UFC3-460-03.pdf

UFC 3-460-03

21 JANUARY 2003

UNIFIED FACILITIES CRITERIA (UFC)

OPERATION AND MAINTENANCE:

MAINTENANCE OF

PETROLEUM SYSTEMS

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

UNIFIED FACILITIES CRITERIA (UFC)

OPERATION AND MAINTENANCE:

MAINTENANCE OF PETROLEUM SYSTEMS

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

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

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY (Preparing Activity)

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

Change No. Date Location

The format of this document does not conform to UFC 1-300-01.

It will be reformatted at the next revision.

This UFC supersedes AFM 85-16, Maintenance of Petroleum Systems.

FOREWORD

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

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

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

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure that they are current.

AUTHORIZED BY:

DONALD L. BASHAM, P.E.

Chief, Engineering and Construction U.S. Army Corps of Engineers

DR. JAMES W WRIGHT, P.E.

Chief Engineer Naval Facilities Engineering Command

KATHLEEN I. FERGUSON, P.E.

The Deputy Civil Engineer DCS/Installations & Logistics Department of the Air Force

Dr. GET W. MOY, P.E.

Director, Installations Requirements and Management Office of the Deputy Under Secretary of Defense (Installations and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf https://www.projnet.org/projnet/cms/public.html http://dod.wbdg.org/

Civil Engineering

MAINTENANCE OF PETROLEUM SYSTEMS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

OPR: HQ AFCESA/CESM (Mr. Pat Mumme) Supersedes: AFM 85-16, 18 August 1981

This manual implements Air Force Policy Directive (AFPD) 32-10, Installations and Facilities, by providing guidance for base and command liquid fuels maintenance (LFM) personnel with guide procedures for field maintenance of permanently installed Air Force-owned, -leased, or -controlled petroleum storage and dispensing systems. It also supplements detailed manufacturers’ instructions on specific equipment and applies to all Air Force systems and activities for which the civil engineer (CE) has maintenance responsibility.

Chapter 1�SCOPE AND RESPONSIBILITY

1.1. Purpose and Scope

1.2. Organizational Responsibilities

Chapter 2. PIPELINE SYSTEMS

2.1. On-Base Pipelines

2.2. Operating On-Base Petroleum Systems

2.3. Maintenance of On-Base Pipelines

2.4. Off-Base Pipeline Systems

2.5. General Pipeline System Components

2.6. General Pipeline System Repairs

2.7. Major Repairs

2.8. Pipeline Cleaning

Chapter 3. MECHANICAL SYSTEMS

3.1. General Information

3.2. Pumps

Figure 3.1. Rotary Vane Pump

Figure 3.2. Horizontal Split-Case Pump

Figure 3.3. Vertical Deepwell Turbine Pump

Figure 3.4. Hydraulic Gradient

3.3. Filter/Separators (F/S)

3.4. Meters

3.5. Valves

Figure 3.5. DBB Valve

Figure 3.6. Ball Valve

Figure 3.7. Full Port Ball Valve

Figure 3.8. Gate Valve

3.6. Sump Pumps

3.7. Line Strainers

3.8. Automatic Air Eliminators

3.9. Truck and Tank Car Offloading

3.10. Tanker or Barge Offloading

3.11. Fill Stands

3.12. Ground Product Fueling Systems

Chapter 4. HYDRANT FUELING SYSTEM, TYPE I (PANERO)

4.1. General Information

4.2. Original Panero

Figure 4.1. Modified Panero, Type I Hydrant System

4.3. Modified Panero System Operation

4.4. System Components

Figure 4.2. Nonsurge/Check Valve (81AF)

Figure 4.3. F/S Control Valve (40AF-2A)

Figure 4.4. Refuel/Defuel Control Valve (302AF)

Figure 4.5. Philadelphia Hydrant Adapter

Figure 4.6. Liquid Level Gauge (Liquidometer)

Figure 4.7. High-Level Shutoff Valve (124AF)

Chapter 5. HYDRANT FUELING SYSTEM, TYPE II (PRITCHARD)

5.1. General Information

Figure 5.1. Pritchard, Type II Hydrant System

5.2. Deep-Well (Vertical) Turbine Pump

5.3. Nonsurge/Check Valve

Figure 5.2. Nonsurge/Check Valve (81AF-8)

5.4. F/S

5.5. F/S Control Valve (FSCV) (40AF-2C)

Figure 5.3. F/S Control Valve (40AF-2C)

5.6. Refueling Control Valve (90AF-8)

Figure 5.4. Refueling Control Valve (90AF-8)

5.7. Pressure Relief Valve (50AF-2)

Figure 5.5. Pressure Relief Valve (50AF-2)

5.8. Defueling Control Valve (134AF)

Figure 5.6. Defueling Control Valve (134AF)

5.9. Dual Rate-of-Flow Control Valve (41AF)

Figure 5.7. Dual Rate-of-Flow Control Valve (41AF)

5.10. Recommended Setting Procedure for Rate-of-Flow Control Valve (41AF)

5.11. Defueling Pump

Figure 5.8. Self-Priming Centrifugal Defueling Pump

Figure 5.9. Centrifugal Priming Pump Operation

5.12. Remote Controls (Electrical and Magnetic)

5.13. Hydrant Adapter and Liquid Control Valve (352AF)

Figure 5.10. Hydrant Adapter (352AF)

5.14. Hydrant Hose Cart

5.15. High-Level Shut-Off (HLSO)

Figure 5.11. HLSO Valve (129AF)

5.16. Type II Modified (Rapid Flow)

Figure 5.12. Combination Dual Rate-of-Flow Control Valve and Solenoid Valve (41AF-10)

Figure 5.13. Dual Pressure Relief, Solenoid Shutoff, and Check Valve (51AF-4)

Figure 5.14. X73 Aluminum Blanking Cap

Chapter 6. CONSTANT-PRESSURE HYDRANT FUELING SYSTEM, TYPE III (PHILLIPS)

6.1. General Information

6.2. Piping

6.3. Receiving and Storage

Figure 6.1. Type III, Constant-Pressure Hydrant Fueling System

Figure 6.2. HLSO Valve (413AF-5A)

6.4. Pumphouse

Figure 6.3. Rate-of-Flow Nonsurge Check Valve (41AF-1A)

Figure 6.4. F/S Control Valve (41AF-2C)

Figure 6.5. ESO Valve (136AF-9B)

Figure 6.6. HCV (362AF-8)

Figure 6.7. BPCV (58AF-9)

Figure 6.8. D/FV (58AF-9-1)

Figure 6.9. PCV (58AF-3)

6.5. Product Recovery System

Figure 6.10. OV (2129AF)

6.6. Sequence of Operations

6.7. Leak Detection

Chapter 7. FUEL STORAGE TANKS

7.1. General Information

Figure 7.1. Air Force Standard Tank

Figure 7.2. Water Draw-Off System

Figure 7.3. Water Draw-Off System Detail

7.2. Types of Tanks

Figure 7.4. Floating Pan

Figure 7.5. Floating Pan Detail

Figure 7.6. Floating Pan Seal

Figure 7.7. New Standard Tank Seal

Figure 7.8. Automatic Float Gauge

Figure 7.9. Automatic Float Gauge Head

Figure 7.10. Automatic Float Gauge – Floating Pan

Figure 7.11. Horizontal Cylindrical Tank

7.3. Maintenance of Storage Tanks

7.4. Pressure Vacuum Vents

Figure 7.12. Pressure Vacuum Vent

Figure 7.13. Belowground Tank Vent

7.5. Diking

Chapter 8. SAFETY AND ENVIRONMENT

8.1. General Safety

8.2. Safety Precautions and Hazards of Liquid Petroleum Products

8.3. First Aid

8.4. Preventing Petroleum Fires

Chapter 9. ELECTRICAL GROUNDING AND BONDING

9.1. General Information

9.2. Static Charge Generation in Refueling Systems

9.3. Preventing Static Electricity

9.4. Relaxation (Release) of Electrostatic Energy

9.5. Grounding or Bonding Procedures

Figure 9.1. Aboveground Tank-Grounding Procedures

Figure 9.2. Typical Method of Grounding Pier, Floating, and Barge Facilities

Figure 9.3. Typical Method of Bonding Ladders on Floating Roof Tanks

Figure 9.4. Truck Fill Stand and Unloading Area Grounding

9.6. Electrical Currents

9.7. Stray Currents

9.8. Electrical Inspection, Testing, and Identification Procedures

Chapter 10. RECURRING MAINTENANCE

10.1. General Information

10.2. Responsibilities

10.3. Recurring Maintenance and Inspections

Table 10.1. Preventive Maintenance References

Chapter 11�ENTRY FOR INSPECTING, CLEANING, REPAIRING, AND COATING LIQUID PETROLEUM TANKS

11.1. Introduction

11.2. Standards

11.3. TES Certification Requirements

11.4. Tank Entry Personnel Requirements

11.5. Confined Space Entry Requirements

11.6. Tank Cleaning Crew

11.7. Tank Entry Coordination

11.8. Tank Entry Preparation

11.9. Emptying the Tank

11.10. Isolating the Tank

11.11. Vapor Freeing

11.12. Atmospheric Testing

11.13. Initial Tank Cleaning from Outside the Tank

11.14. Tank Entry

11.15. Repairs

11.16. Returning to Service

11.17. Inactivation

11.18. Tank Entry Equipment and Personnel Clothing

Chapter 12�CONTRACT WORK

12.1. General Information

12.2. Contract Requirements

12.3. TES

12.4. Air Force Forms Prescribed

Attachment 1. GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION

Attachment 2. CAPACITY OF VERTICAL TANKS

Attachment 3. TEST PROCEDURE FOR SETTING THE PRESSURE

DIFFERENTIAL CONTROL (CDHS-3)

Attachment 4. SUGGESTED VALVE TAGGING METHOD

Attachment 5. PROGRAMMING FUELS PROJECTS

Attachment 6. TANK IN-SERVICE INSPECTION CHECKLIST

Attachment 7. RELATED NATO STANAGS/APS/STUDIES � PETROLEUM

HANDLING EQUIPMENT WORKING GROUP RESPONSIBILITY

Chapter 1

SCOPE AND RESPONSIBILITY

1.1. Purpose and Scope. Clean, water-free fuel of the correct grade is essential to the safety of aircraft and the crews that fly them. This manual emphasizes preventive maintenance to avoid system shutdowns, prevent fuel contamination, and decrease fire, safety, and health hazards. Periodic inspections and servicing are essential to continue efficient safe operations and reduce major repairs.

1.1.1. This is not a design manual. Refer to Military Handbook (MIL-HDBK) 1022A, Petroleum Fuel Facilities, for current construction standards. MIL-HDBK-1022A cannot be used as the only justification to upgrade facilities. It also references standard designs for aboveground storage tanks and Type III and Type IV/V aircraft fueling systems. For related overseas designs contact your major command (MAJCOM) fuels engineer.

1.1.2. This manual applies to all real property facilities used for storing, distributing, and dispensing fuels for reciprocating and jet engine aircraft, unconventional fuels for jet thrust augmentation, liquid propellants for missiles or rockets, automotive fuels, aircraft lubricating oils, and military all-purpose diesel fuel. This manual does not cover mobile fueling equipment because it is not a base civil engineer (BCE) responsibility, nor does it include heating oil systems or power production fuel systems.

1.1.3. This manual establishes the minimum maintenance standards for fueling systems and applies to all active installations. If the installation is in an inactive or surplus status, reduce maintenance standards to a point consistent with the anticipated mission. If existing Department of Defense (DoD) directives are available with clearly outlined maintenance guidance, you will be referred to those publications. This will standardize maintenance requirements between the fuel system operators and the liquid fuels maintenance personnel and reduce revisions and administrative requirements.

1.1.4. All organizations must comply with Federal, state and local environmental regulations. Where conflicts occur, the more stringent regulations will apply. Oversea locations must comply with the final governing standards (FGS) for their respective country or this manual, whichever is more stringent.

1.1.5. Installations with a North American Treaty Organization (NATO) mission, including certain continental United States (CONUS) locations, must comply with applicable NATO Standardization Agreements (STANAG) (see Attachment 7).

1.2. Organizational Responsibilities.

1.2.1. Fuels Management Flight (FMF). The FMF ensures the safe and efficient receipt, storage, handling, issuing, and accounting of all petroleum products.

1.2.1.1. The FMF analyzes fuel quality throughout the system and is responsible for operational maintenance.

1.2.1.2. Operational maintenance is limited to external cleaning, lubrication of mechanical parts (excluding oiling of motors), cleaning strainers, and reporting deficiencies. Other maintenance performed by the FMF is outlined in Technical Order (T.O.) 37-1-1, General Operation and Inspection of Installed Fuel Storage and Dispensing Systems. This does not prevent the FMF and the BCE from establishing a memorandum of agreement (MOA) to have operators perform minor maintenance within their capabilities.

1.2.1.3. FMF is responsible for draining roof drains and interior dike basins.

1.2.2. BCE Responsibilities. BCE maintains, repairs, and constructs real property, including petroleum storage and dispensing systems. Administrative requirements in Air Force Instruction (AFI) 32-1001, Operations Management, apply to this manual. Additionally, the BCE:

1.2.2.1. Maintains a complete and current file of as-built system drawings, detailed master plans, master-certified tank calibration charts, and military and commercial publications that apply to the system.

1.2.2.2. Keeps fire protection facilities in a constant state of readiness according to Air Force Occupational Safety and Health (AFOSH) Standard 91-56, Fire Protection and Prevention.

Training, inspection, maintenance, and repair of fire protection facilities and equipment, including fixed suppression systems, fire extinguishers, blankets, and signs, are the responsibility of the base fire department.

1.2.2.3. Develops and submits project documentation (DD Form 1391, Military Construction Project Data) to the MAJCOM for transmittal (either directly or through the commander) to the Defense Energy Support Center (DESC). DESC is responsible for funding military construction (MILCON), maintenance, repair, and environmental (MRE) contract projects, and replacing equipment items relating to petroleum, oil, and lubricants (POL) systems within their area of responsibility. Recurring maintenance is not typically funded; however, in certain instances funds will be provided where poor fuel quality has caused equipment failure (see Attachment 5).

1.2.2.4. Designs contract projects for fueling systems primarily using architect-engineer (A-E) services. Because there are few engineers (in-house or A-E) experienced in designing fuel systems, bases must consult with the command fuels engineer before starting a project to verify that the proposed approach is feasible. There are many open-end A-E design and design-build contracts available with firms that specialize in DoD fueling systems. Contact the MAJCOM fuels engineer or the Air Force Civil Engineer Support Agency (AFCESA) for assistance.

1.2.3. LFM Responsibilities. The LFM shop has primary responsibility for maintaining and repairing facilities. Routine maintenance is covered in Chapter 10. The LFM shop should:

1.2.3.1. Conduct quality assurance inspections. LFM is responsible for all inspections, repairs, periodic maintenance, and modifications to petroleum systems under its jurisdiction, including inspection of work done by other BCE shops and by contractors. In dealing with contractors, it is not intended that LFM personnel replace the Air Force Contract Management Office (AFCMO);

rather, they should be thoroughly aware of the project scope of work by reviewing project documents during the design phase, periodically observing contractor actions in the presence of the inspector, and participating in the final inspection. Contract discrepancies should be brought to the attention of the contract officer. Care must be exercised to avoid obligating the government either through perceived changes to the contract or delays to the contractor.

1.2.3.2. Aid engineering and FMF in preparing and maintaining flow diagrams and schematics for all systems, and developing the sequence of operations for the systems.

1.2.3.3. Ensure that as-built drawings are current and include changes made to the system either by contract or in-house.

1.2.3.4. Provide and calibrate permanently installed meters (BCE may delegate meter calibration to the motor vehicle maintenance shop when this is advantageous to the Air Force) and schedule meter calibration with the FMF.

1.2.3.5. Ensure all valves are identified both on the charts and on the valve itself by tagging (see Attachment 4). Valve identification is a joint responsibility between LFM and FMF.

1.2.3.6. Provide technical experts to serve as the MAJCOM fuels engineer’s designated representative. Duties include:

1.2.3.6.1. Aiding contract management to ensure work on fuel systems conforms to the applicable regulations and meets the job requirements.

1.2.3.6.2. Recommending approval/disapproval of contract work.

1.2.3.6.3. Overseeing tank cleaning operations.

1.2.3.7. Enforce these mandatory procedures:

1.2.3.7.1. Notify the FMF Resource Control Center (RCC) before removal of a system component or when the system is opened in a manner that may result in a fuel spill.

1.2.3.7.2. Mechanically close off open fuel lines (blind flange, pipe caps, tube fittings) when any system component is removed or altered and left unattended. Except for double block and bleed (DBB) valves, a closed valve upstream that is locked or tagged is not considered a positive shutoff and will not substitute for this requirement. When flanges are used to secure the system, all bolts must be installed. NOTE: The individual who physically removes a component or alters the system is responsible for mechanically closing off open fuel lines prior to leaving the area, so ensuring the integrity of the fueling system. When removing components from any system that remains packed with fuel, provide an alternate means of thermal pressure/vacuum relief if needed. If alternate means are not available, then drain the system until the work is complete. Depending on the volume, 1 °F can cause a pressure change of 75 pounds per square inch (psi) inside a container or pipe.

1.2.3.8. Provide coordination and technical advice to the FMF on proper operation and maintenance (O&M) of the fuel system.

1.2.3.9. Maintain direct server access at the shop, including e-mail and full internet capabilities.

1.2.3.10. Maintain the following records within the shop:

1.2.3.10.1. Facility files. Include copies of completed AF Form 1024, Confined Spaces Entry Permit, AF Form 172, Tank Inspection Summary, hot work permits, strapping charts, waivers, and hose hydrostatic test records.

1.2.3.10.2. Personnel files (health records, respirator fit-test record, training records).

1.2.3.10.3. O&M manuals.

1.2.3.10.4. Current system schematics and as-built drawings.

1.2.3.10.5. Regulations and manuals (Occupational Safety and Health Administration [OSHA], AFOSH, American Petroleum Institute Standards [API Std], MIL-HDBK-1022A).

1.2.3.10.6. Recurring work program (RWP).

1.2.3.10.7. Contractor inspection records (e.g., API 570, Piping Inspection Code: Inspecting, Repair, Alteration, and Rerating of In-Service Piping Systems, API Std 653, Tank Inspection, Repair, Alteration, and Reconstruction, and leak detection reports).

1.2.3.10.8. MAJCOM infrastructure assessment reports.

1.2.3.10.9. Inspection schedules and cathodic protection records.

1.2.4. DESC Responsibilities.

1.2.4.1. DESC manages and funds projects that:

1.2.4.1.1. Directly support the Defense Logistics Agency (DLA) bulk petroleum management mission. Only fixed permanent facilities are eligible. (Contingency facilities do not typically meet these criteria.)

1.2.4.1.2. Either store or distribute DESC product.

1.2.4.1.3. Ensure environmental compliance.

1.2.4.1.4. Protect DESC product from loss or contamination.

1.2.4.1.5. Are of economic benefit to DESC.

1.2.4.1.6. Are directed by DESC, or are necessary to meet minimum inventory level requirements.

1.2.4.2. MILCON Program. DLA and DESC manage the fuels MILCON program (see Attachment 5).

1.2.4.3. DESC manages and funds the MRE program. This program is similar to the O&M program familiar to base-level personnel.

1.2.5. Valve References. Throughout this manual there will be references to automatic valves using Cla-Val model numbers because the majority of Air Force fueling systems are controlled using Cla-Val components. It has also become common practice to refer to valves and pilot valves by the Cla-Val designations, even those provided by other manufacturers. This is not an endorsement of one company over another; rather, it is an expedient to make this manual understandable to the most people. At installations with valves made by other companies, follow the manufacturers’ procedures.

Chapter 2

PIPELINE SYSTEMS

2.1. On-Base Pipelines. On-base pipelines are used to fill base fuel storage tanks, withdraw fuel from base storage tanks, fill trucks, transfer fuel between base storage and operating storage tanks, and fill aircraft from hydrant operating storage tanks and dispensing systems.

2.1.1. Commercial Pipelines. Commercial pipelines deliver fuel to the base fuel storage tanks.

These pipelines are usually underground except at tie-in connections to the base pipelines. These pipelines are constructed on government property by issuing real estate easements. Typically, cross-country pipelines are owned, operated, and maintained by civilian agencies. When a pipeline system is under contract to a civilian agency, civilian responsibility for maintaining the pipeline usually terminates at some point near where the pipeline enters the base. From this point to the bulk fuel storage area, the responsibility for maintenance is assigned to the BCE. The BCE is authorized to perform emergency maintenance on on-base commercial pipelines, if necessary, to protect against environmental damage to public property or meet emergency wartime mission requirements. The real estate easement agreement with the pipeline owner takes note of this and provides for suitable contractor reimbursement to the government. Government-owned or -leased cross-country pipeline systems and marine facilities are in common use in oversea areas. In some areas Air Force personnel maintain these systems.

2.1.2. Bulk Fuel Storage Facility Pipelines. Petroleum fuels may be supplied to bulk fuel storage tanks by inter-terminal pipelines that may be dedicated to serving the particular facility or may be commercial pipelines handling several types or grades of fuel for more than one user. In some cases, the pipeline will be an installation pipeline. Where more than one type of fuel is received or unloaded, separate pipelines and unloading facilities are typically provided for each type of fuel.

2.1.3. Transfer Pipelines. These pipelines carry fuel between base storage, transfer pumphouses, and truck fill stands or hydrant systems. Typically, these pipelines are underground except in the immediate area of the facility involved. Most facilities have separate issue and receipt lines;

however, some facilities use a single line for both.

2.2. Operating On-Base Petroleum Systems. The FMF is responsible for operating on-base petroleum systems, according to AFI 23-201, Fuels Management, and T.O. 37-1-1. The BCE provides the FMF with a current on-base pipeline capacity (in U.S. gallons).

2.3. Maintenance of On-Base Pipelines.

2.3.1. Inspecting Aboveground Piping. Visually inspect for leaks or drips at the same time that other maintenance tasks are performed in these areas. Leaks in an aboveground pipeline require welding for permanent repair (see API Recommended Practice [RP] 1107, Pipeline Maintenance and Welding Practices). Approvals from the MAJCOM fuels engineer, base safety, base environmental engineer, and the base fire department are required before beginning welding or hot work in connection with repairs.

2.3.2. Inspecting Underground Piping. All LFM personnel should be aware of the various underground pipeline routes and make a general visual surveillance when driving by or working in these areas. The pipeline should be walked at least once a year. Leaks in underground pipelines can sometimes be detected by fuel surfacing on the ground, fuel runoff in the storm drainage system, fuel in underground pits or manholes, dead vegetation, or the continuous odor of fuel in a particular area.

Investigate any suspicious circumstances. Consult the base environmental coordinator for guidance before excavating the soil. Periodic documented cathodic protection surveys should be accomplished in accordance with AFI 32-1054, Corrosion Control.

2.3.3. Pipeline Testing. Pipelines must be tested annually for leaks. The MAJCOM fuels engineer may authorize an equivalent methodology as long as state environmental requirements are met.

Pressure tests are affected by weather, so it is best to do them in the spring or fall when fuel, ground, and air temperatures are similar. An overcast day or early in the morning would be preferable to lessen the solar effects on aboveground lines. Maintain all leak test records in the LFM shop for five years unless environmental requirements dictate longer. Send copies of these records to the MAJCOM fuels engineer if requested. Use the following testing approach unless state requirements are more stringent:

2.3.3.1. Annual Pressure Testing. Pressure-test all on-base fuel piping systems annually using existing system pumps. Pressurize unloading, loading, transfer, and hydrant dispensing piping systems by running the appropriate pumps against a closed system until deadhead pressure is reached. Close appropriate valves to trap this pressure in the system, then turn off the pumps.

NOTE: Some ball valves do not provide isolation and require a differential pressure (DP) to seat, so blind flanges may be required. Take pressure gauge readings within fifteen minutes after allowing sufficient time for the fuel pressure to stabilize. Visually check all aboveground piping and piping in concrete pits for leaks. Audibly check closed valves for sound as evidence of an internal valve leak. If no visible or audible leaks occur, then take pressure gauge readings every fifteen minutes for the first hour, and once every half-hour for the next hour. Total time for the pressure test will be two hours. Document all pressure tests by recording the following:

2.3.3.1.1. Name of system test (i.e., refuel header, defuel header, lateral pipelines). Provide facility number.

2.3.3.1.2. Date of test and weather conditions (e.g., sunny and 27 °C [80 °F]; cloudy and 18 °C [64 °F]). NOTE: Record any weather change during the test period.

2.3.3.1.3. Pressure readings:

2.3.3.1.3.1. Start (approximate local time) pressure.

2.3.3.1.3.2. Fifteen minutes (approximate local time) pressure.

2.3.3.1.3.3. Thirty minutes (approximate local time) pressure.

2.3.3.1.3.4. Forty-five minutes (approximate local time) pressure.

2.3.3.1.3.5. One hour (approximate local time) pressure.

2.3.3.1.3.6. One and one-half hours (approximate local time) pressure.

2.3.3.1.3.7. Two hours (approximate local time) pressure.

2.3.3.2. Five-Year Hydrostatic Test. Perform a hydrostatic pressure test every five years on all underground fuel transfer pipelines (product is typically the test media for this test). The MAJCOM fuels engineer sets the specific year. A hand-operated hydraulic pump, or equivalent, with a built-in reservoir tank supplies hydrostatic pressure. This takes the place of the annual pressure test. The hydrostatic test may be conducted using a dual-pressure, temperature-compensating pressure test conducted at the same pressure specified in paragraph 2.3.3.2.2 with MAJCOM fuels engineer approval. The test vendor must have an independent third-party review of the test.

2.3.3.2.1. To test the pipe, first isolate the section being tested with blind or spectacle flanges.

If DBB valves will hold the pressure, blind flanging is not required. NOTE: filter/separators (F/Ss), thermal relief valves, safety valves, and sight glasses may have to be removed or isolated by blind/skillets.

2.3.3.2.2. Using a hand-operated hydrostatic pump, perform a static pressure test to the lesser of 1.5 times the system dead head pressure or 1.896 megapascals (275 pounds per square inch gauge) maximum. Use fuel to perform all tests. Pressure may also be applied with a dead-weight tester or suitable motor-driven pump.

2.3.3.2.3. Once the pressure is stabilized, record the pressure every 15 minutes for the first hour, every 30 minutes the second hour, then every hour thereafter. If at the end of the minimum four-hour test (the longest test possible is recommended. preferably overnight) no leaks are found, further testing is not required. (Use the procedure described in paragraph 2.3.3.1.) If a leak or excessive pressure change is observed, perform a flow test by repressurizing the line with the hydrostatic pump. Measure and record the amount of fluid required to maintain this pressure for four hours. If a leak is found, contact the environmental flight and take action to repair it. Also, promptly notify the command fuels engineer and DESC if additional funding is required for repairs, leak detection, and or location. A drop in pressure could be the result of a decrease in product temperature or absorption by the product of air in the line. To rule this out, you may repressurize the line and extend the test period to at least 24 hours.

2.4. Off-Base Pipeline Systems. Off-base pipelines are used to transfer petroleum products from refineries to air bases, terminals, and points of distribution. They are typically owned, operated, and maintained by civilian contractors (except for government-owned or -leased pipeline systems) and will vary in size, construction, and operation. Additional factors influencing the operation and type of system are terrain features (underwater, aboveground, belowground, road and railway crossing, expansion joints) and age. Pipeline receiving facilities are typically near the base fuel storage area.

These facilities should include an isolation pit, pressure reducing valve and, when used, a pig receiving facility. The Department of Transportation (DoT) regulates pipelines following Title 49, Code of Federal Regulations (CFR), Part 195, Transportation of Hazardous Liquids by Pipeline, current edition.

The following subparagraphs will give a general description of these types of pipelines and O&M procedures that apply to most systems.

2.4.1. Cross-Country Pipelines. Cross-country pipelines are often of the multi-product type. The system consists of one pipeline and a series of pumping stations. The pumping stations have pumps, strainers, pressure regulators, valves, scraper sand traps, and a sump tank to collect sludge and debris.

The number of pumping stations in the cross-country system depends on terrain conditions and the distance the fuel must be transferred.

2.4.2. Off-Base Pipeline Construction. Pipelines are typically constructed of 12.1-meter (40-foot) long steel pipes welded together and installed aboveground or underground. Pipe diameter varies from 101 to 355 millimeters (4 to 14 inches), depending on system capacity. For a more complete understanding of the design and construction of pipelines, see MIL-HDBK-1022A, API RP 1102, Steel Pipelines Crossing Railroads and Highways, and API Std 1104, Welding of Pipelines and Related Facilities.

2.4.3. Operations. In an emergency and at oversea commands, Air Force personnel may be required to take over, operate, and maintain a cross-country pipeline system. The command fuels engineer will provide technical oversight to the BCE responsible for all maintenance of pipelines acquired by the Air Force. Before operating a pipeline, the command fuels engineer or his delegated representative should consider the following:

2.4.3.1. Secure all plans, system diagrams, and information possible to find the location and function of all components (especially valves) in the system. Some installations may require a complete engineering study to secure sufficient information for O&M.

2.4.3.2. Reports should be made to decide the necessary manpower for each installation.

Personnel selected should have experience in the type of equipment they will operate. Skilled engineers, electricians, mechanics, and pump operators are usually required at each pumping station.

2.4.3.3. Inspect all equipment in the pipeline system to ensure proper working condition. Failure at one pumping station can cause a complete shutdown of the entire pipeline.

2.4.4. Off-Base Piping System Inspections:

2.4.4.1. Leak Detection. Pressure checks, volume checks, line patrols, and leak detection apparatuses may be used to detect leaks.

2.4.4.2. Pressure Checks. Pressure-check off-base piping systems annually in the same way prescribed for on-base piping systems (see paragraph 2.3.3.1). Hydrostatically test new piping systems in accordance with API RP 1110, Pressure Testing of Liquid Petroleum Pipelines.

Hydrostatically test systems to the lesser of 1.5 times the operating pressure or 1.896 megapascals (275 pounds per square inch gauge) maximum. During testing, disconnect system components such as storage tanks or equipment that were not designed for the piping test pressure or protect them against damage by over-pressure.

2.4.4.3. Volume Checks. Continuous records are kept on volume and temperature of liquid passed through each pumping station. A difference in meter reading that cannot be accounted for by temperature corrections between two stations usually indicates a leak, but could also indicate theft, out-of-calibration meters, faulty temperature sensors, or human error.

2.4.4.4. Line Patrols. Inspections are made by line walkers, vehicles, and light aircraft. Air patrols should be flown not less than once every three weeks at an elevation of less than 152 meters (500 feet) from the ground and at speeds from 104 to 128 kilometers per hour (65 to 80 miles per hour). The pipeline should be marked with posts or signs at 1.6-kilometer (1-mile) intervals and at bends. The pilot acts as an observer who checks for unnatural changes in vegetation color and oil slicks on lakes and streams which are evidence of leaking pipelines; area construction work (e.g., roads, sewers) that could cross and possibly damage the pipeline; and the overall condition of the right-of-way. Line walkers or vehicle patrols make detailed inspections once a year of the entire pipeline, checking the general condition of the right-of-way, valves in remote areas, supports on aboveground pipelines, and any condition that may indicate a leak.

2.4.4.5. Leak Detection Apparatus. Various types of leak detection apparatus are used by civilian contractors. Vapor or electronic devices are some of the more common types.

2.4.4.6. API 570 Inspections. Besides routine pipeline inspections, periodic inspections by an expert certified to the standards of API 570 will provide documentation of remaining pipeline life and any need for replacement. This may be funded by DESC.

2.5. General Pipeline System Components.

2.5.1. Expansion Joints. Pipelines are arranged to allow for expansion and contraction caused by changes in ambient temperature. Where possible, accommodate expansion and contraction by changes the direction of piping runs, offsets, loops, or bends. When this is not practicable, use flexible ball joint offsets. Do not use expansion devices that use packings, slip joints, friction fits, or other non-fire-resistant arrangements. Ball-type offset joints are used to accommodate possible settling of heavy structures such as storage tanks if piping design cannot provide enough flexibility.

Expansion bends, loops, and offsets are designed within stress limitations of American Society of Mechanical Engineers (ASME) B31.3, Process Piping, and ASME B31.4, Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols.

2.5.2. Manual Valves. Manual valves are used on pipelines to control flow and to permit isolating equipment for maintenance or repair.

2.5.2.1. Full port valves are installed on pipelines to allow pigging.

2.5.2.2. Do not use gate valves in aircraft fueling systems, except where the pipeline is pigable and absolute shut-off is not required.

2.5.2.3. For specific valve types and locations, see MIL-HDBK-1022A.

2.5.3. Surge Suppressors. If the flow of liquid in a pipeline is suddenly stopped, an excessively high pressure is instantly created because the kinetic energy of flow is converted to pressure energy. The resulting shock often causes leaks and damage to connected equipment. A common device designed to decrease shock in pipelines is a surge suppressor of the diaphragm or bladder type. It is equipped with a top-mounted liquid-filled pressure gauge, isolation valve, limited bleed-back check valve, and drains. The surge suppressor will be as close as possible to the point of shutoff that is expected to cause the shock. Surge suppressors can reduce shock pressure but will not end it entirely.

2.5.4. Miscellaneous. Miscellaneous equipment found in pumping stations include control panels, gauges, fire-fighting equipment, water detectors, sump pumps, compressed air systems, and electronic measuring devices. These components vary with the type of system and are considered accessory equipment for the major components of the system.

2.6. General Pipeline System Repairs.

2.6.1. General Pipeline Leaks. Most pipeline leaks are caused by interior or exterior corrosion. Less frequent causes of leaks include cracked welds, split seams and joints, separation at collars, buried flanges, and threaded pipe. Initial repairs can be made by placing clamps over the damaged area and using sealing epoxy components or gaskets to seal the leak. These repairs are usually temporary and modern practice is to weld all leaks (API RP 1107). The LFM should make sure that schematics are annotated to show where major breaks and leaks have occurred in the pipeline.

2.6.2. Pits and Small Leaks. Pits on the exterior of a pipeline are caused by corrosion. If discovered before a leak develops, repair them by arc welding. Welding a circular patch over the hole may repair small leaks.

2.6.3. Large Punctures and Holes. Large holes in pipelines usually create a welding safety hazard because of the spills that have saturated the ground. Clamping a steel plate of the same curvature as the pipe over the damaged area, using petroleum-resistant rubber for a seal, makes temporary line repairs; the area may then be cleared of all hazards. The steel plate clamped over the leak can be permanently welded to the pipe. For most welding operations, the pipeline can stay in service during repairs; however, if there is danger of the arc penetrating the pipe (thin wall or badly corroded pipe), the system should be shut down during repairs. All hot work must be approved by the command fuels engineer, base safety, base bioenvironmental engineer, and base fire department.

2.7. Major Repairs. Major repairs involving several sections of pipe can be done by two methods:

2.7.1. If the pipeline can be taken out of service, replace the damaged section with new pipe.

2.7.2. If the pipeline cannot be taken out of service, a casing can be welded over the damaged sections. Casings are considered temporary and should be used only under extreme conditions.

2.8. Pipeline Cleaning. Pipelines are cleaned with line scrapers forced through the line by the liquid being pumped. Intervals between cleanings vary with the size of the pipe and the type of liquid. A drop in the flow rate, the continual presence of dirt, rust, or particulate in basket strainers, and or shortened filter life may indicate a need for cleaning. Batching pigs are used to separate fuels and prevent contamination. Treatment of batching pigs is the same as for line scrapers. Water slugs are not permitted to separate batches.

2.8.1. Scraper Operation. Decide on the scraper best suited for the operation. Check specifications to be sure it will pass through all valves and bends. Keep accurate records of the time the scraper is started and quantity of fuel pumped to trace the progress of the scraper and find the time of its arrival at the receiving station. It is good practice to bypass meters while scraper sediment is in the line.

The scraper should be run at the minimum velocity (3.2 kilometers per hour [two miles per hour]) with no shutdowns while the scraper is in the line. Shutdowns will permit the scrapings to settle in front of the scraper, causing it to become stuck (this usually requires cutting the line to retrieve it).

2.8.2. Scraper Tracing. Several methods are used to find scrapers stuck in lines. The knife-type scrapers make sufficient noise to be followed by line walkers. Brush-type scrapers are relatively silent and require a transmitting device to reveal their exact location. Their general location can be found from the time and quantity of fuel pumped before the stoppage occurred. Special devices include:

2.8.2.1 Noisemakers fastened to the scraper.

2.8.2.2 Directional antennas.

2.8.2.3. Radioactive material that can be found with a Geiger counter.

2.8.2.4. Magnetized core in the scraper that can be detected with a magnetometer.

Chapter 3

MECHANICAL SYSTEMS

3.1. General Information. This chapter covers receiving, offloading, fill stand, pipelines, and gas station facilities. The components common to each of these systems, as well as the components specific for each system, are described in this chapter. These facilities must have an appropriate system to contain spills. Contact the base environmental coordinator for applicable environmental requirements and refer to MIL-HDBK-1022A for design criteria. Typical applications include direct offloading systems and stripper pumps.

3.2. Pumps. In mechanical systems, pumps are used for unloading, transferring, and dispensing fuels.

There are several types of pumps used in fueling systems.

3.2.1. Rotary positive displacement pumps (Figure 3.1) or self–priming centrifugal pumps are used where suction lifts are high or where the pump may frequently lose prime. These pumps must have an internal pressure relief or a pressure relief must be installed on the downstream side. Positive displacement pumps will not be used as product issue or transfer pumps.

Figure 3.1. Rotary Vane Pump.

3.2.2. Horizontal split-case centrifugal or turbine pumps (Figures 3.2 and 3.3) are used as transfer pumps on aboveground tanks and installed in a position that creates positive or flooded suction.

Vertical turbine pumps are used to pump from underground or cut-and-cover tanks. A “can” pump is another type of vertical turbine pump.

Figure 3.2. Horizontal Split-Case Pump.

Figure 3.3. Vertical Deepwell Turbine Pump.

3.2.3. For new pump installations, use API Std 610, Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Service, centrifugal pumps and vertical turbine pumps. Contact your MAJCOM fuels engineer for additional information as there are many types and configurations of API Std 610 pumps. Figures 3.2 and 3.3 show two types of pumps used as transfer pumps.

3.2.4. A hydraulic gradient (Figure 3.4) is usually used in the design of a pumping and piping system to help in properly sizing lines and selecting pumps to deliver a given amount of fuel in a certain time. An example of a hydraulic gradient for a given system is shown in Figure 3.4. In this sample, fuel is pumped from an aboveground storage tank to two truck fill stands simultaneously, at the rate of 946 liters per minute (250 gallons per minute) to each. The centerline of the tank outlet is

0.91 meter (3 feet) above the eye of the pump. Minimum desirable elevation of the liquid is taken as the line friction loss of 4.22 meters (13.84 feet) to the elevation of the pump, or 2.13 meters (7 feet).

The pump raises the head to 18.29 meters (60 feet). The friction loss in the 102-millimeter line to the connection to the two fill stands drops the elevation to 14.31 meters (46.98 feet). The drop at 946 liters per minute (250 gallons per minute) in each piping system to the truck fill stands drops the elevation to 12.16 meters (39.9 feet). The elevation of the truck fill stand is 7.01 meters (23 feet).

The difference in head (12.16 meters – 7.01 meters = 5.15 meters [16.9 feet]) is the head available for delivering fuel.

Figure 3.4. Hydraulic Gradient.

U

FC

3-460-03

3.3. Filter/Separators (F/S). F/Ss remove undissolved (free) water and solids from petroleum products. Very fine water particles pass through coalescer filter elements and grow in size (coalesce) into larger droplets that collect on a second-stage Teflon screen or treated paper elements and fall to the bottom of the F/S vessel. The solids in the fuel are trapped in the elements and build up a DP across the F/S. Water accumulated in the bottom of the F/S is typically removed manually.

NOTE: Because of environmental problems caused from valve failure, the automatic drain feature originally installed with pre-1994 systems has been disabled, except for certain receipt F/Ss from barges or pipelines with histories of excessive water. F/Ss are equipped with the means to measure DP to find when elements should be changed and a sampling port in the outlet pipe to verify fuel quality. Element change criteria are outlined in paragraph 10.12.1. The piston-type DP gauge is preferred for fueling systems. Replace individual gauges with the piston-type as soon as practicable.

3.3.1. F/S Important Notes:

3.3.1.1. All F/Ss should be modified to accept the new API coalescer elements, or replaced with API F/Ss.

3.3.1.2. Heaters are no longer necessary in F/Ss handling military jet fuel because the fuel contains a fuel system icing inhibitor (FSII).

3.3.1.3. Where possible, move the sight-glass bottom connection to the bottom of the sump to show the entire water content and equip the system with a density ball.

3.3.1.4. All F/S vessels require pressure relief protection.

3.3.1.5. Remove the automatic water drain option at the first opportunity, unless on a receipt vessel that must handle excessive water, or if waived by the MAJCOM fuels engineer.

3.3.1.6. Pressure relief protection should be full ported; no reduction in pipe size is allowed.

3.3.2. Specifications and Qualification Procedures. New F/Ss should be qualified to the current edition of API Publication (Pub) 1581, Specifications and Qualification Procedures for Aviation Jet Fuel Filter/Separators, tested to either Category M or M100 requirements. Category M F/Ss are qualified using JP-8 with an additive package. Category M100 F/Ss, coalescer/separators, and multi-stage systems are qualified using JP-8 with an additive package that also includes dispersant additives such as those that enhance thermal stability. Category M100 F/Ss qualify for Category M F/S at the same flow rate and conditions. Type S F/Ss can be used at filtration points where significant levels of water and dirt in the product can be expected, such as a receipt F/S. Type S-LD F/Ss (also known as coalescer/separators) can be used at all filtration points where significant levels of water but minimal amounts of dirt can be expected in jet fuel (i.e., following a micro-filter). A Type S F/S qualifies as a Type S-LD for the same category at the same flow rate and condition.

3.3.3. Element Replacement for a Vertical F/S:

3.3.3.1. Drain the F/S completely.

3.3.3.2. Raise the cover. CAUTION: Do not touch the new filter elements or the separator canisters with your bare hand. The oil on your hand will cause damage to the water-removal capability of these components.

3.3.3.2.1. Where there is an outer canister, remove, clean (paragraph 3.3.5.1.), and set it aside for reuse.

3.3.3.2.2. Remove and discard the old elements in an approved manner. Coordinate disposal of elements with base environmental engineering.

3.3.3.3. Check the adapter gasket and adapter to make sure the gasket and adapter threads are clean.

3.3.3.4. Complete the installation of the F/S cartridge assemblies by lowering each of the filter element assemblies onto one of the deck plate nipples. Make sure that each of the element assemblies is screwed down onto its deck plate nipple and the gasket is seated properly and seals tightly. Next, apply the procedures in paragraphs 3.3.3.4.1. through 3.3.3.4.6. below:

3.3.3.4.1. Replace the cover gasket with a new gasket of the same grade and manufacture as the old one.

3.3.3.4.2. Swing the cover back into place, lowering the lifting handle as you do so.

3.3.3.4.3. Swing the eyebolts up into place and tighten the nuts using the criss-cross method.

Do this so that the cover gasket and cover are seated properly. When tightening cover bolts and nuts, use a torque wrench. Tighten nuts just enough to prevent leaking through the dome cover seal (refer to manufacturer’s instructions for torque requirements) and to eliminate possible damage to the vessel.

3.3.3.4.4. Close the manual water drain valve.

3.3.3.4.5. Slowly fill the separator.

3.3.3.4.6. Pressurize the vessel to inspect all gaskets and screwed connections for leaks; tighten all loose connections.

3.3.3.5. NOTE: Remember, once a system is opened for any reason it must be sampled before the aircraft is serviced.

3.3.3.6. Notify the FMF that the F/S is ready to be put back into service and is awaiting QC flushing and sampling. (This is necessary to ensure the fuel meets quality requirements.)

3.3.3.7. After the cartridges (elements) have been replaced and the F/S is ready to put back into service, follow the steps below:

3.3.3.7.1. Data decals are provided with…