SMJ-FY12-FAC 10227-Tank 5-FINAL.pdf

MATERIAL APPROVAL SUBMITTAL Form Approval OMB No. 9000-0062

TO: (Contracting Officer Representative) FROM: (Contractor) Date: 14 September 2012 Ms. Hilary Naquin Environmental Quality Management, Inc. (EQM)

CONTRACT NUMBER:

FA3002-09-D-0002; TO 0018

SUBMISSION NUMBER:

DDCO-3328- 073

SUBMITTAL:

New: X

PREVIOUS SUBMISSION NUMBER:

PROJECT NUMBER

030283.0018

Resubmittal:

PROJECT TITLE: Region II Tank Inspections

TO BE COMPLETED BY CONTRACTOR FOR GOVERNMENT USE ONLY

ITEM

NO.

SPECIFICATION

SECTION/ PARA

NO./DRAWING NO

DESCRIPTION OF MATERIAL

AP-

PROVED

DISAP-

PROVED

SEE

REVERSE

INITIAL

SOW

Seymour Johnson AFB, NC Facility 10104-4 (Tank #5)

API 653 Final Inspection Report

BY COMPLETING THIS FORM, THE UNDERSIGNED CONTRACTOR CERTIFIES THAT THE MATERIAL COMPLIES OR IS

COMPATIBLE WITH ALL SPECIFICATIONS OF THE SUBJECT CONTRACT

DATE TYPE OR PRINT NAME AND TITLE SIGNATURE

14 September 2012 Philip Heikkila, Project Manager

TO: (BASE CIVIL ENGINEERING OFFICER)

FOR EVALUATION AND ACTION

TO: (AF Contracting Officer)

RECOMMEND APPROVAL DISAPPROVAL AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE

TO: (Contractor)

APPROVED DISAPPROVED AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE SIDE.

REQUEST RESUBMITTAL ON DISAPPROVED ITEMS WITH IN DAYS OF DATE SHOWN BELOW

COMMENTS

(Number to correspond with applicable Item Number on Reverse Side)

SUBMITTAL HISTORY

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, Manufacture’s Literature and Certificates and Samples of Materials to the Government for approval in accordance wit the provisions of this contract. Unless otherwise

3) Item (s) to be approved will be clearly tapped 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 I

4) Requests submitted shall be numbered consecutively, by contract, in the space entitled “submission number”. This number, in addition to the Contract No., will be used to identify each Material Approval Submittal. Resubmissions will be indicated in th

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.

ER-SEYMOUR JOHNSON AFB-GOLDSBORO, NC-TANK # 5-JULY/2012

i

INTER SPEC, LLC

Environmental Inspection Services 757-622-6299 / Office

464 S Independence Blvd, C-104, Virginia Beach, VA 23452 757-622-9103 / Fax www.interspecllc.net 1-800-546-7853 / Toll Free

API-653 Engineering Inspection Report Tank # 5 (Facility No. 10104-4)

Prepared for

Seymour Johnson AFB; Goldsboro, NC

July 26, 2012

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

Signature (s):

Benyam Berhane, B.S.M.E., API-653 # 28492, API-570 # 34301, STI # 19309, AWS # 10041021

Reviewed By:

William C. Forbes, Jr.; Virginia P.E. Registration Number 8842 http://www.interspecllc.net/ ii

Executive Summary

An API Standard 653 Out-of-Service inspection of Tank # 5 was completed on July 13, 2012 to evaluate the tank’s integrity, collect data, and establish a data base for future inspections and evaluations. A service life evaluation performed on the tank shows it as having greater than 30 years of remaining shell life under current conditions. The bottom life evaluation performed on the tank shows it as having greater than 20 years of remaining life under current conditions. Inspection Results are listed in section

4.1. Maintenance Recommendations are listed in section 4.2. Compliance Requirements are listed in section 4.3. All engineering calculations are provided in Appendix A.

The tank does not meet the compliance requirements mandated by federal, state and local regulatory bodies. Refer to Compliance Requirements section 4.3 for details.

iii

Table of Contents

1.0 Introduction

1.1 Purpose

2.0 References

2.1 American Petroleum Institute

2.2 American Society of Mechanical Engineers Codes

2.3 National Association of Corrosion Engineers

2.4 National Fire Protection Association

2.5 Underwriters Laboratories Inc.

2.6 American Society of Nondestructive Testing

2.7 Code of Federal Regulations

2.8 Unified Facilities Criteria (USC)

2.9 Unified Facilities Guide Specification (UFGS)

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 Equipment Description

4.0 Inspection

4.1 Results

4.2 Maintenance Recommendations

4.3 Compliance Requirements

5.0 Summary of Deficiencies

6.0 Serviceability

Appendices iv

List of Appendices

A Engineering Calculations ................................................................................................................ A-1

B Engineering Drawings. .................................................................................................................... B-1 C Tank Historical Review ................................................................................................................... C-1

D API Checklists................................................................................................................................. D-1 E Photographs ...................................................................................................................................... E-1

F Repair Cost Estimates ....................................................................................................................... F-1 v

Acronyms and Abbreviations

ASNT American Society of Nondestructive Testing API American Petroleum Institute ASME American Society of Mechanical Engineers AST Aboveground Storage Tank CFR Code of Federal Regulations CRDM Continuous Release Detection Method EPA United States Environmental Protection Agency FML Flexible Membrane Liner FRP Fiberglass Reinforced Plastic HHLA High-High Level Alarm HLA High Level Alarm HLS High Level Switch HLV High Liquid Level Shut-Off Valve IFR Internal Floating Roof LLA Low Level Alarm LLLA Low- Low Level Alarm LLS Low Level Switch MFL Magnetic Flux Leakage NACE National Association of Corrosion Engineers NFPA National Fire Protection Association SOW Statement of Work STI Steel Tank Institute UL Underwriters Laboratories Inc.

UT Ultrasonic Thickness UST Underground Storage UFC Unified Facilities Criteria UFGS Unified Facilities Guide Specifications CP Cathodic Protection ATG Automatic Tank Gauge PRV Pressure Relief Valve VPI Valve Position Indicator

1.0 Introduction

1.1 Purpose:

1.1.1 This report presents an analysis of data collected during an inspection conducted on July 13, 2012 for Tank # 5, servicing JP-8, located at the Seymour Johnson AFB facility in Goldsboro, NC. The inspection was performed by a certified API-653 inspector. This report summarizes the results of the inspection meeting the requirements of API Standard 653 and API-650 Appendix H. The primary and secondary containment including the supports, foundation containments, vents, gauges, and appurtenances were evaluated. The inspection was conducted by InterSpec, LLC.

2.0 References

2.1 American Petroleum Institute:

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:

2.2.1 ASME B31.3, Process Piping

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

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

2.3 National Association of Corrosion Engineers:

2.3.1 NACE Recommended Practice, RP0184-91, Repair of Lining Systems

2.3.2 NACE Recommended Practice, RP0193-93, External Cathodic Protection of On-Grade Metallic

Storage Tank Bottoms

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

2.4 National Fire Protection Association:

2.4.1 NFPA-30, Flammable and Combustible Liquids Code

2.4.2 NFPA-70, National Electrical Code

2.4.3 NFPA-780, Standard for the Installation of Lightening Protection Systems

2.5 Underwriters Laboratories Inc:

2.5.1 UL-142, Steel Aboveground Tanks for Flammable and Combustible Liquids

2.6 American Society of Nondestructive Testing:

2.6.1 ASNT-SNT-TC-1A

2.7 Code of Federal Regulations:

United States Department of Labor, Occupational Safety & Heath Administration

2.7.1 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart H, Section 119, Process safety management of highly hazardous chemicals

2.7.2 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart J, Section 147, The control of hazardous energy (lockout/tagout)

2.7.3 CFR, Title 29, Subtitle B, Volume 5, Chapter XVII, Part 1910, Subpart S, Section 331-335, Safety-Related Work Practices

United States Environmental Protection Agency

2.7.4 CFR, Title 40, Volume 21, Chapter I, Subchapter D, Part 112, Oil Pollution Prevention

2.8 Unified Facilities Criteria (UFC)

2.8.1 UFC 3-460-01, Petroleum Fuel Facilties.

2.9 Unified Facilities Guide Specification (UFGS)

2.9.1 UFGS-Ol 3529, Safety And Occupational Health Requirements

2.9.2 UFGS-Ol 3530, Safety, Health, and Emergency Response (HTRW/UST)

2.9.3 UFGS-09 97 13.15 (09970), Epoxy/Fluoropolyurethane Interior Coating of Welded Steel

Petroleum Fuel Tank

2.9.4 UFGS-0997 13.17 (09973), Three Coat Epoxy Interior Coating of Welded Steel Petroleum Fuel

Tanks

2.9.5 UFGS-0997 13.27 (09971), Exterior Coating of Steel Structures

2.9.6 UFGS-09 97 23.13, Interior Lining for Concrete Storage Tanks (for Petroleum Fuels)

2.9.7 UFGS-33 5290.0020, Welding for POL Service Piping

2.9.8 UFGS-33 56 13.13 (13205), Steel Tanks with Fixed Roofs

2.9.9 UFGS-33 65 00 (13219) Cleaning Petroleum Storage Tanks

3.0 Description

3.1 Job Description:

Job Number: 10-1113 Contracted by: QPS Engineering, LLC

3.2 Tank Description:

Owner/Operator: Seymour Johnson AFB Location: Goldsboro, NC Tank Identification: 5 (Facility No. 10104-4) Diameter: 60.00 feet Shell Height: 39.00 feet Capacity: 738,791 Gallons Configuration: Vertical Foundation: Concrete Ringwall Secondary Containment: Concrete Dike with FML Year Installed: 1961 Age: 51 years Construction Code: API-12C Manufacturer: Chicago Bridge & Iron Company Year Reconstructed: 2003 Reconstructed By: Superior Industrial Maintenance Company, Inc.

3.3 Service Description:

Service: JP-8 Specific Gravity: 0.82 Operating Limits:

Minimum Metal Temperature: Ambient Maximum Metal Temperature: 200 ˚F Minimum Pressure: Atmospheric (no vacuum) Maximum Pressure: Product Seismic Zone: 1 Overflow: 34.93 feet (100 %) Max Fill Height: 34.83 feet (99.72 %) Current Fill Height: 33.83 feet (96.85 %) High Level Shut-Off: 34.42 feet (98.52 %)

3.4 Part Description:

Bottom Material: Carbon Steel Specification: Unknown Specification Design: Cone-Down

Shell Material: Carbon Steel Specification: Unknown Specification Design: Cylindrical

Roof Material: Aluminum (Alumadome Cover by CST Industries, Inc.)

Specification: Unknown Specification Design: Dome

3.5 Joint Type Description:

Bottom Plate-to-Plate: Lap-Welded Annular Plate-to Bottom Plate: Lap-Welded Shell Plate-to-Plate: Butt-Welded Floating Roof Plate-to-Plate: Bolted Fixed Roof Plate-to-Plate: Bolted Bottom-to-Shell: Fillet Welded Shell-to-Fixed Roof: Bolted Shell-to-Floating Roof: Seals

3.6 Inspection Description:

Inspection Type: API-653 Out-of-Service Equipment Used: Ultrasonic Thickness Meter Last Inspection Date (s): In-Service Inspection (Unknown or Not Provided)

Out-of-Service Inspection (Unknown or Not Provided but assumed circa 2002 based on last cleaned date of April 2002)

Inspection Date: July 13, 2012 Inspector(s): Benyam Berhane, Jack O’Dell, Robert Whittle, Thomas Ambrose

3.7 Equipment Description:

Ultrasonic Thickness Meter

Manufacturer: Krautkramer Model: DMS 2 Calibration Methods Used: Zeroing Procedure, Copper Coating Calibration Procedure, and

Two Point Calibration Procedure

4.0 Inspection

4.1 Results:

4.1.1 Containment: The tank sits in a concrete secondary containment floor with concrete dike walls. The secondary containment measures 153' x 203' x 153' x 15' x 182' x 15' (measured clockwise from the stair case). The low point of the containment wall is 6'. There is a flexible membrane liner covering the entire containment with pea gravel overtop the floor liner. The liner extends from the tank foundation to the inner edge of the containment wall. Stainless steel batten strips are used to secure the liner at each end. The secondary containment is equipped with a twenty-four inch square drain sump at the west end of the containment. A locked drain valve is provided outside of the containment also at the west end of the containment. The secondary containment was visually evaluated during the inspection for broken concrete, spalling, cracks and vegetation growth. Accessible sections of the liner were also inspected for deterioration, tears and discrepancies that may compromise permeability of the containment.

The liner near the containment stairs has pulled away from the batten strips. The batten strip at the containment sump is loose as a result of a missing anchor bolt. There is an old open conduct through the liner at the south-east section of the tank. There are electrical wires in the conduit.

The termination point of the conduit is unknown but is considered as a breach in the containment. The presence of electrical wires could also compromise the NFPA 30 hazard classification of the area. This location within ten feet of the tank shell is considered Class I, Division 2 in accordance with NFPA 30. The pipe support and sump leak detection pipe are missing sealant at the pipe to liner interface. Fuel resistant sealant is required when there is a liner penetration in the FML. There are areas of spalling and cracks in the top of the containment wall measuring approximately one hundred linear feet. Hairline cracks do not seriously affect the strength of the concrete structures; however, these cracks can be potential access points for moisture or water seepage that could corrode the reinforcing steel (rebar) as well as permit freeze damage in cold weather. The secondary containment is of sufficient size to contain a total tank loss. The top of the concrete dike containment wall is two-feet or more with proper-sloped walls as per NFPA-30. The secondary containment is structurally sound. The secondary containment is in satisfactory condition with the exceptions of discrepancies identified above.

4.1.2 Foundation: The tank sits on a concrete ringwall foundation elevated approximately twelve inches from the containment floor. The foundation was visually evaluated during the inspection for broken concrete, spalling, cracks, and vegetation against the bottom of the tank.

No spalling and vegetation were present. The foundation to chime interface is sealed. There is minor seal deterioration and cracks on foundation to chime seal (throughout the circumference approximately 10 linear feet of seal deterioration and 4 linear feet length of cracks). The top exposed side of the foundation is coated with black epoxy paint. There is minor fading and discoloration in the coating. The batten strips anchored to the side of the foundation are in satisfactory condition with no apparent deterioration. The tank is equipped with through foundation bottom leak detection system. Shell settlement surveys were performed during the inspection in accordance with Appendix B of the API Standard 653. Settlement results are listed in Appendix A. There is no indication of significant settlement.

4.1.3 Cathodic Protection: A section of the Cathodic Protection report dated May 2011 was provided at the time of the inspection. The annual CP survey was conducted by Rummel, Klepper & Kahl, LLP (RK&K). The report indicated that tank # 5 is receiving adequate cathodic protection based on NACE criterion.

4.1.4 Bottom: The tank is a double bottom design with the new bottom installed approximately 10.5 inches above the existing bottom. There are two inch leak detection ports between the two bottoms. The new bottom is constructed of carbon steel of unknown specification (no information provided from the 2003 reconstruction). The bottom is a cone-down design, butt-welded together, consisting of twenty seven sketch plates and twenty-four annular ring plates fillet welded to the shell. The annular plates measure twenty-six and one half inches wide and meet the requirements of API-650 designed tanks. The minimum radial width of annular plates is twenty-four inches per API-650. There were no underside indications or flaws identified on the annular plates or the bottom. The bottom has a thin interior film liner (13 -34 mils). Inspected the interior coating for disbonding, adhesion, deterioration, and discoloration. The condition of the liner is not satisfactory with four areas identified with coating discrepancies (See 4.1.8). The bottom is equipped with a thirty inch sump located at the center of the tank with a depth of nine inches. A visual inspection was conducted over the entire bottom of the tank, including the bottom welds and bottom-to-shell weld. There is a 1/16" undercut at the shell to bottom weld. There was no structural deficiency or compromise to the tank integrity. The undercut however, exceeds API 650/653 requirements and should be repaired. Evaluated attachments and piping supports. See appurtenance section for piping support and other discrepancies. Performed a magnetic flux leakage (MFL) evaluation of the tank bottom to determine the condition of the underside. There were no areas indicating underside corrosion. Measured the general thickness throughout the tank bottom utilizing an ultrasonic thickness tester. Thickness measurements are listed in the engineering data in Appendix A. The engineering calculations, as per API Standard 653, for the service life evaluation are shown in Appendix A under "Bottom Plate Evaluation.”

4.1.5 Shell: The shell is constructed of carbon steel of unknown specification. The shell is of cylindrical design and butt-welded together consisting of five courses. Evaluated the shell for plumbness, roundness, peaking, and banding, all of which were found to be within the allowable tolerances of the API Standard 653. Visually inspected the interior and exterior of the shell.

Inspected the coating for disbonding, adhesion, deterioration, and discoloration. There is minor discoloration and general deterioration on the tank exterior shell. (See painting/insulation section as well as Appurtenance section for nozzle discrepancies). The shell was evaluated for remaining metal thickness utilizing ultrasonic technology. Thickness measurements are listed in the engineering data in Appendix A. A service life evaluation performed shows the shell with greater than 30 years of remaining life under current conditions. The engineering calculations, as per API Standard 653, for the service life evaluation are shown in Appendix A under “Service Life Evaluation.” The tank is equipped with an intermediate stiffening ring welded on the fifth course. Evaluated the stiffener; the condition is unsatisfactory due to some coating failure and corrosion.

4.1.6 Appurtenances: Inspected and evaluated each tank nozzles in accordance with API Standards 650 and 653. Identified the type and use of each shell nozzle and measured the nozzle neck thickness on all accessible shell nozzles. Evaluated all nozzles and reinforcement plates for leaks and corrosion. The south-west manway is oval-shaped, measuring 36" x 20" and is original to the tank. UFC Section 12-3.2 recommends consideration for increasing the size of the manway based on the need for ventilation or equipment requirements. No davit arm is installed on this manway, and there is no telltale hole on the reinforcement pad as required in API 650. Manway covers that weigh over 75 pounds are required to be equipped with a davit arm per API 650. The north-east manway is a thirty-six inch diameter opening with davit arm welded to the flange. The davit arm however, is bent and was disconnected at the time of arrival. The davit arm may have not been installed correctly to accommodate the weight of the cover. The davit arm was also stuck in position and did not have grease fittings. The tank is equipped with high-level alarms as well as high-level shut-off. No discrepancies were evident with the system. There was however, no low-level alarm system installed on the tank. The tank has means of grounding via ground straps. The tank is equipped with a float and tape type mechanical ATG manufactured by Shand & Jurs. The ATG is used without a float with the tape attached directly to the floating roof. Evaluated the ATG and its operation, and the tape is not installed to the floating roof per the manufacturer. It is currently steel wire tied to a bracket see E.38 - E.40. (Note: the grounding wire shown in picture E.40 is not required for tanks that have direct grounding between the tank and the floating roof). The bump checker knob is broken.

An ITT Barton tank gauging system is also provided for tank level gauging. The unit is mounted outside, south of the tank containment. The level probe is enclosed in a six inch stilling well which is not slotted in accordance with UFC and ATG policy letter issued by Defense Logistics Agency. There is an eight inch gauge well that is only slotted at twenty six and forty inches above the bottom with only four (9" x 1") slots. Both wells are part of through-roof access ladder system with a built in aluminum safety rail with datum reference plates. The penetration of the stilling wells through the dome roof is deteriorated. It allows water to enter into the tank. Evaluated the handrails, and their condition was found to be satisfactory with the exception of coating. Inspected the platforms and frames for corrosion and structural soundness, and their conditions are also satisfactory. The water draw-off system has moderate coating failure and appears to be outdated. The product saver tank is also not secured to the foundation and did not have grounding cable. The piping from the saver tank is PVC which was deteriorated and leaking at the time of the inspection. Sight glass shielding rods on the saver tank are not of adequate diameter (stiffness) to protect the glass/tube. Rods deflect excessively with slight load applied. The pump conduit bracket is missing the fastener for the water draw-off system. The low suction nozzle flange has moderate coating failure and corrosion. Fasteners also have moderate corrosion. Six inch receipt piping and eight inch issue piping valves are double block and bleed (DBB) valves. There is product staining at the compression fitting on issue piping valve. Both valves have thermal relief valves but are not mounted in the upright position per the UFC. The TRV on issue piping was manufactured and tested in August 2002 and is due for the ten year bench testing and setting. The TRV on the receipt piping is missing the tag and information could not be derived from it. The interior water draw, low suction, issue and fill piping supports are not IAW Standard Design AW 78-24-27. They do not have restraining loose U-bolts. There was no evidence of excessive movement or stress from any of the interior piping. The issue piping does not have Anti-Vortex plate per UFC and Standard Design AW 78-24-27. The diffuser piping shape and size is not typical to those installed on government facilities and as detailed in the UFC or DoD Standard AW 78-24-27. There was however no functional limitation observed on the diffuser. Anti-rotation cable does not have repad IAW API650/653. There is one installed at south-east end of tank. The UFC and standard design requires a total of three anti-rotation devices. API 650 allows the use of vertical penetration wells as an anti-rotation device. The product piping supports in the containment are also not typical to the UFC, Standard Design or industry piping codes. There is a 6" x ¾" slider bar welded to the piping and it rests on the pipe support. Some locations have horizontal restraining bars of approximately the similar dimension as the slider bar. There are however no restraints from vertical uplift. Additionally, at some areas the restraining bar is in contact with the pipe and is creating abrasive corrosion. There is debris and a bird nest on top of the IFR seals. Damage to the secondary seals and tank interior coating is possible if debris is not removed or if it continues to enter the tank. The bird screen on the dome roof and the overflow slots has gaps and may be allowing birds to enter the tank. ATG brackets, cathodic protection (CP) junction box and pilot tubing support is directly welded to tank without the use of reinforcement pad. (Note: API 650 section 5.8.1.2 does allow permanent attachment to be welded directly to the tank). The tank has adequate identification marking and labels but is not equipped with confined space and NFPA warning placards.

4.1.7 Fixed and Floating Roof: The tank is equipped with a clear-span Alumadome cover manufactured by CST Industries, Inc. It is an aluminum geodesic dome roof that was retrofitted to this tank possibly circa 2003. The dome is joined with stainless steel fasteners with an interlocking panel that has an enclosed gasket in compression for the mechanical seal. The dome roof does not however have external joint seals and is therefore allowing water to enter the tank during heavy rain events. Additional investigation or testing may be required to determine if there are other locations for water infiltration. The internal floating roof (IFR) is a full contact honey comb design that is fitted with double foam log seals. Evaluated the structural integrity of both roofs. Evaluated the condition of the floating roof seals. The seals are in mostly satisfactory condition but have two areas that are sagging because fuel has entered into the seal (approximately 38 linear feet). Both locations are marked on the interior of the tank and are located at the south-east end of the tank. Measured the floating roof annular space at several locations. The IFR is equipped with non-adjustable two position legs. The high leg position is approximately eighty-seven inches and the low leg position is approximately thirty five inches.

4.1.8 Painting/Insulation: The tank shell, stairway, handrails, piping, and appurtenances are coated. There is minor to moderate discoloration and general deterioration on tank shell, stairway, handrails, piping, and appurtenances. Moderate coating failure on piping and appurtenances (water draw-off tank water draw-off pump, piping, piping support, valves, davit arms…). Coating failure with minor corrosion on the interior of the tank shell where weld repair was evaluated from the exterior of the shell on the low suction nozzle. There is also moderate coating failure on the tank bottom at four areas near the water draw and low suction piping.

Areas are marked on the tank bottom and measure approximately sixty square feet.

4.2 Maintenance Recommendations:

4.2.1 Containment: Seal the cracks in the containment with a Sherwin Williams two part Corobond Flexible Joint Sealant, Corobond Crack Filler and Corobond 100 Epoxy Primer/Sealer or equivalent. See 4.3.1.

4.2.2 Foundation: Repair minor seal deterioration and cracks on foundation to chime seal (throughout the circumference less than 10 linear feet) with a Sherwin Williams two part Corobond Flexible Joint Sealant, Corobond Crack Filler and Corobond 100 Epoxy Primer/Sealer or equivalent.

4.2.3 Cathodic Protection: Perform the annual CP survey for 2012.

4.2.4 Bottom: See Appurtenance section for piping support discrepancies and section 4.34.

4.2.5 Shell: See coating section.

4.2.6 Appurtenances: Update the south-west manway to thirty-six inch manway in accordance with the UFC 3-460-01 as necessary if section 1-3 of the UFC is applicable. Install ¼" telltale hole on the reinforcement pad for south-west manway in accordance with API-653.

The reinforcing plate will have to be pneumatically tested with 15 lbf/in2 gauge pressure while the existing interior and exterior welds are soap tested for leaks IAW API 650 section 7.3.4.

Install davit arm on south-west manway and repair/ replace the davit arm on the other manway.

The new or repaired davit arm should be equipped with a grease fitting. API 650 requires all manway covers over 75 lbs to have davit arms. Upgrade Water draw-off system and piping as needed IAW Standard design AW 78-24-27. The new system should be bolted or secured down on the foundation. Install new shielding rods for sight glass or provide other means of protecting sight glass if the existing water draw-off tank is not planned for replacement. Replace or repair the conduit bracket for the water draw-off. Replace the PVC water drain pipe with carbon steel or stainless steel piping. Replace the broken bump check knob on the mechanical ATG. Install a reinforcement plate for the ATG brackets, cathodic protection junction box and pilot tubing supports as necessary. (Note: IAW API 650 permanent attachments may be welded directly to the shell with fillet welds having a maximum leg dimension of 1/2 inch, the edge of any permanent attachment welds shall be at least 3 inches from the horizontal joints of the shell and at least 6 inches from the vertical joints, insert-plate joints, or reinforcing-plate fillet welds).

Install the TRVs in an upright position for both receipt and issue piping. The TRV on receipt piping may have to be replaced or rerated and stamped after bench testing and setting. Bench test and reset the TRV on the issue piping. Repair the compression fitting on the issue DBB valve. Remove debris and bird nest from the top of IFR. Repair or replace the screen on the dome roof and the overflow slots to prevent birds entering the tank. Install stainless steel fasteners on the low suction nozzle flange. Repair the pipe supports within the containment to correct section where pipe is rubbing the supports. Update pipe support where necessary to include installing pipe- sliding type supports per plate 020 of UFC 3-460-01. Update interior pipe supports as necessary to comply with the requirements with Standard design AW 78-24-27 by installing U-bolts during a major rehabilitation period. Similarly, an anti-vortex plate can be added to the suction piping during the same time period.

4.2.7 Fixed and Floating Roof: Repair the seals on the dome roof for the stilling well penetrations. Apply silicone sealant on the dome roof joints to prevent water entering the tank.

At a minimum joint seals may be applied at key areas where water puddle is evident or likely.

The manufacturer has a list of approved sealant that conform to federal specifications and a list of approved brand names. Those brand names that are on the approved list are: Dow Corning 790, GE Silicone Construction 1200, GE Silpruf, GE Silglaze - N 2500 series and GE RTV 109

4.2.8 Painting/Insulation: Mechanically clean or abrasively blast and recoat the tank and appurtenances. Areas of coating failure in the interior of the tank should also be repaired. All coating repairs should be accomplished using an epoxy based coating system or equivalent.

(Note: any subsequent hot work done on the exterior of the tank will require coating repair on the interior of the tank).

4.3 Compliance Requirements:

4.3.1 Containment: Repair containment liner that is pulled away from the batten strip at the stairway and the loose batten strip at the sump. Cap or seal the open conduit in the containment to maintain the impermeability of the containment. Apply epoxy based seal at all pipe supports and other liner penetration to provide leak-free attachments.

4.3.2 Foundation: None.

4.3.3 Cathodic Protection: None

4.3.4 Bottom: Install a twelve inch reinforcement pad with rounded corners under the anti-rotation cable bracket in accordance with API 653. The minimum distance from existing bottom plate welds to the toe of the filler welds of the repad plate shall be two inches (2"). Repair patch plates or reinforcement pads within the critical zone (three inches from the shell measured inward). All repair patches should be visually inspected for defects and shall be tombstone shaped repair plates. In addition to visual inspection, welds can be vacuum tested, penetrant tested or a magnetic particle test can be performed per API 653. Existing weld undercut deemed unacceptable based on suitability for service considerations shall be repaired by additional weld metal, or grinding, as appropriate in accordance with API 653.

4.3.5 Shell: None.

4.3.6 Appurtenances: Install an Enraf system with a fully slotted stilling well for temperature and water at or near the sump and fully slotted stilling well for the level gauge located at or below the datum level. Installation of the Enraf system and the stilling well diameters should be in accordance with UFC and the ATG policy letter issued by Defense Logistics Agency. (Note: the existing six inch and eight inch wells may be retrofitted and used for the Enraf system). Install ATG tape to the floating roof in accordance with the manufacturer’s instruction. Install low level alarms in a four inch chamber mounted externally to the tank and in a location that is accessible for service and testing in accordance with the requirements of UFC and Standard design AW 78-24-27. The level alarm set points are detailed in Plate 014 of UFC 3-460-01 and dimensional requirements given in Standard design AW 78- 24-27 in Sheet 35. All welding and testing requirements must be in accordance with API 653.

The tape may break and retract in the gauge head if the wire tie breaks or cuts the tape. Install NFPA and confined space placards.

4.3.7 Fixed and Floating Roof: Repair the section of the primary foam log seal by replacing the area that is sagging. Alternatively a double wiper elastomeric wiper seals may be retrofitted over the entire IFR.

4.3.8 Painting/Insulation: None.

5.0 Summary of Deficiencies:

5.1.1 Foundation

Minor seal deterioration throughout (less than 10 linear feet). (Near failure) Cracks in the foundation. Approximately 4 feet in cumulative length. (Near failure)

5.1.2 Containment

Spalling and cracks in the top side of the containment wall (approximately 100 linear feet). (Near failure)

Liner is pulled away from batten strip at the containment stairway (approximately 9 feet) (Mandatory repair)

Liner missing epoxy seal at the pipe support and sump leak detection pipe. (Mandatory repair)

Open conduit through the tank liner with no cap or seal. (Mandatory repair) Batten strip loose at the containment sump. (Mandatory repair)

5.1.3 Cathodic Protection

None

5.1.4 Bottom

There is a 1/16" undercut at the shell to bottom weld. There was no structural deficiency or compromise to tank integrity. The undercut however exceeds API 650/653 requirements and should be repaired. (Mandatory repair)

See Appurtenance section for piping support discrepancies and coating.

5.1.5 Shell

See coating section. (Near failure)

5.1.6 Tank Appurtenances

Water draw-off system has moderated coating failure. Upgrade system and piping as needed IAW Standard design AW 78-24-27 (Long-term)

Water-draw off tank is not secured to the foundation. (Mandatory repair/replace) Water-draw off piping is PVC. The PVC was deteriorated and leaking at the time of the inspection. Replace with carbon steel piping IAW with UFC and Standard Design AW 78-24-27. (Mandatory repair/replace)

Conduit bracket is missing fastener for water draw-off piping. (Near failure) Sight glass shielding rods are not of adequate diameter (stiffness) to protect the glass.

Rods deflect excessively with slight load applied. (Near failure) Mechanical ATG bump checker knob is broken. Tape is attached directly to the Internal

Floating Roof (IFR). (Mandatory repair) Install Low level Alarms in accordance with the UFC and Standard Design. (Mandatory

Repair) ATG brackets, cathodic protection (CP) junction box and pilot tubing support is directly welded to tank without the use of reinforcement pad. NOTE: API 650 section 5.8.1.2 does allow permanent attachment to be welded directly to the tank. Repair/upgrade as needed per UFC. (Long-term)

Thermal relief valve is not mounted upright per UFC and is due for ten year bench testing and setting. (Near failure)

The thermal relief valve on the fill valve is missing manufacture tag and is not mounted upright per UFC. Replace relief valve. (Near failure)

There is product staining at the compression fitting on issue piping valve. (Near failure) North-east manway davit arm is bent, does not have end cap and does not have grease fitting. Manway covers that weigh over 75 lb are required to be equipped with a davit arm per API 650. (Mandatory repair)

South west manway is not typical 36" round manway. UFC recommends consideration for increasing size of the manhole. No davit arm installed for the manway. No telltale hole on the reinforcement pad. Manway covers that weigh over 75 lb are required to be equipped with a davit arm per API 650. (Mandatory repair)

Low suction nozzle flange has moderate coating failure and corrosion. Fasteners have moderate corrosion. Replace with stainless steel. (Near failure)

Piping supports utilized are not typical to UFC, Standard Design or industry piping codes. The piping is in contact with the guide. (Mandatory repair)

Bird screen on the dome roof and the overflow slots have gaps and allow birds to enter the tank. (Mandatory repair)

There is moderate coating failure and corrosion on the wind girder and upper stairway.

(Near failure)

Stilling well penetration through the dome roof is deteriorated. It allows water to enter in the tank. (Mandatory repair)

The dome roof does not have external joint seals. Therefore, water is able to enter the tank during heavy rain events. (Near failure)

Stilling wells are not slotted all the way to the top of the tank. Tank is equipped with an ITT Barton level probe. Install/add new stilling wells with the ENRAF system IAW UFC and ATG policy letter issued by Defense Logistics Agency. (Mandatory Repair)

ATG tape is not installed per manufacturer. See E.38 - E.40. (Long-term) There is debris and a bird nest on top of the IFR seals. Damage to the secondary seals and tank interior coating is possible. (Near failure) The IFR is equipped with a foam log seal. The seals are in mostly satisfactory condition but have two areas that are sagging because fuel has entered in the seal (approx. 38 LF).

Replace section of the log seal or replace entire section to elastomeric wiper seals.

(Mandatory Repair)

The interior water draw, low suction, issue and fill piping supports are not IAW Standard Design AW 78-24-27. Install loose U-bolts during rehabilitation. (Long-term)

The suction piping does not have Anti-Vortex plate per UFC and Standard Design AW 78-24-27. Install Anti-Vortex during rehabilitation. (Long-term)

There is coating failure under the fill nozzle and on the water draw piping interior coating. (Near failure)

Anti-rotation cable does not have repad IAW API650/653. There is one installed at south-east end of tank. The UFC and standard design requires total of three anti-rotation devices. API 650 allows the use of vertical penetration wells as an anti-rotation device.

Add addition anti-rotation device as necessary. (Mandatory Repair)

Tank is not equipped with confined space and NFPA warning placards. (Long-term)

5.1.7 Roof

See appurtenance section for joint seal and bird screen.

5.1.8 Coating

Minor discoloration and deterioration on tank shell, piping and appurtenances. (Near failure)

Minor coating failure on tank shell and piping. (Long-term) Moderate coating failure on piping and appurtenances (water draw-off tank water draw-off pump, piping, piping support, valves, davit arms…). (Near failure)

6.0 Serviceability:

6.1 API-653 Schedule:

Tank # 5 is not in compliance with the requirements of API Standard 653 for structural integrity, and the following schedule may be implemented after corrective actions in section 4.3 are completed:

6.1.1 Perform routine monthly visual inspections by owner/operator personnel knowledgeable of the storage facility operations, the tank, and the characteristics of the product stored;

conduct in accordance with API Standard 653.

6.1.2 The next visual external inspection should be accomplished by a Certified API-653

Inspector prior to July, 2017 in accordance with API Standard 653.

6.1.3 The next ultrasonic thickness measurement inspection should be accomplished by a Certified API-653 Inspector prior to July, 2027 in accordance with API Standard 653.

6.1.4 The next internal inspection should be accomplished by a Certified API-653 Inspector prior to July, 2022 in accordance with API Standard 653.

The existing tank and related facilities, (e.g. appurtenances, equipment, stilling/gauging wells, valves, alarms, probes, nozzles, manways, etc.) covered under this report should be evaluated for conformance with current and proposed Unified Facility Criteria (UFC), Unified Facility Guide Specifications (UFGS), US Army Corps of Engineers, (USACE), Naval Facilities Engineering Command (NAVFAC), US Air Force (USAF) and Defense Logistics Agency (DLA) standards, policies, technical memorandums and guidance for bulk fuel storage facilities. Any recommendations for tank facility upgrades beyond the mandatory and recommended repairs as noted in this report and required under API-653/API-650† published and in effect as of the date of this report are at the discretion of the facility owner and beyond the scope of this inspection report.

†API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction, Fourth Edition, Includes Addendum 1 (2010), Addendum 2 (2012)

†API Standard 650, Welded Tanks for Oil Storage, 11th Edition, Includes Addendum 1 (2008), Addendum 2 (2009), Addendum 3 (2011), Errata (October 2011)

Appendix A

Engineering Calculations

1. Bottom Service Life

2. Shell Service Life

3. Settlement Evaluation

4. Data

InterSpec, LLC Rev.21505-1

MRT = minimum remaining thickness at the end of interval Or . This value must meet the requirements of table 6-1 and 4.4.7.4 and 4.4.8, MRT (inches) 0.100 0.050 0.050

MRT =

Or =

To = Original plate thickness, in inches.

TL = Lowest thickness from top side or bottom side deterioration Tmin (CZ) = API recommended thicknes within the Critical Zone (CZ)

Or = in-service interval of operation (years to next internal inspection ) not to exceed that allowed by 6.4.2, 20 years.

RTbc = minimum remaining thickness from bottom side corrosion after repairs, RTip = minimum remaining thickness from topside corrosion after repairs, StPr =

Upr =

StPm =

StPa = Average depth of top side pitting, in inches, measured from the original thickness.

StPcr = Maximum corrosion rate of top side pitting, in inches/year.

UPm = Maximum depth of bottom side pitting, in inches.

UPa = Average depth of bottom side pitting, in inches.

UPcr = Maximum corrosion rate of bottom side pitting, in inches/year.

GCr =

Maximum depth of top side pitting remaining in bottom plates after repairs are completed, in inches, measured from the original thickness.

Maximum rate of corrosion top or bottom side, in inches per year.

Applied tank bottom reinforced lining, > 0.05 in. thick, in accordance with API RP 652

Bottom Plate Evaluation:

Minimum Thickness for Tank Bottom and Remaining life

Tank Bottom/Foundation Design Tank bottom/foundation design with no means for detection and containment of bottom leak Tank bottom/foundation design with means to provide detection and containment of bottom leak

(Minimum of RTbc or RTip) - Or(StPr + Upr)

(Minimum of RTbc or RTip) - MRT (StPr + Upr) maximum rate of corrosion not repaired on the top side. StPr = 0 for coated areas of the bottom. *The expected life of the coating must equal or exceed Or to use StPr = 0 maximum rate of corrosion on the bottom side. To calculate the corrosion rate, use the minimum remaining thickness after repairs.

Assume a linear rate based on the age of the tanks. UPr = 0 for areas that have **effective cathodic protection.

inches 0.000 0.000 inches to= 0.313 inches

0.019 inches 0.009 inches

Rev.21505-2

Tank #: 5

7/13/2012 Uknown UPm = 0.019 inches Uknown UPa = 0.013 inches

2003 (Original 1961) UPcr = 0.0000 inches/year 9 years StPm = 0.000 inches

Yes StPa = 0.000 inches Yes StPcr = 0.0000 inches/year

0.313 inches GCr = 0.0000 inches/year

0.293 inches

0.0000 inches/year

0.156 inches

MRT = 0.050 inches RTbc = 0.293 inches

RTip = 0.313 inches >20 StPcr = 0.000000 inches/year Or = >20 Years * UPcr = 0.002167 inches/year

* Remaining life before repairs based on bottom plate number P27 and 0.293 inches controlling thickness

Repair Recommendation to Correct Problem:

MRT = RTbc = RTip = StPr =

NA Yes 0.10000 0.29300 0.31250 0.00000 NA Yes 0.10000 0.29300 0.31250 0.00000 NA Yes 0.10000 0.29300 0.31250 0.00000 NA Yes 0.10000 0.29300 0.31250 0.00000 NA Yes

Condition After Repairs (No bottom repairs) MRT = 0.100 inches

RTbc = 0.293 inches RTip = 0.313 inches StPr = 0.000000 inches/year Or = >20 Years *

UPr = 0.002167 inches/year

* Remaining life before repairs based on bottom plate number P27 and 0.293 inches controlling thickness

Bottom Plate Evaluation (Continued):

Owner/Operator: Seymour Johnson AFB; Goldsboro, NC

Bottom plate Material: B

TM

Side

Last inspection Date:

Manufactured Date:

Inspection Date :

In-service Years: Top Side

Internal Lining:

Cathodic Protection:

Replace Bottom:

To :

TL :

GCr = Tmin (CZ) =

Condition Before Repairs (Minimum of RTbc or RTip) - MRT

(StPr + UPr)

Add **Cathodic Protection (CP):

*Apply Coating:

Or =

Patch Plate:

Weld Top Side Pits > 0.1218 inches:

Or = (Minimum of RTbc or RTip) - MRT

(StPr + UPr)

Rev.21505-3

Year Thickness MRT Tmin (CZ) 2003 0.313 0.050 0.156 2012 0.293 0.050 0.156 2017* 0.282 0.050 0.156 2022* 0.271 0.050 0.156 2032* 0.250 0.050 0.156

*based on same service and corrosion rate

Anticpated Thickness (10 yrs):

Anticpated Thickness (20 yrs):

Bottom Plate Evaluation (Continued):

Thickness Projection Chart and Graph

Nominal:

Min Measured:

Anticpated Thickness (5 yrs):

0.313 0.293

0.282 0.271

0.250

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

2003 2012 2017* 2022* 2032* in ch es

Thickness Projected

Thickness

MRT

Tmin (CZ)

*based on same service and corrosion rate

Shell Life Evaluation

To determine the remaining shell service life and maximum inspection intervals, calculate the corrosion rate and remaining corrosion allowance for each shell course using the following:

API-653 4.3.3.1a API-653 4.3.3.1b

Where:

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

The nominal shell thickness, in inches.

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

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

The nominal diameter of the tank, in feet.

The height from the bottom of each shell course to the maximum liquid level, in feet.

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

The highest specific gravity of the contents.

Specified minimum yield strength of the plate; use 30,000 pounds per square inch if not known

(N/A for riveted tanks).

The smaller of the specified minimum tensile strength of the plate or 80,000 pounds per square inch;

use 55,000 psi if not known (N/A for riveted tanks).

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

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

The shell corrosion rate, in inches per year.

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

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

The years between the previous measured shell thickness ( ) and the current measured shell thickness ( ), in years.

Plate Specification: Unknown T 55,000 Material: Y 30,000 Manufactured Date: 1961 23595 Tank Specification Unit 25960 D 60.00 feet 0.80Y 0.429T HTank 39.00 feet Smaller of 24,000 23,595 HProduct 33.83 feet the two: 0.88Y 0.472T G 0.82 N/A 26,400 25,960 E 0.85 N/A ΔY 51 years

Course No.

Course Height (feet )

Product Height

Ft (feet )

Maximum Allowable

Stress (psi) (S )

Joint Efficiency

(E )

2Original Measured Thickness (inches) (t prev )

Current Measured Thickness (inches)

(t act )

3Minimum Acceptable Thickness (inches) (t min )

Corrosion Rate

(in./yr) (Cr )

1Remaining Life (ca.)

(years )

Next VT Inspection

(years) (Iv )

Next UT Inspection

(years) (Iut )

Max Fill Height

Ft (feet )

1 7.083 33.830 23,595 0.85 0.406 0.393 0.209 0.00026 >30 5 15…