Attachment J2 - SP-POL-CMP-INSPECT-FY25-FWY Tank 482 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 482

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

(USACE POL-MCX)

12 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 482 located at the Indiana ANG facility in Fort Wayne, Indiana on May 12th, 2021.

Tank No. 482 was constructed to API 650, 5th 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 12th, 2021, an In-Service API 653 inspection was completed on Tank 482 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 2019 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: 12 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: 15 August 2015

API In-Service (External) Inspection Date: Unknown

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

API Out-of-Service (Internal) Inspection Date: August 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 4812 Tank Number 482 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, 5th Edition Date of Construction 1978 (Repair / Alteration Completed in 2019) 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 August 2015 (Out-of-Service) Last Coated 2019 (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 12, 2021, Arctic Testing & Inspection performed an API 653 In-Service Inspection on Tank 482 located at Indiana ANG facility in Fort Wayne, Indiana.

TANK INSPECTION COMMENTS

1. Tank Construction Tank 482 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, 5th 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 481.

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 481 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.

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

The survey found the tank to be out of level by 0.36 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

0.05

0.1

0.15

0.2

0.25

0.3

0.35

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 5.57 2 5.56 3 5.54 4 5.55 5 5.56 6 5.55 7 5.55 8 5.56

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 0.189 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 0.193 0.100 Y 4 8.07 8.07 0.85 26,000 0.191 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 0.192 0.191 0.190 0.190 2 0.192 0.191 0.195 0.191 3 0.193 0.194 0.195 0.192 4 0.191 0.196 0.194 0.191 5 0.189 0.196 0.194 0.192 6 0.186 0.195 0.193 0.193 7 0.185 0.193 0.196 0.191 8 0.186 0.192 0.191 0.190 9 0.184 0.191 0.193 0.189

10 0.190 0.191 0.193 0.188 Avg.: 0.189 0.193 0.193 0.191 Min.: 0.184 0.191 0.190 0.188

READINGS

COURSE 1 PLATES

1 2 3 1 0.195 0.190 0.193 2 0.192 0.195 0.192 3 0.185 0.191 0.191 4 0.187 0.194 0.191 5 0.191 0.186 0.192

Avg.: 0.190 0.191 0.192 Min.: 0.185 0.186 0.191

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 0.256 27 0.249 53 0.247 2 0.258 28 0.272 54 0.263 3 0.258 29 0.244 55 0.258 4 0.261 30 0.255 56 0.257 5 0.253 31 0.263 57 0.263 6 0.255 32 0.269 58 0.254 7 0.267 33 0.267 59 0.257 8 0.267 34 0.266 60 0.253 9 0.269 35 0.264 61 0.255

10 0.263 36 0.266 62 0.284 11 0.257 37 0.264 63 0.255 12 0.253 38 0.268 64 0.248 13 0.255 39 0.258 65 0.276 14 0.284 40 0.269 66 0.254 15 0.264 41 0.251 67 0.262 16 0.255 42 0.253 68 0.252 17 0.267 43 0.257 69 0.258 18 0.263 44 0.255 70 0.259 19 0.267 45 0.268 71 0.264 20 0.258 46 0.263 72 0.262 21 0.259 47 0.267 73 0.254 22 0.265 48 0.267 74 0.268 23 0.262 49 0.259 75 0.256 24 0.251 50 0.261 76 0.259 25 0.252 51 0.248 77 0.253 26 0.256 52 0.253 78 0.255

Avg. 0.260 Min. 0.244

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 0.189 0.00000 0.089 2 1978 2021 0.188 0.193 0.00000 0.093 3 1978 2021 0.188 0.193 0.00000 0.093 4 1978 2021 0.188 0.191 0.00000 0.091

∗ 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 0.196 A 0.493 0.556 0.500 Y 5 B Grounding Lug --- 2.80 --- --- --- --- --- --- --- --- --- --- C Automatic Gauge --- 3.60 --- --- --- --- --- --- --- --- --- --- D Patch Plate --- 3.80 25 6.50 6.50 0.242 B --- --- --- --- 21.50 E Nozzle 4 6.20 20 13 13 0.248 B 0.318 0.899 --- Y 14 F Nozzle 1 7.00 44 --- --- ---- --- 0.253 0.530 --- --- 43 G Stairway Bottom --- 9.10 --- --- --- --- --- --- --- --- --- --- H Grounding Lug --- 14.20 --- --- --- --- --- --- --- --- --- --- I Overflow Vent --- 17.00 --- 24 12 --- --- --- --- --- --- --- Course 4 J Grounding Lug --- 21.80 --- --- --- --- --- --- --- --- --- --- K Patch Plate --- 22.40 4.50 6.50 9 0.245 D --- --- --- --- Flush L Nozzle 1 30.30 65.50 --- --- --- --- 0.241 0.526 --- --- 64.50 M Nozzle 1 30.30 34 --- --- --- --- 0.241 0.532 --- --- 32 N Nozzle 1 30.90 --- --- --- --- --- 0.242 0.531 --- --- --- Course 4 O Nozzle 1 30.90 --- --- --- --- --- 0.239 0.530 --- --- --- Course 4 P Nozzle 2 39.00 15 -- --- --- --- 0.219 0.709 --- --- 14 Q Stairway Top --- 39.90 --- --- --- --- --- --- --- --- --- --- Platform R Nozzle 2 40.80 15 --- --- --- --- 0.216 0.710 --- --- 14 S Grounding Lug --- 41.80 --- --- --- --- --- --- --- --- --- --- T Grounding Lug --- 42.60 --- --- --- --- --- --- --- --- --- --- U Overflow Vent --- 45.70 --- 24 12 --- --- --- --- --- --- --- Course 4 V Grounding Lug --- 60.60 --- --- --- --- --- --- --- --- --- --- W Patch Plate --- 62.40 8.25 16.50 16.50 0.237 D --- --- --- --- Flush X Patch Plate --- 65.70 30 4 4 0.205 B --- --- --- --- 30 Y Patch Plate --- 65.70 5 7 10 0.243 D --- --- --- --- Flush Z Nozzle 6 69.60 13 21 16 0.320 C 0.427 1.013 --- Y 5

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

AA Patch Plate --- 70.90 --- 6 6 --- B --- --- --- --- --- Course 4 BB Patch Plate --- 70.90 --- 6 6 --- B --- --- --- --- --- Course 4 CC Nozzle 1 71.10 28.50 --- --- --- --- 0.244 0.522 --- --- 28 DD Nozzle 8 72.30 12 20 22 0.248 D 0.505 1.123 --- Y Flush EE Overflow Vent --- 74.80 --- 24 12 --- --- --- --- --- --- --- Course 4

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 5.10 2 31.30 3 57.50 4 --- 5 --- 6 --- 7 --- 8 --- 9 --- 10 --- 11 ---

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

2 13.00 3 21.20 4 11.40 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 0.187 0.188 0.186 2 0.186 0.188 0.191 3 0.192 0.191 0.187 4 0.192 0.192 0.194 5 0.198 0.191 0.189 6 0.182 0.188 0.193 7 0.185 0.192 0.193 8 0.191 0.193 0.189

Average: 0.190 Minimum: 0.182

FIXED ROOF NOZZLE / NECK UT MEASUREMENTS

Size (in.)

Plate No.

Neck Thick (in.)

Comments

A Access Hatch 48 x 36 1 / 4 0.242 B Access Hatch 77 x 25 2 / 3 0.123 C Manway 24 3 0.258 D Nozzle 6 3 0.246 E Nozzle 10 3 0.377 Gauge Hatch F Nozzle 10 3 0.383 G Scaffold Support Hitch 4 4 0.242 H Nozzle 8 4 0.322 I Nozzle 10 4 / 6 0.259 Center Vent J Coupling 1.50 5 --- Auto Gauge K Scaffold Support Hitch 4 6 0.243 L Coupling 2 8 --- M Coupling 1.50 8 ---

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

GROUNDING LUG

AUTOMATIC GAUGE

6.50" X 6.50" PATCH PLATE

4" NOZZLE

1" NOZZLE

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= STAIRWAY BOTTOM

H= GROUNDING LUG

I= OVERFLOW VENT

J= GROUNDING LUG

K= 6.50" X 9" PATCH PLATE

L= 1" NOZZLE

M= 1" NOZZLE

N= 1" NOZZLE

O= 1" NOZZLE

P= 2" NOZZLE

4 0.191

0.193

0.193

0.189 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

Q= STAIRWAY TOP

R= 2" NOZZLE

S= GROUNDING LUG

T= GROUNDING LUG

U= OVERFLOW VENT

V= GROUNDING LUG

W= 16.50" X 16.50" PATCH PLATE

X= 4" X 4" PATCH PLATE

Y= 7" X 10" PATCH PLATE

Z= 6" NOZZLE

AA= 6" X 6" PATCH PLATE

BB= 6" X 6" PATCH PLATE

CC= 1" NOZZLE

DD= 8" NOZZLE

EE= OVERFLOW VENT

A B

C

D E F G

Q

H

I

J K L M

N O

P R S T

U

V W X Y Z

AA BB EE

CC DD

COURSE 1

COURSE 2

COURSE 3

COURSE 4

COURSE 1

COURSE 2

COURSE 3

COURSE 4

MDW

05/27/2021

19304

USACE

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= H= I=

48" X 36" ACCESS HATCH

77" X 25" ACCESS HATCH

24" MANWAY

6" NOZZLE

10" NOZZLE

10" NOZZLE

4" SCAFFOLD SUPPORT HITCH

8" NOZZLE

10" NOZZLE

J= 1.50" COUPLING

K= 4" SCAFFOLD SUPPORT HITCH

= PERIPHERAL VENT

= PATCH PLATE

= LOW AREA

FIXED ROOF LAYOUT DRAWING

REVIEWED BY

JJP

I

G

A

L= 2" COUPLING

B

M= 1.50" COUPLING

K

H

M L

1 2

4 3

J

E

CF

PLATFORM

STAIRWAY

100% RAILING

D

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. 4 Acceptable

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 Acceptable

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. 4 Acceptable

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 Separating Moisture Barrier 006 Overview of Containment Area

FOUNDATION (CON’T)

007 Overview of Containment Area 008 Overview of Containment Area

009 Overview of Containment Area 010 Overview of Containment Area

011 Containment Area Drainage 012 Drainage Line into Containment Area

FOUNDATION (CON’T)

013 Hairline Cracking in Containment Area 014 Hairline Cracking in Containment Area

015 Breakage in Containment Area 016 Breakage in Containment Area

SHELL

001 Overview of Tank 002 Overview of Tank

003 Overview of Tank 004 Overview of Tank

005 Original Nameplate 006 Repair - Altered Nameplate

NOZZLES

001 Manway A 002 Grounding Lug B

003 Automatic Gauge C 004 Patch Plate D

005 Nozzle E 006 Nozzle F

NOZZLES (CON’T)

007 Stairway Bottom G 008 Grounding Lug H

009 Overflow Vent I 010 Grounding Lug J

011 Patch Plate K 012 Nozzle L

013 Nozzle M 014 Nozzle N

015 Nozzle O 016 Nozzle P

017 Stairway Top Q 018 Nozzle R

019 Grounding Lugs S and T 020 Overflow Vent U

021 Grounding Lug V 022 Patch Plate W

023 Patch Plate X 024 Patch Plate Y

025 Nozzle Z 026 Patch Plates AA and BB

027 Nozzle CC 028 Nozzle DD

029 Overflow Vent EE

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 Access Hatch A

FIXED ROOF (CON’T)

007 Access Hatch B 008 Manway C

009 Nozzle D 010 Nozzle E

011 Nozzle F 012 Scaffold Support Hitch G

007 Access Hatch B 008 Manway C

009 Nozzle D 010 Nozzle E

011 Nozzle F 012 Scaffold Support Hitch G

013 Nozzle H 014 Nozzle I

015 Coupling J 016 Scaffold Support Hitch K

017 Coupling L 018 Coupling M