Attachment K - FAC AF573 Inspection Report 2017.pdf

US Army Corps of Engineers

Omaha District

API 653 In-Service

Inspection Report

Fort Huachuca, Arizona

Facility AF573

Tank 5

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

USACE POL-MCX

27 December 2017

API 653 In-Service Inspection Report Fort Huachuca, Arizona

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

THIS INSPECTION

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

3. Future Projects

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, NFPA, or CFRs

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

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

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

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

SHELL THICKNESS CALCULATIONS

SHELL AND 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

AFFF Aqueous Film Forming Foam

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CC Carbon Steel

CFR Code of Federal Regulations

CP Cathodic Protection

CS Carbon Steel

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

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

PTFE Polytetrafluoroethylene (e.g., TEFLON)

P/V Pressure/Vacuum

PST Product Saver Tank

SS Stainless Steel

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UG Underground

UT Ultrasonic Testing

GENERAL SUMMARY

Austin Brockenbrough & Associates, LLP (Brockenbrough) was retained by Omaha District USACE under Contract

No. W9128F-12-D-0006 Delivery Order 0024 to perform SPCC Mandated AST/UST Inspections at various locations. As required by this task, Brockenbrough executed a tank inspection site visit to Fort Huachuca located just outside Sierra Vista, Arizona. An API 653 In-service (visual external) Inspection was conducted for Facility No.

AF573, locally known as Tank 5, on August 30, 2017. This inspection was performed in accordance with API

Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. In addition, the shell was ultrasonic thickness inspected and surveyed for roundness. All observations made during this in-service (visual external) inspection were made from the exterior of the tank.

Facility AF573 is a 19-foot diameter by 24-foot and 3-inch tall, single wall, vertical, field-erected tank with a nominal storage capacity of 1,000 barrels of jet fuel (F-24). The tank erector’s nameplate indicates the tank was constructed in 1992. The tank has an aluminum internal floating pan. The repair organization nameplate indicates two 8-inch and one 4-inch aluminum stilling wells were installed in 2011. The SPCC Plan dated February 2010, which was provided by the Base, does not appear to address this tank. Details of tank construction and appurtenances are included in the General Tank Information table on page 6 and comments 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 August 2022. The next ultrasonic thickness inspection of the shell should be performed by August 2032. The guidance provided in the current UFC 3-460-03 includes out-of-service inspection at least every 10 years of service. An upcoming revision allows the frequency to be extended as determined by a certified API 653 tank inspector. The 2011 out-of-service inspection report recommend the next API Standard 653 Out-of-service (internal and external) Inspection be performed by May 2031. This inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology, and a thorough code compliance evaluation.

THIS INSPECTION

API In-Service (External) Inspection Date: 30 August 2017

Equipment Used:

Survey Equipment

Robotic/Reflectorless Total Station: Topcon QS X-Trac 8

Calibrated: December 2015

Field Data Collector: Topcon FC-2500

Ultrasonic Thickness Gauge

Manufacturer: NDT Systems

Model Number: Nova TG110-DL

Calibration Method: Calibration Block

NDT Technician (s): Mike O’Connor

Inspector(s): Mike O’Connor

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: May 2011

API In-Service (External) Inspection Date: NA

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections NA

State Regulation for API Out-of-Service Tank Inspections NA

RECOMMENDED FUTURE INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: May 2031

API Ultrasonic Thickness Inspection of Shell Date: August 2032*

API In-Service (External) Inspection Date: August 2022

* It may be more cost effective to perform the next UT inspection of the shell during the next in-service inspection.

Mike O’Connor

Mechanical Designer

API 653 Inspector No. 6230

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner U.S. Army

Location Fort Huachuca

Facility Number AF573

Tank Number Tank 5

State / Country Arizona / U.S.A.

City Sierra Vista

Inspection Date August 30, 2017

Tank Manufacturer Brown Minneapolis Tank

Design Standard API 650 8th Edition

Date of Construction 1992

Tank Contents Jet Fuel (F-24)

Tank Serial Number 283101

Tank Diameter 19’-0”

Shell Height 24’-3”

Product Height 21’-0” (limited by overflow)

Tank Capacity 1,000 bbl nominal (tank bottom to overflow). 950 bbl useable.

Foundation Cone-down slab (assumed).

Construction

Bottom (8) 1/4-inch lap welded plate.

Shell

All three courses: 1/4" butt-welded plate;

3” roof-to-shell rim angle: butt welded to shell, leg-out.

Floating Roof Petrex aluminum honeycomb.

Fixed Roof Supported cone roof made of 1/4-inch lap welded plate.

Material

Bottom Carbon steel of unknown grade.

Shell A36 steel.

Floating Roof Aluminum honeycomb with flexible double wiper seals

Fixed Roof Carbon steel of unknown grade.

Cathodic Protection None

Interior Coating System Interior 100% coated, likely epoxy.

Exterior Coating System Epoxy/polyurethane assumed.

Level Gauging MTS ATG, manual gauging well.

Overfill Protection ATG Alarms, Float operated high level control valve.

Piping Receipt 4” Welded stainless steel

Issue 6” Welded stainless steel

Low Suction 3” Welded stainless steel

Water Draw-off None NA

Level Alarms ATG level alarms.

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 AF573 an API Standard 653 In‐service (external) Inspection was performed, which included a shell settlement survey and a shell UT inspection. In addition, a shell roundness survey was performed.

2. Site Information

On August 30, 2017 Brockenbrough performed API 653 In‐Service (External) Inspection of Facility

AF573 (Tank 5) located at Fort Huachuca, Arizona. Fort Huachuca is a United States Army installation under the command of the United States Army Installation Management Command. It is located next to the town of Sierra Vista, Arizona, about 15 miles (24 km) north of the border with Mexico and at the northern end of the Huachuca Mountains. In the 2010 census, Fort Huachuca had a population of about

6,500 active duty soldiers, 7,400 military family members and 5,000 civilian employees. Fort Huachuca has over 18,000 people on post during the peak working hours of 0700 and 1600 on week days.

The major units are the United States Army Network Enterprise Technology Command (NETCOM) and the United States Army Intelligence Center. Libby Army Airfield is on post and shares its runway with

Sierra Vista Municipal Airport. Fort Huachuca is also the headquarters of Army Military Auxiliary Radio

System (MARS). Other units include the Joint Interoperability Test Command, the Information Systems

Engineering Command (ISEC) and the Electronic Proving Ground. The Fort has a radar-equipped aerostat, one of a series maintained for the Drug Enforcement Administration. The aerostat supports the DEA drug interdiction mission by detecting low-flying aircraft attempting to enter the United States from Mexico. Fort Huachuca also contains the Western Division of the Advanced Airlift Tactics Training

Center (AATTC) which is based at the 139th Airlift Wing, Rosecrans Air National Guard Base, Saint

Joseph, Missouri.

3. Future Projects

A project currently under construction will allow recirculating the fuel in the tank through the filter/separator.

B. TANK INSPECTION COMMENTS

1. Tank Construction

Tank Facility AF573 is a nominal 1,000 bbl, 19‐foot diameter by 24-foot and 3-inch tall, aboveground, vertical, jet fuel, storage tank. The tank has an aluminum internal floating pan, a lap welded steel cone roof, and a butt-welded steel cone-down bottom. The perimeter of the bottom rests on a concrete ringwall or slab that is even with the top of the foundation berm. The tank erector’s nameplate indicates the tank was constructed in 1992.

https://en.wikipedia.org/wiki/United_States_Army https://en.wikipedia.org/wiki/Military_base https://en.wikipedia.org/wiki/United_States_Army_Installation_Management_Command https://en.wikipedia.org/wiki/Arizona https://en.wikipedia.org/wiki/United_States_Army_Network_Enterprise_Technology_Command_(NETCOM) https://en.wikipedia.org/wiki/United_States_Army_Intelligence_Center https://en.wikipedia.org/wiki/Libby_Army_Airfield https://en.wikipedia.org/wiki/Sierra_Vista_Municipal_Airport https://en.wikipedia.org/wiki/Military_Auxiliary_Radio_System https://en.wikipedia.org/wiki/Military_Auxiliary_Radio_System https://en.wikipedia.org/wiki/JITC https://en.wikipedia.org/wiki/Radar https://en.wikipedia.org/wiki/Aerostat https://en.wikipedia.org/wiki/Drug_Enforcement_Administration https://en.wikipedia.org/wiki/DEA https://en.wikipedia.org/wiki/139th_Airlift_Wing https://en.wikipedia.org/wiki/Rosecrans_Air_National_Guard_Base

2. Tank Foundation

The perimeter of the tank bottom rests on a concrete ringwall or slab that is even with the top of a concrete foundation berm. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. General spider web cracking on the top of the concrete foundation was noted. A shell settlement survey was performed during the inspection in accordance with Appendix B of API Standard 653. The shell settlement evaluation indicates the settlement of the bottom of the shell and perimeter of the tank bottom is acceptable.

3. Tank Shell

The vertical and cylindrical shell consists of three butt‐welded courses. The ultrasonic thickness measurements of the shell and calculations included in Appendix A indicate the shell has more than 30 years of remaining life. API 653 recommends ultrasonic thickness measurements of the shell be taken at least every 15 years.

a. Plumbness, Roundness, Peaking, and Banding

The exterior of the shell was visually inspected and evaluated for plumbness, roundness, peaking and banding.

1) API 650, paragraph 7.5.2 allows a maximum out-of-plumb of the top of a new tank shell, relative to the bottom of the shell, of 1/200 of the height of the shell, a difference of 1 1/2 inches for this

24-foot and 3-inch tall tank. The maximum measured out-of-plumbness was 7/16 inch away from tank center as measured on the south side. The shell also leans toward the tank center

3/16 inch on the opposite side (the north side) of the tank. The out-of-plumbness of the shell is within the limits allowed by API 650 for new construction. The bottom of the shell measures higher on the south side than on the north side by 5/8 inches, which indicates some settlement of the foundation and is counter to the out-of-plumb of the shell.

2) The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 1/2-inch of a new tank shell radius. No localized shell distortions were noted. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top.

That there did not appear to be any significant distortion of the shell, would seem to suggest the tank was built slightly out-of-round. As measuring the out-of-roundness using laser survey methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time.

3) While some minor peaking and banding of the butt-welded shell seams was observed, the peaking-and-banding appeared to be within limits allowed by API 650.

4. Tank Appurtenances

a. Tank Roof

The roof is supported by eight rafters spaced approximately 7 feet and 5 1/2 inches apart. As early as 1996, API 650 required rafter spacing at the perimeter of the tank roof to be no greater than 6 feet and 3 inches apart. Earlier API requirements may have been more stringent. Later editions of

API 650, paragraph 5.10.4.4 increased the maximum allowable spacing to 7 feet. There is evidence of water ponding around the perimeter of the tank roof. However, the scarcity of rain, makes the ponding less significant and will not likely result in significant corrosion. A guardrail made of 2-inch steel angle extends all around the perimeter of the lap-welded cone roof.

b. Internal Floating Pan

Facility records indicate the perimeter seal was replaced in 2011. The floating pan penetration seals are deteriorated or missing. The difference in vertical distances as measured from the roof inspection hatches down to the floating pan indicates the pan was higher at the time of inspection on one side than on the other by approximately 2 1/4 inches. This demonstrates the tendency for floating pans with perimeter seals to hang up in smaller tanks. Recent advances in seal materials and installation techniques reduce the tendency for perimeter seals to hang up in smaller tanks.

c. Venting

The tank has an internal floating pan, three roof perimeter vents, three shell overflow/vents, and a

12-inch diameter roof center vent. While API 650 requires 1/2-inch minimum size openings in vent screen, and the center vent screen has 1/4-inch openings, there is little chance of the screen clogging due to ice or moss.

d. Gauging

The tank has an MTS ATG and a water probe installed in separate aluminum wells and an 8-inch aluminum manual gauging well with a floating plug retriever.

e. Level Alarms

The tank has only ATG level alarms.

f. Stairs and Platforms

The tank’s steel cone roof is accessible by a circumferential stairway, which also includes a lower landing for accessing the upper shell manhole. The circumferential stairway step rise is generally 8 inches continuously from the bottom step to the roof landing, while the bottom step is only 4 inches above the foundation berm. OSHA requires the rise and run of stair steps to be continuous. The width of the stair steps is 30 inches. However, clearance between the stairway handrail and one of the upper shell manhole handles is only 19 inches; OSHA requires 22 inches of clearance.

g. Grounding and Bonding

The tank has eight grounding cables, which are bolted to steel angles, which are welded to the tank bottom extension. The grounding appeared to be in good condition.

5. Tank Coating

The coating was evaluated for deterioration. The coating on the exterior of the roof was spot repaired in 2011 at the locations of the welded repairs. The exterior coating is in good condition. The interior appears to be 100% coated.

6. Tank Piping System

Tank Facility AF573 is a combination bulk and issue tank. The tank’s nominal capacity is approximately half of the nominal capacity for the Base. Fuel is received into the tank filtered via aboveground piping from the adjacent truck off-load stand. Fuel is issued from the tank filtered to an adjacent truck fillstand via aboveground piping. After site modifications are complete, it may be possible to recirculate the fuel through the filter/separators. There is no product saver tank. However, water in the fuel does not appear to be a problem.

7. Fire Protection System

There are three fire hydrants within 300 feet of this tank.

8. Secondary Containment

The tank sits on top of a concrete foundation berm surrounded by a below-grade concrete secondary containment. The secondary containment is connected by a 23-inch deep concrete trench to supplemental remote secondary containment. The secondary containment was visually evaluated during the inspection. The drainage control valve is located just outside the below grade dike area and would not likely be accessible in the event of a fire. The secondary containment basin is sloped away from the tank, but not away from the piping, which is routed over the swale at the edge of the secondary containment. The expansion joint seals in the remote containment basin appear to have failed. The secondary containment appears otherwise to be in good condition. A conservative evaluation of the volume of the secondary containment indicates it is sufficient to hold the contents of the tank full to the bottom of the overflow as required by NFPA 30 plus approximately 12 inches of freeboard. The secondary containment drain was hydrotested and found to be adequate to control drainage.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility AF573 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 could be addressed to reduce long term maintenance, to improve operability, and to more clearly comply with federal, state, and local regulations or military criteria.

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs

Mandatory repairs represent items that require immediate attention to prevent imminent risk to system operators, equipment, or the adjacent environment. The tank would have to be taken out-of-service to complete these repairs. 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. Replace Thermal Relief Valves and Piping

OBSERVATION: The issue piping thermal relief valve data plate indicates a set pressure of 150 psig.

The receipt piping thermal relief valve data plate is unreadable. The receipt thermal relief valve is installed horizontally. Both the receipt and issue thermal relief piping is threaded and includes sight flow indicators. The thermal relief piping does not include isolation valves or testing tees, which inhibits performance of maintenance on the thermal relief valves.

REFERENCE: Guidance for new construction provided in UFC 3-460-01 paragraph 9-3.5.1 recommends a set pressure of 10% above pump deadhead and prohibit installing sight flow indicators on new thermal relief piping. Paragraph 9-8. e) prohibits installing threaded piping on new fuel piping. The manufacturers of thermal relief valves recommend installing the valves in the vertical position to prevent debris from settling in the valve seats. DoD Standard Design AW 78-24-

27 includes isolation valves and testing tees for new thermal relief piping. Due to the environment, maintenance and function of thermal relief valves at this location may be more critical than at some other locations.

RECOMMENDATION: Replace the thermal relief valves and piping around the receipt and issue nozzle isolation valves with valves and piping that comply with UFC and manufacturer recommendations.

b. Replace Expansion Joint Seals

OBSERVATION: The remote secondary containment concrete expansion joint seals are deteriorated.

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

RECOMMENDATION: Replace the expansion joint seals in the remote secondary containment.

c. Provide Stairs to Access Dikes

OBSERVATION: The dike access ladder is not substantial or stable enough to use safely. In addition, animals often get trapped in the below grade secondary containment. As a result, a wooden pallet is leaned against the dike wall to provide more stable access and to allow animals to escape.

REFERENCE: Guidance for new construction provided in UFC 3-460-01 paragraph 8-14.8 and DoD

Standard Design AW 78-24-27 includes steps with handrails for accessing dike areas.

RECOMMENDATION: Replace the ladders currently installed for accessing the dike and supplementary remote secondary containment, with stair steps and handrails.

d. Replace Low Melting Point Valve

OBSERVATION: The level control valve is made of aluminum. There is no isolation valve adjacent and upstream of the level control valve.

REFERENCE: NFPA 30 paragraph 27.4.3 and UFC 3-460-01 paragraph 3-6.7.1 prohibit valves made of aluminum and other low melting point materials. Guidance for rehabilitation of fuel facilities provided in UFC 3-460-01 paragraph 12-9 and guidance for new construction provided in DoD

Design Standard AW-78-24-27 include isolation valves adjacent and upstream of control valves.

RECOMMENDATION: Replace the aluminum level control valve with a steel valve. Provide an isolation valve adjacent to and upstream of the level control valve.

e. Re-plumb Integral Body Cavity Relief Valves

OBSERVATION: The body cavity integral thermal relief valves on the shell nozzle isolation valves are plumbed to relieve away from the tank. The integral thermal relief are differential (not balanced) type and open only when upstream pressure exceeds downstream pressure by a set amount. As the thermal relief for the piping is set at 200 psi, the integral relief valves may not open until the internal pressure in the valve exceeds the sum of the set pressures. This could shorten the life of the seals in the valve and/or could result in damage to the valve.

REFERENCE: Guidance for new construction included in UFC 3-460-01 recommends using balanced thermal relief valves where cascading cannot be avoided.

RECOMMENDATION: Eliminate cascading by replumbing the integral body cavity thermal relief valves on the tank shell nozzle isolation valves to relieve into the tank.

f. Replace Floating Pan Penetration Seals

OBSERVATION: Facility records indicate the perimeter seal was replaced in 2011. However, the floating pan penetration seals are deteriorated or missing.

REFERENCE: Guidance for new construction provided in DoD Standard Design AW 78-24-27 includes floating pan penetration seals.

RECOMMENDATION: Replace the floating pan penetration seals.

g. Relocate the Dike Drain Valve

OBSERVATION: The dike drain valve is located where it could not safely be accessed during a fire.

REFERENCE: NFPA 30 paragraph 22.11.2.7.1. requires the dike drain valve controls to be assessible under fire conditions.

RECOMMENDATION: Provide means to operate the dike drain valve that would be accessible under fire conditions.

Dike Drain Valve

h. Provide Landing

OBSERVATION: The rise of the circumferential stairway is approximately 8 inches. However, the rise of the bottom step above the foundation berm is only 4 inches.

REFERENCE: OSHA regulation 29 CFR 1910.24 (f) requires the step rise to be uniform throughout any flight of stairs including any foundation structure used as one or more treads of the stairs.

RECOMMENDATION: Extend the bottom step of the circumferential stairway to provide a landing at the bottom of the stairs approximately 4 inches above the foundation berm.

i. Provide OSHA Compliant Ladder Access Hatch

OBSERVATION: The internal ladder access hatch provides less than 18 inches of clearance on the climbing side of the ladder, and there are sharp projections on the climbing side.

REFERENCE: OSHA regulation 29 CFR 1910.27 (c) requires 30 inches of clearance on the climbing side of a ladder including at access hatches.

RECOMMENDATION: Provide an OSHA compliant internal ladder access hatch on the tank roof.

j. Modify Stilling Wells Guides

OBSERVATION: The manual and ATG stilling wells were installed in 2011. Facility personnel indicated the sample bottles get hung up on the bolts installed in the bottom of the manual gauging well. This would seem to suggest the stilling wells (Manual and ATG) are attached to the bottom of the tank.

REFERENCE: API 650 paragraph 5.10.4.7 c) does not allow vertical columns to be fastened at both ends (e.g.: to the roof and the tank bottom).

RECOMMENDATION: Modify the stilling well guides at the bottom ends of the Manual and ATG stilling wells to allow the bottom ends of the wells to be guided but not restrained vertically and so that there are no bolts protruding inside the wells that could hang up a sample bottle or an

ATG probe/displacer.

3. 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. Seal Cracks in Foundation

OBSERVATION: The top of the foundation has spiderweb cracks, possibly due to the dry conditions.

If precipitation enters the foundation through the cracks, the water could promote corrosion of the reinforcing steel in the concrete, especially if it froze an expanded. Deterioration of the foundation could lead to inadequate support for the tank.

Reference: API 650 paragraph 5.3.1 and API 653 Appendix B require foundations to provide adequate support.

RECOMMENDATION: Seal the exposed top of the tank foundation.

b. Remove Flammable Material

OBSERVATION: The dike access ladder is not substantial or stable enough to use safely. In addition, animals have a history of getting trapped in the below grade secondary containment. As a result, a wooden pallet is leaned against the dike wall to provide more stable access and allow the animals to escape.

REFERENCE: NFPA 30 paragraph 22.11.2.8 prohibits storing combustible material in the dike area.

RECOMMENDATION: Remove the wooden pallet from the dike area. Provide a non-combustible, stable, temporary means of accessing the dike areas that also allow animals to escape.

c. Continue to Remove Debris and Sand

Observation: The location is generally hot, dry and subject to sand storms. As a result, there is dried plant debris and sand on the tank bottom extension, foundation and in the dike area.

Reference: Guidance for maintenance of fuel storage facilities provided in UFC 3-460-03 paragraph 8-10.3.1 includes inspection of concrete secondary containment for cleanliness and removal of vegetation. NFPA 30 paragraph 22.11.2.8 prohibits storing combustible material in the dike area.

RECOMMENDATION: Continue to remove the dried plant debris and sand from the tank bottom extension, foundation, and in the dike areas.

d. Provide Labels

Observation: The tank is not labeled to indicate the tank number or facility (real property) number.

Reference: Guidance for design of new fuel storage facilities provided in UFC 3-460-01 paragraph

2-18 b) includes marking tanks to indicate the tank number and facility number.

RECOMMENDATION: Provide labels on the exterior of the tank shell to indicate the tank number and facility number.

e. Pressure Wash Roof

OBSERVATION: Facility personnel indicated the animal feces on the tank roof is from a coatimundi.

REFERENCE: API 570 paragraph 4.3.2.3.h) reads, “bird turds can also cause accelerated corrosion and unsightly stains.”

RECOMMENDATION: Include pressure washing of the tank roof to remove loose debris and animal feces in the periodic maintenance checklist.

f. Update the SPCC Plan

OBSERVATION: The SPCC Plan dated February 2010, which was provided by the Base, does not appear to address this tank.

REFERENCE: 40 CFR 112.1 (a) (2) and 40 CFR 112.7 (3) requires the plan to address each oil container with capacity of 55 gallons or greater.

RECOMMENDATION: Update the Fort’s SPCC Plan to address Tank Facility AF573.

4. 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. Provide an Autogauge/Tape Gauge

OBSERVATION: The tank is not equipped with an autogauge (mechanical tape gauge).

REFERENCE: Guidance for new construction provided in UFC 3-460-01, Table 8-1, Item o, and DoD

Standard Design AW 78-24-27 includes a mechanical tape liquid level gauge (autogauge). Some branches of the military do not include autogauges due to a history of failure when installed directly to the floating pan.

RECOMMENDATION: As an accurate installation would require providing an additional penetration in the small diameter floating pan, providing an autogauge is not recommended.

b. Modify Secondary Containment

OBSERVATION: The secondary containment is not sloped away from the piping.

REFERENCE: NFPA 30 paragraph 22.12.2.1 requires secondary containment to be sloped away from the piping.

RECOMMENDATION: Modify the secondary containment to slope way from the piping.

c. Modify the Roof Support Structure

OBSERVATION: As noted in previous inspection reports, the tank’s steel, lap welded, cone roof shows sign of water ponding around the perimeter. There are only eight rafters. The rafters are spaced approximately 7 feet and 6 inches apart at the perimeter of the roof.

REFERENCE: As early as 1996, API 650 required rafter spacing at the perimeter of the tank roof to be no greater than 75 inches apart. Earlier API requirements may have been more stringent. Later editions of API 650, paragraph 5.10.4.4 increased the maximum allowable spacing to 84 inches.

RECOMMENDATION: As rain water and corrosion are not issues at this location, modifying the roof support structure to eliminate the water ponding and bring the roof into compliance with API 650 is not recommended.

d. Provide a Water Bottom Sensor

OBSERVATION: A well for a water bottom sensor was installed in 2011. However, there is no water bottom sensor. There is no water draw-off nozzle or product saver tank.

REFERENCE: Guidance for new construction provided in UFC 3-460-01 Table 8-1 item s includes a well for a water bottom sensor.

RECOMMENDATION: The upgrade is not recommended, as the fuel is received from trucks through a filter/separator system; issued to trucks through a second filter/separator system; and Fort personnel reported little water is ever found in the separator sumps.

e. Replace the Center Vent Screen

OBSERVATION: The 12-inch roof center vent screen has only 1/4-inch openings. There is little chance of the screen clogging due to ice or moss.

REFERENCE: API 650 paragraph H.5.2.2 requires the roof center vent to have a course-mesh screen with 1/2-inch openings.

RECOMMENDATION: As there is little chance of the screen clogging due to ice or moss at this location, modification is not recommended.

f. Modify Stairway

OBSERVATION: Clearance between the stairway handrail and one of the upper shell manhole handles is only 19 inches.

REFERENCE: OSHA regulation 29 CFR 1610.24 (d) requires clearance at a stairway of at least 22 inches. The minimum width of stairs required in API 650 Table 5.18 has increased over the years, from 24 inches in 1993 to 28 inches in the latest edition.

RECOMMENDATION: Modify the stairway and intermediate landing to provide 28 inches of clearance between the stairway handrail and the upper shell manhole handles.

g. Provide Independent Level Alarms

OBSERVATION: The tank does not have shell mounted independent level alarms. The level control valve float pilot is not accessible from the stairway.

REFERENCE: Guidance for new construction provided in UFC 3-460-01, Table 8-1, Item l includes high, high-high, low and low-low level alarms, independent from the tank gauging system, and accessible from the stairway or ground level. Table 8-1 Item k also includes stairs and platforms for accessing the level alarms and controls (float pilot).

RECOMMENDATION: Provide high, high-high, low, and low-low level alarms independent of the tank gauging system. Relocate the high-level control float pilot so it can be accessed from the stairway.

Modify the stairway to provide access to the new independent alarms and relocated float pilot.

Float Pilot

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 1/2-inch of a new tank shell radius. Based on the circumference of the shell measured near the bottom, the radius of the shell should be 9 feet and 6 inches. However, the measured radii of the shell, varies at the bottom from 9 feet and 5 1/2 inches in the northeast to 9 feet and 7 inches in the southwest. Also, the measured radii of the shell, varies at the top from 9 feet and 5 1/2 inches in the northeast to 9 feet and 6 5/8 inches in the south and southwest. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top. That there did not appear to be any significant distortion of the shell, would seem to suggest the tank was built slightly out-of-round.

It is noted that the tolerance for out-of-roundness has been included in API 650 since at least before 1993. API 650

1st Edition was published in 1960. However, it has not been until later years that the industry has had the laser surveying technology and methods available to it to measure it in the upper shell courses. It should be noted that

API 653,10.5.3 – 3rd Edition (published in 2001), and later editions, allow the shell out-of-roundness (radial deviation), at higher than one foot above a bottom of a reconstructed tank, to be as much as three times greater (1

1/2 inches), a subject not addressed in API 653 prior to the year 2001. As measuring the out-of-roundness using such methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended.

Austin Brockenbrough & Associates, L.L.P. Job No. 17-095.02

Location: Fort Huachuca Date: 10/10/2017

Subject: Tank AF573 - Shell Settlement Evaluation By: Mike O'Connor

API 653 Appendix B

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

Diameter (D) = 19 (ft)

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 7.46

Tank Height (H) = 24.3 (ft)

Relative elevation of lowest horizontal weld seam.

* Z U S

0 100.00 0.00 0.00 0.00 0.00

1 100.01 0.01 0.00 -0.01 -0.01

2 100.01 0.01 0.02 0.01 0.02

3 100.04 0.04 0.03 -0.01 -0.01

4 100.05 0.05 0.03 -0.02 -0.02

5 100.01 0.01 0.03 0.02 0.02

6 100.00 0.00 0.02 0.02 0.01

7 100.01 0.01 0.00 -0.01 -0.01

8 100.00 0.00 0.00 0.00 0.00

Maximum out-of-plane deflection = 0.02

* = measured elevation

*HI (Height of Instrument)

Z = calculated ridged body tilt (in)

U = out-of-plane settlement =

S = out-of-plane deflection z-y

Y = yield sterength of shell material (PSI) = 36,000 (A36)

E = Youngs modulas of elasticity (lbf/in2) = 29*10^6

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH)*12 = 0.19 in

R^2 = (Syy - SSE) / Syy = 0.57 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. 17-095.02

Location: Fort Huachuca Date: 10/10/2017

Subject: Tank AF573 - Shell Settlement Evaluation By: Mike O'Connor

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

Open top (yes/no) = no 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 14.9 0.01 0.15 OK

2 14.9 0.02 0.15 OK

6 22.4 0.02 0.23 OK

Si < Smax →

Si < Smax →

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

Si < Smax →

-0.01

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0 2 4 6 8 10

Measured Elevation (in)

Si0

Si2 Si2

Austin Brockenbrough & Associates, L.L.P. 16-095.02

Location: Ft. Huachuca Date: 9/14/17

Subject: FAC AF573 Shell Survey Page 1 of 4

Measured Circumference at Bottom = 59.69 ft

Calculated Diameter = 19.00 ft

Calculated Radius = 9.50 ft

Distance Height

From Radial Radial Above Out

Centerline Deviation Deviation Bottom of

(ft) (ft) (in) (ft) Plumb (in)

South 9.55 0.05 0.66 24.0 S+N 0.54 0.43

9.56 0.06 0.68 21.0 0.86

9.56 0.06 0.68 18.0 0.89

9.55 0.05 0.55 15.0 0.77

9.55 0.05 0.64 12.0 0.88

9.55 0.05 0.62 9.0 0.85

9.54 0.04 0.44 6.0 0.56

9.54 0.04 0.48 3.0 0.61

9.52 0.02 0.23 0.2 0.26

100.05

Southeast 9.53 0.03 0.42 24.0 SE+NW 0.54 0.22

9.52 0.02 0.28 21.0 0.53

9.51 0.01 0.08 18.0 0.52

9.53 0.03 0.31 15.0 0.57

9.55 0.05 0.56 12.0 0.92

9.55 0.05 0.65 9.0 1.15

9.55 0.05 0.59 6.0 1.12

9.54 0.04 0.48 3.0 1.00

9.52 0.02 0.20 0.2 0.43

100.01

Diameter Deviation

(in)

Bottom-of-Shell Elevation

Subject: FAC AF573 Shell Survey Page 2 of 4

Distance Height

From Radial Above Out

Centerline Deviation Deviation Bottom of

(ft) (ft) (in) (ft) Plumb (in)

East 9.48 -0.02 -0.26 24.0 E+W 0.08 -0.32

9.49 -0.01 -0.16 21.0 0.07

9.49 -0.01 -0.18 18.0 0.08

9.47 -0.03 -0.34 15.0 0.31

9.47 -0.03 -0.40 12.0 0.37

9.46 -0.04 -0.48 9.0 0.55

9.48 -0.02 -0.30 6.0 0.18

9.46 -0.04 -0.48 3.0 0.18

9.51 0.00 0.06 0.2 0.34

100.00

Northeast 9.46 -0.04 -0.45 24.0 NE+SW 0.11 0.10

9.47 -0.03 -0.38 21.0 0.54

9.47 -0.03 -0.31 18.0 0.93

9.48 -0.02 -0.29 15.0 1.13

9.47 -0.03 -0.37 12.0 0.99

9.47 -0.03 -0.37 9.0 0.95

9.46 -0.04 -0.50 6.0 0.71

9.46 -0.04 -0.43 3.0 0.72

9.45 -0.05 -0.55 0.2 0.38

100.01

Diameter Deviation

(in)

Subject: FAC AF573 Shell Survey Page 3 of 4

Distance Height

From Radial Above Out

Centerline Deviation Deviation Bottom of

(ft) (ft) (in) (ft) Plumb (in)

North 9.49 -0.01 -0.12 24.0 -0.16

9.51 0.01 0.18 21.0

9.52 0.02 0.20 18.0

9.52 0.02 0.22 15.0

9.52 0.02 0.24 12.0

9.52 0.02 0.23 9.0

9.51 0.01 0.12 6.0

9.51 0.01 0.13 3.0

9.50 0.00 0.04 0.2

100.00

Northwest 9.51 0.01 0.13 24.0 -0.11

9.52 0.02 0.25 21.0

9.54 0.04 0.44 18.0

9.52 0.02 0.25 15.0

9.53 0.03 0.36 12.0

9.54 0.04 0.50 9.0

9.54 0.04 0.53 6.0

9.54 0.04 0.52 3.0

9.52 0.02 0.24 0.2

100.01

Subject: FAC AF573 Shell Survey Page 4 of 4

Distance Height

From Radial Above Out

Centerline Deviation Deviation Bottom of

(ft) (ft) (in) (ft) Plumb (in)

West 9.53 0.03 0.35 24.0 0.07

9.52 0.02 0.23 21.0

9.52 0.02 0.26 18.0

9.50 0.00 0.02 15.0

9.50 0.00 0.02 12.0

9.49 -0.01 -0.07 9.0

9.51 0.01 0.12 6.0

9.55 0.05 0.66 3.0

9.52 0.02 0.28 0.2

100.01

Southwest 9.55 0.05 0.56 24.0 -0.37

9.58 0.08 0.93 21.0

9.60 0.10 1.24 18.0

9.62 0.12 1.42 15.0

9.61 0.11 1.37 12.0

9.61 0.11 1.32 9.0

9.60 0.10 1.21 6.0

9.60 0.10 1.15 3.0

9.58 0.08 0.93 0.6

100.04

SHELL THICKNESS CALCULATIONS

Job No.: 16-095.02

Job Title: FAC AF573 (Tank 5) Fort Huachuca

Subject: Shell Calculations

By: Mike O'Connor Date: 9/20/2017

API-650 Appendix A

API 653

SHELL CALCULATIONS

Diameter 19 feet Wind Velocity 125 mph

Shell Height 24.25 feet

Freeboard 3.25 feet Nom Shell Thk 0.250

Design Fill Height 21.00 feet

Specific Gravity 1.00 API 650 Maximum height of unstiffened shell: 208.6 feet

0.84 API 653

Joint Efficiency 0.70 API 650

Material A36

Yield Strength 36,000 psi (assumed)

Tensile Strength 58,000 psi (assumed)

Original Design Corrosion Allowance

0.000 in (2mm)

Required thickness

Lower Upper

Two

CoursesCourses

Allowable Stress 23595 27376

Height Product Required Thickness

Course (feet) Depth 1/4" min

3 8.25 5.00 0.011 0.013

2 8.00 13.00 0.034 0.040

1 8.00 21.00 0.056 0.067 min 2017 Corrosion Estimated UTM Visual current net 1992 Rate Service Life Inspection Inspection

Course UTM* thick Thickness * in/yr yrs. Interval Interval

3 0.241 0.241 0.258 0.001 >30 15 5

2 0.252 0.252 0.254 0.000 >30 15 5

1 0.241 0.241 0.262 0.001 >30 15 5

The original thicknesses are assumed based on required design thicknessess, overtolerance and the range of the UTMs.

P.O. Box 4800 4800 W. Hundred Road Chester, Virginia 23831 Phone: 804-748-8746 Fax: 804-748-7849 www.brockenbrough.com

SE

2.6HDG

SE

(psi)

API-650

Original

Hydro

21000

API-653

Original

Design

0.100

21000

0.100

0.100

2.6(H-1)DG 2.6(H-1)D

SE

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

Job No.: 16-095.02

Job Title: FAC AF573 (Tank 5) Fort Huachuca

Subject: UT Data

By: Mike O'Connor Date: 9/20/2017

SHELL UTM DATA (0.001 inches)

DFT = 0.000 inches

UTM's include 0 inch DFT coating.

1 2 3

4 5 6

7 8 9

Typical Shell Plate UTMs.

1st course

1 2 3 4 5 6 7 8 9

1-1 260 265 258 265 268 264 275 277 275

1-2 279 259 260 256 258 253 281 258 252

1-3 266 268 263 260 269 267

1-4 242 244 242 268 243 241 268 272 256

1-5

1-6

UTMs Taken From Stairway

2nd course

2-1 252 257 253

2-2

2-3

2-4

2-5

2-6

3rd course

3-1 259 259 256

3-2

3-3

3-4

3-5

3-6

Roof UTMs

Non-slip surface prevented taking UTMs.

P.O. Box 4800 4800 W. Hundred Road Chester, Virginia 23831 Phone: 804-748-8746 Fax: 804-748-7849 www.brockenbrough.com

TANK DRAWINGS,

The following drawings are pages extracted from the 2011 inspection reports. The drawings do not show the modifications that were completed in 2011.

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Ft. Huachuca, Sierra Vista, AZ

CAPE, Inc.

05/19/11 N/A N/A

Tank #5 B-1Bottom Layout

Measured Inside Diameter is 19 feet.

Tank bottom has 8 plates.

4210.50

GRAPHIC SCALE:

Dimensions are in feet.

y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

1 2

3 4

5 6

7 8

V1

V2

V3

A

Shell Nozzles in Course #1

A - 3" Low Point Suction

B

B - 1" Pressure Relief

C

C - 6" Product Issue

D

D - 36" Manway

F

F - 36" Floating Roof Manway

G

G - 24" Clean Out Manway

J

J - 1" Pressure Relief

M

M - 4" Product Receipt

V# - Vertical Seam Number of Shell Course #1

- Anti Rotation Device Anchor

- Floating Roof Leg Striker Plate

B -2

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Ft. Huachuca, Sierra Vista, AZ

CAPE, Inc.

05/19/11 N/A N/A

Tank #5 S-1Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

10543210

GRAPHIC SCALE:

Dimensions are in feet.

1-1

A

B C

D

E

Overflow Vent

2-1

3-1

1-2

F

Overflow Vent

2-2

3-2

1 2 3

A - 3" Low Point Suction

B - 1" Pressure Relief

C - 6" Product Issue

D - 36" Manway

E - 1" Fire Detector

F - 36" Floating Roof Manway

Anchor Bolt

-3

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Ft. Huachuca, Sierra Vista, AZ

CAPE, Inc.

05/19/11 N/A N/A

Tank #5 S-2Shell Layout

Seam #1 is the first seam left of the first manway left of the stairway in the first shell course viewing from the outside.

The number in the upper left corner of each plate identifies the plate by the course and position of the plate in that course.

10543210

GRAPHIC SCALE:

Dimensions are in feet.

1-3

G

H I

J

K

L

M

Overflow Vent

INS-1

2-3

3-3

3 1

G - 24" Clean Out Manway

H - 1" Fire Detection

I - 1.5" Cap

J - 1" Pressure Relief

K - 1" High Level Control Shut Off

L - 1" High Level Control Shut Off

M - 4" Product Receipt

Anchor Bolt

-4

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Ft. Huachuca, Sierra Vista, AZ

CAPE, Inc.

05/19/11 N/A N/A

Tank #5 R-1Fixed Roof Layout

Measured Diameter is 19 feet.

Fixed roof has 8 plates.

4210.50

GRAPHIC SCALE:

Dimensions are in feet.

y x

NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

15 16

17 18

19 20

21 22

A

B

C

D

A - 24" x 24" Manway

B - 8" Electronic Level Gauge

C - 12" Center Vent

D - 64" x 12" Access Hatch

E - 24" x 24 Light Hatch

F - 6" Sample Hatch

B -6

E

F

- 24" x 8" Roof Vent

OSHA ACCESS STRUCTURE REPORT

OSHA Circumferential Stairway Data

OSHA Rq’d Actual

(in) min (in) max (in)

Handrail Height 34 OK 30 34 Step Width 30 OK 22 NA

Step Rise 8 OK NA NA Bottom Step Rise 4 Not OK 7 9

BOTTOM STEP

RISE

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

stainless steel End Conn: Size: 4" Material: stainless steel End Conn: Size: 6"

Issue To:

Interior Coating:

Double Bottom

Brown Minneapolis Tank local and remote, both concrete

Local: 61' Dia by 44" Deep

Remote: 24.5' x 24.5' x 44"

Level Alarms:

Material: Welded

Coated

Plastic / Fiberglass

Other:

Tank Outside Dimensions: Useable Capacity:

(2) leak detection pipe

Original

Overfill Protection:

Tank Facility No.:

Local Tank ID No.:

August 30, 2017

AF573

Tank Manufacturer:

Tank Construction Date:

Tank 5 Tank Inspector Name:

Jet Fuel (F-24)

1,000 bbl

950 bbl

API 653 EXTERNAL INSPECTION CHECKLIST

Fort HuachucaProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

SPCC Mandated AST Inspections

Various Locations

General Inspection Information

16-095.02

Submitted to:

Contract No.:

USACE - Omaha

W9128F-12-D-0006

Receipt From:

Inspector Certification Number:

Tank Construction and Configuration

Rectangular

Double Wall

Fire Resistant

Secondary Containment, Overfill, and CRDM

Welded

Truck fillstand

19'-0" dia by 24'-3"

NA

truck off-load

Concrete slab

Closed Top Dike

Change of Service:

Last Repair:

Tank Coatings:

[(2) 8" and (1) 4" aluminum stilling wells]

Insulated

Nominal Capacity:

Open Type DikeVertical

Single Wall

Release Prevention Barrier

Overfill Protection / Level Alarms:

ATG alarms 4" hydraulic operated OCV control valve

Receipt Piping Configuration Issue Piping Configuration

Tank Piping

Secondary Containment

May 2011

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

Inspection Date:

Design Std

Horizontal

Mike O'Connor

Exterior Coating:

Epoxy - Polyurethane

Epoxy

API 653 EXTERNAL INSPECTION CHECKLIST

Fort HuachucaProject Site:Project Name: SPCC Mandated AST 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 a) b)

C.1.1.6 Housekeeping

Buildup of trash, vegetation, and other inflammables

Settlements into the base

C.1.1.2 Asphalt d) a) b)

c) 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

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

Tank settlement into asphalt base

Review cathodic protection potential readings

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

Check for:

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

C.1.1.4 Rock

C.1.1.5 Site Drainage

C.1.1.7 Cathodic Protection

Measure foundation levelness and bottom elevations (See Annex B) See settlement survey calcs.

ITEM

C.1.1 Foundation

TASK

Indications of bottom leakage at drain openings in ring, back of water-draw basins, and top surface of ring

Piping runs over swale.

Sand and dryed plant debris on tank bottom extension, top of foundation and in dike area.

a) b)

Check for:

Proper operation of dike drains

Check for:

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand

e) Settlement around perimeter of tank

Check for:

STATUS

C.1.1.1 Concrete Ring

Spiderweb cracks in concrete foundation slab.

Check for:

Tank Settlement

COMMENTS

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 c) a)

Pitting on support welds to shell, especially on shell plates d) b)

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

Corrosion loss and wear on the rivets

C.1.2.2 Internal (Floating Roof

Tank)

Bottom-to-Foundation Seal c)

Broken welds and corrosion damage

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

Reinforcing pads welded to shell at supports

Leaks and identify the location by sketch or photo

C.1.2.4 Wind Girder (Floating

Roof Tanks) a)

Check for:

Rivet and seam leaks on external surface

Check for:

Corrosion and thinning on plate and weld after cleaning the bottom angle area a) b) c)

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

C.1.2. Shells

Check for:

Grooving, corrosion, pitting, and coating failures

Check for:

Paint failures, pitting, and corrosion

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

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

Issue TRV set 150 psi. Receipt TRV tag not readible.

e) c)

Proper operation of regulators for tanks with purge gas systems e) f)

Check for:

c) d) a)

Leaks at sample connections and proper valve operation

Damage and test the accuracy of temperature indicators

Adequate manholes flange and cover thickness on mixer manholes

COMMENTS

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

C.1.3.1 Manholes and Nozzles

Sealing of insulation…