EIE Tank 6381 (Tank 59) Final Report (W911KB-15-D-0001-0003).pdf

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

TANK 59 (FACILITY NO. 6381)

API 653 OUT-OF-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 59 (FACILITY NO. 6381)

Enterprise Engineering, Inc. (EEI) has completed an out-of-service external and internal inspection and suitability for service evaluation of Tank 59 at Eielson AFB, Alaska. The inspection was performed on 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 the next API 653 external in-service inspection be scheduled no later than August 2020 (5 years from this 2015 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API 653 internal out-of-service inspection be scheduled no later than August 2025 (10 years from this 2015 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 out-of-service, tank 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

This tank inspection has determined that mandatory repairs are not required prior to return to service. Tank 59 may be returned to service.

Recommended repairs have been identified, and if possible, should be completed before returning the tank to service.

10/15/15

Tank 59 – 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 (Mandatory) Recommended Repairs (Non-Mandatory) Recommended Repairs for Long Term Serviceability

COATING SYSTEM

Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEM

Leak Detection Stand Pipes

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ........................................... 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 59 – API 653 Inspection Page 1

EEI Project No. 8537

TANK 59

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

Eielson AFB, Alaska

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an out-of-service internal and external inspection of Tank 59 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 59 is a field erected, vertical aboveground storage tank. The tank was fabricated and erected in 1973. A double bottom was installed in 1998. The tank is 93 feet in diameter and 51 feet, 2 ½ 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 59 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 59 is considered suitable to return to service. The following are significant findings of the inspection.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Visual inspection of the tank floor, shell, and roof found no holes or indications of leaks. A pit survey was conducted for topside corrosion on the floor and no pits were identified requiring repair. A magnetic flux leakage (MFL) scan of the floor found no relevant indications of corrosion on the bottom side of the floor requiring repair.

Tank 59 – API 653 Inspection Page 2

EEI Project No. 8537

The out-of-service inspection and evaluation found no conditions that affect the hydraulic integrity of the tank.

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof and their attachment.

Ultrasonic inspections of the shell were performed on the first course and on each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

The out-of-service inspection and evaluation found no conditions that affect the structural integrity of the tank.

Next Inspection

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires the interval until the next internal in section be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years. When RBI procedures are used the interval shall not exceed 25. If the tank has a release prevention barrier and leak detection designed in accordance with API 650 Appendix I and RBI procedures are used, the interval shall not exceed 30 years. As an RBI assessment is not included in the scope of this inspection, the interval until the next out-of-service inspection was determined using corrosion rates.

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.

The state may or may not require a reduced inspection interval based on the conditions above.

EEI recommends the next API 653 external in-service inspection be scheduled no later than August 2020 (5 years from this 2015 inspection). The next in-service inspection should be performed sooner if a change in condition or a change in service occurs.

EEI recommends the next API 653 out-of-service inspection be performed no later than August 2025 (10 years from this 2015 inspection). The next out-of-service inspection should be performed sooner if a change in condition or a change in service occurs.

It should be noted that a maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

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EEI Project No. 8537

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. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor, and shall consider the tank has been in petroleum fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs (Mandatory)

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank and are required prior to returning Tank 59 to service.

• The out-of-service inspection of Tank 59 found no significant deficiencies that would require mandatory repair or prevent returning the tank to service.

Recommended Repairs (Non-Mandatory)

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

1. Coating failure was observed on the tank floor at approximately 10 locations. The coating failures are small and isolated, typically found on weld seams.

• 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. Two of the anti-rotation cable seal plugs at the floating roof interface are not sitting properly. One is askew and one has slid down the cable.

• Recommend re-sitting the cable plugs.

3. There are not striker plates installed under the floating pan pressure vent/vacuum breaker on the tank floor.

• Recommend installing striker plates (three locations, 12-inch diameter plates, 5/16-inch thickness).

• 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.

• Repair coating at affected areas.

Tank 59 – API 653 Inspection Page 4

EEI Project No. 8537

4. One tear was observed in the wiper seal.

• Recommend repairing the tear (approximately 6 inches long by ½-inch wide).

5. The ground cables above the floating pan (two total) consist of two pieces of steel cable in a plastic sheathing. At the joint between the two cable pieces, the plastic sheathing was not removed. The ground cable is thus considered noncontinuous and inadequate.

• Recommend replacing the grounding cables with a cable composed of a single wire.

6. Large scale coating failure along the edges of the topside of the floating pan was observed (approximately 50 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.

7. The seals at the gauge tube penetrations have failed.

• Recommend replacing the seals (two locations: 8-inch diameter gauge tubes).

8. Approximately 5 square feet of coating failure was observed on the roof plates.

• 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.

9. One of the floating pan roof top inspection hatches was missing a handle.

• Recommend providing a handle.

10. The non-slip surface on the roof has degraded.

• Recommend replacing the non-slip surface (approximately 400 square feet).

11. Minor coating failure was observed on the roof appurtenance and roof perimeter railing (approximately 5 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.

12. The underside of the floor projection and the deadshell is not coated (entire perimeter – approximately 290 feet length by 6 inches tall down to the batten strip connection for the flexible liner).

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

• Coat the affected areas.

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EEI Project No. 8537

13. Facility personnel reported the 1-inch ball valves and thermal relief valves (TSVs) on the TSV loops leak.

• Recommend replacing the valves (three TSVs, six ball valves).

14. The tank stenciling does not meet MIL-STD-161G.

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

15. The reinforcing plate telltale holes are open to the atmosphere (MH-1, MH-2, MH-2, water draw, low fuel, fill, and issue).

• Recommend packing the telltale holes with grease to prevent moisture migration.

16. Facility personnel reported that the tape gauge is broken.

• Recommend replacing the tape gauge.

17. The existing gauge tubes were evaluated for compliance with the DESC/DLA Memorandum and

UFC 3-460-01.

• Provide 6-inch diameter slotted gauge tube for temperature/water probe located directly over the sump. Provide slotting for full height of gauge tube.

• The 8-inch gauge tube for ENRAF ATG Displacer only has slotting for the bottom 6 feet.

Provide slotting for the full height of the gauge tube.

• The 8-inch gauge tube for the temperature/water probe only has slotting for the bottom 6 feet.

Provide slotting for the full height of the gauge tube. This gauge tube will be used for manual gauging/sampling. Provide manual gauging port on roof nozzle.

18. The tank was evaluated for compliance with current military criteria. The following is noted:

• The interior 8-inch issue piping is not equipped with an anti-vortex plate as required by UFC 3- 460-01. Recommend providing an anti-vortex plate meeting specifications of Standard Design

AW 78-24-27.

• Refer to Appendix B “Assessment of Compliance with Military Criteria” for further discussion.

19. Liquid was observed in the standpipes used for underfloor leak detection.

• Recommend periodically removing water from the stand pipes. Tank 59 is equipped with an oiled sand bed cushion between the new and old floor. Recommend sampling any water removed to confirm any sheen observed is due to the oiled sand bed and that it is not JP-8.

• Recommend providing a drip ring per Section 5.4.5 of API 650 to prevent water from wicking.

The drip ring would consist of a steel ring, welded to the floor projection along the perimeter of the tank. It would extend outward and would prevent moisture from being wicked into the sand cushion

• See “Additional Discussion Items” below for additional information on the stand pipes.

20. 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.

Tank 59 – API 653 Inspection Page 6

EEI Project No. 8537

Recommended Repairs for Long Term Serviceability

1. Program the tank for the next API 653 in-service external inspection no later than August 2020 and the next API 653 out-of-service internal and external inspection no later than August 2025.

2. Test all level alarms and switches as part of ongoing maintenance.

COATING SYSTEM

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.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

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

Floor: 0.007376 inches per year Shell: 0.000900 inches per year Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates for the shell and roof were calculated using an assumed original metal thickness and a 1973 year of construction. The corrosion rate for the floor was calculated using an assumed original metal thickness and a 1998 year of construction

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 17.5 mils, is a thin-film lining. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The floor coating is 17 years old. Although the coating was in good condition, a nominal unrepaired pit depth of 1/16-inch was assumed in the calculations. No pits requiring repair were identified.

Bottom side corrosion with small volumetric metal loss may be present and not detected by MFL scanning. The metal loss used to calculate the bottom side corrosion rate was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits. The MFL floor scanner is not configured to indicate (alarm) for minor metal loss. The tank is not equipped with a cathodic protection (CP) system. For tanks without effective CP, the bottom side corrosion rate (UPr) is the lesser of the MFL threshold or the minimum thickness of a corroded area.

The minimum remaining thickness (MRT) used in the calculations is based on API 653 Section 4.4.5 and Table 4.4. The tank is equipped with the means to detect and contain a bottom leak. It was reported (confirmed with historical design drawings) that there is a liner beneath the sand cushion. Based on this information, the MRT used in the calculations is 0.050-inch.

It was found that the tank floor plate thickness will not be reduced below the limiting MRT at a 10-year inspection interval.

Tank 59 – API 653 Inspection Page 7

EEI Project No. 8537

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 59:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

Foundation Tank sits on a concrete ringwall (Note: the ringwall is covered in ballast). The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Visual inspection of the floor plate joints found no relevant indications. MFL scanning of the floor found no indication of active corrosion on the bottom side. A pit survey was conducted for topside corrosion and no pits were identified requiring repair.

Based upon the calculated corrosion rate, the floor plate thickness will not be reduced below the requirements for minimum floor plate thickness of 0.05 inch at a 10-year inspection interval.

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 noticeable 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: Yes.

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 4.1: Yes.

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

Figure 4.1: Unknown.

The tank, having operated safely for 42 years and having been hydrotested, does not fit the API 653 at-risk profile for brittle fracture failure. Brittle facture, if it were to occur would happen early in the life of the tank.

Seismic Evaluation

Tank 59 is unanchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank is adequately self-anchored and that the shell stresses are within limits at the current fill height of 40 ft 10-3/8 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 1.15.

Acceptable

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EEI Project No. 8537

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item Findings Comments

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

ADDITIONAL DISCUSSION ITEM

Leak Detection Stand Pipes

Tank 59 was repaired in 1998 by the Rockford Corporation. Major repairs included a provision for a new floor by slotting the existing shell, an under tank geomembrane liner system over the existing tank floor, and a leak detection system. The tank floor is welded at the exterior shell on the topside of the floor projection. The underside of the floor projection is sealed with a polysulfide sealant. The 2-inch diameter stainless steel tell-tale pipes run beneath the tank’s center sump and slope downward to the concrete ringwall. The tell-tale pipes penetrate the ringwall and are attached to 6-inch diameter standpipes via a 6-inch by 2-inch forged branch connection. The ringwall was core drilled for the tell-tale pipe penetrations.

The tell-tale pipes were grouted in place. The centerline of the forged connection is approximately 6 inches from the bottom of the standpipe. The tell-tale pipes penetrate the geomembrane liner under the sump and are sealed with a geomembrane boot at the penetration. An oil sand cushion is provided below the new floor and above the membrane liner.

Based on the leak detection configuration, EEI identified the following possible points of water entry or sources of the water

• Tank chine: Possible rain or melt water entry point if there is poor seal (Note the sealant in acceptable condition at time of inspection).

• Liner Breach: Possible groundwater infiltration through a hole or improper seam in the under tank liner.

• Liner Penetration to Tell-Tale Pipe Seal: Possible groundwater infiltration point.

• Breached Tell-Tale Pipe: Possible groundwater infiltration point at a coupling, corroded point, or broken section.

• Breached Connection to Standpipe: Possible groundwater infiltration point.

• Condensation: Possible from the cold fuel and humidity in the spring.

Recommend periodically removing water from the stand pipe. Tank 59 is equipped with an oiled sand bed cushion between the new and old floor. Recommend sampling any water removed to confirm any sheen observed is due to the oiled sand bed and that it is not JP-8.

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EEI Project No. 8537

CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 59 is considered suitable to return to service.

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

Mike Lawrence 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. Principal Engineer, QA Review, API 653 Aboveground Storage Tank Inspector No. 21992

APPENDIX A

TANK INSPECTION DATA SHEET

AND EVALUATION ITEMS

Tank 59 – API 653 Inspection

Appendix A, Page 1

EEI Project No. 8537

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Eielson AFB, Alaska Tank No. 59

Facility No. 6381 Inspection Date(s): August 22 - 26, 2015

Tank Type: Vertical AST Type of Inspection: Internal & External w/ Suitability for Service Evaluation

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 1998.

Diameter: 93’-0” Shell Height: 51'-2 ½”

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

Gross Capacity / Nominal Capacity: 49,406 bbl / 55,000 bbl Design Liquid Level / Safe Fill Height: 44 feet 4 inches (nameplate) / 40 feet 10 3/8 inches (from facility)

GPS Latitude & Longitude: 64 Deg 39’ 18.55” N, 147 Deg 02’ 46.05” W (Source – Google Earth) Foundation Configuration: Concrete ringwall (Note the ringwall by covered in ballast)

Shell Configuration: Butt Welded with 7 courses Roof: Fixed roof, truss supported with no columns.

Cathodic Protection: Not present Still Wells: 8 inch for ENRAF ATG displacer and manual gauging and 8 inch for temperature probe Last Inspection (Type, Date): In-service, 2011

Last Coated Internally (Product): Unknown, 1998 Last Coated Externally (Product): Unknown, Unknown

INSPECTION RESULTS

Can tank return to service? Yes

Deficiencies identified as mandatory repairs: No 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): In-Service: August 2020 (5 Years) Out-of-Service: August 2025 (10 Years)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Not Available

Appendix A, Page 2

EEI Project No. 8537

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

INTERNAL FLOATING ROOF

COATINGS

APPURTENANCES

PIPING

Appendix A, Page 3

EEI Project No. 8537

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

FOUNDATION

Type The tank bears on a concrete ringwall. The ringwall is not visible. As part of repair project which installed the double bottom, the flexible membrane liner was attached to the tank deadshell. After the membrane liner was attached to the deadshell, ballast was brought in to raise the surrounding grade.

Levelness Tank 59 is relatively level. The maximum measured differential between max and min elevations is 0.10 feet.

Tank 59 passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt Tank 59 is slightly tilted. The amount of tilt is

0.66 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The bottom of the floor projection to grade level is approximately 5-inches.

Material Below Tank Floor

The material below the tank floor could not be inspected. Facility personnel report that the material below the floor is an oiled sand bed.

Drainage Around Tank Drainage around the tank appears to be adequate.

Tank Anchors The tank is not equipped with anchors. The tank is stable and not at risk of overturning or sliding due to wind or seismic loads.

Secondary Containment Tank sits within an earthen dike with a membrane liner. Gravel ballast holds the liner in place.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were observed.

Sealed at Foundation The seal between the concrete ringwall and the original floor is covered by the flexible membrane liner attached to the dead shell.

The seal between the deadshell and the bottom of the new floor is by a polysulfide sealant. The sealant was in acceptable condition.

Additional Foundation Items, Comments or Notes:

The tank is equipped with a double bottom. The double bottom was installed in 1998 by slotting the tank shell.

Appendix A, Page 4

EEI Project No. 8537

FLOOR

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type Lap welded steel floor plates, cone down with a center sump.

Annular Ring Plates Tank is not equipped with annular ring plates.

Nominal Thickness Floor consists of 5/16-inch thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.312 inch.

Interior Width See floor drawing.

Floor seam welds No relevant indications were found on the floor plate seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found no areas of concern.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, bottom side pitting/corrosion is not prevalent.

Top Side Floor Pitting/Corrosion

No top side pits or corroded areas were identified for repair.

Patch Plates No patch plates present.

Oil Canning/Flexing No significant flexing of floor plates was observed.

Edge Settlement Edge settlement was not noted.

Floor Bulges, Depressions No relevant bulges or depressions were noted.

Doubler/Striker Plates Doubler plates are present below each of the floating pan legs.

Plug Welds No plug welds were observed.

Weld Artifacts No weld artifacts were observed.

Vacuum Box Testing Vacuum box testing was not performed.

Floor Critical Zone No corrosion or deflection was observed within the critical zone.

Floor Profile The floor is cone down with one sump near the center of the tank.

Sumps The tank is equipped with a 40-inch diameter near center sump.

Leak Detection Below Floor

The tank is equipped with two standpipes for detecting liquid from the under tank floor tell-tale pipes. See main body for full description on construction of the tell-tale pipe system.

Liquid with a sheen was observed in the bottom of the pipe.

Tank 59 reportedly has recurring issues with water entering the standpipes. Refer to ‘Additional Discussion Items’ in the Main Body for additional information.

Drain the water from the standpipes and monitor for fluid accumulation as part of routine maintenance.

Cathodic Protection The tank is not equipped with a CP system.

Additional Floor Items, Comments, Notes:

None.

Appendix A, Page 5

EEI Project No. 8537

SHELL

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK SHELL

Nominal Thickness UT Thickness Coating

1st Course 0.730 inch 12.9 mils

2nd Course 0.591 inch 10.5 mils

3rd Course 0.439 inch 9.6 mils

4th Course 0.364 inch 13.6 mils

5th Course 0.262 inch 12.8 mils

6th Course 0.265 inch 9.3 mils

7th Course 0.263 inch 9.9 mils

Rim Angle 0.370 inch

Plumbness Visual observations found no noticeable out-of-plumbness.

Roundness No noticeable out-of-roundness was observed.

Dents/Buckles No significant dents or buckles requiring repairs were observed.

Banding/Peaking No significant banding or peaking was observed.

Interior Shell pitting/corrosion

No pits or significant corrosion were observed on the interior of the shell.

Exterior Shell pitting/corrosion

No pits or significant corrosion were observed on the exterior of the shell.

Insert plates Five insert plates are present on the first shell course.

Welded Patch Plates No welded patch plates were observed.

Floor Projection The floor projection extends an average of 1.65-inches beyond the tank shell. The average thickness is 0.313-inch.

Interior Shell Welds Visual inspection of the accessible interior shell welds found no indications for further inspections or examinations.

Exterior Shell Welds Visual inspection of the accessible exterior shell welds found no indications for further inspections or examinations.

Door sheet The tank is equipped with two door sheets.

The door sheets are centered on manhole-1 and manhole-2. The door sheets are 9’-6” long by 8’-0” high.

Appendix A, Page 6

EEI Project No. 8537

SHELL

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Floor-to-Shell Weld – Interior

Visual inspection of the interior floor-to-shell weld found no indications for further inspections or examinations.

Floor-to-Shell Weld – Exterior

Visual inspection of the exterior floor-to-shell weld found no indications for further inspections or examinations.

Shell Manholes The tank is equipped with three shell manholes. The two ground level manholes are 36-inch diameter and the manhole for accessing the topside of the floating pan is 30-inch diameter.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Shell Reinforcing Plates

Manway #1

(Size, Thickness, Telltale Hole)

Size: 36-inch diameter nozzle, 0.873 inch thick

(UT).

Reinforcing Plate: Tombstone shaped, 78-inches wide x 0.830-inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Water Draw

(Size, Thickness, Telltale Hole)

Size: 3-inch nozzle, 0.298 inch thick (UT).

Reinforcing Plate: Circular shaped, 12-inch diameter x 0.760 inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Low Fuel

(Size, Thickness, Telltale Hole)

Size: 4-inch nozzle, 0.337 inch thick (UT).

Reinforcing Plate: Circular shaped, 12-inch diameter x 0.761 inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Issue

(Size, Thickness, Telltale Hole)

Size: 8-inch nozzle, 0.483 inch thick (UT).

Reinforcing Plate: Tombstone shaped, 24-inches wide x 28 1/2-inches tall x 0.717-inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Manway #2

(Size, Thickness, Telltale Hole)

Size: 36-inch nozzle, 0.830 inch thick (UT).

Reinforcing Plate: Tombstone shaped, 78-inches wide x 0.830-inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Low-Low Alarm

(Size, Thickness, Telltale Hole)

Size: 2-inch nozzle, 0.219 inch thick (UT).

The low level nozzle is not equipped with a reinforcing plate. Reinforcing plates are not required on nozzles 2-inch diameter and smaller.

Appendix A, Page 7

EEI Project No. 8537

SHELL

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Low Alarm

(Size, Thickness, Telltale Hole)

Size: 2-inch nozzle, 0.219 inch thick (UT).

The low level nozzle is not equipped with a reinforcing plate. Reinforcing plates are not required on nozzles 2-inch diameter and smaller.

Manway #3

(Size, Thickness, Telltale Hole)

Size: 30-inch nozzle, 0.791 inch thick (UT).

Reinforcing Plate: Diamond shaped, 79-inches wide x 0.830-inch thick (UT).

A telltale hole is present and open.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Shell Vents The tank is not equipped with shell vents.

Overflow Ports Tank is equipped with 2 overflow ports in the 6th shell course. The overflow port openings are approximately 43” long by 10” tall.

Wind Girders and Shell Stiffeners (Size & Elevation)

The tank is equipped with 47 vertical shell stiffeners on the 6th/7th shell courses. They are 8” X 4” structural tees.

Tank Nameplate Data (Complete as Possible):

Repaired / Altered to API 653 2nd Edition, Addendum Dec. 96

Original Standard: API 650 5th Edition.

Altered by: Morse Constr. Group Inc.

Rockford Corporation

Morse Job No.: 2230-E1-5807

Shell Course Material: Inserts A131CS

Tank No.: 59

Nominal Diameter: 93’-0”

Nominal Height: 51’-2 ½”

Specific Gravity: JP-8

Original Construction Date: 1973

Year Altered: 1998

Liquid Level Max: 44’-4”

Capacity: 2,260,763 Gallons

Additional Shell Items, Comments or Notes: The tank shell is equipped with seven ¾-inch abandoned sampling ports with plugs.

Appendix A, Page 8

EEI Project No. 8537

ROOF

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK ROOF

Type Fixed roof, truss supported with no columns.

The roof is cone up.

Roof Plate Thickness The roof consists of 3/16th inch (0.1875) thick roof plates. Average measured thickness is

0.199 inch (UT).

Roof Joints Visual inspection from below the roof found no indications of leakage.

Roof Topside Pitting/corrosion

No significant pitting or corrosion was identified on the topside of the roof.

Roof Topside Condition No major dents or bulges identified. Water ponding was not identified.

Roof Welds Visual inspection of the topside roof welds found no indications that require further evaluation.

Frangible Joint (Size/Condition)

The rim angle to roof plate joint meets the definition of a frangible joint.

Roof Vents (Size & Type) There is one 24 inch diameter atmospheric vent located at the center of the roof.

The tank is equipped with four perimeter vents. The vent openings are 43” long by 10” wide. The openings are equipped with screens which are in acceptable condition.

Roof Manways The tank is not equipped with a roof manway.

Construction Hatch The roof is not equipped with a construction hatch.

Roof Nozzles 8-Inch for ENRAF ATG

10-Inch for ENRAF ATG temperature probe

1 ½-Inch for tape gauge penetration

Handrails The roof of the tank is equipped with a perimeter handrail and includes a kick plate.

Roof Access from the Ground

Roof access is via a spiral stair that is supported from the shell.

Roof Access to Adjacent Tank

There is no roof access to adjacent tanks.

Roof Framing/Roof Underside Condition

Visual inspection of the underside of the roof from the floating roof found no indication of leaks and no areas of significant corrosion or other degradation.

Inspection Hatches The roof is equipped with three 2-foot square inspection hatches used to inspect the seal of the floating pan.

One of the inspection hatches is missing a handle. Recommend providing a handle.

Appendix A, Page 9

EEI Project No. 8537

ROOF

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Interior Columns No interior columns. The roof is truss supported.

SEE TANK APPURTENANCES FOR ATG, GAUGING, LEVEL ALARMS, ETC.

Additional Roof Items, Comments or Notes:

Appendix A, Page 10

EEI Project No. 8537

INTERNAL FLOATING ROOF

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Type Tank is equipped with single wall carbon steel floating roof.

Material Type Carbon steel, 3/16-inch thickness nominal.

Roof Bulges/Depressions Flexing of the floating roof was observed however it is typical of single wall carbon steel construction and is not of concern.

Roof Joints Visual inspection of the joints found no relevant indications for further inspection or examination.

Primary Seal Type (Lower) The floating roof is equipped with a wiper seal.

One tear was identified on the wiper seal fabric. Recommend repairing the tear.

Secondary Seal Type (Upper) The floating roof is not equipped with a secondary seal.

Vacuum Breaker/Pressure Relief Floating pan is equipped with three vacuum breaker/pressure relief vents.

Striker plates are not present below the vacuum breaker/pressure relief vents. Recommend providing striker plates.

Access to/from Floating Roof The topside of the floating roof is accessed by a shell manway. Access to the manway is via the shell spiral staircase. There is no roof access.

Shell MH Access Above Roof The tank is equipped with a shell access manway above the floating pan.

Interior Access Above Roof There is one 24-inch diameter manway on the floating roof.

Leg Supports The floating roof is equipped with 27 fixed legs (2-inch diameter carbon steel pipe). The legs are equipped with carbon steel striker plates below the legs welded to the tank floor. The legs are not adjustable.

Note that the legs are not equipped with mouse-holes; the legs are entirely seal welded. If any future hot work is performed on the legs recommend confirming no fuel is trapped within the floating pan legs.

Penetrations The seals at the gauge tube penetrations have failed.

Recommend replacing the gauge tube penetration seals.

Anti-Rotation Method The tank is equipped with four anti-rotation cables.

Two of the anti-rotation cable seal plugs at the floating roof interface are not sitting properly. Recommend re-sitting the plugs.

Foam Dam Floating pan is not equipped with a perimeter foam dam.

Appendix A, Page 11

EEI Project No. 8537

INTERNAL FLOATING ROOF

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Roof Grounding The tank is equipped with two ground cables. The ground cables consists of two pieces of steel cable in a plastic sheathing. At the joint between the two cable pieces the plastic sheathing was not removed. The ground cables are thus considered non continuous and inadequate

Recommend replacing the grounding cables with a cable composed of a single wire.

Additional Internal Floating Roof Items, Comments or Notes:

Appendix A, Page 12

EEI Project No. 8537

COATINGS

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Exterior Coatings

Shell

Type/age Unknown / 1998 The specifications for the 1998 repair project specified the following for exterior coatings:

Primer: Epoxy polyamide, zinc rich primer, formula 159 of MIL-P-24441

Intermediate Coat: Epoxy polyamide, No. 50 gray intermediate coat, formula 157 of MIL-P-24441

Topcoat: Polyurethane coating topcoat of MIL-C-85285, Type II, buff (color 7 DC 4 or equivalent to match adjacent tanks)

General Condition In general, the exterior coating is in good condition with good adherence. Corrosion and coating failure was observed at random locations on the shell, shell nozzles, and shell valves. The underside of the floor projection and the deadshell are not coated.

Remove the coating from the affected areas, clean and recoat.

Recommend providing surface preparation and coating the underside of the floor projection and the deadshell.

Nominal Thickness The average thickness of the shell coating is

11.2 mils; with a maximum thickness of 16.0 mils and a minimum thickness of 5.8 mils.

Lead and Chromate Testing Not performed.

Roof

Type/age Unknown / 1998 See ‘Shell Exterior Coatings’ for exterior coating specification.

General Condition In general, the exterior roof coating is in good condition with good adherence.

Corrosion and coating failure was observed at random locations on the roof plates, roof perimeter hand railing, and roof appurtenances.

The non-slip surface on the roof has degraded.

Remove the coating from the affected areas, clean and recoat.

Recommend replacing the non-slip surface.

Nominal Thickness The average thickness of the roof coating is

14.9 mils; with a maximum thickness of 22.1 mils and a minimum thickness of 9.9 mils.

Interior Coatings

Floor

Type/age Unknown / 1998 The specifications for the 1998 repair project specified the following for interior coatings:

Primer: Epoxy-polyamide, green

Appendix A, Page 13

EEI Project No. 8537

COATINGS

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

primer, formula 150 of MIL-P-24441

Intermediate Coat: Epoxy-polyamide, haze gray intermediate coat, Formula 151 of MIL-P-24441

Top Coat: Epoxy-polyamide, white top coat, formula 152 of MIL-P-24441

General Condition The interior floor coating is generally in good condition. Approximately 10 square feet of scattered coating failure was observed on the floor.

Remove the coating from the affected areas, clean and recoat.

Nominal Thickness The average thickness of the floor coating is

17.5 mils; with a maximum thickness of 32.9 mils and a minimum thickness of 10.2 mils.

Lead and Chromate Testing Not performed.

Shell

Type/age Unknown / 1998 See ‘Floor Interior Coatings’ for interior coating specification.

General Condition In general, the shell coating is in good condition with good adherence. Only the bottom four feet of the shell are coated.

Lead and Chromate Testing Not Performed.

Floating Roof The topside and bottom side of the floating roof are fully coated.

See ‘Floor Interior Coatings’ for interior coating specification.

Type/age Unknown.

General Condition – Roof and Structure

In general, the underside of the floating roof is in good condition. Large scale coating failure was identified on the topside of the floating roof (approximately 50 square feet).

Remove the coating from the affected areas, clean and recoat.

Additional Coating Items, Comments or Notes:

Appendix A, Page 14

EEI Project No. 8537

APPURTENANCES

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

APPURTENANCES

Float Gauge Tank is equipped with a Varec tape gauge.

ATG (Automatic Tank Gauging) or RTG (Remote Tank Gauging) System

Tank is equipped with an ENRAF ATG gauging system.

HI/HI-HI Level Alarms The tank is equipped with Magnetrol high and high-high level alarm float switches.

Low/Low-Low Level Alarms The tank is equipped with Magnetrol low and low-low level alarm float switches.

Independent Level Alarms The Magnetrol floats and ENRAF ATG system are independent from each other.

High Level Shut-off Valve Float Tank 59 is equipped with a high level shut-off valve. The float for the valve is located on the spiral stair railing at the 6th shell course.

Tank Grounding The tank is equipped with four ground wires.

Datum Plate on Floor The 8-inch gauge tube for the temperature probe is equipped with a datum plate. The tank cannot be manually gauged at this location due to the configuration of the roof nozzles.

See report for further gauge tube commentary.

Temperature Probe The tank is equipped with a temperature probe which is connected to the ENRAF ATG system.

Gauge Tube – ATG The probe for the ATG is located within an 8 inch gauge tube. The tank is additionally equipped with an 8-inch gauge tube for the temperature probe.

See report for further gauge tube commentary.

Gauge Tube – Sampling/Testing/Hand Gauging

Gauging and sampling are performed through the ATG probe gauge tube.

See report for further gauge tube commentary.

Fire Suppression System The tank is not equipped with a fire suppression system.

Product Recovery Tank (PRT) The tank is equipped with a product saver tank.

Additional Appurtenance Items, Comments or Notes:

Appendix A, Page 15

EEI Project No. 8537

PIPING

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

PIPING

Issue

Interior Piping Size: 8-inch nozzle, 0.510 inch thick (UT).

The interior issue piping extends inward from the shell to the sump.

The interior issue piping is not equipped with an anti-vortex plate.

Recommend providing an anti-vortex plate.

Exterior Piping 8-inch diameter.

Valve (Type/Condition) Valve: 8-inch General Twin Seal steel double block and bleed valve.

Body Cavity Relief: Valve has manual body cavity relief.

Pressure Relief Piping The pressure relief piping includes two ¼-turn ball valves and a pressure relief valve set at 125 psig.

Facility personnel reported the 1-inch ball valves and the 1-inch pressure relief valve leak. Recommend replacing the valves.

Low Fuel

Interior Piping Size: 4-inch nozzle, 0.332 inch thick (UT).

The interior low fuel piping consists of 4-inch diameter pipe extending inward from the shell to the sump.

Exterior Piping 4-inch diameter.

Valve (Type/Condition) Valve: 4-inch General Twin Seal steel double block and bleed valve.

The valve is equipped body cavity relief.

Pressure Relief Piping The pipe on the ‘pipeline side’ of the valve relieves back to the tank through the TSV loop around the issue line.

Water Draw-Off

Interior Piping Size: 3-inch at shell, 0.299 inch thick

(UT)

The interior water draw-off piping consists of an 8 inch section of 3-inch pipe near the shell. The pipe reduces to 1 ½-inch and extends into the near-center sump.

Exterior Piping 3-inch diameter.

Valve (Type/Condition) Valve: 3-inch steel double block and bleed valve.

Valve has LRDTR.

Fill

Appendix A, Page 16

EEI Project No. 8537

PIPING

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Interior Piping Size: 8-inch nozzle, 0.495 inch thick (UT).

The interior fill piping extends inward from the shell with a 15 inch x 48 inch tapered diffuser on the end.

Exterior Piping 8-inch diameter.

High Level…