Amend_0004_17B0001.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT 1. CONTRACT ID CODE

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7. ADMINISTERED BY (If other than Item 6) CODE

STANDARD FORM 30 (REV. 10-83)

Prescribed by GSA FAR (48 CFR) 53.243

FACILITY CODE

9A. AMENDMENT OF SOLICIATION NO.

9B. DATED (SEE ITEM 11)

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11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers is extended, is not extended.

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods:

(a)By completing items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment your desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

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IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

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Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

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14. DESCRIPTION OF AMENDMENT/MODIFICATION ( Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

PAGE OF PAGES

6. ISSUED BY CODE

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code) (X)

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NSN 7540-01-152-8070

Previous edition unusable

1 1

AM-0004 Aug 31, 2017

CECT – Contracting Division USACE, Honolulu District Bldg 252 (CECT-POH) Ft Shafter, HI 96858-5440

W9128A-17-B-0001

Jul 25, 2017

DESC1704 REPLACE FUEL STORAGE TANKS, DEFENSE FUEL SUPPLY POINT, KWAJALEIN ATOLL, MARSHALL

ISLANDS

1. Amendment 0003 SF30, Block 3, Effective date is "30 Aug 2017".

2.

Appendix B - API 653 Tank Inspection Reports was inadvertently omitted from Amend 0003 and is attached.

3.

SF 1442, Block 13.A. is revised to read "14 Sep 2017".

NFESC CONTRACT N47408-04-D-8503, DELIVERY ORDER 0048

TANK 9

API 653 TANK INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

February 2009

Prepared For:

Naval Facilities Engineering Command Engineering Service Center 1100 23rd Avenue, Code 232 Port Hueneme, California 93043-4370

Presented By:

Shaw Environmental Inc.

6330 Commerce, Suite 190 Irving, Texas 75063

Prepared By:

David A. Stchyrba, P.E., API 653 Certificate No. 27187

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 08-5149

APPENDIX B - API 653 TANK INSPECTION REPORTS

Am #0003

ABSTRACT

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, out-of-service inspection and suitability for service evaluation of Tank 9 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. The inspection was performed on January 6-8, 2009.

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

EEI recommends the next API external in-service inspection be scheduled no later than January 2014 (5 years from 2009 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API internal out-of-service inspection be scheduled no later than January 2019 (10 years from 2009 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653, this report satisfies the requirement for an out-of-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.

February 10, 2009 David A. Stchyrba, P.E.

API 653 AST Inspector Certificate No. 27187

This tank inspection has determined that mandatory repairs are required prior to return to service. Following completion of the identified repairs, Tank 9 will be suitable for service.

Tank 9 – API 653 Inspection TABLE OF CONTENTS Kwajalein Atoll February 2009 EEI Project No. 08-5149 R008

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs Prior to Return to Service (Mandatory) Recommended Repairs Prior to Return to Service (Non-Mandatory) Recommended Repairs per Current Military Criteria Recommended Repairs for Long Term Serviceability Operational/Functionality Issues

COATING REQUIREMENTS

Coating System at Localized Repairs (Interior and Exterior) Interior Coating

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Tank Shell Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEMS

Floating Roof Integrity Gauge Tubes Overall Requirements and Decisions Required

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items...................................................Tab A Non-Destructive Examination (NDE) and Evaluation Criteria...................................Tab B Tank Drawings .........................................................................................................Tab C Tank Photographs....................................................................................................Tab D NDE Results.............................................................................................................Tab E Calculations..............................................................................................................Tab F Repair Documentation............................................................................................. Tab G Field Inspection Report ............................................................................................Tab H

Tank 9 – API 653 Inspection Page 1

EEI Project No.: 08-5149 R008

TANK 9

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

U.S. Army Kwajalein Atoll, Republic of Marshall Islands

SUMMARY

Scope

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, out-of-service inspection and suitability for service evaluation of Tank 9 at U.S. Army Kwajalein Atoll, Republic of Marshall Islands. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. The inspection was performed on January 6-8, 2009.

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 9 is a field erected aboveground storage tank. The tank was constructed in 1954. The tank is 45 feet in diameter, 30 feet high and of welded construction. It is an open top style with butt-welded shell plates and lap-welded floor and roof plates. The tank is equipped with a steel double-deck floating external roof. The primary seal of the floating roof includes a metallic shoe with springs. The tank does not have a conventional fixed cone roof or geodesic aluminum dome, as do most government tanks that were originally erected as open top tanks. The tank floor is of cone up (original) style, with perimeter sump. The nominal shell capacity is 8,000 Bbls. Tank 9 is currently in Mogas service.

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.

Tank 9 is considered suitable for service after all required repairs are completed. The following are significant findings of the inspection.

Hydraulic Integrity

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

Visual inspection of the tank shell found no indications of leakage. A pit survey was conducted for topside corrosion on the floor and no pits were identified requiring repair. One pit was identified on the interior 1st shell course requiring repair. A magnetic flux leakage (MFL) scan of the tank floor found evidence of active corrosion on the bottom side of the floor plates. Seven

Tank 9 – API 653 Inspection Page 2

EEI Project No.: 08-5149 R008 locations were identified requiring repair. The external floating roof had previously partially sunk. Upon examination, several breaches to the hydraulic integrity of the floating roof pontoon were found that most likely was the cause of the sinking. Evidence exists, in the form of exterior lap welded patch plates, that the tank has experienced corrosion of the interior shell at a level consistent with the floating pan resting on its support legs in the high position. Further investigation is recommended. Upon completion of the required repairs and any more repairs identified with further investigation, Tank 9 will be in acceptable hydraulic condition.

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 accessible courses.

From interpretation of ultrasonic test (UT) readings recorded, only plate thickness variances were noticed. Based on this inspection of the accessible components, Tank 9 is in acceptable structural condition.

Next Inspection

API 653 recommends the interval to the next internal inspection be determined based on known corrosion rates, but in no case shall the interval exceed 20 years from the date of inspection.

When corrosion rates are not known or well established, API 653 recommends that the tank be inspected within 10 years. A maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

EEI recommends that the next external in-service inspection be scheduled no later than January 2014 (5 years from 2009 inspection), or sooner if a change in condition has occurred.

EEI recommends the next internal out-of-service inspection be scheduled no later than January 2019 (10 years from 2009 inspection), or sooner if a change in condition has occurred. The 10 year re-inspection is based on a reduced life using the 1997 inspection report findings of the as then floor thickness.

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 per military criteria, recommended for long term serviceability and client requested repairs.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (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 gasoline service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Tank 9 – API 653 Inspection Page 3

EEI Project No.: 08-5149 R008

Required Repairs Prior to Return to Service (Mandatory)

Mandatory refers to those API 653 items that are considered critical to the hydraulic or structural integrity of the tank, or are required to meet code, prior to placing Tank 9 back into service.

1. A MFL floor scan and ultrasonic test (UT) of the accessible areas of the floor resulted in seven (7) locations of bottom-side corrosion requiring patch plates welded to the floor. The floor locations are included in Appendix G. The following repairs are required:

Prepare patch plates per API 653 and size according to the data sheet.

Seal weld the patch plates over the locations with a ¼ inch fillet weld.

Visually inspect the welds for weld profile, fusion to the base metal and penetration.

Remove edge on topside of each plate by grinding a 45-degree chamfered rounded edge.

Perform integrity inspection of the entire weld by vacuum box testing (BT) and either dye penetrant testing (PT) or magnetic particle testing (MT).

Note: The floor already contains 10 patch plates as a result of previous inspections. The additional patch plates will extend the life of the floor not less than 10 years. Complete corrosion calculations and service period determination are in Appendix F.

2. A screw was observed at one location in the floor. The location is included in Appendix G.

The following repairs are required:

Prepare patch plate per API 653 and size according to the data sheet.

Seal weld the patch plate over the location with a ¼ inch fillet weld.

Visually inspect the weld for weld profile, fusion to the base metal and penetration.

Remove edge on topside of each plate by grinding a 45-degree chamfered rounded edge.

3. A pit survey of the interior 1st course shell resulted in one location requiring repair. The location is included in Appendix G. The following repairs are required:

Grind the pit to remove corroded material and/or debris and repair by puddle welding.

Grind the surface of the puddle weld flush with the surrounding surface.

Perform integrity inspection of the entire weld by vacuum box testing (BT) and either dye penetrant testing (PT) or magnetic particle testing (MT).

4. The tank is equipped with six support legs for the floating roof. Each leg includes a sleeve that passes through the pontoon space. It was reported that one of the pontoon “pie shaped” chambers was flooded with a mixture of product and water. A through hole was observed in the sleeve in the same chamber approximately 4 inches above the bottom deck. The product height above the bottom deck is approximately 6 inches. It is believed that product entered the pontoon space from the hole and flooded this chamber. The following repair is required:

Replace the sleeve or patch the hole in the sleeve.

(Note: It was observed that the sleeve corroded from the inside out. The sleeves for each of the remaining pan legs were hammer tested for integrity. No other defects were observed.)

Tank 9 – API 653 Inspection Page 4

EEI Project No.: 08-5149 R008

5. The external floating roof is equipped with a drain line for removing water from the top of the roof. The following repair is required to verify the integrity of the piping and swing joints:

Provide a two-stage hydrostatic test (i.e., pressure test with water) in accordance with Section 7.3.3 of API 575. The first stage is a test at 30 psi for 30 minutes to detect any leaks in the pipe and rigid joints. Reduce the pressure to 5 psi for 30 minutes to test the tightness of the swing joints.

6. A through hole was observed in the top deck of the floating roof. The hole is located above the pontoon portion previously identified as having filled with fluid. The following repair is required to prevent the ingress of water into the pontoon:

Seal weld a 3/16 inch thick x 6 inch round patch plate over the through hole.

Provide a visual examination of the completed weld.

Alternatively, the hole may be repaired by weld build up.

7. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Coating Requirements.

Recommended Repairs Prior to Return to Service (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends these repairs for long-term preservation and integrity of the tank, and believes that the repairs should be performed concurrently with required repairs noted above.

1. Significant coating failure and corrosion was observed on the tank shell behind the floating roof seal. The following further investigation is recommended:

Option 1: Raise the floating roof. Clean and observe the condition of the shell behind the seal. Advise EEI of any observed pits or extensive “lake type” corrosion. Recoat the interior shell.

Option 2: As an alternative to raising the roof, disassemble and remove the mechanical shoe seal.

Note: If Option 1 were selected, it is highly recommended to float the roof with water and verify that none of the pontoon welds cracked as a result of the lifting process.

2. The reinforcing plates for the manways, service, fill, roof drain and water draw-off nozzles are not equipped with tell tales holes. The following repair is recommended:

Provide tell tale holes in the reinforcing plates in accordance with API 653 requirements.

3. Two of the treads on the spiral stair have metal loss due to corrosion. The following repair is recommended:

Remove the stair treads and replace in kind.

4. Tank 9 is equipped with a mechanical shoe seal below a perimeter foam log. It is not equipped with a rain shield to reduce the ingress of water. Utilizing a foam log rather than a

Tank 9 – API 653 Inspection Page 5

EEI Project No.: 08-5149 R008 rain shield is not a standard installation. Gaps in the foam seal allow the ingress of water into the tank. The following repair is recommended:

Remove the foam log and provide a vapor seal.

Provide a rain shield on the top of the floating roof to reduce the ingress of water.

5. A thin-film liner is present on the interior of the 1st shell course up to the height of the bottom deck of the floating roof. Significant coating failure and corrosion was observed on the tank shell behind the floating roof seal. The following repairs are recommended:

Jack the floating roof.

Clean and observe the condition of the shell behind the seal.

Advise EEI of any observed pits or areas of extensive “lake type” corrosion that need corrosion profile mapping . For a service period of 10 years, repair all pits with a depth greater than or equal to 7/64 inch. For 20 years, repair all pits with a depth greater than or equal to 5/64 inch. Shell corrosion calculations have been provided in Appendix F.

Prepare surfaces and recoat.

6. Approximately 140 sq ft of localized areas of coating failure were observed on the tank floor.

The following repair is recommended:

Clean the affected areas and recoat.

7. Coating failure and corrosion was observed on the floor extension. The following repairs are recommended:

Remove the sealant between the floor extension and the concrete ringwall.

Remove the coating from the affected portions of the floor extension.

Clean the surfaces of the concrete ringwall and underside of the floor to be sealed with an abrasive sweep blast.

Recoat the floor extension.

Provide sealant and backer rod between the floor extension and the concrete ringwall.

8. Coating failure and corrosion was observed on the floating roof appurtenances, stair platform structure, vertical leg of the horizontal shell stiffener, stair treads, shell valves and the support structure for rolling ladder. The following repair is recommended:

Remove the coating from the affected areas and recoat to prevent further degradation.

9. The floor directly below the vacuum breaker does not have a doubler plate. The following repair is recommended:

Seal weld a 3/8 inch thick x 12 inch round doubler plate to the floor.

Provide NDE as noted for floor patch plates above.

10. The gasket in the vacuum breaker has deteriorated. The following repair is recommended:

Install a gasket on the vacuum breaker.

11. Holes are present on the top plate of the vacuum breaker allowing the ingress of water into the tank. The following repair is recommended:

Provide patch plates over the holes to prevent the ingress of water.

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EEI Project No.: 08-5149 R008

12. The tank was equipped with a tape gauge system but has since been removed. An opening was provided in the cover plate of a nozzle for the tape. The ingress of water into the tank is possible since the opening for the tape was not covered after it was removed. The following repair is recommended:

Provide a patch plate over the opening in the cover plate.

Note that EEI recommends a manual float gauge be provided with all tanks even when equipped with an Automatic Tank Gauging (ATG) system. On occasion, floating gauges have been removed as a part of ATG programs. Reinstallation of a floating tape gauge system at this time would be possible, if the government takes a position of agreement with EEI recommendations.

13. Each “pie” section of the pontoon is equipped with a 20 inch manway. A through hole was observed in one of the manway cover plates. The following repair is recommended to prevent the ingress of water into the pontoon:

Provide a patch plate over the cover or replace the cover plate.

14. The seals at the 4 inch manual sampling hatch and 8 inch gauge tube have deteriorated. The following repair is recommended to prevent the ingress of water into the tank:

Replace the seals.

15. The seal at the access hatch for the ENRAF ATG displacer has deteriorated. The following repair is recommended:

Replace the seal.

16. The clips securing the access hatch for the ENRAF ATG displacer are severely corroded.

The following repair is recommended:

Remove the existing carbon steel clips and provide stainless steel clips, if available. If not available, provide carbon steel clips and install so they can be easily changed in the future when they corrode.

17. Tank 9 is equipped with cathodic protection (CP). The CP test ports are installed at grade along the perimeter of the tank. One of the lids is broken and has split apart. The following repair is recommended:

Replace the CP test port lid in kind.

18. The top deck of the floating roof is equipped with 13 ground shunts. Four of the shunts are not in contact with the shell. The following repair is recommended:

Reinstall and/or readjust the shuts to ensure contact with the interior of the shell.

Test continuity of ground shunts and resistance between roof and shell.

19. The interior water draw-off piping is unsupported and capable of striking the bottom of the sump. The following repair is recommended:

Provide an “H” type pipe support constructed of 2 inch x 2 inch x ¼ inch angles and a 6 inch square base plate.

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EEI Project No.: 08-5149 R008

Seal weld the base plate to the floor so that fuel and contaminants cannot migrate under the plate.

20. The pressure relief loop (PRL) on the Fill and Issue piping each contain two gate valves. The following repair is recommended:

Provide ¼ turn ball valves.

21. The 2 inch water draw-off piping at the tank shell includes a gate valve. The following repair is recommended:

Provide a double block and bleed plug valve. Field verify the valve size.

22. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Coating Requirements.

Recommended Repairs per Current Military Criteria

The following recommended repairs are in accordance with UFC 3-460-1:

Table 8-1 of UFC 3-460-01 (July 2008 issue pending) describes appurtenances for vertical aboveground storage tanks.

1. Tank 9 is not equipped with item (k) an individual automatic level alarm system independent of the gauging system.

Provide a level alarm system independent of the gauging system.

2. Item (n) is a liquid level gauge calibrated in 1/16 inch graduations. The tape gauge system was previously removed.

Provide a functioning manual tape gauge system.

3. Tank 9 is not equipped with item (q) one 8 inch flange nozzle for ATG (planned or future) near the edge of the roof. The following is noted:

The existing ATG system is located within an 8 inch gauge tube near the stairway.

4. Tank 9 is not equipped with item (r) one 8 inch gauge hatch for water bottom sampling as close to the center as possible. The following is noted:

The tank is equipped with a side sump. Refer to “Gauge Tubes” for additional discussion.

5. Tank 9 is not equipped with item (s) one 8 inch gauge hatch with aluminum, slotted stilling well extended to within 3 inches of the bottom of the lowest point in the tank. The following is noted:

A slotted gauge tube is not possible since the tank is equipped with a floating roof. Refer to “Gauge Tubes” for additional discussion.

6. Tank 9 is not equipped with item (w) a hydraulically operated high level shut-off valve

(HLV).

Provide an HLV.

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EEI Project No.: 08-5149 R008

Recommended Repairs for Long Term Serviceability

1. Program the tank for an API out-of-service internal inspection no later January 2019.

2. Test all level alarms and switches as part of on-going maintenance.

3. The piping from the water draw-off and roof drain downstream of the shell valves appears to be severely corroded. Recommend programming for inspection and possible replacement.

Operational/Functionality Issues

While on site, facility personnel brought the following item to our attention. If funding were available, it may be an opportune time to execute the request. We take no exception as the item is not related to tank integrity. It is included herein for completeness of the tank repairs being considered prior to return-to-service.

1. It has been requested to provide an aluminum geodesic dome on top of Tanks 8 and 9. It is not known if current costs for such a project would fit within minor construction funding.

EEI also points out that the installation of a geodesic dome on government facilities is not always successful in eliminating water intrusion into the product. When a geodesic dome is installed, it is most common to also replace the aging pontoon floating roof with a floating honeycomb aluminum pan, particularly on gasoline storage tanks, as it significantly reduces fire risk associated with steel pontoon external roofs.

2. It also needs to be noted that in the past, EEI has determined that installation of a fixed cone steel roof on similar tanks can be accomplished for similar funding, and may represent a better long term value to the government.

COATING REQUIREMENTS

All repairs involving steel surface grinding, cutting and welding shall be preceded by proper coating removal. At this time it is not known if any of the existing coating layers have significant lead or chromate components. The contractor shall be responsible for testing coating systems for lead and chromate levels, and develop engineered controls to prevent worker safety hazards, and spread of contaminated dusts. Coating removal method shall be contractor determined to suit contamination levels and follow-up steps.

Coating System at Localized Repairs (Interior and Exterior)

Provide repair of localized areas of failed and damaged coating on the interior and exterior of the tank and areas affected by the contractor’s work. Provide a coating system that complies with MIL-PRF-4556F, two-coat, 4 to 8 mils DFT per coat. Provide surface preparation in accordance with the coating manufacturer’s recommendations. For tank interior coating, provide surface preparation in accordance with the coating manufacturer’s recommendations for immersion service. Provide 2 to 3 mil surface profile unless recommended otherwise by the coating manufacturer. Prior to surface preparation, test surfaces for soluble salts, oil and grease and clean as required to remove contaminants. Tank interior coatings shall cure for not less than 14 days prior to introducing fuel into the tank. Provide longer cure time when recommended by the coating manufacturer.

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EEI Project No.: 08-5149 R008

As an alternative for interior repairs, use the 3 coat MIL-DTL-24441 epoxy polyamide system as specified in Unified Facilities Guide Specifications (UFGS) section 09 97 13.17, Interior Coating of Petroleum Storage Tanks. As an alternative for exterior repairs, use the 2 coat MIL-DTL- 24441 epoxy polyamide system with polyurethane topcoat as specified in UFGS section 09 97 13.27, Exterior Coating of Steel Structures.

Interior Coating

Tank 9 is currently out-of-service awaiting repairs. At the time of the inspection, the floor was found in generally good condition with some blisters and corrosion. It should be noted that further degradation of the coating system may occur the longer the tank remains out-of-service.

This can be attributed to possible original application defects such as incorrect surface profile preparation or insufficient removal of chlorides with potable water between coats. At locations where coating repairs have been provided, a defect could include insufficient removal of product between the original coating and the new repair. The resulting repair would “skin” over and appear to adhere. All of these potential defects could result in stress points and cracking during extreme temperature changes.

Inter-layer chloride contaminants, if present, will absorb water from moist air and swell. The coating is generally protected from temperature changes and contact with moist air by immersion in product, thus it may appear to exhibit certain characteristics when first cleaned but degrade over time.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank floor, shell and roof were calculated using assumed nominal metal thicknesses when the tank was constructed in 1954 and the plate thicknesses obtained from UT measurements at the time of the inspection. The corrosion rates are summarized as follows:

Floor: 0.01460 inches per year

Shell: 0.003409 inches per year

Floating Roof: Negligible – Deck plates are within mill tolerance

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 17.0 mils, is a thin-film lining. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The coating is only 2 years old but portions are relatively poor condition. A nominal pit depth of 1/32 inch was assumed to conservatively calculate a product side corrosion rate (StPr). No pits were identified in the floor during the inspection.

Bottom side corrosion with small volumetric metal loss may be present and not detected by MFL scanning. The metal loss used to calculate the bottom side corrosion rate (Upr) was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits. The MFL floor scanner is not setup to indicate (alarm) for minor metal loss. Backside corrosion was detected and seven areas were identified for repair.

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EEI Project No.: 08-5149 R008

The minimum remaining floor thickness (MRT) used in the calculations is based on API 653 Section 4.4.7 and Table 6-1. The tank has not been equipped with the means to detect a bottom leak. Based on this information, the MRT used in the calculations is 0.100 inch.

Initial corrosion calculations indicate that the floor plate thickness will not be reduced below the limiting MRT at a 20-year inspection interval. However, excerpts from 1994, 1997 and 2004 API 653 inspection reports were made available for review. Backside corrosion requiring repairs was identified in the 1997 report. The remaining metal thickness at the repair areas varied from

0.155 inch to 0.180 inch. The criteria was that a repair was required if the remaining metal thickness was less than 0.180 inch. No repairs were identified in the 2004 report. The current inspection has identified locations of backside corrosion with remaining metal thicknesses as low as 0.107 inch. With no repairs identified during the 2004 inspection, and if the repair criteria was 0.180 inch at the time, then the current identified metal loss occurred within the past 5 years.

A conservative floor corrosion rate was recalculated using a metal loss of 0.180 inch – 0.107 inch divided by 5 years.

It was found that the floor plate thickness will not be reduced below the limiting MRT at a 13 year inspection interval. EEI recommends that the next API internal inspection should be scheduled no later than January 2019 (10 years from 2009 inspection), or sooner if a change in condition has occurred.

Tank Shell Corrosion Rates

A 3/16” deep pit was found on the interior of the 1st shell course and identified for repair.

Calculations indicate that the minimum shell thickness for the current product is 0.107 inches.

Based on initial corrosion calculations, it was found that the shell plate thickness will not be reduced below the minimum thickness at a 20 year inspection interval.

Significant coating failure and corrosion was observed on the tank shell behind the floating roof seal. It is recommended to clean and inspect the affected areas. An assessment of pits and extensive “lake type” corrosion would be required. A conservative shell corrosion rate was recalculated using a metal loss of 3/16 inch divided by 55 years.

It was found that all pits greater than or equal to 7/64 inch should be repaired for a service period of 10 years. Repair all pits greater than or equal to 5/64 inch for a service period of 20 years.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 9:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 9 sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Visual inspection of the floor joints found no relevant indications. MFL scanning of the tank floor found indications of active corrosion on the bottom side of the floor. A pit survey was conducted for topside corrosion

Acceptable after completion of repairs.

Tank 9 – API 653 Inspection Page 11

EEI Project No.: 08-5149 R008

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments and no pits were identified requiring repair.

Upon completion of required repairs, the floor plate thickness will not be reduced below the requirements for minimum floor plate thickness of 0.100 inch at a 10-year inspection interval.

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

Acceptable, subject to satisfactory results from inspection behind the floating roof seal.

Floating Roof Inspection of the accessible portions of the floating roof found a hole in a support leg sleeve. A through-hole was observed on the top deck of the roof at one location.

Acceptable after completion of repairs.

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, built in 1954.

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

3. Is the tank shell thickness < 0.5 inch: 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 5-2: Yes.

7. Tank full at lowest one day temperature per API 650 Figure 2.2: Unknown.

The tank, having a shell thickness less than 0.5 inch thick does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank is not at risk of overturning and the compressive stresses are within limits.

Calculations were performed utilizing the specific gravity for Mogas, (S.G. = 0.73), a concrete ringwall foundation, seismic parameters Ss = 1.19, S1 = 0.48 and an importance factor of 1.0.

Acceptable

Wind Evaluation

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

Calculations were performed using an importance factor of

1.0 and a wind velocity of 105 mph.

Evaluation determined that an empty unanchored tank is not at risk of overturning.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 105 mph.

Acceptable

Tank 9 – API 653 Inspection Page 12

EEI Project No.: 08-5149 R008

ADDITIONAL DISCUSSION ITEMS

Floating Roof Integrity

Tank 9 is equipped with a steel double-deck floating external roof. The roof was constructed with six “pie shaped” chambers and a central round chamber. A total of six support legs are present for the floating roof. Each leg includes a sleeve that passes through the pontoon space.

It was reported that one of the chambers was flooded with a mixture of product and water. This caused the roof to tilt and damage to the seals occurred. As discussed in the Mandatory Repairs, holes were observed in both the leg sleeve and the top deck of the roof.

The following inspection steps were taken to ensure the hydraulic integrity of the floating roof:

1. The sleeves in the remaining chambers were hammer tested and no defects were detected.

2. The lap joints in the bottom deck plate within each chamber were visually inspected and no defects were observed.

3. The butt joints in the rim plates were visually inspected within each chamber and no defects were observed.

4. The rim plate to bottom deck plate joint was visually inspected within each chamber and no defects were observed.

5. Liquid penetrant was applied to the outside of the rim plate to bottom deck plate joint of the flooded chamber. No penetrant was observed within the chamber.

It is believed that the holes in the leg sleeve and the top deck were the source of the fluid originally observed in the chamber. All practical inspection methods have been performed for due diligence. However, floating the roof with water, if it can be arranged, would provide proof positive that the leaks have been found, repaired and that no other unobservable defect is present.

Gauge Tubes

Overall Requirements and Decisions Required

The requirements for stilling wells have been reviewed. These requirements are based on our latest understanding for the upcoming SPAWAR executed ATG system as issued by PMO of DESC and other agencies. There have been ongoing discussions with respect to modifications to the current published requirements. At this time, the criteria are still under refinement and formal direction has not been published. The comments below represent concept solutions for this tank. We recommend the concept be submitted to DESC for ratification or redirection.

Field verification of constructability by the prime contractor is also recommended.

Tank Parameter Affecting Gauging and Stilling Wells

Tank 9 is an above ground tank with a cone-up floor, with one side low point sump and a double deck floating roof. The sump has a diameter of 24 inches. Within the sump is the 2 inch water draw-off piping. The tank has a diameter of 45 feet and a height of 30 feet.

The tank does not have a conventional roof to attach gauge tubes. The tank is equipped with a floating pontoon roof with one near center 28 inch roof manway.

Tank 9 – API 653 Inspection Page 13

EEI Project No.: 08-5149 R008

The displacer temperature sensor for the ENRAF ATG system is located in an 8 inch gauge tube that penetrates a 24 inch floating roof nozzle near the side of the tank. There is one 4 inch near center manual gauge hatch. A 20 inch nozzle formerly containing the tape gauge is located within 2 feet of the side sump. There are no additional spare nozzles penetrating the floating roof.

Current Requirements: SK-1, SK-2 and SK-3

Strict adherence to SK-1, SK-2 and SK-3 as provided by the government is not practical or possible due to the configuration of the tank structure and lack of a floating pan. The direction in these documents will most likely change once requirements are clarified.

Manual Gauging

The tank is currently equipped with one 4 inch thief hatch located near the center of the tank.

The thief hatch is not equipped with a gauge tube. Manual gauging is possible near the side of the tank at the nozzle containing the ENRAF ATG system if the displacer is retracted.

It is our understanding that a gauge tube is desirable, but not a mandatory requirement for manual gauging and sampling. Therefore the present manual gauging location should be acceptable for use as is.

Combination Water/Temperature Probe

There appears to be adequate space available to locate the probe directly over the sump. It would be necessary to install a sleeve to penetrate the top and bottom decks of the floating roof.

Alternatively, the nozzle formerly used for the tape gauge system could be utilized as is since it is within 2 feet of the sump. The cover plate could be retrofitted to accommodate the probe if the location is deemed acceptable. A gauge tube will not be possible since the spiral stair and platform are not located near the sump.

ATG Servo Float Stilling Well

The current ATG displacer is located near the tank shell. This location is acceptable for the level displacer and there is an existing gauge tube.

CLOSURE

Conclusions

Based on the extent of this inspection and completion of the mandatory repairs, Tank 9 is considered suitable for service.

Project Team

Site Team

David A. Stchyrba, P.E. Structural Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 27187, API Inspector of Record.

Todd Lichtenberg NDE Technician, Level II Inspector

Support Team

Stephen S. Brooks, P.E. Technical Advisor, QA Review, API 653 Aboveground Storage Tank Inspector Certificate No. 17

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

APPENDIX A AST Tank Inspection Data Sheet Tank 9 – API 653 Inspection February 2009 EEI Project No.: 08-5149

AST TANK INSPECTION DATA SHEET

Tank No. 9 Owner: U.S. Army

Location Kwajalein Atoll, Republic of Marshall Islands

API 653 INSPECTION

Type: Internal & External w/ Suitability for Service Date: January 6-8, 2009

By: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, Alaska 99503

(907) 563-3835

EEI Project No: 08-5149

TANK DATA

API 653 Inspector: David A. Stchyrba, P.E.

API-653 AST Inspector Certificate No. 27187

Type: Vertical AST with Floating Roof Diameter: 45'-0”

Shell Height: 30'-0” Configuration: Butt Welded Shell w/ 5 courses

Foundation: Concrete Ringwall Leak Detection: None present

Date Erected: 1954 API Standard: Unknown, likely API Std 12C 11th Edition Designed By: Unknown Manufacturer Unknown

Erector: Unknown Fuel Stored: Mogas

Design Specific Gravity: 0.73 Safe Fill Height: 26' – 0”

Nominal Capacity: 8,000 bbls Strapped Capacity: (8338 Bbls from 1994 strapping) The tank was being restrapped at the time of the inspection.

Change In Service: None

Current Tank Cleaner: Local cleaners Date Last Strapped: 12/09/1994

Date of Last Inspection: April 4 – 9, 2004 Date of Previous Cleaning: Unknown

As-Built Drawings, Specifications: Not available

GPS Coordinates: 8 Deg 43’ 40.50” N 167 Deg 44’ 16.44” E

Source: Google Earth

EVALUATION CRITERIA

API Standards: API 650, 11th Edition, June 2007

API 653, 3rd Edition, Addendum 3, Feb 2008 Ground Snow: 0 psf (UFC 3-310-01)

Wind Speed: 105 mph (UFC 3-310-01) Seismic: Ss = 1.19, S1 = 0.48 (UFC 3-310-01)

APPENDIX A AST Evaluation Items - TOC Tank 9 – API 653 Inspection February 2009

AST EVALUATION ITEMS

TABLE OF CONTENTS

PAGE

FOUNDATION

FLOOR

SHELL

FLOATING ROOF

COATINGS

APPURTENANCES

PIPING

APPENDIX A - AST Evaluation Items Page 1 Tank 9 – API 653 Inspection February 2009 EEI Project No.: 08-5149

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations (A blank in comments column indicates lack of significance, or condition is acceptable.)

FOUNDATION

Type Concrete ring wall. Minor spalling was observed.

The concrete spalling does not appear to require repair.

Levelness The maximum differential between max and min elevations is 0.06 feet (0.72 inch).

Tank 9 passes API 653 criteria for shell levelness.

Rigid Body Tilt Tank 9 has small amount of tilt. The amount of tilt is 0.04 feet (0.48 inch).

Calculations of data acquired at the shell determine that the tank is slightly tilted but within acceptable limits.

Height of Ringwall Above Grade

The top of the concrete ringwall varies from 7 to 9 inches above grade.

Material Below Tank Floor The material below the tank floor was inaccessible during the inspection.

Drainage Around Tank Drainage around the tank is adequate.

Tank Anchors Tank 9 does not have anchors.

Containment Dike Tank 9 sits within a containment dike.

Secondary Containment Tank 9 sits within a concrete dike wall with a ballasted geo-membrane liner.

Access under the tank was not feasible; therefore, the condition was not evaluated.

Settlement Tank 9 sits on a concrete ring wall – edge settlement is not a factor.

Erosion/Washouts No indications of washouts or erosion were observed.

Sealed at Foundation The sealant between the floor extension (chine) and the ringwall has failed.

Recommend removing the sealant, clean the surfaces and provide backer rod and sealant.

Additional Foundation Items, Comments or Notes:

None.

APPENDIX A - AST Evaluation Items Page 2 Tank 9 – API 653 Inspection February 2009 EEI Project No.: 08-5149

FLOOR

Evaluation Item Finding(s) Comments/Recommendations (A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type The tank floor configuration is cone up with lap welded steel plates oriented in rows.

Nominal Thickness The floor consists of 3/8 (0.375 inch) thick floor plates.

Annular Ring Plates Tank 9 is not equipped with an annular ring.

Thickness The average thickness of the interior floor plates based on 5 UT readings per floor plate is 0.353 inch. The exterior floor extension (chine) has an average thickness of 0.313 inch based on ten locations.

Interior Width The floor plate width varies from 80 inches to 96 inches.

Floor seam welds No relevant indications were found on the floor plate seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found seven (7) areas requiring repair.

Provide lapped patch plates at each location. Refer to Appendix G for the locations and plate dimensions.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, some bottom side pitting/corrosion is present.

Backside corrosion should be vigorously checked during the next out of service inspection.

Top Side Floor Pitting/Corrosion

No pits were identified requiring repair.

However, a screw was observed at one location.

Provide a lapped patch plate. Refer to Appendix G for the locations and plate dimensions.

Patch Plates Ten existing lapped patch plates were observed on the floor.

Doubler/Support Plates A doubler plate is present below each of the six floating roof legs. A doubler plate is not present on the floor below the leg of the vacuum breaker.

Recommend seal welding a 3/8 inch thick x 12 inch round doubler plate to the floor below the leg of the vacuum breaker.

Plug Welds No plug welds were observed.

Weld Artifacts No significant weld artifacts were noted.

Vacuum Box Testing The floor is fully coated. Vacuum box testing not performed.

Helium Leak Testing HLT was not performed.

Floor Bulges, Depressions No significant bulges or depressions were noted.

APPENDIX A - AST Evaluation Items Page 3 Tank 9 – API 653 Inspection February 2009 EEI Project No.: 08-5149

FLOOR

Evaluation Item Finding(s) Comments/Recommendations (A blank in comments column indicates lack of significance, or condition is acceptable.)

Oil Canning/Flexing Minor flexing of floor plates was observed.

Edge Settlement Edge settlement was not noted.

Measurements taken for edge settlement at eight equidistant locations pass API 653, Appendix B criteria.

Floor Critical Zone No corrosion was observed within the critical zone.

Floor Profile The floor is slightly cone up. The average differential height from the shell to the center of the tank is 0.284 feet (3.41 inch). The tank floor has a 1.21% slope to the shell.

Sumps Tank 9 is equipped with one 24 inch side sump. The sump is 12 inches deep and contains the water draw-off piping. The wall thickness is 0.321 inches (UT).

Secondary Liner Below Floor It is not known if there is a secondary liner below the floor.

Leak…