0001_ATPD_2336E_-_Modular_Fuel_System_(MFS)_GPM_12_AUG_2011.pdf

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

U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or emailed to DAMI_STANDARDIZATION@conus.army.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST

Online database at https://assist.daps.dla.mil.

AMSC N/A FSC3835

INCH-POUND

ATPD-2336E

12 August 2011

SUPERSEDING

ATPD-2336D

09 November 2010

PURCHASE DESCRIPTION

MODULAR FUEL SYSTEM (MFS)

This specification is approved for use by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), Research, Development and

Engineering Command (RDECOM), Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This performance specification covers the requirements for a Palletized Load

System (PLS) and Heavy Expanded Mobility Tactical Truck-Load Handling System (HEMTT-

LHS) compatible petroleum storage and distribution system called the Modular Fuel System

(MFS). The MFS will be capable of receiving, storing, filtering, and issuing kerosene based fuels

(i.e. Jet Propellant (JP) JP-5, JP-8, Jet-A, Jet-A1) and diesel fuel. The MFS is an ISO-compatible system that has the ability to be transported using the HEMTT-LHS truck, PLS truck, and PLS trailer as the prime mover, and can be rapidly emplaced, operated, maintained, and recovered by skilled personnel. A single MFS unit will be a 35,000-gallon capacity fuel farm consisting of fourteen tankrack modules (TRM) and two pumprack modules (PRM). The MFS consists of

2,500-gallon (threshold), 3,000-gallon (desired) TRMs, PRMs, a petroleum test kit, a fuel spill control kit, and accessories including hoses, valves, and fittings. The TRM will be capable of top and bottom fill and will be transportable at any level of fuel. The MFS will be capable of wholesale and retail distribution activities. The MFS is capable of evacuating all but residual fuel from the hoses and other system components prior to tear down. Mobility requirements of the HEMTT-LHS and PLS truck, and PLS trailer will not be affected while transporting MFS.

The MFS will be compatible with other US and allied nations, military and commercial fuel systems. The MFS will meet ISO container requirements to allow stacking of TRMs and meet requirements of worldwide shipping by air, rail, marine, and highway without changes in configuration or special considerations.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this document. This section does not include documents cited in other sections of this document or recommended for additional information or as examples.

2.2. Government documents.

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

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

FEDERAL STANDARDS

FED-STD-595/34094 - Green 383

COMERCIAL ITEM DESCRIPTION

A-A-393 - Extinguisher, Fire, Dry Chemical (Hand Portable)

A-A-52030 - Nozzles, Fuel and Oil Servicing, Nonautomatic Shutoff and

Nozzles, Fuel Servicing, Automatic Shutoff

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

A-A-52624 - Antifreeze, Multi Engine Type

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

A-A-59377 - Coupling Assembly, Quick-disconnect, Sexless type

DEPARTMENT OF DEFENSE SPECIFICATIONS

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

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

MIL-DTL-53072 - Chemical Agent Resistant Coating (CARC) System

Application Procedures and Quality Control Inspection

MIL-DTL-83133 - Turbine Fuels, Aviation, Kerosene Types, JP-8 (NATO

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

MIL-PRF-370 - Hose and Hose Assemblies, Nonmetallic: Elastomeric, Liquid Fuel

MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service

MIL-PRF-10924 - Grease, Automotive and Artillery

MIL-PRF-32143 - Batteries, Storage: Automotive, Valve, Regulated, Lead

Acid (VRLA)

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic

MIL-PRF-52308 - Filter-Coalescer Element, Fluid Pressure

MIL-PRF-52747 - Nozzle Assembly, Closed-Circuit Refueling Standards and Arctic Service

MIL-PRF-52849 - Test Kit: Aviation Fuel Contamination (Portable)

DEPARTMENT OF DEFENCE STANDARDS

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

MIL-STD-209 - Lifting and Tiedown Provisions

MIL-STD-461 - Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystem and Equipment

MIL-STD-464 - Electromagnetic Environmental Effects Requirements for

System

MIL-STD-810 - Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-814 - Requirements for Tiedown, Suspension, and Extraction

Provisions on Military Materiel for Airdrop

MIL-STD-913 - Requirements for the certification of sling loaded military equipment external transportation by department of defense helicopters.

MIL-STD-1366 - Transportation Criteria

MIL-STD-1472 - Human Engineering

MIL-STD-3004 - Quality Assurance/Surveillance for Fuels, lubricants, and related products

DEPARTMENT OF DEFENCE HANDBOOKS

MIL-HDBK-669 - Loading Environment and Related Requirements for

Platform Rigged Airdrop Materiel

MIL-HDBK-1791 - Designing for Internal Aerial Delivery in Fixed Wing

Aircraft

MIL-HDBK-138 - Guide to Container Inspection for Commercial and

Military Intermodal Containers

(Copies of these documents are available from https://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA

19111-5094.)

2.2.2 Other government documents, drawings, and publications. The following other

Government documents, drawings, and publications form a part of this document to the extent https://assist.daps.dla.mil/quicksearch/ specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

US ARMY REGULATIONS & PAMPHLETS

AR 70-38 - Research, Development, Test, and Evaluation of Materiel for Extreme Climatic Conditions

AR 750-1 - Army Material Maintenance Policy and Retail

Maintenance Operations

AR 750-43 - Army Test, Measurement, and Diagnostic Equipment

Program

DA PAM 611-21 - Military Occupational Classification and Structure

DA PAM 750-8 - Army Maintenance Management System (TAMMS)

Users Manual

DA PAM 750-35 - Guide for Motor Pool Operations

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

Command, AMSTA-TR_D/210, Warren, MI 48397-5000. Some are also available on-line at – http://www.usapa.army.mil.)

CODE OF FEDERAL REGULATIONS (CFRs)

29 CFR 1910 - Occupational Safety and Health Standards

49 CFR 172.504 - General Placarding Requirements

49 CFR 178.345-346 - Specifications for Packaging 49CFR 180.407-

Requirements for test and inspection of specification cargo tanks

49 CFR 180.411,415 - Acceptable Results of Tests and Inspections, Test and

Inspection Markings

49 CFR 450-453 - Regulation relating to Department of Transportation

(DOT) (International Safe Container Act)

49 CFR 393.28 - Wiring to be protected.

(Copies of these documents are available from www.gpoaccess.gov/cfr/index.html or U.S.

Government Printing Office, P.O. Box 979050, St. Louis, MO 63197-9000.)

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

STANAG 2413 - Demountable Load Carrying Platform

(DLCP/Flatracks)

STANAG 4074 - Auxiliary Power Unit Connection for Starting Tactical

Land Vehicle

STANAG 1135 - Interchangeability of fuels, lubricants and associated products used by the Armed Forces of the North

Atlantic Treaty Nations (NATO) http://www.usapa.army.mil/ http://www.gpoaccess.gov/cfr/index.html

STANAG 3756 - Facilities and Equipment for Receipt and Delivery of

Liquid Fuels

AVTP 03-160W - Dynamic Stability

(Application for copies should be addressed to the Ministry of Defense, Kentigern House, 65

Brown Street, Glasgow, G2 8EX, United Kingdom.)

US ARMY FIELD MANUALS

FM 3-11.5 - Multiservice Tactics, Techniques, and Procedures For

Chemical, Biological, Radiological, and Nuclear

Decontamination

FM 3-100 - Chemical Operations Principles and Fundamentals

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

TR-D/210, Warren, MI 48397-5000. Some are also available on-line at http://155.217.58.58.)

US ARMY DEVELOPMENTAL TEST COMMAND

TOP 2-2-608 - Braking, Wheeled Vehicles

(Copies are available from http://www.dtc.army.mil/publications/topsindex.aspx or US ARMY

Developmental Test Command, Headquarters, 314 Longs Corner Road, Aberdeen proving

Ground, MD 21005.)

PURCHASE DESCRIPTIONS

PD 3930-0108 - Truck, Lift, Fork, Variable reach, Rough terrain, 10,000-pound capacity

ATPD 2206 - Batteries, Storage: Lead-Acid, Maintenance Free

(Metric)

ATPD 2325 - Truck, Lift, Fork, Variable Reach, Rough Terrain, 10,000 – Pound Capacity

(Copies of these purchase descriptions are available from the US Army Tank-automotive and

Armaments Command, AMSTA-TR-D/210, Warren, MI 48397-5000.)

DRAWINGS

11674728 - Vehicle Receptacle Assembly

11682336 - Cable and Plug Assembly, Intervehicle Power

13222E8212 - Coupling Set, NATO, Tank Truck Adapter

13222E8217 - Coupling, Female, Tank Truck

13222E8218 - Coupling, Male, Tank Truck

13222E8219 - Coupling, Rail Tanker NATO

13219E0462 - Ground Rod http://155.217.58.58/ http://www.dtc.army.mil/publications/topsindex.aspx

12479550 - Ground Combat Vehicle Welding Code – Steel

12472301 - Ground Combat Vehicle Welding Code – Aluminum

(Copies of these drawings are available from the US Army Tank-automotive and Armaments command, AMSTA-TR-D/210, Warren, MI 48397-5000.)

AMERICAN PETROLEUM INSTITUTE

API/IP Specification 1581 - Specification and Qualification Procedures for

Aviation Jet Fuel Filter/Separators

(Copies of this document are available from API Publishing Services, 1220 L Street, N.W.,Washington, DC 20005.)

U.S. Army Corrosion Rating System

TACOM Design Guidelines for Prevention of Corrosion in Combat and Tactical

Vehicles, Mar. 1988.

(Copies of USACTS and TACOM Guidelines are available from the US Army Tank-Automotive and Armaments Command, AMSRD-TR-E/267, Warren, MI 48397-5000.)

NBC Contamination Survivability Criteria for Army Materiel (NCSCAM)

(Copies of this document are available from the U.S. Army Nuclear and Chemical Agency, 7150

Heller Loop, Suite 101, Springfield, VA 22150-3198.)

2.3 Non-government publications. The following documents form part of this document to extent specified therein. Unless otherwise specified, the issues of the documents, which are

DOD adopted, are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of the documents not listed in the DODISS are the issues of the documents cited in the solicitation.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 228-1 - Pipe Threads Where Pressure-Tight Joints Are Not Made on the Threads Part 1: Dimensions, Tolerances and Designation-

Fourth Edition

ISO 668 - Containers, Series 1 Freight, Classification, Dimensions and

Ratings

ISO 1161 - Containers, Series 1 Freight —Corner Fittings—

Specification

ISO 1496-3 - Containers, Series 1 Freight - Specification and Testing –

Part 3: Tank Containers for Liquids, Gases and Pressurized

Dry Bulk

ISO 1496-5 - Containers, Series 1 Freight - Specification and Testing –

Part 5: Platform and Platform Base Container

ISO 6346 - Freight Containers – Coding, Identification and Marking

(Application for copies of ISO standards should be addressed to American National Standards Institute, 11 West 42 nd Street, New York, N.Y. 10036.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 385 - Tank Vehicle for Flammable and Combustible Liquids

NFPA 407 - Aircraft Fuel Servicing

(Application for copies should be addressed to the National Fire Protection association, One

Batterymarch Park, Quincy, MA 02269-9101.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J 184 - System, Acquisition, Qualifying a Sound Data

SAE J 534 - Fittings, Lubrication

SAE J 2360 - Oil, Lubricating, Gear Multipurpose (Metric) Military use

SAE-AS-5877 - Nozzle, Aircraft Pressure Refueling

(Copies are available from Society of Automotive Engineers, Department 105, 400

Commonwealth Drive, Warrendale, PA 15096.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 123 - Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products

ASTM D 522 - Mandrel Bend Test of Attached Organic Coatings

ASTM D 610 - Degree of Rusting on Evaluating Painted Steel Surfaces

ASTM B 633 - Zinc on Iron and Steel, Electrodeposited Coatings of

ASTM D 975 - Oils, Diesel Fuel

ASTM D 1171 - Rubber Deterioration - Surface Ozone Cracking Outdoors or

Chamber (Triangular Specimens)

ASTM D 1655 - Aviation Turbine Fuels

ASTM D 3359 - Adhesion by Tape Test, Measuring

(Copies are available from the American Society for Testing and Materials, 100 Barr Harbor

Drive, West Conshohocken, PA 19428-2959.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPVC - Boiler and Pressure Vessel Code

(Copies are available from the American Society of Mechanical Engineers, 3 Park Avenue, New

York, NY 10016.)

GERMAN INDUSTRIAL STANDARDS

DIN 30722 - Pay-Off Dump Trucks up to 32T (Flatrack Critical

Dimensions)

DIN 28450 - Quick-acting Hose Couplings for Tank Trucks

(Copies are available from Global Engineering Documents, an IHS GROUP Company, 15 Inverness Way East, Englewood, Colorado 80112.)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

(DOD Adopted)

(Application for copies should be addressed to the National Electrical Manufacturers

Association, 1300 N. 17 th

Street, Suite 1847, Rosslyn, VA 22209.)

GENERAL MOTORS CORPORATION (GM)

GM 9540P - Accelerated Corrosion Test

(Copies are available from Global Engineering Documents, an IHS GROUP company, 15 Inverness Way East, Englewood, Colorado 80112.)

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

3. REQUIREMENTS

3.1 Description. As written in this purchase description, minimum acceptable performance threshold requirements are indicated with the word ―shall‖ throughout the text. All requirements applicable to the MFS apply to both the TRM and the PRM. As applicable, objective capabilities that are not mandatory are indicated with the words ―should‖, ―desired‖, or

―desirable‖. For the purpose of this purchase description, the MFS is described as an ISO compatible system that shall provide the ability to transport, store and distribute bulk fuel (both unit and supply point distribution) using the HEMTT-LHS truck (M1120); PLS truck (M1074, M1075); and PLS trailer (M1076) towed by the HEMMT-LHS truck, the HEMTT tanker, and the PLS truck (M1074, M1075) as the prime mover. The MFS shall be capable of storing fuel and performing both wholesale and retail operations. The tanks shall be connected to the PRM inlets and the retail hoses shall be connected to the outlet of the PRM. The wholesale capabilities of the MFS shall be utilized for distribution including the tank and pump unit (TPU) and 500-gallon collapsible containers and storage of bulk fuel, while the retail capabilities (see Appendix

B) of the MFS shall allow supply of fuel to unit-level retail refueling operations.

3.2 First article. When required by contract (see 6.2), the MFS shall be subjected to First

Article Testing (FAT) IAW 4.1.3.

3.3 Materials. The materials used in the MFS components shall be as identified and shall meet all of the physical, operational, and environmental requirements specified herein. The contractor shall verify that the components incorporated into the MFS are fabricated from recovered materials to the maximum extent practicable, provided the components meet all other requirements of this specification and subassembly specifications. The materials shall be of sufficient durability to meet all the requirements as specified herein. No material shall have an adverse effect on the health of personnel when used for its intended purposes. Toxic chemicals or ozone depleting chemicals (ODC) shall not be used.

3.3.1 Fuel compatibility. All materials in contact with fuel shall be compatible with the fuels listed in 3.5.9.

3.3.2 Service and storage life. The MFS shall have a service life of not less than 25 years when operated under the operational and environmental conditions specified in 3.8.

Suction and discharge hoses shall have a minimum shelf life of at least 10 years (threshold) 20 years (objective) and a useful life of at least 5 years (threshold) and 10 years (objective) once wetted with fuel.

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

3.3.4 Hazardous materials usage. Asbestos, beryllium, radioactive materials, hexavalent chromium, cadmium, mercury, or other highly toxic or carcinogenic materials, as defined in 29

CFR 1910.1200, with the exception of the Chemical Agent Resistant Coating (CARC), shall not be used in the manufacture, assembly, operation or sustainment of this system without prior approval from the Government. Approval will only be granted when valid technical justification is provided. Class I and Class II Ozone Depleting Substances shall not be used. Lead shall not be used without prior approval of the Government. The use of lead solder may be approved for electrical components where a suitable alternative is not available. Lead-acid batteries may be used without approval from the Government. Hazardous materials requirements shall apply to any components/parts purchased through a subcontractor/vendor or OEM parts, as well as manufactured parts.

3.3.5 Deterioration, prevention, and control. The manufacturer shall select materials capable of meeting all the operational and environmental requirements specified herein. The system components shall be fabricated from compatible materials, inherently corrosion resistant or treated to provide against corrosion and deterioration during storage and operational conditions experienced. Hoseline shall not be crimped or folded by any system components.

3.3.6 Recycled, recovered, and environmentally preferable materials. Recycled, recovered, and environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle cost.

3.3.7 Pipe threading connections. Threaded connections in contact with petroleum products shall have the threads treated with an antiseize compound or pipe thread sealant as appropriate.

3.3.8 Used, rebuilt, or remanufactured components. Used, rebuilt, or remanufactured components shall not be incorporated into the MFS.

3.4 Compatibility.

3.4.1 HEMTT LHS/PLS and PLS trailer compatibility. The MFS shall be compatible with the HEMTT-LHS, PLS, and PLS trailer as well as other military means as specified in 3.6.1 and commercial flatbed trailers. A HEMTT-LHS or PLS truck each coupled with a PLS trailer shall be capable of transporting two modules. These two modules shall be transported in two configurations: two TRMs at any fuel level and one TRM at any fuel level and a PRM, over the terrain specified in the Operational Mode Summary/Mission Profile (OMS/MP) without limitations. When transporting the MFS, the current level of HEMTT-LHS, PLS truck, and PLS trailer mobility (IAW Appendix A) and stability shall be maintained regardless of liquid level.

The TRM shall meet the LHS interface requirements of DIN 30722 and STANAG 2413. It shall be capable of being loaded on and unloaded from the HEMTT-LHS, PLS truck, and PLS trailer using only the HEMTT-LHS and PLS load handling system. The TRM shall be able to couple with the M978 HEMTT Tanker to form a 5,000-gallon distribution platform. The TRM configuration shall allow operators to safely connect hoses and perform other steps necessary to bulk transfer fuel between the TRM and the HEMTT tanker when the TRM is towed by a

HEMTT tanker. The TRM shall be able to perform retail operations using the TRM as the source without disconnecting the HEMTT Tanker from the PLS Trailer. The time to complete all required connects shall be five minutes or less.

3.4.2 ISO compatibility. The TRM and the PRM shall conform dimensionally to the requirements of Table 2 of ISO 668 as a 1CX twenty- (20) foot container. The MFS shall be capable of stacking empty loads on the ISO provisions up to nine units high. The container frame shall have corner fitting locations that conform to ISO 668 for a 1CX container. Upper and lower corner castings shall conform to ISO 1161. When stowed for transport the TRMs and the

PRM including all accessories, components and add-on items as applicable shall fit within the

ISO interface dimensions. The MFS shall be designed for and capable of being lifted from the four top corner fittings, being lifted from the four bottom corner fittings, meeting the stacking requirements, meeting external restraint (longitudinal), and meeting transverse and longitudinal rigidity requirements of ISO 1496-3. Contractor shall obtain ISO certification prior to government Acceptance Inspection and Test (AI&T).

3.4.3 Forklift compatibility. Each TRM, PRM, and any loads to be handled by a forklift, shall have forklift pockets, for lifting, conforming to ISO 1496-5. TRMs shall be empty prior to handling by a forklift. Forklift pockets shall be shielded to prevent the TRM from accidental piercing by the forklift tines. Each TRM, PRM, and any loads to be handled by a forklift shall be capable of being entirely lifted and secured IAW MIL-STD-1366 onto the HEMTT-LHS truck, PLS truck, PLS trailer, and conventional flatbed trailers, by the following standard U.S. Army forklifts: 10,000 Lb. All Terrain Lifter Army System (ATLAS) IAW ATPD 2325 and the M10A

(ref. TM 10-3930-643-10). The TRM and the PRM components shall be within the physical envelope of the ISO frame to avoid contact with the forklift carriage.

3.5 Design and operating requirements.

3.5.1 Operation. The operator shall be capable of performing all MFS loading, unloading, and dispensing operations while the TRM is mounted on the palletized load system

(PLS) trailer, while on the HEMTT-LHS/PLS truck, and while the MFS is sitting on the ground, flat and on slopes up to 5 degrees. Once the MFS modules have been emplaced at the operational location, a MFS shall be fully operational and ready to dispense fuel in a maximum of 1 hour using four MOS 92F soldiers without the need for material handling equipment. The

MFS shall be recovered as specified in 3.5.9.4. The MFS shall be designed to minimize or eliminate environmental quality impact and shall comply with all environmental policy and procedures.

3.5.2 Starting, operation, and stopping.

a. Starting. The MFS shall be capable of starting within 5 minutes under any environmental conditions or combination of conditions as specified in 3.8. The

MFS shall start and operate on inclines up to +/- 5 degrees from horizontal.

b. Operation. The MFS shall be capable of operating under any environmental condition or combination of conditions as specified in 3.8. No leakage, contamination, or damage to the MFS shall result from operation.

c. Stopping. As required, MFS shall be equipped with a manual stop to stop the flow of fuel within 5 seconds after activation.

3.5.3 Failsafe structure. Failure of the TRM bailbar or loading bar shall not result in a rupture of the tank. The head of the tank shall be protected from accidental puncture by the LHS hook when engaging the bailbar or loading bar. The TRM/PRM base and frame shall protect components of the TRM/PRM from damage caused by loading and unloading onto its prime mover, transport, and normal use and abuse in the military environment. Components mounted to the TRM/PRM base and frame shall be protected from accidental contact and damage by foreign objects on the ground.

3.5.4 Weight. The maximum gross weight of the TRM, fully loaded with fuel, and the maximum gross weight of the PRM and all associated components including the container frame, shall not exceed the loading, unloading, and lifting capabilities of the HEMTT-LHS of 26,000 pounds. The center-of-gravity limit for the 26,000 pound flatrack for transport by the HEMTT

1120 is 110.3 inches from the front of the flatrack and 39.9 inches from the bottom of the flatrack.

3.5.5 Component housings and storage boxes. All housings and boxes shall protect a component from damage, reduce noise signature, store equipment, etc. and shall exclude wind driven rain, snow and sand from the interior of the box or housing. All components contained in housings and boxes shall be easily identified and accessible to allow fast and expedient removal and inventory. All housing and box doors shall be self-supporting in the open position, and shall be labeled to indicate items accessible through them. Housings and boxes shall not allow either the buildup of air pressure or the retention of fluid. All component housings shall be removable or allow sufficient interior access to permit performance of all inspection and unscheduled and scheduled maintenance actions including the removal of all major components contained within.

The housings shall have permanently mounted doors allowing access to perform preventive, scheduled and unscheduled maintenance service actions.

3.5.5.1 Equipment box (es). Each TRM and PRM shall be equipped with equipment storage boxes. The storage boxes shall be compartmented, contain a lockable hasp, and have provisions for holding the lid in an open position. Unless specified elsewhere, the box (es) shall provide enough space to organize and protect from corrosion and other damage all tools, accessories, publications, and any other Basic Issue Items (BII) supplied with the MFS.

Equipment boxes shall be accessible by personnel standing at ground level when the MFS is sitting on the ground.

3.5.5.2 Hose storage. The MFS shall have lockable storage tubes capable of storing all non-collapsible hoses as specified in 3.5.7.1. In addition, the PRM shall provide storage capacity for all collapsible hoses as specified in 3.5.7.1. Each TRM shall have storage tubes located where they can be accessible by personnel standing at ground level when the system is truck or trailer mounted. The storage tubes shall have a permanently attached cover at both ends and shall prevent damage to the hoses.

3.5.6 Major Components.

3.5.6.1 Tankrack Module (TRM).

3.5.6.1.1 Capacity. The tank shall have a capacity of 2,500 gallons with a desired capacity of 3,000 gallons (plus 5 percent (%) capacity providing for expansion of the fuel) of bulk petroleum product as specified in 3.5.9. The TRM shall contain secure storage for hoses and nozzles as specified in 3.5.9.2 and 3.5.7.1, and other equipment necessary for maintenance and refueling operations.

3.5.6.1.2 Pressure relief. Relief valves used to relieve over or under pressure in the tank shall not allow flow of liquids, dust, and dirt into or out of the tank and shall be automatic in operation. Relief valves shall prevent deformation of the tank structure and conditions of reduced flow from vacuum or pressure build-ups, through equalization of tank pressure under all loading, unloading, and operating conditions specified herein. Tank vents shall restrict evaporative loss. Tank pressure relief system shall meet the requirements of DOT

49CFR178.346-3. The tank and associated components shall present a closed system that shall not vent externally when in the air transport configuration. Fluids and vapors within the tanks and associated components shall not be permitted to mix with cabin air inside the aircraft cargo compartment under any normal or emergency flight conditions. Aircraft overboard venting shall not be used.

3.5.6.1.3 Load stabilization. The tank shall be equipped with permanent tank baffling, surge plates, or other provisions to minimize longitudinal, lateral, and vertical sloshing of fluid during transport of partial loads to the extent required to meet the requirements of this PD.

3.5.6.1.4 Cleaning. The design shall provide ease of cleaning the complete tank compartment of sediment and contaminants. Provisions to allow the tank to drain to the maximum extent possible as specified in 3.5.9.8 and unassisted when sitting level shall be provided. All inside surfaces of the tank shall be smooth, allow no trapped or freestanding pocketing of fuel when drained, and shall not provide an environment that favors microbial growth. Internal baffles or load stabilization provisions shall not restrict access by personnel to any part of the tank.

3.5.6.1.5 Manhole. The tank shall be equipped with a hinged manhole cover. The manhole shall be designed so that no fuel spillage occurs when loading or unloading the TRM, with fuel at any level, from or to the LHS or PLS truck or trailer. The manhole assembly shall meet the requirements of DOT 49CFR178.345-5. The opening for the manhole shall be raised above the level of the top of the tank a minimum of 2 inches, to prevent debris from falling into the tank when opening the manhole. The manhole shall be lockable with a hasp. Access to the inside of the tank shall allow 5 th percentile female to 95 th percentile male soldier equipped with proper safety equipment to ingress and egress the inside of the tank. Soldier safety shall be considered when designing method of access.

3.5.6.1.6 Fuel level gauges. Each TRM shall be equipped with a fuel level indicator, viewable by a soldier standing on the ground. The level indicator shall not be of a sight-glass type, and shall be accurate within ±5 percent with the TRM sitting level. Each TRM shall be provided with a fuel level gauge stick to physically measure the amount of fuel in the tank through the manhole. A storage location shall be provided on the top of the TRM for the gauge stick.

3.5.6.1.8 TRM interconnection. The TRM shall be capable of being interconnected to another TRM positioned 30 feet apart using non-collapsible hose as specified in 3.5.7.1. The

TRM shall have the ability to interconnect, within the terrain features that might be encountered, to allow for filling and dispensing from more than one TRM at a time. Each TRM shall have provisions that allow the MFS to add TRMs, up to the maximum number of TRMs as specified herein, once the MFS is set up and the suction manifold is full of fuel, without spilling fuel.

Provisions shall minimize pressure drop at the maximum extent.

3.5.6.1.8 Structural durability. Throughout the range of fuel payloads, the MFS shall be capable of withstanding loading and unloading operations to and from the HEMTT-LHS, PLS truck, PLS trailers, and capable of being transported as defined in this document without spilling fuel, developing leaks, or incurring damage, deformation or degradation of the TRM or components. All external TRM dimensions shall be maintained within the allowable tolerances of ISO 668. All TRMs shall meet the applicable requirements of DOT 49 CFR 178.345-3(a), DOT 49 CFR 178.345-4(a), DOT 49 CFR 178.345-6, DOT 49 CFR 178.345-8(b)(2), DOT 49

CFR 178.345-8(c)(1), DOT 49 CFR 178.345-8(c)(2), DOT 49 CFR 178.346-1(b) and DOT 49

CFR 180.411(b). Structural requirements for the tank and all associated hardware and the fluid areas filled to the shipping configuration, shall withstand minimum deceleration forces of 3G longitudinally, 2G vertically up, 1.5 laterally, and 4.5 G vertically down. The tank and associated components shall withstand external loss of pressure up to 13psi.

3.5.6.1.9 Detachable ladder. A ladder shall be provided to safely perform operator-level

Preventive Maintenance Checks and Services (PMCS) and to get access to the stowage cabinet.

The ladder shall be one-person portable and securely stowed on each TRM within the exterior dimensions of the ISO envelope. The ladder shall comply with paragraphs 3.7.1.1 and 3.7.1.2 herein and 29CFR1910.26. The ladder interface points shall be located where PMCS shall be conducted and compatible with the TRM ladder, the PLS ladder, and the HEMTT ladder.

3.5.6.1.10 Pumping assembly. The TRM shall be equipped with pumping capability to dispense filtered fuel at a rate of 17 gpm (threshold) with a desired rate of 50 gpm (Objective).

The rated capacity of the pump shall apply to the designated primary fuel as specified in paragraph 3.5.9 herein. The pump shall be self priming within two minutes of start and shall not require fuel to be poured into the casing for an initial prime. The system shall have the capability to operate at no flow conditions for up to five minutes without harm. The pump shall be continuous-duty for a minimum of two hours and comply with all requirements herein. The

TRM shall be capable of dispensing fuel by gravity flow, while mounted on HEMTT-LHS, PLS truck, and PLS trailer, a minimum of 99 percent of the tank volume. The system shall be capable of evacuating/draining all lines, hoses, and components downstream of the pump. The pumping assembly shall include an adequate number of hose(s) equipped with quick disconnect fittings to allow refueling of vehicles and equipment positioned a minimum of 25 feet away from the TRM.

All pump intake openings should have a removable, cleanable screen to prevent foreign objects from entering the pump. The pumping assembly shall be protected against severe environmental conditions as specified in paragraph 3.8 herein. The pumping assembly shall be capable of withstanding vibration stresses induced by the various modes of transportation without permanent damage, deformation, or performance degradation such as, but not limited to, leaks.

The pump shall be easily removable for maintenance and be capable of being carried by two

MOS 92 soldiers. If the pump is driven by an electric motor, the TRM shall have a remote control on a cable for switching the pump ON/OFF from a location up to 40-feet from the pump.

The remote ON/OFF power switching device shall not interfere with the operation of any other electrical equipment. The cable for the remote power switch shall connect to the pump using a standard connector so the cable and control can be replaced if it is damaged. The pumping assembly shall have an three-position toggle switch mounted on the TRM, to control the pump without the remote power switch. The three-position toggle switch shall be hermetically sealed, and shall be marked for positions to control whether pump is "OFF", "MANUAL ON" (with or without the remote power switch connected), and "REMOTE" selections. The pumping assembly shall include means to prevent unauthorized use.

3.5.6.1.11 Filtration and Water Separation System. The filtration and water separation system shall be capable of removing sediment and undissolved water from bulk fuel at the maximum rated flow of the pumping assembly. The performance of the filtration and water separation system shall be IAW API/IP Specification 1581 Fifth edition, Category M, Type S.

Mandatory filter/separator accessories are required and as specified herein. The filtration and water separation system shall be capable of providing direct reading of differential pressure across the filtration and water separation system without the manipulation of valves. The differential pressure gauge shall have an accuracy of +/- 0.5 psi and shall not require periodic calibration. A means to prevent sediment from obstructing proper operation of the filtration and water system shall be provided. The gauge or device shall be color-coded to indicate ‗normal operating conditions‘, ‗marginal operating condition‘, and ‗immediate service required‘ ranges according to filter-coalescer element manufacturer‘s recommendation. The filtration and water separation system shall be provided with a device to manually or automatically vent trapped air from the top of the filtration and water separation system while minimizing release of fuel during venting. The filtration and water separation system shall be provided with a device to manually drain the water from the sump under operating conditions. The filtration and water separation system shall be provided with a sight gauge that shall clearly show the level of collected water within the sump. A mark on this sight gauge shall be provided to indicate when the water should be discharged before it reaches the bottom of the elements. The discharge outlet shall be equipped to control the discharge flow and direct it safely into an appropriate size and type receptacle. A means to draw fuel samples from the center of fuel flow shall be provided at both the inlet and outlet of the filtration and water separation system. A quick disconnect coupler with dust plug shall be provided at each sampling point. The quick disconnect coupler shall interface with Gammon Actuator Nipple, model GTP-772 (or equivalent) without binding or leaking during sampling. The filtration and water separation system shall be capable of withstanding a hydrostatic test pressure of 60 pounds per square inch (psi) for 10 minutes without leaks or degradation of performance. To insure proper interface and interchangeability with existing US Army filter/separator vessels, the filtration and water separation system shall incorporate filter-coalescer elements fabricated and assembled to the form and dimensions IAW

DESC-X-P-2, Category 2 or 3 (API 6 by 22 inch, or MIL-PRF-52308).

3.5.6.2 Pump Rack Module (PRM). The MFS shall include a PRM capable of refueling both ground vehicles and aircraft. The PRM shall be capable of being transported by the

HEMTT-LHS, PLS, and PLS trailer. All necessary fittings shall be provided to connect the

Hammonds fuel additive injector, part number 4TP-4A-800MIL to the outlet of the pumping assembly IAW 3.5.6.3. The PRM shall contain secure storage as specified in paragraph 3.5.5 and 3.5.5.1 for all hoses, fittings, nozzles, fire extinguishers, petroleum test kit, fuel spill control kit, and other equipment necessary to perform refueling operation.

3.5.6.2.1 Pumping assembly. The pumping assembly shall consist of a self-priming pump and a power source. The pumping assembly shall be easily removable from its module for maintenance purposes.

3.5.6.2.1.1 Pump capacity. The PRM, when connected to the fuel additive injector as specified in paragraph 3.5.6.2, shall be capable of providing filtered fuel according to the following scenarios: bulk refueling at a rate of 400 gallons per minute (GPM) (threshold) and

600 GPM (objective), retail-refueling at a rate of 50 GPM to eight nozzles simultaneously.

Spacing between the dispensing points and PRM shall be a minimum of 100 feet. The system shall have the capability to operate at no flow conditions for up to 5 minutes without harm. The pumping assembly shall operate continually for four hours at maximum performance without being refueled or serviced.

3.5.6.2.1.2 Filtration and Water Separation System. The filtration and water separation system shall be capable of removing sediment and undissolved water from bulk fuel at the maximum rated flow of the pumping assembly. The filtration and water separation system shall be IAW API/IP Specification 1581 Fifth edition, Category M, Type S. Mandatory filter/separator accessories are required and as specified herein. The filtration and water separation system shall be capable of providing direct reading of differential pressure across the filtration and water separation system without the manipulation of valves. The differential pressure gauge shall have an accuracy of +/- .5 psi and shall not require periodic calibration. A means to prevent sediment from obstructing proper operation shall be provided. The gauge or device shall be color-coded to indicate normal operating conditions, marginal operating condition, and immediate service required ranges according to filter-coalescer element manufacturer‘s recommendation. The filtration and water separation system shall be provided with a device to manually or automatically vent trapped air from the top of the filtration and water separation system while minimizing release of fuel during venting. The filtration and water separation system shall be provided with a device to manually drain the water from the sump under operating conditions. The filtration and water separation system shall be provided with a sight gauge that shall clearly show the level of collected water within the sump. A mark on this sight gauge shall be provided to indicate when the water should be discharged before it reaches the bottom of the elements. The drain shall maximize water removal and inhibit discharge of fuel with the water. The discharge outlet shall be equipped to control the discharge flow and direct it safely into an appropriate size and type receptacle. A means to draw fuel samples from the center of fuel flow shall be provided at both the inlet and outlet of the filtration and water separation system. A quick disconnect coupler with dust plug shall be provided at each sampling point. The quick disconnect coupler shall interface with Gammon Actuator Nipple, model GTP-

772 (or equivalent) without binding or leaking during sampling. The filtration and water separation system shall be capable of withstanding a hydrostatic test pressure IAW ASME

BPVC, Sec. VIII, Div. 1. The filtration and water separation system shall incorporate filter-coalescer elements fabricated and assembled to the form and dimensions shown in MIL-PRF-

52308 Figure 1 and Figure 2 to insure proper interface and interchangeability with existing US

Army filter/separator vessels.

3.5.6.2.2 Power source. The power source shall be capable of meeting all performance requirements specified herein. The power source shall be compliant with EPA Tier II non-road exhaust emission standards. Pollution control technologies that are impacted by the sulfur level of the JP-8 fuel either in maintenance or life expectancy shall not be used, e.g., externally cooled

Exhaust Gas Recirculation (EGR), NOX traps, catalytic converters, etc. In addition, lubricity canisters/filters should not be required for proper power source operations. The power source shall be capable of starting and operating in all environmental conditions referenced in section

3.8, and shall be capable of operating on all fuels for extended periods (over 1 year) specified in section 3.5.9 at rated system capacity without damage. The power source shall be equipped with a device to prevent the engine from pumping over the hose maximum pressure, or any other components of the MFS. It shall also be equipped with an integral recharging capability to maintain sufficient battery charge during all modes of operation as specified herein. All lines including fuel lines and fuel line fittings shall be protected from any accidental contact and damage by foreign objects and components of the PRM including the pumping assembly. The exhaust system shall prevent any interference and/or cumulative damage to any part of the PRM such as, but not limited to, the emergency shut off line, and shall be physically safe so as not to be a hazard to operating personnel. The fuel cap shall not leak during any mode of operation, including loading and unloading the PRM.

3.5.6.2.3 Starting system. The PRM power source shall be equipped with electric start capability.

3.5.6.2.4 Control panel. Each PRM shall be equipped with an integrated control panel containing all necessary controls required to operate the pump assembly including an engine-hour meter. Sufficient indicators shall be provided to inform the user of operating status at all times, under both conditions of normal operation and activation of system shut-offs. The control panel shall include an indicator for monitoring system voltage. The control panel shall meet the requirements for NEMA 250 Type 4X enclosures to protect against severe environmental conditions. All switching components shall be hermetically sealed. The control panel shall have the capability of displaying at least volumetric flow rate and the differential pressure across the filtration system to an accuracy of ± two percent (2%). All control panel components including circuit boards, switches, and light-emitting diodes (LEDs) shall be replaceable within ten minutes without special tools (see 3.7.4.2). The control panel shall include the power source‘s diagnostic connector. The diagnostic connector shall be attached to the panel for connecting to the test, measurement, and diagnostic equipment (TMDE) without damaging the connector or wiring. The control panel shall be easily operable by soldiers wearing MOPP IV as specified in

3.7.2. Controls, gauges, and indicators shall be readable in direct sunlight. A space of 25"(L) x

28"(W) x 11"(D) underneath the control panel shall be provided to enable the installation of a tactical display control unit.

3.5.6.2.4.1 Operational fault controls. In addition to the emergency manual stop, as a minimum operational automatic fault shut-offs shall be incorporated into the PRM to prevent system damage or minimize hazard to personnel as a result of:

a. Engine overspeed, low operating pressure, high product temperature, and high engine temperature;

b. Low fuel level/run-dry operation;

c. Excessive electrical currents and voltages (if system is equipped with an on-board electrical power generator)

d. High or low pumping assembly suction and discharge pressure.

When a shut-off is activated, sufficient indication of the condition(s) shall be provided to the operator via the control panel. After the condition that caused activation of the shut-off is resolved, the system shall be capable of resetting to normal operating status. Manual override of shut-off shall be provided. A toggle switch shall be provided on manual overrides. Each toggle switch shall include a red toggle switch safety cover in order to prevent any accidental manipulation of the override.

3.5.6.2.4.2 Lighting. The control panel shall be backlit to allow operation in reduced daylight visibility, nighttime, and blackout conditions.

3.5.6.2.4.2.1 Non-tactical conditions. Permanent backlighting shall be provided to ensure safe operation of the control panel in darkness and periods of reduced visibility. Lighting shall allow the reading of dials and gages, the reading of item identifications, instructions, and warnings, and the operation of switches and controls. Control panel illumination shall not require dark adaptation by the user.

3.5.6.2.4.2.2 Tactical/blackout operations. The control panel shall provide tactical/blackout lighting that meets the following requirements:

a. Ninety-five percent of the light energy emitted by each light source shall be at wavelengths below 700 nanometers.

b. All lighting shall be dimmable to 0.05 foot-Lamberts (fL) or less.

c. All light sources shall be controlled by a single on-off blackout switch, labeled

―LIGHTS.‖

3.5.6.2.5 Emergency shutoff. The MFS shall be equipped with a manual shutoff capability located at the operator‘s position that stops the flow of fuel within 5 seconds after activation in the event of an emergency. In addition to the manual shut-off, the PRM shall include a reel-mounted "dead-man" switch that, when released, stops the flow of fuel from the filtration unit.

3.5.6.2.6 Fuel supply. The PRM shall have an integral fuel supply capacity sufficient to allow no less than 4 hours of operation under full load. Fuel re-supply shall be supplied to the

PRM from the pumpage.

3.5.6.3 Piping system. The piping system shall be designed to allow easy access to all components for maintenance, repair and operation. The piping system shall be designed to prevent contact between the bulk fuel and other operating fluids. All discharge hoses and connections specified herein shall be equipped with sexless dry disconnect fittings IAW A-A-

59377, with captive dust caps. All ports, with the exception of top loading, shall be equipped with shut-off valves. All ports shall be located within the TRM/PRM ISO structure and shall not overlap with the TRM/PRM ISO frame. A shut-off valve shall be provided at all tank/piping system interfaces to allow flow stoppage from the tank. All valves or valve controls shall be easily accessible and identifiable to the operator and shall have provisions that inform the user of operating status (open or closed). Retaining lanyards are not an acceptable solution to securely attach label/tags to the valves. The piping system shall meet the requirements of DOT

49CFR178.345-11(d) as applicable.

3.5.6.3.1 Emergency valve. Each TRM shall be equipped with a self-closing shut-off valve IAW NFPA 385 (paragraph 2-4) to allow flow stoppage from the tank. The emergency valve shall prevent any unintended opening through impact or other inadvertent act. The shut-off valves shall be equipped with a control system that includes a mechanism that permits automatic valve closure of valves in case of emergencies. The setting of the valve (open or closed) shall be easily identifiable from the ground. The operator shall be able to manually and remotely open or close the emergency valve from a control assembly. The valve shall continue to be effective in the event of damage to the external device for controlling the operation of the valve. The controls for manual emergency valve closure shall be located on both sides of the

TRM. Each control location shall be stenciled with the words ―EMERGENCY SHUT-OFF‖.

3.5.6.3.2 Inspection and clean-out.