Attachment K-2 - BRD-FY21-FAC 10418-TANK 2-FINAL-Post Repair.pdf

*+*,+,-,* ..�/0�,*�*120

��!�2�3���������������45����2����(*-6*75..�/0�,*�*12 ��4$#�)�$$��3�8#4��9�%���:#%����� � �##$�!�$� ����4#����; �

)<*,7�2*02%2--.* �� )<*,7�*<�-*./

!��3�?�*.,71

���35��#�07**.

!�����?���A7/-,12,-0- 9 �

��� 4� %� �� %�+�� %�+4�

%# ���!�������� 93�����$���#� ���@����B�5�'������>'���+�

93�����$��C!#���%# ��7�

%��9�#��

%��)��4�

9 #�

D�

8��������

0�

�����#�9 #�

��0/.����@� � *-�2��!#������ ���% �

0- ��12 ����

����3

*0�4� ��0! ���5 �*4� 0��) ��4 �6�5 5��* 7 *)5

*)5 6 �� 5�*6 )+� *)5

�8,�(� �����6 �� ��*��51

#�4������6-,/2�5�"9$�,-*/ �#!$��# �#%�������������,-*,5�)������ ��3 �$#�#!�D��*��=�*

Jake Libby

KEAR Civil Corporation January 5th, 2021 18 Commerce Dr.

Danbury, CT 06810

Attn: Jake Libby Vice President of Operations – KEAR Atlantic 623.742.2322 Email: Jacob.Libby@kearcorp.com

Southwest Tank & Steel Job #: 19-029 Bradley Field Submittal #: 19029-12

The following documents are issued for Approval:

Submittal Type Description Reports Bradley Tank 2 API 653 Inspection Report

The attached submittal and/or submittals have been reviewed and approved by STS and show conformance to project drawings and specifications.

Please call Les Griffith (928) 451-5478 (cell) with any questions regarding these documents.

Regards, Les Griffith Project Manager mailto:Jacob.Libby@kearcorp.com

API 653 Out‐Of‐Service Inspection Report Tank 2 | Bradley Field, Connecticut

Page | 1

API 653 Out-Of-Service Inspection Report

Air National Guard, Bradley Field, Connecticut Bradley Field

Tank 2

Diameter: 32 ft. 9 in.

Capacity: 2,500 bbl.

Inspection date: November 2, 2020

Inspector: John Cloak (API 653 Cert. No. 48193)

Griffith Engineering Services, LLC

December 11, 2020

Page | 2

Table Of Contents

Acronyms and Abbreviations

Inspection Dates

Previous Inspection Dates

Recommended Future Inspection Dates

Section 1 Project Information

1.1 Summary

1.2 General Tank Information

Section 2 Tank Inspection …..……

2.1 General ………

2.2 Foundation

2.3 Bottom

2.4 Shell

2.5 Roof

2.6 Appurtenances

2.7 Coating

Section 3 Recommendations

3.1 Mandatory Repairs

3.2 Significant Findings and Recommended Repairs

Page | 3

List of Appendices Appendix A Engineering Calculations …………………….……………………………………………………………………….…. 12

i. Shell Thickness

ii. Bottom Thickness

Appendix B Drawings ……………………..…....……………..………………………………………………………………..….……….. 14

i. Shell Rollout

ii. Bottom Layout

Appendix C API 653 Checklists for Tank Inspection …….…………………….…………………………………….…..…….. 16

Appendix D Photographs ……………………………………………………………………………………………………….…..…….. 32

Page | 4

LIST OF ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute ASME American Society of Mechanical Engineers ASNT American Society of Non-Destructive Testing AST Aboveground Storage Tank ATG Automatic Tank Gauge bbl Barrel CFR Code of Federal Regulations CP Cathodic Protection DFT Dry Film Thickness

ft. Feet FML Flexible Membrane Liner HLA High Level Alarm HLCS High Level Control Shutoff HHLA High-High Level Alarm

in. Inches LF Linear Feet LLA Low Level Alarm LLLA Low-Low Level Alarm MFL Magnetic Flux Leakage MT Magnetic Particle Testing NDE Nondestructive Examination NFPA National Fire Protection Association PRV Pressure Relief Valve RP Recommended Practice UFC Unified Facilities Criteria USACE United States Army Corps of Engineers UT Ultrasonic Thickness Examination VT Visual Testing

Page | 5

Inspection Date

API Out‐Of‐Service (Internal) Inspection Date: November 2, 2020

Equipment Used: Ultra-sonic thickness meter

Manufacturer: K&M Instruments

Model Number: KT310D

Calibration Method: Two point calibration

Inspector(s): John Cloak (API 653 Cert. No. 48193)

Previous Inspection Dates

API Out‐Of‐Service (Internal) Inspection Date April 2017

API In‐Service (External) Inspection Date None

Recommended Future Inspection Dates

API Out‐Of‐Service (Internal) Inspection Date April 2037

API In‐Service (External) Inspection Date November 2025

John Cloak AZ PE Lic. #53860 API 653 Inspection Cert. #48193

EQUUS

Stamp

Page | 6

Section 1 Project Information

1.1 Summary

Griffith Engineering Services (GES) performed an API 653 out-of-service (internal and external) inspection of Tank 2 (Facility 10418), at ANGB Bradley Field in Connecticut. This inspection was completed on November 2, 2020 in accordance with API Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. Prior to the tank inspection, the floating pan perimeter and penetration seals were removed.

Tank 2 is a 32-foot and 9-inch diameter by 21-foot and 1-inch tall, single wall, vertical, field erected tank with a nominal storage capacity of 2,500 barrels of jet fuel (F-24). The tank has an aluminum internal floating pan. A previous out-of-service (internal) inspection was performed on tank 2 in April 2017 according to the name plate. The tank was originally constructed in 1993 by Witherup Fabrication & Erection Inc. to API 650 standards.

Secondary containment is provided by a concrete dike basin and steel reinforced concrete dike walls.

Details of tank construction and appurtenances are included in the Tank Information Table in Section 1.2.

No mandatory Repairs were identified during the inspection. Additional noted deficiencies are discussed in more detail in Section 3, and should be addressed in a timely manner. Photographs of the deficiencies are also included in Section 3. Additional photographs are included in Appendix D.

The next API Standard 653 In-service (visual external) inspection should be performed by November 2025. The next ultrasonic thickness inspection of the shell should be performed by November 2035.

While the current UFC 3-460-03 requires out-of-service inspection to occur every 10 years of service or as determined by a certified API 653 tank inspector. API would allow the inspection to be performed in 20 years, therefore, we recommend the next API Standard 653 Out-of-service (internal and external) inspection should be performed by April 2037, per the recommendations of the previous out-of-service inspection dated April 2017. This inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology, and a thorough code compliance evaluation.

Page | 7

1.2 General Tank Information

ITEM DESCRIPTION

Owner Connecticut Air National Guard Location ANGB Bradley Field Facility Number 10418 Tank Number Tank 2 State / Country Connecticut / U.S.A.

City East Granby Inspection Date November 2, 2020 Tank Manufacturer Witherup Fabrication and Erection, Inc.

Design Standard API 650 8th Edition Date of Construction 1993 Tank Contents Jet Fuel (F-24) Tank Serial Number 05265A Tank Diameter 32’-9” Shell Height 21’-1” Product Height 17’-0” (limited by overflow) Tank Capacity 2,500 bbl nominal.

Foundation Concrete Ring-wall

Construction

Bottom 0.25 in. Butt welded Shell 0.25 in. 1st-3rd Course Butt welded Floating Roof Aluminum Honeycomb Fixed Roof 0.1875 in. Supported

Material

Bottom Carbon steel (unknown grade) Shell SA-36 Floating Roof Aluminum Honeycomb Fixed Roof Carbon steel (unknown grade)

Cathodic Protection Impressed current Interior Coating System Interior 100% coated, likely epoxy

Exterior Coating System Epoxy/polyurethane assumed

Level Gauging Cameron ATG, Shand and Jurs Autogauge (tape gauge) Overfill Protection Independent high and high-high, level alarms, float operated LCV

Piping

Receipt 6 in. Carbon Steel Issue 12 in. Carbon Steel Low Suction 3 in. Carbon Steel Water Draw-Off 2 in. Carbon Steel

Level Alarms Independent Low, Low-Low, High, High-High level alarms; ATG Alarms

Page | 8

Section 2 Tank Inspection

2.1 General

Tank 2 is a 32’-9” diameter by 21’-1” tall, Jet Fuel (F-24) aboveground vertical storage tank. The tank was originally constructed in 1993 by Witherup Fabrication & Erection Inc., according to the manufacturer’s nameplate. The tank was built with a cone down bottom, aluminum honeycomb internal floating pan, and a center bottom sump. The interior floating pan was not installed during the inspection.

2.2 Foundation

The tank rests on a concrete ring wall foundation. The foundation was visually evaluated during the inspection. No significant spalling or broken concrete was found. The foundation appeared to be in good condition and acceptable for continued service.

2.3 Bottom

The bottom is constructed of carbon steel of A36. It is a cone down bottom design with a center sump. The tank bottom consists of 16 pie-shaped plates and a new annular ring consisting of 12 plates, butt-welded together and fillet-welded to the shell. The bottom has an epoxy coating, upon which various small coating failures have occurred. Evaluated the bottom, bottom welds, and bottom-to-shell weld for corrosion with no other discrepancies noted. Measured the general thickness throughout the tank bottom utilizing an ultrasonic thickness tester. UTMs of the bottom plate indicate 1/4-inch nominal steel for construction. No areas indicating underside corrosion were located. Thickness measurements are listed in the engineering data in Appendix A.

The bottom does not have a uniform slope down to the sump on approximately 50% of the bottom area. The bottom slopes down from the shell to where the annular plate joins with the existing bottom. At this joint, the bottom slopes upward before again sloping down towards the sump. This creates a ponding area in various locations of the bottom plate to annular ring joint. It is recommended that the bottom be monitored for any leaks or weld cracks during and after the hydro test. It is also recommended that during the next out of service API 653 inspection the bottom be evaluated with close attention to possible coating failures and corrosion and signs of excessive stress in the plates and welds.

2.4 Shell

The tank shell consists of three butt-welded courses. The exterior of the shell appeared to be in good condition. The ultrasonic thickness measurements of the shell and calculations included in Appendix A indicate the shell has more than 20 years of remaining life. The interior and exterior of the shell are coated. Isolated coating failures were found in various locations on the interior and exterior shell. As part of the current project, the interior and exterior of the shell is to be recorded. Areas of repair and new construction were not coated. API 653 recommends ultrasonic thickness measurements of the shell be taken at least every 15 years.

Page | 9

2.5 Roof

The tank has a beam supported, lap welded cone roof. The slope of the fixed roof appears to be approximately ¾:12. Several areas of coating failure and rust were found on the roof plates, but no severe corrosion.

2.6 Appurtenances

a. Internal Floating Pan

The interior floating pan was not installed in the tank during the inspection.

b. Venting

The roof is supplied with a center vent that appears to be in good condition along with 4 large perimeter roof vents.

c. Gauging

A new 6 in. ATG water probe well was installed approximately 3 ft. from the center of the tank. The new probe well appeared to be in good condition and installed properly.

d. Interior Piping & Appurtenances

New interior piping and shell nozzles were installed for the water draw, low suction, fill diffuser and issue nozzles. All new piping was constructed with carbon steel. All new pipe supports for interior piping had been installed per API 650/653 requirements. The new 3” diameter low suction nozzle only projects 4 ½” from the exterior shell to the face of the flange.

API 650 requires a 7” projection for 3” nozzles. Inspector noted that this was done to fit with existing exterior piping and valve. It is recommended that this nozzle be monitored for leaks and weld cracks during and after hydro test and monitored for leaks during operation.

e. Level Alarms

The tank has independent (shell mounted) high, high-high, low, and low-low level alarms.

The alarms appeared to be in good working condition. New fittings were installed as part of this contract and old ones removed and shell plates patched. Work seems to meet API requirements.

f. Stairs, Platforms, and Ladders

The tank’s steel cone roof is accessible by a circumferential stairway mounted on the shell of the tank. The circumferential stairway incudes an intermediate landing for accessing the upper shell manholes floating pan at high leg position and another top landing to access the roof. There is an interior ladder to access the top of the floating roof. The stairway, platforms, and interior ladder are in good condition.

2.7 Coating

No coating was present on areas of repair and new construction. As part of the current project, these areas will be recoated. The interior and exterior coatings otherwise appear to be in good condition.

Page | 10

Section 3 Recommendations

The tank facility was found to be in generally fair condition. The inspector was notified that the tank would be recoated at a later date. The tank is otherwise fully serviceable, with no other deficiencies that would require addressing before the tank is returned to service. There were also several items observed, that are not in full compliance with federal, state, and local regulations or other military criteria.

3.1 Mandatory Repairs Per API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards

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.

Page | 11

3.2 Significant Findings & Recommended Repairs

a. Bottom slope

Observation: The bottom does not slope uniformly to the sump at the center of the tank on approximately 50% of the bottom area.

Code Reference: AW 78-24-27 Standards

Recommendation: Monitor bottom plate for leaks and weld cracks during and after hydro test. Evaluate bottom during the next out of service inspection for coating failure and corrosion and signs of excessive stress in the bottom plates and welds.

b. 3” low suction nozzle exterior projection

Observation: Inspector noted the 3” low suction nozzle flange only projects 4 ½” from the shell. API 650 requires a 7” projection from the shell for a 3” nozzle.

Code Reference: API 650/653

Recommendation: Monitor the nozzle for signs of leaking or weld cracks during operation. Inspector noted the nozzle was modified to fit with existing valve and exterior piping.

Page | 12

i. Shell Thickness

SHELL UT READINGS

(Approximate 24" Vertical Spacing)

PLATE UT READING LOCATIONS

(1st Course)

Location SP1 SP2 SP3 SP4 SP5 1 0.261 0.260 0.250 0.249 0.263 2 0.263 0.261 0.251 0.250 0.263 3 0.261 0.262 0.249 0.248 0.263 4 0.263 0.260 0.250 0.249 0.264 5 0.261 0.261 0.251 0.249 0.263

T1 = 0.257 (avg.) (All courses 0.25" original thickness) T2 = 0.248 (min.) *All measurements in inches

Tmax = 0.264

(2nd Course) (3rd Course) Location SP6 Location SP7

1 0.260 1 0.258 2 0.261 2 0.259 3 0.260 3 0.262 4 0.261 4 0.258 5 0.259 5 0.258

T1 = 0.260 (avg.) T1 = 0.259 (avg.)

T2 = 0.259 (min.) T2 = 0.258 (min.)

Tmax = 0.261 Tmax = 0.262

Page | 13

ii. Bottom Thickness

BOTTOM UT READINGS

PLATE UT READING LOCATIONS

Location 1 2 3 4 5 B1 0.239 0.240 0.239 0.240 0.241 B2 0.247 0.248 0.247 0.248 0.249 B3 0.245 0.246 0.244 0.245 0.245 B4 0.248 0.249 0.250 0.248 0.249 B5 0.252 0.251 0.250 0.251 0.252 B6 0.251 0.250 0.252 0.251 0.249 B7 0.244 0.243 0.244 0.243 0.247 B8 0.247 0.248 0.246 0.247 0.248 B9 0.243 0.242 0.242 0.243 0.243 B10 0.253 0.252 0.252 0.253 0.251 B11 0.245 0.246 0.245 0.244 0.245 B12 0.246 0.243 0.244 0.246 0.244 B13 0.244 0.243 0.244 0.242 0.243 B14 0.247 0.246 0.247 0.246 0.246 B15 0.246 0.247 0.248 0.247 0.248 B16 0.248 0.247 0.248 0.247 0.248

AR1 0.241 0.241 0.240 0.241 0.242

AR2 0.245 0.244 0.243 0.245 0.244

AR3 0.241 0.241 0.242 0.242 0.241

AR4 0.241 0.241 0.242 0.240 0.241

AR5 0.242 0.241 0.242 0.241 0.242

AR6 0.242 0.243 0.243 0.242 0.243

AR7 0.241 0.242 0.240 0.241 0.242

AR8 0.242 0.243 0.241 0.242 0.243

AR9 0.264 0.265 0.266 0.264 0.264

AR10 0.266 0.264 0.265 0.268 0.266

AR11 0.243 0.242 0.244 0.243 0.242

AR12 0.244 0.246 0.244 0.243 0.244

avg. 0.246 (0.25" original thickness, nominal) min. 0.239 *All measurements in inches

UT taken in critical zone

Page | 14

Appendix B Drawings

i. Shell Rollout

Page | 15

ii. Bottom Layout

Page | 16

Appendix C API 653 Checklists for Tank Inspection Item Completed Comments

C.1.1 Foundation Measure foundation levelness and bottom elevations X

C.1.1.1 Concrete Ring A) Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt‐welded annular rings under the shell.

X

B) Inspect drain openings in ring, back of waterdraw basins and top surface of ring for indications of bottom leakage.

X

C) Inspect for cavities under foundation and vegetation against bottom of tank.

X None noted

D) Check that runoff rainwater from the shell drains away from tank. X E) Check for settlement around perimeter of tank. X None noted

C.1.1.2 Asphalt A) Check for settling of tank into asphalt base which would direct runoff rain water under the tank instead of away from it.

N/A

B) Look for areas where leaching of oil has left rock filler exposed, which indicates hydrocarbon leakage.

N/A

C.1.1.3 Oiled Dirt or Sand Check for settlement into the base which would direct runoff rain water under the tank instead of away from it.

N/A

C.1.1.4 Rock Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

N/A

C.1.1.5 Site Drainage A) Check site for drainage away from the tank and associated piping and manifolds.

X Good

B) Check operating condition of the dike drains. X C.1.1.6 Housekeeping

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

X

C.1.1.7 Cathodic Protection Review cathodic protection potential readings. N/A

C.1.2 Shells C.1.2.1 External Visual Inspection

A) Visually inspect for paint failures, pitting, and corrosion. X Coating being done B) Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld.

X Chime area collects water. Rust noted.

C) Inspect the bottom‐to‐foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank) Visually inspect for grooving, corrosion, pitting, and coating failures. X None noted

C.1.2.3 Riveted Shell Inspection A) Inspect external surface for rivet and seam leaks. N/A B) Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting).

N/A

C) Inspect rivets for corrosion loss and wear. N/A

Page | 17

D) Inspect vertical seams to see if they have been full fillet lap‐welded to increase joint efficiency.

N/A

E) If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern: number of rows, rivet size, pitch length, and note whether the joint is butt‐riveted or lap riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks) A) Inspect wind girder and handrail for corrosion damage (paint failure), pitting, corrosion product buildup), especially where it occurs at tack‐welded junction, and for broken welds.

N/A

B) Check support welds to shell for pitting, especially on shell plates. N/A C) Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 Shell Appurtenances C.1.3.1 Manways and Nozzles

A) Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates.

X None noticed

B) Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection.

X

C) Inspect for flange leaks and leaks around bolting. X D) Inspect sealing of insulation around manways and nozzles. N/A E) Check for inadequate manway flange and cover thickness on mixer manways.

N/A

C.1.3.2 Tank Piping Manifolds A) Inspect manifold piping, flanges, and valves for leaks. X B) Inspect fire fighting system components. N/A C) Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

N/A

D) Check for adequate thermal pressure relief of piping to the tank. X E) Check operation of regulators for tanks with purge gas systems. N/A F) Check sample connections for leaks and for proper valve operation. N/A G) Check for damage and test the accuracy of temperature indicators. N/A H) Check welds on shell‐mounted davit clips above valves 6 in. and larger.

X New davits mounted manway flange C.1.3.3 Autogauge System

A) Inspect autogauge rape guide and lower sheave housing (floating swings) for leaks.

N/A

B) Inspect autogauge head for damage. N/A C) Bump the checker on autogauge head for proper movement of tape. N/A D) Identify size and construction material of autogauge tape guide

(floating roof tanks).

N/A

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

N/A

F) Compare actual product level to the reading on the autogauge (maximum variation is 2 in.).

N/A

G) On floating roof tanks, when the roof is in the lowest position, check that no more than two ft. of tape are exposed at the end of the tape guide.

N/A

H) Inspect condition of board and legibility of board‐type autogauges. N/A I) Test freedom of movement of marker and float. N/A

C.1.3.4 Shell‐mounted Sample Station A) Inspect sample lines for function of valves and plugging of lines, including drain or return‐to‐tank line.

Page | 18

B) Check circulation pump for leaks and operating problems. N/A C) Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted) Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer A) Inspect for proper mounting flange and support. N/A B) Inspect for leakage. N/A C) Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation A) Non‐floating: Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly.

N/A

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

N/A

C) 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 shows the opposite.

N/A

C.1.3.8 Swing Lines: External Guide System Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition A) For non‐stainless steel cable, check for corrosion over entire length. N/A B) All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison Check for water or gravity differences that would indicate a leaking swing joint.

N/A

C.1.3.12 Roof Drains: Open Systems, Including Emergency Drains Target should indicate direction of swing opening (up or down) and height above bottom where suction will be lost with swing on bottom support.

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).

X No severe corrosion found

C.1.4.2 Deck Plate External Corrosion Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck.

X

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 non‐ level roof with possible leaking pontoons).

X

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 non‐level roof with possible shell out‐of‐round, out‐of‐plumb, leaking pontoons, or hang‐up. On small diameter tanks, an unlevel condition can indicate

Page | 19 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.

N/A

C.1.4.6 Roof Insulation A) Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation.

N/A

B) Inspect for wet insulation under the weather coat. N/A C) Remove small test sections of insulation and check roof plate for corrosion and holes near areas susceptible to water ingress (i.e. roof nozzles, etc.).

N/A

C.1.4.7 Floating Roof Seal Systems A) 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).

N/A

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.

1) __________ ___________ Opposite pair 1.

2) __________ ___________ Opposite pair 2.

N/A

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

N/A

D) Inspect fabric for deterioration, holes, tears, and cracks. N/A E) Inspect visible metallic parts for corrosion and wear. N/A F) Inspect for openings in seals that would permit vapor emissions. N/A G) Inspect for protruding bolt or rivet heads against the shell. N/A H) Pull both primary and secondary seal systems back all around the shell to check their operation.

N/A

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

N/A

J) Inspect wedge‐type wiper seals for flexibility, resilience, cracks, and tears.

N/A

C.1.5 Roof Appurtenances C.1.5.1 Sample Hatch

A) Inspect condition and functioning of sample hatch cover. X B) On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

N/A

C) Check for corrosion and plugging on thief and gauge hatch cover. X D) Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold –off distance.

X

E) Check for reinforcing pad where sample hatch pipe penetrates the roof deck.

N/A

F) On floating roof sample hatch and recoil systems, inspect operation of recoil reel and condition of rope.

N/A

G) Test operation of system. N/A H) On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from

Page | 20 pipe getting into sample).

C.1.5.2 Gauge Well

A) Inspect visible portion of the gauge well for thinning, size of slots, and cover condition.

X Stainless steel ok. Top fitting corrosion noted.

See report and pictures.

B) Check for a hold‐off distance marker and tab with hold‐off distance (legible).

X

C) On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

N/A

D) If accessible, check the distance from the gauge well pipe to the tank shell at different levels.

X

E) If tank has gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

N/A

C.1.5.3 Fixed Roof Scaffold Support Inspect scaffold support for corrosion, wear, and structural soundness. X Vent used ok

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof) A) Check the hatch for corrosion and missing bolts. X B) Look for corrosion on the tape guide’s and float guide’s wire anchors. X

C.1.5.5 Autogauge: Float Well Cover A) Inspect for corrosion. N/A B) Check tape cable for wear or fraying caused by rubbing on the cover. N/A

C.1.5.6 Sample Hatch (Internal Floating Roof) A) Check overall conditions. X B) When equipped with a fabric seal, check for automatic sealing after sampling.

N/A

C) When equipped with a recoil reel opening device, check for proper operations.

N/A

C.1.5.7 Roof‐mounted Vents (Internal Floating Roof) Check condition of screens, locking and pivot pins. X

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.

N/A

C.1.5.9 Emergency Roof Drains 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.

N/A

C.1.5.10 Removable Roof Leg Racks Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers 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.

N/A

C.1.5.12 Rim Vents A) Check condition of the screen on the rim vent cover. N/A B) Check for plating off or removal of rim vents where jurisdictional rules do not permit removal.

N/A

C.1.5.13 Pontoon Inspection Hatches A) Open pontoon inspection hatch covers and visually check inside for pontoon leakage.

N/A

B) Test for explosive gas (an indicator of vapor space leaks). N/A C) If pontoon hatches are equipped with locked down coves, check for N/A

Page | 21 vent tubes. Check that vent tubes are not plugged up. Inspect lock‐ down devices for condition and operation.

C.1.6 Access ways See Tank out‐of‐service Inspection Checklist, Item C.2.12.

NOTES

Page | 22

Item Completed Comments C.2.1 Overview

A) Check that tank has been cleaned, is gas free, and safe for entry. X B) Check that the tank is completely isolated from product lines, all electrical power, and steam lines. X

C) Check that roof is adequately supported, including fixed roof structure and floating roof legs. X

D) Check for presence of falling object hazards, such as corroded through roof rafters, asphalt stalactites, and trapped hydrocarbons in unopened or plugged equipment or appurtenances, ledges, etc.

X

E) Inspect for slipping hazards on the bottom and roof decks. X F) Inspect structural welds on access ways and clips. X G) Check surfaces needing inspection for a heavy scale buildup and check weld seams and oily surfaces where welding needs to be done. Note areas needing more cleaning and blasting.

H) Review cathodic protection potential readings. Not Done C.2.2 Tank Exterior

A) Inspect appurtenances opened during cleaning such as lower floating swing sheave assemblies, nozzle interiors (after removal of valves). X

B) Hammer test or ultrasonically test the roof. X See report and noted repairs

C) Enter and inspect the floating roof pontoon compartments. N/A C.2.3 Bottom Interior Surface

A) Using a flashlight held close to and parallel to the bottom plates, and using the bottom plate layout as a guide, visually inspect and hammer test the entire bottom.

X Plates look good, solid rebound with hammer

B) Measure the depth of pitting and describe the pitting appearance (sharp edged, lake type, dense, scattered, etc.). X None found

C) Mark areas requiring patching or further inspection. X Ok D) Mark locations for turning coupons for inspections. X None needed E) Inspect all welds for corrosion and leaks, particularly the shell‐to‐ bottom weld. X

F) Inspect sketch plates for corrosion. X Note recoating being done on this contract

G) Check condition of internal sump, if applicable. Standing liquid should be removed from the sump to allow for complete inspection and vacuum testing of the weld seams as appropriate. Sump bottom and sidewall plate and seams need to be evaluated for both product‐side and soil‐side corrosion.

H) Locate and mark voids under the bottom. X I) Record bottom data on a layout sketch using existing bottom plates as a grid. List the number and sizes of patches required. X

J) Vacuum test the bottom lap welds. N/A Tank bottom coated K) Hammer test or ultrasonically examine any slightly discolored spots or damp areas. X

L) Check for reinforcing pads under all bottom attached clips, brackets, and supports. X

M) Inspect floating roof leg pads for pitting or cutting, and excessive dimpling (indicating excessive loading). X

N) Check the column bases of fixed roof supports for adequate pads and restraining clips. N/A Self‐supported beam roof

Page | 23

O) In earthquake zones 3 and 4, check that roof supports are not welded down to the tank bottom, but are only restrained from horizontal movements.

N/A Self‐supported beam roof

P) Check area beneath swing line cable for indications of cable cutting or dragging. N/A

Q) Mark old oil and air test connection for removal and patching. N/A R) Identify and report low areas on the bottom that do not drain adequately. X None noted

S) Inspect coating for holes, disbonding, deterioration, and discoloration. X C.2.4 Shell Seams and Plate

A) On cone up bottoms, closely inspect and gauge the depth of metal loss on the lower 2 in. to 4 in. of the shell (area of standing water). N/A Cone down to sump

B) Measure the depth of pitting on each course. N/A None found C) Inspect and estimate the amount of metal loss on the heads of rivets and bolts. N/A Not riveted

D) Inspect shell‐to‐bottom riveted lap joints. N/A Not riveted E) Inspect for vertical grooving damage from seal assembly protrusions. X None noted F) Inspect existing protective coatings for damage, deterioration, and disbonding. X New coating in scope of work

G) Check for areas of rubbing (indicating too much pressure by the seal assembly shoes or inadequate annular space). X None noted

H) Visually inspect the shell plates and seams for indications of leakage. X I) If the shell has riveted or bolted seams, record the leak locations by film or chart in case the locations are lost during surface preparation for painting.

J) Measure annular space at 40‐ft intervals. X K) Survey the shell to check for roundness and plumb. X

C.2.5 Shell‐mounted Overflows A) Inspect overflow for corrosion and adequate screening. X B) Check location of overflow that it is not above any tank valves or equipment. X

C.2.6 Roof Interior Surface C.2.6.1 General

A) Visually inspect the underside surface of the roof plates for holes, scale build up, and pitting. X Looks good coated

B) Hammer test or ultrasonically examine to check for thin areas, particularly in the vapor space of floating roofs and at the edge of roof on cone roof tank.

C) Check all clips, brackets, braces, etc., welded to the roof deck plate for welded reinforcing pads and see that they have not broken free. N/A

D) If no pad is present, penetrant test for cracking of the weld or deck plate. N/A

E) Inspect for protective coating for breaks, disbondment, and deterioration. N/A Recoating planned

F) Spark test the interior surface coating if recoating is not planned. N/A Recoating planned C.2.6.2 Fixed Roof Support Structure

A) Inspect the support columns for thinning in the upper 2 ft. N/A Self‐supported beam roof

B) On API columns (two channels welded together) check for corrosion scale breaking the tack welds, unless the joint between the channels is completely seal welded.

N/A Self‐supported beam roof

Page | 24

C) Check that the reinforcing pad on the bottom is seal‐welded to the tank bottom with horizontal movement restraining clips welded to the pad.

D) Determine if the pipe column supports are concrete filled or open pipe. If open pipe, check for a drain opening in the bottom of the pipe.

E) Inspect and gauge rafters for thinning, particularly near the center of the roof. Report metal loss. X No thinning noted

F) Check for loose or twisted rafters. X None reported G) Inspect girders for thinning and check that they are attached securely to the top of the columns. N/A No girders

H) Report if the columns have cross bracing in the area between the low pump out of the top of the shell (for future internal floating roof installation).

I) Inspect and report presence of any roof‐mounted swing line bumpers. N/A J) Photograph the roof structure if no rafter layout drawing exists. X

C.2.7 Fixed Roof Appurtenances C.2.7.1 Inspection and Light Hatches

A) Inspect the hatches for corrosion, paint and coating failures, holes, and cover sealing. X

B) On loose covers, check for a safety chain in good condition. X C) On light hatches over 30 in. across, check for safety rods. N/A D) Inspect the condition of the gaskets on bolted or latched down hatch covers. X

C.2.7.2 Staging Support Connection Inspect the condition of the staging support for corrosion. N/A

C.2.7.3 Breathers and Vents A) Inspect and service the breather. N/A B) Inspect screens on vents and breathers. X

C.2.7.4 Emergency P/V Hatches A) Inspect and service pressure/ vacuum hatches. (Setting should be high enough to prevent chattering of breather during normal operation.

See breather manufacturer’s guide.).

B) Inspect liquid seal hatches for corrosion and proper liquid level in the seal. N/A

C.2.7.5 Sample Hatch A) Inspect the sample hatch for corrosion. X B) Check that the cover operates properly. X C) If the tank has no gauge well, check for a hold‐off distance marker and check measurement. N/A

C.2.8 Floating Roof C.2.8.1 Roof Deck

A) Hammer test the areas between roof rim and shell. (If access for hammer testing is inadequate, measure the distance from the bottom edge of the roof to the corroded area and then hammer test from inside the pontoon.)

B) In sour water service, clean and test all deck plate weld seams for cracking unless the lower laps have been seal‐welded. N/A

C) Check that either the roof drain is open or the drain plug in the roof is open in case of unexpected rain. N/A

D) On flat bottomed and cone bottom roof decks, check for a vapor dam N/A

Page | 25 around the periphery of the roof. The dam should be continuous without break to prevent escape of vapors to the seal area from under the center of the roof.

C.2.8.2 Floating Roof Pontoons A) Visually inspect each pontoon for liquid leakage. N/A B) Run a light wire through the gooseneck vents on locked down inspection hatch covers to make sure they are open. N/A

C) Inspect lockdown latches on each cover. N/A D) Check and report if each pontoon is either:

1) Vapor tight (bulkhead seal welded on one side on bottom, sides, and top),

2) Liquid tight (seal‐welded on bottom and sides only),

3) Unacceptable (minimum acceptable condition is liquid tight).

C.2.8.3 Floating Roof Cutouts A) Inspect underside of cutouts for mechanical damage. N/A B) Inspect welds for cracks. N/A C) Inspect plate for thinning, pitting, and erosion. N/A D) Measure mixer cutouts and record plate thickness for future mixer installation or replacement.

Plate thickness ______.

C.2.8.4 Floating Roof Supports A) Inspect fixed low and removable high floating roof legs for thinning. N/A B) Inspect for notching at bottom of legs for drainage. N/A C) Inspect for leg buckling or felling at bottom. N/A D) Inspect pin hole in roof guide for tears. N/A E) Check plumb of all legs. N/A F) Inspect for adequate reinforcing gussets on all legs through a single portion of the roof. N/A

G) Inspect the area around the roof legs for cracking if there is no internal reinforcing pad or if the topside pad is not welded to the deck plate on the underside.

H) Inspect the sealing system on the two‐position legs and the vapor plugs in the fixed low leg for deterioration of the gaskets. N/A

I) On shell‐mounted roof supports, check for adequate clearance based on the maximum floating roof movement as determined by the position of the roof relative to the gauge well and/or counter‐ rotational device.

C.2.9 Floating Roof Seal Assemblies C.2.9.1 Primary Shoe Assembly

A) Remove four sections of foam log (foam‐filled seals) for inspection on 90° locations. N/A

B) Inspect hanger attachment to roof rim for thinning, bending, broken welds, and wear of pin holes. N/A

C) Inspect clips welded to roof rim for thinning. N/A D) Shoes—inspect for thinning and holes in shoes. N/A E) Inspect for bent‐metal bolts, clips, and attachments. N/A F) Seal fabric—inspect for deterioration, stiffening, holes, and tears in fabric. N/A

G) Measure length of fabric from top of shoe to roof rim, and check against maximum anticipated annular space as roof operates. N/A

H) Inspect any modification of shoes over shell nozzles, mixers, etc., for N/A

Page | 26 clearance.

I) Inspect shoes for damage caused by striking shell nozzles, mixers, etc. N/A

C.2.9.2 Primary Toroidal Assembly A) Inspect seal fabric for wear, deterioration, holes, and tears. N/A B) Inspect hold‐down system for buckling or bending. N/A C) Inspect foam for liquid absorption and deterioration. N/A

C.2.9.3 Rim‐mounted Secondaries A) Inspect the rim‐mounted bolting bar for corrosion and broken welds. N/A B) Measure and chart seal‐to‐shell gaps. N/A C) Visually inspect seam from below, looking for holes as evidenced by light. N/A

D) Inspect fabric for deterioration and stiffness. N/A E) Inspect for mechanical damage, corrosion, and wear on tip in contact with shell. N/A

F) Inspect for contact with obstructions above top of shell. N/A C.2.10 Floating Roof Appurtenances C.2.10.1 Roof Manways

A) Inspect walls of manways for pitting and thinning. N/A B) On tanks with interference autogauges, check seal around gauge tape cable and guide wires through manway cover. N/A

C) Inspect cover gasket and bolts. N/A C.2.10.2 Rim Vent

A) Check rim vent for pitting and holes. N/A B) Check vent for condition of screen. N/A C) On floating roof tanks where the environmental rules require closing off the vent, check the vent pipe for corrosion at the pipe‐to‐rim joint and check that the blinding is adequate.

C.2.10.3 Vacuum Breaker, Breather Type A) Service and check operation of breather valve. N/A B) Check that nozzle pipe projects no more than ½ in. below roof deck. N/A

C.2.10.4 Vacuum Breaker, Mechanical Type A) Inspect the stem for thinning. Measure how far the vacuum breaker cover is raised off the pipe when the roof is resting on high or low legs.

1) On high legs ______.

2) On low legs ______.

C.2.10.5 Roof Drains: Open Systems, Including Emergency Drains A) Check liquid level inside open roof drains for adequate freeboard.

Report if there is insufficient distance between liquid level and top of drain.

B) If tank comes under Air Quality Monitoring District rules, inspect the roof drain vapor plug. N/A

C) If emergency drain is not at the center of the roof, check that there are at least three emergency drains. N/A

C.2.10.6 Closed Drain Systems: Drain Basins A) Inspect for pitting and thinning. N/A B) Inspect protective coating (topside). N/A C) Inspect basin cover or screen for corrosion. N/A D) Test operation of check valve. N/A E) Check for the presence of check valve where bottom of basin is below product level. N/A

Page | 27

F) Inspect drain basin(s) to roof deck welds for cracking. N/A G) Check drain basin(s) outlet pipe for adequate reinforcement to roof deck (including reinforcement pad). N/A

C.2.10.7 Closed Drain Systems: Fixed Drain Line on Tank Bottom A) Hammer test drain line on tank bottom for thinning and scale/debris plugging. N/A

B) Inspect supports and reinforcing pads for weld failures and corrosion. N/A C) Check that pipe is guided, not rigidly locked to support, to avoid tearing of tank bottom plate. N/A

C.2.10.8 Closed Drain Systems: Flexible Pipe Drain A) Inspect for damage to exterior of pipe. N/A B) Check for obstructions that pipe could catch on. N/A C) Inspect shields to protect pipe from snagging. N/A D) Inspect results of hydrostatic test on flexible roof drain system. N/A

C.2.10.9 Closed Drain Systems: Articulated Joint Drain A) Hammer test rigid pipe in flexible joint systems for thinning and scale/debris plugging. N/A

B) Inspect system for signs of bending or strain. N/A C) Inspect results of system hydrostatic test. N/A D) Inspect landing leg and pad. N/A

C.2.10.10 Autogauge Systems and Alarms A) Check freedom of movement of tape through autogauge tape guide. N/A B) Inspect sheaves for freedom of movement. N/A C) Test operation checker. N/A D) Inspect tape and tape cable for twisting and fraying. N/A E) Test the tape’s freedom of movement through guide sheaves and tape guide pipe. N/A

F) On open‐top tanks, check that gate tapes with cables have no more than one foot of tape exposed with float at lowest point. N/A

G) Check float for leakage. N/A H) Test float guide wire anchors for spring action by pulling on wire and releasing. N/A

I) Inspect float wells in floating roofs for thinning and pitting of walls just above the liquid level. N/A

J) Check that the autogauge tape is firmly attached to the float. N/A K) Inspect the tape cable and float guide wire fabric seals through the float well cover. N/A

L) Inspect the bottom guide wire attachment clip: inspect for a temporary weighted bar instead of a permanent welded down clip. N/A

M) Inspect board‐type autogauge indicators for legibility and freedom of movement of indicator. N/A

N) Measure and record these distances to determine if seal damage will occur if tank is run over from:

1) Shell top angle to underside of tape guide system.

2) Liquid level on floating top to top of secondary seal.

O) Identify floating roofs where the tape is connected directly to the roof. N/A

P) Overfill alarm: inspect tank overfill prevention alarm switches for proper operation. N/A

C.2.11 Common Tank Appurtenances C.2.11.1 Gauge Well

Page | 28

A) Inspect gauge well pipe for thinning at about two‐thirds distance above the bottom: look for thinning at the edge of the slots. X

B) Check for corrosion on the pipe joint. Check that sample cords, weights, thermometers, etc., have been removed from the pipe. X

C) Check for cone at bottom end of pipe about one foot above the bottom. X

D) Check condition of well washer pipe and that its flared end is directed at the near side of the hold off pad. N/A

E) Check that supports for gauge well are welded to pad or to shell and not directly to bottom plate. X

F) Check operation of gauge well cover. X G) Check presence of a hold‐off distance marker in well pipe and record hold off distance.

Hold‐off distance ______.

H) Identify and report size and pipe schedule, and whether pipe is solid or slotted. Report slot size. X See pictures and report I) Check that the hold‐off distance plate is seal welded to the bottom and that any gauge well supports are welded to the plate and not directly to the bottom.

J) Inspect vapor control float and cable. N/A K) Check for presence and condition of gauge well washer. N/A L) Check for bull plug or plate blind on gauge well washer valve. N/A M) Inspect gauge well guide in floating roof for pitting and thinning. N/A N) Inspect the guide rollers and sliding plates for freedom of movement. N/A O) Inspect condition of gauge well pipe seal system. N/A P) On black oil and diesel services: if gauge well is also used for sampling, check for presence of a thief‐ and gauge‐type hatch to avoid spillage. N/A

Q) Visually inspect inside of pipe for pipe weld protrusions which could catch or damage vapor control float. N/A

C.2.11.2 Sampling Systems: Roof Sample Hatches A) Inspect roof‐mounted sample hatches for reinforcing pads and cracking. X

B) Inspect cover for operation. X C) For tanks complying with Air Quality Monitoring District rules, inspect sample hatch covers for adequate sealing. X

D) Check horizontal alignment of internal floating roof sample hatches under fixed roof hatches. N/A

E) Inspect the sealing system on the internal floating roof sample hatch cover. N/A

F) Inspect floating roof sample hatch cover recoil reel and rope. N/A C.2.11.3 Shell Nozzles

A) Inspect shell nozzles for thinning and pitting. X B) Inspect hot tap nozzles for trimming of holes. X None noted C) Identify type of shell nozzles. X D) Identify and describe internal piping, including elbow‐up and elbow‐ down types. X

C.2.11.4 For Nozzles Extended Into the Tank A) Inspect pipe support pads welded to tank bottom. X B) Inspect to see that pipe is free to move along support without strain or tearing action on bottom plate. X Hardware removed for painting

C) Inspect nozzle valves for packing leaks and damaged flange faces. X

Page | 29

D) Inspect heater system nozzle flanges and valves for wire cutting. N/A E) Report which nozzles have thermal pressure relief bosses and valves. X See pictures F) In internal elbow‐down fill line nozzles, inspect the wear plate on the tank bottom. N/A

G) On elbow‐up fill lines in floating roof tanks, check that opening is directed against the underside of the roof, not against vapor space.

Inspect impact are for erosion.

C.2.11.5 Diffusers and Air Rolling Systems A) Inspect diffuser pipe for erosion and thinning. X B) Check holes in diffuser for excessive wear and enlargement. N/A C) Inspect diffuser supports for damage and corrosion. X D) Check that diffuser supports restrain, not anchor, longitudinal line movement. X

E) Inspect air spiders on bottom of lube oil tanks for plugging and damaged or broken threaded joints. N/A

C.2.11.6 Swing Lines A) Inspect flexible joint for cracks and leaks. N/A B) Scribe the flexible joint across the two moving faces and raise end of swing line to check the joint’s freedom of movement, indicated by separation of scribe marks.

C) Check that flexible joints over 6 in. are supported. N/A D) Inspect the swing pipe for deep pitting and weld corrosion. N/A E) Loosen the vent plugs in the pontoons and listen for a vacuum. Lack of vacuum indicates a leaking pontoon. N/A

F) Check the results of air test on pontoons during repairs. N/A G) Inspect the pontoons for pitting. N/A H) Inspect the pull‐down cable connections to the swing. N/A I) Inspect the condition of the bottom mounted support, fixed roof limiting bumper, or shell mounted limiting bumper for wood condition, weld and bolt corrosion, and seal welding to the bottom or shell.

J) Inspect safety hold‐down chain for corrosion and weak links. N/A K) Check that there is a welded reinforcing pad where the chain connects to the bottom. N/A

L) If the floating swing in a floating or internal floating roof tank does not have a limiting device preventing the swing from exceeding 60 degrees, measure and calculate the maximum angle possible with the roof…