33 08 55.pdf

SECTION 33 08 55

FUEL DISTRIBUTION SYSTEM START-UP (NON-HYDRANT)

08/19

PART 1 GENERAL

1.1 SUMMARY/APPLICABILITY

This specification defines the requirements and procedures for startup and performance testing of all equipment, components, control systems, devices, and associated appurtenances which are used for the receipt, storage, transfer and issue of petroleum fuel products for non-hydrant fuel facility systems. It covers requirements for safety, Government scheduling and coordination, device testing, existing and new system cleanliness, systemflushing and cleaning, demonstration of indicated and specified system performance, and final acceptance and reporting. The types of fuel systems covered include:

a. tank truck, rail car, pipeline and marine off-loading and loading systems

b. fuel transfer pumphouses and systems

c. installation pipelines and interterminal pipelines

d. military service station facilities handling gasoline, diesel, and jet fuel that:

(1) refuel (provide motive fuel for) commercial type vehicles.

(2) refuel (provide motive fuel for) military tactical vehicles.

(3) load fuel into the storage tanks of tactical refueler tank trucks.

It does not cover private vehicle fueling stations such as exchange service stations, nor aircraft direct refueling hydrant systems.

1.2 REFERENCES

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

AMERICAN PETROLEUM INSTITUTE (API)

API 570 (2016; Addendum 1 2017; Addendum 2 2018;

ERTA 1 2018) Piping Inspection Code:

In-Service Inspection, Rating, Repair, and Alteration of Piping Systems

API RP 1595 (2012; R 2019; 2nd Ed) Design, Construction, Operation, Maintenance, and Inspection of Aviation Pre-Airfield Storage Terminals

U.S. ARMY CORPS OF ENGINEERS (USACE)

ER 1110-1-8167 (2016) Engineering and Desig -- Petroleum, Oil, and Lubricants Mandatory Center Of Expertise

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-STD-3004-1 (2018) Quality Assurance for Bulk Fuels, Lubricants and Related Products

1.3 ADMINISTRATIVE REQUIREMENTS

1.3.1 Plans

The Contractor must submit detailed written plans prepared by the System Supplier for implementation of the System Start-Up Plan, the Existing System Cleanliness Confirmation Plan, the Fuel Provisioning Plan, and the Performance Testing Plan. The plans must specify a detailed plan incorporating in a sequential manner all work specified in PART 3 EXECUTION of this specification section. Plan elements must include:

a. Personnel. List of Contractor's personnel by trade, list of key personnel, list of safety equipment, list of miscellaneous equipment such as two-way radios, and personnel transportation vehicles.

b. Fluid Used for Hydrotesting, Flushing, and Cleaning. Identify what fluid will be used for each operation in each system section.

c. Fuel. See the Fuel Provisioning Plan.

d. Water. Specification and quantities of water needed for all system start-up activities and water delivery schedules. Water must meet the characteristics requirements specified. In cases where it is not specified, water must be potable and treated and must meet all the requirements of water used for hydrostatic testing in API 570. Plan must include requirements and schedules for Government-provided materials and equipment.

e. Storage-Into. Identify where the contents of the piping will be pushed into including the capacity required, how the storage vessel will be prepared for receiving the piping content, how it will be emptied and how it will be cleaned after the contents are removed.

f. Storage-From. Identify where the fluid that will be drained or pushed into the piping will come from including the capacity required, the number, size and type of the storage vessel, how the storage vessel is filled, how it will be emptied, and how it will be cleaned after the contents are removed.

g. Piping. Notwithstanding the requirements described elsewhere, every pipe section and individual component in the system covered by this specification section must be filled, vented, hydrostatically tested, flushed, cleaned, and tested for fuel quality. It must also be able to be isolated and drained if found that it needs repair.

h. Equipment Tests. Detailed procedures and schedules for each system component to perform all system tests under each operating scenario in accordance with paragraph EQUIPMENT TESTS.

i. Performance Testing. Detailed procedures and schedules for each system component to perform all system tests under each operating scenario in accordance with paragraph PERFORMANCE TESTING.

j. Hydrotesting Plans. See the Work Plan in Section 33 52 40 FUEL

SYSTEMS PIPING (NON-HYDRANT).

k. Schedule. Schedules must be generated with listing dates and durations of all system start-up activities as well as regular coordination and safety meetings and dates of key events for Government participation.

l. Contingency plans. Information on spill and fire contingencies, along with the required Government Fire and Safety Office involvement and approvals.

m. Coordination with Installation. Description of how Contractor [and System Supplier ]must implement system start-up in coordination with ongoing operations at the Installation. Plan must incorporate all phasing and work restriction requirements of the Contract documents.

1.3.2 Copies of API Publication

Provide four copies of API RP 1595 to the Contracting Officer.

1.3.3 Existing System Cleanliness Confirmation Plan

Submit a detailed written plan prepared by the System Supplier for the Contractor to verify and confirm the cleanliness of the existing system before connecting it to the new system or extension. The cleanliness confirmation test of the existing system (pre-cleanliness test) must be per MIL-STD-3004-1. Submit the plan 90 days prior to making the connection to the existing system. The Contractor is responsible for implementing the Existing System Cleanliness Confirmation Plan in coordination with ongoing base operations.

1.3.4 Fuel Testing Laboratory Qualifications

Contractor must submit the qualifications of the DoD Fuel Testing Laboratory which will be used to test the fuel samples.

1.3.5 System Start-up Plan

Submit a detailed written plan prepared by the Contractor and System Supplier for implementation of System Start-Up. Submit the plan 60 days prior to System Start-Up. The Contractor and System Supplier are responsible for implementing System Start-Up in coordination with ongoing operations.

1.3.6 Performance Testing Plan

Submit a detailed written plan prepared by the Single System Supplier for implementation of Performance Testing. Submit the plan 90 days prior to System Start-Up. The Contractor and the System Supplier are responsible for implementing the Performance Testing Plan in coordination with ongoing operations.

1.3.7 Fuel Provisioning Plan

Submit a detailed written Fuel Provisioning Plan prepared by the Contractor.The Fuel Provisioning Plan must include a timeline for the required receipt date(s), grade of fuel, and quantity of fuel on each receipt date required to execute the Start-up and the Performance Testing plans.

1.3.8 Certification (Ready for Start-Up and Performance Testing)

As a prerequisite to fuel system start-up, the Contractor must submit a certificate that certifies all work provided on the fuel system, except for touch-up field painting, has been inspected and approved by the specified approving authorities. Further, the Contractor must certify on this certificate that all specified checks and inspections have been successfully completed prior to start-up. Submit the plan 30 notice prior to commencement of fuel system start-up. The Contractor must submit the Certificate of Completion to the Contracting Officer at least 7 calendar days prior to commencement of system start-up and performance testing.

The Contracting Officer must then be responsible for scheduling the Government representatives for participation in the inspection, performance testing, and final approval activities. Any contractual deficiencies observed must be corrected by the Contractor without cost to the Government.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for Contractor Quality Control approval and are provided to the Government for information only.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-06 Test Reports

Final Reports; G

Equipment Tests; G

Piping Flushing Checklist; G

Piping Cleaning Checklist; G

SD-07 Certificates

Certificate of Calibration; G

Disposal Of Waste Materials

SD-11 Closeout Submittals

Certification of Entire System

1.5 CLOSEOUT SUBMITTALS

1.5.1 Final Reports

Contractor must prepare a final report that documents the execution of the approved start-up and performance testing plan. All items of work specified in the Start-up and Performance Testing plans must be carried out and reported in this report unless otherwise approved by the Contracting Officer. Include as a part of this report:

a. Verification letters of approved fuel storage tank hydrostatic tests and the approved piping hydrostatic tests, as generated under other specification sections.

b. Final settings of the valves and switches.

c. A copy of the flow and pressure output graphs and excel data and charts on CDR media with an explanation of what the graph indicates and what the system is doing.

d. A schematic flow diagram drawing of the resultant system showing major valves with the "normal" position of each manual valve noted, equipment, and the type, location, and setpoints of each safety relief valve and thermal relief valve.

e. A certified pipeline inventory - a detailed list with sizes, lengths, quantity, and volumes must be provided for the systems in this project. Such systems include, but are not limited to: marine receipt, pipeline receipt, truck off-loading receipt, pumphouse, pump pad, truck loading, marine loading, transfer pipeline, product recovery, and other miscellaneous piping systems. Fuel system volume must be calculated using as constructed pipe lengths, internal diameters, fittings, and components. Totals must be provided for all items containing fuel with the exception of tanks which is covered by other specifications.

1.6 QUALITY ASSURANCE

1.6.1 Certification of Entire System

Prior to the acceptance of the newly constructed system by the Government, all installed mechanical and electrical system components must be inspected and approved by the Contracting Officer. Provide the Contracting Officer 60 days notice in order to schedule the Installation and Service Headquarters and/or their designated appointee for participation in the inspection, Performance Testing, and approval. Any deficiencies observed must be corrected by the Contractor without cost to the Government.

1.6.2 Service Headquarters Definition

SME is defined as Service Headquarters Subject Matter Experts: Air Force - The Air Force Fuels Facilities Subject Matter Expert (AFCEC/COS); Army - Headquarters, U.S. Army Corps of Engineers; POL-MCX Facilities Proponent (CECW-EC) through the Army Petroleum Center (APC); Navy/Marine Corps - NAVFAC POL Facility Subject Matter Expert (NAVFAC EXWC, CI11).

ER 1110-1-8167 Engineering and Design Petroleum, Oil, and Lubricants Mandatory Center of Expertise must be followed.

The Service Control Point (SCP) is defined as follows: Army - Army Petroleum Center; Air Force - Air Force Petroleum Office; Navy/Marine Corps - Naval Supply Systems Command - Energy.

1.7 DISPOSAL OF WASTE MATERIALS

The Contractor must be responsible for properly disposing of any sludge, debris, filtration elements, waste water, contact water, and waste fuel resulting from piping and tank flushing and cleaning activities. Comply with all applicable Installation, local State, and Federal Regulations for hazardous waste disposal.

PART 2 PRODUCTS

2.1 GOVERNMENT-FURNISHED MATERIAL AND EQUIPMENT

The Government will furnish the following materials, equipment and services during the performance of the work under this section.

2.1.1 Fuel

Some fuel loss should be expected. Fuel that is lost during flushing and cleaning, equipment testing, and performance testing is viewed as a Start-up and Performance Testing expense and should be budgeted for in Contractor estimates.

The Contractor is responsible for the disposal of any waste product.

The Contractor must establish a Department of Defense Activity Address Code and must reimburse the US Government for any US Government fuel lost resulting from poor workmanship or contamination.

The Government will provide fuel given that the requirements are submitted with sufficient lead time to allow the US Government to secure the grade and volume required and make the necessary transportation requirements.

The Contractor must provide a copy of the Start-up, Fuel Provisioning, and Performance Testing plans a minimum of 90 days in advance of System Start-up.

FLUSHING, CLEANING, EQUIPMENT TESTS and PERFORMANCE TESTING: The flushing and cleaning and testing phases will be identified separately in the start-up and Performance Testing plans. Fuel used for flushing and cleaning, and testing will become contaminated, the fuel must be isolated and is considered off-specification until the quality can be verified.

Fuel volumes required for flushing and cleaning and testing should be minimized to limit costs, so estimates should be made accordingly. The Contractor will be responsible for disposing of any waste product.

Upon satisfactory completion of the flushing and cleaning operations, the Government will supply the additional quantities of fuel required to complete the other work under this section. This larger volume of fuel will not be delivered to the system until the Contractor has satisfactorily completed all work and, in particular, the cleaning and coating of the interior surfaces of the storage tanks and the removal of preservatives and foreign matter from those portions coming in contact with the fuel valves, pumps, filter-separators and other such system components.

2.2 CONTRACTOR-FURNISHED MATERIAL AND EQUIPMENT

2.2.1 Contractor-furnished

Provide material, equipment and labor not specified to be Government-furnished and required for proper System Start-Up of the system. Equipment being provided must be calibrated and the certificate of calibration be submitted to the Contracting Officer prior to use.

Equipment must include but not be limited to the following:

a. Temporary strainers.

b. Pipe spools.

c. Flow meters.

d. Pressure gauges.

e. Electronic sensors and recorders for pressure are included in the Pump Control Panel (PCP). This equipment must be used to monitor and record the system during the "Equipment Tests" and "Performance Testing" portions of this Specification Section. Recorded data must be used by the Contractor and equipment factory representatives to achieve final control valve and equipment adjustments. Recorded data must include:

(1) Fueling pumps discharge pressures.

(2) Storage Tank levels.

(3) Product Recovery Tank levels.

(4) Fueling pumps suction pressures.

(5) Truck Fillstand Flowrate

(6) Back Pressure Control Valve upstream pressures.

(7) Back Pressure Control Valve downstream pressures.

f. Vacuum Trucks for removing water and fuel from pits, drains, and other systems.

g. Fuel Bowser for removing water and fuel from pits, drains, and other systems.

h. Temporary Tankage for [flushing, ][flushing, cleaning ]and draining of the system and for starting up and performance testing.

i. Temporary Piping to form a temporary "looped" piping system for flushing, cleaning and draining of the system and for starting up and performance testing.

j. The Contractor must be responsible for providing the electrical power from a source identified by the Government to the testing locations.

2.2.2 Design Conditions

Use temporary flushing lines and equipment that are equal in strength, stability, and materials to the associated permanent components.

PART 3 EXECUTION

3.1 SEQUENCE OF EVENTS

The following events take place in the Start-Up and Performance Testing of a system and their definitions:

a. System Start-Up Phase: The System Start-Up phase encompasses all of the events described below up to the Performance Tests Phase.

b. Preliminary Requirements: Confirms completion of the system before fuel is received including verification of the cleanliness of the existing piping system being connected to.

c. Preparations for Flushing: Activities that take place before initial receipt of fuel.

d. Pneumatic Testing: Test for leaks in a piping system using air under pressure as the test medium. For requirements see Section 33 52 40

FUEL SYSTEMS PIPING (NON-HYDRANT).

e. Hydrostatic Testing - Water: Use of water to test for leaks in a piping system using liquid under pressure as the test medium. For requirements see Section 33 52 40 FUEL SYSTEMS PIPING (NON-HYDRANT).

f. Initial Fuel Receipt: The point in time at which fuel is introduced into the system with all that implies for safety, spill prevention and control, and inventory control.

g. Soak Testing: Perform "Soak Testing" of the piping system using fuel, as per Section 33 52 40 FUEL SYSTEMS PIPING (NON-HYDRANT)

h. Cleaning (except filter vessels and strainers): In this context, refers to removing the remaining water and contamination from aviation fuel to the quality (allowable) levels suitable for issuing the final product using fuel as the cleaning medium.

i. Cleaning (filter vessels and strainers): Filter vessels and strainers that are designed to be opened for cleaning must be opened and cleaned.

j. Control Valve Adjustment: Control valve adjustment so that equipment can be safely tested and adjusted.

k. Equipment Tests: Tests performed by the Contractor[and the System Supplier to confirm that individual components of the fuel system are correctly installed and are operational.

l. Performance Tests Phase: Government witnessed demonstration of the proper operation of the individual pieces of equipment and the system or systems as a whole.

3.2 PRELIMINARY REQUIREMENTS

All activities listed in paragraph PART 3 EXECUTION must be performed sequentially in the order they are presented. Prior to any on-site system start-up activities, the Contractor must ensure that all requirements of the paragraph SAFETY are satisfied. Project must be substantially complete, except for touch-up field painting, and Contractor's work area must be free of debris, trash and obstacles. Correct functioning of oil/water separator(s) must be verified prior to receipt of fuel. Perform the following activities prior to receipt of fuel:

3.2.1 Safety

Prior to any on-site system start-up activities, the following safety procedures must be accomplished in all fueling areas to be started up and performance tested under this specification section: testing/operation of emergency showers and eyewash stations, placement of Contractor-provided portable eyewash units within 100 feet or 10 seconds from the fueling point, verification of proper grounding throughout system, coordination with Government Fire and Safety Office and Fuels personnel, placement of Contractor-provided spill pads and containment booms, placement of Contractor-provided fire extinguishers capable of extinguishing a fuel fire. Ensure that all radios/devices at all Class I, Division 1 areas are intrinsically safe.

3.2.2 Electrical Preparations

Prior to energizing the electrical system components, verify that short-circuit links have been removed from current transformer and that secondary circuits have been connected. Confirm that all tests required for fire detection and suppression systems have been performed and accepted. Verify all electrical transmitter connections and ensure proper calibration. Verify all electrical system components meet the classification and division as required by the design. Verify correct rotation of all motors prior to testing. Verify paddle type flow switches by physically actuating vanes and checking outputs. Conduit explosion-proof sealoffs must be poured after initial electrical checks but before fuel receipt.

3.2.3 Emergency Fuel Shutoff (EFSO) System Testing

Prior to initial fuel receipt, verify that each switch will trip the circuit breaker of the fuel pump and de-energize the EFSO relay and close the main fuel shut-off valve.

3.2.4 Storage Tanks

Ensure approved performance of storage tank integrity testing, hydrostatic tests, leak detection system, and coating application/inspection per the applicable specifications. Include verification letter of approved test results for information in the Final Reports. Ensure that tank interior is clean and free of any fuel-contaminating debris. Verify operation of tank level alarms by closing tank connection valves and filling housings with fuel to confirm action. Ensure that certified strapping charts for all tanks are available for start-up personnel. API tank inspections have been performed per applicable specifications and the reports are on hand prior to commencement with the initial fill and Performance Testing.

3.2.5 Piping System

Ensure that all piping weld integrity, leak detection systems, and coating inspections have been performed per the applicable specifications.

Provide statement that required testing has been completed in the Final Reports. Evacuate all accumulated water from piping low point drains, valve cavities, and equipment drains. Verify all bolted connections are tightness tested to required torque using a calibrated torque wrench.

Verify that all pressure gauges are properly calibrated, located and installed. Ensure that piping's cathodic protection system is tested, calibrated and operational. Ensure that pipe marking and identification are provided as specified. Ensure that piping system thermal relief provisions are installed as designed. Verify the correct installation of piping expansion loops, joints, and supports.

3.2.6 Existing System Cleanliness Confirmation

Contractor and System Supplier must conduct tests to confirm the cleanliness of the existing system before connecting it to the new system or an extension, upgrade or repair of the existing system. Confirm that the fuel in the existing system meets the intra-governmental receipt limits defined in MIL-STD-3004-1. Sampling must be performed by the Contractor and testing must be done by an independent fuel testing laboratory approved by the Contracting Officer.

3.3 PREPARATIONS FOR FLUSHING

Upon completion of the system to the satisfaction of the Contracting Officer and the Service Headquarters and/or their designated appointee, make the following preparations for flushing the system.

3.3.1 Protection of System Components

The following items must be removed from the system prior to start of flushing operations and, where applicable, replaced with spools of pipe, diameter equal to the item removed.

a. Control valves. This also includes control valve tubing exterior to the valve such as that which runs from tank level control valves up to tank float pilots.

b. Sensors which are exposed to the fluid such as pressure gauges and thermometers.

c. Coalescer and separator elements in filter-separators.

d. Venturi Tubes and Pressure Indicating Transmitters.

e. Meters.

After flushing, the above items must be reinstalled in the system and the spool sections turned over to the Contracting Officer.

3.3.2 Water Draw-off

Remove any accumulated water from piping, equipment, and storage tanks' sumps and bottoms. Drain water and return fuel via filtration to storage tank. Repeat process until all water is removed. Dispose of petroleum contaminated water in accordance with Installation, local, State, and

Federal regulations.

3.4 INITIAL FUEL RECEIPT INTO STORAGE TANK

3.4.1 General

Utilize one storage tank for initial fuel receipt to isolate contaminated fuel. Initial receipt of fuel must be done by gravity if possible. The Contractor must station personnel throughout piping system at high point vents to bleed air. All flanges and system components will be periodically inspected for leaks during filling procedures.

3.4.2 Storage Tanks

Receipt flow rate into an empty storage tank must not exceed 3 feet per second (FPS), as measured in the main receipt piping, until outlet of tank fill tube is submerged.

3.4.3 Components

Ensure that filter-separators and other vessels are filled slowly by closing outlet valves and venting through air eliminators. Differential pressure across strainers must be continuously monitored. Any time a strainer differential pressure reaches 20 psig, it must be cleaned.

3.4.4 Fuel Quality

Fuel used during initial receipt must be considered contaminated and must be positively isolated, with blind flanges or closed, padlocked manual valves, from any active transfer, or aircraft fueling or tank truck loading operations. Fuel isolation must continue until all flushing and cleaning is completed. A method of checking fuel quality that is acceptable to the Contracting Officer must be provided at the beginning and end of any new piping section.

3.4.5 Fuel Receipt

3.4.5.1 Fuel Receipt from Piping System

Start-up personnel must meet with Government personnel in charge of existing fuel storage to discuss fuel transfer procedures. Topics must include: methods of communication to start/stop remote pumps; flow rate and head characteristics of pumps; methods of restricting initial receipt flow rate; methods of straining and filtering initial receipt fuel;

accommodating multiple pump starts resulting from required strainer and filter cleaning operations; required quantity of fuel to be used.

Contractor must provide a written summary of piping fill procedures to the Contracting Officer.

3.4.6 Initial Low Point Flush

Perform an initial low point flush operation by flushing each low point drain through a portable basket strainer for 10 seconds at a system pressure of 30 psig. Repeat flush until basket strainer collects no additional debris.

3.4.7 Storage Tank Tightness Tests

Perform tightness testing and manufacturer's tests of the storage tanks per Specification Section 33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS.

3.4.8 Piping Hydrostatic Tests

Hydrostatically test the piping system with fuel as required by Section

33 52 40 FUEL SYSTEMS PIPING (NON-HYDRANT).

3.4.9 Piping Soak Tests

Upon completion of hydrostatic testing with fuel,perform "Soak Testing" of the piping systems per API RP 1595. Duration of the test must be a minimum of 4 days and maximum of 7 days.

3.5 INITIAL FUEL RECEIPT DIRECTLY INTO PIPING SYSTEM

3.5.1 General

Initial receipt of fuel must be done by gravity if possible. The Contractor must station personnel throughout piping system at high point vents to bleed air. All flanges and system components will be periodically inspected for leaks during filling procedures.

3.5.2 Components

Ensure that filter-separators and other vessels are filled slowly by closing outlet valves and venting through air eliminators. Downstream valves must be throttled to maintain a packed condition in vessels throughout initial fill of piping system. Differential pressure across strainers must be continuously monitored. Any time a strainer DP reaches 20 psig, it must be cleaned.

3.5.3 Fuel Quality

Fuel used during initial receipt must be considered contaminated and must be positively isolated, with blind flanges or closed, padlocked manual valves, from any active transfer, or aircraft fueling or truck loading operations. Fuel isolation must continue until all flushing and cleaning is completed. A method of checking fuel quality that is acceptable to the Contracting Officer must be provided at the beginning and end of any new piping section.

3.5.4 Fuel Receipt

3.5.4.1 Fuel Receipt from Existing Piping System

Start-up personnel must meet with Government personnel in charge of existing fuel system to discuss fuel transfer procedures. Topics must include: methods of communication to start/stop remote pumps; flow rate and head characteristics of pumps; methods of restricting initial receipt flow rate; methods of straining and filtering initial receipt fuel;

accommodating multiple pump starts resulting from required strainer and filter cleaning operations; required quantity of fuel to be used.

Contractor must provide a written summary of piping fill procedures to the Contracting Officer.

3.5.5 Initial Low Point Flush

Perform an initial low point flush operation by flushing each low point drain through a portable basket strainer for 10 seconds at a minimum system pressure of 30 psig. Repeat flush until basket strainer collects no additional debris.

3.5.6 Piping Hydrostatic Tests

Hydrostatically test the piping system with fuel as required by Section

33 52 40 FUEL SYSTEMS PIPING (NON-HYDRANT).

3.5.7 Piping Soak Tests

Upon completion of hydrostatic testing with fuel, perform "Soak Testing" of the piping systems per API RP 1595. Duration of the test must be a minimum of 4 days and maximum of 7 days.

3.6 FLUSHING

Flushing procedures remove gross particulate and water contaminants and must precede cleaning procedures. All piping including but not limited to receipt piping, transfer piping, supply and return lines to the storage tanks, high point vents, low point drains, control valve tubing on the control valves, must be flushed with fuel.

In the event flushing identifies the presence of clay or soil like material in the system, Contractor must immediately notify Contracting Officer for direction.

3.6.1 Flushing Requirements

Begin flushing of fuel system piping at low flow rates using a throttled pump in single pump systems using the downstream isolation valve to throttle the pump. Slowly increase flushing flow rate until a plus or minus12 FPS fuel velocity is achieved. Flush for four piping volumes. For gravity, suction, or other non-pumped piping segments, minimum flushing volume must be four times the pipe volume. Sampling must be performed by the Contractor and testing must be done by an independent fuels testing laboratory approved by the Contracting Officer. Fuel must be free of gross contamination and visible free water to the satisfaction of the Contracting Officer.

In the event flushing identifies the presence of clay or soil like material in the system, Contractor must immediately notify Contracting Officer for direction.

3.6.2 Fueling System Piping

During flushing procedure periodically bleed air through high point vent and drain water through low point drains.

3.6.2.1 High Point Vent Lines and Low Point Drain Lines

During the flushing of pumphouse piping, operate valves and connections on all lines individually to flush their connection to a tank. Put at least 5 times the volume of the line through each line.

3.6.3 Piping Flushing Checklist

The Contractor must generate a comprehensive matrix of all new[ and existing] piping sections in the system. Matrix must serve as an Owner's piping inventory and a checklist for all Contractor-provided flushing operations. Column entries must include pipe section name, location, diameter, approximate length, flushing fuel velocity and volume achieved and acceptable results of sampling.

3.7 CLEANING

After initial flushing is completed, clean each piping segment with product in accordance with the procedure specified hereafter. Isolate Tanks from the system and clean them as specified in Section 33 01 50.55

CLEANING OF PETROLEUM STORAGE TANKS.

In the event cleaning identifies the presence of clay or soil like material in the system, Contractor must immediately notify Contracting Officer.

3.7.1 Preparation for Cleaning

Valves and system components removed for flushing must be reinstalled.

Tanks must be drained, vapor freed and cleaned. Transfer the contents from one tank to the other for the purposes of cleaning where possible.

3.7.2 Cleaning Requirements

Cleaning must continue until the Contracting Officer certifies that the fuel meets the intra-governmental receipt limits as defined in MIL-STD-3004-1. Sampling must be performed by the Contractor and testing must be done by an independent testing laboratory approved by the Contracting Officer.

3.7.3 Cleaning Procedure

During cleaning procedure periodically bleed air through high point vent and drain water through low point drains.

3.7.4 Piping Cleaning Checklist

The Contractor must generate a comprehensive matrix of all new and existing piping sections in the system. Matrix must serve as an Owner's piping inventory and a checklist for all Contractor-provided cleaning operations. Column entries must include pipe section name, location, diameter, approximate length, cleaning fuel velocity and volume achieved and acceptable results of sampling.

3.8 EQUIPMENT TESTS

After completion of flushing, cleaning, and control valve and electrical components adjusting operations, Contractor must complete and submit the Equipment Tests (see Attachment 1 - Equipment Tests). Equipment Tests must be submitted prior to Performance Testing.

3.8.1 Control System and Control Valves

Field adjustment of automatic control valves and automatic pump controls while in operation must be made only by the valve manufacturer's authorized field test engineer. For final adjustment of installed electrical control equipment provide an experienced electrical engineer.

Both the mechanical and electrical components must be adjusted concurrently. Record required data necessary to prepare Equipment Tests Report.

3.8.2 Tank Level Alarms

Position valves to transfer fuel between tanks.

Start fueling pump and pump sufficient fuel out of the first tank to allow the low level alarm (LLA) to stop the fueling pump. Repeat procedure for each fueling pump and each tank until the low-low level alarm (LLLLA) stops the fueling pumps sounds an alarm due to low liquid level in tank.

Repeat testing for high level alarm checking each one in turn. Repeat procedure for each fueling pump and each tank until the high-high level alarm(HHLA) stops the fueling pumps, sounds an alarm due to high liquid level in tank.

3.8.3 Fueling Pump Operation

Demonstrate operation of all pump control start/stop station to start and stop the fueling pumps at the indicated pressure and flow rates in the presence of the Contracting Officer. Repeat the operating sequence with each of the pumps being selected as lead pump if the pumps are controlled by a Pump Control Panel or an automatic control system with a variable lead pump. For this test, measure the flow rates. Witness and record flow rates and test results.

3.8.4 Emergency Shutdown

With one fueling pump circulating fuel through the system, test each "Emergency Stop" pushbutton station to verify that the pump stops and the emergency shutoff solenoid activates and the control valve closes. Repeat above procedure for each fueling pump and "Emergency Stop" pushbutton station. Conduct tests for both the automatic and manual modes. With all the fueling pumps circulating fuel through the system, push an "Emergency Stop" pushbutton station.

3.8.5 Overfill Valve

Place fuel transfer pump in the "off" position. Delivery quantity of fuel to Product Recovery Tank to demonstrate capability of valve to close.

Empty the tank pump to demonstrate capability of valve to open when fuel level drops below set point.

3.9 PERFORMANCE TESTS

Performance testing must occur after the Contractor has performed the Equipment Tests. Performance testing must demonstrate to the satisfaction of the Contracting Officer and Service Headquarters and/or their designated appointee these portions of the fueling system are working as specified. Performance testing must consist of repeating the Equipment Tests (indicated in previous paragraphs) and operating the fueling system during actual operations in the presence of Government Witnesses. The maximum rated capacity of the system must be demonstrated. The Contractor must notify the Contracting Officer 30 calendar days in advance of the test to permit arrangement for the use of Government-furnished items.

During the time period of performance testing, no construction activities will be allowed on the project site. The project site must be considered an operational (fuel) zone (verses a construction zone) during this performance testing period. Personnel, dressed for fuel's operation, will be present to witness testing and participate in Contractor provided training.

3.9.1 Final Performance Test

A final performance test must consist of demonstrating the operation of the system for the purpose for which it is intended:

a. transferring fuel through the piping system to the tanks

b. transferring fuel through the piping system to the engine

3.9.2 Satisfactory Performance

In the event a portion of the system or any piece of equipment fails to meet the test, make the necessary repairs or adjustments and repeat the Performance Test until satisfactory performance is obtained. The determination of satisfactory performance must be made by the Contracting Officer and the Service Headquarters and/or their designated appointee.

3.9.3 Performance Testing Plan

Contractor must edit the example Performance Testing plan and submit for approval. An example Performance Testing plan can be found at the end of this Section as Attachment 2 - Performance Testing Plan. Submit plan a minimum of 60 days prior to performance testing.

3.9.4 Equipment Tests

Contractor must provide 10 hard copies and electronic copies of the completed Equipment Tests to the Service Headquarters and/or their designated appointee at the start of Performance Testing for validation during Performance Testing.

3.9.5 Control Valve Tagging

After the performance testing and system acceptance, tag the control valves with their final adjustments.

3.9.6 Final Acceptance

Fill the system with fuel and operate leak-free prior for acceptance.

Anything wet with fuel is considered to be leaking.

3.9.6.1 Tank High Liquid Level Shut-Off Valve Test and Adjustments

During the final filling of tanks, check the tank automatic high liquid level shut-off valve for proper functioning at least three times by lowering the fuel level and refilling again. Adjust valve to achieve a safe fill level.

3.9.6.2 Tank Level Indicator Adjustments

Also, during the final filling of tanks, adjust and calibrate the tank level indicators including the final setting of the high high level (HHLA) and high level (HLA) alarms. Since the HHLA is at a point higher than the High Liquid Level Shut-Off Valve float set point, an artificial method of simulating HHL must be used.

3.9.6.3 Water Draw-Off System Test

During the performance testing, fill Water Draw-off Systems from tank sump to ensure proper operation. After filling system, allow time for fuel/water mixture to separate. Verify liquid separation through system's sight glasses. Proper operation includes capability to drain separated water and capability to pump separated fuel back to a full tank.

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