Attachment 2 MCAS Yuma HFAM Site Survey Report_v3.pdf

Energy Automation Operational Technology Sustainment (EAOTS)

Hydrant Fueling Automation Maintenance

(HFAM)

Site Survey Report (SSR) / ROM

MCAS Yuma Fixed Wing/ Rotary Wing Hot Pits MCAS Yuma, AZ DoDAAC:SE5C08

Revision 1.0 April 14, 2025

Prepared by:

FAIRBANKS, AK

1603 College Road

Fairbanks, Alaska 99709

Site Survey Report – Fixed Wing/Rotary Wing Hot Pits Control - MCAS Yuma, AZ

Controlled Unclassified Information (CUI)

1. INTRODUCTION

1.1. Purpose

1.2. Report Contents and Site Location

1.3. Location: MCAS Yuma HFAM Hot Pits

2. SITE SURVEY

2.1. Survey Team Members

2.2. Survey Period

3. ACCOMPLISHMENTS

3.1. Site Survey Areas

4. SITE OVERVIEW

4.1. Pump House, Operational Control Center (OCC) Workstation, Motor Control Center (MCC), Bay Associates Control Panel

4.2 Rotary Wing Hot Pits

4.3 Fixed Wing Hot Pits

4.4 Findings

5. RECOMMENDATIONS

1. INTRODUCTION

1.1. Purpose

The objective of this site survey is to evaluate and verify the current site conditions, which include verifying the technical requirements of an existing Modification Request and the request for an additional site survey by the maintenance contractor. This site survey and analysis incorporates site configuration, operational requirements, reviewing As-Built drawings for accuracy, and troubleshooting Start/Stop issues at the Rotary Wing and Fixed Wing hot pits to determine repairs needed and recommendations.

1.2. Report Contents and Site Location

This report describes the participants and activities that occurred during the site survey and outlines the overall accomplishments. In subsequent sections, each surveyed area will be described, variances from supporting documentation noted, and automation listed in each section.

Of note:

1. KRC was provided with an email containing some history on the issue.

1.3. Location: MCAS Yuma HFAM Hot Pits

2. SITE SURVEY

2.1. Survey Team Members

Members of the site survey team, organization, telephone numbers and email addresses are shown below.

NAME ORGANIZATION PHONE NUMBER EMAIL ADDRESS

Paul Bryant KRC - Senior Controls Engineer (843) 909-2599 paul.bryant@kcorpalaska.com

Bill Hayden KRC – Senior Field Engineer (843) 513-2683 bill.hayden@kcorpalaska.com

Table 2-1 Survey Team Members

2.2. Survey Period

The site survey was conducted during a 2-day period from 07-08APR2025. Weather conditions were sunny and warm for the duration and had no negative impact on the successful completion of the survey. Security issues and site access were not an issue during the survey. Site operations personnel provided escorts and transportation for the survey team to have access to all affected areas as needed.

An in-brief was held with KRC, site management, and site operations team to define site survey requirements. The local Start/Stop stations are not operational at both the Fixed Wing and the Rotary Wing hot pits. Because of this the operations teams must run the system in manual causing safety issues, additional resource requirements, and requiring multiple system resets daily. The affected areas are:

- Pump house with MCC, OCC workstation, and Bay Associates control panel

- Rotary Wing hot pits RFP-1 and RFP-2.

- Underground conduit path between the pump house and the Rotary Wing hot pits

- Fixed Wing fueling operations building with RFP - Remote Control Panel.

- Fixed Wing hot pits FP-1 (left and right), FP-2 (left and right), FP-3 (left and right), and FP-4 (left and right).

- Underground conduit path from the pump house to the Fixed Wing operations building.

3. ACCOMPLISHMENTS

3.1. Site Survey Areas

The HFAM system at MCAS Yuma consists of the following areas:

• Pump House with OCC workstation, MCC, and Bay Associates control panel

• Rotary Wing Hot Pits

• Fixed Wing fueling operations building with RFP Remote Control Panel

• Fixed Wing Hot Pits

• Underground duct bank system from the Pump House to the Rotary Wing Hot Pits and Fixed Wing Hot Pits

The team surveyed the HFAM system and conducted troubleshooting on the Start/Stop function at both the Rotary Wing and Fixed Wing hot pits.

4. SITE OVERVIEW

Figure 1. MCAS Yuma HFAM System

4.1. Pump House, Operational Control Center (OCC) Workstation, Motor Control Center (MCC), Bay Associates Control Panel

The Pump House stores the MCC for all Pumps (1-4), the OCC workstation, and the Bay Associates HFAM control panel. Each pump motor control center is equipped with a Hand- Off-Auto (HOA) switch. The Auto position allows the operators to start the system and then use the Start/Stop stations at the fueling positions to start the pumps. The Hand (manual) position bypasses the HFAM system, and the operators must start and stop the pumps from the MCC Start/Stop stations. The operators can oversee operations and system status from the workstation.

4.2 Rotary Wing Hot Pits

The Rotary Wing hot pits consist of two (2) fueling positions, RFP-1 and RFP-2, a Start/Stop station for each RFP, and an E-stop.

4.3 Fixed Wing Hot Pits

The Fixed Wing hot pits consist of a fueling operations building which houses the RFP remote control panel and four (4) fueling positions with a left and right side for each. Each fueling position has a Start/Stop station and E-stop.

4.4 Findings

1. The drawings provided in Inteldocs for the Rotary Wing hot pits are labeled “Preliminary - Not for Construction” and does not show any wiring for the push-button control stations.

2. The Fixed Wing hot pits drawings provided in Inteldocs are labeled “For Construction” but do not include any of the changes found on site or any schematics for the push-button controls beyond a basic typical wiring schematic without any terminal or relay connection points or wire numbers. Both packages require red lines to be updated to match current site conditions.

3. While tracing wires for the Rotary Wing hot pits control stations, KRC found multiple loose wires on terminal blocks and relays for the control circuit. After tightening these, KRC had site start the pumps from the Rotary Wing pits. Controls from the pits worked without issue and continue to work.

Figure 2: Rotary Wing Start Control Relay Loose Wiring Term A2

4. While tracing wires for the Fixed Wing hot pits control circuit, it was found that the RFP panel at the Fixed Wing hot pits is wired incorrectly. The 3PDT relay is not original to the design and the wiring is not shown in the drawing.

1. There is a broken conductor between the Fixed Wing control relay in the pump house and the control relay in the Fixed Wing operations building RFP control panel. Conductors are labeled “3” and “4”.

2. There is transient voltage present on both conductors between the Fixed Wing control relay in the Pump House and the control relay in the Fixed Wing operations building RFP panel. While the conductors are disconnected at both ends, there is voltage present to ground on both conductors.

3. The 3PDT relays in the Bay Associates control panel and the Fixed Wing RFP panel are not original to the design and the wiring is not shown in the drawing.

Figure 3: Fixed Wing RFP Panel BLDG 1505

4. The Start/Stop circuit wiring in the Fixed Wing RFP panel will not work the way it is currently wired; Further wire tracing and toning is needed to provide a correct wiring schematic which will require redlines to the drawing.

5. The coil on the 3PDT relay is 120VAC powered from a local panel. It seems this relay was intended to interpose the low voltage circuit from the pumphouse to compensate for voltage drop.

6. There is a 120VAC circuit going back towards the Pump House and two (2) low voltage circuits on blue 16AWG wires. KRC was able to trace one (1) circuit back to the Pump control panel, but the other is getting lost in the handhole system somewhere. Further tracing/toning is required to find the circuit.

7. The Littlefuse ISS-102ACI-MC I.S. 2-channel switch located in the RFP panel at the Fixed Wing operations building was installed under maintenance to replace the existing Ametek 52-110100 relay because it was all the maintenance sub-contractor had on hand. The only I.S.

circuits in the drawing are for the Emergency Fuel Shut Off (EFSO) circuits.

8. All wiring associated with the HFAM pump controls needs to be labeled to match the drawings. Most wires are currently labeled with a terminal number inside of the panel. There is nothing showing where the wiring is going to or coming from in the field.

9. The Site reports at both the Fixed Wing and Rotary Wing, the start/stop station used to start the pumps must also be used to stop the pumps. If another stop button is used, the pumps will not restart until the original Start/Stop station’s stop button is pressed or the system is reset in the control room. KRC does not see how this is possible given the current wiring and configuration and were unable to recreate the issue while on site. This should be tested and corrected if necessary to ensure this is not the case after the repair is done.

5. The Site reports that the EFSO circuit is working correctly and wired according to the drawings. KRC was unable to test the EFSO circuit to validate this due to site operations and time constraint. During the survey the site was running WTI.

1. The EFSO pushbuttons are wired in series with an addressable module connected to each push-button to send a signal to the safety controller to show which was pressed.

5. RECOMMENDATIONS

1. KRC does not believe an additional site visit should be required. KRC has verified the PWS that was provided is accurate, and there is no concern with intrinsically safe requirements in the pump control circuit.

2. Test the Littlefuse switch and the Start/Stop Control relay in the RFP Panel and replace them if required.

3. Correct the wiring in the RFP panel for the Fixed Wing Start/Stop control circuit relay, and Littlefuse switch.

4. Pull new 14AWG twisted pair shielded cable from the Fixed Wing control relay in the Bay Associates panel at the Pump House to the RFP panel located at Building 1505.

5. Label all wiring with unique wire numbers.

6. Create a combined As-Built site electrical and control drawing to match site conditions.

7. Test the system to ensure proper operation.

2.2. Survey Period

5. RECOMMENDATIONS