W912HV-18-R-0006-Am0008_Revised_Specifications.pdf

FY18 DESC1805 Upgrade Yokose Pier 18SF0002 Yokose, Japan

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 08 55

COMMISSIONING OF FUEL FACILITY SYSTEMS

PART 1 GENERAL

1.1 SUMMARY/APPLICABILITY

1.2 SUBMITTALS

1.3 SAFETY

1.4 COMMISSIONING PLAN

1.5 CERTIFICATION OF COMPLETION

1.6 COMMISSIONING REPORT

1.7 DISPOSAL OF WASTE MATERIALS

PART 2 PRODUCTS

2.1 DESIGN CONDITIONS

2.2 CONTRACTOR PROVIDED MATERIALS AND EQUIPMENT

2.3 GOVERNMENT FURNISHED MATERIALS AND EQUIPMENT

2.3.1 Fuel

2.3.2 Utilities

PART 3 EXECUTION

3.1 PRELIMINARY REQUIREMENTS

3.1.1 Electrical Preparations

3.1.2 Piping System

3.1.2.1 Pier Piping Systems

3.2 PREPARATIONS FOR FLUSHING

3.2.1 Protection Of Equipment

3.3 SWAB PIG RUN - PNEUMATIC

3.4 LOW PRESSURE PNEUMATIC LEAK TEST

3.5 INITIAL FUEL RECEIPT

3.5.1 General

3.5.2 Fuel Quality

3.5.3 Initial Low Point Flush

3.5.4 Piping Hydrostatic Tests with Fuel

3.6 FLUSHING

3.6.1 Flushing Requirements

3.6.2 Pier Piping

3.6.3 Piping Flushing Checklist

3.7 PIPE PIGGING RUNS

3.7.1 General

3.7.2 Cleaning Pig Run

3.7.3 Wire Brush Pig Run

3.8 CLEANING, TESTING, AND SAMPLING

3.8.1 Cleaning Requirements

3.8.2 Cleaning Procedure

3.8.3 Piping Cleaning Checklist

3.9 EQUIPMENT TESTS

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(Am-0008)

3.10 PERFORMANCE TESTS

3.10.1 Fuel Receipt Systems

3.10.1.1 Aboveground systems

3.10.2 Marine Fueling Systems

3.10.3 Satisfactory Performance

3.11 TRAINING / INSTRUCTION FOR GOVERNMENT PERSONNEL

3.12 PROJECT CLOSEOUT

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SECTION 33 08 55

COMMISSIONING OF FUEL FACILITY SYSTEMS

PART 1 GENERAL

1.1 SUMMARY/APPLICABILITY

This specification defines the requirements and procedures for startup and commissioning of fuel facility systems. It covers requirements for safety, Government scheduling and coordination, device testing, system flushing and cleaning, demonstration of indicated and specified system performance and final acceptance and reporting.

System supplier shall have experience commissioning similar hydrocarbon fueling systems.

1.2 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-01 Preconstruction Submittals

Commissioning Plan; G

SD-06 Test Reports

Piping Flushing Checklist; G

Piping Cleaning Checklist; G

Control Valve Checklist; G

Commissioning Report; G

SD-07 Certificates

Certification of Completion

Disposal of Waste Materials

1.3 SAFETY

Prior to any on-site commissioning activities, the following safety procedures shall be accomplished in all fueling areas to be commissioned under this specification section: testing/operation of emergency eyewash facilities, placement of Contractor-provided portable eyewash units within <31 meters> or 10 seconds from the fueling point, verification of proper grounding throughout system, coordination with Government Fire and Safety Office and Fuels personnel, placement of Contractor-provided spill pads and containment booms, placement of Contractor-provided fire extinguishers capable of extinguishing a fuel fire. Ensure that all radios/devices at

W912HV-18-R-0006 SECTION 33 08 55 Page 3 all Class I, Division 1 areas are intrinsically safe.

1.4 COMMISSIONING PLAN

The Contractor shall submit a detailed written plan for implementation of system commissioning. The commissioning plan shall specify a detailed plan incorporating in an sequenced manner all work specified in PART 3 EXECUTION of this specification section. The plan shall be submitted for Government approval 90 calendar days prior to commencement of fuel system commissioning. The plan shall include:

a. Personnel. List of Contractor's personnel by trade, list of key personnel, list of safety equipment, list of miscellaneous equipment such as two-way radios, and personnel transportation vehicles.

b. Performance Testing. Detailed equipment startup procedures and schedules to perform all system tests under each operating scenario in accordance with paragraph entitled "Performance Tests".

c. Pigging Plans. The Contractor shall submit a detailed written plan covering all aspects of the pipeline pigging operation, including anticipated pig runs, types of pigs, sequence of work, and retrieval/repair procedures. For gas-propelled pig runs, propellant shall only be used behind pigs and shall be isolated from the remaining system.

d. Test forms. Develop all test forms required for documenting the fuel system commissioning work. The format of the test forms shall follow the sequencing and terminology of the commissioning plan and shall furnish data grids and ample areas for test data recording.

e. Schedule. Schedules shall generated listing dates and durations of all commissioning activities as well as regular coordination and safety meetings and dates of key events for Government participation.

f. Fuel. The government will provide fuel for commission activities and marine vessel for delivery. Contractor shall coordinate quantities of fuel needed for commissioning activities and fuel delivery prior to submission of commissioning plan. Commissioning plan shall include required quantity of fuel and delivery schedule requirements.

g. Contingency plans. Information on spill and fire contingencies, along with the required Government Fire and Safety Office involvement and approvals.

h. Coordination with Base. Description of how Contractor shall implement system start-up in coordination with ongoing base operations. Plan shall incorporate all phasing and work restriction requirements of the Contract Documents.

1.5 CERTIFICATION OF COMPLETION

As a prerequisite to fuel system commissioning, the Contractor shall submit a Certificate of Completion that certifies all work provided on the fuel system, except for field painting, has been inspected and approved by the specified approving authorities. Further, the Contractor shall certify on this certificate that all specified checks and inspections have been successfully completed prior to commissioning. The Contractor shall give

W912HV-18-R-0006 SECTION 33 08 55 Page 4 the Contracting Officer at least 45 calendar days notice prior to commencement of fuel system commissioning. The Contractor shall submit the Certificate of Completion to the Contracting Officer at least 7 calendar days prior to commencement of system commissioning. The Contracting Officer shall then be responsible for scheduling the Government representatives and appropriate military command authority for participation in the inspection, performance testing, and final approval activities. Any contractual deficiencies observed shall be corrected by the Contractor without cost to the Government.

1.6 COMMISSIONING REPORT

Contractor shall prepare a commissioning report that documents the execution of the approved commissioning plan. All items of work specified in the commissioning plan shall be carried out and reported in this report unless otherwise approved by the Contracting Officer. Include as a part of this report verification letters of approved fuel piping hydrostatic tests, as generated under other specification sections. .

1.7 DISPOSAL OF WASTE MATERIALS

The Contractor shall be responsible for properly disposing of any sludge, debris, filtration elements, and waste fuel resulting from piping cleaning and flushing activities as specified in this Section. Comply with all applicable local, State, and Federal Regulations for hazardous waste disposal.

PART 2 PRODUCTS

2.1 DESIGN CONDITIONS

Temporary flushing lines and equipment shall be equal in strength, stability, and materials to the associated permanent components; however, temporary spools may be carbon steel.

2.2 CONTRACTOR PROVIDED MATERIALS AND EQUIPMENT

The Contractor shall provide all material, equipment and labor required for proper start-up of the system(s), except for that specified to be Government furnished. Equipment shall include but not be limited to the following:

a. Temporary strainers.

b. Flow meters.

c. The Contractor shall be responsible for providing the electrical power from a a source identified by the Government to the testing locations.

d. Pig launching and receiving barrels.

e. Temporary filtration/strainers.

2.3 GOVERNMENT FURNISHED MATERIALS AND EQUIPMENT

The Government will furnish the following materials, equipment and services used during the execution of the commissioning plan. Any damage caused by the Contractor's operations shall be repaired at no additional cost to the Government.

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2.3.1 Fuel

The Government will provide the fuel necessary for system testing. The Contractor shall notify the Contracting Officer a minimum of 60 days in advance of the requirements. Additional fuel will be provided by the Government as required for satisfactory flushing of the system. Upon satisfactory completion of the flushing and cleaning operations, the Government will supply the additional quantities of fuel required to complete the other work under this specification section.

Fuel will not be delivered to the system until the Contractor has satisfactorily completed all work and, in particular, the removal of preservatives and foreign matter from those portions coming in contact with the fuel valves, pumps, filter/separators and other such equipment. Fuel delivered to the system shall remain the property of the Government in accordance with Clause 52.245-1, Government Property, and the Contractor shall reimburse the Government for shortages not attributed to normal handling losses. The Government shall be reimbursed for fuel lost as a result of defective materials or workmanship.

2.3.2 Utilities

Electric power required for the performance of the work under this specification section will be furnished at no charge to the Contractor.

PART 3 EXECUTION

3.1 PRELIMINARY REQUIREMENTS

All activities listed in paragraph "PART 3 EXECUTION" shall be performed sequentially in the order they are presented. Prior to any on-site commissioning activities, the Contractor shall ensure that all requirements of the paragraph entitled "Safety" are satisfied. Project shall be substantially complete and Contractor's work area shall be free of debris, trash and obstacles. Perform the following activities prior to receipt of fuel:

3.1.1 Electrical Preparations

Prior to energizing the electrical equipment, verify that short-circuit links have been removed from current transformer and that secondary circuits have been connected. Confirm that all tests required for fire detection and suppression systems have been performed and accepted. Verify all electrical transmitter connections and ensure proper calibration.

Verify all electrical equipment meets Class I Division 1 requirements.

Verify correct rotation of all motors prior to testing. Verify paddle type flow switches by physically actuating vanes and checking outputs. Conduit explosion-proof sealoffs shall be poured after initial electrical checks but before fuel receipt.

3.1.2 Piping System

Ensure that all piping weld integrity and coating inspections have been performed per the applicable specifications. Include verification of approved test results for information in the commissioning report.

Evacuate all accumulated water from piping low point drains, valve cavities, and equipment drains. Verify all bolted connections are tightness tested to required torque using a calibrated torque wrench.

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Verify that all pressure gauges are properly located and installed. Ensure that piping's cathodic protection system is tested and operational. Ensure that pipe marking and identification is provided as specified. Ensure that piping system thermal relief provisions are installed and operating as designed. Verify the correct installation of piping expansion loops and supports.

3.1.2.1 Pier Piping Systems

For pier delivery/receipt systems or other over-water piping installations, ensure compliance with the Contractor's previously approved spill control plans.

3.2 PREPARATIONS FOR FLUSHING

Upon completion of the construction to the satisfaction of the Contracting Officer, the Contractor shall make the following preparations for system flushing.

3.2.1 Protection Of Equipment

The following components shall be removed from the system prior to start of flushing operations and, where applicable, replaced with pipe spools of internal diameter equal to the item removed.

a. Control valves.

b. Flow and pressure sensors which are exposed to the system flush.

c. Fuel meters.

After flushing and pigging, the above items shall be reinstalled in the system and the spool sections turned over to the Contracting Officer.

3.3 SWAB PIG RUN - PNEUMATIC

Upon completion of the piping system and all associated integrity and coating tests, an initial foam swab pig cleaning run should be performed.

This will provide line proving and bulk cleaning of the interior of the piping system. Contractor-provided pig launching and receiving barrels should be installed. The pig should be constructed of light (2-5 lbs/cu.

ft. density) open cell polyurethane foam, with polyurethane back and transmitter cavity. Propellant shall be pressurized dry air. If piping system has previously been filled with fuel, propellant shall be pressurized nitrogen. The swab pig shall be examined after the initial run for signs of possible pipe blockage or damage which may prevent future pig runs. The Contractor shall prepare a contingency plan for retrieving a stuck pig and repairing any piping deformations per the applicable specifications. Additional runs shall be performed until the amount of collected debris is minimized, as determined by the Contracting Officer.

3.4 LOW PRESSURE PNEUMATIC LEAK TEST

Upon completion of swab pig run a low pressure pneumatic leak test shall be performed per Specification Section 33 52 43.13.

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3.5 INITIAL FUEL RECEIPT

3.5.1 General

The Contractor shall station personnel throughout piping system at high point vents to bleed air. All flanges and equipment will be periodically inspected for leaks during filling procedures.

3.5.2 Fuel Quality

Fuel used during initial receipt shall be considered contaminated and shall be positively isolated, with blind flanges or closed, padlocked manual valves, from any active fuel transfer operations. Fuel isolation shall continue until all flushing and cleaning is completed.

3.5.3 Initial Low Point Flush

Perform an initial low point flush operation by flushing each low point drain through a portable basket strainer for 10 seconds at a system pressure of 30 psig. Repeat flush until basket strainer collects no additional debris.

3.5.4 Piping Hydrostatic Tests with Fuel

After initial receipt of fuel into piping, perform hydrostatic tests with fuel per Specification Section 33 52 43.13. Remaining system piping shall be packed with fuel, following procedures outlined in paragraph "General" above. Perform piping hydrostatic tests of new/modified piping with fuel per the applicable specifications, ensuring the piping system is completely vented of air through the piping high point vent system. Utilize blinds to separate new and existing piping systems. Contractor shall submit a testing checklist to ensure the requirements of this and other applicable specifications are met.

3.6 FLUSHING

The intent of the flushing operation is to remove bulk solids and water from the system. Flushing procedures shall precede cleaning procedures.

All new and modified fuel piping, including the transfer line, receipt system piping, pier piping and product stripping lines shall be flushed with fuel.

3.6.1 Flushing Requirements

Begin flushing of fuel system pipelines at low flow rates using one delivery pump. Slowly increase flushing flow rate with additional pumps to full flow capacity for a minimum of 30 minutes. If 3.5 m/s cannot be achieved using system pumps, the Contractor shall provide additional temporary pumping capacity. Flushing shall continue until the fuel being delivered is free of construction debris to the satisfaction of the Contracting Officer. Samples of fuel shall be taken and tested by the designated Government agency and shall be free of gross contamination and visible free water.

3.6.2 Pier Piping

Pier piping and loading arms should be hydrostatically tested with fuel per the applicable specification. The Contractor will be allowed to use Government-furnished hoses. Government barges/equipment may be used to

W912HV-18-R-0006 SECTION 33 08 55 Page 8 facilitate system flushing.

3.6.3 Piping Flushing Checklist

The Contractor shall generate a comprehensive matrix of all new piping sections in the system. Matrix shall serve as an Owner's piping inventory and a checklist for all Contractor-provided flushing operations. Column entries shall include pipe section name, location, diameter, approximate length, flushing fuel velocity and volume achieved and acceptable results of sampling.

3.7 PIPE PIGGING RUNS

3.7.1 General

Track all pigs, using transmitter and receivers, at no less than 805 m increments, but no less than at four locations. The Contractor shall prepare a contingency plan for retrieving a stuck pig and repairing any piping deformations. After pigging, plug valves shall be flushed of all debris using the drain port at the bottom of the valve. Contractor shall ensure pigs are designed to negotiate 1.5D bends.

3.7.2 Cleaning Pig Run

Contractor-provided pig launching and receiving barrels shall be installed.

Initially, a proving pig run (foam density <32 kg/m 3> should be performed to ensure the system is fully piggable. Upon completion of the successful proving pig run, the piping system shall be cleaned with a standard cleaning pig. This will provide thorough cleaning of the interior of the piping system. Cleaning pig shall be the bi-directional disk scraper style with steel body and replaceable polyurethane guiding and sealing disks, as well as gauge plates of 80 percent pipe diameter with 3 mm segmented aluminum fins. The pig body should include bypass nozzles and transmitter cavity. Propellant shall be pressurized fuel using the main system delivery pumps. The pig shall be examined after the initial run for signs of possible pipe damage, interior slag or other adhered particles.

Additional runs shall be performed until the amount of collected sludge or debris is minimized, as determined by the Contracting Officer.

3.7.3 Wire Brush Pig Run

After the cleaning pig runs, the piping system shall be cleaned with a wire brush style pig. This will remove weld slag and adhered particles from the system. Wire brush pig shall be the bi-directional disk style or directional cup style with two circular steel wire brushes. The pig body should include bypass nozzles and transmitter cavity. Perform wire brush pig runs until the amount of collected weld slag or debris is minimized, as determined by the Contracting Officer.

3.8 CLEANING, TESTING, AND SAMPLING

After the completion of the initial flushing and cleaning pig runs, all new and modified piping shall be cleaned in accordance with the procedure specified hereafter. The intent of this cleaning operation is to remove trace solids and water from the system.

3.8.1 Cleaning Requirements

Pump fuel through all new piping sections in the system. Fuel velocity

W912HV-18-R-0006 SECTION 33 08 55 Page 9 during all cleaning operations shall be full pumping capacity. Cleaning shall continue until Contracting Officer certifies that the fuel contains 2 milligrams per gallon or less of particulate and 10 parts per million or less of free water. Perform sampling at all system discharge points and throughout piping system. Sampling and testing shall be done by the appropriate military service.

3.8.2 Cleaning Procedure

During cleaning procedure periodically bleed air through high point vents and flush low point drains for a minimum of 10 seconds at a system pressure of 207 kPa. In piggable systems, all plug valves shall be flushed of all debris using the drain port at the bottom of the valve.

3.8.3 Piping Cleaning Checklist

The Contractor shall generate a comprehensive matrix of all new piping sections in the system. Matrix shall serve as a checklist for all Contractor-provided cleaning operations. Column entries shall include pipe section name, location, diameter, approximate length, fuel velocity and volume achieved, and acceptable results of sampling.

3.9 EQUIPMENT TESTS

After completion of flushing, cleaning, and electrical component adjustments, the equipment tests and performance tests specified hereinafter shall be performed. For final adjustment of installed electrical control equipment the Contractor shall provide an experienced electrical engineer, factory representative of control panel manufacturer.

Both the mechanical and electrical components shall be adjusted concurrently. Tests will be witnessed by the Contracting Officer and other Government representatives.

3.10 PERFORMANCE TESTS

During performance testing, the Contractor shall demonstrate that all portions of the fuel system are operating as designed and specified. Tests shall be performed under all operating scenarios. Additional tests may be required by the Contracting Officer to fully demonstrate system performance. These tests shall be accomplished by the Contractor at no additional cost to the Government. The Contractor shall notify the Contracting Officer 15 calendar days in advance of the test to permit arrangement for the use of Government furnished items. Record required data necessary to prepare reports specified in paragraph entitled "Commissioning Report". The Contractor shall also prepare and submit a Control Valve Checklist.

3.10.1 Fuel Receipt Systems

3.10.1.1 Aboveground systems

Demonstrate the following features:

a. Static and continuity ground verification system.

b. Manual start/stop pushbutton control.

c. Level probe interconnection with flow control valve solenoids.

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d. Pump shutdown upon no-flow/empty off-loading tanker condition signal from flow switch.

e. Receipt meter performance and verification of proper calibration.

3.10.2 Marine Fueling Systems

Demonstrate the following features:

a. Performance of loading meters and verification of proper calibration.

b. Loading/unloading arm function and operating range.

c. Stripping pump operation.

d. Operation of vents, drains, air eliminators, and hose connections.

Verify correct installation of piping expansion loops and supports. Verify electrical isolation between pier piping and ship. Verify that pier piping thermal relief system is properly installed.

3.10.3 Satisfactory Performance

In the event a portion of the system or any piece of equipment fails to meet the test, the Contractor shall make the necessary repairs or adjustments and repeat the Performance Test until satisfactory performance is obtained. Any component found not to be working as specified shall be repaired/replaced by the Contractor at no additional cost to the Government. The determination of satisfactory performance shall be made by the Contracting Officer and the Military Command Authority and Government representatives. The system shall be filled with fuel and shall be operable and leak-free prior to acceptance. The Contractor shall be responsible for any leaks in the new or modified portions of the system.

Anything wet with fuel is considered to be leaking.

3.11 TRAINING / INSTRUCTION FOR GOVERNMENT PERSONNEL

The contracting authority should provide one or two key personnel from their "operations" and "maintenance" departments to participate in all phases of system commissioning. The Contractor and System Supplier will be responsible for coordinating the involvement and training of these individuals during the startup process, including hands-on familiarization and adjustment of devices, valves, and components.

In addition, the Contractor and System Supplier shall conduct two 8-hour formal training sessions at the conclusion of system performance testing.

These sessions shall include initial classroom system presentations as well as a complete system walk-through. The function, operation and maintenance procedures for all system devices and components will be explained.

Training shall be videotaped and submitted in CD ROM or DVD format.

3.12 PROJECT CLOSEOUT

Ensure that As-Built drawings, equipment warranty documentation, and other project closeout activities are completed per the requirements of the applicable specifications.

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