JBER Tank 740 OOS Final Report with Appendices 2014.pdf

ACOE CONTRACT W911KB-10-D-0006, TASK ORDER 0024

TANK 740 (FACILITY NO. 740)

API 653 OUT-OF-SERVICE INSPECTION

AND SUITABILITY FOR SERVICE

EVALUATION

FINAL REPORT

(PRE-REPAIR)

Joint Base Elmendorf-Richardson (JBER), Alaska

August 2014

Contract Agency:

U.S. Army Engineer District, Alaska P.O. Box 6898 Elmendorf AFB AK 99506-6898

Prepared By:

David A. Stchyrba, P.E., API 653 Certificate No. 27187

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 8115

Page Intentionally Left Blank

SUITABILITY FOR SERVICE STATEMENT – TANK 740 (FACILITY NO. 740)

Enterprise Engineering, Inc. (EEI) has completed an out-of-service external and internal inspection and suitability for service evaluation of Tank 740 at JBER, Alaska. The inspection was performed on June 17– 18, 2014 in accordance with the applicable criteria of API Standard 653, UFC 3-460-01, and the Statement of Work.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair. Recommendations for continued long-term service are also provided.

EEI recommends the next API 653 external in-service inspection be scheduled no later than June 2019 (5 years from this 2014 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API 653 internal out-of-service inspection be scheduled no later than June 2034 (20 years from this 2014 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653 and ADEC Regulation 18AAC75, this report satisfies the requirement for an out-of-service, tank integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

August 5, 2014 David A. Stchyrba, P.E.

API 653 AST Inspector Certificate No. 27187

This tank inspection has determined that mandatory repairs are not required prior to return to service. Tank 740 may be returned to service. Recommended repairs have been identified, an if possible, should be completed before returning the tank to service.

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs (Mandatory) Recommended Repairs (Non-Mandatory) Recommended Repairs for Long Term Serviceability

COATING SYSTEM

Coating Requirements

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEM

Gauge Tubes

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ................................................... Tab A Assessment of Compliance with Military Criteria ...................................................... Tab B Non-Destructive Examination (NDE) and Evaluation Criteria ...................................Tab C Tank Drawings .........................................................................................................Tab D Tank Photographs .................................................................................................... Tab E NDE Results ............................................................................................................. Tab F Calculations ............................................................................................................. Tab G Coating Requirements .............................................................................................Tab H

Tank 740 – API 653 Inspection TABLE OF CONTENTS JBER, Alaska August 2014 EEI Project No. 8115

TANK 740

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

JOINT BASE ELMENDORF-RICHARDSON (JBER), ALASKA

SUMMARY

Scope

Enterprise Engineering Inc. (EEI) has been retained to perform an out-of-service internal and external inspection of Tank 740 at JBER, Alaska. The inspection was performed on June 17-18, 2014. The inspection was performed in accordance with the applicable portions of API Standard 653, UFC 3-460-01 and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. Inspection findings and recommended repairs are provided below.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 740 is a field erected, vertical aboveground storage tank. The tank was fabricated and erected in 1998. The tank is 112 feet in diameter and 51 feet 6 inches high. It is of welded construction with butt-welded shell plates and lap welded floor and roof plates. The nominal shell capacity is 80,000 Bbls. Tank 740 is currently in JP-8 service and is equipped with an aluminum honeycomb floating pan.

INSPECTION ASSESSMENT

The Appendices in this report include a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of data taken. The following discussion only addresses key integrity issues.

Tank 740 is considered suitable to return to service. The following are significant findings of the inspection.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

Visual inspection of the tank floor, shell, and roof found no holes or indications of leaks. A pit survey was conducted for topside corrosion on the floor and no pits were identified requiring repair. A magnetic flux leakage (MFL) scan of the floor found no relevant indications of corrosion on the bottom side of the floor requiring repair.

The out-of-service inspection and evaluation found no conditions that affect the hydraulic integrity of the tank.

Tank 740 – API 653 Inspection Page 1

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof and their attachment.

Ultrasonic inspections of the shell were performed on the first course and on the each course up the exterior spiral stair. From interpretation of ultrasonic thickness (UT) readings recorded, only minor metal loss due to corrosion was observed.

The out-of-service inspection and evaluation found no conditions that affect the structural integrity of the tank.

Next Inspection

The Alaska Department of Environmental Conservation (ADEC) requires an inspection per the requirements of API 653. API 653 requires the interval until the next internal in section be determined using corrosion rate procedures or Risk-Based Inspection (RBI) procedures. When corrosion rate procedures are used, the interval shall not exceed 20 years. When RBI procedures are used the interval shall not exceed 25. If the tank has a release prevention barrier and leak detection designed in accordance with API 650 Appendix I and RBI procedures are used, the interval shall not exceed 30 years. As an RBI assessment is not included in the scope of this inspection, the interval until the next out-of-service inspection was determined using corrosion rates.

It should be noted that ADEC may reduce the inspection interval for a specific storage tank if

(a) The storage tank is older than 30 years,

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion or foundation problems, or

(d) After a significant seismic event.

As none of the criteria is applicable to Tank 740, it is not anticipated that the State will require a reduced inspection interval.

EEI recommends the next API 653 external in-service inspection be scheduled no later than June 2019 (5 years from this 2014 inspection). The next in-service inspection should be performed sooner if a change in condition or a change in service occurs.

EEI recommends the next API 653 out-of-service inspection be performed no later than June 2034 (20 years from this 2014 inspection). The next out-of-service inspection should be performed sooner if a change in condition or a change in service occurs.

It should be noted that a maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

Tank 740 – API 653 Inspection Page 2

REPAIR ITEMS

Based upon the API field inspection, engineering judgment and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory) and recommended for long term serviceability. Refer to Appendix B, “Assessment of Compliance with Military Criteria” for comprehensive comments and recommendations of the tanks compliance with military criteria.

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor, and shall consider the tank has been in petroleum fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs (Mandatory)

Mandatory repairs are repairs that are critical to the hydraulic and structural integrity of the tank and are required prior to returning Tank 740 to service.

• The out-of-service inspection of Tank 740 found no significant deficiencies that would require mandatory repair or prevent returning the tank to service.

Recommended Repairs (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends performing these repairs for the long term preservation and integrity of the tank.

1. The sealant between the floor projection (chine) and the concrete ringwall has failed. Moss was observed growing within the space.

• Remove the sealant and moss from the perimeter of the tank.

• Clean the surfaces of the concrete ringwall and the underside of the floor projection in accordance with sealant manufacturer’s instructions.

• Provide jet fuel-resistant polysulfide sealant.

2. The tank is equipped with an aluminum honeycomb floating pan. The pan is equipped with a primary and secondary fabric covered foam wiper. Fluid was detected within the lower wiper fabric at multiple locations. The extent of the breaches in the seal is not known.

• Provide a solid urethane wiper type seal for the floating pan. Recommend contacting pan manufacturer for recommended style of solid wiper seal.

3. The floating pan wiper seals at the pan penetrations (center column, gauge tubes, ladder leg, anti-rotation cable, etc.) have failed.

• Replace all of the wiper seals.

Tank 740 – API 653 Inspection Page 3

4. The tank is equipped with two standpipes as part of the leak detection system. Water was observed in the bottom of the pipes.

• Drain the water from the standpipes.

• Monitor the standpipes for fluid accumulation as part of routine maintenance. It should be noted that neither a sheen or product odor was detected in either standpipe.

• For a more long-term solution, provide a drip ring at the floor projection per section 5.4.5 of API

650. It is the opinion of EEI that water is infiltrating the sand cushion and migrating to the leak detection standpipes.

5. Stainless steel striker plates are located below each of the floating pan legs. The plates are secured to the floor with a mastic sealant. The seal has failed at 10 of the plates and product was observed draining from under the plates.

• Remove the sealant from all of the striker plates and the floor. Clean all surfaces.

• Bed each striker plate in new epoxy sealant on the floor.

• Alternatively, remove all of the striker plates and provide drainable UHMW plugs in the bottom of each leg.

6. The tank is equipped with six perimeter roof vent/inspection hatches. The jeep style hold down latches are corroding and most have failed.

• Replace the latches on all of the roof vents.

7. The tank is equipped with a tape gauge float. At the time of the inspection, the tape was hung up on the seal in the pan penetration and the float was suspended above the floor.

• Readjust the seal in the pan penetration to allow free movement of the tape gauge float.

8. Localized coating failure was observed on the stairs, landings, the shell valves, anchor bolts, floor projection at the cathodic protection (CP) connections, roof kickplate, roof appurtenances and the roof handrail posts. Approximately 5 square feet of scattered coating failure was observed on the roof plate.

• Remove the coating from the affected areas.

• Clean and provide proper surface preparation on 100% of the areas to be recoated in accordance with coating manufacturer’s written recommendations.

• Recoat affected areas.

9. Approximately 10 square feet of scattered coating failure was observed on the interior tank floor and 5 square feet of localized coating failure on the tank column.

• Remove the coating from the affected areas.

• Clean and provide proper surface preparation on 100% of the areas to be recoated in accordance with coating manufacturer’s written recommendations.

• Recoat the affected areas.

10. Coating failure was observed on approximately 100 square feet of the underside of the roof support framing. The failures appear to be limited to the topcoat with no visible corrosion.

• Clean and provide proper surface preparation on the areas to be recoated in accordance with the coating manufacturer’s written recommendations.

• Recoat the affected areas.

Tank 740 – API 653 Inspection Page 4

11. The telltale holes in the reinforcing plates for the three shell manways, Fill, Issue, Low Fuel and Water Draw-Off nozzles contain a threaded plug.

• Remove the plug from the telltale holes as API criteria require telltale holes to be open to the atmosphere.

• Pack the open telltale hole with general purpose grease to prevent moisture migration between the reinforcing plate and the shell.

12. Black moss was observed on the roof of the tank. The coating is in otherwise good condition.

• Remove the moss by power washing or other suitable non-mechanical means.

• Note: Since the material will travel down the tank shell during cleaning, it is recommended to power wash the entire exterior of the tank.

13. The stainless steel pilot tubing for the high level shutoff valve is routed such that contact is made at the wind girder. Vibration of the tubing may cause abrasion resulting in failure of the tubing.

• Provide Teflon sheet shields wrapped around the tubing to eliminate metal to metal contact between the tubing and the wind girder.

14. Minor piping (LR/DTR) is present on the DB&B valve at the 6 inch Low Fuel nozzle. The piping is open to the elements and there is a risk of damage from falling ice/snow. If the piping were damaged while the tank is in service, it would have to be removed from service and drained in order to complete any repairs.

• Provide an ice/snow shield over the nozzle.

15. There are only 2 bolts present in the flange of the 36 inch diameter roof manway.

• Replace the missing bolts.

16. The existing gauge tubes were evaluated for compliance with the DESC/DLA Memorandum and

UFC 3-460-01.

• Continue to use the 8 inch aluminum combination ladder/gauge tube for manual gauging. (UFC criteria)

• Continue to use the 8 inch aluminum gauge tube for the ITT Barton ATG probe. (DLA directive) A waiver may be required since only the lower 2 feet of the tube has been provided with slots.

• Provide a 6 inch fully slotted aluminum gauge tube and 8 inch roof hatch as close to the center sump as possible for the future water probe. Terminate the gauge tube 24 inches above the floor.

(DLA directive) It should be noted that a new penetration will be required in the aluminum honeycomb floating pan. Based on the arrangement of the structural steel roof framing, a gauge tube may be located in the vicinity of the sump. The sump itself contains the issue, low fuel and water draw-off piping. Reworking of the piping will likely be necessary to accommodate the future probe.

• Note: These recommendations must be validated by DLA-E.

17. The tank was evaluated for compliance with current military criteria. The following is noted:

• The tank has been equipped with all of the recommended appurtenances.

• Refer to Appendix B “Assessment of Compliance with Military Criteria” for further discussion.

18. Hairline cracks were noted in the concrete ringwall including areas with hold down anchor bolts.

• Repair action is not recommended at this time. Monitor the cracks during routine maintenance.

Tank 740 – API 653 Inspection Page 5

19. Water ponding was observed on several of the perimeter roof plates and at the weld seams. The roof plates appear to have been shingled in the wrong direction. Over time, this condition may cause coating failure and corrosion.

• Repair action is not recommended at this time. Monitor for coating failure and corrosion during routine maintenance.

20. Provide surface preparation and recoat all interior and exterior repair areas and areas damaged as a result of repairs in accordance with Tab H - Coating Requirements. When welding on the shell or roof, the coating on the opposite side from the weld shall be inspected and repaired if damaged.

Recommended Repairs for Long Term Serviceability

1. Program the tank for the next API 653 in-service external inspection no later than June 2019 and the next API 653 out-of-service internal and external inspection no later than June 2034.

2. Test all level alarms and switches as part of on-going maintenance.

3. It is the opinion of EEI that water is infiltrating the joint between the ringwall and the floor projection and entering the sand cushion. From the sand cushion, it migrates into the leak detection ports. An alternative to replacing the sealant, it is recommended to provide a drip ring per section 5.4.5 of API

650. The drip ring would consist of a steel ring, welded to the floor projection along the perimeter of the tank. It would extend past the concrete foundation and would prevent moisture from being wicked into the sand cushion.

COATING SYSTEM

Coating Requirements

Refer to Appendix H for complete coating materials and application requirements for type and location of coating repair items identified by the inspection.

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates for the tank floor, shell and roof were calculated using thickness measurements that were obtained during the inspection and are as follows:

Floor: 0.003938 inches per year

Shell: 0.002470 inches per year

Roof: Negligible – Plate thickness is within mill tolerance

The corrosion rates were calculated using an assumed original metal thickness and a 1998 year of construction.

Tank 740 – API 653 Inspection Page 6

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 13.4 mils, is a thin-film lining. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The floor coating is 16 years old. Although the coating was in good condition, a nominal unrepaired pit depth of 1/16 inch was assumed in the calculations. No pits requiring repair were identified.

Bottom side corrosion with small volumetric metal loss may be present and not detected by magnetic flux leakage (MFL) scanning. The metal loss used to calculate the bottom side corrosion rate was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits. The MFL floor scanner is not configured to indicate (alarm) for minor metal loss. The tank is equipped with a functioning cathodic protection (CP) system. For tanks with effective CP, API 653 permits a bottom side corrosion rate (UPr) of 0.00 in/yr which was used in the calculations.

The minimum remaining thickness (MRT) used in the calculations is based on API 653 Section 4.4.5 and Table 4.4. The tank is equipped with the means to detect and contain a bottom leak. It was reported that there is a liner beneath the sand cushion. Based on this information, the MRT used in the calculations is

0.050 inch.

It was found that the tank floor plate thickness will not be reduced below the limiting MRT at a 20 year inspection interval.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 740:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank sits on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

Floor Visual inspection of the floor plate joints found no relevant indications. MFL scanning of the floor found no indication of active corrosion on the bottom side. A pit survey was conducted for topside corrosion and no pits were identified requiring repair.

Based upon the calculated corrosion rate, the floor plate thickness will not be reduced below the requirements for minimum floor plate thickness of 0.05 inch at a 20-year inspection interval.

Acceptable

Shell Visual inspection of the accessible shell joints found no relevant indications. A pit survey was conducted and no locations were identified for repair.

Acceptable

Roof Spot ultrasonic testing of the roof plates found no noticeable thinning of the plates.

Acceptable

Internal Fluid Pressure

Hoop stresses by internal fluid pressure pass API 653 criteria.

Acceptable

Hydrostatic Test

Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

Tank 740 – API 653 Inspection Page 7

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650(7th edition or later, 1980): Yes, constructed in 1998.

2. Has a prior hydrotest been performed demonstrating fitness: Yes, likely when the tank was constructed in 1998.

3. Is the tank shell thickness < 0.5 inch: No.

4. Does the tank operate at metal temperature above 60 deg F?: No.

5. Is the tank membrane stress below 7 ksi?: No.

6. Tank steel exempt per API 650, Figure 4.1 or API

653 Figure 4.1: Yes.

7. Tank full at lowest one day temperature per API 650

Figure 4.1: Unknown.

The tank, having exempt steel and a hydrotest in 1998, does not fit the API 653 at-risk profile for brittle fracture failure.

Seismic Evaluation

Tank 738 is anchored. Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank anchors are adequate and that the shell stresses are within limits at the current fill height of 41 ft 9 inches.

Calculations were performed utilizing the specific gravity for JP-8 (S.G. = 0.84), a ringwall foundation, seismic parameters Ss = 1.50, S1 = 0.68, an importance factor of 1.25.

Acceptable

Wind Evaluation

A wind analysis was performed per API 650, Section 5.11.

Calculations were performed using an importance factor of

1.15 and a wind velocity of 100 mph.

The evaluation determined that an empty tank is stable and not at risk of overturning or sliding.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 100 mph.

Acceptable

ADDITIONAL DISCUSSION ITEM

Gauge Tubes

Gauge Tube Requirements

The requirements for stilling wells have been reviewed. These requirements are based on the DESC/DLA-E Memorandum “Automated Tank Gauge (ATG) Installation Policy” of December 2009.

The comments below represent concept solutions based on the memorandum. It is recommended that the concept be submitted to DESC/DLA-E for ratification or redirection. Field verification of constructability by the prime contractor is also recommended.

Tank 740 – API 653 Inspection Page 8

Tank 740 Existing Conditions

The tank is an AST with a cone-down floor and includes a center sump and an aluminum honeycomb floating pan. The cone up roof is fixed with a center roof support column. The roof plate is supported by rafters that in turn bear on a round center cap plate. The cap plate is located on the top of the center column. There are two 8 inch near shell gauge tubes: one combination ladder/gauge tube and one standalone gauge tube. The combination ladder/gauge tube is fully slotted and is used for manual gauging. The standalone gauge tube only has slots in the lower 4 feet. It contains the probe for the ITT Barton ATG system.

Gauge Tube Recommendations

The following are recommended for compliance with the DESC/DLA Memorandum (for ATG) and UFC 3-460-01 (for operations) based on continuing to use the existing ITT Barton ATG system:

• Continue to use the 8 inch aluminum combination ladder/gauge tube for manual gauging. (UFC criteria)

• Continue to use the 8 inch aluminum gauge tube for the ITT Barton ATG probe. (DLA directive) A waiver may be required since only the lower 4 feet of the tube has been provided with slots.

• Provide a 6 inch fully slotted aluminum gauge tube and 8 inch roof hatch as close to the center sump as possible for the future water probe. Terminate the gauge tube 24 inches above the floor. (DLA directive) It should be noted that a new penetration will be required in the aluminum honeycomb floating pan. Based on the arrangement of the structural steel roof framing, a gauge tube may be located in the vicinity of the sump. The sump itself contains the issue, low fuel and water draw-off piping. Reworking of the piping will likely be necessary to accommodate the future probe.

Note: These recommendations must be validated by DLA-E.

CLOSURE

Conclusions

Based on the extent of this inspection and lack of mandatory repairs, Tank 740 is considered suitable to return to service.

Project Team

Site Team

David A. Stchyrba, P.E. Structural Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 27187, API Inspector of Record

Travis W. Snyder Mechanical Engineer, Tank Technician

Michael B. Morris Mechanical Engineer, Tank Technician

Support Team

Stacy M. Kaplan-McMillan Project Manager

Stephen S. Brooks, P.E. Technical Advisor, QA Review, API 653 Aboveground Storage Tank Inspector Certificate No. 17

Tank 740 – API 653 Inspection Page 9

APPENDIX A

Tank Inspection Data Sheet and Evaluation Items

DLA-E TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Joint Base Elmendorf-Richardson (JBER), Alaska Tank No. 740

Facility No. 740 Inspection Date(s): June 17 - 18, 2014

Tank Type: Vertical AST Type of Inspection: Internal & External w/ Suitability for Service Evaluation

Contract Number, Task Order: W911KB-10-D-0006, 0024 Prime Contractor Name: Enterprise Engineering, Inc.

Inspector, Certificate #: David A. Stchyrba, P.E.

API-653 AST Inspector Certificate No. 27817

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK, 99503

(907) 563-3835

Manufacturer, Date, Design Standard Morse Construction Group, 1998, API 650 9th Edition Diameter: 112'-0"

Shell Height: 51'-6" Product, Specific Gravity: JP-8, 0.84

Design Pressure / Temperature: Atmospheric / -15 Deg. F. Design Metal Temperature Gross Capacity / Nominal Capacity: 83,286 Bbls / 80,000 Bbls

Design Liquid Level / Safe Fill Height: 47 feet 6 inches (nameplate) / 41 feet 9 inches (from facility) GPS Latitude & Longitude: 61 Deg 15’ 47.41” N, 149 Deg 48’ 46.44” W (Source – Google Earth) Foundation Configuration: Concrete ringwall

Shell Configuration: Butt Welded with 7 courses Roof: Fixed, column supported cone up

Cathodic Protection: Present Still Wells: 8 inch for manual gauging and 8 inch for ATG

Last Inspection (Type, Date): In-service, 2010 Last Coated Internally (Product): 1998 – Original coating Last Coated Externally (Product): 1998 – Original coating

INSPECTION RESULTS

Can tank return to service? Yes

Deficiencies identified as mandatory repairs: No Deficiencies identified as recommended repairs: Yes, see paragraph titled “Recommended Repairs” in body of report.

Deficiencies identified as long term repairs: Yes, see paragraph titled “Recommended Repairs for Long Term Serviceability” in body of report

Next Scheduled Inspections (Type, Date): In-Service: June 2019 (5 Years) Out-of-Service: June 2034 (20 Years)

ADDITIONAL ITEMS

Change in Service: None

As-Built Drawings, Specifications: Design drawings available

Tank 740 – API 653 Inspection Appendix A, TANK SUMMARY SHEET JBER, Alaska EEI Project No.: 8115

AST EVALUATION ITEMS

TABLE OF CONTENTS

Page

FOUNDATION

FLOOR

SHELL

ROOF

INTERNAL FLOATING ROOF

COATINGS

APPURTENANCES

PIPING

Tank 740 – API 653 Inspection Appendix A, TABLE OF CONTENTS

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

FOUNDATION

Type The tank bears on a concrete ringwall. Hairline cracks were observed in the ringwall at the anchor locations.

Monitor the crack locations during routine inspections.

Levelness Tank 740 is relatively level. The maximum measured differential between max and min elevations is 0.09 feet.

Tank 740 passes API 653 criteria for levelness and differential settlement.

Rigid Body Tilt Tank 740 is slightly tilted. The amount of tilt is

0.50 inches.

Tilt is within acceptable limits.

Height Above Dike Floor The top of the ringwall is approximately 10 inches above the containment dike floor.

Material Below Tank Floor

The material below the tank floor could not be inspected. Design drawings indicate that there is a sand cushion and liner.

Drainage Around Tank Drainage around the tank appears to be adequate.

Tank Anchors There are 41 tank anchors equidistant around the perimeter of the tank.

Secondary Containment Tank sits within an earthen dike with a membrane liner. Stone ballast holds the liner in place.

Settlement No evidence of excessive settlement was observed.

Erosion/Washouts No indications of washouts or erosion were

Sealed at Foundation

Moss was observed in the space between the floor projection and the concrete ringwall.

The dike liner is attached to the ringwall.

Recommend removing the failed sealant and providing new jet fuel resistant sealant. For a long term fix, it is recommended to provide a drip ring as described in section 5.4.5 of API 650. It is the opinion of EEI that the water is infiltrating the sand cushion space and ending up in the leak detection standpipes.

Additional Foundation Items, Comments or Notes:

None.

Tank 740 – API 653 Inspection Appendix A, Page 1

FLOOR

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type Lap welded steel floor plates.

Annular Ring Plates Tank is not equipped with annular ring plates.

Nominal Thickness Floor consists of 5/16-inch thick floor plates.

Thickness The average thickness of the floor plates based on 5 UT readings per floor plate is 0.314 inch.

Interior Width See floor drawing.

Floor seam welds No relevant indications were found on the floor plate seam welds.

MFL Floor Scan MFL of the accessible areas of the floor found no locations requiring an ultrasonic test (UT) prove-up.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, bottom side pitting/corrosion is not prevalent.

Top Side Floor Pitting/Corrosion

No top side pits or corroded areas were identified for repair.

Patch Plates No patch plates present.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge settlement was not noted.

Floor Bulges, Depressions No relevant bulges or depressions were noted.

Doubler/Striker Plates Doubler plates are present below each of the pipe supports.

The column base has been provided with a doubler plate.

Plug Welds No plug welds were observed.

Weld Artifacts No weld artifacts were observed.

Vacuum Box Testing Vacuum box testing was not performed.

Helium Leak Testing Helium leak testing was not performed.

Floor Critical Zone No corrosion or deflection was observed within the critical zone.

Floor Profile The floor is cone down with one sump near the center of the tank. The tank floor slopes approximately 5% to the sump.

Sumps The tank is equipped with a 40-inch diameter near center sump.

Tank 740 – API 653 Inspection Appendix A, Page 2

FLOOR

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Leak Detection Below Floor

The tank has two standpipes. The standpipes are connected to piping that extends to below the near center sump. Water was observed in the bottom of the pipes.

Drain the water from the standpipes and monitor for fluid accumulation as part of routine maintenance.

Cathodic Protection The tank is equipped with cathodic protection system.

It was reported that the system is in good working order.

Additional Floor Items, Comments, Notes:

Tank 740 – API 653 Inspection Appendix A, Page 3

SHELL

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK SHELL

Nominal Thickness UT Thickness Coating

1st Course 0.650 inch 12.5 mils

2nd Course 0.541 inch 14.2 mils

3rd Course 0.494 inch 14.4 mils

4th Course 0.332 inch 12.2 mils

5th Course 0.261 inch 12.8 mils

6th Course 0.263 inch 13.0 mils

7th Course 0.258 inch 16.5 mils

Rim Angle 0.392 inch

Plumbness Visual observations found no noticeable out-of-plumbness.

Roundness No noticeable out-of-roundness was observed.

Dents/Buckles No significant dents or buckles requiring repairs were observed.

Banding/Peaking No significant banding or peaking was

Interior Shell pitting/corrosion

No pits or significant corrosion were observed on the interior of the shell.

Exterior Shell pitting/corrosion

No pits or significant corrosion were observed on the exterior of the shell.

Insert plates No insert plates were observed in the tank shell.

Welded Patch Plates No welded patch plates were observed.

Floor Projection The floor projection extends an average of 2.4-inches beyond the tank shell. The average thickness is 0.314-inch.

Interior Shell Welds Visual inspection of the accessible interior shell welds found no indications for further inspections or examinations.

Exterior Shell Welds Visual inspection of the accessible exterior shell welds found no indications for further

Door sheet No door sheets were observed.

Tank 740 – API 653 Inspection Appendix A, Page 4

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Floor-to-Shell Weld – Interior

Visual inspection of the interior floor-to-shell weld found no indications for further

Floor-to-Shell Weld – Exterior

Visual inspection of the exterior floor-to-shell weld found no indications for further

Shell Manholes The tank is equipped with three 36-inch manholes.

Flush Cleanouts Tank is not equipped with a flush cleanout.

Shell Reinforcing Plates

Manway #1

(Size, Thickness, Telltale Hole)

Size: 36-inch diameter nozzle, 0.751 inch thick

(UT).

Reinforcing Plate: Tombstone shaped, 79-inches wide x 79-inch x 0.639-inch thick (UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Issue

(Size, Thickness, Telltale Hole)

Size: 12-inch nozzle, 0.506 inch thick (UT).

Reinforcing Plate: Circular shaped, 21.5-inch diameter x 0.656 inch thick (UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Low Fuel

(Size, Thickness, Telltale Hole)

Size: 6-inch nozzle, 0.420 inch thick (UT).

Reinforcing Plate: Circular shaped, 16-inch diameter x 0.647 inch thick (UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Water Draw

(Size, Thickness, Telltale Hole)

Size: 3-inch nozzle, 0.302 inch thick (UT).

Reinforcing Plate: Tombstone shaped, 11-inches wide x 13-inches tall x 0.655-inch thick

(UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Manway #2

(Size, Thickness, Telltale Hole)

Size: 36-inch nozzle, 0.648 inch thick (UT).

Reinforcing Plate: Tombstone shaped, 79-inches wide x 79-inches tall x 0.657 inch thick

(UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Fill

(Size, Thickness, Telltale Hole)

Size: 10-inch nozzle, 0.511 inch thick (UT).

Reinforcing Plate: Circular shaped, 22-inch diameter x 0.656 inch thick (UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Manway #3

(Size, Thickness, Telltale Hole)

Size: 36-inch nozzle, 0.654 inch thick (UT).

Reinforcing Plate: Tombstone shaped, 79-inches wide x 79-inches tall x 0.649 inch thick

(UT).

A plug is present in the telltale hole.

Pack telltale hole with general purpose grease to prevent water migration between the reinforcing plate and the tank shell.

Tank 740 – API 653 Inspection Appendix A, Page 5

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Shell Vents Tank is not equipped with shell vents.

Overflow Ports Tank is equipped with 4 overflow ports in the 7th shell course.

Wind Girders and Shell Stiffeners (Size & Elevation)

The tank is equipped with a wind girder 22.5 inches from the top of the 5th shell course. It is a bent plate with a width varying from 9 to 17 inches. The depth is 5 inches.

Tank Nameplate Data (Complete as Possible):

API 650 9th Edition, Addendum 4, Appendix A, E & H

Year Completed : 1998

Nominal Diameter: 112 feet

Nominal Height: 51 feet 6 inches

Maximum Capacity: 83,286 bbls

Design Liquid Level: 47 feet 6 inches

Design Specific Gravity: 0.87

Design Metal Temperature: -15 Deg. F.

Design Pressure: Atmospheric.

Partial Stress Relief: No.

Fabricated by: Morse Construction Group

Shell Courses 1 -7: A516 Gr.60

Additional Shell Items, Comments or Notes:

Floor and roof plates have mill stamp reading “ASTM A516-GR 60”.

Tank 740 – API 653 Inspection Appendix A, Page 6

ROOF

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK ROOF

Type Column supported fixed cone up roof.

Roof Plate Thickness The roof consists of ¼ inch (0.250) thick roof plates. Average measured thickness is 0.264 inch (UT).

Roof Joints Visual inspection from below the roof found no indications of leakage.

Roof Topside Pitting/corrosion

No significant pitting or corrosion was identified on the topside of the roof.

Roof Topside Condition

Water ponding was observed on several of the perimeter roof plates and at the weld seams. The roof plates appear to have been shingled in the wrong direction. Over time, this condition may cause coating failure and corrosion.

Repair action is not recommended at this time. Monitor for coating failure and corrosion during routine maintenance

Roof Welds Visual inspection of the topside roof welds found no indications that require further evaluation.

Frangible Joint (Size/Condition)

¼ inch nominal roof plates secured to the rim angle with 3/16 inch fillet weld.

The roof connection at the shell meets the definition of a frangible joint for emergency venting.

Roof Vents (Size & Type) There is one 26 inch diameter atmospheric vent located at the center of the roof.

The tank is also equipped with six perimeter roof vent/inspection hatches. The jeep style hold down latches are corroding and most have failed.

Replace the latches on all of the roof vents.

Roof Manways The tank is equipped with one 36 inch roof manway. There are only two bolts in the flange.

Replace the missing bolts.

Construction Hatch The tank is equipped with one 40 inch x 76 inch hatch for the installation/removal of the floating pan.

Roof Nozzles 10 inch nozzle for ATG.

8 inch nozzle for manual sampling hatch located in cover plate of roof manway

(3) 3 inch nozzles for ground wire to floating pan

3 inch nozzle for anti-rotation cable

Tank 740 – API 653 Inspection Appendix A, Page 7

ROOF

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Handrails The roof of the tank is equipped with a perimeter handrail constructed with pipe sections.

Roof Access from the Ground

Roof access is via a spiral stair that is supported from the shell.

Roof Access to Adjacent Tank

There is no roof access to adjacent tanks.

Roof Framing/Roof Underside Condition

Visual inspection of the underside of the roof from the tank floor found no indication of leaks and no areas of significant corrosion or other degradation.

See “Coatings” for further comments

Interior Columns One 18 inch pipe column located at the center of the tank.

SEE TANK APPURTENANCES FOR ATG, GAUGING, LEVEL ALARMS, ETC.

Additional Roof Items, Comments or Notes:

Tank 740 – API 653 Inspection Appendix A, Page 8

INTERNAL FLOATING ROOF

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Type Tank is equipped with an aluminum honeycomb floating roof.

Material Type Aluminum.

Roof Bulges/Depressions No significant bulges or depressions were identified.

Roof Joints Visual inspection of the joints found no relevant indications for further inspection or examination.

Primary Seal Type (Lower) Fabric covered foam wiper. Product was detected within the wiper fabric at multiple locations. The extent of the breaches in the seal is not known.

Recommend replacing the existing upper and lower wiper with a solid urethane wiper.

Secondary Seal Type (Upper) Fabric covered foam wiper. No deficiencies were observed in the secondary seal.

Recommend replacing the existing upper and lower wiper with a solid urethane wiper.

Vacuum Breaker/Pressure Relief Floating pan is equipped with one vacuum breaker/pressure relief combined unit.

Access to/from Floating Roof The deck of the floating roof is accessed by a ladder from the fixed roof.

Shell MH Access Above Roof The tank is not equipped with a shell access manway above the floating pan.

Interior Access Above Roof There is one 36 inch access manway into the interior of the tank.

Leg Supports Stainless steel striker plates are located below each of the floating pan legs.

They are secured to the floor with an epoxy sealant. The seal has failed at 10 locations. Product was observed draining from under the plates.

Remove the sealant from all of the striker plates and the floor. Clean all surfaces and bed each plate in new sealant.

Penetrations The floating pan seals at the pan penetrations have failed.

Replace all of the wiper seals.

Anti-Rotation Method The tank is equipped with an anti-rotation cable. The ladder and gauge tubes also prevent rotation.

Roof Drains The roof is not equipped with a drain.

Foam Dam Floating pan is not equipped with a perimeter foam dam.

Roof Grounding There are 2 grounding cables.

Additional Internal Floating Roof Items, Comments or Notes:

None.

Tank 740 – API 653 Inspection Appendix A, Page 9

COATINGS

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Exterior Coatings

Shell

Type/age Original epoxy coating from 1998.

General Condition In general, the exterior coating is in good condition with good adherence. Corrosion and coating failure was observed at random locations on the stairs, landings, shell valves, anchor bolts, floor projection and the cathodic protection (CP) connections.

Remove the coating from the affected areas, clean and recoat.

Nominal Thickness The average thickness of the shell coating is

13.7 mils; with a maximum thickness of 21.6 mils and a minimum thickness of 8.5 mils.

Lead and Chromate Testing Not performed.

Roof

Type/age Original epoxy coating from 1998.

General Condition In general, the exterior roof coating is in good condition with good adherence.

Localized coating failure was observed on the roof kickplate, roof appurtenances and the roof handrail posts. Approximately 5 square feet of scattered coating failure was observed on the roof plate.

Black moss was observed over much of the tank roof.

Remove the coating from the affected areas, clean and recoat.

Remove the moss by power washing or other suitable non-mechanical means.

Since the material will travel down the tank shell during cleaning, it is recommended to power wash the entire exterior of the tank.

Nominal Thickness The average thickness of the roof coating is

13.9 mils; with a maximum thickness of 19.3 mils and a minimum thickness of 10.6 mils.

Interior Coatings

Floor

Type/age Original epoxy coating from 1998.

General Condition The interior floor coating is generally in good condition. Approximately 10 square feet of scattered coating failure was observed on the floor and 5 square feet of localized coating failure on the tank column.

Nominal Thickness The average thickness of the floor coating is

13.4 mils; with a maximum thickness of 23.4 mils and a minimum thickness of 8.6 mils.

Lead and Chromate Testing Not performed.

Shell

Type/age Original epoxy coating from 1998.

General Condition In general, the shell coating is in good condition with good adherence.

Tank 740 – API 653 Inspection Appendix A, Page 10

COATINGS

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Nominal Thickness The average thickness of the shell coating is

12.1 mils; with a maximum thickness of 17.2 mils and a minimum thickness of 8.5 mils.

Lead and Chromate Testing Not Performed.

Underside Roof

Type/age Original epoxy coating from 1998.

General Condition – Roof and Structure

In general, the roof coating is in good condition with good adherence.

Approximately 100 square feet of coating failure was observed on the underside of the roof framing. The failures appear to be limited to the topcoat with no visible corrosion.

Nominal Thickness Unable to access underside of roof.

Additional Coating Items, Comments or Notes:

None.

Tank 740 – API 653 Inspection Appendix A, Page 11

APPURTENANCES

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

APPURTENANCES

Float Gauge Tank is equipped with a Varec tape gauge.

At the time of the inspection, the tape was hung up on the seal in the pan penetration and the float was suspended above the floor.

Readjust the seal in the pan penetration to allow free movement of the tape gauge float.

ATG (Automatic Tank Gauging) or RTG (Remote Tank Gauging) System

Tank is equipped with an ITT Barton ATG gauging system.

HI/HI-HI Level Alarms The high and high-high level alarms are integrated into the ITT Barton ATG system.

Low/Low-Low Level Alarms The low level alarms are integrated into the ITT Barton ATG system.

Independent Level Alarms Tank is equipped with an independent LOW, HI and HI-HI level alarm system.

Temperature Probe Temperature readings are recorded via the ATG system. There is no shell mounted temperature probe.

Gauge Tube – ATG The probe for the ATG is located within an 8 inch gauge tube.

See report for further gauge tube commentary.

Gauge Tube – Sampling/Testing/Hand Gauging

The tank is equipped with a combination ladder/gauge tube. The 8 inch gauge tube is used for manual gauging.

See report for further gauge tube commentary.

Fire Suppression System The tank is not equipped with a fire suppression system.

Product Recovery Tank (PRT) Tank is equipped with a product recovery tank.

Additional Appurtenance Items, Comments or Notes:

Tank 740 – API 653 Inspection Appendix A, Page 12

PIPING

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

PIPING

Issue

Interior Piping Size: 12-inch nozzle, 0.504 inch thick (UT).

The interior issue piping extends inward from the shell to the sump.

Exterior Piping 8-inch diameter.

Valve (Type/Condition) Valve: 12-inch General Twin Seal steel double block and bleed valve.

Body Cavity Relief: Valve has body cavity relief.

Pressure Relief Piping The pressure relief piping includes two ¼-turn ball valves and a pressure relief valve.

Low Fuel

Interior Piping Size: 6-inch nozzle, 0.418 inch thick (UT).

The interior low fuel piping consists of 4-inch diameter pipe extending inward from the shell to the sump.

Exterior Piping 6-inch diameter.

Valve (Type/Condition) Valve: 6-inch General Twin Seal steel double block and bleed valve.

The valve is equipped with minor piping (LR/DTR). The piping is open to the elements and there is a risk of damage from falling ice/snow.

Provide an ice/snow shield over the nozzle.

Pressure Relief Piping None.

Water Draw-Off

Interior Piping Size: 3-inch nozzle, 0.298 inch thick (UT)

The interior water draw-off piping consists of a 6 inch section of 3-inch pipe near the shell. The pipe reduces to 1 inch and extends into the near-center sump.

Exterior Piping 3-inch diameter.

Valve (Type/Condition) Valve: 3-inch Truseal steel double block and bleed valve.

cavity relief and LR/DTR.

Fill

Tank 740 – API 653 Inspection Appendix A, Page 13

PIPING

Comments/Recommendations

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Interior Piping Size: 10-inch nozzle, 0.513 inch thick (UT).

The interior fill piping extends inward from the shell with a 10 inch x 50 inch tapered diffuser on the end.

Exterior Piping 10-inch diameter.

High Level Shut-Off Valve (Type/Condition)

Tank is equipped with a hydraulically operated high level shut off valve on the exterior piping. It includes stainless steel pilot tubing between the valve and the float mounted in the 6th shell course. The tubing is routed such that contact is made at the wind girder.

Vibration of the tubing may cause…