Attachment J.6 Kwajalein Fac 953 (Tank 17) pre-rpr 2017.pdf

NAVFAC EXWC CONTRACT N62583-09-D-0130, DO 0002

TANK 17 (FACILITY NO. 953)

API 653 TANK INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

(PRE-REPAIR)

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

July 2014

Prepared For:

Naval Facilities Engineering Expeditionary Warfare Center (NAVFAC EXWC) 1100 23rd Avenue, Code 232 Port Hueneme, California 93043-4370

Presented By:

CB&I

1132 Bishop Street, Suite 1900 Honolulu, HI 96813

Prepared By:

ENTERPRISE ENGINEERING, INC.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

James E. Hall, P.E., API 653 Certificate No. 46418

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17

EEI PROJECT NO. 5452

Page Intentionally Left Blank

This tank inspection has determined that mandatory repairs are required prior to return to service. Tank 17 is suitable for service for a period of up to a maximum of two years.

After two years, the remaining mandatory repairs must be completed, or the tank removed from service.

SUITABILITY FOR SERVICE TESTAMENT – TANK 17 (FACILITY NO. 953)

Enterprise Engineering, Inc. (EEI), under contract to CB&I, completed an API 653 out-of-service internal and external inspection of Tank 17 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The in-service external inspection of Tank 17 was performed March 18 and 19, 2010 in advance of the out-of-service inspection of the tank interior. The out-of-service inspection was performed June 2 and 3, 2014.

Conditions observed during the 2010 external inspection were examined during this 2014 out-of-service inspection and any changed conditions were noted. The out-of-service inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 and the Statement of Work.

Inspection findings and recommended repairs are provided below.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair, prior to returning the tank to service. Recommendations for continued long-term service are also provided.

EEI recommends the next API 653 external in-service inspection be performed no later than June 2019 (5 years from 2014 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API internal out-of-service inspection be scheduled no later than June 2024 (10 years from 2014 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653, this report satisfies the requirement for an out-of-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

James E. Hall, P.E.

API 653 AST Inspector Certificate No. 46418

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Mandatory Repairs Recommended API Repairs Recommended Non-API Repairs Recommended Repairs per Current Military Criteria Recommended Repairs for Long Term Serviceability

COATING SYSTEM

Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Tank Shell Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEMS

Seismic Evaluation

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ............................................................................... Tab A Assessment of Compliance with Military Criteria ................................................................................ Tab B Non-Destructive Examination (NDE) and Evaluation Criteria ............................................................ Tab C Tank Drawings ...................................................................................................................................... Tab D Tank Photographs .................................................................................................................................. Tab E NDE Results........................................................................................................................................... Tab F Calculations........................................................................................................................................... Tab G Coating Requirements .......................................................................................................................... Tab H

Tank 17 – API 653 Inspection TABLE OF CONTENTS Kwajalein Atoll, RMI July 2014 EEI Project No.: 5452

TANK 17

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

Kwajalein Atoll, RMI

SUMMARY

Scope

Enterprise Engineering, Inc. (EEI), under contract to CB&I, completed an API 653 out-of-service internal and external inspection of Tank 17 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The in-service external inspection of Tank 17 was performed March 18 and 19, 2010 in advance of the out-of-service inspection of the tank interior. The out-of-service inspection was performed June 2 -3, 2014.

Conditions observed during the 2010 external inspection were examined during this 2014 out-of-service inspection and any changed conditions were noted. The out-of-service inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 and the Statement of Work.

Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 17 is a field erected aboveground storage tank. The tank was constructed in 1954. The tank is 45 feet in diameter and 47 feet 10 inches high. The tank is of welded construction with butt-welded shell plates and a column supported fixed cone roof with lap-welded roof plates. The tank floor is of cone up with a perimeter sump and lap-welded floor plates. The nominal shell capacity is 13,500 BBLS. Tank 17 is currently in F-76 service.

INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

This tank inspection has determined that mandatory repairs are required prior to returning the tank to service. To clarify, under API 653 Mandatory Repairs are considered to be those that are required to eliminate an immediate threat to integrity, as well as those that represent a threat to integrity until the next scheduled API out of service inspection (i.e. 10+ years). The government’s desire is to return the tank to service prior to performing any (mandatory or recommended) repairs. The mandatory repairs can be deferred for a maximum period of two years from the present. As a part of the deferred repair process (before or during repairs), an API 653 certified inspector shall re-visit the tank to ascertain that there have been no changes to the previous findings, and to permit resetting the re-inspection clock from the date of second inspection/repairs (2016), as compared to keeping the re-inspection clock based on this inspection (2014).

Tank 17 – API 653 Inspection Page 1

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Visual inspection of the tank shell found no indications of leakage. A pit survey was conducted for topside corrosion on the floor and no pits were identified requiring repair. A magnetic flux leakage (MFL) scan of the tank floor found one relevant indications of corrosion on the bottom side of the floor requiring repair.

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof and their attachments.

Ultrasonic inspections of the shell were performed on the first course and on the each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

Visual inspection found undercut at the floor-to-shell weld, pitting in doubler plate and patch plate welds, and non-compliant weld clearances at one pipe support doubler plate.

Tank 17 will be in acceptable structural condition pending the completion of repairs and examination of the non-compliant welds.

Next Inspection

API 653 requires an in-service inspection be performed every 5 years or RCA/4N years whichever is less.

RCA is the remaining corrosion allowance of the shell (i.e. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. When shell corrosion rates are unknown, API 653 requires the in-service inspection interval not exceed 5 years.

EEI recommends that the next external in-service inspection be scheduled no later than June 2019 (5 years from 2014 inspection), or sooner if a change in condition has occurred.

API 653 requires the interval until the next internal inspection be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years. When RBI procedures are used, the interval shall not exceed 25. If the tank has a release prevention barrier and leak detection designed in accordance with API 650 Appendix I and RBI procedures are used, the interval shall not exceed 30 years. It should be noted that a maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

EEI recommends that the next API internal out-of-service inspection be scheduled for no later than June 2024 (10 years from 2014 inspection), or sooner if a change in condition has occurred. Although a longer inspection interval is allowed by API 653, we recommend not exceeding 10 years based upon the active and aggressive corrosion observed throughout the facility.

This inspection interval will be in sync with the in-service inspection cycle and is in keeping with the 10 year inspection interval commonly used in many government and commercial facilities.

Tank 17 – API 653 Inspection Page 2

REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as mandatory, recommended API, recommended Non-API, and recommended for long term serviceability.

Standard of Care

All repairs shall strictly meet the requirements of API 650, API 653 and API 570 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements. Obtaining hot work permits and developing appropriate hot work procedures for the tank floor is the responsibility of the repair contractor and shall consider that the tank has been in petroleum service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Prior to welding on the floor, the repair contractor shall be responsible for testing the coating system and establishing engineered controls for worker safety. If lead based coatings are present, all work shall be performed in accordance with UFGS Section 02 82 33.13 20 “Removal/Control and Disposal of Paint with Lead”.

Mandatory Repairs

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank, or are required to meet code, and are required prior to returning Tank 17 to service. At the government’s request, the tank will be returned to service without performing the mandatory repairs for a period of two years.

Mandatory Repairs (To be performed prior to returning tank to service)

No repairs were identified during the inspection to be performed prior to returning the tank to service.

Mandatory Repairs (Deferred for a maximum of two years per request of the Government)

1. Isolated weld undercut up to 0.080 inches deep is present along the floor-to-shell weld around the circumference of the tank. Based on current API-650 requirements, the maximum undercut in the floor-to-shell weld shall not exceed 1/64 inches.

• Repair undercut equal to or greater than 1/64 inches in the shell-to-floor weld by weld overlay.

Approximately 24 inches of undercut is in need of repair.

• Perform vacuum box testing and either magnetic particle or liquid penetrant examination of the repairs. Inspect for cracks, lack of fusion, porosity. Repair all defects found.

2. Tank 17 is equipped with an atmospheric vent but not an emergency vent. Tanks with a diameter in excess of 50 feet and designed with a frangible joint to API 650, are considered adequate for emergency venting. Since the diameter of the tank is only 45 feet, a separate emergency vent is required.

• Provide an emergency vent with a minimum capacity of 742,000 standard cubic feet per hour

(SCFH).

Tank 17 – API 653 Inspection Page 3

• The emergency vent may be installed in the cover plate of the roof manway adjacent to the stair platform. Repair manway cover and nozzle as necessary prior to the installation of the emergency vent.

• Alternatively, provide a new roof penetration for the emergency vent.

3. The welds at one of the pipe supports at the no longer used fill piping have two pits and one void.

• Grind pits and void to a smooth contour.

• Provide weld overlay at three locations to restore weld profile and fill void in weld.

• Provide visual and magnetic particle examination of the completed weld. Inspect for cracks, lack of fusion, and porosity. Repair all defects found by grinding the weld to remove the defect and re-welding.

• Provide vacuum box testing of the completed weld. Repair all leak indications by grinding the weld to remove the defect and re-welding. Perform vacuum box testing of the completed remedial repair to verify that no more leak indications are present.

4. The doubler plate at the pipe support for the fill piping does not comply with API 653 weld spacing requirements.

• Examine the non-compliant welds by magnetic particle examination.

5. One corrosion pit in need of repair on the underside of the floor was found during the inspection.

• Provide a lapped patch plate 6-inch in diameter and 5/16-inch thick. Location will be included in the final report.

• Patch plate shall be welded with a continuous fillet weld. The fillet weld shall have complete penetration and complete fusion with the base material (tank floor and patch plate), and shall be full thickness of patch plate. Finished weld should be in accordance with API requirements.

• Provide visual and magnetic particle examination of the completed weld. Inspect for cracks, lack of fusion, and porosity. Repair all defects found by grinding the weld to remove the defect and re-welding.

• Provide vacuum box testing of the completed weld. Repair all leak indications by grinding the weld to remove the defect and re-welding. Perform vacuum box testing of the completed remedial repair to verify that no more leak indications are present.

6. Pitting was observed in the welds attaching the patch plate to the sump wall.

• Grind pits to a smooth contour.

• Provide weld overlay to restore weld profile.

• Provide visual and magnetic particle examination of the completed weld. Inspect for cracks, lack of fusion, and porosity. Repair all defects found by grinding the weld to remove the defect and re-welding.

7. Provide surface preparation and recoat all repair areas and areas damaged as a result of repairs at the time of repairs in 2 years.

Tank 17 – API 653 Inspection Page 4

Recommended API Repairs

Recommended API repairs are repairs not mandatory per API 653 or for structural and hydraulic integrity of the tank but should be performed if approved by the government in conjunction with the required (mandatory) repairs for the long term preservation and integrity of the tank.

1. The reinforcing plates for the two manholes, Issue, Fill and 6-inch spare nozzles are not equipped with telltale holes.

• Provide telltale holes in the reinforcing plates in accordance with API 653 requirements.

• Pressure test reinforcing plate welds to a pressure of 15 psig. In the event the welds do not pass, notify government for direction.

• Pack the telltale holes with general purpose grease to prevent moisture migration between the reinforcing plate and the tank shell.

2. Four lapped patch plates are present on the tank floor. The plates are 6-inch square and are each topped with a 4-inch round plate. The square plates do not have rounded corners. The following repair is recommended, but considered optional. Technically, API 653 does not prohibit such a repair (plate on plate), except in the critical zone, where it is prohibited. Given the recent age of repairs, consideration should be given to their replacement for consistency with the repairs performed under this current inspection and repair program.

• Remove the patch plates.

• Remove the coating from the affected surfaces and prep surfaces for welding.

• Provide 5/16 inch thick steel plates with radius corners in accordance with API 653 requirements.

Plates shall be a minimum of eight inches square.

• Weld the plates to the floor with a full fillet weld, continuous on all edges of each plate. The completed welds shall have no cracks, porosity or lack of fusion.

• In preparation for recoating, remove edge on topside of plate by grinding a 45-degree chamfered rounded edge.

• Perform integrity inspection of the entire weld by vacuum box testing (BT) and either dye penetrant testing (PT) or magnetic particle testing (MT).

3. The tank was not equipped with tank or product identification stenciling at the time of inspection.

• Provide tank identification stenciling.

• Provide product identification stenciling in accordance with MIL-STD-161G requirements.

4. Coating failure and corrosion was observed on the shell appurtenances, roof appurtenances and stairs.

The following repair is recommended:

• Remove the coating from the affected areas and recoat. Approximately 275 square feet of coating is in need of repair.

5. Coating failure and corrosion was observed on most of the floor projection. At one location, a corroded plate steel artifact, 3 inches wide x 6 inches long has been welded to the face of the floor projection. The sealant between the floor projection and the concrete ringwall is cracked and failing.

• Remove the sealant between the floor projection and the concrete ringwall.

Tank 17 – API 653 Inspection Page 5

• Remove the plate steel artifact.

• Remove the coating from the entire floor projection and the lower 12 inches of the tank shell.

(Note: The floor projection and lower 12 inches of 1st shell course appear to have been recoated sometime in the past.)

• Clean the surfaces of the concrete ringwall and underside of the floor to be sealed.

• Provide jet-fuel resistant sealant and recoat as required.

6. A thermometer display is present in the first shell course. The glass display is broken and water is present inside.

• Temperature measurements are incorporated as part of the ATG system. Remove the thermometer, dress the threads, and provide a threaded bull plug in the existing nozzle.

7. The clips securing the access hatch for the ENRAF ATG displacer are severely corroded.

• Remove the existing carbon steel clips and provide stainless steel clips, if available. If not available, provide carbon steel clips and install so they can be easily changed in the future when they corrode.

8. The ATG displacer has broken and is on the tank floor.

• Notify SPAWAR of the status of the ATG system. Contact DLA-E help desk to schedule SPWAR authorized technician for repair of ATG components.

9. Tank 17 is equipped with a partial roof handrail. Severe corrosion with pitting and through holes are present.

• Replace the handrail, posts and kickplate. Recommend that the replacement include 100% of the roof perimeter to comply with current military guidelines.

10. Tank 17 is equipped with a spiral access stair with 63 treads. Each tread is welded directly to the tank shell. The handrail posts are welded to two treads for stability; the front of each tread and to the top of the tread below. The coating is in poor condition with a significant amount of corrosion. An estimated 8 treads and 16 posts require replacement. The post-to-tread connections require replacement at 16 locations. For planning purposes a total of 12 treads and 20 posts should be assumed.

• Option 1: Replace the corroded treads and posts in-kind.

• Option 2: Program the tank for a new spiral access stair. For a long-term solution to the corrosion problems at Kwajalein, recommend providing an aluminum stair system.

11. The center column restraint clips restrict movement north-south, but could allow significant movement east-west in the event of significant wind or seismic activity.

• Modify the existing center column restraint clips to provide lateral restraint of the column base in both the north-south and east-west directions.

12. Areas of internal corrosion and pitting up to 0.080 inches deep was observed in the bottom 2 inches of the bottom shell course around the tank circumference.

• Repair areas by weld overlay. Approximately 36 square inches of area is in need of repair.

• Perform magnetic particle or liquid penetration of the repairs. Inspect for cracks, lack of fusion, porosity. Repair all defects found.

Tank 17 – API 653 Inspection Page 6

13. The 6-inch internal piping is no longer in service. The piping may trap water, causing excessive corrosion of the piping and nozzle, or trap product, making emptying and cleaning the tank difficult.

• Remove the piping and pipe supports.

14. The reinforcing plate and nozzle welds at all roof appurtenances have severe corrosion and have failed.

• Remove corroded welds at affected locations.

• Provide full depth fillet welds at all locations.

15. The typhoon flapper on the 6-inch atmospheric roof vent is obstructed by the roof plates and does not fully open.

• Recommend extending the roof nozzle so that the flapper can open completely.

16. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Coating Requirements. When welding on the shell or roof, the opposite side from the weld shall be inspected and repaired if damaged.

Recommended Non-API Repairs

The following recommendations are outside the scope of an API 653 inspection as they do not affect the structural or hydraulic integrity of the tank. Where items have not been mandated for inspection by the NAVFAC EXWC scope of work, they have been added as good engineering practice.

1. The tank is located within a containment dike with reinforced concrete walls. The dike walls include expansion and construction joints. The caulking within the joints is cracked and failing.

• Remove the caulking and backer rods, if present, from the joints.

• Clean and prepare the concrete surfaces.

• Provide jet-fuel resistant sealant and backer rod, if required.

• Approximately 120 linear feet of joints are in need of repair.

2. Localized concrete spalls were observed on the concrete containment wall.

• It is recommended to rebuild the damaged areas with a polymer modified repair mortar or similar compatible material. Approximately 100 square feet of spalled concrete is in need of repairs.

3. Cracks were observed in the concrete containment wall at numerous locations.

• It is recommended to repair all of the cracks. Crack repair method will vary with the actual field conditions but would most likely consist of saw cutting the joint, cleaning and filling with sealant.

Smaller cracks only need to be filled with sealant. Approximately 100 linear feet of cracks are in need of repair.

4. Unrepaired core drills through the walls are present for what appears to be 1-inch conduit.

• It is recommended to patch the holes with a concrete repair mortar. There are approximately four through holes in the walls. Note that these through holes are in the shared wall with Tank 16.

Tank 17 – API 653 Inspection Page 7

5. Typical fuel pipe penetrations incorporate a Link-Seal (segmented mechanical elastomeric seal) that has been concealed by concrete grout on either side of the wall. This is unfavorable since it allows moisture to build up and leads to pipe corrosion.

• Remove the concrete at each pipe penetration to expose the Link-Seal.

• Loosen the Link-Seal and temporarily remove. Replace if found to be damaged with an appropriately sized Link-Seal that is compatible with refined petroleum products.

• Inspect the fuel piping for corrosion. Remove corrosion and repair as necessary.

• Remove corrosion and recoat the casing and fuel pipe as required. If there is no casing pipe, ensure that the hole in the concrete is sized correctly for installing the Link-Seal.

• Install/reinstall the Link-Seal, tighten the bolts and ensure that it has the proper seat and seal with the concrete wall and piping.

6. The tank is equipped with PVC monitoring ports around the perimeter of the tank. The monitoring ports are installed at grade. Two of the lids are broken and have split apart.

• Replace the monitoring port lids in-kind.

7. Four of the band clamps at the liner connections to the PVC monitoring ports have failed.

• Provide band clamps or other mechanical device at the failed locations.

8. Coating failure and corrosion was observed on the piping within the containment dike.

• Program piping for a complete recoat. There is approximately 125 lf of 8-inch piping to be recoated.

9. The pipe supports within the containment dike are concrete piers with bolted tees and steel slide pads.

Minor to severe corrosion was observed on the steel components of all pipe supports.

• Replace bolted tees and steel slide pads. There are four 8-inch pipe supports to be replaced. The concrete piers may be reused.

10. Piping within the containment dike is supported by concrete piers with bolted tee and steel slide pipe supports. The distance between pipe supports exceeds the suggested maximum spans for 8-inch pipe.

• Provide additional pipe supports to reduce the spans of the piping. Recommend one additional concrete pier with two pipe support assemblies.

11. As the repairs to this tank are considered significant, it is recommended to engage the Inspector of Record during the construction process to audit repairs via construction inspection records, testimony and photographs. A final “Post Repair” Inspection Report front end will then be prepared and attached to the “Pre-Final” Inspection Report and be more suitable for use by DLA-E and filing on the EBS database for this facility. Additional information can be provided if this is of interest.

Tank 17 – API 653 Inspection Page 8

Recommended Repairs per Current Military Criteria

The repairs listed below are not mandatory. These repairs are recommended for compliance with the DESC/DLA-E Memorandum and/or UFC 3-460-01 criteria. Refer to Appendix B, for UFC 3-460-01 “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks’ compliance with military criteria. Past accepted gauge tube installations for the facility have also been considered.

1. The tank is not equipped with a slotted gauge tube below the nozzle used for manual gauging.

• Provide a 6-inch aluminum slotted gauge tube below the existing 6-inch gauge hatch for manual gauging. The 6-inch size, which is less than the preferred 8-inch size, has been previously accepted by the government for use at the facility (UFC criteria).

2. The tank is not equipped with a slotted gauge tube below the nozzle with the ATG. The ATG is currently located in the manhole cover adjacent to the stair platform.

• Provide a 6-inch aluminum slotted gauge tube below the existing 6-inch nozzle in the roof manhole cover for the ENRAF displacer. The 6 inch size, which is less than the preferred 8-inch size, has been previously accepted by the government for use at the facility (DLA-E directive).

3. The temperature probe for the ENRAF ATG system is not located directly over the sump.

• Provide an 8-inch roof nozzle riser over the tank sump for the future water/temperature probe (DLA-E directive). A gauge tube is not required as the tank is not equipped with an internal floating pan.

4. The tank lacks a liquid level gauge (local tape gauge) calibrated in 1/16 inch gradations.

• Provide a liquid level gauge calibrated in 1/16 inch gradations.

5. The tank lacks a working ATG system.

• Notify SPAWAR of the status of the ATG system. Contact DLA-E help desk to schedule SPAWAR authorized technician for repair of ATG components.

6. The tank lacks main suction piping in accordance with the DoD Standard Design.

• It is not compelling to install internal suction piping to comply with the DoD Standard Design, but could be done at the discretion of the government.

• Note: This is a relatively new UFC requirement and similar tanks at Kwajalein have not been modified to provide internal piping at the main suction.

7. The tank lacks low suction piping in accordance with the DoD Standard Design.

• It is not compelling to install internal low suction piping to comply with the DoD Standard Design, but could be done at the discretion of the government.

• Note: This is a relatively new UFC requirement and similar tanks at Kwajalein have not been modified to provide internal low suction piping.

8. The tank lacks a product recovery system.

• Recommend providing a Product Recovery Tank including associated connections to the tank.

The unit should be standard packaged military product saver, all stainless steel construction, with 50 gallon (nominal) tank and electric pump (hazardous rated) for recirculation and pumpout.

Tank 17 – API 653 Inspection Page 9

9. The tank interior lacks 100% coating.

• UFC 3-460-01 Section 8-3.9 (new tanks) addresses the interior coating of tanks. Section 8-3.9 (a) 1 requires 100% coating of all aviation, F-76, additive and lube oil tanks. For other products, Section 8-3.9 (a) 2 (existing tanks under repair) requires that the floor, lower 40 inches of the tank shell and the underside of the fixed roof shall be coated. Section 12-3.6 states “Re-coat the portion of the tank that is already coated. When tanks are taken out of service for inspection or repairs, inspect the underside of the roof for rust. If conditions merit, coat the underside of the roof in conformance with Chapter 8.”

• Based on the observed conditions in the tank, it is not compelling at this time to program the tank for a complete floor, shell, roof and column coating system.

Recommended Repairs for Long Term Serviceability

1. Program the tank for an API in-service external inspection no later than June 2019.

2. Program the tank for an API out-of-service internal inspection no later than June 2024.

3. Test all level alarms and switches as part of on-going maintenance.

COATING SYSTEM

Coating Requirements

Refer to Appendix H for complete coating materials and application requirements for coating repair items identified by the inspection.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank floor, shell and roof were calculated using thickness measurements that were obtained during the inspection and are as follows:

Floor: 0.003750 inches per year

Shell: 0.000180 inches per year

Roof: Negligible

The corrosion rates were calculated using an assumed original metal thickness when the tank was constructed in 1954. Based on the current corrosion rates, the useful life of the tank floor will exceed a 10 year inspection interval.

Tank Floor Corrosion Rates

The tank floor coating has an average thickness of 15.4 mils. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The coating on the tank floor is in good condition, and therefore a product side corrosion rate (StPr) of 0.00 in/yr was assumed. No significant pits were identified in the floor during the inspection.

Tank 17 – API 653 Inspection Page 10

Bottom side corrosion with small volumetric metal loss may be present and not detected by MFL scanning. The metal loss used to calculate the bottom side corrosion rate (Upr) was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits. The MFL floor scanner is not setup to indicate (alarm) for minor metal loss. Backside corrosion was detected at 10 locations requiring an ultrasonic test (UT) prove-up. One location was identified that is in need of repair.

The minimum remaining floor thickness (MRT) used in the calculations is based on API 653 Section

4.4.5 and Table 4.4. The tank has not been equipped with the means to detect a bottom leak. Based on this information, the MRT used in the calculations is 0.100 inch.

It was found that the floor plate thickness will not be reduced below the limiting MRT at a 10 year inspection interval after repairs are completed. EEI recommends that the next API internal inspection should be scheduled no later than June 2024 (10 years from 2014 inspection), or sooner if a change in condition has occurred.

Tank Shell Corrosion Rates

API 653 4.3.1.3 states that tank shell corrosion can occur in many forms and varying degrees of severity and may result in a generally uniform loss of metal over a large surface area or in localized areas. The corrosion rate for the tank shell was calculated based on the original nominal shell thickness and the minimum recorded shell thickness during the inspection.

The minimum remaining shell thickness was determined based on the formulas provided in API 653 §4.3.3. The shell plate thickness will not be reduced below the minimum value at a 10 year inspection interval.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 17:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Foundation Tank 17 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Projection Bottom side corrosion and thinning were observed at the floor projection.

Acceptable

Floor Visual inspection of the tank floor found non-compliant weld clearances at a pipe support doubler plate.

MFL scanning of the tank floor found one relevant indication of corrosion on the bottom side of the floor in need of repair. A pit survey was conducted for topside corrosion and no pits were identified requiring repair.

Acceptable upon completion of repairs.

Shell Visual inspection of the floor-to-shell welds found isolated weld undercut of up to 0.080 inches deep around the circumference of the tank.

Acceptable upon completion of repairs.

Roof Visual inspection of the underside of the steel roof from the tank floor found no indications of damage or deterioration.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria. Acceptable

Tank 17 – API 653 Inspection Page 11

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Hydrostatic Test Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

Brittle Fracture The API 653, Section 5, Figure 5-1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980):

No, built in 1954.

2. Has a prior hydrotest been performed demonstrating fitness: Unknown.

3. Is the tank shell thickness < 0.5 inch: Yes.

4. Does the tank operate at metal temperature above 60 deg

F?: Yes.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4-1 or API 653 Figure

5-2: Yes.

7. Tank full at lowest one day temperature per API 650 Figure

2.2: Unknown.

The tank, having a shell thickness less than 0.5 inch thick and a metal temperature above 60 deg F, does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Seismic evaluation was performed using API 650 12th Edition and the following parameters:

• Ss = 1.19 per UFC 3-301-01

• S1 = 0.48 per UFC 3-301-01

• Fill Height = 46’-0” (maximum fill height)

• Seismic Use Group (SUG): II

• Importance Factor I = 1.00

• Site Class D

• Un-anchored tank

• Specific Gravity of F-76 (S.G. = 0.86)

Evaluation determined the following:

• Anchorage ratio is greater than 1.54, tank is not stable and cannot be self-anchored at the current fill height of 46’–0”.

• Tank resistance to seismic sliding satisfies criteria.

See “Seismic Evaluation” for Additional Comments

Wind Evaluation Wind evaluation was performed in using API 650 12th Edition and the following parameters:

• Basic Wind Speed: 105 mph per hour (UFC 3-301-01, Jan

2012)

• Exposure D

• Importance Factor I = 1.00

• Un-anchored tank

Evaluation determined the following:

• The tank meets API 650 criteria for resistance to wind overturning.

• Tank resistance to wind sliding satisfies criteria.

Acceptable

Tank 17 – API 653 Inspection Page 12

ADDITIONAL DISCUSSION ITEMS

Seismic Evaluation

API 653 4.3.3.5 stipulates that loads shall be evaluated according to the original standard of construction and that engineering judgment shall be used to evaluate different conditions or new information. The seismic evaluation was performed using the formulas and criteria contained in the 12th edition of API 650 (latest edition). It was found that at a fill height of 46 feet, the tank anchorage ratio J > 1.54 which is considered unstable, although longitudinal stresses are acceptable. It was found that at a fill height of 29 feet 0 inches, the tank anchorage ratio J = 1.53 which is considered stable. However, there is no mandatory requirement to upgrade an existing tank to current API 650 standards as compared to the other prescriptive repair requirements found in API 653.

EEI takes no formal position as to repairing the tank, or accepting the risk of failure and consequence of a release, beyond advising the owner of cases such as this where engineering analysis finds the original design does not meet current tank design and construction standards. The decision to reduce the fill height or maintain the status quo is entirely up to the tank owner and the level of risk that they are willing to assume.

The analysis, provided in Appendix G, determined that the tank is subject to overturning in a seismic event. However, the calculations also indicate that the shell is not at risk of being overstressed. The installation of tank anchors and additional foundation mass would eliminate the risk of overturning due to seismic loading. The size and mass of the existing tank ringwall foundation is unknown and may not be sufficient to prevent overturning even if anchors were installed. If a new floor were installed, a secondary concrete mass could be provided outside of the present ringwall to provide sufficient mass to resist overturning.

CLOSURE

Conclusions

Pending completion of the mandatory repair items noted, Tank 17 appears to have acceptable structural and hydraulic integrity. Tank 17 is suitable to return to service for two more years. At which time, it shall be taken out of service for completion of the mandatory repairs.

Project Team

Site Team

James E. Hall, P.E. Structural Engineer, API 653 AST Inspector Certificate No. 46418, API Inspector of Record.

Andrew D. Litchfield Tank Technician, API 570 Piping Inspector Certificate No. 45020

Support Team

Stacy M. Kaplan-McMillan Project Manager

David A. Stchyrba, P.E. Structural Engineer, API 653 AST Inspector Certificate No. 27187

Stephen S. Brooks, P.E. Technical Advisor, QA Review, API 653 AST Inspector Certificate No. 17

Tank 17 – API 653 Inspection Page 13

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location U.S. Army Kwajalein Atoll, Republic of Marshall Islands Tank No. 17

Facility No. 953 Inspection Date(s): June 02 and 03, 2014

Tank Type: Vertical AST Type of Inspection: Internal & External w/ Suitability for Service Evaluation

Contract Number, Task Order: N62583-09-D-0130, Task Order 0002 Prime Contractor Name: CB&I Inspector, Certificate #: James E. Hall, P.E.

API-653 AST Inspector Certificate No. 46418

Inspection Company: Enterprise Engineering, Inc.

5 Depot Street, Suite 23 Freeport, ME 04032

(207) 869-8006

Manufacturer, Date, Design Standard Unknown, 1954, Not Specified (Assumed API Standard 12C) Diameter: 45'-0"

Shell Height: 47'-10" Product, Specific Gravity: F-76, 0.83 to 0.86

Design Pressure / Temperature: Unknown (assumed atmospheric) Gross Capacity / Nominal Capacity: 13,576 Bbls / 13,500 Bbls

Safe Fill Height: 46 feet 0 inches (from facility) GPS Latitude & Longitude: 8 Deg 43’ 39.13” N, 167 Deg 44’ 15.40” E (Source – Google Earth) Foundation Configuration: Concrete Ringwall

Shell Configuration: Butt Welded, 7 courses Roof: Fixed, column supported cone roof

Cathodic Protection: Impressed Current Still Wells: None

Last Inspection (Type, Date): Out-of-Service, February 4, 2007 by Pacific Tank Works Last Coated Internally (Product): Unknown (Assume 2007 at the time of the out-of-service inspection) Last Coated Externally (Product): Unknown

INSPECTION RESULTS

Can tank return to service? Yes, for a period of 2 years. At which time the tank must be removed from service to complete the mandatory repairs.

Deficiencies identified as mandatory repairs: Yes, see paragraph titled “Mandatory Repairs” in body of report

Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term

Serviceability” in body of report Next Scheduled Inspections (Type, Date): In-Service: June 2019 (5 Years)

Out-of-Service: June 2024 (10 Years)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: None available

Tank 17 – API 653 Inspection Appendix A, TANK SUMMARY SHEET Kwajalein Atoll, RMI

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

COATINGS

APPURTENANCES

PIPING

Tank 17 – API 653 Inspection Appendix A, TABLE OF CONTENTS

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

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

FOUNDATION

Type Concrete ringwall

Levelness Tank 17 is relatively level. The maximum measured differential between max and min elevations is 0.33 feet.

Tank 17 passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt Tank 17 is slightly tilted. The amount of tilt is

0.54 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The concrete ringwall varies from approximately 7 inches to 13 inches above the containment dike floor.

Material Below Tank Floor

The material below the tank floor could not be inspected.

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

Tank Anchors Tank is not equipped with anchors. Calculations show that tank does not meet the requirements for a self-anchored tank at the current fill height of 46 feet. See report for more discussion.

Secondary Containment Tank sits within an earthen dike with a membrane liner and concrete walls. Soil ballast holds the liner in place.

Approximately 100 linear feet of cracks were observed in the concrete containment dike walls.

Approximately 120 linear feet of joints in the containment dike walls are in need of repair.

Approximately 100 square feet of localized concrete spalls were observed on the concrete containment walls.

Recommend repairing cracks by epoxy injection.

Recommend removing failed sealant at the joints and providing fuel resistant sealant and backer rods, if required.

Recommend rebuilding areas with concrete spalls with a polymer repair mortar or similar compatible material.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were

Sealed at Foundation

The floor extension is sealed to the concrete ring wall with an elastomeric sealant. The sealant is cracked and failing.

Recommend removing the sealant areas around the entire perimeter of the tank, clean the surfaces and apply a jet-fuel resistant sealant.

Additional Foundation Items, Comments or Notes:

None.

Tank 17 – API 653 Inspection Appendix A, Page 1

FLOOR

Comments/Recommendations

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

TANK FLOOR

Type Lap welded steel floor plates.

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

Nominal Thickness Floor consists of 3/8-inch thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.369 inch.

Interior Width See floor drawing.

Floor seam welds No relevant indications were found on the floor plate seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found 10 locations requiring an ultrasonic test (UT) prove-up. The UT prove-up identified the minimum thickness at these locations.

Bottom Side Floor Pitting/Corrosion

All MFL indications were checked by UT measurements. The lowest UT measurement was 0.119 inch. One location was observed that requires repair.

Recommend repairing corrosion pit by welding a patch plate over the pitted area for a 20-year service interval. Patch plate shall be 6-inch in diameter and 5/16-inch thick.

Top Side Floor Pitting/Corrosion

Shallow pitting on the topside of the tank floor was observed. Pitting has been arrested by the tank floor coating.

Patch Plates Four 6-inch square plates were observed on the tank floor. The plates are each topped with a 4-inch round patch plate. The square plates do not have rounded corners.

Remove the patch plates and provide patch plates in accordance with API 653.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted.

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

Doubler/Striker Plates The doubler plate at the pipe support for the fill piping does not comply with API 653 weld spacing requirements.

Examine the non-compliant welds by magnetic particle examination.

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

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

Vacuum Box Testing Vacuum box testing was performed at suspect locations of the floor welds. No indications were found.

Helium Leak Testing Helium leak testing was not performed.

Tank 17 – API 653 Inspection Appendix A, Page 2

FLOOR

Comments/Recommendations

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

Floor Critical Zone Ultrasonic thickness examination at approximately 30 spot locations of the critical zone found evidence of backside corrosion and thinning of the floor plates. It is likely that this corrosion occurred in the past, prior to the installation of a cathodic protection system. No indications requiring repair were found.

Floor Profile The floor is cone-up and slopes from the center of the tank towards the perimeter sump.

Sumps The tank is equipped with a 20-inch diameter perimeter sump.

Secondary Liner Below

No evidence of a secondary liner below the tank floor was observed.

Leak Detection Below

The tank is not equipped with leak detection below the floor.

Cathodic Protection The tank is equipped with cathodic protection of the tank floor. Operations personnel report that the system is operational.

Additional Floor Items, Comments, Notes:

Tank 17 – API 653 Inspection Appendix A, Page 3

SHELL

Comments/Recommendations

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

TANK SHELL

Nominal Thickness UT Thickness Coating

1st Course 0.313 inch 16.8 mils

2nd Course 0.320 inch 15.1 mils

3rd Course 0.260 inch 16.7 mils

4th Course 0.255 inch 15.3 mils

5th Course 0.272 inch 12.8 mils

6th Course 0.257 inch 12.4 mils

7th Course 0.242 inch 14.3 mils

Rim Angle Not Accessible

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

Roundness No noticeable out of roundness was observed.

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

Banding/Peaking No significant banding or peaking was

Interior Shell pitting/corrosion

Areas of internal corrosion and pitting up to

0.080 inches deep was observed in the bottom 2 inches of the bottom shell course around the tank circumference. Based on evaluation of API-653 minimum shell thickness requirements, corrosion 0.080 inches or deeper requires repair.

Repair areas 0.08-inches and deeper by weld overlay.

Exterior Shell pitting/corrosion

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

Insert plates No insert plates were observed.

Welded Patch Plates No welded patch plates were observed.

Floor Projection The floor projection extends an average of 1.60-inches beyond the tank shell. The average thickness is 0.314-inch.

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

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

Door sheet No door sheets were observed.

Shell-to-Floor Weld – Interior

Visual inspection of the interior welds found areas of undercut in the floor-to-shell weld around the perimeter of the tank.

Repair undercut by weld overlay.

Tank 17 – API 653 Inspection Appendix A, Page 4

Comments/Recommendations

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

Shell-to-Floor Weld – Exterior

Visual inspection of floor-to-shell weld found no indications for further inspections or…