33_52_43.28_Amd03.pdf

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

Section 33 52 43.28 Page 1

SECTION 33 52 43.28

FILTER SEPARATOR, AVIATION FUELING SYSTEM

11/10

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 B31.3 (2014) Process Piping

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

ASTM INTERNATIONAL (ASTM)

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

ENERGY INSTITUTE (EI)

EI 1581 (2011) Specifications and Qualification Procedures for Aviation Jet Fuel Filter/Separators

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS-P-5315 (2013, Rev B) Butadiene - Acrylonitrile (NBR) Rubber For Fuel-Resistant Seals 60 To 70

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-HDBK-831 (2013; Rev A) Preparation of Test Reports

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

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

Section 33 52 43.28 Page 2

CID A-A-1923 (Rev A; Notice 2) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)

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)

1.2 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

Filter Separator; G

SD-03 Product Data

Filter Separator; G

SD-07 Certificates

Filter Separator

SD-10 Operation and Maintenance Data

Filter Separator; G

1.3 PREPRODUCTION TESTING

Prior to construction of filter separators (FSI-1 THROUGH FSI-3, FSR-1, THROUGH FSR-2) for the Project, preproduction tests shall have been conducted in the presence of Det 3, WR-ALC/AFTH Technical Assistance Team Air Force Petroleum Office Wright-Patterson AFB, OH representative. Notify the Contracting Officer 30 days prior to conductance of factory tests in order to schedule witnessing by representative.

1.3.1 Inspection and Testing

The inspection and testing of the preproduction filter separator shall be conducted on a full-scale test system in accordance with EI 1581 and as specified herein. The test sample shall consist of a complete filter separator with elements installed. Elements shall be representative of a production lot. The filter separator, coalescers, and separator screens shall be identified with the manufacturer's part number.

1.3.2 Deviations from EI 1581

No deviations are allowed.

1.3.3 Data Required Prior to Tests

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Section 33 52 43.28 Page 3

Submit installation data to enable Government representative to verify that the equipment has been installed and operated correctly. Submit certification from the manufacturer that the test vessel has passed a hydrostatic pressure test, and that the design conforms to EI 1581, Category M, Type S. Submit two sets of assembly drawings of the test vessel and accessories for approval.

1.3.4 Submittal of Test Documents

The test report shall be submitted to the Command Fuel Facilities Engineer or Det 3, WR-ALC/AFTH for Government approval. Prepare report in accordance with MIL-HDBK-831. In addition to results, the report shall contain complete records of the tests including data sheets, performance curves, chronological test records, photographs, sample calculations, test procedures, and a description of the test apparatus. Submit color photographs of the sample elements before and after tests. Submit one new coalescer element and one new separator element.

1.3.5 Required Preproduction Tests

a. Examination. A visual examination of the filter separator housing and each element shall be performed to ensure compliance with the Drawings and verify workmanship requirements.

b. Hydrostatic Pressure Tests. The filter separator shall be subjected to a hydrostatic pressure test in accordance with EI 1581, Section 3.2.2.11.1.

c. Full Scale Performance Test. EI 1581. The filter/separator with a full set of coalescer and separator elements shall be tested in accordance with EI 1581 Section 4.4 at 900 gpm (FSI-1 through FSI-3;

FSR-1 and FSR-2).

d. Coalescer Structural Test. A coalescer structural test shall be conducted in accordance with EI 1581 Section 4.5.

e. Disassembly Inspection. Upon completion of the tests specified above, the filter separator shall be disassembled and inspected to determine the condition of the coalescer and separator elements. Defects in the element such as swelling of the elements, or damaged gaskets shall be noted. Swelling of or damage to the elements or other parts shall be cause for rejection.

1.4 WORKMANSHIP

Each filter separator, including all parts and accessories, shall be free from blemishes, defects, burrs and sharp edges. The vessel shall exhibit accuracy of dimensions, accurate radii of fillets and complete marking of parts and assemblies.

1.5 CLEANING

Components of the filter separators shall be cleaned to remove dirt; excess soldering; brazing, and welding flux; welding slag; loose, spattered, or excess solder; metal chips; and other foreign materials before, during and after assembly.

Section 33 52 43.28 Page 4

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 WELDING

Welding shall be in accordance with ASME B31.3.

2.3 MATERIALS AND EQUIPMENT

2.3.1 Housing

a. Carbon steel with internal epoxy coating(FSR-1 and FSR-2) and Type 304 or 316 stainless steel (FSI-1 Thru FSI-3).

b. Float Assembly. Stainless steel.

c. Manual Drain Valve. Stainless steel.

d. Sight Glass. Armored clear Pyrex with nickel-copper alloy ball checks.

e. Differential Gauge. Corrosion resistant piston with stainless-steel valves.

f. Separators. 200 mesh stainless steel wire cloth, polytetrafluorethylene (PTFE) coated on both sides, or synthetic mesh cloth.

2.4 FILTER SEPARATOR CONSTRUCTION

2.4.1 Housing Vessel

Each receipt filter separator (FSR-1 Thru FSR-2, and FSI-1 Thru FS-3) housing shall be fabricated from carbon steel and shall be internally coated with an epoxy coating in accordance with MIL-PRF-4556. Coat the carbon steel exterior with alkalyd 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 275 psig. Each unit shall be horizontal, end-opening type with coalescers and separators mounted side-by-side (coalescers at the bottom of the vessel and separators at the top). The head opening shall be equipped with a hinged or pivoting device to facilitate swinging the head to one side for servicing. The hinges or pivots shall support the head during servicing without distortion or misalignment. Swing-type bolts shall be used on all main closures. Unit shall be provided with 3 inch inside diameter lifting eyes spaced to support a weight of 2-1/2 times the gross weight of the filter separator. The configuration of the pressure vessel shall be as shown on the Drawings. The housing shall be provided with a 3/4 inch inlet compartment fuel drain plug.

A hand hole access plate shall be provided in the inlet compartment. The head shall be sealed to the body by means of an O-ring, meeting requirements

Section 33 52 43.28 Page 5 of SAE AMS-P-5315, mounted in a circular groove at the point of closure.

Threaded base mounting adapters shall be provided for the coalescers. The separators shall be mounted on adapters with blunted Vee-type knife edges.

Height of Vee section to be 0.06 inches, plus or minus 10 percent. Weld ridges shall not prevent liquid from draining. The filter separator vessel shall be able to withstand a force of 2,400 pounds and a moment of 2,400 foot-pounds at the flanges.

2.4.2 Legs

Four 3 by 3 by 1/4 inch angle-shaped legs shall be welded to the housing.

Each leg shall be fitted with a 4 by 4 by 1/2 inch base plate drilled through with a 3/4 inch hole.

2.4.3 Inlet and Outlet Connections

The inlet and outlet connections shall be 6 inch nominal pipe size and shall be located parallel to each other as shown on the Drawings. Inlet connection shall be provided with raised face flanges, faced and drilled in compliance with ASME B16.5, Class 150. Outlet connection flange face shall match Filter Separator Control Valve (FSCV).

2.4.4 Manual Drain Valve

As specified in Paragraph "Accessories".

2.4.5 Sight Gauge

As specified in Paragraph "Accessories".

2.4.6 Differential Pressure Gauge

As specified in Paragraph "Accessories".

2.4.7 Automatic Air Eliminator and Pressure Relief Valves

As specified in Paragraph "Accessories".

2.4.8 Sampling Connections

As specified in Paragraph "Accessories".

2.4.9 Spider Assembly

Each filter separator shall contain a spider assembly to hold the coalescers and separators in position, to support them firmly against vibration. The method of stabilization shall assure an electrical bond between the spider and the vessel.

2.4.10 Coalescer and Separator Cartridges

Each filter separator shall be provided with coalescers and separators that have been qualified to the performance requirements of EI 1581, Category M, Type S. Issue filter separators (FSI-1 Thru FSI-3) shall use coalescers 6 inches in diameter and 56 inches long for a flow-rate of 900 gpm. Receipt Filter Separators (FSR-1 and FSR-2) shall use coalescers 6 inch in diameter and 56 inches long for a flow rate of 900 GPM.

Section 33 52 43.28 Page 6

2.4.11 Control Valve Accessories

Provide each filter separator with a control valve (FSCV), manual water drain valve, and float control valve (FC) with manual tester as specified in Section 33 52 43.14 AVIATION FUEL CONTROL VALVES and shall be of the same manufacturer.

2.4.11.1 Float Control Pilot and Tester

Each housing sump shall be fitted with a float control pilot and tester specified in Section 33 52 43.14 AVIATION FUEL CONTROL VALVES and shall be of the same manufacturer as the control valves. The drain port "D" shall be piped to the drain piping to the product recovery tank.

2.4.12 Identification of Product

Equipment, assemblies, and parts shall be marked for identification in accordance with MIL-STD-130. The main equipment nameplate shall be mounted on the housing, and in addition to the usual MIL-STD-130 requirements, shall include the following markings in letters 3/32 inch high or larger:

Filter Separator, Liquid Fuel

Design Flow-Rate

Design Pressure

Elements

First Stage Mfg. Part No. *

Second Stage Mfg. Part No. *

Contract No. *

Manufacturer *

Specification*

*Applicable information shall be entered by the Contractor.

*Applicable information shall be stenciled by LFM personnel.

2.4.13 Assembly

Each filter separator shall come assembled with all accessories and shall be ready for use. The functions of all components shall be tested prior to shipment and no assembly or field adjustment of valves or components shall be required.

2.5 ACCESSORIES

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Section 33 52 43.28 Page 7

2.5.1 Manual Drain Valve

Each filter separator shall be equipped with a 1 inch stainless steel manual ball valve water and fuel drain. The valve shall be capable of draining all water, fuel and sediment from the filter separator by gravity. The valve shall be installed below the sump of the housing as shown on the Drawings.

2.5.2 Sight Gauge

A 1/2 inch armored, clear borosilicate (Pyrex) liquid level gauge shall be provided for observing the water accumulation in the sump. 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. Liquid level gauges shall be rated for a maximum pressure of 275 psi.

2.5.3 Differential Pressure Gauge

The housing shall be equipped with a direct-reading, piston type differential pressure gauge that measures the differential pressure across both coalescers and separators. The gauge shall consist of a spring-supported, corrosion resistant piston moving inside a glass cylinder, with high pressure applied on top of the piston and low pressure applied below

it. The gauge shall have a peak-hold reading that locks the piston to indicate the maximum differential pressure that is measured until the piston is released by turning a knob, a push button test valve to relieve pressure under the piston, and a pressure relief feature set at 300 psi to protect the gauge if isolation valves have been left closed. Under a differential pressure of 30 psi, leakage past the piston shall not exceed 120 drops per minute. The cylinder shall have stainless steel and flanges with fluoroelastomer (FKM), commonly referred to as Viton, O-ring seals. The high pressure inlet of the gauge shall have a 10 micron pleated paper filter and the low pressure connection shall have a fine mesh stainless steel strainer. The gauge shall have an operating pressure of 300 psi.

Differential pressure range of the gauge through approximately 3 inches of piston movement shall be 0-30 psi with an accuracy of + 0.5 psi, calibrated linearly with 1 PSI scale graduations. High and low pressure connections shall be 1/4 inch NPT female with a stainless steel bar stock valve at each connection. Construction of the gauge shall be such that a 3-valve manifold is not necessary. If only one bar stock valve is closed, the gauge shall not be damaged by up to 300 psi differential pressure in either direction.

The differential pressure gauge shall be attached to the filter separator by a gauge panel. A pressure gauge shall be attached to the differential pressure gauge to indicate the high pressure and have a range of 300 psi.

2.5.4 Automatic Air Eliminator and Pressure Relief Valves

A 1 inch angle pattern pressure relief valve shall be provided on top of each vessel. An automatic air eliminator shall be installed on the highest point of the vessel and shall have check valve feature. The air eliminator shall release at pressures up to 150 psi with no fuel leakage allowed. The relief valve piping shall be routed to the product recovery tank, with all manual valve in the relief path locked open. Relief valve pressure shall be as indicated on the Drawings and shall be a BPVC Section VIII stamped valve.

Air Eliminator piping shall be routed to the product recovery tank.

Section 33 52 43.28 Page 8

2.5.5 Sampling Connections

Sampling connections shall be provided at the inlet and outlet connections to the housing. Each sampling connection shall consist of a 1/4 inch sampling probe where the probe faces upstream, ball valve, a quick disconnect coupling and aluminum dust cap. The sampling connections shall be capable of accepting a sampling kit for drawing the samples required to assure fuel quality.

PART 3 EXECUTION

3.1 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 clearance between equipment components. Equipment apparatus, and accessories requiring normal servicing or maintenance to be accessible.

3.1.1 Anchoring

Anchor equipment in place. Check alignment of anchor bolts before installing equipment and cleanout 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.

Expansion bolt anchors provided shall be in accordance with CID A-A-1923, Type 4, Class One, 1/2 inch size.

3.1.2 Grouting

Equipment, which is anchored to a pad, shall be grouted in place where applicable. 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, coatings and other materials which impair bond. Clean contaminated concrete by grinding or other acceptable means. Provide necessary formwork for placing and retaining grout. Grout to be nonmetallic, nonshrink, 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 power agents, oxidizing agents and inorganic accelerators, including chlorides; proportioned, premixed and packaged at factory with only the addition of water required at the project site.

Grouting to meeting requirements of ASTM C827. Perform grouting in accord with ACI, equipment manufacturer's, and grout manufacturer's published specifications and recommendations.

3.1.3 Leveling and Aligning

Level and align equipment in accordance with respective manufacturer's published data. Do not use anchor bolts, 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

Section 33 52 43.28 Page 9 support. Shims to have smooth surfaces and edges, free from burrs and slivers. Flame or electrode cut edges not acceptable.

3.1.4 Painting and Labeling

Equipment painting shall be as specified in Section 09 97 13.27 EXTERIOR COATING OF STEEL STRUCTURES. Equipment labeling shall be as specified in Section 33 52 43.11 AVIATION FUEL MECHANICAL EQUIPMENT.

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