SMJ-FY15-FAC 10104-Bulk Tank 1-FINAL.pdf

TANK 10104 (Bulk Tank 1)

API 653 IN-SERVICE INSPECTION REPORT

Seymour Johnson AFB - Goldsboro, NC

A/E Contract No. W9128F-12-D-0006; Delivery Order No. 0006

Submitted to:

U.S. Army Corps of Engineers Omaha District

1616 Capital Avenue; Omaha, NE 68102

1 April 2015

Submitted by:

1011 Boulder Springs Drive, Suite 200; Richmond, Virginia 23225 Phone: 804.592.3900 Fax: 804.592.3901 www.brockenbrough.com Job No. 14-101.13

Austin Brockenbrough & Associates, LLP | Est. 1955

1011 Boulder Springs Drive, Suite 200 | Richmond, Virginia 23225 | 804.592.3900 main | 804.592.3901 fax www.brockenbrough.com

Adam Ashton

U.S. Army Corps of Engineers

Omaha District

1616 Capital Avenue

Omaha, Nebraska, 68102

Re: Inspection Report - Tank 10104 (Bulk Tank 1), Seymour Johnson AFB, North Carolina

USACE Omaha Contract No. W9128F-12-D-0006, D.O. 0006

Brockenbrough Job No. 14-101.13 - API 653 In-service Tank Inspections

Various CONUS Locations

Dear Mr. Ashton:

On February 23, 2015, personnel from Austin Brockenbrough & Associates, LLP

(Brockenbrough) performed an API 653 In-service (visual external) Inspection of Tank 10104

(Bulk Tank 1) located at Seymour Johnson Air Force Base located in Goldsboro, North Carolina.

The In-service Inspection of the nominal 9,000 bbl, 42-foot and 5-inch diameter by 38-foot and

10-inch tall, F-24/JAA, aboveground vertical storage tank was performed in accordance with

API Standard 653, “Tank Inspection, Repair, Alteration, and Reconstruction,” and the referenced contract. The confined space between the internal floating roof and the geodesic dome roof was not entered during the inspection. All observations made during this in-service

(visual external) inspection were made from the exterior of the tank.

The tank’s original data plate was missing. However, a repair data plate indicates the tank was built in 1955 and repaired in 2003. The tank has a second bottom installed, which appears to be protected by an impressed current cathodic protection system. An Out-of-Service Inspection report indicates the tank was internal and external inspected in June 2011. An access door located in the tank’s geodesic aluminum dome roof is accessible by a circumferential stairway mounted on the shell of the tank. As-built drawings of the original construction are not available at this time.

Fuel is generally received into the tank through the facility’s filter/separators from commercial pipeline and is issued from the tank through the facility’s filter/separators to truck fillstands and to the hydrant system operating tanks. If necessary, the facility may also issue fuel from the tank directly to the hydrant system.

A list of the tank’s general construction features is included on page 2.

Tank 10104 (Bulk Tank 1) General Construction Data

Item Description

Owner U.S. Air Force

Tank Identification Tank 10104 (Bulk Tank 1)

Location Seymour Johnson AFB, Goldsboro, North Carolina.

Manufacturer Chicago Bridge and Iron/Horton Tank (assumed).

Design Standard API Standard 12C, 12 th

Edition (assumed).

Year Built 1955

Current Product Stored F-24/JAA jet fuel, specific gravity: 0.78 to 0.84, true vapor pressure: 0.04 psia at 100F, flash point: 100-140F, viscosity:

1.6 x 10 -5 ft /s at 100F, Class II combustible liquid.

Dimensions 42’-6” diameter x 38’-10” shell (straight side) height.

Storage Capacity Nominal capacity = 9,000 bbl.

Cleaning, Inspection, or

Repair

Cleaned and inspected in June 2011. Minor repairs followed the

2011 inspection.

Foundation Second bottom installed by the shell slotting method. Original tank bottom below grade.

RPB/Leak Detection Leak detection tell-tale piping suggests a liner (RPB) under the tank bottom.

Bottom Construction Lap welded cone-down, per 2011 inspection report.

Shell Construction (5) butt-welded shell courses, carbon steel plate; wind girder.

Fixed Roof Construction Aluminum geodesic dome.

Stairs/Ladders Circumferential stair; aluminum interior vertical ladder.

Manholes (1) 36” x 20” and (1) 36” shell manhole.

Cathodic Protection Impressed current system.

Interior Coating System 100% of interior. Epoxy-epoxy-epoxy assumed.

Exterior Coating System Epoxy-Epoxy-Polyurethane assumed. Exterior coating spot repaired after the 2011 inspection report.

Level Gauging Shand & Jurs tape level gauge. Enraf ATG.

Overfill Protection/Level

Alarms

Shell mounted high, high-high, low, and low-low level alarms.

Hydraulic operated level control valve.

Piping 8” receipt, 8” issue, 2” low suction; 3” water draw-off.

Venting/Vapor Emission

Controls

Aluminum honeycomb floating pan with double wiper squeegee perimeter seal; center and perimeter vented geodesic dome roof.

Strapping Tables Strapping tables are available.

Water Draw-Off/Product

Recovery System

Product saver tank piped to 3” shell nozzle.

Secondary Containment Gravel covered FML over concrete covered earthen berms.

Fire Protection System (2) fire hydrants within 300 feet.

The results of the inspection are included with the Tank In-Service Inspection Checklist starting on page 5. A checkmark beside an item indicates it was examined and no deficiency was noted.

An “X” beside a checklist item indicates a deficiency and a comment/note is made. During this evaluation, the tank was found to be in a generally good and acceptable condition. However, there were several anomalies or deficiencies noted on the checklist. The irregularities and recommendations for addressing them are noted below in no particular order:

1. As shown in the cover photograph, and Photographs #1 and #2 on page 12, water does not drain away from the tank. The dike area liner and gravel ballast appear to be floating, and water was observed springing up and out of the holes in the liner near the tank. As also shown in Photograph #1, numerous repairs have been made to the liner, and water pools at the invert of the secondary containment drain due to the level of the gravel at the drain being lower than the drain invert. Also, vegetation is growing out of the gravel ballast. Holes were found in the liner as shown in Photograph #3. The seal at the FML attachment to the stairs has failed; and as shown on Photograph #5 on page 14, plants are growing out of the seal.

NFPA 30 and military criteria requires the secondary containment to be impervious and to be sloped so as to drain liquids away from the tank and the piping. The liner and the grade of the secondary containment does not meet current military criteria or NFPA 30. The following action should be performed to correct these deficiencies:

Provide an exposed secondary containment liner per DoD Standard Design AW 78-24-27 and UFGS specification 33 56 63 “Fuel Impermeable Liner System”. The design of the new secondary containment should include verification of the capacity of the secondary containment to meet NFPA and military criteria and should ensure the secondary containment drain pipe adequately drains the secondary containment.

Estimated construction cost, based on providing an exposed liner, is $200,000.

2. As shown in Photograph #4 on page 13, there is isolated coating failure and corrosion on the tank bottom extension and shell-to-bottom weld at several locations. The following action should be taken to correct the deficiency:

Spot repair the coatings on the tank bottom extension and shell-to-bottom weld.

Estimated construction cost is $5,000.

3. There is coating failure and corrosion on top of the stairway platform frame under the grating. The following action should be taken to correct the deficiency:

Spot repair the coatings on the stairway platform frame under the grating.

Estimated construction cost is $5,000.

4. As shown in Photograph #6 on page 14, the 2-inch low suction valve does not have a lock.

NFPA 30 and federal regulations require that the valve have a lock. The following action should be taken to correct the deficiency:

Provide a lock on the low suction valve. Repair may be performed by facility personnel.

Estimated construction cost is $00.

5. The rise of the circumferential stairway measures approximately 8 and 1/2 inches. However, the distance from secondary containment basin walking surface to the lowest circumferential stairway step measures 13 inches. OSHA requires a consistent rise and run from the lower walking surface to the top of the stairs. The following actions should be taken to correct the deficiency:

Provide a landing at the bottom of the stairs approximately 8 1/2 inches below the lowest circumferential stairway step.

Estimated construction cost is $5,000.

6. There is no water draw-off shell nozzle or water draw-off internal piping. The product saver tank is connected to the 3-inch low suction piping. Water draw-off piping for this size tank is normally 3/4-inch or smaller. As the volume of fluid in the 3-inch suction piping is more than half the normal operating capacity of the product saver tank, the internal piping is lower near the center of the tank, and as water is heavier than the fuel, the ability of the product saver tank to remove water from the storage tank is greatly reduced. However, facility personnel report their filter/separator have never stripped much water out of the fuel when issuing. Therefore, there is likely not much water that the product saver could remove at this time. The following actions could be taken to correct these deficiencies:

Keep a record of how much water is removed from the filter separators and from the product saver tank, and report the results to the inspector the next time the tank is inspected. Based on a review of those records by the inspector, modifications to the water draw off system may be required the next time the tank is taken out of service for inspection and repair.

Estimated construction cost is $00.

All repairs and modifications should be performed in accordance with API 653, UFC 3-460-01, DoD Standard Design 78-24-27, and applicable UFGS specifications.

The estimated construction costs noted above are based upon all of the work being performed under a single construction contract. The costs do not include any special conditions or prime contractor markup that might be applicable, but they do include the cost of any coating repairs that would be required due to the contractor’s work. The estimated total cost for all the recommended repairs is approximately $215,000.

TANK INSPECTION, REPAIR, ALTERATION, AND RECONSTRUCTION

Tank In-service Inspection Checklist

Item Completed Comments

C.1.1 Foundation

Measure foundation levelness and bottom elevations (see API 653 Annex B for extent of measurements). See notes.

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.

NA

b)

Inspect drain openings in ring, back of water-draw basins and top surface of ring for indications of bottom leakage.

NA

c) Inspect for cavities under foundation and vegetation against bottom of tank. NA

d) Check that runoff rainwater from the shell drains away from tank. NA

e) Check for settlement around perimeter of tank. NA

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.

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

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. NA

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.

NA

C.1.1.5 Site Drainage

a) Check site for drainage away from the tank and associated piping and manifolds. X See notes.

b) Check operating condition of the dike drains. X See notes.

C.1.1.6 Housekeeping

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

C.1.1.7 Cathodic Protection

Review cathodic protection potential readings. 21V, 0.2A

C.1.2 Shells

C.1.2.1 External Visual Inspection

a) Visually inspect for paint failures, pitting, and corrosion. X See notes.

b) Clean off bottom angle area and inspect for corrosion and thinning on plate and weld.

X See notes.

c) Inspect the bottom-to-foundation seal, if any. NA

C.1.2.2 Internal (Floating Roof Tank)

Visually inspect for grooving, corrosion, pitting, and coating failures No access.

C.1.2.3 Riveted Shell Inspection

a) Inspect external surface for rivet and seam leaks. NA

b) Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for painting). NA

c) Inspect rivets for corrosion loss and wear. NA

d) Inspect vertical seams to see if they have been full fillet lap-welded to increase joint efficiency. NA

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.

Tank In-service Inspection Checklist (Continued)

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.

b) Check support welds to shell for pitting, especially on shell plates.

c) Note whether supports have reinforcing pads welded to shell. None.

C.1.3 Shell Appurtenances

C.1.3.1 Manholes and Nozzles

a) Inspect for cracks or signs of leakage on weld joint at nozzles, manholes, and reinforcing plates.

b) Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection.

c) Inspect for flange leaks and leaks around bolting.

d) Inspect sealing of insulation around manholes and nozzles. NA

e) Check for inadequate manhole flange and cover thickness on mixer manholes. NA

C.1.3.2 Tank Piping Manifolds

a) Inspect manifold piping, flanges, and valves for leaks.

b) Inspect firefighting system components. NA

c) Check for anchored piping which would be hazardous to the tank shell or bottom connections during earth movement.

d) Check for adequate thermal pressure relief of piping to the tank.

e) Check operation of regulators for tanks with purge gas systems. NA

f) Check sample connections for leaks and for proper valve operation. NA

g) Check for damage and test the accuracy of temperature indicators. NA

h) Check welds on shell-mounted davit clips above valves 6 inches and larger. NA

C.1.3.3 Autogauge System

a) Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. NA b)

Inspect autogauge head for damage.

c)

Bump the checker on autogauge head for proper movement of tape.

d) Identify size and construction material of autogauge tape guide (floating roof tanks). No access.

e)

Ask operator if tape tends to hang up during tank roof movement (floating roof tanks).

f)

Compare actual product level to the reading on the autogauge (maximum variation is 2 in.). See notes.

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. NA

h) Inspect condition of board and legibility of board-type autogauges. NA

i) Test freedom of movement of marker and float. NA

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. NA

b) Check circulation pump for leaks and operating problems. NA

c) Test bracing and supports for sample tines and equipment. NA

C.1.3.5 Heater (Shell Manhole Mounted) NA

Inspect condensate drain for presence of oil indicating leakage. NA

Tank In-service Inspection Checklist (Continued)

Item Completed Comments

C.1.3.6 Mixer

a) Inspect for proper mounting flange and support. NA

b) Inspect for leakage. NA

c) Inspect condition of power lines and connections to mixer. NA

C.1.3.7 Swing Lines: Winch Operation

a) Nonfloating. Raise, then lower the swing line with the winch, and check for cable lightness to confirm that swing line lowered properly.

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

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.

NA

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints NA

C.1.3.9 Swing Lines: Identify Ballast Varying Need

Check for significant difference in stock specific gravity. NA

C.1.3.10 Swing Lines: Cable Material and Condition

a) For nonstainless steel cable, check for corrosion over entire length. NA

b) All cable: check for wear or fraying. NA

C.1.3.11 Swing Lines: Product Sample Comparison

Check for water or gravity differences that would indicate a leaking swing joint. NA

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.

NA

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

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

NA

Aluminum geodesic dome.

C.1.4.2 Deck Plate External Corrosion

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

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.)

No access.

C.1.4.4 Level of Floating Roof

At several locations, measure distance (inches) from roof rim to a horizontal weld seam above the roof or fixed roof inspection hatch opening. A variance in the readings indicates a non-level roof with possible shell out-of-round, out-of-plumb, leaking pontoons, or hang-up. On small diameter tanks, an un-level condition can indicate unequal loading at that level.

C.1.4.5 Gas Test Internal Floating Roof

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

0.0 ppm on IFR

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.

b) Inspect for wet insulation under the weather coat. NA

c) Remove small test sections of insulation and check roof plate for corrosion and holes near the edge of the insulated area.

Tank In-service Inspection Checklist (Continued)

C.1.4.7 Floating Roof Seal Systems

a) Inspect the condition of the seal, measure and record maximum rim spaces and seal-to-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).

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.

1) ______ Opposite pair 1.

2) ______ Opposite pair 2.

c) Check if seal fabric on primary shoe seals is pulling shoes away from shell (fabric not wide enough).

No access.

d) Inspect fabric for deterioration, holes, tears, and cracks. No access.

e) Inspect visible metallic parts for corrosion and wear No access.

f) Inspect for openings in seals that would permit vapor emissions. No access.

g) Inspect for protruding bolt or rivet heads against the shell. No access.

h) Pull both primary and secondary seal systems back all around the shell to check their operation.

i) Inspect secondary seals for signs of buckling or indications that their angle with the shell is too shallow.

No access.

j) Inspect wedge-type wiper seals for flexibility, resilience, cracks, and tears. No access.

C.1.5 Roof Appurtenances

C.1.5.1 Sample Hatch

a) Inspect condition and functioning of sample hatch cover.

b) On tanks governed by Air Quality Monitoring District rules, check for the condition of seal inside hatch cover.

c) Check for corrosion and plugging on thief and gauge hatch cover.

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. NA

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

g) Test operation of system. NA

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). Aluminum

C.1.5.2 Gauge Well

a) Inspect visible portion of the gauge well for thinning, size of slots, and cover condition. See notes.

b) Check for a hold-off distance marker and tab with a hold-off distance (legible).

c) On floating roofs, inspect condition of roof guide for gauge well, particularly the condition of the rollers for grooving.

d) If accessible, check the distance from the gauge well pipe to the tank shell at different levels.

e) If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or blind flange.

No access.

C.1.5.3 Fixed Roof Scaffold Support

Inspect scaffold support for corrosion, wear and structural soundess. No access.

C.1.5.4 Autogauge: Inspection Hatch and guides (Fixed Roof)

a) Check the hatch for corrosion and missing bolts. No access.

b) Look for corrosion on the tape guide's and float guide's wire anchors. No access.

Tank In-service Inspection Checklist (Continued)

C.1.5.5 Autogauge: Float Well Cover

a) Inspect for corrosion. No access.

b) Check tape cable for wear or fraying caused by rubbing on the cover. No access.

C.1.5.6 Sample Hatch (Internal Floating Roof)

a) Check overall conditions.

b) When equipped with a fabric seal, check for automatic sealing after sampling. NA

c) When equipped with a recoil reel opening device, check for proper operations. NA

C.1.5.7 Roof-Mounted Vents (Internal Floating Roof)

Check condition of screens, locking and pivot pins.

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 10 and that fabric seal Is above the liquid level.

NA

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. NA

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.

No access.

C.1.5.12 Rim Vents

a) Check condition of the screen on the rim vent cover. No access.

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

No access.

C.1.5.13 Pontoon Inspection Hatches

a) Open pontoon inspection hatch covers and visually check inside for leakage. NA

b) Test for explosive gas (an indicator of vapor space leaks). NA

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.

NA

C.1.6 Accessways (See Tank Out-of-service Inspection Checklist, Item C.2.12.)

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.

1 1/2” coated CS pipe.

b) Inspect for pitting and holes, paint failure.

c) Inspect attachment welds.

d) Identify cold joints and sharp edges. Inspect the handrails and mid-rails.

e) Inspect safety drop bar (or safety chain) for corrosion, functioning, and length. NA

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.

NA

C.2.12.2 Platform Frame

a) Inspect frame for corrosion and paint failure.

b) Inspect the attachment of frame to supports and supports to tank for corrosion and weld failure.

Tank In-service Inspection Checklist (Continued)

Item Completed Comments

c) Check reinforcing pads where supports are attached to shell or roof.

d) Inspect the surface that deck plate or grating rests on, for thinning and holes. X See notes.

e) Check that flat surface–to-flat surface junctures are seal-welded.

C.2.12.3 Deck Plate and Grating

a) Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure

b) Inspect plate-to-frame weld for rust scale buildup.

c) Inspect grating for corrosion-caused thinning of bars and failure of welds.

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.

C.2.12.4 Stairway Stringers

a) Inspect spiral stairway stringers for corrosion, paint failure, and weld failure.

b) Inspect stairway supports to shell welds and reinforcing pads.

c) Inspect steel support attachment to concrete base for corrosion. NA

C.2.12.5 Rolling Ladder

a) Inspect rolling ladder stringers for corrosion. NA

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.

NA

c) Check for wear and corrosion where rolling ladder attaches to gauging platform. NA

d) Inspect pivot bar for wear and that it is secure. NA

e) Inspect operation of self-leveling stairway treads. NA

f) Inspect for corrosion and wear on moving parts. NA

g) Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle. NA

h) Inspect alignment of rolling ladder with roof rack. NA

i) Inspect top surface of rolling ladder track for wear by wheels to assure at least 18 in. of unworn track (track long enough).

NA

j) Inspect rolling ladder track welds for corrosion. NA

k) Inspect track supports on roof for reinforcing pads seal-welded to deck plate. NA

l) Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low legs.

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:

C.1.1: As the tank had a second tank bottom installed by the shell slotting method, the shell settlement was evaluated by measuring the distance from the lowest horizontal shell butt-welded seam to a horizontal level line at 8 equal distant locations starting at southwest and continuing counter-clockwise, with a 9th reading returning to the origin, were: 29 7/8””, 30 7/16”, 31 1/8”, 30 7/8”, 30 7/8”, 30 3/8”, 30 5/8”, 30 7/8”, 30 15/16”. The attached calculations, evaluating the settlement in accordance with API 653 B.2.2.5, indicate the settlement is acceptable.

C.1.1.5.a) Water does not drain away from tank.

C.1.1.5.b) Dike drain invert is above the lowest elevation of the gravel ballast.

C.1.1.6. Numerous small plants and grass growing out of gravel ballast in dike basin. Soil and vegetation around secondary containment drain area.

C.1.2.1.a) b) Isolated coating failure and corrosion on tank bottom extension several places.

C.1.5.2.a) Floating roof was near high level. Therefore, any slots in the well would not have been visible.

C.1.3.3.f) Tape 33’-7 13/16”. ATG reads 33’-7 7/16”.

C.2.12.2.d) Coating failure and corrosion on top of platform frame under grating.

ADDITIONAL NOTES:

Bottom Step 13”. Stairway rise 8 1/2”.

Holes in FML near tank and dike drain. Water under FML. Dike area floating. Water springing up and out of holes in FML at tank.

Seal failed at FML attachment to stairs. Plants growing out of seal.

No lock on 2” low suction ball valve.

Photograph #1 – Secondary Containment

The secondary containment is lower than the secondary containment drain pipe.

Photograph #2 – Dike Liner at Tank

Water does not drain away from the tank.

Photograph #3 –Secondary Containment Liner

There are holes in the secondary containment (dike) liner.

Photograph #4 – Tank Bottom Extension

There is isolated coating failure and corrosion on the tank bottom extension and exterior shell-to-bottom weld at several locations.

Photograph #5 – Liner Attachment to Dike Stairs

The dike liner to access stair seals have failed and plants are growing out of the seals.

Photograph #6 – Low Suction Nozzle

The low suction nozzle does not have a lock.

Austin Brockenbrough & Associates, L.L.P. Job No. 14-101.13

Job Title: Seymour Johnson AFB Date: 3/9/2015

Subject: Tank 10104 - Shell Settlement Evaluation By: Mike O'Connor

API 653 Appendix B

Optimum cosine curve, B 2.2.4.e) Z = a + b x cos(theta + c)

Diameter (D) = 42.5 (ft)

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 16.69

Tank Height (H) = 38.8 (ft)

* Z U S

0 29.88 0.00 0.00 0.00 0.22

1 30.44 0.56 0.00 -0.56 -1.19

2 31.13 1.25 0.00 -1.25 -1.47

3 30.88 1.00 0.00 -1.00 -0.88

4 30.88 1.00 0.00 -1.00 -0.75

5 30.38 0.50 0.00 -0.50 -0.38

6 30.63 0.75 0.00 -0.75 -1.00

7 30.88 1.00 0.00 -1.00 -1.16

8 30.94 1.06 0.00 -1.06 -0.84

Maximum out-of -plane deflection = -1.47

* = measured elevation

Z = calculated ridged body tilt (in)

U = out-of-plane settlement =

S = out-of-plane deflection z-y

Y = yield sterength of shell material (PSI) = 30,000

E = Youngs modulas of elasticity (lbf/in2) = 29*10^6

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH)*12 = 0.49 in

Evaluation by the Arc Length Method is required.

R^2 = (Syy - SSE) / Syy = -4.8 not >=0.9 therefore cosine curve is invalid.

Austin Brockenbrough & Associates, L.L.P. Job No. 14-101.13

Job Title: Seymour Johnson AFB Date: 3/9/2015

Subject: Tank 10104 - Shell Settlement Evaluation By: Mike O'Connor

API 653 B.2.2.5 Evaluation by Settlement Arc Length Method

Per B.3.2.2, K = 10.5

Settlement arc length (ft), Sarc

Out of plate settlement at Point i (Si)

Allowable settlement at point i (Smax) = MIN[K*Sarc*(D/H)*(Y/E), 4]

Point Sarc (ft) Si (in) Smax

1 33.2 0.1 0.39 OK

3 33.2 0.1 0.39 OK

5 66.4 0.5 0.79 OK

Evaluation of the settlement by the arc length method indicates the settlement is acceptable.

0.00

0.50

1.00

1.50

0 2 4 6 8 10

Measured Elevation (in) S5

S1

S3