Attachment J - Fac 2186 Insp Report FY19.pdf

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Langley Air Force Base, Virginia Tank Facility 2186

Tank 5

US Army Corps of Engineers Center of Expertise for Petroleum, Oils and Lubricants

USACE POL-MCX

2 December 2019

API 653 In-Service Inspection Report Langley AFB, Virginia

Table of Contents

ACRONYMS AND ABBREVIATIONS

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

THIS INSPECTION

PREVIOUS INSPECTION DATES

STATE REGULATIONS

RECOMMENDED FUTURE INSPECTION DATES

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

3. Previous Inspection and Repairs

4. Future Projects

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Bottom

4. Tank Roof

5. Tank Shell

6. Tank Appurtenances

7. Tank Coating

8. Tank Piping System

9. Fire Protection System

10. Secondary Containment

11. Cathodic Protection

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs

2. SHORT TERM RECOMMENDATIONS

3. LONG-TERM RECOMMENDATIONS

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

SHELL THICKNESS CALCULATIONS

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

TANK DRAWINGS

OSHA ACCESS STRUCTURE REPORT

SUB-CONSULTANT REPORTS

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX ‘C’: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

AFFF Aqueous Film Forming Foam

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CC Carbon Steel

CFR Code of Federal Regulations

CP Cathodic Protection

CS Carbon Steel

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NA Not Applicable

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

PTFE Polytetrafluoroethylene (e.g., TEFLON)

P/V Pressure/Vacuum

PST Product Saver Tank

SS Stainless Steel

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UG Underground

UT Ultrasonic Testing

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

Austin Brockenbrough & Associates, LLP (Brockenbrough) was retained by Omaha District USACE under Contract No. W9128F-17-D-0017 Delivery Order W9128F19F0049 to perform SPCC Mandated AST/UST Inspections at various locations. As required by this task, Brockenbrough executed a tank inspection site visit to Langley Air Force Base, Hampton, Virginia. An API 653 In-service (visual external) Inspection was conducted for Facility No.

2186, locally known as Tank 5, on September 10, 2019. This inspection was performed in accordance with API Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. Prologue, Inc. was retained by Austin Brockenbrough to perform a 3-D laser scanning survey of the tank to inspect for tank foundation settlement, out-of-roundness, and deformations. All observations made during this in-service (visual external) inspection were made from the exterior of the tank.

Facility 2186 is a 52-foot diameter by 38-foot and 8-inch tall, single wall, vertical, field-erected tank with a nominal storage capacity of 15,000 barrels of Jet A (F-24). The reconstructed manufacturer’s nameplate and repair organization nameplate is available. The tank was originally built in 1958 by an unknown manufacturer and reconstructed in 2000 by Superior Industrial Maintenance. Repairs listed on the repair organization nameplate indicate repairs performed in 2016 included installing a 4-inch water probe well, and 8-inch manual and ATG gauge wells. Details of tank construction and appurtenances are included in the Tank Information Table on page 6 and in Section ‘B’.

This tank was found to be in generally good condition, fully serviceable, with no mandatory repairs noted. If the current standard of care is maintained, this tank is suitable for continued service. Additional noted deficiencies are discussed in more detail in Section ‘C’ and should be addressed in a timely manner. Photographs of the tank are included in Appendix ‘C’.

The next API Standard 653 In-service (visual external) Inspection should be performed by September 2024. The next ultrasonic thickness inspection of the shell should be performed by September 2034. Based on the state requirements (9VAC25-91 Section 130 C.2), an internal (out-of-service) inspection should be performed by March 2025. The inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology and a thorough code compliance evaluation.

THIS INSPECTION

API In-Service (External) Inspection Date: 10 September 2019 Equipment Used:

Scanning Equipment

Laser Scanner: Faro Focus S 70 Calibrated: July 2019

Laser Tracker: Vantage E Calibrated: October 2018

Ultrasonic Thickness Gauge

Manufacturer: NDT Systems Model Number: Nova TG110-DL

Calibration Method: Calibration Block NDT Technician (s): Corey Beyke

Inspector(s): Corey Beyke

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: March 2015 API In-Service (External) Inspection Date: NA

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections September 2024 State Regulation for API Out-of-Service Tank Inspections March 2025

RECOMMENDED FUTURE INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: March 2035 API Ultrasonic Thickness Inspection of Shell Date: September 2034 API In-Service (External) Inspection Date: September 2024

Corey Beyke Mechanical Engineer API 653 Inspector No. 91254

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner Air Force Location Langley Air Force Base Facility Number 2186 Tank Number Tank 5 State / Country Virginia / U.S.A.

City Hampton Inspection Date September 10, 2019 Tank Manufacturer Original – Unknown; Reconstructed – Superior Industrial Maintenance Design Standard API 650 Date of Construction 1958 (per reconstructed nameplate) Tank Contents Jet A (F-24) Tank Serial Number Unknown Tank Diameter 52’-0” Shell Height 38’-8” Product Height 31’-4 3/4” (Tank Nameplate) Tank Capacity 492,150 gallons Nominal (Tank Nameplate) Foundation Concrete ring wall flush with grade.

Construction and Material

Bottom Butt-welded carbon steel plate (5/16 per 2015 inspection report).

Shell Six (6) courses of butt-welded carbon steel plate.

Floating Roof Internal Floating Pan.

Fixed Roof Aluminum Geodesic Dome.

Cathodic Protection Impressed Current.

Interior Coating System Unknown.

Exterior Coating System Epoxy/epoxy/polyurethane assumed.

Level Gauging Enraf ATG and water probe, manual gauging well, Varec autogauge (mechanical tape level gauge).

Overfill Protection Independent high and high-high level alarms, ATG (redundant) alarms, float operated high level control valve.

Piping Receipt 8” Welded carbon steel Issue 8” Welded carbon steel Low Suction 4” Welded carbon steel Water Draw-off 2” Welded carbon steel

Level Alarms Shell mounted (independent) high, high-high, low, and low-low level alarms;

ATG (redundant) Alarms.

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

a. This project will perform API 653 and STI SP001 inspections of various tanks at facilities throughout the United States. Additional consideration is given to federal, state, and local regulations, as well as applicable military criteria and general industry standards. For Facility 2186 an API Standard 653 In-service (External) Inspection was performed, which included a shell settlement survey and a shell UT inspection. In addition, a survey was performed to inspect for plumbness, roundness, peaking, and banding was performed.

2. Site Information On September 10, 2019 Brockenbrough performed API 653 In-Service (External) Inspection of Facility 2186 (Tank 5) located at Langley Air Force Base, Virginia. Langley Air Force Base is the home of the United States Air Force's 633d Air Base Wing (633 ABW), 1st Fighter Wing (1 FW) and the 480th Intelligence Surveillance and Reconnaissance Wing (480 ISRW). It also hosts the Global Cyberspace Integration Center field operating agency, the 192D Fighter Wing of the Virginia Air National Guard and Headquarters Air Combat Command (ACC).

3. Previous Inspection and Repairs The previous inspection report indicates that an out-of-service (internal) inspection was performed in 2015. The repair nameplate indicates that in 2016 two 8-inch and one 4-inch stilling wells were added and existing nozzles were modified.

4. Future Projects Facility personnel report there are currently no projects scheduled for execution in the future that affect the operation of the tank. Personnel indicated that there is a major project in the works to repair the containment area.

B. TANK INSPECTION COMMENTS

1. Tank Construction Tank Facility 2186 is an aboveground, vertical, storage tank, measuring 52 feet in diameter and 38 feet and 8 inches tall with a nominal capacity of approximately 492,150 gallons. Although the tank manufacturer’s nameplate is missing, the reconstruction nameplate indicates the tank was constructed in 1958.

2. Tank Foundation The perimeter of the bottom rests on a concrete ring wall that is flush with grade. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. Small hairline cracks throughout the ring wall were observed, with a majority of the cracks having been filled with grout. A shell settlement survey was performed during the inspection in accordance with Appendix ‘B’ of API Standard 653. The shell settlement evaluation indicates the settlement of the bottom of the shell and perimeter of the tank bottom is acceptable.

3. Tank Bottom Per previous inspection reports, the tank has a 5/16-in lap-welded double bottom and butt-welded annular plate. The new bottom was installed in 2000.

4. Tank Roof The tank roof is a geodesic dome roof. It is constructed out of aluminum support members and aluminum panels. The dome roof structure appears to be in good condition with no visible signs of damage. Entry to the internal ladder is gained through a 2-foot by 4-foot rectangular roof hatch.

5. Tank Shell The vertical and cylindrical shell consists of six (6) butt-welded courses. The ultrasonic thickness measurements of the shell and calculations included in Appendix ‘A’ indicate the shell has more than 30 years of remaining life. API 653 recommends ultrasonic thickness measurements of the shell be taken at least every 15 years.

b. Plumbness, Roundness, Peaking, and Banding The exterior of the shell was visually inspected and evaluated for plumbness, roundness, peaking and banding.

1) API 650, paragraph 7.5.2 allows a maximum out-of-plumb of the top of a new tank shell, relative to the bottom of the shell, of 1/200 of the height of the shell, a difference of 2-5/16 inches for this 38-foot and 8-inch tall tank. The maximum measured out-of-plumbness was 2-1/16 inches.

The out-of-plumbness of the shell is within that allowable tolerance required by API 650.

2) The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 3/4-inch of a new tank shell radius. Minor localized shell distortions were noted. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top. It would suggest the tank was built slightly out-of-round because there did not appear to be any significant distortion of the shell. The out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time.

3) While some minor peaking and banding of the butt-welded shell seams was observed, the peaking-and-banding appeared to be within limits allowed by API 650. The area with the most distortion observed was located at the weld seams for the northwest manhole insert plate. It appears to be resulting from improper heat treatment during the installation process.

6. Tank Appurtenances

a. Gauging The tank’s Honeywell Enraf ATG is installed through an 8-inch fully slotted aluminum gauge well.

The manual gauge well/sample hatch was unlocked and was inspected. The tank also has a Varec tape level gauge. The tape level gauge did not appear to be consistent with the ATG.

b. Level Alarms The tank has shell mounted (independent) high, high-high, low, and low-low level alarms. The tank also has redundant ATG alarms.

c. Stairs and Platforms The tank’s geodesic dome roof is accessible by a circumferential stairway mounted on the shell of the tank. The circumferential stairway step rise is generally 8-1/2 inches continuously from ground level to the step just below the roof landing. It appears that at some time in the past the stair treads were modified with grating. The width of the stair steps is generally 27-1/2 inches.

OSHA requires the stairway handrail height to be between 30 and 34 inches measured from the nose of the steps. The measured height of the stairway handrail is 33 inches. There were areas of localized corrosion observed at the attachment welds of the stair to tank interface. The corrosion was mainly present at the areas where the attachment is not fully seal welded.

d. Grounding and Bonding The tank’s two (2) grounding cables are exothermic welded to shell mounted steel grounding lugs and appeared to be in good condition.

7. Tank Coating The tank’s coatings were evaluated for deterioration. The exterior of the shell and roof show no sign of significant deterioration.

8. Tank Piping System Facility 2186 (Tank 5) is a bulk tank. Fuel is primarily received from barge off-load with backup receipt from truck off-load stations located adjacent to the pumphouse. Fuel is issued to truck fillstands also located adjacent to the pumphouse. The low suction is connected to the main suction. All of the fuel system piping is aboveground and coated carbon steel. There appeared to be adequate thermal relief throughout the piping system.

9. Fire Protection System There are no fire hydrants within 300 feet of the tank.

10. Secondary Containment Secondary containment consists of an earthen berm with shotcrete cover with a flexible membrane liner system on the containment floor which is covered in gravel. The secondary containment was evaluated during the inspection. Due to the presence of gravel in the dike area, a thorough visual inspection of the dike area could not be conducted. The secondary containment was analyzed by Prologue Systems, LLC by using the 3D laser scanning survey. By using the data and subtracting out the geometry of the tank, they determined that the secondary containment has a total capacity of approximately 904,440 gallons. The containment is of sufficient size to contain a total tank loss plus an additional foot of freeboard. The shotcrete berms have begun to show signs of deterioration, primarily on the exterior side of the berm. Significant cracks and spalling were observed. Base personnel mentioned that there is a project in place to repair the shotcrete.

11. Cathodic Protection Impressed current cathodic protection anodes are installed in the sand between the FML liner and the tank bottom. The system is combined with the other five tanks in the area and there is one common rectifier. The cathodic system was reported to be properly working.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 2186 was found to be in generally good condition. The tank is fully serviceable, with no mandatory deficiencies that would require immediate removal of the tank from service. However, there were a few minor items observed that could be addressed to reduce long term maintenance, improve operability, and more clearly comply with federal, state, and local regulations or military criteria.

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs Mandatory repairs represent items that require immediate attention in order to prevent imminent risk to system operators, equipment, or the adjacent environment. The tank would have to be taken out-of-service to complete these repairs. No Mandatory Repairs are required to be performed.

2. SHORT TERM RECOMMENDATIONS

REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Short- Term Repairs that directly relate to the long-term preservation of the asset. Short-term repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment. These items may be required by federal, state and local codes or by military criteria.

a. Recalibrate Autogauge OBSERVATION: The Varec autogauge is inconsistent with the Enraf ATG by more than the allowable criteria.

REFERENCE: UFC 3-460-03 Section 8-9.8.1.1 requires mechanically operated tape gauges to be checked regularly in order to verify accuracy. If the tape is not accurate, UFC 3-460-03 requires calibration. API 653 inspection checklist limits the variation to a maximum of 2 inches.

RECOMMENDATION: Calibrate autogauge in accordance with manufacturer’s recommendations.

Verify calibration against Enraf ATG and sticking the tank.

3. LONG-TERM RECOMMENDATIONS

RECOMMENDED REPAIRS as Part of Regular Maintenance Long-term Repairs that directly relate to repair/upgrade of an asset to bring it up to the current standard from the standard at time of construction. Long-term Repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Repair Concrete OBSERVATION: There are radial hairline cracks in the top of the ring wall foundation above the leak detection telltale holes. If precipitation enters the foundation through the cracks, the water could promote corrosion of the reinforcing steel in the concrete, especially if it expanded upon freezing.

Deterioration of the foundation could lead to inadequate support for the tank and loss of secondary containment. There is also a 1-sq ft section of the concrete that has spalling.

REFERENCE: API 650 paragraph 5.3.1 and API 653 Appendix ‘B’ require foundations to provide adequate support. NFPA 30 paragraph 22.11.2.4 and 40 CFR 112.7(c)(1) require secondary containment to be liquid tight.

RECOMMENDATION: Seal approximately 2 linear feet of cracks in the tank foundation ring wall.

Repair 1-sq ft of spalling.

b. Provide Landing Drain OBSERVATION: The intermediate landing on the circumferential stair is convex, resulting in standing water. The standing water will eventually result in coating failure and corrosion of the metal.

REFERENCE: UFC 3-460-03 requires stairs, platforms, etc. to be inspected for any signs of corrosion, and the corrosion repaired.

RECOMMENDATION: Drill a 1/4-inch hole in the center of the stain to result in a drainage spot. After the repair is completed, perform spot repairs on the coating.

c. Provide Seal Welds OBSERVATION: Some of the attachment welds for the tank stairs are not fully seal welded. This has resulted in localized minor corrosion.

REFERENCE: Guidance for new construction provided in UFC 3-460-01 paragraph 8-3.10 includes exterior coatings. Paragraph 8-3.11 includes seal welded of appurtenances. The latest edition of API 650 paragraph 5.1.3.7 requires all attachments to the exterior of a tank to be seal welded.

RECOMMENDATION: Provide a seal welded attachment connecting the stairs to the tank shell.

d. Provide Manhole Repairs OBSERVATION: There are two 24-inch manholes for this tank. 36-inch manholes are recommended for safety during maintenance and inspection. A tertiary manhole is required above the internal floating pan’s high position.

REFERENCE: UFC 3-460-01 Table 8-1 requires a vertical aboveground tank to be provided with two 36-inch manholes in locations 180 degrees from each other. UFC 3-460-01 also requires a shell manhole located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals.

RECOMMENDATION: Remove the two 24-inch manholes and provide two (2) 36-inch manholes.

Provide manholes in accordance with API Standard 650. Provide an additional 36-inch manhole located above the internal floating pan’s high position. Provide a landing for this manhole and modify the stairway, as required. These repairs may be programmed to occur at the next out-of-service tank inspection when the tank is empty.

e. Remove Gravel Ballast OBSERVATION: The secondary containment liner is covered with a gravel ballast. This ballast makes inspecting the liner not feasible.

REFERENCE: The Commonwealth of Virginia regulation 9VAC25-91-130 requires the integrity of secondary containment at facilities, with over 25,000 gallons of oil, be evaluated and certified by a Professional Engineer at least every ten years.

RECOMMENDATION: Remove the gravel ballast that is covering the secondary containment liner.

Confirm liner is not susceptible to UV damage. Provide sandbags to prevent liner uplift due to wind.

Provide a secondary containment evaluation in accordance with State regulations.

f. Repair Shotcrete OBSERVATION: The earthen berm is covered with shotcrete. The shotcrete has extensive cracking and major spalling issues.

REFERENCE: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require secondary containment to be liquid tight. If the secondary containment has failed at the shotcrete and a leak were to happen, the containment is not liquid tight.

RECOMMENDATION: No separate repair action is recommended because there is a project in place to repair the secondary containment. If the project existing does not move forward, then this repair is recommended.

g. Remove Biological Growth OBSERVATION: The secondary containment liner is covered with a gravel ballast. The gravel promotes vegetative growth. There is mold and algae at the dike drain. There is a mold growth visible on the wind girder.

REFERENCE: UFC 3-460-03 Paragraph 8-10.2 requires the operators to inspect for vegetation that has taken root in seals or cracks. All vegetation must be removed in all cases to prevent penetration of seals, joints or cracks in the concrete.

RECOMMENDATION: Remove the vegetation/moss/algae from the secondary containment. Clean the wind girder and provide a herbicide to prevent future buildup.

h. Repair Tank Labels OBSERVATION: The tank fuel identification labels are peeling at the tank shell.

REFERENCE: UFC 3-460-03 paragraph 2-4.6.1 requires clear identification of petroleum fuel systems and equipment by product type and grade to ensure operational safety and product quality protection.

RECOMMENDATION: Remove the peeling tank labels. Provide labels in accordance with UFC 3-460- 01 and MIL-STD-161.

i. Repair Chime Sealant

OBSERVATION: The chime sealant has various spots where the sealant has failed.

REFERENCE: UF 3-460-03 Paragraph 8-4.1 requires base personnel to visually inspect chime to ringwall sealant. Seal should be maintained in good working order to prevent corrosion of the underside of the tank bottom.

RECOMMENDATION: Remove the damaged portions on the sealant (approximately five linear feet).

Provide new sealant in accordance with UFC 3-460-01, API 653, AW 078-24-27.

j. Repair Coating OBSERVATION: There are minor spot coating repairs required on several areas of the tank. The manhole bolts, water draw-off nozzle, and water probe nozzle have coating failure and minor corrosion.

REFERENCE: UFC 3-460-03 Appendix F – Monthly Tank Inspection Checklists requires base personnel to inspect for evidence of corrosion. These areas should be maintained to extend the service life of the fueling system.

RECOMMENDATION: Provide spot repairs to the coating on the manhole bolts, water draw-off nozzle, water probe nozzle and other appurtenances as needed using coating materials compatible with the existing coatings.

k. Provide Personnel Grounding Plate

OBSERVATION: The circumferential tank stairs do not have a personnel grounding plate at the first step.

REFERENCE: UFC 3-460-03 Section 2-3.2 requires all petroleum fuel system components must be bonded and grounded.

RECOMMENDATION: Provide personnel grounding pad at the bottom stair for the circumferential tank stair. Install bonding conductors no smaller than #6 AWG bare copper grounding wire from each non-current carrying metallic object to a common grounding electrode conductor.

l. Provide Additional Fire Protection OBSERVATION: The AST does not have two fire hydrants located within 300 feet. There are fire hydrants located outside of this distance, and one located inside the fuel farm fence adjacent to the pumphouse.

REFERENCE: UFC 3-460-01 requires two fire hydrants within 300 feet hose length for fire protection of aboveground storage tanks.

RECOMMENDATION: Extend the water line and provide an additional fire hydrant. There is an existing in-ground hydrant and water line located adjacent to the pumphouse. Ensure hydrant has 1,000 gpm flow for 2 hours.

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 3/4-inch of a new tank shell radius. Based on the circumference of the shell measured near the bottom, the radius of the shell should be 26 feet. However, the measured radii of the shell vary at the bottom from 25 feet and 11-29/32 inches to 26 feet and 1-inch. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top because there did not appear to be any significant distortion of the shell would seem to suggest the tank was built slightly out-of-round. It is noted that the tolerance for out-of-roundness has been included in API 650 before 1993. API 650 1st Edition was published in 1960. However, it has not been until later years that the industry has had the laser surveying technology and methods available to measure tank upper shell courses. It should be noted that API 653,10.5.3 – 3rd Edition (published in 2001), and later editions, allow the shell out-of-roundness (radial deviation), at higher than one-foot above a bottom of a reconstructed tank, to be as much as three times greater (2-1/4 inches): a subject not addressed in API 653 prior to the year 2001. As measuring the out-of-roundness using such methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time. The tank settlement appeared to be within tolerance from API 653 Appendix ‘B’. The data points used in the settlement calculation were gathered from the laser scanning survey.

Austin Brockenbrough & Associates, L.L.P. Job No. 19-013.04 Location: Langley AFB Date: 10/9/2019 Subject: Tank 2186 - Shell Settlement Evaluation By: Corey Beyke

API 653 Appendix B Optimum cosine curve, B 2.2.4.e) Z = a + b x cos(theta + c)

Diameter (D) = 52 (ft) Number of equally spaced data points (ft)= 8 L = Arc length between measurement points (ft) = 20.42 Tank Height (H) = 40.0 (ft)

Relative elevation of lowest horizontal weld seam. ( ft)

* Z U S

0 0.002 0.00 0.01 0.01 0.01 1 -0.026 -0.03 0.00 0.03 0.02 2 -0.013 -0.02 -0.01 0.01 -0.01 3 -0.023 -0.02 -0.02 0.01 0.00 4 -0.029 -0.03 -0.02 0.01 0.01 5 -0.009 -0.01 -0.02 0.00 0.01 6 0.031 0.03 -0.01 -0.04 -0.02 7 0.036 0.03 0.00 -0.03 -0.02 8 0.002 0.00 0.01 0.01 0.04

Maximum out-of-plane deflection = 0.04

* = measured elevation *HI (Height of Instrument) Z = calculated ridged body tilt (in) U = out-of-plane settlement = S = out-of-plane deflection z-y Y = yield sterength of shell material (PSI) = 30,000 (unknown) E = Youngs modulas of elasticity (lbf/in2) = 29*10^6 S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH) = 0.06 ft

R^2 = (Syy - SSE) / Syy = 0.20 not >=0.9 therefore cosine curve is invalid.

Evaluation by the Arc Length Method described in API 653 B.2.2.5.1 is required.

Austin Brockenbrough & Associates, L.L.P. Job No. 19-013.04 Location: Langley AFB Date: 10/9/2019 Subject: Tank 2186 - Shell Settlement Evaluation By: Corey Beyke

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

* Open top (yes/no) = yes Per B.3.2.2, K = 7.8

Settlement arc length (ft), Sarc Out of plate settlement at Point i (Si) Allowable settlement at point i (Smax) = MIN[K*Sarc*(D/H)*(Y/E), 4]

Point Sarc (ft) Si (ft) Smax (ft)

1 40.8 0.02 0.04 OK

4 81.7 0.04 0.07 OK

* For the purpose of this evaluation tanks with geodesic domes and barn roofs are consided to be open top, as those types of roofs do not significantly restrain the top of the shell.

Si < Smax →

Evaluation of the settlement by the arc length method indicates the settlement is within acceptable limits.

Si < Smax →

-0.04

-0.02

0.00

0.02

0.04

0 2 4 6 8 10

Measured Elevation (ft)

Si4 Si1

SHELL THICKNESS CALCULATIONS

Job No.: 19-013.04

Job Title: LGY

Subject: FAC 2186 Shell Calculations

By: Corey Beyke Date: 9/18/19

API-650

API 653

SHELL CALCULATIONS

Diameter 52 feet Shell Height 38.75 feet Freeboard 1.6 feet Design Fill Height 37.13 feet Specific Gravity 0.84 API 650

0.84 API 653

Joint Efficiency 1.00 API 650 Material unknown (assumed to be A36) Yield Strength 30,000 psi Tensile Strength 55,000 psi Original Design Corrosion Allowance

0.000 in Required thickness

Lower Upper Two Courses

Allowable Stress Courses 23595 25960

Height Product Required Thickness Course (feet) Depth 1/4" min

6 6.67 3.78

5 6.67 10.45

4 6.67 17.12

3 6.67 23.79

2 6.67 30.46

1 6.67 37.13 min 2014 Corrosion Estimated UTM Visual current net 2000 Rate ** Service Life Inspection Inspection

Course UTM* thick Thickness * in/yr yrs. Interval** Interval** 6 0.245 0.250 0.250 N/A >30 15 5

5 0.294 0.250 0.250 N/A >30 15 5

4 0.245 0.250 0.250 N/A >30 15 5

3 0.243 0.250 0.250 N/A >30 15 5

2 0.244 0.250 0.250 N/A >30 15 5

1 0.278 0.310 0.313 0.000 >30 15 5

* The original thicknesses are assumed based on information from the previous inspection report

** As the shell is coated, the actual corrosion rate is zero and the UTM and Visual Instpection Intervals are 15 and 5 years respectively.

1011 Boulder Springs Drive Richmond, Virginia 23225 Phone: 804-592-3900 Fax: 804-395-3901 www.brockenbrough.com

(psi)

0.174

API-653

0.100

0.100

0.100

0.142

2.6(H-1)DG

SE

0.100

API-650

2.6(H-1)DG 2.6(H-1)D

Original Hydro

0.205

0.057

0.097

0.137

0.177

0.217

0.054

0.092

0.129

0.167

0.016 0.017

Original Design

SESE

20000 22500

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

Job No.: 19-013.04

Job Title: LGY

Subject: FAC 2186 Shell UTMs

By: Corey Beyke Date: 9/18/19

SHELL UTM DATA (0.001 inches) DFT = 0.000 inches UTM's include 0 inch DFT coating.

1 2 3 4 5 6 7 8 9 Typical Shell Plate UTMs.

1 2 3 4 5 6 7 8 9 1-1 0.310 0.313 0.318 0.309 0.316 0.317 0.313 0.318 0.317 1-2 0.300 0.303 0.305 0.301 0.307 0.305 0.297 0.302 0.305 1-3 0.303 0.308 0.306 0.307 0.309 0.311 0.306 0.310 0.309 1-4 0.770 0.770 0.772 0.766 0.790 0.793 0.767 0.772 0.779 1-5 0.302 0.303 0.304 0.304 0.304 0.302 0.305 0.307 0.309 1-6 0.312 0.308 0.310 0.314 0.312 0.310 0.318 0.320 0.318 1-7 0.278 0.301 0.303 0.299 0.304 0.304 0.303 0.305 0.305 1-8 0.787 0.790 0.790 0.777 0.779 0.789 0.779 0.781 0.789 lower shell course

Shell plate 1-1 is the lower shell course plate indicated on the attached drawing Shell plates are numbered clockwise.

2-1 0.244 0.246 0.244

4 5 6 4 5 6 3-1 0.243 0.246 0.247 4-1 0.250 0.255 0.255

4 5 6 4 5 6 5-1 0.294 0.297 0.298 6-1 0.245 0.290 0.290

1011 Boulder Springs Drive Richmond, Virginia 23225 Phone: 804-592-3900 Fax: 804-395-3901 www.brockenbrough.com

TANK DRAWINGS

LG

Y

- 2

TA

NK

SH

EL

L

LA

YO

UT

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LANGLEY AIR FORCE BASE / USAF

AutoCAD SHX Text 9/19/19

AutoCAD SHX Text 19-013.04

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DRAWING TITLE:

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PROJECT:

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OWNER/CLIENT:

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DRAWN BY:

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DATE:

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JOB N0:

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SKETCH NO:

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CSB

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LGY-2186

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SPCC MANDATED SHOP-BUILT AST INSPECTIONS

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SCALE:

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NONE

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24" SHELL MANHOLE

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AUTOGAUGE

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8" ISSUE

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1" TELL-TALE

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4" LOW SUCTION

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(2) 2" WATER DRAW-OFF

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BLANK REPAD

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LOW & LOW-LOW LEVEL ALARMS

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SAMPLE GAUGE

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FLOATING PAN ACCESS

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ATG

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8" RECEIPT

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GROUNDING

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24" SHELL MANHOLE

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HIGH & HIGH-HIGH LEVEL ALARMS

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(TYP)

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OSHA ACCESS STRUCTURE REPORT

OSHA Circumferential Stairway Data

OSHA Rq’d Actual

(in) min (in) max (in)

Handrail Height 33 OK 30 34 Step Width 27 1/2 OK 22 NA

Step Rise 8 1/2 OK NA NA Bottom Step Rise 8 OK 7 1/2 9 1/2

BOTTOM STEP

RISE

SUB-CONSULTANT REPORTS

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

SPCC Mandated AST Inspections

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

Carbon Steel End Conn: Size: 8" Material: Carbon Steel End Conn: Size: 8"

Issue To:

Earthen berm w/liner and graval ballast. Dike wall covered in shotcrete.

Release Prevention Barrier

Overfill Protection / Level Alarms:

High, High-high, Low, Low-low High Level Control Valve and Alarms

Receipt Piping Configuration Issue Piping Configuration

Tank Piping

Secondary Containment

March 1, 2015

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

52'-0" diameter; 38'-8" tall

N/A

API 650

Inspection Date:

Design Std

Tank Inspector Name:

Inspector Certification Number:

Overfill Protection:

Unknown

Tell-Tale

Butt weld

Operating Tanks 1 & 2

Unknown

API 653 EXTERNAL INSPECTION CHECKLIST

LGYProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

Langley AFB, Virginia

General Inspection Information

19-013.04 Submitted to:

Contract No.:

UASCE

W9128F-17-D-0017

Tank Construction and Configuration

Insulated

Coated

Plastic / Fiberglass

Other:

Jet-A

492,510 gallons

N/A

Tank Facility No.:

Local Tank ID No.:

September 10, 2019

Tank Manufacturer:

Tank Construction Date:

Tank 5 Corey Beyke

Vertical

Rectangular

Double Wall

Fire Resistant

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

Exterior Coating:

DoD Three part (assumed)

Unknown

Interior Coating:

Double Bottom

Unknown

Level Alarms:

Material:

Tank Outside Dimensions:

Nominal Capacity:

Useable Capacity:

Secondary Containment, Overfill, and CRDM

Butt weld

91254

Horizontal Single Wall

Open Type Dike

Receipt From: Primarily barge; truck off-load as secondary

API 653 EXTERNAL INSPECTION CHECKLIST

LGYProject Site:Project Name:

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Organic moss /algae located @ dike drain

Hairline cracks located in concrete. Majority have been filled with grout.

Approximately 1 sq ft of spalling located adjacent to the stairs.

TASK

Check for:

Tank Settlement

C.1.1.4 Rock

Measure foundation levelness and bottom elevations (See Annex B)

Review cathodic protection potential readings c)

Check for:

STATUS COMMENTS

a) b)

C.1.1.6 Housekeeping

Build-up of trash, vegetation, and other inflammables

ITEM

C.1.1 Foundation

C.1.1.1 Concrete Ring

Leaching of oil which has left rock filler exposed indicating hydrocarbon leakage

Tank settlement into asphalt base

C.1.1.7 Cathodic Protection

Site drainage away from the tank, associated piping, and manifolds

Check for:

Check for:

Presence of crushed rock under the steel bottom which usually results in severe underside corrosion.

Cavities under foundation; vegetation against bottom of tank

Broken concrete, spalling, and cracks, especially under backup bars used in welding butt-welded annular rings under the shell

Indications of bottom leakage at drain openings in ring, back of water-draw basins, and top surface of ring

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand b)

Settlements into the base

C.1.1.2 Asphalt

e) Settlement around perimeter of tank

C.1.1.5 Site Drainage

Check for:

Proper operation of dike drains d) a) b) a)

8 Amps 20 Volts

LGYProject Site:Project Name:

C.1.2.1 External Visual Inspection

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C.1.2.3 Riveted Shell Inspection

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Isolated areas of minor vegetation.

Rivet and seam leaks on external surface

Check for:

Corrosion and thinning on plate and weld after cleaning the bottom angle area

Paint failures, pitting, and corrosion

Full fillet lap-welded vertical seams to increase joint efficiency b) c) c)

Broken welds and corrosion damage (paint failure, pitting, corrosion, product build-up), especially where it occurs at tack-welded junction d)

Check for:

Grooving, corrosion, pitting, and coating failures b)

Corrosion loss and wear on the rivets

Reinforcing pads welded to shell at supports

Leaks and identify the location by sketch or photo

C.1.2.4 Wind Girder (Floating Roof Tanks) a)

Minor rust located along welds.

Check for:

Pitting on support welds to shell, especially on shell plates a) b)

c) Bottom-to-Foundation Seal

e) Drawings of riveted seams if available. Otherwise, dimension and sketch (or photograph) the rivet pattern: no. of rows, rivet size, pitch length, butt-riveted or lap-riveted joints a)

C.1.2. Shells

Check for:

C.1.2.2 Internal (Floating Roof Tank)

LGYProject Site:Project Name:

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ITEM TASK

a) Leaks at piping manifolds, flanges, and valves

Flange leaks and leaks around bolting

Shell plate dimpling around nozzles, caused by excessive pipe deflection c)

Check for:

C.1.3.3 Autogauge System Check for:

b)

COMMENTS

Cracks or signs of leakage on weld joint at nozzles, manholes, and reinforcing plates

Fire fighting system componentsb) c) d) e) f)

C.1.3.1 Manholes and Nozzles

C.1.3.2 Tank Piping Manifolds

C.1.3 Shell Appurtenances

Damage on welds on shell-mounted davit clips above valves 6 inches and larger g)

Anchored piping which would be hazardous to the tank shell or bottom connections during earth movement

Adequate thermal pressure relief of piping to the tank

Proper operation of regulators for tanks with purge gas systems

Leaks at sample connections and proper valve operation

Damage and test the accuracy of temperature indicators h)

Sealing of insulation around manholes and nozzles

e) Adequate manholes flange and cover thickness on mixer manholes d)

a) (2) 24" diamater manholes; no manhole for access to internal floating pan

Check for:

STATUS

VAREC 2500 ATGa) Leaks on autogauge tape guide and lower sheave housing (floating swings)

b) Damage on autogauge head

LGYProject Site:Project Name:

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c) Pass Fail N/A

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1 1/2" threaded coated carbon steel

VAREC reading of 15'-4" vs. 16'-6" reading of ENRAF unit

h) Condition of board and legibility of board-type autogauges

Freedom of movement of marker and float

C.1.3.3 Autogauge System c) d)

C.1.3.4 Shell-mounted Sample Station a) b)

Check for:

Function of valves and plugging in sample lines, including drain or return-to-tank line

Leaks in circulation pump and operating problems

Inspect condensate drain for presence of oil indicating leakage

C.1.3.5 Heater (Shell Manhole Mounted)

C.1.3.6 Mixer Check for:

c) Condition of power lines and connections to mixer

Bracing and supports for sample lines and equipment i) a) b)

Proper mounting flange and support

Leakage e) f) g)

Proper movement of tape by bumping the checker on autogauge head

Size and construction material of the autogauge tape guide and make note (floating roof tanks)

Proper movement of tape. Ask the operator if the tape tends to hang up during tank roof movement (floating roof tanks).

Actual product level compared to the reading on the autogauge. Make note. (max. variation is 2 in.)

No more than 2 feet of tape are exposed at the end of the tape guide when the roof is in lowest position (floating roof tanks)

ITEM TASK STATUS COMMENTS

LGYProject Site:Project Name:

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b) Pass Fail N/A

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Target should indicate direction of swing opening (up or down) and height above bottom where suction will be lost with swing on bottom support

Floating: With tank half full or more, lower the swing line, then let out the cable and check if the swing has pulled cable tight, indicating that the winch is operating properly

ITEM TASK

Non-floating: Raise, then lower the swing line with the winch and check for cable lightness to confirm the swing line lowered properly

STATUS COMMENTS

C.1.3.7 Swing Lines: Winch a) Operation

Indicator: Check that the indicator moves in the proper direction.

Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite b) c)

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity

Check for:C.1.3.10 Swing Lines: Cable Material and Condition a) Corrosion over entire length, for non-stainless steel cable

Wear or fraying on all types of cable

C.1.3.11 Swing Lines: Product Sample Comparison

Check for water or gravity differences that would indicate a leaking swing joint

C.1.3.12 Swing Lines: Target

LGYProject Site:Project Name:

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Geodesic dome

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. (Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

C.1.4.2 Deck Plate External Corrosion

ITEM TASK STATUS

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck.

C.1.4.3 Roof Deck Drainage Look for indication of standing water.

(Significant sagging of fixed roof deck indicates potential rafter failure.

Large standing water areas on a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons.)

COMMENTS

C.1.4.4 Level of Floating Roof At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a nonlevel roof with possible shell out-of-round, out-of-plumb, leaking pontoons, or hang-up. On small diameter tanks, an unlevel condition can indicate unequal loading at that level.

C.1.4.5 Gas Test Internal Floating Roof

Test for explosive gas on top of the internal floating roof, Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

Not accessible

LGYProject Site:Project Name:

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COMMENTS

C.1.4.6 Roof Insulation Check for:

a) b) c)

Crack and leaks in the insulation weather coat where runoff rain water could penetrate the insulation c) d)

C.1.4.7 Floating Roof Seal a) Systems

Inspect the condition of the seal, measure and record maximum rim spaces and seal-to-shell gaps around the full roof circumference at the level of inspection. NOTE: Inspection of the seal and measurement of the rim spaces and seal-to-shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

STATUS

Wet insulation under the weather coat

Corrosion on the roof plate and holes near the edge of the insulated area by removing small test sections of insulation

ITEM TASK

b) Measure and record annular space at 30-ft spacing (minimum of four quadrants) around roof and record.

Measurements should be taken in directly opposite pairs.

e) f) g)

Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough).

Inspect fabric for deterioration, holes, tears, and cracks.

Inspect visible metallic parts for corrosion and wear.

Inspect for openings in seals that would permit vapor emissions.

Inspect for protruding bolt or rivet heads against the shell.

LGYProject Site:Project Name:

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Check for:

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ITEM TASK STATUS COMMENTS

C.1.4.7 Floating Roof Seal h) Systems i) j)

Pull both primary and secondary seal systems back all around the shell to check their operation.

Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears.

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch g) h)

Operation of system

Presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample) on ultra clean stocks such as JP4 a) b) c) d) e) f)

Condition and functioning of sample hatch cover.

Condition of seal inside hatch cover on tanks governed by Air Quality Monitoring District rules

Corrosion and plugging on thief and gauge hatch cover.

Marker and tab stating hold-off distance, where the sample hatch is used to reel gauge stock level

Reinforcing pad where sample hatch pipe penetrates the roof deck.

Operation of recoil reel and condition of rope on floating roof sample hatch and recoil systems

LGYProject Site:Project Name:

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Reference of 43'-1"

ITEM TASK STATUS COMMENTS

b) Corrosion on the tape guide's and float guide's wire anchors

Corrosion and missing bolts on the hatch

Check for:

Check for:C.1.5.4 Autogauge: Inspection Hatch & Guides (Fixed Roof) a)

Minor corrosion observed

C.1.5.2 Gauge Well Check for:

Valve leakage and for presence of a bull plug or blind flange, if the tank has a gauge well washer a) b) c) d) e)

Thinning, size of slots, and cover condition of the visible portion of the gauge well

A hold-off distance marker and tab with hold-off distance (legible)

Condition of roof guide for gauge well, particularly the condition of the rollers for grooving on floating roofs

The distance from the gauge well pipe to the tank shell at different levels, if accessible

C.1.5.5 Autoguage: Float Well Cover a) Corrosion

Wear or fraying caused by rubbing of the tape cable on the cover b)

Inspect scaffold support for corrosion, wear and structural soundness.

C.1.5.3 Fixed Roof Scaffold Support

C.1.5.6 Sample Hatch (Internal Floating Roof) a) Overall conditions

Automatic sealing after sampling, when equipped with a fabric seal

Proper operations when equipped with a recoil reel opening device b) c)

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check for:

C.1.5.8 Gauging Platform Drip Ring

Check condition of screens, locking and pivot pins.

On fixed roof tanks with drip rings under the gauging platform or sampling area, inspect for plugged drain return to the tank.

LGYProject Site:Project Name:

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2 1/2"x2 1/2"x1/8" coated carbon steel angle

Some welds not fully sealed

STATUS COMMENTS

c) If pontoon hatches are equipped with locked down coves, check for vent tubes. Check that vent tubes are not plugged up. Inspect lock-down devices for condition and operation.

Check for leg racks on roof

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

ITEM TASK

Test for explosive gas (an indicator of vapor space leaks).

b)

C.1.6 Access Ways - See Tank Out-of-Service Inspection Checklist Item C.2.12

C.2.12 Access Structures

C.2.12.1 Handrails a) b) c)

Check for:

a) Condition of the screen on the rim vent cover

b) Plating off or removal of rim vents where jurisdictional rules do not permit removal

C.1.5.13 Pontoon Inspection a) Hatches

Open pontoon inspection hatch covers and visually check inside for pontoon leakage.

C.1.5.9 Emergency Roof Drains

C.1.5.10 Removable Roof Leg Racks

C.1.5.11 Vacuum Breakers

C.1.5.12 Rim Vents

Inspect vapor plugs for emergency drain: that seal fabric discs are slightly smaller than the pipe ID and that fabric seal Is above the liquid level.

d)

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

Inspect for pitting and holes, paint failure.

Inspect attachment welds.

Identify cold joints and sharp edges.

Inspect the handrails and midrails.

LGYProject Site:Project Name:

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Some welds not fully sealed

STATUS COMMENTS

c) Corrosion on steel support…