Documente Academic
Documente Profesional
Documente Cultură
Type:
GEN 115
Issue Date:
30 September 2008
Revision Date:
30 September 2011
Owner:
John Thurston
Approver:
Steve Anderson
Issuer:
Steve Anderson
(b)
(c)
Note that alternative or preferred requirements may be qualified by Air BP in another referenced
document.
Date Issued:
30 September 08
First Issue
Registered Address:
Air BP Limited
Chertsey Road
Sunbury-on-Thames
Middlesex
TW16 7LN
UNITED KINGDOM
Air BP Limited
30 September 2008
TABLE OF CONTENTS
1
INTRODUCTION ....................................................................................................................... 4
2.1
2.2
3.1
3.1.1
3.1.2
Vehicles ..................................................................................................................................... 6
3.1.3
Hoses......................................................................................................................................... 6
3.2
3.2.1
3.2.2
Pipelines .................................................................................................................................... 7
3.2.3
Vehicles ..................................................................................................................................... 7
3.2.4
Hoses......................................................................................................................................... 7
3.3
SUMMARY ................................................................................................................................ 8
Air BP Limited
30 September 2008
INTRODUCTION
Soak testing is carried out after construction work or repairs on fuel systems and vehicles
to ensure that there are no potential contaminants present in the form of solvents from
coatings/linings, welding flux, valve grease, or other general debris. Soak testing shall be
carried out even if the systems are constructed of aluminium or stainless steel as other
contaminants could still be present.
Soak testing shall be completed on the constructed facility rather than on representative
sections of pipe or on individual pieces of equipment (e.g. tanks or filter vessels) prior to
installation. This ensures that the soak test identifies problems caused during fabrication
of the particular piece of equipment as well as problems due to the actual on-site
construction work.
For tie-ins, where in-situ soak testing may not be practicable, the relatively short sections
of pipe, fittings or valves involved may be soak tested before installation, provided
adequate precautions are taken to ensure the cleanliness of the tie-in components until
the new system is put into service.
A soak test consists of filling the system being commissioned with the appropriate fuel
grade and leaving it to stand for a soak period. A retention sample of the fuel used is
taken before filling as a control in an Air BP approved sample container. At the end of the
soak period, the fuel is sampled from the system being commissioned and submitted for
laboratory testing.
The relevant Asset/Country Product Quality Authority or delegate shall review and
approve the site-specific soak test plan prior to commissioning. Any request for
deviations to the requirements set out in this site technical practice shall be agreed by the
Technical Function (Global Product Quality Manager or Operating Management System
Leader) prior to commencing the soak test.
2.1
Air BP Limited
30 September 2008
Air BP Limited
30 September 2008
3.1
Soak Period
Past experience has demonstrated that there is little risk of fuel contamination from an
Air BP approved lining when the lining is properly applied and allowed to fully cure (see
MECH 53, Parts 6 & 7). Other contaminants that may be present such as rolling oils,
welding flux or valve grease will dissolve into the fuel rapidly if hydrocarbon based;
otherwise they will be eliminated through flushing and draining of the system or removed
by filtration. An improperly applied and/or uncured lining will usually cause a soak test
failure within 1 or 2 days long soak times (10+ days) do not significantly improve our
ability to detect fuel contamination by the laboratory tests employed.
If the lining material to be used has not been successfully tested to meet the
requirements of MECH 53 Part 8, is not listed in the Air BP Technical Approvals Manual
(Section 4) and is not covered by a 10 year application and material warranty, a waiver is
required from the Technical Function prior to use. Due to the lack of experience with
unapproved linings it is likely that additional sampling and testing will be imposed to
demonstrate suitability.
3.1.1
3.1.2
Vehicles
For fuellers and dispensers with tanks and piping of aluminium or stainless steel, after
circulation the product shall be left to soak for at least 1 hour before representative
samples are taken and are subjected to laboratory testing. During this test period, all
product flushed through a dispenser into storage or circulated through a fueller shall be
quarantined awaiting the laboratory test results.
The Asset/Country Product Quality Authority shall be consulted for instructions on soak
testing fueller tanks that are manufactured from mild steel and coated with an epoxy
lining prior to placing the vehicle into service.
3.1.3
Hoses
New aircraft fuelling hoses (meeting API/EI 1529 or EN 1361) shall be filled with product
and left to soak for a minimum of eight hours at a temperature of 15C or higher before
flushing with at least 2000 litres. Longer soak times are required where product
temperatures are lower. Flushed product shall be visually inspected until no evidence of
manufacturing residue or discolouration is detected and shall be returned to a storage
tank which is not in service. Soak testing is not required for hoses covered by MECH 83
(Low Pressure/Vacuum Hoses and Hose Assemblies for Road/Rail Delivery).
3.2
Fuel Volume
The general principle is to maximize contact of the fuel with the surface area of the
system under test. In most cases this means filling the system with a large quantity of
fuel. Although increasing the fuel volume could result in a large amount of contaminated
product it actually lowers the risk of generating off-specification fuel due to dilution effects
and offers the best assessment of the fuel system.
Air BP Limited
30 September 2008
Storage Tanks
Fully lined tanks - The potential risk of generating a large quantity of contaminated fuel is
significantly reduced in fully lined storage tanks where an Air BP approved coating is
used and application is in accordance with MECH 53 Parts 6 & 7. Fully lined tanks also
reduce the contamination potential from exposure to bare metal containing rolling oils
from the steel manufacturing process. Filling fully lined storage tanks to the Normal Fill
Level is recommended for soak testing, however, the minimum level shall be enough fuel
to cover the floating or fixed suction and the receipt nozzle to allow circulation of product
without pump cavitation when circulating the fuel through the piping system to flush out
any contaminants.
Partially lined and unlined tanks Due to the potential contamination from rolling oils and
welding flux on bare metal surfaces, partially lined and unlined tanks shall be filled to the
Normal Fill Level for the duration of the soak test.
3.2.2
3.2.3
Pipelines
Vehicles
New and Transfer Vehicles Filling vehicles completely is recommended for soak testing,
however, the minimum level shall be enough to cover the inlet and outlet foot valves to
allow circulation of product through the entire fuel circuit, e.g., piping, filter vessel, hose
reel, valves and meters without pump cavitation. The vehicle shall be driven (Stop/Start)
to promote sloshing of the product in the tank to wash off any contaminants from the tank
walls before circulation of product.
3.2.4
Hoses
3.3
Laboratory Testing
At the end of the soak period a representative sample is taken from the fuel system and a
selection of laboratory tests are carried out to determine the quality of the fuel used in the
soak test. The fuel properties tested shall be compared with the specification limits for
the grade of fuel used and with the pre-soak test results for the fuel used in the soak test.
A successful result requires that all tested properties are within the specification limits
and within the tolerance limits established for re-certification. If any test result does not
fully comply with the applicable specification or falls outside the allowable variances, the
product shall be re-sampled and re-tested. If the fuel is found to be unsuitable for use,
then the reason shall be investigated and the fuel removed (and downgraded to nonaviation use or disposed of), the system re-filled with on-specification fuel and the soak
test repeated until a satisfactory result is obtained. The relevant Asset/Country Product
Quality Authority shall be contacted for advice in the event of any problems with the soak
test. The laboratory tests include:
Test Method
Jet Fuels
Avgas
Appearance
D4176
Existent Gum
D381
540
D1094
289
Water Reaction
ASTM
MSEP
D3948
Conductivity
D2624
Saybolt Colour
D156
D3241
Air BP Limited
IP
274
323
30 September 2008
SUMMARY
The following table and accompanying notes provide a summary of the soak test
requirements for storage tanks, piping, ancillary equipment and vehicles.
Storage Tanks
Fully Lined
Duration
Min Fuel
Volume
Partially
Lined
Pipelines
Unlined
4 days (Note 1)
4 days
4 days
Enough product to
cover the floating or
fixed suction & the
Normal Fill Normal Fill
Level
Level
receipt nozzle to allow
circulation of product
without pump cavitation
Hydrant Supply
Ancillary Equipment
Pumps,
valves,
meters etc.
Filter
Vessels
4 days
Fill lines
completely
Vehicles
(Note 3)
Aluminium or
Stainless Steel
1 hour
(Note 2)
Lab
Testing
Jet Fuel: Appearance, Existent Gum, MSEP, Conductivity, Saybolt Colour, JFTOT
Avgas: Appearance, Existent Gum & Water Reaction
Sample
Volume
Note 4
Hoses Fuel shall be drained after the 8 hour soak period and visually inspected for
appearance, discolouring & solid matter.
Note 1: The 4 day soak period applies to equipment (fully, partially or unlined storage
tanks, pipelines, ancillary equipment and vehicles) where the lining material used is an
Air BP approved epoxy and is covered by a 10 year joint material and applications
warranty from the manufacturer. Use of equipment where the lining material is not an Air
BP approved epoxy and is not covered by a 10 year material and application warranty
shall be subject to approval by the Technical Function prior to use. Additional sampling
and testing may be imposed to mitigate the potential risks of using an unapproved lining.
Note 2: Newly installed ancillary equipment (e.g. pumps, filter vessels, valves, pit valves,
control valves, meters, sense tubing, water drain lines, etc) should be soak tested during
the system-wide soak test. Replacement or repaired equipment is not typically soak
tested prior to use since the ratio of total surface area to fuel volume is very small diluting
any contaminants below harmful levels. However, it is important to confirm that the
replacement or repaired equipment does not contain detrimental materials, e.g.
preservative oil or rust inhibitor coatings, which could contaminate the fuel and render it
unfit for use.
Note 3: New vehicles delivered directly from the manufacturer or vehicles arriving at an
airfield location without records or after repairs at a contractor facility or vehicles that
have been out of service for an extended period shall be treated as new equipment and
subject to a soak test. Vehicles in service up to the time of transfer require the same
filling and soak test period but do not require any laboratory sampling or testing other
than an acceptable visual check before returning to service. The Asset/Country Product
Quality Authority or delegate shall approve the Asset/country specific vehicle soak test
plan in line with these requirements.
Note 4: It is recommended that vehicles are filled completely for the one hour soak test;
however, if the soak test is carried out with a lesser volume, the amount shall be sufficient
to cover the inlet and outlet foot valves to allow circulation of product through the entire
fuel circuit without cavitation. Vehicles with compartmented tanks may carry out the soak
test on individual tanks in a sequential fashion, i.e. each tank is soak tested for one hour
and the contents transferred from one tank to the next until each tank has been soak
tested for at least one hour. The vehicle shall be driven after initial fill and after each
transfer to promote sloshing of the product to wash contaminants off the tanks walls and
from the fuel circuit. Laboratory testing need only be carried out on a single
representative sample from the last tank soak tested.
Air BP Limited
30 September 2008