Eielson AFB-4482 OOS Final Report.pdf

ACOE CONTRACT W911KB-21-D-0006, DELIVERY ORDER W911KB21F0047

TANK 3 (FACILITY NO. 4482)

API 653 IN-SERVICE INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

FINAL INSPECTION REPORT

(PRE-REPAIR)

Eielson Air Force Base, Alaska

November 2021

Contract Agency:

U.S. Army Engineer District, Alaska P.O. Box 6898 Elmendorf AFB AK 99506-6898

Prepared By:

2525 Gambell Street, Suite 200 Anchorage, AK 99503

George M. Markland IV API 653 Certificate No. 54131

Submitted By:

David A. Stchyrba, P.E.

API 653 Certificate No. 27187

EEI Project No. 9812

Page Intentionally Left Blank

Tank 3 – API 653 Inspection SUITABILITY FOR SERVICE STATEMENT Eielson AFB, Alaska November 2021 EEI Project No.: 9812

SUITABILITY FOR SERVICE TESTAMENT

TANK 3 (FACILITY NO. 4482)

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, in-service external integrity inspection and suitability for service evaluation of Tank 3 at Eielson AFB, Alaska. The inspection was performed on September 2, 2021. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, UFC 3-460-03, and the Statement of Work.

The EEI inspection and evaluation found no conditions that affect the hydraulic and structural integrity of the tank. The tank may remain in service.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair. Recommendations for continued long-term service are also provided.

EEI recommends the next API 653 external in-service inspection be scheduled no later than September 2026 (5 years from 2021 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API 653 internal out-of-service inspection be scheduled no later than August 2031 (20 years from the 2011 inspection performed by EEI), or sooner if a change in condition has occurred.

In accordance with API Standard 653 and ADEC Regulation 18AAC75, this report satisfies the requirement for an in-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

November 9, 2021 George M. Markland IV, Inspector of Record Date API 653 AST Inspector Certificate No. 54131

This tank inspection has determined that mandatory repairs are not required at this time. Tank 3 may remain in service. Recommended repairs have been identified. It is recommended that these repairs be performed as soon as feasible, or the next time the tank is removed from service.

Tank 3 – API 653 Inspection TABLE OF CONTENTS

EEI Project No.: 9812

TABLE OF CONTENTS

Page

1.0 SUMMARY

Scope General

2.0 INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

3.0 REPAIR ITEMS

Standard of Care Required Repairs (Mandatory) Recommended Repairs (Non-Mandatory) Recommended Repairs for Long Term Serviceability

4.0 SUITABILITY FOR SERVICE EVALUATION

Historical Discussion Corrosion Rates Tank Shell Corrosion Rates Hydraulic and Structural Integrity Summary

5.0 CLOSURE

Conclusions EEI Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ...................................................................... Appendix A Assessment of Compliance with Military Criteria ....................................................................... Appendix B Non-Destructive Examination (NDE) and Evaluation Criteria ................................................... Appendix C Tank Drawings ............................................................................................................................. Appendix D Tank Photographs ........................................................................................................................ Appendix E NDE Results................................................................................................................................. Appendix F Calculations.................................................................................................................................. Appendix G

Tank 3 – API 653 Inspection Page 1

EEI Project No.: 9812

TANK 3

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

EIELSON AIR FORCE BASE, ALASKA

1.0 SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an in-service external integrity inspection of Tank 3 at Eielson Air Force Base, Alaska. The inspection was performed on September 2, 2021.

The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3- 460-01, UFC 3-460-03, and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs, and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 3 is a vertical field-erected aboveground storage tank. The tank was originally fabricated and constructed in 1954 based on historical records. The tank is 53 feet in diameter and 25 feet 8.75 inches high and is of welded construction with butt-welded shell plates and lap welded roof plates. The tank floor is cone down with lap welded floor plates and a near center sump. The tank is equipped with an internal single wall aluminum floating pan that was installed in 1998 in addition to other modifications.

The nominal shell capacity is 10,000 BBLS. Tank 3 is currently in JP-8 service.

2.0 INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Based on the results of this inspection and lack of mandatory repairs, Tank 3 is suitable to remain in service.

Hydraulic Integrity

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

Inspection of the tank floor projection, shell, and roof found no holes or indications of leaks. A visual inspection of accessible welds found no evidence of deterioration or poor workmanship.

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

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EEI Project No.: 9812

Structural Integrity

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

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

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

Next Inspection

API 653 requires an in-service inspection by an authorized inspector be performed every 5 years or RCA/4N years, whichever is less. RCA is the remaining corrosion allowance of the shell (i.e. the difference between the minimum measured shell thickness and the minimum required shell thickness in mils) and N is the shell corrosion rate in mils per year. When shell corrosion rates are unknown, API 653 requires the in-service inspection interval not to exceed 5 years.

EEI recommends the next API 653 external in-service inspection be scheduled no later than September 2026 (5 years from this 2021 inspection), or sooner if a change in condition or change in service has occurred.

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires the interval until the next internal inspection be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years for tanks without a release prevention barrier or 30 years for tanks with a release prevention barrier.

It should be noted that ADEC may reduce the inspection interval for a specific storage tank if

(a) The storage tank is older than 30 years,

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion, or foundation problems, or

(d) After a significant seismic event.

Although the tank is older than 30 years, it is not anticipated that the state will require a reduced inspection interval.

API 653 requires the interval until the next internal inspection be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years. When RBI procedures are used, the interval shall not exceed 25. If the tank has a release prevention barrier and leak detection designed in accordance with API 650 Appendix I and RBI procedures are used, the interval shall not exceed 30 years. As an RBI assessment is not included in the scope of this inspection, the interval until the next out-of-service inspection was determined using corrosion rates as documented in the 2016 inspection report.

EEI recommends the next API 653 internal out-of-service inspection be performed no later than August 2031 (20 years from the 2011 out-of-service inspection). The next out-of-service inspection should be performed sooner if a change in condition or a change in service occurs.

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EEI Project No.: 9812

3.0 REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory), recommended for long-term serviceability, and recommended for non-tank inspection items. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tank's compliance with military criteria.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, NDE of welding and testing requirements. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor, and shall consider the tank has been in petroleum fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs (Mandatory)

REQUIRED REPAIRS (MANDATORY)

Findings Repair Photo

Mandatory repairs are repairs that are critical to the hydraulic or structural integrity of the tank and may require removing the tank from service.

No mandatory repairs were identified.

Recommended Repairs (Non-Mandatory)

RECOMMENDED REPAIRS (NON‐MANDATORY)

Findings Repair Photo

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank but should be performed if approved by the Government for the long‐term preservation and integrity of the tank.

1. Tank 3 is not provided with a facility number stenciled on the tank shell.

Apply facility number stenciling meeting the requirements of MIL‐ STD‐161H to the tank shell.

2. The stenciling applied to the Product Saver Tank does not meet current military standards.

Apply stenciling meeting the requirements of MIL‐STD‐161H to the Product Saver Tank.

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EEI Project No.: 9812

RECOMMENDED REPAIRS (NON‐MANDATORY)

Findings Repair Photo

3. The piping associated with Tank 3 is not provided with stenciling meeting the current military standards.

Apply stenciling meeting the requirements of MIL‐STD‐161H to the piping associated with Tank 3.

4. The exterior coating of Tank 3 appears to be near the end of its useful life.

Numerous past coating repairs are present and the coating was found to be severely “chalking”. Coating failures were observed at spot locations.

Program Tank 3 for a complete recoat of the exterior shell and roof. It is recommended that the exterior recoat be deferred until the next OOS inspection (August 2031). This recommendation has been carried over from the 2016 in‐service inspection performed by

EEI.

Note: In the interim, remove the coating from the affected areas of the tank shell, roof, and nozzles, clean, and recoat.

Qty: 100 SF

5. Vegetation was observed around the concrete ringwall and throughout the containment area.

Remove the vegetation and monitor for future growth as part of routine maintenance.

6. A large amount of standing water was observed in the containment area.

Facility personnel did not report any issues with the containment drainage system.

Test the containment drainage system, and perform necessary corrective measure to allow for proper drainage of the containment area.

7. The tank nameplate located above Manway #2 has fallen off of the tank.

Affix the nameplate to the tank following the procedures outlined in the current edition of API 650.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

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EEI Project No.: 9812

RECOMMENDED REPAIRS (NON‐MANDATORY)

Findings Repair Photo

8. The tape gauge did not move when bump tested bump tested by the inspector.

Recommend repairing or replacing the tape gauge.

Note: Replacement of the tape gauge may be performed at the next out‐of‐service inspection (August 2031).

9. The reinforcing plates for Manway 1, Manway 2, Manway 3, the 8‐inch blanked nozzle and the 2‐inch water draw have not been provided with telltale holes.

Provide telltale holes in accordance with the requirements of API 650 and 653. Pack the telltale holes with white grease to prevent the ingress of water.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

10. The product saver tank is not provided with a grounding cable.

Provide the product saver tank with a grounding tab and cable.

11. The 1‐inch water draw‐off line from the tank to the product saver tank is running directly above ground level without support. This configuration has created a risk of damage to the line caused by tripping hazards.

Reconfigure the 1‐inch water draw‐off line so that it is elevated above ground level and properly supported.

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EEI Project No.: 9812

RECOMMENDED REPAIRS (NON‐MANDATORY)

Findings Repair Photo

12. The Body Cavity Relief (BCR) tubing associated with the Double Block & Bleed (DB&B) valves on the 8‐inch fill and 4‐inch low fuel lines are relieving to the tank side of the valves.

Reconfigure the BCR tubing so that it relieves to the line side of the DB&B valve.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

13. The DB&B valves on the issue, low fuel, and water draw‐off lines are missing protective grease caps.

Replace the missing grease caps.

Qty: 5 Grease Caps

14. The 12‐inch issue line is resting directly on the pipe support located at the expansion loop.

Provide a low friction interface at the expansion loop pipe support.

15. The handrail affixed to the spiral stair system is not equipped with a midrail.

Provide a handrail meeting the requirements of OSHA and AW 78‐ 24‐27.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

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EEI Project No.: 9812

RECOMMENDED REPAIRS (NON‐MANDATORY)

Findings Repair Photo

16. The in‐service inspection performed in June 2016 recommended the midrail at the three roof vent/inspection hatches be cut to allow the vent/inspection hoods to open fully.

The midrails have been cut and the vent/inspection hoods can now open fully. However, the midrails have no support where they have been cut and can no longer support the design loads required by OSHA.

Provide upright posts constructed of 2‐inch carbon steel pipe at the three locations where the midrails have been cut. The posts shall be welded to the hand rail, midrail, and tank roof.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

17. Tank 3 is not equipped with a manual gauging hatch and slotted stilling well.

Manual gauging is currently performed from the nozzle with the ENRAF ATG displacer after it has been relocated.

Recommend installing a manual gauging hatch and slotted stilling well per the requirements of UFC 3‐460‐01 and AW 78‐24‐27.

Note: It is recommended that this repair be deferred until the next out‐of‐service inspection (August 2031).

18. The roof of Tank 3 has not been provided with non‐slip pathways to roof appurtenances.

Note: It has been observed that the majority of the tanks located at Eielson AFB are provided with non‐slip pathways on the roof.

Recommend applying non‐slip pathways to roof appurtenances that are frequently inspected/monitored during routine operation and maintenance.

19. A limited visual inspection of the Internal Floating Roof (IFR) wiper seal revealed gaps between the tank shell and the wiper seal.

Recommend assessing the condition of the wiper seal to determine if replacement is warranted at the next out‐of‐ service inspection (August 2031).

No Photo

Recommended Repairs for Long Term Serviceability

RECOMMENDED REPAIRS (LONG TERM SERVICEABILITY)

1. Program the tank for the next API 653 in‐service external inspection no later than September 2026 and the next API 653 out‐of‐service internal and external inspection no later than August 2031.

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

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EEI Project No.: 9812

4.0 SUITABILITY FOR SERVICE EVALUATION

Historical Discussion

Previous inspection reports were available for review. Past inspection documentation includes:

In-service inspection report dated September 2016 (performed by EEI).

Out-of-Service inspection report dated October 2011 (performed by EEI).

Corrosion Rates

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

Shell: 0.0003 inches per year Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates were calculated using an assumed original metal thickness and a 1954 year of construction.

Tank Shell Corrosion Rates

API 653 4.3.1.3 states that tank shell corrosion can occur in many forms and varying degrees of severity and may result in a generally uniform loss of metal over a large surface area or in localized areas. The corrosion rate for the tank shell was calculated based on the original nominal shell thickness and the minimum recorded shell thickness during the inspection.

UT readings of the shell were obtained at the bottom shell course and accessible locations from the spiral stairs at the upper shell courses. The shell plate thickness will not be reduced below the minimum value at a 20-year inspection interval.

Hydraulic and Structural Integrity Summary

The following table summarizes the hydraulic and structural integrity of the tank:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 3 sits on a concrete ringwall foundation. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Shell Visual inspection of the accessible shell joints found no relevant indications. A pit survey was conducted and no locations were identified for repair.

Acceptable

Roof Spot ultrasonic testing of the roof plates found no noticeable thinning of the plates.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

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EEI Project No.: 9812

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Hydrostatic Test

Shell is adequate to resist the internal fluid pressure caused by a full‐height hydrostatic test with water.

Acceptable

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980): No, constructed in 1954.

2. Has a prior hydrotest been performed demonstrating fitness: Unknown.

3. Is the tank shell thickness < 0.5 inches: Yes.

4. Does the tank operate at metal temperature above

60 deg F?: No.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4.1 or API 653

Figure 4.1: Yes.

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

Figure 4.1: Unknown.

Tank 3, having a shell thickness less than 0.5 inches and having steel exempt per Figure 5.2, does not fit the API 653 at‐risk profile for brittle fracture failure.

Seismic Evaluation

The tank is unanchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank shell stresses are within limits at the current fill height of 21 feet 7‐3/8 inches.

Calculations were performed utilizing the specific gravity for JP‐8 (S.G. = 0.84), a ringwall foundation, seismic parameters Ss = 0.966, S1 = 0.377, and Risk Category III.

Acceptable

Wind Evaluation

A wind analysis was performed per API 650, Section 5.11.

Calculations were performed using Risk Category III and a wind velocity of 115 mph.

The evaluation determined that an empty tank is stable and not at risk of overturning or sliding.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 115 mph.

Acceptable

5.0 CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 3 is considered suitable to remain in service.

EEI Project Team

Site Team

George M. Markland IV Inspector of Record API 653 AST Inspector Certificate No. 54131

API 570 Piping Inspector Certificate No. 62156

Tank 3 – API 653 Inspection Page 10

EEI Project No.: 9812

Karl R. Schlenker Senior Mechanical Integrity Engineer API 653 Inspector Certificate No. 40225 API 570 Piping Inspector Certificate No. 41177

Support Team

Stacy M. Kaplan-McMillan Senior Project Manager

David A. Stchyrba, P.E. Structural Engineer, QA Review API 653 AST Inspector Certificate No. 27187

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

Tank 3 – API 653 Inspection APPENDIX A, Tank Summary Sheet Eielson AFB, Alaska EEI Project No.: 9812

DLA ENERGY TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location (Site Code): Eielson Air Force Base, Oscar Row Fuels Complex, Alaska Tank No.: 3

Facility No.: 4482 Inspection Date(s): September 2, 2021

Tank Type: Vertical Above Ground Storage Tank Type of Inspection: External w/ Suitability for Service Evaluation

Contract Number, Task Order: W911KB-21-D-0006, Delivery Order W911KB21F0047 Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: George M. Markland IV

API-653 AST Inspector Certificate No. 54131

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard (Original): Unknown, 1954, API 12C (Assumed) Diameter: 53’-0”

Shell Height: 25’-8.75” Product, Specific Gravity: JP-8, 0.84

Design Pressure / Temperature: Atmospheric, unknown Gross Capacity / Nominal Capacity: 10,110 Bbls/10,000 Bbls

Operational Fill Height: 21’-7.375” (Per Facility) GPS Latitude & Longitude: 64 Deg 39’ 07.62” N, 147 Deg 04’ 41.78” W (Source – Google Earth) Foundation Configuration: Concrete Ringwall

Shell Configuration: Butt Welded, 3 courses Roof: Fixed cone, column supported

Floating Pan: Present, Single wall steel pan Cathodic Protection: Not present

Stilling Wells: (1) 8” steel stilling well for ENRAF ATG Displacer

(1) 8” aluminum stilling well for VITO Temperature/Water Probe

Last Inspection (Type, Date): In-Service, June 8-10, 2016 by EEI Out-of-Service, August 16, 2011 by EEI

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

INSPECTION RESULTS

Can tank remain in service?: Yes.

Deficiencies identified as mandatory repairs: No Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term Serviceability” in body of report

Next Scheduled API Inspections (Type, Date): API 653 In-Service: September 2026 (5 Years) API 653 Out-of-Service: August 2031 (20 Years from the 2011 OOS inspection)

Next Scheduled Tank Cleaning (UFC 3-460-03): August 2021 (10 years from last internal tank cleaning)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: None available

API STANDARD 653

TANK IN-SERVICE INSPECTION CHECKLIST

Tank 3 – API 653 Inspection APPENDIX A, Page 1

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM Location: Eielson AFB, Alaska Date: 9/16/2021 EEI Project No.: 9812

Item Completed Comments

C. 1.1 FOUNDATION

Measure foundation levelness and bottom elevations (see Appendix B for extent of measurements) X No evidence of settlement

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 Concrete ringwall in good condition.

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

X Tank is not provided with a standpipe or leak detection ports.

c. Inspect for cavities under foundation and vegetation against bottom of tank. X No issues observed.

d. Check that runoff rainwater from the shell drains away from tank. X No issues observed.

e. Check for settlement around perimeter of tank. X The maximum differential between the max and min elevations is 0.05 feet.

C.1.2 Asphalt

a. Check for settling of tank into asphalt base which would direct runoff rainwater under the tank rather than away from it.

N/A

b. Look for areas where leaking of oil has left rock filler exposed, which indicates hydrocarbon leakage.

C.1.1.3 Oiled Dirt or Sand

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

C. 1.1.4 Rock

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 tank is out of service.

C.1.1.5 Site Drainage

a. Check site for drainage away from the tank and associated piping and manifolds. X

Standing water observed in containment area. Facility personnel state the containment drain is functioning properly

b. Check operating condition of the dike drains.

X

No issues found.

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EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

C.1.1.6 Housekeeping

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

Vegetation observed in the containment area. Recommend removing as part of routine maintenance.

C.1.2 SHELLS

C.1.2.1 External Visual Inspection

a. Visually inspect for paint failures, pitting, and corrosion.

X

Exterior tank coating has reached the end of its life. Recommend a total exterior recoat at next OOS inspection. 100 SF of repairs in the interim.

b. Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X Floor projection thicknesses are within mil tolerances.

c. Inspect the bottom-to-foundation seal, if any.

X

Seal at the floor projection in very good condition. No evidence of holes or cracks.

C.1.2.2 Internal (Floating Roof Tank)

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

A limited visual inspection was performed from the inspection hatches. Inspectors found they could see product between the wiper seal and the tank shell.

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

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.

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.

b. Check support welds to shelf for pitting, especially on shell plates. N/A

Tank 3 – API 653 Inspection APPENDIX A, Page 3

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

c. Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 SHELL APPURTENANCES

C.1.3.1 Manways and Nozzles

a. Inspect for cracks or signs of leakage in weld joint at nozzles, manways, and reinforcing plates. X

Telltale holes are missing from five repads. Recommend installing at the next OOS inspection.

b. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X No issues found.

c. Inspect for flange leaks and leaks around bolting. X No issues found.

d. Inspect sealing of insulation around manways and nozzles. N/A

e. Check for inadequate manway flange and cover thickness on mixer manways.

C.1.3.2 Tank Piping Manifolds

a. Inspect manifold piping, flanges, and valves for leaks. X No issues found

b. Inspect firefighting system components. X AFFF system present. No issues found

c. Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement. X

1-inch stainless steel line from the tank to the PST running at ground level with no support and exposed heat tracing.

Recommend reconfiguring.

d. Check for adequate thermal pressure relief of piping to the tank. X Thermal relief piping present and appears adequate.

e. Check operation of regulators for tanks with purge gas systems. N/A

f. Check sample connections for leaks and proper valve operation. N/A

g. Check for damage and test the accuracy of temperature indicators. X

Temperature probe is integrated with the ATG system. Appears to be functioning properly.

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 No issues found.

b. Inspect autogauge head for damage. X No issues found.

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EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

c. Bump the checker on autogauge head for proper movement of tape. X

Tape gauge did not function properly when bump tested. Recommend repairing/replacing the tape gauge at next OOS inspection.

d. Identify size and construction material of autogauge tape guide (floating roof tanks). N/A

e. Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X Personnel report they rely on the ATG system for product level.

f. Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X

Tape gauge level and ATG level vary by roughly 4 inches. Recommend repairing/replacing the tape gauge.

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.

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 Samples Station

a. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

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

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 connection to mixer. N/A

C. 1.3.7 Swing Lines: Winch Operation

a. Nonfloating. Raise, then lower the swing line with 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

Tank 3 – API 653 Inspection APPENDIX A, Page 5

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM line 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.

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

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

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 the rafters in the center of the roof first.)

X

No issues found.

C.1.4.2 Deck Plate Exterior Corrosion

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck. X No issues found

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 in a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons).

X

No standing water present. Recommend providing non-slip pathways to roof nozzles and appurtenances.

Tank 3 – API 653 Inspection APPENDIX A, Page 6

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

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.

N/A

External inspection only.

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.

N/A

External inspection only.

C.1.4.6 Roof Insulation

a. Visually inspect for cracks or leaks in the insulation weather coat where runoff rainwater could penetrate the insulation.

N/A Tank is uninsulated.

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.

C.1.4.7 Floating Roof Seal System

a. Measure and record maximum seal-to-shell gaps at: N/A

External inspection only. Gaps between the seal and shell observed from the inspection hatches.

1. Low pump out

2. Mid-shell

3. High liquid level

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.

1. __________ _________ Opposite pair 1.

2. __________ _________ Opposite pair 2.

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

d. Inspect fabric for deterioration, holes, tears, and cracks. N/A

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EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

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.

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

Manual gauging performed from the nozzle with the ENRAF ATG displacer.

Recommend providing manual gauging hatch at next OOS per UFC.

b. On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

c. Check for corrosion and plugging on thief and gauge hatch cover. X No Issues

d. Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold-off distance.

e. Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X No Issues

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

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).

C.1.5.2 Gauge Well

a. Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. N/A

Tank 3 – API 653 Inspection APPENDIX A, Page 8

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

b. Check for a hold-off distance marker and tab with hold-off distance (legible). N/A

c. On floating roof, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

d. If accessible, check the distance from the gauge well pipe to the tank shell at different levels.

e. If tank has a gauge well washer, check valve for leakage and presence of a bull plug or blind flange.

C.1.5.3 Fixed Roof Scaffold Support

Inspect scaffold support for corrosion, wear, and structural soundness. N/A

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

a. Check the hatch for corrosion and missing bolts. X No issues found.

b. Look for corrosion on the tape guide and float guide’s wire anchor. X

C.1.5.5 Autogauge: Float Well Cover

c. Inspect for corrosion. X No issues found.

d. Check tape cable for wear or fraying caused by rubbing on the cover. X No issues found.

C.1.5.6 Sample Hatch (Internal Floating Roof)

a. Check overall conditions. N/A

b. When equipped with a fabric seal, check for automatic sealing after sampling. N/A

c. When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check condition of screens, locking, and pivot pins.

X

Tank is equipped with three perimeter roof vents. All are provided with protective screens. All are in good condition.

C.1.5.8 Gauging Platform Drip Ring

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

C.1.5.9 Emergency Roof Drain

Tank 3 – API 653 Inspection APPENDIX A, Page 9

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

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.

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

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.

C.1.5.12 Rim Vents

a. Check condition of the screen on the rim vent cover. X No issues found

b. Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. X No issues found

C.1.5.13 Pontoon Inspection Hatches

a. Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A

b. Test for explosive gas (an indicator of vapor space leaks). N/A

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

C.1.6 Accessways See item C.2.12 below.

C. 2.12 ACCESS STRUCTURES

C. 2.12.1 Handrails

a. Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails. X 2-inch pipe

b. Inspect for pitting and holes, paint failures.

X Coating on roof handrails in good condition.

c. Inspect attachment welds. X Welds in good condition.

d. Identify cold joints and sharp edges. Inspect the handrails and midrails. X No issues found.

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

Safety chains at roof vent hatches. Issues with midrail terminations. See Recommended Repair #16.

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

Tank 3 – API 653 Inspection APPENDIX A, Page 10

EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

C. 2.12.2 Platform Frame

a. Inspect frame for corrosion and paint failure. X Minor coating failures and corrosion.

b. Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure. X Welds in good condition.

c. Check reinforcing pads where supports are attached to shell or roof. N/A

d. Inspect the surface that deck plate or grating rests on, for thinning and holes. X No issues found.

e. Check that flat-surface-to flat-surface junctures are seal welded. X Seal welds are used. No stitch welds found.

C. 2.12.3 Deck Plate and Grating

a. Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure. X Grating is in good condition.

b. Inspect plate–to–frame wells for rust scale buildup. X No issues found.

c. Inspect grating for corrosion-caused thinning of bars and failure of welds. X Welds are in good condition.

d. Check grating tie down clips. Where grating had 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.

X

Welds in good condition.

C. 2.12.4 Stairway Stringers

a. Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. Inspect attachment of stairway treads to stringer.

X Minor coating failures and corrosion observed.

b. Inspect stairway supports to shell welds and reinforcing pads. X Spiral stairway not provided with a midrail. See Recommended Repair #15.

c. Inspect steel support attachment to concrete base for corrosion. X No issues found.

C. 2.12.5 Rolling Ladder

a. Inspect rolling ladder stringers for corrosion. N/A

b. 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.

c. Check for wear and corrosion where rolling ladder attaches to gaging platform. N/A

d. Inspect pivot bar for wear and secureness. N/A

e. Inspect operation of self-leveling stairway treads. N/A

f. Inspect for corrosion and wear on moving parts. N/A

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EEI Project No.: 9812

Tank No.: 3 Prepared by: GMM

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

h. Inspect alignment of rolling ladder with roof track. N/A

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

j. Inspect rolling ladder track welds for corrosion. N/A

k. Inspect track supports on roof for reinforcing pads seal-welded to deck plate. N/A

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

Max angle __________________.

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.

Additional Notes:

None.

APPENDIX B

Assessment of Compliance with Military Criteria

Tank 3 – API 653 Inspection APPENDIX B, Page 1

EEI Project No.: 9812

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance)

YES NO

MANHOLE

c A shell manhole located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals as required by DoD Standard AW 78-24-27.

X

Tank 3 is not equipped with a shell manhole above the floating pan. EEI finds no compelling reason to provide a manhole above the IFR.

The installation of an additional manhole would require a hydrostatic test.

e Roof manholes in accordance with API Std

650. Locate the roof manholes near the perimeter of the roof at opposite ends of diameter and approximately 90 degrees from the shell manholes.

X

The roof is equipped with two 24-inch manholes.

f Shell manholes in accordance with API Std

650. Two 36-inch shell manholes 180 degrees from each other. Align shell manholes parallel with prevailing wind direction. Support shell manhole covers by davits.

X

The tank is equipped with three 36-inch shell manways.

g A bolted cover in the roof for installation and removal of the internal floating pan as required by the tank supplier based on the pan manufacturer.

X

The tank roof is not equipped with a construction hatch. EEI finds no compelling reason to provide a construction hatch. If the IFR were to be replaced in the future, a hatch could be provided at that time.

INSPECTION HATCHES

h A minimum of four 24-inch square inspection hatches on fixed roof tanks with floating pans.

Inspection hatches are not required for tanks without floating pans.

X

The tank roof is equipped with three 24-inch x 24-inch square inspection hatches. EEI finds no compelling reason to provide a fourth.

LADDER/STAIRS

i Internal ladders (in accordance with OSHA criteria) for tanks of 5,000 gallons or larger with floating pans. X

The tank is not equipped with an internal ladder. EEI finds no compelling reason to provide an internal ladder.

k Ladders, railings, toeboards, a spiral stairway, top platform, and handrail in accordance with API Std 650 and OSHA requirements. Provide stairways to access high-level shut-off and alarms. Provide metal bar grating stair tread and platforms. Provide stair tread with non-slip nosings.

X

The tank is provided with the items outlined in Item k, however, the midrails at the perimeter roof vents/inspection hoods have been cut to allow the hoods to open fully. The midrails can no longer support the loads required by OSHA.

http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

Tank 3 – API 653 Inspection APPENDIX B, Page 2

EEI Project No.: 9812

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance)

YES NO

LEVEL ALARMS

l

An individual automatic level alarm system, independent of the gauging device or system for each tank. Include high, high-high, low, and low-low level alarms.

VENTS

m Open atmospheric vents with weather hoods and bird screens or pressure/vacuum vents in lieu of open vents. Comply with NFPA 30, host nation requirements, Chapter 2 of this UFC, API Std 650, API Std 2000, 29 CFR Part 1910.106, and DoD Standard Design AW 78- 24-27, where applicable.

X

The tank is equipped with three 24-inch x 24-inch perimeter roof vents/inspection hatches.

n For higher vapor pressure, or if a vapor recovery system is used, provide pressure/vacuum vents in lieu of open vents.

Consider using pressure/vacuum vents if product quality is at risk by blowing sand, dust, or snow. Comply with NFPA 30, host nation requirements, Chapter 2 of this UFC, API Std 650, API Std 2000, 29 CFR Part 1910.106, and DoD Standard Design AW 78- 24-27, where applicable.

X

Tank operates at atmospheric pressure and does not utilize a vapor recovery system.

p Emergency relief venting with capacity in accordance with NFPA 30 and UL 142, as applicable or a weak roof-to-shell seam, as specified in API Std 650.

GAUGE/GAUGE HATCH/STILLING WELLS

q A liquid level gauge calibrated in 1/16-inch graduations mounted at 60 inches above the walking surface.

X Tank is equipped with a Shand & Jurs tape gauge. However, it was found to be non-functional when bump tested.

S Automatic Tank Gauging (ATG) for all tanks with fuel managed through the Defense Logistics Agency's Business Modernization {BSM Enterprise Resource Programs (ERP) - Fuels section}, that complies with API MPMS Chapter 3.

X

Tank is equipped with an ENRAF ATG system.

V One 10-inch roof flanged nozzle with an 8-inch aluminum, fully slotted, stilling well for ATG near the edge of the roof near the top of the stairway platform.

X

Per the 2011 out-of-service inspection report, the displacer is provided with an 8-inch carbon steel stilling well. Assess the stilling well at the next out-of-service inspection.

Tank 3 – API 653 Inspection APPENDIX B, Page 3

EEI Project No.: 9812

ASSESSMENT OF COMPLIANCE WITH MILITARY CRITERIA

UFC 3-460-01, Table 8-1

(Complete UFC available at www.wbdg.org) Requirements for Vertical Aboveground Storage Tank (V-A) Only

ITEM APPURTENANCE

(UFC REQUIREMENT)

COMPLIANT COMMENTS/RECOMMENDATION

(A blank in comments column indicates UFC compliance)

YES NO

W One 8-inch roof flanged nozzle with a 6-inch aluminum, fully slotted, stilling well for temperature and water bottom sensor, as close to or in the tank sump as…