SMJ-FY15-FAC 10208-Bulk Tank 3-FINAL.pdf

TANK 10208 (Bulk Tank 3)

API 653 IN-SERVICE INSPECTION REPORT

Seymour Johnson AFB, North Carolina

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

8 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 10208 (Bulk Tank 3), Seymour Johnson AFB, NC

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 24th and 25th, 2015, personnel from Austin Brockenbrough & Associates, LLP

(Brockenbrough) performed an API 653 In-service (visual external) Inspection of Tank 10208

(AKA Bulk Tank 3) located at Seymour Johnson Air Force Base, North Carolina. The In-service

Inspection of the nominal 17,658 bbl, 60 feet in diameter by 38 feet and 11 inches tall, F-24 (Jet-

AA), 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 fixed 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 data plates indicate the tank was built in 1955 and reconstructed in 2003. Leak detection is provided by leak detection ports located below the double bottom and through the tank’s shell. The underside of the tank bottom is protected by an impressed current cathodic protection system. The tank’s aluminum geodesic dome roof access door is accessible by a circumferential stairway mounted on the shell of the tank. As-built drawings of the original construction were not available at the time of the inspection. Facility records indicate the tank was cleaned and underwent an out-of-service inspection in October 2009. Repairs were completed in March 2010.

Jet-AA fuel is received into the 17,658 bbl tank from a pipeline through the facility’s filter/separators and is issued from the tanks through filters/separators to a truck fillstand and a hydrant system.

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

Tank 10208 (Bulk Tank 3) General Construction Data

Item Description

Owner U.S. Air Force

Tank Identification 10208 (Bulk Tank 3)

Location Seymour Johnson AFB, Goldsboro, North Carolina

Manufacturer Original - Horton Tank (Chicago Bridge & Iron); Reconstructed -

Superior Industrial Maintenance Company, Inc.

Design Standard Original - API Standard 12C (Assumed); Reconstructed - API 653

Year Built Original - 1955; Reconstructed - 2003

Current Product Stored Jet-AA (F-24) jet fuel, specific gravity: 0.775 to 0.840, true vapor pressure: 0.04 psia at 100F, flash point: 100-150F, viscosity: 1.6 x

10-5 ft2/s at 100F, Class II combustible liquid.

Dimensions 60’-0” diameter x 38’-11” shell (straight side) height.

Storage Capacity Original nominal capacity = 20,000 bbl.

Reconstructed nominal capacity = 17,658 bbl.

Cleaning, Inspection, or

Repair

Cleaned and Out-of-service Inspected – October 2009.

Repairs completed – March 2010.

Foundation Concrete ringwall below grade.

RPB/Leak Detection (5) Leak detection ports suggest a RPB.

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

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

Fixed Roof Construction Aluminum geodesic dome.

Stairs/Ladders Circumferential stairway; aluminum interior vertical ladder.

Manholes (1) 36” diameter and (1) 36”x20” shell manholes.

Cathodic Protection Impressed current system.

Interior Coating System Interior coated. Type unknown.

Exterior Coating System Exterior coated. Type unknown.

Level Gauging Shand & Jurs tape level gauge and Enraf ATG

Overfill Protection/Level

Alarms

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

hydraulic operated level control valve.

Piping 2” low suction, 8” receipt, 10” issue, 3” water draw-off.

Venting/Vapor Emission

Controls

Internal floating roof with perimeter seal, center and perimeter vented geodesic dome roof, (4) shell mounted overflow-vents.

Strapping Tables Strapping tables are available.

Water Draw-Off/Product

Recover System

Product saver tank.

Secondary Containment FML covered with gravel and FML over concrete covered earthen berms.

Fire Protection System Several fire hydrants in vicinity.

The results of the inspection are included with the Tank In-Service Inspection Checklist starting on page 6. 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. There were several anomalies or deficiencies noted, most of which are included on the checklist. These deficiencies, and recommendations for addressing them, are noted below in no particular order:

1. The FML covering the dike area and concrete covered earthen berms is itself covered with gravel ballast. At the time of inspection, the dike area had collected water from a storm. The drains were operational and open, but water had still accumulated around the tank and piping contrary to NFPA requirements. The dike area grading was not allowing the water to drain from the dike. Upon return the day after inspection, temperatures had caused the standing water to freeze as shown in the photograph on the cover this report. There is also some grass and vegetation growth in the gravel ballast throughout the dike area. See Photograph #1 on page 13. Continued growth of vegetation could potentially lead to liner issues as well as continued drainage problems. The dike area liner has holes in the visible portion around the perimeter of the containment. There are many areas that appear to have previous repairs.

The seals around the concrete dike access stairs has also failed. Some areas throughout the containment appear to be floating due to water under the liner. It is assumed that water is entering either through a failure of the liner under the gravel ballast or through the liner to concrete seal around the tank. See Photographs #2 and #3 starting on page 13. The following actions should be performed to correct this deficiency:

The gravel covered secondary containment liner system should be replaced with an exposed secondary containment liner per UFGS specification 33 56 63 “Fuel Impermeable Liner

System”. The design of the new secondary containment should include a sump, drainage away from the tank and the piping, and verification of the capacity of the secondary containment to meet NFPA and military criteria.

Estimated construction cost is $200,000.

2. There is some coating failure and corrosion on the shell plate, the manhole covers, and the manhole cover support frame. There is dirt build-up on the tank bottom exterior extension around the entire perimeter. This build-up could provide a place for corrosion to take place.

The following actions should be taken to correct these deficiencies:

a.) Remove dirt build-up from around the tank bottom extension.

b.) Spot repair the coating on the shell plate, the manhole covers, and the manhole cover support frame.

Estimated construction cost is $5,000.

3. Algae is growing on the topside of the wind girder with isolated coating failures and corrosion, presumably around the entire perimeter. See Photograph #4 on page 14. The following actions should be taken to correct the deficiencies:

a.) Power wash the wind girder.

b.) Provide spot repairs on the wind girder coating.

Estimated construction cost is $10,000.

4. The thermal relief valves and water draw-off, and their associated piping, are threaded. UFC

3-460-01 states to “use threaded connections only where unavoidable…” The thermal relief piping also does not have testing tees as required by the UFC. Threaded connections provide a location for fuel to leak from the system. The following action should be taken to correct this deficiency:

a.) Monitoring of the threaded water draw-off piping and valves for leaks should be added to the periodic maintenance checklists.

b.) Provide welded or flanged connections and testing tees on the thermal relief piping at the next out-of-service inspection.

Estimated construction cost is $15,000.

5. There is some coating failure and corrosion on the tank circumferential stairs, platforms/gratings, handrails, and supports. The tie down clip bolts on the platform also display some corrosion. Photographs #4 to #6 starting on page 14 show some of these areas.

The following actions should be taken to correct these deficiencies:

Remove the corrosion, spot repair the stairway, platforms/gratings, handrails, and supports coating failures, and replace corroded tie down clip bolts.

Estimated construction cost is $5,000.

6. The rise of the circumferential stairway measures approximately 8 3/4" to 9”. However, the distance from the concrete walk around the tank to the top of the lowest stair tread measures approximately 4 1/2" at the tank and 6” at the end of the tread. OSHA requires a consistent rise and run over the entire stairway. The following action should be taken to correct the deficiency:

Install landing at same level as bottom tread.

Estimated construction cost is $5,000.

7. Some of the cut-out openings created for the installation of the perimeter roof vent screens under the geodesic dome are too large. See Photograph #7 on page 16. It is feasible for birds to enter into the tank through some of these openings, possibly contaminating the system.

The following action should be taken to correct this deficiency:

Provide new vent screens around the perimeter of the geodesic dome roof.

Estimated construction cost is $10,000.

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 total estimated cost for all the recommended repairs is $250,000.

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 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.

N/A b)

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

N/A

c) Inspect for cavities under foundation and vegetation against bottom of tank. N/A

d) Check that runoff rainwater from the shell drains away from tank. N/A

e) Check for settlement around perimeter of tank. N/A

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. N/A

C.1.1.4 Rock

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

N/A

C.1.1.5 Site Drainage

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

b) Check operating condition of the dike drains.

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. 24.8V, 0.1A

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.

c) Inspect the bottom-to-foundation seal, if any. N/A

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. N/A

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

c) Inspect rivets for corrosion loss and wear. N/A

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

Tank In-service Inspection Checklist (Continued)

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.

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.

X See notes.

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

c) Note whether supports have reinforcing pads welded to shell. N/A

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. N/A

e) Check for inadequate manhole flange and cover thickness on mixer manholes. N/A

C.1.3.2 Tank Piping Manifolds

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

b) Inspect firefighting system components. N/A

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. X See notes.

e) Check operation of regulators for tanks with purge gas systems. N/A

f) Check sample connections for leaks and for proper valve operation. N/A

g) Check for damage and test the accuracy of temperature indicators. N/A

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

C.1.3.3 Autogauge System

a) Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks. N/A

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. N/A

h) Inspect condition of board and legibility of board-type autogauges. N/A

i) Test freedom of movement of marker and float. N/A

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. N/A

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

c) Test bracing and supports for sample tines and equipment. N/A

C.1.3.5 Heater (Shell Manhole Mounted)

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

Tank In-service Inspection Checklist (Continued)

Item Completed Comments

C.1.3.6 Mixer

a) Inspect for proper mounting flange and support. N/A

b) Inspect for leakage. N/A

c) Inspect condition of power lines and connections to mixer. N/A

C.1.3.7 Swing Lines: Winch Operation

a) Nonfloating. Raise, then lower the swing line with the winch, and check for cable 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.

N/A

C.1.3.8 Swing Lines: External Guide System

Check for leaks at threaded and flanged joints N/A

C.1.3.9 Swing Lines: Identify Ballast Varying Need

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

C.1.3.10 Swing Lines: Cable Material and Condition

a) For nonstainless steel cable, check for corrosion over entire length. N/A

b) All cable: check for wear or fraying. N/A

C.1.3.11 Swing Lines: Product Sample Comparison

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

C.1.3.12 Swing Lines: Target

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

N/A

C.1.4 Roofs

C.1.4.1 Deck Plate Internal Corrosion

For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning.

(Corrosion normally attacks the deck plate at the edge of a fixed roof and at the rafters in the center of the roof first.)

No access

C.1.4.2 Deck Plate External Corrosion

Visually inspect for paint failure, holes, pitting, and corrosion product on roof deck. N/A

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.)

C.1.4.4 Level of Floating Roof

At several locations, measure distance (inches) from roof rim to the horizontal weld seam above the roof. 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.

No access

C.1.4.5 Gas Test Internal Floating Roof

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

0.0 ppm on pan.

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. N/A

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. N/A

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

g) Test operation of system. N/A

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.

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. N/A

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

a) Check the hatch for corrosion and missing bolts. N/A

b) Look for corrosion on the tape guide's and float guide's wire anchors. N/A

Tank In-service Inspection Checklist (Continued)

Item Completed Comments

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. No access

b) When equipped with a fabric seal, check for automatic sealing after sampling. No access

c) When equipped with a recoil reel opening device, check for proper operations. No access

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

Check condition of screens, locking and pivot pins. X See notes.

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.

N/A

C.1.5.10 Removable Roof Leg Racks

Check for leg racks on roof. N/A

C.1.5.11 Vacuum Breakers

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

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. N/A

b) Test for explosive gas (an indicator of vapor space leaks). N/A

c) If pontoon hatches are equipped with locked down coves, check for vent tubes.

Check that vent tubes are not plugged up. Inspect lock-down devices for condition and operation.

N/A

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. See notes.

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. X See notes.

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

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.

N/A

C.2.12.2 Platform Frame

a) Inspect frame for corrosion and paint failure. X See notes.

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

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

Tank In-service Inspection Checklist (Continued)

Item Completed Comments

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

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 N/A

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

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.

X See notes.

C.2.12.4 Stairway Stringers

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

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

c) Inspect steel support attachment to concrete base for corrosion. N/A

C.2.12.5 Rolling Ladder

a) Inspect rolling ladder stringers for corrosion. N/A

b) Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment to stringers and corrosion, particularly where angle rungs are welded to stringers.

N/A

c) Check for wear and corrosion where rolling ladder attaches to gauging platform. N/A

d) Inspect pivot bar for wear and that it is secure. N/A

e) Inspect operation of self-leveling stairway treads. N/A

f) Inspect for corrosion and wear on moving parts. N/A

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

h) Inspect alignment of rolling ladder with roof rack. N/A

i) Inspect top surface of rolling ladder track for wear by wheels to assure at least 18

in. of unworn track (track long enough).

N/A

j) Inspect rolling ladder track welds for corrosion. N/A

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

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

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: The foundation measurements indicate the tank is relatively level and with no appreciable out of plane deflection. The distance measured from the horizontal weld between the first and second shell courses to a horizontal level line at 8 equal distant locations were: 19 13/16” (origin), 19 3/8”, 19 3/4”, 20 3/4", 21 11/16”, 21 9/16”, 20 13/16”, 19 15/16" (low point), 19 7/8” (origin). Calculations evaluating the shell settlement are attached.

C.1.1.5.a) Water does not drain away from tank. There is a lot of standing water in dike area.

C.1.1.6 Grass/vegetation growing in gravel ballast dike area.

C.1.2.1.a) Isolated general coating failure and external corrosion on shell and manhole covers.

C.1.2.4.a) Isolated coating failure and corrosion on wind girder. Algae growth on the topside of the wind girder around the entire perimeter of the tank.

C.1.3.2.d) Thermal relief piping and connections are threaded. There are no testing tees.

C.1.3.3.f) Tape Gauge: 21’-1 1/2"; ATG: 21’-0 3/16” C.1.5.7 Around the roof perimeter vent under the overhang of the geodesic dome, some of the cut-out openings are too large.

C.2.12.1.a) Handrail on stairway is 1 1/2" diameter and 2”x2” angle on the platform.

C.2.12.1.d) Minor isolated surface rust/coating failure at post to stair tread weld.

C.2.12.2.a) Minor isolated surface rust/coating failure at several locations on platform frame.

C.2.12.3.d) Clip bolts at the tie down clips for the platform grating display minor corrosion.

C.2.12.4.a) Coating failure and minor corrosion at bottom stair tread to shell weld.

ADDITIONAL NOTES:

Water draw-off pipe is threaded.

3” water draw-off nozzle is too large to be of any use to the water draw-off system.

Containment area liner has holes near the drain.

Sealant at concrete dike access stairs has failed.

Dike area does not drain water away from tank. Standing water in containment area.

Water is under the liner around tank.

Bottom circumferential stairway tread 6” above concrete at outer edge of tread and 4 1/2" above concrete near tank shell. The rise of the stairway tread measures 8 3/4" to 9”.

Photograph #1 – Dike Area Vegetation and Standing Water

Water does not drain properly and vegetation is growing in the gravel ballast.

Photograph #2 – Access Stair Seal

The seal has failed at the dike access stairs.

Photograph #3 – Containment Liner Failure

There are large holes in the liner at the containment drain.

Photograph #4 – Topside of Wind Girder

There is algae growth, coating failure, and corrosion on the wind girder.

Photograph #5 – Circumferential Stair Tread Corrosion

There is localized corrosion on the stairs.

Photograph #6 – Platform Framing

There is Coating failure and corrosion on the platform framing.

Photograph #7 – Perimeter Roof Vent

There are over sized cut-out openings in the roof perimeter vent screens.

G:\14 Jobs\14-101 API 653 In-Service Inspections\14-101.13 API 653 Inspections - Seymour Johnson AFB\General\Reports\Final Reports\Bulk Fuel Tank 10208 Final Report\Final Report Letter - Tank 10208 Seymour Johnson AFB.docx

While this In-Service (visual external) Inspection found no problems requiring immediate repair and the accessible areas of the tank appear suitable for continued use in its current service, there are some deficiencies that are contrary to API 650, NFPA 30, and/or OSHA. These deficiencies should be addressed in a timely manner.

The next API Standard 653 In-Service (visual external) Inspection should be performed by an

API 653 Inspector by February 2020. The inspection may be performed in conjunction with the next out-of-service inspection if performed before that date.

The Out-of-Service Inspection Report following the October 2009 inspection indicated the tank

“is in suitable condition for continued service”, and recommended an internal inspection be performed by October 2019.

Based on the information contained in the previous Out-of-service Inspection Report and military criteria, we recommend an Out-of Service (internal) Inspection be performed by October

2019. The Out-of-Service (internal) Inspection should include external visual inspection with shell UTMs, and an examination of the tank bottom by magnetic flux leakage (MFL or MFE) technology.

The Out-of-Service Inspection should include a thorough code compliance evaluation. The code compliance evaluation should include 29 CFR Part 1910.106, Occupational Safety and Health

Standards – Flammable and Combustible Liquids; 29 CFR Part 1910 Subpart D, Occupational

Safety and Health Standards – Walking-Working Surfaces; 40 CFR Part 112, Oil Pollution

Prevention; NFPA 30, Flammable and Combustible Liquids Code; and UFC 3-460-01, Design:

Petroleum Fuel Facilities.

Please contact us if you have any questions or need more information.

Sincerely, Austin Brockenbrough & Associates, LLP

Andrew Swenck, PE

Structural Engineer

API 653 Inspector No. 56234

Enclosure – Tank 10208 - Shell Settlement Evaluation

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

Job Title: Seymour Johnson AFB Date: 3/10/2015

Subject: Tank 10208 - Shell Settlement Evaluation By: Andrew Swenck

API 653 Appendix B

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

Dia (ft)= 60

Number of equally spaced data points (ft)= 8

L = Arc length between measurement points (ft) = 23.56

H = Tank Height in Feet = 38.91667

* Z U S

0 19.38 0.00 0.03 0.03 0.13

1 19.75 0.38 0.34 -0.04 0.09

2 20.75 1.38 1.09 -0.28 -0.03

3 21.69 2.31 1.84 -0.47 -0.31

4 21.56 2.19 2.15 -0.04 0.00

5 20.81 1.44 1.84 0.40 0.16

6 19.94 0.56 1.09 0.53 0.41

7 19.88 0.50 0.34 -0.16 -0.44

8 19.38 0.00 0.03 0.03 0.13

Maximum out-of -plane deflection = -0.44

* = measured elevation

Z = calculated ridged body tilt (in)

U = out-of-plane settlement = z-y

S = out-of-plane deflection

Y = yield sterength of shell material (PSI) = 36,000

E = Youngs modulas of elasticity (lbf/in2) = 2.90E+07

S allowable (in) (API 653 B.3.2.1) = (L^2*Y*11)/(2EH)*12 = 1.17 in

>= 0.9 therefore, the curve is valid.

Since the maximum out-of-plane defection (S) is less than the maximum allowable S, the tank shell settlement is within acceptable limits.

0.9R^2 = (Syy - SSE) / Syy =

0.00

0.50

1.00

1.50

2.00

2.50

0 2 4 6 8 10

Best Fit Cosine Curve

Measured Elevation (in)

G:\14 Jobs\14-101 API 653 In-Service Inspections\14-101.13 API 653 Inspections - Seymour Johnson AFB\General\Reports\Final Reports\Bulk Fuel Tank 10208 Final

Report\Tank 10208 Foundation level.xlsx