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PROJECT STANDARD SPECIFICATION

SECTION 15980 - JET A1 FUELING SYSTEM - INSPECTION, CLEANING, FLUSHING, AND

TESTING

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the contract, including conditions of contract and
Division 1 of the specification apply to this section.

1.2 RELATED SECTIONS

A. Division 13, “Jet A1 Fueling System – Cathodic Protection”

B. Division 15, “Jet A1 Fueling System – Basic Mechanical Requirement”
C. Division 15, “Jet A1 Fueling System – Piping Construction”
D. Division 15, “Jet A1 Fueling System – Coating And Corrosion”
E. Division 15, “Jet A1 Fueling System – Monitoring And Control
(EFSO & Leak Detection)”

PART 2 - PRODUCTS

2.1 EQUIPMENT

A. Contractor shall be responsible for furnishing all equipment required, including gauges,
instruments, connections, air compressors, fuel transport trucks, pipe and hose
connections, pumps, and other items specified or required to complete the field inspection,
cleaning, flushing, and testing functions for the subject fueling system.

B. Compressors used for air testing shall have sufficient capacity to bring the system being
tested up to the test pressure in approximately 20 minutes.

C. Jet A-1 Fuel will be provided by the Owner in sufficient quantities to support the
hydrotesting, flushing, and startup activities. The Jet A-1 Fuel will meet ASTM D 1655
requirements for kerosene Jet A-1 type aviation turbine fuel. Any Jet A-1 Fuel drained
out of existing hydrant lines and/or removed from the new hydrant piping during the
hydrotesting and flushing activities for the Jet A-1 Fuel piping system shall be returned to
the Owner.

PART 3 - EXECUTION

3.1 TESTING PROCEDURE

A. General: Testing of fuel piping shall be performed in accordance with ANSI B31.4.

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1. Perform holiday testing of coating systems on all piping prior to pressure testing
and backfilling.

2. Submit detailed procedures for flushing and testing methods for approval by
Engineer before starting pipe installations. This includes all radiographing, pressure
testing, and holiday testing.

3. Water shall not be used for testing or flushing fuel piping.

4. Sectionalize pipe lines as required to facilitate testing.

B. Responsibility of the Contractor:

1. Notify the proper authorities and the Engineer that items are ready for inspection
and testing. Advance notice of the approximate testing time shall be given to the
Engineer at least 7 days in advance of testing followed by not less than 48 hours
notice prior to actual time of performing any inspections and tests. Test results
shall be furnished to the Engineer within 48 hours after completion of each section
of pipe tested.

2. Furnish all necessary equipment, materials and personnel, including pumps,

compressors, gauges, testing equipment, gases and fluids, recording equipment,
utilities, valves, and craftsmen and all incidentals necessary to test and initially
start-up the fuel system. Valves shall be suitable to hold test pressure for the
specified time without leakage.

3. Conduct the tests of all systems in a safe manner and correct all deficiencies.

4. Apply the specified test pressures by means of a pump or compressor connected to

the piping off highest elevation.

5. Be fully responsible for providing qualified and experienced personnel to operate

the equipment throughout the testing and flushing operations.

6. Obtain all necessary approvals, acceptances, and permits.

7. Piping systems shall be tested before backfilling, concealing or covering.

8. Observe diligent care not to waste, spill or contaminate the fuel. The cost of all
fuel spilled, wasted or contaminated shall be paid for by the Contractor. The
Contractor shall also be responsible for any and all required soil remediation
deemed necessary by the Engineer at no additional cost to the Owner.

3.2 CLEANING

A. After all of the new fuel piping has been radiograph inspected and accepted, all piping
shall be cleaned by pigging or hand cleaning. Pigging will only be required if the existing
piping conditions dictates it, otherwise, hand cleaning, flushing as specified will suffice.
Contractor to submit a method statement for approval by the Engineer.

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B. Furnish the necessary materials, equipment, and labor to perform a satisfactory cleaning
operation.

C. The cleaning operations shall be continued for each section of the line until the line is
determined clean by the Engineer.

D. In case pigging is found necessary, as per Clause A above, piping shall be cleaned by
pulling a cleaning pig or swab through the lines prior to making final equipment
connections. It should be noted that the cleaning pig will not pass through the some types
of isolation valves . Provide and install pipe spools in place of these valves for the testing
and cleaning operation.

E. Immediately before flushing the Jet A-1 Fuel piping, all distribution piping, hydrant loop
piping and lateral piping installed as part of this Contract Package and all piping which
potentially may be affected (i.e., cleanliness) by the installation of the subject Contract
Package Jet A-1 Fuel piping shall be, subject to clause A above, pigged using plain
polyurethane foam pigs. Pigs shall have an inner core of 32 kg/cu. m density foam
surrounded by an 128 kg/cu. m density foam. Pigs shall have a parabolic nose and a
dished pressure seal rear end and foam sides. Pigs shall be Scarlet Bare Durafoam as
manufactured by the Girard Polly-Pig Co., Inc., or equal.

F. Clean filtered dry air at minus 30 deg C dewpoint, or compressed nitrogen, shall be used
as the propellant.

G. All installed equipment shall provide clear unobstructed opening or access to the fuel
piping system, without any restrictions, obstacles or interference during the
pigging/cleaning operations. Where necessary, temporarily remove equipment with
internal obstructions and install spools as necessary to perform the pigging/cleaning
operations. Reinstall such equipment after pigging/cleaning is completed.

H. The cleaning operation shall be performed by operators experienced in the pigging

operations and shall be made under the direct supervision of the operator's technical
representative. The cleaning operation shall be continued, for each section of piping, until
the line is free from visible water, dirt, sand, weld spatters, and other foreign objects, to
the satisfaction of the Engineer and the Owner.

3.3 HYDROSTATIC TESTING

A. All new Jet A-1 Fuel piping and all existing Jet A-1 Fuel piping (which is modified or
affected by work performed as part of this Contract Package) shall be given a hydrostatic
pressure test using Jet A-1 Fuel after the completion of all holiday testing and pigging.
Water shall not be used for hydrostatic testing.

Note that the Contractor shall be responsible for investigating the existing piping and
component documentation to verify the design pressures and shall advise the Engineer
accordingly of any problems / limitations that may affect the hydrotesting as outlined
herein, prior to performing any hydrotesting of existing Fuel piping.

B. Pressure shall be maintained for at least one 24-hour cycle after pressure has stabilized;
pressure testing shall be performed as follows: Pressure shall be increased in gradual
steps to the final test pressure and maintained for a 24-hour period, continuously record
temperature and pressure. Final test pressure shall be not less than the “Test Pressure”
value specified in Section 9.03 Division 15192, Part 2.

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C. Provide calibrated temperature and pressure instruments and chart recorders to provide
continuous temperature and pressure reading variations during the tests. Instruments shall
be calibrated for temperature and pressure immediately prior to each test. Recorded charts
shall be submitted to the Engineer for approval prior to final acceptance of the piping.
Calibrated thermocouples may be surface applied by method approved by the Engineer.

D. Repair any leaks detected after the 24-hour test cycle in a manner approved by the
Engineer. Re-test one 24-hour pressure cycle, as described above, as required after all
leaks have been repaired. Repeat the repair and re-testing cycle until the system is
acceptable to the Engineer.

E. Equipment which is not rated by the manufacturer for the test pressure shall be removed
prior to hydrostatic testing. Install temporary connections as necessary. All permanent
plug, gate, and ball valves and process equipment and piping components which are rated
at the test pressure or greater shall be in place during the hydrostatic tests.

F. Tests will be witnessed and approved by the Engineer or Owner.

G. The 24-hour recordings shall be made after temperature and pressure have stabilized and
shall be conducted in accordance with NFPA Codes and API RP1110.

3.4 INSPECTION OF COATINGS

A. Perform a detailed inspection with a electronic holiday tester of all pipe and fitting
external coating and joint coating prior to backfilling.

B. Holiday-tester voltage shall not be higher than the manufacturer's recommended voltage
for the coating tested. Testing shall be for holidays only and not to test the dielectric
strength of the coating materials.

C. All holidays and damaged Jet A-1 Fuel underground pipe coating and any aboveground
surfaces painting/coatings damage shall be repaired in a manner conforming to the
requirements of Section 15193 and approved by the Engineer at the Contractor's expense.

D. All holidays shall be patched as follows:

1. Remove the coating with an appropriate tool, without damaging the pipe or coating
to remain.

2. Wire brush the area to a rough finish.

3. Apply enamel primer to the roughed area in accordance with manufacturer's

instructions.

4. Coating shall consist of the same coating and wrapping materials and the same
number of coats as was applied to the piping in the manufacturer’s shop and as
specified in Section 15192.

3.5 TESTING OF INSULATED FLANGES AND CASINGS

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A. Each insulating flange and joint assembly shall be tested by the Contractor's testing
laboratory using an approved ohmmeter. The testing will be witnessed by the Engineer.

B. Ohmmeter used shall have at least 20 megohms, full scale deflection when using the
meter's highest DC resistance multiplier setting.

C. Ohmmeter tests shall be made when flange assembly is dry, using the highest multiplier
setting, and shall indicate infinity when measured between each stud and each flange, as
well as between flanges.

D. Each insulating flange assembly shall be field tested after installation with a 1000-volt
"Megger" and shall have a minimum resistance of 1 megohm at 1000 volts between each
stud and each flange (when dry), as well as between flanges.

E. Testing laboratory shall submit a certified report to the Engineer identifying insulating
flange assemblies tested with the recorded resistance values for each assembly.

F. After casing installation is complete, additional electrical tests (suitable for determining
electrical isolation of buried structures) shall be performed to verify that the electrical
isolation is maintained (i.e., no shorting).

3.6 FLUSHING

A. General:

1. After all the Jet A-1 Fuel piping has been radiograph inspected, cleaned, pressure
tested, and accepted by the Engineer, all aircraft fuel distribution system piping
shall be flushed by the Contractor. Jet A-1 Fuel distribution piping shall be flushed
with a minimum velocity of 3 m per second. Flushing shall continue until fuel is
free of contamination (i.e., until the acceptance criteria of ASTM D 2276 and
ASTM D 3830 are satisfied for the Jet A-1 Fuel).

2. At least 30 days prior to the flushing operation, submit procedures for flushing with
a list of equipment and labor to be used for the operation for approval by the
Engineer.

3. Take every possible precaution to ensure safe flushing operation. Conform with
fire safety needs of NFPA 30 and 101, all applicable ordinances, laws, regulations
and codes, and local authorities having jurisdiction.

4. Schedule and coordinate all personnel required for this flushing operation. Provide
contaminate tests, temporary pumps, tank vehicles, filter-separator elements, labor
to operate pumps and change-separator elements and return fuel to tank storage for
flushing fuel piping. The regular system pumps at the existing Jet A-1 Fuel tank
farms may be used for flushing (if available), in addition to the required number of
temporary pumps.

5. Ensure that no equipment, valves, pumps, and like items are operated beyond their
intended design capability or limitations.

6. Any temporary cross connections, special fabrication, or adapters, required for

flushing shall be provided by the Contractor.

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7. As previously stated, all Jet A-1 Fuel for filling the system, system hydrotesting,
and hydrant line flushing will be provided by Owner. This fuel will be tested by
the Engineer to ensure quality and shall provide a basis for the determination of
successful flushing.

8. The Contractor shall provide all filtration media required for the system flush.
Throughout the operation, differential pressure across the filter/separator vessels
shall be monitored and recorded at regular intervals. Should the cartridges in the
vessel become fouled and reach a 15 psig differential, supply and replace cartridges.

9. No flushing is allowed through hydrant pit valves.

10. All general service valves and adapters shall be in place throughout the flushing
procedure.

11. Temporary pipe risers shall be extended from the pit flanges. The temporary pipe
risers shall be equipped with shutoff valves and sampling probes. Supply any
temporary manifolds plus sufficient number of single compartment tank trucks and
hoses to allow the desired flow rates to be achieved in a safe manner. Hoses and
couplings shall be aircraft type with a minimum 150 lb. rating and shall be
hydrostatically tested. Recommend four-inch hose size to achieve flow capacities
during flush.

12. All low point drains shall be flushed at least once an hour during all flushing
operations and at the completion of all flushing before system is put into operation.
Vent, drain, and pump-out piping shall be flushed through hoses to an appropriate
tank vehicle or other suitable fuel storage vessel, as required to remove dirt, water,
and solid contaminants from fuel pipe.

13. Test samples shall be drawn immediately ahead of filtration on closed loop
recirculation systems; immediately ahead of storage tanks in receiving manifold in
recirculation systems returning flushed fuel to tankage; or immediately ahead of
transport trucks on single line systems.

14. Any fuel spilled in the pits and vaults shall be cleaned up and shall be legally
disposed of by the Contractor in accordance with local regulations. Notify
Engineer and follow his instructions for fuel disposal.

15. Arrange for Millipore, Aqua-Glo, Microsep and gravimetric tests to be taken as
specified during the fuel flushing operation. All tests shall be performed by a
testing laboratory provided by the Contractor and witnessed by the Engineer or
Owner. Continue flushing until the fuel meets or exceeds the test criteria as
specified herein.

16. A two-test minimum is required to ensure piping cleanliness. The system being
flushed shall be displaced with clean fuel prior to taking second test.

17. After flushing has been completed and approved, remove all temporary cross
connections, etc., and install hydrant valves, small valves, etc.

18. Clean the interior of all filter vessels and fuel storage tanks (if available and used
for the fuel system piping flush operation) after flushing has been completed.

C. Flushing into Tank Trucks:

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1. Caution: All electrical and motorized equipment in area shall be shut down in case
of a mishap or fuel spill. For safety, all persons not involved in the flushing
operation shall be kept a minimum of 30 m away from tank trucks and hydrant pits
used in the flushing operation.

2. Tank truck internal valves should be safety wired in an open position.

3. All quick-release type couplings shall be safety wired when coupled to the bottom
load receptacle and hydrant adapter.

4. Hoses shall be secured in a manner to prevent whipping during flush. Four-inch

hoses shall be used to achieve flow capacities.

5. Bond and ground truck to hydrant system piping.

6. Start product flow slowly before reaching flushing velocity to check for leaks and
system tightness.
7. Fire extinguishers shall be in place in case of emergency.

8. Location of test personnel shall be such that a safe operation is performed.

9. All test personnel shall be equipped with two-way radios.

D. Test Requirements:

1. One test kit shall be furnished by the Contractor as described in this paragraph and
shall become the property of the Owner after completion of the Contract. Test
equipment shall be in good working condition when accepted by the Owner. The
test kit shall be a Combination Kit, Model GTP-323 as manufactured by Gammon
Technical Products, or equal.

2. Aviation Jet A-1 Fuel shall be tested for contamination in accordance with ASTM
D 2276 and ASTM D 3830 using Millipore test equipment as manufactured by
Gammon Technical Products, or equal. Millipore tests shall be made at 30-minute
intervals during flushing.

3. Aviation Jet A-1 Fuel shall be checked for water entrainment in accordance with
ASTM D 3240 using "Aqua-Glo" instrument manufactured by Gammon Technical
Products, or equal.

E. Acceptance Specifications:

1. Visual: All fuel samples shall be clear and bright. Other visual clues shall be
observed and acted upon accordingly; i.e., feel, color, odor, etc.

2. Solids:

a. Particle Assessment: "B" Scale with one-gallon sample.

b. Membrane Color: #3 Rated Wet with one-gallon sample.
c. Note: If color rating exceeds the above limits or is in dispute, a matching
weight gravimetric rating not to exceed 0.5 mg/gal shall govern.

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3. Water: 5 ppm maximum.

4. Water Separation (Microsep) Rating: 85 minimum.

F. Final Acceptance:

1. Furnish, after flushing is completed, a report to the Engineer describing the flushing
of each pipe section and the results of the tests performed in conjunction therewith.

2. It shall be the responsibility of the Owner's fuel quality assurance representative, or

his designee, to have final decision on system cleanliness and acceptance before
aircraft fuel servicing is permitted.

3.7 PERFORMANCE TESTING

A. Subject the fueling system under this contract to such operating tests as required by the
Engineer to demonstrate satisfactory functioning and operating performance of the entire
fueling system. The Jet A-1 Fuel system shall be visually inspected to ensure that all of
the mechanical connections are complete and joints are tightened and that all of the
construction activities have been completed and that the various equipment supplier
recommendations and field installation requirements have been met. The electrical
components and instrumentation shall also be visually inspected and reviewed versus the
Drawings and equipment supplier vendor drawings to ensure that all electrical
components and instrumentation has been installed as required and that the electrical
terminations have been properly completed in accordance with the supplier requirements
and Drawings.

B. All valves shall be individually cycled full-closed to full-open and returned to full-closed
to ensure smooth operation with no mechanical binding.

C. All instruments required to conduct the tests shall be furnished and operated by the
Contractor using experienced and qualified personnel.

D. All tests will be witnessed by the Engineer or the Owner and by the operator.

E. When a system/component fails to meet the requirements of a test, adjustments shall be

made to the equipment or the defective materials shall be removed, and replaced, and the
system/component re-tested.

F. Submit copies of test reports to the Engineer for approval.

END OF SECTION 15980

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