Attachment K - Fac 400 Inspection Report.pdf

TANK 5 (Facility #400) INSPECTION REPORT API 653 In-Service (External) Inspection

Grissom Air Reserve Base

Peru, Indiana

Prepared For:

U.S. Army Corps of Engineers

Omaha District 106 South 15th Street

Omaha, Nebraska 68102

Submitted By:

Pond and Company

3500 Parkway Lane, Suite 600 Norcross, GA 30092

Telephone: 678-336-7740 Facsimile: 678-336-7744 www.pondco.com

August 2015

Tank 5 (Facility #400) – API 653 Inspection Report Pond and Company Grissom Air Reserve Base – Peru, Indiana 1150068 i

PREFACE

Pond & Company, Inc. was under contract to the U.S. Army Corps of Engineers (USACE), Omaha

District to provide an in-service (external) tank inspection for Tank 5 (Facility #400) at Grissom Air

Reserve Base (ARB) in Peru, Indiana.

There are no mandatory repairs required to remove Tank 5 from service. Additional recommendations for repair and upgrade have been made to prolong tank integrity and maintain product quality. This document presents findings of the tank inspection and testing, as well as recommendations for repairs and upgrades.

Brian Hopper performed the API-653 in-service (external) inspection. Brian Lunsford, P.E. reviewed the document and provided technical oversight.

07 August 2015

Brian Hopper Date Integrity Engineer ASNT NDT Level II API 653 Inspector # 56198

07 August 2015

Brian W. Lunsford, P.E. Date Sr. Project Manager Integrity Engineer API 653 Inspector # 28526 ii

TABLE OF CONTENTS

SECTION 1

EXECUTIVE SUMMARY ........................................................................................................................ 1-1

SECTION 2

TANK PHYSICAL AND HISTORICAL DATA ........................................................................................ 2-1

SECTION 3

NON-DESTRUCTIVE TESTING ............................................................................................................ 3-1

3.1 NDT Inspection Scope of Work ...................................................................................... 3-1

3.2 Equipment Used ............................................................................................................. 3-1

3.3 NDT Significant Findings ................................................................................................ 3-1

3.4 Bottom-to-Shell Weld Examination ................................................................................. 3-1

3.5 Shell Examination ........................................................................................................... 3-1

3.6 Shell Nozzle Examination ............................................................................................... 3-2

3.7 Fixed Roof Examination ................................................................................................. 3-2

3.8 Fixed Roof Nozzle Examination. .................................................................................... 3-2

SECTION 4

SIGNIFICANT FINDINGS ....................................................................................................................... 4-1

4.1 Tank Bottom and Foundation ......................................................................................... 4-1

4.2 Shell, Nozzles and Appurtenances ................................................................................ 4-1

4.3 Fixed Roof, Nozzles and Appurtenances ....................................................................... 4-1

4.4 High Level Alarms and Gauging System ........................................................................ 4-2

SECTION 5

RECOMMENDATIONS .......................................................................................................................... 5-1

5.1 Repair and Upgrade Recommendations ........................................................................ 5-1

5.1.1 Mandatory Repairs Required to Remove Tank from Service ................................... 5-1

5.1.2 Repairs Required to Fully Comply with API 653 / 650 .............................................. 5-1

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03 ........................... 5-1

5.1.4 Recommended Repairs As Best Management Practice .......................................... 5-2

5.2 Inspection Intervals ........................................................................................................ 5-3

APPENDICES

APPENDIX A (CAD Drawings) .............................................................................................................. A-1

APPENDIX B (Tank Inspection Data) ................................................................................................... B-1

APPENDIX C (API 653 Checklist) ......................................................................................................... C-1

APPENDIX D (Calculations) .................................................................................................................. D-1

APPENDIX E (Photographs) ................................................................................................................. E-1 iii

ABBREVIATIONS AND ACRONYMS

AFFF Aqueous Film Forming Foam

API American Petroleum Institute

ARB Air Reserve Base

ATG Automatic Tank Gauge

AVG Average

BMP Best Management Practice

CP Cathodic Protection

DFT Dry Film Thickness

FML Flexible Membrane Liner

FT Foot/Feet

GE General Electric

HHLA High-High Level Alarm

HLA High Level Alarm

IAW In Accordance With

IFR Internal Floating Roof

IN Inch/Inches

Jet-A Jet Fuel

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MIL-STD Military-Standard

N/A Not Applicable

NDT Non Destructive Testing

NFPA National Fire Protection Association

PE Professional Engineer

TYP Typical

UFC Unified Facilities Criteria

USACE U.S. Army Corps of Engineers

UTT Ultrasonic Thickness Testing

VT Visual Testing

1-1

SECTION 1

EXECUTIVE SUMMARY

Tank 5 (Facility #400) located at Grissom ARB in Peru, Indiana is a welded, steel, vertical, aboveground Jet-A (F-24) storage tank. The tank was constructed in 1955 by Chicago Bridge & Iron.

It is assumed that the tank was constructed in accordance with (IAW) American Petroleum Institute

(API) 12C based on its date of construction. Tank 5 is 60’-0” in diameter and 30’-4” high with a nominal capacity of 630,000 gallons. The in-service inspection was performed the week of 08 June 2015.

Results of this inspection will provide recommended repairs and upgrades required to comply with applicable industry and military standards. The previous inspection report was available for review and comparison at the time of the inspection.

The testing and inspection was performed IAW applicable sections of API 653, 5th Edition. Contained in this Report is a detailed account of the tank inspection, a summary of the non-destructive testing

(NDT), and conclusions derived from the inspection and testing. Findings of this inspection are detailed in Section 4 of this Report. Repairs and upgrades identified in this section are classified and listed in

Section 5 of this Report.

Foundation and Containment

Tank 5 rests on an earthen foundation located within an earthen secondary containment dike provided with a flexible membrane liner (FML), layer of loose gravel, and sloped earthen berms. Vegetation growth was identified throughout the containment dike and around the tank perimeter. The FML is attached to a bent plate at the tank chime with a batten bar and anchors. The bent plate welded to the tank chime is coated; however, the coating exhibits damage with indications of cracking, deterioration, and flaking. Approximately 10 ft2 of coating failure was identified on the tank chime and bent steel plate. Gravel, standing water, and soil were covering several areas of the tank chime at the time of the inspection. The tank is equipped with eight (8) grounding connections around the tank perimeter. One

(1) grounding cable is frayed.

The transfer piping transitions aboveground within the secondary containment dike adjacent to the tank. Sealant at the soil-to-air interface exhibits disbondment, shrinkage, and compromise. Aqueous film forming foam (AFFF) piping is supported by cradle supports on concrete piers. The sealant at two

(2) concrete piers exhibits failure with indications of disbondment and compromise.

Tank Shell

The tank shell consists of four (4) fully coated butt-welded steel shell courses. Standardized product designation IAW Military Standard (MIL-STD)-161G along with an emergency responder diamond IAW

National Fire Protection Agency (NFPA) 704 is provided on the tank shell. There are no construction or repair/alteration nameplates for the tank. No indications of damage were identified on the tank shell external coating. Two (2) shell overflows equipped with screening are provided on the upper shell course.

1-2

Tank shell nozzles consist of one (1) 24” manway, one (1) 36” x 20” manway, one (1) 8” main suction/receipt, two (2) 6” to ¾” water draw-offs, one (1) 6” blind flange, five (5) AFFF injection points, and one (1) Scully level alarm penetration. The main suction/receipt skin valve is provided with integrated thermal relief. The water draw-off reinforcement pads are not provided with tell-tale holes.

AFFF piping is not coated red IAW MIL-STD-101A.

A wind girder / geodesic dome support ring is provided on the upper shell course. Coarse screening is provided between the wind girder / geodesic dome support ring to prevent bird ingress. Visual inspection of the ring was limited from the spiral staircase and upper platform. A spiral staircase and upper platform are used to access the fixed roof and Scully level alarm.

The tank is equipped with a steel internal floating roof (IFR) with bulkhead compartments and a periphery foam log seal according to the previous inspection report. Visual inspection of the seal was limited from the geodesic dome inspection hatch.

Fixed Roof

The fixed roof consists of a geodesic dome. The geodesic dome aluminum panels sit on the support ring located on the upper shell course. Fixed roof nozzles consist of one (1) 6” automatic tank gauge

(ATG) probe hatch and one (1) 30” x 30” hatch. The ATG probe hatch roof penetration is provided with a rubber boot.

Gauges and Alarms

A Cameron ATG system and Shand & Jurs tape level gauge are used for automatic tank gauging.

Manual gauging is performed in the 6” ATG probe hatch. The ATG probe is currently used for the high-high level alarm (HHLA), high level alarm (HLA), low-level alarm (LLA), low-low level alarm (LLLA), and temperature gauging. A Scully level alarm system is used for the HHLA and HLA and is provided adjacent to the upper platform with a shell penetration on the lower shell course. The tank is not equipped with a high level control valve (HLCV) for overfill protection.

Cathodic Protection (CP)

According to the previous inspection report, the tank bottom is cathodically protected by a sacrificial anode system.

1-3

Recommendations for Repair and Upgrade

Below is a summary of the repair and upgrade recommendations identified during the external API

653 inspection:

1. Provide a corrosion-resistant nameplate IAW API 650. (API)

2. Provide two (2) ¼” tell-tale holes in the reinforcement pads of the two (2) water draw-off nozzles.

(API)

3. Repair one (1) frayed grounding cable and reattach to the shell. (API)

4. Provide the tank with standard under-tank details (concrete ring wall and leak detection tell-tale pipes) as required by UFC 3-460-01. (UFC)

5. Provide a HLCV on the main suction / receipt common line. (UFC)

6. Remove vegetation growth within the secondary containment dike and away from the tank perimeter. (UFC)

7. Provide approximately 190 linear feet of sealant around the tank FML batten bar and a reinforced coating/sleeve at the main suction/receipt soil-to-air interface. (UFC)

8. Replace two (2) manways with 36” manways IAW UFC 3-460-01 and API 650. (UFC)

9. Provide independent LLA, LLLA, HLA, and HHLA IAW UFC 3-460-01. (UFC)

10. Replace the Cameron ATG system with an ENRAF ATG and VITO temperature/water combination probe. (UFC)

11. Replace the foam log seal with a periphery primary and secondary wiper seal. (UFC)

12. Coat the AFFF piping red IAW MIL-STD-101A. (UFC)

13. Provide a heavy grease in all shell nozzle reinforcement pad tell-tale holes to prevent water ingress between the reinforcement pad and tank shell. (BMP)

Recommended Inspections and Intervals

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector w/ UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector (1): API: Twenty (20) Years; January 2024

UFC: Ten (10) Years; January 2014

(1) The previous out-of-service API 653 inspection was performed January 2004. Unified Facilities Criteria (UFC)

3-460-03 intervals are more stringent and therefore should govern the next internal inspection. Internal inspection intervals are based off the previous API 653 inspection report. Based off the date of the previous inspection, Tank 5 is overdue on its next out-of-service API 653 inspection.

2-1

SECTION 2

TANK PHYSICAL AND HISTORICAL DATA

Owner: U.S. Air Force

Tank Number: Tank 5 (Facility #400)

Location: Grissom ARB - Peru, Indiana

Fabricated By: Chicago Bridge & Iron(1)

Erected By: Chicago Bridge & Iron(1)

Design Standard: API 12C (Assumed)

Year Built: 1955(1)

Product: Jet-A (F-24)

Product Specific Gravity: 0.84

Diameter: 60’-0”

Height: 30’-4”

Design Liquid Level: 19’-4 1/8” (Per Tank Shell Labeling)

Nominal Capacity: 630,000 Gallons (Per Tank Shell Labeling)

Foundation: Earth Foundation

Containment Construction: Earthen Dike, FML, and Layer of Loose Gravel

Bottom Construction: Lap-Welded Steel Plates(1)

Shell Construction: Butt-Welded Steel Plates / Four (4) Shell Courses

Internal Floating Roof Construction: Steel Deck with Bulkhead Compartments(1)

Fixed Roof Construction: Geodesic Dome

Cathodic Protection: Impressed Current CP System(1)

Leak Detection: None

Bottom Coating: Thin Film Coating (1)

Shell Coating Internal: Thin Film Coating (1)

Shell Coating External: Thin Film Epoxy

Fixed Roof Internal Coating: N/A – Geodesic Dome

Fixed Roof External Coating: N/A – Geodesic Dome

Stairway Construction: Spiral Staircase with Upper and Work Platforms

Last Inspection: January 2004 (Out-of-Service)

Average Bottom Plate Thickness: 0.240”(1)

Average Shell Plate Thickness: Shell Course 1: 0.375” Shell Course 2: 0.388” Shell Course 3: 0.379” Shell Course 4: 0.391”

Average Fixed Roof Plate Thickness: N/A – Geodesic Dome

GPS Coordinates: N 40° 40' 5.51" W 86° 9' 0.47”

Notes:

(1) Information taken from the previous out-of-service API 653 inspection report dated January 2004.

3-1

SECTION 3

NON-DESTRUCTIVE TESTING

3.1 NDT Inspection Scope of Work

The following NDT examinations were performed to evaluate the tank integrity.

• A Visual Test (VT) was performed on the tank containment, as well as piping and valves located inside the containment.

• VT was performed on the external surfaces of the tank shell and fixed roof.

• VT was performed on the tank nozzles, coatings, appurtenances, and ancillary equipment.

• Ultrasonic thickness testing (UTT) measurements were taken on the tank nozzles, reinforcement pads, and shell plates.

• Dry Film Thickness (DFT) measurements were taken on the external tank shell coating.

• An external settlement survey was performed on the tank foundation.

3.2 Equipment Used

• GE Krautkramer Ultrasonic Thickness Gauge w/ Topcoat o M/N DMS GO+

• Fisher Technologies Dry Film Thickness Gauge o M/N Dual Scope MPOR

• Zip Level Pro-2000 High Precision Altimeter

3.3 NDT Significant Findings

The UTT measurements indicated no significant metal thinning on the tank shell, nozzles, and reinforcement pads.

3.4 Bottom-to-Shell Weld Examination

The external bottom-to-shell weld was examined using VT methods. There were no significant findings; however, the examination was limited due to the external coating.

3.5 Shell Examination

The shell plates were examined using UTT and VT methods. Nine (9) UTT measurements were taken on each plate of the 1st shell course. Nine (9) UTT measurements were taken on the remaining shell course plates using the spiral stairs, work, and upper platform for access.

Refer to Drawing A-1, “Shell Layout” for plate locations and Table B-1, “Shell Plate Ultrasonic

Thickness Readings” for thickness data.

3-2

3.6 Shell Nozzle Examination

The shell nozzles and reinforcement pads were inspected using UTT and VT testing methods. One

(1) UTT measurement was taken on each nozzle with a welded connection and on each reinforcement pad.

Refer to Drawings A-1, “Shell Layout” for nozzle locations and Table B-2, “Nozzles and

Appurtenances” for nozzle data.

3.7 Fixed Roof Examination

The fixed roof was examined using the VT method. Results were limited from the upper platform.

Refer to Drawing A-2, “Fixed Roof Layout” for roof layout.

3.8 Fixed Roof Nozzle Examination

The fixed roof nozzles were examined using UTT and VT methods. One (1) UTT measurement was taken on each nozzle with a welded connection.

Refer to Drawing A-2, “Fixed Roof Layout” for nozzle locations and Table B-2, “Nozzles and

Appurtenances” for nozzle data.

4-1

SECTION 4

SIGNIFICANT FINDINGS

4.1 Foundation and Containment

• Secondary containment consists of an earthen dike provided with a FML, layer of loose gravel, and earthen berms. Widespread vegetation growth along with a marshy dike bottom was observed within the containment dike.

• Transfer piping transitions aboveground within the secondary containment dike adjacent to the tank. The sealant at the soil-to-air interface exhibits disbondment, shrinkage, cracking, and compromise.

• The tank rests on an earthen foundation according to the previous inspection report. The tank chime is flush with the gravel in the containment dike. Gravel, standing water, and soil were found covering the tank chime.

• The FML is attached to a bent plate at the tank with a batten bar and anchors. This attachment point is provided a sealant which exhibits approximately 185 linear feet of sealant failure.

• The tank is equipped with eight (8) grounding connections. One (1) grounding cable is frayed.

• According to the previous inspection report the tank is cathodically protected by a sacrificial anode system. Four (4) test stations are equally spaced around the tank perimeter.

4.2 Shell, Nozzles and Appurtenances

• The tank shell consists of four (4) fully coated butt-welded steel shell courses. No damage identified on exterior tank shell coating.

• The tank is equipped with product designation IAW MIL-STD-161G and an emergency responder diamond IAW NFPA 704.

• Tank shell nozzles consist of one (1) 24” manway, one (1) 36” x 20” manway, one (1) 8” main suction/receipt, two (2) 6” to ¾” water draw-offs, one (1) 6” blind flange, five (5) AFFF injection points, and one (1) Scully level alarm penetration.

• The water draw-off reinforcement pads are not provided with tell-tale holes.

• AFFF pipe supports are provided with a sealant at the penetration in the FML. The sealant at two

(2) AFFF concrete piers exhibits damage and disbondment.

• AFFF piping is not coated red IAW MIL-STD-101A.

• The main suction/receipt skin valve is equipped with integrated thermal relief.

• The tank is equipped with a wind girder / geodesic dome support ring on the upper shell course.

A coarse screen is provided between the geodesic dome plates and wind girder / geodesic dome support ring. Inspection was limited from the spiral staircase and upper platform.

4-2

• The tank shell is equipped with a spiral staircase, work platform, and upper platform for level alarms and fixed roof access.

• Two (2) shell overflows are provided on the upper shell course and are equipped with coarse screening.

• The tank is equipped with a steel deck IFR with several bulkhead compartments. A foam log seal is provided on the IFR according to the previous inspection report. Inspection of the seal was limited from the fixed roof inspection hatch.

4.3 Fixed Roof, Nozzles, and Appurtenances

• The fixed roof is a geodesic dome.

• Fixed roof nozzles consist of one (1) 30” x 30” hatch and one (1) ATG probe hatch. Fixed roof nozzles are equipped with rubber boots at roof penetrations.

4.4 High Level Alarms and Gauging System

• The tank is equipped with a Cameron ATG and Shand and Jurs tape level gauge for automatic tank gauging.

• The ATG probe is provided with a stilling well.

• The tank is equipped with a Scully Level Alarm System. According to the previous inspection report the HHLA, HLA, LLLA, and LLA are incorporated into the ATG.

• The tank is not provided with a HLCV or means of overfill protection.

5-1

SECTION 5

RECOMMENDATIONS

5.1 Repair and Upgrade Recommendations

The following subsections outline the itemized tank repairs/upgrades.

5.1.1 Mandatory Repairs Required to Remove Tank from Service

No mandatory repairs are required to remove tank from service.

5.1.2 Repairs Required to Fully Comply with API 653 / 650

Recommendation 1: Provide a corrosion-resistant nameplate IAW API 650.

Recommendation 2: Provide two (2) ¼” tell-tale holes IAW API 650 in the reinforcement pads of the two (2) water draw-off nozzles. Once tell-tale holes are provided, pressure test the reinforcement pad to verify internal weld integrity. Once pressure test is complete, provide heavy grease to prevent water ingress between the tank shell and reinforcement pad.

Recommendation 3: Repair one (1) frayed grounding cable and reattach to the tank shell.

5.1.3 Repairs Required to Fully Comply with UFC 3-460-01 / 3-460-03

Recommendation 4: Provide the tank with standard under-tank details (concrete ring wall and leak detection tell-tale pipes) as required by UFC 3-460-01. The tank chime is currently flush with grade and is covered by gravel, soil, and standing water.

Recommendation 5: Provide a HLCV on the main suction / receipt common line to provide adequate overfill protection as required by UFC 3-460-01. Piping modifications will be required.

Recommendation 6: Remove vegetation within secondary containment dike and from around tank perimeter.

Recommendation 7: Provide approximately 190 linear feet of sealant around the tank FML batten bar with a flexible, UV-resistant, fuel-resistant sealant and provide a reinforced coating/sleeve at the main suction / receipt and AFFF concrete pier soil-to-air interfaces.

Recommendation 8: Replace two (2) existing manways with 36” manways provided with davit arms

IAW API 650 and UFC 3-460-01.

Recommendation 9: Provide an independent HHLA, HLA, LLA, and LLLA IAW UFC 3-460-01.

Recommendation 10: Replace the Cameron ATG system with an ENRAF ATG and VITO temperature/water combination probe. ENRAF ATG and VITO probe shall be

5-2 provided with fully slotted stilling wells and located near the lowest feasible point in the tank.

Recommendation 11: Replace the foam log seal with a periphery primary and secondary wiper seal.

5.1.4 Recommended Repairs As Best Management Practice

Repairs required as Best Management Practice are recommended to extend the tank service life and maintain product quality, but are not necessarily part of a design or inspection standard.

Recommendation 12: Provide a heavy grease in all shell nozzle reinforcement pad tell-tale holes to prevent water ingress between the reinforcement pad and tank shell.

Recommendation 13: Repair the AFFF pipe supports. The existing supports appear to be sinking and several exhibit damage causing misalignment in the AFFF piping.

5-3

5.2 Inspection Intervals

The interval between inspections of a tank (both internal and external) should be determined by its service history. Inspection intervals can be adjusted based on the known corrosion rates. Corrosion rates can only be determined when a comparison is made between measurements taken over an interval of time. The previous API 653 inspection report dated January 2004 was available for review and comparison at the time of the inspection.

API 653 provides recommendations for inspection intervals which are identified below:

• Routine monthly inspections to monitor the external condition of the tank and associated piping.

Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (includes tank chime to foundation interface, coatings, and appurtenances). The fixed roof should be visually inspected for signs of damage.

• Formal visual external inspection by an API certified inspector every 5 years or RCA/4N years

(where RCA is the difference between the measured shell thickness and the minimum required thickness and N is the shell corrosion rate), whichever is less. Based on the review of shell and roof thickness measurements, the 5-year interval will govern the next formal external visual inspection.

• Ultrasonic thickness measurements of the shell plates can be performed with the tank in service and can be scheduled at a maximum interval of fifteen (15) years or RCA/2N, whichever is less.

Based on shell thickness measurements, the recommended interval for the UTT measurements on the tank shell is fifteen (15) years.

• Bottom corrosion rates govern the internal inspection interval. Per API 653, the next internal inspection should be performed within twenty (20) years of the previous inspection; however, UFC

3-460-03 requires a maximum internal inspection interval of ten (10) years. The internal inspection interval required by UFC is more stringent and therefore should govern when to perform the next internal inspection. The previous out-of-service API 653 inspection was performed in January

2004. The tank is overdue on its out-of-service API 653 inspection based on the previous inspection date; therefore, the next out-of-service API 653 inspection should be scheduled immediately to satisfy the 10-year inspection interval required by UFC.

The recommended inspections and intervals are:

Routine In-Service Inspection by Facility Personnel: Monthly

External Inspection by Authorized Inspector: Five (5) Years; June 2020

External Inspection by Authorized Inspector with UTT: Fifteen (15) Years; June 2030

Internal Inspection by Authorized Inspector: API: Twenty (20) Years; January 2024

UFC: Ten (10) Years; January 2014

A-1

APPENDIX A

CAD Drawings

1-1 1-2 1-3

1-4 1-5 1-6

2-1 2-2 2-3

2-4

3-1 3-2

3-4

3-5 3-6

4-6

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

MW1

N4

N1 N2

N5

IP

UPPER PLATFORM

MID-LEVEL

PLATFORM

FLOAT GAUGE

OVERFLOW VENT (TYP. 2)

MW1

MW2

7'-7"

7'-7"

7'-7"

7'-7"

GROUNDING CABLE (TYP. 8)

3-3

2-5 2-6

.386"

N3

WIND GIRDER / GEODESIC

DOME SUPPORT RING

GRISSOM, INDIANA

GRISSOM ARB

SCALE:

NOT TO SCALE AUGUST 2015

REVISED BY:

WAS

TANK 5

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 40° 40’ 5.51”

W 86° 9’ 0.47”

MANUFACTURER:

CHICAGO BRIDGE AND IRON

DESIGN STANDARD:

API 12C

YEAR BUILT:

PRODUCT:

JET-A

PRODUCT SPECIFIC GRAVITY:

0.84

TANK DIAMETER:

60'-0"

TANK HEIGHT:

30'-4" (4 SHELL COURSES)

CAPACITY:

15,000 BBLS

FACILITY 400

NOTES:

1. REFER TO TABLE B-1, SHELL PLATE ULTRASONIC

THICKNESS READINGS IN APPENDIX B FOR THE

INDIVIDUAL SHELL PLATE ULTRASONIC THICKNESS

READINGS.

2. REFER TO TABLE B-2, NOZZLES AND APPURTENANCES,

FOR NOZZLE DATA.

SHELL LAYOUT

SHEET A1 OF A2

LEGEND:

- INSERT PLATE

- UTT READING

IP

.XXX"

SPIRAL STAIRCASE

UPPER PLATFORM

N7

N6

MID-LEVEL PLATFORM

GRISSOM, INDIANA

GRISSOM ARB

SCALE:

NOT TO SCALE AUGUST 2015

REVISED BY:

WAS

TANK 5

PROJECT MANAGER:

PROGRAM MANAGER:

BWL

LAG

GPS COORDINATES:

N 40° 40’ 5.51”

W 86° 9’ 0.47”

MANUFACTURER:

CHICAGO BRIDGE AND IRON

DESIGN STANDARD:

API 12C

YEAR BUILT:

PRODUCT:

JET-A

PRODUCT SPECIFIC GRAVITY:

0.84

TANK DIAMETER:

60'-0"

TANK HEIGHT:

30'-4" (4 SHELL COURSES)

CAPACITY:

15,000 BBLS

FACILITY 400

NOTES:

1. REFER TO TABLE B-4, NOZZLES AND APPURTENANCES, FOR NOZZLE DATA.

FIXED ROOF LAYOUT

SHEET A2 OF A2

B-1

APPENDIX B

Tank Inspection Data

B-2

Table B-1: Shell Plate Ultrasonic Thickness Readings

Thicknesses represented in inches.

Average shell plate thickness:

Shell Course 1: 0.375” Shell Course 2: 0.388” Shell Course 3: 0.379” Shell Course 4: 0.391” Refer to Drawing A-1 in Appendix A for plate numbers.

Roof

SHELL

COURSE 4

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

.390 .397 .392

.390 .394 .386

.386 .392 .393

AVG. .391

Circumferential weld C4

SHELL

COURSE 3

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

.380 .381 .373

.381 .383 .376

.378 .381 .382

AVG. .379

Circumferential weld C3

SHELL

COURSE 2

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

.386 .395 .388

.383 .397 .390

.377 .387 .391

AVG. .388

Circumferential weld C2

SHELL

COURSE 1

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

.363 .375 .372 .375 .381 .370 .375 .377 .366 .366 .376 .368 .383 .377 .373 .372 .378 .369

.375 .381 .379 .377 .384 .378 .379 .379 .377 .370 .384 .375 .385 .384 .378 .377 .385 .374

.362 .373 .372 .371 .376 .371 .372 .372 .367 .367 .378 .368 .378 .377 .370 .376 .374 .368

AVG. .372 .376 .374 .372 .378 .375

Circumferential weld C1

B-3

Table B-2: Nozzles and Appurtenances

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 1)

NOTES

MW1 24" A 4'-6" x 5'-4" .383 .339 2'-6" 3" 0' Manway 1

N1 8" A 1'-7" x 2'-0" .388 .489 1'-1/2" 3 1/2" 65'-7" Blind Flange

N2 8" A 1'-7" x 2'-0" .384 .505 1'-0" 3" 71'-7" Main Suction/Receipt

MW2 20"x36” A 5'-8" x 3'-10" .364 .352 2'-6" 7" 96'-4" Manway 2

N3 6" B 10" .616 - 8 1/2" 3 1/2" 115'-6" 3/4" Water Draw

N4 1" B 8" .241 .125 5'-0" 4'-8" 121'-3" Scully Level Alarm

N5 6" B 10" .596 - 8 1/2" 3 1/2" 167'-6" 3/4" Water Draw

N6 30" x 30" F 3'-1" x 3'-1" .116 .113 Roof Roof Hatch

N7 6" - - - - Roof ATG probe Hatch

Thickness measurements are in inches.

H1 = Centerline of pipe to edge of roof or chime.

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

TH = Threaded

Repad Shapes:

Refer to Drawings A-1 and A-2 in Appendix A for nozzle numbers and locations.

B-4

Table B-3: Coating Thickness Measurements

External Shell Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

16.17 4.181 20 6.826 22.62

Thickness measurements are in mils.

C-1

APPENDIX C

API 653 Inspection Checklist

C-2

Foundation Inspection

Item Description Comments

1 Foundation description. Tank rests on an earthen foundation within an earthen dike provided with a FML and layer of loose gravel. The FML is attached to a bent plate beneath the tank chime.

2 Inspect for foundation damage or cracking.

N/A – Earthen Foundation

3 Evidence of bottom leakage or stains.

None noted.

4 List all significant cavities or erosion around the foundation.

None noted.

No erosion or cavities noted.

5 Inspect for vegetation under and around tank perimeter.

Vegetation identified along tank perimeter.

Does tank have proper water runoff and drainage away from the tank?

No. The tank chime is flush with the layer of loose gravel and soil.

Is grade or other material covering the floor-to-shell weld or chime bottom plate?

Gravel, standing water, and soil were covering the tank chime in several locations at the time of inspection.

Is any visual settlement noted around the tank perimeter?

None noted.

What is the general condition of the dike area?

Visual inspection of the dike floor was limited due to the layer of loose gravel and soil covering the FML liner. Vegetation growth was identified throughout the containment dike.

C-3

Shell Inspection

Item Description Comments

1 Inspect shell ladders, stairways, platforms, and walkways.

Acceptable.

2 Inspect shell for significant distortions, creases and/or buckling.

Acceptable.

3 Visually inspect shell for out-of-roundness.

Acceptable.

4 Inspect shell support welds for corrosion or damage.

None noted.

5 Inspect wind girder for corrosion or damage.

Acceptable. Visual inspection of the geodesic dome support ring was limited from the spiral staircase and upper platform.

6 Inspect external shell for leaks or significant corrosion areas.

None noted.

7 Inspect exterior shell-to-bottom weld area for corrosion, defects or thinning of the chime bottom plate.

None noted.

8 Inspect shell coating for failure, peeling or fading.

Acceptable.

9 Inspect the internal shell for pitting, corrosion, rubbing or grooving.

N/A – External Inspection.

10 Inspect horizontal and vertical seams for weld or rivet joint details.

Acceptable.

11 Inspect shell overflows for corrosion and screening.

Acceptable.

12 Inspect shell for any lap patches. None noted.

13 Is the tank grounded?

Are the cables and clips in good condition?

Yes. The tank is equipped with eight (8) grounding connections. One (1) grounding cable is currently frayed.

14 Does the tank have a legible data plate?

The tank is not equipped with a name plate.

C-4

Nozzle and Appurtenance Inspection

Item Description Comments

1 Inspect nozzle flanges and bolting for leaks and corrosion.

Acceptable.

2 Inspect nozzles for pipe strain or misalignment.

None noted on transfer piping and nozzles.

3 Inspect valves for leaks or damage. Acceptable.

4 Do nozzles, which require pressure relief, have crossovers at the valve?

The main suction/receipt skin valve is equipped with integrated thermal relief.

Is tank equipped with High Level Control Valve and High Level Alarms?

The tank is equipped with a Scully level alarm system. The main suction and receipt share a common line into the tank. The Cameron ATG system is used for the HHLA, HLA, LLA, and LLLA. The main suction / receipt line is not equipped with a HLCV for overfill protection.

6 Verify operation of gauging system.

• Manual Gauging Hatch?

• Type of Tape Level Gauge?

• Type of Automatic Gauging System?

6” ATG Probe Hatch

Shand and Jurs Tape Level Gauge.

Cameron ATG System.

7 Inspect manways, nozzles, and attachments for signs of corrosion or defects.

Acceptable.

8 Do all nozzle reinforcement pads have tell-tale holes? Are they plugged?

Yes.

No plugged tell-tale holes.

9 Verify adequate reinforcement around nozzles and appurtenances.

Acceptable.

10 Verify adequate nozzle and appurtenances weld spacing.

Acceptable.

11 Verify interior nozzles have been back welded to the shell.

N/A – External Inspection.

12 Check reinforcement pads for adequate fillet welds around pads.

Acceptable.

13 Visually inspect welds for defects on all nozzles and appurtenances.

Acceptable.

14 Does the inlet nozzle have a diffuser?

According to the previous inspection report a diffuser is not provided. Receipt and main suction share a common line into the tank.

C-5

Fixed Roof Inspection

Item Description Comments

1 Inspect fixed roof protective coating system.

N/A – Geodesic Dome.

2 Inspect frangible joint / eave angle for corrosion, defects and coating failure.

N/A – Geodesic Dome.

3 Inspect fixed roof for low spots and external corrosion.

N/A – Geodesic Dome.

4 Conduct VT inspection on roof nozzles and appurtenances.

Acceptable.

5 Visual inspection of internal roof supports, girders, columns and bases.

N/A – External Inspection.

6 Verify open roof vents have screens and covers.

N/A – Geodesic Dome.

7 Verify handrails and tie-off supports are in good condition.

Acceptable.

8 Measure any significant bulges and creases in the roof plates.

N/A – Geodesic Dome

9 Do any roof nozzles or appurtenances have bolt-on type reinforcement pads?

N/A – Geodesic Dome

Notes:

The tank is equipped with a steel deck IFR provided with a foam log seal. Inspection was limited from fixed roof inspection hatch.

D-1

APPENDIX D

Calculations

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

GAB-5 (400)

Inspector

Brian Hopper

Client

1150068 - USACE

Tank No

5 (400)

Date 6/8/2015

1st Crs Plt Spec

Unknown

Y

30000

E

29000000 -0.104

S - Max Permissible

0.104

30.33

-0.052

-0.123

-0.125

0.034

0.052

-0.023

0.000

0.008

U

0.006

-0.035

-0.081

0.071

0.047

-0.049

0.008

0.034

S

SAT

SAT

SAT

SAT

SAT

SAT

SAT

SAT

Results

Notes:

U = Measured out-of-plane settlement in relation to a cosine curve, in feet S = Deflection, in feet, (out-of-plane distortion) L = Arc length between measurement points, in feet Y = Yield strength, in pounds per square inch (psi) E - Young's modulus, in pounds per square inch (psi) H = Tank height , in feet

S <= 11L^2Y/2EH

Feet

0.08High Point

0.31Low Point

0.23

Planar Tilt

Ft

Ft

Ft

L

23.58

2.76 In.

Point 1

Point 2

Point 3

Point 4

Point 5

Point 6

Point 7

Point 8

0.15

0.16

0.19

0.31

0.25

0.09

0.08

0.13

H (ft)

30.3

D (ft)

60.0

D (ft)

H (ft)

0.024 M

0.094 M

7.01 cm

API-653 APPENDIX B SETTLEMENT EVALUATION

SHELL SETTELMENT SURVEY

File No

Report No

GAB-5 (400)

Inspector

Brian Hopper

Client

1150068 - USACE

Tank No

5 (400)

Date 6/8/2015

1st Crs Plt Spec

Unknown

API653 Survey Calculation

0.083

0.125

0.146

0.156

0.188

0.313

0.250

0.094

0.083

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

7 8 1 2 3 4 5 6 7

Survey Point

D e p th ft

File No

Report No

GAB-5 (400)

Inspector

Brian Hopper

Client

1150068 - USACE

Tank No

5 (400)

Date 6/8/2015Tank Shell Minimum Thickness and Remaining Life Calculations

Temp. (°F)

Material

19.33

11.73

4.13

-3.47

0.

0.

0.

0.

0.Unknown

Unknown

Unknown

Unknown

23600

23600

26000

26000

60 0.84 0.85G E 19.3

SE

tmin =

Where:

H = The height above the bottom of the course of study to the maximum liquid level height of the product, in feet (meters). For corroded or pitted areas, H = the height from the bottom of the corroded or pitted area to the maximum liquid level height of the product, in feet (meters).

tmin = The calculated minimum acceptable shell thickness, in inches (must be greater than 0.1 inch (2.5 mm) for any course). The minimum acceptable shell thickness allowed by API-653 for tank size, in inches (mm) or an alternate tmin based on low pressure calulations (int and/or ext pressures) or nominal thickness minus design corrosion allowance.

D = Nominal diameter of tank, in feet (meters).

G = Highest specific gravity of the contents (including test water if tank will, or may, be tested in the future).

S = Maximum allowable stress, in psi. For welded tanks; use the smaller of 0.80Y of 0.429T for bottom and second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks; S = 21,000 psi. (145 MPa)

Y = Specified minimum yield strength of the plate, in psi; use 30,000 psi (200 MPa) if not known (N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80k psi (550 MPa); use

55,000 psi (380 MPa) if not known (N/A for riveted tanks).

E = Original joint efficiency for the tank. For welded tanks; use API-653, Table 4-2 ; use 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 (250 mm) or twice the plate thickness. For riveted tanks; use E =

1.0 for shell plates greater than 6 inches (150 mm) away from rivets; use the value of E from API-

653 Table 2-1 when within 6 inches (150 mm) of rivets.

7.60

7.60

7.60

7.60

Course 1

Course 2

Course 3

Course 4

0.100

0.100

0.100

0.120

SHELL MINIMUM THICKNESS CALCULATIONS

2.6D(H-1)G tmin (in)S (psi)H (ft)Crs H (ft)

Fill Height (ft)D (ft)

File No

Report No

GAB-5 (400)

Inspector

Brian Hopper

Client

1150068 - USACE

Tank No

5 (400)

Date 6/8/2015Tank Shell Minimum Thickness and Remaining Life Calculations

Temp. (°F)

The tank was constructed in 1955. It is assumed to be constructed IAW API 12C based on the date of construction.

tmin

0.100

0.100

0.100

0.1200.375

0.388

0.379

0.391 tact

0.381

0.381

0.382

0.388 tprev Ca

0.288

0.279

0.291

0.255

Cr

0.0005

RL

468.0

0.0000

0.0003

0.0000

>40

1023.0

>40

Where:

Ca = Remaining corrosion allowance of the shell course under consideration, in inches (mm).

Cr = Corrosion rate of the shell course under consideration, in inches (mm) per year.

FHc = Calculated Fill Height = SEtact/2.6DG+1 (SEtact/4.6DG+.3) plus the total product height below the course of study, in feet (meters).

tact = Minimum thickness measurement of the shell course under consideration, as recorded at the time of inspection, in inches (mm).

tmin = minimum required thickness of shell course, at the maximum allowable fill height, in inches (mm) tprev = previous thickness measurement of shell course under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches (mm).

RL = Estimated remaining life of the shell course under consideration, in years.

Y = Time span between thickness readings or age of the tank if nominal thickness is used for tprev, in years.

SHELL REMAINING LIFE CALCULATIONS

Ca = tact-tmin = Remaining Corrosion Allowance (inches (mm))

Cr = tprev-tact / Y = Corrosion Rate (inches (mm) per year)

RL = Ca / Cr = Remaining Life (years)

11Y = = Tank age (years)

Course 1

Course 2

Course 3

Course 4

Course FHc

58.41

68.00

80.12

89.74

D-6

Shell Service Life Evaluation

Shell Course

Previous Thickness

(in.)

Current Thickness

(in.)

Years since Prev.

N Min

Thickness (in.)

RCA

Next

External (years)

Next

UTM

(years)

1 0.381 0.375 11 0.0010 0.120 255 5 15

2 0.381 0.388 11 0.0010 0.100 288 5 15

3 0.382 0.379 11 0.0010 0.100 279 5 15

4 0.388 0.391 11 0.0010 0.100 291 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

E-1

APPENDIX E

Photographs

E-2

Tank 5 Overview

Containment Dike Overview

Vegetation Growth Around Tank Perimeter Sealant / Coating Failure at FML Attachment Point at Tank Chime

E-3

Manway 1 CP Test Station

Typical Grounding Cable Typical Shell Overflow

Blind Flange Main Suction / Receipt

E-4

Main Suction / Receipt Soil-to-Air Interface Tank Labeling and NFPA Diamond

Safe Fill Height Shand and Jurs Tape Level Gauge

Spiral Staircase Manway 2

E-5

Product Designation AFFF Piping

AFFF Piping AFFF Pipe Support

Intermediate and Upper Platforms

E-6

Water Draw-off and Product Recovery Tank

Gravel and Water Covering Chime Wind Girder / Geodesic Dome Support Ring

Cameron ATG System and ATG Probe Hatch

E-7

Cameron ATG Probes Fixed Roof Hatch

Scully Level Alarm

IFR Overview

E-8

IFR Overview Scully Level Alarm System