Attachment K.2 Wright Patterson-Fac 7272 (Tank 272)-FINAL-2017.pdf

[05/18/2017]

API In‐Service Inspection Report Wright Patterson AFB, OH

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

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

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

A.1 SHELL SETTLEMENT SURVEY

A.2 SHELL SERVICE LIFE EVALUATION…………………………………………………………..…………………………………………..18

A.3 SHELL UT MEASUREMENTS

A.4 ROOF UT MEASUREMENTS

A.5 SHELL NOZZLE / REPAD UT MEASUREMENTS

A.6 CRITICAL ZONE SHELL THICKNESS

A.7 SHELL LAYOUT DRAWING

A.8 ROOF LAYOUT DRAWING

A.9 OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS…………………………………………………………………………………………………32

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX D: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

Significant Findings (overview)

GENERAL TANK INFORMATION

Construction Bottom Lap‐Welded (Cone‐Down)

Shell Butt‐Welded (Cylindrical)

Fixed Roof Lap‐Welded (Self‐Supported Cone)

Material Bottom Carbon Steel A‐36 Mod

Shell Carbon Steel A‐36 Mod

Level Alarms

A. GENERAL PROJECT INFORMATION

An API Standard 653 In‐service (External) inspection was performed for Tank 272.

B. TANK INSPECTION COMMENTS

3. Tank Shell

4. Tank Appurtenances

a. Gauging

C. FINDINGS AND RECOMMENDATIONS

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

a. None

protection."

3. RECOMMENDED REPAIRS to fully comply with UFC 3‐460‐01 & AW 78‐24‐27 Standards or as

NO PICTURE AVAILABLE

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

Where:

S max = maximum permissible out-of-plane deflection, in feet.

L = ΠD /N = arc length between measurement points, in feet.

D = tank diameter, in feet N = number of survey points.

Y = yield strength, in pounds per square inch (psi).

E = young's modulus, in pounds per square inch (psi) H = tank height, in feet

D = 34 feet N = 8 L = 3.14(34)/8 = 34 feet Y = 36,000 psi E = 29,000,000 psi H = 30 feet

L 2 = 178.2697 square feet

11(178.2697)(36,000) 2(29,000,000)(30)

1) Maximum Permissible Out-of-Plane Deflection Calculation

S max = = 0.0406 feet

A.1 Shell Settlement Evaluation

API In-Service Inspection Report Wright Patterson AFB, OH

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|S i | = U i - (1/2U i-1 + 1/2U i+1 )

|S i | = magnitude of the calculated out-of-plane deflection, in feet.

U i = Out-of-Plane settlement of point "i ", in feet (+) when above cosine curve (-) when below cosine curve

Point Actual Curve Fit U i U i+1 U i-1 S i |S i |

1 3.187500 3.187500 0.000000 0.005840 -0.004576 -0.004576 0.000632 2 3.187500 3.192076 -0.004576 0.000000 0.005208 0.005208 0.007181 3 3.208333 3.203125 0.005208 -0.004576 0.004576 0.004576 0.005208 4 3.218750 3.214174 0.004576 0.005208 -0.010417 -0.010417 0.007181 5 3.208333 3.218750 -0.010417 0.004576 -0.016257 -0.016257 0.004576 6 3.197917 3.214174 -0.016257 -0.010417 -0.005208 -0.005208 0.008444 7 3.197917 3.203125 -0.005208 -0.016257 0.005840 0.005840 0.000000 8 3.197917 3.192076 0.005840 -0.005208 0.000000 0.000000 0.008444

1) Out-of-Plane Deflection Calculation

A.1 Shell Settlement Evaluation

The out-of-plane deflection is acceptable.

API In-Service Inspection Report Wright Patterson AFB, OH

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Shell Settlement Graph

A.1 Shell Settlement Evaluation

3.185

3.19

3.195

3.2

3.205

3.21

3.215

3.22

1 2 3 4 5 6 7 8 1

F ee t

Data PointsShell Settlement

Optimum Cosine Curve

Min. Settlement at (Pt 1)

Max. Settlement at (Pt 4)

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray 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:

A.2 Shell Service Life Evaluation tmin =

2.6(H−1)DG

SE

Lr = tact − tmin

Cr Cr = tprev − tact Y Iut = tact − tmin 2Cr

Iv = tact − tmin

4Cr

API In-Service Inspection Report Wright Patterson AFB, OH

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1) Minimum Required Thickness

D = 34 feet

G = 0.84

Y = 62 years

Course No.

Plate Specification

Course Height (feet)

Product Height (feet) (H )

Maximum Allowable

Stress (psi) (S )

Joint Efficiency

(E )

Minimum Acceptable Thickness (inches) (t min )

Previous Measured Thickness (inches) (t prev )*

Current Measured Thickness (inches)

(t act )

1 A 36 5 30 24,900 0.75 0.1 0.1875 0.182 2 A 36 5 25 24,900 0.75 0.1 0.1875 0.182 3 A 36 5 20 27,400 0.75 0.1 0.1875 0.185 4 A 36 5 15 27,400 0.75 0.1 0.1875 0.181 5 A 36 5 10 27,400 0.75 0.1 0.1875 0.182 6 A 36 5 5 27,400 0.75 0.1 0.1875 0.185

*The t prev values were based on t nom .

A.2 Shell Service Life Evaluation

0.000

0.050

0.100

0.150

0.200

1 2 3 4

In ch es

Course

Thickness Graph tprev tact tmin

API In-Service Inspection Report Wright Patterson AFB, OH

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A.2 Shell Service Life Evaluation

2) Corrosion Rate, Remaining Life and Inspection Intervals

Course No.

Corrosion Rate

(in./yr) (C r )

Remaining Life

(years) (L r )

Next Visual

Inspection (years)

(I v )

Next Ultrasonic Thickness Inspection

(years) (I ut )

1 0.00009 751 5 15 2 0.00009 924 5 15 3 0.00004 2108 5 15 4 0.00010 772 5 15 5 0.00009 924 5 15

* Let C r =0.0002 inches per year for calculation purposes.

Note: The engineering data used to calculate in-service period of operation (Remaining Life) assumes the tank remains in the same service and all corrosion rates remain constant. The maximum safe fill height for the tank is not limited other than by the established maximum operating liquid level and any other appurtenance such as overflow, vents, or firefighting system.

0.00000

0.00002

0.00004

0.00006

0.00008

0.00010

0.00012

1 2 3 4 5 6

In ch es P er Y ea r

Course

Course Corrosion Rate Graph

Series1

API In-Service Inspection Report Wright Patterson AFB, OH

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3) Projected Thickness Chart and Graph

Course #1:

Year Thickness tmin 2017 0.182 0.1 2022 0.182 0.1 2027 0.181 0.1 2037 0.180 0.1 2047 0.179 0.1

*based on same service and corrosion rates.

Course #2:

Year Thickness tmin 2017 0.182 0.1 2022 0.182 0.1 2027 0.181 0.1 2037 0.180 0.1 2047 0.179 0.1

*based on same service and corrosion rates.

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)* Anticpated Thickness (20 yrs)* Anticpated Thickness (30 yrs)*

Current Thickness:

Current Thickness:

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)* Anticpated Thickness (20 yrs)* Anticpated Thickness (30 yrs)*

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #1 Projected Thickness Graph

Thickness tmin

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #2 Projected Thickness Graph

Thickness tmin

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Course #3:

Year Thickness tmin 2017 0.185 0.1 2022 0.185 0.1 2027 0.185 0.1 2037 0.184 0.1 2047 0.184 0.1

*based on same service and corrosion rates.

Course #4:

Year Thickness tmin 2017 0.181 0.1 2022 0.180 0.1 2027 0.180 0.1 2037 0.179 0.1 2047 0.178 0.1

*based on same service and corrosion rates.

Anticpated Thickness (20 yrs)* Anticpated Thickness (30 yrs)*

Anticpated Thickness (20 yrs)* Anticpated Thickness (30 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)*

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #3 Projected Thickness Graph

Thickness tmin

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #4 Projected Thickness Graph

Thickness tmin

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Course #5:

Year Thickness tmin 2017 0.182 0.1 2022 0.182 0.1 2027 0.181 0.1 2037 0.180 0.1 2047 0.179 0.1

*based on same service and corrosion rates.

Course #6:

Year Thickness tmin 2017 0.185 0.1 2022 0.185 0.1 2027 0.185 0.1 2037 0.184 0.1 2047 0.184 0.1

*based on same service and corrosion rates.

Anticpated Thickness (20 yrs)* Anticpated Thickness (30 yrs)*

Anticpated Thickness (30 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)*

Current Thickness:

Anticpated Thickness (5 yrs)* Anticpated Thickness (10 yrs)* Anticpated Thickness (20 yrs)*

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #6 Projected Thickness Graph

Thickness tmin

0.000

0.050

0.100

0.150

0.200

2017 2019 2021 2023 2025 2027 2029 2031 2033 2035 2037 2039 2041 2043 2045 2047

In ch es

Year

Course #5 Projected Thickness Graph

Thickness tmin

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Point No.

Course #1

Course #2

Course #3

Course #4

Course #5

Course #6

1 0.186 0.184 0.187 0.185 0.186 0.186 2 0.182 0.182 0.185 0.183 0.184 0.185 3 0.183 0.182 0.188 0.181 0.182 0.185 4 0.187 0.182 0.187 0.184 0.183 0.186 5 0.189 0.183 0.186 0.186 0.184 0.186 6 0.184 0.183 0.187 0.184 0.184 0.185 7 0.185 0.184 0.185 0.185 0.183 0.185 8 0.185 0.183 0.188 0.185 0.185 0.185 9 0.183 0.182 0.185 0.183 0.182 0.186

10 0.185 0.183 0.187 0.182 0.185 0.186

NOTE: Thickness measurements are evenly spaced down each course along the path of each drop.

The thickness measurements are in inches. The lowest UT measurements are in RED, and the highest UT measurements are in GREEN for each shell course.

A.3 Shell Plate Thickness Measurements

API In-Service Inspection Report Wright Patterson AFB, OH

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1 2 3 4 5

1 0.185 0.185 0.186 0.185 0.184 A 2 0.182 0.183 0.182 0.181 0.185 E 3 0.188 0.183 0.183 0.182 0.181 E 4 0.182 0.184 0.183 0.186 0.187 C 5 0.189 0.187 0.186 0.185 0.183 E 6 0.181 0.184 0.186 0.184 0.183 E 7 0.185 0.186 0.186 0.185 0.186 E 8 0.184 0.183 0.184 0.185 0.186 E 9 0.187 0.186 0.187 0.183 0.181 E

10 0.183 0.183 0.188 0.185 0.181 E 11 0.185 0.182 0.184 0.181 0.183 E 12 0.186 0.185 0.184 0.183 0.183 E 13 0.182 0.185 0.180 0.187 0.181 E 14 0.184 0.185 0.186 0.186 0.186 E 15 0.187 0.183 0.181 0.189 0.183 E 16 0.185 0.186 0.186 0.185 0.186 E 17 0.184 0.183 0.184 0.185 0.186 B 18 0.182 0.183 0.182 0.181 0.185 E 19 0.188 0.183 0.183 0.182 0.181 E 20 0.183 0.183 0.188 0.185 0.181 D

A.4 Fixed Roof Plate Thickness Measurements

NOTE: The lowest UT measurements are in RED, and the highest UT measurements are in GREEN.

Plate Number

Point No. Plate Type

API In-Service Inspection Report Wright Patterson AFB, OH

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Nom. 0o 90o 180o 270o

A 1" Water Draw 0.133 0.137 0.135 0.136 0.137 B 24" Manhole 0.250 0.250 0.247 0.250 0.248

C 1" High Level Shut-off Valve Float Pilot Assembly

0.133 0.136 0.135 0.135 0.136

D 1" High Level Shut-off Valve Float Pilot Assembly

0.133 0.135 0.136 0.134 0.135

E 1" High Level Alarm 0.133 0.136 0.136 0.136 0.133 F 1" High Level Alarm 0.133 0.138 0.137 0.138 0.137 G 1" Low Level Alarm 0.133 0.130 0.131 0.130 0.130 H 1" Low Level Alarm 0.133 0.135 0.134 0.133 0.136 I 4" Receipt 0.337 0.332 0.338 0.324 0.318 J 4" Issue 0.337 0.312 0.314 0.317 0.321

Nom. 0o 90o 180o 270o

A Tombstone 0.250 0.247 0.246 0.243 0.245 B Tombstone 0.250 0.249 0.250 0.250 0.249 I Tombstone 0.250 0.250 0.246 0.246 0.242 J Tombstone 0.250 0.245 0.247 0.243 0.249

Nozzle Measurements

A.5 Shell Nozzle and Nozzle Reinforcement Measurements

Noz Desig. Reinforcement Description

Thickness Measurements (inches)

Thickness Measurements (inches)Noz Desig. Nozzle Description

NOTE: The Sheet Number corresponds to the shell plate in the first shell course. The X-Axis is measured from the Seam #1 in the first shell course to the center of the nozzle. Seam #1 is the first seam left of the first manway left of the stairway in the first shell course viewing from the outside. The Y-Axis is measured from the tank bottom to the center of the nozzle.

Nozzle Reinforcement Measurements

API In-Service Inspection Report Wright Patterson AFB, OH

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Location # 1 is with 2" of Plate 1 - 1

1 0.187 51 0.184 101 0.176 2 0.187 52 0.174 102 0.187 3 0.188 53 0.185 103 0.186 4 0.188 54 0.183 104 0.187 5 0.187 55 0.185 105 0.184 6 0.188 56 0.185 106 0.174 7 0.185 57 0.180 107 0.185 8 0.187 58 0.185 9 0.184 59 0.184

10 0.174 60 0.187 11 0.185 61 0.187 12 0.183 62 0.188 13 0.185 63 0.188 14 0.185 64 0.188 15 0.180 65 0.187 16 0.185 66 0.188 17 0.184 67 0.185 18 0.187 68 0.187 19 0.187 69 0.184 20 0.188 70 0.174 21 0.181 71 0.181 22 0.187 72 0.187 23 0.176 73 0.187 24 0.187 74 0.187 25 0.186 75 0.188 26 0.187 76 0.188 27 0.184 77 0.187 28 0.174 78 0.188 29 0.185 79 0.185 30 0.183 80 0.187 31 0.185 81 0.184 32 0.185 82 0.174 33 0.180 83 0.185 34 0.187 84 0.180 35 0.187 85 0.185 36 0.188 86 0.184 37 0.181 87 0.187 38 0.187 88 0.187 39 0.187 89 0.188 40 0.187 90 0.181 41 0.188 91 0.187 42 0.188 92 0.176 43 0.187 93 0.187 44 0.188 94 0.186 45 0.185 95 0.187 46 0.187 96 0.187 47 0.184 97 0.188 48 0.174 98 0.188 49 0.185 99 0.188 50 0.187 100 0.187

A.6 Tank Shell 360 degree Measurement every foot (within 12 inches of chime)

Location # Thickness in inches Location # Thickness in inchesLocation #

Thickness in inches

API In-Service Inspection Report Wright Patterson AFB, OH

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Shell Layout [1 of 2] Tank # 272

US Air Force; Wright Patterson Air Force Base, OH

InterSpec, LLC.

5/18/2017 N/A N/A

A - 1'' Water Draw B - 24'' Manhole

ER

-U

S A

IR

FO

R

C E-W

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T PA

TTER

SO

N A

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R C

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-TA

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K -272-M

A Y

/2017

Description:

Remarks/Legend:

Drawing Title:

Owner:

Drawn By:

Date: Rev. No.: Scale:

Modified By: InterSpec, LLC.

IN

TER

SPEC

, LLC

-PR

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PR

IETA

R Y

IN

FO

R M

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TIO

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-FO

R O

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L U

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1-1 1-31-2

2-1 2-22-5 2-3

3-1 3-23-5

4-1 4-2 4-3

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

A

B

API In-Service Inspection Report Wright Patterson AFB, OH

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A.7

1-4 1-5 1-6

2-3 2-4 2-5

3-3 3-4 3-5

4-3 4-4 4-4

5-3 5-4 5-5 6-3 6-4 6-5

1-3

Shell Layout [2 of 2] Tank # 272

US Air Force; Wright Patterson Air Force Base, OH

InterSpec, LLC.

5/18/2017 N/A N/A

C - 1'' High-High Level Shut off D - 1'' High Level Alarm E - 1'' High-High Level Alarm F - 1'' High Level Alarm G - 1'' Low Level Alarm

ER

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S A

IR

FO

R

C E-W

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SO

N A

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K -272-M

A Y

/2017

Description:

Remarks/Legend:

Drawing Title:

Owner:

Drawn By:

Date: Rev. No.: Scale:

Modified By: InterSpec, LLC.

IN

TER

SPEC

, LLC

-PR

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IETA

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L U

SE O

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C D

E F

G I J H

ATG

H - 1'' Low-Low Level Cut Out I - 4'' Fill Line J - 4'' Issue Line

API In-Service Inspection Report Wright Patterson AFB, OH

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A.7

Roof Layout [1 of 1] Tank # 272

US Air Force; Wright Patterson Air Force Base, OH

InterSpec, LLC.

5/18/2017 N/A N/A

E R

-U S A

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R C

E -W

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H T

PA

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T E

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N A

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A

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-TA

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K -272-M

A Y

/2017Description:

Remarks/Legend:

Drawing Title:

Owner:

Drawn By:

Date: Rev. No.: Scale:

Modified By: InterSpec, LLC.

IN

T

E R

SPE

C

, L L

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-PR

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A

B

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D E

F

GH

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Ladder

A - 4'' ENRAF Vito Water Gauge B - 6'' Vent C - 2'' Alarm D - 10'' Blank E - 24'' Access with 8'' Gauge Hatch

F - 10'' ENRAF Level Gauge G - 1'' Manual Tank Gauge H - 6'' Vent I - 2'' Alarm

API In-Service Inspection Report Wright Patterson AFB, OH

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A.9.OSHA ACCESS STRUCTURE REPORT

OSHA Vertical Caged Fixed Ladder Data

OSHA Required

Range

Inches Safety Device Status

Total Length 360 Yes Satisfactory

Section Length >50 feet 360 NA Satisfactory

OSHA Roof Safety Rail Data

Top Rail Height 42 ‐ Satisfactory

Toeboard Height 4.5 ‐ Satisfactory

Toeboard Clearance >0.25 ‐ Satisfactory

API In-Service Inspection Report Wright Patterson AFB, OH

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS

modifications.

API In-Service Inspection Report Wright Patterson AFB, OH

1 2 3 4 5 6 7 8 ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

ΔRadius (inches)

30.0 1.500 1.600 1.700 1.400 -0.600 -0.500 1.100 -0.300

28.0 1.100 1.300 1.000 1.100 -0.900 -0.700 0.800 0.000

26.0 0.200 0.700 0.500 0.400 -0.600 -0.300 0.500 -0.100

22.0 -0.900 1.000 -0.700 0.200 -0.900 0.900 0.200 -0.400

20.0 0.500 0.600 -0.500 0.000 -0.500 -0.100 0.500 0.800

18.0 0.300 0.700 -0.200 0.300 -0.600 -0.900 -0.800 -0.100

16.0 0.200 -0.600 -0.300 0.200 0.000 -0.400 -0.600 -0.400

14.0 0.700 0.400 0.600 0.000 0.400 0.300 -0.600 -0.600

12.0 1.400 0.300 0.200 0.500 -0.100 1.100 -0.800 -0.600

10.0 0.100 0.700 0.000 0.300 0.600 -0.500 -0.500 -0.600

8.0 0.100 -0.400 0.200 0.300 0.400 -0.500 0.300 -0.300

6.0 0.000 -0.700 0.200 0.000 0.500 -0.200 -0.100 0.000

4.0 0.800 -0.200 -0.200 -0.200 -0.100 0.100 -0.200 -0.100

2.0 0.000 0.000 0.600 0.100 -0.200 -0.100 0.000 -0.100

0.0 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Minimum: -0.900 -0.700 -0.700 -0.200 -0.900 -0.900 -0.800 -0.600

Maximum: 1.500 1.600 1.700 1.400 0.600 1.100 1.100 0.800

ΔPlumbness: 2.400 2.300 2.400 1.600 1.500 2.000 1.900 1.400

ΔAllowed: 3.600 3.600 3.600 3.600 3.600 3.600 3.600 3.600

Condition: Satisfactory Satisfactory Satisfactory Satisfactory Satisfactory Satisfactory Satisfactory Satisfactory

Height from Bottom (feet)

Vertical Profile Number Shell Plumbness

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Vertical Profile #1 Vertical Profile #2 Vertical Profile #3 Vertical Profile #4

Shell Plumbness

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Shell Plumbness Vertical Profile #5 Vertical Profile #6 Vertical Profile #7 Vertical Profile #8

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐4 ‐2 0 2 4

API In-Service Inspection Report Wright Patterson AFB, OH

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ΔDiameter (inches) Condition

ΔDiameter (inches) Condition

ΔDiameter (inches) Condition

ΔDiameter (inches) Condition

30.0 0.900 Satisfactory 1.000 Satisfactory 2.800 Satisfactory 1.100 Satisfactory

28.0 0.200 Satisfactory 0.400 Satisfactory 1.800 Satisfactory 1.100 Satisfactory

26.0 -0.400 Satisfactory 0.100 Satisfactory 1.000 Satisfactory 0.300 Satisfactory

22.0 -1.800 Satisfactory 0.100 Satisfactory -0.500 Satisfactory -0.200 Satisfactory

20.0 0.000 Satisfactory 0.100 Satisfactory 0.000 Satisfactory 0.800 Satisfactory

18.0 -0.300 Satisfactory 0.100 Satisfactory -1.000 Satisfactory 0.200 Satisfactory

16.0 0.200 Satisfactory -0.600 Satisfactory -0.900 Satisfactory -0.200 Satisfactory

14.0 1.100 Satisfactory 0.800 Satisfactory 0.000 Satisfactory -0.600 Satisfactory

12.0 1.300 Satisfactory 0.200 Satisfactory -0.600 Satisfactory -0.100 Satisfactory

10.0 0.700 Satisfactory 1.300 Satisfactory -0.500 Satisfactory -0.300 Satisfactory

8.0 0.500 Satisfactory 0.000 Satisfactory 0.500 Satisfactory 0.000 Satisfactory

6.0 0.500 Satisfactory -0.200 Satisfactory 0.100 Satisfactory 0.000 Satisfactory

4.0 0.700 Satisfactory -0.300 Satisfactory -0.400 Satisfactory -0.300 Satisfactory

2.0 -0.200 Satisfactory -0.200 Satisfactory 0.600 Satisfactory 0.000 Satisfactory

0.0 0.000 Satisfactory 0.000 Satisfactory 0.000 Satisfactory 0.000 Satisfactory

#4 and #8 Vertical Profiles

Shell Out-Of-Roundness Height from

Bottom (feet)

#1 and #5 #2 and #6 #3 and #7

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Vertical Profiles #1 & #5 Vertical Profiles #2 & #6 Vertical Profiles #3 & #7 Vertical Profiles #4 & #8

Shell Out-Of-Roundness

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐6 ‐4 ‐2 0 2 4 6

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐6 ‐4 ‐2 0 2 4 6

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐6 ‐4 ‐2 0 2 4 6

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

‐6 ‐4 ‐2 0 2 4 6

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

Shell Out-Of-Roundness (Top View Overlay)

‐20

‐18

‐16

‐14

‐12

‐10

‐8

‐6

‐4

‐2

21 foot Elevation 0 foot Elevation

API In-Service Inspection Report Wright Patterson AFB, OH

Shannon T Gray

APPENDIX C: API 653 CHECKLISTS FOR TANK INSPECTIONS

Tank In‐Service Inspection Checklist

Item Completed

X

C.1.1 Foundation

Measure foundation levelness and bottom elevations (see Annex B for extent of measurements).

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

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

X c Inspect for cavities under foundation and vegetation against bottom of tank. X d Check that runoff rainwater from the shell drains away from tank. X e Check for settlement around perimeter of tank. X

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

NA

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

C.1.1.3 Oiled Dirt or Sand

Check for settlement into the base which would direct runoff rain water under the tank rather than away from it.

NA

C.1.1.4 Rock

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

NA

C.1.1.5 Site Drainage a Check site for drainage away from the tank and associated piping and manifolds. X b Check operating condition of the dike drains. X

C.1.1.6 Housekeeping

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

C.1.1.7 Cathodic Protection

Review cathodic protection potential readings. X

C.1.2 Shells

C.1.2.1 External Visual Inspection a Visually inspect for paint failures, pitting, and corrosion. X b Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X c Inspect the bottom‐to‐foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank)

Visually inspect for grooving, corrosion, pitting, and coating failures. NA

C.1.2.3 Riveted Shell Inspection a Inspect external surface for rivet and seam leaks. NA b Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). NA c Inspect rivets for corrosion loss and wear. NA

Tank In‐Service Inspection Checklist Continued

Item Completed

X d Inspect vertical seams to see if they have been full fillet lap‐welded to increase joint efficiency. X e If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern: number of rows, rivet size, pitch length, and note whether the joint is butt‐riveted or lap‐ riveted.

NA

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

NA

b Check support welds to shell for pitting, especially on shell plates. NA c Note whether supports have reinforcing pads welded to shell. NA

C.1.3 Shell Appurtenances

C.1.3.1 Manways and Nozzles a Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates. X b Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X c Inspect for flange leaks and leaks around bolting. X d Inspect sealing of insulation around manways and nozzles. NA e Check for inadequate manway flange and cover thickness on mixer manways. NA

C.1.3.2 Tank Piping Manifolds a Inspect manifold piping, flanges, and valves for leaks. X b Inspect firefighting system components. NA c Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X d Check for adequate thermal pressure relief of piping to the tank. X e Check operation of regulators for tanks with purge gas systems. NA f Check sample connections for leaks and for proper valve operation. NA g Check for damage and test the accuracy of temperature indicators. NA h Check welds on shell‐mounted davit clips above valves 6 in. and larger. NA

C.1.3.3 Autogauge System a Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X b Inspect autogauge head for damage. X c Bump the checker on autogauge head for proper movement of tape. X d Identify size and construction material of autogauge tape guide (floating roof tanks). NA e Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). NA f Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X g On floating roof tanks, when the roof is in the lowest position, check that no more than two ft of tape is exposed at the end of the tape guide.

NA

h Inspect condition of board and legibility of board‐type autogauges. NA i Test freedom of movement of marker and float. NA

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

b Check circulation pump for leaks and operating problems. NA

Completed

X c Test bracing and supports for sample lines and equipment. NA

C.1.3.5 Heater (Shell Manway Mounted)

Inspect condensate drain for presence of oil indicating leakage. NA

C.1.3.6 Mixer a Inspect for proper mounting flange and support. NA b Inspect for leakage. NA c Inspect condition of power lines and connections to mixer. NA

C.1.3.7 Swing Lines: Winch Operation a Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly.

NA

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

NA

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

NA

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints. NA

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity. NA

C.1.3.10 Swing Lines: Cable Material and Condition a For nonstainless steel cable, check for corrosion over entire length. NA b All cable: check for wear or fraying.

C.1.3.11 Swing Lines: Product Sample Comparison

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

C.1.3.12 Swing Lines: Target

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

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

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

X

C.1.4.2 Deck Plate External Corrosion

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

C.1.4.3 Roof Deck Drainage

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

X

Completed

X

C.1.4.4 Level of Floating Roof

At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a 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.1.4.5 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.

NA

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

NA

b Inspect for wet insulation under the weather coat. NA c Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

NA

C.1.4.7 Floating Roof Seal Systems a Inspect the condition of the seal, measure and record maximum rim spaces and sealto‐ shell gaps around the full roof circumference at the level of inspection.

NOTE Inspection of the seal and measurement of the rim spaces and seal‐to‐shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

b Measure and record annular space at 30‐ft spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly opposite pairs.

NA

1) _______ _______ Opposite pair 1. NA

2) _______ _______ Opposite pair 2. NA c Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough). NA d Inspect fabric for deterioration, holes, tears, and cracks. NA e Inspect visible metallic parts for corrosion and wear. NA f Inspect for openings in seals that would permit vapor emissions. NA g Inspect for protruding bolt or rivet heads against the shell. NA h Pull both primary and secondary seal systems back all around the shell to check their operation. NA i Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

NA

j Inspect wedge‐type wiper seals for flexibility, resilience, cracks, and tears. NA

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch a Inspect condition and functioning of sample hatch cover. X b On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

NA

c Check for corrosion and plugging on thief and gauge hatch cover. NA d Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold‐off distance.

e Check for reinforcing pad where sample hatch pipe penetrates the roof deck. NA

Completed

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

NA

g Test operation of system. NA h On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample).

NA

C.1.5.2 Gauge Well a Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. NA b Check for a hold‐off distance marker and tab with hold‐off distance (legible). NA c On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

NA

d If accessible, check the distance from the gauge well pipe to the tank shell at different levels. NA e If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

NA

C.1.5.3 Fixed Roof Scaffold Support

Inspect scaffold support for corrosion, wear, and structural soundness. NA

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

C.1.5.5 Autogauge: Float Well Cover a Inspect for corrosion. NA b Check tape cable for wear or fraying caused by rubbing on the cover. NA

C.1.5.6 Sample Hatch (Internal Floating Roof) a Check overall conditions. NA b When equipped with a fabric seal, check for automatic sealing after sampling. NA c When equipped with a recoil reel opening device, check for proper operations. NA

C.1.5.7 Roof‐mounted Vents (Internal Floating Roof)

Check condition of screens, locking and pivot pins. NA

C.1.5.8 Gauging Platform Drip Ring

On fixed roof tanks with drip rings under the gauging platform or sampling area, inspect for plugged drain return to the tank.

C.1.5.9 Emergency Roof Drains

Inspect vapor plugs for emergency drain: that seal fabric discs are slightly smaller than the pipe ID and that fabric seal is above the liquid level.

NA

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. NA

C.1.5.11 Vacuum Breakers

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

NA

C.1.5.12 Rim Vents a Check condition of the screen on the rim vent cover. NA

Completed

X b Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. NA

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