ATT_F_-_FM_10-67-1_-_Concepts_and_Equipment_of_Petroleum_Operations.pdf

FM 10-67-1

HEADQUARTERS

DEPARTMENT OF THE ARMY

CONCEPTS AND EQUIPMENT

OF PETROLEUM

OPERATIONS

DISTRIBUTION RESTRICTION:

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED

Attachment F - Concepts and Equipment of Petroleum Operations For Bidding Purposes Only

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*FM 10-67-1

i

FIELD MANUAL

Headquarters No. 10-67-1 Department of the Army

Washington, DC, 2 April 1998

CONCEPTS AND EQUIPMENT OF

PETROLEUM OPERATIONS

Table of Contents

Page PREFACE iv

PART ONE -GENERAL CONSIDERATIONS

CHAPTER 1. ENVIRONMENTAL RESPONSIBILITY 1-1

CHAPTER 2 SAFETY, HEALTH, AND FIRE FIGHTING 2-1

Section I General Safety 2-1 Section II Petroleum Fire Fighting 2-14 Section III Aircraft Refueling Safety 2-18 Section IV Health Hazards 2-26

CHAPTER 3 QUANTITY AND QUALITY CONTROL 3-1

Section I Accountability and Inventory 3-1 Section II Petroleum Product Measurement 3-7 Section III Sampling 3-5 Section IV Petroleum Quality Maintenance 3-31

PART TWO-PETROLEUM TERMINAL AND PIPELINE OPERATIONS

CHAPTER 4 WATERFRONT OPERATIONS 4-1

Section I Loading and Unloading Facilities 4-1 Section II Tank Vessels 4-4 Section III Loading and Unloading Operations 4-7

CHAPTER 5 OFFSHORE PETROLEUM DISCHARGE SYSTEM 5-1

Section I OPDS Tankers 5-1 Section II Major Components (OPDS) Tanker 5-2 Section III Beach Termination Unit Procedures 5-10 Section IV Planning and Administrative Considerations 5-13 Section V Communications and Installation 5-13

CHAPTER 6 TACTICAL PETROLEUM TERMINAL (TPT) 6-1

Section I Concept and Primary Components 6-1 Section II System Components` 6-5 Section III Tank Farm Installation 6-12 Section IV Terminal Operations 6-27 Section V Maintenance 6-32

DISTRIBUTION RESTRICTION: Approved for public release; distribution is unlimited.

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*This publication supersedes FM 10-18, 03 Dec 1986; FM 10-20, 29 Feb 1984; FM 10-68, 29 May 1987;

FM 10-69, 22 Oct 1986; FM 10-70-1, 27 Dec 1983, FM 10-71, 12 May 1978.

CHAPTER 7 INLAND PETROLEUM DISTRIBUTION SYSTEM (IPDS) 7-1

Section I System Components 7-1 Section II Installation 7-10 Section III System Operation 7-16 Section IV Maintenance 7-27

CHAPTER 8 CONTROL OF PRODUCT IN PIPELINES 8-1

CHAPTER 9 PIPELINE OPERATIONS 9-1

Section I Duties of Personnel 9-1 Section II Pipeline Communications System 9-3 Section III Schedules 9-5 Section IV Line Operations 9-10 Section V Dispatching Records and Controls 9-13

CHAPTER 10 PETROLEUM INSTALLATION MAINTENANCE 10-1

Section I Tank Farms and Pipeline Surroundings 10-1 Section II Waterfront Facilities 10-4

CHAPTER 11 TANK CAR OPERATIONS 11-1

Section I Tank Cars and Facilities 11-1 Section II Procedures for Loading Tank Cars 11-5 Section III Procedures for Unloading Tank Cars 11-9

CHAPTER 12 TANKS, TANK CARS, AND TANK VEHICLES MAINTENANCE

AND CLEANING

12-1

Section I Storage Tanks and Tank Maintenance 12-1 Section II Tank Cleaning Precautions and Equipment 12-12 Section III Storage Tank Cleaning 12-18 Section IV Tank Car and Tank Vehicle Cleaning 12-27

PART THREE-AIRCRAFT REFUELING

CHAPTER 13 AVIATION FUELS 13-1

Section I Description of Fuels 13-1 Section II Quality Surveillance 13-2

CHAPTER 14 AIRCRAFT REFUELING EQUIPMENT 14-1

CHAPTER 15 REFUELING FROM REFUELING SYSTEMS 15-1

Section I Forward Area Refueling Equipment 15-1 Section II Temporary amd Semipermanent Refueling Systems 15-11 Section III HEMTT Tanker Aviation Refueling System 15-24 Section IV Fatcow (CH-47) Fare 15-33 Section V C-17 FARP Using the HTARS 15-34

CHAPTER 16 REFUELING FROM TANK VEHICLES 16-1

Section I Refueling Vehicles 16-1 Section II Refueling Operations 16-3

CHAPTER 17 DEFUELING 17-1

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CHAPTER 18 OTHER WAYS OF TRANSPORTING PETROLEUM 18-1

Section I External Loads 18-1 Section II Aerial Bulk Fuel Delivery System 18-8 Section III Wet-Wing Defueling 18-12

CHAPTER 19 AIRCRAFT FIRE FIGHTING AND RESCUE TRAINING 19-1

Section I Basic Fire-Fighting Training 19-1 Section II Basic Crash Rescue Training 19-8 Section III Tactical Fire-Fighting and Rescue Training 19-12

PART FOUR-PETROLEUM SUPPLY POINT OPERATIONS

CHAPTER 20 PUMPS 20-1

Section I Hand-Operated Pumps 20-1 Section II Power-Driven Pumps 20-3

CHAPTER 21 FILTER/SEPARATORS 21-1

CHAPTER 22 STORAGE CONTAINERS AND HANDLING EQUIPMENT 22-1

Section I Packaged Petroleum Products and Fuels 22-1 Section II Bulk Petroleum Containers 22-14

CHAPTER 23 FUEL SYSTEM SUPPLY POINT 23-1

CHAPTER 24 UNIT AND VEHICLES USED TO TRANSPORT BULK

PETROLEUM

24-1

Section I Tank and Pump Unit 24-1 Section II Tank Trucks 24-6 Section III Tank Semitrailers 24-10 Section IV Other Considerations of Tank Vehicles 24-24

CHAPTER 25 REFUEL ON THE MOVE 25-1

CHAPTER 26 CLASS III SUPPLY POINT 26-1

Section I Movement 26-1 Section II Site Selection 26-4 Section III Layout 26-7 Section IV Operation 26-12

CHAPTER 27 HOSELINE OUTFIT (ASSAULT HOSE LINE) 27-1

CHAPTER 28 RECEIPT, STORAGE, AND ISSUE OF BULK PETROLEUM 28-1

Section I Bulk Petroleum Operations 28-1 Section II Receipt 28-2 Section III Storage 28-7 Section IV Issue 28-8

APPENDIX A ALLOWABLE OUTAGE FOR EXPANSION OF PETROLEUM

PRODUCTS IN STORAGE TANKS

A-1

APPENDIX B TANK STRAPPING B-1

APPENDIX C FUNDAMENTALS OF PIPELINE HYDRAULICS C-1

Section I Physical Properties of Petroleum Liquids C-1

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Section II Flow in Pipelines C-7 Section III Examples of Flow C-18

APPENDIX D PMCS CHECKLISTS D-1

APPENDIX E WATER DETECTION (AQUA-GLO) TEST E-1

APPENDIX F PROCEDURES FOR TESTING RESISTANCE TO GROUND F-1

APPENDIX G FILTER MEMBRANE COLOR RATINGS FOR PARTICULATE

CONTAMINATION IN AVIATION TURBINE FUELS

G-1

APPENDIX H STANDARD PETROLEUM CONTAINERS H-1

APPENDIX I VOLUME CONVERSION I-1

APPENDIX J CHECKLIST FOR DELIVERY AND UNLOADING J-1

APPENDIX K CONVERSION CHARTS FOR TANK CARS, TANK TRUCKS AND

US/NATO FUEL CODES AND PLACARD ID NUMBERS

K-1

APPENDIX L PETROLEUM PRODUCT AND CRUDE OIL FACTORS L-1

APPENDIX M FLOW CONVERSION CHART M-1

APPENDIX N MATERIAL SAFETY DATA SHEETS N-1

APPENDIX O FORCE PROVIDER O-1

GLOSSARY Glossary-1

Section I Acronyms and Abbreviations Glossary-1

Section II Terms Glossary-5

REFERENCES Reference-1

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INDEX Index-1

PREFACE

This manual is a guide for commanders, staff officers, supervisors, and other personnel concerned with petroleum concepts, equipment, and operations.

This manual is a consolidation of FMs 10-18, 10-20, 10-68, 10-69, 10-70-1, and 10-71. This manual is divided into four parts. Part One describes general considerations of petroleum operations to include environmental protection, safety, and accountability. Part Two describes bulk petroleum distribution systems. Part Three describes Army aircraft refueling operations. Part Four describes petroleum handling equipment as well as Class III supply point operations. This manual is oriented toward tactical field operations and deals with the responsibilities of both management and operator personnel. It can be used in conventional and NBC warfare.

However, this manual cannot be cited as an authority for requisitions. Requisitions must be based on authority such as tables of allowances or TOEs.

The proponent for this publication is HQ TRADOC. Send comments and recommendations on DA FORM 2028 (Recommended Changes to Publications and Blank Forms) directly to:

COMMANDER

USACASCOM TRAINING DIRECTORATE

ATTN ATCL AQ

801 LEE AVENUE

FORT LEE VA 23801-1713

Unless this publication states otherwise, masculine nouns and pronouns do not refer exclusively to men.

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PART ONE

GENERAL CONSIDERATIONS

The three chapters in this part give general considerations for all petroleum operations in the areas of environmental protection, safety, and accountability. This includes general guidelines for conducting any type of aviation-related activities, to include refueling operations. The rest of the chapters in the book give specific considerations in these areas related to various types of petroleum operations. Anyone involved in planning, evaluating, or conducting petroleum operations should be thoroughly familiar with the contents of these three chapters. They should routinely refamiliarize themselves with them, as well as the other chapters in the book pertaining to the type of operation with which they are involved.

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CHAPTER 1

PETROLEUM UNIT ENVIRONMENTAL RESPONSIBILITIES

“The Army environmental vision is to be a national leader in environmental and natural resource responsibilities for present and future generations as an integral part of our mission.”

SCOPE OF ENVIRONMENTAL RESPONSIBILITY

We must take care of the environment (that is, practice environmental stewardship). The definition of ste w-ardship is taking care of property while also caring about the rights of others. We must plan our operations wit h-out harming the environment. Good environmental stewardship lets leaders take care of soldiers and their fam i-lies. It also saves resources vital to combat readiness.

The Army has the huge task of reducing the environmental impact on its installations and units throughout the United States and the world. Within CONUS, the Army owns 20 million acres of land (an area about half the size of Virginia). This shows the vastness of this task. Each area of our daily operation has some effect on the env i-ronment.

The Army is renewing its emphasis on taking care of the environment. Petroleum and water units by their nature have a huge impact on the environment. It is critical for the leaders and soldiers in these units to follow safe, legal environmental practices. By doing so, they protect their health and the health of those around them.

They also prevent long term environmental damage that can lead to fines and other legal actions.

ENVIRONMENTAL PROTECTION STEWARDSHIP GOALS AND REQUIREMENTS

The Army no longer just complies with laws , they want to be a leader in environmental protection. To do this, the Army has set goals and requirements for its leaders to follow.

Goals

• Make sure operations comply with standards. Do not receive a notice of violation or a fine for not following local, state, and federal environmental regulations.

• Clean up installations. Begin restoring all contaminated sites by 2000.

• Prevent future pollution. Reduce all hazardous waste and toxic releases.

• Integrate NEPA procedures into all operations.

• Protect natural and cultural resources.

Requirements

All Army actions require an appraisal be done on potential environmental impacts of said action. All key Army decision makers and planners are required to attend NEPA training.

ROLE OF ENVIRONMENTAL STEWARDSHIP IN LEADERSHIP

A leader who cares for the environment also cares for his people. He does this by reducing or eliminating u n-due health risks. He saves resources (soldiers or money) vital to his mission. He keeps training areas in excellent condition for training far into the future. He preserves cultural artifacts for study by future generations. Also, he teaches the basic moral duty of soldiers to protect and preserve the United States of America and its allies.

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ENVIRONMENTAL RESPONSIBILITIES OF PERSONNEL

Personnel at all levels must protect our environment. This includes soldiers, NCOs, officers, commanders, and appointed personnel.

Soldiers

These duties include--

• Follow installation environmental policies, unit SOPs, ARs, and environmental laws and regulations.

• Make sound decisions in everyday activities.

• Advise the chain of command on techniques to ensure environmental regulations are followed.

• Identify the environmental risks in individual and team tasks.

• Support the Army recycling program.

• Report HM and HW spills immediately.

NCOs

These responsibilities include--

• Always consider the environment in day-to-day decisions.

• Make sure soldiers know the Army’s environmental ethic.

• Train soldiers to be good environmental stewards.

• Be committed to environmental protection.

• Identify environmental risk associated with tasks.

• Plan and conduct environmentally sustainable actions and training.

• Protect the environment during training and other activities.

• Analyze the influence of the environment on your mission.

• Integrate environmental considerations into unit activities.

• Train peers and soldiers to identify the environmental effects of plans, actions, and missions.

• Counsel soldiers on the importance of protecting the environment and the results of not complying with e n-vironmental laws.

• Incorporate environmental considerations in AARs.

• Support the Army recycling program.

• Report HM and HW spills immediately.

Officers

These duties include--

• Build an environmental ethic in soldiers.

• Train and counsel subordinate leaders on stewardship.

• Seek advice on required personnel training from the local environmental coordinator.

• Lead by example.

• Enforce compliance with laws and regulations.

• Always consider the environment in making day-to-day decisions.

• Make sure subordinates know the Army’s environmental ethic.

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• Train subordinates to be good environmental stewards.

• Commit subordinate leaders to protect the environment.

• Analyze the influence of the environment on the mission.

• Integrate environmental considerations into unit activities, to include identifying the environmental risks a s-sociated with unit tasks.

Unit Commanders The commander must build an environmental ethic in his soldiers. The commander sets the tone for enviro n-mental compliance. He is totally responsible for complying with all applicable environmental laws in the unit.

Commanders train their subordinates on stewardship and counsel them on doing what is right. They must lead by example and enforce compliance with laws. Commanders should--

• Seek advice on required personnel training from the local environmental coordinator.

• Consider the environment in making daily decisions.

• Know about the NEPA, HM, HW, HAZCOM efforts, and spill contingencies.

• Commit subordinates to environmental protection.

• Make sure officers and NCOs know the environmental ethic and train them to be good environmental ste w-ards.

• Counsel officers and NCOs on the importance of protecting the environment and the results of violating laws.

• Ensure officers and NCOs comply with requirements when reporting hazardous substance spills.

• Ensure environmental concerns are addressed throughout the training.

• Identify and assess the environmental consequences of proposed programs and activities.

• Plan and conduct training that complies with environmental laws--including marking areas as “off-limits” during training exercises.

• Discuss environmental concerns during briefings, meeting, and AARs.

• Establish and sustain unit environmental awareness training.

• Appoint an environmental compliance officer and a HW coordinator (the same person can serve both pos i-tions). These appointments ensure environmental compliance occurs at the unit level.

• Ensure the unit SOP covers environmental considerations, conservation, natural resources, and spill proc e-dures.

• Support the Army pollution prevention/recycling program.

• Report HM and waste spills immediately.

• Conduct environmental self-assessment or internal environmental compliance assessments.

• Meet with key installation environmental POCs.

Appointed Personnel

These personnel are appointed by the commander and should receive formal training. Their responsibilities include--

• Act as an advisor on environmental regulatory compliance during training, operations, and logistics fun c-tions.

• Serve as the commander’s eyes and ears for environmental matters.

• Be the liaison between the unit and higher headquarters who are responsible for managing the enviro n-mental compliance programs and who can provide information on training requirements certifications that unit personnel need.

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THE UNIT-LEVEL ENVIRONMENTAL TRAINING PROGRAM

An effective training program allows personnel to carry out their responsibilities. TC 5-400 is the basic ma n-ual for environmental stewardship. Commanders ensure all personnel are trained on environmental issues. He appoints an environmental compliance officer/HW coordinator. This person works with other environmental pe r-sonnel. He also makes sure environmental laws are followed. The commander meets with the battalion S3 and S4 officers and other environmental personnel. He finds what their requirements concerning environmental training and qualifications of unit personnel, ECAS inspections that may affect the unit, and common environmental pro b-lem areas and how to avoid them. The commander also makes sure the SOP details environmental issues and pr o-cedures the unit must follow. The training program should cover—

• HM management

• HW management

• HAZCOM

• Pollution prevention and HAZMIN

• Recycling program

• Spill prevention/response plan

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CHAPTER 2

SAFETY, HEALTH, AND FIRE FIGHTING SECTION

Section I. General Safety

GENERAL PETROLEUM SAFETY

Handling petroleum products presents many unique safety hazards. However, handling POL products co r-rectly is very safe. This chapter gives POL receipt, storage, and issue safety procedures. Table 2-1, page 2-2, lists some general safety procedures. Explosions and fires caused by ignition of combustible mixtures of POL vapors and air causes some of the most serious POL-related accidents. Thus, controlling POL vapor formation and ign i-tion sources at all times is critical. Table 2-2, page 2-3, and Table 2-3, page 2-4, give control methods. Table 2-4, page 2-5, gives safety precautions unique to POL transfer and storage.

SAFETY TRAINING

Safety training is the key to preventing accidents. Safety training must start during the soldier’s initial entry training and it must continue throughout his military service. All fuel handlers should know about petroleum.

They must also know the safety principles for handling and using petroleum products. In addition, they should know self-care techniques, fire prevention, and first aid and emergency safety proc edures.

PETROLEUM FIRE AND EXPLOSION HAZARDS

The primary danger while handling petroleum is the chance of a fire or explosion. The paragraphs below d e-scribe petroleum properties affecting flammability and explosive characteristics. They also discuss issues and techniques related to reducing the chance of fire and explosion when storing and handling petroleum products.

Here are some terms that you must know.

Flash Point

A fuel’s flash point is the lowest temperature the fuel’s vapor will catch fire momentarily (flash) when exposed to a flame. The lower a fuel’s flash point, the more dangerous it is. Some sample flash points are: AVGAS, -50°F, JP-4, -10°F; and JP-8, 100°F. These flash points show that fuels give off ignitable vapors at temperatures normally found in Army units. Aviation-related fuels can ignite even in sub-zero temper atures.

Explosive Range

Petroleum vapor and air may form a range of mixtures that are flammable, and possibly explosive. This range is called the mixture’s “flammability limit,” “explosive range,” or “explosive limit.” A mixture in the explosive range ignites when it contacts a spark, flame, or other ignition source. In open spaces, this causes an intense fire.

In enclosed spaces (such as an empty tanker), the mixture explodes. Gasoline’s explosive range, for example, is from 1 to 8 percent by volume of gasoline vapor per given air volume . Any mixture above 8 percent by volume of gasoline vapor does not ignite because it is too “rich.” For example, there is not enough oxygen present to burn the fuel. This is known as the mixture’s upper explosive limit. A mixture less than 1 percent by volume of gasoline vapor does not ignite because it is too “lean.” For example, there is not enough fuel in the air to burn. This is known as the mixture’s lower explosive limit. A mixture’s lower explosive limit is formed at about the product’s flash point. Thus, AVGAS vapors can burn or explode at temperatures as low as -50 °F. Explosive ranges vary among fuel types. They form over temperature ranges normally found by the military. The key point is an empty or nearly empty petroleum tank or container is still very dange rous due to remaining fuel vapors.

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Table 2-1. Petroleum safety precautions.

RULES REMARKS

No Smoking Strictly enforce NO SMOKING rules.

No Smoking Signs Post NO SMOKING WITHIN 50 FEET signs where they can be seen.

Fire Extinguishers Place fire extinguishers and other fire fighting equipment within easy reach but where it will be safe from a fire.

Flame-and Spark- Producing Equip-ment

Do not use open flames, heating stoves, electrical tools, or other such apparatus in p e-troleum storage and work areas.

Explosion-Proof Equipment

Use only authorized tools, equipment, and clothing. Use explosion proof lights and flashlights.

Tools Keep tools and equipment in safe and good working condition.

Equipment Bonding and Grounding

Bond and ground pumps, tank vehicles, and storage tanks.

Notched-Handle Nozzles

Ensure notched handles are only on nozzles with automatic shutoffs. Tend all nozzles constantly while they are being used in refueling operations. If you must use notched handles on nozzles that do not have automatic shutoffs, make sure the notches are modified so that the nozzles must be held open by hand.

Spills Control spills with a proactive spill prevention program. Immediately clean up and report spills.

Leaks Place drainage tubs or containers under hose connections, faucets, and similar equi p-ment. Repair leaks at once. Replace defective hoses, gaskets, and fa ucets.

Inspections Inspect equipment, safety devices, and work areas frequently to ensure safety and to correct hazards.

Ventilation Make sure work and storage areas are well ventilated.

Fuel Vapors Avoid exposure to fuel vapors for long periods.

Protective Clothing Wear fuel-resistant or rubber gloves and protective clothing to keep fuel off the skin.

Wear ear protection when working in high noise a reas.

Work Area Keep the work area free of loose tools, lumber, and other objects that may cause acci-dents.

First Aid Training Train personnel to give first aid and artificial respiration.

Solvents Use only authorized solvents for cleaning.

Flame and Spark Arrestors

Put flame and spark arrestors on all equipment in and near petroleum storage areas.

Nylon Clothing Never wear nylon clothing when handling petroleum because high electrostatic charges build up in nylon fabric.

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Table 2-2. Precautions for controlling vapor formation.

RULES REMARKS

Avoid spills. Fill container carefully (whether filling a 5-gallon can, tank vehicle, or storage tank) and avoid overflow.

Use drip pans, catch basins, or absorbent materials.

Place them where there may be drips or spills.

Inspect frequently for leaks.

Always inspect tank seams, joints, piping, valves, or pumps for leaks.

Clean up spills or leaks at once.

Treat the area as especially hazardous until vapors are gone. When v a-pors are gone, remove the spill.

Beware of flammable vapors in empty con-tainers.

Be very careful around empty pipeline or storage tanks, drums, cans, or containers that have held a flammable product. They are potentially more dangerous than a filled container.

Inspect drums and containers before use.

Inspect drums and containers before using. Mark them with some sign of approval if they are fit for use.

Keep containers closed.

Close empty or full containers for flammable products.

Open drum bungs carefully.

Be very careful when opening drums filled with flammable products if the drums have been subjected to increased temperature or agitation since they were filled. This prevents the sudden release of pressure that can produce a vapor-air mixture that may include some product.

Beware of unventi-lated spaces.

Be careful around unventilated or confined spaces or pits.

Do not use gasoline for cleaning.

Do not use gasoline and carbon tetrachloride (because it is toxic) for cleaning. Use only authorized cleaning solvents

Consult with others when conducting ventilating and vapor-freeing operations.

Consult other area operations that could be sources of ignition

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Table 2-3. Precautions for controlling ignition sources

RULES REMARKS

No Smoking Strictly enforce NO SMOKING rules. Post NO SMOKING WITHIN 50 FEET signs where they can be seen.

No Matches or Cigarette Lighters

Collect matches and cigarette lighters at the checkpoint before entering the faci l-ity.

No handling of Products During Electrical Storms.

Place fire extinguishers and other fire fighting equipment within easy reach but where it will be safe from a fire.

Disposal of Waste Do not use open flames, heating stoves, electrical tools, or other such apparatus in petroleum storage and work areas.

Explosion-proof Equipment

Use only authorized tools, equipment, and clothing. Use explosion proof lights and flashlights.

Tools Keep tools and equipment in safe and good working condition.

Equipment Bond-ing and Grounding

Bond and ground pumps, tank vehicles, and storage tanks.

Notched-Handle Nozzles

Ensure notched handles are only on nozzles with automatic shutoffs. Tend all nozzles constantly while they are being used in refueling operations. If you must use notched handles on nozzles that do not have automatic shutoffs, make sure the notches are modified so that the nozzles must be held open by hand.

Spills Control spills with a proactive spill prevention program. Immediately clean up and report spills.

Leaks Place drainage tubs or containers under hose connections, faucets, and similar equipment. Repair leaks at once. Replace defective hoses, gaskets, and fa ucets.

Inspections Inspect equipment, safety devices, and work areas frequently to ensure safety and to correct hazards.

Ventilation Make sure work and storage areas are well ventilated.

Fuel Vapors Avoid exposure to fuel vapors for long periods.

Protective Clothing Wear fuel-resistant or rubber gloves and protective clothing to keep fuel off the skin. Wear ear protection when working in high noise a reas.

Work Area Keep the work area free of loose tools, lumber, and other objects that may cause accidents.

First Aid Training Train personnel to give first aid and artificial respiration.

Solvents Use only authorized solvents for cleaning.

Flame and Spark Arrestors

Put flame and spark arrestors on all equipment in and near petroleum storage a r-eas.

Nylon Clothing Never wear nylon clothing when handling petroleum because high electrostatic charges build up in nylon fabric.

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Table 2-4. Precautions for transferring and storing petroleum products.

RULES REMARKS

Bond and ground equipment For all petroleum operations, always bond and ground equipment.

Avoid overhead filling. If you cannot avoid overhead filling, put the filling line inside the tank so that the fuel will be disturbed as little as possible.

Use walkways. Always use walkways to cross tank fire walls. Always use walkways as much as possible.

Ventilate and clean vehicles and containers.

Collapsible tanks, railway tank cars, and tank vehicles must be cleaned and ventilated as prescribed in this FM.

Observe safety rules when refueling aircraft.

Observe all safety precautions described in this chapter.

Observe safety rules when operating, loading, and transferring products.

Observe all safety precautions described in this chapter.

Vapor Pressure

Vapor pressure is a measure of a fuel’s tendency to form vapors (known as its volatility). Laboratory techn i-cians normally use the Reid method to determine a liquid’s vapor pressure. They determine vapor pressures at 100°F for comparison purposes. Knowing a liquid’s vapor pressure has little practical application for petroleum handlers. However, petroleum products’ relatively high vapor pressures (and in particular, gasoline and aviation fuels high vapor pressures) further show how easily fuels form explosive vapor mixtures in normal temper atures.

Distillation Range

Petroleum products are a mixture of hundreds of different chemical compounds. They boil (vaporize) over a relatively broad temperature range compared to pure substances. This temperature range is known as a product’s distillation range. A product’s distillation range is another relative volatility indicator. A product with a relatively low distillation range might vaporize in hoses or pumps, causing “vapor lock.” Aviation fuels in particular have distillation ranges in the temperature ranges encountered during military operations.

Electrostatic Susceptibility

This is the relative degree a fuel will take on or build up a static electrical charge. Aviation peculiar fuels (JP- 4 in particular) have relatively high electro static susceptibilities. This multiplies the danger of these highly vol a-tile, flammable f uels.

Autoignition Temperature

This is the lowest temperature a fuel itself (as opposed to its vapor) will catch fire spontaneously. Some sa m-ple autoignition temperatures are: AVGAS, 825° to 960°F; JP-4, 470° to 480°F; JP-8, 440° to 475°F. Low autoig-nition temperatures present a particular hazard in aviation refueling operations. An idling turbine engine (such as a helicopter engine) produces an exhaust with a temperature between 440 ° to 475°F. Even after the engine is shut down, its temperature stays in this range for quite a time. If this engine temperature radiates to JP-4 or JP-8, the fuel could catch fire or explode. This could happen if a helicopter exhaust blows on a piece of refuel equipment or a fuel handler drags a hose across a hot engine.

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SPECIFIC FUEL FIRE AND EXPLOSION HAZARDS

Fire and explosion hazards related to specific fuel types are given as follows.

Fuel Oil

Boiler fuels are not flammable at ordinary temperatures because of their high flash point. However, fuel oils heated above their flash points can easily ignite. They produce a hot fire that may be difficult to put out. Fuel oil also may have been mixed with lower flash point products that will increase its fla mmability.

Diesel Fuel

Diesel fuels will not ignite at normal storage temperatures unless they are contaminated with a more volatile product. They easily ignite if heated above their flash points. Once ignited, they produce a hot fire that may be hard to put out. These fuels spread quickly on both land and water and burn completely. An open flame or hot exhaust manifold can easily ignite a spray of diesel fuel from a leak or a sudden tank ove rflow.

Kerosene

Kerosene presents safety hazards similar to those of diesel fuel and fuel oil. Kerosene is not easy to ignite at normal operational temperatures. Ho wever, once it is ignited it will form a hot fire that is difficult to put out .

Gasoline

Gasoline, along with jet fuels, is a greater fire and explosion hazard than the fuels discussed above. Gasoline forms explosive mixtures above its surface, at gage openings or vents at temperatures above -70 °F. Vapors from any size gasoline spill easily form explosive mixtures. Gasoline vapors, as all petroleum vapors, are heavier than air. This causes them to spread for long distances along the ground and collect in low places. Such vapors ignite easily. The resultant flash and explosion will travel back to the fuel source igniting it. Preventing small gasoline leaks is difficult. Therefore, there is always a danger of ignition from sparks and flames in gasoline storage and handling areas. Prevent gasoline vapor accumulation by proper storage facility ventilation and maintenance.

Never allow gasoline to enter any drain line or sewer not designed to handle petroleum pro ducts.

Jet Fuels

Jet fuel flammability characteristics vary with fuel grade. However, follow the same safety precautions when handling all jet fuels. This is particularly important at large storage and handling sites where tanks and equipment handle several different fuel grades. JP-4 presents the most extreme safety hazard. JP-8 is replacing JP-4 as the Army’s primary aviation fuel. However, JP-4 is still used in some areas. JP-4 is very dangerous because it forms explosive mixtures over all normal storage and operating temperatures. It also creates large quantities of static electricity when pumped and handled. Follow these precautions when storing and handling jet f uels:

• Use as small a storage tank as necessary to support the mission. When using hard wall storage tanks, avoid shallow tanks with large surface areas for jet fuel storage. If available, use floating roof storage tanks.

• Do not use overhead fill lines that permit product free-fall.

• Keep air out of fill lines.

• Use water bottoms in fixed tanks only when absolutely necessary. When using water bottoms, keep inlet connections above the water to reduce agitation. Water with entrained air rising through fuel creates a static ele c-tricity charge. Bubbles bursting on the fuel surface also create static ele ctricity.

• When pumping fuel, you should pump at a reduced flow rate until the fuel submerges the tank inlet. Also reduce the pumping rate when the fuel level is near the tank top to reduce the risk of flas hover to parts of the roof.

• Continually check bonding and grounding connections. Take special care to bond and ground gaging and sampling equipment properly.

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ATT F - 17 02.01.2016

2-7

FUEL PROPERTIES AND BEHAVIOR AFTER COMBUSTION

Other fuel properties determine behavior after ignition. They also determine fire and explosion control mea s-ures. These properties are given below.

Heat of Combustion

One relative measure of fire intensity or severity is the amount of heat produced as the fuel burns. Aviation peculiar fuels such as JP-4 and AVGAS have higher heats of combustion than multipurpose or motor fuels.

Therefore, they produce more severe fires. In any case, all petroleum fires are intense. They require prompt action to quench the large amounts of heat they pr oduce.

Flame Spread Rate

Aviation fuels containing gasoline (AVGAS) and gasoline and kerosene mixtures (JET B, JP-4) have flame spread rates of from 700 to 800 feet per minute. Kerosene-based fuels (JP-5, JP-8, Jet A-1, DF-2) have flame spread rates of approximately 100 feet per minute. Flame spread through a mist of any fuel type is nearly instant a-neous.

Specific Gravity

Specific gravity is a relative measure of liquid density. Water’s specific gravity is 1.0. All petroleum products have a specific gravity less than 1.0. For example, AVGASs specific gravity is .70 and JP-4’s specific gravity is .78. This means they are lighter than water and will float on any water surface. Using water to put out a petr o-leum fire will cause it to spread as petroleum is carried along on the water stream flowing away from the fire. For this reason, use foams or dry chemicals, if possible, to put out petroleum fires.

Solubility

Fuels will not dissolve in water. This means water-based foams can be used for putting out p etroleum fires.

FLAMMABLE AND COMBUSTIBLE PRODUCTS

Hazardous liquids (including petroleum products) are classified as flammable and combustible. In these broad categories, there are several class designations based on a liquid’s volatility. Flammable liquids (Class I) have a flash point below 100°F (37.8 C) and a vapor pressure not above 40 PSI (absolute) at 100°F. Combustible liquids (Classes II and III) have a flash point at or above 100 ° F (37.8°C). Table 2-5 describes the various flammable and combustible liquids classes. Heated liquids are more volatile. Therefore, heated combustible liquids require the same safety precautions as flammable liquids.

Table 2-5. Flammable and combustible liquids.

CLASSIFICATION FLASH POINT (°F) BOILING POINT (°F)

Flammables:

Class 1 Class 1A Class 1B Class 1C

Combustibles:

Class II Class IIIA Class IIIB

Below 100 Below 73 Above 73 At or above 73 and below 100

At or above 100 and below 140 At or above 140 and below 200 At or above 200

Below 100 At or above 100

*Reprinted with permission from NFPA 30, Flammable and Combustible Liquids Code , Copyright 1984, National Fire Protection Association, Quincy, MA 02269. This reprinted material is not the complete and official position of the NFPA on the refe r-enced subject which is represented only by the standard in its entirety.

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2-8

IGNITION SOURCES

Fires and explosions need an ignition source to start. Petroleum storage and handling sites require constant monitoring to detect and eliminate ignition sources. Some common ignition sources are as follows.

Smoking and Matches

Smoking and matches are the greatest single cause of fires. Units operating Class III supply points should prohibit any smoking-related materials in the supply point. Collect all smoking materials at the entrance chec k-point. Return these items at the exit checkpoint. Post NO SMOKING WITHIN 50 FEET signs at all petroleum handling, storage, and transfer a reas.

Poor Housekeeping

Relatively small heat sources easily ignite trash, rags, scrap wood and other such items. Place such materials in closed metal containers. Dispose of them appropriately each day. Use only fire resistant wall lockers and cu p-boards for storage in petroleum supply areas. Never store newspapers or rags in them. Discard petroleum waste in an environmentally safe manner IAW local procedures. Label safety cans or other flammable liquid waste contai n-ers with a flash point below 100 ° F (37.8° C) (such as gasoline or JP-4) IAW 49CFR Part 172. Do not use waste cans larger than 10 gallons. Take steps to control grass and weeds in POL supply points.

Mechanical or Friction Sparks

Friction or impact between metals and other hard substances can cause sparks. These sparks can ignite fla m-mable products and rubbish. Carefully control spark sources such as tools and grinding wheels around petroleum products and vapors. Nonsparking tools may cause sparks in certain uses. If available, use them; however, treat them as a potential source of sparks also.

Electrical equipment

Electrical equipment and wires create fire hazards when they produce exposed electrical currents (arcs and sparks) or when they create excessive amounts of heat. An arc is a continuous current stream through the air (similar to lightning). Operating knife switches and circuit breakers often produce arcs. The rotating parts of motors, generators, and similar machines produce arcs and sparks when operating. Overloaded electrical circuits produce hazards in two ways. One is by the large amounts of heat they produce. This heat may be enough to i g-nite a petroleum vapor mixture. The second is by arcing through worn or thin insulation. An oil-insulated switch or circuit breaker, designed to quench arcs from interrupted current, becomes a hazard when overloaded because the insulating oil vaporizes. Never put a penny or other conductive materials on the back of a blown plug fuse. A circuit overload can result. Likewise, never use fuses with a higher capacity than the circuit needs. Fixed and portable lights, generators, power tools, and extension cords present the same hazards. Use only explosion-proof electrical equipment where flammable vapors exist. This equipment should comply with Underwriters’ Laboratory Incorporated standards. Also, all wiring and grounding must comply with the National Electric Code. Permit only licensed operators to operate generators. Allow absolutely no one to work on a vehicle’s or aircraft’s electrical system during refueling operations. This includes touching or moving batteries or using battery chargers. Allow vehicle or aircraft radios to be on to receive messages during refueling. However, do not allow radio transmissions due to the danger of arcing.

Static Electricity Static electricity is an electrical charge built up in a material by friction with another electrically dissimilar mat e-rial. You can create static electricity on yourself by rubbing your feet across a carpet. On a low humidity day, you can then dissipate the charge by touching something metal such as a doorknob or car door. This produces a spark and a shock to you as the charge dissipates. In the military, the flow of petroleum through hoses and pumps and into and out of metal tanks produce static electricity. Also, the flow of steam, air, and other gases through tank, pump and hose systems produces these charges. Aircraft or vehicles moving through the air or along roads produce static electrical buildup on them. This buildup cannot be predicted or prevented. However, it is not a danger until it builds into a charge that can spark. Petroleum handlers should assume the presence of static electricity during all petroleum transfer operations. They can prevent sparking by two methods: bonding and grounding (discussed

Attachment F - Concepts and Equipment of Petroleum Operations

ATT F - 19 02.01.2016

2-9 below). Operators must properly bond and ground all equipment involved in a petroleum transfer operation before the start of the operation. Effective bonding and grounding must continue for the entire operation. Petroleum handlers should inspect ground wires and rods daily. They should repair any damage immediately. They should test the grounding system every five years. They should also test it after repairing damage. Static drag chains used on civilian vehicles to dissipate static electricity are not authorized on military veh icles.

Spontaneous Heating

Spontaneous heating of a combustible material takes place when its characteristics and the right enviro n-mental conditions cause a heat-producing chemical reaction. The heat can build to the point where the material ignites on its own. This is called spontaneous combustion. It may happen even if the material is not exposed to an external heat source. One common source of spontaneous heating is oil- or paint-soaked waste or rags, particularly those soaked with linseed oil and paint dryers. Petroleum handlers should consult MSDSs for the products they handle to see if they are subject to spontaneous heating and combustion, and if so, under what conditions. Many factors affect the start and speed of spontaneous heating and combustion. The process may take seconds or weeks with the same end result. Oxygen in the air or in oxygen-producing chemicals (oxidizers) accelerates the process.

Here are several ways to help prevent spontaneous heating and co mbustion.

• Closely follow storage and safety instructions on all MSDSs.

• Keep storage and handling areas for petroleum and petroleum-based items properly ventilated.

• Do not use lockers or supply cupboards to store oily waste and rags. Instead, place them in airtight metal containers. Discard them as soon as possible IAW environmentally-safe local proc edures.

Welding and Cutting

All welding methods present fire hazards. Welding-associated heat causes increased petroleum vaporization.

Welding throws off molten metal globules that can ignite the vapors or liquid petroleum. Welding equipment’s open flame can ignite vapors. Welding may not ignite vapors immediately; however, it can start smoldering fires in materials near the area. Eliminating these hazards completely is difficult or impossible. However, those involved in welding near petroleum products or equipment must closely control the welding process to prevent fires or e x-plosions. Thoroughly clean and reduce vapors to acceptable safety levels in storage tanks, tank cars, tank vehicles, drums, and vehicle fuel tanks before cutting or welding them. Check local policies for doing such work. Usually you must get a permit from the local fire marshal before starting.

Radar

The beam of high frequency radar equipment can ignite a flammable vapor-air mixture. It can ignite the mixture by inducing heat in solid materials in the beam’s path or by intensifying an existing electrical charge or stray current to the point where it will arc or discharge as a spark.

• Dangers. The degree of danger depends on the radar unit’s peak power output. Some radar types are more dangerous than others.

• Safety measures. Take the following safety measures when handling fuel near these types of radar.

••Airborne weather-mapping radar. The crew of an aircraft with a weather-mapping radar unit must shut down the radar before and during aircraft ref ueling.

••Airborne surveillance radar. Airborne surveillance units must shut down before the aircraft approaches within 300 feet of a refueling or fuel storage area.

••Airfield surface-detection radar. Do not refuel an aircraft or store aviation fuel within 100 feet of the a n-tenna of an airfield surface-detection radar.

••Airfield approach and traffic control radar. Do not refuel an aircraft or store aviation fuel within 300 feet of the antenna of an airfield approach and traffic control radar.

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2-10

Open Flames

Any open flame will ignite fuel or a flammable vapor-air mixture. Do not allow any open flame, open-flame device, or lighted smoking materials within 50 feet of a refueling operation. Fuel handling personnel may not carry lighters or matches. Do not use exposed-flame heaters, welding or cutting torches, and flare pots within 50 feet of refueling operations.

STATIC ELECTRICITY CONTROL MEASURES

Static electricity is impossible to eliminate. However, there are several safety measures for controlling it and its effects. Petroleum handlers should always assume that static electricity is present during all phases of oper a-tions. This includes long-term storage. Sparking (and a subsequent fire and explosion) from static electricity is a real and ever-present danger in petroleum transfer operations. The two primary static electricity control methods are bonding and groun ding.

Bonding Bonding is connecting two electrically conductive objects to equalize electrical potential (static charges) on them. Bonding does not dissipate static electricity. It equalizes the charge on the two objects to stop the sparking in the presence of flammable vapors. This will most likely occur when a vehicle or aircraft is being refueled. In this case, a fuel handler should bond the refueling vehicle to the vehicle being fueled. Do this by touching the fuel nozzle to the vehicle before the nozzle dust cap or vehicle fuel tank cap is removed. Maintain the bond until the refuel operation is complete and the nozzle dust cap and vehicle fuel cap are replaced. This will reduce vapors in case a spark occurs when the nozzle touches. Bond all equipment being used in a petr oleum handling operation.

Grounding

The earth, particularly soft damp earth, can accept electrical charges. The charges then dissipate harmlessly.

To ground equipment, you must provide a conductive electrical path into the ground. This prevents a static charge from collecting on the surfaces of equipment where it could discharge as a spark. Fuel handlers form this path by connecting a conductive cable from the piece of equipment to a conductive metal rod driven into the earth to the level of permanent ground moisture. The connection to the equipment must be to a clean unpainted, nonoxidized metal surface. Frozen soil (a particular problem in arctic regions) makes it difficult to get a good ground. Fuel handlers may need to drive in grounding rods at several different locations to as great a depth as possible to ground a single piece of equipment. Another solution is to try to locate a grounding system near a heat source. If there are metal buildings or underground pipes nearby, a ground connection may be made to them. Rocky or sandy soils are poor grounds because they have low conductivity. Chemicals can be used to condition the soil and raise its co n-ductivity. Magnesium sulfate (Epsom salts), copper sulfate (blue vitriol), calcium chloride, sodium chloride (co m-mon table salt), and potassium nitrate (saltpeter) are some of the chemicals used for soil conditioning. Table salt will probably be the easiest to get in the field. To use salt, prepare a grounding site by digging a hole about 1 foot deep and 3 feet across. Mix 5 pounds of salt with 5 gallons of water. Pour the mixture into the hole, and allow it to seep in. Install the ground rod and wire, and keep the soil around the rod moist. Ground rods are usually made of galvanized iron, galvanized steel, or copper-weld steel. The rod regularly used for grounding is LIN S08698, NSN 5975-00-224-5260. This ground rod is 3/4 inch in diameter and 6 feet long. It is made of galvanized steel. It has one pointed end that is driven into the earth and a bolt and nut at the other end for connecting a grounding cable. Use the following procedures to install, mark, test, and inspect ground rods.

• Install. Drive the rod into the earth to a sufficient depth to reach below the permanent ground moisture level. On a fixed airfield apron or ramp, drive the rod to a depth where its top is level with the surrounding su r-face. At other facilities, drive the rod to a depth where its top is low enough or high enough so people will not trip over it. If the rod’s top is level with the surrounding surface remove some soil from around the top to give room for attaching ground cable clips. Fuel handlers may use-tie-down bolts embedded in concrete ramps at fixed ai r-fields as ground connections if they meet resistance requirements.