CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

 Report On Tank 15 Phase 2 As Built 

Repairs 

March, 2006

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Summary

This report is the second report by Dunkin and Bush, Inc. to document weld repairs 

completed in Tank 15. The first report documented 73 weld repairs completed in June 

2005 (D&B repair numbers 15001 – 15073). Those repairs were specified in a 

government provided spreadsheet based on the TESTEX inspection report dated 

2/28/2005. 

This second report documents an additional 89 weld repairs and other repairs / 

modifications completed through March 2006. The additional repairs are based on the 

API 653 Inspection Report by Weston Solutions dated September 2005, and by 

directions received from the government. 

The report by Weston Solutions included recommendations for repairs which were 

completed by Dunkin & Bush consisting of the following: 

Repairs based on API Report Recommendations 

1. 53 patch plates to correct 73 flaws. 

2. 31 weld repairs to existing weld seams. 

3. Removal of unused anchors, clips, and angles at the tank bottom. 

4. Replacement of existing supports on the 18” line at the tank bottom. 

5. Weld repair of interior circumferential joints on the 32” line beneath the tank. 

6. Investigation of grout nozzles not tested (resulting in removal and patch plate 

repair over 5 nozzles). 

7. Performance of coating repairs on 112 each 3” grout nozzles. 

8. Performance of coating repairs to patch plates, weld repairs, grout nozzles, 

expansion joint, and 82 square meters scattered around the lower dome and 

barrel. 

Other Repairs 

Other repairs were completed as directed by the government based on results of 

contract specified testing / inspection, and user requests. These other repairs include: 

1. Removal, repair, and retesting of the existing slop line; supply and installation of 

a new 6” valve. 

2. Relocation of the existing ladder in the central tower from quadrant A to the 

quadrant B side of the tower. 

3. Structural repairs to the central tower (weld repairs and replacement of 

fasteners). 

4. Replacement of sample line valves in the lower tunnel. 

5. Removal of counterweight tube, float, tape, guy wires, and attachments. 

6. Removal of the central tower elevator cage and steps & landing at the tower 

base. 

These repairs are summarized and described in this report. 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Table of Contents 

Section 1 Summary of weld and patch plate repairs 15074 – 15162 

Section 2 Removal of unused anchors, clips, and angles at tank bottom 

Section 3 Replacement of 18” line supports at tank bottom 

Section 4 Repair of 32” line internal circumferential joints 

Section 5 Coating repairs 

Section 6 Other repairs 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 1 

Summary of weld and patch plate repairs 15074 – 15162 

The following table summarizes the patch plate and weld repairs recommended by 

Weston Solutions in table 2.1 of their September 2005 API-653 Inspection Report. 

89 repairs covering 104 flaws are described in the table. Each phase 2 repair has been 

assigned a Dunkin & Bush repair number from 15074 to 15162. Dunkin & Bush also 

assigned a unique number to each of the flaws identified for repair by Weston to keep 

them in sequence. The Dunkin & Bush assigned flaw numbers can be seen in repair 

photographs. 

5 repairs were added as the result of further examination of grout nozzles for flaws 

(15158 – 15162). Five flawed nozzles were removed and patched over with an 8” 

diameter plate. 

Typical patch plate repairs (note the Dunkin & Bush assigned flaw numbers)

Dunkin & Bush, Inc. 

 
Section 1 Tank 15 Phase 2 Weld Repair As Built Summary

Phase 2 D&B Weston

D&B Repair 

No. Quadrant V Drop Row

Flaw 

Number

Flaw 

Number As Built Repair PT Ac

15074 A Barrel 13 28 201 3 8" x 8" x 1/4" patch plate 24-J15075 A Barrel 12 8 to 9 202 53 Weld repair 24-J15076 A Barrel 12 14 203 54 Weld repair 24-J15077 A Barrel 12 14 204 55 Weld repair 24-J15078 A Extension 13 4 205 66 12"x14-3/8"x1/4" patch plate 23-J15079 A Barrel 15 4 206 68 Weld repair 30-J15080 A Barrel 15 5 207 69 Weld repair 24-J15081 A Barrel 16 14 208 71 Weld repair 24-J15082 A Barrel 18 13 209 90A Weld repair 24-J15083 A Barrel 18 13 210 90 Weld repair 24-J15084 A Extension 18 4 211 91 9"x10"x1/4" patch plate 23-J15085 A Extension 14 3 212 153 One 28"x48"x1/4" patch plate covers flaws 153, 150, 23-J

A Extension 14 3 213 150 152, 149, and 151A Extension 14 3 214 152A Extension 14 3 215 149A Extension 14 3 216 151

15086 A Extension 13 3 217 134 One 16"x30"x1/4" patch plate covers flaws 134, 135, 30-J

A Extension 13 3 218 135 136, 137, and 138A Extension 13 3 219 136A Extension 13 3 220 137A Extension 13 3 221 138

15087 A Extension 15 2 222 156 10"x16" patch plate 23-J15088 A Extension 16 1 223 157 8"x1/4" round patch plate 23-J15089 A Barrel 19 3 224 93 Weld repair 30-J15090 A Upper Dome A 18 225 133 8"x1/4" round patch plate 23-J15091 A Upper Dome A 12 226 154 10"x16" patch plate 30-J15092 A Upper Dome A 12 227 155 8"x1/4" round patch plate 23-J15093 A Upper Dome A 15 228 158 10"x8"x1/4" patch plate 23-J15094 B Barrel 4 28 229 1 8"x8"x1/4" patch plate 24-J15095 B Barrel 5 28 230 2 6"x1/4" round patch plate 24-J
Section 1 Tank 15 Phase 2 Weld Repair As Built Summary

Phase 2 D&B Weston

D&B Repair 

No. Quadrant V Drop Row

Flaw 

Number

Flaw 

Number As Built Repair PT Ac

15096 B Extension 3 4 231 6 One 14"x16"x1/4" patch plate covers flaws 6 and 6A 24-J

B Extension 3 4 232 6A

15097 B Barrel 4 1 233 11 One 30"x40"x1/4" insert plate covers flaws 11, 12, 23-J

B Barrel 4 1 234 12 and 13B Barrel 4 1 235 13

15098 B Barrel 2 1 236 10 Weld repair 24-J15099 B Barrel 4 2 237 19 One 10"x16" patch plate covers flaws 19 and 20 23-J

B Barrel 4 2 238 20

15100 B Barrel 4 2 239 22 One 24"x17"x1/4" patch plate covers flaws 22 and 23 23-J

B Barrel 4 2 240 23

15101 B Barrel 4 2 241 16 6"x1/4" round patch plate 23-J15102 B Barrel 6 1 242 28 6"x1/4" round patch plate 29-D15103 B Barrel 6 3 243 29 Weld repair 23-J15104 B Barrel 6 4 244 32 Weld repair 23-J15105 B Barrel 6 7 245 31 Weld repair 23-J15106 B Extension 10 4 246 51 Weld repair 23-J15107 B Extension 10 4 247 52 Weld repair 23-J15108 B Extension 1 3 248 97 One 12"x16"x1/4" patch plate covers flaws 97 and 98 24-J

B Extension 1 3 249 98

15109 B Extension 1 3 250 102 6"x1/4" round patch plate 24-J15110 B Extension 1 3 251 104 One 6"x12"x1/4" patch plate covers flaws 104 and 105 29-D

B Extension 1 3 252 105

15111 B Extension 1 3 253 106 6"x1/4" round patch plate 24-J15112 B Extension 1 3 254 108 6"x10" patch plate 30-J15113 B Extension 1 3 255 107 8"x1/4" round patch plate 9-Ja15114 B Extension 1 3 256 109 8"x8"x1/4" patch plate 9-Ja15115 B Extension 1 3 257 99 One 10"x18"x1/4" patch plate covers flaws 99 and 100 24-J

B Extension 1 3 258 100

15116 B Extension 1 3 259 103 6"x1/4" round patch plate 24-J15117 B Extension 2 3 260 121 One 8"x14"x1/4" patch plate covers flaws 121 and 122 24-J
Section 1 Tank 15 Phase 2 Weld Repair As Built Summary

Phase 2 D&B Weston

D&B Repair 

No. Quadrant V Drop Row

Flaw 

Number

Flaw 

Number As Built Repair PT Ac

B Extension 2 3 261 122

15118 B Extension 2 3 262 123 8"x8"x1/4" patch plate 24-J15119 B Extension 2 3 263 124 8"x1/4" round patch plate 24-J15120 B Extension 2 3 264 125 One 6"x12"x1/4" patch plate covers flaws 125 and 126 29-D

B Extension 2 3 265 126

15121 B Extension 7 2 266 129 10"x10"x1/4" patch plate 30-J15122 B Extension 8 2 267 131 8"x1/4" round patch plate 23-J15123 B Extension 8 1 268 132 Weld repair 23-J15124 B Upper Dome C 28 269 162 10"x10"x1/4" patch plate 30-J15125 C Extension 1 4 270 7 Weld repair 25-J15126 C Extension 1 4 271 7A Weld repair 9-Ja15127 C Barrel 4 6 272 18 Weld repair 9-Ja15128 C Barrel 6 5 273 33 Weld repair 25-J15129 C Barrel 6 5 274 34 Weld repair 25-J15130 C Barrel 6 15 275 38 Weld repair 25-J15131 C Barrel 6 16 276 39 Weld repair 9-Ja15132 C Barrel 6 16 277 40 Weld repair 25-J15133 C Barrel 6 16 278 41 Weld repair 9-Ja15134 C Barrel 9 24 279 43 Weld repair 9-Ja15135 C Barrel 9 10 280 46 Weld repair 25-J15136 C Barrel 11 13 281 48 Weld repair 9-Ja15137 C Upper Dome A 46 282 95 6"x1/4" round patch plate 29-D15138 C Upper Dome A 48 283 94 6"x1/4" round patch plate 29-D15139 C Upper Dome B 52 284 142 6"x1/4" round patch plate 29-D15140 D Barrel 13 18 285 59 8"x1/4" round patch plate 30-J15141 D Barrel 15 14 286 61 One 8"x1/4" round patch plate covers flaws 61 and 62 9-Ja

D Barrel 15 14 287 62

15142 D Barrel 15 11 288 63 8"x1/4" round patch plate 9-Ja15143 D Barrel 16 14 289 65 8"x1/4" round patch plate 24-J15144 D Barrel 17 12 290 77 Weld repair 9-Ja
Section 1 Tank 15 Phase 2 Weld Repair As Built Summary

Phase 2 D&B Weston

D&B Repair 

No. Quadrant V Drop Row

Flaw 

Number

Flaw 

Number As Built Repair PT Ac

15145 D Barrel 17 14 291 80 8"x1/4" round patch plate 24-J15146 D Barrel 18 14 292 84 Weld repair 25-J15147 D Barrel 22 16 293 88 8"x1/4" round patch plate 9-Ja15148 D Extension 13 1 294 111 One 8"x1/4" round patch plate covers flaws 111 29-D

D Extension 13 1 295 112 and 112

15149 D Extension 13 2 296 113 Weld repair 9-Ja15150 D Extension 13 3 297 114 Nozzel removed, hole covered with 8"x1/4" round plate 24-J15151 D Extension 14 1 298 116 6"x1/4" round patch plate 9-Ja15152 D Extension 15 2 299 117 8"x1/4" round patch plate 30-J15153 D Extension 16 1 300 118 6"x10" patch plate 24-J15154 D Extension 18 1 301 119 8"x1/4" round patch plate 30-J15155 D Barrel 23 22 302 8 8"x1/4" round patch plate 30-J15156 D Barrel 23 23 303 9 8"x1/4" round patch plate 30-J15157 D Barrel 13 58 304 145 6"x1/4" round patch plate 9-Ja15158 C Lower Dome 4 1 501 188 Nozzel removed, hole covered with 8"x1/4" round plate 3-Fe15159 C Barrel 5 28 502 187 Nozzel removed, hole covered with 8"x1/4" round plate 9-Ja15160 A Lower Dome 15 4 503 182 Nozzel removed, hole covered with 8"x1/4" round plate 24-J15161 B Barrel 9 2 504 180 Nozzel removed, hole covered with 8"x1/4" round plate 24-J15162 B Barrel 5 2 505 176 Nozzel removed, hole covered with 8"x1/4" round plate 30-J
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 2 

Removal of unused anchors, clips, and angles at tank bottom 

Unused anchors, clips, and angles were removed from the tank bottom as 

recommended by Weston Solutions. Areas where these attachments were removed 

were ground smooth and vacuum box tested (if removed from the bottom plates). 

Tank 15 bottom after anchors and clips were removed. Also note where the elevator 

landing platform and steps were removed from the facing side of the tower structure.

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 3 

Replacement of 18” line supports at tank bottom 

The 18” line supports were removed and replaced as recommended by Weston 

Solutions. Two existing supports were removed, areas where they were attached to the 

tank bottom were ground smooth and vacuum box tested. 

One new support was installed shown in the photograph below. Reinforcing plates 

attached to the tank bottom were PT’d and vacuum box tested. 

 

New 18” line support with re-pads

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 4 

Repair of 32” line internal circumferential joints 

Five internal circumferential weld joints of the 32” line beneath the tank bottom were 

weld repaired and PT’d as recommended by Weston Solutions. Locations are shown on 

the Weston Solutions sketch dated 12/29/5. 

View looking down the 32” line from inside tank 15. Note the circumferential weld before 

the bend. This is weld repair “A” identified in the Weston Solutions sketch.

Dunkin & Bush, Inc. 

 
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02P-1562 an employef!-ownership company
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 5 

Coating repairs 

Coating repairs were completed using the approved single coat paint system with 

surface preparation done in accordance with manufacturers recommendations. 

Coating application was completed in the following areas: 

1. 89 weld and patch plate repairs. 

2. 112 grout nozzles. 

3. Scattered areas of the lower dome and barrel totaling approximately 82 square 

meters. Coating repair areas in the lower dome were described in the Dunkin & 

Bush Report on Coating Failure Observations dated September 30, 2005. 

Tank 15 Lower Dome Coating Repairs 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

Section 6 

Other repairs including slop line, tower, etc. 

Other repairs were completed in tank 15 as directed by the government and based on 

results of contract specified testing, inspection, differing site conditions, and user 

requests. These repairs include: 

1. Removal, repair, reinstallation and testing of the 6” slop line. The existing 

slop was removed as directed by the government. The flexible stainless steel 

portion of the line was found to be leaking at weld joints and was replaced with a 

24 foot section of new 5” diameter flexible stainless steel tubing. The existing 

carbon steel slop line pipe was re used, with a new flange installed at the lower 

tunnel. 

View of new slop line from lower tunnel before installation of 6” valve. 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

2. Relocation of the ladder in the central tower from the quadrant “A” side (facing) 

to the quadrant “D” side (right side of photograph). This required cutting and re 

welding clips connecting the ladder over the full height of the tower. 

Tank 15 relocated ladder – note the clips attaching the ladder to the tower. 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

3. Central tower structural repairs including the installation of 48 missing 

fasteners, and repairs to cracked weld joints below the catwalk platform on the 

tower structure. 

Typical area of replaced fasteners - note plug weld repair of flame cut holes.

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

4. Replacement of sample line valves in the lower tunnel. 

Tank 15 sample line valves at lower tunnel – note added branch and valve for filling 

sample bottles.

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

5. Removal of the existing counterweight tube, gauge float, guy wires and 

attachments. 

View of tank 15 bottom area where gauging equipment and attachments were removed

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

6. Removal of the elevator cage and lower landing & steps from the central tower 

structure. 

Area where elevator cage was removed at the platform level – note the relocated 

ladder. 

Dunkin & Bush, Inc. 

 
CONTRACT NUMBER N62742-03-C-1402 

CLEAN AND REPAIR TANKS 1, 6, 15, AND 16, AT RED HILL 

FLEET AND INDUSTRIAL SUPPLY CENTER, PEARL HARBOR, HAWAII 

View of tank 15 bottom area where the elevator platform and steps were removed. 

Dunkin & Bush, Inc.