W9128F20R0056-Am-0008-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 #0008

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 NOT USED

2.10 NOT USED

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

U.S. DEPARTMENT OF DEFENSE (DOD)

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

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

SECTION 33 52 43.11 Page 3

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-6 *Am-8

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

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

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)

SD-03 Product Data

Pressure Gauges; G-DO

SECTION 33 52 43.11 Page 4

Automatic Pump Controls; G-DO

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

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

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);

SECTION 33 52 43.11 Page 5

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.

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.

SECTION 33 52 43.11 Page 6

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 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

SECTION 33 52 43.11 Page 7 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 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

SECTION 33 52 43.11 Page 8 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 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.

SECTION 33 52 43.11 Page 9

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 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

SECTION 33 52 43.11 Page 10 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.

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

SECTION 33 52 43.11 Page 11 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.

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

SECTION 33 52 43.11 Page 12 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.

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.

SECTION 33 52 43.11 Page 13

2.7.1.11 Overfill Valve (OV-1)

Refer to Section 33 52 43.14 AVIATION FUEL CONTROL VALVES

*Am-4

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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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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SECTION 33 52 43.11 Page 14

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

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*Am-6

2.9 NOT USED

*Am-8

2.10 NOT USED

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 detection. The level indicating system must require no periodic

SECTION 33 52 43.11 Page 15 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 shut-off valves on each end. Wetted parts other than sight glass must be

SECTION 33 52 43.11 Page 16 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. The unit must be explosion-proof, Class I, Division 1, Group D with maximum temperature rating of "T2D" ( 419 degrees F). The motor must not be overloading at any point on the pump curve. Contractor has the option of selecting either centrifugal or positive displacement type pump with the restriction of the positive displacement type pump must include a pressure relief between the discharge and suction protecting the pump from overloading.

2.14.4 Anchoring

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

2.15 BOWSER PUMPOFF PUMP

The pump must be a sliding vane type rotary pump. The pump construction must permit the removal of the rotor and sliding vanes without disconnecting the pump. Pump capacity must be 10 gpm with a differential head of 40 feet when driven at 1800 rpm. The pump and motor must be mounted on a cast iron or steel subbase. The motor must have sufficient power for the service required, must be of a type approved by the manufacturer of the pump, must be suitable for available electric service, must be totally enclosed, fan cooled, TEFC, and must conform to the requirements specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.

Pump must be provided with stainless suction side basket strainer.

*Am-6

2.16 JOCKEY PUMP

Pump capacity of not less than 5 gpm against a total head of 585 feet when driven at 3600 rpm and be a centrifugal type. 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. The unit must be explosion-proof, Class I, Division 1, Group D with maximum temperature rating of T3 (392 degrees F). The motor must not be overloading at any point on the pump curve.

2.17 PUMPHOUSE DRAIN PUMP

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

SECTION 33 52 43.11 Page 17

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2.18 TIGHTNESS MONITORING SYSTEM

The system must 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 must have a guaranteed accuracy to detect a leak of less than 0.0004 gal/h per cubic foot at 150 PSI. The system must 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 must 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 must be unaffected by the temperature change of the fuel, and have a maximum test period of one hour. A local controller must implement and analyze data, store data and be capable of printing results, and be located in the control room of the pumphouse building. Printer must be provided. Controller must utilize 120V, single phase power. Any additional utilities or equipment needed to be added to the fuel system in addition to what is shown on the drawings to allow the Tightness Monitoring System to meet the requirements, will be the requirement of the Tightness Monitoring System. Provide calculations, design, and proof of compliance. Upon completion of 72 hours of continuous system operation and before final acceptance of work, test the Tightness Monitoring System in service to demonstrate compliance with contract requirements. Performance verification must 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.

The existing loop piping has approximately 10,000 gallons. This number will change when a certified pipeline inventory becomes available.

PART 3 EXECUTION

3.1 GENERAL

3.1.1 Installation

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

Follow manufacturer's recommended practices for equipment installation.

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

3.1.2 Anchoring

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

Cut anchor bolts of excess length to the appropriate length without damage to threads. Where anchor bolts or like devices have not been installed, SECTION 33 52 43.11 Page 18 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 must be in accordance with ASTM C827/C827M. Perform all grouting in accordance with equipment manufacturer's and grout manufacturer's published specifications and recommendations.

3.1.4 Leveling and Aligning

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

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

3.1.5 Direct Drives

Alignment procedure follows:

3.1.5.1 Rotation Direction and Speed

Check and correct drive shaft rotation direction and speed.

3.1.5.2 End Play

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

3.1.5.3 Shaft Leveling and Radial Alignment

Pump alignment must 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.

SECTION 33 52 43.11 Page 19

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 must 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, must be stored on blocks or horses at least 18 inches above ground.

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

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

3.2 INSTALLATION OF UNDERGROUND TANKS

Installation must be per tank manufacturer's recommendations, API RP 1615, NFPA 30, 40 CFR 280, state and local codes and as specified herein. If recommendations require tank to be filled, only fuel will be allowed in tanks. Water filling is not acceptable. Before being placed in service, tank must be tightness tested in accordance with NFPA 30.

3.2.1 Coating Testing

The coating must be examined for flaws and tested for thickness. Provide the facilities, personnel, and equipment for testing for flaws and thickness. Thickness must be measured electronically. Coating must be tested directly before placement of the tank with an electric flaw detector, equipped with a bell, buzzer, or other type of audible signal that operates when a flaw is detected. The detector for the type of coating used must have an operating voltage of 10,000 to 35,000 volts.

Check of the holiday detector potential may be made by the Contracting Officer at any time to determine the suitability of the detector. Damaged areas must be repaired with materials identical to those used originally, and after drying, must be retested electrically. Submit test results.

3.2.2 Steel Tanks

a. Cover the concrete hold down slab with 6 inches of tank bedding backfill evenly graded and thoroughly compacted, prior to tank placement.

b. Each tank is to be unloaded and placed on the sand bed using cranes and the rigging procedures provided by the tank manufacturer. Use the tank lifting lugs for lifting the tank into place. The use of slings around the tank is not permitted, nor is the use of chock blocks of any sort.

During handling, carefully inspect the tanks for coating damage and repair any damage whatsoever before proceeding. After placement, check each tank to ensure it is sloped as required. The elevation must be confirmed.

SECTION 33 52 43.11…