Fuel Handling Plan-FINAL.docx

PAFI-FHP-001

Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan

PAFI-FHP-001

FINAL

Date: 12 June 2016

Pafi-FHP-001 Fuel Handling Plan DRAFT Rev IR, dated 5 April 2016

DTFACT-17-R-00018 Attachment C-3

Pafi-FHP-001 Fuel Handling Plan Revision Log:

TABLE OF CONTENTS

Page

LIST OF FIGURES

LIST OF TABLES

LIST OF ACRONYMS

Scope This fuel handling plan for the Piston Aviation Fuels Initiative (PAFI) Phase II Engine Testing was developed to assure that no PAFI Phase II fuels will be mishandled or contaminated before and during engine on ground and in-flight testing. For the success of fuel handling the rules and procedures set up in this plan must be strictly followed. These rules are in accordance with supporting documents and recognized fuel handling standards that are included in Sections 3.

This fuel handling plan is based on the following assumptions:

· The fuel suppliers will send a Certificate of Analysis (COA) for each delivered fuel.

· Fuel samples will be sent to the Dixie Services Inc. for analyses. Dixie will provide new COAs for fuel samples.

· Fuel samples will be sent to Dixie in 5-gallon stainless steel cans sampled directly from a delivery truck once the truck arrives to the POWER Lab’s delivery location.

· All certificates and COAs will be sent to one point of contact from the POWER Lab of the WJHTC.

· Each fuel supplier will be assigned a color code using pre-designated equipment, which will be confirmed cleaned.

· Orange color markings indicate Fuel Supplier A

· Green color markings indicate Fuel Supplier B

· Fuels subjected to in-flight testing are delivered in 55-gallon drums. Fuel quantities are rounded to the nearest 55-gallon mark assuming the drum contains exactly 55-gallons.

· Fuel handling will be conducted in accordance with the following standards:

1. MIL-STD-1518: Storage, Handling, and Servicing of Aviation Fuels, Lubricating Oils and Hydraulic Fluids at Contractor Facilities

2. EI-1550: Handbook on equipment used for the maintenance and delivery of clean aviation fuel

3. ASTM Manual 5: Aviation Fuel Quality Control Procedures

4. ASTM D2276-06(2014): Standard Test Method for Particulate Contaminant in Aviation Fuel by Line Sampling

5. ASTM D4057-12: Standard Practice for Manual Sampling of Petroleum and Petroleum Products

6. ASTM D4306-12: Standard Practice for Aviation Fuel Sample Containers for Tests Affected by Trace Contamination Objectives The objective of this fuel handling plan is to ensure that fuels delivered to the POWER Lab are accepted for engine in-flight and on ground testing to support PAFI Phase II goals. To meet this objective, this plan will address the following issues:

· Fuel handling rules and requirements

· Quality control on fuel handling and delivery

· Daily fuel storage tank inspection

· Tank and drum cleaning procedures

· Periodic fuel sampling process and requirements

· Fuel sample real-time tracking

· Fuel delivery plan

· Fuel mixing procedures and equipment in case fuel mixing is needed

· Fuel sample documentation and inventory

· Environmental and personnel safety during fuels handling process

Supporting Documentation and Reference Standards Documents that support the fuel handling plan consist of the following Standard Operating Procedures ((SOPs) also included in Section 7):

· DOC-62: SOPs of Fuel Management Plan

· DOC-49: Acknowledgment of Receipt

· DOC-60: Incoming Test Fuels Handling and Receiving Plan SOPs

· FM-008: Daily Fuel Management

· FM-009: Engine Test Fuel Management Log

· FM-11: Test Fuels Data Sheet

Fuel Handling Referencing Standards used for this plane:

· MIL-STD-1518 – Storage, Handling, and Servicing of Aviation Fuels, Lubricating Oils and Hydraulic Fluids at Contractor Facilities

· EI-1550 – Handbook on equipment used for the maintenance and delivery of clean aviation fuel

· ASTM Manual 5 Aviation Fuel Quality Control Procedures

· ASTM D2276 Particulate Contamination by line sampling

· ASTM D4057 Standard Practice for Manual Sampling of Petroleum and Petroleum Products

· ASTM D4306 Stand Practice for Aviation Fuel Containers for Tests Affected by Trace Contamination

Processes Fuel handling processes are critical for effective fuel logistics and testing. There are ten major processes as follows:

Fuel Handling Safety

1. Prior to handling any fuel samples, all fuel handling personnel are required to pass Respirator Training, AED Training, Oil Spill, Disposal Training and Fuel Handling Safety Training provided by Pure Safety and Aviation Fuels Research Lab.

2. Engine testing and ETC unit must be completely turned off prior to the arrival of the fuel delivery truck.

3. Forklift must park away from fuel storage tanks and drums to reduce risk of fuel ignition.

4. Before pumping fuel from truck to fuel tanks at Building 211 of the POWER Lab, CCI personnel are required to check license and fuel pumping certificate of the fuel delivery driver. Fuel truck license plate is also needed to be recorded. All this information is required to enter into the fuel management data base in case there is an emergency.

5. Absolutely no smoking within 100 feet around the fueling area.

6. Emergency contact information must be displayed in the fuel handling locations. This includes 911, WJHTC security operation office number (609-485-5303), CCI manager phone number, Aviation Fuels Research Lab manager phone number (609-485-6265), Fuel and Energy Section manager phone number (609-485-4986).

7. Fuel spilling prevention materials and fire extinguishers must be inspected and available before fuel delivery.

8. Gates to access the fuel tanks area must be locked during the entire fuel delivery process. No cars or trucks are permitted to leave or enter the fuel delivery area while the fuel delivery truck is in the yard.

9. Personnel not directly related to the PAFI program are advised not to enter the fuel station during a fuel delivery process.

10. All fuel handling personnel are required to wear double layer Nitrile and PVA gloves, goggles and respirators.

11. Fuel handling personnel are responsible to report any incidents.

Fuel Handling Safety Training Safety relies on efforts from everyone who is involved in this program. Better understanding of fuels and the handling process for our workers can enhance fuel handling safety. This training includes:

1. Introduction to the very basics of aviation gasoline including: (a) Fuel physical properties (appearance, evaporation, fluidity, viscosity, density); (b) Chemical properties (chemical compositions, fuel thermal energy storage and combustion, detonation). Training to be conducted by Aviation Fuels Research Lab lead.

2. Fuel engine emissions basics. Training to be conducted by Aviation Fuels Research Lab lead.

3. Missions and functions of the Aviation Fuels Research Lab. Training to be conducted by Aviation Fuels Research Lab lead.

4. ASTM Standard testing methods and fuel property lab measurement basics. Training to be conducted by Aviation Fuels Research Lab lead.

5. Basic fuel toxicity information and protection of fuel handling workers. Training to be conducted by Aviation Fuels Research Lab lead.

6. Introduction to Certificates of Analysis (COAs). Training to be conducted by Aviation Fuels Research Lab lead.

7. Fuel handling procedures. Training to be conducted by assigned CCI personnel and Aviation Fuels Research Lab lead.

8. Fuel mixing equipment and process. Training to be conducted by assigned CCI personnel and Aviation Fuels Research Lab lead.

9. Management of fuel inventory and data base. Training to be conducted by assigned CCI personnel.

10. Safety gloves and proper PPE. Training to be conducted by assigned CCI personnel.

11. Fuel disposal. Training to be conducted by assigned CCI personnel.

12. Fuel tank cleaning and waste disposal and treatment. Training to be conducted by assigned CCI personnel and Aviation Fuels Research Lab lead.

Fuel Inventory and Data Base

1. Once fuel is received, all incoming test fuels will be photographed and assigned an ICN Inventory Control Number, unless the customer requests a different number other than an original ICN, added to the inventory control system and have a bar code label for identification purposes utilizing the WASP bar code inventory system.

2. The ICN Inventory Control Number is comprised of the following components:

a. Example: ICN 00-030-2014

b. 001 = drum number 1 (if there are more than one drum received, the number will ascend numeric order 001, 002, 003 etc.

c. 030 = Julian Date from the Julian calendar 001 to 365 (030 would be January 30th).

d. 2014 = Year.

3. The WASP Inventory Control System consists of management software, two mobile computers (scanners) and a label printer. These tools will enable fuel handling personnel to track test fuel inventory levels and movements in the fuel storage warehouse and test cells by item, ICN, serial number, type of fuel or lot number. With full visibility into the entire incoming and outbound test fuel inventory, the fuel handlers can make better decisions to maintain dynamic stock levels that meet the demands of the organizational mission and its usage.

4. The WASP bar code system is a proper inventory management solution that will streamline the organization and mission by significantly reducing costs, waste, miss-identification and will give real time visibility on a specific test fuel sampling, usage, remaining balance, warehouse location and disposal.

Fuel Mixing Process and Equipment For fuel mixing process and equipment, please refer to Appendix A. Fuel Mixing Documents for additional information.

Fuel Disposal and Fuel Drum/Tank Cleaning Waste Management

1. Waste fuel disposal.

2. When a fuel tank is steam cleaned, the waste water containing residual fuel from the tank must be collected in waste fuel drums. The drums must be labeled with date and cleaning conditions.

3. Some fuel drums must be cleaned with toluene. The waste toluene containing residual fuel must also be collected in waste drums with labels and date.

4. Contact the fuel disposal company for pick up and drain the waste drums.

5. After fuel drums are empty, the drums need to toluene rinsed and dried before future application.

6. Workers who handle the fuel drum cleaning are required to wear proper PPE, goggles, gloves and respirators.

Document Acquisition Process There will be several important documents produced during the Phase II fuel handling process. These documents fall into one of three categories. These categories include:

1. COAs

2. Certificate of Steam Cleaning

3. Confirmation of Toluene Rinse

1.1.1. COAs

When a fuel supplier delivers a fuel truck to the WJHTC, the delivered fuel will be accompanied by a COA from the supplier. Every time when a fuel sample is sent to Dixie for analysis, Dixie will provide a new COA for the fuel sample. CCI (or POWER Lab) will assign an appropriate POWER Lab fuels team member to document all COAs for future use.

1.1.2. Steam Cleaning Certificate

Prior to the filling of a Phase II testing fuel, a steam cleaning certificate is required for the two 10,000-gallon fuel storage. The two tanks only require initial steam cleaning and no additional cleaning is needed when filling the same fuel samples. Additional steam cleaning is recommended in case the fuel is potentially contaminated. All certificates of steam cleaning will be documented by the assigned WJHTC fuels team member.

1.1.3. Confirmation of Toluene Rinse

A total of 16 55-gallon stainless steel fuel drums and 140 5-gallon stainless steel fuel sample cans will be purchased for handling Phase II fuel. These fuel containers must be confirmed cleaned by means of a toluene rinse before adding a Phase II test fuel into these vessels. The detailed container cleaning process is shown in Section 4.9 of this plan. When toluene rinsing is completed, a Toluene Rinse Sign-Off Form (located in Section 8) will be documented by the assigned WJHTC fuels team member.

Fuel Handling Quality Control

1.1.4. General Fuel Handling Processes

1. In order to minimize contamination of the test fuels during the PAFI Phase II testing, personnel involved in the receipt, handling, and distribution of the fuels must be trained to comply with basic fuel handling protocols including but not limited to the following:

a. Keep tanks, spigots, funnels, drums, and related fuel filling and cleaning device clean. Protect fuel storage and filling area from dust or other airborne particulates.

b. All handling equipment, such as dedicated funnels and gloves, shall be segregated either in accordance with fuel type or shall be confirmed clean before use. Transferring fuel handling devices such as funnels and fuel pumps must be cleaned between uses of two types of fuel samples. The cleaning of these items must use original toluene.

c. A fuel handling technician must change his/her gloves when starting handling a different type of fuel. For non-disposable gloves, the technician must thoroughly clean the gloves prior to handling second different fuel sample. It is the persons’ responsibility to put disposable gloves in a suitable collection location before touching a second testing fuel sample.

d. Handling only one type of fuel at a time. This rule means that prior to handling a second fuel sample the first fuel handling must be completed, the fuel handling area cleared, disposable gloves changed and non-disposable gloves cleaned with toluene, and finally the fuel handling equipment must also be changed or cleaned.

2. Prior to accepting/delivering a fuel, fuel vessels must be visually inspected for cleanliness, damage and potential contamination.

1.1.5. Fuel Handling Quality Control

1. In order to assure fuel handling quality, the fuel identity and physical appearance must be confirmed for each PAFI Phase II fuel.

a. Fuel color and product marking must be confirmed to ensure that the correct fuel is being handled.

b. Confirm the appearance of the fuel is “normal”. This includes that fuel remains clear and bright, no obvious visual contamination, no visible layers or precipitation, and no “unnormal” observations are found.

c. If a non-normal appearance is observed, stop the handling process and notify the responsible authority.

2. If at any time there is known product contamination, for example dispensing one fuel into another fuel’s drum, stop the handling process. Segregate the contaminated volume, and report the incident to the responsible authorities.

Fuel Delivery

1.1.6. WJHTC –Tank Truck Delivery

1. When a fuel delivery truck arrives at the main gate of the WJHTC the driver will be escorted from the Security Office to the area of operation. The driver will escorted by a fuel team member from the gate until truck leaves the WJHTC.

2. The delivery driver will be expected to comply with all local, state and federal DOT, OSHA, and EPA regulation regarding the unloading and dispensing of flammable liquids.

a. At the WJHTC, this includes entering the fuel containment berm at the storage tank location. This berm is sufficient to provide spill containment in the event of an emergency.

3. Confirm the truck and the storage tank has the appropriate earth grounding to avoid the accumulation of static electrical charges.

4. Once the truck is in the proper position and properly grounded, the building access gates shall be closed to prevent unauthorized access to the area.

a. Activate the red, rotating warning beacon.

b. Activate the warning klaxon three times to alert the surrounding facilities that a restricted operation is being conducted.

5. Confirm that all involved personnel have donned the minimum required personal protective equipment (PPE). Minimum PPE includes but is not limited to:

a. Safety glasses with side shields or chemical goggles

b. Chemical resistant laboratory coats or coveralls

c. Two layers of disposable nitrile gloves, or polyvinyl alcohol (PVA) or similar gloves or similar alternative gloves

6. Safety spotters with fire extinguishers will be on hand in the event of an emergency.

7. Fuel spill clean-up kit is within the area of operation in the event of an emergency.

8. Storm drains are covered with absorbent mats to prevent contamination in the event of an emergency.

9. Responsible FAA representative will confirm all local requirements have been complied and authorize the driver to connect the truck to the appropriate storage tank.

a. The FAA representative will confirm fuel delivery identity and confirm appropriate connection to the receiving tank.

10. Prior to, during and at end of delivering fuel, initial check on fuel physical appearance conducted, i.e. fuel is clear and bright, free of visible water and particulate.

11. Once the previous steps have been completed, the driver is authorized to distribute fuel to the tank.

12. Upon completion of the fuel delivery, the delivery hose will be disconnected and stowed in compliance with all local, state, and federal regulations.

13. Sign and accept any provided bills of lading and paperwork.

14. Upon completion of stowing all truck equipment, the rotating beacon is then turned off and the gates are open. Finally, the truck and driver are escorted from the site.

15. Each tank should have a content record. At minimum this record should indicate:

a. Volume received

b. Date

c. Source identification from whom it was received and sample identification, etc.

d. Delivery identification including the trucking company, truck identification and driver’s certificate for fuel handling, etc.

e. Signature of the FAA representative.

f. NOTE: This document should be used to record all receipts from a fuel supplier and dispersals from the POWER Lab’s fuel storage tank.

16. Allow fuel to settle a minimum of two hours (MIL-STD-1518E, Section 5.2.3) prior to fuel testing and sampling.

17. Collect a 5-gallon sample of the as delivered fuel following the procedure in Section 4.11 for Dixie’s laboratory analysis.

a. Examples of laboratory analyses specified in ASTM D910-15 include:

i. Density

ii. Freezing point testing

iii. Distillation

iv. Vapor pressure

v. MON

vi. Performance number

vii. Color

viii. Viscosity

ix. Water content

x. Water reaction

xi. Heat of combustion

xii. Chemical compositions

1.1.7. Non-WJHTC Fuel Deliveries

1. Any locations receiving test fuels shall have a segregated area designated for the storage of the test fuels. This area shall have the minimum fluid containment collection capabilities in compliance with local, state, and federal regulations.

a. This area should have controlled access to the test fuels.

b. Drum storage may be in either horizontal racks, bung side up, or upright storage with protection from the elements.

c. Drum tops should be protected from the accumulation of water.

d. All drums, drum racks, or storage buildings shall have appropriate earth ground.

2. All sample receiving procedures in any local sites must be documented in writing and be provided to the FAA WJHTC representative.

3. When handling fuel drums delivered, minimum personal protective equipment (PPE) is required for the handling workers. Minimum PPE includes but is not limited to:

a. Safety glasses with side shields or chemical goggles,

b. Chemical resistant laboratory coats or coveralls.

c. Two layers of disposable nitrile gloves, PVA gloves or similar alternative gloves

4. The authorized site representative will confirm fuel identifications of the delivered drums, sign any necessary forms and paperwork.

5. All paperwork must be maintained and controlled in a data base. It shall be available for FAA personnel’s review upon request.

Fuel Container Cleaning Procedures

1.1.8. 55-Gallon Stainless Steel Fuel Drum Cleaning

1. Only designated POWER Lab personnel can execute fuel drum cleaning.

a. Any designated personnel must complete FAA WJHTC Safety Office training on fuel handling, including hazardous waste, spill prevention and control, and respiratory training and fit-tests.

2. Fuel drum cleaning requires all personnel handling the cleaning wear personal protective equipment (PPE). Minimum PPE includes but is not limited to:

a. Safety glasses with side shields or chemical goggles,

b. Chemical resistant laboratory coats or coveralls,

c. Two layers of disposable nitrile gloves, PVA gloves or similar alternative gloves

d. Impact resistant and anti-static closed-toe shoes

3. Fill a 55-gallon stainless steel fuel drum with 5 gallons of toluene and then follow the rinsing process:

a. Cap and seal all fuel drum openings

b. Lay the fuel drum horizontally smooth surface or drum/can roller

c. Roll fuel drum back and forth allowing it to complete a full revolution for 20 minutes

d. Dispense rinsed toluene in an appropriate receptacle.

4. Once the rinsing is completed, return fuel drum to an upright position and let it sit for 2 hours to ensure the complete evaporation of any remaining toluene.

5. When fuel drum is confirmed clean, the designated personnel will inspect the fuel drum and sign off the Toluene Rinse Sign-Off Form (located in Section 8).

6. Cap and seal the cleaned fuel drum openings and move it to a controlled storage area to ensure that it is not accidently used for non-Phase II applications.

1.1.9. 5-Gallon Stainless Steel Fuel Sample Can Cleaning

1. Only designated POWER Lab personnel can execute fuel sample can cleaning.

a. Any designated personnel shall attend FAA WJHTC Safety Office training covering fuel handling, hazardous waste management, spill prevention and control, and respiratory training and fit-tests.

2. Fuel sample can cleaning requires all personnel handling the cleaning wear personal protective equipment (PPE). Minimum PPE includes but is not limited to:

a. Safety glasses with side shields or chemical goggles,

b. Chemical resistant laboratory coats or coveralls,

c. Two layers of disposable nitrile gloves, PVA gloves or similar alternative gloves

d. Impact resistant and anti-static closed-toe shoes

3. Fill 5-gallon stainless steel fuel sample with 1 gallon of toluene and follow the rinsing process:

a. Cap and seal all fuel sample can openings,

b. Lay the fuel sample can horizontally on a smooth surface or drum/can roller

c. Roll fuel sample can back and forth allowing it to complete a full revolution for 20 minutes

d. Dispense rinsed toluene in an appropriate receptacle.

4. Once the rinsing is completed, return fuel sample can to an upright position and let it sit for 2 hours to ensure the complete evaporation of any remaining toluene.

5. When fuel sample can is confirmed clean, the designated personnel will inspect the fuel sample can and sign off the Toluene Rinse Sign-Off Form (located in Section 8).

6. Cap and seal fuel sample can openings and move fuel sample can to a controlled storage area to ensure that it is not accidently used for non-Phase II applications.

Drum Filling Procedure

1. Only designated FAA personnel shall execute drum handling and filling.

a. Any designated personnel shall attend FAA WJHTC Safety Office training covering fuel handling, hazardous waste management, spill prevention and control, and respiratory training and fit testing.

2. Chemical contamination results from mixing two hydrocarbon fuels or contacting other chemicals with the fuel. Contamination affects fuel’s chemical and physical properties. Chemical contamination can be prevented by handling different fuels in separate handling systems. In storage area, a fuel sample drum can physically be separated from other fuels. The main factor causing fuel chemical contamination is the carelessness of fuel handling. (Refer to MIL-STD-1518E, Section 4.3.a).

3. Label each fuel container appropriately.

a. Every fuel drum or can must be barcoded and documented in a fuel inventory control system.

b. A fuel drum must be color coded as well. In this fuel handling system, orange color represents from fuel supplier A and green for fuel supplier B.

4. Different fuels are stored in a separated area with the other fuel drums.

5. Confirm storage tanks and receiver drums are appropriately earth grounded.

6. All personnel are required to wear protective equipment (PPE). Minimum PPE includes but is not limited to:

a. Safety glasses with side shields or chemical goggles,

b. Chemical resistant laboratory coats or coveralls,

c. Two layers of disposable nitrile gloves, PVA gloves or similar alternative gloves

d. Impact resistant and anti-static closed-toe shoes

7. Prior to filling a fuel sample from a storage tank to a drum, fuel container identifications (label, barcode and color) must be confirmed to match to the appropriate fuel information of the storage tank.

8. Connect a fuel pump from the fuel storage tank to the fuel drum and begin dispensing. The filling process must be in accordance with the instructions provided by the fuel storage tank company.

9. Dispense a volume equivalent to the 10-20 vol.% of the receiving drum and rinse the interior of the drum (See ASTM D4306, 6.4.2.1).

10. Empty the rinsate into an appropriately labelled waste fuel container.

a. Check the physical appearance of the dispensed fuel. Observe its color, possible contamination and if it appears different from a normal fuel sample. Per MIL-STD-1518E, Section 4.5, “Sediment appears as dust, powder, grains, flakes, and stains. Sources of solids or sediment include storage tanks, ferrous vessels or containers, filer or filer/separator elements, valves, pumps, meters, pipelines, hoses, grease, gaskets, diaphragms, and seals.” Should sample appear no-normal, stop the fill and notify appropriate personnel.

11. Start filling the fuel drum.

12. Upon completion of filling, disconnect and stow the fuel pump accordance with the instructions provided by the fuel storage tank company.

13. Upon completion of filling, install caps or bungs using brass bung wrench or other appropriate tools.

a. For safety reasons, it is recommended that steel tools be avoided due to the potentially creating sparks.

14. Torque the drums to 15-22 ft-lbs

15. Using absorbent cloths, wipe any spills, puddles, or other instances of fuel on the exterior surfaces.

a. Dispose of used cloths in appropriate receptacle.

16. Record sample removal from the storage tank.

a. Record the volume removed including the rinsate.

b. Record the date of the removal.

c. Record the purpose of the removal.

d. Record sample identifications of container, if available.

e. Sign the document and keep it in the fuel inventory system

17. Move the fuel drums to an appropriate drum storage area for distribution.

Miscellaneous Sampling Any miscellaneous sampling process must follow Section 6.4.1.1 of the ASTM D3405-97:

1. Procure appropriate sample container. Unless otherwise directed, the use of new laboratory glass containers with foil lined polypropylene or phenolic lids, is recommended.

2. Permanently label the jars

a. Use of external metal tags attached with safety wire is recommended. If permanent marker is used, be aware fuel samples will remove the ink. Labelling on the lid is recommended.

3. Use required minimum personal protective equipment (PPE).

a. Safety glasses with side shields or chemical goggles,

b. Chemical resistant laboratory coats or coveralls,

c. Two layers of disposable nitrile gloves, PVA gloves or similar alternative gloves

4. Prepare collection method. Confirm cleanliness of all sampling equipment prior to starting sampling operation. Any residual material left in a sampling device or sample container from a previous sample or cleaning operation may contaminate the fuel sample. If possible, the sampling equipment should be rinsed with a small amount of the target fuel. The rinsate should be disposed of into an appropriate waste fuel receptacle. Collection method examples include:

a. Spigot or pour spout from drum

b. Clean syphon tube, preferably glass

c. Clean dipping container.

d. NOTE: Never immerse hands in a fuel sample.

5. Fill the container to its 1/3 volume and cap the container

a. Rinse interior of the container by gentle agitation. The fuel should contact all interior surface areas.

b. Dispense rinsate into approved waste fuel container

c. At minimum, repeat one time of the Steps of a. and b.

6. Confirm that the color of the dispensed fuel is appropriately colored and does not appear different or contaminated, especially by debris or sediment. Per MIL-STD-1518E, Section 4.5, “Sediment appears as dust, powder, grains, flakes, and stains. Sources of solids or sediment include storage tanks, ferrous vessels, pumps, meters, hoses, grease, gaskets, diaphragms, and seals.” Should sample appear non-normal, stop the fill and notify appropriate personnel.

7. Collect the desired volume of the sample and tighten cap of the container.

a. Avoid over-torqueing the lid as it may crack the lid without breaking it and cause fuel leakage later.

b. Using absorbent cloths, wipe any spills, puddles, or other external wetting

c. Dispose of the absorbent cloths in appropriate receptacle

8. Upon completion of filling, close drums, return glassware for washing, etc.

9. Record the volume of the sampling fuel on the storage record sheet.

10. If specimens are to be shipped or stored, use plastic adhesive tape to tape/seal the lid. Tape should be applied in a direction that tightens the lid.

11. When sampling and fuel identification are completed deliver samples and any collection records to the appropriate WJHTC fuels team member.

Stainless Steel Fuel Drum Handling Process Figure 1 shows the cleaning and storage process of new stainless steel fuel drums:

New Empty 55-Gallon Stainless Steel Fuel Drums Serialization/inventory (barcoded) Toluene Rinse Designate Fuel (color code) Fill Fuel Drum with Designated Fuel from a 10,000-Gallon Tank Fuel Drum Storage Engine Testing Refill the Same Fuel when the Drum is Empty

PAFI-FHP-001, PAFI Phase II Fuel Handling Plan FINAL, 12 June 2016 Figure 1. WJHTC Stainless Steel Fuel Drum Handling Process

PAFI-FHP-001, PAFI Phase II Fuel Handling Plan Engine Ground Testing Support Engine ground testing will be conducted at the WJHTC test stands for Original Equipment Manufacturers (OEMs) tests including Lycoming and Continental Engine testing and contracted testing for radial engines. The OEMs tests require two (2) fuel deliveries and radial engine tests four (4) deliveries per each fuel supplier. WJHTC testing requires six (6) fuel deliveries to fill 10,000-gallon fuel tanks per each fuel supplier. The fuels are used for engine detonation/durability tests and Dixie COAs. Figure 2 shows the flow chart of the fuel delivery processes for both Suppliers A and B.

Fuel Supplier A & Supplier B Radial Testing (4 deliveries) OEM Testing (2 deliveries) WJHTC Testing (6 deliveries) 10,000 Gallon Fuel Tanks (Filled by fuel truck s Gallon Stainless Steel Fuel Drum s

(Filled by pump on tank) Gallon Fuel Sample s Radial Engines Tests Lycoming Engines Tests Continental Engines Tests

COA

s Dixie) Document ation Fuel Inventory/Storage Engine Tests (Detonation/Durability) Fuel Usage Tracking Figure 2. Engine Ground Testing Breakdowns by POWER Lab at WJHTC Engine in-Flight Testing Support Figure 3 shows the delivery breakdowns to each test facility participating in the flight testing portion of Phase II testing.

Fuel Suppliers A & B

WJHTC

Testing

(12 deliveries) Radial

Testing

(14 deliveries) Robinson

Testing

(12 deliveries) Textron

Testing

(15 deliveries) Cirrus

Testing

(12 deliveries) Cape Air

Testing

(12 deliveries)

NRC

Testing

(15 deliveries) Figure 3. Flight Engine Tests Breakdowns

10,000-Gallon Fuel Storage Tank Inspection Procedure

1. This tank inspection procedure will be conducted on a weekly basis before the first fueling operation of the week.

a. Evaluate overall tank condition, appearance, and cleanliness.

i. Inspect weld joints for corrosion, cracking or leakage

ii. Remove weeds, trash, or other debris

iii. Check if earth grounding is still in place and functional

iv. Check tank exterior surface for evidence of paint cracking, corrosion, paint peeling, or leakage

b. Check that all fittings are secured to prevent any possibility of a fuel leak.

c. Remove condensate and document the amount removed.

d. If storage tank passes inspection, the personnel conducting the inspection will sign off the Weekly Fuel Storage Tank Inspection Form (located in Section 8).

2. Annually inspect the storage tanks. A storage tank check list is included in Section 8.

Fuel Delivery Requirements Based on the engine on-ground and in-flight test plans, a schedule of fuel delivery has been established with the required fuel volumes per month during the tests.

Engine Tests Tables 1 to 10 list the fuel deliveries schedules and amount needed for the both engine on-ground and in-flight tests.

Table 1. FAA WJHTC Engine Ground Testing Fuel Deliveries

Table 2. Radial Engine Ground Testing Fuel Deliveries

Table 3. OEM Engine Ground Testing Fuel Deliveries

Flight Tests

Table 4. FAA WJHTC in-Flight Testing Fuel Deliveries

Table 5. Robinson in-Flight Testing Fuel Deliveries

Table 6. Cirrus in-Flight Testing Fuel Deliveries

Table 7. Cape Air in-Flight Testing Fuel Deliveries

Table 8. NRC in-Flight Testing Fuel Deliveries

Table 9. Radial in-Flight Testing Fuel Deliveries

Table 10. Textron in-Flight Testing Fuel Deliveries

Pictures The following photographs are supplied to further clarify the detail processes shown in the fuel handling plan. Figure 4 shows an example barcode for the inventory control system. The system can scan the barcode showing the fuel documentation and history of its handling. Figure 5 depicts the 10,000-gallon tanks to be installed at WJHTC. A fuel drum stack with built in spill containment is shown in Figure 6. Figure 7 indicates the location for the two 10,000-gallon fuel storage tanks. Figure 8 is a spill containment pallet useful during the transportation of fuel drums from their storage location to the engine test cells. Figure 9 shows an aviation grade fuel hose to be used with the Phase II testing. Finally, Figure 10 shows the spill containment berm for parking the fuel delivery trucks to prevent contamination to the surrounding area.

Figure 4. Inventory Control Fuel Example Barcode with Inventory Control Number and Pin Number

Figure 5. A 10,000-Gallon Fuel Storage Tank.

Figure 6. Fuel Drum Stacker for Engine Testing with Built in Spill Containment

Figure 7. 10,000-Gallon Fuel Storage Tanks Placement Location

Figure 8. Spill Containment Pallets for Transferring Fuel

Figure 9. Aviation Grade Fire Sleeved Teflon Fuel Hose

Figure 10. Spill Containment Berm

Figure 11. Drum/Can Roller

Relevant Standard Operating Procedures (SOPs) Documents The following SOPs are considered necessary for fuel handling.

FAA WJHTC POWER LAB STANDARD OPERATING PROCEDURE

FAA WJHTC POWER LAB STANDARD OPERATING PROCEDURE

Fuel Management Plan

Fuel Management Plan

FAA WJHTC POWER LAB STANDARD OPERATING PROCEDURE

Fuel Management Plan

Incoming Test Fuels Handling and Receiving Plan

Phase II Fuel Handling Forms

FAA WJHTC POWER LAB FORM

Toluene Rinse Sign-Off Form

FAA WJHTC POWER LAB FORM

Toluene Rinse Sign-Off Form

FAA WJHTC POWER LAB CHECKLIST

10,000-GALLON FUEL STORAGE TANK ANNUAL INSPECTION

FAA WJHTC POWER LAB CHECKLIST

10,000-GALLON FUEL STORAGE TANK ANNUAL INSPECTION

Appendix A. Fuel Mixing Documents

Appendix B. Incident Report and Documentation

1. As soon as an incident occurs, the personnel involved with the incident must report to CCI managers, Aviation Fuels Research Lab and Section Manager.

2. The people who were involved with the incident must submit an Incident Report Form to CCI managers, Aviation Fuels Research Lab and Section Manager for review. The completed form must be recorded and documented.

3. A post-incident meeting must be held within two weeks’ time period with the people involved in the incident, CCI managers, Aviation Fuels Research Lab lead and Section Manger (if available).

4. The meeting will focus on what lessons can be learned from the incident and what precautions are needed to avoid similar events from happening again.

5. Suggestion and recommendations on how to handle fuel more effectively and safely are welcome and encouraged.

Incident Report Form Aviation Fuel Research Lab, Fuel & Energy Section Names

Incident Number

Date/Time

Personal Injury?

Property damage?

Instrument/equipment failure?

Reason and Lesson Learnt

Supervisor Name

Supervisor Signature

Date

Fuel Lab Signature

Fuel & Energy Section Manager

Date

Appendix C. WJHTC Fuel Safety Documents image1.emf image2.jpeg image3.jpeg image4.jpeg image5.jpeg image6.jpeg image7.jpeg image8.png image9.png image10.png image11.png image12.png image13.png image14.png image15.png image16.png image17.png image18.png image19.png image20.png image21.png image22.png image23.jpeg image24.png image25.png image26.png image27.png image28.emf

Fuel mixing technology review (Sneha CCI) (Cunping edits 04-29-2016).docx Summary of Fuel Mixing Technologies

Sneha Gollamudi

Crown Consulting Inc.

Date: April 26, 2016

Introduction

This report summarizes different fuels mixing (blending) technologies and equipment. The standard practice for mixing and handling of liquid fuels and petroleum products can be found in ASTM D5854-96 (2015).

ASTM D5854-96(2015) divides fuel mixing methods into three categories:

1) Power Mixing

a. Insertion Mixing: this method uses standalone mixers to mix fuel samples in drums. It is applicable for a variety of types and sizes of fuel containers. Non-aerating mixers and high- shear mixers are two typical exaples.

b. Closed Loop Mixing: The method is used in conjunction with an automatic pipeline sampling system.

2) Shaking

a. This technology involves manually or mechanically shaking a fuel sample container to eliminate stratification.

3) No Mixing

a. If a fuel sample is homogeneous, no mixing is required.

Possible Options

For the first two categories, power mixing and shaking, listed above, several options are available commercially:

I. Power Mixing Options

1) Pulsair Air mixing tehcnology

a. http://www.pulsair.com/products/mixers/55-gallon-drum-mixer.php

Figure 1- Insertion Mixer

This drum mixer produces pulses of compressed air or gas, generating large bubbles at the bottom of a 55-gallon drum (Figure 1). The rising air bubbles create an immediate vertical circulation pattern to mix the fuel contents in the drum. One disadvantage of this technology is the vapor loss when handling highly volatile fuels.

INDCO Industrial mixers

b. http://www.indco.com/shop/industrial-mixers/drum-mixers

Figure 2- Various types of INDCO mixers

Figure 2 illustrates eight (8) options for mixing fuel contents in a 55-gallon drum. These mixers are inserted inside a drum and impellers of a mixer rotate at high speed to generate flow-driven mixing processes. There are two motor options: electric and pneumatic motors with speed controllers.

2) Mixerdirect technology

a. http://www.mixerdirect.com/industries/oil-and-gas.html

Figure 3- Mixerdirect Mixers

Mixerdirect company offers several different mixers for Oil and Gas industry (Figure 3). These mixers can be inserted inside a fuel drum. Folding props will open automatically using centripetal force and the speed of mixing can be adjusted.

3) Drummates Mixing options

a. http://drummates.com/mix.htm

This website shows similar mixing options as INDCO and MIXERdirect companies.

Disadvantages of Power Mixing Approaches

Inserting mixers use air to mix the contents in a drum. In this scenario, air might contain moisture which could influence the water content of our aviation gasoline samples. These mixers also require an air source which needs air compressors or dry air, pure nitrogen cylinders. For PAFI Phase 2 tasks, we must handle several fuel blends in different drums, causing potential contamination concerns if we use inserted mixers. Therefore, insertion mixers require strict cleaning protocol in order to prevent fuel sample cross contamination. This technology also requires a venting system to prevent fuel vapor pollution.

II. Shaking options

Morse Drum Options

1) Morse Drum Tumblers can be found in the following websites:

a. http://morsedrum.com/products/309-drum-tumblers.htm

b. http://morsedrum.com/products/310-ce_ce-marked-drum-tumblers.htm

Figure 4- A Drum Mixing Tumbler

As shown in Figure 4, a drum is rotated “corner over corner” to thoroughly mix drum contents. The equipment agitates the drum contents without opening the drum itself and homogenizing the contents inside. A control package is also available to control the speed of the mixing along with explosion proof tumblers.

Detailed specification sheets and options can be found at the above websites.

2) Morse Drums: Stationary Drum Rollers

a. http://morsedrum.com/products/5154-Drum-Rollers.htm

Figure 5- 55 gallon drum roller enclosure

A fuel drum can be placed on a roller and the drum is slowly rotated to ensure to rinsing or mixing fuel contents inside the drum. This product is compatible with 55-gallon stainless steel drums. The drum rotation speed is controllable. An option of explosion proof drum rollers is also available with this product line.

Detailed specification sheets and options can be found via the above website.

3) Morse Drums Mixing Option technology: Tilt to Load Drum Rotator

a. http://morsedrum.com/products/310-Tilt-To-Load-Drum-Rotator.htm

b. http://morsedrum.com/products/311.htm

Figure 3- Tilt to Load Drum rotators

A fuel drum is loaded onto the assembly manually by a hand truck or using a hoist. Using this power tilt option, the drum is raised to the rotating position. After the motor is turned on, the drum starts rotating in place. Several options are available with this package, which is similar to the Morse Drums products. The website specifies the options available.

Tinsley Company Option

1) Compaction Table for Vibrating 30 gallon or 55 gallon Drums

a. http://www.tinsleycompany.com/compaction-table-for-vibrating-55-gallon-or-30-gallon-drums/

b. http://best-vibrating-tables.com/sp-vibrating-tables-belts-drums.htm

Figure 4- Vibrating Table for drum mixing

Vibrating compaction table uses compressed air to generate vibration effect for fuel mixing. This device includes a control cabinet to power the pneumatic piston to vibrate and shake the drum to settle and mixe the contents inside a drum.

More information is needed from this company regarding its compatibility with mixing fuels and if a variable speed option and an explosion proof unit are available.

Disadvantages of Shaking

For all of the products listed above, we need to make sure that any options are safe for handling flammable fuel mixing. According to API 2003 (Please see the Appendix below), fuel mixing can generate electrostatic charges which when continue to buildup, could result in a possible explosion. Vigorous mixing of the fuels can also result in electricity discharge, so it is pivotal that the speed drum ration can be controlled to ensure the proper and safe mixing of fuels.

Conclusion

Based on the above technology reviews it is suggested that drum ‘shaking’ and ‘rotation’ methods be for PAFI Phase II fuels mixing and toluene rinsing.

Appendix

API Recommended Practice 2003 (Protection against ignitions arising out of static, lighting and stray currents) states that tank jet mixing and high velocity propeller mixing can stir up water and debris and can generate an electrostatic charge during…