EIE Tank 61 Final API 653 Inspection Report (W911KB-15-D-0001-0003).pdf

ACOE CONTRACT W911KB-15-D-0001, TASK ORDER 0003

TANK 61 (FACILITY NO. 6380)

API 653 IN-SERVICE INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

(PRE-REPAIR)

Eielson AFB, Alaska

October 2015

Contract Agency:

U.S. Army Engineer District, Alaska P.O. Box 6898 Elmendorf AFB AK 99506-6898

Prepared By:

Michael B. Morris, P.E.

API 653 Certificate No. 56148

Submitted By:

Kelly B. Waring, P.E.

Principal, API 653 Certificate No. 21992 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI Project 8537

Page Intentionally Left Blank

SUITABILITY FOR SERVICE STATEMENT

TANK 61 (FACILITY NO. 6380)

Enterprise Engineering, Inc. (EEI) has completed an in-service external inspection and suitability for service evaluation of Tank 61 at Eielson AFB, Alaska. The inspection was performed August 22-26, 2015 in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair. Recommendations for continued long-term service are also provided.

EEI recommends performing the next in-service external inspection no later than August 2020 (5 years from this 2015 inspection), or sooner if a change in condition has occurred.

EEI recommends performing the next out-of-service internal inspection no later than May 2031 (20 years from 2011 out-of-service inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653 and ADEC Regulation 18AAC75, this report satisfies the requirement for an in-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

October 15, 2015 Michael B. Morris, P.E. Date API 653 AST Inspector Certificate No. 56148

No Mandatory Repairs were identified that require removing the tank from service. One mandatory repair was identified however it may be performed while the tank is in service.

Tank 61 is suitable for continued service.

10/15/15

Tank 61 – API 653 Inspection TABLE OF CONTENTS Eielson AFB, Alaska October 2015 EEI Project No. 8537

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs Prior to Return to Service (Mandatory) Recommended Repairs Prior to Return to Service (Non-Mandatory) Recommended Repairs for Long Term Serviceability

COATING SYSTEM

Exterior Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Hydraulic and Structural Integrity

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Checklist ................................................................................. Appendix A Assessment of Compliance with Military Criteria ..................................................................... Appendix B Non-Destructive Examination (NDE) and Evaluation Criteria .................................................. Appendix C Tank Drawings .......................................................................................................................... Appendix D Tank Photographs .......................................................................................................................Appendix E NDE Results ............................................................................................................................... Appendix F Calculations ............................................................................................................................... Appendix G Coating Requirements ............................................................................................................... Appendix H

Tank 61 – API 653 Inspection Page 1

EEI Project No.: 8537

TANK 61

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

Eielson AFB, Alaska

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an in-service external inspection of Tank 61 at Eielson AFB, Alaska. The inspection was performed August 22 - 26, 2015. The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 61 is a field erected, vertical aboveground storage tank. The tank was fabricated and erected in 1973. A double bottom was installed in 1994. The tank is 93 feet in diameter and 51 feet, 2 inches high. It is of welded construction with butt-welded shell plates and lap welded floor and roof plates. The nominal shell capacity is 55,000 barrels. Tank 61 is currently in JP-8 service and is equipped with a single wall steel floating pan.

INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Tank 61 is considered suitable to remain in service. The following are significant findings of the inspection.

Hydraulic Integrity

The in-service inspection and evaluation found no conditions affecting the hydraulic integrity of the tank.

As the tank is in-service, the condition of the floor is unknown.

Structural Integrity

The in-service inspection and evaluation found no conditions affecting the structural integrity of the tank.

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EEI Project No.: 8537

Next Inspection

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires that an in-service inspection be performed every 5 years or RCA/4N years, whichever is less. RCA is the remaining corrosion allowance of the shell (ie. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. The measurements of the fully coated shell found only minor plate thickness variations resulting in a minimal corrosion rate.

It should be noted that ADEC may reduce the inspection interval for a specific storage tank if

(a) The storage tank is older than 30 years,

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion or foundation problems, or

(d) After a significant seismic event.

Although item (a) is the only applicable criteria to the tank, it is not anticipated that the state will require a reduced inspection interval.

EEI recommends that the next in-service inspection should be performed no later than August 2020 (5 years from this 2015 inspection), or sooner if a change in condition or a change in service occurs.

EEI recommends that the next out-of-service inspection should be performed no later than May 2031 (20 years from 2011 out-of-service inspection), or sooner if a change in condition has occurred. The 20-year inspection interval that was established in the 2011 out-of-service inspection report was based on corrosion calculations.

REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory) and recommended for long term serviceability. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, NDE of welding and testing requirements.

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EEI Project No.: 8537

Required Repairs Prior to Return to Service (Mandatory)

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank and or code compliance.

1. Non-compliant weld clearances have been identified with respect to manhole-1, manhole-2, and the 2-inch nozzle with blind flange welds. Specifically, the bottom of the reinforcing plates on manhole- 1 and manhole-2 to the floor-to-shell weld and the bottom of the 2-inch nozzle with blind flange to the floor-to-shell weld are less than the required API minimum. Provide additional inspection per API 653 4.3.9.1.

• Provide magnetic particle examination of the non-compliant welds. Remove the coatings at the non-compliant areas to facilitate inspection. Repair coatings following completion.

• Although this inspection step is considered mandatory under API 653 provisions, it is very unlikely such testing will result in any work other than light grinding of the weld, MT testing and restoration work. In the event that defects may be found that cannot be repaired by light grinding, it is recommended to defer the work until the next out-of-service interval. The tank has been in service in its present condition since 1994 and has performed adequately. There is no compelling reason to repair the condition other than it is a gross violation of API 653.

Recommended Repairs Prior to Return to Service (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends these repairs for long-term preservation and integrity of the tank.

1. Minor coating failure was observed on the floor extension, shell appurtenances, and shell (approximately 10 square feet).

• Remove the coating from the affected areas.

• Clean and provide proper surface preparation on 100% of the areas to be recoated in accordance with coating manufacturer’s written recommendations.

• Recoat the affected areas.

2. There is a large gap between the first stair on the shell spiral stair case and ground elevation (approximately 3 feet).

• Recommend providing a concrete pad at the bottom of the stairs (approximately four foot square) and a two-step metal step stair. Attachment to the existing spiral stair case or the tank shell is not required.

3. Minor cracks were observed in the concrete ringwall (approximately 10 linear feet).

• Recommend sealing the cracks with epoxy injection.

4. Minor spalling was observed on the concrete ringwall. Typically the spalling was small, no larger than 2-inch by 6-inch (10 locations).

• Recommend repairing the spalling.

5. The tank stenciling does not meet MIL-STD-161G (Identification for Bulk Petroleum Products). The product identification marking bands are required to be yellow.

• Provide new tank stenciling meeting MIL-STD-161G.

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EEI Project No.: 8537

6. The reinforcing plate telltale holes are open to the atmosphere (MH-1, MH-2, MH-3, flush clean-out, low fuel, fill, and issue).

• Recommend packing the telltale holes with grease to prevent moisture migration between the reinforcing plate and the tank shell.

7. Minor coating failure was observed on the roof appurtenance and perimeter hand rail (approximately 5 sq. ft.).

• Remove the coating from the affected areas.

• Clean and provide proper surface preparation on 100% of the areas to be recoated in accordance with coating manufacturer’s written recommendations.

• Recoat the affected areas.

8. Tank 61 is not equipped with a non-slip surface to the gauging ports on the roof.

• Recommend providing a non-slip surface path to the gauging ports (approximately 400 sq. ft.).

9. Minor amounts of vegetation were observed in the containment dike.

• Recommend removing the vegetation.

10. The containment area drain pipe has failed.

• Recommend repairing the drain pipe.

11. Tank 61 is equipped with a standpipe as part of the leak detection system. The standpipe appears to have been frost jacked and is tilting.

• Recommend monitoring the standpipe for further movement.

• Note that this condition was noted in the 2011 out-of-service inspection. It was additionally noted in the 2006 investigation of leak detection stand pipe systems. The standpipe was viewed by video inspection as part of the 2006 investigation and it was noted that the frost jacking did not appear to have damaged the standpipe/leak detection pipe interface.

12. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Appendix H - Coating Requirements. When welding on the shell or roof, the coating on the opposite side from the weld shall be inspected and repaired if damaged.

Recommended Repairs for Long Term Serviceability

1. Program the tank for an API 653 in-service inspection no later than August 2020. Program the next API 653 out-of-service internal and external inspection no later than May 2031.

2. Test all level alarms and switches as part of on-going maintenance.

COATING SYSTEM

Exterior Coating Requirements

Refer to Appendix H for complete coating materials and application requirements for type and location of coating repair items identified by the inspection.

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SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank shell and roof were calculated using thickness measurements that were obtained during the inspection and are as follows:

Shell: 0.00093 inches/year Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates were calculated using an assumed original metal thickness and a 1973 year of construction.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 61:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Foundation Tank 61 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Projection The sealant between the ringwall and floor projection on the original tank floor was in acceptable condition.

The top of the deadshell is welded to the underside of new tank floor.

Acceptable

Shell Visual inspection of the accessible shell joints found no relevant indications. A pit survey was conducted and no locations were identified for repair.

Acceptable

Roof Spot ultrasonic testing of the roof plates found no significant thinning of the plates.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria. Acceptable

Hydrostatic Test Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980): No, constructed in 1973.

2. Has a prior hydrotest been performed demonstrating fitness: Unknown.

3. Is the tank shell thickness < 0.5 inch: No.

4. Does the tank operate at metal temperature above 60 deg F?: No.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4.1 or API 653 Figure 5.2: Yes.

7. Tank full at lowest one day temperature per API 650 Figure 4.1:

Unknown.

The tank, having steel exemption per Figure 5.2, does not fit the API 653 at-risk profile for brittle fracture failure.

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EEI Project No.: 8537

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Seismic Evaluation

Tank 61 is not equipped with tank anchors. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank shell stresses are within limits at the current fill height of 40 feet 11 1/8 inches.

Calculations were performed utilizing the specific gravity for JP-8 (S.G. = 0.84), a ringwall foundation, seismic parameters Ss = 1.06, S1 = 0.29, an importance factor of 1.25.

Acceptable

Wind Evaluation A wind analysis was performed per API 650, Section 5.11. Calculations were performed using an importance factor of 1.15 and a wind velocity of 90 mph.

The evaluation determined that an empty tank is stable and not at risk of overturning or sliding.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 90 mph.

Acceptable

CLOSURE

Conclusions

Based on the extent of this inspection, Tank 61 is considered suitable to remain in service. One mandatory repair was identified however the tank may remain in service while it is completed.

Project Team

Site Team

Michael B. Morris, P.E. Mechanical Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 56148, API Inspector of Record

Travis W. Snyder Mechanical Engineer, Tank Technician

Support Team

Stacy M. Kaplan-McMillan Project Manager

David A. Stchyrba, P.E. Structural Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 27187

Kelly B. Waring, P.E. QA Review, API 653 Aboveground Storage Tank Inspector Certificate No. 21992

APPENDIX A

TANK INSPECTION DATA SHEET

AND EVALUATION ITEMS

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 1

EEI Project No.: 8537

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Eielson AFB, Alaska E-11 Complex

Tank No. 61 Facility No. 6380

Inspection Date(s): August 22 - 26, 2015 Tank Type: Vertical AST

Type of Inspection: In-Service External Inspection Contract Number, Task Order: W911KB-15-D-0001, 0003

Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: Michael B. Morris, P.E.

API-653 AST Inspector Certificate No. 56148

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard Chicago Bridge & Iron, 1973, Not Specified, assume API 650 5th Edition. A double bottom was installed in 1994.

Diameter: 93'-0" Shell Height: 51'-2"

Product, Specific Gravity: JP-8, 0.84 Design Pressure / Temperature: Unknown

Gross Capacity / Nominal Capacity: 49,626 Bbls / 55,000 Bbls Design Liquid Level: Unknown

Operational Fill Height: 40’ 11 1/8” (from facility) GPS Latitude & Longitude: 64 Deg 39’ 18.83” N, 147 Deg 02’ 55.07” W

(Source – Google Earth) Foundation Configuration: Concrete Ringwall

Shell Configuration: Butt Welded w/ 7 courses Roof: Fixed roof

Cathodic Protection: Not Present Still Wells: Tank 61 is equipped with 3 stilling wells. The stilling wells were installed following the 2011 out-of-service inspection.

Last Inspection (Type, Date): Out-of-Service, May 2011

Last Coated Internally (Product): 1994, Unknown Last Coated Externally (Product): 1994, Unknown

INSPECTION RESULTS

Can tank remain in service? Yes.

Deficiencies identified as mandatory repairs: Yes, see paragraph titled “Mandatory Repairs” in body of report.

Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term Serviceability” in body of report

Next Scheduled Inspections (Type, Date): Out-of-Service: May 2031 (20 years from 2011 out-of-service inspection) In-Service: August 2020 (5 years).

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Not available.

API STANDARD 653

TANK IN-SERVICE INSPECTION CHECKLIST

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 2

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

C. 1.1 FOUNDATION

Measure foundation levelness and bottom elevations (see Appendix B for extent of measurements) X

Tank 61 is relatively level. The maximum measured differential between max and min elevations is 0.140 feet.

C. 1.1.1 Concrete Ring

a. Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell.

X

Minor cracks were identified on the concrete ringwall (approximately 10 linear feet). Recommend sealing the cracks with epoxy injection.

Minor spalling was observed on the ringwall. Recommend repairing the spalling (10 locations).

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

X No indications of bottom leaks observed.

c. Inspect for cavities under foundation and vegetation against bottom of tank. X No cavities under foundation observed.

d. Check that runoff rainwater from the shell drains away from tank. X Drainage appears adequate.

e. Check for settlement around perimeter of tank. X No settlement observed.

C.1.2 Asphalt

a. Check for settling of tank into asphalt base which would direct runoff rain water under the tank rather than away from it.

N/A

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

N/A

C.1.1.3 Oiled Dirt or Sand

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

N/A

C. 1.1.4 Rock

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

X

Backside corrosion of double bottom will be checked during the next internal inspection. The original floor cannot be inspected.

C.1.1.5 Site Drainage

a. Check site for drainage away from the tank and associated piping and manifolds. X

Drainage around the tank and piping appears adequate.

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 3

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

b. Check operating condition of the dike drains.

N/A

Operation of the drains was not performed. No issues with the drains were reported by facility personnel.

C.1.1.6 Housekeeping

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

Minor vegetation observed within containment area. Recommend removing vegetation.

C.1.2 SHELLS

C.1.2.1 External Visual Inspection

a. Visually inspect for paint failures, pitting, and corrosion.

X

Minor coating failure was identified on the floor projection, shell appurtenances, and shell.

Recommend cleaning and recoating the affected areas.

b. Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X

The floor projection extends an average of 2.83 inches beyond the tank shell. The average thickness is 0.244-inch.

c. Inspect the bottom-to-foundation seal, if any.

X

The bottom of the original floor to the ringwall seal was in acceptable condition.

C.1.2.2 Internal (Floating Roof Tank)

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

The internal shell was viewed through the roof inspection hatches. No concerns were identified with coating as viewed through the hatches.

C.1.2.3 Riveted Shell Inspection The shell is of welded construction.

a. Inspect external surface for rivet and seam leaks. N/A

b. Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A

c. Inspect rivets for corrosion loss and wear. N/A

d. Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A

e. If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern; number of rows, rivet size, pitch length, N/A

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 4

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments and note whether the joint is butt-riveted or lap-riveted.

C.1.2.4 Wind Girder (Floating Roof Tanks) Tank has a fixed roof. The tank is equipped with 48 vertical shell stiffeners.

a. Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds.

N/A

b. Check support welds to shelf for pitting, especially on shell plates. N/A

c. Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 SHELL APPURTENANCES

C.1.3.1 Manways and Nozzles

a. Inspect for cracks or signs of leakage in weld joint at nozzles, manways, and reinforcing plates.

X

None visually noticed.

Non-compliant weld clearances have been identified with respect to manhole-1, manhole-2, and a 2-inch nozzle with blind flange welds. Provide magnetic particle examination of the non-compliant welds (see Main Body for additional information).

b. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X No dimpling detected.

c. Inspect for flange leaks and leaks around bolting. X None detected.

d. Inspect sealing of insulation around manways and nozzles. N/A The tank is not insulated.

e. Check for inadequate manway flange and cover thickness on mixer manways. N/A

The tank is not equipped with mixer manways.

C.1.3.2 Tank Piping Manifolds

a. Inspect manifold piping, flanges, and valves for leaks. X None observed.

b. Inspect firefighting system components. N/A

c. Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X None observed.

d. Check for adequate thermal pressure relief of piping to the tank. X

The thermal relief for the tank fill and issue lines is accomplished through pressure relief loops. The pressure relief setting is 125 psi for the fill and issue.

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 5

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

e. Check operation of regulators for tanks with purge gas systems. N/A

f. Check sample connections for leaks and for proper valve operation. N/A

g. Check for damage and test the accuracy of temperature indicators. N/A

h. Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System Note that the ‘Autogauge’ is in reference to the tape gauge. The tank is equipped with a tape gauge and an ENRAF ATG system.

a. Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. N/A Visual inspection was not available through the roof manway.

b. Inspect autogauge head for damage. X No damage was observed.

c. Bump the checker on autogauge head for proper movement of tape. X No deficiencies observed.

d. Identify size and construction material of autogauge tape guide (floating roof tanks). N/A

Visual inspection was not available through the roof manway.

e. Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X Facility personnel did not report any difficulties with the tape gauge.

f. Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). N/A

g. On floating roof tanks, when the roof is in the lowest position, check that no more than two ft.

of tape are exposed at the end of the tape guide.

N/A

h. Inspect condition of board and legibility of board-type autogages. N/A

i. Test freedom of movement of marker and float. N/A

C.1.3.4 Shell-Mounted Samples Station None Present. Note that the tank shell is equipped with 6 abandoned sampling stations on the tank shell located on the spiral stairway. The abandoned stations are plugged.

a. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

N/A

b. Check circulation pump for leaks and operating problems. N/A

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Appendix A, Page 6

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

c. Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted) None Present.

Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer None Present.

a. Inspect for proper mounting flange and support. N/A

b. Inspect for leakage. N/A

c. Inspect condition of power lines & connection to mixer. N/A

C. 1.3.7 Swing Lines: Winch Operation None Present.

a. Nonfloating. Raise, then lower the swing line with winch, and check for cable tightness to confirm that swing line lowered properly.

N/A

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

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 7

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

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

N/A

C.1.3.8 Swing Lines: External Guide System None Present.

Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need None Present.

Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition None Present.

a. For nonstainless steel cable, check for corrosion over entire length. N/A

b. All cable: check for wear or fraying.

C.1.3.11 Swing Lines: Product Sample Comparison None Present.

Check for water or gravity differences that would indicate a leaking swing joint. N/A

C.1.3.12 Swing Lines: Target None Present.

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

N/A

C.1.4 ROOFS

C.1.4.1 Deck Plate Internal Corrosion

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

X

C.1.4.2 Deck Plate Exterior Corrosion

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

X Minor coating failure was identified on the roof appurtenances and perimeter hand rail. Recommend cleaning and recoating the affected areas.

The roof is not equipped with a non-slip surface path to the gauging ports.

Recommend providing a non-slip surface path.

C.1.4.3 Roof Deck Drainage

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 8

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

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

X None observed.

C.1.4.4 Level of Floating Roof

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

N/A

C.1.4.5 Gas Test Internal Floating Roof

Test for explosive gas on top of the internal floating roof. Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

N/A

C.1.4.6 Roof Insulation The tank is not insulated.

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

N/A

b. Inspect for wet insulation under the weather coat. N/A

c. Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

N/A

C.1.4.7 Floating Roof Seal System

a. Measure and record maximum seal-to-shell gaps at: N/A

Entry above the floating pan was not performed. Inspection limited to examination from roof inspection hatches.

1. Low pump out N/A

2. Mid-shell N/A

3. High liquid level N/A

b. Measure and record annular space at 30-ft.

spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly apposite pairs.

N/A

1. __________ _________ Opposite pair 1. N/A

2. __________ _________ Opposite pair 2. N/A

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 9

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

c. Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough).

N/A

d. Inspect fabric for deterioration, holes, tears, and cracks. N/A

e. Inspect visible metallic parts for corrosion and wear. N/A

f. Inspect for openings in seals that would permit vapor emissions. N/A

g. Inspect for protruding bolt or rivet heads against the shell. N/A

h. Pull both primary and secondary seal systems back all around the shell to check their operation. N/A

i. Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

N/A

j. Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. N/A

C.1.5 ROOF APPURTENANCES

C.1.5.1 Sample Hatch

a. Inspect condition and functioning of sample hatch cover. X Sample hatch is operable.

b. On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

N/A

c. Check for corrosion and plugging on thief and gauge hatch cover. X None observed.

d. Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance.

N/A

e. Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X The manual gauge hatch is equipped with a reinforcing pad.

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

N/A

g. Test operation of system. N/A

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

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 10

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments

C.1.5.2 Gauge Well The gauge well was not visible from the tank exterior.

a. Inspect visible portion if the gauge well for thinning, size of slots, and cover condition. N/A

b. Check for a hold-off distance marker and tab with hold-off distance (legible). N/A

c. On floating roof, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

N/A

d. If accessible, check the distance from the gauge well pipe to the tank shell at different levels. N/A

e. If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

N/A

C.1.5.3 Fixed Roof Scaffold Support None Present.

Inspect scaffold support for corrosion, wear, and structural soundness. N/A

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof)

The tape gauge roof nozzle is not equipped with an inspection hatch.

a. Check the hatch for corrosion and missing bolts. N/A

b. Look for corrosion on the tape guide’s and float guide’s wire anchor. N/A

C.1.5.5 Autogauge: Float Well Cover

c. Inspect for corrosion. N/A

d. Check tape cable for wear or fraying caused by rubbing on the cover. N/A

C.1.5.6 Sample Hatch (Internal Floating Roof)

a. Check overall conditions.

X

The tank is equipped with an 8-inch nozzle with gauging/sampling hatch. The hatch is in acceptable condition. Note, the penetration through the floating roof was not visually inspected.

b. When equipped with a fabric seal, check for automatic sealing after sampling. N/A

c. When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check condition of screens, locking, and pivot pins. X Tank is equipped with four perimeter

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 11

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments vents. The vent openings are 43-inch long by 10-inch wide. The openings are equipped with screens.

C.1.5.8 Gauging Platform Drip Ring

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

N/A

C.1.5.9 Emergency Roof Drain

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

N/A

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers External Inspection only – inspect condition of vacuum breakers at next out-of-service inspection.

Report size, number, and type of vacuum breakers.

Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

N/A

C.1.5.12 Rim Vents

a. Check condition of the screen on the rim vent cover. N/A

The roof is equipped with four perimeter roof vents. The roof vents are equipped with screens in acceptable condition.

b. Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. N/A

C.1.5.13 Pontoon Inspection Hatches The floating pan is of aluminum honeycomb construction.

a. Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A

b. Test for explosive gas (an indicator of vapor space leaks). N/A

c. If pontoon hatches are equipped with locked down covers, check for vent tubes. N/A

C.1.6 Accessways

See Tank Out-of-Service Inspection Checklist, item C.2.12

X

Platforms, stairs, and handrails are in good condition.

There is a large gap between the first stair tread on the shell spiral staircase and grade. Recommend providing a small concrete pad and two-step metal step-stair.

Tank 61 – API 653 Inspection Eielson AFB, Alaska

Appendix A, Page 12

EEI Project No.: 8537

Tank No.: 61 Prepared by: MBM

Location: Eielson AFB, AK Date: 9/29/2015

EEI Project No.: 8537

Item Completed Comments Additional Notes:

1. Telltale holes at the shell reinforcing plates are open to atmosphere. Recommend packing the holes with general purpose grease to prevent moisture migration between plate and shell.

2. The tank stenciling does not meet MIL-STD-161G. The product identification markings are required to be yellow.

Recommend providing new tank stenciling.

3. The leak detection stand pipe has frost jacked and is tilting. Recommend monitoring the stand pipe for further movement.

APPENDIX B

ASSESSMENT OF COMPLIANCE

WITH MILITARY CRITERIA

Appendix B, Page 1

EEI Project No. 8537

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT) COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

MANHOLE

c A shell manhole located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals as required by DoD Standard AW 78-24- 27.

The tank is equipped with a shell manhole above the floating pan.

e Roof manholes in accordance with API Std

650. Locate the roof manholes near the perimeter of the roof at opposite ends of a diameter and approximately 90 degrees from the shell manholes.

The tank roof is not equipped with a manhole.

There is no compelling reason to provide a roof manhole.

f Shell manholes in accordance with API Std

650. Two 36-inch shell manholes 180 degrees from each other. Align shell manholes parallel with prevailing wind direction. Support shell manhole covers by davits.

Tank is equipped with two ground level 30-inch shell manholes. There is no compelling reason to provide 36-inch diameter manholes.

g A bolted cover in the roof for installation and removal of the internal floating pan as required by the tank supplier based on the pan manufacturer.

The tank roof is not equipped with a construction hatch. There is no compelling reason to provide a construction hatch.

INSPECTION HATCHES

h A minimum of four 24-inch square inspection hatches on fixed roof tanks with floating pans. Inspection hatches are not required for tanks without floating pans.

The roof is equipped with three 24-inch square inspection hatches. There is no compelling reason to provide a fourth inspection hatch.

LADDER/STAIRS

i Internal ladders (in accordance with OSHA criteria) for tanks of 5,000 gallons or larger with floating pans.

The tank is not equipped with an internal ladder (per 2011 inspection). There is no compelling reason to provide an internal ladder.

k Ladders, railings, toeboards, a spiral stairway, top platform, and handrail in accordance with API Std 650 and OSHA requirements. Provide stairways to access high level shut-off and alarms. Provide metal bar grating stair tread and platforms. Provide stair tread with non-slip nosings.

Tank is equipped with a spiral stairway, platforms, and handrails in accordance with API 650 and OSHA requirements; meets UFC 3-460-01.

Tank is equipped with metal bar grating treads with non-slip nosings on stairs and platforms;

meets UFC 3-460-01.

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

Appendix B, Page 2

EEI Project No. 8537

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT) COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO

LEVEL ALARMS

l An individual automatic level alarm system, independent of the gauging device or system for each tank. Include high, high-high, low and low-low level alarms.

Tank 61 is equipped with independent level alarms.

VENTS

m Open atmospheric vents with weather hoods and bird screens for tanks to be used for products with true vapor pressure of 0.75 psi or less. For higher vapor pressure, or if a vapor recovery system is used, provide pressure/vacuum vents in lieu of open vents.

Consider pressure/vacuum vents if product quality is at risk by blowing sand, dust or snow. Comply with NFPA 30, host nation requirements, Chapter 2 of this UFC, API Std 650, API Std 2000, 29 CFR Part 1910.106, and DoD Standard Design AW 78-24-27, where applicable. Do not use flame arrestors.

Tank is equipped with atmospheric vent with weather hood and bird screen; meets UFC 3- 460-01.

n Emergency relief venting with capacity in accordance with NFPA 30 and UL 142, as applicable or a weak roof-to-shell seam, as specified in API Std 650.

Tank is equipped with one roof vent and six shell overflow ports. Tank openings meet the minimum required area per API 650 Annex H requirements for emergency venting.

GAUGE/GAUGE HATCH/STILLING WELLS

o A liquid level gauge calibrated in 1/16-inch graduations mounted at 60 inches above the walking surface.

Tank is equipped with a Varec tape gauge.

p Automatic Tank Gauging (ATG) for all tanks with fuel managed through the Defense Logistics Agency's Business Modernization {BSM Enterprise Resource Programs (ERP) - Fuels section}, that complies with API MPMS Chapter 3.

Tank is equipped with an ENRAF ATG system.

r One 10-inch roof flanged nozzle with an 8-inch aluminum, fully slotted, stilling well for ATG near the edge of the roof near the top of the stairway platform.

Gauge tubes were installed following the 2011 inspection. Gauge tubes were not assessed as part of this inspection; external inspection only.

s One 8-inch roof flanged nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor, as close to or in the tank sump as possible. See DoD Standard Design AW 78-24-27.

Gauge tubes were installed following the 2011 inspection. Gauge tubes were not assessed as part of this inspection; external inspection only.

Appendix B, Page 3

EEI Project No. 8537

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM

APPURTENANCE

(UFC REQUIREMENT) COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance) YES NO t One 10-inch roof nozzle and an aluminum, slotted stilling well extended to within 3 inches of the bottom of the tank* for gauging and sampling. A datum plate to establish a gauging zero point.

Gauge tubes were installed following the 2011 inspection. Gauge tubes were not assessed as part of this inspection; external inspection only.

PIPE CONNECTION

u Inlet fill connection. See Facility Plates 016, 017, and 018, as applicable.

Not assessed; external inspection only.

v Main suction and low suction. See DoD Standard Design AW 78-24-27.

Tank is equipped with main suction and low suction line.

OVERFILL PROTECTION

x Overfill protection with a hydraulically operated diaphragm control valve.

The tank is equipped with a hydraulically operated diaphragm control valve.

WATER DRAW-OFF

aa Water draw-off connections. See DoD Standard Design AW 78-24-27.

The tank is equipped with a water-draw off connection and a product saver.

BALL JOINTS

ee Ball joints on pipes to relieve strain caused by tank settling or seismic activity.

It has been the experience of EEI that the integrity of ball joints is suspect and that leaks have been known to occur. It is the opinion of EEI that it is not necessary to retrofit the piping to include ball joints.

CABLE SUPPORTS

ff On the fixed roof of all tanks, provide two scaffold cable supports in accordance with API Std 650.

There is no compelling reason to provide scaffold cable supports.

STRIKER PLATES

gg Striker plates under all openings used for manual gauging in steel tanks and all openings in fiberglass tanks.

Not assessed; external inspection only.

Additional Military Criteria Items, Comments or Notes:

None.

END OF DATA

APPENDIX C

NON-DESTRUCTIVE EXAMINATION (NDE)

AND EVALUATION CRITERIA

Appendix C, Page 1

IN-SERVICE INSPECTION

CODES AND STANDARDS

API Standard 653, 5th Edition, November 2014

API Standard 650, 12th Edition, March 2013, Addendum 1, September 2014

UFC 3-301-01 Structural Engineering, June 2013

NON DESTRUCTIVE EXAMINATION (NDE)

Tank Inspection (General)

API Standard 653 as applicable.

Visual Inspection

1. Inspection Items

• In accordance with API Standard 653 and EEI STD for API 653 In-Service Inspection

• Shell and roof plate welded joints (where accessible).

• Shell and roof plate surfaces.

• Items affecting structural and hydraulic integrity

2. Method

• In accordance with API Standard 653.

Ultrasonic Testing (UT)

Ultrasonic thickness measurements were taken to establish floor, shell, and roof plate thicknesses.

1. Inspection Items

• In accordance with EEI NDE Procedure, EEI-UT-002, Ultrasonic Thickness Examination.

• Shell plates

• Roof plates

• Tank appurtenances

2. Equipment

• Olympus 38DL Plus / Panametrics 37DL Plus

3. Method

• Perform on a spot basis to determine thickness.

• Perform in areas of low UT thickness readings to determine the nature of the low reading that is backside corrosion, lamination, or inclusion within the parent material.

Appendix C, Page 2

• Echo/Echo (E/E) or Thru Coat mode for determining metal thickness and backside corrosion on coated surfaces without including thickness of coating in reading.

Pit Survey

1. Inspection Items

• Tank shell

• Tank roof

2. Equipment

• Mechanical pit gauges

Tank Bottom Settlement Measurements

1. Equipment

• Laser level

2. Method

• In accordance with API Standard 653 Appendix B, measure the floor profile at a minimum of eight locations around the tank perimeter not greater than 30 feet apart.

Coating Thickness Measurements

1. Equipment

• Olympus 38DL Plus (Thru Coat mode) / PosiTector 6000 Thickness Gauge

2. Method

• Measurements taken at UT locations.

APPENDIX D

TANK DRAWINGS

APPENDIX E

TANK PHOTOGRAPHS

All photographs in this report, unless otherwise noted, were taken by Enterprise Engineering, Inc.

Enterprise Engineering, Inc. hereby grants permission to the U.S. Government and its contractors to publish/republish these photos.

Appendix E, Page 1

EEI Project No.: 8537

Tank 61 North Elevation

Tank 61 East Elevation

Appendix E, Page 2

EEI Project No.: 8537

Tank 61 South Elevation

Tank 61 West Elevation

Appendix E, Page 3

EEI Project No.: 8537

30-inch Manway #1

Tank Double Bottom

Appendix E, Page 4

EEI Project No.: 8537

Hydrocarbon Sensor in Dead Shell for Monitoring the Interstitial Space (Typical of 4)

8-inch Issue Nozzle with DB&B Plug Valve with Ice Shield

Appendix E, Page 5

EEI Project No.: 8537

24-inch Flush Clean Out

Tank Ground Wire

Appendix E, Page 6

EEI Project No.: 8537

Leak Detection Standpipe

30-inch Manway #2 (Note that the weld clearance between the bottom of the reinforcing plate and the top of the new floor projection weld does not meet API criteria)

Appendix E, Page 7

EEI Project No.: 8537

2-inch Nozzle with Blind at Former Exterior Stilling Well

Nozzles and Float Switch for Low Level Alarm

Appendix E, Page 8

EEI Project No.: 8537

Roof Access Stairs

30-inch Manway for accessing top of the Floating Pan

Appendix E, Page 9

EEI Project No.: 8537

Nozzles and Float for HI Level Alarm, High Level Shut-Off Valve and HI-HI Level Alarm

Shand & Jurs Tape Gauge Display

Appendix E, Page 10

EEI Project No.: 8537

8-inch Fill Nozzle with DB&B Plug Valve and High Level Shut-Off Valve with Ice Shield

Coating Failure on Fill Piping

Appendix E, Page 11

EEI Project No.: 8537

2-inch Water Draw-Off Nozzle with DB&B Plug Valve (Note: Arrow points to abandoned 1-inch nozzle in dead shell)

Product Saver Tank

Appendix E, Page 12

EEI Project No.: 8537

4-inch Low Fuel Nozzle with Reducer and 3-inch DB&B Plug Valve

Containment Area Drain Piping

(Note that the drain pipe has failed)

Appendix E, Page 13

EE…