DOCUMENT NUMBER: SOP441 TITLE: Fuel Transfer and Storage ... · With the black box fuel pipe connected to the manifold, the operator can pump fuel to any of the tanks from an aircraft

Standard Operating Procedure

Updated: May 1, 2017

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DOCUMENT NUMBER: SOP441

TITLE: Fuel Transfer and Storage at Summit Station, Greenland

PURPOSE:

To instruct the mechanic and competent person(s) at Summit Station how to properly offload fuel from LC-130 military aircraft and transfer fuel to one of four 13,000 US gallon steel fuel tanks or a 10,000 US gallon ATL Petrol-Flex collapsible fuel storage bladder if one or more is being used. All fuel storage has secondary containment.

BACKGROUND:

Fuel is delivered to Summit Station during the summer season only. (April through August)

Fuel may be delivered to Summit Station by the Air National Guard via LC-130 aircraft or by the Greenland Inland Traverse (GrIT) project.

When fuel arrives, it is transferred to storage using a Yanmar diesel powered engine, driving a Gorman-Rupp fuel pump. The pump station or “Black Box” is equipped with a Total Control System 700 Rotary Flow fuel meter and manifold system and can be connected to an external PECOFacet HCS-322-1424 Horizontal Coalescer, “Mechanical Bull Filter”, for fueling aircraft.

Fuel Type and Volume

• Jet A-1: Classified as a type III flammable liquid. One storage unit equals 5 liters.

• JP8 (Jet Propellant 8): Classified as a type II flammable liquid. One storage unit equals

5 liters.

• When full, each fuel bladder contains 9,000 gallons.

• When full, two of the tanks contain 11,404 gallons and two of the tanks contain 11,398 gallons.

Safety Data Sheets (SDS) contain information regarding the safe handling of chemicals. A reference file of SDS is located in the Big House office and is available to all personnel.



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Equipment Description

• ATL Petrol-Flex Collapsible Fuel Bladder

Fuel can be stored in two each ATL Petrol-Flex collapsible fuel bladders. The bladders can be located in individual, appropriately sized containments. They should align in a row atop a snow berm to prevent drifting snow from burying the fuel bladders. The bladders are raised above the snow level 4-6’ every other year. Snow must be shoveled (using plastic shovels only) off and around the bladders prior to refilling.

Each ATL bladder has a capacity of 10,000 US gallons, with a safe fill capacity of 9,000 US gallons, and is fitted with a 2” fill/discharge valve and a 2” air vent located in the center of the bladder.

Vents are capped with PVC 4” tube to prevent blowing snow from entering the bladder. The vents are wired onto the bladder stack to allow removal for dipping the bladders. Bladders are refilled during summer operations.

• Fuel Tank

Fuel is stored in four each steel double-walled fuel tanks. Secondary containment exists in the tank design. The tanks are located adjacent to the fuel bladders and require similar maintenance.

Tanks have a capacity of usable fuel volume of two at 11,404 US gallons and two at 11,396 US gallons. The tanks are fitted with internal submersible Red Jack fuel pumps, tank fuel level gauges, secondary space monitor (gauge), primary and emergency vents, and a 24” manhole with bolted lid and gasket.

• Yanmar Diesel Powered Gorman-Rupp Fuel Pump

Fuel is transferred to storage bladders using a Yanmar diesel powered engine driving a Gorman-Rupp fuel pump. The pump station (Black Box) is equipped with a Total Control System 700 Rotary Flow fuel meter and manifold system and can be connected to an external PECOFacet HCS-322-1424 Horizontal Coalescer, “Mechanical Bull Filter”, for fueling aircraft.

Prior to the first LC-130 flight, the Black Box containing the Yanmar diesel powered fuel transfer pump and the Mechanical Bull Filter are set up near the fuel berm for summer operations. After the last LC-130 flight, they are winterized and stored on the winter berm. The mechanic disconnects all fuel lines from manifold, drains containment and seals up all penetrations for winter storage.

• Total Control System 700 Rotary Flow Fuel Meter and Manifold System

All fuel transfers between LC-130s, Traverse bladders and storage bladders or tanks are routed through the fuel meter located in the black box. Fuel meter readings are taken before and after each transfer and recorded by the operator.



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The manifold system allows fuel to be pumped to any or all storage vessels. The Black Box manifold is connected to the fuel tank trunk line (See SOP442 attachment A) or directly to one of the fuel bladders. With the black box fuel pipe connected to the manifold, the operator can pump fuel to any of the tanks from an aircraft.

• Hoses & Fittings

Two fuel lines are connected to the Black Box manifold system with 2” arctic grade hard wall fuel line. All 2” fuel lines, the Black Box manifold and bladder valves are fitted with cam-lock fittings. These fittings must be pinned or tie wired to prevent them from coming loose.

A long length of 2” lay-flat fuel line is used to connect the fuel system to the LC-130 aircraft. The lay-flat fuel line is fitted with dry break fittings and a special aircraft single point fueling nozzle.

DETAILS:

At least two persons on station shall be trained to operate the fuel pumps, valves and manifold system necessary to complete a fuel offload and transfer. All affected personnel must be trained in this Standard Operating Procedure and Hazard Communication training.

Fuel delivery/storage

• On the morning of a scheduled flight start the black box engine and recirculate some fuel in tank 1 to ensure the system is operating correctly.

• Begin preparing for a LC-130 fuel offload when the plane radios the Summit Site

Supervisor that they are 30 minutes from Station.

• Visually inspect the fuel line connections, Yanmar pump, and bladder area for leaks or

other hazards.

• In the early part of the summer season or if temperatures are below -10F, preheat the

Black Box using the Herman Nelson /fuel-fired heater. This heater is connected to the Black Box using 12” flexible heater hose. The Black Box is equipped with a 12” hose lock ring for this purpose.

• Start and warm the Yanmar engine.

o Before starting, ensure that there is adequate fuel in the Yanmar diesel powered fuel pump fuel tank and check crank case engine oil.

o Open drain valve on Peco Facet filter with a small can underneath to drain any collected water from the filter housing.

o Reset the fuel meter before each operation for accurate record keeping. o If necessary, a 12 volt battery may be connected to start the Yanmar diesel

engine when cold only. Advance throttle to full when starting cold engine.



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▪ Do not use ether to start the Yanmar engine. These methods for starting the Yanmar diesel engine have been proven many times in extreme conditions.

o Line out valves in the Black Box so that fuel may circulate through the Gorman-Rupp fuel pump, the Mechanical Bull Filter and Tank 1 while warming up the Yanmar engine.

▪ Do not operate pump dry. Typically there is an adequate amount of fuel held within the manifold system.

▪ Avoid dead heading the pump at all times.

• Once the Yanmar engine has been started and warmed, walk to the fuel container and open the gate valve to be filled or drawn from. These valves remain closed at all times, except during fuel transfers.

• Visually check all valves in the system to confirm fuel is flowing only to or from the intended tank or bladder.

• Confirm that one end of the lay-flat hose is connected to the Black Box manifold suction.

• Connect the other end of the lay-flat hose to the aircraft fueling nozzle at the dry break. When not in use the fueling nozzle is stored inside the Black Box. In extreme temperatures early or late season, keep the fueling nozzle warm inside the garage until just prior to aircraft arrival.

o When making or taking apart connections, ensure snow or other contaminants do not enter the fuel system. When disconnecting fuel hoses, place containment beneath the connection point and take care to minimize drips and spills.

o Always make sure the hose has no pressure in it by opening a path at either end to a tank or a container.

o No personnel should ever make any changes to the system valves, connections or lines without first consulting with the lead person on the flight deck, generally the station mechanic.

o Any time fuel connections are being made or broken, goggles and gloves will be worn. Pressurized cold fuel can cause serious injuries.

o Place the lay flat hose on the ground in a zig zag pattern “flaked” so that it can be easily pulled to the LC-130 by fuel personnel.

o Remove the fueling nozzle after each offload and store in the Black Box or garage to keep blowing snow from entering the system.

• A static line (cable) on a spool is stored in the Black Box. The operator pulls one end of

the static line to the LC-130 to be connected to the ski. Connect the other end to a point cable attached to the Yanmar engine.

• Air National Guard (ANG) personnel will connect the fuel nozzle to the aircraft and

instruct the operator of the Black Box to begin pumping. o The Gorman-Rupp fuel pump is equipped with a gauge that reads both

pressure and vacuum on the suction side of the pump. The Mechanical Bull Filter is equipped with pressure gauges on both sides of the filter. The gauges allow the operator to maximize the volume of fuel being offloaded.

o Speed the Yanmar engine up to a point that the vacuum gauge reading is zero to one PSI. At no time should a vacuum be drawn on the aircraft.



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• When offload is complete, ANG personnel will signal the operator of the Black Box to shut off the pump.

o Slow down, then Shut down the Yanmar engine. o Close the appropriate valves. o Assist ANG personnel by pulling the lay-flat hose back to the staging point for

the hose.

o Zig zag (Flake) the lay-flat hose for next use.

o Remove fuel nozzle at dry break and store in Black Box. o Reel in the static line and store in Black Box. o Remove and store aircraft fueling nozzle in Black Box.

• Fuel delivery varies each time (flight). Record number of US gallons delivered and

report meter reading to Summit Station Site Supervisor. A physical dip measurement will be taken on the tanks receiving fuel after each flight to confirm the volume metered matches.

• Close and latch all doors and hose openings to ensure blowing snow can’t enter the

Black Box.

Service & Inspections The following services and/or inspections must be performed:

Prior to winter storage on berm:

• Drain all water and fuel from the containment and drain plug at the base of the Black

Box.

• Drain the Mechanical Bull Filter.

• Store water and fuel in appropriate vessels for disposal.

• Hoses that aren’t needed for winter operations are drained into appropriate containment,

then capped, coiled and stored in the gray fuel hose crate. Both ends of the fuel lines

should be tagged to identify location and direction for spring set up.

One week prior to the first Air National Guard flight of the season:

• Summit Station mechanic shall bring the Black Box and the Mechanical Bull Filter into

the garage one week prior to the first Air National Guard flight of the season.

o Melt out any snow blown in during winter season.

o Change 0W-30 synthetic engine oil in Yanmar diesel engine.

o Start and test engine.

o When placing the Black Box at the fuel berm, orient it with the solar panels

to the south.

o Replace the filters in the Mechanical Bull Filter if necessary.

o Prime the Mechanical Bull Filter.

• Check condition of all 2” hoses, cam-lock fittings, and rubber washer seals.



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• Check condition of dry break on aircraft fuel nozzle. Inspect o-ring seals and overall

condition of valves before and after each use.

Emergency Preparedness and Response Procedures

• Ensure that SDS (Safety Data Sheets) are current and available for each product where

storage or transfers are performed.

• Ensure PPE (personal protective equipment) is available for spill clean-up.

• Ensure that spill kits and fire extinguishers are available in case of an emergency.

• Ensure that response personnel are familiar with emergency shut off and fuel handling safety practices.

DOCUMENTATION REQUIREMENTS (SUMMARY):

The following records must be maintained:

• SDS for product

• Hazard communication and training log

• Signed and reviewed AHA’s

• Fuel received/transferred recorded in the Summit Station fuel inventory

RESPONSIBILITIES:

• Heavy Equipment Mechanics: Follow procedures as outlined above and log

activity/details in Summit Station fuel inventory. Ensure that anyone assisting with offload of fuel is qualified and trained.

• Summit Station Site Supervisor: Ensure that anyone assisting with offload of fuel is qualified and trained and that all documentation is completed accurately/timely

Black Box / Fuel filter Setup

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Fuel Filter

To/From Aircraft/Fueling point

M E T E R

To/From Tanks/ Bladders

PUMP

Black Box

Summer set-up for flight ops

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault

To garage/ Roper Pump/ Highland Tank

Winter Setup (No black box or hoses to it)

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


Recirculate Fuel before Flights

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Fuel Filter


M E T E R


PUMP

Black Box

Recirculate Fuel before Flights

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


From LC-130 to Tank 3

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Fuel Filter

From LC-130

M E T E R


PUMP

Black Box

From LC-130 to Tank 3

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


Fuel Highland Tank W/Roper Pump

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


Fuel Highland Tank w/ Red Jacket Pump (Emergency use only)

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


To Any Aircraft From Bladder

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Fuel Filter


M E T E R


PUMP

Black Box

To Any Aircraft From Bladder

To Black Box

= Red Jacket pump

= Valve

= Fill Port

= Foot valve

= 2” Hose

= 2” Pipe

Tank 4

Tank 3

Tank 2

Tank 1

Bladder 1

Vault


Tank 1 (Northern Most)

Tank 2

Red Jacket Pump Switch

To Black Box

Shovel of Awesomeness

Fill Port

Red Jacket Pump Foot Valve

Tank 1 (Northern Most) Detail

Tank 2 To Foot Valve / Red Jacket

To Black Box

To Fill Port

Tank 2


Tank 3 Tank 1

Fill Port Red Jacket Pump

Tank 3


Tank 4

Tank 2

Red Jacket Pump

Fill Port

Tank 4 (Southern Most) To Black Box


Bladders

To Vault / Bladders

Tank 3

Fill Port

Red Jacket Pump

Tank 4 (Southern Most) Detail

To Black Box

To Vault / Bladders

Tank 3

Foot Valve / Red Jacket

Nate’s Feet

Documents

DOCUMENT NUMBER: SOP441 TITLE: Fuel Transfer and Storage ... · With the black box fuel pipe connected to the manifold, the operator can pump fuel to any of the tanks from an aircraft