PAFI-FSP-003 Fuel Sampling Vol 3 flight-FINALVersion.docx

PAFI-FSP-003, Fuel Sampling Plan Vol. 3 FINAL, Dated Oct. 5, 2016

Revision Log:

Correct the number of tests in 4.2 Addition of 6.1 “Definition of Tank Tap” Addition of fuel sampling instructions for 4.2 correction. Adds Sections 9.2.8, 9.2.9, and 9.2.10 Change Section 5 Title Addition of Appendix B, White Paper Regarding Criticality of RVP sampling and testing compliance.

Added footnote to §4.3 to reference Appendix B for discussion of RVP alternatives.

Added torque value for bungs on drums.

Broke document into three volumes, 1) Bulk fuel plan, 2) Engine test fuel plan, and 3) Flight test fuel plan.

Added 6.2 Definition of retain sample Added appendices for procedure check list Deleted Appendix B, White Paper Regarding Criticality of RVP sampling and testing compliance, and added Appendix J Regarding Sampling for Vapor Pressure Samples.

8-9

12-13 15-23, 26-28, 34, 38 15, 18, 23

14, 17, 19, 22, 27

18, 20, 26

Multiple Minor format adjustments Sec 1.1 Add proviso on safety regulation compliance Sec 4.2 Clarified “retain samples” Sec 4.3 Changed “test protocols” to “test plans”. Deleted “Reid”.

Sec 7.1 Clarification of sample carriers Sec 7.2.2 Add “or other grounded structure” Sec 8.1.1 Added metal tag information Sec 8.2 Clarify drums do not require overpack Changed from “FAA POC” to “site POC”

Added note requiring the presence of an independently prepared Certificate of Analysis.

Removed “wire” from the note requiring the stainless steel drums from the FAA to have the opening sealed.

Clarify 100LL versus test fuel sampling in a single fuel tank aircraft Added sampling information regarding defining frequency of sampling to be when the tank is filled, at the end of a tank of fuel, and when fuel is added to the tank. The frequency is dictated by the fuel in the tank not the take offs or landings.

Delete information regarding the use of a chiller to cool sample bottles for vapor pressure testing Deleted duplicate appendices regarding anomalous and normal sampling. Renumbered the appendices so that Appendix C is all anomalous samples, Appendix D is all normal samples, and Appendix E is vapor pressure sampling. Appendix F is information on the criticality of sampling technique on vapor pressure testing.

All from 15 16, 19, 25 Add failure exception for Fuel Gaging test. Remove section 9.1.2 “anomalous samples” from fuel gaging testing. This is a data only test.

Renumber Sections in 9.1 and page numbers.

Modify sampling locations on multi-tank aircraft and clarify explanation.

17, 18, 19, 21, 22, 25, 26, 27 44-45 Changed Document title to PAFI-FSP-003 to indicate the document being Volume 3 to distinguish it from PAFI-FSP-001, Volume 1 and PAFI-FSP-002, Volume 2.

Changed references to D910 testing for certification to the full CoA list in Appendix G.

Added Appendix G, Full Certificate of Analysis Test List

PREFACE

PAFI-FSP-001 VOLUME 3 COMPRISES A DETAILED FUEL SAMPLING PLAN SUPPORTING THE PAFI PHASE II AIRCRAFT FLIGHT TESTING.

THIS FUEL SAMPLING PLAN REFLECTS AVIATION PRACTICE AND REGULATIONS FOR FUEL SAMPLING. THE PROCESSES & PROCEDURES REFLECT PRACTICES FOR COLLECTING FUEL SAMPLES APPROPRIATE FOR LABORATORY FUEL ANALYSES.

TABLE OF CONTENTS

TABLE OF FIGURES

Figure 1 - Example of Sampling Assembly for Vapor Pressure Sample Collection 25

Fuel Sampling Plan

PAFI-FSP-001

PAFI Phase II Testing

1. Scope This Sampling Plan provides the processes and procedures for collecting fuel samples across all PAFI Phase II receipt, engine, and aircraft testing. Sampling will be performed at a number of times from fuel receipt through engine on-ground and in-flight, and engine propeller testing. The purpose of the fuel sampling throughout the PAFI Phase II mission is to provide fuel samples for the documentation of physical and chemical properties at time of receipt, before and after testing, and to provide samples for any posttest investigations.

0. Provisos The following notes identify significant assumptions, requirements, and provisions associated with the testing prescribed within this test plan.

NOTE………The PAFI Phase II test program is not a traditional FAA certification program but rather is a definitive test program using engines and aircraft selected to be representative of the fleet to verify than none of the assumptions that were made with the current fleet was certificated with 100LL operating limitation are invalidated when operating on PAFI fuels.

NOTE….. This plan includes guidance on preparing packages for Hazardous Materials (HazMat) shipping. While the guidance was prepared in compliance with DOT shipping regulations, this document does not replace any local, state, or federal regulations. This document does not replace local facility regulations or procedures for shipping HazMat. This document is not a formal instruction for compliance to 49 CFR 172 hazardous materials shipping requirements.

NOTE……… This document provides safety guidance; it is not intended to be used in place of applicable safety regulations, i.e. CFR 29 part 1910 or NFPA 30. The intent of this guidance is to inform the reader of specific safety concerns as related to the materials and practices within, and may define a higher or more specific safety requirement, but does not replace any organizational, local, state, or federal safety codes.

Objectives The objectives of the PAFI Phase II Fuel Sampling Plan are defined as follows:

1) To provide fuel samples for laboratory testing, including Certificate of Analyses (COA), spot-checks, specific data requests.

2) To provide retain samples available for potential post-test analyses to resolve questions and concerns.

Background A matrix of engine and aircraft tests is required to validate operability with a new unleaded aviation gasoline. The FAA UAT ARC Final Report included a specific recommendation that a common suite of tests be developed which satisfies both ASTM and FAA requirements.

FAA UAT ARC FINAL REPORT SECT 4.6.2………….”Consequently, great efficiencies could be realized by developing one portfolio of tests that could provide data to support both the ASTM process and FAA certification process. This requires that the new ASTM Standard Practice and the FAA regulations and guidance be reviewed to identify where common tests and/or analyses can satisfy both sets of requirements. Test procedures will then be developed for both the common tests and unique tests for use by the FAA Tech Center under the centralized testing concept.”

Accordingly, the test plans prepared for the PAFI Phase II test program provide for development of a common set of validation data supporting compliance with both ASTM and FAA certification requirements.

The test fuels have distinct base chemistries which are distinguishable both from each other and from 100LL. To document the condition of the test fuels, and to provide pre- and post-test fuel data to support the analysis of the test data, multiple fuel samples are collected at the time the fuel is received, before and after engine and flight tests, and as requested.

Fuel Sampling Categories Bulk Fuel Bulk fuel refers to the main fuel at a testing location. This may be from a large fuel storage tank or from fuel received in drums.

Fuel From Engine Testing Four types of engine testing are described in the PAFI Phase II testing program; (1) engine detonation and performance testing; (2) engine durability testing; (3), propeller vibration testing and (4) propeller operability testing. Fuel samples will be collected based on: (1) prior to testing, (2) at designated times during testing, and (3) post-test. The samples are to confirm (1) the fuel is acceptable for use, (2) if fuel conditions have changed during testing and (3) if cross contamination of fuels between tests has occurred. Fuel retain samples will be kept and stored until the completion of PAFI Phase II testing. These samples will be considered to be representative of the fuel at the time of a specific test run.

Fuel From Flight Testing Flight test plans for ten different aircraft have been prepared. Each type of aircraft will have three different flight tests performed; Engine Handling, Engine Cooling, and Fuel System Hot Weather. Engine handling includes a fuel gaging test. Fuel samples will be collected (1) prior to testing, and (2) post-test to confirm the condition of the fuels and to confirm lack of cross contamination of fuels between test runs. These samples are considered to be representative of the fuel in the flight test aircraft’s fuel tank during a specific flight test. Fuel System Hot Weather testing also requires the testing of vapor pressure prior to flight test.

Applicable ASTM Requirements The following is a listing of the applicable FAA and ASTM documents which contain information relevant to the testing specified by this test plan.

ASTM D4057-12 Standard Practice for Manual Sampling of Petroleum and Petroleum Products This practice covers procedures for manually obtaining representative samples of petroleum products.

ASTM D5854-96(2015) STANDARD PRACTICE FOR MIXING AND HANDLING OF LIQUID SAMPLES OF PETROLEUM AND PETROLEUM PRODUCTS This practice covers the handling, mixing, and conditioning procedures that are required to ensure that a representative sample of the liquid petroleum or petroleum product is delivered from the primary sample container/receiver into the analytical test apparatus or into intermediate containers. Current specification was published in 1996 and reapproved in 2015.

Propulsion and airpower Engineering Research (POWER) Lab Health and Safety Plan (HASP), POWER-HASP-001 This document covers the safety and health standards for the POWER Lab. Current document was published in 2016.

Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001 This document covers the requirements for the installation of bulk storage and subsequent handling of the fuels for use in the PAFI Phase II testing. Current document was published in 2016.

Definitions & Terminology Definitions and abbreviations specific to this document are summarized in the following sections.

Tank Tap A tank tap refers to a sampling valve installed near the fuel tank specifically for collecting samples. This tap should be above the tank sump and ideally at a similar level as the outlet of the tank. The tap should be installed in such a way as to minimize the dead volume between the flowing line and the valve. One way to do this is to install the valve in-line as opposed to installing a T-fitting with the valve remote from the flowing line. If tank design necessitates the use of a T-fitting, the volume between the flowing line and the valve on the tap is a dead space and a volume equivalent to this volume must be drained and the fuel disposed of prior to taking a fuel sample.

Retain Sample “Retain sample” refers to a sample collected as part of the original sampling process and reserved for future testing for a specified period of time. It is retained so that if there are questions after a test is executed, there is a representative sample available for testing. If there are no problems, the sample is not subjected to analyses.

Safety Procedures SAFETY PRECAUTIONS………………….. Appropriate safety precautions are the responsibility of the Test Facility conducting the fuel sampling. The facility shall establish and ensure compliance with the applicable safety and health standards. Providing necessary personal protective gear is the responsibility of the Test Facility.

The FAA WJHTC will use the “Propulsion and airpOWer Engineering Research (POWER) Lab Health and Safety Plan (HASP) POWER-HASP-001” as a guiding document for safety and health standards.

Other locations may use existing Health and Safety plans or may request a copy of POWER-HASP-001.

Sample Fill (Reference ASTM D4057-12, Section 5.2) For safety and protection of the integrity of the samples, during transportation and storage, the use of a sample carrier, such as a box with separators between the glass containers is recommended. Because of potential liquid thermal expansion, sample containers that are completely, or nearly full, are not to be transported or stored, unless special precautionary measures such as cold storage are taken. A safe fill of between 70 and 85 vol. % is recommended unless otherwise instructed. Care should be taken to avoid heating samples in containers with gas-tight caps, lids, and stoppers. Care should be taken to assure sufficient torque on the caps to provide positive sealing but not so much torque as to crack any plastic caps.

Static Charge (REFERENCE ASTM D4057-12) Grounding (D4057-12, Section 5.4.1) A number of fires and explosions have occurred as a result of hydrocarbon vapors being ignited by static electricity. If electrical charges are not grounded, they are unable to dissipate and become “static.” This static electric charge can accumulate and freely migrate to a single point on the sample container by a difference in electrical potential, then jump off as a high-energy spark discharge to a nearby less charged surface. The spark may be hot and prolonged enough to ignite nearby hydrocarbon vapors present above the lower explosive limit (LEL). This potential shall be managed by safely dissipating static charges, and through proper grounding, when sampling flammable products Personal Attire (D4057-12, Section 4.5.2) Footwear or clothing, capable of causing sparks, should not to be worn during fuel sampling activities in which flammable vapors are likely to be present. Sampling should not be carried out during periods of atmospheric electric disturbance or hail storms. To ground any static charge on their body, the individual performing the sampling should touch part of the tank structure or other grounded structure at least 1 m (3 ft.) from the sample point immediately before sampling.

Equipment Sample Collection Vessel Depending on the size sample being collected, a clean, labelled container of appropriate size should be obtained from the site point of contact. In some cases, specifically prepared vessels have been provided by the FAA for sampling purposes. Any container used must be either glass bottles or stainless steel vessels and if possible cylindrical with a closure able to prevent contamination from external water and foreign materials. Do not use plastic containers or unlined caps as sample containers. Heavy-duty aluminum foil may be added between the bottle opening and the lid as a liner.

Labelling To mark the sample containers permanently, it is recommended that tags attached to the bottle neck or drum handle with safety wire and clearly marked using indelible ink or labels printed on an automatic labeler (Dymo™) are used. Alternatively, metal tags that have been metal stamped with sample information and wired to the bottle or drums may be used. Full label requirements are provided in “Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001”.

All fuel samples must be labelled at minimum with the following information:

1. Test fuel identification

2. Sample being collected, e.g. At Receipt, Post Settling, Pre-test, Pre-flight

3. Test identifier with date/tests/engine, e.g. -003 Det. Perf, TSIO-520-VB

4. Date collected

5. Signature/Initials Note………………….. Fuel will remove indelible ink written on a glass surface or smooth metal surfaces. Do not label containers directly on the surfaces of a glass bottle and stainless steel tanks. If adhesive labels are used on the surface of a fuel container, make sure the label is sealed to protect the label surface from contact with the test fuel.

250 ml Samples For samples requiring 250 ml or less of fuel, the recommended containers are 250 ml (8 oz.) amber glass Boston round bottles with polytetrafluoroethylene (PTFE) or foil lined lids.

e.g. Qorpak 8 oz. (240 ml) Amber Glass Boston Round Bottle with Black Phenolic foil lined lid, Item GLC-01964 Note………………….. If lids lined with PTFE are chosen, place a layer of heavy duty aluminum foil over the mouth of the bottle before capping.

One Liter Samples For fuel samples requiring one liter or less, the recommended containers are 1-L (33 oz.) amber glass Boston round bottles with PTFE or foil lined lids.

e.g. Qorpak 1-L (33oz) Amber Glass Boston Round Bottle, Item # GLA-07005 and Phenolic Cap, Item number CAP-00222.

Note………………….. If lids lined with PTFE are chosen, place a layer of heavy duty aluminum foil over the mouth of the bottle before capping.

One Gallon or Larger Samples For samples requiring one gallon or larger, the recommended container is a 5-gallon stainless steel, closed head drum with bung.

Note………………….. Stainless steel drums must have been pre-cleaned using the specified process. The fuel drum cleaning process is described in detail in the Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001. These drums are marked with tags and sealed by the WJHTC indicating proscribed cleaning has been completed. Do not use drums without proscribed pre-cleaning marking. These drums may be procured from the identified Point of Contact.

Hazardous Material Shipping Containers Fuel sample shipment must be in compliance with all local, state, and federal regulations. This includes compliance with DOT shipping regulations. All samples in glass bottles must be appropriately packaged in DOT compliant packaging which includes a shipping box meeting drop and crush requirements, an absorbent material and an overpack sufficient for containing any leakage from the sample container, e.g. plastic bag. Metal drums do not require additional overpacking material.

e.g. C.L. Smith Hazardous Material Packaging Kit, 2 x 250 ml/8 oz. or less Absorbent Bag. V Kit, Part number 30-1416 e.g. C.L. Smith Hazardous Material Packaging Kit, 1 x 1 liter/32 oz. or less Absorbent Bag. V Kit, Part number 30-1414 http://clsmith.com/hazardous-materials-packaging/special-permit-packaging/ Test Procedures Flight Test Sampling Flight testing is covered by three separate test plans; engine handling, engine cooling and fuel system hot weather operation.

PURPOSE: To collect a representative sample of the fuel at the beginning and end of engine handling testing.

PRIMARY DATA: Density, distillation, moisture content and confirmation of test fuel identity for comparing pre- and post-test condition.

FREQUENCY OF TESTING: Fuel shall be sampled as described below.

If any flight test is stopped for a failure, a sample identified as “anomalous” must be collected. Fuel gaging is a data only test and has no “anomalous” sample.

Note………………….. It is assumed the test fuel has been sampled and a Certificate of Analysis (CoA) from an independent laboratory has been generated, (See Volume 1, Section 9.1.2). If a CoA is not provided, contact the site POC prior to continuing.

Fuel Gaging Test (See Engine Handling Test Plans) A procedure check sheet is included in Appendix B Fuel Sample from Engine Handling Fuel Gaging Test The handling plan for each aircraft model includes a fuel gaging test. In this test the target fuel tank is drained of fuel, and a progressive fill with gage monitoring is undertaken.

FREQUENCY: A 250 ml sample of the test fuel shall be taken at the beginning of the test, after the 50% maximum tank capacity measurement, and at maximum tank capacity (end of test).

Note………………….. Make sure to account for the additional 14 oz. (1.5 cups) of fluid removed during sampling when filling the tank for gauge testing. It is recommended fuel be sampled after the first gage test measurement and an equivalent volume to the removed sample volume (14 oz.) be added to the calculated fuel quantity being added to reach 25% maximum tank. Add the second 14 oz. equivalent volume to the fuel quantity being added to the tank to reach 75% fill.

1. Obtain a container for collecting waste fuel generated during the rinsing steps. This fuel shall be disposed of in accordance with local, state, and federal regulations.

2. Obtain a clean, labeled 250 ml (8 oz.) amber glass bottle.

3. Confirm the label on the bottle matches the sample being collected.

4. Sampling should be collected using the aircraft sump valve on the tank being used for testing.

5. Open the valve and allow approximately 50 ml (2 oz.) of fuel to dispense into a waste container. This step flushes the line and removes any residual fuel, contamination, or water from the valve.

Note………………….. It is assumed that the aircraft fuel tank has been fully sumped prior to testing. Make sure the sample collected is clean fuel.

6. Fill the 250 ml (8 oz.) bottle approximately ½ full with the sample fuel, cap the bottle, and shake to flush the inside of the bottle. Pour this fuel into the waste container.

7. Fill the sample bottle to 85% full.

8. If necessary, place the layer of foil over the bottle mouth and cap the bottle.

Note………………….. Care should be taken to avoid over-tightening plastic caps of 250 ml and 1-L glass fuel sampling bottles. The cap must be tight enough to ensure good seal. But over-tightening a cap can cause cracks in the cap which may not be immediately visible. The damage can lead to leakage over time.

9. Confirm the sump valve is fully closed.

10. Confirm the label is in place and legible.

11. Submit the sample to the site POC. This sample will be measured for moisture content, density, and sample composition identification.

12. Repeat steps 2 – 11 after the 50% fill, and at the end of the test.

Engine Handling Flight Test FREQUENCY: Fuel samples shall be collected prior to flight test and after completing flight test from both the test fuel tank(s) and from the 100LL test fuel tank(s).

Following an individual flight test there should be a total of a minimum of four samples, two from the 100LL test and two from the test fuel test. In cases where the flight test aircraft has a main and an auxiliary tank, samples are to be collected from both tanks’ drain valves for a minimum total of eight samples at the end of the test; four from the test fuel and four from the 100LL. In cases where the flight test aircraft has a single tank, there will be a minimum total of four samples, two collected from the flight test flown on 100LL and two collected from the flight test flown on the test fuel.

Note………………….. Samples need only be taken when the tank(s) is first filled, any time fuel is added, and at the end of testing, regardless of the number of actual take-offs and landings. Sampling is not required between engine starts and shut downs as long as there is no change to the fuel in the fuel tank.

Any time a test is aborted due to a “Failure”, a full Certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

Note………………….. It is assumed the test fuel has been sampled and a Certificate of Analysis (CoA) from an independent laboratory has been generated, (See Volume 1, Section 9.1.2). If a CoA is not provided, contact the site POC prior to continuing.

Fuel Sample From Engine Handling Flight Test A procedure check sheet is included in Appendix D.

1. Obtain a container for collecting waste fuel generated during the rinsing steps. This fuel shall be disposed of in accordance with local, state, and federal regulations.

2. Obtain a clean, labeled 250 ml (8 oz.) amber glass bottle for each fuel tank being sampled. For a flight test performed with 100LL in one fuel tank and the test fuel in a second fuel tank, a separate sample will be taken from each tank (total two).

3. Confirm the label on the sample bottle matches the sample being collected.

4. Sampling should be performed using the aircraft sump valve on the aircraft fuel tanks following preflight inspection.

Note………………….. It is assumed that the aircraft fuel tank has been fully sumped prior to testing. Make sure the sample collected is clean fuel.

5. Fill the 250 ml (8 oz.) bottle approximately ½ full with the sample fuel, cap the bottle, and shake to flush the inside of the bottle. Pour this fuel into the waste container.

6. Fill the sample bottle to 85% full.

7. If necessary, place a layer of heavy-duty foil over the bottle mouth and cap the bottle.

8. Confirm the sump valve is fully closed.

9. Confirm the label is in place and legible.

Note………………….. Care should be taken to avoid over-tightening plastic caps of 250 ml and 1-L glass fuel sampling bottles. The cap must be tight enough to ensure good seal. But over-tightening a cap can cause cracks in the cap which may not be immediately visible. The damage can lead to leakage over time.

10. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual.

11. Submit the sample to the site POC. This sample will be measured for moisture content, density, and sample composition identification.

12. Repeat steps 1 – 11 if fuel is added to a fuel tank and at the end of the test.

Fuel Sample from Engine Handling Flight Test – Anomalous Sample A procedure checklist is included in Appendix C Any time a test is aborted due to a “Failure”, a full certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

1. Obtain a clean, 5-gallon, stainless steel sample container. These containers have been prepared by and are available from the FAA WJHTC point of contact.

Note………………….. Stainless steel drums must have been pre-cleaned using the specified process. The fuel drum cleaning process is described in detail in the Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001. These drums are marked with tags and sealed by the WJHTC indicating proscribed cleaning has been completed. Do not use drums without proscribed pre-cleaning marking. These drums may be procured from the identified Point of Contact.

2. Prepare a label containing the test information, point of anomaly during the test, sampler’s signature, and date of collection.

3. Break the seal on the drum.

4. Confirm the label on the drum matches the sample being collected.

5. Sampling should be performed using the aircraft sump valve on the target tank.

6. Do not flush the sample line.

7. Fill the sample drum to 85% full or as full as the remaining fuel in the tank permits.

8. Cap the drum and securely tighten the cap.

9. Confirm the sample tap is fully closed.

10. Confirm the label is in place and legible.

11. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual

12. Submit the sample to the site POC. This sample will be measured for full certificate of analysis testing (see Appendix G).

Note………………….. If samples are not being immediately transferred to the POC or other sample handling preparation, make sure samples are stored in a safe location away from excessive heat, e.g. sun or radiators, to avoid damage to the sample or the sample container.

Category - Engine Cooling Test PURPOSE: Collection of a representative sample of the fuel at the beginning and end of engine cooling testing.

PRIMARY DATA: Density, distillation, moisture content, and confirmation of sample identification for comparing pre- and post-test fuel condition.

FREQUENCY: Fuel samples shall be collected prior to flight test and after completing flight test from both the test fuel tank(s) and from the 100LL test fuel tank(s).

Following an individual flight test there should be a total of a minimum of four samples, two from the 100LL test and two from the test fuel test. In cases where the flight test aircraft has a main and an auxiliary tank, samples are to be collected from both tanks’ drain valves for a minimum total of eight samples at the end of the test; four from the test fuel and four from the 100LL. In cases where the flight test aircraft has a single tank, there will be a minimum total of four samples, two collected from the flight test flown on 100LL and two collected from the flight test flown on the test fuel.

Note………………….. Samples need only be taken when the tank(s) is first filled, any time fuel is added, and at the end of testing, regardless of the number of actual take-offs and landings. Sampling is not required between engine starts and shut downs as long as there is no change to the fuel in the fuel tank.

Any time a test is aborted due to a “Failure”, a full certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

Note………………….. It is assumed the test fuel has been sampled and a Certificate of Analysis (CoA) from an independent laboratory has been generated, (See Volume 1, Section 9.1.2). If a CoA is not provided, contact the site POC prior to continuing.

Fuel Sample From Engine Cooling Flight Test A procedure checklist is included in Appendix D.

1. Obtain a container for collecting waste fuel generated during the rinsing steps. This fuel shall be disposed of in accordance with local, state, and federal regulations.

2. Obtain a clean, labeled 250 ml (8 oz.) amber glass bottle for each fuel tank being sampled. For a flight test performed with 100LL in one fuel tank and the test fuel in a second fuel tank, a separate sample will be taken from each tank (total two).

3. Confirm the label corresponds to the sample being collected.

4. Sampling should be performed using the aircraft sump valve on the target tank following preflight inspection.

Note………………….. It is assumed that the aircraft fuel tank has been fully sumped prior to testing. Make sure the sample collected is clean fuel.

5. Fill the 250 ml (8 oz.) bottle approximately ½ full with the sample fuel, cap the bottle, and shake to flush the inside of the bottle. Pour this fuel into the waste container.

7. If necessary, place the layer of foil over the bottle mouth and cap the bottle.

Note………………….. Care should be taken to avoid over-tightening plastic caps of 250 ml and 1-L glass fuel sampling bottles. The cap must be tight enough to ensure good seal. But over-tightening a cap can cause cracks in the cap which may not be immediately visible. The damage can lead to leakage over time.

8. Confirm the sump valve is fully closed.

10. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual

11. Submit the sample to the site POC. This sample will be measured for moisture content, density, and sample composition identification.

12. Repeat steps 1 – 11 at the end of the test.

Fuel Sample from Engine Cooling Flight Test – Anomalous Sample A procedure checklist is included in Appendix C.

If at any time during the test, the run is aborted due to a “Fail”, a full certificate of analysis is required. This requires a 5-gallon sample to be procured.

1. Obtain a clean, 5-gallon, stainless steel sample container. These containers have been prepared by and are available from the FAA WJHTC point of contact.

Note………………….. Stainless steel drums must have been pre-cleaned using the specified process. The fuel drum cleaning process is described in detail in the Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001. These drums are marked with tags and sealed by the WJHTC indicating proscribed cleaning has been completed. Do not use drums without proscribed pre-cleaning marking. These drums may be procured from the identified Point of Contact.

2. Prepare a label containing the test information, point of anomaly during the test, sampler’s signature, and date of collection.

4. Confirm the sample label corresponds to the sample being collected.

5. Sampling should be performed using the aircraft sump valve on the target tank.

6. Do not flush the sample line.

7. Fill the sample drum to 85% full or as full as the remaining fuel in the tank permits.

8. Cap the drum and securely tighten the cap.

9. Confirm the sample tap is fully closed.

10. Confirm the label is in place and legible.

11. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual

12. Submit the sample to the site POC. This sample will be measured for full certificate of analysis testing (see Appendix G).

Note………………….. If samples are not being immediately transferred to the POC or other sample handling preparation, make sure samples are stored in a safe location away from excessive heat, e.g. sun or radiators, to avoid damage to the sample or the sample container.

Category – Fuel System Hot Weather Testing PURPOSE: Collection of a representative sample of the fuel at the beginning and end of Fuel System Hot Weather testing.

Collection of samples to confirm the fuel vapor pressure prior to flight test.

PRIMARY DATA: Density, distillation, moisture content, and confirmation of sample identification for comparing pre- and post-test fuel condition.

Vapor pressure of the fuel at the beginning of flight testing.

FREQUENCY OF TESTING: Fuel shall be sampled as described below.

Any time a test is aborted due to a “Failure”, a full certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

Note………………….. It is assumed the test fuel has been sampled and a Certificate of Analysis (CoA) from an independent laboratory has been generated, (See Volume 1, Section 9.1.2). If a CoA is not provided, contact the site POC prior to continuing.

Vapor Pressure Test Sample Per ASTM D5191 Vapor Pressure of Petroleum Products (Mini-Method) The current PAFI ATP test plans indicate the requirement to measure and adjust the vapor pressure of the fuels used in testing to within 0.3 psi of their maximum specification value prior to starting the testing.

Note………………….. While these instructions directly support ASTM D5191 testing, it is acceptable to execute vapor pressure testing using the ASTM D323 Reid Method at the discretion of the testing site. All sampling procedures are the same however, sample size is increased from 250 ml each to 1000 ml each (1 liter). All other steps, e.g. bottle preparation, fill procedure, and post sample handling requirements are the same.

Note………………….. The sampling method provided is designed to support ASTM D5191, Vapor Pressure of Petroleum Products by the Mini-Method. The same sampling procedures are required to perform RVP (Reid Vapor Pressure) testing per ASTM D323, Vapor Pressure of Petroleum Products (Reid Method), EXCEPT three (3) separate one liter samples instead of three (3) 250 ml samples, collected into chilled amber glass bottles are required.

FREQUENCY: Vapor pressure samples are to be collected prior to testing to establish the correct vapor pressure. The fuel’s vapor pressure can be adjusted by the addition of butane and/or isopentane. Adjustments to the fuel require additional repeated vapor pressure testing to the same sampling procedure.

Fuel Sample from Fuel System Hot Weather Vapor Pressure Testing A procedure checklist is included in Appendix E.

This sampling supports testing for vapor pressure testing by ASTM D5191 - 13, whether the testing is being performed on-site or to be shipped to a laboratory for testing. If testing per ASTM D323-08 is to be performed, sample size must be increased to one liter.

Note………………….. Vapor pressure testing requires specialized testing equipment. This equipment must be procured, or testing must be arranged at a specialized testing facility.

Note………………….. Vapor pressure testing is highly sensitive to proper sample collection, sample handling, and test methods. Even slight deviations from the proscribed methods can result in shifts in resulting data sufficient to invalidate the test.

Note………………….. Sample collection must be done immediately after any adjustment of the test fuel for vapor pressure has been made.

1. Obtain three (3), clean, labelled 250 ml amber glass bottles and caps. Each time a vapor pressure test is required; three (3) separate 250 ml samples must be collected.

Note………………….. Sample bottles should be chilled to a temperature as low as the material in the tank or 0°C (32°F), whichever is greater. See ASTM D5842-04, Section 7.2.2.2, Figure 6 for information on chilling the sample containers.

2. Confirm the label on the sample bottle matches the sample being collected.

3. Obtain a container for collecting waste fuel generated during the rinsing steps. This fuel shall be disposed of in accordance with local, state, and federal regulations.

4. Identify the sampling location. Depending on the source of the test fluid, this may be a sampling tap, the sump valve on the aircraft, or a distribution pump.

Note………………….. The sampling tap should be equipped with a stainless steel or glass tube that extends through the sample bottle opening and fills the jar from the bottom. See ASTM D5842-04 (2009) Figure 5 (reproduced below) for an example. A tube which fits over the sump drain exit, but does not attach is acceptable as long as the fit against the sump valve is tight and the sample bottle fills from the bottom.

Figure 1 - Example of Sampling Assembly for Vapor Pressure Sample Collection

5. Wipe the exterior of the sample filling tube with a clean, lint free cloth.

6. Open the sampling point and flow a sufficient volume of fuel to drain the line, pump, or valve back to the tank. Collect this fuel in the waste container. This removes any residual fuel from line prior to sampling the target fuel. This step is critical as any residual fuel collected with the target sample fuel will skew the measured vapor pressure.

7. Fill the 250 ml sample container 1/3 to ½ full and cap. Shake the container gently to rinse the inside of the container. Repeat for a total of three rinses.

8. Collect a fuel sample into the rinsed 250 ml bottle by filling the bottle 80% full.

9. Immediately cap the bottle to prevent the loss of fuel vapors.

Note………………….. Care should be taken to avoid over-tightening plastic caps of 250 ml and 1-L glass fuel sampling bottles. The cap must be tight enough to ensure good seal. But over-tightening a cap can cause cracks in the cap which may not be immediately visible. The damage can lead to leakage over time.

10. Confirm the sampling valve is fully closed.

11. Confirm the label is in place and legible.

12. Seal the cap to the bottle using plastic tape.

13. Repeat steps 2 – 11 for the remaining 250 ml samples.

14. Submit the sample to the POC for either on-site vapor pressure testing or preparation for shipping to the identified testing facility.

Fuel Sample from Fuel System Hot Weather Flight Testing A procedure checklist is included in Appendix D.

FREQUENCY: Fuel samples shall be collected prior to flight test and after completing flight test from both the test fuel tank(s) and from the 100LL test fuel tank(s).

Following an individual flight test there should be a total of a minimum of four samples, two from the 100LL test and two from the test fuel test. In cases where the flight test aircraft has a main and an auxiliary tank, samples are to be collected from both tanks’ drain valves for a minimum total of eight samples at the end of the test; four from the test fuel and four from the 100LL. In cases where the flight test aircraft has a single tank, there will be a minimum total of four samples, two collected from the flight test flown on 100LL and two collected from the flight test flown on the test fuel.

Note………………….. Samples need only be taken when the tank(s) is first filled, any time fuel is added, and at the end of testing, regardless of the number of actual take-offs and landings. Sampling is not required between engine starts and shut downs as long as there is no change to the fuel in the fuel tank.

Any time a test is aborted due to a “Failure”, a full certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

Note………………….. It is assumed the test fuel has been sampled and a Certificate of Analysis (CoA) from an independent laboratory has been generated, (See Volume 1, Section 9.1.2). If a CoA is not provided, contact the site POC prior to continuing.

1. Obtain a container for collecting waste fuel generated during the rinsing steps. This fuel shall be disposed of in accordance with local, state, and federal regulations.

2. Obtain a clean, labeled 250 ml (8 oz.) amber glass bottle for each fuel tank being sampled. For a flight test performed with 100LL in one fuel tank and the test fuel in a second fuel tank, a separate sample will be taken from each tank (total two).

3. Confirm the label on the bottle matches the sample being collected.

4. Sampling should be performed using the aircraft sump valve on the target tank following preflight inspection.

Note………………….. It is assumed that the aircraft fuel tank has been fully sumped prior to testing. Make sure the sample collected is clean fuel.

5. Fill the 250 ml (8 oz.) bottle approximately ½ full with the sample fuel, cap the bottle, and shake to flush the inside of the bottle. Pour this fuel into the waste container.

7. If necessary, place the layer of foil over the bottle mouth and cap the bottle.

Note………………….. Care should be taken to avoid over-tightening plastic caps of 250 ml and 1-L glass fuel sampling bottles. The cap must be tight enough to ensure good seal. But over-tightening a cap can cause cracks in the cap which may not be immediately visible. The damage can lead to leakage over time.

8. Confirm the sump valve is fully closed.

10. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual

11. Submit the sample to the site POC. This sample will be measured for moisture content, density, and sample composition identification.

12. Repeat steps 1 – 11 any time fuel is added to the fuel tank and at the end of the test.

Fuel Sample from Fuel System Hot Weather Flight Test – Anomalous Sample A procedure checklist is included in Appendix C.

Any time a test is aborted due to a “Failure”, a full certificate of analysis is required. This analysis requires a 5-gallon fuel sample.

1. Obtain a clean, 5-gallon, stainless steel sample container. These containers have been prepared by and are available from the FAA WJHTC point of contact.

Note………………….. Stainless steel drums must have been pre-cleaned using the specified process. The fuel drum cleaning process is described in detail in the Piston Aviation Fuels Initiative (PAFI) Phase II Fuels Handling Plan, PAFI-FHP-001. These drums are marked with tags and sealed by the WJHTC indicating proscribed cleaning has been completed. Do not use drums without proscribed pre-cleaning marking. These drums may be procured from the identified Point of Contact.

2. Prepare a label containing the test information, point of anomaly during the test, sampler’s signature, and date of collection.

4. Confirm the sample label on the drum corresponds to the sample being collected.

5. Sampling should be performed using the aircraft sump valve on the target tank.

6. Do not flush the sample line.

7. Fill the sample drum to 85% full or as full as the remaining fuel in the tank permits.

8. Cap the drum and securely tighten the cap.

9. Confirm the sample tap is fully closed.

10. Confirm the label is in place and legible.

11. The person taking the sample shall fill out a copy of the form located in Appendix A with confirmation of sampling, date, time, and sampler’s signature and certificate number. An entry of sample collection shall also be entered into the aircraft maintenance manual

12. Submit the sample to the site POC. This sample will be measured for full certificate of analysis testing (see Appendix G).

Note………………….. If samples are not being immediately transferred to the POC or other sample handling preparation, make sure samples are stored in a safe location away from excessive heat, e.g. sun or radiators, to avoid damage to the sample or the sample container.

Test Personnel The testing source shall identify a single POC for conduct of the testing equivalent to a Test Director who shall have the authority for oversight and supervision of those conducting the test. The Test Director shall have absolute responsibility during the test for decisions regarding safety and integrity of the test.

Non-FAA locations shall identify a single site POC for information, questions, and source of FAA prepared drums, and the test fuel. The site POC shall have the FAA POC clearly identified and contact information available.

Shipping Procedures Upon completion of the sampling, all samples must be forwarded to the identified contact. Unless otherwise indicated, samples should be sent to TBD.

Note………………….. The following steps provide general guidance on the safe packaging of hazardous materials in preparation for shipment. These steps should not be construed to supersede any local facility regulations on the preparation and shipping of hazardous materials. Where possible the local certified hazardous material point of contact should be engaged in the process.

Note………………….. Samples collected in compliance with this sampling plan should be within the regulated limits of 49 CFR 172.101. Activities beyond the scope of this document are not addressed by this guidance.

Note………………….. Hazardous Material shipping container kits contain all the necessary packing materials. If shipping kits are not used, materials compliant with each step must be procured.

Packing Sample Bottles

1. Obtain approved shipping container appropriate to the size bottle being prepared (See 8.2 Hazardous Material Shipping Containers).

2. Select shipping container matching sample size. Kits are designed with support material matching to the sample container size. If not using a kit, the selected box must meet 49CFR regulations pertaining to crush and drop specifications.

3. Using supplied tape, tape the lid to the bottle. Tape should be applied in the tightening direction. The purpose of this tape is to prevent vibration from unscrewing the cap. Tape such as electrical tape, laboratory tape, or plastic shipping tape may be used. Do not use masking tape or similar paper-based tape.

4. Wrap the bottle in the supplied absorbent material. Other examples of materials that may be used include absorbent pad material.

5. Slide the bottle wrapped in the absorbent material into the supplied plastic bag. A heavy duty zip top bag that completely contains the sample and can be positively zipped may be used.

6. Seal the plastic bag closed by twisting closed and using suppled closure tie. Confirm zip top bags are completely closed.

7. Slide the wrapped sample into the support structure of the shipping box. If not using a kit, provide sufficient packing material to assure the sample cannot be bounced around the box or broken my damage to the box.

8. Insert Safety Data Sheet (SDS). See FAA POC for copies.

9. Close and seal the box with shipping tape.

10. Address box and provide to ground shipper of choice. See local shipping department for specific instructions and necessary paperwork.

Packing 5-gallon Stainless Steel Drums

1. Stainless steel 5-gallon drums do not require additional overpackaging.

2. Torque bungs on the drum to 15-22 ft-lbs.

3. If available, safety wire drum bungs to prevent loosening of the bungs by vibration during shipping.

4. Multiple drums may be banded together, wrapped in shipping plastic and tied down to a pallet.

5. Address box and provide to ground shipper of choice. See local shipping department for specific instructions and necessary paperwork.

References In addition to the reference material of Section 5, the following references are related to the testing described.

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