J-1502000-07.f ufc_3_460_03_2017_c2.pdf

UFC 3-460-03

10 November 2017

Change 2, 24 August 2023

UNIFIED FACILITIES CRITERIA (UFC)

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

PETROLEUM FUEL SYSTEMS

MAINTENANCE

PETROLEUM FUEL SYSTEMS MAINTENANCE

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND \1\/1/

AIR FORCE CIVIL ENGINEER CENTER \1\ (Preparing Activity)/1/

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location 1 29 April 2021 Chapter 1, 2, 3, 4, 5, 6, 7, 8, 11, Appendix A, Appendix, B, Appendix C, Appendix G, Appendix I, Appendix J.

Changes incorporated CCR and administrative changes.

2 24 August

Chapter 1, 2, 3, 6, Appendix A, Appendix, B, Appendix C, Appendix I, Appendix J. Changes incorporated CCR and administrative changes. Added Two-Person Rule in Chapter 2. Changed several maintenance tasks in Appendix C between OM and SM.

This UFC supersedes UFC 3-460-03, dated 21 January 2003.

Change 2, 24 August 2023

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), host nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source: Whole Building Design Guide website https://www.wbdg.org/ffc/dod.

Refer to UFC 1-200-01, DoD Building Code, for implementation of new issuances on projects.

AUTHORIZED BY:

LARRY D. McCALLISTER, PhD, PE, PMP, SES

JOSEPH E. GOTT, P.E.

Chief Engineer

Chief, Engineering and Construction Directorate of Civil Works

Naval Facilities Engineering Command

U.S. Army Corps of Engineers

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Deputy Director of Civil Engineers DCS/Logistics, Engineering & Force Protection

Deputy Assistant Secretary of Defense (Facilities Investment and Management) Office of the Assistant Secretary of Defense (Energy, Installations, and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 https://www.wbdg.org/ffc/dod

CHANGE SUMMARY SHEET

Document: UFC 3-460-03, Petroleum Fuel Systems, Maintenance

Superseding: UFC 3-460-03, dated 21 January 2003

Description: Unified Facilities Criteria (UFC) 3-460-03 contains general inspection and maintenance criteria for military land-based liquid petroleum fuel facilities. It also applies to facilities dispensing Liquefied Natural Gas (LNG) and Compressed Natural Gas (CNG) for ground vehicle fueling. These criteria are applicable to all branches of the Department of Defense (DoD) and the Defense Logistics Agency (DLA).

Reasons for Document: UFC 3-460-03 was developed to harmonize requirements and guidance documents from the Army, Navy, U.S. Marine Corps, Air Force, industry guidelines, standards and codes. Creating a true unified criteria allows military services to define the required tasks for contractors and government personnel in maintaining petroleum fuel facilities.

Other military publications reviewed during the update to UFC 3-460-03 include United States Air Forces in Europe (USAFE) Volume 1 General Description and Operation;

USAFE Volume 2 Maintenance and Repair; Standardization Agreement (STANAG) 3609 Standards for Maintenance of Fixed Aviation Fuel Receipt, Storage and Dispensing Systems; United States Air Force (USAF) Air Force Instruction (AFI) 23-204 Organizational Fuel Tanks; USAF Technical Order (TO) 37-1-1 General Operation and Inspection of Installed Fuel Storage and Dispensing Systems; and Unified Facilities Guide Specifications (UFGS).

Several industry standards, recommended practices, and codes have been incorporated into UFC 3-460-03 criteria including: American Petroleum Institute (API), Airlines for America (A4A), Energy Institute (EI), National Association of Corrosion Engineers (NACE) International, Petroleum Equipment Institute (PEI), Society of Automotive Engineers (SAE) International, and the Steel Tank Institute (STI).

Impact:

• Provides the requirements for tasks and frequencies for the inspection and maintenance of Petroleum Fuel Systems and components such as aircraft hydrant systems, tanks, and pipelines.

• Provides checklists for the inspection and maintenance of Petroleum Fuel Systems.

• Provides fuel quality, safety, environmental, fire protection guidance to follow during the inspection and maintenance of Petroleum Fuel Systems.

Unification Issues: The Army, Navy, U.S. Marine Corps, and Air Force could not unify on tank cleaning requirements listed in Section 8-7. The Air Force will require fuel tanks above 20,000 gallon in capacity to be cleaned on a 10 year cycle. The Army, Navy, and U.S. Marine Corps will require tanks to be cleaned during out of service inspections.

The period of out of service inspections may vary depending on the type and condition of each tank.

This Page Intentionally Left Blank i

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE

1-1.1 Introduction

1-1.2 Applicability

1-1.3 Scope

1-1.4 Design Criteria

1-2 ROLES AND RESPONSIBILITIES

1-2.1 Operational Tasks

1-2.2 Maintenance Tasks

1-3 DEPARTMENT OF DEFENSE FUELS \1\ DISCIPLINE WORKING

GROUP /1/

1-4 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS

1-5 SERVICE CONTROL POINTS

1-6 REGULATORY COMPLIANCE

1-7 WAIVERS AND EXEMPTIONS

1-7.1 Waivers

1-7.2 Exemptions

1-8 REFERENCES

1-9 CAPITALIZED FUEL SYSTEMS

1-10 MAINTENANCE AND INSPECTION FREQUENCIES

CHAPTER 2 GENERAL

2-1 GENERAL MAINTENANCE INFORMATION

2-2 HEALTH AND SAFETY

2-2.1 Safety References

2-2.2 Personal Protective Equipment

2-2.3 Health Hazards

2-2.4 Confined Spaces

2-3 ELECTRICAL SAFETY

2-3.1 Lockout/Tagout

2-3.2 Static Charges

2-3.3 Electrical Currents ii

2-3.4 Hazardous Location Classification

2-4 PETROLEUM FUEL QUALITY

2-4.1 Water Contamination

2-4.2 Prevention and Removal of Water Contamination

2-4.3 Solid Matter Contamination

2-4.4 Prevention and Removal of Solids Contamination

2-4.5 Microbiological Contamination

2-4.6 Other Product Contamination

2-4.7 Special Considerations for Biodiesel Blend B20

2-4.8 Special Considerations for Fuel Ethanol Blend E85

2-5 CHANGES IN TANK PRODUCT

2-6 ENVIRONMENTAL PROTECTION

2-6.1 Spill Planning

2-6.2 Containment

2-6.3 Containment Drain Valves

2-6.4 Waste Disposal

2-7 SIGNAGE AND MARKINGS

2-7.1 Inspection and Maintenance - Signage and Markings

2-8 FIRE PROTECTION

2-8.1 Petroleum Fuel Vapor Sources for Fires and Explosions

2-8.2 Solid Sources for Fires and Explosions

2-8.3 Ignition Sources for Fires and Explosions

2-8.4 Fire and Explosion Preventative Measures

2-9 EMERGENCY ACTION PLANS

2-10 SITE MAINTENANCE PROGRAM

2-10.1 Maintaining Petroleum Fuel Infrastructure

2-10.2 Documentation and Record Retention

2-10.3 As-built Information

2-10.4 Operation and Maintenance Support Information

2-10.5 Safety Reports

CHAPTER 3 BULK TRANSFER FACILITIES

3-1 INTRODUCTION

iii

3-2 TRUCK RECEIPT

3-2.1 Inspection and Maintenance - Truck Receipt

3-3 PIPELINE RECEIPT

3-3.1 Inspection and Maintenance – Pipeline Receipt

3-4 RAIL RECEIPT

3-5 BULK ISSUE

3-5.1 Truck Issue

3-5.2 Pipeline Issue

3-5.3 Rail Issue

3-6 FILTRATION

3-6.1 Pre-Filters

3-6.2 Filter Separators

3-6.3 Haypack Filters

3-6.4 Basket Strainers

3-6.5 Filter Separator Sump Heaters

3-7 METERS

3-7.1 Positive Displacement Meters

3-7.2 Turbine Flow Meters

3-7.3 Orifice Flow Meters

3-8 PUMPS

3-8.1 Centrifugal Pumps

3-8.2 /1/ Vertical Inline Pumps

3-8.3 /1/ Vertical Turbine/Submerged Turbine Pumps

3-8.4 /1/ Positive Displacement Pumps

3-8.5 /1/ Sliding Vane Pumps

3-8.6 /1/ Gear Pumps

3-8.7 /1/ Diaphragm Pumps

3-8.8 /1/ Internal Combustion Drives

3-8.9 /1/ Gearboxes

3-9 HOSES

3-9.1 Loading Fuel Hoses

3-9.2 Offloading Fuel Hoses iv

3-10 AIR ELIMINATORS

3-10.1 Air Eliminator Tanks

3-10.2 Automatic Air Vents

3-11 FUEL ADDITIVE INJECTORS

3-11.1 Inspection and Maintenance – Fuel Additive Injectors

3-12 CODED VESSELS

3-12.1 Inspection and Maintenance – Coded Vessels

CHAPTER 4 AIRCRAFT FUELING FACILITIES

4-1 INTRODUCTION

4-2 HYDRANT SYSTEM – TYPE I

4-3 HYDRANT SYSTEM – TYPE II

4-3.1 General Description

4-3.2 System Specific Control Valves

4-3.3 Type II Modified Control Valves (Rapid Flow)

4-4 HYDRANT SYSTEM – TYPE III

4-4.1 General Description

4-4.2 System-Specific Control Valves

4-5 HYDRANT SYSTEM – TYPE IV

4-5.1 General Description

4-5.2 System-Specific Control Valves

4-6 HYDRANT SYSTEM – TYPE V

4-6.1 General Description

4-7 HYDRANT SYSTEM GENERAL EQUIPMENT

4-7.1 Pantographs

4-7.2 Hydrant Adapters

4-7.3 Fueling Nozzles

4-7.4 Surge Suppressors

4-7.5 Aircraft Fueling Hoses

4-8 HYDRANT SYSTEM PRODUCT RECOVERY

4-8.1 Overfill Valve for Product Recovery Tanks

4-8.2 Product Recovery Tank Release Detection

4-8.3 Product Recovery Tank Automatic Tank Gauges v

4-8.4 Product Recovery Tank Fuel Transfer Pump

CHAPTER 5 MARINE RECEIVING AND DISPENSING FACILITIES

5-1 PIERS AND WHARVES

5-1.1 Inspection and Maintenance – Piers and Wharves

5-1.2 Inspection and Maintenance – Fuel Containment Systems

5-2 MARINE RECEIPT

5-2.1 Inspection and Maintenance – Marine Receipt

5-3 MARINE ISSUE

5-3.1 Inspection and Maintenance – Marine Issue

5-4 MARINE LOADING ARMS

5-4.1 Inspection and Maintenance – Marine Loading Arms

5-5 MARINE AND UNDERWATER HOSES

5-5.1 Marine Transfer Hoses

5-5.2 Underwater Hoses

5-6 DISPENSERS

5-6.1 Inspection and Maintenance – Dispensers

5-7 OFFSHORE MOORING SYSTEMS

5-7.1 Single Point Mooring Systems

5-7.2 Multi-point Mooring Systems

5-8 SUBMERGED PIPING SYSTEMS

5-8.1 Inspection and Maintenance – Submerged Pipelines

5-9 BOOM REELS

5-9.1 Inspection and Maintenance – Boom Reels

CHAPTER 6 PIPING SYSTEMS

6-1 PIPE TESTING AND INSPECTIONS

6-1.1 On-Base Pipelines

6-1.2 Inter-Terminal Pipelines

6-1.3 Aboveground Piping

6-1.4 Double-Wall Piping

6-1.5 Pipe Visual Inspection

6-1.6 Line Walk

6-1.7 Line Patrol vi

6-1.8 Volume Check

6-1.9 API 570 Inspections

6-2 GENERAL PIPELINE CLEANING

6-2.1 Cleaning Operations

6-3 PIPE SYSTEM REPAIRS

6-3.1 Pits and Small Leaks

6-4 PIPELINE INTEGRITY MANAGEMENT PLAN

6-4.1 Certified Pipeline Inventory

6-5 FLANGE GASKETS

6-6 VALVES

6-6.1 Valve Tagging

6-6.2 Manual Valves

6-6.3 Thermal and Pressure Relief Valves

6-6.4 Semi-Automatic Valves

6-6.5 Automatic Control Valves

6-6.6 Motor Operators

6-7 PRESSURE AND VACUUM INSTRUMENTATION

6-7.1 Pressure and Pressure/Vacuum Gauges

6-7.2 Differential Pressure Gauges

6-7.3 Pressure Transmitters

6-7.4 Differential Pressure Transmitters

6-8 FLEXIBLE BALL JOINTS

6-8.1 Flexible Ball Joints

6-9 THERMOMETERS

6-9.1 Dial Thermometers

6-10 PIPE AND EQUIPMENT COATINGS

6-10.1 Aboveground Piping and Equipment Coatings

6-10.2 Underground Piping Coating Repairs

6-10.3 Internal Carbon Steel Pipe Coatings

6-11 UNDERGROUND FUEL PITS

6-11.1 Isolation Valve Pits

6-11.2 Hydrant Fuel Pits vii

6-11.3 High Point Vent Pits

6-11.4 Low Point Drain Pits

6-11.5 Lateral Control Pits

6-12 MINOR PIPING SYSTEMS

6-12.1 Low Point Drains

6-12.2 High Point Vents

6-12.3 Sight Flow Indicators

6-13 ELECTRONIC RELEASE DETECTION MONITORING

6-13.1 General Inspection of Release Detection Systems

6-14 VISUAL RELEASE DETECTION MONITORING

6-14.1 Visual Monitoring

CHAPTER 7 GROUND VEHICLE FUEL FACILITIES

7-1 GENERAL

7-2 DISPENSER NOZZLES

7-2.1 Inspection and Maintenance – Dispenser Nozzles

7-3 DISPENSER HOSES

7-3.1 Inspection and Maintenance – Dispenser Hoses

7-4 BREAKAWAYS

7-4.1 Inspection and Maintenance – Breakaways

7-5 SWIVELS

7-5.1 Inspection and Maintenance – Swivels

7-6 HOSE RETRIEVER

7-6.1 Inspection and Maintenance – Hose Retriever

7-7 DISPENSER CABINET

7-7.1 Inspection and Maintenance – Dispenser Cabinet

7-8 DISPENSER METERS

7-8.1 Inspection and Maintenance – Dispenser Meters

7-9 DISPENSER FILTERS

7-9.1 Inspection and Maintenance – Dispenser Filters

7-10 DISPENSER STRAINERS

7-10.1 Inspection and Maintenance – Dispenser Strainers

7-11 GROUND VEHICLE FUEL PIPING

viii

7-11.1 Inspection and Maintenance – Ground Vehicle Fuel Piping

7-12 EMERGENCY SHUTOFF VALVES (SHEAR VALVES)

7-12.1 Inspection and Maintenance – Emergency Shutoff Valves (Shear Valves)

7-13 DISPENSER SUMPS

7-13.1 Inspection and Maintenance – Dispenser Sumps

7-14 TRANSITION SUMPS

7-14.1 Inspection and Maintenance – Transition Sumps

7-15 DISPENSER PUMPS

7-15.1 Remote Dispenser Pumps

7-15.2 Self-Contained Dispenser Pumps

7-16 EFSO SYSTEMS

7-16.1 Inspection and Maintenance – EFSO Systems

7-17 VAPOR RECOVERY

7-17.1 Stage I Vapor Recovery

7-17.2 Stage II Vapor Recovery

7-17.3 Vapor Burners

7-18 TACTICAL REFUELER LOADING

7-19 ELECTRONIC RELEASE DETECTION MONITORING

7-19.1 General Inspection of Release Detection Systems

7-20 VISUAL RELEASE DETECTION MONITORING

7-20.1 Visual Monitoring

CHAPTER 8 PETROLEUM STORAGE TANKS

8-1 GENERAL INFORMATION

8-2 CONTAMINATION PREVENTION

8-3 TANK SURFACE COATINGS

8-3.1 External Tank Coating Repairs

8-3.2 Internal Tank Coating Repairs

8-4 ABOVEGROUND FIELD-ERECTED TANKS

8-4.1 Inspection and Maintenance – Aboveground Field-Erected Tanks

8-4.2 Geodesic Dome Roofs

8-4.3 Foundations

8-5 SHOP-FABRICATED TANKS

ix

8-5.1 Aboveground Shop-Fabricated Tanks

8-5.2 Self-Diking or Vaulted Tanks

8-5.3 Rectangular Concrete-Encased Tanks

8-5.4 Underground Shop-Fabricated Tanks

8-6 UNDERGROUND FIELD-CONSTRUCTED TANKS (CUT AND COVER

TANKS)

8-6.1 Inspection and Maintenance – Underground Field-Constructed Tanks (Cut and Cover Tanks)

8-7 TANK CLEANING

8-8 RETURNING TO SERVICE AFTER FORMAL OUT OF SERVICE

INSPECTION/REPAIR

8-8.1 Tank Stenciling Requirements

8-9 TANK APPURTENANCES

8-9.1 Floating Roofs and Pans

8-9.2 Secondary Tank Bottoms

8-9.3 Tank Pressure/Vacuum Vents

8-9.4 Emergency Vents

8-9.5 Flame Arrestors

8-9.6 High Level Shut-off Valve (HLSO)

8-9.7 Mechanical Tape Gauges

8-9.8 Automatic Tank Gauges

8-9.9 Level Alarms

8-9.10 Product Saver Tanks

8-9.11 Sidestream Filtration Systems

8-9.12 Fill Ports

8-9.13 Release Detection Monitoring

8-9.14 Floating Suction Lines

8-9.15 Foam Fire Protection Systems

8-9.16 Heating Coils

8-9.17 Stilling Wells

8-10 CONTAINMENT SYSTEMS

8-10.1 Inspection and Maintenance – Containment Systems (General)

8-10.2 Concrete and Cement Brick Dike/Berm Walls and Floors x

8-10.3 Earthen Dike Walls

8-10.4 Self-Diking or Vaulted Tank Containment

8-10.5 Flexible Membrane Liners

8-10.6 Pipe Penetrations

8-11 MISCELLANEOUS USE TANKS

8-11.1 Miscellaneous Use Tanks

CHAPTER 9 ELECTRICAL SYSTEMS

9-1 ELECTRIC CONTROL SYSTEMS AND EQUIPMENT

9-1.1 Scope and Limitations

9-1.2 Electrical Equipment

9-1.3 Power Cables

9-1.4 Motor Controls

9-1.5 Panelboards

9-1.6 Grounding Systems

9-1.7 Electric Motors

9-1.8 Lighting

9-1.9 Electronic Equipment

9-2 CATHODIC PROTECTION SYSTEMS

9-2.1 Cathodic Protection

9-2.2 Electrical Isolation

9-3 CARD AND KEY LOCKS

9-3.1 Inspection and Maintenance - Card and Key Locks

9-4 LIGHTNING PROTECTION SYSTEMS

9-4.1 Inspection and Maintenance – Lightning Protection Systems

9-5 GROUND VERIFICATION SYSTEMS

9-5.1 Inspection and Maintenance – Ground Verification Systems

9-6 ELECTRONIC OVERFILL PROTECTION SYSTEMS

9-6.1 Inspection and Maintenance – Electronic Overfill Prevention Systems. ..

CHAPTER 10 ALTERNATE POL FACILITIES

10-1 LIQUEFIED PETROLEUM GAS

10-1.1 Liquefied Petroleum Tanks

10-1.2 Liquefied Petroleum Pipelines xi

10-1.3 Liquefied Petroleum Vapor Lines

10-1.4 LPG Vaporizers

10-1.5 Petroleum Gas Regulators

10-1.6 Liquefied Petroleum Gas Hoses

10-2 COMPRESSED NATURAL GAS (CNG)

10-2.1 CNG Piping

10-2.2 CNG Compressors

10-2.3 CNG Storage

10-2.4 CNG Dispensers

10-2.5 CNG Dispenser Hoses

10-3 HYDRAZINE CHARGING UNITS

10-3.1 Inspection and Maintenance – Hydrazine Charging Units

10-4 JP-10

10-5 OTTO

CHAPTER 11 SUPPORT FACILITIES

11-1 SECONDARY CONTAINMENT

11-1.1 Fuel Truck \1\ and Rail Car /1/ Containment Areas

11-1.2 Remote Spill Containment

11-2 PROTECTIVE SHELTERS

11-2.1 Pumphouse/Filter Buildings

11-2.2 Canopies

11-3 SAFETY SHOWERS AND EYEWASH FOUNTAINS

11-3.1 Inspection and Maintenance – Emergency Eyewash/Showers

11-4 FUELS LABORATORIES

11-4.1 Ventilation Hoods

11-5 OIL/WATER SEPARATORS

11-5.1 Inspection and Maintenance – Oil/Water Separators

11-6 CRANES AND HOISTS

11-6.1 Inspection and Maintenance – Cranes and Hoists

CHAPTER 12 FUEL FACILITY TEMPORARY DEACTIVATION OR CLOSURE

12-1 DEACTIVATION OF FUELING FACILITIES

12-2 DEACTIVATED PETROLEUM FUEL TANKS

Change 2, 24 August 2023 xii

12-2.1 Inspection and Maintenance – Deactivated Petroleum Fuel Tanks. .. 231

12-3 DEACTIVATED PETROLEUM FUEL PIPELINES

12-3.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pipelines

12-4 DEACTIVATED PETROLEUM FUEL PUMPS

12-4.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pumps. . 232

12-5 MISCELLANEOUS DEACTIVATED COMPONENTS

12-5.1 Inspection and Maintenance – Miscellaneous Deactivated Components.

12-6 TANKS AND PIPELINES

12-7 DOCUMENTATION/RECORDKEEPING

APPENDIX A DLA ENERGY PROJECT PROGRAMING

APPENDIX B CONTAINMENT INTEGRITY TESTING CHECKLIST

APPENDIX C MAINTENANCE TABLE

APPENDIX D MAINTENANCE PROCEDURES

APPENDIX E TANK INSPECTION CHECKLISTS

APPENDIX F TANK INSPECTION CHECKLISTS

APPENDIX G PETROLEUM FUEL PIPELINE PRESSURE TESTING GUIDELINES

AND CRITERIA

APPENDIX H TANK CLEANING GUIDANCE

APPENDIX I /1/ ACRONYMS

APPENDIX J /1/ References

FIGURES

Figure 3-1 Pre-Filter Figure 3-2 Filter Separator Figure 3-3 Positive Displacement Meter Figure 3-4 Turbine Flow Meter Figure 3-5 Split-Case Centrifugal Pump Figure 3-6 Vertical Inline Pump Figure 3-7 Vertical Turbine Pump Figure 3-8 Rotary Vane Pump Figure 3-9 Diaphragm Pump Figure 3-10 Air Eliminator Tank Figure 3-11 Automatic Air Vent Figure 4-1 Modified Panero, Type I Hydrant System Figure 4-2 Pritchard, Type II Hydrant System Figure 4-3 High Level Shut-off Valve (Type II) xiii

Figure 4-4 Non-Surge Check Valve (Type II) Figure 4-5 Filter Separator Control Valve (Type II) Figure 4-6 Refueling Control Valve (Type II) Figure 4-7 Pressure Relief Valve (Type II) Figure 4-8 Defuel Control Valve (Type II) Figure 4-9 Dual Rate-of-Flow Control Valve (Type II) Figure 4-10 Combination Dual Rate-of-Flow Control and Solenoid Valve (Type

II)

Figure 4-11 Dual Pressure Relief, Solenoid Shutoff, and Check Valve (Type II) ...

Figure 4-12 Type III Hydrant System Diagram Figure 4-13 Non-Surge Check Valve Figure 4-14 Filter Separator Control Valve (Type III) Figure 4-15 Defuel/Flush Valve (Type III) Figure 4-16 Issue Venturi Figure 4-17 Back Pressure Control Valve (Type III) Figure 4-18 Pressure Control Valve (Type III) Figure 4-19 Hydrant Control Valve (Type III) Figure 4-20 Emergency Shut-Off Valve (Type III) Figure 4-21 Pantograph Pressure Control Valve Figure 4-22 Fixed Pantograph Figure 4-23 Hydrant Adapter Figure 4-24 Fueling Nozzle Figure 4-25 Surge Suppressor Figure 4-26 Overfill Valve for Product Recovery Tank Figure 5-1 Single Point Mooring System Figure 6-1 Lubricated Plug Valve Figure 6-2 Gate Valve Figure 6-3 Ball Valve Figure 6-4 Double Block and Bleed Plug Valve Figure 6-5 Butterfly Valve Figure 6-6 Globe Valve Figure 6-7 Check Valve Figure 6-8 Line Blank Figure 6-9 Ring Spacer Figure 6-10 Spectacle Blind Figure 6-11 Thermal and Pressure Relief Valve Figure 6-12 Truck Fill Valve Figure 6-13 Flexible Ball Joint Figure 7-1 Dispenser Nozzle Figure 7-2 Emergency Shutoff Valve Figure 8-1 Floating Roof Seal Figure 8-2 Floating Roof Detail Figure 8-3 Standard Tank Seal on Aluminum Honeycomb Pans Figure 8-4 Pressure Vacuum Vent Figure 8-5 External High Level Shut-off Valve xiv

Figure 8-6 Mechanical Tape Gauge Figure 8-7 Magnetostrictive Probe Figure 8-8 Servo Gauge

TABLES

Table 8-1 /1/ Single-walled Underground Shop Fabricated Tank Inspection and Testing Schedules*

Table 8-2 /1/ Double-walled Underground Shop Fabricated Tank Inspection and Testing Schedules*

Table G-1 /1/ Pipe Properties Table G-2 /1/ Definition of Terms Table G-2 /1/ Military Requirements

CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE.

1-1.1 Introduction.

Clean, water-free fuel of the correct grade is essential to the safety of vehicles, ships and aircraft, and their operators and personnel. This manual emphasizes inspection and preventive maintenance to avoid system shutdowns, prevent fuel contamination, and decrease fire, safety, and health hazards. Periodic inspections and maintenance are essential to continue efficient safe operations and reduce major repairs.

1-1.2 Applicability.

UFC 3-460-03 applies to all real property facilities used for storing, distributing, and dispensing fuels for reciprocating and jet engine aircraft, automotive fuels, lubricating oils, and diesel fuel.

1-1.3 Scope.

This manual establishes the minimum inspection and maintenance standards for fueling systems and applies to all active installations. If the installation is in an inactive or surplus status, reduce maintenance standards to a point consistent with the anticipated mission.

1-1.4 Design Criteria.

This is not a design manual. Refer to UFC 3-460-01 for current design and construction standards.

1-2 ROLES AND RESPONSIBILITIES.

A role is a position or job defined by a set of responsibilities. A responsibility is a task or duty required of a designated party. Military services delegate tasks differently to military service-specific petroleum fuel personnel, contracted operations personnel, or maintenance contractors.

UFC 3-460-03 defines minimum maintenance tasks and their frequency. The criteria outlined within UFC 3-460-03 must be accomplished by DoD personnel (active duty/civilian) and/or DoD contractors.

The Command Authority (i.e., Army, Navy, U.S. Marine Corps, Air Force, and/or DLA) defines how tasks are divided among personnel at each facility. DoD 4140.25-M provides requirements applicable to all DoD fuel facilities.

1-2.1 Operational Tasks.

Operational tasks are actions taken to control and run the petroleum fuel system on a day-to-day basis. These tasks include monitoring control systems, bulk issue and receipt, and storage of petroleum fuel. Operating tasks help ensure the safety of personnel and the environment. Operating tasks often include specific measures to maintain petroleum fuel quality.

1-2.2 Maintenance Tasks

Maintenance tasks are recurring, daily, periodic, or scheduled work required to:

preserve a facility, prevent deterioration, prevent component failure, prevent unscheduled outages, and identify components requiring replacement or repair.

Maintenance tasks involve: routine inspection, testing of petroleum fuel systems, and identifying required repairs. Maintenance tasks help ensure product quality, safe working conditions, and environmental safety.

Maintenance tasks are separated into Operator Maintenance (OM) and Systems Maintenance (SM). OM is normally performed by facility operator personnel as part of normal use. SM is normally performed by trained personnel of base facility maintenance, facility operating contracts, or maintenance contracts for recurring maintenance and repair. Military services can delegate maintenance tasks between OM and SM differently. Appendix C includes a list of maintenance tasks included in this UFC and their associated designation as OM or SM for the Army, Navy and U.S. Marine Corps, and the Air Force.

1-3 DEPARTMENT OF DEFENSE FUELS \1\ DISCIPLINE WORKING

GROUP /1/.

UFC 3-460-03 was updated by the DoD Fuels \1\ Discipline Working Group (FDWG) /1/.

For more information on the \1\ FDWG /1/ refer to UFC 3-460-01, Appendix \1\B/1/.

1-4 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS.

Policies, obligations, and responsibilities vary between DoD components. For interpretation of components required in petroleum fuel systems, consult the applicable Service Headquarters Subject Matter Expert (SME). For interpretation, the SME at the appropriate Service Headquarters is defined as follows:

• Army – Headquarters, US Army Corps of Engineers, POL Facilities Proponent (CECW-EC).

• Air Force – The Air Force Fuels Facilities Subject Matter Expert (\1\/1/ AFCEC/COS) through the applicable \1\ Regional Fuels Engineer

(USAFE/PACAF) /1/.

• Navy/Marine Corps: NAVFAC POL Facility Subject Matter Expert

(NAVFAC EXWC, CI11).

1-5 SERVICE CONTROL POINTS.

Service Control Points (SCP) have been established for each of the military services.

SCPs serve as the central management function in coordinating requirements, technical issues, and supply actions with military units and DLA Energy. For interpretations on operation and maintenance requirements of fuel systems, consult the applicable SCP as defined in DoD 4140.25-M, Volume 1, Chapter 1, Section C1.3.1.5.

1-6 REGULATORY COMPLIANCE.

Inspection and maintenance activities must meet the most stringent of UFC and Military Specific requirements as well as applicable host nation, Federal, state, and local codes and regulations. For example, Ramstein Air Base must comply with the more stringent maintenance criteria of UFC 3-460-03, the applicable NATO STANAG, USAFE documents, or German law.

1-7 WAIVERS AND EXEMPTIONS.

Recommended UFC 3-460-03 language generated from recurring waivers and exemptions will be considered by the DoD \1\ FDWG /1/ with supporting rationale for inclusion on \1\ FDWG /1/ voting agendas. Recommended changes to UFC 3-460-03 are reviewed and approved by the voting members of the DoD \1\ FDWG /1/, preferably in a normal recurring meeting.

1-7.1 Waivers.

Waivers are temporary deviations from the stated criteria within UFC 3-460-03. Waivers are valid for up to one year or as stated on the waiver and are submitted to the military service-specific SCP for review. Refer to Military Standard (MIL-STD)-3007G for the waiver process.

1-7.2 Exemptions.

In contrast to waivers, exemptions are permanent deviations from the stated criteria within UFC 3-460-03. Exemption requests must be submitted through the military service-specific SCP for review. Refer to Military Standard (MIL-STD)-3007G for the exemption process. The \1\ FDWG /1/ must be advised when an exemption is granted.

1-8 REFERENCES.

Other sources for criteria related to petroleum fuel facilities are identified in \1\ Appendix J. /1/ Any reference noted is the latest edition (as of the publication of this document) unless otherwise stated. Many of these documents are available within the public domain and can be found on the Internet; others require purchase. Before purchasing copies of referenced documents, contact the military service-specific SME to determine the need to have a complete copy of the referenced document versus obtaining the specific data needed from the referenced document from the SME.

1-9 CAPITALIZED FUEL SYSTEMS.

SM is normally eligible for DLA Energy funding at facilities that contain, handle, or distribute DLA Energy capitalized fuel under the Sustainment, Restoration, and Modernization (SRM) program. Proper coordination and scheduling with facility operators is necessary before conducting SM to ensure minimal mission impact.

DLA Energy also funds other inspection and maintenance programs at petroleum fuel facilities that contain, handle, or distribute DLA Energy capitalized fuel. See \1\ Appendix A /1/ for a list of current maintenance and inspection programs that are funded by DLA Energy.

1-10 MAINTENANCE AND INSPECTION FREQUENCIES.

The maintenance and inspection frequencies provided in this UFC are strict guidelines and are based on regulatory requirements and commercial practices. The military service-specific SCP can authorize deviations and alternate equivalent methodologies for specific individual tasks and only as needed to support the mission requirements.

For example, the military service-specific SCP can authorize deviations to delay or accelerate an out of service inspection of a fuel storage tank to coincide with other work to avoid reducing mission capabilities.

CHAPTER 2 GENERAL

2-1 GENERAL MAINTENANCE INFORMATION.

This chapter contains information general to all chapters of UFC 3-460-03. This chapter includes health and safety information, information related to fuel quality, and general practices and requirements.

2-2 HEALTH AND SAFETY.

Personnel must comply with the measures outlined in this chapter. Petroleum fuel products are hazardous because of their toxic and flammable nature. Health and safety precautions are required and must be strictly adhered to in order to prevent incidents and accidents to personnel and Government property. Before initiating maintenance work on petroleum fuel facilities, a hazard analysis must be completed and procedures must be established to assure recognized hazards have been controlled, items to be serviced are properly isolated and adequate light is available for the task. Only properly trained and authorized personnel are permitted to operate and perform maintenance on petroleum fuel system components. Breaches of safety standards may result in disciplinary action and possible injury or death. Safe efficient maintenance activities require cleanliness, neatness, and order. Each individual is expected to recognize and correct hazardous situations promptly, if qualified, and/or report them to supervisors.

2-2.1 Safety References.

Military service-specific health and safety procedures and information listed in USACE EM 385-1-1, \2\ \1\ DAFMAN 91-203 /1/ /2/, Navy Occupational Safety & Health (NAVOSH) and Occupational Safety and Health Administration (OSHA) regulations, NFPA 2112, NFPA 2113, and ASTM F1449 must be followed as applicable. Refer to Installation Safety Office for additional local and Installation specific safety requirements and procedures.

2-2.2 Personal Protective Equipment.

\1\

a. The purpose of this section is to reduce the health and safety risks associated with the incorrect selection and use of personal protective equipment when personnel are potentially exposed to petroleum fuels and associated fire hazards. Each facility is responsible for performing a hazard analysis in accordance with NFPA 2113 to identify, eliminate, and control recognized and identified hazards. Personnel Protection Equipment (PPE) will be selected to provide the user with the appropriate personal protection. Personnel will be trained in the proper selection, use, care and maintenance of their PPE in accordance with the Installation’s written PPE program. Installations that determine there is the potential for a fire to exist from flammable vapors must utilize PPE that meets the minimal standards of NFPA 2112. Installations must reassess the hazard analysis at least every 5 years, or when a significant change is made to the work environment.

b. Any type of clothing may be worn as outer garments when working with high-flashpoint petroleum fuel (e.g., JP-5, JP-8, JP-10, Jet A, Jet A-1, additized Jet A (F-24) or diesel). However, personnel working with low-flashpoint petroleum fuel (e.g., JP-4, Jet B, aviation gasoline, or motor gasoline) must utilize PPE that meets the requirements of NFPA 2112 where the petroleum fuel facility hazard analysis has demonstrated that flammable materials or vapors are present in quantities that may result in a fire or endanger personnel. Wool socks, wool glove inserts, woolen caps, and underwear of nylon, silk, or polyester pose no significant hazard and are acceptable. Appropriate weather gear is allowed for personnel who are subject to outside work during inclement weather.

c. Conventional 50% polyester and 50% cotton-blend coveralls are adequate for routine maintenance work in petroleum fuel facilities that do not pose a fire hazard potential. When completing tasks in petroleum fuel facilities where petroleum fuel is present (e.g., tank cleaning), the use of disposable protective coveralls having a static-dissipating coating may be necessary. Disposable coveralls may be worn alone or over polyester/cotton-blend coveralls. Replace fuel-contaminated clothing.

/1/

2-2.3 Health Hazards.

The following paragraphs describe health hazards of exposure to petroleum fuel vapors, liquid petroleum fuels, and solids. The paragraphs also provide guidance on administering appropriate types of first aid for personnel exhibiting symptoms resulting from petroleum fuel exposure. Review and become familiar with the health and exposure hazards listed on Safety Data Sheets (SDSs) for the types of fuel stored and handled in fuel systems to be maintained.

2-2.3.1 Petroleum Fuel Vapors.

Petroleum fuel vapors within a confined space, regardless of their toxicity and explosive potential, will displace oxygen and may cause suffocation. Petroleum fuel vapors can be harmful even at concentrations with a Lower Explosive Limit (LEL) of 0 (zero) unless the area has been completely freed of vapor. The Permissible Exposure Limit (PEL) of petroleum fuel vapors that can be safely inhaled is lower than the LEL. To reduce the potential for personnel exposure to hazardous petroleum fuel vapor concentrations, a facility industrial hygiene survey should be completed and safety controls implemented in accordance with applicable military service requirements as well as OSHA requirements and American Conference of Governmental Industrial Hygienists guidelines.

2-2.3.1.1 Petroleum Fuel Vapor Inhalation First Aid.

Safely remove all persons from the work area who exhibit adverse symptoms of exposure to petroleum fuel vapors to include dizziness, nausea, or headache. If a person is overcome by petroleum fuel vapors, first aid should be administered at once by someone trained in first aid, and the person exhibiting symptoms should get prompt medical attention. Recovery from initial exposure to vapors is usually prompt after exposure to fresh air. If breathing has stopped, Cardiopulmonary Resuscitation (CPR) should be administered by a person trained in CPR. Promptly report all incidents or accidents potentially resulting from petroleum fuel vapor inhalation to supervisors.

2-2.3.2 Liquid Petroleum Fuel.

Avoid getting liquid petroleum fuel on skin or clothing. Liquid petroleum fuel products remove protective oils from the skin, causing drying, chapping, and cracking. Swallowed liquid petroleum fuel products may cause central nervous system depression and pneumonia.

2-2.3.2.1 Liquid Petroleum Fuel Contact/Ingestion First Aid.

External Contact: Remove contaminated clothing at once and avoid any source of ignition. Remove liquid petroleum fuel products from the skin by washing with soap and water as soon as possible after contact. Remove liquid petroleum fuel that comes in contact with eyes immediately with an eyewash or other available means of flushing the eye with water. Obtain medical attention as soon as possible after exposure to liquid petroleum fuel. Do not expose a person to flame producing activities once they have been contaminated with liquid petroleum fuel.

Ingestion: Do not induce vomiting except as directed by physician, as uncontrolled vomiting may cause liquid petroleum fuel to go into the lungs. A person that has ingested liquid petroleum fuel should be taken to a medical facility at once. Be sure to inform medical administrators of the type and approximate amount of liquid petroleum fuel ingested.

2-2.3.3 Solids.

Dusts are formed by additives in petroleum fuel products remaining after the volatile liquids have evaporated. Solid particles in sludge may be dispersed as the sludge dries. Dust can also result from scale, sandblast, and rust particles removed from tank walls and strainers during cleaning operations. Consult the Installation Environmental Office for proper procedures for sludge and solid waste cleaning and disposal.

2-2.3.3.1 Solids Contact/Inhalation First Aid.

Solids will enter the body through inhalation of contaminated dust particles. Treat bodily contact with dust as you would with liquid petroleum fuels (Section 2-2.3.2.1) and inhalation of dust as you would with petroleum fuel vapors (Section 2-2.3.1.1). Seek immediate medical attention.

\1\ 2-2.4 Confined Spaces.

A confined space is a space large enough and configured so personnel can bodily enter and perform assigned work, has limited or restricted means for entry or exit, and is not designed for continuous human occupancy. Examples include tanks, pits, manholes, etc.

2-2.4.1 Construction Activities.

Employees engaged in construction activities at a worksite with one or more confined spaces must comply with 29 CFR 1926, Subpart AA, state, local and installation requirements.

2-2.4.2 Hazards.

Personnel entering or working in confined spaces may encounter a number of potentially serious hazards. These hazards may include atmospheric hazards such as oxygen deficiency insufficient to support life, oxygen-enriched levels that increase the danger of fire or explosion, flammable or explosive atmospheres and materials, or toxic gases or materials. In addition, the confined space may include electrical, mechanical, engulfment or entrapment hazards that must be locked out, or controlled by other means of securing hazardous energy. Many of these hazards are not readily apparent, nor detectable by odor, or by sight, which may result in workers entering confined spaces without adequate consideration of potential dangers. Workers must consider that all confined spaces may contain unfavorable and unsafe conditions and must not enter or work in these spaces until tests, evaluation, and locally-developed procedures are performed to ensure safe conditions exist prior to entry and are maintained during the entire work period. /1/

\2\ 2-2.4.3 Two-Person Policy.

Ensure two people are present when entering confined spaces, performing maintenance on fuel systems and tanks, or in and around fuel facilities. /2/

2-3 ELECTRICAL SAFETY.

This section provides general information related to electrical safety with regard to maintenance operations, static electricity, stray electric currents, hazardous locations, and power generators. These hazards must be considered when handling and dispensing petroleum products. See National Fire Protection Association (NFPA) 70, National Electrical Code, for the practical safeguarding of persons and property from hazards arising from the use of electricity. See NFPA 70E, Standard for Electrical

Safety in the Workplace, for electrical safety requirements for employee workplaces that are necessary for the practical safeguarding of employees in their pursuit of gainful employment. See NFPA 77, for additional guidance on static electricity hazards.

2-3.1 Lockout/Tagout.

An electrically safe work condition must be established while operating or performing maintenance on electrical equipment, regardless of whether the equipment is energized or de-energized. NFPA 70E includes detailed information on safety-related work practices, safety-related maintenance requirements, and installation safety requirements.

Establishing and following lockout/tagout procedures is essential for the safe execution of maintenance work on electrical equipment. While specific lockout/tagout procedures can differ from site to site, they must abide by the general principles outlined in NFPA 70E, Article 120, Section 120.2(B). In general, all sources of electrical energy must be controlled in such a way as to minimize personnel exposure to electrical hazards. NFPA 70E also includes Annex G, “Sample Lockout/Tagout Procedure,” which can be used as a basis for establishing a site specific procedure.

2-3.2 Static Charges.

Low-conductivity liquids, such as jet fuel and gasoline, become electrostatically charged while flowing through petroleum fuel systems and during transport in barges, tanker trucks, rail cars and other fuel transport systems. This can produce enough electrical energy to cause ignition, fire, or explosion of petroleum fuel vapor-air mixtures above the liquid petroleum fuel surface.

Grounding and bonding components of petroleum fuel facilities are important to prevent ignition, fire and explosion. All petroleum fuel system components must be bonded and grounded to dissipate static electric charges and stray electrical currents that can discharge in the form of an electric arc. Bonding across flanges is not required provided they are not electrically insulated. UFC 3-460-01, Section \1\ 2-11.3 /1/, includes information on grounding petroleum fuel system equipment in order to prevent the accumulation of static electricity.

2-3.2.1 Personnel Static Prevention Requirements.

Personnel must periodically ground themselves to pump house structures, tanks, and equipment by making firm contact with attached grounding bars or approved grounding points. Personnel must not put on or remove garments while conducting petroleum fuel handling operations.

Personnel must ground sampling devices to grounding bars or approved grounding points before collecting petroleum fuel samples.

2-3.3 Electrical Currents.

Electrical currents originate in generators, transmission systems, wiring, and electrical devices. They are more dangerous than static electric charges because of the continuous electric spark that can be created versus the brief electric spark created by a static electric discharge. Verify all electrical work on petroleum fuel storage and dispensing systems complies with NFPA 70, 501, Class I Locations to reduce electrical current hazards.

2-3.3.1 Stray Currents.

Stray currents flow through unintended paths or are extraneous current in the earth.

Sources of stray currents include electric railways, electric power systems, electric welders, cathodic protection systems, and aircraft aeronautics electrical equipment malfunctions. Since many fixed petroleum fuel systems are in intimate earth contact, stray currents can take paths through the conducting parts of petroleum fuel systems.

Stray currents can cause electric arcs that may ignite combustible petroleum fuel vapor-air mixtures.

\1\ 2-3.3.1.1 Fuel System Grounding Requirements.

Ground systems used to dissipate static electric charges also reduce stray electric current hazards. These systems provide a path to conduct stray electric currents into the earth without arcing.

2-3.3.1.2 Tank Car Loading and Unloading Requirements.

Railroad spurs used for loading and unloading tank cars should be insulated from the main line rails, ensuring isolation from stray currents that may flow in the main line rails.

2-3.3.1.3 Marine Terminal Requirements.

Stray currents from cathodic protection systems at marine terminals require special attention. These systems protect piping and steel piers and cause current flow in the water. Steel hull vessels act as a conductor of these currents. The ship-to-shore fuel-handling hose will act as a conductor and will complete a low-resistance circuit from the vessel to shore-side piping. Arcs may occur between the vessel and the hose when the hose is connected, disconnected, or brought into contact with the vessel's deck. Arcing can be prevented by connecting a bonding cable between shore-side piping and the vessel before operations begin. A switch on the shore side wired inline with the bonding cable must be closed after the cable connection is made and before the petroleum fuel handling hose is taken aboard the vessel.

2-3.3.1.4 Piping Requirements.

Stray current may flow through petroleum fuel piping systems because their electrical resistance is low compared to the surrounding earth. Removal of piping or components will interrupt the continuity of the petroleum fuel system. A bonding jumper wire must be installed prior to removal of piping or components and must remain in place until the items are replaced. Installing a jumper will prevent an arc when the piping or components are removed or replaced.

/1/

2-3.4 Hazardous Location Classification.

NFPA 70 defines hazardous locations including areas where fire or explosion hazards may exist due to flammable gases or vapors, flammable liquids, flammable liquid produced vapors, combustible liquids produced vapors, and combustible dust.

Hazardous locations are classified in three ways: Type (Class), Condition (Division), and Nature (Group). Petroleum fuel facilities are Class 1 where flammable gases or vapors may be present in the air in sufficient quantities to be explosive or ignitable.

Class 1 is divided into two divisions. Division 1 areas include environments where the hazard is to be expected under normal operating conditions, and Division 2 areas include environments where the hazard is not normally present in an explosive concentration or present only through accidental rupture, breakage or unusual faulty operation. The National Electrical Code (NEC) further defines the nature or “group” of the hazardous substance. Most petroleum fuel facilities will fall under Group D:

hydrocarbons, fuels, solvents. Personnel must ensure that all electrical components and equipment installed, operated or replaced meet the required hazardous classification for the intended environment. Refer to UFC 3-460-01 for additional hazardous location information.

2-4 PETROLEUM FUEL QUALITY.

Every type and grade of petroleum fuel or lubricant has been specifically formulated to provide the most satisfactory and economic performance possible for a particular engine, under the operating conditions for which it was designed. Petroleum fuels or lubricants that have become contaminated or have degraded, can cause fires, explosions, injuries, loss of life, and loss of valuable machinery and equipment.

Petroleum fuel product suspected of being contaminated must be reported to the military service-specific SCP.

2-4.1 Water Contamination.

Water contamination usually occurs during the transportation and storage of petroleum fuel. Water contamination is the most common form of contamination and may take one of the following three forms.

\1\ 2-4.1.1 Free Water.

Free water consists of relatively large drops of water which, if left undisturbed, will settle to the bottom of the container. In low density petroleum fuel products with low viscosity, free water settlement can be quite rapid, but in higher density or more viscous petroleum fuel products, settlement will take longer. Some petroleum fuels contain anti-corrosive or cleaning agents otherwise known as surfactants, which tend to prevent the settlement of free water.

2-4.1.2 Dissolved Water.

In this state, the water is invisible, and the petroleum fuel appears to be clear; but a drop in temperature may cause dissolved water to separate from the petroleum fuel in tiny droplets that remain suspended and give the petroleum fuel a cloudy appearance.

2-4.1.3 Emulsified Water.

Emulsions are mechanical dispersion of petroleum fuel and water having a frothy appearance. Emulsions can be very stable and hard to separate. Separation may require special mechanical and chemical treatments.

/1/

2-4.2 Prevention and Removal of Water Contamination.

a. Operate sump drains on tanks, filter separators, and other vessels and equipment and check for free water on a daily basis when the systems are operated.

b. During petroleum fuel flow operations, observe filter separator differential pressure gauges and be sure units are functioning properly.

c. Ensure that operator and system maintenance is properly performed.

d. Newly received aviation petroleum fuels must be allowed to stand undisturbed in receiving tanks to permit settlement of free water before product is dispensed. Aviation petroleum fuel must be allowed to stand for 1 hour per 1 foot (0.31 m) of liquid level rise in storage tanks up to a maximum standing time of 24 hours or in accordance with undisturbed standing time allowed by military service-specific established procedure or policy. Ground vehicle petroleum fuels do not require settlement time before they are dispensed.

e. When field fabricated aboveground vertical tanks are available for entry, they must be inspected for unintended low spots and repaired as required to eliminate unintended low spots which could collect free water.

f. Tank roofs, seals, and fittings of all types must be maintained in good, weather-tight condition.

g. Testing and inspections required for tanks and underground piping must be followed and documented. If unexplained accumulation of water is detected, the underground petroleum fuel tank(s) suspected of leaking must be tested using a temperature-controlled, hydrostatic stand-pipe test.

Underground petroleum fuel piping suspected of leaking must be isolated and subjected to the applicable underground piping annual test as described in Appendix G - Petroleum Fuel Pipeline Pressure Testing Guidelines and Criteria.

2-4.3 Solid Matter Contamination.

Iron rust, scale, sand, and airborne dirt are examples of solid matter contamination most prevalent in petroleum fuel. The principal source of iron rust is corrosion in pipelines, storage tanks, or other inline steel components. Sand and dirt are particularly serious in extremely sandy or dusty areas where they may accumulate around tank gauge hatches, tank manways, or other openings and enter the tank when the covers are removed. The presence of large amounts of particulate matter in petroleum fuel results in restricting or clogging of filter separators, silting and plugging of fuel control components and nozzles, and wear and scoring of petroleum fuel system components by abrasion.

2-4.4 Prevention and Removal of Solids Contamination.

a. Brush away or remove accumulated dirt or…