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 doc umented 73 weld repairs completed in June 2005 (D&B repair numbers 15001 – 15073). Thos e repairs were specified in a government provided spreadsheet based on the TESTEX inspection report dated

2/28/2005.

This second report documents an addition al 89 weld repairs and other repairs / modifications completed through March 2006. The additional repairs are based on the API 653 Inspection Report by Weston So lutions 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, clip s, and angles at the tank bottom. 4. Replacement of existing supports on the 18” line at the tank bottom. 5. Weld repair of interior circumferent ial joints on the 32” line beneath the tank. 6. Investigation of grout nozzles not te sted (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 direct ed by the government based on results of contract specified testing / inspection, and user requests. These other repairs include:

1. Removal, repair, and retest ing 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, fl oat, tape, guy wires, and attachments.

6. Removal of the central tower elevat or 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 in ternal 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 ea ch of the flaws identified for repair by Weston to keep them in sequence. The Dunkin & Bush a ssigned 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 SummaryPhase 2 D&B WestonD&B RepairNo. Quadrant V Drop RowFlawNumberFlawNumber As Built Repair PT AcceptedVac BoxAccepted15074 A Barrel 13 28 201 3 8" x 8" x 1/4" patch plate 24-Jan-06 31-Jan-0615075 A Barrel 12 8 to 9 202 53 Weld repair 24-Jan-06 31-Jan-0615076 A Barrel 12 14 203 54 Weld repair 24-Jan-06 31-Jan-0615077 A Barrel 12 14 204 55 Weld repair 24-Jan-06 31-Jan-0615078 A Extension 13 4 205 66 12"x14-3/8"x1/4" patch plate 23-Jan-06 31-Jan-0615079 A Barrel 15 4 206 68 Weld repair 30-Jan-06 31-Jan-0615080 A Barrel 15 5 207 69 Weld repair 24-Jan-06 31-Jan-0615081 A Barrel 16 14 208 71 Weld repair 24-Jan-06 31-Jan-0615082 A Barrel 18 13 209 90A Weld repair 24-Jan-06 31-Jan-0615083 A Barrel 18 13 210 90 Weld repair 24-Jan-06 31-Jan-0615084 A Extension 18 4 211 91 9"x10"x1/4" patch plate 23-Jan-06 31-Jan-0615085 A Extension 14 3 212 153 One 28"x48"x1/4" patch plate covers flaws 153, 150, 23-Jan-06 31-Jan-06A Extension 14 3 213 150 152, 149, and 151A Extension 14 3 214 152A Extension 14 3 215 149A Extension 14 3 216 15115086 A Extension 13 3 217 134 One 16"x30"x1/4" patch plate covers flaws 134, 135, 30-Jan-06 31-Jan-06A Extension 13 3 218 135 136, 137, and 138A Extension 13 3 219 136A Extension 13 3 220 137A Extension 13 3 221 13815087 A Extension 15 2 222 156 10"x16" patch plate 23-Jan-06 31-Jan-0615088 A Extension 16 1 223 157 8"x1/4" round patch plate 23-Jan-06 31-Jan-0615089 A Barrel 19 3 224 93 Weld repair 30-Jan-06 31-Jan-0615090 A Upper Dome A 18 225 133 8"x1/4" round patch plate 23-Jan-06 31-Jan-0615091 A Upper Dome A 12 226 154 10"x16" patch plate 30-Jan-06 31-Jan-0615092 A Upper Dome A 12 227 155 8"x1/4" round patch plate 23-Jan-06 31-Jan-0615093 A Upper Dome A 15 228 158 10"x8"x1/4" patch plate 23-Jan-06 31-Jan-0615094 B Barrel 4 28 229 1 8"x8"x1/4" patch plate 24-Jan-06 31-Jan-0615095 B Barrel 5 28 230 2 6"x1/4" round patch plate 24-Jan-06 31-Jan-06Section 1 Tank 15 Phase 2 Weld Repair As Built SummaryPhase 2 D&B WestonD&B RepairNo. Quadrant V Drop RowFlawNumberFlawNumber As Built Repair PT AcceptedVac BoxAccepted15096 B Extension 3 4 231 6 One 14"x16"x1/4" patch plate covers flaws 6 and 6A 24-Jan-06 31-Jan-06B Extension 3 4 232 6A15097 B Barrel 4 1 233 11 One 30"x40"x1/4" insert plate covers flaws 11, 12, 23-Jan-06 31-Jan-06B Barrel 4 1 234 12 and 13B Barrel 4 1 235 1315098 B Barrel 2 1 236 10 Weld repair 24-Jan-06 31-Jan-0615099 B Barrel 4 2 237 19 One 10"x16" patch plate covers flaws 19 and 20 23-Jan-06 31-Jan-06B Barrel 4 2 238 2015100 B Barrel 4 2 239 22 One 24"x17"x1/4" patch plate covers flaws 22 and 23 23-Jan-06 31-Jan-06B Barrel 4 2 240 2315101 B Barrel 4 2 241 16 6"x1/4" round patch plate 23-Jan-06 31-Jan-0615102 B Barrel 6 1 242 28 6"x1/4" round patch plate 29-Dec-05 31-Jan-0615103 B Barrel 6 3 243 29 Weld repair 23-Jan-06 31-Jan-0615104 B Barrel 6 4 244 32 Weld repair 23-Jan-06 31-Jan-0615105 B Barrel 6 7 245 31 Weld repair 23-Jan-06 31-Jan-0615106 B Extension 10 4 246 51 Weld repair 23-Jan-06 31-Jan-0615107 B Extension 10 4 247 52 Weld repair 23-Jan-06 31-Jan-0615108 B Extension 1 3 248 97 One 12"x16"x1/4" patch plate covers flaws 97 and 98 24-Jan-06 31-Jan-06B Extension 1 3 249 9815109 B Extension 1 3 250 102 6"x1/4" round patch plate 24-Jan-06 31-Jan-0615110 B Extension 1 3 251 104 One 6"x12"x1/4" patch plate covers flaws 104 and 105 29-Dec-05 31-Jan-06B Extension 1 3 252 10515111 B Extension 1 3 253 106 6"x1/4" round patch plate 24-Jan-06 31-Jan-0615112 B Extension 1 3 254 108 6"x10" patch plate 30-Jan-06 31-Jan-0615113 B Extension 1 3 255 107 8"x1/4" round patch plate 9-Jan-06 31-Jan-0615114 B Extension 1 3 256 109 8"x8"x1/4" patch plate 9-Jan-06 31-Jan-0615115 B Extension 1 3 257 99 One 10"x18"x1/4" patch plate covers flaws 99 and 100 24-Jan-06 31-Jan-06B Extension 1 3 258 10015116 B Extension 1 3 259 103 6"x1/4" round patch plate 24-Jan-06 31-Jan-0615117 B Extension 2 3 260 121 One 8"x14"x1/4" patch plate covers flaws 121 and 122 24-Jan-06 31-Jan-06Section 1 Tank 15 Phase 2 Weld Repair As Built SummaryPhase 2 D&B WestonD&B RepairNo. Quadrant V Drop RowFlawNumberFlawNumber As Built Repair PT AcceptedVac BoxAcceptedB Extension 2 3 261 12215118 B Extension 2 3 262 123 8"x8"x1/4" patch plate 24-Jan-06 31-Jan-0615119 B Extension 2 3 263 124 8"x1/4" round patch plate 24-Jan-06 31-Jan-0615120 B Extension 2 3 264 125 One 6"x12"x1/4" patch plate covers flaws 125 and 126 29-Dec-05 31-Jan-06B Extension 2 3 265 12615121 B Extension 7 2 266 129 10"x10"x1/4" patch plate 30-Jan-06 31-Jan-0615122 B Extension 8 2 267 131 8"x1/4" round patch plate 23-Jan-06 31-Jan-0615123 B Extension 8 1 268 132 Weld repair 23-Jan-06 31-Jan-0615124 B Upper Dome C 28 269 162 10"x10"x1/4" patch plate 30-Jan-06 31-Jan-0615125 C Extension 1 4 270 7 Weld repair 25-Jan-06 31-Jan-0615126 C Extension 1 4 271 7A Weld repair 9-Jan-06 31-Jan-0615127 C Barrel 4 6 272 18 Weld repair 9-Jan-06 31-Jan-0615128 C Barrel 6 5 273 33 Weld repair 25-Jan-06 31-Jan-0615129 C Barrel 6 5 274 34 Weld repair 25-Jan-06 31-Jan-0615130 C Barrel 6 15 275 38 Weld repair 25-Jan-06 31-Jan-0615131 C Barrel 6 16 276 39 Weld repair 9-Jan-06 31-Jan-0615132 C Barrel 6 16 277 40 Weld repair 25-Jan-06 31-Jan-0615133 C Barrel 6 16 278 41 Weld repair 9-Jan-06 31-Jan-0615134 C Barrel 9 24 279 43 Weld repair 9-Jan-06 31-Jan-0615135 C Barrel 9 10 280 46 Weld repair 25-Jan-06 31-Jan-0615136 C Barrel 11 13 281 48 Weld repair 9-Jan-06 31-Jan-0615137 C Upper Dome A 46 282 95 6"x1/4" round patch plate 29-Dec-05 31-Jan-0615138 C Upper Dome A 48 283 94 6"x1/4" round patch plate 29-Dec-05 31-Jan-0615139 C Upper Dome B 52 284 142 6"x1/4" round patch plate 29-Dec-05 31-Jan-0615140 D Barrel 13 18 285 59 8"x1/4" round patch plate 30-Jan-06 31-Jan-0615141 D Barrel 15 14 286 61 One 8"x1/4" round patch plate covers flaws 61 and 62 9-Jan-06 1-Feb-06D Barrel 15 14 287 6215142 D Barrel 15 11 288 63 8"x1/4" round patch plate 9-Jan-06 1-Feb-0615143 D Barrel 16 14 289 65 8"x1/4" round patch plate 24-Jan-06 1-Feb-0615144 D Barrel 17 12 290 77 Weld repair 9-Jan-06 1-Feb-06Section 1 Tank 15 Phase 2 Weld Repair As Built SummaryPhase 2 D&B WestonD&B RepairNo. Quadrant V Drop RowFlawNumberFlawNumber As Built Repair PT AcceptedVac BoxAccepted15145 D Barrel 17 14 291 80 8"x1/4" round patch plate 24-Jan-06 1-Feb-0615146 D Barrel 18 14 292 84 Weld repair 25-Jan-06 1-Feb-0615147 D Barrel 22 16 293 88 8"x1/4" round patch plate 9-Jan-06 1-Feb-0615148 D Extension 13 1 294 111 One 8"x1/4" round patch plate covers flaws 111 29-Dec-05 1-Feb-06D Extension 13 1 295 112 and 11215149 D Extension 13 2 296 113 Weld repair 9-Jan-06 1-Feb-0615150 D Extension 13 3 297 114 Nozzel removed, hole covered with 8"x1/4" round plate 24-Jan-06 1-Feb-0615151 D Extension 14 1 298 116 6"x1/4" round patch plate 9-Jan-06 1-Feb-0615152 D Extension 15 2 299 117 8"x1/4" round patch plate 30-Jan-06 1-Feb-0615153 D Extension 16 1 300 118 6"x10" patch plate 24-Jan-06 1-Feb-0615154 D Extension 18 1 301 119 8"x1/4" round patch plate 30-Jan-06 1-Feb-0615155 D Barrel 23 22 302 8 8"x1/4" round patch plate 30-Jan-06 1-Feb-0615156 D Barrel 23 23 303 9 8"x1/4" round patch plate 30-Jan-06 1-Feb-0615157 D Barrel 13 58 304 145 6"x1/4" round patch plate 9-Jan-06 1-Feb-0615158 C Lower Dome 4 1 501 188 Nozzel removed, hole covered with 8"x1/4" round plate 3-Feb-06 1-Feb-0615159 C Barrel 5 28 502 187 Nozzel removed, hole covered with 8"x1/4" round plate 9-Jan-06 1-Feb-0615160 A Lower Dome 15 4 503 182 Nozzel removed, hole covered with 8"x1/4" round plate 24-Jan-06 1-Feb-0615161 B Barrel 9 2 504 180 Nozzel removed, hole covered with 8"x1/4" round plate 24-Jan-06 1-Feb-0615162 B Barrel 5 2 505 176 Nozzel removed, hole covered with 8"x1/4" round plate 30-Jan-06 1-Feb-06CONTRACT 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 w here these attachments were removed were ground smooth and vacuum box tested (if removed from th e 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 suppor ts were removed, areas wher e 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” ident ified in the Weston Solutions sketch.

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02P-1562 an employef!-ownership companyCONTRACT 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 accordanc e with manufacturers recommendations.

Coating application was comple ted 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 lowe r dome were described in the Dunkin & Bush Report on Coating Failure Observ ations 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, in spection, 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 gov ernment. 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 flexib le stainless steel tubing. The existing carbon steel slop line pipe was re used, wit h a new flange installed at the lower

tunnel.

View of new slop line from lower tunnel before inst allation 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 t he quadrant “A” side (facing) to the quadrant “D” side (right side of phot ograph). This required cutting and re welding clips connecting the ladder ov er the full height of the tower.

Tank 15 relocated ladder – note the clip s 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 jo ints 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 attachme nts 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 el evator platform and steps were removed.

Dunkin & Bush, Inc.