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SECTION 33 52 43.13
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NOTE: This guide specification covers the
requirements for piping and valves for aircraft
refueling systems constructed to the requirements of
the DoD Type III/IV/V, and Cut'n Cover Hydrant
Refueling System Standards. DoD Type III systems
shall conform to Standard Design 078-24-28
PRESSURIZED HYDRANT FUELING SYSTEM (TYPE III). DoD
Type IV/V systems shall conform to Standard Design
078-24-29 AIRCRAFT DIRECT FUELING SYSTEM (TYPE IV)
DESIGN.
PART 1 GENERAL
1.1 REFERENCES
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NOTE: This paragraph is used to list the
publications cited in the text of the guide
specification. The publications are referred to in
the text by basic designation only and listed in
Page 1
this paragraph by organization, designation, date,
and title.
Page 2
AMERICAN WELDING SOCIETY (AWS)
Page 3
ASTM INTERNATIONAL (ASTM)
Page 4
BRITISH STANDARDS INSTITUTE (BSI)
Page 5
Bulk Petroleum Products Systems Including
Hydrocarbon Missile Fuels
Manual Valves
Flexible Ball Joints
Surge Suppressor Tank and Valve
Strainers
Protective Coatings
Sample Connections
Isolating Gasket Kits
Gaskets
Flexible Hoses
1.3 SUBMITTALS
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NOTE: Review submittal description (SD) definitions
in Section 01 33 00 SUBMITTAL PROCEDURES and edit
the following list to reflect only the submittals
required for the project. Submittals should be kept
to the minimum required for adequate quality control.
Page 6
designation to indicate the approving authority.
Codes for Army projects using the Resident
Management System (RMS) are: "AE" for
Architect-Engineer; "DO" for District Office
(Engineering Division or other organization in the
District Office); "AO" for Area Office; "RO" for
Resident Office; and "PO" for Project Office. Codes
following the "G" typically are not used for Navy,
Air Force, and NASA projects.
Pneumatic Test
Hydrostatic Test
Geometry Tool Reports[; G][; G, [_____]]
SD-07 Certificates
Welding
Welding qualified Procedures[; G][; G, [_____]]
Qualifications of Welding Inspectors
Qualifications of Welders
Fittings
Surge Suppressor Tank and Valve[; G][; G, [_____]]
Isolating Gasket Kits
Survey final elevations
Pipeline Pigging Verification[; G][; G, [_____]]
Page 7
Operation and Maintenance Manuals[; G][; G, [_____]]
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NOTE: Specify as directed by the COMMAND FUELS
FACILITY Engineer.
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Welders found making defective welds shall be removed from the work or
shall be required to be requalified in accordance with ASME B31.3.
]PART 2 PRODUCTS
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NOTE: Per COMMAND FUELS FACILITY Engineer.
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Pipe and fittings in contact with fuel shall be stainless steel, interior
epoxy coated carbon steel, or carbon steel as indicated on the drawings.
No zinc coated metals, brass, bronze or other copper bearing alloys shall
be used in contact with the fuel. All carbon steel and stainless steel
underground piping shall have an exterior protective coating and shall be
Page 8
cathodically protected in accordance with Section [26 42 19.00 20 CATHODIC
PROTECTION BY IMPRESSED CURRENT] [26 42 17.00 10 CATHODIC PROTECTION SYSTEM
(IMPRESSED CURRENT)]. Identification of piping shall be in accordance with
MIL-STD-161 unless specified otherwise. Material for manual valves shall
be as specified hereinafter.
a. Piping 305 mm 12-Inches and Larger: Seamless, ASTM A 53/A 53M Grade B
having a wall thickness of 9 mm 0.375-inch.
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NOTE: Pipe smaller than 75 mm (3-Inches) can not be
Coated. Per COMMAND FUELS FACILITY Engineer.
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Before applying the epoxy coating, the inside of the pipe shall be
sandblasted to "white" metal conforming with SSPC SP 5/NACE No. 1. If the
pipe is not internally epoxy lined immediately after cleaning, a rust
preventative coating shall be applied. The rust preventative shall be
approved by the epoxy manufacturer. The ends of the pipe shall be masked
or wiped back a minimum of 25 mm one inch but not more than 37 mm 1-1/2
inches.
After the top coat has cured, the internal epoxy lining shall be tested
electrically using an approved holiday detector and shall be free of
holidays. The ends of the pipe shall then be capped. The shop doing the
application shall have a minimum of five years of experience at applying
internal epoxy coating. The application and holiday testing at the shop
shall be available for inspection at any time by the Contracting Officer.
The shop shall notify the Contracting Officer at least one week before the
pipe and fittings will be cleaned and epoxy coated. Provide a certified
technical representative of the epoxy manufacturer to make at least three
separate inspection trips with at least one day in the shop per trip. Each
trip report shall be submitted to the Contracting Officer. Pipe 62 mm
2-1/2-inches and smaller shall not be interior coated.
Page 9
2.1.2 Stainless Steel Piping
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NOTE: A cyclic fatigue analysis need not be made by
the designer to determine wall thickness of welded
pipe as long as the pipe meets the sizes listed in
TABLE A. The minimum wall thickness that welded
pipe can be is the Schedule 20 listed in TABLE A.
Pressures found in the surge analysis will be used.
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(2) Pipe Ends: All Piping shall be provided with beveled ends per
Chapter V, ASME B31.3, and shall be shipped with the ends capped.
(3) Seam and End Welds: All sections of the piping provided shall be
accepted on the project site if the seam welds meet the
requirements of the paragraph K341 of ASME B31.3 and Appendix 4 of
ASME BPVC SEC VIII D1. One hundred spots may be reinspected at
the project site prior to installation and backfilling at the
request of the Contracting Officer. End welds shall be properly
aligned prior to welding per Chapter V of the ASME B31.3; welds
found to be defective shall be repaired at no additional cost to
the government. Observation by the Contracting Officer of the
manufacturing and field procedures shall be allowed under this
contract.
Page 10
by the Contracting Officer of the manufacturers and the fields
testing and inspection procedures shall be allowed under this
contract. Pipe certification along with pipe markings shall be
submitted before the pipe arrives on the job site.
(8) Submit Quality Assurance Plan for the welding, inspecting and
testing of the welded seam pipe.
TABLE A
Page 11
2.1.3 Protective Coatings for Aboveground Piping
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NOTE: Per COMMAND SERVICE HEADQUARTERS Engineer for
marine environment. Pipe cleaning for severe or
marine environment for lenght of line; pipe mostly
abovegradeand long lengths should consider using
Section 09 97 13.27. pipe cleaning per SSPC SP
6/NACE No.3 will give good surface cleaning but will
not get rust or paint from the bottom of the pits.
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NOTE: The individual A and B components of the
various formulas are not interchangeable.
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Page 12
mixing the components together. After mixing equal volumes of the two
components, this mixture shall again be thoroughly stirred until well
blended. The induction time shall be adhered to, to ensure complete
chemical reactions. Induction time is defined as the time immediately
following the mixing together of components A and B during which the
critical chemical reaction period of these components is initiated
until the mixture is ready for application. This reaction period is
essential to ensure the complete curing of the coating. Volumetric
mixing spray equipment with in-line heaters set at 21-27 degrees C 70
to 80 degrees F may be used without an induction period.
The mixed paint should not be allowed to remain in spray equipment for an
extended period, especially in the sun of a warm area. The paint cures
more rapidly at higher temperatures. When components A and B are mixed
Page 13
together, the pot life of the mixture (including the induction time is 6
hours at 21 degrees C 70 degrees F. Pot life is longer at lower
temperatures and shorter at temperatures above 21 degrees C 70 degrees F.
Spray equipment should be cleaned after using by flushing and washing with
epoxy thinner or aromatic hydrocarbon thinners (xylene or high flash
aromatic naphtha). General cleanup is also done by using these solvents.
Brushes and rollers should be given a final cleaning in warm soapy water,
rinsed clean with warm fresh water and hung to dry.
2.1.5 Fittings
2.1.5.1 General
Page 14
Welding ells, caps, tees, reducers, etc., shall be of materials compatible
for welding to the pipe line in which they are installed, and wall
thickness, pressure and temperature ratings of the fittings shall be not
less than the adjoining pipe line. Unless otherwise required by the
conditions of installation, all elbows shall be the long radius type.
Miter joints are not acceptable. Make odd angle offsets with pipe bends or
elbows cut to the proper angle. Butt weld fittings shall be factory-made
wrought fittings manufactured by forging or shaping. Fabricated fittings
will not be permitted. Welding branch fittings shall be insert type
suitable for radiographic inspections specified herein.
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NOTE: Tees with branch lines 50 percent of the main
line size or more should have guide bars in piggable
systems.
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Page 15
as the welded seam pipe and meet the same requirements as for the
pipe. Elbows located between the pig launcher and the receiver, shall
have a radius three times the pipe diameter. Tees with branches 150 mm
6-inches and larger, shall have guide bars as detailed on the drawings.
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NOTE: Check system pressures, as Type 304L
stainless steel flanges have a pressure rating of 2
MPa (230 PSIG).
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Page 16
microsecond wave form at 50,000 Amperes peak measured at the device
terminals (zero lead length).
f. A UL listed arrester for installation in Class 1, Division 2, Group
D, hazardous areas.
Install the mounting bracket and leads on the flange side of the bolt
insulating sleeve and washer, and size in accordance with this schedule:
Bolts and nuts for pipe flanges, flanged fittings, valves and accessories
shall conform to ASME B18.2.1 and ASME B18.2.2, except as otherwise
specified. Bolts shall be of sufficient length to obtain full bearing on
the nuts and shall project no more than three full threads beyond the nuts
with the bolts tightened to the required torque. Bolts shall be regular
hexagonal bolts conforming to ASME B18.2.1 with material conforming to
ASTM A 193/A 193M, Class 2, Grade B8, stainless steel, when connections are
made where a stainless steel flange is involved, and Grade B7 when only
carbon steel flanges are involved. Bolts shall be threaded in accordance
with ASME B1.1, Class 2A fit, Coarse Thread Series, for sizes 25 mm one inch
and smaller and Eight-Pitch Thread Series for sizes larger than 25 mm one
inch. Nuts shall conform to ASME B18.2.2, hexagonal, heavy series with
material conforming to ASTM A 194/A 194M, Grade 8, stainless steel for
stainless steel bolts, and Grade 7 for carbon steel bolts. Nuts shall be
threaded in accordance with ASME B1.1, Class 2B fit, Coarse Thread Series
for sizes 25 mm one inch and smaller and Eight-Pitch Thread Series for
sizes larger than 25 mm one inch. Provide washers under bolt heads and
nuts. Washers to be ASTM F 436, flat circular stainless steel for
stainless steel bolts, and carbon steel for carbon steel bolts. Torque
wrenches shall be used to tighten all flange bolts to the torque
recommended by the gasket manufacturer. Tightening pattern shall be as
Page 17
recommended by the gasket manufacturer. Anti-seize compound shall be used
on stainless steel bolts.
2.1.7 Gaskets
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NOTE: Per COMMAND FUELS FACILITY Engineer.
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Pressure relief valve discharge lines and drain lines to the product
recovery tank shall be Schedule 40 [API Spec 5L Grade B or ASTM A 53/A 53M
Grade B Carbon Steel] [ASTM A 312/A 312M seamless Type 304L Stainless
Steel]. See Gaskets specified herein before.
Pipe shall be factory coated as specified herein before for steel piping.
The field joints and fittings of all underground piping shall be coated as
herein specified.
Fittings and other irregular surfaces shall be tape wrapped. The tape
shall be a plastic mastic laminated tape having 0.15 mm 6 mil plastic
backing of either polyethylene or polyvinylchlorine and 0.72 to 2.4 mm 29
to 44 mil of synthetic elastomer.
Page 18
Welded joints in steel pipe shall be as specified in Part 3.
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NOTE: Per COMMAND SERVICE HEADQUARTERS Engineer for
marine environment, provide stainless steel valves
on exterior (aboveground and in pits) piping.
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All portions of a valve coming in contact with fuel in stainless steel pipe
lines or epoxy lined carbon steel pipe lines shall be of noncorrosive
material. Valves in stainless steel pipe lines or epoxy lined carbon steel
pipe lines shall be Type 304 or Type 316 stainless steel or carbon steel
internally plated with chromium or nickel or internally electroless nickel
plated. Valves in unlined carbon steel pipelines shall have carbon steel
body. Stem and trim shall be stainless steel for all valves. Manually
operated valves 150 mm 6 inches and larger shall be worm-gear operated and
valves smaller than 150 mm 6 inches shall be lever operated or handwheel
operated. Valves smaller than 50 mm 2 inches shall have lever-type
handles. Valves installed more than 2.4 m 8 feet above finished floor
shall have chain operators and a position indicators visible from ground
level. Sprocket wheel for chain operator shall be aluminum. Valves in the
isolation pits in fuel piping between the pig launchers and the pig
receivers shall be full bore, piggable, double block and bleed type. The
full bore piggable valves at the launcher and the receiver shall be ball
type.
Ball valves shall be fire tested and qualified in accordance with the
requirements of API Std 607 and API STD 608. Ball valves shall be
nonlubricated valves that operate from fully open to fully closed with 90
degree rotation of the ball. Valves 50 mm 2 inches and larger shall
conform to applicable construction and dimension requirements of API Spec 6D,
ANSI Class 150 and shall have flanged ends. Valves smaller than 50 mm 2
inches shall be ANSI class 150 valves with one piece bodies with flanged
ends, unless noted otherwise. The balls in valves 254 mm 10 inches full
port and 305 mm 12 inch regular port and larger shall have trunnion type
support bearings. Except as otherwise specified, reduced port or full port
valves may be provided at the Contractor's option. Balls shall be solid,
not hollow cavity.
2.2.1.1 Materials
Ball valves shall be designed, manufactured, and tested to API Spec 6D,
fire-safe and tested to API Spec 6FA, API Std 607, and BS EN ISO 10497 (BS
6755, Part 2). Valves shall be trunnion-mounted with independent spring
and hydraulically actuated, floating, single piston effect, self-relieving
seat rings, with bi-directional sealing. Ball shall be solid type with
full through-conduit opening, suitable for passage of pipeline pigs. Stem
shall be anti-static, blow-out-proof design with o-ring seals and provided
Page 19
with an emergency sealant injection fitting. Valves shall be 3-piece,
bolted body design with raised-faced ANSI Class 150 flanged connections,
equipped with body drain/bleed valve and vent fitting, and suitable for
double block and bleed service in the closed and open positions. Valves
shall be all stainless steel construction, or carbon steel with stainless
steel stem, and all wetted parts electroless nickel-plated. Valves shall
have nylon or teflon seat inserts, viton B body, stem, and seat o-rings,
with stainless steel and graphite body gaskets and graphite secondary stem
seals. Valves located in vaults or pits shall be equipped with actuator
extensions.
Electric valve actuator shall be as indicated for Plug (Double Block and
Bleed) Valves, electric valve actuator.
API Spec 6D, Type III, ANSI Class 150, non-lubricated, resilient, double
seated, trunnion mounted, tapered lift plug capable of two-way shutoff.
Valve shall have tapered plug of steel or ductile iron with chrome or
nickel plating and plug supported on upper and lower trunnions. Sealing
slips shall be steel or ductile iron, with Viton seals which are held in
place by dovetail connections. Valve design shall permit sealing slips to
be replaced from the bottom with the valve mounted in the piping. Valves
shall operate from fully open to fully closed by rotation of the handwheel
to lift and turn the plug. Valves shall have weatherproof operators with
mechanical position indicators. Indicator shaft shall be stainless steel.
Minimum bore size shall be not less than 65 percent of the internal cross
sectional area of a pipe of the same nominal diameter unless bore height of
plug equals the nominal pipe diameter and manufacturer can show equal or
better flow characteristics of the reduced bore size design. Full port
plug valves in distribution piping shall be provided with a 25 mm 1-inch
flanged body drain.
2.2.2.1 General
Valves in the operating tank suction and fill lines and the valves at the
four valve manifold in the pump room in the tank fill lines shall be
provided with a factory-installed limit switch that is actuated by the
valve closure. Each switch shall have one double pole double throw
contacts or four single pole, double throw contracts, two for open, two for
closed, and shall be watertight and U.L. listed for Class I, Division 1,
Group D hazardous areas.
Rotation of the handwheel toward open shall lift the plug without wiping
the seals and retract the sealing slips so that during rotation of the plug
clearance is maintained between the sealing slips and the valve body.
Rotation of the handwheel toward closed shall lower the plug after the
sealing slips are aligned with the valve body and force the sealing slips
against the valve body for positive closure. When valve is closed, the
slips shall form a secondary fire-safe metal-to-metal seat on both sides of
the resilient seal. Plug valves located in Isolation Valve Pits or vaults
shall be provided with handwheel extensions.
Page 20
ANSI Class 150. Provide plug valves with automatic thermal relief valves
to relieve the pressure build up in the internal body cavity when the plug
valve is closed. Relief valves shall open at 175 kPa 25 psi differential
pressure and shall discharge to the throat of, and to the upstream side, of
the plug valve.
ANSI Class 150, stainless steel body valve. Provide manually operated
bleed valves that can be opened to verify that the plug valves are not
leaking when in the closed position.
e. The actuator shall integrally contain local controls for Open, Close
and Stop and a local/remote three position selector switch: Local
Control Only, Off, and Remote Control plus Local Stop Only. A metallic
Page 21
handwheel shall be provided for emergency operation. The handwheel
drive must be mechanically independent of the motor drive. The remote
control capablity shall be to open and close. Rim pull to operate
valve manually shall not exceed 28 kg 80 pounds.
h. The actuator shall have a local display of position even when power has
been lost.
Swing check valves shall conform to applicable requirements of API Spec 6D,
regular type, ANSI Class 150 with flanged end connections. Check valves
shall conform to API STD 600 and be swing type with material as previously
indicated herein. Discs and seating rings shall be renewable without
removing the valve from the line. The disc shall be guided and controlled
to contact the entire seating surface.
Relief valves shall be the fully enclosed, spring loaded, angle pattern,
single port, hydraulically operated type with plain caps, and shall be
labeled in accordance with ASME BPVC SEC VIII D1. Valve stems shall be
fully guided between the closed and fully opened positions. The valves
shall be factory-set to open at 1.8 MPa 265 psi unless otherwise indicated
on the drawings. Operating pressure shall be adjustable by means of an
enclosed adjusting screw. The valves shall have a minimum capacity of 1.3
L/s 20 GPM at 10 percent overpressure. Valves shall have a replaceable
seat. Relief valves that do not relieve to a zone of atmospheric pressure
or tank must be a balanced type relief or regulator valve.
Valves shall have carbon steel bodies and bonnets with stainless steel
Page 22
springs and trim. Valves shall be Class 150 flanged end connections.
Sight flow indicators shall be ANSI Class 150 and shall have flanged end
connections. Sight flow indicators shall consist of a housing containing a
rotating propeller that is visible through a glass observation port. The
housing shall be stainless steel when installed in stainless steel lines
and carbon steel when installed in carbon steel lines. The glass in the
indicator shall also meet the Class 150 rating.
Pipe sleeves shall be installed where indicated and at all points where the
piping passes through concrete construction. Such sleeves shall be of
sufficient inside diameter to provide a minimum clear distance between the
pipe and the sleeve of 13 mm 1/2-inch. Sleeves through concrete pits or
slabs shall be standard weight carbon steel pipe with a protective
coating. Each sleeve shall extend through the respective pit wall or slab
and shall be provided with a Buna-N casing seal. Sleeves where piping
passes under roads or piping indicated to be double walled shall be
standard weight carbon steel pipe with a protective coating as previously
specified. Alignment of the sleeve and piping shall be such that the pipe
is accurately centered within the sleeve by a nonconductive centering
element. The sleeve shall be securely anchored to prevent dislocation.
Closure of space between the pipe and the pipe sleeve shall be by means of
a mechanically adjustable segmented elastomeric seal. The seal shall be
installed so as to be flush.
2.4.3 Strainers
Page 23
glass cylinder, with high pressure applied on top of the piston and low
pressure applied below it. Under a differential pressure of 21 kPa 30 PSI,
leakage past the piston shall not exceed 120 drops per minute. The
cylinder shall have stainless steel and flanges with Viton O-ring seals.
The high pressure inlet of the gauge shall have a 10-micron pleated paper
filter and the low pressure connection shall have a fine mesh stainless
steel strainer. The gauge shall have an operating pressure of 210 kPa 300
PSI. Differential pressure range of the gauge through approximately 75 mm
3 inches of piston movement shall be 0-21 kPa 0-30 PSI with an accuracy of +
0.034 0.5 PSI, calibrated linearly with one kPa PSI scale graduations.
High and low pressure connections shall be 6 mm 1/4 inch NPT female with a
stainless steel bar stock valve at each connection. Construction of the
gauge shall be such that a 3-valve manifold is not necessary. If only one
bar stock valve is closed, the gauge shall not be damaged by up to 210 kPa
300 PSI differential pressure in either direction. A pressure gauge shall
be attached to the differential pressure gauge to indicate the high
pressure and have a range of 210 kPa 300 psi.
Strainer shall be stainless steel type 304 or 316, 100 mesh screen with the
ratio of net open area of strainer to the area of the connecting pipe shall
be not less than three to one at the pump suction, and 4 mm 5/32-inch
perforations and suitable for bi-directional flow at the inlet to the
hydrant pit control valves.
2.4.4.1 General
Pipe hangers and supports shall conform to MSS SP-58 and MSS SP-69.
Supports shall be provided at the indicated locations. Support channels
for drain lines shall be epoxy coated on all surfaces or hot-dip galvanized
after the channels are cut to length. Coated supports shall be coated with
fusion bonded epoxy resin applied by the fluidized bed method. Thickness
of the coating shall be not less than 0.25 mm 10 mils. Surface preparation
and coating application shall be in accordance with the epoxy
manufacturer's instructions. The coating shall be pinhole free when tested
with a low voltage holiday detector set at no more than 100 times the mm mil
thickness of the coating. All pinholes shall be marked, repaired and
retested to ensure a pinhole free film. The coating material shall be a
100 percent solids, thermosetting, fusion-bonded, dry powder epoxy resin.
The manufacturer shall certify that the material is suitable for fluidized
bed application and that it is approved by the Environmental Protection
Agency. A teflon pad shall be installed between the pipe and the u-bolt.
Adjustable pipe supports shall consist of a cast iron saddle and a threaded
nipple connected to a carbon steel pipe by means of a special reducer
conforming to MSS SP-69. The supports shall be provided with teflon
insulation strips.
Page 24
2.4.4.4 Concrete and Grout
Concrete and grout for anchors and supports shall comply with SECTION
03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE.
d. At both sides of the isolation valve in all the isolation valve pits.
Page 25
Fuel hose shall conform to API Std 1529, Grade 2, Type C, threaded, male
NPT, both ends.
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NOTE: Specify type of nozzle as directed by the
COMMAND FUELS FACILITY Engineer.
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Nozzles shall conform to SAE AS5877, Type [D-1] [D-2] [D-3]. Nozzles and
nozzle components shall be compatible with the fuel to be handled. Nozzles
shall be provided with an internal 60 mesh stainless steel strainer and a
fuel sample connection tapping. Nozzle design shall be for single point
fueling of aircraft. Nozzles shall be provided with a compatible dry break
quick disconnect swivel. Coupler shall allow for quick disconnect and
reconnect of fueling nozzles with corresponding adapters. Coupler and
adapter shall provide a positive, leak proof connection under constant or
surge flow. Coupler shall be designed to prevent blowout of internal
poppet.
The closure shall be hinged, swing bolted closure of the same material as
the pipe and for a Class 150 system. Gasket shall be nitrile. Eye bolts
shall be pinned to lugs on the hub.
2.4.11.2 Signaler
The pig signaler shall be mechanical flag type with manual reset, and be
located on the pig launcher and the pig receiver. Material in contact with
the fuel shall be stainless steel. Units shall be suitable for removal and
installation under line pressure of 275 psig. Signaler shall be capable of
withstanding line pressure of a Class 150 system.
Flexible hoses for fueling pumps shall have ANSI Class 300 flanges to mate
to the pump and Class 150 to connect to the system flanges of stainless
steel construction conforming to ASME B16.5. Flexible hoses shall be of
stainless steel flexible metal hose consisting of an inner corrugated
stainless steel tube with stainless steel braid cover. All components to
be suitable for not less than 2 MPa 275 psig. Length and application of
flexible hoses shall be per manufacturer's written recommendations.
Unit shall have 25 mm one-inch connections and automatically vent air under
pressure, and prevent a vacuum when pressure drops below a positive
Page 26
pressure. As fuel fills the vent, a float shall rise and form a drip-tight
closure. The unit pressure rating shall be a minimum of 2 MPa 275 psi.
The float shall be stainless steel. Body and cover be carbon steel or
ductile iron and be internally epoxy coated.
The unit shall be fabricated from carbon steel, internally coated pressure
vessel with a rubber bladder or a stainless steel diaphram separating the
fuel from the gas charge. The epoxy coating shall be in accordance with
MIL-PRF-4556. The rubber bladder shall be molded synthetic nitrile rubber
(Buna-N). The unit shall be constructed and labeled in accordance with
ASME BPVC SEC VIII D1. The housing shall be designed for a working
pressure of 2 MPa 275 PSIG. The gas precharge shall be dry nitrogen and
shall have a pressure gauge, gas valve, and an adapter for field charging.
Bladder precharge pressure shall be 1 MPa 80 PSIG. The connection to the
piping system shall be Class 150 ANSI flange, size as indicated on the
drawings. The connection shall have a check valve to provide unrestricted
flow into the vessel and restricted flow from the vessel. The flange shall
have a 13 mm 1/2-inch NPT connection with a valve and adapter to relieve
fluid pressure during gas recharging and to drain the vessel during
removal. A charging assembly shall be provided. The surge control
supplier shall furnish a service person trained to provide installation
check-out assistance and to supervise operation and testing necessary to
place the surge control system into service and to provide training on
charging, recharging, and checking the surge suppressor.
PART 3 EXECUTION
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NOTE: Specify as directed by the COMMAND FUELS
FACILITY Engineer.
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After becoming familiar with details of the work, verify dimensions in the
field, and advise the Contracting Officer of any discrepancy before
performing any work.
Keep the interior and ends of all new piping, affected by construction
operations, thoroughly cleaned of foreign matter and water before and after
being installed. Piping systems shall be kept clean during installation by
means of plugs or other approved methods. When work is not in progress,
open ends of piping and fittings shall be closed so that no water or other
foreign substance will enter the pipes or fittings. Piping shall be
inspected before placing into position. The interior of each length of
pipe shall be cleaned after welding insuring that the interior of the
piping is free of foreign matter when it is connected into the system.
Page 27
meet the requirements of Section 31 00 00 EARTHWORK, paragraph "Select
Granular Material". The full length of each section of pipe without any
protective covering shall be excavated to permit installation of the
protective covering. Pipe that has the grade or joint disturbed after
laying, shall be taken up and relaid. Pipe shall not be laid in water or
when the trench or weather conditions are unsuitable for such work. After
testing and application of protective covering to joints, sand backfill
shall be placed and compacted around the pipe or protective coating to a
depth of 305 mm 1 foot above top of pipe. The remainder of the backfill
shall be the same as for other types of pipe.
Keep piping, control tubing, which is not detailed close to structures and
columns so as to take up a minimum amount of space. Ensure that access is
provided for maintenance of equipment, valves and gauges.
3.4.4 Location
3.4.7 Grade
Where profiles of piping lines are shown on the drawings, grade the line
uniformly between changes in slope or direction. Maintain gradient to
Page 28
within + 6 mm 1/4-inch over the entire length of pipe. When backfilling
has been completed to the top of the pipe, the pipe shall be surveyed at
each joint, and logged by station number. Submit to the Contracting
Officer for approval the survey final elevations before backfilling can
continue.
Make changes in pipe size with reducing fittings. Do not use bushings. In
lieu of welding reducing outlet tees for piping 50 mm 2 inches and larger,
welding branches suitable for 100 percent radiographic inspection may be
used. Do not use weldolets unless specifically called out (labeled) on the
drawings.
3.5 WELDING
3.5.1 General
All joints, unless indicated otherwise, in carbon steel and stainless steel
piping systems shall be welded. [Welding of fuel pipe joints shall comply
with Section 33 52 90.00 20 WELDING FOR POL SERVICE PIPING.][ Unless
otherwise approved, all girth welds shall be complete penetration groove
welds made in accordance with qualified welding procedures. Welding
operations, qualifications of welders and welding procedures shall comply
with the provisions of ASME B31.3 and the requirements specified herein.
The root pass on stainless steel and carbon steel pipe shall be by the GMAW
or GTAW process.]
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NOTE: If Section 33 52 90.00 20 WELDING FOR POL
SERVICE PIPING is chosen, delete the rest of the
paragraph.
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d. Weld Preparation shall comply with the requirements of ASME B31.3 and
the qualified Welding Procedure Specification. The use of "rice paper"
as purge blocks is not permitted. Submit alternate method for
approval. Back purge gas shall be used for the root pass and hot pass
of all pipe welds. The use of flux-coated or cored welding rod is
prohibited in making the root pass.
e. Backing Rings. The use of backing rings for making or repairing welds
will not be permitted.]
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3.5.2 Tests
a. All steel pipe welds, except factory seam welds, including high point
vent pipe and low point drain pipe, shall be site examined by
radiographic methods to determine conformance to the paragraph
"Standards of Acceptance". Socket welds and branch connections which
can not be radiographed shall be examined per ASME B31.3, paragraph
341.4.3. All of the socket welds shall be examined, except the socket
welds on the non-pressurized drain lines in the [pumphouse] [filter
building] to the product recovery tank in which a minimum of 10 percent
shall be examined, and 10 percent of the socket welded pipe on the
tanks, and to the conformance of the paragraph "Standards of
Acceptance".
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b. Excessive Concavity of Weld, Undersized Welds, Undercutting: Clean
and deposit additional weld metal.
The removal of weld metal or portions of the base metal shall be done
preferably by chipping, grinding, sawing, machining, or other mechanical
means. Defects also may be removed by thermal cutting techniques. If
thermal cutting techniques are used, the cut surfaces shall be cleaned and
smoothed by mechanical means. In addition, at least 3 mm 1/8-inch of metal
shall be removed by mechanical means from the cut surfaces of stainless
steel.
3.5.4.3 Rewelding
The use of force (peening) or foreign materials to mask, fill in, seal, or
disguise any welding defects shall not be permitted.
3.6 INSTALLATION
3.6.1 Precautions
Take special care to ensure that the protective coating on buried pipe is
not damaged during installation and that the completed system is free of
rocks, sand, dirt, water, weld slag, and foreign objects including
construction debris. Take the following steps to ensure these conditions.
a. Coated pipe shall be handled only with canvas or nylon slings or padded
clamps. Any coating damaged by improper handling or storage shall be
repaired as specified.
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and capped against weather at all times, except to accommodate
immediate installation.
d. The open ends of the pipe system shall be closed at the end of each
day's work or when work is not in progress by use of expansion plugs
and shall not be opened until the work is resumed.
e. A swab, with a leather or canvas belt disc to fit the inside diameter
of pipe, shall be pulled through each length of pipe after welding in
place.
The condition of factory field coated and wrapped piping shall be the
responsibility of the Contractor and all damage to the protective covering
during transit and handling shall be repaired at no additional cost to the
Government. All field coating and wrapping shall be subject to approval by
the Contracting Officer. The entire pipe shall be inspected as specified
in sub-paragraph "Testing of Protective Coatings" under paragraph
"Protective Coatings for Buried Steel Piping." The inspection for holidays
shall be performed just prior to lowering the pipe into the ditch and every
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precaution shall be taken during lowering and backfilling to prevent damage
to the protective covering.
When internally epoxy lined pipe is cut, the lining shall be ground back
from the end a minimum of one inch but not more than 38 mm 1-1/2 inches.
Pipe shall be strung parallel and adjacent to or above a trench. The pipe
shall be supported on padded skids during welding and inspection of
joints. Protective coating shall be inspected and repaired prior to
lowering the pipe into the trench. The pipe shall be lowered using only
canvas or nylon slings. The sling shall be dug from underneath the pipe
after placements and shall not be pulled from underneath the pipe while in
contact with it. Care shall be taken to prevent damage to the pipe, welded
joints or coating and any such damage shall be repaired as directed by the
Contracting Officer. Pressure testing of the pipe shall be done after it
has been placed in final position in the trench.
For the purpose of early warning and identification of buried pipes outside
of building walls during future trenching or other excavation, continuous
identification tapes shall be provided in the trench. Provide metallic
core or metallic-faced, acid- and alkali-resistant, polyethylene plastic
warning tape manufactured for the purpose of early warning and
identification of utilities buried below the tape. Tape shall be at least
75 mm 3 inches in width. Color of tape shall be as standard with the
manufacturer with respect to the type of utility buried below the tape.
Tape shall have lettering at least 25 mm 1 inch high with warning and
identification imprinted in bold black letters continuously over the entire
tape length with not less than the following identification on the tape:
BURIED JET FUEL PIPING BELOW. Tape shall be installed in accordance with
the printed recommendations of the tape manufacturer, as modified herein.
Tapes shall be buried at a depth of 150 mm 6 inches from the top of the
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subgrade or 305 mm 12 inches below the top surface of earth. Provide
permanent color and printing, unaffected by moisture or soil.
3.8.3 Clearances
3.9 TESTING
Special safety measures, including the wearing of face mask, shall be taken
during testing under pressure. Only authorized personnel shall be
permitted in the area during testing. The pneumatic test pressure shall be
applied in increments. A preliminary 167 kPa 25 psig test shall be
applied. Examine joints with soap solution. Leaks revealed by this test
shall be repaired. The full test pressure shall then be applied. Unless
otherwise directed by the Contracting Officer, all piping shall be tested
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at a pressure of [667] [333] kPa [50] [100] psig for not less than 2 hours,
during which time there shall be no drop in pressure, only pressure rises
with temperature. The pressure source shall be disconnected during the
final test period. Any leaks revealed by the test shall be repaired and
the test repeated.
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NOTE: If the COMMAND FUELS FACILITY Engineer
directs the Designer to hydrostatically test the
system to 1.5 times the design pressure, exceeding
the flange rating, the Designer will be required to
write the commissioning hydrostatic testing
procedures; removing all ball valves, control
valves, and instructing the testing people what
valves to close, where to connect the hydrostatic
test pump, blind flange placements, and other safety
requirements.
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3.10.2 Workmanship
Verify pipe bend radii at pipe locations between pig launchers and
receivers. If a pipe bend is less than 3D, replace the bend.
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3.10.3 Pipeline Internal Inspection Operations
3.10.3.1 General
The following pigs will be propelled through the pipeline with product in
order to inspect the pipeline: 1.7 kg 5 pound density foam swab,
combination poly scraper-magnetic, stainless steel wire brush, aluminum
plate gauge, and geometry tool. Tracking devices shall be used on all
pigs. At a minimum, the sequence of pig runs shall be as follows: 1) foam
swab for proving and cleaning, 2) wire brush for cleaning, 3)
scraper-magnetic for cleaning, 4) aluminum plate gauge for gauging internal
anomalies, 5) scraper-magnetic for cleaning, 6) wire brush for cleaning, 7)
scraper-magnetic for cleaning, 8) foam swab for cleaning, (Note: the number
of pig flights of each type of cleaning pigs shall be determined by the
amount and type of debris removed. The conclusion of the cleaning process
shall be when debris recovered is only that from the pigs themselves. This
determination will be determined by the project's system supplier and the
contracting officier), 9) geomety tool. The pipe wall shall be
continuously monitored on a real-time basis during the geometry pig run.
Anomalies such as patches, couplings, or flanges shall also be identified,
and the wall thickness given. The geometry pig's technician will determine
if additional runs are necessary. A permanent data set of internal
inspection survey findings shall be generated.
The Government will bring to the attention of the Contractor all statutes,
rules and regulations relevant to the performance of the work on the site
(on Government property) and will also provide the Contractor with a copy
of its own site regulations (if any). Provide the pigging vendors with
all-available pipeline records and drawings.
**************************************************************************
NOTE: If pig a launcher and a receiver are not
provided in the contract, portable ones will be by
the Contractor during pigging operations.
**************************************************************************
The pig shall be loaded into the pig launcher by the Contractor. The
method of loading and lodging the front pig cup into the launcher shall not
involve the use of uncontrolled mechanical force applied to the rear of the
pig.
All pig runs shall be made with the line packed with product. The system
pumps will be used to propel the pig. The new pig traps will be used for
pig launch and retrieval.
Run a brush pig at least as often as previously indicated. The brush pig
shall be designed and provided by the geometry pig vendor. Additional runs
may be required based upon the amount of debris found in the pipeline. The
onsite geometry pig vendor's personnel shall determine if additional runs
Page 36
are required. Immediately following the brush pig run and immediately
prior to the geometry survey, run, as a minimum, a single batching pig
fitted with a gauge plate equal to 90 percent of the pipeline normal inside
diameter. The plate is to be a segmented aluminum disk of 3 mm 1/8 inch
thickness. The plate gauge pig shall also include a tracker and tracking
equipment. Track the pig assembly above ground during the operation.
After a satisfactory gauging pig run, the pipeline geometric defects shall
be determined by a geometry tool. The geometry tool shall provide accuracy
geometric anomaly detection, and bend radius measuring capability. The
data obtained shall be presented in a PC software format to allow user
friendly analysis and presentation. The geometry tool assembly shall be
capable of:
b. Traversing the pipeline with nominal wall thickness and possible bore
restrictions down to 90 percent of nominal pipe inside diameter.
e. Include a tracker and tracking equipment. Track the pig assembly above
ground during the operation. The battery life of the tracker shall not
be less than 72 hours.
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(2) mechanical damage such as mill defects, dents, internal
gouges, and buckles.
After a satisfactory cleaning, gauging, and geometry pig run, the pipeline
wall thicknesses shall be determined. The tool shall provide accuracy
measurement of pipe wall thickness (+/- 0.25 mm0.01 inch). The data
obtained shall be presented in a PC software format to allow user friendly
analysis and presentation.
The Contractor is responsible for a lost pig, finding the pig, retrieval of
the pig, and all repairs, radiographs to the pipeline system and the pig.
-- End of Section --
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