tank inspection report - · pdf fileconditions noted during the field inspection are...

Northeast Florida State Hospital Tower Tank Inspection Report Project No. 46508

Tank Name: Tower Tank Type: Elevated - Legged City: MacClenny Tank Capacity: 250,000 Gallon State: FL Type of Construction: Welded Steel Built In: 1960 Built By: Taylor Iron Works Cleaned and Inspected By: LEC Maintenance Team 11 – Team Leader Andy Burson

Project Date: April 18th and 19th, 2014 GENERAL This report is a supplement to the visual inspection undertaken for the Northeast Florida State Hospital by Liquid Engineering Corporation of Billings, MT. The Tower is a welded steel elevated tank. The tank has a 250,000-gallon capacity with an overall height of approximately 110’. The tank is founded on concrete footings.

Tank Inspection ReportNortheast Florida State Hospital

Tower Liquid Engineering Corporation Job # 46508


STANDARDS The inspection of this tank was performed by a dive maintenance technician from the hatch of the reservoir and conducted in accordance with all applicable OSHA, EPA, AWWA, NACE, SSPC and ADC requirements and/or recommendations. The inspection consisted of a visual observation of the tank’s interior and exterior components and coating system. The tank was not drained for the inspection and all interior and exterior assessment data was documented using digital still photographs. CONDITION OBSERVATIONS Conditions noted during the field inspection are documented in the following pages and are supplemented with color photographs at the end of the report. Condition ratings used to describe the inspection findings are annotated as follows: Excellent: No deficiencies noted. Good: Minor deficiencies noted. Item is functioning as designed. Fair: Major deficiencies noted. Item is in need of repairs to continue functioning as designed. Poor: Repair or replacement required immediately. Item may no longer function as designed. CONTAMINATION, HEALTH & SAFETY REPORT Con tam in a t i on and Hea l t h Air Vents and Screens – There is a single mushroom style vent on the roof of the tank. It is properly

screened and in good condition, but not outfitted with a security vent shroud. Absence of a vent shroud can allow the intentional introduction of hazardous chemical or biological contaminates. (See Summary for Recommendations)

Hatches – The primary access hatch is properly sealed and secured. Roof to Wall Joint – The welded joint is properly sealed. Roof / Wall Integrity – There are no holes, cracks or standing water present on the roof or walls. Water Clarity – The water is clear; no odor or floating surface debris is present.

Fac i l i t y Sa fe t y Comp l i ance

Ladder – The primary access ladder is 150’ in overall height with an offset landing. The rungs and rails appear to be in fair condition, but the ladder is not equipped with a locking vandal guard.

Rung / Rail Spacing, Depth and Size – The rungs are spaced at 12” and have a toe depth of 7”. The rails are 2” wide, ¼” thick and the rail-to-rail span measures 16”.

Safety Climb – The ladder is equipped with a cage style fall protection system. It is securely attached and in fair condition.

Manway – The manway measures 16” x 22” and has a dogged support structure. The component appears to be in good condition with no visible indications of leaking.

Hatches – The access hatch measures 24” square. The hatch lip is 5” and the overlap is 2”. Balcony & Railing – The balcony is 36” wide and equipped with a 2-piece hand rail. The rail is 37” in

overall height, has a mid-rail at 21” and a toe kick of 7”. OSHA regulations call for the overall rail height to be no less than 42” and the mid-rail to be at least 24”. (See Summary for Recommendations)

Roof – There are six safety tie-off points on the roof of the tank. Each appears to be in good condition.


INTERIOR RESERVOIR INSPECTION REPORT

I n t e r i o r Rese rvo i r Roo f Vents – Extensive corrosion is present on the interior portions of the vent. Using the SSPC corrosion sale

with “10” being the least corroded the vent rates as a “6”. (See Appendix B for the SSPC Legend) Roof Panels– The condition of the roof panels is consistent in all quadrants. Significant corrosion and

dealloying are noted and the panels are given a “5”. Overall Protective Coating Condition – In addition to staining, blisters averaging ¼”, chalking, cracking

and pinholes are present. The coating is in poor condition.

I n t e r i o r Rese rvo i r Wa l l s Wall to Roof Weld – As is the case with the roof panels, advanced corrosion is reported at the weld. The

area is also rated as a “5” on the SSPC scale. Ring Panels – The panels are evaluated by section, lower, middle and upper, and the condition is

consistent throughout the tank. Heavy uniform surface corrosion is present in each area and the panels are rated as “5”. In addition, the lower ring panels also exhibit concentration cell corrosion in each quadrant.

Painter’s Ring – The ring also exhibits significant corrosion, dealloying and heavy staining. It is also given a “5”.

Ladder – The primary access ladder is heavily corroded and should not be used to access the reservoir. It is given a “1”.

Overall Protective Coating Condition – In addition to the discrepancies listed on the roof, pitting of up to 3/16” is noted on the walls.

I n t e r i o r Rese rvo i r F l oo r

Perimeter Joint – Concentration cell corrosion is present in each of the quadrants. The weld is rated as a “5”

Floor Panels – Prior to beginning the final inspection, the crew removed an average of skiff iron sediment and a numerous metal flakes (dealloyed from ladder and overflow stand-offs) from reservoir which allowed for a full inspection of the floor areas. Significant corrosion is also present on the walls and they are also given a “5”.

Overall Protective Coating Condition – The coating on the floor is also in poor condition. Blisters averaging 1/8”, pitting, cracking and staining are noted throughout.

I n t e r i o r Rese rvo i r P l umb ing Compon en ts

Inlet / Outlet Plumbing – The common inlet / outlet, which is positioned at the center of the reservoir, measures 10” in diameter with a 4” rise. Isolated corrosion is present and the component is given a “7”.

Overflow – The interior portion of the 10” overflow is positioned in Quadrant 4. Moderate corrosion in the form of concentration cells are visible on the base and the overflow is rated as an “8”. The upper section, approximately 7” above the floor, is of PVC construction and exhibits only staining. The stand-offs and hardware exhibit heavy surface corrosion and dealloying. (See Summary for Recommendations)

Manway – The manway penetrates the tank in Quadrant 1. Extensive rusting is noted, but no indications of leaking are present. The component is equipped with a gasket which is intact and remains pliable.

Drain – The 4” drain penetrates the floor of the reservoir in Quadrant 2. Moderate corrosion is present and the component is given an “8” on the SSPC scale.


EXTERIOR RESERVOIR INSPECTION REPORT

Ex te r i o r Rese rvo i r Roo f

Vent – Isolated corrosion is noted on the exterior vent; it rates as a “7”. Roof Panels – The panels show extensive uniform surface corrosion in each section and are given a “6” on

SSPC scale. Access Hatch – Surface corrosion and dealloying are present on the hatch. It is given a rating of “6”. Protective Coating – In addition to organic staining, chalking, pinholes, cracking and areas of delamination

are noted. Coating thickness tests performed on the roof average 8 mils and the coating is in poor conditionoverall.

Ex te r i o r Rese rvo i r Wa l l s

Wall to Roof Seam – The welded seam also rates as a “7” on the SSPC scale as isolated corrosion ispresent in each quadrant.

Ring Panels –The wall panels are again inspected in sections; upper middle and lower. Uniform surfacecorrosion is noted on the panels and they are all given the rating of “7”.

Protective Coating – The coating on the outer walls is in similar condition to that on the roof. Coatingthickness tests on the walls average 7.25 mils.

Foo t i ngs / Founda t i on

Footings / Foundation – The footings appear to be in satisfactory condition with only staining noted. Anchor Bolts – Surface corrosion is present on the bolts, but they appear to be properly tightened. Legs/Columns – The legs also appear to be in satisfactory condition. Staining and corrosion are present

and the coating thickness on the legs averages 7 mils. Riser Pipe – The riser pipe has proper alignment, is plumb and appears to be in satisfactory condition. Rods / Turnbuckles - The cotter pins / nuts appear to be in good condition overall and turnbuckles and

rods appear to be properly tightened. Staining is the only noted discrepancy.

GENERAL TANK SECURITY

Secu r i t y

Fencing – The tank is surrounded by a security fence. Perimeter – The area surrounding the tank is well lit to deter vandalism. Ladder – The primary access ladder is not equipped with a vandal guard. Vents- The air vent is not equipped with a vent security shroud to prevent the intentional introduction of

chemical or biological contaminates. This presents significant water tank security vulnerability and shouldbe addressed as a priority. To the best of LEC’s knowledge, the only practical and cost-effective securitysolution is the Omega Vent Security Shroud, evaluated by the EPA and found in its website. Unless yourequest otherwise, LEC will have ARC³’s Omega Vent Security Shroud manufacturer contact you in order toprovide detailed information to assist you in addressing this security vulnerability.

Hatches – The hatch is properly secured, but not equipped with an electronic monitoring device.


SUMMARY The INTERIOR of the tank appears to be in poor condition overall. Recommendations include:

The tank is in critical condition; a complete rehabilitation and recoat should be scheduled immediately, and completed within the next 12 months.

Upon completion of the tank rehabilitation, installation and yearly calibration of a cathodic protection system is recommended as a corrosion prevention measure.

The tank EXTERIOR appears to be in poor to fair condition. Recommendations follow:

Installation of a Vent Security Shroud is recommended for the vent. See “Security” section above for details. In addition, the outer screen material should be replaced.

A locking vandal guard should be installed on the primary access ladder to prohibit unauthorized access to the roof and hatch areas.

In accordance with OSHA regulations, with the rehabilitation, the balcony width should be increased to at least 42”, the overall rail height to 42” and the mid-rail height to a minimum of 24”.

The exterior ladder and access hatch should be replaced, as well.

At a minimum, the utility should continue to clean and inspect this tank every three years. Preventive maintenance of this nature will ensure that the identified discrepancies in this tank are closely monitored and will provide a record of care in the future.

(As a disinterested third-party inspector, LEC does not engage in the construction or rehabilitation of potable water storage facilities. LEC will, in its commitment to our clients and upon request, identify to the client relevant entities that are professionally reliable and best capable of completing the recommended work, or assist the client in research tips that will enable them to make a decision that best serves the utility.)

DISCLAIMER

Unless otherwise noted, the findings documented in this report were neither prepared by nor reviewed by a Licensed Professional Engineer.

Phillip

Florida PE Seal

Phillip

Typewritten Text

6/05/14


APPENDIX A

Photographs


Typical Conditon of Footing (note staining and severe corrosion of rod pins and anchor bolts)

Typical Condition of Balcony and Railing (note advanced corrosion)


Primary Access Hatch (note advanced severe corrosion and metal loss)

Corrosion on Roof Welds


Common Inlet / Outlet (note corrosion)

Drain and Condition of Floor (note concentration cells with pitting)


Staining and Corrosion on Middle Walls

Advanced Corrosion on Base of Overflow


Corrosion and Dealloying of Overflow Stand-Offs

Condition of Roof (note significant corrosion in all quadrants)


APPENDIX B

©Copyright 1998 ‐ 2010 Liquid Engineering Corporation – All rights reserved

DISCLAIMER Liquid Engineering does not provide consulting engineering services. Unless otherwise noted, the findings contained in this report were neither prepared nor reviewed by a licensed

Professional Engineer, but are based on experience, training and visual examination of the Dive Maintenance Technician

Liquid Engineering Corporation

Potable Water Reservoir Contamination, Health and Safety Report

Job Number: Utility: Tank:

Inspector: Dive Controller: Date: Team #:

Complies With: AWWA • OSHA • ANSI • NIOSH • NAVFAC • NFPA

MA NW A Y S

Quantity: Location: Type: Size(s): in. (24” – 18’x22” min)

Support Structure: Condition(s): Leaks:

NOTES:

E X T E R I O R L A D D E R

Quantity: Location: Attachment type: Attachment Condition:

Condition: Offset Landing: Height:

Vandal Guard: Locked: Safety Climb: Safety Climb Condition:

Rail Condition: Rung Condition: Rung Type:

Rung Spacing: in. (max 12”) Rung Toe Depth: in. (min 7”)

Rail Width: in. (min 2”) Rail Thickness: in. (min 1/4”) Rail to Rail: in. (min 16”)

NOTES:

WA L L I N T E G R I T Y

Holes: Cracking: Leaks: Misc.:

Overflow Screened: Mesh Size: Screen Condition Overflow Flapper:

NOTES:

B A L C O N Y / R A I L I N G / D E C K I N G

Type(s): Condition: Width:

Hand Rail Condition: Top Rail Height: in. (min 42”) Mid Rail Height: in. (min 24”)

Toe Rail Condition: Toe Rail Gap: in. (min ¼”) Height: in. (min 4”)

Attachment Condition: Width:

NOTES:

H A T C H E S

Type: Quantity: Size(s): in. (24” – 24’x15” min)

Hatch Lip Height: in. (min 4”) Lid Lip Height: in. (min 2”)

Secured Properly: Properly Sealed:

NOTES:

WA T E R C O N D I T I O N

Odor: Appearance: Floating Debris:

NOTES:

R O O F

Holes: Cracking: Standing Water: Safety Tie‐Off Qty:

Roof / Wall Joint: Sealed: Antennas Qty: Antenna Type(s):

Vent Type(s): Quantity: Screen Condition(s): Mesh Size:

Cathodic Cover Qty: Gasketed: Sealed: Telemetry Penetrations Qty: Gasketed: Sealed:

NOTES:

F L O A T I N G C O V E R

Condition: Holes: Tears:

NOTES:

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Steel Potable Water Reservoir Inspection Report


Inspector: Dive Controller: Date:

I N T E R I O R R E S E R V O I R R O O F

Vents

Roof Panels

Roof Support

Roof Gussets

Painting Ring

Overall Coating Rating Average Blister Diameter Average Pit Depth

Coating Deficiencies: Blistering Delamination Chalking Checking Cracking Growth Pinholes Staining Sags/Runs

I N T E R I O R R E S E R V O I R W A L L S

Wall to Roof weld ‐ ‐

Lower Ring Panels ‐

Middle Ring Panels ‐

Upper Ring Panels

Interior Ladder



I N T E R I O R R E S E R V O I R F L O O R

Perimeter Weld

Floor Panels



AMERICAN WATER WORKS ASSOCIATIONANSI/AWWA M42 / D101‐53

S SPC L e gend

Grade Description 10 No Rusting, or <Φлм҈ ƻŦ ǎǳǊŦŀŎŜ ƛǎ ǊǳǎǘŜŘ 9 Minor rusting, or <.03% of ǎǳǊŦŀŎŜ ƛǎ ǊǳǎǘŜŘ 8 Isolated rust, <.1% of surfacŜ ƛǎ ǊǳǎǘŜŘ 7 Isolated rust, <.3% of ǎǳǊŦŀŎŜ ƛǎ ǊǳǎǘŜŘ 6 Extensive rusting, <1% of surface is rusted 5 Approximately 3% of the surface is rusted 4 Approximately 10% of the surface is rusted 3 Approximately 17% of the surface is rusted 2 Approximately 33% of the surface is rusted 1 Approximately 50% of the surface is rusted 0 Approximately 100% of the surface is rusted

NACE L e g end

Grade Description A None B Uniform Surface Corrosion C Pitting D Concentration Cell Corrosion E Galvanic Corrosion F Stress Corrosion Cracking G Erosion Corrosion H Intergranular Corrosion I Dealloying

AWS L e g end

Grade Description L Satisfactory M Spatter N Porosity O Convexity / Concavity P Cracks Q Inclusions R Incomplete Fusion S Incomplete Penetration T Undercut U Underfill V Overlap W Unable to evaluate

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

QUADRANT 1 QUADRANT 2 QUADRANT 4QUADRANT 3

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Steel Potable Water Reservoir Inspection Report



I N T E R I O R R E S E R V O I R S U P P O R T C O L U M N S

Column Structures ‐ ‐

Column Bases

Column to Roof ‐

Overall Coating Rating Average Blister Diameter Average Pit Depth Coating Deficiencies: Blistering Delamination Chalking Checking Cracking Growth Pinholes Staining Sags/Runs

I N T E R I O R R E S E R V O I R P L U M B I N G C O M P O N E N T S

Inlet Plumbing ‐ ‐

Outlet Plumbing ‐

Manways

Floor Drains

Interior Overflow ‐ ‐

E X T E R I O R R E S E R V O I R R O O F

Vents

Roof Panels

Access Hatches ‐



E X T E R I O R R E S E R V O I R W A L L S

Wall to Roof Weld ‐ ‐

Lower Ring Panels

Mid Ring Panels

Upper Ring Panels

Exterior Overflow ‐ ‐



F O O T I N G S / F O U N D A T I O N

Footings / Foundations: Satisfactory Cracking Spalling Erosion/Exposed Aggregate Anchor Bolts: Satisfactory Loose Rusted Corroded (If excessive) Diameter =

T O W E R S U P P O R T S T R U C T U R E S

Tower Legs/Columns: Satisfactory Alignment Settling Rust /Corrosion Riser Pipe: Satisfactory Alignment Frost Casing Rust /Corrosion Rods & Turnbuckles: Satisfactory Turnbuckle Tension Rod Tension Cotter Pins/Rod Nuts Leg shoes/Brackets: Satisfactory Coating Rust/Corrosion Pitting/Cracking

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

SSPC NACE AWS

QUADRANT 1 QUADRANT 2 QUADRANT 4QUADRANT 3

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Circular Tank Diagram / Information Worksheet

Job Number Utility Name Tank Name

Quadrant 1 Quadrant 2 Quadrant 3 Quadrant 4

ROOF Testing and Discrepancy Locations FLOOR

Q4 Q1

Q3 Q2

Q4 Q1

Q3 Q2

Plumbing & Structure location Plumbing and structure codes O=Outlet X=Inlet Z=Manway V=Vent D=Drain S=Sump L=Ladder H=Hatch P=Overflow F=Float Level Indicator T=Telemetry

Sediment Depth Measurements Average Sediment Depth = The sum of all measurements taken, divided by the number of measurements taken

Avg. Depth Cubic Yardage Sediment Type

Column Placement

Type of Column

Base Structure

Top Structure

Column Construction

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-STAINING

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-STAINING

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ALL QUADRANTS

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-STAINING

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ALL QUADRANTS

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ALL QUADRANTS

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V

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L

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H

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X/O

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D

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P

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Light skiff of Iron on floor of tank




Coating Color


Circular Tank Diagram / NDT DFT Coating Adhesion Presence of lead


Quadrant 1 Quadrant 2 Quadrant 3 Quadrant 4

ROOF Testing and Discrepancy Locations BOWL

Roof Color Bowl Color Pedestal Color Base Leg Color

Q4 Q1 Q3 Q2

Q4 Q1 Q3 Q2

Hydropillar Base Hydropillar Base

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©Copyright 1998 - 2009 Liquid Engineering Corporation – All rights reserved




Steel Potable Water Reservoir Security / Measurement Worksheet


Security Is the area surrounding the tank well lit?

Is the tank surrounded by a Security Fence?

Are the access gates locked?

Is the tank equipped with a Vandal Guard on the primary access ladder?

If so, is the Vandal Guard locked?

Are the vents equipped with security vent shrouds?

Are all of the hatches equipped with electronic monitoring devices?

Are the external plumbing components housed in a secure vault or out-building?

Does the surrounding geography of the tank obscure it from public view?

Does the exterior of the tank show signs of trespass?

Measurements Vent Roof Outside Circumference

Inches

Inlet Outlet Drain Overflow

Inches Inches Inches Inches Inches Inches Inches Inches Overflow Wall Inlet Riser Outlet Riser Inches Inches Feet/Inches Inches Floor Floor Floor

Flange Metal Thickness Inches

Roof to Screen or Flange Inches Flange

Number of Bolt Holes Inches

Size of Bolts Inches

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Common Inlet/Outlet





Steel Potable Water Reservoir Immediate Needs Assessment



1. Health and Safety Items Safety Climb System Installation:

Vent Screen Repairs:

2. Testing Items

Dye Testing for Leak Evaluation:

Presence of Lead Test (Interior/Exterior):

3. Destructive Testing Items

% of Lead Test (Interior/Exterior) (Coating samples are removed for laboratory analysis)

Coating Adhesion Test (Interior/Exterior):

Specific written authorization required to perform destructive testing. Destructive tests include touch‐up of coating system.

4. Repair Items

Epoxy Coating Repairs:

Temporary Leak Repairs:

Float Operated Level Indicator Repairs / Maintenance:

Hypalon Repairs:

5. Security Related Items (Critical security upgrade information is immediately available)

Tank vents are not equipped with a security vent shroud:

Tank hatches are not equipped with a security hatch locking device:

Tank perimeter not adequately secured:

The above mentioned additional work is considered immediately necessary and is recommended to be completed. Some items may be completed in conjunction with work currently being performed while the crew is on site.

Reservoir Inspection Condition Supplemental

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