Technicalorder37-1-1.pdf

T.O. 37-1-1

TECHNICAL MANUAL

GENERAL

OPERATION AND INSPECTION

OF INSTALLED

FUEL STORAGE AND DISPENSING SYSTEMS

(ATOS)

F41608-87-D-A288

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 04-403. 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

31 DECEMBER 2003 CHANGE 1 - 30 JUNE 2006

TO 37-1-1

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 DESTROY SUPERSEDED PAGES.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 . . . . . . . . 31 December 2003 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 30 June 2006

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 42, CONSISTING OF THE FOLLOWING:

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

Title A i - iii iv Blank v - vi 1-1 1-2 Blank 2-1 2-2 - 2-6 2-7 2-8 - 2-9 2-10 Blank 3-1 3-2 - 3-3 3-4 - 3-6 4-1 4-2 Blank 5-1 5-2 Blank 6-1 6-2 - 6-3 6-4 Blank 7-1 7-2 - 7-4 8-1 - 8-4

*Zero in this column indicates an original page

A Change 1 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iii 2.21 Hydrant Issues to Aircraft or Refueling Unit(s) ...................................2-9

2.22 Defueling into Hydrant Systems................2-9

LIST OF TABLES......................................................iii

3 OPERATOR’S INSPECTION AND

MAINTENANCE.................................................3-1

INTRODUCTION........................................................v

3.1 General........................................................3-1

3.2 System Deficiency......................................3-1

SAFETY SUMMARY................................................vi 3.3 Discrepancy Record....................................3-1

3.4 Inspection Guide.........................................3-1

3.5 Active Systems ...........................................3-11 RESPONSIBILITIES................................................1-1

3.6 Files.............................................................3-1

3.7 AFTO Form 39, Page 1 .............................3-11.1 Organizations ..............................................1-1

3.8 AFTO Form 39, Page 2 .............................3-21.2 Fuels Management (FM)............................1-1

3.9 Management Monthly Inspection...............3-21.3 Civil Engineers (CE) ..................................1-1

3.10 Open Discrepancies ....................................3-21.4 Logistics Readiness Squadron

3.11 Operational Inspections ..............................3-2Transportation Officer ...........................1-1

3.12 Weekly Inspections.....................................3-51.5 DET 3, WR-ALC .......................................1-1

3.13 Monthly Inspections ...................................3-6

3.14 Semiannual Inspections ..............................3-62 OPERATING PROCEDURES.................................2-1

4 FLUSHING PRESSURIZED2.1 General........................................................2-1 LOOP/HYDRANT SYSTEMS............................4-12.2 Fire Protection ............................................2-1

2.3 Fuel Receipts ..............................................2-1

4.1 General........................................................4-12.4 Frozen Valves .............................................2-1

4.2 Flushing Frequencies..................................4-12.5 Receipt Operations Tank

4.3 Flushing Procedures ...................................4-1Truck/Car ...............................................2-1

4.4 Sampling .....................................................4-12.6 Pipeline, Barge, and Tanker

Receipts ..................................................2-2 5 LOW POINT DRAINS ............................................5-1

2.7 Transferring Product between

Bulk and Operating Storage ..................2-2 5.1 General........................................................5-1

2.8 Filling Bulk Storage Tanks ........................2-3 5.2 Fuel System Draining Frequencies ............5-1

2.9 Ignition Hazards during Fuel 5.3 Low Point Draining Procedures.................5-1

Transfer from Storage Tanks 5.4 Safety ..........................................................5-1 by Other Than Normal Means ..............2-4 5.5 Environmental.............................................5-1

2.10 Pumps..........................................................2-5

2.11 Product Settling ..........................................2-6 6 LIQUIFIED PETROLEUM GAS (LPG) .................6-1

2.12 Gauging.......................................................2-6

2.13 Leak Detection............................................2-6 6.1 General........................................................6-1

2.14 Product Recovery System and 6.2 Fire Protection ............................................6-1

Oil/Water Separator ...............................2-6 6.3 Storage Containers......................................6-1

2.15 Tank Cleaning and Inspection 6.4 Markings on Bulk Containers ....................6-1

Criteria ...................................................2-6 6.5 Pressure-Relief Valves ...............................6-1

2.16 Servicing Controls ......................................2-7 6.6 Hoses, Hose Connections, and

2.17 Dispensing Fuel from Truck Flexible Connectors ...............................6-2

Fillstand Bottom Loading......................2-7 6.7 Hydrostatic-Relief Valves ..........................6-2

2.18 Tank Truck/Car Top Loading 6.8 Equipment ...................................................6-2

Operation................................................2-7 6.9 Location of Container.................................6-2

2.19 Refueling Unit Return to Bulk 6.10 Fencing........................................................6-2

Storage (RTB)........................................2-8 6.11 Grounding ...................................................6-2

2.20 Service Station Operation...........................2-8

Change 1 i

6.12 Liquid Transfer ...........................................6-2 8.13 Flexible Seals..............................................8-1

8.14 Gauge Hatch ...............................................8-1

7 COMPRESSED NATURAL GAS (CNG)...............7-1 8.15 Grounding ...................................................8-2

8.16 Guide Devices.............................................8-2

7.1 General........................................................7-1 8.17 High Level Shutoff.....................................8-2

7.2 Properties of CNG......................................7-1 8.18 Hydrant Refueling System .........................8-2

7.3 Fire Protection ............................................7-1 8.19 Hydrant Lateral Control Pit .......................8-2

7.4 Fueling Systems..........................................7-1 8.20 Hydrant Outlet Assembly...........................8-2

7.5 Design and Construction of 8.21 Hydrant Coupler .........................................8-2

Containers ..............................................7-1 8.22 Immediate Operating Storage.....................8-2

7.6 Pressure-Relief Devices..............................7-1 8.23 Liquid Level Gauge....................................8-2

7.7 Pressure Gauges and Regulators ................7-2 8.24 Low Level Shutoff .....................................8-3

7.8 Piping ..........................................................7-2 8.25 Low Point Drain .........................................8-3

7.9 Valves .........................................................7-2 8.26 Manhole ......................................................8-3

7.10 Hoses and Hose Connections.....................7-2 8.27 Meter ...........................................................8-3

7.11 CNG Compression, Storage, and 8.28 Oil/Water Separator....................................8-3

Dispensing Systems ...............................7-2 8.29 Pressure and Flow Recorder ......................8-3

7.12 Grounding ...................................................7-3 8.30 Product Recovery System ..........................8-3

7.13 Emergency Shutdown Equipment..............7-3 8.31 Pumphouse..................................................8-3

7.14 Dispensing System Operation ....................7-3 8.32 Pump Selector Panel...................................8-3

8.33 Pumps..........................................................8-3 8 GLOSSARY OF SYSTEM 8.34 Railroad Spur..............................................8-3

COMPONENTS...................................................8-1 8.35 Remote Electrical Control Cables..............8-3

8.36 Rim Vent.....................................................8-3

8.1 General........................................................8-1 8.37 Roof Drain (Open Top Floating

8.2 Air Eliminator.............................................8-1 Roof Tanks) ...........................................8-3

8.3 Automotive Service Stations......................8-1 8.38 Sight Gage/Glass ........................................8-3

8.4 Bonding.......................................................8-1 8.39 Strainers ......................................................8-3

8.5 Bulk Storage ...............................................8-1 8.40 Sump ...........................................................8-4

8.6 Cleanout Connection ..................................8-1 8.41 Surge Suppresser ........................................8-4

8.7 Dome Covers ..............................................8-1 8.42 Switch Loading...........................................8-4

8.8 Dike.............................................................8-1 8.43 Tanks...........................................................8-4

8.9 Emergency Switch......................................8-1 8.44 Valves .........................................................8-4

8.10 Fill Connection ...........................................8-1 8.45 Vapor Recovery System.............................8-4

8.11 Fillstands .....................................................8-1 8.46 Visi-Flo .......................................................8-4

8.12 Filter Separator ...........................................8-1 ii Change 1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

2-1 Tank Truck Grounding ................................ 2-3 2-2 Tank Car Loading ....................................... 2-4

LIST OF TABLES

Number Title Page Number Title Page

2-1 Initial Flow Rates for Storage Tanks ............ 2-4

Change 1 iii/(iv blank)

INTRODUCTION

1. PURPOSE. 2. SCOPE.

This technical order provides policies and guidance for The instructions prescribed by this publication outline fuels management personnel in the operation, inspection, general operational information associated with fuel storage and operator maintenance of permanently installed fuel and dispensing systems and provides the minimum periodic facilities operated under the control of the Base Fuels operator’s maintenance requirements for the systems. This Management Team (FMT). Federal, state, and local envi- technical manual is to be used in conjunction with other ronmental laws and regulations shall be complied with if existing directives governing fuel system operations and this publication is in conflict with them. maintenance requirements; however, this technical order will take precedence where there is a conflict with other publications.

v

SAFETY SUMMARY

1. GENERAL SAFETY INSTRUCTIONS. 4. RESUSCITATION.

The following are general safety precautions and instruc- Personnel working with or near dangerous voltage shall be tions that people must understand and apply during many trained in modern methods of resuscitation. Information phases of operation and maintenance to ensure personal and training may be obtained from the Director of Base safety and health and the protection of Air Force property. Medical Services.

Portions of this may be repeated elsewhere in this publica-tion for emphasis. 5. PERSONAL PROTECTIVE EQUIPMENT (PPE).

2. WARNING AND CAUTION STATEMENTS. If unique local conditions make compliance with the pro-tective clothing or other occupational health requirements

WARNING AND CAUTION statements have been strate- specified in this manual unnecessary or impractical, obtain gically placed throughout this text prior to operating or an evaluation of the operation from the Bio-Environmental maintenance procedures, practices, or conditions consid- Engineer. The Bio-Environmental Engineer will determine ered essential to the protection of personnel (WARNING) the required precautions.

or equipment and property (CAUTION). A WARNING or CAUTION will apply each time the related step is 6. STATIC ELECTRICITY.

repeated. Prior to starting any task, WARNINGs or CAU- TIONs included in the text for that task will be reviewed Grounding and/or bonding of all conductive parts of the and understood. system is an effective means to prevent an electrostatic spark that could cause ignition of petroleum product(s). To

3. WEARING OF JEWELRY. prevent personnel injury, always ground and/or bond equip-ment in accordance with applicable directives.

Remove rings, watches, and other metallic objects which may cause shock or burn hazards. Finger rings will also be 7. CONFINED SPACE ENTRY.

removed when working in areas where the potential exists for rings to catch during a slip or fall, i.e., climbing on Personnel have been overcome by fuel vapors in confined tanks or tank trucks or at the discretion of the Fuels spaces. Prior to entering a confined space, ensure require- Management Flight Commander (FMFC). ments established in AFOSH Standard 91-25 have been met.

vi

CHAPTER 1

RESPONSIBILITIES

property components. CE provides detailed and updated1.1 ORGANIZATIONS.

schematic drawings and certified gauging charts applicable to the installed systems.Responsibility for the operation and maintenance of perma-nently installed base petroleum systems rests with Fuels

1.4 LOGISTICS READINESS SQUADRONManagement (FM) and Civil Engineers (CE). The Trans-portation Officer provides maintenance support for TRANSPORTATION OFFICER.

mobile/portable fueling equipment.

The Logistics Readiness Squadron Transportation Officer

1.2 FUELS MANAGEMENT (FM). provides maintenance support for mobile/portable fueling equipment.

FM shall develop procedures and local operators inspection and maintenance checklists to ensure the safe and efficient 1.5 DET 3, WR-ALC.

operation of installed and mobile fuel systems/equipment.

DET 3, WR-ALC/AFTH is the office of primary responsi-

1.3 CIVIL ENGINEERS (CE). bility for the technical content of this technical order.

Recommended changes and/or improvements to this techni- CE shall perform all maintenance and associated procure- cal order will be submitted In Accordance With (IAW) ment actions on installed fuel systems, to include additive T.O. 00-5-1.

injectors, and nozzle/hose assemblies on truck fillstands.

The hydrant adapters on installed refueling systems are real

1-1/(1-2 blank)

CHAPTER 2

OPERATING PROCEDURES

OPEN FLAME OR IGNITION SOURCE2.1 GENERAL.

WITHIN 50 FEET. These signs should be low profile and visible to approaching personnel.This chapter provides general operating procedures for fuel receipt, storage, transfer, and issue. The systems utilized to

c. The number and location of these signs will beperform these operations will vary in arrangement of determined by the Base CE in consultation withpumps, piping, electrical equipment, and assorted compo- Ground Safety. Coordination with Airfield Man-nents. Personnel performing fuels handling operations with agement IAW AFI 13-213 is required before post-these systems will be proficiency evaluated and qualified ing any signs in the flight line area.IAW AFI 23-201 and AFI 36-2201 prior to performing these duties without supervision. In addition, a working

2.3 FUEL RECEIPTS.knowledge of the design and function of system compo-nents will aid in localizing maintenance problems. Specific When a shipment of fuel arrives on base, the receiptoperating procedures applicable to the installed item will be documentation and inspection procedures will be IAWprovided by the installation CE. Safety precautions and AFMAN 23-110, DoD 4140.25M, TO 42B-1-1, AFIservicing constraints outlined in TO 00-25-172 must be 23-201, and MIL-STD-3004.followed during aircraft fueling operations. Fuels personnel must comply with the lightning and hazardous weather

2.4 FROZEN VALVES.instructions outlined in AFOSH Standard 91-38 and AFI

23-201.

WARNINGa. A two-person policy is required for safety reasons for most fuel handling operations. AFI 23-201 provides specifics.

Under no circumstances shall an open flame or electrical heating element be used for thawingb. Bulk fuel off-loading headers not within secure frozen valves on tank trucks/cars.fenced areas must be key locked IAW AFI 23-201.

A steam jet, hot water, or hot cloth may be used to thawc. The Liquid Fuels Maintenance (LFM) element will frozen tank car/truck valves.coordinate all maintenance activities with the

Resources Control Center (RCC) prior to start and

2.5 RECEIPT OPERATIONS TANK TRUCK/CAR.completion of work on any fuel system.

d. All local procedures and checklists covering the NOTE movement of fuel will contain emergency shut-down procedures. A visual fuel flow indicator will be installed on the off-loading headers to enable the operatore. Before fuel off-loading operations begin, ensure to shut off the pumps when off-loading isthe receiving tank has sufficient ullage to receive complete. See UFC 3-460-01 for indicatorthe product.

specifications.

f. Conspicuously post the Safety Guide for Hydrocar- The following procedures will be used in conjunction withbon Fuels (AFOSH Standard 91-38, Attachment 3) directives referenced in Paragraph 2.3.at permanently installed facilities.

a. Before fuel off-loading operations begin, ensure

2.2 FIRE PROTECTION. the receiving tank is the correct grade and has sufficient ullage to receive the product. Also, to

a. Adequate fire protection shall be provided and remove any internal water perform product recov-properly located as determined by the Base Fire ery operations on the jet fuel tanks that will receive Chief. Danger signs for bulk fuel storage areas will fuel.

be worded as follows: NO OPEN FLAME OR IGNITION SOURCE BEYOND THIS POINT. b. Ensure the fuel transport conveyance is properly positioned to allow for rapid egress in case of

b. When practical, danger signs will be posted 50 feet emergency. Ensure grade, quantity, and seal num-from dike areas, tank vents, low point drains, and bers (if applicable) agree with the DD Form 250, lateral control pits. Signs will be worded NO

Change 1 2-1

Bill of Lading, or contractor delivery ticket. If the j. Upon completion of off-loading product, close documentation is not available upon arrival of the valves IAW local procedures.

conveyance, contact the appropriate DLA quality

k. Ensure tank truck/car is empty, close dome (ifrepresentative and follow the procedures in applicable) and remove off-loading hose.AFMAN 23-110.

l. Remove grounding/bonding cable and drip pan.c. Place danger signs at least 50 feet from tank trucks/cars prior to the beginning of off-loading

2.6 PIPELINE, BARGE, AND TANKER RECEIPTS.operations. Signs are not required when off-loading at the base service station or within posted secured

Ensure communication (hot line, radio, telephone, etc.)areas.

between pipeline pump station, barge, or tanker and receipt

d. Connect grounding/bonding cable to a metal sur- location is established prior to starting any receipt actions.

face on the tank truck/car (see Figure 2-1 and Communication devices in hazardous areas must be suita- Figure 2-2). No grounding/bonding is required for ble for use in Class I, Division 1, Group D areas.

railroad tank cars if the spur tracks are bonded

a. Only trained personnel familiar with the systems’together/grounded or electrically isolated from the operating actions are permitted to perform productmain line as determined by CE Electric Shop receipt.personnel.

b. Barges and tankers will be grounded/bonded IAW

UFC 3-460-03.

WARNING

Due to the inherent fall potential, personnel CAUTION should not routinely climb on top of fuel tank trucks or tank cars. Bases equipped with ATG, Receiving simultaneously into multiple (i.e.Visual Flow-type gauges, and in-line sampling manifold) storage tanks is not authorized unlessconnections on receipt headers shall develop all tanks are equipped with high level alarms orprocedures to minimize the time personnel high level automatic shutoff valves.must go on the top of tank trucks and tank cars to ensure quality/quantity of DESC-owned

c. Check receipt paperwork. Ensure the storageproduct.

tank(s) contain the correct grade of fuel and has sufficient ullage. Product recovery systems will bee. Check seals and perform required fuel quality operated to remove all water prior to receipt.sampling, if required and as necessary.

d. Open valves required to fill the receipt tank(s) IAW local procedures.

WARNING e. When the receipt (off-loading operation) is com-plete, close all valves IAW local procedures.

Do not open tank car manifold valve prior to f. Remove grounding/bonding cables.

connecting the off-loading hose. The valve is spring-loaded and when actuated is 100% open. 2.7 TRANSFERRING PRODUCT BETWEEN BULK

AND OPERATING STORAGE.f. Ensure the off-loading outlet valve is closed and a metal or rubber drip pan is placed under the outlet

The following will be accomplished:and bonded to the tank car/truck prior to removing the dust cap. If rubber containers are used, bonding

a. Ensure adequate communication is availableis not required.

between transfer and receiving points. If telephone communication is used, ensure a telephone alarmg. Connect off-loading hose to tank truck/car can be heard from outside of the transfer andoff-loading outlet.

receiving points.

h. Open valves IAW local procedures.

b. Ensure the storage tank contains the correct grade

i. Observe system for leaks. of fuel and has sufficient ullage. Product recovery systems will be operated to remove water prior to the transfer.

2-2

c. Open appropriate valves IAW local procedures on Time is required for the electrostatic charge in the fuel to selected tanks and piping. relax.

CAUTION CAUTION

Receiving simultaneously into multiple (i.e. Receiving simultaneously into multiple (i.e.

manifold) storage tanks is not authorized unless manifold) storage tanks is not authorized unless all tanks are equipped with high level alarms or all tanks are equipped with an operational high high level automatic shutoff valves. level alarm or high level automatic shutoff valves.

d. Receiving operator must be stationed in the imme-diate vicinity of the tank to monitor the receipt a. Top filling where the fuel free falls or splashes is unless the tank is equipped with a high level alarm prohibited. Electrostatic charges buildup very rap-that can be heard outside of the tank area. idly during this type of operation and can cause an explosion.

e. Upon completion of transfer, close appropriate valves and reposition electrical controls IAW local b. The fill rate for an empty (or nearly empty) tank procedures. must be reduced to prevent excessive agitation, turbulence, spraying, and misting which results in a

f. Complete accounting documents IAW AFMAN high rate of static generation. The fuel velocity

23-110. shall not exceed 3 feet per second until the liquid level is 1 foot above the inlet level. Floating roof

2.8 FILLING BULK STORAGE TANKS. tanks require the same precautions until the roof becomes buoyant (see Table 2-1). CE will provide

Storage tanks present greater electrostatic hazards due to procedures and checklists to ensure the 3 feet per their large size. It is possible to have an electrostatic second is maintained.

discharge from the surface of the liquid to the tank shell or

c. The presence of water, entrapped air, or foreignto objects within the tank or container. Bonding and particles in the fuel tends to increase the staticgrounding do not eliminate this potential interior hazard.

charging rate. Care must be exercised to prevent the entrance of these materials into the fuel system.

Figure 2-1. Tank Truck Grounding

2-3

Figure 2-2. Tank Car Loading

Table 2-1. Initial Flow Rates for Storage Tanks

3 Ft/Second Velocity

Pipe Size Gal/Min Barrels/Hour 4 inches 120 171

6 inches 270 385

8 inches 480 685

10 inches 750 1,071

12 inches 1,080 1,542

14 inches 1,470 2,099

16 inches 1,920 2,741

d. Personnel will not be allowed in pits located on top a. Fires have occurred as a result of using unautho-of underground or cut and covered/hardened tanks rized portable pumps during fuel handling opera-during fuel receipt or transfers. Personnel are also tions. Such accidents have occurred during the restricted from on top of aboveground storage following operations:

tanks during fuel receipt or transfer.

(1) Preparation for and during tank cleaning.

e. Storage tank manual gauging, if required, will not

(2) Transfer of product from a storage tank whenbe performed during or for 30 minutes after filling the installed fuel transfer pump is inoperable.(see Paragraph 2.12).

(3) Transfer of product from a storage tank wheref. Sampling will be IAW T.O. 42B-1-1.

there is no installed fuel transfer pump.

2.9 IGNITION HAZARDS DURING FUEL

(4) Removal of water from fuel tanks where no

TRANSFER FROM STORAGE TANKS BY OTHER sump drains exist.

THAN NORMAL MEANS.

2-4

(5) Removal of water from various pits in the fuel for the transfer of product from the service system where fuel/water may collect. station tank to the truck/trailer.

(6) Handling waste or recoverable fuels. d. Removing water from fuel tanks without sump drains, or from various pits or other areas where water may collect, requires the same precautions as if fuel was being handled. Only approved equip-ment will be used, such as the equipment listed inCAUTION AS 488. Removing water with hand operated pumps is authorized.

In order to maintain quality control of the system, residual fuel or sludge from a tank will 2.10 PUMPS.

not be removed through the manifold/transfer lines.

b. When fuel tanks are being prepared for cleaning or WARNINGmaintenance, fuels personnel will remove fuel to the lowest point possible utilizing the installed pumping system or by gravity flow. Upon comple- The use of internal combustion engine driven, tion, the entire operation will be transferred to CE reciprocating, open-diaphragm pumps (Mud who will remove any recoverable fuel IAW appli- Hog), for pumping petroleum products, is cable directives. Residual fuel or sludge will be prohibited.

removed by the tank cleaning crew assigned by CE or contract. a. Several types of pumps may be used for fuel transfer operations. The pumps may be driven by

c. When fuel is stored in tanks where the installed electric motors, air, or internal combustion engines.

pump is inoperable and cannot be repaired in a In all cases, electrical equipment must conform to timely manner or no installed pump exists, the the safety requirements outlined by the National following will apply, except as noted in Paragraph Fire Protection Association (NFPA) 70, the 2.9c (2) and (3) below. National Electrical Code (NEC) for Class I, Divi-sion I, Group D. All the internal combustion(1) Fuel will be removed by use of:

engines must conform to MIL-HDBK-201 and must be equipped with a spark arresting exhaust(a) One of the pumps in AS 488.

system, shielded ignition system, and totally

(b) A fuel servicing unit selected by the FMFC enclosed spark plug (aircraft engine type) with provided distance pump suction, and safety screw cap.

requirements can be met and quality is not compromised. R-9, R-11, and C-300 NOTE refuelers shall not be used to remove product from underground tanks because of possible Substitution is authorized provided the substi-pump damage. tute pump (if electrical) conforms to Class I, Division I, Group D, as defined by the National

(2) Tanks used for the collection/storage of waste Electrical Code, or (if a combustion engine) fuel are exempt from the requirement for conforms to Paragraph 2.10a.

installed pumps. However, removal of fuel from such tanks must be by pumps listed in AS 488, b. AS 488 specifies the pumps authorized for han-by approved contractor methods, or use of a dling petroleum products. The AS 488 will be vehicle specifically designated for handling amended as other authorized pumping units waste petroleum and so identified with proper become available.

labeling IAW T.O. 36-1-191.

c. Pumps installed for issuing gasoline from military

(3) Fuel tanks, located at military service stations, service stations or organizational issue tanks must which are used to support both vehicle fleets have flow restrictors installed to limit flow rates to and tank truck delivery operations are not maximum of 10 gallons per minute. This require-required to have installed transfer pumps in ment is optional when: (1) organizations handle addition to the normal vehicle delivery pumps. less than 10,000 gallons of gasoline per month, and However, when the installed vehicle service (2) dispensing pumps are dedicated to servicing station pump is used to fill tank trucks, the heavy-duty vehicles.

provisions of Paragraph 2.9c(1)(a) and (b) apply

2-5

(3) Allow water to settle in fuel recovery tank;2.11 PRODUCT SETTLING.

observe the water drain off through the sight glass.Product settling will be IAW T.O. 42B-1-1.

NOTE2.12 GAUGING.

Due to hazards of handling water with FSII concentrations, engineer a system that will pre-WARNING clude any manual handling of tank water bot-toms. T.O. 42B-1-1 and T.O. 42B-1-23 outline

A minimum waiting time of 30 minutes after procedures for handling water bottoms.

completion of fuel receipts, transfers, or move-ments is required before insertion of any object (4) Position appropriate valves and transfer all into storage tanks. This is a safety measure to drained fuel back into tank. To prevent lines permit relaxation of electrostatic charges. from freezing and becoming inoperative at northern tier locations, product recovery sys- When available, Automatic Tank Gauging (ATG) is the tems can remain full of fuel upon completion of primary method of fuel tank inventory control. Whenever water draining operations. This practice will be the accuracy of an ATG is questioned, a calibration for limited to only those locations that experience inventory control must be performed IAW the Manual of routine subfreezing temperatures, and is author- Petroleum Measurement Standards, Chapter 3 (Tank Gaug- ized only during the time of year these tempera-ing), Section 1B (Standard Practice for Level Measurement tures are expected.

of Liquid Hydrocarbons in Stationary Tanks by Automatic Tank Gauging). Accordingly, for manual tank gauging (5) Close appropriate valves upon completion of operations, the procedures outlined in the Manual of Petro- fuel transfer.

leum Measurement Standards, Chapter 3 (Tank Gauging),

(6) Lock the water draw-off valve.Section 1A (Standard Practice for the Manual Gauging of Petroleum and Petroleum Products) must be complied with.

b. Oil/water separators are real property. Maintenance and operation is the responsibility of CE.2.13 LEAK DETECTION.

(1) Position oil skimmer so slot is level with top of The FMT will coordinate with the BCE and the Base water in the separator to properly separate fuel Environmental Manager to ensure leak detection systems from water.

are in place that comply with federal, state, and local environmental requirements. (2) Open the gate valve of the separator pit.

(3) Ensure only fuel is flowing into the relief tank2.14 PRODUCT RECOVERY SYSTEM AND from the oil skimmer.

OIL/WATER SEPARATOR.

(4) Regulate water flow as required.

a. Operation of the product recovery system and water drain system will be constantly attended by a (5) Close the gate valve when water flow has qualified fuels operator and/or LFM personnel. stopped.

(6) Water will be drained and disposed of IAWNOTE federal, state, and local environmental laws and regulations.The fuel/water will not be drained onto the ground. Dispose of IAW local, state, and fed-

2.15 TANK CLEANING AND INSPECTIONeral environmental laws and regulations.

CRITERIA.

(1) Unlock the water draw-off valve and position valves to allow flow into recovery tank. a. FM must be familiar with tank inspection and cleaning requirements IAW UFC 3-460-03. Sam-(2) Ensure the product recovery tank is capable of ple IAW T.O. 42B-1-1 and for Special Fuels IAWholding the recovery line displacement plus 20 T.O. 42B1-1-16.gallons of liquid. Fill the recovery tank with product. If cloudy, drain into a bowser or collec- b. Tank inspections/cleaning will be scheduled tion tank and continue the recovery tank according to UFC 3-460-03. Minor deviation in fill/drain process until the product becomes frequency of tank inspection because of nonavaila-clear in appearance. bility of tank cleaning personnel or a

2-6

Bio-Environmental Engineer, receipt problems, (3) Ground Fuels − MAJCOMS will develop a etc., are permitted for up to 45 days. Periods in positive control method to prevent commingling excess of 45 days must be approved by the of products and implement resource protection MAJCOM Fuels Officer/Fuels Engineer. Locations controls IAW AFI 23-201. The following are with large amounts of dormant storage that cannot recommended servicing controls:

rotate the product to empty tanks to perform tank inspections/cleaning without creating severe opera- NOTE tional problems can request a time extension from their MAJCOM Fuels Officer/Fuels Engineer, pro- Organizational tanks are exempt from bottom vided fuel sample results are satisfactory. loading requirements. Examples of mobile organizational tanks are A1B trailers and skid

2.16 SERVICING CONTROLS. POD tanks.

(a) Diesel Fuel − if two grades of diesel areServicing controls are required to assure the correct grade handled, the couplers will be reversed; i.e.,of fuel is issued by refueling equipment. Refueling equip-diesel fuel unit will have a male fitting with ament must be filled with the correct fuel and the right female fitting on the fillstand; biodiesel fuelequipment must be used to dispense the fuel to the air-unit will have a female fitting with a malecraft/equipment. Quick-disconnect couplers (such as fitting on the fillstand.Kamlok or equivalent) will not be used in permanently installed fillstands. However, quick-disconnect couplers

(b) Unleaded Mogas − the 2-inch dry break typemay be used when storage fillstands are used to support coupler will be used.inter-service refueling equipment such as Army refueling vehicles. If quick-disconnect couplers are required by a TO

2.17 DISPENSING FUEL FROM TRUCKon portable fuel systems (FORCE, FMSE, etc.) all ears on each hose connection will have a functional double locking FILLSTAND BOTTOM LOADING.

device, safety-wired with a minimum 4 strand wraps or secured with nylon cable ties. For locations with more than a. Position the vehicle to prevent stress on compo-one grade of aviation fuel, the use of a locking control nents during connection and fuel transfer. Engage system for bottom loading refueling units from fillstands is the parking brake. Engines on all refueling equip-mandatory. ment will be turned off.

NOTE b. Ensure vehicle is bonded to the fillstand or hose-cart prior to making any fuel nozzle connection.

Additional requirements for servicing controls

c. Position valves and electrical controls IAW localare outlined in AFI 23-201.

procedures. Perform the issue operation.

a. The use of selective couplers for bottom loading of

d. Upon completion of the issue, push stop switch onground fuels from fillstands is required, and the the fillstand to ensure the pump is not operating,type of coupler used for each grade will be deter-position valves and electrical controls IAW localmined by the MAJCOM.

procedures.

b. Bottom Loader Requirements:

e. Complete accountable documents IAW AFMAN

23-110.(1) Jet Fuels − the single point receptacle will be used on jet fuel refueling units with a single

f. Disconnect and stow grounds/bonds.point nozzle on the fillstand. Where more than one grade of jet fuel is handled at a base, the 3-

2.18 TANK TRUCK/CAR TOP LOADINGinch dry break coupler may be used and a lock control system for the refueler bottom loader OPERATION.

control is required. Strainers are not required in fillstand single point nozzles. An approved waiver will be obtained from the parent

MAJCOM Fuels and Safety Officers prior to performing

(2) Avgas − where one grade of avgas and one fuel top loading operations. A recognized hazard of top grade of jet fuel is handled at the base, FM will assure a positive control method is in effect to prevent commingling of fuel.

Change 1 2-7 loading is the turbulence, splashing, and spraying of prod-uct resulting from too high initial fill rate and downspouts

WARNINGnot being extended to the bottom of the tank. The following measures will be used to minimize the potential hazard.

• Cell phones may cause an explosion/fire ifa. The storage operator will direct refueler operator in used when fueling a vehicle with gasoline.positioning the vehicle to prevent stress on compo- Conspicuously post a sign at the pumpsnents during the fuel transfer.

which states: NO CELL PHONES. TURN CELL PHONES OFF PRIOR TO FUEL-b. Ensure the vehicle is bonded to the fillstand.

ING VEHICLE.

c. Position valves and electrical controls IAW local

• Plastic truck bed liners have caused staticprocedures.

buildup that resulted in a fire while filling

d. Begin filling at an initial rate not to exceed 3 feet gasoline cans. Place a danger sign(s) con-per second. This flow will be observed until the spicuously located at the pumps depicting fuel level is at least 1 foot above the opening of the the words: DANGER − FILLING FUEL downspout. CONTAINERS ON PLASTIC BED LIN-

ERS CAN RESULT IN

e. Upon completion of the issue, stop the pump and FIRE/EXPLOSION. PLACE CONTAIN-position valves and electrical controls IAW local ERS IN CONTACT WITH THE procedures. GROUND.

f. Disconnect and stow ground/bond cable. NOTE

g. Complete accountable documents IAW AFMAN Pumps installed for issuing gasoline from mili-23-110.

tary service stations or organizational issue tanks must have flow restrictors installed to2.19 REFUELING UNIT RETURN TO BULK limit flow rates to maximum of 10 gallons per

STORAGE (RTB). minute. This requirement is optional when: (1) organizations handle less than 10,000 gallons

a. The refueling unit operator will position the vehicle of gasoline per month, and (2) dispensing as directed by the storage operator. pumps are dedicated to servicing heavy-duty vehicles.

b. Ensure the vehicle is bonded to the storage system.

The following procedures will be adhered to:

c. The storage operator will ensure there is ullage in the storage tank. Open appropriate valves IAW a. Storage personnel open appropriate issue valve(s) local procedures. and position electrical controls.

d. Upon completion of the operation, position all b. For automated service stations, ensure complete valves IAW local procedures. operating instructions are conspicuously posted.

e. Disconnect and stow grounding/bonding cables. c. See AFI 23-201 and AFOSH Standard 91-38 for guidance associated with operating the Automated

f. Complete accountable documents IAW AFMAN Fuels Service Station during lightning and weather 23-110. warnings.

2.20 SERVICE STATION OPERATION.

2-8

d. Type III pumphouses shall be manned or have an2.21 HYDRANT ISSUES TO AIRCRAFT OR operator in the immediate vicinity when the selec-

REFUELING UNIT(S). tor switch is in the AUTOMATIC mode unless the RCC is equipped with an operable PUMP ON

NOTE indicator light and emergency shutoff switch.

When a Type III system is not going to be used for extended periods, turn the selector switch to OFF.Multiple refueling (hot or cold) on a single

Type II hydrant system lateral is authorized

e. Upon completion of fueling operation, close appro-provided the servicing equipment has an auto-priate valves and reposition electrical controls IAWmatic pressure control valve with a deadman local procedures.control or a pit control valve with a deadman control at the hydrant outlet. Also, the require-

2.22 DEFUELING INTO HYDRANT SYSTEMS.ment for secondary filtration at the skin of the aircraft must be met or the lateral piping must Close monitoring of this operation is required. Ensure therehave internal epoxy coating per T.O. 42B-1-1.

is sufficient ullage in the tank to receive the defuel. It mayEquipment used for hot refueling must be IAW be necessary to transfer fuel to other tanks to prevent anT.O. 00-25-172.

overflow if the system has limited defuel capacity or a high

a. Select operating tank(s). level shutoff/alarm system. Detailed procedures will be developed locally.

b. Position pump selector switch(es) and open appro-priate valves to the tank(s) IAW local procedures. NOTE

c. The MAJCOM Fuels Office shall develop a formal T.O. 00-25-172 identifies the aircraft certifiedFuels Operating Instruction/Policy Document out-for rapid defueling.lining the manning requirements for Type I, II, IV, and V Hydrant Systems.

2-9/(2-10 blank)

CHAPTER 3

OPERATOR’S INSPECTION AND MAINTENANCE

d. One for each liquefied petroleum gas system.3.1 GENERAL.

e. One for each compressed natural gas system.This chapter provides guidance on inspection procedures and reporting deficiencies. Operational, weekly (not to f. One for each deicing fluid system.

exceed 7 days), monthly (not to exceed 31 days), quarterly (not to exceed 90 days), and semiannually (not to exceed 3.5 ACTIVE SYSTEMS.

180 days) inspections are made by the operator or appropri-ate agency to identify deficiencies or maintenance needs The system will be inspected prior to/during each use. The which if uncorrected can compromise the safe and efficient portion of the system being utilized must be monitored operation of the fuel system. The records of inspections and periodically for deficiencies.

deficiencies will assist FM in determining the operational status of the system and to initiate actions to correct any

3.6 FILES.deficiencies. Additional inspection and maintenance pol-icy/guidance is given in UFC 3-460-03.

The completed AFTO Form 39 will be retained by FM for a period of 3 years IAW AFMAN 37-139. AFTO Forms 39

3.2 SYSTEM DEFICIENCY. may be kept on file longer than 3 years if required to support more stringent environmental mandates.

Any deficiency compromising quality of product, hazards to the environment, or safety of operation and personnel

3.7 AFTO FORM 39, PAGE 1.will be considered adequate justification for placing the system out of service utilizing the AF Form 979, Danger

Complete as follows:Tag, IAW AFI 23-201 and AFOSH Standard 91-501. The FMFC will inform the Commander, MAJCOM Fuels a. Facility No. and Type − enter the assigned fuel Office, and affected agencies of any deficiency which system number and type fuel system, i.e., TYPE I, compromises accomplishment of the mission. II, III, etc.

3.3 DISCREPANCY RECORD. b. Date − enter the applicable month and year.

c. Supervisor − enter the name and rank of theFM will report all deficiencies to the CE. Deficiencies will supervisor or person responsible for that particularbe recorded on the AFTO Form 39, Fuel System Inspection system.Guide and Discrepancy Record. Only those items that affect fuel system operations, product quality, or safety will

d. Items to Be Inspected − additional inspection itemsbe recorded on the AFTO Form 39 discrepancy section.

may be incorporated for local use as directed by theGeneral housekeeping items shall not be included (i.e., FMFC. Items not associated with the system beingreplacement of light bulbs, broken windows, leaking water inspected will be marked out on the AFTO Formfaucets, door discrepancies, etc.). General housekeeping

39. For those locations having an automated ser-items being monitored may be filed along with the AFTO vice station, refer to the operation manual andForm 39.

annotate AFTO Form 39 as appropriate.

3.4 INSPECTION GUIDE. e. Items to Be Inspected Weekly − operator will annotate the date of weekly inspection in the

Base fuel systems will be inspected using the AFTO Form blocks provided.

39. A computer generated AFTO Form 39 may be used provided the form does not take away from the intent of the f. Items to Be Inspected Monthly − the operator will current form. Each form provides a monthly record of annotate completion dates.

system inspections and maintenance actions. A separate form will be used for each of the following areas: g. Items to Be Inspected Semiannually − carry for-ward past inspection dates. After the inspection is

a. One for each bulk storage area. performed, change date to reflect the current inspection.

b. One for each immediate operating storage system.

h. Fuels Supervisor Inspection − the fuels storage

c. One for each automotive service station. supervisor must perform weekly inspections and

Change 1 3-1 annotate the AFTO Form 39 in the FUELS LFM/FUELS FACILITIES SUPERVISOR SUPERVISOR INSPECTION section. INSPECTION Section (Page 1). The inspection by the FMFC/Fuels Manager/Superintendent will suf-

i. The signature area with corresponding lines and 31 fice for the weekly inspection performed by the numbered blocks on the AFTO Form 39 may be fuels storage supervisor.

used at the option of the applicable MAJCOM Fuels Office. b. The FMFC and Fuels Manager/Superintendent will review completed AFTO Forms 39 monthly and sign on Page 2 accordingly. The remarks section3.8 AFTO FORM 39, PAGE 2.

will be used to explain circumstances which pre-vent any inspection. Criteria for LFM inspectionThe following is an explanation of the column headings:

frequency is found in UFC 3-460-03.

a. Discrepancy − enter a brief description of each

c. Monthly inspections of unmanned locations will beindividual discrepancy.

performed by the FMFC. This inspection may be

b. Date Disc − enter date the discrepancy is performed by a designated representative provided discovered. the FMFC performs the inspection at least once during each quarter.

c. Date − enter date the discrepancy is reported to CE.

3.10 OPEN DISCREPANCIES.d. Time − enter the time discrepancy is reported to

CE.

When a new AFTO Form 39 is initiated, all open discrep-ancies including the maintenance status will be transcribede. Initial − the individual completing the REPORTED to the new Fuels System Inspection and DiscrepancyTO MAINTENANCE part will initial in this space.

Record.

f. Work Order Number − enter the Job/Work Order Number provided by CE (via telephone or by 3.11 OPERATIONAL INSPECTIONS.

receipt of Job/Work request form).

Items requiring inspection during operation as shown on

g. Maintenance Status − this section will be com- AFTO Form 39 under OPERATIONAL are explained pleted in pencil by LFM personnel. When a status below. Items which are not installed in the system will be code changes, the date will be changed to corre- lined out.

spond to the date the status code changes. If no code change on the carried forward list from the a. Hoses, Nozzles, and Couplers − installation and previous month AFTO Form 39, the storage super- maintenance will be IAW T.O. 37A-1-101.

visor will initial the open entries.

(1) Inspect nozzles and couplers for serviceability.

(1) Date − enter date maintenance action is initiated

(2) Check hose for wear, abrasion, and slippage ator status code is changed.

the coupler. If determined by the FMFC or LFM

(2) Status Code − enter appropriate code. that protection of the hose is needed, hose protection can be provided by the use of a

(3) Follow-up Date − enter date of follow-up action polyurethane plastic sleeve commonly known as for open work orders. a slinky. The slinky can be ordered in 3 colors:

optic orange, NSN 4720-01-328-8846; dark

(4) Initial − individual annotating status code will green, NSN 4720-01-328-8845; and sand matte, enter their initials. NSN 4720-01-328-8844.

3.9 MANAGEMENT MONTHLY INSPECTION. (3) When hose is not in use, store on hangers or racks, and keep covered. Hoses must not be

a. The fuels storage supervisor must perform weekly allowed to be stored with kinks.

inspections and sign/date the AFTO Form 39 in the

(4) All hoses not connected to a nozzle will beLFM/Fuels Supervisor Inspection (Page 1). At least capped IAW T.O. 37A-1-101.once a month, the LFM supervisor and FMFC or

Fuels Manager/Superintendent will conduct an

(5) Keep clean and free from oil and grease.inspection of each storage system. Although pre-ferred, it is not mandatory for both functional areas

(6) Check for hose slippage.to perform the inspection concurrently. Upon com-pletion of the monthly inspection, the LFM super- b. Static Ground/Bonding Hardware (if installed).

visor and the person performing the Fuels inspec-tion shall sign and date the AFTO Form 39 in the

3-2 and high level alarm. On filter separators that do not meet USAF design criteria, the automaticNOTE water discharge valve and line shall be removed or rendered inoperative.Ohm continuity checks required upon initial installation, when repaired, and whenever con- NOTEtinuity questioned.

(1) Clamp − inspect for serviceability. Replace The procedure for removing/disabling filter clamp if jaws are deformed or corroded, spring separator automatic drain valves are addressed is weak, or other defects are evident that would in HQ AFCESA/ENM letter dated 26…