UFC 3-460-03

10 November 2017
Change 2, 24 August 2023

UNIFIED FACILITIES CRITERIA (UFC)

PETROLEUM FUEL SYSTEMS

MAINTENANCE

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

 UFC 3-460-03
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UNIFIED FACILITIES CRITERIA (UFC)

PETROLEUM FUEL SYSTEMS MAINTENANCE

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the
copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND \1\/1/

AIR FORCE CIVIL ENGINEER CENTER \1\ (Preparing Activity)/1/

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

1 29 April 2021 Chapter 1, 2, 3, 4, 5, 6, 7, 8, 11, Appendix A, Appendix,
B, Appendix C, Appendix G, Appendix I, Appendix J.
Changes incorporated CCR and administrative
changes.
2 24 August Chapter 1, 2, 3, 6, Appendix A, Appendix, B, Appendix
2023 C, Appendix I, Appendix J. Changes incorporated CCR
and administrative changes. Added Two-Person Rule in
Chapter 2. Changed several maintenance tasks in
Appendix C between OM and SM.

This UFC supersedes UFC 3-460-03, dated 21 January 2003.

 UFC 3-460-03
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FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides
planning, design, construction, sustainment, restoration, and modernization criteria, and applies
to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance
with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and
work for other customers where appropriate. All construction outside of the United States is
also governed by Status of Forces Agreements (SOFA), host nation Funded Construction
Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)
Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the
SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to
users as part of the Services’ responsibility for providing technical criteria for military
construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities
Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are
responsible for administration of the UFC system. Defense agencies should contact the
preparing service for document interpretation and improvements. Technical content of UFC is
the responsibility of the cognizant DoD working group. Recommended changes with supporting
rationale should be sent to the respective service proponent office by the following electronic
form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following
source: Whole Building Design Guide website https://www.wbdg.org/ffc/dod.

Refer to UFC 1-200-01, DoD Building Code, for implementation of new issuances on projects.

AUTHORIZED BY:

LARRY D. McCALLISTER, PhD, PE, PMP, JOSEPH E. GOTT, P.E.

SES Chief Engineer
Chief, Engineering and Construction Naval Facilities Engineering Command
Directorate of Civil Works
U.S. Army Corps of Engineers

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW

Deputy Director of Civil Engineers Deputy Assistant Secretary of Defense
DCS/Logistics, Engineering & (Facilities Investment and Management)
Force Protection Office of the Assistant Secretary of Defense
(Energy, Installations, and Environment)
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UNIFIED FACILITIES CRITERIA (UFC)

CHANGE SUMMARY SHEET

Document: UFC 3-460-03, Petroleum Fuel Systems, Maintenance

Superseding: UFC 3-460-03, dated 21 January 2003

Description: Unified Facilities Criteria (UFC) 3-460-03 contains general inspection and
maintenance criteria for military land-based liquid petroleum fuel facilities. It also
applies to facilities dispensing Liquefied Natural Gas (LNG) and Compressed Natural
Gas (CNG) for ground vehicle fueling. These criteria are applicable to all branches of
the Department of Defense (DoD) and the Defense Logistics Agency (DLA).

Reasons for Document: UFC 3-460-03 was developed to harmonize requirements and
guidance documents from the Army, Navy, U.S. Marine Corps, Air Force, industry
guidelines, standards and codes. Creating a true unified criteria allows military services
to define the required tasks for contractors and government personnel in maintaining
petroleum fuel facilities.

Other military publications reviewed during the update to UFC 3-460-03 include United
States Air Forces in Europe (USAFE) Volume 1 General Description and Operation;
USAFE Volume 2 Maintenance and Repair; Standardization Agreement (STANAG)
3609 Standards for Maintenance of Fixed Aviation Fuel Receipt, Storage and
Dispensing Systems; United States Air Force (USAF) Air Force Instruction (AFI) 23-204
Organizational Fuel Tanks; USAF Technical Order (TO) 37-1-1 General Operation and
Inspection of Installed Fuel Storage and Dispensing Systems; and Unified Facilities
Guide Specifications (UFGS).

Several industry standards, recommended practices, and codes have been

incorporated into UFC 3-460-03 criteria including: American Petroleum Institute (API),
Airlines for America (A4A), Energy Institute (EI), National Association of Corrosion
Engineers (NACE) International, Petroleum Equipment Institute (PEI), Society of
Automotive Engineers (SAE) International, and the Steel Tank Institute (STI).

Impact:

• Provides the requirements for tasks and frequencies for the inspection and
maintenance of Petroleum Fuel Systems and components such as aircraft
hydrant systems, tanks, and pipelines.

• Provides checklists for the inspection and maintenance of Petroleum Fuel

Systems.

• Provides fuel quality, safety, environmental, fire protection guidance to follow

during the inspection and maintenance of Petroleum Fuel Systems.
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Unification Issues: The Army, Navy, U.S. Marine Corps, and Air Force could not unify
on tank cleaning requirements listed in Section 8-7. The Air Force will require fuel tanks
above 20,000 gallon in capacity to be cleaned on a 10 year cycle. The Army, Navy, and
U.S. Marine Corps will require tanks to be cleaned during out of service inspections.
The period of out of service inspections may vary depending on the type and condition
of each tank.
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This Page Intentionally Left Blank

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TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION ....................................................................................... 1
1-1 PURPOSE AND SCOPE. .......................................................................... 1
1-1.1 Introduction. ........................................................................................... 1
1-1.2 Applicability. ........................................................................................... 1
1-1.3 Scope..................................................................................................... 1
1-1.4 Design Criteria. ...................................................................................... 1
1-2 ROLES AND RESPONSIBILITIES. .......................................................... 1
1-2.1 Operational Tasks. ................................................................................. 2
1-2.2 Maintenance Tasks ................................................................................ 2
1-3 DEPARTMENT OF DEFENSE FUELS \1\ DISCIPLINE WORKING
GROUP /1/. ................................................................................................................. 2
1-4 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS................. 2
1-5 SERVICE CONTROL POINTS. ................................................................. 3
1-6 REGULATORY COMPLIANCE. ................................................................ 3
1-7 WAIVERS AND EXEMPTIONS. ................................................................ 3
1-7.1 Waivers. ................................................................................................. 3
1-7.2 Exemptions. ........................................................................................... 3
1-8 REFERENCES. ......................................................................................... 3
1-9 CAPITALIZED FUEL SYSTEMS. .............................................................. 4
1-10 MAINTENANCE AND INSPECTION FREQUENCIES. ............................. 4
CHAPTER 2 GENERAL ................................................................................................. 5
2-1 GENERAL MAINTENANCE INFORMATION. ........................................... 5
2-2 HEALTH AND SAFETY. ........................................................................... 5
2-2.1 Safety References. ................................................................................ 5
2-2.2 Personal Protective Equipment.............................................................. 5
2-2.3 Health Hazards. ..................................................................................... 6
2-2.4 Confined Spaces. .................................................................................. 8
2-3 ELECTRICAL SAFETY. ............................................................................ 8
2-3.1 Lockout/Tagout. ..................................................................................... 9
2-3.2 Static Charges. ...................................................................................... 9
2-3.3 Electrical Currents. .............................................................................. 10

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2-3.4 Hazardous Location Classification. ...................................................... 11

2-4 PETROLEUM FUEL QUALITY. .............................................................. 11
2-4.1 Water Contamination. .......................................................................... 11
2-4.2 Prevention and Removal of Water Contamination. .............................. 12
2-4.3 Solid Matter Contamination.................................................................. 13
2-4.4 Prevention and Removal of Solids Contamination. .............................. 13
2-4.5 Microbiological Contamination ............................................................. 14
2-4.6 Other Product Contamination. ............................................................. 15
2-4.7 Special Considerations for Biodiesel Blend B20. ................................. 16
2-4.8 Special Considerations for Fuel Ethanol Blend E85. ........................... 16
2-5 CHANGES IN TANK PRODUCT. ............................................................ 17
2-6 ENVIRONMENTAL PROTECTION. ........................................................ 17
2-6.1 Spill Planning. ...................................................................................... 18
2-6.2 Containment. ....................................................................................... 18
2-6.3 Containment Drain Valves. .................................................................. 18
2-6.4 Waste Disposal. ................................................................................... 18
2-7 SIGNAGE AND MARKINGS. .................................................................. 19
2-7.1 Inspection and Maintenance - Signage and Markings. ........................ 19
2-8 FIRE PROTECTION. ............................................................................... 19
2-8.1 Petroleum Fuel Vapor Sources for Fires and Explosions. ................... 20
2-8.2 Solid Sources for Fires and Explosions. .............................................. 20
2-8.3 Ignition Sources for Fires and Explosions. ........................................... 20
2-8.4 Fire and Explosion Preventative Measures.......................................... 21
2-9 EMERGENCY ACTION PLANS. ............................................................. 22
2-10 SITE MAINTENANCE PROGRAM. ......................................................... 22
2-10.1 Maintaining Petroleum Fuel Infrastructure. .......................................... 23
2-10.2 Documentation and Record Retention. ................................................ 23
2-10.3 As-built Information. ............................................................................. 24
2-10.4 Operation and Maintenance Support Information. ............................... 24
2-10.5 Safety Reports. .................................................................................... 25
CHAPTER 3 BULK TRANSFER FACILITIES .............................................................. 27
3-1 INTRODUCTION. .................................................................................... 27

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3-2 TRUCK RECEIPT. ................................................................................... 27

3-2.1 Inspection and Maintenance - Truck Receipt. ...................................... 27
3-3 PIPELINE RECEIPT. ............................................................................... 28
3-3.1 Inspection and Maintenance – Pipeline Receipt. ................................. 28
3-4 RAIL RECEIPT. ....................................................................................... 29
3-5 BULK ISSUE. .......................................................................................... 29
3-5.1 Truck Issue. ......................................................................................... 29
3-5.2 Pipeline Issue. ..................................................................................... 30
3-5.3 Rail Issue. ............................................................................................ 30
3-6 FILTRATION. .......................................................................................... 32
3-6.1 Pre-Filters. ........................................................................................... 32
3-6.2 Filter Separators. ................................................................................. 34
3-6.3 Haypack Filters. ................................................................................... 37
3-6.4 Basket Strainers. ................................................................................. 37
3-6.5 Filter Separator Sump Heaters. ........................................................... 38
3-7 METERS. ................................................................................................. 38
3-7.1 Positive Displacement Meters.............................................................. 38
3-7.2 Turbine Flow Meters ............................................................................ 40
3-7.3 Orifice Flow Meters. ............................................................................. 41
3-8 PUMPS. ................................................................................................... 41
3-8.1 Centrifugal Pumps. .............................................................................. 41
3-8.2 /1/ Vertical Inline Pumps. ..................................................................... 43
3-8.3 /1/ Vertical Turbine/Submerged Turbine Pumps. ................................. 45
3-8.4 /1/ Positive Displacement Pumps. ....................................................... 46
3-8.5 /1/ Sliding Vane Pumps. ...................................................................... 47
3-8.6 /1/ Gear Pumps.................................................................................... 48
3-8.7 /1/ Diaphragm Pumps. ......................................................................... 49
3-8.8 /1/ Internal Combustion Drives............................................................. 50
3-8.9 /1/ Gearboxes. ..................................................................................... 50
3-9 HOSES. ................................................................................................... 51
3-9.1 Loading Fuel Hoses. ............................................................................ 51
3-9.2 Offloading Fuel Hoses. ........................................................................ 52

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3-10 AIR ELIMINATORS. ................................................................................ 52

3-10.1 Air Eliminator Tanks. ............................................................................ 52
3-10.2 Automatic Air Vents. ............................................................................ 54
3-11 FUEL ADDITIVE INJECTORS. ............................................................... 55
3-11.1 Inspection and Maintenance – Fuel Additive Injectors. ........................ 55
3-12 CODED VESSELS. ................................................................................. 55
3-12.1 Inspection and Maintenance – Coded Vessels. ................................... 55
CHAPTER 4 AIRCRAFT FUELING FACILITIES ......................................................... 57
4-1 INTRODUCTION. .................................................................................... 57
4-2 HYDRANT SYSTEM – TYPE I. ............................................................... 57
4-3 HYDRANT SYSTEM – TYPE II. .............................................................. 58
4-3.1 General Description. ............................................................................ 58
4-3.2 System Specific Control Valves. .......................................................... 59
4-3.3 Type II Modified Control Valves (Rapid Flow). ..................................... 67
4-4 HYDRANT SYSTEM – TYPE III. ............................................................. 70
4-4.1 General Description. ............................................................................ 70
4-4.2 System-Specific Control Valves. .......................................................... 71
4-5 HYDRANT SYSTEM – TYPE IV. ............................................................. 83
4-5.1 General Description. ............................................................................ 83
4-5.2 System-Specific Control Valves. .......................................................... 83
4-6 HYDRANT SYSTEM – TYPE V. .............................................................. 86
4-6.1 General Description. ............................................................................ 86
4-7 HYDRANT SYSTEM GENERAL EQUIPMENT. ...................................... 86
4-7.1 Pantographs. ....................................................................................... 86
4-7.2 Hydrant Adapters. ................................................................................ 88
4-7.3 Fueling Nozzles. .................................................................................. 88
4-7.4 Surge Suppressors. ............................................................................. 90
4-7.5 Aircraft Fueling Hoses. ........................................................................ 91
4-8 HYDRANT SYSTEM PRODUCT RECOVERY. ....................................... 91
4-8.1 Overfill Valve for Product Recovery Tanks. ......................................... 91
4-8.2 Product Recovery Tank Release Detection. ........................................ 93
4-8.3 Product Recovery Tank Automatic Tank Gauges. ............................... 93

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4-8.4 Product Recovery Tank Fuel Transfer Pump. ...................................... 93

CHAPTER 5 MARINE RECEIVING AND DISPENSING FACILITIES .......................... 95
5-1 PIERS AND WHARVES. ......................................................................... 95
5-1.1 Inspection and Maintenance – Piers and Wharves. ............................. 95
5-1.2 Inspection and Maintenance – Fuel Containment Systems ................. 95
5-2 MARINE RECEIPT. ................................................................................. 95
5-2.1 Inspection and Maintenance – Marine Receipt. ................................... 96
5-3 MARINE ISSUE. ...................................................................................... 96
5-3.1 Inspection and Maintenance – Marine Issue........................................ 96
5-4 MARINE LOADING ARMS. ..................................................................... 97
5-4.1 Inspection and Maintenance – Marine Loading Arms. ......................... 98
5-5 MARINE AND UNDERWATER HOSES.................................................. 98
5-5.1 Marine Transfer Hoses. ....................................................................... 98
5-5.2 Underwater Hoses. .............................................................................. 99
5-6 DISPENSERS. ....................................................................................... 100
5-6.1 Inspection and Maintenance – Dispensers. ....................................... 100
5-7 OFFSHORE MOORING SYSTEMS. ..................................................... 101
5-7.1 Single Point Mooring Systems. .......................................................... 101
5-7.2 Multi-point Mooring Systems.............................................................. 102
5-8 SUBMERGED PIPING SYSTEMS. ....................................................... 103
5-8.1 Inspection and Maintenance – Submerged Pipelines. ....................... 103
5-9 BOOM REELS. ...................................................................................... 104
5-9.1 Inspection and Maintenance – Boom Reels....................................... 104
CHAPTER 6 PIPING SYSTEMS................................................................................. 105
6-1 PIPE TESTING AND INSPECTIONS. ................................................... 105
6-1.1 On-Base Pipelines. ............................................................................ 105
6-1.2 Inter-Terminal Pipelines. .................................................................... 106
6-1.3 Aboveground Piping. ......................................................................... 107
6-1.4 Double-Wall Piping. ........................................................................... 107
6-1.5 Pipe Visual Inspection. ...................................................................... 108
6-1.6 Line Walk. .......................................................................................... 109
6-1.7 Line Patrol.......................................................................................... 109

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6-1.8 Volume Check. .................................................................................. 109

6-1.9 API 570 Inspections. .......................................................................... 110
6-2 GENERAL PIPELINE CLEANING. ....................................................... 110
6-2.1 Cleaning Operations. ......................................................................... 110
6-3 PIPE SYSTEM REPAIRS. ..................................................................... 110
6-3.1 Pits and Small Leaks. ........................................................................ 111
6-4 PIPELINE INTEGRITY MANAGEMENT PLAN. .................................... 111
6-4.1 Certified Pipeline Inventory. ............................................................... 111
6-5 FLANGE GASKETS. ............................................................................. 112
6-6 VALVES. ............................................................................................... 112
6-6.1 Valve Tagging. ................................................................................... 112
6-6.2 Manual Valves. .................................................................................. 112
6-6.3 Thermal and Pressure Relief Valves. ................................................ 123
6-6.4 Semi-Automatic Valves. ..................................................................... 125
6-6.5 Automatic Control Valves................................................................... 126
6-6.6 Motor Operators................................................................................. 128
6-7 PRESSURE AND VACUUM INSTRUMENTATION. ............................. 128
6-7.1 Pressure and Pressure/Vacuum Gauges. ......................................... 128
6-7.2 Differential Pressure Gauges. ............................................................ 129
6-7.3 Pressure Transmitters........................................................................ 130
6-7.4 Differential Pressure Transmitters. .................................................... 131
6-8 FLEXIBLE BALL JOINTS. .................................................................... 132
6-8.1 Flexible Ball Joints. ............................................................................ 132
6-9 THERMOMETERS. ............................................................................... 132
6-9.1 Dial Thermometers. ........................................................................... 133
6-10 PIPE AND EQUIPMENT COATINGS. ................................................... 133
6-10.1 Aboveground Piping and Equipment Coatings. ................................. 133
6-10.2 Underground Piping Coating Repairs. ............................................... 134
6-10.3 Internal Carbon Steel Pipe Coatings. ................................................. 135
6-11 UNDERGROUND FUEL PITS. .............................................................. 135
6-11.1 Isolation Valve Pits. ........................................................................... 135
6-11.2 Hydrant Fuel Pits. .............................................................................. 136

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6-11.3 High Point Vent Pits. .......................................................................... 137

6-11.4 Low Point Drain Pits. ......................................................................... 137
6-11.5 Lateral Control Pits. ........................................................................... 138
6-12 MINOR PIPING SYSTEMS.................................................................... 139
6-12.1 Low Point Drains................................................................................ 139
6-12.2 High Point Vents. ............................................................................... 139
6-12.3 Sight Flow Indicators. ........................................................................ 139
6-13 ELECTRONIC RELEASE DETECTION MONITORING. ....................... 140
6-13.1 General Inspection of Release Detection Systems. ........................... 140
6-14 VISUAL RELEASE DETECTION MONITORING. ................................. 141
6-14.1 Visual Monitoring. .............................................................................. 141
CHAPTER 7 GROUND VEHICLE FUEL FACILITIES ................................................ 143
7-1 GENERAL. ............................................................................................ 143
7-2 DISPENSER NOZZLES. ....................................................................... 143
7-2.1 Inspection and Maintenance – Dispenser Nozzles. ........................... 143
7-3 DISPENSER HOSES............................................................................. 144
7-3.1 Inspection and Maintenance – Dispenser Hoses. .............................. 144
7-4 BREAKAWAYS. .................................................................................... 144
7-4.1 Inspection and Maintenance – Breakaways....................................... 144
7-5 SWIVELS............................................................................................... 145
7-5.1 Inspection and Maintenance – Swivels. ............................................. 145
7-6 HOSE RETRIEVER. .............................................................................. 145
7-6.1 Inspection and Maintenance – Hose Retriever .................................. 145
7-7 DISPENSER CABINET. ........................................................................ 145
7-7.1 Inspection and Maintenance – Dispenser Cabinet............................. 145
7-8 DISPENSER METERS. ......................................................................... 146
7-8.1 Inspection and Maintenance – Dispenser Meters. ............................. 146
7-9 DISPENSER FILTERS. ......................................................................... 146
7-9.1 Inspection and Maintenance – Dispenser Filters. .............................. 146
7-10 DISPENSER STRAINERS. ................................................................... 146
7-10.1 Inspection and Maintenance – Dispenser Strainers........................... 146
7-11 GROUND VEHICLE FUEL PIPING. ...................................................... 147

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7-11.1 Inspection and Maintenance – Ground Vehicle Fuel Piping............... 147

7-12 EMERGENCY SHUTOFF VALVES (SHEAR VALVES). ...................... 148
7-12.1 Inspection and Maintenance – Emergency Shutoff Valves (Shear
Valves). ........................................................................................................... 148
7-13 DISPENSER SUMPS. ........................................................................... 149
7-13.1 Inspection and Maintenance – Dispenser Sumps. ............................. 149
7-14 TRANSITION SUMPS. .......................................................................... 149
7-14.1 Inspection and Maintenance – Transition Sumps. ............................. 149
7-15 DISPENSER PUMPS. ........................................................................... 149
7-15.1 Remote Dispenser Pumps. ................................................................ 150
7-15.2 Self-Contained Dispenser Pumps. ..................................................... 150
7-16 EFSO SYSTEMS. .................................................................................. 150
7-16.1 Inspection and Maintenance – EFSO Systems.................................. 151
7-17 VAPOR RECOVERY. ............................................................................ 151
7-17.1 Stage I Vapor Recovery. .................................................................... 151
7-17.2 Stage II Vapor Recovery. ................................................................... 151
7-17.3 Vapor Burners.................................................................................... 152
7-18 TACTICAL REFUELER LOADING. ...................................................... 152
7-19 ELECTRONIC RELEASE DETECTION MONITORING. ....................... 152
7-19.1 General Inspection of Release Detection Systems. ........................... 152
7-20 VISUAL RELEASE DETECTION MONITORING. ................................. 154
7-20.1 Visual Monitoring. .............................................................................. 154
CHAPTER 8 PETROLEUM STORAGE TANKS ........................................................ 155
8-1 GENERAL INFORMATION. .................................................................. 155
8-2 CONTAMINATION PREVENTION. ....................................................... 155
8-3 TANK SURFACE COATINGS............................................................... 155
8-3.1 External Tank Coating Repairs. ......................................................... 156
8-3.2 Internal Tank Coating Repairs. .......................................................... 156
8-4 ABOVEGROUND FIELD-ERECTED TANKS. ...................................... 157
8-4.1 Inspection and Maintenance – Aboveground Field-Erected Tanks. ... 158
8-4.2 Geodesic Dome Roofs. ...................................................................... 159
8-4.3 Foundations. ...................................................................................... 159
8-5 SHOP-FABRICATED TANKS. .............................................................. 160
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8-5.1 Aboveground Shop-Fabricated Tanks. .............................................. 160

8-5.2 Self-Diking or Vaulted Tanks. ............................................................ 162
8-5.3 Rectangular Concrete-Encased Tanks. ............................................. 163
8-5.4 Underground Shop-Fabricated Tanks. ............................................... 164
8-6 UNDERGROUND FIELD-CONSTRUCTED TANKS (CUT AND COVER
TANKS). ............................................................................................................... 170
8-6.1 Inspection and Maintenance – Underground Field-Constructed Tanks
(Cut and Cover Tanks). ........................................................................................... 170
8-7 TANK CLEANING. ................................................................................ 171
8-8 RETURNING TO SERVICE AFTER FORMAL OUT OF SERVICE
INSPECTION/REPAIR. ........................................................................................... 172
8-8.1 Tank Stenciling Requirements. .......................................................... 173
8-9 TANK APPURTENANCES.................................................................... 173
8-9.1 Floating Roofs and Pans.................................................................... 173
8-9.2 Secondary Tank Bottoms................................................................... 181
8-9.3 Tank Pressure/Vacuum Vents. .......................................................... 182
8-9.4 Emergency Vents. ............................................................................. 184
8-9.5 Flame Arrestors. ................................................................................ 185
8-9.6 High Level Shut-off Valve (HLSO). .................................................... 185
8-9.7 Mechanical Tape Gauges. ................................................................. 187
8-9.8 Automatic Tank Gauges .................................................................... 188
8-9.9 Level Alarms. ..................................................................................... 193
8-9.10 Product Saver Tanks. ........................................................................ 194
8-9.11 Sidestream Filtration Systems. .......................................................... 194
8-9.12 Fill Ports. ............................................................................................ 195
8-9.13 Release Detection Monitoring. ........................................................... 196
8-9.14 Floating Suction Lines. ...................................................................... 198
8-9.15 Foam Fire Protection Systems........................................................... 199
8-9.16 Heating Coils. .................................................................................... 199
8-9.17 Stilling Wells. ..................................................................................... 201
8-10 CONTAINMENT SYSTEMS. ................................................................. 201
8-10.1 Inspection and Maintenance – Containment Systems (General). ...... 202
8-10.2 Concrete and Cement Brick Dike/Berm Walls and Floors.................. 202

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8-10.3 Earthen Dike Walls. ........................................................................... 203

8-10.4 Self-Diking or Vaulted Tank Containment. ......................................... 203
8-10.5 Flexible Membrane Liners.................................................................. 204
8-10.6 Pipe Penetrations. ............................................................................. 204
8-11 MISCELLANEOUS USE TANKS. ......................................................... 205
8-11.1 Miscellaneous Use Tanks. ................................................................. 205
CHAPTER 9 ELECTRICAL SYSTEMS ...................................................................... 207
9-1 ELECTRIC CONTROL SYSTEMS AND EQUIPMENT. ........................ 207
9-1.1 Scope and Limitations. ...................................................................... 207
9-1.2 Electrical Equipment. ......................................................................... 207
9-1.3 Power Cables. ................................................................................... 208
9-1.4 Motor Controls. .................................................................................. 208
9-1.5 Panelboards....................................................................................... 210
9-1.6 Grounding Systems. .......................................................................... 211
9-1.7 Electric Motors. .................................................................................. 212
9-1.8 Lighting. ............................................................................................. 213
9-1.9 Electronic Equipment. ........................................................................ 214
9-2 CATHODIC PROTECTION SYSTEMS. ................................................ 215
9-2.1 Cathodic Protection. .......................................................................... 215
9-2.2 Electrical Isolation. ............................................................................. 216
9-3 CARD AND KEY LOCKS. ..................................................................... 216
9-3.1 Inspection and Maintenance - Card and Key Locks........................... 216
9-4 LIGHTNING PROTECTION SYSTEMS................................................. 217
9-4.1 Inspection and Maintenance – Lightning Protection Systems. ........... 217
9-5 GROUND VERIFICATION SYSTEMS................................................... 217
9-5.1 Inspection and Maintenance – Ground Verification Systems. ............ 217
9-6 ELECTRONIC OVERFILL PROTECTION SYSTEMS. ......................... 217
9-6.1 Inspection and Maintenance – Electronic Overfill Prevention Systems. ..
........................................................................................................... 217
CHAPTER 10 ALTERNATE POL FACILITIES .......................................................... 219
10-1 LIQUEFIED PETROLEUM GAS. .......................................................... 219
10-1.1 Liquefied Petroleum Tanks. ............................................................... 219
10-1.2 Liquefied Petroleum Pipelines. .......................................................... 219
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10-1.3 Liquefied Petroleum Vapor Lines. ...................................................... 220

10-1.4 LPG Vaporizers. ................................................................................ 220
10-1.5 Petroleum Gas Regulators................................................................. 220
10-1.6 Liquefied Petroleum Gas Hoses. ....................................................... 221
10-2 COMPRESSED NATURAL GAS (CNG). .............................................. 221
10-2.1 CNG Piping. ....................................................................................... 221
10-2.2 CNG Compressors. ........................................................................... 222
10-2.3 CNG Storage. .................................................................................... 222
10-2.4 CNG Dispensers ................................................................................ 223
10-2.5 CNG Dispenser Hoses. ..................................................................... 223
10-3 HYDRAZINE CHARGING UNITS. ......................................................... 223
10-3.1 Inspection and Maintenance – Hydrazine Charging Units. ................ 223
10-4 JP-10. .................................................................................................... 223
10-5 OTTO. .................................................................................................... 224
CHAPTER 11 SUPPORT FACILITIES ....................................................................... 225
11-1 SECONDARY CONTAINMENT. ........................................................... 225
11-1.1 Fuel Truck \1\ and Rail Car /1/ Containment Areas. .......................... 225
11-1.2 Remote Spill Containment. ................................................................ 226
11-2 PROTECTIVE SHELTERS. ................................................................... 227
11-2.1 Pumphouse/Filter Buildings. .............................................................. 227
11-2.2 Canopies............................................................................................ 227
11-3 SAFETY SHOWERS AND EYEWASH FOUNTAINS............................ 227
11-3.1 Inspection and Maintenance – Emergency Eyewash/Showers.......... 227
11-4 FUELS LABORATORIES. .................................................................... 228
11-4.1 Ventilation Hoods............................................................................... 228
11-5 OIL/WATER SEPARATORS. ................................................................ 229
11-5.1 Inspection and Maintenance – Oil/Water Separators. ........................ 229
11-6 CRANES AND HOISTS......................................................................... 230
11-6.1 Inspection and Maintenance – Cranes and Hoists............................. 230
CHAPTER 12 FUEL FACILITY TEMPORARY DEACTIVATION OR CLOSURE ...... 231
12-1 DEACTIVATION OF FUELING FACILITIES. ........................................ 231
12-2 DEACTIVATED PETROLEUM FUEL TANKS ...................................... 231

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12-2.1 Inspection and Maintenance – Deactivated Petroleum Fuel Tanks. .. 231

12-3 DEACTIVATED PETROLEUM FUEL PIPELINES. ............................... 231
12-3.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pipelines. ...
........................................................................................................... 232
12-4 DEACTIVATED PETROLEUM FUEL PUMPS. ..................................... 232
12-4.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pumps. . 232
12-5 MISCELLANEOUS DEACTIVATED COMPONENTS. .......................... 232
12-5.1 Inspection and Maintenance – Miscellaneous Deactivated Components.
........................................................................................................... 233
12-6 TANKS AND PIPELINES. ..................................................................... 233
12-7 DOCUMENTATION/RECORDKEEPING. ............................................. 233
APPENDIX A DLA ENERGY PROJECT PROGRAMING .......................................... 235
APPENDIX B CONTAINMENT INTEGRITY TESTING CHECKLIST ......................... 241
APPENDIX C MAINTENANCE TABLE ...................................................................... 243
APPENDIX D MAINTENANCE PROCEDURES ......................................................... 369
APPENDIX E TANK INSPECTION CHECKLISTS ..................................................... 375
APPENDIX F TANK INSPECTION CHECKLISTS ..................................................... 383
APPENDIX G PETROLEUM FUEL PIPELINE PRESSURE TESTING GUIDELINES
AND CRITERIA .......................................................................................................... 387
APPENDIX H TANK CLEANING GUIDANCE............................................................ 415
APPENDIX I /1/ ACRONYMS ..................................................................................... 423
APPENDIX J /1/ References...................................................................................... 429

FIGURES

Figure 3-1 Pre-Filter ................................................................................................. 32

Figure 3-2 Filter Separator ...................................................................................... 34
Figure 3-3 Positive Displacement Meter ................................................................ 39
Figure 3-4 Turbine Flow Meter ................................................................................ 40
Figure 3-5 Split-Case Centrifugal Pump ................................................................ 42
Figure 3-6 Vertical Inline Pump............................................................................... 44
Figure 3-7 Vertical Turbine Pump ........................................................................... 45
Figure 3-8 Rotary Vane Pump ................................................................................. 48
Figure 3-9 Diaphragm Pump ................................................................................... 49
Figure 3-10 Air Eliminator Tank ............................................................................ 53
Figure 3-11 Automatic Air Vent ............................................................................. 54
Figure 4-1 Modified Panero, Type I Hydrant System ............................................ 57
Figure 4-2 Pritchard, Type II Hydrant System ....................................................... 59
Figure 4-3 High Level Shut-off Valve (Type II) ....................................................... 60
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Figure 4-4 Non-Surge Check Valve (Type II) .......................................................... 61

Figure 4-5 Filter Separator Control Valve (Type II)................................................ 62
Figure 4-6 Refueling Control Valve (Type II) .......................................................... 63
Figure 4-7 Pressure Relief Valve (Type II).............................................................. 64
Figure 4-8 Defuel Control Valve (Type II) ............................................................... 65
Figure 4-9 Dual Rate-of-Flow Control Valve (Type II)............................................ 66
Figure 4-10 Combination Dual Rate-of-Flow Control and Solenoid Valve (Type
II) ............................................................................................................. 67
Figure 4-11 Dual Pressure Relief, Solenoid Shutoff, and Check Valve (Type II) ...
............................................................................................................. 69
Figure 4-12 Type III Hydrant System Diagram ..................................................... 71
Figure 4-13 Non-Surge Check Valve ..................................................................... 72
Figure 4-14 Filter Separator Control Valve (Type III) ........................................... 73
Figure 4-15 Defuel/Flush Valve (Type III) .............................................................. 75
Figure 4-16 Issue Venturi ....................................................................................... 76
Figure 4-17 Back Pressure Control Valve (Type III)............................................. 77
Figure 4-18 Pressure Control Valve (Type III) ...................................................... 79
Figure 4-19 Hydrant Control Valve (Type III) ........................................................ 80
Figure 4-20 Emergency Shut-Off Valve (Type III)................................................. 82
Figure 4-21 Pantograph Pressure Control Valve ................................................. 85
Figure 4-22 Fixed Pantograph ............................................................................... 87
Figure 4-23 Hydrant Adapter ................................................................................. 88
Figure 4-24 Fueling Nozzle .................................................................................... 89
Figure 4-25 Surge Suppressor .............................................................................. 90
Figure 4-26 Overfill Valve for Product Recovery Tank ........................................ 92
Figure 5-1 Single Point Mooring System ............................................................. 102
Figure 6-1 Lubricated Plug Valve ......................................................................... 113
Figure 6-2 Gate Valve ............................................................................................ 114
Figure 6-3 Ball Valve .............................................................................................. 115
Figure 6-4 Double Block and Bleed Plug Valve ................................................... 117
Figure 6-5 Butterfly Valve ...................................................................................... 119
Figure 6-6 Globe Valve .......................................................................................... 120
Figure 6-7 Check Valve.......................................................................................... 121
Figure 6-8 Line Blank............................................................................................. 122
Figure 6-9 Ring Spacer .......................................................................................... 122
Figure 6-10 Spectacle Blind ................................................................................ 123
Figure 6-11 Thermal and Pressure Relief Valve................................................. 124
Figure 6-12 Truck Fill Valve ................................................................................. 127
Figure 6-13 Flexible Ball Joint ............................................................................. 132
Figure 7-1 Dispenser Nozzle ................................................................................. 143
Figure 7-2 Emergency Shutoff Valve.................................................................... 148
Figure 8-1 Floating Roof Seal ............................................................................... 175
Figure 8-2 Floating Roof Detail ............................................................................. 175
Figure 8-3 Standard Tank Seal on Aluminum Honeycomb Pans ....................... 176
Figure 8-4 Pressure Vacuum Vent ........................................................................ 183
Figure 8-5 External High Level Shut-off Valve .................................................... 186

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Figure 8-6 Mechanical Tape Gauge ...................................................................... 189

Figure 8-7 Magnetostrictive Probe ....................................................................... 191
Figure 8-8 Servo Gauge......................................................................................... 192

TABLES

Table 8-1 /1/ Single-walled Underground Shop Fabricated Tank Inspection and
Testing Schedules* ............................................................................................ 166
Table 8-2 /1/ Double-walled Underground Shop Fabricated Tank Inspection and
Testing Schedules* ............................................................................................ 168
Table G-1 /1/ Pipe Properties.................................................................................... 389
Table G-2 /1/ Definition of Terms ............................................................................. 400
Table G-2 /1/ Military Requirements......................................................................... 402

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CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE.

1-1.1 Introduction.

Clean, water-free fuel of the correct grade is essential to the safety of vehicles, ships
and aircraft, and their operators and personnel. This manual emphasizes inspection
and preventive maintenance to avoid system shutdowns, prevent fuel contamination,
and decrease fire, safety, and health hazards. Periodic inspections and maintenance
are essential to continue efficient safe operations and reduce major repairs.

1-1.2 Applicability.

UFC 3-460-03 applies to all real property facilities used for storing, distributing, and
dispensing fuels for reciprocating and jet engine aircraft, automotive fuels, lubricating
oils, and diesel fuel.

1-1.3 Scope.

This manual establishes the minimum inspection and maintenance standards for fueling
systems and applies to all active installations. If the installation is in an inactive or
surplus status, reduce maintenance standards to a point consistent with the anticipated
mission.

1-1.4 Design Criteria.

This is not a design manual. Refer to UFC 3-460-01 for current design and construction
standards.

1-2 ROLES AND RESPONSIBILITIES.

A role is a position or job defined by a set of responsibilities. A responsibility is a task or

duty required of a designated party. Military services delegate tasks differently to
military service-specific petroleum fuel personnel, contracted operations personnel, or
maintenance contractors.

UFC 3-460-03 defines minimum maintenance tasks and their frequency. The criteria
outlined within UFC 3-460-03 must be accomplished by DoD personnel (active
duty/civilian) and/or DoD contractors.

The Command Authority (i.e., Army, Navy, U.S. Marine Corps, Air Force, and/or DLA)
defines how tasks are divided among personnel at each facility. DoD 4140.25-M
provides requirements applicable to all DoD fuel facilities.

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1-2.1 Operational Tasks.

Operational tasks are actions taken to control and run the petroleum fuel system on a
day-to-day basis. These tasks include monitoring control systems, bulk issue and
receipt, and storage of petroleum fuel. Operating tasks help ensure the safety of
personnel and the environment. Operating tasks often include specific measures to
maintain petroleum fuel quality.

1-2.2 Maintenance Tasks

Maintenance tasks are recurring, daily, periodic, or scheduled work required to:
preserve a facility, prevent deterioration, prevent component failure, prevent
unscheduled outages, and identify components requiring replacement or repair.
Maintenance tasks involve: routine inspection, testing of petroleum fuel systems, and
identifying required repairs. Maintenance tasks help ensure product quality, safe
working conditions, and environmental safety.

Maintenance tasks are separated into Operator Maintenance (OM) and Systems
Maintenance (SM). OM is normally performed by facility operator personnel as part of
normal use. SM is normally performed by trained personnel of base facility
maintenance, facility operating contracts, or maintenance contracts for recurring
maintenance and repair. Military services can delegate maintenance tasks between
OM and SM differently. Appendix C includes a list of maintenance tasks included in this
UFC and their associated designation as OM or SM for the Army, Navy and U.S. Marine
Corps, and the Air Force.

1-3 DEPARTMENT OF DEFENSE FUELS \1\ DISCIPLINE WORKING

GROUP /1/.

UFC 3-460-03 was updated by the DoD Fuels \1\ Discipline Working Group (FDWG) /1/.
For more information on the \1\ FDWG /1/ refer to UFC 3-460-01, Appendix \1\B/1/.

1-4 SERVICE HEADQUARTERS SUBJECT MATTER EXPERTS.

Policies, obligations, and responsibilities vary between DoD components. For

interpretation of components required in petroleum fuel systems, consult the applicable
Service Headquarters Subject Matter Expert (SME). For interpretation, the SME at the
appropriate Service Headquarters is defined as follows:

• Army – Headquarters, US Army Corps of Engineers, POL Facilities

Proponent (CECW-EC).
• Air Force – The Air Force Fuels Facilities Subject Matter Expert (\1\/1/
AFCEC/COS) through the applicable \1\ Regional Fuels Engineer
(USAFE/PACAF) /1/.
• Navy/Marine Corps: NAVFAC POL Facility Subject Matter Expert
(NAVFAC EXWC, CI11).

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1-5 SERVICE CONTROL POINTS.

Service Control Points (SCP) have been established for each of the military services.
SCPs serve as the central management function in coordinating requirements, technical
issues, and supply actions with military units and DLA Energy. For interpretations on
operation and maintenance requirements of fuel systems, consult the applicable SCP
as defined in DoD 4140.25-M, Volume 1, Chapter 1, Section C1.3.1.5.

1-6 REGULATORY COMPLIANCE.

Inspection and maintenance activities must meet the most stringent of UFC and Military
Specific requirements as well as applicable host nation, Federal, state, and local codes
and regulations. For example, Ramstein Air Base must comply with the more stringent
maintenance criteria of UFC 3-460-03, the applicable NATO STANAG, USAFE
documents, or German law.

1-7 WAIVERS AND EXEMPTIONS.

Recommended UFC 3-460-03 language generated from recurring waivers and

exemptions will be considered by the DoD \1\ FDWG /1/ with supporting rationale for
inclusion on \1\ FDWG /1/ voting agendas. Recommended changes to UFC 3-460-03
are reviewed and approved by the voting members of the DoD \1\ FDWG /1/, preferably
in a normal recurring meeting.

1-7.1 Waivers.

Waivers are temporary deviations from the stated criteria within UFC 3-460-03. Waivers
are valid for up to one year or as stated on the waiver and are submitted to the military
service-specific SCP for review. Refer to Military Standard (MIL-STD)-3007G for the
waiver process.

1-7.2 Exemptions.

In contrast to waivers, exemptions are permanent deviations from the stated criteria
within UFC 3-460-03. Exemption requests must be submitted through the military
service-specific SCP for review. Refer to Military Standard (MIL-STD)-3007G for the
exemption process. The \1\ FDWG /1/ must be advised when an exemption is granted.

1-8 REFERENCES.

Other sources for criteria related to petroleum fuel facilities are identified in \1\ Appendix
J. /1/ Any reference noted is the latest edition (as of the publication of this document)
unless otherwise stated. Many of these documents are available within the public
domain and can be found on the Internet; others require purchase. Before purchasing
copies of referenced documents, contact the military service-specific SME to determine
the need to have a complete copy of the referenced document versus obtaining the
specific data needed from the referenced document from the SME.

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1-9 CAPITALIZED FUEL SYSTEMS.

SM is normally eligible for DLA Energy funding at facilities that contain, handle, or
distribute DLA Energy capitalized fuel under the Sustainment, Restoration, and
Modernization (SRM) program. Proper coordination and scheduling with facility
operators is necessary before conducting SM to ensure minimal mission impact.

DLA Energy also funds other inspection and maintenance programs at petroleum fuel
facilities that contain, handle, or distribute DLA Energy capitalized fuel. See \1\
Appendix A /1/ for a list of current maintenance and inspection programs that are
funded by DLA Energy.

1-10 MAINTENANCE AND INSPECTION FREQUENCIES.

The maintenance and inspection frequencies provided in this UFC are strict guidelines
and are based on regulatory requirements and commercial practices. The military
service-specific SCP can authorize deviations and alternate equivalent methodologies
for specific individual tasks and only as needed to support the mission requirements.
For example, the military service-specific SCP can authorize deviations to delay or
accelerate an out of service inspection of a fuel storage tank to coincide with other work
to avoid reducing mission capabilities.

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CHAPTER 2 GENERAL

2-1 GENERAL MAINTENANCE INFORMATION.

This chapter contains information general to all chapters of UFC 3-460-03. This chapter
includes health and safety information, information related to fuel quality, and general
practices and requirements.

2-2 HEALTH AND SAFETY.

Personnel must comply with the measures outlined in this chapter. Petroleum fuel
products are hazardous because of their toxic and flammable nature. Health and safety
precautions are required and must be strictly adhered to in order to prevent incidents
and accidents to personnel and Government property. Before initiating maintenance
work on petroleum fuel facilities, a hazard analysis must be completed and procedures
must be established to assure recognized hazards have been controlled, items to be
serviced are properly isolated and adequate light is available for the task. Only properly
trained and authorized personnel are permitted to operate and perform maintenance on
petroleum fuel system components. Breaches of safety standards may result in
disciplinary action and possible injury or death. Safe efficient maintenance activities
require cleanliness, neatness, and order. Each individual is expected to recognize and
correct hazardous situations promptly, if qualified, and/or report them to supervisors.

2-2.1 Safety References.

Military service-specific health and safety procedures and information listed in USACE
EM 385-1-1, \2\ \1\ DAFMAN 91-203 /1/ /2/, Navy Occupational Safety & Health
(NAVOSH) and Occupational Safety and Health Administration (OSHA) regulations,
NFPA 2112, NFPA 2113, and ASTM F1449 must be followed as applicable. Refer to
Installation Safety Office for additional local and Installation specific safety requirements
and procedures.

2-2.2 Personal Protective Equipment.

\1\
a. The purpose of this section is to reduce the health and safety risks
associated with the incorrect selection and use of personal protective
equipment when personnel are potentially exposed to petroleum fuels and
associated fire hazards. Each facility is responsible for performing a
hazard analysis in accordance with NFPA 2113 to identify, eliminate, and
control recognized and identified hazards. Personnel Protection
Equipment (PPE) will be selected to provide the user with the appropriate
personal protection. Personnel will be trained in the proper selection, use,
care and maintenance of their PPE in accordance with the Installation’s
written PPE program. Installations that determine there is the potential for
a fire to exist from flammable vapors must utilize PPE that meets the
minimal standards of NFPA 2112. Installations must reassess the hazard

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analysis at least every 5 years, or when a significant change is made to

the work environment.
b. Any type of clothing may be worn as outer garments when working with
high-flashpoint petroleum fuel (e.g., JP-5, JP-8, JP-10, Jet A, Jet A-1,
additized Jet A (F-24) or diesel). However, personnel working with low-
flashpoint petroleum fuel (e.g., JP-4, Jet B, aviation gasoline, or motor
gasoline) must utilize PPE that meets the requirements of NFPA 2112
where the petroleum fuel facility hazard analysis has demonstrated that
flammable materials or vapors are present in quantities that may result in
a fire or endanger personnel. Wool socks, wool glove inserts, woolen
caps, and underwear of nylon, silk, or polyester pose no significant hazard
and are acceptable. Appropriate weather gear is allowed for personnel
who are subject to outside work during inclement weather.
c. Conventional 50% polyester and 50% cotton-blend coveralls are adequate
for routine maintenance work in petroleum fuel facilities that do not pose a
fire hazard potential. When completing tasks in petroleum fuel facilities
where petroleum fuel is present (e.g., tank cleaning), the use of
disposable protective coveralls having a static-dissipating coating may be
necessary. Disposable coveralls may be worn alone or over
polyester/cotton-blend coveralls. Replace fuel-contaminated clothing.
/1/

2-2.3 Health Hazards.

The following paragraphs describe health hazards of exposure to petroleum fuel vapors,
liquid petroleum fuels, and solids. The paragraphs also provide guidance on
administering appropriate types of first aid for personnel exhibiting symptoms resulting
from petroleum fuel exposure. Review and become familiar with the health and
exposure hazards listed on Safety Data Sheets (SDSs) for the types of fuel stored and
handled in fuel systems to be maintained.

2-2.3.1 Petroleum Fuel Vapors.

Petroleum fuel vapors within a confined space, regardless of their toxicity and explosive
potential, will displace oxygen and may cause suffocation. Petroleum fuel vapors can
be harmful even at concentrations with a Lower Explosive Limit (LEL) of 0 (zero) unless
the area has been completely freed of vapor. The Permissible Exposure Limit (PEL) of
petroleum fuel vapors that can be safely inhaled is lower than the LEL. To reduce the
potential for personnel exposure to hazardous petroleum fuel vapor concentrations, a
facility industrial hygiene survey should be completed and safety controls implemented
in accordance with applicable military service requirements as well as OSHA
requirements and American Conference of Governmental Industrial Hygienists
guidelines.

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2-2.3.1.1 Petroleum Fuel Vapor Inhalation First Aid.

Safely remove all persons from the work area who exhibit adverse symptoms of
exposure to petroleum fuel vapors to include dizziness, nausea, or headache. If a
person is overcome by petroleum fuel vapors, first aid should be administered at once
by someone trained in first aid, and the person exhibiting symptoms should get prompt
medical attention. Recovery from initial exposure to vapors is usually prompt after
exposure to fresh air. If breathing has stopped, Cardiopulmonary Resuscitation (CPR)
should be administered by a person trained in CPR. Promptly report all incidents or
accidents potentially resulting from petroleum fuel vapor inhalation to supervisors.

2-2.3.2 Liquid Petroleum Fuel.

Avoid getting liquid petroleum fuel on skin or clothing. Liquid petroleum fuel products
remove protective oils from the skin, causing drying, chapping, and cracking. Swallowed
liquid petroleum fuel products may cause central nervous system depression and
pneumonia.

2-2.3.2.1 Liquid Petroleum Fuel Contact/Ingestion First Aid.

External Contact: Remove contaminated clothing at once and avoid any source of
ignition. Remove liquid petroleum fuel products from the skin by washing with soap and
water as soon as possible after contact. Remove liquid petroleum fuel that comes in
contact with eyes immediately with an eyewash or other available means of flushing the
eye with water. Obtain medical attention as soon as possible after exposure to liquid
petroleum fuel. Do not expose a person to flame producing activities once they have
been contaminated with liquid petroleum fuel.

Ingestion: Do not induce vomiting except as directed by physician, as uncontrolled

vomiting may cause liquid petroleum fuel to go into the lungs. A person that has
ingested liquid petroleum fuel should be taken to a medical facility at once. Be sure to
inform medical administrators of the type and approximate amount of liquid petroleum
fuel ingested.

2-2.3.3 Solids.

Dusts are formed by additives in petroleum fuel products remaining after the volatile
liquids have evaporated. Solid particles in sludge may be dispersed as the sludge
dries. Dust can also result from scale, sandblast, and rust particles removed from tank
walls and strainers during cleaning operations. Consult the Installation Environmental
Office for proper procedures for sludge and solid waste cleaning and disposal.

2-2.3.3.1 Solids Contact/Inhalation First Aid.

Solids will enter the body through inhalation of contaminated dust particles. Treat bodily
contact with dust as you would with liquid petroleum fuels (Section 2-2.3.2.1) and

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inhalation of dust as you would with petroleum fuel vapors (Section 2-2.3.1.1). Seek
immediate medical attention.

\1\
2-2.4 Confined Spaces.

A confined space is a space large enough and configured so personnel can bodily enter
and perform assigned work, has limited or restricted means for entry or exit, and is not
designed for continuous human occupancy. Examples include tanks, pits, manholes,
etc.

2-2.4.1 Construction Activities.

Employees engaged in construction activities at a worksite with one or more confined

spaces must comply with 29 CFR 1926, Subpart AA, state, local and installation
requirements.

2-2.4.2 Hazards.

Personnel entering or working in confined spaces may encounter a number of

potentially serious hazards. These hazards may include atmospheric hazards such as
oxygen deficiency insufficient to support life, oxygen-enriched levels that increase the
danger of fire or explosion, flammable or explosive atmospheres and materials, or toxic
gases or materials. In addition, the confined space may include electrical, mechanical,
engulfment or entrapment hazards that must be locked out, or controlled by other
means of securing hazardous energy. Many of these hazards are not readily apparent,
nor detectable by odor, or by sight, which may result in workers entering confined
spaces without adequate consideration of potential dangers. Workers must consider
that all confined spaces may contain unfavorable and unsafe conditions and must not
enter or work in these spaces until tests, evaluation, and locally-developed procedures
are performed to ensure safe conditions exist prior to entry and are maintained during
the entire work period. /1/

\2\
2-2.4.3 Two-Person Policy.

Ensure two people are present when entering confined spaces, performing
maintenance on fuel systems and tanks, or in and around fuel facilities. /2/

2-3 ELECTRICAL SAFETY.

This section provides general information related to electrical safety with regard to
maintenance operations, static electricity, stray electric currents, hazardous locations,
and power generators. These hazards must be considered when handling and
dispensing petroleum products. See National Fire Protection Association (NFPA) 70,
National Electrical Code, for the practical safeguarding of persons and property from
hazards arising from the use of electricity. See NFPA 70E, Standard for Electrical

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Safety in the Workplace, for electrical safety requirements for employee workplaces that
are necessary for the practical safeguarding of employees in their pursuit of gainful
employment. See NFPA 77, for additional guidance on static electricity hazards.

2-3.1 Lockout/Tagout.

An electrically safe work condition must be established while operating or performing

maintenance on electrical equipment, regardless of whether the equipment is energized
or de-energized. NFPA 70E includes detailed information on safety-related work
practices, safety-related maintenance requirements, and installation safety
requirements.

Establishing and following lockout/tagout procedures is essential for the safe execution
of maintenance work on electrical equipment. While specific lockout/tagout procedures
can differ from site to site, they must abide by the general principles outlined in NFPA
70E, Article 120, Section 120.2(B). In general, all sources of electrical energy must be
controlled in such a way as to minimize personnel exposure to electrical hazards. NFPA
70E also includes Annex G, “Sample Lockout/Tagout Procedure,” which can be used as
a basis for establishing a site specific procedure.

2-3.2 Static Charges.

Low-conductivity liquids, such as jet fuel and gasoline, become electrostatically charged
while flowing through petroleum fuel systems and during transport in barges, tanker
trucks, rail cars and other fuel transport systems. This can produce enough electrical
energy to cause ignition, fire, or explosion of petroleum fuel vapor-air mixtures above
the liquid petroleum fuel surface.

Grounding and bonding components of petroleum fuel facilities are important to prevent
ignition, fire and explosion. All petroleum fuel system components must be bonded and
grounded to dissipate static electric charges and stray electrical currents that can
discharge in the form of an electric arc. Bonding across flanges is not required provided
they are not electrically insulated. UFC 3-460-01, Section \1\ 2-11.3 /1/, includes
information on grounding petroleum fuel system equipment in order to prevent the
accumulation of static electricity.

2-3.2.1 Personnel Static Prevention Requirements.

Personnel must periodically ground themselves to pump house structures, tanks, and
equipment by making firm contact with attached grounding bars or approved grounding
points. Personnel must not put on or remove garments while conducting petroleum fuel
handling operations.

Personnel must ground sampling devices to grounding bars or approved grounding

points before collecting petroleum fuel samples.

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2-3.3 Electrical Currents.

Electrical currents originate in generators, transmission systems, wiring, and electrical

devices. They are more dangerous than static electric charges because of the
continuous electric spark that can be created versus the brief electric spark created by a
static electric discharge. Verify all electrical work on petroleum fuel storage and
dispensing systems complies with NFPA 70, 501, Class I Locations to reduce electrical
current hazards.

2-3.3.1 Stray Currents.

Stray currents flow through unintended paths or are extraneous current in the earth.
Sources of stray currents include electric railways, electric power systems, electric
welders, cathodic protection systems, and aircraft aeronautics electrical equipment
malfunctions. Since many fixed petroleum fuel systems are in intimate earth contact,
stray currents can take paths through the conducting parts of petroleum fuel systems.
Stray currents can cause electric arcs that may ignite combustible petroleum fuel vapor-
air mixtures.

\1\
2-3.3.1.1 Fuel System Grounding Requirements.

Ground systems used to dissipate static electric charges also reduce stray electric
current hazards. These systems provide a path to conduct stray electric currents into
the earth without arcing.

2-3.3.1.2 Tank Car Loading and Unloading Requirements.

Railroad spurs used for loading and unloading tank cars should be insulated from the
main line rails, ensuring isolation from stray currents that may flow in the main line rails.

2-3.3.1.3 Marine Terminal Requirements.

Stray currents from cathodic protection systems at marine terminals require special
attention. These systems protect piping and steel piers and cause current flow in the
water. Steel hull vessels act as a conductor of these currents. The ship-to-shore fuel-
handling hose will act as a conductor and will complete a low-resistance circuit from the
vessel to shore-side piping. Arcs may occur between the vessel and the hose when the
hose is connected, disconnected, or brought into contact with the vessel's deck. Arcing
can be prevented by connecting a bonding cable between shore-side piping and the
vessel before operations begin. A switch on the shore side wired inline with the bonding
cable must be closed after the cable connection is made and before the petroleum fuel
handling hose is taken aboard the vessel.

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2-3.3.1.4 Piping Requirements.

Stray current may flow through petroleum fuel piping systems because their electrical
resistance is low compared to the surrounding earth. Removal of piping or components
will interrupt the continuity of the petroleum fuel system. A bonding jumper wire must be
installed prior to removal of piping or components and must remain in place until the
items are replaced. Installing a jumper will prevent an arc when the piping or
components are removed or replaced.
/1/

2-3.4 Hazardous Location Classification.

NFPA 70 defines hazardous locations including areas where fire or explosion hazards
may exist due to flammable gases or vapors, flammable liquids, flammable liquid
produced vapors, combustible liquids produced vapors, and combustible dust.
Hazardous locations are classified in three ways: Type (Class), Condition (Division),
and Nature (Group). Petroleum fuel facilities are Class 1 where flammable gases or
vapors may be present in the air in sufficient quantities to be explosive or ignitable.
Class 1 is divided into two divisions. Division 1 areas include environments where the
hazard is to be expected under normal operating conditions, and Division 2 areas
include environments where the hazard is not normally present in an explosive
concentration or present only through accidental rupture, breakage or unusual faulty
operation. The National Electrical Code (NEC) further defines the nature or “group” of
the hazardous substance. Most petroleum fuel facilities will fall under Group D:
hydrocarbons, fuels, solvents. Personnel must ensure that all electrical components and
equipment installed, operated or replaced meet the required hazardous classification for
the intended environment. Refer to UFC 3-460-01 for additional hazardous location
information.

2-4 PETROLEUM FUEL QUALITY.

Every type and grade of petroleum fuel or lubricant has been specifically formulated to
provide the most satisfactory and economic performance possible for a particular
engine, under the operating conditions for which it was designed. Petroleum fuels or
lubricants that have become contaminated or have degraded, can cause fires,
explosions, injuries, loss of life, and loss of valuable machinery and equipment.
Petroleum fuel product suspected of being contaminated must be reported to the
military service-specific SCP.

2-4.1 Water Contamination.

Water contamination usually occurs during the transportation and storage of petroleum
fuel. Water contamination is the most common form of contamination and may take one
of the following three forms.

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\1\
2-4.1.1 Free Water.

Free water consists of relatively large drops of water which, if left undisturbed, will settle
to the bottom of the container. In low density petroleum fuel products with low viscosity,
free water settlement can be quite rapid, but in higher density or more viscous
petroleum fuel products, settlement will take longer. Some petroleum fuels contain anti-
corrosive or cleaning agents otherwise known as surfactants, which tend to prevent the
settlement of free water.

2-4.1.2 Dissolved Water.

In this state, the water is invisible, and the petroleum fuel appears to be clear; but a
drop in temperature may cause dissolved water to separate from the petroleum fuel in
tiny droplets that remain suspended and give the petroleum fuel a cloudy appearance.

2-4.1.3 Emulsified Water.

Emulsions are mechanical dispersion of petroleum fuel and water having a frothy
appearance. Emulsions can be very stable and hard to separate. Separation may
require special mechanical and chemical treatments.
/1/

2-4.2 Prevention and Removal of Water Contamination.

a. Operate sump drains on tanks, filter separators, and other vessels and
equipment and check for free water on a daily basis when the systems are
operated.
b. During petroleum fuel flow operations, observe filter separator differential
pressure gauges and be sure units are functioning properly.
c. Ensure that operator and system maintenance is properly performed.
d. Newly received aviation petroleum fuels must be allowed to stand
undisturbed in receiving tanks to permit settlement of free water before
product is dispensed. Aviation petroleum fuel must be allowed to stand for
1 hour per 1 foot (0.31 m) of liquid level rise in storage tanks up to a
maximum standing time of 24 hours or in accordance with undisturbed
standing time allowed by military service-specific established procedure or
policy. Ground vehicle petroleum fuels do not require settlement time
before they are dispensed.
e. When field fabricated aboveground vertical tanks are available for entry,
they must be inspected for unintended low spots and repaired as required
to eliminate unintended low spots which could collect free water.
f. Tank roofs, seals, and fittings of all types must be maintained in good,
weather-tight condition.

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g. Testing and inspections required for tanks and underground piping must
be followed and documented. If unexplained accumulation of water is
detected, the underground petroleum fuel tank(s) suspected of leaking
must be tested using a temperature-controlled, hydrostatic stand-pipe test.
Underground petroleum fuel piping suspected of leaking must be isolated
and subjected to the applicable underground piping annual test as
described in Appendix G - Petroleum Fuel Pipeline Pressure Testing
Guidelines and Criteria.
2-4.3 Solid Matter Contamination.

Iron rust, scale, sand, and airborne dirt are examples of solid matter contamination most
prevalent in petroleum fuel. The principal source of iron rust is corrosion in pipelines,
storage tanks, or other inline steel components. Sand and dirt are particularly serious in
extremely sandy or dusty areas where they may accumulate around tank gauge
hatches, tank manways, or other openings and enter the tank when the covers are
removed. The presence of large amounts of particulate matter in petroleum fuel results
in restricting or clogging of filter separators, silting and plugging of fuel control
components and nozzles, and wear and scoring of petroleum fuel system components
by abrasion.

2-4.4 Prevention and Removal of Solids Contamination.

a. Brush away or remove accumulated dirt or sand around fill covers,

manholes, and other covered openings before removing them.
b. Whenever petroleum fuel tanks, piping, or equipment are open for
construction, repairs, or inspection, ensure they are protected against
entry of dirt and foreign objects. Normally closed tank openings not
required to be open for ventilation or access must remain closed. Open
ends of piping and equipment such as pumps and meters must be sealed
by temporary closures when they are not required to be open for
inspection or repair.
c. Do not operate petroleum fuel handling equipment unless all filters,
strainers, screens, and nozzle spout caps are properly installed.
d. Never remove filter, strainer basket, or strainer screens for any purpose,
other than cleaning or maintenance. Filters, strainers baskets, and strainer
screens must always be replaced immediately after cleaning or
maintenance.
e. Observe water that is drained from filter separator sumps and report
unusual accumulation of foreign matter to supervisors.
f. The inside of new petroleum fuel pipe must be carefully inspected for
loose scale, dirt, or rust. Debris must be removed by brushes, swabs,
plugs, or pigs before installation. New piping and pipeline systems must
be thoroughly flushed according to UFGS 33 08 55. Temporary strainers

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installed at strategic points to remove trapped matter will assist with

removal of solids.
g. When changing grades of petroleum fuel in a tank, piping or pipeline, the
penetrating action of the new grade may loosen existing scale or rust.
Prior to changing petroleum fuel grade, the tank, piping or pipeline may
need to be thoroughly mechanically or chemically cleaned. Even if a good
cleaning job is done, loosened scale or rust can continue to appear in the
product for several weeks after starting the new operation. Extra
precautions such as more frequent sampling, circulating of petroleum fuel
product, temporary use of strainers, frequent cleaning of strainers, and
use of cleaning pigs may need to be taken. See Section 2-5 Changes in
Tank Product for additional information related to changing grades of
petroleum fuel product in tanks.
h. Ensure replacement parts or equipment, such as hoses, packing, gaskets,
O-rings, seals, and pipe compounds, are made from materials compatible
with the petroleum fuel type and grade.
i. Do not allow petroleum fuel systems to lie unused for long periods of time.
Inactive systems may accumulate water at low points and cause corrosion
or biological activity leading to solids contamination.

2-4.5 Microbiological Contamination

\1\
a. When water and petroleum fuels exist together, yeast, fungus, and,
bacteria may be present at the interface of the two fluids or at the water-
steel interface. These organisms live in water and feed on petroleum fuel.
Only a small amount of water, such as a puddle in a tank bottom, is
required to support large colonies of these organisms.
b. Microbiological contamination usually appears as a brown, black, or gray
slime-like deposit that adheres to the inner surface of fuel tanks. This
results in corrosion of fuel system components also known as Microbial
Induced Corrosion (MIC), clogging of filters, and erratic operation of
petroleum fuel quality indicating systems. Microbiological contamination is
most severe in high temperature/high humidity environments and in
alternative ground vehicle fuel products. Damage from microbiological
induced corrosion is caused by hydrogen sulfide that is produced as waste
by micro-organisms as they metabolize petroleum fuel in the absence of
sufficient oxygen and can cause significant damage to tanks and piping
and environmental problems in very short periods of time.
c. The presence of microbiological contamination in petroleum fuel is a
reliable indication of failure of petroleum fuel filtration equipment,
inadequate water stripping of petroleum fuel storage tanks and a need for
more frequent cleaning of petroleum fuel storage tanks. /1/

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2-4.5.1 Prevention of Microbiological Contamination.

To prevent microbiological contamination, remove water from petroleum fuel systems by

the use of sumps on tanks, filter vessels and low point drains. The use of biocides in
aviation fuels and F-76 is prohibited under current product specifications. Biocides are
allowed on a case-by-case basis on rare occasions and require extensive justification
and approval by the military service-specific SCP.

2-4.6 Other Product Contamination.

The properties of one type or grade of petroleum fuel can be greatly changed by mixing
it with another grade or type of petroleum fuel. Some causes of cross contamination
between petroleum fuels are leaky bulkheads between tanks, leaky valve manifolds
separating product systems, use of multiproduct pipelines, delivery of improper
petroleum fuel grade, and improper cleaning of a tank compartment or pipeline prior to
changing petroleum fuel product service.

“Jelly” or “Apple Jelly” is a contaminant found in petroleum fuel systems, specifically

filtration equipment, resulting from media migration. “Apple Jelly” occurs when free
water particles in the petroleum fuel react with small quantities of super-adsorbent
polymers that pass or migrate into the petroleum fuel as it flows through water
adsorption media filter and/or monitors. The mixture creates an aggressive solvent that
when mixed with other particulates and debris creates a thick “jelly-like” substance.
Fuel System Icing Inhibitor (FSII – Diethylene Glycol Monomethyl Ether (DiEGME)) has
been shown to increase the rate of media migration, and as a result, water adsorption
media filters and/or monitors are no longer used in systems that handle petroleum fuel
containing FSII.

2-4.6.1 Prevention of Other Petroleum Fuel Contamination.

Clear identification of petroleum fuel systems and equipment by product type and grade
is essential to operational safety and product quality protection. Systems must be
clearly identified in accordance with Section 2-7.

a. Be sure that system flow diagrams are available to all operators. Use
arrows to indicate the direction of petroleum fuel flow within pipes. Include
petroleum fuel product labeling on all petroleum fuel tanks, piping, and
load and offload points.
b. Do not begin petroleum fuel transfer operations until markings of all
needed petroleum fuel equipment has been checked and found to agree.
c. Ensure valves in valve manifolds are positively shut-off and locked out
between petroleum fuel products. Do not depend solely on single valves to
separate petroleum fuel products as they may leak. Install spectacle
blinds, blind flanges, or use double block and bleed valves in manifolds
where petroleum fuel product is to be separated.

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d. Be sure that newly arrived petroleum fuel products were not contaminated
during shipment. Take samples per military service-specific quality control
directives or MIL-STD-3004, and if possible, do not ship or use a
petroleum fuel product until test results are confirmed acceptable.
e. Use separate pipelines and equipment for each petroleum fuel product.
Unless designed to act as a multi-product line, or required as an
alternative capability in a contingency, pipelines should never be used for
more than one type of petroleum fuel. Common piping systems must
never be used for incompatible petroleum fuel products.

2-4.7 Special Considerations for Biodiesel Blend B20.

Biodiesel Blend B20 is 20 (±1) volume percent biodiesel conforming to specifications

ASTM 6751 and 80 volume percent petroleum diesel fuel conforming to ASTM D975.

a. Biodiesel fuel is comprised of mono-alkyl esters of long chain fatty acids

derived from vegetable oils or animal fats. Biodiesel is meant to be used
in standard diesel engines and should not be confused with the vegetable
and waste oils used to fuel converted diesel engines.

b. A B20 product must be pre-blended prior to delivery. It is not acceptable to

attempt blending into a Government tank during the delivery.
c. DoD Components and Federal agencies must not order B20 where
projected consumption and product storage duration exceeds three
months, due to extended and unresolved product stability concerns.
d. B20 may be stored in tanks and handled with equipment used for diesel
service. Nevertheless, Defense Energy Support Points (DFSPs) must
comply with standard military service-specific procedures and directives
regarding tank cleaning prior to converting existing storage tanks from
diesel to B20 service.
e. A generally higher cloud point than standard diesel may occasionally
affect B20 cold flow properties. DoD Components and Federal agency
customers should order more frequent, smaller B20 quantities to achieve
advantage of seasonal diesel cloud point adjustments that minimize
potential vehicle and equipment cold weather operation problems.
f. DoD only allows the use of B20 biodiesel in non-tactical equipment.

2-4.8 Special Considerations for Fuel Ethanol Blend E85.

Fuel Ethanol Blend E85 is 75 to 85 volume percent fuel ethanol blended with 25 to 15
volume percent hydrocarbon fuel, usually unleaded gasoline. ASTM 5798 governs E85
procurement as fuel ethanol intended for use in ground vehicles with spark-ignition
engines.

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a. DoD Components and Federal agencies must ensure material

compatibility with storage tanks and dispensing equipment prior to
converting facilities to E85 service.

b. Special materials requirements are described in DOE’s “Handbook for

Handling, Storing, and Dispensing E85.” Pre-1992 fiberglass tanks may
not be suitable to convert to E85 service.
c. Three vapor pressure classes of fuel ethanol (Ed75 – Ed85) with ethanol
content varying between 75 and 85 percent for different seasonal
conditions and geographic regions serve to ensure proper vehicle
operation throughout the year in all locations.
d. High E85 ethanol content may reduce lubricating properties as well as
increase water tolerance. Decreased temperature and increased water
content may reduce hydrocarbon fuel solubility in fuel ethanol.
e. Monitor and keep water content to a minimum, due to water’s miscibility in
fuel alcohol, to minimize performance degradation.
f. Ethanol is not compatible with aluminum, and all aluminum products must
be removed from a gasoline dispensing system that will be used to
dispense E85.
g. In accordance with EPA regulations, all commercial grades of gasoline
must contain certain additives, detergents, and corrosion inhibitors. In a
finished blend of E85, any additive that was found previously in gasoline is
now contained in E85 (although at reduced levels). While adding
detergent to the hydrocarbon component of E85 is necessary, it is not
necessary to add detergent based on the alcohol portion of the product.
Overuse of additives with E85 may result in poor vehicle operation.

2-5 CHANGES IN TANK PRODUCT.

Changes of petroleum fuel product in tank and piping systems must be conducted in
accordance with the more stringent of military service-specific quality control directives
and MIL-STD-3004.

2-6 ENVIRONMENTAL PROTECTION.

The DoD is actively committed to protecting quality of the environment by preventing

and controlling pollution resulting from use and operation of petroleum fuel facilities. The
DoD is required to comply with environmental laws and regulations. Individuals who
violate environmental regulations may be subject to serious civil and criminal penalties,
including fines and jail terms. Significant precautions as listed in UFC 3-460-01, such as
petroleum fuel storage tank, load, and offload secondary containment systems, are
used to prevent the discharge of petroleum fuel products to sanitary and storm sewer
systems, ground water systems, local streams and waterways.

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2-6.1 Spill Planning.

Facilities containing or handling petroleum fuel products are designed and constructed
in a manner that should prevent spillage. Should a spill occur, the facilities should
prevent the spill from leaving the property and/or entering a waterway or ground water
table. Installations must have a Spill Prevention Control and Countermeasure (SPCC)
plan or, for overseas sites, the spill response document required by the Overseas
Environmental Baseline Guidance Document or Environmental Final Governing
Standards, as applicable. Refer to UFC 3-460-01, and included references for SPCC
requirements. Personnel should be familiar with SPCC requirements specific to the
petroleum fuel facility where they are preforming inspections and maintenance.

While performing maintenance activities where a petroleum fuel release is imminent, a

drip pan or other suitable means must be utilized to contain petroleum fuel that may be
released from a system. Spill pads must also be readily available. Bonding the drip
pan to the petroleum fuel system or a grounding rod will reduce the risk of a static
electric discharge. Bonding points for drip pans should be provided where they are put
into regular use.

2-6.1.1 Reference of UFC 3-460-03 in SPCC Plans.

Spill plans, response plans, operational plans, or other plans required by law should not
include UFC 3-460-03 by title for complete inclusion. Only specific items from the
document should be included when required.

2-6.2 Containment.

Secondary containment should be provided for petroleum fuel systems and components
as required by UFC 3-460-01. These systems may include earthen berms, containment
paving, spill kits, and/or liners.

2-6.3 Containment Drain Valves.

Containment areas must be drained as frequently as required to maintain them in a

clean, dry, and accessible state. Debris caught in the drainage inlet grate must be
removed after each draining. Containment drain valves must be maintained as outlined
in Section 6.6 Valves. Coordinate containment area draining with operational
personnel.

2-6.4 Waste Disposal.

To ensure waste is disposed of properly, check that adequate waste disposal containers
are available and disposal procedures are identified. Coordinate waste disposal
procedures with the Installation Environmental Office. Coordination must include strict
adherence to the most stringent of host nation, Federal, state, or local hazardous waste
regulations to include permitting.

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2-7 SIGNAGE AND MARKINGS.

Signs and marking require periodic inspections and maintenances to ensure that
important information is easily accessible.

2-7.1 Inspection and Maintenance - Signage and Markings.

a. Check permanent signs and markings for adequacy and readability.

Repair or replace deteriorated or illegible signs and markings.
Frequency: Weekly
b. Inspect the location of Department of Transportation (DOT) regulated
underground petroleum fuel pipelines and ensure they are marked in
accordance with 49 Code of Federal Regulations (CFR) 195.410.
Frequency: Monthly
c. Check that petroleum fuel pipelines, tanks, valves, pumps, meters, and
other equipment are marked in accordance with UFC 3-460-01 Section 2-
\1\ 17 /1/. If markings are missing or insufficient, repair or add markings in
accordance with UFC 3-460-01.
Frequency: Monthly
d. Ensure petroleum fuel system Emergency Fuel Shutoff (EFSO)
pushbuttons are properly identified at each location. Ensure that signage
is properly secured and that the lettering is legible from 25 feet (7.5
meters) away and not faded.
Frequency: Monthly
e. Verify enough movable or temporary signs are maintained in good
condition to serve anticipated needs; for example: "DANGER," "CLOSED
TO TRAFFIC," “KEEP FLAMES AWAY," "MEN WORKING,” "NO
SMOKING,” "DANGER NO OPEN FLAME OR IGNITION SOURCE
BEYOND THIS POINT.” Use bilingual signs when appropriate.
Frequency: Annually

2-8 FIRE PROTECTION.

\1\
• Three simultaneous conditions are necessary to create petroleum fuel
fires: the petroleum fuel product must be in the form of vapor; petroleum
fuel vapor-air mixture must be present in correct proportions to support
combustion or explosion; and the combustible mixture of petroleum fuel
vapor and air must be raised to its ignition temperature or subjected to a
source of ignition. The absence of any one of these conditions prevents
occurrence of a fire.
• It is not practical to eliminate air completely or to control petroleum fuel
vapor-air proportions where petroleum fuel is handled and dispensed, and

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temperatures cannot be controlled to the point where petroleum fuel

vapors are not possible. Therefore, the elimination of sources of ignition is
the primary controllable factor for the prevention of petroleum fuel fires.
• NFPA 10 details the number and types of portable fire extinguishers that
should be located around petroleum fuel areas and storage locations.
/1/

2-8.1 Petroleum Fuel Vapor Sources for Fires and Explosions.

Petroleum fuel vapors escaping to atmosphere are quickly diluted to within the
flammable or explosive limit, and if ignited will cause fire. Eventually the petroleum fuel
vapor concentration within a tank or vessel is diluted, creating an explosive hazard
within the tank. Petroleum fuel vapors are heavier than air and can travel long distances
before they dissipate into the atmosphere. Any source of ignition may ignite petroleum
fuel vapors causing a fire or explosion.

2-8.2 Solid Sources for Fires and Explosions.

Sludge and other petroleum fuel saturated material (such as sediment, hollow roof
supports, sidewall scale, foam pan seals, and oil-soaked wooden structures) emit
petroleum vapors which can accumulate to the flammable or explosive limit.

2-8.3 Ignition Sources for Fires and Explosions.

Primary causes and sources of ignition are poor maintenance or defective electrical
equipment, negligence, relaxed disciplinary action to violations of safety regulations,
and static or stray electrical currents.

2-8.3.1 Maintenance Tools.

\1\
• Non-sparking tools provide protection against fires and explosions in
petroleum fuel product environments. Non-sparking tools should be used
for operation and maintenance work on highly volatile petroleum fuels with
flash points below 100 °F (38 °C) unless the environment has been
certified to be vapor free. Common non-sparking tool materials are brass,
bronze, copper-nickel alloy, copper-beryllium alloy and copper-aluminum
alloy. Ensure non-sparking tools are kept clean of ferrous or other
contaminants which have sparking properties.
• Electric tools must have a three-wire cord with a ground and be plugged
into a grounded receptacle, be double insulated, or be powered by a low-
voltage isolation transformer. Electric tools must be protected by a ground-
fault circuit interrupter or an assured equipment-grounding conductor
program. All electric power tools, battery or corded, and electrical

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extension cords must be intrinsically safe and Underwriters Laboratory

(UL) listed for the intended hazardous location.
• Refer to OSHA Booklet 3080 Hand and Power Tools (based upon 29
CFR, Part 1910, Subpart P) or military service-specific directives for
additional safety and guidance regarding the appropriate tools for work to
be performed.
/1/

2-8.3.2 Power Generators.

Diesel and gasoline engine-powered generators and other internal combustion powered
tools (e.g. internal combustion engine driving pumps) must only be used in close
proximity to petroleum fuel systems if equipped with spark arrestors. The equipment
must be located outside of petroleum fuel tank containment areas and upwind of
petroleum fuel tanks and at least 50 feet (15.2 meters) from the nearest petroleum fuel
tank manhole or vent.

2-8.3.3 Smoking Clearances.

“No Smoking” signs must be placed conspicuously around petroleum fuel systems.
Smoking must only be permitted in designated smoking areas outside of petroleum fuel
vapor clearances.

2-8.4 Fire and Explosion Preventative Measures.

a. Provide proper ventilation for pump houses, pits, and other enclosed
spaces where petroleum fuel vapors may accumulate.
b. Take precautions to prevent leakage or spillage of petroleum fuel
products.
c. When spillage is expected from petroleum fuel pipes, hoses connections,
or opened equipment, ventilate the area and eliminate sources of ignition.
Direct the expected spillage to an approved container or a drip pan as
applicable. Bonding the drip pan to the petroleum fuel system or a
grounding rod will reduce the risk of a static electric discharge. Bonding
points for drip pans should be provided where they are put into regular
use.
d. If a small amount of petroleum fuel spills on the ground, asphalt or
concrete, cover it with dry absorbent. Remove used absorbent once
petroleum fuel has been absorbed.
e. Where major operations raise a possibility of sizeable petroleum fuel
spills, call fire department authorities for possible standby.
f. Be familiar with local petroleum fuel spill contingency plans and the proper
contact information for the local fire department.

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g. Do not start or run a vehicle in an area where petroleum fuel has been
spilled until all flammable or combustible liquid is removed and the area is
freed of petroleum fuel vapors unless the vehicle is required to clean up
the spill (e.g., vacuum truck or skimmer boat).
h. Do not weld, cut, rivet, do mechanical or other hot work on out of service
petroleum fuel storage tanks, pipe, or other equipment that has contained
flammable or combustible substances until the equipment has been
properly ventilated and certified vapor free. In limited cases, hot work can
be performed safely on in-service equipment with an approved plan.
Always obtain a hot work permit before hot work is conducted on
petroleum fuel systems.
i. Only allow personnel that meet the requirements of UFGS 33 52 90.00 20
to conduct welding on petroleum fuel tanks or vessels that have contained
flammable or combustible liquids or petroleum fuel vapors.
j. Drain, purge, and ventilate petroleum fuel tanks or other equipment
brought back to maintenance buildings for repair and keep them outside of
buildings, well away from open flames and other sources of ignition.
k. Do not allow open flames near Class 1 hazardous areas as established in
NFPA 70.
l. Artificial light and power tools must meet the requirements of Section
2-8.3.1, “Maintenance Tools.”
m. Immediately dispose of petroleum fuel soaked rags or waste, or place
them in approved closed noncombustible containers. Refer to Section 2-
6.4 Waste Disposal for waste disposal procedures.

2-9 EMERGENCY ACTION PLANS.

Agencies that operate and/or maintain petroleum fuel infrastructure must be

knowledgeable of their applicable emergency action plans that include measures to
address a variety of emergency responses including but not limited to natural disasters,
terrorist threat conditions, and environmental protection.

2-10 SITE MAINTENANCE PROGRAM.

Facility maintainers (e.g., Base Civil Engineering, Department of Public Works,

contractors, operators) have the primary responsibility for maintaining and repairing
petroleum fuel infrastructure (e.g., petroleum fuel or lubricant receipt, issue and storage
systems) under their stewardship. DoD petroleum fuel sites may have more than one
facility maintainer depending on the type of mission, the facility owner, or other
contractual relationship. Military services can delegate maintenance tasks between
operator maintenance and system maintenance differently. See Section 1-2.2,
“Maintenance Tasks,” for more information on the delegation of maintenance tasks.

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Agencies responsible for infrastructure maintenance must develop site maintenance

programs that include:

• List and details of petroleum fuel equipment requiring maintenance.

• Coordination requirements and points of contact for other agencies that
may support or provide input on maintenance activities (e.g., cathodic
protection, electrical, environmental, fire department, plumbing, and
safety).
• Documentation and record retention procedures.
• Details for maintaining infrastructure as-built information.
• Details for developing and submitting projects to maintain, repair or
upgrade existing infrastructure and details for coordination with agencies
on requirements for new infrastructure.
• Quality assurance requirements for contractors working on petroleum fuel
infrastructure.

2-10.1 Maintaining Petroleum Fuel Infrastructure.

Petroleum fuel facility maintainers should utilize recurring maintenance systems to track
inspections, scheduled and unscheduled maintenance actions, and equipment
serviceability.

Petroleum fuel facility maintainers and operators must coordinate requirements and
schedule maintenance actions to minimize mission impact.

2-10.2 Documentation and Record Retention.

\1\
a. Petroleum fuel system documentation and record retention must include
maintenance records in sufficient detail to identify each real property or
equipment item’s current maintenance status (e.g., tanks, pumps, valves,
piping). These records must be maintained at the Installation and should
be used to justify recommendations for repair, upgrade, and replacement.
b. Each Installation must develop and have site-specific maintenance
manuals such as Operation and Maintenance Support Information (OMSI)
or Operation, Maintenance, Environmental, and Safety Plan (OMES).
These manuals must include manufacturer’s operation and maintenance
information for the specific equipment and components installed. The
Installation-specific OMSI or OMES manuals must be used in conjunction
with the inspection and maintenance criteria of UFC 3-460-03.
c. Unless otherwise specified by military service-specific or contract
requirements, maintenance agencies must retain petroleum fuel
infrastructure records of tests and inspections (e.g., API Standard 570 and

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API 653). Copies of these records must be issued to the Installation for
official record retention.
d. Environmental regulations typically require retention of records for a
minimum of three to five years. In some cases environmental regulations
require record retention for the life of the system (e.g., tanks). Records
must be maintained for a minimum of three years unless more stringent
military service, Federal, state, host nation, or local requirements apply.
e. For agencies that are responsible for maintenance of DOT regulated
petroleum fuel pipelines, additional inspection and repair information is
required and must comply with 49 CFR 195.310, 195.404, 195.507 and
195.589.
f. For agencies that are responsible for maintenance of underground storage
tanks inspection and repair recordkeeping must comply with 40 CFR
280.34.
g. For agencies that are responsible for maintenance of hose and pipelines
near, over, or through navigation and navigable waters, inspection and
repair recordkeeping must comply with 33 CFR 154.740.
/1/

2-10.3 As-built Information.

Available as-built information for petroleum fuel systems must be preserved and
protected. As-built information must be updated when projects that change the
configuration of the system are executed at petroleum fuel facilities. An accurate
process flow diagram of each petroleum fuel system is the minimum amount of
documentation that must be maintained. Copies of as-built information must be
maintained at the Installation’s petroleum fuel facility operations building and permanent
Installation files.

As-built information required for DOT regulated pipelines must comply with 49 CFR
195.404.

2-10.4 Operation and Maintenance Support Information.

Each Installation must maintain a current library or access to manufacturer’s operation

and maintenance manuals for all equipment that is associated with petroleum fuel
infrastructure under the Installation’s responsibility.

Operation and maintenance information required for DOT regulated pipelines must
comply with 49 CFR 195, Section 402. Operation and maintenance information
required for facilities that conduct petroleum fuel transfer to or from marine vessels must
comply with 33 CFR Part 154 Sections 300 to 325.

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2-10.5 Safety Reports.

All petroleum fuel facilities must follow military service or contract requirements when
reporting safety and risk assessments on infrastructure.

Facilities regulated by DOT have additional reporting requirements that are governed by
49 CFR 195 Subpart B. The facility operators or maintainers must copy DLA Energy
and/or military service commands when notifying the Pipeline and Hazardous Materials
Safety Administration (PHMSA) of a regulated pipeline incident.

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CHAPTER 3 BULK TRANSFER FACILITIES

3-1 INTRODUCTION.

This chapter applies to permanent petroleum fuel infrastructure and is not intended for
contingency or mobility equipment or temporary petroleum fuel receipt or issue systems.

3-2 TRUCK RECEIPT.

Major components of petroleum fuel truck offloading facilities include offloading hoses,
piping, basket strainers, air eliminator tanks, pumps, meters, pre-filters, filter separators,
grounding systems, ground verification systems and control panels.

a. Piping used to distribute petroleum fuel from truck offloading positions to

petroleum fuel tanks may be installed underground, aboveground, or in a
combination of aboveground and underground segments.
b. Sometimes these systems use drop tanks which can be underground,
vaulted, or low-profile equipped with submerged turbine pumps.
c. Pumps are typically self-priming centrifugal or rotary vane positive
displacement.
d. Underground or low-profile petroleum fuel tanks typically receive fuel by
gravity offload.

3-2.1 Inspection and Maintenance - Truck Receipt.

a. Refer to Section 3-9.2, “Offloading Fuel Hoses,” for inspection and

maintenance requirements of offloading hoses.
b. Refer to Section 6-1, “Pipe Testing And Inspections,” for inspection and
maintenance requirements of pipelines and piping.
c. Refer to Section 3-6.4, “Basket Strainers, “for inspection and maintenance
requirements of basket strainers.
d. Refer to Section 3-10.1, “Air Eliminator Tanks,” for inspection and
maintenance requirements of air eliminator tanks.
e. Refer to Section 3-8, “Pumps,” for inspection and maintenance
requirements of petroleum fuel pumps.
f. Refer to Section 3-7, “Meters,” for inspection and maintenance
requirements of petroleum fuel meters.
g. Refer to Section 3-6.1, “Pre-Filters,” for inspection and maintenance
requirements of pre-filters.
h. Refer to Section 3-6.2, “Filters Separators,” for inspection and
maintenance requirements of filter separators.

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i. Refer to Section 9-1.6, “Grounding Systems,” for inspection and

maintenance requirements of grounding systems.
j. Refer to Section 9-5, “Ground Verification Systems,” for inspection and
maintenance requirements of ground verification systems.
k. Refer to Section 9-1.9, “Electronic Equipment,” for inspection and
maintenance requirements of control panels.

3-3 PIPELINE RECEIPT.

Fuel can be supplied to petroleum fuel storage tanks from on-base or off-base pipelines.
These pipelines can be Government Owned/Government Operated (GOGO),
Government Owned/Contractor Operated (GOCO), or Contractor Owned/Contractor
Operated (COCO).

Major components of pipeline receipt systems include piping, basket strainers,

automatic air vents, meters, pre-filters, filter separators, grounding systems, and control
panels.

3-3.1 Inspection and Maintenance – Pipeline Receipt.

a. Refer to Section 6-1, “Pipe Testing and Inspections,” for inspection and
maintenance requirements of pipelines and piping.
b. Refer to Section 3-6.4, “Basket Strainers,” for inspection and maintenance
requirements of basket strainers.
c. Refer to Section 3-10.2, “Automatic Air Vents,” for inspection and
maintenance requirements of automatic air vents.
d. Refer to Section 3-7, “Meters,” for inspection and maintenance
requirements of petroleum fuel meters.
e. Refer to Section 3-6.1, “Pre-Filters,” for inspection and maintenance
requirements of pre-filters.
f. Refer to Section 3-6.2, “Filter Separators,” for inspection and maintenance
requirements of filter separators.
g. Refer to Section 9-1.6, “Grounding Systems,” for inspection and
maintenance requirements of grounding systems.
h. Refer to Section 9-1.9, “Electrical Equipment,” for inspection and
maintenance requirements of control panels.

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3-4 RAIL RECEIPT.

Rail receipt systems use components that are similar to the components used for truck
receipt. Refer to Section 3-2 Truck Receipt for a list of typical components that should
be expected in a rail receipt system and associated maintenance requirements.

3-5 BULK ISSUE.

3-5.1 Truck Issue.

The preferred connection system for jet fuel issue is a metal, counterbalanced, swivel
type pantograph constructed of aluminum or stainless steel; although an approved
loading fuel hose is acceptable. Loading fuel hoses, if provided, must be stored away
from direct sunlight.

Major components of petroleum fuel truck issue facilities include piping, basket
strainers, pumps, filter separators, meters, Truck Fill Valve (TFV), loading fuel hoses,
fixed pantographs, fueling nozzles, grounding systems, ground verification equipment,
electronic overfill protection systems, and control panels.

3-5.1.1 Inspection and Maintenance – Truck Issue.

a. Refer to Section 6-1, “Pipe Testing and Inspections,” for inspection and
maintenance requirements of pipelines and piping.
b. Refer to Section 3-6.4, “Basket Strainers,” for inspection and maintenance
requirements of basket strainers.
c. Refer to Section 3-8, “Pumps,” for inspection and maintenance
requirements of petroleum fuel pumps.
d. Refer to Section 3-6.2, “Filter Separators,” for inspection and maintenance
requirements of filter separators.
e. Refer to Section 3-7, “Meters,” for inspection and maintenance
requirements of petroleum fuel meters.
f. Refer to Section 6-6.5.1, “Truck Fill Valves,” for inspection and
maintenance requirements of TFVs.
g. Refer to Section 3-9.1, “Loading Fuel Hoses,” for inspection and
maintenance requirements of loading fuel hoses.
h. Refer to Section 4-7.1.1, “Fixed Pantographs,” for inspection and
maintenance requirements of fixed pantographs.
i. Refer to Section 4-7.3, “Fueling Nozzles,” for inspection and maintenance
requirements of fueling nozzles.

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j. Refer to Section 9-1.6, “Grounding Systems,” for inspection and

maintenance requirements of grounding systems.
k. Refer to Section 9-5, “Ground Verification Systems,” for inspection and
maintenance requirements of ground verification systems.
l. Refer to Section 9-6, “Electronic Overfill Prevention Systems,” for
inspection and maintenance requirements of electronic overfill prevention
systems.
m. Refer to Section 9-1.9, “Electrical Equipment,” for inspection and
maintenance requirements of control panels.

3-5.2 Pipeline Issue.

Major components of pipeline issue systems include piping, basket strainers, automatic
air vents, pumps, filter separators, meters, grounding systems, and control panels.

3-5.2.1 Inspection and Maintenance – Pipeline Issue.

a. Refer to Section 6-1, “Pipe Testing and Inspections,” for inspection and
maintenance requirements of pipelines and piping.
b. Refer to Section 3-6.4, “Basket Strainers,” for inspection and maintenance
requirements of basket strainers.
c. Refer to Section 3-10.2, “Automatic Air Vents,” for inspection and
maintenance requirements of automatic air vents.
d. Refer to Section 3-8, “Pumps,” for inspection and maintenance
requirements of petroleum fuel pumps.
e. Refer to Section 3-6.2, “Filter Separators,” for inspection and maintenance
requirements of filter separators.
f. Refer to Section 3-7, “Meters,” for inspection and maintenance
requirements of petroleum fuel meters.
g. Refer to Section 9-1.6, “Grounding Systems,” for inspection and
maintenance requirements of grounding systems.
h. Refer to Section 9-1.9, “Electrical Equipment,” for inspection and
maintenance requirements of control panels.

3-5.3 Rail Issue.

Counterbalanced articulated (swivel-type) tank car loading pantographs or loading fuel

hoses are used to load railcars.

Major components of rail issue facilities include piping, basket strainers, pumps, filter
separators, meters, TFV, loading fuel hoses, fixed pantographs, fueling nozzles,

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grounding systems, ground verification systems, electronic overfill protection, and

control panels.

3-5.3.1 Inspection and Maintenance – Rail Issue.

a. Refer to Section 6-1, “Pipe Testing and Inspections,” for inspection and
maintenance requirements of pipelines and piping.
b. Refer to Section 3-6.4, “Basket Strainers,” for inspection and maintenance
requirements of basket strainers.
c. Refer to Section 3-8, “Pumps,” for inspection and maintenance
requirements of petroleum fuel pumps.
d. Refer to Section 3-6.2, “Filter Separators,” for inspection and maintenance
requirements of filter separators.
e. Refer to Section 3-7, “Meters,” for inspection and maintenance
requirements of fuel meters.
f. Refer to Section 6-6.5.1, “Truck Fill Valves,” for inspection and
maintenance requirements of TFVs.
g. Refer to Section 3-9.1, “Loading Fuel Hoses,” for inspection and
maintenance requirements of loading fuel hoses.
h. Refer to Section 4-7.1.1, “Fixed Pantographs,” for inspection and
maintenance requirements of fixed pantographs.
i. Refer to Section 4-7.3, “Fueling Nozzles,” for inspection and maintenance
requirements of fueling nozzles.
j. Refer to Section 9-1.6, “Grounding Systems,” for inspection and
maintenance requirements of grounding systems.
k. Refer to Section 9-5, “Ground Verification Systems,” for inspection and
maintenance requirements of ground verification systems.
l. Refer to Section 9-6, “Electronic Overfill Prevention Systems,” for
inspection and maintenance requirements of electronic overfill prevention
systems.
m. Refer to Section 9-1.9, “Electrical Equipment,” for inspection and
maintenance requirements of control panels.

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3-6 FILTRATION.

3-6.1 Pre-Filters.

\1\
a. Micronic pre-filters meeting the requirements of UFGS 33 52 43.28 are
sometimes installed upstream of filter separators to extend the life of
coalescer cartridges in filter separators. Pre-filters remove particles that
cause contamination. Petroleum fuel to be filtered enters the lower part of
the housing and flows through the filter cartridges from outside to inside.
Coarse dirt particles settle immediately; finer particles are absorbed by the
pleated paper type filter cartridges.
b. An elevated differential pressure measurement indicates dirty filter
cartridges. Investigate sudden drops or spikes in differential pressure
measurement reading. A drop in the flow rate or an increase in pressure
of a system may indicate filters cartridges are fouled with debris or
contaminants. A sudden increase in flow rate or decrease in pressure
may indicate that the filter cartridges are damaged or torn. Replacement
filter cartridges must meet the filter cartridge requirements of UFGS 33 52
43.28.
c. The Installation must maintain an inventory of filter cartridges. The
inventory must be sufficient to allow the Installation to change the filter
cartridges of all pre-filters at an Installation once. The inventory must be
kept in a temperature controlled environment in accordance with
manufacturer recommendations.
/1/

Figure 3-1 Pre-Filter

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3-6.1.1 Inspection and Maintenance – Pre-Filters.

Stencil pre-filters in accordance with Section 3-6.1.3 Stenciling of Pre-Filters when filter
cartridges are changed. Pre-filters require the following inspection and maintenance:

a. Open drains under flow conditions until clear fuel is observed from the
drain valve.
Frequency: Daily
b. Monitor differential pressure in filter cartridges. Chart differential
pressure measurements from readings taken during normal operations.
Frequency: Daily
c. Operate pre-filter isolation valves.
Frequency: Quarterly
d. Replace filter cartridges when the acceptable maximum differential
pressure is reached, the maximum in-service duration has passed, or the
fuel becomes visibly dirty or discolored. Acceptable maximum differential
pressure for a specific pre-filter is dependent on the system flow rate. The
military service-specific SCP may extend in-service duration filter cartridge
replacement period based on differential pressure for high throughput
systems. Check expiration date of replacement filter cartridges before
installation.
Frequency: When differential pressure has reached the lower of
manufacturer’s recommendation or 20 psid (140 kPa), filter cartridge
in-service period of 24 months has expired, or when fuel becomes
visibly dirty or discolored.
e. Refer to Section 6-7.2, “Differential Pressure Gauges,” for inspection and
maintenance requirements of differential pressure gauges.
f. Refer to Section 3-10.2, “Automatic Air Vents,” for inspection and
maintenance requirements of automatic air vents.
g. Refer to Section 6-6.3, “Thermal and Pressure Relief Valves,” for
inspection and maintenance requirements of thermal and pressure relief
valves.
h. Conduct inspections of code rated vessels in accordance with UFC 3-430-07.

3-6.1.2 Pre-Filter Waste Disposal.

Refer to Section 2-6.4 Waste Disposal for proper disposal of filtered waste and used
filter cartridges.

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3-6.1.3 Stenciling of Pre-Filters.

Use stencils or embossing tape (0.75 to 1-inch (19 to 25 mm) letters) to permanently
mark pre-filters when filter cartridges are changed with date changed, due date for next
change, and maximum differential pressure.

3-6.2 Filter Separators.

Filter separators meeting which meet the requirements of UFGS 33 52 43.28 remove
undissolved (free) water and solids from petroleum products. Very fine water particles
pass through coalescer cartridges from inside to outside and grow in size (coalesce)
into larger droplets that fall to the water collection sump.

Figure 3-2 Filter Separator

Second-stage Teflon or nylon coated screens or treated paper cartridges (separator)

repels water droplets and prevents them from leaving the filter separator and cause
them to fall to the water collection sump. The solids in the fuel are trapped in the
coalescer cartridges and build up a differential pressure across the filter separator.
Water accumulated in the water collection sump at the bottom of the filter separator is
typically removed manually under flow conditions. Additional important notes for filter
separators are as follows:

a. Filter separators must be equipped with coalescer and separator

cartridges that meet the requirements of UFGS 33 52 43.28. Older units
must be modified to accept these cartridges or must be replaced with
modern units.
b. If installed, remove automatic water drain option from filter separators at
the first opportunity, unless they are installed on a receipt system that
must handle excessive water, or if waived by the military service-specific

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SME. If automatic water drains are to remain they must be piped to a

product recovery or drain tank.
c. Filter separators are equipped with differential pressure gauges to indicate
when coalescer cartridges should be changed. The piston-type differential
pressure gauge is preferred for petroleum fuel systems. Replace individual
gauges with the piston-type as soon as practical.
d. Filter separators have a sampling port in the outlet pipe used to obtain
petroleum fuel quality samples. Check the flow direction arrow on sample
probes to ensure they are installed in the proper orientation.
e. The Installation must maintain an inventory of coalescer and separator
cartridges. The inventory must allow the Installation to change the
coalescer and separator cartridges of all filter separators at an Installation
once. The inventory must be kept in a temperature controlled
environment in accordance with manufacturer recommendations.

3-6.2.1 Inspection and Maintenance – Filter Separators.

Stencil filter separators in accordance with Section 3-6.2.4 Stenciling of Filter

Separators when coalescer cartridges are changed. Filters separators require the
following inspection and maintenance:

a. Open drain under flow conditions until clear fuel is observed from the drain
valve.
Frequency: Daily
b. Monitor differential pressure of coalescer cartridges. The acceptable
maximum differential pressure for a specific filter separator is dependent on
the system flow rate. Monitor and chart differential pressure measurements
of filter separators from readings taken during normal operations. Investigate
sudden drops or spikes in differential pressure measurement readings.
Frequency: Daily
c. Operate filter separator isolation valves.
Frequency: Quarterly
d. Inspect components and check operation of water shutoff system.
Frequency: Quarterly
e. Change coalescer cartridges. Refer to Section 3-6.2.2 Replacement of
Coalescer Cartridges for general instructions on replacement of coalescer
cartridges. Military service-specific SCP may extend the coalescer cartridge
replacement frequency based on differential pressure if filters separators are
used on high throughput systems. Check expiration date of replacement
coalescer cartridges before installation.
Frequency: Every 36 months or sooner if required by differential
pressure.

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f. Inspect and clean separator cartridges at time of coalescer cartridge change

in accordance with Section 3-6.2.3 Separator Cleaning. Worn or damaged
separator cartridges must be replaced.
Frequency: Every 36 months or sooner if required by differential
pressure.
g. Refer to Section 6-7.2, “Differential Pressure Gauges,” for inspection and
maintenance requirements of differential pressure gauges.
h. Refer to Section 3-10.2, “Automatic Air Vents,” for inspection and
maintenance requirements of automatic air vents.
i. Refer to Section 6-6.3, “Thermal and Pressure Relief Valves,” for inspection
and maintenance requirements of thermal and pressure relief valves.
j. Refer to Section 4-4.2.2, “Filter Separator Control Valves,” for inspection and
maintenance requirements of filter separator control valves.
k. Conduct inspections of code rated vessels in accordance with UFC 3-430-07.

3-6.2.2 Replacement of Coalescer Cartridges.

General instructions for the replacement of filter separator coalescer cartridges are
included in Appendix D. Refer to manufacturer’s maintenance and operation manual for
additional guidelines.

3-6.2.3 Separator Cleaning.

Separator cartridges, when new, operate in a satisfactory manner, but over time they
gradually become less effective. Every time the coalescer cartridges are changed, the
separator cartridges must be inspected and cleaned. Typical instructions for cleaning
separator cartridges are included in Appendix D. Refer to manufacturer’s operation and
maintenance manual for additional guidelines.

3-6.2.4 Stenciling of Filter Separators.

Use stencils or embossing tape (0.75 to 1-inch (19 to 25 mm letters) to permanently

mark filter separators when coalescer cartridges are changed with date changed, due
date for next change, and maximum differential pressure.

3-6.2.5 Initial Filling of Filter Separators.

Internal flash fires have occurred within filter separators. In some cases, there were no
audible sounds or immediate indications of a problem. These incidents are mainly due
to electrostatic ignition of the petroleum fuel vapor-air mixture during the initial filling
operation. Ignition inside filter separators is possible regardless of the type of petroleum
fuel handled (e.g., JP-4, JP-5, JP-8, Jet A, additized Jet A (F-24)). Filling a filter
separator must take a minimum of ten minutes to perform. Slow filling is the only
authorized method of refilling an empty filter separator. This slows buildup of static

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electricity in fuel, reducing the possibility of a spark igniting the explosive atmosphere
inside the vessel. In most cases, coalescer elements cannot be grounded or bonded to
dissipate the static electric charge that is generated during filling.

3-6.3 Haypack Filters.

Haypack filters are typically only used for marine barge and tanker offloading where
large amounts of water are expected to be present in the fuel.

3-6.3.1 Inspection and Maintenance – Haypack Filter.

Refer to manufacturer’s operation and maintenance manual for inspection and

maintenance requirements of haypack filters. Refer to Section 2-6.4 Waste Disposal for
disposal of requirements.

3-6.4 Basket Strainers.

Basket strainers, which meet the requirements of UFGS 33 52 43.13, remove large
particulate matter from petroleum fuel streams. Basket strainers are typically equipped
with 60 mesh (0.25 mm sieve) wire strainer screens. In most cases basket strainers are
equipped with differential pressure gauges that can be used to measure the differential
pressure across the strainer. The maximum retaining capacity of rust and sediment in
the basket strainer is reached when the acceptable maximum differential pressure is
indicated across the strainer. The acceptable maximum differential pressure for a
specific basket strainer is dependent on the size of the strainer and the system flow
rate. Reference the manufacturer’s data sheet for the maximum differential pressure of
a particular basket strainer.

Dirty strainer screens can be washed (using air jets or pressurized liquid streams) and
reused as long as they are not ruptured or otherwise damaged. Gum or tar can be
removed by soaking strainer screens in a high flash point petroleum fuel, such as
kerosene. In order to reduce shutdown time, it is advisable to have extra strainer
screens on hand.

3-6.4.1 Inspection and Maintenance - Basket Strainers.

a. Monitor and chart differential pressure measurements of basket strainers

from readings taken during normal operations. Investigate sudden drops or
spikes in differential pressure measurement reading.
Frequency: Daily
b. Clean and inspect basket and strainer screen. Basket strainer isolation
valves must be closed and the strainer body must be drained before
removing the cover. After cleaning, the strainer screen must be inserted in
the strainer body, and the head tightened and checked for leakage. If
strainer is not equipped with means to measure differential pressure, unit
must be opened monthly and inspected.

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Frequency: Semi-annually if basket strainer is equipped with means to

measure differential pressure; otherwise monthly.
c. Refer to Section 6-7.2, Differential Pressure Gauges, for inspection and
maintenance requirements of differential pressure gauges.

3-6.5 Filter Separator Sump Heaters.

Heaters are used in sumps to prevent freezing of separated water during winter months
in cold climates. Sump heaters are not approved for DoD systems. If heaters are
installed contact the military service-specific SCP for guidance. Existing heaters
installed in systems must be maintained.

3-6.5.1 Inspection and Maintenance – Filter Separator Sump Heaters.

a. Inspect filter separator sump and drain line heater elements for proper
operation per manufacturer’s operation and maintenance manual. Ensure
heater elements meet manufacturer’s requirements by measuring
resistance of heater elements with an ohm meter.
Frequency: Semi-annually.

3-7 METERS.

3-7.1 Positive Displacement Meters.

\1\
Positive displacement meters that meet the requirements of \1\ UFGS 33 57 55 /1/ are
used to record the amount of petroleum fuel received, transferred, or issued. Flow
control devices and strainers are sometimes installed upstream of meters to help
ensure accuracy and protect meter internals.

Truck and railcar loading meters may be equipped with a preset feature. This feature is
used to slow the petroleum fuel flow to a predetermined rate when the preset petroleum
fuel total is approached. Slower fill rates allow a more accurate final fill and reduce the
likelihood of hydraulic shock to the system once flow of petroleum fuel is stopped.
Meters installed at custody transfer points may be equipped with temperature
compensation. This feature allows the meter to adjust the measurement of the flow rate
to a standard temperature.

/1/

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Figure 3-3 Positive Displacement Meter

3-7.1.1 Inspection and Maintenance – Positive Displacement Meters.

Component wear and accumulation of solids make periodic calibration necessary.

Certified master meters or volumetric prover tanks are used for calibration. Master
meters must have been certified within a year of calibration operations. Master meters
are tested at a predetermined flow rate. Master meters must be calibrated within ±10%
of the normal operating flow rate through the inline positive displacement meter.
Volumetric prover tanks must have been certified within the last five (5) years of
calibration operations.

a. Inspect counter head for unusual noises and smooth operation.

Frequency: Monthly
b. Positive displacement meters must be inspected and calibrated semi-
annually or when improper performance is suspected; when unusual sounds
or register actions develop; or after repairs have been made which may affect
performance. Positive displacement meters are satisfactory when the
measurement error in the normal flow direction is within ±0.3% of actual
quantity delivered (e.g., ±1.8 gallons for a 600-gallon test (±6.8 liters for a
2275-liter test)). Adjustment of the meter’s register will be in accordance with
manufacturer’s instructions. Identify the next calibration date on meters
(example: Mar 14 for March 2014). Use weather resistant label that will
remain legible and affixed for at least one year.
Frequency: Semi-annually or as required
c. \2\ Positive displacement meters with temperature compensator feature must
be inspected and calibrated semi-annually. Calibration procedures will be
followed according to manufacturer’s recommendation.
Frequency: Semi-annually /2/

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d. Inspect temperature element operation of meters equipped with temperature

compensation feature per manufacturer’s operation and maintenance
manual.
Frequency: Semi-annually

3-7.2 Turbine Flow Meters

Turbine flow meters that meet the requirements of UFGS 33 52 43.11 utilize an axially
aligned rotor to measure fluid flow. Clearances between the rotor and housing allow
some slippage which can reduce the accuracy of the flow meter.

Figure 3-4 Turbine Flow Meter

3-7.2.1 Inspection and Maintenance- Turbine Flow Meters.

Component wear makes periodic calibration necessary. Certified master meters or

volumetric prover tanks are used for calibration of turbine flow meters in accordance
with API Manual of Petroleum Measurement Standards. Master meters must have
been certified within a year of calibration operations. Master meters are tested at a
predetermined flow rate. Master meters must be calibrated within ±10% of the normal
operating flow rate through the turbine meter. Volumetric prover tanks must have been
certified within the last five (5) years of calibration operations. Refer to the
manufacturer’s operation and maintenance manual for turbine flow meter-specific
calibration procedures.

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a. \2\ Turbine flow meters must be inspected and calibrated semi-annually or

when improper performance is suspected, when unusual sounds or register
actions develop, or after repairs have been made which may affect
performance. /2/ Turbine flow meters are satisfactory when the measurement
error in the normal flow direction is within ±0.5% of actual quantity delivered
(e.g., ±3 gallons for a 600-gallon test (±11 liters for a 2275-liter test)).
Adjustment of the meter’s register will be in accordance with the
manufacturer’s instructions. Identify the next calibration date on meters
(example: Mar 14 for March 2014). Use weather resistant label that will
remain legible and affixed for at least one year.
Frequency: Semi-annually or as required

b. \2\ Turbine flow meters with temperature compensator feature must be

inspected and calibrated semi-annually. Calibration procedures will be
followed according to manufacturer’s recommendation
Frequency: Semi-annually /2/

c. Inspect temperature element operation of meters equipped with temperature

compensation feature per manufacturer’s operation and maintenance
manual.
Frequency: Semi-annually

3-7.3 Orifice Flow Meters.

Orifice flow meters that meet the requirements of UFGS 33 52 43.11 typically do not
require calibration. Orifice flow meters are customized to a specific flow rate and are
only accurate over a small range.

3-7.3.1 Inspection and Maintenance - Orifice Flow Meters.

Refer to manufacturer’s operation and maintenance manual for unit-specific

maintenance requirements.

a. Refer to Section 6-7.2, Differential Pressure Gauges, for inspection and

maintenance requirements of differential pressure gauges.
b. Refer to Section 6-7.4, Differential Pressure Transmitters, for inspection
and maintenance requirements of differential pressure transmitters.

3-8 PUMPS.

3-8.1 Centrifugal Pumps.

\1\
a. Centrifugal pumps work best if the impeller is completely immersed in
liquid. It is important to prevent air pockets from delivery trucks and hoses
from entering pumps. If air gets into a pump the performance can be
drastically reduced. Air eliminator tanks and automatic air vents are used

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to release air from the suction lines of pumps. In some cases air
eliminators are attached directly to the housing of pumps.
b. Centrifugal pumps must have proper shaft alignment with the motors. The
pumps must also be properly shimmed and mounted securely. Both inlet
and outlet pipe connections should be made with vibration dampeners.
The bearings must be adequately lubricated and the mechanical seals
should show no signs of leaks.
c. Mechanical seals require maintenance, but they provide reliable service if
properly installed on a true shaft. Frequent trouble is usually caused by
shaft vibration, wear, or improper installation. It is most important to
protect seal faces from contact with skin, grease, or metal particles, which
can contaminate the seal and cause premature seal failure./1/
Figure 3-5 Split-Case Centrifugal Pump

3-8.1.1 Inspection and Maintenance - Centrifugal Pumps.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual.

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a. Check for proper operations while pump is in use. Check suction and
discharge pressure gauges for abnormal readings.
Frequency: Quarterly
b. Check for unusual noise, vibration, and overheating of bearings or case.
Frequency: Quarterly
c. If equipped with lubricating oil charge, check oil level and adjust as
necessary.
Frequency: Quarterly
d. Tighten or replace loose, missing or damaged nuts, bolts, or screws.
Frequency: Quarterly
e. Inspect suction and discharge isolation dampeners for misalignment and
wear.
Frequency: Quarterly
f. Inspect mechanical seals, if possible, for proper operating temperature,
drips, leaks and dirt.
Frequency: Quarterly
g. Check for alignment, clearances, and rotation of shaft and coupler
(requires removal of coupler shroud or cover).
Frequency: Annually
h. Lubricate pump bearings.
Frequency: Annually
i. If equipped with lubricating oil charge, drain old oil, and fill with new oil to
full mark on sight indicator (also fill bulb).
Frequency: Annually
j. Refer to Section 9-1.7, “Electric Motors,” for inspection and maintenance
requirements of electric motors.
\1\

3-8.2 /1/ Vertical Inline Pumps.

Vertical inline pumps should meet the requirements of \1\ UFGS 33 52 43.23 /1/. Off-
loading pump can operate at lower liquid levels than similarly sized end suction pumps
due to the geometry of the impeller location and are used frequently in petroleum fuel
offloading applications. Vertical inline pumps must be properly supported to prevent
unnecessary stress on inlet and outlet piping.

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Figure 3-6 Vertical Inline Pump

\1\
3-8.2.1 /1/ Inspection and Maintenance – Vertical Inline Pumps.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual.

a. Check for proper operations while pump is in use. Check suction and
discharge pressure gauges for abnormal readings.
Frequency: Quarterly
b. Check for unusual noise, vibration, and overheating of bearings.
Frequency: Quarterly
c. Tighten or replace loose, missing or damaged nuts, bolts, or screws.
Frequency: Quarterly
d. Inspect suction and discharge isolation dampeners for misalignment and
wear.
Frequency: Quarterly
e. Inspect mechanical seals, if possible, for proper operating temperature,
drips, leaks and dirt.
Frequency: Quarterly
f. Check for alignment, clearances, and rotation of shaft and coupler
(requires removal of coupler shroud or cover).
Frequency: Annually

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g. Lubricate pump bearings.

Frequency: Annually
h. Refer to Section 9-1.7 Electric Motors for inspection and maintenance
requirements of electric motors.

\1\
3-8.3 /1/ Vertical Turbine/Submerged Turbine Pumps.

Submerged turbine pumps that meet the requirements of UFGS 33 52 43.23 are used
to pump from aboveground, underground, and cut and cover tanks. This type of pump
is also used to transfer fuel from drop tanks used in some petroleum fuel truck
offloading systems. A “can” pump is another type of vertical turbine pump.

Submerged turbine pumps are sometimes used in military service station applications to
supply fuel to vehicle fuel dispensers and petroleum fuel truck loading positions. Refer
to manufacturer's operation and maintenance manual for more information on each type
of pump.

Figure 3-7 Vertical Turbine Pump

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\1\
3-8.3.1 /1/ Inspection and Maintenance – Vertical Turbine/Submerged
Turbine Pumps.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual.

a. Check for proper operation while pump is in use. Check discharge

pressure gauge for abnormal readings.
Frequency: Quarterly
b. Check for unusual noise, vibration, and overheating of bearings or case.
Frequency: Quarterly
c. If equipped with lubricating oil charge, check oil level and adjust as
necessary.
Frequency: Quarterly
d. Tighten or replace loose, missing or damaged nuts, bolts, or screws.
Frequency: Quarterly
e. Inspect mechanical seals, if possible, for proper operating temperature,
drips, leaks and dirt.
Frequency: Quarterly
f. Inspect anti-rotation device for proper operation.
Frequency: Semi-annually
g. Check for alignment, clearances, and rotation of shaft and coupler
(requires removal of coupler shroud or cover).
Frequency: Annually
h. Lubricate pump bearings.
Frequency: Annually
i. If equipped with lubricating oil charge, drain old oil, and fill with new oil to
full mark on sight indicator (also fill bulb).
Frequency: Annually
j. Refer to Section 9-1.7 Electric Motors for inspection and maintenance
requirements of electric motors.
\1\
3-8.4 /1/ Positive Displacement Pumps.

Positive displacement pumps have an expanding cavity on the suction side and a
decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on
the suction side expands and the liquid flows out of the discharge as the cavity
collapses. The pumped volume is constant given each cycle of operation.

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\1\
3-8.5 /1/ Sliding Vane Pumps.

Sliding vane pumps (sometimes referred to as rotary vane pumps) are self-priming
positive displacement pumps used where suction lifts are high or where the pump may
frequently lose prime such as petroleum fuel truck offload systems. These pumps must
have internal or downstream pressure relief.

\1\
3-8.5.1 /1/ Inspection and Maintenance – Sliding Vane Pumps.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual.

a. Inspect pump for unusual noise, vibrations, and overheating of bearings

and case.
Frequency: Quarterly
b. Inspect mechanical seals, if possible, for drips or leaks and dirt.
Frequency: Quarterly
c. Lubricate pump bearings.
Frequency: Quarterly
d. Inspect pump and motor coupling for proper alignment.
Frequency: Annually
e. Refer to manufacturer’s operation and maintenance manual for internal
pressure relief testing and calibration procedures.
Frequency: Annually
f. Refer to Section 3-8.4 Gearboxes for inspection and maintenance of
reduction gearboxes.
g. Refer to Section 9-1.7 Electric Motors for inspection and maintenance
requirements of electric motors.

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Figure 3-8 Rotary Vane Pump

\1\
3-8.6 /1/ Gear Pumps.

Gear pumps may be used to transfer petroleum fuel at moderate flow rates and can
operate at high pressures.

\1\
3-8.6.1 /1/ Inspection and Maintenance – Gear Pumps.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual.

a. Inspect pump for unusual noise, vibrations, and overheating of bearings

and case.
Frequency: Quarterly
b. Inspect mechanical seals, if possible, for drips or leaks and dirt.
Frequency: Quarterly
c. Lubricate pump bearings.
Frequency: Quarterly
d. Inspect pump and motor coupling for proper alignment.
Frequency: Annually

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e. Refer to Section 3-8.4 Gearboxes for inspection and maintenance of

reduction gearboxes.
f. Refer to Section 9-1.7 Electric Motors for inspection and maintenance
requirements of electric motors.

\1\
3-8.7 /1/ Diaphragm Pumps.

Diaphragm pumps are relatively low maintenance pumps that provide good
performance for transferring high viscosity liquids such as petroleum sludge left in a
tank.

Figure 3-9 Diaphragm Pump

\1\
3-8.7.1.2 /1/ Inspection and Maintenance – Diaphragm Pumps

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of pump. Follow applicable
general maintenance and safety requirements listed in the manufacturer’s operation and
maintenance manual. Ensure pump, hoses, and fittings are kept clean and are stored
in a protected area out of the elements when is not in use.

a. Inspect hoses for cracks or dry rot.

Frequency: Quarterly
b. Inspect compressed air connections and hose couplings for signs of leaks.
Frequency: Quarterly
c. Inspect compressed air hose coupling safety pins or safety wires for wear
and damage. Replace damaged components.
Frequency: Quarterly

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d. Diaphragm pumps should have the internal diaphragm replaced if the

pump shows decreased performance. Also check operation of actuator
valve and ensure ball checks seat properly.
Frequency: As required

\1\
3-8.8 /1/ Internal Combustion Drives.

Internal combustion drives are used where equipment is needed on a temporary or

portable basis such as temporary pumps or power generators. Internal combustion
drives are also used to operate permanent power generators when standard power is
interrupted such as emergency backup generators, and where large power feeds for
large equipment is not available or cost effective to install such as petroleum fuel
transfer pumps installed in remote locations.

\1\
3-8.8.1 /1/ Inspection and Maintenance – Internal Combustion Drives.

a. Refer to manufacturer’s operation and maintenance manual for specific

maintenance procedures and schedules associated with a specific model
of internal combustion drive. Follow all applicable general maintenance
and safety requirements listed in the manufacturer’s operation and
maintenance manual.
Frequency: As required
\1\
3-8.9 /1/ Gearboxes.

Gearboxes transmit power from motors to pumps and other rotating equipment.
Gearboxes must be monitored for proper alignment and oil level. Do not overfill
gearboxes during maintenance.

\1\
3-8.9.1 /1/ Inspection and Maintenance – Gearboxes.

When replacing lubricating oil, verify metal shaving content is within manufacturer’s
recommendations. Refer to manufacturer’s operation and maintenance manual for oil
testing procedures, proper oil levels, and proper type of oil which should be used. Refer
to the applicable manufacturer’s operation and maintenance manual for specific
maintenance procedures and schedules, and follow applicable general maintenance
and safety requirements.

a. Inspect gearboxes for signs of smoke near shaft connections or

discoloration of the gearbox from overheating.
Frequency: Quarterly

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b. Verify that the oil in the sight glass is not dark or appears to have foam.
Adjust oil level if required.
Frequency: Quarterly
c. Lubricate bearings per manufacturer’s recommendations.
Frequency: Semi-annually
d. Check motor and gear box and gear box and pump couplers for wear and
alignment.
Frequency: Semi-annually
e. Inspect gear alignment within gearbox.
Frequency: Annually
f. Replace lubricant oil in accordance with manufacturer’s specifications and
recommendations.
Frequency: Annually

3-9 HOSES.

3-9.1 Loading Fuel Hoses.

Loading fuel hoses must meet the requirements of aviation fueling hoses listed in
\1\ UFGS 33 57 55 /1/. General requirements for loading fuel hose use are as follows:

a. Hoses must be stored away from direct exposure to sun and extreme
weather such as rain and snow in a hinged enclosure when not in use.
b. Dust covers or other protective devices must be used to keep out dirt and
water.
d. Hoses must be installed within 2 years of the date of the hose’s
manufacture, and have a maximum service life of 10 years from the date
of manufacture.

3-9.1.1 Inspection and Maintenance – Loading Fuel Hoses.

a. Visually inspect hoses for loose covers, cracks, brittle surface coatings,
exposed wire braids, exposed reinforcement, flattening, kinks, and bulges
or soft spots which might indicate broken or displaced reinforcement.
Frequency: Monthly
b. Pressurize hose to normal working pressure. Check flanged and threaded
connections for leaks and inspect hose couplers for fluid seepage by
pushing at the base of the coupling with thumbs. A hose softened by
petroleum fluid seepage must be replaced.
Frequency: Monthly

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c. Check for coupling slippage. Replace hose that shows signs of coupling
slippage.
Frequency Quarterly
d. \1\ /1/
e. Conduct test of petroleum fuel hose electrical resistivity using an
electrostatic meter in accordance with NFPA 77 and API 2003.
Frequency: Annually

3-9.2 Offloading Fuel Hoses.

Offloading petroleum fuel hoses meeting the requirements of UFGS 33 52 43.11 are
used for offloading operations. Offloading petroleum fuel hoses must be stored away
from direct sunlight in a hinged enclosure when not in use or must be purchased with
ultraviolet (UV) light protection.

3-9.2.1 Inspection and Maintenance - Offloading Fuel Hoses.

a. Visually inspect hoses for cracks, brittle surface coatings, exposed wire
braids, exposed reinforcement, flattening, kinks, and bulges or soft spots
which might indicate broken or displaced reinforcement.
Frequency: Monthly
b. Check flanged and threaded connections for leaks and inspect hose
couplers for fluid seepage by pushing at the base of the coupling with
thumbs. A hose softened by petroleum fluid seepage must be replaced.
Damaged or leaking hoses must be replaced immediately or isolated and
taken out of service. Frequency:
Quarterly
c. Conduct test of offloading petroleum fuel hose electrical resistivity as
directed in NFPA 77 and API 2003.
Frequency: Annually

3-10 AIR ELIMINATORS.

Air eliminators are used to remove non-condensing gases such as air from petroleum
fuel systems.

3-10.1 Air Eliminator Tanks.

\1\
a. Air eliminator tanks meeting the requirements of UFGS 33 52 43.11 are
used to remove air from petroleum fuel offloading systems. Air eliminator
tanks should include a sight gauge, float vent valve, level sensors, and a
pressure/vacuum vent.

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b. A float vent valve is installed at the top of air eliminator tanks in an

extractor fitting at the base of the vent pipe. The float and body of the
valve are suspended from the extractor fitting inside the air eliminator
tank. The float of the valve is buoyant in petroleum fuel and rises to close
the float vent valve and block off the vent pipe when the air eliminator tank
is full of petroleum fuel. When the level of petroleum fuel in the air
eliminator tank drops, the float of the float vent valve drops and opens the
vent pipe.
c. A pressure/vacuum vent is installed at the end of the vent pipe. The
pressure/vacuum vent allows air to vent from the tank when a small
positive pressure is developed in the air eliminator tank and allows air to
enter the vent line when a small negative pressure is developed inside the
air eliminator tank.
d. Level sensing probes are installed at two or three locations in the air
eliminator tank. The level probes are used by the offloading control
system to control the operation of the offloading pump.
/1/

Figure 3-10 Air Eliminator Tank

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3-10.1.1 Inspection and Maintenance - Air Eliminator Tanks.

a. Inspect operation of petroleum fuel level probes. Ensure probes operate

correctly when the level of petroleum fuel in the tank rises to the level of
the probe sensing unit.
Frequency: Annually
b. Remove the float vent valve from the air eliminator tank. Clean and
inspect the sealing surfaces of the float vent valve. Ensure the float is
buoyant in petroleum fuel and test the valve to ensure it closes properly.
Frequency Annually
c. Refer to Section 8-9.3 Tank Pressure/Vacuum Vents for inspection and
maintenance requirements of pressure vacuum vents.

3-10.2 Automatic Air Vents.

Automatic air vents meeting the requirements of UFGS 33 52 43.13 automatically vent
air under pressure and prevent a vacuum when pressure drops below positive pressure.
The vents are operated by a float ball that is buoyant in petroleum fuel. When air is
present the float will drop allowing air to escape, and when petroleum fuel is present the
ball will float and seal the vent opening. In most cases, automatic air vents are piped to
a tank such as a product recovery tank.

Figure 3-11 Automatic Air Vent

3-10.2.1 Inspection and Maintenance - Automatic Air Vents.

a. Check for proper operation of the automatic air vent. Ensure the vent
opens to allow air to escape and ensure the float of the vent is buoyant in
petroleum fuel and rises to close the vent when the float is suspended in
petroleum fuel.
Frequency: Annually

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3-11 FUEL ADDITIVE INJECTORS.

Fuel additive injectors are used to inject additives into fuel to change its grade such as a
change from Jet A to F-24.

3-11.1 Inspection and Maintenance – Fuel Additive Injectors.

Refer to the manufacturer’s operation and maintenance manual for specific calibration
and maintenance procedures and schedules and follow all applicable general
maintenance and safety requirements.

a. Inspect injectors to ensure they are operating properly.

Frequency: When system has flow through it, inspect injectors
weekly. When system is idle, inspect injectors monthly.
b. Calibrate injector to ensure proper additive to fuel ratio.
Frequency: Annually

3-12 CODED VESSELS.

Coded vessels such as filter separators, filters, and relaxation tanks are used when
spaces larger than standard piping is required to conduct operations such as filtering or
static dissipation in petroleum fuel systems.

3-12.1 Inspection and Maintenance – Coded Vessels.

Pressure vessels used in petroleum fuel system are built to applicable pressure vessel
codes and stamped with plates that provide information on the coded vessel. These
vessels must follow inspection and maintenance requirements included in
UFC 3-430-07.

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CHAPTER 4 AIRCRAFT FUELING FACILITIES

4-1 INTRODUCTION.

This chapter contains a brief operational description of each type of hydrant system and
the major components included in each system. Hydrant systems are site-specific. The
settings provided within this manual are derived from standard designs and may vary
due to configuration, climate, and location of an installed system. Before systems or
components are calibrated or maintained, personnel should consult as-built and start up
data and must be familiar with proper settings of the specific system.

4-2 HYDRANT SYSTEM – TYPE I.

Type I hydrant systems are known as Panero systems. Panero systems were built in
the 1940’s and 50’s, and were the first hydrant system used by the DoD. Panero
systems have been superseded by more modern hydrant systems, but a limited number
are still in use. Panero systems pump petroleum fuel to refueling outlets, and aircraft
are moved to outlets to conduct refueling operations. These systems typically use
vertical turbine pumps and underground horizontal storage tanks. Original Panero
systems had automatic control valves on the issue and defuel lines in filter/meter pits.
Major modifications to the original Panero created the Modified Panero system. The
Modified Panero system uses one automatic control valve to perform both issue and
defuel operations and uses MH-2 hose carts instead of filter/meter pits. With these
systems defuel operations are conducted by gravity to a dedicated defuel tank.

Figure 4-1 Modified Panero, Type I Hydrant System

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4-3 HYDRANT SYSTEM – TYPE II.

4-3.1 General Description.

Type II hydrant systems are known as Pritchard systems. Pritchard systems were
developed in 1955 to improve hydrant refueling operating characteristics. These
systems employ Lateral Control Pits (LCPs) and typically use vertical turbine pumps
and underground horizontal storage tanks. Pritchard systems can service multiple
hydrant outlets per LCP. This system allows flexibility in hydrant outlet locations and
enables aircraft to be refueled at parking positions. The Type II Pritchard pumphouse is
similar to the Type I, but the Type II Pritchard pumphouse does not include a separate
defuel tank. Instead, one of the system operating tanks is designated as the defuel tank
on a rotational basis. LCPs include a defueling pump and automatic valves. The MH-2
hose cart equipped with a filter separator, meter, and hoses is used for connecting
hydrant outlets to aircraft, and as a result, filtration or meters are not required in LCPs.
The following is a simplified description of operation:

a. Fuel Issue: When fuel is required at a hydrant outlet, the operator places a
magnet on the refueling magnetic control assembly. This causes a
preselected pump in the pumphouse to start and energizes a solenoid on
the refueling control valve in the LCP that supplies the activated hydrant
outlet. Fuel moves from the pumphouse into the fueling manifold and to
the LCP. Fuel enters the refueling control valve and causes it to open. The
refueling control valve provides pressure reduction, non-surge, pressure
relief, excess flow shutoff, and emergency shutoff capabilities. Fuel flows
through the hydrant outlet adapter and to the MH-2 hose cart and into the
aircraft. During fuel issue operations, the defueling valve solenoid is de-
energized and the defuel valve is held closed. The pressure relief valve
relieves excess pressure from the upstream side of the refueling control
valve into the defuel line if required.
b. Defueling: When a defuel operation is required the operator places the
magnet on the defuel refueling magnetic control assembly switch. This
causes a solenoid on the defueling valve connected to the hydrant pit to
energize and the associated defuel pump to start. When the defuel
solenoid energizes the defuel valve opens and fuel is drawn through the
defuel pump and forced through the rate-of-flow control valve into the
defuel line at a rate of 200 gallons per minute (gpm) (12.5 Liters per
Second (lps)). Fuel flows to the operating tank designated to receive
defuel product.

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Figure 4-2 Pritchard, Type II Hydrant System

4-3.2 System Specific Control Valves.

4-3.2.1 General System Control Valves.

Petroleum fuel system control valves use hydraulic pressure from the upstream side of
petroleum fuel piping connected to the valve to open or close the valve. The valves are
equipped with flexible diaphragms and control pilots that are used to operate the valves.
The valves can be used to perform many functions. The functionality of the valve is
dependent on the type of control pilot that is installed on the valve and the orientation of
flow through the valve.

4-3.2.1.1 Inspection and Maintenance - General System Control Valves.

a. Verify operating settings of valve. Valve adjustment must be in
accordance with manufacturer's operation and maintenance manuals and
final start-up and commissioning set points. Use of DoD standard set
points should only be used as a reference starting point as pipe size and
other hydraulic factors influence final system settings.
Frequency: Quarterly
b. Remove and clean strainer installed in the petroleum fuel supply line to
the pilot and main valve diaphragm. This strainer is provided to prevent
clogging of the orifice in the supply line. Clogging of the screen will cause
malfunctioning of the valve.
Frequency: Annually for unfiltered systems and as required for
filtered systems.

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c. Diaphragms must be removed and inspected for deterioration and breaks

at the flexing joint. Damage is often caused by pipe scale, pipe tape, and
thread sealant compound that collect above the diaphragm and become
lodged between the diaphragm and bonnet of the valve. Damage may
also be caused by a change of operational petroleum fuel type or grade
(such as a change from JP-4 to JP-8).
Frequency: Every 10 years

4-3.2.2 High Level Shut-off Valve.

For information on the operation and maintenance of a High Level Shut-Off (HLSO)
valves, refer to Section 8-9.6 High Level Shut-off Valve (HLSO).

Figure 4-3 High Level Shut-off Valve (Type II)

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4-3.2.3 Non-Surge Check Valves.

Type II system non-surge check valves are similar in design and operation to Type III
non-surge check valves. Refer to Section 4-4.2.1 Non-Surge Check Valves for
information on inspection and maintenance of non-surge check valves.

Figure 4-4 Non-Surge Check Valve (Type II)

4-3.2.4 Filter Separator Control Valves.

Type II system filter separator control valves are similar in design and operation to Type
III filter separator control valves. Refer to Section 4-4.2.2 Filter Separator Control
Valves for information on inspection and maintenance of filter separator control valves.

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Figure 4-5 Filter Separator Control Valve (Type II)

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4-3.2.5 Refuel Control Valves.

The diaphragm actuated refuel control valve provides five functions: pressure reduction;
non-surge; pressure relief; excess flow shutoff; and emergency shutoff for Type II
systems.

Figure 4-6 Refueling Control Valve (Type II)

4-3.2.5.1 Inspection and Maintenance – Refuel Control Valves.

a. Verify refuel control valve is set to maintain 100 psig (690 kPa) (typical
operating pressure) as measured at the furthest hydrant outlet.
Frequency: Quarterly
b. Verify pressure-reducing control will open at 5 psig (35 kPa) above normal
operating pressure (typically 105 psig (725 kPa) as measured at the
farthest hydrant outlet).
Frequency: Quarterly

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c. Verify refueling control valve opening rate is set between 15 and 20

seconds. The valve should open as quickly as possible without tripping
the pressure differential control shut-off.
Frequency: Quarterly
d. Verify operation of excess flow shutoff function.
Frequency: Quarterly
e. Verify operation of solenoid.
Frequency: Quarterly
f. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-3.2.6 Pressure Relief Valves.

The pressure relief valve is installed in the LCP between the fuel issue line and the
defueling line. Pressure relief valves are provided to relieve excessive pressure caused
by closing a downstream valve or thermal expansion in a closed section of pipeline.
This valve is designed for petroleum fuel to flow under the seat disc inside the valve so
that it "fails safe" in the open position if the main valve diaphragm fails.

Figure 4-7 Pressure Relief Valve (Type II)

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4-3.2.6.1 Inspection and Maintenance – Pressure Relief Valves.

a. Verify pressure relief valve will open at 10 psig (69 kPa) above normal
inlet pressure to the refuel control valve.
Frequency: Semi-annually
b. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-3.2.7 Defuel Control Valve.

The defueling control valve is a diaphragm-actuated solenoid shutoff valve. This valve
and the defueling pump energize simultaneously. When the solenoid valve on the defuel
control valve is energized, it allows the defuel control valve to open and permit defueling
through the system.

Figure 4-8 Defuel Control Valve (Type II)

4-3.2.7.1 Inspection and Maintenance – Defuel Control Valves.

a. Verify the defuel control valve opens when the solenoid on the defuel
control valve is energized.
Frequency: Quarterly

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b. Refer to Section 4-3.2.1 General System Control Valves for additional

inspection and maintenance requirements.

4-3.2.8 Dual Rate-of-Flow Control Valves.

The dual rate-of-flow control valve is a combination rate-of-flow control valve and fast
closing, hydraulically operated check valve that closes the main valve against reverse
flow. It performs two distinct functions: maintaining a preset flow rate (typically set at
200 gpm (12.5 lps)), and acting as a check valve to prevent reverse flow.

Figure 4-9 Dual Rate-of-Flow Control Valve (Type II)

4-3.2.8.1 Inspection and Maintenance – Dual Rate-of-Flow Control Valves.

a. Verify dual rate-of-flow control valve is set to maintain a flow rate of 200
gpm (12.5 lps).
Frequency: Quarterly
b. Verify operation of check valve feature.
Frequency: Quarterly
c. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

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4-3.3 Type II Modified Control Valves (Rapid Flow).

The rapid flow modification was done on some Type II systems to increase defuel rates
from 200 to 300 gpm (12.5 to 19 lps). A pump on the aircraft is used to transfer
petroleum fuel from the aircraft through the LCP and into the designated defuel tank.
The defueling pump in the LCP is only used to evacuate the hose cart after the aircraft
pump is de-energized. Two modified control valves are used in the rapid flow system
(combination dual rate-of-flow control valve and solenoid valve and dual pressure relief,
solenoid shutoff, and check valve).

4-3.3.1 Combination Dual Rate-of-Flow Control and Solenoid Valves.

Combination dual rate-of-flow control and solenoid valves operate like the standard dual
rate-of-flow control valves, with the addition of a solenoid for remote-control operations.
All settings and functions are the same as the standard dual rate-of-flow control valve.

Figure 4-10 Combination Dual Rate-of-Flow Control and Solenoid Valve (Type II)

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4-3.3.1.1 Inspection and Maintenance – Combination Dual Rate-of-Flow

Control and Solenoid Valves.

a. Verify valve is set to maintain a flow rate of 300 gpm (19 lps).
Frequency: Quarterly
b. Verify operation of check valve feature.
Frequency: Quarterly
c. Verify solenoid operation.
Frequency: Quarterly
d. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-3.3.2 Dual Pressure Relief, Solenoid Shutoff, and Check Valves.

The dual pressure relief, solenoid shutoff, and check valve is installed in the modified
hydrant lateral control pit downstream of the refueling control valve between the issue
and defuel line. This relief valve performs two functions: relieves excess pressure in the
issue line caused by quick-closing valves during the refueling operation; and maintains
a minimum pressure of 5 psig (35 kPa) on the issue line piping when the refueling
pumps are not in operation. This valve also has a flow control used to slowly close the
valve during rapid defuel operations.

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Figure 4-11 Dual Pressure Relief, Solenoid Shutoff, and Check Valve (Type II)

4-3.3.2.1 Inspection and Maintenance – Dual Pressure Relief, Solenoid

Shutoff, and Check Valves.

a. Verify high pressure relief control will open at 5 psig (35 kPa) above the
refuel control valve pressure relief control set point (typically set at 110
psig (760 kPa)).
Frequency: Quarterly
b. Verify low pressure relief control will open at 5 psig (35 kPa) when
refueling pumps are stopped.
Frequency: Quarterly
c. Verify closing speed provides a smooth; pulsation free operation.
Frequency: Quarterly
d. Verify operation of solenoid valve.
Frequency: Quarterly
e. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

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4-4 HYDRANT SYSTEM – TYPE III.

4-4.1 General Description.

The DoD large-frame aircraft direct fueling system is referred to as the Type III
pressurized fueling system. This system is generally comprised of two operating
storage tanks, a pumphouse, a hydrant loop, and hydrant outlets at aircraft parking
positions. Two redundant Program Logic Controllers (PLCs) are used to control the
operation of the system including the pumps and control valves. The system is
constantly pressurized when operating. Petroleum fuel is pumped from the tanks,
through filter separators and an issue venturi into the hydrant loop. The petroleum fuel
flows through the appropriate hydrant valve, through a hydrant servicing vehicle or
mobile pantograph and into the aircraft. A backpressure control valve keeps the
hydrant loop at a pre-set pressure and a return venturi measures flow back to the
storage tank. Working in conjunction with the return venturi, pumps are turned on and
off depending on petroleum fuel issue requirements. Systems are generally sized in
600 gpm (38 lps) increments up to 2,400 gpm (152 lps). Issue pumps are sized to
provide a minimum of 100 psig (690 kPa) at the furthest hydrant outlet. Each hydrant
pit control valve is equipped with a pressure control and surge shutdown pilot and
newer systems also include a differential pilot. (See UFGS 33 52 43.14 for more
information). The pilot controls are set at 45 psig (310 kPa) and 50 psig (345 kPa),
respectively. Hydrant control valves allow flow rates up to 900 gpm (57 lps) using 4-
inch (DN100) valve bodies. Hydrant control valves are typically set to 600 gpm (38 lps).
Flow rates of up to 1,200 gpm (76 lps) are possible using 6-inch (DN150) hydrant
control valve bodies.

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Figure 4-12 Type III Hydrant System Diagram

4-4.2 System-Specific Control Valves.

4-4.2.1 Non-Surge Check Valves.

Diaphragm non-surge check valves that meet the requirements of UFGS 33 52 43.14
are used as a flow control feature on the discharge of pumps. A non-surge check valve
is used to prevent a pump from running out of its curve when petroleum fuel is flowing
through multiple filter separators and to prevent backflow through the pump.

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Figure 4-13 Non-Surge Check Valve

4-4.2.1.1 Inspection and Maintenance – Non-Surge Check Valves.

For more information on features, valve settings, and replacement, refer to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

a. Verify main valve opening speed (typically 20 seconds). Adjust if required.

Frequency: Semi-annually
b. Verify valve maintains 650 gpm (41 lps) flow rate (some instances 950
gpm (60 lps) flow rate). Adjust if required.
Frequency: Semi-annually
c. Ensure the check valve function is operating properly.
Frequency: Semi-annually
d. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

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4-4.2.2 Filter Separator Control Valves.

Filter Separator Control Valves (FSCVs) that meet the requirements of UFGS
33 52 43.14 are used to control the rate of flow through filter separators, prevent
reverse flow, prevent water discharge when the water level float control reaches the
high position, and act as an emergency shutoff valve when equipped with an
emergency stop solenoid valve. Most FSCVs operate at 600, 900 or 1,200 gpm (38, 57
or 76 lps) based on the rated flow capacity of the filter separator.

Figure 4-14 Filter Separator Control Valve (Type III)

4-4.2.2.1 Inspection and Maintenance – Filter Separator Control Valves.

a. Test FSCV emergency shut off solenoid under flow conditions and ensure
that valve closes within 10 seconds of EFSO button activation.
Coordinate with overall EFSO test listed in Section 9-1.2.1 Inspection and
Maintenance - Electrical Equipment.
Frequency: Quarterly
b. Operate test button (if installed) to ensure the FSCV closes at high water
level. Physically press the test button, while recirculating fuel, and ensure
the FSCV closes. Note: closing speed is a function of the number of open
filters separators and the number of pumps operating. With all filters open
and only one pump operating, the valve will close very slowly.
Frequency: Quarterly
c. Verify valve maintains flow rate (typically 600 gpm (38 lps), operating
range based on commissioning documentation). Adjust flow rate if
required. Flow rate is determined by filter separator vessel gpm (lps)
rating, or element flow rate, whichever is less. Use return venturi to
measure and confirm flow rate during valve testing and adjustment.
Frequency: Annually

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d. Ensure the check valve function is operating properly.

Frequency: Annually
e. Test buoyancy of water level float. Remove the ball or float assembly and
place it in a bucket of water. Correctly operating ball or float will float at the
top of the water’s surface.
Frequency: When coalescer cartridges are changed
f. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-4.2.3 Defuel/Flush Valves.

\1\
a. Defuel/Flush Valves (D/FV) that meet the requirements of UFGS
33 52 43.14 are controlled by two different solenoids. Solenoid A controls
the defuel portion of the main valve and holds the valve closed any time a
fuel pump is running. Solenoid B controls the flush portion of the main
valve and functions only when the system is placed in flush mode. When
the lead pump de-energizes, solenoid A energizes, allowing the valve to
open and drop the system pressure to 80 psig (550 kPa) (typical set
pressure). While the system is in the idle position, the valve will open to
allow defueling when the hydrant loop pressure rises above 80 psig (550
kPa) (typical set pressure).
b. Defueling can be conducted using a Hydrant Hose Truck (HHT) to pump
fuel off aircraft and force fuel into the hydrant loop. The HHT pump will
overcome the 80 psig (550 kPa) setting of the D/FV and open the valve.
c. Solenoid B energizes only when the system is placed in flush mode. Flush
mode is used to move fuel through the system in order to clean the loop.
Flushing procedures vary based on system design and should be
approved by the military service-specific SME.
/1/

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Figure 4-15 Defuel/Flush Valve (Type III)

4-4.2.3.1 Inspection and Maintenance – Defuel/Flush Valves.

For more information on features, settings, and replacement, refer to commissioning

documents, as-builts, and manufacturer’s operation and maintenance manuals.

a. Ensure Solenoids A and B are de-energized with system in automatic

mode and lead pump operating.
Frequency: Quarterly
b. Ensure Solenoid A is energized and Solenoid B is de-energized to allow
main valve to open and drop system pressure to 80 psig (550 kPa) (typical
set pressure) with system in automatic mode and lead pump off.
Frequency: Quarterly
c. Ensure Solenoid A is de-energized and Solenoid B is energized when
system is in flush mode.
Frequency: Quarterly
d. Ensure Solenoids A and B are de-energized when system is in tightness
test mode.
Frequency: Quarterly

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e. Check opening and closing speed. Speed should be as fast as possible

while still maintaining smooth operation.
Frequency: Quarterly
f. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-4.2.4 Issue Venturi.

The issue venturi is downstream of the issue filter separator manifold and is typically
rated at 2,400 gpm (151 lps). The venturi has upstream and downstream sensing line
connections for two redundant Differential Pressure Transmitters (DPTs). The control
PLCs determines the flow rate using electronic signals from the DPTs.

Figure 4-16 Issue Venturi

4-4.2.4.1 Inspection and Maintenance - Issue Venturi.

a. Ensure issue venturi DPTs are reading the same value within ± 2% full
scale.
Frequency: Semi-annually
b. Refer to Section 6-7.4 Differential Pressure Transmitters for inspection
and maintenance requirements of DPTs.

4-4.2.5 Return Venturi.

The return venturi is located upstream of the Back-Pressure Control Valve (BPCV). It is
similar to the issue venturi but is typically rated at 800 gpm (50 lps).

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4-4.2.5.1 Inspection and Maintenance - Return Venturi.

a. Ensure return venturi DPTs are reading the same value within ±2% full
scale.
Frequency: Semi-annually
b. Refer to Section 6-7.4 Differential Pressure Transmitters for inspection
and maintenance requirements of DPTs.

4-4.2.6 Back Pressure Control Valves.

Back Pressure Control Valves (BPCVs) that meet the requirements of UFGS
33 52 43.14 are used to maintain a constant hydrant loop pressure. The valve is
typically 6-inch (DN 150), and the valve is typically set to maintain 100 psig (690 kPa)
fuel pressure at the furthest hydrant outlet.

Figure 4-17 Back Pressure Control Valve (Type III)

4-4.2.6.1 Inspection and Maintenance – Back Pressure Control Valves.

For more information on features, valve settings, and replacement, refer to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

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a. Verify constant upstream pressure is maintained at the set point

established and listed in the system commissioning documents. Adjust
setting of BPCV as necessary.
Frequency: Quarterly
b. Ensure Solenoid A is energized and Solenoid B is de-energized while lead
pump is operating in automatic mode.
Frequency: Quarterly
c. Ensure Solenoids A and B are de-energized prior to lead pump shutdown
and system going to stand-by.
Frequency: Quarterly
d. Ensure Solenoids A and B are de-energized while system is in flush
mode.
Frequency: Quarterly
e. Ensure that Solenoid A is de-energized and Solenoid B is energized while
system is in tightness test mode.
Frequency: Quarterly
f. Verify closing speed control. Valve should close as fast as possible while
still maintaining smooth operation.
Frequency: Quarterly
g. Check solenoid EFSO feature when equipped. Coordinate test with overall
EFSO test listed in Section 9-1.2.1 Inspection and Maintenance -
Electrical Equipment.
Frequency: Quarterly
h. Refer to Section 4-4.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-4.2.7 Pressure Control Valves.

Pressure Control Valves (PCV) meeting the requirements of UFGS 33 52 43.14 reduce
system pressure down to 75 psig (515 kPa) during system shutdown process and
provide thermal relief during idle periods. The valves are typically 2-inch (DN50). A
solenoid installed on the valve energizes to close the valve when the lead pump is
operating and de-energizes when the lead pump stops. When the solenoid is de-
energized, the valve opens to reduce the system pressure to 75 psig (515 kPa) and the
thermal relief function is operable. If the pressure rises above 75 psig (515 kPa), the
valve opens and excess pressure flows to the operating storage tank. The valve
opening and closing speed controls are typically set at three (3) seconds. In some
cases, to prevent valve chattering, the PCV pressure-sensing line is connected to the
large defuel/flush line.

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Figure 4-18 Pressure Control Valve (Type III)

4-4.2.7.1 Inspection and Maintenance – Pressure Control Valves.

For more information on features, valve settings, and replacement refer, to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

a. Ensure Solenoid A is energized and Solenoid B is de-energized while

system is in automatic mode and lead pump is operating.
Frequency: Quarterly
b. Ensure Solenoids A and B are de-energized while system is in automatic
mode and lead pump is off. Verify valve opens to maintain system
pressure at 75 psig (515 kPa).
Frequency: Quarterly
c. Ensure Solenoid A is energized and Solenoid B is de-energized while
system is in flush mode and lead pump is operating.
Frequency: Quarterly
d. Ensure Solenoids A and B are de-energized while system is in flush mode
and pumps are off.
Frequency: Quarterly

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e. Ensure Solenoids A and B are energized while system is in tightness test

mode.
Frequency: Quarterly
f. Verify closing speed control. Valve should close as fast as possible while
still maintaining smooth operation.
Frequency: Quarterly
g. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-4.2.8 Hydrant Control Valves.

Hydrant Control Valves (HCV) meeting the requirements of UFGS 33 52 43.14 provide
constant nozzle pressure and relieve excess pressure. An air-sensing line is connected
from the HHT to the HCV three-way hydraulically operated/diaphragm actuated globe
valve. When the HHT's pneumatic deadman is depressed, air is supplied to the three-
way valve, allowing the valve to open. A fuel-sensing line is connected from the HHT
venturi to the Pressure-Reducing Control (CRA) and the Pressure-Relief Control (CRL)
on the HCV. The venturi is calibrated to provide the same pressure as the actual nozzle
pressure at the skin of the aircraft. The CRA maintains 45 psig (310 kPa) at the nozzle.
The HCV is designed to close rapidly when the nozzle pressure exceeds the 50 psig
(345 kPa) setting of the CRL. It reopens when the pressure drops below the 50 psig
(345 kPa) set point.

Some Type III systems use towable pantographs instead of HHTs. The operation of a
towable pantograph with a HCV is similar to the operation with a HHT.

Figure 4-19 Hydrant Control Valve (Type III)

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4-4.2.8.1 Inspection and Maintenance – Hydrant Control Valves.

For more information on features, valve settings, and replacement, refer to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

a. Verify HCV maintains 45 psig (310 kPa) nozzle pressure at a flow of 50 to

600 gpm (3 to 38 lps).
Frequency: Quarterly
b. Verify HCV closes when nozzle pressure exceeds 50 psig (345 kPa).
Frequency: Quarterly
c. Verify HCV opening speed is set at a minimum of 20 seconds.
Frequency: Quarterly
d. Verify HCV opens when the deadman control lever is pressed.
Frequency: Quarterly
e. Verify HCV closes within two to five seconds after the deadman lever is
released.
Frequency: Quarterly
f. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-4.2.9 Emergency Shut-off Valves.

This valve has been removed from the standard Type III design, but it still exists in
some systems. New Type III systems achieve the same function as the emergency
shut-off valve by including a similar function on the FSCVs.

Emergency Shut-Off (ESO) valves that meet the requirements of UFGS 33 52 43.14
have two solenoids that are energized when power is on, enabling the main valve to
open when fuel is flowing. Should power fail or an emergency stop button be pushed,
the solenoids will de-energize and the main valve will close within 10 seconds. The
valve also has a thermal relief feature that relieves excess cover chamber pressure
back to the valve inlet, and a differential control is used to maintain a relatively constant
differential pressure between the inlet and outlet of the main valve.

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Figure 4-20 Emergency Shut-Off Valve (Type III)

4-4.2.9.1 Inspection and Maintenance – Emergency Shut-off Valves.

For more information on features, valve settings, and replacement, refer to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

a. Ensure Solenoids A and B are energized under normal operations.

Frequency: Quarterly
b. Ensure Solenoids A and B are de-energized during emergency stop
conditions.
Frequency: Quarterly
c. Test emergency stop function of the valve under flow conditions. Ensure
the valve closes within 10 seconds of EFSO button activation. Coordinate
test with overall EFSO test listed in Section 9-1.2.1 Inspection and
Maintenance - Electrical Equipment.
Frequency: Quarterly
d. Verify differential control maintains a constant seven psig (48 kPa)
differential pressure between the inlet and outlet of the valve.
Frequency: Quarterly

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e. Ensure thermal relief function (ball check valve) relieves excess pressure
when cover chamber pressure exceeds inlet pressure. Frequency:
Quarterly
f. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-5 HYDRANT SYSTEM – TYPE IV.

4-5.1 General Description.

Type IV hydrant systems are similar in function to the Type III systems except that the
Type IV system uses fixed pantographs, designed for fixed-wing, small frame aircraft
direct fueling stations. Type IV systems are often designed to support hot refueling
operations.

4-5.2 System-Specific Control Valves.

4-5.2.1 High Level Shut-off Valve (HLSO).

Refer to Section 8-9.6 High Level Shut-off Valves (HLSO) for inspection and
maintenance requirements of Type IV HLSOs.

4-5.2.2 Non-Surge Check Valves.

Refer to Section 4-4.2.1 Non-Surge Check Valves for inspection and maintenance
requirements of non-surge check valves.

4-5.2.3 Filter Separator Control Valve (FSCV).

Refer to Section 4-4.2.2 Filter Separator Control Valves for inspection and maintenance
requirements of Type IV FSCVs.

4-5.2.4 Defuel/Flush Valve (D/FV).

Refer to Section 4-4.2.3 Defuel/Flush Valves for inspection and maintenance

requirements of Type IV D/FV. Ignore the maintenance and inspection requirements for
Type IV systems that are not equipped with a defuel/flush valve.

4-5.2.5 Flush Valves.

Refer to Section 4-4.2.3 Defuel/Flush Valves for inspection and maintenance

requirements of Type IV flush valve. Ignore the maintenance and inspection
requirements for Type IV systems that are not equipped with a flush valve.

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4-5.2.6 Issue Venturi.

Refer to Section 4-4.2.4 Issue Venturi for inspection and maintenance requirements of
issue venturi.

4-5.2.7 Return Venturi.

Refer to Section 4-4.2.5 Return Venturi for inspection and maintenance requirements of
return venturi.

4-5.2.8 Back Pressure Control Valves.

Refer to Section 4-4.2.6 Back Pressure Control Valves for inspection and maintenance
requirements of back pressure control valves.

4-5.2.9 Pressure Control Valves.

Refer to Section 4-4.2.7 Pressure Control Valves for inspection and maintenance
requirements of pressure control valves.

4-5.2.10 Hydrant Control Valve (HCV).

Refer to Section 4-4.2.8 Hydrant Control Valves for inspection and maintenance
requirements of Type IV HCVs.

4-5.2.11 Emergency Shut-off Valve (ESO).

Refer to Section 4-4.2.9 Emergency Shut-off Valves for inspection and maintenance
requirements of Type IV ESOs.

4-5.2.12 Pantograph Control Valves.

The Pantograph Control Valve (PTCV) is used to control flow and pressure of fuel
through the pantograph. The unit operates in conjunction with a pantograph venturi
installed downstream of the PTCV. The valve is equipped with a deadman control
lever.

4-5.2.12.1 Inspection and Maintenance – Pantograph Control Valves.

a. Verify PTCV maintains 55 psig (380 kPa) nozzle pressure at a flow of 50

to 600 gpm (3 to 38 lps).
Frequency: Quarterly
b. Verify PTCV opens when the deadman control lever is pressed.
Frequency: Quarterly

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c. Verify PTCV closes in a maximum of 10 seconds after deadman lever is

released.
Frequency: Quarterly
d. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

4-5.2.13 Pantograph Pressure Control Valves.

The Pantograph Pressure Control Valve (PPCV) relieves pressure from the pantograph
downstream of the PTCV. The PPCV is set to open at 75 psig (515 kPa) and prevents
excessive pressure from reaching the aircraft fuel tank.

Figure 4-21 Pantograph Pressure Control Valve

4-5.2.13.1 Inspection and Maintenance – Pantograph Pressure Control Valves.

a. Verify PPCV opens at 75 psig (515 kPa).

Frequency: Quarterly
b. Verify PPCV opening and closing speed are three seconds maximum.
Frequency: Quarterly

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4-6 HYDRANT SYSTEM – TYPE V.

4-6.1 General Description.

Type V hydrant systems are similar to the Type IV systems except that the refueling
points are located in hardened aircraft shelters.

4-7 HYDRANT SYSTEM GENERAL EQUIPMENT.

4-7.1 Pantographs.

Pantographs that meet the requirements of UFGS 33 52 43.12 are used in aircraft
fueling facilities. Pantographs can be fixed at a single location or mounted on a towable
frame to make them mobile. Pantographs have a number of swivel joints. The focus of
a pantograph’s maintenance centers on the care of the joints. Most pantographs have a
sufficient number of swivel joints to prevent excessive strain. The movable joints
require periodic lubrication when equipped with lubricated swivels and replacement of
packings, seals, or O-rings. Once existing lubricated swivels show signs of leaks and
failure, they should be replace with stainless steel non-lubricated type swivels.

Care must be taken to ensure that grounding or bonding wire is not damaged during
maintenance or allowed to deteriorate. Pantographs are treated roughly during refueling
operations. Personnel who perform preventive maintenance must be alert for leaks, wet
spots, and erratic mechanical operation.

4-7.1.1 Fixed Pantographs.

Fixed pantographs are connected to piping at a single location and are not relocated.

4-7.1.1.1 Inspection and Maintenance – Fixed Pantographs.

a. Place entire pantograph under static pump head pressure and check for
leaks, ease of movement, and damaged grounding or bonding wire.
Frequency: Monthly
b. Inspect wheels (if equipped) for warping, cracking, and uneven wear.
Frequency: Quarterly
c. Inspect exposed piping and components for corrosion.
Frequency: Quarterly
d. Refer to Section 4-7.3 Fueling Nozzles for inspection and maintenance
requirements of fueling nozzle.

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Figure 4-22 Fixed Pantograph

4-7.1.2 \1\ Detachable /1/ Pantographs.

Mobile pantographs are used in locations that are not equipped with fixed pantographs
or hydrant hose trucks. These pantographs are mounted on wheels and can be towed
to the use point. Each pantograph is equipped with a hydrant adaptor used to connect
to a HCV and a fueling nozzle used to connect to the aircraft receiving fuel.

4-7.1.2.1 Inspection and Maintenance – \1\ Detachable/ 1/ Pantographs.

a. Place pantograph under static pump head pressure and check for leaks,
ease of movement, and damaged grounding or bonding wire.
Frequency: Monthly
b. Inspect exposed piping and components for corrosion.
Frequency: Quarterly
c. Lubricate wheels.
Frequency: Quarterly
d. Inspect wheels for warping, cracking, and uneven wear.
Frequency: Quarterly
e. Refer to Section 4-7.2 Hydrant Adapters for inspection and maintenance
requirements of pantograph hydrant adapters.
f. Refer to Section 4-7.3 Fueling Nozzles for inspection and maintenance
requirements of fueling nozzles.

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4-7.2 Hydrant Adapters.

Hydrant adaptors are used to connect to hydrant control valves. Hydrant adaptors are
installed on hydrant hose trucks and mobile pantographs.

4-7.2.1 Inspection and Maintenance – Hydrant Adapters.

a. Inspect hydrant adapter for proper operation, damage, and wear.

Frequency: Quarterly

b. Test operation of dry break system.

Frequency: Quarterly

Figure 4-23 Hydrant Adapter

4-7.3 Fueling Nozzles.

Fueling nozzles are used to connect issue systems to refueler trucks and aircraft. They
are installed on fuel issue hoses, pantographs, R-11 refuelers, R-12 hydrant hose
trucks, and other systems that issue fuel. The fueling nozzle is equipped with 60-100
wire mesh screen (0.25-0.15 mm sieve) to trap particulates from the issue system.

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Figure 4-24 Fueling Nozzle

4-7.3.1 Inspection and Maintenance – Fueling Nozzles.

a. Inspect the condition of the dust cap at the aircraft adapter end and
ensure it is in good working order. Dust caps must be attached to nozzles
when they are not is use.
Frequency: Monthly
b. Test leak resistance of poppet valve against full pump pressure. Unusual
conditions found during this test indicate that repair is necessary and the
nozzle must be removed from service.
Frequency: Monthly
c. Inspect storage racks for moisture or dirt accumulation. Correct conditions
that may be attributing to accumulation of moisture or dirt in the storage
racks.
Frequency: Monthly
d. Remove nozzle for inspection of content impinged upon the mesh screen.
Clean and dry screens before nozzles are returned to service. If a strainer
ball valve is installed upstream of the nozzle only the strainer in the
strainer ball valve needs to be check. Nozzles should not be used while
strainers are removed from upstream strainer ball valves.
Frequency: Monthly
e. Tests nozzle interlocks. Ensure interlocks prevent release of fuel when
the fueling nozzle is not properly connected. Adjust the seating of the
poppet valve if required.
Frequency: Monthly
f. Check the operation of the manual valve crank assembly for smooth and
positive motion on a special test stand.
Frequency: Monthly

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4-7.4 Surge Suppressors.

If the flow of liquid in a pipeline is suddenly stopped, a high pressure wave can be
created as kinetic energy of flow is converted to pressure. The resulting pressure spike
can cause leaks and damage to connected equipment. A common device designed to
decrease pressure spikes in pipelines is a surge suppressor. Surge suppressors can
reduce pressure spikes but will not eliminate them entirely.

Surge suppressors can be constructed with diaphragms or bladders. Surge

suppressors are equipped with a top-mounted pressure gauge, isolation valve, limited
bleed-back check valve, and drains.

4-7.4.1 Inspection and Maintenance - Surge Suppressors.

a. Inspect for nitrogen leaks.

Frequency: Quarterly
b. Bladder pressure inside surge suppressors must be validated and
recharged as needed with nitrogen. Some surge suppressors are also
equipped with needle valves. Settings established in the startup and
commissioning documents should be maintained. Adjust nitrogen charge
per manufacturer’s recommendations.
Frequency: Quarterly

Figure 4-25 Surge Suppressor

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\1\
4-7.5 Aircraft Fueling Hoses.

Fuel issue hoses must meet the requirements of aviation fueling hoses listed in UFGS
33 52 43.12.

4-7.5.1 Inspection and Maintenance - Fuel Issue Hoses.

a. Visually inspect hoses for loose covers, cracks, brittle surface coatings,
exposed wire braids, exposed reinforcement, flattening, kinks, and bulges
or soft spots which might indicate broken or displaced reinforcement.
Frequency: Monthly
b. Pressurize hose to normal working pressure. Check flanged and threaded
connections for leaks and inspect hose couplers for fluid seepage by
pushing at the base of the coupling with thumbs. A hose softened by
petroleum fluid seepage must be replaced.
Frequency: Monthly
c. Check for coupling slippage. Replace hose that shows signs of coupling
slippage.
Frequency Quarterly
d. For hot pit refueling hoses only, refer to Appendix D, Section D-2.1
Loading Hose Hydrostatic Test for loading hose hydrostatic testing
requirements and procedures.
Frequency: Annually
e. Conduct test of petroleum fuel hose electrical resistivity using an
electrostatic meter in accordance with NFPA 77 and API 2003.
Frequency: Annually /1/

4-8 HYDRANT SYSTEM PRODUCT RECOVERY.

This system stores fuel from drain lines, filter separator drains, thermal relief valves and
other components. It permits fuel and water to separate, the water to be drained off, and
fuel to be returned to storage tanks.

4-8.1 Overfill Valve for Product Recovery Tanks.

Overfill Valves (OVs) that meet the requirements of UFGS 33 52 43.14 are installed on
product recovery tanks. Overfill valves are used to stop flow of fuel into product
recovery tanks when the product recovery tanks reach a high level condition. A high-
level alarm is activated at 85% full capacity, a high-high level alarm is activated at 90%
full capacity, and the OV closes at 95% full capacity.

The valve is equipped with a pressure reservoir which supplies hydraulic pressure
required to operate the valve. Reservoir pressure is supplied by the Fuel Transfer

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Pump (FTP) installed on the product recovery tank. When the FTP operates,
pressurized fuel is supplied to the reservoir. The reservoir utilizes a check valve to
isolate the pressure in the reservoir. Automatic opening and closing of the OV is
controlled by a float installed in the product recovery tank. The OV will close upon loss
of reservoir pressure.

Figure 4-26 Overfill Valve for Product Recovery Tank

4-8.1.1 Inspection and Maintenance - Overfill Valve for Product Recovery

Tanks.

For more information on features, valve settings, and replacement, refer to

commissioning documents, as-builts, and manufacturer’s operation and maintenance
manuals.

a. Verify that a green light is illuminated on the pump control panel graphic
display when OV is open.
Frequency: Semi-annually
b. Ensure pressure reservoir bladder is charged with 13 to 15 psig (90 to 103
kPa) of nitrogen and that the reservoir holds fuel pressure.
Frequency: Semi-annually
c. Verify that the OV closes when the control float is lifted (normally 95%
full). Use the manual tester to lift the float. NOTE: When the float in the
product recovery tank rises and the OV closes, the pressure in the
pressure reservoir tank will decrease.
Frequency: Semi-annually

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d. Verify that a red light is illuminated and that an alarm is activated on the
pump control panel graphic display when OV is closed. Alarm is activated
by a limit switch installed on the OV.
Frequency: Semi-annually
e. Ensure the pressure reservoir tank holds FTP deadhead pressure when
the pump is deactivated.
Frequency: Semi-annually
f. Open and clean reservoir inlet strainer.
Frequency: Semi-annually
g. Refer to Section 6-6.3 Thermal and Pressure Relief Valves for inspection
and maintenance requirements of thermal and pressure relief valves.

4-8.2 Product Recovery Tank Release Detection.

Underground double-walled product recovery tanks are provided with release detection
in the annular space between the inside and outside walls of the underground tank.

4-8.2.1 Inspection and Maintenance - Product Recovery Tank Release

Detection.

Refer to Section 8-9.13 Release Detection Monitoring for inspection and maintenance
requirements of product recovery tank release detection systems.

4-8.3 Product Recovery Tank Automatic Tank Gauges.

Underground product recovery tanks are typically equipped with automatic tank gauges
that are similar to underground storage tanks equipped with automatic tank gauges.

4-8.3.1 Inspection and Maintenance - Product Recovery Tank Automatic

Tank Gauges.

Refer to Section 8-9.8 Automatic Tank Gauges for inspection and maintenance
requirements of product recovery tank automatic tank gauges.

4-8.4 Product Recovery Tank Fuel Transfer Pump.

Product recovery tanks are equipped with transfer pumps that are used to transfer
recovered fuel back to store tanks for use.

4-8.4.1 Inspection and Maintenance - Product Recovery Tank Fuel Transfer

Pump.

Refer to Section 3-8.1.3 Vertical Turbine/Submerged Turbine Pumps for inspection and
maintenance requirements of product recovery tank fuel transfer pumps.

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CHAPTER 5 MARINE RECEIVING AND DISPENSING FACILITIES

5-1 PIERS AND WHARVES.

A pier is a deck structure supported above the water on piles (open type), a solid fill
structure retained by bulkheads (closed type with apron), or a combination of the two. It
extends outward from the shore into a harbor or other navigable waters to permit
berthing along one or both sides of its length.

A wharf is a deck structure supported above the water on piles (open type), a solid-fill
structure retained by bulkheads (closed), or a combination of the two. It runs parallel to
the shore and is connected to it at more than one point (usually continuously) to provide
berthing along one side.

5-1.1 Inspection and Maintenance – Piers and Wharves.

Refer to UFC 4-150-07 for inspection and maintenance requirements of piers and
wharves.

\1\
5-1.2 Inspection and Maintenance – Fuel Containment Systems

a. Containment systems on piers and wharves degrade and will collect

debris, which can clog drainage inlets or prevent drain valves from sealing
properly. Hydrostatically test the secondary containment and associated
drainage systems to include containment concrete/sealant, drain inlets,
drain lines and containment drain valves to ensure containment is liquid
tight. This test may use opportune rainfall by holding rainwater in the
containment system for one hour. Where evaporation is a concern,
conduct the testing when this concern would be minimized, such as at
night/early morning or during a time of year when this would not be as
much of an issue. Record the water level at the start of the 60 minute
(minimum) hold period. If the water level drops by 1/8 inch or more,
perform and record an investigation to determine the cause and any
required repairs. Once repairs are completed, a new test must be
completed. Refer to Appendix B for testing procedures and to document
the testing.
Frequency: Every 3 Years
/1/

5-2 MARINE RECEIPT.

These facilities include piers or wharves equipped with petroleum fuel transfer piping.
Major components of marine receipt systems include marine hoses, marine loading
arms, piping, strainers, fuel meters, stripper pumps, and grounding systems.

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5-2.1 Inspection and Maintenance – Marine Receipt.

a. Conduct a shore side inspection of the pier or wharf for signs of damage
as soon as marine barge or tanker disembarks.
Frequency: After each use
b. Inspect the ground switch used between the marine barge or tanker and
the petroleum fuel receipt piping.
Frequency: Monthly
c. Inspect mooring lines, cleats, bollards, bitts, pulley blocks, steel wire
ropes, and winches. Use UFC 4-150-08 as a guide when conducting
inspections. Repair or replace damaged components as required.
Frequency: Monthly
d. Refer to Section 6-1 Pipe Testing and Inspections for inspection and
maintenance requirements of petroleum fuel pipelines installed above
water surfaces. These pipelines are regulated under 33 CFR 154 and
156. Any additional requirements listed under 33 CFR 154 and 156 must
also be followed.
e. Refer to Section 5-1.1 Marine Transfer Hoses for inspection and
maintenance requirements of petroleum fuel marine hoses.
f. Refer to Section 5-4 Marine Loading Arms for inspection and maintenance
requirements of petroleum fuel marine loading arms.
g. Refer to Section 3-6.4 Basket Strainers for inspection and maintenance
requirements of basket strainers.
h. Refer to Section 3-7 Meters for inspection and maintenance requirements
of petroleum fuel meters.
i. Refer to Section 3-8.2 Positive Displacement Pumps for inspection and
maintenance requirements of stripper pumps.
j. Refer to Section 9-1.6 Grounding Systems for inspection and maintenance
requirements of grounding systems.

5-3 MARINE ISSUE.

Marine petroleum fuel issue systems are used to transfer petroleum fuel from shore
storage systems to marine barges and tankers.

5-3.1 Inspection and Maintenance – Marine Issue.

Major components of marine petroleum fuel issue systems include piping, basket
strainers, pumps, meters, marine hoses, marine loading arms, stripper pumps, and
grounding systems.

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a. Inspect pier or wharf for signs of damage as soon as marine barge or

tanker disembarks.
Frequency: After each use
b. Inspect the ground switch used between the marine barge or tanker and
the petroleum fuel issue piping.
Frequency: Monthly
c. Inspect mooring lines, cleats, bollards, bitts, pulley blocks, steel wire
ropes, and winches. Use UFC 4-150-08 as a guide when conducting
inspections. Repair or replace damaged components as required.
Frequency: Monthly
d. Refer to Section 6-1 Pipe Testing and Inspections for inspection and
maintenance requirements of petroleum fuel pipelines installed above
water surfaces. These pipelines are regulated under 33 CFR 154 and
156. Any additional requirements listed under 33 CFR 154 and 156 must
also be followed.
e. Refer to Section 3-6.4 Basket Strainers for inspection and maintenance
requirements of basket strainers.
f. Refer to Section 3-8 Pumps for inspection and maintenance requirements
of marine loading and stripper pumps.
g. Refer to Section 3-7 Meters for inspection and maintenance requirements
of petroleum fuel meters.
h. Refer to Section 5-5.1 Marine Transfer Hoses for inspection and
maintenance requirements of petroleum fuel marine hoses.
i. Refer to Section 5-4 Marine Loading Arms for inspection and maintenance
requirements of petroleum fuel marine loading arms.
j. Refer to Section 9-1.6 Grounding Systems for inspection and maintenance
requirements of grounding systems.

5-4 MARINE LOADING ARMS.

\1\
a. Marine loading arms are used to connect shore based petroleum fuel
receipt and issues systems to marine barges and tankers.
b. The swivel, or swing joint attaching the arm to supply piping can be a
source of leaks, especially if the arm is subject to stress when attached to
the vessel. A program of periodic lubrication and inspection will ensure
longer swivel life. If seals leak in spite of lubrication and seal replacement,
complete refurbishment of the swivel may be required and the reason for
the recurring failures should be identified. Non-lubricated swivels should
not be lubricated.

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c. A common cause of failure is inadequate support for the arm. Fully

stocked kits are available to complete seal or joint renewal. Non-
lubricated type swivels must be refurbished or replaced by the original
equipment manufacturer.
d. Additional information pertinent to loading arms can be found in UFC 3-
460-01 Section 5-8.a.
/1/

5-4.1 Inspection and Maintenance – Marine Loading Arms.

Signs of leaking lubricant or grease contaminated with fuel are clear signs of swivel joint
failure. Refer to the manufacturer’s operation and maintenance manual for specific
maintenance procedures and schedules and follow applicable general maintenance
requirements.

a. Check swivel for smooth operation. Check seals for signs of wear and
discoloration which may indicate a seal or ball bearing failure.
Frequency: Quarterly
b. Inspect ball bearings when accessible. Rough and/or uneven wear on the
surface are indications of swivel joint failure.
Frequency: Annually
c. Conduct pressure test of marine loading arms in accordance with 33 CFR
156.170 Equipment Tests and Inspections, Section (f)(1).
Frequency: Annually

5-5 MARINE AND UNDERWATER HOSES.

5-5.1 Marine Transfer Hoses.

\1\
a. Many fueling operations are completed between piers and smaller vessels
with non-buoyant hoses because the distance between the vessel and
pier is minimal, and because the fuel hose will never touch the water
during these fueling operations. Hose sizes can range from 2 to 6 inches
(50 to 150 mm) in diameter and range in length from 25 to 100 feet (7.5 to
30.5 meters). These hoses are used to issue and receive petroleum
products. The hoses must meet the requirements of 33 CFR 154.500.
b. In some cases floating hoses are used to attach between shore-based
facilities and marine barges and tankers. Floatation buoyancy is typically
built into the petroleum fuel hose string components, but it can also be
externally attached. Hose strings are made up of 30 to 40-foot (9 to 12 m)
long sections of individual hose lengths bolted together by steel flanges
built into the ends of each floating hose. Each hose connection should

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have a drain connection on the marine barge or tanker side of the block
valve.
c. Floating petroleum fuel hose diameters are standardized, in accordance
with Oil Companies International Marine Forum (OCIMF) best practices,
and range from 6-inch (DN150) to a maximum of 24-inch (DN600) internal
diameter. The hose string length is determined by mooring equipment,
marine barge or tanker size, and manifold location. Floating petroleum fuel
hose strings will typically end in a blind flange that must be removed by
the marine barge or tanker crew before the petroleum fuel hose can be
connected to the marine barge or tanker. Floating petroleum fuel hose
strings include a pick-up line which is attached to the marine barge or
tanker end of the petroleum fuel hose. This pick-up line is used to bring
the petroleum fuel hose onto the marine barge or tanker and is connected
to a marker buoy which makes the free end of the petroleum fuel hose
pick-up line easier to locate.

/1/

5-5.1.1 Inspection and Maintenance – Marine Transfer Hoses.

a. Visually inspect petroleum fuel marine transfer hoses. Transfer hoses

must have no loose covers, kinks, bulges, soft spots, and no gouges, cuts
or slashes that penetrate the hose reinforcement. Hoses must also have
no external deterioration.
Frequency: Before each use
b. Visually survey petroleum fuel marine hoses. Observe the general
condition and look for fluid puddles, fine mists, physical damage such as
jacket abrasion or deformation, and deteriorated joints. Use sense of smell
to detect petroleum vapor. Look for improper hose handling that may
overstress the hose by stretching, relative movement, or kinking.
Frequency: During each use
c. Refer to Appendix D, Section D-2.2 Marine and Underwater Transfer Hose
Hydrostatic Test for marine transfer hose hydrostatic testing requirements
and procedures.
Frequency: Annually or not less than 30 days prior to the first
transfer conducted past one year from the date of the last test and
inspection.

5-5.2 Underwater Hoses.

Underwater petroleum fuel hoses are similar in construction to petroleum fuel marine
transfer hoses but may have additional chafing gear covering some sections. External
reinforcements may also be added to prevent kinking due to tidal motion when they are
used in petroleum fuel transfer service in offshore moorings. Experience has shown that
some sections of the underwater hose consistently wear more than others. Hose life

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can be extended by periodically changing the position of individual sections in the hose
string. Ensure that the proper stainless steel bolts and Monel nuts are used to
reassemble the string.

5-5.2.1 Inspection and Maintenance – Underwater Hoses.

It is recommended that, when equipment is available to lift buoys, anchors, chains, and
other offshore mooring equipment, an effort be made to schedule hose inspection and
testing concurrently, regardless of the duration since the last test. Work on the mooring
systems can cause additional strain and wear on hoses.

a. Refer to Appendix D, Section D-2.2 Marine and Underwater Transfer Hose

Hydrostatic Test for underwater hose hydrostatic testing requirements and
procedures.
Frequency: Annually or not less than 30 days prior to the first
transfer conducted past one year from the date of the last test and
inspection.

5-6 DISPENSERS.

Dispenser systems located at marine facilities are similar to military service station type
dispensers and typically include hose reels to refuel various types of watercraft. Hoses
are routinely pulled across concrete and other abrasive surfaces that can cause
damage to hoses. Automatic nozzle shut-off clips must be removed from marine fuel
dispensing nozzles.

5-6.1 Inspection and Maintenance – Dispensers.

a. Refer to Section 7-2 Dispenser Nozzles for inspections and maintenance

of requirements of dispenser nozzles.
b. Refer to Section 7-3 Dispenser Hoses for inspections and maintenance
requirements of dispenser hoses.
c. Refer to Section 7-4 Breakaways for inspections and maintenance
requirements of dispenser hose breakaways.
d. Refer to Section 7-5 Swivels for inspections and maintenance
requirements of dispenser hose swivels.
e. Refer to Section 7-8 Dispenser Meters for inspections and maintenance
requirements of dispenser meters.
f. Refer to Section 7-9 Dispenser Filters for inspections and maintenance
requirements of dispenser filters.
g. Refer to Section 7-10 Dispenser Strainers for inspections and
maintenance requirements of dispenser strainers.

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h. Refer to Section 7-12 Emergency Shutoff Valves for inspections and

maintenance requirements of emergency shutoff valves installed in the
petroleum fuel supply line at the base of dispensers.
i. Refer to Section 7-15 Dispenser Pumps for inspections and maintenance
requirements of dispenser pumps.

5-7 OFFSHORE MOORING SYSTEMS.

Offshore moorings designed in accordance with UFC 4-159-03 are located out of
navigable shipping lanes with necessary anchorage suitable for holding specific
capacity marine tankers. Typically a single steel pipeline connected to the shore
petroleum fuel storage system extends underwater from the shore to the area of the
mooring. This pipeline is used to handle all petroleum fuel products. Underwater
petroleum fuel hose, flanged to the underwater pipeline provides a flexible connection to
marine tankers. The mooring anchors installed for marine tankers are marked with
buoys. The underwater petroleum fuel hose is equipped with a spool piece and a chain
at the marine tanker end. The chain is connected to a marker buoy and is used to lift the
petroleum fuel hose from the sea bottom for connection to the marine tanker.

Inspection and maintenance of offshore mooring systems focuses on buoy coatings,

anchors, and chains. Cathodic protection systems are used to protect the anchors and
chains and require routine inspection and replacement of sacrificial anodes.

5-7.1 Single Point Mooring Systems.

Single point moorings (monobuoys) consist of a single buoy. The buoy is attached to
marine tankers by means of bow lines or anchor chain. The ship is free to swing 360
degrees around the buoy as it responds to environmental loading conditions (weather
vane). This type of mooring may use either a riser or non-riser buoy system.

A diesel engine-driven air compressor is located in the interior of the buoy; its purpose
is to provide compressed air displacement for the float/sink hoses. The product hoses
are packed at all times, either with petroleum product or water, depending on the
operational requirements.

5-7.1.1 Inspection and Maintenance – Single Point Mooring Systems.

\2\ Refer to UFC 4-159-03 for frequencies of inspection and additional maintenance
required for mooring systems. /2/ Required underwater inspections and testing must be
performed by experienced professional divers.

a. Inspect and, if necessary, repair or replace all mooring hawsers or lines,

deck hose, chain, chair stoppers, flange adaptors, gaskets or other gear
used in mooring the marine tanker and in connecting hoses.
Frequency: Monthly

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b. Inspect air-compressor for proper operation.

Frequency: Annually
c. \2\ Inspect navigation aids and mooring buoys in accordance with
UFC 4-159-03 for evidence of damage and possible movement or
dragging by marine tankers, current or winds. /2/
Frequency: Annually
d. Divers must conduct underwater inspections of mooring chains, shackles
and anchors attaching buoys to bay/harbor floors.
Frequency: Annually
e. Conduct overhaul of single point mooring buoys every 3 to 5 years. Single
point mooring buoys must be brought ashore for repair in these instances.
Frequency: Every 5 years

Figure 5-1 Single Point Mooring System

5-7.2 Multi-point Mooring Systems.

Multi-point moorings are designed for use by a single ship secured by its bow and stern
lines to buoy systems. This mooring is normally installed near a shoreline, parallel to the
direction of water current, and outside the normal navigational channel. Riser buoy
systems are normally used in this type of mooring.

5-7.2.1 Inspection and Maintenance – Multi-point Mooring Systems.

\2\ Refer to UFC 4-159-03 for frequencies of inspection and additional maintenance
required for mooring systems. /2/ Required underwater inspections and testing must be
performed by experienced professional divers.

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a. Inspect and, if necessary, repair or replace all mooring hawsers or lines,

deck hose, chain, chair stoppers, flange adaptors, gaskets or other deck
gear used in mooring the marine tanker and in connecting underwater
hoses.
Frequency: Monthly
b. Inspect navigation aids and mooring buoys, in accordance with NAVFAC
MO- for evidence of damage and possible movement or dragging by
marine tanker, current or winds.
Frequency: Annually
c. Divers must conduct underwater inspections of mooring chains, shackles
and anchors attaching buoys to bay/harbor floors.
Frequency: Annually

5-8 SUBMERGED PIPING SYSTEMS.

Submerged piping is used to connect shore based petroleum fuel systems to mooring
locations of marine tankers. A hose is typically installed to connect the submerged
piping to the moored marine tanker.

5-8.1 Inspection and Maintenance – Submerged Pipelines.

Required underwater inspections and testing must be performed by experienced

professional divers.

a. Inspect water above submerged pipelines and their seaward end for tell-
tale petroleum fuel slicks indicating leakage from pipes or underwater
hoses.
Frequency: Weekly
b. If equipped, electrically check the cathodic protection rectifier for proper
performance.
Frequency: Six times each calendar year with intervals not
exceeding 2½ months.
c. Divers must inspect submerged pipe and hoses for signs of incipient
failure or indications of rapid wear of parts subject to wave motion or
abrasion on the ocean floor.
Frequency: Semi-annually
d. Conduct annual pipe test as specified in Appendix G – Petroleum Fuel
Pipeline Pressure testing Guidelines and Criteria. Testing requirements of
marine pipelines are regulated under 33 CFR 154 and 156, particularly 33
CFR 156 Section 170.
Frequency: Annually
e. Conduct cathodic protection tests on the protected pipeline as specified in
Section 9.2.1 Cathodic Protection at least once each calendar year with

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intervals not exceeding 15 months between tests from consecutive years.

Frequency: Annually

5-9 BOOM REELS.

Boom reels are hydraulic or manually operated. They are used to store floating spill
containment booms that are used to surround marine barges and tankers and contain
spills.

5-9.1 Inspection and Maintenance – Boom Reels.

a. Visually inspect hydraulic drives and hose connections for leaks.

Frequency: Quarterly
b. Grease bearings.
Frequency: Quarterly
c. Inspected boom reel for signs of corrosion. Inspect breaking system and
ensure it is in good working order.
Frequency: Quarterly
d. Inspect boom for wear, rips, and tears. Repair or replace as required to
ensure containment of petroleum fuel in the event of a spill.
Frequency: Annually

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CHAPTER 6 PIPING SYSTEMS

6-1 PIPE TESTING AND INSPECTIONS.

This chapter includes information on testing and inspection requirements of pipelines

and piping.

6-1.1 On-Base Pipelines.

On-base pipelines are routed exclusively within an Installation’s property and do not
pass outside of Installation boundaries. The pipelines are not regulated by the
Department of Transportation (DOT). Where more than one type of petroleum fuel is
transferred, separate pipelines are typically provided for each type of petroleum fuel.
These pipelines include transfer lines between petroleum fuel truck and rail offloading
and storage tanks, pump houses and petroleum fuel truck and rail loading systems,
transfer lines between storage areas, and hydrant supply and return lines.

6-1.1.1 Inspection and Maintenance – On-Base Pipelines.

a. Conduct petroleum fuel pipeline visual Inspection of aboveground piping in

accordance with Section 6-1.5 Pipeline Visual Inspection.
Frequency: Monthly
b. Conduct line walk in areas of petroleum fuel piping in accordance with
Section 6-1.6 Line Walk.
Frequency: Conduct during transfer operations, or monthly, at a
minimum.
c. Conduct annual test as specified in Appendix G – Petroleum Fuel Pipeline
Pressure Testing Guidelines and Criteria.
Frequency: Annually
d. Conduct cathodic protection tests as specified in Section 9.2.1 Cathodic
Protection on protected petroleum fuel pipelines at least once each
calendar year, but with intervals not exceeding 15 months.
Frequency: Annually
e. Conduct five year test as specified in Appendix G – Petroleum Fuel
Pipeline Pressure Testing Guidelines and Criteria.
Frequency: Every 5 years
f. Conduct petroleum fuel pipeline API 570 inspection in accordance with
Section 6-1.9 API 570 Inspections.
Frequency: Every 5 or 10 years depending on API class piping or in
accordance with Pipeline Integrity Management Plan (PIMP).
g. Conduct petroleum fuel pipeline cleaning in accordance with Section 6-2
General Pipeline Cleaning.
Frequency: As required to ensure fuel quality.

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6-1.2 Inter-Terminal Pipelines.

\1\
a. Inter-terminal petroleum fuel pipelines which cross outside of an
Installation’s property for more than one mile and are operated by non-
government personnel are regulated by the DOT. Operation and
maintenance of DOT regulated pipelines must comply with 49 CFR 195.
Inter-terminal pipelines which cross outside of an Installation’s property for
more than one mile and are operated by government personnel are
currently exempt from 49 CFR 195 requirements. Although government
operated pipelines are not subject to DOT regulations, certain states may
regulate or force an activity to adhere to a standard such as 49 CFR 195.
b. Inter-terminal pipelines supplying petroleum fuels to DoD petroleum fuel
facilities may be dedicated to serving a single facility or may handle
several types or grades of petroleum fuel for more than one user. These
pipelines may be owned, operated, and maintained by DoD or commercial
agencies; however, only those operated by contractors or non-government
entities are potentially DOT regulated.
c. Inter-terminal pipelines owned, operated, and maintained by commercial
agencies delivering petroleum fuel to DoD petroleum fuel facilities may be
constructed on DoD property in order for the inter-terminal pipelines to
reach the DoD petroleum fuel facilities located on DoD property.
Responsibility of commercial agencies for maintaining inter-terminal
pipelines owned and operated by commercial agencies usually terminates
at the custody transfer point located on the DoD Installation. The custody
transfer point is typically located close to the location where the
commercial inter-terminal pipeline crosses into the Installation and is
usually demarcated by a custody transfer valve.
d. In some cases supplier and operator contracts allow the responsible
Installation activity to perform emergency maintenance on on-base
segments of commercial inter-terminal pipelines, if necessary, to protect
against environmental damage to public property or meet emergency
wartime mission requirements.
/1/

6-1.2.1 Inspection and Maintenance – Non-DOT Regulated Inter-Terminal

Pipelines (Operated by DoD).

a. Conduct petroleum fuel pipeline volume check in accordance with Section

6-1.8 Volume Check.
Frequency: Monthly

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b. Conduct line patrol in areas of underground petroleum fuel pipeline in

accordance with Section 6-1.7 Line Patrol.
Frequency: Annually
c. Government operated inter-terminal petroleum fuel pipelines must follow
the maintenance requirements listed in Section 6-1.1.1 On-Base
Pipelines.

6-1.2.2 Inspection and Maintenance – DOT Regulated Inter-Terminal

Pipelines.

DOT regulated petroleum fuel pipelines must be maintained and operated in

accordance with the provisions of 49 CFR 195. This includes but is not limited to O&M
Plans, Integrity Management Plans, and Operator Qualification Plans, which are outside
the scope of this document.

6-1.3 Aboveground Piping.

Aboveground piping includes visible piping installed outside and inside of buildings.
This piping is supported on aboveground pipe supports or in open trenches or trenches
with removable covers.

6-1.3.1 Inspection and Maintenance – Aboveground Piping.

a. Conduct petroleum fuel piping visual Inspection in accordance with

Section 6-1.5 Pipeline Visual Inspection.
Frequency: Weekly
b. Conduct petroleum fuel piping annual test as specified in Appendix G –
Petroleum Fuel Pipeline Pressure Testing Guidelines and Criteria.
Frequency: Annually
c. Conduct petroleum fuel piping API 570 inspection in accordance with
Section 6-1.9 API 570 Inspections.
Frequency: Every 5 or 10 years depending on API class piping or in
accordance with Pipeline Integrity Management Plan (PIMP).
d. Conduct cleaning of petroleum fuel piping in accordance with Section 6-2
General Pipeline Cleaning.
Frequency: As required to ensure fuel quality.

6-1.4 Double-Wall Piping.

Double-wall piping is required by some states or host nations. In the event that the
carrier pipe develops a leak, there are techniques for detecting the presence of fuel in
the interstitial space of the double-wall piping. See Section 6-13.1 General Inspection of
Release Detection Systems for more information on systems used for monitoring the
interstitial space.

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6-1.4.1 Inspection and Maintenance – Double-Wall Piping.

a. Conduct petroleum fuel pipeline visual Inspection of aboveground piping in

accordance with Section 6-1.5 Pipeline Visual Inspection.
Frequency: Monthly
b. Conduct line walk in areas of petroleum fuel piping in accordance with
Section 6-1.6 Line Walk.
Frequency: Conduct during transfer operations, or monthly, at a
minimum.
c. Conduct annual carrier pipe test as specified in Appendix G – Petroleum
Fuel Pipeline Pressure Testing Guidelines and Criteria.
Frequency: Annually
d. Conduct cathodic protection tests as specified in Section 9.2.1 Cathodic
Protection on protected petroleum fuel pipelines at least once each
calendar year, but with intervals not exceeding 15 months.
Frequency: Annually
e. Conduct containment pipe test as specified in Appendix G – Petroleum
Fuel Pipeline Pressure Testing Guidelines and Criteria.
Frequency: Every three years
f. Conduct petroleum fuel pipeline API 570 inspection in accordance with
Section 6-1.9 API 570 Inspections.
Frequency: Every 5 or 10 years depending on API class piping or in
accordance with Pipeline Integrity Management Plan (PIMP).
g. Conduct petroleum fuel pipeline cleaning in accordance with Section 6-2
General Pipeline Cleaning.
Frequency: As required to ensure fuel quality.

6-1.5 Pipe Visual Inspection.

Visually inspect aboveground petroleum fuel piping for leaks (e.g., drips, mist spray).
Repair identified leaks. Some leaks can be repaired by replacing or repairing
mechanical components. Other leaks will require welding of the pipe for permanent
repair. Approval through local work management processes is required before
beginning welding or hot work in connection with repairs. The following list is a baseline
for petroleum fuel pipeline operability:

a. Visually inspect piping and coatings for signs of corrosion or damage.

Schedule maintenance or repair as necessary.
b. Inspect flanges and gaskets.
c. Inspect pipe supports to ensure pipe is properly supported without binding,
misalignment, or tipping. Ensure insulating or sliding material between the

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supports and piping is securely fastened and not missing or deteriorated.

Ensure contact points between support and pipe are not corroded.
d. Inspect pipe support anchor bolts and grout for signs of cracking,
corrosion, or missing fasteners. Repair as required.
e. Visually inspect expansion bellows for cracks, tears, leaks, or
misalignments. Expansion bellows cannot be repaired and must be
replaced if damaged.
f. Inspect braided hoses and vibration dampeners for wear and damage to
braiding. Also check for compression or tension that could indicate
improper loading on the hose or dampener.
g. Visually inspect grounding wires and connection points between pipes and
grounding rods.

6-1.6 Line Walk.

Line walkers or vehicle patrols must make detailed inspections of area conditions
around aboveground petroleum fuel piping and above underground petroleum fuel
piping. Inspections must include general condition of the right-of-way, valves in remote
areas, and conditions that may indicate a leak. Leaks in underground pipelines can be
detected by fuel surfacing on the ground, fuel runoff in storm drainage systems, fuel in
underground pits or manholes, dead vegetation, or the continuous odor of fuel in a
particular area. Investigate suspicious circumstances.

Inspections of DOT regulated petroleum fuel pipelines must be in accordance with 49

CFR 195, Subpart F, Section 195.402 , which requires inspections of right-of-way
conditions at intervals not exceeding 3 weeks, but at least 26 times each calendar year.

6-1.7 Line Patrol.

Line patrols should occur on sections of petroleum fuel pipelines not easily accessible
by vehicle or foot. Line patrols are conducted by observations from aircraft. Line patrols
should be flown at an elevation of less than 500 feet (152 meters) from the ground and
at speeds from 65 to 80 miles per hour (105 to 130 kilometers per hour). Petroleum fuel
pipelines must be marked with posts or signs at 1 mile (1.6 kilometer) intervals and at
bends. During line patrols the pilot acts as an observer who checks for unnatural
changes in vegetation color and oil slicks on lakes and streams, which are evidence of
leaking petroleum fuel pipelines; area construction work (e.g., roads, sewers) that could
cross and possibly damage the petroleum fuel pipeline; and the overall condition of the
right-of-way.

6-1.8 Volume Check.

Compare records kept on volume and temperature of petroleum fuel that has passed
through each pumping station. Differences in meter readings not accounted for by

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temperature corrections between two stations may indicate a leak, but could also
indicate theft, out-of-calibration meters, faulty temperature sensors, or human error.

6-1.9 API 570 Inspections.

Periodic inspections by an API 570 certified inspector must provide documentation of

remaining pipeline life; recommended repairs; and/or need for replacement. Intervals for
inspection are based on the class of piping and corrosion rate of the piping.

• Class 1: Over water – 5 years maximum.

• Class 2: Natural Gas – 10 years maximum.
• Class 3: Aboveground and underground petroleum fuel piping – 10 years
maximum.

6-2 GENERAL PIPELINE CLEANING.

Petroleum fuel pipelines designed as suitable for pigging may be cleaned using various
cleaning pigs. Intervals between cleanings are based on site conditions and the type of
petroleum fuel. A drop in the flow rate; the continual presence of dirt, rust, or particulate
in basket strainers; and/or shortened filter life may indicate a need for cleaning.

6-2.1 Cleaning Operations.

\1\
a. Decide on the cleaning tool best suited for the pipe system and operation.
For most petroleum fuel applications, a foam pig may be sufficient. For
heavier petroleum fuel applications, or extensive cleaning requirements,
brush and magnet pigs may be required. Verify operational specifications
to be sure the pig will pass through all valves and bends.
b. Keep accurate time records of run start and quantity of petroleum fuel
pumped to trace pig progress and determine its arrival at the receiving
station. Meters must be bypassed during cleaning operations to avoid
fouling. Cleaning pigs must be run at the manufacturer’s suggested
minimum velocity with no shutdowns while the pig is in the line.
Shutdowns cause debris to settle in front of the pig and may cause it to
become stuck.
c. Pigging operations may produce debris in the pipe system and extensive
flushing and filtering should be performed once a pigging operation is
completed. Flushing and filtering should be continued until all debris is
removed from the pipe system.

6-3 PIPE SYSTEM REPAIRS.

a. Temporary repairs are defined as repairs made to piping systems that

restore sufficient integrity to continue safe operation until permanent

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repairs can be scheduled and accomplished. The military service-specific

SCP must be notified of temporary repairs and must have jurisdiction on
how long a temporary repair may stay in place. The military service-
specific SCP may require increased inspection while temporary repairs
are in place.
b. Permanent repairs generally require planning and potentially welding or
patching of the pipeline. Approvals through local work management
processes are required before beginning welding or hot work in
connection with repairs. All welding pipe repairs must meet the
requirements of UFGS \1\33 52 23.15/1/ including documentation of
welding procedures and welder qualifications before welding repairs are
conducted.
c. Pipeline failures can create a welding safety hazard due to fuel-soaked
soil in the area of the leak. Temporary pipeline repairs can be
accomplished by clamping a steel plate of the same curvature as the pipe
over the damaged area (i.e., clockspring repair) and using petroleum-
resistant rubber, epoxy compounds, or gaskets for a seal. Once a
temporary repair is in place, the area should be cleared of hazards.
Permanent repairs may require replacement of failed sections.
/1/

6-3.1 Pits and Small Leaks.

Pitting on pipeline exterior surface is caused by corrosion and can lead to pipeline
failure. Pitting can be repaired in a number of ways, but severe pitting must be repaired
by either a patch plate or pipe replacement. In some cases, a full encirclement sleeve
should be considered. All pipeline welded repairs must meet the requirements of UFGS
\1\ 33 52 23.15 /1/ including documentation of welding procedures and welder
qualifications before welding repairs are conducted.

6-4 PIPELINE INTEGRITY MANAGEMENT PLAN.

Each petroleum fuel pipeline facility should have a Pipeline Integrity Management Plan
(PIMP) to assist with and guide pipeline integrity maintenance. PIMPs improve the
integrity management of piping systems and help prevent leaks or pipeline failures. The
plans are developed based on the principles of API Standard 570 Federal, state, host
nation, and local codes and regulations.

\1\
6-4.1 Certified Pipeline Inventory.

DLA-E requires that a fuel system volume be calculated using as-constructed pipe
lengths, internal diameters, fittings, and components of a system; i.e., all items
containing fuel with the exception of tanks. If the inventory does not exist, record and

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provide a detailed list with sizes, lengths, quantity, and volumes for each of the systems
inspected or repaired. /1/

6-5 FLANGE GASKETS.

When installing a gasket, measure the gap between the flanges to ensure consistent
dimensions around the circumference of the connection. The faces of each flange must
be inspected for scratches, burs, or other signs of damage before gaskets are installed.
Pipe can expand and contract during temperature changes and gaskets should be
replaced during consistent temperature conditions.

6-6 VALVES.

6-6.1 Valve Tagging.

\1\ Mark valves, pumps, meters, and other system components with easily discernible
painted numbers or numbered corrosion-resistant metal or plastic tags attached with a
suitable fastener. Ensure numbers correspond to those on the schematic flow diagrams
and other drawings for the installation. /1/

6-6.2 Manual Valves.

Manual valves are used to isolate portions of fuel systems and equipment, to control
flow, or to direct the flow of fuel to a desired location.

6-6.2.1 Plug Valves – Lubricated.

Lubricated plug valves are not allowed in aircraft petroleum fuel systems and must be
replaced. If lubricated plug valves are installed in other systems and cannot be
replaced, they must be inspected regularly for proper operation.

Lubricated plug valves require lubrication and occasional flushing to keep them working
properly. The valves require lubrication through a grease fitting on top of the valve that
forces grease into feed channels within the valve plug. The plug is lubricated so that it
passes freely over the seats without binding.

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Figure 6-1 Lubricated Plug Valve

6-6.2.1.1 Inspection and Maintenance – Plug Valves – Lubricated.

a. Open and close valve to check for ease of operation.

Frequency Quarterly
b. Lubricate valve operator stems and grease fittings.
Frequency: Semi-annually
c. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Semi-annually

6-6.2.2 Plug Valves – Non-lubricated.

Non-lubricated plug valves use cylindrical or conically shaped plugs that are rotated
within the valve body. They are used as block valves, or where shut-off is required in
various parts of the system. Plug valves can be either reduced port or full port
depending on the location.

6-6.2.2.1 Inspection and Maintenance – Plug Valves – Non-Lubricated.

a. Open and close valve to check for ease of operation. Adjust or replace
packing as needed.
Frequency Quarterly
b. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Semi-annually

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6-6.2.3 Gate Valves.

A gate valve is equipped with a round or rectangular wedge that is lifted out of the path
of fluid to allow flow, and lowered back to its seat to block flow. Gate valves are not
designed for throttling. They are designed to be either fully open or fully closed. Gate
valves are either of the rising stem type, to visually see that the gate is opening or
closing as the stem rises and falls; or of the non-rising stem type, where the hand wheel
is fixed and the stem threads are internal to the valve. Rising stem gate valves are
preferred in order to keep the stem threads out of the fluid. Gate valves should be
equipped with a stem position indicator to indicate the open or closed position. Gate
valves are equipped with a bonnet to ensure leak-proof closure of the valve body and
are equipped with a valve stem packing tightening mechanism.

Figure 6-2 Gate Valve

6-6.2.3.1 Inspection and Maintenance – Gate Valves.

a. Open and close valve to check for ease of operation. Adjust or replace
packing as needed.
Frequency Quarterly
b. Lubricate valve operator stem.
Frequency: Semi-annually

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c. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Semi-annually

6-6.2.4 Ball Valves.

Figure 6-3 Ball Valve

Ball valves are used as quick shut-off (block) valves in applications such as piping to
hydrant outlets, between pumps and headers, and between pumps and filter separators.
They are quarter turn, 0 to 90 degree, open to close type valves consisting of a solid
metal ball with either reduced or full port, usually of stainless steel, and
tetraflouroethylene (TFE) or fluoroelastetomer (FKM, commonly referred to as Viton)
seats, body seals and stem seals. When the valve ball is in its open position (0
degrees) flow is through the open port. When the valve is in its closed position the port
is 90 degrees perpendicular to the flow, allowing no flow through the valve. The valves
are lever operated or gear operated, depending on the size.

6-6.2.4.1 Inspection and Maintenance – Ball Valves.

a. Open and close valve to check for ease of operation.

Frequency Quarterly
b. Lubricate overhead valve chain operator gears.
Frequency: Quarterly

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c. Adjust packing per manufacturer’s specifications as needed.

Frequency: Quarterly
d. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Quarterly
e. Refer to Section 6-6.2.10 Manual Valve Gear Operators for inspection and
maintenance of gear operators if equipped.

6-6.2.5 Double Block and Bleed Valves.

Double block and bleed (DBB) valves provide positive shutoff that can be verified by
opening the cavity between the two blocks. They are used as positive isolation valves
around tanks and in piping runs. They comply with API Specification 6D. Refer to UFC
3-460-01 for recommended locations.

DBB valves can be plug, ball, or gate type, and reduced or full port depending on the
location. Typically reduced port plug type DBB valves are used around tanks and in
piping systems that do not require periodic pigging. Full port ball DBB valves are
required in pipelines that require pigging.

a. Plug type DBB valves are equipped with non-lubricated, resilient, double-
seated, trunnion-mounted, tapered lift plugs capable of two-way shutoff.
The tapered plug is usually of ductile iron with chrome or nickel plating
with the plug supported on upper and lower trunnions. Sealing slips are
usually of steel or ductile iron with Viton seals which are held in place by
dovetail connections. The sealing slips are removable and replaceable
from the bottom of the valve while the valve is mounted in the pipeline in
the open position. The valve hand wheel operates the valve from fully
closed to fully open by first lifting the plug off the seats and then turning
the plug so that the valve is in the fully open position.
b. Ball type DBB valves are equipped with non-lubricated, trunnion-mounted
independent spring and hydraulically actuated, floating, single piston
effect, self-relieving seat rings with bi-directional sealing. The ball is solid
with a flow through conduit opening, suitable for the passage of pipeline
pigs. The stems are anti-static, blow-out-proof design with O-ring seals
and are provided with an emergency sealant injection fitting. The valves
are 3-piece, bolted body design with flanged connections and are
equipped with body drain, bleed valve and vent fitting.
c. Gate type DBB valves, when applicable per UFC 3-460-01 are non-
lubricated with a bolted bonnet using an expanding gate which does not
require pressure to produce a proper two-way seal. These valves are
intended for fully open or fully closed operation and must not be used to
throttle. The gate segments are usually of ductile iron with chrome or
nickel plating. The hand wheel operates the valve from fully open to fully

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closed by moving the expanding gate into position then wedging the
segments against the seats. The valves use flanged connections and are
equipped with a body drain, bleed valve and vent fitting.

Figure 6-4 Double Block and Bleed Plug Valve

6-6.2.5.1 Inspection and Maintenance – DBB Valves.

Refer to valve manufacturer’s operation and maintenance manual for disassembly,

parts, additional maintenance for specific models, reassembly parts, and repair of DBB
valves.

a. Open and close valve to check for ease of operation.

Frequency Quarterly
b. Lubricate overhead valve chain operator gears if equipped.
Frequency: Quarterly
c. Adjust packing per manufacturer’s specifications as needed.
Frequency: Quarterly
d. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Quarterly

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e. Operate the body cavity drain when the valve is in the closed position to
ensure that the valve is closing properly.
Frequency: Quarterly
\1\
f. Keep the valve operator housing full of lubricant to displace and prevent
moisture from accumulating and freezing, in accordance with
manufacturer’s recommendations.
Frequency: Semi-annually

g. Remove bottom drain plug and drain valve.

Frequency: Annually
h. Refer to Section 6-6.2.10 Manual Valve Gear Operators for inspection and
maintenance of gear operators if equipped.
i. Some double block and bleed valves are equipped with integrated
pressure/thermal relief valves. Refer to Section 6-6.3 Thermal and
Pressure Relief Valves for inspection and maintenance requirements of
pressure/thermal relief valves
/1/

6-6.2.6 Butterfly Valves.

\1\
a. UFC 3-460-01 does not allow butterfly valves to be used as isolation
valves in the construction of new petroleum fuel systems, as they are not
considered positive shut-off valves. However, UFC 3-460-01 does specify
that high-performance wafer trunnion butterfly type valves with synthetic
seating material and a metal-to-metal seat that comply with API Std 607,
equipped with a self-closing mechanism and a fusible link, must be used
in two locations on Army and Navy projects. These locations are the inlet
to truck fillstands, and on supply and return risers at aircraft direct fueling
stations.
b. A butterfly valve is a short face to face valve incorporating a trunnion
mounted flat disc that when closed is held tight against a synthetic seating
material. Butterfly valves meeting the requirements of API Std 607 include
a metal-to-metal seat as a back-up to the synthetic seat which enables the
valve to continue to block flow in the closed position if the synthetic seat is
burned out in a fire.
c. Butterfly valves are available in flanged, wafer, and lug style
configurations. The wafer configuration does not include flanges on the
valve body and fits between mating flanges installed in piping. A wafer
style valve is centered inside the flange bolts of mating flanges when
installed. Lug style valves include threaded lug bolts holes on the body of
the valve. A lug style valve can be bolted to mating flanges from either

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side. For example, a lug style butterfly valve can be used at the end of a
pipeline on a single mating pipe flange with the other end open, such as
on a drain line.
d. Existing butterfly valves installed in petroleum fuel systems must be
inspected and maintained.
/1/

6-6.2.6.1 Inspection and Maintenance – Butterfly Valves.

a. Open and close valve to check for ease of operation. Ensure that lever
operators and locking mechanisms are in place and working properly.
Frequency Quarterly
b. Adjust packing per manufacturer’s specifications as needed. If butterfly
valves are leaking or not shutting off flow, tightening the gland flange to
tighten the stem packing or remove the valve from service and replace the
seats as necessary.
Frequency: Quarterly
c. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Quarterly

Figure 6-5 Butterfly Valve

6-6.2.7 Globe Valves.

Globe valves are used for isolation and throttling purposes. Hand wheel operated globe
valves consist of a disc that is tightened via the hand wheel against a seat. These
valves are equipped with a gland seal mechanism to seal the packing against the valve
stem. The valve stem packing is accessible through a gland seal on top of the valve,
and the valve seat is typically accessible through the valve bonnet.

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Figure 6-6 Globe Valve

6-6.2.7.1 Inspection and Maintenance – Globe Valves.

a. Open and close valve to check for ease of operation.

Frequency Quarterly
b. Adjust packing per manufacturer’s specifications as needed.
Frequency: Quarterly
c. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Quarterly

6-6.2.8 Check Valves.

Check valves are used to prevent backflow through pumps, branch lines, meters, or
other locations where reverse flow must be prevented. Check valves may be of the
swing disk, globe, dual plate hinged disk, spring-loaded poppet, ball, or diaphragm-
actuated types. Check valves require upstream pressure in order for the check valve
mechanism to close. Check valves must conform to API Specification 6D.

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Figure 6-7 Check Valve

6-6.2.8.1 Inspection and Maintenance – Check Valves.

Refer to the particular check valve manufacturer’s operation and maintenance manual
for additional maintenance and parts.

a. Use external test lever to make sure the valve is not sticking if equipped.
If a check valve is suspected of not checking and cannot be serviced in
place, it must be removed from the piping system and serviced in a shop.
Frequency: Quarterly
b. Inspect valve exterior for corrosion and tightness of bolts. Repaint and
retighten as required.
Frequency: Quarterly

6-6.2.9 Line Blanks, Ring Spacers, and Spectacle Blinds.

\1\
a. A line blank is a flat plate designed to fit between two flanges as an
isolation device. They are designed to fit between flanges inside the bolt
circle with gaskets on either side. For example, blanks may be used at
tank connections to isolate a tank from an active system while the tank is
being cleaned or inspected. Line blanks are equipped with a handle that
protrudes between flange bolts and is visible when it is installed. The
handle should be stamped with information about the design of the blank.
These are often referred to as blinds or skillets.
b. A ring spacer is a metal ring with gasket seating surfaces with an inner
open hole matching the inner diameter of the pipe flanges where it is
installed. Ring spacers are used to allow flow in a location where a blank
may be installed to block flow. The ring spacer and the associated blank
should have the same take-out dimensions and both should fit in the gap
installed between the associated pipe flanges. Ring spacers should be
equipped with a handle that protrudes between flange bolts and is visible

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when it is installed. The handle should be stamped with information about

the design of the ring spacer.
c. Spectacle blinds include a blank and a ring spacer in one unit. They look
like a pair of round eye glasses with one side open to flow and one side
blanked off to prevent flow. These allow a line to be drained and the
spectacle blind to be flipped to allow flow or provide isolation.
/1/

Figure 6-8 Line Blank

Figure 6-9 Ring Spacer

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Figure 6-10 Spectacle Blind

6-6.2.9.1 Inspection and Maintenance – Line Blanks, Ring Spacers, and

Spectacle Blinds.

a. Inspect exposed side of spectacle blinds. The exposed side must be kept
clean and free of corrosion.
Frequency: Quarterly
b. Spectacle blinds should be inspected to ensure they are installed with the
correct orientation for the desired flow or no-flow condition.
Frequency: Quarterly

6-6.2.10 Manual Valve Gear Operators.

Gear operators are used to open and close large valves. Gear operators can be
installed on most types of large valves.

6-6.2.10.1 Inspection and Maintenance – Manual Valve Gear Operators.

a. Lubricate gear driven operators and check for smooth operation.

Frequency: Quarterly

6-6.3 Thermal and Pressure Relief Valves.

\1\
a. Thermal and pressure relief valves are used to relieve high pressures in
piping and system components. Thermal and pressure relief valves are
factory set to relieve at a specified pressure and are furnished with
certified test paperwork. Pressure relief valves are typically sized for an
operating pressure and a flow rate. The flow rate required for a pressure
relief valve will be dependent on the system that it is used to protect and
may be based on vessel size, vessel surface area, pump operating

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capacity, or piping flow rate. Thermal relief valves are typically only sized
for operating pressure and the flow rate is not specified.
b. Thermal relief valves are used to relieve relatively small volumes of fluid
from static or blocked-off systems that may develop high pressures do to
thermal heating of the petroleum fuel isolated in piping or a pressure vessel.
The coefficient of expansion of liquid petroleum fuel at 60 °F (16 °C) is
0.0005 gallon per gallon per degree F (0.0009 L per L per degree C). The
total volume generated in most cases is very small, but the pressure
increase resulting from this expansion can equate to as much as 75 psi
(515 kPa) for every degree rise in the fuel temperature if not relieved.
Therefore, it is absolutely essential that all closed systems have a pressure
relief bypass system (thermal release by-pass valve and or check valve).
Relieved fuel should be directed to a tank vented to atmosphere.
c. There are two primary types of thermal and pressure relief valves:
conventional and balanced type. Conventional spring-loaded relief valves
are affected by back pressure. For these valves an increase in
downstream back pressure is applied to the seating mechanism and
increases the valve opening relief pressure setting. Balanced relief valves
are designed so that the downstream back pressure is not applied to the
valve seating mechanism and the opening relief pressure setting is not
impacted by the back pressure.
d. Thermal and pressure relief valves must be replaced with models that
match the type, size, flow rate, and function of valves they are replacing.
/1/
Figure 6-11 Thermal and Pressure Relief Valve

6-6.3.1 Inspection and Maintenance – Thermal and Pressure Relief Valves.

a. Thermal and pressure relief valves must be inspected for signs of leak-by.
Inspect relief valves for leaks by visually inspecting downstream flow
indicators (if installed) for flow. If no flow indicators are installed listen for

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possible leaks. If suspect: isolate and test the relief valve; check opening
pressure; and verify re-seating. Malfunctioning valves must be repaired or
replaced.
Frequency: Monthly
b. Ensure manual isolation valves installed upstream and downstream of
thermal and pressure relief valves are open with valve handles removed,
wired open or locked.
Frequency: Monthly
c. Inspect exterior of thermal and pressure relief valves for corrosion.
Repaint as required. Information plates attached to thermal and pressure
relief valves must not be painted over.
Frequency: Quarterly
d. \2\ Visually inspect and verify thermal and pressure relief valve setting by
consulting as-built and historical data. /2/
Frequency: Annually
e. Thermal and pressure relief valves must be validated for proper calibration
by isolating the valve and using the test connection provided on the piping
in conjunction with a hand pump and portable reservoir. The operating
pressure must be checked against the set pressure listed on the stamped
information plate attached to the valve. The operating pressure must be
adjusted to the stamped set pressure if necessary. \1\ If there is no test
connection provided, isolate the relief valve and remove the valve to test.
If there is no valve isolation or test connection, consider adding these to
simplify future testing. /1/
Frequency: \2\ Test every five years /2/

6-6.4 Semi-Automatic Valves.

6-6.4.1 Fire Valves.

Fire valves are spring loaded to close in case of a fire to prevent fuel flow. The valves
usually incorporate a fusible link that holds the valve open until it melts at 165 °F (74 °C)
and allows the valve to close. Fusible link check valves are installed at some locations
to close against the flow of fuel when the fusible link melts.

Fire-safe ball valves are sometimes used with a fusible link and a spring actuated
closing mechanism.

6-6.4.1.1 Inspection and Maintenance – Fire Valves.

a. Ensure the fusible link mechanism is attached properly to actuate in case

of a fire and that it has not been by-passed, blocked, or damaged in any
manner. Ensure the fusible link is not filled with debris or paint which
could impact operation. \1\ Maintain fusible links per manufacturer’s

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recommendation. /1/
Frequency: Quarterly
b. Check the closing mechanism to ensure that it closes the valve properly.
Frequency: Annually

6-6.4.2 Fusible Link Butterfly Valves.

Fusible link butterfly valves must be fire rated for use on petroleum fuel systems.

6-6.4.2.1 Inspection and Maintenance - Fusible Link Butterfly Valves.

Fusible links are designed to yield under heat generated by a nearby fire. Once the
fusible link breaks a spring operated actuator closes the butterfly valve.

a. Ensure the fusible link mechanism is attached properly to actuate in case

of a fire and that it has not been by-passed, blocked, or damaged in any
manner. Ensure the fusible link is not filled with debris or paint which
could impact operation. \1\ Maintain fusible links per manufacturer’s
recommendation. /1/
Frequency: Quarterly
b. Test the operation of spring closure unit. Ensure that the spring actuator
closes the valve and that the valve closes securely against the seat.
Frequency: Annually
c. Refer to Section 6-6.2.6 Butterfly Valves for additional inspection and
maintenance requirements of butterfly valves.

6-6.5 Automatic Control Valves.

Automatic valves that meet the requirements of UFGS 33 52 43.14 are found
throughout fuel systems and are typically of the diaphragm actuated globe type design.
Flow through the valve can be either up and over the seat or under the seat and out,
depending on the configuration and function of the control valve. The diaphragm is
actuated by hydraulic pressure that forces the valve disc against the seat to close the
valve or to open or throttle the valve for flow control purposes. An orifice plate is
installed with the valve in some instances to control flow based on pressure differential.
In other cases a separate float mechanism is installed to actuate the valve, such as in
high-level shutoff valves. Almost all fuel control valves are installed in a fail-safe position
(i.e., if the main valve diaphragm ruptures the valve will close or open to a safe
operating position). Automatic valves can be installed in either a Normally Open (NO) or
Normally Closed (NC) position.

Due to the many types of diaphragm-operated automatic valves in service, it is best to

consult the particular valves schematic flow diagram and related parts list to understand
the parts involved and to maintain and troubleshoot the valve if service is needed.

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6-6.5.1 Truck Fill Valves.

Truck fill valves (TFV) meeting the requirements of UFGS 33 52 43.14 are used for
petroleum fuel truck loading. TFVs include a deadman feature that is used to start and
stop flow through the valve.

Figure 6-12 Truck Fill Valve

6-6.5.1.1 Inspection and Maintenance - Truck Fill Valves.

Deadman control is used to open and close TFVs on fillstands. Deadman controls may
be hydraulic or electric. If deadman control fails functional check, remove deadman
control from service and repair.

a. Verify TFV maintains 35 psig (240 kPa) nozzle pressure at a flow range of
50 to 600 gpm (3 to 38 lps).
Frequency: Quarterly
b. Verify TFV closes rapidly when outlet pressure exceeds control set point.
Frequency: Quarterly
c. Verify TFV opens when the deadman control lever is pressed.
Frequency: Quarterly
d. Verify TFV closes after the deadman control lever is released.
Frequency: Quarterly

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e. If equipped, verify operation of solenoid connected to grounding

verification system. Ground verification system should energize solenoid
when an acceptable ground is detected by the ground verification unit.
Frequency: Quarterly
f. Systems that have overflow protection systems must be inspected and
maintained concurrently with the inspection and maintenance of TFVs.
Frequency: Quarterly
g. Refer to Section 4-3.2.1 General System Control Valves for additional
inspection and maintenance requirements.

6-6.6 Motor Operators.

Motor operators provide electrical actuation of valves for open or closed service.

6-6.6.1 Inspection and Maintenance – Motor Operators.

Refer to the motor operator manufacturer’s operation and maintenance manual for
particular repair instructions and additional maintenance and parts.

a. Visually inspect motor operators to ensure smooth movement during

opening and closing operation and adjust, if necessary, to ensure that they
are opening and closing fully. Listen for and investigate unusual noises
during operation.
Frequency: Quarterly
b. Lubricate mechanical overrides (if equipped).
Frequency: Quarterly
c. Refer to Section 9-1.7 Electric Motors for inspection and maintenance
requirements of electric motors.

6-7 PRESSURE AND VACUUM INSTRUMENTATION.

6-7.1 Pressure and Pressure/Vacuum Gauges.

Round scale type pressure gauges are used to directly indicate line pressure. In some
cases these gauges are liquid filled with a silicon based oil.

6-7.1.1 Inspection and Maintenance – Pressure and Pressure/Vacuum

Gauges.

Refer to the manufacturer’s operation and maintenance manual for specific calibration
procedures.

a. Check operation of gauge. Ensure gauge is indicating pressure of the

system.
Frequency: Monthly

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b. Clean outside of gauge glass.

Frequency: Quarterly
c. Inspect liquid filled gauges for leakage, refill or replace as needed.
Frequency: Semi-annually
d. Conduct calibration check by comparing readings of the process gauge
with the readings of a certified master calibration gauge which has been
calibrated within the last year. The process gauge and the master
calibration gauge must be connected to the same pressure source for
testing. Verify accuracy of gauge is within ±2% of full scale. Calibrate
gauge if required.
Frequency: Annually

6-7.2 Differential Pressure Gauges.

Differential pressure gauges are used to measure the difference in pressure between
two sensing points.

6-7.2.1 Inspection and Maintenance - Differential Pressure Gauges.

Refer to the manufacturer’s operation and maintenance manual for specific calibration
procedures.

a. Verify proper operation of differential gauge in accordance with gauge

manufacturer’s procedures.
Frequency: Monthly
b. Clean outside of gauge glass.
Frequency: Quarterly
c. Conduct calibration check by comparing readings of the differential
process gauge with the readings of a certified differential master
calibration gauge which has been calibrated within the last year. The
differential process gauge and the differential master calibration gauge
must be connected to the same pressure source for testing. Verify
accuracy of gauge is within ±2% of full scale. Calibrate if required.
Frequency: Annually
d. Some differential pressure gauges have a small gauge protection filter
located at the high pressure inlet of the gauge that must be checked and
replaced as needed. Filters need to be replaced if the indicator is moving
slow or sluggishly inside the sight glass or if the sight glass is dirty. Refer
to manufacturer’s operation and maintenance manual for filter
replacement procedures.
Frequency: Annually for inspections and maximum 5 years of
service between filter replacements.

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6-7.3 Pressure Transmitters.

Pressure transmitters are used to measure pressure at sensing points. These units
transmit a 4 to 20 mA (common in US installations) or 0 to 20 mA (common in European
installations) electrical signal to a display or a PLC to indicate pressure.

6-7.3.1 Inspection and Maintenance - Pressure Transmitters.

a. Inspect the exterior of the transmitter enclosure for accumulated oil, dust,
and dirt. Clean if required.
Frequency: Quarterly
b. Check that both enclosure caps are fully threaded onto the enclosure,
compressing the O-ring between the cap and the enclosure. The O-ring
must not be cracked, broken, or otherwise damaged.
Frequency: Quarterly
c. Inspect the display viewing glass for cleanliness and damage. Replace the
enclosure cap assembly if the glass is damaged or missing. No
accumulation of dust, dirt, or water (condensate) should be present inside
the enclosure.
Frequency: Quarterly
d. Inspect transmitter and mounting bracket hardware for tightness. Tighten
loose hardware as necessary.
Frequency: Quarterly
e. Inspect for loose, bent, or cracked sensing lines. Replace damaged
sensing lines.
Frequency: Quarterly
f. Check operation of transmitter. Ensure transmitter is indicating accurate
pressure of the system.
Frequency: Quarterly
g. Bleed sensing lines between the transmitter and the main line to ensure
they are clean and free of suspended solids and air.
Frequency: Semi-annually
h. Check that all wire connections inside enclosure are tight.
Frequency: Annually
i. Pressure transmitters (PTs) and pressure indicating transmitters (PITs)
must be calibrated mechanically and electrically with test equipment and
adjusted if applicable. The presence of air in the sensing line of a
pressure transmitter is a common cause for failure. Conduct calibration
check by comparing readings of the PT or PIT with the readings of a
certified master calibration gauge which has been calibrated within the last
year. The PT or PIT and the master calibration gauge must be connected

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to the same pressure source for testing. Verify accuracy of PT or PIT

gauge is within ±2% of full scale. Calibrate in accordance with
manufacturer’s operation and maintenance manual if required.
Frequency: Annually

6-7.4 Differential Pressure Transmitters.

Differential pressure transmitters (DPT) are used to measure the difference in pressure
between two sensing points. These units transmit a 4 to 20 mA (common in US
installations) or 0 to 20mA (common in European installations) electrical signal to a
display or a PLC to indicate differential pressure. These same signals can also be used
to determine flow rate measurements using a function that correlates pressure
differential to flow.

6-7.4.1 Inspection and Maintenance - Differential Pressure Transmitters.

a. Inspect the exterior of the transmitter enclosure for accumulated oil, dust,
and dirt. Clean as required.
Frequency: Quarterly
b. Check that both enclosure caps are fully threaded onto the enclosure,
compressing the O-ring between the cap and the enclosure. The O-ring
must not be cracked, broken, or otherwise damaged.
Frequency: Quarterly
c. Inspect the display viewing glass for cleanliness and damage. Replace the
enclosure cap assembly if the glass is damaged or missing. No
accumulation of dust, dirt, or water (condensate) should be present inside
the enclosure.
Frequency: Quarterly
d. Inspect transmitter and mounting bracket hardware for tightness. Tighten
loose hardware as necessary.
Frequency: Quarterly
e. Inspect for loose, bent, or cracked sensing lines. Replace damaged
sensing lines.
Frequency: Quarterly
f. Check operation of transmitter. Ensure transmitter is indicating accurate
differential pressure measurement.
Frequency: Quarterly
g. Bleed sensing lines between the transmitter and the main line to ensure
they are clean and free of suspended solids and air.
Frequency: Semi-annually
h. Check that all wire connections inside enclosure are tight.
Frequency: Annually

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i. DPTs must be calibrated mechanically and electrically with test equipment

and adjusted, if applicable. The presence of air in sensing lines of
differential pressure transmitters is a common cause for failure. Conduct
calibration check by comparing readings of the DPT with the readings of a
certified differential master calibration gauge which has been calibrated
within the last year. The DPT and the differential master calibration gauge
must be connected to the same pressure source for testing. Verify
accuracy of DPT is within ±2% of full scale. Calibrate in accordance with
manufacturer’s operation and maintenance manual if required.
Frequency: Annually

6-8 FLEXIBLE BALL JOINTS.

6-8.1 Flexible Ball Joints.

Flexible ball joints are used to provide flexibility in connections between petroleum fuel
tanks and pipelines. These joints may also be used in other areas where flexibility is
required.

Figure 6-13 Flexible Ball Joint

6-8.1.2 Inspection and Maintenance – Flexible Ball Joints.

Flexible ball joints can be a source of leaks, especially if the piping is subject to stress
when it mates to a tank or coupling adapter. A program of periodic lubrication and
inspection will ensure longer joint life, since a fully lubricated joint will not allow dirt to
enter. However, if seals leak despite lubrication and seal replacement, the entire joint
must be replaced.

a. Lubricate ball joints and inspect for wear and stress.

Frequency: Monthly

6-9 THERMOMETERS.

Thermometers are used to measure temperature at the sensing point.

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6-9.1 Dial Thermometers.

Dial thermometers indicate the temperature on the face of a dial.

6-9.1.1 Inspection and Maintenance – Dial Thermometers.

Thermometers are typically bi-metallic or volatile fluid based, and must be periodically
inspected.

a. Inspect thermometer for cracked face and proper operational condition.

Replace if damaged.
Frequency: Quarterly
b. Check accuracy of thermometer against calibrated master thermometer.
Ensure process and calibrated master thermometers are reading the
same heat source. Verify accuracy of thermometer is within ±2% of full
scale. Calibrate process thermometer if required.
Frequency: Annually

6-10 PIPE AND EQUIPMENT COATINGS.

This section includes information related to periodic inspection of external coating

systems that are typically applied to DoD piping systems.

6-10.1 Aboveground Piping and Equipment Coatings.

A three coat system (primer, intermediate, and top coat) is the primary protective
coating system for aboveground piping. The primer and intermediate coats should be a
two component epoxy-polyamide system and the topcoat should be a UV resistant
polyurethane. Refer to UFGS 33 52 43.13 or UFGS 09 97 13.27 for current
aboveground exterior pipe coating system requirements. Do not paint stainless steel,
aluminum or galvanized surfaces.

6-10.1.1 Inspection and Maintenance – Aboveground Piping and Equipment

Coatings.

Coating repairs of aboveground piping, piping in pits, equipment, pipe supports, filter
separators, and miscellaneous metal should match color of finish and reflectivity of
existing, consistent with the Installation’s Architectural Standards.

Maintenance personnel must determine existing external coating type prior to repairs to
ensure proper adhesion. It is recommended to protect surrounding areas of repair by
squaring off with masking tape. Ensure the area to be repaired is clean and dry. All
surface corrosion or damage coating must be removed per coating manufacturer’s
requirements. In addition, abrade immediate area surrounding repair to feathered edge
to allow proper adhesion of repair coating layers. Remove all dust particles by brush or
vacuum and clean surface with appropriate solvents to prepare area for coating system.
Apply coating system in accordance with manufacturer’s instructions. The protective

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coatings section of UFGS 09 97 13.27 includes coating information and application

instructions that should be followed.

a. Visually inspect coatings for signs of deterioration, corrosion or damage.

Repair damaged or deteriorated coatings.
Frequency: Quarterly

6-10.2 Underground Piping Coating Repairs.

\1\
a. Three coating types have recently been used for underground piping: 2-
layer extruded polyolefin coating over soft adhesive per AWWA C215,
fusion-bonded epoxy coatings per AWWA C213, and Federal
Specification L-C-530C. Refer to UFGS 33 52 80 or UFGS 33 52 43.13 for
current underground exterior coating requirements.
b. Maintenance personnel must determine existing coating type prior to
repairs to ensure proper adhesion and longevity of repairs. Polyolefin
(AWWAC215), fusion-bonded epoxy (AWWA C213), and Federal
Specification L-C-530C are common, but other types of coatings may be
encountered. Some older pipes may be coated with a coal tar asbestos
wrap. Ensure the coating is identified and that proper procedures are
used to handle the hazard level associated with the identified coating.
Contact the military service-specific SME with questions regarding coating
types and appropriate repair methods.
c. In all cases, surfaces must be clean, dry, grease-free, dust-free, free of
rust and damaged coatings and prepared in accordance with repair
method chosen and the manufacturer’s published procedures. UFGS 33
52 80 includes additional coating information and application instructions
that should be followed.
/1/
6-10.2.1 Two-Layer Extruded Polyolefin Coating Repairs.

The following repair methods must be used for two-layer extruded polyolefin coating:

• Coal Tar Enamel per AWWA C203, Type II enamel, Type III outer wrap.
• Coal Tar Tape per AWWA C203.
• Cold Applied Tape per AWWA C209.
• Petroleum or Petroleum Wax Tape Coating per AWWA C217.
• Heat Shrink Sleeve per AWWA C216.

The military service-specific SME must determine the best repair method for the type of
repair required. Weld beads must be covered with one wrap of tape prior to spiral
wrapping. Fittings must be wrapped spirally beginning with one complete wrap three

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inches back from each edge of the coating. For pipe less than 4-inches (100 mm) in
diameter, one layer half-lapped must be used. For pipe 4-inches (100 mm) and larger in
diameter, two layers half-lapped must be used with the second layer wrapped opposite
hand of the first.

6-10.2.2 Fusion-Bonded Epoxy Repairs.

Fusion-bonded epoxy must be repaired with a fusion-bonded epoxy coating per NACE
Recommended Practice (RP) 0402 to match existing coating or Liquid-Epoxy Coating
System per AWWA C210.

Maintenance personnel must coordinate with military service-specific SME to determine

best repair method for the type of repair required.

6-10.2.3 Federal Specification L-C-530C Coating Repairs.

Coatings that meet the requirements of Federal Specification L-C-530C have been used
on underground fuel piping. The coating is no longer covered by a UFGS specification
but it has continued to be used on a case by case basis. Repair of these coatings must
be in accordance with manufacturer’s instructions.

6-10.3 Internal Carbon Steel Pipe Coatings.

Epoxy coatings systems meeting the requirements of MIL-PRF-4556 (two component

epoxy system) or AWWA C213 (fusion bonded epoxy system) are sometimes used on
the interior of carbon steel piping used for the transport of petroleum fuels. These
coatings are applied to the piping at the factory and are not typically repaired in the field.
The inside edges of each pipe segment is left uncoated 1 to 1.5-inches (25 to 40 mm)
from each end to prevent coating damage during welding operations. The inside areas
of the welds are left uncoated after welding is complete.

6-11 UNDERGROUND FUEL PITS.

Fuel pits such as low point drain pits, high point vent pits, lateral control valve pits,
isolation valve pits, and hydrant pits are included in many fueling systems.

6-11.1 Isolation Valve Pits.

Isolation valve pits are buried fiberglass or concrete pits with a rolling or hinged cover
designed in accordance with the DoD Standard Design AW 78-24-28 for isolation valves
installed in non-traffic areas on underground petroleum fuel piping systems. Valve pits
and valve operators are typically designed so that valves can be operated by personnel
without confined space entry.

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6-11.1.1 Inspection and Maintenance – Isolation Valve Pits.

a. Isolation valve pits should be inspected to ensure that the pits are dry and
clean and that all components within the pit are clean and in good working
order. Maintain seals and boot seals as appropriate. Obtain necessary
confined space entry permits before entry. Inspect the pit for signs of fuel
or water. Water or fuel should be removed from the pit as soon as
possible and the source of water infiltration or fuel leak determined.
Frequency: Monthly, or more often based on local conditions.
b. Check for cracks in concrete and check piping penetrations through pit
wall or bottom to ensure that mechanical seals and boot seals are in good
working condition and are allowing no seepage of water into the pits.
Make note of cracks in concrete and schedule maintenance as necessary.
Check for fuel leaks at all flanged and other piping connections. Check for
rusted or deteriorated ladders or grating platforms that might make entry
unsafe. Check pit lids for proper sealing. Check rolling pit covers for ease
of operation and signs of deterioration, damage or corrosion. Make sure
required locks are in place and locking mechanisms are not broken.
Frequency: Monthly, or more often based on local conditions.

6-11.2 Hydrant Fuel Pits.

Hydrant fuel pits are located close to the aircraft parking positions. Hydrant fuel pits
contain fuel block valves, pressure gauges, and hydrant control valves. The pits are
equipped with counter-weighted lids. A sump out connection is provided to sump
collected water or fuel from the pit. Grating installed in the pit provides access to valves
and is removable to allow close inspecting of pit pipe penetration seals and general
maintenance.

6-11.2.1 Inspection and Maintenance – Hydrant Fuel Pits.

a. Hydrant fuel pits must be inspected to ensure that they are dry and clean
and that all fueling components within the pit are clean and in good
working order. Obtain necessary confined space entry permits before
entry. Inspect the pit for fuel or water. Fuel or water found in the pit must
be sumped out as soon as possible.
Frequency: Monthly, or more often based on local conditions.
b. Check pipe penetrations through pit walls or bottom to ensure that
mechanical and boot seals are in good working condition and are allowing
no water seepage into the pits.
Frequency: Monthly
c. Check for fuel leaks at all flanged and other piping connections.
Frequency: Monthly Check pipe penetrations through pit walls or bottom
to ensure that mechanical and boot seals are in good working condition

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and are allowing no water seepage into the pits.

Frequency: Monthly
d. Check pit lids to ensure that seals are in good working order and are
preventing water entry into the pits.
Frequency: Monthly, or more often based on local conditions.
e. Inspect hydrant fuel pit bonding cables for corrosion and ensure electrical
continuity between bonded equipment.
Frequency: Monthly

6-11.3 High Point Vent Pits.

High point vent pits are located throughout fueling systems. High point vents are used
to vent air from fuel lines during start-up and operation.

6-11.3.1 Inspection and Maintenance – High Point Vent Pits.

a. Inspect high point vent pits to ensure they are dry and free of water and
other debris and that pit and piping components are leak free and in good
working condition. Inspect the pit for fuel or water. Fuel or water found in
the pit must be sumped out as soon as possible
Frequency: Monthly
b. Check pipe penetrations through pit walls or bottom to ensure that
mechanical and boot seals are in good working condition and are allowing
no water seepage into the pits.
Frequency: Monthly
c. Check pit lid seals for deterioration and replace as necessary.
Frequency: Monthly
d. Ensure that high point vent valves, quick-disconnect couplings or pit lids
are lockable and that locking mechanisms are in good working order.
Frequency: Monthly
e. Inspect high point vent pit bonding cables for corrosion and ensure
electrical continuity between bonded equipment.
Frequency: Monthly

6-11.4 Low Point Drain Pits.

Low point drain pits are located throughout fueling systems. Low point drains are used
to sump fuel piping where water in the fuel may settle and for draining the pipeline.

6-11.4.1 Inspection and Maintenance – Low Point Drain Pits.

a. Inspect low point drain pits to ensure they are dry and free of water and
other debris and that all pit and piping components are leak free and in

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good working condition. Inspect the pit for fuel or water. Fuel or water
found in the pit must be sumped out as soon as possible.
Frequency: Monthly
b. Check pipe penetrations through pit wall or bottom to ensure that
mechanical seals and boot seals are in good working condition and are
allowing no water seepage into the pits.
Frequency: Monthly
c. Check pit lid seals for deterioration and replace as necessary.
Frequency: Monthly
d. Ensure that low point vent valves, quick-disconnect couplings or pit lids
are lockable and that locking mechanisms are in good working order.
Frequency: Monthly
e. Inspect low point drain pit bonding cables for corrosion and ensure
electrical continuity between bonded equipment.
Frequency: Monthly

6-11.5 Lateral Control Pits.

Lateral control pits are buried fiberglass or concrete pits with rolling or hinged covers.
Valve operators installed in lateral control pits are typically designed so that the valves
can be operated by personnel without confined space entry. Lateral control pits may
include isolation valves and hydrant system automatic control valves.

6-11.5.1 Inspection and Maintenance – Lateral Control Pits.

a. Inspect lateral control pits to ensure they are dry and free of water and
other debris and that all pit and piping components are leak free and in
good working condition. Inspect the pit for fuel or water. Fuel or water
found in the pit must be sumped out as soon as possible.
Frequency: Monthly
b. Check pipe penetrations through pit wall or bottom to ensure that
mechanical seals and boot seals are in good working condition and are
allowing no water seepage into the pit.
Frequency: Monthly
c. Check pit lid seals for deterioration and replace as necessary.
Frequency: Monthly
d. Check for fuel leaks at all flanged and other piping connections.
Frequency: Monthly
e. Ensure that pit lids are lockable and that locking mechanisms are in good
working order.
Frequency: Monthly

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f. Inspect lateral control pit bonding cables for corrosion and ensure
electrical continuity between bonded equipment.
Frequency: Monthly

6-12 MINOR PIPING SYSTEMS.

6-12.1 Low Point Drains.

Water and other fuel contaminants that are not removed by filtration tend to end up at
low points in a fuel system. Low point drains are provided at low points in a fuel system
to allow water and contaminants to be removed.

6-12.1.1 Inspection and Maintenance – Low Point Drains.

a. Visually inspect low point drains. Ensure that quick-disconnect dust caps
are in place and that valves are locked closed.
Frequency: Weekly
b. Operate low point drains when system is not under operating pressure. If
there is an absence of sufficient line pressure close the low point drain
and pressurize the system. Once adequate pressure is available,
continue draining until the piping fuel sample is clear and bright with no
visible water.
Frequency: Monthly or as required by local conditions. Verify low
point drains are closed after maintenance.

6-12.2 High Point Vents.

High point vents are provided in fuel systems to provide a means of venting trapped air.

6-12.2.1 Inspection and Maintenance – High Point Vents.

a. Inspect high point vents. If fuel leaks are observed they should be
repaired as soon as possible. Ensure that quick-disconnect dust caps are
in place and that high point vent valves are locked.
Frequency: Weekly

6-12.3 Sight Flow Indicators.

Sight flow indicators are used to visually confirm that fuel is flowing through a system.
These devices use a wheel installed in the fluid stream behind a transparent glass or
plastic film. Flow is indicated when the wheel turns.

6-12.3.1 Inspection and Maintenance - Sight Flow Indicators.

a. Verify there are no leaks around pipe connection fittings and glass seals.
Also check glass for indications of cracks.
Frequency: Daily or at each use

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6-13 ELECTRONIC RELEASE DETECTION MONITORING.

6-13.1 General Inspection of Release Detection Systems.

Piping release detection systems are designed to quickly detect fuel leaks from
concealed and underground portions of fueling systems. A licensed and/or certified
technician is required to troubleshoot or inspect leak/release sensors for operation. If
an issue is suspected, appropriate military service-specific SCP or Installation
Environmental Office personnel should be contacted for support. Refer to SPCC plan
for further direction on who to contact.

Host nation, state, and local agencies may have additional design, inspection, and
maintenance requirements that may be more stringent than DoD or Federal guidance.
Facility operators and maintainers must be familiar with the site’s SPCC plan in order to
comply with all inspection and recordkeeping requirements

6-13.1.1 Rope Sensor Systems.

Rope sensors are installed along the length of underground piping, either within the
interstice of double-wall piping (common) or direct buried (uncommon). Rope sensors
can be installed in service pits and sumps as well. This system uses a discrete sensor
built along the length of a rope. Rope sensors send a signal to a monitoring panel
indicating the location of the detected liquid within a few feet. Rope sensors are
sensitive to the presence of any petroleum based product and care should be taken
when handling the rope sensor. A licensed and/or certified technician is required to
troubleshoot or inspect rope sensors for operation.

6-13.1.1.1 Inspection and Maintenance - Rope Detector Systems.

a. Ensure the monitoring panel associated with the rope sensor(s) is

powered on and no alarms are present.
Frequency: Daily
b. Test rope sensor system and ensure it is functional.
Frequency: Annually

6-13.1.2 Point Sensor – Dry.

Dry point sensors are installed at the lowest point within the space between the fueling
system and secondary barrier. Dry point sensors send a signal to a monitoring panel
indicating liquid detection. Dry point sensors may include float switches, or electrical
resistor switches. A licensed and/or certified technician is required to troubleshoot or
inspect dry point sensors for correct operation.

In double-wall piping systems these sensors are placed in the low points of the piping
and continuously monitor for the presence of fuel in the annulus of the double-wall pipe.

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6-13.1.2.1 Inspection and Maintenance - Point Sensor – Dry.

a. Ensure the monitoring panel associated with the point sensor(s) is

powered on and no alarms are present.
Frequency: Daily
b. Ensure monitoring space is clear and free of debris and liquid.
Frequency: Monthly
c. Test sensor and ensure it is functional.
Frequency: Annually

6-14 VISUAL RELEASE DETECTION MONITORING.

6-14.1 Visual Monitoring.

Release detection method utilizing inspection ports to visually inspect for the presence
of liquids.

6-14.1.1 Inspection and Maintenance – Visual Monitoring.

a. Visually inspect ports for signs of leaks. Remove debris or foreign objects
obstructing the view.
Frequency: Weekly

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CHAPTER 7 GROUND VEHICLE FUEL FACILITIES

7-1 GENERAL.

This chapter contains inspection and maintenance information associated with ground
vehicle fuel systems.

7-2 DISPENSER NOZZLES.

Dispenser nozzles that meet requirements of \1\UFGS 33 57 55/1/are designed to

automatically close when the dispenser nozzle handle is released. When the dispenser
nozzle vacuum sensing port is blocked by petroleum fuel it will cause the internal
poppet valve to close. This feature helps prevent overfilling vehicle tanks. Dispenser
nozzles can also be equipped with automatic nozzle shut-off clips to allow the operator
to latch dispenser nozzles open during fuel dispensing. When the dispenser nozzle
senses fuel at the vacuum sensing port, the shut-off clip disengages and the nozzle
closes. Do not remove automatic shut-off clips on ground vehicle fuel dispenser
nozzles. Dispenser nozzles should have splash guards in case of overfill.

Figure 7-1 Dispenser Nozzle

7-2.1 Inspection and Maintenance – Dispenser Nozzles.

a. Inspect dispenser nozzle spout. Ensure it is tight, round, has no cracks, or

excessive wear. Inspect automatic shutoff hole. Ensure the hole is open
and free of obstructions. Inspect nozzle hold-open latch. Ensure the latch
is straight, moves freely, and the return spring operates correctly. Inspect
body of nozzle. Ensure the body is in good condition and that the valve
stem is clean and free of fuel. Inspect the nozzle to hose connection and
ensure it is clean and free of fuel.
Frequency: Daily
b. \1\ /1/

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c. Test automatic shutoff feature and ensure it is operating properly. Test

automatic shutoff at all nozzle hold-open latch positions.
Frequency: Annually

7-3 DISPENSER HOSES.

Dispenser hoses that meet requirements of \1\UFGS 33 57 55/1/are designed to

transfer petroleum fuel from dispensers to motor vehicle fuel tanks. Hoses must be
reinforced with metallic mesh that prevents kinks and collapse. Reinforcement mesh
also provides a conductive path to direct static charges to ground. The outer surface of
hoses must be resistant to abrasion, cuts, and degradation from the surrounding
environment. No more than 6 feet (1.8 meters) of the dispenser hose may touch the
ground. Hose retractors may be installed to elevate long dispenser hoses. Dispenser
hoses with a working pressure under 20 psi (138 kPa) do not require annual pressure
testing.

Dispenser systems equipped for Stage II vapor recovery require coaxial hoses which
are used to provide a path for reclaimed fuel vapors to return to the petroleum fuel
storage tank.

7-3.1 Inspection and Maintenance – Dispenser Hoses.

a. Inspect dispenser hoses and hose whips for gouges, cuts, blisters, or
outside wear that may lead to rupture during use. Replace hose or hose
whips that show signs of wear. Inspect connection points of hoses and
hose whips to the dispenser, breakaways, swivels, and the nozzle and
ensure the connection points are clean and free of fuel.
Frequency: Daily

7-4 BREAKAWAYS.

Fuel hose breakaways that meet requirements \1\UFGS 33 57 55/1/are used to connect
dispenser hoses to dispensing units. Breakaways are designed to disconnect hoses
from dispensers if hoses are subjected to strong tensile stresses such as strong pulling
forces. Breakaways are double bonnet systems designed to close off fuel flow.

7-4.1 Inspection and Maintenance – Breakaways.

a. Inspect breakaways for loose connections and signs of damage to

poppets. Ensure breakaways are clean and free of fuel.
Frequency: Daily
b. Inspect breakaway for an expiration date established by the manufacturer.
Breakaways must be replaced before the indicated expiration date.
Frequency: Monthly

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7-5 SWIVELS.

Fuel hose swivels are installed between dispenser nozzles and hoses. They provide
flexibility and reduce strain on hoses by allowing nozzles to rotate around the swivel.
They also make it easier for operators to handle hoses during fuel dispensing.

7-5.1 Inspection and Maintenance – Swivels.

a. Inspect swivel for loose connections and signs of damage. Ensure swivel
rotates easily and is clean and free of fuel.
Frequency: Daily
b. Inspect swivel for expiration date established by manufacturer. Swivels
must be replaced before the indicated expiration date.
Frequency: Monthly

7-6 HOSE RETRIEVER.

Hose retrievers support the hose and limit contact of the hose with the ground.

7-6.1 Inspection and Maintenance – Hose Retriever

a. Test hose retriever and ensure it is operating correctly and supporting the
hose.
Frequency: Monthly

7-7 DISPENSER CABINET.

Dispenser cabinets enclose the inner components of fuel dispensers. The cabinets
protect the inner components from the elements and protect the connection points of
the underground supply piping.

7-7.1 Inspection and Maintenance – Dispenser Cabinet.

a. Inspect outside of cabinet and ensure it is free of damage. Inspect for fuel
stains on the concrete island around the cabinet and on the outside of the
cabinet. Ensure the cabinet is free of dirt and fuel.
Frequency: Monthly
b. Open both sides of the cabinet and inspect the inside of the cabinet.
Ensure the inside of the cabinet and all of the components inside the
cabinet are clean and free of fuel.
Frequency: Monthly
c. Ensure door panels and locks operate easily. Inspect anchor bolts of
cabinet to dispenser island and ensure the bolts are in good condition.
Frequency: Annually

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7-8 DISPENSER METERS.

Dispenser meters allow operators to monitor the amount of fuel dispensed into a given
vehicle fuel tank. Intelligent dispenser meters can reconcile all fuel dispensed against
the operating storage tank level readings to verify usage. Meters are able to constantly
recalibrate due to changes in temperature that affect the volumetric flow rate.

7-8.1 Inspection and Maintenance – Dispenser Meters.

a. Inspect meter and ensure meter is clean and free of fuel. Ensure
calibration mechanism is sealed.
Frequency: Monthly
b. Since moving parts inside meters are subject to wear, periodic calibration
is necessary. Meters must be recalibrated utilizing a certified 5 gallon (20
liter) prover can or other approved method. Meters are considered
satisfactory for further operation when the error does not exceed ±0.2% of
actual quantity delivered.
Frequency: Annually

7-9 DISPENSER FILTERS.

Dispenser filters that meet requirements of \1\UFGS 33 57 55/1/are used to collect

particulates in fuel systems. \1\ Depending on the fuel type different filter strategies may
be recommended. Refer to UFC 3-460-01 for filter strategies for each fuel type. /1/

7-9.1 Inspection and Maintenance – Dispenser Filters.

a. Inspect filter and ensure filter is clean and free of fuel and that filter is
labeled with a legible installation date.
Frequency: Monthly
b. Replace dispenser filters annually or when a change in flow rate is noted.
Frequency: Annually or as needed

7-10 DISPENSER STRAINERS.

Dispenser strainers are designed to capture particulates and protect dispenser pumps
and meters in self-contained units or meters in remote units.

7-10.1 Inspection and Maintenance – Dispenser Strainers

a. Inspect and clean strainers. Inspect strainer cover gasket for cracks,
distortion, and dry rot. If breaks are detected in strainer mesh, replace the
strainer.
Frequency: Annually

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7-11 GROUND VEHICLE FUEL PIPING.

Underground lines for ground vehicle petroleum fuel products must be constructed in
accordance with UFC 3-460-01 and 40 CFR Part 280.

In addition to 40 CFR Part 280, host nation, state, and local regulations may have
additional design, inspection, and maintenance requirements that may be more
stringent than DoD or Federal guidance. Facility operators and maintainers must be
familiar with the site’s SPCC plan in order to comply with all inspection and
recordkeeping requirements.

7-11.1 Inspection and Maintenance – Ground Vehicle Fuel Piping.

a. Visually inspect aboveground lines for leaks. Shut down systems that are
found with leaks and repair.
Frequency: Daily
b. Visually inspect leak detection systems installed on underground piping.
Inspections include line leak detectors and leak detection sensors installed
in transition sumps and dispenser sumps. Perform leak testing on
pressurized underground piping with installed leak detection equipment
and record results.
Frequency: Monthly
c. Test leak detection systems installed on underground piping used for
ground vehicle petroleum fuel products. Underground leak detection
systems include discrete detection sensors installed in transition and
dispenser sumps, and line leak detectors installed at the outlet of pumps
used to supply pressurized liquid petroleum fuel to underground lines.
Repair faulty components. Execution of this work may require state
certification or license.
Frequency: Annually
d. Conduct service station aboveground piping annual test as outlined in
Appendix G – Petroleum Fuel Pipeline Pressure Testing Guidelines and
Criteria. Execution of this work may require state certification or license.
Frequency: Annually
e. Conduct service station underground piping annual test outlined in
Appendix G – Petroleum Fuel Pipeline Pressure Testing Guidelines and
Criteria. Execution of this work may require state certification or license.
Frequency: Annually
f. Refer to Section 2.7 Signage and Markings for inspection and
maintenance requirements of ground vehicle petroleum fuel pipe
markings.

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g. Refer to Section 6-10.1 Aboveground Piping and Equipment Coatings for

inspection and maintenance requirements of ground vehicle petroleum
fuel pipe coatings.

7-12 EMERGENCY SHUTOFF VALVES (SHEAR VALVES).

Emergency shutoff valves that meet the requirements of \1\ UFGS 33 57 55 /1/ are
located at the base of ground vehicle fuel dispensers and are designed to close if the
dispenser is struck or exposed to a fire. Emergency shutoff valves are securely
mounted to stabilizer bars installed in the containment sumps mounted under
dispensers. The valve is designed to break at a weak point in the body of the valve if
the dispenser is struck and dislodged. The valve is also designed to close if the valve is
subjected to shock of an impact to the dispenser. In addition, the valve is equipped with
a fusible link that will melt in the event of a fire and cause the valve to close.

Figure 7-2 Emergency Shutoff Valve

7-12.1 Inspection and Maintenance – Emergency Shutoff Valves (Shear

Valves).

a. Inspect stabilizer bar to ensure that it is securely mounted below the base
of the dispenser. Inspect the mounting bolts that secure the emergency
shutoff valve to the stabilizer bar.
Frequency: Monthly
b. Inspect fusible link and ensure it is not obstructed. Ensure valve body is
clean and free of fuel.
Frequency: Monthly
c. Inspect mechanical links of the valve for correct operation. Conduct test
of valve to ensure it operates correctly. Execution of this work may
require state certification or license.
Frequency: Annually

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7-13 DISPENSER SUMPS.

Dispenser sumps are used to protect and provide access to valves and fuel pipe
installed below dispensers.

7-13.1 Inspection and Maintenance – Dispenser Sumps.

a. Inspect for signs of water, fuel, trash, and debris inside sumps. Remove
and properly dispose of collected water, fuel, trash, and debris. Visually
inspect penetration fittings. If fuel or water is detected investigate the
source and repair.
Frequency: Monthly, or more often based on local conditions.
b. Inspect sump pipe transition fittings for tears, cracks, or other signs of
deterioration. Check hose clamp seals to ensure they are securely
tightened.
Frequency: Quarterly
c. Test dispenser sumps and ensure they are liquid tight by using vacuum,
pressure, or liquid testing in accordance with 40 CFR 280, Section 43.
Frequency: Every three years

7-14 TRANSITION SUMPS.

Transition sumps are used to protect piping as it transitions from aboveground to below
ground. In many cases the piping will change configuration as it transitions from
aboveground pipe to underground pipe.

7-14.1 Inspection and Maintenance – Transition Sumps.

a. Inspect for signs of water, fuel, trash, and debris inside sumps. Remove
and properly dispose of collected water, fuel, trash, and debris. Visually
inspect penetration fittings. If fuel or water is detected investigate the
source and repair.
Frequency: Monthly, or more often based on local conditions.
b. Inspect sump pipe transition fittings for tears, cracks, or other signs of
deterioration. Check hose clamp seals to ensure they are securely
tightened.
Frequency: Quarterly
c. Test sumps and ensure they are liquid tight by using vacuum, pressure, or
liquid testing in accordance with 40 CFR 280, Section 43.
Frequency: Every three years

7-15 DISPENSER PUMPS.

Dispenser pumps are either installed as an integral unit to the fuel dispenser or as a
remote pump. Integral pumps are typically sliding vane pumps installed in the base of

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the dispenser unit. Remote pumps are typically submerged turbine pumps mounted on
petroleum fuel storage tanks.

7-15.1 Remote Dispenser Pumps.

Fuel dispensers in remote pump systems do not house pumps. Remote dispenser
pumps are typically tank mounted submerged turbine pumps. The manufacturer's
instructions for installation, operation, and maintenance will further describe pumping
unit and parts requiring periodic inspection and maintenance.

7-15.1.1 Inspection and Maintenance – Remote Dispenser Pumps.

a. Refer to Section 7-19.1.2 Automatic Line Leak Detector for maintenance

and inspection requirements of automatic line leak detectors installed on
submersible turbine pumps.
b. Refer to Section 3-8.1.3 Vertical Turbine/Submerged Turbine Pumps for
inspection and maintenance requirements of remote dispenser pumps.

7-15.2 Self-Contained Dispenser Pumps.

Self-contained dispenser pumps are typically belt-driven, sliding vane type positive
displacement pumps mounted within the dispenser housing. The pumps draw fuel to
the dispenser by creating suction on the fuel line attached to the petroleum fuel storage
tank.

7-15.2.1 Inspection and Maintenance – Self-Contained Dispenser Pumps.

a. Inspect self-contained dispenser pump v-belt drives for proper tension and
excess wear. Replace belt as recommended by manufacturer.
Frequency: Monthly
b. Inspect pump body. Ensure pump body is clean and free of fuel. Inspect
air eliminator. Ensure air eliminator is clean and free of fuel and that the
vent tube is not obstructed.
Frequency: Monthly

7-16 EFSO SYSTEMS.

Emergency Fuel Shut-Off (EFSO) systems disable power to dispensers at service

stations. Typically military service stations are unattended and require keys or cards to
operate the dispensers. EFSO buttons to deactivate the dispensers are typically
installed in close proximity to dispensers and at a distance of between 20 and 100 feet
(6 to 30 meters) away from dispensers. EFSO systems can be activated by pushing
one of the EFSO buttons.

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7-16.1 Inspection and Maintenance – EFSO Systems.

a. Check the operation of the EFSO system by activating the fueling system
and then pressing each of the EFSO buttons. Ensure that each button
disables power to all of the dispensers and fuel pumps installed at the
service station.
Frequency: Quarterly
b. Refer to Section 2-7 Signage and Markings for inspection and
maintenance requirements of EFSO pushbutton signs.

7-17 VAPOR RECOVERY.

Vapor recovery at service stations is typically classified as Stage I or Stage II. These
types of systems are required on fuels with high vapor pressures in many states. For
military service station applications this is usually limited to Motor Gasoline (MOGAS).

7-17.1 Stage I Vapor Recovery.

Stage I Vapor Recovery is used for bulk receipt and issue operations and typically
includes a vapor balance pipe. The vapor balance pipe is used to connect the head
space of the fuel storage tank to the head space of the fuel truck. This allows vapors to
move between the fuel storage tank and the fuel truck during receipt and issue
operations.

7-17.1.1 Inspection and Maintenance - Stage I Vapor Recovery.

a. Inspect vapor recovery hoses for gouges, cuts or outside wear that may
result in vapor leaks.
Frequency: Daily or before each use
b. Inspect caps and camlock fittings for tightness and leaks.
Frequency: Quarterly
c. Refer to Section 7-11 Ground Vehicle Fuel Piping for inspection and
maintenance requirements of Stage I vapor recovery piping.

7-17.2 Stage II Vapor Recovery.

Stage II vapor recovery includes the collection of vapors at the dispenser nozzle and
may also include the collection of vapors developed from normal tank operations. In
most cases these systems include vacuum pumps mounted in dispensers that collect
and transfer vapors to petroleum fuel storage tanks. Stage II vapor recovery is no
longer a Federal requirement but may still be required by some states. Existing Stage II
vapor recovery systems may be phased out in accordance with state regulations. Stage
II vapor recovery systems that have not yet been decommissioned (whether required or
not) must still be maintained and inspected in accordance with state regulations.

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7-17.2.1 Inspection and Maintenance - Stage II Vapor Recovery.

There are several approved vendors for Stage II Vapor Recovery systems. Consult the
manufacturer’s operation and maintenance manual that was provided with the system
for periodic maintenance requirements.

7-17.3 Vapor Burners.

Vapor burners are used to combust vapors from tanks that would otherwise be vented
to atmosphere.

7-17.3.1 Inspection and Maintenance - Vapor Burners.

Consult the manufacturer’s operation and maintenance manual that was provided with
the system for specific periodic maintenance requirements of the unit that is installed.

a. Inspect vapor burners to ensure that the pilot flame system is operating
properly. Fans, duct work, and dampeners must also be inspected to
ensure proper air to fuel vapor mixtures allow for complete burns.
Frequency: Quarterly
b. Inspect burner knock out pots for condensed fuel vapors and water if
equipped.
Frequency: Quarterly
c. Inspect thermowells and gas detection monitors for operability.
Frequency: Quarterly

7-18 TACTICAL REFUELER LOADING.

Tactical refueler loading operations at military service stations are similar to petroleum
fuel truck issue systems. Refer to Section 3-5.1 Truck Issue for inspection and
maintenance requirements of tactical refueler loading equipment.

7-19 ELECTRONIC RELEASE DETECTION MONITORING.

7-19.1 General Inspection of Release Detection Systems.

Release detection systems are designed to quickly detect fuel leaks from concealed
and underground portions of fueling systems. A licensed and/or certified technician is
required to troubleshoot or inspect leak/release sensors for operation. If an issue is
suspected, appropriate military service-specific SCP or Installation Environmental Office
personnel should be contacted for support. Refer to Installation SPCC plan for further
direction on who to contact.

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7-19.1.1 Point Sensor – Dry.

Dry point sensors are installed at the lowest point within the space between the fueling
system and secondary barrier. Dry point sensors send a signal to a monitoring panel
indicating liquid detection. Dry point sensors may include float switches or electrical
resistor switches. A licensed and/or certified technician is required to troubleshoot or
inspect dry point sensors for operation.

These sensors are placed in the low points of the dispenser sumps and fuel pipe
transition sumps and continuously monitor for the presence of fuel or water in the
sumps.

7-19.1.1.1 Inspection and Maintenance - Point Sensor – Dry.

a. Ensure the monitoring panel associated with the point sensor(s) is

powered on and no alarms are present.
Frequency: Daily
b. Ensure monitoring space is clear and free of debris and liquid.
Frequency: Monthly
c. Test sensor and ensure it is functional.
Frequency: Annually

7-19.1.2 Automatic Line Leak Detector.

Automatic line leak detector systems are used on underground pressurized piping to
alert the operator to the presence of a leak by restricting or shutting off the flow through
the piping or visual alarm. Automatic line leak detectors are commonly installed on
submersible turbine pumps and less commonly installed remotely on other pump types.

7-19.1.2.1 Inspection and Maintenance – Automatic Line Leak Detector.

a. Ensure the monitoring panel associated with the detector(s) is powered on

and no alarms are present.
Frequency: Daily
b. Simulate a 3 gallons per hour leak at 10 pounds per square inch; the
automatic line leak detector must activate within one hour. A licensed
and/or certified technician is required to, test, troubleshoot, or calibrate for
operation.
Frequency: Annually

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7-20 VISUAL RELEASE DETECTION MONITORING.

7-20.1 Visual Monitoring.

Release detection method utilizing inspection ports to visually inspect for the presence
of liquids.

7-20.1.1 Inspection and Maintenance – Visual Monitoring.

a. Visually inspect at inspection ports for signs of leaks. Remove debris or

foreign objects obstructing the view.
Frequency: Weekly

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CHAPTER 8 PETROLEUM STORAGE TANKS

8-1 GENERAL INFORMATION.

\1\
a. This chapter includes information on inspection and maintenance of
petroleum fuel storage tanks and associated equipment for the purpose
of maintaining mechanical and operational integrity.
b. Commercial codes API 653 and STI SP001 have been used to determine
baseline inspection requirements for DoD-owned petroleum fuel tanks.
API 653 has been used for field-erected tanks and STI SP001 has been
used for shop-fabricated tanks. In some cases API 653 and STI SP001
can be applied to field erected tanks. In cases where API 653 or STI
SP001 could be applied, the option to use either protocol has been
provided. After a tank's inspection protocol has been set, it should
continue following that inspection protocol unless the change is approved
by the military service-specific SCP or SME. Contact the military service-
specific SCP or SME for guidance if unsure of proper inspection protocol.
c. In some cases API 653 and STI SP001 do not directly apply to a type of
petroleum fuel tank installed in the field (e.g. cut and cover tanks). In
these cases the requirements of the codes must be adjusted to fit the
actual tank installed in the field. Contact military service-specific SCP or
SME for guidance.
d. Multi-compartment petroleum fuel tanks are a special case of shop-
fabricated tank. Each compartment within a multi-compartment tank
should be treated as a separate/individual tank, even though they may
share components and secondary containment systems.
/1/

8-2 CONTAMINATION PREVENTION.

Petroleum fuel storage tanks are environments where water can promote
microbiological growth which can damage inner tank surfaces, restrict flow, damage
downstream components, and degrade petroleum fuel product stability. Though water
or other debris are inherent to petroleum fuel handing operations, maintaining petroleum
fuel tank (e.g., floating roof seals, vent screens) integrity is critical to preventing
additional contamination from entering tanks. Water is typically removed via draw off
systems or draining directly from petroleum fuel tank sumps.

8-3 TANK SURFACE COATINGS.

Only coating touch-up repair is performed by staff maintenance personnel on petroleum

fuel tanks. Coating repair or replacement for an entire petroleum fuel tank is usually
performed under contract.

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Interior coating systems are programmed for replacement at 20 year intervals. Exterior
coatings may fail more rapidly due to weathering and microbial growth. Numerous
factors including surface preparation can lead to failure of the coating material. If
inspection shows coating is in acceptable condition, the life may be extended past 20
years. There is generally no need to recoat the interior of petroleum fuel tanks unless
the coating has failed or a significant change of petroleum fuel service type is planned.
The condition of the internal coatings can only be determined during out-of-service
internal tank inspections.

8-3.1 External Tank Coating Repairs.

\1\
a. The external surfaces of petroleum storage tanks are protected with
coatings that meet the requirements of UFGS 09 97 13.27. Existing tanks
may be protected by alternative coating systems not listed in UFGS
specifications. Questions regarding alternative coatings that are
encountered in the field should be directed to the military service-specific
SME.
b. Maintenance personnel must determine existing external coating type
prior to repairs to ensure proper adhesion. It is recommended to protect
surrounding areas of repair by squaring off with masking tape. Ensure the
area to be repaired is clean and dry. All surface corrosion or damage
coating must be removed per coating manufacturer’s requirements. In
addition, abrade immediate area surrounding repair to feathered edge to
allow proper adhesion of repair coating layers. Remove all dust particles
by brush or vacuum and clean surface with appropriate solvents to
prepare area for coating system.
c. Application information and instructions provided in UFGS 09 97 13.27
must be strictly adhered to when this type of coating system is applied to
the exterior of tanks.
8-3.1.1 Vapor Corrosion Inhibitors.

Vapor Corrosion Inhibitors (VCI) technology has potential. VCIs are acceptable for
tanks where the underbottom cathodic protection has failed. The tank’s ringwall and
liner system must not be compromised, such as drilling thru the concrete and flexible
membrane liner, for the injection of the VCI. The amount of VCI must be checked
annually to determine if additional VCI is required. VCI is not considered as a
permanent repair. The cathodic protection system should be repaired during the tank’s
next out-of-service inspection. /1/

8-3.2 Internal Tank Coating Repairs.

There are two primary coating system types used for tank interiors: low VOC epoxy
novolac polysulfide coatings that meet the requirements of UFGS 09 97 13.15, and two
component epoxy coatings that meet the requirements of UFGS 09 97 13.17. Existing

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tanks may be protected by alternative coating systems not listed in UFGS. Questions
regarding alternative coatings that are encountered in the field should be directed to the
military service-specific SME.

\1\
8-3.2.1 Low VOC Epoxy Novolac Polysulfide Interior Coating.
/1/

Epoxy novolac polysulfide interior coating systems are comprised of primer or base coat
and top coat that are identical in material except for contrasting colors to allow for
identification. When applied correctly, this coating system will last approximately 50
years.

Application information and instructions provided in UFGS 09 97 13.15 must be strictly

adhered to when this type of coating system is applied to the interior of tanks.

\1\
8-3.2.2 Two Component Epoxy Interior Coating.
/1/

Two component epoxy coating systems are comprised of an epoxy polyamide primer or
base coat in accordance with MIL-DTL-24441/29, and epoxy polyamide intermediate
and top coats in accordance with MIL-DTL-24441/31. All primer and intermediate
coating materials are supplied by one supplier. When applied correctly, this coating
system will last approximately 20 years.

Application information and instructions provided in UFGS 09 97 13.17 must be strictly

adhered to when this type of coating system is applied to the interior of tanks.

8-4 ABOVEGROUND FIELD-ERECTED TANKS.

\1\
a. The majority of the above ground field-erected tanks used for petroleum
products are built and/or repaired in accordance with API-650 and DoD
Standard Design AW 78-24-27.
b. A baseline internal inspection must be conducted on aboveground field-
erected tanks before they are placed into service. The baseline inspection
must include floor, shell, and roof wall-thickness measurements. These
initial measurements will be used by later inspectors to monitor and
evaluate corrosion rates of specific tanks.
c. Military service-specific, host nation, state or local regulations may require
additional inspections or increased frequency of inspections of field-
erected tanks. The Installation must follow the more stringent of this UFC
or military service-specific, host nation, state, or local regulations.
/1/

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8-4.1 Inspection and Maintenance – Aboveground Field-Erected Tanks.

a. Visually inspect for evidence of leaks; shell distortions; signs of settlement;

corrosion, condition of tank foundation, condition of coating, insulation
systems, and appurtenances. Inspection must include all components
and equipment located inside the containment area such as piping, pipe
supports, containment valves, and product saver tanks. Items noted
during the inspection will be documented for follow-up action by an
authorized inspector. See Appendix F for the Field-Erected Tank Monthly
Inspection Checklist.
Frequency: Monthly
b. Visually inspect \1\ bottom edge projection (chime) /1/ to ringwall sealant.
Seal should be maintained in good working order to prevent corrosion of
the underside of the tank bottom.
Frequency: Monthly
c. Visually inspect the exterior of the tank for leaks, corrosion, or
irregularities such as tilting, settling, or out-of-roundness. Give special
attention to seams and anchor bolts. Visual inspection must include all
components and equipment located inside the tank containment area such
as piping, pipe supports, containment valves, and product saver tanks.
Retain records of inspections reports for five years. See Appendix F for
the Field-Erected Tank Annual Inspection Checklist.
Frequency: Annually
d. Perform a formal in-service external inspection of the tank in accordance
with API 653 or STI SP001 to evaluate the tank for conditions which may
affect the operational integrity of the storage tank, including minimum shell
thickness measurements. This inspection must be performed by an
applicable certified inspector. Inspection must include all components and
equipment located inside the tank containment area such as piping, pipe
supports, containment valves, and product saver tanks.
Frequency: Every five years or as required by an appropriately
certified tank inspector in the previous API 653 or STI SP001
inspection report.
e. Perform an out-of-service API 653 or STI SP001 inspection to evaluate
the tank for conditions which may affect the operational integrity of the
tank floor, shell, roof and floating roof or pan. API 653 or STI SP001
provides a checklist to be used as part of the assessment. This inspection
must be performed by an appropriately certified API 653 or STI SP001
inspector. Inspection must include all components and equipment
located inside the tank containment area such as piping, pipe supports,
containment valves, and product saver tanks. \1\ The API 653 or STI
SP001 inspector must recommend the date of the next inspection. The
inspection interval must be based on the date the Suitability for Service

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Letter is issued immediately prior to when the tank is returned to service.

Frequency: As recommended by the API 653 or STI SP001 inspector. If
there is not a previous recommendation, the inspection must be performed
within ten years after the tank was placed into operation. /1/
8-4.2 Geodesic Dome Roofs.

Geodesic dome roofs for aboveground vertical petroleum fuel storage tanks are
constructed of aluminum and either welded or bolted to the vertical wall of the petroleum
tank or wind girder and are self-supporting. Geodesic dome roofs are typically installed
on petroleum fuel tanks originally constructed with external floating roofs to reduce
infiltration of rainwater into the petroleum fuel tank, to protect the floating roof, seals,
and internal coatings from the effects of weather, and to help reduce emissions and fuel
odors.

8-4.2.1 Inspection and Repair – Geodesic Dome Roofs.

Internal geodesic dome inspections are most effective when the petroleum fuel in the
tank is near or at high level and the floating roof is close to its highest position. Access
to an internal floating roof is considered a permit required confined space, therefore all
military service-specific safety procedures must be followed.

a. Conduct external inspection of geodesic dome roofs, where accessible, for

corrosion of tank-to-shell bolts, gasket connections, visible signs of
corrosion, apparent roof leaks, clogging or deterioration of vent screens,
and damage to the structure or panels.
Frequency: Monthly
b. Conduct internal inspection of geodesic dome roofs from the floating roof,
where accessible, for corrosion of tank-to-shell bolts, gasket connections,
visible signs of corrosion, apparent roof leaks, clogging or deterioration of
vent screens, and damage to the structure or panels.
Frequency: Annually
8-4.3 Foundations.

Field erected petroleum fuel tanks are generally constructed on a concrete ring wall
foundation. In some cases tanks are constructed on a concrete mat foundation.
Typically the tank is elevated and the tank containment floor is sloped away from the
tank shell.

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8-4.3.1 Inspection and Repair – Foundations.

a. Inspect visible components of tank foundations for signs of erosion due to

heavy rains, wash-down, etc. and repaired as necessary. Also inspect
tank foundations for structural cracks, signs of settlement, spalling, or
general deterioration. Remove vegetation found around the tank
foundation.
Frequency: Monthly

8-5 SHOP-FABRICATED TANKS.

\1\
a. The most common types of shop fabricated tanks for petroleum fuel
storage are horizontal cylindrical tanks; however, there are also vertical
and rectangular tanks (e.g., Lube Cube® lube oil tanks and ConVault
tanks). Shop-fabricated tanks can be constructed with integral secondary
containment and fire protection. The most common tanks used for fuel
service are described in the sections that follow.
b. A baseline internal inspection must be conducted on shop-fabricated tanks
before they are placed into service. The baseline inspection must include,
floor, shell, roof, and end wall-thickness measurements as applicable for a
specific type of tank. These initial measurements will be used by later
inspectors to monitor and evaluate corrosion rates of specific tanks.
c. Military service-specific, host nation, state or local regulations may require
additional inspections or increased frequency of inspections of shop-
fabricated tanks. The Installation must follow the more stringent of this
UFC or military service-specific, host nation, state, or local regulations.
/1/

8-5.1 Aboveground Shop-Fabricated Tanks.

\1\
a. UFC 3-460-01 Section 8-4 limits shop-fabricated tank size diameters to 12
feet (3.66 meter) and maximum capacities of 50,000 gallons (190,000
liters). Aboveground single-wall tanks are designed and constructed to
meet the requirements of UL 142.
b. Double-wall tanks are designed with a UL 142 compatible inner tank. Fire
resistant doubled-walled tanks are equipped with an outer tank design to
meet UL 2080. Protected double-walled tanks are equipped with an outer
tank designed to meet UL 2085 requirements. Additional considerations
and guidance are specified in NFPA 30. NFPA 30A should be consulted
for requirements of tanks used to dispense fuel to ground vehicles or
watercraft.

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c. In general, inspections fall into the categories of internal (first or

subsequent), external (periodic or formal), and leak test. Unless more
frequent inspection and testing is specified by military service-specific
directives, host nation, state or local regulations or certified inspector as a
result of the previous inspection, the inspection and testing protocol
defined by STI SP001 based on the classification system shown in \1\ STI
SP001 /1/ must be used to determine inspection and testing requirements
of aboveground shop fabricated tanks.
d. Inspection protocols must be assigned by the military service-specific SCP
or SME. Where multiple inspection protocols could be applied, once
selected, the initial inspection protocol should not be changed without prior
coordination with the military service-specific SCP or SME. Prior
inspection history is key to subsequent inspections being able to identify
issues. Each tank’s inspection protocol should be clearly documented and
used as the basis for future projected inspections.
e. When applying STI SP001 formal testing schedules, select the internal
inspection option if the tank is physically able to be entered. Otherwise
select the leak test option\1\/1/. Only tanks equipped with a manway at
least 18 inches wide (455 mm) should be entered.
f. For multi-compartment tanks, the “tank size” is equivalent to the individual
compartment that is being inspected.
/1/

\1\ /1/

\1\ /1/

8-5.1.1 Inspection and Maintenance – Aboveground Shop Fabricated Steel

Tank Inspections.

a. Monthly External Inspection (Identified as P in \1\ STI SP001)/1/: Visually

inspect for exterior signs of corrosion or coating deterioration. Visually
inspect weld seams, tank-to-saddle connections, tank supports, tank
anchors, foundation and anchor bolts, overfill valves and alarms, normal
vents, emergency vents, leak detection probe or water/petroleum
accumulation in the interstice on double-walled tanks, leaking valves, fittings,
or components, spill containment systems and release prevention barriers.
Leaking valves, fittings or components must be repaired immediately or
immediately removed from service and isolated to prevent further discharge.
Any irregularities, (e.g., missing valve handles, bolts, nuts, screens) will be
assessed for priority and repaired as soon as possible or as required
depending on the nature of the defect (see Appendix E for an example of the
STI SP001 Standard Monthly Inspection Checklist).
Frequency: Monthly

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b. Annual External Inspection (Identified as P in \1\ STI SP001 /1/): A more

detailed examination of the tank and appurtenances must be performed
on an annual basis (See Appendix E for an example of the STI SP001
Standard Annual Inspection Checklist).
Frequency: Annually
c. Formal External Inspection (Identified as E in \1\ STI SP001 /1/): A formal
external inspection as defined in STI SP001 must be conducted by
certified STI SP001 inspector.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001. /1/
d. Formal Internal Inspection (Identified as I in \1\ STI SP001 /1/): A formal
internal inspection as defined in STI SP001 must be performed by a
certified STI SP001 inspector. \1\ The API 653 or STI SP001 inspector
must recommend the date of the next inspection. The inspection interval
must be based on the date the Suitability for Service Letter is issued
immediately prior to when the tank is returned to service. /1/
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001. /1/
e. Leak Test (Identified as L in \1\ STI SP001 /1/): A leak test as defined in
STI SP001 must be performed in accordance with STI SP001.
Frequency: As established by SCP based on tank size and
category\1\ as defined in STI SP001. /1/

8-5.2 Self-Diking or Vaulted Tanks.

Self-diking tanks are designed to UL142 can be of either single or double-wall

construction and are designed to sit within a fabricated steel containment dike. The
dike is designed to contain small spills or the entire tank contents in the event of a major
leak or rupture. These tanks usually range in size from 250 to 12,000 gallons (946 to
45,424 liters) but can be larger. NFPA 30 and NFPA 30A have specific criteria that
must be met before using this type of tank. Secondary containment dikes may only be
opened for draining purposes and performed in accordance with the Installation’s SPCC
plan. At a minimum, secondary containment drain valves will be monitored during
draining, closed and locked after use.

8-5.2.1 Inspection and Maintenance – Self Diking or Vaulted Tank

Inspections.

a. Monthly External Inspection (Identified as P in \1\ STI SP001 /1/): Visually

inspect for exterior signs of corrosion or coating deterioration. Visually
inspect weld seams, tank-to-saddle connections, tank supports, tank
anchors, foundation and anchor bolts, overfill valves and alarms, normal
vents, emergency vents, leak detection probe or water/petroleum
accumulation in the containment area, leaking valves, fittings, or

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components. Leaking valves, fittings or components must be repaired

immediately or immediately removed from service and isolated to prevent
further discharge. Any irregularities, (e.g., missing valve handles, bolts,
nuts, screens) will be assessed for priority and repaired as soon as
possible or as required depending on the nature of the defect (See
Appendix E for an example of the STI SP001 Standard Monthly Inspection
Checklist).
Frequency: Monthly
b. Annual External Inspection (Identified as P in \1\ STI SP001 /1/): A more
detailed examination of the tank and appurtenances must be performed
annually. (See Appendix E for an example of the STI SP001 Standard
Annual Inspection Checklist).
Frequency: Annually
c. Formal External Inspection (Identified as E in \1\ STI SP001 /1/): A formal
external inspection as defined in STI SP001 must be conducted by
certified STI SP001 inspector.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001. /1/
d. Formal Internal Inspection (Identified as I in \1\ STI SP001 /1/): A formal
internal inspection as defined in STI SP001 must be performed by a
certified STI SP001 inspector.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001. /1/
e. Leak Test (Identified as L in \1\ STI SP001 /1/): A leak test as defined in
STI SP001 must be performed in accordance with STI SP001.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001. /1/
8-5.3 Rectangular Concrete-Encased Tanks.

Concrete-encased tanks are constructed in accordance with UL 2085 (e.g., ConVault

Tanks). The tank by design has an integral secondary containment in the form of a
petroleum resistant plastic sheet encased in concrete. The concrete surface is exposed
on the exterior of the tank as opposed to a steel shell. These tanks are maintained and
inspected in a similar manner as a double-wall or protected steel tanks. Any formal
testing of the primary (interior) tank or interstice must be conducted in accordance with
manufacturer’s instructions.

8-5.3.1 Inspection and Maintenance – Concrete-Encased Tank Inspections.

a. Monthly External Inspection (Identified as P in \1\ STI SP001 /1/): Visually

inspect tank supports, anchors and anchor bolts, overfill valve and alarms,
normal vent, emergency vent, leaking valves, fittings or other components.
In addition the exterior concrete must be visually inspected for cracking,

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degradation, excessive calcareous deposits or signs of damage. Leaking

valves, fittings or components must be repaired immediately or isolated to
prevent further discharge. Any other deficiencies or irregularities noted
must be repaired as soon as possible or as required depending on the
nature of the defect (See Appendix E for an example of the STI SP001
Standard Monthly Inspection Checklist).
Frequency: Monthly
b. Annual External Inspection (Identified as P in \1\ STI SP001 /1/): A more
detailed examination of the tank and appurtenances must be performed
on an annual basis (See Appendix E for an example of the STI SP001
Standard Annual Inspection Checklist).
Frequency: Annually
c. Formal External Inspection (Identified as E in \1\ STI SP001 /1/): A formal
external inspection must be conducted by certified STI SP001 inspector.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001 /1/.
d. Formal Interior Inspection \1\ STI SP001 /1/: A modified formal internal
inspection as defined in manufacturer’s instructions or STI SP001 must be
performed on concrete-encased tanks by a certified STI SP001 inspector
if the tank interior is accessible.
Frequency: As established by SCP based on tank size and category
\1\ as defined in STI SP001 /1/.
8-5.4 Underground Shop-Fabricated Tanks.

\1\
a. UFC 3-460-01 requires tanks to be constructed to meet requirements of
NFPA 30 and, if required, NFPA 30A.
b. Underground steel horizontal cylindrical storage tanks are constructed in
accordance with UL-58 and conform to environmental requirements of 40
CFR 280.
c. Underground fiberglass horizontal cylindrical storage tanks are
constructed in accordance with UL 1316 and also meet requirements of 40
CFR 280.
d. Military service-specific, host nation, state or local regulations may require
additional inspections or increased frequency of inspections of shop-
fabricated underground tanks. The Installation must follow the more
stringent of this UFC or military service-specific, Host
e. Nation, state, or local regulations.
/1/

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8-5.4.1 Single-walled Underground Shop-Fabricated Tanks.

\1\
a. Underground shop-fabricated tanks for fuel and oil service installed or
replaced after April 11, 2016 must be secondarily contained and use
interstitial monitoring in accordance with 40 CFR 280 Section 43. The use
of existing single-walled tanks that have been upgraded and are
maintained in accordance with 40 CFR 280 Section 21 Upgrading of
Existing UST Systems is allowed to continue.
b. In general, inspections fall into the categories of internal, external (monthly
and annual), and tightness test. Unless more frequent inspection and
testing is specified by military service-specific directives, host nation, state
or local regulations or certified inspector as a result of the previous
inspection, the inspection and testing protocol defined in \1\ Table 8-1 /1/
must be used to determine inspection and testing requirements of single-
walled underground shop fabricated tanks.
c. Strong consideration should be given to the replacement of single-walled
underground tanks that are over 30 years old with double-walled tanks
equipped with interstitial monitoring that meet the requirements of 40 CFR
280 Section 43.
/1/

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\1\
Table 8-1 /1/ Single-walled Underground Shop Fabricated Tank Inspection
and Testing Schedules*

Steel with
Release Steel with Cathodic
Tank Size 1 Detection Cathodic Fiberglass or Steel Protection and Aviation Fuel
(Gallons) Type Protection2 with Interior Lining3 Interior Lining2,3 Tank

111 - 1000 RD-1 P P P P

1001 - 50,000 RD-2 I(10), P I(INT-1), P I(15), P I(10), P

1001 - 50,000 RD-3 I(10), T(INT-2), P I(INT-1), T(INT-2), P I(15), T(INT-2), P I(10), T(INT-2), P

P = periodic inspection (monthly and annual) Use PEI 900 checklists.

I = formal internal inspection by certified inspector. If tank cannot be entered, tanks should be cleaned
and inspected with lights and/or cameras through existing openings as deemed practical by a certified
tank inspector.
T = tightness test.
( ) = maximum inspection interval, in years.
1 = single-walled tank installed on or before April 11, 2016, that meet the requirements of 40 CFR 280
Section 21 for internal lining, cathodic protection, or both.
2 = Cathodic Protection: At time of cathodic protection installation the integrity of the tank must have been
ensured using one of the following methods:
1) The tank was internally inspected and assessed to ensure that the tank was structurally sound
and free of corrosion holes prior to installing the cathodic protection system; or
2) The tank had been installed for less than 10 years and has been monitored monthly for releases
by automatic tank gauging, vapor monitoring, groundwater monitoring, or statistical inventory
reconciliation as defined in 40 CFR 280 Section 43; or
3) The tank had been installed for less than 10 years and was assessed for corrosion holes by
conducting two tightness tests. The first tightness test must have been conducted prior to
installing the cathodic protection system. The second tightness test must have been conducted
between three and six months following the first operation of the cathodic protection system.
3 = interior lining in accordance with 40 CFR 280 Section 33 or constructed of fiberglass.
RD-1 = monitored for release at least every 30 days by automatic tank gauging, vapor monitoring,
groundwater monitoring or manual tank gauging as detailed in 40 CFR 280 Section 43.
RD-2 = monitored for release at least every 30 days by automatic tank gauging, vapor monitoring, or
groundwater monitoring as defined in 40 CFR 280 Section 43.
RD-3 = monitored for leak detection by inventory control and manual tank gauging as defined in 40 CFR
280 Section 43.
INT-1 = within 10 years after lining, and every 5 years thereafter.
INT-2 = at least every 5 years until 10 years after the tank was installed.
* Military service-specific, host nation, state, or local regulations may require additional inspections or
increased frequency of inspections. The installation must follow the more stringent of this UFC or military
service-specific, host nation, state, or local regulations.

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8-5.4.1.1 Inspection and Maintenance – Single-walled Underground Shop-

Fabricated Tanks.

a. Monthly External Inspection (Identified as P in \1\ Table 8-1 /1/): Ensure

all tank port covers are present, are in good condition, and seated firmly
on the correct tank. Inspect tank stick gauge and ensure markings are
legible and that the stick gauge is not warped or broken. Inspect tank for
water using ATG or stick gauge with water-finding paste. Remove water
found in tank. Open and inspect tank-top containment sumps and ensure
no fuel or water is collected in the sumps. Check for and remove
obstructions in tank fill pipe.
Frequency: Monthly
b. Annual External Inspection (Identified as P in \1\ Table 8-1 /1/): Inspect
electrical connections and junction boxes in underground sumps and
access ports on tank. Ensure boxes are sealed, and that boxes, conduit,
and electrical fittings are not corroded. Inspect submerged turbine pumps
if present. Ensure pumps are in good condition and that pumps and
fittings show no signs of leaking. Inspect tank top containment sumps for
cracks, holes, and budges. Ensure tank top containment sump electrical
and pipe penetrations are intact and secured. For double-walled piping
systems that drain into the tank top containment sump, ensure interstitial
space of piping is open and that sump sensor is properly mounted at the
bottom of the sump. Ensure tank top containment sump lid gasket and
seals are in good condition. Inspect road access covers. Ensure covers
are in good condition, that all bolts are present and that handles and lift
mechanism is in good condition as applicable. Inspect concrete installed
over tank and ensure there is no significant cracking.
Frequency: Annually
c. Tank Tightness Test (Identified as T in \1\ Table 8-1 /1/): Perform test in
accordance with 40 CFR 280, Section 43.
Frequency: As established by SCP based on tank size and release
detection type listed in \1\ Table 8-1 /1/.
d. Formal Internal Inspection (Identified as I in \1\ Table 8-1 /1/): A formal
modified internal inspection in accordance with STI must be conducted by
a certified STI SP001 inspector if the interior is accessible. The inspector
will need to supplement and/or adapt portions of STI SP001 to evaluate
the specific concerns of an underground tank. Check the tank for
settlement and ensure that the tank slopes towards the water drain.
Frequency: As established by SCP based on tank size and release
detection type listed in \1\ Table 8-1 /1/ or as recommended by an STI
SP001 certified tank inspector in the previous inspection report.

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e. Test tank-top containment sumps and ensure they are liquid tight by using
vacuum, pressure, or liquid testing in accordance with 40 CFR 280,
Section 43.
Frequency: Every three years

8-5.4.2 Double-walled Underground Shop-Fabricated Tanks.

Underground shop-fabricated tanks for fuel and oil service installed or replaced after
April 11, 2016 must be secondarily contained and use interstitial monitoring in
accordance with 40 CFR 280 Section 43.

In general, inspections fall into the categories of internal and external (monthly and
annual) inspections. Unless more frequent inspection and testing is specified by military
service-specific directives, host nation, state or local regulations or certified inspector as
a result of the previous inspection, the inspection protocol defined in \1\ Table 8-2 /1/
must be used to determine inspection requirements of double-walled underground shop
fabricated tanks.
\1\
Table 8-2 /1/ Double-walled Underground Shop Fabricated Tank Inspection
and Testing Schedules*

Double-wall
Steel Non- Double-wall Steel
Tank Size4 Release Aviation Fuel aviation Interior with no Interior Double-wall
(Gallons) Detection Type Tank6 Coated5 Coating Fiberglass
111 - 1000 RD-4 P P P P
1001 - 50,000 RD-5 I(10), P I(20), P I(20), P I(20), P
P = periodic inspection (monthly and annual) Use PEI 900 checklists.
I = formal internal inspection by certified inspector. If tank cannot be entered, tanks should be cleaned
and inspected with lights and/or cameras through existing openings as deemed practical by a certified
tank inspector.
( ) = maximum inspection interval, in years.
4 = double-walled tank that meets the requirements of 40 CFR 280 Section 20.
5 = interior epoxy coating.
6 = operating tank that issues fuel to aircraft.
RD-4 = monitored for release at least every 30 days by automatic tank gauging, vapor monitoring,
groundwater monitoring, interstitial monitoring or manual tank gauging as detailed in 40 CFR 280
Section 43.
RD-5 = tank installed on or before April 11, 2016, monitored for release at least every 30 days by
automatic tank gauging, vapor monitoring, groundwater monitoring, interstitial monitoring, or statistical
inventory reconciliation or tanks installed after April 11, 2016 monitored for release at least every 30
days by interstitial monitoring as defined in 40 CFR 280 Section 43.
* Military service-specific, host nation, state, or local regulations may require additional inspections or
increased frequency of inspections. The installation must follow the more stringent of this UFC or military
service-specific, host nation, state, or local regulations.

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8-5.4.2.1 Inspection and Maintenance – Double-Walled Underground Shop-

Fabricated Tanks.
a. Monthly External Inspection (Identified as P in \1\ Table 8-2 /1/): Ensure all
tank port covers are present, are in good condition, and seated firmly on
the correct tank. Inspect tank stick gauge and ensure markings are legible
and that the stick gauge is not warped or broken. Inspect tank for water
using ATG or stick gauge with water-finding paste. Remove water found
in tank. Open and inspect tank-top containment sumps and ensure no
fuel or water is collected in the sumps. Check for and remove
obstructions in tank fill pipe.
Frequency: Monthly
b. Annual External Inspection (Identified as P in \1\ Table 8-2 /1/): Inspect
electrical connections and junction boxes in underground sumps and
access ports on tank. Ensure boxes are sealed, and that boxes, conduit,
and electrical fittings are not corroded. Inspect submerged turbine pumps
if present. Ensure pumps are in good condition and that pumps and
fittings show no signs of leaking. Inspect tank top containment sumps for
cracks, holes, and budges. Ensure tank top containment sump electrical
and pipe penetrations are intact and secured. For double-walled piping
systems that drain into the tank top containment sump, ensure interstitial
space of piping is open and that sump sensor is properly mounted at the
bottom of the sump. Ensure tank top containment sump lid gasket and
seals are in good condition. Inspect road access covers. Ensure covers
are in good condition, that all bolts are present and that handles and lift
mechanism is in good condition as applicable. Inspect concrete installed
over tank and ensure there is no significant cracking.
Frequency: Annually
c. Formal Internal Inspection (Identified as I in \1\ Table 8-2 /1/): A formal
modified internal inspection in accordance with STI must be conducted by
a certified STI SP001 inspector if the interior is accessible. The inspector
will need to supplement and/or adapt portions of STI SP001 to evaluate
the specific concerns of an underground tank. Check the tank for
settlement and ensure that the tank slopes towards the water drain.
Frequency: As established by SCP based on tank size and release
detection type listed in \1\ Table 8-2 /1/ or as recommended by an STI
SP001 certified tank inspector in the previous inspection report.
d. Test tank-top containment sumps and ensure they are liquid tight by using
vacuum, pressure, or liquid testing in accordance with 40 CFR 280,
Section 43.
Frequency: Every three years

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8-6 UNDERGROUND FIELD-CONSTRUCTED TANKS (CUT AND COVER

TANKS).
\1\
a. Underground field-constructed tanks are vertical or horizontally
constructed and can be constructed of welded steel or welded steel
interior with concrete exterior. The tanks are covered with soil or buried in
the ground.
b. The tank design includes manways that extend to grade level for access
to the interior of the tank for inspection and cleaning purposes. Deep-well
vertical turbine pumps are mounted to the top of the tank and are
enclosed in a small pump house or vault, or tanks are gravity fed and
tunnels are used to access tank connections and skin valves. The fill
connection extends to the bottom of the tank and is usually equipped with
a splash deflector or diffuser. The tank is equipped with a sump pump to
remove water from the tank, pressure-vacuum vents, level indicators and
transmitters, and level switches.
c. A baseline internal inspection must be conducted on underground field-
constructed tanks before they are placed into service. The baseline
inspection must include, floor, shell, and roof wall-thickness
measurements. These initial measurements will be used by later
inspectors to monitor and evaluate corrosion rates of specific tanks.
d. Military service-specific, host nation, state or local regulations may require
additional inspections or increased frequency of inspections of
underground field-constructed tanks. The Installation must follow the
more stringent of this UFC or military service-specific, host nation, state,
or local regulations.
/1/

8-6.1 Inspection and Maintenance – Underground Field-Constructed Tanks

(Cut and Cover Tanks).

a. Check the level gauge records and interstitial monitoring ports to

determine if the tank is leaking.
Frequency: Daily
b. Apply field-erected tank monthly external inspection to the maximum
extent possible. Visually inspect tank and appurtenances for evidence of
leaks, shell distortions, signs of corrosion, and settlement at accessible
locations. Items noted during the inspection will be documented for follow-
up action by an authorized inspector (See Appendix F for the Field-
Erected Tank Monthly Inspection Checklist).
Frequency: Monthly

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c. Check tank under static storage conditions for 24 hours using existing
inventory management system to determine if petroleum losses are
occurring. If leakage is noted, further investigation must be conducted in
accordance with military service-specific guidelines.
Frequency: Monthly
d. Apply field-erected tank annual external inspection to the maximum extent
possible. Visually inspect tank and appurtenances for evidence of leaks,
shell distortions, signs of corrosion, and settlement at accessible locations.
Visually inspect pump/equipment vaults for leaks and cracking in concrete
walls and floors. Retain records of inspections reports for five years (See
Appendix F for the Field-Erected Tank Annual Inspection Checklist).
Frequency: Annually
e. Perform a modified out-of-Service API 653 internal inspection to evaluate
the tank for conditions which may affect the operational integrity of the
tank floor, shell, columns and roof by certified API 653 inspector. API 653
provides a checklist to be used as part of the assessment; however the
certified API 653 inspector must modify this checklist to incorporate
specific needs of underground field-constructed tanks. \1\ The API 653 or
STI SP001 inspector must recommend the date of the next inspection.
The inspection interval must be based on the date the Suitability for
Service Letter is issued immediately prior to when the tank is returned to
service.
Frequency: As recommended by the API 653 or STI SP001 inspector.
If there is not a previous recommendation, the inspection must be
performed within ten years after the tank was placed into operation.
/1/
8-7 TANK CLEANING.

Tank cleaning operations are detailed in Appendix H for government personnel.

Contractors must utilize UFGS\1\33 01 50.65/1/for cleaning requirements of tanks.
Appendix H provides the minimum standards for safe entry of petroleum tanks.

a. Conduct Tank Cleaning: Unless otherwise mandated by operational

concerns or military service directives, schedule and conduct tank
cleaning based upon the frequency listed below. After cleaning tanks
must be stenciled in accordance with Section 8-8.1 Tank Stenciling
Requirements.
Frequency:
• Air Force – Tanks above 20,000 gallon (75,700 liters) in
capacity - Every 10 years unless required more frequently due
to fuel quality issues. Contact AFPET and AF Fuel SME for
deviations on schedule. Schedule changes are typically
accepted based on TO 42B1-1 requirements.

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• Air Force – Tanks 20,000 gallon (75,700 liters) in capacity and

under - During out of service inspection cycle unless required
more frequently due to potential fuel quality issues.
• Army, Navy, U.S. Marine Corps – During out-of-service
inspection cycle unless required more frequently due to
potential fuel quality issues.

8-8 RETURNING TO SERVICE AFTER FORMAL OUT OF SERVICE

INSPECTION/REPAIR.

\1\
• Re-install all valves, piping, and manhole covers using new non-asbestos
gasket material compatible with the product being stored. Gasket
thickness must not be less than the thickness of the gasket replaced.
Restore the entire area to its original condition. Reconnect and activate
cathodic protection system.
• Limit the fill line and discharge velocity in the piping of the incoming liquid
stream into petroleum fuel tanks to 3 feet per second (fps) (0.9 meter per
second (mps)) until the fill pipe is submerged in fuel by either two pipe
diameters or 2 feet (60 cm), whichever is less. In the case of a floating-
roof or pan equipped tank, observe the 3 fps (1 mps) velocity limitation
until the roof or pan becomes buoyant. For additional information, see API
2003.
NOTE: Wait thirty minutes after loading or unloading an aboveground fuel tank
before gauging a tank. Wait at least 18 hours before attempting entry onto a
floating roof or pan after an initial fill.

• At the completion of a tank inspection or cleaning operation, ensure the

tank is stenciled in accordance with Section 8-8.1 Tank Stenciling
Requirements.
• Documentation that should be provided before a tank is placed back into
service after a formal out of service inspection or repair includes the
following:
/1/
- A statement signed by an applicable code certified tank inspector
indicating the tank is suitable for return to service including any
caveats, clarifications, or limitations that would affect tank operations
after return to service. The statement must include due dates for the
next applicable formal inspections (internal, external, and leak test)
and any repairs required prior to those next inspections. Next
inspection due dates must be the maximum allowable by code,
calculated from the latest of the inspection or repair completion dates.

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- A completed inspection report compliant with the applicable code

including all required calculations and analysis. Preliminary or field
reports cannot be substituted for this requirement.
- A list of repairs identified during the inspection, including completed
repairs and repairs that are still pending. All pending repairs must be
annotated with a due date.
- Third-party certified calibration (“strapping”) charts when a tank is first
placed in service, when certified calibration charts did not previously
exist, or when repairs were made that would be reasonably expected
to change the tank’s calibration. For shop-fabricated tanks,
manufacturer-provided calibration charts require third-party certification
before they can be accepted.
- A statement signed from the Execution Agent and repair contractor
that custody of the tank is returned to the Installation and that items
listed above have been delivered to the Government.

8-8.1 Tank Stenciling Requirements.

Tank stencils should be 0.75 to 1-inch (19-25 mm) height letters. The information must
be stenciled on or next to the manhole covers for aboveground tanks, or stenciled on
the manhole cover or tank pit wall for underground tanks. The following information
must be stenciled if known:

• Date of the tank cleaning (Month/Year).

• Cleaning completed by (i.e., in-house or contractor’s name).
• Name of the individual certifying the cleaning.
• If applicable, the address or contact information for the contractor.
• Date of last formal internal inspection (Month/Year).
• Date of next formal internal inspection (Month/Year).

8-9 TANK APPURTENANCES.

8-9.1 Floating Roofs and Pans.

\1\
a. Floating roofs and pans rest directly on the petroleum surface, minimizing
vapor space directly above the petroleum surface when storing light-
weight volatile liquids and jet fuels. Floating roofs and pans also minimize
water and contaminant infiltration into the petroleum and mitigate fire risks.
b. Floating pans can be constructed of steel or aluminum. Pans float by
displacement and are not equipped with large voids or hollow
compartments to help provide buoyancy. When aluminum is used the

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design can include an internal honeycomb in the sheet material. This

internal honeycomb includes small void spaces that give the pan
additional buoyancy.
c. Pontoon floating pans can be constructed of steel or aluminum. Pontoon
floating pans use hollow compartments to provide buoyancy. Typically the
hollow compartments are constructed in a circle on the outside diameter of
the pontoon floating pan. The compartments or pontoons are individually
sealed.
d. Floating roofs are installed on tanks that are not equipped with a sealed
cone type roof. In most cases these tanks have been retrofitted with
geodesic domes or steel framed roofs to mitigate water entrance into the
tank through the open top. Floating roofs are typically constructed of steel
and include pontoons for buoyancy. These type roofs are typically
equipped with a drain system that will allow rain water that collects on the
top of the roof to drain to a point outside of the tank. These roofs drain by
sloping to a center sump. The center sump is connected to a hose or
multi-jointed pipe extending through the fuel to an outside water draw-off
valve.
e. Tanks are typically equipped with internal ladders that can be used to
access the top of the floating roof or pan from the top of the tank. In some
cases these ladders are installed on rollers and the angle of the ladder
changes as the floating roof or pan changes elevation. In other cases
these ladders are vertical and penetrate the floating roof or pan and a
rubber seal is installed on the floating pan or roof to close the annular
space between the ladder and the metal of the floating roof or pan.
f. Floating roofs or pans are equipped with anti-rotation cables or pipes.
These anti-rotation devices keep the floating roof or pan in position as the
elevation of the floating roof or pan changes due to fuel level changes.
They also prevent the floating roof or pan from rotating due to currents
produced from fuel receipt or issue operations.
g. Most petroleum fuel tanks are equipped with gauge wells. These wells
are used for temperature and level measurement devices. The wells are
constructed of vertical pipes that penetrate the floating roof or pan. A
rubber seal is installed on the floating roof or pan to close the annular
space between the gauge wells and the floating roof or pan. In some
cases the vertical risers of vertical ladders are also used as gauge wells.
/1/

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Figure 8-1 Floating Roof Seal

Figure 8-2 Floating Roof Detail

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Figure 8-3 Standard Tank Seal on Aluminum Honeycomb Pans

8-9.1.1 Inspection and Maintenance - Aluminum Honeycomb Floating Pans.

Perform visual inspections from fixed roof hatch. Access to internal floating pans is
considered a permit-required confined space, therefore all appropriate safety
procedures must be followed before conducting internal inspections.

a. Visually inspect pan guide/anti-rotation cables and centering of pan.

Frequency: Monthly
b. Visually inspect pan grounding cables for proper attachment and wear or
binding.
Frequency: Monthly
c. Visually inspect for buckling or damage to the pan.
Frequency: Monthly
d. Inspect grounding cables for proper attachment and wear or binding.
Frequency: Annually

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e. Inspect all floating roof penetration seals, such as ladder seals, stilling well
seals, and other seals to ensure that they are in good working condition.
Frequency: Annually
f. Clean and inspect perimeter tank/pan seals.
Frequency: At time of out of service internal inspection.
g. Refer to Section 8-9.1.5, “Floating Roof and Pan Pressure/Vacuum
Vents,” for inspection and maintenance requirements of floating pan
pressure/vacuum vents.
h. Refer to Section 8-9.1.6, “Floating Roof and Pan Legs,” for inspection and
maintenance requirements of floating pan legs.
8-9.1.2 Inspection and Maintenance – Steel Floating Pans.

Perform visual inspections from fixed roof hatch. Access to internal floating pans is
considered a permit-required confined space, therefore all appropriate safety
procedures must be followed before conducting internal inspections.

a. Visually inspect pan guide/anti-rotation cables or pipe and centering of

pan.
Frequency: Monthly
b. Visually inspect pan grounding cables for proper attachment and wear or
binding.
Frequency: Monthly
c. Visually inspect for buckling or damage to the pan.
Frequency: Monthly
d. Visually inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Monthly
e. Inspect grounding cables for proper attachment and wear or binding.
Frequency: Annually
f. Inspect all floating pan penetration seals, such as gauge well seals to
ensure that they are in good working condition.
Frequency: Annually
g. Inspect gauge wells for abrasions that might indicate out of roundness, or
improper centering.
Frequency: Annually
h. Inspect vertical ladder for abrasions that might indicate out of roundness,
or improper centering (if equipped).
Frequency: Annually
i. Inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Annually

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j. Clean and inspect perimeter tank/pan seals.

Frequency: At time of out of service internal inspection
k. Refer to Section 8-9.1.5, “Floating Roof and Pan Pressure/Vacuum
Vents,” for inspection and maintenance requirements of floating pan
pressure/vacuum vents.
l. Refer to Section 8-9.1.6, “Floating Roof and Pan Legs,” for inspection and
maintenance requirements of floating pan legs.
8-9.1.3 Inspection and Maintenance – Pontoon Floating Pans.

Perform visual inspections from fixed roof hatch. Access to pontoon floating pans is
considered a permit-required confined space, therefore all appropriate safety
procedures must be followed before conducting internal inspections.

a. Visually inspect pan guide/anti-rotation cables or pipes and centering of

pan.
Frequency: Monthly
b. Visually inspect grounding cables for proper attachment and wear or
binding.
Frequency: Monthly
c. Visually inspect for buckling or damage to the pan.
Frequency: Monthly
d. Visually inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Monthly
e. Inspect pontoons for standing liquid and presence of strong vapors.
Frequency: Annually
f. Remove mechanical gauge float cover and ensure float is securely
fastened to gauge tape. Check gauge tape for ease of movement.
Frequency: Annually
g. Inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Annually
h. Inspect vertical internal ladder and internal ladder/pan seals for abrasions
that might indicate out of roundness, or improper centering (if equipped).
Frequency: Annually
i. Inspect gauge wells and gauge well/pan seals for abrasions that might
indicate out of roundness, or improper centering.
Frequency: Annually
j. Inspect steel floating pan coatings for corrosion. Touch up with
compatible coating if required (aluminum pans do not require coatings).
Frequency: Annually

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k. Clean and inspect perimeter tank/pan seals.

Frequency: At time of out of service internal inspection.
l. Refer to Section 8-9.1.5, “Floating Roof and Pan Pressure/Vacuum
Vents,” for inspection and maintenance requirements of floating pan
pressure/vacuum vents.
m. Refer to Section 8-9.1.6, “Floating Roof and Pan Legs,” for inspection and
maintenance requirements of floating pan legs.
8-9.1.4 Inspection and Maintenance – Floating Roofs.

Perform visual inspections from fixed roof hatch. Access to floating roofs is considered
a permit-required confined space, therefore all appropriate safety procedures must be
followed before conducting internal inspections.

a. Visually inspect the center primary roof drain system. Confirm it is water-
free.
Frequency: Monthly
b. Visually inspect anti-rotation pipes/roof guides and centering of roof.
Frequency: Monthly
c. Visually inspect grounding cables for proper attachment and wear or
binding.
Frequency: Monthly
d. Visually inspect for buckling or damage to the roof.
Frequency: Monthly
e. Visually inspect for standing water on roof deck.
Frequency: Monthly
f. Visually inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Monthly
g. Ensure that the drip-tight plug is placed in the roof drain opening.
Frequency: Annually
h. Ensure that the roof drain valve is closed. The drain valve is kept in the
closed position except after each rain or snowfall when it is opened just
long enough to drain the roofline. Tanks with retrofitted geodesic domes
or metal roofs may have had the floating roof drain line removed, so
before opening the roof drain valve ensure the roof drain line has not been
removed.
Frequency: Annually
i. Inspect pontoons for standing liquid and presence of strong vapors.
Frequency: Annually

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j. Remove mechanical gauge float cover and ensure float is securely

fastened to gauge tape. Check gauge tape for ease of movement.
Frequency: Annually
k. Ensure emergency drain is not blocked with debris (if equipped).
Frequency: Annually
l. Inspect for damage or deflection in the rolling ladder (if equipped).
Frequency: Annually
m. Inspect vertical internal ladder and internal ladder/roof seals for abrasions
that might indicate out of roundness, or improper centering (if equipped).
Frequency: Annually
n. Inspect gauge wells and gauge well/roof seals for abrasions that might
indicate out of roundness, or improper centering.
Frequency: Annually
o. Inspect the floating roof coating for corrosion. Touch up with compatible
coating if required.
Frequency: Annually
p. Clean and check perimeter tank/roof seals.
Frequency: At time of out of service internal inspection.
q. Refer to Section 8-9.1.5, “Floating Roof and Pan Pressure/Vacuum
Vents,” for inspection and maintenance requirements of floating roof
pressure/vacuum vents.
r. Refer to Section 8-9.1.6, “Floating Roof and Pan Legs,” for inspection and
maintenance requirements of floating roof legs.
8-9.1.5 Floating Roof and Pan Pressure/Vacuum Vents.

Floating roof and pan pressure/vacuum vents are used to relieve vacuum pressure on
the floating roof or pan when the legs of the floating roof or pan make contact with the
tank bottom and a vapor space is created between the surface of the liquid and the
bottom of the floating roof or pan as the liquid level continues to drop. The
pressure/vacuum vent also relieves positive pressure as the fluid below the floating roof
or pan rises before the surface of the liquid makes contact with the bottom of the
floating roof or pan.

8-9.1.5.1 Inspection and Maintenance - Floating Roof and Pan

Pressure/Vacuum Vents.

a. Inspect the floating roof or pan pressure/vacuum vent to ensure that the
seats and retaining straps or guides are in good working order and that
the pressure/vacuum vent is not stuck to its seats, but instead lift easily off
of its seats and reseats properly. Inspect gaskets for wear and replace as
required. Refer to the manufacturer’s operation and maintenance manual

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provided with the floating roof or pan for additional guidance on servicing
the pressure/vacuum vent.
Frequency: At time of out of service internal inspection.
8-9.1.6 Floating Roof and Pan Legs.

Floating roof and pan legs support the floating roof or pan in its high position for
maintenance (approximately 6 foot-3 inch (1.9 meter) clearance from bottom of floating
roof or pan to tank bottom), and limit the low position of the floating roof or pan when
fuel is drawn down to approximately 2 foot 5-inches (0.7 meter) of clearance from
bottom of floating roof or pan to tank bottom or minimum of 6-inch (150 mm) from the
top of any internal nozzle flange to the bottom of the floating roof or pan, whichever is
higher.

8-9.1.6.1 Inspection and Maintenance - Floating Roof and Pan Legs.

a. Inspect the floating roof or pan legs and tank bottom striker plates for
wear; inspect the seals where the legs penetrate the floating roof or pan
for leaks; inspect the low leg position stops to make sure they are securely
fastened to the legs and will stop the floating roof or pan at the low
position; inspect the leg keeper straps to make sure they are securely
fastened to the legs to prevent the legs from falling off or through the
floating roof or pan; inspect the threaded keeper caps or high position
locking mechanisms to ensure they are in proper working order for
securing the floating roof or pan in the high position. Refer to the
maintenance manual provided with the floating roof or pan for additional
guidance on floating roof or pan legs and associated hardware.
Frequency: At time of out of service internal inspection.
8-9.2 Secondary Tank Bottoms.

Secondary tank bottoms are installed to repair original tank bottoms that degraded.
Secondary tank bottoms are installed approximately 1-foot (300 mm) above the existing
tank bottom. In most cases sand is installed between the original and secondary
bottom, although in some cases a new release protection barrier is installed between
the original and secondary tank bottom. Tanks equipped with secondary tank bottoms
can be identified by the presence of a second chime about 1-foot (300 mm) above the
original chime at the tank to concrete foundation interface.

8-9.2.1 Inspection and Maintenance - Secondary Tank Bottoms.

a. Tanks designed with secondary tank bottoms should have tell-tale devices
(leak detection ports) to allow for monitoring of the tank’s floor integrity.
The tell-tale devices are typically configured as valves or inspection ports
to allow for visual monitoring of liquid that may be present between the
foundation and the tank floor. The presence of water would indicate a
breach in the foundation seals or flooring while the presence of petroleum

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would indicate integrity loss in the tank floor. Open and check tell-tale
valves or inspection ports. Verify the absence of water or petroleum.
Frequency: Monthly
8-9.3 Tank Pressure/Vacuum Vents.

The pressure/vacuum vent allows air to escape when filling the tank and allows air to
enter the tank when the tank is being emptied, or drawn down, in order to keep from
damaging the tank and to keep fuels with high vapor pressures from evaporating from
the tank. Pressure/vacuum vents are typically installed on petroleum fuel storage tanks
storing petroleum fuels with vapor pressures exceeding 0.75 psi (5 kPa). They are not
usually installed on API 650 tanks with floating roofs and atmospheric vents. The type
and size of vent used can vary greatly.

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Figure 8-4 Pressure Vacuum Vent

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8-9.3.1 Inspection and Maintenance – Tank Pressure/Vacuum Vents.

a. On underground shop fabricated tanks, ensure tank pressure/vacuum vent

is present and that the riser pipe is securely supported and vertical.
Frequency: Monthly
b. Inspect vent settings. Pressure and vacuum settings for pressure/vacuum
vents are usually specified on the vent nameplate or in the manufacturer’s
manual for the vent.
Frequency: Annually
c. Clean the pressure/vacuum vent. Information on the type of
pressure/vacuum vent and procedures for the removal of covers, hoods
and/or pallet removal and reinstallation should be found in the
manufacturer’s operation and maintenance manual. Before removing the
pallets, brush all accumulations from the protecting screens, the pallets,
and all surfaces of the valve. Brush the screens from inside the valve so
that dirt and other objects fall to the outer sides. Remove heavy loading
weights prior to removing the pallet assembly. Remove deposits or
foreign matter using reasonable care not to damage diaphragms or seats.
Frequency: Annually
d. Inspect gaskets, seats, diaphragm, pallet stems and stem guides. Check
all mating surfaces which must be free of nicks, cuts, cracks or deposits
that might interfere with the proper seating or tightness of the valve. Test
the pallets to ensure they move freely up and down over the full range of
travel.
Frequency: Annually
8-9.4 Emergency Vents.

Emergency vents are installed on most tanks built to UL 142, UL 2080, UL 2085 and
API 650 standards. The type and size of the vent used can vary greatly and is
determined by the wetted surface (square feet) or venting capacity (cubic feet per hour)
of the tank.

8-9.4.1 Inspection and Maintenance – Emergency Vents.

a. Inspect emergency vents for external damage, such as dents, rusting,

severe pitting or obstruction by other equipment, piping or conduits.
Frequency: Annually
b. Remove the vent, if possible, and inspect the seals and diaphragms for
cracking or breakdown. Inspect retaining cables to ensure they are
fastened to the vent and the manway or tank. Inspect guides to ensure
emergency vents can function properly and re-seat.
Frequency: Annually

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c. Verify that emergency vents have not been removed or modified.

Emergency vents should not be replaced with ATGs, manual sample
ports, level alarms, etc.
Frequency: Annually
d. Tanks that are equipped with manways for emergency vents must be
inspected for appropriate type, length, number of bolts, and lift clearance
of the manway in accordance with UL-142, Sections 8 and 9.
Frequency: Annually
8-9.5 Flame Arrestors.

Flame arrestors are intended to provide a positive flame-stop and prevent a fire from
spreading to the interior of storage tanks and are typically installed in conjunction with a
pressure/vacuum vent. Flame arrestors normally utilize a tube bank consisting of
alternate flat and corrugated metal sheets around a solid core of like material
sandwiched between two end sections with uniform precision-ground faces to ensure a
tight seal.

8-9.5.1 Inspection and Maintenance – Flame Arrestors.

a. The tube bank must be removed and cleaned of foreign matter by

immersing in an approved solvent solution, taking care not to damage the
tube bundle. Gaskets must be inspected and replaced as necessary.
Frequency: Annually
8-9.6 High Level Shut-off Valve (HLSO).

High level shut-off valves are designed to shut off receipts into the tank when a
predetermined level is reached.

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Figure 8-5 External High Level Shut-off Valve

8-9.6.1 External High Level Shut-off Valves (HLSO).

\1\
a. External High Level Shut-off (HLSO) valves are installed in the receipt
piping of tanks. Tanks are configured for the HLSO valve to close at the
high alarm level or between the high and high-high alarm level. In most
cases, these valves use hydraulic pressure from the upstream side of the
fuel piping connected to the valve to open. The valves are equipped with
flexible diaphragms and control pilots used to operate the valves. In other
cases the valves are solenoid operated and require power to open.
b. Hydraulic actuated valves are controlled by a separate float valve
assembly. The float valve can be installed in a sensing chamber on the
outside of the tank, or internally installed. The float of the float valve is
buoyant in fuel and will rise up to activate the float valve when fuel in the
tank reaches the predetermined high level.
c. External float valve sensing chambers are usually accessible from stairs
or a platform installed on the outside of tanks. Internal floats are installed
in manway covers or tank nozzles at the top of tanks. Tubing from the
inlet side of a hydraulic HLSO valve is routed to the float valve and back to
both the outlet side of the HLSO valve and to the diaphragm of the HLSO
valve. When the level float valve is activated it relieves hydraulic pressure
from the diaphragm of the HLSO valve and causes the valve to close.
d. Some newer hydraulic HLSOs are equipped with a solenoid valve that will
activate to relieve pressure from the diaphragm of the HLSO valve and

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cause it to close if the fuel in the tank reaches the high-high level. This
solenoid is interlocked with the high-high level alarm. The solenoid
feature is installed as a backup to the primary float valve closing feature.
/1/
8-9.6.1.1 Inspection and Maintenance – External HLSO Valve.
a. Activate the tank high-high level alarm and ensure the solenoid valve (if
equipped) activates on the HLSO valve. Ensure the HLSO valve closes
when the solenoid valve is activated.
Frequency: Quarterly
b. Isolate, drain, and then vent the external float valve chamber (if equipped).
Refill (either manually or via the storage tank product saver tank pump)
the float chamber to test the float valve. Ensure the HLSO closes when
the float is raised.
Frequency: Annually
c. Lift the manual test lever of internally mounted float valve (if equipped).
Ensure that the HLSO closes when the float of the float valve is raised.
Frequency: Annually

8-9.6.2 Internal HLSO Valve.

Internal HLSO valves are installed in the internal fill tube of tanks. Internal HLSO valves
incorporate a float that closes the valve when the float rises. In some cases these
valves also include a by-pass valve mechanism. When the level in the tank reaches a
pre-determined height, approximately 90%, the float of the HLSO valve rises and closes
the main valve. When the main valve closes at the 90% level the by-pass valve (if
equipped) opens and allows approximately 5 gpm (0.3 lps) to enter the tank. If the level
in the tank continues to rise and reaches the 95% level the by-pass valve will close and
prevent additional fuel from entering the tank.

8-9.6.2.1 Inspection and Maintenance – Internal HLSO Valves.

a. Inspect and test the high level shut-off valve and float mechanism,
counter-weights, float rods, and floats to ensure the float mechanism is
moving freely and functioning properly to close the high level shut-off
valve. If valve is not equipped with a manual test mechanism the level of
the tank must be raised to the high level shutoff valve set point in order to
test the valve. Ensure valve is installed at a proper height.
Frequency: Annually

8-9.7 Mechanical Tape Gauges.

The mechanical tape gauge readout window is typically mounted in a convenient
location on the side of the tank and is visible to the tank operator. On aboveground
vertical storage tanks, the tape gauge readout device is typically mounted near the base

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of the tank stairs. The other end of the tape is attached via a stainless steel cable or
tape, enclosed in a conduit with sheaves and pulleys, either to a float that rides on the
petroleum fuel surface inside the tank or to a weight that rests directly on top of the
floating roof or pan. Note: When attached to a weight that rests on top of the floating
roof or pan, the petroleum fuel level will not read below the setting of the floating roof or
pan legs.
8-9.7.1 Inspection and Maintenance - Mechanical Tape Gauges.

a. Visually check that a liquid level is indicated and that the measurement
appears to be accurate.
Frequency: Daily
b. Check the mechanical tape gauge against the automatic electronic tank
gauge (if installed) or by manually gauging the tank for relative accuracy
and proper working condition. Consult the manufacturer’s operation and
maintenance manual for additional maintenance and inspection
requirements.
Frequency: Quarterly

8-9.8 Automatic Tank Gauges

Automatic Tank Gauges (ATG) are used to measure the fuel level in petroleum fuel tanks.

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Figure 8-6 Mechanical Tape Gauge

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8-9.8.1 Mechanically Operated Tape Gauge.

The gauge can be installed on the tank roof or the side of a tank. The level
measurement is displayed using a mechanical dial and counter built into the gauge
head. An incrementally perforated tape runs from the gauge head through a conduit
down into the tank with a float attached at the end. The float moves up and down with
the petroleum fuel level. Petroleum fuel level data is electronically transmitted by a level
transmitter fitted to the gauge.

The end of the tape should never be attached directly to a floating roof or pan. This
type of installation may result in damage to the gauge head or the tape. Existing
installations that are currently attached directly to the floating roof or pan should be
retrofitted by attaching the tape to a weight placed on top of the floating roof or pan.
Varec recommends a ten pound (4.5 kg) weight, and Sand and Jurs recommends a six
pound (2.7 kg) weight.

8-9.8.1.1 Inspection and Maintenance – Mechanically Operated Tape Gauge.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of mechanical float, tape
gauge, and electronic level transmitter.

a. Visually inspect the gauge to ensure the power is on, there are no warning
alarms or lights and a liquid measurement is indicated and the tank level
reading appears to be accurate.
Frequency: Daily
b. Inspect gauge head for buildup of sediment.
Frequency: Quarterly
c. Inspect tape conduit for deformations that would inhibit movement of tape
up and down.
Frequency: Quarterly
d. Gauge level accuracy must be checked against a hand dip measurement
of the tank. Calibrate as required.
Frequency: Semi-annually
e. Inspect float and guide cable through an opened manway or access cover.
Verify that the guide wire is taut and free of kinks. Verify that the float is
buoyant and free of sludge or sediment build up.
Frequency: Semi-annually
f. Inspect power and control wires for damage.
Frequency: Semi-annually
g. Inspect wire connection termination points for damage or loose
connections.
Frequency: Semi-annually

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h. Lubricate moving parts of the gauge head with recommended lubricant.

Frequency: Annually

8-9.8.2 Magnetostrictive Probes.

Magnetostrictive probes are tank gauges that use floats to detect fuel and water levels
in tanks. These gauges do not require a stilling well and are typically used on horizontal
tanks.
Figure 8-7 Magnetostrictive Probe

8-9.8.2.1 Inspection and Maintenance – Magnetostrictive Probes.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of probe and electronic
level transmitter.

a. Visually inspect the gauge to ensure the power is on, there are no warning
alarms or lights and a liquid measurement is indicated and the tank level
reading appears to be accurate
Frequency: Daily
b. Inspect probe assembly for buildup of sediment.
Frequency: Quarterly
c. Inspect probe assembly and probe shaft for deformations that would
inhibit movement of probe.
Frequency: Quarterly
d. Level probe accuracy must be checked against a hand dip measurement
of the tank. Calibrate as required.
Frequency: Semi-annually
e. Verify that the probe float is buoyant and free of sludge or sediment build up.
Frequency: Semi-annually
f. Inspect power and control wires for damage.
Frequency: Semi-annually

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g. Inspect wire connection termination points for damage or loose

connections.
Frequency: Semi-annually

8-9.8.3 Servo Gauge.

Servo gauges are tank top mounted, requiring a stilling well for the gauge’s float to
follow the fuel level up and down the tank.

Figure 8-8 Servo Gauge

8-9.8.3.1 Inspection and Maintenance – Servo Gauge.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of servo gauge and
electronic level transmitter.

a. Visually inspect the gauge to ensure the power is on, there are no warning
alarms or lights and a liquid measurement is indicated and the tank level
reading appears to be accurate.
Frequency: Daily
b. Inspect gauge head for buildup of sediment.
Frequency: Quarterly
c. Gauge level accuracy must be checked against a hand dip measurement
of the tank. Calibrate as required.
Frequency: Semi-annually

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d. Inspect float and guide cable through an opened manway or access cover.
Verify that the guide wire is taut and free of kinks. Verify that the float is
buoyant and free of sludge or sediment build up.
Frequency: Semi-annually
e. Inspect power and control wires for damage.
Frequency: Semi-annually
f. Inspect all wire connection termination points for damage or loose
connections.
Frequency: Semi-annually
g. Inspect stilling well. Ensure the stilling well is straight and vertical with no
dents so that the float can move freely.
Frequency: Annually
h. Lubricate moving parts of the gauge head.
Frequency: Annually

8-9.9 Level Alarms.

Alarms can include high-high, high, low, and low-low level alarms. On small or
underground tanks the level alarms may be suspended inside the tank. On field-
erected vertical tanks the alarm switches are typically mounted in chambers mounted to
the outside of the tank.

8-9.9.1 Externally Mounted Level Alarms.

Externally mounted level alarm switches are installed in sensing chambers mounted to
the outside of the tank. Manual valves are installed at the sensing chamber tank
connection points. These valves are used to isolate the chambers in order to perform
periodic maintenance and testing of the switches without increasing or decreasing the
fuel level within the storage tank.

On newer installations, the product saver system pump is configured to supply fuel to
the sensing chambers and to drain fuel back to the product saver tank to facilitate alarm
switch testing. Vent valves are also provided on the sensing chambers.

8-9.9.2 Inspection and Maintenance – Externally Mounted Level Alarms.

a. Test level alarm switches by isolating the chambers from the tank using
the sensing chamber isolation valves. Vent and drain the chambers.
Slowly pour product into the chambers through a funnel on top of the
chamber to test the level switch at the specified level setting.
Frequency: Semi-annually

8-9.9.3 Internally Mounted Level Alarms.

Internal level alarms are suspended inside the tank.

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8-9.9.4 Inspection and Maintenance – Internally Mounted Level Alarms.

a. Test level alarm switches by activating manual testing levers, if equipped.

If alarms switches are not equipped with manual testing levers, adjust the
level of fuel in the tank to the alarm points in order to test the alarm
switches. If it is not feasible to adjust the level of the fuel in the tank to all
of the alarm set points, remove the alarm switches from the tank and test
the alarms externally. Reinstall alarm switches in the tank once testing is
complete.
Frequency: Annually

8-9.10 Product Saver Tanks.

Product saver tanks are used to remove water from tank bottoms and return useable
fuel back to the tank. The product saver tank typically consists of a 55 gallon (208 liter)
tank with a cone down bottom and removable top. The tank includes a sight glass with
density ball to monitor the fuel to water interface. The tank is equipped with a water
draw-off connection and either an electric pump or a hand pump to return useable fuel
to the storage tank and/or pump water off to a portable container. Some product saver
tanks are configured to pump fuel to the external high level switch chambers and
external high level shut-off valve float chambers to facilitate testing those devices.

8-9.10.1 Inspection and Maintenance – Product Saver Tanks.

a. Inspect the product saver tank to ensure all valves are working properly,
sight level gauges with density balls are working properly and are not
broken, and hand pumps or electric pumps are working properly and are
not leaking.
Frequency: Quarterly

8-9.11 Sidestream Filtration Systems.

Sidestream filtration systems are used to filter or polish fuel stored in tanks. Typically,
the system consists of a 100 gpm (6.3 lps) pump that draws fuel from the tank low
suction line, which extends to the center sump, and then pumps the fuel through a 100
gpm (6.3 lps) filter separator back to the tank’s fill line. A connection is sometimes
provided downstream of the filter separator to pump fuel off to a tank truck or bowser.
The filter separator will polish the fuel, but will also remove water from the bottom of the
tank. The filter separator is equipped with a water level conductance probe and a float
control pilot to shut the filter separator flow control valve if too much water is present in
the filter separator sump. In this case, the product recovery system should first be
utilized to draw as much water off the tank bottom as possible before the sidestream
filtration operation is continued.

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8-9.11.1 Inspection and Maintenance – Sidestream Filtration Systems

a. Check filter separator vent tank (typically 5 gallon (19 liters), if

incorporated) and ensure it is empty.
Frequency: Monthly
b. Refer to Section 6-1 Pipe Testing and Inspections for inspection and
maintenance requirements of piping.
c. Refer to Section 3-6.4 Basket Strainers for inspection and maintenance
requirements of basket strainers.
d. Refer to Section 3-8 Pumps for inspection and maintenance requirements
of fuel pumps.
e. Refer to Section 3-6.2 Filter Separators for inspection and maintenance
requirements of filter separators.
f. Refer to Section 4-4.2.2 Filter Separator Control Valves for inspection and
maintenance requirements of filter separator control valves.
g. Refer to Section 9-1.6 Grounding Systems for inspection and maintenance
requirements of grounding systems.
h. Refer to Section 9-1.9 Electronic Equipment for inspection and
maintenance requirements of control panels.

8-9.12 Fill Ports.

Fill ports are used to protect tank fuel receipt and vapor balance connection points.
They are typically installed on underground and aboveground horizontal tanks. The fill
ports can be installed in a pit installed above the tank (underground storage tanks) or on
stands installed in close proximity to the tanks (aboveground storage tanks). They also
provide a small volume of containment below the receipt connection points. In some
cases the fill port is equipped with a small pump or valve that can be used to transfer
fuel that collects in the fill port containment area into the receipt line of the respective
tank.

8-9.12.1 Inspection and Maintenance - Fill Ports.

a. Ensure fill port covers are installed and are not damaged or broken.
Ensure fill port covers are identified by fuel type and are installed on the
correct tank. Visually inspect the fill port spill bucket to ensure there are
no cracks, budges, or holes. Ensure the spill bucket is clean of dirt, trash,
water, and fuel.
Frequency: Daily
b. Inspect drain valve in spill bucket and ensure it is in good condition.
Ensure the caps installed on the receipt connection points are vapor tight
and are not broken, cracked, or chipped. Ensure the poppet valve of the

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vapor recovery port seals tightly and no vapor is escaping from the tank
when the valve is closed.
Frequency: Monthly
c. \1\ Hydrostatically test fill-port to ensure containment is liquid-tight. This
test may use opportune rainfall by holding rainwater in the fill-port
containment area for one hour. Where evaporation is a concern, conduct
the testing when this concern would be minimized, such as at night/early
morning or during a time of year when this would not be as much of an
issue. Record the water level at the start of the 60 minute (minimum) hold
period and if the water level drops by 1/8 inch or more, perform and record
an investigation to determine the cause and any required repairs. Once
repairs are completed, a new test must be completed. Refer to Appendix
B for testing procedures and to use to document the testing. /1/ Ensure
secondary containment area of fill port is fuel tight. Ensure the manual
transfer pump or drain valve is operational.
Frequency: \1 \Every 3 years /1/

8-9.13 Release Detection Monitoring.

Release detection is installed on aboveground and underground petroleum fuel storage

tanks. Release detection measures vary based on the age and type of tank.

In addition to 40 CFR Part 280, host nation, state, and local regulations may have
additional design, inspection, and maintenance requirements that may be more
stringent than DoD or Federal guidance. Facility operators and maintainers must be
familiar with the Installation’s SPCC plan in order to comply with all inspection and
recordkeeping requirements

8-9.13.1 Point Sensor – Dry.

Dry point sensors are installed at the lowest point within the space between the fueling
system and secondary barrier. Dry point sensors send a signal to a monitoring panel
indicating liquid detection. Dry point sensors may include float switches, or electrical
resistor switches. A licensed and/or certified technician is required to troubleshoot or
inspect dry point sensors for operation.

Underground and aboveground double-wall tanks (such as product recovery tanks)

often have point sensor(s) installed through a connection on top of the tank that extends
down near the bottom of the interstitial space between the primary and secondary tank
shells. The sensor is used to determine if the primary tank is leaking into the interstitial
space between the shells or if groundwater is leaking into the interstitial space. The
point sensor is typically of the continuous surveillance type and provides an audible and
visible alarm at the operator control panel.

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8-9.13.1.1 Inspection and Maintenance – Point Sensor – Dry.

a. Ensure the monitoring panel associated with the point sensor(s) is

powered on and no alarms are present.
Frequency: Daily
b. Ensure monitoring space is clear and free of debris and liquid.
Frequency: Monthly
c. Test sensor and ensure it is functional.
Frequency: Annually

8-9.13.2 Point Sensor – Wet.

Wet point sensors are installed within liquid reservoirs that monitor the liquid filled space
between the primary tank and secondary barrier (USTs only). A licensed and/or
certified technician is required to troubleshoot or inspect wet point sensors for operation.

8-9.13.2.1 Inspection and Maintenance – Point Sensor – Wet.

a. Ensure the monitoring panel associated to the wet point sensor(s) is

powered on and no alarms are present.
Frequency: Daily
b. Ensure level of monitoring fluid is within normal range.
Frequency: Monthly
c. Test sensor and ensure it is functional.
Frequency: Annually

8-9.13.3 Point Sensor – Pressure/Vacuum.

Pressure/vacuum point sensors are installed at points within the space between a
fueling system and secondary barrier. This space may be under pressure or a vacuum
depending on the configuration. Pressure/vacuum point sensors send a signal to a
monitoring panel indicating loss of pressure or loss of vacuum. A licensed and/or
certified technician is required to troubleshoot or inspect pressure/vacuum point sensors
for operation.

8-9.13.3.1 Inspection and Maintenance – Point Sensor – Pressure/Vacuum.

a. Ensure the monitoring panel associated with the pressure/vacuum point

sensor(s) is powered on and no alarms are present.
Frequency: Daily
b. Test vacuum sensor for proper operation.
Frequency: Annually

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8-9.13.4 Visual Leak Detection.

\1\
a. Visual leak detection systems include the use of tell-tale holes and leak
detection ports.
b. Reinforcement plate tell-tale holes are present in reinforcement plates
used on steel storage tanks at pipe connection points and appurtenance
connection points. The tell-tale holes allow for leaks that form in the
interstitial space between the reinforcement plate and tank shell to be
seen through visual inspection by leaking of fuel through the tell-tale hole.
Never install plugs in reinforcement plate tell-tale holes.
c. Leak detection ports (tell-tales) are present on storage tank structures with
ring wall foundations and are located around the perimeter of the ring wall
foundations or at a single collection point. Leak detection ports can be
manually opened to inspect for leaks.
/1/

8-9.13.4.1 Inspection and Maintenance – Visual Leak Detection.

a. Visually inspect leak detection ports (tell-tales) for signs of leaks. If there
are debris or objects obstructing the view, appropriate measures must be
taken to remove the debris or remedy the obstructions.
Frequency: During routine inspection of other components or
monthly, whichever comes first.
b. Visually inspect reinforcement plate tell-tale holes for signs of leaks.
Ensure tell-tale holes have not been plugged by debris or a cap. Pack
reinforcement plate tell-tales with white grease to prevent insect nesting
and buildup of debris.
Frequency: Quarterly

8-9.14 Floating Suction Lines.

Floating suction lines are used to pull petroleum from a predetermined level below the
petroleum liquid surface. The suction line is typically suspended by pontoon-type floats.
A cable system connected to the suction arm moves a visual target external to the tank
for visual confirmation that the arm is moving properly.

8-9.14.1 Inspection and Maintenance - Floating Suction Lines.

a. Check external floating suction line position indicator to ensure floating

suction line is moving freely as the level in the tank rises or falls.
Frequency: Quarterly
b. Inspect cables, floats, and swing joint. Ensure interior of floats have not
collected fuel. Ensure cables are securely fastened to anchor points and

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are in good working order. Ensure the suction pipe flange used to support
the swing joint is level and true and that swing joint moves freely up and
down and does not bind.
Frequency: When tank is taken out of service for internal cleaning or
inspection.

8-9.15 Foam Fire Protection Systems.

Aqueous Film Forming Foam (AFFF) systems are sometimes installed on petroleum
fuel storage tanks. When equipped, AFFF spray nozzles are installed at the top of the
tank and, when activated, spray foam into the interior vapor space of the tank. When
the foam is sprayed it forms an aqueous film that floats at the top of the petroleum fuel
and separates the petroleum fuel from atmospheric oxygen.

8-9.15.1 Inspection and Maintenance - Foam Fire Protection Systems.

Refer to UFC 3-601-02 for inspection and maintenance requirements of tank foam fire
protection systems.

8-9.16 Heating Coils.

Some petroleum storage tanks in heavy fuel or lube oil service are equipped with
heating coils or heaters to warm the petroleum and lower the viscosity for transfer
operations. Coils may also be present on storage tanks for other types of petroleum in
cold climates.

8-9.16.1 Steam Type Heating Coils.

Steam is a very effective means of heating heavy petroleum fuel and lube oils. Steam
coils are typically installed in the bottom of tanks and can be in a variety of different
configurations. Internal corrosion of the coils due to the presence of condensate in the
heater coils or tubes is a primary problem in these systems. Depending on the type of
heater used, this corrosion can lead to oil in the steam heating system or water in the
petroleum. To avoid corrosion, steam coils must be shut off at the tank connections
when not in use. Inactive coils must be plugged or removed from tanks. The flow of
steam to the heating coil is typically controlled by an automatic temperature-regulating
valve to prevent overheating the petroleum in the tank.

8-9.16.1.1 Inspection and Maintenance – Steam Type Heating Coils.

a. Observe the regulating valve and check it against a thermometer to be

sure that it controls the tank temperature within a safe range, usually not
over 150 °F (65 °C) for No. 6 burner fuel oil. Steam traps must be
inspected for proper operation to ensure condensate is evacuated from
the steam coil.
Frequency: At each operation

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b. Pressure check heating coils to 10% above normal operating pressure.

Frequency: Annually
c. Steam coils must be cleaned and inspected for visible signs of corrosion
or wear when the tank is emptied and cleaned for inspection. All
components of the steam heating coils, such as weld joins, support points,
valves, temperature wells, control valves, and steam traps must be
inspected and checked for proper operation and visible wear or damage.
The coil may be carefully pressurized with steam and visually checked for
leaks if necessary. Leaks or damage found must be repaired.
Frequency: When the tank is taken down for formal internal
inspection or sooner if steam heating coil damage is suspected.

8-9.16.2 Thermal Fluid Type Heating Coils.

Thermal fluids are sometimes used instead of steam in tank heating coils for heavy lube
oils and other fuel oils. Thermal fluids do not pose the corrosion problems associated
with steam and condensate, but do require inspection and maintenance for proper
operation. Thermal heating coils are typically installed in the bottom of the tank and can
be in a variety of configurations. The flow of thermal fluid to the heating coil is typically
controlled by an automatic temperature-regulating valve to prevent overheating the fuel
oil in the tank.

8-9.16.2.1 Inspection and Maintenance – Thermal Fluid Type Heating Coils.

a. Observe the regulating valve and check it against a thermometer to be

sure that it controls the tank temperature within a safe range, usually not
over 150 °F (65 °C) for No. 6 burner fuel oil. All external valves, fittings,
and other components must be inspected for visible signs of leaks during
operation.
Frequency: At each operation
b. Pressure check heating coils to 10% above normal operating pressure.
Frequency: Annually
c. When tanks are emptied and cleaned for inspection, the heating coils
must be cleaned and inspected for visible signs of corrosion, wear, or
damage. The coils can be pressurized and checked for leaks at that time
with the thermal heating fluid at normal operating pressure, but at ambient
temperature to alleviate possible burns to personnel. Leaks must be
repaired.
Frequency: When the tank is taken down for formal internal
inspection or sooner if thermal heating coil damage is suspected.

8-9.16.3 Electric Rod Type Heating.

Electric rod type heaters are sometimes used to heat liquids directly or they are inserted
into sealed pipes that extend into tanks to indirectly heat the fluid. Typically, electric

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heaters are controlled by a thermostat in conjunction with a thermometer for a visual

check to regulate the heat in the tank and turn the electric heater on and off as required.

8-9.16.3.1 Inspection and Maintenance – Electric Rod Type Heating.

Refer to the manufacturer’s operation and maintenance manual for additional

maintenance requirements.

a. Inspect heater to ensure no fluid leakage around the heater to tank

connection and that the heater is performing properly.
Frequency: At each operation.

8-9.17 Stilling Wells.

Stilling wells are used to minimize movement of level and temperature sensing probes
and floats in petroleum fuel tanks. Stilling wells are constructed of vertical pipe and are
slotted with holes to ensure that the level of fuel in the stilling well matches the level of
petroleum fuel in the tank.

8-9.17.1 Inspection and Maintenance - Stilling Wells.

a. Stilling wells must be visually inspected to be vertically straight and free of

dents or indentations. Sometimes tank stilling wells are made of bare
carbon steel pipe. In these instances the stilling wells must be replaced
with aluminum.
Frequency: At time of out of service internal inspection.
b. Inspect floating seals inside stilling wells to ensure they are not worn and
are sealing the inside of the stilling well property.
Frequency: At time of out of service internal inspection.

8-10 CONTAINMENT SYSTEMS.

Petroleum storage tanks have various types of secondary containment to protect

surrounding areas from petroleum contamination. Secondary containment systems
include metal enclosures, diked/bermed areas and remote impounding systems.
Secondary containment systems can be made of metal, concrete, concrete with liner,
brick, or earthen material equipped with an impervious liner.

Military services typically assign draining of containment areas to various organizations;

in all cases, removing of water must be conducted in accordance with the Installation’s
SPCC or other stormwater pollution prevention plan to ensure only water without sheen
is released. Secondary containment areas must be drained based upon local
requirements or monthly, whichever comes first.

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8-10.1 Inspection and Maintenance – Containment Systems (General).

a. Inspect containment systems for cleanliness, if accessible.

Frequency: Daily
b. Secondary containment systems degrade and will collect debris, which
can clog drainage inlets or prevent drain valves from sealing properly. \1\
Hydrostatically test the drainage systems to include containment drain
inlets, drain lines and containment drain valves to ensure the containment
is liquid tight. This test may use opportune rainfall by holding rainwater in
the containment system for one hour. Where evaporation is a concern,
conduct the testing when this concern would be minimized, such as at
night/early morning or during a time of year when this would not be as
much of an issue. Record the water level at the start of a 60-minute
(minimum) hold period and if the water level drops by 1/8 inch or more,
perform and record an investigation to determine the cause and any
required repairs. Once repairs are completed, a new test must be
completed. Refer to Appendix B for testing procedures and to use to
document the testing
American Concrete International (ACI) Standards 224R “Control of
Concrete Cracking” and ACI’s Concrete Repair Manual are two standards
that owners/operators can follow to maintain the integrity of the concrete
secondary containment. /1/
Frequency: \1\ Every 3 years /1/

8-10.2 Concrete and Cement Brick Dike/Berm Walls and Floors.

Aboveground petroleum tanks that have containment system walls constructed of

concrete or cement brick must be maintained and inspected to ensure containment
system integrity.

8-10.2.1 Inspection and Maintenance – Concrete and Cement Brick

Dike/Berm Walls.

a. Inspect for vegetation that has taken root in seals or cracks. All vegetation
must be removed in all cases to prevent penetration of seals, joints or
cracks in the concrete.
Frequency: Daily
b. Inspect walls constructed of bricks for signs of deterioration (e.g., spalling
caused by freeze-thaw conditions, cracks, and joint cracks between
bricks). Walls constructed of bricks must be patched immediately to
prevent further penetration of the wall structure.
Frequency: Daily
c. Inspect walls constructed of concrete for signs of deterioration (e.g.,
spalling caused by freeze-thaw conditions and cracks). Clean and seal

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cracks with a fuel resistant sealant.

Frequency: Semi-annually
d. Inspect seals and joints in concrete walls. Joint sealant that has retracted
from the joint or become unbonded with the joints must be removed and
replaced with fuel resistant sealant.
Frequency: Semi-annually

8-10.2.2 Inspection and Maintenance – Dike/Berm Floors.

a. Inspect for vegetation that has taken root in seals or cracks. All vegetation
must be removed in all cases to prevent penetration of seals, joints or
cracks in the concrete.
Frequency: Daily
b. Inspect floors made of concrete for signs of deterioration (e.g., spalling
caused by freeze-thaw conditions and cracks). Clean and seal cracks
with a fuel resistant sealant.
Frequency: Semi-annually
c. Inspect joints and seals. Joint sealant that has retracted from the joint or
become unbonded with the joints must be removed and replaced with a
fuel resistant sealant.
Frequency: Semi-annually

8-10.3 Earthen Dike Walls.

Earthen dike wall secondary containment systems typically include sloped walls with a
level surface at the top.

8-10.3.1 Inspection and Maintenance – Earthen Dike Walls.

a. Inspect for vegetation that has taken root. All vegetation must be removed
in all cases.
Frequency: Daily
b. Prevent the growth of vegetation inside the containment area. Use
fireproof chemicals for sterilization. Only herbicides approved by the
Installation Environmental Office must be used.
Frequency: Monthly
c. Inspect for signs of erosion. Inspections should be performed particularly
after heavy rains or storms. Repair areas that have deteriorated due to
erosion.
Frequency: Quarterly

8-10.4 Self-Diking or Vaulted Tank Containment.

Tanks built using self-diking or vaulted secondary containment features must meet
NFPA 30 and in cases where the tank is used for dispensing to vehicles or watercraft,

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the tank must meet requirements detailed in NFPA 30A. Additional requirements are
specified in NFPA 1: Chapter 20, NFPA 1: Chapter 66, and UL 2085.

8-10.4.1 Inspection and Maintenance – Self-Diking or Vaulted Tank

Containment.

a. Secondary containment structures on self-diking or vaulted tanks must be

inspected visually for integrity breaches with special attention given to pipe
penetrations and interstitial drain valves.
Frequency: Daily

8-10.5 Flexible Membrane Liners.

Flexible Membrane Liners (FML) are sometimes installed under concrete in storage
tank secondary containment areas and over earthen dikes used as secondary
containment. Typically FML is installed over geotextile membranes and the FML is
brought up and sealed to the concrete tank foundation on the inside of the secondary
containment area and to concrete dike walls that enclose the perimeter of the
secondary containment area. Pipe penetrations through the secondary containment
area, such as piers and pipe supports, are also sealed to the FML, preventing product
from seeping through the liner along the pipe.

8-10.5.1 Inspection and Maintenance – Flexible Membrane Liners.

a. Remove vegetation growing in the gravel and dirt, taking note if the roots
have penetrated the FML.
Frequency: Daily
b. Visibly inspect FMLs where attached to ringwalls, dike walls, concrete
piers and other projections for deterioration due to weather or wear and
repair as necessary.
Frequency: Quarterly
c. Visually inspect FMLs covered with smooth rock or gravel for bare spots
where the gravel has been washed away due to storms or heavy rains for
tears. Replace gravel taking care not to puncture the liner.
Frequency: Quarterly
d. Visually inspect exposed FML for tears or punctures and repair.
Frequency: Quarterly

8-10.6 Pipe Penetrations.

Some pipe penetrations through containment walls incorporate a pipe sleeve through
which the carrier pipe is placed. The carrier pipe is sealed to the pipe sleeve with a link-
type mechanical compression seal at both ends. Boot seals between the end of the
pipe sleeve and the carrier pipe are sometimes added as an additional containment
measure.

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In some cases the carrier pipe directly penetrates concrete containment paving and
walls. In these cases, the space between the carrier pipe and the concrete paving or
wall is sealed with fuel resistant sealant.

8-10.6.1 Inspection and Maintenance – Pipe Penetrations.

a. Inspect boot seals and mechanical link-type seals for wear and cracking.
Ensure the seals are in good working order to seal out water or retain the
petroleum product as intended. Repair or replace defective boot and link-
seals.
Frequency: \2\ Monthly /2/
b. Inspect sealant between pipes and concrete walls, berms, and floors.
Sealant that has retracted from the concrete or pipe surfaces must be
removed and replaced with new fuel resistant sealant.
Frequency: Semi-annually

8-11 MISCELLANEOUS USE TANKS.

8-11.1 Miscellaneous Use Tanks.

Miscellaneous tanks include electric generator tanks, fire pump tanks, waste oil tanks,
ballast water tanks, lube oil tanks, and others. In most cases standalone tanks are
below 10,000 gallon (37,850 liter) capacity and fall into the shop fabricated category and
are designed and built to UL 142, UL 2080 or UL 2085 standards. However, in some
cases the tanks are large field erected tanks and fall into the vertical or cut and cover
category. In some cases the tanks are integrated into the system or skid and are built
to the skid manufacturer’s specifications. This occurs with generator or fire pump belly
tanks.

8-11.1.1 Inspection and Maintenance – Miscellaneous Use Tanks.

a. Standalone aboveground tanks that fall into the vertical field erected
category must follow the inspection and maintenance requirements listed
in Section 8-4 Field-Erected Tanks.
b. Standalone tanks that fall into the shop fabricated tank category must
follow the inspection and maintenance requirements listed in Section 8-5
Shop-Fabricated Tanks.
c. Standalone tanks that fall into the cut and cover category must follow the
inspection and maintenance requirements listed in Section 8-6
Underground Field-Constructed Tanks.
d. Integrated tanks that are supplied as part of an equipment skid or system
must follow manufacturer’s inspection and maintenance
recommendations.

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8-11.1.2 Generator Tanks and Fire Pump Tanks.

These tanks typically hold diesel or kerosene-based fuel use with piston driven engines
to operate electrical generators and fire water pumps.

8-11.1.3 Waste Oil Tanks.

Waste oil tanks store petroleum products that are not suitable for use or reclamation.
This product is typical stored until appropriate quantities are accumulated for
economical sale or disposal. Waste oil tanks take on many types of configurations, and
for integrity testing and maintenance, are considered petroleum tanks.

8-11.1.4 Ballast Water Tanks.

Ballast water tanks are used to store water-fuel mixtures that are pumped from marine
vessel fuel tanks.

8-11.1.5 Lube Oil Tanks.

Lube oil tanks are used to store and distribute lube oil for turbines and gears, hydraulic
equipment and general mechanical lubrication.

8-11.1.6 Additive Tanks.

Additive tanks store bulk additives used to additize jet fuel. They are typically small
aboveground tanks.

8-11.1.7 Heating Oil Tanks.

These tanks typically include heating coils which are used to preheat oil before it can be
used. These tanks may be field erected tanks, shop fabricated, or cut and cover tanks.

8-11.1.7.1 Inspection and Maintenance – Heating Oil Tanks.

Refer to Section 8-9.16 Heating Coils for inspection and maintenance requirements of
heating coils.

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CHAPTER 9 ELECTRICAL SYSTEMS

9-1 ELECTRIC CONTROL SYSTEMS AND EQUIPMENT.

9-1.1 Scope and Limitations.

The intent of this section is to provide guidelines for maintenance of electrical

equipment rated for up to 1,000 V. The intended audience is electrical maintenance
staff or electrical contractors who are engaged in performance of electrical
maintenance. Electrical work must be completed by qualified/licensed electricians
equipped with the proper PPE (e.g., Arc Flash, CPR, First Aid) for the type of work
conducted. The recommended procedures are not intended to contradict electrical
codes. The main objectives of this section are:

• To outline procedures to maintain optimal operating conditions of the

electrical equipment.
• To establish a system for early detection of potential faults in electrical
equipment in an effort to plan repair or replacement before catastrophic
failure occurs.
If in the process of implementing the outlined procedures it is determined that more
extensive testing is required, then such tests should be performed in accordance with
the applicable codes. Due to safety concerns, the maintenance of equipment rated
above 1,000 V is not addressed. This equipment must be maintained only by specially
trained personnel in accordance with manufacturer’s recommendations.

9-1.2 Electrical Equipment.

Maintenance procedures for electrical equipment usually require enclosures to be

opened, inspected and cleaned. This poses higher risk of injury than during normal
operation and basic rules for electrical safety should be followed:

• Always follow approved lockout/tagout procedures.

• Never work alone when testing electrical equipment. A second person
who is First Aid and CPR qualified should be present.
• Never work on energized equipment. Tests that require energized
equipment should be performed by specially trained and licensed
personnel.
• Use V-rated tools and V-rated gloves. V-rated tools are tools rated and
tested for the maximum line-to-line voltage upon which work will be done.
V-rated gloves are gloves rated and tested for the maximum line-to-line
voltage upon which work will be done.
• Use appropriately rated Personal Protective Equipment (PPE) as indicated
by arc flash hazard warning labels as required by NFPA 70E. If such
labels are not installed, perform arc flash hazard analysis before

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implementing electrical maintenance procedures to determine the

appropriate level of PPE.

The preceding list is not exhaustive and does not intend to contradict safety
requirements mandated by codes or regulations.
\2\
9-1.2.1 Inspection and Maintenance – Electrical Equipment.
/2/
a. Electrical control systems include: deadman control; ground verification
systems; EFSO operation; control panels, motor control, and pump
start/stop buttons. These systems must be tested on a periodic basis to
ensure proper operation and functionality. In addition, control system
Uninterruptible Power Supplies (UPS) must be inspected and replaced as
necessary.
Frequency: Quarterly

9-1.3 Power Cables.

The assessment of cable condition is performed mainly by visual inspections. Based on

the observations, certain cables may be scheduled for dielectric testing. Visual
inspection is usually done while inspecting the equipment to which the cable is
connected. Moving or touching of the cables must only be done when the system is de-
energized and locked out.

9-1.3.1 Inspection and Maintenance – Power Cables.

a. Visual inspection: Verify that there are no sharp bends. Verify that the
cable insulation is intact. Verify that cables are appropriately tagged or
otherwise identified. Verify that all connections are tight and not corroded.
Open manholes and handholes. Verify that they are not flooded, clogged
with debris or infested by pests.
Frequency: Annually

b. Insulation resistance test: This test measures the resistance of the

insulation with an Insulation Resistance Tester. During the test, the cable
will be disconnected from both ends. Acceptable test values are 100
megaOhms for cables rated between 120 V to 1,000 V. Insulation
resistance testing for voltages higher than 1,000 V is to be performed by
specialized testing company.
Frequency: As needed based on visual inspection

9-1.4 Motor Controls.

Motor control equipment generally refers to the following: across the line motor starters,
reduced voltage auto transformer starters, wye delta starters, partial winding starters,
solid state starters, reversing starters, and adjustable frequency drives. All motor control
equipment has common components which can be classified as:

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a. Overcurrent and overload protective device – circuit breaker or fuse.

b. Electromagnetic contactor.

c. Control logic elements (e.g., relays, switches, pushbuttons).

The motor control equipment may be installed in a motor control center (MCC) or in a
standalone enclosure dedicated to a single starter. Usually this equipment is installed in
electrical rooms and is protected from the elements. However, standalone enclosures
are sometimes located in close proximity to the driven equipment and are exposed to
the elements. In such cases special attention should be paid to the physical condition of
the enclosure. The maintenance of motor control equipment should be performed
together with the maintenance of the motor.

9-1.4.1 Inspection and Maintenance - Motor Controls.

a. Verify the labeling is consistent with the drawings and specifications.

Frequency: Semi-annually
b. Verify that pushbuttons are easy to operate and are not stuck. Verify that
there is no grease accumulation around the seating.
Frequency: Semi-annually
c. Verify that indicating lights are functional and replace as needed.
Frequency: Semi-annually
d. Verify that electrical and mechanical interlocks operate according to the
design intent. In case of key interlocks, ensure that the number of keys
corresponds to the interlock intent. Having more keys than required
defeats the intent of the interlocking and poses danger to the service
personnel and equipment. If extra keys are found, they should be removed
from the equipment.
Frequency: Semi-annually
e. Inspect the enclosure for visible signs of corrosion.
Frequency: Interior annually/exterior semi-annually
f. Open the enclosure – be mindful of insects, rodents and reptiles,
particularly if located outdoors. Look for signs of corrosion, dust
accumulation, spider webs, etc. Clean the enclosure with compressed air
and apply rust inhibitors and paint as needed.
Frequency: Annually
g. Inspect the overcurrent protective devices for proper seating. Verify that
rating is appropriate for the motor. Look for signs of attached wire and
device overheating.
Frequency: Annually

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h. Inspect the arch shoots of contactors and clean as needed. Check that
partitions are not burned.
Frequency: Annually
i. Inspect contactors for abnormal wear. Check contacts for pitting,
roughness and oxidation. Verify that contact gap, alignment and pressure
are in accordance with manufactures recommendations.
Frequency: Annually
j. When contactors are used, listen for the chatter of contacts or buzzing
noise. These are indicative of a faulty contactor.
Frequency: Annually
k. Verify that relays and switches are firmly seated in their bases and there
are no signs of overheating or vibration.
Frequency: Annually
l. Look for frayed or broken strands in the flexible control wiring and replace
if such are found.
Frequency: Annually
m. Perform a functional test of protective devices if they are equipped with
self-testing circuits or switches.
Frequency: Annually
n. Perform a functional test of all manual switches and verify proper
operation against intended design logic. Replace switches and relays if
operation is not satisfactory.
Frequency: Annually
o. Perform insulation resistance test for the control wiring.
(Note: Testing of the control wires may require substantial down time.
Therefore, this should only be performed on a case by case basis if there
are reasons to suspect that the insulation of the control wiring is
deteriorating.)
Frequency: As required

9-1.5 Panelboards.

Panelboards are used to control power supply to equipment, buildings, and structures.

9-1.5.1 Inspection and Maintenance – Panelboards.

Conduct the following actions to complete the inspection:

a. Verify that there are no physical obstructions blocking access to the

panelboard. Remove physical obstructions.
Frequency: Quarterly

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b. Inspect the enclosure and the surrounding area for water damage and
corrosion.
Frequency: Annually
c. Verify that all breakers are either in the “On” or the “Off” position. If there
are tripped breakers, investigate the cause of the trip.
Frequency: Annually
d. Verify that there is a breaker schedule. If there is no breaker schedule or
the schedule is worn and out-of-date, create and post a new one.
Frequency: Annually
e. Verify that the breaker operation matches the description on the panel
schedule.
Frequency: Annually
f. Observe breakers, wires and terminals for signs of overheating or short
circuiting.
Frequency: Annually
g. Verify that all breakers are firmly seated and locked in place by slightly
shaking them.
Frequency: Annually
h. Verify that all grounding wires are firmly connected to the grounding bar.
Frequency: Annually
i. If a breaker malfunction is identified, leave breaker in the open position
and replace as soon as possible. If a breaker cannot disconnect its circuit,
the entire panelboard must be switched off using its main disconnecting
means and locked out until the breaker is repaired.
Frequency: Annually

9-1.6 Grounding Systems.

Visual inspection of the integrity of the grounding should be performed together with the
visual inspection of the grounded equipment, such as motors, motor control centers,
piping, filter vessels, petroleum fuel tanks, and transformers. A typical facility will include
two types of grounding systems: power grounding and static grounding. Power
grounding provides a low-impedance path for the fault current in case of equipment,
conductor, and raceway failures. Static grounding provides a path for static electricity
discharge to dissipate static electricity build up on equipment.

9-1.6.1 Inspection and Maintenance – Power Grounding Systems.

a. The connections to the grounding system must be surveyed and verified
for continuity. If a connection is suspected to be loose, perform further
testing. In some occasions, it is more cost effective to replace the
suspected connection instead of performing diagnostic tests.
Frequency: Annually

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b. Measure the voltage between the equipment grounding conductor and the
electrode grounding conductor (usually bare copper). Investigate test
results above 3 VAC for a potential ground fault.
Frequency: Annually
c. Measure the voltage between the chassis of the equipment and the
electrode grounding conductor. Investigate if the readings exceed 2 VAC.
Frequency: Annually
d. Facility ground resistance check: This type of testing is performed with a
four lead, low resistance ohmmeter or digital ohmmeter. Recommended
values are between 3 and 5 ohms. In no case should the grounding
resistance be higher than 25 ohms.
Frequency: Every five years

9-1.6.2 Inspection and Maintenance – Static Grounding Systems.

a. Inspect ground reels for corrosion. Ensure ground reels are securely
mounted to a rigid base. Inspect clamps for serviceability. Replace clamp
if jaws are deformed or corroded, spring is weak, or other defects are
evident that would prevent a good connection. Inspect cable wires.
Replace if more than one-third of the cable wires are broken.
Frequency: Quarterly
b. The connections to the grounding system must be surveyed and verified
for continuity. If a connection is suspected to be loose, perform further
testing. In some occasions it is more cost effective to replace the
suspected connection instead of performing diagnostic tests.
Frequency: Annually
c. Resistance measurement on static grounds: Measure static ground
resistance of new and damaged ground rods. Static ground with a
resistance greater than 10,000 ohms will be removed or replaced. Static
ground mechanically damaged will be repaired and retested.
Frequency: When observed to be physically damaged.

9-1.7 Electric Motors.

a. Based on the operational parameters, motors can be classified as:

• Induction (squirrel cage or asynchronous) motors: These are the
most common type and widely used in pumps, fans and other
industrial equipment.
• Synchronous motors: These are usually relatively large (500 hp and
above) and are used when constant speed is required regardless of
the torque on the shaft or power factor correction needed.

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• DC motors: These type of motors are rare in industrial applications

and are used mainly in traction, cranes and sometimes in elevators.
b. Depending on the applied voltage, motors can be:
• Low voltage (< 1,000 V).
• Medium voltage (2,300 V to 6,000 V). These motors are usually
rated 300 hp to 15,000 hp (225 kW to 11.2 MW).
c. Depending on the number of phases, motors are:
• Single phase: Usually small motors less than 10 hp (7.5 kW) and
often less than 3 hp (2.2 kW).
• Three phase: Most commonly used for industrial applications larger
than 0.5 hp (375 W).
d. The maintenance of synchronous and DC motors should be performed by
specialized companies and in accordance with the written instructions of
the motor manufacturer.

9-1.7.1 Inspection and Maintenance – Electric Motors.

Refer to manufacturer’s operation and maintenance manual for specific maintenance

procedures and schedules associated with a specific model of motor. Follow all
applicable general maintenance and safety requirements listed in the manufacturer’s
operation and maintenance manual.

a. Lubricate motor bearings and inspect for vibration and overheating.

Frequency: Quarterly
b. Check for debris and other foreign material in the fan housing.
Frequency: Semi-annually
c. Check motor ground wires. Ensure they are firmly connected to the
housing or the junction box.
Frequency: Annually
d. If the motor is installed in a hazardous location, verify that the seals of the
connection boxes and conduits are intact.
Frequency: Annually

9-1.8 Lighting.

The purpose of the lighting maintenance is to ensure a relatively constant illumination

level and lighting quality for internal and external lighting systems. Most often, the
lighting maintenance involves lamp replacement. There are two possible approaches for
regular lamp replacement:

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1. Spot re-lamping is performed when the lamps in a light fixture are

replaced on an as-needed basis. If there is more than one lamp in the light
fixture, it is recommended to replace all of the lamps at the same time.
This ensures more uniform light output and equal utilization of the lamps.
2. Group re-lamping involves simultaneous replacement of all lamps in a
given area regardless of whether they are operational or not.

9-1.8.1 Inspection and Maintenance – Lighting.

a. Verify proper operation of light switch, lighting contactor, photocell or timer

as appropriate. If a lighting contactor is used, listen for the chatter of
contacts or buzzing noise. These are indicative of a faulty contactor.
Replace if required.
Frequency: Annually
b. With the lights turned on, observe individual luminaries for flicker or lights
turning on and off. The former is indicative of a faulty choke. The latter is
indicative of a faulty starter. Replace the faulty components as required.
Frequency: Annually
c. When light fixtures are located in hazardous areas, verify that the seals
are intact and the hazardous rating of the fixture is maintained.
Frequency: Annually
d. Thoroughly clean dust, bugs, and debris from the luminaires. Light
solvents or cleaning agents may be used.
Frequency: Annually (in dusty areas the luminaries may require
cleaning at shorter intervals)
e. Re-Lamping: With the lights turned off, replace the lamps. In order to
prevent accidental turning on of the lights, it is mandatory to switch off and
lockout the breaker of the lighting circuit. Ensure the replacement lamps
are the same type as those they are replacing. Verify the proper operation
of all light fixtures after the lamp replacement.
Frequency: Annually or as required

9-1.9 Electronic Equipment.

Electronic equipment usually operates at voltages less than 120 V and does not have
rotating components. As a result, electronic equipment tends to accumulate dust, which
interferes with cooling. Overheating is the most likely cause for failure of electronic
equipment.

9-1.9.1 Inspection and Maintenance - Electronic Equipment.

If the inspection and maintenance of the equipment does not require functional and
operational testing, de-energize and lockout the power source to the equipment.

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a. Inspect the outside of the equipment enclosures for dust and evidence of
corrosion. Vacuum clean the dust to ensure unobstructed air circulation.
Frequency: Annually
b. Open the enclosure and vacuum clean the dust to ensure unobstructed air
circulation. Pay particular attention to fans and air passages. If there is
evidence of corrosion, verify that there is no water damage on printed
circuit boards or contacts. If water or humidity damage is observed, the
electronic components may not work properly and further testing is
required.
Frequency: Annually
c. Verify proper operation of the space heater if one is installed.
Frequency: Annually
d. Check fans for proper operations and rotation.
Frequency: Annually
e. Look for signs of overheating such as discoloration and charring.
Frequency: Annually
f. Replace air filters.
Frequency: Annually or more frequently based on local
environmental conditions.
g. Verify connection tightness. Lightly pull wires on soldered and terminal
screws and ensure the wires are not loose.
Frequency: Annually
h. Verify that circuit boards are properly seated. Ensure that board locking
tabs are fully engaged. Do not unplug and plug connectors to verify
seating. This will wear out the pins. Unplug only if connector malfunction is
suspected.
Frequency: Annually
i. Observe wires for excessive strain, braiding, or wear due to vibration.
Replace as required.
Frequency: Annually

9-2 CATHODIC PROTECTION SYSTEMS.

9-2.1 Cathodic Protection.

Cathodic protection must be maintained by appropriately trained personnel (NACE CP

tester certified). Personnel must ensure the cathodic protection system is maintained in
accordance with UFC 3-570-06 and the most stringent of applicable host nation,
Federal, state or local regulations.

Cathodic protection systems are installed on underground piping systems, at the bottom
of steel tanks, on underground steel tanks, and on marine pier and anchor systems.

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Cathodic protection systems are used to prevent corrosion of these systems and are
specifically designed for the system that they are intended to protect.

9-2.1.1 Inspection and Maintenance - Cathodic Protection.

a. Inspect rectifiers in in accordance with UFC 3-570-06.

Frequency: \2\ Monthly /2/
b. Inspect cathodic protection systems in accordance with UFC 3-570-06.
Frequency: Annually

9-2.2 Electrical Isolation.

Electrical isolation components and lightning surge arresters are installed on

underground piping systems as part of a complete corrosion protection system.

9-2.2.1 Lightning Surge Arresters.

Lightning surge arresters are devices that protect dielectric insulating flanges from over-
voltage transients. These transients are caused by lightning or AC fault currents. The
arresters block AC and DC voltages up to a predetermined voltage threshold. Upon
voltage exceeding the threshold, the arrester allows the current to safely pass around
the insulating flange.

9-2.2.1.1 Inspection and Maintenance – Lightning Surge Arresters.

a. Newer lightning surge arresters are designed to withstand unlimited

surges at 50,000 amperes; however, manufacturers of older surge
arresters may provide a maximum number of surge events that can occur
before it must be replaced. If surge arresters include a maximum number
of surge events, a spare arrester must be kept on hand. Refer to the
surge arrester manufacturer’s operation and maintenance manual for
particular inspection instructions and parts. Inspect as part of an overall
cathodic protection system inspection.
Frequency: Annually

9-3 CARD AND KEY LOCKS.

Card and proximity readers are used at Automated Fuel Service Station (AFSS) to
activate the systems. Card and key lock system issues must be called into the
Business System Modernization-Energy (BSME) Help Desk for all issues outside of the
annual preventive maintenance visits.

9-3.1 Inspection and Maintenance - Card and Key Locks.

a. Conduct operational check of card and key lock system and ensure that all
features provided with the installed system are operational.
Frequency: Annually

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9-4 LIGHTNING PROTECTION SYSTEMS.

Lightning protection systems are typically designed to \1\/1/UFC 3-575-01. The
systems include air terminals that are installed on top of buildings, canopies, or tall
equipment. The air terminals are connected together with heavy-gauge copper or
aluminum wires. These copper or aluminum wires are also attached to grounding loops
or ground rods installed at the base of the building, canopy, or equipment.

9-4.1 Inspection and Maintenance – Lightning Protection Systems.

a. Inspect air terminals to make sure they are securely attached to the roof of
the building, canopy, or the piece of equipment. Check all connections
between the air terminals and the grounding loop or grounding rods.
Repair damaged or loose connections and perform continuity check after
repairs.
Frequency: Annually

9-5 GROUND VERIFICATION SYSTEMS.

Ground verification systems are used in petroleum fuel truck and rail offloading and
loading systems. The systems are used to verify that the trucks or rail cars are
grounded. In most cases, the systems are interlocked with the receipt or issues
controls and will prevent the receipt or issue system from operating if an acceptable
ground connection between the truck or rail car and the fueling system is not detected.
9-5.1 Inspection and Maintenance – Ground Verification Systems.

a. Conduct an operational check of the ground verification system and

ensure that all features provided with the installed system are operational.
Inspect the plug for corrosion, weakness, or loose nuts and replace if
heavily dented or deformed.
Frequency: Quarterly

9-6 ELECTRONIC OVERFILL PROTECTION SYSTEMS.

Overfill protection systems are used on petroleum fuel truck and rail issue systems. In
some cases, overfill protection switches are permanently installed on petroleum fuel
trucks or rail cars. In other cases, probes from the system are applied to the trucks or
rail cars at the time of petroleum fuel issue. The overfill protection systems are
interlocked with petroleum fuel issues systems and will stop the issue process if a high
petroleum fuel level is detected in a truck or rail car.

9-6.1 Inspection and Maintenance – Electronic Overfill Prevention

Systems.
a. Conduct operational check of overfill prevention system and ensure that
all features provided with the installed system are operational.
Frequency: Quarterly

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CHAPTER 10 ALTERNATE POL FACILITIES

10-1 LIQUEFIED PETROLEUM GAS.

This section includes inspection and maintenance information related to Liquefied

Petroleum Gas (LPG) storage and distribution systems. These systems differ from
typical fuel systems due to the pressures involved and are covered by additional
regulations. LPG systems must follow the equipment, installation and maintenance
requirements listed in NFPA 58. Operation and maintenance manuals required for LPG
systems by NFPA 58 must be developed for each installation.

10-1.1 Liquefied Petroleum Tanks.

Liquefied petroleum tanks are pressure vessels with typical maximum allowable working
pressure of 250 psig. These tanks are built to ASME standards for non-fired pressure
vessels. These tanks follow the requirements listed in NFPA 58 and API 2510.

10-1.1.1 Inspection and Maintenance – Liquefied Petroleum Tanks.

a. Inspect fuel tank for leaks. If a leak is occurring, the odorizing agent of the
gas should be detectable. Use a soap and water solution to spray on
areas suspected of leaks. Systems that are found with leaks must be
taken out of service.
Frequency: Monthly
b. Test operation of emergency shutoff valves. Ensure the fusible link
mechanism is attached properly to actuate in case of a fire and that it has
not been by-passed, blocked, or damaged in any manner. Ensure the
fusible link is not filled with debris or paint which could impact operation.
Frequency: Semi-annually
c. Check settings of tank safety valves and calibrate if required.
Frequency: Every 5 Years

10-1.2 Liquefied Petroleum Pipelines.

Liquefied petroleum lines transfer liquefied petroleum gas between the delivery vehicle
and the storage tanks, and between vaporizers and other equipment and storage tanks.
These lines operate at the storage pressure of the tank.

10-1.2.1 Inspection and Maintenance – Liquefied Petroleum Pipelines.

a. Conduct visual inspection of pipelines for potential damage and leak

points. Use a soap and water solution to spray on areas suspected of
leaks. Systems that are found with leaks must be taken out of service and
repaired.
Frequency: Monthly

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b. Inspect coatings and markings on piping. Repair coating deterioration and

replace labels that are fading and are difficult to read.
Frequency: Semi-annually

10-1.3 Liquefied Petroleum Vapor Lines.

Liquefied petroleum vapor lines are used to transfer vaporized petroleum gas between
the delivery vehicle and the LPG tank and from the LPG tank to use points. Vapor
transfer between the LPG tank and the delivery vehicle is at the tank operating pressure
and transfer from the tank to the use points is typically at a reduced pressure.

10-1.3.1 Inspection and Maintenance – Liquefied Petroleum Vapor Lines.

a. Inspect vapor lines for leaks. If leaks are occurring, the odorizing agent in
the gas should be detectable. Use a soap and water solution to spray on
areas suspected of leaks. Systems that are found with leaks must be
taken out of service and repaired.
Frequency: Monthly
b. Inspect coatings and markings on piping. Repair coating deterioration and
replace labels that are fading and are difficult to read.
Frequency: Semi-annually

10-1.4 LPG Vaporizers.

At large use points, vaporizers are used to vaporize the pressurized liquid into gas for
use.

10-1.4.1 Inspection and Maintenance – LPG Vaporizers.

a. Inspect vaporizers for leaks. If leaks are occurring, the odorizing agent in
the gas should be detectable. Use a soap and water solution to spray on
areas suspected of leaks. Systems that are found with leaks must be
taken out of service and repaired.
Frequency: Monthly
b. The manufacturer maintenance schedules and recommendations provided
with the LPG vaporizer must be followed.
Frequency: As required

10-1.5 Petroleum Gas Regulators.

Regulators are used to reduce the pressure of petroleum gas before it is used or
transferred to the use point.

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10-1.5.1 Inspection and Maintenance – Petroleum Gas Regulators.

a. Inspect petroleum gas regulators for leaks. If leaks are occurring, the
odorizing agent in the gas should be detectable. Use a soap and water
solution to spray on areas suspected of leaks. Systems that are found
with leaks must be taken out of service and repaired.
Frequency: Monthly

10-1.6 Liquefied Petroleum Gas Hoses.

Liquefied petroleum gas hoses are used to transfer liquid and vapor between LPG
storage tanks and delivery vehicles.

10-1.6.1 Inspection and Maintenance – Liquefied Petroleum Gas Hoses.

a. Inspect hoses for damage and leaks. If leaks are occurring, the odorizing
agent in the gas should be detectable. Use a soap and water solution to
spray on areas suspected of leaks. If leaks are detected from a hose
discontinue use of the hose and remove it from service. Inspect for
damage to outer cover that exposes reinforcement. Inspect for kinks or
flattened areas, soft spots or bulges. Inspect couplings and ensure they
have not slipped on the hose or been damaged.
Frequency: Annually

10-2 COMPRESSED NATURAL GAS (CNG).

This section includes inspection and maintenance information related to compressed

natural gas systems. These systems used compressed gas at pressures up to 5,000
psig (34.5 MPa). CNG systems must follow the equipment, installation and maintenance
requirements listed in NFPA 52. Operation and maintenance manuals required for CNG
stations by NFPA 52 must be develop for each installation.

10-2.1 CNG Piping.

CNG piping is used between the natural gas source and the compressor. It is also used
between the compressor and the CNG tubes or storage tanks and storage and the CNG
dispenser. The lines vary from low pressure to high pressure. Some CNG lines may
have pressure ratings as high as 5,000 psig (34.5 MPa).

10-2.1.1 Inspection and Maintenance – CNG Piping.

a. Inspect CNG lines for leaks. Inspection of high-pressure CNG lines and
equipment must be conducted using proper PPE including but not limited
to safety glasses, a face shield, hard hat and fire resistant clothing. If leaks
are occurring, the odorizing agent in the gas should be detectable. Use a
soap and water solution to spray on areas suspected of leaks. Systems

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that are found with leaks must be taken out of service and repaired.
Frequency: Daily
b. Inspect coatings and markings on piping. Repair coating deterioration and
replace labels that are fading and are difficult to read.
Frequency: Semi-annually

10-2.2 CNG Compressors.

Compressors are used to boost the pressure of natural gas from the supply pressure to
the high-pressure tube storage pressure. The compressors include up to four stages of
compression and are driven by electrical motors or natural gas engines. Designs of
compressors and compressor drivers vary by manufacturers.

10-2.2.1 Inspection and Maintenance – CNG Compressors.

a. Compressors will require maintenance based on the model included in the

system. Consult the compressor manual for manufacturer’s maintenance
requirements.
Frequency: As required

10-2.3 CNG Storage.

High-pressure tubes or spherical storage tanks are used to store CNG at pressures of
up to 5,000 psig (34.5 MPa). The tubes and tanks should be ASME stamped pressure
vessels. The tubes are typically assembled in bundles of twenty (20).

10-2.3.1 Inspection and Maintenance – CNG Storage.

a. Inspect CNG tubes and tanks for leaks. Inspection of high-pressure CNG
lines and equipment must be conducted using proper PPE including but
not limited to safety glasses, a face shield, hard hat and fire resistant
clothing. If leaks are occurring, the odorizing agent in the gas should be
detectable. Use a soap and water solution to spray on areas suspected of
leaks. Systems that are found with leaks must be taken out of service and
repaired.
Frequency: Daily
b. Inspect coatings and markings on storage tubes or tanks. Repair coating
deterioration and replace labels that are fading and are difficult to read.
Frequency: Semi-annually
c. Check operation and calibration of safety valves on tubes and tanks.
Frequency: Every 3 years

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10-2.4 CNG Dispensers

Dispensers (Vehicle Fuel Appliances) are used to transfer CNG between storage tubes
or tanks and CNG vehicle storage tanks. The system uses a series of valves to
cascade the compressed gas from the tubes or tanks into the vehicle storage tank.

10-2.4.1 Inspection and Maintenance – CNG Dispensers

a. Dispensers are listed for service with CNG and will vary by manufacture.
Consult the maintenance manual that was supplied with the system for
manufacturer’s maintenance required for the CNG dispenser.
Frequency: As required

10-2.5 CNG Dispenser Hoses.

Hoses and fill adaptors are used to make the connection between the CNG dispenser
and the vehicle storage tank.

10-2.5.1 Inspection and Maintenance – CNG Dispenser Hoses.

a. Inspect hoses for damage, leaks, and cracks. If leaks are occurring, the
odorizing agent in the gas should be detectable. Use a soap and water
solution to spray on areas suspected of leaks. If leaks are detected from a
hose, discontinue the use of the hose and remove it from service.
Frequency: Monthly
b. Test hoses for leaks following manufacturer recommended frequencies
and procedures.
Frequency: As required

10-3 HYDRAZINE CHARGING UNITS.

Hydrazine is transferred from 55 gallon (208 liter) drums to small aircraft holding tanks
by a closed system charging unit.

10-3.1 Inspection and Maintenance – Hydrazine Charging Units.

a. Hydrazine charging units are self-contained factory fabricated systems.

Refer to the manufacturer’s maintenance manual that was provided with
the system for required periodic maintenance.
Frequency: As required

10-4 JP-10.

JP-10 is a gas turbine fuel developed for missiles. Maintenance for JP-10 system
components should follow maintenance requirements for fuel system components listed
in this document.

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10-5 OTTO.

Information on OTTO fuels is contained in Naval Sea Systems Command (NAVSEA)

S6340-AA-MMA-010. Distribution of this document is restricted. Requests for
information are handled by Naval Sea Systems Command.

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CHAPTER 11 SUPPORT FACILITIES

11-1 SECONDARY CONTAINMENT.

The military services assign responsibility for inspection, maintenance, and draining of
secondary containment structures to various organizations (including contractors).

Those organizations or contractors must inspect and maintain secondary containment

structures in accordance with military service-specific directives or applicable contract
requirements. Refer to Section 8-10 Containment Systems for tank secondary
containment inspection and maintenance procedures.

11-1.1 Fuel Truck \1\ and Rail Car /1/ Containment Areas.

Fuel truck \1\ and rail car /1/ containment areas such as refueler parking areas, refueler
loading areas, and commercial truck offloading \1\ and loading areas, rail car loading
and offloading /1/ areas are equipped with secondary containment. Typically these
areas are provided with security fence and overhead lighting.

11-1.1.1 Inspection and Maintenance – Fuel Truck \1\ and Rail Car /1/
Containment Areas.

a. Remove debris from around security fence.

Frequency: Monthly
b. Inspect fence grounding points. Ensure connections are not loose or
damaged.
Frequency: Monthly
c. Inspect the parking area for cracks in the concrete containment paving
and curbs. Remove vegetation that may have established roots in the
buildup of dirt or from exposed earth under cracks. Thoroughly clean and
seal cracks with a fuel resistant sealant.
Frequency: Quarterly
d. \1\ Secondary containment systems degrade and will collect debris which
can clog drainage inlets or prevent drain valves from sealing properly.
Hydrostatically test secondary containment and associated drainage
systems to include containment concrete/sealant, drain inlets, drain lines
and containment drain valves to ensure containment is liquid tight. This
test may use opportune rainfall by holding rainwater in the containment
system for one hour. Where evaporation is a concern, conduct the testing
when this concern would be minimized, such as at night/early morning or
during a time of year when this would not be as much of an issue. Record
the water level at the start of a 60-minute (minimum) hold period and if the
water level drops by 1/8 inch or more, perform and record an investigation
to determine the cause and any required repairs. Once repairs are

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completed, a new test must be completed. Refer Appendix B for testing

procedures and to document the testing. /1/
Frequency: \1\ Every 3 years /1/
e. Verify continuity of vehicle grounding system connections. If a connection
is suspected to be loose, perform further testing. In some occasions it is
more cost effective to replace the suspected connection instead of
performing diagnostic tests.
Frequency: Annually
f. Inspect pavement markings and vehicle movement lines for wear and
fading. Repair faded or worn pavement markings.
Frequency: Annually
g. Inspect security fence for wear and rust. Inspect barbed wire and ensure
it is adequately secured to outriggers. Repair loose fencing components
and coatings at areas that show rust.
Frequency: Annually
h. Refer to Section 9-1.8 Lighting for inspection and maintenance
requirements of area lighting.

11-1.2 Remote Spill Containment.

Fuel truck parking, loading and offloading areas \1\ and rail car loading and offloading
areas, /1/ are typically equipped with remote containment basins. These basins are
used to increase the overall containment volume of the system. The basins are
constructed of concrete walls and a concrete floor.

11-1.2.1 Inspection and Maintenance – Remote Spill Containment.

a. Inspect the remote containment basin for cracks in the concrete

containment paving, walls, and curbs. Remove vegetation that may have
established roots in the buildup of dirt or from exposed earth under cracks.
Thoroughly clean cracks with a water spray or air jet. Seal cracks with a
fuel resistant sealant.
Frequency: \2\ Monthly /2/
b. If equipped, inspect spill containment sump pump for proper operation.
Frequency: \2\ Monthly /2/
c. \1\ Secondary containment systems degrade and will collect debris which
can clog drainage inlets or prevent drain valves from sealing properly.
Hydrostatically test secondary containment and associated drainage
systems to include containment concrete/sealant, drain inlets, drain lines and
containment drain valves to ensure containment is liquid tight. This test may
use opportune rainfall by holding rainwater in the containment system for
one hour. Where evaporation is a concern, conduct the testing when this
concern would be minimized, such as at night/early morning or during a time

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of year when this would not be as much of an issue. Record the water level
at the start of a 60-minute (minimum) period and if the water level drops by
1/8 inch or more, perform and record an investigation to determine the cause
and any required repairs. Once repairs are completed, a new test must be
completed. Refer Appendix B for testing. /1/.
Frequency: \1\ Every 3 years /1/
11-2 PROTECTIVE SHELTERS.

11-2.1 Pumphouse/Filter Buildings.

Pump and filter equipment is typically enclosed within a building or covered by a shelter.
These buildings can be constructed of pre-engineered metal or concrete. The floors of
these areas should provide secondary containment for the piping and equipment that is
installed in the building or under the shelter.

11-2.1.1 Inspection and Maintenance – Pumphouse/Filter Buildings.

a. Inspect the floor and containment curbs for cracks. Thoroughly clean
cracks with a water spray or air jet. Seal cracks with a fuel resistant
sealant.
Frequency: Annually
b. Refer to \1\ UFC 3-110-03 /1/ for inspection and maintenance
requirements of pumphouse and filter building roof systems.

11-2.2 Canopies.

Canopies are used to cover service station dispensers, containment basins, fuel truck
loading and offloading equipment, and equipment installed in remote areas.

11-2.2.1 Inspection and Maintenance – Canopies.

a. Inspect and maintain canopies in accordance with \1\ UFC 3-110-03 /1/.

11-3 SAFETY SHOWERS AND EYEWASH FOUNTAINS.

Emergency safety showers and eyewash fountains are installed around fueling areas
and pumphouses. They are typically equipped with an activation alarm that energizes a
strobe light and horn. In some cases emergency eyewash/showers are equipped with
tempered water systems that supply warm water to the emergency eyewash/shower.

11-3.1 Inspection and Maintenance – Emergency Eyewash/Showers.

a. Test operation of the emergency eyewash/shower by pushing on the

activation handles. Ensure the water is not brown in color, due to rust in
the piping or dirt seeping in from a hole in the buried piping. For systems
with tempered water, ensure that the water that is being supplied by the
emergency eyewash/shower is between 60 and 100 °F (16 and 39 °C).

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For systems with a horn and strobe light, ensure that the horn and strobe
light activate when the activation lever on the emergency eyewash/shower
is pushed. For systems that interface with Installation or fire emergency
systems, pre-coordinate before testing. At some Installations emergency
eyewashes and showers act as EFSOs and are tied into the fire alarm
systems.
Frequency: Weekly
b. Inspect portable/packaged safety showers and eyewash stations for
proper operation. Check fluid levels. Where tap water is used, fluid must
be replaced monthly. Less frequent intervals of fluid change, as
recommended by the manufacturer, are acceptable where a solution or
water additive is used. Ensure packaged eyewash supplies are within the
listed expiration date. Tags or labels must be attached to the unit or
adjacent to it, indicating the fluid change schedule.
Frequency: Monthly
c. Inspect the exterior coatings of permanently installed units and repair
damaged coatings or rust.
Frequency: Quarterly
d. For systems with tempered water systems inspect components of the
water heater for correct operation and temperature control. Ensure that
the safety valve on the hot water heater tank is not leaking.
Frequency: Semi-annually
e. Inspect signage and labels on the emergency eyewash/shower. Replace
missing labels or signage that has become loose. Signs that are faded
must be replaced.
Frequency: Annually

11-4 FUELS LABORATORIES.

Fuels laboratories are typically equipped with ventilation hoods. These systems will be
periodically inspected to ensure proper operation. Laboratories must comply with the
general facility requirements of UFC 3-600-01 and NFPA 45.

11-4.1 Ventilation Hoods.

Ventilation hoods are used to prevent the buildup of flammable and noxious vapors
inside of fuels laboratories. The hoods are typically equipped with sliding or rollup doors
that can be used to reduce the opening area of the hood. Additional ventilation hood
designs employed include laminar flow, elephant trunk and canopy hoods. The systems
pull air from inside of the lab through the hood and exhausts outside of the lab through a
ventilation stack. Fume hoods must comply with military service-specific directives
and/or 29 CFR 1910.1450, and ANSI (American National Standards Institute)/AIHA
Laboratory Ventilation Z9.5.

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11-4.1.1 Inspection and Maintenance – Ventilation Hoods

a. Inspect the operation of the doors. Ensure that they close and open
smoothly.
Frequency: Quarterly
b. Inspect the lights inside of the hood to make sure they are operating
properly. Replace light bulbs that are no longer working.
Frequency: Semi-annually
c. Verify that all electrical equipment is properly classified in accordance with
NFPA 70.
Frequency: Annually
d. Inspect the ventilation system (ductwork, fans, etc.) for signs of disrepair
and air leakage and ensure it is operational and pulling air through the
hood. Inspect and assure that the lab hood air measuring device for
assuring proper air flow is permanently attached and working properly.
The ventilation hood must be inspected and \1\ approved by a service
specific industrial hygienist or bioenvironmental engineer /1/ in accordance
with OSHA, 29 CFR 1910.1450, and ANSI/AIHA Laboratory Ventilation
Z9.5.
Frequency: Annually
e. Verify negative pressure is present through the ventilation hood to the
exhaust.
Frequency: Annually

11-5 OIL/WATER SEPARATORS.

Oil/water separators are used to remove water from oil/water mixtures. Oil/water
separators are sized for a maximum flow rate and this maximum flow rate must not be
exceeded. Inspections and maintenance must be conducted in accordance with the
regulating authority for the particular location (e.g., Federal, host nation, state and local)
and in accordance with the OEM specifications so as not to void warranty.

11-5.1 Inspection and Maintenance – Oil/Water Separators.

a. Inspect the oil/water separator for the buildup of collected petroleum fuel
or oil. Remove and properly dispose of accumulated petroleum fuel or oil.
Frequency: Quarterly or as needed based on precipitation events.
b. Drain, clean, and inspect the interior of the oil/water separator. Ensure all
divider plates and screens are in good working order. Replace or repair
damaged components.
Frequency: Annually or more frequently based on local
environmental conditions.

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11-6 CRANES AND HOISTS.

Cranes and hoists are used inside of pumphouses and maintenance areas to assist in
the removal and installation of petroleum fuel system components.

11-6.1 Inspection and Maintenance – Cranes and Hoists.

a. Inspect cranes and hoists for smooth operation. If the crane or hoist is
equipped with electronic controls, check power supply and operational
control cords for nicks or damage. A crane service technician must
correct binding that may prevent smooth operation and repair damage to
power cords.
Frequency: Before each use
b. Apply lubricant or grease to areas that require periodic greasing.
Frequency: Annually
c. Military services-specific, host nation, state, and/or local regulations
require cranes and hoists to be certified for operation. Follow the more
stringent of military services-specific, host nation, state or local
regulations.
Frequency: Annually

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CHAPTER 12 FUEL FACILITY TEMPORARY DEACTIVATION OR CLOSURE

12-1 DEACTIVATION OF FUELING FACILITIES.

Prior to deactivation of a fuel facility, maintainers must contact the Installation’s

Environmental Office to review the requirements and coordinate to ensure that the
deactivated facility remains in regulatory compliance throughout the deactivation period.
Note: USTs deactivated for an extended period of time may be subject to closure
notifications per Federal, state, and local requirements. Contact Installation
Environmental Office for further information.

12-2 DEACTIVATED PETROLEUM FUEL TANKS

Deactivated petroleum fuel tanks that require ballast must be filled with a water or anti-
corrosion solution to protect against floatation and overturning. Piping connections of
tanks must be disconnected and blind flanged. Remaining active pressure relief
systems attached to deactivated tanks must be reconnected to active tanks. Tanks
must be labeled to indicate the present status of the tanks and the previous contents.
Cathodic protection systems on deactivation tanks must continue to be used and
maintained.

12-2.1 Inspection and Maintenance – Deactivated Petroleum Fuel Tanks.

a. Inspect water or anti-corrosion level in tank. If level has dropped,

investigate potential leak points such as blind flanges. Repair leaks that
are detected and refill to appropriate level.
Frequency: Quarterly
b. Check exterior coatings and labels. Repair peeling coatings and/or rusting
areas and replace or repair labels which have become faded and difficult
to read.
Frequency: Quarterly
c. Inspect cathodic protection system on deactivated tanks for proper
operation.
Frequency: Annually

12-3 DEACTIVATED PETROLEUM FUEL PIPELINES.

Deactivated petroleum fuel pipelines must be drained of fuel, vapor freed and isolated
by the use of blind flanges, blanks, or spectacle blinds. Once the petroleum fuel
pipeline is isolated it must be charged with nitrogen to a pressure of 10 psig (69 kPa), or
as otherwise determined based on the size and thickness of the pipe material. Pipeline
cathodic protection systems must remain in operation and in good working order
throughout the deactivation period.

Inter-terminal pipelines regulated by the DOT must have a written deactivation plan
describing the process to be used. The deactivation plan must be submitted to the

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Installation Environmental Office and the Pipeline Regulatory Compliance Agency for
review and approval prior to taking the inter-terminal pipeline out of service and
reclassifying the pipeline into inactive status. Refer to 49 CFR 195 for additional
information on closure of DOT regulated pipelines.

12-3.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pipelines.

a. Inspect the pressure of the nitrogen charge applied to the petroleum fuel
pipeline with a pressure gauge. If the pressure of the charge has dropped
investigate and repair leak points. Once leak points are repaired,
recharge with nitrogen.
Frequency: Quarterly
b. Check exterior coatings and labels. Repair peeling coatings and/or rusting
areas and replace or repair labels which have become faded and are
difficult to read.
Frequency: Quarterly
c. Inspect cathodic protection system for proper operation.
Frequency: Annually

12-4 DEACTIVATED PETROLEUM FUEL PUMPS.

Deactivated petroleum fuel pumps must be disconnected from supply and discharge
piping and the interior of the pumps must be treated with a light corrosion-inhibiting oil.
The suction and discharge ports of the pump must be equipped with blind flanges or
plugs.

12-4.1 Inspection and Maintenance – Deactivated Petroleum Fuel Pumps.

a. Manually rotate pump through several rotations. Ensure that the pump
turns freely.
Frequency: Quarterly
b. Check exterior coatings. Repair peeling coatings and/or rusting areas and
replace or repair labels which have become faded and are difficult to read.
Frequency: Quarterly
c. Remove isolation flanges and recoat interior of pump with light corrosion-
inhibiting oil.
Frequency: Annually

12-5 MISCELLANEOUS DEACTIVATED COMPONENTS.

Deactivated control valves and specialized components must be removed from piping
and tanks. The connection ports of the removed components must be equipped with
blind flanges, dust caps, or plugs in order to protect the internal surfaces and working
parts of the components from environmental exposure. The pipe or tank connection

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points of the removed components must also be equipped with blind flanges or plugs in
order to protect the internal surfaces of the piping or tanks from environmental
exposure. The removed components must be stored in a clean dry area protected from
the elements.

12-5.1 Inspection and Maintenance – Miscellaneous Deactivated

Components.

a. Ensure that blind flanges are tight. Inspect exterior coatings and labels.
Repair peeling coatings and/or rusting areas and replace or repair labels
that have become faded and are difficult to read.
Frequency: Annually

12-6 TANKS AND PIPELINES.

Refer to Chapter 14 of UFC 3-460-01 for facility closure requirements.

12-7 DOCUMENTATION/RECORDKEEPING.

Refer to Section 14-3 of UFC 3-460-01 for inventory requirements of closed systems.

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\1\
APPENDIX A DLA ENERGY PROJECT PROGRAMING

A-1 PROJECT PLANNING STUDIES.

The Planning Study Program is a fence-to-fence analysis of Installation-level

infrastructure holding DLA Energy capitalized fuel to identify deficiencies. They are
scheduled in 5 year intervals. The program has three over-arching phases:

• Planning Study Site Visit. This phase involves an on-location site visit to
identify deficiencies in the fuels infrastructure.
• Planning Study Design Package Development. This phase involves the
creation and refinement of the report used to document deficiencies that
will be compiled into projects for funding.
• Planning Study Construction Project. This phase involves the construction
required to rectify deficiencies identified during the planning study site visit
phase.

A-2 RECURRING MAINTENANCE MINOR REPAIR PROGRAM.

The DLA Energy Recurring Maintenance Program is a contract vehicle which provides
quarterly, semi-annual, and annual maintenance service for capitalized Installation level
real property. Also included is a minor repair and emergency response services for
mission essential repairs of a non-technical nature within an established dollar amount.
This program is currently executed by the United States Army Corps of Engineers
(USACE); however, other executing agencies may be used to address recurring
maintenance requirements not covered by this contract.

A-3 FILTER REPLACEMENT PROGRAM.

For facilities eligible for DLA Energy SRM Program, funds have been made available to
purchase replacement filter separator cartridges and associated parts such as O-rings
and gaskets. \2\ Refer to the current DLA energy filter requisitioning policy document for
further guidance in accordance with DLA-Energy P-22, Procedures for Requisition,
Funding Requests, or Reimbursement of Filter/Coalescer Elements. /2/

A-4 DLA CENTRALLY MANAGED PROGRAMMING.

The Centrally Managed Program (CMP) manages regulatory, compliance, and best
practice maintenance processes for deficiencies on assets that are common to all
Services.

A-4.1 Tank Integrity Management Program.

The Tank Integrity Management Program for DLA Energy capitalized tanks uses
industry standard API 653, Tank Inspection, Repair, Alteration, and Reconstruction

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document or STI SP001, Standard for the Inspection of Aboveground Storage Tanks, as
the basis of meeting regulatory requirements included in 40 CFR 112 Oil Pollution
Prevention and state regulations. Many military tanks, such as cut and cover and mined
styles, do not fit well into the API 653 standard so the code is applied to the maximum
extent possible. It is the policy of DLA Energy to require professional engineering
oversight of all inspection and repair programs.

DLA Energy sanctions the use of STI Standard for the Inspection of Aboveground
Storage Tanks, SP001 as the inspection standard for small shop fabricated DLA Energy
capitalize tanks, typically aboveground, horizontal, and up to 45,000 gallons in size.
Host nation standards, such as the German TUEV (Technischer Ueberwachungsverein
[German safety and standards institution]), are addressed as an “add-on” to the base
inspection program.

Military service-specific SCP identifies tanks coming due, are past due or are without a
record of inspection and coordinates inspections with DLA Energy. Inspection
frequencies are in accordance with applicable standards and codes.

A-4.2 Pipeline Integrity Management Program.

The Pipeline Integrity Management Program provides for the development of Pipeline
Integrity Management Plans (PIMPs) and funds API 570 inspections of piping systems.

A-4.3 Pressure Vessel Integrity Management Program.

The Pressure Vessel Integrity Management Program provides for the physical
inspection of pressure vessels (e.g., filter separators, micronic or cyclonic separators,
relaxation chambers, and air eliminators tanks) in accordance with API 510. Its goal is
to reduce the risk of failure, thereby reducing potential environmental damage and/or
mission readiness consequences.

A-4.4 Cathodic Protection System Integrity Management Program.

The Cathodic Protection System Integrity Management Program provides for the annual
inspection, repair and maintenance of cathodic protection systems. Cathodic protection
is a form of corrosion protection applied to underground or underwater metallic
structures. Cathodic protection usually works in conjunction with protective coatings on
steel/stainless steel structures. Common applications include buried pipelines,
underground fuel storage tanks, and the bottom of aboveground fuel storage tanks.
Other applications include water storage tanks, and submerged pilings/fender piles on
piers and wharves. Federal and state regulations require cathodic protection for many
fuel related applications and UFC 3-570-06 requires cathodic protection for all metallic
fuel containing structures in direct contact with soil and water.

Corrosion inhibitors are another form of corrosion control covered under this program.
Corrosion inhibitors are used in areas where cathodic protection is not possible, usually
due to space requirements. A typical inhibitor project would replace a failed or absent

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cathodic protection system where anode replacement or installation is not economical

or feasible. These systems follow the same guidelines and inspection cycle as cathodic
protection systems.

A-4.5 Maritime Fuel Facilities/Piers Program.

The Maritime Fuel Facilities/Piers Program provides for the inspection and repair of
piers. Routine pier inspections are conducted to identify, quantify, and document
deficiencies observed on marine fuel facility structural, electrical, and mechanical
systems. The results from inspections are utilized by professional engineers to assess a
facility’s overall condition and operational readiness (fit for purpose), and to produce
maintenance plans and specifications for repairs.

A-4.6 Marine Loading Arm Program.

The Marine Loading Arm (MLA) Program provides for the inspection and repair of
loading arms used in Defense Working Capital Fund (DWCF) loading/unloading
operations at fixed real property energy infrastructure.

A-4.7 Underwater Hose Program.

Only underwater hoses used in Defense Working Capital Fund (DWCF)

loading/unloading operations are eligible for DLA Energy SRM funds. This funding is
provided by the Underwater Hose Program.

A-4.8 Dredging Program.

The Dredging Program provides funds for dredging projects. Deficiencies are identified
by the Installation. Dredging of dedicated waterways used for vessel movement and
delivery of DWCF products is eligible for DLA Energy funding consideration under this
program. Dredging of shared-use waterways is cost shared based on a benefit
assessment involving all users or in accordance with established Energy Infrastructure
Facility Sustainment Model (FSM) rules.

A-4.9 Rails Program.

The Rails Program provides for the maintenance and sustainment of railcar loading/off-
loading infrastructure and rail spurs from the Installation fence line. The program covers
these systems when they are used for the DWCF fuel mission and coded for DLA
Energy sustainment.

A-4.10 Demolition Program.

The Demolition Program provides funds for demolition projects when the real property is
no longer required by DLA Energy or the applicable military service. Deficiencies are
identified by the Installation. DLA Energy will fund demolition of real property
infrastructure if the facility last contained DLA Energy owned product and for which DLA

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Energy had SRM funding responsibility. DLA Energy may, depending on the situation,
also fund facility demolition using Military Construction (MILCON) appropriation when
the MILCON project involves demolition of existing energy infrastructure.

A-4.11 Automated Fuel Handling Equipment/Automatic Tank Gauging

Program.

The Automated Fuel Handling Equipment (AFHE)/Automatic Tank Gauging (ATG)

Program provides for installation and maintenance of automation systems. Professional
engineering assessments, which are required by DLA Energy on capitalized fuel
systems, are conducted under this program. These assessments improve overall fuel
facility controls, improve inventory accountability, provide fail-safe engineering for spill
prevention, increase efficiency, and execute routine maintenance.

This program supports automation programs for AFHE, Automated Fuel Service Station
(AFSS), ATG, ATGR, Hydrant Automation Monitoring System (HAMS), Independent
Alarm System (IAS), Overfill Protection Equipment (OPE) and Temperature
Compensating Meter (TCM). The DLA Energy Installation Support Automation Branch
coordinates with the military service-specific SCPs, the Space and Naval Warfare
System Center (SPAWAR), and Installations to identify needed projects.

This program also supports automation maintenance programs for AFHE, ATG, IAS,
AFSS, OPE, and Hydrant Fueling Automation Maintenance (HFAM). The life cycle
maintenance support includes annual preventative maintenance and as-needed
corrective maintenance support. Maintenance activities follow an annual cycle, are
initiated after the warranty period, have an indefinite duration, and are reviewed
annually. This program is also used to provide system support which includes on-call
technical support, logistics support, configuration management, system enhancements
and modifications.

Deficiencies are grouped into projects based on several factors such as geographic
location and the preferences of the executing agents, military service-specific SCPs or
other affected parties. Capital automation projects require the development of a
Business Case Analysis (BCA), must be included in the Capital Budget 5-Year Plan,
listed on the annual Master Operating Plan (MOP) and have the approval of a Capital
Execution Package.

A-4.12 Leak Detection Program.

The Leak Detection Program is an Environmental managed and funded program to

execute annual, biennial, and quarterly testing and monthly monitoring of DLA
capitalized underground fuel storage and distribution systems worldwide for storage
tanks, transfer and distribution piping, hydrant systems and ground fuel facilities.
Testing is performed to meet environmental regulatory requirements and DLA best
management practice testing requirements. The program encompasses leak detection
testing, leak confirmation, location and/or inspection and rapid response of suspect
leaks at DLA capitalized fuel facilities worldwide.

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The Leak Detection program also includes support for permanently installed leak
detection systems. This includes the maintenance, repair and certification of the
permanently installed leak detection systems and the installation of new permanent leak
detection systems at DLA capitalized fuel facilities worldwide.

A-5 REPAIR PROJECTS.

Provide adequate information for input of a deficiency into the DLA Energy Enterprise
Business System (EBS) database. Required information for project development
include: a cost estimate, justification, impact if not provided, and project description as
well as an indication of the expected funding type. The funding types that are available
include: Minor Construction (MC), Maintenance and Repair (MR), Maintenance (M) and
Environmental (E).

A-6 CAPITALIZED ENVIRONMENTAL FUNDING.

DLA Energy also has an Environmental Managed and Funded Program for the
development and revisions of environmental documents and will also support
environmental compliance and restoration funding of capitalized fuel facilities for
sampling and testing of petroleum, oil, and lubricants (POL) emissions and discharges,
removal and disposal of POL wastes (except consumables), fees for spill cooperatives,
permit fees, fines and penalties, spill cleanup, removal and disposal of POL wastes
associated with facility maintenance projects and update of environmental compliance
documents.

/1/

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\1\
APPENDIX B CONTAINMENT INTEGRITY TESTING CHECKLIST

Secondary Containment/Drainage System Integrity Testing

UST Facility Person Conducting Test
Facility Name Facility ID# Tester's Name:

Physical Address Testing Company:

City State City State

Testing Requirements
□ Code of practice developed by a nationally recognized
Type of Test
association or independent testing
□ Notice of Alleged Violation
Purpose of Test □ Required Annual Test
□ Post Repair Test
Liquid Tight Test Procedure
1. Clean containment of any debris.
2. Visually exam containment area for problem areas (gaps, cracks, sealant failure, etc.)
3. Make sure drainage valve is completely closed, IF adding water.
4. Add water to observe standing water at a highest point within the containment area (or conduct this test after a rain
event where water has filled the secondary containment area).
\2\ 4a. Fill all containments other than truck fill stands to minimum 1 inch water depth. /2/
5. Ensure water is calm (i.e. it is not still raining), and mark and record the high water line (e.g. using a tape measure
with 1/16-in increments).
6. Leave water in containment, undisturbed for one hour (i.e. no operations are taking place).
7. Compare the starting water level to the ending level:
• If the water level is the same or changed less than 1/8th (vertical) inch, the containment passed the test.
• If the water level has dropped 1/8th inch or more, an investigation must be conducted.
8. After the investigation, justify why this is not a leak or identify the leak and necessary repairs.
Test Data Table
Test Date
Containment Item ID No.
Test Start Time
Test End Time
Test Beginning Water Level
Test Ending Water Level
Test Result (P/F)
Comments:

I hereby certify that all the information contained in this report is true, accurate, and in full compliance with legal
requirements. Maintain six (6) years of test records. (Two Test Periods)

Tester's Signature: ___________________________________ Date:_____________________

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Secondary Containment Drainage System Integrity Testing

General Guidance
Who must complete this form?
Any person or their authorized representative (such as a tester or contractor) that conducts the secondary
containment liquid tight testing.

What sites must complete this testing?

All underground secondary containment drainage systems to include bulk fuel storage, aircraft fueling
systems, truck and railcar loading & unloading areas, marine facilities, and ground vehicle fuel facilities.

Petroleum Equipment Institute (PEI) Recommended Practice 1200-17: Recommended Practices for the
Testing and Verification of Spill, Overfill, Leak Detection and Secondary Containment Equipment at
Underground Storage Tank Facilities is an acceptable protocol.

Instructions for Completing the Fill-Port Containment Integrity Form:

UST Facility Information: Enter name and complete address of the facility, and the permit identification
number for the facility.
Person Conducting the Test: Enter the tester's name and their company (if not completed by site operator)
including the city and state from which they operate.
2) Purpose of the Test: Indicate by checking the box why the test is being done. Note: Testing must occur
after repairs or replacement of parts connected to secondary containment.
Liquid Tight Test Procedure: Please review the methodology (if this is the desired test) before conducting the
test.

Test Data Table:

1) Test Date: Indicate the date YYYYMMDD the test was completed
2) Indicate the starting and ending time for each Fill-Port Containment being tested.
3) Indicate the starting and ending water level for each Fill-Port Containment being tested.
4) Indicate if the test passed (P) or failed (F).
5) Comments: Add any comments or notes, particularly if there were any failing results.

Tester's Signature: The person conducting the test must sign and date the test.

/1/

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APPENDIX C MAINTENANCE TABLE

Inspection and maintenance tasks listed below are the minimum required. Additional
operation and maintenance tasks may be performed based on specific installation
requirements set by facility command.

OM stands for Operator Maintenance, and SM stands for System Maintenance. See
Section 1-2 for more information on roles and responsibilities.

Navy/ Air
ITEM PARAGRAPH FREQUENCY Army
USMC Force
SIGNAGE AND MARKINGS

Signage and Markings (Section 2-7)

A. Check permanent signs and Monthly OM OM OM

markings for adequacy and
readability. Repair or replace
deteriorated or illegible signs and
markings.

B. Inspect the location of

Department of Transportation
(DOT) regulated underground
pipelines and ensure they are
marked in accordance with 49
Code of Federal Regulations
(CFR) 195.410.

C. Check that all non-DOT

Signage and regulated pipelines, tanks,
Markings valves, pumps, meters, and
other equipment are marked in
accordance with UFC 3-460-01.
Section \1\ 2-17 /1/. If markings
are missing or insufficient, repair
or add markings in accordance
with UFC 3-460-01.

D. Ensure petroleum fuel system

Emergency Fuel Shutoff (EFSO)
push buttons are properly
identified at each location.
Ensure that signage is properly
secured and that the lettering is
legible from 25 feet (7.5 meters)
away and not faded.

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E. Verify enough movable or Annually OM OM OM

temporary signs are maintained
in good condition to serve
anticipated needs; for example:
"DANGER," "CLOSED TO
TRAFFIC," “KEEP FLAMES
AWAY," "MEN WORKING,” "NO
SMOKING,” "DANGER NO
OPEN FLAME OR IGNITION
SOURCE BEYOND THIS
POINT.” Use bilingual signs
when appropriate.
FILTRATION

Pre-Filter Vessels (Section 3-6.1)

A. Open drains under flow Daily OM OM OM

conditions until clear fuel is
observed from the drain valve.

B. Monitor differential pressure in

filter cartridges. Chart
differential pressure
measurements from readings
taken during normal operations.
C. Operate pre-filter isolation Quarterly SM \2\ OM /2/ SM
valves.

D. Replace filter cartridges when When SM SM SM

Pre-Filter the acceptable maximum differential
Vessels differential pressure is reached, pressure has
the maximum in-service reached the
duration has passed, or the fuel lower of
manufacturer’s
becomes visibly dirty or
recommendatio
discolored. Acceptable n or 20 psid
maximum differential pressure (140 kPa), filter
for a specific pre-filter is cartridge in-
dependent on the system flow service period
rate. The military service- of 24 months
specific SCP may extend in- has expired, or
service duration filter cartridge when fuel
replacement period based on becomes
differential pressure for high visibly dirty or
discolored.
throughput systems. Check
expiration date of replacement

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filter cartridges before
installation.

E. Refer to Section 6-7.2 As required SM SM SM

Differential Pressure Gauges for
inspection and maintenance
requirements of differential
pressure gauges.

F. Refer to Section 3-10.2

Automatic Air Vents for
inspection and maintenance
requirements of automatic air
vents.

G. Refer to Section 6-6.3 Thermal

and Pressure Relief Valves for
inspection and maintenance
requirements of thermal and
pressure relief valves.

H. Conduct inspections of code

rated vessels that meet the
requirements of UFC 3-430-07

Filter Separators (Section 3-6.2)

A. Open drain under flow Daily OM OM OM

conditions until clear fuel is
observed from the drain valve.

B. Monitor differential pressure of

coalescer cartridges. The
Filter acceptable maximum differential
Separators
pressure for a specific
filter/separator is dependent on
the system flow rate. Monitor
and chart differential pressure
measurements of filter
separators from readings taken
during normal operations.
Investigate sudden drops or

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spikes in differential pressure
measurement readings.

C. Operate filter separator isolation Quarterly \2\ OM /2/ \2\ OM /2/ SM

valves.

D. Inspect components and check

operation of water shutoff
system.

E. Change coalescer cartridges. Every 36 SM SM SM

Refer to Section 3-6.2.2 months or
Replacement of Coalescer sooner if
Cartridges for general required by
instructions on replacement of differential
pressure.
coalescer cartridges. Military
service-specific SCP may
extend the coalescer cartridge
replacement frequency based
on differential pressure if filters
separators are used on high
throughput systems. Check
expiration date of replacement
coalescer cartridges before
installation.

F. Inspect and clean separator

cartridges at time of coalescer
cartridge change in accordance
with Section 3-6.2.3 Separator
Cleaning. Worn or damaged
separator cartridges must be
replaced.

G. Refer to Section 6-7.2 As required SM SM SM

Differential Pressure Gauges for
inspection and maintenance
requirements of differential
pressure gauges.

H. Refer to Section 3-10.2

Automatic Air Vents for
inspection and maintenance
requirements of automatic air
vents.

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I. Refer to Section 6-6.3 Thermal
and Pressure Relief Valves for
inspection and maintenance
requirements of thermal and
pressure relief valves.

J. Refer to Section 4-4.2.2 Filter

Separator Control Valves for
inspection and maintenance
requirements of filter separator
control valves.

K. Conduct inspections of code

rated vessels that meet the
requirements of UFC 3-430-07.

\2\ Haypack Filters (Section 3-6.3)

A. Refer to manufacturer's SM SM SM
operation and maintenance Per
manufacturer's
manual for inspection and
specifications
maintenance requirements of
haypack filters.

B. Refer to Section 2-6.4, Waste SM SM SM /2/

As required
Disposal, for disposal
requirements.

Basket Strainers (3-6.4)

A. Monitor and chart differential OM OM OM

pressure measurements of
basket strainers from readings Daily
Basket
taken during normal operations.
Strainers
Investigate sudden drops or
spikes in differential pressure
measurement reading.

B. Clean and inspect basket and OM OM OM

strainer screen. Basket strainer Semi-annually
isolation valves must be closed if basket
and the strainer body must be strainer is
equipped with
drained before removing the
means to
cover. After cleaning, the
measure
strainer screen must be inserted differential
in the strainer body, and the pressure;
head tightened and checked for

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leakage. If strainer is not otherwise
equipped with means to measure monthly.
differential pressure, unit must
be opened monthly and
inspection.

C. Refer to Section 6-7.2 SM SM SM

Differential Pressure Gauges for
inspection and maintenance As required
requirements of differential
pressure gauges.

Filter Separator Sump Heaters (Section 3-6.5)

A. Inspect filter separator sump and SM SM SM

drain line heater elements for
proper operation per
Filter manufacturer’s operation and
Separator
maintenance manual. Ensure Semi-annually
Sump
heater elements meet
Heaters
manufacturer’s requirements by
measuring resistance of heater
elements with an ohm meter.

METERS

Positive Displacement Meters (Section 3-7.1)

A. Inspect counter head for unusual Monthly OM OM OM

noises and smooth operation.

B. Positive displacement meters Semi-annually SM SM SM

must be inspected and calibrated or as required
semi-annually or when improper
performance is suspected; when
Positive unusual sounds or register
Displacement actions develop; or after repairs
Meters
have been made which may
affect performance. Positive
displacement meters are
satisfactory when the
measurement error in the normal
flow direction is within ±0.3% of
actual quantity delivered (e.g.,
±1.8 gallons for a 600-gallon test
(±6.8 liters for a 2275-liter test)).

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Adjustment of the meter’s
register will be in accordance
with manufacturer’s instructions.
Identify the next calibration date
on meters (example: Mar 14 for
March 2014). Use weather
resistant label that will remain
legible and affixed for at least
one year.

C. Inspect temperature element

operation of meters equipped
with temperature compensation
feature per manufacturer’s
operation and maintenance
manual.

Turbine Flow Meters (Section 3-7.2)

A. Turbine flow meters must be Semi-annually SM SM SM

inspected and calibrated semi- or as required
annually or when improper
performance is suspected,
register actions develop, or after
repairs have been made which
may affect performance. Turbine
flow meters are satisfactory
when the measurement error in
the normal flow direction is within
±0.5% of actual quantity
delivered (e.g., ±3 gallons for a
600-gallon test (±11 liters for a
Turbine Flow
2275-liter test)). Adjustment of
Meters
the meter’s register will be in
accordance with the
manufacturer’s instructions.
Identify the next calibration date
on meters (example: Mar 14 for
March 2014). Use weather
resistant label that will remain
legible and affixed for at least
one year.

B. Inspect temperature element

operation of meters equipped
with temperature compensation
feature per manufacturer’s

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operation and maintenance
manual.

Orifice Flow Meters (Section 3-7.3)

A. Refer to Section 6-7.2 Differential As required SM SM SM

Pressure Gauges for inspection
and maintenance requirements
of differential pressure gauges.
Orifice Flow
Meters B. Refer to Section 6-7.4 Differential
Pressure Transmitters for
inspection and maintenance
requirements of differential
pressure transmitters.

PUMPS

Centrifugal Pumps (Section 3-8.1)

A. Check for proper operations SM SM SM

while pump is in use. Check
suction and discharge pressure
gauge for abnormal readings.

B. Check for unusual noise,

vibration, overheating of
bearings or case.

C. If equipped with lubricating oil

charge, check oil level and
Centrifugal adjust as necessary.
Quarterly
Pumps
D. Tighten or replace loose,
missing or damaged nuts, bolts,
or screws.

E. Inspect suction and discharge

isolation dampeners for
misalignment and wear

F. Inspect mechanical seals, if

possible, for proper operating
temperature, drips, leaks and
dirt.

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G. Check alignment, clearances, SM SM SM
and rotation of shaft and coupler
(requires removal of coupler
shroud or cover).

H. Lubricate pump bearings. Annually

I. If equipped with lubricating oil

charge, drain old oil, and fill with
new to full mark on sight
indicator (also fill bulb).

J. Refer to Section 9-1.7 Electric SM SM SM

Motors for inspection and
maintenance requirements of
As required
electric motors.

Vertical Inline Pumps (Section 3-8.1.2)

A. Check for proper operations SM SM SM

while pump is in use. Check
suction and discharge pressure
gauges for abnormal readings.

B. Check for unusual noise,

vibration, overheating of
bearings.
Quarterly
C. Tighten or replace loose,
missing or damaged nuts, bolts,
Vertical Inline or screws.
Pumps
D. Inspect suction and discharge
isolation dampeners for
misalignment and wear.

E. Inspect mechanical seals, if

possible, for proper operating
temperature, drips, leaks and
dirt.

Annually SM SM SM
F. Check alignment, clearances,
and rotation of shaft and

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coupler (requires removal of
coupler shroud or cover).

G. Lubricate pump bearings.

H. Refer to Section 9-1.7 Electric SM SM SM

Motors for inspection and As required
maintenance requirements of
electric motors.

Vertical Turbine/Submerged Turbine Pumps (Section 3-8.1.3)

A. Check for proper operations SM SM SM

while pump is in use. Check
discharge pressure gauge for
abnormal readings.

B. Check for unusual noise,

vibration, overheating of
bearings or case.

C. If equipped with lubricating oil Quarterly

charge, check oil level and
adjust as necessary.

D. Tighten or replace loose,

Vertical missing or damaged nuts, bolts,
Turbine/Sub- or screws.
merged
Turbine E. Inspect mechanical seals, if
Pumps possible, for proper operating
temperature, drips, leaks and
dirt.

F. Inspect anti-rotation device for Semi-annually SM SM SM

proper operation.

G. Check alignment, clearances, SM SM SM

and rotation of shaft and
coupler (requires removal of
coupler shroud or cover). Annually

H. Lubricate pump bearings.

I. If equipped with lubricating oil

charge, drain old oil, and fill with

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new oil to full mark on sight
indicator (also fill bulb).

J. Refer to Section 9-1.7 Electric SM SM SM

Motors for inspection and As required
maintenance requirements of
electric motors.

Sliding Vane Pumps (Section 3-8.2.1)

A. Inspect pump for unusual noise, SM SM SM

vibrations, and overheating of
bearings and case.

B. Inspect mechanical seals, if Quarterly

possible, for drips or leaks and
dirt.

C. Lubricate pump bearings.

D. Inspect pump and motor SM SM SM

coupling for proper alignment.

Sliding Vane E. Refer to manufacturer’s

Annually
Pumps operation and maintenance
manual for internal pressure
relief testing and calibration
procedures.

F. Refer to Section 3-8.4 SM SM SM

Gearboxes for inspection and
maintenance of reduction
gearboxes.
As required
G. Refer to Section 9-1.7 Electric
Motors for inspection and
maintenance requirements of
electric motors.

Gear Pumps (Section 3-8.2.2)

A. Inspect pump for unusual noise, SM SM SM

Gear Pumps vibrations, and overheating of Quarterly
bearings and case.

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B. Inspect mechanical seals, if
possible, for drips or leaks and
dirt.

C. Lubricate pump bearings

D. Inspect pump and motor SM SM SM

Annually
coupling for proper alignment.

E. Refer to Section 3-8.4 SM SM SM

Gearboxes for inspection and
maintenance of reduction
gearboxes.
As required
F. Refer to Section 9-1.7 Electric
Motors for inspection and
maintenance requirements of
electric motors.

Diaphragm Pumps (Section 3-8.2.3)

A. Inspect hose for cracks or dry SM SM SM

rot.

B. Inspect compressed air

connections for signs of leaks.
Quarterly
C. Inspect compressed air hose
coupling safety pins or safety
Diaphragm wires for wear and damage.
Pumps
Replace damaged components.

D. Diaphragm pumps should have SM SM SM

the internal diaphragm replaced
if the pump shows decreased
As required
performance. Also check
operation of actuator valve and
ensure ball checks seat
properly.
Internal Combustion Drives (Section 3-8.3)

A. Refer to manufacturer’s SM SM SM
Internal operation and maintenance
Combustion manual for specific As required
Drives maintenance procedures and
schedules associated with a
specific model of internal

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combustion drive. Follow all
applicable general maintenance
and safety requirements listed
in the manufacturer’s operation
and maintenance manual.
Gearboxes (Section 3-8.4)

A. Inspect gearboxes for signs of SM SM SM

smoke near shaft connections
or discoloration of the gearbox
from overheating.
Quarterly
B. Verify that the oil in the sight
glass is not dark or appears to
have foam. Adjust oil level if
required.

C. Lubricate bearings per SM SM SM

manufacturer’s
Gearboxes recommendations.
Semi-annually
D. Check motor and gear box and
gear box and pump couplers for
wear and alignment.

E. Inspect gear alignment within SM SM SM

gearbox.

F. Replace lubricant oil in Annually

accordance with manufacturer’s
specifications and
recommendations.

HOSES

Loading Fuel Hoses (Section 3-9.1)

A. Visually inspect hoses for loose Weekly OM OM OM

covers, cracks, brittle surface
coatings, exposed wire braids,
Loading Fuel exposed reinforcement,
Hoses flattening, kinks, and bulges or
soft spots which might indicate
broken or displaced
reinforcement.

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B. Pressurize hose to normal Monthly OM OM OM
working pressure. Check
flanged and threaded
connections for leaks and
inspect hose couplers for fluid
seepage by pushing at the base
of the coupling with your
thumbs; a hose softened by
fluid seepage must be replaced.

C. Check for coupling slippage. Quarterly SM \2\ OM /2/ SM

Replace hose that shows signs
of coupling slippage.

D. \1\/1/ Annually SM SM SM

E. Conduct test of fuel hose

electrical resistivity using an
electrostatic meter in
accordance with NFPA 77 &
API 2003.

Offloading Fuel Hoses (Sections 3-9.2)

A. Visually inspect hoses for Weekly OM OM OM

cracks brittle surface coatings,
exposed wire braids, exposed
reinforcement, flattening, kinks,
and bulges or soft spots which
might indicate broken or
displaced reinforcement.

B. Check flanged and threaded \2\ Monthly /2/ \2\ OM /2/ \2\ OM /2/ \2\ OM/ 2/
Offloading connections for leaks and
Fuel Hoses inspect hose couplers for fluid
seepage by pushing at the base
of the coupling with thumbs; a
hose softened by petroleum
fluid seepage must be replaced.
Damaged or leaking hoses
must be replaced immediately
or isolated and taken out of
service.
C. Conduct test of offloading fuel Annually SM SM SM
hose electrical resistivity as

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directed in NFPA 77 and API
2003.
AIR ELIMINATOR TANKS

Air Eliminator Tanks (Section 3-10.1)

A. Inspect operation of fuel level Annually SM SM SM
probes. Ensure probes operate
correctly when the level of fuel
in the tank rises to the level of
the probe sensing unit.
B. Remove the float vent valve
from the air eliminator tank.
Air Eliminator Clean and inspect the sealing
Tanks surfaces of the float vent valve.
Ensure the float is buoyant in
fuel and test the valve to ensure
it closes properly.
C. Refer to Section 8-9.3 Tank As required SM SM SM
Pressure/Vacuum Vents for in-
spection and maintenance
require- ments of pressure
vacuum vents.
Automatic Air Vents (Section 3-10.2)
a. Check for proper operation of Annually SM SM SM
the automatic air vent. Ensure
the vent opens to allow air to
Automatic Air escape and ensure the float of
Vents the vent is buoyant in petroleum
fuel and rises to close the vent
when the float is suspended in
petroleum fuel.

FUEL ADDITIVE INJECTORS

Fuel Additive Injectors (Section 3-11)

When fuel OM OM OM
system has
a. Inspect injectors to ensure they flow through it,
Fuel Additive
inspect weekly.
Injectors are operating properly.
When fuel
system is
sitting idle,
inspect

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injectors
monthly.

b. Calibrate injector to ensure Annually SM SM SM

proper additive to fuel ratio.

CONTROL VALVES – TYPE II HYDRANT SYSTEM

General System Control Valves (Section 4-3.2.1)

A. Verify operating settings of SM SM SM

valve. Valve adjustment must
be in accordance with
manufacturer's operation and
maintenance manuals and final
start-up and commissioning set
Quarterly
points. Use of DoD standard
set points should only be used
as a reference starting point as
pipe size and other hydraulic
factors influence final system
settings.

B. Remove and clean strainer SM SM SM

installed in the petroleum fuel
supply line to the pilot and main Annually for
General
valve diaphragm. This strainer is unfiltered
System
systems and as
Control provided to prevent clogging of
required for
Valves the orifice in the supply line.
filtered
Clogging of the screen will systems.
cause malfunctioning of the
valve

C. Diaphragms must be removed SM SM SM

and inspected for deterioration
and breaks at the flexing joint.
Damage is often caused by pipe
scale, pipe tape, and thread
sealant compound that collect Every 10 years
above the diaphragm and
become lodged between the
diaphragm and bonnet of the
valve. Damage may also be
caused by a change of
operational petroleum fuel type

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or grade (such as a change
from JP-4 to JP-8).

Refuel Control Valves (Section 4-3.2.5)

A. Verify refuel control valve is set SM SM SM

to maintain 100 psig (690 kPa)
(typ- ical operating pressure) as
meas- ured at the furthest
hydrant outlet.

B. Verify pressure-reducing control

will open at 5 psig (35 kPa)
above normal operating
pressure (typ- ically 105 psig
(725 kPa) as meas- ured at the
farthest hydrant outlet)
Quarterly
C. Verify refueling control valve
Refuel opening rate is set between 15
Control
and 20 seconds. The valve
Valves
should open as quickly as
possible without tripping the
pressure differential control
shut-off.

D. Verify operation of the excess

flow shut-off function.

E. Verify operation of solenoid.

F. Refer to Section 4-3.2.1 General As required SM SM SM

System Control Valves for
additional inspection and
maintenance requirements.

Pressure Relief Valves (Section 4-3.2.6)

A. Verify pressure relief valve will Semi-annually SM SM SM

open at 10 psig (69 kPa) above
Pressure normal inlet pressure to the
Relief Valves refuel control valve.

B. Refer to Section 4-3.2.1 General As required SM SM SM

System Control Valves for

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additional inspection and
maintenance requirements.

Defuel Control Valves (Section 4-3.2.7)

A. Verify the defuel control valve SM SM SM

opens when the solenoid on the
defuel control valve is Quarterly
Defuel energized.
Control
Valves B. Refer to Section 4-3.2.1 General SM SM SM
System Control Valves for
As required
additional inspection and
maintenance requirements.

Dual Rate-of-Flow Control Valves (Section 4-3.2.8)

A. Verify dual rate-of-flow control SM SM SM

valve is set to maintain a flow
rate of 200 gpm (12.5 lps).
Quarterly

Dual Rate-of- B. Verify check valve feature is

Flow Control operational.
Valves
C. Refer to Section 4-3.2.1 General SM SM SM
System Control Valves for
As required
additional inspection and
maintenance requirements.

Combination Dual Rate-of-Flow Control and Solenoid Valves (Section 4-3.3.1)

A. Verify valve is set to maintain a SM SM SM

Combination flow rate of 300 gpm (19 lps).
Dual Rate-of-
Flow Control B. Verify operation of check valve Quarterly
and Solenoid feature.
Valves
C. Verify solenoid operation.

D. Refer to Section 4-3.2.1 SM SM SM

General System Control Valves
As required
for additional inspection and
maintenance requirements.

Dual Pressure Relief, Solenoid Shutoff, and Check Valves (Section 4-3.3.2)

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A. Verify high pressure relief SM SM SM
control will open at 5 psig (35
kPa) above the refuel control
valve pressure relief control set
point (typically set at 110 psig
(760 kPa)).
Dual
Pressure B. Verify low pressure relief control
Relief, will open at 5 psig (35 kPa)
Solenoid Quarterly
when refueling pumps are
Shutoff, and
Check stopped.
Valves
C. Verify closing speed provides a
smooth, pulsation free
operation.

D. Verify operation of solenoid

valve.

E. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for
As required
additional inspection and
maintenance requirements.

CONTROL VALVES – TYPE III HYDRANT SYSTEM

Non-Surge Check Valves (Section 4-4.2.1)

A. Verify main valve opening SM SM SM

speed (typically 20 seconds).
Adjust if required.

B. Verify valve maintains 650 gpm

(41 lps) flow rate (some Semi-annually
instances 950 gpm (60 lps) flow
rate). Adjust if required.
Non-Surge
Check
C. Ensure the check valve function
Valves
is operating properly.

D. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for
additional inspection and
As required
maintenance requirements

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Filter Separator Control Valves (Section 4-4.2.2)

A. Test FSCV emergency shut off SM SM SM

solenoid under flow conditions
and ensure that valve closes
within 10 seconds of EFSO
button activation. Coordinate
with overall EFSO test listed in
Section 9-1.2.1 Inspection and
Maintenance - Electrical
Equipment.

B. Operate test button (if installed)

to ensure the FSCV closes at Quarterly
high water level. Physically
press the test button, while
recirculating fuel, and ensure
the FSCV closes. Note: closing
speed is a function of the
number of open filters
separators and the number of
pumps operating. With all filters
open and only one pump
Filter operating, the valve will close
Separator
very slowly.
Control
Valves C. Verify valve maintains flow rate SM SM SM
(typically 600 gpm (38 lps),
operating range based on
commissioning documentation).
Adjust flow rate if required.
Flow rate is determined by filter
separator vessel gpm (lps)
rating, or element flow rate, Semi-annually
whichever is less. Use return
venturi to measure and confirm
flow rate during valve testing
and adjustment.

D. Ensure check valve function is

operating properly.

E. Test buoyancy of water level SM SM SM

float. Remove the ball or float When
assembly and place it in a coalescer
bucket of water. Correctly cartridges are
operating ball or float will float at changed.
the top of the water’s surface.

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F. Refer to Section 4-3.2.1 General SM SM SM
System Control Valves for As required
additional inspection and
maintenance requirements.

Defuel/Flush Valves (Section 4-4.2.3)

A. Ensure Solenoids A and B are SM SM SM

de-energized with system in
automatic mode and lead pump
operating.

B. Ensure Solenoid A is energized

and Solenoid B is de-energized
to allow main valve to open and
drop system pressure to 80 psig
(550 kPa) (typical set pressure)
with system in automatic mode
and lead pump off.
Defuel/Flush
Quarterly
Valves C. Ensure Solenoid A is de-
energized and Solenoid B is
energized when system is in
flush mode.

D. Ensure Solenoids A and B are

de-energized when system is in
tightness test mode.

E. Check opening and closing

speed. Speed should be as fast
as possible while still
maintaining smooth operation.

F. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for As required
additional inspection and
maintenance requirements.

Issue Venturi (Section 4-4.2.4)

A. Ensure issue venturi DPTs are SM SM SM

reading the same value within ± Semi-annually
2% full scale.
Issue Venturi
B. Refer to Section 6-7.4 SM SM SM
As required
Differential Pressure
Transmitters for inspection and

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USMC Force
maintenance requirements of
DPTs

Return Venturi (Section 4-4.2.5)

A. Ensure return venturi DPTs are SM SM SM

Return
reading the same value within ± Semi-annually
Venturi
2% full scale.

B. Refer to Section 6-7.4 SM SM SM

Differential Pressure
Transmitters for inspection and As required
maintenance requirements of
DPTs.

Back Pressure Control Valves (Section 4-4.2.6)

A. Verify constant upstream SM SM SM

pressure is maintained at the
setpoint established and listed
in the system commissioning
documents. Adjust setting of
BPCV as necessary.

B. Ensure Solenoid A is energized

and Solenoid B is de-energized
while lead pump is operating in
automatic mode.

C. Ensure Solenoids A and B are

Back de-energized prior to lead pump
Pressure shutdown and system going to
Quarterly
Control stand-by.
Valves
D. Ensure Solenoids A and B are
de-energized while system is in
flush mode.

E. Ensure that Solenoid A is de-

energized and Solenoid B is
energized while system is in
tightness test mode.

F. Verify closing speed control.

Valve should close as fast as
possible while still maintaining
smooth operation.

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G. Check solenoid EFSO feature
when equipped. Coordinate test
with overall EFSO test listed in
Section 9-1.2.1 Inspection and
Maintenance - Electrical
Equipment.

H. Refer to Section 4-4.2.1 General SM SM SM

System Control Valves for
As required
additional inspection and
maintenance requirements.

Pressure Control Valves (Section 4-4.2.7)

A. Ensure Solenoid A is energized SM SM SM

and Solenoid B is de-energized
while system is in automatic
mode and lead pump is
operating.

B. Ensure Solenoids A and B are

de-energized while system is in
automatic mode and lead pump
is off. Verify valve opens to
maintain system pressure at 75
psig (515 kPa).

C. Ensure Solenoid A is energized

Pressure and Solenoid B is de-energized Quarterly
Control while system is in flush mode
Valves and lead pump is operating.

D. Ensure Solenoids A and B are

de-energized while system is in
flush mode and pumps are off.

E. Ensure Solenoids A and B are

energized while system is in
tightness test mode.

F. Verify closing speed control.

Valve should close as fast as
possible while still maintaining
smooth operation.

G. Refer to Section 4-3.2.1 General As required SM SM SM

System Control Valves for

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additional inspection and
maintenance requirements.

Hydrant Control Valves (Section 4-4.2.8)

A. Verify HCV maintains 45 psig SM SM SM

(310 kPa) nozzle pressure at a
flow of 50 to 600 gpm (3 to 38
lps).
B. Verify HCV closes when nozzle
pressure exceeds 50 psig (345
kPa).
C. Verify HCV opening rate is set Quarterly
Hydrant at a minimum of 20 seconds.
Control
D. Ensure HCV opens when the
Valves
deadman control level is
pressed.
E. Verify HCV closes in five
seconds maximum after the
deadman lever is released.
F. Refer to Section 4-3.2.1 General SM SM SM
System Control Valves for As required
additional inspection and
maintenance requirements.

Emergency Shut-off Valves (Section 4-4.2.9)

A. Ensure Solenoids A and B are SM SM SM

energized under normal
operations.

B. Ensure Solenoids A and B are

de-energized during emergency
stop conditions.
Emergency
Shut-off C. Test emergency stop function of Quarterly
Valves the valve under flow conditions.
Ensure the valve closes within
10 seconds of EFSO button
activation. Coordinate test with
overall EFSO test listed in
Section 9-1.2.1 Inspection and
Maintenance - Electrical
Equipment.

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D. Verify differential control
maintains a constant seven psig
(48 kPa) differential pressure
between the inlet and outlet of
the valve.

E. Ensure thermal relief function

(ball check valve) relieves
excess pressure when cover
chamber pressure exceeds inlet
pressure.

F. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for
As required
additional inspection and
maintenance requirements.

CONTROL VALVES – TYPE IV AND V HYDRANT SYSTEMS

Pantograph Control Valves (Section 4-5.2.12)

A. Verify PTCV maintains 55 psig SM SM SM

(380 kPa) nozzle pressure at a
flow of 50 to 600 gpm (3 to 38
lps).

B. Verify PTCV opens when the

Quarterly
deadman control lever is
Pantograph pressed.
Control
Valves C. Verify PTCV closes in a
maximum of 10 seconds after
deadman lever is released.

D. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for As required
additional inspection and
maintenance requirements.

Pantograph Pressure Control Valves (Section 4-5.2.13)

A. Verify PPCV opens at 75 psig SM SM SM

Pantograph (515 kPa).
Pressure
Quarterly
Control B. Verify PPCV opening and
Valves closing speed are three
seconds.

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Fixed Pantographs (Section 4-7.1.1)

A. Place entire pantograph under OM OM OM

static pump head pressure and
check for leaks, ease of Monthly
movement, and damaged
grounding or bonding wire.
B. Inspect wheels (if equipped) for SM SM SM
Fixed warping, cracking, and uneven
Pantographs wear. Quarterly
C. Inspect exposed piping and
components for corrosion.
D. Refer to Section 4-7.3 Fueling SM SM SM
Nozzles for inspection and As required
maintenance requirements of
fueling nozzle.

\1\ Detachable /1/ Pantographs (Section 4-7.1.2)

A. Place entire pantograph under OM OM OM

static pump head pressure and
check for leaks, ease of
Monthly
movement, and damaged
grounding or bonding wire.
B. \2\ Inspect exposed piping and
components for corrosion. /2/
C. Lubricate wheels. SM SM SM
\1\ Quarterly
Detachable D. Inspect wheels for warping,
/1/ cracking and uneven wear.
Pantographs
E. Refer to Section 4-7.2 Hydrant SM SM SM
Adapters for inspection and
maintenance requirements of
pantograph hydrant adapters.
As required
F. Refer to Section 4-7.3 Fueling
Nozzles for inspection and
maintenance requirements of
fueling nozzles.

HYDRANT ADAPTERS AND NOZZLES

Hydrant Adapters (Section 4-7.\1\2/1/)

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A. Inspect hydrant adapter for SM SM SM
proper operation, damage, and
Hydrant
wear. Quarterly
Adapters
B. Test operation of dry break
system.

Fueling Nozzles (Section 4-7.\1\3/1/)

A. Inspect the condition of the dust OM OM OM

cap at the aircraft adapter end
and ensure it is in good working
order. Dust caps must be
attached to nozzles when they
are not is use.
B. Test leak resistance of poppet
valve against full pump
pressure. Unusual conditions
found during this test indicate
that repair is necessary and the
nozzle must be removed from
service.
C. Inspect storage racks for
moisture or dirt accumulation.
Correct conditions that may be
attributing to accumulation of
Fueling
moisture or dirt in the storage \1\Monthly/1/
Nozzles
racks.

D. Remove nozzle for inspection of

content impinged upon the
mesh screen. Clean and dry
screens before nozzles are
returned to service. If a strainer
ball valve is installed upstream
of the nozzle only the strainer in
the strainer ball valve needs to
be check. Nozzles should not
be used while strainers are
removed from upstream strainer
ball valves.

E. Tests nozzle interlocks. Ensure

interlocks prevent release of
fuel when the fueling nozzle is
not properly connected. Adjust

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the seating of the poppet valve
if required.

F. Check the operation of the

manual valve crank assembly
for smooth and positive motion
on a special test stand.

SUPPRESSORS

Surge Suppressors (Section 4-7.\1\4/1/)

A. Inspect for nitrogen leaks. SM SM SM

B. Bladder pressure inside surge

suppressors must be validated
and recharged as needed with
nitrogen. Some surge
Surge suppressors are also equipped Quarterly
Suppressors with needle valves. Settings
established in the startup and
commissioning documents
should be maintained. Adjust
nitrogen charge per
manufacturer’s
recommendations.

\2\ Aircraft Fueling Hoses (Section 4-7.5)

A. Visually inspect hoses for loose OM OM OM

covers, cracks, brittle surface
coatings, exposed wire braids,
exposed reinforcement,
Monthly
flattening, kinks, and bulges or
soft spots which might indicate
broken or displaced
reinforcement.
Aircraft
Fueling
B. Pressurize hose to normal OM OM OM
Hoses
working pressure. Check
flanged and threaded
connections for leaks and
inspect hose couplers for fluid Monthly
seepage by pushing at the base
of the coupling with thumbs. A
hose softened by petroleum
fluid seepage must be replaced.

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C. Check for coupling slippage. SM SM SM
Replace hose that shows signs Quarterly
of coupling slippage.

D. For hot pit refueling hoses only, SM SM SM

refer to Appendix D, Section
D-2.1, Loading Hose
Annually
Hydrostatic Test, for loading
hose hydrostatic testing
requirements and procedures.

E. Conduct test of petroleum SM SM SM /2/

fuel hose electrical resistivity
using an electrostatic meter in Annually
accordance with NFPA 77 and
API 2003.

HYDRANT SYSTEM PRODUCT RECOVERY

Overfill Valve for Product Recovery Tanks (Section 4-8.1)

A. Verify that a green light is SM SM SM

illuminated on the pump control
panel graphic display when OV
is open.
B. Ensure pressure reservoir
bladder is charged with 13 to 15
psig (90 to 103 kPa) of nitrogen
and that the reservoir holds fuel
pressure.
Overfill Valve C. Verify that the OV closes when
for Product the control float is lifted Semi-annually
Recovery (normally 95% full). Use the
Tanks manual tester to lift the float.
NOTE: When the float in the
product recovery tank rises and
the OV closes, the pressure in
the pressure reservoir tank will
decrease.
D. Verify that a red light is
illuminated and that an alarm is
activated on the pump control
panel graphic display when OV
is closed. Alarm is activated by

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a limit switch installed on the
OV.
E. Ensure the pressure reservoir
tank holds FTP deadhead
pressure when the pump is
deactivated.
F. Open and clean reservoir inlet
strainer.
G. Refer to Section 6-6.3 Thermal SM SM SM
and Pressure Relief Valves for
inspection and maintenance As required
requirements of thermal and
pressure relief valves.
MARINE RECEIVING AND DISPENSING EQUIPMENT

\1\ Piers and Wharves Fuel Containment Systems (5-1.2) /1/

\1\
A. Hydrostatically test the
secondary containment and
associated drainage systems to
include containment
concrete/sealant, drain inlets,
drain lines and containment
drain valves to ensure
containment is liquid tight. This
test may use opportune rainfall
by holding rainwater in the
containment system for one
\1\ Piers and hour. Where evaporation is a \1\ Every 3
concern, conduct the testing \1\ SM /1/ \1\ SM /1/ \1\ SM /1/
Wharves /1/ Years /1/
when this concern would be
minimized, such as at
night/early morning or during a
time of year when this would not
be as much of an issue.
Record the water level at the
start of the 60-minute
(minimum) hold period. If the
water level drops by 1/8 inch or
more, perform and record an
investigation to determine the
cause and any required repairs.
Refer to Appendix B for testing

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procedures and to document
the testing./1/.

Marine Receipt (5-2)

A. Conduct a shore side inspection After each use OM OM OM

of the pier or wharf for signs of
damage as soon as marine
barge or tanker disembarks.
B. Inspect the ground switch used Monthly OM OM OM
between the marine barge or
tanker and the petroleum fuel
receipt piping.
C. Inspect mooring lines, cleats,
bollards, bitts, pulley blocks,
steel wire ropes, and winches.
Use UFC 4-150-08 as a guide
when conducting inspections.
Repair or replace damaged
components as required.
D. Refer to Section 6-1 Pipe As required SM SM SM
Testing and Inspections for
inspection and maintenance
Marine requirements of petroleum fuel
Receipt pipelines installed above water
surfaces. These pipelines are
regulated under 33 CFR 154
and 156. Any additional
requirements listed under 33
CFR 154 and 156 must also be
followed.
E. Refer to Section 5-5.1 Marine
Transfer Hoses for inspection
and maintenance requirements
of petroleum fuel marine hoses.
F. Refer to Section 5-4 Marine
Loading Arms for inspection and
maintenance requirements of
petroleum fuel marine loading
arms.
G. Refer to Section 3-6.4 Basket
Strainers for inspection and
maintenance requirements of
basket strainers.

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H. Refer to Section 3-7 Meters for
inspection and maintenance
requirements of petroleum fuel
meters.
I. Refer to Section 3-8.2 Positive
Displacement Pumps for
inspection and maintenance
requirements of stripper pumps.
J. Refer to Section 9-1.6
Grounding Systems for
inspection and maintenance
requirements of grounding
systems.

Marine Issue (Section 5-3)

A. Inspect pier or wharf for signs of After each use OM OM OM

damage as soon as marine
barge or tanker disembarks.

B. Inspect the ground switch Monthly OM OM OM

between the fueling tanker/barge
and the fuel system.
C. Inspect mooring lines, cleats,
bollards, bitts, pulley blocks,
steel wire ropes, and winches.
Use UFC 4-150-08 as a guide
when conducting inspections.
Repair or replace damaged
Marine Issue components as required.
D. Refer to Section 6-1 Pipe As required SM SM SM
Testing and Inspections for
inspection and maintenance
requirements of petroleum fuel
pipelines installed above water
surfaces. These pipelines are
regulated under 33 CFR 154
and 156. Any additional
requirements listed under 33
CFR 154 and 156 must also be
followed.
E. Refer to Section 3-6.4 Basket
Strainers for inspection and

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maintenance requirements of
basket strainers.
F. Refer to Section 3-8 Pumps for
inspection and maintenance
requirements of marine loading
and stripper pumps.

G. Refer to Section 3-7 Meters for

inspection and maintenance
requirements of petroleum fuel
meters.
H. Refer to Section 5-5.1 Marine
Transfer Hoses for inspection
and maintenance requirements
of petroleum fuel marine hoses.
I. Refer to Section 5-4 Marine
Loading Arms for inspection and
maintenance requirements of
petroleum fuel marine loading
arms.
J. Refer to Section 9-1.6
Grounding Systems for
inspection and maintenance
requirements of grounding
systems.

Marine Loading Arms (Section 5-4)

A. Check swivel for smooth \2\ Monthly /2/ \2\ OM /2/ \2\ OM /2/ \2\ OM /2/
operation. Check seals for
signs of wear and discoloration
which may indicate a seal or ball
bearing failure.

Marine B. Inspect ball bearings when Annually SM SM SM

Loading accessible. Rough and/or
Arms uneven wear on the surface are
indications of swivel joint failure
C. Conduct pressure test of marine
loading arms in accordance with
33 CFR 156.170 Equipment
Tests and Inspections, Section
(f)(1).

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Marine Bulk Transfer Hoses (Section 5-5.1)

A. Visually inspect transfer hoses. Before each OM OM OM

Transfer hoses must have no use
loose covers, kinks, bulges, soft
spots, and no gouges, cuts or
slashes that penetrate the hose
reinforcement. Hoses must also
have no external deterioration.
B. Visually survey petroleum fuel During each OM OM OM
marine hoses. Observe the use
general condition and look for
fluid puddles, fine mists,
physical damage such as jacket
Marine Bulk abrasion or deformation, and
Transfer deteriorated joints. Use sense of
Hoses smell to detect petroleum vapor.
Look for improper hose handling
that may overstress the hose by
stretching, relative movement,
or kinking.
Annually or not SM SM SM
C. Refer to Appendix D, Section D- less than 30
2.2 Marine and Underwater days prior to
Transfer Hose Hydrostatic Test the first transfer
conducted past
for marine transfer hose
one year from
hydrostatic testing requirements the date of the
and procedures. last test and
inspection.
Underwater Hoses (Section 5-5.2)

Annually or not SM SM SM
A. Refer to Appendix D, Section D- less than 30
2.2 Marine and Underwater days prior to
Underwater Transfer Hose Hydrostatic Test the first transfer
Hoses conducted past
for underwater hose hydrostatic
one year from
testing requirements and the date of the
procedures. last test and
inspection.
Single Point Mooring Systems (Section 5-7.1)

A. Inspect and, if necessary, repair OM OM OM

Monthly
or replace all mooring hawsers
or lines, deck hose, chain, chair

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stoppers, flange adaptors,
gaskets or other gear used in
mooring the marine tanker and
in connecting hoses.
B. Inspect air-compressor for SM SM SM
proper operation.
C. Inspect navigation aids and
mooring buoy, in accordance
with NAVFAC MO-124 Mooring
Maintenance Manual, for
Single Point evidence of damage and Annually
Mooring
possible movement or dragging
Systems
by vessels, current or winds.
D. Divers must conduct underwater
inspections of mooring chains,
shackles and anchors attaching
buoys to bay/harbor floors.
E. Conduct overhaul of single point SM SM SM
mooring buoys every 3 to 5
years. Single point mooring Every 5 years
buoys must be brought ashore
for repair in these instances.

Multi Point Mooring Systems (Section 5-7.2)

A. Inspect and, if necessary, repair OM OM OM

or replace all mooring hawsers
or lines, deck hose, chain, chair
stoppers, flange adaptors,
Monthly
gaskets or other deck gear used
in mooring the marine tanker
and in connecting underwater
hoses.
Multi Point
Mooring B. Inspect navigation aids and SM SM SM
Systems mooring buoys, in accordance
with NAVFAC MO-124 Mooring
Maintenance Manual, for
evidence of damage and
Annually
possible movement or dragging
by vessels, current or winds.

C. Divers must conduct underwater

inspections of mooring chains,
shackles and anchors attaching

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buoys to bay/harbor floors.

SUBMERGED PIPING SYSTEMS

Submerged Piping Systems (Section 5-8)

A. Inspect water above submerged OM OM OM

pipelines and their seaward end
for tell-tale petroleum fuel slicks Weekly
indicating leakage from pipes or
underwater hoses.

Six times each SM \2\ OM /2/ SM

B. If equipped, electrically check calendar year
the cathodic protection rectifier with intervals
for proper performance. not exceeding
2½ months

C. Divers must inspect submerged SM SM SM

pipe and hoses for signs of
incipient failure or indications of
Semi-annually
rapid wear of parts subject to
wave motion or abrasion on the
Submerged ocean floor.
Piping
Systems D. Conduct annual pipe test as SM SM SM
specified in Appendix G –
Petroleum Fuel Pipeline
Pressure testing Guidelines and
Criteria. Testing requirements
of marine pipelines are
regulated under 33 CFR 154
and 156, particularly 33 CFR
156 Section 170. Annually
E. Conduct cathodic protection
tests on the protected pipeline
as specified in Section 9.2.1
Cathodic Protection at least
once each calendar year with
intervals not exceeding 15
months between tests from
consecutive years.

Boom Reels (Section 5-9)

Boom Reels Quarterly SM SM SM

A. Visually inspect hydraulic drives

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and hose connections for leaks.
B. Grease bearings.
C. Inspected boom reel for signs of
corrosion. Inspect breaking
system and ensure it is in good
working order.

D. Inspect boom for wear, rips, and SM SM SM

tears. Repair or replace as
required to ensure containment Annually
of petroleum fuel in the event of
a spill.

ON-BASE PIPELINES

On-Base Pipelines (Section 6-1.1)

A. Conduct petroleum fuel pipeline Monthly \2\ OM /2/ \2\ OM /2/ SM

visual Inspection of
aboveground piping in
accordance with Section 6-1.5
Pipeline Visual Inspection.
Conduct during OM OM OM
B. Conduct line walk in areas of
transfer
petroleum fuel piping in operations, or
accordance with Section 6-1.6 monthly, at a
Line Walk.. minimum

C. Conduct annual test as specified Annually SM \2\ OM /2/ SM

in Appendix G – Petroleum Fuel
On-Base Pipeline Pressure Testing
Pipelines Guidelines and Criteria.
D. Conduct cathodic protection Annually SM SM SM
tests as specified in Section
9.2.1 Cathodic Protection on
protected petroleum fuel
pipelines at least once each
calendar year, but with intervals
not exceeding 15 months.
E. Conduct five year test as Every five SM SM SM
specified in Appendix G – years
Petroleum Fuel Pipeline
Pressure Testing Guidelines
and Criteria.

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F. Conduct petroleum fuel pipeline Every 5 or 10 SM SM SM
API 570 inspection in years depend-
accordance with Section 6-1.9 ing on API
API 570 Inspections. class piping or
in accordance
with Pipeline
Integ-rity
Manage-ment
Plan (PIMP).
G. Conduct petroleum fuel pipeline As required to SM SM SM
cleaning in accordance with ensure fuel
Section 6-2 General Pipeline quality.
Cleaning.

INTER-TERMINAL PIPELINES

Non-DOT Regulated (Section 6-1.2.1)

A. Conduct petroleum fuel pipeline Monthly OM OM OM

volume check in accordance
with Section 6-1.8 Volume
Check.
B. Conduct line patrol in areas of Annually OM OM OM
Non-DOT underground petroleum fuel
Regulated pipeline in accordance with
Section 6-1.7 Line Patrol.
C. Government operated inter- As required SM/OM SM/OM SM/OM
terminal petroleum fuel pipelines
must follow the maintenance
requirements listed in Section 6-
1.1.1 for On-Base Pipelines.

Aboveground Piping (Section 6-1.3)

A. Conduct petroleum fuel piping Weekly OM OM OM

visual Inspection in accordance
with Section 6-1.5 Pipeline
Visual Inspection.
B. Conduct petroleum fuel piping Annually SM SM SM
Aboveground annual test as specified in
Piping Appendix G – Petroleum Fuel
Pipeline Pressure Testing
Guidelines and Criteria.
C. Conduct petroleum fuel piping Every 5 or 10 SM SM SM
API 570 inspection in years depend-
accordance with Section 6-1.9 ing on API
class piping or

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API 570 Inspections. in accordance
with Pipeline
Integ-rity
Manage-ment
Plan
(PIMP).Manage
ment Plan
(PIMP).
D. Conduct cleaning of petroleum As required to SM SM SM
fuel piping in accordance with ensure fuel
Section 6-2 General Pipeline quality.
Cleaning.

Double-Wall Piping (Section 6-1.4)

A. Conduct petroleum fuel pipeline Monthly OM OM OM

visual Inspection of
aboveground piping in
accordance with Section 6-1.5
Pipeline Visual Inspection.
B. Conduct annual carrier pipe test Annually SM SM SM
as specified in Appendix G –
Petroleum Fuel Pipeline
Pressure Testing Guidelines
and Criteria.

C. Conduct cathodic protection

tests as specified in Section
9.2.1 Cathodic Protection on
protected petroleum fuel
Double-Wall
pipelines at least once each
Piping
calendar year, but with intervals
not exceeding 15 months.

D. Conduct containment pipe test Every three SM SM SM

as specified in Appendix G – years
Petroleum Fuel Pipeline
Pressure Testing Guidelines
and Criteria.

E. Conduct petroleum fuel pipeline Every 5 or 10 SM SM SM

API 570 inspection in years depend-
accordance with Section 6-1.9 ing on API
API 570 Inspections. class piping or
in accordance
with Pipeline
Integ-rity
Manage-ment

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Plan
(PIMP).Manage
ment Plan
(PIMP).
F. Conduct petroleum fuel pipeline As required to SM SM SM
cleaning in accordance with ensure fuel
Section 6-2 General Pipeline quality.
Cleaning.

MANUAL VALVES

Plug Valves – Lubricated (Section 6-6.2.1)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation.

Plug Valves -
Lubricated B. Lubricate valve operator stems Semi-annually SM SM SM
and all grease fittings.

C. Inspect valve exterior for

corrosion and tightness of bolts.
Repaint/tighten as required.

Plug Valves – Non-lubricated (Section 6-6.2.2)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation. Adjust or
replace packing as needed.
Plug Valves
Non-
Lubricated B. Inspect valve exterior for Semi-annually SM SM SM
corrosion and tightness of bolts.
Repaint and retighten as
required.

Gate Valves (Section 6-6.2.3)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation. Adjust or
Gate Valves replace packing as needed.

B. Lubricate valve operator stem. Semi-annually SM SM SM

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C. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint and retighten as
required.

Ball Valves (Section 6-6.2.4)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation.

B. Lubricate overhead ball valve

chain operator gears.

C. Adjust packing per

manufacturer’s specifications.
Ball Valves
D. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint/tighten as required.

E. Refer to Section 6-6.2.10 As required SM SM SM

Manual Valve Gear Operators
for inspection and maintenance
of gear operators if equipped.

Double Block and Bleed Valves (Section 6-6.2.5)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation.

B. Lubricate overhead valve chain

operator gears if equipped.

C. Adjust packing per

Double Block manufacturer’s specifications.
and Bleed
Valves
D. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint and tighten as required.

E. Operate the body cavity drain

when valve is in closed position
to ensure that the valve is
closing properly.

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F. \2\ Keep the valve operator Semi-Annually SM SM SM
housing full of lubricant to
displace and prevent moisture
from accumulating and freezing,
in accordance with
manufacturer’s
recommendations.

G. Remove bottom drain plug and Annually SM SM SM

drain valve.

H. Refer to Section 6-6.2.10, As required SM SM SM

Manual Valve Gear Operators,
for inspection and maintenance
of gear operators, if equipped.
I. Some double block and bleed
valves are equipped with
integrated pressure/thermal
relief valves. Refer to Section 6-
6.3, Thermal and Pressure
Relief Valves, for inspection and
maintenance requirements of
pressure/thermal relief valves.
/2/

Butterfly Valves (Section 6-6.2.6)

A. Open and close valve to check Quarterly SM SM SM

for ease of operation. Ensure
that lever operators and locking
mechanisms are in place and
working properly.
B. Adjust packing per
manufacturer’s specifications as
needed. If butterfly valves are
Butterfly leaking or not shutting off flow,
Valves tightening the gland flange to
tighten the stem packing or
remove the valve from service
and replace the seats as
necessary.
C. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint and retighten as
required

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Globe Valves (Section 6-6.2.7)

A. Open and close valve to check SM SM SM

for ease of operation.
B. Adjust packing per
Globe Valves manufacturer’s specifications as Quarterly
needed.
C. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint/tighten as required

Check Valves (Section 6-6.2.8)

A. Use external test lever to make Quarterly SM SM SM

sure the valve is not sticking if
equipped. If a check valve is
suspected of not checking and
cannot be serviced in place, it
Check must be removed from the
Valves piping system and serviced in a
shop.
B. Inspect valve exterior for
corrosion and tightness of bolts.
Repaint and retighten as
required.
Line Blanks, Ring Spacers, and Spectacle Blinds (Section 6-6.2.9)

A. Inspect exposed side of SM SM SM

spectacle blinds. The exposed
Line Blanks, side must be kept clean and
Ring free of corrosion.
Spacers,
B. Spectacle blinds should be Quarterly
and
Spectacle inspected to ensure they are
Blinds installed with the correct
orientation for the desired flow
or no-flow condition.

Manual Valve Gear Operators (Section 6-6.2.10)

Manual Valve A. Lubricate gear driven operators SM SM SM

Gear Quarterly
and check for smooth operation
Operators

RELIEF VALVES

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Thermal and/or Pressure Relief Valves (Section 6-6.3)

A. Thermal and pressure relief Monthly OM OM SM

valves must be inspected for
signs of leak-by. Inspect relief
valves for leaks by visually
inspecting downstream flow
indicators (if installed) for flow.
If no flow indicators are installed
listen for possible leaks. If
suspect: isolate and test the
relief valve; check opening
pressure; and verify re-seating.
Malfunctioning valves must be
repaired or replaced.

B. Ensure manual isolation valves

installed upstream and
downstream of thermal and
pressure relief valves are open
with valve handles are removed,
wired open or locked.

Thermal and C. Inspect valve exterior of thermal Quarterly SM SM SM

Pressure
and pressure relief valves for
Relief Valves
corrosion. Repaint as required.
Information plates attached to
thermal and pressure relief
valves must not be painted over.

D. Verify thermal and pressure Annually SM SM SM

relief valve setting by consulting
as-built and historical data.

E. Thermal and pressure relief

valves must be validated for
proper calibration by isolating
the valve and using the test
connection provided on the
piping in conjunction with a hand
pump and portable reservoir.
The operating pressure must be
checked against the set
pressure listed on the stamped
information plate attached to the
valve. The operating pressure
must be adjusted to the

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stamped set pressure if
necessary.

SEMI-AUTOMATIC VALVES

Fire Valves (Section 6-6.4.1)

A. Ensure the fusible link SM SM SM

mechanism is attached properly
to actuate in case of a fire and
that it has not been by-passed,
blocked, or damaged in any
manner. Ensure the fusible link Quarterly
is not filled with debris or paint
Fire Valves which could impact operation.
\1\ Maintain fusible links per
manufacturer’s
recommendation./1/
B. Check the closing mechanism to SM SM SM
ensure that it closes the valve Annually
properly.

Fusible Line Butterfly Valves (Section 6-6.4.2)

A. Ensure the fusible link Quarterly SM SM SM

mechanism is attached properly
to actuate in case of a fire and
that it has not been by-passed,
blocked, or damaged in any
manner. Ensure the fusible link
is not filled with debris or paint
which could impact operation.
\1\ Maintain fusible links per
Fusible Link manufacturer’s
Butterfly recommendation./1/
Valves
B. Test the operation of spring Annually SM SM SM
closure unit. Ensure that the
spring actuator closes the valve
and that the valve closes
securely against the seat.
C. Refer to Section 6-6.2.6 As required SM SM SM
Butterfly Valves for additional
inspection and maintenance
requirements of butterfly valves.

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AUTOMATIC VALVES

Truck Fill Valves (Section 6-6.5.1)

A. Verify TFV maintains 35 psig SM SM SM

(240 kPa) nozzle pressure at a
flow range of 50 to 600 gpm (3
to 38 lps).

B. Verify TFV closes rapidly when

outlet pressure exceeds control
set point.

C. Verify TFV opens when the

deadman control lever is
pressed.

D. Verify TFV closes after the

deadman control lever is
released. Quarterly

Truck Fill E. If equipped, verify operation of

Valves solenoid connected to
grounding verification system.
Ground verification system
should energize solenoid when
an acceptable ground is
detected by the ground
verification unit.

F. Systems that have overflow

protection systems must be
inspected and maintained
concurrently with the inspection
and maintenance of TFVs.

G. Refer to Section 4-3.2.1 General SM SM SM

System Control Valves for
As required
additional inspection and
maintenance requirements.

Motor Operators (Section 6-6.6)

A. Visually inspect motor operators SM SM SM

Motor to ensure smooth movement Quarterly
Operators
during opening and closing
operation and adjust, if

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necessary, to ensure that they
are opening and closing fully.
Listen for and investigate
unusual noises during operation.
B. Lubricate mechanical overrides
(if equipped).
C. Refer to Section 9-1.7 Electric SM SM SM
Motors for inspection and As required
maintenance requirements of
electric motors

PRESSURE/VACUUM INSTRUMENTATION

Pressure and Pressure/Vacuum Gauges (Section 6-7.1)

A. Check operation of gauge. Monthly OM OM OM

Ensure gauge is indicating
pressure of the system.

B. Clean outside of gauge glass. Quarterly SM SM SM

C. Inspect liquid filled gauges for Semi-annually SM SM SM

leakage, refill/replace as
needed.
Pressure and D. Conduct calibration check by Annually SM SM SM
Pressure/ comparing readings of the
Vacuum process gauge with the readings
Gauges of a certified master calibration
gauge which has been
calibrated within the last year.
The process gauge and the
master calibration gauge must
be connected to the same
pressure source for testing.
Verify accuracy of gauge is
within ±2% of full scale.
Calibrate gauge if required.

Differential Pressure Gauges (Section 6-7.2)

A. Verify proper operation of Monthly \2\ OM /2/ \2\ OM /2/ \2\ OM /2/
Differential differential gauge in accordance
Pressure with gauge manufacturer’s
Gauges procedures.

B. Clean outside of gauge glass. Quarterly OM OM OM

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C. Conduct calibration check by Annually SM SM SM
comparing readings of the
differential process gauge with
the readings of a certified
differential master calibration
gauge which has been
calibrated within the last year.
The differential process gauge
and the differential master
calibration gauge must be
connected to the same pressure
source for testing. Verify
accuracy of gauge is within ±2%
of full scale. Calibrate if
required.
D. Some differential pressure Annually for SM SM SM
gauges have a small gauge inspections and
protection filter located at the maximum 5
high pressure inlet of the gauge years of service
that must be checked and between filter
replacements.
replaced as needed. Filters
need to be replaced if the
indicator is moving slow or
sluggishly inside the sight glass
or if the sight glass is dirty.
Refer to manufacturer’s
operation and maintenance
manual for filter replacement
procedure.

Pressure Transmitters (Section 6-7.3)

A. Inspect the exterior of the Quarterly SM SM SM

transmitter enclosure for
accumulated oil, dust, and dirt.
Clean if required.
B. Check that both enclosure caps
are fully threaded onto the
Pressure enclosure, compressing the O-
Transmitters
ring between the cap and the
enclosure. The O-ring must not
be cracked, broken, or
otherwise damaged.
C. Inspect the display viewing
glass for cleanliness and
damage. Replace the enclosure

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cap assembly if the glass is
damaged or missing. No
accumulation of dust, dirt, or
water (condensate) should be
present inside the enclosure.
D. Inspect transmitter and
mounting bracket hardware for
tightness. Tighten loose
hardware as necessary.

E. Inspect for loose, bent, or

cracked sensing lines. Replace
damaged sensing lines.
F. Check operation of transmitter.
Ensure transmitter is indicating
accurate pressure of the
system.
G. Bleed sensing lines between SM SM SM
the transmitter and the main line
to ensure they are clean and Semi-annually
free of suspended solids and
air.
H. Check that all wire connections SM SM SM
inside enclosure are tight.
I. Pressure Transmitters (PTs)
and Pressure Indicating
Transmitters (PITs) must be
calibrated mechanically and
electrically with test equipment
and adjusted if applicable. The
presence of air in the sensing
line of a pressure transmitter is
a common cause for failure. Annually
Conduct calibration check by
comparing readings of the PT
or PIT with the readings of a
certified master calibration
gauge which has been
calibrated within the last year.
The PT or PIT and the master
calibration gauge must be
connected to the same
pressure source for testing.
Verify accuracy of PT or PIT

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gauge is within ±2% of full
scale. Calibrate in accordance
with manufacturer’s operation
and maintenance manual if
required.

Differential Pressure Transmitters (Section 6-7.4)

A. Inspect the exterior of the \2\ OM /2/ SM \2\ OM /2/

transmitter enclosure for
accumulated oil, dust, and dirt.
Clean as required.

B. Check that both enclosure

caps are fully threaded onto
the enclosure, compressing the
O-ring between the cap and
the enclosure. The O-ring must
not be cracked, broken, or
otherwise damaged.

C. Inspect the display viewing

glass for cleanliness and
damage. Replace the
enclosure cap assembly if the
glass is damaged or missing.
Differential No accumulation of dust, dirt, Quarterly
Pressure or water (condensate) should
Transmitters be present inside the
enclosure.

D. Inspect transmitter and

mounting bracket hardware for
tightness. Tighten loose
hardware as necessary.

E. Inspect for loose, bent, or

cracked sensing lines. Replace
damaged sensing lines.

F. Check operation of transmitter.

Ensure transmitter is indicating
accurate pressure of the
system

G. Bleed sensing lines between Semi-annually SM SM SM

the transmitter and the main

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line to ensure they are clean
and free of suspended solids
and air.

H. Check that all wire connections SM SM SM

inside enclosure are tight.

I. DPTs must be calibrated

mechanically and electrically
with test equipment and
adjusted, if applicable. The
presence of air in sensing lines
of differential pressure
transmitters is a common
cause for failure. Conduct
calibration check by comparing
readings of the DPT with the
readings of a certified Annually
differential master calibration
gauge which has been
calibrated within the last year.
The DPT and the differential
master calibration gauge must
be connected to the same
pressure source for testing.
Verify accuracy of DPT is
within ±2% of full scale.
Calibrate in accordance with
manufacturer’s operation and
maintenance manual if
required.

FLEXIBLE BALL JOINTS

Flexible Ball joints (Section 6-8)

Flexible Ball A. Lubricate ball joints and inspect \2\ OM /2/ \2\ OM /2/ SM
Monthly
Joints for wear and stress.

THERMOMETERS

Dial Thermometer (Section 6-9.1)

Dial A. Inspect thermometer for cracked SM SM SM

face and proper operational Quarterly
Thermometer
condition. Replace if damaged.

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B. Check accuracy of thermometer SM SM SM
against calibrated master
thermometer. Ensure process
and calibrated master
thermometer are reading the Annually
same heat source. Verify
accuracy of thermometer is
within ±2% of full scale.
Calibrate process thermometer
if required.

PIPE COATINGS

Aboveground Piping and Equipment Coatings (Section 6-10.1)

Aboveground A. \2\ Visually inspect coatings for \2 \Monthly /2/ \2\ OM /2/ \2\ OM /2/ SM
Piping and signs of minor deterioration,
Equipment corrosion, or damage. Repair
Coatings damaged or deteriorated
coatings.
B. Coatings needing major repairs
will be accomplished by system
maintainers. /2/

UNDERGROUND FUEL PITS

Isolation Valve Pits (Section 6-11.1)

A. Isolation valve pits should be OM OM OM

inspected to ensure that the pits
are dry and clean and that all
components within the pit are
clean and in good working order.
Main- tain seals and boot seals
as appro- priate. Obtain Monthly, or
necessary confined space entry more often
permits before entry. Inspect the based on local
Isolation conditions
Valve Pits pit for signs of fuel or water.
Water or fuel should be removed
from the pit as soon as possible
and the source of water
infiltration or fuel leak
determined.
B. Check for cracks in concrete and
check piping penetrations
through pit wall or bottom to
ensure that mechanical seals

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and boot seals are in good
working condition and are
allowing no seepage of water
into the pits. Make note of
cracks in concrete and schedule
main- tenance as necessary.
Check for fuel leaks at all flanged
and other piping connections.
Check for rusted or deteriorated
ladders or grating platforms that
might make entry unsafe. Check
pit lids for proper sealing. Check
rolling pit covers for ease of
operation and signs of
deterioration, damage or
corrosion. Make sure required
locks are in place and locking
mechanisms are not broken.
Hydrant Fuel Pits (Section 6-11.2)

A. Hydrant fuel pits must be OM OM OM

inspected to ensure that they
are dry and clean and that all
fueling components within the
pit are clean and in good
working order. Obtain
necessary confined space entry
permits before entry. Inspect
the pit for fuel or water. Fuel or
water found in the pit must be Monthly, or
sumped out as soon as more often
Hydrant Fuel possible. based on local
Pits conditions
B. Check pipe penetrations
through pit walls or bottom to
ensure that mechanical and
boot seals are in good working
condition and are allowing no
water seepage into the pits.

C. Check for fuel leaks at all

flanged and pipe connections.

D. Check pit lids to ensure that

seals are in good working order

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and are preventing water entry
into the pits.

E. Inspect hydrant fuel pit bonding

cables for corrosion and ensure
electrical continuity between
bonded equipment.

High Point Vent Pits (Section 6-11.3)

A. Inspect high point vent pits to OM OM OM

ensure they are dry and free of
water and other debris and that
pit and piping components are
leak free and in good working
condition. Inspect the pit for fuel
or water. Fuel or water found in
the pit must be sumped out as
soon as possible.

B. Check pipe penetrations

through pit walls or bottom to
ensure that mechanical and
boot seals are in good working
condition and are allowing no Monthly
High Point
water seepage into the pits.
Vent Pits
C. Check pit lid seals for
deterioration and replace as
necessary.

D. Ensure that high point vent

valves, quick-disconnect
couplings or pit lids are lockable
and that locking mechanisms
are in good working order.

E. Inspect high point vent pit

bonding cables for corrosion
and ensure electrical continuity
between bonded equipment.

Low Point Drain Pits (Section 6-11.4)

Low Point A. Inspect low point drain pits to OM OM OM

Monthly
Drain Pits ensure they are dry and free of
water and other debris and that

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all pit and piping components
are leak free and in good
working condition. Inspect the
pit for fuel or water. Fuel or
water found in the pit must be
sumped out as soon as
possible.

B. Check pipe penetrations

through pit wall or bottom to
ensure that mechanical seals
and boot seals are in good
working condition and are
allowing no water seepage into
the pits.

C. Check pit lid seals for

deterioration and replace as
necessary.

D. Ensure that low point vent

valves, quick-disconnect
couplings or pit lids are lockable
and that locking mechanisms
are in good working order.

E. Inspect low point drain pit

bonding cables for corrosion
and ensure electrical continuity
between bonded equipment.

Lateral Control Pits (Section 6-11.5)

A. Inspect lateral control pits to OM OM OM

ensure they are dry and free of
water and other debris and that
all pit and piping components
are leak free and in good
working condition. Inspect the Monthly
Lateral
pit for fuel or water. Fuel or
Control Pits
water found in the pit must be
sumped out as soon as
possible.

B. Check pipe penetrations

through pit wall or bottom to
ensure that mechanical seals

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and boot seals are in good
working condition and are
allowing no water seepage into
the pit.

C. Check pit lid seals for

deterioration and replace as
necessary.

D. Check for fuel leaks at all

flanged and other piping
connections.

E. Ensure that pit lids are lockable

and that locking mechanisms
are in good working order.

F. Inspect lateral control pit

bonding cables for corrosion
and ensure electrical continuity
between bonded equipment.

MINOR PIPING EQUIPMENT

Low Point Drains (Section 6-12.1)

A. Visually inspect low point OM OM OM

drains. Ensure that quick-
disconnect dust caps are in Weekly
place and that valves are locked
closed.

B. Operate low point drains when OM OM OM

Low Point system is not under operating
Monthly or as
Drains pressure. If there is an absence required by
of sufficient line pressure close local
the low point drain and conditions.
pressurize the system. Once Verify low point
adequate pressure is available, drains are
continue draining until the closed after
piping fuel sample is clear and maintenance
bright with no visible water.

High Point Vents (Section 6-12.2)

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A. Inspect high point vents. If fuel OM OM OM
leaks are observed they should
be repaired as soon as possible.
High Point
Ensure that quick-disconnect Weekly
Vents
dust caps are in place and that
high point vent valves are
locked.

Sight Flow Indicators (Section 6-12.3)

A. Verify there are no leaks around OM OM OM

Sight Flow pipe connection fittings and Daily or at each
Indicators glass seals. Also check glass use
for indications of cracks.

ELECTRONIC RELEASE DETECTION MONITORING

Rope Sensor Systems (Section 6-13.1.1)

A. Ensure the monitoring panel OM OM OM

associated with the rope
Daily
sensor(s) is powered on and no
Rope Sensor
alarms are present.
System
B. Test rope sensor system and SM SM SM
Annually
ensure it is functional.

Point Sensor - Dry (Section 6-13.1.2)

A. Ensure the monitoring panel OM OM OM

associated with the point
Daily
sensor(s) is powered on and no
alarms are present.
Point Sensor
- Dry B. Ensure monitoring space is OM OM OM
clear and free of debris and Monthly
liquid.
C. Test sensor and ensure it is Annually SM SM SM
functional.

Visual Monitoring (Section 6-14.1)

A. Visually inspect ports for signs OM OM OM

Visual of leaks. Remove debris or Weekly
Monitoring foreign objects obstructing the
view.

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FILLING STATION DISPENSERS

Dispenser Nozzles (Section 7-2)

A. Inspect dispenser nozzle spout. OM OM OM

Ensure it is tight, round, has no
cracks, or excessive wear.
Inspect automatic shutoff hole.
Ensure the hole is open and
free of obstructions. Inspect
nozzle hold-open latch. Ensure
the latch is straight, moves Daily
freely, and the return spring
operates correctly. Inspect
body of nozzle. Ensure the
Dispenser body is in good condition and
Nozzles that the valve stem is clean and
free of fuel. Inspect the nozzle
to hose connection and ensure
it is clean and free of fuel.
B. \1/ \1/ \1/ \1/ \1/

C. Test automatic shutoff feature SM SM SM

and ensure it is operating
properly. Test automatic shutoff Annually
at all nozzle hold-open latch
positions

Dispenser Hoses (Section 7-3)

A. Inspect dispenser hoses and OM OM OM

hose whips for gouges, cuts,
blisters, or outside wear that
may lead to rupture during use.
Replace hose or hose whips
Dispenser that show signs of wear.
Daily
Hoses Inspect connection points of
hoses and hose whips to the
dispenser, breakaways, swivels,
and the nozzle and ensure the
connection points are clean and
free of fuel.

Breakaways (Section 7-4)

Breakaways A. Inspect breakaways for loose Daily OM OM OM

connections and signs of

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damage to poppets. Ensure
breakaways are clean and free
of fuel.

B. Inspect breakaway for an OM OM OM

expiration date established by
the manufacturer. Breakaways Monthly
must be replaced before the
indicated expiration date

Swivels (Section 7-5)

A. Inspect swivel for loose OM OM OM

connections and signs of
damage. Ensure swivel rotates Daily
easily and is clean and free of
fuel.

Swivels B. Inspect swivel for expiration OM OM OM

date established by
manufacturer. Swivels must be
replaced before the indicated Monthly
expiration date.

Hose Retriever (Section 7-6)

A. Test hose retriever and ensure it OM OM OM

Hose
is operating correctly and Monthly
Retriever
supporting the hose.

Dispenser Cabinet (Section 7-7)

A. Inspect outside of cabinet and OM OM OM

ensure it is free of damage.
Inspect for fuel stains on the
concrete island around the
cabinet and on the outside of
Dispenser
the cabinet. Ensure the cabinet Monthly
Cabinet
is free of dirt and fuel.

B. Open both sides of the cabinet

and inspect the inside of the
cabinet. Ensure the inside of
the cabinet and all of the

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components inside the cabinet
are clean and free of fuel.

C. Ensure door panels and locks SM SM SM

operate easily. Inspect anchor
bolts of cabinet to dispenser Annually
island and ensure the bolts are
in good condition.

Dispenser Meters (Section 7-8)

A. Inspect meter and ensure meter OM OM OM

is clean and free of fuel.
Monthly
Ensure calibration mechanism
is sealed.

B. Since moving parts inside SM SM SM

meters are subject to wear,
Dispenser periodic calibration is
Meters necessary. Meters must be
recalibrated utilizing a certified 5
gallon (20 liter) prover can or Annually
other approved method. Meters
are considered satisfactory for
further operation when the error
does not exceed ±0.2% of
actual quantity delivered.

Dispenser Filters (Section 7-9)

A. Inspect filter and ensure filter is OM OM OM

Dispenser clean and free of fuel and that
Monthly
Filters filter is labeled with a legible
installation date.

B. Replace dispenser filters SM SM SM

Annually or as
annually or when a change in
needed
flow rate is noted.

Dispenser Strainer (Section 7-10)

A. Inspect and clean strainers. SM SM SM

Inspect strainer cover gasket for
Dispenser
cracks, distortion, and dry rot. If Annually
Strainers
breaks are detected in strainer
mesh, replace the strainer.

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GROUND FUEL PIPING

Ground Vehicle Fuel Piping (Section 7-11)

A. Visually inspect aboveground OM OM OM

lines for leaks. Shut down
Daily
systems that are found with
leaks and repair.

B. Visually inspect leak detection \2\ OM /2/ \2\ OM /2/ \2\ OM /2/
systems installed on
underground piping. Inspections
include line leak detectors and Monthly
leak detection sensors installed
in transition sumps and
dispenser sumps.\2\ /2/

C. Perform leak testing on SM SM SM

pressurized underground piping
with installed leak detection
equipment and record results.

D. Test leak detection systems

Ground installed on underground piping
Vehicle Fuel
used for ground vehicle
Piping
petroleum fuel products.
Underground leak detection
systems include discrete
detection sensors installed in
transition and dispenser sumps,
and line leak detectors installed Annually
at the outlet of pumps used to
supply pressurized liquid
petroleum fuel to underground
lines. Repair faulty
components. Execution of this
work may require state
certification or license.

E. Conduct service station

aboveground piping annual test
as outlined in Appendix G –
Petroleum Fuel Pipeline
Pressure Testing Guidelines
and Criteria. Execution of this

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work may require state
certification or license.

F. /2/Conduct service station

underground piping annual test
outlined in Appendix G –
Petroleum Fuel Pipeline
Pressure Testing Guidelines
and Criteria. Execution of this
work may require state
certification or license.

G. Refer to Section 2.7 Signage SM SM SM

and Markings for inspection and
maintenance requirements of
ground vehicle petroleum fuel
pipe markings.
As required
H. Refer to Section 6-10.1
Aboveground Piping and
Equipment Coatings for
inspection and maintenance
requirements of ground vehicle
petroleum fuel pipe coatings.

Emergency Shutoff Valves (Shear Valves) (Section 7-12)

A. Inspect stabilizer bar to ensure OM OM OM

that it is securely mounted
below the base of the dispenser.
Inspect the mounting bolts that
secure the emergency shutoff
Monthly
valve to the stabilizer bar.
Emergency
Shutoff B. Inspect fusible link and ensure it
Valves is not obstructed. Ensure valve
(Shear body is clean and free of fuel.
Valves)
C. Inspect mechanical links of the SM SM SM
valve for correct operation.
Conduct test of valve to ensure
Annually
it operates correctly. Execution
of this work may require state
certification or license.

Dispenser Sumps (Section 7-13)

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A. Inspect for signs of water, fuel, OM OM OM
trash, and debris inside sumps.
Remove and properly dispose of
collected water, fuel, trash, and
Monthly
debris. Visually inspect
penetration fittings. If fuel or
water is detected investigate the
source and repair.

Dispenser B. Inspect sump pipe transition SM SM SM

Sumps fittings for tears, cracks, or other
signs of deterioration. Check Quarterly
hose clamp seals to ensure they
are securely tightened.

C. Test dispenser sumps and SM SM SM

ensure they are liquid tight by
Every three
using vacuum, pressure, or
years
liquid testing in accordance with
40 CFR 280, Section 43.

Transition Sumps (Section 7-14)

A. Inspect for signs of water, fuel, OM OM OM

trash, and debris inside sumps.
Remove and properly dispose
of collected water, fuel, trash,
Monthly
and debris. Visually inspect
penetration fittings. If fuel or
water is detected investigate the
source and repair.

Transition B. Inspect sump pipe transition SM SM SM

Sumps fittings for tears, cracks, or other
signs of deterioration. Check Quarterly
hose clamp seals to ensure they
are securely tightened.

C. Test sumps and ensure they are SM SM SM

liquid tight by using vacuum,
Every three
pressure, or liquid testing in
years
accordance with 40 CFR 280,
Section 43.

DISPENSER PUMPS

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Remote Dispenser Pumps (Section 7-15.1)

A. Refer to Section 7-19.1.2 SM SM SM

Automatic Line Leak Detector
for maintenance and inspection
requirements of automatic line
leak detectors installed on
Remote submersible turbine pumps.
Dispenser As required
Pumps
B. Refer to Section 3-8.1.3 Vertical
Turbine/Submerged Turbine
Pumps for inspection and
maintenance requirements of
remote dispenser pumps.

Self-Contained Dispenser Pumps (7-15.2)

A. Inspect self-contained dispenser \2\ OM /2/ \2\ OM /2/ SM

pump v-belt drives for proper
tension and excess wear.
Replace belt as recommended
Self- by manufacturer.
Contained
Monthly
Dispenser B. Inspect pump body. Ensure
Pumps pump body is clean and free of
fuel. Inspect air eliminator.
Ensure air eliminator is clean
and free of fuel and that the vent
tube is not obstructed.

EFSO SYSTEMS

EFSO Systems (Section 7-16)

A. Check the operation of the SM SM SM

EFSO system by activating the
fueling system and then
pressing each of the EFSO
Quarterly
EFSO buttons. Ensure that each
Systems button disables power to all of
the dispensers and fuel pumps
installed at the service station.

B. Refer to Section 2-7 Signage As required SM SM SM

and Markings for inspection and

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maintenance requirements of
EFSO pushbutton signs.

VAPOR RECOVERY

Stage I Vapor Recovery (Section 7-17.1)

A. Inspect vapor recovery hoses OM OM OM

Daily or before
for gouges, cuts or outside wear
each use
that may result in vapor leaks

B. Inspect caps and camlock SM SM SM

Stage I Quarterly
fittings for tightness and leaks.
Vapor
Recovery
C. Refer to Section 7-11 Ground SM SM SM
Vehicle Fuel Piping for
inspection and maintenance As required
requirements of Stage I vapor
recovery piping.

\2\ Stage II Vapor Recovery (Section 7-17.2)

A. There are several approved SM SM SM /2/

vendors for Stage II Vapor
Stage II Recovery systems. Consult the Per
Vapor manufacturer's operation and manufacturer's
Recovery maintenance manual provided specifications
with the system for periodic
maintenance requirements.

Vapor Burners (Section 7-17.3)

A. Inspect vapor burners to ensure SM SM SM

that the pilot flame system is
operating properly. Fans, duct
work, and dampeners must also
be inspected to ensure proper
Vapor
air to fuel vapor mixtures allow Quarterly
Burners
for complete burns.

B. Inspect burner knock out pots

for condensed fuel vapors and
water if equipped.

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C. Inspect thermowells and gas
detection monitors for
operability.

ELECTRONIC RELEASE DETECTION MONITORING

Point Sensor - Dry (Section 7-19.1.1)

A. Ensure the monitoring panel OM OM OM

associated with the point
Quarterly
sensor(s) is powered on and no
alarms are present.

Point Sensor
B. Ensure monitoring space is OM OM OM
- Dry
clear and free of debris and Monthly
liquid

C. Test sensor and ensure it is SM SM SM

Annually
functional.

Automatic Line Leak Detector (Section 7-19.1.2)

A. Ensure the monitoring panel OM OM OM

associated with the detector(s)
Daily
is powered on and no alarms
are present.

Automatic B. Simulate a 3 gallons per hour SM SM SM

Line Leak leak at 10 pounds per square
Detector inch; the automatic line leak
detector must activate within
Annually
one hour. A licensed and/or
certified technician is required
to, test, troubleshoot, or
calibrate for operation.

Visual Monitoring (Section 7-20.1)

A. Visually inspect at inspection OM OM OM

Visual ports for signs of leaks. Remove
Weekly
Monitoring debris or foreign objects
obstructing the view.

STORAGE TANKS

Aboveground Field-Erected Tanks (Section 8-4)

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A. Visually inspect for evidence of OM OM OM
leaks; shell distortions; signs of
settlement; corrosion, condition
of tank foundation, condition of
coating, insulation systems, and
appurtenances. Inspection
must include all components
and equipment located inside
the containment area such as
piping, pipe supports,
containment valves, and product
saver tanks. Items noted during Monthly
the inspection will be
documented for follow-up action
by an authorized inspector. See
Appendix F for the Field-Erected
Tank Monthly Inspection
Checklist.

B. Visually inspect chime to

ringwall sealant. Seal should be
maintained in good working
Aboveground order to prevent corrosion of the
Field-Erected underside of the tank bottom.
Tanks
C. Visually inspect the exterior of OM OM OM
the tank for leaks, corrosion, or
irregularities such as tilting,
settling, or out-of-roundness.
Give special attention to seams
and anchor bolts. Visual
inspection must include all
components and equipment
located inside the tank Annually
containment area such as
piping, pipe supports,
containment valves, and product
saver tanks. Retain records of
inspections reports for five
years. See Appendix F for the
Field-Erected Tank Annual
Inspection Checklist.
D. Perform a formal in-service Every five SM SM SM
external inspection of the tank in years or as
accordance with API 653 or STI required by an
SP001 to evaluate the tank for appropriately
conditions which may affect the certified tank

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operational integrity of the inspector in the
storage tank, including minimum previous API
shell thickness measurements. 653 or STI
This inspection must be SP001
performed by an applicable inspection
report.
certified inspector. Inspection
must include all components
and equipment located inside
the tank containment area such
as piping, pipe supports,
containment valves, and product
saver tanks.
E. Perform an out-of-service SM SM SM
API 653 or STI SP001
inspection to evaluate the
tank for conditions which
may affect the operational
integrity of the tank floor,
shell, roof and floating roof
or pan. API 653 or STI
SP001 provides a checklist \2\ As recom-
to be used as part of the mended by the
assessment. This inspection API 653/STI
must be performed by an SP001
appropriately certified API inspector. If
653 or STI SP001 inspector. there is not a
Inspection must include all previous
components and equipment recom-
mendation, the
located inside the tank
inspection must
containment area such as
be performed
piping, pipe supports, within ten years
containment valves, and after the tank
product saver tanks. \2\ The was placed into
API 653 or STI SP001 operation. /2/
inspector must recommend
the date of the next
inspection. The inspection
interval must be based on
the date the Suitability for
Service Letter is issued
immediately prior to when
the tank is returned to
service. /2/
Geodesic Dome Roofs (Section 8-4.2)
A. Conduct external inspection of Monthly OM OM OM
geodesic dome roofs, where

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accessible, for corrosion of tank-
to-shell bolts, gasket
connections, visible signs of
corrosion, apparent roof leaks,
clogging or deterioration of vent
screens, and damage to the
structure or panels.
Geodesic B. Conduct internal inspection of OM OM OM
Dome Roofs geodesic dome roofs from the
floating roof, where accessible,
for corrosion of tank-to-shell
bolts, gasket connections, Annually
visible signs of corrosion,
apparent roof leaks, clogging or
deterioration of vent screens,
and damage to the structure or
panels.
Foundations (Section 8-4.3)

A. Inspect visible components of OM OM OM

tank foundations for signs of
erosion due to heavy rains,
wash-down, etc. and repaired
as necessary. Also inspect tank
Foundations foundations for structural Monthly
cracks, signs of settlement,
spalling, or general
deterioration. Remove
vegetation found around the
tank foundation.

Aboveground Shop Fabricated Tanks (Section 8-5.1)

A. Monthly External Inspection OM OM OM

(Identified as P in \1\STI
SP001/1/): Visually inspect for
exterior signs of corrosion or
coating deterioration. Visually
Aboveground inspect weld seams, tank-to-
Shop saddle connections, tank Monthly
Fabricated
supports, tank anchors,
Tanks
foundation and anchor bolts,
overfill valves and alarms,
normal vents, emergency vents,
leak detection probe or
water/petroleum accumulation in
the interstice on double-walled

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tanks, leaking valves, fittings, or
components, spill containment
systems and release prevention
barriers. Leaking valves, fittings
or components must be repaired
immediately or immediately
removed from service and
isolated to prevent further
discharge. Any irregularities,
(e.g., missing valve handles,
bolts, nuts, screens) will be
assessed for priority and
repaired as soon as possible or
as required depending on the
nature of the defect (See
Appendix E for an example of
the STI SP001 Standard
Monthly Inspection Checklist).

B. Annual External Inspection OM OM OM

(Identified as P in \1\STI
SP001/1/): A more detailed
examination of the tank and
appurtenances must be Annually
performed on an annual basis
(See Appendix E for an example
of the STI SP001 Standard
Annual Inspection Checklist).

C. Formal External Inspection SM SM SM

(Identified as E in\1\ STI SP001
/1/): A formal external inspection
as defined in STI SP001
Standard for the Inspection of
Aboveground Storage Tanks
must be conducted by certified As established
STI SP001 inspector. by SCP based
on tank size
and category
D. Formal Internal Inspection
listed in \1\ STI
(Identified as I in\1\ STI SP001 SP001 /1/
/1/): A formal internal inspection
as defined in STI SP001
Standard for the Inspection of
Aboveground Storage Tanks
must be performed by a
certified STI SP001 inspector.
\2\ The API 653 or STI SP001

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inspector must recommend the
date of the next inspection. The
inspection interval must be
based on the date the Suitability
for Service Letter is issued
immediately prior to when the
tank is returned to service. /2/

E. Leak Test (Identified as L in \1\

STI SP001 /1/): A leak test as
defined in STI SP001 Standard
for the Inspection of
Aboveground Storage Tanks
must be performed in
accordance with STI SP001
Standard for the Inspection of
Aboveground Storage Tanks.

Self-Diking or Vaulted Tanks (Section 8-5.2)

A. Monthly External Inspection OM OM OM

(Identified as P in \1\STI SP001
/1/): Visually inspect for exterior
signs of corrosion or coating
deterioration. Visually inspect
weld seams, tank-to-saddle
connections, tank supports, tank
anchors, foundation and anchor
bolts, overfill valves and alarms,
normal vents, emergency vents,
leak detection probe or
water/petroleum accumulation in
Self-Diking or the containment area, leaking
Vaulted Monthly
valves, fittings, or components.
Tanks
Leaking valves, fittings or
components must be repaired
immediately or immediately
removed from service and
isolated to prevent further
discharge. Any irregularities,
(e.g., missing valve handles,
bolts, nuts, screens) will be
assessed for priority and
repaired as soon as possible or
as required depending on the
nature of the defect (See
Appendix E for an example of

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the STI SP001 Standard
Monthly Inspection Checklist).
B. Annual External Inspection \2\ SM /2/ OM \2\ SM /2/
(Identified as P in \1\STI
SP001/1/): A more detailed
examination of the tank and
appurtenances must be Annually
performed annually. (See
Appendix E for an example of
the STI SP001 Standard Annual
Inspection Checklist).
C. Formal External Inspection SM SM SM
(Identified as E in \1\ STI SP001
/1/): A formal external inspection
as defined in STI SP001
Standard for the Inspection of
Aboveground Storage Tanks
must be conducted by certified
STI SP001 inspector.

D. Formal Internal Inspection

(Identified as I in \1\ STI SP001
/1/): A formal internal inspection As established
as defined in STI SP001 by SCP based
on tank size
Standard for the Inspection of
and category
Aboveground Storage Tanks
listed in \1\ STI
must be performed by a certified SP001 /1/
STI SP001 inspector.

E. Leak Test (Identified as L in

\1\STI SP001/1/): A leak test as
defined in STI SP001 Standard
for the Inspection of
Aboveground Storage Tanks
must be performed in
accordance with STI SP001
Standard for the Inspection of
Aboveground Storage Tanks.

Rectangular Concrete-Encased Tanks (Section 8-5.3)

Rectangular A. Monthly External Inspection OM OM OM

Concrete- (Identified as P in \1\ STI SP001
Monthly
Encased /1/): Visually inspect tank
Tanks supports, anchors and anchor
bolts, overfill valve and alarms,

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normal vent, emergency vent,
leaking valves, fittings or other
components. In addition the
exterior concrete must be
visually inspected for cracking,
degradation, excessive
calcareous deposits or signs of
damage. Leaking valves,
fittings or components must be
repaired immediately or isolated
to prevent further discharge.
Any other deficiencies or
irregularities noted must be
repaired as soon as possible or
as required depending on the
nature of the defect (See
Appendix E for an example of
the STI SP001 Standard
Monthly Inspection Checklist)..

B. Annual External Inspection SM SM SM

(Identified as P in \1\ STI SP001
/1/): A more detailed
examination of the tank and
appurtenances must be Annually
performed on an annual basis
(See Appendix E for an example
of the STI SP001 Standard
Annual Inspection Checklist).

C. Formal External Inspection SM SM SM

(Identified as E in \1\ STI SP001
/1/): A formal external inspection
must be conducted by certified
STI SP001 inspector.
As established
D. Formal Interior Inspection by SCP based
(Identified as I in \1\ STI SP001 on tank size
/1/): A modified formal internal and category
inspection as defined in listed in \1\ STI
SP001 /1/
manufacturer’s instructions or
STI SP001 Standard for the
Inspection of Aboveground
Storage Tanks must be
performed on concrete-encased
tanks by a certified STI SP001

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inspector if the tank interior is
accessible.

Underground Single-walled Shop-Fabricated Tanks (Section 8-5.4.1)

A. Monthly External Inspection OM OM OM

(Identified as P in Table 8-
\1\1/1/): Ensure all tank port
covers are present, are in good
condition, and seated firmly on
the correct tank. Inspect tank
stick gauge and ensure
markings are legible and that
the stick gauge is not warped or Monthly
broken. Inspect tank for water
using ATG or stick gauge with
water-finding paste. Remove
water found in tank. Open and
inspect tank-top containment
sumps and ensure no fuel or
water is collected in the sumps.
Check for and remove
obstructions in tank fill pipe.
Underground B. Annual External Inspection SM SM SM
Single-walled (Identified as P in Table 8-
Shop- \1\1/1/): Inspect electrical
Fabricated connections and junction boxes
Tanks in underground sumps and
access ports on tank. Ensure
boxes are sealed, and that
boxes, conduit, and electrical
fittings are not corroded.
Inspect submerged turbine
pumps if present. Ensure
pumps are in good condition Annually
and that pumps and fittings
show no signs of leaking.
Inspect tank top containment
sumps for cracks, holes, and
budges. Ensure tank top
containment sump electrical and
pipe penetrations are intact and
secured. For double-walled
piping systems that drain into
the tank top containment sump,
ensure interstitial space of
piping is open and that sump

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sensor is properly mounted at
the bottom of the sump. Ensure
tank top containment sump lid
gasket and seals are in good
condition. Inspect road access
covers. Ensure covers are in
good condition, that all bolts are
present and that handles and lift
mechanism is in good condition
as applicable. Inspect concrete
installed over tank and ensure
there is no significant cracking.
As established SM SM SM
C. Tank Tightness Test (Identified by SCP based
as T in Table 8-\1\1/1/): Perform on tank size
and release
test in accordance with 40 CFR
detection type
280, Section 43. listed in Table
8-\1\1/1/.
D. Formal Internal Inspection SM SM SM
(Identified as I in Table 8-1): A
formal modified internal As established
inspection in accordance with by SCP based
STI SP001 Standard for the on tank size
Inspection of Aboveground and release
detection type
Storage Tanks must be
listed in Table
conducted by a certified STI 8-\1\1/1/ or as
SP001 inspector if the interior is recommended
accessible. The inspector will by an STI
need to supplement and/or SP001 certified
adapt portions of STI SP001 to tank inspector
evaluate the specific concerns in the previous
of an underground tank. Check inspection
the tank for settlement and report.
ensure that the tank slopes
towards the water drain.
E. Test tank-top containment SM SM SM
sumps and ensure they are
liquid tight by using vacuum, Every three
pressure, or liquid testing in years
accordance with 40 CFR 280,
Section 43.

Underground Double-walled Shop-Fabricated Tanks (Section 8-5.4.2)

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A. Monthly External Inspection OM OM OM
(Identified as P in Table 8-
\1\2/1/): Ensure all tank port
covers are present, are in good
condition, and seated firmly on
the correct tank. Inspect tank
stick gauge and ensure
markings are legible and that
the stick gauge is not warped or Monthly
broken. Inspect tank for water
using ATG or stick gauge with
water-finding paste. Remove
water found in tank. Open and
inspect tank-top containment
sumps and ensure no fuel or
water is collected in the sumps.
Check for and remove
obstructions in tank fill pipe.
B. Annual External Inspection SM SM SM
(Identified as P in Table 8-
Underground \1\2/1/): Inspect electrical
Double- connections and junction boxes
walled Shop- in underground sumps and
Fabricated access ports on tank. Ensure
Tanks boxes are sealed, and that
boxes, conduit, and electrical
fittings are not corroded.
Inspect submerged turbine
pumps if present. Ensure
pumps are in good condition
and that pumps and fittings
show no signs of leaking. Annually
Inspect tank top containment
sumps for cracks, holes, and
budges. Ensure tank top
containment sump electrical and
pipe penetrations are intact and
secured. For double-walled
piping systems that drain into
the tank top containment sump,
ensure interstitial space of
piping is open and that sump
sensor is properly mounted at
the bottom of the sump.
Ensure tank top containment
sump lid gasket and seals are in

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good condition. Inspect road
access covers. Ensure covers
are in good condition, that all
bolts are present and that
handles and lift mechanism is in
good condition as applicable.
Inspect concrete installed over
tank and ensure there is no
significant cracking.
C. Formal Internal Inspection SM SM SM
(Identified as I in Table 8-
\1\2/1/): A formal modified
As established
internal inspection in by SCP based
accordance with STI SP001 on tank size
Standard for the Inspection of and release
Aboveground Storage Tanks detection type
must be conducted by a certified listed in Table
STI SP001 inspector if the 8-\1\ 2 /1/ or as
interior is accessible. The recommended
inspector will need to by an STI
SP001 certified
supplement and/or adapt
tank inspector
portions of STI SP001 to
in the previous
evaluate the specific concerns inspection
of an underground tank. Check report.
the tank for settlement and
ensure that the tank slopes
towards the water drain.
D. Test tank-top containment SM SM SM
sumps and ensure they are liquid Every three
tight by using vacuum, pressure, years
or liquid testing in accordance
with 40 CFR 280, Section 43.

Underground Field-Constructed Tanks (Cut and Cover Tanks) (Section 8-6)

A. Check the level gauge records OM OM OM

and interstitial monitoring ports Daily
to determine if the tank is
leaking.
Underground
Field- B. Apply field-erected tank monthly OM OM OM
Constructed external inspection to the
Tanks maximum extent possible.
Monthly
Visually inspect tank and
appurtenances for eviden- ce of
leaks, shell distortions, signs of
corrosion, and settlement at

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accessible locations. Items noted
during the inspection will be
docu- mented for follow-up action
by an authorized inspector (See
Appendix F for the Field-Erected
Tank Month- ly Inspection
Checklist).
C. Check tank under static storage
conditions for 24 hours using
exist- ing inventory management
system to determine if
petroleum losses are occurring.
If leakage is noted, further
investigation must be con-
ducted in accordance with
Military service-specific
guidelines.
D. Apply field-erected tank annual SM SM SM
ex- ternal inspection to the
maximum extent possible.
Visually inspect tank and
appurtenances for eviden- ce of
leaks, shell distortions, signs of
corrosion, and settlement at ac-
cessible locations. Visually Annually
inspect pump/equipment vaults
for leaks and cracking in
concrete walls and floors. Retain
records of inspec- tions reports
for five years (See Appendix F
for the Field-Erected Tank
Annual Inspection Checklist).
E. Perform a modified out-of- SM SM SM
Service API 653 internal
inspection to eval- uate the tank Every ten years
for conditions which may affect or as
the operational integrity of the recommended
by an
tank floor, shell, columns and
appropriately
roof by certified API 653 certified tank
inspector. API 653 provides a inspector in the
checklist to be used as part of previous API
the assessment; however the 653 inspection
certified API 653 ins- pector must report.
modify this checklist to
incorporate specific needs of

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under- ground field-constructed
tanks.
Tank Cleaning (Section 8-7)

a. Air Force – SM SM SM
Tanks above
20,000 gallon
(75,700 liters)
in capacity -
Every 10 years
unless required
more frequently
due to fuel
quality issues.
Contact AFPET
and AF Fuel
SME for
deviations on
schedule.
Schedule
changes are
A. Conduct Tank Cleaning: Unless typically
accepted
otherwise mandated by
based on TO
operational concerns or military 42B1-1
service directives, schedule and requirements.
Tank conduct tank cleaning based
Cleaning upon the frequency listed b. Air Force –
Tanks 20,000
below. After cleaning tanks
gallon (75,700
must be stenciled in accordance liters) in
with Section 8-8.1 Tank capacity and
Stenciling Requirements. under - During
out of service
inspection
cycle unless
required more
frequently due
to potential fuel
quality issues.
c. Army, Navy,
U.S. Marine
Corps – During
out-of-service
inspection
cycle unless
required more
frequently due
to potential fuel
quality issues.

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Aluminum Honeycomb Floating Pan (Section 8-9.1.1)

A. Visually inspect pan guide/anti- OM OM OM

rotation cables and centering of
pan.

B. Visually inspect pan grounding Monthly

cables for proper attachment
and wear or binding.

C. Visually inspect for buckling or

damage to the pan.
D. Inspect grounding cables for SM SM SM
proper attachment and wear or
binding.
E. Inspect all floating roof
penetration seals, such as Annually
Aluminum ladder seals, stilling well seals,
Honeycomb and other seals to ensure that
Floating Pan they are in good working
condition.

F. Clean and inspect perimeter At time of out of SM SM SM

tank/pan seals. service internal
inspection
G. Refer to Section 8-9.1.5 Floating SM SM SM
Roof and Pan Pressure/Vacuum
Vents for inspection and
maintenance requirements of
floating pan pressure/vacuum
vents. As required
H. Refer to Section 8-9.1.6 Floating
Roof and Pan Legs for
inspection and maintenance
requirements of floating pan
legs.
Steel Floating Pan (Section 8-9.1.2)

A. Visually inspect pan guide/anti- OM OM OM

Steel
rotation cables and centering of Monthly
Floating Pan
pan.

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B. Visually inspect pan grounding
cables for proper attachment
and wear or binding.

C. Visually inspect for buckling or

damage to the pan.

D. Visually inspect for damage or

deflection in the rolling ladder (if
equipped).

E. Inspect grounding cables for SM SM SM

proper attachment and wear or
binding.

F. Inspect all floating pan

penetration seals, such as
gauge well seals to ensure that
they are in good working
condition.

G. Inspect gauge wells for

Annually
abrasions that might indicate out
of roundness, or improper
centering.
H. Inspect vertical ladder for
abrasions that might indicate out
of roundness, or improper
centering (if equipped).
I. Inspect for damage or deflection
in the rolling ladder (if
equipped).

J. Clean and inspect perimeter At time of out of SM SM SM

tank/pan seals. service internal
inspection
K. Refer to Section 8-9.1.5 Floating SM SM SM
Roof and Pan Pressure/Vacuum
Vents for inspection and
maintenance requirements of
floating pan pressure/vacuum As required
vents.
L. Refer to Section 8-9.1.6 Floating
Roof and Pan Legs for
inspection and maintenance

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requirements of floating pan
legs.

Pontoon Floating Pan (Section 8-9.1.3)

A. Visually inspect pan guide/anti- OM OM OM

rotation cables or pipes and
centering of pan.

B. Visually inspect pan grounding

cables for proper attachment
and wear or binding. Monthly
C. Visually inspect for buckling or
damage to the pan.
D. Visually inspect for damage or
deflection in the rolling ladder (if
equipped).
E. Inspect pontoons for standing SM SM SM
liquid and presence of strong
vapors.
F. Remove mechanical gauge float
cover and ensure float is
Pontoon securely fastened to gauge
Floating Pan tape. Check gauge tape for
ease of movement.
G. Inspect for damage or deflection
in the rolling ladder (if
equipped).
H. Inspect vertical internal ladder
Annually
and internal ladder/pan seals for
abrasions that might indicate out
of roundness, or improper
centering (if equipped).
I. Inspect gauge wells and gauge
well/pan seals for abrasions that
might indicate out of roundness,
or improper centering.
J. Inspect steel floating pan
coatings for corrosion. Touch
up with compatible coating if
required (aluminum pans do not
require coatings).

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K. Clean and inspect perimeter At time of out of SM SM SM

service internal
tank/pan seals.
inspection
L. Refer to Section 8-9.1.5 Floating SM SM SM
Roof and Pan Pressure/Vacuum
Vents for inspection and
maintenance requirements of
floating pan pressure/vacuum
vents.
As required
M. Refer to Section 8-9.1.6 Floating
Roof and Pan Legs for
inspection and maintenance
requirements of floating pan
legs.

Floating Roof (Section 8-9.1.4)

A. Visually inspect the center OM OM OM

primary roof drain system is
water-free

B. Visually inspect anti-rotation

pipes/roof guides and centering
of roof.

C. Visually inspect grounding

cables for proper attachment
and wear or binding. Monthly

D. Visually inspect for buckling or

Floating damage to the roof.
Roofs
E. Visually inspect for standing
water on roof deck.

F. Visually inspect for damage or

deflection in the rolling ladder (if
equipped).

G. Ensure that the drip-tight plug is SM SM SM

placed in the roof drain opening.
Annually
H. Ensure that the roof drain valve
is closed. The drain valve is
kept in the closed position
except after each rain or

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snowfall when it is opened just
long enough to drain the
roofline. Tanks with retrofitted
geodesic domes or metal roofs
may have had the floating roof
drain line removed, so before
opening the roof drain valve
ensure the roof drain line has
not been removed.

I. Inspect pontoons for standing

liquid and presence of strong
vapors.

J. Remove mechanical gauge float

cover and ensure float is
securely fastened to gauge
tape. Check gauge tape for
ease of movement.

K. Ensure emergency drain (if

equipped) is not blocked with
debris.

L. Inspect for damage or deflection

in the rolling ladder (if
equipped).

M. Inspect vertical internal ladder

and internal ladder/roof seals for
abrasions that might indicate out
of roundness, or improper
centering (if equipped).

N. Inspect gauge wells and gauge

well/roof seals for abrasions that
might indicate out of roundness,
or improper centering.

O. Inspect the floating roof coating

for corrosion. Touch up with
compatible coating if required.

P. Clean and inspect perimeter At time of out of SM SM SM

service internal
tank/pan seals.
inspection

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Q. Refer to Section 8-9.1.5 Floating SM SM SM
Roof and Pan Pressure/Vacuum
Vents for inspection and
maintenance requirements of
floating roof pressure/vacuum
vents. As required
R. Refer to Section 8-9.1.6 Floating
Roof and Pan Legs for
inspection and maintenance
requirements of floating roof
legs.

Floating Roof and Pan Pressure/Vacuum Vents (Section 8-9.1.5)

A. Inspect the floating roof or pan SM SM SM

pressure/vacuum vent to ensure
that the seats and retaining
straps or guides are in good
working order and that the
pressure/vacuum vent is not
Floating Roof stuck to its seats, but instead lift
and Pan easily off of its seats and At time of out of
Pressure/ service internal
reseats properly. Inspect
Vacuum inspection
Vents gaskets for wear and replace as
required. Refer to the
manufacturer’s operation and
maintenance manual provided
with the floating roof or pan for
additional guidance on servicing
the pressure/vacuum vent.

Floating Roof and Pan Legs (Section 8-9.1.6)

A. Inspect the floating roof or pan SM SM SM

legs and tank bottom striker
plates for wear; inspect the
seals where the legs penetrate
the floating roof or pan for leaks;
Floating Roof inspect the low leg position At time of out of
and Pan stops to make sure they are service internal
Legs securely fastened to the legs inspection
and will stop the floating roof or
pan at the low position; inspect
the leg keeper straps to make
sure they are securely fastened
to the legs to prevent the legs
from falling off or through the

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floating roof or pan; inspect the
threaded keeper caps or high
position locking mechanisms to
ensure they are in proper
working order for securing the
floating roof or pan in the high
position. Refer to the
maintenance manual provided
with the floating roof or pan for
additional guidance on floating
roof or pan legs and associated
hardware.

Secondary Tank Bottoms (Section 8-9.2)

A. Tanks designed with secondary OM OM OM

tank bottoms should have tell-
tale devices (leak detection
ports) to allow for monitoring of
the tank’s floor integrity. The
tell-tale devices are typically
configured as valves or
inspection ports to allow for
visual monitoring of liquid that
Secondary may be present between the
Tank Monthly
foundation and the tank floor.
Bottoms
The presence of water would
indicate a breach in the
foundation seals or flooring
while the presence of petroleum
would indicate integrity loss in
the tank floor. Open and check
tell-tale valves or inspection
ports. Verify the absence of
water or petroleum.

Tank Pressure/Vacuum Vents (Section 8-9.3)

A. On underground shop fabricated OM OM OM

tanks, ensure tank
Tank pressure/vacuum vent is Annually
Pressure/ present and that the riser pipe is
Vacuum securely supported and vertical.
Vents
B. Inspect vent settings. Pressure SM SM SM
Annually
and vacuum settings for
pressure/vacuum vents are

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usually specified on the vent
nameplate or in the
manufacturer’s manual for the
vent.

C. Clean the pressure/vacuum

vent. Information on the type of
pressure/vacuum vent and
proced- ures for the removal of
covers, hoods and/or pallet
removal and reinstallation
should be found in the
manufacturer’s operation and
maintenance manual. Before
removing the pallets, brush all
accumulations from the
protecting screens, the pallets,
and all surfaces of the valve.
Brush the screens from inside
the valve so that dirt and other
objects fall to the outer sides.
Remove heavy loading weights
prior to removing the pallet
assembly. Remove deposits or
foreign matter using reasonable
care not to damage diaphragms
or seats.
D. Inspect gaskets, seats,
diaphragm, pallet stems and
stem guides. Check all mating
surfaces which must be free of
nicks, cuts, cracks or deposits
that might interfere with the
proper seating or tightness of
the valve. Test the pallets to
ensure they move freely up and
down over the full range of
travel.
Emergency Vents (Section 8-9.4)
A. \2\ Inspect emergency vents for OM OM SM /2/
Emergency external damage, such as dents,
rusting, severe pitting, or Annually
Vents
obstruction by other equipment,
piping, or conduits.

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B. Remove the vent, if possible, SM SM SM
and inspect the seals and
diaphragms for cracking or
breakdown. Inspect retaining
cables to ensure they are
fastened to the vent and the
manway or tank. Inspect guides
to ensure emergency vents can
function properly and re-seat.
C. Verify that emergency vents
have not been removed or
modified. Emergency vents
should not be replaced with Annually
ATGs, manual sample ports,
level alarms, etc.
D. Tanks that are equipped with
manways for emergency vents
must be inspected for
appropriate type, length, number
of bolts, and lift clearance of the
manway in accordance with UL
142 Standard for Steel
Aboveground Tanks for
Flammable and Combustible
Liquids, Section 8 and 9.

Flame Arrestors (Section 8-9.5)

A. The tube bank must be removed SM SM SM
and cleaned of foreign matter by
Flame immersing in an approved
solvent solution, taking care not Annually
Arrestors
to damage the tube bundle.
Gaskets must be inspected and
replaced as necessary.

External High Level Shutoff Valves (HLSO) (Section 8-9.6.1)

A. Activate the tank high-high level SM SM SM
alarm and ensure the solenoid
valve (if equipped) activates on Quarterly
External High
Level Shutoff the HLSO valve. Ensure the
Valves HLSO valve closes when the
(HLSO) solenoid valve is activated.
B. Isolate, drain, and then vent the SM SM SM
Annually
external float valve chamber (if
equipped). Refill (either

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manually or via the storage tank
product saver tank pump) the
float chamber to test the float
valve. Ensure the HLSO closes
when the float is raised.
C. Lift the manual test lever of
internally mounted float valve (if
equipped). Ensure that the
HLSO closes when the float of
the float valve is raised.
Internal HLSO Valve (Section 8-9.6.2)

A. Inspect and test the high level SM SM SM

shut-off valve and float
mechanism, counter-weights,
float rods, and floats to ensure
the float mechanism is moving
freely and functioning properly
Internal to close the high level shut-off
Annually
HLSO Valves valve. If valve is not equipped
with a manual test mechanism
the level of the tank must be
raised to the high level shutoff
valve set point in order to test
the valve. Ensure valve is
installed at a proper height.

Mechanical Tape Gauges (Section 8-9.7)

A. Visually check that a liquid level OM OM OM

is indicated and that the
Daily
measurement appears to be
accurate.

B. Check the mechanical tape SM SM SM

gauge against the automatic
Mechanical electronic tank gauge (if
Tape Gauges installed) or by manually
gauging the tank for relative
accuracy and proper working Quarterly
condition. Consult the
manufacturer’s operation and
maintenance manual for
additional maintenance and
inspection requirements

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Automatic Tank Gauges

Mechanically Operated Tape Gauge (Section 8-9.8.1)

A. Visually inspect the gauge to OM OM OM

ensure the power is on, there
are no warning alarms or lights
Daily
and a liquid measurement is
indicated and the tank level
reading appears to be accurate.

B. Inspect gauge head for buildup SM SM SM

of sediment.
Quarterly
C. Inspect tape conduit for
deformations that would inhibit
movement of tape up and down.
D. Gauge level accuracy must be SM SM SM
performed against a hand dip
measurement of the tank.
Mechanically Calibrate as required.
Operated
Tape Gauge E. Inspect float and guide cable
through an opened manway or
access cover. Verify that the
guide wire is taut and free of
kinks. Verify that the float is Semi-annually
buoyant and free of sludge or
sediment build up.

F. Inspect power and control wires

for damage.

G. Inspect wire connection

termination points for damage or
loose connections.

H. Lubricate moving parts of the SM SM SM

Annually
gauge head

Magnetostrictive Probes (Section 8-9.8.2)

A. Visually inspect the gauge to OM OM OM

Magnetostrici ensure the power is on, there Daily
tve Probes
are no warning alarms or lights
and a liquid measurement is

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indicated and the tank level
reading appears to be accurate.

B. Inspect probe assembly for SM SM SM

buildup of sediment.

C. Inspect probe assembly and Quarterly

probe shaft for deformations
that would inhibit movement of
probe.

D. Level probe accuracy must be SM SM SM

performed against a hand dip
measurement of the tank.
Calibrate as required.

E. Verify that the probe float is

buoyant and free of sludge or
sediment build up. Semi-annually

F. Inspect power and control wires

for damage.

G. Inspect wire connection

termination points for damage or
loose connections.

Servo Gauge (Section 8-9.8.3)

A. Visually inspect the gauge to OM OM OM

ensure the power is on, there
are no warning alarms or lights
Daily
and a liquid measurement is
indicated and the tank level
reading appears to be accurate.

B. Inspect gauge head for buildup SM SM SM

Quarterly
Servo Gauge of sediment.

C. Gauge level accuracy must be SM SM SM

performed against a hand dip
measurement of the tank.
Calibrate as required. Semi-annually

D. Inspect float and guide cable

through an opened manway or
access cover. Verify that the

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guide wire is taut and free of
kinks. Verify that the float is
buoyant and free of sludge or
sediment build up.

E. Inspect power and control wires

for damage.

F. Inspect all wire connection

termination points for damage or
loose connections.

G. Inspect stilling well to be straight SM SM SM

and vertical with no dents so
that the float can move freely.
Annually
H. Lubricate moving parts of the
gauge head.

Level ALARMS

Externally Mounted Level Alarms (Section 8-9.9.1)

A. Test level alarm switches by SM SM SM

isolating the chambers from the
tank using the sensing chamber
Externally isolation valves. Vent and drain
Mounted the chambers. Slowly pour Semi-annually
Level Alarms product into the chambers
through a funnel on top of the
chamber to test the level switch
at the specified level setting.

Internally Mounted Level Alarms (Section 8-9.9.3)

A. Test level alarm switches by SM SM SM

activating manual testing levers,
if equipped. If alarms switches
are not equipped with manual
Internally testing levers, adjust the level of
Mounted fuel in the tank to the alarm Annually
Level Alarms points in order to test the alarm
switches. If it is not feasible to
adjust the level of the fuel in the
tank to all of the alarm set
points, remove the alarm
switches from the tank and test

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the alarms externally. Reinstall
alarm switches in the tank once
testing is complete.

PRODUCT SAVER TANKS

Product Saver Tanks (Section 8-9.10)

A. Inspect the product saver tank SM SM SM

to ensure all valves are working
properly, sight level gauges with
Product density balls are working
Quarterly
Saver Tanks properly and are not broken,
and hand pumps or electric
pumps are working properly and
are not leaking.

SIDESTREAM FILTRATION SYSTEMS

Sidestream Filtration Systems (Section 8-9.11)

A. Check (typically 5 gallon (19 OM OM OM

liters), if incorporated) filter
Monthly
separator vent tank and ensure
it is empty.

B. Refer to Section 6-1 Pipe SM SM SM

Testing and Inspections for
inspection and maintenance
requirements of piping.

C. Refer to Section 3-6.4 Basket

Sidestream Strainers for inspection and
Filtration maintenance requirements of
Systems basket strainers.

D. Refer to Section 3-8 Pumps for As required

inspection and maintenance
requirements of fuel pumps.

E. Refer to Section 3-6.2 Filter

Separators for inspection and
maintenance requirements of
filter separators.
F. Refer to Section 4-4.2.2 Filter
Separator Control Valves for
inspection and maintenance

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requirements of filter separator
control valves.
G. Refer to Section 9-1.6
Grounding Systems for
inspection and maintenance
requirements of grounding
systems.
H. Refer to Section 9-1.9 Electronic
Equipment for inspection and
maintenance requirements of
control panels.

FILL PORTS

Fill Ports (Section 8-9.12)

A. Ensure fill port covers are OM OM OM

installed and are not damaged
or broken. Ensure fill port
covers are identified by fuel
type and are installed on the
correct tank. Visually inspect Daily
the fill port spill bucket to ensure
there are no cracks, budges, or
holes. Ensure the spill bucket is
clean of dirt, trash, water, and
fuel

B. Inspect drain valve in spill \2\ OM /2/ \2\ OM /2/ SM

bucket and ensure it is in good
Fill Ports condition. Ensure the caps
installed on the receipt
connection points are vapor
tight and are not broken, Monthly
cracked, or chipped. Ensure
the poppet valve of the vapor
recovery port seals tightly and
no vapor is escaping from the
tank when the valve is closed.

C. \1\Hydrostatically test fill-port to SM SM SM

ensure containment is liquid-
tight. Where evaporation is a \1\Every 3
Years/1/
concern, conduct the testing
when this concern would be
minimized, such as at

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night/early morning or during a
time of year when this would not
be as much of an issue.
Record the water level at the
start of the 60-minute
(minimum) hold period. If the
water level drops by 1/8 inch or
more, perform and record an
investigation to determine the
cause and any required repairs.
Once repairs are completed, a
new test must be completed.
Refer to Appendix B for testing
procedures and to use to
document the testing./1/ Ensure
secondary containment area of
fill port is fuel tight. Ensure the
manual transfer pump or drain
valve is operational.

LEAK DETECTION

Point Sensor - Dry (Section 8-9.13.1)

A. Ensure the monitoring panel OM OM OM

associated with the point
Daily
sensor(s) is powered on and no
alarms are present.

Point Sensor
B. Ensure monitoring space is \2\ OM /2/ \2\ OM /2/ \2\OM/2/
- Dry
clear and free of debris and Monthly
liquid

C. Test sensor and ensure it is SM SM SM

Annually
functional

Point Sensor - Wet (Section 8-9.13.2)

A. Ensure the monitoring panel OM OM OM

associated to the wet point
Daily
sensor(s) is powered on and no
Point Sensor alarms are present.
- Wet
B. Ensure level of monitoring fluid \2\ OM /2/ \2\ OM /2/ SM
Monthly
is within normal range.

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C. Test sensor and ensure it is Annually SM SM SM
functional.

Point Sensor – Pressure/Vacuum (Section 8-9.13.3)

A. Ensure the monitoring panel OM OM OM

associated with the
Point Sensor pressure/vacuum point Daily
– Pressure/ sensor(s) is powered on and no
Vacuum alarms are present.
B. Test vacuum sensor for proper Annually SM SM SM
operation

Visual Leak Detection (Section 8-9.13.4)

A. Visually inspect leak detection During routine OM OM OM

ports (tell-tales) for signs of inspection of
leaks. If there are debris or other
objects obstructing the view, components or
appropriate measures must be monthly,
taken to remove the debris or whichever
comes first.
remedy the obstructions.
Visual Leak
Detection B. Visually inspect reinforcement OM OM OM
plate tell-tale holes for signs of
leaks. Ensure tell-tale holes
have not been plugged by
debris or a cap. Pack Quarterly
reinforcement plate tell-tales
with white grease to prevent
insect nesting and buildup of
debris

FLOATING SUCTION LINES

Floating Suctions Lines (Section 8-9.14)

A. Check external floating suction SM SM SM

line position indicator to ensure
floating suction line is moving Quarterly
freely as the level in the tank
Floating rises or falls.
Suction Lines
B. Inspect cables, floats, and swing When tank is SM SM SM
joint. Ensure interior of floats taken out of
have not collected fuel. Ensure service for
cables are securely fastened to internal

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anchor points and are in good cleaning or
working order. Ensure the inspection
suction pipe flange used to
support the swing joint is level
and true and that swing joint
moves freely up and down and
does not bind.

HEATING COILS

Steam Type Heating Coils (Section 8-9.16.1)

A. Observe the regulating valve OM OM OM

and check it against a
thermometer to be sure that it
controls the tank temperature
within a safe range, usually not At each
over 150 °F (65 °C) for No. 6 operation
burner fuel oil. Steam traps
must be inspected for proper
operation to ensure condensate
is evacuated from the steam
coil.
B. Pressure check heating coils to SM SM SM
10% above normal operating Annually
pressure.
Steam Type
Heating Coils C. Steam coils must be cleaned SM SM SM
and inspected for visible signs of
corrosion or wear when the tank
is emptied and cleaned for
inspection. All components of When the tank
is taken down
the steam heating coils, such as
for formal
weld joins, support points,
internal
valves, temperature wells, inspection or
control valves, and steam traps sooner if steam
must be inspected and checked heating coil
for proper operation and visible damage is
wear or damage. The coil may suspected.
be carefully pressurized with
steam and visually checked for
leaks if necessary. Leaks or
damage found must be repaired.

Thermal Fluid Type Heating Coils (Section 8-9.16.2)

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A. Observe the regulating valve OM OM OM
and check it against a
thermometer to be sure that it
controls the tank temperature
within a safe range, usually not At each
over 150 °F (65 °C) for No. 6 operation
burner fuel oil. All external
valves, fittings, and other
components must be inspected
for visible signs of leaks during
operation.
B. Pressure check heating coils to SM SM SM
Thermal 10% above normal operating Annually
Fluid Type pressure.
Heating Coils
C. When tanks are emptied and SM SM SM
cleaned for inspection, the
heating coils must be cleaned
When the tank
and inspected for visible signs is taken down
of corrosion, wear, or damage. for formal
The coils can be pressurized internal
and checked for leaks at that inspection or
time with the thermal heating sooner if
fluid at normal operating thermal heating
pressure, but at ambient coil damage is
temperature to alleviate possible suspected.
burns to personnel. Leaks must
be repaired.

Electric Rod Type Heating (Section 8-9.16.3)

A. Inspect heater to ensure no fluid OM OM OM

Electric Rod leakage around the heater to At each
Type Heating tank connection and that the operation
heater is performing properly.

STILLING WELLS

Stilling Wells (Section 8-9.17)

A. Stilling wells must be visually SM SM SM

inspected to be vertically At time of out of
Stilling Wells straight and free dents or service internal
indentations. Sometimes tank inspection
stilling wells are made of bare
carbon steel pipe. In these

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instances the stilling wells must
be replaced with aluminum.

B. Inspect floating seals inside

stilling wells to ensure they are
not worn and are sealing the
inside of the stilling well
property.

CONTAINMENT SYSTEMS

Containment Systems (General) (Section 8-10.1)

A. Inspect containment systems for Daily OM OM OM

cleanliness, if accessible.
B. Secondary containment systems SM SM SM
degrade and will collect debris
which can clog drainage inlets or
prevent drain valves from seating
properly. \1\Hydrostatically test
the drainage systems to include
containment drain inlets, drain
lines and containment drain
valves to ensure the containment
is liquid tight. This test may use
opportune rainfall by holding
rainwater in the containment
system for one hour. Where
Containment
Systems evaporation is a concern,
(General) conduct the testing when this \1\Every 3
concern would be minimized, years/1/
such as at night/early morning or
during a time of year when this
would not be as much of an
issue. Record the water level at
the start of the 60-minute
(minimum) hold period. If the
water level drops by 1/8 inch or
more, perform and record an
investigation to determine the
cause and any required repairs
Record the water level at the
start of the 60 minute (minimum)
hold period. If the water level
drops by 1/8 inch or more,
perform and record an

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investigation to determine the
cause and any required repairs.
Refer to Appendix B for testing
procedures and to use to
document the testing
American Concrete International
(ACI) Standards 224R “Control of
Concrete Cracking” and ACI’s
Concrete Repair Manual are two
standards that owners/operators
can follow to maintain the integrity
of the concrete secondary
containment./1/

Concrete and Cement Brick Dike/Berm Walls and Floors (Section 8-10.2)

A. Inspect for vegetation that has OM OM OM

taken root in seals or cracks. All
vegetation must be removed in
all cases to prevent penetration
of seals, joints or cracks in the
concrete.

B. Inspect walls constructed of Daily

bricks for signs of deterioration
(e.g., spalling caused by freeze-
thaw conditions, cracks, and
joint cracks between bricks).
Concrete and Walls constructed of bricks must
Cement Brick be patched immediately to
Dike/Berm
prevent further penetration of
Walls and
the wall structure.
Floors
C. Inspect walls constructed of SM SM SM
concrete for signs of
deterioration (e.g., spalling
caused by freeze-thaw
conditions and cracks). Clean
and seal cracks with a fuel Semi-annually
resistant sealant.
D. Inspect seals and joints in
concrete walls. Joint sealant
that has retracted from the joint
or become unbonded with the
joints must be removed and

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replaced with fuel resistant
sealant.

Dike/Berm Floors (Section 8-10.2.2)

A. Inspect for vegetation that has OM OM OM

taken root in seals or cracks. All
vegetation must be removed in Daily
all cases to prevent penetration
of seals, joints or cracks in the
concrete.
B. Inspect floors made of concrete SM SM SM
for signs of deterioration (e.g.,
Dike/Berm
spalling caused by freeze-thaw
Floors
conditions and cracks). Clean
and seal cracks with a fuel
resistant sealant.
Semi-annually
C. Inspect joints and seals. Joint
sealant that has retracted from
the joint or become unbonded
with the joints must be removed
and replaced with a fuel
resistant sealant.

Earthen Dike Walls (Section 8-10.3)

A. Inspect for vegetation that has OM OM OM

taken root. All vegetation must Daily
be removed in all cases.

B. Prevent the growth of vegetation OM OM OM

inside the containment area.
Use fireproof chemicals for
sterilization. Only herbicides Monthly
Earthen Dike approved by the Installation
Walls
Environmental Office must be
used.
C. Inspect for signs of erosion. SM SM SM
Inspections should be
performed particularly after Quarterly
heavy rains or storms. Repair
areas that have deteriorated due
to erosion.

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Self-Diking or Vaulted Tank Containment (Section 8-10.4.)

A. Secondary containment OM OM OM
structures on self-diking or
Self-Diking or vaulted tanks must be inspected
Vaulted Tank visually for integrity breaches Daily
Containment with special attention given to
pipe penetrat- ions and
interstitial drain valves.

Flexible Membrane Liners (Section 8-10.5)

A. Remove vegetation growing in OM OM OM

the gravel and dirt, taking note if Daily
the roots have penetrated the
FML.
B. Visibly inspect FMLs where \2\ OM /2/ \2\ OM /2/ \2\ OM /2/
attached to ringwalls, dike walls,
concrete piers and other
projections for deterioration due
to weather or wear and repair as
Flexible
necessary.
Membrane
Liners C. Visually inspect FMLs covered
with smooth rock or gravel for
\2\ Monthly /2/
bare spots where the gravel has
been washed away due to
storms or heavy rains for tears.
Replace gravel taking care not
to puncture the liner.
D. Visually inspect exposed FML
for tears or punctures and
repair.

Pipe Penetrations (Section 8-10.6)

A. Inspect boot seals and \2\ OM /2/ \2\ OM /2/ \2\ OM /2/
mechanical link-type seals for
wear and cracking. Ensure the
seals are in good working order \2\ Monthly /2/
Pipe to seal out water or retain the
Penetrations petroleum product as intended.
Repair or replace defective boot
and link-seals.
B. Inspect sealant between pipes SM SM SM
Semi-annually
and concrete walls, berms, and
floors. Sealant that has

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retracted from the concrete or
pipe surfaces must be removed
and replaced with new fuel
resistant sealant.

ELECTRICAL CONTROL SYSTEMS AND EQUIPMENT

Electrical Equipment (Section 9-1.2)

A. Electrical control systems SM SM SM
include: deadman control; ground
verifica- tion systems; EFSO
operation; con- trol panels, motor
control, and pump start/stop
Electrical buttons. These sys- tems must
be tested on a periodic basis to Quarterly
Equipment
ensure proper operation and
functionality. In addition, con- trol
system Uninterruptible Power
Supplies (UPS) must be
inspected and replaced as
necessary.
Power Cables (Section 9-1.3)
A. Visual inspection: Verify that SM SM SM
there are no sharp bends. Verify
that the cable insulation is intact.
Verify that cables are
appropriately tagged or
otherwise identified. Verify that Quarterly
all connections are tight and not
corroded. Open manholes and
handholes. Verify that they are
not flooded, clogged with debris
or infested by pests.
Power
B. Insulation resistance test: This SM SM SM
Cables
test measures the resistance of
the insulation with an Insulation
Resistance Tester. During the
test, the cable will be
disconnected from both ends. As needed
Acceptable test values are 100 based on visual
megaohms for cables rated inspection
between 120 V to 1000 V.
Insulation resistance testing for
voltages higher than 1000 V are
to be performed by specialized
testing company.

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Motor Controls (Section 9-1.4)

A. Verify that the labeling is SM SM SM

consistent with the drawings and
specifications.
B. Verify that pushbuttons are easy
to operate and are not stuck.
Verify that there is no grease
accumulation around the seating
Verify that indicating lights are
functional and replace if
required.
C. Verify that indicating lights are
functional and replace as
needed. Semi-annually
D. Verify that electrical and
mechanical interlocks operate
according to the design intent. In
case of key interlocks, ensure
that the number of keys
corresponds to the interlock
intent. Having more keys than
Motor required defeats the intent of the
Controls interlocking and poses danger to
the service personnel and
equipment. If extra keys are
found, they should be removed
from the equipment.
Interior SM SM SM
E. Inspect the enclosure for visible annually/
signs of corrosion. exterior semi-
annually
F. Open the enclosure – be SM SM SM
mindful of insects, rodents and
reptiles, particularly if located
outdoors. Look for signs of
corrosion, dust accumulation,
spider webs, etc. Clean the
Annually
enclosure with compressed air
and apply rust inhibitors and
paint as needed.

G. Inspect the overcurrent

protective devices for proper
seating. Verify that rating is

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appropriate for the motor. Look
for signs of attached wire and
device overheating.
H. Inspect the arch shoots of
contactors and clean as needed.
Check that partitions are not
burned.
I. Inspect contactors for abnormal
wear. Check contacts for pitting,
roughness and oxidation. Verify
that contact gap, alignment and
pressure are in accordance with
manufactures
recommendations.
J. When contactors are used,
listen for the chatter of contacts
or buzzing noise. These are
indicative of a faulty contactor.
K. Verify that relays and switches
are firmly seated in their bases
and there are no signs of
overheating or vibration.
L. Look for frayed or broken
strands in the flexible control
wiring and replace if such are
found.
M. Perform a functional test of
protective devices if they are
equipped with self-testing
circuits or switches.
N. Perform a functional test of all
manual switches and verify
proper operation against
intended design logic. Replace
switches and relays if operation
is not satisfactory.
O. Perform insulation resistance SM SM SM
test for the control wiring.
(NOTE: Testing of the control
As required
wires may require substantial
down time. Therefore, this
should only be performed on a
case by case basis if there are

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reasons to suspect that the
insulation of the control wiring is
deteriorating.)

Panelboards (Section 9-1.5)

A. Verify that there are no physical OM OM OM

obstructions blocking access to
Quarterly
the panelboard. Remove
physical obstructions

B. Inspect the enclosure and the SM SM SM

surrounding area for water
damage and corrosion.

C. Verify that all breakers are

either in the “On” or the “Off”
position. If there are tripped
breakers, investigate the cause
of the trip.

D. Verify that all breakers are

either in the “On” or the “Off”
position. If there are tripped
breakers, investigate the cause
of the trip.
Panelboards
E. Verify that the breaker operation
matches the description on the
Annually
panel schedule.

F. Observe breakers, wires and

terminals for signs of
overheating or short circuiting.

G. Verify that all breakers are firmly

seated and locked in place by
slightly shaking them.

H. Verify that all grounding wires

are firmly connected to the
grounding bar.

I. If a breaker malfunction is
identified, leave breaker in the
open position and replace as
soon as possible. If a breaker
cannot disconnect its circuit, the

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entire panelboard must be
switched off using its main
disconnecting means and
locked out until the breaker is
repaired.

Grounding Systems (Section 9-1.6.1)

A. The connections to the SM SM SM

grounding system must be
surveyed and verified for
continuity. If a connection is
suspected to be loose, perform
further testing. In some
occasions, it is more cost
effective to replace the
suspected connection instead of
performing diagnostic tests.

B. Measure the voltage between

Annually
the equipment grounding
conductor and the electrode
grounding conductor (usually
bare copper). Investigate test
Power results above 3 VAC for a
Grounding
potential ground fault.
Systems
C. Measure the voltage between
the chassis of the equipment
and the electrode grounding
conductor. Investigate if the
readings exceed 2 VAC.

D. Facility ground resistance SM SM SM

check: This type of testing is
performed with a four lead, low
resistance ohmmeter or digital
Every five
ohmmeter. Recommended
years
values are between 3 and 5
ohms. In no case should the
grounding resistance be higher
than 25 ohms

Grounding Systems (Section 9-1.6.2)

A. Inspect ground reels for Quarterly SM SM SM

corrosion. Ensure ground reels

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are securely mounted to a rigid
base. Inspect clamps for
serviceability. Replace clamp if
jaws are deformed for corroded,
spring is weak, or other defects
are evident that would prevent a
good connection. Inspect cable
wires. Replace if more than
one-third of the cable wires are
broken.

B. The connections to the SM SM SM

grounding system must be
surveyed and verified for
Static continuity. If a connection is
Grounding suspected to be loose, perform
Annually
Systems further testing. In some
occasions it is more cost
effective to replace the
suspected connection instead of
performing diagnostic tests.

C. Resistance measurement on SM SM SM
static grounds: Measure static
ground resistance of new and
damaged ground rods. Static When observed
ground with a resistance greater to be physically
than 10,000 ohms will be damaged.
removed or replaced. Static
ground mechanically damaged
will be repaired and retested.

Electric Motors (Section 9-1.7)

Quarterly SM SM SM
A. Lubricating motor bearings and
inspect for vibration and
overheating.

Electric
Motors B. Check for debris and other Semi-annually SM SM SM
foreign material in the fan
housing

C. Check motor ground wires. Annually SM SM SM

Ensure they are firmly

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connected to the housing or the
junction box.

D. If the motor is installed in a

hazardous location, verify that
the seals of the connection
boxes and conduits are intact.

Lighting (Section 9-1.8)

A. Verify proper operation of light SM SM SM

switch, lighting contactor,
photocell or timer as
appropriate. If a lighting
contactor is used, listen for the
chatter of contacts or buzzing
noise. These are indicative of a
faulty contactor. Replace if
required.

B. With the lights turned on,

observe individual luminaries for Quarterly
flicker or lights turning on and
off. The former is indicative of a
faulty choke. The latter is
indicative of a faulty starter.
Replace the faulty components
as required.
Lighting
C. When light fixtures are located
in hazardous areas, verify that
the seals are intact and the
hazardous rating of the fixture is
maintained.
Annually (in SM SM SM
D. Thoroughly clean dust, bugs, dusty areas the
and debris from the luminaire. luminaries may
require
Light solvents or cleaning
cleaning at
agents may be used. shorter
intervals)
E. Re-Lamping: With the lights SM SM SM
turned off, replace the lamps. In
order to prevent accidental Annually or as
required
turning on of the lights, it is
mandatory to switch off and
lockout the breaker of the

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lighting circuit. Ensure the
replacement lamps are the
same type as those they are
replacing. Verify the proper
operation of all light fixtures after
the lamp replacement.

Electronic Equipment (9-1.9)

A. Inspect the outside of equipment SM SM SM

enclosures for dust and
evidence of corrosion. Vacuum
clean the dust to ensure
unobstructed air circulation.
B. Open the enclosure and
vacuum clean the dust to
ensure unobstructed air
circulation. Pay particular
attention to fans and air
passages. If there is evidence of
corrosion, verify that there is no
water damage on printed circuit
boards or contacts. If water or
humidity damage is observed,
the electronic components may
not work properly and further
Electronic testing is required.
Annually
Equipment
C. Verify proper operation of the
space heater if one is installed.

D. Check if fans for proper

operations and rotation.

E. Look for signs of overheating

such as discoloration and
charring.

F. Replace air filters.

G. Verify connection tightness.

Lightly pull wires on soldered
and terminal screws and ensure
the wires are not loose.

H. Verify that circuit boards are

properly seated. Ensure that

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board locking tabs are fully
engaged. Do not unplug and
plug connectors to verify
seating. This will wear out the
pins. Unplug only if connector
malfunction is suspected.

I. Observe wires for excessive

strain, braiding, or wear due to
vibration. Replace as required.

CATHODIC PROTECTION SYSTEMS

Cathodic Protection (Section 9-2.1)

A. Inspect rectifiers in in \2\ OM /2/ \2\ OM /2/ SM

\2\ Monthly /2/
accordance with UFC 3-570-06
Cathodic
Protection B. Inspect cathodic protection SM SM SM
systems in accordance with Annually
UFC 3-570-06

Lightning Surge Arresters (Section 9-2.2.1)

A. Newer lightning surge arresters SM SM SM

are designed to withstand
unlimited surges at 50,000
amperes; however,
manufacturers of older surge
arresters may provide a
maximum number of surge
events that can occur before it
Lightning must be replaced. If surge
Surge arresters include a maximum Annually
Arresters number of surge events, a spare
arrester must be kept on hand.
Refer to the surge arrester
manufacturer’s operation and
maintenance manual for
particular inspection instructions
and parts. Inspect as part of an
overall cathodic protection
system inspection.

Card and Key Locks (Section 9-3)

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A. Conduct operational check of SM SM SM
card and key lock system and
Card and
ensure that all features provided Annually
Key Locks
with the installed system are
operational.

Lightning Protection Systems (Section 9-4)

B. Inspect air terminals to make SM SM SM

sure they are securely attached
to the roof of the building,
canopy, or the piece of
Lightning equipment. Check all
Protection connections between the air Annually
Systems terminals and the grounding
loop or grounding rods. Repair
damaged or loose connections
and perform continuity check
after repairs.

Ground Verification System (Section 9-5)

A. Conduct an operational check of SM SM SM

the ground verification system
and ensure that all features
Ground provided with the installed
Verification Quarterly
system are operational. Inspect
System
the plug for corrosion, weakness,
or loose nuts and replace if
heavily dented or deformed.

Electronic Overfill Protection Systems (Section 9-6)

A. Conduct operational check of SM SM SM

Electronic overfill prevention system and
Overfill
ensure that all features provided Quarterly
Protection
with the installed system are
Systems
operational.

ALTERNATE POL FACILITIES

Liquefied Petroleum Tanks (Section 10-1.1)

Liquefied A. Inspect fuel tank for leaks. If a OM OM OM

Petroleum leak is occurring, the odorizing Monthly
Tanks agent of the gas should be
detectable. Use a soap and

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water solution to spray on areas
suspected of leaks. Systems
that are found with leaks must
be taken out of service.

B. Test operation of emergency SM SM SM

shutoff valves. Ensure the
fusible link mechanism is
attached properly to actuate in
case of a fire and that it has not
Semi-annually
been by-passed, blocked, or
damaged in any manner.
Ensure the fusible link is not
filled with debris or paint which
could impact operation.

C. Check settings of tank safety SM SM SM

Every 5 years
valves and calibrate if required

Liquefied Petroleum Pipelines (Section 10-1.2)

A. Conduct visual inspection of OM OM OM

pipelines for potential damage
and leak points. Use a soap and
water solution to spray on areas Monthly
suspected of leaks. Systems
Liquefied that are found with leaks must
Petroleum be taken out of service and
Pipelines repaired.
B. Inspect coatings and markings SM SM SM
on piping. Repair coating
deterioration and replace labels Semi-annually
that are fading and are difficult
to read.

Liquefied Petroleum Vapor Lines (Section 10-1.3)

A. Inspect vapor lines for leaks. If OM OM OM

leaks are occurring, the
odorizing agent in the gas
Liquefied should be detectable. Use a
Petroleum soap and water solution to spray Monthly
Vapor Lines on areas suspected of leaks.
Systems that are found with
leaks must be taken out of
service and repaired.

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B. Inspect coatings and markings SM SM SM
on piping. Repair coating
deterioration and replace labels Semi-annually
that are fading and are difficult
to read.

LPG Vaporizers (Section 10-1.4)

C. Inspect vaporizers for leaks. If OM OM OM

leaks are occurring, the
odorizing agent in the gas
should be detectable. Use a
soap and water solution to spray Monthly
on areas suspected of leaks.
LPG Systems that are found with
Vaporizers leaks must be taken out of
service and repaired.
D. The manufacturer’s SM SM SM
maintenance schedules and
recommendations provided with As Required
the LPG vaporizer must be
followed.
Petroleum Gas Regulators (Section 10-1.5)

A. Inspect petroleum gas OM OM OM

regulators for leaks. If leaks are
occurring, the odorizing agent in
Petroleum the gas should be detectable.
Gas Use a soap and water solution Monthly
Regulators to spray on areas suspected of
leaks. Systems that are found
with leaks must be taken out of
service and repaired.

Liquefied Petroleum Gas Hoses (Section 10-1.6)

A. Inspect hoses for damage and OM OM OM

leaks. If leaks are occurring, the
odorizing agent in the gas
should be detectable. Use a
Liquefied soap and water solution to spray
Petroleum Monthly
on areas suspected of leaks. If
Gas Hoses
leaks are detected from a hose
discontinue use of the hose and
remove it from service. Inspect
for damage to outer cover that
exposes reinforcement. Inspect

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for kinks or flattened areas, soft
spots or bulges. Inspect
couplings and ensure they have
not slipped on the hose or been
damaged.

CNG Piping (Section 10-2.1)

A. Inspect CNG lines for leaks. OM OM OM

Inspection of high-pressure
CNG lines and equipment must
be conducted using proper PPE
including but not limited to
safety glasses, a face shield,
hard hat and fire resistant
clothing. If leaks are occurring, Daily
the odorizing agent in the gas
should be detectable. Use a
CNG Piping soap and water solution to spray
on areas suspected of leaks.
Systems that are found with
leaks must be taken out of
service and repaired.

B. Inspect coatings and markings SM SM SM

on piping. Repair coating
deteriora- tion and replace Semi-annually
labels that are fading and
becoming difficult to read.

CNG Compressors (Section 10-2.2)

A. Compressors will require SM SM SM
CNG maintenance based on the
model included in the system. As Required
Compressors
Consult the compressor manual
for maintenance requirements

CNG Storage (Section 10-2.3)

A. Inspect CNG tubes and tanks OM OM OM
for leaks. Inspection of high-
pressure CNG lines and
equipment must be conducted
CNG Storage Daily
using proper PPE including but
not limited to safety glasses, a
face shield, hard hat and fire
resistant clothing. If leaks are
occurring, the odorizing agent in

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the gas should be detectable.
Use a soap and water solution
to spray on areas suspected of
leaks. Systems that are found
with leaks must be taken out of
service and repaired.
B. Inspect coatings and markings SM SM SM
on storage tubes or tanks.
Repair coating deterioration and Semi-annually
replace labels that are fading
and becoming difficult to read.
C. Check operation and calibration SM SM SM
of safety valves on tubes or Every 3 years
tanks.

CNG Dispensers (Section 10-2.4)

A. Dispensers are listed for service SM SM SM
with CNG and will vary by
CNG manu- facturer. Consult the
maintenance manual that was As Required
Dispensers
supplied with the system for
manufacturer’s maintenance
required for the CNG dispenser.
CNG Dispenser Hoses (Section 10-2.5)

A. Inspect hoses for damage, OM OM OM

leaks, and cracks. If leaks are
occurring, the odorizing agent in
the gas should be detectable.
Use a soap and water solution
Monthly
to spray on areas suspected of
CNG leaks. If leaks are detected
Dispenser
from a hose, discontinue the
Hoses
use of the hose and remove it
from service.

B. Test hoses for leaks following SM SM SM

manufacturer recommended As required
frequencies and procedures.

Hydrazine Charging Units (Section 10-3)

Hydrazine A. Hydrazine charging units are SM SM SM

Charging As Required
self-contained factory fabricated
Units
systems. Refer to the

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manufacturer’s maintenance
manual that was provided with
the system for required periodic
maintenance.

SUPPORT FACILITIES

Fuel Truck \1\and Rail/1/ Containment Areas (Section 11-1.1)

A. Remove debris from around OM OM OM

security fence.
B. Inspect fence grounding points.
Ensure connections are not
loose or damage.
C. \2\ Inspect the parking area for Monthly
cracks in the concrete
containment paving and curbs.
Remove vegetation that may
have established roots in the
buildup of dirt or from exposed
earth under cracks. /2/
D. Inspect the parking area for SM SM SM
cracks in the concrete
containment paving and curbs.
Remove vegetation that may
Fuel Truck
Containment have established roots in the Quarterly
Areas buildup of dirt or from exposed
earth under cracks. Thoroughly
clean and seal cracks with a fuel
resistant sealant.

E. \1\ Secondary containment SM SM SM

systems degrade and will
collect debris which can clog
drainage inlets or prevent drain
valves from sealing properly.
Hydrostatically test secondary
containment and associated \1\Every 3
Years/1/
drainage systems to include
containment concrete/sealant,
drain inlets, drain lines and
containment drain valves to
ensure containment is liquid
tight. This test may use
opportune rainfall by holding

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rainwater in the containment
system for one hour. Where
evaporation is a concern,
conduct the testing when this
concern would be minimized,
such as at night/early morning
or during a time of year when
this would not be as much of an
issue. Record the water level at
the start of the 60-minute
(minimum) hold period. If the
water level drops by 1/8 inch or
more, perform and record an
investigation to determine the
cause and any required repairs.
Once repairs are completed, a
new test must be completed.
Refer Appendix B for testing
procedures and to document
the testing. /1/.
F. Verify continuity of vehicle
grounding system connections.
If a connection is suspected to
be loose, perform further testing.
In some occasions it is more
cost effective to replace the
suspected connection instead of
performing diagnostic tests.
G. Inspect pavement markings and
vehicle movement lines for wear
and fading. Repair faded or
worn pavement markings.
H. Inspect security fence for wear
and rust. Inspect barbed wire
and ensure it is adequately
secured to outriggers. Repair
loose fencing components and
coatings at areas that show rust.

I. /2/Refer to Section 9-1.8 SM SM SM

Lighting for inspection and
As required
maintenance requirements of
area lighting

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Remote Spill Containment (Section 11-1.2)

A. Inspect the remote containment \2\OM/2/ /2/OM/2/ \2\OM/2/

basin for cracks in the concrete
containment paving, walls, and
curbs. Remove vegetation that
may have established roots in
the buildup of dirt or from
\2\Monthly/2/
exposed earth under cracks.
\2\ /2/

B. If equipped, inspect spill

containment sump pump for
proper operation.

C. \2\ Inspect the remote SM SM SM

containment basin for cracks in
the concrete containment
paving, walls, and curbs.
Quarterly
Thoroughly clean cracks with a
water spray or air jet. Seal
cracks with a fuel-resistant
sealant. /2/
Remote Spill
Containment D. \1\ Secondary containment \2\ SM /2/ \2\ SM /2/ \2\ SM /2/
systems degrade and will
collect debris which can clog
drainage inlets or prevent drain
valves from sealing properly.
Hydrostatically test secondary
containment and associated
drainage systems to include
containment concrete/sealant,
drain inlets, drain lines and
containment drain valves to \1\Every 3
ensure containment is liquid Years/1/
tight. This test may use
opportune rainfall by holding
rainwater in the containment
system for one hour. Where
evaporation is a concern,
conduct the testing when this
concern would be minimized,
such as at night/early morning
or during a time of year when
this would not be as much of an
issue. Record the water level at

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the start of the 60-minute
(minimum) hold period. If the
water level drops by 1/8 inch or
more, perform and record an
investigation to determine the
cause and any required repairs.
Once repairs are completed, a
new test must be completed.
Refer Appendix B for testing.
/1/.

Pumphouse/Filter Buildings (Section 11-2.1)

A. Inspect the floor and SM SM SM

containment curbs for cracks.
Thoroughly clean cracks with a
Annually
water spray or air jet. Seal
Pumphouse/ cracks with a fuel resistant
Filter sealant.
Buildings
B. Refer to UFC \1\ 3-110-03 /1/ for SM SM SM
inspection and maintenance
As required
requirements of pumphouse and
filter building roof systems

Canopies (Section 11-2.2)

A. Inspect and maintain canopies SM SM SM

Canopies according to UFC \1\ 3-110-03 As required
/1/.

Emergency Eyewash/Showers (Section 11-3)

A. Test operation of the emergency \1\OM/1/ \1\OM/1/ \1\OM/1/

eyewash/shower by pushing on
the activation handles. Ensure
water is not brown in color, due
to rust in the piping or dirt
Emergency seeping in from a hole in the
Eyewash/ buried piping. For systems with Weekly
Showers tempered water, ensure that
water that is being supplied by
the emergency eyewash/shower
is between 60 and 100 °F (16
and 39 °C). For systems with a
horn and strobe light, ensure that
the horn and strobe light activate

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when the activation lever on the
emergency eyewash/shower is
pushed. For systems that
interface with Installation or fire
emergency systems, pre-
coordinate before testing. At
some Installations emergency
eyewashes and showers act as
EFSOs and are tied into the fire
alarm systems.

B. Inspect portable/packaged \1\OM/1/ \1\OM/1/ \1\OM/1/

safety showers and eyewash
stations for proper operation.
Check fluid levels. Where tap
water is used, fluid must be
replaced monthly. Less
frequent intervals of fluid
change, as recommended by
the manufacturer, are Monthly
acceptable where a solution or
water additive is used. Ensure
packaged eyewash supplies are
within the listed expiration date.
Tags or labels must be attached
to the unit or adjacent to it,
indicating the fluid change
schedule.

C. Inspect the exterior coatings of SM SM SM

permanently installed units and Quarterly
repair damaged coatings or rust.

D. For systems with tempered SM SM SM

water systems inspect
components of the water heater
for correct operation and Semi-annually
temperature control. Ensure
that the safety valve on the hot
water heater tank is not leaking.

E. Inspect signage and labels on SM SM SM

the emergency Annually
eyewash/shower. Replace
missing labels or signage that

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has become loose. Signs that
are faded must be replaced

Ventilation Hoods (Section 11-4.1)

A. Inspect the operation of the SM SM SM

doors. Ensure that they close Quarterly
and open smoothly.

B. Inspect the lights inside of the SM SM SM

hood to make sure they are
operating properly. Replace Semi-annually
light bulbs that are no longer
working.

C. Verify that all electrical SM SM SM

equipment is properly classified
in accordance with NFPA 70
National Electrical Code.

D. Inspect the ventilation system

(ductwork, fans, etc.) for signs of
disrepair and air leakage and
Ventilation ensure it is operational and
Hoods pulling air through the hood.
Inspect and assure that the lab
hood air measuring device for
assuring proper air flow is
permanently attached and
Annually
working properly. The ventilation
hood must be inspected and
\1\approved by a service
specific industrial hygienist or
bioenvironmental engineer/1/ in
accordance with OSHA, 29 CFR
1910.1450 Occupational
Exposure to Hazardous
Chemicals in Laboratories, and
ANSI/AIHA Laboratory
Ventilation Z9.5.
E. Verify negative pressure is
present through the ventilation
hood to the exhaust.

Oil/Water Separators (Section 11-5)

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A. Inspect the oil/water separator SM SM SM
for the buildup of collected Quarterly or as
petroleum fuel or oil. Remove needed based
and properly dispose of on precipitation
accumulated petroleum fuel or events
Oil/Water oil.
Separators
B. Drain, clean, and inspect the Annually or SM SM SM
interior of the oil/water more frequently
separator. Ensure all divider based on local
plates and screens are in good environmental
working order. Replace or conditions.
repair damaged components.
Cranes and Hoists (Section 11-6)
A. Inspect cranes and hoists for OM OM OM
smooth operation. If the crane
or hoist is equipped with
electronic controls, check power
supply and operational control Before each
cords for nicks or damage. A use
crane service technician must
correct binding that may prevent
smooth operation and repair
damage to power cords.
Cranes and
Hoists B. Apply lubricant or grease to SM SM SM
areas that require periodic
greasing.
C. Military services-specific, host
nation, state, and/or local
Annually
regulations require cranes and
hoists to be certified for
operation. Follow the more
stringent of military services-
specific, host nation, state or
local regulations.
FUEL FACILITY TEMPORARY DEACTIVATION OR CLOSURE

Deactivated Fuel Tanks (Section 12-2)

A. Inspect water or anti-corrosion SM SM SM
Deactivated level in tank. If level has
Quarterly
Fuel Tanks dropped, investigate potential
leak points such as blind
flanges. Repair leaks that are

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detected and refill to appropriate
level.
B. Check exterior coatings and
labels. Repair peeling coatings
and/or rusting areas and replace
or repair labels which have
become faded and difficult to
read.
C. Inspect cathodic protection Annually SM SM SM
system for proper operation.
Deactivated Pipelines (Section 12-3)

A. Inspect the pressure of the SM SM SM

nitrogen charge applied to the
petroleum fuel pipeline with a
pressure gauge. If the pressure
of the charge has dropped
investigate and repair leak
points. Once leak points are Quarterly
Deactivated repaired, recharge with nitrogen.
Pipelines B. Check exterior coatings and
labels. Repair peeling coatings
and/or rusting areas and replace
or repair labels which have
become faded and are difficult
to read.
C. Inspect cathodic protection Annually SM SM SM
system for proper operation.
Deactivated Pumps (Section 12-4)

A. Manually rotate pump through SM SM SM

several rotations. Ensure that
the pump turns freely.
B. Check exterior coatings. Repair Quarterly
Deactivated peeling coatings and/or rusting
Pumps areas and replace or repair
labels which have become
faded and difficult to read.
C. Remove isolation flanges and SM SM SM
recoat interior of pump with light Annually
corrosion-inhibiting oil.
Miscellaneous Deactivated Components (Section 12-5)

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A. Ensure that blind flanges are SM SM SM
tight. Inspect exterior coatings
Miscellaneou and labels. Repair peeling
s Deactivated coatings and/or rusting areas Annually
Components and replace or repair labels that
have become faded and are
difficult to read.

Note: Follow manufacturer’s recommendation and published operation and

maintenance manuals for items and equipment not discussed in this document.

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APPENDIX D MAINTENANCE PROCEDURES

D-1 D-1 FILTER SEPARATOR COALESCER CARTRIDGE

REPLACEMENT AND SEPARATOR CARTRIDGE CLEANING.

D-1.1 Coalescer Cartridge Replacement in Vertical Filter Separator.

a. Drain the filter separator completely.

b. Raise the cover. CAUTION: Do not touch new coalescer cartridges or the
separator cartridges with your bare hand. The oil on your hand will cause
damage to the water-removal capability of these components.

c. Where there is an outer separator cartridge, remove, clean (D-1.3), and

set it aside for reuse.

d. Remove and discard the old coalescer cartridges in an approved manner.

Coordinate disposal of coalescer cartridges with Installation Environmental
Office.

e. Check the adapter gasket and adapter to make sure the gasket and
adapter threads are clean.

f. Complete the installation of the coalescer cartridge assemblies by

lowering each of the coalescer cartridge assemblies onto one of the deck
plate nipples. Make sure that each of the coalescer cartridge assemblies
is screwed down onto its deck plate nipple and the gasket is seated
properly and seals tightly. Next, apply the procedures in items (1) through
(6) below:

1. Replace the cover gasket with a new gasket of the same grade and
manufacturer as the old one.
2. Swing the cover back into place, lowering the lifting handle as you do
so.
3. Swing the eyebolts up into place and tighten the nuts using the
crisscross method. Do this so that the cover gasket and cover are
seated properly. When tightening cover bolts and nuts, use a
torque wrench. Tighten nuts just enough to prevent leaking through
the dome cover seal (refer to manufacturer’s instructions for torque
requirements) and to eliminate possible damage to the vessel.
4. Close the manual water drain valve.
5. Slowly fill the separator. Filling a filter separator must take a
minimum of ten minutes to perform. Conduct slow filling by use of
the slow fill valve on the filter separator, if equipped, or by filling all
of the filter separators on a system at one time. Slow filling is the

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only authorized method of refilling an empty filter separator. This

slows buildup of static electricity in fuel, reducing the possibility of a
spark igniting the explosive atmosphere inside the vessel. In most
cases, coalescer elements cannot be grounded or bonded to
dissipate the static electric charge that is generated during filling.
6. Pressurize the vessel to inspect all gaskets and screwed
connections for leaks; tighten all loose connections.
g. Note: Remember, once a system is opened for any reason it must be
sampled before aircraft are serviced.

h. Notify the facility supervisor that the filter separator is ready to be put back
into service and is awaiting QC flushing and sampling. (This is necessary
to ensure the fuel meets quality requirements.)

i. After the coalescer cartridges have been replaced and the filter separator
is ready to be put back into service, follow the steps below:

1. Stencil the filter separator in accordance with Section 3-6.2.4.

2. Set up and keep a logbook or wall chart in the maintenance shop.
Record the following information in this book or chart: pumphouse
facility number; filter separator number; month and year
replacement coalescer cartridges were installed; serial number of
the coalescer cartridges; number of coalescer cartridges; and
manufacturer’s coalescer cartridge lot number, if available.

D-1.2 Coalescer Cartridge Replacement in Horizontal Filter Separator.

a. After the vessel has been drained thoroughly, remove the head flange
bolts and open the vessel. For the original KMU-416/F modification kit,
use the following method:

1. Starting with the bottom (left) coalescer cartridge, loosen the 0.5-
inch (12.7-millimeter) nut on the adapter mounting rod. Slowly
drain the fuel trapped in the manifold by loosening the bottom
coalescer cartridge.
2. After the fuel has been drained from the manifold, remove the
fifteen coalescer cartridges on the outlet side of the manifold.
3. To remove the coalescer cartridge hold-down plate, use a
screwdriver for leverage to pry the seals outward from the cartridge.
The O-ring seals on the cartridge mounts may be removed more
easily by applying a slight twisting motion instead of a direct pull.
4. Loosen and remove the Victaulic coupling from the inlet pipe,
sliding the sealing gasket down on the manifold pipe section. Be
sure to use a static bonding wire.

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5. Remove the manifold. This requires two people to slide the

manifold forward, using the protruding coalescer cartridge hold-
down rods as handles to help in removing the manifold. CAUTION:
Have a container available to place the manifold in and catch fuel
that might spill out of the manifold. Dispose of the used coalescer
cartridges in an approved manner. Do not allow fuel-soaked
coalescer cartridges to be left in the area or disposed of in a
manner that can create a safety or fire hazard. Be careful when
handling used coalescer cartridges because they are toxic and
combustible or flammable, depending on the fuel’s flashpoint.
6. Remove the separator cartridges and follow the steps outlined in
Section D-1.3 when cleaning.
7. Clean the inside of the filter separator with rags.
8. Install new coalescer cartridges and cleaned separator cartridges
on the manifold and reinstall the manifold.
9. Align and bolt in the Victaulic coupling.
10. Replace cover and tighten bolts using the crisscross method.
Tighten nuts just enough to prevent leaking through the dome cover
seal (refer to manufacturer’s instructions for torque requirements) to
eliminate possible damage to the vessel.

b. For modified KMU-416/F (300 gallons per minute (1135 liters per minute)
kits with nine additional coalescer cartridges on the back side of the
manifold, remove only the bottom front six coalescer cartridges instead of
all fifteen. This will balance the manifold, and make it easier to remove.
Remove the manifold from the vessel.

c. For KMU-417/F kits (600 gallons per minute (2271 liters per minute), leave
all coalescer cartridges in place when removing the manifold. This
provides balance and lets you remove the manifold easily.

D-1.3 Separator Cartridge Cleaning, Repairing, and Handling.

a. Cleaning: Separator cartridges, when new, operate in a satisfactory

manner, but after processing millions of gallons of fuel that contain additives
and contaminants they gradually become less effective. Every time the
coalescer cartridges are changed the separator cartridges should be
inspected and cleaned according to the following procedure:

1. Connect a water hose to a hot water supply. Attach a nozzle to the

hose and direct a high-velocity stream of water at a downward
angle against the outer surface of the separator cartridge. Hold the
separator cartridge assembly vertically by the end to avoid touching
the cartridge surface. Begin at the top and work downward along

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the length of the separator cartridge. Rotate the separator cartridge

slowly so the entire surface is subject to the jet of hot water.
Repeat as necessary until the separator cartridge is clean.
2. After cleaning, shake excess water from the separator cartridge
and allow the remaining water to evaporate, or use clean, dry, oil-
free compressed air. Air quality must be very clean. If the air
quality is doubtful, do not use.
3. After each separator cartridge is dry, hold it horizontally and pour
tap water onto the cartridge from a height of 1 to 2 inches (25 to 50
millimeters) above the cartridge. Pour water along the entire length
of the separator cartridge while slowly rotating the cartridge. Under
test, observe the way the water appears on the surface of the
separator cartridge. If the water soaks through the separator
cartridge instead of beading up or rolling off, the cartridge must be
recleaned.
4. The Teflon or nylon coating of the separator cartridge must be
visually inspected for small cuts and breaks. Small breaks in the
Teflon or nylon coating of the separator cartridge can be repaired
for temporary service by patching with a fuel-resistant sealant,
epoxy adhesive, or epoxy-base putty. If major holes appear in the
Teflon or nylon coating of the separator cartridge, rendering it
impracticable to repair, the separator cartridge should be replaced.
b. Installation and Handling: Just before installing separator cartridges, agitate
the cartridges briefly in a container of clean fuel to flush off all remaining
water. (Use the same type of fuel being filtered). Extra care must be taken
during installation to ensure separator cartridges are not damaged.
Separator cartridges must be installed very carefully to prevent physical
damage to the Teflon or nylon coating. When installing the separator
cartridge assembly, the securing nut should not be over torqued, as this can
damage the cartridge assembly.

D-2 D-2 HOSE HYDROSTATIC TEST.

D-2.1 Loading Hose Hydrostatic Test.

a. Prior to hydrostatic test of fuel loading hose, determine the maximum

allowable pressure rating of attached valves, meters, or swivels to prevent
possible injury to personnel or damage to the equipment. It may be
necessary to remove the fueling hose prior to testing.

b. Test fluid may be water or liquid petroleum fuel with a flash point of 100 °F
(37.7 °C) or more. If liquid petroleum fuel is used as the test medium, the
test should be conducted in a place where contamination of adjacent
waters will not occur if there is spillage.

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c. Provide blind flanges, nipples, valves, pressure gauges, and pumps of

appropriate size and rating for the test to be performed.

d. Lay the hose out flat and straight, uniformly supported.

e. Fill the hose with test fluid, expel all air and raise the pressure to 10 psig
(69 kPa).

f. Hold the pressure for at least five minutes. During the test interval,
measure the length of the hose, end-of-rubber to end-of-rubber. Record
the measured length as original length.

g. If the hose is maintaining 10 psig, raise the pressure to the lower of 1.5
times the pump deadhead pressure or the maximum allowable working
pressure of the hose and hold the pressure for a minimum of 15 minutes.
Measure the length of the hose, end-of rubber to end-of-rubber and record
the measured length as test pressure length.

h. During the test the hose must not burst, bulge, leak, or abnormally distort
under static liquid pressure.

i. Calculate the elongation as a percentage of original length versus test

pressure length. If the elongation of the hose exceeds 15% it is an
indication that there is a serious internal weakness and the hose should
be removed from service and retired.

D-2.2 Marine and Underwater Transfer Hose Hydrostatic Test.

a. Hydrostatic testing of marine and underwater petroleum fuel transfer

hose must meet the requirements of 33 CFR 156, Section 170.

b. Prior to hydrostatic test the hose must meet the following requirements:

1. Have no unrepaired loose covers, kinks, bulges, soft spots or other

defects which would permit the discharge of fuel through the hose
material, and no gouges, cuts, or slashes that penetrate the first
layer of the hose reinforcement.
2. Have no external deterioration and, to the extent internal inspection
is possible with both ends of the hose open, no internal
deterioration.
c. Test fluid may be water or liquid petroleum fuel with a flash point of 100 °F
(37.7 °C) or more. If liquid petroleum fuel is used as the test medium, the
test should be conducted in a place where contamination of adjacent
waters will not occur if there is spillage.

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d. Provide blind flanges, nipples, valves, pressure gauges, and pumps of

appropriate size and rating for the test to be performed.

e. Lay the hose out flat and straight, uniformly supported.

f. Fill the hose with test fluid, expel all air and raise the pressure to 10 psig
(69 kPa).

g. Hold the pressure for at least five minutes.

h. If the hose is maintaining 10 psig, raise the pressure to 1.5 times the
maximum allowable working pressure of the hose and hold the pressure
for a minimum of 15 minutes.

i. During the test the hose must not burst, bulge, leak, or abnormally distort
under static liquid pressure.

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APPENDIX E TANK INSPECTION CHECKLISTS

STI SP001 MONTHLY INSPECTION CHECKLIST

General Inspection Information:

Inspection Date: Prior Inspection Date: Retain Until Date:

Inspector Name (print): Title:

Inspector’s Signature:

Tanks Inspected (ID #’s):

Regulatory facility name and ID number (if applicable)

Inspection Guidance:

 This checklist is intended as a model. Locally developed checklists are acceptable as long as they are substantially equivalent (as applicable). Inspections of multiple tanks may be
captured on one form as long as the tanks are substantially the same.
 For equipment not included in this Standard, follow the manufacturer recommended inspection/testing schedules and procedures.
 The periodic AST Inspection is intended for monitoring the external AST condition and its containment structure. This visual inspection does not require a Certified Inspector. It must be
performed by an owner’s inspector per paragraph 4.1.2 of the standard.
 Upon discovery of water in the primary tank, secondary containment area, interstice, or spill container, remove promptly or take other corrective action. Inspect the liquid for regulated
products or other contaminants and dispose of properly.
 Non-conforming items important to tank or containment integrity require evaluation by an engineer experienced in AST design, a Certified Inspector, or a tank manufacturer who will
determine the corrective action. Note the non-conformance and corresponding corrective action in the comment section.
 Retain the completed checklists for at least 36 months.
 After severe weather (snow, ice, wind storms) or maintenance (such as painting) that could affect the operation of critical components (normal and emergency vents, valves),
an inspection of these components is required as soon as the equipment is safely accessible after the event.

ITEM STATUS COMMENTS/DATE CORRECTED

Tank and Piping
Is tank exterior (roof, shell, heads, bottom, connections,
fittings, valves, etc.) free of visible leaks?
1 □Yes □No
Note: If "No", identify tank and describe leak and actions
taken.

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ITEM STATUS COMMENTS/DATE CORRECTED

Is the tank liquid level gauge legible and in good working □Yes □No
2
condition? □N/A
Is the area around the tank (concrete surfaces, ground,
3 □Yes □No
containment, etc.) free of visible signs of leakage?
Is the primary tank free of water or has another
preventative measure been taken? NOTE: Refer to
□Yes □No
4 paragraph 6.10 and 6.11 of the standard for alternatives
□N/A
for Category 1 tanks. N/A is only appropriate for these
alternatives.
For double-wall or double bottom tanks or CE-ASTs, is
□Yes □No
5 interstitial monitoring equipment (where applicable) in
□N/A
good working condition?
For double-wall or double bottom tanks or CE-ASTs, is
□Yes □No
6 interstice free of liquid? Remove the liquid if it is found.
□N/A
If tank product is found, investigate possible leak.
Equipment on Tank
If overfill equipment has a "test" button, does it activate
□Yes □No
7 the audible horn or light to confirm operation? If battery
□N/A
operated, replace battery if needed.
Is overfill prevention equipment in good working
□Yes □No
8 condition? If it is equipped with a mechanical test
□N/A
mechanism, actuate the mechanism to confirm operation.
Is the spill container (spill bucket) empty, free of visible □Yes □No
9
leaks and in good working condition? □N/A
Are piping connections to the tank (valves, fittings,
10 pumps, etc.) free of visible leaks? Note: If "No", identify □Yes □No
location and describe leak.
Do the ladders/platforms/walkways appear to be secure □Yes □No
11
with no sign of severe corrosion or damage? □N/A
Containment (Diking/Impounding)
Is the containment free of excess liquid, debris, cracks,
□Yes □No
12 corrosion, erosion, fire hazards and other integrity
□N/A
issues?
Are dike drain valves closed and in good working □Yes □No
13
condition? □N/A

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ITEM STATUS COMMENTS/DATE CORRECTED

Are containment egress pathways clear and any □Yes □No
14
gates/doors operable? □N/A
Concrete Exterior AST (CE-AST)
Inspect all sides for cracks in concrete. Are there any □Yes □No
15
cracks in the concrete exterior larger than 1/16"? □N/A
Inspect concrete exterior body of the tank for cleanliness,
□Yes □No
16 need of coating, or rusting where applicable. Tank
□N/A
exterior in acceptable condition?
Visual inspect all tank top openings including nipples,
manways, tank top overfill containers, and leak detection □Yes □No
17
tubes. Is the sealant between all tank top openings and □N/A
concrete intact and in good condition?
Other Conditions
Is the system free of any other conditions that need to be
18 □Yes □No
addressed for continued safe operation?

Additional Comments:

Additional Comments:

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STI SP001 Annual Inspection Checklist

General Inspection Information:

Inspection Date: Prior Inspection Date: Retain Until Date:

Inspector Name (print): Title:

Inspector’s Signature:

Tanks Inspected (ID #’s):

Regulatory facility name and ID number (if applicable)

Inspection Guidance:

 This checklist is intended as a model. Locally developed checklists are acceptable as long as they are substantially equivalent (as applicable).
 For equipment not included in this Standard, follow the manufacturer recommended inspection/testing schedules and procedures.
 The periodic AST Inspection is intended for monitoring the external AST condition and its containment structure. This visual inspection does not require a Certified Inspector. It must be
performed by an owner’s inspector per paragraph 4.1.2 of the standard.
 Remove promptly standing water or liquid discovered in the primary tank, secondary containment area, interstice, or spill container. Before discharge to the environment, inspect the liquid
for regulated products or other contaminants and disposed of it properly.
 In order to comply with EPA SPCC (Spill Prevention, Control and Countermeasure) rules, a facility should regularly test liquid level sensing devices to ensure proper operation (40 CFR
112.8(c)(8)(v)).
 Non-conforming items important to tank or containment integrity require evaluation by an engineer experienced in AST design, a Certified Inspector, or a tank manufacturer who will
determine the corrective action. Note the non-conformance and corresponding corrective action in the comment section.
 Retain the completed checklists for at least 36 months.
 Complete this checklist on an annual basis supplemental to the owner monthly-performed inspection checklists.
 Note: If a change has occurred to the tank system or containment that may affect the SPCC plan, the condition should be evaluated against the current plan requirement by a
Professional Engineer knowledgeable in SPCC development and implementation.

ITEM STATUS COMMENTS/DATE CORRECTED

Tank Foundation/Supports

1 Free of tank settlement or foundation washout? □Yes □No

2 Concrete pad or ring wall free of cracking and spalling? □Yes □No □N/A

3 Tank supports in satisfactory condition? □Yes □No □N/A

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ITEM STATUS COMMENTS/DATE CORRECTED

Is water able to drain away from tank if tank is resting
4 □Yes □No □N/A
on a foundation or on the ground?
Is the grounding strap between the tank and
5 □Yes □No □N/A
foundation/supports in good condition?
Tank Shell, Heads and Roof

6 Free of visible signs of coating failure? □Yes □No

Free of noticeable distortions, buckling, denting, or
7 □Yes □No
bulging?
8 Free of standing water on roof? □Yes □No □N/A

9 Are all labels and tags intact and legible? □Yes □No

Tank Manways, Piping, and Equipment

Flanged connection bolts tight and fully engaged with
10 □Yes □No □N/A
no sign of wear or corrosion?
Tank Equipment

11 Normal and emergency vents free of obstructions? □Yes □No

Normal vent on tanks storing gasoline equipped with
12 □Yes □No □N/A
pressure/vacuum vent?
Are flame arrestors free of corrosion and are air
13 □Yes □No □N/A
passages free of blockage?
Is the emergency vent in good working condition and
functional, as required by manufacturer? Consult
14 □Yes □No □N/A
manufacturer's requirements. Verify that components
are moving freely (including long-bolt manways).

Is interstitial leak detection equipment in good

condition? Are windows on sight gauges clear? Are
15 □Yes □No □N/A
wire connections intact? If equipment has a test
function, does it activate to confirm operation?

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ITEM STATUS COMMENTS/DATE CORRECTED

Are all valves free of leaks, corrosion and other
damage? Follow manufacturers' instructions for regular
maintenance of these items. Check the following and
verify (as applicable):

□Anti-siphon valve □Yes □No □N/A

□Check Valve □Yes □No □N/A
16 □Yes □No □N/A
□Gate Valve
□Pressure regulator valve □Yes □No □N/A
□Expansion relief valve □Yes □No □N/A
□Solenoid valve □Yes □No □N/A
□Fire valve □Yes □No □N/A
□Shear valve □Yes □No □N/A

17 Are strainers and filters clean and in good condition? □Yes □No □N/A

Insulated Tanks

Free of missing Insulation?

18 Insulation free of visible signs of damage? □Yes □No □N/A
Insulation adequately protected from water intrusion?

19 Insulation free of noticeable areas of moisture? □Yes □No □N/A

20 Insulation free of mold? □Yes □No □N/A

21 Free of visible signs of coating failure? □Yes □No □N/A

Tank/Piping Release Detection

Is inventory control being performed and documented if
22 □Yes □No □N/A
required?
Is release detection being performed and documented
23 □Yes □No □N/A
if required?

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ITEM STATUS COMMENTS/DATE CORRECTED

Other Equipment

24 Are electrical wiring and boxes in good condition? □Yes □No □N/A

Has the cathodic protection system on the tank been

25 □Yes □No □N/A
tested as required by the designing engineer?

Additional Comments:

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APPENDIX F TANK INSPECTION CHECKLISTS

Field Erected Tank Monthly Inspection Checklist

General Inspection Information:
Inspection Date: Retain Until Date: (36 months from inspection date)

Prior Inspection Date: Inspector Name:

Tanks Inspected (ID #’s):

Item Task Status Comments

1. Inspect the reinforcement plate Yes No N/A

weep holes for signs of fuel and
remove pipe plugs if installed.
2. Inspect all tank bottom tell tales Yes No N/A
and monitoring wells. Remove any
water if present.
3. For tanks equipped with floating- Yes No N/A
roof ensure the center primary roof
drain system is free of water, the
drip-tight plug is placed in the roof
drain opening, and drain valve is
closed.
4. Inspect floating roof systems for:
4.1. Inspect the roof for buckling Yes No N/A
or damage.
4.2. Inspect for standing water on Yes No N/A
the roof deck.
4.3. Ensure the roof drain system Yes No N/A
is water-free.
4.4. Check the floating roof Yes No N/A
guides.
4.5. Visually inspect the roof for Yes No N/A
centering.
5. Check the product recovery Yes No N/A
system for; proper pump operation;
sight glass is clear; float assembly
is functioning.

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Item Task Status Comments

6. Ensure the ladders, platforms, Yes No N/A
handrails, and stairs are secured to
the structure and inspect for signs
of corrosion.
7. Visually check the exterior of the Yes No N/A
tank (i.e., welds, plates, bolts, fill
ports, appurtenances) for leaks,
corrosion.
8. Visually inspect tank foundation Yes No N/A
berms for signs of erosion, and
irregularities such as tilting,
settling, out-of-roundness, and
growth of vegitation.
9. Visually inspect tank concrete ring Yes No N/A
wall foundations for cracks or signs
of settlement.
10. Inspect and clean the protective Yes No N/A
screens at pressure and vacuum
ports and tank exterior.
11. Inspect the manual liquid level Yes No N/A
gauge for proper operation. If
installed verify manual gauge to
the ATG.
12. If applicable; inspect swing lines Yes No N/A
for fraying and operability.
13. Check all signs and markings for Yes No N/A
adequacy and readability.
14. If additional maintenance actions Yes No N/A
are required, compile list of
discrepancies and submit for
correction.
Additional Comments:

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Field Erected Tank Annual Inspection Checklist

General Inspection Information:

Inspection Date: Retain Until Date: (36 months from inspection date)

Prior Inspection Date: Inspector Name:

Tanks Inspected (ID #’s):

Item Task Status Comments

1. Pack the reinforcement plate weep Yes No N/A

holes with white grease to prevent
water and/or dirt infiltration
2. Inspect floating roof seals for:
2.1. Inspect and clean perimeter Yes No N/A
tank seals.
2.2. Roof guide cables for wear, Yes No N/A
fraying, and corrosion.
2.3. Roof grounding cables for Yes No N/A
binding and secure attachment.
2.4. Inspect the ladder for damage Yes No N/A
and deflection (if equipped).
2.5. Check interior shell for Yes No N/A
abrasions that may indicate shell
out of roundness or improper
centering.
2.5.1. If abrasions are discovered, Yes No N/A
inspect seals for wear.
2.6. Check floating roof for Yes No N/A
corrosion, apply touch up with
compatible coating.
2.7. Inspect pontoons for standing Ye* No N/A
liquid and presence of vapors.
3. Ensure the ladders, platforms, Yes No N/A
handrails, and stairs are secured to
the structure and inspect for signs
of corrosion.

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Item Task Status Comments

4. Visually check the exterior of the Yes No N/A
tank (i.e., welds, plates, bolts,
appurtenances) for leaks,
corrosion, or irregularities such as
tilting, settling, or out-of-roundness.
5. Inspect, clean, and repair tank
vacuum and pressure vents as
follows:
5.1. Clean seating surfaces of Yes No N/A
pallets and valve seats carefully
with an approved suitable cleaning
solvent.
5.2. Inspect seating surfaces for Yes No N/A
damage or undue wear.
6. Inspect and clean the protective Yes No N/A
screens at pressure and vacuum
ports and tank exterior.
7. Remove mechanical gauge float Yes No N/A
cover and ensure float is securely
fastened to gauge tape. Check
gauge tape for ease of movement.
8. Check all signs and markings for Yes No N/A
adequacy and readability.
9. If additional maintenance actions Yes No N/A
are required, compile list of
discrepancies and submit for
correction.

Additional Comments:

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APPENDIX G PETROLEUM FUEL PIPELINE PRESSURE TESTING GUIDELINES AND

CRITERIA

G-1 INTRODUCTION.

G-1.1 Scope.

This appendix contains general criteria and standard guidelines for Petroleum, Oil, and
Lubricant (POL) pipeline pressure testing. These procedures are based on current codes
and criteria in addition to field experience and best management practices. This appendix
clarifies the requirements for the procedures, frequency, duration, and test pressures for
POL pipeline integrity testing. This appendix also provides a consistent definition of many
of the terms used for pressure testing guidelines and procedures. In addition, an overall
criteria list surrounding pipeline pressure testing is provided, along with a statement on the
impact to the guidance given.

G-2 PIPELINE PRESSURE TESTING GUIDELINES.

G-2.1 Introduction.

G-2.1.1 Best Management Practice.

Testing criteria is to be adopted on a best management practice basis, with overall

guidelines and minimum criteria established for a broad range of piping, with exceptions
and special cases noted where required.

G-2.1.2 Regulations.

Host nation, Federal, state and local regulations with jurisdiction must be followed when
more stringent than criteria outlined herein.

G-2.1.3 New Pipelines.

Testing of new pipelines, segments of existing pipelines after major repairs, or segment
replacement must be in accordance with current piping codes and UFGS specifications.

G-2.1.4 Existing Pipelines.

Testing of existing pipelines must be in accordance with site specific criteria developed to
provide integrity management consistent with the published guidelines and the procedures
stated in Sections G-2.2 thru G-2.5.

G-2.2 GENERAL REQUIREMENTS.

G-2.2.1 Aboveground Pipe Testing.

Aboveground pipe testing should be based on the premise that it can be visually inspected
on a regular basis, and is observable during the testing process. Overwater or near

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overwater piping is a special case and should receive a higher level of integrity testing due
to the consequence of failure (and in some cases higher risk of failure due to increased
corrosion).

G-2.2.2 Underground Pipe Testing.

Underground pipe testing should be based on the premise that it cannot be visually
inspected during the test. The testing program needs to address greater safety factors,
frequency of testing, and procedures to minimize the impact of temperature change of fuel
during testing to assure integrity of testing.

G-2.2.3 Overall Testing Methodology Criteria.

The following items apply to all integrity pressure testing.

a. A job-specific written procedure (pressure test plan) must be used when

performing a pressure test. Detailed procedures must be developed to
address safety, procedural, and equipment issues for each pipeline
segment.
b. Periodic testing must determine both long term safety of operation, as well
as determining if the pipeline is currently leaking.
c. Preferred testing is via increasing pressure to a level consistent with
reasonably predictable peak pressures, plus a comfort factor that reflects
time between testing, future risk of failure, and consequence of failure.
d. Integrity testing using a fuel inoculant (e.g. tracer additive) can be
considered in certain cases. In order to qualify as an integrity test, the
procedure should utilize a pressure consistent with integrity management
principles, instead of the minimum pressure required to conduct the test.
e. Integrity testing using a third-party certified, National Work Group on Leak
Detection Evaluations (NWGLDE) listed, short duration proprietary
procedure is acceptable in principle. Selected method must be certified for
system parameters such as pipe size and liquid volume. To qualify as an
integrity test the procedure must utilize a pressure consistent with integrity
management principles, instead of the minimum pressure required to
conduct the test. Alternatively, a lower pressure third-party certified leak test
can be conducted after a strength test meeting the requirements of Section
G-2.2.11 has been conducted.

G-2.2.4 Test Fluid.

Test fluid should be the system fuel such as DF-2, JP-5, JP-8, or F-76 when testing is
within normal ANSI Class 150 ranges, and stress does not exceed 50% of Specified
Minimum Yield Stress (SMYS) of the pipe. Table G-2.1 provides examples of maximum
test pressures for a selection of frequently used carbon and stainless steel pipe based on

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SMYS calculations (pipe only, not flanges, components). Testing with fuel with a pressure
that induces a yield greater than 50% of SMYS is possible but factors such as pipe
location (off-base or on-base) and proximity to occupied structures must be carefully
considered. The method of calculating the pipe pressure properties for off base pipelines
may require a slight variation and therefore should use the appropriate design code.

\1\
Table G-1 /1/ Pipe Properties

SMYS / allowable Max Design Pressure @ Pressure @

Pipe Size stress (S) psi Pressure psi SMYS psi (kPa) 50% of SMYS
(D) x (t) Material (kPa) (kPa) (note 1) (note 1) psi (kPa)
8.625 dia. ASTM A 53/A 53M, 35,000/20,000 1,539 2,614 1,307
x .322 Type S Grade B (241,316.5/137,895. (10611.0) (18022.9) (9011.4)
10.75 dia. ASTM A 53/A 53M, 35,000/20,000 1,396 2,376 1,188
x .365 Type S Grade B (241,316.5/137,895. (9625.1) (16381.0) (8191.0)
12.75 dia. ASTM A 53/A 53M, 35,000/20,000 1,205 2,058 1,029
x .375 Type S Grade B (241,316.5/137,895. (8308.1) (14189.4) (7094.7)
1)
14.00 dia. ASTM A 358/A 25,000/16,700 605 892 446
x .250 358M, Grade 304L (172,368.9/115,142. (4171.3) (6150.0) (3075.1)
16.00 dia. ASTM A 358/A 4)
25,000/16,700 528 781 390
x .250 358M, Grade 304L (172,368.9/115,142. (3640.4) (5384.8) (2689.0)
20.00 dia. ASTM A 358/A 25,000/16,700 422 625 312
x .250 358M, Grade 304L (172,368.9/115,142. (2909.6) (4309.2) (2151.2)
Note 1: P= 2SEt/D, E=1 for seamless and ERW pipe (ASME B31.3 Barlow equation).
Consult ASME B31.3 and/or API 570 for other pipe materials, quality factors and wall
thickness

G-2.2.5 Exceptions to Test Fluid.

Testing with water should be limited as much as possible to high pressure testing (greater
than 450 psig (3102.6 kPa), testing over water, testing at high pressures outside of military
property, and where mandated by regulatory jurisdiction (when waiver cannot be
obtained). Testing with JP-8 which has a minimum flash point of 100 °F (37.8 °C) may
require special permission when regulations permit testing with the fuel only when the
associated flash point is above 120 °F (48.9 °C). Testing of motor gasoline lines must use
potable water due to its low flash point and associated safety concerns.

G-2.2.6 Thermal Relief and Surge Considerations.

All testing programs need to consider system pressures that may be developed by thermal
relief valve settings and possible dynamic transient surge (water hammer) conditions.
Testing at a pressure less than these potential conditions will not provide adequate
assurances of system integrity.

Pressure relief valve settings should be confirmed prior to pressurization to ensure correct
test pressure and relief valve operation.

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G-2.2.7 Dynamic Surge.

Evaluate the maximum surge pressure for systems known to have dynamic surge
potential. The test pressure must be such that the qualified maximum operating pressure
is high enough to support predictable surge pressure. (Under ASME B31.3 max surge =
133% of qualified maximum allowable operating pressure, under ASME B31.4 max surge
= 110% of qualified maximum operating pressure).

G-2.2.8 System Components.

Testing programs need to consider all components within the test segments, such as
strainers, sight glasses, meters, pressure gauges, pressure transmitters, check valves,
instrumentation fittings and filter separators. Testing at 150% of the maximum operating
pressure may overpressure system components and must be accordingly considered.
Removal of lower pressure components from test segments by valve closure or blinding
should be considered rather than reducing test pressure. In accordance with API RP
1110, these components should be identified with information from the component
manufacturer such as maximum operating pressure, serial numbers, and other pertinent
information. These components and manufacturer’s information should be listed in the
pressure test plan.

Special consideration must be given to systems having non-standard fittings such as

mitered elbows, orange peel reducers, stab-in connections, and similar. Note that under
ASME B31.3, some of these fittings are acceptable when operation pressure results in
stress less than 20% of SMYS.

G-2.2.9 Pressure Test Plan.

For all pressure class systems, a specific plan must be developed for pressure testing. For
pressure class systems greater than ANSI Class 150, prepare a very detailed site specific
engineering evaluation and code documentation to assure adequate and safe pressure
testing. Some systems can contain more than one class of flange, so the pressure test
plan must be based on the lowest class of flange present. For OCONUS locations, confirm
pressure class of non-ASME components. Some OCONUS locations may incorporate a
lower pressure class of flanges/components.

Any test section that includes an elevation difference of over 100 feet (30.5 meters)
requires a pressure versus elevation plot and associated calculations to ensure that the
lower points in the piping are not over pressurized and the highest points are subjected to
the proper test pressure. These calculations and plot must be included in the pressure test
plan.

G-2.2.10 Conventional Leak Test.

A conventional leak test as used in this report is a temperature compensated and

volume/pressure change reconciled pressure test at not less than 150% of pump

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deadhead pressure by a qualified individual/organization with API 1110 developed

procedures.

G-2.2.11 Strength Test.

A strength test as used in this report is a pressure test at not less than the greater of
150% of pump deadhead pressure or thermal pressure relief valve resultant pressure,
including cascade, conducted with a calibrated pressure gauge, for a duration of not less
than four (4) hours. The strength test does not attempt to reconcile pressure change with
fuel temperature change as required by the conventional leak test. As a result, low volume
leaks may go unrecognized when conducting this test.

G-2.2.12 US Coast Guard Criteria for Marine Pipelines.

Testing of lines under USCG criteria needs to carefully consider required test pressure,
and jurisdiction of testing (i.e., how much of system). Testing to 150% of “tanker rail”
pressure may not be high enough. USCG rules require consideration of either pump
deadhead pressure, safety shutoff, or over pressure thermal relief settings as the basis for
the 150% test. Commonly this may result in a test pressure requirement of 225 psig
(1550 kPa). Another factor with USCG jurisdiction systems is possible deadhead
pressure when pumping to tankers, which may exceed tanker offload pressures, and thus
may require a test pressure higher than 225 psig (1550 kPa). The governing worst case
scenario may be the dynamic surge possible when outloading with terminal pumps and a
pier side emergency stop valve is rapidly closed.

G-2.2.13 Off-Base Systems.

Receipt pipelines from or connected to commercial off-base systems must be tested at a

pressure that recognizes deviations or maximum system capability within flange ratings,
which are normally much higher than pressures from normal receipt operations. Many off-
base pipelines are constructed to ANSI Class 300 standards and connect to ANSI Class
150 systems at the point of pipeline ownership change. Discussions with off-base pipeline
operators is important to determine operating characteristics, including pump deadhead
pressure, safety shutdown considerations, and protection of lower pressure class piping.
Federal regulations (49 CFR 195) mandate that a means of “over pressure prevention” is
required if a higher pressure class pipeline is connected to a lower pressure class
pipeline.

An overpressure condition can be caused by rapidly closing a Base valve, or startup of a

receipt operation against a closed Base valve.

G-2.2.14 Minimum Test Pressure.

The test pressure for all pipelines subject to pump discharge pressure must not be less
than 100 psig (689.4 kPa). The test pressure for pump suction lines may be between 50
psig (344.7 kPa) to 100 psig (689.4 kPa).

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G-2.2.15 Maximum Test Pressures.

G -2.2.15.1 General Requirements.

Ensure that the flanges are stamped with B16.5, otherwise the flange may not conform to
B16.5. Additionally, prior to testing, verify that all the nuts and bolts are properly engaged
with sufficient threads past the nut.

G-2.2.15.2 ASME B16.5 Flange Ratings.

Test must not exceed test pressures permitted by ASME B16.5 (Flange Ratings) as
follows:

• Carbon Steel, ANSI Class 150: 450 psig (3102.6 kPa)

• Stainless Steel, ANSI Class 150, with 304 or 304/304L flanges: 425 psig
(2930.3 kPa)
• Stainless Steel, ANSI Class 150, with 304L flanges: 350 psig (2413.2 kPa)
• Carbon Steel, ANSI Class 300: 1050 psig (7239.5 kPa)
• No ANSI Class Flange: As noted by code authority

G-2.2.16 Service Station Piping.

Service station piping is considered a special case and is discussed in Section G-2.5, with
separate criteria for integrity testing.

G-2.2.17 Non-metallic Piping.

Systems containing non-metallic piping such as fiberglass or coaxial flexible systems must
be evaluated for pressure rating, or practical pressure limits based on historical failures of
these types of piping systems.

\1\ G-2.2.18 Small Bore Piping.

Small bore piping, less than 4 inches (100 mm) in diameter, typically leading to and from
small fuel tanks should be run aboveground. Inspection of these lines is required per
Service Station Piping as discussed in Section G-2.5. Do not remove paint as part of the
visual inspection. If the piping is in a containment area, such as a tank dike, the piping is
not required to be pressure tested. In addition, if the piping cannot be pressure tested due
to no means (tank valve) of isolation, a visual inspection for exterior pipe corrosion will
satisfy integrity requirements. /1/

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G-2.3 DEPARTMENT OF DEFENSE (DoD) PETROLEUM FUEL PIPELINES.

G-2.3.1 General.

Consistent with API 570, underground systems should undergo periodic pressure tests
above normal operating pressures, whereas fully inspectable aboveground piping should
undergo periodic pressure testing at normal operating pressure. Note that the Service
Control Points can authorize deviations and alternate equivalent testing methodologies
from these criteria. Section G-5 provides a summary of pipeline pressure testing
guidelines.

G-2.3.2 On-Base Aboveground Piping Annual Test.

The test pressure for the annual test must not be less than pump deadhead pressure, the
pressure resulting from thermal relief valve settings, or 100 psig (689.4 kPa) (whichever is
greater) for a duration of two hours minimum. The duration of the test may extend longer
to allow time to inspect the entire aboveground piping section being tested. When piping
is not subject to pump discharge pressures a minimum test pressure of 100 psig (689.4
kPa) is required for the annual test. The pressure for the annual test may be reduced to
50 psig (344.7 kPa) for systems not subject to pump discharge pressure that contain
threaded components. All components undergoing the annual test must be visually
inspected for leaking during the test. Addition or withdrawal of fuel during the annual test
is permitted due to loss of pressure from valve seat bypass or to prevent overpressure
(thermal gain). On-Base aboveground piping does not require a five year test, as long as
annual testing is conducted.

G-2.3.3 On-Base Single-Wall Underground Piping Annual Test.

G-2.3.3.1 Pressure Testing Options.

The options to complete the test include:

a. Annual Option 1: The test pressure for the annual test must not be less than
pump deadhead pressure, or the pressure resulting from thermal relief valve
settings (whichever is greater) for duration of two hours minimum. Perform
accurate pressure and ambient temperature monitoring. All instrumentation
should be of sufficient quality to Ensure accurate test data collection. The
pressure change, if any, must be within a small range and/or reconciled with
fuel temperature change. To minimize the effect of changing temperature,
the fuel should be allowed to reach equilibrium, and testing is to occur at
time of day with little solar influence or rapid temperature change. The
acceptable pressure deviation or pressure change criteria are to be
established by the Service Control Point. The allowable pressure change is
to be based on installation’s location, size of system, and historical testing
results.

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b. Annual Option 2: Perform annual test at not less than pump deadhead
pressure or the pressure resulting from thermal relief valve settings
(whichever is greater), with third-party certified NWGLDE listed leak test. By
doing annual third-party certified test at NOT LESS THAN the pump
deadhead pressure or the pressure resulting from thermal relief valve
settings (whichever is greater), the requirement for a five-year test is waived.

G-2.3.4 On Base Double-Wall Underground Carrier Piping Annual Test.

Test the carrier pipe using piping test methods, as applicable, as described in Section
G-2.3.3 \1\/1/. After testing, confirm that there is no product at all low point locations in the
secondary containment system. If the “double wall” system cannot be tested for both
pressure integrity and presence of fuel leaks or water intrusion the system must be treated
as a single-walled pipe and the requirements listed in section G-2.3.6 for the five-year test
must be conducted in addition to the tests required in this section.

G-2.3.5 \1\ On /1/ Base Double-Walled Underground Containment Piping Test.

Interstitial Breach of Integrity testing must take place at three to five year intervals,
depending on regulatory requirements and local practice.

The containment pipe of a double-wall pipe system must have the ability to be check for
leakage thru low point check points. In addition, the annular space between the
containment pipe and the carrier pipe must have the ability to be air-tested for the
presence of hydrocarbon vapor with a calibrated atmospheric meter. Most secondary
containment piping is equipped with test ports at each end and may be equipped with low
point drains.

In the event that the pipeline is located in a jurisdiction that requires double wall systems,
and the secondary system fails, then the system will be considered out of compliance. The
system should then either be repaired or taken out of service.

G-2.3.5.1 Interstitial Breach of Integrity Testing Three-to-Five-Year Test.

Conduct a containment interstitial space breach of integrity test per manufacturer’s

instructions. This test pressure is normally 5-10 psig (34.4-68.9 kPa) and held for two
hours. The test could be a vacuum test if leaks are suspected as a safe alternative. All
test equipment should be calibrated and suitable for the low pressure. A failure of the
containment pipe test and a successful carrier pipe test would indicate defective end seals
(depending on the type of containment piping: i.e.: FRP, SS, CS, etc.) or a breach in the
wall of the containment pipe. The acceptable pressure deviation or pressure change
criterion is 0%.

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G-2.3.6 On Base Single-Wall Underground Piping Five-Year Test.

G-2.3.6.1 Test Pressure.

The test pressure for the five-year pressure test must be 150% of pump deadhead
pressure minimum (including elevation difference from base of tank to pump plus full tank
fuel level). Preferably, perform a pump deadhead test to confirm peak pressure, and
adjust for fuel level in tank. Reasonable consideration should be taken to assure that
selected test pressure is not less than 110% of pressures resulting from thermal pressure
relief valve settings, which may be much higher than pump deadhead pressure (such as
Type III Hydrant Systems).

G-2.3.6.2 Pressure Testing Options.

The options to complete the test include:

a. Five-year Option 1: Perform a strength test and conventional leak test at not
less than 150% of pump deadhead or at 110% of the pressure resulting from
thermal relief valve settings (whichever is greater). The testing must be
executed by a qualified individual/organization experienced with using
procedures meeting API 1110 procedures and performing
pressure/temperature compensation calculations. Test duration must be a
minimum of four hours for the strength test and four hours for the
conventional leak test. The conventional leak test must immediately follow
the strength test. A thorough visual inspection during the strength test
should identify leaking flanges, instrument fittings, relief lines, valve stems,
valve seats, etc. These deficiencies should be corrected prior to the
conventional leak test by removing the components, installing flange skillets,
plugging, or other methods of isolation or repair.
b. Five-year Option 2A: Perform a four hour strength test at not less than 150%
of pump deadhead pressure or 110% of the pressure resulting from thermal
relief valve settings (whichever is greater), and monitor calibrated gauges for
potential leak causing pressure decay. Immediately follow the strength test
by a third-party certified NWGLDE listed leak test at a pressure consistent
with the certification of the system, and optimum for testing (generally 120
psig (827.4 kPa) to 150 psig (1034.1 kPa)).
c. Five-year Option 2B: Pressurized to the test pressure, and hold the
pressure for two hours prior to a third-party certified test. Next, perform a
third-party certified NWGLDE listed leak test at a pressure not less than 150
% of pump deadhead pressure or 110% of the pressure resulting from
thermal relief valve settings (whichever is greater).

If the pipeline has been tested ANNUALLY by a third-party certified test at a pressure
NOT LESS THAN pump deadhead pressure or the pressure resulting from thermal relief
valve settings (whichever is greater), the requirement for a five-year test is waived.

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G-2.3.7 Third Party Certified “Leak Detection” Systems.

Monthly testing with permanently installed proprietary vendor third-party certified “leak
detection” systems that have received listing by the NWGLDE organization can be
substituted for on base underground single-walled piping five year test as noted in
Sections G-2.3.6.2(e) and G-2.3.3.1(b). Test must be conducted at NOT LESS THAN the
pump deadhead pressure or the pressure resulting from thermal relief valve settings
(whichever is greater). These systems are required to receive annual re-certification by
the equipment vendor.

G-2.3.8 Off-Base Transfer or Supply Pipeline Annual Test.

An engineering assessment must be made to determine appropriate annual test pressure.

In most cases, provide annual pump deadhead pressure test as noted for on-base
pipeline systems in Section G-2.3.3, so long as flange ratings are not exceeded. Note that
this will result in portion of the piping on longer pipelines being subject to test pressures
considerably higher than normal operating pressures and thus is most appropriate when
the system is constructed as an ANSI Class 150 system with a maximum allowable
operating pressure of 275 psig (1896.1 kPa), and maximum test pressure of 450 psig
(3102.6 kPa). For systems of higher ANSI pressure class construction and operating
characteristics, a testing program must be developed and consider actual operating
pressures along the pipeline, type of development along pipeline, age of system, history of
cathodic protection, results from in-line intelligent pigging program and test liquid (fuel or
water).

G-2.3.9 Off-Base Transfer or Supply Pipeline Five Year Test.

An engineering assessment must be made to determine appropriate five-year test

pressure, or equivalent means of integrity management. Perform five-year test regime as
follows:

a. Provide five-year strength and conventional leak test at a pressure higher

than operating conditions only when required by state or Federal regulations
or Service Control Point. Particular attention needs to be given to actual test
pressures based on pipeline pumping operations, elevation changes along
the pipeline, surge potential and type of development and population density
along the pipeline. Test media (water or fuel) must be determined in
accordance with regulatory and criteria documents. Testing with fuel is the
preferred method.
b. Test methods as noted in Section G-2.3.6 for on-base pipeline systems can
be considered, and must be coordinated with the Federal, state, and local
regulations, and the Service Control Point.
c. For piggable off base pipelines, the use of in-line intelligent pigging on
periodic basis (10 years maximum) to monitor corrosion and mechanical
damage can significantly improve integrity management and eliminate the

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need for a 5-year pressure test regime, except when required by state or
local regulatory body. Note that a written integrity management plan using
in-line intelligent pigging has resulted in some regulatory bodies waiving the
need for a 150% pump deadhead pressure test.
d. Note that under 49 CFR 195.452, if a pipeline is located in a “High
Consequence Area,” use of intelligent pigging on a five year increment is
mandatory, (when the pipeline is considered regulated) and recommended
otherwise, as a powerful threat assessment approach. The five year smart
pigging interval will satisfy the need to perform a five-year pressure test, and
has the added advantage of not resulting in testing of a pipeline with fuel at
pressures far above normal operating pressure.

G-2.4 MARINE PIPELINES.

This section applies to areas under direct United States Coast Guard (USCG) jurisdiction,
and Outside Continental United States (OCONUS) Installations with over-the-water fuel
transfers.

G-2.4.1 33 CFR 154 and 33 CFR 156.

Marine facilities (or installation components that fall under marine conditions) must be
tested in accordance with USCG regulations 33 CFR 154 and 33 CFR 156.

G-2.4.2 Piping Over Water.

Piping over water and not having a secondary containment system should consider testing
with water when testing is above the maximum normal operating pressure. Pressure
testing at maximum normal operating pressure may be with fuel. Where testing with fuel
the use of spill containment booms around the test area is encouraged.

G-2.4.3 Tanker Offload Pressure.

The test pressure for the annual pressure test must be not be less than 150% of maximum
delivery tanker pressure at the tanker rail before loading arm or hose, taking into
consideration the pressure relief valve setting or high pressure cut off switch setting. It is
recommended that the test pressure be not less than 225 psig (1551.3 kPa) based on
most tankers’ shutdown pressure setting of 150 psig (1034.1 kPa).

G-2.4.4 Barge Offload Pressure.

The test pressure for the annual pressure test must not be less than 150% of maximum
delivery barge pressure at the barge rail before loading arm or hose, taking into
consideration the pressure relief valve setting or high pressure cut off switch setting. It is
recommended that the test pressure be not less than 175 psig (1206.6 kPa) based on
most barges’ shutdown pressure setting of 115 psig (792.9 kPa).

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G-2.4.5 Issue Pressure.

When issuing to tankers and barges is possible, issue test pressure must be evaluated.
The issue test pressure must consider the deadhead pressure of installation pumps, the
static elevation difference, and the dynamic surge caused by pier emergency stop valves.
It is possible for the issue test pressure to exceed the tanker/barge offload test pressure.
When such conditions exist, use the issue test pressure for all piping, loading arm and
hoses up to the point of connection to the receiving tanker/barge.

G-2.4.6 Aboveground Marine Piping Annual Test.

The test pressure for the annual pressure test must be derived from paragraphs G-2.4.3,
G-2.4.4 and G-2.4.5 for duration of two hours minimum. All components must be visually
inspected for leaking. Addition or withdrawal of fuel during testing is permitted due to loss
of pressure from valve seat bypass or to prevent overpressure (thermal gain). Addition or
withdrawal of fuel during testing is only permitted if entire system is aboveground. If any
portion of the piping is underground and cannot be visually inspected, underground
pipeline testing procedures must apply.

G-2.4.7 Underground Marine Piping Annual Test.

The options to complete the test include:

a. Annual Option 1: Perform a strength test and conventional leak test at a

pressure derived from paragraphs G-2.4.3, G-2.4.4, or G-2.4.5 as
appropriate. The testing must be executed by a qualified
individual/organization experienced using procedures meeting API 1110
procedures and performing pressure/temperature compensation
calculations. Test duration must be a minimum of four hours for the strength
test and four hours for the conventional leak test. The leak test must
immediately follow the strength test. A thorough visual inspection during the
strength test should identify leaking flanges, instrument fittings, relief lines,
valve stems, valve seats, etc. These deficiencies should be corrected prior
to the conventional leak test by removing the components, installing flange
skillets, plugging, or other methods of isolation or repair.
b. Annual Option 2: Conduct a two hour pressure soak at a pressure derived in
paragraphs G-2.4.3, G-2.4.4, or G-2.4.5 as appropriate, and monitor
calibrated gauges for potential leak causing pressure decay, followed by
third-party certified NWGLDE listed leak test, at the same pressure, with the
permission of the USCG Captain of the Port (COTP). Note: During a
pressure soak, the tester blocks in the pressure and does not allow for
volume change. During the test, pressure is relieved to prevent over-
pressurizing if required.

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G-2.5 SERVICE STATION PIPELINES.

G-2.5.1 General Requirements.

Due to the multiple types of piping system materials, single or double-wall pipe, piping
components (line leak detectors, leak detection systems), fiberglass and coaxial piping,
small bore piping (2 inch and less) and low operating pressures (less than 50 psig (344.7
kPa)), the annual and 5-year testing requirements as described in Section G-2.3 do not
translate well for this type of system. Wherever possible, the requirements of state or host
nation rules must be utilized to satisfy pipe integrity investigation to maintain consistency
on regulated tank and connected piping installations. When specific state or host nation
rules are lacking, the piping integrity must be considered. The use of a third-party certified
NWGLDE listed leak test (see NWGLDE website, many vendors and systems are
approved) may be appropriate. Even when tanks are aboveground, if underground piping
is used to service dispensers, the use of a NWGLDE vendor and procedure is still
appropriate.

G-2.5.2 Service Station Aboveground Piping Annual Test.

The test pressure for the annual pressure test must be not less than pump deadhead
pressure for duration of two hours minimum. All components must be visually inspected
for leaking. Addition or withdrawal of fuel during testing is permitted due to loss of
pressure from valve seat bypass or to prevent overpressure (thermal gain). Note that in
very small systems receiving fuel from delivery vehicle pump, observation of the receipt
line under pressure is sufficient when there is no means (tank valve) to otherwise test the
receipt line. When a small system consists of a suction withdrawal from the tank, with
closely positioned dispenser with pump, and the suction line cannot be tested when there
is no means (tank valve) of isolation, a visual inspection for exterior pipe corrosion will
satisfy integrity requirements.

G-2.5.3 Service Station Underground Piping Annual Test.

The test pressure for the annual pressure test must be not less than pump deadhead
pressure for duration of two hours minimum unless being tested in combination with an
attached UST. The test procedure must be as required and approved by the host nation,
state or local regulatory jurisdiction.

G-2.5.4 Service Station Combined Aboveground and Underground Annual

Test.

When testing aboveground and underground piping together due to configuration of

system, use of a third-party certified and NWGLDE procedure is encouraged, or utilizes a
pump deadhead pressure test only when the underground piping is in secondary
containment. The test must include a check of secondary containment for fuel after the
pressure test.

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G-3 CRITICAL TERM DEFINITION.

G-3.1 Introduction.

This section provides guidance on the definition of terms normally used in developing
pressure testing documentation. Several of the guidance/criteria documents use poorly
defined terms. Table G-3.1 summarizes what can be determined or inferred from the
available information. Unfortunately, mixing the definition of the terms, or applying them
too loosely may result in inappropriate conclusion

\1\
Table G-2 /1/ Definition of Terms

Item Term Abbreviation For Definition and Commentary

A MOP, “Colloquial version” Must be the worst case sustained internal pressure under
MAOP Maximum Operating the worst combination of internal and external pressure at a
Pressure, or Maximum given point on a pipeline, and must consider deadhead of
Allowable Operating pumping, static head, and resultant pressure from thermal
Pressure relief conditions (and cascade). Some exceptions apply
depending on frequency and duration. Pressure must be
supported by a qualifying hydrostatic test at 125% (B31.4)
or 150% (B31.3).Does not include transient pressure, such
as a surge event, which can exceed (to a limit) MOP under
many codes.
B MAWP Maximum Allowable “The maximum internal pressure permitted in the piping
Working Pressure system for continued operation at the most severe
API 570 §3.1.49 condition of coincident internal or external pressure and
temperature (minimum or maximum) expected during
service. It is the same as the design pressure, as defined
in ASME B31.3 and other code sections, and is subject to
the same rules relating to allowances for variations of
pressure or temperature or both.”
C NOP “Colloquial version” Generally considered the pressure of dynamic operations,
Normal Operating such as the pressure gauge on a pump discharge, or the
Pressure pressure at any point on a pipeline taking into consideration
elevation and pressure gradient.
D From ASME B31.4 § “internal design pressure: internal pressure used in
400.2 calculations or analysis for pressure design of a piping
component (see para. 4-1.2.2):
Comment: Internal design pressure must be not less
than maximum steady state operating pressure.
E MOP Maximum Operating “Maximum operating pressure (MOP) means the maximum
Pressure defined pressure at which a pipeline or segment of a pipeline may
under 40 CFR be normally operated under this part.”
195 § 195.2 (Similar to ASME B31.4 definition for NOP)

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Item Term Abbreviation For Definition and Commentary

F NOP NOP from ASME B31.4 § “maximum steady state operating pressure: Maximum
400.2 pressure (sum of static head pressure, pressure required to
overcome friction losses, and any back pressure) at any
point in a piping system when the system is operating under
steady state conditions.
G MAWP Maximum Allowable “(b) The maximum allowable working pressure (MAWP)
Working Pressure for each hose assembly must be more than the sum of
33 CFR 154.500 the pressure of the relief valve setting (or the maximum
pump pressure when no relief valve is installed) plus
the static head pressure of the transfer system, at the
H design pressure “The pressure at the most severe condition of coincident
API 570 § 3.1.18 internal or external pressure and temperature (minimum or
maximum) expected during service.”

I overwater piping “Piping located where leakage (liquid or solids) would

API 570 § 3.1.60 result in discharge into streams, rivers, bays, etc.,
resulting in a potential environmental incident.”
(Note, does not require pipe to be physically over the water)

G-4 CRITERIA SURROUNDING PIPELINE PRESSURE TESTING.

G-4.1 INTRODUCTION.

This section provides the current criteria for pipeline pressure testing and the discussion of
its applicability to the Department of Defense POL pipelines and methods of testing and
determination for integrity assessment. Tables G-4.1 and G-4.2 lists the criteria and
provides a discussion of its applicability to the guidelines stated in Section G-2.

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\1\
Table G-2 /1/ Military Requirements

Item Issue - Parameter Testing Requirement

i 1 Testing Requirement – UFGS Specification Section 33 52 43 “Aviation Fuel Distribution Systems,”
UFGS 33 52 43 May 2011. This specification is to be used for new piping or major
renovated piping systems. Extract of pressure testing requirements
follows:

2 Waivers and The Air Force, Army, and Navy Criteria specialists (Service HQ) are
Deviations to able to grant waivers or deviations.
Criteria
3 Comment and Pressures stated in the UFGS were derived from ASME B16.5.
Recommendation Water can be used and easily disposed of if the piping is new and no
part of it has ever had fuel in it, and it can be thoroughly drained from
the pipeline.
ASTM B31.3 permits testing with fuels having a flash point of 120 °F
(48.9 °C). Testing with fuel is acceptable in special cases (i.e., when
draining of water is not obtainable). Obtain waiver for testing with JP-8
(100° minimum flash point) when needed.

Notes:
1. Pump deadhead pressure is the maximum pressure at no flow with fuel level at or near high
condition in source tank. For the purposes of the pressure determination, do not use normal
operating pressure. Dead head pressure is normally 10% to 25% above normal operating
pressure. Determine deadhead pressure by starting pump and slowly closing discharge valve
and reading the maximum discharge pressure. Do not operate at no flow for more than a
minute.
2. Most thermal pressure relief valves associated with pump discharge piping in the pumphouse
in particular must be set above pump deadhead otherwise they would discharge every time the
pump deadheads. Normally they should be set a minimum of 10% above system deadhead
pressure. If system testing is only to pump deadhead, it is not as high as the relief valve
settings. For annual testing this is generally considered acceptable. For periodic integrity
testing (i.e. five-year test), the test pressure should exceed the thermal relief valve pressure, in
order to provide a valid strength test. This is the case with a five-year test at 150% of pump

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deadhead. As thermal relief most likely is 10%-20% above pump deadhead, a test at 150%
above deadhead will be above peak pressure of thermal relief valves.
3. ANSI Class 150 systems may be tested to the limit of flanges, per ASME B16.5 as follows:

Maximum Maximum
Operating Test
Pipe Class and Material Pressure Pressure
Class 150 Carbon Steel 285 psig 450 psig
1965.0 kPa 2102.6 kPa
Class 150 Stainless Steel (with 275 psig 425 psig
304 or 304/304L flanges) 1896.1 kPa 2930.3 kPa
Class 150 Stainless Steel (with 230 psig 350 psig
304L flanges) 1585.8 kPa 2413.2 kPa

\1\
Table G-3 /1/ Commercial and Industrial Guidelines

ISSUE -
ITEM PARAMETER TESTING REQUIREMENT
A 1 Testing protocol & API 570 Piping Inspection Code, Third Edition (11-2009)
Requirement – API
570
2 Test Pressure Criteria The majority of API 570 addresses aboveground piping. API 570 5.8
and duration- states ”Pressure tests are not normally conducted as a part of
aboveground piping. routine inspection”, but when performed, must be completed in
accordance with ASME B31.3 requirements.
3 Test Pressure Criteria, 8.2.7 covers pressure testing after making system repairs or
modified systems modifications that include welding of the pipe, in accordance with
¶5.8. When pressure testing is not practical, certain NDE steps may
be substituted for the pressure test so long as other installation
requirements are met.
4 Pressure Testing 5.8.5 Addresses special cases: “Appropriate NDE must be
Alternatives specified and conducted when a pressure test is not performed
after a major repair or alteration. Substituting NDE procedures for a
pressure test after an alteration is allowed only after the engineer
and inspector have approved the substitution.
For cases where UT is substituted for radiographic inspection, the
owner/user must specify industry-qualified UT shear wave examiners
or the application of ASME B31 Code Case 179/181, as applicable,
for closure welds that have not been pressure tested and for welding
repairs identified by the engineer or inspector.

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ISSUE -
ITEM PARAMETER TESTING REQUIREMENT
5 Test Pressure Criteria 9.3.7 Indicates that a pressure test may be used as an integrity
and duration- management tool in lieu of other methods. The pressure test is a leak
underground piping test at not less than 110% of the maximum operating pressure, at an
(Section 9 specifically interval shown in Table 9-1 for a cathodically protected system and
deals with at ½ the interval for an underground system that is not cathodically
underground piping) protected.
The test must be 8 hours in duration, with the first 4 hours to stress
the system, and the last 4 hours being the actual data collection
period.
If the pressure drops more than 5% over the course of the test, an
investigation must be conducted, including internal and external
evaluation of corrosion.
6 Comment: Table 5 below is primarily the intervals indicated for smart pigging or
direct excavation, when deemed important for determining integrity of
system, but is also used for the intervals for pressure testing as noted
above.
7 Table 5 from API 570

8 API 570 9.3.7 also recognizes the use of other testing procedures
including temperature corrected volumetric, pressure, and addition of
a tracer inoculant.
9 Comment and API 570 supports the premise that a leak, pressure or hydrostatic
Interpretation test provides satisfactory investigation into the integrity of
underground piping. Note that API 2611 (draft) calls for 150%
testing of MOP, not 110% of MOP as in API 570. This may be a
result of pressure testing of terminal piping that may not be done to
a standard as high as in a refinery.
Lacking other evidence (such as leak history) or direct knowledge on
pipe surface condition from excavation or smart pigging, use of
pressure/leak testing is the appropriate degree of investigation
necessary. Use of smart pigging, LRUT, or excavation is not a
mandatory API requirement. As API 570 does not clearly identify
what is “maximum operating pressure”. This document defines it to
be the greater of maximum system deadhead, or thermal relief valve
setting.
10 Test Fluid 5.8.1 states that test fluid must be water, unless damage may occur
due to freezing, or unless contamination presents unacceptable
environmental risk. If tested with fuel, the flash point must be 120 °F
(48.9 °C) or greater.

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11 Comment and JP-8 (100 °F (37.8 °C) flash point) is regularly used in the military for
Interpretation pipeline pressure and hydrotesting due to the greater risk of product
contamination from testing with water. JP-5 (140 °F (60 °C) flash
point) meets the criteria. The military has accepted the risk of using
JP-8 for testing.
Need to confirm state requirements as well to see if a waiver is
needed. Some states, such as CA, mandate water but have
permitted using JP-5 on some tests.
B 1 Testing protocol & API RP 2611 1st Edition, June 01, 2011, Terminal Piping Inspection –
Requirement – Inspection of In-Service Terminal Piping Systems.
API RP 2611 Note, the document is in response to the industry needing a
companion to API 570 that better reflects operating conditions, risk
and consequence of terminal operations, as compared to refinery
operations covered under API 570.
2 Test Pressure Criteria API RP 2611 5.5.5 states that leak testing is not a stand-alone
and duration- integrity test, but should be performed in conjunction with other
aboveground piping. integrity tests such as corrosion under insulation and wall thickness
analysis.
3 Test Pressure Criteria § 7 addresses the overall assessment of underground piping and
and duration - stresses use of both knowledge of the age and history of a system,
underground piping. cathodic testing and coating testing procedures, but does not
specifically call for pressure testing. However pressure testing is
noted as a viable means of integrity assessment, with little stated on
its pressure levels or duration. The frequency of testing is dependent
on a variety of factors noted, and ranges from 5 to 25 years.
4 Frequency of Inspection Table 6-1 in API RP 2611 is primarily the intervals indicated for smart
pigging or direct excavation, when deemed important for determining
integrity of system, but is also used for the intervals for pressure
testing as noted.
5 Comment and • API RP 2611 supports the premise that a leak, pressure or
interpretation hydrostatic test provides satisfactory investigation into the integrity of
underground piping.
• Lacking other evidence (such as leak history) or direct knowledge
on pipe surface condition from excavation, use of pressure/leak
testing is an appropriate degree of investigation necessary. Use of
smart pigging, Long-Range Ultrasonic testing (LRUT), or excavation
is not a mandatory API requirement.
As API RP 2611 does not clearly identify what is “maximum
operating pressure”. This document defines it to be the greater of
maximum system deadhead, or thermal relief valve setting.

C 1 Testing protocol & ASME B31.3 Process Piping, 2012

Requirement
-ASME B31.3

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2 Test Pressure Criteria 345.4.2 states that pipe must be tested to not less than 1.5 times the
and Duration maximum design pressure. "Design Pressure is the most severe
combination of internal and external pressure expected during
service" (ASME B31.3 Par 301.2.1).
Note that the test pressure is limited to the maximum rating for flange
testing per ASTM B16.5, Flanges. Per 345.2.2, the minimum test
duration for examination of connections and joints is 10 minutes.
Most systems will take longer to physically inspect. 345.2.1 (b)
permits the use of a pneumatic test at up to 25 psig (172.4 kPa) to
find major leaks, prior to the liquid hydrotesting.
3 Comment and ASME B31.3 was written for new piping installation into a new, or
Interpretation modified system. It was not written for periodic integrity testing.
Several codes, such as API 570, reference ASME B31.3 as the
governing document for pressure testing in certain circumstances.
4 Test Fluid 345.4.1 states that test fluid must be water, unless damage may
occur due to freezing, or unless contamination presents
unacceptable environmental risk. If tested with fuel, the flash point
must be 120 °F (48.9 °C) or greater.

5 Comment and JP-8 (100 °F (37.8 °C) flash point) is regularly used in the military for
Interpretation pipeline pressure and hydrotesting due to the greater risk of product
contamination from testing with water. JP-5 (140 °F (60 °C) flash
point) meets the criteria.
6 Closure Weld Testing 345.2.3 Addresses testing of closure welds (tie-in welds). So long as
the components/piping being installed into the system have been
pre- tested, the final closure or tie-in weld need not be leak tested
provided the weld is examined in-process in accordance with 344.7
and passes with 100% radiography or 100% ultrasonic examination
in accordance with 344.6.
7 Comment and This paragraph is important as it validates not hydrotesting an existing
Interpretation system, when a change or repair is made, so long as more rigorous
examinations are made of the tie-in weld, and the new components
are pretested.
8 Testing of Vessels and 345.4.3 addresses the testing of vessels and pipe together so long as
piping together the following is met:
If the test pressure of the pipe is equal or less than test pressure of
the vessel, testing to the piping test pressure is permitted.
If the test pressure of the pipe exceeds the test pressure of the
vessel, combined testing is permitted at the vessel test pressure,
provided the owner approves of the reduced test pressure, and the
pressure is not less than 77% of the piping test pressure calculated in
accordance with 345.4.2(b)

9 Comment and Testing together simplifies many testing scenarios.

Interpretation

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D 1 Testing protocol & ASME B31.4 Pipeline Transportation for Liquid Hydrocarbons – 2012
Requirement - Although commonly applied to cross country pipelines, ASME B31.4
ASME B31.4 can also be applied to connected terminals, in lieu of ASME B31.3,
although there is no particular advantage in doing so.

2 Test Pressure Criteria 437.4.1 states that piping systems operated at a hoop stress of more
and duration than 20% of Specified Minimum Yield Strength (SMYS) must be proof
tested to not less than 1.25 times the internal design pressure at that
point per 401.2.2. The test duration is not less than 4 hours.

401.2.2 "Internal Design Pressure” is not less than the steady state
operating pressure at that location, or static pressure when higher.

Per 437.4.1(2) if the line undergoing testing is not fully inspectable

for leaks, the proof test must be followed by a leak test at not less
than 1.10 times the internal design pressure, for not less than an
additional 4 hours.
3 Comment and This piping code was written for long transportation pipelines with
Interpretation potential large grade and hydraulic grade changes. Once placed in
operation these lines have a greater predictable operating pressure
range, thus the less conservative 1.25 test as compared to ASME
B31.3 with a 1.5 times pressure test.

4 Test Fluid 437.l.1(c) Test fluid must be water, except liquid petroleum that does
not vaporize rapidly may be used provided:
The pipeline is outside of a city and populated area, and is not
underwater.
All buildings within 300 ft (91.5 meters) of the pipeline are
unoccupied during the test when the pressure produces a hoop
stress exceeding 50% of SMYS.
5 Comment and JP-8 (100 °F (37.8 °C) flash point) meets the criteria of permissible
Interpretation petroleum for testing.
6 Tie-in Weld Testing 437.1.4 Addresses testing of closure welds (tie-in welds). So long as
the components/piping being installed into the system have been
pre-tested, the final closure or tie-in weld need not be leak tested
provided the weld is examined in- process and passes with 100%
radiography or 100% ultrasonic examination in accordance with
434.8.5(a)(4).
7 Comment and This paragraph is important as it validates not hydrotesting an
Interpretation existing system, when a change or repair is made, so long as more
rigorous examinations are made of the tie-in weld, and the new
components are pretested.

E 1 Testing Protocol & Subpart E – Pressure Testing

Requirement - 49 CFR
195

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2 Test Pressure Criteria § 195.304 “…maintain for 4 hours at a pressure equal to 125%, or
and duration more, of the operating pressure and, in the case of a pipeline that is
not visually inspected for leakage during the test for at least an
additional 4 continuous hours at a pressure equal to 110% or more,
of the maximum operating pressure. (Nov. 4, 1998).
3 Comment and “Maximum Operating Pressure is defined in § 195.2 “Definitions” as:
Interpretation Maximum operating pressure (MOP) means the maximum pressure
at which a pipeline or segment of a pipeline may be normally
operated under this part.
B31.4 uses the term “maximum internal design pressure” as the basis
for design, as well as the starting point for the 125% test pressure.
B31.4 further states that the maximum internal design pressure must
not be less than the steady state operating pressure at any point on a
pipeline.
Taking the above into consideration, the design engineer may use
steady state operating pressure or deadhead pressure as the basis
for the 125% pressure test. Presumably, if the steady state pressure
is used, there must be operational controls that are failsafe in not
permitting a pipeline to deadhead at a higher pressure than steady
state pressure.
For typical short military pipelines this report recommends using
deadhead as the basis for any pressure testing due to any means of
preventing a dead head (such as startup) is an unrealistic
expectation.
4 Test Fluid §195.306 Requires water to be used for testing but permits the use of
a flammable liquid if the pipeline is not offshore and is outside of
cities and populated areas, the fluid does not rapidly vaporize, and if
the test pressure results in a hoop stress greater than 50% of SMYS,
all buildings must be unoccupied within 300 feet (91 meters) of the
pipeline under test, and there is continuous communication along
the entire test section.
5 Comment and The use of water and fuel as a test medium is similar in nature to
Interpretation ASME B31.3, except an actual flash point of the fuel is not noted.
F 1 Testing protocol & 33 CFR Part 154 Facilities Transferring Oil or Hazardous Material in
Requirement - 33CFR Bulk 33 CFR Part 156 Oil and Hazardous Material Transfer
Part 154 and Part 156 Operations (i.e., USCG regulations for ports)
2 Test Pressure Criteria §156.170, Equipment Tests and Inspections, (c)(iii) requires that hose
and duration- and loading arms not burst at 1½ times the Maximum Allowable
aboveground piping and Working Pressure (MAWP).
equipment. The Operations Manual must indicate per §154.310(a)(16) “The
maximum allowable working pressure (MAWP) of each loading arm,
transfer pipe hose assembly required to be tested by §156.170 of this
chapter, including the maximum relief valve setting (or maximum
system pressure when relief valves are not provided) for each
transfer system.”

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3 Test Pressure Criteria §156.170 (f)(1) Requires the tests to have been accomplished within
and duration- the last 12 months prior to a transfer ¶(h) permits alternative
compliance testing when approved by the Captain of the Port (COTP).
§154.105 “Definitions” defines “Marine Transfer Area” to be the part
of the waterfront area between the vessel and the first valve inside a
containment required by 40 CFR 112 or 49 CFR 195, or if no
containment area, to the valve on the receiving tank.
4 Comment and The requirements for testing of piping and systems under USCG
Interpretation jurisdiction is not clear, and requires a read of various sections as
noted above.
Traditionally the maximum over the water transfer pressure is limited
to 150 psig (1034.1 kPa) by agreement or mandate of the COTP.
This does vary.
Traditionally the maximum over the water transfer pressure at
government facilities is 100 psig (689.4 kPa). This has been
attributed to tradition or in some cases, the contract maximum under
the MSLC tanker contracts, but has not been verifiable.
Traditionally the required test pressure in many ports has been 150
psig x 150% = 225 psig (1034.1 kPa x 150% = 1551.3 kPa). This
however can be deficient when a variety of factors and system
features could lead to a higher surge pressure that is within the
capability of a properly tested ANSI Class 150 system.
It is clear testing is required annually.
It is not clear what the duration or test standard requirement is.
Traditionally the test is for one hour, with procedures left up to the
local region and owner.
Consideration must be given to issue to ships and barges operations
having higher deadhead conditions than a delivery tanker, thus
hydrotesting must be accomplished to a higher pressure.

5 Test Fluid §156.170 (c)(iv) The test medium does not need to be water.

6 Comment and This paragraph is discussing the testing of hoses, which is normally
Interpretation done above deck, within a contained area, thus testing with fuel is
possible if deemed appropriate. This paragraph should not be
considered a justification to test over the water piping with fuel. That
decision is best made based on the risk of failure and consequential
spill to the water.

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G-5 PIPELINE PRESSURE TESTING GUIDELINES AND CRITERIA

SUMMARY TABLE

Pipeline Pressure Testing Guidelines and Criteria

SUMMARY TABLE
Pipe Location/Test Basis of Test Pressure Duration Type of Testing Comments
USCG/Marine Service, Over 150% of highest delivery 2 hr 100% observation for leaks (1) 225 psig (1551.3 kPa) test suggested
water/aboveground pressure (relief valve or in most cases (based on tankers with
- Annual Pressure Test pressure switch) 150 psig (1034.1 kPa)
relief/shutdown) or 175 psig (1206.6
kPa) (based on barges with 115 psig
(792.9 kPa) relief/shutdown).
Also, the issue pressure must be
calculated as this pressure may
exceed offload pressures.
USCG/Marine Service, 150% of highest delivery 2 hr (min) Accurate pressure monitor, 225 psig (1551.3 kPa) test suggested
Underground - Annual pressure (relief valve or reconcile temperature- in most cases (based on tankers with
Pressure Test pressure switch) pressure change (2) 150 psig (1034.1 kPa) relief/
5-year Option 1 testing meets shutdown) or 175 psig (1206.6 kPa)
criteria. 5-year Option 2B (based on barges with 115 psig (792.9
acceptable with permission of kPa) relief/shutdown).
the USCG COTP Also, the issue pressure must be
calculated as this pressure may
exceed offload pressures.

Base Piping, Aboveground - Greater of pump 2 hr 100% observation for leaks (1) Suggest not less than 50-100 psig
Annual deadhead, or PSV (344.7-689.4 kPa) for pump suction
setting/cascade lines not subject to discharge
pressure.
Base Piping, Underground - Greater of pump 2 hr (min) Accurate pressure monitoring, To minimize effect of changing
Annual deadhead, or PSV pressure change, if any, must temperature, fuel should be allowed
(Annual Option 1) setting/cascade be within small range and or to reach equilibrium, and testing
reconciled with fuel occur at time of day with little solar
temperature change (2) influence or rapid temperature
change.
Base Piping, Underground - Test at greater of Per certs Third-party certified and If conducted every year this
Annual deadhead or PSV NWGLDE listed and DLA-E procedure, with lower pressure
(Annual Option 2) setting/cascade using approved procedure (6) testing also satisfies the 5-year 150%
third- party certified testing requirement.
procedure
Base Piping, Double Wall Test carrier pipe using Per above Per above procedure selected After testing, confirm no product at
Underground – Annual (with USCG or non-USCG all low points in secondary
air testable and low point annual piping (as containment system.
checking secondary applicable) Every 5 years provide secondary
containment capability) (8) containment integrity test per
manufacturer’s instructions,
normally a 2 hour 10-15 psig
(68.9-103.4 kPa) test.
Base Piping, Underground - Greater of 150% of 8 hr Precision temperature and Minimum 4 hour analysis period over
(5-year Option 1) deadhead or 110% of pressure measurement and test cycle.
PSV setting/cascade reconciliation of temperature-
pressure change (3)
Base Piping, Underground - Strength test at greater 4 hr Strength (4) Acceptable even when 150% strength
(5-year Option 2A) of 150% of deadhead or strength Leak – Third-party certified and test pressure is above leak test
110% of PSV setting/ NWGLDE listed (5) pressure.
cascade, followed by
third-party certified leak
test

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Pipeline Pressure Testing Guidelines and Criteria

SUMMARY TABLE
Pipe Location/Test Basis of Test Pressure Duration Type of Testing Comments
Base Piping, Underground - Test at greater of 150% 2 hr soak 2 hr “soak” at test pressure to Generally appropriate only when the
(5-year Option 2B) of deadhead or 110% of bring to equilibrium, followed 150% test pressure is within the third-
PSV setting/cascade by third-party certified and party certified test protocol limits.
using third-party NWGLDE listed (5) (10)
certified leak test
Base Piping, Underground - Per third-party Per certs Third-party certified and Annual recertification required.
with in- situ leak detection certification, scheduled NWGLDE listed (5)
system for testing on monthly
frequency minimum
Off Base, Underground - Greater of pump 2 hr Accurate pressure monitor, Actual test pressure needs to be
Annual deadhead, or PSV reconcile temperature- validated and to consider resultant
setting/cascade pressure change (2) pressure along entire pipeline, test
media (flash point restrictions), and
density/type of population.
Off Base, Underground - Leak test Per certs Leak – Third-party certified and An engineering review required to
Annual (Alternative) NWGLDE listed (5) determine appropriate test pressure.
Off Base, Underground - 5- Higher then operating- Per reg Precision temperature and Only required when mandated by
year deadhead conditions, pressure measurement and regulations. (Not a normal
but must be assessed. reconciliation of temperature- requirement) Consider intelligent
In some cases use of pressure change (3) pigging as integrity management tool
high pressure shutdown (7).
is acceptable. (may be
up to 150%)
Off Base, Underground - 5- Equal to or higher then Per reg Strength (4) Only required when mandated by
year -Alternative operating-deadhead Leak – Third-party certified and regulations or Service Control Point.
conditions, but must be NWGLDE listed (5) (Not a normal requirement) Consider
assessed. In some cases intelligent pigging as integrity
use of high pressure management tool (7).
shutdown is acceptable.
Service Station, Above and Pump deadhead, or per Per reg If all aboveground, visual. If Meet UST regulations.
Underground - Annual or state Regulations above and underground,
Periodic precision test as
required/approved by
l o c a l /state regulatory
jurisdiction (9)

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Pipeline Pressure Testing Guidelines and Criteria

SUMMARY TABLE
Pipe Location/Test Basis of Test Pressure Duration Type of Testing Comments
1. Visual test, maintain pressure over duration and inspect 100% of system for weeps and leaks.
2. Acceptable pressure deviation or pressure change criteria established by Service Control Point, taking into consideration installation location,
size of system, and historical testing results.
3. A conventional pressure test as used in this Table is a temperature compensated and volume/pressure change leak test at not less than 150% of
pump deadhead by a qualified individual/organization with API 1110 developed procedures. Use of the California State Fire Marshall’s
procedure is acceptable, but not necessarily conclusive in all cases.
4. A strength test as used in this Table is a pressure test at not less than 150% of pump deadhead, conducted with a calibrated pressure gauge,
for a duration of not less than 4 hours, but does not attempt to reconcile pressure change with fuel temperature change as is required by
conventional pressure test. Low volume leaks may go unrecognized. To qualify for integrity testing, a strength test must be followed by a
conventional leak test.
5. Integrity testing using a third-party certified and National Work Group on Leak Detection Evaluations (NWGLDE) listed short duration
proprietary procedures are acceptable in principle. Selected method must be certified for system parameters such as pipe size and liquid
volume. To qualify as an integrity test the procedure must utilize a pressure consistent with integrity management principles, not just a
minimum pressure required to conduct the test. Alternatively, a lower pressure third-party certified leak test can be conducted after a strength
test.
6. Note that a third-party certified NWGLDE listed procedure, if conducted every year at not less than greater of pump deadhead or PSV settings
is an acceptable means of meeting the 5-year testing requirement (without requiring a 5-year 150% test).
7. For piggable off base pipelines, the use of in-line intelligent pigging on periodic basis (10 years maximum) to monitor corrosion and mechanical
damage can significantly improve integrity management and eliminate the need for any 5-year testing regime, except when required by local or
state regulatory body.
8. If secondary containment is not air pressure testable and capable of being checked at all low points for liquid, the primary carrier piping system
must be tested using any one of the appropriate underground pipe testing methods.
9. Due to the myriad of piping system materials, single or double wall pipe, and piping components (line leak detectors, leak detection
systems), fiberglass and coaxial piping, the annual and 5-year testing requirements do not translate well for this type of system, with small
bore piping (2” and less) and low operating pressures (less than 50 psig (344.7 kPa)), thus use of a certified testing procedure and company is
more appropriate company is more appropriate. Even when tanks are aboveground, if underground piping used to service dispensers, the use
of UST testing organizations still is appropriate.
10. It is the intent that the 2-hour “soak” permit the piping segment under test be visually inspected for leaks and weeps, and to stretch to test
pressure, thus improving testing accuracy. This 2-hour soak can be coincident with a similar purpose procedure of the testing organization,
b t tb 2h i d ti i t f l t t f th t ll kt t

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APPENDIX H TANK CLEANING GUIDANCE

This Appendix provides minimum standards for safe entry, inspection, and cleaning
guidance of liquid petroleum fuel tanks for DoD personnel.

H-1 RESPONSIBILITY.

Military services will comply with their respective safety equipment certification (e.g.,
respirator) and task training certification (e.g., confined space entry, tank cleaning,
medical) programs.

H-2 COORDINATION.

Coordinate with facility agencies (i.e., tank operators, Installation Environmental Office,
Installation Safety Office, local fire department, and military service-specific
headquarters), when applicable, to facilitate lowering product levels in tanks, alternate
tank use during cleaning, hot work permits, disposal of waste, and coordination of safety
related procedures (i.e., egress, rescue, and fire).

H-3 TANK CLEANING PREPARATION.

H-3.1 Unless superseded by Military service-specific directives, the following

guidance details the minimum requirements for tank preparation prior to cleaning.

H-3.2 Secure (e.g., fence, rope, tape) and clear the work areas of all non-
essential personnel. Isolate tank openings by establishing a perimeter of 50 feet (15.2
meters) and post warning signs (e.g., Do Not Enter Tank Entry in Progress) to identify
the work being accomplished. If the area is subject to high foot or vehicle traffic; tank
cleaning team members should be posted to ensure that unauthorized personnel and
vehicles do not enter the established perimeter.

H-3.3 Consider projected weather conditions to ensure a safe working

environment throughout the cleaning process. The potential of electrical storms, severe
weather, or changes in the direction may produce hazardous conditions that could
impact the cleaning process.

H-3.4 Remove all ignition sources from surrounding areas.

H-3.5 Move all flame-producing devices to a designated safe area prior to entry.

H-3.6 Inspect equipment and tools for serviceability and hazards. Complete
necessary adjustments and calibrations prior to entry. Cleaning equipment and tools
should be placed upwind of tank openings and at the highest elevation possible to
minimize hazards. Cleaning equipment and tools should never be placed in an area
lower than the surrounding terrain.

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H-3.7 Inspect grounding and bonding cable connection points, wires, and clips
for serviceability. In addition, check wire and connections for electrical continuity with an
ohmmeter. Replace damaged and broken items prior to beginning tank cleaning
operations.

H-3.8 Turn off cathodic protection systems prior to disconnecting pipelines from
tanks.

H-3.9 Verify PPE is in proper working order.

H-3.10 Test the area around the tank for explosive vapors using a combustible
gas detector before equipment is started which may be a source of ignition.

H-3.11 Ensure an emergency shower/eyewash is available and serviceable in the

immediate area. Portable emergency eyewash units are acceptable if approved by the
facility’s authorizing agency.

H-4 TANK PREPARATION.

H-4.1 Isolate the tank to ensure product does not reenter the tank once draining
procedures have commenced.

H-4.2 Tank isolation must be conducted in accordance with military service or

contract lockout/tagout procedures. Ensure tank isolation is established to prevent
product from reentering the tank.

H-4.3 Lockout/tagout all electrical equipment and necessary valves. Isolate all
piping by removing valves and installing blind flanges, spectacle blinds, or skillet flanges
to prevent fuel or vapors from returning to the tank.

H-4.4 Blind and spectacle flanges must be able to withstand any pressure the
system is able to produce. If spectacle blinds are used, insert the blind between the tank
valve and the flange nearest the tank.

H-4.5 No valve or piping is to be disconnected from any tank component until it

is verified that the line has been emptied of product and a bonding cable has been
installed between pipe flanges.

H-4.6 Tanks with floating roofs or pans pose additional inspection requirements.
All applicable military service directives or industry standards will apply when inspecting
floating roofs or pans (e.g. harness, confined space, atmospheric testing).

H-4.7 Qualified personnel must visually inspect the floating roof or pan to ensure
the roof or pan is safe for inspection. Personnel will ensure the roof or pan support legs
and sleeves (to the extent possible) have the ability to support the roof or pan.

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H-4.8 Inspect the roof or pan pontoons, buoyant foam panels, and seals for fuel
and water and drain as necessary to facilitate vapor and gas freeing of the tank space.

H-4.9 Qualified personnel must inspect anti-rotation pipes and guide cables to
ensure proper function as the roof or pan descends.

H-4.10 Floating roof or pan leg pins must be placed in the high roof or pan
position to allow for maximum space under the roof or pan to facilitate tank cleaning
operations.

H-4.11 If the tank has a double bottom, a qualified individual must inspect the
bottom annular space to ensure the space is free of petroleum product or vapors.

H-4.12 Ensure tank operators or responsible organizations have removed

petroleum from the tank to the lowest point possible using installed pumps. Extra
precautions such as gravity flow and reduced pumping rates must be considered to
ensure the floating roof or pan settles and rests on legs as the fuel level drops below the
high leg position of the roof or pan. If applicable use secondary pumps (i.e., air-
operated, double-diaphragm pumps, explosion proof electric) to remove remaining
petroleum fuel once the petroleum fuel level drops below the installed pumps suction
point. Secondary pumps must be located upwind of the tank and at least 50 feet (15.2
meters) from the farthest manhole or vent.

H-5 VAPOR FREEING.

H-5.1 The tank must be ventilated using air-operated eductors, such as COPIS
or Lamb air movers. The roof and shell manhole covers must be removed to allow air to
circulate freely by natural ventilation to aid in removing vapors. Do not use air moving
systems that would blow air into the tank.

H-5.2 Consider local conditions when placing ventilating equipment. Ventilation

discharge locations must be selected to maximize diffusion of vapors into the
surrounding air. This will minimize the possibility of a flammable mixture forming at
ground level. Position ventilating equipment to push vapor through roof manholes.

H-5.3 Petroleum vapors are heavier than air and usually accumulate in the
bottom of tanks. Blowing air into a tank can dilute the vapors, but it may take longer for
the vapor-air ratio to drop to an acceptable level. Eductor-type air movers with a flexible
oil-proof hoses inserted near the bottom of the tank will remove vapors in a shorter
period of time.

H-5.4 The primary goals of tank preparation prior to entry are to eliminate
sources of ignition and reduce the amount of fuel sludge. A near vapor free work area
will drastically reduce the possibility of hazardous conditions (toxicity, asphyxiation, fire,
explosion) inside the tank and in the surrounding area.

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H-5.5 Eductors must be operated for at least one hour or until LEL and oxygen
are within safe limits. Test the tank for LEL and oxygen immediately prior to entry and
throughout the operation to ensure a safe atmosphere.

H-5.6 The interior of the tank is considered an explosive atmosphere until all
sludge and loosely adhering rust and scale has been removed, regardless of the type of
petroleum stored.

H-5.7 All personnel entering the tank prior to and during cleaning must wear
authorized PPE including supplied air respirator (SAR) with emergency egress SCBA
until the tank is declared hazard-free in accordance with military service-specific
directives.

H-5.8 Before entry to the tank without PPE, the LEL reading must be zero,
oxygen levels between 19.5% and 23.5%, and lead, benzene, and other toxic material
levels within safe limits. Refer to API Standard 2015 for additional information.

H-5.9 The tank being cleaned will be considered leaded unless positive proof
exists that the tank has never contained leaded fuel, or the tank has been coated.

H-5.10 Vapors will be present as long as petroleum product, scale, or sludge are
inside the tank. Operate air eductors continuously until all these materials have been
removed.

H-6 ATMOSPHERIC TESTING.

H-6.1 Tank entrants will follow military services directives detailing specific
safety, medical, certification, and testing procedures for confined spaces and safe
atmospheric standards.

H-6.2 Personnel will not enter a tank without proper respiratory protection unless
the LEL is zero, the oxygen level is within tolerances (19.5% to 23.5%), and the facility’s
authorized agency has determined that airborne benzene and other toxic vapors are
within permissible exposure limits. Personnel may enter the tank when vapor levels are
below 10% of LEL if they are equipped with approved SAR with emergency SCBA.

H-6.3 Provided personnel are wearing appropriate PPE based upon the current
LEL, toxicity, and oxygen levels, eductors may be shutdown while workers are in the
tank if the eductors impair the ability of personnel to communicate.

H-6.4 If vapor levels cannot be reduced below the 10% LEL, or in some cases
below 20% LEL, the following situations may exist:

H-6.4.1 Insufficient time has passed to reduce vapor concentrations (which in turn
can affect facility mission requirements and maintenance costs).

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H-6.4.2 The amount of remaining fuel and solid sludge has not been reduced to an
appropriate level.

H-7 TANK CLEANING.

H-7.1 All entrants must be equipped with approved PPE. In addition, the entry
supervisor (or Military service equivalent) must be aware of equipment that is used
inside the tank and ensure equipment (where applicable) is explosion proof, has ground
fault interrupters and is bonded to the tank. If pressure washers are used, the washer
nozzle must be electrically bonded to the tank.

H-7.2 Tanks must be cleaned from the outside first. Ventilation and vapor
readings at the manhole must continue during cleaning from the outside. Entry is
authorized once the flammable atmosphere tester registers 10% LEL or less. Since
vapors will be present as long as fuel, scale, or sludge remains inside the tank, continue
forced ventilation until all such material has been removed.

H-7.3 Maintain an uninterrupted air supply until all persons are out of the tank
and have removed their face pieces. Personnel who are inside the tank while wearing
PPE that detect an odor (such as petroleum products) must leave the tank immediately
and not re-enter until the cause has been determined and equipment repaired or
replaced.

H-7.4 Unless otherwise directed by military service-specific directives, continue

testing for explosive vapors at fifteen-minute intervals while personnel are in the tank.
Stirring sludge releases vapors and increases the vapor concentration. Remove
puddles of fuel-water sludge to keep vapor readings below 20% LEL.

H-7.5 Personnel will continue to remove sludge from the tank by scraping the
bottom of the tank and 3 feet (0.9 meters) up the sides of the tank until all loosely
adhering rust and scale have been removed.

H-7.6 Wash down the remainder of the tank with high-pressure hoses. Include
the metal supports, braces, the upper portion of horizontal tanks, and the decks (tops)
of vertical tanks. Wash these areas until the water pumped out of the tank is clean.

H-7.7 Water discharged from the tank must be contained and disposed of as
instructed by the authorized facility environmental agency.

H-7.8 Remaining non-recoverable sludge residue and deposits may be removed

by several different methods, including, but not limited to:

H-7.8.1 Wash brush, squeegee, and sweep material (i.e., sludge, deposits) into
portable containers.

H-7.8.2 Spray or wash down material with water hose streams and remove by
pump or vacuum. If additional liquids are needed to reduce tank material (e.g., sludge,

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deposits) the use of diesel, solvent, or approved chemicals can be used in accordance
with military service-specific directives.

H-7.9 Use of solvents and soap can create additional undesired reactions if used
incorrectly, the tank cleaning team must only use approved substances in accordance
with manufacturer’s instructions.

Solvents and soaps reactions can range from polymerization (depletion of inhibitor or
excessively high temperature), saponification (creation of hard soap forming a layer on
the tank requiring acid cleaning or even removal by hydroblasting), or drying/hardening
(formation of hard debris that is no longer soluble, requiring treatment with a solvent).

H-7.10 Once washing is completed, allow the floor to dry. When interior tank
vapor readings are 0% of the LEL on unleaded tanks, personnel may enter the tank
without protective equipment if the testing required by API Standard 2015 has been
done, and the facility’s authorized agent determines that airborne benzene and other
toxic vapors are below the permissible exposure limits.

A clean dry tank that has been ventilated overnight will provide the best atmosphere for
entry without protective gear.

H-7.11 Pipes used for center poles and braces, pontoons, and leaking bottoms
are potential sources of explosive vapors even after the tank is cleaned. In as little as
one to two hours a safe tank may reach the explosive range because of these sources.
While unprotected personnel are in the tank, take hazardous atmosphere readings at
least every fifteen minutes. Where pontoon-type floating roofs or pans are installed in
aboveground tanks, check each pontoon with a hazardous atmosphere tester.

H-7.12 Petroleum products irritate and burn the skin and may cause serious
discomfort and injury. Promptly remove clothing that becomes splashed with sludge or
fuel to prevent contact with the skin. Before continuing work, wash the affected area
with soap and water (if a small area), or shower and put on a fresh change of clothing.
Clothing contaminated by petroleum products must be kept away from any source of
ignition.

H-7.13 Unless a full-face respirator is worn, wear goggles during scraping and
spreading loose absorbent material. If hands are frequently wet with fuel and it is not
practical to wear protective gloves, the hands may be coated with commercial non-
greasy cream that gives the desired protection. NOTE: If work site has contained leaded
gasoline, approved protective gloves or other impermeable gloves must be worn
throughout the operation.

H-7.14 Keep manholes and adjacent areas clear of equipment or material that
would hamper rescue operations in an emergency situation.

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H-8 MATERIAL TREATMENT AND DISPOSAL.

Residue (i.e., sludge, deposits) will be treated and disposed of in accordance with
Military service-specific environmental directives or contract requirements.

H-9 RETURNING TANK TO SERVICE.

H-9.1 The tank cleaning team supervisors must inspect the tank after cleaning to
evaluate the condition of the tank for any follow-on repairs.

H-9.2 Once the inspection is complete and any necessary work completed, the
tank must be brought back into service by reinstalling all valves, piping, and manhole
covers using new non-asbestos gasket material compatible with the product being
stored. The gasket thickness must not be less than the thickness of the gasket that is
being replaced.

H-9.3 Refer to UFC 3-460-03 Section 8-8, “Returning to Service after Formal
Out of Service Inspection/Repair,” for maximum fuel line velocities for initial fills of
petroleum fuel tanks that will be returned to service.

H-9.4 Petroleum fuel tanks must be stenciled before they are returned to service
after cleaning. Refer to UFC 3-460-03 Section 8-8.1, “Stenciling Requirements.”

H-10 TANK CLEANING EQUIPMENT AND PROTECTIVE CLOTHING.

H-10.1 Tank cleaning equipment must meet the following requirements:

H-10.1.1 All electrical equipment and conductors used within 50 feet (15.2 meters)
of petroleum pipes or storage tanks, or where a hazardous accumulation of flammable
vapors may exist, will be NFPA 70 for Class 1, Division 1, Group D (or higher) (or Class
1, Zone 0, or Zone 1) locations. The maximum temperature rating will be "T2D" – 419 °F
(215 °C), as defined in the NEC for use in hazardous (explosive) areas.

H-10.1.2 Hazardous atmosphere detectors must meet military service

requirements.

H-10.1.3 Air movers will be of the eductor type capable of educting vapors from the
tank, and will be either air-driven or explosion-proof electrically operated. Electrically
operated air movers must meet the minimum requirements of NFPA 70 for Class 1,
Division 1, Group D (or higher) (or Class 1, Zone 0, or Zone 1) locations.

H-10.2 Tank cleaning personnel must be equipped and trained to use protective
clothing (i.e., impervious coveralls, gloves, footwear, head coverings, face shields) that
is compliant with safety related military service directives.

H-10.2.1 The tank cleaning team will review the Safety Data Sheets of the
petroleum product to select the type of respirator that is applicable with the type of tank

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and petroleum product used. Caution must be exercised to select a respirator that will
not deteriorate or corrode when exposed to the petroleum product or solvents used in
the tank cleaning process.

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\1\
APPENDIX I /1/ ACRONYMS

ACRONYMS

A4A Airlines for America

AFCEC Air Force Civil Engineering Center

AFHE Automated Fuel Handling Equipment

AFI Air Force Instruction

AFSS Automated Fuel Service Station

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

AST Aboveground Storage Tank

ATG Automatic Tank Gauge

AWS American Welding Society

BIA Bilateral Infrastructure Agreement

BPCV Back Pressure Control Valve

BSME Business System Modernization-Energy

CFR Code of Federal Regulations

CMP Centrally Managed Program

CNG Compressed Natural Gas

CP Cathodic Protection

CPR Cardiopulmonary Resuscitation

CRA Pressure-Reducing Control

CRL Pressure-Relief Control

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DBB Double Block and Bleed

D/FV Defuel/Flush Valve

DLA Defense Logistics Agency

\2\ DAFMAN Department of the Air Force Manual /2/

DoD Department of Defense

DOE Department of Energy

DOT Department of Transportation

DPT Differential Pressure Transmitter

DWCF Defense Working Capital Fund

EBS Enterprise Business System

EFSO Emergency Fuel Shutoff

EI Energy Institute

ESO Emergency Shut-Off

\1\ FDWG Fuels Discipline Working Group /1/

FML Flexible Membrane Liner

FPS Feet per Second

FSCV Filter Separator Control Valve

GPM Gallons Per Minute

HAMS Hydrant Automation Monitoring System

HCV Hydrant Control Valve

HDBK Handbook

HFAM Hydrant Fuels Automation Maintenance

HNFA host nation Funded Construction Agreements

HQUSACE Headquarters, U.S. Army Corps of Engineers

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IAS Independent Alarm System

IAW In Accordance With

LCP Lateral Control Pit

LEL Lower Explosive Limit

LNG Liquefied Natural Gas

LPS Liter per Second

MIL Military

MILCON Military Construction

MLA Marine Loading Arm

MOGAS Motor Gasoline

MPS Meter per Second

NACE National Association of Corrosion Engineers

NATO North Atlantic Treaty Organization

NAVFAC Naval Facilities Engineering Command

NAVOSH Navy Occupational Safety & Health

NAVSEA Naval Sea Systems Command

NEC National Electrical Code

NFPA National Fire Protection Association

OSHA Occupational Safety and Health Administration

OM Operator Maintenance

OMES Operation, Maintenance, Environment, and Safety Plan

OMSI Operation and Maintenance Support Information

PCV Pressure Control Valve

PEI Petroleum Equipment Institute

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PIT Pressure Indicating Transmitter

PHMSA Pipeline and Hazardous Material Safety Administration

PLC Program Logic Controller

POL Petroleum, Oil, and Lubricant

RP Recommended Practice

SAE Society of Automotive Engineers

SCP Service Control Point

SOFA Status of Forces Agreements

SM System Maintenance

SME Subject Matter Expert

SPAWAR Space and Naval Warfare Systems Center

SPCC Spill Prevention Control and Countermeasures

SRM Sustainment, Restoration, and Modernization

STANAG Standardization Agreement

STI Steel Tank Institute

STD Standard

TM Technical Manual

TO Technical Order

UFC Unified Facility Criteria

UFGS Unified Facilities Guide Specification

UL Underwriters Laboratory

UPS Uninterruptible Power Supply

USAF United States Air Force

USAFE United States Air Force Europe

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UST Underground Storage Tank

\1\ VCI Vapor Corrosion Inhibitors /1/

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This Page Intentionally Left Blank

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\1\
APPENDIX J /1/ REFERENCES

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI/AIHA Laboratory Ventilation Z9.5

AMERICAN PETROLEUM INSTITUTE

API Manual of Petroleum Measurement Standards

API RP 2003, Protection Against Ignitions Arising Out of Static, Lightning, and Stray
Currents

API RP 1110, Recommended Practice for the Pressure Testing of Steel Pipelines for the
Transportation of Gas, Petroleum Gas, Hazardous Liquids, Highly Volatile Liquids, or
Carbon Dioxide

API Specification 6D, Specifications for Pipeline and Piping Valves

API STD 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair,
and Alteration

API STD 570, Piping Inspection Code: In-Service Inspection, Rating, Repair, and
Alteration of Piping Systems

API STD 607, Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic
Seats

API STD 650, Welded Steel Tanks for Oil Storage

API STD 653, Tank Inspection, Repair, Alteration, and Reconstruction

AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASME Section IX, Boiler and Pressure Vessel Code

AMERICAN SOCIETY FOR TESTING AND MATERIALS

ASTM D975, Standard Specification for Diesel Fuel Oils

ASTM F1449, Standard Guide for Industrial Laundering of Flame, Thermal, and Arc
Resistant Clothing

ASTM 5798 Standard Specification for Fuel Ethanol (Ed75-Ed85) for Automotive Spark-
Ignition Engines

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ASTM 6751, Standard Specification for Biodiesel Fuel Stock (B100) for Middle Distillate
Fuels

AMERICAN WATER WORKS ASSOCIATION

AWWA C203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines—
Enamel and Tape—Hot Applied

AWWA C209, Standard for Cold-Applied Tape Coatings for the Exterior of Special
Sections, Connections, and Fittings for Steel Water Pipelines

AWWA C210 Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water
Pipelines

AWWA C213 Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water
Pipelines

AWWA C215 Extruded Polyolefin Coatings for the Exterior of Steel Water Pipelines

AWWA C216 Heat-Shrinkable Cross-Linked Polyolefin Coatings for the Exterior of Special
Sections, Connections, and Fittings for Steel Water Pipelines

AWWA C217 Petrolatum and Petroleum Wax Tape Coatings for the Exterior of
Connections and Fittings for Steel Water Pipelines

\2\ DEFENSE LOGISTICS AGENCY

DLA-Energy P-22, Procedures for Requisition, Funding Requests, or Reimbursement of

Filter/Coalescer Elements /2/

DEPARTMENT OF ENERGY

DOE/GO-102016, Handbook for Handling, Storing, and Dispensing E85 and Other
Ethanol-Gasoline Blends

FEDERAL SPECIFICATION

L-C-530C Coating, Pipe, Thermoplastic Resen

DEPARTMENT OF DEFENSE

\2\ DoD Standard Design AW 78-24-27, Aboveground Vertical Steel Fuel Tanks with Fixed
Roofs /2/

DoD Standard Design AW 78-24-28 Pressurized Hydrant Fueling System

DoD 4140.25-M Volume V, Management of Bulk Petroleum Products, Storage, and

Distribution Facilities

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ARMY CORPS OF ENGINEERS

EM 385-1-1, Safety and Health Requirements Manual

UNITED STATES MILITARY DETAIL SPECIFICATION SHEET

MIL-DTL-24441/29, Paint, Epoxy-Polyamide, Green Primer, Formula 150, Type IV

MIL-DTL-24441/31, Paint, Epoxy-Polyamide, White, Formula 152, Type IV

UNITED STATES MILITARY PERFORMANCE SPECIFICATION

MIL-PRF-4556 Coating Kit, Epoxy, For Interior of Steel Fuel Tanks

UNITED STATES MILITARY STANDARD

MIL-STD-3004, Quality Assurance/Surveillance for Fuels, Lubricants and Related

Products

MIL-STD-3007G, Standard Practice for Unified Facilities Criteria and Unified Facilities
Guide Specifications

AIR FORCE

AFI 23-201, Fuels Management

AFI 32-1065, Grounding Systems

\2\ \1\ DAFMAN 91-203, Air Force Occupational Safety, Fire, And Health Standards /1/ /2/

T.O. 37-1-1, General Operation and Inspection of Installed Fuel Storage and Dispensing
Systems

United States Air Force Europe (USAFE) Volume 1 General Description and Operation

USAFE Volume 2 Maintenance and Repair, Standardization Agreement (STANAG) 3609

Standards for Maintenance of Fixed Aviation Fuel Receipt, Storage and Dispensing
Systems

NAVY

\2\ /2/

NATIONAL ASSOCIATION OF CORROSION ENGINEERS

NACE RP 0402, Field-Applied Fusion-Bonded Epoxy (FBE) Pipe Coating Systems for
Girth Weld Joints: Application, Performance, and Quality Control

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NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 1, Fire Code

NFPA 10, Standard for Portable Fire Extinguishers

NFPA 30, Flammable and Combustible Liquids

NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages

NFPA 45, Standard on Fire Protection for Laboratories using Chemicals

NFPA 52 Vehicular Gaseous Fuel Systems Code

NFPA 58, Liquefied Petroleum Gas Code

NFPA 70, NEC, National Electrical Code

NFPA 70, NEC, Article 501, Class I Locations for Class I liquids

NFPA 70E, Standard for Electrical Safety in the Workplace

NFPA 77, Recommended Practice on Static Electricity

NFPA 2112, Standard on Flame-Resistant Garments for Protection of Industrial Personnel

Against Flash Fire

NFPA 2113, Selection, Care, Use, and Maintenance of Flame-Resistant Garments for
Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire

PETROLEUM EQUIPMENT INSTITUTE

PEI/RP900, Recommended Practices for Inspection and Maintenance of UST Systems

STEEL TANK INSTITUTE

STI Standard for the Inspection of Aboveground Storage Tanks, SP001

UNDERWRITERS LABORATORY

UL 58, Standard for Steel Underground Tanks for Flammable and Combustible Liquids

UL 142, Standard for Steel Aboveground Tanks for Flammable and Combustible Liquids

UL 1316 Glass-Fiber-Reinforced Plastic Underground Storage Tanks for Petroleum

Products, Alcohols, and Alcohol-Gasoline Mixtures

UL 2080 Standard for Fire Resistant Tanks for Flammable and Combustible Liquids

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UL 2085, Standard for Protected Aboveground Tanks for Flammable and Combustible
Liquids

UNIFIED FACILITIES CRITERIA

\1\ UFC 3-110-03, Roofing /1/

UFC 3-430-07, Operations and Maintenance: Inspection and Certification of Boilers and
Unfired Pressure Vessels

UFC 3-460-01, Design: Petroleum Fuel Facilities

UFC 3-570-06, Operation and Maintenance: Cathodic Protection Systems

UFC 3-575-01, Lightning and Static Electricity Protection Systems

UFC 3-600-01, Fire Protection Engineering for Facilities

UFC 3-601-02, Operation and Maintenance: Inspection, Testing, and Maintenance of Fire
Protection Systems

UFC 4-150-07, Maintenance and Operation: Maintenance of Waterfront Facilities

\2\ UFC 4-150-08, Mooring Hardware Inspection /2/

\2\ UFC 4-159-03, Moorings /2/

UNIFORM FIRE CODE

UFC Article 52, Motor Vehicle Fuel Dispensing Stations: Public and Private Operations

UFC Article 79 Flammable and Combustible Liquids

UNIFIED FACILITIES GUIDANCE SPECIFICATIONS

UFGS 09 97 13.15, Low VOC Polysulfide Interior Coating of Welded Steel Petroleum Fuel
Tanks

UFGS 09 97 13.17, Three Coat Epoxy Interior Coating of Welded Steel Petroleum Fuel
Tanks

\2\ UFGS 09 97 13.27, High Performance Coating for Steel Structures /2/

UFGS 33 08 55, Commissioning of Fuel Facility Systems

\2\ \1\ UFGS 33 52 23.15, POL Service Piping Welding /1/ /2/

UFGS 33 52 43.11, Aviation Fuel Mechanical Equipment

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UFGS 33 52 43.12, Aviation Fuel Pantographs

UFGS 33 52 43.13, Aviation Fuel Piping

UFGS 33 52 43.14, Aviation Fuel Control Valves

UFGS 33 52 43.23, Aviation Fuel Pumps

UFGS 33 52 43.28, Filter Separator, Aviation Fueling System

UFGS 33 52 80, Liquid Fuels Pipeline Coating System

\2\ \1\ UFGS 33 57 55, Fuel Systems Components (Non-Hydrant) /1/ /2/

CODE OF FEDERAL REGULATIONS

29 CFR 1910.1450, Occupational Exposure to Hazardous Chemicals in Laboratories

29 CFR 1910, Subpart P / OSHA 3080, Hand and Power Tools)

33 CFR Part 154, Facilities Transferring Oil or Hazardous Materials in Bulk

33 CFR Part 156, Oil and Hazardous Material Transfer Operations

40 CFR Part 112, Oil Pollution Prevention

40 CFR Part 280, Technical Standards and Corrective Action Requirements for Owners
and Operators of Underground Storage Tanks

49 CFR Part 195, Transportation of Hazardous Liquids by Pipeline

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