Attachment K.2 FAC 30951 Inspection Report 2017.pdf

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Fort Rucker, Alabama

FAC 30951

Tank 2

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

USACE POL-TCX

6 September 2017 g6edxan9 Sticky Note

POL-MCX

API 653 In-Service Inspection Report Fort Rucker, Alabama

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

THIS INSPECTION

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES

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 Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

C. FINDINGS AND RECOMMENDATIONS

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

2. SIGNIFICANT FINDINGS per API 653, UFC 3-460-01, or AW 78-24-27 Standards

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

4. RECOMMENDED REPAIRS as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATIONS

SHELL/ROOF ULTRASONIC THICKNESS MEASUREMENTS

TANK DRAWINGS

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX C: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCV High Level Control Valve

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MFE Magnetic Flux Exclusion

MT Magnetic Particle Testing

NA Not Applicable

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

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

UT Ultrasonic Testing

VT Visual Testing

GENERAL SUMMARY

Austin Brockenbrough & Associates, LLP (Brockenbrough) was retained by Omaha District USACE under Contract No. W9128F-12-D-0006 Delivery Order No. 0023 to perform API Standard 653 In-Service Inspections. As required by this task order, Brockenbrough executed a tank inspection site visit to Fort Rucker, Cairns Army Airfield, located in Dale County, Alabama. An API 653 In-Service (visual external) Inspection was conducted for Tank Facility No.

30951 (Tank 2) on June 22, 2017. This inspection was performed in accordance with API Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. The confined space between the internal floating roof and the fixed roof was not entered during the inspection. All observations made during this in-service (visual external) inspection were made from the exterior of the tank.

Tank Facility 30951 is a 33-foot and 3-inch diameter by 28-foot and 3-inch tall, single wall, vertical, field erected tank with a nominal storage capacity of 3,714 barrels of jet fuel (F-24). A tank data plate was present; however, the tank manufacturer information was not legible on the plate. Based on information obtained from previous inspection reports the tank was manufactured by Pittsburg Tank & Tower Co. Inc. The tank was constructed in 1995 in accordance with API 650 9th Edition. Secondary containment is provided by a concrete containment area with vertical concrete dike walls and a flexible membrane liner underneath the concrete containment. The tank is built on an elevated concrete ringwall and has four leak detection ports. Since there are no as-built drawings of the tank available at the time of this inspection, the presence of a release prevention barrier could not be determined.

Also, the tank is equipped with a typical under tank impressed current cathodic protection system. Details of the tank construction and appurtenances are included in Section ‘B’.

There are no mandatory repairs noted that need immediate attention. Additional noted deficiencies are discussed in more detail in Section ‘C’, and should be addressed in a timely manner. Photographs of the tank are included in Appendix ‘C’.

The next API Standard 653 In-Service (visual external) Inspection should be performed by an API 653 Inspector by June 2022. The last out-of-service inspection was performed in June 2011. The inspection schedule indicated herein is based on that report. The next ultrasonic thickness inspection of the shell should be performed by June 2026. While the current version of UFC 3-460-03 requires the next out-of-service inspection occur after 10 years, an upcoming revision allows the frequency to be extended as determined by a certified API 653 tank inspector. As the tank was inspected in 2011, we recommend the next API Standard 653 Out-Of-Service (internal and external) Inspection should be performed by June 2031. This inspection should include an external and internal inspection and include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology and an ultrasonic thickness inspection of the tank shell. This inspection should include a thorough code compliance evaluation as well.

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Army

Location Fort Rucker – Cairns Army Airfield

Facility Number Facility 30951

Tank Number Tank 2

State / Country Alabama / U.S.A.

City Daleville

Inspection Date June 22, 2017

Tank Manufacturer Pittsburg Tank & Tower Co. Inc (Per previous tank inspection report)

Design Standard API Std 650, 9th Edition

Date of Construction 1995

Tank Contents Jet Fuel (F-24)

Tank Serial Number Unknown

Tank Diameter 33’-3”

Shell Height 28’-3”

Product Height 8’ – 9 1/16” (ATG reading at the time of inspection)

Tank Capacity 3,714 barrels (Nominal capacity)

Foundation Elevated Concrete Ringwall

Construction

Bottom Lap-welded cone down bottom (Per previous tank inspection report)

Shell (4) butt-welded shell courses

Floating Roof Internal Aluminum Honeycomb Floating Pan

Fixed Roof Self-supported, lap-welded, domed

Material

Bottom A36 Carbon steel (Per tank data plate)

Shell A36 Carbon steel (Per tank data plate)

Floating Roof Aluminum (Internal)

Fixed Roof A36 Carbon steel (Per tank data plate)

Cathodic Protection Impressed Current Cathodic Protection System

Interior Coating System Epoxy-Epoxy-Epoxy (assumed)

Exterior Coating System Epoxy-Epoxy-Polyurethane (assumed)

Level Gauging Shand & Jurs Tape Level Gauge; Enraf Automatic Tank Gauge (ATG)

Overfill Protection High Level Control Valve; Independent High and High-high Level Alarms

Piping Receipt 6” Carbon Steel

Issue 8” Carbon Steel

Low Suction 4” Carbon Steel

Water Draw-Off 1” Stainless Steel

Level Alarms Independent High-high, High, and Low Level Alarms

Type of Internal Floating Roof Aluminum Honeycomb Floating Pan

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

This project will perform API 653 Inspections of various tanks at facilities throughout the United States.

Additional consideration is given to federal, state, and local regulations as well as applicable military criteria and general industry standards.

For Facility 30951, an API Standard 653 In‐service (visual external) Inspection was performed. This inspection also included a foundation settlement survey.

2. Site Information

On June 22, 2017 Brockenbrough performed an API 653 In‐Service (visual external) Inspection of Tank

Facility 30951 located at Fort Rucker. Fort Rucker is located in Dale County, Alabama, and is surrounded by the neighboring cities of Daleville, Ozark and Enterprise. Fort Rucker is a primary flight training base for Army Aviation and is home to the United States Army Aviation Center of Excellence

(USAACE) and the United States Army Aviation Museum.

B. TANK INSPECTION COMMENTS

1. Tank Construction

Tank Facility 30951 is a nominal 3,714 barrel, 33-foot and 3-inch diameter by 28-foot and 3-inch tall, F-

24, aboveground vertical storage tank. Per the previous tank inspection report, the tank was constructed by Pittsburg Tank & Tower Co. Inc. to API 650, 9th Edition in 1995. Base personnel have strapping tables for determining tank volume.

2. Tank Foundation

The tank rests on a 30-inch high concrete ringwall foundation and has four leak detection ports. Since there were no as-built drawings of the tank available at the time of this inspection, the presence of a release prevention barrier could not be determined. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The concrete ringwall was found to be in good condition with only a few minor hairline cracks. Part of the bottom-to-foundation seal has cracked or failed and needs to be replaced. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard 653 and was found to be acceptable. Settlement results are listed in Appendix A.

3. Tank Shell

The vertical and cylindrical shell consists of four carbon steel butt‐welded courses. The exterior of the shell was visually inspected and evaluated for plumbness, roundness, peaking and banding. The shape of the shell appears to be within the allowable tolerances of API Standard 653.

4. Tank Appurtenances

a. Tank Roof

The tank is constructed with a self-supported lap-welded domed roof. Isolated areas of coating failure and corrosion were observed on the center vent, flanges, nozzles, nuts, and bolts. There was excessive mold and algae growth on the tank roof and roof appurtenances. However, the coating https://en.wikipedia.org/wiki/United_States_Army_Aviation_Branch https://en.wikipedia.org/wiki/United_States_Army_Aviation_Center_of_Excellence https://en.wikipedia.org/wiki/United_States_Army_Aviation_Museum system appeared to be in good condition with no areas of corrosion noted at the time of this inspection.

b. Venting

This tank features a 6-inch pressure/vacuum vent, an 18-inch emergency vent, and a 24-inch atmospheric center vent. The tank is also equipped with four perimeter circulation vents/inspection hatches and has four shell-mounted overflow vents. These vent/hatches provide adequate venting capacity based on the size of the tank.

c. Gauging

The tank’s Enraf ATG is installed through an 8-inch roof nozzle. The tank also has a Shand & Jurs tape level gauge which provided a reading outside of the allowable tolerance at the time of this inspection. There is a dedicated 8-inch sample gauging hatch with plug and reel and an additional

8-inch gauging hatch mounted on the 36-inch roof manhole.

d. Level Alarms

The low, high, and high-high level alarm chambers are mounted on the exterior of the tank shell and are independent of the tank gauging system. An independent low-low level is not present as required by military criteria.

e. Stairs and Platforms

The tank’s steel roof is accessible by a circumferential stairway mounted on the shell of the tank.

There are reinforcing pads on the platform plate and on the stairway steps where they are welded to the tank shell. The coating system on the circumferential stairway, platforms, and handrails appeared to be in good condition with a few areas of coating failure and minor corrosion. The width and rise of the stairway steps and the height of the handrails appear to be in general compliance with OSHA criteria.

f. Grounding and Bonding

There are four grounding cables connected to ground lugs welded to the tank anchor chairs.

5. Tank Coating

The interior coating system of the tank is assumed to be epoxy-epoxy-epoxy. The external coating system appeared to be a standard military coating system (epoxy-epoxy-polyurethane). The coating system on the tank shell appeared to be in good condition and no areas of corrosion were observed during this inspection. Mold and algae growth were observed on the tank shell and tank bottom extension. As the tank is used to store oil and the interior is coated with epoxy, deterioration of the interior of the shell since the previous inspection was performed is extremely unlikely. Minor coating failure and corrosion were observed on several places on the roof nozzles, handrails, platforms, and stairs. There was excessive mold and algae growth observed on the tank roof and tank shell.

6. Tank Piping System

Fuel is received through 6‐inch carbon steel piping from adjacent Truck Off-load Stations and is issued through 8-inch carbon steel piping to the adjacent Truck Fillstands. The pipeline coating system and the coating system on the carbon steel valves has failed.

7. Fire Protection System

There are several fire hydrants noted within 300 feet of this tank.

8. Secondary Containment

Secondary containment is provided by a concrete containment area with vertical concrete dike walls with a flexible membrane liner underneath the containment slabs. The interior of the perimeter dike walls is coated. The secondary containment was visually evaluated during the inspection. The secondary containment area appears to be in good condition with the exception of approximately 10 linear feet of joint sealant on the concrete floor around the drainage drop inlet has failed. Also, the sealant in one of the containment wall expansion joints has failed. The coating on the interior of the perimeter walls has failed. There are small amounts of organic debris, sludge, and vegetation located in the secondary containment area. The product piping is located over the drainage swale and water tends to collect underneath it. There is one access stair for ingress and egress from the containment area. The containment is of sufficient size to contain a total tank loss plus approximately 8 1/2 inches of freeboard. This is in compliance with NFPA 30 requirements, however, does not meet the latest UFC

3-460-01 requirements which requires total tank capacity plus 1 foot of freeboard.

Recommend one of 3 possible COAs:

1.) Increase height of dike containment walls to provide for 12" of free board as required. Tank can remain in-service during this work.

2.) Decrease operating level of tank such that 12" of free board will remain in the event of tank failure.

3.) Status quo, if this option is selected a targeted risk assessment should be completed as sufficient free board will not be maintained in the event of tank failure.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 30951 was found to be in generally good condition. The tank is fully serviceable, with no mandatory deficiencies that would require immediate removal of the tank from service. However, there were several items observed that are not in full compliance with federal, state, and local codes or military criteria.

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 integrity, or the adjacent environment. The tank should remain out of service until these repairs are completed. No mandatory repairs are required to be performed.

2. SIGNIFICANT FINDINGS per API 653, UFC 3-460-01, or AW 78-24-27 Standards

The following information identifies the significant findings found during the tank inspection.

a. Repair Hairline Cracks in Ringwall Foundation

OBSERVATION: Minor hairline cracking was present on several areas within the concrete ringwall foundation.

CODE REFERENCE: UFC 3-460-03, Section 8-4.3.1 and 8-10.2.1 require all cracks to be cleaned and sealed with a fuel resistant sealant.

RECOMMENDATION: Clean and seal all the hairline cracks within the concrete ringwall and concrete dike wall with a fuel resistant sealant.

Concur with recommendation.

b. Replace Tank Bottom-to-Foundation Seal

OBSERVATION: The tank bottom-to-foundation seal has deteriorated and cracked for approximately

20 linear feet in total.

CODE REFERENCE: UFC 3-460-03, Section 8-4.10 B, requires the seal to be maintained in good working order to prevent corrosion of the underside of the tank bottom.

RECOMMENDATION: Replace approximately 20 linear feet of tank bottom-to-foundation seal. Prep and coat the tank bottom protrusion per AST standards and replace the required areas of tank bottom-to-foundation seal.

c. Repair Coating System on Tank and Tank Appurtenances

OBSERVATION: Localized coating failure and minor corrosion were observed on several places on the tank anchor bolts, roof appurtenances, roof nozzles, safety chains, platforms, and stairs. Also, rust streaking was observed around the shell manhole reinforcing pad tell-tale holes.

CODE REFERENCE: UFC 3-460-01, Section 8-3.10, requires the exterior of fuel storage tanks and appurtenances to be coated.

RECOMMENDATION: Remove corrosion from all the isolated areas of deterioration. Clean and prep all the areas that require coating repairs and apply a compatible coating system that meets military criteria. The nuts and bolts should be removed and replaced with corrosion resistant nuts and bolts.

Concur with recommendation.

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Concur with recommendation. Ensure that nuts and bolts are replaced in such a manner as to allow tank to remain in-service during repairs. Ensure that dissimilar metals are not selected for replacement hardware.

d. Repair Weep Holes on Shell Reinforcement Pads

OBSERVATION: The tell-tale holes on the shell reinforcement pads around the tank nozzles are creating rust streaks/stains on the tank shell.

CODE REFERENCE: API 650, sections 5.7.5.1 and 5.7.6.1 require tell-tales on all shell reinforcement pads for leak detection around the nozzles to be open to the atmosphere.

RECOMMENDATION: Remove the grease plugs and repair the corrosion of the tell-tale holes in the reinforcement pads. Install elbowed drain plug for leak detection.

e. Repair Joint Sealant in Secondary Containment Area

OBSERVATION: Approximately 10 linear feet of joint sealant has failed within the secondary containment area.

CODE REFERENCE: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require dike areas to be liquid tight.

RECOMMENDATION: Remove and replace the failed/defective joint sealant in the secondary containment area.

Concur with recommendation.

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Concur with recommendation. If any vegetative growth has occurred within damaged areas, ensure that herbicide is applied to prevent future growth that may compromise repairs.

f. Replace Level Control Valve

OBSERVATION: The 6-inch level control valve is constructed out of aluminum.

CODE REFERENCE: NFPA 30 paragraph 27.4.3 does not allow valves made of low melting point materials to be used within secondary containment areas. UFC 3-460-01 paragraph 3-6.7 prohibits use of aluminum valves in DoD Fuel Systems.

RECOMMENDATION: Replace the 6-inch aluminum control valve with a steel or ductile iron level control valve.

g. Recalibrate Tape Level Gauge System

OBSERVATION: The variation between the tape level gauge and the ATG readout exceeds the allowable limit set by API 653 External Inspection Checklist C.1.3.3. The tape level gauge read

8 feet and 6 inches, while the ATG read 8 feet and 9 1/16 inches.

CODE REFERENCE: API 653 External Inspection Checklist C.1.3.3 allows a maximum variation of 2 inches between tape level gauge and ATG.

RECOMMENDATION: Recalibrate the tape level gauge system to show accurate fuel level readout.

If possible to isolate control valve by means of valves on both sides replace with acceptable (code compliant) alternative. If this is not possible complete work during next scheduled out-of-service inspection.

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Concur with recommendation. If confined space entry is required wait until next scheduled out-of-service inspection.

h. Provide Hold-Off Distance Marker at Sampling/Gauging Hatch

OBSERVATION: There are no hold-off distances painted or stenciled on or adjacent to the sampling/gauging hatches.

CODE REFERENCE: API 653 In-Service Checklist, C1.5.2b.

RECOMMENDATION: Provide a stencil indicating the hold-off distance and marking adjacent to or directly on the sample/gauging hatches.

i. Repair Joint Sealant in Secondary Containment Wall Joint

OBSERVATION: The sealant in one of the containment wall expansion joints has failed.

CODE REFERENCE: NFPA 30 paragraph 22.11.2.4 and CFR 112.7(c)(1) require dike areas to be liquid tight.

RECOMMENDATION: Remove and replace the failed/defective joint sealant in the secondary containment wall.

Concur with recommendation. Coordinate work with any coating/paint repairs.

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

These items represent repairs and/or upgrades that could be performed to bring the tank into full compliance with current standards, but that do not represent potential risks to system operators, equipment integrity, or the adjacent environment. Our recommendations to perform or not to perform these repairs and/or upgrades take into consideration the cost of the repair, the operational benefit of the repairs, the age of the tank/system, operator safety, environmental risks, and equipment integrity.

a. Upgrade Thermal Relief System

OBSERVATION: The existing thermal relief valve piping on the tank receipt and issue piping have sight flow indicators.

CODE REFERENCE: UFC 3-460-01, Section 9-3.5.1 does not allow sight flow indicators in thermal relief piping.

RECOMMENDATION: Modify and upgrade thermal relief piping to remove sight flow indicators.

b. Provide Scaffold Supports

OBSERVATION: There are no scaffold cable supports present on the tank roof.

CODE REFERENCE: UFC 3-460-01, Table 8-1, Item ff requires two scaffold cable supports on the fixed roof in accordance with API 650.

RECOMMENDATION: Provide two scaffold cable supports in accordance with API 650.

Concur. Perform work during next scheduled out-of-service inspection.

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Concur. Perform work during next scheduled out-of-service inspection.

c. Upgrade Water Draw-off Piping

OBSERVATION: The water draw-off piping consists of 1-inch pipe with a ball valve at the tank skin.

Also, the piping in the water draw-off system, including the tank nozzle, consists of threaded valves and fittings.

CODE REFERENCE: UFC 3-460-01, Section 9-8 requires welded or flanged connections for joining steel pipes. UFC 3-460-01, Table 8-1, Item z, requires water draw-off piping to include a 2-inch double block and bleed valve as the tank skin valve.

RECOMMENDATION: Upgrade the water draw-off piping to 2-inch and provide a 2-inch double block and bleed valve at the skin of the tank. Also, replace all threaded fittings and connections with welded or flanged connections.

d. Provide Low-low Level Alarm

OBSERVATION: The tank has low, high, and high-high level switches, but does not have a low-low level switch.

CODE REFERENCE: UFC 3-460-01, Table 8-1, Item l requires independent high-high, high, low, and low-low level alarms.

RECOMMENDATION: Modify low level alarm shell mounted chamber and provide low-low level alarm.

e. Provide Circumferential Stair Landing

OBSERVATION: There is no circumferential stairway landing for maintaining the high-level alarm chamber.

CODE REFERENCE: DoD Standard Design AW 78-24-27 requires new storage tank designs to include a circumferential stairway landing for maintaining shell-mounted level alarms.

RECOMMENDATION: Provide a circumferential stairway landing for maintaining the shell-mounted level alarms.

Concur. Perform work during next out-of-service inspection.

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f. Provide Additional Access Stair into Dike Containment Area

OBSERVATION: The dike containment area is currently only accessible via one stair access.

CODE REFERENCE: AW 78-24-27 requires at least two means of access to tank containment areas. It is also safe practice to have multiple egresses in case of emergency.

RECOMMENDATION: Provide additional dike access stair for ingress/egress from containment area.

Concur. Coordinate work with other similar work to reduce total mobilization costs.

4. RECOMMENDED REPAIRS as Part of Regular Maintenance

Recommended repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Remove Vegetation within the Dike Area

OBSERVATION: There is buildup of dried leaves and other vegetation in the dike area.

CODE REFERENCE: NFPA 30, paragraph 6.9.4 requires dike areas to be kept free of weeds and other unnecessary combustible materials. UFC 3-460-03, 8-4.3.1, 8-10.2.1, 8-10-3.1,8-10.5.1, and

Appendix C require vegetation to be removed from dike areas in addition to applying an herbicide.

RECOMMENDATION: Remove all vegetation from the dike area and perform regular maintenance to prevent deterioration of the containment slab. Apply an herbicide on a regular basis to prevent any future growth/vegetation.

b. Replace Missing Bolts on Center Vent

OBSERVATION: The tank center vent is missing half of the flange bolts.

CODE REFERENCE: N/A

RECOMMENDATION: Provide and install missing bolts on center vent.

Concur. Additionally ensure that any area (concrete) through which growth occurred in repaired and recoated.

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Concur. Ensure bolts are corrosion resistant and not of dissimilar metal to vent.

c. Remove Mold and Algae

OBSERVATION: There is mold and algae growing on the tank roof, shell, and appurtenances. The mold and algae growth may cause and/or accelerate degradation of the exterior coating system.

CODE REFERENCE: UFC 3-460-01 paragraph 8-3.10 requires the exterior of the tank to be coated.

RECOMMENDATION: Power wash the exterior of the tank and apply an algae and mold inhibitor on a regular basis.

d. Maintain Safety Chains

OBSERVATION: At one of the openings in the perimeter roof handrail adjacent to a roof hatch, the safety chains were noted as being installed but were not connected to both sides of the handrail.

This creates an opening for a potential fall hazard.

CODE REFERENCE: N/A

RECOMMENDATION: Maintain and inspect the safety chains regularly to ensure satisfactory condition and use.

e. Replace Containment Dike Wall Coating System

OBSERVATION: The perimeter dike containment walls are coated, but the coating is failing and peeling off the wall.

CODE REFERENCE: N/A

RECOMMENDATION: Facility personnel indicated the coating system is to be repaired as part of a future maintenance project. Therefore, no further recommendations are warranted at this time.

Concur. Additionally if safety chains are found to be defective they should be immediately replaced.

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Concur. If option "A" is selected for containment height issue, recommend that work be completed after increasing wall height to prevent rework from being necessary.

f. Provide NFPA Hazard Label

OBSERVATION: The tank is not labeled with a NFPA hazard warning label.

CODE REFERENCE: NFPA 30, paragraph 21.7.2.1 requires ASTs to be labeled in accordance with

NFPA 704.

RECOMMENDATION: Provide a new NFPA hazard warning label in accordance with NFPA 704.

Concur. Coordinate work with other recoat/paint work.

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

Austin Brockenbrough & Associates, L.L.P. Job No. 16-088.01

Location: Fort Rucker Date: 07/11/2017

Subject: Tank 2 Shell Settlement Evaluation By: Andrew C. Swenck

API 653 Appendix B

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

Diameter (D) = 33.25 (ft)

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 13.06

Tank Height (H) = 28.25 (ft)

Height of

Weld * Z U S

0 25.250 0.00 0.13 0.13 0.25

1 25.625 0.38 0.20 -0.18 -0.17

2 25.750 0.50 0.36 -0.14 -0.06

3 25.750 0.50 0.52 0.02 0.05

4 25.750 0.50 0.58 0.08 0.07

5 25.750 0.50 0.52 0.02 -0.02

6 25.625 0.38 0.36 -0.02 0.00

7 25.500 0.25 0.20 -0.05 -0.11

8 25.250 0.00 0.13 0.13 0.07

Maximum out-of-plane deflection = 0.25

* = measured elevation

*HI (Height of Instrument)

Z = calculated rigid body tilt (in)

U = out-of-plane settlement =

S = out-of-plane deflection = z-y

Y = yield strength of shell material (PSI) = 30,000

E = Youngs modulus of elasticity (lbf/in2) = 2.90E+07

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH)*12 = 0.41 in

R^2 =(Syy - SSE)/Syy = 0.72 not >=0.9 therefore cosine curve is invalid.

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

Austin Brockenbrough & Associates, L.L.P. Job No. 16-088.01

Location: Fort Rucker Date: 07/11/2017

Subject: Tank 2 Shell Settlement Evaluation By: Andrew C. Swenck

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

Per B.3.2.2, K = 10.5

Settlement arc length (ft), Sarc

Out of plate settlement at Point i (Si)

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

Point Sarc (ft) Si (in) Smax

0 65.3 0.500 0.83 OK

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

Si < Smax →

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0 2 4 6 8 10

Measured Elevation (in)

Si0

SHELL THICKNESS CALCULATIONS

The following shell thickness analysis is taken from a previous API 653 Internal Inspection Report prepared by

Pond & Company in July of 2011. The analysis is included as a reference and should be used for informational purposes only.

SHELL THICKNESS EVALUATION

Shell Plate Thickness and Safe Fill Height Calculations The following calculations determine the minimum acceptable shell plate thickness (tmin) and safe fill heights (product and water) for tanks equal to or less than 200 feet in diameter in accordance with Section 4 of API 653.

Minimum Acceptable Shell Plate Thickness (tmin) tmin = 2.6 D (H - 1) G Where:

S E tmin = Minimum acceptable shell plate thickness (in.)

D = Tank Diameter (ft.)

H = Height from bottom of the shell course under consideration to the maximum liquid level (ft.)

G = Specific Gravity of product S = Allowable stress from API 653 (lbf/in2) E = Joint Efficiency CA = Corrosion Allowance (in.)

Variables

Tank Height (ft): 28.00

D (ft): 33.25

G (Water): 1.00

G (Product): 0.82

Course

Height (ft) H (ft) Allowable Stress

S (Psi) Joint Efficiency

E CA (in) Shell

Height (ft)

1 8.00 28.00 24,900 1.00 0.010 8.00

2 8.00 20.00 24,900 1.00 0.010 16.00

3 6.00 12.00 27,400 1.00 0.010 22.00

4 6.00 6.00 27,400 1.00 0.010 28.00

The following table shows the checks required for tmin:

Check No.

Measured Thickness* Check Calculated Thickness Limit

1 tave > = t(LV) = t(min) + CA

2 t1 > = t(LV) = t(min) + CA

3 t2 > = t(LV) = 0.6 x t(min) + CA

4 tp > = t(LV) = 0.5 x t(min) tave = average UT readings in uncorroded areas t1 = lowest average thickness in “pitted area” t2 = minimum thickness in “pitted area” tp = remaining shell thickness at an isolated pit

* All tanks will have a tave for each course, but many tanks will have no other measurements for t1, t2, or tp if no corrosion or pitting exists in that course.

Using above formula/variables, the following table shows the checks required for tmin:

Check #1 Check #2 Check #3 Check #4 t(ave) t(LV)* ** t1 t(LV)* ** t2 t(LV)* ** tp t(LV)* **

Course (in) (in) P/F (in) (in) P/F (in) (in) P/F (in) (in) P/F

1 0.232 0.110 P N/A N/A -- N/A N/A -- N/A N/A --

2 0.248 0.110 P N/A N/A -- N/A N/A -- N/A N/A --

3 0.253 0.110 P N/A N/A -- N/A N/A -- N/A N/A --

4 0.242 0.110 P N/A N/A -- N/A N/A -- N/A N/A --tave = average UT readings on shell of tank.

t(LV) = calculated limited thickness value P/F indicates shell course passes or fails calculation/checks.

Checks 2, 3, and 4 are not applicable because there were no areas of corrosion or pitting on the shell courses.

Safe Fill Height

Controlling Safe Fill Height

Fluid Height (ft)

Water No Restriction

Product No Restriction

Shell Service Life Evaluation and Corrosion Rates

Shell

Nominal Thickness

(in.)

Current Thickness

(in.)

Years since Construction

N Min

Thickness (in.)

RCA

Next

External (years)

Next

UTM

(years)

1 0.250 0.232 16 0.0011 0.110 108 5 15

2 0.250 0.248 16 0.0011 0.110 123 5 15

3 0.250 0.253 16 0.0011 0.110 127 5 15

4 0.250 0.242 16 0.0010 0.110 132 5 15

N = Corrosion rate, if N is 0 then use the N of the next lower shell course

RCA = Remaining Corrosion Allowance

Interval to next formal external inspection = RCA/4 or 5 years maximum

Interval to next Ultrasonic Thickness Measurements = RCA/2 or 15 years maximum

SHELL/ROOF ULTRASONIC THICKNESS MEASUREMENTS

The following shell and roof thickness analysis is taken from a previous API 653 Internal Inspection Report prepared by Pond & Company in July of 2011. The analysis is included as a reference and should be used for informational purposes only.

APPENDIX B

Tank Inspection Data

Table B-1 Floor Plate Ultrasonic Thickness Readings (Spot)

PLATE 1 PLATE 2 PLATE 3 PLATE 4 PLATE 5

.315 .315 .312 .316 .317 .314 .315 .312 .316 .312

.314 .310 .315 .315 .315

.309 .308 .310 .312 .314

AVG. .313 .312 .314 .314 .314

PLATE 6 PLATE 7 PLATE 8 PLATE 9 PLATE 10

.314 .309 .311 .315 .315 .316 .313 .308 .314 .310

.314 .312 .316 .313 .316

.310 .304 .312 .312 .309

AVG. .312 .311 .315 .312 .312

PLATE 11 PLATE 12 PLATE 13 PLATE 14

.314 .308 .314 .310 .314 .308 .313 .313

.313 .304 .311 .304

.306 .311 .308 .308

AVG. .310 .310 .310 .310

Average Floor Plate Thickness = 0.312” Thickness measurements are in inches.

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

Table B-2 Floor Plate Ultrasonic Thickness Readings (Circumferential)

0' 2' 4' 6' 8' 10' 12' 14' 16' 18' 20' 22' 24' 26' 28'

.310 .309 .309 .315 .315 .319 .310 .308 .319 .320 .311 .316 .310 .312 .313

30' 32' 34' 36' 38' 40' 42' 44' 46' 48' 50' 52' 54' 56' 58'

.309 .312 .304 .312 .315 .318 .310 .309 .320 .321 .320 .314 .315 .309 .304

60' 62' 64' 66' 68' 70' 72' 74' 76' 78' 80' 82' 84' 86' 88'

.320 .310 .307 .304 .320 .320 .321 .317 .310 .308 .312 .315 .318 .303 .321

90' 92' 94' 96' 98' 100' 102'

AVG. 0.313

.315 .324 .314 .318 .312 .307 .308

0' = MANWAY; LOCATIONS ARE 6" IN FROM SHELL-TO-FLOOR WELD, COUNTERCLOCKWISE AROUND

TANK. THICKNESS MEASUREMENTS ARE IN INCHES.

Table B-3 Shell Plate Ultrasonic Thickness Readings

Roof

SHELL

COURSE

PLATE 4-1 PLATE 4-2 PLATE 4-3 PLATE 4-4 PLATE 4-5 PLATE 4-6

Scanned Scanned Scanned Scanned Scanned Scanned

AVG.

Circumferential weld C4

SHELL

COURSE

PLATE 3-1 PLATE 3-2 PLATE 3-3 PLATE 3-4 PLATE 3-5 PLATE 3-6

Scanned Scanned Scanned Scanned Scanned Scanned

AVG.

Circumferential weld C3

SHELL

COURSE

PLATE 2-1 PLATE 2-2 PLATE 2-3 PLATE 2-4 PLATE 2-5 PLATE 2-6

.252 .250 .251 .245 .246 .251 .255 .244 .250 .252 .254 .248 .253 .249 .246 .249 .250 .246

.249 .251 .257 .251 .243 .249 .251 .243 .244 .246 .249 .249 .251 .247 .251 .251 .247 .249

.246 .256 .254 .249 .253 .245 .247 .246 .246 .248 .251 .253 .245 .254 .250 .253 .254 .247

AVG. .252 .248 .247 .250 .250 .250

Circumferential weld C2

SHELL

COURSE

PLATE 1-1 PLATE 1-2 PLATE 1-3 PLATE 1-4 PLATE 1-5 PLATE 1-6

.226 .219 .227 .230 .232 .231 .238 .231 .237 .234 .237 .235 .230 .227 .228 .229 .223 .226

.223 .218 .225 .228 .231 .229 .234 .232 .234 .238 .235 .238 .233 .229 .227 .223 .222 .224

.221 .220 .222 .224 .229 .227 .232 .235 .238 .236 .239 .233 .231 .234 .231 .227 .224 .228

AVG. .222 .229 .235 .236 .230 .225

Circumferential weld C1

Thicknesses represented in inches.

Shell courses 3 and 4 were scanned with the ultrasonic tank crawler.

Refer to Drawing A-2 in Appendix A for plate numbers.

Refer to Appendix F for UT crawler data.

Table B-4 Fixed Roof Plate Ultrasonic Thickness Readings

PLATE 1 PLATE 2 PLATE 3 PLATE 4 PLATE 5

.249 .262 .258 .255 .256

.253 .264 .263 .259 .258

.250 .263 .263 .258 .258

AVG. .251 .263 .261 .257 .257

PLATE 6 PLATE 7 PLATE 8 PLATE 9 PLATE 10

.269 .259 .258 .272 .269

.279 .257 .259 .274 .270

.275 .256 .256 .273 .269

AVG. .274 .257 .258 .273 .269

PLATE 11 PLATE 12 PLATE 13 PLATE 14 PLATE 15

.269 .251 .251 .244 .249

.275 .250 .254 .250 .256

.272 .249 .251 .250 .255

AVG. .272 .250 .252 .248 .253

PLATE 16 PLATE 17 PLATE 18 PLATE 19 PLATE 20

.246 .250 .250 .259 .255

.251 .253 .253 .262 .262

.252 .254 .254 .259 .259

AVG. .250 .252 .252 .260 .259

PLATE 21 PLATE 22 PLATE 23 PLATE 24 PLATE 25

.252 .250 .253 .254 .253

.256 .258 .257 .260 .258

.255 .254 .256 .260 .251

AVG. .254 .254 .255 .258 .254

PLATE 26 PLATE 27 PLATE 28 PLATE 29 PLATE 30

.254 .259 .251 .253 .247

.256 .260 .249 .257 .256

.254 .256 .258 .252 .252

AVG. .255 .258 .253 .254 .252

Average Thickness = 0.257” Thicknesses represented in inches.

Refer to Drawing A-3 in Appendix A for plate numbers.

Table B-5 Nozzles and Appurtenance Table

NOZZLE

NOZZLE SIZE

(Diameter or

Width/Height)

REPAD

SHAPE

REPAD

SIZE

(W X H)

REPAD

THICKNESS

NOZZLE

THICKNESS

H1 H2

NOZZLE LOCATION

(Measured circumferentially from Manway A)

NOTES

MWA 36" A 7'-8"x6'-5" .243 .488 3'-6" 4" 0'-0" Manway

MWB 36" A 7'-8"x6'-5" .240 .491 3'-6" 4" 52'-9" Manway

MWC 36" A 7'-8"x6'-5" .245 .487 9'-6" 6'-8" 19'-4" Manway (Mid-Height)

N1 1" - - - - 11" - 31'-6" LLA

N2 1" - - - - 2'-3" - 31'-6" Plugged

N3 1" - - - - 3'-3" - 31'-6" LLA

N4 3" B 10" .320 .265 2'-0" 1'-7" 59'-6" Flanged

N5 3" B 10" .325 .264 7'-0" 6'-7" 59'-6" Flanged

N6 6" B 1'-4" .252 .431 1'-0" 4" 72'-8" Receipt

N7 3/4" - - - - 5" - 90'-6" Water Draw-off

N8 4" B 1'-0" .308 .314 10" 3 3/4" 95'-0" Low Suction

N9 8" B 1'-5" .244 .495 1'-0" 3 1/2" 99'-4" Main Suction (Issue)

N10 1 1/4" - - - - 21'-10" - 33'-6" Flanged

N11 1" - - - - 23'-0" - 36'-7" HHLA

N12 1" - - - - 24'-5" - 36'-7" Plugged

N13 1" - - - - 25'-6" - 36'-7" HHLA

N14 1" - - - - 22'-9" - 35'-4" HLCV Float

N15 1" - - - - 25'-5" - 35'-4" HLCV Float

N16 1" - - - - 22'-4" - 34'-4" HLA

N17 1" - - - - 23'-8" - 34'-4" Plugged

N18 1" - - - - 24'-10" - 34'-4" HLA

N19 2 1/2" - - - - - - - Fire Protection

N20 2 1/2" - - - - - - - Fire Protection

N21 2 1/2" - - - - - - - Fire Protection

N22 24" B 3'-0" .317 .245 Roof Center Vent

N23 20" B 2'-4" .235 .249 Roof Emergency Vent

N24 10" B 1'-10" .314 .359 Roof MTS ATG

N25 6" B 1'-4" .270 .437 Roof P/V Vent

N26 1 3/4" - - - - Roof Tape Level Gauge

Hatch 1 36" B 6'-0" .310 .254 Roof Hatch w/ Gauging Hatch

Hatch 2 2'-2"x6'-2" - - .251 Roof Rectangular Hatch

Thickness measurements are in inches.

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

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

REPAD SHAPES:

Refer to Drawings A-2 and A-3 in Appendix A for nozzle numbers and locations.

Table B-6 Coating Thickness Measurements

Internal Shell Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

10.96 2.540 10 8.556 16.20

* First Shell Course Only

External Shell Coating Thickness

11.08 3.930 20 7.094 21.75

Tank Floor Coating Thickness

20.8 4.372 20 10.62 29.64

Roof Coating Thickness (External)

8.744 3.025 20 4.699 14.86

The coating measurements are represented in mils.

APPENDIX F

UT Crawler Scans

TANK DRAWINGS

The following tank drawings are taken from a previous API 653 Internal Inspection Report prepared by Pond &

Company in July of 2011. Drawings are included as a reference and should be used for informational purposes only. Locations of appurtenances, shell and roof plates, etc. are approximate.

APPENDIX A

CAD Drawings

Drawing A-1 Tank Bottom Layout

MWB

MWA

ISSUE

LOW SUCTION

WATER DRAW

RECEIPT

SOLID SW

INTERIOR

LADDER

ANTI-ROTATION

CLIP

- FLOATING PAN SUPPORT LEG

- COATING FAILURE (VISUAL SIGNS OF BLISTERING AND CHIPPING)

- ULTRASONIC THICKNESS MEASUREMENT LOCATION

N

0.468"

0.499"

0.496" 0.493"

0.494"

0.467"0.468"

CENTER SUMP

Drawing A-2 Shell Plate Layout

N20

N18 N15

N17 N14

N16

N13

N12

N11

N10

MWC

MWB

MWA

N19

N5

N4 N6 N7

N8

N3

N2

N1

6'-0"

6'-0"

8'-0"

8'-0"

TAPE

LEVEL

GAUGE

LOWER

PLATFORM

UPPER

PLATFORM

1-1 1-2 1-3 1-4 1-5 1-6

2-1 2-2 2-3 2-4 2-5 2-6

3-1 3-2 3-3 3-5 3-63-4

4-1 4-2 4-3 4-4 4-5 4-6

SHELL OVERFLOW

PORTS (TYP)

GROUND

(TYP)

ANCHOR

(TYP)

N21

N9

= ULTRASONIC THICKNESS MEASUREMENTS

Refer to Table B-3, “Shell Plate Ultrasonic Thickness Readings” and Appendix F for tank shell thickness measurements.

Drawing A-3 Roof Layout

N

OSHA ACCESS STRUCTURE REPORT

OSHA Stairway Data

Handrail Actual

(in)

OSHA Rq’d min (in) max (in)

Handrail Height 34 1/2 -- 30 34 Step Width 30 -- 22 NA Step Rise 7 -- NA NA

Bottom Step Rise 7 -- 8 8

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

Coated CS End Conn: Size: 6" Material: Coated CS End Conn: Size: 8"

Issue To:

Tank Specifications

Continuous Release Detection Monitoring

Type:

Secondary Containment, Overfill, and CRDM

N/AUnknown

Tank Construction and Configuration

F-24 jet fuel

3,714 BBL

N/A

Single Wall

Open Type Dike

Release Prevention BarrierSecondary Containment

Overfill Protection / Level Alarms:

Low, high, & high-high independent level alarms High level control valve on receipt piping

Receipt Piping Configuration Issue Piping Configuration

Tank Piping

Receipt From: Tank truck off-load

Concrete dike

36" deep

Level Alarms:

Material: Welded

Liner w/ tell-tales

Overfill Protection:

N/A

Date Installed:

Tank Outside Dimensions: 33'-3"ø x 28'-3" tall

Andrew Swenck

Vertical

Rectangular

Double Wall

Fire Resistant

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

Exterior Coating:

3-part epoxy (assumed)

Unknown

Tank Facility No.:

Local Tank ID No.:

6/22/2017

30951

Tank Manufacturer:

Tank Construction Date:

Tank 2

2011Previous Tank Inspection Date:

Interior Coating:

56234

API 653 EXTERNAL INSPECTION CHECKLIST

Cairns Airfield, Ft. RuckerProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

Ft. Rucker Tank Inspections Cairns Airfield, Ft. Rucker

General Inspection Information

16-088.01 Submitted to:

Contract No.:

USACE POL - TCX

W9128F-12-D-0006

Horizontal

Inspection Date:

Design Std

Tank Inspector Name:

Inspector Certification Number:

Insulated

Coated

Plastic / Fiberglass

Other:

Nominal Capacity:

Useable Capacity:

Welded

Truck fillstands

Double Bottom

Current Product:

API 653 EXTERNAL INSPECTION CHECKLIST

Cairns Airfield, Ft. RuckerProject Site:Project Name: Ft. Rucker Tank Inspections

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A Review cathodic protection potential readings

Check for:

b)

Dike drop inlet located underneath issue lines

TASK

Tank Settlement

C.1.1.4 Rock

Cavities under foundation; vegetation against bottom of tank

Broken concrete, spalling, and cracks, especially under backup bars used in welding butt-welded annular rings under the shell Indications of bottom leakage at drain openings in ring, back of water-draw basins, and top surface of ring

Hairline cracks in ringwall

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand e)

Check for:

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

d)

ITEM

C.1.1 Foundation

C.1.1.1 Concrete Ring

STATUS COMMENTS

Check for:

Measure foundation levelness and bottom elevations (See Annex B) See level survey results

Check for:

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

b) C.1.1.6 Housekeeping

Buildup of trash, vegetation, and other inflammables

Tank settlement into asphalt base a)

Settlements into the base

C.1.1.7 Cathodic Protection

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

C.1.1.5 Site Drainage

Check for:

Proper operation of dike drains

C.1.1.2 Asphalt Settlement around perimeter of tank

25V, 0.3A

Organic debris, vegetation, and organic sludge in dike. Joint sealant failure (approximately 10 lf) around drop inlets. Joint sealant in wall expansion has failed

C.1.2.1 External Visual Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A No access

C.1.2.3 Riveted Shell Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Check for:

COMMENTS

Rivet and seam leaks on external surface

Check for:

c) Bottom-to-Foundation Seal

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

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

a) b)

C.1.2.4 Wind Girder (Floating Roof Tanks) a)

Approximately 20 lf of sealant needs replacement

Leaks and identify the location by sketch or photo

ITEM TASK

Grooving, corrosion, pitting, and coating failures

C.1.2.2 Internal (Floating Roof Tank) c) c) d) b)

Broken welds and corrosion damage (paint failure, pitting, corrosion, product buildup), especially where it occurs at tack-welded junction

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

Paint failures, pitting, and corrosion

STATUS

Check for:

C.1.2. Shells

Corrosion loss and wear on the rivets

Pitting on support welds to shell, especially on shell plates Reinforcing pads welded to shell at supports

Check for:

Mold and algae growth on tank shell

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.3.3 Autogauge System

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

Adequate thermal pressure relief of piping to the tank

Leaks at sample connections and proper valve operation Damage and test the accuracy of temperature indicators

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

Check for:

Proper operation of regulators for tanks with purge gas systems

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

b) Damage on autogauge head

ITEM

a) b)

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

C.1.3.1 Manholes and Nozzles Check for:

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

a) Leaks at piping manifolds, flanges, and valves

C.1.3 Shell Appurtenances

STATUS

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

Sealing of insulation around manholes and nozzles

e) Adequate manholes flange and cover thickness on mixer manholes

C.1.3.2 Tank Piping Manifolds

COMMENTSTASK

Check for:

Flange leaks and leaks around bolting

Reinforcing pad tell-tale holes are plugged with grease

TRVs - SFIs are installed in TRV assemblies

Water draw-off piping is threaded and isolation valve at tank is 1" ball valve

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A No access

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

c) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A Pass Fail N/A

Pass Fail N/A

Leaks in circulation pump and operating problems

Inspect condensate drain for presence of oil indicating leakage c)

Proper movement of tape by bumping the checker on autogauge head Size and construction material of the autogauge tape guide and make note (floating roof tanks) Proper movement of tape. Ask the operator if the tape tends to hang up during tank roof movement (floating roof tanks).

Actual product level compared to the reading on the autogauge. Make note.

(max. variation is 2 in.)

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

a) b)

Proper mounting flange and support Check for:

i)

C.1.3.5 Heater (Shell Manhole Mounted) C.1.3.6 Mixer

Leakage

Bracing and supports for sample water draw-off lines and equipment b)

Check for:

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

ITEM TASK

h)

Condition of power lines and connections to mixer e) f) g)

COMMENTS

Condition of board and legibility of board-type autogauges Freedom of movement of marker and float

8' - 6" (tape); 8' - 9 1/16" (ATG)

1 1/2" ø coated pipe

STATUS

C.1.3.3 Autogauge System c) d)

C.1.3.4 Shell-mounted Sample Station Water Draw-Off System a)

Tape gauge needs recalibration

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

b) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

COMMENTS

Check for leaks at threaded and flanged joints Check for significant difference in stock specific gravity Check for:C.1.3.10 Swing Lines: Cable Material and Condition a) Corrosion over entire length, for non-stainless steel cable Wear or fraying on all types of cable

C.1.3.11 Swing Lines: Product Sample Comparison

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

Indicator: Check that the indicator moves in the proper direction. Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite b) c)

C.1.3.8 Swing Lines: External Guide System

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

C.1.3.9 Swing Lines: Identify Ballast Varying Need

C.1.3.7 Swing Lines: Winch a) Operation

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

ITEM TASK

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

STATUS

C.1.3.12 Swing Lines: Target

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A No access

Pass Fail N/A

Mold and algae growth on tank roof plates

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.

C.1.4.4 Level of Floating Roof

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

(Significant sagging of fixed roof deck indicates potential rafter failure. Large standing water areas on a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons.)

ITEM TASK

C.1.4.1 Deck Plate Internal Corrosion For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. (Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

C.1.4 Roofs

STATUS

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

COMMENTS

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

C.1.4.2 Deck Plate External Corrosion

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A