TO 42B1-1-22.pdf

TO 42B1-1-22

TECHNICAL MANUAL

QUALITY CONTROL OF AVIATION GASOLINE

PREPARED BY AFSC COMMODITY TEAM

F41608-90-D-1819

THIS MANUAL SUPERSEDES TO 42B1-1-22, DATED 23 JULY 2012.

THIS MANUAL WAS TRANSFERRED TO A NEW PUBLISHING SYSTEM. THE STYLE AND FORMAT WERE EXTENSIVELY CHANGED/

REVISED, THEREFORE, CHANGE BARS ARE OMITTED IN THIS RELEASE.

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 04-407. 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 FEBRUARY 2018

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . . .1 February 2018

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 48, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv Blank v vi Blank vii viii Blank 1-1 - 1-3 1-4 Blank 2-1 2-2 Blank 3-1 - 3-3 3-4 Blank 4-1 - 4-5 4-6 Blank 5-1 - 5-4 A-1 A-2 Blank B-1 B-2 Blank C-1 - C-11 C-12 Blank D-1 D-2 Blank

TO 42B1-1-22

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.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.

* Zero in this column indicates an original page.

A USAF

TABLE OF CONTENTS

Chapter Page

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

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

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

SAFETY SUMMARY . . . . . . . . . . . . . . . . . vii

1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 GENERAL SAFETY AND ENVI-

RONMENT

CONSIDERATIONS. . . . . . . . . 1-1

1.2 FUNCTIONS AND

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

1.2.1 Defense Logistics Agency-Energy

(DLA Energy) . . . . . . . . . . . . . 1-1

1.2.2 Air Force Petroleum Office

(AFPET). . . . . . . . . . . . . . . . . 1-1

1.2.3 Joint Petroleum Office (JPO)/Sub-

Area Petroleum Office

(SAPO) . . . . . . . . . . . . . . . . . 1-1

1.2.4 COCOM Air Force Component Fu-

els (Air Component A4) . . . . . . 1-1

1.2.5 Fuels Engineer. . . . . . . . . . . . . . . 1-1

1.2.6 Base Civil Engineers (Water Fuels

System Maintenance

(WFSM)) . . . . . . . . . . . . . . . . 1-1

1.2.7 Logistics Readiness Squadron

(LRS)/Fuels Management Flight (2F0X1 Personnel) . . . . . . . . . . 1-1

1.3 STANDARDIZED OPERATIONAL

GUIDANCE AND

PROCEDURES . . . . . . . . . . . . 1-1

1.4 PRODUCT PROCUREMENT . . . . 1-2

1.5 RESPONSIBILITIES FOR FUEL

QUALITY . . . . . . . . . . . . . . . 1-2

1.6 QUALITY ASSURANCE

RESPONSIBILITY. . . . . . . . . . 1-2

1.7 QUALITY SURVEILLANCE AT

BASE LEVEL . . . . . . . . . . . . . 1-2

2 AVIATION GASOLINE . . . . . . . . . . . . . . . 2-1

2.1 PROCUREMENT

REQUIREMENTS . . . . . . . . . . 2-1

2.2 COLOR . . . . . . . . . . . . . . . . . . . 2-1

2.3 VOLATILITY . . . . . . . . . . . . . . . 2-1

2.3.1 Distillation . . . . . . . . . . . . . . . . . 2-1

Chapter Page

2.3.2 Vapor Pressure. . . . . . . . . . . . . . . 2-1

2.4 WATER AND SEDIMENT . . . . . . 2-1

3 FUEL HANDLING. . . . . . . . . . . . . . . . . . . 3-1

3.1 SCOPE. . . . . . . . . . . . . . . . . . . . 3-1

3.2 PRODUCT STORAGE AND

HANDLING . . . . . . . . . . . . . . 3-1

3.3 DIFFERENTIAL PRESSURE . . . . 3-2

3.4 CONVERTING REFUELING

UNITS FROM ONE PRODUCT

TO ANOTHER . . . . . . . . . . . . 3-2

4 QUALITY CONTROL OF AVIATION

GASOLINES . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 GENERAL . . . . . . . . . . . . . . . . . 4-1

4.2 LABORATORY TECHNICIAN

QUALIFICATIONS . . . . . . . . . 4-1

4.3 LABORATORY

OPERATIONS. . . . . . . . . . . . . 4-2

4.3.1 Cleaning Glassware . . . . . . . . . . . 4-2

4.3.2 Microscopic Analysis . . . . . . . . . . 4-2

4.3.3 Disposition of Samples . . . . . . . . . 4-2

4.4 SAMPLING AND TESTING . . . . . 4-2

4.4.1 Types of Samples . . . . . . . . . . . . . 4-2

4.4.2 Sampling Equipment. . . . . . . . . . . 4-2

4.4.3 General Sampling Procedures. . . . . 4-3

4.5 PRODUCT RECEIPT -

AVGAS . . . . . . . . . . . . . . . . . 4-3

4.6 SAMPLING

REQUIREMENTS . . . . . . . . . . 4-3

4.7 DEPLOYED/TEMPORARY OR

LOCATIONS WITHOUT A

BASE FUELS

LABORATORY . . . . . . . . . . . . 4-4

5 SAMPLE SUBMISSION TO OFF-BASE

LABORATORIES. . . . . . . . . . . . . . . . . . 5-1

5.1 SCOPE. . . . . . . . . . . . . . . . . . . . 5-1

5.2 SAMPLE SUBMISSION. . . . . . . . 5-1

5.3 SHIPPING CONTAINERS AND

PREPARATION. . . . . . . . . . . . 5-1

5.4 MARKING AND IDENTIFYING

SAMPLES . . . . . . . . . . . . . . . 5-2

5.5 SAMPLES OF LONG TERM

STORAGE (DORMANT

STOCKS) . . . . . . . . . . . . . . . . 5-2

i

Chapter Page

5.6 FUEL AND OIL SAMPLES FROM

CRASHED AIRCRAFT OR

FUEL-RELATED

INCIDENT . . . . . . . . . . . . . . . 5-2

APPENDIX A AVGAS EQUIPMENT. . . . . . A-1

A.1 EQUIPMENT . . . . . . . . . . . . . . . A-1

APPENDIX B MISCELLANEOUS EQUIP-

MENT FOR LABORATORY TESTING . . . B-1

B.1 MISCELLANEOUS

EQUIPMENT . . . . . . . . . . . . . B-1

APPENDIX C TEST PROCEDURES . . . . . . C-1

C.1 TEST FOR VISUAL FREE WATER

AND PARTICULATE

CONTAMINATION . . . . . . . . . C-1

C.1.1 Summary . . . . . . . . . . . . . . . . . . C-1 C.1.2 Significance of Test . . . . . . . . . . . C-1 C.1.3 Equipment. . . . . . . . . . . . . . . . . . C-1 C.1.4 Procedures . . . . . . . . . . . . . . . . . C-1 C.1.5 Calculation and Report . . . . . . . . . C-1 C.1.6 Calibration . . . . . . . . . . . . . . . . . C-1

C.2 TEST FOR COLOR AND PAR-

TICULATE MATTER. . . . . . . . C-1

C.2.1 Summary . . . . . . . . . . . . . . . . . . C-1 C.2.2 Significance of Test . . . . . . . . . . . C-1 C.2.3 Equipment. . . . . . . . . . . . . . . . . . C-1 C.2.4 Procedures . . . . . . . . . . . . . . . . . C-2 C.2.5 Calculation and Report . . . . . . . . . C-3 C.2.6 Calibration . . . . . . . . . . . . . . . . . C-3

C.3 TEST FOR PARTICULATE MAT-

TER BY MATCHED-WEIGHT

METHOD. . . . . . . . . . . . . . . . C-3

Chapter Page

C.3.1 Summary . . . . . . . . . . . . . . . . . . C-3 C.3.2 Significance of Test . . . . . . . . . . . C-3 C.3.3 Equipment. . . . . . . . . . . . . . . . . . C-3 C.3.4 Procedures . . . . . . . . . . . . . . . . . C-3 C.3.5 Calculation and Report . . . . . . . . . C-4 C.3.6 Calibration . . . . . . . . . . . . . . . . . C-4

C.4 FREE WATER

DETERMINATION . . . . . . . . . C-8

C.4.1 Summary . . . . . . . . . . . . . . . . . . C-8 C.4.2 Significance of Test . . . . . . . . . . . C-8 C.4.3 Equipment. . . . . . . . . . . . . . . . . . C-8 C.4.4 Procedures . . . . . . . . . . . . . . . . . C-8 C.4.5 Reporting . . . . . . . . . . . . . . . . . . C-9 C.4.6 Calibration . . . . . . . . . . . . . . . . . C-9

C.5 TEST FOR DETECTION OF

HEAVY HYDROCARBON

CONTAMINATION IN AVIA-

TION GASOLINE . . . . . . . . . . C-10

C.5.1 Summary . . . . . . . . . . . . . . . . . . C-10 C.5.2 Significance of Test . . . . . . . . . . . C-10 C.5.3 Equipment. . . . . . . . . . . . . . . . . . C-10 C.5.4 Procedures. . . . . . . . . . . . . . . . . . C-10 C.5.5 Calculation and Report . . . . . . . . . C-10 C.5.6 Calibration . . . . . . . . . . . . . . . . . C-10

APPENDIX D REQUIREMENTS

WORKSHEET . . . . . . . . . . . . . . . . . . . . . D-1

D.1 OUT-OF-CYCLE (SPOT BUY)

PURCHASE REQUESTS, AND

ESTABLISHING A NEW CON-

TRACT REQUIREMENT OR

AMENDMENT . . . . . . . . . . . . D-1

D.2 OCONUS/CONTINGENCY PUR-

CHASE REQUESTS . . . . . . . . D-1

TO 42B1-1-22

TABLE OF CONTENTS - CONTINUED

ii

LIST OF ILLUSTRATIONS

Number PageTitle

C-1 Test Procedure C.2, Bonding Wire for Mil-lipore In-Line Sampler . . . . . . . . . . . C-5

C-2 Test Procedure C.2, 3-Way Valves In-Line Samplers . . . . . . . . . . . . . . . . . . . . . C-6

Number PageTitle

C-3 Test Procedure C.3, Bonding Wire for Mil-lipore In-Line Sampler . . . . . . . . . . . C-7

C-4 Test Procedure C.5, Holder Chromatogra-phy Strip Wood Components . . . . . . . C-11

LIST OF TABLES

Number PageTitle

4-1 AVGAS Sampling Requirements and Test Limits. . . . . . . . . . . . . . . . . . . . . . . 4-5

5-1 Minimum Sampling and Testing Frequen-cies of Long Term Storage (Dormant Stock). . . . . . . . . . . . . . . . . . . . . . . 5-2

Number PageTitle

5-2 AFPET Fuel Laboratories . . . . . . . . . . . 5-4 A-1 AVGAS Equipment. . . . . . . . . . . . . . . . A-1 B-1 Miscellaneous Equipment for Laboratory

Testing . . . . . . . . . . . . . . . . . . . . . . B-1 iii/(iv blank)

INTRODUCTION

1 PURPOSE.

This technical order (TO) prescribes the procedures for as-suring the quality of Aviation Gasoline (AVGAS) used by Air Force activities.

2 SCOPE.

Where content of this TO may conflict with AVGAS quality instructions or procedures contained in other government documents or publications, the provisions of this TO take precedence. These instructions will be used in conjunction with Air Force Occupational Safety and Health (AFOSH)

Standards, wherever applicable. The provisions of this manual are compatible with NATO Standardization Agree-ment (STANAG) 3149, Minimum Quality Surveillance for Fuels, STANAG 1135, Interchangeability of Fuels, Lubri-cants and Associated Products Used by the Armed Forces of the North Atlantic Treaty Nations, AFIC (Five Eyes Air Force Interoperability Council; formerly Air and Space Interoper-ability Council (ASIC)) AIR STD 4020, Minimum Quality Surveillance of Petroleum Products, and AIR STD FG 4024, Interchangeability Chart of Standardised Fuels, Lubricants, and Associated Products. This TO is the established quality control program as required by DOD 4140.25-M, DoD Man-agement of Bulk Petroleum Products, Natural Gas, and Coal.

v/(vi blank)

SAFETY SUMMARY

1 GENERAL PRECAUTIONS.

The following are general safety precautions and instructions that people must understand and apply during many phases of operations in fuel handling and laboratory operations to ensure personal safety and health and the protection of Air Force Property.

2 WARNING AND CAUTION STATEMENTS.

WARNING and CAUTION statements have been strategi-cally placed throughout this text prior to operating or main-tenance procedures, practices, or conditions considered es-sential to the protection of personnel (WARNING) or equipment and property (CAUTION). WARNINGs and CAUTIONs will apply each time the related step is repeated.

Prior to starting any task, the WARNINGs or CAUTIONs included in the text for the task will be reviewed. Compli-ance is mandatory prior to performing the next step in the task. Consult the local Bio-Environmental Engineer for spe-cific protective equipment and ventilation requirements.

3 GIVE CLEANERS/CHEMICALS SPECIAL CARE.

Keep cleaners/chemicals in approved safety containers and in minimum quantities. Some cleaners/chemicals may have an adverse effect on skin, eyes, and respiratory tract. Ob-serve manufacturer WARNING labels; Safety Data Sheet (SDS) instructions for proper handling, storage, and disposal;

and current safety directives. Use cleaners/chemicals only in authorized areas. Discard soiled cloths into safety cans. Un-less otherwise indicated in the text, use as described in this TO should not result in any immediate health concerns.

4 PERSONAL PROTECTIVE EQUIPMENT (PPE).

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

5 CHEMICAL DISPOSITION.

For proper disposition of chemicals cited for use in this tech-nical order, review applicable SDS and consult with local

Environmental Management and Bio-Environmental Engi-neering Offices for guidance.

6 DEFINITIONS.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in in-jury to, or death of, personnel or long-term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in dam-age to, or destruction of, equipment or loss of mis-sion effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

Shall and Will Indicate mandatory requirements.

Will is also used to express a declaration of purpose.

Should Indicates a preferred method of accomplishment.

May Indicates an acceptable, optional, or suggested means of accomplishment.

vii/(viii blank)

CHAPTER 1

GENERAL

1.1 GENERAL SAFETY AND ENVIRONMENT CON-

SIDERATIONS.

AVGAS is extremely flammable. Harmful if in-haled. Vapors are easily ignited by electrostatic discharges, causing flash fire.

Petroleum products are hazardous due to toxic, explosive, flammable, and environmentally damaging properties. Pre-scribed safety precautions will be strictly followed for the safety and protection of personnel, equipment, and the envi-ronment. Fire hazards are present wherever petroleum prod-ucts are handled due to leaks, spills, vapor accumulation, improper grounding/bonding of equipment, or ignition from a heat source. Leaks or spills must be eliminated to prevent pollution of waterways and underground water tables. CFR Title 40, Part 112.7, General Requirements for Spill Preven-tion, Control and Countermeasure Plans provides guidance on establishing an adequate spill prevention control program.

All spills will be promptly reported to the applicable agen-cies (Fire Department, Safety Office, Bio-Environmental Representative, etc.). Air Force Instruction (AFI) 23-201, Fuels Management and AFI 91-203, Air Force Consolidated Safety Instruction and applicable standards, outlining general safety guidelines to be followed. TO 42B-1-23, Management of Recoverable and Waste Liquid Petroleum Products pro-vides guidance in the collection, segregation, and disposition of recoverable and waste liquid petroleum products.

1.2 FUNCTIONS AND RESPONSIBILITIES.

1.2.1 Defense Logistics Agency-Energy (DLA Energy).

DLA Energy has the ultimate responsibility for procurement, contracting, and international fuel agreements for Bulk Pe-troleum Products.

1.2.2 Air Force Petroleum Office (AFPET). AFPET is

the Air Force Service Control Point for fuel quality issues and provides technical guidance on equipment and infrastruc-ture. AFPET validates, consolidates, and coordinates Petro-leum Products requirements with DLA Energy and COCOM Air Force Components A4. AFPET also provides units with support involving AVGAS equipment/infrastructure require-ments, AVGAS contamination, specification requirements, and quality control to assist units in managing fuels opera-tions.

1.2.3 Joint Petroleum Office (JPO)/Sub-Area Petro-

leum Office (SAPO). JPO/SAPO is responsible for the overall planning of petroleum logistic support for joint op-erations within an area of responsibility.

1.2.4 COCOM Air Force Component Fuels (Air Com-

ponent A4). COCOM Air Force Component A4 coordinates requirements for Petroleum Products, personnel, and support equipment. Close coordination between COCOM Air Force Component A4, AFPET, and DLA Energy under the direc-tion of the JPO/SAPO is critical to a successful joint opera-tion.

1.2.5 Fuels Engineer. MAJCOM A4C or Air Force In-

stallation Mission Support Center (AFIMSC) (or AFPET Fa-cilities Engineer if delegated by AFISMC Fuels Engineer) coordinate with Base Civil Engineers (BCE) for fixed fuels infrastructure procurement (pumping, filtration, tank design, environmental) including construction and environmental protection measures.

1.2.6 Base Civil Engineers (Water Fuels System Main-

tenance (WFSM)). WFSM maintains normal responsibili-ties of liquid fuels maintenance for fixed facilities including construction and environmental protection measures except at some locations with DLA Energy contractor support that includes system maintenance.

1.2.7 Logistics Readiness Squadron (LRS)/Fuels

Management Flight (2F0X1 Personnel). LRS provides standardized refueling support. LRS implements and assures fuels accounting, handling, and quality of product received through point of sale (end user).

1.3 STANDARDIZED OPERATIONAL GUIDANCE

AND PROCEDURES.

a. AFPD 23-2, Management of US Air Force Bulk Petro-leum and Related Products, and AFI 23-201 imple-ment guidance contained in DOD 4140.25-M, DoD Management of Bulk Petroleum Products, Natural Gas, and Coal, regarding management of bulk fuels within the Air Force. AVGAS fuels management operations shall be established, managed, and operated IAW AFI 23-201. Compliance with all supporting AFIs, techni-cal publications, DoD standards, and specifications are mandatory. The following guidance and procedures are

1-1 intended to provide general guidance and minimum standards on procurement, and quality control of AV- GAS equipment/infrastructure.

b. At locations where the Air Force is a tenant organiza-tion, assigned 2F0X1 personnel will coordinate fuels management functions with host service or nation. The 2F0X1s may be assigned to host/lead LRS, operational flying/maintenance unit, or tasked as part of a Unit Type Code. Refer to AFP 23-221, Fuels Logistics Plan-ning, for standardized equipment and personnel Unit Type Codes for initial stand up of AVGAS operations at deployed locations.

c. Organizations at operating locations without 2F0X1 or equivalent qualified personnel assigned must request a waiver to AFI 23-201 through AFPET Current Opera-tions at “AFPET.ptoc@dla.mil”. Air National Guard units will coordinate their waiver request through the NGB/A4RMF staff. The waiver request must include a training outline documenting how the unit will provide the training/task qualification to ensure the intent of this technical order and referenced AFI’s are being complied with.

1.4 PRODUCT PROCUREMENT.

a. Fuel procurement will be accomplished IAW DOD 4140.25-M and applicable DLA Energy Interim Poli-cies and Procedures.

b. For new AVGAS requirements at CONUS locations the requesting unit will submit a DLA Energy Require-ments Worksheet (See Appendix D) to AFPET for validation/submission to DLA Energy. All Requirement Worksheets will have the special requirements line an-notated with “Fuel must conform to ASTM D910 or DEF STAN 91-090, Gasoline Aviation”. Pending final contract award, units will submit an Open Market Pur-chase Request on an as-required basis to provide AV- GAS. Once a resupply contract has been awarded, units will submit orders through the DLA Energy External Enterprise Business Portal, (EEBP).

c. For new AVGAS requirements at OCONUS locations, the requesting unit will submit a DLA Energy Require-ments Worksheet (See Appendix D) through the CO- COM Air Force Component A4 to JPO for validation/ submission to DLA Energy. For limited duration requirements or until regular re-supply can be estab-lished, units will submit an emergency requirement to their COCOM Air Force Component A4 for submis-sion to the JPO or AFPET Requirements IAW Appen-dix D for delivery. All Requirement Work sheets will have the special requirements line annotated with “Fuel must conform to ASTM D910 or DEF STAN 91-090, Gasoline Aviation”.

1.5 RESPONSIBILITIES FOR FUEL QUALITY.

Petroleum products require quality surveillance from the point of initial acceptance by the government until con-sumed. Every agency and individual in the supply system share the responsibility for some phase of quality control.

1.6 QUALITY ASSURANCE RESPONSIBILITY.

a. The Defense Logistics Agency-Energy (DLA Energy) Quality Assurance Representative (QAR) is an organi-zational title assigned to the individual responsible for the US Government contract quality assurance (CQA) function. QARs have cognizance over the procurement of product or services at contractor facilities such as refineries, terminals, packaging plants, laboratories, and into-plane sites. For the US Government, CQA is a method to determine if supplier of product and/or services fulfilled its contract obligations pertaining to products and/or services provided. CQA responsibility is fulfilled when the product and/or service is inspected and accepted by the Government and the product no longer belongs to the contractor or the service is com-plete. DLA Energy procurement contracts are either FOB Origin, final inspection and acceptance at origin, or FOB Destination, final inspection and acceptance at destination. On the majority of DLA Energy FOB Des-tination contracts the receiving activity, which may be a military installation, is responsible for performing the final inspection and acceptance of the product(s) or services. DLA Energy QARs perform both contract quality assurance and quality surveillance (QS) func-tions. QS is the aggregate of measures (blending, stock rotation, sampling, testing, etc.) used to determine and maintain the quality of government-owned products throughout the supply chain in order to ensure that such products are suitable for their intended use. DLA Energy and the applicable military service control point must be contacted, in accordance with the procedures in DoD 4140.25-M and MIL-STD-3004, Department of Defense Standard Practice Quality Assurance/Sur-veillance for Fuels, Lubricants and Related Products when product-related irregularities or discrepancies arise.

b. During contingency or wartime operations the quality inspection responsibilities, as identified above, may be contracted to a commercial inspection company. These contracted inspection responsibilities do “not” include acceptance of product, because acceptance can only be performed by an authorized US Government represen-tative.

1.7 QUALITY SURVEILLANCE AT BASE LEVEL.

a. Fuels Management Team (FMT) is responsible for the quality of all Defense Working Capital Fund (DWCF)

1-2 products from the point of inspection and acceptance through the point of sale. In addition, FMT is respon-sible for the quality of product procured under “local purchase”. FMT also provides advice and analysis on products issued from DWCF stocks.

b. Submit reports of product not meeting specification to AFPET Current Operations Division with info copies to the MAJCOM A4R/COCOM Air Force Component A4 or NGB/A4RMF. AFPET will coordinate with DLA Energy-QA for further action as required. The report shall be in writing using the SF368 or any other type correspondence (facsimile, e-mail, or message) format to include the following information:

1. Specification and Grade

2. Quantity

3. Location

4. Date of Receipt

5. Name of Manufacturer/Shipper, Contract Number, Batch Number, Qualification Number, Date of Manufacturer/Shipment, Transportation Mode, and Company, etc.

6. Type of Container or Storage

7. Accountable Military/Civilian Department. Mili-tary petroleum products require quality surveil-lance

8. Need for Replacement Product

9. Detailed laboratory test results from base level and area laboratory analysis

10. Mission impact

1-3/(1-4 blank)

CHAPTER 2

AVIATION GASOLINE

2.1 PROCUREMENT REQUIREMENTS.

All AVGAS is procured to ASTM International (ASTM) D910, Standard Specification for Leaded Aviation Gasolines and DEF STAN 91-090. AVGAS is an aviation grade gaso-line which has specific properties suitable for fueling aircraft powered by reciprocating spark ignition engines. AVGAS is a mixture of relatively volatile hydrocarbons with small quantities of additives including tetraethyl lead.

2.2 COLOR.

Aviation gasoline is dyed to identify the grade of fuel: red identifies Grade 80, brown identifies Grade 91, green identi-fies Grade 100, and blue identifies Low Lead (100LL). Cur-rently the blue 100LL is the only authorized aviation gaso-line. AVGAS of any other color shall not be used until analysis is performed to determine product suitability for use.

2.3 VOLATILITY.

The volatility of AVGAS is a critical characteristic which reflects the tendency for AVGAS to vaporize and burn. Vola-tility is determined by performing distillation and vapor pressure. As AVGAS is a volatile fuel, a major threat to the integrity of these properties is in the storage and handling of the product.

2.3.1 Distillation. The initial boiling point through the

10% evaporated value is essential for cold start-up and smooth engine operation. The 40% evaporated temperature is reported to reflect the potential for the fuel to contribute to carburetor icing. The 50% evaporated location is very stable and less likely to be affected by the loss of light ends through normal volatilization associated with handling and storage.

The 90% evaporated and End point (Final Boiling Point) indicates the presence of heavy hydrocarbons such as JP-8.

The 10% + 50% value provides an additional measure to monitor the volatility of the fuel.

2.3.2 Vapor Pressure. High vapor pressure fuels exposed

to high temperatures can cause vapor-lock. Low vapor pres-sure indicates the fuel has lost the light ends or lower boiling point fractions needed for cold starting and efficient engine warm up. The distillation 10% evaporation and vapor pres-sure have a correlation with the light end volatility charac-teristics.

2.4 WATER AND SEDIMENT.

Contamination by excessive water and sediment should be monitored and controlled within the transportation, storage, handling and servicing systems in order to avoid serious problems in the operation of aircraft and resultant degrada-tion of the supply readiness position.

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CHAPTER 3

FUEL HANDLING

3.1 SCOPE.

This chapter describes Air Force fuel systems and discusses the relationship of specific system components in maintain-ing fuel quality. Specific operating guidance is provided in this chapter to ensure product quality. Sources and types of contamination are identified to aid base personnel in pre-venting quality degradation.

3.2 PRODUCT STORAGE AND HANDLING.

NOTE

If questions arise about specific equipment or in-frastructure qualifications, contact AFPET Current Operations Division for assistance. Every effort shall be made to ensure AVGAS infrastructure meets Air Force minimum specifications, stan-dards, and criteria to ensure safe operations and maintain fuel quality.

a. Steel Tank Institute (STI) double wall above ground steel tanks generally qualifying to UL 142, UL 2080, or UL 2085 are preferred due to construction cost and ease of installation. Requirements for new tanks and fuel systems shall be coordinated with the local Civil Engineer Squadron via AF Form 332. If an AVGAS system is to be DLA funded as a capitalized infrastruc-ture asset, a deficiency must be established in Enter-prise Business System (EBS) supported by the AF 332 or DD Form 1391. System design shall be executed by AFCEC or USACE/Omaha, and shall include a state-ment of work, the proposed site location, annotated/ edited Unified Facility Guide Specifications (UFGS), and Professional Engineer stamped drawings. Design documents shall be reviewed by AFPET’s Infrastruc-ture Division, AFPET Current Operations and NGB (A4O and A4RMF) if appropriate. The tank/systems shall be operated and maintained in accordance with the Unified Facilities Criteria (UFC) 3-460-03, Opera-tion and Maintenance: Maintenance of Petroleum Sys-tems and TO 37-1-1, General Operation and Inspec-tion of Installed Fuel Storage and Dispensing Systems.

(1) All AVGAS fuel systems (including STI tanks) shall meet standard designs as identified in: UFC 3-460-01, Design: Petroleum Fuel Facilities, STI Standards, UL Standards, NFPA 30 and 30A (30A where applicable), and/or the international equiva-lent standards for design and construction of re-fueling systems. Contact AFPET’s Infrastructure Division for assistance.

(2) AVGAS storage tank systems shall meet require-ments for emergency venting/pressure relief, spacing and separation criteria, and distance cri-teria from loading/offloading points and spill con-tainment (see UFC 3-460-01 and NFPA 30/30A).

Tank shall have appropriate AVGAS pressure/ vacuum vent to minimize loss of volatile fuel components that could result in off-spec fuel (va-por pressure). In desert like environments, con-sider use of canopies over the storage tanks to reduce solar thermal effects and volatility. ASTs shall not be placed in aircraft shelters. Use of canopies shall be approved by the AFPET Infra-structure Division in coordination with the Air Field Facility Engineer per UFC 3-460-01.

b. Other than the 3K ABFDS bladders, all other collaps-ible tanks (bladders) manufactured on or after 4 May 2015 shall not be used to store AVGAS due to material incompatibility.

c. Bulk Fuel Containers (BFC) or ISO containers are managed and established by DLA-Energy contract and/or lease agreements.

d. Collapsible fabric drums or seal drums (blivets) are rubber, non-vented containers for transporting and stor-ing fuel in 500 gallon capacities. Blivets are con-structed of 4 ply tire cord with swivel plates. Anchor shackles at both ends allow for tie down aboard air-craft, and ground towing (rolling) using a special lift-ing and towing yoke. Internal tanks are equipped with fuel/defuel valves and external fuel servicing adapters.

Blivets are filled and emptied through an elbow cou-pler valve and check valve adapter. Because blivets are non-vented, they must be kept shaded to prevent fuel expansion and rupture. Blivets should not be used for long term storage of AVGAS. Blivets must be used and maintained IAW TO 37A3-2-3-1, 500 Gal Capac-ity Liquid Fuel (Nonvented) Collapsible Fabric Drum.

e. 55-gallon metal drums will be checked for leaks, and those found defective should be segregated for deter-mination of usability. Drums should be stored by batch number, and issued on a first-in, first-out basis. Drums should be placed horizontally (on sides) in rows, butt-to-butt, with bungs and vents facing outward. Bungs and vents should be positioned horizontally. Drums should not be stacked more than three high. Drums stored outside should be positioned and placed on dun-

3-1 nage with proper blocking and bracing as necessary.

AVGAS drums shall be covered or shaded to minimize environmental impacts and maintain product quality.

f. Equipment can include mobile refueling vehicles (R- 11, modified C-300/301, R-13) or towable low flow pumping/filtration systems (PMU-27). Appendix A pro-vides a recommended list of existing refueling equip-ment deemed suitable for use with AVGAS. Standard configuration C-300/301 and R-11 refuelers shall not be used for AVGAS storage for more than 30 days.

Under no condition shall the tank Emergency or Ther-mal vents be tampered with. These vents are specifi-cally rated to DOT design of the tank. These vents are not designed for storage of AVGAS for more than 30 days. AVGAS stored longer than 30 days in improp-erly equipped refuelers will lose volatile fuel compo-nents that will result in off-spec fuel (vapor pressure).

Only refuelers specifically configured for and approved by WR-ALC/GRVEB and AFPET Current Operations Division for AVGAS to include proper tank, vent, and filtration can be used to permanently store AVGAS in lieu of infrastructure. Commercial refuelers specifically configured for AVGAS to include proper tank, vent, and filtration must be approved by AFPET Current Operations Division and WR-ALC/GRVEB before they can be used for permanent storage. Equipment must be maintained and operated by qualified personnel IAW applicable technical guidance.

g. Proper equipment for AVGAS must be available to off-load, transfer, and issue, from delivery conveyance through storage to final issue point. All equipment not listed in Appendix A must be submitted for approval to AFPET Current Operations Division.

h. Filtration systems must be qualified to or meet the per-formance specification of EI 1581, Specification and Qualification Procedures for Jet Fuel Filter/Water Separators. Filtration systems for aviation fuels that incorporate absorbent monitors or absorbent media are not authorized under any circumstances. AVGAS must pass through a minimum of two (2) separate filtrations prior to issue to a weapon system. At least one (1) filtration must be between the storage system/mobile refueling equipment and the aircraft maintenance oper-ated ground support issue equipment. When mobile re-fueling equipment is used for storage, the equipment must be able to provide filtration on receipt and issue.

i. Infrastructure and equipment markings shall be IAW MIL-STD-161, Identification Methods for Bulk Petro-leum Products Systems Including Hydrocarbon Missile Fuels or TO 36-1-191, Technical and Managerial Ref-erence for Motor Vehicle Maintenance.

3.3 DIFFERENTIAL PRESSURE.

Particulate contaminants in fuel may affect the filtering sur-face of filter separator coalescer elements. During fuel han-dling operations as the filtering surface collects solid con-taminants, there is a corresponding increase in Differential Pressure (DP) across the coalescer elements. An increase in DP is reflected as an increase in pressure on the DP gauge installed on the instrument panel or vessel.

3.4 CONVERTING REFUELING UNITS FROM ONE

PRODUCT TO ANOTHER.

Top filling where the fuel free falls or splashes is prohibited. Electrostatic charges buildup very rap-idly during this type of operation and can cause an explosion.

AVGAS shall not be used to fuel the drive engines for refueling units.

a. To convert refuelers to AVGAS:

(1) Completely drain refueling unit. Particular atten-tion must be given to sumps, pumps, filters, hoses and other components likely to trap quantities of liquid. In all cases lines, etc, are to be drained to the fullest extent practical.

(2) Change unit markings to new grade and make necessary changes to use a product selection de-vice (different size couplers and nozzles) or lock control system.

(3) Fill unit with 1,000 gallons of gasoline, fill through the bottom loader at the lowest attainable flow rate to avoid static build up, flash fires and filter damage. At the lowest attainable flow rate, rotate 1,000 gallons through the bottom loader.

Flush content of over the wing discharge hoses into a suitable container and dispose of IAW local waste product procedures.

(4) Return the gasoline to storage. Completely drain refueling unit. Particular attention must be given

3-2 to sumps, pumps, filters, hoses and other compo-nents likely to trap quantities of liquid. In all cases lines, etc, are to be drained to the fullest extent practical.

(5) Take a one gallon reference sample from receipt source prior to discharge and fill refueler with

AVGAS.

(6) After AVGAS receipt, fill the filter separator at the lowest attainable flow rate to avoid static build up, flash fires and filter damage. At the lowest attainable flow rate rotate 1,000 gallons through the filter separator. Flush content of discharge hoses into a suitable container and dispose of IAW local waste product procedures.

(7) After rotation, take a sample from the refueling unit and perform a heavy hydrocarbon test in ac-cordance with Appendix C, Paragraph C.5, utiliz-ing the one gallon sample obtained in Step a(5) as reference fuel. When a failure of the heavy hydrocarbon test occurs or questions arise on above procedures, contact AFPET Current Opera-tions Division DSN: 427-8705.

b. Converting fuel equipment (other than refuelers) to

AVGAS:

(1) Completely drain equipment. Particular attention must be given to sumps, pumps, filters, hoses and other components likely to trap quantities of liq-uid. In all cases lines, etc, are to be drained to the fullest extent practical.

(2) Change equipment markings to new grade and make necessary changes to use a product selec-tion device (different size couplers and nozzles) or lock control system.

(3) Fill equipment to capacity with gasoline at the lowest attainable flow rate to avoid static build up, flash fires and filter damage. Rotate/flush equipment to ensure all residual aviation turbine fuel is removed.

(4) Return gasoline to storage through discharge port(s).

(5) Take a one gallon reference sample from receipt source prior to discharge and fill equipment with

AVGAS. Rotate at the lowest attainable flow rate to avoid static build up, flash fires and filter dam-age. Flush discharge ports into a suitable con-tainer and dispose of IAW local waste product procedures.

(6) After rotation, take a sample from equipment and perform a heavy hydrocarbon test in accordance with Appendix C, Paragraph C.5, utilizing the one gallon sample obtained in Step b(5) as reference fuel. When a failure of the heavy hydrocarbon test occurs or questions arise on above proce-dures, contact AFPET Current Operations Divi-sion DSN: 427-8705.

c. To convert refueling units/equipment back to turbine fuel, aviation/kerosene based.

(1) Completely drain refueling unit. Particular atten-tion must be given to sumps, pumps, filters, hoses and other components likely to trap quantities of liquid. In all cases lines, etc, are to be drained to the fullest extent practical.

(2) Change filter elements/separators IAW TO 37A- 1-101.

(3) Change refuelers/equipment markings to new grade and make necessary changes to use a prod-uct selection device (different size couplers and nozzles) or lock control system.

(4) Fill refuelers/equipment with turbine fuel, avia-tion/ kerosene based.

(5) After fill of aviation turbine fuel, filter separators (equipment/refueling units) shall be filled at the lowest attainable flow rate to avoid static build up, flash fires and filter damage. At the lowest attainable flow rate, rotate 2,000 gallons through filter separators. Flush content of discharge hoses/ ports into a suitable container and dispose of IAW local waste product procedures.

(6) Test IAW TO 42B-1-1, Table 4-1. Additionally use the one quart sample to perform flash point test, minimum limits IAW 42B-1-1, Table 2-1.

3-3/(3-4 blank)

CHAPTER 4

QUALITY CONTROL OF AVIATION GASOLINES

4.1 GENERAL.

a. This chapter establishes quality control procedures per-formed by the FM on aviation gasoline at Air Force managed installations. AFPET Current Operations Di-vision will be notified when fuel is suspected of being contaminated or unsuitable for use. The following in-formation will be provided: amount of fuel, brief de-scription of suspected problem, date, and shipping tracking numbers of samples submitted to area lab.

b. These procedures assure that base fuels handling sys-tems dispense clean, dry fuel on a continual basis. Fuel testing as required in this chapter and test methods contained in Appendix C should provide a minimum surveillance of base fuel stocks. Base laboratory per-sonnel are responsible for performing the analysis as outlined in this chapter. The routine surveillance samples prescribed in Table 4-1 shall not be forwarded to, or performed by, area laboratory personnel.

4.2 LABORATORY TECHNICIAN QUALIFICATIONS.

a. The fuels laboratory at Air Force managed operations will be staffed with personnel with the requisite train-ing and experience in accordance with AFI 23-201.

b. Non Air Force Managed Operations: Personnel will be well trained and completely understand all of the tech-nical and operational requirements necessary to ensure fuel quality. Organizations should develop an Operat-ing Instruction (OI) to address fuels accounting, han-dling, and quality control. AFI 23-204, Organizational Fuel Tanks, may be used as a reference in the devel-opment of the OI for the accounting and handling of AVGAS that is considered organizationally owned fuel.

To assist in ensuring fuel quality and safe fuels opera-tions, AFPET Current Operations Division and CO- COM Air Force Component fuel staffs, or designated representative, should perform scheduled site surveil-lance as requested.

(1) Difficulties may exist in having individuals within the unit obtain the required fuels laboratory Spe-cial Experience Identifier (SEI) 039. Alternative processes and procedures will be implemented to ensure fuel quality monitoring requirements of this TO are achieved. All deviations from these procedures shall be coordinated with and ap-proved by AFPET Current Operations Division DSN: 427-8705 or afpet.ptoc@dla.mil prior to commencing AVGAS operations.

(2) To ensure a quality control program is initiated and maintained, the following actions must be ac-complished:

(a) The unit will develop an on-the job training plan to address how a designated laboratory technician will be provided the required train-ing for quality control of AVGAS as speci-fied in this TO.

(b) Every effort should be made to ensure train-ing is conducted by fully qualified laboratory technicians with testing experience (2F0X1 SEI 039). On-site training should be coordi-nated and arranged through the Air Force In-stallation and Mission Support Center, AF- IMSC A4 fuels staff.

(c) All costs associated with site visits and train-ing will be funded by the unit requiring train-ing.

(d) Training plans must be reviewed by the AF- IMSC A4 Fuels Staff and AFPET and ap-proved by the Fuels Career Field Manager.

(e) Designated laboratory technician shall have a record of training on file reflecting dates of completion for all tests performed associated with this alternate training program.

(f) The trainer will be a person designated in writing by the AFIMSC A4 Fuels Staff.

(g) The training will require the laboratory tech-nician to demonstrate proper laboratory test-ing techniques and possess knowledge of the scope and significance of each test performed.

(3) The terms of this exception to TO requirements is predicated on a final site evaluation by a team consisting of AFIMSC A4 Fuels Staff and AFPET personnel. This visit shall serve as a review of the entire fuel handling process and quality surveil-lance program. A copy of site survey final report will be provided to AFPET Current Operations.

4-1

4.3 LABORATORY OPERATIONS.

4.3.1 Cleaning Glassware.

SCALDING HAZARD: Exposure to 130° F water will cause 3rd degree burn to unprotected skin.

Skin must be protected using appropriate personal protective measures. Coordinate this requirement with local occupational hazard health personnel.

4.3.1.1 Solution and water temperatures while cleaning

glassware shall not exceed 130° F.

4.3.1.2 Follow manufacturer instructions regarding the use

of glassware cleaning solution.

4.3.1.3 Rinse all glassware three times with tap water and

perform a final rinse using distilled or demineralized water, then air or oven dry.

4.3.2 Microscopic Analysis. If excessive or abnormal sol-

ids are obtained, examine the solid material using a micro-scope. Identify the types of contaminants using examples of reference materials. These reference samples should include fibers, lint, aircraft reticulated foam, sand, dirt, metal shav-ings, and rust. Solid contamination which cannot be identi-fied shall be forwarded to the area laboratory at Wright Pat-terson AFB, OH addressed to the attention of the Technical Assistance Division.

4.3.3 Disposition of Samples. Return unused portions of

fuel samples to inventory. Every effort will be made to use this product as intended. Fuel samples containing petroleum ether should not be considered waste fuel, however, should be returned to bulk storage. Aviation fuel samples contami-nated with hydraulic fluid or aircraft engine oil may not be returned to the fuel system until coordination is completed as prescribed in Paragraph 1.6.

4.4 SAMPLING AND TESTING.

4.4.1 Types of Samples.

NOTE

When access is restricted, do not draw samples from gauge/sampling hatches on tanks containing Automatic Tank Gauging (ATG) equipment. Take samples at ground level from the tank discharge line at the inlet side of downstream filtration equipment.

a. Composite Sample − a single sample consisting of representative samples from more than one storage container.

b. All-Level Sample − obtained by submerging a closed sampler to a point near the draw-off level, opening and raising the sampler at a rate which will ensure the sampler is nearly full when emerging from the liquid.

c. Top Sample − from 6 inches below the surface of the tank contents.

d. Upper Sample − from the middle of the upper third of the tank contents.

e. Middle Sample − from the middle of the tank con-tents.

f. Lower Sample − from the middle of the lower third of the tank contents.

g. Bottom Sample − from the lowest point of the tank contents.

h. Continuous Sample − from a line through which product is flowing containing a representative average of the stream.

i. Tube or Thief Sample − obtained as a core sample or spot sample from a specific point in a container. An all- level sample from a drum can be taken with these samplers.

j. Drain Sample − taken from a drain line. Drain and bottom samples are usually taken to check for water, sludge, or scale. A drain sample may be the same as a bottom sample, as in a tank car.

k. All samples taken from filter separators will be taken from the downstream side unless otherwise noted.

l. Refueling Unit Sampling − Routine sampling of refu-eling units may be performed from the pump compart-ment (cambox) location. All re-samples or samples taken while investigating high particulates and/or con-tamination of any kind shall be taken from the single point nozzle as fuel is being recirculated through the bottom loader.

4.4.2 Sampling Equipment.

NOTE

The gold-colored sampler provided by Gammon Technical Products is anodized aluminum and is satisfactory for fuel sampling.

Sampling equipment is designed for specific purposes and types as samples referenced above. These samplers include, but are not limited to, weighted bottle, bacon bomb, drum thief, and in-line samplers. Do not use yellow metal sam-plers with Avgas.

4-2

4.4.3 General Sampling Procedures.

a. Take a truly representative sample. Cleanliness of the equipment is extremely important. Use only lint-free materials or soft paper towels.

b. Do not sample or gauge storage tanks during filling operations or within 30 minutes after product receipt to allow static charges to dissipate.

c. The preferred method for sampling an underground tank is an in-line sample between the pump and filter separator during flow. Do not take samples through the storage tank clean-out line.

d. Drums may only be sampled using a drum thief or hose. For additional information on sampling, refer to Chapter 8 of API Manual of Petroleum Measurement Standards (MPMS).

e. Only sample containers used for shipment to area lab or first-time use shall be flushed three times with 10 to 20% of the product being sampled. For each flush, the container shall be closed and shaken for 10 seconds and product replaced for the next flush. Return the flushed fuel into a suitable container for return to in-ventory. Exceptions to this rinsing requirement apply to limited quantity samples, such as aircraft incident samples or sump drain samples. Sample containers consistently utilized for gravimetric analysis are con-sidered clean after the 4-time petroleum ether rinse which occurs during previous bottle method test.

f. When sampling mobile equipment with an in-line sam-pler, the mobile equipment must be bonded through the sampler to the 1 gallon recovery can. See Para-graph C.2 for instructions on how this can be accom-plished.

g. After all filter element changes, rotate a minimum of 2,000 gallons of fuel through the filter separator and sample the filter separator IAW Table 4-1.

h. Obtain the minimum sample quantity required for all tests. Samples taken for visual analysis will be one quart. Samples taken for all other testing shall be 1 gallon unless otherwise specified. Sample testing will be completed within the duty hours of the day the sample was taken.

i. Each time a sample fails, a resample shall be taken immediately and another analysis performed.

j. Fuels laboratories will use a bondable steel funnel when transferring fuel as specified by this TO. Stain-less steel is preferred.

k. Test all fuel samples as soon as possible after sam-pling. The color and particle assessment method for solids analysis may be performed as instructed in Para-graph C.2 or Paragraph C.3 on all samples taken down-stream of the filter separator. Free water determination shall be determined by method in Paragraph C.1.

l. When a retest confirms a failure for solids or free wa-ter, conduct an investigation to determine the cause. It may be necessary to sample upstream of the filter separator to locate the source of the contaminant. Con-tact AFPET Current Operations Division for additional guidance.

m. When contamination downstream of aircraft servicing filter separators exceeds Color max = 4. Particle max = Acceptable. Retest failures using matched-weight, 0.5 mg/L or when free water is greater than 10 ppm, the servicing equipment shall be taken out of service and investigative action performed.

n. When the term WEEKLY is used for sampling fre-quency, it means every seven days. The term MONTHLY means every thirty days. The sample may be taken at any time within the 24-hour clock on the due date.

o. Samples taken under flow conditions shall require a minimum of 10 psi at the sampling point to permit proper flow through the in-line sampler.

p. Flush and sample Fuels Support Equipment (FSE) prior to initial in-service use.

q. Follow guidance in TO 37A-1-101, Fuel, Water, and Lubricant Dispensing Equipment or UFC 3-460-03 for separator cleaning and inspection procedures.

4.5 PRODUCT RECEIPT - AVGAS.

DD Form 250/Vendor Delivery Ticket shipping and receiv-ing documents must accompany all fuel shipments. Docu-ments should contain contract number, contractor name, ship-ment number, product specification/nomenclature, and the name of the authorized US Government representative or contracted inspection company. Depending on the type of contract, a copy of the product analysis may accompany the DD Form 250/Vendor Delivery Ticket. When there is a prob-lem with the documentation, notify the authorized US Gov-ernment representative. All samples which fail the manda-tory resample/retest shall be reported to AFPET Current Operations Division, and the applicable DLA Energy Region or DLA Energy-Q through a Product Quality Deficiency Re-port, as outlined in Paragraph 1.7, Step b.

4.6 SAMPLING REQUIREMENTS.

a. AVGAS Tank Truck Receipts - Obtain an all-level sample from the conveyance prior to off-loading. Pro-tect the sample from sunlight. Perform a visual analy-sis on the sample as prescribed in Paragraph C.1. The

4-3 color…