TO_42B-1-1.pdf

TO 42B-1-1

TECHNICAL MANUAL

QUALITY CONTROL OF FUELS

AND LUBRICANTS

(ATOS)

F41608-90-D-1819

Prepared By: TRI-COR Industries, Inc.

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

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

Published Under Authority of the Secretary of the Air Force

1 AUGUST 2014 CHANGE 1 - 15 AUGUST 2014

SP4510-16-Q-1018

Attachment 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 DESTROY SUPERSEDED PAGES.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 shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . 1 August 2014 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . 15 August 2014

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 86, 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 2-1 - 2-2 3-1 - 3-4 3-5 - 3-6 3-7 - 3-10 4-1 - 4-11 4-12 Blank 5-1 - 5-7 5-8 Blank 6-1 - 6-3 6-4 Blank 7-1 - 7-7 7-8 Blank A-1 - A-5 A-6 Blank B-1 B-2 Blank C-1 - C-23 C-24 Blank

*Zero in this column indicates an original page

A Change 1 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iii 3.19 Differential Pressure ...................................3-7

4 QUALITY CONTROL OF AVIATION

LIST OF TABLES......................................................iii FUELS..................................................................4-1

4.1 General........................................................4-1 INTRODUCTION........................................................v 4.2 Laboratory Technician Qualifica-tions ........................................................4-1

4.3 Laboratory Operations................................4-1

SAFETY SUMMARY................................................vi 4.4 Sampling and Testing.................................4-1

4.4.1 Types of Samples .......................................4-1

4.4.2 Sampling Equipment ..................................4-21 GENERAL ................................................................1-1

4.4.3 General Sampling Procedures ....................4-2

4.5 Product Receipt — Aviation Fuel .............4-31.1 Air Force Petroleum Agency

4.6 Secure Fuel Test Procedures......................4-8(AFPA)...................................................1-1

4.7 Procedure for Soaking, Flushing,1.2 General Safety and Environment and Sampling Hoses ..............................4-8Considerations........................................1-1

4.8 Deployed/Temporary or Loca-1.3 Temperature Control...................................1-1 tions without a Base Fuels1.4 Responsibilities for Fuel Quality ...............1-1 Laboratory ..............................................4-91.5 Quality Assurance at Origin.......................1-1

4.9 Procedures for Aircraft Sump1.6 Quality Surveillance at Base Lev- Samples ..................................................4-9el.............................................................1-1

1.7 List of Forms ..............................................1-2 5 SAMPLE SUBMISSION TO OFF-BASE LABORATORIES................................................5-12 AVIATION FUELS..................................................2-1

5.1 Scope...........................................................5-12.1 Turbine Fuels..............................................2-1

5.2 Sample Submission.....................................5-12.2 Aviation Gasoline (AVGAS) .....................2-1

5.3 Shipping Containers and Prepara-2.3 Fuel Additives.............................................2-1 tion .........................................................5-1

5.4 Marking and Identifying Samples .............5-23 FUEL HANDLING ..................................................3-1

5.5 Turbine Fuel Correlation Samples .............5-2

5.6 Samples of Dormant Stocks.......................5-23.1 Scope...........................................................3-1

5.7 Fuel and Oil Samples from3.2 Responsibilities ...........................................3-1

Crashed Aircraft or Fuel Re-3.3 Strainers ......................................................3-1 lated Incident..........................................5-33.4 Filters/Filter Separators (F/S).....................3-1

3.5 Tanks...........................................................3-2 6 GROUND FUELS ....................................................6-13.6 Tank Inspections and Cleaning..................3-3

3.7 Product Settling ..........................................3-3

6.1 General........................................................6-13.8 Contamination.............................................3-3

6.2 Motor Gasolines .........................................6-13.9 Water...........................................................3-4

6.3 Diesel Fuels ................................................6-13.10 Solid Contaminants.....................................3-4

6.4 Ground Fuel Receipts (All3.11 Line Displacement......................................3-4

Grades Except Heating Oil) ..................6-13.12 Identification and Marking of Fu-

6.5 Periodic Sampling and Testing ..................6-2el Handling Systems ..............................3-4

6.6 Cold Weather Operations ...........................6-33.13 Servicing Controls ......................................3-4

6.7 Conversion of Ground Fuel Prod-3.14 Converting Refueling Units from ucts .........................................................6-3One Product to Another ........................3-5

6.7.1 E85 Conversion ..........................................6-33.15 Recovering, Blending or

6.7.2 Bio-Diesel Conversion ...............................6-3Down-Grading Petroleum

Products..................................................3-5 7 AIRCRAFT ENGINE OILS AND OTH-

3.16 Defueling Aircraft/Bowsers........................3-5 ER PETROLEUM PRODUCTS .........................7-1

3.17 Multi-Product Pipeline Shipments .............3-6

3.18 Filtration Requirements ..............................3-6 i

7.1 General........................................................7-1 C.4.1 Summary ....................................................C-9

7.2 Unopened Packaged Petroleum C.4.2 Significance of Test...................................C-9

Products..................................................7-1 C.4.3 Equipment ..................................................C-9

7.3 Extension of Packaged Petroleum C.4.4 Sample Container ......................................C-9

Products..................................................7-2 C.4.5 Procedures..................................................C-9

7.4 Special Instructions for Opened C.4.6 Calculation and Report............................C-10

Containers ..............................................7-3 C.4.7 Calibration................................................C-11

7.5 Submission of Samples ..............................7-7 C.5 Free Water Determination.......................C-13

7.6 Special Instructions for Packaged C.5.1 Summary ..................................................C-13

Aircraft Engine Oils ..............................7-7 C.5.2 Significance of Test.................................C-13

7.7 Bulk Aviation Oil (AVOIL).......................7-7 C.5.3 Equipment ................................................C-13

C.5.4 Procedures................................................C-13 A ADDITIVE BLENDING PROCEDURES C.5.5 Reporting..................................................C-14

TURBINE FUELS ..............................................A-1 C.5.6 Calibration................................................C-14 C.6 Test for Fuel System Icing Inhib-

A.1 General.......................................................A-1 itor (FSII) Concentration in A.2 Fuel System Icing Inhibitor ......................A-1 Jet Fuel................................................C-14 A.3 Corrosion Inhibitor/Lubricity Im- C.6.1 Summary ..................................................C-14 prover ....................................................A-1 C.6.2 Significance of Test.................................C-14 A.4 Static Disapater Additive ..........................A-1 C.6.3 Equipment ................................................C-14 A.5 Thermal Stability Additive........................A-1 C.6.4 Procedures................................................C-14 A.6 Calculating Additive Ratios ......................A-1 C.6.5 Calculation and Report............................C-15 A.7 Injecting/Blending Methods ......................A-2 C.6.6 Calibration................................................C-15 A.8 Leak Detection Additives..........................A-3 C.7 Test Method for Determining the

Electrical Conductivity of B MISCELLANEOUS EQUIPMENT FOR Aviation Fuel ......................................C-15

LABORATORY TESTING................................B-1 C.7.1 Summary ..................................................C-15 C.7.2 Significance of Test.................................C-15

B.1 Miscellaneous Equipment..........................B-1 C.7.3 Equipment ................................................C-15 C.7.4 Procedures................................................C-15C TEST PROCEDURES .............................................C-1 C.7.5 Calculation and Report............................C-15 C.7.6 Calibration................................................C-15C.1 Test for Visual Free Water and C.8 Flash Point of Petroleum Prod-Particulate Contamination ....................C-1 ucts ......................................................C-17C.1.1 Summary ....................................................C-1 C.8.1 Summary ..................................................C-17C.1.2 Significance of Test...................................C-1 C.8.2 Significance of Test.................................C-17C.1.3 Equipment ..................................................C-1 C.8.3 Equipment ................................................C-17C.1.4 Procedures..................................................C-1 C.8.4 Procedures................................................C-17C.1.5 Calculation and Report..............................C-1 C.8.5 Calculation and Report............................C-17C.1.6 Calibration..................................................C-1 C.8.6 Calibration................................................C-18C.2 Test for Color and Particulate C.9 Test for API Gravity of Petrole-Matter ....................................................C-1 um Products ........................................C-20C.2.1 Summary ....................................................C-1 C.9.1 Summary ..................................................C-20C.2.2 Significance of Test...................................C-1 C.9.2 Significance of Test.................................C-20C.2.3 Equipment ..................................................C-1 C.9.3 Equipment ................................................C-20C.2.4 Procedures..................................................C-2 C.9.4 Procedures................................................C-20C.2.5 Calculation and Report..............................C-2 C.9.5 Calculation and Report............................C-20C.2.6 Calibration..................................................C-2 C.9.6 Calibration................................................C-20C.3 Test for Particulate Matter by C.10 Particulate Matter Content ofMatched Weight Method......................C-5

Diesel and Bio-Diesel Fuels...............C-22C.3.1 Summary ....................................................C-5 C.10.1 Summary ..................................................C-22C.3.2 Significance of Test...................................C-5 C.10.2 Significance of Test.................................C-22C.3.3 Equipment ..................................................C-5 C.10.3 Equipment ................................................C-22C.3.4 Procedures..................................................C-5 C.10.4 Procedures................................................C-22C.3.5 Calculation and Report..............................C-6 C.10.5 Calculation and Report............................C-23C.3.6 Calibration..................................................C-6 C.10.6 Calibration................................................C-23C.4 Particulate Contamination in Avi-ation Fuels by Laboratory Fil-tration (Bottle Method).........................C-9 ii

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

3-1 Vessel Pressure Drop Characteristics C-5 Test Procedure C.4, Apparatus for De-with SPENT Cartridges ........................ 3-10 termining Total Contaminant .............. C-11

C-1 Test Procedure C.2, Bonding Wire for C-6 Test Procedure C.4, Bottle Method Millipore In-Line Sampler .................... C-3 Stand .................................................... C-12

C-2 Test Procedure C.2, 3-Way Valves C-7 Test Procedure C.8, Pensky-Martens In-Line Samplers ................................... C-4 Assembly Standard .............................. C-19

C-3 Test Procedure C.3, Bonding Wire for C-8 Test Procedure C.9, Hydrometer Scale Millipore In-Line Sampler .................... C-7 Reading for Transparent Liquids ........ C-21

C-4 Test Procedure C.3, 3-Way Valves In-Line Samplers ................................... C-8

LIST OF TABLES

Number Title Page Number Title Page

2-1 Turbine Fuel Characteristics ......................... 2-2 7-1 Retest Frequency of Tested Proprietary 3-1 Conversion Chart for Refueling Units .......... 3-9 Products ..................................................... 7-3 4-1 Aviation Turbine Fuel Sampling and 7-2 Retest Frequency of Packaged Petroleum

Testing Requirements ............................... 4-4 Products ..................................................... 7-4 4-2 Secure Fuel Test Limits .............................. 4-11 A-1 Additive Blending Quantities (Calcula- 5-1 Minimum Sampling and Testing Fre- tions are based on neat fuel) ................... A-4 quencies of Dormant Petroleum Prod- A-2 Approved Volatile Chemical Tracer Leak ucts ............................................................ 5-3 Detection Additives ................................. A-5

5-2 US Military Fuel Laboratories ...................... 5-5 B-1 Miscellaneous Equipment for Laboratory 5-3 US Military Fuel Laboratories — Europe Testing ...................................................... B-1 and Southwest Asia .................................. 5-6 C-1 Test Procedure C.7, Conductivity vs 5-4 US Military Fuel Laboratories — Pacif- Temperature ........................................... C-16 ic ................................................................ 5-7 6-1 Periodic Sampling and Testing Require-ments ......................................................... 6-2 iii/(iv blank)

INTRODUCTION

may conflict with fuel quality instructions or procedures1. PURPOSE.

contained in other government documents or publications, the provisions of this technical order take precedence.This technical order prescribes the procedures for assuring These instructions will be used in conjunction with Airthe quality of fuels and lubricants used by Air Force Force Instruction (AFI) 91-203 (Air Force Consolidatedactivities. This technical order applies to both Continental Occupational Safety Instructions) wherever applicable. TheUnited States (CONUS) and overseas areas (OCONUS).

provisions of this manual are compatible with NATO Standardization Agreement (STANAG) 3149, 1135, ASIC2. SCOPE.

AIR Standard 15/09 and ASIC AIR Standard ACS (FG) 4020. This technical order is the established quality controlProcedures and instructions prescribed by this publication program as required by DoD 4140.25M (DoD Managementapply to receiving, storing, handling, testing, and dispens-of Bulk Petroleum Products, Natural Gas, and Coal) and ining of fuels at Air Force installations. At Air Force conjunction with MIL-STD-3004. In case of conflictassigned intermediate depots, where the Air Force has between this technical order and the aircraft flight manual,Quality Surveillance (QS) responsibilities, the quality pro-the aircraft flight manual shall take precedence. Userscedures outlined in MIL-STD-3004 (Department of should contact the appropriate System Program OfficeDefense Standard Practice Quality Assurance/Surveillance (SPO) or System Management Support Office in regard tofor Fuels, Lubricants, and Related Products) and this tech-aircraft operations.nical order apply. Where content of this technical order v

SAFETY SUMMARY

1. GENERAL PRECAUTIONS. 5. CHEMICAL DISPOSITION.

Personnel must understand general safety instructions and For proper disposition of chemicals cited for use in this apply precautions during fuel handling and laboratory oper- technical order, review applicable MSDS and consult with ations to ensure personal safety and health as well as local Environmental Management and Bio-Environmental protection of Air Force property. Engineering Offices for guidance.

2. WARNING AND CAUTION STATEMENTS. 6. DEFINITIONS.

WARNING and CAUTION statements have been strategi- WARNINGcally placed throughout this text prior to operating or maintenance procedures, practices, or conditions consid-ered essential to the protection of personnel (WARNING)

Highlights operating procedures or practicesor equipment and property (CAUTION). WARNINGs and which, if not correctly followed, could result inCAUTIONs will apply each time the related step is personnel injury or loss of life.repeated. Prior to starting any task, the WARNINGs or

CAUTIONs included in the text for the task will be reviewed. Compliance is mandatory prior to performing the CAUTION next step in the task.

3. GIVE CLEANERS/CHEMICALS SPECIAL CARE. Highlights operating procedures or practices which, if not strictly observed, could result in

Keep cleaners/chemicals in approved safety containers and damage to or destruction of equipment and/or in minimum quantities. Some cleaners/chemicals may have property.

an adverse effect on skin, eyes, and respiratory tract.

Observe manufacturer WARNING labels; Material Safety NOTE Data Sheet (MSDS) instructions for proper handling, stor-age, and disposal; and current safety directives. Use clean- An essential operating or maintenance proce-ers/chemicals only in authorized areas. Discard soiled dure, condition, or statement, which must be cloths into safety cans. Unless otherwise indicated in the highlighted.

text, use as described in this TO should not result in any immediate health concerns. Shall and Indicate mandatory requirements. Will is

Will also used to express a declaration of pur-

4. PERSONAL PROTECTIVE EQUIPMENT (PPE). pose.

Should Indicates a preferred method of accomplish- Wear protective clothing/equipment (gloves, apron, eye ment.

protection, etc.) approved for the materials and tools being

May Indicates an acceptable, optional, or suggest-used. Contact supervisor for guidance. Contact the ed means of accomplishment.Bio-Environmental Engineer or Base Safety Office for guidance.

vi

CHAPTER 1

GENERAL

OF RECOVERABLE AND WASTE LIQUID PETRO-1.1 AIR FORCE PETROLEUM AGENCY (AFPA).

LEUM PRODUCTS provides guidance in the collection, segregation, and disposition of recoverable and waste liquidAir Force Fuels Service Control Point (SCP):

petroleum products.

a. AFPA Operations Directorate provides planning, policy, and procedures, regarding all Air Force 1.3 TEMPERATURE CONTROL.

petroleum operations. Within the AFPA Operations Directorate is the AFPA Current Operations Divi- Maintain Base Fuels Laboratories at a temperature of 73° ± sion and can be reached as DSN 427-8705 or 5°F (23° ± 3°C). Large temperature fluctuations adversely e-mail afpa.afl@dla.mil. affect laboratory equipment and fuel samples. This could cause inaccurate analysis of fuel properties and allow issue

b. AFPA Technical Assistance Division is responsible of contaminated fuel to aircraft.

for the quality control of Air Force petroleum products worldwide. The Technical Assistance 1.4 RESPONSIBILITIES FOR FUEL QUALITY.

Team is available to assist Fuels Management (FM) personnel worldwide in identifying and cor- Petroleum products require quality surveillance from the recting quality problems. Requests for assistance point of initial acceptance by the government until con-will be submitted through the AFPA Current Oper- sumed. Every agency and individual in the supply system, ations Division as prescribed in AFI 23-201. For share the responsibility for some phase of quality control.

Air National Guard (ANG) units, requests for assistance will be coordinated through the 1.5 QUALITY ASSURANCE AT ORIGIN.

NGB/A4RMF staff.

Quality Assurance Representatives (QAR) and Quality Sur-c. AFPA/PTP – Product Support Directorate, main-veillance Representatives (QSR) of DLA Energy monitortains and operates Aerospace Fuels Laboratories fuel quality during production, storage, testing, loading,worldwide. Additional responsibilities include and shipping. Quality surveillance of US Governmentquality of aircraft engine oils and other packaged owned petroleum products is the responsibility of DLApetroleum products. Requests for assistance will be Energy or the military service owning or operating thesubmitted to either the AFPA Current Operations terminal. The authorized government representative identi-Division or Science and Technology Division. For fied on the shipping document and applicable militaryANG units, requests for assistance will be coordi-service control point must be contacted when irregularitiesnated through the NGB/A4RMF staff.

or discrepancies arise during receipt of fuels.

1.2 GENERAL SAFETY AND ENVIRONMENT

1.6 QUALITY SURVEILLANCE AT BASE LEVEL.

CONSIDERATIONS.

a. FM is responsible for the quality of all Defense

Petroleum products are hazardous due to toxic, explosive, Working Capitol Fund (DWCF) fuel through the flammable, and environmentally damaging properties. Pre- point of sale. FM shall support all CONUS and scribed safety precautions will be strictly followed for the host nation environmental compliance require-safety and protection of personnel, equipment, and the ments for sampling and testing of petroleum prod-environment. Fire hazards are present wherever petroleum ucts. See AFI 32-7040 AIR QUALITY COMPLI-products are handled due to leaks, spills, vapor accumula- ANCE AND RESOURCE MANAGEMENT.

tion, improper grounding/bonding of equipment, or ignition

b. Upon DLA Energy-FEQA concurrence, rejecting afrom a heat source. Leaks or spills must be eliminated to receipt prior to/or during offloading the SF Formprevent pollution of waterways and underground water 368 shall be used. For products received or withintables. CFR Title 40, Part 112.7, GUIDELINES FOR THE the inventory a DLA Form 1960 will be used.PREPARATION AND IMPLEMENTATION OF A SPILL AFPA will evaluate and coordinate with DLAPREVENTION CONTROL AND COUNTERMEASURE Energy-FEQA for further action as required.PLAN provides guidance on establishing an adequate spill prevention control program. All spills will be promptly

c. Specification and receipt limits for specific turbinereported to the applicable agencies (Fire Department, fuel types are shown in Table 4-1. SpecificationSafety Office, Bio-Environmental Representative, etc.). Air limits only apply to receipts from a destinationForce Instructions which outline general safety guidelines contract. Receipt limits apply to governmentshall be followed. TO 42B-1-23, titled MANAGEMENT

1-1

SP4510-16-Q-1018

mailto:afpa.afl@dla.mil owned product transfers from a military service or with AFPA will assist in determining a quality hold from a Defense Fuel Support Point (DFSP). and sampling plan.

d. The Logistics Readiness Squadron Commander is 1.7 LIST OF FORMS.

responsible for quality surveillance of packaged petroleum products including aviation oils main- a. DD Form 250 Series Forms are Used for Record Con-tained in the base FP stock record account trol of Fuel Shipments.

(Table 7-1 and Table 7-2).

b. AF Form 979, Danger Tag.

e. Aircraft Maintenance Organizations are responsi-ble for quality surveillance of packaged products in c. AF Form 980, Caution Tag.

their possession. Quality procedures are contained

d. AFTO Form 148, JP-8+100 Acknowledgment.in Chapter 7 of this publication.

e. AFTO Form 149, Fuel Inoculation Record.f. Quality surveillance of petroleum products in orga-nizational support tanks is the responsibility of the

f. AFTO Form 422, Fuel Filter Pressure Differentialorganizational tank custodian.

Log.

g. Approval for use of an aviation fuel which does not

g. AFTO Form 475, Fuels and Lubricant Sample.meet specification limits must be granted by the specific weapon system Original Equipment Manu-

h. Standard Form 368, Product Quality Deficiency Re-facturer (OEM) and/or the engineering function in port.the SPO.

i. Standard Form 364, Report of Discrepancy.h. In any event where the fuel quality is questionable or suspected of contamination, the base is directed j. Form 1960, DLA Energy Fuel Disposition Form.

to notify AFPA/Current Operations. Coordination

1-2

CHAPTER 2

AVIATION FUELS

MIL-DTL-25524 is the specification for this prod-2.1 TURBINE FUELS.

uct. Quality control procedures for this product are contained in TO 42B1-1-16.

NOTE

g. Jet A is a commercial fuel procured to the ASTM

All annotations to aviation turbine fuel in this D1655 specification. Jet A does not require SDA, T.O. reference the fuels listed below unless FSII, or CI/LI.

otherwise noted. Bases must be cognizant of

h. Jet A-1 is a commercial fuel procured to the ASTMthe fuels handled at their locations.

D1655 or DEFENSE STANDARD (DEF STAN)

Turbine fuel is a mixture of hydrocarbons, broadly classi- 91-91 specifications and does not require SDA, fied as kerosene based. Table 2-1 provides information on FSII, or CI/LI.

some key properties of aviation turbine fuels.

i. Jet A (NATO F-24) is a commercial fuel procured

a. JP-8 (NATO F-34) – this fuel is procured to to the ASTM D1655 specification and requires

MIL-DTL-83133 and is the standard USAF turbine FSII, SDA, and CI/LI per concentrations pre-engine fuel. This fuel is similar to commercial Jet scribed in MIL-DTL-83133.

A-1 with the addition of Corrosion Inhibi-

j. Jet A+100 (NATO F-27) is a commercial fueltor/Lubricity Improver (CI/LI), Fuel System Icing procured to the ASTM D1655 specification andInhibitor (FSII), and Static Dissipator Additive requires FSII, SDA, CI/LI, and +100 per concen-(SDA).

trations prescribed in MIL-DTL 83133.

b. JP-5 (NATO F-44) – this fuel is procured to MIL-DTL-5624 and is the standard US Navy tur- 2.2 AVIATION GASOLINE (AVGAS).

bine engine fuel. The requirements applicable when used to purge aircraft are found in TO 1-1-3. NOTE

c. JP-4 (NATO F-40) – this fuel is procured to All quality and handling of AVGAS relatedMIL-DTL-5624 and is a highly flammable fuel issues shall be directed to the digitalcontaining gasoline and kerosene fractions. This TO 42B1-1-22, Quality Control of Aviationgrade is maintained by select bases to aid in cold Gasoline.weather starting.

All Avgas (NATO F-18) is procured to meet ASTM D910NOTE or DEF STAN 91-90 specifications. Aviation gasoline is a mixture of relatively volatile hydrocarbons with small

Since JP-4 is no longer used by the Air Force, quantities of additives including tetraethyl lead. Commer-except for cold weather starts, this technical cial Grade 100 Low Lead (100LL) is blue.

order will omit all references to this fuel in the remaining chapters.

2.3 FUEL ADDITIVES.

d. TS-1/TC-1 is a fuel produced to GOST 10227

a. Fuel System Icing Inhibitor (FSII) conforming tosupplied in the Commonwealth of Independent MIL-DTL-85470 is added to aviation turbine fuels.States (CIS) and locations in southwest Asia. This This inhibitor is Diethylene Glycol Monomethylfuel must include the standard U.S. military addi- Ether (DiEGME). This icing inhibitor lowers thetive package including FSII, SDA, and CI/LI. Use freezing point of small quantities of free water inof Russian additive package is not authorized with-fuel. This has no effect on the actual freezing pointout approval from the weapon system Pro-of fuel.gram/Single Manager.

b. Corrosion Inhibitor/Lubricity Improver (CI/LI)e. JP-8+100 (NATO F-37) is a grade of fuel that conforming to MIL-PRF-25017 is added to avia-contains an additive consisting of antioxidants, tion turbine engine fuels to prevent corrosion ofdetergent/dispersants, metal deactivators, and sol-steel surfaces. CI/LI also provides lubricity to thevents. JP-8+100 has been demonstrated to reduce fuel pumps and fuel controls.fuel system fouling/coking in jet engine nozzles.

c. Static Dissipator Additive (SDA) in fuel enhancesf. Thermally Stable Jet Fuel (JPTS) is used in limited safety during handling and flight. Electrostaticquantities for special applications.

2-1 relaxation times are decreased by increasing the e. Thermal Stability Additive – Thermal stability conductivity of the fuel. Stadis 450 is the only additive is designed to increase the thermal stabil-approved conductivity additive. ity of aviation turbine fuels by 100°F. Fuel contain-ing this additive is referred to as +100.

d. Other Additives – antioxidants must be added to

JP-8 and JP-5 when hydrogen treated blend stocks are used in the refining process.

Table 2-1. Turbine Fuel Characteristics

API Gravity Weight Product Spec Flash Point Freezing Point Range Range lb/gal

JP-8 MIL-DTL-83133 38°C, Min −47°C, Max 37 − 51 6.5 − 7.0

JP-5 MIL-DTL-5624 60°C, Min −46°C, Max 36 − 48 6.6 − 7.0

Jet A ASTM D1655 38°C, Min −40°C, Max 37 − 51 6.5 − 7.0

Jet A-1 ASTM D1655 38°C, Min −47°C, Max 37 − 51 6.5 − 7.0

TS-1/TC-1 GOST 10227 28°C, Min −60°C, Max 51 Max 6.5 Min

NOTE

For logistics planning purposes, see average weights in TO 42B1-1-14 or AFP 23-221.

2-2

CHAPTER 3

FUEL HANDLING

or cone strainer must have the seating surfaces3.1 SCOPE.

sealed to prevent fuel from bypassing. A bypassed or broken screen or strainer must be replaced.This chapter describes Air Force fuel systems and discusses the relationship of specific system components in maintain-

c. When fixed facilities and mobile refueling equip-ing fuel quality. Specific operating guidance is provided in ment require filter changes, they shall have EI 1581this chapter to ensure product quality. Sources and types of latest edition filters installed according to UFCcontamination are identified to aid base personnel in 3-460-03 or TO 37A-1-101. Water absorption ele-preventing quality degradation.

ments meeting the criteria of EI 1583 are not authorized for DoD use.

3.2 RESPONSIBILITIES.

3.4 FILTERS/FILTER SEPARATORS (F/S).a. FM is responsible for the operation of base fuel systems and operator maintenance of these systems

a. Where FILTER and FILTER SEPARATOR(fixed and mobile).

appears in this technical order, the terms are defined as follows:b. The Base Civil Engineer and Water Fuels System

Maintenance (WFSM) are responsible for mainte-

(1) FILTER, refers to a micronic filter vessel con-nance of fixed systems beyond operator mainte-taining 1 or more filter elements. Very fewnance as detailed in Unified Facilities Code (UFC) micronic filters are in use, but those remaining3-460-03.

consist of treated paper elements or cartridges housed in cylindrical vessels. Filters removec. Base Vehicle Maintenance is responsible for the very fine particles from fuel, thus the namemaintenance of mobile refueling equipment beyond micronic filters. Elements are treated to repelthe scope of operator maintenance.

water, but will not coalesce water from fuel.

d. The DLA funds projects related to maintenance,

(2) The term FILTER SEPARATOR, is used inrepair, environmental compliance, and minor con-reference to a vessel containing two stages. Thestruction of DoD owned fuel handling systems first is a micronic paper filter and fiberglasscontaining DWCF fuel.

strand coalescer element. The second stage is a Teflon screen canister or separator element that3.3 STRAINERS.

separates free water from fuel. Both vertical and horizontal types are in use in Air Force systems.a. Strainers are metal screens installed at selective The coalescing function is performed as the fuelpoints in base receiving and dispensing systems for passes through the first stage or first section ofthe removal of large solid contaminants. The most the element assembly. As the fuel passescommon types are basket strainers and cone strain-through the elements, small droplets of waterers. Strainers with various size openings are used that may be suspended in fuel are coalesced intoas required in TO 37A-1-101 and UFC 3-460-03.

large droplets. Since the openings of the coa-Mesh size refers to the number of openings per lescing elements are very small, removal of finelinear inch, i.e., 100-mesh screen has 100 openings particles also occurs. Fuel then passes through aper linear inch or 10,000 openings per square inch.

water repellent media, such as Teflon coatedAn opening this size is equivalent to a particle size screen, to prevent coalesced water from beingof 150 microns.

discharged with the fuel. The separated water drops to a sump for removal through a manualb. A properly designed and installed strainer directs drain valve.all flow through the screen. The proper size basket

3-1 minimum of weekly. Maintaining a quantity of water in the tank for gauging purposes isWARNING prohibited.

Exercise caution when draining systems under (2) Gauge barge/tanker compartments for water pressure. prior to acceptance and discharge. Pump off excess water prior to acceptance.

b. Draining vertical and horizontal filters and filter separator sumps under pressure is necessary to (3) Operate pipeline receiving tank water removal ensure removal of all water and contaminants. systems before and after receiving operations.

(1) Drain (under pressure) daily when used a mini- (4) Inspect uncovered floating roof tanks and mum of one-gallon (continuous, without stop- remove water following heavy rains using the ping) from all vertical and horizontal filter and water removal system.

filter separator sumps (preferably into a bowser,

(a) Water removed from tanks, filters separators,ceramic white bucket, or equivalent). Perform a water removal systems, low point drains, fuelvisual analysis for color, water and solids using bowsers, etc., containing an unknown con-a clean clear quart jar. Continue the sampling centration of FSII requires proper handling.until a clear and bright sample is obtained.

Do not drain such product on the ground orWhen any gelatinous substance is detected, into the installation storm drainage system.retain this material, contact AFPA Current Consult the Environmental Coordinator toOperations Division.

ensure compliance with local, county, state,

(2) An excessive increase in differential pressure and federal environmental laws and regula-over a short time or after little fuel throughput tions. The Environmental Coordinator, in indicates a system malfunction or product con- coordination with the Base Civil Engineer, tamination. Determine the cause and take cor- will identify sanitary sewer inlets suitable for rective action. the disposal of water/FSII concentrations from the sources identified. Alternate proce-

(3) A drop in differential pressure usually indicates dures will be provided where necessary.

a malfunction of the vessel, such as ruptured elements, unless the reading is taken at lower (b) All tanks will be equipped with a water flow rates. removal system. After separation of the fuel/water emulsion in the water removal system the free water is drained and then the3.5 TANKS.

recovered fuel is transferred back into the tanks. All storage tanks in a high waterThe Above Ground Storage Tank Standard Design environment should be programmed for a(AGSTSD) incorporates Automatic Tank Gauge (ATG) Side Stream Filtration system. Also programand Water Detection Probe Stilling Wells which will be tanks during the out of service API 653 tanklocated in the tank sump. All new tanks will be built to this inspection to have the ATG and Water Probestandard. All other existing tanks will be modified to the installed. Report any failure of these systemsnew standard as the tanks undergo API 653 Inspections.

to operate properly or need for maintenance.There is also a design for Side Stream Filtrations for AF units in a high water environment such as barge/tanker

(c) Secure water drawoffs by padlock in thereceipts locations. The AGSTSD changes the issue draw closed position when there is no productoff location to one half of the diameter of the tank. This no movement.longer provides fuel draw off from the center of the tank.

b. For non standard design tanks, the determination ofa. For locations with ATG and Water Probe installed water will be made with ATG equipment or byin the sump, product recovery operations will not gauge and plumb bob using water indication pastebe performed until there is an indication of water in meeting the performance characteristics ofthe sumps. The following guidance is limited to MIL-W-83779. However, be advised that waterthose features, practices, and operations directly detected by the ATG or plumb bob is cause foraffecting fuel quality:

concern. The tank may contain an extremely large amount of water as both the ATG and plumb bob(1) Do not maintain water bottoms (removable manually use the tank datum plate as a referencewater) in petroleum storage tanks. For non stan-point that is not at the tank bottom. Two NSNsdard designed fuel tank, the active tank water apply for MIL-W-83779, 6850-00-001-4193 (jar)removal systems will be operated on a daily and 6850-00-001-4194 (tube). Water indicatingbasis prior to any product movement. Inactive paste will separate during storage or periods oftank water removal systems will be operated at a

3-2 nonuse. Keep water indicating paste well-mixed hours provided the AFPA Current Operations Divi-during use. The jar is recommended in lieu of the sion provides concurrence. When operational tube to enhance mixing. Report quality deficiencies requirements repeatedly limit settling time to less to the AFPA Current Operations Division. than 8 hours, confer with the AFPA Current Opera-tions Division to determine the correct course of action. Simultaneous receipt and issue from the3.6 TANK INSPECTIONS AND CLEANING.

same tank is not authorized.

Tank inspection and cleaning requirements are stated in

b. Operating tanks which receive product from bulkTO 37-1-1 and UFC 3-460-03.

storage (where the fuel has already been allowed to settle for at least 8 hours) do not require a settlinga. Excessive solids upstream of filter separators or period. Observe a two-hour settling period, orrapid build-up of differential pressure in fixed longer, when mission requirements allow.system filter separators are indications that the tank needs to be inspected and cleaned, if needed.

c. Settling time for ground fuel tanks greater than

84,000 gallons is one hour per foot of fuelb. Change of product does not necessarily require received. If less than one foot is received, a mini-tank cleaning. Contact the AFPA Current Opera-mum one hour settling time is required. For tankstions Division at DSN 427-8705 or under 84,000 gallons a minimum 30 minutes set-afpa.afl@dla.mil for guidance/instructions. In most tling time is required after receipt. Observe acases, if the tank was recently cleaned, or deter-longer settling time when mission requirementsmined to be clean by inspection, removal of all allow.product is all that is necessary. However, change of product service from black oil to clean product (aviation fuels) requires chemical cleaning of tank 3.8 CONTAMINATION.

in addition to normal cleaning.

Fuel contamination is generally classified as chemical, biological, or material.3.7 PRODUCT SETTLING.

a. Chemical contamination results from mixing 2 dif- NOTE ferent types of hydrocarbon fuels or mixing other chemicals with fuel. Both the chemical and physi- Requirements outlined in MIL-STD-3004 and cal properties of fuel are affected. Laboratory test- DLA Energy P-7 call for an 8-hour settling ing can usually detect this contamination. Chemical period (at a minimum) after receipts to allow contamination is prevented by isolating different for settling of water and particulates. This set- products in separate handling systems, positive tling time also allows the RO to obtain an physical separation between systems, strict adher-accurate custody transfer of the receipt. The ence to established operating procedures, and the Responsible Officer accepts fiduciary responsi- alertness of operating personnel. Carelessness is bility upon the acceptance of receipts and the major cause of this type contamination.

should make every effort to obtain accurate receipt quantities. It is impossible to obtain an b. Biological contamination results from growth of accurate quantity determination until the prod- bacteria and/or fungi in water deposits within fuel uct has had an opportunity to settle. This is systems. Growths of these microorganisms have a especially true when issue evolutions are con- consistency of slime or mayonnaise at the interface ducted while receiving product. As DLA of fuel and water. This contamination can plug Energy N (DFSP Management) has the over- aircraft filters, cause quantity probe malfunctions, arching responsibility of management and over- and corrode integral fuel tanks. While fuel system sight of DWCF fuel, all waivers pertaining to icing inhibitor acts as a biostat, microbial contami-settling time, inventory and/or accountability nation is most effectively controlled by keeping be additionally coordinated through DLA water out of the fuel system.

Energy N and Q (Quality).

c. Material contamination consists of water, sediment,

a. Aviation fuel received into bulk storage or directly and other materials described herein. Precautions into hydrants must be allowed to settle for a must be taken to prevent introduction and subse-minimum of 8 hours prior to issue or transfer. This quent issue of material contaminants particularly will allow ample time for water and particulate whenever repairs are made to fuel system. Remove settling. Observe a longer settling period when particles, shavings, welding rods, mud packs, and mission requirements allow. In case of emergency, other debris introduced during repairs to systems.

the product may be issued/transferred in less than 8

3-3

SP4510-16-Q-1018

3.9 WATER. 3.11 LINE DISPLACEMENT.

Water is present to some extent in all fuel systems. It can Aviation fuel in the base pipeline system from bulk storage enter tanks during product receipt, especially from tankers to operating storage or truck fillstands will be displaced at and barges. It may enter through leaks in underground least every 30 days. This will preclude deterioration of storage tanks. It may also be introduced as vapor which some of the properties of fuels such as thermal stability or condenses within the system. Both fresh and salt water can gum content and protect the line against corrosion.

be present as dissolved, entrained, or free water.

3.12 IDENTIFICATION AND MARKING OF FUEL

a. Dissolved water is in solution with fuel and is

HANDLING SYSTEMS.always present to some extent. The amount of dissolved water that can be in fuel depends upon

Clearly identify each petroleum piping system by the use ofthe temperature of the fuel and its chemical compo-standard markings as prescribed in MIL-STD-161. A yel-sition. The aromatic compounds in fuels are chiefly low arrow in the line adjacent to the painted bands and titleresponsible for the amount of water a fuel can markings will indicate the direction of flow of product indissolve. The quantity of dissolved water in fuel is the line. Clearly identify each mobile refueling unit andsmall and is measured in parts per million. Dis-hose cart with the grade of fuel as specified by TO 35-1-3solved water cannot be removed by equipment in and TO 36-1-191.the fuel handling system. Water can precipitate or drop out of fuel when the fuel cools.

NOTE

b. Entrained water is free water in suspension, in fuel as extremely small droplets. Small amounts are not All fuel vehicles, bowsers, drums, and contain-usually visible to the naked eye, but larger amounts ers used for the segregation and collection of create a milky haze or cloud in fuel. Water can Recoverable and Waste (R&W) products will become entrained in fuel by condensation of be isolated, marked, and controlled to avoid atmospheric moisture in the vapor/air mixture in a commingling of products and issue of tank when the ambient temperature drops. Free off-specification products. Refer to water can be emulsified with fuel by mechanical TO 42B-1-23 for guidelines on handling R&W action such as passing through pumps. Most products.

entrained water will settle out of fuel provided there are not excessive surfactant contaminants 3.13 SERVICING CONTROLS.

present, which will hold water in suspension.

Entrained water is removed by the coalescing a. Servicing controls are required to assure the correct action of filter separators. grade of fuel is issued by refuelers. Refuelers must be filled with the right fuel and the correct refueler

c. Free water is not dissolved in the fuel. The term must be used to dispense the fuel to the free water is usually used to indicate water which aircraft/equipment.

settled out of fuel or which coalesced into large droplets for removal from the system. b. +100 aviation turbine fuel is only authorized for aircraft which have received approval through the

3.10 SOLID CONTAMINANTS. applicable aircraft Original Equipment Manager

(OEM) and System Program Office (SPO) as

a. Sediment appears as dust, powder, grains, flakes, reflected in the associated AFTO 781, Job Guide, and stains. Sources of sediment are storage tanks, or technical order relevant to that aircraft. In the metal vessels, filter or filter separator elements, event of an emergency when +100 must be ser-valves, pumps, meters, pipelines, hose gaskets, viced to an unauthorized aircraft, the aircraft com-diaphragms, and seals. Rust is the most common mander must justify the emergency on an AFTO solid contaminant. Extremely small particles, mea- Form 148 prior to aircraft servicing. Fuels person-sured by the micron scale, can cause damage. Fine nel will follow the form distribution instructions particles are difficult to detect without the sampling within 24 hours of fuel issue.

and testing prescribed by this publication.

c. Installations that host foreign military requesting

b. When replacing lubricated valves is necessary, +100 on a permanent basis will submit a waiver only non-lubricated valves will be used as pre- request to the AFPA Current Operations Division.

scribed in UFC 3-460-03. Valves used in sampling For ANG units, requests for assistance will be lines will not contain a stem packing material such submitted through the NGB/A4RMF staff. Include as graphite. a Letter of Agreement signed by Wing Commander or designated official and their foreign military counterpart containing the type of aircraft to be

3-4 serviced, duration of the agreement, and documen- afpa.afl@dla.mil using DLA Energy Fuel Disposition Form tation of approval by foreign military weapons 1960.

system program office or equivalent.

3.16 DEFUELING AIRCRAFT/BOWSERS.

d. +100 is not authorized for use in mobile or ground equipment. Aviation fuel mission support refuelers/defuelers will not be used to defuel bowsers, product collection tanks, pits, or

3.14 CONVERTING REFUELING UNITS FROM to recover reclaimable, recyclable, or waste petroleum products, except as outlined in TO 42B-1-23 or in anONE PRODUCT TO ANOTHER.

emergency. AFPA Current Operations Division (or for ANG units through the NGB/A4RMF staff) must approvea. For conversions not listed below, refer to emergency limits.Table 3-1.

a. One-time defuels are authorized using in-serviceb. To convert aviation turbine fuel refuelers to refuelers. For one-time defuels, filtration require-AVGAS, follow the procedures in TO 42B1-1-22.

ments are met by the fuel being filtered and issued through a single filter separator on the mobilec. To convert the refueler back to aviation turbine refueling unit. One-time refuels using dedicatedfuel, completely empty the unit draining all hoses, defuel units are not authorized.the tank, and filter separator sumps. Change unit markings and servicing controls as necessary. Fill

b. Consult with maintenance personnel to determinerefueler with aviation turbine fuel. Rotate 500 the fuel grade/additives and assure the aircraftgallons of fuel through the refueler filter separator sumps have been drained. Specifically confirm theensuring each discharge hose is flushed with 250 fuel to be defueled is not contaminated or sus-gallons. Obtain flow sample and ensure flash point pected of being contaminated with aircraft enginemeets minimum requirements. Place refueler back oil or hydraulic fluid. When defueled aviationin service.

turbine fuel is suspected of contamination, other than water and sediment, place the product in ad. To convert from aviation turbine fuel to +100 and holding tank or retain the product in the defuelvice versa, the following procedures apply:

unit. Place the tank or truck on QC hold. Submit a

(1) Drain and refill with new grade, flush each hose sample to the area laboratory for testing. When with 250 gallons through the bottom loader.