J.3_AEC Tank 1583 API 653 Ext.Final 2020.pdf

API 653 In‐Service Inspection Report

US Army Corps of Engineers Center of Expertise for Petroleum, Oils and Lubricants

USACE POL‐MCX

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 SETTLEMENT ANALYSIS

TANK DRAWINGS

OSHA ACCESS STRUCTURE REPORT

APPENDIX ‘B’: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX ‘C’: PHOTOGRAPHS

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 Airforce Base, Tennessee. An API 653 In-Service (visual external) Inspection was conducted for Facility No. 1583, on June 29, 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 in-service (visual external) inspection were made from the exterior of the tank.

Facility 1583, or Tank 19 is a 30-foot diameter by 40-foot tall, single wall, vertical, field-erected tank constructed in 1955 with a nominal storage capacity of 5,000 barrels (per dataplate) of F-24. A repair nameplate indicates repairs to the structure were made 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’.

Tennessee aboveground storage tank regulations require in-service and out-of-service inspections to be performed at intervals in accordance with API 653. The next API In-Service (external) inspection of Tank 19 should be performed by July 2025. The August 2009 out-of-service inspection report recommended an internal inspection to be performed by August 2029 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 1583 (Tank 19) located at Arnold Air Force Base, Tennessee. For Tank 19, an API 653 In-Service (external visual) Tank Inspection was performed on June 29, 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. 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 wetlands which are home to the Gopher Frog.

3. Previous Inspection and Repairs An inspection report indicates the tank was internally inspected in May 2008. The secondary containment joints and concrete were flagged for repair. The report recommended installing a lap welded reinforcement pad underneath the fixed roof support column, repairing the hair line coating crack around the base of the roof support column, and coating to cover 100 percent of the interior surface area in accordance with NACE standards. Other repairs included installing a 1/4-inch telltale hole in the water draw reinforcement, a new hinge pin to gauge well hatch/top, and a manway through the shell. Replacement of the corroded nuts on the anchor bolts and removal of deteriorated coating and surface rust from the external water draw piping were also recommended.

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 19 is an aboveground, vertical storage tank, measuring 30 feet in diameter and 40 feet tall, with a nominal capacity of 5,000 BBLs (per data plate). The tank has no shell overflow ports. The tank manufacturer’s original nameplate indicates that the tank was constructed to API in 1955 by Horton Tank. The tank was cleaned, inspected, and repaired/altered to API 653 in 2009 by ITSI.

2. Tank Foundation The perimeter of the bottom rests on a concrete ringwall. 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 the chime sealant had dry rotted and failed in several locations. The chime sealant should be replaced.

3. Tank Bottom The previous inspection report indicates that the bottom consists of cone-down lap welded steel plates.

4. Tank Roof The tank roof is a lap-welded cone roof, constructed out of steel plate with a center column. The shell has a spiral staircase and upper platform walkway for the roof. There is also extensive mold/mildew/algae growth in the surface of the roof as well as ponding.

5. Tank Shell The vertical and cylindrical shell consists of seven butt welded courses. The exterior of the shell was visually inspected and evaluated. The exterior was extensively covered in mildew.

6. Tank Appurtenances

a. Gauging The tank is equipped with a Varec 2500 series Model B tape gauge. The ATG and the mechanical tape gauge read 5 feet and 11 inches. As the readings are within 2 inches of each other, they pass.

b. Level Alarms The tank is provided with Cla-Val high, high-high, low, and low-low level alarms.

c. Stairs and Platforms The tank’s steel cone roof is accessible by a circumferential stairway mounted on the shell of the tank. The circumferential stairway step rise is generally 9 inches continuously from ground level to the top landing. The width of the stair steps is generally 22-1/2 inches. The bottom step was 18 inches above finished floor. The handrail height was 30 inches. There was minor corrosion observed on the handrail, stair treads, and top platform supports.

d. Grounding and Bonding The tank is grounded with one grounding cable.

7. Tank Coating The tank’s coatings were evaluated for deterioration. There was significant growth of mold/mildew/algae on the tank surface.

8. Tank Piping System Tank 19 has associated piping located within the containment dike. It is carbon steel piping supported by saddle-type stanchion supports. The piping penetrates the concrete containment walls via a steel casing provided with a mechanically adjustable segmented elastomeric seal.

9. Fire Protection System There are three aqueous film forming foam (AFFF) and firefighting cannons on the perimeter of the concrete dike.

10. Secondary Containment Secondary containment consists of an earthen berm with concrete cover. The secondary containment was evaluated during the inspection. Minor vegetation is present in the containment area at the perimeter and ringwall. The containment is of sufficient size to contain a total tank loss plus one foot of freeboard.

11. Cathodic Protection The tank bottom is protected by a sacrificial anode system. The system is combined with the adjacent tanks and there is one common rectifier located outside the west side of the containment area.

GENERAL TANK INFORMATION

ITEM DESCRIPTION

Owner United States Air Force Location Arnold AFB Facility Number 1583 Tank Number Tank 19 State / Country Tennessee / U.S.A.

City Tullahoma Inspection Date June 29, 2020 Tank Manufacturer Horton Tank Design Standard API 650 – 9th Edition (assumed) Date of Construction 1955 Tank Contents F-24 Tank Serial Number Control Number 6_9333 Tank Diameter 30’ Shell Height 40’ Overflow Height N/A Tank Capacity 5,000 BBL nominal Foundation Concrete ring wall

Construction and Material

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

Cathodic Protection Sacrificial Anode Bed

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 to 4” piping Welded carbon steel

Issue 6” nozzle to 4” piping Welded carbon steel Water Draw-off 2” Welded carbon steel

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

ATG (redundant) Alarms.

C. FINDINGS AND RECOMMENDATIONS

Tank Facility 1583 (Tank 19) 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.

No Short-term Repairs are required to be performed.

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. Remove Vegetation OBSERVATION: Some vegetation is present in the concrete joints and cracks of the secondary containment, especially at the perimeter, ringwall, and under the flush cleanout.

REFERENCE: UFC 3-460-03 paragraph 8-20.2.2 requires periodic inspection of secondary containment areas and removal of vegetation.

RECOMMENDATION: Continue to inspect the secondary containment and remove the vegetation on a regular basis.

b. Remove Mold, Mildew and Algae OBSERVATION: There is mold, mildew and algae growing on the tank roof, roof appurtenances, on and around the circumferential stairway, etc. The mold and algae may cause degradation of the coating and exterior.

REFERENCE: UFC 3-460-01, Section 8-3.10 requires the exterior of fuel storage tanks to be coated.

RECOMMENDATION: Before coating repairs are performed, pressure wash the exterior of the tank and apply a mold and algae inhibitor periodically.

c. Repair Coating OBSERVATION: There is minor coating failure and corrosion on bolts flanges, roof appurtenances, and more. The “Jet Fuel Jet A” label is peeling.

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: Provide approximately 50 square feet of spot repairs to the coatings on the aforementioned areas. Fix the Jet Fuel Label.

d. Repair Concrete OBSERVATION: There are cracks and spalling in the secondary containment and stairways. 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 secondary containment could lead to loss of secondary containment.

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 cracks and patch spalling concrete in the secondary containment area.

There is roughly 25 square feet of spalling that requires repair and approximately 50 linear feet of cracking in the secondary containment area.

e. Repair the Tank Bottom-to-Foundation Seal OBSERVATION: The tank bottom-to-foundation sealant has failed in several places.

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: Remove and provide roughly 55 feet of new chime sealant. Add the item to the checklist used by the facility to perform monthly and annual maintenance.

f. Provide Landing OBSERVATION: The rise of the circumferential stairway is approximately 9 inches. However, the rise of the bottom step above the concrete dike floor is approximately 18 inches.

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 landing at the bottom of the stairs approximately 8 inches below the bottom step. Do not block access to the bottom-to-foundation seal.

g. Provide Manhole Repairs OBSERVATION: The 36-inch manhole is not 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 36-inch diameter shell manholes with cover davits.

RECOMMENDATION: Provide the existing shell manhole with a davit in accordance with the UFC and AST standard. These repairs may be programmed to occur at the next out-of-service tank inspection when the tank is empty.

h. Modify Thermal Relief Piping OBSERVATION: The thermal relief piping is threaded on the receipt/issue piping and has SFIs.

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

RECOMMENDATION: Demolish threaded thermal relief piping and provide new welded pipe per UFC 3-460-01 requirements.

i. Provide Roof Perimeter Guardrail OBSERVATION: There is only a roof wing-rail, which provides fall protection on the roof only at the top of the stairs. As there is no guardrail around the remainder of the roof perimeter, the remainder of the roof is inaccessible without personal fall protection.

REFERENCE: 29 CFR Part 1910.28 (b) (June 2018) requires every open-sided floor or platform 4 feet or more above adjacent floor or ground level to be guarded by a standard railing. Guidance for design of the new tanks, provided in DoD Standard Design AW 78-24-27, includes a guardrail around the top of vertical ASTs.

RECOMMENDATION: The next time other major repairs to the tank are performed, provide a guardrail all around the perimeter of the tank roof.

j. Install Double Block and Bleed Isolation Valves OBSERVATION: The tank skins 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 two existing 4-inch isolation ball valves and one 2-inch ball valve and install double block and bleed valves on the water draw-off, tank issue, and tank receipt pipelines.

k. Repair Coating on the AFFF Piping OBSERVATION: The AFFF pipe has extensive coating failure and some surface corrosion.

REFERENCE: NFPA 30, paragraph 6.7.6 requires that fire protection system be maintained.

RECOMMENDATION: Coat 50 square feet of AFFF piping.

l. Repair Joint Sealant OBSERVATION: The concrete joint sealant in the dike area has 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.

m. Ponding on Roof OBSERVATION: There is ponding on the roof at three locations. Ponding areas are prone to coating failure and corrosion.

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.

n. Repair Conduit OBSERVATION: A conduit is broken inside the dike area.

REFERENCE: NFPA 70 paragraph 500.5(B)(2)(1) and Guidance for new construction, provided in UFC 3-460-01 Paragraph 2-11.1.2, considers all outdoor locations within 10 feet of fuel storage tanks and locations within, and extending upward to the top of, the dikes that surround aboveground tanks containing liquid fuels to be Class I, Division 2 in accordance with NFPA

70. NFPA 70 paragraph 501.15 requires conduit in Class I, Division 2 locations to be sealed.

RECOMMENDATION: Repair conduit so that it is sealed and not open to atmosphere inside the containment area.

APPENDIX ‘A’: ENGINEERING CALCULATIONS AND DRAWINGS

TANK OUT-OF-ROUNDNESS AND SETTLEMENT SURVEYS

There are no definitive criteria for determining tolerance of roundness in API 653 for an existing tank. The shape of the shell appears to exceed the allowable API 650 tolerance of plus or minus 1-inch of a new tank shell radius.

Based on the circumference of the shell measured near the bottom, the diameter of the shell at the bottom should be 30 feet. The actual measured shell diameter varies at the bottom with a deviation ranging from -3.05 inches to

3.80 inches. The actual measured shell diameter varies at the top of the tank with a deviation ranging from -2.33 inches to 2.81 inches. The tank was calculated to be out of plumb by 1.15 inches in the south. The maximum out-of-plane deflection was 0.36 inches. This is a negligible amount of settlement. 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.

It is recommended that the roundness be monitored at the next inspection. Survey roundness and settlement data as well as the shell settlement evaluation are included in the pages following.

Roundness Survey Equipment Used: Survey Equipment

Topcon QS X-Trac 8 Robotic/Reflectorless Total Station Last Calibrated – November 2017

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

SHELL SETTLEMENT ANALYSIS

Austin Brockenbrough & Associates, L.L.C. Job No. 20-018.01 Location: Arnold AFB Date: 8/28/20 Subject: Tank 19 - 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) = 30 (ft) Number of equally spaced data points (ft)= 8 L = Arc length between measurement points (ft) = 11.78 Tank Height (H) = 40.0 (ft)

Relative elevation of lowest horizontal weld seam. (ft)

* Z U S

0 7.97 0.00000 0.00 0.00 0.01 1 7.97 0.00000 0.00 0.00 0.00 2 7.97 0.00000 0.00 0.00 0.01 3 7.98 0.01000 0.00 -0.01 -0.01 4 7.97 0.00000 0.00 0.00 -0.01 5 7.95 -0.02000 0.00 0.02 0.02 6 7.97 0.00000 0.00 0.00 0.00 7 7.98 0.01000 0.00 -0.01 -0.01 8 7.97 0.00000 0.00 0.00 0.01

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 = 0.07 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 19 - 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)

5 47.1 0.03 0.03 OK

1 47.1 0.03 0.03 OK

* 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 →

Evaluation of the settlement by the arc length method indicates the settlement is within acceptable limits.

Si < Smax →

-0.03

-0.02

-0.01

0.00

0.01

0.02

0 2 4 6 8 10 Measured Elevation (ft)

Si1 Si5

TANK DRAWINGS

Job No.: 20-018.01

Job Title: SPCC Tank Inspections - Srnolf AFB

Subject: Tank Facility 19

By: Steffen Schilstra Date: 9/4/20

SHELL UTM DATA (0.001 inches)

1 3

2 4 Typical Shell Plate UTMs.

1 2 3 4 1-1 274 274 270 273 1-2 259 266 256 258 1-3 236 239 240 247 1-4 247 251 251 253 1-5 269 268 270 263

UTMs Taken From Stairway

1-5 263 277 269

2-3 234 249 235

3-3 180 181 172

4-3 184 188 182

5-3 201 200 199

6-2 188 201 187

Roof UTMs 1 2 3 4 5 6 7 8 9

241 243 194 193 193 189

P.O. Box 4800 4800 W. Hundred Road Chester, Virginia 23831 Phone: 804-748-8746 Fax: 804-748-7849 www.brockenbrough.com

OSHA ACCESS STRUCTURE REPORT

OSHA Circumferential Stairway Data

OSHA Rq’d Actual

(in) min (in) max (in)

Handrail Height 30 OK 30 34 Step Width 22.5 OK 22 NA

Step Rise 9 OK NA NA Bottom Step Rise 18 Not OK 7.75” 9.75”

BOTTOM STEP

RISE

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", 6" nozzle

Material: coated CS End Conn: Size:

4", 6" nozzle

Issue To:

Release Prevention Barrier

Overfill Protection / Level Alarms:

High, High-high, and Low HLCV

Receipt Piping Configuration Issue Piping Configuration Tank Piping

Secondary Containment

May 1, 2008

Tank Specifications

Previous Tank Inspection Date:

Continuous Release Detection Monitoring

Type:

Date Installed:

Current Product:

30'-0" diameter; 40'-0" tall

N/A

API 650

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

Fillstand *One nozzle serves as both issue and receipt

Unknown

Design Std

Tank Inspector Name:

Closed Top Dike

Change of Service:

Last Repair:

Tank Facility No.:

Local Tank ID No.:

June 29, 2020

Tank Manufacturer:

Tank Construction Date:

Tank 19

Inspector Certification Number:Inspection Date:

Daniel Caldwell

Vertical

Rectangular

Double Wall

Fire Resistant

Tank Coatings:

Exterior Coating:

DoD Three part (assumed)

Unknown

Interior Coating:

Double Bottom

Nameplate Illegible

Level Alarms:

Material: Butt weld/flanged

Other:

F-24

5,000 BBL

N/A

Secondary Containment, Overfill, and CRDM

Overfill Protection:

Unknown

Unknown

Unknown

Concrete Dike

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

Measure foundation levelness and bottom elevations (See Annex B)

ITEM

C.1.1 Foundation

COMMENTS

Settlement around perimeter of tank Check for:

d)

TASK

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

C.1.1.1 Concrete Ring Check for:

Tank Settlement

C.1.1.4 Rock a)

b) C.1.1.6 Housekeeping

Build-up of trash, vegetation, and other inflammables

Vegetation and mold in dike area, small weeds and grass growing up through joints in dike floor and around ringwall.

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

Sacrificial anodes?

a) b) a)

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

Extensive mold and mildew on roof, shell and chime.

Chime sealant failed in several places.

Jet A label peeling off.

Rivet and seam leaks on external surface 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:

Full fillet lap-welded vertical seams to increase joint efficiency

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)

Check for:

Grooving, corrosion, pitting, and coating failures

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

a) b)

Pitting on support welds to shell, especially on shell plates b)

C.1.2. Shells

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a) Leaks at piping manifolds, flanges, and valves

C.1.3.3 Autogauge System Check for:

COMMENTS

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

Check valves, threaded piping, SFIs, SS tubing Tank isolation valve - fusible link ball valve - No DBBs Minor corrosion on flanges, nuts and bolts

Manhole is hinged, no davits.

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)

ITEM TASK

Check for:

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 a) d)

Check for:

STATUS

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

b) Damage on autogauge head

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VAREC reading of 5'-11" vs. 5'-11 2/16" reading of ENRAF

1-1/2" CS

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) 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

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

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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

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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.)

2 areas with standing water on roof, no corrosion observed. Wet with red/black mold.

C.1.4 Roofs

TASK

Mold on roof - surface rust on appurtenances and flanges/bolts C.1.4.2 Deck Plate External Corrosion

ITEM 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.

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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.

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

C.1.4.7 Floating Roof Seal a) Systems

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Check for:

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Minor corrosion on flanges/bolting.

Minor corrosion on anterior of hatch.

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

Small SS tag.

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

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

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.

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:

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

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 e) c)

C.1.5.7 Roof-Mounted Vents

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Tank roof does not have full perimeter guardrail.

Lichen and minor corrosion on roof perimeter rail.

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.

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.

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)

ITEM

b) c)

1-1/2" CS pipe with coated grating and treads 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.

Identify cold joints and sharp edges.

Inspect the handrails and midrails.

d)

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.

TASK STATUS

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STATUS COMMENTS

c) Corrosion on steel support attachment to concrete base

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

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) c) d)

Check for:

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)

Check for:

ITEM TASK

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

Minor surface corrosion on grating.

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.

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.

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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) g) h)

Inspect rolling ladder stringers for corrosion.

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.

ITEM TASK

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.

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

1. Coating failure on 3" AFFF piping

7. Dike expansion joint failed in several places and around top perimeter of dike.

6. No DBB at tank skin.

5. Mold, algae on roof, nozzles, shell and chime.

Additional Findings and Comments:

2. Non-OSHA compliant approach step.

3. Chime sealant failed in several locations.

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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)

22.5

APPENDIX ‘C’: PHOTOGRAPHS

C.1: View of Tank from Northwest Vantage C.2: View of Tank from Northwest

C.3: View of Tank from Southwest C.4: View of Tank from Southeast

C.5: View of Tank from Northeast C.6: Flush Cleanout

1011 Boulder Springs Drive, Suite 200 Richmond, Virginia 23225

Phone: 804.592.3900 Fax: 804.592.3901 www.brockenbrough.com