E1_13_100_CONT_INSP_RESP_Approved_Amend_0002.pdf

E1.13.100 CONTRACTOR INSPECTION RESPONSIBILITIES (JP-10/PF-1) (AEROSPACE ENERGY) (DLA ENERGY

JUN 2013)

(a) QUALITY CONTROL PLAN.

(1) The Contractor is required (unless otherwise instructed by the Government) to provide and maintain an inspection system and a written description (Quality Control Plan (QCP)) acceptable to the Government. The Contractor has the option to provide and maintain an inspection system that, as a minimum, incorporates the requirements of ISO9001, Quality Management Systems. If the Contractor chooses to comply with ISO9001 all the specific Quality Assurance contract provisions of this contract must be included in the ISO9001 written quality plan. A copy of the QCP, in English, shall be presented to the Government Quality Assurance Representative (QAR) for their review and acceptance prior to commencement of production or services. The QCP shall be reviewed and updated when deemed necessary by the Contractor or the Government, to include changes necessary to prevent the recurrence of quality problems or whenever changes are made to the inspection system. Revisions shall be presented to the QAR for review and acceptance prior to implementation. The Contractor must sign and date the original copy and each revision to the QCP.. When acceptable to the Government, the original QCP, and any revisions, shall be signed and dated by the QAR.

(2) The Contractor shall require subcontractors (unless otherwise instructed by the Government) to provide and maintain inspection systems and QCPs that are acceptable to the Government. The Contractor must require subcontractor(s) to sign and date each revision to the subcontractor(s) QCP.

(3) The QCP shall include an identification of key operational positions, a schematic diagram of plant facilities pertinent to the inspection system indicating all inspection points, and a description covering the following operations relating to the supplies to be furnished under the contract:

(i) RECEIVING. Procedures used to assure quality of additives blended into product supplied under this contract;

(ii) BLENDING AND COMPOUNDING. Identification of component base stocks used to produce finished product. Procedures to be used for adding, prior to batching, all required additives at all locations. When procedures for line injection of additives for products in accordance with a contract provision that contains LINE INJECTION OF ADDITIVES is used, the QCP will provide procedures for proportionately injecting additives throughout the entire loading process to ensure the additive is homogeneously blended into the propellant, and procedures for maintaining records evidencing the homogeneous blending of all line injected additives.

Prior to shipment, a sample of the propellant with all additives required by the contract shall be tested to verify compliance with the required specification;

(iii) SAMPLING. Procedures for sampling additives, blend tanks, shipping tanks, lines, and conveyances/containers shall be in accordance with API Manual of Petroleum Measurement Standards (MPMS), Chapter 8, Section 1, (ASTM D 4057) Manual Sampling of Petroleum and Petroleum Products, and/or Section 2, (ASTM D 4177), Automatic Sampling of Petroleum and Petroleum Products. Procedures include sample location , frequency, quantity, minimum tests required on sample, and sample retention procedures. For other than f.o.b. origin shipments, Automatic In-Line Sampling is preferred at the custody transfer point, but representative samples taken in accordance with MPMS Chapter 8, Section 1, are acceptable. See Table I, Minimum Sampling and Testing Requirements, below;

(iv) TESTING. Types of tests and test methods/procedures to be performed on samples taken from each location identified in (iii) above may be incorporated by test method reference in the QCP, if complete reference is available at the place of performance. See Table II, Definitions of Test Series below;

(v) CALIBRATION. Program for testing and measuring equipment shall be in accordance with ISO 10012, Measurement Management Systems – Requirements for Measurement Processes and Measuring Equipment, or equivalent local regulation as appropriate. A program for calibrating meters used to determine quantity shall comply with the API MPMS, Chapters 4, 5, and 6, or equivalent foreign standard. For items not covered by ASTM, API or IP publications, the applicable manufacturer's recommended calibration method, or methods outlined in the applicable industry publication, shall be used if acceptable to the Government;

(vi) STORAGE AND HANDLING. Procedures for storage and handling shall include a description of storage and handling equipment including tanks, lines, valves, and manifolds used. It shall also include identification of dedicated/common product system including description of line segregation and controls to assure capability for proper gauging, sampling, draining of water, filtration, circulation, drying; and identification of any other process/system used in maintaining product integrity during storage and handling;

(vii) LOADING AND SHIPPING, GENERAL. Procedures for product movement and related quality/quantity checks shall include a description of the transfer point from shipping tank(s) to custody transfer point in order to maintain product integrity. Lines shall have a low point drain to enable complete draining of the entire line or for obtaining line samples. Dedicated line is defined as a piping system that shall be used exclusively for fuels typed JP-10 and PF-1 and blends thereof. The lines must be flushed and drained with new fuel when some other blend of the aforementioned fuels has been used in the dedicated lines. Valve bodies in JP-10/PF- 1 systems will be constructed of stainless steel or aluminum. All gaskets/seals shall be Teflon, viton, or nitrile (seals, seats and gasket material of zinc, bronze, brass or copper bearing materials are not acceptable). Carbon steel valves are permitted, provided they are internally plated with chromium. Electroplated nickel is permitted for double-seated plug valves and on nodular iron diaphragm control valves within the tank dike area. Do not furnish or install cast iron or bronze-bodied valves in JP-10 or PF-1 systems. System used for loading and transferring this product shall be a dedicated or properly isolated common system incorporating blind flanges, spectacle plates, or double valves between them to prevent contamination. Single valves designed to provide the same protection are also acceptable if positive isolation is assured. Systems with single valve (excluding twin seal single valves) isolation require specific procedures to be included in the QCP to assure product integrity after the last single valve and prior to the acceptance point. When single valves are present in the system, the Contractor shall provide their quality control procedures from the first single valve to the custody transfer point at time of bid to the Contracting Officer for determination of acceptability. Line systems used for receipt, transfer and filling of drums and loading of tank trucks shall be constructed of stainless steel, epoxy-lined mild steel, or aluminum.

(viii) PRELOAD INSPECTION - TANK CARS, TANK TRUCKS, AND INTERMODAL CONTAINERS.

Inspect conveyances prior to loading to determine quality/quantity suitability to load as follows:

(A) JP-10/PF-1 conveyances shall meet the requirements of MIL-STD-3004, Table XXVI, Conversion Chart for Truck (TT), Tank Cars, Truck (Tank Wagon (TW)), Tank and Trailer (TRR) and Intermodal Containers (IMC) in regard to the cleaning process and allowable product carried. The Contractor shall refrain from loading and immediately contact DLA Energy-FEQ (San Antonio) when conveyance does not meet the requirements of MIL-STD,3004.

(B) Verify discharge hoses are clean and capped, and pump housing is clean and dry. Tank truck manifold outlet shall be capped.

(C) Verify interior of conveyance is visibly clean, dry and has been prepared for loading. Remove caps from loading connections and visually inspect interior surfaces to ensure cleanliness. Interior surfaces shall be free of any presence of moisture, corrosion, scale, dirt, grease and foreign matter.

(D) Inspect tankers for general over-the-road readiness (tires, lights, no loose or missing components), and verify readiness for loading.

(ix) LOADING _ TANK CARS, TANK TRUCKS, AND INTERMODAL CONTAINERS. Loading of conveyances may only proceed after having passed all pre-load inspections.

(A) Loading racks shall be equipped with filter separators that are located as near the loading or filling point as practicable. Loading rack filters shall be filter/separator (F/S) types conforming to EI 1581 and shall be located on the fill line upstream of the fill nozzle header (allow 30 seconds relaxation time between the F/S and the issue nozzle). The F/S shall be equipped with coalescer cartridge elements. Elements shall be changed in accordance with manufacturer recommendations.

(B) Filled conveyances shall be sampled and tested in accordance with Table I of this clause.

(C) Prior to releasing conveyances from the loading rack, check tank exterior, valves, flanges and welds for leaks. Perform final inspection of conveyance and attach seal(s) in accordance with the clause entitled CONTRACTOR SEALS REQUIREMENT annotating seal number on the shipping documents.

(x) DRUM SHIPMENTS - The following minimum procedures are applicable when filling drums:

(A) When drummed JP-10/PF-1 is required, the Contractor will be responsible for providing the containers, pallets, and other services. The Contractor is responsible for drumming and palletizing product.

(B) Only new (unused) steel drums shall be filled. Drums used shall be 55 gallon capacity meeting, as a minimum, the Performance-Oriented Packaging wall thickness and testing criteria for the UN1A1 specification packaging of Packing Group III hazardous materials, as specified in Title 49 of the Code of Federal Regulations.

(C) Drums shall be internally coated (including bungs) with epoxy conforming to MIL-PRF-23236. Prior to filling drums, remove bung and inspect interior of each drum with a suitable drop light. Interior shall be free of rust, dirt, oil, water and all foreign matter. Damage to the epoxy coating, including blisters, cuts, bare spots and other defects will be cause for rejection of the drum.

(D) The exterior of the drum shall be protected from external corrosion in adverse climates through the use of appropriate surface preparations and applications of a corrosion preventive coating compatible with JP-10 and PF-1.

(E) The dedicated line and filling system will be flushed and drained with product to be loaded or filled immediately prior to initial use or when the line sample shows no contamination or product degradation.

(F) Drain low point or fill line and filter separator before and after each filling operation until the sump sample is clear, bright and free of water and sediment. EI 1581 filter separator shall be outfitted with coalescer elements (elements to be changed in accordance with manufacturer recommendation).

(G) Fill drums with 53 +/- 1 gallon of JP-10 or PF-1, verified in accordance with the DETERMINATION OF QUANTITY CLAUSE of this contract.

(H) Sample drums in accordance with Table I. Sample failure shall result in rejection of drums represented by sample. Rejection of a filled drum will be cause to stop filling operations. Filling will not resume until the cause for rejection has been determined and corrective action taken.

(I) Insert bungs, tighten with bung wrench sufficient to stop any leakage, and cap seal all bungs.

(xi) CORRECTIVE ACTION. Actions to be followed to effect correction of any deficiency affecting product quality or quantity determination, such as handling of off-specification product (waivers, conveyance rejections, etc.): The corrective action procedures shall include notification of the QAR.

(4) The QCP shall identify one individual to serve as a point of contact for quality/quantity matters relating to the inspection system description in the plan.

(5) The Contractor is responsible for all inspection systems, QCPs, and product quality and quantity.

(6) The Government QAR will be available to review and discuss the Contractor's proposed QCP; however, the Contractor shall remain responsible for developing and describing acceptable quality control procedures.

(b) The Contractor shall perform all inspection and acceptance tests required by the specifications of the supplies to be furnished under this contract or shall have such tests performed in a laboratory acceptable to the Government. When such tests are performed at origin on supplies to be accepted at destination, documentation that will enable verification of the original test results shall be provided to the Government at the time of acceptance.

(c) The Contractor shall inspect all shipping conveyances prior to loading to determine suitability for loading. If the Contractor and the QAR disagree as to the suitability for loading of Government furnished conveyance for supplies to be accepted at origin, the determination of the QAR shall govern. Procedures to determine suitability to load tank trucks and tank cars shall include but not be limited to visual inspection of interior compartments to assure cleanliness and dryness. Manifolds, pumps and discharge hoses must be drained and be clean and dry for intended product.

(d) The Contractor shall keep all quality and quantity records, complete and available to the Government during the performance of this contract and for three years after final payment under this contract.

(e) Immediately following award of this contract, the Contractor shall notify the QAR of the source or sources of the supplies to be furnished under any item calling for delivery f.o.b. destination. The Contractor shall also notify the QAR of any changes in source in sufficient time to permit inspection by the Government.

(f) The inspection system and related operations provided or performed pursuant to this provision shall be subject to surveillance by the QAR.

TABLE I

MINIMUM SAMPLING AND TESTING REQUIREMENTS

LOCATION

WHEN SAMPLED TYPE OF SAMPLE TYPE OF TEST

(See Table II for definition of Type A, B, and C testing.)

1. Refinery/Terminal Shipping Tank

Each Batch Prior to Commencement of Shipping or Drumming. (2)

2-Gallon All Level or Single Tank Composite

A (1)

2. Shipping Line (All Modes):

Dedicated Line

Prior to Loading/Shipping.

Line

C

3. Custody Transfer Point

Immediately After Start of Shipment.

Line C; Test results must be within ASTM reproducibility limits when compared to bulk tank test report results.

4. Tank Car/Truck/IMCs Loading Rack

After change of source tank. Line

C test plus additive analysis for FSII if line injected.

5. Tank Cars/Truck/IMCs

After filling. All Level Workmanship; C

6. Drum Fill Rack Prior to start of drum filling operation for each batch.

Nozzle C test plus Particulate Matter FSII content (if FSII is injected);

results must be within ASTM reproducibility limits when compared to bulk tank results.

7. Drums 10% of drums from packaged lot (minimum of one drum when lot consists of less than 10 drums).

Tube, Drum Thief All Levels or Composite

Workmanship and C tests.

NOTES FOR TABLE I:

(1) AFTER TESTING AN UPPER, MIDDLE, AND LOWER SAMPLE TO VERIFY BATCH CONFORMANCE TO HOMOGENEITY REQUIREMENT. HOMOGENEITY CAN BE ASSUMED WHEN UPPER, MIDDLE, AND LOWER SAMPLE TEST RESULTS FOR DENSITY/API GRAVITY (AND FSII, IF FSII IS PRESENT) FALL WITHIN THE

REPRODUCIBILITY LIMIT ESTABLISHED BY THE TEST METHOD.

(2) NO PRODUCTION BATCH SHALL BE RELEASED FOR SHIPMENT UNTIL FULL SPECIFICATION SAMPLE RESULTS

HAVE BEEN REVIEWED AND APPROVED BY GOVERNMENT ASSIGNED REPRESENTATIVE.

TABLE II

DEFINITIONS OF TEST SERIES

I. TYPE A: Includes full quality conformance testing in accordance with the physical requirements table in the product specification plus any additional contractual requirements.

II. TYPE B & C: As shown in the table below for each product. Properties and test methods will be in accordance with the product specification for each grade identified in the solicitation/contract.

JP-10 PF-1

TEST PROPERTIES B C B C

Appearance Workmanship

Particulate content

Color

Density or API Gravity or Specific Gravity

Existent Gum

Freeze Point

Flash Point

FSII Content

Viscosity

Chemical Composition (in accordance with Appendices)

* THE PROCEDURE TO BE USED FOR CONDUCTING THESE TESTS WILL BE AS STATED IN THE APPROPRIATE

PRODUCT SPECIFICATION AND/OR CONTRACT.

MINIMUM SAMPLING AND TESTING REQUIREMENTS