jet a1 fueling system

Saudia Aerospace Engineering Industries

Aircrafts Maintenance Hangars

JET A1 FUELING SYSTEM - BASIC MECHANICAL REQUIREMENT 40052 - Page 1 of 14 S09063-01D-PD-SPC-ME-02 REV 1

SECTION 40052 - JET A1 FUELING SYSTEM BASIC MECHANICAL REQUIREMENT

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 40, Jet A1 Fueling System Cathodic Protection

B. Division 40, Jet A1 Fueling System Piping Construction

C. Division 40, Jet A1 Fueling System Coating And Corrosion

D. Division 40, Jet A1 Fueling System Monitoring And Control (EFSO & Leak Detection)

E. Division 40, Jet A1 Fueling System Inspection, Cleaning, Flushing, And Testing

1.3 SUMMARY

A. Installations to include all necessary apparatus, excavating, backfilling, pipes valves, and

fittings herein described or called for on the Drawings and/or Specifications or as necessary

to make the installations operational in a safe and satisfactory manner.

B. It is of vital importance to keep the jet fuel network operational all the time. The contractor

is to take all required precautions and coordinate with all authorities to meet this requirement.

Disruption of the refueling system is not allowed for any reason related to the execution of

the required work of this contract.

The scope of work of the contract shall include the following:

Coordinate with the Civil Aviation Authorities for the phasing of the work.

1. Prior to start of work, perform a complete survey of all existing conditions within the

limit of the contract. The survey is needed to verify the location of the connection

points, profiles and consequently the preparation of the network shop drawings.

2. Supply and install new fuel hydrant pipe.

3. Supply and install new hydrant pits.

4. For the newly installed fuel pipeline establish low point drains with low point drain

pits and piping connections.

5. For the newly installed fuel pipeline, along the aircraft parking areas, establish high

point vents to coincide with the hydrant points. This hydrant / vent will serve the dual

purpose of aircraft loading and venting as required during the appropriate operation.




High point vents in other sections will be provided with the standard venting

arrangement.

6. Connect the MOVs, to the PLC remote I/O panel.

7. Supply, install and test the Emergency Fuel Shut Off (EFSO) system and PLC Panel

as shown and specified on the project drawings. The EFSO stations shall be connected to the new PLC remote I/O Panel with spare I/O modules.

8. Install a leak detection system to cover the new pipelines.

9. Make the required connection between the existing and new fuel pipes. Coordinate

and schedule phasing of shutdown to allow for new connections without interruption

of fuel supply.

10. Establish pipe protective coating on the newly installed pipe section

11. Execute all civil, instrumentation and electrical works associated with the above

mentioned work

12. Establish, supply and install cathodic protection for the fuel system under this

contract.

13. Cleaning, flushing, testing, and commissioning of the fuel hydrant network affected

by the above works.

14. Certification of the above works and installation as specified.

C. Provide and pay for all materials, supervision, labor, tools, equipment, supplies, scaffolding

and transportation required to execute the work specified or indicated on the drawings,

except as otherwise noted.

D. Perform all works described above as required by these specifications and/or indicated on the

drawings.

E. The completed works are to be aligned, grouted, and adjusted, and are permanent, and of safe

and satisfactory operation. Furnish and install components not indicated but necessary for

satisfactory and safe operation.

F. Provide 380 VAC and 220 VAC power wiring and conduits to serve the required power

needs.

G. Fit all apparatus, equipment, piping, etc., into the space provided at such time and in such a

manner as to avoid damage to existing structures or property, and as required by the work

progress schedule.

H. Cooperate and coordinate with the Engineer in the scheduling of work, moving of material,

delivery and location of anchor bolts, sleeves, etc.

I. Coordinate with other Contractors operating on site to ensure no interference or conflict.




J. Coordinate with concerned Authorities to ensure that all matters related to security, safety,

access, and services etc are being followed in full compliance with their regulations.

K. Coordinate with Civil Aviation Authorities and other on-site Authorities for phasing of the

Work in order to avoid any disturbance to the operation of flights and ground services.

L. Coordinate with Jet Fuel Network Operator for proper execution, and compliance with their

functional, safety and operational requirements.

M. Coordinate with the Jet Fuel Network Operator for all data on existing network including

related drawings and documents.

N. Do not interrupt existing utilities serving facilities occupied by the Owner or others except

when permitted in writing by the Engineer and then only after acceptable temporary utility

services have been provided.

O. Maintain access for vehicular and pedestrian traffic as required for other activities in the area

and as discussed/directed by the Engineer.

P. Review, stamp approved, and submit in orderly sequence, all Shop Drawings and Equipment

Lists of materials and equipment required by the Contract Documents so as to cause no delay

to the work progress schedule.

Q. Interface the mechanical work of this contract with existing systems as required by the

Contract Documents.

R. Inspect, flush, clean, test and demonstrate the operation of the completed systems and train

personnel for their use.

S. Obtain and pay for all permits and licenses, but not permanent easements, pay all fees and

taxes, and give all notices bearing on the conduct of the mechanical work as drawn and/or

specified.

T. Receive the approvals or acceptances from all authorities having jurisdiction over the work

and deliver to the Engineer.

U. All systems and appurtenances are subject to inspection by the Engineer. Such inspection

shall not relieve the Contractor of his responsibility of furnishing materials and labor of the

highest quality which are in strict compliance with code requirements and these

Specifications. Materials, equipment, labor, or procedures rejected by the Engineer shall be

replaced or corrected by the Contractor at no additional charge to the Owner.

V. Fixtures and equipment shall be tightly covered and protected against dirt, water, moisture

and chemical or mechanical injury. Pipe openings shall be closed with caps or plugs during

installation.

W. Instruction and warning signs shall be provided as necessary for operation and safety. Such

signs shall be in both English and Arabic. The signs shall be sized to facilitate quick

recognition, be non-corrosive, and be standardized in shape and material.

X. Unless otherwise specified, all internal and external surfaces that require painting or coating

for appearance or protection shall be cleaned and coated as specified in Section 40192, "Jet




A1 Fueling System - Piping Construction" and/or Section 40193, "Jet A1 Fueling System -

Coatings and Corrosion Protection", as appropriate.

1.3 ENGINEER'S DRAWINGS

A. Engineer's Drawings are diagrammatic and are not to be scaled. Measurements are to be

made from established benchmarks.

B. Engineer's Drawings are to serve as working drawings for Contractor's shop drawings.

C. No portion of the work requiring a shop drawing or sample submission is to be commenced

until submission has been reviewed and approved by the Engineer. All such portions of the

work are to be in accordance with approved shop drawings and samples.

1.4 SUBMITTALS

A. Product Data:

1. General: Submit manufacturer's specifications, recommendations and installation

instructions for mechanical work products required by these specifications. Include

manufacturer's published data or certified laboratory test data indicating that each

work product meets the specified requirements. Meet the Product Data submittal

procedures specified in the following Paragraph.

2. Data Included: Product data to include the following as applicable:

a. Product name and model or catalog designation, and manufacturer's name.

b. Physical description, dimensions, and weights.

c. Product properties, characteristics, capabilities and limitations.

d. Data for coordination with other project work.

e. Clear spaces required for handling, installing, operating and maintaining

products.

f. Required installation clearances and tolerances, and the location and size of

openings or sleeves necessary for installation.

g. Applicable reference standard designations.

h. Product specifications, including protective coatings.

i. Information on any protective devices (e.g., stop blocks) or protective

coatings that are applied to the equipment for protection during shipment that

must be removed upon receipt at the Project site prior to installation.

j. Methods and details for anchorage to supporting construction.

k. Data which affects design and construction of supporting structure, including

maximum reactions imposed on supporting structures at each connection or

bearing point.

3. Certification: When required, product data shall be certified by product

manufacturer.




B. Shop Drawings:

1. General: Submit shop drawings for works required, Product Data and Samples, and

additional requirements. Shop drawings shall indicate plan and section view layout

of the works. Prepare and submit shop drawings. Shop drawings indicating the

works associated with Jet A-1 fuel valve and hydrant pits or other congested areas

shall be drawn at minimum scale of 1:50. When necessary for clarity shop drawings

shall include sections drawn at a minimum scale of 1:20.

2. Data Included: Shop drawings to include following, as applicable.

a. Label and title which indicates the manufacturer's name and address, the

drawing scale, and which clearly defines the item being submitted.

b. General arrangement, physical description, dimensions, and weight of

product.

c. Enlarged scale details giving dimensions for locating the product and as

required to clarify installation clearances and tolerances.

d. Assembly drawings for work furnished consisting of two or more

components.

e. Design and actual details of manufacture or fabrication, including material

specifications, dimensions, joining methods and protective coatings.

f. Diagrams of wiring arrangement, actual arrangement of external connections

as seen by the installer and terminal identification designation on actual

product.

g. Diagrams for operation and control of work, including location and function

of instrumentation and control devices.

3. Certification: When required, shop drawings shall be certified by originator of work.

C. Inspection and Test Reports:

1. General: Submit inspection and test reports for mechanical works required.

2. Definition: Inspection and test reports shall be documented statements of methods,

procedures, results and evaluations prepared by Contractor, an installer,

manufacturer or supplier, or an Independent testing laboratory employed by any of

these parties to indicate properties, characteristics and capabilities of a product or

portion of the work.

3. Presentation: Inspection and test reports shall identify products or work by

designations indicated in the Contract Documents.

4. Data Included: Inspection test reports shall include the following:

a. Identification of product or work area represented by inspection or test.

b. Methods, procedures and results of inspections and tests, including

observations of unusual conditions.

c. Evaluation of results, and acceptability and use limitations.




5. Certification: Inspection and test reports shall be certified by organization who

performed inspections, tests and evaluations.

D. Compliance Certificates:

1. General: Submit compliance certificates for mechanical work in accordance with the

following requirements.

2. Certification: Compliance certificates shall be certified by issuing organization

3. Certificates Required: Submit compliance certificates for the following, in addition

to compliance certificates required.

a. Welding Procedures and Certification: Submit qualified welding procedures

and welder certifications as applicable for required type of welding work.

b. Products not of the manufacturer's standard design, modified to suit these

requirements.

c. Equipment bearing UL Listing Mark.

E. Certified Submittals: Submittals for mechanical work required shall be certified.

F. Operation and Maintenance Data: Prepare and submit operating and maintenance manuals.

Submit operating and maintenance data, including instructions, schedules and parts lists, and

recommended spare parts lists.

G. Maintenance Products:

1. General: Furnish maintenance products for work required.

2. Delivery: Deliver maintenance products to the Project site at completion of the

work; unload, and place in storage as directed by the Engineer.

3. Maintenance Products Required: Furnish the following maintenance products:

a. Special Tools: Tools required for servicing work.

b. Touch-Up Finish Paint: When major products are required to be factory

finished, furnish one quart of each type and color finish coat paint applied to

product for field touch-up.

H. Record Documents: Submit record documents of work.

1.5 QUALITY ASSURANCE - FUEL HYDRANTS

A. General:

1. Perform the work to the satisfaction of the Engineer and inspecting authorities having

jurisdiction.




2. Notify the Engineer in writing of any instances in the Specifications or on the

Drawings that are in conflict with any of the aforementioned authorities; required

changes shall be adjusted before the Contract is awarded. If the Contractor performs

any work contrary to such laws, rules, or regulations without notice, he shall bear all

costs arising therefrom.

3. Deviations from the Drawings and/or Specifications required for conformance with

the applicable codes and/or laws shall be corrected immediately but not until such

deviations have been brought to the attention of the Engineer.

4. Applicable codes and/or laws to govern the minimum requirements only; where the

Drawings and/or Specifications call for materials, vents, piping, sizes, etc., in excess

of the code requirements, the Drawings and Specifications shall govern.

B. Contractor Qualifications: All fueling system mechanical construction shall be by companies

who have previously installed aviation fuel hydrant and fueling systems at major

installations.

1. All work done on the fuel system shall be performed by a company who has at least 5

years experience.

2. In addition, the person in charge of all craft personnel shall have at least 5 years

experience in installing an aircraft fueling system.

3. Prior to any activity under this specification section and no later than 30 days after

Notice to Proceed, provide a listing of jobs which the company and the person in

charge have performed which would qualify them to perform work under this

specification section. This listing shall include job name, cost, location, duration,

description of work and person whom the work was performed for, along with their

telephone number(s).

C. Welder Qualifications: All welding shall be performed by welders qualified to ANSI B31.4

in accordance with the standards of American Welding Society. All welders shall be tested

and certified as specified in AWS B3.0 Qualification Procedure, shall be qualified to perform

any of the welding in compliance with standards and codes required irrespective of pressure

or position classification. Test position required for each welder shall be 5G, inclined groove

weld in pipe made by uphill procedures. All pipe welders shall be assigned an identification

mark. Contractor shall secure the services of an Independent Testing Laboratory to certify

each welder in accordance with ASME Boiler and Pressure Vessel Code, Section IX,

Radiographic Examination. Welders failing to qualify after two unsuccessful attempts shall

not be retested. Test welds shall be radiographed and radiographs shall be approved by the

Engineer. Each welder shall possess a currently approved certificate issued by an

Independent Testing Laboratory for this Contract; evidence of qualifications and certificate

of possession shall be presented to the Engineer prior to performing welding under this

Contract. Cost of welding certifications and radiographs shall be borne by Contractor.

Contractor shall maintain an accurate, up-to-date list of welder identification marks.

D. Mechanical Work Superintendent: Keep a competent superintendent and any necessary

assistant satisfactory to the Engineer in charge during the progress of the work.

Superintendent shall properly coordinate and time mechanical work with the work of other

trades and in particular with concrete, masonry and formwork to avoid errors and delays.

Contractor shall pay cost involved due to failure to comply with these requirements or due to

failure to acquaint himself with the work and progress of other trades.




E. Mechanical Work Coordinator:

1. In addition to Contractor's Superintendent, furnish a coordinator for mechanical

work. Coordinator shall be knowledgeable in the fabrication, assembly, and

operation of the required mechanical systems and equipment, and the engineering

essentials, including metallurgy, welding, rigging, and safety requirements.

Coordinator shall be capable of reading, interpreting and coordinating the drawings,

specifications, and submittal data of the mechanical work.

2. Coordinator shall plan and expedite delivery of mechanical products to the Project

site, and to schedule labor to meet the progress schedule of the work.

3. Coordinator shall work with mechanical subcontractors and the contractors of other

disciplines to coordinate the safe and timely completion of the work.

F. Regulatory Requirements: The following codes, standards, and regulations cover the design,

general hardware, construction, and quality control requirements for the fuel storage and

handling systems. Unless otherwise indicated, the latest edition of the following codes and

standards shall apply to the extent indicated herein:

ANSI A13.1 Identification of Piping System

ANSI B16.5 Steel Pipe Flanges and Flanged Fittings

ANSI B16.9 Steel Butt Welded Fittings

ANSI B16.10 Face to Face and End to End Dimensions of Ferrous Valves

ANSI B16.11 Forge Steel Fittings, Socket Welding and Threaded

ANSI B16.25 Butt Welded Ends

ANSI B16.34 Valves, Flanged and Butt Welding Ends

ANSI B18.2 Square and Hex Nuts

ANSI B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia, and Alcohols

ANSI B36.10 Welded Seamless Wrought Steel Pipe

ANSI B40.1 Gauges, Pressure indicating type, Elastic Element

ANSI Z49.1 Welding and Cutting, Safety In

API 5L Specification for Line Pipe

API 6D Specification for Pipeline Valves, Enclosures, Connectors

and Swivels

API 601 Metallic Gaskets for piping, double Jacketed Corrugated

and Spiral Wound




API 607 Valve Fire Safe

API 609 Dimensional Standard for Butterfly Valves

API 610 Centrifugal Pumps and Refinery Service

API 1104 Standard for Welding Pipelines and Related Facilities

API 1500 Storage and Handling of Aviation Fuels for Airports

API 1529 Aviation Fueling Hose

API 1542 Airport Equipment Marking for Fuel Identification

API 1581 Specification and Qualification Procedures: Aviation jet

Fuel Filter/Separators

API 1584 Four Inch Hydrant System Components and Arrangements

API RP2003 Protection Against Ignitions Arising out of Static, Lightning,

Stray Currents

API 2513 Cleaning Petroleum Storage Tanks

ASME Section VIII Division 1 and 2 of Boiler and Pressure Vessel/Code

(Unfired Pressure Vessels)

ASTM A 36 Structural Steel

ASTM A 53 Pipe, Steel, Black and Hot Dipped, Zinc-Coated Welded

ASTM A 105 Forging, Carbon Steel for Piping Components

ASTM A 216 Steel Castings, Carbon Suitable for Fusion Welding for

High Temperature

ASTM A 234 Piping Fittings or Wrought Carbon Steel and Alloy Steel

for Moderate and Elevated Temperatures

ASTM A 307 Carbon Steel Bolts and Studs, 60,000 psi Tensile

Strength

ASTM A 563 Carbon and Alloy Steel Nuts

ASTM D 229 Rigid Sheet and Plate materials Used for Electrical Insulation

ASTM E 94 Radiographic Testing

NFPA 11 Four Inch Hydrant System Components

NFPA 30 Flammable and Combustible Liquids Code

NFPA 70 National Electrical Code




NFPA 78 Lightning Protection

NFPA 410 Standard Aircraft Maintenance

NFPA 407 Standard for Aircraft Fuel Servicing

NFPA 415 Standard on Aircraft Fueling Ramp Drainage

NFPA 419 Airport Water Systems

SSPC SP-1 Solvent Cleaning

SSPC-SP-10 Near-White Blast Cleaning

1.6 PRODUCT HANDLING

A. Provide and pay for all freight, express, trucking, transportation, cartage and handling of

equipment and materials; assure materials, etc., be delivered to the Project site in ample

quantities to ensure uninterrupted progress of work; provide and pay for extra handling and

shipping expenses incurred in expediting materials, etc., to prevent interruption of the overall

job progress.

B. Protect all equipment, materials, specialties, etc., from any causes during shipment, storage,

and erection until final acceptance by the Owner and be responsible for damages or losses

incurred by these or other causes.

C. Jet A-1 fuel Piping: Segregate aviation fuel piping from all other steel and follow special handling requirements. Take appropriate precautions and measures to protect the integrity of

the Jet A-1 Fuel piping shop applied internal lining and externally applied coated or painted

surfaces during receipt, storage, inspection, and installation, start-up and testing operations

until final acceptance by the Owner and be responsible for damages or losses incurred by

field handling operations.

1.7 WARRANTY

A. General: Warranty all works meeting provisions of the Conditions of the Contract, except

warranty to include the additional provisions of this Article.

B. Warranty shall extend to corrections of the work found to be defective or nonconforming to

the Contract Documents at no additional charge to the Owner. Included are damages

resulting from such defects or nonconformance with the Contract Documents. Excluded are

defects resulting from improper maintenance, operation, or normal wear.

C. Time Period: Repairs or replacement made to work within the warranty period shall be

warranted for one year from date of final acceptance of each repair or replacement.

PART 2 - PRODUCTS




2.1. All equipment and material shall be new, undamaged, of the best grade, unless otherwise

specified; decisions concerning quality, fitness of materials, or workmanship shall be by the

Engineer.

2.2. Where items exceed one in number provide products with identical construction, model

numbers, and appearance, from the same manufacturer.

2.3. Insofar as possible, products shall be the standard design of the manufacturer. Manufacturer

shall submit evidence that he has been engaged in the manufacture of the product for a

minimum of 5 years. When standard products are modified to suit these Contract

Documents, manufacturer shall certify operating conditions, ratings and capacity of the

product and Contractor shall submit compliance certificates.

2.4. Acceptable Products: Certain makes and/or manufacturers of material and equipment are

specified herein and/or indicated on the accompanying Drawings as acceptable products.

Prior to submittal, use manufacturer's published data to verify that the product meets the

requirements of the Contract Documents. Notify the Engineer of conflicts.

PART 3 - EXECUTION

3.1 INSPECTION

A. General: Examine the areas and conditions under which work is to be installed or performed,

and remedy any conditions detrimental to the proper and timely completion of the work. Do

not proceed with the work until unsatisfactory conditions have been corrected.

B. Existing Facilities: Verify existence, location and operation of existing mechanical facilities

to be abandoned, removed or altered.

C. Cutting and Patching: Existing conditions of the work including elements subject to damage

or to movement during cutting and patching. After uncovering work, inspect the conditions

affecting installation of products, or performance of work.

3.2 INSTALLATION

A. General: Install work, meeting the requirements of the Contract Documents and in

accordance with product manufacturer's instructions and recommendations.

B. Workmanship:

1. Perform the work as defined above in accordance with the best engineering practice

and standards for this type of work. Follow the recommendations and instructions of

the product manufacturer, unless otherwise specified or shown on the Contract

Documents.

2. Employ only competent, orderly persons, satisfactory to the Owner, who are skilled

in the class of work to be performed.

C. Cutting and Patching:




1. Perform all cutting, patching, carpentry, and masonry work required to accommodate

work and to achieve the following:

a. Make parts fit together properly.

b. Remove and replace defective work.

c. Remove and replace work not in conformance with Contract requirements.

d. Remove samples of installed work as required for testing.

e. Provide for penetration of non-structural surfaces for installation of piping,

ducts, and electrical testing.

f. Provide for previously approved penetration of structural surface for

installation of piping, ducts, and electrical conduits.

2. Provide adequate temporary support as necessary to assure structural value or

integrity of affected portion of work. Provide devices or methods to protect other

portions of Project which may be exposed to cutting and patching work.

3. Patching shall conform to the surrounding surfaces in every respect, including

painting, tiling, etc. Perform no cutting or patching without first obtaining approval

of the Engineer. Cutting and patching of new concrete or masonry is not to be

permitted unless absolutely necessary.

4. Execute cutting and any demolition by methods which will prevent damage to other

work, and will provide proper surface to receive installation of repairs.

5. Execute fitting and adjustment of products to provide a finished installation to

comply with specified products, functions, tolerance and finishes.

6. Restore work which has been cut or removed; install new products to provide

complete work in accordance with requirements of Contract Documents.

7. Refinish entire surfaces as necessary to provide an even finish to match adjacent

finishes. For continuous surfaces, refinish entire surface to the nearest natural break

line.

8. Fit work airtight and fire safe to pipes, sleeves, ducts, conduit and other penetrations

through surfaces as required by the Contract Documents.

9. Openings in existing concrete or masonry shall be core drilled, or perimeter scored,

both sides, prior to removing construction from opening area.

10. Do not cut metallic components, such as electrical conduits, piping and reinforcing

steel, embedded in concrete for masonry construction, except after metallic

components are identified and determined to be out of service or otherwise suitable

for cutting.

11. Do not permit fluid associated with cutting tools to migrate outside of immediate

cutting area or into embedded conduit or piping.

D. Welding:

1. When required for safety, properly shield the welding area.




2. Jet A-1 Fuel Piping Welding: Refer to Section 40192, "Jet A1 Fueling System -

Piping Construction".

3. Miscellaneous Welding: Welding procedure shall be governed by applicable service

type specification of AWS D1.1.

E. Surface Finishes: All surfaces and edges of miscellaneous steel, concrete, etc., shall be

smooth and free of marks, burrs, roughness, and other defects. Finish welds to match parent

material. Where possible, grind welds smooth; remove flux, oxide, splatter or any other

residue from the weld and adjacent areas of exterior and interior surfaces. Do not use

synthetic type filler putty as metal filler.

F. Painting, Coatings, and Linings:

1. All Jet A-1 Fuel piping to be installed below ground shall have the internal surfaces

shop epoxy lined and the external surfaces shop coated in accordance with the

instructions and requirements specified in Section 40193, Jet A1 Fueling System -

Coatings and Corrosion Protection. All Jet A-1 Fuel piping to be installed

aboveground shall be internally epoxy lined and externally primed and painted in

accordance with Section 40193, Jet A1 Fueling System - Coatings and Corrosion

Protection.

2. All other miscellaneous items to be installed aboveground shall be primed and

painted in accordance with the instructions and requirements specified in Section

40193, Jet A1 Fueling System - Coatings and Corrosion Protection.

3. Contractor shall be responsible for priming and painting all Jet A-1 fuel piping and

ferrous metal surfaces not already suitably primed and painted in accordance with the

requirements and limitations of Section 40193, Jet A1 Fueling System - Coatings

and Corrosion Protection and the manufacturers instructions and recommended

procedures.

4. All machined surfaces shall be coated with a suitable rust preventative.

G. Identification and Labeling:

1. Provide labels and signs as called for in the Contract Documents and permanently

attach or support same; piping identification in accordance with API 1542.

2. All grades of pipe shall be identified by color code and also stamped with

specification and grade. Shop wrapped pipe shall be stamped within 75 mm of ends

to permit identification-after wrapping.

H. Clean Up: Prior to acceptance tests and inspections, clean the Project site. Remove all

miscellaneous construction equipment, dispose of all trash and unnecessary excavated

material in a manner acceptable to the Engineer. Make the Project site as safe, clean and

completely finished as possible.

I. Inspections and Tests:

1. General: Test all of the works covered by this Specification and demonstrate its

proper operation to the Owner. Furnish all required labor, testing, instruments and

devices required for tests and pay for all expenses involved in conducting such tests.




If tests show work or equipment to be defective, immediately make all changes

necessary to correct work and performance to the satisfaction of the Owner. Give 48

hours written notice to the Owner of all tests and demonstrations. Provide safe

access to the test area if the work is in preparation or in progress. Contractor will be

given reasonable time to correct defects. If such correction of defects or performance

requirements are neglected, the right is reserved to have defects remedied and to

charge the cost of same against the account of the Contractor.

2. Covered Equipment: No pipe or equipment shall be insulated or covered until

hydrostatic or other required tests have been completed and approved. Where the

Contractor considers this procedure unfeasible, he shall request a waiver from this

requirement in writing which clearly defines, in a method statement, the exception to

the procedure and the extent of the work involved. Where it is determined that

taking exception to the procedure results in an increase in the cost of the project

either in the first cost of material and labor or as a result of defects in the pipe or

equipment which could have been corrected in a less costly fashion through the

required tests prior to covering, the Contractor shall bear all costs associated with the

exception to the procedure.

3. Inspection: Inspection includes but is not limited to:

a Blocking: Remove blocks and other similar devices used to block shafts

during shipment to the field or during alignment work.

b. Alignment: Check whether equipment has been aligned.

c. Tension: Check belt or chain tension.

d. Tightening: Tighten bolts, capscrews and other fasteners.

e. Safety Guards: Check safety guards.

J. Equipment Installation Acceptance: Before final acceptance, top-off all fluids, check all

connections, and remove all remaining debris. Equipment installation will be accepted by

Owner after running equipment under load in permanent operation.

K. Contractor shall obtain prior approval from the Engineer when an existing fuel hydrant

system is to be shutdown for modifications and or to support tie-in activities associated with

the new fuel piping. Contractor shall obtain prior approval from the Engineer before cutting

into any existing hydrant line(s).

L. Jet A-1 Fuel drained out of existing hydrant lines, as part of or as a result of the Contractors

work, shall be removed and returned to the Owner.

END OF SECTION 40052



JET A1 FUELING SYSTEM - CATHODIC PROTECTION 40120 - Page 1 of 3 S09063-01D-SPC--ME-02 REV 1

40120 - JET A1 FUELING SYSTEM - CATHODIC PROTECTION

PART 1 GENERAL





A. Division 40, Jet A1 Fueling System Basic Mechanical Requirement

B. Division 40, Jet A1 Fueling System Inspection, Cleaning, Flushing, And Testing

1.3 SUMMARY

This Section details the minimum requirement for establishing, testing, commissioning and

acceptance of the cathodic protection (CP) for the new fuel hydrant system.

1.4 APPLICABLE CODES, STANDARD AND REGULATIONS

The following International Codes, Standards and Regulation should be used as general

source of reference:

NACE RP0169-96 Control of External Corrosion on Underground or

Submerged Metalic Piping Systems.

BS 7361: Part 1: 1991 Cathodic Protection Part 1 Code of Practice for Land and

Marine Applications.

IEC 60502 External solid dielectric insulated power cables for rated

voltages of 600/1000V up to 30kV

PART 2 MATERIAL

2.1 CP SYSTEM DESCRIPTION

A. The CP system for the airside fuel line shall comprise of a CP transformer-rectifier (CP

T/R) and a deep well groundbed. Location of CP transformer-rectifier to be within the fuel

farm. Coordinate with engineer for location approval.

Monitoring of the effectiveness of the CP system is made at test points installed along the

route of the airside fuel line. The total number of test points shall be verified and justified

through calculations and shall be submitted for Engineer approval.




B. CP Transformer-Rectifier: The rating of the CP T/R is [60V / 100A] DC. The

groundbed is assumed to be rated for minimum 20 years life at 100A output, but

commissioning date is unavailable.

C. CP Monitoring: The monitoring system shall comprise:

1. Test facility as either,

a) Cast iron heavy duty surface box Stanton, UK, model HB03, 225AN, BS grade A,

test load 343kN c/w internal terminal board

b) Cott Engineering, USA, Big Fink test post, c/w terminal board

2. Permanent Cu/CuSO4 reference electrode at each test facility, Borin, USA STELTH 2

brand, model SRE-007-CUY, c/w cable tail 15m of # 14 RHH-RHW.

3. Test Cables as 1c x 16mm stranded Cu/HMWPE or XLPE/PVC (black)

D. Summary: Sufficient capacity should be allowed in the installed cathodic protection system

to allow for future piping additions. Allow for 200% extra capacity.

2.2 TECHNICAL REQUIREMENT

A. Scope of Work

1. Submit calculation report justifying adequacy of cathodic protection system and

describing monitoring philosophy.

2. Confirm quantities and supply all cathodic protection equipment for fuel hydrant

system.

3. Install, test and commissioning all cathodic protection equipment.

B. Material Specification

1. Test Facilities

Test facilities shall be Big Fink type at insulated flange/ insulation joint locations and

flush surface box at other locations. The types shall be as detailed in 2.1.3 para a)

above. A minimum of one test facility shall be provided between two fuel hydrant

sectionalizing valves.

2. Permanent Reference Cells

These devices shall be as detailed in 2.1C.

3. DC Cable

This shall be 16mm copper conductor HMWPE or XLPE/PVC insulated.

4. Ancillary Items




Items such as insulating materials, surge diverters, pipe connection material, cable lugs

etc. shall be offered for acceptance by CONTRACTOR and are deemed included in

scope of supply.

PART 3 - EXECUTION

A. Installation

The CONTRACTOR shall produce method statements and procedures for all installation

activities, for EMPLOYER/ENGINEER approval, prior to commencing on-site activities.

B. Commissioning

The CONTRACTOR shall produce method statements and procedures for all pre-

commissioning and commissioning tests. These shall confirm satisfactory operation of all

installed equipment and shall achieve protection of all structures in accordance with

industry standards.

A fully detailed commissioning report shall be produced.

C. Operation and Maintenance

A detailed O&M manual shall be produced containing all data pertaining to supply,

installation, testing, commissioning, operation and maintenance of the completed CP

system.

END OF SECTION 40120



JET A1 FUELING SYSTEM - PIPING CONSTRUCTION 40192 - Page 1 of 16 S09063-01D-PD-SPC-ME-02 REV 1

SECTION 40192 - JET A1 FUELING SYSTEM - PIPING CONSTRUCTION

PART 1 - GENERAL





A. Division 140, Jet A1 Fueling System Cathodic Protection

B. Division 40, Jet A1 Fueling System Basic Mechanical Requirement

C. Division 40, Jet A1 Fueling System Coating And Corrosion

D. Division 40, Jet A1 Fueling System Monitoring And Control (EFSO & Leak Detection)

E. Division 40, Jet A1 Fueling System Inspection, Cleaning, Flushing, And Testing

PART 2 - PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

A. Materials and equipment shall be standard products of a manufacturer regularly engaged in

the manufacturing of such products, which are of a similar material, design and

workmanship. The standard products shall have been in satisfactory commercial or industrial

use for 5 years prior to bid opening. The 5 year use shall include applications of equipment

and materials under similar circumstances and of similar size. The 5 years experience shall

be satisfactorily completed by a product that has been sold or is offered for sale on the

commercial market through advertisements, manufacturer's catalogs, or brochures. Products

having less than a 5 year field service record shall not be acceptable. Products shall be

supported by a service organization. System components shall be environmentally suitable

for the indicated locations.

B. Refer to Division 1 Section 01600, Paragragh 2.1

2.2 PIPING MATERIALS

A All Contractor supplied materials and equipment shall be new products of manufacturers

regularly engaged in production of such equipment. All products shall conform to the

applicable code or standard for its manufacturing, fabricating and installation.

B. No zinc, cadmium, copper, or copper-bearing material shall be in liquid contact with the

product fuel, unless otherwise specifically noted.




C. Certification:

1. All Contractor supplied pipe and fittings shall be tested and certified at the mill for

conformance with the appropriate API or ASTM specification.

2. Mill certification of all piping shall be submitted to the Engineer for approval.

3. Mill identification shall be stamped and clearly visible within 50 mm of the pipe or

fitting end. The mill identification on the pipe shall be directly traceable to the mill

certification report, in order to specifically identify each piece of pipe or fitting as being

fabricated from the steel tested under the mill certification.

D. The ends of the pipe shall be capped at the factory using suitable galvanized metal or plastic

caps, secured with a double wrap of 50-mm-wide pressure-sensitive tape. Plastic caps shall

not be used in plugging or capping pipes after installation.

E. Piping shall be internally epoxy lined and externally coated or painted in accordance with

Section 40193 "Jet A1 Fueling System - Coatings and Corrosion Protection".

2.3 PIPING SPECIFICATIONS

A Jet A-1 Fuel Specification:

Service Design Conditions Test

Jet A-1 Fuel piping, including 264 psig; ambient 50C 396psig

fuel drain and vent piping

(including all lateral piping,

and the normally pressurized

portion of drain and vent piping).

Jet A-1 Fuel piping vents and 264psig; ambient 50C 25 psig leak test.

drain piping (normally non- (Compressed air

pressurized portion of each of test with soap

these lines) bubble check

leaks)

Jet A-1 Fuel piping, Double 264psig; ambient 50C 396psig

Containment Pipe

B. Piping and Fittings details:

Item 2 Inch & Smaller 2-1/2 Inch & Larger

Pipe API 5L Grade B Schedule 80, API 5L

Seamless, plain ends. Grade B, Beveled ends Seamless or

ERW, Schedule 40 for 3" to 10",

standard wall thickness for 12" to

16", and 0.500" nominal

wall thickness pipe for 20" and 24

diameter, longitudinal seam SAW or

EFW, 0.500 nominal wall thickness

for pipes 28 diameter and above.




(SWA spiral seams are acceptable

for casing pipe).

Joints Use socket welded or Butt-weld

screwed joints as specified

for the piping construction on

Design/Vendor drawings and/or

to match the connecting equip-

ment joint type/rating. Screwed

joints shall not be used on any

underground piping; screwed

joints may be used only above

ground or in pits (as required to

connect to valves or equipment

with threaded connections.)

Flanges 150 lb. ANSI, B16.5 carbon steel, 150 lb. ANSI*, carbon steel,

ASTM A 181 Class 70 or ASTM A 181 Class 70 or

ASTM A 105 weld neck, RF ASTM A 105 weld neck,

flanges. raised face (RF) flanges.

*Note, that the 6 x 4 Hydrant Valves

will be supplied with ANSI 300# RF

flanged inlet connections. For each

of these connections, use 300 lb.

ANSI, carbon steel ASTM A181

Class 70 weld neck RF flanges.

Fittings ANSI b16.5 carbon steel,

ASTM A 105, 3000 lb. rated Butt weld, ANSI B16.9, carbon

for all underground services; steel, ASTM A 234 Grade B,

Socket weld or screwed wall thickness to match pipe

3000 lb. forge steel, ASTM

A 105 Grade II, ANSI B16.11

for aboveground services.

Bolts, Same as 2-1/2 Inch & Larger Carbon steel, cadmium plated*,

Studs, Nuts machine bolts and studs per ASTM

A 193 Grade B7. Nuts shall be

heavy hexagon, ASTM A 194 Grade

2H, cadmium plated. *Note,

cadmium shall not come into contact

with the Jet A-1 Fuel and therefore

these cadmium plated bolts, studs,

and nuts shall only be used on the

exterior of the Jet A-1 Fuel

equipment and piping.

Gaskets Same as 2-1/2 Inch & Larger Spiral-wound, Flexitallic Style

CG.




2.4 LINING, COATING, AND PAINTING

A. External surfaces of all mechanical equipment and aboveground steel piping shall be painted

as specified in Section 40193 "Jet A1 Fueling System - Coatings and Corrosion Protection".

Jet A-1 Fuel piping and fittings shall be internally epoxy lined and externally coated or

painted as specified in Section 40193 "Jet A1 Fueling System - Coatings and Corrosion

Protection".

2.5 FITTINGS

A. Butt-weld type carbon steel, ASTM A 234 Grade B, ANSI B16.9 for sizes 2-1/2 inches and

larger. Wall thickness of fittings shall match wall thickness of pipe.

B. Socket weld or screwed forged steel, ASTM A 105 Grade II, conforming to ANSI B16.11 for

sizes 2 inches and smaller.

C. Elbows shall be long radius 1.5D or 3D suitable for cleaning by pigging, unless otherwise

specified and/or indicated on Drawings.

D. Changes in direction of pipe, of other than 45 degrees or 90 degrees, shall be made as

follows:

1. With long-radius weld elbows cut to the proper angle and shop beveled.

2. At the option of the Contractor, use long radius pipe-bends. Pipe roundness shall be

maintained to factory tolerance for straight pipe lengths. Submit shop drawings of all

bends and bending procedures for approval.

3. Pipe bends are permitted in accordance with the requirements of ANSI B31.4.

4. Pipe miters are not allowed.

E. Branch Connections:

1. Fabricated fittings may be used in lieu of butt welding tees branch connections.

Fabricated fittings shall be forged steel fabricated from materials conforming to ASTM A

105, standard weight steel, and shall conform to ANSI B16.11. Thickness shall match

wall thickness of pipe.

2. Forged fittings such as sweepolets or weldolets, or butt weld vesselets are to be as

allowed under the requirements of ANSI B31.4.

3. Threadolets or sockolets shall only be used for gauge, vent, sampling, and instrument

connections.

F. Finish of flange surfaces mating the gasket shall be phonographically serrated.

G. Flange facings shall correspond to the equipment to which the piping is joined and shall,

unless otherwise required, be standard 1.6-mm raised face flanges. Flanges for the

horizontally installed Jet A-1 Fuel piping shall be oriented/ installed such that the bolt hole

arrangement straddles the vertical line unless this conflicts with the flange bolt holes of

interconnecting equipment (i.e., valves). Flange rating and drilling shall match the rating and

drilling on equipment flanges.




2.6 GASKETS

A. Gaskets shall be resistant to the effects of aviation hydrocarbon fuels and manufactured of

fire-resistant materials.

B. Ring gaskets shall be used for steel flanged joints with raised face flanges.

C. Gaskets shall be spiral-wound construction with an integral 1/8-inch-thick metal gauge ring.

D. Gasket shall be constructed from metal windings and an enclosed filler to a thickness of

4.4 mm to compress to 3.2 mm to 3.4 mm under proper bolt torque.

E. The metal windings shall be Type 304 stainless steel.

2.7 BOLTS AND NUTS

A. Machine alloy stud bolts shall be full thread, cadmium-plated carbon steel, heavy hexagon,

conforming to ANSI B18.2.1 and ASTM A 193 Grade B7. Note: The cadmium plated

material shall not be used at locations where it may come into contact with the Jet A-1 Fuel.

Therefore, the use of cadmium-plated bolts, studs, nuts, washers, etc. is limited to Jet A-1

Fueling system piping and equipment exterior applications.

B. Nuts shall be cadmium-plated carbon steel, heavy hexagon conforming to ANSI B18.2.2 and

ASTM A 194 Grade 2H.

C. Cadmium plating shall be electro-deposit in accordance with ASTM A 165, Coating type TS.

D. Provide washers under bolt head and nuts. Washers shall be cadmium plated ASTM F 436

hardened steel washers.

2.8 GATE VALVES

A. Valves shall be steel valve, ANSI class 150, fire-safe rated in accordance with API 6FA,

6FB, and 6FC. Valve flanges shall be steel, class 150 in accordance with ANSI B16.5.

Valves shall be double block & bleed.

B. Valves shall be rated for a minimum of 285 psig working pressure at 50 deg C.

C. Valves shall be furnished with weatherproof handwheel operator and locking device.

Valves 8 inches and larger shall be furnished with weatherproof gear operators with

handwheel and locking device.

D. Valve components shall be manufactured of the following materials:

1. Valve body shall be cast carbon steel conforming to ASTM A 216, Grade WCB, or approved equal.

2. Valve trim shall be 316 stainless steel, or approved equal.

3. Seats and seals shall be Viton, or approved equal.

4. Valve handle shall be Vinyl coated, plated carbon steel.




2.9 BALL VALVES

A. Valves shall be ANSI class 150 valves, rated for 285 psig working pressure at 50 deg C.

B. Valves shall be furnished with locking lever operators.

C. Valve components shall be manufactured of the following materials:

1. Valve body shall be cast carbon steel conforming to ASTM A 216, Grade WCB, or approved equal.

2. Ball and trim shall be Type 316 stainless steel.

3. Seats and seals shall be stainless steel or Viton.

4. Handle shall be Vinyl coated, cadmium-plated carbon steel.

D. Ball valves shall be rated fire safe in accordance with API 607.

E. Acceptable Manufacturers:

1. Grove Valve and Regulator Company

2. Jamesbury Ball Valve.

3. DeZurik, Unit of General Signal.

4. Approved equal.

2.10 DOUBLE BLOCK AND BLEED VALVES

A. Double Block and Bleed (DB & B) plug valves shall be similar to Tru-Seal valves as

manufactured by Orbit Valve Company or Twin Seal high-integrity positive shut-off

valves, series C-800 as manufactured by General Valve Company or approved equal. The

specifications listed below are for indication only. The DB&B valves shall meet the

following requirements:

1. Valves shall be quarter turn reduced port, non-lubricated, resilient seal, tapered

plugged type with a mechanical means of freeing the plug before it is rotated from the

closed to the opened position.

2. Valves shall have manual body bleed valve to check scale integrity of valve in the

closed position. Also each valve shall be provided with a thermal relief valve for

body bleed.

3. Valves shall have position indicator flag to show the exact plug position.

B. Valve shall have ANSI 150 pound rating raised face body flanges.

C. Valves smaller than 6 inch shall have hand wheel operators. Valves 6 inch and larger

shall have gear operators with hand wheels.

D. Valve components shall be manufactured of the following materials:

1. Valve body, bonnet and plug shall be cast iron steel ASTM A 216-WCB chrome

plated; or approved equal.

2. Valve O-ring and back-up ring shall be viton.

3. Seating slips shall be ductile iron ASTM A 536 GF 80-55-06; or approved equal




2.11 WALL PENETRATION SEALS

A. Pipe sleeves shall be installed at all points where the piping passes through concrete

construction. Pipe-to-wall penetration closures shall be modular mechanical type, made

up of jet fuel resistant interlocking rubber links shaped to fill the annular area between

pipe and wall opening or outer casing, and joined together with machine bolts and nuts.

Seal shall have sufficient inside diameter to provide a minimum of 13-mm clear distance

between the pipe and the sleeve after being positioned and expanded against the outer

wall by tightening the bolts. Seal shall be electrically non-conductive. Bearing plates or

washers between seal elements and bolt heads and nuts shall be electrically non-

conductive.

B. Sleeves through concrete pits or slabs shall be 6.35 mm thick metal. Each sleeve shall

extend through the respective pit wall or slab and shall be such that the pipe is accurately

centered within the sleeve. The sleeve shall be securely anchored to prevent dislocation.

C. Seal assembly shall be constructed of materials resistant to aviation jet fuels. "Link-Seal"

seals as manufactured by Thunderline Corp., or approved equal, shall be deemed suitable

to meet the requirements for wall penetration sealing.

2.12 CASING INSULATORS

A. Provide concentric insulators in pipe casing in intervals recommended by the insulator

manufacturer, to support pipe without sags along the flow line gradient shown on the

drawings, or as directed by the Engineer.

B. Casing spacers shall be 300 mm wide, fusion coated, seal casing insulators with 50 mm wide,

glass reinforced runners. The steel casing insulator shall be completely formed with runner

studs, degreased, primed and heated. A polyvinyl chloride coating shall than be applied to a

minimum thickness of 0.254 mm. Casing spacers shall be model C12G-2 as manufactured by

PSI Industries, or approved equal.

C. Insulators shall keep inner fuel pipe in concentric alignment throughout the casing length

without obstruction continues draining and venting capabilities of the casing.

2.13 HYDRANT VALVES

A. New hydrant pit valves shall be manufactured by Avery-Hardoll, J.C. Carter, or approved

equal. The specifications listed here-in after are for indication only.

B. Hydrant pit valves will be 4" x 4" dual manually lanyard/air operated hydrant valves using

dual operated pilot, with 4, 150 # ANSI B16.5 RF inlet flange, and outlet (top) connection

shall be a 4 inch API 1584 adapter outlet flange. Valve assemblies shall include integral pilot

valve and pressure equalizing valve, inlet side isolation valve (for maintenance of the upper

valve assembly and pilot valve), integral 20 mesh screen, and 4 mesh inlet stone guard.

C. Hydrant pit valve shall be supplied with inlet isolation ball valve for ease of removal and

maintenance of the hydrant valve while the system is under pressure. The inlet isolation

valve ball valve shall have 4 outlet to match the 4 inlet of the hydrant valve and 6, 300 #

ANSI B 16.5 RF, inlet flange to match the 6 inch 300 # ANSI B16.5, RF flange suitable for

handling type A-1 Jet Fuel. (Warner Lewis model WL 5518 or approved equal).

D. Valve outlet shall consist of a self-sealing male coupling (API 1584 adapter) with a tethered

dust cap. The hydrant valve outlet adapter shall be suitable for coupling the hydrant valve to




the hydrant dispenser inlet hose and shall be designed so that the hydrant dispensers can be

connected or disconnected without spillage of fuel.

E. Valve closing time shall be adjustable from 2 to 5 seconds.

F. Materials:

1. Outer housing shall be epoxy coated ASTM A 536, Grade 60-14-80 ductile iron; or

approved equal.

2. Trim shall be stainless steel, or approved equal.

G. Valves shall be provided with 4 mesh stone guard (stainless steel strainer at inlet 6 inch

flange), conical type.

H. Hydrant valves shall not be installed until all tests and flushing are completed.

2.14 LOW POINT AND HIGH POINT VALVES

A. New low and high pit valves shall be similar to Avery-Hardoll, or approved equal, twin,

40mm fire safe ball valves. The specifications listed here in after are for indication only.

B. Valves shall be operated manually.

C. Valves to be fitted with a standard 6 ANSI 300 (BS1560) flange it can be installed in

standard hydrants pit externals.

D. Venting valves shall be installed at high points in the hydrant line and at low draining points

in the hydrant line.

E. Vent and drainage valves shall not be installed until all tests are completed.

2.15 HYDRANT VALVE, LOW-POINT DRAIN VALVE, AND HIGH-POINT VENT VALVE

PITS

A. Pits: Pits shall be environmentally friendly, prefabricated spehroidal graphite cast iron

internally white epoxy coated in accordance with MIL-C-4556 D, and externally coated with

black coal tar epoxy. Pits shall be accommodated with welded riser pipe, COPON, or

approved equal, painted internally for bottom connection of fuel lines. Fuel piping

connection to the pits shall be as shown on the Drawings and with sizes as follows:

1. Hydrant Pits: 6-inch fuel line.

2. Low-Point Drain Pits: 6-inch fuel line.

3. High-Point Vent Pits: 6-inch fuel line.

B. Pits: Pits shall have welded steel construction inner housing complete with 6" ANSI 300 lb

raised face, made of carbon steel epoxy coated in accordance with MIL-C-4556D, with bolts,

nuts and washers made of yellow anodized carbon steel with 3 spacer centralizing lugs. Pit

shall be accommodated with fuel resistant sealing bellows type, elastometer, installed




between the outer housing and inner box to allow movement between boxes and shall be

provided with removable leveling brackets to support the pit box while setting in concrete.

C. Pit Covers:

Light weight 18 inch diameter pit lid made of aluminium alloy designed to withstand aircraft

tire loads with retaining cable secured with swivel fitting to prevent twisting/kinking, and

fuel resilient pit lead seal.

D. Potential Manufacturers include:

1. Avery Hardoll.

2. Warner Lewis.

3. Dabico.

4. or approved equal.

PART 3 - EXECUTION

3.1 PREPARATION FOR SHIPMENT - PIPE AND FITTINGS

A General: Any Contractor furnished piping materials shall comply with the following marking

requirements. After the piping coating has been inspected and approved, the following

information shall be clearly stenciled onto the coated pipe surface. The paint used for

stenciling shall not have any adverse effects on the coating.

1. Purchasers name and purchase order number.

2. Pipe and pipe tally number.

B. The lined, coated pipe lengths and fittings shall be adequately cushioned for transport in

order to prevent damage to the pipes or coating while loading and transporting. Suitable

cushions may consist of wood-wool within sealed polyethylene sleeves.

C. Unless otherwise specified, on completion of all coating work, pipe internals shall be visually

inspected for cleanliness. Any dust or other debris shall be removed prior to fitting

breathable covers for subsequent shipment.

3.2 PIPE CLEANING REQUIREMENTS

A. The importance of keeping the interior of the piping system thoroughly clean at all times is

critical. Keep the interior of the piping clean of all visible dirt or foreign matter at all times

and under all conditions. If, for any reason, the inside of the piping contains dirt or foreign

matter, rectify this condition to the Engineer's satisfaction with all necessary material, labor,

and equipment for cleaning being furnished at the Contractor's expense.

B. The pipe shall be factory cleaned, internal surfaces epoxy lined, and external surfaces coated

to a point 75 mm from each end in accordance with Section 40193 "Jet A1 Fueling System -

Coatings and Corrosion Protection". The pipe shall be delivered to the Project site sealed.

The seals shall not be removed until the pipe is installed. After each day's work, the open




ends of all pipes being installed shall be sealed closed with an expansion type weatherproof

seal manufactured for this purpose.

C. All fittings and valves shall be kept in a covered dry storage area until ready for installation.

D. Pipe shall not be installed in ditches containing water or mud.

E. At openings for branches in pipe, all material, which falls into the pipe, shall be removed

before welding in the branch fittings.

3.3 HANDLING PIPE

A. Shipping, delivering, and installing pipe and accessories shall be handled in such manner as

to ensure a sound undamaged condition. Particular care shall be taken not to injure pipe

internal lining or external coating when storing pipe, lowering it into trench and when

backfilling.

B. No other pipe or materials of any kind shall be placed inside a pipe or fitting after the coating

has been applied.

C. Storage rack materials shall be 150 mm in bearing width and placed not more than 1830 mm

apart.

D. Do not rack pipe 10 inches in diameter and larger more than 2 sections in height; and pipe 8

inches and smaller not more than 4 sections in height.

E. Protect and prevent movement of all racked pipe by use of suitable padded material between

sections.

F. All trucks handling coated pipe shall have properly padded bolsters, padded chains, and

padded binders so as to not damage the coating.

G. Pipe shall not be dropped or rolled off the truck, but shall be carefully lowered onto skids

using padded mechanical equipment.

H. Coated and wrapped sections of pipe shall be lifted with nylon slings of approved width and

shall not be dragged or pulled into position.

3.4 LAYING UNDERGROUND PIPE

A. Lay, embed, and maintain all underground pipelines to the flow-line elevation and grades

shown on the Drawings or as directed by the Engineer. Pipelines shall be sloped uniformly

between invert elevations.

B. Unless otherwise specified on the Drawings or permitted by the Engineer, all pipe shall be

installed in open cut trenches with vertical sides. Trenches shall be sheathed and braced to

the extent necessary to maintain the sides of the trench in sloped or vertical position

throughout the construction period. Adequacy of the sheathing and bracing shall be the

responsibility of the Contractor. Excavation work shall be executed in accordance with the

requirements specified below under "Civil Works Fuel Hydrants". Excavation work shall

be planned such that the amount of trench can be safely excavated, the pipe laid, and the

trench backfilled within a two day period. All trenching, excavation, sleeving and shoring




needed to cross under a utility shall be performed in accordance with the requirements

specified below under "Civil Works Fuel Hydrants" and in the manner required by the

party owning the utility and in such a manner as to assure no dislocation of the existing

utility. Surface water and subsurface or ground water shall be prevented from flowing into

trench excavations. Any accumulated water shall be promptly removed from the trench to

prevent softening of the trench bottoms and soil changes detrimental to stability of the

subgrade. Although trench size shall be minimized, the trench width and depth shall be such

that proper clearance is provided adjacent to and beneath all parts of the piping and fittings

for placement of the bedding material, cradle, jacket, etc. The minimum clearance on each

side of the piping is 300 mm; the minimum clearance beneath the piping is 150 mm.

C. All piping shall be installed in a continuous envelope of pipe bedding material. The bedding

material shall extend from 150 mm below to 300 mm above the outer parts of the pipe,

fittings, and accessories over the entire width of the excavation. Acceptable bedding

materials/placement shall be as follows:

1. Pipe Bedding: Sand: On-site borrow material, clay to silty fine sands that have been

sampled, tested and approved by the Engineer and which complies with the requirements

specified below under "Civil Works Fuel Hydrants". Place the bedding material such

that the lower quarter of the pipe circumference is in continuous contact with backfill.

Place the material carefully and uniformly up each side of the pipe in 0.15 m layers in a

manner that assures compaction along the sides and haunches. Compact the bedding

material uniformly under and around the pipe.

2. Backfill: Backfill material, which is tested and complies with the requirements specified

below under "Civil Works Fuel Hydrants". Place backfill immediately after the pipe

has been bedded. When required by Section 40980, "Jet A1 Fueling System - Inspection,

Cleaning, Flushing, and Testing", or by the Engineer, leave all joints exposed until all

required testing is performed and accepted. Place and compact trench backfill to

preclude a depression from ultimately forming at the surface along the trench.

D. Complete backfill from top of bedding to grade with backfill. Place backfill materials in

layers not more than 0.25 m in loose depth for material compacted by heavy compaction

equipment and not more than 0.10 m in loose depth for material compacted by hand-operated

equipment. Before compaction, moisten or aerate each layer as necessary to provide

optimum moisture content of the soil material. Compact each layer to the required density

for each area classification as defined below. Place backfill materials evenly adjacent to

piping, tanks, and structures to the required elevations. Do not place layer of loose material

until after compacted layer is tested and accepted by the Engineer.

E. Compaction Density Requirements: Compaction of materials and compaction testing shall be

in accordance with the requirements specified below under, "Civil Works". Results of the

testing shall be submitted to the Engineer for evaluation and approval.

F. Area Classification - Density: Compact soil materials for following area classifications to not

less than the specified in-place density applicable for the type of soil material:

1. Pipe Bedding - Sand: Compact top 150 mm of subgrade and each layer of backfill

material to minimum of 98 percent maximum dry density at 2 percent of optimum

moisture content.

2. Backfill (Balance of Pipe Trench Excavations):




i. Within Structure Lines or Under Pavements: Compact each layer of backfill

material to minimum of 98 percent maximum dry density at 2 percent of

optimum moisture content.

ii. Other areas: Compact each layer of backfill material to minimum of 90 percent

maximum dry density.

G. The full length of each section of pipe shall rest solidly upon the bedding material.

H. Any pipe that has the grade or joint disturbed after being laid shall be taken up and re-laid.

I. Do not lay pipe in water or when trench conditions are, in the judgment of the Engineer,

unsuitable.

J. Anchor pipe, in an approved manner, during installation to prevent flotation prior to

placement in service. If the buoyancy requirements require the installation of concrete

coating or installation of pipe weights, the Contractor shall notify, and obtain prior approval

from, the Engineer, prior to proceeding with these installations.

K. When work is not in progress, securely close open ends of pipe or fittings using approved

expanding type watertight plugs to prevent trench water, earth, or other foreign substance

from entering the pipe or fittings.

L. Pipe coating shall be inspected with an electronic holiday tester in accordance with Section

40980, "Jet A1 Fueling System - Inspection, Cleaning, Flushing, and Testing" prior to

backfilling.

3.5 WELDING

A. Shop Welding: Piping shall be delivered to the Project site in double random pipe lengths.

The shop welding shall be full penetration welds performed in accordance with welders and

procedures qualified (certified) under API 1104 or Section IX of the ASME Boiler and

Pressure Vessel Code. The pipe shall be designed and fabricated to the requirements of

ANSI B31.4 and all shop welds shall be performed and 100 percent radiographically

inspected in accordance with the requirements of API 1104. Welding operations,

qualification of welders and welding procedures shall comply with the provisions of ANSI

B31.4 and the requirements specified herein. Welding shall be done only by qualified

welders and their qualifications shall be certified by the Contractor. Complete piping

material certificates, weld records, welder qualification reports and weld inspections and

radiographic records shall be submitted to the Engineer and piping and fittings materials

delivered to the Project site.

B. Field Welding, General: Unless otherwise approved, all field girth welds shall be complete

penetration groove welds made in accordance with qualified welding procedures. Field

welding operations, qualification of welders and welding procedures shall comply with the

provisions of ANSI B31.4 and API 1104 and the requirements specified herein. Welding

shall be accomplished by the use of the shielded metallic arc process and shall be performed

in accordance with the requirements of ANSI B31.4. Welding processes and/or procedures

that comply with any other standard will not be accepted. Welding shall be done only by

qualified welders and their qualifications shall be certified by the Contractor.

1. Definitions shall be in accordance with AWS A3.0.




2. Symbols shall be in accordance with AWS A2.4 for welding and non-destructive testing,

unless otherwise indicated.

3. Safety precautions shall conform to ANSI Z49.1.

4. Weld preparation shall comply with the requirements of ANSI B31.4 and the

Contractors qualified Welding Procedures.

C. Welding electrodes shall be designed and made for use with the specific pipe metal to which

it is applied and shall conform to the applicable AWS Specifications for welding rods and

electrodes. Welding electrodes shall be suitably shielded. Prior to the start of field welding,

Contractor shall obtain approval on the use of the specific welding electrode

materials/procedures selected for the application.

D. Not less than 15 days prior to performing any weld, submit to the Engineer for approval the

welding procedure specifications (meeting the requirements of ANSI B31.4 and API 1104)

proposed to be used on the work. Submittal shall include, as a minimum, the following:

1. Certified copies of the procedure qualification test records confirming that the procedures

have been qualified in accordance with ANSI B31.4 and Section IX of the ASME Code.

2. Submit the records in a form similar to the "Procedure Qualification Record" and include

the information required by Section IX of the ASME Code and ANSI B31.4.

3. Welding procedure shall be designed for the conditions of this Project and shall be

complete and specific, and shall differentiate between shop and field welding.

4. Secure the services of a qualified independent testing laboratory to certify each welder.

Welds shall be made and tested as required by ANSI B31.4, API 1104, and Section IX of

the ASME Boiler Code. The following conditions shall apply for qualification testing of

each welder:

i. All welds shall be made in the uphill method.

ii. All pipe groove welds shall be in test position 5G.

iii. No backing rings shall be used.

iv. All test welds shall be given a radiographic examination prior to the

performance of bend test.

v. All test welds shall be given the performance bend test.

vi. Welders failing to qualify after two unsuccessful attempts shall not be re-

tested and shall not be permitted to perform any welds on this Project.

vii. All test results shall be submitted to the Engineer for approval.

5. In addition to the above, each welder shall possess a currently approved certificate,

meeting the requirements of these Specifications, issued by an approved testing authority.

Satisfactory evidence as to qualifications and certificate possession shall be presented to

the Engineer for each welder employed prior to any welding being performed.

6. Costs incidental to these procedures and the welders qualification tests shall be borne by

the Contractor.

E. Identification:

1. Each welder shall identify his weld with specific code marking signifying his name and

assigned number.




2. The Contractor shall maintain an up-to-date record of the welders and the code assigned

to each welder.

3. The welder shall stamp his code on the pipe, not farther than 100 mm from a weld, using

a "low stress" steel stamp or other approved methods that will not damage the pipe or

pipe coating system.

4. The Contractor shall indicate, on his set of drawings for submittal as record drawings (as-

built), the location of each weld by number and the respective welder's identification

code. The identification methods to be used by the Contractor shall be submitted to the

Engineer along with the respective welders' qualification test records.

F. Preparation of Pipe Ends for Butt Welding:

1. Preparing pipe ends shall be in accordance with ANSI B31.4.

2. Shop and field bevels shall be machine cut; manual flame cutting will not be permitted.

G. Backing rings shall not be used.

H. All welds shall have full penetration and fusion and shall conform to ANSI B31.4.

I. Align pipe joints with pipe clamps prior to welding. Clamps or other alignment devices shall

not reduce the internal pipe diameter.

J. Any weld or weld repair, once started, shall be continued until the weld has been completed.

K. Defective welds shall be repaired or redone, in accordance with ANSI B31.4 and approved

procedures at the Contractor's expense. Defects discovered between passes shall be repaired

before additional weld material is deposited. Whenever a defect is removed and repair by

welding is not required, the affected area shall be blended into the surrounding surface so as

to avoid sharp notches, crevices, or corners. After a defect is thought to have been removed,

and prior to rewelding, the area shall be examined by suitable methods to ensure that the

defect has been eliminated. After repairs have been made, the repaired area shall be

reinspected and shall meet the standards of acceptance for the original weld. Any indication

of a defect shall be regarded as a defect unless reevaluation by nondestructive methods

and/or by surface conditioning shows that no unacceptable defect is present.

L. Repairs to defective welds shall not be made prior to authorization. The Engineer will

determine on the basis of the testing laboratory report if repairs may be made or if the entire

joint shall be cut out and welded again.

M. No weld metal shall project within the piping at completion of the welding. All weld

material and burrs protruding outside the pipe's outer surface shall be ground smooth.

N. Prior to welding, each joint shall be cleaned and all rust and loose debris and contaminants

removed.

O. Any welder producing more than a total of 3 defective welds shall be disqualified and

prohibited from performing any more welds on this Contract.




3.6 RADIOGRAPHING AND MAGNETIC PARTICLE TESTING

A. All welds on carbon steel pipe shall be examined by radiographic methods to determine

conformance to the paragraph entitled "Standards of Acceptance". The Contractor shall

employ, at no cost to the Owner, a recognized independent testing laboratory to test the items

indicated below by radiography. All fillet and seal welds shall be tested by magnetic particle

testing method. All costs of testing, including re-testing of repaired welds, shall be borne by

the Contractor. Tests shall be performed for:

1. 100 percent of all circumferential shop welds.

2. 100 percent of all circumferential field welds on underground piping/fittings.

3. Standards of Acceptance: Interpretation of test results for inadequate penetration,

incomplete fusion, porosity or gas pockets, cracks, etc. in welds shall comply with the

requirements set forth under "Standards of Acceptability - Nondestructive Testing" in

API 1104.

B. The Contractor shall cooperate with the testing laboratory and shall give the Owner, the

Engineer, and the testing laboratory adequate advance notice of when welds will be available

for radiographing and that all the work required by the Contractor in connection with the

welding prior to radiographing is properly completed.

C. Laboratory testing report shall be timely submitted, to the Engineer, throughout the progress

of the work, and the Contractor will be notified of any encountered deficiency.

D. Reports of all radiographing and magnetic particle testing shall be prepared in accordance

with the requirements of ANSI B31.4. The reports shall include welder's code, weld

identification and description, whether the weld meets the specification requirements, the

film type and size, and remarks on imperfections. All subsequent report formats shall be in

accordance with the requirements of Section IX of the ASME Code.

E. Radiograph exposure film negatives will be kept on file by the Engineer; the record for such

radiograph film negative will show the date, location of tested weld (coordinate d with weld

location as shown on the Contractor's as-built drawings), area, film number, serial number,

film combination, time, source-film distance, angulation and other pertinent information for

each weld radiographed.

F. A summary of these records along with an expert interpretation of the tests shall be prepared

by the testing laboratory and submitted in a report form for each weld, to the Engineer.

Interpretation of negatives shall be by a Level 3 radiographic technician certified by

examination by the American Society of Non-Destructive Testing.

G. All welds shall be left exposed until all testing (radiographing and magnetic particle) is

completed and welds have been accepted by the Engineer.

H. Acceptance criteria for welds shall be in accordance with ANSI B31.4 and API 1104

requirements for severe cyclic conditions. Welds which do not meet the standards of

acceptability will be judged unacceptable and shall be repaired or cut out and rewelded by

the Contractor as directed by the Engineer at no additional cost to the Owner. Repaired and

rewelded joints shall then be re-radiographed. If the same joint, after the second welding and

radiographing fails again, then the section(s) of involved pipe shall be removed and replaced

at no cost to the Owner.




I. All the costs of the original radiographing and re-radiographing of unacceptable w

jet a1 fueling system

Documents

efso system

system coating

system monitoring

system inspection

jet fuel network operational

leak detection system

new fuel pipes

new fuel hydrant pipe