Henderson Water Utilitystorage.hkywater.org/adobe/bids/201838_4_Star_Tank_Inspection_Report.pdfAWWA D100-11; 12.6.1: Foundations states "The top of the piers shall be 6" above the

Henderson Water Utility

111 Fifth Street

Henderson, KY 42420

RE: 4- Star Tank

1,000,000 Gallon E.W.T.

March 12, 2014

Mr. Tom Williams, P.E.

General Manager

(270) 869-6621

Job No. 314031- C

If you would like to speak with Patrick Heltsley concerning this report, call (270) 826-9000, Ext 253

For additional copies of this report call (270) 826-9000 Ext. 253


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

2

Pittsburg Tank & Tower Maintenance Co., Inc. March 12, 2014

Photo shows the condition of 1 of the 9 foundations. AWWA D100-11; 12.6.1: Foundations states "The top of the piers shall be 6" above the finished grade." We recommend clearing any dirt, debris and other loose gravel away from the tank foundations, down to a minimum 6” below top of foundations.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

3


Photo shows the condition of the foundation. We recommend repairing any cracks and spalling in the concrete and grout beneath the plates with a commer-cial non-shrinking grout. We further recommend sealing the foundation piers with a sealant.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

4


Photo shows 1 out of 9 piers, which appears to be in good condition. We recom-mend the tank be electrically grounded for lightning protection as required by OSHA 29 CFR 1926, Subpart K.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

5


Photos show the condition of 1 of 22 anchor bolts. The structural integrity of the anchor bolts should be maintained to withstand 100 m.p.h. winds blowing from any direction as required by AWWA D100-11; 3.8: Foundation bolts. We recom-mend cleaning the area around the anchor bolts, tightening the anchor bolt nuts to specifications and tack weld the bolt to nut and nut to base plate connections to prevent from loosening. We further recommend touching up areas effected by repair process.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

6


Photos show more of the condition of the anchor bolts. Minor surface rust is pre-sent on a few of them.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

7


Photo shows the base of the riser pipe. Currently there is no riser drain valve. A drain valve performs two functions it allows the tank to be drained and it is used as a blowout to remove silt and scale from the lower portion of the tank. We rec-ommend installing a frost proof drain valve, complete with locking device to pre-vent unauthorized draining of the tank and a splash pad to direct water away from the foundation.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

8


Photo shows the tank name plate, which appears to be in good condition.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

9


Photos show the condition of the 18” riser manway. This manway would restrict entry in an emergency. We recommend replacing the existing riser manway with an TSS; 7.0.8: Access, AWWA D100-11: 5.4.4 approved 30" manway, complete with a hinge, a Confined Space Entry sign and maintenance free galvanized steel bolts. As an alternative option, we recommend installing a davit arm.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

10


Photos show the condition of the 8” overflow pipe system. To bring overflow in compliance with TSS; 7.0.7: Overflow (B) states, “The overflow shall be screened with a twenty-four mesh non-corrodible screen. The screen shall be installed within the overflow pipe at a location least susceptible to damage by vandalism.” Notice a twenty-four mesh is not present and is allowing ingress of insects. We recommend to install a screen as preventive maintenance and paint overflow where needed.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

11


Photo shows the condition of the tower access ladder. We recommend cutting the ladder at the point of deflection, realigning ladder and then reconnecting lad-der by welding.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

12


The tower access ladder in above photos is 16” wide. The following is required to bring the ladder in compliance with TSS; 7.0.12: Safety, AWWA D100-11; 5.4.2.4: Ladders. We recommend an aluminum lockable ladder guard to prevent unauthorized access. We further recommend posting a Fall Protection Re-quired sign to bring the ladder into compliance with OSHA 1926.1053(a)


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

13


Photos show the condition of the windage rods. The windage rods are in tune and are properly adjusted.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

14


Photo shows the condition of the strut end connections. The strut ends have been seal welded and appear to be in good condition.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

15


Photo shows the sections of the riser pipe and riser cone and bowl. The riser stay rods are in good condition and properly adjusted.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

16


Photos show the condition of the existing handrail system, which is in good con-dition and is in compliance with OSHA 29 CFR 1910.23(e)(1). We recommend installing a stainless steel chain gate at the top and intermediate rail openings at the junction of the tower access ladder and structural girder as required by OSHA 29 CFR 1910.23(e)(1).


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

17


Photos show the condition of the balcony floor. The arrows are pointing to show where water is ponding, causing deterioration of the paint and steel. We recom-mend drilling additional weep holes in the balcony floor to prevent ponding of water.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

18


Photo shows the condition of the existing 24” shell manway. The following items are required to bring the tank into compliance with TSS; 7.0.8: Access and OSHA 1910.36: General requirements.

We recommend :

Install 30'' secondary shell manway 180º from primary manway

Install davit slide on both shell manways

Post Confined Space Entry signs


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

19


Photo shows the posthead connections, which appear to be in good condition.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

20


Shell/roof access ladder in above photos is equipped with anti-skid rungs and is 16'' wide. Notice the missing safety climb. TSS; 7.0.12: Safety and OSHA 1910.27 Ladders states: "Minimum clear distance between the sides of individu-al rung/step ladders and between the side rails of other fixed ladders must be 16 inches (41 cm)." We recommend installing a cable type ladder safety device.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

21


Photo shows more of the condition of the existing 16” wide shell/roof access lad-der. Safe climbing procedure requires a person to climb a ladder with their hands on the side rails of the ladder and not the ladder rungs. Notice a coax is mounted on the ladder side rail, creating a climbing safety hazard. We rec-ommend removing the coax from the ladder and securing it, with standoffs to the tank shell to eliminate this climbing safety hazard.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

22


Photos show that the tank roof is not equipped with a required fall protection system. OSHA 1910.23 Subpart c requires fall protection on the edges of all walking working surfaces. We recommend installing a 42" high handrail system around the circumference of the tank roof, complete with toeboard, intermediate rail and a stainless steel gate chain at the junction of the shell-to-roof access ladder and tank roof.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

23


Photo shows the condition of the 24” primary manway. Roof openings on this tank require the following to be in compliance with TSS; 7.0.8: Access, OSHA 29 CFR 1910.23(a)(1) and AWWA D100-11 5.4.3.1: roof openings.

We recommend:

Post Confined Space Entry sign

Install new lock on existing manway


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

24


Photo shows the condition of the 24” secondary roof manway. Roof openings on this tank require the following to be in compliance with TSS; 7.0.8: Access, OSHA 29 CFR 1910.23(a)(1) and AWWA D100-11 5.4.3.1: roof openings.

We recommend:

Replace 24” secondary roof manway with a 30” manway Post Confined Space Entry sign


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

25


Photos show the condition of the existing 24” roof vent. TSS; 7.0.9: Access and AWWA D100-11; 5.5.2: Screening states, "When the vent is provided with screening against insects, a pressure-vacuum screened vent or a separate pressure-vacuum relief mechanism shall be provided that will operate in the event that the screens frost over or become clogged." An improperly vented tank may cause external pressure to act on the tank which can cause buckling even at low pressure differential. We recommend replacing the ex-isting roof vent with a 24” vacuum-pressure, frost proof vent and screen.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

26


Photos show the tank is equipped with a sonar liquid level indicator, which ap-pears to be in good condition.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

27


Photos show the tank exterior coating system, which is estimated at 1%- 2% paint failure with very minimal areas of rust.. We recommend pressure washing the tank exterior with (minimum 3,500 psi at 3.0 gpm), then remove all loose rust and scale with wire brushes and hand scrapers in accordance with SSPC#2 (hand tool cleaning) and touch up paint on flaky areas to prolong the life of the tank.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

28


Photos show more of the tank exterior coating system.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

29




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

30




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

31




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

32




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

33


Photos show the condition of the interior roof. Notice the rust forming at the roof lap seams. We recommend seam sealing using Sikaflex® 1a on all un-welded interior roof lap seams to prevent failure of the interior liner.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

34


Interior access ladder in above photo is equipped with anti-skid rungs and is 16” wide. TSS; 7.0.12: Ladders and OSHA 29 CFR 1926.1050-1060 states: "Rungs… must be corrugated, knurled, dimpled, coated with skid-resistant ma-terial or treated to minimize slipping " We recommend installing a stainless steel cable type ladder safety device.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

35


Interior bowl ladder in above photo is equipped with anti-skid rungs and is 16” wide. To be in compliance with TSS; 7.0.12: Ladders and OSHA 29 CFR 1926.1050-1060. We recommend installing a stainless steel cable type ladder safety device.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

36


Photo shows the bowl to riser access ladder is 16” wide and is equipped with anti-skid. To be in compliance with TSS; 7.0.12: Ladders and OSHA 29 CFR 1926.1050-1060. We recommend installing a cable type ladder safety device.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

37


Above photo shows before the clean out was preformed. Bottom photo shows after clean out was preformed.

We also recommend installing a passive cathodic protection system on the inte-rior of the tank.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

38


Photo shows the riser access ladder is 16” wide and is equipped with anti-skid rungs. To be in compliance with OSHA 29 CFR 1926.1050-1060. We recom-mend installing a cable type ladder safety device.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

39


Photos show riser opening is not equipped with handrails as required by OSHA

1910.23 (c)(1). We recommend installing an OSHA approved 42” high handrail

system around the circumference of the riser to bowl opening, complete with in-termediate rail and toeboard. We further recommend to remove the safety grat-ing in accordance with installing handrails around riser to bowl opening.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

40


Photo shows a fill pipe on the tank interior. A temperature difference between the water in the top and bottom of a tank, even as little as 1-2 degrees Fahren-heit, is an indication of thermal stratification, and the tank water not completely mixed. Incomplete mixing would result in short-circuiting and localized increase in water age would develop inside the tank. This typically leads to water quality problems, such as loss of residual, DBP spikes, HPC spikes, bacteria regrowth, formation of biofilm, changes in pH and dissolved oxygen. We recommend in-stalling a mixing system.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

41


Photo shows the tank is not equipped with a syphon line, to drain the remaining water out of the lower portion of the bowl. We recommend installing a 2” sy-phon line in the riser.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

42


Photos show the interior coating system, which is at 10% - 15% paint failure. We recommend sandblasting all rusted and abraded areas of the tank interior to an SSPC #10 (near white blast) condition, brush blast all remaining areas, stripe coat all seams and welds, then apply an epoxy liner to achieve 8-10 mils of dry film thickness.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

43


Photos show more of the interior coating system.


RE: 4- Star Tank

1,000,000 Gallon E.W.T.

44




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

45




RE: 4- Star Tank

1,000,000 Gallon E.W.T.

46




111 Fifth Street

Henderson, KY 42420

March 12, 2014

Mr. Tom Williams, P.E.

General Manager

(270) 869-6621

ELEVATED TANK INSPECTION REPORT

JOB NO: INSPECTOR: Levi Marez (WG)

TANK OWNER: Henderson Water Utility

OWNER’S REPRESENTATIVE: Mr. Tom Williams, P.E.

TITLE: General Manager

MAILING ADDRESS: 111 Fifth Street Henderson, KY 42420

PHYSICAL ADDRESS: 111 Fifth Street Henderson, KY 42420

CITY, STATE: ZIP: Henderson, KY 42420 COUNTY: Henderson County

TELEPHONE: (270) 869-6621 FAX: (270) 826-2428

LOCATION OF TANK: 4- Star Tank

ORIGINAL CONTRACT NO: 5818 YEAR BUILT: 2003

ORIGINAL MANUFACTURER: PT & T CAPACITY: 1,000,000 Gallon

DATE OF LAST INSPECTION: Unknown TYPE: Potable

DIAMETER: 70’-0” HIGH WATER LEVEL: 158’-0”

HEAD RANGE: 40’-0”

TYPE CONSTRUCTION: WELDED: X RIVETED: BOLTED:

ACCOUNT EXECUTIVE: Vicky Caudill

314031- C

E-MAIL: [email protected]

LOW WATER LEVEL: 118’-10”

48

Henderson Water Utility- C 1,000,000 Gallon E.W.T.

Exterior Interior

Lead Check Negative Negative

Adhesion Test @ Mil Thickness Reading A3 @ 12.2 A3 @ 18.6

49


Page # Work Proposed

Crit

ical

Def

icie

ncy

NO

N-C

riti

cal D

efic

ienc

y

OSH

A

Stru

ctur

al

Prev

enti

ve M

aint

enan

ce

2Clear any dirt, debris and other loose gravel away from the tank

foundation, down to a minimum 6" below top of foundations .X

Repair any cracks and spal l ing in the concrete and grout

beneath the plates with a commercia l non-shrinking grout.X

Seal the foundation piers with a sea lant. X

4 Electrica l ly ground the tank for l ightning protection. X X

Clean the area around the anchor bolts and tighten the anchor

bolt nuts to speci fications , then tack weld around the

ci rcumference of the bolt-to-nut and nut-to-base plate

connections to to prevent from loosening.

X

Touch up areas effected by repair process . X

7

Insta l l a frost-proof dra in va lve complete with locking device to

prevent unauthorized dra ining of the tank and a splash pad to

di rect water away from the foundation.

X

Replace the exis ting 18" ri ser manway with a 30" ri ser manway. X

Insta l l hinge on manway. X

Post Confined Space Entry s ign. X

Insta l l maintenance free ga lvanized s teel bolts . X

Alternative option, insta l l a davi t arm XInsta l l a screen on the overflow pipe as preventive

maintenance X X

Paint overflow where needed. X

11Cut the ladder at the point of deflection, rea l ign ladder and

then reconnect ladder by welding.X

Insta l l an a luminum ladder guard at the tower access ladder X X

Post Fall Protection Required s ign. X

16

Insta l l a s ta inless s teel chain gate at the top and intermediate

ra i l openings at the junction of the tower access ladder and

s tructura l gi rder.

X

17Dri l l additional weep holes in the ba lcony floor to prevent

ponding of water.X

Insta l l 30" secondary shel l manway 180º from primary manway. X

Insta l l davi t s l ides on both shel l manways . X

Post Confined Space Entry s igns . X

3

5

9

12

18

10

50


Page # Work Proposed

Criti

cal D

efic

ienc

y

NO

N-C

ritic

al D

efic

ienc

y

OSH

A

Stru

ctur

al

Prev

entiv

e M

aint

enan

ce

20Insta l l a cable type ladder safety device at shel l /roof access

ladder.X

21

Remove the coax from the shel l /roof access ladder and secure i t

with s tandoffs to the tank shel l to el iminate this cl imbing

safety hazard.

X

22

Insta l l a 42" high handra i l system around the ci rcumference of

the tank roof, complete with toeboard, intermediate ra i l and a

s ta inless s teel gate chain at the junction of the shel l -to-roof

access ladder and tank roof.

X

Post Confined Space Entry s ign at primary roof manway. X

Insta l l new lock on exis ting manway. X

Replace 24” secondary roof manway with a 30” manway. X

Post Confined Space Entry s ign. X

25Replace the exis ting roof vent with a 24" vacuum-pressure , frost

proof vent and screen.X X X

27

Pressure wash the tank exterior with (minimum 3,500 ps i at 3.0

gpm), then remove a l l loose rust and sca le with wire brushes

and hand scrapers in accordance with SSPC#2 (hand tool

cleaning) and touch up paint on flaky areas to prolong the l i fe

of the tank.

X

33Seam seal ing us ing Sikaflex® 1a on a l l un-welded interior roof

lap seams. X

34Insta l l a s ta inless s teel cabel type ladder safety device on the

interior access ladder.X

35Insta l l a s ta inless s teel cabel type ladder safety device on the

interior bowl ladder.X

36Insta l l a s ta inless s teel cable type ladder safety device on the

bowl to ri ser access ladder.X

37Insta l l a pass ive cathodic protection system on the interior of

the tank.X

38 Insta l l a cable type ladder safety device on riser access ladder. X

Insta l l an approved 42” high handra i l system around the

ci rcumference of the ri ser opening, complete with intermediate

ra i l and toeboard.

X

Remove the safety grating. X

40 Insta l l a mixing system. X

41 Insta l l a 2” syphon l ine in the ri ser. X

42

Sandblast a l l rusted and abraded areas of the tank interior to

an SSPC #10 (near white blast) condition, brush blast a l l

remaining areas , s tripe coat a l l seams and welds , then apply

an epoxy l iner to achieve 8-10 mi ls of dry fi lm thickness .

X

39

24

23

Documents

Henderson Water Utilitystorage.hkywater.org/adobe/bids/201838_4_Star_Tank_Inspection_Report.pdfAWWA D100-11; 12.6.1: Foundations states "The top of the piers shall be 6" above the