4-_15061.pdf

SECTION 15061 Page 1

SECTION 15061

FUELING SYSTEM REPAIRS

PART 1 GENERAL

1.1 REFERENCES

Waiver to Use MilStds and MilSpecs in Air Force Fuel Projects, HQ AFCESA/CESM (01/29/96.

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN PETROLEUM INSTITUTE (API)

API SPEC 6D (1994) Pipeline Valves (Gate, Plug, Ball, and Check Valves)

API STD 607 (1993) Fire Test for Soft-Seated Quarter-Turn Valves

API STD 608 (1995) Ball Valves

API RP 1110 (1991) Pressure Testing of Liquid

Petroleum Pipeline

ASME INTERNATIONAL (ASME)

ASME-16 (1992; Addenda Dec 1992, Dec 1992, Dec 1994) Boiler and Pressure Vessel Code;

Section VIII, Pressure Vessels DIVISION 1

ASME-17 (1992; Addenda Dec 1992, Dec 1993, Dec

1994) Boiler and Pressure Vessel Code;

Section IX, Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators

ASME B1.1 (1989) Unified Inch Screw Threads (UN and

UNR Thread Form)

ASME B16.5 (1988; Errata Oct 88; B16.5a) Pipe Flanges and Flanged Fittings

ASME B16.9 (1993) Factory-Made Wrought Steel

Buttwelding Fittings

ASME B16.11 (1991) Forged Fittings, Socket-Welding and Threaded

ASME B16.20 (2000) Metallic Gaskets for Pipe Flanges -

Ring-Joint, Spiral Wound, and Jacketed

ASME B16.21 (1992) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B18.2.1 (1981; R 1992) Square and Hex Bolts and

Screws Inch Series

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ASME B18.2.2 (1987) Square and Hex Nuts (Inch Series)

ASME B31.3 (1990; B31.3a-1990; Errata; B31.3b-1991) Chemical Plant and Petroleum Refinery Piping

ASTM INTERNATIONAL (ASTM)

ASTM A182 (1996e) Forged or Rolled Alloy-Steel Pipe

Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193 (1996b) Alloy-Steel and Stainless Steel

Bolting Materials for High-Temperature Service

ASTM A194 (1996) Carbon and Alloy Steel Nuts for

Bolts for High-Pressure and High-Temperature Service

ASTM A269 (1996) Seamless and Welded Austenitic

Stainless Steel Tubing for General Service

ASTM A312 Stainless Steel Pipe

ASTM A358 (1995) Electric-Fission-Welded Austenitic Chromium-Nickel Alloy Steel Pipe for High-Temperature Service

ASTM A403 (1996) Wrought Austenitic Stainless Steel

Piping Fittings

ASTM D229 (1991) Rigid Sheet and Plate Materials Used for Electrical Insulation

ASTM F436 (1991) Hardened Steel Washers

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (1990) Flammable and Combustible Liquids Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J 514 (1989) Hydraulic Tube Fittings, Standard

U.S. DEPARTMENT OF DEFENSE (DOD)

FS L-C-530 or Thermosetting Epoxy

FS L-T-1512 (Rev A; Reinst) Tape, Pressure Sensitive

Adhesive, Pipe Wrapping MIL-STD-161 (Rev F; Notice 2) Bulk Petroleum Products

System Including Hydrocarbon Missile Fuels

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

The following shall be submitted in accordance with Section 01330 SUBMITTAL

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PROCEDURES:

SD-01 Preconstruction Submittals

Contractor Qualifications; G, AE

Work Plan; G, AE

SD-03 Product Data

Stainless Steel Piping; G, AE

Rock Shield; G, AE

SD-06 Test Reports

Hydrostatic (Strength) Test

1.3 QUALITY ASSURANCE

1.3.1 Material and Equipment Qualifications

Provide materials and equipment that are standard products of a manufacturer regularly engaged in the manufacturing of such products, that are of a similar material, design and workmanship. Materials and equipment shall have been in satisfactory commercial or industrial use for a minimum 2 years prior to bid opening. The 2 year period shall include applications of the equipment and materials under similar circumstances and of similar size. Materials and equipment shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period. Products having less than a 2 year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours, exclusive of the manufacturer's factory tests, can be shown.

Repair kits shall be supplied by original component manufacturer.

1.3.2 Contractor Qualifications

The installation Contractor shall have successfully completed at least 3 projects that consist of major Air Force Type III Hydrant System (or similar navy system) new, and or major repair of the same scope and the same size or larger within the last 6 years. Each installation Contractor shall demonstrate specific installation experience in regard to the specific system installation to be performed with special emphasis on the repair of stainless steel hydrant piping systems. Each installation Contractor shall have taken, if applicable, manufacturer's training courses on the installation of piping and shall meet the licensing requirements in the state. Submit a letter listing prior projects, the date of construction, a point of contact for each prior project, the scope of work of each prior project, and a detailed list of work performed.

1.3.3 Work Plan

Submit a comprehensive work plan that provides sufficient detail to demonstrate a thorough understanding of the project. Document that all components to be provided will function together and produce the results expected by the Government. Include any proposed dates for piping system shutdowns as well as the Contractor's ability to complete the work within the allotted shutdown periods. Show proposed dates and nature of piping system operations required of the Government. Include a list of manpower, spare piping and equipment that will be on hand for each phase of the work.

Describe, in detail, the means of:

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a. Coordinating work with Government and third parties.

b. Preparing for safe piping repair work.

c. Pressure Testing new piping sections.

d. Purging piping.

e. Vapor monitoring.

f. Preparations for containing and disposal of residual fuel.

g. Cutting, sealing, and welding into existing systems.

h. Welding tie-ins in place, including detailed discussion on backside gas purge procedures.

i. Examining repair section tie-in welds.

j. Collecting, storing and disposing of waste fuel generated during work.

k. System piping particle blast cleaning to remove weld slag

l. System filling with fuel and air venting

m. System pressure (strength) hydrotesting

n. System pigging for debris removal

o. Flushing to remove particulates

p. System operation for cleaning

q. System leak testing (3rd Party Certified)

r. System control valve set-up, testing tuning

1.4 DELIVERY, STORAGE, AND HANDLING

Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items.

1.5 PROJECT/SITE CONDITIONS

1.5.1 Fuel Supply

Fuel required for the flushing and cleaning efforts as specified in this section will be provided and delivered by the Contracting Officer. Do not flush, clean, or test any system with fuel or liquid not intended for final system operation. Fuel used in the system shall remain the property of the Government. Fuel shortages not attributable to normal handling losses shall be reimbursed to the Government.

PART 2 PRODUCTS

EQUIPMENT, FUELING SYSTEM.

2.1 MATERIALS

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2.1.1 General

Piping and fittings in contact with fuel shall be stainless steel, interior epoxy coated carbon steel as indicated on the drawings. No zinc coated metals, brass, bronze or other copper bearing alloys shall be used in contact with the fuel. All carbon steel and stainless steel underground piping shall have a protective coating. Identification of piping shall be in accordance with MIL-STD-161 unless specified otherwise. Material for manual valves shall be as specified hereinafter.

2.1.2 Stainless Steel Piping

a. Piping 2 1/2-Inches and Larger:

(1) ASTM A358, Grade 304L, Class 1 or Class 3 with supplementary requirements of S1, S2 and S3, or ASTM A312 Type 304L, seamless (only).

Any agreements between the purchaser and the manufacturer or supplier as referenced in the applicable ASTM shall include the Contracting Officer as a party to the agreement. All piping welds will receive 100 percent radiographic inspection, 100 percent liquid penetrant inspection, 100 percent visual inspection and all tests as required by the applicable ASTM Standard. Piping shall be provided with a nominal wall thickness as shown in Table A for ASTM A358 with the deviation from the nominal wall thickness less than 0.01-inch. ASTM A312 seamless piping shall be provided with a minimum schedule 10S wall thickness.

(2) Pipe Ends: All Piping shall be provided with beveled ends per Chapter V, ASME B31.3, and shall be shipped with the ends capped.

(3) Seam Welds: All sections of the piping provided shall be accepted on the project site if the seam welds meet the requirements of the paragraph K341 of ASME B31.3 and Appendix 4 of ASME-16. Ten spots may be reinspected at the project site prior to installation and backfilling at the request of the Contracting Officers Representative.

(4) Welders Qualifications: Piping shall be welded in accordance with qualified procedures using performance qualified welders and welding operators. Procedures and welders shall be qualified in accordance with

ASME-17.

(5) Factory Testing and Inspection Records: Per Table K341.3.2A of Chapter IX of ASME B31.3, visual, radiographic and liquid penetrant tests shall be performed for each section of piping provided as all sections are subjected to cyclic conditions. All testing and inspections records shall be submitted to the Contracting Officers Representative and shall indicate the pipe mark and installed location of what piping section on the project site. Observation by the contracting Officers Representatives of the manufacturers testing and inspection procedures shall be allowed under this contract. Pipe certification along with pipe markings shall be submitted before the pipe arrives on the job site.

(6) Quality Assurance Plan shall be submitted for the welding, inspecting and testing of the welded seam pipe.

TABLE A

Nominal Nominal (Average)

TABLE A

Pipe Size Pipe O.D. Wall Thickness(tn)

16 in. 16.000 in. 0.312 in.

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14 in. 14.000 in. 0.312 in.

12 in. 12.750 in. 0.250 in.

10 in. 10.750 in. 0.250 in.

8 in. 8.625 in. 0.250 in.

6 in. 6.625 in. 0.219 in.

4 in. 4.500 in. 0.219 in.

2 1/2 in. 2.875 in. 0.156 in.

b. Piping Two-Inches and Smaller: Schedule 80 ASTM A312 seamless Type 304L for threaded piping and schedule 40 (unless otherwise indicated) ASTM A312 seamless Type 304L for welded piping.

2.1.3 Protective Coatings for Buried Steel Piping

Provide pipe with FS L-C-530 coating system of factory-applied adhesive undercoat and continuously extruded plastic resin coating; minimum thickness of plastic resin shall be 36 mils for pipe sizes 6 inches and larger. Fittings, couplings, irregular surfaces, damaged areas of pipe coating, and existing piping affected by the Contractor's operations shall be clean, dry, grease free, and primed before application of tape. Tape shall overlap the pipe coating not less than three inches. Waterproof shrink sleeves may be provided in lieu of tape and shall overlap the pipe coating not less than six inches. Pipe coating and adhesive undercoat surfaces to be wrapped with tape shall be primed with a compatible primer prior to application of tape. Primer shall be as recommended by tape manufacturer and approved by pipe coating manufacturer.

a. Damaged Areas of Pipe Coating: Provide FS L-T-1512, 20 mils nominal thickness of tape over damaged areas. Residual material from damaged areas of pipe coating shall be pressed into the break or trimmed off. Apply tape spirally with one-third overlap as tape is applied. A double wrap of one full width of tape shall be applied at right angles to the axis to seal each end of the spiral wrapping.

b. Fittings, Couplings, and Regular Surfaces: Provide FS L-T-1512, 10 mils nominal thickness tape overlapped not less than 1.0 inch over damaged areas. Initially stretch and apply first layer of tape to conform to component's surface. Then apply and press a second layer of tape over first layer of tape.

c. Testing of Protective Coatings: Perform tests with an approved silicone rubber electric wire brush or an approved electric spring coil flaw tester. Tester shall be equipped with an operating bell, buzzer, or other audible signal which will sound when a holiday is detected at minimum testing voltage equal to 1,000 times the square root of the average coating thickness in mils. Tester shall be a type so fixed that field adjustment cannot be made. Calibration by tester manufacturer shall be required at six-month intervals or at such time as crest voltage is questionable.

Certify in writing the calibration date and crest voltage setting.

Maintain the battery at ample charge to produce the crest voltage during tests. Areas where arcing occurs shall be repaired by using material identical to original coating or coating used for field joints. After installation, retest the exterior surfaces, including field joints, for holidays. Promptly repair holidays. Note that all existing underground piping exposed for this project shall receive testing of protective coatings specified herein. Repair all damage.

d. Rock Shield: Provide a minimum 3/8 inch thick perforated rock shield around buried piping. Rock shield shall consist of a polyethylene outer surface bonded to a closed cell foam substrate with uniform perforations intended for use with cathodic protection systems. Rock shield shall overlap on itself no less than 6 inches. Secure rock shield tightly to the pipe using either strapping tape or plastic ties. Air filled cell type

SECTION 15061 Page 7 rock shield is prohibited.

2.1.4 Fittings

2.2.4.1 General

Welding ells, caps, tees, reducers, etc., to be of materials compatible for welding to the pipe line in which they are installed, and wall thickness, pressure and temperature ratings of the fittings shall be not less than the adjoining pipe line. Unless otherwise required by the conditions of installation, all elbows shall be the long radius type. Miter joints shall not be acceptable. Make odd angle offsets with pipe bends or elbows cut to the proper angle. Butt weld fittings to be factory-made wrought fittings manufactured by forging or shaping. Fabricated fittings will not be permitted. Welding branch fittings shall be insert type suitable for radiographic inspections specified herein.

a. Unions. Conforming to ASTM A312, Grade 304 or 316.

2.2.5 Field Applied Protective Coatings

The field joints and fittings of all underground piping shall be coated as herein specified.

2.2.5.1 Welded Joints

Heat shrinkable radiation-cross-linked polyolefin wraparound type sleeves shall be applied to all welded joints. Joints shall not be coated until pressure testing is complete. Apply sleeves consisting of 40 mil polyolefin backing and 40 mil thermoplastic mastic adhesive in accordance with the manufacturer's instructions.

PART 3 EXECUTION

All welding process and qualification of welders shall be in accordance with Section 02559 WELDING FOR POL SERVICE PIPING.

3.1 INSTALLATION

3.1.1 Precautions

Special care shall be taken by the Contractor to insure that the protective coating on buried pipe is not damaged during repairs and installation and that the completed system is free of rocks, sand, dirt, water, welding slag, and foreign objects including any purge dam materials and construction debris. The Contractor shall take the following steps to insure these conditions.

a. Coated pipe shall be handled only with canvas or nylon slings or padded clamps. Any coating damaged by improper handling or storage shall be repaired as specified.

b. Pipe brought to the site shall be stored on blocks or horses at least 18 inches above the ground. Padded blocks or horses shall be used for coated pipe. The method and height of storing coated pipe shall be in accordance with the coating manufacturer's instructions.

c. Visual inspection shall be made of the inside of each length of pipe to ensure that it is clear and clean prior to installation.

d. The open ends of the pipe system shall be closed at the end of

SECTION 15061 Page 8 each day's work or when work is not in progress with an expansion plug and shall not be opened until the work is resumed.

e. A swab, with a leather or canvas belt disc to fit the inside diameter of pipe, shall be pulled through each length of pipe after welding in place, with the exception of pipe inserts that have no open end after welding.

f. Obstruction remaining in the pipe after completion of the system shall be removed at the expense of the Contractor.

3.1.2 Protective Coatings

3.1.2.1 Application of Tape Wrapping

Surfaces to receive tape shall be clean, dry, grease-free and dust-free.

Extruded polyethylene coating and adhesive undercoat surfaces to be tape wrapped shall be primed with a compatible primer prior to application of the tape. The primer shall be as recommended by the tape manufacturer and approved by the extruded polyethylene coating manufacturer. Weld beads shall be wire brushed. Burrs and weld spatter shall be removed. Weld beads shall be covered with one wrap of tape prior to spiral wrapping.

Fittings shall be wrapped spirally beginning with one complete wrap three inches back from each edge of the extruded polyethylene coating. For pipe less than four-inch size, one layer half-lapped shall be used. For pipe four-inch size and larger, two layers half-lapped shall be used, with the second layer wrapped opposite hand to the first. On irregular surfaces one layer shall be applied half-lapped and stretched to conform to the surface, followed by a second layer half-lapped and applied with the tension as it comes off the roll.

3.1.2.2 Inspection and Testing

The condition of factory field coated and wrapped piping shall be the responsibility of the Contractor and all damage to the protective covering during transit and handling shall be repaired by the Contractor at no additional cost to the Government. All field coating and wrapping shall be subject to approval by the Contracting Officer. The entire pipe exposed as a part of this work shall be inspected as specified in sub-paragraph "Testing of Protective Coatings" under paragraph "Protective Coatings for Buried Carbon Steel and Stainless Steel Piping."

3.1.2.3 Damage Repair

Damaged areas of extruded polyethylene coating shall be repaired by tape wrapping as specified in the preceding paragraph for fittings. Residual material from the extruded polyethylene coating shall be pressed into the break or shall be trimmed off; all areas to be taped shall be primed, and the tape shall be applied half-lapped.

3.2 VERIFICATION OF DIMENSIONS

The Contractor shall become familiar with details of the work, shall verify dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing any work.

3.3 CLEANING OF PIPING

The Contractor shall keep the interior and ends of all new piping affected by the Contractor's operations thoroughly cleaned of foreign matter and water before and after being installed. Piping systems shall be kept clean during installation by means of plugs or other approved methods. When work is not in progress, open ends of piping and fittings shall be closed so that no water or other foreign substance will enter the pipes or fittings.

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Piping shall be inspected before placing into position. The interior of each length of pipe shall be cleaned after welding. It shall be the Contractor's responsibility for insuring that the interior of the piping is free of foreign matter when it is connected into the system.

3.4 TRENCHING AND BACKFILLING

Trenching and backfilling shall conform to Section 02300 EARTHWORK.

3.5 INSTALLATION OF UNDERGROUND PIPE

Underground fuel pipelines shall be pitched as shown on the drawings.

Where not indicated they shall be pitched a minimum of 2 inches per 100 feet. Branch lines to the hydrant pits shall slope up to the pit and if not indicated shall be pitched a minimum of 6 inches per 100 ft. Vent and drain lines shall terminate in male cam-type locking end dry breaks with matching female dust covers and installed in pits. The pipe shall have cover as shown on the drawings. Drain lines shall be installed at the slopes indicated.

3.5.1 Pipe Assembly

Pipe shall be strung parallel and adjacent to or above a trench. The pipe shall be supported on padded skids during welding and inspection of joints.

Protective coating shall be inspected and repaired prior to lowering the pipe into the trench. The pipe shall be lowered using only canvas or nylon slings. The sling shall be dug from underneath the pipe after placements and shall not be pulled from underneath the pipe while in contact with it.

Care shall be taken to prevent damage to the pipe, welded joints or coating and any such damage shall be repaired as directed by the Contracting Officer. Pressure testing of the pipe shall be done after it has been placed in final position in the trench.

3.5.2 Warning Tapes in Earth Trenches

For the purpose of early warning and identification of buried pipes outside of building walls during future trenching or other excavation, continuous identification tapes shall be provided in the trench. Tape shall be nonmagnetic plastic tape or aluminum foil plastic backed tape manufactured for the purpose of early warning and identification of utilities buried below the tape. Tape shall be at least three inches in width. Color of tape shall be as standard with the manufacturer with respect to the type of utility buried below the tape. Tape shall have lettering at least one inch high with not less than the following identification on the tape: BURIED JET FUEL PIPING BELOW. Tape shall be installed in accordance with the printed recommendations of the tape manufacturer, as modified herein.

Tapes shall be buried at a depth of six inches from the top of the subgrade.

3.5.3 Clearances

Install pipe to be clear of contact with other pipes, pipe sleeves, casings, reinforcing steel, conduits, cables, or other metallic structures.

Where pipes cross other pipes or structures with a separation of less than six inches, install an insulating separator. Protect the pipe from contact with a 12-inch square by 1 inch thick bituminous-impregnated canefiber board.

3.5.4 Protective Coating

When the protective coating on pipe is damaged, the Contracting Officer shall be notified and shall inspect the pipe before the coating is patched.

If the damage to the pipe is deeper than 0.050-inch, the damage shall be repaired by welding in accordance with paragraph "WELDING". If the pipe is dented, out of round or damaged to the point that welding will not make it

SECTION 15061 Page 10 good as new, the length of pipe shall be rejected.

3.6 PIPING LAYOUT REQUIREMENTS

3.6.1 Pipe Fabrication

Fabricate piping to measurements established on the project site and position into place without springing or forcing. Make provisions for absorbing expansion and contraction without undue stress in any part of the system.

3.6.2 Interferences and Measurements

Provide offsets, fittings, and accessories required to eliminate interferences and to match actual equipment connection locations and arrangements. Verify measurements before commencing work. Submit discrepancies for clarification before proceeding with the installations to the Contracting Officer.

3.6.3 Structural Support

Provide supplementary or intermediate steel or other structural members as required for transmission of loads to members forming part of the supporting structure.

3.6.4 Grade

Where profiles of piping lines are shown on the drawings, grade the line uniformly between changes in slope or direction. Maintain gradient to within + 1/4-inch over the entire length of pipe. When backfilling has been completed to the top of the pipe, the pipe shall be surveyed at each joint, logged by station number, and submitted to the Contracting Officer and approved before backfilling can continue.

3.6.5 Direction Changes

Make changes in the horizontal direction of pipes with long radius fittings. Provide special fittings when required. Do not make miter welds. Make odd-angle offsets with pipe bends or elbows cut to the proper angle.

3.7 TESTING

Piping shall be tested by hydrostatic pressure. Testing shall comply with applicable requirements of ASME B31.3, NFPA 30 and the requirements specified herein. Hydrostatic testing shall be performed using fuel as the liquid. Water shall not be introduced into the system for testing.

Pressure and hydrostatic testing shall be performed only after welding inspection has been completed.

3.7.1.1 Hydrostatic (Strength) Test

Upon completion of welding and x-ray and after backfilling, hydrostatically test the loop and hydrant laterals, plus flushing station return line piping system with fuel at 225 psig in accordance with ASME B31.3 and API RP 1110, with no leakage or reduction in gauge pressure for four hours.

The Contractor shall furnish electricity, instruments, connecting devices, and personnel for test. Fuel shall be furnished by the Government.

Defects in work provided by the Contractor shall be corrected by him at his own expense, and the test repeated until the work is proven to be in

SECTION 15061 Page 11 compliance with the Contract requirements.

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