Attachment J.6 - Fac 1348 (Tank 1) OOS 2012.pdf

API STANDARD 653 INSPECTION REPORT

OUT-OF-SERVICE INSPECTION

TANK #1 (1348)

LITTLE ROCK AFB

JACKSONVILLE, ARKANSAS

Prepared for:

United States Army Corps of Engineers Omaha District

1616 Capitol Avenue Omaha, Nebraska 68192-4901

Prepared by:

CAPE Environmental Management Inc.

4013A Seaboard Court, Suite 1

Portsmouth, Virginia 23701

(757) 405-1291

Project Number: 00075.002.901

November 5, 2012

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

ER-LITTLEROCKAFB-TANK1

EXECUTIVE SUMMARY

An API Standard 653 Out-of-Service Inspection of Tank #1 was completed on October 31, 2012.

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 9 years. 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 October 2032 in accordance with API Standard 653. Inspection Results are listed in 4.0.

The foundation was evaluated for shell settlement in accordance with API 653 Appendix B paragraph B.2.2.4 and exceeds the maximum permissible out-of-plane settlement with a cosine curve R^2 value of 0.496-inches. When the shell settlement exceeds the maximum permissible out-of-plane settlement with a cosine curve R^2 value less than 0.900-inches (no well-defined rigid plane), API 653 recommends considering re-evaluating the shell settlement in accordance with API 653 Appendix B paragraph B.2.2.5.1 (a more rigorous curve-fitting procedure). The shell settlement was re-evaluated and conducted in accordance with API 653 Appendix B paragraph B.2.2.5.1 and all points were within the acceptable maximum permissible out-of-plane settlement set forth in API 653 Appendix B (All shell settlement data is located in Appendix A of the report). There is no open atmosphere vent installed on the fixed roof. An open atmosphere vent equipped with a weatherhood and bird screen should be installed on the fixed tank roof in accordance with API 2000 and API 650.

The tank is not equipped with a 4-inch gauge hatch with a drop down tube near the tank center for water sampling. A 4-inch gauge hatch with a drop down tube should be installed near the tank center for water bottom sampling. The tank has an existing 8-inch stilling well that is used for manual gauging of the tank. The stilling well is not in accordance with current standards. The manual stilling well should be modified per UFGS guidelines. There is no 8-inch ATG installed on the tank. An 8-inch aluminum, slotted stilling well used for automatic gauging of the tank should be installed per UFGS guidelines.

There are no low, low-low, or high-high level alarms installed on the tank. Low, low-low, and high-high level alarms should be installed.

See Sections 4.0 through 7.0 for all other significant findings and recommendations.

ii

TABLE OF CONTENTS

Section Page

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

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

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 Fixed Roof

4.10 Fixed Roof Appurtenances

5.0 Recommendations in Compliance with API 653

5.1 Secondary Containment

5.2 Foundation

5.3 Cathodic Protection

5.4 Bottom

5.5 Shell

5.6 Shell Appurtenances

5.7 Accessways

5.8 Fixed Roof

iii

TABLE OF CONTENTS

Section Page

5.9 Fixed Roof Appurtenances

6.0 UFC 3-460-1 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 Fixed Roof

6.10 Fixed Roof Appurtenances

7.0 Other Recommendations

7.1 Secondary containment

7.2 Foundation

7.3 Cathodic Protection

7.4 Bottom

7.5 Shell

7.6 Shell Appurtenances

7.7 Accessways

7.8 Fixed Roof

7.9 Fixed Roof Appurtenances

8.0 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 iv

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 v

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 Management 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 #1 located at the Little Rock AFB facility in Jacksonville, Arkansas. This report summarizes the results of an API Standard 653 Out-of-Service Inspection conducted by CAPE Environmental Management Inc., Project Number 00075.002.901.

1.1.3 This inspection was completed on October 31, 2012.

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.

3.0 TANK DESCRIPTION

3.1 Tank Description:

Owner/Operator: Little Rock AFB Location: Jacksonville, Arkansas GPS Coordinates: Longitude: N 34° 54' 16" ; Latitude: W 92° 7' 44" Tank Number: 1 Service: Jet A Specific Gravity: 0.84 Nominal Diameter: 60 feet Nominal Shell Height: 40.71 feet Maximum Liquid Level: 34.83 feet Low-Low Level Alarm: None Low Level Alarm: None High Level Alarm: 34.83 feet High Level Control Shutoff: 34.83 feet High-High Level Alarm: None Capacity: 840,000 gallons; 20,000 barrels Configuration: Vertical Aboveground Storage Tank Foundation: Earthen Material Construction: Bottom: Lap-Welded

Shell: Butt-Welded Fixed Roof: Lap-Welded/Butt-Welded

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

Tank Built: 1954 Tank Age: 58 years Operating Limits: Minimum Metal Temperature: 15oF

Maximum Metal Temperature: 200oF Operating Temperature: Ambient Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product

Seismic Zone: 1 Construction Code: API Standard 650 Inspection Type: Out-of-Service Inspection Inspection Date: October 31, 2012 Last Out-of-Service Inspection Year: 2006

4.0 INSPECTION RESULTS

4.1 Secondary Containment: The secondary containment area is constructed from a concrete ring and a high density polyethylene (HDPE) Geo-membrane liner. The permeability and capacity of the secondary containment area appears to be sufficient to contain and hold the stored product. The secondary containment area 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: Approximately 30 linear feet of the sealant installed in the concrete expansion joints of the concrete ring is damaged and deteriorating. The original bottom was cut out when the new tank bottom sump was installed and no secondary liner was installed underneath the original tank bottom.

4.2 Foundation: The tank bears on top of earthen material. The tank bottom has leak detection ports installed. The foundation was evaluated for shell settlement in accordance with API Standard 653 and is in satisfactory condition.

4.2.1 Significant Findings: There is no foundation-to-bottom sealant installed for the original tank bottom (approximately 190 linear feet). The leak detection ports do not have valves installed. The foundation was evaluated for shell settlement and is beyond acceptable limits set forth in API Standard 653 Appendix B paragraph B.2.4.1. The survey was re-evaluated in accordance with API 653 Appendix B paragraph B.2.2.5.1 and all points were within the maximum permissible out-of-plane settlement. (see Appendix A of the report for further details).

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

4.3.1 Significant Findings: The cathodic protection system for the tank and the tanker trucks that connect to the tank piping during fuel transfers negates each other when transferring fuel.

4.4 Bottom: The tank has a lap-welded cone-down type bottom. The bottom has a thin film coating that ranged from 11.3 mils to 25.9 mils in thickness. The tank bottom has leak detection and does not have secondary containment under the tank bottom. The nominal thickness of the bottom is 0.3125 inches. The bottom was scanned (approximately 95 percent) 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 during the MFL scan. The bottom topside was not examined with a flashlight held parallel to the floor, since the tank bottom is coated. The general thickness of each bottom plate was measured using ultrasonic technology (UT). The general thickness of the bottom ranged from a minimum of 0.303 inches to a maximum of 0.320 inches, excluding the underside corrosion indications located by the MFL scan. 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. Vacuum box testing was not be performed, since the welds were coated. Magnetic particle testing was not performed, since the welds were coated. 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 October 2032 in accordance with API Standard 653. The bottom service life evaluation is shown in Appendix A.

4.4.1 Significant Findings: There is approximately 5 square feet (14 locations) of coating failure on the bottom plates. There is an approximate 2 square foot area of excessive coating build-up on the tank bottom between the shell and the piping support braces for the 8-inch Product Issue (shell nozzle C). The bottom one-quarter of the bottom sump wall has coating failure amounting to approximately 2 square feet. The two (2) ATG float guide wire anchors are welded directly to the tank bottom. An area of the bottom plate lap-weld seam for plate seven (7) near the South shell manway (shell nozzle A) has lack of filler metal (pinholes). All of the internal piping support bearing plates have size and shape out-of-tolerances.

4.5 Shell: The tank consists of five (5) butt-welded courses. The exterior of the shell has a thin coating system that ranged between 7.83 and 21.5 mils in thickness. The interior of the shell has a thin coating system that ranged between 9.53 and 24.2 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. 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 coating failures amounting to approximately 12 square feet.

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 8-inch Product Issue (shell nozzle C), the 1-inch Water Draw (shell nozzle M), and the 3-inch Low Point Suction (shell nozzle O) were internal elbow-down nozzles. The 12-inch Product Receipt (shell nozzle B), the 8-inch Product Issue (shell nozzle C), the 8-inch Product Issue (shell nozzle H), and the 8-inch Product Issue (shell nozzle N) have over-pressure protection. The 8-inch Product Issue (shell nozzle H) and the 8-inch Product Issue (shell nozzle N) are currently out-of-service. 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 ATG system is in satisfactory condition.

4.6.1 Significant Findings: The ultrasonic thickness measurements on the nozzles revealed no significant loss of metal from corrosion and erosion. All nozzles were adequately reinforced. The pressure relief piping for the 8-inch Product Issue (shell nozzle C) and the 12-inch Product Receipt (shell nozzle B) lacks a Tee for testing of the pressure relief valves. The pressure relief piping for the 8-inch Product Issue (shell nozzle H) and the 8-inch Product Issue (shell nozzle N) is not in accordance with current standards. The Water Draw (shell nozzle M) piping is 1-inch in diameter with a 1-inch coupling shell penetration. The 8-inch Product Issue (shell nozzle C) internal piping extends to the center of the tank. One of the shell manways currently installed is 30-inch x 20-inch (shell nozzle P). There is no telltale hole installed in the shell reinforcement plate for the 30-inch x 20-inch shell manway (shell nozzle P). The shell reinforcement plates for the two (2) out-of-service Product Issues (shell nozzles H and N) are diamond shaped and butted up against the shell-to-bottom weld. There are no low, low-low, or high-high level alarms installed on the tank. The u-bolt on the inner most support brace for the 3-inch Low Point Suction internal piping is loose, allowing the piping to slide off the support.

4.7 Accessways: The fixed roof is accessible via a spiral stairway.

4.7.1 Significant Findings: There is Approximately two percent of coating failure on the tank spiral stairway and fixed roof walkway platforms, handrails, stringers, and treads. There is no internal ladder installed to allow access to the tank bottom from the fixed tank roof. The bottom of the tank spiral stairway treads are not seal-welded to the tank shell.

4.8 Floating Roof: There is no full contact internal floating pan currently installed.

Installation of an internal floating roof will require modifications to the tank. Modifications to the tank will or may require, a total of four (4) 24-inch x 24-inch inspection hatches, modification of the existing spiral stairway platforms, the fixed roof walkway, installation of shell overflow vents, and the potential relocation of the existing high level alarm and high level shut-off nozzles.

4.8.1 Significant Findings: The tank does not support installation of an internal floating roof without modifications.

4.9 Fixed Roof: The topside coating of the floating roof measured between 11.2 and 21.2 mils in thickness. The fixed roof was evaluated for remaining metal thickness using ultrasonic technology. The fixed roof thickness ranged from a minimum of 0.165 inches to a maximum of

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

4.9.1 Significant Findings: There is approximately 6 square feet (8 areas) of coating failure on the underside of the roof. There are no fixed scaffold cable supports installed on the roof. There is mildew staining throughout the fixed tank roof.

4.10 Fixed Roof Appurtenances:

4.10.1 Significant Findings: There is no open atmosphere center vent with weather hood and bird screen installed on the tank roof. There are coating failures on the two 6-inch Emergency Vents (roof nozzles F and H), the 8-inch Manual Stilling Well (roof nozzle E), and the 24-inch roof manway (roof nozzle G). There is no ATG stilling well installed.

The current 8-inch Stilling Well (roof nozzle E) used for manually gauging the tank is not in accordance with current standards. There is no center 4-inch gauge hatch with a drop down tube for water sampling installed. There are no inspection hatches installed on the roof.

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 Remove all of the existing internal pipe support pads that are welded to the tank bottom and replace with support pads in accordance with API 653 Figure 9.13. Repair coatings as needed, or have an engineer experienced in storage tank design review and accept the currently installed internal piping support pads; Ref. API 653 Sec. 9.10.1.3.

5.4.2 Remove the out-of-tolerance ATG float wire guide anchors and install a bearing plate(s) in accordance with API 653 Fig. 9-13. Weld the anchors to the bearing plate(s), repair coatings as needed or have an engineer experienced in storage tank design review and accept the current configuration; Ref. API 653 Sec. 9.10.13.

5.4.3 Remove coating from the tank bottom plate lap-weld where the defects exist, repair the weld in accordance with API 650 Sec. 8.5, and repair the coating to restore 100 percent coverage;

Ref. API 653 Sec. 12.1.7.1.

5.5 Shell:

5.5.1 No recommendations at this time.

5.6 Shell Appurtenances:

5.6.1 Install a 1/4-inch diameter hole on the centerline of the shell reinforcement plate for the 30"-inch x 20-inch shell manway (shell nozzle P); Ref API 650 Fig. 5-8.

5.6.2 Remove or modify the out-of-tolerance shell reinforcement plates for the two out-of-service 8-inch Product Issues (shell nozzles H and N) in accordance with API 653 9.9.2.1 through 9.9.2.3, or provide documentation that the criteria in API 653 Sec. 9.10.2.7 (ii) e) was performed when the new bottom was installed. ; Ref. API 653 Sec. 9.9.2, API 653 Sec. 9.10.2.7.

5.7 Accessways:

5.7.1 No recommendations at this time.

5.8 Fixed Roof:

5.8.1 No recommendations at this time.

5.9 Fixed Roof Appurtenances:

5.9.1 No recommendations at this time.

6.0 UFC 3-460-1 RECOMMENDATIONS

6.1 Secondary Containment:

6.1.1 No recommendations at this time.

6.2 Foundation:

6.2.1 No recommendations at this time.

6.3 Cathodic Protection:

6.3.1 No recommendations at this time.

6.4 Bottom:

6.4.1 Repair the approximate 5 square feet (14 areas) of failed coating on the tank bottom plates to restore 100 percent coverage; Ref. UFC 3-460-1 Sec. 8-3.9 a) (1).

6.4.2 Repair the approximate 2 square feet of failed coating on the bottom one-quarter of the sump wall to restore 100 percent coverage; Ref. UFC 3-460-1 Sec. 8-3.9 a) (1).

6.5 Shell:

6.5.1 Repair the approximate 12 square feet of coating failure on the external courses of shell courses one and two to restore 100 percent coverage; Ref. UFC 3-460-1 Sec. 8-3.10 a).

6.6 Shell Appurtenances:

6.6.1 Install low, low-low, and high-high level alarms; Ref. UFC 3-460-1 Table 8-1 (k).

6.6.2 Modify the existing pressure relief piping for the 8-inch Product Issue (shell nozzle C) and the 10-inch Product Receipt (shell nozzle B) in accordance with AW 78-24-27; Ref. AW 78-24-27 A3 D.07.

6.6.3 Modify the existing 8-inch Product Issue (shell nozzle C) internal piping to extend into the tank no greater than 1/2 the radius of the tanks diameter; Ref. AW 78-24-27 C4 D.07.

6.6.4 Install a 2-inch plate flange coupled with a 2-inch double block and bleed valve for the 1/2-inch water draw (shell nozzle M); Ref. UFC 3-460-1 Table 8-1 (y).

6.7 Accessways:

6.7.1 Repair the approximate two percent of coating failure on the tank spiral stairway and fixed roof walkway platforms, handrails, stringers, and treads to restore 100 percent coverage;

Ref. UFC 3-460-1 Sec. 8-3.10 a).

6.7.2 Seal weld the bottom of all stairway treads to the tank shell and apply coatings as needed to establish 100 percent coverage; Ref. AW 78-24-27 Sec. 2.15.15.

6.7.3 Install an internal vertical ladder to allow access to the tank bottom from the fixed tank roof in accordance with OSHA criteria; Ref. UFC 3-460-1 Table 8-1 (h).

6.8 Floating Roof:

6.8.1 Install a full contact internal floating pan in accordance with AW 78-24-27. Make the necessary modifications to the tank in order to support installation of the floating roof; Ref. UFC 3-460-1 Sec. 8-8.3 a).

6.9 Fixed Roof:

6.9.1 Repair the approximate 6 square feet (8 areas) of coating failure on the underside of the fixed tank roof to restore 100 percent coverage; Ref. UFC 3-460-1 Sec. 8-3.9 a) (1).

6.9.2 Install two (2) fixed scaffold cable supports on the fixed tank roof in accordance with API

650. Locate the supports near the center of the roof; Ref. UFC 3-460-1 Table 8-1 (ee).

6.10 Fixed Roof Appurtenances:

6.10.1 Repair the coating failures on the two (2) 6-inch emergency roof vents (roof nozzles F and H), the 8-inch manual stilling well (roof nozzle E), and the 24-inch manway (roof nozzle G) to restore 100 percent coverage; Ref. UFC 3-460-1 Sec. 8-3.10 a).

6.10.2 Install two (2) 24-inch x 24-inch inspection hatches on the fixed tank roof approximately 90 degrees adjacent to the two shell manways; Ref. UFC 3-460-1 Table 8-1 (e).

6.10.3 Install a 4-inch gauge hatch with a drop down tube near the center of the tank for water bottom sampling; Ref. UFC 3-460-1 Table 8-1 (r).

6.10.4 Install an aluminum slotted 8-inch diameter stilling well used for automatic gauging of the tank and make it accessible from the tank stairway; Ref. UFC 3-460-1 Table 8-1 (q).

6.10.5 Modify or replace the existing non-slotted 8-inch stilling well used for manual gauging of the tank per current UFGS guidelines; Ref. UFC 3-460-1 Table 8-1 (s).

6.10.6 Install an open atmospheric center vent equipped with a weather hood and bird screen in accordance with API 650, AW 78-24-27, and API 2000 where applicable; Ref. UFC 3-460-1 Table 8-1 (I).

7.0 OTHER RECOMMENDATIONS

7.1 Secondary Containment:

7.1.1 Replace the areas of failed sealant (approximately 30 linear feet) in the concrete expansion joints of the concrete ring.

7.1.2 Consider options for installing a secondary liner underneath the tank bottom.

7.2 Foundation:

7.2.1 Install an approved sealant between the original tank bottom and the tank foundation around the full circumference of the bottom-lip-extension (approximately 190 linear feet).

7.2.2 Install new 2-inch lockable ball valves on all four leak detection ports.

7.3 Cathodic Protection:

7.3.1 Have an engineer experienced in cathodic protection systems design and installation evaluate the current cathodic protection system to assure the system is configured properly and operating correctly.

7.4 Bottom:

7.4.1 No recommendations at this time.

7.5 Shell:

7.5.1 No recommendations at this time.

7.6 Shell Appurtenances:

7.6.1 Remove the spool piece downstream of the plug valve and thermal piping and install a new ball valve. Install blind flanges on the plug valve, new ball valve, and attached piping for the two out-of-service 8-inch Product Issues (shell nozzles H and N). Label the pipelines as "Out-of-Service".

7.6.2 The currently installed 30-inch x 20-inch shell manway (shell nozzle P) is sufficient for tank access along with the other installed 36-inch shell manway (shell nozzle A). No recommendation for replacement of the 30-inch x 20-inch or installation of an additional 36-inch manway will be made at this time. If decisions for installation of a 36-inch manway are made, install the manway in accordance with AW 78-24-27.

7.6.3 Tighten the existing u-bolt on the inner most pipe support brace for the 3-inch Low Point Suction (shell nozzle O) internal piping, to assure the piping remains secured to the support brace during operation.

7.7 Accessways:

7.7.1 No recommendations at this time.

7.8 Fixed Roof:

7.8.1 Wash the tank roof to remove the mildew staining, taking care not to damage the existing coatings. Monitor the condition of coatings during monthly tank inspections.

7.9 Fixed Roof Appurtenances:

7.9.1 No recommendations at this time.

ER-LITTLEROCKAFB-T ANK I

8.0 SERVICEABILITY

8.1 Tank repair requirements per API Standard 653 :

8.1.1 All repair work must be authorized by a Certified Inspector or an Engineer experienced in storage tank design, before commencement of the work by a repair organization. A Certified Inspector must designate inspection hold points required during the repair or alteration sequence and minimum documentation to be submitted upon job completion. The Certified Inspector may give prior general authorization for limited or routine repairs as long as a Certified Inspector is sure that the repairs will not require hydrostatic testing or do not require an engineering evaluation.

8.1.2 All proposed design, work execution, materials, welding procedures, examination, and testing methods must be approved by a Certified Inspector or by an Engineer experienced in storage tank des,ign. A Certified Inspector or an Engineer experienced in storage tank design shall approve all specified repair and alteration work at the designated hold points and after repairs and alterations have been completed in accordance with the requirements of API Standard 653.

8.2 Recommendations to bring the tank into compliance to API Standard 653, along with additional recommendations, to bring the tank and other components into compliance with other Codes and Standards, have been identified in this report. Completion of these items is recommended to ensure successful long term service.

8.3 Upon completion of the repairs as described in 5.0 and the requirements of7.1, the tank will be in compliance with the requirements of API Standard 653, and the following schedule may be implemented:

8.3.1 The next external visual inspection should be accomplished by a Certified Inspector prior to May 2017 in accordance with API Standard 653.

8.3.2 The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to May 2027 in accordance with API Standard 653.

8.3.3 The next internal inspection should be accomplished by a Certified Inspector prior to May 2032 in accordance with API Standard 653.

Signatures:

Justin T. Wearsch CAPE Environmental Management Inc.

Certified API-653 Inspector, #42179

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 deteriorating/deteriorated thin film coating system.

The tank bottom did not have a cathodic protection system. The tank bottom has leak detection and did not have secondary containment under the tank bottom.

MRTbc or MRTip

RTip

RTbc

StPr

UPr

0.10 inches

0.3125 inches

0.2725 inches * 0 inches/year

0.0009 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).

Orbc = RTbc - MRTbc =

0.2725 - 0.10 = 191 years(StPr + UPr) (0 + 0.0009)

Orip = RTip - MRTip =

0.3125 - 0.10 = 236 years(StPr + UPr) (0 + 0.0009)

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

23.56 feet 30,000 psi 29,000,000 psi

40.71 feet

0.0776 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

-0.0100 -0.0017 0.0700

-0.0117 0.0400

-0.0183 -0.0300 -0.0083 feet feet feet feet feet feet feet feet

S1

S2

S3

S4

S5

S6

S7

S8

-0.0050 -0.0317 0.0767

-0.0667 0.0550

-0.0233 -0.0167 0.0117 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, 0.0767 feet, is less than the magnitude of the maximum permissible out-of-plane deflection, 0.0776 feet.

A-5

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Little Rock AFB

CAPE Environmental Management Inc.

11/05/12 N/A N/A

Tank #1 SS-1Internal Shell Settlement Evaluation

Point #1 is at Seam #1 and each point is 45 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 1 2 3

3.94

3.95

3.96

3.97

3.98

3.99

4.00

4.01

4.02

A-6

TANK SETTLEMENT SURVEY

(for 8 point survey)

Smax, in = min[K*Sarc*(D/H)*(Y/E), (4.0)

D = tank diameter, in feet (ft) E = Young's Modulus,psi H = tank height, in feet (fl) K = factor from table in API-653 B.3.2.2

Sarc = effective settlement arc, see 8.2.2.5.1, in feet (ft) Smax = permissible out-of-plane settlement, in inches (in.)

D Y E H K

60.00 30000 29000000 39.083 5.8 Fixed Roof

Graph Plot Sarc (ft) S -Feet S-(in) Results Smax, in + Smax, in -

Point 4 117.8 -0.076 -0.912 SAT 1.085 -1.085 Point 5 70.7 0.0000 0.000 Not Chkd Not Chkd Not Chkd Point 6 70.7 -0.0233 -0.280 SAT 0.651 -0.651

Point 7 70.7 -0.0167 -0.200 SAT 0.651 -0.651 Point 8 117.8 0.0000 0.000 Not Chkd Not Chkd Not Chkd Point 1 117.8 -0.0340 -0.408 SAT 1.085 -1.085 Point 2 117.8 -0.0580 -0.696 SAT 1.085 -1.085 Point 3 117.8 -0.0020 -0.024 SAT 1.085 -1.085 Point 4 117.8 -0.076 -0.912 SAT 1.085 -1.085

SETTLEMENT PLOT

Evaluation in accordance with API-653 para. B.2.2.5.1

0.000

0.020

0.040

0.060

0.080

0.100

1 2 3 4 5 6 7 8 9

Settlement Points (Ui) Determined Plane

A-7

TANK SETTLEMENT SURVEY

(for 8 point survey)

Smax, in = min[K*Sarc*(D/H)*(Y/E), (4.0)

D = tank diameter, in feet (ft) E = Young's Modulus,psi H = tank height, in feet (fl) K = factor from table in API-653 B.3.2.2

Sarc = effective settlement arc, see 8.2.2.5.1, in feet (ft) Smax = permissible out-of-plane settlement, in inches (in.)

D Y E H K

60.00 30000 29000000 39.083 5.8 Fixed Roof

Graph Plot Sarc (ft) S -Feet S-(in) Results Smax, in + Smax, in -

Point 4 94.2 -0.030 -0.360 SAT 0.868 -0.868 Point 5 94.2 0.0400 0.480 SAT 0.868 -0.868 Point 6 94.2 0.0000 0.000 Not Chkd Not Chkd Not Chkd

Point 7 94.2 0.0100 0.120 SAT 0.868 -0.868 Point 8 94.2 0.0300 0.360 SAT 0.868 -0.868 Point 1 94.2 0.0100 0.120 SAT 0.868 -0.868 Point 2 94.2 0.0000 0.000 Not Chkd Not Chkd Not Chkd Point 3 94.2 0.0500 0.600 SAT 0.868 -0.868 Point 4 94.2 -0.030 -0.360 SAT 0.868 -0.868

SETTLEMENT PLOT

Evaluation in accordance with API-653 para. B.2.2.5.1

0.000

0.020

0.040

0.060

0.080

0.100

1 2 3 4 5 6 7 8 9

Settlement Points (Ui) Determined Plane

A-8

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 DY 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).

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

A-9

Shell Service Life Evaluation

Present Condition:

Plate Material: Carbon Steel, Unknown Grade

D H G

DY

60 feet

34.83 feet 0.84 58 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 6.75 23,595 0.85 0.34 0.314 0.2210 0.000448 207 5 15

2 7.83 23,595 0.85 0.27 0.263 0.1769 0.000121 711 5 15

3 8.16 25,960 0.85 0.25 0.234 0.1143 0.000276 433 5 15

4 8.16 25,960 0.85 0.25 0.233 0.1000 0.000293 453 5 15

5 8.16 25,960 0.85 0.25 0.242 0.1000 0.000138 1,028 5 15

The current measured thickness is based on the lowest ultrasonic thickness measurement for that course. The remaining life of the shell is 207 years under present conditions. The current maximum liquid level is 34.83 feet based on the high-high level alarm, which is satisfactory.

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 October 2017 in accordance with API Standard 653. The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to October 2027 in accordance with API Standard 653.

A-10

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-11

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

DY 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.

DY = Years between tprev and tact, in years.

A-12

Nozzle A: 36" Manway (Course #1) d = 36 - 2(0.5) = 35 inches t = 0.314 inches DY = 58 years

Rn = 35/2 = 17.5 inches tr = 0.1 inches Dp = 78 inches

P = 0.433(0.84)(32.83) = 12 psi tn = 0.5 inches te = 0.5 inches h = 0 inches ti = 0 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.494 inches

Minimum Required Thickness Calculation:

trn = PRn =

(12)(17.5) = 0.0105 inches

SE - 0.6P (20,000)(1) - (0.6)(12)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.494 = 0.000103 inches/year

DY 58

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

Remaining Life Calculation:

LR =

tact - trn =

0.494 - 0.1 = 1970 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (35)(0.1) = 3.5 in2

A1

= d(t-tr) = (35)(0.314-0.1) = 7.49 in2

= 2(t+tn)(t-tr) = (2)(0.314+0.5)(0.314-0.1) = 0.3484 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.314) = 0.628 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.314)[(2.5)(0.5)+0.5] = 1.099 in2

A3

= 5t ti = (5)(0.314)(0) = 0 in2

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

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

A5 = (Dp-d-2tn)te = [78-35-(2)(0.5)](0.5) = 21 in2

Area provided by A1 + A2 + A3 + A5 = 7.49 in2 + 0.628 in2 + 0 in2 + 21 in2 = 29.118 in2. This is greater than the required area of 3.5 in2, therefore, the reinforcement is adequate.

A-13

Nozzle B: 12" Product Receipt (Course #1) d = 12.75 - 2(0.5) = 11.75 inches t = 0.314 inches DY = 58 years

Rn = 11.75/2 = 5.875 inches tr = 0.1522 inches Dp = 28 inches

P = 0.433(0.84)(33.91) = 12 psi tn = 0.5 inches te = 0.34 inches h = 2 inches ti = 0.5 inches

Sn = 20,000 psi tprev = 0.5 inches

E = 1 tact = 0.501 inches

Minimum Required Thickness Calculation:

trn = PRn =

(12)(5.875) = 0.0035 inches

SE - 0.6P (20,000)(1) - (0.6)(12)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.5 - 0.501 = -0.000017 inches/year

DY 58

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

Remaining Life Calculation:

LR =

tact - trn =

0.501 - 0.1 = 2005 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (11.75)(0.1522) = 1.7884 in2

A1

= d(t-tr) = (11.75)(0.314-0.1522) = 1.9012 in2

= 2(t+tn)(t-tr) = (2)(0.314+0.5)(0.314-0.1522) = 0.2634 in2

A2

= 5(tn-trn)t = (5)(0.5-0.1)(0.314) = 0.628 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.314)[(2.5)(0.5)+0.34] = 0.9985 in2

A3

= 5t ti = (5)(0.314)(0.5) = 0.785 in2

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

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

A5 = (Dp-d-2tn)te = [28-11.75-(2)(0.5)](0.34) = 5.185 in2

Area provided by A1 + A2 + A3 + A5 = 1.9012 in2 + 0.628 in2 + 0.785 in2 + 5.185 in2 = 8.4992 in2. This is greater than the required area of 1.7884 in2, therefore, the reinforcement is adequate.

A-14

Nozzle C: 8" Product Issue (Course #1) d = 8.625 - 2(0.408) = 7.809 inches t = 0.314 inches DY = 58 years

Rn = 7.809/2 = 3.9045 inches tr = 0.1633 inches Dp = 20 inches

P = 0.433(0.84)(33.74) = 12 psi tn = 0.408 inches te = 0.34 inches h = 1.632 inches ti = 0.408 inches

Sn = 20,000 psi tprev = 0.408 inches

E = 1 tact = 0.397 inches

Minimum Required Thickness Calculation:

trn = PRn =

(12)(3.9045) = 0.0023 inches

SE - 0.6P (20,000)(1) - (0.6)(12)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact =

0.408 - 0.397 = 0.00019 inches/year

DY 58

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

Remaining Life Calculation:

LR =

tact - trn =

0.397 - 0.1 = 1485 years

Cr 0.0002

Reinforcement Calculations:

Formulas are simplified

A = dtr = (7.809)(0.1633) = 1.2752 in2

A1

= d(t-tr) = (7.809)(0.314-0.1633) = 1.1768 in2

= 2(t+tn)(t-tr) = (2)(0.314+0.408)(0.314-0.1633) = 0.2176 in2

A2

= 5(tn-trn)t = (5)(0.408-0.1)(0.314) = 0.4836 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.408-0.1)(0.314)[(2.5)(0.408)+0.34] = 0.6576 in2

A3

= 5t ti = (5)(0.314)(0.408) = 0.6406 in2

= 5ti ti = (5)(0.408)(0.408) = 0.8323 in2

= 2hti = (2)(1.632)(0.408) = 1.3317 in2

A5 = (Dp-d-2tn)te = [20-7.809-(2)(0.408)](0.34) = 3.8675 in2

Area provided by A1 + A2 + A3 + A5 = 1.1768 in2 + 0.4836 in2 + 0.6406 in2 + 3.8675 in2 = 6.1685 in2. This is greater than the required area of 1.2752 in2, therefore, the reinforcement is adequate.

A-15

Nozzle D: 1" Plug (Course #1) d = 1.315 - 2(0) = 1.315 inches t = 0.314 inches DY = 58 years

Rn = 1.315/2 = 0.6575 inches tr = 0.1835 inches Dp = N/A

P = 0.433(0.84)(33.58) = 12 psi tn = N/A te = N/A h = N/A ti = N/A

Sn = 20,000 psi tprev = N/A

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(12)(0.6575) = 0.0004 inches

SE - 0.6P (20,000)(1) - (0.6)(12)

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-16

Nozzle E: 1" Plug (Course #2) d = 1.315 - 2(0) = 1.315 inches t = 0.263 inches DY = 58 years

Rn = 1.315/2 = 0.6575 inches tr = 0.1337 inches Dp = N/A

P = 0.433(0.84)(24.62) = 9 psi tn = N/A te = N/A h = N/A ti = N/A

Sn = 20,000 psi tprev = N/A

E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn =

(9)(0.6575) = 0.0003 inches

SE - 0.6P (20,000)(1) - (0.6)(9)

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 F: 1" Plug (Course #3)…