Attachment J1 - SP-POL-CMP-INSPECT-FY25-FWY Tank 481 FINAL 2021.pdf

API 653 In-Service Inspection Report Fort Wayne, Indiana

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

FORT WAYNE, INDIANA

TANK 481

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

(USACE POL-MCX)

11 MAY 2021

Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

SUMMARY OF INSPECTION

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

ARCTIC TESTING & INSPECTION PRESONNEL

GENERAL TANK INFORMATION

GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

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

FINDINGS AND RECOMMENDATIONS

REQUIRED REPAIRS TO FULLY COMPLY WITH API 653, UFC 3-460-01, OR AW 78-24-27 STANDARDS

RECOMMENDED REPAIRS AS PART OF REGULAR MAINTENANCE

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATION

SHELL UT MEASUREMENTS

CRITICAL ZONE SHELL THICKNESS

NEXT INSPECTION

SHELL NOZZLE / REPAD UT MEASUREMENTS

ROOF UT MEASUREMENTS

FIXED ROOF NOZZLE / NECK UT MEASUREMENTS

SHELL LAYOUT DRAWING

FIXED ROOF LAYOUT DRAWING

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX E: 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

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

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

SUITABILITY FOR SERVICE

It is recommended that the owner / user reviews, evaluates, and implements the recommendations set forth in Section

3. Inspection Summary, of this report or, the owner / user may determine that no action(s) need be taken prior to continued service and such decision(s) should be documented in the AST historical record file.

It is recommended that the owner / user adheres to the safe fill height recommendations given herein in Section 3 for continued service until such time as tank operating conditions change or another inspection assessment per API 653 guidelines determines that an adjustment in safe operating height for this tank should be made.

SUMMARY OF INSPECTION

USACE contracted with Arctic Testing & Inspection, to provide an API 653 In-Service (Visual and Ultrasonic Thickness inspection) for Tank 481 located at the Indiana ANG facility in Fort Wayne, Indiana on May 11th, 2021.

Tank No. 481 was constructed to API 650, 6th Edition by Chicago Bridge & Iron Co. in 1978 with a nominal diameter and height of 25.00 ft x 24.00 ft. and a nominal capacity of 85,000 gallons of Jet Fuel (F-24. The Tank was modified in 2004 to increase the shell height from 24.00 ft. to 31.10 ft. with a maximum liquid level height of 29.10 ft and a capacity of 109,645 gallons (per Repair / Alteration Nameplate).

May 11th, 2021, an In-Service API 653 inspection was completed on Tank 481 by Arctic Testing & Inspection. The findings and recommendations are based on field observations, and previous inspection.

The tank is resting on a concrete ringwall with adequate impressed current deep bed anode cathodic protection system.

Per previous report, an underground secondary tank is present beneath the containment area. The concrete containment area is shared with Tank 481 and Tank 482.

In 2018 all repairs and upgrades that were noted in the 2015 out-of-service inspection by Cape Environmental Management Inc. were performed.

The next out-of-service internal inspection is due in 2025.

The next Visual (VT) external inspection should be conducted within 5 years and no later than May 2026 (ref. API 653, Para. 6.3.2.1).

Shell Ultrasonic (UT) testing should be conducted again within 5 years and no later than May 2026 (ref. API 653, Para.

6.3.3.2.b) to establish an accurate corrosion rate. Complete API 653 out-of-service inspection prior to this date would supplement the next external inspection requirement.

No mandatory repairs were discovered during this inspection.

INSPECTION DATE

API In-Service (External) Inspection Date: 11 May 2021

Equipment Used:

Ultrasonic

MODEL SERIAL NO.

Olympus Epoch 650 150074607

TRANSDUCER SERIAL NO. FREQUENCY SIZE

BD-317RM B7933 5 MHz 0.312 inch

CALIBRATION BLOCK SERIAL NO.

5 Step Calibration Block 07-5106

Level

TYPE MODEL

Self-Leveling Laser Rugby 100

The pit gauge utilized was a W.R. Thorpe Co. standard pipe pit gauge.

Inspector(s): Nick Solomon and Matt Windham

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: 23 September 2015

API In-Service (External) Inspection Date: Unknown

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

API Out-of-Service (Internal) Inspection Date: September 2025

API In-Service (External) Inspection Date: May 2026

API Ultrasonic Thickness Inspection of Shell Date: May 2026

ARCTIC TESTING & INSPECTION PRESONNEL

Nick Solomon

API 653 Aboveground Storage Tank Inspector

44063

Matt Windham

Level II NDE Inspector

Report Created by:

Candice Theriot

Technical Report Writer

Reviewed by:

Jose Parrales

API 653 Aboveground Storage Tank Inspector

87413

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Army Location ANGB - 122ND Fighter Wing Facility Number 4811 Tank Number 481 State / Country Indiana / U.S.A City Fort Wayne Inspection Date May 11, 2021 Tank Manufacturer Chicago Bridge and Iron Company Design Standard API 650, 6th Edition Date of Construction 1978 (Repair / Alteration Completed in 2018) Tank Contents Jet Fuel A (F-24) Design Specific Gravity 1.00 (per Nameplate) / 0.85 (per Repair / Alteration Nameplate) Product Specific Gravity 0.76 to 0.84 Design Pressure Atmospheric Tank Serial Number N/A Nameplate Present Yes and Repair / Alteration Nameplate Tank Diameter 25.00 ft.

Shell Height 31.10 ft. (per Repair / Alteration Nameplate) Product Height 29.10 ft. (per Repair / Alteration Nameplate) Tank Capacity 109,654 gals (per Repair / Alteration Nameplate) Foundation Concrete Ringwall w/ Concrete Apron

Construction

Bottom Lap Welded Shell Butt Welded Floating Roof N/A - In-Service Fixed Roof Lap Welded Cone w/ Framing

Material

Bottom N/A - In-Service Shell A283-C Floating Roof N/A - In-Service Fixed Roof Carbon Steel of Unknown Grading

Cathodic Protection Yes Interior Coating System N/A – In-Service Exterior Coating System White Paint – External (Coating Specs Unknown) Last Inspection September 2015 (Out-of-Service) Last Coated 2018 (Coating Specs Unknown) Fixed Roof Access Spiral Stairway Floating Roof Access Fixed Roof Access Hatch Type of Internal Floating Roof N/A - In-Service

GENERAL PROJECT INFORMATION

1. API 653 Inspection API 653 In-Service (Visual & Ultrasonic Thickness) Inspection was performed.

2. Site Information May 11, 2021, Arctic Testing & Inspection performed an API 653 In-Service Inspection on Tank 481 located at Indiana ANG facility in Fort Wayne, Indiana.

TANK INSPECTION COMMENTS

1. Tank Construction Tank 481 is a nominal 109,654 gallons, 25-ft. diameter by 31.10-ft., jet fuel (F-24), aboveground storage tank. Per the information on the tank data plate, the tank was constructed in 1978 by Chicago Bridge & Iron Company to API 650 design standard, 6th Edition. As-built drawings of the original construction are not available at this time.

2. Tank Foundation The tank rests on a concrete ringwall foundation. Per previous report, an underground secondary tank is present beneath the containment area. The foundation was visually evaluated during the inspection and was found to be in acceptable condition. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard 653 and was found to be acceptable. Settlement results are listed in Appendix A.

3. Tank Shell The vertical tank shell consists of four butt-welded courses. A 7-inch insert ring was installed in 2004 above Course 4 to raise the height of the tank from 24.00 ft to 31.10 ft. The exterior of the shell was visually inspected and found to be in acceptable condition. The shape of the shell appears to be within the allowable tolerance if API Standard 653. The coating was also evaluated and in acceptable condition. The current In-service external inspection performed in May 2021 included ultrasonic thickness measurements of the shell and indicated the shell had more than 30 years of remaining life at that time.

4. Tank Appurtenances

a. Fixed Roof

The tank is constructed with a lap welded Cone with framing fixed roof. The fixed roof was found to be in acceptable condition. One 10-inch center Vent and (4) perimeter hood vents, perimeter guardrail, roof nozzles and associated flanges, and (2)access hatches.

b. Gauging The tank’s gauging system (manufactured by Honeywell) located at the containment walkway is installed through a 10-inch nozzle on the Fixed Roof adjacent to the stairway platform. The tank also has a ATG (Automatic Tank Gauge) (manufactured by Shand & Jurs) tape level gauge does not appear to be working properly.

c. Level Alarms The high-level alarm chamber is mounted on the exterior of the tank shell and is accessible from the stairway. The tank is equipped with low-low, low, high, and high-high level alarms independent of the tank gauging system as required by military criteria.

d. Stairs and Platforms The tank’s steel roof is accessible by a circumferential stairway mounted on the shell of the tank. Stairway was found to be in acceptable condition.

e. Grounding and Bonding There are four grounding cables connected to ground lugs welded to the tank shell.

5. Tank Coating The external coating system appeared to be a standard military coating system (epoxy-epoxy-polyurethane). The exterior coating system on the tank shell and fixed roof was found to be in good condition overall.

6. Tank Piping System There is an 8-inch carbon steel piping (Issue Line) and a 6-inch carbon steel piping (Receipt Line). There is also a 4-inch carbon steel (Not Labeled) pipe adjacent to the manway that runs to Tank 482.

7. Fire Protection System There is no fire protection system present on the tank. UFC 3-460-01 does not require AFFF systems on tanks storing Class II and Class III liquids.

8. Secondary Containment The tank sits within a shared concrete secondary containment area with vertical concrete walls. The containment is of sufficient size to contain a total tank loss plus. The secondary containment floor slops towards the drain that is approximately 20 ft. away from Tank 482 to allow for drainage away from the tank, not to the dike wall as required by NFPA 30. The secondary containment was visually evaluated during the inspection. The secondary containment expansion joint seals have failed in isolated areas. There is a small amount of vegetation growth located in the containment area joints.

FINDINGS AND 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.

Manways

OBSERVATION: Tank currently has one (1) 24-inch Manway present and was found to be in acceptable condition per API 650 / 653 requirements.

REFERENCE: UFC 3-460-01 Table 8-1, Item F RECOMMENDATION: Installing two (2) 36-inch Manways, at 180 degrees from each other, with davits arms.

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.

Concrete Containment Area

OBSERVATION: The tank is resting in a concrete containment area. The Visual (VT) inspection noted isolated areas of hairline cracking and breakage present on the containment bottom and walls.

RECOMMENDATION: These areas should be sealed to minimize further degradation of the foundation from moisture penetration corroding the reinforcement or from freeze / thaw cycling further opening these cracks.

Subdivision

OBSERVATION: Containment area should require a subdivision to separate the area from each tank due to tanks exceeding 2,000 bbls.

REFERENCE: UFC 3-460-01, Para. 8-14.1 RECOMMENDATION: Install subdivision to separate the tanks.

Moisture Barrier for Containment

OBSERVATION: The moisture barrier in the containment area was found to be deteriorating in isolated areas at the time of the inspection.

REFERENCE: UFC 3-460-01, Para. 8-14.5 RECOMMENDATION: Installing or repairing the affected areas with an appropriate moisture barrier to seal against water intrusion under the tank bottom.

Vegetation

OBSERVATION: There are isolated areas of vegetation growth present in the containment area.

REFERENCE: NFPA 30, Para. 6.9.4 and UFC 3-460-03, 8-4.3.1, 8-10.2.1, 8-10-3.1,8-10.5.1, and UFC 3- 460- 03, Appendix C RECOMMENDATION: Removing the vegetation.

Moisture Barrier for Foundation

OBSERVATION: The moisture barrier is starting to separate from the external bottom edge projection plate and the concrete ringwall in isolated areas around the tank at the time of the inspection.

REFERENCE: UFC 3-460-01 Para. 8-8.5.

RECOMMENDATION: Repairing the affected areas with an appropriate moisture barrier to seal against water intrusion under the tank bottom.

Shell

OBSERVATION: There are isolated areas of minor shell deformation noted around the tank that appears to have been caused by repairs.

RECOMMENDATION: Performing a verticality survey at the next out-of-service inspection.

Fixed Roof

OBSERVATION: There are isolated low areas around the fixed roof perimeter with dirt and debris present.

RECOMMENDATION: Properly cleaning and re-coating the affected areas if necessary, at the next available opportunity.

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

The survey found the tank to be out of level by 0.60 inch. API 653 calculation for deflection of this tank is 0.18 inch. API 653 maximum deflection permitted for this tank is calculated to be 0.21 inch. Differential settlement calculations for this tank do not exceed the API allowable (ref. API 653, Annex B, Para. B.3.2).

0.05

0.18

0.31

0.36

0.31

0.18

0.05

0.00

0.36

0.24

0.12

0.24

0.12 0.12

0.24

0.36

0.1

0.2

0.3

0.4

1 2 3 4 5 6 7 8 1

SE

TT

LE

M

EN

T

(IN

STATION LOCATION

Shell Settlement (Survey Data) Vs.

Planar Settlement (Cosine Curve)

Cosine Survey

-0.25 -0.20 -0.15 -0.10 -0.05 0.00 0.05 0.10 0.15 0.20 0.25

1 2 3 4 5 6 7 8 1

D ef le ct io n

(in

Station Location

Differential Settlement Evaluation Calculated Deflection Positive Permissible Negative Permissible

The survey was conducted counterclockwise from the reference Shell Manway A located at Station

0.00. The circumferential distance between the readings is 9.81 feet.

Point No.

Shell Settlement Reading (ft.)

1 5.89 2 5.87 3 5.84 4 5.84 5 5.85 6 5.85 7 5.85 8 5.86

SHELL THICKNESS CALCULATION

The minimum acceptable shell plate thickness for tanks with a diameter equal to or less than 200 feet is calculated as follows (API 653, Para. 4.3.3.1):

t

H DG

SE

min

−2 6 1

Where:

S = See Table = Allowable Stress (psi) D = 25.00 = Nominal Diameter of Tank (ft.)

G = 1.00 = Highest Specific Gravity of Contents H = See Table = Product Height (ft.)

E = See Table = Joint Efficiency

Course Course Height

(ft.)

Product Height

(ft.)

Joint Efficiency

Allowable Stress (psi)

Average Thickness

(in.)

Required Thickness

(in.)

Meets Required Thickness

1 8.00 31.10 0.85 23,600 0.186 0.100 Y 2 8.00 23.10 0.85 23,600 0.193 0.100 Y 3 7.03 15.10 0.85 26,000 0.196 0.100 Y 4 8.07 8.07 0.85 26,000 0.206 0.100 Y

Shell thickness calculations indicate the safe fill height of 31.10 feet can be utilized with product (design) specific gravities up to 1.00 (ref. API 653, Para. 4.3.3.1). These calculations do not take into account operational restrictions imposed by such items as any internal or external floating roof, internal pressure, overflow vents, etc.

SHELL UT MEASUREMENTS

SHELL ULTRASONIC THICKNESS READINGS

(in inches)

RDG

NO/ID

DROP 1 (STAIRWAY)

COURSE 1 COURSE 2 COURSE 3 COURSE 4

1 0.186 0.192 0.177 0.194 2 0.187 0.191 0.202 0.193 3 0.188 0.193 0.206 0.194 4 0.191 0.193 0.205 0.215 5 0.186 0.196 0.207 0.217 6 0.185 0.197 0.208 0.216 7 0.184 0.194 0.190 0.216 8 0.183 0.192 0.188 0.192 9 0.183 0.193 0.188 0.212

10 0.183 0.192 0.188 0.206 Avg.: 0.186 0.193 0.196 0.206 Min.: 0.183 0.191 0.177 0.192

READINGS

COURSE 1 PLATES

1 2 3 1 0.188 0.185 0.194 2 0.184 0.194 0.187 3 0.188 0.193 0.192 4 0.181 0.185 0.186 5 0.192 0.184 0.186

Avg.: 0.187 0.188 0.189 Min.: 0.181 0.184 0.186

2 5

CRITICAL ZONE SHELL THICKNESS

PROJECTION PLATE ULTRASONIC THICKNESS READINGS

(1 FT. INCREMENTS)

UT

POINT

PROJECTION PLATE

POINT READINGS

UT

POINT

PROJECTION

PLATE POINT

READINGS

UT

POINT

PROJECTION PLATE

POINT READINGS

1 0.259 27 0.257 53 0.259 2 0.248 28 0.263 54 0.251 3 0.237 29 0.254 55 0.248 4 0.251 30 0.257 56 0.253 5 0.252 31 0.253 57 0.247 6 0.245 32 0.255 58 0.263 7 0.249 33 0.284 59 0.258 8 0.242 34 0.264 60 0.257 9 0.244 35 0.255 61 0.263

10 0.255 36 0.267 62 0.269 11 0.248 37 0.263 63 0.267 12 0.246 38 0.267 64 0.266 13 0.244 39 0.258 65 0.264 14 0.237 40 0.256 66 0.266 15 0.252 41 0.256 67 0.264 16 0.258 42 0.258 68 0.268 17 0.259 43 0.251 69 0.258 18 0.264 44 0.253 70 0.269 19 0.262 45 0.255 71 0.251 20 0.254 46 0.267 72 0.253 21 0.258 47 0.267 73 0.257 22 0.256 48 0.269 74 0.255 23 0.259 49 0.263 75 0.268 24 0.253 50 0.264 76 0.263 25 0.255 51 0.257 77 0.267 26 0.255 52 0.258 78 0.267

Avg. 0.257 Min. 0.237

NEXT INSPECTION

Shell thickness calculations indicate the safe fill height of 31.10 feet can be utilized with product (design) specific gravities up to 1.00 (ref. API 653, Para. 4.3.3.1). These calculations do not take into account operational restrictions imposed by such items as any internal or external floating roof, internal pressure, overflow vents, etc.

When the corrosion rate is not known, the maximum interval shall be 5 years (API 653, Para. 6.3.3.2 a). when the corrosion rate is known, the maximum interval shall be the smaller of RCA / 2N years or fifteen (15) years (API 653, Para 6.3.3.2 b).

Course Year

Original Construction

Year Thickness Measured

*Assumed Nominal

Thickness (in.)

*2021 Measured Thickness

(in.)

Shell Course Corrosion

Rate (in./yr.)

Remaining Corrosion Allowance

(in.)

1 1978 2021 0.188 0.186 0.00005 0.086 2 1978 2021 0.188 0.193 0.00000 0.093 3 1978 2021 0.188 0.196 0.00000 0.096 4 1978 2021 0.188 0.206 0.00000 0.106

∗ The above calculations are based on the average measured thicknesses and assumed nominal thicknesses. Remaining life could not be determined on courses where the actual thicknesses were greater than or equal to the past thickness readings.

The next Visual (VT) external inspection should be conducted within 5 years and no later than May 2026 (ref. API 653, Para. 6.3.2.1). This calculation is based on the formula RCA/4N (where RCA is the difference between the measured shell thickness and the minimum required thickness in mils, and N is the shell corrosion rate in mils per year).

Corrosion rate analysis could not be performed at this time due to lack of any previous shell thickness data available. Shell Ultrasonic (UT) testing should be conducted again within 5 years and no later than May 2026 (ref. API 653, Para. 6.3.3.2.a).

Complete API 653 out-of-service inspection prior to this date would supplement the next external inspection requirement.

SHELL NOZZLE / REPAD UT MEASUREMENTS

Item Description Pipe Size (in.)

Station (ft.)

CL

Elev.

(in.)

Reinforcing Plate Neck Thick (in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

(in.)

Comments Width

(in.)

Height

(in.)

Thick (in.) Shape

A Manway 24 0.00 30 60 50 0.198 A 0.497 0.584 0.495 Y 5 B Nozzle 8 6.60 13 20 22 0.253 D 0.495 1.141 --- Y Flush C Nozzle 2 7.80 30 --- --- --- --- 0.217 0.708 --- --- 28 D Coupling 0.75 8.50 --- --- --- --- --- --- --- --- --- --- Course 4 E Coupling 0.75 8.50 --- --- --- --- --- --- --- --- --- --- Course 4 F Coupling 0.75 8.50 --- --- --- ---- --- --- --- --- --- --- Course 4 G Nozzle 6 9.30 13 20 16 0.320 C 0.431 1.001 --- Y 5.50 H Patch Plate --- 13.20 4.50 7 9 0.238 D --- --- --- --- Flush I Patch Plate --- 13.30 30 4 4 0.187 B --- --- --- --- 28 J Overflow Vent --- 16.60 --- 24 12 --- --- --- --- --- --- --- Course 4 K Patch Plate --- 16.60 8 14 16 0.252 D --- --- --- --- Flush L Grounding Lug --- 18.40 --- --- --- --- --- --- --- --- --- --- M Overflow Vent --- 34.60 --- 24 12 --- --- --- --- --- --- --- Course 4 N Grounding Lug --- 35.70 --- --- --- --- --- --- --- --- --- --- O Stairway Top --- 38.10 --- --- --- --- --- --- --- --- --- --- Platform P Nozzle 1 46.90 65 -- --- --- --- 0.251 0.529 --- --- 64 Q Nozzle 1 46.90 34 --- --- --- --- 0.255 0.535 --- --- 33 R Nozzle 1 48.40 --- --- --- --- --- 0.256 0.535 --- --- --- Course 4 S Nozzle 1 48.40 --- --- --- --- --- 0.250 0.560 --- --- --- Course 4 T Nozzle 2 48.50 7 --- --- --- --- 0.207 0.711 --- --- 6 U Nozzle 2 50.30 7 --- --- --- --- 0.211 0.741 --- --- 6 V Grounding Lug --- 55.20 --- --- --- --- --- --- --- --- --- ---

Stations are measured in feet counterclockwise from Manway A.

Shape

COMMENTS

1-Inadequate weld spacing 2-Inadequate repad thickness 3-Inadequate repad dimensions 4-Inadequate centerline elevation 5-Less than 90° intersection w/ weld 6-No reinforcing plate 7-Square-cornered repad 8-Inadequate neck thickness 9-Plugged telltale hole 10-No telltale hole

A B C D E GF H I J LK

SHELL NOZZLE / REPAD UT MEASUREMENTS (CON’T)

Pipe Size (in.)

Station (ft.)

CL

Elev.

(in.)

Reinforcing Plate Neck Thick (in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

(in.)

Comments Width

(in.)

Height

(in.)

Thick (in.) Shape

W Overflow Vent --- 69.30 --- 24 12 --- --- --- --- --- --- --- Course 4 X Stairway Bottom --- 69.50 --- --- --- --- --- --- --- --- --- --- Y Nozzle 4 72.60 10 12 12 0.245 B 0.334 0.967 --- Y 3.50 Z Nozzle 1 73.10 34.50 --- --- --- --- 0.248 0.529 --- --- 33

AA Patch Plate --- 74.90 24 7 7 0.255 B --- --- --- --- 20 BB Grounding Lug --- 74.90 --- --- --- --- --- --- --- --- --- --- CC Automatic Gauge --- 75.90 --- --- --- --- --- --- --- --- --- ---

Shape

COMMENTS

1-Inadequate weld spacing 2-Inadequate repad thickness 3-Inadequate repad dimensions 4-Inadequate centerline elevation 5-Less than 90° intersection w/ weld 6-No reinforcing plate 7-Square-cornered repad 8-Inadequate neck thickness 9-Plugged telltale hole 10-No telltale hole

VERTICAL WELD SEAM LOCATIONS:

1 21.40 2 47.60 3 73.80 4 --- 5 --- 6 --- 7 --- 8 --- 9 --- 10 --- 11 ---

VERTICAL WELD OFFSET FOR COURSES 2, 3, 4, ETC.

2 3.10 3 11.20 4 5.90 5 --- 6 --- 7 --- 8 --- 9 ---

Total Strapped Circumference (feet): 78.60

A B C D E GF H I J LK

ROOF UT MEASUREMENTS

FIXED ROOF ULTRASONIC THICKNESS READINGS

(in inches)

PLATE

NO/ID

READING

READING

READING

1 0.221 0.202 0.219 2 0.198 0.196 0.204 3 0.200 0.200 0.194 4 0.192 0.192 0.194 5 0.190 0.189 0.193 6 0.188 0.194 0.193 7 0.215 0.194 0.195 8 0.222 0.196 0.199

Average: 0.199 Minimum: 0.188

FIXED ROOF NOZZLE / NECK UT MEASUREMENTS

Size (in.)

Plate No.

Neck Thick (in.)

Comments

A Nozzle 8 3 0.307 B Scaffold Support Hitch 4 3 0.243 C Nozzle 10 3 / 5 0.255 Center Vent D Nozzle 10 4 0.348 Gauge Hatch E Nozzle 10 4 / 5 0.346 F Access Hatch 77 x 25 5 0.180 G Scaffold Support Hitch 4 5 0.246 H Coupling 1.25 6 --- Auto Gauge I Coupling 1.50 6 --- Auto Gauge J Coupling 1.25 6 --- Auto Gauge K Coupling 2 7 --- Capped-Off L Access Hatch 48 x 36 8 0.243

06/01/2021

19304

USACE- FT. WAYNE

SHELL ROLLOUT

TITLE

CLIENT

TANK NUMBER

PROJECT NUMBER

DATE

NOTE: DRAWING NOT TO SCALE

T E S T I N G + I N S P E C T I O N

10865 STRANG ROAD

LA PORTE, TEXAS 77571

ITEM IDENTIFICATION

A= B= C= D= E= F=

24" MANWAY

8" NOZZLE

2" NOZZLE

0.75" COUPLING

0.75" COUPLING

0.75" COUPLING

GENERAL INFORMATION

1. DESIGN STANDARD: API 650

2. MATERIAL: CARBON STEEL (A283-C)

3. HEIGHT: 31'.10"

6. JOINT EFFICIENCY:

7. JOINT TYPE: BUTT WELDED

8.

9.

10. PRODUCT: JET FUEL A (F-24)

0.85

CONSTRUCTION YEAR: 1978

MANUFACTURER: CHICAGO BRIDGE AND IRON CO.

5. COURSES: 4

11. STAIRWAY: SPIRAL (CW UP)

12. COATING: WHITE PAINT-EXTERNAL

4. DIAMETER: 25'.00"

COURSE

AVERAGE

THICKNESS

(INCH)

REQUIRED

THICKNESS

(INCH)

HEIGHT

(FT.)

SHELL

G= 6" NOZZLE

H= 7" X 9" PATCH PLATE

I= 4" X 4" PATCH PLATE

J= OVERFLOW VENT

K= 14" X 16" PATCH PLATE

L= GROUNDING LUG

M= OVERFLOW VENT

N= GROUNDING LUG

O= STAIRWAY TOP

P= 1" NOZZLE

Q= 1" NOZZLE

R= 1" NOZZLE

S= 1" NOZZLE

4 0.206

0.196

0.193

0.186 0.100

0.100

0.100

0.100

8.00

8.00

7.03

8.07

SHELL LAYOUT DRAWING

MDW

DRAWN BY REVIEWED BY

JJP

A B C

ED F

G H I

J

K L

M W

N

O

XQP

R S

T U V Y Z

COURSE 1

COURSE 2

COURSE 3

COURSE 4

COURSE 1

COURSE 2

COURSE 3

COURSE 4

T= 2" NOZZLE

U= 2" NOZZLE

V= GROUNDING LUG

W= OVERFLOW VENT

X= STAIRWAY BOTTOM

Y= 4" NOZZLE

Z= 1" NOZZLE

AA= 7" X 7" PATCH PLATE

BB= GROUNDING LUG

CC= AUTOMATIC GAUGEAA BB

CC

MDW

05/27/2021

19304

USACE- FT. WAYNE

FIXED ROOF LAYOUT

REFERENCE

N

TITLE

CLIENT

TANK NUMBER

PROJECT NUMBER

DATE

DRAWN BY

NOTE: DRAWING NOT TO SCALE

T E S T I N G + I N S P E C T I O N

10865 STRANG ROAD

LA PORTE, TEXAS 77571

NOZZLE IDENTIFICATION

LEGEND

A= B= C= D= E= F= G=

8" NOZZLE

4" SCAFFOLD SUPPORT HITCH

H= I=

10" NOZZLE

10" NOZZLE

10" NOZZLE

77" X 25" ACCESS HATCH

4" SCAFFOLD SUPPORT HITCH

1.25" COUPLING

1.50" COUPLING

= PERIPHERAL VENT

= PATCH PLATE

= LOW AREA

FIXED ROOF LAYOUT DRAWING

REVIEWED BY

JJP

1 2

4 3

5 6

C

B

A

E

D

F

H

I

J

L

K

G

J= 1.25" COUPLING

K= 2" COUPLING

L= 48" X 36" ACCESS HATCH

PLATFORM

STAIRWAY

100% RAILING

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

FOUNDATION

ITEM DESCRIPTION GRADE COMMENTS

1 Inspect foundation for damage. 4 Acceptable

2 Search for indications of bottom leakage. 4 Acceptable

3 Inspect containment area for damage. 3 Reference Summary

4 Inspect for cavities under foundation of tank. 4 Acceptable

Inspect the area for buildup of trash, vegetation, and other flammable materials.

4 Acceptable

6 Check for proper water runoff and drainage away from the tank. 4 Acceptable

Check for grade or other material covering the shell-to-bottom junction. Detail findings.

4 Acceptable

8 Check for settlement around the perimeter of the tank. 4 Acceptable

9 Check for presence or condition of moisture barrier. 3 Reference Summary

Check for anchorage. Record sizes, spacing between anchors and condition.

N/A ---

11 Check for the presence of cathodic protection or leak detection. 4 Acceptable

12 Review cathodic protection potential readings (if available). N/A ---

SHELL

ITEM DESCRIPTION GRADE COMMENTS

Perform shell thickness calculations (ref. API 653, Paras. 4.3.3.1, 4.3.4,

4.3.8 & 4.3.10).

4 Acceptable

2 Inspect external shell for leaks, coating failure and / or corrosion. 4 Acceptable

Inspect external shell-to-bottom weld area for corrosion, defects, or thinning on weld, shell, or bottom.

4 Acceptable

Inspect weld seams for corrosion or defects. Visually inspect and record rivet joint details.

4 Acceptable

5 Inspect wind girder / stiffening ring for corrosion or damage. N/A ---

6 Check support welds to shell for corrosion or defects. 4 Acceptable

7 Note whether supports have reinforcing pads welded to shell. 4 Acceptable

8 Conduct Visual Inspection of shell insulation and inspect for damage. N/A ---

9 Visually inspect shell for out-of-roundness and plate deformation. 3 Reference Summary

10 Check shell mounted vents for debris and condition of screens. 4

Acceptable

Type: Overflow Vent Size: (3) 24-inch x 12-inch

11 Conduct Ultrasonic inspection of the shell. 4

Acceptable

Ten (10) readings up the spiral stairway

Five (5) readings per plate on Course 1

NOZZLE AND APPURTENANCE

Inspect for signs of corrosion or other defects around all manways, nozzles, and attachments externally.

4 Acceptable

Evaluate nozzles / manways to current API 650 / 653 guidelines. Neck thickness, centerline and etc..

3 Reference Summary

3 Inspect for flange leaks and leaks around bolts. 4 Acceptable

4 Check piping and valves for leaks, thermal relief, or signs of damage. 4 Acceptable

5 Inspect condition of stairway, ladder, and platform. 4 Acceptable

Check welds on shell mounted davit clips above large valves or equipment.

4 Acceptable

7 Describe and verify operability of gauging devices, if applicable. 4 Acceptable

8 Inspect mixer for support, leakage, and defects. N/A ---

9 Check for adequate reinforcement around nozzles and appurtenances. 4 Acceptable

10 Verify adequate weld spacing around nozzles and appurtenances. 4 Acceptable

Verify presence of telltale holes in all reinforcing plates and ensure the holes are open to the atmosphere.

4 Acceptable

Temperature indicators / probes (broken glass or damage dial and corrosion).

N/A ---

FIXED ROOF

Describe condition of fixed roof.

(Coating failure, pitting and corrosion). Identify any defects and locate on layout.

4 Acceptable

2 Visually inspect low spots on roof for external corrosion. Locate on layout. 3 Reference Summary

Conduct Visual inspection of roof nozzles and appurtenances. Locate on layout.

4 Acceptable

3 Conduct Visual inspection of frangible joint. 4 Acceptable

5 Conduct Visual inspection of roof insulation. Inspect for damage. N/A ---

6 Scaffold cable support is present and is in good condition. 4 Acceptable

Check conditions of vents, missing or clogged screens, pallets, and gaskets.

Condition of vent or gauge hatch etc.… Note possible insufficient venting (buckles near frangible joint).

4 Acceptable

8 Identify pressure vacuum vents / vents (quantity and size). 4

Acceptable

Type: Center Vent

Size: (1) 10-inch

9 Perform Ultrasonic inspection of the roof deck plates. 4 Three (3) readings per

Plate

APPENDIX E: PHOTOGRAPHS

FOUNDATION

001 Overview of Foundation 002 Overview of Foundation

003 Overview of Foundation 004 Overview of Foundation

005 Overview of Foundation 006 Separating Moisture Barrier

FOUNDATION (CON’T)

007 Overview of Containment Area 008 Overview of Containment Area

009 Overview of Containment Area 010 Overview of Containment Area

011 Overview of Containment Area 012 Overview of Containment Area

FOUNDATION (CON’T)

013 Breakage in Containment Area 014 Deteriorated Moisture Barrier

015 Deteriorated Moisture Barrier

SHELL

001 Overview of Tank 002 Overview of Tank

003 Overview of Tank 004 Original Nameplate

005 Repair - Altered Nameplate 006 7-Inch Shell Insert Ring

SHELL (CON’T)

007 Shell Deformation (TYP)

NOZZLES

001 Manway A 002 Nozzle B

003 Nozzle C 004 Couplings D, E and F

005 Nozzle G 006 Patch Plate H

NOZZLES (CON’T)

007 Patch Plate I 008 Overflow Vent J

009 Patch Plate K 010 Grounding Lug L

011 Overflow Vent M 012 Grounding Lug N

007 Patch Plate I 008 Overflow Vent J

009 Patch Plate K 010 Grounding Lug L

011 Overflow Vent M 012 Grounding Lug N

013 Stairway Top O 014 Nozzle P

015 Nozzle Q 016 Nozzle R

017 Nozzle S 018 Nozzle T

019 Nozzle U 020 Grounding Lug V

021 Overflow Vent W 022 Stairway Bottom X

023 Nozzle Y 024 Nozzle Z

025 Patch Plate AA 026 Grounding Lug BB

027 Automatic Gauge CC

FIXED ROOF

001 Overview of Fixed Roof 002 Overview of Fixed Roof

003 Overview of Fixed Roof 004 Overview of Fixed Roof

005 Overview of Fixed Roof 006 Nozzle A

FIXED ROOF (CON’T)

007 Scaffold Support Hitch B 008 Nozzle C

009 Nozzle D 010 Nozzle E

011 Access Hatch F 012 Scaffold Support Hitch G

007 Scaffold Support Hitch B 008 Nozzle C

009 Nozzle D 010 Nozzle E

011 Access Hatch F 012 Scaffold Support Hitch G

013 Couplings H, I and J 014 Coupling K

015 Access Hatch L 016 Low Area (TYP)

017 Low Area (TYP)