Attachment K.4 FAC 40951 Inspection Report 2017.pdf

US Army Corps of Engineers

Omaha District

API 653 In-Service

Inspection Report

Fort Rucker, Alabama

FAC 40951

Tank 2

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

USACE POL-TCX

25 August 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

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, Lowe Army Heliport, located in Dale County, Alabama. An API 653 In-Service (visual external) Inspection was conducted for Tank Facility No.

40951 (Tank 2) on June 21, 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 40951 is a 33.25-foot diameter by 28.25-foot 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 Pittsburgh 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 2011, however, a report was not available at the time of this inspection. A previous out-of-service inspection report dated February 2006 was available. The inspection schedule indicated herein is based on the 2006 report. If the 2011 inspection report details more stringent inspection intervals, it is recommended that they be considered along with the intervals herein. The next ultrasonic thickness inspection of the shell should be performed by February 2021. 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 2006, we recommend the next API Standard 653 Out-Of-Service (internal and external) Inspection should be performed by 2026. 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

Facility Number Facility 40951

Tank Number Tank 2

State / Country Alabama / U.S.A.

City Daleville

Inspection Date June 21, 2017

Tank Manufacturer Pittsburgh 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 13’ – 9 2/16” (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-high and 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 40951, an API Standard 653 In-service (visual external) Inspection was performed. This inspection also included a foundation settlement survey.

2. Site Information

On June 21, 2017 Brockenbrough performed an API 653 In-Service (visual external) Inspection of Tank

Facility 40951 located at Fort Rucker. Fort Rucker is a 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 40951 is a nominal 3,714 barrel, 33.25-foot diameter by 28.25-foot tall, F-24, aboveground vertical storage tank. Per the previous tank inspection report, the tank was constructed by Pittsburgh 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 28-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. The bottom-to-foundation seal appears to have failed in several areas around the circumference of the tank bottom.

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 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 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 appears to be inoperable 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 and high level alarm chambers are mounted on the exterior of the tank shell. The tank is equipped with low, high and high-high level alarms independent of the tank gauging system. An independent low-low level alarm 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 no reinforcing pads on the platform frame nor on the stairway steps where they are welded to the tank shell. The circumferential stairway is directly welded to the shell. The coating system on the circumferential stairway, platforms, and handrails appear 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 appeared 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. There is also an Aqueous Film

Forming Foam (AFFF) system installed, however, the system has been decommissioned and the piping connected to the tank has been removed.

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Recommend AFFF system be removed during next scheduled out-of-service inspection.

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 secondary containment was visually evaluated during the inspection. The secondary containment area appears to be in good condition with the exception of approximately 5 linear feet of joint sealant on the concrete floor adjacent to the tank has failed. There is a small amount of leaves 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 six 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 40951 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. Some sections of the ringwall appeared to have been previously repaired but have failed again.

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.

b. 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.

g6edxan9 Sticky Note Concur with recommendation. Special attention should be given to areas that have been previously repaired.

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Concur. Coordinate coating repairs with any paint work that must be completed. Ensure that nuts and bolts are compatible with base metal where they are installed. Replace nuts and bolts in such a manner to allow tank to remain in-service during work.

c. Repair the Tank Bottom Extension and Bottom-to-Foundation Seal

OBSERVATION: The tank bottom-to-foundation seal has deteriorated and starting to fail. However, no evidence of corrosion nor coating failure at the tank bottom extension was observed.

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: Remove the bottom-to-foundation seal. Prep and coat the tank bottom extension per AST standards and replace the tank bottom-to-foundation seal.

Concur with recommendation.

d. Repair Weep Holes on Shell Reinforcement Pads

OBSERVATION: The tell-tale holes on the shell reinforcement pads around the tank nozzles are plugged with a grease plug and 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 5 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.

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. Replace Tape Level Gauge System

OBSERVATION: The tape level gauge read 9 feet and 11 1/2 inches, while the ATG read 15 feet and 6 13/16 inches. There is condensation on the inside of the reading window.

CODE REFERENCE: UFC 3-460-01, Table 8-1, Item 0, requires a liquid level gauge.

RECOMMENDATION: Replace the tape level gauge system. Ensure new tape is attached to a weight resting on top of the floating pan and not directly attached to the pan or as recommended by the manufacturer.

If possible to isolate control valve by means of valves on both sides work may be performed with tank in-service. If this is not possible, perform work during next out-of-service inspection.

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Concur with recommendation. Perform work during next regularly 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. Seal Weld Tank Stairs

OBSERVATION: The circumferential stairway treads are welded directly to the tank shell.

However, the tank stairway treads are not fully seal welded to the shell.

CODE REFERENCE: API 650, paragraph 5.1.3.6.2 and UFC 3-460-01, paragraph 8-11 require tank attachments (appurtenances) to be seal welded to prevent corrosion and rust streaking.

RECOMMENDATION: Seal weld circumferential stairway treads to the tank shell to prevent corrosion and rust streaking.

Concur. Coordinate work with coating repair work and any other paint work necessary.

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

j. 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 coating repair work and any other paint work to be performed.

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 and do not have testing tees.

CODE REFERENCE: AW 78-24-27 requires the thermal relief piping to be equipped with isolation valves and testing tees. UFC 3-460-01, Section 9-3.5.1 does not allow sight flow indicators in thermal relief piping. UFC 3-460-01, Section 9-8 requires welded or flanged connections for joining steel pipes.

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

b. 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 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.

g6edxan9 Sticky Note Concur. Perform work during next regularly scheduled out-of-service inspection.

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c. 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.

d. Provide Low-low Level Alarm

OBSERVATION: The tank has low, high, and high-high levels 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 regularly scheduled 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 similar projects to reduce 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 UFC 3-

460-03, Appendix C requires 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 repair any areas that may be damaged as a result of vegetative growth.

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Concur. Ensure bolts are both a compatible material and corrosion resistant/protected.

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. Repair Coating System on Secondary Containment Walls

OBSERVATION: The coating system on the vertical dike walls is failing and needs replacement.

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

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. Tank operator should at a minimum perform this work on a regularly scheduled basis and should only deviate from schedule to include additional cleanings/applications.

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Concur. If an increase in containment dike height is selective to correct free board issues, these two activities should be coordinated.

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 40951 Shell Settlement Evaluation By: Jeffrey W. King

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 17.125 0.00 0.12 0.12 0.19

1 17.250 0.13 0.19 0.06 0.02

2 17.500 0.38 0.34 -0.03 -0.19

3 17.375 0.25 0.50 0.25 0.23

4 17.625 0.50 0.57 0.07 0.00

5 17.750 0.63 0.50 -0.12 -0.02

6 17.750 0.63 0.34 -0.28 -0.13

7 17.500 0.38 0.19 -0.19 -0.11

8 17.125 0.00 0.12 0.12 0.25

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 = 0.51 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 40951 Shell Settlement Evaluation By: Jeffrey W. King

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 52.2 0.505 0.67 Si < Smax → OK

3 39.2 0.213 0.50 Si < Smax → OK

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

0.00

0.20

0.40

0.60

0.80

0 2 4 6 8 10

Measured Elevation (in)

Si3 Si0

SHELL THICKNESS CALCULATIONS

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

HMT Inspection in February of 2006. The analysis is included as a reference and should be used for informational purposes only.

API 653 Out-of-Service Inspection Report for U.S. Army Tank No. 2

Fort Rucker, AL

HMT Inspection

February 11-15, 2006

APIRPTSE.DOT REV 1 272-70889/2 (Lowe)r2 3/7/2006 3:18:00 PM

4.3.2 SHELL THICKNESS CALCULATIONS

The minimum acceptable shell plate thickness for tanks with a diameter equal to or less than two-hundred (200) feet is calculated as follows (Ref. API 653, Para. 4.3.3.1):

SE

DGHt )1(6.2 min

Where:

S = See Table = Allowable Stress (psi) D = 32.25 = Nominal Diameter of Tank (ft.)

G = 1.00 = Highest Specific Gravity of Contents H = See Table = Product Height (ft.)

E = See Table = Joint Efficiency

Course

Course Height

(in.)

Product Height

(ft.)

Allowable Stress (psi)

Joint Efficiency

Average Thickness

(in.)

Required Thickness

(in.)

1 95.5 28.42 23,600 1.00 0.244 0.100 2 95.5 20.46 23,600 1.00 0.244 0.100 3 73.5 12.50 26,000 1.00 0.244 0.100 4 76.5 6.38 26,000 1.00 0.243 0.100

Shell thickness calculations indicate the safe fill height of 28.42 feet can be utilized with product specific gravities up to 1.0 (ref. API 653, Para. 4.3.3.1). For products with a specific gravity over 1.0, additional calculations should be performed (ref. API 653, Para.

4.3.3.1). These calculations do not take into account operational restrictions from such items as shell vents, high-level alarms or owner/operator-imposed safe fill restrictions.

SHELL/ROOF ULTRASONIC THICKNESS MEASUREMENTS

The following shell and roof thickness analysis is taken from a previous API 653 Internal Inspection Report prepared by HMT Inspection in February of 2006. The analysis is included as a reference and should be used for informational purposes only.

U.S. Army

TABLE B

BOTTOM PLATE READINGS

(in inches)

PLATE

NO.

Reading

Reading

Reading

Reading

Reading

1 0.320 0.321 0.315 0.310 0.319 2 0.307 0.310 0.320 0.309 0.322 3 0.310 0.315 0.322 0.308 0.315 4 0.309 0.317 0.307 0.305 0.320 5 0.321 0.318 0.315 0.317 0.320 6 0.306 0.309 0.315 0.318 0.321 7 0.308 0.310 0.312 0.309 0.319 8 0.320 0.322 0.325 0.315 0.322 9 0.315 0.319 0.309 0.312 0.319

10 0.324 0.320 0.322 0.314 0.310 11 0.309 0.315 0.310 0.320 0.321 12 0.311 0.316 0.319 0.315 0.320 13 0.319 0.320 0.325 0.319 0.315 14 0.308 0.310 0.324 0.319 0.323

Min: 0.305 Avg: 0.316

U.S. Army

TABLE C

SHELL READINGS

(in inches)

Course 1

Location Drop 1 Drop 2 Drop 3 Drop 4 1 0.239 0.247 0.250 0.239 2 0.240 0.249 0.251 0.242 3 0.245 0.250 0.248 0.240 4 0.237 0.239 0.247 0.245 5 0.249 0.240 0.239 0.250 6 0.250 0.242 0.240 0.249 7 0.251 0.237 0.242 0.240 8 0.247 0.235 0.244 0.237 9 0.245 0.240 0.239 0.239 10 0.243 0.241 0.250 0.244 11 0.240 0.250 0.248 0.240 12 0.252 0.251 0.245 0.251 13 0.251 0.249 0.247 0.238 14 0.249 0.240 0.240 0.241 15 0.240 0.237 0.244 0.237 16 0.245 0.248 0.241 0.245

MIN. 0.235 AVG. 0.244

Course 2

Location Drop 1 Drop 2 Drop 3 Drop 4 1 0.247 0.239 0.244 0.242 2 0.245 0.242 0.240 0.240 3 0.240 0.245 0.245 0.237 4 0.251 0.250 0.239 0.245 5 0.250 0.251 0.235 0.241 6 0.253 0.249 0.240 0.240 7 0.249 0.240 0.242 0.237 8 0.240 0.245 0.249 0.248 9 0.242 0.241 0.244 0.249 10 0.248 0.237 0.250 0.240 11 0.241 0.242 0.251 0.238 12 0.239 0.244 0.247 0.236 13 0.245 0.250 0.239 0.240 14 0.240 0.248 0.244 0.249 15 0.248 0.241 0.241 0.251 16 0.244 0.245 0.237 0.252

MIN. 0.235 AVG. 0.244

U.S. Army

TABLE C (CONT.)

SHELL READINGS

(in inches)

Course 3

Location Drop 1 Drop 2 Drop 3 Drop 4 1 0.237 0.250 0.238 0.247 2 0.240 0.248 0.240 0.240 3 0.245 0.249 0.250 0.235 4 0.242 0.245 0.249 0.238 5 0.237 0.239 0.251 0.240 6 0.239 0.241 0.248 0.237 7 0.235 0.251 0.252 0.244 8 0.240 0.250 0.243 0.250 9 0.241 0.248 0.240 0.251 10 0.240 0.240 0.247 0.247 11 0.247 0.241 0.244 0.244 12 0.243 0.237 0.239 0.240 13 0.241 0.239 0.245 0.245 14 0.238 0.235 0.240 0.249 15 0.250 0.241 0.241 0.251 16 0.251 0.240 0.240 0.250

MIN. 0.235 AVG. 0.243

Course 4 Location Drop 1 Drop 2 Drop 3 Drop 4

1 0.250 0.236 0.249 0.247 2 0.251 0.238 0.250 0.240 3 0.248 0.240 0.252 0.235 4 0.240 0.237 0.249 0.238 5 0.241 0.245 0.247 0.240 6 0.237 0.242 0.239 0.237 7 0.238 0.240 0.244 0.244 8 0.235 0.239 0.240 0.250 9 0.240 0.248 0.250 0.251 10 0.244 0.251 0.247 0.247 11 0.247 0.247 0.245 0.244 12 0.238 0.243 0.237 0.240 13 0.250 0.239 0.240 0.245 14 0.245 0.241 0.242 0.249 15 0.240 0.247 0.238 0.251 16 0.241 0.240 0.250 0.250

MIN. 0.235 AVG. 0.244

U.S. Army

TABLE D

FIXED ROOF READINGS

PLATE

NO.

Reading

Reading

Reading

Reading

Reading

1 0.248 0.250 0.249 0.247 0.251 2 0.250 0.253 0.250 0.251 0.252 3 0.241 0.245 0.248 0.250 0.249 4 0.250 0.252 0.255 0.249 0.251 5 0.247 0.248 0.250 0.252 0.250 6 0.249 0.251 0.250 0.251 0.247 7 0.254 0.250 0.252 0.251 0.250 8 0.251 0.250 0.248 0.247 0.250 9 0.243 0.245 0.248 0.250 0.247

10 0.241 0.245 0.248 0.251 0.245 11 0.250 0.252 0.251 0.249 0.253 12 0.252 0.250 0.248 0.247 0.245 13 0.243 0.245 0.240 0.242 0.245 14 0.250 0.249 0.252 0.251 0.248 15 0.243 0.242 0.241 0.250 0.249 16 0.252 0.249 00.250 0.251 0.248 17 0.241 0.245 0.243 0.247 0.245 18 0.245 0.247 0.253 0.254 0.250 19 0.250 0.251 0.254 0.249 0.247 20 0.254 0.250 0.251 0.249 0.248 21 0.253 0.254 0.250 0.251 0.245 22 0.247 0.245 0.240 0.249 0.252 23 0.250 0.252 0.254 0.249 0.253 24 0.243 0.247 0.250 0.249 0.253 25 0.248 0.253 0.250 0.252 0.249 26 0.251 0.250 0.255 0.248 0.250 27 0.245 0.248 0.243 0.249 0.250 28 0.243 0.251 0.254 0.249 0.247 29 0.251 0.249 0.247 0.250 0.251 30 0.246 0.279 0.253 0.246 0.249

Min: 0.240 Avg: 0.249

U.S. Army

TABLE E

SUMP READINGS

N-S READING E-W READING

1 0.475 1 0.480 2 0.481 2 0.479 3 0.479 3 0.483 4 0.483 4 0.480 5 0.480 5 0.478 6 0.515 6 0.536 7 0.520 7 0.538 8 0.530 8 0.543 9 0.525 9 0.547

10 0.526 10 0.549 11 0.520 11 0.550 12 0.523 12 0.541 13 0.521 13 0.530 14 0.524 14 0.526 15 0.526 15 0.525 16 0.483 16 0.476 17 0.481 17 0.480 18 0.470 18 0.476 19 0.477 19 0.483 20 0.480 20 0.481

TANK DRAWINGS

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

Inspection in February of 2006. Drawings are included as a reference and should be used for informational purposes only. Locations of appurtenances, shell and roof plates, etc. are approximate.

4.4.2 NOZZLE AND APPURTENANCE TABLE Page 22 of 59

Reinforcing Plate

Item

Description Pipe Size (in.)

Station

(ft.)

CL

Elev.

Width

Thick

Shape

Neck

(in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

Comments

A Manway 36 0.0 42 94 78 0.262 A 0.497 0.773 0.762 Yes 3.5 w/Telltale Plug B Coupling 1.25 5.05 9.75 -- -- -- -- -- -- -- -- 8.75 Level Alarm C Coupling 1.25 5.05 26.5 -- -- -- -- -- -- -- -- 25.5 Plugged D Coupling 1.25 5.05 39 -- -- -- -- -- -- -- -- 38 Level Alarm E Stairway Start -- 12.4 -- -- -- -- -- -- -- -- -- -- F Foam Nozzle 3 17.6 C4 -- -- -- -- N/A -- -- -- C4 G Platform -- 19.9 63 -- -- -- -- -- -- -- -- 60 H Manway 36 19.9 117 94 78 0.244 A 0.495 0.514 0.519 Yes 78.5 w/Telltale Plug I Coupling 1.25 32.8 C3 -- -- -- -- -- -- -- -- C3 w/ Blind Flange, IWS

J Conduit -- 34.1 -- -- -- -- -- -- -- -- -- -- K Coupling 1.25 34.2 C4 -- -- -- -- -- -- -- -- C4 Level Alarm L Coupling 1.25 34.2 C4 -- -- -- -- -- -- -- -- C4 Plugged M Coupling 1.25 34.2 C4 -- -- -- -- -- -- -- -- C4 Level Alarm N Coupling 1.25 35.1 C4 -- -- -- -- -- -- -- -- C4 O Coupling 1.25 36.1 C4 -- -- -- -- -- -- -- -- C4 Level Alarm P Coupling 1.25 36.1 C4 -- -- -- -- -- -- -- -- C4 Plugged Q Coupling 1.25 36.1 C4 -- -- -- -- -- -- -- -- C4 Level Alarm R Stairway End -- 44.3 -- -- -- -- -- -- -- -- -- -- S Manway 36 52.35 43 94 78 0.241 A 0.490 0.766 0.756 Yes 3.5 w/Telltale Plug T Foam Nozzle 3 52.35 C4 -- -- -- -- N/A -- -- -- C4 U Nozzle 3 58.95 23 10.5 10.5 0.310 B 0.292 0.923 0.934 Yes 18 w/Telltale Plug &

Blind Flange V Nozzle 3 58.95 83 10.5 10.5 N/A B N/A N/A N/A Yes 78 w/Telltale Plug &

Blind Flange W Nozzle 6 72 11.25 17 17 0.265 B 0.435 0.980 -- Yes 3.5 w/Telltale Plug X Foam Nozzle 3 87.2 C4 -- -- -- -- N/A -- -- -- C4 Y Coupling 1 89.25 4.5 -- -- -- -- -- -- -- -- 3.5 Z Conduit -- 90.25 -- -- -- -- -- -- -- -- -- --

The stations are measured circumferentially counterclockwise from Manway A.

4.4.2 NOZZLE AND APPURTENANCE TABLE (CONT’D)

Reinforcing Plate

Item

Description Pipe Size

Station

(ft.)

CL

Elev.

Width

Neck

(in.)

Flng Thick (in.)

Cover Thick (in.)

Tell-tale

Weld Space

Comments

AA Automatic Gauge -- 91.8 -- -- -- -- -- -- -- -- -- -- Shand & Jurs BB Nozzle 4 93.75 9 12 12 0.310 B 0.334 0.902 -- Yes 3.25 w/Telltale Plug CC Nozzle 8 98.1 11.5 19 21.5 0.313 D 0.520 1.144 -- Yes Flush w/Telltale Plug

The stations are measured circumferentially counterclockwise from Manway A.

IWS= Insufficient Weld Space VERTICAL WELD SEAM LOCATIONS: (Measured in feet circumferentially counterclockwise from Manway A)

1) 6.9 2) 26.85 3) 46.8 4) 66.75 5) 86.65 6) 91.55 7) 8) 9) 10) 11) VERTICAL WELD OFFSET FOR COURSES 2, 3, 4, etc.

2) 9.5 3) 6.9 4) 9.5 5) 6) 7) 8) 9)

Total Strapped Circumference = 104.6 ft.

OSHA ACCESS STRUCTURE REPORT

OSHA Stairway Data

Handrail Actual

(in)

OSHA Rq’d min

(in) max

(in)

Handrail Height 34 1/2 34 1/2 30 34

Step Width 30 30 22 NA

Step Rise 7 7 NA NA

Bottom Step Rise 7 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:

N/AUnknown

36" deep

Level Alarms:

Material: Welded

Tank Outside Dimensions:

Secondary Containment, Overfill, and CRDM

F-24 jet fuel

3,714 BBL

N/A

Release Prevention Barrier

Concrete dike w/ FML under concrete

Current Product:

33'-3"ø x 28'-3" tall

Nominal Capacity:

Useable Capacity:

Welded

Truck fillstands

Liner w/ tell-tales

Overfill Protection:

Continuous Release Detection Monitoring

Type:

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

N/A

Date Installed:

2011Previous Tank Inspection Date:

Interior Coating:

54102

Horizontal

Inspection Date:

Design Std

Tank Specifications

Tank Inspector Name:

Inspector Certification Number:

Insulated

Coated

Plastic / Fiberglass

Other:Double Bottom

Tank Construction and Configuration

Single Wall

Open Type Dike

API 653 EXTERNAL INSPECTION CHECKLIST

Lowe Airfield, Ft. RuckerProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

Ft. Rucker Tank Inspections

Lowe Airfield, Ft. Rucker

General Inspection Information

16-088.01

Submitted to:

Contract No.:

USACE POL - TCX

W9128F-12-D-0006

Tank Facility No.:

Local Tank ID No.:

6/21/2017

40951

Tank Manufacturer:

Tank Construction Date:

Tank 2 Jeff King

Vertical

Rectangular

Double Wall

Fire Resistant

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

Exterior Coating:

3-part epoxy (assumed)

Unknown

Receipt From: Tank truck off-load

Secondary Containment

API 653 EXTERNAL INSPECTION CHECKLIST

Lowe 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

C.1.1.6 Housekeeping

Buildup of trash, vegetation, and other inflammables

Tank settlement into asphalt base

Hairline cracks in ringwall. Ringwall elevated approximately 28"

C.1.1.1 Concrete Ring a)

C.1.1.2 Asphalt

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

C.1.1.7 Cathodic Protection

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

Measure foundation levelness and bottom elevations (See Annex B) c)

Check for:

C.1.1.5 Site Drainage

Check for:

Proper operation of dike drains

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

See level survey results

ITEM

C.1.1 Foundation

STATUS COMMENTSTASK

Tank Settlement b)

Run-off rainwater from shell draining away from the tank

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

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 a) d)

Settlement around perimeter of tank

Review cathodic protection potential readings

Check for:

b)

C.1.1.4 Rock Check for:

b)

5V, 0.5A

Organic debris and vegetation growth

Dike drain inlet located underneath both tanks issue piping a)

Settlements into the base

Check for:

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:

Corrosion loss and wear on the rivets

Pitting on support welds to shell, especially on shell plates

Mold and algae growth on tank shell and chimes

Reinforcing pads welded to shell at supports

Paint failures, pitting, and corrosion

Check for:

b)

Grooving, corrosion, pitting, and coating failures

C.1.2.2 Internal (Floating Roof Tank) c)

Check for:

Broken welds and corrosion damage

(paint failure, pitting, corrosion, product buildup), especially where it occurs at tack-welded junction d)

C.1.2. Shells

ITEM TASK STATUS 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)

Seal has failed in several areas (10 lf)

Leaks and identify the location by sketch or photo c)

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

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

Proper operation of regulators for tanks with purge gas systems

AFFF has been demolished

Reinforcing pad tell-tale holes are plugged with grease

Check for:

Leaks at piping manifolds, flanges, and valves

TRVs - SFIs are installed in TRV assemblies

C.1.3 Shell Appurtenances

Pipe coating and coating on valves and equipment has failed

C.1.3.2 Tank Piping Manifolds

COMMENTS

Damage on autogauge head

TASK 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

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

Check for:

d) a) b)

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

C.1.3.1 Manholes and Nozzles

Flange leaks and leaks around bolting

Check for:

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

ITEM

a)

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

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

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

9' - 11 1/2" (tape); 13' - 9 2/16" (ATG)

Tape gauge is inoperable

C.1.3.3 Autogauge System c) d)

C.1.3.4 Shell-mounted Sample

Station Water Draw-Off System a)

ITEM TASK

h)

Tape gauge is inoperable

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

Condition of board and legibility of board-type autogauges

Freedom of movement of marker and float

Check for:

i)

C.1.3.5 Heater (Shell Manhole

Mounted)

C.1.3.6 Mixer

1 1/2" ø pipe

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 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

STATUS COMMENTS

Leaks in circulation pump and operating problems

Inspect condensate drain for presence of oil indicating leakage

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

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

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

C.1.3.9 Swing Lines: Identify Ballast

Varying Need

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

C.1.3.7 Swing Lines: Winch a)

Operation

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

COMMENTS

Check for leaks at threaded and flanged joints

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A No access

Pass Fail N/A

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

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

Mold and algae growth on tank roof plates

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.)

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

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.

f) g)

Check if seal fabric on primary shoe seals is pulling shoes away from shell

(fabric not wide enough).

Inspect fabric for deterioration, holes, tears, and cracks.

ITEM TASK

C.1.4.6 Roof Insulation b) c)

Crack and leaks in the insulation weather coat where runoff rain water could penetrate the insulation

Check for:

a) c) d) e)

Wet insulation under the weather coat

Corrosion on the roof plate and holes near the edge of the insulated area by removing small test sections of insulation

Inspect visible metallic parts for corrosion and wear.

Inspect for openings in seals that would permit vapor emissions.

Inspect for protruding bolt or rivet heads against the shell.

C.1.4.7 Floating Roof Seal a)

Systems

Inspect the condition of the seal, measure and record maximum rim spaces and seal-to-shell gaps around the full roof circumference at the level of inspection.