McGuire-Fac 1842 (Tank 1)-FINAL-2017.pdf

McGuire‐Dix Tank 1

US Army Corps of Engineers Center of Expertise for Petroleum, Oils and Lubricants

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

GENERAL SUMMARY

INSPECTION DATE

STATE REGULATIONS

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

GENERAL TANK INFORMATION

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

C. FINDINGS AND RECOMMENDATIONS

1. MANDATORY REPAIRS per API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards

2. RECOMMENDED REPAIRS to Fully Comply with API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards

3. RECOMMENDED REPAIRS as Part of Regular Maintenance

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

SHELL SETTLEMENT SURVEY

SHELL THICKNESS CALCULATION

SHELL UT MEASUREMENTS

ROOF THICKNESS CALCULATION

ROOF UT MEASUREMENTS

SHELL NOZZLE THICKNESS CALCULATION

SHELL NOZZLE UT MEASUREMENTS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

CRITICAL ZONE SHELL THICKNESS

SHELL LAYOUT DRAWING

ROOF LAYOUT DRAWING

NEXT INSPECTION

OSHA ACCESS STRUCTURE REPORT

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS

OUT OF PLUMBNESS (VERTICALLY)

ISOLATED SHELL DISTORTION

OUT‐OF‐ROUNDNESS

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX E: PHOTOGRAPHS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

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

HLCS High Level Control Shutoff

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

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

GENERAL SUMMARY

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Inspectors:

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

GENERAL TANK INFORMATION

Construction

Bottom lap welded cone down

Shell Butt welded steel plates

Floating Roof IFR Aluminum

Fixed Roof Lap welded

Material

Bottom Unknown Carbon steel

Shell A‐36 Carbon Steel

Floating Roof IFR Aluminum

Interior Coating System Epoxy

Exterior Coating System Epoxy

Low Suction 4” Stainless Steel

Water Draw‐Off 3/4” Stainless Steel

Level Alarms High Level Alarm (HLA) / High‐High Level Alarm (HHLA)/Low Level Alarm(LLA)

Type of Internal Floating Roof

Aluminum Honeycomb IFR

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

A. GENERAL PROJECT INFORMATION

B. TANK INSPECTION COMMENTS

N/A

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

b. Gauging

C. FINDINGS AND RECOMMENDATIONS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

No mandatory repairs are required for continued service.

2. RECOMMENDED REPAIRS to Fully Comply with API 653, UFC 3‐460‐01, or AW 78‐24‐27 Standards

VALVE

VALVE

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

APPENDIX A: ENGINEERING CALCULATIONS AND DRAWINGS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL SETTLEMENT SURVEY

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL THICKNESS CALCULATION

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL UT MEASUREMENTS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

ROOF THICKNESS CALCULATION

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

ROOF UT MEASUREMENTS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL NOZZLE THICKNESS CALCULATION

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL NOZZLE UT MEASUREMENTS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

CRITICAL ZONE SHELL THICKNESS

See course 1 thickness readings for critical zone.

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

SHELL LAYOUT DRAWING

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

ROOF LAYOUT DRAWING

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

NEXT INSPECTION

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

OSHA ACCESS STRUCTURE REPORT

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

APPENDIX B: 3‐D DOCUMENTATION AND ANALYSIS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

OUT OF PLUMBNESS (VERTICALLY)

The tank was checked by using laser measurements taken from fixed locations at 8 points around tank from chime weld to the roof weld. The Tank’s plumbness is in satisfactory condition at this time.

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

ISOLATED SHELL DISTORTION

There was no significant shell distortion noted at this time.

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

OUT‐OF‐ROUNDNESS

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

APPENDIX D: API 653 CHECKLISTS FOR TANK INSPECTIONS

Tank In‐Service Inspection Checklist

Item Completed

X

C.1.1 Foundation

Measure foundation levelness and bottom elevations (see Annex B for extent of measurements). X

C.1.1.1 Concrete Ring a Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in welding butt‐ welded annular rings under the shell.

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

X c Inspect for cavities under foundation and vegetation against bottom of tank. X d Check that runoff rainwater from the shell drains away from tank. X e Check for settlement around perimeter of tank. X

C.1.1.2 Asphalt a Check for settling of tank into asphalt base which would direct runoff rain water under the tank instead of away from it.

N/A b Look for areas where leaching of oil has left rock filler exposed, which indicates hydrocarbon leakage. N/A

C.1.1.3 Oiled Dirt or Sand

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

N/A

C.1.1.4 Rock

Presence of crushed rock under the steel bottom usually results in severe underside corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer testing, or turning of coupons) when the tank is out of service.

N/A

C.1.1.5 Site Drainage a Check site for drainage away from the tank and associated piping and manifolds. X b Check operating condition of the dike drains. X

C.1.1.6 Housekeeping

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

C.1.1.7 Cathodic Protection

Review cathodic protection potential readings. N/A

C.1.2 Shells

C.1.2.1 External Visual Inspection a Visually inspect for paint failures, pitting, and corrosion. X b Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld. X c Inspect the bottom‐to‐foundation seal, if any. X

C.1.2.2 Internal (Floating Roof Tank)

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

C.1.2.3 Riveted Shell Inspection a Inspect external surface for rivet and seam leaks. N/A b Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). N/A c Inspect rivets for corrosion loss and wear. N/A

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Tank In‐Service Inspection Checklist Continued

Item Completed

X d Inspect vertical seams to see if they have been full fillet lap‐welded to increase joint efficiency. N/A e If no record exists of vertical riveted seams, dimension and sketch (or photograph) the rivet pattern: number of rows, rivet size, pitch length, and note whether the joint is butt‐riveted or lap‐ riveted.

N/A

C.1.2.4 Wind Girder (Floating Roof Tanks) a Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion product buildup), especially where it occurs at tack‐welded junction, and for broken welds.

N/A b Check support welds to shell for pitting, especially on shell plates. N/A c Note whether supports have reinforcing pads welded to shell. N/A

C.1.3 Shell Appurtenances

C.1.3.1 Manways and Nozzles a Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing plates. X b Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. X c Inspect for flange leaks and leaks around bolting. X d Inspect sealing of insulation around manways and nozzles. X e Check for inadequate manway flange and cover thickness on mixer manways. X

C.1.3.2 Tank Piping Manifolds a Inspect manifold piping, flanges, and valves for leaks. X b Inspect fire fighting system components. X c Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

X d Check for adequate thermal pressure relief of piping to the tank. X e Check operation of regulators for tanks with purge gas systems. X f Check sample connections for leaks and for proper valve operation. X g Check for damage and test the accuracy of temperature indicators. X h Check welds on shell‐mounted davit clips above valves 6 in. and larger. X

C.1.3.3 Autogauge System a Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. X b Inspect autogauge head for damage. X c Bump the checker on autogauge head for proper movement of tape. X d Identify size and construction material of autogauge tape guide (floating roof tanks). X e Ask operator if tape tends to hang up during tank roof movement (floating roof tanks). X f Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). X g On floating roof tanks, when the roof is in the lowest position, check that no more than two ft of tape are exposed at the end of the tape guide.

X h Inspect condition of board and legibility of board‐type autogauges. X i Test freedom of movement of marker and float. X

C.1.3.4 Shell‐Mounted Sample Station a Inspect sample lines for function of valves and plugging of lines, including drain or return‐to‐tank line.

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

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Completed

X c Test bracing and supports for sample lines and equipment. N/A

C.1.3.5 Heater (Shell Manway Mounted)

Inspect condensate drain for presence of oil indicating leakage. N/A

C.1.3.6 Mixer a Inspect for proper mounting flange and support. N/A b Inspect for leakage. N/A c Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation a Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness to confirm that swing line lowered properly.

N/A b Floating. With tank half full or more, lower the swing line, then let out cable and check if swing has pulled cable tight, indicating that the winch is operating properly.

N/A c Indicator. Check that the indicator moves in the proper direction: Floating swing line indicators show a lower level as cable is wound up on the winch. Non‐floating swing line indicators show the opposite.

N/A

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints. N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity. N/A

C.1.3.10 Swing Lines: Cable Material and Condition a For nonstainless steel cable, check for corrosion over entire length. N/A b All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison

Check for water or gravity differences that would indicate a leaking swing joint. N/A

C.1.3.12 Swing Lines: Target

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

N/A

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. (Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

X

C.1.4.2 Deck Plate External Corrosion

Visually inspect for paint failure, holes, pitting, and corrosion product on the roof deck. X

C.1.4.3 Roof Deck Drainage

Look for indication of standing water. (Significant sagging of fixed roof deck indicates potential rafter failure. Large standing water areas on a floating roof indicate inadequate drainage design or, if to one side, a nonlevel roof with possible leaking pontoons.)

X

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Completed

C.1.4.4 Level of Floating Roof

At several locations, measure distance from roof rim to a horizontal weld seam above the roof. A variance in the readings indicates a nonlevel roof with possible shell out‐of‐round, out‐of‐plumb, leaking pontoons, or hang‐up. On small diameter tanks, an unlevel condition can indicate unequal loading at that level.

C.1.4.5 Gas Test Internal Floating Roof

Test for explosive gas on top of the internal floating roof. Readings could indicate a leaking roof, leaking seal system, or inadequate ventilation of the area above the internal floating roof.

N/A

C.1.4.6 Roof Insulation a Visually inspect for cracks or leaks in the insulation weather coat where runoff rain water could penetrate the insulation.

N/A b Inspect for wet insulation under the weather coat. N/A c Remove small test sections of insulation and check roof deck for corrosion and holes near the edge of the insulated area.

N/A

C.1.4.7 Floating Roof Seal Systems a Inspect the condition of the seal, measure and record maximum rim spaces and sealto‐ shell gaps around the full roof circumference at the level of inspection.

NOTE Inspection of the seal and measurement of the rim spaces and seal‐to‐shell gaps at more than one level may be necessary to more fully determine if any problems exist at other levels of tank operation).

N/A b Measure and record annular space at 30‐ft spacing (minimum of four quadrants) around roof and record. Measurements should be taken in directly opposite pairs.

N/A

1) _______ _______ Opposite pair 1. N/A

2) _______ _______ Opposite pair 2. N/A c Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough). N/A d Inspect fabric for deterioration, holes, tears, and cracks. N/A e Inspect visible metallic parts for corrosion and wear. N/A f Inspect for openings in seals that would permit vapor emissions. N/A g Inspect for protruding bolt or rivet heads against the shell. N/A h Pull both primary and secondary seal systems back all around the shell to check their operation. N/A i Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

N/A j Inspect wedge‐type wiper seals for flexibility, resilience, cracks, and tears. N/A

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch a Inspect condition and functioning of sample hatch cover. X b On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

X c Check for corrosion and plugging on thief and gauge hatch cover. X d Where sample hatch is used to reel gauge stock level, check for marker and tab stating hold‐off distance.

e Check for reinforcing pad where sample hatch pipe penetrates the roof deck. X

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Completed

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

X g Test operation of system. X h On ultra clean stocks such as JP4, check for presence and condition of protective coating or liner inside sample hatch (preventing rust from pipe getting into sample).

X

C.1.5.2 Gauge Well a Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. N/A b Check for a hold‐off distance marker and tab with hold‐off distance (legible). N/A c On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

N/A d If accessible, check the distance from the gauge well pipe to the tank shell at different levels. N/A e If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

N/A

C.1.5.3 Fixed Roof Scaffold Support

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

C.1.5.4 Autogauge: Inspection Hatch and Guides (Fixed Roof) a Check the hatch for corrosion and missing bolts. X b Look for corrosion on the tape guide’s and float guide’s wire anchors. X

C.1.5.5 Autogauge: Float Well Cover a Inspect for corrosion. X b Check tape cable for wear or fraying caused by rubbing on the cover. X

C.1.5.6 Sample Hatch (Internal Floating Roof) a Check overall conditions. N/A b When equipped with a fabric seal, check for automatic sealing after sampling. N/A c When equipped with a recoil reel opening device, check for proper operations. N/A

C.1.5.7 Roof‐mounted Vents (Internal Floating Roof)

Check condition of screens, locking and pivot pins. X

C.1.5.8 Gauging Platform Drip Ring

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

C.1.5.9 Emergency Roof Drains

Inspect vapor plugs for emergency drain: that seal fabric discs are slightly smaller than the pipe ID and that fabric seal is above the liquid level.

N/A

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

Report size, number, and type of vacuum breakers. Inspect vacuum breakers. If high legs are set, check for setting of mechanical breaker in high leg position.

N/A

C.1.5.12 Rim Vents a Check condition of the screen on the rim vent cover. X

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Completed

X b Check for plating off or removal of rim vents where jurisdictional rules do not permit removal. X

C.1.5.13 Pontoon Inspection Hatches a Open pontoon inspection hatch covers and visually check inside for pontoon leakage. N/A b Test for explosive gas (an indicator of vapor space leaks). N/A c If pontoon hatches are equipped with locked down coves, check for vent tubes. Check that vent tubes are not plugged up. Inspect lock‐down devices for condition and operation.

C.1.6.1 Accessways

See Tank Out‐of‐service Inspection Checklist, Item C.2.12. X

Tank Out‐of‐Service Inspection Checklist Continued

Completed

X

C.2.12 Access Structures

C.2.12.1 Handrails a Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of handrails. X b Inspect for pitting and holes, paint failure. X c Inspect attachment welds. X d Identify cold joints and sharp edges. Inspect the handrails and midrails. X e Inspect safety drop bar (or safety chain) for corrosion, functioning, and length. X f Inspect the handrail between the rolling ladder and the gauging platform for a hazardous opening when the floating roof is at its lowest level.

X

C.2.12.2 Platform Frame a Inspect frame for corrosion and paint failure. X b Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure. X c Check reinforcing pads where supports are attached to shell or roof. X d Inspect the surface that deck plate or grating rests on, for thinning and holes. X e Check that flat‐surface‐to‐flat‐surface junctures are seal‐welded. X

C.2.12.3 Deck Plate and Grating a Inspect deck plate for corrosion‐caused thinning or holes (not drain holes) and paint failure. X b Inspect plate‐to‐frame weld for rust scale buildup. X c Inspect grating for corrosion‐caused thinning of bars and failure of welds. X d Check grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating surface and compare with other risers on the stairway.

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

Tank Out‐of‐Service Inspection Checklist Continued

Completed

X

C.2.12.4 Stairway Stringers a Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. Inspect attachment of stairway treads to stringer.

X b Inspect stairway supports to shell welds and reinforcing pads. X c Inspect steel support attachment to concrete base for corrosion. X

C.2.12.5 Rolling Ladder a Inspect rolling ladder stringers for corrosion. N/A b Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment to stringers and corrosion, particularly where angle rungs are welded to stringers.

N/A c Check for wear and corrosion where rolling ladder attaches to gaging platform. N/A d Inspect pivot bar for wear and secureness. N/A e Inspect operation of self‐leveling stairway treads. N/A f Inspect for corrosion and wear on moving parts. N/A g Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle. N/A h Inspect alignment of rolling ladder with roof rack. N/A i Inspect top surface of rolling ladder track for wear by wheels to assure at least 18 in. of unworn track (track long enough).

N/A j Inspect rolling ladder track welds for corrosion. N/A k Inspect track supports on roof for reinforcing pads seal‐welded to deck plate. N/A l Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs. N/A

Max. angle ____________ .

m If rolling ladder track extends to within 5 ft of the edge of the roof on the far side, check for a handrail on the top of the shell on that side.

NOTES:

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

APPENDIX E: PHOTOGRAPHS

E.1: Second 36 Inch Manway E.2: Issue Line

E.3: Tank High‐level Alarms and HLCV Float E.4: Receipt Line

E.5: Low Level Alarm E.6: Tank Tape Gauge

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

E.7: Product Recovery Tank E.8: Tank Pump‐out Line

E.9: Tank Leak detection vault E.10: Primary Manway

E.11: Seal Inspection Hatch/Vent E.12: Roof Manway

API 653 In‐Service Inspection Report McGuire‐Dix, New Jersey

E.13: Enraf System E.14: Tank Center Vent

E.15: Tank Overflow/Vent E.16: Tank Foam Box