Hancock-Fac 20000 (Tank 1)-DRAFT-2015.pdf

500 Pinnacle Court, Suite 100 ▲ Norcross, GA 30071

(770) 908-7200

DATE: April 04, 2015

TO: Mr. – Jason Harre, COR

USACE, Omaha District Attn: CENWO-CD-RR 1616 Capitol Avenue Omaha, Nebraska 68192-4901

RE: Preliminary Findings and Recommendations Hancock Field, NY FAC 20000 / Tank 1 Contract W9128F-10-D-0075, Task Order 0008, Tank Group #20

On April 04, 2015 an API Standard 653 out-of-service inspection was performed on Tank #001 / (aka Tank 20000) located at the Hancock Field facility in New York. The purpose of the inspection was to gather data necessary to determine serviceability of the tank and compliance with applicable codes and standards.

The findings and recommendations are based on field observations, the historical construction drawings when available, as well as feedback from the tank Owner/Operators.

Please find attached the Preliminary Findings / Recommendations Report and supporting photographic documentation.

Regards, Jerry Dupre Jr API 653 Inspector (3062)

Attachments:

Tank Data Preliminary Findings / Recommendations Report – Tank #001 / 20000, Hancock Field, New York

Cc: Project Team; Project File

Tank Location Hancock Field, New York Tank No. (plus previous identified) 1 Facility Number 20000 Inspection Dates (s) 4-Apr-15 Tank Type Above Ground Storage Tank (AST) Type of Inspection Out-of-Service, IAW API Standard 653 Contract Number, Task Order W9128F-10-D-0075, Task Order 008 Prime Contractor Name Cape Environmental Management, Inc.

Inspector, Cert. #, Inspection Company Jerry J. Dupre Jr, Certification ID: 3062, CAPE Manufacturer, Date, Design Standard Pittsburgh Tank & Tower / 1997 / API 650 9th Edition/ App E, F, H

Diameter 27'-0" Shell Height/Safe Fill Height 28'-3" / 25'-0"" Product/Specific Gravity Jet-A / 0.85 Design Pressure/Temperature Atmosphere / Product Head / Ambient Gross Capacity/Nominal Capacity 2500 Barrels / 105,000 gallons GPS Latitude & Longitude Latitude: N 43° 6'-9.39 / Longitude: W 76° 5' -54.56" Foundation Configuration Concrete Ringwall Shell Configuration Butt-welded Floor Configuration Lap-Welded, Cone Down Bottom, Pie Shaped Plates

Roof (Fixed, Floating or Both, Seal Type) Cone-up Lap-welded / Aluminum Panel / Wiper Seal.

Cathodic Protection Impressed Current Stilling Wells (Size, Application) 8" ATG / 4" Water Probe Last Inspection (Type, Date) Out-of-Service / 2008 Last Coated Internally (Product) 1997 / Milspec Last Coated Externally (Product) 1997 / Milspec

Tank Re-Calibration to 1/16 in. N/A Stilling Wells N/A Coating (Specify Systems, Location) N/A Floor (Including Sump) N/A Shell N/A Vents / Appurtenances N/A Secondary Containment N/A Other: N/A General Comments N/A

Tank Inspection Summary Sheet

Upgrades / Repairs Made at this Time

Preliminary Findings / Recommendations Report

Tank #001 / 20000 , Hancock Field, NY

1.0 Background and Overview

Tank #001 (aka Tank 20000 on the Bidding Schedule) is a 2500 barrel Above Ground Storage Tank that currently stores Jet-A fuel. The tank is 1 of 2 currently used in bulk storage capacity. The tank was originally constructed in 1997 to API 650 / 9th Edition / Appendix E, F, and H design standard with a nominal diameter of 27’-0” feet and a nominal shell height of 28’-3” per original construction. The tank bottom configuration is a 0.250” nominal thickness with a butt-welded annular ring and lap welded pie shaped floor plates that cone down or slope to the center sump. The fixed roof consists of a self-supported CS lap welded cone up design. The fixed roof rafters are welded to pads that are welded to the shell. The tank currently has Petrex aluminum honeycomb pan (IFR) full contact floating roof with double wiper seals. The tank currently does have an impressed current cathodic protection system. The tank rests on a concrete ringwall and does have under tank secondary containment. An MFL bottom scan was conducted revealing a total of zero (0) areas of underside corrosion at 0.225” remaining Plate thickness or less. The tank secondary containment consists of a concrete slabs with vertical walls that has been epoxy coated.

API mandatory repairs were discovered during the inspection preventing return to service. Following completion of the inspection, Tank #001 / 20000 was not returned to service to meet installation mission requirements. Consideration should be given to the other findings and recommended repairs listed below. The next scheduled out-of-service internal inspection is due within 10 years. The next external ultrasonic inspection is due within 15 years. The next external visual inspection is due within 5 years. The findings listed below are based upon observations while on site and historical information obtained from the Owner/Operator in the form of previous inspection reports.

2.0 Findings and Recommendations

On April 08, 2015 an out-of-service inspection was completed on Tank #001 / 20000 at the Hancock Field, Bulk storage facility in New York by Cape Environmental Management Inc, Certified API 653 Inspector Jerry Dupre Jr (Certification ID: 3062). The purpose of the inspection was to gather data necessary to determine the serviceability of the tank and compliance with applicable codes and standards. The findings and recommendations are based on field observations, historical drawings and previous inspections.

The following tables show a summary of findings and corresponding recommendations from the out-of-service inspection. Where applicable, notes are included in the recommendations concerning the current SOW associated with programmed repairs on this TO. The findings are separated into four categories:

Mandatory Recommendations (Table 1): Items that require immediate action based on tank failure during next in-service operation. Local Federal or State regulations that are not met. Items that need to be made to prevent safety failures or accidents.

Near Term Recommendations (Table 2): Items that are a significant deficiency based on API 650 & 653, UFC, and UFGS guidelines that impact daily operation of tank.

Long Term Recommendations (Table 3): Items that do not meet current guidelines that do not present the unsafe operation of the tank.

Monitoring Recommendations (Table 4): Items that are performed by the Owner/Operator as regular maintenance.

Stilling Well Configuration (Table 5): Provides information concerning the existing or planned configuration of stilling wells as applicable.

This table also conveys the type tank gauging system that is installed.

Table 1- Mandatory Recommendations Item # Finding Recommendation

1.1 Internal Floating Roof:

Internal floating roof (IFR) primary seal was torn in two (2) places.

Also all of the IFR penetration seals are bad and need to be replaced.

Install new double wiper seals per current API, and DoD guidelines.

Note: The installation of new wiper seals is part of the original SOW.

Table 2- Near Term Recommendations

2.1

Bottom Near Term Findings:

The internal piping supports are currently not configured to DoD designs. Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail A4.

Replace the internal piping supports with supports in accordance with DoD Standard Design guidelines. (11 Each)

2.2

The current configuration on the existing 8” SS stilling well is completely slotted however the existing base do not meet current DoD guidelines. Ref: UFC 3-460-01, Table 8-1(q) and UFGS 33 56

13.13 Section 2.13.4.

Recommend installing one (1) new 8” aluminum stilling well per current DoD Guidelines for the MTG and modifying the existing base on the ATG stilling well to current DoD guidelines.

Note: The 8” stilling well currently accommodates the ITT Barton tank gauging system.

2.3

The internal SS product issue piping currently does have an anti-vortex plate, however it is not 1/2 radius from the shell and extends to the tank center sump. Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail A1.

Modify the internal product issue piping per DoD Standard Design guidelines.

2.4 The tank bottom currently has four (4) reinforcing or striker plates that do not meet current API 653 Guidelines.

Recommend performing a MT or PT test on these pads to ensure there is no cracking per current API guidelines.

2.5

The tank bottom currently has an impressed current cathodic protection system installed. Upon inspection of the system it is not energized. When you reset the breaker the system energizes and then trips the breaker after a few minutes.

Recommend having the system checked to correct the issue of the breaker tripping and not operating properly.

g6cdxjr9 Sticky Note SP-C: Concur. In SOW.

POL-TCX: Concur.

g6cdxjr9 Sticky Note SP-C: Non-concur.

POL-TCX: Non-concur.

g6cdxjr9 Sticky Note SP-C: Non-concur

POL-TCX: Non-concur.

g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Concur.

g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Concur g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur

2.6

Shell and Appurtenances Near Term Findings:

Tank 001 / 20000 currently does have a Schultz water draw tank with an electric pump however it is not heated. Currently there is no piping configured to test the level alarms. Ref: UFC 3-460-01, Table 8-1(z) and DoD Standard Design AW 78-24-27, Drawing D.13, Note A1.

Install a new heated water draw tank with a heated tracer line to the tank shell and the necessary piping to test the tank level alarms per current AW 78-24- 27 Standard Design guidelines Section 33.56.13.13. Paragraph 2.13.14.

2.7

The receipt and issue lines currently do not have a thermal relief system installed at the tank shell per current DoD guidelines. Ref:

UFC 3-460-01, Table 8-1(k); UFGS 33 56 13.13 Section 3.5; and DoD Standard Design AW 78-24-27, Drawing D.10, Detail A3.

Install new thermal relief piping on the receipt and issue lines per current UFC, UFGS, and AW 78-24-27 guidelines.

Note: The current pressure setting on the PRV valves is 125 psi in the pump house.

2.8 There is currently no 2-inch DDB valve installed at the shell for the water draw system. Ref: Ref: UFC 3-460-01, Table 8-1(z).

Install a new 2-inch DBB valve on the tank shell per UFGS 33 52 43.13

2.9

There are currently two (2) 36” manways installed in the 1st shell course with no filler drums and currently have hinges installed to hold the covers when unbolted. There is currently an intermediate manway with “I” beam and chain to hold the cover with filler drum when opening. Ref: UFC 3-460-01, Table 8-1(f) and DoD Standard Design AW 78-24-27, Drawing D.10, Detail A4 and C4.

Consideration should be given to installing a new davit arm and filler drums on the existing 36” manways located in the first shell course per UFGS

33.56.13.13 para.2.13.16

2.10

The tank currently has no HHLA or LLLA.

Upgrade alarm system to current DoD guidelines.

No picture of this item.

2.11

The internal shell coating has excessive entrapment and where previous weld repairs have been made the coating repairs are failing.

Ref: API Standard 653, Annex C, Section C.1.4.2.; UFC 3-460-01, Section 8-3.10(a); and DoD Standard Design AW 78-24-27, Drawing G.03, Note E.13.

Note: the coating were originally installed in 1995.

Recommend removing the existing coatings and installing a new protective coatings on the entire shell per current UFGS guidelines

2.12 Internal Floating Roof (IFR) Near Term Findings:

The tank bottom has five (5) IFR support leg striker plate that are SS and glued down to the tank bottom.

Recommend removing the glued down SS striker plates and installing Teflon feet in the legs or installing ¼” thick seal welded CS plates to the tank bottom. All API 653 guidelines should be met when the plates are installed.

g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Non Concur; Do not install heated water draw tank or heated tracer line. Do install necessary piping to test tank level alarms.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Install filler drums. No need to install davit arms as long as the hinges and I-beam assemblage are functioning properly.

g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Concur, in SOW.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Concur; Install Teflon feet in the legs, do not install CS plates to tank bottom.

2.13 The current configuration of the IFR does not have a foam dam. The tank currently has a fire suppression system that is disconnected.

Consideration should be given to installing a foam dam on the IFR per current DoD guidelines if the AFFF fire system is to be used..

2.14 The current configuration of the tank has no vertical ladder to access the internal floating roof.

Note: the tank does have an intermediate manway.

Install new aluminum vertical ladder per current API, OSHA and UFGS

33.56.13.13 para.2.13.10 guidelines with a safety climb.

No picture of this item

2.15 The three (3) 36” manways have tell-tale holes that are plugged. Recommend removing the plugs and testing the re-pads per current API guidelines.

2.16 The current configuration of the receipt line piping does not have a valve on the pipeline side of the Cla-Valve to isolate it if repairs or maintenance has to be performed.

Consideration should be given to installing a new DBB valve on the receipt piping to isolate the control valve per current AW 78-24-27 guidelines.

2.17

Containment Near Term Findings:

The concrete containment has a coating on it that makes the concrete impervious to the stored product. However the coating was installed poorly with voids in the coating where honeycomb exists and excessive thickness that has caused cracking and failures.

Remove and install a new coating in the containment area per current DoD

SP-C: Concur

POL-TCX: Concur g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Non Concur; Verify with Base if the fire suppression system is used, do not install foam dam if not functioning.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Nonconcur, current DoD standards require an impermeable liner such as a FML to be installed. Recommend installing liner over existing concrete.

g6cdxjr9 Sticky Note SP-C: POL-TCX review

POL-TCX: Concur.

Table 3- Long Term Recommendations

3.1 The fixed roof perimeter has numerous low spots (11). There is currently no active corrosion developing in these areas.

Recommend monitoring this area to ensure the coating integrity does not allow corrosion or rust discoloration to develop.

3.2 The current configuration of the internal diffuser is round and not oval per current AW 78-24-27 guidelines.

There has been no reported issue with the diffuser operating improperly.

Note: see item 2.1 new support will be installed due to the existing supports not adjustable and welded to the directly to the tank bottom.

3.3 Tank 001 currently has no Varec or Shand & Jurs manual tape gauging system installed.

Consideration should be given to installing a new Varec tank gauge system per current API and DoD guidelines.

Table 4- Monitoring Recommendations

4.1 Perform regular in-house inspections of the tank. Maintain the inspection records for historical reference.

Table 5- Stilling Well Recommendations

5.1

The tank does not have an 8" MTG stilling wells installed per UFC 3-460-01, Table 8-1(p).

Install an 8" MTG, and modify the existing ATG stilling well per UFC guidelines.

Note: No picture of this item.

Stilling well installation / upgrade are part of the existing SOW Note: See items2.2

SP-C: Concur

POL-TCX: Non-Concur; Pictures show rust forming on the roof tank, recommend cleaning and repainting effected areas.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Leave as-is.

g6cdxjr9 Sticky Note SP-C: Non-concur

POL-TCX: Most tanks now have the Automatic Tank Gauging System installed. Most of the time the ATG has a read-out close to the tank. If there is one, the ATG read-out meets the requirements of the UFC. If one does not exist, then install the mechanical tape level gauge.

g6cdxjr9 Sticky Note SP-C: Concur

POL-TCX: Concur g6cdxjr9 Sticky Note SP-C: Concur. In SOW

POL-TCX: Concur g6edxncd

POL-TCX: The temperature/water sampling gauge well shall be at least 6". The one currently visible in the photographs is too small. Provide in accordance with the SOW.

Photographs

Item 1.1- Primary Wiper Seal Torn

Item 2.1 - Internal Piping Supports Non Adjustable

Item 2.2 – Existing 8” SS Stilling Well Base

Item 2.3 – Internal Issue Line Piping

Item 2.4 – Reinforcement Plate with Weld Spacing Issues

Item 2.5 – Cathodic Protection System not Energized

Item 2.6 – Water Draw Tank

Item 2.7 – Issue and Receipt Line Piping

Item 2.8 – Water Draw Nozzle

Item 2.9 – Manway Hinge

Item 2.11 – Internal Shell Coatings Entrapment

Item 2.12 – IFR Support Leg Striker Plate

Item 2.13 – IFR with no Foam Dam

Item 2.14 – Manway with Plugged Tell-Tale Hole

Item 2.16– Receipt Line Piping

Item 2.17– Concrete Containment Area

Item 2.17 – Concrete Containment Area

Item 2.17 – Concrete Containment Area

Item 3.1 – Fixed Roof Low Spot

Item 3.2 – Internal Diffuser

Item 3.1-Fixed Roof Low Spot

Item 3.2- Internal Diffuser

External View A

External View B

External View C

External View D

Fixed Roof View A

Fixed Roof View B

Fixed Roof View C

Fixed Roof View D

Internal View A

Internal View B

Internal View C

Internal View D