Attachment J2 - QSA-FY21-FAC 111-Tank 1-FINAL.pdf

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Quonset State Airport ANG Base, Rhode Island Tank Facility 111 (Tank 1)

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

USACE POL-MCX

24 November 2020

API 653 In-Service Inspection Report Quonset State ANG Base, Rhode Island

Table of Contents

ACRONYMS AND ABBREVIATIONS

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

THIS INSPECTION

PREVIOUS INSPECTION DATES

STATE REGULATIONS

RECOMMENDED FUTURE INSPECTION DATES

A. GENERAL PROJECT INFORMATION

1. SPCC Mandated AST Inspections

2. Site Information

3. Previous Inspection and Repairs

4. Future Projects

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Bottom

4. Tank Roof

5. Tank Shell

6. Tank Appurtenances

7. Tank Coating

8. Tank Piping System

9. Fire Protection System

10. Secondary Containment

11. Cathodic Protection

GENERAL TANK INFORMATION

C. FINDINGS AND RECOMMENDATIONS

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

2. SHORT TERM RECOMMENDATIONS

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT ANALYSIS

ULTRASONIC THICKNESS READINGS AND REMAINING LIFE CALCULATION

TANK DRAWINGS

OSHA ACCESS STRUCTURE REPORT

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX ‘C’: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

AFFF Aqueous Film Forming Foam

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CC Carbon Steel

CFR Code of Federal Regulations

CP Cathodic Protection

CS Carbon Steel

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NA Not Applicable

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

PTFE Polytetrafluoroethylene (e.g., TEFLON)

P/V Pressure/Vacuum

PST Product Saver Tank

SS Stainless Steel

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UG Underground

UT Ultrasonic Testing

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

Austin Brockenbrough & Associates, LLC (Brockenbrough) was retained by Omaha District USACE under Contract

No. W9128F-17-D-0017 Delivery Order W9128F20F0024 to perform SPCC Mandated AST Inspections at various locations. As required by this task, Brockenbrough executed a tank inspection site visit to Quonset State Airport

Air National Guard Base, Rhode Island. An API 653 In-Service (visual external) Inspection was conducted for

Facility No. 111 on Wednesday, August 5, 2020. This inspection was performed in accordance with API Standard

653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. The inspection included a tank foundation settlement evaluation and UT assessment of the tank shell. All observations made during this in-service (visual external) inspection were made from the exterior of the tank.

Facility 111 (locally identified as Tank 1) is a 27’-0” diameter by 28’-3” tall single wall, vertical, field-erected tank with a nominal storage capacity of 2,500 barrels of Jet Fuel (F-24). The tank was erected in accordance with API 5th edition in 1980. The tank does not have a manufacturer’s nameplate, but a repair nameplate was provided in 2018 when new tank gauging was added, and other miscellaneous repairs were performed. Details of tank construction and appurtenances are included in the Tank Information Table in Section ‘B’.

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

The Rhode Island Oil Pollution Control Regulations require a ten-year internal inspection cycle for tanks above

10,000 gallons. The 2015 out-of-service inspection report recommended an internal inspection to be performed by July 2025 in accordance with standard military criteria at that time. The inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology and a thorough code compliance evaluation.

A. GENERAL PROJECT INFORMATION

1. SPCC Mandated AST Inspections

This project will perform an API 653 inspection of various tanks at facilities throughout the United

States. The specific inspection performed is based on available information on the tank type, product being stored, and recommendations from previous inspection reports (if available). Additional consideration is given to federal, state, and local regulations, as well as applicable military criteria and general industry standards.

For this Task Order, Brockenbrough performed an inspection of Facility 111 (locally identified as Tank

1) located at Quonset State Airport Air National Guard Base, Rhode Island. This tank is one of two that are used for bulk storage at this facility. For the Tank Facility 111, an API 653 In-Service (external)

Tank Inspection was performed on August 5, 2020. The inspection included a shell settlement survey and UT inspection of the shell and roof.

2. Site Information

Quonset Point Air National Guard Base is the home base of the Rhode Island Air National Guard’s 143rd

Airlift Wing. Naval Air Station Quonset Point was deactivated in 1974. Next to NAS Quonset Point was

Camp Endicott at Davisville, home of the Naval Construction Battalions known as the Seabees. Quonset

Point also gave its name to the Quonset hut, a standardized temporary structure used by the U.S.

military starting in World War II. Former U.S. President Richard M. Nixon went through basic naval officer training at Quonset Point in 1942.

3. Previous Inspection and Repairs

In 2015 an out-of-service inspection report was submitted and indicated several significant repairs were needed for this tank. The resultant repair project was completed in 2018 and included adding new ATG and Water Probe appurtenances, upgrading the floating pan to include double wiper seals plus several other miscellaneous repairs to the tank. New coating was provided for the tank bottom and exterior, and several repairs to the piping were all provided as part of this repair project.

4. Future Projects

Facility personnel report there are currently no projects scheduled for execution in the future that affect the operation of the tank.

https://en.wikipedia.org/wiki/Rhode_Island_Air_National_Guard https://en.wikipedia.org/wiki/143d_Airlift_Wing https://en.wikipedia.org/wiki/143d_Airlift_Wing https://en.wikipedia.org/wiki/Camp_Endicott https://en.wikipedia.org/wiki/Seabee_(US_Navy) https://en.wikipedia.org/wiki/Quonset_hut https://en.wikipedia.org/wiki/Temporary_structure https://en.wikipedia.org/wiki/World_War_II https://en.wikipedia.org/wiki/Richard_Nixon

B. TANK INSPECTION COMMENTS

1. Tank Construction

Tank Facility 111 (locally identified as Tank #1) is an aboveground, vertical, storage tank, measuring

27’-0” diameter by 28’-3” tall, with a nominal capacity of 2,500 barrels of jet fuel (F-24). The tank does not have an original manufacturer’s nameplate, but a repair nameplate indicates the tank was constructed in 1980 to API 650 5th Edition.

2. Tank Foundation

The perimeter of the bottom rests on a concrete ringwall. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The tank foundation was found to be in good condition, with only a few minor hairline cracks noted in the concrete. It should be noted that per the previous inspection report and discussion with the operators, the tank reportedly does not have a cathodic protection system of leak detection system under the bottom. The tank is anchored to the foundation at eight equally spaced locations.

3. Tank Bottom

The previous inspection report indicates that the tank bottom consists of cone-down lap welded steel plates.

4. Tank Roof

The tank features a fixed lap-welded cone-up roof, constructed out of 3/16” steel plate. The roof is equipped with a perimeter handrail. The tank has an aluminum honeycomb floating pan, which has been retrofitted with a perimeter wiper seal.

5. Tank Shell

The vertical and cylindrical shell consists of seven butt welded courses of 1/4” steel plate. The exterior of the shell was visually inspected and evaluated. The exterior was just recoated as part of the repair project completed in 2018.

6. Tank Appurtenances

a. Gauging

The tank has a Varec mechanical tape gauge reading a fuel level of 8’-2 1/8”. The tank also was equipped with an Enraf tank gauge reading a fuel level of 8’ -2.00”. Both the Enraf gauge and the associated Vito water probe were recently installed in 2018. A hold-off marker of 30’-6” was noted by the manual gauging hatch.

b. Level Alarms

The tank is provided with shell mounted high, high-high, low, and low-low level alarms. In addition, a float operated high-level shut-off control valve has been provided on the tank receipt line.

c. Stairs and Platforms

The tank’s steel cone roof is accessible by a circumferential stairway mounted on the shell of the tank. The circumferential stairway step rise is generally 9 inches continuously from the first step to the top landing. The height of the railing is 34 inches. The stairs were elongated at the location of the high and high-high level alarms to allow additional clearance. The access platform for floating pan access was the same width as the stair but provided the required clearance for passing by the manhole cover. The handrail was a 1-1/2” x 1-1/2” x 1/8” angle and was at a height of 36 inches.

The stairs were in good condition, with no signs of coating failure or corrosion.

d. Grounding and Bonding

There are two grounding lugs on the tank that appear to be in overall good condition. The grounding wires are combined with the grounds from the water draw-off system and the circumferential stair.

7. Tank Coating

The tank’s coatings were evaluated for deterioration. The exterior of the shell and roof were in very good condition and show little to no sign of deterioration as it was recoated as part of the repairs performed in 2018. The coating was found to be in good condition, with no noted locations of failure or resultant corrosion.

8. Tank Piping System

The piping system associated with the tank is 6-inch diameter aluminum piping. It is carbon steel piping supported by fabricated steel supports. The piping penetrates the concrete containment walls through a steel casing. Upgraded thermal relief valves and other piping appurtenances were provided as part of the repairs performed in 2018. At locations where repairs to the piping were provided, stainless steel spool pieces were used.

There are no pipe anchors for the receipt and issue piping within the tank containment area. In addition, there were no ball joints located on either the receipt or issue pipelines. However, no evidence of stress from pipe movement or independent settlement on the tank shell was noted.

9. Fire Protection System

There are several fire hydrants located with 300 feet of this storage tank. No additional fire protection measures were in place or were required.

10. Secondary Containment

Secondary containment for this tank is provided by a depressed, concrete covered, bermed containment area measuring approximately 80-foot square. Berm height is approximately 44 inches.

This provides adequate containment for full tank volume plus 12 inches of freeboard per the applicable requirements. There were signs of previous cracking within the concrete containment floor, but the cracks have been repaired and appear to be in good condition.

11. Cathodic Protection

Previous reports, along with findings from the site visit indicate that this tank bottom is not protected by a cathodic protection system.

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner Rhode Island Air National Guard

Location Quonset State Airport

Facility Number 111

Tank Number Tank 1

State / Country Rhode Island / U.S.A.

City Quonset

Inspection Date August 5, 2020

Tank Manufacturer Unknown

Design Standard API 650 – 5th Edition (per repair organization nameplate)

Date of Construction 1980 (per repair organization nameplate)

Tank Contents Jet fuel (F-24)

Tank Serial Number Unknown

Tank Diameter 27’-0”’

Shell Height 28’-3”

Overflow Height N/A

Tank Capacity 2,500 BBL nominal

Foundation Concrete ring wall

Construction and Material

Bottom Lap-welded carbon steel plate / Cone-Down

Shell Four courses of butt-welded carbon steel plate

Floating Roof Aluminum honeycomb with double wiper seal

Fixed Roof Lap welded steel cone roof

Cathodic Protection None

Interior Coating System Epoxy 100% (per previous inspection report – coating replacement performed in 2018)

Exterior Coating System Three-part DoD zinc rich epoxy/epoxy/polyurethane (per previous inspection report – coating replacement performed in 2018)

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

Overfill Protection Independent high and high-high level alarms, high level control valve

Piping Receipt 6” Aluminum

Issue 6” Aluminum

Water Draw-off 2” Welded carbon steel

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

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 111 was found to be in generally good condition. The tank is fully serviceable, with no mandatory deficiencies that would require immediate removal of the tank from service. However, there were a few minor items observed that could be addressed to reduce long-term maintenance, improve operability, and more clearly comply with federal, state, and local regulations or military criteria.

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

Mandatory repairs represent items that require immediate attention in order to prevent imminent risk to system operators, equipment, or the adjacent environment. The tank would have to be taken out-of-service to complete these repairs.

No Mandatory Repairs are required to be performed.

2. SHORT TERM RECOMMENDATIONS

REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Short-

Term Repairs that directly relate to the long-term preservation of the asset. Short-term repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment. These items may be required by federal, state, and local codes or by military criteria.

a. Replace Aluminum Piping

OBSERVATION: The 6-inch issue and receipt piping for this tank is butt-welded aluminum. 304 stainless steel spool pieces have been provided for the upgraded piping appurtenances as part of the repairs performed in 2018, but the main product piping is aluminum.

REFERENCE: For new construction, UFC 3-460-01 Section 9.6 allows aviation fuel piping to be constructed of only stainless steel or carbon steel. Aluminum is not a fire safe material and should not be used for fuel piping – especially within a containment area.

RECOMMENDATION: Remove the aluminum piping and replace with stainless steel or interior coated carbon steel piping. Approximately 750 feet of 4-inch and 6-inch aluminum piping would be required for this entire fueling system.

3. LONG-TERM RECOMMENDATIONS

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

a. Repair Concrete

OBSERVATION: There are several very minor hairline cracks in the concrete ringwall. If precipitation enters the concrete through the cracks, the water could promote corrosion of the reinforcing steel in the concrete and damage concrete during freezing conditions.

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

RECOMMENDATION: Seal cracks in the concrete ringwall to prevent future issues.

b. Repair Receipt Piping

OBSERVATION: There is no isolation valve upstream and adjacent to the high level control valve.

REFERENCE: Guidance provided in UFC 3-460-01 paragraph 4-6.i.7 and DoD Standard Design AW 78-24-27 include an isolation valve upstream of the level control valve on new storage tanks.

RECOMMENDATION Provide a ball valve upstream and adjacent to the high level control valve.

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT ANALYSIS

Austin Brockenbrough & Associates, L.L.C. Job No. 19-091.05

Location: Quonset State ANG Date: 108/8/2020

Subject: Tank 111 - Shell Settlement Evaluation By: Bryan Strayer

API 653 Appendix B

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

Diameter (D) = 27 (ft)

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 10.60

Tank Height (H) = 28.3 (ft)

Relative elevation of lowest horizontal weld seam. (ft)

* Z U S

0 4.21 0.00000 0.00 0.00 0.01

1 4.22 0.01000 0.00 -0.01 -0.0061

2 4.22 0.01000 0.01 0.00 0.0050

3 4.23 0.02000 0.01 -0.01 -0.0089

4 4.22 0.01000 0.01 0.00 0.0065

5 4.22 0.01000 0.01 0.00 -0.0039

6 4.21 0.00000 0.01 0.01 0.0100

7 4.22 0.01000 0.00 -0.01 -0.01

8 4.21 0.00000 0.00 0.00 0.00

Maximum out-of-plane deflection = 0.01

* = measured elevation

*HI (Height of Instrument)

Z = calculated ridged body tilt (in)

U = out-of-plane settlement =

S = out-of-plane deflection z-y

Y = yield sterength of shell material (PSI) = 30,000 (unknown steel)

E = Youngs modulas of elasticity (lbf/in2) = 29*10^6

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH) = 0.02 ft

R^2 = (Syy - SSE) / Syy = 0.36 not >=0.9 therefore cosine curve is invalid.

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

Austin Brockenbrough & Associates, L.L.C. Job No. 19-091.05

Location: Quonset State ANG Date: 108/8/2020

Subject: Tank 111 - Shell Settlement Evaluation By: Bryan Strayer

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

* Open top (yes/no) = no Per B.3.2.2, K = 10.5

Settlement arc length (ft), Sarc

Out of plate settlement at Point i (Si)

Allowable settlement at point i (Smax) = MIN[K*Sarc*(D/H)*(Y/E), 4]

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

2 31.8 0.02 0.03 OK

5 53.0 0.02 0.05 OK

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

Si < Smax →

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

Si < Smax →

0.00

0.01

0.01

0.02

0.02

0.03

0 2 4 6 8 10

Measured Elevation (ft)

Si2 Si5

ULTRASONIC THICKNESS READINGS AND REMAINING LIFE CALCULATION

Job No.: 19-091.05

Job Title: SPCC AST Inspection - Quonset State ANG

Subject: Tank 111 Shell Calculations

By: Bryan Strayer Date: 10/18/20

API 653

Wind Velocity 125 mph

SHELL CALCULATIONS

Diameter 27 feet Average Shell Thk 0.242 Inches Shell Height 28.25 feet Freeboard 3.25 feet Maximum height of unstiffened shell: 113.7 feet Design Fill Height 25.00 feet Specific Gravity 0.85 API 12C

0.84 API 653

Joint Efficiency 0.70 API 650 Appendix A 7th Edition Assumed Material unknown

Yield Strength 30,000 psi (assumed)

Tensile Strength 55,000 psi (assumed)

Original Design Corrosion Allowance

0.000 in

Required thickness

Lower Upper

Two

Courses Courses Allowable Stress 23595 25960

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

4 7.67 2.63

3 7.46 10.08

2 7.46 17.54

1 7.46 25.00 min 2020 Corrosion Estimated UTM Visual current net 1980 Rate Service Life Inspection Inspection

Course UTM* thick Thickness * in/yr yrs. Interval Interval

4 0.261 0.216 0.250 0.001 >30 15 5

3 0.273 0.228 0.250 0.001 >30 15 5

2 0.275 0.230 0.250 0.000 >30 15 5

1 0.271 0.226 0.250 0.001 >30 15 5

* The original thicknesses are assumed based on required design thicknessess, overtolerance and the range of the UTMs.

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

API-653

API-650

OriginalOriginal

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

SE

2.6HDG

SE

(psi)

Hydro 2250020000

Design

0.038

0.007

0.101

0.070

0.100

0.100

0.100

0.100

SE

0.107

0.007

0.040

0.074

Job No.: 19-091.05

Job Title: SPCC AST Inspection - Quonset State ANG

Subject: Tank 111 UTMs

By: Bryan Strayer Date: 10/18/20

SHELL UTM DATA (0.001 inches) DFT = 0.045 inches

UTM's include 0.045 inch DFT coating.

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

Course 1 UTMs 1 2 3 4 5 6 7 8 9

1-1 285 293 304 285 297 290 283 291 297 1-2 278 291 306 278 294 292 283 296 278 1-3 288 302 290 286 291 286 295 293 291 1-4 291 284 284 279 288 279 302 301 303 1-5 288 279 291 279 279 271

Roof 178 181 192 169 177 192 170 172

UTMs Course 4 261 278 265

Course 3 273 293 289

Course 2 278 275 290

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

TANK DRAWINGS

OSHA ACCESS STRUCTURE REPORT

OSHA Circumferential Stairway Data

OSHA Rq’d Actual

(in) min (in) max (in)

Handrail Height 34 OK 30 34 Step Width 34 OK 22 NA

Step Rise 9 OK NA NA Bottom Step Rise 10 OK 8 10

BOTTOM STEP

RISE

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

Aluminum End Conn: Size: 6-inch Material: Aluminum End Conn: Size: 6-inch

Release Prevention Barrier

Overfill Protection / Level Alarms:

Independent High, High-high, Low, and Low-Low Alarms High & High-high level alarms; Float Actuated Control Shut-off valve

Receipt Piping Configuration Issue Piping Configuration

Tank Piping

Secondary Containment

July 8, 2015

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

27'-0" d x 28'-3" h

API 650 5th Edition

Inspection Date:

Design Std

Tank Inspector Name:

Inspector Certification Number:

Overfill Protection:

Original Construction

Visual

Original Construction

Welded

Secondary Containment

API 653 EXTERNAL INSPECTION CHECKLIST

Quonset State ANGProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

SPCC AST Inspections

Rhode Island

General Inspection Information

19-091.01

Submitted to:

Contract No.:

POL MCX Omaha District

W9128F-17-D-0017

Tank Construction and Configuration

Insulated

Coated

Plastic / Fiberglass

Other:

Jet Fuel (F-24)

2,500 Barrels

Tank Facility No.:

Local Tank ID No.:

August 5, 2020

Tank Manufacturer:

Tank Construction Date:

Tank 1 Bryan Strayer

Vertical

Rectangular

Double Wall

Fire Resistant

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

Exterior Coating:

Epoxy/Epoxy/Polyurethane

Coated, but Unkown Type

Interior Coating:

Double Bottom

Unknown

1980 (per repair nameplate)

Concrete w/ bermed walls

80' w x 80' l x 44" tall

Level Alarms:

Material:

Tank Outside Dimensions:

Nominal Capacity:

Useable Capacity:

Secondary Containment, Overfill, and CRDM

Welded

70720

Horizontal Single Wall

Open Type Dike

API 653 EXTERNAL INSPECTION CHECKLIST

Quonset State ANGProject Site:Project Name: SPCC AST Inspections

Issue To: Pumphouse / Truck Fill areaReceipt From: Truck Off-loading area

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

TASK

Check for:

Tank Settlement

C.1.1.4 Rock

Measure foundation elevations and evaluate levelness Foundation survey completed using Laser Level c)

STATUS COMMENTS

Some very minor cosmetic hairline cracks noted a) b)

C.1.1.6 Housekeeping

Build-up of trash, vegetation, and other inflammables

ITEM

C.1.1 Foundation

C.1.1.1 Concrete Ring

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

Tank settlement into asphalt base

C.1.1.7 Cathodic Protection

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

Check for:

Check for:

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

Cavities under foundation;

vegetation against bottom of tank

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

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

e) Settlement around perimeter of tank

C.1.1.5 Site Drainage

Check for:

Proper operation of dike drains d)

Review cathodic protection potential readings

Check for:

b)

Settlements into the base b) a)

No Cathodic protection for this tank

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand

C.1.1.2 Asphalt a)

Drains and PIV's reportedly working properly

C.1.2.1 External Visual Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.2.3 Riveted Shell Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Rivet and seam leaks on external surface

Check for:

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

Paint failures, pitting, and corrosion

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

C.1.2.4 Wind Girder (Floating

Roof Tanks) a)

Check for:

Tank was repaired in 2018 and coating, sealant, and other aspects are in extremely good condition.

Grooving, corrosion, pitting, and coating failures b)

Corrosion loss and wear on the rivets

Reinforcing pads welded to shell at supports

Leaks and identify the location by sketch or photo

Check for:

Broken welds and corrosion damage

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

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

c) Bottom-to-Foundation Seal

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

C.1.2. Shells

Check for:

C.1.2.2 Internal (Floating Roof

Tank)

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

ITEM TASK

a) Leaks at piping manifolds, flanges, and valves

Flange leaks and leaks around bolting

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

Check for:

C.1.3.3 Autogauge System Check for:

b)

COMMENTS

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

Tank piping is not anchored within the containment area. Piping does not have ball joints installed.

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

C.1.3.1 Manholes and Nozzles

C.1.3.2 Tank Piping Manifolds

C.1.3 Shell Appurtenances

Sealing of insulation around manholes and nozzles

e) Adequate manholes flange and cover thickness on mixer manholes

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

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

Adequate thermal pressure relief of piping to the tank

Proper operation of regulators for tanks with purge gas systems

Leaks at sample connections and proper valve operation

Damage and test the accuracy of temperature indicators h) d) a)

Check for:

STATUS

a) Leaks on autogauge tape guide and lower sheave housing (floating swings)

b) Damage on autogauge head

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

c) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

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

Freedom of movement of marker and float

C.1.3.3 Autogauge System c) d)

C.1.3.4 Shell-mounted Sample

Station a) b)

Check for:

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

Leaks in circulation pump and operating problems

Inspect condensate drain for presence of oil indicating leakage C.1.3.5 Heater (Shell Manhole

Mounted)

C.1.3.6 Mixer Check for:

c) Condition of power lines and connections to mixer

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

Proper mounting flange and support

Leakage e) f) g)

Proper movement of tape by bumping the checker on autogauge head

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

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

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

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

(floating roof tanks)

ITEM TASK STATUS COMMENTS

Varec Tape Gauge reading of 2'-8-1/8".

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

b) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

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

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

ITEM TASK

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

STATUS

C.1.3.7 Swing Lines: Winch a)

Operation

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

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

C.1.3.8 Swing Lines: External

Guide System

Check for leaks at threaded and flanged joints

C.1.3.9 Swing Lines: Identify

Ballast Varying Need

Check for significant difference in stock specific gravity

Check for:C.1.3.10 Swing Lines: Cable

Material and Condition a) Corrosion over entire length, for non-stainless steel cable

Wear or fraying on all types of cable

C.1.3.11 Swing Lines: Product

Sample Comparison

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

C.1.3.12 Swing Lines: Target

COMMENTS

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail 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.)

C.1.4.2 Deck Plate External

Corrosion

ITEM TASK STATUS

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

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

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

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

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

C.1.4.5 Gas Test Internal Floating

Roof

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

Could only access floating roof at one location.

No fuel odor noted when hatch was open

COMMENTS

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

C.1.4.6 Roof Insulation Check for:

a) b) c)

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

C.1.4.7 Floating Roof Seal a)

Systems

Inspect the condition of the seal, measure and record maximum rim spaces and seal-to-shell gaps around the full roof circumference at the level of inspection. NOTE:

Inspection of the seal and measurement of the rim spaces and seal-to-shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

Wet insulation under the weather coat

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

ITEM TASK

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

Measurements should be taken in directly opposite pairs.

c) d) e) f) g)

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

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

Inspect visible metallic parts for corrosion and wear.

Inspect for openings in seals that would permit vapor emissions.

Inspect for protruding bolt or rivet heads against the shell.

Floating pan was observed from the tank roof only. From that vantage point, everything appeared to be in good condition. Pan seals were replaced as part of the 2018 repair project.

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Check for:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

ITEM TASK STATUS COMMENTS

C.1.4.7 Floating Roof Seal h)

Systems i) j)

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

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

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

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch g) h)

Operation of system

Presence and condition of protective coating or liner inside sample hatch

(preventing rust from pipe getting into sample) on ultra clean stocks such as JP4 a) b) c) d) e) f)

Condition and functioning of sample hatch cover.

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

Monitoring District rules

Corrosion and plugging on thief and gauge hatch cover.

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

Reinforcing pad where sample hatch pipe penetrates the roof deck.

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

Gauging hatch was upgraded as part of the 2018 repairs. The hatch and all components appeared to be in good condition, and reportedly all aspects of the gauging hatch are working properly

Hold-Off distance was marked at 30'-6"

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

ITEM TASK STATUS COMMENTS

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

Corrosion and missing bolts on the hatch

Check for:

Check for:C.1.5.4 Autogauge: Inspection

Hatch & Guides (Fixed Roof) a)

C.1.5.2 Gauge Well Check for:

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

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

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

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

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

C.1.5.5 Autoguage: Float Well

Cover a) Corrosion

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

Inspect scaffold support for corrosion, wear and structural soundness.

C.1.5.3 Fixed Roof Scaffold

Support

C.1.5.6 Sample Hatch (Internal

Floating Roof) a) Overall conditions

Automatic sealing after sampling, when equipped with a fabric seal

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

C.1.5.7 Roof-Mounted Vents

(Internal Floating Roof)

Check for:

Check condition of screens, locking and pivot pins.

Pass Fail 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.

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

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

Check for leg racks on roof

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

ITEM TASK

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

b)

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

C.2.12 Access Structures

C.2.12.1 Handrails a) b) c)

Check for:

a) Condition of the screen on the rim vent cover

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

C.1.5.13 Pontoon Inspection a)

Hatches

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

C.1.5.9 Emergency Roof Drains

C.1.5.10 Removable Roof Leg

Racks

C.1.5.11 Vacuum Breakers

C.1.5.12 Rim Vents

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

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

Inspect for pitting and holes, paint failure.

Inspect attachment welds.

Floating pan was perimeter wiper seal, not pontoons. This was updated as part of the 2018 repair project.

Pass Fail N/A

d) Identify cold joints and sharp edges.

Inspect the handrails and midrails.

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

C.2.12.1 Handrails e) f)

C.2.12.2 Platform Frame a) b) c)

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

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

Check for:

ITEM TASK

d) e) b)

Corrosion and paint failure on frame

Corrosion and weld failure on the attachment of frame to supports and supports to tank

Reinforcing pads where supports are attached to shell or roof.

Thinning and holes on the surface that deck plate or grating rests on

Seal-weld on flat surface–to-flat surface junctures

Check for:

Corrosion-caused thinning or holes

(not drain holes) and paint failure on the deck plate

Rust scale buildup on plate-to-frame weld

C.2.12.3 Deck Plate and Grating a)

Corrosion-caused thinning of bars and failure of welds on grating

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

Check for:

Corrosion, paint failure, and weld failure on spiral stairway stringers c) d)

C.2.12.4 Stairway Stringers a)

b) Stairway supports to shell welds and reinforcing pads.

No reinforcing pads present where platform struts attach to tank

Pass Fail N/A

c) Corrosion on steel support attachment to concrete base

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

ITEM TASK STATUS COMMENTS

m) If rolling ladder track extends to within 5 ft of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

C.2.12.5 Rolling Ladder a) b) c) d) e) f) g) h)

Inspect rolling ladder stringers for corrosion.

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

Check for wear and corrosion where rolling ladder attaches to gauging platform.Inspect pivot bar for wear and that it is secure.

Inspect operation of self-leveling stairway treads.

Inspect for corrosion and wear on moving parts.

i) j) k) l)

Inspect rolling ladder track welds for corrosion.

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

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

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

Inspect alignment of rolling ladder with roof rack.

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

No rolling ladder

2. This tank and appurtenances was in very good, due to repair project completed in 2018.

1. Receipt and issue lines feature aluminum piping.

Additional Findings and Comments:

APPENDIX ‘C’: PHOTOGRAPHS

C.1: Jet Fuel System Overview C.2: Tank 111 Viewed from the East

C.3: Tank 111 Viewed from the North C.4: Concrete Secondary Containment Area

C.5: Tank Issue Piping (Outlet) C.6: Tank Receipt Piping (Inlet)

C.7: Water Draw-off System and Low-Level Alarms C.8: Circumferential Stair

C.9: Access Manhole and Tape Gauge C.10: Rooftop Appurtenances

C.11: Floating Pan C.12: Fuel Pump Station and Truck Area

1011 Boulder Springs Drive, Suite 200

Richmond, Virginia 23225 Phone: 804.592.3900 Fax: 804.592.3901 www.brockenbrough.com