SMJ-FY17-FAC 10242-Tank 2-FINAL.pdf

(USACE POL‐TCX)

5/16/2017

API 653 Out-of‐Service Inspection Report Tank #2 (Facility 10242)

Seymour Johnson AFB, North Carolina

GENERAL SUMMARY

INSPECTION DATE

PREVIOUS INSPECTION DATES

RECOMMENDED FUTURE INSPECTION DATES (CALCULATIONS SHALL BE PROVIDED)

A. GENERAL PROJECT INFORMATION

1. API 653 Inspection

2. Site Information

B. TANK INSPECTION COMMENTS

1. Tank Construction

2. Tank Foundation

3. Tank Shell

4. Tank Appurtenances

5. Tank Coating

6. Tank Piping System

7. Fire Protection System

8. Secondary Containment

C. FINDINGS AND RECOMMENDATIONS

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

2. REQUIRED REPAIRS to Fully Comply with API 653, OR federal, state, and local codes

APPENDIX A: ENGINEERING CALCULATIONS

APPENDIX B: ENGINEERING DRAWINGS

APPENDIX C: ENGINEERING DATA

APPENDIX D: TANK HISTORY

APPENDIX E: API 653 CHECKLISTS FOR TANK INSPECTIONS

APPENDIX F: PHOTOGGRAPHS

API 653 Out-of‐Service Inspection Report

ACRONYMS AND ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non‐Destructive Testing

ATG Automatic Tank Gauge

BBL Barrel

CFR Code of Federal Regulations

CP Cathodic Protection

DFT Dry Film Thickness

HLA High Level Alarm

HLCS High Level Control Shutoff

HHLA High‐High Level Alarm

LLA Low Level Alarm

LLLA Low‐Low Level Alarm

MFL Magnetic Flux Leakage

MT Magnetic Particle Testing

NACE National Association of Corrosion Engineers

NDT Non‐Destructive Testing

NFPA National Fire Protection Association

PSI Pounds per Square Inch

PT Penetrant Testing

P/V Pressure/Vacuum

RP Recommended Practice

PST Product Saver Tank

RT Radiography Testing

TML Thickness Measurement Location

TRV Thermal Relief Valve

UFC Unified Facilities Criteria

UFGS Unified Facilities Guide Specifications

ULS Ultra Low Sulfur

UT Ultrasonic Testing

VT Visual Testing

API 653 Out-of‐Service Inspection Report

An API Standard 653 Out-of-Service inspection of Tank #2 (Facility 10242) at Seymour Johnson Air Force Base (AFB) in Goldsboro, NC was completed on May 16, 2017. The bottom service life evaluation shows the out-of-service interval of operation (years to next internal inspection) to be greater than 30 years under current conditions.

The shell service life evaluation performed as having greater than 30 years of remaining shell life under current conditions.

Significant Findings (overview)

1. The 16-inch issue line does not have an anti-vortex plate.

2. The ENRAF ATG and VITO water probe share a common 8-inch slotted stilling well. The VITO water probe should be installed in a separate slotted stilling well that is a close to the sump as possible. The current configuration would allow water to reach the shell-to-bottom weld before detecting any water.

3. The low level alarm is not at the appropriate height. The low level alarm upper nozzle elevation is at the top of the issue line nozzle.

4. The tank does not have a low-low level alarm as required by UFC.

5. The low level alarm switch assembly has minor coating failure and corrosion.

6. The high level alarm switch and high level shut-off control assemblies have minor coating failure and corrosion.

7. The product saver tank is not grounded.

8. The tank does not have a low suction line. The tank does have a 4-inch line that extends to the sump, with a blanked double-block and bleed valve. The 4-inch line is not tied into the issue line.

The purpose of a low suction line is to draw the tank completely down.

9. The tank grounding cables are bolted to the tank and not CAD welded.

10. The receipt line double-block and bleed isolation valve has moderate coating failure and corrosion.

11. The receipt line has moderate coating failure and corrosion.

12. The receipt line thermal relief line has two sight glass flow indicators.

13. The high level shut-off valve control tubing has a weep near the shell nozzle.

14. The issue line double-block and bleed isolation valve has minor coating failure and corrosion.

15. The issue line has moderate coating failure and corrosion.

16. The issue line thermal relief line has one sight glass flow indicator.

17. The reinforcement pad of the issue line is less than 3/8-inch from the bottom extension end.

18. The stairway base lower stair tread is 15.5 inches from the containment floor.

19. The fixed roof does not have any API scaffolding supports.

20. The tank does not have a NFPA 704 diamond label and does not have a product label.

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

Procedure, and Two Point Calibration Procedure

Model: 3D DISTO Calibration Methods Used: Manufacturer

Wayne K. Bailey, API-653 #1331

Construction

Material

Piping

Level Alarms

Shutoff:

(activity did not have information)

Type of Internal Floating Roof

Petrex® Aluminum Honeycomb Flat Panel with Double Wiper Seals

API 653 Out-of‐Service Inspection Report

A. GENERAL PROJECT INFORMATION

For Tank #2 (Facility 10242), an API Standard 653 Out‐of‐Service inspection was performed.

B. TANK INSPECTION COMMENTS

4. Tank Appurtenances

a. Gauging

API 653 Out-of‐Service Inspection Report vertical ladder. The exterior coating on the stairway and platforms was in satisfactory condition.

a. None

criteria.

reinforcement pad is less than 3/8‐inch as required by API Standard 653 Section 4.4.5.7.

projection of the bottom plate beyond the outside toe of the issue line reinforcement pad.

(Quantity: 1)

down anchor bolts. API Standard 653 allows a minimum of 3/8‐inch projection of the bottom beyond the toe of the shell‐to‐bottom weld. The existing chime at each anchor bolt notch varies from a minimum of flush to ¼‐inch.

does not have any significant corrosion, the deficiency is the result of original construction, deficiency does not pose any structural or integrity concerns, and the tank has demonstrated continued reliable service with deficiency for more than 10 years. This tank can be safely operated without repairing this deficiency.

does not meet the tread rise and run requirements of 29 CFR 1910.

rise and run requirements of 29 CFR 1910 in accordance with AW 78‐24‐27 Drawing D.11 Detail 4.

(Quantity: 1)

API 653 Out-of‐Service Inspection Report

accordance with UFC 3‐460‐01 Table 8‐1 Item (ff).

5.8.8. (Quantity: 2)

label.

environment.

78‐24‐27 Drawing D.08 Detail 4.

CODE REFERENCE: AW 78‐24‐27 Drawing D.08 Detail 4.

RECOMMENDATION: Install an anti‐vortex plate on the issue line in accordance with AW 78‐24‐27

Drawing D.08 Detail 4. (Quantity: 7)

The VITO water probe should be installed in a separate slotted stilling well that is a close to the sump as possible in accordance with AW 78‐24‐27 Drawing D.07 Details 3 and 5. The current configuration would allow water to reach the shell‐to‐bottom weld before detecting any water.

CODE REFERENCE: AW 78‐24‐27 Drawing D.07 Details 3 and 5.

RECOMMENDATION: Install an ATG water probe well (stilling well) in accordance with AW 78‐24‐27

Drawing D.07 Details 3 and 5. (Quantity: 1)

API 653 Out-of‐Service Inspection Report

UFC 3‐460‐01 Table 8‐1 Item (l). The upper nozzle of the low level alarm switch is at the same height as the top of the issue line piping. The low level switch configuration is not in accordance with AW

78‐24‐27 Drawing D.12 Details 1 and 4. The issue line has a drilled hole on top of the line near the elbow, to allow air to escape during initial filling. The current configuration would allow air introduction into the system, due to the drilled hole when pumping is stopped between the low level and low‐low level alarm set points and would provide an air slug into the separators that would damage the filters if the pump is restarted during this condition.

CODE REFERENCE: UFC 3‐460‐01 Table 8‐1 Item (l) and AW 78‐24‐27 Drawing D.12 Details 1 and 4.

RECOMMENDATION: Reconfigure the low and low‐low level switches in accordance with AW 78‐24‐

27 Drawing D.12 Details 1 and 4. (Quantity: 1)

8‐1 Item (v) and AW 78‐24‐27 Drawing G.05. The tank does have a 4‐inch line that extends to the sump with a blanked double‐block and bleed valve. The 4‐inch line is not tied into the issue line.

The purpose of a low suction line is to draw the tank completely down.

CODE REFERENCE: UFC 3‐460‐01 Table 8‐1 Item (v) and AW 78‐24‐27 Drawing G.05.

RECOMMENDATION: Tie‐in the 4‐inch hose connection to the issue line to complete the low suction line circuit in accordance with AW 78‐24‐27 Drawing G.05 and UFC 3‐460‐01 Table 8‐1 Item (v).

(Quantity: 1)

exothermically welded to the tank ground lug in accordance with AW 78‐24‐27 Drawing ED.02 Detail

2.

CODE REFERENCE: AW 78‐24‐27 Drawing ED.02 Detail 2.

RECOMMENDATION: Exothermically weld the grounding cables to the tank ground lug in accordance with AW 78‐24‐27 Drawing ED.02 Detail 2. (Quantity: 7)

24‐27 Drawing D.13 Detail 5.

78‐24‐27 Drawing D.13 Detail 5 (Quantity: 1)

sight flow indicators are not permissible in accordance with UFC 3‐460‐01 Section 9‐3.5.1.

the receipt line. (Quantity: 2)

flow indicators are not permissible in accordance with UFC 3‐460‐01 Section 9‐3.5.1.

the issue line. (Quantity: 1)

valve above the shell nozzle. (Quantity: 1 fitting)

and corrosion.

accordance with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 1 valve)

accordance with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 20 SF)

and corrosion.

accordance with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 1 valve)

accordance with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 20 SF)

coating failure and corrosion.

control assemblies in accordance with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 20 SF)

with UFC 3‐460‐03 Paragraph 7.3. (Quantity: 20 SF)

A-1

MRT

RT ip

RT bc

StP r

UP r

O r

RT bc

StP r UP r StP r UP r

O r

A-2

API 653 Out-of‐Service Inspection Report

Thickness MRT

A-3

API 653 Out-of‐Service Inspection Report t min t min t nom t act t prev t nom

D H

H c

G Y

T

S Y T Y T

S

E E E

E E

L r

C r

I ut

I v

Y t prev t act tmin

H DG

SE

Lr tact tmin

Cr Cr tprev tact Y Iut tact tmin Cr

Iv tact tmin

Cr

A-4

API 653 Out-of‐Service Inspection Report

D = G = Y =

H S E t min t prev t act t prev t nom tprev tact tmin

A-5

API 653 Out-of‐Service Inspection Report

C r L r I v I ut

C r

Corrosion Rate

A-6

API 653 Out-of‐Service Inspection Report

Thickness tmin

A-7

API 653 Out-of‐Service Inspection Report

A-8

API 653 Out-of‐Service Inspection Report

A-9

API 653 Out-of‐Service Inspection Report

S max

L D N D N Y E H

D N L Y E H L

S max

A-10

API 653 Out-of‐Service Inspection Report

S i | U i U i-1 U i+1

S i | U i i

U i U i+1 U i-1 S i S i

A-11

API 653 Out-of‐Service Inspection Report

Fe et

Data Points

A-12

API 653 Out-of‐Service Inspection Report

A-13

A-14

A-15

A-16

A-17

A-18

A-19

A-20

A-21

B-1

R em ar ks

/L eg en d:

O w ne r/

O pe ra to r:

In sp ec tio n F irm

D at e:

R ev is io n

N um be r:

R ev is io n D at e:

D ra w in g T itl e:

T an k D es cr ip tio n:

D ra w in g

N um be r:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

N /A

T an k #2

F ac ili ty

B

-1 B ot to m L ay ou t

M ea su re d In si de

D ia m et er is

4.

fe et

T an k bo tto m h as pl at es

0G R

A P

H

IC

S C

A

LE

D im en si on s ar e in fe et y x N W y x

N E y x

S E y xS W

X Y

O rie nt at io n

X Y

O rie nt at io n is in r ef er en ce to

P la n N or th

S ee

B ot to m

P la te F la w

M ea su re m en ts ta bl e fo r de ta ile d m ea su re m en ts

V

V

V

V

V

A

S he ll N oz zl es in

C ou rs e

#1 A

6" M an w ay

B

B

Lo w

L ev el C on tr ol

C

C

Lo w

L ev el C on tr ol

H

H

6"

M an w ay

I

I -

R ec ei pt L in e

J

J

3/ 4"

W at er D ra w

K

K

B la nk ed

V al ve

L

L

Is su e Li ne

V

V er tic al S ea m

N um be r of S he ll

C ou rs e

#1

8" S til lin g W el l

(E N

R A

F

V

IT

O

S um p

A nt i-R ot at io n D ev ic e

A nt i-R ot at io n D ev ic e

La dd er w ith 8"

S til lin g

W el l

F lo at in g R oo f S tr ik er P la te

B-2

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

O w ne r/

O pe ra to r:

In sp ec tio n F irm

D at e:

R ev is io n

N um be r:

R ev is io n D at e:

D ra w in g T itl e:

T an k D es cr ip tio n:

D ra w in g

N um be r:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

N /A

T an k #2

F ac ili ty

S

-1 S he ll

La yo ut

S ea m is th e fir st s ea m le ft of th e fir st m an w ay le ft of th e st ai rw ay in th e fir st s he ll co ur se v ie w in g fr om th e ou ts id e.

T he n um be r in th e up pe r le ft co rn er o f e ac h pl at e id en tif ie s th e pl at e by th e co ur se a nd po si tio n of th e pl at e in th at c ou rs e.

0G

R A

P H

IC

S

C A

LE

D im en si on s ar e in fe et

1-

A

O ve rf lo w V en t

A T

G

2-

3-

4-

5-

6-

1-

B C

D E

F G

O ve rf lo w V en t

2-

3-

4-

5-

6-

A

6"

M an w ay

B

Lo w

L ev el C on tr ol C

Lo w L ev el

C on tr ol

D

H ig h Le ve l S hu to ff E

H ig h

Le ve l S hu to ff

F

H ig h Le ve l C on tr ol G

H ig h

Le ve l C on tr ol

A nc ho r

B ol t

B-3

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

O w ne r/

O pe ra to r:

In sp ec tio n F irm

D at e:

R ev is io n

N um be r:

R ev is io n D at e:

D ra w in g T itl e:

T an k D es cr ip tio n:

D ra w in g

N um be r:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

N /A

T an k #2

F ac ili ty

S

-2 S he ll

La yo ut

S ea m is th e fir st s ea m le ft of th e fir st m an w ay le ft of th e st ai rw ay in th e fir st s he ll co ur se v ie w in g fr om th e ou ts id e.

T he n um be r in th e up pe r le ft co rn er o f e ac h pl at e id en tif ie s th e pl at e by th e co ur se a nd po si tio n of th e pl at e in th at c ou rs e.

0G

R A

P H

IC

S

C A

LE

D im en si on s ar e in fe et

1-

H

O ve rf lo w V en t

2-

3-

4-

5-

6-

1-

I

O ve rf lo w V en t

O ve rf lo w V en t

2-

3-

4-

5-

6-

H

6"

M an w ay

I -

R ec ei pt L in e

A nc ho r

B ol t

B-4

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

O w ne r/

O pe ra to r:

In sp ec tio n F irm

D at e:

R ev is io n

N um be r:

R ev is io n D at e:

D ra w in g T itl e:

T an k D es cr ip tio n:

D ra w in g

N um be r:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

N /A

T an k #2

F ac ili ty

S

-3 S he ll

La yo ut

S ea m is th e fir st s ea m le ft of th e fir st m an w ay le ft of th e st ai rw ay in th e fir st s he ll co ur se v ie w in g fr om th e ou ts id e.

T he n um be r in th e up pe r le ft co rn er o f e ac h pl at e id en tif ie s th e pl at e by th e co ur se a nd po si tio n of th e pl at e in th at c ou rs e.

0G

R A

P H

IC

S

C A

LE

D im en si on s ar e in fe et

1-

J K

LO

ve rf lo w V en t

2-

3-

4-

5-

6-

J

3/ 4"

W at er D ra w

K

B la nk ed

V al ve L

Is su e

Li ne

A nc ho r

B ol t

B-5

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

O w ne r/

O pe ra to r:

In sp ec tio n F irm

D at e:

R ev is io n

N um be r:

R ev is io n D at e:

D ra w in g T itl e:

T an k D es cr ip tio n:

D ra w in g

N um be r:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

N /A

T an k #2

F ac ili ty

R

-1 F ix ed

R oo f L ay ou t

M ea su re d D ia m et er is

3.

fe et

F ix ed r oo f h as pl at es

0G R

A P

H

IC

S C

A

LE

D im en si on s ar e in fe et y x N W y x

N E y x

S E y xS W

X Y

O rie nt at io n

X Y

O rie nt at io n is in r ef er en ce to

P la n N or th

7 8

14 15

A

A

E N

R A

F

V

IT

O W at er

P ro be B

6" H at ch w ith

In te rn al

L ad de r an d

8" S am pl e G au ge

W el l C

4" V en t

D

A cc es s

H at ch E

R oo f C irc ul at io n V en t/I ns pe ct io n H at ch

F

P lu g G

M an ua l T ap e Le ve l G au ge

B

C

D

E

F

F

G

F

F

F F

E

E

E

B-6

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

C om pa ny

D ra w n

B y:

D at e:

R ev . N o.

S ca le

D ra w in g T itl e:

S ea ym ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

1/ fe et

T yp e

III

S ite

L ay ou t

T an k #1

T an k #2

P S

T

D ra in D ra in

P S

T

8" R ec ei pt

Is su e

8" R ec ei pt

Is su e

N O

R T

H

B-7

API 653 Out-of‐Service Inspection Report ar ks

/L eg en d:

C om pa ny

D ra w n

B y:

D at e:

R ev . N o.

S ca le

D ra w in g T itl e:

T an k D es cr ip tio n:

S ey m ou r Jo hn so n A

F B

In te rS pe c

LL

C

/1

6/

N /A

1/ fe et

S ec on da ry C on ta in m en t

T an k #2

F ac ili ty

T an k #1

S ec on da ry C on ta in m en t

T an k #2

(F ac ili ty

D ra in

P S

T

8" R ec ei pt

Is su e

S ec on da ry c on ta in m en t i s co ns tr uc te d fr om co nc re te s lo pe d flo or a nd v er tic al c on cr et e w al ls

S ec on da ry c on ta in m en t d ra in h as a lo ck ab le ris in g st em d ra in v al ve

D ra in V al ve

B-8

API 653 Out-of‐Service Inspection Report

C-1

C-2

C-3

C-4

C-5

C-6

C-7

C-8

C-9

C-10

C-11

D-1

D-2

E-1

E-2

E-3

E-4

E-5

E-6

E-7

E-8

E-9

E-10

E-11

E-12

E-13

E-14

E-15

NOTES:

E-16

API 653 Out-of‐Service Inspection Report

F-1

F-2

F-3

F-4

F-5

F-6

F-7

F-8

F-9

F-10

F-11

F-12

F-13

F-14

F-15

F-16

F-17

F-18

F-19

F-20

F-21

F-22

F-23

F-24

F-25