Attachment K.1 - Dyess-Fac 5220 (Tank 5220)-FINAL-2017.pdf

PDF 3 MB Posted Jul 12, 2022

Attached to: POL Tank Inspection, Dyess AFB, TX
Solicitation number: W9128F22Q0084
Issued by: Department of the Army Corps of Engineers Engineering District Omaha

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Attachment D - Monthly Conctractors Progress Management and Status Report.xlsx	XLSX spreadsheet	Jul 12, 2022
Attachment A - General Installation Security Requirements.pdf	PDF	Jul 12, 2022
W9128F22Q0084 Solicitation.pdf	PDF	Jul 12, 2022
Attachment J - API External Inspection Template.pdf	PDF	Jul 12, 2022
Attachment B - Fuel Storage Tank List.xlsx	XLSX spreadsheet	Jul 12, 2022
Attachment K.2 - Dyess-Fac 5220 (Tank 5220)Post Repairs-FINAL-2019.pdf	PDF	Jul 12, 2022
Attachment C - Fuel Storage Tank Excel Document.xlsx	XLSX spreadsheet	Jul 12, 2022

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US	Army	Corps	of	Engineers
Omaha	District

API	653	Out‐of‐Service
Inspection	Report

Dyess	AFB,	TX
Facility	Number	5220
Tank	Number	5220

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

(USACE	POL‐TCX)
May	11,	2017

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Bottom

4. Tank Shell

5. Tank Appurtenances

6. Tank Coating

7. Tank Piping System

8. Fire Protection System

9. Secondary Containment

10. Cathodic Protection

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS per API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards

2. REQUIRED REPAIRS to Fully Comply with API 653, or, Federal, State, and Local Codes

3. RECOMMENDED

REPAIRS

fully

comply

with

UFC

3‐460‐01

78‐24‐27

Standards

Part

Regular

Maintenance .................................................................................................................................................. 18

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS ................................................................................... A‐1

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS .................................................................................................... B‐1

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS ...................................................................................... C‐1

APPENDIX D: PHOTOGRAPHS .......................................................................................................................................... D‐1

APPENDIX E: AS‐BUILT DRAWING OF TANK 5220………………………………………………………………………………………………………….E‐1

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ARD Anti‐rotation device

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

GENERAL	SUMMARY
Summary	of	Inspection

API

Standard

653

Out‐of‐Service

inspection

Tank

5220

(Facility

5220)

Dyess

Air

Force

Base

was

completed

May

11,

2017

evaluate

the

tank’s

integrity,

collect

data,

and

establish

database

for

future

inspections

and

evaluations.

service

life

evaluation

performed

the

tank

shows

having

greater

than

years

remaining

shell

life

under

current

conditions.

The

bottom

life

evaluation

performed

the

tank

shows

having

greater

than

years

remaining

life

after

patch

plate

repairs

are

completed

the

bottom.

Inspection

Results

are

listed

Section

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

INSPECTION	DATE
API	Out‐of‐Service	(Internal)	Inspection	Date:	11	May	2017

Equipment (s) Used:

Manufacturer:	General	Electric
Model:	DMS	Go+
Calibration	Methods	Used:	Zeroing	Procedure,	Copper	Coating	Calibration	Procedure,	and	Two	Point

Calibration Procedure

Manufacturer:	MFE	Enterprises
Model:	2412	Mark	I
Calibration	Methods	Used:	Sensitivity	adjacent	on	manufacturer	supplied	test	plate	with	simulated

anomalies and notch

Manufacturer:

Leica

Geosystem

Model:

Disto

Calibration

Methods

Used:

Tilt

sensor

calibration

automatically

performed

with

unit

set

3°

and

crosshairs calibration using target at a distance > 25 m

Inspector(s): Daniel Bailey

STATE	REGULATIONS
State	Regulation	for	API	In‐Service	Tank	Inspections		N/A
State	Regulation	for	API	Out‐of‐Service	Tank	Inspections	N/A

NOTE:

there

are

state

regulations

for

tank

inspections,

N/A

shall

reside

in‐place

the

number

years

between

inspections.

state

regulations

reside,

the

recommended

future

inspection

dates

shall

based

whichever

stringent

between

the

API

inspector’s

calculations

and

the

state

regulations.

PREVIOUS	INSPECTION	DATES
API	Out‐of‐Service	(Internal)	Inspection	Date:	5	January	2008
API	In‐Service	(External)	Inspection	Date:	27	January	2015

RECOMMENDED	FUTURE	INSPECTION	DATES	(CALCULATIONS	SHALL	BE	PROVIDED)
API	Out‐of‐Service	(Internal)	Inspection	Date:			11	May	2037
API	In‐Service	(External)	Inspection	Date:			11	May	2022
UFC	Out‐of‐Service	(Internal)	Inspection	Date:		11	May	2027

Daniel Bailey Inspector

InterSpec,	LLC
API	653	Certified	Inspector	No.	56207

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

GENERAL TANK INFORMATION

ITEM	DESCRIPTION
Owner		Dyess	Air	Force	Base
Location		Dyess	Air	Force	Base
Facility	Number		5220
Tank	Number		5220
State	/	Country		Texas/USA
City		Abilene
Inspection	Date	11	May	2017
Tank	Manufacturer		Chicago	Bridge	&	Iron	Company
Design	Standard		API	650,	7th	Edition
Date	of	Construction		1986
Tank	Contents		Jet‐A
Tank	Serial	Number	NA
Tank	Diameter		43’	6”
Shell	Height		42’	3”
Normal	Fill	Level		34’	6”
Nominal	Capacity		10,000	BBL
Foundation		Concrete	Ringwall

Construction

Bottom Lap‐Welded (Cone‐Down)

Shell Butt‐Welded (Cylindrical)

Floating Roof Steel Floating Pan

Fixed Roof Self‐Supported Cone

Material

Bottom Carbon Steel A‐36 M

Shell Carbon Steel A‐36 M

Floating Roof Carbon Steel A‐36 M

Fixed	Roof		ASTM	A36
Cathodic	Protection		None
Interior	Coating	System		Thin	Film	Epoxy
Exterior	Coating	System		Thing	Film	Epoxy/	Polyurethane
Level	Gauging		Honeywell	Enraf	ATG	with	Varec	2500	Mechanical	Tape	Gauge
Overfill	Protection		Automatic	Shut‐Off	(Set	at	37’	4‐3/4”)
Piping	Receipt	8"	Carbon	Steel
		Issue	18"	Carbon	Steel
		Low	Suction	4"	Carbon	Steel
		Water	Draw‐Off	1"	Carbon	Steel

Level Alarms

Low‐Low	Level	Alarm:	2’	0‐1/8”
Low‐Level	Alarm:	3’	0‐3/16”
High‐Level	Alarm:	37’	2”
High‐Level	Control	Valve:	37’	4‐3/4”
High‐High	Level	Alarm	37’	6‐5/16”

Type of Internal Floating Roof

Internal Steel Floating Pan w/ Landing Actuated Vent

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

A. GENERAL PROJECT INFORMATION

1. API

653

Inspection

This

project

will

perform

API

653

inspections

various

tanks

facilities

throughout

the

United

States.

Additional

consideration

given

federal,

state,

and

local

regulations,

well

applicable

military

criteria

and

general

industry

standards.

An API Standard 653 Out‐of‐Service (Internal/External) inspection was performed for Tank 5220.

2. Site

Information

May

11,

2017,

Burns

McDonnell

and

our

sub‐consultant

(InterSpec)

performed

API

653

Out‐

of‐Service

(Internal

and

External)

inspection

Tank

5220

(Facility

5220)

Dyess

Air

Force

Base,

Texas.

Dyess

AFB

6,409

acre

base

with

over

13,000

military

and

civilian

personnel

and

home

the

7th

Bomb

Wing.

The

base

located

the

southwest

corner

Abilene,

and

about

200

miles

west

Dallas.

The

base

employs

than

5,000

people,

making

the

single

largest

employer

the

area.

addition

bulk

storage,

Tank

5220

one

four

aboveground,

operating

storage

tanks

for

jet

fuel

supporting

the

installation

fueling

needs.

B. TANK INSPECTION COMMENTS

1. Tank

Construction

Tank

5220

nominal

10,000

BBL,

43’

6”

diameter

42’

3”

tall,

F‐24

(Jet

Fuel),

aboveground

vertical

storage

tank.

The

tank

was

constructed

Chicago

Bridge

and

Iron

1986

API

Standard

650,

under

contract

No.

S‐5901.

The

tank

had

some

modifications

existing

nozzles

completed

CAPE

2008,

under

Job

No.

60022.006.500.

The

as‐built

drawings

for

the

tank

were

not

available

for

review

the

time

the

inspection,

but

as‐built

drawing

was

later

provided

and

included

Appendix

2. Tank

Foundation

The

tank

sits

concrete

ringwall

foundation

elevated

approximately

above

the

containment

floor.

The

ringwall

includes

sand

filled

supporting

medium

designed

with

leak

detection

(tell‐tale)

system.

Accessible

sections

the

foundation

were

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

against

the

bottom

the

tank.

spalling

and

vegetation

were

present.

The

foundation

chime

interface

sealed.

Shell

settlement

surveys

were

performed

during

the

inspection

accordance

with

Annex

API

Standard

653.

Settlement

results

are

listed

Appendix

There

indication

significant

settlement.

Overall,

the

foundation

satisfactory

condition.

3. Tank

Bottom

The

bottom

constructed

from

carbon

steel

material

with

ASTM

A36

material

specification.

The

bottom

cone‐down

design,

lap‐welded

together,

consisting

twenty

(20)

plates

lap‐welded

together

and

fillet‐welded

the

shell.

The

bottom

has

thin

film

interior

liner.

The

interior

coating

was

evaluated

for

dis‐bonding,

adhesion,

deterioration,

and

discoloration

and

was

found

mostly

satisfactory

condition,

with

some

deficiencies

listed

below.

visual

inspection

all

the

welded‐on

plates

was

performed

for

indications

cracked

welds,

cracked

coating,

and

capillary

effects

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

residues.

Dry

film

thickness

(DFT)

readings

typically

ranged

between

12‐21

mils.

With

the

exception

local

coating

repairs,

the

tank

bottom

lining/coating

appears

the

original

installed

1986.

Evaluated

the

bottom,

bottom

welds,

and

bottom‐to‐shell

weld

for

corrosion,

with

other

discrepancies

noted.

Performed

magnetic

flux

leakage

(MFL)

evaluation

the

tank

bottom

determine

the

condition

the

underside;

ninety‐five

plus

percent

was

scanned.

Several

areas

indicating

underside

corrosion

were

located

and

proved

up,

see

Section

C(1)(a)

below

and

the

Bottom

Drawing

Appendix

for

location

data.

ultrasonic

inspection

the

bottom

suggests

original

nominal

thickness

0.250".

4. Tank

Shell

The

tank

shell

constructed

ASTM

carbon

steel

material.

The

shell

cylindrical

design,

butt‐

welded

together,

and

consisting

five

(5)

courses.

Evaluated

the

shell

for

plumbness,

roundness,

peaking,

and

banding;

all

which

were

found

within

the

allowable

tolerances

the

API

Standard

653.

Visually

inspected

both

the

interior

and

exterior

the

shell.

Inspected

the

coating

for

dis‐

bonding,

adhesion,

deterioration,

and

discoloration.

The

tank

shell

equipped

with

two

30"

manways

(one

them

being

the

2nd

course

manway

access

the

top

the

IFR).

Note:

given

the

IFR

high

leg

position,

the

intermediate

tank

shell

manway

obstructed

the

IFR

and

does

not

provide

practical

access

the

top

the

IFR

when

the

IFR

landed

the

tank

bottom.

The

tank

equipped

with

shell

mounted

low‐level

and

high‐high

level

mercury

switches,

well

high‐level

shut‐off.

The

shell

was

evaluated

for

remaining

metal

thickness

utilizing

ultrasonic

technology.

The

ultrasonic

thickness

measurements

and

thickness

measurement

locations

(TML)

are

listed

the

Shell

Plate

Thickness

Measurements

table

Appendix

service

life

evaluation

performed

shows

the

shell

with

greater

than

years

remaining

life

under

current

conditions.

The

engineering

calculations,

per

API

Standard

653,

for

the

service

life

evaluation

are

shown

Appendix

under

“Service

Life

Evaluation.”

The

tank

shell

satisfactory

mechanical

condition.

5. Tank	Appurtenances
a. Internal	Floating	Roof

The

tank

equipped

with

full

contact

steel

internal

floating

pan.

The

internal

floating

roof

(IFR)

lap‐welded

together,

and

consisting

thirty

(18)

plates

each.

The

top

IFR

deck

accessible

via

access

ladder

from

the

fixed

roof.

The

IFR

resting

approximately

97"

(measured

the

perimeter)

above

the

tank

bottom

and

supported

nine

(9)

floating

roof

legs.

22‐inch

circular

striker

bearing

plate

welded

the

tank

bottom

for

each

IFR

support

leg.

Evaluated

the

structural

integrity

both

the

top

and

underside

the

floating

roof.

Evaluated

the

condition

the

floating

roof

seals.

The

primary

IFR

perimeter

seal

(foam

log)

and

secondary

perimeter

seal

(wiper

seal)

were

found

completely

deteriorated

and

were

removed

during

the

inspection.

Seals

around

the

stilling

wells

and

ladder

were

also

found

deteriorated.

The

IFR

was

evaluated

for

remaining

metal

thickness

utilizing

ultrasonic

technology.

The

ultrasonic

thickness

measurements

and

thickness

measurement

locations

(TML)

are

listed

the

Shell

Plate

Thickness

Measurements

table

Appendix

Measured

the

annular

space

several

locations

from

the

tank

bottom,

and

the

floating

roof

determined

properly

centered

inside

the

tank.

The

IFR

equipped

with

two

12‐inch

vacuum

breakers

with

guided

leg

long

enough

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

contact

the

tank

bottom.

When

the

leg

contacts

the

tank

bottom,

the

guided

leg

mechanically

opens

the

breaker

lifting

the

cover

off

the

well.

b. Fixed

Roof

The

fixed

roof

self‐supported

cone

roof.

The

fixed

roof

has

epoxy

coating

system

the

interior

and

epoxy/polyurethane

exterior.

The

coating

was

inspected

for

dis‐

bonding,

adhesion,

deterioration,

and

discoloration;

satisfactory

condition.

The

nominal

thickness

the

fixed

roof

was

0.1875

inches.

The

fixed

roof

was

evaluated

for

remaining

metal

thickness

using

ultrasonic

technology.

The

fixed

roof

thickness

ranged

from

minimum

0.181

inches

maximum

0.192

inches.

The

ultrasonic

thickness

measurements

and

ultrasonic

thickness

locations

(TML)

are

listed

the

Fixed

Roof

Plate

Thickness

Measurements

table

Appendix

The

roof

had

areas

standing

water

and

sediment,

but

coating

failure

was

present.

c. Gauging

The

tank’s

Enraf

Servo

ATG

installed

through

fully

slotted

8‐inch

aluminum

gauge

well.

Manual

gauging

performed

through

the

non‐slotted

8‐inch

carbon

steel

well

the

IFR

access

hatch

(one

side

the

IFR

access

ladder).

The

tank

also

equipped

with

fully‐

slotted

aluminum

8‐inch

sample

gauge

well

with

floating

plug.

The

tank

equipped

with

mechanical

gauge

manufactured

Varec

(Model

2500).

The

tape

has

detached

from

the

floating

roof

and

longer

functioning.

d. Level

Alarms

High

and

high‐high

level

mercury

switches

are

mounted

the

shell

but

are

not

fully

accessible

via

the

circumferential

mounted

stairway.

The

tank

also

equipped

with

low

and

low‐low

level

alarms.

Automatic

shut‐off

provided

high‐level

control

valve

that

actuates

hydraulic

CLA‐VAL

control

valve

the

receipt

line.

e. Stairs

and

Platforms

The

tank’s

fixed

roof

and

internal

ladder

are

accessible

circumferential

stairway

mounted

the

shell

the

tank.

The

stairway

was

inspected

for

corrosion

and

structural

soundness.

The

overall

general

condition

the

stairs

satisfactory.

The

IFR

deck

accessible

via

hatch

and

access

ladder

from

the

fixed

roof.

There

also

manway

the

second

course

access

the

IFR,

but

the

IFR

blocks

the

opening

when

resting

its

legs.

The

legs

the

IFR

are

configured

low

leg

position,

but

hole

the

legs

for

the

retaining

lacking

secure

the

leg

the

low

leg

position.

The

stairway

width

extended

the

high‐level

alarms,

but

platform

provided,

and

the

alarms

are

not

accessible.

The

handrail

consists

welded

2‐inch

angle.

copper

grounding

bar

for

personnel

static

electric

discharge

mounted

the

handrail.

f. Grounding and Bonding

There

are

four

grounding

cables

connected

lugs

the

tank’s

shell,

and

each

end

mechanically

fastened

grounding

rod.

The

internal

floating

roof

bonded

the

tank.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

6. Tank

Coating

The

exterior

coatings

appear

epoxy

with

polyurethane

top

coat.

The

shell,

interior,

and

fixed

roof

are

light

tan

color.

The

associated

piping

within

the

secondary

containment

coated

with

similar

tan

coating.

There

are

numerous

existing

coating

repairs

the

tank

shell,

but

overall,

the

existing

coating

appears

satisfactory

condition,

with

minor

deficiencies

that

are

noted

the

report.

The

tank

internal

and

IFR

lining

appear

thin

film

epoxy.

7. Tank

Piping

System

The

fuel

received

through

8‐inch

carbon

steel

piping

that

fitted

with

inlet

diffuser.

The

diffuser

rolled

circular

transition,

with

final

outlet

diameter

NPS

12.

The

product

issued

from

the

tank

through

18‐inch

carbon

steel

pipe

that

extends

the

center

sump

inside

the

tank.

Other

auxiliary

piping

for

the

water

draw

(NPS

and

low

suction

(NPS

are

installed,

and

both

extend

the

center

tank

bottom

sump.

Inspected

and

evaluated

each

tank

nozzle

accordance

with

API

Standards

650

and

653.

Identified

the

type

and

use

each

shell

nozzle

and

measured

the

nozzle

neck

thickness

all

accessible

shell

nozzles.

Evaluated

all

nozzles

and

reinforcement

plates

for

leaks

and

corrosion.

8. Fire

Protection

System

The

tank

previously

had

foam

fire

protection

system

that

has

been

mostly

removed.

Part

the

piping

still

exists

the

top

the

tank,

and

the

portion

where

the

vertical

piping

coming

down

the

tank

shell

was

removed,

now

forms

dead

leg

that

may

experience

accelerated

corrosion

water

and

residue

still

remain

the

line.

9. Secondary

Containment

The

tank

sits

inside

concrete

secondary

containment

area

with

vertical

sloped

concrete

dike

walls.

The

overall

dimension

the

secondary

containment

103

feet

103

feet

with

berm

height

approximately

60‐inches.

The

secondary

containment

equipped

with

24"

drain

inlet/sump

and

locked

drain

valve.

The

drain

line

5‐inch

6‐inch

oval

cut‐out

the

sump.

The

drain

inlet

was

hydrostatically

tested

for

integrity

filling

the

inlet

with

water

level

least

1‐2

inches

below

the

top

the

inlet

structure.

The

test

was

held

for

hours

and

the

level

water

did

not

change;

thus

the

test

passed.

The

secondary

containment

was

visually

evaluated

during

the

inspection

for

broken

concrete,

spalling,

cracks,

and

vegetation

growth.

few

areas

were

noted

where

piping

equipment

penetrates

the

dike

floor

but

are

not

sealed,

bringing

into

question

the

permeability

the

secondary

containment

area.

These

areas

are

listed

deficiencies

below

under

mandatory

repairs.

formal

secondary

containment

evaluation,

accordance

with

CFR

112,

may

required

order

satisfy

federal,

state,

and

local

requirements.

The

secondary

containment

equipped

with

lockable

secondary

containment

drain

valve.

10. Cathodic

Protection

This

tank

currently

does

not

have

cathodic

protection

installed

protect

the

tank

bottom

from

corrosion.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

C. FINDINGS AND RECOMMENDATIONS

The

tank

generally

not

accordance

with

current

military

criteria

for

some

the

tank

appurtenance

and

piping

configuration;

these

recommendations

are

not

meant

bring

the

tank

into

full

compliance

with

UFC

3‐

460‐01,

78‐24‐27

standards,

but

rather

identify

these

items

for

the

owner/user’s

planed

upgrades,

rehabilitation,

and

priority

repairs.

Mandatory

repairs

should

completed

assure

compliance

with

industry

standards,

well

federal

state

jurisdictional

requirements.

All

repairs

and

modifications

should

performed

accordance

with

API

standard

653,

UFC

3‐460‐01,

DoD

Standard

Design

78‐24‐27,

and

applicable

UFGS

specifications.

1. MANDATORY

REPAIRS

per

API

653,

UFC

3‐460‐01,

78‐24‐27

Standards

Mandatory

repairs

represent

items

that

require

immediate

attention,

order

prevent

imminent

risk

system

operators,

equipment

integrity,

the

adjacent

environment.

The

tank

should

remain

out

service

until

these

repairs

are

completed.

a. MFL

Indications

OBSERVATION:

areas

underside

corrosion

were

located

during

the

MFL

evaluation.

Remaining

thicknesses

these

areas

ranged

from

0.188

inches

remaining

plate

0.099

inches

remaining

plate

REFERENCE:

API‐653

Table

4.4

RECOMMENDATION:

Areas

with

remaining

thickness

under

0.160

inches

will

need

repaired

accordance

with

API‐653

9.10

order

reach

the

20‐year

inspection

interval

and

stay

above

the

remaining

thickness

requirement

0.100

inch

accordance

with

API‐653.

Corroded

areas

are

indicated

the

tank

bottom

red

paint

marker

and

also

the

drawing

located

Appendix

(Quantity:

areas

less

equal

0.160

inch,

area

currently

under

API

minimum

0.100

inch).

Alternatively, consider replacing the bottom in accordance with API‐653 9.10.2.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

b. Floating

Roof

Perimeter

Seals

OBSERVATION:

The

primary

foam

log

seal

for

the

floating

roof

was

found

saturated

with

fuel.

The

secondary

urethane

wiper

seal

was

warped

and

cracked/dry‐rotted

several

areas.

Both

seals

were

removed

during

the

inspection

and

will

need

replacement

before

the

tank

placed

back

service.

REFERENCE:

The

owner

operator

shall

repair

any

observed

determined

failures

according

paragraphs

(d)(1)

and

(2)

CFR

65.43

for

facilities

who

elect

control

storage

vessel

regulated

material

emissions

using

fixed

roof

and

internal

floating

roof.

Note

UFGS

13.13

Section

2.13.2.7,

requires

flexible

double

wiper

squeegee

seals

made

closed

cell

cast

urethane.

Foam

filled

coated‐fabric

seals

shall

not

accepted.

(Additional

requirements

UFC

3‐460‐

Section

8‐8.3,

API

650

Appendix

RECOMMENDATION:

Install

new

double

wiper

perimeter

IFR

seal.

The

current

configuration

was

rim

mounted

primary

perimeter

foam

log

seal

and

secondary

perimeter

wiper

seal.

The

new

perimeter

seal

should

designed

eliminate

the

presence

air‐vapor

mixture

under

the

floating

roof.

The

IFR

seal

shall,

minimum,

meet

the

specifications

and

the

intent

the

latest

edition

API

Standard

650,

Annex

c. Secondary

Containment

Piping

Seals

OBSERVATION:

Several

the

penetrations

through

the

dike

floor

for

the

18‐inch

issue

line

supports

and

8‐inch

receipt

piping

supports

(receipt

piping

from

tank

5018

that

passes

through

5220

containment)

are

not

sealed.

Lack

proper

pipe

seals

calls

into

question

the

integrity

the

containment.

REFERENCE:

CFR

Section

112

RECOMMENDATION:

Seal

the

areas

where

piping

penetrates

the

dike

floor.

Sealants

should

silicone

urea

urethane

compounds

that

conform

Federal

Spec

TT‐S‐00230C,

unless

another

material

required

for

compatibility

with

the

stored

materials.

(Quantity:

areas

not

sealed).

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

d. Spiral

Stairway

Initial

Step

OBSERVATION:

The

first

step

for

the

spiral

stairway

measured

15.25‐inches

off

the

ground.

This

poses

safety

hazard

for

personnel

using

the

stairway.

REFERENCE:

1910.25(c)(2)

RECOMMENDATION:

Install

concrete

approach

step

the

base

the

stairway,

meet

the

stairway

riser

height

requirements

OSHA.

e. Weld

Spacing

Tank

Bottom

OBSERVATION:

Three

areas

inadequate

weld

spacing

accordance

with

API‐653

Figure

9.13

were

noted

the

tank

bottom.

API‐653

requires

spacing

two‐inches

these

areas.

Areas

are

marked

the

bottom

drawing

Appendix

REFERENCE:

API‐653

Figure

9.13,

API

653

9.10.3.1

RECOMMENDATION:

determined

this

as‐built

arrangement

the

tank

bottom

and

changes

are

required

this

time.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

2. REQUIRED

REPAIRS

Fully

Comply

with

API

653,

or,

Federal,

State,

and

Local

Codes

Recommended

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

These

items

may

required

federal,

state,

and

local

codes

military

criteria.

f. Gaskets

for

Roof

Access

Hatches

OBSERVATION:

The

gasket

material

for

the

two

30”

access

hatches

missing

deteriorated.

REFERENCE:

API‐653

C.2.7.1

(d)

RECOMMENDATION:

Replace

the

gaskets

the

30”

access

hatches.

accordance

with

API‐650,

gasket

material

shall

either

silicone,

Buna‐N,

urea

urethane

meeting

ASTM

C509

Federal

Spec

ZZ‐R‐765C,

unless

another

material

required

for

compatibility

with

the

stored

product.

g. Center

Roof

Vent

Screen

OBSERVATION:

The

screen

mesh

for

the

24‐inch

center

vent

the

fixed

roof

too

fine.

REFERENCE:

API

650

5.8.5

RECOMMENDATION:

Replace

the

fine

mesh

screen

the

24‐inch

center

vent

with

½‐inch

corrosion

resistant

bird

screen

accordance

with

API‐650.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

h. Weld

Failure

Center

Vent

OBSERVATION:

Lack

fusion

type

weld

failure

was

noted

the

24‐inch

center

vent

nozzle

re‐pad

weld

the

fixed

roof.

REFERENCE:

API

650

7.2.1.1

RECOMMENDATION:

Remove

and

re‐weld

the

section

failed

weld

the

24‐inch

center

vent

nozzle

re‐pad

weld

the

fixed

roof.

i. Interior

reinforcement

pads

OBSERVATION:

There

are

reinforcement

pads

under

the

supports

for

the

18‐inch

issue

line,

4‐inch

low

suction

line,

anti‐rotation

devices,

and

IFR

access

ladder/gauge

supports

inside

the

tank.

REFERENCE:

API

653

C.2.3(l)

RECOMMENDATION:

Install

circular

welded

support

pads

under

the

supports

for

the

18‐inch

issue

line,

4‐inch

low

suction

line,

anti‐rotation

devices,

and

IFR

access

ladder/manual

gauge

supports

inside

the

tank.

And

adjust

and

adjust

support

for

equal

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

j. Interior

Low

Suction

Support

OBSERVATION:

The

4‐inch

low

suction

line

not

completely

resting

one

its

supports

inside

the

tank.

This

could

cause

fatigue

type

weld

cracking

the

pipe‐

to‐

shell

weld

due

cyclic

stresses.

The

support

height

adjustable.

REFERENCE:

API

650

E.7.3

RECOMMENDATION:

Adjust

the

support

necessary

adequately

support

the

pipe.

k. Horizontal

TRV’s

OBSERVATION:

Thermal

relief

valves

for

the

18‐inch

issue

and

8‐inch

receipt

lines

are

mounted

horizontally.

TRV’s

should

mounted

vertically.

TRV

mounted

non‐vertical

orientation

may

not

perform

expected;

the

seat

tightness,

operation,

and

set

pressure

the

valve

may

affected.

The

TRVs

lack

lockable

isolation

valves,

test

connections,

and

flange,

etc.

REFERENCE:

API

530

13.1

RECOMMENDATION:

Reinstall

the

TRV’s

vertical

position;

adherence

AW‐78‐24‐27

covered

under

another

item.

recommended

upgrade

all

UFC

and

compliance

upgrades

noted

section

3.j,

while

performing

these

API

compliance

repairs.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

l. Manway

Davit

Arms

OBSERVATION:

The

(2)

30‐inch

manways

the

tank

shell

not

have

davit

arms

installed

help

with

the

safe

removal

the

covers.

API‐650

requires

davit

arms

for

manways

weighing

75lbs

more.

REFERENCE:

API

650

5.8.3.5

RECOMMENDATION:

Install

davit

arms

the

shell

manways.

Adherence

AW‐78‐24‐27

covered

under

another

item.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

3. RECOMMENDED

REPAIRS

fully

comply

with

UFC

3‐460‐01

78‐24‐27

Standards

Part

Regular

Maintenance

Recommended

repairs

represent

items

that

should

addressed

timely

manner,

order

prevent

future

potential

risks

system

operators,

equipment

integrity,

the

adjacent

environment.

a. Standing

Water

Fixed

Roof

OBSERVATION:

Several

areas

indicating

standing

water

were

noted

the

roof.

Coating

was

still

intact

these

areas.

REFERENCE:

General

Maintenance

RECOMMENDATION:

Reshape

the

roof

plates

encourage

draining

periodically

sweep

water

off

the

roof

after

precipitation.

b. Hinged

Circulation

Vents

OBSERVATION:

The

five

circulation

vents

located

along

the

perimeter

the

fixed

roof

are

not

hinged

allow

for

visual

inspection

the

floating

roof

seals.

REFERENCE:

78‐24‐27

Drawing

D.09

Detail

RECOMMENDATION:

Install

least

four

hinged

circulation

vents

along

the

perimeter

the

fixed

roof,

allow

for

visual

inspection

the

floating

roof

seals

accordance

with

78‐24‐27

Drawing

D.09

Detail

Existing

non‐hinged

vents

may

able

modified

with

hinges

meet

the

criteria.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

c. Fixed

Roof

Railing

OBSERVATION:

The

railing

top

the

fixed

roof

cuts

across

the

center

the

roof

and

does

not

around

the

entire

perimeter.

REFERENCE:

General/Safety

RECOMMENDATION:

Install

OSHA

compliant

safety

railing

around

the

entire

perimeter

the

fixed

roof.

d. Stilling

Wells

OBSERVATION:

The

stilling

well

for

the

manual

gauge

(side

IFR

access

ladder)

constructed

carbon

steel

and

not

slotted.

The

stilling

well

for

the

Vito

probe

not

slotted.

REFERENCE:

28‐24‐27

Drawing

D.07,

UFC

3‐460‐01

8‐8.3

(a)

RECOMMENDATION:

Install

aluminum

slotted

stilling

well

for

the

2‐inch

Vito

probe.

Discontinue

use

the

8‐inch

manual

gauge

well

(side

IFR

access

ladder)

measurements

taken

through

the

un‐

slotted

well

may

not

accurately

reflect

the

actual

level

product

the

tank.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

e. Mechanical

Tape

Gauge

OBSERVATION:

The

mechanical

tape

gauge

(Varec

2500)

tape

detached

from

the

IFR

tank

and

has

disconnected

from

the

floating

roof.

Activity

reports

that

this

gauge

has

had

several

problems

over

the

years.

REFERENCE:

General

Maintenance

RECOMMENDATION:

understood

separate

contract

exists

rebuild

the

Varec

gauge.

recommended

reattach

the

tape

the

IFR

accordance

with

Varec’s

recommendation

and

rebuild

the

gauge

while

the

tank

out

service

replace

the

mechanical

gauge

with

new

gauge.

f. Interior

Issue

Line

OBSERVATION:

The

18‐inch

issue

line

inside

the

tank

not

flanged

the

tank

shell,

extends

all

the

way

the

center

sump

(not

half‐radius),

and

has

anti‐vortex

plate

installed.

REFERENCE:

78‐24‐27

Drawing

D.08

Detail

RECOMMENDATION:

Install

flange

the

tank

shell,

cut

back

half

the

tank

radius,

and

install

anti‐vortex

plate

the

18‐inch

issue

line

the

tank

interior

accordance

with

78‐24‐27

Drawing

D.08

Detail

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

g. Manual/Sample

Gauge

Well

Base

OBSERVATION:

The

base

the

manual

and

sample

gauge

stilling

wells

are

not

accordance

with

78‐24‐27

Drawing

D.07

Detail

There

datum

plate

level

with

the

bottom

the

shell.

The

bolt

holes

are

not

slotted

allow

slight

vertical

movement.

REFERENCE:

78‐24‐27

Drawing

D.07

Detail

and

API

650

H5.1.5.

RECOMMENDATION:

Modify

the

bases

the

manual

and

sample

gauge

stilling

wells

accordance

with

78‐24‐27

Drawing

D.07

Detail

h. Interior

Support

Design

OBSERVATION:

The

supports

the

inside

the

tank

are

not

designed

accordance

with

78‐24‐

Drawing

D.08

Detail

There

are

loosely

installed

Teflon

coated

U‐bolts.

Abrasive

coating

failure

was

noted

one

the

diffuser

supports.

REFERENCE:

78‐24‐27

Drawing

D.08

Detail

RECOMMENDATION:

Install

internal

pipe

supports

accordance

with

78‐24‐27

Drawing

D.08

Detail

Repair

the

coating

failure

the

diffuser,

caused

the

rubbing

support.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

i. IFR

Manway

Access

OBSERVATION:

Access

through

the

IFR

manway

the

2nd

course

blocked

the

IFR,

when

the

roof

resting

high

legs.

The

height

the

IFR

inside

the

tank

was

8‐feet

the

perimeter.

REFERENCE:

General

RECOMMENDATION:

Adjust

the

height

the

floating

roof

legs,

that

manway

access

the

top

the

floating

roof

can

achieved.

Ensure

the

roof

meets

all

height

requirements

API‐650,

UFC

3‐460‐

01,

and

78‐24‐27

after

repair.

Modifications

the

existing

IFR

leg

would

include

providing

low

leg

position

and

holes

for

retaining

pins.

j. Interior

Coating

OBSERVATION:

Minor

areas

coating

failure

were

noted

inside

the

tank:

Two

small

holidays

plate

15,

one

the

support

pads

for

the

Vito

probe,

minor

areas

inside

the

sump,

and

the

IFR

leg

striker

plates,

where

the

leg

makes

contact

with

the

plate.

The

existing

internal

lining

appears

the

original

lining

installed

1986.

REFERENCE:

General,

API

652

(Linings

Aboveground

Petroleum

Storage

Tank

Bottoms).

RECOMMENDATION:

Mechanically

clean

and

recoat

the

areas

coating

failure

inside

the

tank.

Repairs

should

accomplished

using

two

part

epoxy

accordance

with

military

standards.

the

typical,

service

life

thin

film

epoxy

tank

lining

can

last

over

years,

and

the

ling

Tank

5220

appears

years

old

with

the

exception

local

coating

repairs,

suggested

consideration

given

replacing

the

tank

bottom

lining

only.

Product

side

tank

bottom

corrosion

can

aggressive

where

water

trapped

accumulating

and

coating

failure

exist.

Work

shall

conform

UFGS

13.17.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

k. Cracked

Concrete

Support

Base

OBSERVATION:

Two

the

concrete

bases

for

supports

the

18‐inch

issue

line

and

8‐inch

receipt

line

have

cracked

and

fallen

apart.

This

does

not

affect

the

integrity

the

piping

containment.

REFERENCE:

General

RECOMMENDATION:

Repair

replace

the

concrete

base

the

pipe

supports

the

18‐inch

issue

line

and

8‐inch

receipt

line;

where

failed,

remove

and

replace

with

non‐shrink

grout

accordance

with

military

standards.

(Quantity:

total

three

locations,

two

the

18‐inch

issue

piping

and

one

adjacent

the

8‐inch

tank

fill

nozzle).

l. Thermal

Relief

Valve/Piping

OBSERVATION:

Thermal

relief

piping

for

the

18‐inch

issue

line

and

8‐inch

receipt

line

are

not

designed

accordance

with

78‐24‐27

Drawing

D.10

Detail

The

piping

has

union

and

not

flanged

connections,

not

stainless

steel,

has

Viso‐Flo

glass

sight

indicators,

does

not

have

lockable

ball

valves

the

inlet

and

outlet

side

the

valve,

does

not

have

“T”

for

testing

the

valve

the

system,

and

the

valves

have

indication

calibration

posted

the

valve.

REFERENCE:

78‐24‐27

Drawing

D.10

Detail

UFC

3‐460‐01

Section

3‐3.1.2(j).

RECOMMENDATION:

Design

TRV

piping

that

accordance

with

78‐24‐27

Drawing

D.10

Detail

Calibrate

the

valves

annually

and

post

calibration

sticker

the

valve.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

m. Exterior

Coating

Failure

OBSERVATION:

Coating

failure

was

noted

the

tank

shell

behind

conduit/junction

boxes

for

the

issue

line

electronic

valve

and

low‐level

alarm,

the

low/high‐level

alarm

sensor

heads,

and

the

platform

for

the

IFR

manway.

The

platform

holds

water

the

perimeter

and

experiencing

accelerated

corrosion

due

this.

REFERENCE:

General

Maintenance

RECOMMENDATION:

Mechanically

clean

and

recoat

areas

coating

failure

the

tank

exterior.

Coating

repairs

should

made

conforming

UFGS

13.27.

Seal

weld

per

API

650

5.1.3.7

along

with

coating

repairs

conforming

UFGS

13.27

and

13.17.

n. Manways

OBSERVATION:

UFC

3‐460‐01

currently

requires

two

36‐inch

manways

along

the

first

course

180

degrees

apart

and

one

36‐inch

manway

located

3.5‐feet

above

the

IFR

high

legs

access

the

top

the

IFR

for

inspection/maintenance.

The

tank

currently

has

one

30‐inch

manway

the

first

course

and

one

30‐inch

manway

for

the

IFR.

REFERENCE:

UFC

3‐460‐01

Table

8‐1

and

c).

RECOMMENDATION:

Install

36‐inch

manways

accordance

with

UFC

3‐460‐01.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

o. Water

Draw/Low

Suction

OBSERVATION:

The

4‐inch

low

suction

line

does

not

have

DBB

valve

the

skin

valve

the

tank

and

not

designed

accordance

with

78‐24‐27.

The

low

suction

line

should

tied

into

the

tank’s

issue

line.

Note:

the

4‐inch

low

suction

line

located

90‐degrees

around

the

tank

shell

from

the

18‐

inch

issue

nozzle.

The

water

draw‐off

piping

does

not

have

DBB

valve

the

skin

valve

the

tank.

The

existing

product

saver

tank

and

external

water

draw‐off

piping

have

been

disconnected

from

the

tank

part

another

project.

our

understanding

another

project

performing

upgrades

bring

the

product

saver

tank

into

conformance

with

current

military

standards.

suggested

the

1”

water

draw‐off

nozzle

include

2”

1”

eccentric

reducers

(flat

bottom)

the

inlet

and

outlet

new

2”

double

block

and

bleed

(DBB)

plug

valve

the

1”

existing

water

draw‐off

line

adjacent

the

tank

shell

with

the

installation

the

new

product

saver

tank

(currently

site).

Provide

new

8‐

inch

DBB

plug

valve

the

inlet

the

existing

8‐inch

high

level

control

valve

(HLCV)

accordance

with

current

military

standard

(AW

78‐24‐27).

REFERENCE:

78‐24‐27

Drawing

G.05

RECOMMENDATION:

Design

low‐suction

with

DBB

valve,

TRV

and

piping,

and

tied

into

the

issue

line

accordance

with

78‐24‐27.

Ensure

that

new

installation

the

product

saver

tank

and

water

draw‐off

system

meets

the

requirements

and

intent

the

latest

edition

78‐24‐27

and

UFC

3‐

460‐01.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

p. AFFF

Piping

Dead

Leg

OBSERVATION:

The

abandoned

AFFF

piping

the

top

the

tank

forms

dead

leg

where

has

been

blinded

off.

This

area

difficult

access

for

inspection

and

could

experiencing

accelerated

corrosion

any

moisture

trapped

inside.

REFERENCE:

General

Maintenance

(removing

the

unnecessary

piping

will

eliminate

maintenance).

RECOMMENDATION:

recommended

completely

remove

the

AFFF

piping

will

longer

used.

minimum,

consider

removing

the

dead

leg

and

leaving

the

piping

flush.

q. External

Piping

Supports

OBSERVATION:

The

Teflon

material

between

the

piping

and

supports

for

all

external

supports

has

deteriorated

missing

(including

sister

Tank

5218

piping

supports

within

Tank

5220’s

containment

area)

and

should

replaced

REFERENCE:

General

Maintenance,

UFC

3‐460‐01

Facility

Plate

020

RECOMMENDATION:

Replace

and

secure

the

Teflon

material

between

the

piping

and

support

for

all

external

piping

supports.

(Quantity:

21).

Work

shall

include

local

pipe

coating

repairs

all

pipe

supports

accordance

with

13.27.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

r. Low

and

High‐Level

Alarms

OBSERVATION:

The

low/low

low‐low

level

and

high

and

high‐high

level

switches

are

not

designed/constructed

accordance

with

UFC

3‐460‐01

and

78‐24‐27.

Piping

should

stainless

steel

with

flanged

fittings,

and

alarms

should

accessible

for

testing

with

the

tank

empty,

and

lockable

ball

valves

should

provided

prevent

inadvertent

opening,

especially

onto

the

floating

roof

(Approximately

200

gallons

fuel

were

removed

from

the

top

the

floating

roof

during

the

inspection;

the

spillage

was

caused

inadvertent

opening

unlocked

ball

valve

the

HLA).

REFERENCE:

UFC

3‐460‐01

Table

8‐1,

78‐24‐27

Drawing

D.12

RECOMMENDATION:

Design

low

and

high

and

high‐high

level

switches

accordance

with

78‐24‐

Drawing

D.12.

Design

platform

support

shown

78‐24‐27

Drawing

D.11

Detail

for

the

high‐level

alarm/shut‐off

piping,

accessible

for

maintenance

and

testing.

(Currently

not

reachable

from

stairway)

Install

locks

ball

valves

prevent

accidental

opening.

Provide

solenoid

valve

and

new

stainless

steel

pilot

tubing

existing

high

level

control

valve

(HLCV)

accordance

with

current

military

standards.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

s. Tank

Grounding

Lugs

OBSERVATION:

The

tank

grounding

straps

are

bolted

the

tank

shell

and

have

reinforcement

plates

grounding

lug

installed,

shown

78‐24‐27

Drawing

ED.02

Detail

REFERENCE:

78‐24‐27

Drawing

ED.02

Detail

(See

also

API

650

Section

5.8.11.3)

RECOMMENDATION:

Exothermically

weld

the

grounding

cables

the

lug

and

install

reinforcement

the

shell,

accordance

with

78‐24‐27

Drawing

ED.02

Detail

Note:

repairs

are

elected

not

done,

the

paint

should

removed

where

the

cable

bolts

the

lug,

provide

better

connection

ground.

t. Corrosion

Piping

Supports

Containment

Interface

OBSERVATION:

Coating

failure

and

corrosion

was

noted

one

the

supports

for

the

18‐inch

issue

line,

where

penetrates

the

containment

floor

(3rd

support

from

tank

shell)

REFERENCE:

General

RECOMMENDATION:

Repair

the

failed

coating

the

pipe

support;

sealant

support

containment

floor

covered

under

another

item.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

u. Cathodic

Protection

OBSERVATION:

The

tank

not

equipped

with

cathodic

protection

system

accordance

with

UFC

3‐

460‐01

Sections

2‐13.1

and

8‐8.5,

and

78‐24‐27

Drawing

D.15.

REFERENCE:

UFC

3‐460‐01

Sections

2‐13.1

and

8‐8.5,

and

78‐24‐27

Drawing

D.15.

RECOMMENDATION:

Install

cathodic

protection

system

accordance

with

UFC

3‐460‐01

Sections

2‐

13.1

and

8‐8.5,

and

78‐24‐27

Drawing

D.15.

Note:

NACE

Certified

Corrosion

Expert

should

design

the

cathodic

protection

system

per

UFC

3‐460‐01.

PHOTO

AVAILABLE.

API 653 Out‐of‐Service Inspection Report Dyess AFB, Texas

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1	BOTTOM	SERVICE	LIFE	EVALUATION
A.2	SHELL	SERVICE	LIFE	EVALUATION
A.3	SHELL	SETTLEMENT	EVALUATION
A.4	ULTRASONIC	UT	DATA
A.5	BOTTOM	LAYOUT	DRAWING
A.6	SHELL	LAYOUT	DRAWING
A.7	FIXED	ROOF	LAYOUT	DRAWING
A.8	FLOATING	ROOF	LAYOUT	DRAWING
A.9	FLOATING	ROOF	GAP	MEASUREMENTS
A.10	CONTAINMENT	LAYOUT	DRAWING
A.11	OSHA	ACCESS	STRUCTURE	REPORT

Shannon T Gray Typewritten Text A-1

Present Condition:

1) In-Service Interval of Operation (years to next internal inspection)

No Yes No No

MRT = 0.1 inches

RT ip = 0.25 inches

RT bc 0.099 inches

StP r = 0 inches/year

UP r = 0.004871 inches/year

Therefore, the in-service interval of operation (years to next internal inspection) is:

Bottom Service Life Evaluation (Before Repair)

Containment of Bottom:

Bottom Leak Detection:

Cathodic Protection:

Bottom Coated:

O r = -0.2 years

*The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than 0.020 inches in depth, based on company experience. No significant underside corrosion was detected.

Therefore, RT bc is established at 0.355 inches (original thickness of 0.375 inches minus 0.020 inches).

0.099 - 0.1 0 + 0.004871

**Since StP r = 0 and UP r = 0; use StP r + UP r = 0.0002 inches/year for calculation purposes.

= O r

Bottom Service Life Evaluation (Before Repair)

2) Projected Thickness Chart and Graph

Year Thickness MRT

1986 0.250 0.1 2017 0.099 0.1 2022 0.075 0.1 2027 0.050 0.1 2037 0.002 0.1 2047 -0.047 0.1

*based on same service and corrosion rates.

Nominal:

Current Lowest Remaining Thickness:

Anticipated Thickness (5 yrs)*:

Anticipated Thickness (10 yrs)*:

Anticipated Thickness (20 yrs)*:

Anticipated Thickness (30 yrs)*:

0.000

0.050

0.100

0.150

0.200

0.250

0.300

1986 1993 2000 2007 2014 2021 2028 2035

In ch es

Year

Projected Thickness Graph

Thickness MRT

1) In-Service Interval of Operation (years to next internal inspection)

No Yes No No

MRT = 0.1 inches

RT ip = 0.25 inches

RT bc 0.16 inches

StP r = 0 inches/year

UP r = 0.002903 inches/year

Therefore, the in-service interval of operation (years to next internal inspection) is:

O r = 20.6 years

Therefore, RT bc is established at 0.355 inches (original thickness of 0.375 inches minus 0.020 inches).

0.16 - 0.1 0 + 0.002903

**Since StP r = 0 and UP r = 0; use StP r + UP r = 0.0002 inches/year for calculation purposes.

= O r

Bottom Service Life Evaluation (After Repair)

Containment of Bottom:

Bottom Leak Detection:

Cathodic Protection:

Bottom Coated:

Where:

t min = minimum acceptable shell thickness for each course, in inches; however, t min shall not be less than 0.1 inch for any tank course.

t nom = nominal shell thickness, in inches.

t act = current measured shell thickness, excluding pits and corrosion, in inches.

t prev = previous measured shell thickness, excluding pits and corrosion or t nom , in inches.

D = nominal diameter of the tank, in feet.

H = height from the bottom of the shell course under considerations to the established maximum liquid level, in feet.

H c = calculated safe fill height, in feet, for the current product.

G = specific gravity of the contents.

Y = specified minimum yield strength of the plate; use 30,000 pounds per square inch if not known

(N/A for riveted tanks).

T = smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch;

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

S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of

0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S =21,000 psi. For elevated temperatures above 200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API Standard 650 Appendix M or the product design stress value listed in Table M-1a or M-1b of API Standard 650.

E = original joint efficiency for the tank. Use Table 4-2 from API Standard 653 if original E is unknown; 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 or twice the plate thickness. For riveted tanks, use E =1.0 for shell plates when greater than 6 inches from rivets; use the value of E from API Standard 653 Table 4-3 when within 6 inches of rivets.

L r = remaining life of the shell, in years.

C r = shell corrosion rate, in inches per year.

I ut = inspection interval for the next ultrasonic inspection, in years (not to exceed 15 years).

I v = inspection interval for the next visual external inspection, in years (not to exceed 5 years).

Y = years between the previous measured shell thickness (t prev ) and the current measured shell thickness (t act ), in years.

The maximum inspection intervals are determined by the most restrictive shell course in regard to the remaining life and the corrosion rate calculations for each shell course using the following formulas:

Shell Service Life Evaluation tmin =

2.6(H−1)DG

Lr = tact − tmin

Cr Cr = tprev − tact

Y Iut = tact − tmin 2Cr

Iv = tact − tmin

4Cr

Bottom Service Life Evaluation (After Repair)

2) Projected Thickness Chart and Graph

Year Thickness MRT

1986 0.250 0.1 2017 0.160 0.1 2022 0.145 0.1 2027 0.131 0.1 2037 0.102 0.1 2047 0.073 0.1

*based on same service and corrosion rates.

Anticipated Thickness (20 yrs)*:

Anticipated Thickness (30 yrs)*:

Nominal:

Current Lowest Remaining Thickness:

Anticipated Thickness (5 yrs)*:

Anticipated Thickness (10 yrs)*:

0.000

0.050

0.100

0.150

0.200

0.250

0.300

1986 1993 2000 2007 2014 2021 2028 2035

In ch es

Year

Projected Thickness Graph

Thickness MRT

1) Minimum Required Thickness

D = 43.5 feet

G = 0.79

Y = 31 years

Course No.

Plate Specification

Course Height…

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