Attachment J.8 Kwajalein Fac 957 (tank 11) Old Report 2006.pdf

FIELD INSPECTION REPORT

TANK 11

Kwajalein

Prepared for USAKA

Inspector:

Prepared by: Pacific Tank Works May 3, 2006

FIELD-Out of Service-Tank 11-Kwajalein

SUMMARY

Pacific Tank Works conducted an In-Service inspection of Tank 11 on January 19 and 20, 2006 and an out of service inspection between April 19 and May 3, 2006. The inspection was performed in accordance with the requirements of API standard 653, NFPA and CFR.

TABLE OF CONTENTS

1.0 Introduction

2.0 References

3.0 Tank Data

4.0 Inspection results

5.0 Recommendations

5.1. Compliance

5.2. Other

6.0 Evaluation

6.1. Tank Service Life

APPENDICES

A. CALCULATIONS

B. DRAWINGS

C. DATA

D. CHECKLIST

E. PHOTOGRAPHS

1.0 INTRODUCTION

1.1. This report provides an evaluation of the aboveground tank 11 located at the United States Army fuel facility in Kwajalein Atoll. The inspection was conducted in accordance with the applicable sections of API (American Petroleum Institute) Standard 653, NFPA (National Fire Protection Association) and the CFR (Code of Federal Regulations).

1.2. In compliance with API Standard 653, 11.2, the following table is provided:

11.2.1 Calculations for:

a. Component evaluation for integrity, including brittle fracture considerations Section 4, Appendix A

b. Rerating (including liquid level). Appendix A

c. Repair and alteration considerations. Section 5

11.2.2. Construction and repair drawings. Appendix B

11.2.3 Additional support data:

a. Inspections (including thicknesses) Section 4, Appendix C

b. Material test reports/certifications NA

c. Tests Section 4

d. Radiographs NA

e. Brittle fracture considerations NA (Mean low temperature > 60o F)

f. Original tank construction data Section 3

g. Location and identification Section 3

h. Description of tank Section 3

i. Design Conditions Section 3

j. Shell material and thickness by course Section 3, Appendix C

k. Tank perimeter evaluations Section 4, Appendix C

l. Construction completion record NA

m. Basis for hydrostatic test exemption NA (no major repairs performed)

2.0 REFERENCES

2.1. American Petroleum Institute (API):

2.1.1. API Standard 650, Welded Steel tanks for Oil Storage, Tenth Edition, Addendum

2, November 2001.

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

2.1.3. API Standard 653, Tank Inspection, Repair, Alteration and Reconstruction, Third Edition, December 2001.

2.2. American Society of Mechanical Engineers (ASME):

2.2.1. ASME Boiler and Pressure Vessel code, Section V, Non-Destructive

Examination, 2001

2.3. Code of Federal Regulations (CFR):

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

2.3.2. 40 CFR 280, Requirements for Petroleum UST Systems.

2.4. National Association of Corrosion Engineers:

2.4.1. NACE Recommended Practice, RP0288-94, Inspection Of Linings on Steel and

Concrete.

2.5. National Fire Protection Association (NFPA):

2.5.1. NFPA-30, Flammable and Combustible Liquids Code.

2.5.2. NFPA-70, National Electric Code.

3.0 TANK DATA

Description: Tank 11

Diameter: 45 feet

Height: 48.92 feet

Construction Date: 1954

Construction Code: API Standard 12C

Design: General: Cylindrical, Vertical Aboveground Shell: Vertical, butt welded Fixed Roof: Fixed Cone

Product: DFM (F-76)

Maximum Operating Height: 48.92 feet

Type of Inspection: Out-of-Service

Inspection Date: May 2006

4.0 INSPECTION RESULTS

4.1. Shell:

4.1.1. Exterior: The tank shell was inspected for plumbness, peaking and banding and was satisfactory. Thickness readings were taken on the shell plates using ultrasonic technology. The shell was evaluated for safe fill height using these thickness readings. The results indicate that the safe fill height is not limited.

The shell was inspected for non-planar tilt using a laser transit and measuring rod. The results were satisfactory. The coating on the exterior of the tank shell has failed, has drips, sags peeling and cracking. There is excessive undercut and insufficient filler metal throughout the bottom to shell weld.

4.1.2. Interior: The bottom to shell weld has excessive undercut, insufficient size and severe corrosion in numerous areas. There are screws welded to the tank at an interval of every three (3) feet, approximately five (5) feet above the bottom.

These apparently were used during the installation of the fiberglass coating.

4.2. Bottom:

4.2.1. Interior: Then tank bottom was scanned using a MFE, Inc. floor scanner. No underside indications were detected. Ultrasonic thickness readings in the areas inaccessible to the floor scanner showed a remaining thickness of approximately

0.375 (3/8) inch. There is “caulking” used as a spacer under the fixed roof support column “H-Frame” footer. There is no reinforcement plate under this footer. The horizontal movement clips are too short. There are four (4) patch plates on the floor. These have additional lap patches on top of them. These were threaded fittings. Ultrasonic thickness readings of the top patches indicate no active underside corrosion. The brackets on the internal ladder are welded directly to the shell, rather than to reinforcement plates. There is no indication of weld cracking due to the stress normally requiring the reinforcement plates. The intake line has no diffuser. With the present transfer rates at the fuel farm, this is not a concern, but could be at a later date. There is no striker plate under the gauge hatch. Manual gauging in the future could damage the new coating to be applied. The “abandoned” internal intake piping has numerous supports that are welded directly to the tank bottom rather than to reinforcement plates. The piping is welded to these supports and cannot “float” should the bottom shift.

There is some pitting near the shell where the “caulking” had been installed.

There is one significant pit, measuring 0.18” deep, on plate #1, next to the intake line.

Inspection Results (cont’d)

4.3. Fixed Cone Roof:

The roof was inspected visually and with UT for thickness. The general thickness of the roof is between 0.17 and 0.195”. There are severe areas of corrosion with remaining thickness of 0.120 or less. This is also true on the manway and the Gauging and Temperature sensors. The manway has no reinforcement plate. The vent is experiencing severe corrosion, the bolts and nuts are wasted and there is no reinforcement plate. The scaffold support is not to API standard and is wasted in several locations. The temperature sensor and auto gauge nozzles are wasted. The fittings on the top of the auto gauge are wasted. (The fittings for the auto gauge have previously been identified by POL personnel and are scheduled for replacement).

There are through holes in the light hatch cover and its nozzle is wasted. The light hatch has no reinforcement plate. The hold off distance marker at the gauge hatch is missing.

4.4. Appurtenances:

All attachments to the shell are welded to the shell vice reinforcement plates. This is causing active corrosion. The bypass line relief valves for the 8” discharge double block and bleed valve and the gate valve are severely corroded. The discharge line gate valve is exhibiting signs of active corrosion. The piping into all thread-o-lets throughout the piping system are threaded, vice welded. The intake double block and bleed valve bypass piping between the relief valve discharge and the union is severely corroded. The intake and discharge double block and bleed valves have severe active corrosion on their fittings, studs and nuts. The under bottom drain line is not accessible for inspection. The thermometer well has excessive caulking at the shell penetration.

4.5. Accessways:

The roof is accessed via a spiral stairway and platform. The ladder treads are welded to the tank shell vice reinforcement plates. There is severe active corrosion along the stairway and platform. The handrail is wasted along the stairway and at the platform.

There is severe corrosion of the round bars throughout the spiral stairway.

Specifically, stairs 12, 15, 17, 18, 19, 20, 21, 25, 26, 32, 34, 35, 37, 41, 42 and 60.

Additionally, a 2” x 4” section of the tread of stair 8 is severely corroded. The stairs were numbered from the top for a total of 63.

4.6. Containment:

The containment consists of a concrete wall, impervious liner from the wall to the ringwall, and earth and vegetation cover. The containment is properly graded to drain water away from the tank as required by NFPA 30-2.3.4.3(a). The containment appears to be in satisfactory condition.

Inspection Results (cont’d)

4.7. Foundation:

The foundation of the tank is a concrete ringwall. The seal between the ringwall and the tank bottom chime area is broken and is resulting is accelerated corrosion of the chime.

5.0 RECOMMENDATIONS

5.1. Compliance Recommendations:

5.1.1. Shell: Grind out any undercut and add filler metal to the bottom to shell weld.

Remove the screws welded to the inside of the tank shell.

5.1.2. Bottom: Install a diffuser on the intake line. Grind out any undercut and add filler metal to the bottom to shell weld. Install a striker plate under the gauge hatch. Modify the internal piping supports such that the supports do not restrain the piping, in the event of floor movement. Add reinforcement plates under those supports without them. Install reinforcement plates under the fixed roof support column. Fill the deep pit on plate #1 with weld metal.

5.1.3. Fixed Cone Roof: Install reinforcement plates under the tank vent, manway, light hatch and scaffold support. Replace the corroded nuts and bolts on the vent. Replace the scaffold support with one meeting API Standard 650. Replace the auto gauge and temperature sensor nozzles. This will require an electrician to isolate and remove the sensors. Replace the light hatch and cover. Measure the hold off distance once repairs are made and install a hold off distance marker at the gauge hatch. When the tank is empty, remove the areas of active corrosion throughout the roof and evaluate remaining thickness.

5.1.4. Appurtenances: Replace the relief valves on the bypass lines on the discharge piping. Rework the gate valve on the discharge line. Weld all nipples into the thread-o-lets for the bypass lines and drain lines on the piping. Replace the piping between the relief valve and the union on the intake double block and bleed valve. Rework/replace the intake and discharge double block and bleed valves. Excavate and install a pit for the under bottom drain piping. Remove the caulking around the thermometer and well. Evaluate if repairs are needed.

5.1.5. Accessways: Replace the handrail on the stairway and platform. Replace the corroded round bar supports. Repair stairway tread 8. Blast the stairway to identify any additional repairs needed.

5.1.6. Containment: None.

5.1.7. Foundation: Repair/replace the old sealant between the tank chime area and the ringwall.

5.2. Other Recommendations

5.2.1. Shell: Replace the coating system.

5.2.2. Fixed Cone Roof: Repair/replace the coating system.

5.2.3. Appurtenances: None.

5.2.4. Accessways: Repair/replace the coating system.

5.2.5. Containment: None.

5.2.6. Foundation: None.

6.0 EVALUATION

6.1. Tank Service Life:

6.1.1. Tank 11 will be in compliance with the requirements of API Standard 653 when the repairs listed in section 5.1 are completed.

APPENDIX A

CALCULATIONS

1. Minimum Thickness Calculation for Welded Tank Shell

A - 1

MINIMUM THICKNESS FOR TANK BOTTOM PLATE

T0 – GCa –StPa – UPm – MRT1 Or1 = StPr + Upr + GCr

T0 – GCa –StPm – UPa – MRT2 Or2 = StPr + Upr + GCr

Where:

MRT1, MRT2 = minimum remaining thickness at the end of the in-service period of operation, in inches. MRT1 represents minimum remaining thickness due to average internal pitting and maximum external pitting. MRT2 represents minimum remaining thickness due to maximum internal pitting and average external pitting.

T0 = Original plate thickness, in inches.

StPa = Average depth of internal pitting, in inches, measured from the original thickness.

StPm = Maximum depth of internal pitting remaining in the bottom plates after repairs are completed, in inches, measured from the original thickness.

UPa = Average depth of underside pitting, in inches.

UPm = Maximum depth of underside pitting, in inches.

StPr = Maximum internal pitting rate, in inches per year; StPr = 0 if the tank bottom is internally lined (see API RP 652).

Upr = Maximum underside pitting rate, in inches per year; Upr = 0 if tank bottom is cathodically protected (see API RP 651).

Or = Anticipated in-service period of operation (normally 10 years).

GCa = Average depth of generally corroded area, in inches.

GCr = Maximum rate of general corrosion, in inches per year.

A - 2

Existing Conditions: The tank has an internal coating system with failures.

There is a cathodic protection system installed.

MRT1, MRT2 = 0.1 inches

T0 = 0.375 inches StPa = 0.003 inches StPm = 0.18 inches UPa = 0.001 inches UPm = 0.048 inches StPr = 0.00346 inches/year Upr = 0.0009 inches/year GCa = 0.048 inches GCr = 0.0009 inches/year

0.375 – 0.048 – 0.003 – 0.048 - 0.1 Or1 =

0.00346 + 0.0009 + 0.0009

Or1 = 33 Years

T0 – GCa –StPm – UPa – MRT2

Or2 = StPr + Upr + GCr

0.375 – 0.048 – 0.18 – 0.001 – 0.1 Or2 =

0.00346 + 0.0009 + 0.0009

Or2 = 8 YEARS

NOTE: These calculations are based on corrosion rates remaining constant.

A - 3

After Recommended Repairs: Repair the 0.18” pit, install a new interior coating system on the floor, and maintain the cathodic protection system.

MRT1, MRT2 = 0.1 inches

T0 = 0.375 inches StPa = 0.003 inches StPm = 0.14 inches UPa = 0.001 inches UPm = 0.048 inches StPr = 0 inches/year Upr = 0.0009 inches/year GCa = 0.048 inches GCr = 0.0009 inches/year

0.375 – 0.048 – 0.003 – 0.048 - 0.1 Or1 =

0 + 0.0009 + 0.0009

Or1 > 40 Years

T0 – GCa –StPm – UPa – MRT2

Or2 = StPr + Upr + GCr

0.375 – 0.048 – 0.14 – 0.001 – 0.1 Or2 =

0 + 0.0009 + 0.0009

Or2 > 40 YEARS

NOTE: These calculations are based on corrosion rates remaining constant.

A - 4

MINIMUM THICKNESS CALCULATION

FOR

WELDED TANK SHELL

2.6 HDG Tmin = SE

Where:

Tmin = The minimum acceptable thickness, in inches, as calculated from the above formula; however, Tmin shall not be less than

0.1 inch for any tank course.

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

H = Height, in feet, from the bottom of the length L (see API 653

2.3.2.1) for the most severely corroded area in each shell course to the maximum design liquid level.

G = Highest specific gravity of the contents (including test water, if tank will, or may be, tested in the future).

S = Maximum allowable stress in pounds per square inch; use the smaller of 0.80 Y or 0.426 T for bottom and second course; use the smaller of 0.88 Y or 0.472 T for all other courses. Note: For reconstructed tanks, S shall be in accordance with the current applicable standard.

Y = Specified minimum yield strength of the plate: use 30,000 pounds per square inch if not known.

T = The smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch; use 55,000 pounds per square inch if not known.

E = Original joint efficiency for the tank. Use API 653, table 2.1 if original E is unknown. E = 1.0 for 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.

A - 5

MINIMUM THICKNESS CALCULATION

FOR

WELDED TANK SHELL

2.6 HDG Tmin = SE

S E H (ft)

G Tmin (in)

Tactual (in)

T0 (in)

Corrosion Rate

Shell Life

Course 1 23595 0.85 48.92 1 0.269 0.304 0.3125 0.000163462 >40 Course 2 23595 0.85 41.92 1 0.230 0.254 0.28125 0.000524038 >40 Course 3 25960 0.85 34.92 1 0.173 0.252 0.28125 0.0005625 >40 Course 4 25960 0.85 28 1 0.138 0.241 0.25 0.000173077 >40 Course 5 25960 0.85 21 1 0.102 0.245 0.25 9.61538E-05 >40 Course 6 25960 0.85 14 1 0.100 0.246 0.25 7.69231E-05 >40 Course 7 25960 0.85 7 1 0.100 0.234 0.25 0.000307692 >40

The shell life is greater than 40 years at the present corrosion rate and with the current stored product.

The original shell course thickness is not known. There are no records of construction or previous inspections.

A - 6

APPENDIX B

DRAWINGS

1. Bottom Layout

2. Shell Layout

3. Fixed Roof Layout

4. Rafter Layout

TITLE

DWG NO SIZE REV

SHEET SCALE

CAGE CODE

A

TANK BOTTOM LAYOUT

TANK 11

1" = 5 ' 1 OF 1

N/AN/A

DRAWN BY: PACIFIC TANK WORKS (GK)

FOR: USAKA/KRS

MANWAY

Date April 2006

MANWAY

Sump

Under-Bottom Drain

- Proposed Reinforcement Plates For Fixed Roof Support

- Existing Patch Plate

- 0.18" deep Pit

Blanked Intake Line

SHEET SCALE

CAGE CODE

1" = 20" 1 of 1

N/A

TANK 11 SHELL LAYOUT

DRAWN BY: PACIFIC TANK WORKS (GK)

FOR: United States Army Kwajalein Atoll

N/A

DATE

JANUARY 2006

A

A - 22" Manway B - 4" Blanked C - 14" Fire Fighting D - 8" Discharge E - 8" Intake F - 6" Blanked G - 20" Manway H - 1" Thermometer Well

A B D E F

C

G H

Stairway

Platform

SHEET SCALE

CAGE CODE

1" = 8' 1 of 1

N/A

TANK 11 ROOF LAYOUT

DRAWN BY: PACIFIC TANK WORKS (GK)

FOR: United States Army Kwajalein Atoll

N/A

DATE

JANUARY 2006

A

Scaffold Support

Light Hatch

Gauge Hatch

Manway - Gauge

- Temperature Sensor

Vent

Areas with 0.06" remaining thickness

SHEET SCALE

CAGE CODE

A

TANK ROOF RAFTER LAYOUT

TANK 11

1" = 5 ' 1 OF 1

N/AN/A

DRAWN BY: PACIFIC TANK WORKS (GK)

FOR: USAKA/KRS

Date

MAY 2006

FIELD-Out Of Service-Tank 11-Kwajalein

APPENDIX C

Data

1. Bottom Thickness Readings

2. Shell Thickness Readings

3. Nozzle and Reinforcement Plate Data

4. Tank Settlement Survey Data

FIELD-Out Of Service-Tank 11-Kwajalein

BOTTOM THICKNESS READINGS

1 2

2 3

1 2

Bottom Plate Thickness Readings Plate # Point

Point

Point

Point

Point

1 0.370 0.377 0.374 NA NA

2 0.374 0.381 0.371 0.381 0.388

3 0.354 0.348 0.330 NA NA

4 0.383 0.380 0.382 0.365 0.372 5 0.379 0.380 0.367 0.382 0.376 6 0.371 0.381 0.379 0.373 0.376 7 0.378 0.377 0.373 0.375 0.379 8 0.369 0.371 0.327 0.363 0.368 9 0.384 0.368 0.384 0.382 0.375 10 0.380 0.364 0.381 0.384 0.382 11 0.378 0.379 0.380 0.372 0.370 12 0.366 0.378 0.370 0.361 0.391 13 0.377 0.349 0.380 0.377 0.374 14 0.375 0.382 0.393 0.395 0.390 15 0.382 0.389 0.372 0.369 0.365

16 0.352 0.359 0.335 NA NA

17 0.370 0.346 0.379 0.372 0.331

18 0.361 0.353 0.333 NA NA

C - 2

Kwajalein Tank 11 - 2006

3C -

SHELL PLATE THICKNESS READINGS

Shell Course #1

POINT

Plate 1-1

Plate 1-2

Plate 1-3

Plate 1-4

Plate 1-5

Plate 1-6

1 0.315 0.312 0.318 0.307 0.314 0.311 2 0.316 0.308 0.321 0.310 0.316 0.323 3 0.259 0.306 0.310 0.311 0.304 0.317 4 0.311 0.300 0.315 0.303 0.313 0.316 5 0.308 0.300 0.311 0.254 0.307 0.315 6 0.291 0.311 0.310 0.262 0.308 0.308 7 0.306 0.311 0.304 0.303 0.307 0.300 8 0.308 0.298 0.310 0.304 0.314 0.316 9 0.304 0.304 0.302 0.312 0.313 0.309 10 0.306 0.299 0.316 0.301 0.313 0.306

Average 0.307 Minimum 0.254 Maximum 0.323

Spiral Stairway Drop:

Point #1 Point #2 Point #3 Point #4 Point #5 Point #6 Point #7 Point #8 Course # 1 0.304 0.311 0.309 0.315 0.316 0.312 0.312 0.310 Course # 2 0.254 0.274 0.277 0.274 0.266 0.280 0.275 0.268 Course # 3 0.252 0.257 0.256 0.256 0.259 0.254 0.252 0.256 Course # 4 0.241 0.244 0.245 0.244 0.243 0.246 0.247 0.245 Course # 5 0.245 0.246 0.250 0.251 0.253 0.252 0.248 0.252 Course # 6 0.248 0.246 0.253 0.252 0.258 0.255 0.253 0.253 Course # 7 0.236 0.239 0.238 0.239 0.240 0.241 0.235 0.234

NOZZLE AND REINFORCEMENT PLATE DATA

W

L

H

ND

Y

C

X

For Circular: W = L.

For Tombstone: H = 0.

R = Round Corner Radius (Tombstone or Square).

L1

W1

Nozzle/Repad Measurements

Ultrasonic Thickness Readings Nozzle

ID

Description Diameter (inches)

X (feet)

Height (inches) Top Bottom Right Left

A Manway 20 18.4 30 0.269 0.284 0.290 0.284 B Blanked 4 43.4 14 0.228 0.220 0.206 0.221 C Fire Fighting 14 52.1 708 NA D Discharge 8 57.6 13 0.482 0.450 0.427 0.412 E Intake 8 60.1 13 0.504 0.427 0.369 0.498 F Blanked 6 74 11 0.397 0.412 0.411 0.423 G Manway 20 89.3 30 0.295 0.263 0.290 0.297 H Thermometer Well 116.8 1 30 NA

Reinforcement Plates ID Description/Type W

(inches) L

(inches) H

(inches) Ultrasonic Thickness Readings

(inches)

A DWR 57 46 6.5 0.311

B ROUND 10 10 8.5 0.260

C ROUND 14 14 701 NA

D DWR 24 18 4.5 0.306

E DWR 24 18 4.5 0.321

F OVAL 20 16 3 0.321

G DWR 55 47 6.5 0.310

DWR – Diamond with Rounded Corners DWS – Diamond with Square Corners OCT – Octagonal

C - 4

Tank Settlement Survey Data:

Settlement readings were taken using a laser transit and tape measure from the exterior of the tank. Point 1 was shell seam 1 on the first course. The eight measurement locations were an equal distance from each other going in a counterclockwise direction around the tank.

Measurement

Point Reading Difference

6 29 1/8 0 7 29 ¼ -0.125 8 29 1/8 = 53 ¼ -0.250 1 53 ¼ -0.250 2 53 3/8 -0.125 3 53 1/7 = 29 5/8 -0.250 4 29 5/8 -0.250 5 29 ¾ -0.125 6 29 7/8 0

These readings are within the construction tolerances for the foundation. No rigid body tilt (planar tilt) or out-of-plane settlement (differential settlement) was detected.

C - 5

KWAJALEIN TANK 11-2006

APPENDIX D

CHECKLIST

1. API 653 Out-Of-Service Checklist

D - 1

TANK OUT-OF-SERVICE CHECKLIST

Item

Completed

Comments

C.2.1 OVERVIEW

a. Check that tank has been cleaned, is gas free, and safe for entry. a

b. Check that the tank is completely isolated from product lines, all electrical power, and steam lines.

a

c. Check that roof is adequately supported, including fixed roof structure and floating roof legs.

a

d. Check for presence of falling object hazards, such as corroded-through roof rafters, asphalt stalactites, and trapped hydrocarbons in unopened or plugged equipment or appurtenances, ledges, etc.

a

e. Inspect for slipping hazards on the bottom and roof decks. a

f. Inspect structural welds on accessways and clips. a

g. Check surfaces needing inspection for a heavy-scale buildup and check weld seams and oily surfaces where welding is to be done.

Note areas needing more cleaning.

a

C.2.2 TANK EXTERIOR

a. Inspect appurtenances opened during cleaning such as lower floating swing sheave assemblies, nozzle interiors (after removal of valves).

a

b. Hammer test or ultrasonically test the roof. a

c. Enter and inspect the floating roof pontoon compartments. NA

C.2.3 BOTTOM INTERIOR SURFACE

a. Using a flashlight held close to and parallel to the bottom plates, and using the bottom plate layout as a guide, visually inspect and hammer test the entire bottom.

a

b. Measure the depth of pitting and describe the pitting appearance (sharp edged, lake type, dense, scattered, etc.)

a Minimal

c. Mark areas requiring patching or further inspection. NA

d. Mark locations for turning coupons for inspection. NA

e. Inspect all welds for corrosion and leaks, particularly the shell-to-bottom weld.

a

f. Inspect sketch plates for corrosion a

g. Locate and mark voids under the bottom.

h. Record bottom data on a layout sketch using the existing bottom plates as a grid. List the number and sizes of patches required.

a

i. Vacuum test the bottom lap welds. a

J. Hammer test or ultrasonically examine any slightly discolored spots or damp areas.

a

k. Check for reinforcing pads under all bottom attached clips, brackets, and supports.

a

l. Inspect floating roof leg pads for pitting or cutting, and excessive dimpling (indicating excessive loading).

NA

m. Check the column bases of fixed roof supports for adequate pads and restraining clips.

a

n. In earthquake zones 3 and 4, check that roof supports are not welded down to the tank bottom, but are only restrained from horizontal movement.

NA

o. Check area beneath swing line cable for indications of cable cutting or dragging.

NA

p. Mark old oil and air test connection for removal and patching. a

q. Identify and report low areas on the bottom that do not drain adequately.

NA

r. Inspect coating for holes, disbonding, deterioration, and discoloration.

a To be replaced

D - 2

TANK OUT-OF-SERVICE CHECKLIST-Continued

C.2.4 SHELL SEAMS AND PLATE

a. On cone up bottoms, closely inspect and gauge the depth of metal loss on the lower 2 to 4 inches of the shell (area of standing water).

a

b. Measure the depth of pitting on each course. a 0.004”

c. Inspect and estimate the amount of metal loss on the heads of rivets and bolts.

NA

d. Inspect shell-to-bottom riveted lap joints. NA

e. Inspect for vertical grooving damage from seal assembly protrusions.

NA

f. Inspect existing protective coatings for damage, deterioration, and disbonding.

a Being replaced

g. Check for areas of rubbing (indicating too much pressure by the seal assembly shoes or inadequate annular space).

NA

h. Visually inspect the shell plates and seams for indications of leakage.

a

i. If the shell has riveted or bolted seams, record the leak locations by film or chart in case the locations are lost during surface preparation for painting.

NA

j. Measure annular space at 40-foot intervals. NA

k. Survey the shell to check for roundness and plumb. a

C.2.5 SHELL-MOUNTED OVERFLOWS

a. Inspect overflow for corrosion and adequate screening. NA

b. Check location of overflow that it is not above any tank valves or equipment

NA

C.2.6 ROOF INTERIOR SURFACE

C.2.6.1 General

a. Visually inspect that underside surface of the roof plates for holes, scale buildup, and pitting.

a

b. Hammer test or ultrasonically examine to check for thin areas, particularly in the vapor space of floating roofs and at edge of roof on cone roof tank.

a

c. Check all clips, brackets, braces, etc., welded to the roof deck plate for welded reinforcing pads and see that they have not broken free.

a

d. If no pad is present, penetrant test for cracking of the weld or deck plate.

a

e. Inspect the protective coating for breaks, disbondment, and deterioration.

a None

f. Spark test the interior surface coating if recoating is not planned. NA C.2.6.2 Fixed Roof Support Structure

a. Inspect the support columns for thinning in the upper two feet. a

b. On API columns (two channels welded together) check for corrosion scale breaking the tack welds, unless the joint between the channels is completely seal welded.

a

c. Check that the reinforcing pad on the bottom is seal welded to the tank bottom with horizontal movement restraining clips welded to the pad.

a No pad

d. Determine if pipe column supports are concrete filled or open pipe.

If open pipe, check for a drain opening in the bottom of the pipe.

NA

e. Inspect and gauge rafters for thinning, particularly near the center of the roof. Report metal loss.

a Minimal

f. Check for loose or twisted rafters. a

g. Inspect girders for thinning and check that they are attached securely to the top of the columns.

NA

D - 3

h. Report if the columns have cross bracing in the area between the low pump out of the top of the shell (for future internal floating roof installation).

a None

i. Inspect and report presence of any roof mounted swing line bumpers. a None

j. Photograph the roof structure if no rafter layout drawing exists. a

C.2.7 FIXED ROOF APPURTENANCES

C.2.7.1 Inspection and Light Hatches

a. Inspect the hatches for corrosion, paint and coating failures, holes, and cover sealing a

b. On loose covers, check for a safety chain in good condition. NA

c. On light hatches over 30 inches across, check for safety rods. NA

d. Inspect the condition of the gaskets on bolt or latched down hatch covers.

a

C.2.7.2 Staging Support Connection

a. Inspect the condition of the staging support for corrosion. a

C.2.7.3 Breathers and Vents

a. Inspect and service the breather. NA

b. Inspect screens on vents and breathers. a

C.2.7.4 Emergency P/V Hatches

a. Inspect and service pressure/vacuum hatches. (Setting should be high enough to prevent chattering of breather during normal operation. See breather manufacturer’s guide.)

NA

b. Inspect liquid seal hatches for corrosion and proper liquid level in the seal.

NA

C.2.7.5 Sample Hatch

a. Inspect sample hatch for corrosion. a

b. Check that the cover operates properly. a

c. If the tank has no gauge well, check for a hold off distance marker and check measurement.

NA

C.2.8 FLOATING ROOF

C.2.8.1 Roof Deck

a. Hammer test the area between roof rim and shell. (If access for hammer testing is inadequate, measure the distance from the bottom edge of the roof to the corroded area and then hammer test from inside the pontoon.)

NA

b. In sour water service, clean and test all deck plate weld seams for cracking unless the lower laps have been seal welded.

NA

c. Check that either the roof drain is open or the drain plug in the roof is open in case of unexpected rain.

NA

d. On flat bottomed and cone down roof decks, check for a vapor dam around the periphery of the roof. The dam should be continuous without break to prevent escape of vapors to the seal area from under the center of the roof.

NA

C.2.8.2 Floating Roof Pontoons

a. Visually inspect each pontoon for liquid leakage. NA

b. Run a light wire through the gooseneck vents on locked down inspection hatch covers to make sure they are open.

c. Inspect lockdown latches on each cover. NA

D - 4

d. Check and report if each pontoon is: NA

1. Vapor tight (bulkhead seal welded on one side on bottom, sides, and top).

NA

2. Liquid tight (seal welded on bottom and sides only), or NA

3. Unacceptable (minimum acceptable condition is liquid tight). NA

C.2.8.3 Floating Roof Cutouts

a. Inspect underside of cutouts for mechanical damage. NA

b. Inspect welds for cracks. NA

c. Inspect plate for thinning, pitting and erosion. NA

d. Measure mixer cutouts and record plate thickness for future mixer installation or replacement. Plate Thickness ________.

NA

C.2.8.4 Floating Roof Supports

a. Inspect fixed low and removable high floating roof legs for thinning. NA

b. Inspect for notching at bottom of legs for drainage. NA

c. Inspect for leg buckling or felling at bottom. NA

d. Inspect pin hole in roof guide for tears. NA

e. Check plum of all legs. NA

f. Inspect for adequate reinforcing gussets on all legs through a single portion of the roof.

NA

g. Inspect the area around the roof legs for cracking if there is no internal reinforcing pad or if the topside pad is not welded to the deck plate on the underside.

NA

h. Inspect the sealing system on the two-position legs and the vapor plugs in the fixed low leg for deterioration of the gaskets.

NA

i. On shell mounted roof supports, check for adequate clearance based on the maximum floating roof movement as determined by the position of the roof relative to the gauge well and/or counter rotational device.

NA

C.2.9 FLOATING ROOF SEAL ASSEMBLIES

C.2.9.1 Primary shoe Assembly

a. Remove four sections of foam log (foam filled seals) for inspection on 90o locations

NA

b. Inspect hanger attachment to roof rim for thinning, bending, broken welds, and wear of pin holes.

NA

c. Inspect clips welded to roof rim for thinning. NA

d. Shoes-inspect for thinning and holes in shoes. NA

e. Inspect for bi-metallic bolts, clips and attachments. NA

f. Seal fabric-inspect for deterioration, stiffening, holes and tears in fabric.

NA

g. Measure length of fabric from top of shoe to roof rim, and check against maximum anticipated annular space as roof operates.

NA

h. Inspect any modification of shoes over shell nozzles, mixers, etc., for clearance.

NA

i. Inspect shoes for damage caused by striking shell nozzles, mixers, etc.

NA

C.2.9.2 Primary Toroidal Assembly

a. Inspect seal fabric for wear, deterioration, holes, and tears. NA

D - 5

b. Inspect hold down system for buckling or bending. NA

c. Inspect foam for liquid absorption and deterioration NA

C.2.9.3 Rim Mounted Secondaries.

a. Inspect the rim-mounted bolting bar for corrosion and broken welds. NA

b. Measure and chart seal-to-shell gaps. NA

c. Visually inspect seam from below, looking for holes as evident by light.

NA

d. Inspect fabric for deterioration and stiffness. NA

e. Inspect for mechanical damage, corrosion, and wear on tip in contact with shell.

NA

f. Inspect for contact with obstructions above top of shell. NA

C.2.10 FLOATING ROOF APPURTENANCES

C.2.10.1 Roof Manways

a. Inspect walls of manways for pitting and thinning. NA

b. On tanks with interface autogauges, check seal around gauge tape cable and guide wires through manway cover.

NA

c. Inspect cover gasket and bolts. NA C.2.10.2 Rim Vent

a. Check rim vent for pitting and holes. NA

b. Check vent for condition of screen. NA

c. On floating roof tanks where the environmental rules require closing off the vent, check the vent pipe for corrosion at the pipe-to-rim joint and check that the blinding is adequate.

NA

C.2.10.3 Vacuum Breaker, Breather Type

a. Service and check operation of breather valve. NA

b. Check that nozzle pipe projects no more than ½ inch below roof deck.

NA

C.2.10.4 Vacuum Breaker, Mechanical Type

a. Inspect the stem for thinning. Measure how far the vacuum breaker cover is raised off the pipe when the roof is resting on high or low legs.

NA

1. On high legs: NA

2. On low legs: NA

C.2.10.5 Roof Drains: Open Systems, Including Emergency drains

a. Check liquid level inside open roof drains for adequate freeboard.

Report if there is insufficient distance between liquid level and top of drain.

NA

b. If tank comes under Air Quality Monitoring District rules, inspect the roof drain vapor plug.

NA

c. If emergency drain is not at the center of the roof, check that there are at least three emergency drains.

NA

C.2.10.6 Closed Drain Systems: Drain Basins

a. Inspect for thinning and pitting. NA

b. Inspect protective coating (topside). NA

c. Inspect basin cover or screen for corrosion. NA

d. Test operation of check valve. NA

D - 6

e. Check for presence of check valve where bottom of basin is below product level.

NA

f. Inspect drain basin(s) to roof deck welds for cracking. NA

g. Check drain basin(s) outlet pipe for adequate reinforcement to roof deck (including reinforcing pad).

NA

2.10.7 Closed Drain Systems: Fixed Drain Line on Tank Bottom

a. Hammer test fixed drain line on tank bottom for thinning and scale/debris plugging.

NA

b. inspect supports and reinforcing pads for weld failures and corrosion.

NA

c. Check that pipe is guided, not rigidly locked to support, to avoid tearing of tank bottom plate.

NA

C.2.10.8 Closed Drain Systems: Flexible Pipe Drain

a. Inspect for damage to exterior of pipe. NA

b. Check for obstructions that pipe could catch on. NA

c. Inspect shields to protect pipe from snagging. NA

d. Inspect results of hydrotest on flexible roof drain system. NA

C.2.10.9 Closed Drain Systems: Articulated Joint Drain

a. Hammer test rigid pipe in flexible joint systems for thinning and scale/debris plugging.

NA

b. Inspect system for signs of bending or strain. NA

c. Inspect results of hydrotest. NA

d. Inspect landing leg and pad. NA

C.2.10.10 Autogauge System and Alarms

a. Check freedom of movement of tape through autogauge tape guide. NA

b. Inspect sheaves for freedom of movement. NA

c. Test operation checker. NA

d. Inspect tape and tape cable for twisting and fraying. NA

e. Test the tape’s freedom of movement through guide sheaves and tape guide pipe.

NA

f. On open-top tanks, check that gauge tapes with cables have no more than one foot of tape exposed with float at lowest point.

NA

g. Check float for leakage. NA

h. Test float guide wire anchors for spring action by pulling on wire and releasing.

NA

i. Inspect floatwells in floating roofs for thinning and pitting of walls just above the liquid level.

NA

j. Check that the autogauge tape is firmly attached to the float. NA

k. Inspect the tape cable and float guide wire fabric seals through the float well cover.

NA

l. Inspect the bottom guide wire attachment clip; inspect for a temporary weighted bar instead of a permanent welded down clip.

NA

m. Inspect board-type autogauge indicators for legibility and freedom of movement of indicator.

NA

n. Measure and record these distances to determine if seal damage will occur if tank is run over from:

NA

1. Shell top angle to underside of tape guide system. NA

2. Liquid level on floating top to top of secondary seal. NA

o. Identify floating roofs where the tape is connected directly to the roof.

NA

p. Overfill alarm: Inspect tank overfill prevention alarm switches for proper operation.

D-7

C.2.11 COMMON TANK APPURTENANCES

C.2.11.1 Gauge Well

a. Inspect gauge well pipe for thinning at about two-thirds distance above the bottom; look for thinning at the edge of the slots.

a

b. Check for corrosion on the pipe joint. Check that sample cords, weights, thermometers, etc., have been removed from the pipe.

NA

c. Check for cone at bottom end of pipe about one foot above the bottom. a

d. Check condition of well washer pipe and that its flared end is directed at the near side of the hold off pad.

NA

e. Check that supports for gauge well are welded to pad or to shell and not directly to bottom plate.

a

f. Check operation of gauge well cover. a

g. Check presence of a hold-off distance marker in well pipe and record hold-off distance. Hold-off distance .

NA

h. Identify and report size and pipe schedule, and whether pipe is solid or slotted. Report slot size.

a 6” SCH 40, slotted

i. Check that the hold-off distance plate is seal welded to the bottom and that any gauge well supports are welded to the plate and not directly to the bottom.

a

j. Inspect vapor control float and cable. NA

k. Check for presence and condition of gauge well washer. a

l. Check for bull plug or plate blind on gauge well washer valve. a

m. Inspect gauge well guide in floating roof for pitting and thinning. NA

n. Inspect the guide rollers and sliding plates for freedom of movement. NA

o. Inspect condition of gauge well pipe seal system. NA

p. On black oil and diesel services: If gauge well is also used for sampling, check for presence of a thief-and gauge-type hatch to avoid spillage.

NA

q. Visually inspect inside of pipe for pipe weld protrusions which could catch or damage vapor control float.

a

C.2.11.2 Sampling Systems: Roof Sample Hatches

a. Inspect roof mounted sample hatches for reinforcing pads and cracking. a

b. Inspect cover for operation. a

c. For tanks complying with Air Quality Monitoring district rules, inspect sample hatch covers for adequate sealing.

NA

d. Check horizontal alignment of internal floating roof sample hatches under fixed roof hatches.

NA

e. Inspect the sealing system on the internal floating roof sample hatch cover. NA

f. Inspect floating roof sample hatch cover recoil reel and rope. NA C.2.11.3 Shell Nozzles

a. Inspect shell nozzles for thinning and pitting. a

b. Inspect hot tap nozzles for trimming of holes. NA

c. Identify type of shell nozzles. a

d. Identify and describe internal piping, including elbow up and elbow down types.

a

D-8

C.2.11.4 For Nozzles Extended Into the Tank

a. Inspect pipe support pads welded to tank bottom. a

b. Inspect to see that pipe is free to move along support without strain or tearing action on bottom plate.

a NO

c. Inspect nozzle valves for packing leaks and damaged flange faces. a

d. Inspect heater steam nozzle flanges and valves for wire cutting. NA

e. Report which nozzles have thermal pressure relief bosses and valves. a

f. In internal elbow-down fill line nozzles, inspect the wear plate on the tank bottom.

NA

g. On elbow-up fill lines in floating roof tanks, check that opening is directed against underside of roof, not against vapor space. Inspect impact area for erosion.

NA

C.2.11.5 Diffusers and Air Rolling Systems

a. Inspect diffuser pipe for erosion and thinning. a

b. Check holes in diffuser for excessive wear and enlargement. NA

c. Inspect diffuser supports for damage and corrosion. a

d. Check that diffuser supports restrain, not anchor, longitudinal line movement.

a NO

e. Inspect air spiders on bottom of lube oil tanks for plugging and damaged or broken threaded joints.

NA

C.2.11.6 Swing Lines

a. Inspect flexible joint for cracks and leaks. NA

b. Scribe the flexible joint across the two moving faces and raise end of swing line to check the joint’s freedom of movement, indicated by separation of scribe marks.

NA

c. Check that flexible joints over six inches are supported. NA

d. Inspect the swing pipe for deep pitting and weld corrosion. NA

e. Loosen the vent plugs in the pontoons and listen for a vacuum. Lack of a vacuum indicates a leaking pontoon.

NA

f. Check the results of air test on pontoons during repairs. NA

g. Inspect the pontoons for pitting. NA

h. Inspect the pull-down cable connections to the swing. NA

i. Inspect the condition of the bottom-mounted support, fixed roof limiting bumper, or shell mounted limiting bumper for wood condition, weld and bolt corrosion, and seal welding to bottom or shell.

NA

j. Inspect safety hold-down chain for corrosion and weak links. NA

k. Check that there is a welded reinforcing pad where the chain connects to the bottom.

NA

l. If the floating swing in a floating or internal floating roof tank does not have a limiting device preventing the swing from exceeding 60 degrees, measure and calculate the maximum angle possible with the roof on overflow.

Max. angle on overflow . (If the calculated angle exceeds 65 degrees, recommended installation of a limiting bracket.)

NA

m. Inspect pull down cable for fraying. NA

n. Inspect for three cable clamps where cable attaches to end of swing line (single-reeved) or to roof assembly (double-reeved). Inspect sheaves for freedom of movement.

NA

o. Inspect winch operation and check the height indicator for legibility and accuracy.

NA

p. Inspect bottom-mounted sheave assembly at end of pontoon for freedom of rotation of sheave.

NA

q. Inspect shell-mounted lower sheave assembly for freedom of rotation of sheave, corrosion thinning, and pitting of sheave housing.

D-9

r. Inspect upper sheave assembly for freedom of movement of sheave. NA

s. Inspect the cable counterbalance assembly for corrosion and freedom of operation.

NA

C.2.11.7 Manway Heater Racks

a. Inspect the manway heater racks for broken welds and bending of the sliding rails.

NA

b. Measure and record the length of the heater and length of the track. NA C.2.11.8 Mixer Wear Plates and Deflector Stands.

a. Inspect bottom and shell plates and deflector stands. NA

b. Inspect for erosion and corrosion on the wear plates. Inspect for rigidity, structural soundness, corrosion, and erosion of deck plates and reinforcing pads that are seal welded to the bottom under the deflector stand legs.

NA

c. Measure for propeller clearance between the bottom of deflector stand and roof when the roof is on low legs.

NA

C.2.12 ACCESS STRUCTURES

C.2.12.1 Handrails

a. Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails.

a 1 ½” angle iron with round bar verticals

b. Inspect for pitting and holes, paint failure. a Numerous

c. Inspect attachment welds. a

d. Identify cold joints and sharp edges. Inspect the handrails and midrails.

a

e. Inspect safety drop bar (or safety chain) for corrosion, functioning, and length.

NA

f. Inspect the handrail between the rolling ladder and the gauging platform for a hazardous opening when the floating roof is at its lowest level.

NA

C.2.12.2 Platform Frame

a. Inspect frame for corrosion and paint failure. a

b. Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure.

a

c. Check reinforcing pads where supports are attached to shell or roof. a None

d. Inspect the surface that deckplate or grating rests on, for thinning and holes.

a

e. Check that flat-surface to flat-surface junctures are seal welded. a Stitch welded C.2.12.3 Deck Plate and Grating

a. Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure.

NA

b. Inspect plate-to-frame weld for rust scale buildup. NA

c. Inspect grating for corrosion-caused thinning of bars and failure of welds.

a

d. Check grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating surface and compare with other risers on the stairway.

a

C.2.12.4 Stairway Stringers

a. Inspect spiral stairway strings for corrosion, paint failure, and weld failure. Inspect attachment of stairway treads to stringer.

a

b. Inspect stairway supports to shell welds and reinforcing pads. a No rp’s

c. Inspect steel support attachment to concrete base for corrosion. NA

D-10

C.2.12.5 Rolling Ladder

a. Inspect rolling ladder stringers for corrosion. NA

b. Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment tot stringers and corrosion, particularly where angle rungs are welded to stringers.

NA

c. Check for wear and corrosion where rolling ladder attaches to gauging platform.

NA

d. Inspect pivot bar for wear and secureness. NA

e. Inspect operation of self-leveling stairway treads. NA

f. Inspect for corrosion and wear on moving parts. NA

g. Inspect rolling ladder wheels for freedom of movement, flat spots and wear on axle.

NA

h. Inspect alignment of rolling ladder with roof rack. NA

i. Inspect top surface of rolling ladder track for wear by wheels to assure at least 18 inches of unworn track (track long enough).

NA

j. Inspect rolling ladder track welds for corrosion. NA

k. Inspect track supports on roof for reinforcing pads seal welded to deck plate.

NA

l. Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs. Max. angle .

NA

m. If rolling ladder track extends to within five feet of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

D-11

FIELD-Out of Service-Tank 11 Kwajalein

APPENDIX E

PICTURES

Fixed Roof Support Column Internal Piping Hold Downs

E - 2

Discharge Piping Screw on Shell

Blanked Intake Piping Sump and Patch Plate

C.2.12.5 Rolling Ladder