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Saudia Aerospace Engineering Industries

Aircrafts Maintenance Hangars

SECTION 40052 - JET A1 FUELING SYSTEM BASIC MECHANICAL REQUIREMENT

PART 1 - GENERAL

1.1

RELATED DOCUMENTS

A.

1.2

RELATED SECTIONS

A.
B.
C.
D.
E.

1.3

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

Division 40, Jet A1 Fueling System Cathodic Protection


Division 40, Jet A1 Fueling System Piping Construction
Division 40, Jet A1 Fueling System Coating And Corrosion
Division 40, Jet A1 Fueling System Monitoring And Control (EFSO & Leak Detection)
Division 40, Jet A1 Fueling System Inspection, Cleaning, Flushing, And Testing

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.

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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.

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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

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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.
b.
c.
d.
e.
f.
g.
h.
i.

j.
k.

3.

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


Physical description, dimensions, and weights.
Product properties, characteristics, capabilities and limitations.
Data for coordination with other project work.
Clear spaces required for handling, installing, operating and maintaining
products.
Required installation clearances and tolerances, and the location and size of
openings or sleeves necessary for installation.
Applicable reference standard designations.
Product specifications, including protective coatings.
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.
Methods and details for anchorage to supporting construction.
Data which affects design and construction of supporting structure, including
maximum reactions imposed on supporting structures at each connection or
bearing point.

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


manufacturer.

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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.
b.
c.
d.
e.
f.

g.

3.

Label and title which indicates the manufacturer's name and address, the
drawing scale, and which clearly defines the item being submitted.
General arrangement, physical description, dimensions, and weight of
product.
Enlarged scale details giving dimensions for locating the product and as
required to clarify installation clearances and tolerances.
Assembly drawings for work furnished consisting of two or more
components.
Design and actual details of manufacture or fabrication, including material
specifications, dimensions, joining methods and protective coatings.
Diagrams of wiring arrangement, actual arrangement of external connections
as seen by the installer and terminal identification designation on actual
product.
Diagrams for operation and control of work, including location and function
of instrumentation and control devices.

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.

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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.

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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.
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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,


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

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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


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

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Procedures:

Aviation

jet

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1.6

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

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

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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:


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1.

Perform all cutting, patching, carpentry, and masonry work required to accommodate
work and to achieve the following:
a.
b.
c.
d.
e.
f.

Make parts fit together properly.


Remove and replace defective work.
Remove and replace work not in conformance with Contract requirements.
Remove samples of installed work as required for testing.
Provide for penetration of non-structural surfaces for installation of piping,
ducts, and electrical testing.
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.

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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.

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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
b.
c.
d.
e.

Blocking: Remove blocks and other similar devices used to block shafts
during shipment to the field or during alignment work.
Alignment: Check whether equipment has been aligned.
Tension: Check belt or chain tension.
Tightening: Tighten bolts, capscrews and other fasteners.
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

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40120 - JET A1 FUELING SYSTEM - CATHODIC PROTECTION

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 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.

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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.

2.2

Summary: Sufficient capacity should be allowed in the installed cathodic protection system
to allow for future piping additions. Allow for 200% extra capacity.

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

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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 precommissioning 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

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SECTION 40192 - JET A1 FUELING SYSTEM - PIPING CONSTRUCTION

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.
B.
C.
D.
E.

Division 140, Jet A1 Fueling System Cathodic Protection


Division 40, Jet A1 Fueling System Basic Mechanical Requirement
Division 40, Jet A1 Fueling System Coating And Corrosion
Division 40, Jet A1 Fueling System Monitoring And Control (EFSO & Leak Detection)
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.

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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


fuel drain and vent piping
(including all lateral piping,
and the normally pressurized
portion of drain and vent piping).

264 psig; ambient 50C

396psig

Jet A-1 Fuel piping vents and


drain piping (normally nonpressurized portion of each of
these lines)

264psig; ambient 50C

25 psig leak test.


(Compressed air
test with soap
bubble check
leaks)

Jet A-1 Fuel piping, Double


Containment Pipe

264psig; ambient 50C

396psig

B. Piping and Fittings details:


Item

2 Inch & Smaller

2-1/2 Inch & Larger

Pipe

API 5L Grade B Schedule 80,


Seamless, plain ends.

API 5L
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.

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(SWA spiral seams are acceptable


for casing pipe).
Joints

Use socket welded or


screwed joints as specified
for the piping construction on
Design/Vendor drawings and/or
to match the connecting equipment 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.)

Butt-weld

Flanges

150 lb. ANSI, B16.5 carbon steel,


ASTM A 181 Class 70 or
ASTM A 105 weld neck, RF
flanges.

150 lb. ANSI*, carbon steel,


ASTM A 181 Class 70 or
ASTM A 105 weld neck,
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
for all underground services;
Socket weld or screwed
3000 lb. forge steel, ASTM
A 105 Grade II, ANSI B16.11
for aboveground services.

Butt weld, ANSI B16.9, carbon


steel, ASTM A 234 Grade B,
wall thickness to match pipe

Bolts,
Studs, Nuts

Same as 2-1/2 Inch & Larger

Carbon steel, cadmium plated*,


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.

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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.

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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.

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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.
E.

Ball valves shall be rated fire safe in accordance with API 607.
Acceptable Manufacturers:

1.
2.
3.
4.
2.10

Grove Valve and Regulator Company


Jamesbury Ball Valve.
DeZurik, Unit of General Signal.
Approved equal.

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

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2.11

2.12

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 nonconductive.

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.
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
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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
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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.
2.
3.
4.

Avery Hardoll.
Warner Lewis.
Dabico.
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

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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

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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):

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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.

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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.
ii.
iii.
iv.

All welds shall be made in the uphill method.


All pipe groove welds shall be in test position 5G.
No backing rings shall be used.
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 retested 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.
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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 (asbuilt), 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.

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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.

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I.

3.7

All the costs of the original radiographing and re-radiographing of unacceptable welds and
the accompanying reports and interpretation shall be paid by the Contractor.

HYDRANT RISER PIPE INSTALLATION DETAILS

A. The hydrant riser pipes to the hydrant pits shall be installed plumb at the locations as
indicated on the Drawings. Base flanges for the hydrant boxes and sample points shall be set
and welded level to both axes and accurately located at the correct level.
B. The riser pipe shall be cold cut and an expandable plug inserted before the base flanges are
welded on in order to avoid extraneous material from entering the main header.

3.8

FIELD PAINTING
A. Preparation, painting and touch-up of all surfaces of piping and equipment installed
aboveground shall be in accordance with Section 40193 "Jet A1 Fueling System - Coatings
and Corrosion Protection".

3.9

CIVIL WORKS-FUEL HYDRANTS


A. Concrete Work
Contractor shall provide all cast-in-place reinforced concrete work for pipeline anchor
blocks, foundations and bases for equipment and piping support and all other concrete
required.
For concrete, concrete placement, reinforcement bars, testing, etc refer to the Structural
Specifications.
B. Trenching
The trench for the buried pipeline shall be dug to a depth of 1000 mm plus the diameter of
the pipe, and to a width at the bottom of 300 mm plus the diameter of the pipe.
The finished bottom of the trench shall be trimmed and leveled to permit even bedding of the
pipeline, and shall be free from extraneous matter which might damaged the pipe coating,
such ad rock outcrops, loose rock, hard clods, trash, etc
The spoil from the excavated trench shall not be allowed to fall on or be mixed with materials
which are not suitable to be included in the trench backfill such as vegetation, debris, ashes,
decayable material, camp refuse, oil or oil-soaked dirt, etc
Only excavated material suitable for use as backfill shall be doposited alongside the trench.
Contractor shall clean the spoil from all rock larger than 100 mm in any dimension.

END OF SECTION 40192

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SECTION 40193 - JET A1 FUELING SYSTEM - COATINGS AND CORROSION PROTECTION

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 Basic Mechanical Requirement


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

1.3

DESCRIPTION

A.

Externally paint piping, equipment, valves, fittings, flanges, structural and miscellaneous
steel and other appurtenances aboveground and in pits. All pipe and fittings which are not
externally factory coated as defined in Paragraph 1.3.B shall be externally painted (i.e., all
aboveground piping, fittings, and equipment and all piping and valves located within
underground valve pits except for those shop coated portions as noted below). For shop
painted piping, the paint shall be applied over all external surfaces up to 75 mm from each
end. For those items which are shop coated/painted, the work under this Section shall be
limited to field inspection, field testing, and application of any needed paint/coating
touch-ups of external surfaces.

B.

Piping to be partially or completely buried, and piping and fittings in underground


structures (e.g., fuel system valve pits) shall be externally factory or field coated. Pipes
and fittings to be located underground (or within 0.3 meters above finish grade, concrete,
or asphalt surface level) and any pipe located within an underground valve pit (within 0.3
meters of the finish surface of the valve pit wall or floor) shall be externally coated or
field tape wrapped as specified herein. For shop coated piping, the shop coating shall be
applied over all external surfaces up to 75 mm from each end. Once the final pipe-to-pipe
or pipe-to-fitting weld is completed, inspected and accepted, the joint shall be field coated
or wrapped as specified herein. Perform field inspections, apply wrapping and coating to
those external surfaces not coated in the shop (e.g., over field welds for pipe-to-pipe and
pipe-to-fitting welded joints), and provide touch-up of those shop coated piping and
fittings surfaces which may have been damaged during handling, shipment, or Project site
storage operations.

C.

Jet A-1 Fuel piping 4 inches and larger and any special shop fabricated fittings shall be
internally epoxy coated. Jet A-1 Fuel system standard 4 inch nominal diameter size and
larger fittings (e.g., elbows and bends, tees, flanges, reducers) for piping 4 inches and
larger shall also be shop internally epoxy coated. For shop lined Jet A-1 Fuel piping, the
internal lining (coating) system shall be applied over all internal surfaces up to 75 mm
from each end of the finished pipe segment which will be shipped to the Project site.

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Piping 3 inches and smaller, flanges (all sizes), and pipe fittings 3 inches and smaller need
not be internally epoxy coated.
D.

1.4

For existing piping and equipment, the existing coating must be stripped, and then recoated as described above.
QUALITY ASSURANCE

A.

B.

1.5

Applicator's Qualifications:
1.

All coating, lining and painting shall be performed by applicators with prior
experience in applying the systems specified.

2.

Applicator(s) shall be individually certified by the coating, lining and painting


system manufacturers and shall submit documentation that the manufacturers
warrant the applied systems.

Single-Source Responsibility: Although painting systems supplied by a number of


different manufacturers/suppliers will likely be utilized for the subject work, the paint
materials comprising an individual painting system (i.e., primer, intermediate coat(s), and
finish coat) applied to a given surface shall be the materials of one manufacturer only.

DELIVERIES, STORAGE, AND HANDLING


A.

Coating, lining, and paint materials shall be delivered to the place of application (e.g.,
pipe fabricator's shop or the Project site) in the manufacturer's unopened, sealed original
containers, bearing a legible product designation, batch number, date of manufacture,
manufacturer's name, type of paint, brand name, color designation and instructions for
mixing and/or reducing. Containers which are damaged to the extent that the quality of
the contents are compromised shall not be used.

B.

Provide adequate storage facilities. The coating, lining, and paint materials shall be
handled and stored in accordance with the manufacturer's published instructions, and shall
be protected from damage, moisture, direct sunlight, temperatures below a minimum
ambient temperature of 10 deg. C or above 34 deg. C, with a relative humidity below 80
percent (or as otherwise specified if more stringent temperature and/or humidity
requirements are specified by the coating, lining, and painting system manufacturer. All
materials shall be stored in a well-ventilated area.

C.

Take precautionary measures to prevent fire hazards and spontaneous combustion.

D.

Containers of coatings or components shall not be opened except for immediate use.

E.

The materials shall be used within the manufacturer's recommended shelf life.

F.

Surfaces which have been lined, coated, or painted shall be protected from damage during
lifting and handling. Non-abrasive supports/materials shall be used for shipment and
storage. Chains or cables shall not be used for lifting pipe; use nylon slings for lifting
pipes.

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1.6

EXTRA MATERIALS
A.

The piping or equipment supplier shall furnish not less than one unopened container (4 L
minimum) of each product and color used.

B.

Extra lining, coating, and painting materials shall be stored on the Project site where
directed by the Engineer.

PART 2 - PRODUCTS

2.1

MANUFACTURERS
A.

Painting and Coatings (for external aboveground pipe and equipment surfaces). The
painting system shall conform to the following:
1.

Available Manufacturers: Subject to compliance with requirements, manufacturers


offering products that may be incorporated in the Work include but are not limited
to, the following:
a.

Carboline Co.

b.

Sherwin Williams

c.

Tnemec Company, Inc.


d.

2.

Or Approved Equal.

The following coatings systems provided by any of the above manufacturers, or


equal, are deemed suitable for the piping and equipment painting for aboveground
outdoor service. Primer, intermediate, and finish coat materials for painting a given
component or piping shall be the products of a single manufacturer:
a.

Inorganic Zinc Primer (2.0 - 4.0 mils dry film thickness [DFT]):
1) Carboline Co.

Carboline CZ11

2) Sherwin Williams

Zinc Clad II, B69V3/B69D11

3) Tnemec Company

Tneme-Zinc 90E92

4) Or Approved Equal.
b.

Intermediate Epoxy (4.0 - 6.0 mils DFT):


1) Carboline Co.

Carboline 890

2) Sherwin Williams

Tile-Clad II Epoxy, B62

Series/B60VA7

3) Tnemec Company

Tnemec 66 Hi-Build Epoxoline II

4) Or Approved Equal.
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c.

Polyurethane Finish Coat (1.0 - 2.0 mils DFT):


1) Carboline Co.

Carboline 134

2) Sherwin Williams

Hi-Bild Aliphatic Polyurethane,


B65 Series/B60V2

3) Tnemec Company

Series 74, Endura-Shield

4) Or Approved Equal.

B.

3.

Primer, intermediate, and finish coat materials for painting a given component or
piping shall be the products of a single manufacturer.

4.

Piping and equipment surfaces to be painted shall be prepared in accordance with


the requirements of SSPC SP - 10 with a profile of 1 to 3 mils. For existing piping
and equipment, the existing protective coating must be stripped first and then
prepared as described above. The surfaces shall receive, as a minimum, the
following painting system and application:
a.

Inorganic zinc primer, application and dry film thickness of nominally 2.0 to
4.0 mils DFT and as specified by the paint manufacturer.

b.

Epoxy intermediate coat, application and dry film thickness of nominally 4.0
to 6.0 mils DFT and as specified by the paint manufacturer.

c.

Polyurethane finish coat and application shall be as specified by the paint


manufacturer. The finish coat DFT shall be as recommended by the painting
system manufacturer or as a minimum: 1.0 to 2.0 mils DFT total. Thus the
total DFT shall be nominally 7.0 to 12.0 mils total. The finish paint shall be
weather resistant and suitable for either indoor or outdoor installations and
shall be compatible with the primer coat material.

d.

The primer, intermediate, and finish coat materials shall be the products of a
single painting system manufacturer and shall be suitable for coating of
ferrous piping and piping components.

Jet A-1 Fuel piping internal epoxy lining (coating) System: The coating system shall
conform to the following:
1.

Available Manufacturers: Subject to compliance with requirements, manufacturers


offering products that may be incorporated in the Work include but are not limited
to, the following:
a. COPON EA4 2217
b. International Paint
Or Approved Equal.

2.

The coating system shall be a two pack epoxy resin based material plus polyamine,
polyamine adduct or polyamide curing agent..

3.

The coating system shall not contain metallic zinc, aluminum, lead, copper or
copper alloys and shall be free of chromate (hexavelant).

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C.

4.

The coating system shall comply with Air BP requirements for lining materials in
contact with aviation fuel.

5.

The coating system shall conform to MIL-PRF-4556 F and DEF STD 80-97/3.
Submit manufacturer certificate of conformity as required by DEF STD 80-97/3 for
the effect of aviation fuel (test 14) from an accredited laboratory.

3.

Application: Two separate coats each of minimum - 0.0625mm DFT (0.125mm


DFT total) shall be applied to the inside surfaces of all underground Jet A-1 Fuel
piping (4-inch and larger).

Jet A-1 Fuel piping external polyurethane (coating) system : The coating system shall
conform the following :
1.

Available Manufacturers: Subject to compliance with requirements, manufacturers


offering products that may be incorporated in the Work include but are not limited
to, the following:.

a.
b.

PROTEGOL UR Coating 32-55


International Paint

Or Approved Equal

D.

2.

The coating system shall be a solvent free (100% solids), airless, sprayable, black,
two component liquid comprising of either polyurethane or polyurethane-modified
resin and an isocyanate activator/hardner.

3.

The properties of the cured coating film shall conform to the requirements of either
EN 10290 (type 3) or DIN 30671. Submit manufacturer certified test results for the
cured applied coating in accordance with the requirement of either EN 10290 or
DIN 30671.

4.

Application : A coating film thickness of 1.500mm DFT shall be applied to the


external surfaces of all underground Jet A-1 Fuel Piping (4 inch and larger) in
conformance with factory recommendations.

Piping Identification:
1.

Pipes and pipe insulation shall be color coded with field-applied pressure sensitive
tapes. Tape shall be the product of one manufacturer only.

2.

Available Manufacturers: Subject to compliance with requirements, manufacturers


offering products that may be incorporated in the Work include, but are not limited
to, the following:
a.

Seton Corp.

b.

Westline Products

c.

General Painting Co.

d.

Or Approved equal.

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3.

Colors specified for marker color code shall match the following manufacturer's
standard colors:
Color

Manufacturer's Identification

Yellow
Medium Gray
Green
Red
4.

Carboline Yellow 626 or Approved equal


Carboline Gray 724 or Approved equal
Carboline Green 2383 or Approved equal
Carboline Red 1526 or Approved equal

Markers:
a.

Furnish and install tape with specified wording in English and Arabic, and
flow arrows, in colors specified, with sizes as follows:
1)

Pipe or insulation 100-mm-diameter and larger: 25-mm letters, 100mm arrow length.

2)

Pipe or insulation under 100-mm-diameter:


arrow length.

b.

Install markers in accordance with manufacturer's instructions after the piping


and insulation installation is completed.

c.

These markers, together with arrows indicating direction of flow, shall be


installed at intervals of not more than 6m for straight pipe runs, adjacent to
each change in direction.

d.

Lettering shall be in black, except that white lettering shall be used on


markers with red background. Marker background color shall be as follows:

Legend

Background Color

Fuel supply
Fuel return
E.

15-mm letters, 75-mm

Yellow
Yellow

Safety Marking: Signs and color of fire protection equipment shall be red. Markings for
projections, low beams, pipes and similar hazards shall be yellow.

PART 3 - EXECUTION

3.1

EXAMINATION
A.

Thoroughly examine surfaces scheduled to be coated, lined, or painted prior to


commencement of work. Correct conditions and report in writing to Engineer any
condition that may potentially affect proper application. Do not commence until such
defects have been corrected.

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3.2

SHOP-APPLIED INTERNAL EPOXY LINING (COATING) FOR PIPING


A.

General: All new Jet A-1 Fuel piping including fuel drains and fuel vents piping 4 inches
and larger in size and all Jet A-1 Fuel pipe fittings 8 inches and larger in size shall be
internally coated in the manufacturer's shop or in the mill of an approved internal epoxy
applicator with a two-coat high-solids amine-cured epoxy system in accordance with the
following requirements. The epoxy coating shall be shop applied to all Jet A-1 Fuel
piping and fittings in accordance with the epoxy coating system manufacturer procedures
and recommended practices. For Jet A-1 Fuel piping, the internal coating system
materials and application, inspection, cleaning, testing, acceptance criteria, and
preparation for shipment shall meet the requirements as specified herein.

B.

Surface Preparation:
1.

2.

3.

C.

The amine adduct cured epoxy pipe lining system shall be applied at the pipe/fitting
fabrication shop or other suitable shop location. Prior to blast cleaning, the pipes
shall be inspected and, when necessary, pre-cleaned to remove all grease, soil, dirt,
and salts which might adversely affect blast cleaning or contaminate the abrasive.
This work shall be completed in accordance with SSPC SP-1.
The contact surface of flanges and threaded areas of threaded fittings shall be
protected by attaching sized metal or wooden rings or by taping as appropriate prior
to blast cleaning.
Blast cleaning shall be carried out in a shop separate from the area that paint
(coating material) is to be applied. Surfaces to be coated shall be blast cleaned in
accordance with SSPC SP-10 with a profile of 1.0 to 3.0 mils, after preheating pipe
to remove all moisture. Blast cleaned surfaces shall be compared with SSPC
VIS-1.

4.

Burrs, slivers, and scabs which become visible after blasting the surface shall be
removed and the specified cleaning repeated for the affected area.

5.

Each pipe, including shop supplied pipe which has been externally coated for
underground service or painted for aboveground service, shall be given a unique
serial number marked on the outside after satisfactory shot/grit blasting and
inspection. For coated/painted pipe, this marking shall be applied on top of the
coating/paint. The marking materials shall not result in any degradation of the
piping coating/painted surfaces.

6.

Weld bevels, flange contact faces, and threads on fittings shall be suitably masked
from painting.

Application:
1.

As a minimum, no lining (coating) shall take place when the atmospheric


temperature is above 34 deg C or below 10 deg C or when the surface temperature
of the pipe is below the dewpoint, when the relative humidity is above 85 percent,
or when airborne dust may be deposited on the surface being (lined) coated (or as
otherwise directed by the epoxy coating manufacturer's instructions when more
stringent conditions are specified).

2.

Each batch of epoxy paint shall be mixed in accordance with the manufacturer's
instructions and the details of the mix recorded on appropriate documentation
forms.

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3.

D.

The epoxy lining shall be applied within the required temperature range and time
constraints and in accordance with the manufacturer's instructions. As a minimum
the pipe lining (coating) must commence prior to visible rust or contamination
formation. If rust or contamination is observed, the pipe surface shall be re-blasted.
The mixed lining (coating) may be applied by spray unless otherwise specified by
the manufacturer. Note that rollers or brushes should not be used except for touchup of small localized areas where the lining has been compromised due to
mechanical damage.

Inspection and Testing:


1.

The paint shall be fully cured before the external coating application is started. The
finished epoxy paint film shall be tested for thickness, cure, and adhesion as
specified below.

2.

The number of coats applied, the thickness of each coat, minimum/maximum recoat
times, and the finish shall be in accordance with the coating manufacturer's
recommendations or as a minimum:
a.
b.

3.

3.3

Two coats - 0.055mm DFT minimum each; total of 0.110mm DFT minimum.
The lining shall be glossy, and free from sags, runs, curtaining and any other
defects which may detract from the performance of the lining system.

A ketone Test or other suitable test for cure shall be conducted. The ketone test
shall consist rubbing the coating with a clean white rag soaked in methyl ethyl
keytone (MEK) for one minute after which time the lining shall not be softened as
indicated by scratching with a finger nail. The surface rubbed by the ketone rag
shall show no obvious signs of discoloration.

SHOP-APPLIED EXTERNAL PIPE COATING


A.

All new pipe and fittings to be installed underground and in underground structures (e.g.,
valve pits) shall have an external coating system applied either in the pipe manufacturer's
shop or in the mill of an approved custom applicator, except as specifically excluded in
Paragraph 1.3.

B.

Coating system for the piping and fittings which will be installed underground (direct
buried) and/or in pits shall consist of meet the requirements for the coating materials
specified; surface preparation; coating materials application and thickness; final surfaces
inspection, testing, and acceptance criteria; and preparation for shipment as specified
herein.

C.

General: The external polyurethane black coating shall be shop applied in a factory
controlled conditions to all Jet A-1 Fuel piping and fittings which are to be installed
underground in accordance with the coating system manufacturer's procedures and
recommended practices. In addition to the Submittals as specified elsewhere within this
Section, the piping supplier shall be responsible for submitting and obtaining the
Engineer's approval for the coating and lining systems written procedures and forms used
to document the application of the coating and lining systems prior to proceeding with any
coating/lining work. The piping supplier's proposed Surface Preparation and Coatings
Inspection Form(s) for inspection records shall be submitted for review and shall be
accepted by the Engineer prior to commencing with any coating or lining systems work.

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C.

Surface Preparation: Before coating, the pipe/fitting surface shall be freed from grease
and all dirt, rust, scale, and shall be abrasive blast cleaned to near white (according to
DIN55928 standard degree of cleanliness Sa 2 ).

E.

Application:
1. Immediately after blast cleaning, the base coat shall be applied. Later coating shall be
only permissible when the original degree of cleanliness is maintained.

F.

2.

As a minimum, coating shall be applied when the temperature of the substrate is at


least 3 oC above the dew point of the ambient conditions in order to avoid moisture
and condensation, or as otherwise directed by the manufacturers when more stringent
conditions are specified.

3.

Each batch of polyurethane two component, airless coating shall be mixed in


accordance with manufacturers mixing ratio and details of the mix shall be recorded
on appropriate documentation forms.

4.

The final surface finish shall be smooth, free of voids and wrinkles, and to a final
overall thickness of not less than the value specified by the coating manufacturer or
1.00 mm minimum, whichever is greater.

Testing and Inspection:


1.

A detailed inspection shall be performed with a electronic holiday tester of all pipe
and fitting coating in accordance with Section 40980. Holiday-tester voltage shall
not be higher than the manufacturer's recommended voltage for the coating tested.
Testing shall be for holidays only and not to test the dielectric strength of the
coating materials.

2.

All holidays and any damaged Jet A-1 Fuel piping coating shall be repaired in a
manner approved by the Engineer at the Contractor's expense.

3.

All holidays shall be patched as follows:


a.

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

b.

Wire brush the area to a rough finish.

c.

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


instructions.
Coating shall consist of the same coating and wrapping materials and the
same number/thickness of coats as was originally applied to the piping.

d.

3.4

FIELD-REPAIR OF SHOP APPLIED COATINGS AND FIELD APPLICATION OF


EXTERNAL COATING FOR UNDERGROUND PIPE
A.

For underground Jet A-1 Fuel piping and fittings, all field weld areas, fittings, and any
surfaces where the shop applied coating has been damaged, apply a field-applied external
protective coating system in accordance with Paragraph 3.3. The above is also applicable
to existing underground piping affected by the work under this contract.

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3.5

SHOP APPLIED AND FIELD APPLIED PAINTING


PIPE/EQUIPMENT AND PIPE/VALVES IN VALVE PITS
A.

B.

OF

ABOVEGROUND

Protection:
1.

Protect other surfaces from paint and damage.


inadequate or unsuitable protection.

Repair damage as a result of

2.

Furnish sufficient drop cloths, shields and protective equipment to prevent spray or
droppings from fouling surfaces not being painted and, in particular, surfaces within
storage and preparation area.

3.

Place cotton waste, cloths and material which may constitute a fire hazard in closed
metal containers and remove daily from the Project site.

Surface Preparation:
1.

Base material or previously applied coatings shall be clean and dry when coated.
Copies of the manufacturer's instructions shall be conspicuously posted whenever
materials are prepared for application.

2.

Ferrous Metals:
a.

Surfaces shall be abrasive-blasted in accordance with SSPC SP-10 with a


profile of 1 to 3 mils.

b.

Abrasive-blasting shall be coordinated with primer application which shall be


applied as soon as possible after blasting. Surfaces shall be re-blasted if
visible rusting or contamination occurs subsequent to the abrasive blasting
and prior to the primer application.

c.

Care shall be taken to prevent grease, oil, or other organic matter from
contacting the blasted surface prior to application of the prime coat.

d.

Before topcoating over inorganic zinc silicate primer, the primed surfaces
shall be examined for damage, for formation of zinc hydroxide or carbonate
salts, and for unprimed areas. Such affected areas shall be blast cleaned.
Where blast-cleaning is not practicable, the affected areas shall be cleaned
with power tools in accordance with the requirements of SSPC SP-3. After
cleaning, the affected areas shall be touched up with epoxy intermediate coat
paint material as specified in Part 2 to match the original type and DFT.
Primed steel shall be free of loose deposits, grease and oil.

e.

Before topcoating over primer other than inorganic zinc primer, the primed
surfaces shall be examined for damage and for unprimed areas. Such
affected areas shall be power-cleaned in accordance with the requirements of
SSPC SP-3. Small areas shall be touched up by brushing the area with primer
to match the original type and DFT. Primed steel shall be free of loose
deposits, grease and oil.

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C.

Mechanical mixers shall be used to thoroughly mix the pigment and vehicle to keep the
pigment in suspension.

D.

Thinning shall not be done unless approved and in accordance with the manufacturer's
instructions.

E.

Safety Precautions: Fume concentrations creating an explosive or flammable hazard shall


not be permitted. Forced ventilation sufficient to keep fume concentrations at a safe level
shall be provided for enclosed spaces. Air hoods shall be worn inside enclosed spaces
where toxic fumes cannot be controlled by forced ventilation.

F.

General Application Requirements:


1.

Paint materials shall be prepared and applied as specified and in accordance with
the instructions of the paint manufacturer and this specification. Copies of the
manufacturer's instructions shall be conspicuously posted wherever materials are
prepared for application.

2.

Touch-up coat on previously primed steel and the first prime application on freshly
cleaned steel shall be brush-painted. A combination of spray application followed
by thorough brushing into the surface shall be in accordance with manufacturer's
instructions. Surfaces shall be painted the same day as cleaned.

3.

Dry film thickness shall be as specified and as recommended by the manufacturer


for each type of prime or finish coat.

4.

The ends of pipe and fittings shall have the paint wiped back 50mm with cloth or
other approved absorbent material. Masking the ends will not be acceptable as a
thin film of paint is desired to prevent rust until installation of the material.

5.

Apply one coat of inorganic zinc primer. The thickness of the cured primer shall be
not less than 0.07mm, but shall not exceed 0.10mm; or as otherwise specified by the
painting system manufacturer.

6.

Apply one coat of off-white suitable epoxy intermediate coat and one coat of
polyurethane finish coating. The cured thickness of the intermediate and finish coat
shall be as specified under Part 2 or as otherwise specified by the painting system
manufacturer.

7.

Each coat shall differ slightly in color or shade from the preceding coat to ensure
complete coverage, although top coat (final coat) shall match approved color.

8.

Paint shall be applied without sags or runs and with minimum overspray. Welds,
bolts, fasteners, edges, crevices, and other irregularities shall be thoroughly coated
and shall receive additional coating as necessary to provide the same resistance to
moisture penetration as adjacent smooth surfaces which have been coated to the
specified thickness.

9.

Indoor paints shall not be applied until the area is enclosed. Surfaces which will be
inaccessible for painting after construction shall be coated as specified prior to
becoming inaccessible.

10.

Surfaces scheduled for different colors shall meet in a clear line or natural juncture
of materials or planes.

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11.

Precautions shall be taken to protect adjacent surfaces, instruments and equipment


from spill, splash, or physical damage during surface preparation and application.

12.

Each coat shall follow the preceding coat within the time limits set by the
manufacturer. Glossy or hard coatings shall receive additional preparation as
specified or recommended by the manufacturer to ensure adequate adhesion of
additional coats.

13.

Take precautionary measures to prevent fire hazards and spontaneous combustion.

G.

Dry film thickness shall be spot checked at random on 10 percent of the coated surfaces.
If dry film thickness is not specified or if less than the manufacturer's recommendations,
the manufacturer's recommendations shall be followed. Dry film thickness for finish
coats, where specified, is in addition to the prime coat. If film thickness is not found to be
uniform and to specification, apply additional coats until the specified film thickness has
been obtained. Dry film thickness shall be checked by the Contractor at his expense.

H.

If, in the opinion of the Engineer, the coatings show ridges, waves, runs or holidays
indicating uneven coverage or improper applications, repair or remove and reapply the
coatings.

I.

External paint color shall match PPG white diamond pearl.

J.

Touch-Up of Equipment: Factory-finished items which require touch-up shall be touchedup with the same material and color as the factory-finish coat to restore it to the original
condition. Damaged surfaces of shop-applied finish coating of mechanical and electrical
equipment and fittings shall be cleaned. Apply touch-up coat to match the original finish.
Touch-up paints shall be furnished with each item of shop-coated equipment. Surfaces
shall receive painting systems and shop/field touch-up work shall be as follows:

K.

Field repairs of damaged piping coated/painted surfaces shall comply with the following
general requirements:

L.

1.

Repair all damages to pipe coating systems on pipe and fittings before the piping is
holiday tested in accordance with the procedures identified in the various
Paragraphs above and as recommended by the coating/painting system
manufacturer.

2.

Repair all cuts, breaks, voids, bruised or scarred spots, and any other damage
caused prior to delivery, or resulting from handling or installation of the pipe and
fittings, or from any cause whatsoever.

3.

Repair the coating where welds are made and where the coating is damaged or
broken by the installation of instrumentation or other accessories or appurtenances.

4.

Repairs to shop-applied coating shall be such as to provide a thickness equal to or


greater than the shop-applied coating.

Inspection: In areas where measurements indicate insufficient dry film thickness, apply
additional coat or coats to obtain the specified thickness. In areas where measurements
indicate excessive dry film thickness, remove the paint as directed, including primer, and
re-apply the required coats in the specified thickness. This determination will need to be
made on a case-by-case basis.

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3.6

CLEANING
A.

As work proceeds with upon completion, promptly remove paint where spilled, splashed
or spattered.

B.

During progress of work, keep premises free from any unnecessary accumulation of tools,
equipment, surplus material and debris. Remove waste materials from painting operations
daily.

C.

Upon completion of work, leave premises neat and clean, as approved by the Engineer.

3.7

FIELD QUALITY CONTROL


A.

The Contractor or shop equipment manufacturer responsible for applying coating, lining,
and/or painting shall secure the services of manufacturer's technical representative.
Owner reserves the right to witness the coating, lining, and/or painting application and
testing and to certify that the surfaces were prepared, cleaned, and coatings, linings, and
paint applied using methods and materials conforming with the specified requirements.

B.

The Contractor shall be responsible for obtaining the services of the coating, lining and
paint manufacturers to provide on-site technical assistance.

C.

A final inspection report shall be submitted by the manufacturer's technical representative


certifying the system was installed and tested according to and meets the manufacturer's
requirements.

3.8

TESTING
A.

3.9

Holiday test all external field applied pipe coating and field painted surfaces in
accordance with the requirements of Paragraph 3.3.F.

CERTIFICATION
A. A log of mill procedure and quality control tests shall be kept daily by the coating, lining and
wrapping applicators and a certified copy of this log(s) shall be submitted to the Engineer
along with each delivery of pipe and equipment.

END OF SECTION 40193

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SECTION 40980 - JET A1 FUELING SYSTEM - INSPECTION, CLEANING, FLUSHING, AND


TESTING

PART 1 - GENERAL

1.1

RELATED DOCUMENTS

A.

1.2

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

RELATED SECTIONS

A.
B.
C.
D.
E.

Division 40, Jet A1 Fueling System Cathodic Protection


Division 40, Jet A1 Fueling System Basic Mechanical Requirement
Division 40, Jet A1 Fueling System Piping Construction
Division 40, Jet A1 Fueling System Coating And Corrosion
Division 40, Jet A1 Fueling System Monitoring And Control
(EFSO & Leak Detection)

PART 2 - PRODUCTS

2.1

EQUIPMENT
A.

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

B.

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

C.

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

PART 3 - EXECUTION

3.1

TESTING PROCEDURE
A.

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

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B.

3.2

1.

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

2.

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

3.

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

4.

Sectionalize pipe lines as required to facilitate testing.

Responsibility of the Contractor:


1.

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

2.

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


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

3.

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

4.

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


the piping off highest elevation.

5.

Be fully responsible for providing qualified and experienced personnel to operate


the equipment throughout the testing and flushing operations.

6.

Obtain all necessary approvals, acceptances, and permits.

7.

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

8.

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

CLEANING
A.

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

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B.

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

C.

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

D.

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

E.

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

F.

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

G.

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

H.

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


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

3.3

HYDROSTATIC TESTING
A.

All new Jet A-1 Fuel piping and all existing Jet A-1 Fuel piping (which is modified or
affected by work performed as part of this Contract Package) shall be given a hydrostatic
pressure test using Jet A-1 Fuel after the completion of all holiday testing and pigging.
Water shall not be used for hydrostatic testing.
Note that the Contractor shall be responsible for investigating the existing piping and
component documentation to verify the design pressures and shall advise the Engineer
accordingly of any problems / limitations that may affect the hydrotesting as outlined
herein, prior to performing any hydrotesting of existing Fuel piping.

B.

Pressure shall be maintained for at least one 24-hour cycle after pressure has stabilized;
pressure testing shall be performed as follows: Pressure shall be increased in gradual
steps to the final test pressure and maintained for a 24-hour period, continuously record
temperature and pressure. Final test pressure shall be not less than the Test Pressure
value specified in Section 9.03 Division 40192, Part 2.

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C.

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

D.

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

E.

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

F.

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

G.

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

3.4

INSPECTION OF COATINGS
A.

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

B.

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

C.

All holidays and damaged Jet A-1 Fuel underground pipe coating and any aboveground
surfaces painting/coatings damage shall be repaired in a manner conforming to the
requirements of Section 40193 and approved by the Engineer at the Contractor's expense.

D.

All holidays shall be patched as follows:


1.

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

2.

Wire brush the area to a rough finish.

3.

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


instructions.

4.

Coating shall consist of the same coating and wrapping materials and the same
number of coats as was applied to the piping in the manufacturers shop and as
specified in Section 40192.

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3.5

TESTING OF INSULATED FLANGES AND CASINGS


A.

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

B.

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

C.

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

D.

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

E.

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

F.

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

3.6

FLUSHING
A.

General:
1.

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

2.

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

3.

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

4.

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

5.

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

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6.

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


flushing shall be provided by the Contractor.

7.

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

8.

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

9.

No flushing is allowed through hydrant pit valves.

10.

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

11.

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

12.

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

13.

Test samples shall be drawn immediately ahead of filtration on closed loop


recirculation systems; immediately ahead of storage tanks in receiving manifold in
recirculation systems returning flushed fuel to tankage; or immediately ahead of
transport trucks on single line systems.

14.

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

15.

Arrange for Millipore, Aqua-Glo, Microsep and gravimetric tests to be taken as


specified during the fuel flushing operation. All tests shall be performed by a
testing laboratory provided by the Contractor and witnessed by the Engineer or
Owner. Continue flushing until the fuel meets or exceeds the test criteria as
specified herein.

16.

A two-test minimum is required to ensure piping cleanliness. The system being


flushed shall be displaced with clean fuel prior to taking second test.

17.

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

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18.

C.

D.

E.

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

Flushing into Tank Trucks:


1.

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

2.

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

3.

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

4.

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


hoses shall be used to achieve flow capacities.

5.

Bond and ground truck to hydrant system piping.

6.
7.

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

8.

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

9.

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

Test Requirements:
1.

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

2.

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

3.

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

Acceptance Specifications:
1.

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

2.

Solids:
a.

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

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b.
c.

F.

3.7

Membrane Color: #3 Rated Wet with one-gallon sample.


Note: If color rating exceeds the above limits or is in dispute, a matching
weight gravimetric rating not to exceed 0.5 mg/gal shall govern.

3.

Water: 5 ppm maximum.

4.

Water Separation (Microsep) Rating: 85 minimum.

Final Acceptance:
1.

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

2.

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


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

PERFORMANCE TESTING
A.

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

B.

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

C.

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

D.

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

E.

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


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

F.

Submit copies of test reports to the Engineer for approval.

END OF SECTION 40980

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