Technicalorder42B-1-1.pdf

T.O. 42B-1-1

TECHNICAL MANUAL

QUALITY CONTROL OF FUELS

AND LUBRICANTS

(ATOS)

F41608-90-D-1819

Prepared By: TRI-COR Industries, Inc.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Requests for this document must be referred to DET 3, WR-ALC/AFTT, 2430 C Street, Bldg 70, Area B, Wright-Patterson AFB, OH 45433-7632. PA Case Number AFMC 04-405. Submit recommended changes or problems with this Technical Order to WR-ALC/AFTT.

HANDLING AND DESTRUCTION NOTICE: Handle in compliance with the distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

1 AUGUST 2004 CHANGE 3 - 31 JULY 2006

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . 1 August 2004 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . 15 March 2006 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . 1 June 2005 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 31 July 2006

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 134, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title . . . . . . . . . . . . . . . . . . . . . . . . . 3 5-20 - 5-21 . . . . . . . . . . . . . . . . . . . 0 C-1 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5-22 . . . . . . . . . . . . . . . . . . . . . . . . . 2 C-2 Blank i - iii . . . . . . . . . . . . . . . . . . . . . . . . . 2 5-23 . . . . . . . . . . . . . . . . . . . . . . . . . 0 D-1 - D-2 iv Blank . . . . . . . . . . . . . . . . . . . . . . 2 5-24 v - vi . . . . . . . . . . . . . . . . . . . . . . . . 0 5-25 - 5-26 1-1 - 1-2 . . . . . . . . . . . . . . . . . . . . . 1 5-27 - 5-28 2-1 - 2-2 . . . . . . . . . . . . . . . . . . . . . 3 5-29 - 5-36 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-37 2-4 Blank . . . . . . . . . . . . . . . . . . . . 0 5-38 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6-1 - 6-2 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6-3 3-2.1 Added . . . . . . . . . . . . . . . . . . 1 6-4 3-2.2 Blank . . . . . . . . . . . . . . . . . . . 1 6-5 - 6-6 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6.1 3-4 - 3-5 . . . . . . . . . . . . . . . . . . . . . 2 6-6.2 Blank 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6-7 3-6.1 . . . . . . . . . . . . . . . . . . . . . . . . 3 6-8 3-6.2 Blank . . . . . . . . . . . . . . . . . . 3 6-9 - 6-11 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6-12 Blank 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6-13 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6-14 Blank 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-1 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7-2 - 7-3 4-2 - 4-3 . . . . . . . . . . . . . . . . . . . . . 2 7-4 Blank 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8-1 - 8-2 4-5 - 4-6 . . . . . . . . . . . . . . . . . . . . . 1 8-2.1 Added 4-7 - 4-10 . . . . . . . . . . . . . . . . . . . . 0 8-2.2 Blank 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8-3 - 8-4 5-2 - 5-3 . . . . . . . . . . . . . . . . . . . . . 2 8-5 - 8-9 5-4 - 5-6 . . . . . . . . . . . . . . . . . . . . . 3 8-10 5-6.1 Added . . . . . . . . . . . . . . . . . . 2 A-1 - A-4 5-6.2 Blank . . . . . . . . . . . . . . . . . . . 2 A-5 5-7 - 5-8 . . . . . . . . . . . . . . . . . . . . . 1 A-6 - A-7 5-9 - 5-10 . . . . . . . . . . . . . . . . . . . . 0 A-8 5-11 - 5-12 . . . . . . . . . . . . . . . . . . . 2 A-9 - A-13 5-13 - 5-15 . . . . . . . . . . . . . . . . . . . 1 A-14 Blank 5-16 . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-1 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . 3 B-2 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-3 - B-4 5-19 . . . . . . . . . . . . . . . . . . . . . . . . . 1 B-5 - B-6

*Zero in this column indicates an original page

A Change 3 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iii 4 SAMPLE SUBMISSION TO OFF-BASE

LABORATORIES................................................4-1

LIST OF TABLES......................................................iii 4.1 General........................................................4-1

4.2 Sample Submission.....................................4-1

4.3 Types of Samples .......................................4-1

INTRODUCTION........................................................v 4.4 Turbine Fuel Correlation/Aircraft Servicing Sample ...................................4-2

4.5 Samples of Dormant Stocks.......................4-2SAFETY SUMMARY................................................vi

4.6 Shipping Containers ...................................4-3

4.7 Marking and Identifying Samples..............4-3

4.8 Sampling Equipment ..................................4-31 GENERAL ................................................................1-1

4.9 General Sampling Procedures ....................4-3

4.10 Fuel and Oil Samples from1.1 General Safety and Environment

Crashed Aircraft.....................................4-4Considerations........................................1-1

4.11 Class A Incident .........................................4-41.2 Temperature Control...................................1-1

1.3 Responsibilities for Fuel Quality ...............1-1

5 QUALITY CONTROL OF AVIATION1.4 Quality Assurance at Origin.......................1-1

FUELS..................................................................5-11.5 Quality Surveillance at Base Level.......................................................1-1

5.1 General........................................................5-11.6 DET 3, WR-ALC/AFT Technical

5.2 Laboratory Technician Qualifica-Division..................................................1-2 tions ........................................................5-11.7 List of Forms ..............................................1-2

5.3 Sampling and Testing.................................5-1

5.4 Product Receipt — Aviation Fuel ............5-12 AVIATION FUELS..................................................2-1

5.5 Sampling Requirements and Test

Limits .....................................................5-32.1 Turbine Fuels..............................................2-1

5.6 Sampling and Test Procedures for2.2 Aviation Gasoline (AVGAS) .....................2-1

Solids......................................................5-32.3 Fuel Additives.............................................2-2

5.7 Color and Particle Assessment

Method ...................................................5-43 FUEL HANDLING ..................................................3-1

5.8 Matched-Weight Monitor Method ............5-5

5.9 Bottle Method .............................................5-63.1 Scope...........................................................3-1

5.10 Free Water Determination..........................5-83.2 Responsibilities ...........................................3-1

5.11 FSII Test Procedures ................................5-103.3 Strainers ......................................................3-1

5.12 Conductivity Additive Test Proce-3.4 Filters/Filter Separators ..............................3-1 dures .....................................................5-113.5 Tanks...........................................................3-2

5.13 Fibers Test Procedures .............................5-123.6 Tank Inspections and Cleaning..................3-3

5.14 Flash Point ................................................5-123.7 Product Settling ..........................................3-3

5.15 Detection of Heavy Hydrocarbons3.8 Contamination.............................................3-3 in AVGAS ...........................................5-143.9 Water...........................................................3-4

5.16 Procedures for Aircraft Sump3.10 Solid Contaminants.....................................3-4

Samples ................................................5-143.11 Line Displacement......................................3-4

5.17 Aircraft Electrostatic Fire Incident ..........5-153.12 Identification and Marking of Fuel

5.18 Procedures for Soaking, Flushing,Handling Systems ..................................3-4 and Sampling New Hose.....................5-153.13 Servicing Controls ......................................3-5

5.19 API Gravity Determination ......................5-153.14 Converting Refueling Units from

5.20 Visual Inspection Procedure.....................5-16One Product to Another ........................3-5

5.21 Microscopic Analysis ...............................5-163.15 Recovering, Blending or Down-

5.22 Disposition of Samples.............................5-16Grading Petroleum Products..................3-5

5.23 Record of Laboratory Results ..................5-163.16 Defueling Aircraft/Bowsers........................3-6

5.24 Cleaning Glassware ..................................5-163.17 Multi-Product Pipeline Shipments ............3-6

5.25 Secure Fuel Test Procedures....................5-173.18 Filtration Requirements ..............................3-6

5.26 Dormant Storage Testing .........................5-173.19 Differential Pressure ...................................3-7

Change 2 i

5.27 AVGAS Receipts......................................5-17

5.28 AVGAS Issues from Drums ....................5-24 8.1 General........................................................8-1

8.2 Unopened Packaged Petroleum

6 GROUND FUELS ....................................................6-1 Products..................................................8-1

8.3 Extension of Packaged Petroleum

6.1 General........................................................6-1 Products..................................................8-2

6.2 Motor Gasoline (MOGAS).........................6-1 8.4 Special Instructions for Opened

6.2.1 MOGAS Receipts .......................................6-1 Containers ...........................................8-2.1

6.3 Gasohol .......................................................6-1 8.5 Submission of Samples ..............................8-3

6.3.1 Gasohol Receipts ........................................6-1 8.6 Special Instructions for Packaged

6.4 E85 Ethanol ................................................6-2 Aircraft Engine Oils ..............................8-3

6.5 Sampling Equipment ..................................6-2 8.7 Bulk AVOIL...............................................8-4

6.6 E85 Fueling Systems..................................6-2

6.7 E85 Receipt Operations..............................6-3 A ADDITIVE BLENDING PROCEDURES

6.8 E85 Operational Tank Sampling................6-4 TURBINE FUELS ..............................................A-1

6.9 Propane Motor Fuel....................................6-4

6.10 MOGAS and Diesel Fuel Tank A.1 General.......................................................A-1

Cleaning .................................................6-4 A.2 Fuel System Icing Inhibitor ......................A-1

6.11 Dormant Storage Testing ...........................6-4 A.3 CI/LI...........................................................A-2

6.12 Diesel Fuel..................................................6-4 A.4 SDA............................................................A-2

6.12.1 Diesel Fuel Receipts...................................6-5 A.5 Leak Detection Additives..........................A-3

6.12.2 Periodic Sampling and Testing ..................6-5 A.6 Thermal Stability Additive........................A-5

6.13 Cold Weather Operations ...........................6-5 A.7 Field Additive Injection

6.14 Blending Diesel Fuel...............................6-6.1 Procedures .............................................A-6

6.15 Diesel Fuel Stabilizer Additive...............6-6.1

B EQUIPMENT FOR LABORATORY6.16 Biodiesel (B20)...........................................6-7 TESTING ............................................................B-16.16.1 B20 Receipts...............................................6-7

6.16.2 Periodic Sampling and Testing ..................6-7

6.17 B20 Low Temperature Perform-

C TEST PROCEDURES .............................................C-1ance ........................................................6-7

6.18 Heating Fuel Oil .........................................6-8

C.1 Test Procedures..........................................C-1

7 QUALITY CONTROL PROCEDURES

D AIRCRAFT SUMP SAMPLINGAT TEMPORARY AND AUXILIARY

PROCEDURES ...................................................D-1LOCATIONS .......................................................7-1

D.1 Sampling Equipment Required .................D-17.1 General........................................................7-1 D.2 Procedures..................................................D-17.2 Sampling Requirements..............................7-1 D.3 Base Fuels Laboratory Analysis ...............D-17.3 Solids Determination ..................................7-1 D.4 Contamination Limits ................................D-17.4 Submission of Turbine Fuel Sam- D.5 Recommended Actions Requiredples .........................................................7-1

When Contamination Exceeds7.5 Blending Additives into Turbine Limits ....................................................D-1Fuels .......................................................7-2

D.6 General.......................................................D-1

8 AIRCRAFT ENGINE OILS AND OTHER

PETROLEUM PRODUCTS................................8-1

ii Change 2

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

3-1 Vessel Pressure Drop Characteristics 5-3 Bonding Wire for Millipore In-Line with SPENT Cartridges ........................ 3-10 Sampler ................................................. 5-30

4-1 Standard Sampling Containers for Bot- 5-4 Holder Chromatography Strip (Sheet 1 tle Sampling ............................................ 4-8 of 2) ...................................................... 5-31

4-2 Bacon Bomb Thief for Bottom ................... 4-8 5-5 Holder Chromatography Strip Wood 4-3 Thief for Sampling Drums .......................... 4-8 Components .......................................... 5-33 4-4 Container Assemblies for Bottle or 5-6 Base Fuels Laboratory Test Data Re-

Beaker Sampler ...................................... 4-9 cord (Sheet 1 of 2) ............................... 5-34 4-5 Locally Fabricated Bottle Holder (Op- 5-7 Hydrometer Scale Reading for Trans-tional Use) ............................................ 4-10 partent Liquids ...................................... 5-36 5-1 Apparatus for Determining Total Con- 5-8 Bottle Method Stand ................................. 5-37 taminant ............................................... 5-6.1 5-9 Pensky-Martens Assembly Standard ........ 5-38 5-2 3-Way Valves In-Line Samplers .............. 5-29 6-1 Cloud Point Test Apparatus ...................... 6-13

LIST OF TABLES

Number Title Page Number Title Page

2-1 Turbine Fuel Characteristics ....................... 2-3 6-3 Overseas Tenth Percentile Tempera- 3-1 Conversion Chart for Refueling Units ....... 3-8 tures, °C ................................................ 6-11 3-2 DELETED ................................................... 3-9 6-4 DELETED ................................................. 6-11 4-1 U.S. Military Fuel Laboratories .................. 4-5 7-1 Turbine Fuel Sampling Requirements 4-2 U.S. Military Fuel Laboratories — and Test Limits ....................................... 7-2

Europe and Southwest Asia ................... 4-6 8-1 Retest Frequency of Tested Proprieta- 4-3 U.S. Military Fuel Laboratories — Pa- ry Products .............................................. 8-4 cific ......................................................... 4-7 8-2 Retest Frequency of Packaged Petrole- 5-1 Turbine Fuel Sampling Requirements um Products ............................................ 8-5 and Test Limits ..................................... 5-18 8-3 Laboratory Areas of Responsibility .......... 8-10 5-2 Aviation Turbine Fuel Limits ................... 5-23 A-1 SDA Blending Quantities .......................... A-4 5-3 AVGAS Sampling Requirements and A-2 Approved Volatile Chemical Tracer

Test Limits ............................................ 5-24 Leak Detection Additives ...................... A-9 5-4 Conductivity vs Temperature .................... 5-25 A-3 FSII — Portable Multi-Additive Injec- 5-5 Temperature Conversion ........................... 5-26 tor ......................................................... A-10 5-6 Secure Fuel Test Limits ............................ 5-27 A-4 CI/LI & SDA — Portable Multi-Addi- 6-1 Minimum Sampling and Testing Fre- tive Injector .......................................... A-11 quencies of Dormant Petroleum A-5 Gauging 55-gallon Drums (Approxi- Products .................................................. 6-8 mate) .................................................... A-12

6-2 Tenth Percentile Minimum Tempera- A-6 GE Betz 8Q462 Injection Rate ................ A-13 tures, °C .................................................. 6-9 B-1 Equipment for Laboratory Testing ............ B-1

C-1 Test Procedures .......................................... C-1

Change 2 iii/(iv blank)

INTRODUCTION

procedures outlined in MIL-STD-3004 and this technical1. PURPOSE.

order apply. Where content of this technical order may conflict with fuel quality instructions or procedures con-This technical order prescribes the procedures for assuring tained in other government documents or publications, thethe quality of fuels and lubricants used by Air Force provisions of this technical order take precedence. Theseactivities. It applies both to overseas areas and to the instructions will be used in conjunction withContinental United States (CONUS).

MIL-STD-3004 and Air Force Occupational Safety and Health (AFOSH) Standards, wherever applicable. The pro-2. SCOPE.

visions of this manual are compatible with NATO Stan-dardization Agreement (STANAG) 3149, 1135, ASCC AIRProcedures and instructions prescribed by this publication Standards 15/1 and 15/3D. This technical order is theapply to receiving, storing, handling, testing, and dispens-established quality control program as required by DoDing of fuels and lubricants at Air Force installations. At Air 4140.25M.Force assigned intermediate depots, where the Air Force has Quality Surveillance (QS) responsibilities, the quality v

SAFETY SUMMARY

1. The following are general safety precautions and 5. CHEMICAL DISPOSITION.

instructions that people must understand and apply during many phases of operations in fuel handling and laboratory For proper disposition of chemicals cited for use in this operations to ensure personal safety and health and the technical order, review applicable MSDS and consult with protection of Air Force Property. local Environmental Management and Bio-Environmental

Engineering Offices for guidance.

2. WARNING AND CAUTION STATEMENTS.

6. DEFINITIONS.

WARNING and CAUTION statements have been strategi-cally placed throughout this text prior to operating or

WARNINGmaintenance procedures, practices, or conditions consid-ered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). WARNINGs and

Highlights operating procedures or practicesCAUTIONs will apply each time the related step is which, if not correctly followed, could result inrepeated. Prior to starting any task, the WARNINGs or personnel injury or loss of life.CAUTIONs included in the text for the task will be reviewed. Compliance is mandatory prior to performing the next step in the task. Consult the local Bio-Environmental CAUTION Engineer for specific protective equipment and ventilation requirements.

Highlights operating procedures or practices

3. GIVE CLEANERS/CHEMICALS SPECIAL CARE. which, if not strictly observed, could result in damage to or destruction of equipment and/or Keep cleaners/chemicals in approved safety containers and property.

in minimum quantities. Some cleaners/chemicals may have an adverse effect on skin, eyes, and respiratory tract. NOTE Observe manufacturer’s WARNING labels; Material Safety Data Sheet (MSDS) instructions for proper handling, An essential operating or maintenance proce-storage, and disposal; and current safety directives. Use dure, condition, or statement, which must be cleaners/chemicals only in authorized areas. Discard soiled highlighted.

cloths into safety cans. Unless otherwise indicated in the text, use as described in this T.O. should not result in any Shall and Indicate mandatory requirements. Will is immediate health concerns. Consult the local Will also used to express a declaration of pur- Bio-Environmental Engineer and Safety Office for specific pose.

protective equipment and ventilation requirements.

Should Indicates a preferred method of accomplish-ment.

4. PERSONAL PROTECTIVE EQUIPMENT (PPE).

May Indicates an acceptable, optional, or suggest-ed means of accomplishment.Wear protective clothing/equipment (gloves, apron, eye protection, etc.) approved for the materials and tools being used. Contact supervisor for guidance. If necessary, the Bio-Environmental Engineer or the Base Safety Office should be contacted for guidance.

vi

CHAPTER 1

GENERAL

1.1 GENERAL SAFETY AND ENVIRONMENT 1.4 QUALITY ASSURANCE AT ORIGIN.

CONSIDERATIONS.

Quality Assurance Representatives (QAR) and Quality Sur-veillance Representatives (QSR) of the Defense EnergyPetroleum products are hazardous due to their toxic, explo- Support Center (DESC), monitor fuel and lubricant qualitysive, flammable, and environment damaging natures. Pre-through surveillance of supplier’s production, storage, test-scribed safety precautions will be strictly followed for the ing, loading, and shipping procedures. Quality assurance ofsafety and protection of personnel, equipment, and the petroleum products at procurement and quality surveillanceenvironment. Fire hazards are present wherever petroleum of USG-owned petroleum products is the responsibility ofproducts are handled due to leaks, spills, vapor accumula- DESC or the military service owning or operating thetion, improper grounding/bonding of equipment, or ignition terminal. The authorized Government Representativefrom a heat source. Leaks or spills must be eliminated to whose name appears on the shipping document must beprevent pollution of waterways and underground water contacted when irregularities arise with receipts of fuels ortables. CFR Title 40, Part 112.7, GUIDELINES FOR THE lubricants.PREPARATION AND IMPLEMENTATION OF A SPILL

PREVENTION CONTROL AND COUNTERMEASURE

1.5 QUALITY SURVEILLANCE AT BASE LEVEL.PLAN provides guidance on establishing an adequate spill prevention control program. All spills will be promptly

a. Fuels Management (FM) is responsible for thereported to the applicable agencies (Fire Department, quality of all Defense Working Capitol FundSafety Office, Bio-Environmental Representative, etc.). Air (DWCF) fuel through the point of sale. The FMForce Instruction (AFI) 23-201 and Air Force Occupational also provides advice and analysis on productsSafety and Health (AFOSH) Standard 91-38 outline general issued from DWCF stocks.safety guidelines to be followed. T.O. 42B-1-23, titled

MANAGEMENT OF RECOVERABLE AND WASTE b. Submit reports of product not meeting specification LIQUID PETROLEUM PRODUCTS provides guidance in requirements or receipt limits to DET 3, the collection, segregation, and disposition of recoverable WR-ALC/AFTH with info copies to the MAJCOM and waste liquid petroleum products. and HQ USAF/ILGM. DET 3, WR-ALC/AFTH will evaluate and determine if further assis-

1.2 TEMPERATURE CONTROL. tance/action is required by DESC-BQ. The report shall be in writing using the SF 368 or any other Maintain Base Fuels Laboratories at a temperature of 73° ± type correspondence (facsimile, e-mail, or mes- 5°F (23° ± 2°C). Large temperature fluctuations adversely sage) using the SF 368 format. As a minimum, the affect laboratory equipment and fuel samples. This could report will contain the following information:

cause inaccurate analysis of fuel properties and allow issue of contaminated fuel to aircraft. • Specification and Grade

• QuantityNOTE

• LocationHot water used for cleaning laboratory glass-ware will be a minimum of 130°F (54°C) at the • Date of Receipt tap.

• Name of Manufacturer/Shipper, Contract

1.3 RESPONSIBILITIES FOR FUEL QUALITY. Number, Batch Number, Qualification Num-ber, Date of Manufacturer/Shipment, Transpor- Military petroleum products require quality surveillance tation Mode, and Company, etc., as applicable from the point of initial acceptance by the government until they are actually used. Every agency in the supply system • Type of Container or Storage that transports, stores, distributes, or issues these products

• Accountable Military/Civilian Departmentis responsible for some phase of quality control. Every individual who physically handles petroleum products

• Need for Replacement Productshares this responsibility.

Change 1 1-1

• Detailed Laboratory Test Results Including, if a. Maintains and operates Aerospace Fuels Laborato-known, Degree of Contamination and Contam- ries which provide testing services for AF bases inated Materials − test results reported shall and establishes requirements for the services of include all known characteristics, whether various commercial laboratories to perform specifi-on-specification or off-specification, and cation testing on an emergency basis at specified appropriate Type A or B test results performed locations. Table 4-1 shows the geographical area of on stock just prior to identification of contami- responsibility for each Continental United States nation problem. (CONUS) and overseas area laboratory.

• Recommended Alternate Use, Disposition, or b. The POL Technical Assistance Team is available Proposed Recovery Measures, if appropriate to assist FM personnel worldwide in identifying and correcting quality problems. The Technical

c. Specification and receipt limits for each turbine Assistance Team can be reached at DSN:

fuel type are shown in Table 5-2. Specification 785-8070. Requests for assistance will be coordi-limits apply only to product received direct from a nated with the MAJCOM.

refinery. Receipt limits apply to government owned product transfers from a military service or from a c. Provides technical guidance on facilities, equip- Defense Fuel Support Point (DFSP). When product ment, and training of personnel with respect to is received or contaminated on-base beyond the handling or testing petroleum products.

limits specified in this technical order, obtain dis position instructions from the DET 3, 1.7 LIST OF FORMS.

WR-ALC/AFTH, DSN: 785-8070.

a. DD Form 250 Series Forms are Used for Record Con-

d. The Logistics Readiness Squadron Commander is trol of Fuel Shipments responsible for quality surveillance of packaged petroleum products including aviation oils main- b. AF Form 979, Danger (Tags) tained in the base FP stock record account

c. AF Form 980, Caution TAG(Table 8-1 and Table 8-2).

d. AFTO Form 148, JP-8+100 Acknowledgmente. Aircraft Maintenance Organizations are responsi-ble for quality surveillance of packaged products in

e. AFTO Form 149, Fuel Inoculation Recordtheir possession. Quality procedures are contained in Chapter 8 of this publication.

f. AFTO Form 422, Fuel Filter Pressure Differential Log

f. Quality surveillance of petroleum/gasohol products

g. AFTO Form 475, Fuels and Lubricant Sample Tagin organizational support tanks is the responsibility of the tank custodian.

1.6 DET 3, WR-ALC/AFT TECHNICAL DIVISION.

DET 3, WR-ALC/AFT Technical Division provides techni-cal support for fuels and lubricants quality surveillance as follows:

1-2 Change 1

CHAPTER 2

AVIATION FUELS

2.1 TURBINE FUELS.

NOTE

Turbine fuels are mixtures of hydrocarbons, broadly classi- Since JP-4 is no longer used by the Air Force,fied as kerosene or naphtha based. JP-8, which is now the except for cold weather starts, this technicalstandard turbine fuel used by the U.S. Air Force and U.S.

order will omit all references to this fuel in theArmy and to some extent by the U.S. Navy, is a kerosene remaining chapters.based fuel similar to commercial Jet A and Jet A-1. JP-5 is a kerosene based fuel used primarily in Navy carrier

d. TS-1 grade fuel is normally supplied in the Com-aircraft because of its higher flash point. JP-4, a wide-cut monwealth of Independent States (CIS) and loca-fuel containing approximately equal portions of naphtha tions in southwest Asia. Typically, it has a lowerand kerosene, was replaced by JP-8 primarily for safety and flash point than JP-8.environmental considerations. There is no specified color standard for JP-8, JP-5, or JP-4 other than the fuel must be

e. JP-8+100 (NATO F-37) is a grade of fuel thatclear and bright. Color can range from water-white to contains an additive consisting of antioxidants,yellow (straw) or pastel green color. Table 2-1 provides detergent/dispersants, metal deactivators, and sol-information on some key properties of JP-8 and JP-5. TO vents. JP-8+100 has been demonstrated to reduce42B1-1-14, FUELS FOR USAF AIRCRAFT, specifies the fuel system fouling/coking in jet engine nozzles.approved fuel grades to be used in USAF aircraft.

Tests have shown that JP-8+100 will not disarm API 3rd Edition and API 5th Edition M100 seriesa. JP-8 (NATO F-34) − this grade is the standard coalescer elements.USAF turbine engine fuel. JP-8 is a kerosene type fuel similar to commercial Jet A-1 with the addi-

f. Thermally Stable Jet Fuel (JPTS) is used in limitedtion of Corrosion Inhibitor/Lubricity Improver quantities for special applications. MIL-DTL-(CI/LI), Fuel System Icing Inhibitor (FSII), and 25524 is the specification for this product. QualityStatic Dissipator Additive (SDA). It is procured to control procedures for this product are contained inMIL-DTL-83133.

TO 42B1-1-16.

b. JP-5 (NATO F-44) − this grade is used primarily in

2.2 AVIATION GASOLINE (AVGAS).Navy carrier aircraft, because of its higher flash point (140°F). It is a kerosene type fuel covered by All AVGAS is procured according to American Society forMIL-DTL-5624. Types of tests required and sam- Testing and Materials (ASTM) D 910. Aviation gasoline ispling frequencies for JP-5, when used by the Air a mixture of relatively volatile hydrocarbons with smallForce, will be the same as JP-8. The requirements quantities of additives including tetraethyl lead. Commer-applicable to JP-5 used by aircraft maintenance cial Grade 100 Low Lead (LL), (NATO F-18) is blue inactivities to purge aircraft fuel systems are con-color and has a maximum allowable tetraethyl lead contenttained in TO 1-1-3.

of 2.0 ml/gal. Commercial Grade 80 is red in color and has

c. JP-4 (NATO F-40) − this grade is a wide-cut a maximum allowable tetraethyl lead content of 0.5 ml/gal.

turbine engine fuel and was the primary jet fuel for the U.S. Air Force and U.S. Army from 1951 − 1993. It was procured to MIL-DTL-5624. JP-4 is a highly flammable fuel containing gasoline and ker-osene fractions. It closely resembles commercial Jet B fuel. This grade is maintained by select bases to aid in cold weather starting. Types of tests (excluding flash point) required and sampling fre-quencies for JP-4, when used by the Air Force, will be the same as JP-8.

Change 3 2-1

b. Corrosion Inhibitor/Lubricity Improver (CI/LI)2.3 FUEL ADDITIVES.

conforming to MIL-PRF-25017 is required in JP-8 and JP-5 to prevent corrosion of steel surfaces.

CI/LI also provides added lubricity to fuel for more effective operation of aircraft system components, WARNING such as fuel pumps and fuel controls. The amount blended into fuel depends upon the type used as outlined in the Quality Products Listing (QPL-Undiluted fuel additives (FSII, SDA, and 25017). The Ball-On-Cylinder Lubricity EvaluatorCI/LI) present increased risk to personnel. FSII (BOCLE), ASTM D 5001, or the High-Frequencyis both combustible and toxic. It is harmful if Reciprocating Rig (HFRR), ASTM D 6079, is usedinhaled or absorbed through the skin and causes to measure the lubricity property of fuel. Thiseye irritation. In laboratory studies, FSII caused property, although not a specification requirement,birth defects and had adverse effects on preg-is monitored from the correlation/aircraft servicingnancy. Prolonged and repeated exposure also sample submitted every 90 days. If the results ofcauses damage to male reproductive organs.

the sample show there is not enough lubricity, thenBefore handling undiluted FSII, consult appro-the addition of CI/LI is normally the correctivepriate safety and occupational health action.authorities.

c. The use of a SDA in fuels enhances safety duringa. FSII conforming to MIL-DTL-85470 is added to handling and flight. Electrostatic relaxation timesJP-8 and JP-5. This inhibitor is Diethylene Glycol are decreased by increasing the conductivity of theMonomethyl Ether (DIEGME). An icing inhibitor fuel. Stadis 450 is the only approved conductivityeffectively lowers the freezing point of small quan-additive used in JP-8 and JP-5 by the Air Force.tities of free water in fuel. This prevents the The Navy does not use SDA in JP-5. However,formation of ice in the fuel which can clog filter SDA is added where JP-5 is stored for issue andelements and result in engine stalls. FSII does not purging of Air Force tactical aircraft. The receiptlower the freezing point of the fuel, but lowers the and use limits for SDA are 50 − 700 CU whenfreezing point of water present in the fuel. This measured at the ambient fuel temperature or 85°Finhibitor also has properties which restrict bacterial (29°C) whichever is lower. Discontinue CU testinggrowth in fuel systems. Water removes FSII from when fuel temperatures are below 32°F (0°C).fuel; therefore, introduction of water must be Conductivity levels increase with an increase inavoided to the greatest extent possible and free fuel temperature and decrease when the tempera-water must be removed at any point where it can ture is lowered. APPENDIX A to this technicalaccumulate, including aircraft tanks. A decrease in order contains instructions for blending and inject-FSII content in fuel is an indication of the presence ing SDA to increase conductivity. The use of SDAof water in a system, requiring immediate investi-does not reduce or eliminate the need to followgation and corrective action.

grounding/bonding procedures.

SAFETY PRECAUTIONS

d. Other Additives − antioxidants must be added to

JP-8 and JP-5 if blend stocks are hydrotreated in1. Protective butyl rubber gloves will be worn the refining process. Antioxidants prevent forma-when handling undiluted FSII. Goggles and tion of peroxides which accelerate failure of rubberan air purifying respirator are not required materials. The addition of metal deactivators by thewhen handling undiluted FSII in an out-supplier is optional. Metal deactivators are used todoor environment.

enhance thermal stability of the fuel. Thermal stability is measured by the Jet Fuel Thermal2. Skin contact with undiluted FSII shall be Oxidation Tester (JFTOT) and is a specificationavoided, but in the event of skin contact, requirement. Thermal stability is a very criticalthe FSII shall be removed with soap and property of fuel and is controlled to reduce cokingwater.

or fuel fouling in engine fuel nozzles, afterburner

3. In the event of eye contact, immediately spray assemblies, and manifolds. The JFTOT test is wash the eye with water. run every 90 days on the correlation/aircraft servic-ing sample submitted from each base.

4. Continue the wash for 15 minutes and seek medical help as soon as possible. e. Thermal Stability Additive − the Air Force is adding a thermal stability additive to select aircraft.

5. When the additive is diluted with jet fuel This additive increases the thermal stability from a the health hazards are significantly re- typical 325°F (163°C) to 425°F (218°C) and is duced. referred to as JP-8+100. This additive is a high

2-2 Change 3 surfactant and is normally injected downstream of and SDA during transient operations. However, fillstand filter separators. this should not be misconstrued with the fact that some aircraft are operationally limited on fuels

f. The three additives, FSII, CI/LI, and SDA are without one or more of these additives. Additive mandatory in fuels utilized by USAF aircraft dur- blending procedures are contained in ing sustained operations. Commercial turbine fuels APPENDIX A.

such as Jet A and Jet A-1 are often issued to USAF aircraft on into-plane contracts without FSII, CI/LI, Table 2-1. Turbine Fuel Characteristics

Flash Freeze Vapor API Typical Point Point Pressure Gravity Weight

JP-8 (100°F) −53°F Negligible 37 − 51 6.7 lb/gal (38°C) (−47°C)

Minimum Maximum

JP-5 (140°F) −51°F Negligible 36 − 48 6.8 lb/gal (60°C) (−46°C)

Minimum Maximum

2-3/(2-4 blank)

CHAPTER 3

FUEL HANDLING

equipment strainers will be cleaned and inspected3.1 SCOPE.

IAW UFC 3-460-03 and T.O. 37-1-1. Nozzle strainers are not required in fillstand bottom load-This chapter describes Air Force fuel systems and discusses ers. The amount and types of material found inthe relationship of specific system components in maintain-strainers are indicative of problem areas such asing fuel quality. Specific operating guidance is provided in deteriorated hoses, dirty pipelines and tanks, rup-this chapter to ensure product quality. Sources and types of tured filter separator elements, etc.contamination are identified to aid base personnel in preventing quality degradation.

3.4 FILTERS/FILTER SEPARATORS.

3.2 RESPONSIBILITIES.

a. Where FILTER and FILTER SEPARATOR appears in this technical order, the terms area. FM is responsible for the operation of base fuel defined as follows:systems and operator maintenance of these systems.

(1) FILTER, refers to a micronic filter vessel con-taining 1 or more filter elements. Very fewb. The Base Civil Engineer is responsible for mainte-micronic filters are in use, but those remainingnance of fixed systems beyond operator mainte-consist of treated paper elements or cartridgesnance as Detailed in Unified Facilities Criteria housed in cylindrical vessels. Filters remove(UFC) 3-460-03.

very fine particles from fuel, thus the name micronic filters. Elements are treated to repelc. Base Vehicle Maintenance is responsible for the water, but will not coalesce water from fuel.maintenance of mobile refueling equipment beyond the scope of operator maintenance.

(2) The term FILTER SEPARATOR, is used in reference to a vessel containing 2 stages. Thed. The DESC funds projects related to maintenance, first is a micronic paper filter and fiberglassrepair, environmental compliance, and minor con-strand coalescer element. The second stage is astruction of DoD owned fuel handling systems.

Teflon screen canister or separator element that separates free water from fuel. Both vertical and3.3 STRAINERS.

horizontal types are in use in Air Force systems.

The coalescing function is performed as the fuela. Strainers are metal screens installed at selective passes through the first stage or first section ofpoints in base receiving and dispensing systems for the element assembly. As the fuel passesthe removal of large solid contaminants. The most through the elements, small droplets of watercommon types are basket strainers and cone strain-that may be suspended in fuel are coalesced intoers. Strainers with various size openings are used large droplets. Since the openings of the coa-as required in T.O. 37A-1-101 and UFC 3-460-03.

lescing elements are very small, removal of fineMesh size refers to the number of openings per particles also occurs. Fuel then passes through alinear inch, i.e., 100-mesh screen has 100 openings water repellent media, such as Teflon coatedper linear inch or 10,000 openings per square inch.

screen, to prevent coalesced water from beingAn opening this size is equivalent to a particle size discharged with the fuel. The separated waterof 150 microns.

drops to a sump for removal through an auto-

b. A properly designed and installed strainer directs matic or manual drain valve.

all flow through the screen. The proper size basket

(3) Deletedor cone strainer must be installed and the seating surfaces must be sealed to prevent fuel from bypas- (4) Deleted sing. If fuel bypasses the screen or if it is broken, the strainer is useless.

c. Clean and inspect mobile equipment strainers In Accordance With (IAW) T.O. 37A-1-101. Fixed

Change 2 3-1

(1) An excessive increase in differential pressure over a short time or after little fuel throughput

WARNING indicates a system malfunction or product con-tamination. Determine the cause and take cor-rective action.Exercise caution when draining systems under pressure. (2) A drop in differential pressure usually indicates a malfunction of the filter separator, such asb. Draining vertical and horizontal filters and filter ruptured elements, unless the reading is taken atseparator sumps under pressure is necessary to lower flow rates.ensure removal of all water and contaminants.

Follow the procedures below:

3.5 TANKS.

(1) Drain all fixed and mobile filter and filter Descriptions of tanks for bulk or operating storage serviceseparator vessels under pressure daily when at Air Force installations are given in UFC 3-460-03. Theused. Inspect the product drained from the following guidance is limited to those features, practices,sumps for the presence of water or a thick and operations directly affecting fuel quality.gelatinous substance.

a. Do not maintain water bottoms (removable water)(2) Drain (under pressure) a minimum of one-gallon in petroleum storage tanks. Active tank water(continuous, without stopping) from all vertical removal systems will be operated daily prior to anyand horizontal filters and filter separator sumps product movement. Inactive tank water removal(preferably into a bowser, ceramic white bucket, systems will be operated a minimum of weekly.or equivalent); then perform a visual analysis Maintaining a quantity of water in the tank forfor color, water, and solids using a clean, clear gauging purposes is prohibited.quart jar. If the visual analysis fails, continue the procedure above until a clear and bright sample

b. Gauge barge/tanker compartments for water prioris obtained. If a brownish gelatinous substance to acceptance and discharge. Pump off excessis detected, contact DET 3, WR-ALC/AFTH, water prior to acceptance.DSN 785-8070 for guidance/instructions and increase sumping throughout the fuel system to c. Operate pipeline receiving tank water removal sys-twice daily/each shift. Typical analysis of the tems before and after receiving operations.

gelatinous substance is 40 − 50% FSII, 40 − 50% water, and 1 − 4% other substances. This d. Inspect uncovered floating roof tanks and remove substance can migrate through filters, disarm water following heavy rains using the water filter elements, and cause corrosion in fueling removalsystem.

systems. Keeping free water out of fuel is the best preventive measure for minimizing the for- (1) Water removed from tanks, filter separators, mation of the substance. Request LFM/RFM water removal systems, low point drains, fuel open and inspect filter separator vessels to bowsers, etc., containing an unknown concen-determine if elements require changing. Con- tration of FSII requires proper handling. Do not tinue increased sumping until the substance is drain such products on the ground or into the no longer evident. installation storm drainage system. FSII is a biodegradable hydrocarbon based substance that

c. Replace fixed system filters IAW UFC 3-460-03. should present no difficulty in the concentra-

Replace mobile equipment elements IAW TO tions present in the water removed from tanks, 37A-1-101. After elements are placed in service, filter separators, water removal systems, low there should be a gradual increase in differential point drains, fuel bowsers, etc., when drained pressure. into the sanitary sewer system. Consult the

3-2 Change 3

Environmental Coordinator to ensure compli- (3) Secure water drawoffs by padlock in the closed ance with local, county, state, and federal envi- position when not in use.

ronmental laws and regulations. The Environ-

e. The determination of water will be made withmental Coordinator, in coordination with the Automatic Tank Gauging (ATG) equipment or byBase Civil Engineer, will identify sanitary sewer gauge and plumb bob using water indicating pasteinlets suitable for the disposal of water/FSII meeting the performance characteristics ofconcentrations from the sources identified.

MIL-W-83779. However, be advised that waterAlternate procedures will be provided where detected by the ATG or plumb bob is cause fornecessary.

concern. The tank may contain an extremely large

(2) Tanks equipped with water removal systems amount of water as both the ATG and plumb bob provide a more efficient means of removing normally use the tank datum plate as a reference water. After separation of the fuel/water emul- point that is not at the tank bottom. Two national sion in the water removal system the free water stock numbers apply for MIL-W-83779, is drained and then the recovered fuel is trans- 6850-00-001-4193 (jar) and 6850-00-001-4194 ferred back into the tank. All new storage tanks (tube). Water indicating paste will separate during should be programmed for a water removal storage or periods of nonuse. Keep water indicating system that has the ability to re-circulate prod- paste well-mixed during use. The jar, NSN uct through water removal filtration and back 6850-00-001-4193, is recommended in lieu of the through the receipt inlet. Also program new tube to enhance mixing. Report quality deficiencies tanks to incorporate a water detection capability encountered with this product to DET 3, in the sump. Report any failure of these systems WR-ALC/AFTT, DSN: 785-8050.

to operate properly or need for maintenance.

Change 1 3-2.1/(3-2.2 blank)

(3) Deleted3.6 TANK INSPECTIONS AND CLEANING.

b. Operating tanks that receive product from bulkTank inspection and cleaning requirements are stated in storage (where the product has been allowed toT.O. 37-1-1 and UFC 3-460-03.

settle for at least 8 hours) does not require a settling period. However, observe a two-hour set-a. Excessive solids upstream of filter separators or tling period, or longer, if mission requirementsrapid build-up of differential pressure in fixed allow.system filter separators are indications that the tank needs to be inspected and cleaned, if needed.

c. Settling time for ground fuel tanks greater than

84,000 gallons is one hour per foot of fuel in theb. Change of product service from aviation gasoline tank following a receipt. For tanks under 84,000to jet fuel or vice versa, does not in itself require gallons a settling time of 30 minutes minimum istank cleaning. In most cases, if the tank was required. Observe a longer settling period if mis-recently cleaned, or determined to be clean by sion requirements allow.inspection, removal of all product is all that is necessary. However, change of product service

3.8 CONTAMINATION.from black oil to clean product (aviation fuels) requires chemical cleaning of tank in addition to Fuel contamination is generally classified as chemical,normal cleaning.

biological, or material.

3.7 PRODUCT SETTLING.

a. Chemical contamination results from mixing 2 dif-ferent types of hydrocarbon fuels or mixing othera. Aviation fuel received into bulk storage or directly chemicals with fuel. Both the chemical and physi-into hydrants must be allowed to settle for a cal properties of fuel are affected. Laboratory test-minimum of 8 hours prior to issue or transfer.

ing can usually detect this contamination. ChemicalObserve a longer settling period if mission require-contamination is prevented by isolating differentments allow. Prior to issuing or transferring prod-products in separate handling systems, positiveuct following the settling period, drain the tank physical separation between systems, strict adher-water removal systems and perform a visual test ence to established operating procedures, and thefor water and particulates downstream of the issue alertness of operating personnel. Carelessness isor transfer filter. In case of emergency, the product the major cause of this type contamination.may be transferred/issued in less than 8 hours provided the MAJCOM Fuels Division provides b. Biological contamination results from growth of concurrence. If operational requirements repeatedly bacteria and/or fungi in water deposits within fuel limit settling time to less than 8 hours, confer with systems. Growths of these microorganisms have a the MAJCOM to determine the correct course of consistency of SLIME or MAYONNAISE at the action. interface of fuel and water. This contamination can

(1) Deleted

(2) Deleted

Change 1 3-3 plug aircraft filters, cause quantity probe malfunc- which settled out of fuel or which coalesced into tions, and corrode integral fuel tanks. While fuel large droplets for removal from the system.

system icing inhibitor acts as a biostat, microbial contamination is most effectively controlled by 3.10 SOLID CONTAMINANTS.

keeping water out of the fuel system.

a. Sediment appears as dust, powder, grains, flakes,

c. Material contamination consists of water, sediment, and stains. Sources of sediment are storage tanks, and other materials described herein. Precautions metal vessels, filter or filter separator elements, must be taken to prevent introduction and subse- valves, pumps, meters, pipelines, hose gaskets, quent…