J.2 - Columbus AFB Tank 2 (Facility 145) Inspection and Evaluation Report - Final.pdf

Gilbane Tanks K1002 and W0003 – Post Repair API 653 Inspections

June 19, 2019

All Pond marketing materials are printed on papers containing post-consumer recycled fibers and are FSC Certified.

April 14, 2020

Susie J. Brunotte

Fuels Project Manager

Susie.j.brunotte@usace.army.mil

USACE, Omaha District

Contract Number: W9128F-17-D-0016

Task Order Number: W9128F19F0328

Submittal Number: 021a

Per SOW para 2.4.1 & 2.4.1.2, see attached for the following documents:

1. Columbus AFB Tank 2 (Facility 145) Inspection and Evaluation Report – (Final)

Respectfully submitted, Pond

Anthony E, Chinn, EIT

Program Manager | Mechanical Integrity chinna@pondco.com

678-591-5242

CC: Eric Bausch – Eric.L.Bausch@usace.army.mil

Brandon Sims - brandon.sims.2@us.af.mil mailto:chinna@pondco.com mailto:Eric.L.Bausch@usace.army.mil

API 653 In-Service Inspection Report Columbus AFB, Mississippi

US Army Corps of Engineers Omaha District

API 653 In-Service Inspection Report

Columbus Air Force Base Facility 145

Tank 2

US Army Corps of Engineers Center of Expertise for Petroleum, Oils and Lubricants 4/14/2020

Table of Contents

ACRONYMS AND ABBREVIATIONS

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 IN-SERVICE (EXTERNAL) INSPECTION

2. SITE INFORMATION

B. TANK INSPECTION COMMENTS

1. TANK CONSTRUCTION

2. TANK FOUNDATION

3. CATHODIC PROTECTION

4. TANK SHELL

5. TANK APPURTENANCES

6. TANK AND PIPING COATING

7. TANK PIPING SYSTEM

8. FIRE PROTECTION SYSTEM

9. SECONDARY CONTAINMENT

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS PER API 653, UFC 3-460-01, OR DoD AW 78-24-27 STANDARDS

2. REPAIRS TO FULLY COMPLY WITH API 650/653, UFC 3-460-01/3-460-03, AND NFPA 407

3. RECOMMENDED REPAIRS AS PART OF REGULAR MAINTENANCE

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

NEXT INSPECTION

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX C: PHOTOGRAPHS

ACRONYMS AND ABBREVIATIONS

AFB Air Force Base

API American Petroleum Institute

ATG Automatic Tank Gauge

BBL Barrel

BMP Best Management Practice

CP Cathodic Protection

DFT Dry Film Thickness

DoD Department of Defense

FTW Flying Training Wing

HHLA High-High Level Alarm

HLA High Level Alarm

HLCV High Level Control Valve

IAW In Accordance With

ICCP Impressed Current Cathodic Protection

IFK Isolation Flange Kit

IFR Internal Floating Roof

LLA Low Level Alarm

LLLA Low-Low Level Alarm

NDT Non-Destructive Testing

NFPA National Fire Protection Association

OOS Out of Service

OSHA Occupational Safety and Health Administration

PRT Product Recovery Tank

TLG Tape Level Gauge

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

USACE United States Army Corps of Engineers

UTT Ultrasonic Thickness Testing

VT Visual Testing

GENERAL SUMMARY

Pond was retained by the United States Army Corps of Engineers (USACE) to provide an in-service tank inspection for Tank 2 (Facility 145) at Columbus Air Force Base (AFB) in Columbus, Mississippi.

The in-service inspection was performed 25 February 2020. Results of this inspection identified recommended repairs/upgrades to fully comply with applicable sections of American Petroleum Institute (API) 650/653, Unified

Facilities Criteria (UFC) 3-460-01/3-460-03, Department of Defense (DoD) Standard AW 78-24-27, National Fire

Protection Association (NFPA) 407, best management practice (BMP) and industry standards.

Tank 2 is a welded, steel, vertical, aboveground Jet-A storage tank. The tank was constructed by GATX in 1955 in accordance with (IAW) API 12C and repaired by CAPE in 2016 IAW API 653. The tank is 42’-6” in diameter and 39’-

1 ⅛” high with a nominal capacity of 9,872 barrels (BBL) (414,624 gallons).

Testing and inspection activities were performed IAW applicable sections of API 653, 5th Edition. This report contains a detailed account of the tank inspection, non-destructive testing (NDT) methods, and conclusions derived from the inspection and testing activities. Findings from this inspection are further detailed in Section B - General

Project Information. Recommended repairs and upgrades identified in Section B are further classified and listed in

Section C – Findings and Recommendations.

INSPECTION DATE

API In-Service (External) Inspection Date: 24-25 February 2020 Equipment Used:

Manufacturer: GE Krautkramer Ultrasonic Thickness Gauge Model Number: DMS GO+ Calibration Method: One-Point Calibration

Manufacturer: Fischer Technologies Dry Film Thickness (DFT) Gauge Model Number: Dual Scope MPOR Calibration Method: Calibration to Known Thickness Standard

Manufacturer: Technidea Corporation Model Number: ZipLevel Pro 2000 Calibration Method: Manufacturer Calibrated

Inspector(s):

Andrew D. Morrissette Christopher R. Peterson

STATE REGULATIONS

State Regulation for API In-Service Tank Inspections: N/A State Regulation for API Out-of-Service Tank Inspections: N/A

PREVIOUS INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: May 13, 2003 API In-Service (External) Inspection Date: May 13, 2003

RECOMMENDED FUTURE INSPECTION DATES

API Out-of-Service (Internal) Inspection Date: Unknown* API In-Service (External) Inspection Date: February 2025

*Out-of-service (OOS) inspection interval not included on the previous OOS inspection report dated May 2003.

Andrew D. Morrissette Christopher R. Peterson

Integrity Engineer Integrity Engineer

API 653 Inspector # 80109

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner United States Air Force

Location Columbus AFB

Facility Number 145

Tank Number 2

State / Country Mississippi, USA

City Columbus

Inspection Date 25 February 2020

Tank Manufacturer

GATX*

Repaired by CAPE in 2016

Design Standard Original: API 12C Repaired to API 653 in 2016

Date of Construction 1955

Tank Contents Jet-A

Tank Serial Number N/A

Tank Diameter 42’-6”

Shell Height 39’-1 1/8”

Product Height 33’-7 3/4”

Tank Capacity 9,872 BBL (414,624 Gallons)

Foundation Concrete Ringwall

Construction

Bottom: Lap-Welded*

Shell: Butt-Welded

Floating Roof: Lap-Welded Pontoon

Geodesic Dome Roof: Bolted Aluminum

Material

Bottom: Carbon Steel (Unknown Grade)

Shell: Carbon Steel (Unknown Grade)

Floating Roof: Carbon Steel (Unknown Grade)

Geodesic Dome Roof: Aluminum

Cathodic Protection (CP) Impressed Current Cathodic Protection (ICCP)

Interior Coating System Thin-Film Epoxy*

Exterior Coating System Epoxy with Polyurethane Topcoat (Assumed)

Level Gauging Enraf automatic tank gauge (ATG) and Varec tape level gauge (TLG)

Overfill Protection High Level Alarm (HLA) / High-High Level Alarm (HHLA) / High-level control valve (HLCV) Float Pilot

Piping Receipt 6-inch Carbon Steel

Main Suction 10-inch Carbon Steel

Low Suction 4-inch Carbon Steel

Product Recovery Tank (PRT) Return 2-inch Carbon Steel

Water Draw-Off 2-inch Carbon Steel

Level Alarms HLA/HHLA; Low Level Alarm (LLA) / Low-Low Level Alarm (LLLA)

Type of Internal Floating Roof Steel Pontoon

Notes:

*Based on previous OOS inspection report dated May 2003.

A. GENERAL PROJECT INFORMATION

1. API 653 IN-SERVICE (EXTERNAL) INSPECTION

The in-service inspection was performed 24-25 February 2020. Results of this inspection identified recommended repairs/upgrades to fully comply with applicable sections of API 650/653, UFC 3-460-

01/3-460-03, DoD standard AW 78-24-27, NFPA 407, and industry standards.

2. SITE INFORMATION

Columbus AFB is home to the 14th Flying Training Wing (FTW) of Air Education and Training

Command's 19th Air Force. The 14th FTW mission statement is "Cultivate Airmen, Create Pilots, Connect." The wing's mission is specialized undergraduate pilot training in the T-6 Texan II, T-38C

Talon, and T-1A Jayhawk aircraft. Each day the wing flies an average of 260 sorties on its three parallel runways. In addition to the flying training mission, Columbus AFB maintains more than 900 highly trained individuals capable of deploying at a moment's notice to support worldwide taskings and contingencies.

B. TANK INSPECTION COMMENTS

1. TANK CONSTRUCTION

Tank 2 is a welded, steel, vertical, aboveground Jet-A storage tank. The tank was constructed in 1955 to the design standard API 12C by GATX and repaired by CAPE to API 653 in 2016. The tank is 42’-6” in diameter and 39’-1 ⅛” high with a nominal capacity of 9,872 BBL (414,624 gallons).

2. TANK FOUNDATION

Tank 2 rests on a concrete ring wall foundation. Sealant at the ring wall-to-dike floor joint exhibits shrinkage, disbondment, and voids.

A settlement survey was performed during the inspection. The settlement evaluation criteria IAW API

653 Annex B was not satisfied, however, no visual sign of excessive settlement or stress on the shell was observed. Settlement should be monitored during future inspections. See Appendix A for settlement results.

3. CATHODIC PROTECTION

The tank is equipped with an ICCP system for protecting the tank bottom from corrosion. According to the previous CP report dated July 2018, all test points met either the -850 mV or 100 mV polarization

NACE protection criteria, indicating the tank is receiving adequate CP. No soil-side corrosion was noted on the previous inspection report.

4. TANK SHELL

The tank shell is equipped with five (5) butt-welded, fully coated, steel courses. Shell plates were examined using ultrasonic thickness testing (UTT) and visual testing (VT) methods. Nine (9) UTT measurements were taken on each plate of the 1st shell course. Ten (10) UTT measurements were taken on each of the 2nd through 5th shell courses using the spiral staircase for access. UTT measurements indicated no significant signs of metal loss on shell plates.

Tank 2 is equipped with twenty-one (21) nozzle penetrations: Two (2) 36-inch manways, one (1) 6-inch receipt, one (1) 10-inch main suction, one (1) 4-inch low suction, one (1) 3-inch blind flange (labeled as clean out stub on the shell), one (1) 2-inch water draw-off, one (1) 2-inch PRT return, one (1) 3-inch roof drain, two (2) 1 1/2-inch penetrations LLA / LLLA assembly, two (2) 1 1/2-inch penetrations for the HLA

/ HHLA / HLCV float pilot assembly, four (4) 2” threaded plugs, two (2) 1 ½” threaded plugs, and two (2) threaded plugs.

An unused length of conduit is mounted on conduit supports adjacent to the Varec TLG. Fasteners for the blind flange exhibit base metal exposure with surface corrosion.

Four (4) inward shell deformations were observed on the 1st shell course. Deformations were observed near insert plates and extended to the shell-to-bottom weld. All deformations are acceptable IAW API

650, Section 7.5, as the maximum allowable depth of deformation for the tank is 2.35” and the maximum depth measured for deformations was 1.5”.

5. TANK APPURTENANCES

a. GEODESIC DOME ROOF

The tank is equipped with a geodesic dome roof. The geodesic dome roof was examined using

VT methods. Evidence of water accumulation was observed on the internal floating roof (IFR) and water accumulation was noted inside the tank by facility personnel, indicating that the geodesic dome roof is not properly sealed. According to facility personnel, the geodesic dome roof regularly leaks during rain.

The geodesic dome roof is provided with five (5) nozzle penetrations: One (1) Enraf ATG, one

(1) sampling hatch, one (1) Vito temperature/water combination probe, one (1) Varec TLG, and one (1) center vent.

b. GAUGING

The tank is provided with a sampling hatch for manual gauging and sampling operations, an

Enraf ATG system for automatic tank gauging, and a mechanical Varec TLG for monitoring product level from the ground. The TLG passed the operability check.

c. LEVEL ALARMS

The tank is provided with independent, shell mounted alarms in the low, low-low, high, and high-high positions and a HLCV float pilot for overfill protection. According to facility personnel, all level alarms and the HLCV float pilot are functioning properly.

d. STAIRS AND PLATFORMS

The tank is provided a spiral staircase with one (1) lower landing platform, one (1) work platform for level alarm and HLCV float pilot access, and one (1) upper platform for roof access. The spiral staircase exhibits flaking and base metal exposure with surface corrosion.

Stair tread widths were measured and are approximately 27 1/2-inches wide. API 650 and the Occupational Safety and Health Association (OSHA) mandates that staircases have a minimum stair tread width of 28-inches and 22-inches, respectively. Stairway handrails were measured and are 46-inches high. API mandates that handrails should be between 30-inches to 34-inches tall while OSHA 1910.29(f)(1)(i) mandates handrails be between 30-inches to

38-inches tall. The stair tread width or handrail heights are not in compliance with API 650 and the handrails for the spiral staircase are not in compliance with API or OSHA

1910.29(f)(1)(i).

A rolling ladder is provided to access the IFR. Stair treads are not provided for the rolling ladder. API 650 Annex C requires that rolling ladders have non-slip walking surfaces and self-leveling treads.

e. GROUNDING AND BONDING

The tank shell is equipped with five (5) grounding cables. Grounding cables are in good overall condition with no signs of fraying or disbondment. Grounding cable conduits are not provided sealant at the dike penetration, allowing a pathway for fluid to escape in the event of a spill. Vegetation growth was observed at the conduit dike penetration.

6. TANK AND PIPING COATING

The tank is assumed to be provided with an epoxy/polyurethane coating system. The external tank shell coating exhibits chalking, indicating the polyurethane topcoat is near the end of its life cycle. It is recommended to conduct a coating condition survey to determine if the entire coating system should be replaced, or if a topcoat reapplication will suffice.

Coating for the receipt, main suction, low suction, water draw off, and PRT return piping exhibits corrosion staining, flaking, cracking, intermediate coating exposure, and base metal exposure with surface corrosion.

7. TANK PIPING SYSTEM

One (1) thermal relief valve (TRV) is provided for both the 10-inch main suction piping and the 6-inch receipt piping and are rated for liquid service. The piping for the main suction and receipt do have flow arrows, but there are no product identification labels. The receipt and issue piping are not provided with isolation flange kits (IFK) before transitioning underground to isolate the tank from the piping CP system.

The PRT is provided with uncoated carbon steel piping adjacent to the containment drain. During rain events, the piping is submerged. The PRT piping exhibits surface corrosion. No weeping or leakage was observed during inspection.

8. FIRE PROTECTION SYSTEM

For internal fire protection, Tank 2 is provided with a pontoon, lap welded, carbon steel IFR. Water accumulation and water staining were observed on the IFR.

9. SECONDARY CONTAINMENT

Tank 2 is provided a concrete containment dike with sloped walls. The volume of the secondary containment is approximately 655,000 gallons and meets the capacity requirement of approximately

550,000 gallons per UFC. The secondary containment is equipped with one (1) drain with a valve in the normally closed position. The containment drain grating is constructed with multiple grates that are tack welded together. According to facility personnel, the tack welds have corroded previously due to rainwater accumulation, presenting a safety hazard for personnel accessing the area.

The main dike entrance is a concrete staircase with handrail. The dike entry handrail does not have sealant at the floor penetration. An unused, unsealed section of piping penetrates the dike floor adjacent to the dike entry stairs. There are four (4) unused support clips within the secondary containment.

Sealant at control joints exhibits shrinkage, voids, and vegetation growth. Sealed and unsealed cracking was observed. Sealant at cracking exhibits voids.

C. FINDINGS AND RECOMMENDATIONS

Based on the in-service API 653 inspection of Tank 2 located at Columbus AFB in Columbus, Mississippi, repair/upgrade recommendations have been identified. The following recommendations outline observations from this inspection. All repair recommendations are based on applicable sections of API

650/653, UFC 3-460-01/3-460-03, DoD AW 78-24-27, NFPA 407, and industry standards.

1. MANDATORY REPAIRS PER API 653, UFC 3-460-01, OR DoD AW 78-24-27 STANDARDS

Mandatory repairs represent items that require immediate attention to prevent imminent risk to system operators, equipment integrity, or the adjacent environment. The tank should be taken out of service until these repairs are completed.

No mandatory repairs are required to remove Tank 2 from service.

2. REPAIRS TO FULLY COMPLY WITH API 650/653, UFC 3-460-01/3-460-03, AND NFPA 407

Short-term Repairs that 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. Internal Floating Roof Rolling Ladder

OBSERVATION: Stair treads are not provided for the IFR rolling ladder.

REFERENCE: API 650, Annex C.3.7

RECOMMENDATION: Provide self-leveling stair treads for the IFR rolling ladder.

b. Tank Shell Coating

OBSERVATION: External coating on the tank shell exhibits chalking, indicating the polyurethane topcoat is nearing the end of its life cycle.

REFERENCE: UFC 3-460-03, Section 8-3.1

RECOMMENDATION: Provide a full recoat of the external tank shell, approximately 6,250 ft2. Prior to recoat, conduct a coating condition survey to determine if the entire coating system should be replaced, or if a topcoat application will suffice.

c. Tank Nozzles and Appurtenances Coating

OBSERVATION: Coating for the receipt, main and low suction, water draw-off, and PRT return piping exhibits corrosion staining, flaking, cracking, intermediate coating exposure, and base metal exposure with surface corrosion.

REFERENCE: UFC 3-460-03, Section 6-10.1.1

RECOMMENDATION: Provide approximately 20 ft2 of spot coating repair at the receipt, main and low suction, water draw-off, and PRT return.

d. Tank Piping Labeling

OBSERVATION: Piping for the main suction and receipt is provided directional flow arrows, but not product designation labeling.

REFERENCE: UFC 3-460-01, Section 2-17

RECOMMENDATION: Provide piping with product designation labeling IAW MIL-STD-161H.

e. Tank Spiral Staircase Coating

OBSERVATION: Coating provided for the spiral staircase exhibits flaking and base metal exposure with surface corrosion.

REFERENCE: UFC 3-460-03, Section 8-3.1

RECOMMENDATION: Provide approximately 30 ft2 of spot coating repair on the tank spiral staircase.

f. Geodesic Dome Roof

OBSERVATION: The tank is equipped with a geodesic dome roof. According to facility personnel, the roof regularly leaks and water enters the product as a result. This was confirmed during rain at the time of inspection.

REFERENCE: UFC 3-460-01, Section 12-3.4

RECOMMENDATION: Provide the tank with a fixed roof.

g. Secondary Containment Control Joints

OBSERVATION: Sealant at control joints within the containment dike exhibits shrinkage, vegetation growth, and voids.

REFERENCE: UFC 3-460-03, Section 8.10.2.2 (C)

RECOMMENDATION: Provide approximately 55 linear feet of sealant repair at control joints.

h. Secondary Containment Cracking

OBSERVATION: Cracking was observed within the containment dike. Sealant at areas of sealed cracking exhibits voids.

REFERENCE: UFC 3-460-03, Section 8-10.2.2(B)

RECOMMENDATION: Provide approximately 5 linear feet of sealant repair to sealed cracking and approximately 10 linear feet of sealant to unsealed cracks.

i. Concrete Ring Wall-to-Dike Floor Joint

OBSERVATION: Sealant at the concrete ring wall-to-dike floor joint exhibits shrinkage, disbondment, and voids.

REFERENCE: UFC 3-460-03, Section 8-4.3.1

RECOMMENDATION: Provide approximately 140 linear feet (100% replacement) of sealant repair at the ring wall-to-floor joint.

j. Grounding Cable Conduit Dike Penetrations

OBSERVATION: Grounding cable dike penetrations are not provided with sealant. Vegetation growth was observed at the penetrations.

REFERENCE: UFC 3-460-03, Section 8-10.2.2(C)

RECOMMENDATION: Provide approximately one linear foot of sealant to each of the five (5) grounding cable dike penetrations.

k. Secondary Containment Dike Entry Handrail

OBSERVATION: Sealant is not provided at the dike entry handrail containment floor penetration.

REFERENCE: UFC 3-460-03, Section 8-10.2.2(C)

RECOMMENDATION: Provide approximately 1 linear foot of sealant at the dike entry handrail containment penetration.

l. PRT Piping

OBSERVATION: PRT piping is routed along the floor of the secondary containment dike, adjacent to the dike drain. During rain events, the piping is submerged in water that collects at the containment drain.

REFERENCE: UFC 3-460-01, Section 9.3

RECOMMENDATION: Elevate PRT piping via standard pipe supports IAW AW 78-24-27. See

Recommendation n

m. Receipt and Issue Piping

OBSERVATION: Receipt and issue aboveground piping are not provided with IFKs prior to transitioning underground.

REFERENCE: UFC 3-460-01, Section 9-8(l)

RECOMMENDATION: Provide the receipt and issue piping with IFKs at the aboveground-to-underground transition flange to isolate the tank from the piping CP system.

n. PRT Piping

OBSERVATION: PRT piping is of carbon steel and stainless-steel construction. The piping is in contact at a threaded joint, which creates a galvanic cell between dissimilar metals if not properly isolated, accelerating corrosion of the carbon steel piping.

REFERENCE: AW 78-24-27, Sheet D.13 Detail 5 & UFC 3-460-01, Section 9-8(j)

RECOMMENDATION: Replace carbon steel piping with stainless steel piping and provide a socket welded connection at the joint. See Recommendation l

o. Spiral Staircase Height

OBSERVATION: The spiral staircase handrails and stair tread width provided for Tank 2 do not meet OSHA or API standards. The handrail for the spiral staircase measures 46-inches in height, while OSHA mandates a maximum height for handrails at 38-inches. Stair tread widths were measured and are approximately 27 1/2-inches wide, where API mandates stair tread widths be a minimum of 28-inches wide.

REFERENCE: API 650, Table 5-18, Line 6; OSHA 1910.29(f)(1)(i)

RECOMMENDATION: Provide a spiral staircase that meets all API and OSHA standards. OSHA mandates handrails shall not be more than 38-inches nor less than 30 inches from the upper surface of the handrail to the surface of the tread, in line with the face of the riser at the forward edge of the tread. API 650 and OSHA mandates that staircases have a minimum stair tread width of 28-inches and 22-inches, respectively.

3. RECOMMENDED REPAIRS AS PART OF REGULAR MAINTENANCE

Regular maintenance repairs that relate to repairs/upgrades of an asset to bring it up to the current applicable standard from the standard at time of construction. These repairs represent items that should be addressed in a timely manner to prevent future potential risks to system operators, equipment integrity, or the adjacent environment.

p. Blind Flange Fasteners

OBSERVATION: Fasteners at the blind flange exhibit corrosion.

REFERENCE: Best Management Practice (BMP)

RECOMMENDATION: Replace four (4) fasteners at the blind flange.

q. Unused Conduit

OBSERVATION: An unused length of conduit runs adjacent to the Varec TLG conduit.

REFERENCE: BMP

RECOMMENDATION: Remove the unused conduit.

r. Bird’s Nest

OBSERVATION: A bird’s nest was observed on the tank spiral staircase.

RECOMMENDATION: Remove the bird’s nest on the spiral staircase.

s. Spiral Staircase and Geodesic Dome Support Girder

OBSERVATION: Bio-growth and debris were observed on the upper portion of the spiral staircase and at the geodesic dome support girder. Bio-growth accelerates deterioration of coatings and may accelerate corrosion.

REFERENCE: BMP

RECOMMENDATION: Pressure wash bio-growth and debris on the spiral staircase and geodesic dome support girder.

t. Secondary Containment Unused Supports

OBSERVATION: Unused support clips are present within the secondary containment.

REFERENCE: BMP

RECOMMENDATION: Remove four (4) unused support clips and provide sealant at the areas, as necessary. Unused clips are a trip hazard.

u. Secondary Containment Pipe Penetration

OBSERVATION: An unused section of tubing penetrates the secondary containment dike adjacent to the entry stairs.

RECOMMENDATION: Provide approximately 1 linear foot of sealant at the penetration.

v. Containment Drain Grate

OBSERVATION: The containment drain grating is constructed of multiple segments tack welded together. According to facility personnel, the tack welds have a history of corroding due to water accumulation at the drain. This presents a safety hazard to personnel accessing the drain area, as the grate may break apart due to corroded welds.

REFERENCE: BMP

RECOMMENDATION: Replace the containment drain grating with a single piece grate or join the segments with stainless steel grating clips to mitigate the risk of the grate breaking apart when the area is accessed by personnel.

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

NOZZLE

SCHEDULE

NOZZLE SIZE SHELL LAYOUT

MW1 36" MANWAY

N1 6" RECEIPT

N2 - THREADED PLUG

N3 - THREADED PLUG

N4 3" BLIND FLANGE

N5 10" MAIN SUCTION

N6 4" LOW SUCTION

N7 1 1/2" THREADED PLUG

N8 1 1/2" THREADED PLUG

N9 1 1/2" HLA/HLCV

N10 1 1/2" HLA/HLCV

N11 1 1/2" LLA/LLLA

N12 1 1/2" LLA/LLLA

N13 2" THREADED PLUG

N14 2" THREADED PLUG

N15 2" THREADED PLUG

N16 2" THREADED PLUG

MW2 36" MANWAY

N17 2" PRT RETURN

N18 2" WATER DRAW OFF

N19 3" ROOF DRAIN

8'-2"

8'-0"

8'-0"

8'-0"

6'-10"

GROUNDING CABLE

(TYP. 5)

PARTIAL PERIMETER

HANDRAIL

SPIRAL STAIRCASE

UPPER PLATFORM

TANK FOUNDATION

THICKENED

INSERT PLATE

.497

.493

.494

MW1

.494

LLA/LLLA

ASSEMBLY

SUPPORT

(TYP. 2)

.495

.493

.497

.496

N6

N19

TLG SUPPORT

(TYP. 5)

THICKENED

INSERT PLATE

1'-0"

SECONDARY TANK BOTTOM

PRIMARY TANK BOTTOM

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

GEODESIC DOME ROOF

4-5 4-1

4-2

4-3 4-4

2-1 2-2 2-3 2-42-5

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

5-5 5-1 5-2 5-35-4

GEODESIC DOME ROOF

SUPPORT

.255

.256

.254.253

MW2

HLA/HHLA

ASSEMBLY

SUPPORT

(TYP. 2)

CONDUIT SUPPORT

(TYP. 4)

MID STAIRCASE

PLATFORM

TANK SPIRAL

STAIRCASE

ENTRY

PLATFORM

N2

N3

N7

N8

N14

N16

N10

N11

N9

N12

N13

N5

N4

N1

LEAK DETECTION

PORT (TYP. 4)

A

B

C

D

PLATFORM

SUPPORT (TYP. 4)

N15

N18

N17

INSERT PLATE

INSERT

PLATE

NOTES:

1. REFER TO TABLE 1, "SHELL UTT MEASUREMENTS", IN

APPENDIX A FOR INDIVIDUAL SHELL PLATE UTT

READINGS.

2. REFER TO TABLE 2, "SHELL NOZZLE/REPAD UTT

MEASUREMENTS", FOR NOZZLE DATA.

C O

N T

R A

C T

N

O

F I L E

A M

E

D W

N

B

Y

C K

D

B

Y

D E

S I G

N E

D

B

Y

D E

S C

R I P

T I O

N

D

2 3

C

A

B

M A

R K

A P

P R

D A

T E

F I L

U M

B E

R

S I Z

E

S U

B M

I T

T E

D

B

Y

P L O

T

S

C A

L E

P

L O

T

D

A T

E

D A

T E

M A

R K

D E

S C

R I P

T I O

N

D E

L I V

E R

Y

O

R D

R

SHEET

IDENTIFICATION

D A

T E

A P

P R

SHEET OF

U S

A

R M

Y

C

O R

P S

F

E

N G

I N

E E

R S

O M

A H

A

N

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TANK INFORMATION

TANK NO.: TANK 2

MANUFACTURER: GATX

YEAR BUILT: 1955

TANK DIAMETER: 42'-6"

TANK HEIGHT: 40'-0"

NOMINAL CAPACITY: 10,115 BBL

PRODUCT: JET-A

PRODUCT SPECIFIC GRAVITY: 0.85

GPS COORDINATES: 33.62328°, -88.4442°

N A

S H

E L

L

L

A Y

O U

T

A-1

LEGEND:

- UTT THICKNESS READING

- SHELL DEFORMATION

.XXX

TABLE 1 - SHELL UT MEASUREMENTS

Roof

Shell Course

Plate 5-1 Plate 5-2 Plate 5-3 Plate 5-4 Plate 5-5

.246 .249 .248

.247 .249 .244

.246 .249 .250 .251

Avg. .248

Circumferential Weld C5

Shell Course

Plate 4-1 Plate 4-2 Plate 4-3 Plate 4-4 Plate 4-5

.254 .255 .253

.255 .258 .258

.254 .255 .250 .257

Avg. .255

Circumferential Weld C4

Shell Course

Plate 3-1 Plate 3-2 Plate 3-3 Plate 3-4 Plate 3-5

.260 .257 .254

.266 .263 .263

.252 .264 .258 .264

Avg. .260

Circumferential Weld C3

Shell Course

Plate 2-1 Plate 2-2 Plate 2-3 Plate 2-4 Plate 2-5

.246 .245 .240

.240 .241 .249

.247 .249 .238 .253

Avg. .245 Circumferential Weld C2

Shell Course

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

.251 .253 .257 .250 .252 .255 .310 .311 .309 .258 .263 .276 .257 .257 .263 .253 .261 .256

.258 .256 .260 .252 .257 .255 .308 .311 .312 .263 .263 .277 .258 .262 .265 .254 .260 .257

.246 .255 .254 .250 .253 .253 .307 .309 .311 .259 .262 .273 .256 .259 .258 .254 .260 .260

Avg. .254 .253 .310 .266 .259 .257 Circumferential Weld C1

Notes Thickness represented in inches.

Average Shell Course 1: .267 Average Shell Course 3: .260 Average Shell Course 5: .248 Average Shell Course 2: .245 Average Shell Course 4: .255

TABLE 2 - SHELL NOZZLE / REPAD UT MEASUREMENTS

Nozzle Nozzle Size

(Diameter or Width/Height)

Repad Shape

Repad Size (W X H)

Repad Thickness

Nozzle Thickness

H1 H2

Nozzle Location (Measured circumferentially from Manway 1)

Notes 0⁰ 90⁰ 180⁰ 270⁰

MW1 36'' D* 72" x 72" See A-1 .251 .250 .254 .259 3'-4" 1'-10" 0'-0" Manway N1 6" D 20 1/3" x 24" .309 .437 .424 .428 .410 1'-2 ½" 0'-0" 12'-1" Receipt N2 - - - - TH TH TH TH - - 16'-5" Threaded Plug N3 - - - - TH TH TH TH - - 16'-5" Threaded Plug N4 3" D 15" x 14" .315 .303 .289 .305 .302 0'-7 ½" 0'-0" 19'-3" Blind Flange N5 10" F* 42" x 24" See A-1 .499 .518 .500 .507 1'-0" 0'-5 ¾" 35'-2" Main Suction N6 4" B 12" .316 .319 .315 .341 .332 1'-0" 0'-5 ½" 38'-10" Low Suction N7 1 ½" - - - TH TH TH TH 34'-0" 33'-11 ¼" 50'-9" Threaded Plug N8 1 ½" - - - TH TH TH TH 33'-5 ½" 33'-4 ¾" 50'-9" Threaded Plug

N9 1 ½" - - - - .264 .250 - 34'-0" 33'-11 ¼" 51'-2" HLA/HHLA

N10 1 ½" - - - - .251 .260 - 32'-0" 31'-11 ¼" 51'-2" HLA/HHLA

N11 1 ½" - - - - .266 .263 - 4'-1/2" 3'-11 ¾" 51'-2" LLA/LLLA

N12 1 ½" - - - - .260 .263 - 2'-7" 2'-6 ¼" 51'-2" LLA/LLLA

N13 2" - - - TH TH TH TH 35'-9" 35'-8" 52'-10" Threaded Plug N14 2'' - - - TH TH TH TH 34'-2 ½" 33'-1 ½" 52'-10" Threaded Plug N15 2'' - - - TH TH TH TH 32'-8" 32'-7" 52'-10" Threaded Plug N16 2'' - - - TH TH TH TH 32'-2" 32'-1" 52'-10" Threaded Plug

MW2 36" B* 16" See A-1 .459 .470 .489 .480 3'-4" 1'-10" 73'-6" Manway N17 2" - - - .382 .376 .386 .384 0'-9" 0'-7 ½" 87'-5" PRT Return N18 2" - - - TH TH TH TH 0'-9" 0'-7 ½" 89'-6" Water Draw N19 3" D 15" x 20" .334 .288 .318 .302 .307 1'-1/2" 0'-0" 96'-1" Roof Drain

Refer to drawing A-1 in Appendix A for nozzle numbers and locations.

Thicknesses are represented in inches.

* = Thickened insert plate TH = Threaded H1 = Centerline of pipe to the tank chime.

H2 = Lower weld toe of reinforcement pad or nozzle to the tank chime or shell plate weld.

Repad Shapes:

TABLE 3 - SHELL DFT MEASUREMENTS

External Shell Coating Thickness

Average Standard Deviation Number of Readings Minimum Maximum

18.63 3.64 20 13.74 28.71

Thicknesses are represented in mils.

TABLE 4 - SHELL SETTLEMENT MEASUREMENTS

Point Arc Length (ft.) Tank Chime (ft.)

1 0.00 2.200 2 26.31 2.217 3 52.62 2.200 4 78.93 2.150 5 105.24 2.150 6 131.55 2.183 7 157.87 2.433 8 184.18 2.467

Settlement points were measured clockwise from MW1.

The listed data should be used in future API inspections for comparison.

API-653 APPENDIX B SHELL SETTLEMENT EVALUATION

(para. B.2.2.4)

Report No Client Inspector Vessel Date Columbus AFB Tank

2 USACE Andrew Morrissette (POND) Tank 2 02/27/2020

Base Elev Max Elev Elev

FT 2.150 2.467 0.317 R^2 = 0.831

IN 25.800 29.604 3.804

MorrissetteA Text Box The optimum cosine curve used in the shell settlement evaluation per API 653 para. B.2.2.4 is invalid as R2 is less than 0.90. As an alternative, the evaluation provided in API 653 para. B.2.2.5 was used in determining shell settlement. See next page.

(para. B.2.2.5) Report No. Client Inspector Vessel Date

Columbus AFB Tank 2 USACE Andrew Morrissette

(POND) Tank 2 2/27/2020

Base Elev Max Elev Elev

FT 2.150 2.467 0.317

IN 25.800 29.604 3.804

Report No.: Columbus AFB Tank 2

D H Roof Type 1st Crs Plt Spec Y E K

42.500 39.1 F Unknown 30000 29000000 10.500

Where:

D = Tank Diameter, in ft H = Tank Height, in ft Roof Type: F = fixed, O = Open Y = Yield strength of shell 1st course , in pounds per Sq.Inch (psi) E - Young's modulus, in pounds per Sq.Inch (psi) K = factor from table in B.3.2.2 (API-653 App. B) PE2 = Predicted elevation (for secondary evaluation), in ft Sarc = the effective settlement arc length, see B.2.2.5.1, in ft Si = out-of-plane settlement, in inch Smax = Maximum allowed out-of-plane settlement, in inch (min(K*Sarc*(D/H)*(Y/E), 4.0)

Point Elevation PE2 Sarc Si Smax Results

1 2.200 0 2.342 33.4 1.704 0.394 UNSAT

2 2.217 45 2.217 100.1 0.000 1.182 SAT

3 2.200 90 2.259 100.1 0.704 1.182 SAT

4 2.150 135 2.300 100.1 1.804 1.182 UNSAT

5 2.150 180 2.342 100.1 2.304 1.182 UNSAT

6 2.183 225 2.384 100.1 2.408 1.182 UNSAT

7 2.433 270 2.425 100.1 0.092 1.182 SAT

8 2.467 315 2.467 33.4 0.000 0.394 SAT

MorrissetteA Text Box The settlement evaluation is not satisfied at points 1, 4, 5, and 6 as Si is greater than Smax. No visual signs of excessive settlement or stresses on the shell were observed during the time of inspection. Settlement should be monitored during future API 653 inspections as well as inspections performed by facility personnel.

SHELL MINIMUM THICKNESS CALCULATIONS

Tank Shell Minimum Thickness and Remaining Life Calculations Date 02/27/2020

File No. Report No. Client Tank No. Temp. (degF) Initials

3648 Columbus AFB Tank

USACE Tank 2 Andrew Mo tmin = 2.6(H-1)DG

SE

Where:

H = The height above the bottom of the course of study to the maximum liquid level height of the product, in ft. For corroded or pitted areas, H = the height from the bottom of the corroded or pitted area to the maximum liquid level height of the product, in ft.

tmin = The calculated minimum acceptable shell thickness, in inch (cannot be less than

0.10 inch for any course). The minimum acceptable shell thickness allowed by API-653 and STI-SP001 for tank size, in inch .

D = Nominal diameter of tank, in ft.

G = Highest specific gravity of the contents (including test water if tank will, or may, be tested in the future).

S = Maximum allowable stress, in psi. For welded tanks; use the smaller of 0.80Y of 0.429T for bottom and second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks; S = 21000 psi. For STI Tank Inspections S = 26000 psi (E = 1)

Y = Specified minimum yield strength of the plate, in psi; use 30000 psi if not known (N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80000 psi; use 55000 psi if not known (N/A for riveted tanks).

E = Original joint efficiency for the tank. For welded tanks; use API-653, Table 2-1 ; use E =

1.0 when evaluating the retirement thickness in a corroded plate, when away from welds or joints by at least the greater of one inch or twice the plate thickness. For riveted tanks; use E = 1.0 for shell plates greater than 1 inch away from rivets; use the value of E from API- 653 Table 2-1 when within 1 inch of rivets. For STI Tank Inspections E = 1 where S = 26000 psi.

D (ft) 42.50 G 0.84 E 0.85 Fill Height (ft) 37.8

Material Crs H (ft) H (ft) S (psi) tmin (inch) Course 1 Unknown 6.83 37.8 23600 0.170 Course 2 Unknown 8 31.0 23600 0.139 Course 3 Unknown 8 23.0 26000 0.100 Course 4 Unknown 8 15.0 26000 0.100 Course 5 Unknown 8.17 7.0 26000 0.100

SHELL REMAINING LIFE CALCULATIONS

Tprev is based on measurements from the previous OOS inspection report dated May 2003.

Tank Shell Minimum Thickness and Remaining Life Calculations Date 02/27/2020

File No. Report No. Client Tank No. Temp. (degF) Initials

3648 Columbus AFB Tank

USACE Tank 2 Andrew Mo

Ca = tact-tmin = Remaining Corrosion Allowance (inch) Cr = tprev-tact / Y = Corrosion Rate (inch/Yr) RL = Ca / Cr = Remaining Life (year)

Y = 17 = Tank age (year)

Where:

Ca = Remaining corrosion allowance of the shell course under consideration, in inch.

Cr = Corrosion rate of the shell course under consideration, in inch per year.

FHc = Calculated fill Height = (SEtact/2.6DG+1) + (product height below course of interest), in ft.

tact = Minimum thickness measurement of the shell course under consideration, as recorded at the time of inspection, in inch.

tmin = minimum required thickness of shell course, at the maximum allowable fill height, in inch.

tprev = previous thickness measurement of shell course under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inch.

RL = Estimated remaining life of the shell course under consideration, in year.

Y = Time span between thickness readings or age of the tank if nominal thickness is used for tprev, in year.

tprev tact tmin Ca Cr RL FHc Course 1 0.252 0.267 0.170 0.097 0.0000 >40 58.70 Course 2 0.240 0.244 0.139 0.105 0.0000 >40 60.57 Course 3 0.257 0.260 0.100 0.160 0.0000 >40 77.74 Course 4 0.251 0.255 0.100 0.155 0.0000 >40 84.55 Course 5 0.243 0.248 0.100 0.148 0.0000 >40 90.88

NEXT INSPECTION

The interval between tank inspections (both internal and external) should be determined by the tank service history.

Inspection intervals can be adjusted based on known corrosion rates. Corrosion rates can only be determined when a comparison is made between UTT measurements taken over an interval of time. In this case, corrosion rates were determined using thicknesses provided by the inspection report dated May 2003 and UTT measurements taken during this inspection. Listed below are recommended inspection intervals:

1. Routine In-service Inspection

Facility personnel shall perform a visual inspection of the tank exterior surfaces and associated piping. Gross defects, leaks, shell distortions, signs of settlement, and corrosion should all be monitored along with the foundation condition (including tank chime-to-foundation joint), coating, and appurtenances.

a. Interval: Monthly

2. External Visual Inspection

Formal visual external inspection shall be performed by an API certified inspector every five (5) years or RCA/4N years (where RCA is the difference between the measured shell thickness and the minimum required thickness and

N is the shell corrosion rate), whichever is less. Based on the review of shell thickness measurements, the 5-year interval will govern the next external visual inspection. This inspection includes inspection requirements listed in a routine in-service inspection as well as a visual inspection of the tank grounding system.

b. Interval: Five (5) years; February 2025

3. External Visual Inspection with Ultrasonic Thickness Testing

An API certified inspector with the assistance of an NDT examiner shall perform this inspection. UTT measurements shall be taken to verify thickness of the tank shell and associated components. Obtained UTT measurements are used to determine corrosion rates and remaining life of the tank shell. UTT measurements of shell plates can be performed with the tank in service and scheduled at a maximum interval of fifteen (15) years or RCA/2N, whichever is less.

Based on shell thickness measurements and corrosion rates, the recommended interval for this inspection is fifteen

(15) years.

c. Interval: Fifteen (15) years; February 2035

4. Internal Inspection

An API certified inspector with the assistance of an NDT examiner shall perform this inspection. This inspection consists of verifying that the tank bottom is not severely corroded and/or leaking, identifying and evaluation tank bottom settlement, and inspection requirements listed in both external visual inspections. The out-of-service API

653 inspection report dated May 2003, did not specify the next internal inspection interval.

d. Interval: Unknown

OSHA ACCESS STRUCTURE REPORT

API/OSHA Stairway Data API Required OSHA Required

Handrail Actual (in) Min (in) Max (in) Min (in) Max (in) Pass/Fail

Height: 46 30 34 30 38 Fail (API and OSHA)

Width: 27 ½ 28 N/A 22 N/A Fail (API)

APPENDIX B: API 653 CHECKLISTS FOR TANK INSPECTIONS

Tank In-Service Inspection Checklist

Item Completed

X

C.1.1 Foundation

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

C.1.1.1 Concrete Ring a Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt-welded annular rings under the shell.

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

X c Inspect for cavities under foundation and vegetation against bottom of tank. X d Check that runoff rainwater from the shell drains away from tank. X e Check for settlement around perimeter of tank. X

C.1.1.2 Asphalt a Check for settling of tank into asphalt base which would direct runoff rain water under the tank instead of away from it.

N/A b Look for areas where leaching of oil has left rock filler exposed, which indicates hydrocarbon leakage. N/A

C.1.1.3 Oiled Dirt or Sand

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

N/A

C.1.1.4 Rock a Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

N/A

C.1.1.5 Site Drainage a Check site for drainage away from the tank and associated piping and manifolds. X b Check operating condition of the dike drains. X

C.1.1.6 Housekeeping

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

C.1.1.7 Cathodic Protection a Review cathodic protection potential readings. X

C.1.2 Shells

C.1.2.1 External Visual Inspection a Visually inspect for paint failures, pitting, and corrosion. X b Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X c Inspect the bottom-to-foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank)

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

C.1.2.3 Riveted Shell Inspection a Inspect external surface for rivet and seam leaks. N/A b Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A c Inspect rivets for corrosion loss and wear. N/A

Tank In-Service Inspection Checklist Continued

Item Completed

X d Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. N/A e If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern:

number of rows, rivet size, pitch length, and note whether the joint is butt-riveted or lap-riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks) a Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack-welded junction, and for broken welds.

X b Check support welds to shell for pitting, especially on shell plates. X c Note whether supports have reinforcing pads welded to shell. X

C.1.3 Shell Appurtenances

C.1.3.1 Manways and Nozzles a Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates. X b Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X c Inspect for flange leaks and leaks around bolting. X d Inspect sealing of insulation around manways and nozzles. N/A e Check for inadequate manway flange and cover thickness on mixer manways. N/A

C.1.3.2 Tank Piping Manifolds a Inspect manifold piping, flanges, and valves for leaks. X b Inspect fire fighting system components. X c Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X d Check for adequate thermal pressure relief of piping to the tank. X e Check operation of regulators for tanks with purge gas systems. X f Check sample connections for leaks and for proper valve operation. N/A g Check for damage and test the accuracy of temperature indicators. N/A h Check welds on shell-mounted davit clips above valves 6 in. and larger. N/A

C.1.3.3 Autogauge System a Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X b Inspect autogauge head for damage. X c Bump the checker on autogauge head for proper movement of tape. X d Identify size and construction material of autogauge tape guide (floating roof tanks). X e Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X f Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X g On floating roof tanks, when the roof is in the lowest position, check that no more than two ft of tape are exposed at the end of the tape guide.

N/A h Inspect condition of board and legibility of board-type autogauges. N/A i Test freedom of movement of marker and float. N/A

C.1.3.4 Shell-Mounted Sample Station a Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

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

Completed

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

C.1.3.5 Heater (Shell Manway Mounted)

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

C.1.3.6 Mixer a Inspect for proper mounting flange and support. N/A b Inspect for leakage. N/A c Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation a Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly.

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

c

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

C.1.3.8 Swing Lines: External Guide System

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

C.1.3.9 Swing Lines: Identify Ballast Varying Need

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

C.1.3.10 Swing Lines: Cable Material and Condition a For nonstainless steel cable, check for corrosion over entire length. N/A b All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison

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

C.1.3.12 Swing Lines: Target 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.

N/A

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

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

C.1.4.2 Deck Plate External Corrosion

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

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.)

X

Completed

X

C.1.4.4 Level of Floating Roof a

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

N/A

C.1.4.5 Gas Test Internal Floating Roof a Test for explosive gas on top of the internal floating roof. Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

N/A

C.1.4.6 Roof Insulation a Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation.

N/A b Inspect for wet insulation under the weather coat. N/A c Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

N/A

C.1.4.7 Floating Roof Seal Systems 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).

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.

N/A

1) _______ _______ Opposite pair 1. N/A

2) _______ _______ Opposite pair 2. N/A c Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough). N/A d Inspect fabric for deterioration, holes, tears, and cracks. N/A e Inspect visible metallic parts for corrosion and wear. N/A f Inspect for openings in seals that would permit vapor emissions. N/A g Inspect for protruding bolt or rivet heads against the shell. N/A h Pull both primary and secondary seal systems back all around the shell to check their operation. N/A i Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

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

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch a Inspect condition and functioning of sample hatch cover. X b On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

N/A c Check for corrosion and plugging on thief and gauge hatch cover. X d Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance.

X e Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X

Completed

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

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

X

C.1.5.2 Gauge Well a Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. X b Check for a hold-off distance marker and tab with hold-off distance (legible). X c On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

N…