SOW Fuel Blivets.pdf

Statement of Work FY24

Fuel Blivets

Joint Base McGuire-Dix-Lakehurst

1. General The contractor shall provide non-vented cylindrical, 500-gallon capacity, collapsible rubber drum, primarily used for storage and transport of liquid fuel as current blivets are approaching the end of their service life.

2. Scope of Work Per AFMAN 24-604 Preparing Hazardous Materials for Military Air Shipments, Paragraph A7.2.7, “MIL-D-23119 500-gallon capacity collapsible fabric drums authorized under mobility operations conducted according to DTR 4500.9-R, Part III”. As such, these drums need to meet the following saliant characteristics:

2.1 DIMENSIONS

2.2.2 62 inches long X 52 inches wide (commonly known as a “shortie” fuel drum)

2.2 FUEL CAPACITY

2.2.1 Drums must be capable of holding a maximum of 500 gallons of liquid fuel.

2.2.2 Blivets must be capable of being filled to maximum capacity while fitted inside the Wel-Fab WFI-500 Overpack Containers. These containers are approved for use aboard C-130, C-141, C-17, and C-5 aircraft for secondary containment by the Air Transportation Test Loading Activity (ATTLA) Office. Any blivets that cannot be filled to maximum capacity while fitted inside the secondary containment unit will not be considered technically acceptable.

2.3 MATERIAL

2.3.1 Inner Liner Compound. The inner liner rubber compound shall conform to

ASTM D 2000, composition M5BC610A14EF21. The maximum volume swell requirement under EF21 shall be 35 percent. (reference: MIL-D-23119G, para 3.3.1)

2.3.2 Outer Cover Compound. The outer cover rubber compound shall conform to ASTM D 2000, composition M5BC610A14EF21. The maximum volume swell requirement under EF21 shall be 40 percent when tested in accordance with table 4 of ASTM D 2000 (reference: MIL-D-23119G, para 3.3.2).

2.3.3 Cord or Fabric Rubber Compound. The cord or fabric rubber compound shall conform to ASTM D 2000, composition M5BG610A14EF21. The maximum volume swell requirement under EF21 shall be 40 percent (reference: MIL-D- 23119G, para 3.3.3)

2.4 CONSTRUCTION

2.4.1 Body Drum. The drum shall be cord or fabric reinforced rubber construction, with an inner liner of material as specified in 4.1.1, and an outer cover of material as specified in 4.1.2. The cord or fabric reinforced center layer shall be impregnated with rubber compound as specified in 4.1.3. After complete fabrication and prior to assembly of the drum, the inside and outside shall be cleaned of all foreign material. The color of the outer surface shall be black.

2.4.2 Fuel/Defuel Valve. Valve(s) shall be capable of performing the fueling/defueling cycle to either shut off flow to the drum upon reaching an internal pressure of

4.5 ±0.5 pounds per square inch gage (PSIG) above local atmospheric pressure, or to open upon the application of a negative pressure at the adapter inlet. The fuel/defuel valve shall neither extend externally more than 1.125 inches beyond the bearing plate nor extend internally more than 3.250 inches beyond the inside face of the closure plate. All surfaces of the valve that shall contact the drum wall shall be smooth and rounded with no sharp edges or a radius smaller than 0.5 inch. The weigh of the valve shall not be more than 5.25 pounds. The dust cap shall be tethered to the fuel/defuel valve be means of a cable, chain, or other suitable means.

2.4.3 Sleeve and Rope Assembly. The sleeve and wire rope assembly shall have a breaking strength of not less than 12,000 lbs.

2.5 PHYSICAL CHARACTERISTICS

2.5.1 Permeability of Fluid. The permeability rate of reference fuel B through the drum wall shall not be more than 0.10 fluid ounce per square foot per 24 hours (fl oz/sq ft/24 hrs) when tested in accordance with 3.4.1.1.

2.5.2 Unwashed gum. The existent (unwashed) gum content shall be no more than 60 mg/100 mL when tested in accordance with 3.4.1.2.

2.5.3 Existent gum. The heptane-washed existent gum content shall be no more than 5 mg/100 mL when tested in accordance with 3.4.1.3.

2.5.4 Puncture Resistance. the drum wall (excluding the reinforced ends) shall withstand a force of not less than 325 pounds without being punctured when tested in accordance with 3.4.1.4.

2.5.5 Adhesion. The adhesion between the cover and cord plies, between cord plies, and between the liner and cord plies shall be 10 pounds per inch (lbs/in) minimum when tested in accordance with 3.4.1.5. The adhesion after immersion in fuel between the liner and cord plies and between cord plies shall be 5 pounds per inch (lbs/in) minimum when tested in accordance with 3.4.1.5.

2.5.6 Expansion Dimensions. Drum dimensional changes shall be not more than the following, when subjected to a pressure of 30 pounds per square inch gage (PSIG) for 7 hours, when tested in accordance with 3.4.2.1.

a. Overall Length – 1 inch.

b. Diameter – 5 inches.

2.5.7 Weight. The weight of the completely assembled drum when tested in accordance with 3.4.2.2 shall not be more than 3770 pounds maximum.

2.6 PERFORMANCE

2.6.1 Hydraulic Pressure Test. The drum shall withstand a hydraulic pressure test of

45 PSIG, without any visual evidence of leakage, loss of pressure, external or internal component layer separation, delamination, or blistering when tested in accordance with 3.4.2.3.

2.6.2 Proof Pressure. Each drum shall withstand the proof pressure of 30 PSIG without any visual evidence of leakage, inner liner separation, delamination, cracks, or splits when tested in accordance with 3.4.2.4.

2.6.3 Fuel Storage. The drum shall withstand the 72 hour fuel storage test without any visual evidence of leakage, inner liner separation, cracks, splits, or deterioration when tested in accordance with 3.4.2.5.1.

2.6.4 Airdrop. The drum shall withstand six succussive airdrops from a height not less than 12.7 feet without any visual evidence of leakage when tested in accordance with 3,4.2.5.2.

2.6.5 Rolling Tow Test. The drum shall be capable of being towed as a wheel for 10 miles over paved road without any visual evidence of leakage when tested in accordance with 3.4.2.5.3.

2.6.6 Low Temperature Collapsibility. The drum shall be collapsible and capable of being emptied at -30 ±2 °F, with not more than 20 gallons of gasoline remaining in the emptied drum. The drum shall show no visual evidence of leakage, blistering, delamination, splits, or cracks, chipping, or sloughing when tested in accordance with 3.4.2.5.4.

2.6.7 Ambient Temperature Collapsibility. The drum shall be filled and emptied through 75 cycles, without any visual evidence of leakage, external or internal blistering, delamination, splits, cracks, or chipping when tested in accordance with 3.4.2.5.5.

2.6.8 Leakage. The drum shall withstand the leakage test specified in 3.4.2.5.6.

without any visual evidence of leakage.

3. Testing and Quality Assurance.

All of the following Testing and Quality Assurance guidance is sourced from MILSPEC MIL-D- 23119G and should be referred to for any additional references and supplements.

The inspection set forth in this Statement of Work shall become a part of the contractor’s overall inspection system or quality program and be completed prior to delivery. The absence of any inspection requirements in the Statement of Work shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to acceptance of defective material.

The contractor is responsible for ensuring that components and materials used are manufactured, examined, and tested in accordance with referenced specifications, standards, and drawings, prior to delivery.

The contractor shall ensure the fuel drums are free of operational defects at the time of pickup and either repair or replace any part of the product that proves defective by reason of improper workmanship or materials for a period of 365 days from date of delivery. Repaired parts or replacement products will be provided by the contractor on an exchange basis and will be either new or refurbished to be functionally equivalent to new. If the contractor is unable to repair or replace the fuel drum, they will provide a suitable replacement.

3.1 FIRST ARTICLE INSPECTION

3.1.1 Examination. The first article drums shall be examined as specified in 3.3.1.

Presence of one or more defects shall be cause for rejection.

3.1.2 Tests. The first article drums and material samples shall be subjected to tests marked “X” in column 1 of table 1. Every test specified in 3.4.2, except 3.4.2.4 and 3.4.2.5.6, shall be conducted on one of three drums so that approximately one-third of the tests shall be performed on each drum. Tests specified in

3.4.2.4 and 3.4.2.5.6 shall be conducted on each of three drums. All tests specified in 3.4.1 shall be performed on the material samples. The material samples shall be representative of materials used to fabricate the drum body.

Failure of any tests shall be cause for rejection.

3.2 QUALITY CONFORMANCE INSPECTION

3.2.1 Lot. A lot shall consist of not more than 300 drums or one month’s production of the same type, each drum having successfully passed the tests specified in 3.2.4.1.

3.2.2 Sampling for Examination and Tests

3.2.2.1 Drums. Three drums shall be selected at random from each lot for tests. A lot shall be accepted when zero defects are found and rejected when one or more defects are found.

3.2.2.2 Drum Body Material. One sample of drum body material approximately 2-foot square and of the approximate thickness of the drum body shall be prepared from the rubber compounds and cord or fabric used in fabricating the drums of the lot. The drum body material sample shall be cured equivalent to the drums.

3.2.3 Examination. All three drums selected (see 3.2.2.1) shell be examined as specified in 3.3.1. Presence of one or more defects shall be cause for rejection.

3.2.4 Tests

3.2.4.1 Individual. Each drum shall be subjected to the tests marked “X” in column

2 of Appendix A. Failure any test shall be cause for rejection of the drum.

3.2.4.2 Samples.

3.2.4.2.1 Drums. Drums selected in accordance with 3.2.2 shall be subjected to tests marked “X” in column 3 of Appendix A as follows: One of the drums shall be tested as specified in 3.4.2.2 and 3.4.2.3. The remaining two drums shall be tested as specified in 3.4.2.5 and

3.4.2.1. Failure of any test shall be cause for rejection of the represented lot of drums.

3.2.4.2.2 Drum Material Samples. Samples selected in accordance with 3.2.2 shall be tested as specified in 3.4.1.1 and 3.4.1.5. Failure of any test shall be cause for rejection of the represented drums.

3.3 INSPECTION PROCEDURE

3.3.1 Examination. The drum shall be examined as specified herein for the following defects:

A. Components fractured, split, sprung, malformed, or missing.

B. Material not as specified.

C. Inner liner rubber compound not as specified.

D. Outer cover rubber compound not as specified.

E. Cord or fabric rubber compound not as specified.

F. Used, Rebuilt, or remanufactured components, pieces and parts incorporated in the drum.

G. Drum body not as specified.

H. Fittings not as specified.

I. Finish of fittings not as specified.

J. Inside and outside of drum not cleaned of all foreign materials.

K. Color not specified.

3.4 TESTS

3.4.1 Drum Material Sample. The drum material sample shall be tested as follows:

3.4.1.1 Permeability Test. The permeability test shall be conducted in accordance with ASIM D 814, except that the sample shall be identical in construction and material to the total cross section of the drum and of the thickness of the drum wall. This test may be performed using an aluminum cup with a suitable clamping device in lieu of the permeability jar specified in ASTM D

814. The test liquid shall be ASTM D 471, reference fuel B. If aluminum cups are used, a nylon solution (Elvamide 8061) can be used to seal the edges.

The average of three determinations shall be reported. Nonconformance to

2.5.1 shall constitute failure of this test.

3.4.1.2 Unwashed Gum. Cut a 5 gram specimen from the drum interior coating compound into 0.0635 inch squares and place in a flask containing 250 mL of ASTM D 471 reference fuel B and allow to stand for 48 hours at 73 ±3 °F.

Decant and filet the contaminated fluid through Whatmen 41H filter paper, or equal. Determine the unwashed gum in accordance with section 10 of ASTM D 381 using the air jet vaporizing medium and an evaporation time of 45 minutes. The average of three determinations shall be reported.

Nonconformance to 2.5.2 shall constitute failure of this test.

3.4.1.3 Existent Gum. Samples from 3.4.1.2 may be used to determine the heptane-washed existent gum in accordance with Section 10 of ASTM D 381. The average of three determinations shall be reported. Nonconformance to

2.5.3 shall constitute failure of this test.

3.4.1.4 Puncture Resistance Test. The drum wall (excluding the reinforced ends) shall be puncture tested as specified in MIL-T-6396, except that the force required shall be 325 pounds. The average of three determinations shall be reported. Nonconformance to 2.5.4 shall constitute failure of this test.

3.4.1.5 Adhesion test. One set of drum material samples shall be tested in accordance with ASTM D 751 for a minimum adhesion of 10lbs/in. between the cover and cord plies. Between cord plies, and between the liner and cord plies. A second set of drum material samples shall be immersed in ASTM reference fuel B at 73°F for 70 hours. After immersion the samples shall be tested in accordance with ASTM D 751 for a minimum adhesion of 5lbs/in. between the liner and cord plies and between cord plies.

Nonconformance to 2.5.5 shall constitute failure of this test.

3.4.2 Drums.

3.4.2.1 Expansion Test. The drum shall be filled with water to a pressure of 30 PSIG.

The length and diameter shall be measured within 15 minutes. The length shall be measured by placing a 90 degree square upright at each end and measuring the distance between the squares. The diameter shall be similarly measured by placing the square upright against each side at the center of the drum and measuring the distance between squares. These measurements shall be the original dimensions. The drum shall be maintained at 30 PSIG for 7 hours; at the end of the 7 hours the measurements of length and diameter shall be repeated as previously described. The difference between these final measurements and the original measurements shall be regarded as the changes in dimensions.

Nonconformance to 2.5.6 shall constitute failure of this test.

3.4.2.2 Weight Test. The emptied drum with hardware shall be weighed.

Nonconformance to 2.5.7 shall constitute failure of this test.

3.4.2.3 Hydraulic Pressure Test. The drum shall be filled with water and subjected to pressure of 45 PSIG for 30 minutes to determine compliance with 2.6.1.

The test pressure must be applied continuously and evenly and must be constant throughout the test period. After performance of the hydraulic pressure test, the drum shall be emptied and visually examined, both externally and internally. Nonconformance to 2.6.1 shall constitute failure of this test.

3.4.2.4 Proof Pressure Test. Each drum shall be subjected to a hydrostatic pressure of 30 PSIG and allowed to stand for 30 minutes. At the end of 5 minutes, the pressure shall be readjusted to 30 PSIG if the pressure has dropped due to expansion of the drum. Nonconformance to 2.6.2 shall constitute failure of this test.

3.4.2.5 Fuel Storage and Airdrop Tests

3.4.2.5.1 Fuel Storage Test. The drum shall be filled with a minimum of 450 gallons of gasoline conforming to MIL-G-46015, type I and allowed to stand for a period of 72 hours at ambient temperature (40-90°F).

At the end of each 24 hour period the drum shall be rotated 180 degrees and then examined for leakage. After completion of the 72 hour period the drum shall be emptied and the hardware shall be removed for visual examination of the inner liner. Nonconformance to 2.6.3 shall constitute failure of this test. The gasoline will be analyzed for existent and unwashed gum levels both before and after the storage and the results reported.

3.4.2.5.2 Airdrop Test. After completion of the fuel storage test, the drum shall be reassembled and refilled with a minimum of 450 gallons of fluid having a specific gravity of between 0.72 and 1.00. The drum shall then be lifted by the two anchor shackles on the fill end until the opposite end has a minimum ground clearance of 12.7 feet. The drum shall then free fall onto unprepared ground such as grass, sand, or bare earth. The soil shall not contain excessive water to form a viscous liquid. This drop procedure shall be repeated until a total of 3 consecutive drops are recorded. The drum shall then be lifted within its cylindrical side parallel to the ground to a height of not less than 12.7 feet. This heigh shall be measured from the lowest point on the bottom of the drum to the ground. The drum shall then free fall onto the unprepared ground such as grass, sand, or bare earth. The solid shall not contain excessive water to form a viscous liquid. The drop procedure shall repeated until a total of 3 consecutive drops are recorded. After completing the 6 airdrops, the drum shall be visually examined for leaks; then emptied and visually examined, internally and externally, for evidence of broken hardware and separation of component layers of the drum body.

Nonconformance to 2.6.4 shall constitute failure of this test.

3.4.2.5.3 Rolling Tow Test. The drum shall be filled with a minimum of 350 gallons of water. A tow bar conforming to MIL-Y-4062B shall be attached to the lugs, and the drum shall be towed as a wheel for not less than 10 miles over a paved road. The rate of speed of towing shall be between 5 to 10 miles per hour (mph). Nonconformance to

2.6.5 shall constitute failure of this test.

3.4.2.5.4 Low Temperature Collapsibility Test. The emptied drum shall be cooled to -30 ±2 °F and filled with a measured 460 gallons of gasoline conforming to MIL-G-46015, type I which has been cooled to -30 ±2 °F. The drum shall then be emptied of not less than 440 gallons of gasoline using a suitable pump and subjected to a minimum vacuum of 12 inches of mercury (Hg). This test shall be conducted at -30 ±2 °F with the drum in a horizontal position.

Nonconformance to 2.6.6 shall constitute failure of this test.

3.4.2.5.5 Ambient Temperature Collapsibility Test. The empty drum shall be filled with 460 gallons of gasoline conforming to MIL-G-46015, type I. The drum shall then be emptied of not less than 435 gallons of gasoline using a suitable pump and the drum subjected to a minimum vacuum of 12 inches HG. This test shall be conducted at ambient temperature with the drum in a horizontal position. The drum shall be filled and emptied 75 times. The drum hardware shall be disassembled for examination of the drum internal carcass.

Nonconformance to 2.6.7 shall constitute failure of this test.

3.4.2.5.6 Leakage Test. Each drum shall be inflated with air to 6 ±0.5 PSIG, and sprayed with soap or detergent sudsing solution over the entire surface to determine compliance with 2.6.8. Leakage shall be determined by observing areas for bubbling of sudsing solution.

3.4.2.5.7 Fuel/Defuel Valve Test This test shall be performed by installing the fuel/defuel valve in a representative drum. The drum shall be filled to capacity at a flow rate of 200 gallons per minute (gpm) minimum and line pressure of 55 to 60 PSIF at the nozzle inlet with a D-1 nozzle. Upon completion of filling, the pressure within the drum shall be observed to determine compliance with 2.4.2. The drum shall then be defuled by means of the D-1 nozzle to determine proper opening of the valve. Nonconformance to 2.4.2 shall constitute failure of this test.

3.4.2.5.8 Sleeve and Wire Rope Assembly Test. The sleeve and wire rope assembly shall be tested in accordance with ASTM E 8.

Nonconformance to 2.4.3 shall constitute failure of this test.

4. Deliverables

a. Delivery shall occur within 90 days of award.

b. POC for this request is MSgt Craig Bennett

i. Telephone: 609-754-7436

ii. Email: craig.bennett.3@us.af.mil

iii. Address: Bldg 1907, McGuire AFB, NJ 08641

Appendix A

Test Schedule

First Article

Quality Conformance

Test Test Paragraph

Requirement Paragraph

Individual Sample 1 2 3 4 5 6 X - X Permeability 3.4.1.1 2.5.1 X - X Unwashed Gum 3.4.1.2 2.5.2 X - X Existent Gum 3.4.1.3 2.5.3 X - X Puncture Resistance 3.4.1.4 2.5.4 X - X Adhesion 3.4.1.5 2.5.5 X - X Expansion 3.4.2.1 2.5.6 X - X Weight 3.4.2.2 2.5.7 X - X Hydraulic Pressure 3.4.2.3 2.6.1 X X - Proof Pressure 3.4.2.4 2.6.2 X - X Fuel Storage 3.4.2.5.1 2.6.3 X - X Airdrop 3.4.2.5.2 2.6.4 X - - Rolling Tow 3.4.2.5.3 2.6.5 X - - Low Temperature Collapsibility 3.4.2.5.4 2.6.6 X - - Ambient Temperature Collapsibility 3.4.2.5.5 2.6.7 X X - Leakage Assembly 3.4.2.5.6 2.6.8 X - X Fuel/Defuel Valve 3.4.2.5.7 2.4.2 X - X Sleeve and Wire Rope Assembly 3.4.2.5.8 2.4.3 mailto:craig.bennett.3@us