33_52_43.11.pdf

Replace POL Facilities, Hill AFB, Utah HU05

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 52 43.11

AVIATION FUEL MECHANICAL EQUIPMENT

02/10

PART 1 GENERAL

1.1 REFERENCES

1.2 ADMINISTRATIVE REQUIREMENTS

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Types of Fuel

2.1.2 Composition of Materials

2.1.3 Gaskets

2.1.4 Bolts and Nuts

2.2 EQUIPMENT AND MATERIAL

2.2.1 General

2.2.2 Supplier

2.3 ELECTRICAL EQUIPMENT

2.4 PRESSURE GAGES

2.5 AUTOMATIC PUMP CONTROLS

2.5.1 Flow Switches

2.5.2 Pressure Sensor

2.5.3 Pressure Indicating Transmitters

2.6 METERS

2.7 PRODUCT RECOVERY TANK AND ACCESSORIES

2.7.1 Tank Construction

2.7.1.1 Steel Tank

2.7.1.2 Not Used

2.7.1.3 Not Used

2.7.1.4 Not Used

2.7.1.5 Not Used

2.7.1.6 Not Used

2.7.1.7 Not Used

2.7.1.8 Float Switch Assembly

2.7.1.9 Fuel Transfer Pump (FTP-1)

2.7.1.10 Not Used

2.7.1.11 Lockable Cap

2.7.1.12 Spill Containment Basin

2.7.1.13 Overfill Valve (OV-1)

2.7.1.14 Tank Calibration

2.8 TRUCK OFFLOAD SYSTEM

2.8.1 Offload Pump (OP)

2.8.2 Air Eliminator Tank

2.8.2.1 Tank Housing

2.8.2.2 Sight Gauge

2.8.2.3 High Level Shutoff

SECTION 33 52 43.11 Page 1 Revised in Accordance with Am #0002

2.8.2.4 Level Sensors

2.8.2.5 Vent

2.8.3 Non-Surge Check/Air Block Valve

2.8.4 Offload Fuel Hose

2.8.5 Offload Sight Flow Indicator

2.8.6 Flood Lights

2.8.7 Flowmeter

2.8.8 Other Offload Equipment

2.9 HIGH POINT VENT AND LOW POINT DRAIN PITS

2.9.1 Pit Assembly

2.9.2 Pit

2.9.3 Pit Cover, General Requirements

2.9.4 Pit Cover Materials, Design, and Testing

2.9.5 Pipe Riser Seal

2.10 NOT USED

2.11 OPERATING TANK LEVEL SWITCHES

2.12 WATER DRAW-OFF SYSTEM

2.12.1 Tank

2.12.2 Sight Glass

2.12.3 Return Pump

2.12.4 Anchoring

2.13 BOWSER PUMPOFF PUMP

2.14 TIGHTNESS MONITORING SYSTEM

2.15 TRUCK FILLSTAND OVERFILL PROTECTION AND GROUND VERIFICATION UNIT

2.16 PUMPHOUSE DRAIN PUMP (RP-1)

PART 3 EXECUTION

3.1 GENERAL

3.1.1 Installation

3.1.2 Anchoring

3.1.3 Grouting

3.1.4 Leveling and Aligning

3.1.5 Direct Drives

3.1.5.1 Rotation Direction and Speed

3.1.5.2 End Play

3.1.5.3 Shaft Leveling and Radial Alignment

3.1.5.4 Angular Alignment and End Clearance

3.1.5.5 Final Recheck

3.1.6 Precautions

3.2 NOT USED

3.3 INSTALLATION OF FIBERGLASS PITS

3.4 POSTED OPERATING INSTRUCTIONS

3.4.1 Each System

3.4.2 Each Tank

3.4.3 Each Item

3.4.4 Diagrams

3.4.5 Volume of Fuel

-- End of Section Table of Contents --

SECTION 33 52 43.11 Page 2

SECTION 33 52 43.11

AVIATION FUEL MECHANICAL EQUIPMENT

02/10

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

ASME INTERNATIONAL (ASME)

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

ASME BPVC SEC VIII D1 (2015) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM C827/C827M (2016) Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14) National Electrical Code

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-83133 (2015; Rev J) Turbine Fuels, Aviation, Kerosene Type, JP-8 (NATO F-34), NATO F-35 and JP-8 + 100 (NATO F-37)

MIL-PRF-370 (2002; Rev J) Hose And Hose Assemblies, Nonmetallic: Elastomeric, Liquid Fuel

MIL-PRF-4556 (1998; Rev F; Am 1 1999; CANC Notice 1 2011) Coating Kit, Epoxy, for Interior of Steel Fuel Tanks

MIL-STD-130 (2007; Rev N; Change 1 2012) Identification Marking of U.S. Military Property

MIL-STD-161 (2005; Rev G; Notice 1 2010)

SECTION 33 52 43.11 Page 3

Identification Methods for Bulk Petroleum Products Systems Including Hydrocarbon Missile Fuels

1.2 ADMINISTRATIVE REQUIREMENTS

Submit detail drawings consisting of illustrations, schedules, performance charts, instructions, brochures, diagrams, and other information to illustrate the requirements and operation of the equipment and systems.

Provide the drawings as one package with the design analysis. Shop fabrication drawings shall include type of material, configuration, thickness, and necessary details of construction of the steel tank and vault. Shop drawings shall also show the steel grating and supports.

Submit Manufacturer's Catalog Data and Certificates of Compliance.

Operation and maintenance information shall be submitted for the equipment items or systems listed in PART 2. Automatic pump controls shall include step-by-step procedures required for system startup, operation, and shutdown. Refer to Section 01 78 23.33 OPERATION AND MAINTENANCE MANUALS FOR AVIATION FUEL SYSTEMS for the information to be submitted for various types of equipment and systems.

1.3 SUBMITTALS

[*Am-2] Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Meters; G-OMA Water Draw-off System; G-OMA Truck Offload System; G-OMA High Point Vent and Low Point Drain Pits; G-OMA Product Recovery Tank and Accessories; G-OMA Bowser Pumpoff Pump; G-OMA Truck Fillstand Overfill Protection and Ground Verification Unit;

G-OMA

Tightness Monitoring System; G

SD-03 Product Data

Pressure Gages; G-OMA Automatic Pump Controls; G-OMA Meters; G-OMA.

Product Recovery Tank and Accessories; G-OMA Truck Offload System; G-OMA.

High Point Vent and Low Point Drain Pits; G-OMA Operating Tank Level Switches; G-OMA Water Draw-Off System; G-OMA

Bowser Pumpoff Pump; G-OMA Truck Fillstand Overfill Protection and Ground Verification Unit;

G-OMA

Tightness Monitoring System; G-OMA Pumphouse Drain Pump (RP-1); G, OMA

SD-06 Test Reports

SECTION 33 52 43.11 Page 4

Tightness Monitoring System; G

SD-07 Certificates

System Supplier; G Tightness Monitoring System; G

SD-10 Operation and Maintenance Data

Automatic Pump Controls; G Product Recovery Tank and Accessories; G Truck Offload System; G Water Draw-off System; G.

Truck Fillstand Overfill Protection and Ground Verification Unit; G Tightness Monitoring System; G

1.4 QUALITY ASSURANCE

Submit the following data for approval:

a. Certification stating that the system supplier has provided and installed at least five PLC-based pump control systems in the last five years, for automatic cycling of pumps based upon varying dispensing demands, utilizing multiple pumps. These systems shall be for dispensing jet fuel.

b. Certification that six systems have been successfully operated over the last three years and are currently in service.

c. Project names, locations, system description, and items provided at these installations. Include user point-of-contact and current telephone numbers.

PART 2 PRODUCTS

2.1 MATERIALS

Materials of construction shall be stainless steel, aluminum or nonferrous material except meter case may be steel with electrolyses nickel plated internals coated to 3 mil thickness. No ferrous or zinc-coated material bronze, brass or other copper bearing alloys shall be used in contact with the fuel.

2.1.1 Types of Fuel

Components shall be suitable for use with JP-8 turbine fuel; specific gravity 0.81 at 60 degrees F; viscosity 1.62 CS at 60 degrees F; Reid vapor pressure less than 0.05 psi, MIL-DTL-83133. Components to be ANSI Class 150 ( 275 PSIG at 100 degrees F.) unless noted otherwise. Components to be suitable for outside, unsheltered location, and to function normally in ambient temperatures between 0 degrees F and 120 degrees F.

2.1.2 Composition of Materials

Materials in contact with the fuel shall be noncorrosive. No zinc-coated metals, brass, bronze, iron, lead or lead alloys, copper or copper alloys, or other light metal alloys containing more than 4 percent copper shall be used in contact with the fuel.

SECTION 33 52 43.11 Page 5

2.1.3 Gaskets

Gaskets shall be in accordance with Section 33 52 43.13 AVIATION FUELING

PIPING.

2.1.4 Bolts and Nuts

Bolts and nuts shall be in accordance with Section 33 52 43.13 AVIATION

FUELING PIPING.

2.2 EQUIPMENT AND MATERIAL

2.2.1 General

All items of equipment and material shall be new and of the best quality used for the purpose in commercial practice and shall be products of reputable manufacturers. Each major component of equipment shall have the manufacturer's name, address and catalog number on a plate securely affixed in a conspicuous place. The nameplate of a distributing agent only will not be acceptable. The gears, couplings, projecting set screws, keys and other rotating parts located so that any person may come in close proximity thereto shall be fully enclosed or properly guarded. Equipment, assemblies and parts shall be marked for identification in accordance with MIL-STD-130 and MIL-STD-161. Pump and filter vessel numbers shall be as indicated on the drawings. In addition, filter vessels shall include element numbers and the date of the next element change. Identification tags made of brass, stainless steel, or engraved anodized aluminum, indicating valve number and normally open (NO) or normally closed (NC) shall be installed on valves. Tags shall be 1-3/8 inch minimum diameter, and marking shall be stamped or engraved. Indentations shall be black, for reading clarity.

Tags shall be attached to valves with No 12 AWG, copper wire, stainless or aluminum hanging wires, or chrome-plated beaded chain designed for that purpose.

2.2.2 Supplier

Since the pump control system, including but not limited to pump control panel, venturi tubes, transmitters, flow switches, fueling system pumps, all field instrumentation, tightness monitoring system, and control valves with all hardware and software, is an integrated system it shall be furnished by a single systems supplier regularly engaged in the supplying of this equipment. System Supplier shall be a company whose regular, normal, and primary business is representing manufacturers in the distribution and start-up of aviation fueling facilities, and have no affiliation with the Contractor other than as a seller to the Contractor.

Supplier shall provide all equipment and appurtenances regardless of manufacture, be a factory authorized certified representative, and be responsible to the Contractor for satisfactory operation of the entire system, and shall oversee the installation of the equipment. Substitutions of functions specified will not be acceptable. The Contractor and the System Supplier shall be present at the system commissioning, and shall coordinate and schedule the work during construction, testing, calibration, and acceptance of the system. The System Supplier shall be responsible to the Contractor for scheduling all Contractor, Sub-contractor, and manufacturer's service personnel during system start-up and final commissioning.

SECTION 33 52 43.11 Page 6

2.3 ELECTRICAL EQUIPMENT

Motors, manual or automatic motor control equipment except where installed in motor control centers, and protective or signal devices required for the operation specified herein shall be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Any wiring required for the operation specified herein, but not shown on the electrical plans, shall be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

2.4 PRESSURE GAGES

Pressure gages shall conform to ASME B40.100 with metal cases and 4-inch diameter white dials. Gages shall be bottom connected, without back flanges. A pulsation dampener, adjustable to the degree of dampening required, shall be provided for each gage. Range of gages shall be as indicated. A ball valve shall be provided for each pressure gage. Gages shall have all parts immersed in silicone oil. Gages shall be labeled with the calibration date.

2.5 AUTOMATIC PUMP CONTROLS

The pressure and flow transmitters specified in this paragraph shall be obtained from a single supplier of such products. The same supplier shall also furnish the associated venturi tubes and GPM meter. The supplier shall be responsible for furnishing components that are compatible and that operate as a system to perform the required pump control functions.

Control tubing between controls/instruments and fuel lines shall be installed to eliminate air entrapment. Control tubing shall be as specified in Section 33 52 43.13 AVIATION FUELING PIPING. Each item of equipment specified hereafter shall have manufacturer's authorized service personnel present to assist in PERFORMANCE TESTING as specified in Section 33 08 53 AVIATION FUEL DISTRIBUTION SYSTEM START-UP. Items specified under this paragraph shall be submitted for approval concurrently with items specified in Section 33 09 53 AVIATION FUEL PUMP CONTROL AND ANNUNCIATION

SYSTEM.

2.5.1 Flow Switches

Switches shall be actuating vane type flow switch with single adjustable set-point. Switches shall mount on ASME B16.5 Class 150 raised face flange. Flange material shall match the piping material at their connection to the system. Provide snap action switch mechanism U.L. listed for Class I, Division 1, Group D hazardous locations. Switches to be double pole double throw (DPDT). Switch power shall be 120 volts, single phase, 60 hertz, 10 amps minimum.

2.5.2 Pressure Sensor

Sensor shall be UL, FM, or CSA listed for Class 1, Division 1, Group D hazardous environment as defined by NFPA 70, with maximum temperature rating T2D ( 419 degrees F). Excitation voltage shall be 12-28 VDC.

Output signal shall be 4-20 mA. Unit shall have 0.25 percent accuracy and have built-in high pressure snubbers, minimum pressure range shall be 0-300 PSI. Wetted material shall be stainless steel.

[ [*Am-2]

SECTION 33 52 43.11 Page 7

2.5.3 Pressure Indicating Transmitters

Pressure indicating transmitters shall consist of a capacitance sensor operating on a differential in pressure of fuel (one side being open to atmospheric pressure). The output shall be a 4 - 20 mA dc, linear signal between 0 - 100 percent of the input. It simultaneously will produce a digital HART (Highway Addressable Remote Transducer) output signal. Loop power shall be provided from remote power supply located in the pump control panel (PCP).

a. Transmitter body shall be stainless steel with stainless steel diaphragm capsule process connecting to a 1/2 inch NPT. Drain and vent valves to be stainless steel. Accuracy shall be + 0.20 percent of calibrated span including combined effects of linearity, hysteresis and repeatability.

b. Pressure transmitters shall be UL, FM, or CSA listed for Class 1, Division 1, Group D hazardous environment as defined by NFPA 70, with maximum temperature rating T2D ( 419 degrees F). Each transmitter and dial shall be supplied with a factory assembled two valve stainless steel manifold. Vent valves shall be furnished on upper ports of each transmitter and dial. Pressure transmitters and the indicating dial shall be suitable for mounting on a 2-inch pipe stand. Complete installation shall be in accordance with manufacturer's recommendations.

c. Provide a HART (Highway Addressable Remote Transducer) protocol interface handheld calibration device. Communicator to be intrinsically safe and have Class 1, Div 1, Group C and D approval.

Device to include NIST traceable modules, one 0-500 psig range, one 0-2000 wc, and also one protection module for open sensor bay. Unit shall be furnished in hard carrying case and to include 250 ohm shunt for HART communicator, A900 HART test lead kit, 145 psig pressure pump with variator, low pressure fittings and tubing kit. Hand-held pump capable of producing a minimum of 300 psig pressure.

2.6 METERS

Meter shall be a one-way flow, temperature compensating, positive displacement type meter designed for a continuous flow of 600 GPM at the truck fill stand. Meter shall have ANSI Class 150 flanges and body working pressure of not less than 275 psig and shall be suitable for hydrostatic testing of 275 psig. Meter shall be factory calibrated for JP-8 jet fuel and capable of being calibrated in the field. The register shall have a non-setback total indicator and a setback type run indicator so that individual runs can be registered without affecting the total of all runs as shown on the indicator. The total indicator shall have a minimum of eight figures and the setback run indicator shall have a minimum of five figures. The register shall read in gallons and the smallest unit of indicated delivery shall be 1 gallon. Accuracy shall be within +0.3 percent between ten percent and maximum rated flow. Meters shall be provided with a suitable drain at the bottom, equipped with a ball valve.

Pressure loss through the meter shall not exceed 3 psi at 600 gpm flow rate.

[*Am-2]

2.7 PRODUCT RECOVERY TANK AND ACCESSORIES

2.7.1 Tank Construction

Product recovery tank shall be a U.L. labeled, double wall, steel tank, SECTION 33 52 43.11 Page 8 with interstitial monitor. Tank shall be provided with calibrated gage stick, strapping chart, and a steel vault attached to tank. Vault shall be provided with a rolling pit cover and removable access grating. Minimum inner and outer tank wall thickness shall be 0.167 inches.

2.7.1.1 Steel Tank

[*Am-2] For further product recovery tank and accessories information, see Specification Section 33 56 10 FACTORY FABRICATED STEEL STORAGE TANKS .

2.7.1.2 Not Used

2.7.1.3 Not Used

2.7.1.4 Not Used

2.7.1.5 Not Used

2.7.1.6 Not Used

2.7.1.7 Not Used

2.7.1.8 Float Switch Assembly

The float switch assembly shall be the top mounted, float operated type with vertical float rod. The switch assembly shall be suitable for flange mounting and float and trim shall be stainless steel. The switch shall be magnetically latching reed or actuated mercury switch suitable for operation on 120 volt, 60 hertz AC power. Rating of the switch contacts shall be adequate for the indicated functions shown on the drawings. This float switch assembly shall be used to start and stop the Fuel Transfer Pump, indicate a high level and high-high level and activate an alarm in the PCP.

2.7.1.9 Fuel Transfer Pump (FTP-1)

Refer to Section 33 52 43.23 AVIATION FUEL PUMPS [*Am-2]

2.7.1.10 Not Used2.7.1.11 Lockable Cap

Provide a lockable cap for the 2-inch gravity fill line.

2.7.1.12 Spill Containment Basin

Container shall be constructed of fiberglass reinforced plastic, be compatible with the type of fuel being handled, have a minimum 3 gal fuel storage capacity, and form a water-tight seal around the fuel piping to prevent spilled fuel from entering the soil. Container shall be provided with a drain and have an easily removable cover constructed of either cast aluminum or cast iron. Covers shall be weather-resistant and shall prevent the influx of water.

2.7.1.13 Overfill Valve (OV-1)

Refer to Section 33 52 43.14 AVIATION FUEL CONTROL VALVES

2.7.1.14 Tank Calibration

Provide a certified tank calibration chart in increments reading in gal.

Tank certification shall be done onsite and stamped by a P.E.

SECTION 33 52 43.11 Page 9

2.8 TRUCK OFFLOAD SYSTEM

The truck offload system shall be a factory fabricated and skid mounted unit.

2.8.1 Offload Pump (OP)

Refer to Section 33 52 43.23 AVIATION FUEL PUMPS

2.8.2 Air Eliminator Tank

2.8.2.1 Tank Housing

Each Tank housing shall be fabricated from carbon steel and shall be internally coated with an epoxy coating in accordance with MIL-PRF-4556.

Coat the exterior with alkyd resin primer (universal metal primer). Each unit shall be constructed and labeled in accordance with ASME BPVC SEC VIII D1. The housing shall be designed for a working pressure of 90 psig. The inlet and outlet connections shall be provided with raised face flanges faced and drilled in compliance with ASME B16.5, Class 150. The configuration of the air eliminator tanks shall be as shown on the drawings.

2.8.2.2 Sight Gauge

Provide a 5-inch armored, clear borosilicate (Pyrex) glass liquid level gauge for observing fuel level in the tank. The gauge shall be equipped with stainless steel ball checks in both the upper and lower fittings, an upper and lower shutoff valve, and a bottom blowoff cock. The gauge will contain a colored density sensitive ball. Glass shall be protected by a minimum of four guard rods.

2.8.2.3 High Level Shutoff

The vent connection shall have a stainless steel high level shutoff mechanism to act as an overfill prevention device to keep fuel from going out the vent.

2.8.2.4 Level Sensors

The level sensors shall be ultrasonic tip sensitive level control switches, NEMA 7/9, weatherproof, explosion proof for Class I, Div I, Group D, temperature T2D (419 degrees F), 120-volt input power, SPST relay output, 1-inch flanged mounting.

2.8.2.5 Vent

Tank vent outlet shall be equipped with pressure-vacuum breather vent, aluminum construction with weather hood and with fluoroelastomer pallet seat inserts, high density screens, stainless steel internals, with pressure relief setting at 0.5 oz per square inch, and vacuum relief set at 32 oz per square inch. Pressure venting capacity shall be 5400 cubic feet per hour, vacuum capacity shall be 5000 cubic feet per hour.

2.8.3 Non-Surge Check/Air Block Valve

Refer to Section 33 52 43.14 AVIATION FUEL CONTROL VALVES

SECTION 33 52 43.11 Page 10

2.8.4 Offload Fuel Hose

The offload fuel hose shall be 4-inch, lightweight, flexible, minimum 8-inch bend radius, non-pressurized offloading hose constructed of nitrile rubber, rigid PVC helix, synthetic braiding, smooth bore, corrugated outer diameter, conforming to MIL-PRF-370 (formerly CID A-A-52554), non-collapsible, threaded, male NPT, both ends, and have UV protection.

2.8.5 Offload Sight Flow Indicator

The Truck Offload sight flow indicator shall be four inch wafer pattern sight glass, plane indicator aluminum construction.

2.8.6 Flood Lights

Mount three 100 Watt HPS floodlights on the off load skid, approximately 12 foot high, two on one pole, one on another pole to provide light in the off load area. Fixtures shall operate on 277 volts, single phase, 60 Hz.

Fixtures shall be rated for installation in wet locations and have narrow vertical and wide horizontal beam spread. Fixtures shall be bronze in color and accept 2-inch knuckle mounting.Provide a manual switch for control. See Section 26 56 00 EXTERIOR LIGHTING for applicable requirements.

2.8.7 Flowmeter

Meter shall be a temperature compensating, turbine type meter designed for a continuous flow of 600 GPM. Meter shall have ANSI Class 150 flanges and body working pressure of not less than 275 psig and shall be suitable for hydrostatic testing of 275 psig. Materials of construction shall be stainless steel. Meter shall be factory calibrated and capable of being calibrated for JP-8 jet fuel in the field. Pressure loss through the meter shall not exceed 4 psi at maximum flow rate for water. The register shall be explosion proof and have a total indicator and a rate indicator. The total indicator shall have a minimum of eight figures and the setback rate indicator shall have a minimum of five figures. The register shall read in gal and the smallest unit of indicated delivery shall be 1 gal. Accuracy shall be within +0.3 percent between ten percent and maximum rated flow.

2.8.8 Other Offload Equipment

For other equipment shown on the drawings as part of the offload system, refer to this Section and refer to Section 33 52 43.13 AVIATION FUELING

PIPING

2.9 HIGH POINT VENT AND LOW POINT DRAIN PITS

Use for On-Shoulder and On-Apron installations.

2.9.1 Pit Assembly

Each pit shall incorporate the following items built into a self-contained assembly.

2.9.2 Pit

The basic pit shall consist of 0.25-inch wall fiberglass liner with a main body approximately 23-inches in diameter and a minimum of 37-inches deep.

The pit shall contain two integral concrete anchors. The fiberglass top

SECTION 33 52 43.11 Page 11 flange shall require no exposed corrosive material, weldments, or strongbacks within the pit to support the cast aluminum ring and cover assembly. The pits shall be the standard products of a firm regularly engaged in the manufacture of such product and shall essentially duplicate items that have been in satisfactory use for at least three (3) years prior to bid opening. Proof of experience will be submitted.

2.9.3 Pit Cover, General Requirements

The pit cover shall include a removable outer ring frame and an interior 18-inch diameter (clear opening) hinged lid that opens 160 degrees. Each cover lid shall move smoothly through its entire range of motion and shall require a maximum opening force of 35 pound-force to be applied at a single lifting handle. Each handle shall provide a comfortable, secure grip for an average adult male's full gloved hand. Tools shall not be required to engage the lifting handle. Projections of the lid's hinges or handles above the plane of the lid, whether temporary or permanent, shall not be allowed. The pit service shall be integrally cast in raised letters on the top surface of each lid. The lettering shall be a minimum of 1-inch high and 0.0625-inch deep. The weight bearing flanges of the fiberglass pit liner and the aluminum cover frame (and lid) shall be machined to assure uniform weight distribution.

2.9.4 Pit Cover Materials, Design, and Testing

The cover frames and lids shall be designed and manufactured by a qualified company having a minimum of five years successful experience in the production of similar airport apron slab fixtures. All cover lids and frames shall be designed using an appropriate cast aluminum alloy or rolled aluminum plate to support an aircraft wheel load simulated by a roving 200,000-pound test-load applied perpendicular to a 200-square-inch contact area( 10 by 20 inches) of the cover's top surface. The aluminum alloy material selected for design shall be ductile, corrosion-resistant, impact-resistant, and suitable for the intended use. All covers shall be non-skid surface construction and free of injurious defects. Welding for the purpose of structural repair of casting defects shall not be allowed.

Minor cosmetic welding is acceptable. The cover shall be capable of supporting the test-load without failure regardless of the location or orientation of the load. Localized yielding or cracking or excessive deformations shall be considered as failure. Actual load-tests shall be performed on a minimum of 10 percent of all the covers supplied.

Load-tested units shall be randomly selected. Load-test conditions shall model field-installed conditions as nearly as practicable. The 200 Kip test-load shall be applied to the cover for a minimum duration of 5 minutes. Absolute maximum deflection of the cover lid under the test-load shall not exceed 1/180th of the interior diameter of the fiberglass pit body. Maximum deflection of the cover lids, remaining after removal of the test load shall be + 0.010-inches to assure that no permanent set has taken place. Upon removal of the test-load, the cover lid and frame shall be carefully examined for cracks or localized areas of permanent deformation.

All results shall be submitted for review and approval. A single failure to meet any of the stated criteria shall be considered sufficient grounds for the testing of 50 percent of the units.

2.9.5 Pipe Riser Seal

The riser pipe penetration through the pit floor shall be sealed by means of a Buna-N boot. The boot shall be secured to a metal collar welded to the pipe riser and to a flange at the floor opening by stainless steel

SECTION 33 52 43.11 Page 12 clamps. Collar shall be fabricated from the same material as the pipe.

[*Am-2]

2.10 NOT USED

2.11 OPERATING TANK LEVEL SWITCHES

a. System must be designed and installed in such a way that the system must be continuously and automatically self-checking. Switches must be an external mount with a stainless steel fluid chamber. Electronic level sensors must be thermistors or optic type, and be intrinsically safe Class I, Division 1, Group D for hazardous environments, with recognized FM, CSA or UL approval. The sensor holder/junction box must be accessible from the stairway. Units must have provisions to check level switch operations without increasing the fuel level in the tanks as shown on the contract drawings.

b. Level alarms must be mechanically and electrically independent and be totally isolated from the gauging system. The level switches must receive power and send their signal to the Pump Control Panel.

Circuitry and cables from the PCP to the electronic level sensors in the tank must be intrinsically safe.

2.12 WATER DRAW-OFF SYSTEM

A water draw-off system shall be provided for each Operating Tank. Water draw-off system shall gravity drain. Each system shall include tank, product return pump and all necessary pipe, pressure relief system, valves, and fittings.

2.12.1 Tank

Water draw-off tank shall be a 55-gal fabricated stainless steel tank with supporting legs as shown. Tank and support legs shall be fabricated from Type 304 stainless steel.

2.12.2 Sight Glass

Sight glasses for tank shall be standard tubular gages with density ball and shut-off valves on each end. Wetted parts other than sight glass shall be stainless steel. If glass breakage should occur, a stainless steel ball in the valve shall close preventing product loss. Glass shall be protected by minimum of four guard rods.

2.12.3 Return Pump

Product return pump (PRP-1 and PRP-2) shall have the capacity of not less than 5 gpm against a total head of 60 feet when driven at 1750 rpm. The pump shall have flange connections and shall be constructed of stainless steel or aluminum so as to have no zinc, brass or other copper bearing alloys in contact with the fuel. The unit shall be explosion-proof, Class I, Division 1, Group D with maximum temperature rating of "T2D" ( 419 degrees F). The motor shall not be overloading at any point on the pump curve. Contractor has the option of selecting either centrifugal or positive displacement type pump with the restriction of the positive displacement type pump shall include a pressure relief between the discharge and suction protecting the pump from overloading.

SECTION 33 52 43.11 Page 13

2.12.4 Anchoring

All units of the water draw-off system shall be installed plumb and level and secured in place by anchor bolts.

2.13 BOWSER PUMPOFF PUMP

The pump shall be a sliding vane type rotary pump. The pump construction shall permit the removal of the rotor and sliding vanes without disconnecting the pump. Pump capacity shall be 10 gpm with a differential head of 50 feet when driven at 1800 rpm. The pump and motor shall be mounted on a cast iron or steel subbase. The motor shall have sufficient power for the service required, shall be of a type approved by the manufacturer of the pump, shall be suitable for available electric service, shall be totally enclosed, fan cooled, TEFC, and shall conform to the requirements specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

Pump shall be provided with stainless suction side basket strainer.

2.14 TIGHTNESS MONITORING SYSTEM

The system shall be a permanent, fully automated, pressure step (no volume measurement)leak detection system, and will be used for tightness testing the hydrant loop pipeline. System shall have a guaranteed accuracy to detect a leak of less than 0.0004 gal/h per cubic foot at 150 PSI. The system shall be US EPA Third Party Certified to the above sensitivity with a Probability of Detection greater than or equal to 95 percent and a Probability of False Alarm of less than or equal to 5 percent. System will have performed satisfactorily on at least five (5) projects involving quantities and complexities at least equal to those required under this Contract. Equipment shall be compatible with equipment furnished and installed under Section 33 52 43.11 AVIATION FUEL MECHANICAL EQUIPMENT, and Section 33 09 53 AVIATION FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM, where the individual equipment components are common to both the Tightness Monitoring System functional operation, and the Hydrant Fuel Control System functional operation. Test results shall be unaffected by the temperature change of the fuel, and have a maximum test period of one hour. A local controller shall implement and analyze data, store data and be capable of printing results, and be located in the control room of the pumphouse building. Printer shall be provided. Controller shall utilize 120V, single phase power. Any additional utilities or equipment needed to be added to the fuel system in addition to what is shown on the drawings to allow the Tightness Monitoring System to meet the requirements, will be the requirement of the Tightness Monitoring System. Provide calculations, design, and proof of compliance. Upon completion of 72 hours of continuous system operation and before final acceptance of work, test the Tightness Monitoring System in service to demonstrate compliance with contract requirements. Performance verification shall be coordinated with overall fuel system start-up, and commissioning of fueling facilities.

Perform performance verification in such a way as to obtain complete tightness information within the required accuracy stated herein and provided Tightness Certification on each pipe section tested.

2.15 TRUCK FILLSTAND OVERFILL PROTECTION AND GROUND VERIFICATION UNIT

System shall include connection plug, control cable, and monitoring and control module. System shall be the self-checking type that automatically and continually monitors the liquid-level within a tank truck's storage compartment during fueling. The system shall be compatible with the Scully Duocept w/Truck Identification Module (T.I.M.) P/N 09061 to monitor truck

SECTION 33 52 43.11 Page 14 liquid level, provide ground verification and provide a method to electronically prevent product commingling. System shall be rated for an explosion-proof environment in accordance with NFPA 70 for Class I, Division I, Group D locations. Module shall include status lights and a switch contact to allow interlock functions. Control cable shall be the spiral, self-retracting type. Cable shall be a minimum 30 feet in length.

The fillstand tank level sensor shall signal the fillstand control valves to shutdown and shall serve as the primary fill stand overfill system.

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2.16 PUMPHOUSE DRAIN PUMP (RP-1)

The pump must be a sliding vane type rotary pump. The pump construction must permit the removal of the rotor and sliding vanes without disconnecting the pump. Pump capacity must be 5 gpm with a differential head of 50 feet when driven at 1800 rpm. The pump and motor must be mounted on a cast iron or steel subbase. The motor must have sufficient power for the service required, must be of a type approved by the manufacturer of the pump, must be suitable for available electric service, must be totally enclosed, fan cooled, TEFC, and must conform to the requirements specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

PART 3 EXECUTION

3.1 GENERAL

3.1.1 Installation

Install equipment and components in position, true to line, level and plumb, and measured from established benchmarks or reference points.

Follow manufacturer's recommended practices for equipment installation.

Provide required clearances between equipment components. Equipment, apparatus, and accessories requiring normal servicing or maintenance to be accessible.

3.1.2 Anchoring

Anchor equipment in place. Check alignment of anchor bolts before installing equipment and clean-out associated sleeves. Do not cut bolts because of misalignment. Notify Contracting Officer of errors and obtain the Contracting Officer's acceptance before proceeding with corrections.

Cut anchor bolts of excess length to the appropriate length without damage to threads. Where anchor bolts or like devices have not been installed, provide appropriate self-drilling type anchors for construction condition.

3.1.3 Grouting

Equipment which is anchored to a pad is to be grouted in place. Before setting equipment in place and before placing grout, clean surfaces to be in contact with grout, including fasteners and sleeves. Remove standing water, debris, oil, rust, and coatings which impair bond. Clean contaminated concrete by grinding. Clean metal surfaces of mill scale and rust by hand or power tool methods. Provide necessary formwork for placing and retaining grout. Grout to be non-metallic, non-shrink, fluid precision grout of a hydraulic cementitious system with graded and processed silica aggregate, Portland cement, shrinkage compensating agents, plasticizing and water reducing agents; free of aluminum powder agents, oxidizing agents and inorganic accelerators, including chlorides; proportioned, pre-mixed and packaged at factory with only the addition of water required at the project

SECTION 33 52 43.11 Page 15 site. Grouting shall be in accordance with ASTM C827/C827M. Perform all grouting in accordance with equipment manufacturer's and grout manufacturer's published specifications and recommendations.

3.1.4 Leveling and Aligning

Level and align equipment in accordance with respective manufacturer's published data. Do not use anchor bolt, jack-nuts or wedges to support, level or align equipment. Install only flat shims for leveling equipment.

Place shims to fully support equipment. Wedging is not permitted. Shims to be fabricated flat carbon steel units of surface configuration and area not less than equipment bearing surface. Shims to provide for full equipment support. Shim to have smooth surfaces and edges, free from burrs and slivers. Flame or electrode cut edges not acceptable.

3.1.5 Direct Drives

Alignment procedure follows:

3.1.5.1 Rotation Direction and Speed

Check and correct drive shaft rotation direction and speed.

3.1.5.2 End Play

Run drive shafts at operational speed. Determine whether axial end play exists. Run drive shaft at operational speed and mark drive shaft axial position when end play exists. Block drive shaft in operating position when aligning drive shaft with driven shaft.

3.1.5.3 Shaft Leveling and Radial Alignment

Pump alignment shall be accomplished by the factory technician or a millwright trained in pump alignment, and with the use of dial gauges or laser alignment equipment.

3.1.5.4 Angular Alignment and End Clearance

Check angular alignment and end clearance by inserting a feeler gage at 4 points, 90 degrees apart around outer edges of coupling halves.

3.1.5.5 Final Recheck

Check adjustments with dial indicator after completing recheck. Align shafts within 0.001 inch tolerance, except as other-wise required by more stringent requirements of equipment manufacturer.

3.1.6 Precautions

Special care shall be taken to ensure that equipment and materials are stored properly to prevent damage and maintain cleanliness, and that the completed system is free of rocks, sand, dirt, and foreign objects. Take the following steps to insure these conditions.

a. Equipment brought to the site and not stored inside, shall be stored on blocks or horses at least 18 inches above ground.

b. Visual inspection shall be made of each piece of equipment to ensure that it is clean prior to installation.

SECTION 33 52 43.11 Page 16

c. The open ends of equipment shall be closed when work with that piece of equipment is not in progress.

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3.2 NOT USED3.3 INSTALLATION OF FIBERGLASS PITS

Submit recommended installation procedures and setting tolerances from the pit manufacturer/supplier for the fiberglass pit and the aluminum cover.

These procedures shall indicate recommended methods of supporting the pit in its proper position in the open excavation prior to and during concrete placement operations. Also, required installation tolerances, especially for flatness/levelness of the fiberglass pit lip, shall be provided.

Follow these recommendations and apply other procedures as required to ensure the integrity of the pit liner and cover assemblies in their installed positions. All penetrations through the fiberglass pit liner shall be tightly sealed by suitable means to preclude water infiltration, with consideration for potential relative movements between the penetrating objects and the pit liner. Reference the Contract drawings for additional installation requirements.

3.4 POSTED OPERATING INSTRUCTIONS

For each designated system or equipment item, provide instructions for guidance of operating and maintenance personnel. Following approval of content, prepare these instructions in a form and scale that will be readily legible when displayed in appropriate locations, to be designated by the Contracting Officer and meet the following requirements:

3.4.1 Each System

For each system, include diagrams of equipment, piping, wiring and control. Define control sequences.

3.4.2 Each Tank

For each tank provide a P.E. stamped certified tank calibration chart in 1/16-inch increments reading in gallons.

3.4.3 Each Item

For each equipment item, include starting, adjustment, operation, lubrication, safety precautions and shut-down procedures. Identify procedures to be performed in event of equipment failure. Provide other instructions recommended by the manufacturer.

3.4.4 Diagrams

Provide a professionally prepared isometric piping diagram of the fueling system apparatus. Diagram shall be 36 by 54 inches and shall be color coded to match PCP color diagrams. Diagram shall show the entire facility and shall include all equipment and the operational sequences of all equipment with equipment numbers displayed. Diagram shall show all valves along with the valve numbers shown on the drawings and listed as normally open/closed. It shall be wall mounted under glass.

3.4.5 Volume of Fuel

Provide a certified system inventory of fuel in the pipe, tank, pumphouse, etc. The piping will show length of pipe, size of pipe, gal/foot, and

SECTION 33 52 43.11 Page 17 total gal. Verify during initial fill.

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SECTION 33 52 43.11 Page 18