EXWC REPORT 558 TANK Colts Neck NJ.pdf

Distribution authorized to the DoD and U.S. DoD contractors only for administrative/operational purposes; June 2021. Other requests shall be referred to NAVFAC EXWC.

ENGINEERING AND EXPEDITIONARY WARFARE CENTER

Port Hueneme, California 93043-4370

Contractor Report

CR-NAVFAC EXWC-CIOFP-2129

2021 WATER TANK INSPECTION AND ASSESSMENT AT

NAVAL WEAPONS STATION EARLE COLTS NECK, NEW

JERSEY

By

TANK INDUSTRY CONSULTANTS

June 2021

CUI

CUI CR-NAVFAC EXWC-CIOFP-2129

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i

WATER TANK INSPECTIONS AND ASSESSMENTS

NAVAL WEAPONS STATION EARLE COLTS NECK, NEW JERSEY

EXECUTIVE SUMMARY

This report was prepared as part of the Water Tank Inspection Program administered by the Naval Facilities Engineering and Expeditionary Warfare Center (NAVFAC EXWC).

This program provides safety, sanitary, and structural inspection for water tank facilities.

All of these services, including this report, were provided by Tank Industry Consultants (TIC), under the responsible charge of Gregory R. “Chip” Stein, P.E., in accordance with Contract No. N39430-16-D-1815.

One tank was evaluated by Tank Industry Consultants in June 2021. Tank 558 is a ground-level welded steel tank located at the Naval Weapons Station Earle in Colts Neck, New Jersey.

The purpose of this report is to present the findings of the comprehensive inspections and to make recommendations for the repair, recoating, structural condition, and maintenance of the tanks, including budgetary estimates to perform repair work. The following is a summary of inspection findings and identified deficiencies that should be rectified for full compliance with industry standards. Organizations and standards cited throughout the report are: American National Standards Institute (ANSI), American Petroleum Institute (API), American Water Works Association (AWWA), American Concrete Institute (ACI), American Society of Civil Engineers (ASCE), Occupational Safety and Health Administration (OSHA), and The Society for Protective Coatings

(SSPC).

Tank 558

Tank 558 is a ground-level welded steel tank storing 300,000 gallons of non-potable water used exclusively for the purposes of fire protection for the Naval Weapons Station Earle in Colts Neck, New Jersey.

This tank received a structural condition rating of 83.

The coating on the exterior of the tank appears to be in fair to poor overall condition as corrosion is located on several areas of the roof and shell. Tank Industry Consultants recommends the exterior should be recoated within the next 2 to 3 years. The interior surfaces should be drained and inspected before the rehabilitation of the tank. The interior coating appears to be in fair to poor overall condition as corrosion is located on areas of the roof, support structure, and shell. Tank Industry Consultants recommends the interior should be recoated within the next 2 to 3 years.

ii

OSHA and Safety-Related Deficiencies:

the valve vault was not locked prior to or after the field evaluation, the electrical outlets at the water level indicating device equipment on the roof are not equipped with ground fault interrupt circuits, the size of the shell manhole is too small (AWWA D100-11 Sec. 7.4.4), the tank is equipped with only one shell manhole (AWWA D100-11 Sec. 7.4.4), the exterior shell ladder is not equipped with a vandal deterrent, the roof safety railing access opening is not equipped with a self-closing gate (29

CFR 1910.28(b)(3)(iv)), and the gap between the roof safety railing toe bar and the roof is too large (29 CFR

1910.29(k)(1)(iii)).

It is recommended that these deficiencies be rectified to be in compliance with OSHA and safety-related standards.

Operational and AWWA Deficiencies:

the overflow pipe discharges near the top of the shell which allows the potential of ice-formation of the effluent on the shell during freezing weather, the projection of the stub overflow pipe from the shell is too small (AWWA D100-11

Sec. 7.3), the roof manhole was not locked prior to or after the field evaluation (AWWA D100-

11 Sec. 7.4.3), and the roof vent is not clog-resistant (AWWA D100-11 Sec. 7.5).

These deficiencies should be corrected.

If the work is not performed within the next 2 to 3 years, the structure should be reevaluated prior to the preparation of specifications and the solicitation of bids. Proper maintenance after completing the recommendations listed in this report would include periodic washouts and evaluations approximately every 3 to 5 years.

v

WATER TANK

INSPECTIONS AND ASSESSMENTS AT

NAVAL WEAPONS STATION EARLE COLTS NECK, NEW JERSEY

TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................ 1-1

1.1 BACKGROUND/OBJECTIVES ............................................................................ 1-1

1.2 INSPECTION BRIEFINGS ................................................................................... 1-2

2. ACTIVITY DESCRIPTION .......................................................................................... 2-1

2.1 TANKS INSPECTED ........................................................................................... 2-1

3. TANKS INSPECTED .................................................................................................. 3-1

3.1 TANK 558 ............................................................................................................ 3.1-1

3.1.1 Description of the Facility ............................................................................... 3.1-1

3.1.2 Observed Conditions ...................................................................................... 3.1-3

3.1.3 Comparison of Previous Inspection Results ................................................... 3.1-37

3.1.4 Structural Condition Assessment.................................................................... 3.1-37

3.1.5 Recommendations .......................................................................................... 3.1-38

3.2 CLOSURE ........................................................................................................... 3.2-1

APPENDIX A – KEY PERSONNEL ............................................................................... A-1

APPENDIX B – INSPECTION PROCEDURES ............................................................. B-1

APPENDIX C – STRUCTURAL DATA .......................................................................... C-1

APPENDIX D – PERTINENT BACKGROUND INFORMATION .................................... D-1

APPENDIX E – SUBSTANTIATION OF COST ESTIMATES ........................................ E-1

APPENDIX F – COST ESTIMATES SUMMARY ........................................................... F-1

APPENDIX G - REFERENCES ..................................................................................... G-1 vi

LIST OF FIGURES

Figure No. Title Page No.

FIG. 3.1-1 Tank 558 .............................................................................................. 3.1-2 vii

LIST OF PHOTOGRAPHS

Photo 3.1-1 Tank 558 and site ............................................................................... 3.1-8

Photo 3.1-2 Tank 558 and site ............................................................................... 3.1-8

Photo 3.1-3 Building adjacent to the tank .............................................................. 3.1-9

Photo 3.1-4 Fenced building and antenna tower on site ........................................ 3.1-9

Photo 3.1-5 Valve vault access ............................................................................ 3.1-10

Photo 3.1-6 Valve vault piping covered with jacketed insulation and corrosion on uncovered piping ......................................................................... 3.1-10

Photo 3.1-7 Valve vault piping covered with jacketed insulation, corrosion on uncovered piping, and water on the vault floor ............................ 3.1-11

Photo 3.1-8 Partially buried foundation, and corrosion on bottom plates and stiffener ............................................................................................. 3.1-11

Photo 3.1-9 Minor corrosion and metal loss along bottom plates and stiffener .... 3.1-12

Photo 3.1-10 Capped pipe projecting from the shell between the two bottom plates ................................................................................................ 3.1-12

Photo 3.1-11 Pipe covered with jacketed insulation extending from building and penetrating the tank shell .......................................................... 3.1-13

Photo 3.1-12 Pipe equipped with a valve and covered with jacketed insulation penetrating the tank shell ................................................................. 3.1-13

Photo 3.1-13 Pipe covered with jacketed insulation and wiring extending from the valve vault ........................................................................................ 3.1-14

Photo 3.1-14 Wiring extending from the valve vault connected to a threaded and plugged coupling in the tank shell.............................................. 3.1-14

Photo 3.1-15 Pipe equipped with a valve and covered with jacketed insulation penetrating near the bottom of the shell, shell manhole, and pipe bollards ............................................................................................. 3.1-15

Photo 3.1-16 Shell manhole ................................................................................... 3.1-15

Photo 3.1-17 Tank information decal on the shell manhole cover ......................... 3.1-16

Photo 3.1-18 Welded steel insert plate in the shell around the shell manhole and pipe penetrating near the bottom of the shell ................................... 3.1-16

Photo 3.1-19 Threaded and plugged coupling in the shell ..................................... 3.1-17

Photo 3.1-20 Unused studs and coating failure, corrosion, and rust staining on area of previous cabinet on the shell exterior ................................... 3.1-17

Photo 3.1-21 Unused stud remains and coating failure, corrosion, and rust staining on area of previous cabinet bracket on the shell exterior .... 3.1-18

Photo 3.1-22 Unused stud remains and coating failure, corrosion, and rust staining on areas of previous cabinet brackets on the shell exterior 3.1-18 viii

LIST OF PHOTOGRAPHS (CONT'D)

Photo No. Description ................................................................................. Page No.

Photo 3.1-23 Conduit and brackets on the shell exterior ....................................... 3.1-19

Photo 3.1-24 Conduit extending up the shell and brackets on the shell exterior .... 3.1-19

Photo 3.1-25 Conduits extending up the shell adjacent to the exterior shell ladder ............................................................................................... 3.1-20

Photo 3.1-26 Corrosion on conduit bracket ............................................................ 3.1-20

Photo 3.1-27 Stub overflow pipe equipped with perforated plate screening .......... 3.1-21

Photo 3.1-28 Corrosion and rust staining on the exterior shell ladder.................... 3.1-21

Photo 3.1-29 Corrosion on exterior shell ladder rungs and brackets ..................... 3.1-22

Photo 3.1-30 Corrosion and rust staining on the exterior shell ladder.................... 3.1-22

Photo 3.1-31 Exterior shell ladder and safety cage................................................ 3.1-23

Photo 3.1-32 Roof access and safety railing .......................................................... 3.1-23

Photo 3.1-33 Electrical cabinet attached to the roof safety railing and water level indicating device within uncovered enclosure on the roof ........ 3.1-24

Photo 3.1-34 Capped water level indicating device equipment equipped with electrical outlets within uncovered enclosure on the roof ................. 3.1-24

Photo 3.1-35 Wiring penetrating circular hand hole cover plate on the roof ........... 3.1-25

Photo 3.1-36 Corrosion on the interior of the roof manhole cover and curb ........... 3.1-25

Photo 3.1-37 Corrosion on the roof manhole curb and wiring penetrating the curb 3.1-26

Photo 3.1-38 Wiring extending from conduit junction box penetrating circular hand hole cover plate on the roof ..................................................... 3.1-26

Photo 3.1-39 Conduit extending across the roof exterior ....................................... 3.1-27

Photo 3.1-40 Wiring extending from conduit junction box penetrating circular hand hole cover plate on the roof ..................................................... 3.1-27

Photo 3.1-41 Corrosion on areas of the roof exterior ............................................. 3.1-28

Photo 3.1-42 Corrosion on areas of the roof exterior ............................................. 3.1-28

Photo 3.1-43 Corrosion on areas of the roof exterior ............................................. 3.1-29

Photo 3.1-44 Sealant around bolt in the roof ......................................................... 3.1-29

Photo 3.1-45 Sealant around rusty stud in the roof ................................................ 3.1-30

Photo 3.1-46 Corrosion on bolted rectangular plate on the roof exterior ................ 3.1-30

Photo 3.1-47 Corrosion on threaded and plugged coupling on the roof ................. 3.1-31

Photo 3.1-48 Roof vent .......................................................................................... 3.1-31

Photo 3.1-49 Rust staining on the roof vent neck and corrosion along stiffener .... 3.1-32

Photo 3.1-50 Widespread corrosion on roof vent perforated plated screening ...... 3.1-32 ix

LIST OF PHOTOGRAPHS (CONT'D)

Photo No. Description ................................................................................. Page No.

Photo 3.1-51 Roof interior and support structure ................................................... 3.1-33

Photo 3.1-52 Spots of corrosion on the center column .......................................... 3.1-33

Photo 3.1-53 Lugs on the center column ............................................................... 3.1-34

Photo 3.1-54 Roof interior and support structure ................................................... 3.1-34

Photo 3.1-55 Float equipment inside the tank ........................................................ 3.1-35

Photo 3.1-56 Pitting in shell interior ....................................................................... 3.1-35

Photo 3.1-57 Dirt on the shell interior ..................................................................... 3.1-36 x

TABLES

Table No. Title Page No.

TABLE 2-1 Tanks Inspected ................................................................................ 2-1

TABLE C.1-1 Tank 558 Exterior Coating and Metal Condition ............................ C.1-4

TABLE C.1-2 Tank 558 Evaluation of Steel Ground Water Tanks....................... C.1-5

TABLE C.1-3 Tank 558 Summary Condition Evaluation Standards ...................C.1-16

TABLE D-1 Heavy Metal Test Results from Tank 558 ......................................... D-2

1-1

1. INTRODUCTION

1.1 BACKGROUND/OBJECTIVES

This report was prepared as part of the Water Tank Inspection Program administered by the Naval Facilities Engineering and Expeditionary Warfare Center, NAVFAC EXWC.

This program provides inspection, assessment, repair recommendations, and estimates of repair costs for water tank facilities. All of these services, including this report, were provided by Tank Industry Consultants, under the responsible charge of

Gregory R. “Chip” Stein, P.E., in accordance with Contract No. N39430-16-D-1815.

One tank was evaluated by Tank Industry Consultants on June 21, 2021 under the responsible charge of Chad D. Mitchell, NACE-Certified Coating Inspector, Level 2

(#56876). Additional key personnel involved with the evaluation and report are listed in

Appendix A.

Tank 558 is a ground-level welded steel tank located at the Naval Weapons

Station Earle in Colts Neck, New Jersey.

1-2

INSPECTION BRIEFINGS

The following individuals were present at the inspection briefing and/or the field evaluations:

G. Blair Clark

NAVFAC EXWC

(202) 433-5177 gordon.b.clark1@navy.mil

Ryan W. Christensen NWS Earle PWD Utilities

(732) 866-2863

Chad D. Mitchell Tank Industry Consultants

(317) 271-3100

Jamie L. Stewart Tank Industry Consultants

(317) 271-3100

2-1

2. ACTIVITY DESCRIPTION

TABLE 2-1

TANKS INSPECTED

Tank No. Capacity

(Gallons)

Type Dimensions Water

Purpose

NFA

558 300,000 Ground-Level Welded Steel

Approx. 50 ft (15.2 m) diameter, Approx. 22 ft (6.7 m) shell height

Non-Potable Fire Protection

NFA100000927973

3-1

3. TANKS INSPECTED

The following sections contain discussion of observations from the field evaluations and recommendations for rehabilitation of the tanks. Each section is divided into the following sub-sections

1. Description of the Facilities

2. Observed Conditions

3. Comparison of Previous Inspection Results

4. Structural Condition Assessment

5. Recommendations

The inspection procedure is presented in Appendix B and structural data appears in Appendix C.

3.1-1

3.1 TANK 558

Tank 558 is located at the Naval Weapons Station Earle in Colts Neck, New

Jersey, and stores non-potable water used exclusively for the purposes of fire protection.

3.1.1 Description of the Facility

Tank 558 is a 300,000 gallon welded steel ground storage tank located at the

Naval Weapons Station Earle in Colts Neck, New Jersey. According to information on the tank information stencil, the tank has a capacity of 300,000 gallons. Measurements taken during the field evaluation indicate the tank is approximately 50 ft (15.2 m) in diameter and has a shell height of approximately 22 ft (6.7 m). (See Figure 3.1-1)

3.1-2

TANK 558

Distribution limited to the DoD and U.S. DoD contractors only;

administrative/operational use June 2021.

Contract No.

N39430-16-D-1815

NAVAL FACILITIES ENGINEERING

COMMAND

ENGINEERING AND EXPEDITIONARY

WARFARE CENTER

Fig. No. 3.1-1

STUB

OVERFLOW PIPE

BUILDING

ROOF SAFETY RAILING

SHELL

MANHOLE

PIPING

EXTERIOR

LADDER &

SAFETY

CAGE

3.1.2 Observed Conditions

Tank 558 is located at the Naval Weapons Station Earle in Colts Neck, New

Jersey (See photos 3.1-1 to 3.1-4). A fenced storage yard and open areas are adjacent to the tank site. The nearest overhead power lines are located west of the tank on the site.

The tank site is covered with well-maintained grass and is flat. The immediate tank site is not fenced. A building and antenna tower enclosed within a chain link fence topped with barbed wire are located west of the tank on the site (See photo 3.1-4).

Building 559 is located south of the tank on the site (See photo 3.1-3).

A valve vault is located south of the tank on the site (See photos 3.1-5 to 3.1-7).

Areas of the valve vault extend below the tank and Building 559. The access into the valve vault was not locked prior to or after the field evaluation. Several pipes inside the valve vault are covered with jacketed insulation which restricted their evaluation.

Widespread corrosion is present on the uncovered piping inside the valve vault (See photos 3.1-6 and 3.1-7). The vault is not equipped with a sump or pump, and water is present on the vault floor. The valve vault was not locked prior to or after the field evaluation which is a safety-related deficiency.

The tank rests on a concrete foundation (See photo 3.1-8). The foundation does not meet the AWWA recommended minimum projection of 6 in. (152 mm) and is mostly buried. The visible areas of the foundation appear to be in adequate condition. A white colored coating is visible on the foundation. No grout or sealant is present between the foundation and bottom plate, and gaps are located between the foundation and bottom plate (See photo 3.1-9).

The floor of the tank may have been previously replaced as the tank is equipped with two bottom plates (See photos 3.1-8 to 3.1-10). The upper bottom plate is located approximately 4 in. (102 mm) above the lower bottom plate.

Corrosion is present on random areas along the upper bottom plate and minor metal loss is present along the lower bottom plate. A flat bar stiffener is located just below the upper bottom plate and is seam welded along the top side only. Grass clippings and leaves are located on the bottom plates.

3.1-3

3.1-4

The shell’s contour appears to be in adequate condition. The coating on the exterior shell is in fair overall condition as corrosion is present on areas of the shell (See photos 3.1-20 and 3.1-22). The coating has chalked, and drips, sags, and debris are present in the coating. Mildew is located on areas of the shell. The exterior shell coating has fair adhesion to the underlying coating. Several unused stud remains are located on the south side of the shell, and coating failure, corrosion, and rust staining are present on the areas where cabinets were previously located (See photos 3.1-20 to

3.1-22). An approximately 5 ft 6 in. (1.7 m) x 9 ft 1 in. (2.7 m) welded steel insert plate with rounded corners is located in the shell around the shell manhole and pipe penetrating near the bottom of the shell (See photo 3.1-18). Two threaded and plugged couplings are located on the south side of the shell (See photo 3.1-19). Another threaded and plugged coupling is located on the south side of the shell, and a wire extends from the valve vault and connects to this coupling (See photos 3.1-13 and 3.1-

14). Two electrical conduits extend along the shell between the two bottom plates on the south side. Three electrical conduits extend up the shell on the southwest side adjacent to the exterior shell ladder, and corrosion is present on the conduit brackets

(See photos 3.1-25 and 3.1-26). Another conduit extends up the shell on the south side

(See photos 3.1-23 and 3.1-24).

Capped water level indicating device equipment penetrates near the edge of the roof and is located within an uncovered enclosure (See photo 3.1-34). The device is equipped with electrical outlets which do not include ground fault interrupt circuits. Four capped pipes project from the shell between the two bottom plates (See photo 3.1-10).

A pipe equipped with a valve and covered with jacketed insulation extends from the valve vault, along the site, and penetrates near the bottom of the shell on the west side

(See photos 3.1-13 and 3.1-15). Two pipe bollards are adjacent to this pipe penetration. A pipe equipped with a valve and covered with jacketed insulation extends from Building 559 and penetrates the tank shell (See photos 3.1-11 and 3.1-12). The shell plate surrounding the pipe penetration is equipped with a reinforcing plate, and an unplugged weep hole is located in the reinforcing plate (See photo 3.1-12). The electrical outlets at the water level indicating device equipment on the roof are not equipped with ground fault interrupt circuits which is a safety deficiency.

3.1-5

The tank is equipped with one flanged and bolted circular shell manhole located on the west side of the tank (See photo 3.1-16). A tank information decal and two handles are located on the cover of the shell manhole (See photo 3.1-17). The cover for the flanged and bolted manhole is not equipped with a hinged support on the tank exterior. The shell plate surrounding the manhole is not equipped with a reinforcing plate. Spots of coating failure, corrosion, and rust staining are located around the shell manhole bolts. The shell manhole bolts and nuts are not equipped with washers.

Safety-related and AWWA deficiencies include: (1) the 24 in. (610 mm) diameter manhole does not meet the minimum required 30 in. (762 mm) diameter size (AWWA

D100-11 Sec. 7.4.4), and (2) the tank is equipped with only one shell manhole (AWWA

D100-11 Sec. 7.4.4).

The stub overflow pipe exits near the top of the shell and immediately discharges

(See photo 3.1-27). The discharge end of the overflow pipe is equipped with a perforated plate screening. No significant coating failure or corrosion are present on the overflow pipe. AWWA and operational deficiencies include: (1) the overflow pipe discharges near the top of the shell which allows the potential of ice-formation of the effluent on the shell during freezing weather, and (2) the 3 in. (76 mm) projection of the overflow pipe from the shell does not meet the minimum required 12 in. (305 mm) projection (AWWA D100-11 Sec. 7.3).

An exterior ladder provides access from the ground to the tank roof (See photos

3.1-28 to 3.1-32). The ladder is not equipped with a safe-climbing device; however, OSHA does not require safe-climbing devices on ladders less than 24 ft (610 mm) high.

The ladder is equipped with a safety cage constructed of welded and bolted flat bar members. The base of each safety cage section is flared. The ladder is bolted to brackets which are welded to the shell. Widespread corrosion is present on the ladder rungs, rust staining is present on the ladder side rails, and corrosion is present on the brackets (See photos 3.1-29 and 3.1-30). The exterior shell ladder is not equipped with a vandal deterrent which is a safety-related deficiency.

A roof safety railing is located at the shell ladder access to the roof and adjacent to the roof manhole (See photos 3.1-32 and 3.1-33). The roof safety railing is constructed of welded angle and flat bar members. No significant coating failure or corrosion is present on the safety railing. An electrical cabinet is attached to the roof safety railing, and the mid-rail is replaced with a bracket in this area (See photo 3.1-33).

3.1-6

Wiring extends from the cabinet and penetrates a hand hole cover plate on the roof

(See photo 3.1-35). Safety-related and OSHA deficiencies include: (1) the roof safety railing access opening is not equipped with a self-closing gate (29 CFR

1910.28(b)(3)(iv)), and (2) the 1/2 in. (13 mm) gap between the roof safety railing toe bar and the roof is more than the maximum allowed 1/4 in. (6 mm) (29 CFR

1910.29(k)(1)(iii)).

The contour of the roof is adequate. The exterior roof coating appears to be in fair to poor condition as corrosion is located on several areas of the roof (See photos

3.1-41 to 3.1-43). The roof coating has chalked, and debris is present in the coating.

The roof coating has good adhesion to the underlying coating. Twenty circular hand holes and cover plates are located on the roof (See photos 3.1-38 to 3.1-40). A conduit extends across the roof, and wiring from the conduit junction boxes penetrates hand hole cover plates on the roof (See photos 3.1-38 to 3.1-40). Several unused conduit brackets are bolted to the roof. Seventeen rectangular cover plates are bolted to the roof, and corrosion is present on the plates (See photo 3.1-46). These plates are equipped with gaskets, but the gaskets have deteriorated. Several bolts are missing from these plates. Threaded and plugged couplings are located on the roof, and corrosion is present on the couplings (See photo 3.1-47). Nine studs are located in the roof, and sealant is located around the bolts (See photos 3.1-44 and 3.1-45).

The roof is equipped with one hinged-cover manhole which is welded on the exterior and interior (See photos 3.1-36 and 3.1-37). Significant corrosion is present on the interior of the roof manhole cover and along the curb. Wires penetrate the roof manhole curb. The roof manhole was not locked prior to or after the field evaluation which is a safety-related and AWWA deficiency (AWWA D100-11 Sec. 7.4.3).

A mushroom-cover vent is located near the center of the roof (See photos 3.1-48 to 3.1-50). The roof vent neck is equipped with a flat bar stiffener (See photo 3.1-49).

The roof vent is equipped with horizontally-oriented perforated plate screening, and widespread corrosion and rust staining are present on the perforated plate (See photo

3.1-50). The roof vent is not clog-resistant which is an AWWA and operational deficiency (AWWA D100-11 Sec. 7.5).

3.1-7

From the limited area observed during the ROV evaluation, the coating on the roof interior and support structure appears to be in fair overall condition as corrosion is located on areas of the roof and support structure (See photos 3.1-51 to 3.1-54). The roof interior support structure consists of radial roof rafters and a center column. The outer ends of the rafters were not visible during the ROV evaluation. The inner ends of the rafters are attached to a center hub which is located on the top of a column. The center column appears to be constructed of two channels welded together. Spots of corrosion are located on the column (See photo 3.1-52). The column base was not visible during the ROV evaluation. Lugs are located on the center column (See photo

3.1-53). Note: the lugs should not be used for rigging purposes.

From the limited area observed during the ROV evaluation, the coating on the interior shell appears to be in fair to poor condition as corrosion and pitting which had occurred prior to the previous repainting are located on areas of the shell (See photos

3.1-56 and 3.1-57). Dirt is present on the shell.

Float equipment attached to pipe brackets extending down from the roof is located on the interior of the tank (See photo 3.1-55). It was not determined if the float equipment is operating properly during the ROV evaluation.

The overflow inlet was not visible during the ROV evaluation. Cursory calculations indicate that approximately 8 in. (203 mm) would be required to provide adequate freeboard. As the overflow inlet was not visible during the ROV evaluation, it could not be determined if the existing freeboard satisfies the seismic requirements.

The interior floor surfaces were not visible during the ROV evaluation.

3.1-8

PHOTO 3.2-X PHOTO 3.1-1 Tank 558 and site.

PHOTO 3.2-X PHOTO 3.1-2 Tank 558 and site.

3.1-9

PHOTO 3.2-X PHOTO 3.1-3 Building adjacent to the tank.

PHOTO 3.2-X PHOTO 3.1-4 Fenced building and antenna tower on site.

3.1-10

PHOTO 3.2-X PHOTO 3.1-5 Valve vault access.

PHOTO 3.2-X PHOTO 3.1-6 Valve vault piping covered with jacketed insulation and corrosion on uncovered piping.

3.1-11

PHOTO 3.2-X PHOTO 3.1-7 Valve vault piping covered with jacketed insulation, corrosion on uncovered piping, and water on the vault floor.

PHOTO 3.2-X PHOTO 3.1-8 Partially buried foundation, and corrosion on bottom plates and stiffener.

3.1-12

PHOTO 3.2-X PHOTO 3.1-9 Minor corrosion and metal loss along bottom plates and stiffener. Note grass clippings and leaves on the bottom plates.

PHOTO 3.2-X PHOTO 3.1-10 Capped pipe projecting from the shell between the two bottom plates.

3.1-13

PHOTO 3.2-X PHOTO 3.1-11 Pipe covered with jacketed insulation extending from building and penetrating the tank shell.

PHOTO 3.2-X PHOTO 3.1-12 Pipe equipped with a valve and covered with jacketed insulation penetrating the tank shell. Note unplugged weep hole in the reinforcing plate.

3.1-14

PHOTO 3.2-X PHOTO 3.1-13 Pipe covered with jacketed insulation and wiring extending from the valve vault.

PHOTO 3.2-X PHOTO 3.1-14 Wiring extending from the valve vault connected to a threaded and plugged coupling in the tank shell.

3.1-15

PHOTO 3.2-X PHOTO 3.1-15 Pipe equipped with a valve and covered with jacketed insulation penetrating near the bottom of the shell, shell manhole, and pipe bollards.

PHOTO 3.2-X PHOTO 3.1-16 Shell manhole. Note tank information decal on the shell manhole cover.

3.1-16

PHOTO 3.2-X PHOTO 3.1-17 Tank information decal on the shell manhole cover.

PHOTO 3.2-X PHOTO 3.1-18 Welded steel insert plate in the shell around the shell manhole and pipe penetrating near the bottom of the shell.

3.1-17

PHOTO 3.2-X PHOTO 3.1-19 Threaded and plugged coupling in the shell.

PHOTO 3.2-X PHOTO 3.1-20 Unused studs and coating failure, corrosion, and rust staining on area of previous cabinet on the shell exterior.

3.1-18

PHOTO 3.2-X PHOTO 3.1-21 Unused stud remains and coating failure, corrosion, and rust staining on area of previous cabinet bracket on the shell exterior.

PHOTO 3.2-X PHOTO 3.1-22 Unused stud remains and coating failure, corrosion, and rust staining on areas of previous cabinet brackets on the shell exterior.

3.1-19

PHOTO 3.2-X PHOTO 3.1-23 Conduit and brackets on the shell exterior.

PHOTO 3.2-X PHOTO 3.1-24 Conduit extending up the shell and brackets on the shell exterior.

3.1-20

PHOTO 3.2-X PHOTO 3.1-25 Conduits extending up the shell adjacent to the exterior shell ladder.

PHOTO 3.2-X PHOTO 3.1-26 Corrosion on conduit bracket.

3.1-21

PHOTO 3.2-X PHOTO 3.1-27 Stub overflow pipe equipped with perforated plate screening.

PHOTO 3.2-X PHOTO 3.1-28 Corrosion and rust staining on the exterior shell ladder.

3.1-22

PHOTO 3.2-X PHOTO 3.1-29 Corrosion on exterior shell ladder rungs and brackets.

PHOTO 3.2-X PHOTO 3.1-30 Corrosion and rust staining on the exterior shell ladder.

3.1-23

PHOTO 3.2-X PHOTO 3.1-31 Exterior shell ladder and safety cage.

PHOTO 3.2-X PHOTO 3.1-32 Roof access and safety railing.

3.1-24

PHOTO 3.2-X PHOTO 3.1-33 Electrical cabinet attached to the roof safety railing and water level indicating device within uncovered enclosure on the roof.

PHOTO 3.2-X PHOTO 3.1-34 Capped water level indicating device equipment equipped with electrical outlets within uncovered enclosure on the roof.

3.1-25

PHOTO 3.2-X PHOTO 3.1-35 Wiring penetrating circular hand hole cover plate on the roof.

PHOTO 3.2-X PHOTO 3.1-36 Corrosion on the interior of the roof manhole cover and curb.

3.1-26

PHOTO 3.2-X PHOTO 3.1-37 Corrosion on the roof manhole curb and wiring penetrating the curb.

PHOTO 3.2-X PHOTO 3.1-38 Wiring extending from conduit junction box penetrating circular hand hole cover plate on the roof.

3.1-27

PHOTO 3.2-X PHOTO 3.1-39 Conduit extending across the roof exterior.

PHOTO 3.2-X PHOTO 3.1-40 Wiring extending from conduit junction box penetrating circular hand hole cover plate on the roof.

3.1-28

PHOTO 3.2-X PHOTO 3.1-41 Corrosion on areas of the roof exterior.

PHOTO 3.2-X PHOTO 3.1-42 Corrosion on areas of the roof exterior.

3.1-29

PHOTO 3.2-X PHOTO 3.1-43 Corrosion on areas of the roof exterior. Note threaded and plugged coupling and bolted rectangular plate on the roof exterior.

PHOTO 3.2-X PHOTO 3.1-44 Sealant around bolt in the roof.

3.1-30

PHOTO 3.2-X PHOTO 3.1-45 Sealant around rusty stud in the roof.

PHOTO 3.2-X PHOTO 3.1-46 Corrosion on bolted rectangular plate on the roof exterior. Note deteriorated gasket.

3.1-31

PHOTO 3.2-X PHOTO 3.1-47 Corrosion on threaded and plugged coupling on the roof.

PHOTO 3.2-X PHOTO 3.1-48 Roof vent.

3.1-32

PHOTO 3.2-X PHOTO 3.1-49 Rust staining on the roof vent neck and corrosion along stiffener.

PHOTO 3.2-X PHOTO 3.1-50 Widespread corrosion on roof vent perforated plated screening.

3.1-33

PHOTO 3.2-X PHOTO 3.1-51 Roof interior and support structure.

PHOTO 3.2-X PHOTO 3.1-52 Spots of corrosion on the center column.

3.1-34

PHOTO 3.2-X PHOTO 3.1-53 Lugs on the center column.

PHOTO 3.2-X PHOTO 3.1-54 Roof interior and support structure.

3.1-35

PHOTO 3.2-X PHOTO 3.1-55 Float equipment inside the tank.

PHOTO 3.2-X PHOTO 3.1-56 Pitting in shell interior.

3.1-36

PHOTO 3.2-X PHOTO 3.1-57 Dirt on the shell interior.

3.1-37

3.1.3 Comparison of Previous Inspection Results

No previous evaluation reports are provided.

3.1.4 Structural Condition Assessment

The conditions reported herein reflect the condition of the tank as observed on the date of the evaluation, using reasonable care in making the observations, and safety in gaining access to the tank. Should latent defects be discovered during the cleaning of the structure, they should be brought to the attention of the Navy and the Engineer.

This tank is located in a region of moderate seismic activity. This evaluation and the reporting of the condition of this tank do not warrant the structural condition of the tank or any of the original design for seismic loadings. Likewise, recommendations for this tank do not include modifications which may be required for compliance with present structural codes. It is possible the tank was erected in compliance with pre-existing industry standards which have since been replaced by more restrictive standards.

3.1-38

3.1.5 Recommendations

Foundation and Site:

Site Maintenance: The Navy should consider installing a chain link fence topped with barbed wire around the immediate tank site for improved tank and site security. The site should be regraded so that the top of the foundation projects a minimum of 6 in. (152 mm) above grade and so that proper drainage away from the foundation continues. Site maintenance should be performed with the mower discharge directed away from the base of the tank to prevent rock chips in the coating and the accumulation of grass and leaves on the bottom plates.

Foundation: When the next exterior recoating is performed, any unsound concrete should be chipped to sound material and the concrete should be brush-off blasted. Any deteriorated areas or voids found should have a bonding agent and a vinyl emollient modified concrete patching mortar applied to build up the surface to its original contour. The concrete should then be painted with a concrete sealer.

Install Sealant: When the exterior repainting is performed, a flexible polyurethane sealant should be installed between the foundation and lower bottom plate.

Valve Vault: A sump with pump should be installed inside the valve vault to eliminate the water on the vault floor. The jacketed insulation on the piping should be removed, and the piping inspected to determine its condition. The piping and valves located in the valve vault should be cleaned and painted in accordance with the interior coating recommendations at the time of the tank cleaning and coating. The exterior concrete surfaces should be cleaned to the equivalent of a brush-off blast cleaning and painted with a concrete sealer. The valve vault access should be locked at all times in order to limit liability to the Owner and to protect water system security. Freeze protection should be provided on all control piping and static water lines.

3.1-39

Exterior Surfaces:

Life of the Exterior Coating: The coating on the exterior of the tank appears to be in fair to poor overall condition as corrosion is located on several areas of the roof and shell. Tank Industry Consultants recommends the exterior should be recoated within the next 2 to 3 years.

Coating Testing: Prior to preparation of specifications for the cleaning and coating of the exterior of the tank, samples of the exterior coating system should be subjected to laboratory analysis to test for ingredients which may at that time be subject to regulations concerning their handling and disposal.

Cleaning: When the exterior is to be cleaned, all varieties of containment should be investigated. Containment of the wind-blown debris spent cleaning and paint overspray may will be required due to the proximity of the adjacent buildings.

Recommended Coating System:

Complete Cleaning and Repainting: The optimum long-life coating system presently available for this site is an zinc-polyurethane coating system, AWWA D102-17 Outside Coating System No. 6 (OCS-6). Properly formulated and applied polyurethanes have good resistance to condensation, mildew, and chipping. The polyurethanes also have excellent color and gloss retention and the longest expected service life of any of the common exterior tank coatings.

The use of zinc-primed coatings may increase the cost of exterior tank recoating.

However, this type of coating system normally eliminates the requirement of completely removing the coating system for future exterior tank recoating. The typical life of a properly applied epoxy-polyurethane coating system is approximately 15 to 20 years. These coatings also presently meet current VOC requirements.

Coating Application: The entire shell exterior should be cleaned to the equivalent of an SSPC-SP 6, Commercial Blast Cleaning and have an epoxy-primed, epoxy intermediate and polyurethane finish coating system applied. Due to the presence of mill scale, an SSPC-SP 10, Near-White Blast Cleaning will likely be required. However, care must be taken during the application of this

3.1-40 particular coating system because this coating does have poor dry-fall characteristics, and potential damage to the surrounding property must be taken into consideration. The polyurethane coatings also require close monitoring of temperature and humidity during application.

Effective Service Life: Tank Industry Consultants defines the life of a coating as the amount of time before repainting becomes necessary due to coating failure and corrosion. During the coating life the Navy should expect the coating to lose its gloss, start to chalk, show signs of weathering, and possibly some rust staining. Future touch-up may be required on isolated coating failures. If aesthetics are a concern, the Navy may have to topcoat the repainted tank prior to the end of the expected service life.

However, future topcoating would be less expensive than complete cleaning and recoating and could delay the next complete cleaning and repainting for many years.

Other Systems: With air emission volatile organic compounds (VOC) restrictions being put in place around the nation, alternative coating systems may become available which would be viable options for this tank. The Navy should review the available systems prior to preparing specifications for the recoating project.

Coating Curing: It would be more economical to paint the tank exterior at the same time the interior is painted, since the tank must be drained while the exterior is painted, and the applied coatings cure. This will also reduce mobilization and observation costs.

Rehabilitation Schedule: To obtain the lowest possible prices for the work outlined in the recommendations, the Navy should have the specifications prepared and the work bid in the spring, with the work scheduled to start in early summer, if possible.

Grinding and Bracket Removal: Any unused brackets, studs, or erection lugs should be removed prior to the exterior repainting. Any weld burrs, weld spatter, or erection scars should be ground off to provide a smooth surface for the application of the coating. This includes the unused stud remains located on the shell.

Electrical Apparatus: All unused electrical conduit, fixtures, and electrical metering equipment should be removed from the tank and tank site. All required equipment should be repaired and maintained in accordance with the National Electric

Code (NEC).

3.1-41

Level Indicating Device: The electrical outlets at the level indicating device equipment on the roof should be equipped with ground fault interrupt circuits. The proper operation of the level indicating device should be verified. If the Owner does not wish to operate or replace the level indicating device floats and wires, all associated couplings, brackets, and components should be removed from the tank. Patch plates should be welded over the openings created by the indicating device removal. The patch plates should be completely seal welded on both the interior and exterior surfaces.

Exterior Piping: The jacketed insulation on the exterior piping penetrating the tank should be removed, and the piping inspected to determine its condition. The unplugged weep hole in the reinforcing plate around the pipe penetration on the west side of the shell should be tapped and plugged.

Existing Shell Manhole: At the time of recoating and repairs, the gasket for the shell manhole should be replaced, and the bolts and nuts equipped with new galvanized washers. The existing shell manhole should be equipped with a hinged support arm located on the shell exterior.

Additional Shell Manhole: Tank Industry Consultants interprets OSHA standards as defining a water storage tank as a confined space, and as such, a second means of emergency egress and ventilation during cleaning and coating or inspection operations is required to achieve compliance with OSHA, safety-related standards, and

TIC’s recommended best practices. Tank Industry Consultants recommends that tanks have two shell manholes or similar entry/egress points (at least one of which is a minimum of 30 in. in diameter) so “Acceptable Entry Conditions” as defined in 29 CFR

1910.146 can be maintained during tank entry for evaluation, repair, cleaning, and other interior tank service activities. The availability of two entry/egresses points also provides the Owner means to meet their obligations for the safety requirements stated in 29 CFR 1910.146 (c)(8). The presence of a second shell manhole would provide an unobstructed means of entry/egresses during interior tank service activities during which hoses, cords, fans and other standard equipment are present in one of the manhole openings. AWWA Standard D100 also requires a second shell manhole.

Therefore, the tank should be equipped with a second hinged shell manhole. The additional manhole and cover should be 30 in. in diameter, should be designed in accordance with current industry and safety standards, should be equipped with a

3.1-42 hinged arm located on the shell exterior, and should be located approximately 180 degrees from the existing shell manhole.

Overflow Pipe: Stub overflow pipes result in the potential for ice formation on the exterior of a tank as well as erosion of the soil due to effluent discharge. Such icing conditions can cause damage and accelerated corrosion and metal loss rates.

Therefore, Tank Industry Consultants and the 10 State Standards recommend extending the pipe to near grade. The overflow pipe should exit the top shell ring and extend to approximately 24 in. above grade attached to the shell by welded steel brackets. The overflow pipe discharge could be equipped with a screened, counter-weighted flap gate or elastomeric check valve if desired by the Navy. The air break should be adequately sized to allow the proper functioning of the new flap gate. The overflow effluent should be directed away from the foundation using a concrete splash block and rip rap.

Exterior Ladder: A safety cage is not required on ladders with safe-climbing devices. To reduce cleaning and painting costs and future maintenance costs, and because OSHA is phasing out the use of safety cages in lieu of the installation of safe-climbing devices, the cage could be removed and a safe-climbing device installed. The exterior ladder did not include slip-resistant rungs. Slip-resistant rungs are required for all ladders constructed after March 1991 by the OSHA Construction standards and is considered to be best practice. However, slip-resistant rungs are not required by the

OSHA General Industry standards for ladders or by AWWA D100.

Vandal Deterrent: When the existing safety cage is removed, a new vandal deterrent should be installed. Installing a vandal deterrent would offer the Navy further protection from unauthorized access to the ladder and tank.

Roof Safety Railing: The roof safety railing access opening should be equipped with a self-closing gate as is now required by OSHA. The roof safety railing toe bar should be lowered such that the gap between the toe bar and the roof is less than 1/4

in. (6 mm) as required by OSHA.

Cover Plates on Roof: The missing or rusty bolts on the bolted cover plates on the roof should be replaced. The existing gaskets at the cover plates should be replaced with new ones.

3.1-43

Clog-Resistant Vent: The tank is not equipped with a clog-resistant vent.

AWWA Standards recommend that all vents with screening against insects be designed to ensure "fail-safe" operation if the insect screens become occluded. Inadequate ventilation could cause a tank collapse if the tank is rapidly drained while the screen is occluded or frosted over. Therefore, a clog-resistant vent should be installed near the center of the roof. The existing vent opening should be equipped with a large flanged opening for evaluating, cleaning, repairing, and painting the interior roof structure ends and the center hub. The flanged opening will then be used to mount a clog-resistant vent at the center of the roof. The vent should be designed so that it is removable in order to access the ends of the roof rafter and center hub.

Existing Roof Manhole: The roof manhole and cover should be locked to improve water system security.

Additional Roof Manhole: Best practices recommend a second roof manhole for emergency egress during coating and repairing operations. Therefore, if the existing vent is not replaced with one attached to a 24 in. (610 mm) diameter flanged opening, a second roof manhole should be installed in the roof.