Attachment J - Previous Inspection Report.pdf

Wright Patterson AFB, OH API-653 In-Service Inspection September 27, FINAL Facility 07272

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Wright Patterson Air Force Base Facility 07272

Tank 272

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

(USACE POL-MCX)

[27/9/22]

API 653 In -Service Inspection Report Wright Patterson AFB, OH

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

9. Cathodic Protection

C. FINDINGS AND RECOMMENDATIONS

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

2. RECOMMENDED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATION

SHELL ROLL-OUT

ROOF LAYOUT

THICKNESS MEASUREMENTS

CRITICAL ZONE SHELL THICKNESS

ROOF THICKNESS

NOZZLE /REPAD THICKNESS/SUMP

CONTAINMENT DRAWING

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3-D DOCUMENTATION AND ANALYSIS

SETTLEMENT SURVEY DIAGRAM

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

EWI Environmental Works, Inc.

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TALON Talon Veteran Services, Inc.

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

GENERAL SUMMARY

Summary of Inspection

An API Standard 653 In-Service inspection of Tank #272 (Facility 07272) at Wright Patterson AFB in Dayton, OH was completed on September 27, 2022. The shell service life evaluation performed as having greater than 30 years of remaining shell life under current conditions. The significant findings are summarized below.

Significant Findings (overview)

• Tank 272 is not equipped with a grounding cable.

• The secondary containment access stairway was severely damaged outside of the containment dike and the liner seal was split on the side of the bottom step.

• The top of the ringwall had paint coating failure.

• The tank did not have an NFPA fire diamond placard.

• The shell had paint coating failure.

• The shell manway did not have a “Danger Confined Space” stencil.

• The manual tape gauge readout housing is currently filled with fluid.

• Galvanic corrosion was noted on the roof nozzle fasteners.

• The roof had paint coating failure and small holidays, with visible external corrosion.

• The issue and receipt lines were supported by a single saddle support in the containment dike without a teflon pad between the support and pipe.

• The issue and receipt lines were not supported at the skin of the tank with the required anchor type support

• The issue and receipt lines had coated carbon steel thermal relief piping.

• The manhole and the manway cover did not have davit arm.

• The tank is only equipped with one manway, which is not adequate for means of egress for out of service inspection.

• The tank did not have a spiral stairway for accessing shell and roof appurtenances and conducting maintenance.

• The High-Level Alarm, high level shutoff, HHLA, Low Level Alarm, and LLLA piping were coated carbon steel.

• The issue and receipt nozzle necks lacked a fuel sample connector.

• The tank did not have a product saver tank, with water draw and return line. The current water draw serves as the low suction for the tank. The water draw and PST return require 2-inch nozzles and the low suction requires a 4-inch nozzle on the skin of the tank.

• The fixed roof does not have the standard AW78-24-27 vents and appurtenances for an internal floating roof. Note: Internal floating roofs are not required for the product stored in the tank, but fire protection.

• The issue and receipt lines had coated carbon steel thermal relief piping, which does not conform to the standard specified stainless steel.

• The high level, HHLA, HLCV, LLA, and LLLA piping were coated carbon steel, which does not conform to the AW 78-24-27 standard stainless steel.

• The secondary containment drain did not have an inlet sump and the drain valve failed the pressure test.

27 September 2022

INSPECTION DATE

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

Manufacturer: Olympus Model Number: 38 DL Plus Calibration Method: Two Point Calibration Procedure

Inspector(s): Jason Mitchell API 653 Inspector No. 62965

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections N/A State Regulation for API Out-of-Service Tank Inspections N/A

NOTE: If there are no state regulations for tank inspections then N/A shall reside in-place of the number of years between inspections. If state regulations reside, the recommended future inspections dates shall be based on whichever is more stringent between the API inspector’s calculations and the State regulations.

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: 18 June 2009 API In-Service (External) Inspection Date: 18 May 2017

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

API Out-of-Service (Internal) Inspection Date: 18 June 2019 (Past Due) API In-Service (External) Inspection Date: 27 September 2027

Jason Mitchell Tank Inspector Environmental Works, Inc.

API 653 Certified Inspector No. 62965

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner Wright Patterson AFB Location Dayton, OH Facility Number 07272 Tank Number 272 State / Country Ohio, United States City Dayton Inspection Date 27 September 2022 Tank Manufacturer Unknown Design Standard API-12C Date of Construction Circa 1955 Tank Contents Diesel Tank Serial Number 60022.014.511 Tank Diameter 34’ – 0” Shell Height 30’ – 0” Product Height Maximum Fill: 28.50’ Tank Capacity 200,000 Gallons / 4,616 Barrels Foundation Concrete Ringwall

Construction Bottom Lap Welded (Cone-Down)

Shell Butt Welded (Cylindrical)

Fixed Roof Lap-Welded (Self-Supported Cone)

Material Bottom Carbon Steel A-36 Mod

Shell Carbon Steel A-36 Mod

Fixed Roof Carbon Steel A-36 Mod Cathodic Protection Impressed Current

Interior Coating System Unknown

Exterior Coating System Thin Film Epoxy / Polyurethane

Level Gauging Manual Tape Gauge / ENRAF Electronic Gauging Overfill Protection Automatic Shut-Off Piping Receipt 4” Carbon Steel

Issue 4” Stainless Steel Low Suction / Water Draw 1” Carbon Steel

Level Alarms LLLA, LLA, HLA, HHLA, HLCA Type of Internal Floating Roof N/A

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection This project will perform API 653 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.

2. Site Information On September 27, 2022, Talon and our sub-consultant (EWI) performed an API 653 In-Service (External) inspection of Tank 272, located at Wright Patterson AFB in Dayton, Ohio. Wright-Patterson Air Force Base is located northeast of Dayton, Ohio and encompasses parts of Greene and Montgomery counties.

The base has a rich aviation heritage. The pioneering work of Orville and Wilbur Wright from 1899 to 1903, enabled them to achieve the first manned, powered flight. After their success at Kitty Hawk, they returned home to Dayton, Ohio, where in 1904 and 1905, they perfected their flying skills while turning the Wright Flyer into the first practical airplane capable of fully-controlled flight. They accomplished this work at the Huffman Prairie Flying Field, now a part of Wright-Patterson Air Force Base. From 1910 to 1916, the brothers operated a flying school at Huffman Prairie. Among their 119 students were Henry "Hap" Arnold, who commanded the Army Air Forces in World War II, and H. Roy Brown, the Canadian ace who was credited with shooting down the Red Baron in World War I. Tank 272 is located within the perimeter of the Fuels Facility Farm. It is one of four remaining tanks on site.

B. TANK INSPECTION COMMENTS

1. Tank Construction Tank 272 is a nominal 4,616 barrel, 34-foot diameter by 30-foot tall, Diesel, aboveground vertical storage tank. The repaired/altered nameplate is available and legible. The altered nameplate lists the tank as being repaired/altered to API-653 by CAPE in 2009. The original manufacturer was unknown, and the original manufacturer name plate was illegible.

2. Tank Foundation The tank rests on a concrete ringwall foundation. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard

653. Settlement results are listed in Appendix A.

3. Tank Shell The shell is constructed of A-36 Modified carbon steel material. The shell is of cylindrical design, butt-welded together, consisting of seven (7) courses. The shell exterior has a thin film epoxy coating system. The coating was inspected for disbonding, adhesion, deterioration, and discoloration; which had chalking, holidays and visible corrosion through failed coating in several areas. The shell was evaluated for remaining metal thickness utilizing ultrasonic technology. The ultrasonic thickness measurements and thickness measurement locations (TML) are listed in the Shell Plate Thickness Measurements table in Appendix A. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of greater than 30 years under current conditions. The shell service life evaluation is shown in the Shell Service Life Evaluation table in Appendix A. Roundness, plumbness, peaking, and banding of the shell are all within the allowable tolerances of API Standard 653. The tank is stable and does not appear to be in danger of overturning or buckling due to high winds or seismic conditions.

4. Tank Appurtenances

a. Fixed Roof

The tank is equipped with a lap welded, coated carbon steel frangible roof. The roof coating had holidays and coating failure in several locations and external corrosion.

b. Gauging The tank is equipped with a Honeywell ENRAF ATG to gauge the fuel inside of the tank.

Manual gauging may be performed through the 8-inch gauge port located on the roof. An ENRAF VITO water level gauge, gauges if there is water present in the tank.

c. Level Alarms High and high-high level alarms are mounted on the top shell course of the tank and are accessible by way of the fixed ladder attached to the shell of the tank. The tank was equipped with low and low-low level alarms. The current thickness measurements indicate that the nominal thickness of the nozzles were 1-inch schedule 80 XS, which indicates inaccuracies in the previously reported thickness measurements.

d. Roof Access The fixed roof was accessible via a fixed ladder. The ladder had a cage and fall protection device and the roof had a circumferential handrail.

e. Grounding and Bonding The tank did not have a grounding cable.

5. Tank Coating The exterior coating was an epoxy material, which was degrading and missing in several areas.

6. Tank Piping System Fuel is received and issued through 6-inch carbon steel pipes that reduce to 4-inch at the valves. The carbon steel piping had no noticeable coating degradation, holidays, or external corrosion.

7. Fire Protection System A fire hydrant was noted nearby the tank.

8. Secondary Containment The tank sits within an earthen secondary containment. The secondary containment is lined with a HDPE liner and is equipped with a containment drain pipe. The top of the earthen containment berm has a flat section two foot or more and is properly sloped in accordance with NFPA-30. The containment floor is properly sloped to allow for drainage away from the tank as required by NFPA-30.

The containment was visually evaluated during the inspection. The containment appears to be of sufficient size to contain a total tank loss. However, the containment liner had damage in the form of a tear around the bottom step of the concrete access stairway, therefore the secondary containment lacked integrity thus not satisfying the requirements of API Standard 653 and OSHA 40 CFR 112. The hydrostatic test performed to assess the integrity of the drain valve, revealed the valve could not contain pressure and the containment lacked the specified sump, inlet.

9. Cathodic Protection The 2019 CP Survey issued by Pond Engineering listed the Diesel Area as having an independent impressed current cathodic protection (ICCP) system, which was installed in 2009. The ICCP system was deenergized and depolarized. The recommended repairs for the rectifier (diodes etc.) should have been confirmed in the 2020 annual survey, which was not provided in the archived data for tank 272.

C. FINDINGS AND RECOMMENDATIONS

The following information identifies the significant findings found during the tank inspection:

1. MANDATORY REPAIRS per API 653, UFC 3-460-01, or AW 78-24-27 Standards Mandatory repairs represent items that require immediate attention, in order to prevent imminent risk to system operators, equipment integrity, or the adjacent environment. The tank should remain out of service until these repairs are completed.

There are no indications of compromise to the structural or hydraulic integrity of the tank. Visual inspection did not reveal any indication of leakage and the Ultrasonic Thickness Testing (UTT) scans performed did not reveal any areas of anomalies requiring corrective actions.

2. RECOMMENDED 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. Short-Term Repair: Grounding OBSERVATION: Tank 272 is not equipped with grounding cable.

REFERENCE: NFPA-30, AW 78-24-27, Sheet ED.02, API 650 Section 5.8.11.3 RECOMMENDATION: Install (4) grounding cables with exothermically welded connections to lugs with reinforcement pads, evenly spaced around the circumference of the tank.

b. Short-Term Repair: Secondary Containment OBSERVATION: The secondary containment access stairway was severely damaged outside of the containment dike and the liner seal was split on the side of the bottom step.

REFERENCE: OSHA 40 CFR 112.7 (c), 112.8 (c) (2) and 112.12(c) (2) RECOMMENDATION: Repair the concrete, secondary containment access stairway and the split in the liner at the bottom of the stairway. (Concrete: 32 CF, Liner 2LF)

c. Short-Term Repair: Ringwall Coating OBSERVATION: Coating on the ringwall, exhibits cracking, flaking, and has several holidays.

REFERENCE: UFC 3-460-01, SECTION 8-3.10

RECOMMENDATION: Provide a full recoat of the ringwall (approximately 150 ft2).

d. Short-Term Repair: NFPA Placard OBSERVATION: The tank shell did not have the required NFPA fire diamond.

REFERENCE: NFPA 30

RECOMMENDATION: Install NFPA placards at the top of the shell per the NFPA code (Quantity: 2).

e. Short-Term Repair: Nozzles, Piping, and Appurtenances Coating OBSERVATION: Coating on the tank shell, exhibits corrosion staining, flaking, base metal exposure with surface corrosion, and widespread chalking.

REFERENCE: UFC 3-460-01, Section 8-3.10, UFGS 09 97 13.27 RECOMMENDATION: Repair areas exhibiting paint coating failure (approximately 150 SF).

f. Short-Term Repair: Confined Space Signage OBSERVATION: The shell and roof manways lack the proper confined space labeling.

REFERENCE: OSHA 1910.146 (c)(2) RECOMMENDATION: Install proper “danger confined space” labeling on all manways (Quantity: 3).

g. Short-Term Repair: Manual Tape Gauge OBSERVATION: The manual tape gauge readout housing was filled with dark fluid.

REFERENCE: AW78-24-27 Drawing D.07, Detail 1 RECOMMENDATION: Remove mechanical tape gauge if directed by service headquarters.

h. Short-Term Repair: Roof Nozzle Fasteners OBSERVATION: Fasteners for the ENRAF ATG exhibit surface corrosion.

REFERENCE: BMP

RECOMMENDATION: Replace twenty (20) carbon steel fasteners at the ENRAF ATG with stainless steel fasteners or provide isolation flange washers.

i. Short-Term Repair: Roof Coating OBSERVATION: The tank roof had paint coating failure and small holidays, with visible external corrosion.

REFERENCE: UFGS 09 97 13.27

RECOMMENDATION: Repair the roof coating in areas of visible coating failure (Quantity: 40 SF)

j. Short-Term Repair: Issue and Receipt Line Supports OBSERVATION: The issue and receipt lines were supported by a single saddle support in the containment dike without a teflon pad between the support and pipe.

REFERENCE: UFC 3-460-01, Section 8-3.10 RECOMMENDATION: Install an anchor type support at the skin of the tank and Teflon pads between the pipe and adjustable saddle supports (Teflon Pads: 2, Anchor Supports: 2).

3. 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. Long-Term Repair: Manway Davit OBSERVATION: Manway 1 is not provided a davit arm with grease fitting to facilitate handling of the cover plate.

REFERENCE: API 650, Section 5.8.3.5, AW 78-24-27 Drawing D.10 Detail 3 RECOMMENDATION: Provide Manway 1 with a davit arm with grease fitting to facilitate handling of the cover plate during maintenance and inspection activities.

b. Long-Term Repair: Manway OBSERVATION: The tank is only equipped with one manway, which is not adequate for means of egress for out of service inspection.

REFERENCE: AW 78-24-27 Drawing D.10.02 RECOMMENDATION: Provide an additional bottom shell course manway for means of egress and an intermediate shell manway for servicing an IFR, if the tank is provided an IFR. Tanks without floating pans do not require upper shell manways.

c. Long-Term Repair: Spiral Stairway OBSERVATION: The tank did not have a spiral stairway with an exothermically welded ground cable and copper grounding bar brazed to the guardrail.

REFERENCE: AW 78-24-27 Drawing D.11 Detail 4 RECOMMENDATION: Install a spiral stairway with grounding. (Quantity: 1)

d. Long-Term Repair: Issue and Receipt Nozzles OBSERVATION: The issue and receipt lines are not equipped with a fuel sample connectors.

REFERENCE: AW 78-24-27 Drawing D.08 Detail 1 and D.13 Detail 4 RECOMMENDATION: Install 1/4-inch fuel sample connectors on the nozzle necks of the receipt and issue lines, per the standard specification.

e. Long-Term Repair: Water Draw-Off and PST OBSERVATION: The 1-inch water draw-off line lacks a 2-inch double block and bleed (DBB) plug valve at the skin of the tank and the water draw-off nozzle serves at the low suction for the tank. The tank did not have a product saver tank.

REFERENCE: AW 78-24-27 Drawing D.13 Detail 5, and Drawing G.05 RECOMMENDATION: Install a product saver tank and replace the water draw and PST return line and install a DBB plug valve on the skin of the tank with a tell-tale hole on the reinforcement pad. Install a 4-inch low suction nozzle with DBB plug valve at the skin of the tank and specified crossover line and thermal relief as specified in AW 78-24-27 (Quantity: 1 Product Saver Tank, 2 2-inch nozzles with DBB valves for 1-inch water draw and PST return lines, 1 4-inch nozzle with DBB valve, crossover line to issue and thermal relief)

f. Long-Term Repair: Fixed Roof Appurtenances OBSERVATION: The fixed roof does not have the standard AW78-24-27 vents and appurtenances for an internal floating roof. Note: Internal floating roofs are not required for the product stored in the tank, but fire protection REFERENCE: AW 78-24-27 Drawing 10.01, 10.02 and D.06, D.07, D.08, D.09. or G.04, API 650, Annex H.4.4.4 Item c RECOMMENDATION: Consider installing: an aluminum, honeycomb type internal floating roof with double wiper squeegee perimeter seals, access hatches, an access ladder, a center vent and perimeter vents, a sample gauge well with manual winch retriever, a Vito water probe and stilling well and all required upgrades to bring the roof to the AW78-24-27 standard for tanks with internal floating roofs.

g. Long-Term Repair: Thermal Relief Piping OBSERVATION: The issue and receipt lines had coated carbon steel thermal relief piping.

REFERENCE: AW 78-24-27 Drawing D.10, D.12 RECOMMENDATION: Replace the coated carbon steel thermal relief lines and valves with stainless steel. (Quantity: 2 TRV Lines)

h. Long-Term Repair: Liquid Level Alarm Piping OBSERVATION: The high level, HHLA, HLCV, LLA, and LLLA piping were coated carbon steel, which does not conform to the AW 78-24-27 standard.

REFERENCE: AW 78-24-27 Drawing D.12 RECOMMENDATION: Replace the liquid level alarm piping with stainless steel.

i. Long-Term Repair: Secondary Containment Drain OBSERVATION: The secondary containment drain valve did not hold pressure and the secondary containment lacked an inlet sump.

REFERENCE: AW 78-24-27 CD.09, OSHA 40 CFR 112.7 (c), 112.8 (c) (2) and 112.12(c) (2) RECOMMENDATION: Replace the secondary containment drain line and valve and install an inlet sump in accordance with the AW 78-24-27 standard.

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL SETTLEMENT SURVEY

Previous readings were converted to the nearest foot, the field measured values are represented in this table, which were recorded in the nearest 1/16-inch.

SHELL THICKNESS CALCULATION

SHELL THICKNESS CALCULATION

SHELL ROLL-OUT

ROOF LAYOUT

THICKNESS MEASUREMENTS

THICKNESS MEASUREMENTS

CRITICAL ZONE SHELL THICKNESS

ROOF THICKNESS

NOZZLE /REPAD THICKNESS/SUMP

NOZZLE /REPAD THICKNESS/SUMP

The current thickness measurements indicate that the nominal thickness of the Low Lev. and Water Draw nozzles were 1-inch schedule 80 XS, which indicates inaccuracies in the previously reported thickness measurements.

CONTAINMENT DRAWING

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3-D DOCUMENTATION AND ANALYSIS

The purpose of this study is to determine the tank shell out-of-roundness, locations of buckled areas, flat spots, and peaking and banding at weld joints. Shell distortion can be caused by many conditions such as foundation settlement, over- or under-pressuring, high wind, poor shell fabrication, or various repair techniques or tank modifications.

Out-of-Plumbness (Verticality) – There was no measurable out of plumbness.

Out-of-Roundness: The maximum allowable out-of-roundness at 1-foot shell height for this tank is 1 inch in accordance with API Standard 653. Evaluation of roundness at 1-foot shell height can only be accurately performed from inside the tank. The shell out-of-roundness at 1-foot was not evaluated.

Isolated Shell Distortion – There were no defect shell distortion measurements along the exterior of the tank.

Tank Bottom Elevation – A laser level was utilized to measure edge settlement in accordance with the requirements of API-653. The attached diagram below illustrates the points measured to assess settlement around the perimeter of the tank bottom. No significant edge settlement was noted.

SETTLEMENT SURVEY DIAGRAM

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

Tank In-Service Inspection Checklist

Item Completed

X C.1.1 Foundation

Measure foundation levelness and bottom elevations (see Annex B for extent of measurements). X C.1.1.1 Concrete Ring a Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell. X b Inspect drain openings in ring, back of waterdraw basins and top surface of ring for indications of bottom leakage. X c Inspect for cavities under foundation and vegetation against bottom of tank. X d Check that runoff rainwater from the shell drains away from tank. X e Check for settlement around perimeter of tank. X

C.1.1.2 Asphalt a Check for settling of tank into asphalt base which would direct runoff rain water under the tank instead of away from it. N/A b Look for areas where leaching of oil has left rock filler exposed, which indicates hydrocarbon leakage. N/A C.1.1.3 Oiled Dirt or Sand

Check for settlement into the base which would direct runoff rain water under the tank rather than away from it. N/A

C.1.1.4 Rock

Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

N/A

C.1.1.5 Site Drainage a Check site for drainage away from the tank and associated piping and manifolds. X b Check operating condition of the dike drains. X

C.1.1.6 Housekeeping Inspect the area for buildup of trash, vegetation, and other inflammables buildup. X

C.1.1.7 Cathodic Protection Review cathodic protection potential readings. X

C.1.2 Shells C.1.2.1 External Visual Inspection a Visually inspect for paint failures, pitting, and corrosion. X b Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X c Inspect the bottom-to-foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank) Visually inspect for grooving, corrosion, pitting, and coating failures. N/A

C.1.2.3 Riveted Shell Inspection a Inspect external surface for rivet and seam leaks. N/A b Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A c Inspect rivets for corrosion loss and wear. N/A

Tank In-Service Inspection Checklist Continued

Item Completed

X d Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A e If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern: number of rows, rivet size, pitch length, and note whether the joint is butt-riveted or lap-riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks) a Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds. N/A b Check support welds to shell for pitting, especially on shell plates. X c Note whether supports have reinforcing pads welded to shell. X

C.1.3 Shell Appurtenances C.1.3.1 Manways and Nozzles a Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates. X b Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X c Inspect for flange leaks and leaks around bolting. X d Inspect sealing of insulation around manways and nozzles. N/A e Check for inadequate manway flange and cover thickness on mixer manways. N/A

C.1.3.2 Tank Piping Manifolds a Inspect manifold piping, flanges, and valves for leaks. N/A b Inspect fire fighting system components. X c Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement. X d Check for adequate thermal pressure relief of piping to the tank. X e Check operation of regulators for tanks with purge gas systems. N/A f Check sample connections for leaks and for proper valve operation. N/A g Check for damage and test the accuracy of temperature indicators. N/A h Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System a Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X b Inspect autogauge head for damage. X c Bump the checker on autogauge head for proper movement of tape. X d Identify size and construction material of autogauge tape guide (floating roof tanks). N/A e Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). N/A f Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). N/A g On floating roof tanks, when the roof is in the lowest position, check that no more than two ft of tape are exposed at the end of the tape guide. N/A h Inspect condition of board and legibility of board-type autogauges. X i Test freedom of movement of marker and float. X

C.1.3.4 Shell-Mounted Sample Station a Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line. N/A b Check circulation pump for leaks and operating problems. N/A Tank In-Service Inspection Checklist Continued

Item Completed

X c Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted) Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer a Inspect for proper mounting flange and support. N/A b Inspect for leakage. N/A c Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation a Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly. N/A b Floating. With tank half full or more, lower the swing line, then let out cable and check if swing has pulled cable tight, indicating that the winch is operating properly. N/A c 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.

N/A

C.1.3.8 Swing Lines: External Guide System Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition a For nonstainless steel cable, check for corrosion over entire length. N/A b All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison Check for water or gravity differences that would indicate a leaking swing joint. N/A

C.1.3.12 Swing Lines: Target

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

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.)

N/A

C.1.4.2 Deck Plate External Corrosion Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck. X

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.)

X

Tank In-Service Inspection Checklist Continued

Item Completed

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.

N/A

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. N/A

C.1.4.6 Roof Insulation a Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation. N/A b Inspect for wet insulation under the weather coat. N/A c Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area. N/A

C.1.4.7 Floating Roof Seal Systems a Inspect the condition of the seal, measure and record maximum rim spaces and sealto- 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).

N/A 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. N/A

1) _______ _______ Opposite pair 1. N/A

2) _______ _______ Opposite pair 2. N/A c Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough). N/A d Inspect fabric for deterioration, holes, tears, and cracks. N/A e Inspect visible metallic parts for corrosion and wear. N/A f Inspect for openings in seals that would permit vapor emissions. N/A g Inspect for protruding bolt or rivet heads against the shell. N/A h Pull both primary and secondary seal systems back all around the shell to check their operation. N/A i Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow. N/A j Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. N/A C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch a Inspect condition and functioning of sample hatch cover. X b On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover. N/A c Check for corrosion and plugging on thief and gauge hatch cover. X d Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance. N/A e Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X Tank In-Service Inspection Checklist Continued

Item Completed

X f On floating roof sample hatch and recoil systems, inspect operation of recoil reel and condition of rope. N/A g Test operation of system. N/A h On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample). N/A

C.1.5.2 Gauge Well a Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. X b Check for a hold-off distance marker and tab with hold-off distance (legible). N/A c On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving. N/A d If accessible, check the distance from the gauge well pipe to the tank shell at different levels. N/A e If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange. N/A

C.1.5.3 Fixed Roof Scaffold Support Inspect scaffold support for corrosion, wear, and structural soundness. N/A

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof) a Check the hatch for corrosion and missing bolts. N/A b Look for corrosion on the tape guide’s and float guide’s wire anchors. N/A

C.1.5.5 Autogauge: Float Well Cover a Inspect for corrosion. N/A b Check tape cable for wear or fraying caused by rubbing on the cover. N/A

C.1.5.6 Sample Hatch (Internal Floating Roof) a Check overall conditions. N/A b When equipped with a fabric seal, check for automatic sealing after sampling. N/A c When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-mounted Vents (Internal Floating Roof) Check condition of screens, locking and pivot pins. N/A

C.1.5.8 Gauging Platform Drip Ring

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

C.1.5.9 Emergency Roof Drains

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. N/A

C.1.5.10 Removable Roof Leg Racks Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

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. N/A

C.1.5.12 Rim Vents a Check condition of the screen on the rim vent cover. N/A

Tank In-Service Inspection Checklist Continued

Item Completed b Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. N/A C.1.5.13 Pontoon Inspection Hatches a Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A b Test for explosive gas (an indicator of vapor space leaks). N/A 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. N/A

C.1.6.1 Accessways See Tank Out-of-service Inspection Checklist, Item C.2.12. N/A

APPENDIX D: PHOTOGRAPHS

E.1: Tank 272 North View E.2: Tank 272 South View

E.3: Tank 272 East View E.4: Tank 272 West View

E.5: Tank Low Level Alarm E.6: Tank High Level Alarm

E.7: The east corner of the containment dike E.8: The CAPE alteration name plate

E.9: The original manufacturer name plate E.10: The shell manway

E.11: The issue and receipt lines E.12: The water draw and low suction

E.13: The ENRAF readout at the bottom of the tank E.14: The containment dike drain

E.15: An interstitial leak detection valve E.16: The secondary containment access stairway

E.15: The roof access ladder E.16: The ENRAF ATG on top of the tank

E.15: The Vito probe on top of the tank E.16: The roof manway and sample well

E.15: A spare roof nozzle E.16: The west side of the roof

E.15: The east side of the roof E.16: The mechanical tape gauge