Fort Wayne-Fac 481 (Tank 481)-DRAFT-2015.pdf

DATE: November 13, 2015

TO: Mr. Jason Harre USACE, Omaha District Attn: CENWO-CD-RR 1616 Capitol Avenue Omaha, Nebraska 68192-4901 RE: Preliminary Findings and Recommendations Indiana ANG, Fort Wayne, Indiana, Tank 481 Contract W9128F-10-D-0075, Task Order 008, Tank Group #20

On September 23, 2015 an API Standard 653 out-of-service inspection was performed on Tank #481 located at the Indiana ANG facility in Fort Wayne, Indiana. The purpose of the inspection was to gather data necessary to determine serviceability of the tank and compliance with applicable codes and standards.

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

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

Regards, Jerry Dupre Jr API 653 Inspector (3062)

Attachments:

Tank Data Preliminary Findings / Recommendations Report – Tank #481, Indiana ANG, Fort Wayne, IN

Cc: Project Team; Project File

500 Pinnacle Court, Suite 100 ▲ Norcross, GA 30071

(770) 908-7200

Tank Location Indiana ANG / Fort Wayne, Indiana Tank No. (plus previous identified) Tank #481 Facility Number 481 Inspection Dates (s) 23-Sep-15 Tank Type Above Ground Storage Tank (AST) Type of Inspection Out-of-Service, IAW API Standard 653 Contract Number, Task Order W9128F-10-D-0075, Task Order 008 Prime Contractor Name Cape Environmental Management, Inc.

Inspector, Cert. #, Inspection Company Jerry J. Dupre Jr, Certification ID: 3062, CAPE Manufacturer, Date, Design Standard ChicagoBridge & Iron / 1978 / API 650 6th Edition Diameter 25'-0" Shell Height/Safe Fill Height 31'-10" / 29'-10" Product/Specific Gravity Jet-A / 0.85 Design Pressure/Temperature Atmosphere / Product Head / Ambient Gross Capacity/Nominal Capacity 109,654 Gallons GPS Latitude & Longitude Latitude: N 40 59'-6.86" / Longitude: W 85 40'-41.16" Foundation Configuration Concrete Ringwall Shell Configuration Butt-welded Floor Configuration Flat / Lap welded Roof (Fixed, Floating or Both, Seal Type) Cone-up, lap welded / Aluminum Honeycomb Panel / Wiper Seals

Cathodic Protection Yes Stilling Wells (Size, Application) None Last Inspection (Type, Date) OOS January 2004 Last Coated Internally (Product) 2004 (Milspec) Last Coated Externally (Product) 2004 (Milspec)

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

Tank Inspection Summary Sheet

Upgrades / Repairs Made at this Time

Preliminary Findings / Recommendations Report Tank #481 , Indiana ANGB( Fort Wayne), Indiana

1.0 Background and Overview

Tank #481 is an 85,000 Gallon Above Ground Storage Tank that currently stores Jet-A fuel. The tank is 1 of 2 currently used in bulk storage capacity.

The tank was originally constructed in 1978 to API 650 6th Edition design standard with a nominal diameter of 25’-0” feet and a nominal shell height of 24’-0” per original construction. The tank was modified in 2004 to increase the shell height to 31’-10”. The tank bottom configuration is a 0.250” nominal thickness with a lap welded floor plates that are flat and does not slope to the center of the tank. The fixed roof consists of a center column CS lap welded cone up design. The fixed roof rafters are welded to shell. The tank currently has a Petrex aluminum honeycomb panel floating roof with cast rubber wiper seals. The tank currently has an impressed current with anode bed cathodic protection system. The tank rests on a concrete ring-wall and does have a under tank secondary containment. The containment area is constructed of concrete slabs with caulked joints.

API mandatory repairs were discovered during the inspection. The primary and secondary cast rubber wiper seals had very significant deterioration and areas with the wiper torn or missing. The tank will be removed from service to complete the repairs and upgrades required in early spring 2016.

Note: the Fort Wayne ANG placed the tank back in service due to mission requirements see attached letter from the installation. Consideration should be given to the other findings and recommended repairs listed below. The next scheduled out-of-service internal inspection is due within 10 years. The next external ultrasonic inspection is due within 5 years. The next external visual inspection is due within 5 years. The findings listed below are based upon observations while on site and historical information obtained from the Owner/Operator in the form of previous inspection reports.

2.0 Findings and Recommendations

On September 23, 2015 an out-of-service API 653 inspection with MFL floor-scan was completed on Tank #481 at the Indiana ANGB, Bulk storage facility in Indiana by Cape Environmental Management Inc, Certified API 653 Inspector Jerry Dupre Jr (Certification ID: 3062). The purpose of the inspection was to gather data necessary to determine the serviceability of the tank and compliance with applicable codes and standards. The findings and recommendations are based on field observations, historical drawings and previous inspections.

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

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

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

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

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

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

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

Table 1- Mandatory Recommendations

Item # Finding Recommendation

1.1

Internal Floating Roof (IFR) Mandatory Findings:

The internal floating roof (IFR) primary and secondary rubber wiper seals have significant deterioration. They have areas that are torn and missing sections of the seal. The tank will be removed from service in the near future to perform repairs and upgrades. Due to the base mission requirements the tank was placed back in service.

See attached letter from the installation.

1) Ref: API Standard 650, Section H.4.4 and UFC 3-460-01, Section 2-14.4.2.

Install a new double wiper peripheral seal on the IFR per UFGS 33.56.13.13.

Para.2.13.2.7 guidelines.

Note: The new double wiper seal is part of the current SOW.

g6cdxjmh Sticky Note SP-C - Concur - IN SOW

POL-TCX: Concur.

ITEM 1.1- Primary and Secondary Wiper Seal Missing

ITEM 1.1- Secondary Wiper Seal

Table 2- Near Term Recommendations

2.1

Bottom Near Term Findings:

The current configuration of the internal issue piping is as follows:

1) The piping extends approximately 18” from the shell

2) Has no internal piping supports

3) Has no internal flange at the shell

4) Has no anti-vortex plate

5) Has a 90 degree butt-welded elbow that is directed at the tank bottom.

Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail A4. D.08, Detail C1.

Note: the tank bottom configuration currently has no center sump.

Install a new flange, vortex plate and internal adjustable piping supports in accordance with DoD Standard Design guidelines.

2.2

The current configuration of the internal receipt line piping is as follows:

1) Has no diffuser

2) The piping extends approximately 36” from the shell

3) Has no piping supports

4) Has no internal flange

5) Has a 90 degree butt-welded elbow that is directed at the tank bottom.

Ref: DoD Standard Design AW 78-24-27, Drawing D.08, Detail C1

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

2.3

The IFR currently has two (2) anti-rotation cable installed with the base welded directly to the tank bottom with no pads.

Install new pads or bearing plates under the existing anti-rotation cable as well as install one (1) new ¼” anti-rotation cable per current AW 78-24-27 guidelines Sec.2.9.1.11. Provide a minimum of three 6 mm ¼-inch diameter anti-rotation cables made of 304 stainless steel conforming to ASTM A 492.

2.4

The current internal bottom coatings appear to be installed in 2004 when modifications to the tank were made. The coatings have significant failures with entrapment, bubbling, and areas of total failure. Ref: API Standard 653, Annex C, Section C.1.4.2.; UFC 3- 460-01, Section 8-3.10(a); and DoD Standard Design AW 78-24-27, Drawing G.03, Note E.13.

Recommend installing a new protective coating system on the internal tank bottom. The current SOW is limited to 500 SF of coating repairs.

Note: Paint chips were taken for analysis of lead and hex-a-chrome on the tank bottom. The results are as follows:

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note SP-C- Install Bearing Plates

POL-TCX: Concur with SP-C.

g6cdxjmh Sticky Note

SP-C- CONCUR

Table 2- Near Term Recommendations

2.5 The existing fixed roof center column base does not meet current API 650 & 653 guidelines.

Recommend installing a seal welded bearing plate to the tank bottom with lateral clips per current API guidelines.

2.6 The tank bottom has an abandoned float gauge base that is welded directly to the tank bottom with no pad.

Recommend removing the existing base and repair affected coatings.

SP-C- Reference POL-TCX

POL-TCX: Concur.

g6cdxjmh Sticky Note SP-C- Concur

ITEM 2.1- Internal issue line piping

ITEM 2.2- Internal receipt line piping

ITEM 2.3- Anti-rotation cable base

ITEM 2.4- Bottom coating failure

ITEM 2.4- Bottom Coating Failure

ITEM 2.5- Fixed roof support column base

ITEM 2.6- Abandoned tank gauge base

2.7

Shell and Appurtenances Near Term Findings:

The current water draw / product recovery system is an unknown manufacturer. The following observations were observed:

1) No 2” DDB at the shell

2) No ability to test alarms

3) The current internal piping is ¾”.

4) The water draw tank and external piping needs to be heated.

5) Has one tank that is connected to tank 481 and 482.

6) The current pump is CS and does not work properly.

7) Has piping that is not fitted correctly.

8) No vent on the cover.

Ref: UFC 3-460-01, Table 8-1(z) and DoD Standard Design AW 78- 24-27, Drawing D.13, Note A1.

Recommend making the following repairs:

1) Remove the existing water draw tank and install a new one for each tank that is heated.

2) Install 2-2” DBB valves at the shell per current DoD guidelines.

3) Install the necessary piping to test the High Level alarms per current DoD

4) Install new piping from the tank to shell.

2.8

The receipt and issue lines currently have a mix of SS ¾” and 1” piping installed for the thermal relief system. The following observations were identified:

1) There is currently no test tees installed.

2) The current configuration of threaded connections that had minor product seepage at time of inspection..

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

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

Note: The current PRV valve setting is 65 psi.

2.9 The existing 8” ball valve on the issue line does not hold and allow product to seep by when closed.

Install a new 8” DBB valve per current DoD guidelines.

2.10

There is currently one (1) 24” manway installed in the 1st shell course. This manway does not have a filler drum or davit arm installed. Ref: UFC 3-460-01, Table 8-1(f) and DoD Standard Design AW 78-24-27, Drawing D.10, Detail A4 and C4.

Recommend installing a new davit arm and filler drum on this manway per current DoD guidelines.

Consideration should also be given to installing 2-36” manway’s per current DoD guidelines.

2.11

The following observations were made on the Tank Alarm system:

1) There are currently no LLA’s.

2) The tank currently has a HLA and HHLA.

3) The HLSO is not accessible by the spiral stairway.

Recommend making the following repairs:

1) Install a new LLA per current DoD guidelines.

2) Move the existing HLSO system so that it is accessible from the spiral stairway.

3) Modify the existing spiral stairway to include platform so that you can safely access the tank alarms. The current stairway width is 22” wide.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note SP-C- Install Davit Arm

POL-TCX: Install Davit Arm.

g6cdxjmh Sticky Note

SP-C- CONCUR IN SOW

2.12 The current personnel grounding station is on the spiral stairway prior to access. However it is not built to current DoD guidelines.

Ref: DoD Standard Design AW 78-24-27, Drawing D.11, Detail A1

Recommend installing a new personnel grounding system per current DoD guidelines.

Note: no picture of this item

2.13

The external shell and fixed roof coatings are in very poor condition.

These coatings are thin, chalking, allowing rust discoloration to develop and have isolated total failures. Ref: API Standard 653, Annex C, Section C.1.4.2.; UFC 3-460-01, Section 8-3.10(a); and DoD Standard Design AW 78-24-27, Drawing G.03, Note E.13.

Recommend installing a new protective coating system on the external shell, fixed roof, and all piping in the containment area per current DoD guidelines.

The current SOW is limited to 500 SF of coating repairs.

NOTE: Paint chip samples were taken to analyze for lead and hexavalent chromium content.

2.14 There is currently no moisture barrier installed on the tank bottom to concrete ring-wall junction.

Install a new moisture barrier per current UFGS guidelines. NOTE the current SOW includes up to 1,400 LF of sealant, this task requires 79 LF.

2.15 The underside of the spiral stairway treads are not completely seal welded. Total of 44.

Recommend completely seal welding the treads per current API and DoD guidelines.

2.16 The existing tank tape gauge is broken and does not operate properly per current DoD guidelines. Ref. AW 78-24-27 Drawing D.07 Detail C1

Recommend installing a new Varec 2500 Series Model B tank gauge per current DoD guidelines.

2.17

The existing under tank bottom leak detection ports do not penetrate the concrete ringwall. They extend vertically from the concrete containment slabs are currently full of liquid. The current system also does not have a 4” leak detection well. Ref: AW 78-24-27 Drawing D.03 Detail A4

Recommend proper repairs per current DoD guidelines.

2.18

The internal shell and underside of the fixed roof protective coatings were installed in 1998 and they are in poor condition. They have significant entrapment, blistering, peeling and failures. Ref: API Standard 653, Annex C, Section C.1.4.2.; UFC 3-460-01, Section 8- 3.10(a); and DoD Standard Design AW 78-24-27, Drawing G.03, Note E.13.

Recommend installing a new protective coating system on the internal shell, and underside of the fixed roof per current DoD guidelines. The current SOW is limited to 500 SF of coating repairs.

Note: The IFR should be removed due to significant being performed above it Ref: UFGS Spec. 09.97 13.17 Para. 1.4.3 NOTE: Paint chip samples were taken to analyze for lead and hex-a-chrome content.

2.19

The following items do not have pads or bearing plates welded between them and the shell:

1) HLSO control tubing piping supports. (7) total

2) Spiral stairway platform supports. (2-3’x3”- “L” angle)

3) The tank tape gauge supports. (2)

The following repairs are recommend:

1) Remove existing HLSO tubing supports and reroute control tubing along the spiral stairway so that it is accessible.

2) Install 2 plates 8” diameter

3) Install 2 plates 4” diameter

All plates to be installed per current API 653 guidelines.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Nonconcur. Leave as is.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR IN SOW

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Nonconcur. Leave as is.

g6cdxjmh Sticky Note SP-C- NON CONCUR Recommend removal .

POL-TCX: Concur with SP-C.

g6cdxjmh Sticky Note SP-C- Reference POL-TCX g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

POL-TCX: Nonconcur. Perform MT.

2.20 Tank 481 currently has a 1” threaded sample port located in the 1st shell course that is a hot tap and has not been back-welded internally.

Recommend removing the 1” threaded connection and installing a lap patch per current API guidelines.

2.21

The current configuration of the 6” receipt line piping does not have a valve on the pipeline side of the HLCV (Cla-Valve) to isolate it if repairs or maintenance has to be performed. Ref: DoD Standard Design AW 78-24-27, Drawing D.12, Detail A1

Consideration should be given to installing a new 6” DBB valve on the receipt piping to isolate the control valve per current DoD guidelines.

Note: the current receipt line piping is aluminum construction.

2.22

Tank 481 currently has no 4” low suction line per current DoD guidelines. DoD Standard Design AW 78-24-27, Drawing D.07, Detail A3

Recommend installing a new 4” low suction line per current DoD guidelines Note: no picture of this item.

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Nonconcur. Leave as is.

g6cdxjmh Sticky Note

ITEM 2.7- Water draw system Valve

ITEM 2.7- Water draw system piping

ITEM 2.7- Water draw system

ITEM 2.8- Issue line thermal relief system

Item 2.8- Receipt line thermal relief system

ITEM 2.9- Issue line ball valve

ITEM 2.10- Manway

ITEM 2.11- HLSO system tubing

ITEM 2.11- HLA in fixed roof nozzle

ITEM 2.12- Personnel grounding

ITEM 2.13- Fixed roof coating failures

ITEM 2.13- External shell coating failures

ITEM 2.14- Moisture barrier

ITEM 2.15- Underside of spiral stairway

ITEM 2.16- Shand & Jurs tank gauge

ITEM 2.17- Leak detection port

ITEM 2.18- Internal shell coating failure

ITEM 2.18- Underside of fixed roof

ITEM 2.19- Tank gauge piping support

ITEM 2.19- HLSO tubing support

ITEM 2.20- Sample port

ITEM 2.21- Receipt line piping

ITEM 2.22- Control valve product seepage

2.23

Fixed Roof Near Term Findings:

The current configuration of the fixed roof has no scaffold supports.

Ref: API 650 Sec.5.9- Fig. 5-22 & UFGS 33.56.13.13 para.2.13

Install scaffold supports on the fixed roof per current API & DoD guidelines.

Note: no picture of this item

2.24

Tank 482 currently has no 360 degree handrails per current AW 78- 24-27 guidelines. Ref AW 78-24-27 Drawing D11. Detail A4

Recommend installing a new fixed roof perimeter handrail per current DoD guidelines.

2.25

The current fixed roof has no hinged roof edge vent/inspection covers

Install four (4) new roof edge vent/inspection covers per current API and UFGS 33.56.13.13 para.2.13.13 guidelines. Note: No picture of this item.

No picture of this item.

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

ITEM 2.24- No fixed roof perimeter handrail

2.26

Internal Floating Roof Near Term Findings:

Access to the topside of the IFR from below is provided through the 30-inch vacuum breaker. The current standard requires a manway access be provided.

Ref: UFGS Section 33 56 13.13 Part 2.13.2.9

Install a new IFR manway per the current DoD guidelines.

2.27

The current configuration of the IFR supports legs base is a glued down SS plate for the legs to land on with no PTFE feet. Ref: UFGS Sec 33 56 13.13 Part 2.13.2.6

Recommend installing PTFE feet per current DoD guidelines.

2.28

Tank 482 currently has no internal vertical ladder with safety climb. Install new aluminum vertical ladder with safety climb per current API, OSHA and UFGS 33.56.13.13 para.2.13.10 guidelines with a safety climb.

Note: No picture of this item

SP-C- NON CONCUR

POL-TCX: Nonconcur. Leave as is.

g6cdxjmh Sticky Note

SP-C- CONCUR

POL-TCX: Concur.

g6cdxjmh Sticky Note

ITEM 2.26- IFR vacuum breaker

ITEM 2.27- IFR support leg base

2.29

Containment Area Near Term Findings:

The containment area consists of earth with a FML liner attached to the concrete ringwall and vertical concrete containment walls. The liner ballast consist of concrete slabs with the joints caulked. The following is a of items noted during the inspection:

A. The containment drain valves hold and operate properly B. During rain incidents the rain water bubbles up from the earth through the failed caulking in joints.

C. There is approximately 2413 linear feet of failed caulking in the containment area.

The following repairs are recommended:

A. No additional work required.

B. For information only C. Properly clean and install new caulking.

All repairs to be completed per current DoD designs.

POL-TCX: Concur with Item C.

ITEM 2.29- Containment Cracking

Table 3- Long Term Recommendations

3.1 The existing petrex hatch located on the fixed roof has a cover that is clamped on and not bolted.

Consideration should be given to bolting this cover on versus the clamps.

3.3

The current bottom configuration is 0.250” nominal plate thickness and does not have a 5% slope towards the center of the tank.

The current configuration does not meet the current DoD guidelines.

Consideration should be given to replacing the entire bottom and replacing with one that meets the current DoD and API guidelines.

SP-C- CONCUR

g6cdxjmh Sticky Note

SP-C- NON CONCUR

POL-TCX: Leave as is.

ITEM 3.1- Existing Petrex hatch cover

Table 4- Monitoring Recommendations

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

Table 5- Stilling Well Recommendations

5.1

The tank does not have an 6” water probe, 8" MTG, or 8” ATG stilling well installed per UFC 3-460-01, Table 8-1(p).

Install a new 6” water probe, 8” ATG, and 8" MTG stilling wells per UFC guidelines.

Note: No picture of this item.

Stilling well installation / upgrade are part of the existing SOW, however a 4” water probe stilling well is included in the scope of work, consideration should be given to changing to a 6” water probe stilling well per current design standards.

POL-TCX: Concur. Install 6" water probe.

External View A

External View B

External View C

External View D

Photographs

Internal View A

Fixed Roof View A

Fixed Roof View B

Fixed Roof View C

Fixed Roof View D

IFR View A

IFR View B

IFR View C

IFR View D