TG30 ILG Fac. 5042 Tank1 API 653 OOS Report.pdf
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- W9128F21R0035
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|---|---|---|
| Q_and_A_Scott_ILG_21R0035_29 JAN 2021.pdf | ||
| Modification_Copy_1449_PWS_Edit.pdf | ||
| Conformed_Copy_1449_PWS_Edit.pdf | ||
| Q_and_A_Scott_IGL_21R0035_21 JAN 2021_First Set(002).pdf | ||
| Q_and_A_Scott_IGL_21R0035_21 JAN 2021_Second Set.pdf | ||
| Q_and_A_21R0035_ILG_20 JAN 2021.pdf | ||
| Attachment E (API In-Service Template).docx | DOCX document | |
| ATT C-Fuel Storage Excel Document.xlsx | XLSX spreadsheet | |
| ATT D-Monthly Contractors Progress Management and Status Reports.xlsx | XLSX spreadsheet | |
| Attch B_ILG_Tank Info.xlsx | XLSX spreadsheet | |
| ATT A-General Installation Security Requirements.docx | DOCX document | |
| W9128F21R0035 SCOTT ANGB_ IL.pdf |
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Text version
For Evaluation and Action
Elizabeth Wergin
AFICA Contracting Officer
Jeff Biggar
Gilbane Federal
FA3002-08-D-0008, TO: TG30
Jeff Biggar, Fuels Project Manager
Gilbane Federal
(YYYYMMDD)
(YYYYMMDD)
(YYYYMMDD)
(YYYYMMDD)
(YYYYMMDD)
Form Approved OMB No 9000-0062 Expires May 31, 2005
MATERIAL APPROVAL SUBMITTAL
(See Instructions on Reverse)
Public reporting burden for this collection of information is estimated to average 20 minutes per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to the Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project OMB No 9000-0062, Washington DC 20503. Please DO NOT RETURN your form to either of these addresses. Send your completed form to: SAF/AQCP, 1060 Air Force Pentagon, Washington DC 20330-1060.
TO: (Contracting Officer) FROM: (Contractor) DATE
CONTRACT NUMBER SUBMISSION NUMBER SUBMITTAL
NEW RESUBMITTAL
PREVIOUS SUBMISSION NUMBER PROJECT NUMBER
TO BE COMPLETED BY CONTRACTOR FOR GOVERNMENT USE ONLY
ITEM SPECIFICATION SECTION/ DESCRIPTION OF MATERIAL AP-
PROVED
DISAP-
PROVED
SEE
REVERSE INITIAL
BY COMPLETING THIS FORM, THE UNDERSIGNED CONTRACTOR CERTIFIES THAT
THE MATERIAL COMPLIES WITH ALL SPECIFICATIONS OF SUBJECT CONTRACT.
DATE TYPE OR PRINT NAME AND TITLE SIGNATURE
FOR GOVERNMENT USE ONLY
TO: (Base Civil Engineering Officer)
DATE TYPE OR PRINT NAME AND GRADE SIGNATURE
TO: (AF Contracting Office)
RECOMMEND APPROVAL DISAPPROVAL AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE
DATE TYPE OR PRINT NAME AND GRADE SIGNATURE
TO: (Contractor)
DISAPROVED AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE SIDE. REQUEST
APPROVED
RESUBMITTAL ON DISAPPROVED ITEMS WITHIN DAYS OF DATE SHOWN BELOW.
DATE TYPE OR PRINT NAME AND GRADE SIGNATURE
AF IMT 3000, 20030901, V1 PREVIOUS EDITION IS OBSOLETE.
NO. PARA NO./DRAWING NO. (Include Type, Model Number, Catalog Number, Mfg., etc.)
20160501
023a X
API 653 Inspection Report - Scott ANG, IL Facility 5042 (Tank 1) CDRL A015d
SOW Para 3.2.1.1
20160501
JBiggar Stamp
JBiggar Typewritten Text
TG30
JBiggar Typewritten Text P.2013.00169, P.2013.00192, P.2013.00193, P.2013.00310
JBiggar Typewritten Text P.2014.00153, P.2014.00154, P.2014.00320, P.2014.01373, P.2014.01464
JBiggar Typewritten Text P.2014.01467, P.2015.01633, P.2015.01594
1256390724E Stamp
1256390724E Stamp
1256390724E Typewritten Text
SADII
1256390724E Typewritten Text
AFCEC/CFSD
1256390724E Typewritten Text 772 ESS/PKA Attn: Ms. Elizabeth L. Wergin
1256390724E Typewritten Text 20160509
1256390724E Typewritten Text Stanley A. Dabney II Contracting Officer's Rep.
1256390724E Typewritten Text Elizabeth L. Wergin Contracting Officer
1256390724E Stamp
1104397618C Stamp
1104397618C Typewritten Text 20160512
1104397618C Typewritten Text
COMMENTS
(Number to correspond with applicable Item Number on reverse)
INSTRUCTIONS TO CONTRACTORS
1. The term "material" is defined as articles, supplies, raw materials, equipment, parts, components, and end items that are to be incorporated into the work required by the contract.
2. This form is to be used by contractors for submitting Shop Drawings, Equipment Data, Manufacturer's Literature and Certificates and samples of Materials to the Government for approval in accordance with the provisions of this contract. Unless otherwise specified, it is to be prepared in 4 copies, signed, and provided to the contracting officer with appropriate attachments.
3. Item(s) to be approved will be clearly tabbed or identified. Data pertaining to item(s) to be approved will be clearly identified or tabbed, particularly where documents are voluminous, in order to properly evaluate the materials or articles to be incorporated in the work. Each attachment will be numbered to correspond with the item number shown on the face of this form.
4. Requests submitted shall be numbered consecutively, by contract, in the space entitled "Submission No.". This number, in addition to the Contract No., will be used to identify each Material Approval Submittal. Resubmissions will be indicated in the appropriate block and the insertion of previous submission number and data in addition to a new submission number. A single submission should be used for all work of a section of the specifications, but in NO instance should the submission include work for more than one (1) contract. Submittals requiring priority handling will be submitted by separate submittal using the form and so marked across the face of the form.
5. This Material Approval Submittal is not valid unless it is signed by the contracting officer. This approval is required as called for by the contracting officer under the terms of this contract.
AF IMT 3000, 20030901, V1 (REVERSE)
1256390724E Typewritten Text AFCEC/CFSD: recommend approval, conditional to notations for 0008-TG30 submittal 023A "API 653 Inspection Report - Scott ANG, IL Facility 5042 (Tank 1)". Per para. 7.2, the Government reclassifies the following corrective actions:
1. 6.1.1. Recommended Repair (Prolong- Level 2).
2. 6.1.2. Recommended Repair (Prolong- Level 2).
3. 6.5.3. Future Recommended Repair (Upgrade- Level 1).
4. 6.6.2. Recommended Repair (Upgrade- Level 1). Note: this is the 3-inch low suction line, not a 3-inch issue line.
1104397618C Typewritten Text Repairs outside the original scope of work of the contract will need to be submitted through the RFI process with a cost (ROM) and schedule impact and may only be completed by contract modification.
API STANDARD 653 INSPECTION REPORT
OUT-OF-SERVICE INSPECTION
SCOTT AIR NATIONAL GUARD
BELLEVILLE, ILLINIOS
TANK #1 (FACILITY 5042)
Prepared for:
1655 Grant Street Floor 12 Concord, California 94520
Contract Number: FA3002-08-D-0008 TG30
Prepared by:
Inter Spec LLC Environmental Inspection Services
464 S Independence Blvd, C-104 Virginia Beach, Virginia 23452
(757) 622-6299 Project Number: 15-0164
Inspection Date: January 21, 2016
API Standard 653 recommends this document containing valuable historical information be retained for the life of the tank.
Signature(s):
Richard M. Bailey, API-653 Inspector
Wayne K. Bailey, API-653 Inspector
Jared Shuman, PE, API-653 Inspector
3/31/2016
SCOTT ANG, IL-TANK #1 (FACILITY 5042)-API653 OOS-JAN2016
ii
EXECUTIVE SUMMARY
An API Standard 653 Out-of-Service inspection of Tank #1 (Facility 5042) at Scott ANG Base, IL was completed on January 21, 2016. The bottom service life evaluation shows that the out of service interval of operation (years to next internal inspection) to be greater than 30 years under current conditions. The shell service life evaluation performed as having greater than 30 years of remaining shell life under current conditions. The next internal inspection should be accomplished by a Certified Inspector prior to January 2046 in accordance with the API Standard 653 based on bottom corrosion rates and release prevention barrier under the tank bottom. UFC 3-460-03 currently requires the out-of-service inspection to be every 10 years; therefore, the next out-of-service inspection is due by January 2026. Inspection Results are listed in section 4.0. Recommendations for Compliance with API Standard 653 are listed in section 5.0. Other Recommendations are listed in section 6.0. The significant findings are summarized below.
Significant Findings (overview)
The tank is not equipped with a cathodic protection system.
The floating roof anti-rotation clip and VAREC mechanical tape level gauge internal float bracket are welded to the floor without a lap-welded reinforcement pad.
The sump has coating failure.
The spiral stairway treads, the mechanical tape level gauge supports, and the uni-strut supports for the automatic tank shut off control tubing and electronic gauging conduit are welded directly to the shell.
The issue line does not have a flanged fitting located internally next to the shell, is not one-half of the tank radius, and does not have an anti-vortex plate.
The 3-inch low suction line does not have a double block and bleed valve for tank isolation.
The water draw off system does not have 1-inch stainless steel welded and flanged piping, welded shell coupling, and 2-inch double block and bleed valve. The exterior piping has corrosion and coating failure.
The product saver tank is not stainless steel, does not have a vent, and is not grounded.
The steel thermal relief systems for the issue line, receipt line, and low-point suction line have VISI-
FLOW glass sight flow indicators, and do not have welded and flanged stainless steel piping, welded coupling on piping, lockable ball valves, and test TEE’s.
Both manways do not have davit arms to aid in the safe removal of the covers.
The tank does not have a 36-inch shell manway located above the internal floating pan’s high position.
The tank is not equipped with an ENRAF ATG system.
The tank is not equipped with an ATG water probe stilling well (VITO system).
The existing 6-inch aluminum stilling wells for sample gauge well and ATG gauging well are not slotted.
The low level alarm assembly is not welded stainless steel piping with flanged connections, does not have a welded coupling on shell, and does not have lockable valves. The elevation of the low level alarm assembly nozzles are too low. The piping and assembly have corrosion and coating failure.
The high-high level alarm assembly, high level alarm assembly, and high level shut-off assembly are not stainless steel with flanged connections. The assemblies are accessible from the stairway for routine testing. The assemblies do not have 1-inch piping extending to the product saver tank to allow routine testing. The assemblies have corrosion and coating failure on the piping and assemblies.
The issue line, receipt line, and low suction line pipe supports have metal to metal contact.
The double block and bleed valves for the receipt line and issue line have areas of coating failure and corrosion.
The exterior coating on the fixed roof has completely failed, and has exceeded useful life.
iii
TABLE OF CONTENTS
Section Page
Cover ................................................................................................................................................... i Executive Summary ........................................................................................................................... ii List of Appendices ............................................................................................................................. v List of Attachments ............................................................................................................................ v List of Acronyms and Abbreviations ................................................................................................ vi
1.0 Introduction
1.1 Purpose
2.0 References
2.1 American Petroleum Institute (API)
2.2 American Society of Mechanical Engineers Codes (ASME)
2.3 American Society of Nondestructive Testing (ASNT)
2.4 Code of Federal Regulations (CFR)
2.5 National Association of Corrosion Engineers (NACE)
2.6 National Fire Protection Association (NFPA)
2.7 Unified Facilities Criteria (UFC)
2.8 Unified Facilities Guide Specifications
2.9 Department of Defense (DoD) Standard Designs
3.0 Description
3.1 Job Description
3.2 Tank Description
3.3 Service Description
3.4 Part Description
3.5 Joint Type Description
3.6 Inspection Description
3.7 NDT Equipment Description
4.0 Inspection Results
4.1 Secondary Containment
4.2 Foundation
4.3 Cathodic Protection
4.4 Bottom
4.5 Shell
4.6 Appurtenances
4.7 Accessways
4.8 Floating Roof
4.9 Fixed Roof
iv
TABLE OF CONTENTS
Section Page
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 Appurtenances
5.7 Accessways
5.8 Floating Roof
5.9 Fixed Roof
6.0 Other Recommendations
6.1 Secondary Containment
6.2 Foundation
6.3 Cathodic Protection
6.4 Bottom
6.5 Shell
6.6 Appurtenances
6.7 Accessways
6.8 Floating Roof
6.9 Fixed Roof
7.0 Serviceability
LIST OF APPENDICES
Appendix A Engineering Calculations Appendix B Engineering Drawings Appendix C Engineering Data Appendix D Tank Historical Review Appendix E API Standard 653 Checklists for Tank Inspections Appendix F Photographs
LIST OF ATTACHMENTS
Attachment 1 Detailed Repair Cost Estimates and DD Form 1391 (provided by Gilbane Federal)
Attachment 2 Lead-Based Paint (LBP), Hexavalent Chromium (Hex-Chrome), and Asbestos Containing Material (ACM) (provided by Gilbane Federal) v
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
BBL Barrel
CFR Code of Federal Regulations
CP Cathodic Protection
DFT Dry Film Thickness
HLA High Level Alarm
HLSO High Level Shut-Off
HHLA High-High Level Alarm
LLA Low Level Alarm
LLLA Low-Low Level Alarm
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
P/V Pressure/Vacuum
RP Recommended Practice
PST Product Saver Tank
RT Radiography Testing
TML Thickness Measurement Location
TRV Thermal Relief Valve
UFC Unified Facilities Criteria
UFGS Unified Facilities Guide Specifications
UT Ultrasonic Testing
VT Visual Testing
1.0 INTRODUCTION
1.1 Purpose
1.1.1 The purpose of this inspection was to collect data and establish a data base for present and future inspections and evaluations.
1.1.2 The on-site inspection information acquired for this tank, as well as historical information was analyzed under InterSpec, LLC’s inspection program, 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.
1.1.3 This report presents an analysis of data collected during an inspection conducted for Tank #1 (Facility 5042), servicing Jet-A, located at the Scott Air National Guard Base in Shiloh, IL.
1.1.4 This inspection was completed on January 21, 2016.
1.1.5 The inspection was performed by a Certified API-653 inspector.
1.1.6 This report summarizes the results of the inspection meeting the requirements of API Standard 653. The inspection was conducted by InterSpec, LLC.
1.1.7 Our policy is: "Providing professional service, with professional people, to obtain professional results."
2.0 REFERENCES
2.1 American Petroleum Institute (API)
2.1.1 API Standard 650, Welded Steel Tanks for Oil Storage
2.1.2 API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction
2.1.3 API RP 652, Lining of Aboveground Petroleum Storage Tank Bottoms
2.1.4 API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks
2.1.5 API RP 575, Inspection of Atmospheric and Low-Pressure Storage Tanks
2.1.6 API RP 577, Welding Inspection and Metallurgy
2.1.7 API RP 2000, Venting Atmospheric and Low Pressure Storage Tanks
2.1.8 API Standard 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems
2.1.9 API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
2.2 American Society of Mechanical Engineers Codes (ASME)
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
2.3 American Society of Nondestructive Testing (ASNT)
2.3.1 ASNT-TC-1A, Personnel Qualification and Certification in Nondestructive Testing
2.4 Code of Federal Regulations (CFR)
United States Department of Labor, Occupational Safety & Heath Administration
2.4.1 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart H, Section 119, Process safety management of highly hazardous chemicals
2.4.2 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart J, Section 147, The control of hazardous energy (lockout/tagout)
2.4.3 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart S, Section 331-335, Safety-Related Work Practices
2.4.4 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1926, Subpart S, Section 1053, Stairways and Ladders
United States Environmental Protection Agency
2.4.5 CFR, Title 40, Volume 21, Chapter I, Subchapter D, Part 112, Oil Pollution Prevention
2.5 National Association of Corrosion Engineers (NACE)
2.5.1 NACE Recommended Practice, RP0184-91, Repair of Lining Systems
2.5.2 NACE Recommended Practice, RP0193-93, External Cathodic Protection of On- Grade Metallic Storage Tank Bottoms
2.5.3 NACE Recommended Practice, RP0288-94, Inspection of Linings on Steel and Concrete
2.6 National Fire Protection Association (NFPA)
2.6.1 NFPA-30, 2012 Ed., Flammable and Combustible Liquids Code
2.6.2 NFPA-70, 2011 Ed., National Electrical Code
2.6.3 NFPA-780, 2008 Ed., Standard for the Installation of Lightning Protection Systems
2.7 Unified Facilities Criteria (UFC)
2.7.1 UFC 3-460-01 Change 1 November 2013, Design: Petroleum Fuel Facilities
2.7.2 UFC 3-460-03 (21 JAN 2003), Operation and Maintenance: Maintenance of Petroleum Systems
2.7.3 UFC 3-190-06, Protective Coatings and Paints
2.8 Unified Facilities Guide Specifications (UFGS)
2.8.1 UFGS 07 92 00, Joint Sealant
2.8.2 UFGS 09 97 13.17, Three Coat Epoxy Interior Coating of Welded Steel Petroleum Fuel Tanks
2.8.3 UFGS 09 97 13.27, Exterior Coating of Steel Structures
2.8.4 UFC 3-190-06, Protective Coatings and Paints
2.9 Department of Defense (DoD) Standard Designs
2.9.1 AW-78-24-27 October 2011, Standard Fuels Systems; Aboveground Vertical Steel Tanks with Floating Pans and Fixed Roofs
3.0 TANK DESCRIPTION
3.1 Job Description
Job Number: 15-0164 Contracted by: Gilbane Federal
3.2 Tank Description
Owner/Operator:
Location:
Tank Identification:
Nominal Diameter:
Nominal Height:
Capacity:
Configuration:
Foundation:
Secondary Containment:
Scott Air National Guard (126th Refueling Wing) Scott
ANG, IL
Tank #1 (5042) 30’ 0” 40’ 0” 206,200 gallons Vertical, Aboveground Concrete Ringwall Concrete Containment with HDPE Liner Underneath
Year Installed: 1999 Tank Age: 17 years Construction Code: API Standard 650, 9th Edition Manufacturer: Fisher Tank Seismic Zone: 2A Lead/Asbestos: See Attachment 2 (Lead, Hex Chromium, and Asbestos
Containing Material Report)
3.3 Service Description
Service: Jet A Specific Gravity: 0.80 Operating Limits: Minimum Metal Temperature: Ambient
Maximum Metal Temperature: 200 ˚F Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product
Safe Fill Height: Unknown (activity did not have information) Maximum Fill Height: 39’ 0” Low-Low Level Alarm: Unknown (activity did not have information) Low Level Alarm: 4’ 2” High Level Alarm: 35’ 6” High Level Control Shutoff: 35’ 0” High-High Level Alarm: 38’ 9”
3.4 Part Description
Cathodic Protection System Type: None
Bottom Material: Carbon Steel Specification: Unknown Design: Cone-Down
Shell Material: Carbon Steel Specification: A-36 Design: Cylindrical
Floating Roof Material: Aluminum Specification: Unknown Design: Flat Pan (Full Contact Honeycomb)
Fixed Roof Material: Carbon Steel Specification: Unknown Design: Self-Support Cone Roof
3.5 Joint Type Description
Bottom Plate-to-Plate: Butt-Welded Bottom-to-Shell: Fillet-Welded Shell Plate-to-Plate: Butt-Welded Floating Roof Plate-to Plate: Threaded Fasteners Fixed Roof Plate-to-Plate: Lap-Welded
3.6 Inspection Description
Inspection Type: API-653 Out-of-Service Inspection Completion Date: January 21, 2016 Inspector(s): Richard Bailey
3.7 NDT Equipment Description
Ultrasonic Thickness and Dry Film Thickness Manufacturer: Krautkramer Model: DMS 2 Calibration Methods Used: Zeroing Procedure, Copper Coating Calibration Procedure, and Two Point Calibration Procedure
Magnetic Flux Leakage Manufacturer: MFE Enterprise Model: MFE 2412 Mark II Calibration Methods Used: Manufacturer Calibration Procedure
4.0 INSPECTION RESULTS
The inspection significant findings (deficiencies) are based on the following definitions:
Urgent (significant findings include: (a) bottom and/or shell thickness below the minimum thickness requirements of API Standard 653; (b) tank leaks or suspected to be leaking to include welds; or, (c) any other identifiable feature that poses an imminent danger to life, limb or property if continued normal service). The tank should not be placed into service for any reason unless emergency operations of the tank are required.
Compliance (significant findings include: (a) API non-conformances; (b) tank service life is less than 10 year inspection intervals; or, (c) Federal, State and/or Local Regulations non-conformances to include NFPA 30, CFR, or OSHA, as a minimum).
The API significant findings are based on the API standards at the time of the original construction, repairs, and/or upgrades. The regulatory regulations are based on current regulations. The tank can be placed back into normal service; however, these significant findings should be scheduled for corrective action as soon as possible.
Upgrade (significant findings include: (a) UFC 3-460-01 requirements; (b) UFC 3- 460-03 requirements; (c) DoD Standards; or, (e) other applicable military standards).
These significant findings are not required to be corrected. The tank can be placed back into normal service until these significant findings are scheduled for corrective action, if warranted.
Prolong (significant findings include any identifiable features to prolong the life of the tank not included in the Upgrade category and/or are of good engineering/ operational practices). These significant findings are not required to be corrected;
however, they will increase the service life of the tank and/or are of good engineering/operational practices.
Rehabilitation (significant findings include identifiable features that were compliant to the API standards at the time of the original construction, repairs, and/or upgrades and do not conform to current standards). These significant findings are not required to be corrected; however, any repairs and upgrades conducted that affect these items may require repair to meet current standards.
The inspection significant findings (deficiencies) requires a corrective action (repair), which are identified as follows:
Level 1 (corrective action requires the tank to be out-of-service).
Level 2 (correction action does NOT require the tank to be out-of-service).
Level 3 (No corrective action suggested).
4.1 Secondary Containment
4.1.1 General Findings: 40 CFR 112.7(c) states that the entire secondary containment system, “including walls and floor, must be capable of containing oil and must be constructed so that any discharge from a primary containment system ... will not escape containment before cleanup occurs.” 40 CFR Sections 112.8(c) (2) and 112.12(c) (2) state that diked areas must be “sufficiently impervious to contain oil.” The purpose of the secondary containment requirement is to prevent discharges as described in 40 CFR 112.1(b); therefore, effective secondary containment methods must be able to contain oil until the oil is cleaned up. The secondary containment area consists of a concrete floor with vertical concrete walls with an HDPE liner underneath. An informal containment evaluation was conducted. Field assessment indicates that the containment is of sufficient size to contain a total tank loss and thus satisfies the requirements of API Standard 653.
The secondary containment area appears to be properly graded to drain water away from the tank in accordance with NFPA 30. The containment drain is in satisfactory condition.
4.1.2 Significant Findings:
1) Prolong: The containment floor has failed expansion joint sealant that has cracked, deteriorated, and lost seal from the concrete, which may prevent containment of product as required by 40 CFR 112. (Quantity: 450 linear feet)
2) Prolong: The interior containment walls have failed expansion joint sealant that has cracked, deteriorated, and lost seal from the concrete, which may prevent containment of product as required by 40 CFR 112. (Quantity: 140 linear feet)
4.2 Foundation
4.2.1 General Findings: The tank rests on top of a concrete ringwall. The tank has secondary containment underneath the bottom with bottom leak detection system. The top of the ringwall was covered by a rain shield and as such, the inspection was limited.
The foundation was evaluated for shell settlement in accordance with API Standard 653 and is in satisfactory condition. The shell settlement calculations are shown in Appendix A.
4.2.2 Significant Findings: No significant findings noted.
4.3 Cathodic Protection
4.3.1 General Findings: No general findings noted.
4.3.2 Significant Findings
1) Upgrade: The tank is not equipped with a cathodic protection system in accordance with UFC 3-460-01 Sections 2-13.1 and 8-8.5, and AW 78-24-27 Drawing D.15. (Quantity: 1)
SCOTT ANG, IL-TANK #1 (FACILITY 5042)-API653 OOS-JAN2016
1256390724E Underline
1256390724E Cross-Out
4.4 Bottom
4.4.1 General Findings: The tank floor consists of 12 plates that are of a lap-welded, cone-down configuration. The bottom was scanned with MFL technology (95%) and no areas of significant underside corrosion were located. Ultrasonic thickness readings were taken on the bottom plates. The bottom has a thin film epoxy coating system. The coating was inspected for disbonding, adhesion, deterioration, and discoloration, which is in satisfactory condition except as noted in the significant findings below. 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. The MFL scan did not reveal any areas of underside corrosion. The bottom has no significant stockside (top side) pitting. The general thickness of each bottom plate was measured using ultrasonic technology. The general thickness measurements and associated thickness measurement locations (TML) are listed in the Bottom Plate Thickness Measurements table in Appendix C. The bottom is equipped with a circular 30-inch sump having a depth of 15 inches located in the center of the floor. The general thickness of the sump was measured using ultrasonic technology, which is in satisfactory condition. The bottom plate butt-welds, shell-to-bottom weld, attachment welds, piping supports, and support pads were visually examined and appear to be in satisfactory condition, except as noted in Significant Findings below. The visual examination of the welds for defects was extremely limited since the welds are coated. The bottom service life evaluation shows that the out of service interval of operation (years to next internal inspection) to be greater than 30 years under current conditions. The bottom service life evaluation is shown in Appendix A.
4.4.2 Significant Findings
1) Upgrade: The floating roof anti-rotation clip is welded to the floor without a lap-welded reinforcement pad in accordance with AW 78-24-27 Drawing D.8 Detail A3. (Quantity: 1)
2) Upgrade: The VAREC mechanical tape level gauge internal float bracket is welded to the floor without a lap-welded reinforcement pad. (Quantity:
1)
3) Prolong: The sump has coating failure. (Quantity: 2 square feet)
4.5 Shell
4.5.1 General Findings: The shell is constructed of A-36 carbon steel material. The shell is a cylindrical design, butt-welded together, consisting of five courses. The shell (interior and exterior) has a thin film epoxy coating system. The coating was inspected for disbonding, adhesion, deterioration, and discoloration, which is in satisfactory condition except as noted in the significant findings below. The shell was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and thickness measurement locations (TML) are listed in the Shell Plate Thickness Measurements table in Appendix C. A shell service life evaluation performed on all shell
SCOTT ANG, IL-TANK #1 (FACILITY 5042)-API653 OOS-JAN2016
1256390724E Underline courses shows that the shell has a remaining life of greater than 30 years under current conditions. 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. The tank is stable and does not appear to be in danger of overturning or buckling due to high winds or seismic conditions.
4.5.2 Significant Findings
1) Upgrade: The spiral stairway treads are welded directly to the shell and do not have reinforcement pads installed in accordance with AW 78-24-27 Drawing D.10 Detail A1. (Quantity: (56) 14-inch x 5-inch pads)
2) Upgrade: The mechanical tape level gauge supports are welded directly to the shell and do not have support pads in accordance with AW 78-24-27 Drawing D.10 Detail A1. (Quantity: (10) 6-inch circular pads)
3) Upgrade: The Uni-Strut supports for the automatic tank shut off control tubing, and electronic gauging conduit are welded directly to the shell. The supports do not have stand offs in accordance with AW 78-24-27 Drawing D.10 Detail A1. (Quantity: (5) sections of Uni-Strut)
4.6 Appurtenances
4.6.1 General Findings: The tank is properly grounded via ground straps in accordance with NFPA 30. The product issue, receipt and low point suction lines have thermal relief valves. The accessible shell nozzles and reinforcements were evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements on the nozzles revealed no significant loss of metal from corrosion or erosion. All nozzles have an estimated minimum remaining life of greater than 30 years.
All nozzles were adequately reinforced. All of the shell nozzle reinforcement plates have tell-tale holes to allow visible indication of weeping due to any possible weld failure. The product level is monitored by a VAREC mechanical tape level gauge and by an electronic BARTON 3500 automatic tank gauge (ATG) system, which are both in satisfactory condition. The tank is equipped with a High Level Alarm (HLA), High Level Control Shutoff (HLCO), High-High Level Alarm (HHLA), Low Level Alarm (LLA), and Low- Low Level Alarm (LLLA) as required by UFC, which are in satisfactory condition.
4.6.2 Significant Findings
1) Upgrade: The 12-inch issue line fully extends to the sump. The issue line does not have a flanged fitting located internally next to the shell, is not one-half of the tank radius, and does not have an anti-vortex plate. The current configuration of the issue line is not in accordance with UFC 3-460-01 Table 8-1 Item (v) and AW 78-24-27 Drawing D.13 Detail A1. (Quantity: 1)
2) Upgrade: The 3-inch low suction line has a ball valve for tank isolation.
UFC 3-460-01 Section 3-6.7.3 requires double block and bleed valves for tank isolation. (Quantity: 1)
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3) Upgrade: The water draw off system consists of 3/4-inch threaded carbon steel piping threaded coupling on shell, and ball valve. The water draw off system does not have 1-inch stainless steel welded and flanged piping, welded shell coupling, and 2-inch double block and bleed valve. The exterior piping has corrosion and coating failure. The current configuration of the water draw off system is not in accordance with AW 78-24-27 Drawing D.13 Detail A1.
(Quantity: 1)
4) Upgrade: The existing water draw-off system includes a carbon steel product saver tank. The product saver tank is not stainless steel, does not have a vent, and is not grounded. The current configuration of the product saver tank is not in accordance with AW 78-24-27 Drawing D.13 Detail A1. (Quantity: 1)
5) Upgrade: The steel thermal relief systems for the issue line, receipt line, and low-point suction line consists of 1-inch threaded carbon steel, threaded coupling on piping, non-locking ball valves, and VISI-FLOW glass sight flow indicators. The thermal relief systems do not have welded and flanged stainless steel piping, welded coupling on piping, lockable ball valves, and test TEE’s. No glass sight flow indicators are allowed in accordance with UFC 3-460-01 Section 9-3.5.1. The current configuration of the thermal relief system of the issue line and receipt line are not in accordance with AW 78-24-27 D.10 Detail A3.
(Quantity: 3 systems)
6) Upgrade: The tank has two 36-inch diameter manways with filler drums on the bottom shell course. Both manways do not have davit arms to aid in the safe removal of the covers in accordance with AW 78-24-27 Drawing D10 Detail C4. (Quantity: 2)
7) Upgrade: The tank does not have a 36-inch shell manway located above the internal floating pan’s high position to aid in venting the tank during cleaning and to provide access to the floating pan’s elastomeric wiper seals in accordance with UFC 3-460-01 Table 8-1 Item (c) and AW 78-24-27 Drawing D.10 Detail A4. (Quantity: 2)
8) Upgrade: The tank is not equipped with an ENRAF ATG system in accordance with AW 78-24-27 Drawing D.07 Detail A1 and ATG policy per the letter issued by Defense Logistics Agency. (Quantity: 1) (Quantity: 1)
9) Upgrade: The tank is not equipped with an ATG water probe stilling well (VITO system) in accordance with AW 78-24-27 Drawing D.07 Detail C4 and ATG policy per the letter issued by Defense Logistics Agency. (Quantity: 1)
10) Upgrade: The existing 6-inch aluminum stilling wells for sample gauge well and ATG gauging well are not slotted and not 8-inch diameter in accordance with AW 78-24-27 Drawing D.7 Details A1 and C3. (Quantity: 2)
11) Upgrade: The low level alarm assembly consists of carbon steel threaded shell couplings, threaded carbon steel piping, and non-locking ball valves. The
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12) Upgrade: The high-high level alarm assembly, high level alarm assembly, and high level shut-off assembly each consists of carbon steel threaded shell couplings, 1-inch threaded carbon steel piping, and locking ball valves. The assemblies are not stainless steel with flanged connections. The assemblies are accessible from the stairway for routine testing. The assemblies do not have 1-inch piping extending to the product saver tank to allow routine testing. The assemblies have corrosion and coating failure on the piping and assemblies. The current configuration of the high level alarm assembly is not in accordance with AW 78-24-27 Drawing D.12 Detail C3 and Drawing D.13 Detail A1. (Quantity:
3 systems)
13) Upgrade: The issue line, receipt line, and low suction line pipe supports consists of square stock carbon steel with TEFLON between the pipe and support.
The piping is secured to the supports by u-clamps and has metal to metal contact.
The pipe supports do not conform to UFC 3-460-01 Section 9-3.2 and Plate 020.
(Quantity: (10) 3-inch supports (3) 6iinch supports and (3) 12-inch supports).
14) Prolong: The double block and bleed valves for the receipt line and issue line have areas of coating failure and corrosion. (Quantity: 2 valves)
4.7 Accessways
4.7.1 General Findings: The fixed roof is accessible via a spiral stairway. A grated platform is located at the roof. The floating roof is accessible by a vertical ladder.
4.7.2 Significant Findings: No significant findings noted.
4.8 Floating Roof
4.8.1 General Findings: The tank is equipped with a PETREX internal floating roof.
The floating roof is of aluminum honeycomb construction. The roof opening gaskets were inspected for tears and deterioration. The annular space between the floating roof and the shell was satisfactory. The floating roof had foam log seals, which was replaced with a double wiper seal during this inspection. The new double wiper seal installation was inspected and is in satisfactory condition. The floating roof seal to shell gap is satisfactory on the new double wiper seal.
4.8.2 Significant Findings: No significant findings noted.
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4.9 Fixed Roof
4.9.1 General Findings: The fixed roof is a self-supported cone roof constructed of carbon steel material. The fixed roof has an epoxy coating system on the interior and exterior. The coating was inspected for disbonding, adhesion, deterioration, and discoloration. The fixed roof was evaluated for remaining metal thickness using ultrasonic technology. The ultrasonic thickness measurements and ultrasonic thickness locations (TML) are listed in the Fixed Roof Plate Thickness Measurements table in Appendix C.
4.9.2 Significant Findings
1) Prolong: The exterior coating on the fixed roof has completely failed, and has exceeded useful life. Recommended Repair (Prolong-Level 2): Repair the coating failure on the (Quantity: 710 square feet)
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5.0 RECOMMENDATIONS FOR COMPLIANCE WITH API
STANDARDS
The inspection revealed findings that should be corrected within the near future. The corrective action (repairs) are categorized based on the scope of work, Mandatory Repairs Group 1 (required repairs to return the facility to service); Mandatory Repairs Group 2 (repairs that can be performed while the facility is in service); Recommended Repairs (repairs recommended but not required to return the facility to service); and Future Recommended Repairs (repairs that can be performed at the next inspection).
5.1 Secondary Containment: No recommendations at this time.
5.2 Foundation: No recommendations at this time.
5.3 Cathodic Protection: No recommendations at this time.
5.4 Bottom: No recommendations at this time.
5.5 Shell: No recommendations at this time.
5.6 Appurtenances: No recommendations at this time.
5.7 Accessways: No recommendations at this time.
5.8 Floating Roof: No recommendations at this time.
5.9 Fixed Roof: No recommendations at this time.
6.0 OTHER RECOMMENDATIONS
6.1 Secondary Containment
6.1.1 Mandatory Repair Group 2 (Compliance-Level 2): Remove damaged joint sealant and shall install new backer rods and sealant within the containment area. The sealant shall be adequate to accommodate joint compression equal to 50 percent of the width of the joint. The backer rod shall be compressible rod stock of polyethylene foam, polyurethane foam, butyl rubber foam, or other flexible, non-absorptive material as recommended by the sealant manufacturer. Sealant shall conform to UFGS 07 92 00 Joint Sealant. (Quantity: 450 linear feet)
6.1.2 Mandatory Repair Group 2 (Compliance-Level 2): Remove damaged joint sealant and shall install new backer rods and sealant within the containment area. The sealant shall be adequate to accommodate joint compression equal to 50 percent of the width of the joint. The backer rod shall be compressible rod stock of polyethylene foam, polyurethane foam, butyl rubber foam, or other flexible, non-absorptive material as recommended by the sealant manufacturer. Sealant shall conform to UFGS 07 92 00 Joint Sealant. (Quantity: 140 linear feet)
6.2 Foundation: No recommendations at this time.
6.3 Cathodic Protection
6.3.1 Future Recommended Repair (Upgrade-Level 1): Install a cathodic protection system in accordance with UFC 3-460-01 Sections 2-13.1 and 8-8.5, and AW 78-24-27 Drawing D.15. Note: A NACE Certified Corrosion Expert should design the cathodic protection system per UFC 3-460-01. (Quantity: 1)
6.4 Bottom
6.4.1 Recommended Repair (Upgrade-Level 1): Provide a lap-welded reinforcement pad under the floating roof anti-rotation attachment clip in accordance with AW 78-24-27 Drawing D.8 Detail A3. (Quantity: 1)
6.4.2 Recommended Repair (Upgrade-Level 1): Install an 18-inch by 4-inch rectangular lap-welded reinforcement pad with rounded corners (minimum 2 inch radius) under the float bracket in accordance with API Standard 653. (Quantity: 1)
6.4.3 Recommended Repair (Prolong-Level 1): Repair the coating failure in the sump in accordance with UFGS 09 97 13.17, Three Coat Epoxy Interior Coating of Welded Steel Petroleum Fuel Tanks. Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP- 10/NACE No. 2, at areas receiving interior coatings. The epoxy primer coat shall be formula 150, Type IV, Green (3- 5 mils DFT). The Epoxy intermediate coat shall be formula 152, Type IV, White (3 – 5 mils DFT). The top coat shall be formula 152, Type IV, White (3 – 5 mils DFT). (Quantity: 2 square feet)
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6.5 Shell
6.5.1 Future Recommended Repair (Upgrade-Level 1): Install reinforcement pads for the spiral stairway treads in accordance with AW 78-24-27 Drawing D.10 Detail A1.
NOTE: Reinforcement pad to extend a minimum of 2 inches beyond stair tread and weld spacing to meet API Standard 650 Section 5.7.3. (Quantity: (56) 14-inch x 5-inch pads)
6.5.2 Future Recommended Repair (Upgrade-Level 1): Install reinforcement pads for the mechanical tape level gauge supports in accordance with AW 78-24-27 Drawing D.10 Detail A1. NOTE: Reinforcement pad to extend a minimum of 2 inches beyond supports and weld spacing to meet API Standard 650 Section 5.7.3. (Quantity: (10) 6-inch circular pads)
6.5.3 Future Recommended Repair (Level 1): Install stand offs for the uni-strut supports for the automatic tank shut off control tubing, and electronic gauging conduit in accordance with AW 78-24-27 Drawing D.10 Detail A1. (Quantity: (5) sections of Uni- Strut)
6.6 Appurtenances
6.6.1 Recommended Repair (Upgrade-Level 1): Remove the existing 12-inch issue line inside the tank, install new pipe supports, and modify the piping to be one-half of the tank radius in accordance with AW 78-24-27 Drawing D.08 Detail A1. (Quantity: 1)
6.6.2 Recommended Repair (Level 1): Replace the 3-inch issue line ball valve with a double block and bleed valve as required by UFC 3-460-01 Section 3-6.7.3. (Quantity:
1)
6.6.3 Recommended Repair (Upgrade-Level 1): Reconfigure the water draw off system in accordance with AW 78-24-27 Drawing D.12 Details D.13 Detail A1.
(Quantity: 1)
6.6.4 Recommended Repair (Upgrade-Level 1): Replace the existing product saver tank with a 55 gallon stainless steel tank, add venting, and install grounding in accordance with AW 78-24-27 Drawing D.13 Detail A1. (Quantity: 1)
6.6.5 Recommended Repair (Upgrade-Level 1): Reconfigure the thermal relief system for the issue line, receipt line, and low-point suction line in accordance with AW 78-24-27 D.10 Detail A3. Remove the glass sight flow indicator in accordance with UFC 3-460-01 Section 9-3.5.1. (Quantity: 3 systems)
6.6.6 Recommended Repair (Upgrade-Level 1): Install davits for the existing manways in accordance with AW 78-24-27 Drawing D10 Detail C4. (Quantity: 2)
6.6.7 Recommended Repair (Upgrade-Level 1): Install a 36-inch manway 3’-6” above upper surface of floating pan at high leg position in accordance with AW 78-24-27 Drawing D.10 Detail A4. Note: The spiral stairway will need modification with an
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6.6.8 Recommended Repair (Upgrade-Level 1): Install an automatic tank gauge ENRAF system with stilling well in accordance with AW 78-24-27 Drawing D.07 Detail A1 to meet the ATG policy letter issued by the Defense Logistics Agency. Note: Install 8-inch aluminum slotted stilling well (ENRAF ATG). The 8-inch slotted stilling well shall be located at a point on the tank that is either at or below the existing datum plate. The Contractor shall core in the receipt valve box (if required). The Contractor shall install a nozzle, 2-inch riser, and 16 by 16-inch striker plate. (Quantity: 1)
6.6.9 Recommended Repair (Upgrade-Level 1): Install an automatic tank gauge water probe (VITO system) and stilling well as close to the tank center as possible in accordance with AW 78-24-27 Drawing D.07 Detail C4 to meet the ATG policy letter issued by the Defense Logistics Agency. (Quantity: 1)
6.6.10 Recommended Repair (Upgrade-Level 1): Remove existing 6-inch and install new 8-inch stilling wells in accordance with AW 78-24-27 Drawing D.7 Details A1 and C3. (Quantity: 2)
6.6.11 Recommended Repair (Upgrade-Level 1): Relocate the low level alarm assembly to the appropriate height in accordance with UFC 3-460-01 Table 8-1 Item (l) and Plate 014, and AW 78-24-27 Drawing D12 Detail A3, and reconfigure the low level alarm assembly accordance with AW 78-24-27 Drawing D.12 Detail C1. (Quantity: 1 system)
6.6.12 Recommended Repair (Upgrade-Level 1): Relocate and reconfigure the high level alarm assembly and high level shut-off assembly with a 1-inch line to the product saver tank in accordance with AW 78-24-27 Drawing D.12 Detail C3. Notes: This may require widening the stairway at this location to allow adequate clearance of 22 inches in accordance with OSHA requirements. It is suggested to modify the high level shut-off assembly tubing to allow product flow into the bottom of the assemblies through a locking ball valve. (Quantity: 3 systems)
6.6.13 Recommended Repair (Upgrade-Level 2): Replace the pipe supports inside the secondary containment in accordance with UFC 3-460-01 Section 9-3.2 and Plate 020.
At a minimum, install TEFLON material between the pipe and u-clamps. (Quantity:
(10) 3-inch supports (3) 6iinch supports and (3) 12-inch supports).
6.6.14 Recommended Repair (Prolong-Level 2): Repair the coating failure on the double block and bleed valves for the receipt line and issue line in accordance with UFGS 09 97 13.27, Exterior Coating of Steel Structures. Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP 10/NACE No. 2, as recommended by manufacturer. The epoxy-polyamide primer coat shall be formula 159, Type IV, Green (3-5 Mils DFT). The Epoxy intermediate coat shall be formula 152, Type IV, White (3-5 Mils DFT). The topcoat formula shall be formula 152, Type IV, White (3-5 Mils DFT).
(Quantity: 2 valves)
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6.7 Accessways: No recommendations at this time.
6.8 Floating Roof: No recommendations at this time.
6.9 Fixed Roof
6.9.1 Recommended Repair (Prolong-Level 2): Repair the coating failure on the exterior of the fixed roof in accordance with UFGS 09 97 13.27, Exterior Coating of Steel Structures. Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP 10/NACE No. 2, as recommended by manufacturer. The epoxy-polyamide primer coat shall be formula 159, Type IV, Green (3-5 Mils DFT). The Epoxy intermediate coat shall be formula 152, Type IV, White (3-5 Mils DFT). The topcoat formula shall be formula 152, Type IV, White (3-5 Mils DFT). (Quantity: 710 square feet)
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7.0 SERVICEABILITY
7.1 Tank repair requirements per API Standard 653:
7.1.1 All repair work must be authorized by a Certified Inspector or an Engineer experienced in storage tank design, before commencement of the work by a repair organization. A Certified Inspector must designate inspection hold points required during the repair or alteration sequence and minimum documentation to be submitted upon job completion. The Certified Inspector may give prior general authorization for limited or routine repairs as long as a Certified Inspector is sure that the repairs will not require hydrostatic testing or do not require an engineering evaluation.
7.1.2 All proposed design, work execution, materials, welding procedures, examination, and testing methods must be approved by a Certified Inspector or by an Engineer experienced in storage tank design. A Certified Inspector or an Engineer experienced in storage tank design shall approve all specified repair and alteration work at the designated hold points and after repairs and alterations have been completed in accordance with the requirements of API Standard 653.
7.2 Recommendations to bring the tank into compliance with API Standard 653, along with additional recommendations, to bring the tank and other components into compliance with other Codes and Standards, have been identified in this report.
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