TO 37-1-1.pdf

TO 37-1-1

TECHNICAL MANUAL

GENERAL

OPERATION AND INSPECTION

OF INSTALLED

FUEL STORAGE AND DISPENSING SYSTEMS

(ATOS)

F41608-87-D-A288

Prepared By: TRI-COR Industries, Inc.

This publication supersedes TO 37-1-1, dated 15 July 2013, which will be removed from active files.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Requests for this document must be referred to AFPET/PTPS, 2430 C Street, Bldg 70, Area B, Wright-Patterson AFB, OH 45433-7632. PA Case Number AFMC 04-403. Submit recommended changes or problems with this Technical Order to AFPET/PTPS.

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 2015

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 DESTROY SUPERSEDED PAGES.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 2015

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 54, CONSISTING OF THE FOLLOWING:

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

Title A i - iii iv Blank v - vi 1-1 1-2 Blank 2-1 - 2-13 2-14 Blank 3-1 - 3-7 3-8 Blank 4-1 - 4-2 5-1 5-2 Blank 6-1 - 6-2 7-1 - 7-3 7-4 Blank 8-1 - 8-3 8-4 Blank A-1 - A-7 A-8 Blank

*Zero in this column indicates an original page

A USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iii

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

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

SAFETY SUMMARY................................................vi

1 RESPONSIBILITIES................................................1-1

1.1 Responsibilities ...........................................1-1

1.1.1 Government Owned/Government

Operated (GOGO)..................................1-1

1.1.2 Government Owned/Contractor

Operated (GOCO)..................................1-1

1.2 Fuels Management (FM)............................1-1

1.3 Facility Maintenance ..................................1-1

1.4 Organizational Tanks..................................1-1

1.5 Technical Assistance Division ...................1-1

2 OPERATING PROCEDURES.................................2-1

2.1 General........................................................2-1

2.1.1 Fire Protection ............................................2-1

2.1.2 Frozen Valves .............................................2-1

2.1.3 Fuel Receipts ..............................................2-1

2.1.4 Filling Bulk Storage Tanks ........................2-2

2.1.5 Receipt Operations Tank

Truck/Car ...............................................2-2

2.1.6 Pipeline, Barge, and Tanker Re-

ceipts ......................................................2-4

2.1.7 Transferring Product between

Bulk and Operating Storage ..................2-4

2.1.8 Ignition Hazards During Fuel

Transfer from Storage Tanks by Other Than Normal Means .............2-5

2.1.9 Pumps..........................................................2-6

2.1.10 Product Settling ..........................................2-6

2.1.11 Gauging.......................................................2-6

2.1.12 Leak Detection............................................2-9

2.1.13 Product Saver Tank System and

Oil/Water Separator ...............................2-9

2.1.14 Tank Cleaning and Inspection

Criteria ...................................................2-9

2.1.15 Servicing Controls ......................................2-9

2.1.16 Dispensing Fuel from Truck Fill-

stand-Bottom Loading .........................2-10

2.1.17 Tank Truck/Car Top Loading

Operation..............................................2-11

2.1.18 Refueling Unit Return to Bulk

Storage (RTB)......................................2-11

2.1.19 Service Station Operation.........................2-11

2.1.20 Hydrant Issues to Aircraft or Re-

fueling Unit(s)......................................2-11

2.1.21 Defueling into Hydrant Systems..............2-13

3 OPERATOR’S INSPECTION AND

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

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

3.1.1 System Deficiency......................................3-1

3.1.2 Discrepancy Record....................................3-1

3.1.3 Inspection Guide.........................................3-1

3.1.4 Active Systems ...........................................3-1

3.1.5 Files.............................................................3-1

3.1.6 AFTO Form 39, Page 1 .............................3-1

3.1.7 AFTO Form 39, Page 2 .............................3-2

3.1.8 Inspections ..................................................3-2

3.1.9 Open Discrepancies ....................................3-2

3.1.10 Operational Inspections ..............................3-2

3.1.11 Weekly Inspections.....................................3-5

3.1.12 Monthly Inspections ...................................3-6

3.1.13 Semiannual Inspections ..............................3-7

3.1.14 Annual Inspections .....................................3-7

4 FLUSHING HYDRANT SYSTEMS.......................4-1

4.1 General........................................................4-1

4.1.1 Flushing Frequencies..................................4-1

4.1.2 Flushing Procedures ...................................4-1

5 LOW POINT DRAINS ............................................5-1

5.1 General........................................................5-1

5.1.1 Fuel System Draining Frequen-

cies .........................................................5-1

5.1.2 Low Point Draining Procedures.................5-1

5.1.3 Environmental.............................................5-1

6 LIQUEFIED PETROLEUM GAS (LPG)................6-1

6.1 General........................................................6-1

6.1.1 Fire Protection ............................................6-1

6.1.2 Storage Containers......................................6-1

6.1.3 Markings on Bulk Containers ....................6-1

6.1.4 Pressure-Relief Valves ...............................6-1

6.1.5 Hoses, Hose Connections, and

Flexible Connectors ...............................6-2

6.1.6 Hydrostatic-Relief Valves ..........................6-2

6.1.7 Equipment ...................................................6-2

6.1.8 Location of Container.................................6-2 i

6.1.9 Fencing........................................................6-2

6.1.10 Grounding ...................................................6-2

6.1.11 Liquid Transfer ...........................................6-2

7 COMPRESSED NATURAL GAS (CNG)...............7-1

7.1 General........................................................7-1

7.1.1 Properties of CNG......................................7-1

7.1.2 Fire Protection ............................................7-1

7.1.3 Fueling Systems..........................................7-1

7.1.4 Design and Construction of Con-

tainers .....................................................7-1

7.1.5 Pressure-Relief Devices..............................7-1

7.1.6 Pressure Gauges and Regulators ................7-1

7.1.7 Piping ..........................................................7-2

7.1.8 Valves .........................................................7-2

7.1.9 Hoses and Hose Connections.....................7-2

7.1.10 CNG Compression, Storage, and

Dispensing Systems ...............................7-2

7.1.11 Grounding ...................................................7-3

7.1.12 Emergency Shutdown Equipment .............7-3

7.1.13 Dispensing System Operation ....................7-3

8 GLOSSARY OF SYSTEM COMPO-

NENTS .................................................................8-1

8.1 General........................................................8-1

8.1.1 Air Eliminator.............................................8-1

8.1.2 Bonding.......................................................8-1

8.1.3 Bulk Storage ...............................................8-1

8.1.4 Cleanout Connection ..................................8-1

8.1.5 Dome Covers ..............................................8-1

8.1.6 Dike.............................................................8-1

8.1.7 Emergency Switch......................................8-1

8.1.8 Fill Connection ...........................................8-1

8.1.9 Fillstands .....................................................8-1

8.1.10 Filter Separator (F/S)..................................8-1

8.1.11 Flexible Seals..............................................8-1

8.1.12 Gauge Hatch ...............................................8-1

8.1.13 Grounding ...................................................8-1

8.1.14 Guide Devices.............................................8-1

8.1.15 High Level Shutoff.....................................8-1

8.1.16 Hydrant Refueling System .........................8-1

8.1.17 Hydrant Lateral Control Pit .......................8-2

8.1.18 Hydrant Outlet Assembly...........................8-2

8.1.19 Hydrant Coupler .........................................8-2

8.1.20 Immediate Operating Storage.....................8-2

8.1.21 Liquid Level Gauge....................................8-2

8.1.22 Intellitrol .....................................................8-2

8.1.23 Low Level Shutoff .....................................8-2

8.1.24 Low Point Drain .........................................8-2

8.1.25 Manhole ......................................................8-2

8.1.26 Meter ...........................................................8-2

8.1.27 Military Service Station .............................8-2

8.1.28 Oil/Water Separator....................................8-2

8.1.29 Pressure and Flow Recorder ......................8-2

8.1.30 Product Recovery Tank..............................8-2

8.1.31 Product Saver Tank (Traditional-

ly used interchangeably with Product Recovery or Water Draw-off system) ...................................8-3

8.1.32 Pumphouse..................................................8-3

8.1.33 Pump Selector Panel...................................8-3

8.1.34 Pumps..........................................................8-3

8.1.35 Railroad Spur..............................................8-3

8.1.36 Remote Electrical Control Cables .............8-3

8.1.37 Rim Vent.....................................................8-3

8.1.38 Roof Drain (Open Top Floating

Roof Tanks) ...........................................8-3

8.1.39 Sight Gage/Glass ........................................8-3

8.1.40 Strainers ......................................................8-3

8.1.41 Sump ...........................................................8-3

8.1.42 Surge Suppresser ........................................8-3

8.1.43 Switch Loading...........................................8-3

8.1.44 Tanks...........................................................8-3

8.1.45 Valves .........................................................8-3

8.1.46 Vapor Recovery System.............................8-3

8.1.47 Visi-Flo .......................................................8-3

A ATTACHMENTS ....................................................A-1

A.1 Scope..........................................................A-1 ii

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

2-1 Tank Truck Grounding ................................ 2-3 2-2 Tank Car Loading ....................................... 2-4 2-3 Tape and Bob Example ............................... 2-7 2-4 Tank Paste Application ............................... 2-8 A-1 Example Static Pressure Test Checklist

(Sheet 1 of 2) ......................................... A-2

A-2 Example Hydrant Flush Checklist (Sheet 1 of 2) ......................................... A-4

A-3 Example Service Station Warning Sign .... A-6 A-4 Scully Troubleshooting Procedures ........... A-7

LIST OF TABLES

Number Title Page Number Title Page

2-1 Initial Flow Rates for Storage Tanks ............ 2-2 iii/(iv blank)

INTRODUCTION

1. PURPOSE.

This Technical Order (TO) provides policies and guidance for fuels management personnel in the operation, inspec-tion, and operator maintenance of permanently installed fuel facilities operated under the control of the Base Fuels Management Team (FMT). Federal, state, and local envi-ronmental laws and regulations shall be complied with if this TO is in conflict with them.

2. SCOPE.

The instructions prescribed by this TO outline general operational information associated with fuel storage and dispensing systems and provides the minimum periodic operator’s maintenance and inspection criteria requirements for the systems. This TO is to be used in conjunction with other existing directives governing fuel system operations and maintenance requirements; however, this TO will take precedence where there is a conflict with other TOs.

3. ABBREVIATION LIST.

AFIMSC Air Force Installation Mission Sup-port Center

AFPET Air Force Petroleum AST Aboveground Storage Tank AVGAS Aviation Gasoline BCE Base Civil Engineers BPCV Back Pressure Control Valve CE Civil Engineers CNG Compressed Natural Gas

COR Contacting Officer Representative DOT Department of Transportation DP Differential Pressure F/S Filter Separators FM Fuels Management FMT Fuels Management Team FSC Fuels Service Center FSE Fuels Support Equipment FSII Fuel System Icing Inhibitor GOCO Government Owned/Contractor Oper-ated GOGO Government Owned/Government Op-erated HA Hydrant Automation HAMS Hydrant Automated Monitoring Sys-tem HD Hydrocarbon Detection IAW In Accordance With LPG Liquefied Petroleum Gas NEC National Electrical Code NFPA National Fire Protection Association OI Operating Instruction OPE Overfill Prevention Equipment QAE Quality Assurance Evaluator RTB Return to Bulk TC Transport Canada TM Terminal Manager TO Technical Order VIP Vehicle Identification Prover WFSM Water Fuel System Maintenance v

SAFETY SUMMARY

1. GENERAL SAFETY INSTRUCTIONS.

Personnel must understand and apply safety standards, for both personnel and property, during operation and mainte-nance of fuel systems.

2. WARNING AND CAUTION STATEMENTS.

WARNING AND CAUTION statements have been strate-gically placed throughout this text prior to operating or maintenance procedures, practices, or conditions consid-ered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING or CAUTION will apply each time the related step is repeated.

Prior to starting any task, WARNINGs or CAUTIONs included in the text for that task will be reviewed and understood. Compliance is mandatory prior to performing the next step in the task.

3. WEARING OF JEWELRY.

Remove rings, watches, and other metallic objects which may cause shock or burn hazards. Finger rings will be removed when working in areas where the potential exists for rings to catch during a slip or fall, i.e., climbing on tanks, trucks ladders, etc., or when directed by the FMT.

4. PERSONAL PROTECTIVE EQUIPMENT (PPE).

PPE requirements are outlined in AFI 91-203. For assis-tance contact supervisor.

5. STATIC ELECTRICITY.

Grounding and/or bonding of all conductive parts of the system is an effective means to prevent an electrostatic spark that could cause ignition of petroleum product(s). To prevent personnel injury, always ground and/or bond equip-ment In Accordance With (IAW) applicable directives.

6. EMERGENCY EYEWASH/SHOWER.

Permanently installed and self-contained emergency eye wash stations and showers will be maintained in accor-dance with AFI 91-203. Inspections will be documented on the AFTO Form 39.

7. CONFINED SPACE ENTRY.

Personnel have been overcome by fuel vapors in confined spaces. Prior to entering a confined space, ensure require-ments established in AFI 91-203 have been met.

8. EMERGENCY STOPS.

Fuel system emergency stop controls can be part of ener-gized circuits carrying dangerous voltage. Due to the poten-tial for arc flash hazards when operating and resetting emergency stops, FMT shall consult with Base Civil Engi-neer (BCE) to determine which emergency stop circuits can be reset by fuels personnel.

vi

CHAPTER 1

RESPONSIBILITIES

1.1 RESPONSIBILITIES.

Responsibility for operation and maintenance of perma-nently installed base petroleum systems are as follows:

1.1.1 Government Owned/Government Operated

(GOGO). GOGO, Logistics Readiness Squadron FMT, and Base Civil Engineers (BCE) Water Fuel System Main-tenance (WFSM). Note: AFI 23-204, Organizational Fuel Tanks, provides guidance for support tank owners.

1.1.2 Government Owned/Contractor Operated

(GOCO). GOCO systems are the responsibility of the contractor personnel In Accordance With (IAW) UFC 3-460-03. The Contracting Officer, with assistance from the Contacting Officer Representative (COR), has overall responsibility. For locations utilizing DLA Energy’s Recur-ring Maintenance and Minor Repair contract, the Con-tracting Officer, with assistance from the Quality Assur-ance Evaluator (QAE), has overall responsibility for service-order work (any work not performed by WFSM).

1.2 FUELS MANAGEMENT (FM).

FMT/Terminal Manager (TM) shall develop procedures and local operator inspection and maintenance checklists IAW the following instructions to ensure the safe and efficient operation of installed and mobile fuel sys-tems/equipment. Instructions will be developed jointly with CE Water and Fuel System Maintenance (CE/WFSM) when applicable.

a. FMTs will provide signature blocks for all required signing authorities, including FMT, CE/WFSM, MAJCOM A7 Fuels Engineer or Air Force Installa-tion Mission Support Center (AFIMSC) Fuels Engi-neer (or Air Force Petroleum (AFPET) Facilities Engineer if delegated by AFIMSC Fuels Engineer) and AFPET Operations Director or NGB/A4RMF as applicable.

b. FMTs will forward unsigned checklists in Microsoft (MS) Word format to AFPET Current Operations for review. Air National Guard locations will forward checklists to NGB/A4RMF for review.

c. AFPET or NGB/A4RMF as applicable will coordinate with MAJCOM A7 Fuels Engineer or AFIMSC Fuels Engineer for approval.

d. Once MAJCOM A7 Fuels Engineer or AFIMSC Fuels Engineer approval is received, AFPET or NGB/A4RMF as applicable will convert the MS Word document to Adobe pdf, with digital signature blocks and return to FMT/WSFM and appropriate Fu-els Engineer for signature. Signed documents will be returned to AFPET or NGB/A4RMF as applicable.

e. Once received, AFPET or NGB/A4RMF as applicable will digitally sign checklist and return to the FMT for implementation.

f. All checklists required under this Technical Order (TO) that are designated as being approved by NGB/A4RMF will be submitted to AFPET Current Operations for a technical review prior to final NGB/A4RMF approval.

1.3 FACILITY MAINTENANCE.

CE, GOCO fuel system maintenance contractors, and DLA Energy SRM Division shall perform all maintenance and associated procurement actions on installed fuel systems.

The hydrant adapters on installed refueling systems are real property components. CE provides the FMT with detailed and updated schematic drawings and certified gauging charts applicable to the installed systems.

1.4 ORGANIZATIONAL TANKS.

Organizational tanks are maintained and operated by the owning organization IAW AFI 23-204. The FMT will provide tank custodian training to assigned tank custodians.

1.5 TECHNICAL ASSISTANCE DIVISION.

AFPET Technical Assistance Division is the office of primary responsibility for the technical content of this TO.

Recommended changes and/or improvements to this TO will be completed IAW TO 00-5-1 and submitted IAW AFI 23-201.

1-1/(1-2 blank)

CHAPTER 2

OPERATING PROCEDURES

2.1 GENERAL.

This chapter provides general operating procedures for fuel receipt, storage, transfer, and issue. The systems utilized to perform these operations will vary in arrangement of pumps, piping, electrical equipment, and assorted compo-nents. Personnel performing fuels handling operations with these systems will be proficiency evaluated and qualified In Accordance With (IAW) AFI 23-201 and AFI 36-2201 prior to performing these duties without supervision. Spe-cific operating procedures applicable to the installed fuels facility will be provided by the installation Civil Engineer.

Safety precautions and servicing constraints outlined in TO 00-25-172 must be followed during aircraft fueling opera-tions. Fuels personnel must comply with the lightning and hazardous weather instructions outlined in AFI 91-203 and

AFI 23-201.

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

b. Bulk fuel off-loading headers not within secure fenced areas must be key locked IAW AFI 23-201.

c. All maintenance activities shall be coordinated with the Fuels Service Center (FSC) prior to start and com-pletion of work on any fuel system.

d. All local procedures and checklists covering the movement of fuel will contain emergency shutdown procedures.

e. Before fuel off-loading operations begin, ensure the receiving tank has sufficient ullage to receive the product.

f. All fuels handling personnel will be trained on the safe handling of hydrocarbon fuels. Refer to AFI 91-203 chapter on HYDROCARBON FUELS. Train-ing will be documented on the AF Form 55 or equiv-alent commercial document for contractor personnel.

2.1.1 Fire Protection.

2.1.1.1 Adequate fire protection shall be provided and

properly located as determined by the Base Fire Chief.

Danger signs for bulk fuel storage areas will be worded as follows: NO OPEN FLAME OR IGNITION SOURCE

BEYOND THIS POINT.

2.1.1.2 When practical, danger signs will be posted 50

feet from dike areas, tank vents, low point drains, and lateral control pits. Signs will be worded NO OPEN

FLAME OR IGNITION SOURCE WITHIN 50 FEET.

These signs should be low profile and visible to approach-ing personnel.

2.1.1.3 The number and location of these signs will be

determined by the Base CE in consultation with Ground Safety. Coordination with Airfield Management IAW AFI 13-213 is required before posting any signs in the flight line area.

2.1.2 Frozen Valves.

WARNING

Under no circumstances shall an open flame or electrical heating element be used for thawing frozen valves. Using an open flame or electrical element to thaw frozen valves risks fire and explosion.

A steam jet, hot water, or hot cloth may be used to thaw frozen valves. Under no circumstances shall an open flame or electrical heating element be used for thawing frozen valves.

2.1.3 Fuel Receipts.

NOTE

Simultaneous issue and receipt operations from the same tank are not authorized. Doing so prevents accurate inventory control.

2.1.3.1 When a shipment of fuel arrives on base, the

receipt documentation and inspection procedures will be IAW DoD 4140.25M, DLA Energy guidance, TO 42B-1-1, AFI 23-201, and MIL-STD-3004. Simultaneous issue and receipt operations are not authorized from the same tank.

2.1.3.2 Only trained personnel are permitted to perform

product receipt.

2-1

2.1.4 Filling Bulk Storage Tanks. Storage tanks pre-

sent greater electrostatic hazards due to their large size. It is possible to have an electrostatic discharge from the surface of the liquid to the tank shell or to objects within the tank or container. Bonding and grounding do not eliminate this potential interior hazard. Time is required for the electro-static charge in the fuel to relax.

WARNING

• Electrostatic charge buildup in tanks can cause explosion or fire hazards to personnel.

• Top filling where the fuel free falls or splashes is prohibited. Drop tube that reaches fuel level must be used to eliminate free fall. Electrostatic charges buildup very rapidly during this type of operation and can cause an explosion.

• Personnel will not be allowed in pits located on top of underground or cut and cov-ered/hardened tanks during fuel receipt or transfers. Personnel are also restricted from on top of above ground storage tanks during fuel receipt or transfer operations.

CAUTION

Receiving simultaneously into multiple (i.e.

manifold) storage tanks is not authorized, unless all tanks are equipped with independent high level alarms and high level automatic shutoff valves. Danger of fuel spill or damage to equipment may result if not followed.

2.1.4.1 The fill rate for an empty (or nearly empty) tank

must be reduced to prevent excessive agitation, turbulence, spraying, and misting which results in a high rate of static generation. The fuel velocity shall not exceed 3 feet per second fuel flow through the piping until the liquid level is 1 foot above the inlet level. Floating roof tanks require the same precautions until the roof becomes buoyant (refer to Table 2-1). CE will provide procedures and checklists to ensure the 3 feet per second is maintained.

2.1.4.2 The presence of water, entrapped air, or foreign

particles in the fuel tends to increase the static charging rate. Care must be exercised to prevent the entrance of these materials into the fuel system.

2.1.4.3 Sampling will be IAW TO 42B-1-1.

2.1.5 Receipt Operations Tank Truck/Car. The fol-

lowing procedures will be used in conjunction with direc-tives referenced in Paragraph 2.1.3.

a. A visual flow indicator will be installed on off-loading headers. Operators use the visual flow indicators to determine when fuel flow has stopped to determine when to shut off pumps. Failure to observe visual flow indicators could result in over heating and damage to off-loading pumps.

b. Before fuel off-loading operations begin, ensure the receiving tank is the correct grade and has sufficient ullage to receive the product. Remove any internal water by performing product saver tank operations on the jet fuel tanks that will receive fuel. If the tank is equipped with a properly installed and operational Enraf Vito probe in the sump, water removal is only required when water presence is shown on the tank side indicator.

c. Ensure the fuel transport conveyance is properly positioned to allow for rapid egress in case of emergency. Ensure grade, quantity, and seal num-bers (if applicable) agree with the DD Form 250, Bill of Lading, or contractor delivery ticket. If the documentation is not available upon arrival of the conveyance, contact the appropriate DLA quality representative and follow the procedures in DLA Energy guidance.

Table 2-1. Initial Flow Rates for Storage Tanks

3 Ft/Second Velocity Gal/Min Barrels/HourPipe Size

4 inches 120 171

6 inches 270 385

8 inches 480 685

10 inches 750 1,071

12 inches 1,080 1,542

14 inches 1,470 2,099

16 inches 1,920 2,741

2-2

d. Place danger signs at least 50 feet from tank trucks/cars prior to the beginning of off-loading operations. Signs are not required when off-loading at the base service station or within posted secured areas.

e. Connect grounding/bonding cable to a metal sur-face on the tank truck/car (see Figure 2-1 and Figure 2-2). No grounding/bonding is required for railroad tank cars if the spur tracks are bonded together/grounded or electrically isolated from the main line as determined by CE Electric Shop personnel.

WARNING

Due to the inherent fall potential, personnel should not routinely climb on top of fuel tank trucks or tank cars. Bases equipped with ATG, Visual Flow-type gauges, and in-line sampling connections on receipt headers shall develop procedures to minimize the time personnel must go on the top of tank trucks and tank cars to ensure quality/quantity of DLA Energy-owned product.

f. Check seals and perform required fuel quality sampling, as required. For sampling requirements, refer to TO 42B-1-1.

WARNING

Do not open tank car manifold valve prior to connecting the off-loading hose. The valve is spring-loaded and when actuated is 100% open.

g. Ensure the off-loading outlet valve is closed and a metal or rubber drip pan is placed under the outlet and bonded to the tank car/truck prior to removing the dust cap. If rubber containers are used, bonding is not required.

h. Connect off-loading hose to tank truck/car off-loading outlet.

i. Open valves IAW local procedures.

j. Observe system for leaks.

k. Upon completion of off-loading product, close valves IAW local procedures.

l. Ensure tank truck/car is empty, close dome (if applicable) and remove off-loading hose.

m. Remove grounding/bonding cable and drip pan.

Figure 2-1. Tank Truck Grounding

2-3

Figure 2-2. Tank Car Loading

2.1.6 Pipeline, Barge, and Tanker Receipts. Ensure

communication (hot line, radio, telephone, etc.) between pipeline pump station, barge, or tanker and receipt location is established prior to starting any receipt actions. Commu-nication devices in hazardous areas must be suitable for use in Class I, Division 1, Group D areas.

a. Barges and tankers will be grounded/bonded IAW

UFC 3-460-03.

CAUTION

Receiving simultaneously into multiple (i.e.

manifold) storage tanks is not authorized, unless all tanks are equipped with independent high level alarms and high level automatic shutoff valves. Danger of fuel spill or damage to equipment may result if not followed.

b. Check receipt paperwork. Ensure the storage tank(s) contain the correct grade of fuel and has sufficient ullage for receipt. Product saver tanks systems will be operated to remove all water prior to receipt. When tank is equipped with a fully operational Enraf Vito probe in the sump and with tank-side indicator, water removal is only required when water is indicated.

c. Open valves IAW local procedures.

d. Observe for leaks.

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

f. Remove grounding/bonding cables.

2.1.7 Transferring Product between Bulk and

Operating Storage. The following will be accomplished:

a. Ensure adequate communication is available between transfer and receiving points. If telephone communication is used, ensure a telephone alarm can be heard from outside of the transfer and receiving points.

b. Ensure the receiving tank is the correct grade and has sufficient ullage to receive the product.

Remove any internal water by performing product saver tank operations on the transferring and receipt jet fuel tanks. If the tank is equipped with a properly installed and operational Enraf Vito probe in the sump, water removal is only required when water presence is shown on the tank side indicator.

c. Open valves IAW local procedures.

2-4

CAUTION

Receiving simultaneously into multiple (i.e.

manifold) operational storage tanks is not authorized, unless all tanks are equipped with independent high level alarms and high level automatic shutoff valves. Danger of fuel spill or damage to equipment may result if not followed.

d. The operator must be stationed in the immediate vicinity of tanks equipped with high level alarms.

Immediate vicinity requires being near enough to periodically observe the operation for problems and quickly respond. During the last 30 minutes of receipt, the operator shall be present at the tank. If a tank does not have operational high level alarms, the receiving operator must continually monitor the receipt operation.

e. Upon completion of transfer, close appropriate valves and reposition electrical controls IAW local procedures.

f. Complete accounting documents IAW DLA Energy guidance.

2.1.8 Ignition Hazards During Fuel Transfer from

Storage Tanks by Other Than Normal Means.

2.1.8.1 Fires have occurred as a result of using unautho-

rized portable pumps during fuel handling operations. Such accidents have occurred during the following operations:

a. Preparation for and during tank cleaning.

b. Transfer of product from a storage tank when the installed fuel transfer pump is inoperable.

c. Transfer of product from a storage tank where there is no installed fuel transfer pump.

d. Removal of water from fuel tanks where no sump drains exist.

e. Removal of water from various pits in the fuel system where fuel/water may collect.

f. Handling waste or recoverable fuels.

CAUTION

In order to maintain quality control of the system, residual fuel or sludge from a tank will not be removed through the manifold/transfer lines.

2.1.8.2 When fuel tanks are being prepared for cleaning

or maintenance, fuels personnel will remove fuel to the lowest point possible utilizing the installed pumping system or by gravity flow. Upon completion, the entire operation will be transferred to CE/Contract personnel who will remove any recoverable fuel IAW applicable directives.

Residual fuel or sludge will be removed by the tank cleaning crew assigned by CE or contract.

2.1.8.3 When fuel is stored in tanks where the installed

pump is inoperable and cannot be repaired in a timely manner or no installed pump exists, the following will apply, except as noted in Paragraph 2.1.8.3.2 and Paragraph

2.1.8.3.3 below.

2.1.8.3.1 Fuel will be removed by use of:

a. One of the pumps in AS 488 or AS 924.

b. A fuel servicing unit selected by the FMT provided distance pump suction, and safety requirements can be met and quality is not compromised. Aircraft refuelers shall not be used to remove product from under-ground tanks because of possible pump damage.

c. C-300/301 refuelers are authorized for pumping un-derground tanks.

2.1.8.3.2 Tanks used for the collection/storage of waste

fuel are exempt from the requirement for installed pumps.

However, removal of fuel from such tanks must be by pumps listed in AS 488 or AS 924, by approved contractor methods, or use of a vehicle specifically designated for handling waste petroleum and so identified with proper labeling IAW TO 36-1-191. Waste fuel removed from tanks will be handled IAW TO 42B-1-23.

2.1.8.3.3 Fuel tanks, located at military service stations, which are used to support both vehicle fleets and tank truck delivery operations are not required to have installed trans-fer pumps in addition to the normal vehicle delivery pumps.

However, when the installed vehicle service station pump is used to fill tank trucks, the provisions of Paragraph 2.1.8.3.1, Items a and b apply for the transfer of product from the service station tank to the truck/trailer.

2.1.8.4 Removing water from fuel tanks without sump

drains, or from various pits or other areas where water may collect, requires the same precautions as if fuel was being handled. Only approved equipment will be used, such as the equipment listed in AS 488 or AS 924. Removing water with hand operated pumps is authorized.

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2.1.9 Pumps.

WARNING

The use of internal combustion engine driven, reciprocating, open-diaphragm pumps (Mud Hog), for pumping petroleum products, is prohibited.

2.1.9.1 Several types of pumps may be used for fuel

transfer operations. The pumps may be driven by electric motors, air, or internal combustion engines. In all cases, electrical equipment must conform to the safety require-ments outlined by the National Fire Protection Association (NFPA) 70, the National Electrical Code (NEC) for Class I, Division I, Group D. All the internal combustion engines must conform to MIL-HDBK-201 and must be equipped with a spark arresting exhaust system, shielded ignition system, and totally enclosed spark plug (aircraft engine type) with screw cap.

NOTE

Substitution is authorized provided the substi-tute pump (if electrical) conforms to Class I, Division I, Group D, as defined by the National Electrical Code, or (if a combustion engine) conforms to Paragraph 2.1.9.1 above.

2.1.9.2 AS 488 or AS 924 specifies the pumps authorized

for handling petroleum products. The AS 488 or AS 924 will be amended as other authorized pumping units become available.

2.1.9.3 Pumps installed for issuing gasoline from military

service stations or organizational issue tanks must have flow restrictors installed to limit flow rates to maximum of 10 gallons per minute. This requirement is optional when dispensing pumps are dedicated to servicing heavy-duty vehicles.

2.1.10 Product Settling. Product settling will be IAW

TO 42B-1-1.

2.1.11 Gauging.

WARNING

A minimum waiting time of 30 minutes after completion of fuel receipts, transfers, or move-ments is required before insertion of any object into storage tanks. This is a safety measure to permit relaxation of electrostatic charges.

2.1.11.1 Inventory control for fuel systems shall be con-

ducted IAW DLA Energy policy.

2.1.11.2 When manually gauging tanks, wait a minimum

of 30 minutes after completion of fuel receipts, transfers, or movement of fuel before inserting the tape and bob (Figure 2-3), and/or sampling device into the storage tank.

This is a safety measure to permit relaxation of electrostatic charges. The steel tape and bob are graduated into feet, inches, and sixteenths of an inch. A 1/16-inch mistake causes an error ranging from a few gallons to hundreds of gallons. When gauging tanks, a thin coat of water-finding paste will be applied to the lower 3 inches of the weighted bob (Figure 2-4). Apply a thin coat of fuel-finding paste to the numbered side of the gauge tape approximately 3 inches above and 3 inches below the estimated product depth. (Figure 2-4) Example 12-foot estimate depths of product apply fuel paste 3 inches on either side of 12-foot mark of tape.

WARNING

Failure to maintain constant contact between the gauging tape and the gauging hatch during insertion can result in electrical arcing that risks fire or explosion.

2.1.11.3 Keep the gauging tape in constant contact with

the gauging hatch at all times. Open the gauge hatch and gently lower the tape and bob into the tank. Allow the bob to rest vertically on the tank floor until a clean cut is obtained on the fuel/water paste. The cut is the point at which the fuel finding paste changes colors, or dissolves, and washes off the tape and the water finding paste changes color. Both the fuel- and water-finding pastes are made especially for gauging purposes and in no way contaminate the petroleum products. Slowly remove the tape and bob from the tank, maintaining contact between the gauging hatch and steel tape. Record the fuel and water readings. To ensure an accurate gauge reading, operator shall obtain a minimum of two identical gauge readings before recording official reading on the tank.

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Figure 2-3. Tape and Bob Example

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Figure 2-4. Tank Paste Application

2-8

2.1.12 Leak Detection. The FMT will coordinate with

the Base Civil Engineer (BCE) and the Base Environmental Manager to ensure leak detection systems are in place that comply with federal, state, and local environmental requirements.

2.1.13 Product Saver Tank System and Oil/Water

Separator.

2.1.13.1 Operation of the product saver tank system and

water drain system will be constantly attended by a quali-fied fuels operator and/or Water Fuel System Maintenance (WFSM) personnel.

NOTE

The fuel/water will not be drained onto the ground. Dispose of IAW local, state, and fed-eral environmental laws and regulations.

a. Unlock the water draw-off valve and position valves to allow flow into product saver tank.

b. Ensure the product saver tank is capable of holding the saver line displacement plus an additional 20 gallons of liquid. Fill the product saver tank with product. If cloudy, drain into a bowser or collection tank and continue the product saver tank fill/drain process until the product becomes clear in appearance.

c. Allow water to settle in fuel product saver tank;

observe the water drain off through the sight glass.

NOTE

Due to hazards of handling water with Fuel System Icing Inhibitor (FSII) concentrations, engineer a system that will preclude any man-ual handling of tank water bottoms.

TO 42B-1-1 and TO 42B-1-23 outline proce-dures for handling water bottoms.

d. Position appropriate valves and transfer all drained fuel back into tank. To prevent lines from freezing and becoming inoperative at northern tier locations, product saver tank systems can remain full of fuel upon completion of water draining operations. This practice will be limited to only those locations that experience routine subfreezing temperatures, and is authorized only during the time of year these temperatures are expected.

e. Close appropriate valves upon completion of fuel transfer.

f. Lock the water draw-off valve in the closed position.

2.1.13.2 Oil/water separators are real property. Mainte-

nance and operation is the responsibility of CE.

a. Position oil skimmer so slot is level with top of water in the separator to properly separate fuel from water.

b. Open the gate valve of the separator pit.

c. Ensure only fuel is flowing into the relief tank from the oil skimmer.

d. Regulate water flow as required.

e. Close the gate valve when water flow has stopped.

f. Water will be drained and disposed of IAW fed-eral, state, and local environmental laws and regulations.

2.1.14 Tank Cleaning and Inspection Criteria.

2.1.14.1 FM must be familiar with tank inspection and

cleaning requirements IAW UFC 3-460-03. Sample IAW TO 42B-1-1 and for Special Fuels IAW TO 42B1-1-16.

2.1.14.2 Tank inspections/cleaning will be scheduled

according to UFC 3-460-03. Minor deviation in frequency of tank inspection because of nonavailability of tank clean-ing personnel or a Bio-Environmental Engineer, receipt problems, etc., are permitted for up to 45 days. Periods exceeding 45 days must be coordinated with Air Force Petroleum (AFPET) Current Operations or NGB/A4RMF as applicable and approved by MAJCOM Fuels Engineer.

Locations with large amounts of dormant storage that cannot rotate product to empty tanks to perform tank inspections/cleaning without creating severe operational problems can requests extensions through the above chan-nels provided fuels sample results are satisfactory.

2.1.15 Servicing Controls. Positive servicing control

methods are required to prevent commingling fuel prod-ucts. FMTs will determine the specific type of coupler used for each product.

NOTE

Additional requirements for servicing controls are outlined in AFI 23-201.

2.1.15.1 Fuel product fill stands must be fitted with either

different sized couplers or couplers that can be selectively set to prevent connection to trucks carrying a different grade of product. For locations with more than one grade of aviation fuel, the use of a locking control system for bottom loading refueling units is mandatory. FMT must physically test the servicing controls to ensure products cannot be commingled.

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2.1.15.2 Scully Intellitrol systems on ground product fill-

stands will be programmed with the appropriate corre-sponding grade and refueling unit TIM number. FMT’s must have strict written procedures defining when the system override can be used and identifying the appropriate approval authority.

2.1.15.3 Cam and groove couplers (if required by Techni-

cal Order (TO) on portable fuel systems, i.e. Fuels Support Equipment (FSE)) all ears on each hose connection will have a functional double locking device, safety wired with a minimal four strand wraps, or secured with nylon cable ties.

2.1.15.4 The use of selective couplers for bottom loading

of ground fuels from fillstands is required. Dry-break couplers will be used.

2.1.15.5 Minimum Bottom Loader Requirements (one or

more must be applied):

a. Jet Fuels – the single point receptacle will be used on jet fuel refueling units with a single point nozzle on the fillstand. Where more than one grade of jet fuel is handled at a base, the 3-inch dry break coupler may be used and a lock control system for the refueler bottom loader control is required. Strainers are re-quired in fillstand single point nozzles. 100 mesh strainers will be used.

b. Scully Overfill Prevention Equipment (OPE) with the Vehicle Identification Prover (VIP) featured enabled.

c. Aviation gasoline (AVGAS) – where one grade of AVGAS and one grade of jet fuel is handled at the base, FM will assure a positive control method is in effect to prevent commingling of fuel.

d. Diesel Fuel – if two grades of diesel are handled, the couplers will be reversed; i.e., diesel fuel unit will have a male fitting with a female fitting on the fill-stand; biodiesel fuel unit will have a female fitting with a male fitting on the fillstand.

e. Unleaded Mogas – the 2-inch dry break type coupler will be used.

NOTE

Organizational tanks are exempt from bottom loading requirements. Examples of mobile organizational tanks are A1B trailers and skid POD tanks.

2.1.16 Dispensing Fuel from Truck Fillstand-Bottom

Loading.

NOTE

Fillstands equipped with Scully controls utilize an umbilical cord with the bonding cable included. It will take the place of the vehicle bonding cable connection.

a. Position the vehicle to prevent stress on compo-nents during connection and fuel transfer. Engage the parking brake. Engines on all refueling equip-ment will be turned off. Energize the Scully In Cab switch.

b. Check Scully Intellitrol Status. Red (Non-Permissive) Main Indicator Light, Standby Light (when VIP is active) and Dynacheck Indica-tor should be on. Verify the Intellicheck 2 is turned on and operating by verifying the LED lights.

Refer to attachment A for Scully system trouble-shooting information.

c. Connect the Scully plug and cable assembly to truck. If Scully is not installed, ensure vehicle is bonded to the fillstand or hosecart prior to making any fuel nozzle connection.

d. Viewing Scully Intellitrol at fillstand - Red Main Status Indicator should change illumination from Red to Green (Permissive). Main Status Indicator, Vehicle Identification Authorized and Communica-tion Vehicle indicators should be lighted.

e. Position valves and electrical controls IAW local procedures. Perform the truck fill operation.

f. Refueling unit operator will perform a high-level pre-check operation during the first 500 gallons of fuel received. If the pre-check test does not shut off fuel flow, the fill will be terminated and the refuel-ing unit will be taken out of service and reported to refueling maintenance.

g. Upon completion of the issue, push stop switch or release dead man whichever is applicable. Intelli-trol® Main Status Indicator should change illumi-nation to red. Ensure pump is not operating and position valves and electrical controls IAW local procedures.

h. Unplug Scully umbilical cord or disconnect and stow grounds/bonds as applicable.

i. Complete accountable documents IAW DLA policy.

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2.1.17 Tank Truck/Car Top Loading Operation. An

approved waiver will be obtained from the AFPET Current Operations Division and the Base Safety Office prior to performing fuel top loading operations. Recognized hazards of top loading include: static discharge, turbulence, splashing and spraying of product resulting from too high initial fill rate, and downspouts not being extended to the bottom of the tank. The following measures will be used to minimize the potential hazard.

NOTE

A refueling unit operator will be positioned on top of the vehicle to ensure refueling vehicle is not overfilled. Refueling vehicle operator will maintain constant visual and verbal contact with fillstand operator.

a. The storage operator will direct refueler operator in positioning the vehicle to prevent stress on compo-nents during the fuel transfer.

b. Ensure the vehicle is bonded to the fillstand.

c. Position valves and electrical controls IAW local procedures.

d. Begin filling at an initial rate not to exceed 3 feet per second. This flow will be observed until the fuel level is at least 1 foot above the opening of the downspout.

e. Upon completion of the issue, stop the pump and position valves and electrical controls IAW local procedures.

f. Disconnect and stow ground/bond cable.

g. Complete accountable documents IAW DLA Policy.

2.1.18 Refueling Unit Return to Bulk Storage

(RTB).

a. The refueling unit operator will position the vehicle as directed by the storage operator.

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

c. The storage operator will ensure there is ullage in the receipt tank. Open appropriate valves IAW local procedures.

d. Upon completion of the operation, position all valves IAW local procedures.

e. Disconnect and stow grounding/bonding cables.

f. Complete accountable documents IAW DLA Policy.

2.1.19 Service Station Operation.

NOTE

Pumps installed for issuing gasoline from mili-tary service stations or organizational issue tanks must have flow restrictors installed to limit flow rates to maximum of 10 gallons per minute. This requirement is optional when dis-pensing pumps are dedicated to servicing heavy equipment vehicles.

The following procedures will be adhered to:

a. Storage personnel open appropriate issue valve(s) and position electrical controls.

b. For automated service stations, ensure complete operating instructions, warning notices, and emer-gency shutdown procedures are conspicuously posted IAW AFI 91-203. Refer to Appendix A of this TO for example warning signs.

c. Refer to AFI 23-201 for guidance associated with operating the Automated Fuels Service Station dur-ing lightning and weather warnings.

2.1.20 Hydrant Issues to Aircraft or Refueling

Unit(s).

NOTE

Multiple refueling (hot or cold) on a single Type II hydrant system lateral is authorized provided the servicing equipment has an auto-matic pressure control valve with a deadman control or a pit control valve with a deadman control at the hydrant outlet. Follow guidance in TO 42B-1-1.

a. Select operating tank(s).

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

c. Type III, IV and V pump houses at bases where the FSC is equipped with the FMD Hydrant Automa-tion (HA) modification with Hydrocarbon Detec-tion (HD) installed in the pump house, and an operable PUMP ON indicator light and emergency shutoff switch in the FSC do not need to be manned while the system is in automatic mode.

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WARNING

During any Type III, IV, and V operation, unexplained system pressure drops and flow rate fluctuations will be investigated immedi-ately and system will be shutdown until the cause of unusual behavior is determined. In addition, unexplained system on-off cycling and all alarms will be investigated immediately and system will be shutdown until cause of on-off cycling/alarm is determined.