Draft - Appendix B - Attachment 3 Recurring Maintenacne Report Template.pdf

Task Number Section Frequency Responsibility -

Army Responsibility -

Navy/USMC Responsibility -

Air Force Notes

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

Monthly OM OM 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 OM 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 OM 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 OM 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 OM OM

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

Daily OM OM OM

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

Daily OM OM OM

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

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

As required SM SM SM

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

As required SM SM 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 SM 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 SM 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 OM 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 OM OM

16 C. Operate filter separator isolation valves. Quarterly OM OM SM

17 D. Inspect components and check operation of water shutoff system. Quarterly OM OM 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 SM 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 SM 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 li d t th C t t

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

As required SM SM SM

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, Change 2, 24 August 2023

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.

UFC Change 2, 24 August 2023 are highlighted and in bold below

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.

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

Monthly OM OM OM

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

As required SM SM 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 SM SM

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 SM 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 SM 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 SM SM

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

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

Daily OM OM 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 OM OM

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

As required SM SM 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 SM SM

31 A. Inspect counter head for unusual noises and smooth operation. Monthly OM OM 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 SM SM Calibration shall be done by SO if QAE requests an out of cycle calibration due to circumstances beyond normal operation.

C. Positive displacement meters with temperature compensator feature must be inspected and calibrated semi-annually. Calibration procedures will be followed according to manufacturer’s recommendation.

Semi-annually SM SM SM

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

Semi-annually or as required SM SM SM

A. Turbine flow 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. 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 SM SM Calibration shall be done by SO if QAE requests an out of cycle calibration due to circumstances beyond normal operation.

B. Turbine flow meters with temperature compensator feature must be inspected and calibrated semi-annually. Calibration procedures will be followed according to manufacturer’s recommendation.

Semi-annually SM SM SM

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 SM SM

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

As required SM SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

Annually SM SM SM

47 H. Lubricate pump bearings. Annually SM SM SM

48 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 SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

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

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

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

Annually SM SM SM

56 G. Lubricate pump bearings. Annually SM SM SM 57 H. Refer to Section 9-1.7 Electric Motors for inspection and maintenance requirements of electric motors As required SM SM SM

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

63 F. Inspect anti-rotation device for proper operation. Semi-annually SM SM SM 64 G. Check alignment, clearances, and rotation of shaft and coupler (requires removal of coupler shroud or cover) Annually SM SM SM

65 H. Lubricate pump bearings. Annually SM SM SM

66 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 SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

69 B. Inspect mechanical seals, if possible, for drips or leaks and dirt. Quarterly OM OM OM 70 C. Lubricate pump bearings. Quarterly SM SM SM 71 D. Inspect pump and motor coupling for proper alignment. Annually SM SM SM

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

Annually SM SM SM

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

As required SM SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

76 B. Inspect mechanical seals, if possible, for drips or leaks and dirt. Quarterly SM SM SM 77 C. Lubricate pump bearings. Quarterly SM SM SM 78 D. Inspect pump and motor coupling for proper alignment. Annually SM SM SM

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

As required SM SM 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)

Sliding Vane Pumps (Section 3-8.5)

Gear Pumps (Section 3-8.6)

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

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

As required SM SM SM

81 A. Inspect hose for cracks or dry rot. Quarterly SM SM SM 82 B. Inspect compressed air connections for signs of leaks. Quarterly SM SM SM

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

Quarterly SM SM 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 SM SM Repairs should be performed by service order.

85 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 SM SM

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

Quarterly SM SM SM

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

Adjust oil level if required.

Quarterly SM SM SM

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

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

Semi-annually SM SM SM

90 E. Inspect gear alignment within gearbox. Annually SM SM SM

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

Annually SM SM 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 OM 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 OM OM

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

Quarterly SM OM 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 N/A N/A This task has been deleted.

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

Annually SM SM 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 OM 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.

Monthly OM OM OM Repairs should be performed by service order unless otherwise covered in the

PWS.

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

Annually SM SM 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 SM 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 SM SM

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

As required SM SM SM

103 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 SM 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 OM OM

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

109 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 SM 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 SM 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 SM SM

112 D. Verify operation of the excess flow shut-off function. Quarterly SM SM SM 113 E. Verify operation of solenoid. Quarterly SM SM SM

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

As required SM SM SM

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

Semi-annually SM SM 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 SM 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

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

Quarterly SM SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

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

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

As required SM SM SM

122 A. Verify valve is set to maintain a flow rate of 300 gpm (19 lps). Quarterly SM SM SM 123 B. Verify operation of check valve feature. Quarterly SM SM SM 124 C. Verify solenoid operation. Quarterly SM SM SM

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

As required SM SM 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 SM SM

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

Quarterly SM SM SM

128 C. Verify closing speed provides a smooth, pulsation free operation. Quarterly SM SM SM 129 D. Verify operation of solenoid valve. Quarterly SM SM SM

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

As required SM SM SM

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

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

Semi-annually SM SM SM

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

Diaphragm Pumps (Section 3-8.7)

Gearboxes (Section 3-8.9)

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)

C

O N

TR

O

L

VA

LV

ES

TY

PE

II

H

YD

R A

N T

SY

ST

EM

General System Control Valves (Section 4- 3.2.1)

Refuel Control Valves (Section 4-3.2.5)

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)

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

As required SM SM 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 SM 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 SM 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 SM SM

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

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

As required SM SM SM

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

Quarterly SM SM 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 SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

As required SM SM SM

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

Semi-annually SM SM SM

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

As required SM SM SM

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

Semi-annually SM SM SM

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

As required SM SM 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 SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

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

Quarterly SM SM 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 SM SM

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

As required SM SM SM

159 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 SM 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 SM SM

161 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 SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

167 B. Verify HCV closes when nozzle pressure exceeds 50 psig (345 kPa). Quarterly SM SM SM 168 C. Verify HCV opening rate is set at a minimum of 20 seconds. Quarterly SM SM SM 169 D. Ensure HCV opens when the deadman control level is pressed. Quarterly SM SM SM

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

Quarterly SM SM SM

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

As required SM SM SM

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

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

Quarterly SM SM 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 SM SM

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

Quarterly SM SM SM

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

Quarterly SM SM SM

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

As required SM SM SM

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

Quarterly SM SM SM

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

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

Quarterly SM SM SM

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

As required SM SM SM

182 A. Verify PPCV opens at 75 psig (515 kPa). Quarterly SM SM SM 183 B. Verify PPCV opening and closing speed are three seconds. Quarterly SM SM SM

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

Monthly OM OM OM

185 B. Inspect wheels (if equipped) for warping, cracking, and uneven wear. Quarterly SM SM SM 186 C. Inspect exposed piping and components for corrosion. Quarterly SM SM SM

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

As required SM SM SM

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

Monthly OM OM OM

189 B. Inspect exposed piping and components for corrosion. Monthly OM OM OM 190 C. Lubricate wheels. Quarterly SM SM SM 191 D. Inspect wheels for warping, cracking and uneven wear. Quarterly SM SM SM

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

As required SM SM SM

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

As required SM SM SM

194 A. Inspect hydrant adapter for proper operation, damage, and wear. Quarterly SM SM SM 195 B. Test operation of dry break system. Quarterly SM SM 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 OM 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 OM 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 OM 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 OM OM

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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)

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Pressure Control Valves (Section 4-4.2.7)

Hydrant Control Valves (Section 4-4.2.8)

Emergency Shut-off Valves (Section 4-4.2.9)

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)

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 OM OM

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

Monthly OM OM OM

202 A. Inspect for nitrogen leaks. Quarterly SM SM 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 SM 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 OM 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 OM OM

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

Quarterly SM SM 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 SM SM

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

Annually SM SM SM

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

Semi-annually SM SM SM

210 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 SM 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 SM 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 SM SM

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

Semi-annually SM SM SM

214 F. Open and clean reservoir inlet strainer. Semi-annually SM SM 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 SM SM

216 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 SM 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.

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 OM OM

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

Monthly OM OM 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 OM 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 SM 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.

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

As required SM SM SM

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

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

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

As required SM SM SM

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

As required SM SM SM

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

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

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

As required SM SM SM

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

After each use OM OM OM

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

Monthly OM OM 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 OM 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 SM 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.

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

As required SM SM SM

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

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

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

As required SM SM SM

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

As required SM SM SM

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

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

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

As required SM SM SM

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

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

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Surge Suppressors (Section 4-7.4)

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

Marine Receipt (Section 5-2)

Marine Issue (Section 5-3)

Marine Loading Arms (Section 5-4)

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Aircraft Fueling Hoses (Section 4-7.5)

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

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

Annually SM SM 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 OM 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 OM 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 SM 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.

243 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 SM 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 OM OM

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

C. Inspect navigation aids and mooring buoy, in accordance with UFC 4-159- 03, for evidence of damage and possible movement or dragging by vessels, current or winds.

Annually SM SM 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 SM 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 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 SM 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 OM OM

B. Inspect navigation aids and mooring buoys, in accordance with UFC 4-159- 03, for evidence of damage and possible movement or dragging by vessels, current or winds.

Annually SM SM 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 SM 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 OM OM

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

Six times…