Hancock-Fac 20005 (Tank 2)-FINAL-2009.pdf

API STANDARD 653 INSPECTION REPORT

OUT-OF-SERVICE INSPECTION

TANK #2

HANCOCK FIELD ANG

SYRACUSE, NEW YORK

Prepared for:

TolTest, Inc.

1480 Ford St.

Maumee, Ohio 43537

Prepared by:

Environmental Technology, Incorporated 4013A Seaboard Court, Suite 1

Portsmouth, Virginia 23701

(757) 405-1291

Project Number: 10704

May 18, 2009

API Standard 653 recommends this document containing valuable historical information be retained for the life of the tank.

ER-HANCOCKFIELDANG-2

EXECUTIVE SUMMARY

An API Standard 653 Out-of-Service Inspection of Tank #2 was completed on May 14, 2009. The purpose of this inspection was to collect data and establish a data base for present and future inspections and evaluations. The evaluation of the shell settlement was satisfactory. The shell nozzle and reinforcement evaluation of the accessible nozzles shows that the nozzles are adequately reinforced and have a minimum remaining life of 32 years. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of 376 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to May 2014, and the next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to May 2024 in accordance with API Standard 653. The bottom service life evaluation shows that the in-service interval of operation (years to next internal inspection) to be twenty years under current conditions, thereby, the next internal inspection should be accomplished by a Certified Inspector prior to May 2029 in accordance with API Standard 653. Inspection Results are listed in 4.0.

Significant Findings: The bottom-to-foundation sealant has visible cracking and separation from the bottom plate extension. The MFL bottom scan revealed two areas of underside corrosion. The thinnest underside corroded area measured 0.227 inches. The internal piping for the 10-inch Product Receipt Diffuser, Nozzle B, is not in contact with the horizontal support bracket. The restraining clips on the 8-inch gaugewell tube have broken welds. The restraining clips are welded directly to the tank bottom. The exterior coating of the shell has minor visible failures and corrosion. The spiral stairway platforms and treads have minor visible coating failure and corrosion. The topside and underside of the fixed roof have minor visible coating failures and corrosion. The fixed roof has evidence of standing water. The Owner/Operator reports that the gaugewell tube will be repaired, a honeycomb sandwich panel floating roof will be installed and the plugs in the tell-tale holes will be removed before the tank is returned to service. Recommendations for Compliance with API Standard 653 are made in 5.0, and Other Recommendations are made in 6.0.

ii

TABLE OF CONTENTS

Section Page

Signature Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv List of Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1.0 Introduction

1.1 Purpose

2.0 References

2.1 American Petroleum Institute

2.2 American Society of Mechanical Engineers

2.3 Code of Federal Regulations

2.4 National Association of Corrosion Engineers

2.5 National Fire Protection Association

3.0 Tank Description

4.0 Inspection Results

4.1 Secondary Containment

4.2 Foundation

4.3 Cathodic Protection

4.4 Bottom

4.5 Shell

4.6 Shell Appurtenances

4.7 Accessways

4.8 Fixed Roof

4.9 Fixed Roof Appurtenances

5.0 Recommendations for Compliance with API Standard 653

5.1 Secondary Containment

5.2 Foundation

5.3 Cathodic Protection

5.4 Bottom

5.5 Shell

5.6 Shell Appurtenances

5.7 Accessways

5.8 Fixed Roof

5.9 Fixed Roof Appurtenances

iii

TABLE OF CONTENTS

Section Page

6.0 Other Recommendations

6.1 Secondary Containment

6.2 Foundation

6.3 Cathodic Protection

6.4 Bottom

6.5 Shell

6.6 Shell Appurtenances

6.7 Accessways

6.8 Fixed Roof

6.9 Fixed Roof Appurtenances

7.0 Serviceability

LIST OF APPENDICIES

Appendix A Engineering Calculations Appendix B Engineering Drawings Appendix C Engineering Data Appendix D API Standard 653 Checklists for Tank Inspection Appendix E Photographs iv

LIST OF ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-Destructive Testing

ATG Automatic Tank Gauge

BL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

ETI Environmental Technology, Incorporated

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non-Destructive Testing

NFPA National Fire Protection Association

PSI Pounds Per Square Inch

PT Penetrant Testing

RP Recommended Practice

RT Radiography Testing

TML Thickness Measurement Location

UT Ultrasonic Testing

VT Visual Testing v

1.0 INTRODUCTION

1.1 Purpose:

1.1.1 The on-site inspection information acquired for this tank, as well as, historical information was analyzed under Environmental Technology, Inc.'s inspection program Version 3.4, to provide a standardized report format of tank conditions, recommendations, and serviceability requirements to satisfy federal, state and local regulations, in addition to the API Standards and/or construction standards for this tank.

1.1.2 This report provides an engineering evaluation of Tank #2 located at the Hancock Field ANG facility in Syracuse, New York. This report summarizes the results of an API Standard 653 Out-of-Service Inspection conducted by Environmental Technology, Inc., Project Number 10704.

1.1.3 This inspection was completed on May 14, 2009.

1.1.4 Our policy is: "Provide to the storage tank owner and/or manager the most precise and complete inspection and report possible, using experienced Inspectors and technicians, advanced technologies, and analytical software."

2.0 REFERENCES

2.1 American Petroleum Institute:

2.1.1 API Recommended Practice 574, Inspection Practices for Piping System Components.

2.1.2 API Recommended Practice 575, Inspection of Atmospheric and Low-Pressure Storage Tanks.

2.1.3 API Standard 650, Welded Steel Tanks for Oil Storage.

2.1.4 API Recommended Practice 651, Cathodic Protection of Aboveground Petroleum Storage Tanks.

2.1.5 API Recommended Practice 652, Lining of Aboveground Petroleum Storage Tank Bottoms.

2.1.6 API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction.

2.2 American Society of Mechanical Engineers Codes:

2.2.1 ASME Boiler and Pressure Vessel Code; Section V, Non-Destructive Examination.

2.2.2 ASME Boiler and Pressure Vessel Code; Section IX, Welding and Brazing Qualifications.

2.2.3 ASME Boiler and Pressure Vessel Code; Section VIII, Division 1, Rules for Construction of Pressure Vessels.

2.3 Code of Federal Regulations:

2.3.1 29 CFR 1910, Permit-Required Confined Spaces for General Industry.

2.3.2 40 CFR 112, Oil Pollution Prevention.

2.4 National Association of Corrosion Engineers:

2.4.1 NACE Recommended Practice, RP0184-91, Repair of Lining Systems.

2.4.2 NACE Recommended Practice, RP0193-93, External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms.

2.4.3 NACE Recommended Practice, RP0288-94, Inspection of Linings on Steel and Concrete.

2.5 National Fire Protection Association:

2.5.1 NFPA-30, Flammable and Combustible Liquids Code.

3.0 TANK DESCRIPTION

3.1 Tank Description:

Owner/Operator: Hancock Field ANG Location: Syracuse, New York Tank Number: 2 Service: JP-8 Specific Gravity: 0.84 Diameter: 27 feet Shell Height: 28.25 feet Product Height: 23.5 feet Capacity: 105,000 gallons; 2,500 barrels Configuration: Vertical Aboveground Storage Tank Foundation: Concrete Ringwall Construction: Bottom: Lap-Welded

Shell: Butt-Welded Fixed Roof: Lap-Welded

Material: Bottom: A 36 Shell: A 36 Fixed Roof: A 36

Tank Built: 1996 Tank Age: 13 years Operating Limits: Minimum Metal Temperature: 0oF

Maximum Metal Temperature: Ambient Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product

Seismic Zone: 1 Construction Code: API Standard 650, Ninth Edition, Appendix E, F & H Manufacturer: Pittsburgh Tank & Tower Co.

Inspection Type: Out-of-Service Inspection w/ MFL Bottom Scan Inspection Date: May 14, 2009 Last External Visual Inspection Year: 1996 Last External Ultrasonic Thickness Inspection Year: 1996 Last Out-of-Service Inspection Year: 1996

4.0 INSPECTION RESULTS

4.1 Secondary Containment: The secondary containment area is constructed from concrete.

The permeability and capacity of the secondary containment area appears to be sufficient to contain and hold the stored product. The secondary containment area appears to be properly graded to drain water away from the tank bottom. The secondary containment drain system is in satisfactory condition.

4.1.1 Significant Findings: No significant findings were noted during this inspection.

4.2 Foundation: The tank bears on top of a concrete ringwall with a secondary containment liner underneath the tank bottom. The tank bottom has leak detection. The foundation was evaluated for shell settlement in accordance with API Standard 653 and is in satisfactory condition.

4.2.1 Significant Findings: The bottom-to-foundation sealant has failed (see Photographs in Appendix E).

4.3 Cathodic Protection: The tank does not have a cathodic protection system.

4.3.1 Significant Findings: No significant findings were noted during this inspection.

4.4 Bottom: The tank is a lap-welded cone-down type bottom. The bottom plates are in an annular configuration. The bottom has a thin film coating that ranged from 9.69 mils to 10.8 mils in thickness. The tank has leak detection and secondary containment under the bottom. The nominal thickness of the bottom plates is 0.3125 inches. The bottom was scanned (approximately 95%) for underside corrosion using Magnetic Flux Leakage (MFL) technology.

The MFE 2412 Mark II unit was used for the MFL floor scan. All indications of the MFL unit were ultrasonically scanned to measure the remaining metal thickness. The bottom has no significant stockside (top side) pitting. The general thickness of each bottom plate was measured using ultrasonic technology (UT). The general thickness of the bottom ranged from a minimum of 0.290 inches to a maximum of 0.312 inches, excluding the underside corrosion indications located by the MFL scan. The general thickness measurements and associated thickness measurement locations (TML) are listed in the Bottom Plate Thickness Measurements table in Appendix C. The general thickness of the sump is measured using ultrasonic technology (UT) and is in satisfactory condition. The floor welds were visually examined and are in satisfactory condition. The bottom service life evaluation shows that the in-service interval of operation (years to next internal inspection) to be twenty years under current conditions, thereby, the next internal inspection should be accomplished by a Certified Inspector prior to May 2029 in accordance with API Standard 653. The bottom service life evaluation is shown in Appendix A.

4.4.1 Significant Findings: The MFL scan revealed two areas of underside corrosion, which were ultrasonically scanned to measure the amount of remaining metal. The thinnest underside corroded area measured 0.227 inches. The underside corroded areas are shown on the Bottom Layout drawing in Appendix B, as well as, listed in the Bottom

Plate Flaw Measurements table in Appendix C. The internal piping for the 10-inch Product Receipt Diffuser, Nozzle B, is not in contact with the internal horizontal support bracket (see Photographs in Appendix E). The gaugewell restraining clips are welded directly to the tank bottom (see Photographs in Appendix E). The gaugewell restraining clip welds have broken free from the gaugewell tube (see Photographs in Appendix E).

4.5 Shell: The tank consists of four (4) butt-welded courses. The exterior of the shell has a thin coating system that ranged between 4.8 and 8.5 mils in thickness. The interior of the shell has a thin coating system that ranged between 9.45 and 10.9 mils in thickness. The interior coating of the shell is in satisfactory condition. The shell was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Shell Plate Thickness Measurements table in Appendix C. A shell service life evaluation performed on all shell courses shows that the shell has a remaining life of 376 years under current conditions, thereby, the next external visual inspection should be accomplished by a Certified Inspector prior to May 2014, and the next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to May 2024 in accordance with API Standard 653. The shell service life evaluation is shown in the Shell Service Life Evaluation table in Appendix A. Roundness, plumbness, peaking, and banding of the shell are within the allowable tolerances of API Standard 653.

4.5.1 Significant Findings: The exterior coating system has minor visible coating failures and corrosion (see Photographs in Appendix E).

4.6 Shell Appurtenances: The accessible shell nozzles and reinforcements were evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements are listed in the Shell Nozzle and Nozzle Reinforcement Measurements table in Appendix C.

The shell nozzle and reinforcement evaluation is performed on all accessible nozzles. The ultrasonic thickness measurements on the nozzles revealed no significant loss of metal from corrosion and erosion. All nozzles that were accessible to ultrasonic examination have a minimum remaining life of 32 years. All nozzles were adequately reinforced. The shell nozzle and reinforcement evaluation is shown in the Shell Nozzle and Reinforcement Evaluation table in Appendix A. Nozzle C (12" Product Issue) and Nozzle D (4" Water Draw) were internal elbow-down nozzles. The nozzles are shown on the Shell Layout drawings in Appendix B, as well as, listed in the Shell Nozzle and Nozzle Reinforcement Measurements table in Appendix C.

The product level is electronically monitored. The ATG system is in satisfactory condition.

4.6.1 Significant Findings: The nozzle reinforcement plates for the three tank manways have plugs in the tell-tale holes. Shell Nozzles A, H and I. The tell-tale holes should open to the atmosphere in accordance with API Standard 650, section 5.7.2.10 (see Photographs in Appendix E). The tank nozzles have minor visible coating failure and corrosion (see Photographs in Appendix E). The high level alarms and controls were tested by Toltest, Inc. and are in satisfactory condition.

4.7 Accessways: The fixed roof is accessible via a spiral stairway.

4.7.1 Significant Findings: The spiral stairway treads, platforms and railing have minor visible coating failure and corrosion (see Photographs in Appendix E).

4.8 Fixed Roof: The fixed roof is a self-supported cone roof. The underside coating of the floating roof measured between 4.69 and 7.63 mils in thickness. The nominal thickness of the fixed roof is 0.1875 inches. The fixed roof was evaluated for remaining metal thickness using ultrasonic technology. The fixed roof thickness ranged from a minimum of 0.184 inches to a maximum of 0.196 inches. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Fixed Roof Plate Thickness Measurements table in Appendix C.

4.8.1 Significant Findings: The topside and underside of the fixed roof have minor visible coating failures and corrosion (see Photographs in Appendix E). There is evidence of standing water on the fixed roof (see Photographs in Appendix E).

4.9 Fixed Roof Appurtenances:

4.9.1 Significant Findings: No significant findings were noted during this inspection.

5.0 RECOMMENDATIONS FOR COMPLIANCE

WITH API STANDARD 653

5.1 Secondary Containment:

5.1.1 No recommendations at this time.

5.2 Foundation:

5.2.1 No recommendations at this time.

5.3 Cathodic Protection:

5.3.1 No recommendations at this time.

5.4 Bottom:

5.4.1 No recommendations at this time.

5.5 Shell:

5.5.1 No recommendations at this time.

5.6 Shell Appurtenances:

5.6.1 Remove the plugs from the reinforcement plate tell-tale holes on shell nozzles A, H and I.

5.7 Accessways:

5.7.1 No recommendations at this time.

5.8 Fixed Roof:

5.8.1 No recommendations at this time.

5.9 Fixed Roof Appurtenances:

5.9.1 No recommendations at this time.

6.0 OTHER RECOMMENDATIONS

6.1 Secondary Containment:

6.1.1 No recommendations at this time.

6.2 Foundation:

6.2.1 Remove the failed bottom-to-foundation sealant and replace it with a suitable material resistant to the stored product.

6.3 Cathodic Protection:

6.3.1 Install a cathodic protection system to reduce the current underside corrosion rate.

6.4 Bottom:

6.4.1 Install patch plates over the two underside corrosion areas on bottom plate #8 to increase the calculated remaining life of the bottom. Install the plates in accordance with API Standard 653, Section 9.10.1 and Table 9-6.

6.4.2 Repair the horizontal support bracket for the internal piping for the 10-inch Product Receipt Diffuser so that the piping is in contact with the horizontal bracket and properly supports the internal piping.

6.4.3 Remove the gaugewell clips from the tank bottom and install a reinforcement plate beneath the gaugewell tube. Replace the restraining clips on the reinforcement plate so that they properly restrain the gaugewell tube.

6.5 Shell:

6.5.1 Repair the minor coating failures and remove the corrosion on the tank shell and recoat to prevent further corrosion.

6.6 Shell Appurtenances:

6.6.1 Repair the minor coating failures and remove the corrosion on the shell nozzles and recoat to prevent further corrosion.

6.7 Accessways:

6.7.1 Repair the minor coating failures and remove the corrosion on the spiral stairway treads, platforms and railing and recoat to prevent further corrosion.

6.8 Fixed Roof:

6.8.1 Repair the minor coating failures and remove the corrosion on the topside and underside of the fixed roof and recoat to prevent further corrosion.

6.8.2 Reshape the areas on the fixed roof where standing water is present to freely allow the water to drain from the roof to prevent coating failures and corrosion.

6.9 Fixed Roof Appurtenances:

6.9.1 No recommendations at this time.

Appendix A

Engineering Calculations

1.

2.

3.

4.

Bottom Service Life Evaluation Internal Shell Settlement Evaluation Shell Service Life Evaluation Shell Nozzle and Reinforcement Evaluation

A-1

Bottom Service Life Evaluation

MRTbc = RTbc - Orbc(StPr + UPr)

MRTip = RTip - Orip(StPr + UPr)

Orbc = RTbc - MRTbc

(StPr + UPr)

Orip = RTip - MRTip

(StPr + UPr)

Where:

MRTbc or MRTip = Minimum remaining thickness at the end of the in-service period of operation, in inches.

Or or Orbc or Orip = In-service interval of operation (years to next internal inspection), in years; however, Or shall not exceed 20 years.

RTbc = Minimum remaining thickness from bottom side corrosion after repairs, in inches.

RTip = Minimum remaining thickness from internal corrosion after repairs, in inches.

StPr = Maximum rate of corrosion not repaired on the top side, in inches per year. StPr = 0 for coated areas of the bottom. The expected service life of the coating must equal or exceed Orip to use StPr = 0.

UPr = Maximum rate of corrosion on the bottom, in inches per year. To calculate the corrosion rate, use the minimum remaining thicknesses after repairs. Assume a linear rate based on the age of the tanks.

UPr = 0 for areas that have effective cathodic protection.

Note: For areas of a bottom that have been scanned by the magnetic flux leakage (or exclusion) process, and do not have effective cathodic protection, the thickness used for calculating UPr must be the lesser of the MFL threshold or the minimum thickness of corrosion areas that are not repaired. The MFL threshold is defined as the minimum remaining thickness to be detected in the areas inspected. The MFL unit used for scanning the bottom does not have a threshold set point. This unit visually displays all anomalies. The confidence level of this unit diminishes greatly for underside pitting/corrosion that is less than 0.04 inches in depth, based on company experience.

Areas of bottom side corrosion that are repaired should be evaluated with the corrosion rate for the repaired area unless the cause of corrosion has been removed. The evaluation is done by using the corrosion rate of the repaired area for UPr, and adding the patch plate (if used) thickness to the term "minimum of RTbc or RTip".

NOTE: The engineering data used to calculate the in-service interval of operation (Or) assumes the tank remains in the same service and all corrosion rates remain constant.

A-2

Present Condition: The tank bottom has a thin film coating system that is in satisfactory condition. The tank does not have a cathodic protection system. The tank does have leak detection and secondary containment under the bottom.

MRTbc or MRTip RTip RTbc StPr UPr

0.050 inches

0.3125 inches

0.227 inches

0.0002 inches/year*

0.0066 inches/year *Although there is no stockside corrosion, a StPr of 0.0002 in/yr is used for calculation purposes.

Orbc = RTbc - MRTbc = 0.227 - 0.050 = 26 years(StPr + UPr) (0.0002 + 0.0066)

Orip = RTip - MRTip = 0.3125 - 0.050 = 38 years(StPr + UPr) (0.0002 + 0.0066)

Therefore, the in-service interval of operation (years to next internal inspection) is:

Or = 26 years

A-3

Repaired Condition #1: Install patch plates of at least 0.25 inches in thickness over the corroded areas on the bottom in accordance with API Standard 653, Section 9.10.1 and Table 9-6.

The tank bottom has a thin film coating system that is in satisfactory condition. The tank does not have a cathodic protection system. The tank does have leak detection and secondary containment under the bottom.

MRTbc or MRTip RTip RTbc StPr UPr

0.050 inches

0.3125 inches

0.477 inches (0.227 inches + 0.25 inches = 0.477 inches)

0.0002 inches/year*

0.0066 inches/year

*As a conservative approach, a StPr and UPr of 0.0002 in/yr are used for calculation purposes.

Orbc = RTbc - MRTbc = 0.477 - 0.050 = 62 years(StPr + UPr) (0.0002 + 0.0066)

Orip = RTip - MRTip = 0.3125 - 0.050 = 38 years(StPr + UPr) (0.0002 + 0.0066)

Therefore, the in-service interval of operation (years to next internal inspection) is:

Or = 38 years

A-4

Repaired Condition #2: Install patch plates of at least 0.25 inches in thickness over the corroded areas on the bottom in accordance with API Standard 653, Section 9.10.1 and Table 9-6. Install a cathodic protection system to reduce the underside corrosion rate.

The tank bottom has a thin film coating system that is in satisfactory condition. The tank does not have a cathodic protection system. The tank does have leak detection and secondary containment under the bottom.

MRTbc or MRTip RTip RTbc StPr UPr

0.050 inches

0.3125 inches

0.477 inches (0.227 inches + 0.25 inches = 0.477 inches)

0.0002 inches/year*

0.0002 inches/year*

*As a conservative approach, a StPr and UPr of 0.0002 in/yr are used for calculation purposes.

Orbc = RTbc - MRTbc = 0.477 - 0.050 = 1067 years(StPr + UPr) (0.0002 + 0.0002)

Orip = RTip - MRTip = 0.3125 - 0.050 = 656 years(StPr + UPr) (0.0002 + 0.0002)

Therefore, the in-service interval of operation (years to next internal inspection) is:

Or = 20 years

A-5

Internal Shell Settlement Evaluation

Maximum Permissible Out-of-Plane Deflection

| S | < 11L2Y

2EH

Where:

S L Y E H

Maximum permissible out-of-plane deflection, in feet.

Arc length between measurement points, in feet Yield strength, in pounds per square inch (psi) Young's modulus, in pounds per square inch (psi) Tank height, in feet

L Y E H S

10.6 feet 36,000 psi 29,000,000 psi

28.25 feet

0.0272 feet

A-6

Internal Shell Settlement Evaluation

Out-of-Plane Deflection

Si = Ui - (1/2Ui-1 + 1/2Ui+1) Where:

S U

Calculated out-of-plane deflection, in feet.

Out-of-Plane settlement of point "i", in feet (+) when above cosine curve (-) when below cosine curve

U1 U2 U3 U4 U5 U6 U7 U8

0.0150 -0.0073 0.0200 0.0127

-0.0050 -0.0227 0.0000

-0.0027 feet feet feet feet feet feet feet feet

S1 S2 S3 S4 S5 S6 S7 S8

0.0200 -0.0248 0.0173 0.0052 0.0000

-0.0202 0.0127

-0.0102 feet feet feet feet feet feet feet feet

The out-of-plane deflection is satisfactory since the magnitude of the highest calculated out-of-plane deflection, 0.0248 feet, is less than the magnitude of the maximum permissible out-of-plane deflection, 0.0272 feet.

A-7

Remarks/Legend:

Owner/Operator:

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Wright-Patterson AFB

Environmental Technology Inc.

05/14/09 N/A N/A

Tank #252 SS-1Internal Shell Settlement Evaluation

Point #1 is at Seam #1 and each point is 45 degrees apart to the left viewing from the inside.

Seam #1 is the first seam right of the first manway right of the ladder in the first shell course viewing from the inside.

Out-of-Plane Settlement

Shell Settlement

Cosine Function Curve

Feet

Points 2 3 4 5 6 7 8 1 2

3.74

3.75

A -8

Shell Service Life Evaluation

The maximum inspection intervals are determined by the most restrictive shell course in regard to the remaining life and the corrosion rate calculations for each shell course using the following formulas:

tmin=

2.6(H-1)DG

SE

Lr= tact - tmin Cr= tprev - tact Iut= tact - tmin Iv= tact - tmin

Cr !Y 2Cr 4Cr

Where:

tmin = The minimum acceptable shell thickness for each course, in inches; however, tmin shall not be less than 0.1 inch for any tank course.

tnorm = The nominal shell thickness, in inches.

tact = The current measured shell thickness, excluding pits and corrosion, in inches.

tprev = The previous measured shell thickness, excluding pits and corrosion or tnorm, in inches.

D = The nominal diameter of the tank, in feet.

H = The height from the bottom of the shell course under considerations to the maximum liquid level, in feet.

Hc = The calculated safe fill height, in feet, for the current product.

G = The highest specific gravity of the contents.

Y = Specified minimum yield strength of the plate; use 30,000 pounds per square inch if not known (N/A for riveted tanks).

T = The smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch; use 55,000 psi if not known (N/A for riveted tanks).

S = The maximum allowable stress, in pounds per square inch. For welded tanks, use the smaller of 0.80Y or 0.429T for the bottom and the second course or the smaller of 0.88Y or 0.472T for all other courses. For riveted tanks, use S=21,000 psi. For elevated temperatures above 200OF, the maximum allowable stress shall be the smaller of 2/3 the minimum yield strength multiplied by the M-factor (M) of API-650 Appendix M or the product design stress value listed in Table 3-2 of API-650.

E = The original joint efficiency for the tank. Use Table 2-1 from API Standard 653 if original E is unknown; E=1.0 when evaluating the retirement thickness in a corroded plate, when away from welds or joints by at least the greater of one inch or twice the plate thickness. For riveted tanks, use E=1.0 for shell plates when greater than 6 inches from rivets; use the value of E from API-653 Table 2-1 when within 6 inches of rivets.

Lr = The remaining life of the shell, in years.

Cr = The shell corrosion rate, in inches per year.

Iut = The inspection interval for the next ultrasonic inspection, in years (not to exceed 15 years).

Iv = The inspection interval for the next visual external inspection, in years (not to exceed 5 years).

!Y = The years between the previous measured shell thickness (tprev) and the current measured shell thickness (tact), in years.

A-9

Shell Service Life Evaluation

Present Condition:

Plate Material: A 36

D H G

!Y

27 feet

23.5 feet 0.84 13 years

Course No.

Course Height (feet)

Maximum Allowable

Stress (psi) (S)

Joint Efficiency

(E)

Previous Measured Thickness (inches)

(tprev)

Current Measured Thickness (inches)

(tact)

Minimum Acceptable Thickness (inches)

(tmin)

Corrosion Rate

(in./yr) (Cr)

Remaining Life

(years) (Lr)

Next Visual

Inspection (years)

(Iv)

Next Ultrasonic Thickness Inspection

(years) (Iut)

1 96 24,882 1.00 0.25 0.245 0.1 0.000385 376 5 15 2 96 24,882 1.00 0.25 0.256 0.1 0.000200 780 5 15 3 72 27,376 1.00 0.25 0.251 0.1 0.000200 755 5 15 4 72 27,376 1.00 0.25 0.245 0.1 0.000385 376 5 15

The current measured thickness is based on the lowest ultrasonic thickness measurement for that course. The remaining life of the shell is 376 years under present conditions. The current maximum operating level of 23.5 feet is satisfactory. The next external visual inspection should be accomplished by a Certified Inspector prior to May 2014 in accordance with API Standard

653. The next external ultrasonic thickness measurement inspection should be accomplished by a Certified Inspector prior to May 2024 in accordance with API Standard 653.

A-10

Shell Nozzle and Reinforcement Evaluation nt pD nR rnt

C hUse smaller value t2.5 or 2.5 tn t2.5 or 2.5 t + ten Use smaller value t rt d et nd +or Rn+ t td +or R + t tnn Use larger value Use larger value

For nozzle wall abutting the vessel wallFor nozzle wall inserting through the vessel wall

A

A

A

= A

= A

= A3

A A1

2A

A3

A

A

= A42

= A5

= 5 ti ti fr2

= 5 ti ti fr2

= 5 ti ti fr2

= 5(tn- trn ) fr2 t = 5(tn- trn ) fr2 tn

= 2( t + tn) (E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)d

(E1 -F rt ) - 2 tnt ( E1 -F rtt )(1 - fr1)

= +Frt 2 tn (1 - fr1)d tr F

= outward nozzle weld = (leg) fr2

= inward nozzle weld = (leg)2 rf 2

= Same as A = Same as

, above A1, above

= 5(tn- trn ) fr2 t = 5(tn- trn ) fr2 t (2.5 tn+ te ) fr2

= Same as A3, above

= outward nozzle weld = (leg) fr3

= outer element weld = (leg) fr4

= inward nozzle weld = (leg) fr2

= ( pD - fr4d - 2 tn)te

If A1 + 2A + A3+ 41A + A42

A If A1 + 2A + A3+ 41A + A42 A

If A1 + 2A + A3+ 41A + A42 A>+ 43A + 5A

Area required

Area available in shell; use larger value

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle; use the smallest value

Area available in outward weld Area available in inward weld

Opening is adequately reinforced Opening is NOT adequately reinforced; reinforcement required

Area required Area available in shell

Area available in nozzle projecting outward; use smaller value

Area available in inward nozzle

Area available in outward welds Area available in outer welds Area available in inward welds

Area available in element

Opening is adequately reinforced If A

A + A

A + A

A+

A +

A Opening is NOT adequately reinforced; additional reinforcement required<

Without Reinforcing Element

With Reinforcing Element

A-11

Minimum Required Thickness for Nozzles shall be determined from ASME Section VIII, Division 1, Part UG-27 as follows:

trn = PRn

SE - 0.6P

The remaining life of a tank or any of its components shall be determined using the formulas from API RP 575 as follows:

Cr = tprev - tact Lr = tact - trn

!Y Cr

Where:

Dp = Outside diameter of reinforcing element as measured vertically, inches.

D = Outside diameter of pipe, inches.

d = finished diameter of circular opening in shell (inside diameter of nozzle), inches;

Where d = D - 2tn

E = Joint efficiency of nozzle; Use E = 1.0 for API calculations.

F = Correction factor for different plane variations; Use F = 1.0 for API calculations.

h = Distance nozzle projects beyond the inner surface of the wall, inches. Not to exceed 4tn for API calculations.

P = Internal design pressure, psi. Where, P = 0.433GH

Rn = Inside radius of nozzle, inches; Where Rn = d/2 Sn = Allowable stress in nozzle, psi.

fr = Strength reduction factor; Use fr = 1.0 for API calculations.

leg = Weld leg length, inches; Use leg = 0 for API calculations.

t = actual measured thickness of shell, inches; Use tact from Shell Service Life Evaluation.

tact = Actual measured thickness of nozzle, inches.

tprev = Previous measured thickness of nozzle or tn, inches.

te = Thickness of reinforcement plate or thickness of thickened insert less the actual measured thickness of the shell (t), inches.

tr = Minimum required shell thickness at the bottom of the nozzle, inches;

Where, tr = 2.6HDG/SE, however, tr shall not be less than 0.1 inch; Use E = 1.0 for API calculations; Use D and S from Shell Service Life Evaluation.

tn = External nominal pipe wall thickness, inches.

ti = Internal nominal pipe wall thickness, inches; Use ti = tn if nozzle projects inward for

API calculations.

trn = Required thickness of nozzle wall, inches.

G = Product specific gravity; Use G from Shell Service Life Evaluation.

H = Maximum liquid level above bottom of nozzle, feet.

Cr = Corrosion rate of nozzle, inches per year; Use Cr = 0.0002 inches/year, if Cr calculates to be less than 0.0002 inches/year.

LR = Remaining life of nozzle, years.

!Y = Years between tprev and tact, in years.

A-12

Nozzle A: 36" Manway (Course #1) d = 36 - 2(0.5) = 35 inches t = 0.245 inches !Y = 13 years Rn = 35/2 = 17.5 inches tr = 0.1 inches Dp = 78 inches P = 0.433(0.84)(21.5) = 8 psi tn = 0.5 inches te = 0.25 inches h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.5 inches E = 1 tact = 0.475 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(17.5) = 0.006 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.5 - 0.475 = 0.001923 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.475 - 0.1 = 195 years Cr 0.001923

Reinforcement Calculations:

Formulas are simplified A = dtr = (35)(0.1) = 3.5 in2

A1 = d(t-tr) = (35)(0.245-0.1) = 5.075 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.5)(0.245-0.1) = 0.2161 in2

A2 = 5(tn-trn)t = (5)(0.5-0.1)(0.245) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.245)[(2.5)(0.5)+0.25] = 0.735 in2

A3

= 5t ti = (5)(0.245)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [78-35-(2)(0.5)](0.25) = 10.5 in2

Area provided by A1 + A2 + A3 + A5 = 5.075 in2 + 0.49 in2 + 0 in2 + 10.5 in2 = 16.065 in2. This is greater than the required area of 3.5 in2, therefore, the reinforcement is adequate.

A-13

Nozzle B: 10" Product Receipt (Course #1) d = 10.75 - 2(0.5) = 9.75 inches t = 0.245 inches !Y = 13 years Rn = 9.75/2 = 4.875 inches tr = 0.1 inches Dp = 25 inches P = 0.433(0.84)(22.92) = 8 psi tn = 0.5 inches te = 0.25 inches h = 2 inches ti = 0.5 inches

Sn = 23,200 psi tprev = 0.5 inches E = 1 tact = 0.514 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(4.875) = 0.0017 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.5 - 0.514 = -0.001077 inches/year !Y 13

Since tprev is less than tact, let Cr=0.0002 inches/year for calculation purposes.

Remaining Life Calculation:

LR = tact - trn = 0.514 - 0.1 = 2070 years Cr 0.0002

Reinforcement Calculations:

Formulas are simplified A = dtr = (9.75)(0.1) = 0.975 in2

A1 = d(t-tr) = (9.75)(0.245-0.1) = 1.4138 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.5)(0.245-0.1) = 0.2161 in2

A2 = 5(tn-trn)t = (5)(0.5-0.1)(0.245) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.245)[(2.5)(0.5)+0.25] = 0.735 in2

A3

= 5t ti = (5)(0.245)(0.5) = 0.6125 in2

= 5ti ti = (5)(0.5)(0.5) = 1.25 in2

= 2hti = (2)(2)(0.5) = 2 in2

A5 = (Dp-d-2tn)te = [25-9.75-(2)(0.5)](0.25) = 3.5625 in2

Area provided by A1 + A2 + A3 + A5 = 1.4138 in2 + 0.49 in2 + 0.6125 in2 + 3.5625 in2 = 6.0788 in2. This is greater than the required area of 0.975 in2, therefore, the reinforcement is adequate.

A-14

Nozzle C: 12" Product Issue (Course #1) d = 12.75 - 2(0.5) = 11.75 inches t = 0.245 inches !Y = 13 years Rn = 11.75/2 = 5.875 inches tr = 0.1 inches Dp = 25 inches P = 0.433(0.84)(23) = 8 psi tn = 0.5 inches te = 0.25 inches h = 2 inches ti = 0.5 inches

Sn = 23,200 psi tprev = 0.5 inches E = 1 tact = 0.479 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(5.875) = 0.002 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.5 - 0.479 = 0.001615 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.479 - 0.1 = 235 years Cr 0.001615

Reinforcement Calculations:

Formulas are simplified A = dtr = (11.75)(0.1) = 1.175 in2

A1 = d(t-tr) = (11.75)(0.245-0.1) = 1.7038 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.5)(0.245-0.1) = 0.2161 in2

A2 = 5(tn-trn)t = (5)(0.5-0.1)(0.245) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.245)[(2.5)(0.5)+0.25] = 0.735 in2

A3

= 5t ti = (5)(0.245)(0.5) = 0.6125 in2

= 5ti ti = (5)(0.5)(0.5) = 1.25 in2

= 2hti = (2)(2)(0.5) = 2 in2

A5 = (Dp-d-2tn)te = [25-11.75-(2)(0.5)](0.25) = 3.0625 in2

Area provided by A1 + A2 + A3 + A5 = 1.7038 in2 + 0.49 in2 + 0.6125 in2 + 3.0625 in2 = 5.8688 in2. This is greater than the required area of 1.175 in2, therefore, the reinforcement is adequate.

A-15

Nozzle D: 4" Water Draw (Course #1) d = 4.5 - 2(0.337) = 3.826 inches t = 0.245 inches !Y = 13 years Rn = 3.826/2 = 1.913 inches tr = 0.1 inches Dp = 25 inches P = 0.433(0.84)(22.47) = 8 psi tn = 0.337 inches te = 0.25 inches h = 1.348 inches ti = 0.337 inches

Sn = 23,200 psi tprev = 0.337 inches E = 1 tact = 0.328 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(1.913) = 0.0007 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.337 - 0.328 = 0.000692 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.328 - 0.1 = 329 years Cr 0.000692

Reinforcement Calculations:

Formulas are simplified A = dtr = (3.826)(0.1) = 0.3826 in2

A1 = d(t-tr) = (3.826)(0.245-0.1) = 0.5548 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.337)(0.245-0.1) = 0.1688 in2

A2 = 5(tn-trn)t = (5)(0.337-0.1)(0.245) = 0.2903 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.337-0.1)(0.245)[(2.5)(0.337)+0.25] = 0.3172 in2

A3

= 5t ti = (5)(0.245)(0.337) = 0.4128 in2

= 5ti ti = (5)(0.337)(0.337) = 0.5678 in2

= 2hti = (2)(1.348)(0.337) = 0.9086 in2

A5 = (Dp-d-2tn)te = [25-3.826-(2)(0.337)](0.25) = 5.125 in2

Area provided by A1 + A2 + A3 + A5 = 0.5548 in2 + 0.2903 in2 + 0.4128 in2 + 5.125 in2 = 6.3829 in2. This is greater than the required area of 0.3826 in2, therefore, the reinforcement is adequate.

A-16

Nozzle E: 3" Fire Fighting (Course #4) (Nozzle is above liquid level) d = 3.5 - 2(0.3) = 2.9 inches t = 0.245 inches !Y = 13 years Rn = 2.9/2 = 1.45 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.3 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.3 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(1.45) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

Reinforcement Calculations:

Formulas are simplified A = dtr = (2.9)(0.1) = 0.29 in2

A1 = d(t-tr) = (2.9)(0.245-0.1) = 0.4205 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.3)(0.245-0.1) = 0.1581 in2

A2 = 5(tn-trn)t = (5)(0.3-0.1)(0.1) = 0.245 in2

= 5(tn-trn)tn = (5)(0.3-0.1)(0.3) = 0.3 in2

A3

= 5t ti = (5)(0.245)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

Area provided by A1 + A2 + A3 = 0.4205 in2 + 0.245 in2 + 0 in2 = 0.6655 in2. This is greater than the required area of 0.29 in2, therefore, the reinforcement is adequate.

A-17

Nozzle F: 1" Fire Indicator (Course #4) (Nozzle is above liquid level) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-18

Nozzle G: 1" Low-Level Indicator (Course #1) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(23.13) = 8 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (8)(0.4785) = 0.0002 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-19

Nozzle H: 36" Floating Roof Manway (Course #2) d = 36 - 2(0.5) = 35 inches t = 0.256 inches !Y = 13 years Rn = 35/2 = 17.5 inches tr = 0.1 inches Dp = 78 inches P = 0.433(0.84)(13.58) = 5 psi tn = 0.5 inches te = 0.25 inches h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.5 inches E = 1 tact = 0.474 inches

Minimum Required Thickness Calculation:

trn = PRn = (5)(17.5) = 0.0038 inches

SE - 0.6P (23,200)(1) - (0.6)(5)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.5 - 0.474 = 0.002 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.474 - 0.1 = 187 years Cr 0.002

Reinforcement Calculations:

Formulas are simplified A = dtr = (35)(0.1) = 3.5 in2

A1 = d(t-tr) = (35)(0.256-0.1) = 5.075 in2

= 2(t+tn)(t-tr) = (2)(0.256+0.5)(0.256-0.1) = 0.2161 in2

A2 = 5(tn-trn)t = (5)(0.5-0.1)(0.256) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.256)[(2.5)(0.5)+0.25] = 0.735 in2

A3

= 5t ti = (5)(0.256)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [78-35-(2)(0.5)](0.25) = 10.5 in2

Area provided by A1 + A2 + A3 + A5 = 5.075 in2 + 0.49 in2 + 0 in2 + 10.5 in2 = 16.065 in2. This is greater than the required area of 3.5 in2, therefore, the reinforcement is adequate.

A-20

Nozzle I: 36" Manway (Course #1) d = 36 - 2(0.5) = 35 inches t = 0.245 inches !Y = 13 years Rn = 35/2 = 17.5 inches tr = 0.1 inches Dp = 78 inches P = 0.433(0.84)(21.5) = 8 psi tn = 0.5 inches te = 0.25 inches h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.5 inches E = 1 tact = 0.475 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(17.5) = 0.006 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.5 - 0.475 = 0.001923 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.475 - 0.1 = 195 years Cr 0.001923

Reinforcement Calculations:

Formulas are simplified A = dtr = (35)(0.1) = 3.5 in2

A1 = d(t-tr) = (35)(0.245-0.1) = 5.075 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.5)(0.245-0.1) = 0.2161 in2

A2 = 5(tn-trn)t = (5)(0.5-0.1)(0.245) = 0.49 in2

= 5(tn-trn)t(2.5tn+te) = (5)(0.5-0.1)(0.245)[(2.5)(0.5)+0.25] = 0.735 in2

A3

= 5t ti = (5)(0.245)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

A5 = (Dp-d-2tn)te = [78-35-(2)(0.5)](0.25) = 10.5 in2

Area provided by A1 + A2 + A3 + A5 = 5.075 in2 + 0.49 in2 + 0 in2 + 10.5 in2 = 16.065 in2. This is greater than the required area of 3.5 in2, therefore, the reinforcement is adequate.

A-21

Nozzle J: 1" Level Indicator (Course #4) (Nozzle is above liquid level) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-22

Nozzle K: 1" Level Indicator (Course #4) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0.88) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-23

Nozzle L: 1" High-Level Shut-Off (Course #4) (Nozzle is above liquid level) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-24

Nozzle M: 1" Plug (Course #4) (Nozzle is above liquid level) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-25

Nozzle N: 1" High-Level Shut-Off (Course #4) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(1.04) = 0 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(0.4785) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

A-26

Nozzle O: 3" Fire Fighting (Course #4) (Nozzle is above liquid level) d = 3.5 - 2(0.3) = 2.9 inches t = 0.245 inches !Y = 13 years Rn = 2.9/2 = 1.45 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(0) = 0 psi tn = 0.3 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.3 inches E = 1 tact = N/A

Minimum Required Thickness Calculation:

trn = PRn = (0)(1.45) = 0 inches

SE - 0.6P (23,200)(1) - (0.6)(0)

As a conservative approach, let trn=0.1 inches.

The Corrosion Rate Remaining Life Calculations cannot be calculated since thickness measurements cannot be taken on this nozzle. Visual inspection revealed no active corrosion. The remaining life of this nozzle is estimated to be greater than 50 years.

Reinforcement Calculations:

Formulas are simplified A = dtr = (2.9)(0.1) = 0.29 in2

A1 = d(t-tr) = (2.9)(0.245-0.1) = 0.4205 in2

= 2(t+tn)(t-tr) = (2)(0.245+0.3)(0.245-0.1) = 0.1581 in2

A2 = 5(tn-trn)t = (5)(0.3-0.1)(0.1) = 0.245 in2

= 5(tn-trn)tn = (5)(0.3-0.1)(0.3) = 0.3 in2

A3

= 5t ti = (5)(0.245)(0) = 0 in2

= 5ti ti = (5)(0)(0) = 0 in2

= 2hti = (2)(0)(0) = 0 in2

Area provided by A1 + A2 + A3 = 0.4205 in2 + 0.245 in2 + 0 in2 = 0.6655 in2. This is greater than the required area of 0.29 in2, therefore, the reinforcement is adequate.

A-27

Nozzle P: 1" Blank (Course #1) d = 1.315 - 2(0.179) = 0.957 inches t = 0.245 inches !Y = 13 years Rn = 0.957/2 = 0.4785 inches tr = 0.1 inches Dp = N/A P = 0.433(0.84)(21.04) = 8 psi tn = 0.179 inches te = N/A h = 0 inches ti = 0 inches

Sn = 23,200 psi tprev = 0.179 inches E = 1 tact = 0.156 inches

Minimum Required Thickness Calculation:

trn = PRn = (8)(0.4785) = 0.0002 inches

SE - 0.6P (23,200)(1) - (0.6)(8)

As a conservative approach, let trn=0.1 inches.

Corrosion Rate Calculation:

Cr = tprev - tact = 0.179 - 0.156 = 0.001769 inches/year !Y 13

Remaining Life Calculation:

LR = tact - trn = 0.156 - 0.1 = 32 years Cr 0.001769

A-28

Appendix B

Engineering Drawings

1.

2.

3.

Bottom Layout Shell Layout Fixed Roof Layout

B-1

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Hancock Field ANG, Syracuse, NY

Environmental Technology, Inc.

05/18/09 N/A N/A

Tank #2 B-1Bottom Layout

Measured Inside Diameter is 27 feet.

Tank bottom has 18 plates.

GRAPHIC SCALE:

Dimensions are in feet.

y x NW y x

NE

y x

SEy x

SW

XY Orientation

XY Orientation is in reference to Plan North

Underside Corrosion

See Bottom Plate Flaw Measurements table for detailed measurements.

V1

V2

V3

V4

V5

A

Shell Nozzles in Course #1 A - 36" Manway

B

B - 10" Product Receipt

C

C - 12" Product Issue

D

D - 4" Water Draw

E

E - 3" Fire Fighting

F

F - 1" Fire Indicator

G

G - 1" Low-Level Indicator

H

H - 36" Floating Roof Manway

I

I - 36" Manway

J

J - 1" Level Indicator

K

K - 1" Level Indicator

L

L - 1" High-Level Shut-Off

M

M - 1" Plug

N

N - 1" High-Level Shut-Off

O

O - 3" Fire Fighting

P

P - 1" Blank

V# - Vertical Seam Number of Shell Course #1

B -2

Client:

TolTest, Inc.

Inspection Firm:

Date: Revision Number: Revision Date:

Drawing Title: Tank Description: Drawing Number:

Hancock Field ANG, Syracuse, NY

Environmental Technology, Inc.

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