**************************************************************************

USACE / NAVFAC / AFCEC / NASA

Preparing Activity:

UFGS-33 08 55 (July 2007)

-------------------------Superseding
UFGS-23 14 00 (April 2007)

AFCEC

UNIFIED FACILITIES GUIDE SPECIFICATIONS

**************************************************************************
SECTION TABLE OF CONTENTS
DIVISION 33 - UTILITIES
SECTION 33 08 55
COMMISSIONING OF FUEL FACILITY SYSTEMS
07/07
PART 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
PART 2

GENERAL
SUMMARY/APPLICABILITY
SUBMITTALS
SAFETY
SYSTEM SUPPLIER INVOLVEMENT
COMMISSIONING PLAN
CERTIFICATION OF COMPLETION
COMMISSIONING REPORT
DISPOSAL OF WASTE MATERIALS
PRODUCTS

2.1
DESIGN CONDITIONS
2.2
CONTRACTOR PROVIDED MATERIALS AND EQUIPMENT
2.3
GOVERNMENT FURNISHED MATERIALS AND EQUIPMENT
2.3.1
Fuel
2.3.2
Utilities
2.3.3
Tank Trucks
2.3.4
Hydrant Hose Trucks
2.3.5
Defuel Cart
2.3.6
Pantographs
PART 3

EXECUTION

3.1
PRELIMINARY REQUIREMENTS
3.1.1
Electrical Preparations
3.1.2
Emergency Fuel Shutoff (EFSO) System Testing
3.1.3
Storage Tanks
3.1.4
Piping System
3.1.4.1
Pier Piping Systems
3.2
PREPARATIONS FOR FLUSHING
3.2.1
Protection Of Equipment
3.2.2
Strainers
3.2.3
Water Draw-Off
3.3
SWAB PIG RUN - PNEUMATIC
3.4
INITIAL FUEL RECEIPT
SECTION 33 08 55

Page 1

3.4.1
General
3.4.2
Storage Tanks
3.4.3
Components
3.4.4
Fuel Quality
3.4.5
Fuel Receipt
3.4.5.1
Fuel Receipt by Pipeline
3.4.5.2
Receipt by Commercial Truck
3.4.6
Initial Low Point Flush
3.4.7
Storage Tank and Piping Hydrostatic Tests with Fuel
3.5
FLUSHING
3.5.1
Flushing Requirements
3.5.2
Fueling System Piping
3.5.3
Pier Piping
3.5.4
Piping Flushing Checklist
3.6
PIPE PIGGING RUNS
3.6.1
General
3.6.2
Cleaning Pig Run
3.6.3
Wire Brush Pig Run
3.7
CLEANING, TESTING, AND SAMPLING
3.7.1
Preparation for Cleaning
3.7.2
Cleaning Requirements
3.7.3
Cleaning Procedure
3.7.4
Piping Cleaning Checklist
3.8
CONTROL VALVE [AND VENTURI ]ADJUSTMENT
3.8.1
Control Valve Checklist
3.8.2
Venturi Adjustment
3.8.3
Pantograph Venturi Needle Valve
3.9
EQUIPMENT TESTS
3.9.1
Emergency Fuel Shutoff System
3.9.2
Filter/Separator Control Valve
3.10
PERFORMANCE TESTS
3.10.1
Fuel Receipt Systems
3.10.1.1
Aboveground systems
3.10.1.2
Drop tank systems
3.10.2
Storage Tank Systems
3.10.3
Transfer/Delivery Systems
3.10.4
Hydrant Systems
3.10.5
Marine Fueling Systems
3.10.6
Truck Fillstands
3.10.7
Satisfactory Performance
3.11
TRAINING / INSTRUCTION FOR GOVERNMENT PERSONNEL
3.12
PROJECT CLOSEOUT
-- End of Section Table of Contents --

SECTION 33 08 55

Page 2

**************************************************************************
USACE / NAVFAC / AFCEC / NASA
Preparing Activity:

UFGS-33 08 55 (July 2007)

-------------------------Superseding
UFGS-23 14 00 (April 2007)

AFCEC

UNIFIED FACILITIES GUIDE SPECIFICATIONS

**************************************************************************
SECTION 33 08 55
COMMISSIONING OF FUEL FACILITY SYSTEMS
07/07
**************************************************************************
NOTE: This guide specification covers the
requirements for commissioning of petroleum fuel
systems. A "Fuel System" includes all equipment,
components, control systems, devices, and associated
appurtenances which are used for the receipt,
storage, transfer and issue of petroleum fuel
products. The following types of systems are
covered: receipt systems, storage tank systems,
transfer systems, hydrant systems, marine fueling
systems, truck fillstands.
For "Type III" Hydrant System commissioning, use
Specification Section 15899 of DoD Standard Design
Number AW-078-24-28.
The designer should include the Contractor's /
subcontractor's efforts associated with system
startup and commissioning in any required
Construction Cost Estimates.
Adhere to UFC 1-300-02 Unified Facilities Guide
Specifications (UFGS) Format Standard when editing
this guide specification or preparing new project
specification sections. Edit this guide
specification for project specific requirements by
adding, deleting, or revising text. For bracketed
items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in
respective project, whether or not brackets are
present.
Comments, suggestions and recommended changes for
this guide specification are welcome and should be
submitted as a Criteria Change Request (CCR).
**************************************************************************

SECTION 33 08 55

Page 3

PART 1
1.1

GENERAL
SUMMARY/APPLICABILITY

This specification defines the requirements and procedures for startup and
commissioning of fuel facility systems. It covers requirements for safety,
Government scheduling and coordination, device testing, system flushing and
cleaning, demonstration of indicated and specified system performance and
final acceptance and reporting.
1.2

SUBMITTALS

**************************************************************************
NOTE: Review submittal description (SD) definitions
in Section 01 33 00 SUBMITTAL PROCEDURES and edit
the following list to reflect only the submittals
required for the project.
The Guide Specification technical editors have
designated those items that require Government
approval, due to their complexity or criticality,
with a "G." Generally, other submittal items can be
reviewed by the Contractor's Quality Control
System. Only add a G to an item, if the submittal
is sufficiently important or complex in context of
the project.
For submittals requiring Government approval on Army
projects, a code of up to three characters within
the submittal tags may be used following the "G"
designation to indicate the approving authority.
Codes for Army projects using the Resident
Management System (RMS) are: "AE" for
Architect-Engineer; "DO" for District Office
(Engineering Division or other organization in the
District Office); "AO" for Area Office; "RO" for
Resident Office; and "PO" for Project Office. Codes
following the "G" typically are not used for Navy,
Air Force, and NASA projects.
An "S" following a submittal item indicates that the
submittal is required for the Sustainability
Notebook to fulfill federally mandated sustainable
requirements in accordance with Section 01 33 29
SUSTAINABILITY REQUIREMENTS.
Choose the first bracketed item for Navy, Air Force
and NASA projects, or choose the second bracketed
item for Army projects.
**************************************************************************
Government approval is required for submittals with a "G" designation;
submittals not having a "G" designation are [for Contractor Quality Control
approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for
the Government.] Submittals with an "S" are for inclusion in the
Sustainability Notebook, in conformance to Section 01 33 29SUSTAINABILITY
REQUIREMENTS. Submit the following in accordance with Section 01 33 00
SUBMITTAL PROCEDURES:
SECTION 33 08 55

Page 4

SD-01 Preconstruction Submittals

Commissioning Plan[; G][; G, [_____]]
SD-06 Test Reports
Piping Flushing Checklist[; G][; G, [_____]]
[Piping Cleaning Checklist[; G][; G, [_____]]]
Control Valve Checklist[; G][; G, [_____]]
Commissioning Report[; G][; G, [_____]]
SD-07 Certificates
Certification of Completion
Disposal of Waste Materials
1.3

SAFETY

Prior to any on-site commissioning activities, the following safety

procedures shall be accomplished in all fueling areas to be commissioned
under this specification section: testing/operation of emergency eyewash
facilities, placement of Contractor-provided portable eyewash units within
<31 meters><100 feet> or 10 seconds from the fueling point, verification of
proper grounding throughout system, coordination with Government Fire and
Safety Office and Fuels personnel, placement of
[Contractor-][Government-]provided spill pads[ and containment booms],
placement of [Contractor-][Government-]provided fire extinguishers capable
of extinguishing a fuel fire. Ensure that all radios/devices at all Class
I, Division 1 areas are intrinsically safe.
1.4

[SYSTEM SUPPLIER INVOLVEMENT

**************************************************************************
NOTE: Include bracketed text if previous
specifications require the use of a system supplier
for equipment/controls supply, coordination and
installation verification.
**************************************************************************
The System Supplier is defined in Specification [_____]. The Contractor
and the System Supplier shall work together to prepare the work plan,
commissioning plan, test reports and final reports. They shall both be
present during all commissioning activities and shall coordinate and
schedule the work during construction, testing, calibration and acceptance
of the system, and operator training. The System Supplier shall be
responsible to the Contractor for scheduling all Contractor,
sub-Contractor, and manufacturer's service personnel during system startup
and final commissioning.
]1.5

COMMISSIONING PLAN

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

SECTION 33 08 55

Page 5

a.

Personnel. List of Contractor's personnel by trade, list of key

personnel, list of safety equipment, list of miscellaneous equipment
such as two-way radios, and personnel transportation vehicles.

b.

Performance Testing. Detailed equipment startup procedures and

schedules to perform all system tests under each operating scenario in
accordance with paragraph entitled "Performance Tests".

[c.

Pigging Plans. The Contractor shall submit a detailed written plan

covering all aspects of the pipeline pigging operation, including
anticipated pig runs, types of pigs, sequence of work, and
retrieval/repair procedures. For gas-propelled pig runs, propellant
shall only be used behind pigs and shall be isolated from the remaining
system.]

d.

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

e.

Schedule. Schedules shall generated listing dates and durations of all

commissioning activities as well as regular coordination and safety
meetings and dates of key events for Government
[ and AFPET] participation.

f.

Fuel. Quantities of fuel needed for all commissioning activities and

fuel delivery schedules. Plan shall include requirements and schedules
for Government-provided materials and equipment.

g.

Contingency plans. Information on spill and fire contingencies, along

with the required Government Fire and Safety Office involvement and
approvals.

**************************************************************************
NOTE: Designer should identify all base-specific
phasing and operational issues for incorporation in
the contract documents.
**************************************************************************
h.

1.6

Coordination with Base. Description of how Contractor [and system

supplier ]shall implement system start-up in coordination with ongoing
base operations. Plan shall incorporate all phasing and work
restriction requirements of the Contract Documents.
CERTIFICATION OF COMPLETION

As a prerequisite to fuel system commissioning, the Contractor shall submit

a Certificate of Completion that certifies all work provided on the fuel
system, except for field painting, has been inspected and approved by the
specified approving authorities. Further, the Contractor shall certify on
this certificate that all specified checks and inspections have been
successfully completed prior to commissioning. The Contractor shall give
the Contracting Officer at least [45][30][____] calendar days notice prior
to commencement of fuel system commissioning. The Contractor shall submit
the Certificate of Completion to the Contracting Officer at least
[7][____] calendar days prior to commencement of system commissioning. The
Contracting Officer shall then be responsible for scheduling the Government
representatives [and appropriate military command authority ]
[and designers ]for participation in the inspection, performance testing,
SECTION 33 08 55

Page 6

and final approval activities. Any contractual deficiencies observed shall

be corrected by the Contractor without cost to the Government.
1.7

COMMISSIONING REPORT

Contractor shall prepare a commissioning report that documents the

execution of the approved commissioning plan. All items of work specified
in the commissioning plan shall be carried out and reported in this report
unless otherwise approved by the Contracting Officer. Include as a part of
this report verification letters of approved fuel storage tank hydrostatic
tests and the piping hydrostatic tests, as generated under other
specification sections. The commissioning report shall include the final
settings of the control valves and pressure and flow switches [and a copy
of the PLC-generated data spreadsheets and trend analysis
graphs/charts] [and a copy of the strip chart graphs ]with an explanation
of what each graph indicates and what the system is doing.
1.8

DISPOSAL OF WASTE MATERIALS

The Contractor shall be responsible for properly disposing of any sludge,

debris, filtration elements, and waste fuel resulting from piping and tank
cleaning and flushing activities as specified in Section [____]. [Comply
with all applicable local, State, and Federal Regulations for hazardous
waste disposal.]
PART 2
2.1

PRODUCTS
DESIGN CONDITIONS

Temporary flushing lines and equipment shall be equal in strength,

stability, and materials to the associated permanent components; however,
temporary spools may be carbon steel.
2.2

CONTRACTOR PROVIDED MATERIALS AND EQUIPMENT

**************************************************************************
NOTE: Delete all bracketed materials and equipment
which do not apply to this project.
**************************************************************************
The Contractor shall provide all material, equipment and labor required for
proper start-up of the system(s), except for that specified to be
Government furnished. Equipment shall include but not be limited to the
following:
a.

Temporary strainers.

b.

Pipe spools[ to include spool pieces with a Single Point Receptacle on

each end to allow defueling of the refueler tank trucks through the
hydrant hose truck].

c.

Flow meters.

d.

Pressure Gages[ to include bayonet type gage to be used on the SPR on

the Government truck. Gage shall be turned over to the Government after
startup is complete].

[ e.

Electronic sensors and [PLC data logging feature][strip recorders] for

pressure and flow recording are included in the PCP[, except for a
SECTION 33 08 55

Page 7

sensor and cable for the data from the Hydrant Control Valve, to be
plugged into the PCP]. This equipment shall be used to monitor and
record the system during the "Equipment Test" and "Performance Testing"
portions of this Specification Section. Recorded data shall be used by
the Contractor and equipment factory representatives to achieve final
control valve and equipment adjustments. Recorded data shall include:

f.

(1)

Fueling pumps discharge pressures.

(2)

Supply Venturi flow rates.

(3)

Hydrant Control Valve pressures.

(4)

Back Pressure Control Valve upstream pressures.

(5)

Back Pressure Control Valve downstream pressures.

(6)

Return Venturi flow rates.]

The Contractor must have on hand sufficient filter/separator elements

and cartridges to adequately clean the system to aircraft quality use
limits. During cleaning operation specified in paragraph below,
"Cleaning, Testing and Sampling", Contractor shall provide a flow
versus pressure drop graph for each filter/separator[, including
pantograph-mounted units]. Contractor shall change elements and
cartridges upon reaching a differential pressure (DP) of <15 psi at
[600][300] gpm> <103 kPa at [38][19] lps> or per manufacturer's
recommended maximum DP at the actual flow rate, or when pressure drop
is less than previously graphed or fails to increase properly. A
minimum of one complete set of coalescer cartridges and separator
elements for each filter/separator shall be turned over to the
Government after new coalescer cartridges and separator elements are
installed in each vessel and after completion of acceptance testing.

[ g.

The Contractor must have on hand sufficient fuel quality monitor

elements to adequately clean the system to aircraft quality use
limits. During cleaning operation as described in the paragraph below,
"Cleaning, Testing and Sampling", Contractor shall provide a flow
versus pressure drop graph for each vessel[, including
pantograph-mounted units]. Contractor shall change elements upon
reaching a differential pressure (DP) of <15 psi at [600][300] gpm>
<103 kPa at [38][19] lps> or per manufacturer's recommended maximum DP
at the actual flow rate, or when pressure drop is less than previous
graph or fails to increase properly. A minimum of one complete set of
elements for each vessel shall be turned over to the Government after
new elements are installed in each vessel and after completion of
acceptance testing.]

[ h.

Refueled tanker trucks for flushing and draining of the system.]

[ i.

Hydrant hose trucks for fueling and defueling of aircraft.]

[ j.

Defuel carts for defueling operation.]

[ k.

The Contractor shall be responsible for providing the electrical power

from a a source identified by the Government to the testing locations.]

[ l.

Pig launching and receiving barrels.]

SECTION 33 08 55

Page 8

[ m.

Temporary filtration/strainers.]

2.3

GOVERNMENT FURNISHED MATERIALS AND EQUIPMENT

**************************************************************************
NOTE: Delete all bracketed materials and equipment
which do not apply to this project.
**************************************************************************
The Government will furnish the following materials, equipment and services
used during the execution of the commissioning plan. Any damage caused by
the Contractor's operations shall be repaired at no additional cost to the
Government.
2.3.1

Fuel

The Government will provide the fuel necessary for system testing. The
Contractor shall notify the Contracting Officer a minimum of sixty (60)
days in advance of the requirements. Additional fuel will be provided by
the Government as required for satisfactory flushing of the system. Upon
satisfactory completion of the flushing and cleaning operations, the
Government will supply the additional quantities of fuel required to
complete the other work under this specification section.
Fuel will not be delivered to the system until the Contractor has
satisfactorily completed all work and, in particular, the cleaning and
coating of the interior surfaces of the storage tanks and the removal of
preservatives and foreign matter from those portions coming in contact with
the fuel valves, pumps, filter/separators and other such equipment. Fuel
delivered to the system shall remain the property of the Government and the
Contractor shall reimburse the Government for shortages not attributable to
normal handling losses.[ The Contractor shall be responsible for the
disposal of any contaminated fuel.] The Government shall be reimbursed for
fuel lost as a result of defective materials or workmanship.
2.3.2

[Utilities

Electric power required for the performance of the work under this
specification section will be furnished at no charge to the Contractor.
]2.3.3

[Tank Trucks

Refueler tank trucks[ and defueler tank trucks] will be furnished and
operated by Government personnel.
]2.3.4

[Hydrant Hose Trucks

The Government will furnish and operate the hydrant hose trucks required
for ground refueling and defueling of aircraft at hydrant pits.
]2.3.5

[Defuel Cart

**************************************************************************
NOTE: Select defuel cart for systems using
hydraulic pantographs.
**************************************************************************
The Government will furnish a defuel cart for the defueling operation on
systems using pantographs.
SECTION 33 08 55

Page 9

]2.3.6

[Pantographs

The Government will furnish and operate additional mobile pantographs for
systems which do not provide enough pantographs to accomplish the full flow
testing.
]PART 3
3.1

EXECUTION

PRELIMINARY REQUIREMENTS

**************************************************************************
NOTE: Delete bracketed text if system does not
include an Oil/Water Separator.
**************************************************************************
All activities listed in paragraph "PART 3 EXECUTION" shall be performed
sequentially in the order they are presented. Prior to any on-site
commissioning activities, the Contractor shall ensure that all requirements
of the paragraph entitled "Safety" are satisfied. Project shall be
substantially complete and Contractor's work area shall be free of debris,
trash and obstacles. [Correct functioning of oil/water separator(s) shall
be verified prior to receipt of fuel. ] Perform the following activities
prior to receipt of fuel:
3.1.1

Electrical Preparations

Prior to energizing the electrical equipment, verify that short-circuit

links have been removed from current transformer and that secondary
circuits have been connected. Confirm that all tests required for fire
detection and suppression systems have been performed and accepted. Verify
all electrical transmitter connections and ensure proper calibration.
Verify all electrical equipment meets Class I Division 1 requirements.
Verify correct rotation of all motors prior to testing. Verify paddle type
flow switches by physically actuating vanes and checking outputs. Conduit
explosion-proof sealoffs shall be poured after initial electrical checks
but before fuel receipt.
3.1.2

Emergency Fuel Shutoff (EFSO) System Testing

**************************************************************************
NOTE: Select appropriate functions/valve(s) of EFSO
system.
**************************************************************************
Prior to initial fuel receipt, verify that each switch will trip the
circuit breaker of the fuel pump[s][ and de-energize the EFSO relay and
close the [main emergency fuel shut-off valve] [flow control valve of each
filter/separator].]
3.1.3

Storage Tanks

**************************************************************************
NOTE: Select appropriate tank features.
**************************************************************************
Ensure approved performance of storage tank integrity testing, hydrostatic
tests and coating application/inspection per the applicable specifications.
Include verification letter of approved test results for information in
SECTION 33 08 55

Page 10

shall be packed with fuel, following procedures outlined in paragraph

"General" above. Perform piping hydrostatic tests with fuel per the
applicable specifications, ensuring the piping system is completely vented
of air through the piping high point vent system. Contractor shall submit
a tank and piping testing checklist to ensure the requirements of this and
other applicable specifications are met.
3.5

FLUSHING

**************************************************************************
NOTE: Select type of piping system being flushed.
Select pantographs or hydrant hose truck.
**************************************************************************
The intent of the flushing operation is to remove bulk solids and water
from the system. Flushing procedures shall precede cleaning procedures.
All new [and modified ]fuel piping, including the transfer line, receipt
system piping, pier piping, pump house piping, apron loop, supply and
return lines to the storage tanks, hydrant and fillstand piping, product
recovery lines and [pantograph] [hydrant hose truck] lines shall be flushed
with fuel.
3.5.1

Flushing Requirements

**************************************************************************
NOTE: Select bracketed text based on available
pumping capacity. Require temporary pumps only
after A/E feasibility review; if used, provide
detailed work sequence/limitations on contract
documents.
**************************************************************************
Begin flushing of fuel system pipelines at low flow rates using one
delivery pump. Slowly increase flushing flow rate with additional pumps
[until a +/-12 FPS fuel velocity is achieved][to full flow capacity] for a
minimum of 30 minutes.[ If 12 FPS cannot be achieved using system pumps,
the Contractor shall provide additional temporary pumping capacity.] [For
gravity, suction, or other non-pumped piping segments, minimum flushing
volume shall be four times the pipe volume. ]Flushing shall continue until
the fuel being delivered is free of construction debris to the satisfaction
of the Contracting Officer. Samples of fuel shall be taken and tested by
the designated Government agency and shall be free of gross contamination
and visible free water[, maximum of 8.0 mg/gallon solids and free water not
to exceed 2 ml per quart for aviation fuel systems].
3.5.2

Fueling System Piping

The flushing of system pipelines shall be accomplished by pumping fuel from

one storage tank through the fueling system piping[ and back to another
tank]. After high-speed flush of main system piping, all piping laterals
shall be flushed with at least one refueling truck (5000 gallons) of fuel.
Air shall be bled from system high points. The procedure shall be
continued until the fuel being delivered into the tanks is acceptable to
the Contracting Officer. After the main piping system has been flushed to
the satisfaction of the Contracting Officer, and periodically during the
flushing operation, the Contractor shall flush all high point vents and low
point drains for a minimum of 10 seconds at a pressure of 30 psig. Remove
any accumulated water from storage tank sumps and bottoms. [In piggable
systems, all plug valves shall be flushed of all debris using the drain
SECTION 33 08 55

Page 14

port at the bottom of the valve. ]Strainers shall be kept clean in order
to insure maximum flow rate. All accumulated material from the strainers
shall be reviewed and identified, including source if possible. Upon
completion of the first flushing operations, the cone strainers shall be
[removed from the system.][cleaned, reinstalled, and remain in the
system.] In addition, baskets from all strainers shall be removed and
cleaned.
3.5.3

[Pier Piping

**************************************************************************
NOTE: Modify to suit project-specific
facilities/water availability at pier.
**************************************************************************
Pier piping and loading arms should be hydrostatically tested with fresh
water per the applicable specification. After testing, flush piping with
fresh water at 12 FPS for 30 minutes. [The Contractor will be allowed to
use Government-furnished hoses. ]Drain all water from piping system and
refill with product. Perform flushing with product at 12 FPS for 30
minutes. [The Contractor shall be allowed to use Government
barges/equipment to facilitate system flushing.]
]3.5.4

Piping Flushing Checklist

The Contractor shall generate a comprehensive matrix of all new[ and

existing] piping sections in the system. Matrix shall serve as an Owner's
piping inventory and a checklist for all Contractor-provided flushing
operations. Column entries shall include pipe section name, location,
diameter, approximate length, flushing fuel velocity and volume achieved
and acceptable results of sampling.
3.6
[PIPE PIGGING RUNS
**************************************************************************
NOTE: Select bracketed paragraph if system is
designed to be piggable. Standard cleaning pig runs
are recommended on all systems.
**************************************************************************
3.6.1

General

**************************************************************************
NOTE: Include bracketed text for non-stainless
piping systems, or if excessive contamination is
anticipated.
**************************************************************************
The Contractor shall track all pigs, using transmitter and receivers, at no
less than 1/2 mile increments, but no less than at four (4) locations. The
Contractor shall prepare a contingency plan for retrieving a stuck pig and
repairing any piping deformations. After pigging, plug valves shall be
flushed of all debris using the drain port at the bottom of the valve.
[The Contractor shall be responsible for insuring that the fuel that is
returned to the storage tanks during the pig runs is free of gross
contamination and passes the color assessment method, and meets the
requirements of MIL-STD-3004A. The Contractor may need to provide
temporary storage tanks for the high particulate and dark color fuel that
accumulates in front of and behind each pig. The contractor will be
responsible for [cleaning the off-spec fuel in order to meet the
SECTION 33 08 55

Page 15

requirements of MIL-STD-3004A] [dispose of the off-spec fuel

off-base][obtain permission from the Contracting officer to downgrade the
fuel and dispose of it in the appropriate tank.]
]3.6.2

Cleaning Pig Run

[Contractor-provided pig launching and receiving barrels shall be

installed. ]Initially, a proving pig run (foam density <2 lb/ft3<32 kg/m3>
should be performed to ensure the system is fully piggable. Upon
completion of the successful proving pig run, the piping system shall be
cleaned with a standard cleaning pig. This will provide thorough cleaning
of the interior of the piping system. Cleaning pig shall be the
bi-directional disk scraper style with steel body and replaceable
polyurethane guiding and sealing disks, as well as gauge plates of 80
percent pipe diameter with 1/8-inch segmented aluminum fins. The pig body
should include bypass nozzles and transmitter cavity. Propellant shall be
pressurized fuel using the main system delivery pumps. The pig shall be
examined after the initial run for signs of possible pipe damage, interior
slag or other adhered particles. Additional runs shall be performed until
the amount of collected sludge or debris is minimized, as determined by the
[Contracting Officer][System Supplier].
3.6.3

[Wire Brush Pig Run

**************************************************************************
NOTE: Select wire brush cleaning pig option if
excessive slag or other adhered particles are
suspected on the pipe interior. Require stainless
steel brushes on stainless steel piping systems.
Note: Never perform wire brush cleaning pig on
interior epoxy coated piping systems.
**************************************************************************
After the cleaning pig runs, the piping system shall be cleaned with a wire
brush style pig. This will remove weld slag and adhered particles from the
system. Wire brush pig shall be the bi-directional disk style or
directional cup style with two circular [stainless] steel wire brushes.
The pig body should include bypass nozzles and transmitter cavity. Perform
wire brush pig runs until the amount of collected weld slag or debris is
minimized, as determined by the [Contracting Officer][System Supplier].
]]3.7

[CLEANING, TESTING, AND SAMPLING

**************************************************************************
NOTE: Include this paragraph and subparagraphs only
when this paragraph is covering the commissioning of
aviation fuel systems.
**************************************************************************
After the completion of the initial flushing[ and cleaning pig runs], all
new[ and modified] piping shall be cleaned in accordance with the procedure
specified hereafter. The intent of this cleaning operation is to remove
trace solids and water from the system.
3.7.1

Preparation for Cleaning

Filter elements shall be installed in the filter/separators.[ Elements

shall be installed in the fuel quality monitors.] Adjust filter/separator
SECTION 33 08 55

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shall be packed with fuel, following procedures outlined in paragraph

"General" above. Perform piping hydrostatic tests with fuel per the
applicable specifications, ensuring the piping system is completely vented
of air through the piping high point vent system. Contractor shall submit
a tank and piping testing checklist to ensure the requirements of this and
other applicable specifications are met.
3.5

FLUSHING

**************************************************************************
NOTE: Select type of piping system being flushed.
Select pantographs or hydrant hose truck.
**************************************************************************
The intent of the flushing operation is to remove bulk solids and water
from the system. Flushing procedures shall precede cleaning procedures.
All new [and modified ]fuel piping, including the transfer line, receipt
system piping, pier piping, pump house piping, apron loop, supply and
return lines to the storage tanks, hydrant and fillstand piping, product
recovery lines and [pantograph] [hydrant hose truck] lines shall be flushed
with fuel.
3.5.1

Flushing Requirements

**************************************************************************
NOTE: Select bracketed text based on available
pumping capacity. Require temporary pumps only
after A/E feasibility review; if used, provide
detailed work sequence/limitations on contract
documents.
**************************************************************************
Begin flushing of fuel system pipelines at low flow rates using one
delivery pump. Slowly increase flushing flow rate with additional pumps
[until a +/-12 FPS fuel velocity is achieved][to full flow capacity] for a
minimum of 30 minutes.[ If 12 FPS cannot be achieved using system pumps,
the Contractor shall provide additional temporary pumping capacity.] [For
gravity, suction, or other non-pumped piping segments, minimum flushing
volume shall be four times the pipe volume. ]Flushing shall continue until
the fuel being delivered is free of construction debris to the satisfaction
of the Contracting Officer. Samples of fuel shall be taken and tested by
the designated Government agency and shall be free of gross contamination
and visible free water[, maximum of 8.0 mg/gallon solids and free water not
to exceed 2 ml per quart for aviation fuel systems].
3.5.2

Fueling System Piping

The flushing of system pipelines shall be accomplished by pumping fuel from

one storage tank through the fueling system piping[ and back to another
tank]. After high-speed flush of main system piping, all piping laterals
shall be flushed with at least one refueling truck (5000 gallons) of fuel.
Air shall be bled from system high points. The procedure shall be
continued until the fuel being delivered into the tanks is acceptable to
the Contracting Officer. After the main piping system has been flushed to
the satisfaction of the Contracting Officer, and periodically during the
flushing operation, the Contractor shall flush all high point vents and low
point drains for a minimum of 10 seconds at a pressure of 30 psig. Remove
any accumulated water from storage tank sumps and bottoms. [In piggable
systems, all plug valves shall be flushed of all debris using the drain
SECTION 33 08 55

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port at the bottom of the valve. ]Strainers shall be kept clean in order
to insure maximum flow rate. All accumulated material from the strainers
shall be reviewed and identified, including source if possible. Upon
completion of the first flushing operations, the cone strainers shall be
[removed from the system.][cleaned, reinstalled, and remain in the
system.] In addition, baskets from all strainers shall be removed and
cleaned.
3.5.3

[Pier Piping

**************************************************************************
NOTE: Modify to suit project-specific
facilities/water availability at pier.
**************************************************************************
Pier piping and loading arms should be hydrostatically tested with fresh
water per the applicable specification. After testing, flush piping with
fresh water at 12 FPS for 30 minutes. [The Contractor will be allowed to
use Government-furnished hoses. ]Drain all water from piping system and
refill with product. Perform flushing with product at 12 FPS for 30
minutes. [The Contractor shall be allowed to use Government
barges/equipment to facilitate system flushing.]
]3.5.4

Piping Flushing Checklist

The Contractor shall generate a comprehensive matrix of all new[ and

existing] piping sections in the system. Matrix shall serve as an Owner's
piping inventory and a checklist for all Contractor-provided flushing
operations. Column entries shall include pipe section name, location,
diameter, approximate length, flushing fuel velocity and volume achieved
and acceptable results of sampling.
3.6
[PIPE PIGGING RUNS
**************************************************************************
NOTE: Select bracketed paragraph if system is
designed to be piggable. Standard cleaning pig runs
are recommended on all systems.
**************************************************************************
3.6.1

General

**************************************************************************
NOTE: Include bracketed text for non-stainless
piping systems, or if excessive contamination is
anticipated.
**************************************************************************
The Contractor shall track all pigs, using transmitter and receivers, at no
less than 1/2 mile increments, but no less than at four (4) locations. The
Contractor shall prepare a contingency plan for retrieving a stuck pig and
repairing any piping deformations. After pigging, plug valves shall be
flushed of all debris using the drain port at the bottom of the valve.
[The Contractor shall be responsible for insuring that the fuel that is
returned to the storage tanks during the pig runs is free of gross
contamination and passes the color assessment method, and meets the
requirements of MIL-STD-3004A. The Contractor may need to provide
temporary storage tanks for the high particulate and dark color fuel that
accumulates in front of and behind each pig. The contractor will be
responsible for [cleaning the off-spec fuel in order to meet the
SECTION 33 08 55

Page 15

requirements of MIL-STD-3004A] [dispose of the off-spec fuel

off-base][obtain permission from the Contracting officer to downgrade the
fuel and dispose of it in the appropriate tank.]
]3.6.2

Cleaning Pig Run

[Contractor-provided pig launching and receiving barrels shall be

installed. ]Initially, a proving pig run (foam density <2 lb/ft3<32 kg/m3>
should be performed to ensure the system is fully piggable. Upon
completion of the successful proving pig run, the piping system shall be
cleaned with a standard cleaning pig. This will provide thorough cleaning
of the interior of the piping system. Cleaning pig shall be the
bi-directional disk scraper style with steel body and replaceable
polyurethane guiding and sealing disks, as well as gauge plates of 80
percent pipe diameter with 1/8-inch segmented aluminum fins. The pig body
should include bypass nozzles and transmitter cavity. Propellant shall be
pressurized fuel using the main system delivery pumps. The pig shall be
examined after the initial run for signs of possible pipe damage, interior
slag or other adhered particles. Additional runs shall be performed until
the amount of collected sludge or debris is minimized, as determined by the
[Contracting Officer][System Supplier].
3.6.3

[Wire Brush Pig Run

**************************************************************************
NOTE: Select wire brush cleaning pig option if
excessive slag or other adhered particles are
suspected on the pipe interior. Require stainless
steel brushes on stainless steel piping systems.
Note: Never perform wire brush cleaning pig on
interior epoxy coated piping systems.
**************************************************************************
After the cleaning pig runs, the piping system shall be cleaned with a wire
brush style pig. This will remove weld slag and adhered particles from the
system. Wire brush pig shall be the bi-directional disk style or
directional cup style with two circular [stainless] steel wire brushes.
The pig body should include bypass nozzles and transmitter cavity. Perform
wire brush pig runs until the amount of collected weld slag or debris is
minimized, as determined by the [Contracting Officer][System Supplier].
]]3.7

[CLEANING, TESTING, AND SAMPLING

**************************************************************************
NOTE: Include this paragraph and subparagraphs only
when this paragraph is covering the commissioning of
aviation fuel systems.
**************************************************************************
After the completion of the initial flushing[ and cleaning pig runs], all
new[ and modified] piping shall be cleaned in accordance with the procedure
specified hereafter. The intent of this cleaning operation is to remove
trace solids and water from the system.
3.7.1

Preparation for Cleaning

Filter elements shall be installed in the filter/separators.[ Elements

shall be installed in the fuel quality monitors.] Adjust filter/separator
SECTION 33 08 55

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flow control valve. Valves and equipment removed for flushing shall be
reinstalled.[ Cone strainers shall be removed.][ Cone strainers shall be
cleaned, reinstalled, and remain in the system. ]Tanks[, including the
product recovery tank] shall be drained, vapor freed and cleaned per the
tank cleaning specification. Transfer the contents from one storage tank
to the other through the filter/separators for the purposes of cleaning.
[Provide temporary filtration as required to prevent cross-contamination of
fuel.]
3.7.2

Cleaning Requirements

Fuel shall be pumped through all new[ and existing] piping sections[
including pantographs] in the system. Fuel velocity during all cleaning
operations shall be full pumping capacity.[ Minimum cleaning volume
through non-pumped piping segments shall be four times the pipe volume.]
Cleaning shall continue until Contracting Officer certifies that the fuel
contains 2 milligrams per gallon or less of particulate and 10 parts per
million or less of free water. Perform sampling at all system discharge
points, at tanks, and throughout pumphouse and piping system. Sampling and
testing shall be done by [the appropriate military service][an independent
testing laboratory].
3.7.3

Cleaning Procedure

During cleaning procedure periodically bleed air through high point vents
and flush low point drains for a minimum of 10 seconds at a system pressure
of 30 psig. Monitor pressure drop through the filter/separators[ and fuel
quality monitor][ including pantograph-mounted units] during each cleaning
operation and provide flow vs. pressure drop graphs. Any time
filter/separator[ or fuel quality monitor] DP reaches its maximum allowable
value, vessel elements should be replaced. [In piggable systems, all plug
valves shall be flushed of all debris using the drain port at the bottom of
the valve.]
3.7.4

Piping Cleaning Checklist

The Contractor shall generate a comprehensive matrix of all new[ and

existing] piping sections in the system. Matrix shall serve as a checklist
for all Contractor-provided cleaning operations. Column entries shall
include pipe section name, location, diameter, approximate length, fuel
velocity and volume achieved, and acceptable results of sampling.
]3.8

CONTROL VALVE [AND VENTURI ]ADJUSTMENT

All control valve settings shall be checked and field adjusted from the
factory settings at start-up as necessary to provide a smooth operation.
Adjustments to valves shall be made only by the Valve Manufacturer's
authorized Field Test Engineer.
3.8.1

Control Valve Checklist

The Contractor shall generate a comprehensive matrix of all control valves

in the system. Matrix shall serve as a checklist of all required control
valve features, settings, and functions as specified. Column entries shall
include control valve name, valve tag, pilot features, solenoid control
features (if applicable), factory settings, and field adjusted settings.
Submit matrix with commissioning "Final Reports".

SECTION 33 08 55

Page 17

3.8.2

[Venturi Adjustment

Calibrate and adjust each venturi and its associated transmitter readout to
demonstrate accurate florae measurement.
]3.8.3

[Pantograph Venturi Needle Valve

**************************************************************************
NOTE: DELETE IF PANTOGRAPHS ARE NOT USED.
**************************************************************************
Venturi needle valve shall be adjusted to ensure a pressure equal to nozzle
pressure at maximum flow possible. After initial setting, valve shall be
locked in adjusted position.
]3.9

EQUIPMENT TESTS

After completion of flushing[, cleaning], and control valve and electrical

component adjustments, the equipment tests and performance tests specified
hereinafter shall be performed. [After cleaning is complete and ]prior to
performance testing, field adjustment of automatic control valves and
automatic pump controls while in operation shall be made only by the valve
manufacturer's authorized field test engineer. For final adjustment of
installed electrical control equipment the Contractor shall provide an
experienced electrical engineer, factory representative of control panel
manufacturer[ and factory representative of pressure and flow device
manufacturers]. Both the mechanical and electrical components shall be
adjusted concurrently. Tests will be witnessed by the Contracting Officer
and other Government representatives.
3.9.1

Emergency Fuel Shutoff System

With one fueling pump operating, test each "Emergency Stop" pushbutton
station to verify that the pump stops and the[ main emergency shutoff
valve][fuel control valve of each filter/separator] closes.[ Demonstrate
operation of the EFSO station at the control center.] Repeat this
procedure for each fueling pump and "Emergency Stop" pushbutton station.
Conduct tests for both the automatic and manual modes. With all the fueling
pumps circulating fuel through the system, push an "Emergency Stop"
pushbutton station, ensure all pumps stop, and emergency fuel shutoff
valve[s] close[s].
3.9.2

Filter/Separator Control Valve

Using the manual float control test lever on each filter/separator, slowly
lift the weight from the float ball and verify the operation and closure of
the water slug shut-off feature on the Filter/Separator Control Valve.
3.10

PERFORMANCE TESTS

During performance testing, the Contractor shall demonstrate that all

portions of the fuel system are operating as designed and specified. Tests
shall be performed under all operating scenarios. Additional tests may be
required by the Contracting Officer [and Command Fuels Engineer ]to fully
demonstrate system performance. These tests shall be accomplished by the
Contractor at no additional cost to the Government. The Contractor shall
notify the Contracting Officer [15][___] calendar days in advance of the
test to permit arrangement for the use of Government furnished items.
Record required data necessary to prepare reports specified in paragraph
SECTION 33 08 55

Page 18

**************************************************************************
USACE / NAVFAC / AFCEC / NASA
Preparing Activity:

UFGS-33 08 55 (July 2007)

-------------------------Superseding
UFGS-23 14 00 (April 2007)

AFCEC

UNIFIED FACILITIES GUIDE SPECIFICATIONS

**************************************************************************
SECTION TABLE OF CONTENTS
DIVISION 33 - UTILITIES
SECTION 33 08 55
COMMISSIONING OF FUEL FACILITY SYSTEMS
07/07
PART 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
PART 2

GENERAL
SUMMARY/APPLICABILITY
SUBMITTALS
SAFETY
SYSTEM SUPPLIER INVOLVEMENT
COMMISSIONING PLAN
CERTIFICATION OF COMPLETION
COMMISSIONING REPORT
DISPOSAL OF WASTE MATERIALS
PRODUCTS

2.1
DESIGN CONDITIONS
2.2
CONTRACTOR PROVIDED MATERIALS AND EQUIPMENT
2.3
GOVERNMENT FURNISHED MATERIALS AND EQUIPMENT
2.3.1
Fuel
2.3.2
Utilities
2.3.3
Tank Trucks
2.3.4
Hydrant Hose Trucks
2.3.5
Defuel Cart
2.3.6
Pantographs
PART 3

EXECUTION

3.1
PRELIMINARY REQUIREMENTS
3.1.1
Electrical Preparations
3.1.2
Emergency Fuel Shutoff (EFSO) System Testing
3.1.3
Storage Tanks
3.1.4
Piping System
3.1.4.1
Pier Piping Systems
3.2
PREPARATIONS FOR FLUSHING
3.2.1
Protection Of Equipment
3.2.2
Strainers
3.2.3
Water Draw-Off
3.3
SWAB PIG RUN - PNEUMATIC
3.4
INITIAL FUEL RECEIPT
SECTION 33 08 55

Page 1

a.

Tank overfill valve closure upon tank high level condition.

b.

Level alarm actuation.

c.

Pump shutdown on tank low level condition.

d.

Tank leak detection system performance (remove probe[s] and

actuate by dipping into water/fuel test buckets).

f.

Tank gauging system.

g.

Fire detection/suppression system performance (if AFFF system is

used, do not test into tanks).

h.

[_____].

Ensure certified strapping charts are provided to the Contracting Officer.

Demonstrate all other tank features and functions per the applicable
specifications.
3.10.3

Transfer/Delivery Systems

Demonstrate the following features:

a.

Manual start/stop pushbutton control.

b.

Pump shutdown upon no-flow condition signal from flow switch,

c.

Pump shutdown upon signal from remote EFSO switch.

d.

[____].

3.10.4

Hydrant Systems

Demonstrate the following features:

a.

Operation of all pressure and flow devices to automatically start

and stop the fueling pumps at the indicated pressures and flow
rates. The operating sequence shall be repeated with each of the
pumps being selected as lead pump.

b.

Completely redundant, independent programmable logic controller

capability.

c.

System's ability to deliver fuel to multiple fueling points at

specified flow rates.

d.

Hydrant control valve surge shutdown and pressure control

features.

[e.

Defueling performance of system under static conditions, with one

fueling pump operating, and in the "Flush" mode. ]

[f.

Operation of HSV/Pantograph checkout and flushing station.]

[g.

System performance in all operating[ and pressure test/leak

detection] modes.]

[h.

Operation of emergency generators during a simulated power

SECTION 33 08 55

Page 20

outage.]
i.
3.10.5

[____]
Marine Fueling Systems

Demonstrate the following features:

a.

Performance of loading meters[ and verification of proper

calibration].

b.

Performance of filter/separators.

c.

Loading/unloading arm function and operating range.

d.

Stripping pump operation.

e.

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

f.

[____].

Verify correct installation of piping expansion loops and supports. Verify

electrical isolation between pier piping and ship. Verify that pier piping
thermal relief system is properly installed.
3.10.6

Truck Fillstands

Demonstrate the following features:

a.

Manual start/stop pushbutton control.

b.

Static and continuity ground verification (with actual

ground/continuity readings) and overfill prevention system.

c.

Control valve deadman control, surge shutdown, and pressure

control features.

d.

Issue meter performance[ and preset controls][ and verification of

proper calibration].

[e.

Control valve and meter preset interconnections for flow control

and automatic shutdown.]

[f.

Additive injector system.]

[g.

Bypass mode.]

h.
3.10.7

[____]
Satisfactory Performance

In the event a portion of the system or any piece of equipment fails to

meet the test, the Contractor shall make the necessary repairs or
adjustments and repeat the Performance Test until satisfactory performance
is obtained. Measured flow rates should be within [ ] percent of design.
Tank level gauging and alarm measurements should be within [
] of
design. Any component found not to be working as specified shall be
repaired/replaced by the Contractor at no additional cost to the
Government. The determination of satisfactory performance shall be made by
SECTION 33 08 55

Page 21

the Contracting Officer[ and the Military Command Authority[ and Government
representatives]]. The system shall be filled with fuel and shall be
operable and leak-free prior to acceptance. The Contractor shall be
responsible for any leaks in the new or modified portions of the system.
Anything wet with fuel is considered to be leaking.
3.11

TRAINING / INSTRUCTION FOR GOVERNMENT PERSONNEL

The contracting authority should provide one or two key personnel from
their "operations" and "maintenance" departments to participate in all
phases of system commissioning. The Contractor and System Supplier will be
responsible for coordinating the involvement and training of these
individuals during the startup process, including hands-on familiarization
and adjustment of devices, valves, and components.
In addition, the Contractor and System Supplier shall conduct two 8-hour
formal training sessions at the conclusion of system performance testing.
These sessions shall include initial classroom system presentations as well
as a complete system walk-through. The function, operation and maintenance
procedures for all system devices and components will be explained.
Training shall be videotaped and submitted in CD ROM or DVD format.
3.12

PROJECT CLOSEOUT

Ensure that As-Built drawings, equipment warranty documentation, and other

project closeout activities are completed per the requirements of the
applicable specifications.
-- End of Section --

SECTION 33 08 55

Page 22