Attachment J4 - Dugway-Fac 5661 (Tank 5661)-FINAL-2015.pdf

TANK 5661 INSPECTION REPORT

API 653 In-Service (External) Inspection

Dugway Proving Ground

Dugway, Utah

Prepared For:

U.S. Army Corps of Engineers

Omaha District 106 South 15th Street

Omaha, Nebraska 68102

Submitted By:

Pond and Company

3500 Parkway Lane, Suite 600 Norcross, GA 30092

Telephone: 678-336-7740 Facsimile: 678-336-7744 www.pondco.com

July 2015

Tank 5661 – API 653 Inspection Report Pond and Company Dugway Proving Ground – Dugway, Utah 1150068 i

PREFACE

Pond & Company, Inc. was under contract to the U.S. Army Corps of Engineers (USACE), Omaha

District to provide an in-service (external) tank inspection on Tank 5661 at Dugway Proving Ground in Dugway, Utah.

There are no mandatory repairs required to remove Tank 5661 from service. Additional recommendations for repair and upgrade have been made to prolong tank integrity and maintain product quality. This document presents findings of the tank inspection and testing, as well as the recommendations regarding repairs and upgrades.

Anthony E. Chinn performed the API-653 in-service (external) inspection and Brian W. Lunsford, P.E.

reviewed the API 653 inspection report.

31 July 2015

Anthony E. Chinn, E.I.T. Date Integrity Engineer ASNT NDT Level II API 653 Inspector # 50662

31 July 2015

Brian W. Lunsford, P.E. Date Sr. Project Manager Integrity Engineer API 653 Inspector # 28526 ii

TABLE OF CONTENTS

SECTION 1

EXECUTIVE SUMMARY .................................................................................................................. 1-1

SECTION 2_Toc425944113

TANK PHYSICAL AND HISTORICAL DATA .................................................................................... 2-1

SECTION 3

NON-DESTRUCTIVE TESTING ....................................................................................................... 3-1

3.1 NDT Inspection Scope of Work .................................................................................... 3-1

3.2 Equipment Used .......................................................................................................... 3-1

3.3 NDT Significant Findings ............................................................................................. 3-1

3.4 Bottom-to-Shell Weld Examination .............................................................................. 3-1

3.5 Shell Examination ........................................................................................................ 3-1

3.6 Shell Nozzle Examination ............................................................................................ 3-2

3.7 Fixed Roof Examination ............................................................................................... 3-2

3.8 Fixed Roof Nozzle Examination ................................................................................... 3-2

SECTION 4

SIGNIFICANT FINDINGS ................................................................................................................. 4-1

4.1 Foundation and Containment ....................................................................................... 4-1

4.2 Shell, Nozzles and Appurtenances .............................................................................. 4-1

4.3 Fixed Roof, Nozzles and Appurtenances ..................................................................... 4-1

4.4 Level Alarms and Gauging System .............................................................................. 4-2

SECTION 5

RECOMMENDATIONS ..................................................................................................................... 5-1

5.1 Repair and Upgrade Recommendations ...................................................................... 5-1

5.1.1 Mandatory Repairs Required to Remove Tank from Service ............................. 5-1

5.1.2 Repairs Required to Fully Comply with API 653 / 650 ........................................ 5-1

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03 ...................... 5-1

5.1.4 Recommended Repairs As Best Management Practice ..................................... 5-2

5.2 Inspection Intervals ...................................................................................................... 5-2

APPENDICES

APPENDIX A (CAD Drawings) .......................................................................................................... A-1

APPENDIX B (Tank Inspection Data) ................................................................................................ B-1

APPENDIX C (API 653 Inspection Checklist) .................................................................................... C-1

APPENDIX D (Calculations) .............................................................................................................. D-1

APPENDIX E (Photographs) ............................................................................................................. E-1 iii

ABBREVIATIONS AND ACRONYMS

API American Petroleum Institute

ATG Automatic Tank Gauge

AVG Average

BMP Best Management Practice

CP Cathodic Protection

DFT Dry Film Thickness

FT Foot/Feet

GE General Electric

HHLA High-High Level Alarm

HLA High Level Alarm

HLCV High Level Control Valve

IAW In Accordance With

IFR Internal Floating Roof

IN Inch/Inches

LLA Low Level Alarm

MIL-STD Military Standard

MT Magnetic Particle Testing

MW Manway

N/A Not Applicable

NDT Non Destructive Testing

NFPA National Fire Protection Association

NTS Not To Scale

P/V Pressure/Vacuum

PE Professional Engineer

TRV Thermal Relief Valve

TYP Typical

UFC Unified Facilities Criteria

USACE U.S. Army Corps of Engineers

UTT Ultrasonic Thickness Testing

VT Visual Testing

W/ With

1-1

SECTION 1

EXECUTIVE SUMMARY

Tank 5661 is located at Dugway Proving Ground in Dugway, Utah. Tank 5661 is a welded, steel, vertical aboveground Diesel (FS-2) storage tank that was fabricated and erected by Hamond Iron in

1955 in accordance with (IAW) American Petroleum Institute (API) 12C. The tank was repaired/altered in 2009 by CAPE IAW API 653. Repairs/alterations included the installation of two (2) 8” and one (1)

2” aluminum poles, three (3) 1” nozzles, four (4) 1” half couplings, and one (1) 36” shell manway. Tank

5661 is 25’-0” in diameter and 36’-0” high with a nominal capacity of 125,000 gallons. The in-service inspection was performed on 23 June 2015. Results of this inspection will provide recommended repairs and upgrades required to comply with applicable industry and military standards. The previous

API 653 inspection report was not available; however, as-built drawings of the tank repairs were available for review and comparison.

Testing and inspection were performed IAW applicable sections of API 653, 5th Edition. Contained in this report is a detailed account of the tank inspection, a summary of the non-destructive testing (NDT), and conclusions derived from the inspection and testing. Findings from this inspection are further detailed in Section 4 of this report. Repairs and upgrades identified in this section are further classified and listed in Section 5 of this report.

Foundation and Containment

Tank 5661 is located in an earthen containment dike covered with a geo-membrane liner and paver ballasts. Vegetation was observed along the containment access stairs-to-dike floor control joint. The tank perimeter rests on a 17” high concrete ring wall foundation. The foundation is equipped with twenty-three

(23) equally spaced seismic anchors. Three (3) seismic anchors are welded directly to manway (MW) 1 and MW2 reinforcement pads instead of directly to the tank shell.

The tank bottom is provided with a leak detection system via four (4) equally spaced monitoring pipes along the concrete ring wall.

Tank Shell

The tank shell consists of seven (7) butt-welded steel shell courses. External coating on the tank shell is in good overall condition with no indications of coating failure. The tank is provided with standardized product designation IAW Military Standard (MIL-STD)-161G; it is not provided with a National Fire

Protection Agency (NFPA) emergency responder diamond.

Shell nozzles consist of one (1) 24” manway, six (6) 1” penetrations for the high-high level alarm

(HHLA)/high level alarm (HLA), high level control valve (HLCV) shut-off switch chamber, and low level alarm (LLA), one (1) 36” manway, one (1) 4” product receipt, one (1) 4” product suction, and one (1)

1” water draw-off. The product receipt/suction line is a dual purpose 4” transfer pipeline from the adjacent pump house. Prior to entering the tank, the dual purpose line splits into one (1) 4” product receipt and one (1) 4” product suction.

1-2

Approximately 2 ft2 of coating failure and surface corrosion was observed at the product receipt HLCV and product receipt/suction thermal relief valve (TRV) connecting flanges. Crossover piping for the product receipt/suction TRV is equipped with a sight flow indicator. Sight flow indicators are no longer used for this application as they are a potential leak path.

Fixed Roof

The roof is a lap-welded, steel, cone-up fixed roof. External coating on the fixed roof is in good overall condition with no evidence of coating failure.

Fixed roof nozzles consist of two (2) 1 ¼” penetrations for the Varec float gauge guide wires, one (1) 2”

Varec float gauge, one (1) 4” blind flange, one (1) 24” emergency vent, one (1) 10” blind flange, one (1)

6” pressure vacuum (P/V) vent, one (1) 8” gauging hatch, one (1) 24” manway w/ a MTS liquid level transmitter. Approximately 1 ft2 of cracked coating was found at the 10” blind flange.

The tank is not provided with a full contact aluminum honeycomb internal floating roof (IFR). Based on the tank operation and location (hot, desert-like climate), an aluminum honeycomb IFR is required to eliminate the fuel-to-air interface and provide fire suppression.

Gauges and Alarms

The tank is equipped with a roof mounted MTS liquid transmitter for automatic tank gauging. The MTS is mounted on the 24” fixed roof manway cover plate and is not provided with a fully slotted stilling well. The tank is equipped with an 8” manual gauging hatch for tank gauging operations. The 8” gauging hatch is provided with a fully slotted stilling well.

The tank is provided with shell mounted LLA, HLA, and HHLA. For overfill protection, there is a shell mounted HLCV shut-off switch chamber and a HLCV at the product receipt.

The tank is provided with a Varec 2500B float gauge for monitoring liquid level at ground level.

Cathodic Protection

The tank bottom is cathodically protected by an impressed current cathodic protection (CP) system.

1-3

Recommendations for Repair and Upgrade

Below is a summary of the repair and upgrade recommendations identified during the external API

653 inspection:

1. Remove and relocate three (3) seismic anchors that are welded to MW1 and MW2 reinforcement pads. In the event that the seismic anchors are not relocated, perform magnetic particle testing

(MT) and monitor the affected areas during future API 653 inspections. (API)

2. Provide tank with a full contact, aluminum honeycomb IFR. (UFC)

3. Provide approximately 3 ft2 of spot coating repair on the product receipt HLCV, the product receipt/suction TRV connecting flanges, and fixed roof 10” blind flange. (UFC)

4. Replace the MTG liquid level transmitter with an Enraf ATG system and VITO temperature/water combination probe. (UFC)

5. Remove one (1) sight flow indicator from the product receipt/suction thermal relief crossover piping. (UFC)

6. Remove vegetation along the containment dike access stairs-to-dike floor interface. (UFC)

7. Provide the tank with a NFPA emergency responder diamond IAW NFPA 704. (UFC)

Recommended Inspections and Intervals

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector w/ UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector (1): API: Twenty (20) Years; July 2029

UFC: Ten (10) Years; July 2019

(1) Internal inspection intervals are based on the previous tank cleaning and inspection dated July 2009. The internal inspection interval per UFC is more stringent, therefore it governs the next internal inspection.

2-1

SECTION 2

TANK PHYSICAL AND HISTORICAL DATA

Owner: U.S. Army

Tank Number: Tank 5661

Location: Dugway, Utah

Fabricated By: Hamond Iron

Erected By: Hamond Iron

Design Standard: API 12C

Year Built: 1955

Year Repaired/Altered: 2009

Product: Diesel (FS-2)

Product Specific Gravity: 0.88

Diameter: 25’-0”

Height: 36’-0”

Design Liquid Level: 35’-0”

Nominal Capacity: 125,000 Gallons

Foundation: Concrete Ring Wall

Bottom Construction: N/A – External Inspection

Shell Construction: Butt-Welded Steel Plates / Seven (7) Shell Courses

Fixed Roof Construction: Lap-Welded Steel Plates / Cone-Up / Self- Supported

Internal Floating Roof Construction: N/A – Not Provided w/ an IFR

Cathodic Protection: Impressed Current

Leak Detection: Four (4) Perimeter Monitoring Pipes

Bottom Coating: N/A – External Inspection

Shell Coating Internal: N/A – External Inspection

Shell Coating External: White Epoxy

Fixed Roof Internal Coating: N/A – External Inspection

Fixed Roof External Coating: White Epoxy

Stairway Construction: Spiral Staircase with Upper Platform

Last Inspection: July 2009*

Average Bottom Plate Thickness: N/A – External Inspection

Average Shell Plate Thickness: Shell Course 1: 0.245” Shell Course 2: 0.182” Shell Course 3: 0.182” Shell Course 4: 0.183” Shell Course 5: 0.189” Shell Course 6: 0.186” Shell Course 7: 0.187”

Average Fixed Roof Plate Thickness: 0.181”

GPS Coordinates: N 40° 12' 37.93" W 112° 45' 5.45"

Notes:

*Inspection report was not available; however, the as-built drawings for the tank repairs were available for review and comparison.

3-1

SECTION 3

NON-DESTRUCTIVE TESTING

3.1 NDT Inspection Scope of Work

The following NDT examinations were performed to evaluate the tank integrity.

• A Visual Test (VT) was performed on the tank containment, as well as piping and valves located inside the containment.

• VT was performed on external surfaces of the tank shell and fixed roof.

• VT was performed on the tank nozzles, coatings, appurtenances, and ancillary equipment.

• Ultrasonic thickness testing (UTT) measurements were taken on the tank nozzles, reinforcement pads, shell plates, and fixed roof plates.

• Dry Film Thickness (DFT) measurements were taken on the external tank shell and fixed roof coatings.

• An external settlement survey was performed on the tank foundation.

3.2 Equipment Used

• GE Krautkramer Ultrasonic Thickness Gauge w/ Topcoat o M/N DMS GO+

• Fisher Technologies Dry Film Thickness Gauge o M/N Dual Scope MPOR

• Zip Level Pro-2000 High Precision Altimeter

3.3 NDT Significant Findings

UTT measurements indicated no significant metal thinning on the tank nozzles, reinforcement pads, shell plates, and fixed roof plates. The tank shell and fixed roof coating is in good condition with no indications of coating failure.

3.4 Bottom-to-Shell Weld Examination

The external bottom-to-shell weld was examined using VT methods. There were no significant findings. The examination was limited due to external coating.

3.5 Shell Examination

Shell plates were examined using UTT and VT methods. Nine (9) UTT measurements were taken on each plate of the 1st shell course. Nine (9) UTT measurements were taken on the remaining shell course plates using the spiral staircase for access.

Refer to Drawing A-1, “Shell Layout” for plate locations and Table B-1, “Shell Plate Ultrasonic

Thickness Readings” for thickness data.

3-2

3.6 Shell Nozzle Examination

Shell nozzles and reinforcement pads were inspected by UTT and VT testing methods. One (1) UTT measurement was taken on each nozzle with a welded connection and on each reinforcement pad.

Refer to Drawings A-1, “Shell Layout” for nozzle locations and Table B-3, “Nozzles and

Appurtenances” for nozzle data.

3.7 Fixed Roof Examination

Fixed roof plates were examined using UTT and VT methods. Five (5) UTT measurements were taken on each roof plate.

Refer to Drawing A-2, “Fixed Roof Layout” for plate locations and Table B-2, “Roof Plate Ultrasonic

Thickness Readings” for plate thickness data.

3.8 Fixed Roof Nozzle Examination

Fixed roof nozzles and reinforcement pads were examined using UTT and VT methods. One (1) UTT measurement was taken on each nozzle with a welded connection and on each reinforcement pad.

Refer to Drawing A-2, “Fixed Roof Layout” for nozzle locations and Table B-3, “Nozzles and

Appurtenances” for nozzle data.

4-1

SECTION 4

SIGNIFICANT FINDINGS

4.1 Foundation and Containment

• The tank is located in an earthen containment dike covered with a geo-membrane liner and paver ballasts. Vegetation was observed along the containment access stairs-to-dike floor interface.

• The tank perimeter rests on a 17” high concrete ring wall.

• The tank is equipped with twenty-three (23) equally spaced seismic anchors. Three (3) seismic anchors are welded directly to MW1 and MW2 reinforcement pads.

• The tank is provided with two (2) grounding cables. Both grounding cables are in good condition with no signs of damage or detachment.

• The tank bottom is cathodically protected with an impressed current CP system.

• The tank bottom is provided with four (4) perimeter monitoring pipes for leak detection.

4.2 Shell, Nozzles and Appurtenances

• The shell is equipped with seven (7) fully coated butt-welded steel shell courses.

• The shell is equipped with a spiral staircase and upper platform for accessing HHLA/HLA, HLCV shut-off switch chamber, and fixed roof.

• The tank shell is provided with standardized product designation IAW MIL-STD-161G; however, the tank is not provided with a NFPA emergency responder diamond.

• Shell nozzles consist of one (1) 24” manway, six (6) 1” penetrations for the HHLA/HLA, HLCV shut-off switch chamber, and LLA, one (1) 36” manway, one (1) 4” product receipt, one (1) 4” product suction, and one (1) 1” water draw-off.

• Crossover piping at the product receipt/suction TRV is equipped with a sight flow indicator.

• Coating failure (flaking and staining) and surface corrosion was observed at the product receipt

HLCV and product receipt/suction TRV connecting flanges.

4.3 Fixed Roof, Nozzles and Appurtenances

• The fixed roof is of cone-up construction with fully coated lap-welded steel plates.

• Fixed roof nozzles consist of two (2) 1 ¼” penetrations for the Varec float gauge guide wires, one

(1) 2” Varec float gauge, one (1) 4” blind flange, one (1) 24” emergency vent, one (1) 10” blind flange, one (1) 6” P/V vent, one (1) 8” gauging hatch, one (1) 24” manway w/ a MTS liquid level transmitter.

• Approximately 1 ft2 of cracked coating was found at the 10” blind flange.

• The fixed roof is equipped with a full perimeter handrail and toe board.

4-2

4.4 Level Alarms and Gauging System

• The tank is equipped with a MTS liquid level transmitter for automatic tank gauging. The MTS is mounted on the 24” fixed roof manway cover plate and is not provided with a fully slotted stilling well.

• The tank is equipped with shell mounted LLA, HLA, and HHLA.

• The tank is equipped with a Varec 2500B float gauge for monitoring liquid level from ground level.

• The fixed roof is equipped with an 8” manual gauging hatch for tank gauging operations. The 8” gauging hatch is provided with a fully slotted stilling well.

• For overfill protection, the tank is equipped with a HLCV at the product receipt and a shell mounted

HLCV shut-off switch chamber.

5-1

SECTION 5

RECOMMENDATIONS

5.1 Repair and Upgrade Recommendations

The following subsections outline the itemized tank repairs/upgrades.

5.1.1 Mandatory Repairs Required to Remove Tank from Service

Mandatory repairs are repairs required to maintain hydraulic and structural integrity over the required 5-year in-service (external) inspection interval.

No mandatory repairs required to remove tank from service.

5.1.2 Repairs Required to Fully Comply with API 653 / 650

Recommendation 1: Remove and relocate three (3) seismic anchors that are in contact with MW1 and MW2 reinforcement pads. The seismic anchors should be relocated to an adjacent location that is not in contact with reinforcement pads. In the event that seismic anchors are not relocated, MT should be performed and the affected areas monitored during future API 653 inspections.

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03

Recommendation 2: Provide the tank with a full contact, aluminum honeycomb IFR IAW API 650.

Recommendation 3: Provide spot coating repair on the product receipt HLCV, product receipt/suction

TRV connection flanges, and fixed roof 10” blind flange. External coating exhibits cracking, flaking, staining, and surface corrosion. Approximately 3 ft2 of spot coating repair is required.

Recommendation 4: Replace the MTS liquid level transmitter with an Enraf ATG system and VITO temperature/water combination probe. The Enraf ATG and VITO combination probe should be provided with fully slotted stilling wells and the combination probe should be located directly above the tank sump, or at the lowest feasible point.

Recommendation 5: Remove one (1) sight flow indicator from the product receipt/suction thermal relief crossover piping.

Recommendation 6: Remove vegetation along the containment access stairs-to-dike floor interface.

Recommendation 7: Provide the tank with a NFPA emergency responder diamond IAW NFPA 704.

5-2

5.1.4 Recommended Repairs As Best Management Practice

Repairs required as Best Management Practice are recommended to extend the tank service life and maintain product quality, but are not necessarily part of a design or inspection standard.

No recommended repairs are required as BMP.

5.2 Inspection Intervals

The interval between tank inspections (both internal and external) should be determined by the tank service history. Inspection intervals can be adjusted based on known corrosion rates. Corrosion rates can only be determined when a comparison is made between measurements taken over an interval of time. The previous API 653 inspection report was not available; however, as-built drawings for the tank repairs were available for review and comparison.

Listed below are the recommended inspection intervals per API 653:

• Routine monthly inspections to monitor the external condition of the tank and associated piping.

Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (includes tank chime to foundation interface), coatings, and appurtenances. The fixed roof should be visually inspected for signs of damage.

• Formal visual external inspection by an API certified inspector every 5 years or RCA/4N years

(where RCA is the difference between the measured shell thickness and the minimum required thickness and N is the shell corrosion rate), whichever is less. Based on the review of shell and roof thickness measurements, the 5-year interval will govern the next formal external visual inspection.

• Ultrasonic thickness measurements of the shell plates can be performed with the tank in service and can be scheduled at a maximum interval of fifteen (15) years or RCA/2N, whichever is less.

Based on shell thickness measurements, the recommended interval for the UTT measurements on the tank shell is fifteen (15) years.

• Bottom corrosion rates govern the internal inspection interval. Per API 653, the next internal inspection should be performed within twenty (20) years of the previous inspection; however, UFC

3-460-03 requires a maximum internal inspection interval of ten (10) years. The tank was previously cleaned and inspected in July 2009; therefore, it is recommended to perform the next internal inspection within ten (10) years of the July 2009 inspection.

The recommended inspections and intervals are:

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector w/ UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector: API: Twenty (20) Years; July 2029

UFC: Ten (10) Years; July 2019

A-1

APPENDIX A

CAD Drawings

MW1

MW2

N1 N3

N2 N4

N5

N6

N7

N8

N9

1-1

1-2 1-4

2-1

2-3 2-4

3-4 3-1 3-2 3-3

4-3

4-4 4-1

4-2

5-1 5-4

5-3

6-1 6-46-36-2

7-1

7-2

7-3 7-4

3'-1

2'

6'

6'

5'-11.5"

5'-11

5'-11

3"

2-2 2-5

1-3

1-5

SPIRAL STAIRCASE

SEISMIC ANCHORS (TYP. 23) GROUNDING CABLE (TYP. 2)

FLOAT

GAUGE

SPIRAL STAIRCASE

5-2

DUGWAY, UTAH

DUGWAY PROVING GROUND

SCALE:

NOT TO SCALE JULY 2015

REVISED BY:

EHY

TANK 5661

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 40° 12’ 37.93”

E 112° 45’ 5.45”

MANUFACTURER:

HAMOND IRON

DESIGN STANDARD:

API 12C

YEAR BUILT:

PRODUCT:

DIESEL (FS-2)

PRODUCT SPECIFIC GRAVITY:

0.88

TANK DIAMETER:

25'-0"

TANK HEIGHT:

36'-0" (7 SHELL COURSES)

CAPACITY:

125,000 GALLONS

NOTES:

1. REFER TO TABLE B-1, SHELL PLATE ULTRASONIC

THICKNESS READINGS IN APPENDIX B FOR THE

INDIVIDUAL SHELL PLATE ULTRASONIC THICKNESS

READINGS.

2. REFER TO TABLE B-3, NOZZLES AND APPURTENANCES,

FOR NOZZLE DATA.

SHELL LAYOUT

A1 OF A2

LP

LP

LP

LP

LP

LP

LP

LP

LP

N10

N11

N12

N13

N14

N15

N16

N17

1 2

8 9

MW3

UPPER PLATFORM

W/ SPIRAL STAIRCASE

WORK PLATFORM

DUGWAY, UTAH

DUGWAY PROVING GROUND

SCALE:

NOT TO SCALE JULY 2015

REVISED BY:

EHY

TANK 5661

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 40° 12’ 37.93”

E 112° 45’ 5.45”

MANUFACTURER:

HAMOND IRON

DESIGN STANDARD:

API 12C

YEAR BUILT:

PRODUCT:

DIESEL (FS-2)

PRODUCT SPECIFIC GRAVITY:

0.88

TANK DIAMETER:

25'-0"

TANK HEIGHT:

36'-0" (7 SHELL COURSES)

CAPACITY:

125,000 GALLONS

LEGEND:

- LAP PATCH

NOTES:

1. REFER TO TABLE B-2, ROOF PLATE ULTRASONIC THICKNESS READINGS IN

APPENDIX B FOR THE INDIVIDUAL FIXED ROOF PLATE ULTRASONIC THICKNESS

READINGS.

2. REFER TO TABLE B-3, NOZZLES AND APPURTENANCES, FOR NOZZLE DATA.

FIXED ROOF LAYOUT

A2 OF A2

B-1

APPENDIX B

Tank Inspection Data

B-2

Table B-1: Shell Plate Ultrasonic Thickness Readings

Roof

SHELL

COURSE

PLATE 7-1 PLATE 7-2 PLATE 7-3 PLATE 7-4

.187 .189 .184

.189 .188 .185

.191 .183 .183

AVG. .187

Circumferential Weld C7

SHELL

COURSE

PLATE 6-1 PLATE 6-2 PLATE 6-3 PLATE 6-4

.183 .187 .189

.185 .182 .185

.185 .187 .188

AVG. .186

Circumferential Weld C6

SHELL

COURSE

PLATE 5-1 PLATE 5-2 PLATE 5-3 PLATE 5-4

.184 .186 .196

.186 .187 .195

.187 .185 .195

AVG. .189

Circumferential Weld C5

SHELL

COURSE

PLATE 4-1 PLATE 4-2 PLATE 4-3 PLATE 4-4

.180 .184 .185

.182 .184 .184

.182 .185 .185

AVG. .183

Circumferential Weld C4

SHELL

COURSE

PLATE 3-1 PLATE 3-2 PLATE 3-3 PLATE 3-4

.182 .182 .183

.182 .181 .180

.182 .184 .183

AVG. .182

Circumferential Weld C3

SHELL

COURSE

PLATE 2-1 PLATE 2-2 PLATE 2-3 PLATE 2-4 PLATE 2-5

.171 .170 .171 .178 .178 .176 .197 .190 .199 .188 .184 .180 .170 .170 .171

.178 .177 .173 .172 .179 .178 .197 .198 .197 .188 .187 .181 .175 .175 .173

.177 .177 .175 .179 .179 .180 .194 .199 .200 .189 .186 .181 .177 .178 .178

AVG. .174 .178 .197 .185 .174

Circumferential Weld C2

SHELL

COURSE

PLATE 1-1 PLATE 1-2 PLATE 1-3 PLATE 1-4 PLATE 1-5

.245 .246 .245 .243 .244 .244 .244 .247 .242 .242 .244 .246 .243 .246 .243

.246 .244 .246 .245 .247 .244 .246 .247 .245 .245 .246 .245 .245 .246 .246

.242 .242 .242 .248 .248 .246 .246 .249 .247 .246 .247 .247 .245 .247 .247

AVG. .244 .245 .246 .245 .245

Circumferential Weld C1

Thicknesses represented in inches.

Average shell plate thickness:

Shell Course 1: 0.245” Shell Course 5: 0.189” Shell Course 2: 0.182” Shell Course 6: 0.186” Shell Course 3: 0.182” Shell Course 7: 0.187” Shell Course 4: 0.183”

Refer to Drawing A-1 in Appendix A for plate numbers.

B-3

Table B-2: Fixed Roof Plate Ultrasonic Thickness Readings

PLATE 1 PLATE 2 PLATE 3 PLATE 4 PLATE 5

.153 .167 .186 .192 .178 .183 .159 .188 .159 .176

.157 .194 .182 .173 .171

.150 .144 .186 .176 .162 .178 .168 .191 .167 .184

AVG. .154 .187 .177 .176 .171

PLATE 6 PLATE 7 PLATE 8 PLATE 9 PLATE 10

.182 .186 .190 .191 .194 .195 .183 .188 .180 .153

.189 .187 .195 .189 .164

.185 .187 .192 .185 .189 .194 .183 .181 .163 .181

AVG. .186 .189 .193 .185 .168

PLATE 11 PLATE 12 PLATE 13 PLATE 14 PLATE 15

.175 .189 .186 .185 .182 .185 .191 .193 .184 .183

.190 .186 .184 .195 .182

.172 .184 .186 .185 .181 .185 .194 .194 .181 .182

AVG. .182 .186 .183 .193 .182

Thicknesses represented in inches.

Average fixed roof plate thickness: 0.181” Refer to Drawing A-2 in Appendix A for plate numbers.

B-4

Table B-3: Nozzles and Appurtenances

NOZZLE

NOZZLE SIZE

(Diameter or

Width/Height)

REPAD

SHAPE

REPAD SIZE

(W X H)

REPAD

THICKNESS

NOZZLE

THICKNESS

H1 H2

NOZZLE

LOCATION

(Measured circumferentially from Manway 1)

NOTES

MW1 24" D 55" x 50" .250 .196 2'-3" - 0' Manway

N1 1" - - - TH 35'-3" - 35'-5" HHLA/HLA

N2 1" - - - TH 33'-4" - 35'-5" HHLA/HLA

N3 1" - - - TH 35'-3" - 37'-10" HLCV Shut-off Switch Chamber

N4 1" - - - TH 33'-4" - 37'-10" HLCV Shut-off Switch Chamber

N5 1" - - - .182 2'-6" - 36'-9 LLA

N6 1" - - - .186 6" - 36'-10 LLA

MW2 36" D 64" x 60" .252 .362 3'-0" - 42'-11" Manway

N7 4" D 16" x 12" .366 .344 10" - 62'-10" Product Receipt

N8 4" D 21 1/2" X14" .245 .329 14 1/2" - 66'-6" Product Suction

N9 1" - - - .182 6" - 73'-0" Water Draw-off

N10 1 1/4" - - - TH Roof Float Gauge Guide Wire

N11 2" - - - TH Roof Float Gauge

N12 1 1/4" - - - TH Roof Float Gauge Guide Wire

N13 4" B 12" .251 .213 Roof Blind Flange

N14 24" B 48" .239 .249 Roof Emergency Vent

N15 10" B 24" .256 .366 Roof Blind Flange

N16 6" B 16" .237 .268 Roof P/V Vent

N17 8" B 24" .253 .365 Roof Gauging Hatch

MW3 24" - - - .248 Roof Manway w/ an ATG

Thickness measurements are in inches.

H1 = C/L of pipe to edge of roof or chime.

H2 = Edge of tank or chime to nearest weld toe.

TH = Threaded Repad Shapes:

Refer to Drawings A-1 and A-2 in Appendix A for nozzle numbers and locations.

B-5

Table B-4: Coating Thickness Measurements

External Shell Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

8.715 3.259 22 5.553 18.04

External Roof Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

10.02 2.528 15 6.731 17.01

Thickness measurements are represented in mils.

C-1

APPENDIX C

API 653 Inspection Checklist

C-2

Foundation Inspection

Item Description Comments

1 Foundation description Tank rests on a concrete ring wall within an earthen containment dike that is covered with a geo-membrane liner and paver ballasts.

2 Inspect for foundation damage or cracking.

None noted.

3 Evidence of bottom leakage or stains.

None noted.

4 List all significant cavities or erosion around the foundation.

None noted.

No erosion or cavities noted.

5 Inspect for vegetation under and around tank perimeter.

None noted.

Does tank have proper water runoff and drainage away from the tank?

Yes. Tank is elevated.

Is grade or other material covering the floor-to-shell weld or chime bottom plate?

Is any visual settlement noted around the tank perimeter?

What is the general condition of the dike area?

The containment dike is in good overall condition with no evidence of damage or compromise to the geo-membrane liner.

Vegetation was observed along the containment access stairs-to-dike floor interface.

Notes:

The tank bottom is provided with leak detection, via four (4) perimeter monitoring pipes.

C-3

Shell Inspection

Item Description Comments

1 Inspect shell ladders, stairways, platforms, and walkways.

Acceptable.

2 Inspect shell for significant distortions, creases and/or buckling.

None noted.

3 Visually inspect shell for out-of-roundness.

Acceptable.

4 Inspect shell support welds for corrosion or damage.

None noted.

5 Inspect wind girder for corrosion or damage.

N/A – Tank not equipped w/ wind girder.

6 Inspect external shell for leaks or significant corrosion areas.

None noted.

7 Inspect exterior shell-to-bottom weld area for corrosion, defects or thinning of the chime bottom plate.

None noted.

Inspection was limited due to external coating.

8 Inspect shell coating for failure, peeling or fading.

Coating is in good overall condition with no indications of coating failure.

9 Inspect the internal shell for pitting, corrosion, rubbing or grooving.

N/A – External Inspection.

10 Inspect horizontal and vertical seams for weld or rivet joint details.

Acceptable.

11 Inspect shell overflow vents for corrosion and screening.

N/A – The tank is not equipped with shell overflow vents.

12 Inspect shell for any lap patches. None noted.

13 Is the tank grounded?

Are the cables and clips in good condition?

Yes. The tank shell is equipped with two (2) grounding lugs and cables. Both grounding cables are in good overall condition with no evidence of damage and/or detachment.

14 Does the tank have a legible data plate?

Yes. The tank is equipped with the original and repaired/altered nameplate.

C-4

Nozzle and Appurtenance Inspection

Item Description Comments

1 Inspect nozzle flanges and bolting for leaks and corrosion.

External coating at the product receipt/suction TRV connecting flanges exhibit flaking and staining.

2 Inspect nozzles for pipe strain or misalignment.

No signs of visual pipe strain or misalignment.

3 Inspect valves for leaks or damage. None Noted.

4 Do nozzles, which require pressure relief, have crossovers at the valve?

The product receipt/suction line is equipped with a

TRV.

Is Tank equipped with High Level Control Valve and High Level Alarms?

Yes. The tank is equipped with a HLCV at the product receipt and shell mounted LLA, HLA, and HHLA, and HLCV shut-off switch chamber.

6 Verify operation of gauging system.

• Manual Gauging Hatch?

• Type of Gauge?

• Type of Automatic Gauging System?

8” manual gauging hatch w/ a fully slotted stilling well.

Varec 2500B Float Gauge

A MTS liquid level transmitter.

7 Inspect manways, nozzles and attachments for signs of corrosion or defects.

Note Noted.

8 Do all nozzle reinforcement pads have tell-tale holes? Are they plugged?

All shell reinforcement pads are provided with unplugged tell-tale holes.

9 Verify adequate reinforcement around nozzles and appurtenances.

Acceptable.

10 Verify adequate nozzle and appurtenances weld spacing.

Acceptable.

11 Verify interior nozzles have been back welded to the shell.

N/A – External Inspection

12 Check reinforcement pads for adequate fillet welds around pads.

Acceptable.

13 Visually inspect welds for defects on all nozzles and appurtenances.

Acceptable.

14 Does the inlet nozzle have a diffuser?

N/A – External Inspection

C-5

Fixed Roof Inspection

Item Description Comments

1 Inspect fixed roof protective coating system.

Good overall condition with no evidence of coating failure.

2 Inspect frangible joint / eave angle for corrosion, defects and coating failure.

Acceptable.

3 Inspect fixed roof for low spots and external corrosion.

None noted.

4 Conduct VT / UTT on roof nozzles and appurtenances.

Cracked coating was found at the 10” blind flange.

5 Visual inspection of internal roof supports, girders, columns and bases.

N/A – External Inspection

6 Verify open roof vents have screens and covers.

Acceptable.

7 Verify handrails and tie-off supports are in good condition.

Acceptable.

8 Measure any significant bulges and creases in the roof plates.

None noted.

9 Do any roof nozzles or appurtenances have bolt-on type reinforcement pads?

D-1

APPENDIX D

Calculations

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Tank No

Date 6/23/2015

1st Crs Plt Spec

Unknown

Y

30000

E

29000000 -0.015

S - Max Permissible

0.015

-0.010

-0.006

-0.010

-0.005

0.000

0.016

0.010

0.015

U

-0.015

0.004

-0.005

0.000

-0.006

0.011

-0.006

0.015

S

SAT

SAT

SAT

SAT

SAT

SAT

SAT

SAT

Results

Notes:

U = Measured out-of-plane settlement in relation to a cosine curve, in feet S = Deflection, in feet, (out-of-plane distortion) L = Arc length between measurement points, in feet Y = Yield strength, in pounds per square inch (psi) E - Young's modulus, in pounds per square inch (psi) H = Tank height , in feet

S <= 11L^2Y/2EH

Feet

4.43High Point

4.53Low Point

0.10

Planar Tilt

Ft

Ft

Ft

L

9.818

1.20 In.

Point 1

Point 2

Point 3

Point 4

Point 5

Point 6

Point 7

Point 8

4.52

4.51

4.47

4.44

4.43

4.46

4.49

4.53

H (ft)

36.0

D (ft)

25.0

D (ft)

H (ft)

1.350 M

1.381 M

3.05 cm

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Tank No

Date 6/23/2015

1st Crs Plt Spec

Unknown

API653 Survey Calculation

4.427

4.458

4.490

4.531

4.521

4.510

4.469

4.438

4.427

4.36

4.38

4.40

4.42

4.44

4.46

4.48

4.50

4.52

4.54

5 6 7 8 1 2 3 4 5

Survey Point

D e p th

File No

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Tank No

Date 6/23/2015Tank Shell Minimum Thickness and Remaining Life Calculations

Temp. (°F)

Material

35.00

29.05

27.05

21.10

15.15

9.20

3.25

0.

0.

0.

0.

0.

0.

0.

0.Unknown

Unknown

Unknown

Unknown

Unknown

Unknown

Unknown

23600

23600

26000

26000

26000

26000

26000

25 0.88 0.85G E 35.0

SE

tmin =

Where:

H = The height above the bottom of the course of study to the maximum liquid level height of the product, in feet (meters). For corroded or pitted areas, H = the height from the bottom of the corroded or pitted area to the maximum liquid level height of the product, in feet (meters).

tmin = The calculated minimum acceptable shell thickness, in inches (must be greater than 0.1 inch (2.5 mm) for any course). The minimum acceptable shell thickness allowed by API-653 for tank size, in inches (mm) or an alternate tmin based on low pressure calulations (int and/or ext pressures) or nominal thickness minus design corrosion allowance.

D = Nominal diameter of tank, in feet (meters).

G = Highest specific gravity of the contents (including test water if tank will, or may, be tested in the future).

S = Maximum allowable stress, in psi. For welded tanks; use the smaller of 0.80Y of 0.429T for bottom and second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks; S = 21,000 psi. (145 MPa)

Y = Specified minimum yield strength of the plate, in psi; use 30,000 psi (200 MPa) if not known

(N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80k psi (550 MPa); use

55,000 psi (380 MPa) if not known (N/A for riveted tanks).

E = Original joint efficiency for the tank. For welded tanks; use API-653, Table 4-2 ; use E = 1.0 when evaluating the retirement thickness in a corroded plate, when away from welds or joints by at least the greater of one inch (250 mm) or twice the plate thickness. For riveted tanks; use E =

1.0 for shell plates greater than 6 inches (150 mm) away from rivets; use the value of E from API-

653 Table 2-1 when within 6 inches (150 mm) of rivets.

5.95

2.00

5.95

5.95

5.95

5.95

5.95

Course 1

Course 2

Course 3

Course 4

Course 5

Course 6

Course 7

0.110

0.110

0.110

0.110

0.110

0.110

0.110

SHELL MINIMUM THICKNESS CALCULATIONS

0.11 0.11 0.11 0.11 0.11 0.11 0.11

2.6D(H-1)G tmin (in)S (psi)H (ft)Crs H (ft)

Fill Height (ft)D (ft)

File No

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Tank No

Date 6/23/2015Tank Shell Minimum Thickness and Remaining Life Calculations

Temp. (°F)

Nominal thicknesses are assumed based on current thickness measurements.

tmin

0.110

0.110

0.110

0.110

0.110

0.110

0.1100.245

0.182

0.182

0.183

0.189

0.186

0.187 tact

0.250

0.187

0.187

0.187

0.187

0.187

0.187 tprev Ca

0.072

0.072

0.073

0.079

0.076

0.077

0.135

Cr

0.0001

RL

1620.0

0.0001

0.0001

0.0001

0.0000

0.0000

0.0000

864.0

864.0

1095.0

>40

4560.0

>40

Where:

Ca = Remaining corrosion allowance of the shell course under consideration, in inches (mm).

Cr = Corrosion rate of the shell course under consideration, in inches (mm) per year.

FHc = Calculated Fill Height = SEtact/2.6DG+1 (SEtact/4.6DG+.3) plus the total product height below the course of study, in feet (meters).

tact = Minimum thickness measurement of the shell course under consideration, as recorded at the time of inspection, in inches (mm).

tmin = minimum required thickness of shell course, at the maximum allowable fill height, in inches (mm) tprev = previous thickness measurement of shell course under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches (mm).

RL = Estimated remaining life of the shell course under consideration, in years.

Y = Time span between thickness readings or age of the tank if nominal thickness is used for tprev, in years.

SHELL REMAINING LIFE CALCULATIONS

Ca = tact-tmin = Remaining Corrosion Allowance (inches (mm))

Cr = tprev-tact / Y = Corrosion Rate (inches (mm) per year)

RL = Ca / Cr = Remaining Life (years)

60Y = = Tank age (years)

Course 1

Course 2

Course 3

Course 4

Course 5

Course 6

Course 7

Course FHc

86.92

70.78

79.27

85.60

93.87

98.66

105.00

D-6

Shell Service Life Evaluation

Shell Course

Previous Thickness

(in.)

Current Thickness

(in.)

Years since Prev.

N

(in. /yr.)

Min Thickness

(in.)

RCA

(mils)

Next External (years)

Next

UTM

(years)

1 0.250 0.245 60 0.0010 0.110 135 5 15

2 0.187 0.182 60 0.0010 0.110 72 5 15

3 0.187 0.182 60 0.0010 0.110 72 5 15

4 0.187 0.183 60 0.0010 0.110 73 5 15

5 0.187 0.189 60 0.0010 0.110 79 5 15

6 0.187 0.186 60 0.0010 0.110 76 5 15

7 0.187 0.187 60 0.0010 0.110 77 5 15

N = Corrosion rate, if N is 0 then use the N of the next lower shell course RCA = Remaining Corrosion Allowance Interval to next formal external inspection = RCA/4 or 5 years maximum Interval to next Ultrasonic Thickness Measurements = RCA/2 or 15 years maximum

D-7

Nozzle Service Life Evaluation

See the following page for nozzle service life calculations. Component ID (Comp. Disc.) correlates with Table B-3, “Nozzles and Appurtenances” nozzle numbers. Only welded connections are included in the calculation. “tprev” is based on thicknesses from the previous API 653 inspection report or assumed nominal wall thicknesses for standard weight piping.

Nozzle/Pipe Remaining Life Calculations

Minimum Thickness Determinations:

a) The following pipe minimum thicknesses are based on the current in-house engineering standards, which take into consideration, pressures, structural integrity and localized corrosion allowance.

Size <=2" 3" 4" 6" 8" 10" 12" >12" t min

API-653 STORAGE TANK EVALUATION

0.080 0.100 0.100 0.125 0.125 0.156 0.188 0.188

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Vessel

Date

6/23/2015

Size t prev t act t min Ca Cr RL

Nozzle Remaining Life Calculations:

CML Comp. Disc.Age

MW1 0.250 0.196 0.188 0.008 0.00090 9001 2460 0.000

N5 0.179 0.182 0.080 0.102 0 >20002 160 0.000

N6 0.179 0.186 0.080 0.106 0 >20003 160 0.000

MW2 0.179 0.362 0.188 0.174 0 >20004 3660 0.000

N7 0.337 0.344 0.100 0.244 0 >20005 460 0.000

N8 0.337 0.329 0.100 0.229 0.00013 1718006 460 0.000

N9 0.179 0.182 0.080 0.102 0 >20007 160 0.000

N13 0.337 0.213 0.100 0.113 0.00207 55008 460 0.000

N14 0.250 0.249 0.188 0.061 0 >20009 2460 0.000

N15 0.365 0.366 0.156 0.210 0 >20010 1060 0.000

N16 0.280 0.268 0.125 0.143 0.00020 715011 660 0.000

N17 0.365 0.365 0.125 0.240 0 >20012 860 0.000

N18 0.250 0.248 0.188 0.060 0 >20013 2460 0.000

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-653 ATMOSPHERIC STORAGE TANK FIXED ROOF EVALUATION

File No

Report No

DUG-5661

Inspector

Anthony Chinn

Client

1150068-USACE

Tank No

Date

6/23/2015

DCa

Units

U.S.

Temp. °F

Where;

Ca = remaining corrosion allowance of the tank component under consideration, in inches (mm)

(t act - t min).

Cr = corrosion rate of the tank component under consideration, in inches (mm) per year (t prev - t act / Y).

DCa = original design corrosion allowance of the tank component under consideration, in inches (mm)

KPa = kilopascal - (1 KPa = 1000 Pa) (1 KPa=0.146psi) unit of pressure. It is a measure of force per unit area. 1 pascal (Pa) = 1 N/m2 = 1 J/m3 = 1 kg/(m·s2) oz = unit of measurement, (weight, in ounces, per square inch), (16 oz per pound) psi = unit of measurement, (weight, in pounds, per square inch)

RL = estimated remaining life of the tank component under consideration, in years (Ca / Cr).

t act = actual thickness measurement of the tank component under consideration, as recorded at the time of inspection, in inches (mm).

t min = minimum required thickness of tank component, at the design MAWP at the design temperature

(200°F for atm AST's), in inches (mm) (greater of psi/wt or 0.090" (2.3mm). Where tmin calculates to greater than tprev, tprev - 0.063" (1.6mm)).

t nom = design nominal thickness of tank component under consideration, in inches (mm).

t prev = previous thickness measurement of the tank component under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches (mm).

t yn = thickness of the tank component under consideration at the next inspection at twice the calculated corrosion rate, in inches (mm) (t act - (2*Cr*Yn).

wt = weight of plate per cubic inch.

wc = unit of measurement, (height, in inches, of water column bearing on 1 square inch area), (27.7 wc per pound)

Y = time span between thickness readings or age of the tank component if tnom is used for tprev, in years.

Yn = estimated time span to next inspection of the tank component under consideration, in years

Y t prev

0.187 t act

0.181 t min

0.110

Cr

0.00010

RL

ROOF PLATES - REMAINING LIFE

Ca

0.071

E-1

APPENDIX E

Photographs

Unless otherwise noted, all photographs contained in this report were taken by POND. POND hereby grants permission to the U.S. Government and its contractors to publish/republish these photos.

E-2

Tank 5661 Overview

Original Nameplate Repaired/Altered Nameplate

Containment Dike Overview

E-3

Vegetation at Containment Access Ladder-to-Dike Floor Interface

Ring Wall Overview Tank Chime-to-Ring Wall Interface

Typical Leak Detection Pipe Geo-Membrane Liner

E-4

Typical Grounding Cable Varec 2500B Float Gauge

MW1 Seismic Anchor Welded to MW1 Reinforcement

Pad

LLA HHLA/HLA and HLCV Shut-off Switch Chamber

E-5

MW2 Seismic Anchor Welded to MW2 Reinforcement

Pad

Product Receipt/Suction Line

Product Receipt/Suction TRV Crossover Piping with a Sight Flow Indicator and Coating Failure

E-6

Product Receipt Coating Failure at the Product Receipt HLCV

Product Suction

Water Draw-off System

E-7

Fixed Roof Overview

MTS Liquid Level Transmitter

Manual Gauging Hatch Emergency Vent

E-8

10” Blind Flange w/ Coating Failure

P/V Vent CP Recifier and Test Station