FORCE PDs-.pdf

AMSC N/A

FSC-4930 DISTRIBUTION STATEMENT A. Approved for public release.

PD10WRGBGBEC11

Purchase Description (PD)

FUELS OPERATIONAL READINESS CAPABILITY EQUIPMENT (FORCE)

SYSTEM

1. SCOPE

1.1 Background. Air Force contingency operations supporting Overseas Contingency Operations (OCO), specifically Operation Enduring Freedom (OEF), have seriously degraded the Air Force’s fuels support capability. Lessons learned during OEF and Operation Iraqi Freedom show a dire need to upgrade and reconstitute this vital capability. Existing equipment, fuel specifications, and quality control procedures date back to the 1960s and a study of current fuels technology is necessary to ensure we reconstitute this capability with updated technology, correct design deficiencies, and meet the needs of our combatant commanders. Some of the design problems and deficiencies with the current fuels capability are:

a. Fuel filters are not interchangeable on the main pumping unit (R-14), receipt filters (FFU- 15E), and refueling vehicles (R-11).

b. Some systems are 4-inch and others are 3-inch, causing interchangeability problems and choke points in the fuel receipt and delivery system. To sustain the massive quantities dispensed at some bases during Enduring Freedom, a standard 6-inch system is needed.

c. Some pumps operate at 900 gallons per minute (gpm) and some at 600 gpm, but the filter separators are only rated at 600 gpm. This results in inefficiencies that hinder mission accomplishment.

d. Most systems require pressurized air cylinders to open valves. If air leaks out or is exhausted, the system will not work.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are

INCH POUND

DRAFT

PD10WRGBGBEC11

listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-83133K Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP- 8), NATO F-35, and JP-8+100

2.2.2 Purchase Descriptions (PD’s).

PD10WRGBGBEC12 Trailer Mounted, 900 gpm, Multi-Fuel Engine, Flammable Liquid Pumping Assembly

PD10WRGBGBEC13 Trailer Mounted Multi-Aircraft Servicing Platform PD10WRGBGBEC14 FORCE Mission Support Plumbing Assembly PD10WRGBGBEC15 Trailer Mounted 600 gpm Filter Separator, Flammable

Liquid (Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.3 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2 FORCE system. The complete FORCE Type III Portable Hydrant System shall consist of the following subsystems, in the indicated quantities, properly assembled and interconnected. Each subsystem shall be in accordance with its associated subsystem PD. Each subsystem shall be compatible with current FORCE systems. The system may be further broken down into the Force Starter (FS), Sustainment Capability (SC), and Receipt Capability (RC) configurations (see table FS, SC, and RC for specific quantities).

http://assist.daps.dla.mil/quicksearch/

Table I. FORCE system.

Subsystem PD

Nomenclature

Quantity

PD10WRGBGBEC15 Trailer Mounted 600 gpm Filter Separator, Flammable Liquid

PD10WRGBGBEC13 Trailer Mounted Multi-Aircraft Servicing Platform

PD10WRGBGBEC12 Trailer Mounted, 900 gpm, Multi-Fuel Engine, Flammable Liquid Pumping Assembly

PD10WRGBGBEC14

PD10WRGBGBEC14-FS-JFDFS

PD10WRGBGBEC14-SC-JFDSC

PD10WRGBGBEC14-RC-JFDRC

FORCE Mission Support Plumbing Assembly 1

Table II. Force starter (FS) configuration.

PD10WRGBGBEC15 Trailer Mounted 600 gpm Filter Separator, Flammable Liquid

PD10WRGBGBEC13 Trailer Mounted Multi-Aircraft Servicing Platform

PD10WRGBGBEC12 Trailer Mounted, 900 gpm, Multi-Fuel Engine, Flammable Liquid Pumping Assembly

PD10WRGBGBEC14

PD10WRGBGBEC14-FS-JFDFS

Table III. Sustainment capability (SC) configuration.

PD10WRGBGBEC15 Trailer Mounted 600 gpm Filter Separator, Flammable Liquid

PD10WRGBGBEC13 Trailer Mounted Multi-Aircraft Servicing Platform

PD10WRGBGBEC12 Trailer Mounted, 900 gpm, Multi-Fuel Engine, Flammable Liquid Pumping Assembly

PD10WRGBGBEC14

PD10WRGBGBEC14-SC-JFDSC

Table IV. Receipt capability (RC) configuration.

PD10WRGBGBEC15 Trailer Mounted 600 gpm Filter Separator, Flammable Liquid

PD10WRGBGBEC12 Trailer Mounted, 900 gpm, Multi-Fuel Engine, Flammable Liquid Pumping Assembly

PD10WRGBGBEC14

PD10WRGBGBEC14-RC-JFDRC

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (4.2).

4.2 First article inspection. The contractor shall conduct a first article test of the system to ensure proper operation of all the FORCE components in conjunction with each other and current FORCE system. The first article inspection shall include the operational test in accordance with 4.5.12 of PD10WRGBGBEC12 and detailed inspection requirement in accordance with 4.3.3 of PD10WRGBGBEC11 as shown by Figures 1, 2 and 3. The contractor shall provide or arrange for all test equipment and facilities. In lieu of fuel bladders and unless otherwise specified, the contractor shall use fuel tanks or fuel storage tanks to simulate the pumping configuration required. The system shall be able to meet the system fuel flow rate of 900 gpm maximum at maximum 150 pounds per square inch (psi) at the pump discharge without the assistance of gravity from the weight of the fuel in a storage container. Recirculation of fuel shall be allowed during testing.

4.3 Inspection requirements

4.3.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

Unless otherwise specified herein, in the Government approved test procedure, or in the detailed component specifications, the test fluid shall be Aviation Turbine Fuel, Grade JP-8 in accordance with MIL-DTL-83133.

4.3.2 Test rejection criteria. Throughout all tests specified herein, the system shall be closely observed for the following conditions, which shall be cause for rejection:

a. Failure to conform to design or performance requirements specified herein.

b. Any spillage or leakage of any liquid, including fuel, coolant, lubricant, or hydraulic fluid, under any condition, except as allowed herein.

c. Structural failure of any component, including permanent deformation, or evidence of impending failure.

d. Evidence of excessive wear.

e. Interference between the system components.

f. Misalignment of components.

g. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

h. Overheating of any system component.

i. Evidence of corrosion.

4.3.3 Detailed inspection requirements. The following tests as specified are required for first article.

4.3.3.1 Mechanical operation. A thorough check shall be made of the system modules to ensure proper functioning of all mechanical parts; accessibility of all controls and levers; and other checks that shall ensure safety and performance.

4.3.3.2 Flow tests. The rpm shall be at 100 percent of the rpm that produces 900 gpm flow and 150 psi discharge pressure. The suction characteristics of the pump (net positive suction head required) at 100 percent rpm shall be obtained at flow rates of 400, 800, and 900 gpm for the scenarios as depicted in Figures 2 and 3.

4.3.3.2.1 Endurance interoperability test. The system shall be subjected to the following 80 hour endurance test at a flow rate of 900 gpm. The system shall show no indication of impending failure, degradation, leaks or any other of the conditions as specified in 4.3.2 due to this test. A maximum of eight hours is allowed for servicing and repairs as required during the test.

4.3.3.2.2 Start/stop intervals. The pump shall be started and stopped five times at equally spaced intervals during each of the gpm flow rate parameters. The system shall be inspected during the spaced intervals. Any subsequent modifications that are required during the test in order to meet gpm and maximum psi requirements or any other verification and test parameters as specified in the system and subsystem PD’s will be documented in the first article test report.

4.3.3.3 Handheld remote controls performance test. The handheld remote controls shall be tested five times using both the wired and radio frequency modes of communications, and shall be tested to verify the following:

a. Programmable to operate with all FORCE servicing platforms and pumping units, as applicable.

b. Operate at a minimum range of 200 feet.

c. When the FORCE pumping unit dead-man system is activated, it adjusts the FORCE pump from any throttle position to RUN position.

d. When the dead-man is deactivated, the FORCE pump is adjusted from RUN to IDLE position.

e. When the emergency stop system is activated, the FORCE pumps are adjusted from any throttle position to STOP.

f. All functions shall occur within two seconds when depressed.

g. The remote control panel (RCP) ten-position selector switch, which shall designate the pump unit by number in the FORCE dispensing system, shall be tested. Each RCP shall be tested for communication with all FORCE servicing platforms and with all other pump units in the system in a “control by exception” communications scheme (Figure 2). Each RCP equipped with a receiving unit that shall receive emergency stop and engine throttle position commands from a Hand-held Pump Control Unit (HPCU) or a Hand-held Control Unit (HCU) shall be tested and the relay signals to a Programmable Logic Controller (PLC) shall be tested. In addition, the pump emergency stop switch located on the RCP shall be tested. When the emergency stop system is activated, it shall adjust all FORCE pumps in the FORCE dispensing system from any engine throttle position to STOP. Upon activation, the emergency stop system must be reset on the RCP for each FORCE pump. This capability shall be tested.

h. The HCU for the pump accurately changes the throttle position to optimum engine speed using the manual throttle when the dead-man switch is activated.

4.3.3.4 Remote controls tests. The pump (PD10WRGBGBEC12) and the aircraft servicing platform (PD010WRGBGBEC13) shall be tested with a remote control system that operates in a system configuration as depicted by Figures 2 and 3. The dead-man and emergency stop controls that work in concert with the FORCE servicing platform shall be tested. The manual override capability to bypass the remote control system shall be tested.

4.3.3.4.1 First article interoperability for remote controls. The remote controls shall be tested in accordance with the test requirements of paragraphs 4.3.3.3 and 4.3.3.4. Testing of the remote controls shall be conducted during the first article interoperability as specified in paragraph 4.3.3.2.1.

4.3.3.5 Reliability and maintainability. Guidance for use of a failure reporting, analysis, and corrective action system during development tests is provided in Appendix A. Use of Appendix A is mandatory. The following information shall be documented:

a. All failures, maintenance, and other events recorded shall be identified by accumulated operating time, miles, cycles, or position in the test procedure as appropriate. Test conditions during the failures or irregular operations identified shall be recorded.

b. Summary of the engineering reasoning and of any tests conducted to determine assignable causes for all failures and irregular operations identified.

c. Summary of the engineering reasoning behind any corrections made, to be made on production items, or proposed to be made and the predicted effectiveness of these corrections.

d. Test activity or contractor comments on item features or requirements that, if modified, should improve the item.

e. Test activity or contractor comments on field conditions or procedures to be avoided or cultivated to increase the reliability and useful life of the item.

5. PACKAGING

5.1 Packaging requirements. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When actual packaging of materiel is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command. Packaging data retrieval is available from the managing Military Department's or Defense Agency's automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES.

(This section contains information of a general or explanatory nature which may be helpful, but is not mandatory.)

6.1 Intended use. The FORCE module system is intended for fuel transfer and issue of fuel between aircraft and fuel bladders or between trucks and fuel bladders. The system shall be used to off-load commercial fuel trucks at a base perimeter and transfer the fuel through a system of hose lines to tactical fuels storage areas. The system shall also transfer fuel from these tactical storage areas forward to the flight line and service aircraft directly through the use of a FORCE servicing platform.

6.2 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of the specification.

b. Issue of DoDISS to be cited in the solicitation, and if required, the specific issue of individual documents referenced (see 2.2.1).

c. If first article inspection is required (see 3.1).

FIGURE 1. Test scheme for pump (PD10WRGBGBEC12), plumbing assembly

(PD10WRGBGBEC14).

FIGURE 2. Test scheme for servicing platform and pump (PD10WRGBGBEC13 and

PD10WRGBGBEC12).

FIGURE 3. Test scheme for filter separator (PD10WRGBGBEC15) and pump

(PD10WRGBGBEC12).

APPENDIX A

RELIABILITY

A.1. SCOPE

A.1.1 Scope.

This appendix details the use of a failure reporting, analysis, and corrective action system during the development tests. This appendix is a mandatory part of the specification. The information contained herein is intended for compliance.

A.2 APPLICABLE DOCUMENTS

This section is not applicable to this appendix.

A.3 REQUIREMENTS

A.3.1 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all failures that occur during the development tests. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to the requirements of MIL-HDBK-785 and this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions.

A.3.1.1 Problem and failure action. At the occurrence of a problem or failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test with minimum interruption to the other test sample continuing on test.

A.3.1.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or failure of contractor hardware and software, and Government-furnished equipment (GFE). The report shall contain the information required to permit determination of the origin and correction of failures. The existing failure report forms may be used with minimum changes necessary to conform to the requirements of this specification and shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair action taken to return the test sample to operational readiness.

c. Information describing the results of the investigation, the analysis of all part failures, an analysis of the system design, and the corrective action taken to prevent failure recurrence. If no corrective action is taken, the rationale for this decision shall be recorded.

A.3.1.1.2 Identification and control of failed items. A failure tag shall be affixed to the failed part immediately upon the detection of any failure or suspected failure. The failure tag shall provide space for the failure report serial number and for other pertinent entries from the test sample failure record. All failed parts shall be marked conspicuously or tagged and controlled to ensure disposal in accordance with contract requirements. Failed parts shall not be handled in any manner which may obliterate facts which might be pertinent to the analysis. Failed parts shall be stored pending disposition by the authorized approval agency of the failure analysis.

A.3.1.1.3 Problem and failure investigations. An investigation and analysis of each reported failure shall be performed. Investigation and analysis shall be conducted to the level of hardware or software necessary to identify causes, mechanisms, and potential effects of the failure. Any applicable method (i.e., test, microscopic analysis, applications study, dissection, X-ray analysis, spectrographic analysis, et cetera) of investigation and analysis which may be needed to determine failure cause shall be used. When the removed part is not defective or the cause of failure is external to the part, the analysis shall be extended to include the circuit, higher hardware assembly, test procedures, and subsystem if necessary. Investigation and analysis of GFE failures shall be limited to verifying that the GFE failure was not the result of the contractor's hardware, software, or procedures. This determination shall be documented for notification of the procuring activity.

A.3.1.1.4 Failure verification. Reported failures shall be verified as actual failures or an acceptable explanation provided to the procuring activity for lack of failure verification. Failure verification is determined either by repeating the failure mode of the reported part or by physical or electrical evidence of failure (leakage residue, damaged hardware, etc.). Lack of failure verification, by itself, is not sufficient rationale to conclude the absence of a failure.

A.3.1.1.5 Corrective action. When the cause of failure has been determined, a corrective action shall be developed to eliminate or reduce the recurrence of the failure. Repairs shall be made in accordance with normal field operating procedures and manuals. The procuring activity shall review the corrective actions at the scheduled test status review prior to implementation. In all cases the failure analysis and the resulting corrective actions shall be documented. The effectiveness of the corrective action shall be demonstrated by restarting the test at the beginning of the test cycle in which the original failure occurred.

A.3.1.1.6 Problem and failure tracking and closeout. The closed loop failure reporting system shall include provisions for tracking problems, failures, analyses, and corrective actions. Status of corrective actions for all problems and failures shall be reviewed at scheduled test status reviews.

Problem and failure closeout shall be reviewed to assure their adequacy.

A.3.2 Failure categories. All failures shall be classified as relevant or non-relevant. Relevant failures shall be further classified as chargeable or non-chargeable. The procuring activity will make the final determination of failure classifications.

A.3.2.1 Relevant failures. Relevant failures shall be as specified in a through d:

a. Intermittent failures.

b. Unverified failures (failures which cannot be duplicated, which are still under investigation or for which no cause could be determined).

c. Verified failures not otherwise excluded under A.3.2.2.

d. Pattern failures.

A.3.2.2 Non-relevant failures. Non-relevant failures shall be as specified in a through g:

a. Installation damage.

b. Accident or mishandling.

c. Failures of the test facility or test-peculiar instrumentation.

d. Test sample failures caused by an externally applied overstress condition, in excess of the approved test requirements.

e. Normal operating adjustments (non-failures) specified in the approved vehicle operating instructions.

f. Secondary failures within the test sample, which are directly caused by non-relevant or relevant primary failures. The secondary failures must be proved to be dependent on the primary failure.

g. Failures caused by human errors.

A.3.2.3 Chargeable failures. Chargeable failures shall be as specified in a through d:

a. Intermittent failures.

b. Unverified or verified failures.

c. Independent failures.

1. System design.

2. System manufacturing.

3. Part design.

4. Part manufacturing.

5. Software errors identified, corrected, and verified during the pretest and the test, shall not be chargeable as test sample failures.

6. Contractor furnished equipment operating, maintenance, or repair procedures that cause test sample failures.

d. Relevant failures.

A.3.2.4 Non-chargeable failures. Non-chargeable failures shall be as specified in a through c:

a. Non-relevant failures.

b. Failures induced by Government furnished equipment operating, maintenance, or repair procedures.

c. Failures of parts having a specified life expectancy and operated beyond the specified replacement time of the parts.

A.4 TESTING PROVISIONS

A.4.1 Reliability test requirements. The reliability tests shall be conducted in accordance with the reliability test procedures which have been approved by the procuring activity. Testing shall be continued until a reject decision has been reached or the total required test time has been completed, whichever comes first.

A.4.2 Reliability test records. Reliability test records shall be maintained as specified in the approved test procedure.

A.4.3 Performance parameter measurements. The test sample performance parameters to be measured and the frequency of measurement shall be as specified herein. When the value of any required performance parameter is not within specified limits, a failure shall be recorded. If the exact time of failure cannot be determined, the failure shall be presumed to have occurred at the time of the last recorded observation or successful measurement of that same parameter. Observations and measurements shall be made at the specified interval and recorded during the test cycle. At least one set of measurements shall be recorded when a test sample is first energized after any specified shutdown period.

A.4.4 Reliability compliance. Reliability compliance shall be reviewed by the procuring activity after each test sample failure is categorized or at any other appropriate time. Compliance shall be based on the total accumulated test time and the total number of chargeable failures at the time of the review.

AMSC N/A FSC 4930

DISTRIBUTION STATEMENT A. Approved for public release.

PD10WRGBGBEC12

Rev XXXX

CAGE 98752

DRAFT

PURCHASE DESCRIPTION (PD)

TRAILER MOUNTED, 900 gpm, MULTI-FUEL ENGINE, FLAMMABLE LIQUID PUMP

UNIT

Fuels Operational Readiness Capability Equipment (FORCE)

l. SCOPE. This purchase description describes the design and test requirements for the procurement of the FORCE trailer-mounted, multi-fuel-engine-driven flammable liquid pump unit (hereafter called “pump unit”, A/E32R-18).

2. APPLICABLE DOCUMENTS.

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this document to the extent specified herein.

COMMERCIAL ITEM DESCRIPTIONS (CID)

A-A-393A Extinguisher, Fire, Dry Chemical (Hand Portable) A-A-52464C Coupler, Drawbar, Ring:Light Duty, 60,000 LB GVW; Offset

(Taper Shank), 60,000 lb GVW; and Heavy-Duty 120,000 LB GVW A-A-55804A Rods, Ground

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-32550 Zinc Rich Coatings MIL-DTL-27267D Hose, Polytetrafluoroethylene, 450degF, Medium Pressure MIL-PRF-32550 Zinc Rich Coatings MIL-DTL-5624W Turbine Fuel, Aviation, Grades Jet A-1, JP-4, JP-5, JPTS and JP-

INCH POUND

PD10WRGBGBEC12

5/JP-8 ST

MIL-DTL-83133K Turbine Fuels, Aviation, Kerosene Types, NATOF-34 (JP-

8), NATOF-35, and JP-8+100 MIL-PRF-85285E Coating Polyurethane, Aircraft and Support Equipment

AIR FORCE DRAWING

Drawing 50C24046 Coupling-male, 6 inch air duct

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N Identification Marking Of U.S. Military Property MIL-STD-161H Identification Methods for Bulk Petroleum Products Systems

Including Hydrocarbon Missile Fuels MIL-STD-276A Impregnation of Porous Metal Castings and Powdered Metal

Components MIL-STD-461G Requirements For the Control Of Electromagnetic Interference

Characteristics of Subsystems and Equipment MIL-STD-810H Environmental Test Methods and Engineering Guidelines MIL-STD-882E Standard Practice for System Safety MIL-STD-889 C Dissimilar Metals MIL-STD-1791C(1) Design for Internal Aerial Delivery in Fixed Wing Aircraft

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-808 Finish, Protective and Codes for Finishing Schemes for Ground and Ground Support Equipment

(Copies of these documents, except for MIL-HDBK-1791 C-17 Appendix, are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. A copy of MIL-HDBK-1791 C-17 Appendix can be obtained from the Procuring Contracting Officer (PCO) or requested by contacting Air Transportability Test Loading Agency (ATTLA) at 937-255-6296.

2.3 Non-government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN PETROLEUM INSTITUTE (API)

API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

API 609 Butterfly Valves: Double Flanged, Lug- and Water-Type

(Copies are available from the American Petroleum Institute, 1220 L Street, NW, Washington DC 20005.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

http://assist.daps.dla.mil/quicksearch/

ASME B31.3 Process Piping ASME Y14.100 Engineering Drawing Practices

(Copies are available from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York NY 10017.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D910 Specification for Aviation Gasoline ASTM D975-19 Standard Specification for Diesel Fuel Oil ASTM D1655 Standard Specification for Aviation Turbine Fuels

(Copies are available from the American Society for Testing and Materials, 1916 Race Street, Philadelphia PA 19103.)

AMERICAN WELDING SOCIETY (AWS)

D1.1/D1.1M Structural Welding Code–Steel–23th Edition D1.2/D1.2M Structural Welding Code–Aluminum–Sixth Edition

(Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami FL 33126.)

CODE of FEDERAL REGULATIONS (CFR)

CFR49 Transportation

(Copies are available from the U.S. Government Printing Office, 732 N. Capital Street, Washington, DC 20401)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J447 Prevention of Corrosion of Motor Vehicle Body and Chassis Components

SAE J833 Human Physical Dimensions AMS-STD-1595 Qualification of Fusion Welders AMS-STD595/26173 Grey, Semi-gloss

(Copies are available from the Society of Automotive Engineers, 400 Commonwealth Dr.

Warrendale, PA 15096.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

S1.4-PART1/2/3 Specification for Sound Level Meters S1.6 Preferred Frequencies, Frequency Levels, and Band

Numbers for Acoustical Measurements

(Send an electronic message to ANSI to request information about the publications and services)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS.

3.1 First article. When specified (see 6.2), a pump unit shall be subjected to first article inspection in accordance with 4.2.

3.2 Materials. All components and materials shall be selected based on the defined purpose for the specified service life at the environmental extremes stated herein. Materials shall be certifiable for the application. Proprietary materials or processes shall not be used. Components shall not be used outside their published ratings. All components and materials (to include gaskets, fittings, valves, adhesives) that normally come into contact with the fuel during operation shall be proven fuel-resistant materials, shall not degrade, or be affected by fuels cited in this specification. The pump units shall be fabricated from strong, durable, and lightweight materials to the maximum extent possible to reduce overall unit weight. The pump units shall be fabricated from compatible materials, inherently corrosion-resistant, or treated to provide protection against the various forms of corrosion and deterioration that may be encountered.

3.2.1 Prohibited materials. Magnesium alloys, wood products, PVC (except for wire harnesses), polyester, room temperature vulcanizing (yielding acetic acid), or asbestos shall not be used in any component of this pump unit.

3.2.2 Metals. All metallic non-aluminum fuel handling components shall be corrosion resistant and fuel resistant. All aluminum fuel-handling components shall be anodized or chemically conversion-coated without deleterious effects on the function, performance or availability of these components.

Copper-based materials shall not come in direct contact with fuel, except when approved by program management office. Dissimilar metals and methods of protection are provided in MIL-

STD-889.

3.2.3 Impregnation of castings. Aluminum castings shall be impregnated in accordance with MIL- STD-276 or 100% hydrostatically tested.

3.2.4 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotive compatible abutting surfaces is acceptable. The use of dissimilar metals separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur.

3.2.5 Elastomers. Elastomeric materials used shall be compatible with fuels conforming to ASTM D910, ASTM D-975, MIL-DTL-5624, ASTM-D-1655, and MIL-DTL-83133.

3.2.6 Protective treatment. Materials used in the construction of the fuel pump assembly shall be protected against deterioration likely to occur due to climatic or environmental conditions during service usage. However, that protection will in no way prevent compliance with the performance requirements of this specification. The manufacturer shall avoid using any protective coating that will crack, chip, or scale with use, age, or extremes of climatic and environmental conditions.

Guidance is provided in MIL-HDBK-808.

3.2.7 Servicing provisions. Special tools shall not be required to access drains, lubrication, or service checkpoints. The design shall minimize the number of parts to be dissembled and reassembled and to minimize the different types of hand tools required for maintenance.

3.2.8 Fool-proofing. Components shall be designed, by shape or by mounting pattern, to prevent improper installation.

3.2.9 Foreign object damage (FOD). Any metal cap, plug, pin, or plate that must be removed for inspection, service or operation, shall be retained by wire rope lanyard or chain to prevent it from becoming separated from the pump unit platform. “Dog tag” style beaded chains shall not be provided.

3.2.10 Bonding. All metal components shall be bonded in accordance with the guidelines of API RP 2003. A braid, with less than 10 ohms resistance, shall be attached to all system drains as a bonding point for the drain bucket.

3.2.11 Prevention of static electricity. Nonmetallic components shall be certified to a resistance of 10 ohms or less to ground.

3.3 Recycled, reclaimed, or recovered materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

3.4 Design. The pump unit shall conform to all Federal laws and regulations applicable for this type equipment in effect on date of issuance of solicitation. The pump units shall be designed as follows:

a. All components shall be capable of being readily removed, serviced, and operated by personnel or maintenance technician wearing Mission Oriented Protective Posture (MOPP) level IV gear or arctic-weather gloves.

b. Rapid installation, maintenance, and repair of equipment.

c. The pump unit shall be trailer mounted.

d. The pump unit, including trailer, shall not exceed 105 inches in width, 102 inches in height, 150 inches in length, and a maximum weight of 5,000 lbs.

e. The pump unit shall be capable of delivering hydrocarbon fuels through a 6 inch hose line.

f. Capable of delivering fuels 1 mile with an elevation difference of ± 50 feet.

g. Minimum flow rate of 900 gpm.

h. Maximum of 150 psi at the pump discharge.

i. Minimum of 475 feet of Total Dynamic Head (TDH).

j. The pump unit shall provide 15 feet of suction lift at 600F and a minimum flow rate of 450 gpm.

k. Parts shall not work loose while in service and shall be inherently capable of withstanding the stresses, jars, vibrations, and other conditions incident to shipping, storage, installation, and service.

l. Prohibit parts from extending past the frame of the trailer to prevent accidental damage.

m. The pump unit shall be designed and constructed for safety of operation. Pins, brackets, collars, dust covers, dust plugs which are detachable in normal operation, shall be attached to the assembly by lanyards, cord, wire, or similar to prevent loss. "Dog tag" style beaded chains shall not be provided. Special engineering attention shall be given to the design and durability of construction of the 8-inch male to double-6-inch female Y adapter on the inlet side of the pump to prevent leaks and stress damage.

3.5 Safety. A system safety program that complies with the requirements of MIL-STD-882 shall be established. A System Safety Analysis (SSA) shall establish the risk levels associated with the fueling systems. A Subsystem Hazard Analysis (SSHA) shall include, in industry terms, a Failure Mode Effects and Criticality Analysis (FMECA). The SSHA shall include pumping, controls systems, and include methods for controlling any identified hazard.

3.6 Inadvertent ignition. System shall be designed to preclude inadvertent ignition and to perform effectively, during or after exposure to the operational electromagnetic environment and while operating electronic controls in a fueling environment. Equipment shall be intrinsically safe.

3.7 Components. The pump units shall consist of the following major components:

3.7.1 Trailer. The pump shall be mounted on a trailer. This trailer shall comply with SAE 8090, Type II, Group C; have a suspension of torsion bar, leaf, or coil spring design; have a Type II drawbar lunette coupler conforming to CID A-A-52464 and include safety chains. The trailer shall have a minimum capacity of the weight of all installed components plus a factor of safety 2 to 1 and shall be mounted on four wheels with pneumatic tires. The trailer shall be able to be towed by flight line towing vehicles and a pintle hook shall be installed on the rear frame to allow additional units to be towed in tandem. Provisions shall be included to allow the unit to be moved by forklift.

Forklift tine openings shall be a minimum of 3 inches high and 10 inches wide. Parking brakes shall be furnished, shall apply to at least two wheels, and be capable of holding the pump unit on a 20° slope. The pumping unit shall be mounted to the trailer as to minimize overhanging of parts.

3.7.2 Fire extinguisher. One Type I, Class 2, Size 20 fire extinguisher shall be installed on the trailer, as specified in CID A-A-393. The extinguisher shall be accessible while standing on the ground and shall be protected from tire splash.

3.7.3 Engine. The engine shall be a heavy-duty commercial, multiple-cylinder, multi-fuel engine.

The engine speed shall not exceed 2,500 rpm at rated condition. The primary fuel to be used for engine operation during military use will be JP-8/JP-5; however, the engine shall also be able to operate on the following fuels without performance degradation:

a. ASTM D-1655, Jet A-1, without corrosion inhibitor/lubricity improver (CL, LI), Fuel System Icing Inhibitor (FSII), and Static Dissipater additives

b. ASTM D 1655, Jet A, without corrosion inhibitor/lubricity improver additives

c. ASTM D-975 Diesel Fuel

The engine shall be provided with a fuel tank having sufficient capacity to provide a minimum of four hours of operation at idle without refueling. The necessary piping, float assembly, and valves shall be provided to permit automatic filling and maintaining a three-quarters-filled condition using fuel and pressure from the discharge side of the pump. A valve shall be provided to permit manual control of this fuel flow. The filler opening shall be designed to receive a nozzle 2 inches in diameter and shall be located to prevent spillage or overflow from contacting hot components. The filler cap shall be connected to the filler opening and shall be firmly retained during shipment and operation.

A drain plug shall be provided to permit complete drainage of the fuel tank. A fuel level gauge shall be provided, which is graduated to show “Empty” to “Full”. No exposed surfaces will have a temperature exceeding 750°F. The engine shall be in accordance with Appendix A, Diesel (Multi- Fuel) Engine Performance Requirements.

3.7.4 Priming system. If the engine requires a priming system, said priming system shall permit controlled priming and be capable of using bulk fluid and priming fluids containing upper cylinder lubricant.

3.7.5 Cranking system. The cranking system shall be electrical, using a totally-enclosed electrical cranking motor and a totally-enclosed or brushless alternator of sufficient size and output to power the area lighting system (3.7.33).

3.7.6 Battery(s). The battery shall be maintenance free, sealed lead acid, starved electrolyte, gas recombination design or equivalent. The batteries shall have sufficient capacity at -25°F to provide a minimum of two engine starts. A suitable slave receptacle shall be provided for connecting an external electrical cable (not provided) to the batteries.

3.7.7 Battery storage container. The battery or batteries may be stored either within the engine enclosure adequately secured to a tray or in a separate battery storage container. If a battery storage container is used, the battery storage container shall be fabricated from non-corrosive material such as polyvinyl or stainless steel with a hinged cover with latches for holding the cover in a closed position, and shall include provisions for holding the cover in the open position. The cover shall permit the enclosure to breathe. The batteries shall be rigidly retained in the container. Electrolyte checking and filling and battery removal and replacement shall be easily accomplished with the cover in the open position. There shall be a minimum of ¼ inch clearance between the uppermost extremity of the battery and the cover to prevent arcing and a minimum 1 inch clearance between the battery terminals and the container sides to facilitate removal. Provisions shall be furnished for catching and discharging spilled electrolyte.

3.7.8 Throttle. The engine throttle shall operate in concert with the remote controls (3.7.28). The throttle will also be designed with a manual control for engine speed through the engine governor for all pumping operations, unless overridden by the safety controls. The remote control shall select the throttle to idle or run based on pressure or flow conditions. The manual throttle shall provide for sufficient movement and smooth operation to allow personnel to select previously-determined operating speed within ±100 rpm and shall include a preset stop to prevent exceeding the over-speed control setting. A turn-to-lock mechanism shall be provided to allow the throttle to be locked at any desired setting. The pump shall incorporate features to sense a no-flow condition on the suction side of the pump or a hose rupture on the discharge side and reduce the throttle to idle using flow switches, pressure switches, and/or timers.

3.7.9 Housing. The engine shall be completely enclosed. The housing shall provide protection from rain, snow, and sand; shall incorporate sound reduction features; shall include a heater adapter and hinged sections using full-length, piano-type hinges with corrosion-resistant hinge pins to permit ready access for periodic and major maintenance. The hinged sections shall be provided with hold-open devices and hand-operated latches to hold them closed and shall also be removable. All panels shall be integrally constructed, reinforced, and designed to prevent bending, warping, or other types of damage due to vibration and other forces encountered during normal operation or transportation.

All joints shall be tight. Sharp edges and corners, which could be a hazard to operating or maintenance personnel, are not acceptable.

3.7.10 Heater adapter. The heater adapter shall be a 6-inch connector in accordance with drawing 50C24046. The adapter shall be flush-mounted and provided with a cover or louver. If a cover is used, provide a means to secure the cover. The adapter shall be mounted to provide the best natural circulation around the engine to permit cold-weather (-40°F) starting. The mounting position shall also allow adequate clearance for easy attachment of the heating duct.

3.7.11 Muffler. The exhaust system shall be designed and placed in such a manner that splashing fuel will not present an ignition or fire hazard. The muffler shall be provided with a rain cap to prevent water from entering the exhaust system.

3.7.12 Oil drainage. The engine oil drain plug shall be replaced with a spring-loaded ball valve that is actuated in the (normally) closed position and is capable of withstanding the oil temperatures created by the engine without damage. In addition, an appropriate length of flexible tubing shall be connected to the valve discharge. The tubing shall be long enough to easily permit the discharging of oil into a container placed adjacent to the pumping assembly. The tubing shall be stored within the housing when not in use.

3.7.13 Pump. The pump shall be a certified, self-priming centrifugal pump and shall not incorporate the use of an injector. The pump shall be close-coupled to the engine and rigidly mounted to the base with provisions for aligning. The pump shall be of standard commercial manufacture, utilizing wear- and corrosion-resistant parts and self-lubricating seals and bearings. Radial and thrust bearings shall be interchangeable and designed for a minimum bearing life (Lh) of 15,000 hours.

The pump shall be capable of producing the flows and pressures required to meet the requirements specified herein.

3.7.14 Pump housing. The pump housing shall be capable of withstanding a hydrostatic pressure of 1½ times the shutoff head developed by the pump when operating at maximum engine rpm. The pump-suction entrance flow shall be tapered to the impeller(s) inlet to minimize losses and maximize suction lift capability. The pump casing shall be spherical rather than rectangular in order to maximize recirculation of fluid, purging of air in order to effect self-priming action, and minimize the priming time. Pump casing shall be a dual-volute design to minimize radial reactionary forces onto the pump shaft and bearings.

3.7.15 Semi-dry operation. The pump shall operate at maximum rated pump speed for five continuous minutes without appreciable wear or damage after fuel flow is stopped prior to the inlet.

3.7.16 Coupling. The pump shall be close-coupled to the engine with an interface of flexible design to absorb torsional vibrations and prevent misalignment. Any life limited elastomeric elements shall be readily replaceable without dismounting the engine or pump. The coupling shall be designed to prevent the pump shaft from becoming uncoupled from the engine, except when desired by the operator. If required, any setscrews or keys shall have thread-locking sealant applied to them to prevent loosening during operation. To maximize reliability, special engineering attention shall be given to the engine pump’s coupling interface.

3.7.17 Pump intermediate. The pump intermediate shall connect the engine housing to the volute in order to facilitate proper alignment of the engine to the volute casing. Multi-piece subassemblies shall not be utilized due to complexity of maintenance. It shall be a single-piece design to ensure maximum reliability and minimize the total number of parts subject to failure.

3.7.18 Threaded fasteners. The use of studs shall be minimized to prevent stripping of holes, except in areas where bolt and nut arrangement cannot be readily applied. No less than two threads shall protrude from each nut fastener. Where studs are used, a suitable thread-locking agent shall be applied to prevent loosening.

3.7.19 Impeller. The pump impeller shall include a self-lubricating, self-adjusting, mechanical- type seal and bearings capable of absorbing the thrust created by the pump. The pump impeller shall be securely attached to the shaft, yet easily removable when required. The impeller shall be an enclosed type with a sufficient number of vanes to maximize pump efficiency and to minimize flow separation and recirculation losses. In addition, the pump impeller shall incorporate wearing surfaces on both front and back to equalize the axial thrust and its load onto the bearings.

3.7.20 Pump shaft. The pump shaft shall be constructed of high-strength alloy steel. The pump shaft shall be designed to yield a maximum deflection of 0.002 inch at the impeller’s wearing surfaces.

3.7.21 Basket strainer. The pump shall include a basket strainer, located on the suction side of the pump and firmly supported to the frame in order to prevent damage. The working and test pressures shall be 150 psig and 225 psig, respectively. The basket strainer shall include an 8- mesh screen oriented in such a manner as to minimize spillage when checking/cleaning and not require draining of the entire pump assembly to complete these operations. The basket strainer shall have a drain plug with a ball valve for ease of draining. The basket strainer shall be protectively oriented to prevent damage during shipment. In addition, the basket strainer shall be of a design and construction that facilitates removal, cleaning, and reinstallation within five minutes.

3.7.22 Air eliminator. An automatic air eliminator shall be installed on the highest point of the pump and shall have a check valve feature to prevent large volumes of air from entering the pump. The air eliminator shall also have a manual isolation ball valve to allow for pump operation in the event of air eliminator failure. The liquid fuel and mist shall be returned to the pump through the vapor trap inlet connection or to the fuel tank. The air eliminator shall be designed so that it will discharge introduced air while under fuel pressure without discharging liquid fuel or fuel/air mist.

3.7.22.1 Air evacuation system. An air evacuation system shall be installed on the pump unit in order to create a vacuum and eliminate the air in the suction hoses, if required to prime the pump.

The system shall create sufficient vacuum in 140 feet of 6 inch suction hose to establish pumping operations within 20 minutes after start.

3.7.23 Control valve/recirculation loop. Discharge pressure shall be strictly controlled to 150 psi by using a control valve and backpressure control recirculation loop to return excess pressure to the inlet side of the pump.