J.1_AEC Tank 804 API 653 Ext.Final 2020.pdf

API 653 In‐Service Inspection Report

Arnold Air Force Base, Tennessee

Tank Facility 804 (Tank 7)

29 September 2020

API 653 In-Service Inspection Report Arnold AFB, Tennessee

Table of Contents

ACRONYMS AND ABBREVIATIONS

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

THIS INSPECTION

PREVIOUS INSPECTION DATES

STATE REGULATIONS

RECOMMENDED FUTURE INSPECTION DATES

A. GENERAL PROJECT INFORMATION

1. SPCC Mandated AST Inspections

2. Site Information

3. Previous Inspection and Repairs

4. Future Projects

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Bottom

4. Tank Roof

5. Tank Shell

6. Tank Appurtenances

7. Tank Coating

8. Tank Piping System

9. Fire Protection System

10. Secondary Containment

11. Cathodic Protection

GENERAL TANK INFORMATION

C. FINDINGS AND RECOMMENDATIONS

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

2. SHORT TERM RECOMMENDATIONS

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

TANK DRAWINGS

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

AFFF Aqueous Film Forming Foam

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CC Carbon Steel

CFR Code of Federal Regulations

CP Cathodic Protection

CS Carbon Steel

DFT Dry Film Thickness

FAC Facility

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High-High Level Alarm

LLA Low Level Alarm

LLLA Low-Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NA Not Applicable

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

PTFE Polytetrafluoroethylene (e.g., TEFLON)

P/V Pressure/Vacuum

PST Product Saver Tank

SS Stainless Steel

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

UG Underground

UT Ultrasonic Testing

EXECUTIVE SUMMARY AND SUITABILITY FOR CONTINUED SERVICE

Austin Brockenbrough & Associates, LLC (Brockenbrough) was retained by Omaha District USACE under Contract No. W9128F-17-D-0017 Delivery Order W9128F20F0079 to perform SPCC Mandated AST/UST Inspections at various locations. As required by this task, Brockenbrough executed a tank inspection site visit to Arnold AFB, Tullahoma, Tennessee. An API 653 In-Service (visual external) Inspection was conducted for Facility No. 804 (Tank 7), on June 30, 2020. This inspection was performed in accordance with API Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. The inspection included a tank foundation settlement evaluation. All observations made during this API In-Service (visual external) inspection were made from the exterior of the tank.

Facility 804 is a 20-foot diameter by 18-foot tall, single wall, vertical, field-erected tank with a nominal storage capacity of 1,000 barrels (per dataplate) of F-24. The repair organization’s nameplate indicates the tank was erected in accordance with API 650 in 1954. The repair organization’s nameplate also indicates the installation of two new stilling wells, level alarms, ladder, and handrails/platform on the roof were completed in 2008. Details of tank construction and appurtenances are included in the Tank Information Table in Section ‘B’.

This tank was found to be in generally good condition, fully serviceable, no mandatory repairs noted, and suitable for continued service. Additional noted deficiencies are discussed in more detail in Section ‘C’ and should be addressed in a timely manner. Photographs of the tank are included in Appendix ‘C’.

The next API In-Service (visual external) inspection of Tank 804 should be performed by June 2025. The August 2008 in-service inspection report recommended an internal inspection to be performed by August 2028 to meet API requirements. The inspection should include an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology and a thorough code compliance evaluation. However, it may be advantageous to schedule the external and internal inspections concurrently.

A. GENERAL PROJECT INFORMATION

1. SPCC Mandated AST Inspections This project will perform an API 653 inspection of various tanks at facilities throughout the United States. The specific inspection performed is based on available information on the tank type, product being stored, and recommendations from previous inspection reports (if available). Additional consideration is given to federal, state, and local regulations, as well as applicable military criteria and general industry standards.

For this Task Order, Brockenbrough performed Inspection of Facility 804 located at Arnold Air Force Base, Tennessee. For the Tank Facility 804, an API 653 In-Service (external) tank inspection was performed on June 30, 2020. The inspection included a shell settlement survey.

2. Site Information Arnold Air Force Base, formerly Camp Forrest, is located in Tullahoma, Tennessee. It has been in use since 1950 and is home to the Arnold Engineering Development Complex (AEDC). The building of this complex was authorized by congress for $100 million in 1949 and it was dedicated to General Henry Arnold by President Truman in 1951. The airfield was decommissioned in 2009 but helicopters still occupy space on Arnold AFB as mission support for Fort Campbell. Arnold AFB contains wetland which is home to the Gopher Frog.

3. Previous Inspection and Repairs A 2008 out-of-service inspection report indicates the tank was internally inspected in August 2008. Per the previous report, after the inspection was complete and prior to the tank being put back in service the following repairs were performed: relocated HLCV float assembly to permit maintenance and testing, repaired roof catwalk, replaced external ladder, repaired caulking at the tank chime, installed ATG stilling well and ATG, installed manual tank gauge hatch and stilling well, installed water probe stilling well, recoated tank roof and shell, and installed level alarms.

4. Future Projects Facility personnel report there are currently no projects scheduled for execution in the future that affect the operation of the tank.

B. TANK INSPECTION COMMENTS

1. Tank Construction Tank Facility 804 is an aboveground, vertical, storage tank, measuring 20 feet in diameter and 18 feet tall, and with a nominal capacity of 1,000 BBLs (per data plate). The tank manufacturer’s nameplate indicates the tank was constructed in 1954 in accordance with API 650 and repaired/altered to API 653 in 2008.

2. Tank Foundation The tank bottom rests on an elevated concrete foundation pad. The tank appears to be resting on a gasket to protect the steel from contact with the concrete. There was no chime sealant observed at this interface. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank. The inspection found that there was some cracking/spalling in the concrete foundation. The concrete cracking/spalling should be repaired to prevent further degradation of the tank concrete foundation pad.

3. Tank Bottom The previous inspection report indicates that the bottom consists of lap welded steel plates. The tank bottom projection is approximately 3/4 inches from the tank shell which is less than the required 2 inches per API 650, however it is more than 3/8” minimum required by API 653. The tank bottom projection is in good condition and not showing any signs of corrosion or deterioration.

4. Tank Roof The tank roof is a lap-welded cone roof, constructed out of steel plate. The shell has a vertical ladder for accessing the tank roof. The tank roof has an upper catwalk with handrails for access roof appurtenances. The fixed roof features two (2) 1-1/2-inch float gauge guide wire penetrations, one (1) 1-1/2-inch float gauge penetration, one (1) 6-inch center vent, one (1) 3-inch pressure/vacuum vent, one (1) 8-inch gauging hatch, one (1) 8-inch ATG probe, and one (1) 3-inch ATG water probe penetration. There was evidence of water ponding at three locations on the edge of the roof adjacent to the tank access ladder, although there was no corrosion or paint deterioration noted at these locations.

Tank roof coating system appeared to be in fair condition with several areas showing rust streaking due to coating failure. There was mold/algae growth observed on the tank roof.

5. Tank Shell The vertical and cylindrical shell consists of three butt welded courses. The exterior of the shell was visually inspected and evaluated. Mold and algae streaks were evident on the tank shell, however, the coating system appeared to be in good condition.

6. Tank Appurtenances

a. Gauging

The tank’s Enraf ATG read a fuel level of 6 feet and 11-13/16 inches. The Varec tape gauge read a fuel level of 6 feet and 11-3/4 inches. The ATG and level gauge are within the required tolerance of 2 inches per API 653. There was minor corrosion noted on the ATG flange mount and manual gauge hatch flanges.

b. Level Alarms The tank is provided with an independent, shell mounted high-high, high, and low level alarms.

c. Stairs and Platforms The tank’s steel cone roof is accessible by an external galvanized, vertical ladder.

d. Grounding and Bonding There is one grounding lug on the tank.

7. Tank Coating The tank’s coatings were evaluated for deterioration. The exterior of the shell shows little to no sign of significant deterioration since it was coated in 2008. The exterior of the roof is showing sign of deterioration in several places and showing evidence of rust streaking. The shell and roof are covered with mold and algae. The mold and algae should be treated with a fungicide and the coating system on the tank roof be removed and replaced.

8. Tank Piping System Facility 804 has associated piping located within the containment dike. It is carbon steel piping supported by stanchion-type supports. The piping penetrates the concrete containment walls via linkseal. The receipt and issue piping are 4-inch diameter and transition to 6-inch tank nozzles at the first flange of the tank. One concrete pipe support base cracked and spalled and should be repaired to prevent further degradation of the pipe support.

9. Fire Protection System Fire protection is provided by surrounding AFFF cannons and piping system that surround the tank and adjacent storage tanks.

10. Secondary Containment Secondary containment consists of a concrete dike area with vertical concrete walls. The secondary containment was evaluated during the inspection. The expansion joint sealants in the concrete dike are dry rotted and have started to fail in several locations. The containment is of sufficient size to contain a total tank loss plus one foot of freeboard.

11. Cathodic Protection The tank bottom rests directly on an elevated concrete foundation pad. The tank bottom does not have cathodic protection.

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner Air Force Location Arnold AFB Facility Number 804 Tank Number Tank 7 State / Country Tennessee / U.S.A.

City Tullahoma Inspection Date June 30, 2020 Tank Manufacturer Unknown Design Standard API 650 – 12th Edition (assumed) Date of Construction 1954 (per nameplate) Tank Contents F-24 Tank Serial Number Unknown Tank Diameter 20’ Shell Height 18’ Overflow Height N/A Tank Capacity 1,000 BBL nominal Foundation Concrete ring wall

Construction and Material

Bottom Lap-welded carbon steel plate Shell Three courses of butt-welded carbon steel plate Floating Roof N/A Fixed Roof Lap welded steel cone roof

Cathodic Protection None

Interior Coating System Epoxy 100% (assumed)

Exterior Coating System Three-part DoD zinc rich epoxy/epoxy/polyurethane (assumed)

Level Gauging Enraf ATG and water probe, manual gauging well, Varec autogauge (mechanical tape level gauge).

Overfill Protection Independent high and high-high level alarms, ATG (redundant) alarms Piping Receipt 6” nozzle (4” piping) Welded carbon steel Issue 6” nozzle (4” piping) Welded carbon steel Water Draw-off 4” Welded carbon steel

Level Alarms Shell mounted (independent) high, high-high, and low-level alarms; ATG (redundant) Alarms.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 804 was found to be in generally good condition. The tank is fully serviceable, with no mandatory deficiencies that would require immediate removal of the tank from service. However, there were a few minor items observed that could be addressed to reduce long term maintenance, improve operability, and more clearly comply with federal, state, and local regulations or military criteria.

1. MANDATORY REPAIRS per API 653, NFPA, or CFRs Mandatory repairs represent items that require immediate attention in order to prevent imminent risk to system operators, equipment, or the adjacent environment. The tank would have to be taken out-of-service to complete these repairs.

No Mandatory Repairs are required to be performed.

2. SHORT TERM RECOMMENDATIONS

REQUIRED REPAIRS to Fully Comply with API 653, UFC 3-460-01, or AW 78-24-27 Standards Short- Term Repairs that directly relate to the long-term preservation of the asset. Short-term repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment. These items may be required by federal, state and local codes or by military criteria.

a. Remove Threaded Plug OBSERVATION: There is a threaded plug present on the tell-tale hole on the repad of the 30-inch manhole. Plugged tell-tale hole will prevent observation of any leaks within repad periphery weld seam.

REFERENCE: API 650 paragraph 5.7.2.10 requires that the telltale hole in the reinforcing plates be open to the atmosphere.

RECOMMENDATION: Remove threaded plug from tell-tale hole on the repad.

3. LONG-TERM RECOMMENDATIONS

RECOMMENDED REPAIRS as Part of Regular Maintenance Long-term Repairs that directly relate to repair/upgrade of an asset to bring it up to the current standard from the standard at time of construction. Long-term Repairs represent items that should be addressed in a timely manner in order to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

a. Repair Concrete OBSERVATION: There are minor areas of cracks and spalling in the elevated concrete tank foundation. If precipitation enters the foundation through the cracks, the water could promote corrosion of the reinforcing steel in the concrete and damage concrete during freezing conditions.

Deterioration of the foundation could lead to inadequate support for the tank.

REFERENCE: API 650 paragraph 5.3.1 and API 653 Appendix ‘B’ require foundations to provide adequate support. NFPA 30 paragraph 22.11.2.4 and 40 CFR 112.7(c)(1) require secondary containment to be liquid tight.

RECOMMENDATION: Seal approximately 10 linear feet of cracks and patch approximately 2 square feet of spalling concrete in the tank foundation.

b. Provide Manhole Repairs OBSERVATION: There are two tank shell manholes. One is 18 inches and the other is 30 inches in diameter. Neither manhole is equipped with a davit, which makes it difficult to remove and could be unsafe for inspection/maintenance personnel.

REFERENCE: Guidance for new construction, provided in UFC 3-460-01, Table 8-1 Item f) and DoD Standard Design AW 78-24-27, requires (2) 36-inch diameter shell manholes with cover davits.

RECOMMENDATION: Provide manholes with davits. This repair may be programmed to occur at the next out-of-service tank inspection when the tank is empty. Note: Due to the size of this tank it is not recommended that the manhole sizes be increased.

c. Repair Coating OBSERVATION: There is minor coating failure and corrosion on the gauge hatch nozzle flange and the ATG nozzle flange and at the roof perimeter vent/inspection hatch hinges. There is scattered isolated coating failure and corrosion on the tank roof. The tank shell has mold/algae growth on exterior.

REFERENCE: Guidance for new construction, provided in UFC 3-460-01, paragraph 8-3.10, includes coating the exterior. UFC 3-460-01, Appendix F (Monthly Tank Inspection Checklists) requires Facility personnel to inspect for evidence of corrosion.

RECOMMENDATION: Remove and replace approximately 315 square feet of the DoD coating system on tank roof. Remove mold/algae from tank shell to prevent degradation of tank shell coating.

d. Repair Joint Sealant OBSERVATION: The concrete joint sealant in the dike area have dry-rotted and failed in several locations. This may result in further deterioration of the sealant and void the secondary containment.

REFERENCE: NFPA 30 paragraph 22.11.2.4 and 40 CFR 112.7(c )(1) require dikes to be liquid tight.

RECOMMENDATION: Remove and provide approximately 400 linear feet of new joint sealant in the concrete secondary containment area.

e. Provide Tank Bottom-to-Foundation Seal OBSERVATION: The tank bottom-to-foundation does not have a seal to prevent water from infiltrating underneath the tank.

REFERENCE: UFC 3-460-03 paragraph 8-4.1 requires facility personnel to periodically inspect and repair the bottom-to-foundation seal but does not include the item in its tank inspection checklists included in Appendix ‘F’ of UFC 3-460-03.

RECOMMENDATION: Provide approximately 63 linear feet of chime sealant.

f. Provide Roof Perimeter Guardrail OBSERVATION: The tank roof only has a perimeter guardrail adjacent to the vertical access ladder.

Personnel are required to utilize fall protection measures (harness, lanyards, etc.) when performing maintenance and accessing the top of the tank.

REFERENCE: OSHA regulation 29 CFR 1910.25 (b) requires the step rise to be uniform throughout any flight of stairs including any foundation structure used as one or more stair treads.

RECOMMENDATION: Provide a roof perimeter guardrail, approximately 63 linear feet, around the entire tank roof to promote safe access and working environment for personnel.

g. Replace Thermal Relief Assemblies OBSERVATION: The thermal relief piping is constructed from check valves, tubing, and threaded pipe and fittings. There are also sight flow indicators installed in the relief piping, which are known leak points. Testing of the thermal relief valves requires complete disassembly of the thermal relief piping.

REFERENCE: Guidance for the design of piping systems provided in UFC 3-460-01 paragraph 9-8(e) discourages threaded piping connections.

RECOMMENDATION: Demolish four existing thermal relieve assemblies and provide new angle pattern thermal relief valves, welded pipe and isolation valves and testing tees per UFC 3-460-01 requirements.

h. Ponding on Roof OBSERVATION: There is ponding on the roof at three locations. Ponding areas are prone to coating failure and corrosion, although there is currently no evidence of that as the tank was recently coated.

REFERENCE: Guidance for new construction, provided in UFC 3-460-01, paragraph 8-3.10, includes coating the exterior. UFC 3-460-01, Appendix ‘F’ (Monthly Tank Inspection Checklists) requires Facility personnel to inspect for evidence of corrosion.

RECOMMENDATION: Facility personnel should visually inspect the ponding after heavy rains and perform water removal as required to prevent the potential for coating failure and corrosion.

i. Install Double Block and Bleed Isolation Valves OBSERVATION: The tank skin valves on the issue, receipt, and water draw-off piping are ball valves.

REFERENCE: UFC 3-460-01, paragraph 13-3.7 requires double block and bleed isolation valves on the tank nozzles on tanks larger than 12,000 gallons.

RECOMMENDATION: Remove three existing 4-inch isolation ball valves and install double block and bleed valves on the water draw-off, tank issue, and tank receipt pipelines.

j. Monitor Reinforcing Pads for Signs of Stress OBSERVATION: The reinforcing pad weld clearance at the chime of the 30-inch manhole is not in compliance with API 650 weld spacing requirements. The weld seam of the repad is directly overlapping the tank shell to bottom weld. No visible signs of stress were noted at this location during this inspection.

REFERENCE: API 650 Table 5.6 indicates the minimum weld spacing between a diamond manhole repad and the bottom to shell weld. Per API 653 paragraph 4.3.9.1 this weld spacing could be acceptable if it is examined by the magnetic particle method and it has no rejectable defects or indications.

RECOMMENDATION: Perform a magnetic particle examination of the welds to determine if the welds are acceptable or if the repad needs to be replaced with a doghouse style repad.

k. Repair Concrete Base of Pipe Support

OBSERVATION: The concrete base associated with a pipe support in the dike containment area has deteriorated and is showing signs of severe spalling.

REFERENCE: UFC 3-460-01, paragraph 13-13.2 requires damaged pipe supports to be repaired.

RECOMMENDATION: Repair concrete base of damaged pipe support.

l. Repair Drain Line to PST OBSERVATION: The drain line to the product saver tank from the water draw-off line is threaded, close to grade, and sits in water when it rains.

REFERENCE: UFC 3-460-01, paragraph 9-3 requires new piping to be supported so that it is clear of any flooding or ponding, and paragraph 9-8 (e) requires the use of welded connections.

RECOMMENDATION: Reconfigure the piping so that it is not submerged in water after a rain event.

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL ROUNDNESS SURVEY AND SETTLEMENT

The shape of the shell appears to slightly exceed the allowable API 650 tolerance of plus or minus 3/4-inch of a new tank shell radius. Based on the circumference of the shell measured near the bottom, the radius of the shell should be 10 feet. However, the measured radii of the shell vary at the bottom from approximately 9 feet and 9- 7/8 inches to 9 feet and 11-1/2 inches. The measured radii of the shell vary at the top from approximately 10 feet and 1-11/16 inches to 9 feet 10-7/16-inches. The tank bottom and roof should restrain the shell from deflection near the bottom and near the top because there did not appear to be any significant distortion of the shell would seem to suggest the tank was built slightly out-of-round. It is noted that the tolerance for out-of-roundness has been included in API 650 before 1993. API 650 1st Edition was published in 1960. However, it has not been until later years that the industry has had the laser surveying technology and methods available to measure tank upper shell courses. It should be noted that API 653,10.5.3 – 3rd Edition (published in 2001), and later editions, allow the shell out-of-roundness (radial deviation), at higher than one-foot above a bottom of a reconstructed tank, to be as much as three times greater (2-1/4 inches): a subject not addressed in API 653 prior to the year 2001. As measuring the out-of-roundness using such methods is not normally included in an API 653 Inspection of an existing and not reconstructed tank, and as the out-of-roundness does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time.

The tank settlement is outside of the tolerances allowed by the API 653 Appendix ‘B’ calculations, but this calculation methodology is not accurate for tanks with small diameters (less than 50 feet). The total measured settlement is less than the allowed settlement tolerances for a new tank. Since the tank was constructed in 1954 and the settlement does not appear to be a detriment to the structural integrity of the tank, no action is required or recommended at this time. The data points used in the settlement calculation were gathered from the laser scanning survey.

ROUNDNESS SURVEY

EQUIPMENT USED: Survey Equipment

Topcon QS X-Trac 8 Robotic/Reflectorless Total Station Last Calibrated – June 2019

Topcon FC-5000 Field Data Collector Last Calibrated – None needed

SHELL SETTLEMENT SURVEY

EQUIPMENT USED: Survey Equipment

Topcon QS X-Trac 8 Robotic/Reflectorless Total Station Last Calibrated – June 2019

Topcon FC-2500 Field Data Collector Last Calibrated – None needed

Austin Brockenbrough & Associates, L.L.C. Job No. 20-018.01 Location: Arnold AFB Date: 8/28/20 Subject: Tank 7 - Shell Settlement Evaluation By: Steffen Schilstra

API 653 Appendix B Optimum cosine curve, B 2.2.4.e) Z = a + b x cos(theta + c)

Diameter (D) = 20 (ft) Number of equally spaced data points (ft)= 8 L = Arc length between measurement points (ft) = 7.85 Tank Height (H) = 18.0 (ft)

Relative elevation of lowest horizontal weld seam. (ft)

* Z U S

0 6.01 0.00000 0.01 0.01 0.01 1 6.03 0.02000 0.00 -0.02 -0.01 2 6.02 0.01000 0.00 -0.01 0.00 3 6.00 -0.01000 -0.01 0.00 0.00 4 5.99 -0.02000 -0.01 0.01 0.01 5 6.01 0.00000 -0.01 -0.01 -0.02 6 6.00 -0.01000 0.00 0.01 0.01 7 6.01 0.00000 0.00 0.00 0.00 8 6.01 0.00000 0.01 0.01 0.00

Maximum out-of-plane deflection = 0.02

* = measured elevation *HI (Height of Instrument) Z = calculated ridged body tilt (in) U = out-of-plane settlement = S = out-of-plane deflection z-y Y = yield sterength of shell material (PSI) = 30,000 (unknown steel) E = Youngs modulas of elasticity (lbf/in2) = 29*10^6 S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH) = 0.02 ft

R^2 = (Syy - SSE) / Syy = 0.34 not >=0.9 therefore cosine curve is invalid.

Evaluation by the Arc Length Method described in API 653 B.2.2.5.1 is required.

Austin Brockenbrough & Associates, L.L.C. Job No. 20-018.01 Loca Arnold AFB Date: 8/28/20 Subj Tank 7 - Shell Settlement Evaluation By: Steffen Schilstra

API 653 B.2.2.5.1 Evaluation by Settlement Arc Length Method

* Open top (yes/no) = no Per B.3.2.2, K = 10.5

Settlement arc length (ft), Sarc Out of plate settlement at Point i (Si) Allowable settlement at point i (Smax) = MIN[K*Sarc*(D/H)*(Y/E), 4]

Point Sarc (ft) Si (ft) Smax (ft)

1 31.4 0.02 0.03 OK

5 15.7 0.02 0.02 No good) 1 15.7 0.06 0.02 No good)

* For the purpose of this evaluation tanks with geodesic domes and barn roofs are consided to be open top, as those types of roofs do not significantly restrain the top of the shell.

Si < Smax → Si < Smax →

Evaluation of the settlement by the arc length method indicates the settlement exceeds the applicable limits described in API 653 B.3.2.2.

Si < Smax →

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

0 2 4 6 8 10

Measured Elevation (ft)

Si2 Si5

SHELL AND ROOF ULTRASONIC THICKNESS MEASUREMENTS

Job No.: 20-018.01

Job Title: Inspect AST Arnold AFB

Subject: FAC 804

By: Jeffrey King Date: 44075

SHELL UTM DATA (0.001 inches) DFT = 0.000 inches UTM's include 0 inch DFT coating.

1 2 3 4 5 6 7 8 9 Typical Shell Plate UTMs.

1 2 3 4 5 6 7 8 9 1-1 170 168 166 172 173 172 169 167 164 1-2 168 167 168 168 169 168 165 164 164 1-3 168 171 173 178 183 180 174 172 171 1-4 179 178 179 189 185 184 173 175 179 1-5 1-6

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

4 5 6 4 5 6 4 5 6 3-1 4-1 5-1 3-2 . 4-2 5-2 3-3 4-3 5-3 3-4 4-4 5-4 3-5 4-5 5-5 3-6 4-6 5-6

UTMs every 3 feet and 2 inches above tank bottom 1-1 1-2 1-3 1-4 1-5 1-6

8 UTMs near 0.135, 3 UTMs near 0.250 and 10 UTMS over 0.320 inches taken in a 3" wide x 16" high area may indicate an area of possible plate inclusions and/or delamination.

TANK DRAWINGS

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

SPCC Mandated AST Inspections

UL SWRI

API Other

Protected

Type: Type:

Size: Date Installed:

coated CS End Conn: Size: 4" Material: coated CS End Conn: Size: 4"

Issue To:

Release Prevention Barrier

Overfill Protection / Level Alarms:

High, Low 4" Cla-val, shell mounted float pilot

Receipt Piping Configuration Issue Piping Configuration Tank Piping

Secondary Containment

August 1, 2008

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

20'-0" diameter; 18'-0" tall

N/A

API 650

Inspection Date:

Design Std

Tank Inspector Name:

Inspector Certification Number:

UnknownConcrete Dike, partial FML

API 653 EXTERNAL INSPECTION CHECKLIST

Fort CampbellProject Site:Project Name:

Project Location:

Brockenbrough Job No.:

Fort Campbell, Kentucky

General Inspection Information 20-018.02

Submitted to:

Contract No.:

UASCE

W9128F-17-D-0017

Tank Construction and Configuration

Insulated

Coated

Plastic / Fiberglass

Butt weld/flanged

Engine test cells

Closed Top Dike

Change of Service:

Last Repair:

Tank Facility No.:

Local Tank ID No.:

June 30, 2020

Tank Manufacturer:

Tank Construction Date:

Tank 7 Daniel Caldwell

Vertical

Rectangular

Double Wall

Fire Resistant

Tank Coatings:

Exterior Coating:

DoD Three part (assumed)

Unknown

Interior Coating:

Double Bottom

No nameplate

40'x50'x4'

Level Alarms:

Material: Butt weld/flanged

Other:

F-24

1,000 BBL

N/A

Secondary Containment, Overfill, and CRDM

Overfill Protection:

Unknown

Unknown

Unknown

Tank Outside Dimensions:

Nominal Capacity:

Useable Capacity:

70855

Horizontal Single Wall

Open Type Dike

Receipt From: Truck off-load

API 653 EXTERNAL INSPECTION CHECKLIST

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.1.4 Rock

Cracking/spalling in concrete ringwall.

Measure foundation levelness and bottom elevations (See Annex B)

ITEM

C.1.1 Foundation

Check for:

Tank Settlement

COMMENTS

Settlement around perimeter of tank Check for:

d)

TASK

Drains to "pit" adjacent to tank through pipe at base of dike wall

Run-off rainwater from shell draining away from the tank

Check for :C.1.1.3 Oiled Dirt or Sand

C.1.1.2 Asphalt e)

Review cathodic protection potential readings c)

Check for:

STATUS

a)

b) C.1.1.6 Housekeeping

Build-up of trash, vegetation, and other inflammables

C.1.1.1 Concrete Ring

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

Tank settlement into asphalt base

C.1.1.7 Cathodic Protection

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

Check for:

Check for:

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

Cavities under foundation; vegetation against bottom of tank

Broken concrete, spalling, and cracks, especially under backup bars used in welding butt-welded annular rings under the shell Indications of bottom leakage at drain openings in ring, back of water-draw basins, and top surface of ring b)

Settlements into the base

C.1.1.5 Site Drainage

Proper operation of dike drains a) b) a)

Water ponding at water draw-off, but not touching shell

Few places where vegetation is growing through joint sealant; joint sealant failed/starting to fail in containment area.

Fort CampbellProject Site:Project Name:

C.1.2.1 External Visual Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.2.3 Riveted Shell Inspection

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Rivet and seam leaks on external surface

No access; no floating pan.

rim angle is too short, less than 3/4" in some places c) c)

Broken welds and corrosion damage (paint failure, pitting, corrosion, product build-up), especially where it occurs at tack-welded junction d)

Check for:

Check for:

Grooving, corrosion, pitting, and coating failures

Full fillet lap-welded vertical seams to increase joint efficiency

Check for:

Corrosion and thinning on plate and weld after cleaning the bottom angle area

Paint failures, pitting, and corrosion b)

Corrosion loss and wear on the rivets

Reinforcing pads welded to shell at supports

Pitting on support welds to shell, especially on shell plates

a) b)

c) Bottom-to-Foundation Seal

e) Drawings of riveted seams if available. Otherwise, dimension and sketch (or photograph) the rivet pattern: no. of rows, rivet size, pitch length, butt-riveted or lap-riveted joints a)

Check for:

C.1.2.2 Internal (Floating Roof Tank)

Leaks and identify the location by sketch or photo

C.1.2.4 Wind Girder (Floating Roof Tanks) a)

No bottom to foundation sealant; moss on conc ringwall below bottom projection b)

C.1.2. Shells

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

ITEM TASK

a) Leaks at piping manifolds, flanges, and valves

Check for:

C.1.3.3 Autogauge System Check for:

b)

COMMENTS

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

Set at 165 psi, check vlave only, includes threaded piping and SFIs

No davits on manhole

Fire fighting system componentsb) c) d) e) f)

Damage on welds on shell-mounted davit clips above valves 6 inches and larger g)

Anchored piping which would be hazardous to the tank shell or bottom connections during earth movement

Adequate thermal pressure relief of piping to the tank Proper operation of regulators for tanks with purge gas systems Leaks at sample connections and proper valve operation Damage and test the accuracy of temperature indicators h)

Shell plate dimpling around nozzles, caused by excessive pipe deflection c)

Sealing of insulation around manholes and nozzles

e) Adequate manholes flange and cover thickness on mixer manholes

Flange leaks and leaks around bolting

C.1.3.1 Manholes and Nozzles

C.1.3.2 Tank Piping Manifolds

C.1.3 Shell Appurtenances d)

Check for:

a)

STATUS

VAREC tape gaugea) Leaks on autogauge tape guide and lower sheave housing (floating swings)

b) Damage on autogauge head

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

c) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A Pass Fail N/A

Pass Fail N/A

VAREC reading of 6'-11.75" vs. 6'-11-13/16" reading of ENRAF

h) Condition of board and legibility of board-type autogauges Freedom of movement of marker and float

Bracing and supports for sample lines and equipment

C.1.3.3 Autogauge System c) d)

C.1.3.4 Shell-mounted Sample Station a)

Check for:

c) Condition of power lines and connections to mixer i)

1 1/2" threaded coated carbon steel b)

Check for:

Function of valves and plugging in sample lines, including drain or return-to-tank line Leaks in circulation pump and operating problems

Inspect condensate drain for presence of oil indicating leakage

C.1.3.5 Heater (Shell Manhole Mounted) C.1.3.6 Mixer bump checker continuously rotates, but does go back to original setting

a) b)

Proper mounting flange and support Leakage e) f) g)

Proper movement of tape by bumping the checker on autogauge head Size and construction material of the autogauge tape guide and make note (floating roof tanks) Proper movement of tape. Ask the operator if the tape tends to hang up during tank roof movement (floating roof tanks).

Actual product level compared to the reading on the autogauge. Make note. (max. variation is 2 in.)

No more than 2 feet of tape are exposed at the end of the tape guide when the roof is in lowest position (floating roof tanks)

ITEM TASK STATUS COMMENTS

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

b) Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

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

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

ITEM TASK

Non-floating: Raise, then lower the swing line with the winch and check for cable lightness to confirm the swing line lowered properly

STATUS

C.1.3.7 Swing Lines: Winch a) Operation

Indicator: Check that the indicator moves in the proper direction.

Floating swing line indicators show a lower level as cable is wound up on the winch. Non-floating swing line indicators show the opposite

COMMENTS

b) c)

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity Check for:C.1.3.10 Swing Lines: Cable

Material and Condition a) Corrosion over entire length, for non-stainless steel cable Wear or fraying on all types of cable

C.1.3.11 Swing Lines: Product Sample Comparison

Check for water or gravity differences that would indicate a leaking swing joint

C.1.3.12 Swing Lines: Target

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.4.1 Deck Plate Internal Corrosion

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

Ponding in (3) areas

C.1.4 Roofs

ITEM TASK

Minor corrosion on manhole and roof nozzle flanges C.1.4.2 Deck Plate External Corrosion

STATUS

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

C.1.4.3 Roof Deck Drainage Look for indication of standing water.

(Significant sagging of fixed roof deck indicates potential rafter failure.

Large standing water areas on a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons.)

COMMENTS

C.1.4.4 Level of Floating Roof At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a nonlevel roof with possible shell out-of-round, out-of-plumb, leaking pontoons, or hang-up. On small diameter tanks, an unlevel condition can indicate unequal loading at that level.

C.1.4.5 Gas Test Internal Floating Roof

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

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Inspect the condition of the seal, measure and record maximum rim spaces and seal-to-shell gaps around the full roof circumference at the level of inspection. NOTE: Inspection of the seal and measurement of the rim spaces and seal-to-shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

STATUS COMMENTS

C.1.4.6 Roof Insulation Check for:

a) b) c)

Crack and leaks in the insulation weather coat where runoff rain water could penetrate the insulation

b) Measure and record annular space at 30-ft spacing (minimum of four quadrants) around roof and record.

Measurements should be taken in directly opposite pairs.

C.1.4.7 Floating Roof Seal a) Systems

ITEM TASK

e) f) g)

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

Inspect fabric for deterioration, holes, tears, and cracks.

Inspect visible metallic parts for corrosion and wear.

Inspect for openings in seals that would permit vapor emissions.

Inspect for protruding bolt or rivet heads against the shell.

c) d)

Wet insulation under the weather coat Corrosion on the roof plate and holes near the edge of the insulated area by removing small test sections of insulation

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Check for:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

C.1.4.7 Floating Roof Seal h) Systems i) j)

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

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

Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears.

C.1.5 Roof Appurtenances

ITEM TASK STATUS COMMENTS

a) b) c) d) e) f)

Condition and functioning of sample hatch cover.

C.1.5.1 Sample Hatch

g) h)

Operation of system Presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample) on ultra clean stocks such as JP4

Condition of seal inside hatch cover on tanks governed by Air Quality Monitoring District rules Corrosion and plugging on thief and gauge hatch cover.

Marker and tab stating hold-off distance, where the sample hatch is used to reel gauge stock level Reinforcing pad where sample hatch pipe penetrates the roof deck.

Operation of recoil reel and condition of rope on floating roof sample hatch and recoil systems

Not accessible

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A b)

ITEM TASK STATUS COMMENTS

Check for:

C.1.5.2 Gauge Well Check for:

Valve leakage and for presence of a bull plug or blind flange, if the tank has a gauge well washer

Corrosion on the tape guide's and float guide's wire anchors

Corrosion and missing bolts on the hatch

Check for:

a) b) c) d)

Automatic sealing after sampling, when equipped with a fabric seal Proper operations when equipped with a recoil reel opening device b) e) c)

C.1.5.7 Roof-Mounted Vents

Thinning, size of slots, and cover condition of the visible portion of the gauge well A hold-off distance marker and tab with hold-off distance (legible) Condition of roof guide for gauge well, particularly the condition of the rollers for grooving on floating roofs The distance from the gauge well pipe to the tank shell at different levels, if accessible

C.1.5.5 Autoguage: Float Well Cover a) Corrosion

Wear or fraying caused by rubbing of the tape cable on the cover b)

Inspect scaffold support for corrosion, wear and structural soundness.

C.1.5.3 Fixed Roof Scaffold Support

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

Check for:

C.1.5.8 Gauging Platform Drip Ring

Check condition of screens, locking and pivot pins.

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

C.1.5.6 Sample Hatch (Internal Floating Roof) a) Overall conditions

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

c) If pontoon hatches are equipped with locked down coves, check for vent tubes. Check that vent tubes are not plugged up. Inspect lock-down devices for condition and operation.

ITEM TASK

Identify cold joints and sharp edges.

Inspect the handrails and midrails.

Check for:

a) Condition of the screen on the rim vent cover

b) Plating off or removal of rim vents where jurisdictional rules do not permit removal

C.1.5.13 Pontoon Inspection a) Hatches

Open pontoon inspection hatch covers and visually check inside for pontoon leakage.

C.1.5.9 Emergency Roof Drains

C.1.5.10 Removable Roof Leg Racks C.1.5.11 Vacuum Breakers

C.1.5.12 Rim Vents

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

Check for leg racks on roof

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

Test for explosive gas (an indicator of vapor space leaks).

b)

C.1.6 Access Ways - See Tank Out-of-Service Inspection Checklist Item C.2.12 C.2.12 Access Structures C.2.12.1 Handrails a) b) c)

Handrail only extends partway around tank perimeter, galv angle d)

Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails.

Inspect for pitting and holes, paint failure.

Inspect attachment welds.

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

c) Corrosion on steel support attachment to concrete base

No stairs or platforms, ladder access only

Inspect safety drop bar (or safety chain) for corrosion, functioning, and length.

Inspect the handrail between the rolling ladder and the gauging platform for a hazardous opening when the floating roof is at its lowest level.

Corrosion-caused thinning or holes (not drain holes) and paint failure on the deck plate Rust scale buildup on plate-to-frame weld

C.2.12.3 Deck Plate and Grating a) c) d)

Check for:

ITEM TASK

Corrosion and paint failure on frame Corrosion and weld failure on the attachment of frame to supports and supports to tank Reinforcing pads where supports are attached to shell or roof.

C.2.12.4 Stairway Stringers a)

b) Stairway supports to shell welds and reinforcing pads.

d) e) b)

C.2.12.1 Handrails e) f)

C.2.12.2 Platform Frame a) b) c)

Thinning and holes on the surface that deck plate or grating rests on Seal-weld on flat surface–to-flat surface junctures Check for:

Corrosion-caused thinning of bars and failure of welds on grating Grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating surface and compare with other risers on the stairway.

Check for:

Corrosion, paint failure, and weld failure on spiral stairway stringers

Fort CampbellProject Site:Project Name:

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

Pass Fail N/A

STATUS COMMENTS

Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment to stringers and corrosion, particularly where angle rungs are welded to stringers.

Check for wear and corrosion where rolling ladder attaches to gauging

C.2.12.5 Rolling Ladder a) b) c) d) e) f)

m) If rolling ladder track extends to within 5 ft of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

g) h)

Inspect rolling ladder stringers for corrosion.

Max Angle: _______________ i) j) k) l)

Inspect rolling ladder track welds for corrosion.

Inspect track supports on roof for reinforcing pads seal-welded to deck plate.

Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs.

Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle.

Inspect alignment of rolling ladder with roof rack.

Inspect top surface of rolling ladder track for wear by wheels to assure at least 18 in. of unworn track (track long enough).

Inspect pivot bar for wear and that it is secure.

Inspect operation of self-leveling stairway treads.

Inspect for corrosion and wear on moving parts.

ITEM TASK

Fort CampbellProject Site:Project Name:

8. No DBBs at skin of tank.

4. Minor concrete spalling and cracking on concrete ringwall

1. Galvanized ladder, no cage

7. Water draw-off threaded.

6. Ponding water on dike floor beneath water draw-off, drain to PST submerged in water.

10. Roof perimeter handrail does not extend all the way around the roof.

9. Ponding on roof perimeter at 3 locations.

5. TRV threaded, SFIs, check valves

Additional Findings and Comments:

2. Minor corrosion on roof nozzles.

3. Chime sealant failed in several locations.

Fort CampbellProject Site:Project Name:

min max

(in) (in) Handrail

Height 30 34

Step Width 22 NA

Step Rise NA NA

Bottom

OSHA Stairway Data OSHA Req’d

Actual

(in) n/a - ladder only n/a - ladder only n/a - ladder only n/a - ladder only

APPENDIX ‘C’: PHOTOGRAPHS

C.1: View of Tank from North C.2: View of Tank from West

C.3: View of Tank from East C.4: View of Tank from South

C.5: Secondary Confinement Area

C.6: Secondary Confinement Area

1011 Boulder Springs Drive, Suite 200 Richmond, Virginia 23225

Phone: 804.592.3900 Fax: 804.592.3901 www.brockenbrough.com