tank 15 (FAC 955).

2. Site

Information

September

29,

2017

Burns

McDonnell

and

our

sub‐consultant

(InterSpec)

performed

API

653

In‐Service

(External)

inspection

Tank

(Facility

955)

located

U.S.

Army

Garrison

Kwajalein

Atoll,

RMI.

USAG

Kwajalein

Atoll

(USAG‐KA)

home

the

Ronald

Reagan

Ballistic

Missile

Defense

Test

Site.

The

Reagan

Test

Site

Major

Range

and

Test

Facility

Base

under

the

DoD

with

the

primary

mission

researching,

developing

tests,

and

developing

missile

defense

and

space

programs.

Tank 15 is used as an aboveground diesel fuel storage tank supporting the installation fueling needs.

B. TANK INSPECTION COMMENTS

1. Tank

Construction

Tank

(FAC

955)

nominal

13,500

BBL,

45‐foot

diameter

47.83‐foot

tall,

F‐76

(diesel),

aboveground

vertical

storage

tank.

The

tank

was

constructed

1954

presumably

API

STD

12C

Eleventh

Edition.

There

are

data

name

plates

affixed

the

tank.

There

were

indications

significant

modifications

since

the

original

construction.

There

were

documentations

indicating

repairs

modifications.

The

tank

retrofitted

with

level

alarms

and

high

liquid

level

shut‐off

system,

well

repairs

made

the

circumferential

stairway

tread.

2. Tank

Foundation

The

tank

sits

concrete

ring

wall

foundation

that

approximately

14"

above

the

secondary

containment

floor.

The

foundation

not

designed

with

leak

detection

(tell‐tale)

system

that

extends

the

center

the

tank.

The

flexible

membrane

liner

(FML)

for

the

secondary

containment

attached

the

foundation,

but

the

batten

strips

were

not

visible

the

area

excavated.

Accessible

sections

the

foundation

were

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

against

the

bottom

the

tank.

spalling

and

vegetation

were

present.

The

foundation‐to‐

chime

interface

sealed.

Minor

sealant

deterioration

present

throughout,

with

approximate

total

linear

feet

deteriorated

caulking

identified.

Shell

settlement

surveys

were

performed

during

the

inspection

accordance

with

Annex

API

Standard

653.

Settlement

results

are

listed

Appendix

There

indication

significant

settlement.

Overall,

the

foundation

appears

satisfactory

condition.

3. Tank

Shell

The

tank

shell

constructed

from

carbon

steel

material

unknown

specification.

The

shell

cylindrical

design,

butt‐welded

together,

and

consisting

seven

(7)

courses

fillet‐welded

the

fixed

roof.

Evaluated

the

shell

for

plumbness,

roundness,

peaking,

and

banding;

all

which

were

found

within

the

allowable

tolerances

the

API

Standard

653.

Visually

inspected

the

exterior

the

shell.

Inspected

the

coating

for

dis‐bonding,

adhesion,

deterioration,

and

discoloration.

The

tank

shell

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

equipped

with

20"

manholes

(180°

apart).

The

tank

equipped

with

shell

mounted

low

level

alarm

and

high‐high

level

alarms,

well

high‐level

shut‐off.

The

shell

was

evaluated

for

remaining

metal

thickness

utilizing

ultrasonic

technology.

The

ultrasonic

thickness

measurements

and

thickness

measurement

locations

(TML)

are

listed

the

Shell

Plate

Thickness

Measurements

table

Appendix

service

life

evaluation

performed

shows

the

shell

with

greater

than

years

remaining

life

under

current

conditions.

The

engineering

calculations,

per

API

Standard

653,

for

the

service

life

evaluation

are

shown

Appendix

under

“Service

Life

Evaluation.”

The

tank

shell

satisfactory

mechanical

condition.

4. Tank	Appurtenances
a. Geodesic	Dome	Roof

None (equipped with carbon steel fixed roof).

b. Gauging

The

tank’s

Enraf

(Model

854)

ATG

installed

through

6‐inch

nozzle

mounted

the

roof

manhole

cover.

not

known

the

stilling

well

slotted

equipped

with

8‐inch

well

inside

the

tank.

The

Enraf

system

was

reported

not

working

order

the

time

the

inspection.

There

six

inch

manual

gauging

and

sampling

hatch,

but

does

not

have

stilling

well

inside

the

tank.

The

ATG

water

probe

installed

the

same

roof

manhole

cover

with

four

inch

nozzle

flange.

The

tank

equipped

with

float

and

tape

type

mechanical

tape

gauge

manufactured

Shand

Jurs

(Model

92021).

The

system

working

condition

and

has

reported

product

level

44.094’.

c. Level

Alarms

The

high

level

alarm,

the

HLV

float

chamber,

and

the

high‐high

level

alarm

are

mounted

the

shell

and

are

accessible

via

the

circumferential

stairway.

The

tank

equipped

with

low‐level

alarm,

but

independent

low‐low

level

alarm

system

was

installed,

required

military

criteria.

d. Stairs

and

Platforms

The

tank’s

fixed

roof

accessible

circumferential

stairway

mounted

the

shell

the

tank

with

top

platform.

The

stairs

and

platform

were

inspected

for

corrosion

and

structural

soundness.

The

circumferential

stairway

handrail

constructed

with

1½"

angle

iron

handrails

and

coated

steel

plate

treads

with

non‐slip

profile.

The

top

platform

carbon

steel

grating

type,

and

several

circumferential

stairway

treads

were

replaced

the

past

with

carbon

steel

grating.

The

overall

general

condition

the

stairs

and

platform

are

mostly

satisfactory

(with

some

exception

–

See

Section

C).

e. Grounding

and

Bonding

There

one

grounding

cable

mechanically

connected

lug

the

tank’s

shell

and

one

structure

lead

cable

that

exothermically

attached

the

bottom

extension.

The

grounding

rod

penetrates

through

the

secondary

containment

floor

liner

and

attached

grounding

cable.

The

tank

not

equipped

with

copper

grounding

bar

for

personnel

static

electric

discharge

(typically

required

military

criteria).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

5. Tank

Coating

The

tank

shell,

roof,

circumferential

stairway,

handrails,

piping,

and

appurtenances

are

coated.

The

exterior

coating

epoxy

with

polyurethane

top.

The

coating

the

exterior

the

tank

was

completed

September

2012.

The

interior

coating

also

listed

being

completed

September

2012

(presumably

the

bottom

and

partial

the

first

shell

course).

Isolated

coating

failure

was

noted

the

appurtenances,

circumferential

stairway,

platform,

product

piping,

and

valves

within

the

secondary

containment.

6. Tank

Piping

System

The

fuel

received

through

8‐inch

carbon

steel

piping,

and

product

issued

from

the

tank

through

8‐inch

carbon

steel

pipe.

The

tank

also

equipped

with

other

auxiliary

piping

for

the

water

draw

(NPS

2),

but

did

not

have

product

saver

tank

(PST).

There

6‐inch

blind

flange,

and

presumed

either

low

suction

piping

water

draw.

Inspected

and

evaluated

each

tank

nozzle

accordance

with

API

Standards

650

and

653.

Identified

the

type

and

use

each

shell

nozzle

and

measured

the

nozzle

neck

thickness

all

accessible

shell

nozzles.

Evaluated

all

nozzles

and

reinforcement

plates

for

leaks

and

corrosion.

7. Fire

Protection

System

The

storage

tank

equipped

with

surface

application

fixed

foam

fire

suppression

system

that

uses

mobile

foam

supply.

One

NPS

foam

chamber

mounted

approximately

inches

down

from

the

top

the

tank

shell

course

seven.

All

Victaulic

couplings

for

the

fire

suppression

system

piping

have

deteriorated

fasteners.

fire

hydrants

were

noted

near

the

tank

during

the

inspection.

8. Secondary

Containment

The

tank

sits

inside

earthen

secondary

containment

basin

with

geotextile

liner

positioned

approximately

eight

ten

inches

below

the

soil

and

concrete

dike

walls.

The

overall

dimension

the

secondary

containment

131.42

feet

131.25

feet,

with

vertical

height

68.5"‐

78"

(to

top

soil).

The

secondary

containment

equipped

with

drain

inlet

and

drain

valve

that

tie

the

underground

PVC

piping

system

the

OWS.

The

secondary

containment

release

valve

housed

inside

valve

pit

adjacent

the

drain

inlet

within

the

dike.

The

PVC

piping

system

manifolded

together

and

cannot

individually

isolated

outside

the

valve

pit.

The

drain

line,

the

drain

inlet,

and

valve

pit

were

visually

evaluated

determine

the

drainage

system

liquid‐tight.

The

valve

pit

has

rain

covers,

but

standing

water

was

noted

the

valve

pit.

Additional

testing

and

evaluation

may

required

determine

the

valve

pit

liquid‐tight.

The

liquid

the

valve

pit

was

lower

than

the

liquid

the

adjacent

drain

inlet

and

thus

suggests

that

the

drain

inlet

satisfactory.

However,

the

source

the

standing

water

the

valve

pit

should

determined.

The

secondary

containment

was

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

growth.

Minor

hairline

cracks

(temperature

cracks)

and

some

moderate

cracks

were

noted

the

secondary

containment

wall.

approximate

total

118

linear

feet

cracks

the

secondary

containment

wall

were

identified.

Hairline

cracks

not

seriously

affect

the

strength

the

concrete

structures;

however,

these

cracks

can

potential

access

points

for

moisture

water

seepage

that

could

corrode

the

reinforcing

steel

(rebar).

There

are

several

test

port/anode

access

PVC

openings

around

the

perimeter

the

tank

that

penetrate

the

FML.

Some

these

PVC

openings

have

deteriorated

caulking.

The

secondary

containment

mostly

satisfactory

mechanical

condition,

with

the

exception

the

discrepancies

identified

Section

below.

Field

assessment

indicates

that

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

the

secondary

containment

sufficient

size

contain

total

tank

loss.

The

secondary

containment

partially

sloped

allow

for

drainage

away

from

the

tank.

formal

secondary

containment

evaluation,

accordance

with

CFR

112,

may

required

order

satisfy

federal,

state,

and

local

requirements.

9. Cathodic

Protection

impressed

current

Cathodic

Protection

(CP)

system

installed

this

tank

and

serves

multiple

ASTs

the

tank

farm

(Tank

10,

11,

12,

15,

16,

and

17).

The

system

manufactured

Corrpower

(Model

COYSE

50‐34R

Serial

CO11957).

This

unit

volt

ampere

air‐cooled

rectifier

unit

(numbered

and

mounted

the

outside

the

pumphouse

the

northeast

end

the

secondary

containment.

The

January

2017

report

provided

indicated

that

Tank

receiving

cathodic

protection

based

the

NACE

criterion.

The

rectifier,

anode

junction

box,

and

tank

junction

box

all

are

satisfactory

condition.

the

time

the

inspection,

the

rectifier

was

powered

and

serviceable

operation

condition.

Base

personnel

performed

the

required

testing

and

data

logging.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

C. FINDINGS AND RECOMMENDATIONS

The

tank

generally

not

accordance

with

current

military

criteria

for

some

the

tank

design,

appurtenances,

and

piping

configuration.

Therefore,

the

recommendations

are

not

meant

bring

the

tank

into

full

compliance

with

UFC

3‐460‐01

78‐24‐27

standards

but

rather

identify

these

items

for

the

owner/user’s

planed

upgrades,

rehabilitation,

and

priority

repairs.

Mandatory

repairs

should

completed

assure

compliance

with

industry

standards,

well

federal

state

jurisdictional

requirements.

During

this

evaluation,

the

tank

was

found

generally

serviceable

condition,

with

imminent

risk

operation

and

overall

integrity.

However,

there

were

several

deficiencies

that

were

noted.

These

noted

deficiencies

are

listed

below

particular

order,

with

repair

recommendations.

All

repairs

and

modifications

should

performed

accordance

with

API

standard

653,

UFC

3‐460‐01,

DoD

Standard

Design

78‐24‐27,

and

applicable

UFGS

specifications.

1. MANDATORY

REPAIRS

per

API

653,

UFC

3‐460‐01,

78‐24‐27

Standards

Mandatory

repairs

represent

items

that

require

immediate

attention,

order

prevent

imminent

risk

system

operators,

equipment

integrity,

the

adjacent

environment.

The

tank

should

remain

out

service

until

these

repairs

are

completed.

No mandatory repairs were identified for this tank.

2. REQUIRED

REPAIRS

Fully

Comply

with

API

653

Federal,

State,

and

Local

Codes

Required

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

These

items

are

required

API‐653

federal,

state,

and

local

codes.

a. Secondary

Containment

Cracks

OBSERVATION:

Unsealed

cracks

were

identified

the

secondary

containment

wall

(this

includes

areas

that

were

previously

sealed).

Code

REFERENCE:

CFR

Section

112.7(c)

states

that

the

entire

secondary

containment

system,

“including

walls

and

floor,

must

capable

containing

oil

and

must

constructed

that

any

discharge

from

primary

containment

system

...

will

not

escape

containment

before

cleanup

occurs.”

§§112.8(c)(2)

and

112.12(c)(2)

state

that

diked

areas

must

“sufficiently

impervious

contain

oil.”

RECOMMENDATION:

Repair

all

exposed

cracks

the

secondary

containment

walls

grinding

V‐shape

pattern,

with

least

¼‐inch

width

the

surface

and

depth

least

¼‐inch

and

sealing

with

flexible

urethane

(e.g.

Sikaflex

1c)

similar

approved

sealant

(Quantity:

118

linear

feet).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

b. Secondary

Containment

Drain

OBSERVATION:

The

valve

pit

has

rain

covers,

but

standing

water

was

noted

the

valve

pit.

The

liquid

the

valve

pit

was

the

same

level

the

adjacent

drain

inlet

and

thus

suggests

that

the

drain

inlet

could

possibly

leaking.

The

source

the

standing

water

the

valve

pit

should

determined.

The

liquid

the

valve

pit

was

not

clear,

and

the

drain

valve

was

not

visible.

The

liquid

looks

sludge,

but

there

hydrocarbon

odor.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Upgrade

the

concrete

drain

inlet

detailed

78‐24‐27

Drawing

CD.09

Detail

similar.

Use

ductile

iron

piping

lieu

the

PVC

dike

drain

lines.

minimum,

investigate

and

repair

the

source

water/sludge

inside

the

valve

pit.

Slope

dike

basin

surfaces

minimum

for

drainage.

Drainage

swales

should

sloped

flatter

than

0.5%

drainage

inlet

(see

78‐24‐27).

c. Secondary

Containment

Penetration

OBSERVATION:

The

secondary

containment

has

liner

with

earthen

cover.

The

condition

the

liner

unknown,

but

some

penetration

including

the

PVC

cathodic

protection

anode

access

caps

and

the

tank

grounding

rod

sleeves

have

deteriorated

caulking

and

loose

hose

clamps.

higher

rate

rain

displacement

was

noted

for

this

secondary

containment

compared

the

other

AST

dike

systems

(Particularly

Tank

and

without

earthen

cover).

Some

the

water

displacement

likely

due

the

water

absorption

rate

the

soil/vegetation.

However,

the

evaporation

the

excess

water

above

grade

expected

constant

for

all

dikes

unless

there

deteriorated

liner.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Reseal

all

PVC

FML

penetrations

and

secure

the

hose

clamps.

See

similar

application

over

concrete

78‐24‐27

Drawing

CD.02

Detail

Drain Valve Valve Pit Rain Cover

Drain Inlet (holes)

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

d. Secondary

Containment

Liner

Mounting

Strip

OBSERVATION:

The

secondary

containment

has

liner

with

earthen

cover.

The

liner

adhered

the

tank

foundation

but

does

not

appear

have

batten

strips.

section

the

foundation

was

excavated

hand,

and

the

perimeter

mounting

strip

could

not

located

(see

second

photo

below).

The

perimeter

the

dike

walls

and

pipe

support

piers

are

not

accessible

for

inspection.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Remove

multiple

sections

and

investigate

the

conditions

the

liner

attachments

the

perimeter

the

foundation,

dike

walls,

and

pipe

support

piers.

Consider

upgrading

78‐24‐27

Drawing

D.03

Detail

with

anchorage

bolts,

batten

strips,

and

sealant

(similar

the

rest

the

ASTs).

e. Secondary

Containment

Wall

Penetration

OBSERVATION:

The

containment

piping

penetrates

through

the

secondary

containment

walls

without

the

use

adequate

pipe

sleeve/seal.

Some

have

been

retrofitted

with

compression

seals

but

not

have

pipe

sleeves

(Quantity:

6).

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above)

RECOMMENDATION:

Reseal

all

secondary

containment

wall

penetrations.

Consider

upgrading

all

secondary

containment

wall

penetrations

per

78‐24‐27

Drawing

CD.08

Detail

(CONCRETE

WALL

PENETRATION

DETAIL)

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

f. Deteriorated

Victaulic

coupling

(Associated

with

the

Fire

Suppression

System)

OBSERVATION:

All

Victaulic

couplings

for

the

fire

suppression

piping

have

deteriorated

bolts.

Several

locations

have

completely

failed

Victaulic

couplings.

This

could

result

breach

the

secondary

containment

because

this

pipe

extends

outside

the

secondary

containment,

and

similar

type

corrosion

was

noted

coupling

fasteners

outside

the

dike.

section

the

fire

suppression

piping

also

routed

underground

outside

the

dike,

and

the

tightness

the

piping

unknown.

The

fire

suppression

system

will

not

function

with

these

deteriorated

coupling

fasteners.

Code

REFERENCE:

CFR

Section

112.7(c)

(See

reference

from

above).

Also

NFPA

Section

4.7.1.4,

“Where

exposed

corrosive

influences,

the

piping

shall

corrosion

resistant

protected

against

corrosion”

InterSpec

concludes

the

integrity

the

piping

dependent

the

fasteners

thus

incorporating

the

code

reference

for

the

coupling

fasteners.

RECOMMENDATION:

Replace

all

deteriorated

bolts,

couplings,

and

pipe.

Repair

the

pipe

meet

the

requirements

NFPA

Section

4.7.1.4

installing

stainless

steel

fasteners.

g. Corrosion

and

Pitting

Containment

Piping

OBSERVATION:

Coating

failure

and

corrosion

was

noted

the

product

piping

inside

the

secondary

containment.

There

are

isolated

coating

failure

and

pitting

throughout

the

dike

area.

Code

REFERENCE:

API

574

Section

7.4.14

(Crevice

Corrosion).

API

574

Section

10.1.6.3

(Loss

thickness)

RECOMMENDATION:

Replace

the

spools

piping

that

have

significant

pitting

and

corrosion.

may

practical

conduct

detailed

API

STD

570

inspection

the

containment

piping

get

overall

condition

assessment.

NDT

tools

such

guided

wave

examination

can

also

employed

get

the

condition

the

inaccessible

areas

between

pipe

supports,

sleeved

piping,

wrapped

piping,

through

the

dike

wall

penetration.

Guided

wave

examination

screening

tool

used

inspect

large

sections

piping

from

single

test

location.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

h. Tank

Grounding

Lug

OBSERVATION:

The

tank

grounding

strap

bolted

the

tank

shell

(mechanical

joint

coated

interface)

and

has

reinforcement

plates

per

API

STD

6560

and

78‐24‐27

Drawing

ED.02

Detail

2. It

covered

with

foam

material.

Code

REFERENCE:

78‐24‐27

Drawing

ED.02

Detail

(See

also

API

650

Section

5.8.11.3)

RECOMMENDATION:

Exothermically

weld

the

grounding

cable

the

lug

and

install

reinforcement

the

shell,

accordance

with

78‐24‐27

Drawing

ED.02

Detail

Note:

repairs

are

elected

not

done,

the

paint

should

removed

where

the

cable

bolts

the

lug,

provide

better

connection

the

ground

(Quantity:

ground

connections).

Note

the

current

edition

API

STD

650

suggests

maximum

lug

spacing

100

ft.

with

minimum

four

lugs.

i. Shell

Manhole

Cover

with

Hinge

Davit

Arm

OBSERVATION:

The

shell

manhole

covers

are

not

equipped

with

hinge

davit

arm

facilitate

the

handling

the

manhole

cover

plates.

Code

REFERENCE:

API

STD

650

Section

5.8.3.5

states,

“Shell

manhole

covers

shall

have

two

handles.

Those

covers

weighing

than

(75

lb)

shall

equipped

with

either

hinge

davit

facilitate

the

handling

the

manhole

cover

plate.

The

davit

support

arm

shall

not

welded

directly

the

shell

without

reinforcing

plate.”

Also

78‐24‐27

drawing

D.10

detail

RECOMMENDATION:

Install

shell

manhole

davit

arm

IAW

with

API

STD

650

and

78‐24‐27

drawing

D.10

detail

(Quantity:

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

j. Top

Platform

Grating

Not

Secured

Down

OBSERVATION:

The

circumferential

stairway

top

platform

does

not

have

anchor/saddle

clips.

Code

REFERENCE:

OSHA

and

78‐24‐27

Drawing

D.11

Detail

“Grating

shall

anchored

with

saddle

clips.”

RECOMMENDATION:

Secure

the

grating

with

anchors.

k. Cracked

Gasket

OBSERVATION:

The

TRV

test

check

valve

flange

for

the

product

issue

nozzle

has

cracked

gasket.

Code

REFERENCE:

API

574

Section

10.3.5.1,

“Sites

should

have

program

assure

that

flanges

are

made

properly.

Proper

make‐up

every

flange

piping

system

important

for

reliability.

Proper

make‐up

includes

the

use

the

proper

gasket

and

fastener

material,

type

and

size,

proper

positioning

the

gasket

and

proper

torquing

the

fasteners.

The

assurance

program

should

include

procedures

for

gasket

and

fastener

selection

and

for

fastener

torquing.”

RECOMMENDATION:

Replace

the

gasket

(1”

flange).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

l. Nonstandard

Gasket

OBSERVATION:

The

TRV

valve

flange

for

the

receipt

and

issue

nozzles

not

have

standard

gasket.

Code

REFERENCE:

API

574

Section

10.3.5.1

(See

above)

RECOMMENDATION:

Isolate

the

valve

and

replace

all

gaskets

associated

with

TRV

(12

flanges,

NPS

1).

m. Circumferential

Stairway

Tread

Corrosion

OBSERVATION:

There

minor

moderate

coating

failure

with

associated

corrosion.

Code

REFERENCE:

OSHA

CFR

1910,

Subpart

“Walking‐working

surfaces

are

maintained

free

hazards

such

sharp

protruding

objects,

loose

boards,

corrosion,

leaks,

spills,

snow,

and

ice.”

RECOMMENDATION:

Repair

the

coating

and

replace

the

treads

with

excessive

corrosion

treads

noted).

All

future

tread

replacement

should

provide

rises

that

are

uniform

throughout

the

height

the

circumferential

stairway.

Replace/repair

the

corroded

treads

(4).

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

n. Corrosion

Piping

and

Pipe

Supports

OBSERVATION:

The

piping

and

pipe

supports

within

the

tank’s

secondary

containment

have

moderate

corrosion.

The

majority

the

pipe

supports

have

completely

deteriorated.

Code

REFERENCE:

API

574

Section

7.4.14

(Contact

Point

Corrosion)

API

574

Section

8.2

(Proper

position

and

function

supports,

hangers,

and

anchors).

accordance

with

API

570

Section

7.5,

“Piping

shall

supported

and

guided

that

(a)

its

weight

carried

safely,

(b)

has

sufficient

flexibility

for

thermal

expansion

contraction,

and

(c)

does

not

vibrate

excessively.”

RECOMMENDATION:

Repair

the

coating

failure

the

piping.

Replace

the

deteriorated

piping

supports

per

78‐24‐27

Drawing

CD.13

Detail

and

o. No

Faded

Confined

Space

Markings

Manholes

OBSERVATION:

The

tank

not

equipped

with

confined

space

marking.

Code

REFERENCE:

accordance

with

OSHA

Regulation

CFR

1910.146(c)(2),

“If

the

workplace

contains

permit

spaces,

the

employer

shall

inform

exposed

employees,

posting

danger

signs

any

other

equally

effective

means,

the

existence

and

location

and

the

danger

posed

the

permit

spaces.

NOTE:

sign

reading

DANGER

‐‐

PERMIT‐REQUIRED

CONFINED

SPACE,

NOT

ENTER

using

other

similar

language

would

satisfy

the

requirement

for

sign.”

RECOMMENDATION:

Install

confined

space

markings

all

tank

entry

points.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

p. Conduit,

Junction

Boxes,

Fittings,

and

Mounting

Hardware

OBSERVATION:

The

conduits,

junction

boxes,

fittings,

and

mounting

hardware

within

the

secondary

containment

have

deteriorated.

This

will

not

meet

the

Class

Division

rating

requirements

for

hazardous

locations.

There

are

corroded

conduit

support

clamps

along

the

circumferential

stairway.

Code

REFERENCE:

All

wiring

and

fittings

Class

location

that

bulk

plant

terminal

must

comply

with

the

applicable

provisions

NEC

Article

501

Article

505

[515.7].

RECOMMENDATION:

Replace

all

corroded/deteriorated

conduits,

junction

boxes,

fittings,

and

mounting

hardware.

q. Tank

Foundation

Spalling/Break

OBSERVATION:

There

area

spalling/break

measuring

approximately

9‐inch

10‐inch

and

crack

approximately

6‐inch

long

near

the

abandoned

water

draw

nozzle

through

the

foundation.

Code

REFERENCE:

API

STD

653

Section

4.5.1,

“Temperature

cracks

(hairline

cracks

uniform

width)

not

seriously

affect

the

strength

the

concrete

foundation

structure;

however,

these

cracks

can

potential

access

points

for

moisture

water

seepage

that

could

eventually

result

corrosion

the

reinforcing

steel.”

RECOMMENDATION:

Repair

the

area

spalling/break

and

recoat

deter

water

intrusion

the

rebar.

r. Corroded

Fasteners

HLV

OBSERVATION:

There

significant

corrosion

the

body

cover

fastener

the

High

Liquid

Level

shut‐off

valve

(HLV).

The

fasteners

not

appear

have

sufficient

thread

engagement

due

the

corrosion.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

Code

REFERENCE:

API

570

Section

5.15,

“Flange

fasteners

should

examined

visually

for

corrosion

and

thread

engagement.

Fasteners

should

fully

engaged.

Any

fastener

failing

considered

acceptably

engaged

the

lack

complete

engagement

not

than

one

thread.”

RECOMMENDATION:

Replace

the

corroded

studs

and

bolts.

s. Corroded

Valve

Hand

Wheel

DBB

Valves

OBSERVATION:

Both

the

receipt

and

issue

valve

handles

have

moderate

corrosion

with

through

holes.

Note

the

valve

hand

wheel

may

break

off

making

valve

closure

difficult

impossible.

Code

REFERENCE:

NFPA

Section

22.13.2

“Each

connection

aboveground

tank

through

which

liquid

can

normally

flow

shall

provided

with

internal

external

valve

located

practical

the

shell

the

tank.”

RECOMMENDATION:

Replace

the

valve

handles

(Quantity:

NPS

DAN‐EX

valves).

t. Drips

Tubing

Fittings

OBSERVATION:

Small

drips

were

noted

the

stainless

steel

tubing

compression

fitting

pilot

valve

for

the

high

liquid

level

shut‐off

valve.

Code

REFERENCE:

accordance

with

NFPA

30,

paragraph

21.8.6,

“Storage

tanks

and

their

appurtenances,

including

normal

vents,

emergency

vents,

overfill

prevention

devices,

and

devices,

shall

inspected

and

maintained

ensure

that

they

function

intended

accordance

with

written

procedures.”

RECOMMENDATION:

Repair

the

fittings.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

u. Pitting

NPS

Blank

Nozzle

OBSERVATION:

area

inactive

piping

was

noted

the

NPS

blank

nozzle

neck.

pitting

depth

approximately

0.1875"

was

recoded.

The

nozzle

neck

ultrasonic

thickness

reading

0.412".

There

sufficient

thickness

meet

the

requirements

API

standards,

and

repair

required.

Code

REFERENCE:

API

574

Section

7.4.14

(Crevice

Corrosion).

API

574

Section

10.1.6.3

(Loss

thickness).

RECOMMENDATION:

Evaluate

the

API

STD

653

inspection.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

3. RECOMMENDED

REPAIRS

Part

Regular

Maintenance

Recommended

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

a. Tank

Bottom

Extension

(Chime)

OBSERVATION:

The

foundation‐to‐chime

interface

sealed.

Minor

sealant

deterioration

present.

Code

REFERENCE:

Maintain

waterproof

seal

the

tank

chime

ring

wall

foundation

interface

(UFC

3‐

460‐03

Section

10.3.3).

RECOMMENDATION:

Repair

the

areas

failed

sealant

applying

polysulfide

mastic

sealant

caulking.

NOTE:

not

caulk

the

end

(side)

the

chime.

See

78‐24‐27

Drawing

D.04

Detail

Repair

the

coating

the

chime

area.

(Quantity:

linear

feet).

b. Exterior

Coating

Failures

Tank

and

Appurtenances

OBSERVATION:

There

isolated

coating

failure

the

exterior

shell

mostly

around

the

top

platform,

circumferential

stairway,

shell

manholes,

and

fixed

roof.

Similar

isolated

coating

failure

was

noted

the

HLV

tubing

support

mounting

brace.

There

moderate

coating

failure

and

corrosion

noted

the

LLA,

HLA,

HHLA,

and

HLV

pipe

nipples

and

flanges.

All

the

level

sensor

chambers

also

have

moderate

corrosion.

Code

REFERENCE:

UFC

3‐460‐01,

Section

8‐3.10

and

Section

9‐10

RECOMMENDATION:

Mechanically

clean

and

recoat

the

areas

coating

failure

the

tank

shell,

circumferential

stairway,

landing,

piping,

and

appurtenances.

Repairs

should

accomplished

using

epoxy

based

coating

system

equivalent.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

c. Product

Saver

Tank

(PST)

OBSERVATION:

The

tank

not

equipped

with

Product

Saver

Tank

(PST).

Code

REFERENCE:

Install

water

draw

off

system

per

78‐24‐27

Drawing

D.13

Detail

IAW

UFC

3‐460‐01

Section

3‐6.6.7.

“Mount

permanently

installed

pumps

substantial

foundations

reinforced

concrete

designed

accordance

with

Hydraulic

Institute

Standards.”

RECOMMENDATION:

Add

new

PST

accordance

with

78‐24‐27.

d. Tank

Electronic

ATG

and

Water

Probe

OBSERVATION:

The

tank’s

Enraf

(Model

854)

installed

through

6‐inch

nozzle

mounted

the

roof

manhole

cover.

not

known

the

stilling

well

slotted

equipped

with

8‐inch

well

inside

the

tank.

The

Enraf

system

was

reported

non‐working

order

the

time

the

inspection.

There

are

moderate

coating

failure

and

corrosion

the

adapter

flange

for

both

the

ATG

and

water

probe.

Code

REFERENCE:

UFC

3‐460‐01

Table

8‐1

(item

and

78‐24‐27

Drawing

D.07

Detail

and

RECOMMENDATION:

Replace

repair

the

ATG.

Install

stilling

wells

IAW

with

78‐24‐27.

e. Independent

Low‐Low

Level

Alarm

OBSERVATION:

The

tank

not

equipped

with

independent

low‐low

level

alarm.

There

low

level

alarm

sensor

installed

the

side

the

tank

shell

(see

photo

below).

Code

REFERENCE:

UFC

460

3‐460‐01

Table

8‐1(k)

and

78‐24‐27

Drawing

D.12

Detail

RECOMMENDATION:

Install

independent

low‐low

level

alarm.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

f. Sample

Gauge

Well

OBSERVATION:

There

are

two

manual

sampling/gauging

wells.

The

tank

equipped

with

six

inch

and

four

inch

gauge

hatch

the

fixed

roof.

Code

REFERENCE:

UFC

460

3‐460‐01

Table

8‐1(s)

and

78‐24‐27

Drawing

D.07

Detail

RECOMMENDATION:

Install

10‐inch

roof

nozzle

and

aluminum,

slotted

stilling

well

that

extends

within

inches

the

bottom

the

tank

for

gauging

and

sampling

with

datum

plate

establish

gauging

zero

point.

g. Fixed

Roof

Perimeter

Guardrail

OBSERVATION:

The

fixed

roof

has

partial

perimeter

guardrails.

REFERENCE:

78‐24‐27

Drawing

D.11

Detail

RECOMMENDATION:

Install

perimeter

guardrail

around

the

circumference

the

fixed

roof

IAW

78‐24‐27

Drawing

D.11.

h. Tank

Marking

(NFPA

Diamond)

OBSERVATION:

The

tank

not

equipped

with

NFPA

marking.

Code

REFERENCE:

Mark

the

tank

accordance

with

NFPA

704.

78‐24‐27

Drawing

D.13

Detail

Note

4) “Provide

hazard

identification

system

labeling

accordance

with

NFPA

704.”

RECOMMENDATION:

Install

NFPA

704

marking.

i. Block

and

Bleed

Valve

Missing

Tube

OBSERVATION:

The

product

receipt

and

issue

DBB

valves

are

missing

the

manual

bleed

valve

goose

neck

tube.

Coating,

water,

and

some

corrosion

were

noted

inside

the

differential

thermal

relief

(DTR)

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

valves,

and

long

term

exposure

the

internal

section

the

DTR

valve

could

cause

the

system

not

perform

designed.

The

DTR

valve

handles

were

noted

have

coating

failure

and

corrosion

Code

REFERENCE:

General

maintenance/manufacturer

drawing.

RECOMMENDATION:

Reinstall

the

goose

neck

tube

prevent

drainage

body

liquid

and

prevent

water

and

debris

from

entering

the

DTR

valve.

The

tube

should

above

the

highest

point

the

body

cavity.

steel

plug

can

also

used

prevent

water

intrusion.

j. Block

and

Bleed

Valve

VPI

Corrosion

OBSERVATION:

The

water

draw

nozzle

DBB

valve

has

moderate

corrosion.

The

valve

position

indicator

(VPI)

corroded.

The

valve

position

will

difficult

detect

from

distance

when

the

VPI

completely

deteriorated.

The

dust

cap

missing.

Code

REFERENCE:

General

maintenance/manufacturer

drawing.

RECOMMENDATION:

Replace

the

valve

operator.

Install

Camlock

cap.

k. Personnel

Static

Electric

Discharge

OBSERVATION:

The

tank

not

equipped

with

copper

grounding

bar

for

personnel

static

electric

discharge

(typically

required

military

criteria).

Code

REFERENCE:

UFC

3‐460‐03

Section

2‐3.21

and

78‐24‐27

Drawing

D.11

Detail

RECOMMENDATION:

Install

copper

grounding

bar

for

personnel

static

electric

discharge

the

base

the

circumferential

stairway.

API 653 In‐Service Inspection Report USAG Kwajalein‐Atoll

l. AST Exterior

Fire

Protection

Water

Systems

OBSERVATION:

The

tank

does

not

appear

meet

the

equipment

requirement

for

AST

exterior

fire

protection

system.

The

stand

post

mounted

water

jet

monitor

was

noted

along

the

facility

fence

line

northeast

corner

the

dike.

Code

REFERENCE:

UFC

3‐460‐03

Section

2‐15.2.1

RECOMMENDATION:

Install

additional

services

for

the

tank

exterior

fire

protection

water

systems

IAW

UFC

3‐460‐01

Section

2‐15.2.1

(fire

protection

water

mains,

hydrants,

valves,

pumps,

and

application

devices

outside

dike)

control

brush

and

grass

fires

and

cooling

storage

tanks

the

event

fire

exposure.

API 653 In-Service Inspection Report USAG Kwajalein-Atoll

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1 SHELL SERVICE LIFE EVALUATION

A.2 SHELL SETTLEMENT EVALUATION

A.3 ULTRASONIC UT DATA

A.4 CONTAINMENT LAYOUT DRAWING

A.5 SHELL LAYOUT DRAWING

A.6 ROOF LAYOUT DRAWING

A.7 OSHA ACCESS STRUCTURE REPORT

Where:

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

t nom = nominal shell thickness, in inches.

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

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

D = nominal diameter of the tank, in feet.

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

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

G = specific gravity of the contents.

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

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

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

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

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

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

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

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

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

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

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

A.1 Shell Service Life Evaluation tmin =

2.6(H−1)DG

Lr = tact − tmin

Cr Cr = tprev − tact

𝞓Y

Iut = tact − tmin

2Cr Iv = tact − tmin

4Cr

1) Minimum Required Thickness

D = 45 feet

G = 0.86

𝞓Y = 63 years

Course

No.

Plate

Specification

Course

Height

(feet)

Product

Height

(feet)

(H )

Maximum

Allowable

Stress

(psi)

(S )

Joint

Efficiency

(E )

Minimum

Acceptable

Thickness

(inches)

(t min )

Measured

Thickness

(inches)

(t prev )*

Current

Measured

Thickness

(inches)

(t act )

1 Unknown 6.92 46.00 23,600 0.85 0.226 0.328 0.313

2 Unknown 6.08 39.08 23,600 0.85 0.191 0.297 0.276

3 Unknown 6.96 33.00 26,000 0.85 0.146 0.281 0.249

4 Unknown 6.96 26.04 26,000 0.85 0.114 0.281 0.256

5 Unknown 6.96 19.08 26,000 0.85 0.100 0.281 0.252

6 Unknown 6.96 12.13 26,000 0.85 0.100 0.281 0.264

7 Unknown 6.96 5.17 26,000 0.85 0.100 0.281 0.27

*The t prev values were based on t nom .

A.1 Shell Service Life Evaluation

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

1 2 3 4 5 6 7

In c h e s

Course

Thickness Graph tprev tact tmin

A.1 Shell Service Life Evaluation

2) Corrosion Rate, Remaining Life and Inspection Intervals

Course

No.

Corrosion

Rate

(in./yr)

(C r )

Remaining

Life

(years)

(L r )

Visual

Inspection

(years)

(I v )

Ultrasonic

Thickness

Inspection

(years)

(I ut )

1 0.00024 364 5 15

2 0.00033 256 5 15

3 0.00051 202 5 15

4 0.00040 354 5 15

5 0.00046 327 5 15

6 0.00027 600 5 15

7 0.00018 956 5 15

Note: The engineering data used to calculate in-service period of operation (Remaining Life) assumes the tank remains in the same service and all corrosion rates remain constant. The maximum safe fill height for the tank is not limited other than by the established maximum operating liquid level and any other appurtenance such as overflow, vents, or firefighting system.

0.00000

0.00010

0.00020

0.00030

0.00040

0.00050

0.00060

1 2 3 4 5 6 7

In c h e s P e r

Y e a r

Course

Course Corrosion Rate Graph

Corrosion Rate

3) Projected Thickness Chart and Graph

Course #1:

Year Thickness tmin

2017 0.313 0.22571785

2022 0.312 0.22571785

2027 0.311 0.22571785

2037 0.308 0.22571785

2047 0.306 0.22571785

*based on same service and corrosion rates.

Course #2:

Year Thickness tmin

2017 0.276 0.191

2022 0.274 0.191

2027 0.273 0.191

2037 0.269 0.191

2047 0.266 0.191

*based on same service and corrosion rates.

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

Anticpated Thickness (20 yrs)*

Anticpated Thickness (30 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

Anticpated Thickness (20 yrs)*

Anticpated Thickness (30 yrs)*

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In c h

Year

Course #1 Projected Thickness Graph

Thickness tmin

0.000

0.050

0.100

0.150

0.200

0.250

0.300

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In c h

Course #2 Projected Thickness Graph

Thickness tmin

Course #3:

Year Thickness tmin

2017 0.249 0.146

2022 0.246 0.146

2027 0.244 0.146

2037 0.239 0.146

2047 0.234 0.146

*based on same service and corrosion rates.

Course #4:

Year Thickness tmin

2017 0.256 0.114

2022 0.254 0.114

2027 0.252 0.114

2037 0.248 0.114

2047 0.244 0.114

*based on same service and corrosion rates.

Anticpated Thickness (20 yrs)*

Anticpated Thickness (30 yrs)*

Anticpated Thickness (20 yrs)*

Anticpated Thickness (30 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

0.000

0.050

0.100

0.150

0.200

0.250

0.300

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In c h

Course #3 Projected Thickness Graph

Thickness tmin

0.000

0.050

0.100

0.150

0.200

0.250

0.300

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In c h

Course #4 Projected Thickness Graph

Course #5:

Year Thickness tmin

2017 0.252 0.100

2022 0.250 0.100

2027 0.247 0.100

2037 0.243 0.100

2047 0.238 0.100

*based on same service and corrosion rates.

Course #6:

Year Thickness tmin

2017 0.264 0.100

2022 0.263 0.100

2027 0.261 0.100

2037 0.259 0.100

2047 0.256 0.100

*based on same service and corrosion rates.

Anticpated Thickness (20 yrs)*

Anticpated Thickness (30 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)*

Anticpated Thickness (10 yrs)*

Anticpated Thickness (20 yrs)*

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File details come from the government source that posted it. Updated Sep 25, 2023.