W9128F-20-R-0056_0005 Specifications.pdf

Hydrant Fuel System Replacement, Ellsworth AFB, SD EL84

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 52 43.11

AVIATION FUEL MECHANICAL EQUIPMENT

08/18

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 GAUGES

2.4.1 Quick Disconnect

2.5 AUTOMATIC PUMP CONTROLS

2.5.1 Pressure Indicating Transmitters

2.5.2 Flow Switches

2.5.3 Venturi Tubes

2.5.4 Differential Pressure Transmitter

2.5.5 Pressure Sensor

2.6 RECEIPT FLOW METER

2.7 ABOVEGROUND PRODUCT RECOVERY TANK AND ACCESSORIES (4,000 GALLON)

2.7.1 Tank Construction

2.7.1.1 Automatic Tank Gauging (ATG) and Leak Detection Monitor

2.7.1.1.1 ATG

2.7.1.1.2 Leak Detection

2.7.1.1.3 Control Panel

2.7.1.2 Tank Appurtenances and Fittings

2.7.1.3 Not Used

2.7.1.4 Not Used

2.7.1.5 Not Used

2.7.1.6 Float Switch Assembly

2.7.1.7 Fuel Transfer Pump (FTP-1)

2.7.1.8 Electric Pump

2.7.1.9 Lockable Cap

2.7.1.10 Spill Containment Basin

2.7.1.11 Overfill Valve (OV-1)

2.7.1.12 Not Used

2.7.1.13 Tank Catwalk

2.8 ABOVEGROUND PRODUCT RECOVERY TANK AND ACCESSORIES (500 GALLON)

SECTION 33 52 43.11 Page 1 Am #0004

2.8.1 Tank Construction

2.8.1.1 Not Used

2.8.1.2 Tank Appurtenances and Fittings

2.8.1.3 Not Used

2.8.1.4 Not Used

2.8.1.5 Fuel Transfer Pump (FTP-2)

2.8.1.6 Lockable Cap

2.8.1.7 Tank Overfill Prevention Valve

2.9 ISOLATION VALVE PITS

2.9.1 Pit Cover

2.9.2 Pit Cover Materials, Design, and Testing

2.9.3 Pipe Seal

2.10 HIGH POINT VENT AND LOW POINT DRAIN PITS

2.10.1 Pit Assembly

2.10.2 Pit

2.10.3 Pit Cover, General Requirements

2.10.4 Pit Cover Materials, Design, and Testing

2.10.5 Pipe Riser Seal

2.11 OPERATING TANK LEVEL INDICATOR

2.12 NOT USED

2.13 OPERATING TANK LEVEL SWITCHES

2.14 WATER DRAW-OFF SYSTEM

2.14.1 Tank

2.14.2 Sight Glass

2.14.3 Return Pump

2.14.4 Anchoring

2.15 BOWSER PUMPOFF PUMP

2.16 JOCKEY PUMP

2.17 PUMPHOUSE DRAIN PUMP

2.18 TIGHTNESS MONITORING SYSTEM

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 INSTALLATION OF UNDERGROUND TANKS

3.2.1 Coating Testing

3.2.2 Steel Tanks

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

08/18

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.

AMERICAN PETROLEUM INSTITUTE (API)

API RP 1615 (2011) Installation of Underground Petroleum Storage Systems

ASME INTERNATIONAL (ASME)

ASME B16.5 (2017) 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/C827M (2016) Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures

ASTM D1655 (2018a) Standard Specification for Aviation Turbine Fuels

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2018) Flammable and Combustible Liquids Code

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; TIA 17-15; TIA 17-16; TIA 17-17 )

National Electrical Code

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)

SECTION 33 52 43.11 Page 3

Identification Marking of U.S. Military Property

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

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

40 CFR 280 Technical Standards and Corrective Action Requirements for Owners and Operators of Underground Storage Tanks (UST)

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 must include type of material, configuration, thickness, and necessary details of construction of the steel tank and vault. Shop drawings must also show the steel grating and supports.

Submit Manufacturer's Catalog Data and Certificates of Compliance.

Operation and maintenance information must be submitted for the equipment items or systems listed in PART 2. Automatic pump controls must 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.

*Am-3

1.3 SUBMITTALS

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

Venturi Tubes; G-DO

Water Draw-Off System; G-DO

Isolation Valve Pits; G-DO

High Point Vent and Low Point Drain Pits; G-DO

ABOVEGROUND PRODUCT RECOVERY TANK AND ACCESSORIES (4,000 GALLON);

G-DO

Bowser Pumpoff Pump; G-DO

Jockey Pump; G-DO

SECTION 33 52 43.11 Page 4

Pumphouse Drain Pump; G-DO

Tightness Monitoring System; G-DO

Aboveground Product Recovery Tank And Accessories (500 GALLON)

SD-03 Product Data

Pressure Gauges; G-DO

Automatic Pump Controls; G-DO

Aboveground Product Recovery Tank and Accessories (4,000 GALLON);

G-DO

Isolation Valve Pits; G-DO

High Point Vent and Low Point Drain Pits; G-DO

Operating Tank Level Indicator; G-DO

Operating Tank Level Switches; G-DO

Water Draw-Off System; G-DO

Venturi Tubes; G-DO.

Bowser Pumpoff Pump; G-DO

Jockey Pump; G-DO

Pumphouse Drain Pump; G-DO

Tightness Monitoring System; G-DO

Aboveground Product Recovery Tank And Accessories (500 GALLON);

G-DO

SD-06 Test Reports

Leak Detection Monitor; G-DO

Tightness Monitoring System; G-DO

Coating Testing; G-DO

SD-07 Certificates

System Supplier; G-DO

Tightness Monitoring System; G-DO

SD-10 Operation and Maintenance Data

Automatic Pump Controls; G-RO

Aboveground Product Recovery Tank and Accessories (4,000 GALLON);

G-RO

SECTION 33 52 43.11 Page 5

Operating Tank Level Indicator; G-RO

Water Draw-off System; G-RO.

Bowser Pumpoff Pump; G-RO

Jockey Pump; G-RO

Pumphouse Drain Pump; G-RO

Tightness Monitoring System; G-RO

Aboveground Product Recovery Tank And Accessories (500 GALLON);

G-RO

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 must 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 must 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 must be used in contact with the fuel.

2.1.1 Types of Fuel

Components must be suitable for use with F-24 turbine fuel (Jet A with additives FSII, CI/LE, and SDA); specific gravity 0.81 at 60 degrees F;

viscosity 1.62 CS at 60 degrees F; Reid vapor pressure less than 0.05 psi, ASTM D1655. 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 -10 degrees F and 100 degrees F.

2.1.2 Composition of Materials

Materials in contact with the fuel must 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 must be used in contact with the fuel.

SECTION 33 52 43.11 Page 6

2.1.3 Gaskets

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

PIPING.

2.1.4 Bolts and Nuts

Bolts and nuts must 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 must be new and of the best quality used for the purpose in commercial practice and must be products of reputable manufacturers. Each major component of equipment must 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 must be fully enclosed or properly guarded. Equipment, assemblies and parts must be marked for identification in accordance with MIL-STD-130 and MIL-STD-161. Pump and filter vessel numbers must be as indicated on the drawings. In addition, filter vessels must include stenciled or embossing tape letters 3/4 to 1 inch tall which indicate element numbers, date element changed, due date of the next element change, and maximum differential pressure. Identification (ID) tags made of brass, stainless steel, or engraved anodized aluminum, indicating valve number and normally open (NO) or normally closed (NC) must be installed on valves. Tags must be 1-3/8 inch minimum diameter, and marking must be stamped or engraved.

Indentations must be black, for reading clarity. Tags must 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 must be furnished by a single systems supplier regularly engaged in the supplying of this equipment. System Supplier must 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 must 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 must oversee the installation of the equipment. Substitutions of functions specified will not be acceptable. The Contractor and the System Supplier must be present at the system commissioning, and must coordinate and schedule the work during construction, testing, calibration, and acceptance of the system. The System Supplier must be on-site with their mechanical and control personnel to supervise and assist the contractor during pre-commissioning check-out of the mechanical systems and control systems, initial fuel receipt, initial filling, hydrostatic testing, pigging, flushing, cleaning, Equipment Tests, Performance Testing, and training all for the owner's representatives. The System Supplier must

SECTION 33 52 43.11 Page 7 be responsible to the Contractor for scheduling all Contractor, Sub-contractor, and manufacturer's service personnel during system start-up, Equipment Tests, Performance Testing, and training.

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 must 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, must be provided under this section in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

2.4 PRESSURE GAUGES

Pressure gauges must conform to ASME B40.100 with metal cases and 4-inch diameter white dials. Gauges must be bottom connected, without back flanges. A pulsation dampener, adjustable to the degree of dampening required, must be provided for each gauge. Range of gauges must be as indicated. A ball valve must be provided for each pressure gauge. Gauges must be labeled with the calibration date.

2.4.1 Quick Disconnect

If indicated on drawings provide quick disconnect on pressure gauge. Quick disconnects must be double shut-off, dry-break design, 316 stainless steel construction, with Fluorocarbon (Viton) seals, minimum working pressure of 1000 psig at 100°F., with ½" female NPT threaded connections for both coupler and adapter, manufactured in accordance with ISO 7241, Series B.

The quick disconnect assembly must consist of a coupler, half to be connected to the pressure snubber under the pressure gauge, and a nipple/adapter half to be connected above the pressure gauge isolation ball valve. The coupler and nipple/adapter are to be provided with aluminum dust caps to protect the fittings when the gauge is removed.

2.5 AUTOMATIC PUMP CONTROLS

The pressure and flow transmitters specified in this paragraph must be obtained from a single supplier of such products. The same supplier must also furnish the associated venturi tubes and GPM meter. The supplier must 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 must be installed to eliminate air entrapment. Control tubing must be as specified in Section 33 52 43.13 AVIATION FUELING PIPING. Each item of equipment specified hereafter must 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 must be submitted for approval concurrently with items specified in Section 33 09 53 AVIATION FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM.

2.5.1 Pressure Indicating Transmitters

Pressure indicating transmitters must consist of a capacitance sensor operating on a differential in pressure of fuel (one side being open to atmospheric pressure). The output must 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

SECTION 33 52 43.11 Page 8 power must be provided from remote power supply located in the pump control panel (PCP).

a. Transmitter body must 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 must be + 0.20 percent of calibrated span including combined effects of linearity, hysteresis and repeatability.

b. One pressure indicating dial must be supplied with each pair of transmitters. Pressure indicating dials must 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 must be dual opposed, liquid filled, rupture-proof type with bellows movement converted to rotation and transmitted by a torque tube. Bellows housing must be stainless steel and must 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 must be suitable for the expected minimum ambient temperature. The indicating dial must be at least 6 inches in diameter with a weatherproof glass cover. The case must be finished with a weather resistant epoxy resin enamel. The indicating pointer must traverse a 270 degrees arc. The scales must be graduated over the selected pressure ranges so that the pressure can be read in psig. Indicator accuracy must be 0.75 percent of full scale.

Pressure indicating dial must be provided with suitable over-range protection.

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

d. Pressure transmitters must 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 must be supplied with a factory assembled two valve stainless steel manifold. Vent valves must be furnished on upper ports of each transmitter and dial. Pressure transmitters and the indicating dial must be suitable for mounting on a 2-inch pipe stand. Complete installation must be in accordance with manufacturer's recommendations.

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 must 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.

2.5.2 Flow Switches

Switches must be actuating vane type flow switch with single adjustable set-point. Switches must mount on ASME B16.5 Class 150 raised face flange. Flange material must 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 must be 120 volts, single phase, 60 hertz, 10 amps minimum. Units installed on 2 inch piping and smaller may be

SECTION 33 52 43.11 Page 9 threaded.

2.5.3 Venturi Tubes

a. The venturi tubes must 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 must be considered as a required portion of the controls package.

c. The venturi tubes must 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 must be velocity head, impact, differential producing devices designed to measure differential pressure of F-24 fuel. They must 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 must be of sufficient thickness to with-stand the same stresses as the upstream and downstream piping. Each venturi tube must have a minimum of four 1/2-inch connections. An individual head-capacity curve must be furnished for each venturi tube.

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

(1) Issue Venturi Tube. Minimum inlet-to-throat differential pressure at 2,400 gpm: 200 in H2O.

(2) Return Venturi Tube. Minimum inlet-to-throat differential pressure at 600 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 must be independent of Beta over a Beta range of 0.4 to 0.75. Pressure loss must be less than 24 percent of differential pressure generated by the venturi tube.

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

2.5.4 Differential Pressure Transmitter

Differential pressure transmitter must consist of a capacitance sensor operating on a differential in pressure of fuel. The output must 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 must be provided from remote power supply located in

SECTION 33 52 43.11 Page 10 the pump control panel (PCP).

a. Transmitter body must 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 must be + 0.20 percent of calibrated span including combined effects of linearity, hysteresis and repeatability.

b. One differential pressure dial must be supplied with each pair of transmitters. Differential pressure dial must 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 must be dual opposed, liquid filled, rupture-proof type with bellows movement converted to rotation and transmitted by a torque tube. Displacement of bellows must be 1.5 cubic inches for full scale travel. Bellows housing must be stainless steel and must have a rated working pressure of not less than 500 psi. Liquid used to fill the bellows must be suitable for the expected minimum ambient temperature.

The indicating dial must be at least 6 inches in diameter with a weatherproof glass cover. The case must be finished with a weather resistant epoxy resin enamel. The indicating pointer must traverse a 270 degree arc. The scales must be graduated over the selected pressure ranges so that the flow rate can be accurately read in gallons per minute. Indicator accuracy must be 0.5 percent of full scale.

Differential pressure indicating dial must be provided with built-in pulsation damper and suitable over-range protection.

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

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

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

(1) Issue Venturi Tube - 0 to 2400 GPM (full range)

(2) Return Venturi Tube - 0 to 800 GPM (full range)

e. Differential pressure transmitters must 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 indicating dial must be supplied with a factory assembled five valve stainless steel manifold. Vent valves must be furnished on upper ports of each transmitter and indicating dial. Differential pressure transmitters and the indicating dial must be suitable for mounting on a 2-inch pipe stand. Complete installation must be in accordance with manufacturer's recommendations.

2.5.5 Pressure Sensor

Sensor must 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 must be 12-28 VDC. Output signal must be 4-20 mA. Unit must have 0.25 percent accuracy and have built-in high pressure snubbers, minimum pressure range must be 0-300 PSI.

Wetted material must be stainless steel.

SECTION 33 52 43.11 Page 11

2.6 RECEIPT FLOW METER

Meter must consist of corner tapped orifice flanges, orifice flange plate, differential pressure gauge, and associated flow chart. The normal flow range is 0 to 600 gpm. Orifice flanges must be ANSI Class 150 and must be constructed of Type 304 or 304L stainless steel. Orifice Beta value must be 0.7, with a maximum pressure loss of no more than 3 psi at 600 gpm.

Differential pressure gauge must have a display of 0-100 feet water column.

A hand chart must be provided which shows the flow (gpm) for the pressure drop indicated on the differential pressure gauge. A note must be added:

Tank must not be filled faster than 450 gpm (3 fps) when ever the fuel is not in contact with the floater (tank fuel receipt outlet is covered by 3 feet of fuel when no floater is present).

2.7 ABOVEGROUND PRODUCT RECOVERY TANK AND ACCESSORIES (4,000 GALLON)

2.7.1 Tank Construction

Tank and appurtenances must be in accordance with Section 33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS. Product recovery tank must be a U.L.

labeled, double wall, steel tank, with interstitial monitor. Tank must be provided with calibrated gage stick and strapping chart.

2.7.1.1 Automatic Tank Gauging (ATG) and Leak Detection Monitor

2.7.1.1.1 ATG

ATG must be the mechanically or electronically actuated type that can continuously monitor a tank's usable liquid level storage capacity. The system must provide a digital readout of a tank's liquid level in terms of inches and gallons. The system must be accurate to plus or minus 1/16 inch.

The system must measure water accumulation in inches from 3/4 to 5 inches off the bottom of a storage tank. Construct system components to be chemically compatible with the fuel to be handled.

2.7.1.1.2 Leak Detection

a. Provide an annular space between the primary and secondary shells to allow for the free flow and containment of all leaked product from the primary tank.

b. Provide the tank with a leak monitoring system capable of sensing leaks in the secondary containment space. The system must detect a leak of fuel through the inner shell to the area between the inner and outer shells. The detector and any equipment in the area of the fuel tanks must be rated for the environment in which it is installed. The system must be a continuous surveillance type. The sensor must be electronic or hydraulic type and must be connected to a control panel. Totally flooded containment space reservoir system must not be permitted. The alarm must be manually reset at the control panel. Use an inert gas that is heavier than air in containment space of the tanks to prevent the forming of condensation. The tank monitoring system must be compatible with the tank furnished and must be as recommended by the tank manufacturer. Provide instructions and equipment required for calibration of the monitoring system and calibration maintenance schedule. Access must be provided to the tank sensor for testing and maintenance.

SECTION 33 52 43.11 Page 12

2.7.1.1.3 Control Panel

The control panel must be located where shown on the plans. Panel must be a standard industrial enclosure. Panel doors must swing left or right. The panel must display the digital readout of each monitored tank on an LCD mounted exterior to the panel. The panel must also have external controls to allow operators to toggle between information on the LCD without having to open the panel. The panel must provide an audible and visible alarm if a leak or preset high or high-high level is detected. Panel must discrimiate and indicate if the leak is fuel or water. Leak detection, high level and high-high level alarms must be provided to the pump control panel(PCP), see Section 33 09 53 AVIATION FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM .

Provide system operating instructions inside of the control panel. Unit must be Veeder-Root ATG TLS, or Government approved equal and compatible with the Base Fuels Automated System (FAS).

2.7.1.2 Tank Appurtenances and Fittings

Provide tank appurtenances and fittings as indicated. Nozzles for appurtenances must be as indicated or per manufacturer's recommendations and installed plumb. Spill bucket must be provided with locking cap. The flange on the Fuel Transfer Pump pumpway must be an ASME Class 150 flange.

*Am-4

2.7.1.3 Not Used

2.7.1.4 Not Used

2.7.1.5 Not Used

2.7.1.6 Float Switch Assembly

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

2.7.1.7 Fuel Transfer Pump (FTP-1)

Refer to Section 33 52 43.23 AVIATION FUEL PUMPS

2.7.1.8 Electric Pump

The electric 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 gal per minute with a differential head of 50 feet. 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. Pump must be provided with stainless suction screen, foot valve, stainless steel pipe, and aluminum 1-1/2-inch cam type quick disconnect with dust cap.

2.7.1.9 Lockable Cap

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

SECTION 33 52 43.11 Page 13

2.7.1.10 Spill Containment Basin

Container must be constructed of carbon steel, 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.

Container must be provided with a drain and have an easily removable cover constructed of either cast aluminum or cast iron. Covers must be weather-resistant and must prevent the influx of water.

2.7.1.11 Overfill Valve (OV-1)

Refer to Section 33 52 43.14 AVIATION FUEL CONTROL VALVES

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2.7.1.12 Not Used

2.7.1.13 Tank Catwalk

Provide a platform, complete with guardrails in accordance with Section 05 52 00 METAL RAILINGS, centered above and along the full length of the tank. A minimum clear distance of 1 inch shall be provided between the bottom of the platform beams and the top of the tank. Live load deflections must be limited to the clear span divided by 360 (L/360).

The platform must be wide enough to satisfy OSHA 29 CFR 1910 requirements and allow protected access to the tank manholes and gauges. The catwalk must be designed with removable grates that allow access to the tank appurtenances. Grating elevation must be set below the manway hatches. Any appurtenances or manways, which stick above the grating, must be painted yellow. Refer to Section 05 51 00 METAL STAIRS for additional platform requirements.

The catwalk system may be directly attached to the tank if a structural analysis and a letter stamped by the manufacturer states that the tank adequately supports the additional loads without yielding or failing. Field welding on the tank shell must not be permitted as a means to attach the catwalk system directly to the tank or to perform any other feature of work. Any and all attachments to a newly installed AST must be achieved through pre-fabricated features of the AST. Any field modification to a newly installed AST, which impacts its current UL certification or which presents a violation of any other pertinent code or standard, is not allowed. If not approved or supplied by the manufacturer, the platforms must not be supported off of the tank and will require individual foundations.

Provide a stairway for accessing one end of the tank platform in accordance with Section 05 51 00 METAL STAIRS and OSHA 29 CFR 1910.

2.8 ABOVEGROUND PRODUCT RECOVERY TANK AND ACCESSORIES (500 GALLON)

2.8.1 Tank Construction

Tank and appurtenances must be in accordance with Section 33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS. Product recovery tank must be a U.L.

labeled, single wall, steel tank. Tank must be provided with calibrated gage stick and strapping chart.

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SECTION 33 52 43.11 Page 14

2.8.1.1 Not Used

2.8.1.2 Tank Appurtenances and Fittings

Provide tank appurtenances and fittings as indicated. Nozzles for appurtenances must be as indicated or per manufacturer's recommendations and installed plumb. Spill bucket must be provided with locking cap. The flange on the Fuel Transfer Pump pumpway must be an ASME Class 150 flange.

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2.8.1.3 Not Used

2.8.1.4 Not Used

*Am-4

2.8.1.5 Fuel Transfer Pump (FTP-2)

The electric 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 gal per minute with a differential head of 200 feet. 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. Pump must be provided with stainless suction screen, foot valve, stainless steel pipe, and aluminum 1-1/2-inch cam type quick disconnect with dust cap.

2.8.1.6 Lockable Cap

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

2.8.1.7 Tank Overfill Prevention Valve

Valve must be the two-stage, float-activated, shutoff type that is an integral part of the drop tube used for filling. The first stage must restrict the flow of fuel into the tank to approximately 5 gpm when the liquid level rises above 87.5 percent of tank capacity. The second stage must completely stop the flow of fuel into the tank when the liquid level rises above 92.5 percent of tank capacity. Valve must be constructed of the same material as the fill tube. All materials must be compatible with military aviation fuel

*Am-4 - Text Deleted

2.9 ISOLATION VALVE PITS

Use this paragraph for On-shoulder and On-apron installation. Pantograph and hydrant hose truck hydrant outlet pits and isolation valve pits must be prefabricated units that are the standard products of a firm regularly engaged in the manufacture of such products and must essentially duplicate items that have been in satisfactory use for at least (3) years prior to bid opening. The basic pit must consist of a 0.50-inch thick fiberglass walls and floor with main body dimensions as shown on the drawings. The pit must contain twelve (minimum) integral concrete anchors or two integral anchors that run continuous on three sides of pit. The integral fiberglass top flange must require no exposed corrosive material, weldments, or strongbacks within the pit to support the aluminum cover assembly. The manufacturer must have had a minimum of three years successful experience

SECTION 33 52 43.11 Page 15 in the production and usage of their fiberglass service pits and must supply proof of experience at time of submittals. Pits must be provided with a 2-inch pump-out line terminating with a male cam type bronze connector with female dust cap. Pits must be provided with removable aluminum grating platform suitable for loading of 400 pounds per square foot. The grating must cover the entire opening when the lid is in the open position. The grating platform must have outside edges and cut-outs framed. The inside of the lid must have a 14 by 10 inch permanently attached sign which says "DANGER CONFINED SPACE ENTER BY PERMIT ONLY". The sign must be white with black letters, made of PVC, completely and permanently encapsulated 50-mil plastic.

2.9.1 Pit Cover

The pit cover assembly must 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 must 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 must be equipped with a device to hold the lid in its fully-opened position. This lid-staying device must automatically engage when the lid is opened to its fully-opened position. The device must also be provided with a quick-release mechanism designed to be operated with one hand. The lid must be considered fully-open when it is rotated approximately 90 degrees from its closed position. Each cover lid must move smoothly through its entire range of motion and must 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 must be approximately 50 pounds.

In addition, the cover must 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) must be provided for each lid. Each handle must provide comfortable, secure grip for and average adult male's full (gloved) hand. All covers must 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 must not be required to engage (or disengage) the latch or the lid lifting handles.

Latch and handle designs must 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, must not be allowed. The weight bearing flange surfaces of both the fiberglass pit liner and the aluminum cover lid must be machined flat to assure uniform weight distribution. The word FUEL must be integrally cast in raised letters on the top surface of each lid.

The lettering must be a minimum of 1-inch high and 0.0625-inch deep.

2.9.2 Pit Cover Materials, Design, and Testing

All cover lids and frames must 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 must be ductile, corrosion-resistant, impact-resistant, and suitable for the intended use.

All covers must be non-skid surface construction and free of injurious defects. Welding for the purpose of structural repair of casting defects must not be allowed. Minor cosmetic welding is acceptable. The cover must

SECTION 33 52 43.11 Page 16 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 must be considered as failure. Actual load-tests must be performed on a minimum of 10 percent of all the covers supplied.

Load-tested units must be randomly selected. Load-test conditions must model field-installed conditions as nearly as practicable. The 200 Kip test-load must be applied to the cover for a minimum duration of 5 minutes. Absolute maximum deflection of the cover lid under the test-load must 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, must be + 0.010-inches to assure that no permanent set has taken place. Upon removal of the test-load, the cover lid and frame must be carefully examined for cracks or localized areas of permanent deformation. All results must be submitted for review and approval. A single failure to meet any of the stated criteria must be considered sufficient grounds for the testing of 50 percent of the units.

2.9.3 Pipe Seal

The pipe penetrations through the pit floor or wall must be sealed by means of a Buna-N boot. The boot must 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 must be in accordance with

SAE AMS3275.

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2.10 HIGH POINT VENT AND LOW POINT DRAIN PITS

Use for On-Shoulder and On-Apron installations.

2.10.1 Pit Assembly

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

2.10.2 Pit

The basic pit must 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 must contain two integral concrete anchors. The fiberglass top flange must require no exposed corrosive material, weldments, or strongbacks within the pit to support the cast aluminum ring and cover assembly. The pits must be the standard products of a firm regularly engaged in the manufacture of such product and must 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.

2.10.3 Pit Cover, General Requirements

The pit cover must include a removable outer ring frame and an interior 18-inch diameter (clear opening) hinged lid that opens 160 degrees. Each cover lid must move smoothly through its entire range of motion and must require a maximum opening force of 35 pound-force to be applied at a single lifting handle. Each handle must provide a comfortable, secure grip for an average adult male's full gloved hand. Tools must 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, must not be allowed. The pit service must be integrally cast in raised letters on the top surface of each lid. The lettering must be a minimum of 1-inch high and

SECTION 33 52 43.11 Page 17

0.0625-inch deep. The weight bearing flanges of the fiberglass pit liner and the aluminum cover frame (and lid) must be machined to assure uniform weight distribution.

2.10.4 Pit Cover Materials, Design, and Testing

The cover frames and lids must 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 must 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 must be ductile, corrosion-resistant, impact-resistant, and suitable for the intended use. All covers must be non-skid surface construction and free of injurious defects. Welding for the purpose of structural repair of casting defects must not be allowed.

Minor cosmetic welding is acceptable. The cover must 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 must be considered as failure. Actual load-tests must be performed on a minimum of 10 percent of all the covers supplied.

Load-tested units must be randomly selected. Load-test conditions must model field-installed conditions as nearly as practicable. The 200 Kip test-load must be applied to the cover for a minimum duration of 5 minutes. Absolute maximum deflection of the cover lid under the test-load must 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 must be + 0.010-inches to assure that no permanent set has taken place. Upon removal of the test-load, the cover lid and frame must be carefully examined for cracks or localized areas of permanent deformation.

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

2.10.5 Pipe Riser Seal

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

Collar must be fabricated from the same material as the pipe.

2.11 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 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/ 10-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

SECTION 33 52 43.11 Page 18 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.

Level accuracy + 0.05 inches Corrected volume accuracy + 0.1 percent Density accuracy + 1 percent Temperature accuracy + 1 degrees F 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 must include an ENDRESS+HAUSER RTU 8130 and a local display similar or equal to a CP/2500. The RTU must transmit data to the Base FAS System located in the RCC via telephone lines as shown on the drawings. Base personnel must coordinate reprogramming of the FAS System to accept this new data.

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2.12 NOT USED

2.13 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 mounted on top of the tank, in the pump house, as indicated.

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.

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.

2.14 WATER DRAW-OFF SYSTEM

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

2.14.1 Tank

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

2.14.2 Sight Glass

Sight glasses for tank must be standard tubular gages with density ball and

SECTION 33 52 43.11 Page 19 shut-off valves on each end. Wetted parts other than sight glass must be stainless steel. If glass breakage should occur, a stainless steel ball in the valve must close preventing product loss. Glass must be protected by minimum of four guard rods.

2.14.3 Return Pump

Product return pump (PRP-1 and PRP-2) must have the capacity of not less than 10 gpm against a total head of 47 feet when driven at 1800 rpm. The pump must have flange connections and must be constructed of stainless steel or aluminum so as to have no zinc, brass or other copper bearing alloys in contact with the fuel.