8.0 Appendix G_UFC 3-460-03 Maintenance Table- v4.3.pdf

Task Number Section Description Frequency Responsibility Notes

1 A. Check permanent signs and markings for adequacy and readability. Repair or replace deteriorated or illegible signs and markings.

Monthly OM

B. Inspect the location of Department of Transportation (DOT) regulated underground pipelines and ensure they are marked in accordance with 49 Code of Federal Regulations (CFR) 195.410.

Monthly OM

C. Check that all non-DOT regulated pipelines, tanks, valves, pumps, meters, and other equipment are marked in accordance with UFC 3- 460-01 Section 2-

17. If markings are missing or insufficient, repair or add markings in accordance with UFC 3-460-01.

Monthly OM

D. Ensure petroleum fuel system Emergency Fuel Shutoff (EFSO) push buttons are properly identified at each location. Ensure that signage is properly secured and that the lettering is legible from 25 feet (7.5 meters) away and not faded.

Monthly OM

E. Verify enough movable or temporary signs are maintained in good condition to serve anticipated needs; for example: "DANGER," "CLOSED TO TRAFFIC,"

"KEEP FLAMES AWAY," "MEN WORKING," "NO SMOKING," "DANGER NO

OPEN FLAME OR IGNITION SOURCE BEYOND THIS POINT." Use bilingual signs when appropriate.

Annually OM

6 A. Open drains under flow conditions until clear fuel is observed from the drain valve.

Daily OM

7 B. Monitor differential pressure in filter cartridges. Chart differential pressure measurements from readings taken during normal operations.

Daily OM

8 C. Operate pre-filter isolation valves. Quarterly SM

D. Replace filter cartridges when the acceptable maximum differential pressure is reached, the maximum in-service duration has passed, or the fuel becomes visibly dirty or discolored. Acceptable maximum differential pressure for a specific pre-filter is dependent on the system flow rate. The Military Service-specific SCP may extend in-service duration filter cartridge replacement period based on differential pressure for high throughput systems.

Check expiration date of replacement filter cartridges before installation.

When differential pressure has reached the lower of manufacturer’s recommendation or 20 psid (140 kPa), filter cartridge in-service period of 24 months has expired, or when fuel becomes visibly dirty or discolored.

SM Routine filter changes for sites that do not self perform shall be priced under CLIN 6 FFP maintenance activities. Existing maintenance schedules when provided will be located in Appendix J. If no existing schedules have been provided, assume filter changes in Base Year and thereafter following the required service period indicated in this section. Filter changes required due to a repair, out of sequence, or other circumstance beyond normal system operation shall be performed by service order. Filter cartridges will be purchased by the Government and supplied to the Contractor.

10 E. Refer to Section 6-7.2 Differential Pressure Gauges for inspection and maintenance requirements of differential pressure gauges.

As required SM

11 F. Refer to Section 3-10.2 Automatic Air Vents for inspection and maintenance requirements of automatic air vents.

As required SM

G. Refer to Section 6-6.3 Thermal and Pressure Relief Valves for inspection and maintenance requirements of thermal and pressure relief valves.

As required SM

H. Conduct inspections of code rated vessels that meet the requirements of UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and Unfired Pressure Vessels.

As required by UFC 3-430-07 SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

14 A. Open drain under flow conditions until clear fuel is observed from the drain valve.

Daily OM

B. Monitor differential pressure of coalescer cartridges. The acceptable maximum differential pressure for a specific filter/separator is dependent on the system flow rate. Monitor and chart differential pressure measurements of filter separators from readings taken during normal operations. Investigate sudden drops or spikes in differential pressure measurement readings.

Daily OM

16 C. Operate filter separator isolation valves. Quarterly SM

17 D. Inspect components and check operation of water shutoff system. Quarterly SM

E. Change coalescer cartridges. Refer to Section 3-6.2.2 Replacement of Coalescer Cartridges for general instructions on replacement of coalescer cartridges. Military Service-specific SCP may extend the coalescer cartridge replacement frequency based on differential pressure if filters separators are used on high throughput systems. Check expiration date of replacement coalescer cartridges before installation.

Every 36 months or sooner if required by differential pressure.

SM Routine coalescer changes for sites that do not self perform shall be priced under CLIN 6 maintenance activities. Existing maintenance schedules when provided will be located in Appendix J. If no existing schedules have been provided, assume coalescer changes in Base Year and thereafter following the required service period indicated in this section. Coalescer changes required due to a repair, out of sequence, or other circumstance beyond normal system operation shall be performed by service order. Coalescer cartridges will be purchased by the Government and supplied to the Contractor.

F. Inspect and clean separator cartridges at time of coalescer cartridge change in accordance with Section 3-6.2.3 Separator Cleaning. Worn or damaged separator cartridges shall be replaced.

Every 36 months or sooner if required by differential pressure.

SM Routine separator cartridge cleaning or replacement for sites that do not self perform shall be priced under CLIN 6 maintenance activities. Existing maintenance schedules when provided will be located in Appendix J. If no existing schedules have been provided, assume separator changes/cleaning in Base Year and thereafter following the required service period indicated in this section.

Separator cleaning or changes required due to a repair, out of sequence, or other circumstance beyond normal system operation shall be performed by service order. Separator cartridges will be purchased by the Government and supplied to the Contractor.

20 G. Refer to Section 6-7.2 Differential Pressure Gauges for inspection and maintenance requirements of differential pressure gauges.

As required SM

21 H. Refer to Section 3-10.2 Automatic Air Vents for inspection and maintenance requirements of automatic air vents.

As required SM

I. Refer to Section 6-6.3 Thermal and Pressure Relief Valves for inspection and maintenance requirements of thermal and pressure relief valves.

As required SM

Tasks with responsibility identified as OM shall not be performed unless otherwise noted.

UFC Change 1, 29 April 2021 are highlighted and in bold below.

APPENDIX G – MAINTENANCE TABLE

SI

G N

A G

E A

N D

M A

R K

IN

G

S

Signage and Markings (Section 2-7)

FI

LT

R A

TI

O

N

Pre-Filters (Section 3-6.1)

Filter Separators (Section 3-6.2)

The contractor must perform maintenance tasks in accordance with the most current version of UFC 3-460-03.

Section and Appendices referred to in this maintenance table are referenced from UFC 3-460-03, 10 November 2017, Change 1, 29 April 2021

Maintenance tasks are separated into Operator Maintenance (OM) and Systems Maintenance (SM).

Tasks with responsibility identified as SM shall be performed with identified frequency as part of this contract unless otherwise noted.

23 J. Refer to Section 4-4.2.2 Filter Separator Control Valves for inspection and maintenance requirements of filter separator control valves.

As required SM

K. Conduct inspections of code rated vessels that meet the requirements of UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and Unfired Pressure Vessels.

As required by UFC 3-430-07 SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

25 A. Refer to manufacturer's operation and maintenance manual for inspection and maintenance requirements of haypack filters.

Per manufacturer's specifications

SM

26 B. Refer to Section 2-6.4 Waste Disposal for disposal requirements. As required SM

A. Monitor and chart differential pressure measurements of basket strainers from readings taken during normal operations. Investigate sudden drops or spikes in differential pressure measurement reading.

Daily OM

B. Clean and inspect basket and strainer screen. Basket strainer isolation valves shall be closed and the strainer body shall be drained before removing the cover. After cleaning, the strainer screen shall be inserted in the strainer body, and the head tightened and checked for leakage. If strainer is not equipped with means to measure differential pressure, unit shall be opened monthly and inspection.

Semi-annually if basket strainer is equipped with means to measure differential pressure; otherwise quarterly

OM

29 C. Refer to Section 6-7.2 Differential Pressure Gauges for inspection and maintenance requirements of differential pressure gauges.

As required SM

30 Filter Separator Sump Heaters (Section 3-6.5)

A. Inspect filter separator sump and drain line heater elements for proper operation per manufacturer’s operation and maintenance manual. Ensure heater elements meet manufacturer’s requirements by measuring resistance of heater elements with an ohm meter.

Semi-annually SM

31 A. Inspect counter head for unusual noises and smooth operation. Monthly OM

B. Positive displacement meters shall be inspected and calibrated semi-annually or when improper performance is suspected; when unusual sounds or register actions develop; or after repairs have been made which may affect performance. Positive displacement meters are satisfactory when the measurement error in the normal flow direction is within ±0.3% of actual quantity delivered (e.g., ±1.8 gallons for a 600-gallon test (±6.8 liters for a 2275-liter test)). Adjustment of the meter’s register will be in accordance with manufacturer’s instructions. Identify the next calibration date on meters (example: Mar 14 for March 2014). Use weather resistant label that will remain legible and affixed for at least one year.

Semi-annually or as required SM Calibration shall be done by SO if QAE requests an out of cycle calibration due to circumstances beyond normal operation.

C. Inspect temperature element operation of meters equipped with temperature compensation feature per manufacturer's operation and maintenance manual.

Semi-annually or as required SM

A. Turbine flow meters shall be inspected and calibrated semi-annually or when improper performance is suspected, register actions develop, or after repairs have been made which may affect performance. Turbine flow meters are satisfactory when the measurement error in the normal flow direction is within ±0.5% of actual quantity delivered (e.g., ±3 gallons for a 600-gallon test (±11 liters for a 2275-liter test)). Adjustment of the meter’s register will be in accordance with the manufacturer’s instructions.

Identify the next calibration date on meters (example: Mar 14 for March 2014).

Use weather resistant label that will remain legible and affixed for at least one year.

Semi-annually or as required SM Calibration shall be done by SO if QAE requests an out of cycle calibration due to circumstances beyond normal operation.

B. Inspect temperature element operation of meters equipped with temperature compensation feature per manufacturer's operation and maintenance manual.

Semi-annually or as required SM

36 A. Refer to Section 6-7.2 Differential Pressure Gauges for inspection and maintenance requirements of differential pressure gauges.

As required SM

B. Refer to Section 6-7.4 Differential Pressure Transmitters for inspection and maintenance requirements of differential pressure transmitters.

As required SM

A. Check for proper operations while pump is in use. Check suction and discharge pressure gauge for abnormal readings.

Quarterly SM

39 B. Check for unusual noise, vibration, overheating of bearings or case. Quarterly SM

40 C. If equipped with lubricating oil charge, check oil level and adjust as necessary.

Quarterly SM

41 D. Tighten or replace loose, missing or damaged nuts, bolts, or screws. Quarterly SM

42 E. Inspect suction and discharge isolation dampeners for misalignment and wear.

Quarterly SM

43 F. Inspect mechanical seals, if possible, for proper operating temperature, drips, leaks and dirt.

Quarterly SM

44 G. Check alignment, clearances, and rotation of shaft and coupler (requires removal of coupler shroud or cover).

Annually SM

45 H. Lubricate pump bearings. Annually SM

46 I. If equipped with lubricating oil charge, drain old oil, and fill with new to full mark on sight indicator (also fill bulb).

Annually SM

47 J. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors.

As required SM

48 A. Check for proper operations while pump is in use. Check suction and discharge pressure gauges for abnormal readings.

Quarterly SM

49 B. Check for unusual noise, vibration, overheating of bearings. Quarterly SM

50 C. Tighten or replace loose, missing or damaged nuts, bolts, or screws. Quarterly SM

51 D. Inspect suction and discharge isolation dampeners for misalignment and wear.

Quarterly SM

52 E. Inspect mechanical seals, if possible, for proper operating temperature, drips, leaks and dirt.

Quarterly SM

53 F. Check alignment, clearances, and rotation of shaft and coupler (requires removal of coupler shroud or cover).

Annually SM

54 G. Lubricate pump bearings. Annually SM

55 H. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors.

As required SM

56 A. Check for proper operations while pump is in use. Check discharge pressure gauge for abnormal readings.

Quarterly SM

57 B. Check for unusual noise, vibration, overheating of bearings or case. Quarterly SM

58 C. If equipped with lubricating oil charge, check oil level and adjust as necessary.

Quarterly SM

59 D. Tighten or replace loose, missing or damaged nuts, bolts, or screws. Quarterly SM

60 E. Inspect mechanical seals, if possible, for proper operating temperature, drips, leaks and dirt.

Quarterly SM

61 F. Inspect anti-rotation device for proper operation. Semi-annually SM

62 G. Check alignment, clearances, and rotation of shaft and coupler (requires removal of coupler shroud or cover).

Annually SM

63 H. Lubricate pump bearings. Annually SM

64 I. If equipped with lubricating oil charge, drain old oil, and fill with new oil to full mark on sight indicator (also fill bulb).

Annually SM

65 J. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors.

As required SM

66 A. Inspect pump for unusual noise, vibrations, and overheating of bearings and case.

Quarterly SM

67 B. Inspect mechanical seals, if possible, for drips or leaks and dirt. Quarterly SM 68 C. Lubricate pump bearings. Quarterly SM 69 D. Inspect pump and motor coupling for proper alignment. Annually SM

PU

M

PS

Centrifugal Pumps (Section 3-8.1)

Vertical Inline Pumps (Section 3-8.2)

Vertical Turbine/Submerged Turbine Pumps (Section 3-8.3)

S (S )

Basket Strainers (Section 3-6.4)

Positive Displacement Meters (Section 3-7.1)

Turbine Flow Meters (Section 3-7.2)

Orifice Flow Meters (Section 3-7.3)

Haypack Filters (Section 3-6.3)

M

ET

ER

S

70 E. Refer to manufacturer’s operation and maintenance manual for internal pressure relief testing and calibration procedures.

Annually SM

71 F. Refer to Section 3-8.4 Gearboxes for inspection and maintenance of reduction gearboxes.

As required SM

72 G. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors.

As required SM

73 A. Inspect pump for unusual noise, vibrations, and overheating of bearings and case.

Quarterly SM

74 B. Inspect mechanical seals, if possible, for drips or leaks and dirt. Quarterly SM 75 C. Lubricate pump bearings. Quarterly SM 76 D. Inspect pump and motor coupling for proper alignment. Annually SM

77 E. Refer to Section 3-8.4 Gearboxes for inspection and maintenance of reduction gearboxes.

As required SM

78 F. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors.

As required SM

79 A. Inspect hose for cracks or dry rot. Quarterly SM 80 B. Inspect compressed air connections for signs of leaks. Quarterly SM

81 C. Inspect compressed air hose coupling safety pins or safety wires for wear and damage. Replace damaged components.

Quarterly SM

D. Diaphragm pumps should have the internal diaphragm replaced if the pump shows decreased performance. Also check operation of actuator valve and ensure ball checks seat properly.

As required SM Repairs should be performed by service order.

83 Internal Combustion Drives (Section 3-8.8)

A. Refer to manufacturer’s operation and maintenance manual for specific maintenance procedures and schedules associated with a specific model of internal combustion drive. Follow all applicable general maintenance and safety requirements listed in the manufacturer’s operation and maintenance manual.

As required by manufacturer's operation and maintenance requirements

SM

84 A. Inspect gearboxes for signs of smoke near shaft connections or discoloration of the gearbox from overheating.

Quarterly SM

85 B. Verify that the oil in the sight glass is not dark or appears to have foam.

Adjust oil level if required.

Quarterly SM

86 C. Lubricate bearings per manufacturer’s recommendations. Semi-annually SM

87 D. Check motor and gear box and gear box and pump couplers for wear and alignment.

Semi-annually SM

88 E. Inspect gear alignment within gearbox. Annually SM

89 F. Replace lubricant oil in accordance with manufacturer’s specifications and recommendations.

Annually SM

A. Visually inspect hoses for loose covers, cracks, brittle surface coatings, exposed wire braids, exposed reinforcement, flattening, kinks, and bulges or soft spots which might indicate broken or displaced reinforcement.

Weekly OM

B. Pressurize hose to normal working pressure. Check flanged and threaded connections for leaks and inspect hose couplers for fluid seepage by pushing at the base of the coupling with your thumbs; a hose softened by fluid seepage must be replaced.

Monthly OM

C. Check for coupling slippage. Replace hose that shows signs of coupling slippage.

Quarterly SM When a new hose is placed in service, stencil the date (MM/YYYY) installed and paint a 50 mm (2-inch) band at each coupling. This will aid in identifying if slippage occurs and when testing is due.

D. Refer to Appendix D, Section D-2.1 Loading Hose Hydrostatic Test for loading hose hydrostatic testing requirements and procedures. Task deleted in UFC 3-460-03 Change 1.

N/A This task has been deleted.

94 E. Conduct test of fuel hose electrical resistivity using an electrostatic meter in accordance with NFPA 77 & API 2003.

Annually SM

A. Visually inspect hoses for cracks brittle surface coatings, exposed wire braids, exposed reinforcement, flattening, kinks, and bulges or soft spots which might indicate broken or displaced reinforcement.

Weekly OM

B. Check flanged and threaded connections for leaks and inspect hose couplers for fluid seepage by pushing at the base of the coupling with thumbs;

a hose softened by petroleum fluid seepage must be replaced. Damaged or leaking hoses shall be replaced immediately or isolated and taken out of service.

Quarterly SM Repairs should be performed by service order unless otherwise covered in the

PWS.

97 C. Conduct test of offloading fuel hose electrical resistivity as directed in NFPA 77 and API 2003.

Annually SM

A. Inspect operation of fuel level probes. Ensure probes operate correctly when the level of fuel in the tank rises to the level of the probe sensing unit.

Annually SM

B. Remove the float vent valve from the air eliminator tank. Clean and inspect the sealing surfaces of the float vent valve. Ensure the float is buoyant in fuel and test the valve to ensure it closes properly.

Annually SM

100 C. Refer to Section 8-9.3 Tank Pressure/Vacuum Vents for inspection and maintenance requirements of pressure vacuum vents.

As required SM

101 Automatic Air Vents (Section 3-10.2)

A. Check for proper operation of the automatic air vent. Ensure the vent opens to allow air to escape and ensure the float of the vent is buoyant in petroleum fuel and rises to close the vent when the float is suspended in petroleum fuel.

Annually SM

A. Inspect injectors to ensure they are operating properly. When fuel system has flow through it, inspect weekly.

When fuel system is sitting idle, inspect injectors monthly.

OM

103 B. Calibrate injector to ensure proper additive to fuel ratio. Annually SM

A. Verify operating settings of valve. Valve adjustment shall be in accordance with manufacturer's operation and maintenance manuals and final start-up and commissioning set points. Use of DoD standard set points should only be used as a reference starting point as pipe size and other hydraulic factors influence final system settings.

Quarterly SM

B. Remove and clean strainer installed in the petroleum fuel supply line to the pilot and main valve diaphragm. This strainer is provided to prevent clogging of the orifice in the supply line. Clogging of the screen will cause malfunctioning of the valve.

Annually for unfiltered systems and as required for filtered systems.

SM

C. Diaphragms shall be removed and inspected for deterioration and breaks at the flexing joint. Damage is often caused by pipe scale, pipe tape, and thread sealant compound that collect above the diaphragm and become lodged between the diaphragm and bonnet of the valve. Damage may also be caused by a change of operational petroleum fuel type or grade (such as a change from JP-4 to JP-8).

Every 10 years SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

107 A. Verify refuel control valve is set to maintain 100 psig (690 kPa) (typical operating pressure) as measured at the furthest hydrant outlet.

Quarterly SM

B. Verify pressure-reducing control will open at 5 psig (35 kPa) above normal operating pressure (typically 105 psig (725 kPa) as measured at the farthest hydrant outlet).

Quarterly SM

C. Verify refueling control valve opening rate is set between 15 and 20 seconds. The valve should open as quickly as possible without tripping the pressure differential control shut-off.

Quarterly SM

110 D. Verify operation of the excess flow shut-off function. Quarterly SM 111 E. Verify operation of solenoid. Quarterly SM

112 F. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

R A

N T

SY

ST

EM

General System Control Valves (Section 4- 3.2.1)

Refuel Control Valves (Section 4-3.2.5)

H O

SE

S

Loading Fuel Hoses (Section 3-9.1)

Offloading Fuel Hoses (Sections 3-9.2)

A U

TO

M

A

TI

C A

IR

V

EN

TS

Air Eliminator Tanks (Section 3-10.1)

FU

EL

A D

D

IT

IV

Fuel Additive Injectors (Section 3-11)

Sliding Vane Pumps (Section 3-8.5)

Gear Pumps (Section 3-8.6)

Diaphragm Pumps (Section 3-8.7)

Gearboxes (Section 3-8.9)

A. Verify pressure relief valve will open at 10 psig (69 kPa) above normal inlet pressure to the refuel control valve.

Semi-annually SM Maintenance procedure shall include process to verify that the valve has properly reseated after all maintenance activities are performed on pressure relief valves or thermal and pressure relief valves.

B. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM Maintenance procedure shall include process to verify that the valve has properly reseated after all maintenance activities are performed on pressure relief valves or thermal and pressure relief valves.

115 A. Verify the defuel control valve opens when the solenoid on the defuel control valve is energized.

Quarterly SM

116 B. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

117 A. Verify dual rate-of-flow control valve is set to maintain a flow rate of 200 gpm (12.5 lps).

Quarterly SM

118 B. Verify check valve feature is operational. Quarterly SM

119 C. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

120 A. Verify valve is set to maintain a flow rate of 300 gpm (19 lps). Quarterly SM 121 B. Verify operation of check valve feature. Quarterly SM 122 C. Verify solenoid operation. Quarterly SM

123 D. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

A. Verify high pressure relief control will open at 5 psig (35 kPa) above the refuel control valve pressure relief control set point (typically set at 110 psig (760 kPa)).

Quarterly SM

125 B. Verify low pressure relief control will open at 5 psig (35 kPa) when refueling pumps are stopped.

Quarterly SM

126 C. Verify closing speed provides a smooth, pulsation free operation. Quarterly SM 127 D. Verify operation of solenoid valve. Quarterly SM

128 E. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

129 A. Verify main valve opening speed (typically 20 seconds). Adjust if required. Semi-annually SM

130 B. Verify valve maintains 650 gpm (41 lps) flow rate (some instances 950 gpm (60 lps) flow rate). Adjust if required.

Semi-annually SM

131 C. Ensure the check valve function is operating properly. Semi-annually SM

132 D. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

A. Test FSCV emergency shut off solenoid under flow conditions and ensure that valve closes within 10 seconds of EFSO button activation. Coordinate with overall EFSO test listed in Section 9-1.2.1 Inspection and Maintenance - Electrical Equipment.

Quarterly SM

B. Operate test button (if installed) to ensure the FSCV closes at high water level. Physically press the test button, while recirculating fuel, and ensure the FSCV closes. Note: closing speed is a function of the number of open filters separators and the number of pumps operating. With all filters open and only one pump operating, the valve will close very slowly.

Quarterly SM

C. Verify valve maintains flow rate (typically 600 gpm (38 lps), operating range based on commissioning documentation). Adjust flow rate if required. Flow rate is determined by filter separator vessel gpm (lps) rating, or element flow rate, whichever is less. Use return venturi to measure and confirm flow rate during valve testing and adjustment.

Semi-annually SM

136 D. Ensure check valve function is operating properly. Semi-annually SM

E. Test buoyancy of water level float. Remove the ball or float assembly and place it in a bucket of water. Correctly operating ball or float will float at the top of the water’s surface.

When coalescer cartridges are changed.

SM

138 F. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

139 A. Ensure Solenoids A and B are de-energized with system in automatic mode and lead pump operating.

Quarterly SM

B. Ensure Solenoid A is energized and Solenoid B is de-energized to allow main valve to open and drop system pressure to 80 psig (550 kPa) (typical set pressure) with system in automatic mode and lead pump off.

Quarterly SM

141 C. Ensure Solenoid A is de-energized and Solenoid B is energized when system is in flush mode.

Quarterly SM

142 D. Ensure Solenoids A and B are de-energized when system is in tightness test mode.

Quarterly SM

143 E. Check opening and closing speed. Speed should be as fast as possible while still maintaining smooth operation.

Quarterly SM

144 F. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

145 A. Ensure issue venturi DPTs are reading the same value within ± 2% full scale.

Semi-annually SM

146 B. Refer to Section 6-7.4 Differential Pressure Transmitters for inspection and maintenance requirements of DPTs.

As required SM

147 A. Ensure return venturi DPTs are reading the same value within ± 2% full scale.

Semi-annually SM

148 B. Refer to Section 6-7.4 Differential Pressure Transmitters for inspection and maintenance requirements of DPTs.

As required SM

A. Verify constant upstream pressure is maintained at the setpoint established and listed in the system commissioning documents. Adjust setting of BPCV as necessary.

Quarterly SM

150 B. Ensure Solenoid A is energized and Solenoid B is de-energized while lead pump is operating in automatic mode.

Quarterly SM

151 C. Ensure Solenoids A and B are de-energized prior to lead pump shutdown and system going to stand-by.

Quarterly SM

152 D. Ensure Solenoids A and B are de-energized while system is in flush mode. Quarterly SM

153 E. Ensure that Solenoid A is de-energized and Solenoid B is energized while system is in tightness test mode.

Quarterly SM

154 F. Verify closing speed control. Valve should close as fast as possible while still maintaining smooth operation.

Quarterly SM

G. Check solenoid EFSO feature when equipped. Coordinate test with overall EFSO test listed in Section 9-1.2.1 Inspection and Maintenance - Electrical Equipment.

Quarterly SM

156 H. Refer to Section 4-4.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

157 A. Ensure Solenoid A is energized and Solenoid B is de-energized while system is in automatic mode and lead pump is operating.

Quarterly SM

B. Ensure Solenoids A and B are de-energized while system is in automatic mode and lead pump is off. Verify valve opens to maintain system pressure at 75 psig (515 kPa).

Quarterly SM

159 C. Ensure Solenoid A is energized and Solenoid B is de-energized while system is in flush mode and lead pump is operating.

Quarterly SM

160 D. Ensure Solenoids A and B are de-energized while system is in flush mode and pumps are off.

Quarterly SM

161 E. Ensure Solenoids A and B are energized while system is in tightness test mode.

Quarterly SM

Pressure Control Valves (Section 4-4.2.7)

C O

N

TR

O L

VA

LV

ES

TY

PE

II

H

YD

Pressure Relief Valves (Section 4-3.2.6)

Defuel Control Valve (Section 4-3.2.7)

Dual Rate-of-Flow Control Valves (Section 4- 3.2.8)

Combination Dual Rate-of-Flow Control and Solenoid Valves (Section 4-3.3.1)

Dual Pressure Relief, Solenoid Shutoff, and Check Valves (Section 4-3.3.2)

Non-Surge Check Valves (Section 4-4.2.1)

Filter Separator Control Valves (Section 4- 4.2.2)

Defuel/Flush Valves (Section 4-4.2.3)

Issue Venturi (Section 4-4.2.4)

Return Venturi (Section 4-4.2.5)

Back Pressure Control Valves (Section 4- 4.2.6)

C O

N

TR

O L

VA

LV

ES

TY

PE

II

I H

YD

R

A N

T

SY

ST

EM

162 F. Verify closing speed control. Valve should close as fast as possible while still maintaining smooth operation.

Quarterly SM

163 G. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

164 A. Verify HCV maintains 45 psig (310 kPa) nozzle pressure at a flow of 50 to 600 gpm (3 to 38 lps).

Quarterly SM

165 B. Verify HCV closes when nozzle pressure exceeds 50 psig (345 kPa). Quarterly SM 166 C. Verify HCV opening rate is set at a minimum of 20 seconds. Quarterly SM 167 D. Ensure HCV opens when the deadman control level is pressed. Quarterly SM

168 E. Verify HCV closes in five seconds maximum after the deadman lever is released.

Quarterly SM

169 F. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

170 A. Ensure Solenoids A and B are energized under normal operations. Quarterly SM

171 B. Ensure Solenoids A and B are de-energized during emergency stop conditions.

Quarterly SM

C. Test emergency stop function of the valve under flow conditions. Ensure the valve closes within 10 seconds of EFSO button activation. Coordinate test with overall EFSO test listed in Section 9-1.2.1 Inspection and Maintenance - Electrical Equipment.

Quarterly SM

173 D. Verify differential control maintains a constant seven psig (48 kPa) differential pressure between the inlet and outlet of the valve.

Quarterly SM

174 E. Ensure thermal relief function (ball check valve) relieves excess pressure when cover chamber pressure exceeds inlet pressure.

Quarterly SM

175 F. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

176 A. Verify PTCV maintains 55 psig (380 kPa) nozzle pressure at a flow of 50 to 600 gpm (3 to 38 lps).

Quarterly SM

177 B. Verify PTCV opens when the deadman control lever is pressed. Quarterly SM

178 C. Verify PTCV closes in a maximum of 10 seconds after deadman lever is released.

Quarterly SM

179 D. Refer to Section 4-3.2.1 General System Control Valves for additional inspection and maintenance requirements.

As required SM

180 A. Verify PPCV opens at 75 psig (515 kPa). Quarterly SM 181 B. Verify PPCV opening and closing speed are three seconds. Quarterly SM

182 A. Place entire pantograph under static pump head pressure and check for leaks, ease of movement, and damaged grounding or bonding wire.

Monthly OM

183 B. Inspect wheels (if equipped) for warping, cracking, and uneven wear. Quarterly SM 184 C. Inspect exposed piping and components for corrosion. Quarterly SM

185 D. Refer to Section 4-7.3 Fueling Nozzles for inspection and maintenance requirements of fueling nozzle.

As required SM

186 A. Place entire pantograph under static pump head pressure and check for leaks, ease of movement, and damaged grounding or bonding wire.

Monthly OM

187 B. Inspect exposed piping and components for corrosion. Quarterly SM 188 C. Lubricate wheels. Quarterly SM 189 D. Inspect wheels for warping, cracking and uneven wear. Quarterly SM

190 E. Refer to Section 4-7.2 Hydrant Adapters for inspection and maintenance requirements of pantograph hydrant adapters.

As required SM

191 F. Refer to Section 4-7.3 Fueling Nozzles for inspection and maintenance requirements of fueling nozzles.

As required SM

192 A. Inspect hydrant adapter for proper operation, damage, and wear. Quarterly SM 193 B. Test operation of dry break system. Quarterly SM

A. Inspect the condition of the dust cap at the aircraft adapter end and ensure it is in good working order. Dust caps must be attached to nozzles when they are not is use.

Monthly OM

B. Test leak resistance of poppet valve against full pump pressure. Unusual conditions found during this test indicate that repair is necessary and the nozzle shall be removed from service.

Monthly OM

C. Inspect storage racks for moisture or dirt accumulation. Correct conditions that may be attributing to accumulation of moisture or dirt in the storage racks.

Monthly OM

D. Remove nozzle for inspection of content impinged upon the mesh screen.

Clean and dry screens before nozzles are returned to service. If a strainer ball valve is installed upstream of the nozzle only the strainer in the strainer ball valve needs to be check. Nozzles should not be used while strainers are removed from upstream strainer ball valves.

Monthly OM

E. Tests nozzle interlocks. Ensure interlocks prevent release of fuel when the fueling nozzle is not properly connected. Adjust the seating of the poppet valve if required.

Monthly OM

199 F. Check the operation of the manual valve crank assembly for smooth and positive motion on a special test stand.

Monthly OM

200 A. Inspect for nitrogen leaks. Quarterly SM

B. Bladder pressure inside surge suppressors must be validated and recharged as needed with nitrogen. Some surge suppressors are also equipped with needle valves. Settings established in the startup and commissioning documents should be maintained. Adjust nitrogen charge per manufacturer’s recommendations.

Quarterly SM

A. Visually inspect hoses for loose covers, cracks, brittle surface coatings, exposed wire braids, exposed reinforcement, flattening, kinks, and bulges or soft spots which might indicate broken or displaced reinforcement.

Monthly OM

B. Pressurize hose to normal working pressure. Check flanged and threaded connections for leaks and inspect hose couplers for fluid seepage by pushing at the base of the coupling with thumbs. A hose softened by petroleum fluid seepage must be replaced.

Monthly OM

204 C. Check for coupling slippage. Replace hose that shows signs of coupling slippage.

Quarterly SM

D. For hot pit refueling hoses only, refer to Appendix D, Section D-2.1 Loading Hose Hydrostatic Test for loading hose hydrostatic testing requirements and procedures.

Annually SM

E. Conduct test of petroleum fuel hose electrical resistivity using an electrostatic meter in accordance with NFPA 77 and API 2003.

Annually SM

207 A. Verify that a green light is illuminated on the pump control panel graphic display when OV is open.

Semi-annually SM

208 B. Ensure pressure reservoir bladder is charged with 13 to 15 psig (90 to 103 kPa) of nitrogen and that the reservoir holds fuel pressure.

Semi-annually SM

C. Verify that the OV closes when the control float is lifted (normally 95% full).

Use the manual tester to lift the float. NOTE: When the float in the product recovery tank rises and the OV closes, the pressure in the pressure reservoir tank will decrease.

Semi-annually SM

D. Verify that a red light is illuminated and that an alarm is activated on the pump control panel graphic display when OV is closed. Alarm is activated by a limit switch installed on the OV.

Semi-annually SM

211 E. Ensure the pressure reservoir tank holds FTP deadhead pressure when the pump is deactivated.

Semi-annually SM

212 F. Open and clean reservoir inlet strainer. Semi-annually SMA N

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Overfill Valve for Product Recovery Tanks (Section 4-8.1)

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Aircraft Fueling Hoses (Section 4-7.5)

Hydrant Control Valves (Section 4-4.2.8)

Emergency Shut-off Valves (Section 4-4.2.9)

Surge Suppressors (Section 4-7.4)

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Pantograph Control Valves (Section 4-5.2.12)

Pantograph Pressure Control Valves (Section 4-5.2.13)

Fixed Pantographs (Section 4-7.1.1)

Detachable Pantographs (Section 4-7.1.2)

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Hydrant Adapters (Section 4-7.2)

Fueling Nozzles (Section 4-7.3)

G. Refer to Section 6-6.3 Thermal and Pressure Relief Valves for inspection and maintenance requirements of thermal and pressure relief valves.

As required SM

214 Piers and Wharves Fuel Containment Systems (5-1.2)

A. Hydrostatically test the secondary containment and associated drainage systems to include containment concrete/sealant, drain inlets, drain lines and containment drain valves to ensure containment is liquid tight. This test may use opportune rainfall by holding rainwater in the containment system for one hour. Where evaporation is a concern, conduct the testing when this concern would be minimized, such as at night/early morning or during a time of year when this would not be as much of an issue. Record the water level at the start of the 60-minute (minimum) hold period. If the water level drops by 1/8 inch or more, perform and record an investigation to determine the cause and any required repairs. Refer to Appendix B for testing procedures and to document the testing.

Every 3 Years SM Note: Hydrostatic Containment testing shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

All other Pier and Wharf Fuel Containment Systems inspection and maintenance shall be in accordance with PWS requirements.

215 A. Conduct a shore side inspection of the pier or wharf for signs of damage as soon as marine barge or tanker disembarks.

After each use OM

216 B. Inspect the ground switch used between the marine barge or tanker and the petroleum fuel receipt piping.

Monthly OM

C. Inspect mooring lines, cleats, bollards, bitts, pulley blocks, steel wire ropes, and winches. Use UFC 4-150-08 Inspection of Mooring Hardware as a guide when conducting inspections. Repair or replace damaged components as required.

Monthly OM

D. Refer to Section 6-1 Pipe Testing and Inspections for inspection and maintenance requirements of petroleum fuel pipelines installed above water surfaces. These pipelines are regulated under 33 CFR 154 and 156. Any additional requirements listed under 33 CFR 154 and 156 shall also be followed.

As required SM Pipeline pressure testing shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

219 E. Refer to Section 5-5.1 Marine Transfer Hoses for inspection and maintenance requirements of petroleum fuel marine hoses.

As required SM

F. Refer to Section 5-4 Marine Loading Arms for inspection and maintenance requirements of petroleum fuel marine loading arms.

As required SM This task is being performed by another CMP and not required under this contract.

221 G. Refer to Section 3-6.4 Basket Strainers for inspection and maintenance requirements of basket strainers.

As required SM

222 H. Refer to Section 3-7 Meters for inspection and maintenance requirements of petroleum fuel meters.

As required SM

I. Refer to Section 3-8.2 Positive Displacement Pumps for inspection and maintenance requirements of stripper pumps.

As required SM This task is being performed by another CMP and not required under this contract.

224 J. Refer to Section 9-1.6 Grounding Systems for inspection and maintenance requirements of grounding systems.

As required SM

225 A. Inspect pier or wharf for signs of damage as soon as marine barge or tanker disembarks.

After each use OM

226 B. Inspect the ground switch between the fueling tanker/barge and the fuel system.

Monthly OM

C. Inspect mooring lines, cleats, bollards, bitts, pulley blocks, steel wire ropes, and winches. Use UFC 4-150-08 Inspection of Mooring Hardware as a guide when conducting inspections. Repair or replace damaged components as required.

Monthly OM

D. Refer to Section 6-1 Pipe Testing and Inspections for inspection and maintenance requirements of petroleum fuel pipelines installed above water surfaces. These pipelines are regulated under 33 CFR 154 and 156. Any additional requirements listed under 33 CFR 154 and 156 shall also be followed.

As required SM Pipeline pressure testing shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

229 E. Refer to Section 3-6.4 Basket Strainers for inspection and maintenance requirements of basket strainers.

As required SM

F. Refer to Section 3-8 Pumps for inspection and maintenance requirements of marine loading and stripper pumps.

As required SM Stripper pump maintenance is being performed by another CMP and not required under this contract.

231 G. Refer to Section 3-7 Meters for inspection and maintenance requirements of petroleum fuel meters.

As required SM

232 H. Refer to Section 5-5.1 Marine Transfer Hoses for inspection and maintenance requirements of petroleum fuel marine hoses.

As required SM

I. Refer to Section 5-4 Marine Loading Arms for inspection and maintenance requirements of petroleum fuel marine loading arms.

As required SM This task is being performed by another CMP and not required under this contract.

234 J. Refer to Section 9-1.6 Grounding Systems for inspection and maintenance requirements of grounding systems.

As required SM

A. Check swivel for smooth operation. Check seals for signs of wear and discoloration which may indicate a seal or ball bearing failure.

Quarterly SM This task is being performed by another CMP and not required under this contract.

B. Inspect ball bearings when accessible. Rough and/or uneven wear on the surface are indications of swivel joint failure.

Annually SM This task is being performed by another CMP and not required under this contract.

C. Conduct pressure test of marine loading arms in accordance with 33 CFR

156.170 Equipment Tests and Inspections, Section (f)(1).

Annually SM This task is being performed by another CMP and not required under this contract.

A. Visually inspect transfer hoses. Transfer hoses shall have no loose covers, kinks, bulges, soft spots, and no gouges, cuts or slashes that penetrate the hose reinforcement. Hoses shall also have no external deterioration.

Before each use OM

B. Visually survey petroleum fuel marine hoses. Observe the general condition and look for fluid puddles, fine mists, physical damage such as jacket abrasion or deformation, and deteriorated joints. Use sense of smell to detect petroleum vapor. Look for improper hose handling that may overstress the hose by stretching, relative movement, or kinking.

During each use OM

C. Refer to Appendix D, Section D-2.2 Marine and Underwater Transfer Hose Hydrostatic Test for marine transfer hose hydrostatic testing requirements and procedures.

Annually or not less than 30 days prior to the first transfer conducted past one year from the date of the last test and inspection.

SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

241 Underwater Hoses (Section 5-5.2)

A. Refer to Appendix D, Section D- 2.2 Marine and Underwater Transfer Hose Hydrostatic Test for underwater hose hydrostatic testing requirements and procedures.

Annually or not less than 30 days prior to the first transfer conducted past one year from the date of the last test and inspection.

SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

A. Inspect and, if necessary, repair or replace all mooring hawsers or lines, deck hose, chain, chair stoppers, flange adaptors, gaskets or other gear used in mooring the marine tanker and in connecting hoses.

Monthly OM

243 B. Inspect air-compressor for proper operation. Annually SM

C. Inspect navigation aids and mooring buoy, in accordance with NAVFAC MO- 124 Mooring Maintenance Manual, for evidence of damage and possible movement or dragging by vessels, current or winds.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

D. Divers shall conduct underwater inspections of mooring chains, shackles and anchors attaching buoys to bay/harbor floors.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

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Marine Receipt (Section 5-2)

Marine Issue (Section 5-3)

Marine Loading Arms (Section 5-4)

Marine Transfer Hoses (Section 5-5.1)

Single Point Mooring Systems (Section 5-7.1)

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E. Conduct overhaul of single point mooring buoys every 3 to 5 years. Single point mooring buoys must be brought ashore for repair in these instances.

Every 5 years SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

A. Inspect and, if necessary, repair or replace all mooring hawsers or lines, deck hose, chain, chair stoppers, flange adaptors, gaskets or other deck gear used in mooring the marine tanker and in connecting underwater hoses.

Monthly OM

B. Inspect navigation aids and mooring buoys, in accordance with NAVFAC MO-124 Mooring Maintenance Manual, for evidence of damage and possible movement or dragging by vessels, current or winds.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

C. Divers shall conduct underwater inspections of mooring chains, shackles and anchors attaching buoys to bay/harbor floors.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

A. Inspect water above submerged pipelines and their seaward end for tell-tale petroleum fuel slicks indicating leakage from pipes or underwater hoses.

Weekly OM

B. If equipped, electrically check the cathodic protection rectifier for proper performance.

Six times each calendar year with intervals not exceeding 2½ months

SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

C. Divers shall inspect submerged pipe and hoses for signs of incipient failure or indications of rapid wear of parts subject to wave motion or abrasion on the ocean floor.

Semi-annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

D. Conduct annual pipe test as specified in Appendix G - Petroleum Fuel Pipeline Pressure testing Guidelines and Criteria. Testing requirements of marine pipelines are regulated under 33 CFR 154 and 156, particularly 33 CFR 156 Section 170.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

E. Conduct cathodic protection tests on the protected pipeline as specified in Section 9.2.1 Cathodic Protection at least once each calendar year with intervals not exceeding 15 months between tests from consecutive years.

Annually SM This task shall be performed by SO or another contract. The contractor shall identify when this task is required in the Facility Maintenance Plan.

255 A. Visually inspect hydraulic drives and hose connections for leaks. Quarterly SM 256 B. Grease bearings. Quarterly SM

257 C. Inspected boom reel for signs of corrosion. Inspect breaking system and ensure it is in good working order.

Quarterly SM

258 D. Inspect boom for wear, rips, and tears. Repair or replace as required to ensure containment of petroleum fuel in the event of a spill.

Annually SM Repairs shall be performed by SO.

259 A. Conduct petroleum fuel pipeline visual Inspection of aboveground piping in accordance with Section 6-1.5 Pipeline Visual Inspection.

Quarterly SM Repairs shall be performed by SO.

B. Conduct line walk in areas of petroleum fuel piping in accordance with Section…