33_52_43.11_Amd03.pdf

C-17 Type III Fuel System & Ramp Expansion FJRP159073 145th Airlift Wing, North Carolina Air National Guard

Section 33 52 43.11 Page 1

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

ASTM INTERNATIONAL (ASTM)

ASTM C827 (2010) Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2016) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2015) Flammable and Combustible Liquids Code

NFPA 30A (2015) Code for Motor Fuel Dispensing Facilities and Repair Garages

NFPA 70 (2017) National Electrical Code

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

AFLP-3747 (2013; Rev 9) Guide Specifications (Minimum Quality Standards) for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40 And F-44)

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS3275 (2009; Rev C) Sheet, Acrylonitrile Butadiene (NBR) Rubber and Non-Asbestos Fiber Fuel and Oil Resistant

U.S. DEPARTMENT OF DEFENSE (DOD)

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

Section 33 52 43.11 Page 2

MIL-STD-161 (2005; Rev G; Notice 1 2010) Identification Methods for Bulk Petroleum Products Systems Including Hydrocarbon Missile Fuels

UNDERWRITERS LABORATORIES (UL)

UL 142 (2006; Reprint Jul 2013) Steel Aboveground Tanks for Flammable and Combustible Liquids

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

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Venturi Tubes; G

Water Draw-Off System; G

Hydrant Outlet Pits and Isolation Valve Pits; G

High Point Vent and Low Point Drain Pits; G

Day Tank; G

Tightness Monitoring System; G

SD-03 Product Data

Pressure Gages; G

Automatic Pump Controls; G

Day Tank; G

Pressure Indicating Transmitters; G

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Section 33 52 43.11 Page 3

Flow Switches; G

Pressure Transmitter; G

Differential Pressure Transmitter; G

Hydrant Outlet Pits and Isolation Valve Pits; G

High Point Vent and Low Point Drain Pits; G

Operating Tank Level Indicator; G

Operating Tank Level Switches; G

Water Draw-Off System; G

Venturi Tubes; G

Tightness Monitoring System; G

SD-06 Test Reports

Tightness Monitoring System; G

Coating Testing; G

SD-07 Certificates

System Supplier; G

Tightness Monitoring System; G

SD-10 Operation and Maintenance Data

Automatic Pump Controls; G

Day Tank; G

Operating Tank Level Indicator; G

Water Draw-off System; 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.

Section 33 52 43.11 Page 4

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 DESIGN CONDITIONS

Components shall be suitable for use with AFLP-3747 Jet A (F-24) turbine fuel with a specific gravity of 0.775 to 0.84, a viscosity 1.5 cSt at 100 degrees F, and a Reid Vapor Pressure 0.05 psia. Components shall be ASME Class 150 (275 psi at 100 degrees F) unless otherwise noted. Components to be suitable for outdoor, unsheltered location, and to function normally in ambient temperatures between 0 and 100 degrees F.

2.2 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.

2.2.1 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.

2.2.2 Gaskets

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

PIPING.

2.2.3 Bolts and Nuts

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

FUELING PIPING.

2.3 EQUIPMENT AND MATERIAL

2.3.1 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, ../Word/33 52 43.13.doc

Section 33 52 43.11 Page 5 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.

2.3.2 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.

2.4 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.

2.5 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.

2.6 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

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Section 33 52 43.11 Page 6 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.

2.6.1 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. One pressure indicating dial shall be supplied with each pair of transmitters. Pressure indicating dials shall consist of a bellows type pressure sensing element operating on a differential in pressure of fuel (one side being open to atmospheric pressure) and a mechanical indicator (driven by the bellows unit). The bellows shall be dual opposed, liquid filled, rupture-proof type with bellows movement converted to rotation and transmitted by a torque tube. Bellows housing shall be stainless steel and shall have a rated working pressure of not less than 500 psi with a minimum differential pressure range of 0 to 250 psi. Liquid used to fill the bellows shall be suitable for the expected minimum ambient temperature. The indicating dial shall be at least 6 inches in diameter with a weatherproof glass cover. The case shall be finished with a weather resistant epoxy resin enamel. The indicating pointer shall traverse a 270 degrees arc. The scales shall be graduated over the selected pressure ranges so that the pressure can be read in psig. Indicator accuracy shall be 0.75 percent of full scale. Pressure indicating dial shall be provided with suitable over-range protection.

c. Display at the pressure transmitter shall be LCD, one per each transmitter. The digital scale shall be a 4 digit LCD capable of being read in low light/no light conditions. Indicator scale shall be in psig.

d. 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 T3 (392 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.

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Section 33 52 43.11 Page 7

e. 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.

2.6.2 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.

2.6.3 Venturi Tubes

a. The venturi tubes shall be provided in conjunction with Section 33 09

53 AVIATION FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM.

b. Start-up, adjustments and calibration, and instruction of personnel in the operation and maintenance of the venturi tubes shall be considered as a required portion of the controls package.

c. The venturi tubes shall be low loss differential pressure producers consisting of a short housing piece and a fully machined, contoured throat section providing a restriction at the center, with both inlet approach and exit having geometrically symmetrical curves. They shall be velocity head, impact, differential producing devices designed to measure differential pressure of F-24 fuel. They shall be constructed of 304L stainless steel with ANSI Class 150 flanges on each end and be suitable for operation of 275 psig at 100 degrees F. They shall be of sufficient thickness to with-stand the same stresses as the upstream and downstream piping. Each venturi tube shall have a minimum of four 1/2-inch connections. An individual head-capacity curve shall be furnished for each venturi tube.

d. Operating conditions for the venturi tubes shall be as follows:

(1) Issue Venturi Tube. Minimum inlet-to-throat differential pressure at 1,800 gpm: 200 in H2O.

(2) Return Venturi Tube. Minimum inlet-to-throat differential pressure at 900 gpm: 200 in H2O.

(3) Venturi tubes discharge coefficient "C" to be greater than or equal to 0.97 over pipe Reynolds number range between 200,000 and 1,000,000 and shall be independent of Beta over a Beta range of 0.4 to 0.75. Pressure loss shall be less than 24 percent of differential pressure generated by the venturi tube. Repeatability

Section 33 52 43.11 Page 8 of the discharge coefficient "C" shall be 2 percent for Reynolds number range of 10,000 to 1,000,000.

(4) Provide two portable GPM Meters, one for each size of venturi. The meters shall be complete with valves, hoses and connecting disconnects, and carrying case. The meters shall have stainless steel bellows, mounting bracket, 500 psi swp, 6-inch dial with 270 degrees arc. Dial shall read GPM Jet Fuel. Range of scale shall match the flow transmitter for issue and return. The venturi manufacturer shall provide the portable meters with the venturi in order to be compatible. The venturi tubes shall also be provided with a suitable table to convert inches differential pressure to gallons per minute.

2.6.4 Differential Pressure Transmitter

Differential pressure transmitter shall consist of a capacitance sensor operating on a differential in pressure of fuel. The output shall be a 4 - 20mA dc, square root signal between a minimum of 4 - 100 percent of the input. It may be linear between 0 - 4 percent. 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 plus or minus 0.20 percent of calibrated span including combined effects of linearity, hysteresis and repeatability.

b. One differential pressure dial shall be supplied with each pair of transmitters. Differential pressure dial shall consist of a bellows type pressure sensing element, operating on a differential in pressure of fuel, and a mechanical indicator, driven by the bellows unit. The bellows shall be dual opposed, liquid filled, rupture-proof type with bellows movement converted to rotation and transmitted by a torque tube. Displacement of bellows shall be 1.5 cubic inches for full scale travel. Bellows housing shall be stainless steel and shall have a rated working pressure of not less than 500 psi. Liquid used to fill the bellows shall be suitable for the expected minimum ambient temperature. The indicating dial shall be at least 6 inches in diameter with a weatherproof glass cover. The case shall be finished with a weather resistant epoxy resin enamel. The indicating pointer shall traverse a 270 degree arc. The scales shall be graduated over the selected pressure ranges so that the flow rate can be accurately read in gallons per minute. Indicator accuracy shall be 0.5 percent of full scale. Differential pressure indicating dial shall be provided with built-in pulsation damper and suitable over-range protection.

c. Display at the transmitter shall be LCD, one per each differential pressure transmitter. The digital scale shall be a 4 digit LCD, capable of being read in low light/no light conditions. Indicator scale shall be in gallons per minute.

d. Each venturi tube shall have two transmitters and one indicating dial per function and shall be installed as indicated on the drawings.

Section 33 52 43.11 Page 9

Differential pressure ranges shall be selected as necessary to operate in conjunction with associated venturi tube:

(1) Issue Venturi Tube - 0 to 1,800 GPM (full range).

(2) Return Venturi Tube - 0 to 1,100 GPM (full range).

e. Differential 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 T3 (392 degrees F). Each transmitter and indicating dial shall be supplied with a factory assembled five valve stainless steel manifold. Vent valves shall be furnished on upper ports of each transmitter and indicating dial.

Differential 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.

2.6.5 Pressure Transmitter

Transmitter 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 T3 (392 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.

2.7 PRODUCT RECOVERY TANK AND ACCESSORIES

See Specification Section 33 56 10 FACTORY FABRICATED FUEL STORAGE TANK for product recovery tank and accessories.

2.8 HYDRANT OUTLET PITS AND ISOLATION VALVE PITS

Hydrant hose truck hydrant outlet pits and isolation valve pits shall be prefabricated units that are the standard products of a firm regularly engaged in the manufacture of such products and shall essentially duplicate items that have been in satisfactory use for at least (3) years prior to bid opening. The basic pit shall consist of a 0.50 inch thick fiberglass walls and floor with main body dimensions as shown on the drawings. The pit shall contain twelve (minimum) integral concrete anchors or two integral anchors that run continuous on three sides of pit. The integral fiberglass top flange shall require no exposed corrosive material, weldments, or strongbacks within the pit to support the aluminum cover assembly. The manufacturer shall have had a minimum of three years successful experience in the production and usage of their fiberglass service pits and shall supply proof of experience at time of submittals. Pits shall be provided with a 2 inch pump-out line terminating with a male cam type bronze connector with female dustcap. Pits shall be provided with removable aluminum grating platform suitable for loading of 400 pounds per square foot. The grating shall cover the entire opening when the lid is in the open position. The grating platform shall have outside edges and cut-outs framed. The inside of the lid shall have a 14 by 10 inch permanently attached sign which says "DANGER CONFINED SPACE ENTER BY PERMIT ONLY". The sign shall be white with black letters, made of PVC, completely and permanently encapsulated 50 mil plastic.

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Section 33 52 43.11 Page 10

2.8.1 Pit Cover

The pit cover assembly shall consist of a completely removable one-piece aluminum lid attached to a rigid frame which is an integral part of the fiberglass pit. The lid shall be attached to the frame with hinges which do not carry wheel loads applied to the top surface of the lid in its closed position. The lid shall be equipped with a device to hold the lid in its fully-opened position. This lid-staying device shall automatically engage when the lid is opened to its fully-opened position. The device shall also be provided with a quick-release mechanism designed to be operated with one hand. The lid shall be considered fully-open when it is rotated approximately 90 degrees from its closed position. Each cover lid shall move smoothly through its entire range of motion and shall be counterbalanced sufficiently to require an externally-applied opening force of 35 pounds (maximum) to be applied to the center of the long side of the cover (opposite the hinge side). Similarly, the maximum closing force required to be applied at the same point shall be approximately 50 pounds.

In addition, the cover shall be counterbalanced in such a fashion that the cover will not close under its own weight if released when open to any angle greater than 70 degrees (from its closed position). Operation of the lid will not have spring assist. Lifting handles (two minimum) shall be provided for each lid. Each handle shall provide comfortable, secure grip for and average adult male's full (gloved) hand. All covers shall be provided with a latch, operable from the exterior of the vault, to securely hold the lid to the frame in the closed position. The latch will be capable of being released from either lifting handle. Tools shall not be required to engage (or disengage) the latch or the lid lifting handles. Latch and handle designs shall be weather-resistant with features to prelude freeze-up and the collection of dirt and precipitation. Projections of the lid's hinges, lifting handles, or latches above the plane of the lid, whether temporary or permanent, shall not be allowed. The weight bearing flange surfaces of both the fiberglass pit liner and the aluminum cover lid shall be machined flat to assure uniform weight distribution. The word FUEL 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. Pit lid shall be designed for resisting debris and water accumulation at seals, load bearing surfaces, hinges, and handle pockets. Seal shall be an elastomeric perimeter seal, easy to replace, secured to lid by dovetail grooves, no adhesive. Push buttons are not allowed.

2.8.2 Pit Cover Materials, Design, and Testing

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

Section 33 52 43.11 Page 11 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 minimum interior opening dimension 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.

2.8.3 Pipe Seal

The pipe penetrations through the pit floor or wall shall be sealed by means of a Buna-N boot. The boot shall be secured to the pipe and to a steel sleeve bonded to the pit wall at the pit penetration by stainless steel clamps. Buna-N (Nitrile Butadiene) material shall be in accordance with SAE AMS3275. Segmented elastomeric seals shall be used to seal between the steel sleeve and carrier pipe.

2.8.4 Hydrant Outlet Pit Equipment

At the Contractor's option, hydrant pits may be furnished complete with hydrant control valves and shutoff valves assembled in a pipe riser. All valves and piping furnished by the pit manufacturer shall comply with the requirements specified herein. All control valves shall be of the same manufacturer.

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 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. The pit shall have a tamperproof cover. The removable outer ring shall have anchors to provide for means to secure the manhole and its moveable cover and lid to the "concrete" fiberglass containment. The inner hinged lid shall have a means of being locked. Each cover lid shall move smoothly through its

Section 33 52 43.11 Page 12 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 plus 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 clamps.

Collar shall be fabricated from the same material as the pipe. Segmented elastomeric seals shall be used to seal between the steel sleeve and carrier pipe.

2.10 OPERATING TANK LEVEL INDICATOR

The level indicating system must perform tank gauging and have local tank readout. The level indicating system must use a servo to measure all the various locations required for the primary measurement. The level indicating system must be able to measure and compute fuel level, fuel

Section 33 52 43.11 Page 13 density, fuel actual volume, fuel and water corrected volume, and fuel ambient temperature. The reference point for all level measurements must be from the tank's datum plate. The servo system must attach to the tank's 10 inch riser/8 inch stilling well to minimize the effects of turbulence on the measurements and still allow the government access to take quality control samples. The level indicating system must be able to measure in underground, aboveground and cut and cover tanks with all floor and roof types. The level indicating system must be able to measure multiple tanks with a single field interface unit. The level indicating system must be able to determine whether the tank is issuing or receiving fuel while in the transfer mode and also with the same unit be able to perform leak detection.

The level indicating system must require no periodic calibration after installation is complete. The level indicating system must be approved for installation in a hazardous area and certified intrinsically safe by an approved agency and provide lightning protection. The level indicating system must be able to interface with government owned information systems.

The level indicating system must provide five sets of alarm outputs; high, intermediate high, low, intermediate low, and static tank movement alarm.

a. Level accuracy plus or minus 0.05 inches.

b. Corrected volume accuracy plus or minus 0.1 percent.

c. Density accuracy plus or minus 1 percent.

d. Temperature accuracy plus or minus 1 degrees F.

e. Detect water in the tank sump to a level equal to or slightly above the water draw-off pipe.

It will be an ENRAF Servo Gauge Model 854 Automatic Tank Gauging System or approved equal. Equality being determined by compatibility with the Base FAS System. The system shall include a relocated RTU 8130 and a new local display similar or equal to a Varec OIT 8650. The Varec OIT 8650 shall be programmed to display inventory data, including all parameters identified above, of each operating tank and product recovery tank. The RTU shall transmit data to the Base FAS System located in the Operations Building 39 via fiber communications as shown on the drawings. Base personnel shall coordinate reprogramming of the FAS System to accept this new data.

2.11 OPERATING TANK LEVEL SWITCHES

The switches shall be an external mount liquid level switch with a stainless steel float chamber and stainless steel, type 304 or 316, float and trim.

Switch contacts shall be two single pole double throw switches factory mutual approved or U.L. listed for use in Class I, Division 1, Group D hazardous location with a maximum temperature rating of T3 (392 degrees F).

Units shall have provisions to check level switch operations without increasing the fuel level in the tanks as shown on the Contract Drawings.

a. System shall be designed and installed in such a way that the system shall be continuously and automatically self-checking. Switches shall be an external mount with a stainless steel fluid chamber. Electronic level sensors shall 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 shall be accessible from the stairway. Units shall have provisions to check

Section 33 52 43.11 Page 14 level switch operations without increasing the fuel level in the tanks as shown on the contract drawings.

b. Level alarms shall be mechanically and electrically independent and be totally isolated from the gauging system. The level switches shall 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 shall be intrinsically safe.

2.12 WATER DRAW-OFF SYSTEM

Provide a water draw-off system complete with all equipment and controls and connected to the ASTs as indicated. System shall remove fuel from its associated storage tank, separate the fuel and water by gravity, return the fuel back to the storage tank, and discharge the water. The system and its components shall meet the requirements of the Specification herein. The system shall include, but is not limited to, the following piping, fittings, valves, equipment, and controls.

2.12.1 Tank

Product Saver Tank: Provide a product saver tank with the tank, piping and fittings packaged and fabricated as a single system. Fabricate tank and support legs from Type 304 stainless steel with tank volume of 55 gallons.

Provide tank with removable top, 1 inch inlet line, 1 inch drain line, and other lines as indicated, all with full port ball valves and cam-type connections. Provide tank with concrete mounting pad and anchor tank to it.

2.12.2 Product Saver Pump

Pump shall be a close coupled centrifugal having a capacity of 10 gpm at not less than 60 feet of head and with a Net Positive Suction Head of more than 3 feet. Pump motor shall be in accordance with NEMA MG 1. All pump components in contact with fuel shall be stainless steel. The unit shall be UL listed and labeled for use in Class I, Division 1, Group D hazardous environments as defined by NFPA 70, with a maximum temperature rating of T3 (392 degrees F). The motor shall be non-overloading at every 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 an internal and external pressure relief valve between the discharge and suction piping to protect the pump from overloading. Internal relief valve shall be set at 45 psi and external relief valve shall be as specified in under "Safety Relief Valves" in specification section 33 52 43.13 AVIATION FUEL PIPING.

2.12.3 Piping, Valves, Fittings, and Instruments

Pipe, pipe fittings, flanges, manual valves, gaskets, and bolting shall be in accordance with Section 33 52 43.13 AVIATION FUEL PIPING. Materials of construction shall be as described in this Specification Section in "Materials for Equipment, Pipe, and Fittings," except as modified herein.

2.12.4 Controls

Provide a pump start/stop pushbutton station with red (run) and green (stop) lights. All lights shall be push to test type. All equipment shall be rated for Class I, Division 1, Group D service.

Section 33 52 43.11 Page 15

2.12.5 Electrical

Provide completely pre wired with single point of service connection at horsepower rated disconnect switch. Provide combination motor/starter with HOA switch for pump motor. Provide suitable for Class I, Division 1, Group D service.

2.12.6 Basis of Design of Water Draw-Off System

The system shall be arranged in the same general configuration as indicated.

However, these are not fabrication drawings and are for basis of design only. The Contractor shall be responsible for providing a complete and usable system.

2.12.6.1 Detail Drawing

Submit detailed drawings showing the Water Draw-Off System, including types, sizes, location, and installation details for:

a. Pipe hangers and supports.

b. Grounding.

c. Tank.

d. Pump.

e. Controls.

f. Valves.

g. Piping.

2.13 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

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Section 33 52 43.11 Page 16

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.

2.14 DAY TANK

A day tank shall be provided in the pumphouse.

2.14.1 Tank

The day tank shall be a 50-gal fabricated stainless steel tank with supporting legs. Tank and support legs shall be fabricated from Type 304 stainless steel.

2.14.2 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.

2.14.3 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 T3 (392 degrees F), 120-volt input power, single pole, single throw (SPST) relay output, 1-inch flanged mounting.

2.14.4 Anchoring

The tank shall be installed plumb and level and secured in place by anchor bolts.

2.14.5 Pressure/Vacuum Conservation Vent

Size and construct vent pipe in accordance with NFPA 30, NFPA 30A, and UL

142. Provide a Pressure/Vacuum Conservation Vent at the termination point of each vent pipe. Vent to be sized to maintain a maximum of 1/2-ounce per square inch pressure or vacuum. Vent body shall be constructed of 316 Stainless Steel. Seats to be replaceable and comprised of Teflon. Provide a minimum 40-mesh stainless-steel insect screen. The vent hood shall prevent rain, snow, or ice from entering the vent piping. Vent opening shall be a minimum of 12 ft above grade.

PART 3 EXECUTION

3.1 GENERAL

Section 33 52 43.11 Page 17

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 site. Grouting shall be in accordance with ASTM C827. 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

Section 33 52 43.11 Page 18

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.

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

3.2 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.

3.3 POSTED OPERATING INSTRUCTIONS

Section 33 52 43.11 Page 19

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:

3.3.1 Each System

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

Define control sequences.

3.3.2 Each Tank

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

3.3.3 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.

3.3.4 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.