Attachment J1 - API 653_Molinelli Tank 2_18 Feb 2015.pdf

500 Pinnacle Court, Suite 100 ▲ Norcross, GA 30071

(770) 908-7200

DATE: February 19, 2015

TO: Mr. Michael Martin

USACE, Omaha District Attn: CENWO-CD-RR 1616 Capitol Avenue Omaha, Nebraska 68192-4901

RE: Preliminary Findings and Recommendations Fort Rucker, AL, Tank No. 25647 Contract W9128F-10-D-0075, Task Order 0008, Tank Group 17

On February 019, 2015 an API Standard 653 out-of-service inspection was performed on Tank # 25647 located at the Molinelli Stagefield Field, Ft. Rucker, AL. The purpose of the inspection was to gather data necessary to determine serviceability of the tank and compliance with applicable codes and standards.

The findings and recommendations are based on field observations, the historical construction drawings when available, as well as feedback from the tank Owner/Operators.

Please find attached the Preliminary Findings / Recommendations Report and supporting photographic documentation.

Regards, Jerry Dupre Jr API 653 Inspector (3062)

Attachments:

Tank Data Preliminary Findings / Recommendations Report – Tank # 25647, Fort Rucker Molinelli Field, Alabama

Cc: Project Team; Project File

Tank Location Fort Rucker, AL Molinelli Field Tank No. (plus previous identified) Tank No. 25647 Facility Number Unknown Inspection Dates (s) 19-Feb-15 Tank Type Above Ground Storage Tank (AST) Type of Inspection Out-of-Service, IAW API Standard 653 Contract Number, Task Order W9128F-10-D-0075, Task Order 006 Prime Contractor Name Cape Environmental Management, Inc.

Inspector, Cert. #, Inspection Company Jerry J Dupre Jr, Certification ID: 3026, CAPE Manufacturer, Date, Design Standard Unknown/ 1995 / API 650 Diameter 27'-0" Shell Height/Safe Fill Height 28'-2" / 23'-2" Product/Specific Gravity Jet-A / 0.85 Design Pressure/Temperature Unknown / Ambient Gross Capacity/Nominal Capacity 2500 Barrels GPS Latitude & Longitude Latitude: N 31° 28'43.25"N / Longitude: W 85° 50.42"W Foundation Configuration Concrete Ringwall Shell Configuration Butt-welded Floor Configuration Lap-Welded, Cone Down Roof (Fixed, Floating or Both, Seal Type) Self Supporting Umbrella Dome, Full Contact Aluminum Panel, Double Foam Log Type Seal.

Cathodic Protection Impressed Current Stilling Wells (Size, Application) 1- 8" CS Stilling Well (Vertical Ladder) and 1-10" CS Last Inspection (Type, Date) 2004, Out-of-Service Last Coated Internally (Product) Unknown Last Coated Externally (Product) Unknown

Tank Re-Calibration to 1/16 in. N/A Stilling Wells N/A Coating (Specify Systems, Location) N/A Floor (Including Sump) N/A Shell N/A Vents / Appurtenances N/A Secondary Containment N/A Other: N/A General Comments N/A

Tank Inspection Summary Sheet

Upgrades / Repairs Made at this Time

Preliminary Findings/Recommendations Report Tank # 25647, Fort Rucker, AL Molinelli Field

1.0 Background and Overview

Tank # 25647 is a 2,500 barrel Above Ground Storage Tank that currently stores Jet-A fuel. The tank is 1 of 2 currently used in bulk storage capacity.

The tank was originally constructed in 1995 to API 650 design standard with a nominal diameter of 27’-0” feet and a nominal shell height of 28’-2” per original construction. The tank bottom configuration is a 0.3125” nominal thickness cone down lap-welded bottom and what appears to have 5% downward slope to the center sump. The fixed roof consists of a self-supported CS lap welded umbrella dome cone up design. The fixed roof rafters are welded to pads that are welded to the shell. The internal floating roof (IFR) is a full contact aluminum honeycomb panel type roof with a double foam log type seal manufactured by Petrex. The tank has an impressed current cathodic protection system. The tank has secondary containment and leak detection under the bottom. An MFL bottom scan was conducted revealing no significant underside corrosion. The containment area is constructed of earth with FML liner with concrete slabs and vertical walls. The tank foundation consists of a concrete ringwall.

Tank #1 does not meet the minimum requirements of API standards to remain in service. The primary seal had product trapped in it and did not contact the shell. The seal is currently scheduled to be replaced with a double wiper seal as part of the current SOW on this tank. Consideration should be given to the other findings and recommended repairs listed below. The next scheduled out-of-service internal inspection is due within 10 years. The next external ultrasonic inspection is due within 15 years. The next external visual inspection is due within 5 years. The findings listed below are based upon observations while on site and historical information obtained from the Owner/Operator in the form of previous inspection reports.

2.0 Findings and Recommendations

On February 19, 2015 an out-of-service inspection was completed on Tank # 25647 at the Molinelli Stagefield facility Fort Rucker, in Alabama by Cape Environmental Management Inc, Certified API 653 Inspector Jerry Dupre Jr (Certification ID: 3062). The purpose of the inspection was to gather data necessary to determine the serviceability of the tank and compliance with applicable codes and standards. The findings and recommendations are based on field observations, historical drawings and previous inspections.

The following tables show a summary of findings and corresponding recommendations from the out-of-service inspection. Where applicable, notes are included in the recommendations concerning the current SOW associated with programmed repairs on this TO. The findings are separated into four categories:

Mandatory Recommendations (Table 1): Items that require immediate action based on tank failure during next in-service operation. Local Federal or State regulations that are not met. Items that need to be made to prevent safety failures or accidents.

Near Term Recommendations (Table 2): Items that are a significant deficiency based on API 650 & 653, UFC, and UFGS guidelines that impact daily operation of tank.

Long Term Recommendations (Table 3): Items that do not meet current guidelines that do not present the unsafe operation of the tank.

Monitoring Recommendations (Table 4): Items that are performed by the Owner/Operator as regular maintenance.

Stilling Well Configuration (Table 5): Provides information concerning the existing or planned configuration of stilling wells as applicable.

This table also conveys the type tank gauging system that is installed.

Table 1- Mandatory Recommendations

Item # Finding Recommendation

1.1

Internal Floating Roof (IFR) Mandatory Findings:

The internal floating roof (IRF) double foam log seal was found to have product in the seal and not in contact with the shell. The seal was cut to allow the product to drain in order to gas free the tank.

Ref: API Standard 650, Section H.4.4 and UFC 3-460-01, Section 2- 14.4.2.

Install a new double wiper peripheral seal on the IFR per UFGS 33.56.13.13.

Para.2.13.2.7 guidelines.

Note: The new double wiper seal is part of the current SOW.

Table 2- Near Term Recommendations

2.1

Bottom Near Term Findings:

The internal piping supports are nonadjustable. Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail A4.

Replace the internal piping supports with supports in accordance with DoD Standard Design guidelines. 11 Each

2.2 The current configuration on the existing 10” CS stilling well is not completely slotted and has a base that does not meet current DOD guidelines.

Recommend installing a new stilling base per current DOD Guidelines.

Note: this stilling well currently accommodates the ENRAF tank gauging system.

2.3

The tank currently has a vertical ladder with a safety climb installed to allow access to the top side of IFR while the tank is in service.

The vertical ladder has an 8” CS stilling well that is not completely slotted.

Recommend installing a new 8-inch stilling well per current DOD designs.

NOTE: this is currently required under the existing SOW

2.4 The tank bottom has an abandoned tank gauge float base welded directly to the tank bottom with no pad.

Recommend removing the abandoned float base.

2.5 The tank bottom coating has an excessive amount of coating repairs with isolated areas of failure.

Recommend removing the existing coating and installing a new protective coating system per current UFGS guidelines. NOTE: See item 2.20 below.

2.6

Shell and Appurtenances Near Term Findings:

Tank 1 currently has a water draw tank with an electric pump that does not work. The motor is mounted on the containment floor and goes under water during significant rain events. However their currently is no piping configured to test the level alarms. Ref: UFC 3-460-01, Table 8-1(z) and DoD Standard Design AW 78-24-27, Drawing D.13, Note A1.

Install a new Water Draw tank and the necessary piping to test the tank level alarms per current AW 78-24-27 Standard Design guidelines Section

33.56.13.13. Paragraph 2.13.14.

Note: 1) The pump motor needs to be mounted horizontally and off the containment bottom.

2) The water draw tank on tank 2 does not work as well.

G6ODMMJM

Sticky Note SP-C: Included in TG 17 T.O. SoW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Nonconcur. Leave as is.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required. Installation of new 8" alum. stilling well is included in the TG 17 T.O. SoW. Removal of the existing well would be a MOD, but the installation of a new well would not. Physically modifying the existing well and allowing reuse would not be a MOD.

POL-TCX: Add slots to existing stilling well to be completely slotted in accordance with DOD AW 78-24-27.

G6ODMMJM

Sticky Note

SP-C:

- Abandon existing ladder/well combo to operate solely as a ladder.

- POL-TCX guidance required on need to slot existing well if it is abandoned in place.

- Installation of 8" well included in TG 17 T.O. SOW.

POL-TCX: Concur

- The existing ladder/well combo does not require slotting.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Concur.

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note

SP-C:

- Concur on electric pump replacement and relocation to a higher elevation.

- Concur on repair of non-functional PRT appurtenances (discussed with CAPE via phone conversation on 3/11/15).

- Non-Concur on PRT replacement in its entirety.

- Piping to test the level alarms is included in the TG 17 T.O. SOW.

POL-TCX: Concur with SP-C

APC0042

Sticky Note APC Concurs with the replacement of the pipe supports. They are non-standard, and causing the coating to wear off the pipe.

2.7

The receipt and issue lines currently have a thermal relief system installed they have a mix of threaded and welded connections.

However the 1” mix of CS & SS piping has no test tees, lockable valves, and currently has visiflow valves installed. Ref: UFC 3-460- 01, Table 8-1(k); UFGS 33 56 13.13 Section 3.5; and DoD Standard Design AW 78-24-27, Drawing D.10, Detail A3.

Modify the existing thermal relief piping on the receipt and issue lines per current UFC, UFGS, and AW 78-24-27 guidelines.

2.8 The product issue piping currently does have a anti-vortex plate, however it is not 1/2 radius and extends to the tank center sump.

Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail A1.

Modify the internal product issue piping per DoD Standard Design guidelines.

2.9 There is currently no 2-inch DDB valve installed at the shell for the water draw system. Ref: Ref: UFC 3-460-01, Table 8-1(z).

Install a new 2-inch DBB valve on the tank per UFGS 33 52 43.13 guidelines.

Note: the current internal water draw piping is ¾” diameter and not 1” per current DOD guidelines.

2.10 The external shell coating is in fair condition. However there was isolated areas of failure noted. Approximately 5 square feet

Recommend installing a new protective coating system on the areas of failure. The current SOW is limited to 500 SF of coating repairs.

2.11 The two (2) 36” manways in the 1st shell course have hinges.

NOTE: The intermediate man way in the second shell course has a “I” beam and winch to remove the cover.

Consideration should be given to installing new davit arms per UFGS

33.56.13.13 para.2.13.16 on the two manways.

2.12 The 2 existing 36” manway in the 1st shell course. Cover does not have a filler drum to protect the IFR seals if the IFR is placed in the low leg position.

Install new filler drum per current UFGS guidelines section 33.56.13.13 para.2.13.16. No picture of this item.

2.13 The current LLA does not work properly in conversation with base personnel.

Recommend repair of the LLA – Alarm system repair is currently covered by the SOW Note current alarm is a magnetrol.

2.14 The current moisture barrier has failed around the entire perimeter of tank 1.

Install a new moisture barrier per current UFGS guidelines. NOTE the current SOW includes up to 1,400 LF of sealant, this task requires 85 LF

2.15 The existing Varec tank gauge piping supports are welded directly to the shell with no pads. (4)

Recommend installing 4 new pads per current API 653 guidelines.

2.16 The existing internal piping for the 8” stripper, 8” issue, 4” stripper, and ¾” water draw piping do not have flanges at the shell.

Recommend installing flanges at the shell per current DOD and API guidelines.

2.17 The spiral stairway platform support attachment to shell have no pads. (4)

Recommend installing pads under these items per current API guidelines.

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur on installation of 2" DBBV and code compliant piping.

POL-TCX: Concur with installing DBB. Leave piping as 3/4"

G6ODMMJM

Sticky Note SP-C: Concur. 500 SF of repair included in the TG 17 T.O. SOW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Leave as is.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Install new filler drum

G6ODMMJM

Sticky Note SP-C: Included in TG 17 T.O. SOW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur. 1400 LF of repair included in the TG 17 T.O. SOW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Leave as is.

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Nonconcur. Leave as is.

2.18 The shell currently has a 1” abandoned temperature probe and 2 additional couplings in the shell.

Recommend removing the abandoned 1” couplings and installing a new lap patch over the area per current API 653 guidelines.

2.19 The underside of the spiral stairway treads are not completely seal welded to the shell.

Recommend seal welding the 39 treads per current DOD and API guidelines.

2.20

The internal shell coating are in poor condition with areas of isolated failure and very excessive entrapment that is damaging the IFR seals.

Recommend removing the existing coatings and installing a new protective coatings on the entire shell per current UFGS guidelines: NOTE see item

2.29 below. Due to the extent of failures to the internal protective coating system, consideration should be given to complete internal coatings. If complete internal coatings are required by the owner, consideration should be given to replacement of the IFR, this will expedite internal coatings effort.

On small diameter tanks such as this, this approach is generally lower in cost than attempting to paint over the IFR, or remove and re-install the IFR.

2.21

Internal Floating Roof (IFR) Near Term Findings:

There is one (1) existing anti-rotation cable clip that is attached to the tank bottom with no bearing plate.

Install 2 new ¼” anti-rotation cables per current AW 78-24-27 guidelines

2.22 The existing vacuum breaker, vertical ladder, and manway seals have significantly deteriorated and do not have a bonding strap connecting them to the IFR.

Install new seals and grounding straps per current UFGS 33.56.13.13 para.2.13.2.9 guidelines. NOTE: See Item 1.1

2.23

The tank bottom has four (4) IFR support legs with no Teflon feet installed. The current configuration has seal welded CS plates.

These legs currently do have notches in them to allow product drainage.

Recommend installing Teflon feet on the four legs to prevent coating damage.

2.24 The IFR currently has one (1) hole in it. Recommend making proper repair on this hole per manufacturer recommendations.

2.25 The 36” IFR manway cover is missing the cover hold down bar and wing-nut.

Recommend installing a new hold down bar and wing-nut per manufacturer guidelines.

No picture of this item.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Nonconcur. Leave as is.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Nonconcur. Leave as is.

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur. Discuss with owner extents of repairs.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Provide one additional anti-rotation cable opposite of the existing cable.

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur with installation of Teflon feet and notching of the leg bottoms to allow drainage.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

APC0042

APC recommends the full coating and the replacement of the IFR. USACE PM should coordinate with Mike Ingram for final approval based on mission impact due to additional out of service time.

2.26 The top side of the IFR has a significant amount of spent blast media on it trapped between the foam dam and seal.

Recommend removing the spent blast media

2.27

Fixed Roof Near Term Findings:

The current configuration of the fixed roof has no scaffold supports.

Install scaffold supports on the fixed roof per current API & UFGS

33.56.13.13 para.2.13 guidelines.

Note: Consider programming this requirement the next time the full exterior of the tank requires coating.

2.28

The fixed roof has isolated areas coating failures on the roof and nozzles with heavy mildew across the entire roof. The 360 degree handrails and walkway grating coating has failed completely it is peeling and not bonded.

Recommend repairing the failed areas of protective coating system per UFGS guidelines. Total of 600 square feet.

2.29

The underside of the fixed roof coating has failed across the entire roof

Recommend removing and installing a new protective coating on the underside of the fixed roof. Total area is approximately 825 SF which includes an allowance of 3-feet of the upper shell to tie into the shell coatings.

NOTE: see Item 2.20 above, the SF area would be reduced if the internal shell is recoated.

2.30 The current configuration of the fixed roof does not have a center vent per current API and DOD guidelines.

Recommend installing a new center vent per current API guidelines.

2.31 The fixed roof perimeter vents are not hinged to allow visual inspection of the IFR during operation.

Recommend removing the existing perimeter vents and installing new hinged perimeter inspection / vent hatches per current API and DOD guidelines.

2.32

Containment Area Near Term Findings:

The existing containment area consists of earth with a FML liner and concrete slabs for ballast. The liner where attaches to the four

(4) leak detection piping has failed and is deteriorated and not bonded to the liner or piping. Also the valves are pvc and not lockable.

Repair the Failed liner per manufacturer recommendation and install new 2’ diameter valves.

Note: if the valves are to be replaced the concrete ballast slab will have to be removed in these area.

G6ODMMJM

SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Non-Concur - Install scaffold supports upon re-coating of tank exterior.

POL-TCX: Concur with SP-C

G6ODMMJM

Sticky Note SP-C: Concur. 500 SF of repair included in the TG 17 T.O. SOW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Leave as-is. The roof manway is in the center of the roof. The roof plates themselves serve as the roof structure (no roof framing) so adding an additional roof penetration may affect the structural integrity of the roof itself.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Nonconcur. Leave as is.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Repair failed liner per manufacturer recommendations. Do not install new valves.

Table 3- Long Term Recommendations

3.1 The current bottom nominal thickness is 0.250” and not 0.3125” per current DOD guidelines.

The MFE floor-scan and ultrasonic thickness reading measurements revealed no significant metal loss. Recommend monitoring and at the next out-of-service inspection compare the new readings to verify no metal loss.

3.2 The current internal diffuser is oval shaped and not cowbell and is pointed in the wrong direction per current DOD guidelines.

If deemed necessary per engineering or tank owner replace with new diffuser per current DOD guidelines.

3.3 The current screening on the shell overflow and fixed roof perimeter vent allow a significant amount of wasps in the tank on top of the

IFR.

Consideration should be given to installing insect screening on these items.

3.4 The crossover stairs into the tank containment area has a run of 4” and a rise of 9”. This makes climbing these steps unsafe and you have to turn your feet sideways when climbing.

Consideration should be given to installing a set of crossover stairs per current OSHA guidelines.

3.5 All of the tank marking have deteriorated or missing. NATO, receipt, issue, stripper, and water draw markings as well a gauge heights.

Recommend installing all new tank markings per current DOD guidelines.

Table 4- Monitoring Recommendations

4.1 Perform regular in-house inspections of the tank. Maintain the inspection records for historical reference.

4.2

When the bottom was installed during original construction the chime extension was notched to accommodate the anchor bolts. This notching leaves the extension less than 2”. There was no visual evidence of corrosion or thinning at the time of inspection.

Due to the successful in service operation and no history of failure. It is recommend to monitor this area and verify that no corrosion or thinning develops during the next in service operation.

Table 5- Stilling Well Recommendations

5.1

The tank does not have a 8" MTG or ATG stilling well installed per UFC 3-460-01, Table 8-1(p).

Install an 8" MTG and ATG stilling well per UFC guidelines.

Note: No picture of this item.

Stilling well installation / upgrade are part of the existing SOW Note: See items 2.2 and 2.3.

G6ODMMJM

SP-C: Included in the TG 17 T.O. SOW.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance is required.

POL-TCX: Concur

G6ODMMJM

Sticky Note

SP-C:

- Non-concur on diffuser replacement.

-THERE IS NO WRONG DIRECTION. The inclusion of this recommendation was due to a recent comment from the military, which was determined to be unfounded.

POL-TCX: Concur with SP-C

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Insect screens are not allowed, only bird screens. Leave as-is.

G6ODMMJM

Sticky Note SP-C: POL-TCX guidance required.

POL-TCX: Concur

G6ODMMJM

Sticky Note SP-C: Concur.

POL-TCX: Concur

Photographs

Item 1.1- IFR Foam Log Seal

Item 2.1 - Internal Piping Supports Non Adjustable

Item 2.2 – Existing 10” CS Stilling Well Base

Item 2.3 – Vertical Ladder Base

Item 2.4 – Abandoned Tank Gauge Float Base

Item 2.5 – Tank Bottom Coatings

Item 2.5 – Tank Bottom Coatings

Item 2.6 – Water Draw Tank

Item 2.7 – Thermal Relief Lines

Item 2.7 – Thermal Relief Lines

Item 2.8 – Internal Issue Line Piping

Item 2.9 – Water Draw Valve

Item 2.11 – Manway Cover Hinge

Item 2.13 – LLA

Item 2.14– Moisture Barrier

Item 2.15– Varec Tank Gauge Piping Supports

Item 2.16– Internal Piping with no Flange at Shell

Item 2.17 – Spiral Stairway Supports

Item 2.18 – Abandoned Temperature Probe

Item 2.19 – Underside of Spiral Stairway Treads

Item 2.20- Internal Shell Coating Failure

Item 2.20- Internal Shell Coating Failure

Item 2.21- Existing Anti-Rotation Cable Base

Item 2.22 – IFR Penetration Seal Failure

Item 2.23- IFR Support Leg Base

Item 2.24- Hole in IFRItem 3.1- Intermediate Manway

Item 2.26- Spent Blast Media on Top of IFR

Item 2.28- Fixed Roof Coating Failure

Item 2.29- Underside of Fixed Roof Coating Failure

Item 2.30- No Center Vent on Fixed Roof

Item 2.31- Fixed Roof Perimeter Vent

Item 2.32- Leak Detection Ringwall Penetration

Item 3.2- Receipt Line Internal Diffuser

Item 4.2- Anchor Chair with Chime Extension Notched