Attachment_0009_-_ATPD-2321A.pdf

Comments, suggestions, or questions on this document should be addressed to the

Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: RDTA-

EN/STND/TRANS, MS-268, Warren, MI 48397-5000 by letter or emailed to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil.

UNCLASSIFIED: Distribution Statement A. Approved for public release.

INCH-POUND

ATPD 2321A

11 April 2013

SUPERSEDING

ATPD 2321

25 June 2003

PURCHASE DESCRIPTION

FOR THE

FUEL ADDITIVE INJECTOR OUTFIT

1. SCOPE

1.1 Scope. This purchase description (PD) describes the performance requirements of the Fuel Additive Injector Outfit, here after referred to as the “injector”. Up to three additives can be injected simultaneously into bulk kerosene-based commercial and military fuels, to bring the fuel additive concentration levels to specified JP-8 fuel levels in a single pass through the injector.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this PD. This section does not include documents cited in other sections of this PD or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications and standards. The following specifications and standards form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents shall be those listed in the issue of the Department of Defense

Index of Specifications Standards (DoDISS) and supplement thereto, cited in the solicitation (see 6.2).

SPECIFICATIONS

FEDERAL

A-A-52557 - Fuel Oil, Diesel; for Posts, Camps and Stations

A-A-59326 - Coupling Halves, Quick-Disconnect, Cam-Locking

Type, General Specification For

DEPARTMENT OF DEFENSE

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-PRF-25017 - Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble

(NATO S-1747)

MIL-DTL-53039 - Coating, Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO

F-34), NATO F-35 and JP-8+100 (NATO F-37)

MIL-DTL-85470 - Inhibitor, Icing, Fuel System, High Flash NATO Code

Number S-1745

STANDARDS

FEDERAL

FED-STD-595/33446 - Desert Tan 686A

DEPARTMENT OF DEFENSE

MIL-STD-129 - Military Marking for Shipment and Storage

MIL-STD-130 - Identification Marking of U.S. Military Property

MIL-STD-209 - Interface Standard for Lifting and Tie down Provisions

MIL-STD-810 - Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-1366 - Interface Standard for Transportability Criteria

MIL-STD-1472 - Human Engineering

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins

Ave, Building 4D, Philadelphia, PA 19111-5094, or at http://assist.dla.mil).

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

http://assist.dla.mil/

US ARMY PAMPHLETS

AR 70-75 - Survivability of Army Personnel and Materiel.

AR 750-1 - Army Material Maintenance Policy.

DA Pam 611-21 - Military Occupational Classification and Structure.

DA Pam 738-750 - Functional Users Manual for the Army Maintenance

Management System (TAMMS).

DA Pam 750-35 - Guide for Motor Pool Operations.

(Copies are available from the US Army Tank-automotive and Armaments

Command, AMSTA-TR-D/210, Warren, MI 48397-5000. Some are also available online at http://www.usapa.army.mil.)

2.3 Non-Government publications. The following document(s) form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents, which are DoD adopted, are those listed in the issue of the DoDISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the

DoDISS are the issues of the documents cited in the solicitation (see 6.2).

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

D 975 - Standard Specification for Diesel Fuel Oils

D 1655 - Standard Specification for Aviation Turbine Fuels

D 2276 - Standard Test Method for Particulate Contaminant in Aviation Fuel by Line Sampling

D 7524 - Standard Test Method for Determination of Static Dissipater

Additives (SDA) in Aviation Turbine Fuel and Middle Distillate

Fuels – High Performance Liquid Chromatography (HPLC) Method

(Applications for copies should be addressed to The American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, or at www.astm.org).

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. The injector shall be subjected to first article inspection and tests in accordance with 4.1.1 (see 6.2).

3.2 Materials. The contractor shall verify that the materials used in injector components are as identified and shall meet all of the operational and environmental requirements specified. The components incorporated into the injector shall be newly http://www.usapa.army.mil/ http://www.astm.org/ fabricated from recovered materials to the maximum extent practicable, provided the components meet all other requirements of this specification.

3.2.1 Deterioration prevention and control. The manufacturer shall select materials capable of meeting all the operational and environmental requirements specified herein.

The injector components shall be fabricated from compatible materials, inherently corrosion resistant or treated to provide against corrosion and deterioration during storage and operational conditions experienced. In addition, the injector shall not be adversely effected or suffer reduction in performance as the result of continuous contact with the fuels and additives listed in 3.3.3.

3.2.2 Dissimilar metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

3.2.3 Recycled, recovered, or environmentally preferable materials. Recovered materials shall be used to the maximum extent practicable, provided the components meet all other requirements of this specification. Used, rebuilt, or remanufactured components shall not be incorporated into the injector.

3.3 Design and Operational requirements.

3.3.2 Additives. The injector shall be capable of injecting the following additives;

fuel system icing inhibitor, static dissipater additive and corrosion inhibitor (see 3.3.3), at controlled, manually adjustable blending ratios. The injector shall be capable of drawing from three separate containers of additives, with a separate injection line for each additive.

3.3.3 Fuel/additive compatibility and injection ratios.

a. The injector shall be capable of meeting the operational requirements when in contact with the following fuels and additives throughout the required operational environment (see 3.6) without modifications or kits:

Fuels Additives

MIL-DTL-83133

MIL-DTL-5624

Fuel System Icing Inhibitor, MIL-DTL-85470

Static Dissipater, Stadis 450 by Octel America

A-A-52557

ASTM-D-975

Corrosion Inhibitor, MIL-PRF-25017

ASTM-D-1655

b. The injector shall mix each additive with the influent fuel at a constant injection ratio; in order to bring the additive concentration levels in the fuel up to predetermined target levels. The additive concentration limits for JP8 turbine fuel are specified in Table 1. The normal operating range for the fuel additive injector shall be at a minimum 150 gpm to 700 gpm over a pressure range of 50 psi to 75 psi. In the normal operating range, the injection ratio shall not vary more than 5% of the total volume injected. The Fuel Additive Injector shall be capable of operation at pressures of up to

150 psi. (see 3.3.4).

Table 1. Additive Concentration Levels in Effluent Fuel

Additive Minimum Maximum

Fuel System Icing Inhibitor, vol % 0.10 0.15

Static Dissipater Additive, mg/L 3 5

Corrosion Inhibitor, mg/L 9 22.5

3.3.4 General performance. The injector shall not require outside electrical, mechanical, or compressed air power to inject additives into bulk fuel. (PSIG).

3.3.5 Hydrostatic pressure. Each injector shall be capable of withstanding a hydrostatic test pressure of 225 PSIG for a period of 10 minutes.

3.3.6 Protective device. The injector shall contain a permanently attached frame and/or enclosure to prevent damage caused by loading/unloading, transport, inadvertent rollover and usage in the environment specified herein and facilitate manual and mechanical handling.

3.3.7 Controls.

3.3.7.1 Additive shutoff. The capability shall exist to shutoff each additive, without affecting the injection of the other additives.

3.3.7.2 Injection ratio adjustment. The capability to adjust the amount of additive injected shall exist, without affecting the injection ratio of the other additives. The capability shall contain a numeric scale that indicates the amount of additive being injected.

3.3.7.3 Calibration. The injector shall have the capability to calibrate each additive to the proper injection ratio by the operator in the field. All necessary support items, such as flow meters, gauges, valves, hoses, tools, additive supply tanks, required to perform the complete calibration task for each additive shall be identified and delivered with the injector. A securable container to stow and protect these support items shall be permanently attached to the injector. Calibration instructions for each additive and when to calibrate the injector shall be specified in the operator’s manual specified in 3.11.

3.3.7.4 Drain valve. The injector shall be provided with a device to drain residual fluids when preparing for shipment and storage. There shall be no leakage from the device during operation of the injector.

3.3.8 Adapter and sampling probe. The injector shall be furnished with an adapter and sampling probe that can be used on the either the fuel inlet or outlet of the injector.

Figure 1 is an example of a suitable adapter. The sampling probe shown in the figure shall be as specified in ASTM D 2276, Annex A2. See 3.3.9 for the injector coupling interface size.

3.3.9 Fittings. The inlet and outlet connections for the injector shall be 4” cam-locking fittings per A-A-59326. The inlet shall be female and the outlet shall be male.

The end fittings shall be provided with captive dust cap in accordance with A-A-

59326/10-9 and plug in accordance with A-A-59326/11-9. The fittings shall have a minimum working pressure of 150 psi. The coupling halves and gaskets shall be compatible for use with the fuels listed in 3.3.3.

3.3.10 Dimensions and Weight. The injector assembly shall not exceed the following overall dimensions, 48”L x 40”W x 40”H. The injector assembly with tool box, tools and all over pack equipment shall not weigh more than 1100 lbs uncrated.

3.4 Interface requirements.

3.4.1 Container interface.

3.4.1.1 Static Dissipater Additive and Corrosion Inhibitor. Containers shall be of sufficient size to hold a minimum of 5-gallons of each additive. These containers shall be secured to the injector and contain an additive level gauge, fill port, filtered air vent, drain valve and suction supply valve. The containers shall prevent exposure of the additives to the environment during operation and storage.

3.4.1.2 Fuel System Icing Inhibitor (FSII). FSII is supplied in 55-gallon drums. The drum contains 2-inch and ¾-inch NPT bungs. The FSII additive injector line shall be secured to the drum with a device that prevents exposure of the additives to the environment during operation.

3.4.2 Transportability. The injector shall be transportable by all modes of military and commercial transportation, including rail, highway, marine, and air in accordance with

MIL-STD-1366.

3.4.2.1 Tiedown provisions. The injector shall include tiedowns in accordance with

MIL-STD-209 to allow for transportation. The tiedown provisions shall restrain the unit(s) without weld failure, permanent deformation, cracking, loosening, or breaking of the provision or its connecting structural components.

3.4.2.2 Slinging provisions. The injector shall be equipped with slinging provisions.

The provisions shall enable the injector to be lifted. Slinging provisions, in accordance with MIL-STD-209, shall be located so that at least 1.00-inch clearance is maintained between slings and all exterior parts. Reinforcement may be fastened to members that shall withstand stresses, consistent with the amount and direction of pull. Slinging provisions may also be used as tiedown provisions when such provisions meet the requirements specified in 3.4.2.1. All slinging/tiedown provisions shall be labeled

"LIFT", “TIEDOWN", or "LIFT TIEDOWN", as appropriate, in 1-inch (2.54 cm) high letters.

3.4.2.3 Ground transport and handling. The injector shall be capable of transport by the specified US Army trucks listed below, and lifted by material handling equipment as listed below:

a. Vehicles. The injector shall be transportable by the appropriate size standard

US Military 5-ton and heavier capacity cargo trucks and their designated trailers, and appropriately sized military and commercial tractor and trailer combinations.

b. Material handling equipment As a minimum, any required mechanical handling of the injector shall be accomplished without restrictions or additional kits by appropriately sized standard US Army forklifts of the types and series described below.

Equivalent commercial forklifts that are capable of safely lifting not less than 10,000 lbs.

with 48-in. load centers and a minimum of 72-in. tines may be used in lieu of the M10A and ATLAS.

(1) 10,000 lb capacity All Terrain Lifter Army System (ATLAS).

(2) 10,000 lb forklift truck, M10A.

3.5 Ownership and support requirements.

3.5.1 Safety. All electrical wiring and any rotating or reciprocating parts shall be electrically and physically safe, and shall be guarded so as not to be a hazard to operating personnel and to minimize the hazard of fire in the event of a fuel spillage or leakage from hoses and connections. Danger or caution signs, labels, and markings shall be used to warn of potential or specific hazards.

3.5.2 Human factors engineering. Human engineering criteria, principles, and practices shall be considered as part of unit construction. MIL-STD-1472 shall be used as applicable for human factor engineering. The injector shall be capable of being operated by the 5 th percentile female to the 95 th percentile male military personnel as defined in MIL-STD-1472 wearing gloves, mittens, or equipped with Mission Orientated

Protective Posture (MOPP IV) gear (see 3.12). Emphasis shall be given but not limited to general requirements, control and display integration, controls, labeling, maintainability, anthropometry, and hazard and safety criteria, as applicable.

3.5.3 Environmental hazard prevention. The injector shall be designed to prevent inadvertent or uncontrolled fuel or additive discharge or leakage during operation, storage, and maintenance.

3.5.4 Grounding, bonding, and clamps. The injector shall provide complete electrical continuity throughout the injector and shall include a metal-to-metal contact between the injector to ground. Grounding rod and grounding wires equipped with plier-type clamps shall be provided for grounding during operation. The grounding wires shall be permanently attached to the ground rods or means shall be provided for attachment, without tools, that will ensure electrical continuity. The grounding rod shall include an integral hammer and anvil, of sufficient size to drive the rods into compact soil. The grounding rod, which may be collapsible, shall be secured to the injector, and shall be not less than 68 inches long when in operational service configuration.

3.5.5 Servicing, operation, and maintenance. The injector support concept shall use two-level organic maintenance, and shall conform to the requirements and guidance according to AR 750-1, DA Pam 750-35, and DA Pam 738-750. The injector shall require as few special tools or test equipment as possible, and the maximum utilization of existing DoD and US Army tools and support equipment is required. If test, measurement, and diagnostic equipment (TMDE) are required, it shall be subject to

Government approval.

3.5.5.1 Operator. All tools, special tools, and test equipment required to perform operator-level Preventive Maintenance Checks and Services (PMCS) shall be provided with each injector along with the required stowage space.

3.5.5.2 Organizational and Depot Support (DS). All tools, special tools, and test equipment required to adjust, maintain, and repair the injector that are not already available to the repair level echelons above organization that would normally provide these services to the using unit during the required injector service life shall be provided.

The contractor shall select the equipment in the following order of preference: (1) tools available in specified tool kits; (2) Test, Measurement and Diagnostic Equipment

(TMDE) which is currently part of the DoD; and (3) commercially available items, not previously identified. The contractor shall identify all special tools required to service or repair the injector and incorporate the special tools and test equipment lists into the maintenance manual.

3.6 Environmental. The injector shall be capable of being stored, maintained, and operated under the following environmental conditions.

3.6.1 Operational temperature. The injector shall operate as specified at any ambient temperature from -25F to +120 o F.

3.6.2 Storage temperature. The injector shall not be damaged by any ambient temperature from - 30 o F to +160 o F.

3.6.3 Sand. The injector shall perform as specified herein in a blowing sand environment when subjected to a minimum sand concentration of 0.062 ± 0.015 gram per cubic foot (g/ft

) at a minimum wind velocity of 3540 feet per minute (ft/min).

3.6.4 Dust. The injector shall perform as specified herein in a blowing dust environment when subjected to a minimum dust concentration of 0.3 ± 0.2 g/ft at a minimum wind velocity of 300 ft/min.

3.6.5 Humidity. The injector shall perform as specified under relative humidity of up to 88%.

3.6.6 Solar radiation. The injector shall perform as specified with up to 355 British thermal units (BTUs) per square foot per hour of solar radiation.

3.6.7 Rain. The injector shall perform as specified herein when subjected to a blowing rain environment of up to 4 inches per hour.

3.6.8 Salt fog. The injector shall withstand damage from being exposed to salt fog.

3.6.9 Altitude. The FSSP components, in storage configuration, shall withstand the low-pressure environment at a minimum altitude of 40,000 ft. The FSSP shall perform as specified at altitudes up to and including 5,000 ft above sea level at a maximum temperature of 107F.

3.7 Identification, marking and information. The injector shall be identified and marked in accordance MIL-STD-130 to include, at a minimum, design activity code, manufacturer and Commercial and Government Entity Code (CAGEC), item nomenclature, serial number, NSN, weight, contract number, date of manufacture, technical manual number, and U.S. military property identification.

3.8 Personnel integration (MANPRINT) requirements. The injector shall be operable and maintainable by the following military-trained personnel, as designated by

DA Pam 611-21:

a. Military Occupational Specialty (MOS) 77F (Petroleum Supply Specialist).

b. MOS 63J (Quartermaster and Chemical Equipment Repairman).

3.9 Corrosion control performance. The injector shall operate without corrosion affecting form, fit, or function during a 20-year service life. Service life can include varying or extended periods in corrosive environments involving one or more of the following: high humidity, salt spray, road de-icing agents, gravel impingement, atmospheric contamination, and temperature extremes. During the 20-year service life, surface corrosion, which may include red, black, and/or white corrosion products, shall be a maximum of 1% of the surface. The loss of the original thickness of the base metal shall be no greater than 2% or 0.001 in., whichever is less.

3.10 Treatment and coating.

a. Unless otherwise specified (see 6.2), all external surfaces of the injector except as noted below, regardless of the material selected, shall have a finish coat of Chemical

Agent Resistant Coating (CARC) in accordance with MIL-C-53039. The color shall be

Desert Tan 686A, color number 33446 in accordance with FED-STD-595.

b. The color of all other surfaces, to include those within a housing, those behind insulation material, and the insulation retainer, if used, shall be Desert Tan 686A, color number 33446 or black, color number 37030 in accordance with FED-STD-595 or the manufacturer's standard color, if approved by the Government.

c. The following items shall not be coated: terminal wiring connections, , instruction diagrams and plates, , instrumentation, rubber, lubrication fittings, hoses, nozzles, dry break couplings, and all other parts whose operation or function would be adversely affected if coated. Insulation material shall be coated unless the sound absorbing characteristics of the material are compromised.

d. Identification plates shall be installed following application of the final finish coat.

e. CARC paint is not required on surfaces that have been anodized.

3.11 Manuals and special instructions. The injector shall require technical manuals

(TM) and may require other special instructions. Operator manuals and other special instructions shall be included as part of the end-item when specified by the contract or order (see 6.2) or scope of work.

3.12 Tools, special tools and test equipment. When specified by the contract or order

(see 6.2) or scope of work, tools, special tools, and test equipment shall be included as part of the end-item in addition to the requirements of 3.5.5.

3.13 Nuclear, biological, and chemical (NBC) decontamination. The injector shall be capable of being decontaminated to negligible risk levels as defined in U.S. Army-approved NBC contamination survivability criteria and AR 70-75.

3.14 Basic Issue Items (BII). Each injector shall be provided with BII and stowage space for the BII.

3.15 Components of the end item (COEI). The injector shall be provided with COEI.

COEI are part of the end item but are removed and stowed for transportation or shipment.

4. VERIFICATION.

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article test/inspection (FAT) (see 4.1.1).

b. Control Test (CT) (see 4.1.2)

c. Conformance inspection (CI) (see 4.1.3).

4.1.1 First article test/inspection (FAT). A First Article Test shall be conducted by the contractor on not less than one (1) test sample and shall include the test and inspections of paragraphs 4.1.2 through 4.8. The contractor shall deliver a FAT Test

Report to the government for approval. Nonconformance to any specified requirement, the presence of one or more defects, or the failure of the test shall constitute cause for rejection of the FAT and the FAT Test Report.

4.1.2 Conformance Inspection (CI). CI shall be performed by the contractor on each

Fuel Additive Injector. CI shall consist of the examinations listed in Table II and the

Operational Testing in paragraph 4.3.1 and the Hydrostatic Pressure Testing in paragraph

4.3.2. . Presence of one or more defects shall be cause for rejection of the Fuel Additive

Injector Assembly. The contractor shall document the results of the CI and submit them to the government.

TABLE II. Examination schedule.

Number Examination description Method of inspection

101. Materials not as specified (3.2). Visual/ Docs

102. Power requirements not as specified. (3.3.4) Visual/ Docs

103. Protective device(s) not as specified or missing. (3.3.6) Visual/ Docs

104. Controls not as specified or missing. (3.3.7) Visual/ Docs

105. Adapter and sampling probe not as specified or missing. (3.3.8) Visual/ Docs

106. Inlet and outlet connections not as specified. (3.3.9) Visual/Docs

107. Dimensions and weight exceeded. (3.3.10) Docs

108. Interface requirements not as specified or missing. (3.4) Visual/ Docs

109. Ownership and support requirements not as specified (3.5) Visual/ Docs

110. Identification and marking not as specified or missing. (3.7) Visual/ Docs

111. Corrosion control performance not as specified (3.9) Visual/ Docs

112. Treatment and coating not as specified or missing. (3.10) Visual/ Docs

113. Manuals/special instructions not as specified or missing. (3.11) Visual/ Docs

114. Tools/sp. tools/test equipment not as specified or missing. (3.12) Visual/ Docs

115. Basic Issue Items not supplied (3.14) Visual/ Docs

116. Components of the end item not supplied (3.15) Visual/ Docs

117. Packaging and preservation not as specified or missing. (5.1) Visual/ Docs

Doc = Documentation

4.2 Test conditions, schedules, other required reports or certifications, and prohibitions.

4.2.1 Test Conditions and Tolerances for Test Conditions. Unless specified otherwise, all testing and examinations shall be conducted IAW paragraphs 5.1 and 5.2, MIL-STD-

810. The contractor or test activity may, with prior Government permission, use observations and test results obtained using actual on-site conditions that are recorded as actual and corrected values to +77°F± 3°F and the humidity and barometric pressure ranges allowed in the preceding sentence.

4.2.2 Schedule and sequence of tests. The contractor shall determine the schedule and sequence of tests, except where specified. Advance planning and provisions shall be made to insure that each item of the schedule and sequence shall not have a detrimental effect or preclude the performance of a subsequent test/examination on any test sample.

4.2.3 Advance notice of schedule. Appropriate advance notice of the test schedule, location(s), or changes shall be provided to the Government, subcontractor, designated test site/facility, and regulatory agency personnel to allow participation or oversight.

4.2.4 Certificates of Conformance (CoC). When specified, CoC’s shall be:

a. provided by the contractor and in contractor format, except when specified otherwise by the contract, with sufficient supporting technical information to insure adequate evaluation and comment by the Government.

b. required for delivery to the Government, and may be required for delivery to other activities or agencies to verify safety, HAZMAT, operational, and other requirements prior to delivery for test or acceptance in order to assure safe operation.

c. included in all Final Test Reports and, when specified, Conformance Inspection

(CI).

4.2.5 Test, operation, and demonstration fluids. The test fluid and additives for FAT and CT shall be as specified by the manufacturer of the Injector Assembly and shall be adequate to successfully validate the performance of the Injector Assembly.

4.2.5.1 Recycling and disposal. The use, reuse, and disposal of the required test fluid, lubricants, and other expendable items shall be in compliance with all applicable US statutory, regulatory, and local requirements for the proper storage and disposal of hazardous wastes and waste water discharges. Economic use and recycling for contractor in process and other testing is encouraged to reduce costs to the Government.

4.3 Design and operational requirements. The following test, observations, and

COC’s (see 4.2.4) shall be used to verify compliance with paragraph 3.3. For those requirements of 3.3 which do not have specific testing requirements identified below, verification shall be accomplished by 1) contractor CoC’s based on engineering analysis, demonstrated applicable commercial/military experience and expertise on the same or similar items and by 2) actual performance which shall be observed and recorded during the FAT and included in the FAT Test Report. Absence of each CoC, test failures, and failure to demonstrate compliance to the requirements of each Section 3.3 paragraph shall constitute failure.

4.3.1 Operational testing. The injector shall be operated for not less than 30 minutes, as specified in 3.3.2 and 3.3.3. The injector shall be operated at flow rates of 200, 350 and 700GPM at a pressure of not less than 60 psi. The amount of additives dispensed shall be measured and recorded at three timed intervals (beginning, middle and end) for each flow rate. Compliance to 3.3.4 shall be verified by observation and the results shall be separately recorded in the FAT Test Report. Failure to comply with the requirements specified in 3.3.2, 3.3.3, and 3.3.4 shall constitute failure of these tests.

4.3.2 Hydrostatic pressure. The injector shall be subjected to a hydrostatic pressure test of 225 psig for 10 minutes. Failure to comply with the requirement specified in

3.3.5, evidence of leakage, permanent deformation, or other defects that affect the performance and serviceability of the injector shall constitute failure of this test.

4.3.3 Fuel/additive compatibility. In addition to the requirements of 4.3 above, the contractor (OEM) shall provide a COC for 1) each additive identified in 3.3.3 to verify suitability for intended use for each fuel identified, and 2) a separate COC to verify injector material compatibility with each fuel and additive in accordance with 3.2.1.

Failure to provide the required COC’s or comply with the requirements specified in 3.3.3 or 3.2.1 without modifications or kits shall constitute failure of this requirement. After the contractor has completed the testing in paragraph 4.3.3 and 4.3.2 the fuel additive injector assembly shall be, cleaned, dried and preserved in as new condition.

4.4 (Reserved.)

4.5 (Reserved.)

4.6 Environmental testing/verification. Conformance to the requirements of 3.6 shall be verified by testing in accordance with the test procedures of MIL-STD-810. On a continuing basis during and at the conclusion of each procedure of this test, each test sample shall be examined for any damage, leakage, failure of the item to operate as required, or degradation of performance and operational capabilities. Not less than one test sample shall be tested according to each requirement, unless otherwise specified.

Any damage, leakage, failures, inability of the injector to operate, reduction in injector operational capabilities, or failure to perform to the requirements of each test shall constitute failure.

4.6.1 High operational and storage temperatures. To verify conformance to 3.6.1 and

3.6.2, the injector shall be consecutively tested IAW Procedure I (Storage) and Procedure

II (Operation) of Method 501. Temperature sensors shall be located in all locations and in operational fluids that may be harmed by exposure to high temperatures. As a minimum, housing temperatures shall be monitored and recorded at regular intervals.

Test temperatures shall be as specified in 3.6.1 and 3.6.2. Test duration shall be seven cycles for Procedure I and constant temperature exposure for Procedure II. The injector shall be operated until all recorded temperatures have stabilized or a minimum of 4 hours.

Failure of the injector to operate as specified, or any damage or degradation of performance as a result of exposure to the temperature extremes, shall result in failure of this test.

4.6.2 Low operational and storage temperatures. To verify conformance to 3.6.1 and

3.6.2, the injector shall be tested IAW Procedures I, II, and III of Method 502.

Temperature sensors shall be located in all locations and in operational fluids that may be harmed by exposure to low temperatures. As a minimum, housing temperatures shall be monitored and recorded at regular intervals. Test temperatures shall be as given in 3.6.1 and 3.6.2. Test duration for storage is not less than 4 hours and not less than 4 hours for operation or until recorded temperatures stabilize. Failure of the injector to operate as specified, or any damage or degradation of performance as a result of exposure to the temperature extremes, shall result in failure of this test.

4.6.3 Sand. To verify conformance to 3.6.3, the injector shall be tested IAW

Procedure II of Method 510. The injector shall be subjected to blowing sand condition for a minimum total of 360 minutes, 90 minutes per side. The blowing sand concentration shall be maintained at 0.0623 ± 0.015 g/ft . The air velocity shall be 3540 ft/min for blowing sand. The injector shall be operated during the last hour of the test.

Upon test completion the injector shall be started and operated for a period of not less than 30 minutes. Failure of the injector to operate as specified shall result in failure of

4.6.4 Dust. To verify conformance to 3.6.4, the injector shall be tested IAW

Procedure I (Dust) of Method 510. The injector, in full operational mode (running), shall be subjected to blowing dust condition for a minimum of six hours. The dust concentration for the blowing dust test shall be maintained at 0.3 0.2 g/ft . The air velocity shall be 300 ft/min for blowing dust. At the conclusion of this test, the injector shall be inspected for visible signs of damage and operated for not less than 30 minutes.

Failure of the injector to operate as specified shall result in failure of this test.

4.6.5 Humidity. To verify conformance to 3.6.5, the injector shall be tested IAW

Method 507. The test shall be conducted for 5 cycles IAW figure 507-1. Failure of the injector to operate as specified shall result in failure of this test.

4.6.6 Solar radiation. To verify conformance to 3.6.6, the injector shall be tested

IAW Procedure I of Method 505. Test duration shall be not less than 5 cycles of 24 hours each. Temperature sensors shall be located in critical areas where temperature can be expected to be the highest. The diurnal cycle shall be for hot-dry conditions. Upon completion of the test the injector shall be examined for damage and operated for not less than 30 minutes. Failure of the injector to operate as specified shall result in failure of

4.6.7 Rain. To verify conformance to 3.6.7, the injector shall be tested IAW

Procedure I (Rain and Blowing Rain) of Method 506. The water distribution device shall deliver water at a pressure from 30 to 40 psi and flow rate of 5 gph for a 30-minute period per side. A rainfall rate of up to 4 in. per hour impinging on the injector at angles from the vertical up to 45 degrees shall be used. Test item temperature shall be a minimum of 20F higher than the rain temperature at the beginning of each exposure period. A wind velocity of up to 40 mph shall be used for this test. On completion of exposure, the injector shall be operated at full capacity for not less than 30 minutes.

Failure of the injector to operate as specified shall result in failure of this test.

4.6.8 Salt fog. To verify conformance to 3.6.8, the injector shall be tested IAW

Procedure I of Method 509. Duration of this test shall be 48 hours. Upon completion of the test the injector shall be examined for damage and operated for not less than 30 minutes. Failure of the injector to operate as specified or any visible surface corrosion of any metal parts, coated or uncoated, shall result in failure of this test.

4.6.9 Altitude. To verify conformance to 3.6.9, the injector shall be tested IAW

Procedure I (Storage/Air Transport) and Procedure II (Operation/Air Carriage) of Method

500. Procedure I shall be conducted for a one hour storage period at an altitude of not less than 40,000 ft above sea level. Procedure II shall be conducted for a one-hour storage period at an altitude of not less than 5,000 ft above sea level with the injector operating at rated capacity for not less than one hour. Failure of the injector to operate as specified, or any damage or degradation of performance as a result of exposure to the altitude extremes, shall result in failure of this test.

4.6.10 Shock. To verify conformance to 3.3.6, the injector shall be dropped on an 8 inches (20 cm) thick bed of dry sand, from a height of 60 inches (152.4 cm). All drops shall be made so that the injector falls freely through the distance specified. The injector shall be dropped four times on each bottom corner. Upon completion of the test the injector shall be examined for damage and operated for not less than 30 minutes. Failure of the injector to operate as specified shall result in failure of this test. Hammonds recommends that the control panel be shock mounted, and braided stainless hose be used instead of tubing and that the calibration gauges be shock mounted. These changes add

$800.00 per injector.

4.6.11 Vibration. To verify conformance to 3.4.2.3, the injector shall be tested IAW

Category 4 (Truck/trailer/tracked - restrained cargo), Method 514.5. Test time shall be 1 hour in each of three mutually perpendicular directions, for a total of 3 hours. Prior to and following the test the injector shall be operated for not less than 30 minutes. Upon completion of the test the injector shall be examined for damage. Failure of the injector to operate as specified shall result in failure of this test.

4.7 Verification. Verification of each of the following Section 3 paragraphs shall be accomplished by 1) contractor CoC’s for each individual paragraph based on engineering analysis, demonstrated applicable commercial/military experience and expertise on the same or similar items; 2) requirement and specification testing that is specifically called out within each paragraph; or 3) actual performance and compliance which shall be observed and recorded during the FAT and included in the FAT Test Report. Absence of each CoC, test failures, and failure to demonstrate compliance to the requirements of each Section 3 paragraph listed below shall constitute failure.

a. 3.3.7 Controls

b. 3.3.10 Dimensions and weight.

c. 3.4 Interface requirements.

d. 3.5 Ownership and support requirements.

e. 3.7 Identification, marking and information.

f. 3.8 Personnel integration (MANPRINT) requirements.

g. 3.9 Corrosion control performance.

h. 3.10 Treatment and painting.

i. 3.11 Manuals and special instructions.

j. 3.12 Tools, special tools and test equipment.

k. 3.13 NBC.

l. 3.14 Basic Issue Items (BII).

m. 3.15 Components of the end item (COEI).

5. PACKAGING.

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When actual packaging of material is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activity within the Military

Department or Defense Agency, or within the Military Department’s Command.

Packaging data retrieval is available from the managing Military Department or Defense

Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES.

(This section contains information of a general or explanatory nature, which may be helpful but is not mandatory.)

6.1 Intended use. The intended use of the Fuel Additive Injector Outfit is to inject up to three additives simultaneously into bulk commercial Jet-A grade fuel to bring the fuel additive concentration levels to specified JP-8 fuel levels in a single pass through the injector.

6.2 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of this publication.

b. Issue of DoDISS to be cited in the solicitation, and if required, the specific issue of individual documents referenced (see 2.2.1 and 2.3).

c. When a first article is required for inspection and approval, time frame for submission, and the number of units required (see 3.1 and 4.2).

d. When treatment and painting is other than as specified (see 3.10).

e. When an operator manuals and other special instructions is required (see 3.11).

f. When tools, special tools, and test equipment are required (see 3.12).

g. Packaging requirement (see 5.1).

6.3 First article. When a first article inspection is required, the item to be tested should be selected by the Government from the first production lot. The first article should consist of a complete injector. The contracting officer should include specific instructions in acquisition documents regarding arrangements for Government furnished property, examinations, tests, approval, and disposal of the first article (see 4.2).

6.4 Data requirements. The contracting officer should include requirements for such data as technical publications, instructional materials, illustrated parts lists, and contractor’s maintenance and operation manuals to be furnished with each injector.

Custodians: Preparing Activity:

Army -- AT Army -- AT

1 2

DIRECTION OF FLOW

FIND

NO.

NOMENCLATURE REFERENCE

1 Dust Plug ASTM F 1122

2 Gasket ASTM F 1122

3 Coupling Half, Female ASTM F 1122

4 Dust Cap ASTM F 1122

5 Coupling Half, Male ASTM F 1122

6 Probe Assembly, Detector Kit ASTM D 2276 and ASTM D 3240

7 Hexagonal Nut ASME B18.2.2

8 Pipe Coupling SAE AS 4859

9 Pipe Nipple SAE AS 4860

10 Antiseize Tape A-A-58092

Reference: NSN 6640-00-244-9478

FIGURE 1. Adapter and sampling probe. – Example